Boron-compounded cable production method and boron-compounded cable structure

Abstract

In particular, the invention relates to a boron-compounded cable production method, which enables increasing the resistance against physical and chemical external factors such as fire, corrosion, moisture, impact, extending the cable life and reducing the damage to human / environmental health by using boron compound as raw material in the production of filling, insulation and / or sheath parts of the cable containing conductors such as aluminum and creating a protection layer on it by using boron oil and a boron-compounded cable structure.

Description

[0001] BORON-COMPOUNDED CABLE PRODUCTION METHOD AND BORON-COMPOUNDED CABLE STRUCTURE

[0002] Technical Field

[0003] The invention relates to a boron-compounded cable production method, which enables the physical strength and service life of the cable to be increased by using boron material in conductorcontaining cable production and a boron-compounded cable structure.

[0004] In particular, the invention relates to a boron-compounded cable production method, which enables increasing the resistance against physical and chemical external factors such as fire, corrosion, moisture, impact, extending the cable life and reducing the damage to human / environmental health by using boron compound as raw material in the production of filling, insulation and / or sheath parts of the cable containing conductors such as aluminum and creating a protection layer on it by using boron oil and a boron-compounded cable structure.

[0005] State of the Art

[0006] Various cable structures developed for different conduction processes such as energy, data and signal conduction are used in the cable industry. To prevent loss of data, signal and / or energy transmitted in cables with a wide range of uses and to ensure security, protection against physical external influences, especially fire resistance, must be provided. Generally, aluminum or copper wire is used as conductor material in voltage cables that provide electrical power transmission, and multiple layers such as filling, insulation and sheath layers are used to insulate and protect this conductive part from external influences. These layers are mostly produced using polyvinyl chloride (PVC) and polyethylene (PE) materials, which contain different types of organic and / or inorganic components.

[0007] PVC polymer is a thermoplastic insulating material widely used in the cable industry, and the filling, insulation and sheath part of a cable is generally made of PVC polymer matrix. Different organic and inorganic additives added to the polymer in the production of these cables can improve the non-flammability and processability properties of the cable. However, considering the rates of toxic gases and fumes that PVC cables release into the environment during a fire, according to the building materials regulation (CPR), these cables can be used at most in the Copper Clad Aluminum Wire (CCA) cable standard. The chlorine (halogen) in PVC produces thick, toxic, black smoke when burned, which can cause serious health and environmental problems in the event of a fire.

[0008] Halogen-free cables, developed especially against fire hazard, are preferred to reduce toxic smoke emissions in case of fire, protect environmental health and prevent the destruction of flammable materials. Halogen-free, flame retardant HFFR doped cables help to slow down the rate of fire spread in the event of a fire, achieve low smoke density and reduce possible loss of life and property by providing non-toxic gas production. Also, HFFR cables provide resistance to aging factors (UV rays, ozone, humidity, temperature, chemicals). However, HFFR cables are more expensive than plain PVC cables because the additives used in HFFR cables increase the cost of the cable, which limits its use. PVC cables with HFFR have lower dielectric constant and higher dielectric loss performance than plain cables, which negatively affects the electrical conductivity performance. Besides, in general, the process temperatures of such cables are lower than those of normal PVC cables and therefore their use in areas where temperatures rise, such as high-power transmission, is not efficient, reducing their overall range of uses.

