GB2439355A - Method and apparatus for manufacturing an insulated electrical cable. - Google Patents
Method and apparatus for manufacturing an insulated electrical cable. Download PDFInfo
- Publication number
- GB2439355A GB2439355A GB0612253A GB0612253A GB2439355A GB 2439355 A GB2439355 A GB 2439355A GB 0612253 A GB0612253 A GB 0612253A GB 0612253 A GB0612253 A GB 0612253A GB 2439355 A GB2439355 A GB 2439355A
- Authority
- GB
- United Kingdom
- Prior art keywords
- insulated electrical
- metallic particles
- layer
- electrical conductor
- metallic
- 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.)
- Withdrawn
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 18
- 238000000034 method Methods 0.000 title claims description 14
- 239000013528 metallic particle Substances 0.000 claims abstract description 41
- 239000004020 conductor Substances 0.000 claims abstract description 27
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000004411 aluminium Substances 0.000 claims abstract description 6
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910052802 copper Inorganic materials 0.000 claims abstract description 6
- 239000010949 copper Substances 0.000 claims abstract description 6
- 238000012216 screening Methods 0.000 claims abstract description 6
- 230000001681 protective effect Effects 0.000 claims abstract description 5
- 238000007664 blowing Methods 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 59
- 238000000151 deposition Methods 0.000 claims description 12
- 230000001105 regulatory effect Effects 0.000 claims description 7
- 239000011810 insulating material Substances 0.000 claims description 5
- 239000011241 protective layer Substances 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims 2
- 238000009413 insulation Methods 0.000 abstract description 4
- 239000002923 metal particle Substances 0.000 abstract 2
- 239000000463 material Substances 0.000 description 6
- 239000002245 particle Substances 0.000 description 4
- 230000009970 fire resistant effect Effects 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Classifications
-
- 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
- H01B13/0026—Apparatus for manufacturing conducting or semi-conducting layers, e.g. deposition of metal
-
- 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
- H01B7/1805—Protections not provided for in groups H01B7/182 - H01B7/26
-
- 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
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
- H01B19/04—Treating the surfaces, e.g. applying coatings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
- H01B9/027—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients composed of semi-conducting layers
-
- 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
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
-
- 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
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/002—Inhomogeneous material in general
- H01B3/004—Inhomogeneous material in general with conductive additives or conductive layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
An insulated electrical cable comprises an insulated 12 electrical conductor 10 with a powdered metallic particles 18 deposited onto the outer surface on the insulation to form an outer metallic layer which preferably acts either as an electrically non-conductive mechanical sheath or an electrically conductive screening layer. Preferably, the powdered metallic particles are deposited onto the insulated electrical conductor by blowing the metallic particles using compressed air thorough a nozzle or by electrostatically charging the metallic particles. The metal particles are either copper or aluminium. Additionally a protective sheath 20 covering the metal particle layer may also be included.
Description
<p>THOD AND APPARATUS FOR MANUFACTURING</p>
<p>AN INSULATED ELECTRICAL CABLE</p>
<p>This invention relates to a method of manufacturing an insulated electrical cable, an apparatus for manufacturing an insulated electrical cable and a cable produced according to the method. In particular, this invention relates to a method and apparatus for depositing powdered metallic particles onto an insulated electrical conductor to form an outer metallic layer which acts either as an electrically non-conductive mechanical sheath or an electrically conductive screening layer.</p>
<p>As is well known in the art, during the manufacture of an insulated electrical cable, an insulating material 12 (e.g. PVC, PE etc.) is extruded over an electrical conductor core 10 to form a single core cable as shown in Fig. 1. For multi-core cables, a further layer of sheathing material 14 is extruded over the group of insulated cores 10, 12, as depicted in Fig. 2.</p>
