EP0981821A1 - Cable with impact-resistant coating - Google Patents
Cable with impact-resistant coatingInfo
- Publication number
- EP0981821A1 EP0981821A1 EP98928233A EP98928233A EP0981821A1 EP 0981821 A1 EP0981821 A1 EP 0981821A1 EP 98928233 A EP98928233 A EP 98928233A EP 98928233 A EP98928233 A EP 98928233A EP 0981821 A1 EP0981821 A1 EP 0981821A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- cable
- coating
- expanded
- polymer material
- polymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/185—Sheaths comprising internal cavities or channels
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/189—Radial force absorbing layers providing a cushioning effect
Definitions
- the present invention relates to a coating for cables which is capable of protecting the cable from accidental impacts.
- This armor may be in the form of tapes or wires (generally made of steel) , or alternatively in the form of a metal sheath (generally made of lead or aluminum) ; this armor is, in turn, usually clad with an outer polymer sheath.
- a cable structure is described in US patent 5,153,381.
- the Applicant has observed that the presence of the abovementioned metal armor has a certain number of drawbacks.
- the application of the said armor includes one or more additional phases in the processing of the cable.
- the presence of the metal armor increases the weight of the cable considerably, in addition to posing environmental problems since, if it needs to be replaced, a cable constructed in this way is not easy to dispose of.
- the Japanese patent published under the number (Kokai) 7-320550 describes a domestic cable with an impact-resistant coating 0.2-1.4 mm in thickness, placed between the insulator and the outer sheath. This impact-resistant coating is a non-expanded polymer material containing a polyurethane resin as main component .
- German patent application no. P 15 15 709 discloses the use of an intermediate layer between the outer plastic sheath and the inner metallic sheath of a cable, in order to increase the resistance of the outer plastic sheath to low temperatures. No mention is made in such document about protecting the inner structure of the cable with said intermediate layer.
- such intermediate layer should compensate for elastic tensions generated in the outer plastic sheath due to temperature's lowering and may consist of loosely disposed glass fibers or of a material which may either be expanded or incorporating hollow glass spheres.
- German utility model no. G 81 03 947.6 discloses an electric cable for use in connections inside apparatuses and machines, having particular mechanical resistance and flexibility. Said cable is specifically designed for passing on a pulley and is sufficiently flexible in order to recover its straight structure after the passage on said pulley. Accordingly, this kind of cable is specifically aimed to resist to mechanical loads of the static type (such as those generated during the passage onto a pulley) , and its main feature is the flexibility. It is readily apparent to those skilled in the art that this kind of cable substantially differs from low- or medium-tension power transmission or distribution having a metal armor which, rather to be flexible, should be capable of withstanding dynamic loads due to impacts of a certain strength onto the cable.
- Coaxial cables are usually intended to carry high-frequency signals, such as coaxial cables for TV (CATV) (10-100 MHz), satellite cables (up to 2 GHz), coaxial cables for computers (above 1 MHz); traditional telephone cables usually carry signals with frequencies of about 800 Hz.
- CATV coaxial cables for TV
- satellite cables up to 2 GHz
- coaxial cables for computers above 1 MHz
- traditional telephone cables usually carry signals with frequencies of about 800 Hz.
- the purpose of using an expanded insulator in such cables is to increase the transmission speed of the electrical signals, in order to approach the ideal speed of signal transmission in an aerial conductive metal (which is close to the speed of light) .
- K dielectric constant
- US patent 4,711,811 describes a signal transmission cable having an expanded fluoro- poly er as insulator (thickness of 0.05-0.76 mm) clad with a film of ethylene/tetrafluoroethylene or ethylene/chlorotrifluoroethylene copolymer (thickness of 0.013-0.254 mm).
- the purpose of the expanded polymer is to insulate the conductor, while the purpose of the film of non- expanded polymer which clads the expanded polymer is to improve the mechanical properties of the insulation, in particular by imparting the necessary compression strength when two insulated conductors are twisted to form the so-called "twisted pair".
- Patent EP 442,346 describes a signal transmission cable with an insulating layer based on expanded polymer, placed directly around the conductor; this expanded polymer has an ultramicrocellular structure with a void volume of greater than 75% (corresponding to a degree of expansion of greater than 300%) .