[0009] In the state-of-the-art patent document no WO1999019395A1, polyvinyl chloride-based plenum cable compositions with flame retardant properties containing a poly(vinyl chloride) resin, a chlorinated poly(vinyl chloride) resin or a mixture thereof are described. Formula 1 in the document describes a halogen, polyhaloalkylphosphate and / or polyhaloalkylthiophosphate flame retardant and a compatibilizing agent (exudation inhibitor) where M is sulfur or oxygen and XI, X2 and X3 are each independently selected from the group consisting of chlorine and bromine. Preferably, the compositions comprise sufficient flame retardant and other halogenated additives to provide a composition having a halogen content greater than about 2.0% by weight of poly(vinyl chloride) resin, chlorinated poly(vinyl chloride) resin or a mixture thereof. The vinyl halide resin (PNC and / or CPVC) contains about 5 to 15 phr (parts per hundred parts of vinyl halide resin) of polyhaloalkylphosphate and / or polyhaloalkylthiophosphate phosphate flame retardant and about 1 to 8 phr of a coupling agent. These compositions also contain 2 to 10 phr of boron oxide or boron-containing salt. The document does not mention a solution to create a protection layer on the conductor by using boron oil together with the use of boron compound as raw material in the production of filling, insulation and / or sheath sections. Patent document US6339189B1 of the known art discloses a fire-retardant electrical cable comprising a metal conductor and at least one double layer polymer coating disposed surrounding the metal conductor. The double-layer coating defines an inner and an outer layer. Herein, the inner layer comprises a polymer matrix, a first predetermined amount of flame-retardant inorganic filler, and a predetermined amount of a coupling agent. The outer layer comprises a polymer matrix and a second predetermined amount of flame-retardant inorganic filler. The inner layer uses a first predetermined amount of inorganic filler in a lower amount than the second predetermined amount of inorganic filler in the outer layer. The inner layer contains a predetermined amount of coupling agent that will keep the long-term insulation resistance of the cable substantially constant upon passing the cable through the cold-water bath. The document in question does not mention a solution for the use of boron compound as a raw material in the production of filling, insulation and / or sheath sections, as well as the use of boron oil to create a protection layer on it.

[0010] As a result, there is a need to develop a boron-compounded cable production method and a boron- compounded cable structure obtained with this method, which enables the use of boron compound as a raw material in the production of filling, insulation and / or sheath sections of the conductorcontaining cable and the creation of an extra protection layer on it by using boron oil, increasing the resistance efficiency against physical and chemical external factors such as fire, corrosion, moisture, impact and reducing the production cost and damage to human / environmental health.

[0011] Purpose of the Invention

[0012] The present invention relates to a boron-compounded cable production method and boron- compounded cable structure that meets the above-mentioned requirements, eliminates possible disadvantages and provides some additional advantages.

[0013] The main purpose of the boron-compounded cable production method and boron-compounded cable structure subject to the invention is to obtain a boron-compounded cable production method and cable structure that enables the use of boron compound as raw material in the production of filling, insulation and / or sheath sections and the creation of an extra protection layer on the conductor by using boron oil, thereby increasing the resistance efficiency against physical and chemical external factors such as fire, corrosion, moisture, rust, impact. Another aim of the invention is to obtain a boron-compounded cable production method and cable structure that reduces the total production cost of the cable as well as the harm to human / environmental health.

[0014] Another aim of the invention is to obtain a safe boron-compounded cable production method and cable structure that slows down the spread of flames in case of fire and reduces smoke density and toxic gas emissions.

[0015] Another aim of the invention is to obtain an effective boron-compounded cable production method and cable structure that reduces the dielectric constant and dielectric loss performance and increases the electrical conductivity performance.

[0016] Another aim of the invention is to obtain an effective boron-compounded cable production method and cable structure that makes the surface of the protection layer coated on the conductor appear bright (visual improvement), increases flame retardant effectiveness and resistance to corrosion, and reduces surface roughness and outer surface friction coefficient.

[0017] Another aim of the invention is to obtain a functional boron-compounded cable production method and cable structure that increases the flexibility of the cable while increasing its strength and impact resistance and extending its service life.

[0018] Another aim of the invention is to obtain a functional boron-compounded cable production method and cable structure that allows increasing the usage area and diversity of the cable.

[0019] Another aim of the invention is to obtain a boron-compounded cable production method and cable structure that allows increasing the density and homogeneous distribution rate of boron and silane compounds in the cable structure.

[0020] A boron-compounded cable production method, which enables the production of a cable structure containing at least one conduction layer to achieve the above objectives in the most general form, and to increase its resistance and flexibility against physical external influences, insulation and transmission efficiency, and to reduce surface friction resistance and toxic gas emission in case of ignition includes the steps of adding at least one boron compound to at least one first material and obtaining a powder mixture; blending the first mixture and obtaining granular pellets by blending and granulating the first mixture; impregnating the granular pellets with at least one silane compound; transferring the pellets impregnated with silane compound to the extrusion line to be used as raw material for at least one first protection layer; forming the cable structure by coating the first protection layer on the conduction layer in such a way as to wrap the conduction layer.

