EP1647996B1 - Verkupfertes Aluminium Strangkabel und sein Herstellungsverfahren - Google Patents
Verkupfertes Aluminium Strangkabel und sein Herstellungsverfahren Download PDFInfo
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- EP1647996B1 EP1647996B1 EP05356180A EP05356180A EP1647996B1 EP 1647996 B1 EP1647996 B1 EP 1647996B1 EP 05356180 A EP05356180 A EP 05356180A EP 05356180 A EP05356180 A EP 05356180A EP 1647996 B1 EP1647996 B1 EP 1647996B1
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- Prior art keywords
- nickel
- wire
- copper
- wires
- conductor
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 39
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 39
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 28
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 24
- 239000010949 copper Substances 0.000 title claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 9
- 238000000034 method Methods 0.000 title claims description 21
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 106
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 53
- 239000004020 conductor Substances 0.000 claims abstract description 42
- 238000012360 testing method Methods 0.000 claims abstract description 17
- 239000010410 layer Substances 0.000 claims description 39
- 238000005868 electrolysis reaction Methods 0.000 claims description 27
- 239000002344 surface layer Substances 0.000 claims description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 229920001021 polysulfide Polymers 0.000 claims description 11
- 238000000137 annealing Methods 0.000 claims description 10
- 238000005238 degreasing Methods 0.000 claims description 10
- 239000005077 polysulfide Substances 0.000 claims description 10
- 150000008117 polysulfides Polymers 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 9
- LNOPIUAQISRISI-UHFFFAOYSA-N n'-hydroxy-2-propan-2-ylsulfonylethanimidamide Chemical compound CC(C)S(=O)(=O)CC(N)=NO LNOPIUAQISRISI-UHFFFAOYSA-N 0.000 claims description 9
- 230000007935 neutral effect Effects 0.000 claims description 9
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 8
- 238000000151 deposition Methods 0.000 claims description 7
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims description 6
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 claims description 4
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 4
- KERTUBUCQCSNJU-UHFFFAOYSA-L nickel(2+);disulfamate Chemical compound [Ni+2].NS([O-])(=O)=O.NS([O-])(=O)=O KERTUBUCQCSNJU-UHFFFAOYSA-L 0.000 claims description 4
- 229910052757 nitrogen Inorganic materials 0.000 claims description 4
- 239000004642 Polyimide Substances 0.000 claims description 3
- 238000005530 etching Methods 0.000 claims description 3
- 229920001721 polyimide Polymers 0.000 claims description 3
- -1 polytetrafluoroethylene Polymers 0.000 claims description 3
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 3
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 3
- 239000004094 surface-active agent Substances 0.000 claims description 3
- 238000002604 ultrasonography Methods 0.000 claims description 3
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims 1
- 239000004411 aluminium Substances 0.000 abstract description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 8
- 239000000243 solution Substances 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 239000008367 deionised water Substances 0.000 description 5
- 229910021641 deionized water Inorganic materials 0.000 description 5
- 238000011282 treatment Methods 0.000 description 5
- 229910000838 Al alloy Inorganic materials 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000007774 longterm Effects 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 239000012085 test solution Substances 0.000 description 3
- 238000005491 wire drawing Methods 0.000 description 3
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 238000007865 diluting Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000010926 purge Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- HYHCSLBZRBJJCH-UHFFFAOYSA-N sodium polysulfide Chemical compound [Na+].S HYHCSLBZRBJJCH-UHFFFAOYSA-N 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 241000135309 Processus Species 0.000 description 1
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000001464 adherent effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- GRVFOGOEDUUMBP-UHFFFAOYSA-N sodium sulfide (anhydrous) Chemical compound [Na+].[Na+].[S-2] GRVFOGOEDUUMBP-UHFFFAOYSA-N 0.000 description 1
- IIACRCGMVDHOTQ-UHFFFAOYSA-M sulfamate Chemical compound NS([O-])(=O)=O IIACRCGMVDHOTQ-UHFFFAOYSA-M 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 230000004584 weight gain Effects 0.000 description 1
- 235000019786 weight gain Nutrition 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/026—Alloys based on copper
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/02—Stranding-up
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/008—Power cables for overhead application
Definitions
- the present invention relates to conductors made of aluminum or copper-plated and nickel-plated aluminum alloy. It relates more particularly to electrical cables comprising at least one core conductor made of aluminum or aluminum alloy covered with a layer of copper itself covered with a layer of nickel.
