JPH11213766A - 発泡電線 - Google Patents
発泡電線Info
- Publication number
- JPH11213766A JPH11213766A JP10024026A JP2402698A JPH11213766A JP H11213766 A JPH11213766 A JP H11213766A JP 10024026 A JP10024026 A JP 10024026A JP 2402698 A JP2402698 A JP 2402698A JP H11213766 A JPH11213766 A JP H11213766A
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- Prior art keywords
- foamed
- insulating layer
- polyolefin
- foaming
- insulated wire
- Prior art date
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0233—Cables with a predominant gas dielectric
Landscapes
- Organic Insulating Materials (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
mm以下の発泡ポリオレフィン絶縁電線で、 (イ)等価誘
電率<1.45、 (ロ)耐潰れ変形率≦20%の両方の要
件を兼備する、発泡ポリオレフィン絶縁電線。 ポリ
オレフィンとしてアイオノマー/ポリプロピレン樹脂=
20:80〜80:20重量部よりなる混合物を使用す
ること。絶縁層が、発泡絶縁層/他のポリオレフィン
を主体とする充実絶縁層の複合構造。絶縁層が、ポリ
エチレン又は酸変性ポリエチレンの充実絶縁層/発泡絶
縁層/他のポリオレフィンを主体とする充実絶縁層の複
合構造。 【効果】 薄肉から厚肉までの比較的広い範囲の絶縁層
肉厚に対して高発泡度の発泡ポリオレフィン絶縁電線が
製造できる。
Description
信ケーブル用の情報電線に用いられる薄肉から厚肉まで
の高発泡ポリオレフィン絶縁電線に関する。詳細には、
本発明は、耐変形性及び絶縁性等の電気特性に優れた、
様々な発泡絶縁層厚みで且つ高発泡度の、特に薄肉ポリ
オレフィン絶縁電線に関する。
は、通常、ポリオレフインに化学発泡剤を添加した組成
物を使用するかあるいは不活性ガス発泡剤を使用して発
泡させている。情報伝送速度の高速化、電子機器の軽薄
短小化を進めるために、情報電線は更なる高発泡化、細
径化、薄肉化が要求されている。これに対応すべく通信
ケーブル用の情報電線の絶縁被覆として、これまで様々
な密度、分子量、分子量分布を持ったポリエチレンに化
学発泡剤を添加した組成物を使用するかあるいは不活性
発泡剤を使用して発泡させた発泡絶縁層を用いている
が、60%以上の発泡度と絶縁層肉厚2mm以下を両立
して安定に製造できる材料では、外からの圧力に対して
電線が変形しやすく、電気特性が安定しない。また、通
信ケーブル用の情報電線の絶縁被覆として、60%以上
の発泡度と絶嫁層肉厚2mm以下を比較的安定に製造で
きる材料でも、導体と絶縁層の間に隙間が生じやすく導
体が電線の中心から移動し電気特性が安定しない。
について種々検討した結果、特定のパラメータで表され
た耐潰れ変形性及び絶縁性等の電気特性に優れた発泡絶
縁層を有する新規な様々な発泡絶縁層厚みで且つ高発泡
度の発泡ポリオレフィン絶縁電線が通信ケーブル用に適
することを見出し、且つ特に、発泡ポリオレフィン絶縁
電線を構成する発泡絶縁材としてアイオノマー樹脂とポ
リプロピレン樹脂との特定割合の混合物を使用すること
により、特に薄肉で且つ高発泡の発泡ポリオレフィン絶
縁電線を提供できることを見出し、本発明を完成するに
至った。
ポリオレフィン絶縁電線であって、 等価誘電率が1.45より小さい、 耐潰れ変形率が20%以下である、 という両方の要件を兼備する、発泡ポリオレフィン絶縁
電線を提供する。また、(2) ポリオレフィンとしてカ
ルボン酸又はカルボン酸無水物基含有共単量体を含む共
重合体の部分金属塩/ポリプロピレン樹脂が20:80
〜80:20重量部よりなる混合物を使用する点にも特
徴を有する。また、(3) (1) 記載の発泡ポリオレフィ
ン絶縁電線の発泡絶縁層の上層に、更に他のポリオレフ
ィンを主体とする樹脂組成物からなる充実絶縁層を設け