<p>Depending upon the application or environment intended for the cable, the insulated electrical core 10, 12 or layer of sheathing material 14 is often surrounded by a cylindrical metallic foil or metallic outer layer. This metallic outer layer may be used to provide a screening layer which finds application in signal cables and shielded power cables or to give fire resistant properties in fire resistant cables. Alternatively, the metallic outer layer may be used to provide some form of mechanical protection, such as, for example, with steel wire armoured cables. Nevertheless, whenever a metallic foil or metallic outer layer is included in the cable, the inclusion of such a layer involves a further manufacturing step, which is both consuming in terms of manufacturing time and cost.</p>
<p>It is therefore an object of the present invention to provide a method and apparatus for manufacturing an insulated electrical cable which includes a metallic layer that is quick and straightforward to manufacture.</p>
<p>An insulated electrical cable manufactured according to the method and apparatus can be manufactured much more quickly and at a lower cost.</p>
<p>According to the present invention there is provided a method of manufacturing an insulated electrical cable, comprising the steps of: extruding an insulating material over at least one electrical conductor; and depositing powdered metallic particles onto the insulated electrical conductor to form an outer metallic layer.</p>
<p>Also according to the present invention there is provided an apparatus for manufacturing an insulated electrical cable, comprising: means for extruding an insulating material over at least one electrical conductor; and means for depositing powdered metallic particles onto the insulated electrical conductor to form an outer metallic layer.</p>
<p>Further according to the present invention there is provided an insulated electrical cable, comprising: at least one insulated electrical conductor; and a metallic layer deposited onto said at least one insulated electrical conductor, said metallic layer being formed from powdered metallic particles.</p>
<p>In a preferred embodiment, the density and/or size of said powdered metallic particles is regulated to form either an electrically conductive or electrically non-conductive outer metallic layer. In use, said electrically conductive metallic layer acts as a screening layer. Said electrically non-conductive metallic layer acts a mechanically protective layer.</p>
<p>Preferably, depositing powdered metallic particles onto the insulated electrical conductor is performed by blowing said metallic particles through at least one nozzle using compressed air.</p>
<p>In an alternative embodiment, depositing powdered metallic particles onto the insulated electrical conductor is performed by electrostatically charging said metallic particles.</p>
<p>Further preferably, the powdered metallic particles are copper or aluminium.</p>
<p>In use, the present invention further comprises the step of bonding a protective outer sheath over said outer metallic layer.</p>
<p>It is believed that a method and apparatus for manufacturing an insulated electrical cable in accordance with the present invention at least addresses the problems outlined above. In particular, the advantages of the present invention are that a method and apparatus for manufacturing an insulated electrical cable including a metallic layer that is quick and straightforward to manufacture is provided. Advantageously, an insulated electrical cable manufactured according to the method and apparatus can be manufactured much more quickly and at a lower cost. By regulating the density and/or size of the metallic particles, a metallic layer can be produced which has either electrically conductive or electrically non-conductive properties, depending on the application of the cable.</p>
<p>It will be obvious to those skilled in the art the variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.</p>
<p>A specific non-limiting embodiment of the invention will now be described by way of example and with reference to the accompanying drawings, in which:</p>
<p>Fig. 1 illustrates a cross-section of a prior art</p>
<p>standard insulated core;</p>
<p>Fig. 2 shows a cross-section of a prior art</p>
<p>multi-core insulated cable; Fig. 3 illustrates one embodiment of the present invention whereby the metallic layer is formed by depositing powdered metallic particles onto an insulated electrical conductor; Figs. 4 and 5 shows how the metallic particles can be dispersed in the insulating layer and how such metallic particles can be configured to form an electrically non-conductive or electrically conductive rn metallic layer, respectively; Fig. 6 illustrates a cross-section of an electrical conductor produced according to the present invention, whereby the metallic layer is electrically non-conductive; Fig. 7 shows a cross-section of an electrical conductor produced according to the present invention, whereby the metallic layer is electrically conductive; Figs. 8 and 9 illustrate corresponding multi-core cables having electrically non-conductive or electrically conductive metallic layers, respectively; Figs. 10 and 11 show further insulated cores according to the present invention in which a further outer insulating sheath has been bonded over the metallic layer; and Figs. 12 and 13 illustrate further multi-core cables according to the present invention, whereby the metallic layer is surrounded by an outer insulating sheath.</p>