- the word “aluminum” broadly designates aluminum and its alloys.
- the word “conductor” refers to an elongated electrically conductive body, the length of which is large relative to its cross-section, and which is generally in the form of a wire.
- Aluminum-based electrical conductors are widely used in the transportation of electrical energy.
- Aluminum-core electrical wires and cables may include a coating of insulating material, and single wires or strands may be assembled to form the conductive core of a cable.
- aluminum conductors can be used in the raw state, that is to say without special treatment of the conductor surface.
- Nickel plated aluminum wire strand electrical cables have already been used for example in aeronautical applications. There are more than one hundred kilometers of such cables in some current airliners.
- aluminum has the advantage of reducing weight: for the same electrical resistance, an aluminum conductor weighs about half the weight of a copper conductor.
- the document DE 196 33 615 A1 discloses the use of an aluminum wire having a copper coating on which is applied an outer layer of nickel.
- the document FR 2,083,323 discloses an aircraft cable having copper coated aluminum wires itself coated with a nickel layer. Each conductor is isolated by one or more layers of plastic material.
- the object of the invention is to propose a new structure of stranded cable for conduction of electric current having both a low electrical resistivity, good flexibility, a sufficiently large breaking load, good electrical contact properties, good anticorrosive properties for long-term use in aggressive conditions, and good capacities to absorb mechanical tightenings of electrical connection.
- a problem is in particular to provide a protective nickel surface layer which has a satisfactory quality, both in sealing and in adhesion on the lower layer of the conductor, but which does not substantially disturb the other properties of the conductor such as electrical conductance , flexibility, weight, load at break.
- the invention proposes an electric conductor of the aluminum cable type comprising at least one strand based on conducting wires having an aluminum core covered with an intermediate layer of copper, the intermediate layer of copper being itself covered with a surface layer of nickel.
- the invention provides such a surface layer of nickel in a thickness of between about 1.3 ⁇ m and 3.0 ⁇ m, this superficial layer of nickel having sufficient continuity to withstand a polysulfide bath continuity test for at least 30 seconds without showing visible copper etching areas at 10x magnification.
- the polysulfide bath continuity test is defined by the ASTM B298 standard established by the American Society for Testing Materials.
- the thickness of the nickel surface layer is between about 2 ⁇ m and 3 ⁇ m.
- it may be a cable comprising a strand of 37 son of 0.32 or 0.25 mm in diameter.
- the cable may comprise a strand of 19 son of 0.30 or 0.25 or 0.20 mm in diameter.
- nickel-plated copper alloy core wire surrounded by six nickel-plated copper aluminum wires of about 0.25 or 0.20 mm in diameter.
- the cable can be stranded according to one or more concentric strands or concentric strands, or concentric unilay.
- the strand or strands and / or the cable may then be covered with an insulating layer of polyimide, and an outer layer of polytetrafluoroethylene.
- This method makes it possible in particular to avoid the appearance of oxides at the interfaces between the layers, in particular under the nickel layer, which oxides may then cause, during the drawing, discontinuities in the nickel surface layer, and thus reduce the protective and contact properties of this layer.
- the neutral gas may advantageously be nitrogen.
- the temperature can be about 250 ° C. for a period of at least about two hours.
- Step d) is particularly critical.
- the temperature of the electrolysis bath can be maintained between about 55 ° C and 65 ° C
- the pH of the electrolysis bath can be maintained between about 2.3 and 3.0
- the current density can be between 10 and 16 amperes per square decimetre (A / dm 2 )
- the nickel concentration can be kept below about 140 grams per liter in the electrolysis bath. This makes it possible to more surely achieve a conductor that satisfies the optical polysulfide bath protection test mentioned above.
- step d it is possible to predict that the temperature of the electrolysis bath is about 60 ° C., that the pH of the electrolysis bath is about 2.4, that the density current is about 15 to 16 amperes per square decimetre (A / dm 2 ).
- the method may comprise a step prior to o ) calibrating the copper-plated aluminum roughing wire in size and hardness.
- the copper-plated aluminum roughing wire may have, for example, a load at break less than or equal to 20 decaNewtons per square millimeter (daN / mm 2 ) approximately, and an elongation of between 2 and about 3%. In this way, it is still avoided, during drawing, the appearance of gaps or discontinuities in the surface layer of nickel.