[0021] The boron-compounded cable structure obtained by the boron-compounded cable production method developed with the present invention, which includes at least one conduction layer, which provides increased flexibility, insulation and transmission efficiency with resistance to fire, physical external influences, surface friction resistance and reduction of toxic gas emission in case of ignition, includes at least one first protection layer that protects the conduction layer from physical external influences, and a second protection layer whose mechanical properties and physical strength are higher than the first protection layer mentioned.

[0022] The structural and characteristic features and all advantages of the invention will be more clearly understood by means of the figures given below and the detailed description written by making references to these figures, and therefore, the evaluation should be made by considering these figures and detailed description.

[0023] Figures to Help Understand the Invention

[0024] To best understand the structure and advantages of the present invention, it should be evaluated together with the figures described below.

[0025] Figure 1 : A front view of the boron-compounded cable structure that is the subject of the invention. Figure 2: A cross-sectional view of the boron-compounded cable structure that is the subject of the invention.

[0026] Part References

[0027] 1. Conduction layer

[0028] 2. First protection layer

[0029] 3. Second protection layer

[0030] 4. Third protection layer Detailed Description of the Invention

[0031] In this detailed description, the inventive boron-compounded cable production method and the preferred embodiments of the boron-compounded cable structure are described only for a better understanding of the subject matter and without any limiting effect.

[0032] A boron-compounded cable production method, the exemplary appearance of which is given in Figure 1, developed with the present invention, preferably made of aluminum material, comprising at least one conduction layer (1) includes the steps of providing electrical power, data and / or signal transmission, preferably suitable for use in systems operating at high temperatures such as solar systems, and enabling the production of a cable structure suitable for use in systems operating at high temperatures such as solar systems, and increasing its resistance and flexibility against physical and chemical external effects such as fire, corrosion, moisture, impact, increasing insulation and transmission efficiency, reducing surface friction resistance and toxic gas emission in case of ignition, at least one reinforcing material, preferably polyvinyl chloride (PVC) and / or polyethylene (PE), preferably containing a UV stabilizer, radical initiator, lubricant, strength enhancer and / or anti-static agent, in at least one first material with polymer properties, providing joint and structure formation, adding at least one boron compound, preferably zinc borate, sodium metaborate, calcium borate and / or barium metaborate, and a silane compound, preferably with a vinyl group, and obtaining the powder mixture, preferably using a spiral mixer; blending of the first mixture by extrusion process, preferably using a double screw extruder, and then obtaining granular pellets by turning the blend obtained into granule / pellet form, preferably using a granulator; impregnation of at least one silane compound, preferably siloxane compounds containing vinyl groups (Vinyl Terminated Polydimethyl Siloxane (PDMS), Vinyltrimethoxysilane, Vinyltriethoxysilane etc.), preferably under 2-10 bar pressure value and in a closed environment with a temperature value of 30-40 °C for 20-26 hours; preferably by centrifugation after impregnation ), at least one silane compound, preferably under a pressure of 2-10 bar and a temperature of 30-40 °C in a closed environment for 20-26 hours; preferably after the impregnation process, the silane compound is separated from the granule pellets by centrifugation and then the impregnation process is repeated; preferably by continuously increasing the pressure and / or temperature to increase the amount of silane compound impregnated so that the glass transition temperature Tg of the polymer remains below the limit value; the pellets impregnated with silane compound are transferred to the extrusion line to be used as raw material for at least one first protection layer (2), preferably a filling, insulating and / or sheathing layer, which provides protection of the transmission layer (1); coating the first protection layer (2) impregnated with a silane compound and containing a boron compound on the conduction layer (1), preferably by extrusion at a temperature of 160-180°C, so as to envelop the conduction layer (1) and to form the cable structure.

[0033] In an exemplary application of the boron-compounded cable production method developed with the present invention, the raw materials of the polymeric materials to be used for insulation, filling and outer sheath are PVC (polyvinyl chloride) and PE (polyethylene). By using the necessary reinforcing elements (UV stabilizer, radical initiator, lubricant, strength enhancer, anti-static agent, etc.) and catalysts, the polymeric material is made suitable for cross-linked cabling with groups containing HFFR (halogen free flame retardant) agents (Magnesium Hydroxide and / or Alimunium Hydroxide) and HMDZ and / or Maleic Andidrite. EVA is generally used as a plasticizer in polymeric materials with HFFR properties. PE, zinc borate, sodium metaborate, calcium borate, barium metaborate, ATH (aluminum hydroxide), MDH (magnesium hydroxide), EVA (ethylene vinyl acetate) and silane compounds are added to PVC polymeric material with the help of a double screw extruder and these materials are included in the production process by providing fire retardant properties. All compounds in powder form, except silane compound and including stabilizers, are mixed in spiral mixers and then blended with PVC or PE with the help of a double screw extruder to obtain the desired particle size in the granulator line to form granules. After granular pellets are produced, silane compounds are impregnated into these granules in a closed container under pressure. For 24 hours, the silane compound is impregnated into the granules at a temperature of 30-40 °C under pressure between 2-10 bar. After separation of the residual silane compound from the granules by centrifugation, the same process is repeated for further impregnation. The percentage amount of the impregnated silane compound is evaluated by weight determination and if the amount of silane compound remains below a targeted value, the targeted value is reached by continuous mixing under increasing pressure and temperature (provided that the Tg value of the polymer remains below). Through this method, the decrease in the mechanical properties of the polymer, which occurs in the process of doping silane compounds into polymer granules by double screw extruder method, is minimized. At the same time, there is a more homogeneous silane doping. After impregnating the polymer with silane compound, PVC granules in pellet form are produced by mixing other additives in powder form homogeneously in a double screw extruder. After the silane compound-impregnated boron-compounded composite material is used as a filling and / or insulation raw material, it is included in the extrusion line to create the outer sheath of the cable. The outer sheathed cable structure exits the last stage of the extrusion line at a temperature of 170°C and is cooled to form the cable structure. In this method, the doping of PVC polymer with PE and silene compounds improves the mechanical performance of the polymer, resulting in a cable structure with a first protection layer (2) containing a longer lasting filling and insulation material.

[0034] In a preferred embodiment of the invention, the mentioned boron-compounded cable production method uses halogen-free flame retardant (HFFR) agent, Magnesium Hydroxide and / or Aluminum Hydroxide, Ethylene Vinyl Acetate (EVA), aluminum hydroxide (ATH) into the said first material, and / or adding at least one second material containing magnesium hydroxide (MDH).

[0035] In another preferred embodiment of the invention, said boron-compounded cable production method comprises the step of cooling the hot cable structure formed after the coating process by immersing it in boron oil and forming a second protection layer (3) on said first protection layer (2) with mechanical properties and physical strength higher than said first protection layer (2) by impregnating said first protection layer (2) with boron oil. In cable structure production, by cooling the cable structure with boron oil at the exit of the extruder, the wear resistance of the first protection layer (2) and the corrosion resistance of the said conduction layer (1) are increased. On the other hand, through the anti-bacterial properties of boron compounds, the cable structure produced features such as preventing bacterial growth and reducing smoke formation during fire due to its flame dampening properties. With the addition of boron, radiation absorbing properties are also obtained along with the protection of the cable structure against possible rodents. Also, by adding flexibility to the cable structure, the possibility of use is increased, especially in solar cables with aluminum conductors.

[0036] A boron-compounded cable production method, which is mentioned in another preferred embodiment of the invention includes the step of coating the conductor layer (1), the diameter of which is preferably brought to a value suitable for the field of use of the cable by rolling or hot forming process, by immersion in boron oil before the coating process, and the step of forming a third protection layer (4) between the said conductor layer (1) and the first protection layer (2), which reduces the surface roughness of the conductor layer (1) and increases its resistance to flammability and abrasion and its brightness.

[0037] A boron-compounded cable structure developed with the present invention, obtained by the boron- compounded cable production method, comprising at least one conduction layer (1) providing electrical power, data and / or signal transmission, providing resistance to physical external effects such as fire, corrosion, moisture, rust, impact, increasing flexibility, insulation and transmission efficiency, surface friction resistance and reducing toxic gas emission in case of ignition, positioned on the conduction layer (1) so as to surround it, at least one first material with polymer properties, at least one reinforcing material, preferably a UV stabilizer, radical initiator, lubricant, strength enhancer and / or anti-static agent, halogen free flame retardant (HFFR) agent, at least one second material containing Magnesium Hydroxide and / or Aluminum Hydroxide, Ethylene Vinyl Acetate (EVA), aluminum hydroxide (ATH) and / or magnesium hydroxide (MDH), at least one boron compound, preferably zinc borate, sodium metaborate, calcium borate and / or barium metaborate and at least one silane compound, preferably siloxane compounds containing vinyl groups (Vinyl Terminated Poly dimethyl Siloxane (PDMS), Vinyltrimethoxy silane, Vinyltriethoxysilane, Vinyltriethoxysilane, etc.), at least one first protection layer (2), preferably a filling, insulation and / or sheath layer, which provides protection of the conduction layer (1) from physical external influences, at least one first protection layer (2) containing at least one silane compound (Vinyl Terminated Polydimethyl Siloxane (PDMS), Vinyltrimethoxysilane, Vinyltriethoxysilane, Vinyltriethoxysilane, etc.), preferably a filling, insulation and / or sheath layer, which provides protection of the transmission layer (1) from physical external influences; a second protection layer (3), which is positioned above the first protection layer (2) so as to surround it, contains boron oil, and has mechanical properties and physical resistance strength higher than the first protection layer (2); a third protection layer (4), preferably positioned between the conduction layer (1) and the first protection layer (2), containing boron oil, which reduces the surface roughness of the conduction layer (1) and increases its flame and abrasion resistance and brightness.

[0038] Through the boron compounded-cable production method and cable structure developed with the present invention, it is ensured that boron and silane compounds are used as raw materials in the production of filling, insulation and / or sheath sections of the cable including the conductor layer (1) and an extra protection layer is formed on the conductor layer (1) and / or the first protection layer (2) by using boron oil. Besides, an effective, functional, efficient and safe boron- compounded cable production method and boron-compounded cable structure obtained with this method, which enables the penetration of silane compounds into the pellets and homogeneous dispersion rate of silane compounds, increasing the resistance efficiency against physical and chemical external factors such as fire, corrosion, moisture, impact, improving mechanical properties and reducing the production cost as well as the harm to human / environmental health, is obtained by impregnating silane compounds into granule pellets.

Claims

CLAIMS1. A boron-compounded cable production method that enables the production of a cable structure including at least one conduction layer (1) that provides electrical power, data and / or signal transmission and increases its resistance to physical and chemical external influences such as fire, corrosion, moisture, impact, as well as its flexibility, insulation and transmission efficiency, surface friction resistance and reduction of toxic gas emission in case of ignition, the method comprising the steps of: adding at least one boron compound to at least one first material with polymer properties and obtaining the powder mixture; blending the said first mixture by extrusion and then obtaining granule pellets by turning the resulting blend into granule / particle form; impregnating the granular pellets with at least one silane compound under the influence of pressure; transferring the pellets impregnated with the silane compound to the extrusion line for use as raw material for at least one first protection layer (2), which ensures the protection of said conduction layer (1); coating the first protection layer (2) impregnated with silane compound and containing boron compound on said conduction layer (1) by extrusion process so as to envelop said conduction layer (1) and forming the cable structure.

2. A boron-compounded cable production method according to claim 1, wherein the said conduction layer (1) is made of aluminum material.

3. A boron-compounded cable production method according to claim 1, wherein the said cable structure is suitable for use in high temperature systems such as solar systems.

4. A boron-compounded cable production method according to claim 1, wherein the first material is polyvinyl chloride (PVC) and / or polyethylene (PE).

5. A boron-compounded cable production method according to claim 1, comprising the step of adding at least one reinforcing material, preferably containing a UV stabilizer, radical initiator, lubricant, strength enhancer and / or anti-static agent, together with the boron compound, to the first material, providing j oint and structure formation.

6. An organic-content cable according to claim 1, comprising the step of adding the silane compound into the first material.

7. A boron-compounded cable production method according to claim 1, wherein the said boron compound is zinc borate, sodium metaborate, calcium borate and / or barium metaborate.

8. A boron-compounded cable production method according to claim 1, comprising the step of obtaining the powder mixture using a spiral mixer.

9. A boron-compounded cable production method according to claim 1, comprising the step of blending said first mixture by extrusion using a double screw extruder.

10. A boron-compounded cable production method according to claim 1, comprising the step of obtaining granular pellets by blending the blended first mixture into granules / pellets using a granulator.

