EP1647996B2 - Cable toronne en aluminium cuivre, et procede pour sa fabrication - Google Patents

Cable toronne en aluminium cuivre, et procede pour sa fabrication Download PDF

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Publication number
EP1647996B2
EP1647996B2 EP05356180.9A EP05356180A EP1647996B2 EP 1647996 B2 EP1647996 B2 EP 1647996B2 EP 05356180 A EP05356180 A EP 05356180A EP 1647996 B2 EP1647996 B2 EP 1647996B2
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EP
European Patent Office
Prior art keywords
wire
nickel
copper
bath
aluminum
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.)
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Application number
EP05356180.9A
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German (de)
English (en)
French (fr)
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EP1647996A1 (fr
EP1647996A9 (fr
EP1647996B1 (fr
EP1647996B9 (fr
Inventor
épouse Allaire Isabelle Michel
Louis Salvat
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FSP - One
F S P One
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FSP - One
F S P One
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Application filed by FSP - One, F S P One filed Critical FSP - One
Priority to DE602005005598.3T priority Critical patent/DE602005005598T3/de
Priority to PL05356180T priority patent/PL1647996T3/pl
Publication of EP1647996A1 publication Critical patent/EP1647996A1/fr
Publication of EP1647996A9 publication Critical patent/EP1647996A9/fr
Publication of EP1647996B1 publication Critical patent/EP1647996B1/fr
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    • 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 the manufacture of aluminum conductors or copper-plated and nickel-plated aluminum alloys. It relates more particularly to the manufacture of electrical cables comprising at least one conductor core of aluminum or aluminum alloy covered with a copper layer 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.
  • a difficulty is to achieve industrially, at low cost, the continuous layer of nickel, adherent and sealed.
  • the invention proposes a manufacturing procedure according to claim 1.
  • the polysulfide bath continuity test is defined by the ASTM B298 standard established by the American Society for Testing Materials.
  • Step d) is particularly critical.
  • the temperature of the electrolysis bath maintained between 55 ° C and 65 ° C
  • the pH of the electrolysis bath maintained between 2.3 and 3.0
  • the current density between 10 and 16 amperes by square decimetre (A / dm 2 )
  • the nickel concentration kept below about 140 grams per liter in the electrolysis bath, make it possible to achieve more definitely a conductor which satisfies the protection test in a polysulphide bath. optical examination mentioned above.
  • oxides may then cause, during drawing, discontinuities in the superficial layer of nickel, 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 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 conductive wire 1 obtained by a method according to the present 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 . This produces strands mixed 7, in which one increases by this structure the load at break and simultaneously reduces the conductivity at the expense of weight.
  • the thickness E of the surface layer 4 of nickel must be greater than 1.3 microns, otherwise it is found that the surface layer 4 of nickel is not sufficiently continuous to provide 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 hydrochloric acid solution having 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 thread 1 is examined, for example using a binocular loupe 41 in magnification x 10. It will not be worn. attention to the end zones of the wire sample 1, ie 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 obtained by a process 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, particularly in 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)
  • Ropes Or Cables (AREA)
  • Wire Processing (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)
EP05356180.9A 2004-10-12 2005-10-05 Cable toronne en aluminium cuivre, et procede pour sa fabrication Active EP1647996B2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE602005005598.3T DE602005005598T3 (de) 2004-10-12 2005-10-05 Verkupfertes Aluminium Strangkabel und sein Herstellungsverfahren
PL05356180T PL1647996T3 (pl) 2004-10-12 2005-10-05 Kabel linowy z aluminium pokrytego miedzią oraz sposób jego wytwarzania

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0411024A FR2876493B1 (fr) 2004-10-12 2004-10-12 Cable toronne en aluminium cuivre, et procede pour sa fabrication.

Publications (5)

Publication Number Publication Date
EP1647996A1 EP1647996A1 (fr) 2006-04-19
EP1647996A9 EP1647996A9 (fr) 2006-07-05
EP1647996B1 EP1647996B1 (fr) 2008-03-26
EP1647996B9 EP1647996B9 (fr) 2008-08-13
EP1647996B2 true EP1647996B2 (fr) 2016-11-16

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EP05356180.9A Active EP1647996B2 (fr) 2004-10-12 2005-10-05 Cable toronne en aluminium cuivre, et procede pour sa fabrication

Country Status (9)

Country Link
US (1) US7105740B2 (pl)
EP (1) EP1647996B2 (pl)
CN (1) CN1760993B (pl)
AT (1) ATE390694T1 (pl)
DE (2) DE05356180T1 (pl)
ES (1) ES2259944T1 (pl)
FR (1) FR2876493B1 (pl)
PL (1) PL1647996T3 (pl)
TW (1) TWI391525B (pl)

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JP5385683B2 (ja) * 2009-05-22 2014-01-08 矢崎総業株式会社 コネクタ端子
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US9324472B2 (en) 2010-12-29 2016-04-26 Syscom Advanced Materials, Inc. Metal and metallized fiber hybrid wire
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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
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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
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DE602005005598D1 (de) 2008-05-08
EP1647996A1 (fr) 2006-04-19
DE602005005598T3 (de) 2017-04-06
DE602005005598T2 (de) 2009-04-30
EP1647996A9 (fr) 2006-07-05
US20060102368A1 (en) 2006-05-18
ATE390694T1 (de) 2008-04-15
US7105740B2 (en) 2006-09-12
ES2259944T1 (es) 2006-11-01
FR2876493B1 (fr) 2007-01-12
EP1647996B1 (fr) 2008-03-26
TW200626746A (en) 2006-08-01
CN1760993B (zh) 2011-05-11
DE05356180T1 (de) 2006-10-12
PL1647996T3 (pl) 2008-09-30
CN1760993A (zh) 2006-04-19
EP1647996B9 (fr) 2008-08-13
FR2876493A1 (fr) 2006-04-14

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