- the sulfamic acid bath may advantageously have a concentration of about 40 grams per liter.
- the initial diameter of the copper-plated aluminum roughing wire may be between about 1.2 and 0.8 mm.
- the nickel deposit is then carried out in a thickness of about 10 to 15 ⁇ m.
- the final diameter of the coppered and nickel-plated aluminum wire is between 0.51 mm and 0.20 mm.
- the stranding step g) is preferably carried out before the annealing step h).
- the annealing step h) is preferably carried out before the stranding step g).
- FIG. 1 illustrates the structure of a conductor wire 1 according to one embodiment of the invention.
- a core 2 of aluminum covered with an intermediate layer 3 of copper, itself covered with a surface layer 4 of nickel.
- the aluminum constituting the core 2 may be pure aluminum or an aluminum alloy.
- a 99.5% aluminum alloy having at most 0.10% silicon and at most 0.40% iron may be preferred.
- the wire may have a final total diameter D F of between about 0.51 mm and 0.20 mm. Other diameter values may however be used, depending on the characteristics sought.
- the copper of the intermediate layer 3 may advantageously represent 15% by volume of the wire. This leads to a wire having the following characteristics: a density at 20 ° C of about 3.60 kilograms per cubic decimeter, a resistivity of 2.78 ⁇ 10 -8 ohms per meter, a conductivity of 60% to 64% IACS, typically 62% IACS, a breaking load of 138 Newtons per square millimeter and a minimum elongation of 6%.
- the above son are stranded together by the usual techniques of forming cables.
- a strand 5 of 19 wires, such as wire 1 in a concentric strand structure, the layers being of alternate directions.
- a strand 6 of 19 wires, such as the wire 1 was made according to a strand structure unilay, the layers being of the same direction.
- Smaller section structures may comprise seven-stranded strands 7 having a central strand 7a and six peripheral strands 7b-7g, as illustrated in FIG. figure 4 .
- the central strand 7a may be made of nickel-plated copper alloy
- the peripheral strands 7b-7g are made of copper-plated and nickel-plated aluminum like the wire 1 of the figure 1 .
- Mixed strands 7 are thus produced in which the load at break is increased by this structure and the conductivity is reduced simultaneously, to the detriment of the weight.
- the thickness E of the surface layer 4 of nickel must be greater than 1.3 ⁇ m, failing which it is found that the surface layer 4 of nickel is not sufficiently continuous to provide a effective protection of the intermediate layer 3 of copper. It is not advantageous to make a nickel layer whose thickness is greater than about 3 ⁇ m, since this adversely affects the other properties of the conductor such as electrical conductance, flexibility, load at break, and this reduces substantially the speed of manufacture of the driver.
- the thickness E of the surface layer 4 of nickel will be between about 2 ⁇ m and 3 ⁇ m, and a good compromise is obtained with a surface layer 4 whose thickness E is equal to about 2.3 ⁇ m.
- cables will be made with different numbers of wires and strands depending on the range.
- a cable may comprise 7 strands of 10 or 15 wires each, the wires having a unit diameter of about 0.51 mm.
- a cable is formed comprising seven strands of 19 son each, the son having a unit diameter of about 0.275 mm.
- a cable is formed comprising a strand of 61 wires of about 0.32 mm in diameter.
- the cable comprises a strand of 37 wires of about 0.32 or 0.25 mm.
- the cable comprises a strand of 19 wires of about 0.30 or 0.25 or 0.20 mm, in a structure of Figures 2 or 3 .
- the cables with smaller section will consist of a nickel-plated copper alloy core wire 7a, surrounded by six son 7b-7g of copper-plated and nickel-plated aluminum of 0.25 or 0.20 mm in diameter.
- the strands can then be covered with an insulating layer of polyimide and an outer layer of polytetrafluoroethylene.
- the roughing wire 8 was processed by an illustrated method on the figures 6 and 7 .
- the roughing wire 8 consisted of an aluminum core 8a, covered with a copper surface layer 8b, the copper representing 15% by volume of the assembly.
- FIG. 6 schematically illustrates the general structure of a device for manufacturing a wire according to a method of the invention.
- the roughing wire 8 passes firstly into an ultrasound device 9, which performs a first degreasing.
- the wire then passes into an anode degreasing tank 10, which performs anodic degreasing in a bath 11 which may for example contain sodium hydroxide and surfactants.
- a bath 11 which may for example contain sodium hydroxide and surfactants.
- the wire then passes into a rinsing device 12, producing a rinsing of the wire with demineralised water.
- the yarn then passes into a tray 13 containing a sulfamic acid bath 14.
- the sulfamic acid concentration may advantageously be about 40 grams per liter. This provides a surface treatment of the copper layer, facilitating the subsequent adhesion of nickel.
- the wire then passes into an electrolytic nickel deposition device 15, which provides a suitable deposition of a surface layer of nickel.
- the device will be described in more detail in relation to the figure 7 .
- the wire then passes into a second rinsing device 16, which rinses the wire with demineralised water.
- the wire then passes into a wire drawing device 17, in which a complete oil drawing is carried out to the final diameter, that is to say in the range of about 0.51 - 0.20 mm in diameter.
- wire drawing takes place at a different speed than previous treatments. It is therefore necessary to provide an intermediate step during which the wire is packaged in a coil after the rinsing step in the rinsing device 16, and the wire is coated with a film of whole oil which protects it until to a subsequent drawing treatment.
- the wire passes through an oven 18 associated with a source of neutral gas 19 such as nitrogen, in which the wire is annealed under nitrogen at about 240 ° C. for about two hours. This gives a wire 1 output, as illustrated on the figure 1 .
- a source of neutral gas 19 such as nitrogen
- the result obtained by this method may depend on the size and the structure of the blank wire 8.
- a roughing wire having a breaking load of less than or equal to about 20 daN per mm 2 , and an elongation of between about 2 and 3%, with a constant dimension selected from the range of diameters between three and a half. times and five times the desired final diameter of the wire.
- the device comprises an internal overflow tank 20, containing the electrolysis bath 21 which discharges, as indicated by the arrow 22, into an external tank 23 which contains the internal tank 20.
- the liquid collected in the outer tank 23 is sent by pipes 24 in a storage tank 25, from which the liquid is returned to the inner tank 20 by a pump 26 and a pipe 27.
- a nickel metal reserve 28 is housed in the inner tank 20, inside the electrolysis bath 21.
- the blank wire 8 is moved and guided through the inner tank 20, in several passages, and comes out after depositing a layer of nickel on its surface.
- the nickel reserve 28 is electrically connected to the positive pole of an electric generator 29 whose negative pole is connected to the wire 8.
- the electrolysis bath 21 contains nickel sulphamate in aqueous solution. Good results require permanent control of the concentration of the electrolysis bath 21. This is done by connecting the storage tank 25 to a water supply 30, to a purge line 31, to a source of sulfamic acid 32 The pH of the electrolysis bath 21 is controlled by a pH sensor 33 acting on a regulator which controls the operation of the corresponding valves to withdraw a quantity of liquid from the electrolysis bath 21 via the purge pipe 31, to add water by the water supply 30, and to add sulfamic acid by the sulfamic acid source 32.
- the pH of the electrolysis bath was advantageously maintained between about 2.3 and 3.0, preferably close to 2.4.
- the temperature of the electrolysis bath 21 was also regulated, by means of a temperature sensor 34 and heating means 35, so that the electrolysis bath was for example at a temperature of approximately 60 ° C.
- the nickel sulfamate concentration in the electrolysis bath 21 was kept low, for example less than 140 grams per liter of nickel. Otherwise, the superficial layer of nickel would have been too hard, and would have poorly supported the subsequent drawing.
- the electric generator 29 is adapted to regulate the electrolysis current density.
- the electrolysis current density has advantageously been maintained within a range of values of between 10 and 16 A / dm 2 ; preferably between 15 and 16 A / dm 2 .
- a difficulty has been in determining the good, acceptable or poor quality of the nickel coating produced by the process.
- a polysulfide bath test according to ASTM B298 has been successfully used, with a specific optical examination, which provides an overall result of quality control of the coating, highlighting any gaps or microcracks in the nickel coating.
- a sample of yarn 1 is first defatted by immersion in a suitable organic solvent such as benzene, trichlorethylene or a mixture of ether and alcohol for at least 3 minutes. It is then removed and dried by wiping with a soft, clean cloth. The wire sample 1 should be held in the tissue until the test is complete, and should not be touched by hand.
- a suitable organic solvent such as benzene, trichlorethylene or a mixture of ether and alcohol
- a concentrated solution of polysulfide is prepared by dissolving sodium sulphide crystals in deionized water until saturation at about 21 ° C and adding enough sulfur flower to obtain complete saturation, which can be controlled by the presence of an excess of sulfur when the solution has sat for at least 24 hours.
- the test solution was made by diluting a portion of the concentrated solution with deionized water to a specific gravity of 1.142 at 15.6 ° C.
- the sodium polysulfide test solution should have sufficient strength to fully blacken a section of copper wire within 5 seconds. The test solution will not be considered exhausted as long as it can blacken a piece of copper.
- a solution of hydrochloric acid is prepared simultaneously by diluting the commercial hydrochloric acid with distilled water to a density of 1.088 measured at 15.6 ° C. A portion of the acid solution hydrochloric acid with a volume of 180 milliliters will be considered exhausted if it can not suppress in 45 seconds the silver discoloration due to immersion in the polysulfide.
- the sample of yarn 1 having a length of at least 114 mm was immersed for 30 seconds in a polysulfide bath 37 containing the above-described solution of sodium polysulfide maintained at a temperature of between 15.degree. 6 ° C and 21 ° C.
- wire sample 1 is rinsed with deionized water 38, and dried with a soft, clean cloth.
- the sample of yarn 1 was immediately immersed for 15 seconds in a hydrochloric acid solution described above, then washed thoroughly with deionized water and dried with a clean, soft cloth.
- the sample of wire 1 is examined, for example using a binocular loupe 41 in magnification x 10. No attention will be paid to the end zones of the wire sample. 1, that is, the areas within 12.7 mm of each end.
- a sample of yarn 1 taken from a thread of good quality, illustrated in the photograph of the figure 9 does not show a visible mark of attack of the lower layer of copper by the polysulfide bath. It is estimated that an attack mark is visible when it has an area of at least 0.02 mm 2 in magnification x 10 (corresponding to a spot of 0.01 mm side at magnification 1).
- the electrical conductors according to the present invention may advantageously be used in all types of applications requiring a good compromise between conductivity, load at break, flexibility, weight, and long-term protection, especially in the aeronautics, in the automobile, and generally in all types of mobiles.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Non-Insulated Conductors (AREA)
- Insulated Conductors (AREA)
- Electroplating Methods And Accessories (AREA)
- Conductive Materials (AREA)
- Processes Specially Adapted For Manufacturing Cables (AREA)
- Wire Processing (AREA)
- Ropes Or Cables (AREA)
Claims (21)
- Elektrischer Leiter des Typs Aluminiumkabel mit mindestens einer Litze auf Basis von leitenden Drähten (1) mit einer Seele (2) aus Aluminium, die mit einer Zwischenschicht (3) aus Kupfer beschichtet ist, die ihrerseits mit einer Beschichtung (4) aus Nickel beschichtet ist, dadurch gekennzeichnet,
daß:- die Beschichtung (4) aus Nickel eine Dicke (E) zwischen ca. 1,3 µm und 3 µm hat,- die Beschichtung (4) aus Nickel eine Kontinuität hat, die ausreicht, einem Kontinuitätstest in einem Bad aus Polysulfid (37) für mindestens 30 Sekunden zu widerstehen, ohne Angriffszonen (42) von sichtbarem Kupfer bei einer Vergrößerung von x 10 erscheinen zu lassen. - Leiter nach Anspruch 1, dadurch gekennzeichnet,