11. A boron-compounded cable production method according to claim 1, wherein the silane compounds are siloxane compounds containing vinyl groups (Vinyl Terminated Polydimethyl Siloxane (PDMS), Vinyltrimethoxysilane, Vinyltriethoxysilane etc.)12. A boron-compounded cable production method according to claim 1, comprising the step of impregnating the silane compound for 20-26 hours in a closed environment under a pressure value of 2-10 bar and a temperature value of 30-40 °C.

13. A boron-compounded cable production method according to claim 1, comprising the step of separating the silane compound from the granule pellets by centrifugation after the impregnation process, and then repeating the impregnation process.

14. A boron-compounded cable production method according to claim 1, comprising the step of applying continuous mixing process by increasing the pressure and / or temperature values to increase the amount of impregnated silane compound so that the glass transition temperature of the polymer remains below the Tg limit value.

15. A boron-compounded cable production method according to claim 2, wherein the first protection layer (2) is a filling, insulation and / or sheathing layer.

16. A boron-compounded cable production method according to claim 1, wherein the said extrusion process is at a temperature of 160-180°C.

17. A boron-compounded cable production method according to claim 1, comprising the step of adding at least one second material containing halogen free flame retardant (HFFR) agent, Magnesium Hydroxide and / or Aluminum Hydroxide, Ethylene Vinyl Acetate (EVA), aluminum hydroxide (ATH) and / or magnesium hydroxide (MDH) and / or EIMDZ and / or Maleic Andydride to the first material.

18. A boron-compounded cable production method according to claim 1, comprising the step of cooling the hot cable structure formed after the coating process by immersing it in boron oil and impregnating said first protection layer (2) with boron oil to form a second protection layer (3) on said first protection layer (2), the mechanical properties and physical strength of which are higher than said first protection layer (2).

19. A boron-compounded cable production method according to claim 1, comprising the step of coating the conduction layer (1), the diameter of which is brought to a value suitable for the field of use of the cable, preferably by rolling or hot forming process, by immersion in boron oil before the coating process, and the step of forming a third protection layer (4) between the said conduction layer (1) and the first protection layer (2), which reduces the surface roughness of the conductive layer (1) and increases its resistance to flammability and abrasion and its brightness.

20. A boron-compounded cable structure obtained by a boron-compounded cable production method according to any one of the preceding claims, comprising at least one conduction layer (1) providing electrical power, data and / or signal transmission, increasing flexibility,insulation and transmission efficiency with resistance to physical and chemical external effects such as fire, corrosion, moisture, impact, increasing surface friction resistance and reducing toxic gas release in case of ignition, characterized in that: at least one first protection layer (2), which is positioned above said conduction layer (1) so as to surround it, comprises at least one first material having polymer properties, at least one boron compound and at least one silane compound, which protects said conduction layer (1) from physical external influences; a second protection layer (3) which is positioned on top of the first protection layer (2) so as to surround it, comprises boron oil, wherein it provides mechanical properties and physical resistance strength higher than the first protection layer (2).

21. A boron-compounded cable structure according to claim 20, wherein the first protective layer (2) comprises at least one reinforcing material which is a UV stabilizer, radical initiator, lubricant, strength enhancer and / or anti-static agent.

22. A boron-compounded cable structure according to claim 20, wherein the first protective layer (2) comprises at least one second material containing halogen free flame retardant (HFFR) agent, Magnesium Hydroxide and / or Aluminum Hydroxide, Ethylene Vinyl Acetate (EVA), aluminum hydroxide (ATH) and / or magnesium hydroxide (MDH) and / or HMDZ and / or Maleic Andydride.

23. A boron-compounded cable structure according to claim 20, wherein the boron compound is zinc borate, sodium metaborate, calcium borate and / or barium metaborate.

24. A boron-compounded cable structure according to claim 20, wherein the silane compounds are siloxane compounds comprise vinyl groups (Vinyl Terminated Polydimethyl Siloxane (PDMS), Vinyltrimethoxysilane, Vinyltriethoxysilane, etc.).

25. A boron-compounded cable structure according to claim 20, wherein the first protection layer (2) is a filling, insulation and / or sheathing layer.

26. A boron-compounded cable structure according to claim 20, wherein the structure further comprises a third protection layer (4) of said cable structure, positioned between saidconduction layer (1) and the first protection layer (2), containing boron oil, which reduces the surface roughness of said conduction layer (1) and increases its flame and abrasion resistance and gloss.

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