EP2850619B1 - Process for producing an energy cable having a thermoplastic electrically insulating layer - Google Patents

Process for producing an energy cable having a thermoplastic electrically insulating layer Download PDF

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Publication number
EP2850619B1
EP2850619B1 EP12728796.9A EP12728796A EP2850619B1 EP 2850619 B1 EP2850619 B1 EP 2850619B1 EP 12728796 A EP12728796 A EP 12728796A EP 2850619 B1 EP2850619 B1 EP 2850619B1
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thermoplastic material
copolymer
process according
dielectric fluid
impregnated
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German (de)
English (en)
French (fr)
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EP2850619A1 (en
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Gabriele Perego
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Prysmian SpA
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Prysmian SpA
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06Insulating conductors or cables
    • H01B13/14Insulating conductors or cables by extrusion
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/20Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances liquids, e.g. oils
    • H01B3/22Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances liquids, e.g. oils hydrocarbons
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/441Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes

Definitions

  • the present invention relates to a process for producing an energy cable.
  • the present invention relates to a process for producing an energy cable for transporting or distributing electric energy, especially medium or high voltage electric energy, said cable having at least one thermoplastic electrically insulating layer.
  • Cables for transporting electric energy generally include at least one cable core.
  • the cable core is usually formed by at least one conductor sequentially covered by an inner polymeric layer having semiconductive properties, an intermediate polymeric layer having electrically insulating properties, an outer polymeric layer having semiconductive properties.
  • Cables for transporting medium or high voltage electric energy generally include at least one cable core surrounded by at least one screen layer, typically made of metal or of metal and polymeric material.
  • the screen layer can be made in form of wires (braids), of a tape helically wound around the cable core or a sheet longitudinally surrounding the cable core.
  • the polymeric layers surrounding the at least one conductor are commonly made from a polyolefin-based crosslinked polymer, in particular crosslinked polyethylene (XLPE), or elastomeric ethylene/propylene (EPR) or ethylene/propylene/diene (EPDM) copolymers, also crosslinked, as disclosed, e.g., in WO 98/52197 .
  • XLPE crosslinked polyethylene
  • EPR elastomeric ethylene/propylene
  • EPDM ethylene/propylene/diene copolymers
  • thermoplastic materials i.e. polymeric materials which are not crosslinked and thus can be recycled at the end of the cable life.
  • energy cables comprising at least one coating layer, for example the insulation layer, based on a polypropylene matrix intimately admixed with a dielectric fluid are known and disclosed, for example, in WO 02/03398 , WO 02/27731 , WO 04/066317 , WO 04/066318 , WO 07/048422 , WO 08/058572 , and WO 11/092533 .
  • the polypropylene matrix useful for this kind of cables comprises polypropylene homopolymer or copolymer or both, characterized by a relatively low cristallinity such to provide the cable with a suitable flexibility, but not to impair mechanical properties and thermopressure resistance at the cable operative and overload temperatures.
  • Performance of the cable coating, especially of the cable insulating layer, is also affected by the presence of the dielectric fluid intimately admixed with said polypropylene matrix.
  • the dielectric fluid should not impair the above mentioned mechanical properties and thermopressure resistance and should be intimately and homogeneously admixed with the polymeric matrix.
  • thermoplastic electrically insulating layer For an industrial production of the above energy cables having a thermoplastic electrically insulating layer it is therefore necessary to envisage and develop a process which allows to homogenously admix the dielectric fluid with the thermoplastic material in a predetermined amount, without prejudicing stability of the extrusion process, which can be negatively influenced by the presence of the dielectric fluid in the early extrusion steps, when the polymer is not yet molten. In fact, because of the lubricant properties of the dielectric fluid, it can cause irregularities in the movement and plasticization of the polymeric material along the extruder barrel.
  • thermoplastic coating which comprises: extruding a thermoplastic polymer and at least one dielectric liquid; passing said thermoplastic material through at least one static mixer; depositing and shaping said thermoplastic material around a conductor so as to obtain a layer of thermoplastic coating on said conductor.
  • the addition of the dielectric liquid to the thermoplastic polymer is preferably carried out, as shown in the working examples, by injecting the liquid into the extruder in a zone wherein the polymer is already in a molten state, i.e. in a downstream zone of the extruder.
  • the dielectric liquid may be added to the thermoplastic polymer when said polymer is in the solid state, namely: a) during the feeding of the thermoplastic polymer into the extruder; b) before the above feeding; or c) in a zone of the extruder wherein the thermoplastic polymer is in a solid state.
  • the addition of the dielectric liquid can be carried out during a previous step of compounding the polymer in a mixer (batchwise or continuously) or by impregnating the polymer in the form of granules or powder.
  • a homogenization step must be performed downstream of the extrusion step by means of a static mixer.
  • International Patent Application WO 02/27731 relates to a cable comprising at least one electrical conductor and at least one extruded covering layer based on a thermoplastic polymer material in admixture with a dielectric liquid.
  • the mixing of the polymer base with the dielectric liquid may be carried out, for example, by an internal mixer having tangential or interpenetrating rotors, or by a continuous mixer, e.g. a Ko-Kneader (Buss) mixer or a co- or counter-rotating double-screw extruder.
  • US Patent No. 3,445,394 relates to a dielectric composition consisting of a solid phase polyolefin, in particular polyethylene, having dispersed therein an aromatic hydrocarbon oil and a voltage stabilizing additive.
  • the additive-oil blends are also effective as voltage stabilizers in high density (low pressure) polyethylene and in other polyolefins, e.g. polyproylene.
  • the blend of highly aromatic hydrocarbons and voltage stabilizing additive is used in the polyolefin in an amount effective to act as a voltage stabilizer, particularly an amount of from 1 to 10% by weight based on the amount of the polyolefin.
  • the compositions are prepared by blending the oil and the stabilizer.
  • the blend is added to a tumbling bin into which the polyolefin has previously been introduced.
  • the polyolefin is granular and absorbs the blend upon tumbling. Subsequently the tumbled composition is shaped by extrusion to form wire insulation.
  • an electric cable or wire having an insulation comprising a solid olefin polymer together with one or more voltage stabilizers constituted by polymerisable aromatic or other cyclic monomeric compounds.
  • These monomeric compounds may, for example, be introduced into the olefin polymer by impregnation of granular olefin polymer before extrusion.
  • Even very small amounts of the voltage stabilizer, e.g. 0.1% of styrene, are sufficient to achieve a substantial improvement in the dielectric strength of the insulation.
  • the Applicant's experience in principle it is possible to further improve dielectric strength of a thermoplastic material as disclosed above by increasing the amount of the dielectric fluid added therein.
  • a large amount of the dielectric fluid e.g. higher than 10 wt%, may cause drawbacks in the extrusion process for producing the insulating layer.
  • the dielectric fluid cannot be added to the polymer granules when fed into the extruder, and also it cannot be injected upstream into the extruder barrel, namely in an initial portion of the extruder where the polymeric material is still solid, since the dielectric fluid exerts a remarkable lubricating action on the material, thus causing sliding of the same on the metallic surface of the extruder barrel and screw.
  • the prior art teaches that it is mandatory, after the impregnation step, to further improve dispersion of the dielectric fluid into the polymer matrix by subjecting the impregnated material to an additional mechanical processing in the molten state, either before or after the extrusion step, to cause homogenization of the same.
  • thermoplastic material just downstream of the extrusion step and before deposition on the conductive core, the material is passed through a static mixer to obtain the desired homogeneity, while according to WO 02/27731 , to obtain a homogeneous distribution of the dielectric fluid, the thermoplastic material must be passed through multiple mixing steps by extrusion.
  • the above multi-step mixing causes an increased complexity of the production plants. Such increased complexity is not only disadvantageous from the economical point of view, but also can enhance the risk of contamination by pollutants and degradation of the insulating layer.
  • the present invention relates to a process for producing an energy cable comprising at least one electrically conductive core and at least one thermoplastic electrically insulating layer, which comprises the steps of:
  • electrically conductive core an electrically conducting element usually made from a metallic material, more preferably aluminium, copper or alloys thereof, either as a rod or as a stranded multi-wire, or a conducting element as above coated with a semiconductive layer.
  • the term “medium voltage” generally means a voltage of between 1 kV and 35 kV, whereas “high voltage” means voltages higher than 35 kV.
  • electrically insulating layer it is meant a covering layer made of a material having insulating properties, namely having a dielectric rigidity (dielectric breakdown strength) of at least 5 kV/mm, preferably greater than 10 kV/mm.
