CA1288971C - Heat sensitive cable and method of making same - Google Patents
Heat sensitive cable and method of making sameInfo
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- CA1288971C CA1288971C CA000530620A CA530620A CA1288971C CA 1288971 C CA1288971 C CA 1288971C CA 000530620 A CA000530620 A CA 000530620A CA 530620 A CA530620 A CA 530620A CA 1288971 C CA1288971 C CA 1288971C
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Abstract
ABSTRACT OF THE DISCLOSURE
A heat sensitive cable capable of generating a temperature representative measurable voltage. The cable includes a pair of thermoelectric conductors disposed in contacting side-by-side relation together with an electrical insulation for passively self-generating a temperature rep-resentative measurable voltage between the conductors when the cable is exposed to ambient temperature. A flexible outer jacket formed of an electrically non-conductive mater-ial is provided to completely surround the conductors. The electrical insulation causes a change in the temperature representative measurable voltage with an increase or de-crease in temperature at every location along the jacket. A
change in the temperature representative measurable voltage under such condition is representative of a change in ambi-ent temperature. The electrical insulation also causes a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket. With this arrangement, the heat sensitive cable may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature.
A heat sensitive cable capable of generating a temperature representative measurable voltage. The cable includes a pair of thermoelectric conductors disposed in contacting side-by-side relation together with an electrical insulation for passively self-generating a temperature rep-resentative measurable voltage between the conductors when the cable is exposed to ambient temperature. A flexible outer jacket formed of an electrically non-conductive mater-ial is provided to completely surround the conductors. The electrical insulation causes a change in the temperature representative measurable voltage with an increase or de-crease in temperature at every location along the jacket. A
change in the temperature representative measurable voltage under such condition is representative of a change in ambi-ent temperature. The electrical insulation also causes a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket. With this arrangement, the heat sensitive cable may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature.
Description
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SPECIFICATION
HEAT SENSITIVE CABLE
AND METHOD OF MAKING SAME
Backqround Of The Invention The present invention relates to heat sensitive devices and, more particularly, to a heat sensitive cable and method of making same.
Heat sensitive cables which are characterized by the use of semiconductive materials having inverse tempera-ture-resistance characteristics in conjunction with dissimi-1-~ lar thermoelectric conductors are now well known in the art.
Such cables are particularly suitable where it is desired to monitor the greatest temperature existing along the length of the cable, and are exemplified in connection with a sys-tem for measuring and locating temperature conditions of interest in U.S. Patent Nos. 3,408,607 and 4,324,138. Ther-mistor cables which are characterized by a core of semicon-ductive material surrounded by a mass of temperature-resist-ant electrically-insulating material covered with a protec-tive metallic sheath are also well known in the art.
Despite the clear advantages and many applications for such cables, they have simply not evolved to the point of providing the desired degree of versatility. It has remained to develop a heat sensitive cable capable of gener-ating a measurable and predictable voltage when the entire length of cable is at ambient, e.g., 72F, wherein the cable is also adapted to provide a change in the temperature rep-resentative measurable voltage with an increase in tempera-ture above the prevailing ambient at any location along the cable. If this could be achieved with an electrical insula-tion having a negative temperature coefficient, the thermo-electric output of the cable or a section thereof would bealtered in a predictable fashion.
Moreover, if this could be achieved, the cable location where an increase in temperature takes place could be located electronically. This could be done, for in-stance, as fully disclosed and claimed in my earlier U.S.Patent No. 4,324,138, issued April 13, 1982, for a method of and apparatus and system for determlning temperature candi-tion~. As set forth therein, the applications are ~irtually limitless.
While the value of heat sensitive cable has l~ng been recognized, it has remained to provide such a cable having the requisite versatility ~or the many applications to be benefited by use thereof. In fact, despite my many prior inventions in this field, as exemplified by U.S. Pat-ent Nos. 3,408,607 and 3,513,432, the missing link to pro-viding a highly versatile cable has remained. Despite the advantages that will be recognized by those skilled in the art, heat sensitive cable which may not only be utilized to monitor ambient temperature but also may be utilized to monitor for any localized increase above ambient temperature has simply not been available.
Accordingly the present invention seeks to provide a heat sensitive cable having means for generat-lng a temperature re~resentative measurable voltage.
Further the present invention seeks to provide a cable of the type described utilizing a pair of thermoelectric conductors disposed in contacting side-by-side relation together with means for passively self-gener-ating a temperature representative measurable voltage be-tween the conductors when the cable is exposed to ambient temperature.
Further still the present invention seeks to provide a cable of the type described utiliæing a flexible outer jacket formed of an electrically non-conductive mater-ial to completely surround the conductors.
The present invention also seeks to provide a cable of the type described which is not only passive and self-generating to generate a voltage potential between the thermoelectric conductors indicati~e o the temperature exis~i~g alo~g ~he entire length o~ the ca~le, i.e., the ambient temperature, but which also generates a voltage potential between the ~onductorc indicative of the hottest point along the length of the cable i~ the tempera-tures ~re une~ual.
Still further the present in~ention seeks to provide a cab~e of the type described in which the passive self-generating characteristic causes a change in the temperature representative measurable voltage with an increase or decrease in temperature at every location along the jacket.
Furthe,,r still the present invention seeks to provide a cable of the type described in which the passive self-generating characteristic causes a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket.
Further still the present'invention seeks to provide a cable of the type described capable of precise, non-perishable, reproducible measurement of the temperature and identification of the location of the hot-test spot when monitoring with a high input impedance tem-perature device.
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The present invention still further seeks to provide a cable of the type described wherein the outer jacket and the thermoelectric conductors can be formed of various materials and combinations of materials to yield various mechanical properties and temperature-voltage response curves.
These and other aspects, advantages and features of the present invention will be apparent from a consideration of the accompanying specification, claims and drawings.
Summary Of The Invention Accordingly the present invention in one aspect provides a heat sensitive cable operable in a predictable fashion over a range of temperatures for generating a measurab~e voltage indicative of the temperature along the cable to proyide a contin~s tempelature sensor. The cable includes a pair of thermoelectric conductors disposed in contacting side-by-side relation with the conductors being formed of thermoelectrically dissimilar materials and with means for passively self-generating a continuous temperature xepresentative measurable voltage between the conductors when the cable is exposed to ambient temperature without the use of an external power source. The continuous temperature representative measurable voltage is adapted for conversion into ambient temperature measured in degrees, the passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of the conductors. A flexible outer jacket is formed of an electrically non-conductive material completely surrounding the conductors, the jacket holding the conductors firmly together substantially along their entire length. The passive self-generating means causes an increase or decrease in thecontinuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along the cable, the change in the voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion ~nto a new ambient temperature along the cable measured in degrees. The passive self-generating means also causes a change in the continuous temperature representative measurable ~oltage responsi~e to an associated increase in temperature above the prevailing ambient at any location along the cable, the change in the voltage under such condition also being measurable and representative of an increase in localized ternperature and adapted for '7~L
conversion into a maximum temperature along the cable measured in degrees. Thus the hea-t sensitive cable may be utili2ed not only to monitor ambient temperature but also to monitor for any localized increase in temperature over the range of temperatures for the cable in a predictable fashion to provide a continuous temperature sensor.
In a preferred embodiment, the passive self-generating means includes an electrical insulation having a negative temperature coefficient disposed on the surface of at least one oE the conductors. Preferably, the conductor is coated with a solution of manganese nitrate or the surface of the conductor is covered with heat treated manganese dioxide~
By so doing, the resulting electrical insulation which is formed on the surface of the conductor has a negative temperature coefficient and will provide the required temperature representative measurable voltage throughout the desired range of temperatures.
In addition, the pair of thermoelectric conductors disposed in contacting side-by-side relation are advantageously formed of thermoelectrically dissimilar materials. It has been found suitable, for instance, for one of the conductors to be formed of a nickel/chromium alloy and the other of the conductors to be formed of a copper/nickel alloy.
Specifically, the nickel/chromium alloy may comprise approximately 90 percent nickel and 10 percent chromium and the copper/nickel alloy may comprise approximately 55 percent copper and 45 percent nickel.
With regard to the flexible outer jacket, it is preferably formed of a material -that may be applied to completely surround the conductors in a fashion applying pressure to hold the conductors in contacting side-by-side relation. In this connection, the material may be of a type adapted to be extruded onto the conductors, or a material of -the type adapted to be heat shrunk onto the conductors, or a material of the type adapted to be wrapped onto the conductors.
Once -the material has been applied to the conductors to form the flexible outer jacket, the heat sensitlve cable may be stored on spools due to lts 1exibility and later may be removed and cut to length for use as needed.
~0 The invention also contemplates a method of manufacturing a heat sensitive cable operable in a predictable Eashion over a range of temperatures for generating a measurable voltage indica-tive of the temperature along the ~2~
cable to provide a continuous temperature sensor. The method includes providing a pair of thermoelectric conductors adapted to be disposed in contacting side-by-side relation, the conductors being formed of thermoelectrically dissimilar materials, providing means for passively self-generating a continuous temperature representative measurable voltage between the conductors when the cable is exposed to ambient temperature without the use of an external power source, the continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees and the passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of the conductors. The method ~urther includes positioning the pair o~ therm~electric conductors so as to be disposed in contacting side by-side relatian and applying a flexible outer jacket to the conductors formed of an electrically non-conductive material so that the conductors are com~letely surro~ded by the jac~et and the jacket is holding the conductors firmly together substantially along their entire length. The passive self-generating means is selected so as to cause an increase or decrease in the continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along the cable, the change in the voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along the cable measured in degrees. The passive self-generating means also is selected so as to cause a change in the continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along the cable, the change in the voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along the cable measured in degrees. Thus, the manufacturing method provides a heat sensitive cable which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature over the range of temperatures for the cable in a predictable fashion to provide a continuous temperature sensor.
Brief Description Of The Drawinqs In the drawings:
Figure 1 is a perspective view of a section of heat sensitive cable in accordance with the present inven-tion Figure 2 is a cross-sectional view of the ca~le illustrated in Figure 1:
Figure 3 is an elevational view of a spool con-taining the cable illustrated in Figure l;
1~ Figure 4 is a 6chematic view of a method of manu-facturing heat sensitive cable in accordance with the pres-ent invention:
~igure 5 i6 a top plan view taken along the line ~-~ of Figure 4;
Figure 6 is an elevational view of a section of heat sensitive ca~le manufactured in accor~ance with the method of Figure 4;
Figure 7 is a cross-sectional view taken along the line 7-7 of Figure 6;
Figure 8 is a schematic view of an alternative method of manufacturing heat sensitive cable in accordance with the present invention;
Figure 9 is a top plan view taken along the line 9-9 of Figure 8:
Figure 10 is an elevational view of a section of heat sensitive cable manufactured in accordance with the method of Figure 8:
Figure 11 is a cross-sectional view taken along the line 11-11 of Figure 10;
Figure 12 is a schematic view of another alterna-tive method of manufacturing heat sensitive cable in accord-ance with the present invention;
~ 7~ A92-451 Figure 13 is an elevational view of a section of heat sensitive cable manufactured in accordance with the method of Figure 12;
Figure 14 is a cross sectional view taken along the line 14-14 of Figure 13; and Figure 15 is a schematic view of still another alternative method of manufacturing heat sensitive cable in accordance with the present invention.
Detailed Descri~tion Of The Preferred Embodlments Referring to the drawings, and first to Fiqure ~, the reference numeral lO designates generally a heat sensi-tiYe ca~le capab~e of generating a temperature representa-tive measura~le ~ltage. The cable 10 includes a pair of thermoelectric conductors 12 and 14 disposed in contacting side-by-side rel~tion t~ether with means ~or ~assively self-generating a temperature representative measurable voltage between the conductors 12 and 14 when the cable 10 is exposed to ambient temperature. A flexible outer jacket 18 formed of an electrically non-conductive material is provided to completely surround the conductors 12 and 14.
The passive self-generating means includes means for causing a change in the temperature representative mecsurable volt-age with an increase or decrease in temperature at every location along the jacket 18. A change in the temperature representative measurable voltage under such condition is representative of a change in ambient temperature. The passive self-generating means also includes means for caus-ing a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket 18. With this arran~ement, the heat sensitive cable 10 may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature.
In a preferred embodiment, the passive self-gener-ating means includes an electrical insulation 16 having a negative temperature coefficient disposed on the surface of at least one of the conductors 12 and 14. Preferably, the conductor 12, for instance, is coated with a solution of manganese nitrate or heat treated manganese dioxide on the order of 2 to 6 mils thick. By so doing, the resulting electrical insulation 16 which is formed on the surface of the conductor 12 will provide the required temperature rep-resentative measurable voltage throughout the desired rangeof temperatures.
With regard to the electrical insulation 16, the conductor 12 is provided with a treated surface in one em-bodiment by coating the conductor 12 with a manganese ni-trate solution. After the conductor 12 has been coated withthe solution, which is preferably approximately 61 percent manganese nitrate, the conductor is heated to a temperature of between 300 and 450DF to complete the surface treatment process whereby the conductor 12 has an electrical insula-tion 16 with a negative temperature coefficient. Moreover,as shown in Figure 1, the conductor 14 also preferably has an electrical insulation ~0 having a negative temperature coefficient provided by a like surface treatment process.
In practice, it has been found advantageous to provide the solution of manganese nitrate by heating man-ganese nitrate at a temperature of approximately 100F. The manganese nitrate is heated at this temperature until melted and thereafter the melted manganese nitrate is heated at between approximately 400 to 500F for approximately 3 minutes. With this procedure, the manganese nitrate is first reduced from a solid to a thin liquid and is then converted from a thin liquid to a thick, black substance.
Referring to Figure 2, it will be appreciated that the elements comprising the heat sensitive cable 10 have 3 ~ A92-451 been exaggerated in size to enhance the illustration. The electrical insulation 16 on the conductor 12 and the elec-trical insulation 20 on the conductor 14 both comprise very thin surface coatings which are sufficient to permit the conductors 12 and 14 to be disposed in contacting side-by-side relation, but separated and electrically insulated by the thin coatings of electrical insulation 16 and 20. By reason of the intimate electrically insulated contact of the conductors 12 and 14, the heat sensitive cable 10 may be utilized to monitor temperature as indicated in a completely satisfactory manner.
In the embodiment illustrated in Figure 2, the conductors 12 and 14 disposed in contacting side-by-side relation are formed of thermoelectrically dissimilar mater-ials, e.g., one of the conductors 12 is preferably formed ofa nickel/chromium alloy and the other of the conductors 14 is preferably formed of a copper/nickel alloy. It will be appreciated, however, that all of the embodiments illustrat-ed in the drawings need only be formed of thermoelectrically dissimilar materials, e.g., those commonly known as ANSI K, E, J, or T thermoelectric pairs, or any other conductors formed of thermoelectrically dissimilar materials. Never-theless, when nickel/chromium and copper/nickel alloys are selected, it has been found advantageous for the nickel/
chromium alloy to comprise approximately 90 percent nickel and 10 percent chromium and the copper/nickel alloy to com-prise approximately 55 percent copper and 45 percent nickel.
Considering the flexible outer jacket 18, it may be formed of any of a number of electrically non-conductive materials with the desired flexibility characteristics. It is contemplated that the outer jacket 18 may be formed, for instance, of a material adapted to be extruded onto the conductors 12 and 14, or of a material adapted to be heat shrunk onto the conductors 12 and 14, or of a material ~ A92-451 adapted to be wrapped onto the conductors 12 and 14. Re-gardless of the method of applying the material to the con-ductors 12 and 14, it is only necessary that the material hold the conductors 12 and 14 together under some pressure in contacting side-by-side relation and be sufficiently flexible to permit the cable to be wound on a spool 22, as shown in Figure 3.
With respect to the method of manufacturing the cable, a pair of thermoelectric cGnductors is initially provided. Next, means are provided for passively self-gen-erating a temperature representative measurable voltage between the conductors when the cable is exposed to ambient temperature. The conductors are then positioned so as to be disposed in contacting side-by-side relation. Finally, a flexible outer jacket formed of an electrically non-conduc-tive material is applied to the conductors so that the con-ductors are completely surrounded by the jacket. The pass-ive self-generating means is selected so as to include means for causing a change in the temperature representative meas-urable voltage with an increase or decrease in temperatureat every location along the jacket. A change in the temper-ature representative measurable voltage under such condition is representative of a change in the ambient temperature.
The passive self-generating means is also selected so as to include means for causing a change in the temperature repre-sentative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jack-et. With the manufacturing method of the invention, a heat sensitive cable is provided which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature.
As previously mentioned, the surface of the con-ductor is treated by coating the conductor with a manganese nitrate solution. It is preferable for the solution to ~2~71 A92-451 comprise app~oximately 61 percent manganese nitrate. After the conductor has been coated, it is heated to a temperature of between 3000 and 450F to provide an electrical insula-tion having ~ negative temperature coefficient.
While the invention is not to be construed as limited to any specific components, one practical embodiment utilizes either extruded or heat shrinkable rubber for the flexible outer jacket 18. In this embodiment, one of the two conductors 12 is 14 gauge Chromel brand wire of Hoskins Manufacturing Co., Detroit, Michigan, and the other of the conductors 14 is 24 gauge Constantan brand wire available from the same co~pany, where both of the wires have been subjected to a surface treatment process in which they have first been abrasively cleaned and then coated with a chemi-cal, such as a manganese nitrate solution, which when heated and applied under controlled conditions results in a perma-nent change in the electrical resistivity of the outside surface of the wires. Specifically, the two wires are treated by dipping or otherwise coating them in a solution of 61 percent manganese nitrate and then subjecting them to temperatures of 300 to 400F for a short period of time in the range of approximately 3 to 5 minutes.
Referring now to Figures 4 through 7, an alterna-tive embodiment of the present invention is illustrated.
The heat sensitive cable 24 is preferably identical to the heat sensitive cable 10 with a single exception, i.e., the electrical insulation 26 provided on the surface of at least one of the conductors 28 and 30. As shown, the electrical insulation 26 is comprised of a powder embedded in a bonding material.
As illustrated, the surface of the conductor 28 is provided by coating the conductor 29 with a bonding material as at 32. Heat is applied to the conductor 28 as at 34 tand/or prior to application of the bonding material) and * Trade Marks ~2~7~
the powdered clectrical insulation is applied as at 36 and 38. As will be seen, the powdered electrical insulation as at 36 and 38 is embedded in the bonding material 32 by means of rollers at 40 and 42, respectively. Heat is then applied as at 44 after the powdered electrical insulation has been embedded in the bonding material. Finally, the conductors 28 and 30 are inserted into a flexible outer jacket 46, which is preferably made of heat shrinkable material, after which heat is applied as at 48 to shrink the flexible outer jacket 46 thereby forcing the conductors 28 and 30 into intimate contact with one another.
As for the bonding material, any material capable of use within the desired temperature limits can be util-ized. For instance, clear silicone rubber caulk manufac-tured by General Electric Company is suitable as the bondingmaterial for many applications because it is unaffected by temperatures ranging from -65DF to 500~F, and it is also possible to use a conducti~e adhesive such as Amicon CT--5047-2, C-840, or C-950 sold by the Polymer Products Divi-sion of Amicon Corporation. When a conductive adhesive isused, it is possible to provide a heavier coating on the conductors than silicone will normally permit.
With regard to the powdered electrical insulation, it is preferably heat treated manganese dioxide following the teachings in myu.s. patent No. 4,491,82~, issued January 1, 1985 and divisionals thereof including my patents No. 4,614,024 granted September 30, 1986 and No. 4,540,972 granted September 10, 1985. With this material, the insulation has an insulation resistance of between approximately 3,000 and 6,000 ohms at approximately 72F which has been found sufficient to produce a negative temperature coefficient insulator operable over a wide temperature range.
* Trade Mark ~ ~s~7~ A92-451 Referring now to Figures 8 through 11, another alternative embodiment of the present invention is illus-trated. The heat sensitive cable 50 is comprised of thermo-electrically dissimilar conductors 52 and 54, and electrical insulation as at 56 applied on the surface of at least one of the conductors 54, and a flexible outer jacket 58. As shown, the electrical insulation as at 56 is applied in a unique fashion.
In particular, the surface of the conductor 54 ls provided with an electrical insulation by utilizing a flex-ible wrap material 60. The flexible wrap material 60, which can be any flexible material but preferably one that is absorbent, is covered with a bonding material as at 62 and the bonding material is embedded with a powdered electrical insulation as at 64 and 66. Thereafter, the conductor 54 is wrapped with the flexi~le wr~p material 60.
Once again, the bonding material as at 62 is pref-erably a temperature resistant adhesive and the powdered electrical insulation as at 64 and 66 is preferably heat treated manganese dioxide. The flexible wrap material 60 may be heated before and/or after application of the bonding material as at 67, it is then rolled as at 68 and 70 immedi-ately after application of the powdered electrical insula-tion as at 64 and 66, respectively, and heat is applied subsequent to rolling as at 71. After the flexible wrap material 60 has been prepared, it is then wrapped about the conductor 54, the conductors 52 and 54 are inserted in a flexible outer jacket 58 of heat shrinkable material, and heat is applied as at 72.
As shown in Figure 10, the electrical insulation 56 need not totally cover the outer surface of the conductor 54. It is only necessary that the treated flexible wrap material 60 comprising the electrical insulation 56 be wrapped sufficiently close together to maintain the surfaces ~ 7~ A92-451 of the conductors 52 and 54 out of contact with one another.
As long as this condition is met, the cable 50 will function in the intended fashion.
Referring now to Figures 12 through 14, still another alternative embodiment of the present invention is illustrated. This embodiment is similar to the embodiment discussed in connection with Figures 8 through 11, but dif-fers in that the flexible wrap material which is treated with bonding material and heat treated manganese dioxide in Figure 8 has been replaced by a wire 74 formed of heat treated manganese dioxide as at 76. In other respects, the cable 78 is essentially the same as the cable 50 in Figures 8 through 11.
In particular, the cable 78 is comprised of a pair of thermoelectrically dissimilar conductors 80 and 82. The wire 74, which may be manufactured in accordance with any desired techni~ue, e.g., the continuous casting method dis-closed in U.S. Patent No. 3,881,541, is then wrapped about the conductor 82, the conductors 80 and 82 are inserted into a flexible outer jacket 84 of heat shrinkable material, and heat is applied as at 86 to complete the manufacturing pro-cess. When this has been done, the cable 78 will function in like fashion to the cable 50 in Figures 8 through 11.
Finally, Figure 15 illustrates one method of manu-facturing the heat sensitive cable 10 discussed in connec-tion with Figures 1 through 3. It will be seen that the cable 10 can be formed by applying the manganese nitrate solution (prepared as previously discussed) to at least one of the conductors 14 of the pair of thermoelectrically dis-similar conductors 14 and 16, and this can be done by spong-ing on the manganese nitrate solution as at 88, then apply-ing heat as at 90, and again sponging on manganese nitrate solution as at 92, and then applying heat as at 94, and these steps, i.e., sponging on manganese nitrate solution ~ 7~ A92-451 and thereafter heating, can be used once, twice, or as many times as desired to build up a coating of the desired thick-ness in assembly line fashion. When the coating has been applied to the conductor 14, the conductors 14 and 16 are inserted into the flexible outer jacke~ ~8 ~ he~t shrink-able material and heat is applied as at g6 to force the conductors 14 and 16 into intimate contact.
Still referring to Figure 15, it will be observed that the positive conductor 14 is larger in diameter than the negative conductor 16. This is done to facilitate wir-ing the cable to suitable monitoring equipment by assuring that even untrained personnel will be able to visually iden-tify the positive conductor and thereafter attach it to the positive terminal of the equipment and in like fashion iden-tify the negative conductor and attach it to the negativeterminal, particularly when it is considered that the posi-tive and negative conductors will usually be the same color.
When it is considered that the size of the conductors can be as small as approximately 0.012 inches, the advantage of providing a visibly larger diameter positive conductor will be apparent.
With regard to coating the surface of one or both conductors with an electrical insulation, the sole criteria is to apply a coating that remains ductile. In other words, the coating is provided with a thickness wherein the cable is capable of being bent around a small diameter, e.g., one-half to one inch in diameter without cracking or other-wise impairing the surface coating of electrical insulation.
Depending on the diameter of the conductors, the coating will be thicker or thinner to achieve this result.
With the present invention, a heat sensitive cable has been provided which is capable of generating a measur-able voltage when exposed to a temperature of, e.g., 72F.
The voltage measured is representative of that temperature ~ A92-451 (ambient) and the thermoelectric output of the cable or a section thereof when exposed to a higher temperature will generate a voltage representative of the higher temperature.
Noreover, the heat sensitive cable is capable of generating a measurable and predictable voltage as the ambient to which the entire length is exposed is raised above or reduced below 72F., e.g., a temperature between around -20F and 500F or higher depending upon the limitations of the mater-ials being used. The voltage measured is representative of that temperature (a new ambient) and the thermoelectric output of the cable or a section thereof when exposed to a higher temperature would again generate a voltage represent-ative of the higher temperature. Therefore, the heat sensi-tive cable may be utilized not only to monitor ambient tem-perature but also to monitor for any localized increaseabove ambient temperature, and the exact location along the cable where any localized increase occurs can be located electronically.
As previously mentioned, the conductors include chemically treated surfaces, preferably treated with a solu-tion of manganese nitrate, to provide a permanent insulation having a high negative temperature coefficient. The thermo-electric conductors when placed in contacting side-by-side relation along their entire axial length and held firmly together by means of the flexible outer jacket over their entire axial length, as required for a specific application or measurement, will generate a voltage representative of the highest temperature along the length of the cable.
Additionally, the cable may be provided with a continuous metallic sheath for certain applications in accordance with the teachings of U.S. Patent No. 3,737,997.
As will be appreciated, the heat sensitive cable of the present invention will constantly generate a measur-able voltage. This voltage is usable with conventional, inexpensive pyrometers, analog meters, digital readout indi-cators, strip chart recorders, temperature controllers and transmitters, state of the art microprocessor based data loggers, calculating data loggers, programmable controllers, etc. Further, with the use of conventional time domain reflectometers and electronic circuitry, the exact-location along the cable where the maximum temperature exists may be located.
While all of the embodiments illustrated in the drawings utili~e a pair of conductors, it will be appreciat-ed that one or more additional conductors may also be pro-vided. Such an additional conductor, whether insulated or non-insulated, may be useful, for instance, where a bridge network type of location device will be u~ed. Accordingly, the present invention is to be construed as requiring a minimum of two thermoelectric conductors.
With the present invention, an inexpensive product has been provided which may be easily installed by inexper-ienced persons utilizing the same conventional means as used in modern home construction and wiring. The cable is also reusable (within the limits of the cable materials) and effectively provides a continuous temperature sensor. More-over, the present invention results in the formation of a permanent, flexible, exterior surface insulation condition with a high negative temperature coefficient.
Finally, it is possible to provide an essentially continuous heat sensitive cable, i.e., the cable can be produced in lengths of thousands of feet, at a fraction of the cost of making conventional types of constructions of heat sensitive devices or cables.
With the present invention, the heat sensitive cable provides a thermocouple temperature monitoring device which consists of a pair of conductors having surfaces treated with an electrical insulation having a negative ~ ~ A92-451 temperature coefficient within a flexible outer jacket. The cable is passive and self-generating to generate a voltage potential between the thermoelectric conductors which is indicative of the temperature existing along its entire length, or if the temperatures are unequal, at the hottest point along the cable length when subjected to external temperatures. When monitored by a high input impedance temperature device, the heat sensitive cable is capable of (1) precise, nonperishable, reproducible measurement of the temperature and (2) identification of the location of the hottest spot, and is capable of utilizing varying combina-tions of materials to yield various mechanical properties and temperature-voltage response curves.
Various changes coming within the spirit of the present invention may suggest themselves to those s~illed in the art. Hence, it will be understood that the invention is not to be limited to the specific embodiments shown and described or the uses mentioned. On the contrary, the spe-cific embodiments and uses are intended to be merely exem-plary with the present invention being limited only by thetrue spirit of the scope of the appended claims.
SPECIFICATION
HEAT SENSITIVE CABLE
AND METHOD OF MAKING SAME
Backqround Of The Invention The present invention relates to heat sensitive devices and, more particularly, to a heat sensitive cable and method of making same.
Heat sensitive cables which are characterized by the use of semiconductive materials having inverse tempera-ture-resistance characteristics in conjunction with dissimi-1-~ lar thermoelectric conductors are now well known in the art.
Such cables are particularly suitable where it is desired to monitor the greatest temperature existing along the length of the cable, and are exemplified in connection with a sys-tem for measuring and locating temperature conditions of interest in U.S. Patent Nos. 3,408,607 and 4,324,138. Ther-mistor cables which are characterized by a core of semicon-ductive material surrounded by a mass of temperature-resist-ant electrically-insulating material covered with a protec-tive metallic sheath are also well known in the art.
Despite the clear advantages and many applications for such cables, they have simply not evolved to the point of providing the desired degree of versatility. It has remained to develop a heat sensitive cable capable of gener-ating a measurable and predictable voltage when the entire length of cable is at ambient, e.g., 72F, wherein the cable is also adapted to provide a change in the temperature rep-resentative measurable voltage with an increase in tempera-ture above the prevailing ambient at any location along the cable. If this could be achieved with an electrical insula-tion having a negative temperature coefficient, the thermo-electric output of the cable or a section thereof would bealtered in a predictable fashion.
Moreover, if this could be achieved, the cable location where an increase in temperature takes place could be located electronically. This could be done, for in-stance, as fully disclosed and claimed in my earlier U.S.Patent No. 4,324,138, issued April 13, 1982, for a method of and apparatus and system for determlning temperature candi-tion~. As set forth therein, the applications are ~irtually limitless.
While the value of heat sensitive cable has l~ng been recognized, it has remained to provide such a cable having the requisite versatility ~or the many applications to be benefited by use thereof. In fact, despite my many prior inventions in this field, as exemplified by U.S. Pat-ent Nos. 3,408,607 and 3,513,432, the missing link to pro-viding a highly versatile cable has remained. Despite the advantages that will be recognized by those skilled in the art, heat sensitive cable which may not only be utilized to monitor ambient temperature but also may be utilized to monitor for any localized increase above ambient temperature has simply not been available.
Accordingly the present invention seeks to provide a heat sensitive cable having means for generat-lng a temperature re~resentative measurable voltage.
Further the present invention seeks to provide a cable of the type described utilizing a pair of thermoelectric conductors disposed in contacting side-by-side relation together with means for passively self-gener-ating a temperature representative measurable voltage be-tween the conductors when the cable is exposed to ambient temperature.
Further still the present invention seeks to provide a cable of the type described utiliæing a flexible outer jacket formed of an electrically non-conductive mater-ial to completely surround the conductors.
The present invention also seeks to provide a cable of the type described which is not only passive and self-generating to generate a voltage potential between the thermoelectric conductors indicati~e o the temperature exis~i~g alo~g ~he entire length o~ the ca~le, i.e., the ambient temperature, but which also generates a voltage potential between the ~onductorc indicative of the hottest point along the length of the cable i~ the tempera-tures ~re une~ual.
Still further the present in~ention seeks to provide a cab~e of the type described in which the passive self-generating characteristic causes a change in the temperature representative measurable voltage with an increase or decrease in temperature at every location along the jacket.
Furthe,,r still the present invention seeks to provide a cable of the type described in which the passive self-generating characteristic causes a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket.
Further still the present'invention seeks to provide a cable of the type described capable of precise, non-perishable, reproducible measurement of the temperature and identification of the location of the hot-test spot when monitoring with a high input impedance tem-perature device.
, ...
The present invention still further seeks to provide a cable of the type described wherein the outer jacket and the thermoelectric conductors can be formed of various materials and combinations of materials to yield various mechanical properties and temperature-voltage response curves.
These and other aspects, advantages and features of the present invention will be apparent from a consideration of the accompanying specification, claims and drawings.
Summary Of The Invention Accordingly the present invention in one aspect provides a heat sensitive cable operable in a predictable fashion over a range of temperatures for generating a measurab~e voltage indicative of the temperature along the cable to proyide a contin~s tempelature sensor. The cable includes a pair of thermoelectric conductors disposed in contacting side-by-side relation with the conductors being formed of thermoelectrically dissimilar materials and with means for passively self-generating a continuous temperature xepresentative measurable voltage between the conductors when the cable is exposed to ambient temperature without the use of an external power source. The continuous temperature representative measurable voltage is adapted for conversion into ambient temperature measured in degrees, the passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of the conductors. A flexible outer jacket is formed of an electrically non-conductive material completely surrounding the conductors, the jacket holding the conductors firmly together substantially along their entire length. The passive self-generating means causes an increase or decrease in thecontinuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along the cable, the change in the voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion ~nto a new ambient temperature along the cable measured in degrees. The passive self-generating means also causes a change in the continuous temperature representative measurable ~oltage responsi~e to an associated increase in temperature above the prevailing ambient at any location along the cable, the change in the voltage under such condition also being measurable and representative of an increase in localized ternperature and adapted for '7~L
conversion into a maximum temperature along the cable measured in degrees. Thus the hea-t sensitive cable may be utili2ed not only to monitor ambient temperature but also to monitor for any localized increase in temperature over the range of temperatures for the cable in a predictable fashion to provide a continuous temperature sensor.
In a preferred embodiment, the passive self-generating means includes an electrical insulation having a negative temperature coefficient disposed on the surface of at least one oE the conductors. Preferably, the conductor is coated with a solution of manganese nitrate or the surface of the conductor is covered with heat treated manganese dioxide~
By so doing, the resulting electrical insulation which is formed on the surface of the conductor has a negative temperature coefficient and will provide the required temperature representative measurable voltage throughout the desired range of temperatures.
In addition, the pair of thermoelectric conductors disposed in contacting side-by-side relation are advantageously formed of thermoelectrically dissimilar materials. It has been found suitable, for instance, for one of the conductors to be formed of a nickel/chromium alloy and the other of the conductors to be formed of a copper/nickel alloy.
Specifically, the nickel/chromium alloy may comprise approximately 90 percent nickel and 10 percent chromium and the copper/nickel alloy may comprise approximately 55 percent copper and 45 percent nickel.
With regard to the flexible outer jacket, it is preferably formed of a material -that may be applied to completely surround the conductors in a fashion applying pressure to hold the conductors in contacting side-by-side relation. In this connection, the material may be of a type adapted to be extruded onto the conductors, or a material of -the type adapted to be heat shrunk onto the conductors, or a material of the type adapted to be wrapped onto the conductors.
Once -the material has been applied to the conductors to form the flexible outer jacket, the heat sensitlve cable may be stored on spools due to lts 1exibility and later may be removed and cut to length for use as needed.
~0 The invention also contemplates a method of manufacturing a heat sensitive cable operable in a predictable Eashion over a range of temperatures for generating a measurable voltage indica-tive of the temperature along the ~2~
cable to provide a continuous temperature sensor. The method includes providing a pair of thermoelectric conductors adapted to be disposed in contacting side-by-side relation, the conductors being formed of thermoelectrically dissimilar materials, providing means for passively self-generating a continuous temperature representative measurable voltage between the conductors when the cable is exposed to ambient temperature without the use of an external power source, the continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees and the passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of the conductors. The method ~urther includes positioning the pair o~ therm~electric conductors so as to be disposed in contacting side by-side relatian and applying a flexible outer jacket to the conductors formed of an electrically non-conductive material so that the conductors are com~letely surro~ded by the jac~et and the jacket is holding the conductors firmly together substantially along their entire length. The passive self-generating means is selected so as to cause an increase or decrease in the continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along the cable, the change in the voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along the cable measured in degrees. The passive self-generating means also is selected so as to cause a change in the continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along the cable, the change in the voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along the cable measured in degrees. Thus, the manufacturing method provides a heat sensitive cable which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature over the range of temperatures for the cable in a predictable fashion to provide a continuous temperature sensor.
Brief Description Of The Drawinqs In the drawings:
Figure 1 is a perspective view of a section of heat sensitive cable in accordance with the present inven-tion Figure 2 is a cross-sectional view of the ca~le illustrated in Figure 1:
Figure 3 is an elevational view of a spool con-taining the cable illustrated in Figure l;
1~ Figure 4 is a 6chematic view of a method of manu-facturing heat sensitive cable in accordance with the pres-ent invention:
~igure 5 i6 a top plan view taken along the line ~-~ of Figure 4;
Figure 6 is an elevational view of a section of heat sensitive ca~le manufactured in accor~ance with the method of Figure 4;
Figure 7 is a cross-sectional view taken along the line 7-7 of Figure 6;
Figure 8 is a schematic view of an alternative method of manufacturing heat sensitive cable in accordance with the present invention;
Figure 9 is a top plan view taken along the line 9-9 of Figure 8:
Figure 10 is an elevational view of a section of heat sensitive cable manufactured in accordance with the method of Figure 8:
Figure 11 is a cross-sectional view taken along the line 11-11 of Figure 10;
Figure 12 is a schematic view of another alterna-tive method of manufacturing heat sensitive cable in accord-ance with the present invention;
~ 7~ A92-451 Figure 13 is an elevational view of a section of heat sensitive cable manufactured in accordance with the method of Figure 12;
Figure 14 is a cross sectional view taken along the line 14-14 of Figure 13; and Figure 15 is a schematic view of still another alternative method of manufacturing heat sensitive cable in accordance with the present invention.
Detailed Descri~tion Of The Preferred Embodlments Referring to the drawings, and first to Fiqure ~, the reference numeral lO designates generally a heat sensi-tiYe ca~le capab~e of generating a temperature representa-tive measura~le ~ltage. The cable 10 includes a pair of thermoelectric conductors 12 and 14 disposed in contacting side-by-side rel~tion t~ether with means ~or ~assively self-generating a temperature representative measurable voltage between the conductors 12 and 14 when the cable 10 is exposed to ambient temperature. A flexible outer jacket 18 formed of an electrically non-conductive material is provided to completely surround the conductors 12 and 14.
The passive self-generating means includes means for causing a change in the temperature representative mecsurable volt-age with an increase or decrease in temperature at every location along the jacket 18. A change in the temperature representative measurable voltage under such condition is representative of a change in ambient temperature. The passive self-generating means also includes means for caus-ing a change in the temperature representative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jacket 18. With this arran~ement, the heat sensitive cable 10 may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature.
In a preferred embodiment, the passive self-gener-ating means includes an electrical insulation 16 having a negative temperature coefficient disposed on the surface of at least one of the conductors 12 and 14. Preferably, the conductor 12, for instance, is coated with a solution of manganese nitrate or heat treated manganese dioxide on the order of 2 to 6 mils thick. By so doing, the resulting electrical insulation 16 which is formed on the surface of the conductor 12 will provide the required temperature rep-resentative measurable voltage throughout the desired rangeof temperatures.
With regard to the electrical insulation 16, the conductor 12 is provided with a treated surface in one em-bodiment by coating the conductor 12 with a manganese ni-trate solution. After the conductor 12 has been coated withthe solution, which is preferably approximately 61 percent manganese nitrate, the conductor is heated to a temperature of between 300 and 450DF to complete the surface treatment process whereby the conductor 12 has an electrical insula-tion 16 with a negative temperature coefficient. Moreover,as shown in Figure 1, the conductor 14 also preferably has an electrical insulation ~0 having a negative temperature coefficient provided by a like surface treatment process.
In practice, it has been found advantageous to provide the solution of manganese nitrate by heating man-ganese nitrate at a temperature of approximately 100F. The manganese nitrate is heated at this temperature until melted and thereafter the melted manganese nitrate is heated at between approximately 400 to 500F for approximately 3 minutes. With this procedure, the manganese nitrate is first reduced from a solid to a thin liquid and is then converted from a thin liquid to a thick, black substance.
Referring to Figure 2, it will be appreciated that the elements comprising the heat sensitive cable 10 have 3 ~ A92-451 been exaggerated in size to enhance the illustration. The electrical insulation 16 on the conductor 12 and the elec-trical insulation 20 on the conductor 14 both comprise very thin surface coatings which are sufficient to permit the conductors 12 and 14 to be disposed in contacting side-by-side relation, but separated and electrically insulated by the thin coatings of electrical insulation 16 and 20. By reason of the intimate electrically insulated contact of the conductors 12 and 14, the heat sensitive cable 10 may be utilized to monitor temperature as indicated in a completely satisfactory manner.
In the embodiment illustrated in Figure 2, the conductors 12 and 14 disposed in contacting side-by-side relation are formed of thermoelectrically dissimilar mater-ials, e.g., one of the conductors 12 is preferably formed ofa nickel/chromium alloy and the other of the conductors 14 is preferably formed of a copper/nickel alloy. It will be appreciated, however, that all of the embodiments illustrat-ed in the drawings need only be formed of thermoelectrically dissimilar materials, e.g., those commonly known as ANSI K, E, J, or T thermoelectric pairs, or any other conductors formed of thermoelectrically dissimilar materials. Never-theless, when nickel/chromium and copper/nickel alloys are selected, it has been found advantageous for the nickel/
chromium alloy to comprise approximately 90 percent nickel and 10 percent chromium and the copper/nickel alloy to com-prise approximately 55 percent copper and 45 percent nickel.
Considering the flexible outer jacket 18, it may be formed of any of a number of electrically non-conductive materials with the desired flexibility characteristics. It is contemplated that the outer jacket 18 may be formed, for instance, of a material adapted to be extruded onto the conductors 12 and 14, or of a material adapted to be heat shrunk onto the conductors 12 and 14, or of a material ~ A92-451 adapted to be wrapped onto the conductors 12 and 14. Re-gardless of the method of applying the material to the con-ductors 12 and 14, it is only necessary that the material hold the conductors 12 and 14 together under some pressure in contacting side-by-side relation and be sufficiently flexible to permit the cable to be wound on a spool 22, as shown in Figure 3.
With respect to the method of manufacturing the cable, a pair of thermoelectric cGnductors is initially provided. Next, means are provided for passively self-gen-erating a temperature representative measurable voltage between the conductors when the cable is exposed to ambient temperature. The conductors are then positioned so as to be disposed in contacting side-by-side relation. Finally, a flexible outer jacket formed of an electrically non-conduc-tive material is applied to the conductors so that the con-ductors are completely surrounded by the jacket. The pass-ive self-generating means is selected so as to include means for causing a change in the temperature representative meas-urable voltage with an increase or decrease in temperatureat every location along the jacket. A change in the temper-ature representative measurable voltage under such condition is representative of a change in the ambient temperature.
The passive self-generating means is also selected so as to include means for causing a change in the temperature repre-sentative measurable voltage with an increase in temperature above the prevailing ambient at any location along the jack-et. With the manufacturing method of the invention, a heat sensitive cable is provided which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature.
As previously mentioned, the surface of the con-ductor is treated by coating the conductor with a manganese nitrate solution. It is preferable for the solution to ~2~71 A92-451 comprise app~oximately 61 percent manganese nitrate. After the conductor has been coated, it is heated to a temperature of between 3000 and 450F to provide an electrical insula-tion having ~ negative temperature coefficient.
While the invention is not to be construed as limited to any specific components, one practical embodiment utilizes either extruded or heat shrinkable rubber for the flexible outer jacket 18. In this embodiment, one of the two conductors 12 is 14 gauge Chromel brand wire of Hoskins Manufacturing Co., Detroit, Michigan, and the other of the conductors 14 is 24 gauge Constantan brand wire available from the same co~pany, where both of the wires have been subjected to a surface treatment process in which they have first been abrasively cleaned and then coated with a chemi-cal, such as a manganese nitrate solution, which when heated and applied under controlled conditions results in a perma-nent change in the electrical resistivity of the outside surface of the wires. Specifically, the two wires are treated by dipping or otherwise coating them in a solution of 61 percent manganese nitrate and then subjecting them to temperatures of 300 to 400F for a short period of time in the range of approximately 3 to 5 minutes.
Referring now to Figures 4 through 7, an alterna-tive embodiment of the present invention is illustrated.
The heat sensitive cable 24 is preferably identical to the heat sensitive cable 10 with a single exception, i.e., the electrical insulation 26 provided on the surface of at least one of the conductors 28 and 30. As shown, the electrical insulation 26 is comprised of a powder embedded in a bonding material.
As illustrated, the surface of the conductor 28 is provided by coating the conductor 29 with a bonding material as at 32. Heat is applied to the conductor 28 as at 34 tand/or prior to application of the bonding material) and * Trade Marks ~2~7~
the powdered clectrical insulation is applied as at 36 and 38. As will be seen, the powdered electrical insulation as at 36 and 38 is embedded in the bonding material 32 by means of rollers at 40 and 42, respectively. Heat is then applied as at 44 after the powdered electrical insulation has been embedded in the bonding material. Finally, the conductors 28 and 30 are inserted into a flexible outer jacket 46, which is preferably made of heat shrinkable material, after which heat is applied as at 48 to shrink the flexible outer jacket 46 thereby forcing the conductors 28 and 30 into intimate contact with one another.
As for the bonding material, any material capable of use within the desired temperature limits can be util-ized. For instance, clear silicone rubber caulk manufac-tured by General Electric Company is suitable as the bondingmaterial for many applications because it is unaffected by temperatures ranging from -65DF to 500~F, and it is also possible to use a conducti~e adhesive such as Amicon CT--5047-2, C-840, or C-950 sold by the Polymer Products Divi-sion of Amicon Corporation. When a conductive adhesive isused, it is possible to provide a heavier coating on the conductors than silicone will normally permit.
With regard to the powdered electrical insulation, it is preferably heat treated manganese dioxide following the teachings in myu.s. patent No. 4,491,82~, issued January 1, 1985 and divisionals thereof including my patents No. 4,614,024 granted September 30, 1986 and No. 4,540,972 granted September 10, 1985. With this material, the insulation has an insulation resistance of between approximately 3,000 and 6,000 ohms at approximately 72F which has been found sufficient to produce a negative temperature coefficient insulator operable over a wide temperature range.
* Trade Mark ~ ~s~7~ A92-451 Referring now to Figures 8 through 11, another alternative embodiment of the present invention is illus-trated. The heat sensitive cable 50 is comprised of thermo-electrically dissimilar conductors 52 and 54, and electrical insulation as at 56 applied on the surface of at least one of the conductors 54, and a flexible outer jacket 58. As shown, the electrical insulation as at 56 is applied in a unique fashion.
In particular, the surface of the conductor 54 ls provided with an electrical insulation by utilizing a flex-ible wrap material 60. The flexible wrap material 60, which can be any flexible material but preferably one that is absorbent, is covered with a bonding material as at 62 and the bonding material is embedded with a powdered electrical insulation as at 64 and 66. Thereafter, the conductor 54 is wrapped with the flexi~le wr~p material 60.
Once again, the bonding material as at 62 is pref-erably a temperature resistant adhesive and the powdered electrical insulation as at 64 and 66 is preferably heat treated manganese dioxide. The flexible wrap material 60 may be heated before and/or after application of the bonding material as at 67, it is then rolled as at 68 and 70 immedi-ately after application of the powdered electrical insula-tion as at 64 and 66, respectively, and heat is applied subsequent to rolling as at 71. After the flexible wrap material 60 has been prepared, it is then wrapped about the conductor 54, the conductors 52 and 54 are inserted in a flexible outer jacket 58 of heat shrinkable material, and heat is applied as at 72.
As shown in Figure 10, the electrical insulation 56 need not totally cover the outer surface of the conductor 54. It is only necessary that the treated flexible wrap material 60 comprising the electrical insulation 56 be wrapped sufficiently close together to maintain the surfaces ~ 7~ A92-451 of the conductors 52 and 54 out of contact with one another.
As long as this condition is met, the cable 50 will function in the intended fashion.
Referring now to Figures 12 through 14, still another alternative embodiment of the present invention is illustrated. This embodiment is similar to the embodiment discussed in connection with Figures 8 through 11, but dif-fers in that the flexible wrap material which is treated with bonding material and heat treated manganese dioxide in Figure 8 has been replaced by a wire 74 formed of heat treated manganese dioxide as at 76. In other respects, the cable 78 is essentially the same as the cable 50 in Figures 8 through 11.
In particular, the cable 78 is comprised of a pair of thermoelectrically dissimilar conductors 80 and 82. The wire 74, which may be manufactured in accordance with any desired techni~ue, e.g., the continuous casting method dis-closed in U.S. Patent No. 3,881,541, is then wrapped about the conductor 82, the conductors 80 and 82 are inserted into a flexible outer jacket 84 of heat shrinkable material, and heat is applied as at 86 to complete the manufacturing pro-cess. When this has been done, the cable 78 will function in like fashion to the cable 50 in Figures 8 through 11.
Finally, Figure 15 illustrates one method of manu-facturing the heat sensitive cable 10 discussed in connec-tion with Figures 1 through 3. It will be seen that the cable 10 can be formed by applying the manganese nitrate solution (prepared as previously discussed) to at least one of the conductors 14 of the pair of thermoelectrically dis-similar conductors 14 and 16, and this can be done by spong-ing on the manganese nitrate solution as at 88, then apply-ing heat as at 90, and again sponging on manganese nitrate solution as at 92, and then applying heat as at 94, and these steps, i.e., sponging on manganese nitrate solution ~ 7~ A92-451 and thereafter heating, can be used once, twice, or as many times as desired to build up a coating of the desired thick-ness in assembly line fashion. When the coating has been applied to the conductor 14, the conductors 14 and 16 are inserted into the flexible outer jacke~ ~8 ~ he~t shrink-able material and heat is applied as at g6 to force the conductors 14 and 16 into intimate contact.
Still referring to Figure 15, it will be observed that the positive conductor 14 is larger in diameter than the negative conductor 16. This is done to facilitate wir-ing the cable to suitable monitoring equipment by assuring that even untrained personnel will be able to visually iden-tify the positive conductor and thereafter attach it to the positive terminal of the equipment and in like fashion iden-tify the negative conductor and attach it to the negativeterminal, particularly when it is considered that the posi-tive and negative conductors will usually be the same color.