daß die Dicke (E) der Beschichtung (4) aus Nickel zwischen ca. 2 µm und 3 µm liegt. - Leiter nach Anspruch 2, dadurch gekennzeichnet,
daß die Dicke (E) der Beschichtung (4) aus Nickel ca. 2,3 µm beträgt. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er aus einem Kabel von sieben Litzen mit jeweils 10 oder 15 Drähten besteht, wobei die Drähte einen einheitlichen Durchmesser von ca. 0,51 mm haben. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er aus einem Kabel von sieben Litzen mit jeweils 19 Drähten besteht, wobei die Drähte einen einheitlichen Durchmesser von ca. 0,275 mm haben. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er aus einem Kabel besteht, das eine Litze von 61 Drähten mit einem Durchmesser von ca. 0,32 mm enthält. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er aus einem Kabel besteht, das eine Litze mit 37 Drähten mit einem Durchmesser von ca. 0,32 mm oder 0,25 mm enthält. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er aus einem Kabel besteht, das eine Litze (5, 6) von 19 Drähten mit ca. 0,30 oder 0,25 oder 0,20 mm enthält. - Leiter nach irgendeinem der Ansprüche 1 bis 3, dadurch gekennzeichnet,
daß er einen zentralen Draht (7a) aus einer Legierung von vernickeltem Kupfer enthält, der von sechs Drähten (7b-7g) aus verkupfertem, vernickeltem Aluminium von ca. 0,25 oder 0,20 mm Durchmesser umgeben ist. - Leiter nach irgendeinem der Ansprüche 1 bis 9, dadurch gekennzeichnet,
daß das Kabel mit einem oder mehreren gegenläufig konzentrischen oder gleichläufig konzentrischen Litzen verseilt ist. - Leiter nach irgendeinem der Ansprüche 1 bis 10, dadurch gekennzeichnet,
daß die Litze oder die Litzen und/oder das Kabel mit einer Isolierschicht aus Polyimid und einer äußeren Schicht aus Polytetrafluorethylen beschichtet sind. - Verfahren zur Herstellung eines Leiters nach irgendeinem der Ansprüche 1 bis 11, bei welchem man ein Herstellverfahren für einen verkupferten und vernickelten Aluminiumdraht vorsieht, das folgende Schritte enthält:a) Bereitstellen eines Rohdrahtes (8) mit einer Seele aus Aluminium (8a), die mit einer Schicht aus Kupfer (8b) beschichtet ist, die 10 Volumen% bis 20 Volumen% darstellt, mit einem Durchmesser (DI), der zwischen dem zweifachen und dem fünffachen des endgültigen Durchmessers (DF), der für den Draht gewünscht wird, liegt,b) Entfetten des Rohdrahtes (8),c) Behandeln mit einer Ätzung des Rohdrahtes (8) mit sulfatischer Säure (14),d) Abscheiden einer Schicht aus Nickel mittels Elektrolyse in einem Elektrolysenbad (21) aus wässrigem Nickelsulfamat auf den Rohdraht (8), die Temperatur des Elektrolysebades (21) zwischen ca. 55°C und 65°C gehalten bleibt, der pH-Wert des Elektrolysebades (21) zwischen ungefähr 2,3 und 3,0 gehalten bleibt, die Stromdichte (j) zwischen 10 und 16 A/dm2 liegt, die Konzentration von Nickel unter ca. 140 Gramm pro Liter im Elektrolysebad (21) ist,e) Spülen des erhaltenen Drahtes mit demineralisiertem Wasser,f) Ziehen des erhaltenen Drahtes in reinem Öl bis zum endgültigen Durchmesser,g) Verseilen mehrerer so erhaltener Drähte zu Bündeln von Drähten,h) Unterziehen eines Glühens unter neutralem Gas.
- Verfahren nach Anspruch 12, dadurch gekennzeichnet, daß während des Schrittes h) des Glühens unter neutralem Gas das neutrale Gas Stickstoff ist.