<p>Referring now to the drawings, the implementation of the present invention is illustrated in Figs. 3 to 13.</p>
<p>Figs. 3 to 5 show one embodiment of the present invention whereby an insulating 12 or sheathing material 14 (e.g. PVC, PE etc.) is extruded over the metallic core 10 or cores. As the insulated electrical core 10, 12 or layer of sheathing material 14 leaves the extruder (not shown), powdered metallic particles 18, such as copper or aluminium, are blown using compressed air through a nozzle 16 into the insulation 12 or sheathing material 14 causing the particles to embed in.</p>
<p>By regulating the density and/or size of the metallic particles 18 and also the speed of the insulated electrical core 10, 12 or cores through the extruder, this would form either an electrically conductive or electrically non-conductive outer metallic layer of various thicknesses to be applied to the external layer of the insulation 12 or sheathing 14, as is depicted in Figs. 5 and 4, respectively. The skilled person will appreciate that although Fig. 3 shows only a single nozzle 16, clearly a number of such nozzles 16 could be situated around the insulated electrical core 10, 12 or cores, or, alternatively, a single nozzle 16 which is rotated around the periphery of the insulated electrical core 10, 12 or cores.</p>
<p>In an alternative embodiment of the present invention (not shown), the powdered metallic particles 18 are deposited onto the insulating 12 or sheathing layer 14 by electrostatically charging the metallic particles 18. Again, the speed of the insulating 12 or sheathing layer 14 through the extruder and the density and/or size of particles 18 can be varied to form either an electrically conductive (Fig. 5) or electrically non-conductive outer metallic layer (Fig. 4) Fig. 4 shows that the spray or particle size can be regulated in order to give a spaced dispersion of metallic particles 18, and this will cause the newly-formed top metallic layer to be non-conductive and form a mechanically protective layer.</p>
<p>If the density or size of the sprayed particles 18 is increased, this causes the metallic particles 18 to be connected and would then allow for electrical conductivity. This layer could then be used for carrying electrical current and voltage or to act as a screening layer, as shown in Fig. 5.</p>
<p>Examples of completed cores 10 are shown in Figs. 6 and 7. These clearly show non-conductive and conductive metallic layers, respectively. Completed multi-core cables are illustared in Figs. 8 and 9. Fig. 8 shows an insulated multi-core cable having a newly-formed top metallic layer which is electrically non-conductive.</p>
<p>Likewise, Fig. 9 shows an insulated multi-core cable having a newly-formed top metallic layer which is electrically conductive.</p>
<p>In the examples shown in Figs. 6 to 9, the newly-formed metallic layer is retained as the final outer layer. The skilled person will appreciate that often a further layer of insulation sheathing material 20 can then be extruded over the metallic layer to give the usual core or cable finish, as shown in Figs. 10 to 13.</p>
<p>Various alterations and modifications may be made to the present invention without departing from the scope of the invention.</p>
Claims (1)
- <p>CLAIMS</p><p>1. A method of manufacturing an insulated electrical cable, comprising the steps of: extruding an insulating material over at least one electrical conductor; and depositing powdered metallic particles onto the insulated electrical conductor to form an outer metallic layer.</p><p>2. The method as claimed in claim 1, wherein the density and/or size of said powdered metallic particles is regulated to form either an electrically conductive or electrically non-conductive outer metallic layer.</p><p>3. The method as claimed in claim 1, wherein the step of depositing powdered metallic particles onto the insulated electrical conductor is performed by blowing said metallic particles using compressed air.</p><p>4. The method as claimed in claim 1, wherein the step of depositing powdered metallic particles onto the insulated electrical conductor is performed by electrostatically charging said metallic particles.</p><p>5. The method as claimed in any preceding claim, wherein said powdered metallic particles are copper or aluminium.</p><p>6. The method as claimed in claim 1, further comprising the step of cooling the insulated electrical conductor.</p><p>7. The method as claimed in claim 1, further comprising the step of bonding a protective outer sheath over said outer metallic layer.</p><p>8. An apparatus for manufacturing an insulated electrical cable, comprising: means for extruding an insulating material over at least one electrical conductor; and means for depositing powdered metallic particles onto the insulated electrical conductor to form an outer metallic layer.</p><p>9. The apparatus as claimed in claim 8, wherein the density and/or size of said powdered metallic particles is regulated to form either an electrically conductive or electrically non-conductive outer metallic layer.