る点にも特徴を有する。また、(4) 更に、導体と上記
発泡絶縁層との間にポリエチレン又はその酸変性ポリエ
チレンからなる充実絶縁層を介在させる点にも特徴を有
する。
泡樹脂材としては、特に、アイオノマー樹脂とポリプロ
ピレン樹脂との20:80〜80:20重量部、好まし
くは40:60〜60:40よりなる混合物を使用する
ことが必要である。ここで言うアイオノマー樹脂とは、
カルボン酸又はカルボン酸無水物基含有共単量体を含む
共重合体の部分金属塩を指し、代表的にはエチレンとカ
ルボン酸又はカルボン酸無水物、特にα,β不飽和カル
ボン酸又はそのカルボン酸無水物との共重合体の部分金
属塩を指し、例えば特公昭39−6810号公報に記載
される方法によって製造できる。
ー樹脂が20%未満であると、50%以上の高発泡の発
泡ポリオレフィン絶縁電線が得られない。一方、アイオ
ノマー樹脂が80%を越えると発泡層の肉厚が200〜
2000μmであって、零に近い比較的低い発泡度から
80%前後の高い発泡度までの発泡ポリオレフィン絶縁
電線が得られるが、発泡絶縁層が柔らかくなり、外から
の圧力に対して電線が変形し易く、電気特性が安定しな
い。ところが、発泡絶縁層を構成するアイオノマー樹脂
とポリプロピレン樹脂との割合が20:80〜80:2
0重量部の範囲で構成されていると、50μm〜200
0μmまで、特に1mm以下の薄肉の発泡絶縁層厚みで
比較的低い発泡度から80%前後の高い発泡度まで、特
に60%以上の高発泡度の発泡ポリオレフィン絶縁電線
を得ることができる。
構成する要素の1つであるアイオノマーは、カルボン酸
又はカルボン酸無水物基含有共単量体を含む共重合体の
部分金属塩を指す。具体的には、エチレンとアクリル
酸、メタクリル酸、エタクリル酸、イタコン酸、フマル
酸等の炭素数3〜8のα,β不飽和カルボン酸又はその
カルボン酸無水物との共重合体;またはこれに更にアク
リル酸メチル、アクリル酸エチル、アクリル酸イソブチ
ル、アクリル酸nブチル、メタクリル酸メチル、メタク
リル酸エチル、メタクリル酸nブチル、メタクリル酸イ
ソブチル、フマル酸ジメチル等の炭素数4〜8のα,β
不飽和カルボン酸エステルを第3成分として含有する3
元共重合体中のカルボン酸又はその無水物基の一部又は
全部を金属イオン架橋させたものである。
は2種以上を混合して用いても良い。このように、上記
共重合体の部分金属塩は、特にエチレンと炭素数3〜8
のα,β不飽和カルボン酸又はそのカルボン酸無水物と
の共重合体の分子間が金属イオンで架橋された構造を有
するものである。好ましくはエチレンとアクリル酸及び
/又はメタクリル酸の共重合体の亜鉛、ナトリウム、カ
リウム、マグネシウムの部分金属塩である。該共重合体
の部分金属塩のMFRは、約0.1〜500、好ましく
は約1〜100である。共重合体の部分金属塩のMFR
が約0.1未満では成形性が不良となり、逆に500を
超えると発泡層の強度が不足する。
水物成分の含有量は、一般に約0.5〜15モル%、好
ましくは約1〜6モル%である。共重合体中のカルボン
酸又はカルボン酸無水物成分の含有量が約0.5%未満
では導体との接着力が不足となるし、また15モル%を
超えて含有しても電線被覆が変形し易くなり好ましくな
い。更に、第3成分としてα,β不飽和カルボン酸エス
テルを含有させても良く、そのエステルの含有量は、一
般に約0.2〜15モル、好ましくは約1〜10モル%
である。
しては、リチウム、ナトリウム、カリウム、セシウム等
の1価金属イオン;マグネシウム、カルシウム、ストロ
ンチウム、バリウム、銅、亜鉛等の2価金属イオンまた
はアルミニウム、鉄等の3価金属イオンが挙げられる。
特に、金属イオンとして亜鉛イオン、ナトリウムイオン
を用いたものは、低吸湿性であるために電気特性の変化
が少なく好ましい。金属化合物の形で用いられる金属イ
オンは、上記共重合体中の酸の含量、190℃及び21
50g荷重におけるMFR(メルトフローレート、g/
10分)等によってその添加量が変化するが、一般には
約10%以上、好ましくは約15〜80%のカルボン酸
又はその無水物基を中和する量で用いられる。
プロピレン:発泡絶縁層に用いるアイオノマー樹脂とブ
レンドするポリプロピレン樹脂としては、ポリプロピレ
ンホモポリマーの他にエチレンとのブロックコポリマー
やランダムコポリマーを用いても良い。該ポリプロピレ
ン樹脂のMFRはアイオノマーと十分にブレンドできて
発泡成形できれば特に制限されないが、通常0.5〜1
0、好ましくは2〜5を用いるのが望ましい。
は、必要に応じて通常樹脂に含まれる添加剤を配合して
もよい。該添加剤としては、酸化防止剤、光安定剤、紫
外線防止剤、帯電防止剤、滑剤、有機又は無機の充填
剤、金属不活性化剤、核剤、染顔料等を挙げることがで
きる。
実絶縁層: (i) (最)上層のポリオレフィン系充実絶縁層 本発明では、発泡絶縁層の(最)上層に他のポリオレフ
ィンを主体とする樹脂組成物からなる充実(即ち、未発
泡)絶縁層を設けても良い。このように未発泡層を最外
層に配置することで、耐摩耗性の向上、側圧による発泡
電線の変形が少なくなる等の機械的特性に加えて、発泡
時の発生ガスが絶縁体中に留まり易くなるために更なる
高発泡化が可能となる。該ポリオレフィンとしては、ポ
リエチレン、ポリプロピレン、エチレン−αオレフィン
共重合体、エチレン−酢酸ビニル共重合体、エチレン−
アクリル酸エチル共重合体、エチレン−アクリル酸メチ
ル共重合体等が挙げられる。特にポリエチレン、例えば
低密度、直鎖状低密度、超低密度、中密度又は高密度の
ポリエチレン;或いはポリプロピレン、例えばポリプロ
ピレンホモポリマー、エチレン−プロピレンブロック又
はランダム共重合体を使用することが好ましい。
て、導体と発泡絶縁層との間にポリエチレン又はその酸
変性ポリエチレン(例えば無水マレイン酸変性ポリエチ
レン)からなる充実絶縁層を介在させても良い。導体/
ポリエチレン充実絶縁層/発泡絶縁層/他のポリオレフ
ィン充実絶縁層の3層構造発泡ポリオレフィン絶縁電線
にすると、発泡時の発生ガスが導体側に抜けることも防
ぐことができ、また導体と絶縁層の隙間も一層低減する
ことができ、高発泡化と電気特性の安定化が期待でき
る。
み:ポリオレフィン系充実絶縁層の厚みは、特に制限さ
れないが、一般に0.01〜0.5mm程度のその機能
を発揮できる範囲とする比較的薄い厚みの適用が望まし
い。
フィン系充実絶縁層との複合絶縁層の押出被覆:このよ
うな複合絶縁層の形成には、多層押出機を用いて、例え
ば二層押出機の一方のダイ通路に加熱溶融したポリオレ
フィン系材料を導体上に一定の厚みで押出被覆し、更に
他方のダイ通路に発泡剤混入済みポリオレフィン材料を
上記ポリオレフィン系充実絶縁層上に発泡押出被覆させ
る。勿論、更に、導体に密接してポリオレフィン系充実
絶縁層を設ける複合絶縁層を形成する場合には、三層押
出機を用いて、最内層に相当するダイ通路に加熱溶融し
たポリオレフィン系材料を導入すれば良い。これら押出
被覆は同時でも逐次操作でも良い。
φ以下の導体上に、発泡絶縁被覆厚2mm以下となるよ
うに発泡度を調整し発泡押出被覆して、 等価誘電率が1.45より小さく、 耐潰れ変形
率が20%以下の両方の要件を兼備するように、発泡ポ
リオレフィン絶縁電線とする必要がある。上記発泡絶縁
材料は、予め単軸又は多軸押出機、バンバリーミキサー
を用いて混練して均一配合物にすることが望ましい。
と発泡絶縁厚 本発明では、発泡樹脂材としてアイオノマー樹脂/ポリ
プロピレン樹脂との特定割合の混合物を発泡押出するの
で、発泡導体径1mmφ以下、好ましくは0.5mmφ
以下の細径導体上に、発泡絶縁被覆厚2mm以下、好ま
しくは0.8mmφ以下に押出被覆することができる。
この場合、導体径の下限については一定の電線強度が得
られるなら特に制限されないが、通常0.2mmφ程度
あれば良い。また、発泡絶縁層の厚みの下限は、低い等
価誘電率が得られ且つ耐潰れ変形率が20%以下と変形
し難いなら特に制限されないが、通常0.1mm程度あ
れば良い。
発泡剤(蒸発型発泡剤)を練り込んだ発泡絶縁材料を押
出機に装填して導体上に、一般に溶融押出温度150〜
250℃で、幅広い発泡度(低発泡度から高発泡度ま
で)で、特に60%以上の高発泡の様々な発泡絶縁層厚
みで且つ行われる。上記発泡剤の使用量は、目的とする
発泡倍率、使用する発泡剤の種頚により適宜選択すれば
よい。アイオノマーの含量が所定の範囲にあれば発泡度
は任意に設定でき、低発泡度から高発泡度のものまで発
泡押出できて、広い範囲の発泡絶縁厚みの発泡絶縁層が
得られる。
い、高発泡度及び低い耐潰れ変形率で表される高い強度
と低い等価誘電率で表される良好な電気特性を示す発泡
絶縁厚とについて、本発明によると発泡度と発泡絶縁厚
との両立が可能となり、即ち、60%以上、好ましくは
65%以上の発泡度でも、発泡絶縁厚2mm以下、好ま
しくは0.8mm以下の薄肉の発泡絶縁層を形成でき
て、 (イ)等価誘電率<1.45で、 (ロ)耐潰れ変形率≦
20%と言う両方の要件を兼備する発泡絶縁電線が得ら
れる。
レフィン樹脂材料に練り込んだものを押出発泡を行う