- Verfahren nach einem der Ansprüche 12 oder 13, dadurch gekennzeichnet,
daß während des Schrittes h) des Glühens unter neutralem Gas die Temperatur während einer Dauer von mindestens ungefähr zwei Stunden bei ungefähr 250°C liegt. - Verfahren nach irgendeinem der Ansprüche 12 bis 14, dadurch gekennzeichnet,
daß während des Schrittes d) die Temperatur des Elektrolysebades (21) bei ungefähr 60°C liegt, der pH-Wert des Elektrolysebades (21) bei ungefähr 2,4, die Stromdichte bei ungefähr 15 bis 16 A/dm2 ist. - Verfahren nach irgendeinem der Ansprüche 12 bis 15, dadurch gekennzeichnet,
daß es einen vorhergehenden Schritt a0) des Kalibrierens des Rohdrahtes (8) aus verkupfertem Aluminium hinsichtlich Abmessung und hinsichtlich Härte enthält. - Verfahren nach irgendeinem der Ansprüche 12 bis 16, dadurch gekennzeichnet,
daß nach einem eventuellen Schritt des Kalibrierens a0) der Rohdraht (8) aus verkupfertem Aluminium eine Bruchlast von unterhalb oder gleich etwa 20 daN/mm2 hat und eine Längung von ungefähr zwischen 2 und 3 %. - Verfahren nach irgendeinem der Ansprüche 12 bis 17, dadurch gekennzeichnet,
daß während des Schrittes c) das Bad aus sulfatischer Säure eine Konzentration von ungefähr 40 Gramm pro Liter hat. - Verfahren nach irgendeinem der Ansprüche 12 bis 18, dadurch gekennzeichnet,
daß der Anfangsdurchmesser (DI) des Rohdrahtes (8) aus verkupfertem Aluminium zwischen ungefähr 1,2 und 0,8 mm liegt, die Abscheidung von Nickel sich gemäß einer Dicke von ungefähr 10 bis 15 µm bewirkt, der endgültige Durchmesser des Drahtes (1) aus verkupfertem und vernickeltem Aluminium zwischen ungefähr 0,51 mm und 0,20 mm liegt. - Verfahren nach irgendeinem der Ansprüche 12 bis 19, dadurch gekennzeichnet,
daß der Schritt b) des Entfettens des Drahtes enthält:b1) Entfetten des Rohdrahtes (8) mittels Ultraschall,b2) Bearbeiten des Rohdrahtes (8) mittels einer anodischen Entfettung in einem Bad (11), das Natron und Tenside enthält,b3) Spülen des Rohdrahtes (8) mit demineralisiertem Wasser. - Verfahren nach irgendeinem der Ansprüche 12 bis 20, dadurch gekennzeichnet,
daß bei Drähten mit einem Durchmesser von weniger oder gleich 0,25 mm man den Schritt g) des Verseilens vor dem Schritt h) des Glühens durchführt, während man bei Drähten mit größerem Durchmesser den Schritt h) des Glühens vor dem Schritt g) des Verseilens durchführt.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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PL05356180T PL1647996T3 (pl) | 2004-10-12 | 2005-10-05 | Kabel linowy z aluminium pokrytego miedzią oraz sposób jego wytwarzania |
DE602005005598.3T DE602005005598T3 (de) | 2004-10-12 | 2005-10-05 | Verkupfertes Aluminium Strangkabel und sein Herstellungsverfahren |
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FR0411024A FR2876493B1 (fr) | 2004-10-12 | 2004-10-12 | Cable toronne en aluminium cuivre, et procede pour sa fabrication. |
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EP1647996A1 EP1647996A1 (de) | 2006-04-19 |
EP1647996A9 EP1647996A9 (de) | 2006-07-05 |
EP1647996B1 true EP1647996B1 (de) | 2008-03-26 |
EP1647996B9 EP1647996B9 (de) | 2008-08-13 |
EP1647996B2 EP1647996B2 (de) | 2016-11-16 |
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EP05356180.9A Active EP1647996B2 (de) | 2004-10-12 | 2005-10-05 | Verkupfertes Aluminium Strangkabel und sein Herstellungsverfahren |
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Country | Link |
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US (1) | US7105740B2 (de) |
EP (1) | EP1647996B2 (de) |
CN (1) | CN1760993B (de) |
AT (1) | ATE390694T1 (de) |
DE (2) | DE602005005598T3 (de) |
ES (1) | ES2259944T1 (de) |
FR (1) | FR2876493B1 (de) |
PL (1) | PL1647996T3 (de) |
TW (1) | TWI391525B (de) |