</p><p>10. The apparatus as claimed in claim 8, wherein said means for depositing powdered metallic particles onto the insulated electrical conductor further comprises at least one pressurised nozzle for blowing said metallic particles using compressed air.</p><p>11. The apparatus as claimed in claim 8, wherein said means for depositing powdered metallic particles onto the insulated electrical conductor further comprises means for electrostatically charging said metallic particles.</p><p>12. The apparatus as claimed in any preceding claim, wherein said powdered metallic particles are copper or aluminium.</p><p>13. The apparatus as claimed in claim 8, further comprising means for cooling the insulated electrical conductor.</p><p>14. The apparatus as claimed in claim 8, further comprising means for bonding a protective outer sheath over said outer metallic layer.</p><p>15. An insulated electrical cable, comprising: at least one insulated electrical conductor; and a metallic layer deposited onto said at least one insulated electrical conductor, said metallic layer being formed from powdered metallic particles.</p><p>16. The insulated electrical cable as claimed in claim 15, wherein the density and/or size of said powdered metallic particles is regulated to form either an electrically conductive or electrically non-conductive metallic layer.</p><p>17. The insulated electrical cable as claimed in claim 16, wherein said electrically conductive metallic layer acts as a screening layer.</p><p>18. The insulated electrical cable as claimed in claim 16, wherein said electrically non-conductive metallic layer acts a mechanically protective layer.</p><p>19. The insulated electrical cable as claimed in claim 15, wherein said powdered metallic particles are copper or aluminium.</p><p>20. The insulated electrical cable claimed in claim 15, further comprising a protective outer sheath bonded over said metallic layer.</p><p>21. A method of manufacturing an insulated electrical cable as hereinbefore described.</p><p>22. An apparatus for manufacturing an insulated electrical cable as described herein with reference to Figs. 3 to 13 of the accompanying drawings.</p><p>23. An insulated electrical cable as described herein with reference to Figs. 3 to 13 of the accompanying drawings.</p>
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0612253A GB2439355A (en) | 2006-06-21 | 2006-06-21 | Method and apparatus for manufacturing an insulated electrical cable. |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0612253A GB2439355A (en) | 2006-06-21 | 2006-06-21 | Method and apparatus for manufacturing an insulated electrical cable. |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0612253D0 GB0612253D0 (en) | 2006-08-02 |
| GB2439355A true GB2439355A (en) | 2007-12-27 |
Family
ID=36803584
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0612253A Withdrawn GB2439355A (en) | 2006-06-21 | 2006-06-21 | Method and apparatus for manufacturing an insulated electrical cable. |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2439355A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105374441A (en) * | 2015-11-28 | 2016-03-02 | 陈国涛 | Novel cable wire |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2211584A (en) * | 1937-10-09 | 1940-08-13 | Ruben Samuel | Coaxial electrical conductor |
| GB1122235A (en) * | 1964-11-07 | 1968-07-31 | English Numbering Machines | Metallizing insulating surfaces |
| US4424403A (en) * | 1979-06-14 | 1984-01-03 | Virginia Patent Development Corporation | Cable assembly having shielded conductor and method and apparatus for terminating same |
| JPH01100805A (en) * | 1987-10-12 | 1989-04-19 | Toyobo Co Ltd | Cable with shield |
| JPH09320353A (en) * | 1996-06-04 | 1997-12-12 | Furukawa Electric Co Ltd:The | Power cable |
| EP1148517A1 (en) * | 2000-04-18 | 2001-10-24 | Nexans | Telecommunication cable |
| JP2006040806A (en) * | 2004-07-29 | 2006-02-09 | Tatsuta System Electronics Kk | Extra-fine coaxial cable and its manufacturing method |
-
2006
- 2006-06-21 GB GB0612253A patent/GB2439355A/en not_active Withdrawn
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2211584A (en) * | 1937-10-09 | 1940-08-13 | Ruben Samuel | Coaxial electrical conductor |
| GB1122235A (en) * | 1964-11-07 | 1968-07-31 | English Numbering Machines | Metallizing insulating surfaces |
| US4424403A (en) * | 1979-06-14 | 1984-01-03 | Virginia Patent Development Corporation | Cable assembly having shielded conductor and method and apparatus for terminating same |
| JPH01100805A (en) * | 1987-10-12 | 1989-04-19 | Toyobo Co Ltd | Cable with shield |
| JPH09320353A (en) * | 1996-06-04 | 1997-12-12 | Furukawa Electric Co Ltd:The | Power cable |
| EP1148517A1 (en) * | 2000-04-18 | 2001-10-24 | Nexans | Telecommunication cable |
| JP2006040806A (en) * | 2004-07-29 | 2006-02-09 | Tatsuta System Electronics Kk | Extra-fine coaxial cable and its manufacturing method |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105374441A (en) * | 2015-11-28 | 2016-03-02 | 陈国涛 | Novel cable wire |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0612253D0 (en) | 2006-08-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |