KR101206092B1 - Cable and method of making the same - Google Patents

Abstract

The present invention relates to a cable and a cable manufacturing method. Embodiments of this cable are useful, for example, as overhead power transmission lines.

Cable, wire, core, fiber, coefficient of thermal expansion, stress

Description

Cable and its manufacturing method {CABLE AND METHOD OF MAKING THE SAME}

In general, composites (including metal matrix composites (MMCs)) are known. Composites generally include a matrix reinforced with particulates, whiskers or fibers (eg, short or long fibers). Examples of metal matrix composites include aluminum matrix composite wires (eg, silicon carbide fibers embedded in an aluminum matrix, carbon fibers, boron fibers, or polycrystalline alpha alumina fibers), titanium matrix composite tapes (eg, silicon carbide fibers embedded in a titanium matrix) ) And a copper matrix composite tape (e.g., silicon carbide fibers or boron fibers embedded in a copper matrix). Examples of the polymer matrix composite material include carbon fibers or graphite fibers of an epoxy resin matrix, glass fibers or aramid fibers of a polyester resin, and carbon fibers and glass fibers of an epoxy resin.

In one application of composite wire (eg, metal matrix composite wire), the composite wire is utilized as a reinforcing member of an exposed overhead power transmission cable. According to the need to increase the transmission capacity of existing transmission facilities, one typical requirement for cables arises.

Preferred performance requirements for cables applied in overhead transmission applications include corrosion resistance, durability to the environment (eg ultraviolet and moisture), resistance to loss of strength at high temperatures, creep resistance, relatively high modulus of elasticity, Low density, low coefficient of thermal expansion, high conductivity and high strength. Overhead power transmission cables comprising aluminum matrix composite wires are known, but there is a constant need for improvements in some applications, for example for more desirable sag characteristics.

According to one aspect, the present invention provides a cable comprising a longitudinal core having a coefficient of thermal expansion and a plurality of wires collectively having a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the core, the plurality of wires being aluminum wire, copper At least one of a wire, an aluminum alloy wire or a copper alloy wire, the wire is stranded around the core, and the cable has a stress parameter of less than 0 MPa (in some embodiments -5 MPa, -10 MPa, -15 MPa, -20 MPa, Stress parameters up to -25 MPa, -30 MPa, -35 MPa, -40 MPa, -45 MPa or -50 MPa, and in some embodiments 0 to -50 MPa, 0 to -40 MPa, 0 to -30 MPa, 0 to -25 MPa Stress parameters in the range of less than 0 to less than -20 MPa or less than 0 to -10 MPa. In some embodiments, the plurality of wires has a tensile strength at break of at least 90 MPa or at least 100 MPa (calculated according to ASTM B557 / B557M (1999)).

According to another aspect, the present invention provides a preliminary twisted pair cable, comprising: stranding a plurality of wires including at least one of an aluminum wire, a copper wire, an aluminum alloy wire, or a copper alloy wire around a longitudinal core to provide a preliminary stranded cable; Providing a cable having an outer diameter by adding a sealed die having an inner diameter, the die inner diameter being in the range of 1.00 times to 1.02 times the outer diameter of the cable.

As used herein, the following terms are defined as follows unless otherwise specified.

"Ceramic" means glass, crystalline ceramics, glass ceramics, and combinations thereof.

"Continuous fiber" means a fiber that is relatively very long in length when compared to the average fiber diameter. Generally, this means that the fiber has an aspect ratio (i.e., the ratio of fiber length to fiber average diameter) of at least 1 × 10 ⁵ (in some embodiments, at least 1 × 10 ⁶ or at least 1 × 10 ⁷ ). It means to have. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more.

"Shape memory alloy" refers to a metal alloy that undergoes martensitic transformation such that the metal alloy can be deformed by a twinning mechanism below the transformation temperature, and this deformation refers to a twin structure Can be deformed when is heated above the transformation temperature and returned to its original state.

The cable according to the invention can be utilized, for example, as a power transmission cable. In general, the cable according to the invention exhibits an improved deflection characteristic (ie a reduction in the amount of deflection).

1 to 5 are schematic cross-sectional views of exemplary embodiments of a cable according to the invention.

6 is a schematic diagram of an exemplary ultrasonic penetrating device used to penetrate molten metal into a fiber in accordance with the present invention.

7, 7A and 7B are schematic views of an exemplary twisted pair device used to manufacture a cable according to the present invention.

8 is a graph plotting cable deflection data for an illustrative example.

9 is a graph plotting cable deflection data for an example and a machining example 1. FIG.

10 is a graph plotting cable deflection data for Comparative Example 1 and Example 1. FIG.

11 is a schematic cross-sectional view of an exemplary embodiment of a cable according to the present invention.

The present invention relates to a cable and a method of manufacturing the cable. An exemplary cable 10 according to the invention is shown in cross section in FIG. 1. The cable 10 includes a core 12 and two layers of circular stranded wire 14, the core 12 having a wire 16 (as shown, a metal matrix composite wire). composite wire)].

Another exemplary cable 20 according to the invention is shown in cross section in FIG. 2. The cable 20 includes a core 22 and three layers of stranded wire 24, the core 22 comprising a wire 26 (as shown, a metal matrix composite wire).

Another exemplary cable 30 according to the invention is shown in cross section in FIG. 3. The cable 30 includes a core 32 and a trapezoidal twisted pair wire 34, and the core 32 includes a wire 36 (as shown, a metal matrix composite wire).

Another embodiment of a cable 40 according to the invention is shown in cross section in FIG. The cable 40 includes a core 42 and stranded wire 44.

In some embodiments, the core has a longitudinal thermal expansion coefficient in the range of about 5.5 ppm / ° C. to about 7.5 ppm / ° C. over at least a temperature range of about −75 ° C. to about 450 ° C.

Examples of the material comprising the core include aramid, ceramic, boron, poly (p-phenylene-2,6-benzobisoxazole), graphite, carbon, Titanium, tungsten and / or shape memory alloys. In some embodiments, such material is in the form of fibers (generally continuous fibers). In some embodiments, the core comprising aramid has a longitudinal thermal expansion coefficient in the range of about −6 ppm / ° C. to about 0 ppm / ° C. over at least a temperature range of about 20 ° C. to about 200 ° C. In some embodiments, the core comprising the ceramic has a longitudinal thermal expansion coefficient ranging from about 3 ppm / ° C. to about 12 ppm / ° C. over a temperature range of at least about 20 ° C. to about 600 ° C. In some embodiments, the core comprising boron has a longitudinal thermal expansion coefficient in the range of about 4 ppm / ° C. to about 6 ppm / ° C. over at least a temperature range of about 20 ° C. to about 600 ° C. In certain embodiments, a core comprising poly (p-phenylene-2,6-benzobisoxazole) comprises from about -6 ppm / ° C to about 0 ppm / ° C over a temperature range of at least about 20 ° C to about 600 ° C. It has a longitudinal coefficient of thermal expansion in the range. In some embodiments, the core comprising graphite has a longitudinal coefficient of thermal expansion in the range of about −2 ppm / ° C. to about 2 ppm / ° C. over a temperature range of at least about 20 ° C. to about 600 ° C. In some embodiments, the core comprising carbon has a longitudinal thermal expansion coefficient in the range of about −2 ppm / ° C. to about 2 ppm / ° C. over a temperature range of at least about 20 ° C. to about 600 ° C. In some embodiments, the core comprising titanium has a longitudinal thermal expansion coefficient ranging from about 10 ppm / ° C. to about 20 ppm / ° C. over a temperature range of at least about 20 ° C. to about 800 ° C. In some embodiments, the core comprising tungsten has a longitudinal coefficient of thermal expansion in the range of about 8 ppm / ° C. to about 18 ppm / ° C. over a temperature range of at least about 20 ° C. to about 1000 ° C. In some embodiments, the core comprising the shape memory alloy has a longitudinal coefficient of thermal expansion in the range of about 8 ppm / ° C. to about 25 ppm / ° C. over a temperature range of at least about 20 ° C. to about 1000 ° C. In some embodiments, the core comprising glass has a longitudinal coefficient of thermal expansion in the range of about 4 ppm / ° C. to about 10 ppm / ° C. over at least a temperature range of about 20 ° C. to about 600 ° C.

Examples of the fibers for the core include aramid fibers, ceramic fibers, boron fibers, poly (p-phenylene-2,6-benzobisoxazole) fibers, graphite fibers, carbon fibers, titanium fibers, tungsten fibers and / or shape memories Alloy fibers.

Exemplary boron fibers are commercially available from Textron Specialty Fibers, Inc., for example, in Lowell, Massachusetts. Generally, such boron fibers are at least 50 meters long and may have a length of up to several kilometers or more. Generally, the average fiber diameter of continuous boron fibers ranges from about 80 micrometers to about 200 micrometers. This average fiber diameter is more typically no greater than 150 micrometers and most typically ranges from 95 micrometers to 145 micrometers. In some embodiments, the boron fiber has an average tensile strength of at least 3 GPa, or at least 3.5 GPa. In some embodiments, the boron fiber has a modulus in the range of about 350 GPa to about 450 GPa, or in the range of about 350 GPa to about 400 GPa.

In some embodiments, the ceramic fiber has an average tensile strength of at least 1.5 GPa, 2GPa, 3GPa, 4GPa, 5GPa, 6GPa, or at least 6.5 GPa. In some embodiments, the ceramic fiber has an elastic modulus in the range of 140 GPa to about 500 GPa, or in the range of 140 GPa to about 450 GPa.

Exemplary carbon fibers are, for example, 2000 fiber, 4000 fiber, 5000 fiber and 12000 fiber under the trade name "THORNEL CARBON" from Amoco Chemicals, Alpharetta, GA Hexcel Corporation, Stamford, Connecticut, of Grafil Inc. (a subsidiary of Mitsubishi Rayon Co., Ltd.), Sacramento, California, USA, is commercially available. Corporation is sold under the trade name "PYROFIL", and Toray Rayon, Tokyo, Japan, is sold under the trade name "TORAYCA". Zolt Corporation (Zolt), marketed under the trade name "BESFIGHT" from St. Louis, Missouri, USA. are sold under the trade names "PANEX" and "PYRON" from ek Corporation, and "12K20" and "12K50" from Inco Special Products, Wickcorp, NJ. Nickel plated carbon fiber). In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. Generally, the average fiber diameter of continuous carbon fibers ranges from about 4 micrometers to about 12 micrometers, from about 4.5 micrometers to about 12 micrometers, or from about 5 micrometers to about 10 micrometers. In some embodiments, the carbon fiber has an average tensile strength of at least 1.4 GPa, at least 2.1 GPa, at least 3.5 GPa, or at least 5.5 GPa. In some embodiments, the carbon fiber has an elastic modulus greater than 150 GPa and up to 450 GPa or up to 400 GPa.