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DE102006041355B4 (de) * | 2006-09-01 | 2011-07-21 | W.C. Heraeus GmbH, 63450 | Aluminium-Bonddrähte mit eingebetteten Kupferfasern |
US20080196926A1 (en) * | 2007-02-17 | 2008-08-21 | Kevin Yang | Copper clad ballast wire |
FR2918786A1 (fr) * | 2007-07-10 | 2009-01-16 | Nexans Sa | Fil electrique de transmission de signaux destine a l'industrie aeronautique et spatiale. |
JP5177848B2 (ja) * | 2007-12-21 | 2013-04-10 | 矢崎総業株式会社 | 複合電線 |
MY147054A (en) * | 2008-03-07 | 2012-10-15 | Joinset Co Ltd | Solderable elastic electric contact terminal |
DE102008014814B4 (de) * | 2008-03-18 | 2010-07-08 | Alexander Binzel Schweisstechnik Gmbh & Co. Kg | Schlauchpaket |
WO2010006313A1 (en) * | 2008-07-10 | 2010-01-14 | Robert Norman Calliham | Method for producing copper-clad aluminum wire |
JP5385683B2 (ja) * | 2009-05-22 | 2014-01-08 | 矢崎総業株式会社 | コネクタ端子 |
US20110079427A1 (en) * | 2009-10-07 | 2011-04-07 | Lakshmikant Suryakant Powale | Insulated non-halogenated covered aluminum conductor and wire harness assembly |
WO2011112647A1 (en) | 2010-03-09 | 2011-09-15 | Dyno Nobel Inc. | Sealer elements, detonators containing the same, and methods of making |
WO2012092505A1 (en) | 2010-12-29 | 2012-07-05 | Syscom Advanced Materials | Metal and metallized fiber hybrid wire |
US20130008708A1 (en) * | 2011-07-07 | 2013-01-10 | Burke Thomas F | Electrical shielding material composed of metallized aluminum monofilaments |
CN103117114B (zh) * | 2013-02-21 | 2016-07-06 | 罗志昭 | 一种铜与铝合金配合使用方法 |
CN104283351A (zh) * | 2013-07-02 | 2015-01-14 | 丹佛斯(天津)有限公司 | 定子、三相感应电机和压缩机 |
WO2015109060A1 (en) * | 2014-01-15 | 2015-07-23 | Fisk Alloy, Inc. | High strength, light weight, high conductivity hybrid cable conductor |
CN103871655A (zh) * | 2014-03-26 | 2014-06-18 | 中利科技集团股份有限公司 | 通信电源用铝芯阻燃软电缆 |
CN104064256B (zh) * | 2014-07-16 | 2016-05-04 | 武汉纵缆通模具有限公司 | 异型线绞合电缆导体及其生产方法 |
FR3050066A1 (fr) * | 2016-04-11 | 2017-10-13 | Nexans | Cable electrique presentant une resistance a la corrosion galvanique amelioree |
CN106238950A (zh) * | 2016-08-26 | 2016-12-21 | 武汉市润之达石化设备有限公司 | 不锈钢麻花辫焊接材料及其制作方法 |
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DE102017211543A1 (de) * | 2017-07-06 | 2019-01-10 | Siemens Aktiengesellschaft | Modularer Mehrpegelenergiewandler |
WO2020189689A1 (ja) * | 2019-03-20 | 2020-09-24 | 住友電気工業株式会社 | アルミニウム基線材 |
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-
2004
- 2004-10-12 FR FR0411024A patent/FR2876493B1/fr active Active
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2005
- 2005-10-05 DE DE602005005598.3T patent/DE602005005598T3/de active Active
- 2005-10-05 PL PL05356180T patent/PL1647996T3/pl unknown
- 2005-10-05 ES ES05356180T patent/ES2259944T1/es active Pending
- 2005-10-05 EP EP05356180.9A patent/EP1647996B2/de active Active
- 2005-10-05 AT AT05356180T patent/ATE390694T1/de not_active IP Right Cessation
- 2005-10-05 DE DE05356180T patent/DE05356180T1/de active Pending
- 2005-10-11 US US11/247,834 patent/US7105740B2/en active Active
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Also Published As
Publication number | Publication date |
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FR2876493B1 (fr) | 2007-01-12 |
TW200626746A (en) | 2006-08-01 |
US20060102368A1 (en) | 2006-05-18 |
DE602005005598D1 (de) | 2008-05-08 |
DE602005005598T3 (de) | 2017-04-06 |
ATE390694T1 (de) | 2008-04-15 |
FR2876493A1 (fr) | 2006-04-14 |
DE05356180T1 (de) | 2006-10-12 |
CN1760993B (zh) | 2011-05-11 |
EP1647996A9 (de) | 2006-07-05 |
EP1647996B2 (de) | 2016-11-16 |
DE602005005598T2 (de) | 2009-04-30 |
ES2259944T1 (es) | 2006-11-01 |
US7105740B2 (en) | 2006-09-12 |
EP1647996A1 (de) | 2006-04-19 |
TWI391525B (zh) | 2013-04-01 |
CN1760993A (zh) | 2006-04-19 |
PL1647996T3 (pl) | 2008-09-30 |
EP1647996B9 (de) | 2008-08-13 |
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