- the ultramicrocellular structure of this polymer should be such that it is compressed by at least 10% under a load of 6.89 x 10 4 Pa and recovers at least 50% of its original volume after removal of the load; these values correspond approximately to the typical compression strength values which the material needs to have in order to withstand the compression during twisting of the cables.
- the term "impact” is intended to encompass all those dynamic loads of a certain energy capable to produce substantial damages to the structure of conventional unarmored cables, while while having negligible effects on the structure of conventional armored cables.
- such an impact may be considered an impact of about 20-30 joule produced by a V-shaped rounded-edge punch, having a curvature radius of about 1 mm, onto the outer sheath of the cable.
- an expanded polymer material used as a coating for cables according to the invention makes it possible to obtain an impact strength which is better than that obtained using a similar coating based on the same polymer which is not expanded.
- One aspect of the present invention thus relates to a power transmission cable comprising a) a conductor; b) at least one layer of compact insulating coating, c) a coating made of expanded polymer material, wherein said polymer material has predetermined mechanical strength properties and a predetermined degree of expansion so as to impart impact resistant properties to said cable.
- the expanded polymer material is obtained from a polymer material which has, before expansion, a flexural modulus at room temperature, measured according to ASTM standard D790, higher than 200 MPa, preferably between 400 MPa and 1500 MPa, values of between 600 MPa and 1300 MPa being particularly preferred.
- said polymer material has a degree of expansion of from abuot 20% to about 3000%, preferably from about 30% to about 500%, a degree of expansion of from about 50% to about 200% being particularly preferred.
- the coating of expanded polymer material has a thickness of at least 0.5 mm, preferably between 1 and 6 mm, in particular between 2 and 4 mm.
- this polyolefin polymer or copolymer based on PE and/or PP contains a predetermined amount of vulcanized rubber in powder form, preferably between 10% and 60% of the weight of the polymer.
- Another aspect of the present invention relates to a method for imparting impact strength to a cable, which comprises coating this cable with a coating made of expanded polymer material.
- this method for imparting impact strength to a cable moreover comprises coating this expanded coating with an outer protective sheath.
- this peel strength is measured between the layer of insulating coating and the outer layer of semiconductive coating.
- degree of expansion of the polymer is understood to refer to the expansion of the polymer determined in the following way:
- the three cores are roped together and the star-shaped areas between them are filled with a filling material (9) (generally elasto- meric mixtures, polypropylene fibers and the like) in order to make the cross-sectional structure circular, the whole in turn being coated with an inner polymer sheath (8), an armor of metal wires (7) and an outer polymer sheath (6).
- a filling material generally elasto- meric mixtures, polypropylene fibers and the like
- the impact-resistant expanded polymer coating may consist of any type of expandable polymer such as, for example, polyolefins, polyolefin copolymers, ole- fin/ester copolymers, polyesters, polycarbonates, poly- sulfones, phenolic resins, ureic resins and mixtures thereof.
- expandable polymer such as, for example, polyolefins, polyolefin copolymers, ole- fin/ester copolymers, polyesters, polycarbonates, poly- sulfones, phenolic resins, ureic resins and mixtures thereof.
- a polymer material chosen from those mentioned above is particularly suitable for this purpose, this material having, before expansion, a flexural modulus at room temperature of greater than 200 MPa, preferably of at least 400 MPa, measured according to ASTM standard D790.
- a polymer material which has a flexural modulus at room tempera- ture of less than 2000 MPa is particularly suitable.
- Polymer materials which are particularly suitable for this purpose are those which have, before expansion, a flexural modulus at room temperature of between 400 and 1800 MPa, a polymer material with a flexural modulus at room temperature of between 600 and 1500 MPa being particularly preferred.
- this coating will have to have a minimum apparent density of about : 0.40 g/cm 3 for LDPE (Mf of about 200);
- the protective outer sheath which clads the layer of expanded polymer may conveniently be of the type normally used.
- Materials for the outer coating which may be used are polyethylene (PE) , in particular medium-density PE (MDPE) and high-density PE (HDPE) , polyvinyl chloride (PVC), mixtures of elastomers and the like. MDPE or PVC is preferably used.
- the polymer material which forms this outer sheath has a flexural modulus of between about 400 and about 1200 MPa, preferably between about 600 MPa and about 1000 MPa.
- the Applicant has observed that the presence of the outer sheath contributes towards providing the coating with the desired impact strength characteristics, in combination with the expanded coating. In particular, the Applicant has observed that this contribution of the sheath towards the impact strength, for the same thickness of expanded coating, increases as the degree of expansion of the polymer which forms this expanded coating increases.
- the thickness of this outer sheath is preferably greater than 0.5 mm, in particular between 1 and 5 mm, preferably between 2 and 4 mm.
- cores are then roped together and the star-shaped spaces are filled with a conventional filling material (for example elastomeric mixtures, polypropylene fibers and the like) , typically by means of extrusion of the filler over the roped cores, so as to obtain a semi-processed cable with a circular cross-section.
- a conventional filling material for example elastomeric mixtures, polypropylene fibers and the like
- the coating of expanded polymer (10) is then extruded over the filling material.
- the die of the extruder head will have a diameter slightly smaller than the final diameter of the cable with expanded coating, in order to allow the polymer to expand outside the extruder.
- the peel strength of the coating layer may be measured according to the French standard HN 33-S-52, according to which the force needed to be applied to separate the outer semiconductive layer from the insulating layer is measured.
- the Applicant has observed that by measuring this force continuously, at the points at which the impact takes place, force peaks are measured which indicate a variation in the cohesive force between the two layers. It was observed that these variations are generally associated with a decrease in the insulating capacity of the coating. The variation will be proportionately larger the smaller the impact strength provided by the outer covering (which, in the case of the present invention, consists of the expanded coating and the outer sheath) .
- test pieces were prepared by extruding variable thicknesses of a few polymers with various degrees of expansion over a core composed of a multi-wire conductor about 14 mm in thickness coated with a layer of 0.5 mm of semiconductive material, a layer of 3 mm of an insulating mixture based on EPR and a further layer of 0.5 mm of "easy stripping" semiconductive material based on EVA supplemented with carbon black, for a total core thickness of about 22 mm.
- Low density polyethylene LDPE
- high density polyethylene HDPE
- polypropylene PP
- PP-EPR PP modified with EPR rubber
- the extrusion system consists of a male die capable of providing a smooth throughput of the core to be coated (generally with a diameter which is about 0.5 mm greater than the diameter of the core to be coated) , and a female die in which the diameter is chosen so as to have a size about 2 mm less than the diameter of the cable with the expanded coating; in this way, the extruded material expands on exiting the extrusion head rather than inside this head or inside the extruder.
- the throughput speed of the core to be coated (speed of the extrusion line) is set as a function of the desired thickness of expanded material (see Table 2) .
- a cooling pipe containing cold water
- composition of the polymer material/ expander mixture and the extrusion conditions were varied appropriately, as described in Table 2 below.
- the peel strength was measured according to the French standard HN 33-S-52, according to which the force needed to be applied in order to separate the outer semiconductive layer from the insulating layer is measured. By measuring this force continuously, force peaks are measured at the points at which the impact occurred. For each test piece, at the point of impact, a "positive" force peak was measured, corresponding to an increase in the force (relative to the average value) required to separate the two layers, and a "negative” force peak (decrease relative to the average value). From the difference between the maximum (Fmax) and minimum (Fmin) of the force peaks measured, the maximum variation in the peel strength at the point of impact is obtained.
- % variation 100 (Fmax-Fmin) /F ⁇ >
- Table 5 gives the values of the variation in the peel strength for samples 0-17a.
- sample 13 By comparing sample 13 with sample 15, it is seen how an increase in the degree of expansion of the polymer (from 22 to 124%), for the same thickness of the layer of expanded material and of the outer sheath, entails an increase in the impact strength of the coating (going from 16-17% to 10% of variation in the peel strength) . This trend is confirmed by comparing sample 16 with sample 17. However, by comparing samples 16a and 17a (without outer sheath) with the respective samples 16 and 17, it may be seen how the contribution provided by the outer sheath towards the impact protection increases as the degree of expansion increases .
- Cable no. 10 has been tested versus a conventional armored cable, in order to verify the impact strength efficiency of the expanded coating layer.
- the armored cable has the same core as cable no. 10 (i.e. a multi-wire conductor about 14 mm in thickness coated with a layer of 0.5 mm of semiconductive material, a layer of 3 mm of an insulating mixture based on EPR and a further layer of 0.5 mm of "easy stripping" semiconductive material based on EVA supplemented with carbon black, for a total core thickness of about 22 mm) .