Exemplary graphite fibers are commercially available in units of 1000 fibers, 3000 fibers and 6000 fibers under the trade name " T-300 ", for example, from BP Amoco, Alpharetta, Georgia. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. Generally, the average fiber diameter of continuous graphite fibers ranges from about 4 micrometers to about 12 micrometers, from about 4.5 micrometers to about 12 micrometers, or from about 5 micrometers to about 10 micrometers. In some embodiments, the graphite fiber has an average tensile strength of at least 1.5 GPa, 2GPa, 3GPa, or at least 4GPa. In some embodiments, the graphite fiber has an elastic modulus in the range of about 200 GPa to about 1200 GPa, or about 200 GPa to about 1000 GPa.

Exemplary titanium fibers are available, for example, from TIMET, Henderson, Nevada, USA. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. Generally, the average fiber diameter of continuous titanium fibers ranges from 50 micrometers to about 250 micrometers. In some embodiments, the titanium fiber has an average tensile strength of at least 0.7 GPa, 1 GPa, 1.5 GPa, 2 GPa, or at least 2.1 GPa. In some embodiments, the ceramic fiber has an elastic modulus in the range of about 85 GPa to about 100 GPa, or about 85 GPa to about 95 GPa.

Exemplary tungsten fibers are available, for example, from the California Fine Wire Company, Grover Beach, California. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. Generally, the average fiber diameter of continuous tungsten fibers ranges from about 100 micrometers to about 500 micrometers, from about 150 micrometers to about 500 micrometers, or from about 200 micrometers to about 400 micrometers. In some embodiments, the tungsten fiber has an average tensile strength of at least 0.7 GPa, 1 GPa, 1.5 GPa, 2 GPa, or at least 2.3 GPa. In some embodiments, tungsten fibers have modulus of elasticity greater than 400 GPa and up to about 420 GPa or up to 415 GPa.

Exemplary shape memory alloy fibers are available, for example, from Johnson Matthey, West Whiteland, Pennsylvania. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. In general, the average fiber diameter of continuous shape memory alloy fibers ranges from about 50 micrometers to about 400 micrometers, from about 50 micrometers to about 350 micrometers, or from about 100 micrometers to about 300 micrometers. In some embodiments, the shape memory alloy fiber has an average tensile strength of at least 0.5 GPa, or at least 1 GPa. In some embodiments, the shape memory alloy fiber has an elastic modulus in the range of about 20 GPa to about 100 GPa, or about 20 GPa to about 90 GPa.

Exemplary aramid fibers are commercially available under the trade name “KEVLAR” from DuPont, Wilmington, Delaware, USA. In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. In general, the average fiber diameter of continuous aramid fibers ranges from about 10 micrometers to about 15 micrometers. In some embodiments, the aramid fibers have an average tensile strength of at least 2.5 GPa, 3 GPa, 3.5 GPa, 4 GPa, or at least 4.5 GPa. In some embodiments, the aramid fibers have an elastic modulus in the range of about 80 GPa to about 200 GPa, or about 80 GPa to about 180 GPa.

Poly (p-phenylene-2,6-benzobisoxazole) fibers are marketed under the trade name " ZYLON ", for example, from Toyobo Co., Osaka, Japan. Generally, these fibers are at least 50 meters long and may be several kilometers or more. Generally, the average fiber diameter of continuous poly (p-phenylene-2,6-benzobisoxazole) fibers ranges from about 8 micrometers to about 15 micrometers. In certain embodiments, the poly (p-phenylene-2,6-benzobisoxazole) fiber has an average tensile strength of at least 3GPa, 4GPa, 5GPa, 6GPa, or at least 7GPa. In certain embodiments, the poly (p-phenylene-2,6-benzobisoxazole) fiber has an elastic modulus in the range of about 150 GPa to about 300 GPa, or about 150 GPa to about 275 GPa.

Examples of ceramic fibers include metal oxide (such as alumina) fibers, boron nitride fibers, silicon carbide fibers and combinations of these fibers. In general, ceramic oxide fibers are crystalline ceramics and / or mixtures of crystalline ceramics and glass (ie, the fibers may comprise both a crystalline ceramic phase and a glass phase). In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. In general, the average fiber diameter of the continuous crystalline ceramic fibers is from about 5 micrometers to about 50 micrometers, from about 5 micrometers to about 25 micrometers, from about 8 micrometers to about 25 micrometers, or from about 8 micrometers to about 20 micrometers. Up to the micrometer range. In some embodiments, the crystalline ceramic fibers have an average tensile strength of at least 1.4 GPa, at least 1.7 GPa, at least 2.1 GPa, or at least 2.8 GPa. In some embodiments, the crystalline ceramic fibers have an elastic modulus of greater than 70 GPa and up to about 1000 GPa or up to 420 GPa.

Examples of monofilament ceramic fibers include silicon carbide fibers. Generally, silicon carbide monofilament fibers are crystalline and / or a mixture of crystalline ceramics and glass (ie, the fibers may comprise both crystalline ceramic phases and glass phases). In general, the length of such fibers is at least 50 meters and may be up to several kilometers or more. Generally, the average fiber diameter of continuous silicon carbide monofilament fibers ranges from about 100 micrometers to about 250 micrometers. In some embodiments, the crystalline ceramic fibers have an average tensile strength of at least 2.8 GPa, at least 3.5 GPa, at least 4.2 GPa, or at least 6 GPa. In some embodiments, the crystalline ceramic fibers have an elastic modulus of greater than 250 GPa and up to about 500 GPa or up to 430 GPa.

Exemplary glass fibers are also available, for example, from Corning Glass, Corning, NY. Generally, the average fiber diameter of continuous glass fibers ranges from about 3 micrometers to about 19 micrometers. In some embodiments, the glass fibers have an average tensile strength of at least 3 GPa, 4 GPa, or at least 5 GPa. In some embodiments, the glass fiber has an elastic modulus in the range of about 60 GPa to 95 GPa, or about 60 GPa to about 90 GPa.

In some embodiments, the ceramic fiber and carbon fiber are formed in a tow form. Such tows are known in the fiber art and refer to a plurality of (individual) fibers (generally at least 100 fibers, more generally at least 400 fibers) bound in a roving-like form. In some embodiments, there are at least 780 individual fibers per tow, and in some cases at least 2600 individual fibers per tow. Tow of ceramic fibers is available in various lengths of 300 meters, 500 meters, 750 meters, 1000 meters, 1500 meters, 1750 meters and more. Such fibers have a circular or oval cross-sectional shape. In certain embodiments of carbon fibers, there are at least 2000 individual fibers, 5000 individual fibers, 12000 individual fibers, or at least 50000 individual fibers per tow.

Alumina fibers are disclosed, for example, in US Pat. Nos. 4,954,462 (Wood et al.) And 5,185,29 (Wood et al.). In some embodiments, the alumina fiber is a polycrystalline alpha alumina fiber, and based on the theoretical oxide, more than 99% by weight of Al ₂ O ₃ and 0.2 to 0.5% by weight of SiO ₂ based on the total weight of the alumina fiber. Include. According to another aspect, certain preferred polycrystalline alpha alumina fibers comprise alpha alumina having an average particle size of less than 1 micrometer (or, in some embodiments, less than 0.5 micrometer). According to another aspect, in some embodiments the polycrystalline alpha alumina fiber has an average tensile strength of at least 1.6 GPa (in some embodiments up to at least 2.1 GPa, or at least 2.8 GPa). Exemplary alpha alumina fibers are sold under the trade name "NEXTEL 610" from 3M Company, St. Paul, Minn., USA.

Aluminosilicate fibers are disclosed, for example, in US Pat. No. 4,047,965 (Karst et al.). Aluminosilicate fibers are marketed under the trade names "NEXTEL 440", "NEXTEL 550" and "NEXTEL 720" from 3M Company, St. Paul, Minn. have.

Aluminoborosilicate fibers are disclosed, for example, in US Pat. No. 3,795,524 (Sowman et al.). Aluminoborosilicate fibers are marketed under the trade name "NEXTEL 312" from 3M Company.

Boron nitride fibers can be prepared, for example, as disclosed in US Patent Publication Nos. 3,429,722 (Economy) and 5,780,154 (Okano et al.).

Exemplary silicon carbide fibers are commercially available in units of 500 fibers under the trade name " NICALON " from COI Ceramics, San Diego, Calif., Ube Industries, Japan. Is sold under the trade name "TYRANNO" from Industries, and under the trade name "SYLRAMIC" from Dow Corning, Midland, Michigan, USA.

Exemplary silicon carbide monofilament fibers are trademarked "SCS-9", "SCS-6", "Ultra-SCS", for example, from Textron Specialty Materials, Lowell, Massachusetts. And are sold under the trade name "Trimarc" from Atlantic Research Corporation, Gainesville, Virginia.

Commercially available fibers generally include organic sizing materials that are added to the fibers during manufacture to provide lubricity to the fibers and to protect the strands of fibers during handling of the fibers. In addition, such protectors may assist in handling during the draw-molding process with the polymer for producing the polymer composite core wire. The protective agent can be removed, for example, by dissolving or burning the protective agent from the fiber. In general, it is desirable to remove the protective agent before forming the metal matrix composite wire.

The fiber may be provided with a coating used, for example, to improve the wettability of the fiber and to reduce or prevent the reaction between the fiber and the molten metal matrix material. Such coatings and their formation techniques are known in the textile and composite arts.

In some embodiments, at least 85% (in some embodiments, at least 90%, or at least 95%) is continuous, based on the number of fibers in the core.

Examples of matrix materials for composite cores and wires include polymers (such as epoxy, esters, vinyl esters, polyimides, polyesters, cyanate esters, phenol resins, bismaleimide resins and thermoplastic resins), and metals. [For example, an alloy of pure aluminum with high purity (greater than 99.95%) aluminum element or other element such as copper]. In general, the metal matrix material is chosen such that the fiber does not react significantly chemically with the matrix material (ie, the fiber material and the matrix material do not react relatively chemically) such that there is no need to form a protective coating on the exterior of the fiber, for example. do. Metal matrix materials include aluminum, zinc, tin, magnesium and their alloys (such as alloys of aluminum and copper). In some embodiments, the matrix material preferably comprises aluminum and its alloys.

In some embodiments, the metal matrix material comprises at least 98 weight percent aluminum, at least 99 weight percent aluminum, more than 99.9 weight percent aluminum, or up to 99.95 weight percent aluminum. Exemplary aluminum alloys of aluminum and copper include at least 98% by weight of aluminum (Al) and up to 2% by weight of copper (Cu). In some embodiments, useful alloys are aluminum alloys of the 1000, 2000, 3000, 4000, 5000, 6000, 7000 and / or 8000 series (American Aluminum Association designation). High purity metals are preferred for making wires of higher tensile strength, but low purity metals may also be usefully utilized.

Suitable metals are commercially available. For example, aluminum is commercially available from Alcoa, Pittsburgh, Pennsylvania, under the trade name “SUPER PURE ALUMINUM; 99.99% Al”. For example, aluminum alloys (such as aluminum-2% by weight copper (0.03% by weight impurities)) can be obtained from Belmont Metals, New York, NY. For example, zinc and tin are available from Metal Services, St. Paul, Minn., USA (99.999% pure "pure zinc" and 99.95% pure "pure tin"). Magnesium, for example, is sold under the trade name "PURE" from Magnesium Elektron, Manchester, England. Magnesium alloys are available, for example, from TIMET Co., Denver, Colorado, USA (eg, WE43A, EZ33A, AZ81A and ZE41A).

Composite cores and wires generally comprise at least 15% by volume (up to at least 20, 25, 30, 35, 40, 45, or 50% by volume) of fibers based on the total combined volume of fibers and matrix material. It includes. More generally, composite cores and wires generally comprise 40 to 75 volume percent (45 to 70 volume percent in some embodiments) fibers based on the total combined volume of fibers and matrix material.

In general, the average diameter of the core is in the range of about 1 mm to about 15 mm. In some embodiments, the average diameter of the preferred core is at least 1 mm, at least 2 mm, or up to about 3 mm. In general, the average diameter of the composite wire is in the range of about 1 mm to 12 mm, 1 mm to 10 mm, 1 mm to 8 mm, or 1 mm to 4 mm. In some embodiments, the average diameter of the preferred composite wire is at least 1 mm, at least 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, or at least 12 mm.

Composite cores and wires can be manufactured using techniques known in the art. Continuous metal matrix composite wires can be produced, for example, by the continuous metal matrix penetration method. One suitable method is disclosed, for example, in US Pat. No. 6,485,796 (Carpenter et al.). Wires comprising polymers and fibers can be made by a draw molding method known in the art.

An exemplary apparatus 60 for making a continuous metal matrix wire is shown schematically in FIG. Continuous fiber tow 61 is fed from feed spool 62 and bound into a circular bundle that is thermally washed while passing through tubular furnace 63. The fiber tow 61 is then evacuated from the vacuum chamber 64 before being introduced into a crucible 67 containing a melt 65 of metal matrix material (also referred to as " molten metal " hereinafter). The fiber tow is pulled from the feed spool 62 by a caterpuller 70. An ultrasonic probe 66 is positioned in the melt 65 near the fiber to allow the melt 65 to penetrate into the fiber tow 61. The molten metal of the wire 71 is cooled and cured after being discharged from the crucible 67 through the discharge die 68, where some cooling may be performed before the wire 71 is completely discharged from the crucible 67. . Cooling of the wire 71 is facilitated by a gas or liquid stream that enters through the cooling device 69 and is injected into the wire 71. Wire 71 is collected on spool 72.

As described above, heat-cleaning the fibers may reduce or eliminate the protective agents, absorbed water, and other one-off or volatile materials that may be present on the surface of the fibers. Generally, it is desirable to heat wash the fibers until the carbon content of the fiber surface is less than 22% area ratio. Generally, the temperature of the tubular furnace 63 is at least 300 ° C., more generally at least 1000 ° C., and the fibers remain in the tubular furnace 63 at a constant temperature for at least a few seconds, with the specified temperature (s) and time ( S) can be determined, for example, according to the washing requirements of the particular fiber used.

In some embodiments, the fiber tow 61 is evacuated before it is introduced into the melt 67 because of this formation of defects, such as localized areas with dry fibers (ie, fibrous areas where the matrix has not penetrated). This has been found to reduce or prevent In general, the fiber tow 61 is evacuated to a vacuum pressure of up to 20 torr, up to 10 torr, up to 1 torr, or up to 0.7 torr in some embodiments.

An exemplary suitable vacuum system 64 has an inlet tube formed in a size corresponding to the diameter of the fiber tow 61 bundle. The inlet tube may be, for example, stainless steel or alumina tube, and its length is generally at least about 20-30 cm. Vacuum chamber 64 generally has a diameter in the range of about 2 to 20 cm and a length in the range of about 5 to 100 cm. The capacity of the vacuum pump is in some embodiments at least about 0.2-1 m 3 / min. The evacuated fiber tow 61 is inserted into the melt 65 through a tube of a vacuum system 64 through a metal bath (ie, the evacuated fiber tow 61 bundle is melted in a vacuum). 65), wherein the melt 65 is at atmospheric pressure. The inner diameter of the discharge pipe corresponds to the diameter of the fiber tow 61 bundle. Part of the discharge pipe is contained in the molten metal. In some embodiments, about 0.5 to 5 cm of the tube is submerged in the molten metal. The tube is selected to be stable in the molten metal material. In general, examples of suitable tubes include silicon nitride tubes and alumina tubes.

Generally, the action of penetration of the molten metal 65 into the fiber tow 61 bundle by ultrasonic waves is facilitated. For example, a vibration horn 66 is located on the molten metal 65 in proximity to the fiber tow 61 bundle.

In some embodiments, horn 66 is driven to vibrate at frequencies of about 19.5 to 20.5 kHz and about 0.13 to 0.38 mm (0.005 to 0.015 inch) in air. Further, in some embodiments, the horn is connected to a titanium waveguide connected to an ultrasonic transducer (eg available from Sonics & Materials, Danbury, Conn.).

In some embodiments, the fiber tow 61 bundle is within about 2.5 mm (in some embodiments within about 1.5 mm) of the horn tip. In some embodiments, the horn tip is made of niobium, or a niobium alloy such as 95% niobium (Nb) -5% molybdenum (Mo) and 91% niobium-9% molybdenum, for example Available from PMTI, Pittsburgh, Pennsylvania, USA. Such alloys can, for example, produce cylinders of 12.7 cm (5 inches) in length and 2.5 cm (1 inch) in diameter. The cylinder can be adjusted to the desired frequency (eg, about 19.5-20.5 kHz) by changing its length. Further details on the ultrasonic waves used to make metal matrix composite products can be found in U.S. Patent Publication Nos. 4,649,060 (Ishikawa et al.), 4,779,563 [Ishikawa et al.] And 4,877,643 [Ishikawa]. US Patent Publication No. 6,180,232 (McCullough et al.), 6,245,425 (McCullough et al.), 6,336,495 (McCullough et al.), 6,329,056 [Dev ( Deve et al.], 6,344,270 (McCullough et al.), 6,447,927 [McCullough et al.], 6,460,597 [McCullough et al.], 6,485,796 [Carpenter et al. And 6,544,645 (McCullough et al.), US Patent Application No. 09 / 616,741, filed Jul. 14, 2000, and WO02, published on January 24, 2002. / 06550.

In general, molten metal 65 is degassed during and / or prior to infiltration (eg, the amount of gas dissolved in molten metal 65 (eg, hydrogen in aluminum) is reduced). . Techniques for degassing the molten metal 65 are known in the metal processing art. The degassed melt 65 lowers the gas porosity of the wire. For molten aluminum, the hydrogen concentration of the melt 65 is in some embodiments less than about 0.2 cm 3, less than 0.15 cm 3, or less than 0.1 cm 3 per 100 grams of aluminum.

The discharge die 68 is configured to be able to form the desired wire diameter. In general, it is desirable for the ejection die to form a uniform circular wire along its length. For example, the diameter of the silicon nitride discharge die for the aluminum composite wire including 58 volume% alumina fiber is the same as the diameter of the wire 71. In some embodiments, discharge die 68 is preferably made of silicon nitride, although other materials may be used. Conventional alumina is mentioned as another material that has been used in the art as an evacuation die. However, it has been found by the applicant that silicon nitride evacuation dies are significantly less wear than conventional alumina dies, making them more useful for forming wires of desired diameter and shape, especially when the wires are long. Turned out.

Generally, the wire 71 is cooled by contacting liquid (eg water) or gas (eg nitrogen, argon or air) introduced through the cooling device 69 after exiting the discharge die 68. By such cooling, desired circularity, uniformity and nonporosity can be achieved. Wire 71 is collected on spool 72.

When defects such as intermetallic phases, dry fibers such as pores due to internal gas (such as hydrogen or water vapor) voids or shrinkage, etc. are present in the metal matrix composite wire, properties such as wire strength may be degraded. Is known. Therefore, it is desirable to reduce or minimize such defects.

For cores composed of wires, in some embodiments, it is desirable to hold the wires together, for example using a tape overwrap or binder, with or without adhesive (see, eg, US Pat. No. 6,559,385B1 (Johnson) Johnson et al.). For example, another embodiment of a cable 50 according to the present invention having a core wrapped with tape is shown in cross section in FIG. The cable 50 comprises a core 52 and two layers of stranded wire 54, the core 52 comprising a wire 56 (composite wire as shown) wrapped with tape 55. . For example, the core can be formed by twisting (eg, spirally winding) the wire of the first layer around the center wire utilizing techniques known in the art. In general, the helical stranded core may comprise from seven individual wires to more than 50 wires. Stranding devices are known in the art (eg, Cortinovis Spa, Bergamo, Italy, and Watson Machinery International, Paterson, NJ). Possible planetary cable stranders]. Before being wound together in a spiral, the individual wires are provided in separate bobbins and then placed in a plurality of motor drive carriages of the twisted pair arrangement. Generally, one carriage is provided for each layer of completed twisted pair cable. The wires of each layer are tied together at the outlet of each carriage and are disposed above the first center wire or above the previous layer. During the cable twisted pair process, a cable that will have one or more additional layers wound around it as a central wire, or an intermediate, unfinished stranded cable, is towed through the center of several carriages, with each carriage stranded in one layer. Add it to the cable. The individual wires to be added as one layer are rotated about the central axis of the cable by the motor drive carriage while being pulled simultaneously from their respective bobbins. This is done sequentially for each desired layer. As a result, a spiral stranded core is formed. For example, in order to be able to bind the stranded wire together, a tape may be attached to the stranded core formed as above. One tape attachment is commercially available from Watson Machine International (eg, model 300 Concentric Taping Head). As an example of such a tape, an aluminum thin film is commercially available under the trade name "Foil / Glass Cloth Tape 363" from 3M Company of St. Paul, Minn. Tape], a tape provided with a polyester backing tape and a glass-reinforced backing. In some embodiments, the thickness of the tape ranges from 0.05 mm to 0.13 mm (0.002 to 0.005 inches).

In some embodiments, the tape is wrapped such that each successive wrap is attached without gaps and without overlap with the previous wrap. In some embodiments, for example, the tape may be spaced apart so that successive wraps form a gap between each wrap.

The length of the core, composite wire, cable and the like is at least 100 meters, at least 200 meters, at least 300 meters, at least 400 meters, at least 500 meters, at least 600 meters, at least 700 meters, at least 800 meters, or at least 900 meters.