When it is considered that the size of the conductors can be as small as approximately 0.012 inches, the advantage of providing a visibly larger diameter positive conductor will be apparent.
With regard to coating the surface of one or both conductors with an electrical insulation, the sole criteria is to apply a coating that remains ductile. In other words, the coating is provided with a thickness wherein the cable is capable of being bent around a small diameter, e.g., one-half to one inch in diameter without cracking or other-wise impairing the surface coating of electrical insulation.
Depending on the diameter of the conductors, the coating will be thicker or thinner to achieve this result.
With the present invention, a heat sensitive cable has been provided which is capable of generating a measur-able voltage when exposed to a temperature of, e.g., 72F.
The voltage measured is representative of that temperature ~ A92-451 (ambient) and the thermoelectric output of the cable or a section thereof when exposed to a higher temperature will generate a voltage representative of the higher temperature.
Noreover, the heat sensitive cable is capable of generating a measurable and predictable voltage as the ambient to which the entire length is exposed is raised above or reduced below 72F., e.g., a temperature between around -20F and 500F or higher depending upon the limitations of the mater-ials being used. The voltage measured is representative of that temperature (a new ambient) and the thermoelectric output of the cable or a section thereof when exposed to a higher temperature would again generate a voltage represent-ative of the higher temperature. Therefore, the heat sensi-tive cable may be utilized not only to monitor ambient tem-perature but also to monitor for any localized increaseabove ambient temperature, and the exact location along the cable where any localized increase occurs can be located electronically.
As previously mentioned, the conductors include chemically treated surfaces, preferably treated with a solu-tion of manganese nitrate, to provide a permanent insulation having a high negative temperature coefficient. The thermo-electric conductors when placed in contacting side-by-side relation along their entire axial length and held firmly together by means of the flexible outer jacket over their entire axial length, as required for a specific application or measurement, will generate a voltage representative of the highest temperature along the length of the cable.
Additionally, the cable may be provided with a continuous metallic sheath for certain applications in accordance with the teachings of U.S. Patent No. 3,737,997.
As will be appreciated, the heat sensitive cable of the present invention will constantly generate a measur-able voltage. This voltage is usable with conventional, inexpensive pyrometers, analog meters, digital readout indi-cators, strip chart recorders, temperature controllers and transmitters, state of the art microprocessor based data loggers, calculating data loggers, programmable controllers, etc. Further, with the use of conventional time domain reflectometers and electronic circuitry, the exact-location along the cable where the maximum temperature exists may be located.
While all of the embodiments illustrated in the drawings utili~e a pair of conductors, it will be appreciat-ed that one or more additional conductors may also be pro-vided. Such an additional conductor, whether insulated or non-insulated, may be useful, for instance, where a bridge network type of location device will be u~ed. Accordingly, the present invention is to be construed as requiring a minimum of two thermoelectric conductors.
With the present invention, an inexpensive product has been provided which may be easily installed by inexper-ienced persons utilizing the same conventional means as used in modern home construction and wiring. The cable is also reusable (within the limits of the cable materials) and effectively provides a continuous temperature sensor. More-over, the present invention results in the formation of a permanent, flexible, exterior surface insulation condition with a high negative temperature coefficient.
Finally, it is possible to provide an essentially continuous heat sensitive cable, i.e., the cable can be produced in lengths of thousands of feet, at a fraction of the cost of making conventional types of constructions of heat sensitive devices or cables.
With the present invention, the heat sensitive cable provides a thermocouple temperature monitoring device which consists of a pair of conductors having surfaces treated with an electrical insulation having a negative ~ ~ A92-451 temperature coefficient within a flexible outer jacket. The cable is passive and self-generating to generate a voltage potential between the thermoelectric conductors which is indicative of the temperature existing along its entire length, or if the temperatures are unequal, at the hottest point along the cable length when subjected to external temperatures. When monitored by a high input impedance temperature device, the heat sensitive cable is capable of (1) precise, nonperishable, reproducible measurement of the temperature and (2) identification of the location of the hottest spot, and is capable of utilizing varying combina-tions of materials to yield various mechanical properties and temperature-voltage response curves.
Various changes coming within the spirit of the present invention may suggest themselves to those s~illed in the art. Hence, it will be understood that the invention is not to be limited to the specific embodiments shown and described or the uses mentioned. On the contrary, the spe-cific embodiments and uses are intended to be merely exem-plary with the present invention being limited only by thetrue spirit of the scope of the appended claims.
Claims (42)
1. A heat sensitive cable operable in a predictable fashion over a range of temperatures for generating a measurable voltage indicative of the temperature along said cable to provide a continuous temperature sensor, comprising:
a pair of thermoelectric conductors disposed in contacting side-by-side relation, said conductors being formed of thermoelectrically dissimilar materials;
means for passively self-generating a continuous temperature representative measurable voltage between said conductors when said cable is exposed to ambient temperature without the use of an external power source, said continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees, said passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of said conductors;
a flexible outer jacket formed of an electrically non-conductive material completely surrounding said conductors, said jacket holding said conductors firmly together substantially along their entire length;
said passive self-generating means causing an increase or decrease in said continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along said cable, the change in said voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along said cable measured in degrees, said passive self-generating means also causing a change in said continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along said cable, the change in said voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along said cable measured in degrees;
whereby said heat sensitive cable may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature over said range of temperatures for said cable in a predictable fashion to provide a continuous temperature sensor.
a pair of thermoelectric conductors disposed in contacting side-by-side relation, said conductors being formed of thermoelectrically dissimilar materials;
means for passively self-generating a continuous temperature representative measurable voltage between said conductors when said cable is exposed to ambient temperature without the use of an external power source, said continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees, said passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of said conductors;
a flexible outer jacket formed of an electrically non-conductive material completely surrounding said conductors, said jacket holding said conductors firmly together substantially along their entire length;
said passive self-generating means causing an increase or decrease in said continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along said cable, the change in said voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along said cable measured in degrees, said passive self-generating means also causing a change in said continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along said cable, the change in said voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along said cable measured in degrees;
whereby said heat sensitive cable may be utilized not only to monitor ambient temperature but also to monitor for any localized increase in temperature over said range of temperatures for said cable in a predictable fashion to provide a continuous temperature sensor.
2. The heat sensitive cable as defined by Claim 1 wherein said material comprising said passive self-generating means is an electrical insulation disposed on the surface of at least one of said conductors.
3. The heat sensitive cable as defined by claim 2 wherein said electrical insulation on said surface of said conductor is provided by coating said conductor with a man-ganese nitrate solution.
4. The heat sensitive cable as defined by Claim 3 wherein said manganese nitrate solution is provided by heating manganese nitrate at a temperature of approximately 100°F until melted and thereafter heating said melted manga-nese nitrate at between approximately 400° to 500°F for approximately 3 minutes.
5. The heat sensitive cable as defined by Claim 4 wherein said electrical insulation on said surface of said conductor is provided by heating said conductor after coat-ing with said manganese nitrate solution.
6. The heat sensitive cable as defined by Claim 5 wherein said conductor is coated with a solution of ap-proximately 51 percent manganese nitrate and said conductor is heated to a temperature of between 3000 and 450°F.
7. The heat sensitive cable as defined by Claim 2 wherein said electrical insulation on said surface of said conductor is provided by coating said conductor with a bonding material and embedding said bonding material with a powdered electrical insulation.
8. The heat sensitive cable as defined by Claim 7 wherein said electrical insulation on said surface of said conductor is provided by heating said conductor after covering said conductor with said bonding material and embedding said bonding material with said powdered electrical insulation after heating.
9.The heat sensitive cable as defined by Claim 8 wherein said electrical insulation on said surface of said conductor is provided by heating said conductor after embedding said bonding material with said powdered electri-cal insulation.
10. The heat sensitive cable as defined by Claim 9 wherein said bonding material is a temperature resistant adhesive and said powdered electrical insulation is heat treated manganese dioxide.
11. The heat sensitive cable as defined by Claim 2 wherein said electrical insulation on said surface of said conductor is provided by utilizing a flexible wrap material, covering said flexible wrap material with a bonding material and embedding said bonding material with a powdered electri-cal insulation, said conductor being wrapped with said flex-ible wrap material.
12. The heat sensitive cable as defined by Claim 11 wherein said bonding material is a temperature resistant adhesive and said powdered electrical insulation is heat treated manganese dioxide.
13. The heat sensitive cable as defined by Claim 2 wherein said electrical insulation on said surface of said conductor is provided by wrapping said conductor with a wire having a negative temperature coefficient.
14. The heat sensitive cable as defined by Claim 13 wherein said wire is formed of heat treated manganese dioxide.
15. The heat sensitive cable as defined by Claim 1 wherein one of said conductors is formed of a nickel/chromium alloy and the other of said conductors is formed of a copper/
nickel alloy.
nickel alloy.
16. The heat sensitive cable as defined by Claim 15, wherein said nickel/chromium alloy comprises approximately 90 percent nickel and 10 percent chromium and said copper/nickel alloy comprises approximately 55 percent copper and 45 percent nickel.
17. The heat sensitive cable as defined by Claim 1 wherein said flexible outer jacket is formed of a material adapted to be extruded onto said conductors to hold said conductors together under pressure along their entire length.
18. The heat sensitive cable as defined by Claim 1 wherein said flexible outer jacket is formed of a material adapted to be heat shrunk onto said conductors to hold said conductors together under pressure along their entire length.
19. The heat sensitive cable as defined by Claim 1 wherein said flexible outer jacket is formed of a material adapted to be wrapped onto said conductors to hold said conductors together under pressure along their entire length.
20. The heat sensitive cable as defined by Claim 1 wherein the heat sensitive cable is operable in a predictable fashion over a range of temperatures of between around at least -20°F and 500°F.
21. The heat sensitive cable of Claim 1 wherein one of said conductors is larger than another of said conductors.
22. The heat sensitive cable as defined by Claim 21 wherein the larger of said conductors is the positive conductor and the smaller of said conductors is the negative conductor.
23. A method of manufacturing a heat sensitive cable operable in a predictable fashion over a range of temperatures for generating a measurable voltage indicative of the temperature along said cable to provide a continuous temperature sensor, comprising:
providing a pair of thermoelectric conductors adapted to be disposed in contacting side-by-side relation, said conductors being formed of thermoelectrically dissimilar materials;
providing means for passively self-generating a continuous temperature representative measurable voltage between said conductors when said cable is exposed to ambient temperature without the use of an external power source, said continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees, said passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of said conductors;
positioning said pair of thermoelectric conductors so as to be disposed in contacting side-by-side relation; and applying a flexible outer jacket to said conductors formed of an electrically non-conductive material so that said conductors are completely surrounded by said jacket and said jacket is holding said conductors firmly together substantially along their entire length;
said passive self-generating means being selected so as to cause an increase or decrease in said continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along said cable, the change in said voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along said cable measured in degrees, said passive self-generating means also being selected so as to cause a change in said continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along said cable, the change in said voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along said cable measured in degrees;
whereby said manufacturing method provides a heat sensitive cable which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature over said range of temperatures for said cable in a predictable fashion to provide a continuous temperature sensor.
providing a pair of thermoelectric conductors adapted to be disposed in contacting side-by-side relation, said conductors being formed of thermoelectrically dissimilar materials;
providing means for passively self-generating a continuous temperature representative measurable voltage between said conductors when said cable is exposed to ambient temperature without the use of an external power source, said continuous temperature representative measurable voltage being adapted for conversion into ambient temperature measured in degrees, said passive self-generating means comprising a material having a negative temperature coefficient associated with the surface of at least one of said conductors;
positioning said pair of thermoelectric conductors so as to be disposed in contacting side-by-side relation; and applying a flexible outer jacket to said conductors formed of an electrically non-conductive material so that said conductors are completely surrounded by said jacket and said jacket is holding said conductors firmly together substantially along their entire length;
said passive self-generating means being selected so as to cause an increase or decrease in said continuous temperature representative measurable voltage responsive to an associated increase or decrease in ambient temperature at every location along said cable, the change in said voltage under such condition being measurable and representative of an increase or decrease in ambient temperature and adapted for conversion into a new ambient temperature along said cable measured in degrees, said passive self-generating means also being selected so as to cause a change in said continuous temperature representative measurable voltage responsive to an associated increase in temperature above the prevailing ambient at any location along said cable, the change in said voltage under such condition also being measurable and representative of an increase in localized temperature and adapted for conversion into a maximum temperature along said cable measured in degrees;
whereby said manufacturing method provides a heat sensitive cable which may be utilized not only to monitor ambient temperature but also to monitor for any localized increase above ambient temperature over said range of temperatures for said cable in a predictable fashion to provide a continuous temperature sensor.
24. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein said step of providing said material comprising said passive self-generating means includes applying an electrical insulation to the surface of at least one of said conductors.
25. The method of manufacturing a heat sensitive cable as defined by Claim 24 wherein said applying step includes coating said conductor with a manganese nitrate solution.
26. The method of manufacturing a heat sensitive cable as defined by Claim 25 wherein said manganese nitrate solution is provided by heating manganese nitrate at a tem-perature of approximately 100°F until melted and thereafter heating said melted manganese nitrate at between approxi-mately 400° to 500°F for approximately 3 minutes.
27. The method of manufacturing a heat sensitive cable as defined by Claim 25 wherein said applying step includes heating said conductor after coating with said manganese nitrate solution.
28. The method of manufacturing a heat sensitive cable as defined by Claim 27 wherein said conductor is coat-ed with a solution of approximately 61 percent manganese nitrate and said conductor is heated to a temperature of between 300° and 450°F.
29. The method of manufacturing a heat sensitive cable as defined by Claim 24 wherein said applying step includes coating said conductor with a bonding material and embedding said bonding material with a powdered electrical insulation.
30. The method of manufacturing a heat sensitive cable as defined by Claim 29 wherein said applying step includes heating said conductor after covering said conduct-or with said bonding material, said bonding material there-after being embedded with said powdered electrical insula-tion.
31. The method of manufacturing a heat sensitive cable as defined by Claim 30 wherein said applying step includes heating said conductor after said bonding material has been embedded with said powdered electrical insulation.
32. The method of manufacturing a heat sensitive cable as defined by Claim 31 wherein said bonding material is a temperature resistant adhesive and said powdered elec-trical insulation is heat treated manganese dioxide.
33. The method of manufacturing a heat sensitive cable as defined by Claim 24 wherein said applying step includes providing a flexible wrap material, covering said flexible wrap material with a bonding material, embedding said bonding material with a powdered electrical insulation, and wrapping said conductor with said flexible wrap materi-al.
34. The method of manufacturing a heat sensitive cable as defined by Claim 33 wherein said bonding material is a temperature resistant adhesive and said powdered elec-trical insulation is heat treated manganese dioxide.
35. The method of manufacturing a heat sensitive cable as defined by Claim 24 wherein said applying step includes providing a wire having a negative temperature coefficient and wrapping said conductor with said wire.
36. The method of manufacturing a heat sensitive cable as defined by Claim 35 wherein said wire is formed of heat treated manganese dioxide.
37. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein one of said conductors is a nickel/chromium alloy and the other of said conductors is a copper/nickel alloy.
38. The method of manufacturing a heat sensitive cable as defined by Claim 37 wherein said nickel/chromium alloy comprises approximately 90 percent nickel and 10 percent chromium and said copper/nickel alloy comprises approximately 55 percent copper and 45 percent nickel.
39. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein said flexible outer jacket is applied by extruding said electrically non-conductive material onto said conductors to hold said conductors together under pressure along their entire length.
40. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein said flexible outer jacket is applied by heat shrinking said electrically non-conductive material onto said conductors to hold said conductors together under pressure along their entire length.
41. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein said flexible outer jacket is applied by wrapping said electrically non-conductive material onto said conductors to hold said conductors together under pressure along their entire length.
42. The method of manufacturing a heat sensitive cable as defined by Claim 23 wherein the heat sensitive cable is operable in a predictable fashion over a range of temperatures of between around at least -20°F and 500°F.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000530620A CA1288971C (en) | 1987-02-25 | 1987-02-25 | Heat sensitive cable and method of making same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000530620A CA1288971C (en) | 1987-02-25 | 1987-02-25 | Heat sensitive cable and method of making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1288971C true CA1288971C (en) | 1991-09-17 |
Family
ID=4135051
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000530620A Expired - Fee Related CA1288971C (en) | 1987-02-25 | 1987-02-25 | Heat sensitive cable and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1288971C (en) |
-
1987
- 1987-02-25 CA CA000530620A patent/CA1288971C/en not_active Expired - Fee Related
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