  • semiconductive layer it is meant a covering layer made of a material having semiconductive properties, such as a polymeric matrix added with, e.g., carbon black such as to obtain a volumetric resistivity value, at room temperature, of less than 500 ⁇ m, preferably less than 20 ⁇ m.
  • carbon black such as to obtain a volumetric resistivity value, at room temperature, of less than 500 ⁇ m, preferably less than 20 ⁇ m.
  • the amount of carbon black can range between 1 and 50% by weight, preferably between 3 and 30% by weight, relative to the weight of the polymer.
  • thermoplastic material is impregnated in the form of granules or pellets, having an average dimension of from 2 to 7 mm, more preferably from 3 to 6 mm.
  • the thermoplastic material is impregnated with an amount of the dielectric fluid of from 8% to 40% by weight, more preferably of from 10% to 30% by weight, even more preferably from 15% to 25% by weight, with respect to the weight of the thermoplastic material.
  • the impregnation step is preferably carried out in a mixer.
  • the mixer may be, e.g., selected from: ribbon blenders, tumble mixers, turbomixers.
  • the time required to obtain a complete impregnation mainly depends on the properties of the thermoplastic material and of the dielectric fluid, and also on the efficiency of the mixer and on the impregnation temperature.
  • the impregnation time may range from 10 to 60 minutes, preferably from 15 to 45 minutes.
  • the fact that the thermoplastic material has a melting enthalpy equal to or lower than 70 J/g, preferably from 30 to 60 J/g, allows to obtain a substantially complete absorption of the dielectric fluid, since the thermoplastic material has a reduced crystallinity and therefore is highly compatible with the dielectric fluid, so as to quickly receive even large amounts of the same.
  • the granules or pellets of the thermoplastic material are substantially dry, with a non-sticky and non-oily surface. This is of great advantage for the subsequent handling and processing of the impregnated material.
  • the impregnation step may be preceded by a step of heating the thermoplastic material at a temperature of from 30°C to 110°C, more preferably from 50°C to 90°C (pre-heating step).
  • the pre-heating step facilitates the absorption of the dielectric fluid into the thermoplastic material.
  • the impregnation step may be carried out with satisfactory results thanks to the relatively low melting enthalpy of the thermoplastic material, but with a longer impregnation time.
  • the pre-heating step may be carried out before charging the thermoplastic material into the mixer or after said charging, before adding the dielectric fluid.
  • the impregnation step can be carried out batchwise, therefore the dimensions of the mixer wherein the impregnation is performed is suitably selected so as to guarantee a continuous feeding of the extrusion apparatus, mainly on the basis of the impregnation time and of the extrusion speed.
  • a step of temporarily storing the impregnated thermoplastic material so as to guarantee a continuous feeding of the extrusion apparatus.
  • the impregnated thermoplastic material is also subjected to a sort of "maturation", which can further increase absorption and homogeneous distribution of the dielectric fluid into the thermoplastic material.
  • the process according to the present invention allows to produce energy cables with a high production speed, usually of at least 20 m/min, preferably of at least 30 m/min for medium voltage cables.
  • a high production speed usually of at least 20 m/min, preferably of at least 30 m/min for medium voltage cables.
  • the upper speed limit it depends on other manufacturing conditions, such as the model and size of extruder or the kind other apparatus downstream the extrusion step; of course, a higher manufacturing speed makes the process more attractive from an industrial point of view.
  • the extrusion speed of high voltage energy cables an improvement of 30-50% can be achieved by the process according to the present invention, taking into account that the high voltage energy cables are usually produced with an extrusion speed of about 1-2 m/min.
  • the impregnated thermoplastic material in subdivided form is preferably directly fed to a single-screw extruder, wherein the material, after an initial kneading in the solid form, is melted and then extruded onto said at least one electrically conductive core, so as to form said at least one thermoplastic electrically insulating layer.
  • a single screw extruder has as foremost goal that of melting the thermoplastic polymer and building pressure in the so obtained melted material, so that it can be extruded through a die or injected into a mould.
  • Other processing machines particularly twin screw extruders, not only melt the thermoplastic material, but also exert a remarkable mixing effect on the same. In other words, substantially no mixing of the components of the thermoplastic material can be achieved by using a single screw extruder, while a mixing action is typically performed by a twin screw extruder.