Wires stranded around the core to form the cable according to the invention are known in the art. Aluminum wires are manufactured from Nexans, Wenburn, Canada, or Southwire Company, Carrollton, GA, USA, to provide "1350-H19 ALUMINUM" and "1350-H0 ALUMINUM." ALUMINUM) "is sold under the trade name. Generally, aluminum wire has a coefficient of thermal expansion in the range of about 20 ppm / ° C. to about 25 ppm / ° C. over a temperature range of at least about 20 ° C. to about 50 ° C. In some embodiments, an aluminum wire (eg, “1350-H19 aluminum”) has a tensile strength of at least 138 MPa (20 ksi), at least 158 MPa (23 ksi), at least 172 MPa (25 ksi), at least 186 MPa (27 ksi), or at least 200 MPa (29 ksi). Has breaking strength. In some embodiments, the aluminum wire (eg, “1350-H0 aluminum”) has a tensile strength at break of greater than 41 MPa (6 ksi) up to 97 MPa (14 ksi) or less than 83 MPa (12 ksi). Aluminum alloy wire is traded under the trade name "ZTAL" from Sumitomo Electric Industries, Osaka, Japan, and "6201" under the Southwire Company, Carrollton, GA. Is commercially available. In some embodiments, the aluminum alloy wire has a coefficient of thermal expansion in the range of about 20 ppm / ° C. to about 25 ppm / ° C. over a temperature range of at least about 20 ° C. to about 500 ° C. Copper wire is commercially available from Southwire Company, for example, in Carrollton, Georgia, USA. Generally, the copper wire has a coefficient of thermal expansion in the range of about 12 ppm / ° C. to about 18 ppm / ° C. over a temperature range of at least about 20 ° C. to about 800 ° C. Examples of copper alloys of copper alloy wires include Cu-Si-X, Cu-Al-X, Cu-Sn-X, Cu-Cd, where X is Fe, Mn, Zn, Sn and / or Si. Bronze, such as Bronze, commercially available from Southwire Company, Carrollton, GA, USA, and OMG Americas Corporation, Research Triangle Park, NC, USA. And oxide dispersion-enhanced copper sold under the trade name "GLIDCOP". In some embodiments, the copper alloy wire has a coefficient of thermal expansion in the range of about 10 ppm / ° C. to about 25 ppm / ° C. over a temperature range of at least about 20 ° C. to about 800 ° C. The wire can have any of a variety of shapes (eg, round, oval and trapezoidal).

In general, a cable according to the invention can be produced by stranding wire over a core. The core may comprise, for example, a single wire, or stranded (eg spirally wound) wire. In some embodiments, for example 7, 19 or 37 wires are used. A cable manufacturing apparatus 80 according to the present invention is shown in FIGS. 7, 7A and 7B. A spool 81 of core material is provided in the head of the conventional planetary twisted pair device 80, and the spool 81 is freely rotated by a tension force applied through the braking system, and the braking system is zero at payoff. Tensile forces ranging from 0 to 200 pounds (91 kg) may be applied to the core. The core 90 is conveyed through the bobbin carriages 82 and 83 and the closing dies 84 and 85 to be transported around the capstan wheel 86 and attached to the winding spool 87.

Prior to attaching the outer stranded wire layer, individual wires are provided in separate bobbins 88 located in the plurality of motor drive carriages 82, 83 of the twisted pair device. In some embodiments, the tensile force required to pull the wires 89A, 89B from the bobbin 88 is generally 4.5 to 22.7 kg (10 to 50 pounds). In general, there is one carriage for each layer of completed twisted pair cable. The wires of each layer are tied together at the outlet of each carriage of the hermetic dies 84 and 85 and are disposed over the center wire or over the previous layer. The layers are spirally twisted in opposite directions so that the outer layer forms a right hand lay state. During the cable twisted pair process, a cable that will have one or more additional layers wound around it as a central wire, or an intermediate, unfinished stranded cable, is towed through the center of several carriages, with each carriage stranded in one layer. Add it to the cable. The individual wires to be added as one layer are rotated about the central axis of the cable by the motor drive carriage while being pulled simultaneously from their respective bobbins. This is done sequentially for each desired layer. The result is a spiral stranded cable 91 that can be handled and cut without loss of shape or loosening.

The ability to handle twisted pair cables is a desirable feature. Since the metal wire is subjected to stresses that exceed the yield stress of the wire material during manufacture, but with a lower bending stress than ultimate stress or breaking stress, the cable can maintain its spiral stranded arrangement. This stress is applied because the wire is spirally wound around the previous layer or center wire of a relatively small radius. Additional stress is applied at the sealing dies 84 and 85, which apply radial and shear forces to the cable during manufacture. Thus, the wire is plastically deformed to maintain its spiral strand shape.

The core material and the wire for the given layer are brought into close contact with the sealing die. 7A and 7B, sealing dies 84A and 85A are generally sized to minimize strain stresses applied to the wires of the layer being wound. The inner diameter of the hermetic die is adapted to the size of the outer diameter of the layer. In order to minimize the stress applied to the wires of the layer, the sealed die is sized such that it is 0 to 2.0% larger than the outer diameter of the cable (ie, the die inner diameter is 1.00 to 1.02 times the outer diameter of the cable).

The closed die shown in FIGS. 7A and 7B are cylinders, and are held in place using, for example, bolts or other suitable attachments. Such a die may for example be made of hardened tool steel.

The cable thus formed can be moved through another twisted pair station if necessary and wound on a winding spool 87 having a diameter sufficient to prevent cable damage. In some embodiments, a straightening technique of cables known in the art may be preferably utilized. For example, a finished cable may be formed of rollers (each roller is, for example, 10 to 15 cm (4 to 6 inches) and arranged linearly in two banks, each row having, for example, five to nine rollers. Is provided] can be transferred through a straightening device configured. The spacing between the two rows of rollers can be changed so that the rollers act directly on the cable or cause the cable to bend significantly. Two rows of rollers are located on opposite sides of the cable, where a row of rollers corresponds to the space formed by the rollers of the other row opposite. Thus, the two rows can be biased from each other. When the cable is transported through the straightening device, the cable is bent back and forth on the rollers, allowing the stranded wire to extend the same length in the conductor, thereby reducing or eliminating the loose stranded wire.