が、ベース樹脂全体にこれらの発泡剤を練り込んでも良
いし、予め樹脂の一部に高濃度で発泡剤を練り込んだマ
スターバッチを作っておき、これをベース樹脂とドライ
ブレンドして押出しても良い。 4)発泡度は比重法で測定され、その場合下記式(1)で
定義される。
は、 (イ)化学発泡剤をポリオレフィン絶縁材料に添加し
た混合物を溶融押出機で導体に被覆し押出と同時に発泡
させる化学発泡法、 (ロ)物理発泡剤を溶融押出機内で圧
入し、ポリオレフィン絶縁材料を導体に被覆して押出と
同時に発泡させるガス発泡法或いは (ハ)化学発泡剤の使
用量を極めて少量にして両方式を併用しても良い。
上に加熱されると窒素、二酸化炭素、アンモニア等のガ
スを発生する有機及び無機化合物であり、例えばアゾジ
カルボンアミドおよびその金属塩、4,4’−オキシビ
ス(ベンゼンスルホニルヒドラジド)、各種金属の炭酸
塩、ジニトロソペンタメチレンテトラミン、トルエンス
ルホニルヒドラジド等を挙げることができ、特にアゾジ
カルボンアミドの使用が好ましい。これらの化学発泡剤
は単独又は2種以上を組み合わせて使用しても良い。
ン、炭酸ガス等の不活性ガス;メタン、プロパン、ブタ
ン、ペンタン、ヘキサン、フルオロカーボン等の気体を
挙げることができ、特に窒素の使用が好ましい。 4)発泡助剤;更に、発泡助剤を併用しても良い。例え
ば尿素、尿素系化合物、亜鉛華、ステアリン酸亜鉛等の
発泡助剤を挙げることができる。
ペアケーブルとしたり、複数本を含む多芯ケーブルとし
たり、平行にならべたテープ状電線とすることもでき
る。さらに、この電線に予め架橋剤を配合して行う化学
架橋を行っても或いは電子線などの放射線を照射して架
橋しても良い。
法で製造されるが、導体径1mmφ以下、発泡絶縁被覆
厚2mm以下であって、且つ 等価誘電率が1.45より小さく、好ましくは1.
4より小さく、より好ましくは1.35以下である。 耐潰れ変形率が20%以下、好ましくは15%以
下、より好ましくは10%以下である。 上記の場合に、 等価誘電率が1.45以上と高い
と、信号の伝送速度が遅くなり好ましくない。また、
耐潰れ変形率が20%を超えて大きいと、配線時或いは
配線後に電線に側圧を受けた時に電気性能が不安定にな
る。
を、製造した発泡ポリオレフィン絶縁電線の上に図1に
示すように載せ、500gの荷重をかけて10分間放置
して、耐潰れ変形率の測定を行う。荷重をかける前の導
体外径と荷重をかけた後の電線外径を測定して次式(2)
で定義される変形率を求める。 2)耐潰れ変形率は下記式(2)で定義される。
変形率が大きいと、配線時或いは配線後に電線に側圧を
受けた時に電気性能が不安定になる。
比較例により詳細に説明するが、これらは本発明の範囲
を制限するものではない。 ・電線の外径および各層の厚みは電線断面の光学顕微鏡
撮影により行った。 ・等価誘電率は静電容量、導体外径、電線外径を測定
し、下記式(3)により計算した。
各材料を170℃に設定した8インチのオープンロール
ミキサーで混練した後、ベレタイザーにてベレット化
し、0.3mmφのニッケルメッキ線に単軸溶融押出機
(30mmφ、L/D=24)を用いて、押出温度20
0℃の条件で押出成型して発泡電線を作成した。また、
充実(未発泡)層と発泡層との積層構造の電線も単軸押
出機(30mm¢、L/D=24)を組み合わせた装置
にて、各層同時に押出成型する。
ロピレン樹脂=80:20重量部で50〜2000μm
の発泡絶縁体で発泡度約80%が達成できることが判
る。これに対して、アイオノマー樹脂/ポリプロピレン
樹脂=90:10重量部の比較例1、2では、発泡度が
70〜75%前後と比較的高発泡度が可能となるが、変
形率が大きく良好でない。
リプロピレン樹脂=20:80重量部でやはり約80%
の高発泡度が得られることが判る。これに対して、アイ
オノマー樹脂/ポリプロピレン樹脂=10:90重量部
の比較例3では、発泡度が60%に達しない。 3)アイオノマーを使用しない比較例4、5、6では、
例えば比較例4、5では発泡度が50%前後に留まり高
発泡度が得られず、また比較例6では発泡度が70%以
上と高発泡であるが変形率が50%とやはり良好でな
い。
ピレンの代わりにポリエチレンを用いたものでもやはり
発泡度は80%に遠く及ばない。 5)実施例6、7では、それぞれ実施例2、3の発泡ポ
リオレフィン絶縁電線の発泡絶縁層の外層にポリエチレ
ンの未発泡層を被覆したものであるが、未発泡層が無い
ものよりも発泡度が向上し好ましい。
6、7で導体周りに酸変性ポリエチレンの未発泡充実層