- cable no. 10 i.e. a multi-wire conductor about 14 mm in thickness coated with a layer of 0.5 mm of semiconductive material, a layer of 3 mm of an insulating mixture based on EPR and a further layer of 0.5 mm of "easy stripping" semiconductive material based on EVA supplemented with carbon black, for a total core thickness of about 22 mm
- Said core is encircled, from the inside towards the outside of the cable by: a) a layer of rubber-based filling material of about 0.6 mm thickness; b) a sheath of PVC of about 0.6 mm thickness; c) 2 armoring steel tapes of about 0.5 mm thickness each; d) an outer sheath of MDPE of about 2 mm thickness.
- a dynamic machine of the "falling weight" type CEAST, mod. 6758
- the cable of the invention shows even better impact strength performances than a conventional armored cable .
Landscapes
- Insulated Conductors (AREA)
- Organic Insulating Materials (AREA)
- Ropes Or Cables (AREA)
- Paints Or Removers (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP98928233A EP0981821B2 (en) | 1997-05-15 | 1998-05-08 | Cable with impact-resistant coating |
SI9830219T SI0981821T1 (en) | 1997-05-15 | 1998-05-08 | Cable with impact-resistant coating |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP97107969 | 1997-05-15 | ||
EP97107969 | 1997-05-15 | ||
US4712797P | 1997-05-20 | 1997-05-20 | |
US47127P | 1997-05-20 | ||
EP98928233A EP0981821B2 (en) | 1997-05-15 | 1998-05-08 | Cable with impact-resistant coating |
PCT/EP1998/002698 WO1998052197A1 (en) | 1997-05-15 | 1998-05-08 | Cable with impact-resistant coating |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0981821A1 true EP0981821A1 (en) | 2000-03-01 |
EP0981821B1 EP0981821B1 (en) | 2002-07-03 |
EP0981821B2 EP0981821B2 (en) | 2008-12-31 |
Family
ID=8226797
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98928233A Expired - Lifetime EP0981821B2 (en) | 1997-05-15 | 1998-05-08 | Cable with impact-resistant coating |
Country Status (38)
Country | Link |
---|---|
EP (1) | EP0981821B2 (en) |
JP (1) | JP2002510424A (en) |
KR (1) | KR100493625B1 (en) |
CN (1) | CN1308964C (en) |
AP (1) | AP1121A (en) |
AR (1) | AR015677A1 (en) |
AT (1) | ATE220240T1 (en) |
AU (1) | AU743873B2 (en) |
BR (1) | BR9809119B1 (en) |
CA (1) | CA2289748C (en) |
CZ (1) | CZ293006B6 (en) |
DE (1) | DE69806377T3 (en) |
DK (1) | DK0981821T3 (en) |
DZ (1) | DZ2490A1 (en) |
EA (1) | EA001727B1 (en) |
EE (1) | EE04446B1 (en) |
EG (1) | EG21959A (en) |
ES (1) | ES2178223T5 (en) |
GE (1) | GEP20022663B (en) |
HU (1) | HU223994B1 (en) |
ID (1) | ID24381A (en) |
IL (1) | IL132408A (en) |
MA (1) | MA24545A1 (en) |
MY (1) | MY117958A (en) |
NO (1) | NO327795B1 (en) |
NZ (1) | NZ337909A (en) |
OA (1) | OA11303A (en) |
PL (1) | PL187115B1 (en) |
PT (1) | PT981821E (en) |
SI (1) | SI0981821T1 (en) |
SK (1) | SK286369B6 (en) |
TN (1) | TNSN98064A1 (en) |
TR (1) | TR199902729T2 (en) |
TW (1) | TW405126B (en) |
UY (1) | UY25000A1 (en) |
WO (1) | WO1998052197A1 (en) |
YU (1) | YU58199A (en) |
ZA (1) | ZA984027B (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9947438B2 (en) | 2013-09-23 | 2018-04-17 | Prysmian S.P.A. | Lightweight and flexible impact resistant power cable and process for producing it |
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US9947438B2 (en) | 2013-09-23 | 2018-04-17 | Prysmian S.P.A. | Lightweight and flexible impact resistant power cable and process for producing it |
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