  • the process according to the invention does not require any mechanical homogenization step in a molten state of the impregnated material in order to improve dispersion of the dielectric fluid into said thermoplastic material.
  • This is a considerable advantage in terms of productivity as well as of initial and maintenance costs for the production plant.
  • the single screw extruder used to extrude the impregnated thermoplastic material onto the electrically conductive core, does not exert an actual mechanical homogenization on the material itself.
  • a single-screw extruder has remarkable advantages with respect to twin-screw extruders.
  • a single screw extruder can build up a significant pressure on the melted material which thus can be effectively fed to the extrusion head.
  • the pressure on the melted material built up by a twin-screw extruder is sometimes insufficient to effectively extrude the thermoplastic material onto the conductive core, thus requiring the addition on a suitable pump to increase the pressure of the melted material before feeding it to the extrusion head.
  • the thermoplastic material may be constituted by a single thermoplastic polymer or by a mixture of at least two thermoplastic polymers. As reported above, the thermoplastic material has a melting enthalpy equal to or lower than 70 J/g, preferably from 30 to 60 J/g, which is to be intended as the overall melting enthalpy measured on the thermoplastic material by Differential Scanning Calorimetry (DSC) analysis.
  • DSC Differential Scanning Calorimetry
  • thermoplastic polymer material is selected from:
  • heteropolymer it is meant a copolymer in which elastomeric domains, e.g. of ethylene-propylene elastomer (EPR), are dispersed in a propylene homopolymer or copolymer matrix.
  • EPR ethylene-propylene elastomer
  • the at least one electrically insulating layer can have a thickness of at least 8 mm, for example of at least 12 mm.
  • the thickness of the insulating layer depends on the voltage intended to be carried by the cable and on the overall structure of the cable (conductor compositions and configuration, kind of material employed for the insulating layers, etc.).
  • a polyethylene insulated cable intended for carrying 400 kV and having a single conductor made of stranded copper wires can have an insulating layer 27 mm thick.
  • the thermoplastic polymer material has a melt flow index (MFI), measured at 230°C with a load of 21.6 N according to ASTM Standard D1238-00, of from 0.05 dg/min to 10.0 dg/min, more preferably from 0.4 dg/min to 5.0 dg/min.
  • MFI melt flow index
  • the olefin comonomer in copolymer (i) is preferably present in an amount equal to or lower than 15 mol%, more preferably equal to or lower than 10 mol%.
  • said olefin is selected from propylene, 1-butene, isobutylene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-dodecene, or mixtures thereof.
  • Propylene, 1-butene, 1-hexene and 1-octene are particularly preferred.
  • At least one copolymer (ii) is a linear low density polyethylene (LLDPE) copolymer.
  • LLDPE linear low density polyethylene
  • the olefin comonomer in LLDPE is present in an amount from 2 to 12 wt%.
  • copolymer (i) or copolymer (ii) or both are random copolymers.
  • random copolymer it is meant a copolymer in which the comonomers are randomly distributed along the polymer chain.
  • an elastomeric phase is present in an amount equal to or greater than 45 wt% with respect to the total weight of the copolymer.
  • heterophasic copolymers (i) or (ii) are those wherein the elastomeric phase consists of an elastomeric copolymer of ethylene and propylene comprising from 15 wt% to 50 wt% of ethylene and from 50 wt% to 85 wt% of propylene with respect to the weight of the elastomeric phase.
  • Preferred heterophasic copolymers (ii) are propylene copolymers, in particular:
  • Heterophasic copolymers can be obtained by sequential copolymerization of: 1) propylene, possibly containing minor quantities of at least one olefin comonomer selected from ethylene and an ⁇ -olefin other than propylene; and then of: 2) a mixture of ethylene with an ⁇ -olefin, in particular propylene, optionally with minor portions of a polyene.
  • polyene generally means a conjugated or non-conjugated diene, triene or tetraene.
  • this comonomer generally contains from 4 to 20 carbon atoms and is preferably selected from: linear conjugated or non-conjugated diolefins such as, for example, 1,3-butadiene, 1,4-hexadiene, 1,6-octadiene, and the like; monocyclic or polycyclic dienes such as, for example, 1,4-cyclohexadiene, 5-ethylidene-2-norbornene, 5-methylene-2-norbornene, vinylnorbornene, or mixtures thereof.
  • this comonomer When a triene or tetraene comonomer is present, this comonomer generally contains from 9 to 30 carbon atoms and is preferably selected from trienes or tetraenes containing a vinyl group in the molecule or a 5-norbornen-2-yl group in the molecule.
  • triene or tetraene comonomers which may be used in the present invention are: 6,10-dimethyl-1,5,9-undecatriene, 5,9-dimethyl-1,4,8-decatriene, 6,9-dimethyl-1,5,8-decatriene, 6,8,9-trimethyl-1,6,8-decatriene, 6,10,14-trimethyl-1,5,9,13-pentadecatetraene, or mixtures thereof.
  • the polyene is a diene.
  • copolymer (i) or copolymer (ii) or both have a melting point of from 140°C to 180°C.
  • copolymer (i) has a melting enthalpy of from 25 J/g to 80 J/g.
  • copolymer (ii) has a melting enthalpy of from 10 J/g to 90 J/g when heterophasic, and from 50 J/g to 100 J/g when homophasic (substantially free from heterophasic phase).
  • thermoplastic material of the insulating layer comprises a blend of copolymer (i) and copolymer (ii)
  • the ratio between copolymer (i) and copolymer (ii) is of from 1:9 to 8:2, preferably of from 2:8 to 7:3.
  • thermoplastic material of the insulating layer comprises a blend of a propylene homopolymer and at least one of copolymer (i) and copolymer (ii)
  • the ratio between the propylene homopolymer and copolymer (i) or copolymer (ii) or both is of from 0.5:9.5 to 5:5, preferably from 1:9 to 3:7.
  • the thermoplastic material of the insulating layer comprises a blend of a propylene homopolymer with one copolymer (i) and two copolymers (ii); in this case, one of the copolymers (ii) is a heterophasic copolymer, while the other is homophasic.
  • the dielectric fluid As to the dielectric fluid, high compatibility between the dielectric fluid and the thermoplastic material is necessary to obtain a microscopically homogeneous dispersion of the dielectric fluid in the polymer material.
  • the dielectric fluid suitable for forming the thermoplastic electrically insulating layer should comprise no polar compounds or only a limited quantity thereof, in order to avoid a significant increase of the dielectric losses.
  • the concentration by weight of said at least one dielectric fluid in said thermoplastic material is lower than the saturation concentration of said dielectric fluid in said thermoplastic material.
  • the saturation concentration of the dielectric fluid in the thermoplastic polymer material may be determined by a fluid absorption method on Dumbell specimens as described, for example, in WO 04/066317 .
  • thermomechanical properties of the insulating layer are maintained and exudation of the dielectric fluid from the thermoplastic material is avoided.
  • the at least one dielectric fluid is generally compatible with the thermoplastic material.
  • “Compatible” means that the chemical composition of the fluid and of the thermoplastic material is such as to result into a microscopically homogeneous dispersion of the dielectric fluid into the polymer material upon mixing the fluid into the polymer, similarly to a plasticizer.
  • the dielectric fluid has a melting point or a pour point of from -130°C to +80°C.
  • Suitable dielectric fluids for use in the cable of the invention are described, e.g., in WO 02/03398 , WO 02/27731 , WO 04/066318 , WO 07/048422 and WO 08/058572 , all in the Applicant's name.
  • the dielectric fluid has a predetermined viscosity in order to prevent fast diffusion of the liquid within the insulating layer and hence its outward migration, as well as to enable the dielectric fluid to be easily fed and absorbed by the thermoplastic material in solid subdivided form.
  • the dielectric fluid of the invention has a viscosity, at 40°C, of from 1 cSt to 100 cSt, preferably of from 5 cSt to 100 cSt (measured according to ASTM standard D445-03).
  • a dielectric fluid according to the invention has a ratio of number of aromatic carbon atoms to total number of carbon atoms (hereinafter also referred to as C ar /C tot ) greater than or equal to 0.3.
  • C ar /C tot is lower than 1.
  • C ar /C tot is from 0.4 to 0.9.
  • the number of aromatic carbon atoms is intended to be the number of carbon atoms which are part of an aromatic ring.
  • the ratio of number of aromatic carbon atoms with respect to the total number of carbon atoms may be determined according to ASTM standard D3238-95(2000)e1.
  • suitable dielectric fluids are: aromatic oils, either monocyclic, polycyclic (condensed or not) or heterocyclic (i.e. containing at least one heteroatom selected from oxygen, nitrogen or sulfur, preferably oxygen), wherein aromatic or heteroaromatic moieties are substituted by at least one alkyl group C 1 -C 20 , and mixtures thereof. When two or more cyclic moieties are present, such moieties may be linked by an alkenyl group C 1 -C 5 .
  • the dielectric fluid comprises at least one alkylaryl hydrocarbon having the structural formula (I): wherein:
  • the dielectric fluid comprises at least one diphenyl ether having the following structural formula (II): wherein R 5 and R 6 are equal or different and represent hydrogen, a phenyl group non-substituted or substituted by at least one alkyl group, or an alkyl group non-substituted or substituted by at least one phenyl.
  • alkyl group it is meant a linear or branched C 1 -C 24 , preferably C 1 -C 20 , hydrocarbon radical, with the proviso that the ratio of number of aromatic carbon atoms to total number of carbon atoms is greater than or equal to 0.3.
  • the dielectric fluid can be selected from mineral oils, for example, naphthenic oils, aromatic oils, paraffinic oils, polyaromatic oils, said mineral oils optionally containing at least one heteroatom selected from oxygen, nitrogen or sulfur; liquid paraffins. Paraffinic oils and naphthenic oils are preferred.
  • Mineral oils as dielectric fluid can comprise polar compound/s.
  • the amount of polar compound/s advantageously is up to 2.3 wt%. Such a low amount of polar compounds allows obtaining low dielectric losses.
  • additives may be added in minor amounts (for example, from 0.1 wt% to 1 wt% each) to the thermoplastic material, including antioxidants, processing aids, voltage stabilizers, nucleating agents, or mixtures thereof.
  • said additives may be possibly added to the thermoplastic material during the impregnation step or during the step of feeding the impregnated thermoplastic material to the single-screw extruder.
  • an additive when an additive is in solid form, it may be advantageously dispersed into the dielectric fluid before impregnation.
  • antioxidants suitable for the purpose are, for example, distearyl- or dilauryl-thiopropionate and pentaerythrityl-tetrakis [3-(3,5-di-t-butyl-4-hydroxyphen-yl)-propionate], or mixtures thereof.
  • Antioxidants in liquid form or, if solid, soluble or dispersible in the dielectric fluid are preferred in the process of the invention.
  • Processing aids which may be added to the polymer composition include, for example, calcium stearate, zinc stearate, stearic acid, or mixtures thereof.
  • the cable according to the present invention includes also at least one semiconductive layer.
  • the semiconductive layer is preferably formed by a semiconductive material comprising the thermoplastic material and the dielectric fluid as disclosed above, and at least one conductive filler, preferably a carbon black filler.
  • the at least one conductive filler is generally dispersed within the thermoplastic material in a quantity such as to provide the material with semiconductive properties, namely to obtain a volumetric resistivity value, at room temperature, of less than 500 ⁇ m, preferably less than 20 ⁇ m.
  • the amount of carbon black can range between 1 and 50% by weight, preferably between 3 and 30% by weight, relative to the weight of the polymer.
  • the use of the same base polymer composition for both the insulating layer and the semiconductive layers is particularly advantageous in producing cables for medium or high voltage, since it ensures excellent adhesion between adjacent layers and hence a good electrical behaviour, particularly at the interface between the insulating layer and the inner semiconductive layer, where the electrical field and hence the risk of partial discharges are higher.
  • the polymer composition of the invention may be used for coating electrical devices in general and in particular cable of different type, for example low voltage cables (i.e. cables carrying a voltage lower than 1 kV), telecommunications cables or combined energy/telecommunications cables, or accessories used in electrical lines, such as terminals, joints, connectors and the like.
  • low voltage cables i.e. cables carrying a voltage lower than 1 kV
  • telecommunications cables or combined energy/telecommunications cables or accessories used in electrical lines, such as terminals, joints, connectors and the like.
  • the cable (1) comprises a conductor (2), an inner layer with semiconductive properties (3), an intermediate layer with insulating properties (4), an outer layer with semiconductive properties (5), a metal screen layer (6) and a sheath (7).
  • the combination of conductor (2) and inner layer with semiconductive properties (3) corresponds to the electrically conductive core as described above.
  • the conductor (2) generally consists of metal wires, preferably of copper or aluminium or alloys thereof, stranded together by conventional methods, or of a solid aluminium or copper rod.
  • the insulating layer (4) is produced according to the present invention.
  • the semiconductive layers (3) and (5) are also made by extruding polymeric materials usually based on polyolefins, preferably a thermoplastic material as described above, which is made semiconductive by adding at least one conductive filler, usually carbon black.
  • a metal screen layer (6) is usually positioned, made of electrically conducting wires or strips helically wound around the cable core or of an electrically conducting tape longitudinally wrapped and overlapped (preferably glued) onto the underlying layer.
  • the electrically conducting material of said wires, strips or tape is usually copper or aluminium or alloys thereof.
  • the screen layer (6) may be covered by a sheath (7), generally made from a polyolefin, usually polyethylene.
  • the cable can be also provided with a protective structure (not shown in Figure 1 ) the main purpose of which is to mechanically protect the cable against impacts or compressions.
  • This protective structure may be, for example, a metal reinforcement or a layer of expanded polymer as described in WO 98/52197 in the name of the Applicant.
  • FIG 2 a schematic representation of a plant to carry out the process according to the present invention is provided.
  • the plant comprises a mixer (8) wherein the thermoplastic material and the dielectric fluid are fed, which may come from, respectively, a pellet container (9) and a tank (10).
  • the thermoplastic material Before being fed into the mixer (8), the thermoplastic material is preferably heated in a heater (17), for example at a temperature of 50-100°C. Alternatively, the thermoplastic material can be heated into the mixer (8) before the addition of the dielectric fluid and, optionally, of additives, e.g. antioxidant.
  • the step of impregnation occurs, and the impregnated thermoplastic material is then fed to the extruder (13) usually by means of a hopper (12).
  • a storage unit (11) can be provided between the mixer (8) and the hopper (12) in order to temporarily store the impregnated thermoplastic material so as to guarantee a continuous feeding of the extrusion apparatus and a "maturation" of the impregnated material.
  • the extruder (13) comprises a barrel (14) and a screw (15) wherein the impregnated thermoplastic material (11) is melted and kneaded.
  • the extruder (13) is driven by an engine to cause rotation of the screw and is provided by suitable heating units, in order to heat and melt the polymer material (not represented in Fig. 2 ), according to well known techniques.
  • thermoplastic material is usually carried out by means of an extrusion head (16) placed at the end of the extruder (13).
  • the extrusion head is preferably a triple extrusion head, which allows to coextrude onto the conductor, in a single pass, the inner semiconductive layer, the intermediate electrically insulating layer, and the outer semiconductive layer.
  • a tandem method can be performed, wherein individual extruders are arranged in series. Further apparatuses are included in the production plant to provide the cable with the metal screen layer and the sheath.
  • thermoplastic insulating material is extruded on a cable core (18), comprising an electrical conductor surrounded by an inner semiconductive layer, by the extrusion head (16). Subsequently, the outer semiconductive layer is formed onto the external surface of the thermoplastic insulating layer by means of another extruder (not represented in Fig. 2 ).
  • FIGS. 1 and 2 show only one embodiment of the present invention. Suitable modifications can be made to this embodiment according to specific technical needs and application requirements without departing from the scope of the invention.
  • the composition comprised, as polymeric base, a first polypropylene copolymer having a melting enthalpy of 30 J/g and a second polypropylene copolymer having a melting enthalpy of 65 J/g, the first and second polypropylene copolymer being in a weight ratio of 75/25.
  • dielectric fluid a naphthenic oil having a viscosity of 25 cSt (at 40°C) was used.
  • the composition further comprised an antioxidant in an amount of 0.3 wt% which was added to the thermoplastic material together with the dielectric fluid.
  • Both prototypes had a 70 mm 2 aluminum conductor and were extruded with a catenary line.
  • the semiconductive composition was the same thermoplastic polypropylene composition as indicated above, added with conductive carbon black.
  • the insulation of the first cable was prepared and extruded as follows. Polypropylene pellets were charged in a turbomixer, mixed and heated up to 90°C. Upon reaching said temperature, a dielectric fluid in an amount of 15 wt% was added to the polypropylene pellets and the mixing was continued at 90°C. After 25 minutes of mixing, the dielectric fluid was absorbed by the polypropylene pellets, which resulted to be dry.
  • the polypropylene/dielectric fluid material was discharged and fed into a single screw extruder and the extrusion was carried out with the following extrusion temperature profile: zone 1: 160°C; zone 2: 180°C; zone 3: 200°C; zone 4: 200°C; zone 5: 200°C; zone 6: 210°C.
  • the screw rotation speed was 7 rpm.
  • the insulation of the second cable was extruded by directly injecting 15 wt% of dielectric fluid in the barrel of an identical single screw extruder as used above. Polypropylene feeding was carried out with pellets as obtained from the raw material supplier, without any preliminary treatments. The extrusion temperature profile was the same as indicated above. The screw speed was 10 rpm.
  • the insulation extrusion speed was initially fixed at 2 m/min for both cables and apparently no significant phenomena were observed. Then, the extrusion speed was increased to 3 m/min: in the second cable quite evident morphological defects appeared, due to the incomplete mixing and absorption of the dielectric fluid. These defects significantly affected the insulation quality and cannot be tolerated. Moreover, an abnormal bulging of the insulation layer was observed in some points of the extruded cable, with breakage of the outer semiconductive layer, due to local accumulation of the dielectric fluid. Conversely, the insulation layer of the first cable, obtained by the process according to the present invention, showed no defects at 3 m/min speed.

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  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Organic Insulating Materials (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
EP12728796.9A 2012-05-18 2012-05-18 Process for producing an energy cable having a thermoplastic electrically insulating layer Active EP2850619B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2012/052507 WO2013171550A1 (en) 2012-05-18 2012-05-18 Process for producing an energy cable having a thermoplastic electrically insulating layer

Publications (2)

Publication Number Publication Date
EP2850619A1 EP2850619A1 (en) 2015-03-25
EP2850619B1 true EP2850619B1 (en) 2019-07-10

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EP (1) EP2850619B1 (zh)
CN (1) CN104364853B (zh)
AU (1) AU2012379976B2 (zh)
BR (1) BR112014028453B1 (zh)
CA (1) CA2873531C (zh)
DK (1) DK2850619T3 (zh)
ES (1) ES2749509T3 (zh)
RU (1) RU2590904C1 (zh)
WO (1) WO2013171550A1 (zh)

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WO2016005791A1 (en) 2014-07-08 2016-01-14 Prysmian S.P.A. Energy cable having a thermoplastic electrically insulating layer
WO2016097819A1 (en) 2014-12-17 2016-06-23 Prysmian S.P.A. Energy cable having a cold-strippable semiconductive layer
FR3069799B1 (fr) * 2017-08-01 2020-09-18 Nexans Procede de fabrication d'un cable electrique par extrusion d'une composition a base d'un polymere de propylene et d'un liquide dielectrique
CA3078829A1 (en) * 2017-10-12 2019-04-18 Prysmian S.P.A. Electric cable with improved thermoplastic insulating layer
IT201800007853A1 (it) 2018-08-03 2020-02-03 Prysmian Spa Cavo trifasico ad alta tensione.
CN109243698A (zh) * 2018-09-28 2019-01-18 上海电缆研究所有限公司 架空导线用热塑性复合芯体及其制造方法
TW202128865A (zh) 2019-11-18 2021-08-01 美商陶氏全球科技有限責任公司 抗熱老化之可撓性聚烯烴調配物

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Publication number Publication date
AU2012379976B2 (en) 2016-12-15
AU2012379976A1 (en) 2014-11-27
BR112014028453A2 (pt) 2017-06-27
ES2749509T3 (es) 2020-03-20
CN104364853A (zh) 2015-02-18
WO2013171550A1 (en) 2013-11-21
EP2850619A1 (en) 2015-03-25
BR112014028453B1 (pt) 2020-08-11
RU2590904C1 (ru) 2016-07-10
DK2850619T3 (da) 2019-10-14
CA2873531C (en) 2019-09-17
CA2873531A1 (en) 2013-11-21
CN104364853B (zh) 2018-03-16

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