を被覆したものであるが、発泡絶縁層の外側に未発泡層
を被覆した実施例6、7の場合ものより更に発泡度が大
きくなることが判った。これに対して、比較例8、9、
10、11では、発泡層の外側あるいは/および導体周
りに未発泡層を被覆しても、発泡層がアイオノマー樹脂
/ポリプロピレン樹脂=20:80〜80:20重量部
含まれて構成されていないと80%の高発泡度が得られ
ないことが示されている。
ば、薄肉から厚肉までの比較的広い範囲の絶縁層肉厚に
対して高発泡度の発泡ポリオレフィン絶縁電線が製造で
きる。
模式図である。
Claims (4)
- 【請求項1】 導体径1mmφ以下、絶縁被覆厚2mm
以下の発泡ポリオレフィン絶縁電線であって、 等価誘電率が1.45より小さい、 耐潰れ変形率が20%以下である、 という両方の要件を兼備することを特徴とする、発泡ポ
リオレフィン絶縁電線。 - 【請求項2】 ポリオレフィンとしてカルボン酸又はカ
ルボン酸無水物基含有共単量体を含む共重合体の部分金
属塩/ポリプロピレン樹脂が20:80〜80:20重
量部よりなる混合物を使用することを特徴とする、請求
項1記載の発泡ポリオレフィン絶縁電線。 - 【請求項3】 請求項1記載の発泡ポリオレフィン絶縁
電線の発泡絶縁層の上層に、更に他のポリオレフィンを
主体とする樹脂組成物からなる充実絶縁層を設けること
を特徴とする、請求項1又は2記載の発泡ポリオレフィ
ン絶縁電線。 - 【請求項4】 更に、導体と上記発泡絶縁層との間にポ
リエチレン又はその酸変性ポリエチレンからなる充実絶
縁層を介在させることを特徴とする、請求項3記載の発
泡ポリオレフィン絶縁電線。
Priority Applications (2)
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---|---|---|---|
JP02402698A JP3267228B2 (ja) | 1998-01-22 | 1998-01-22 | 発泡電線 |
US09/196,741 US6239377B1 (en) | 1998-01-22 | 1998-11-20 | Foamed-polyolefin-insulated wire |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP02402698A JP3267228B2 (ja) | 1998-01-22 | 1998-01-22 | 発泡電線 |
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Publication Number | Publication Date |
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JPH11213766A true JPH11213766A (ja) | 1999-08-06 |
JP3267228B2 JP3267228B2 (ja) | 2002-03-18 |
Family
ID=12127024
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JP02402698A Expired - Fee Related JP3267228B2 (ja) | 1998-01-22 | 1998-01-22 | 発泡電線 |
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US (1) | US6239377B1 (ja) |
JP (1) | JP3267228B2 (ja) |
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- 1998-01-22 JP JP02402698A patent/JP3267228B2/ja not_active Expired - Fee Related
- 1998-11-20 US US09/196,741 patent/US6239377B1/en not_active Expired - Fee Related
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KR100375663B1 (ko) * | 2000-12-18 | 2003-03-15 | 삼성종합화학주식회사 | 압출코팅용 폴리프로필렌 수지 조성물 |
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