In some embodiments, the core may be at a temperature above ambient temperature (eg 22 ° C.) (eg at least 25 ° C., 50 ° C., 75 ° C., 100 ° C., 125 ° C., 150 ° C., 200 ° C., 250 ° C., 300 ° C., 400 ° C.). Degrees Celsius, or in some embodiments, up to at least 500 degrees Celsius). The core may be formed at a desired temperature, for example by heating the core wound on a spool (eg, a core on a metal (eg steel)) in an oven for several hours. The heated core is located on a pay-off spool of the twisted pair device (see, for example, feed spool 81 in FIG. 7). Preferably, when the hot spool is in the twisted pair process, the core is still maintained at the desired or near desired temperature (generally for about 2 hours). It may also be desirable for the wire on the supply spool to form the outer layer of the cable to be formed at ambient temperature. That is, in some embodiments, it may be desirable for a temperature difference to be formed between the core and the wire forming the outer layer during the twisted pair process.

In some embodiments, it may be desirable to perform the twisted pair process with a core tension of at least 100 kg, 200 kg, 500 kg, 1000 kg, or at least 5000 kg.

In some embodiments of the cable according to the invention, it is preferable to bind the wire stranded around the core with a tape overlap or binder, for example with or without adhesive. For example, in a cross section of a cable of another embodiment, the cable includes a core 112 with a wire core 116 and two layers of stranded wire 114, the cable 110 being a tape ( 118). For example, the tape may be attached to the twisted pair cable to bind the twisted pair wire together. In some embodiments, the cable is wrapped with adhesive tape using a conventional taping device. One tape attachment is commercially available from Watson Machine International (eg, model 300 Concentric Taping Head). Such tapes are metal thin film tapes (e.g., aluminum thin film tapes sold under the trade name "Foil / Glass Cloth Tape 363" from 3M Company, St. Paul, Minn.), Polyester-based tape and tape with glass-reinforced substrate. In some embodiments, the thickness of the tape ranges from 0.05 mm to 0.13 mm (0.002 to 0.005 inches).

In some embodiments, the tape is wrapped so that each successive wrap overlaps the previous wrap. In some embodiments, the tape is wrapped such that each successive wrap is attached without gaps and without overlap with the previous wrap. In some embodiments, for example, the tape may be spaced apart so that successive wraps form a gap between each wrap.

In some embodiments, the cable is wrapped under tension during the twisted pair process. Referring to Figure 7, for example, a taping device may be located between the final hermetic die 85 and the capstan 86.

Deflection  How to measure

The conductors are selected to be 30 to 300 meters in length and finished with conventional epoxy fittings to ensure that the layers maintain the same relative position as in the manufacturing state. The outer wire extends through the epoxy fitting and outward to the other side, and is then reconfigured to form a connection for AC power using conventional terminal connectors. Epoxy fittings are injected into an aluminum speller socket connected to a tension-bearing turnbuckle. On one side, a load cell is connected to the turnbuckle, which is attached to the pulling eye at both ends. The eye is connected to a large concrete pillar that is large enough to minimize the end deformation of the system when the system is under tension. For the test, the tensile force is raised to a value in the range of 10-30% of the conductor's rated breaking strength. The temperature is measured at three points along the length of the conductor (one quarter, one half and three quarters of the total span interval from the towing eye to the towing eye) using nine thermocouples. At each point, three thermocouples are positioned in three different radial positions within the conductor, i.e. between the outer wire strands, between the inner wire strands, and adjacent (i.e., adjacent to) the outer core wire. do. The amount of deflection is three points along the length of the conductor (1/4 of span spacing, using a traction wire potentiometer (available from SpaceAge Control Inc., Palmdale, CA)). 1/2 point and 3/4 point). The traction wire potentiometer is positioned to measure the vertical motion of three points. AC current is applied to the conductor to raise the temperature to the desired value. The temperature of the conductor is raised from room temperature (about 20 ° C. (68 ° F.)) to about 240 ° C. (464 ° F.) at a rate of 60 to 120 ° C./minute (140 to 248 ° F.). The highest temperature of all thermocouples is used as a control.

Sag _total of the conductors is calculated at various temperatures in 1 ° C. from room temperature (about 20 ° C. (68 ° F.)] to about 240 ° C. (464 ° F.) using the following equation.

[Equation 1]

here,

And Sag _1/2 is the deflection measured at the half-point of the span interval of the conductor,

Sag _1/4 is the deflection measured at a quarter of the span interval of the conductor,

Sag _3/4 is the deflection measured at the 3/4 point of the span interval of the conductor.

The effective "inner span" length is the horizontal spacing between 1/4 and 3/4 points. This is the span length used to calculate the deflection.

Derivation of Stress Variables

The measured droop and temperature data are shown in the droop versus temperature graph. The calculation curve is obtained from Alcoa Fujikura Ltd. of Greenville, SC, USA under the brand name "SAG10" (version 3.0 update 3.9.7) under the brand name Alcoa Sag 10 ( Alcoa Sag10) is fitted to the measurement data using graphical techniques. The stress parameter is a fitting parameter of "sag 10" called "built-in aluminum stress" and can be changed to fit to other parameters when a material other than aluminum (eg aluminum alloy) is used. This is a fitting parameter that can adjust the position of the inflection point of the prediction graph and the amount of deflection in the region behind the high temperature inflection point. A description of this stress parameter theory is described in the literature Theory of Compressive Stress in Aluminum of ACSR in the Alcoa Sag 10 User Manual (version 2.0). The following conductor parameters are required for the input of Sag10 software: area, diameter, weight per unit length and rated breaking strength. The following line loading conditions, span length, initial tensile force at room temperature (20-25 ° C.) are required for input of Sag 10 software. The following variables: intrinsic wire stress, wire area (ratio to total area), number of wire layers in the conductor, number of stranded wires in the conductor, number of core strands, stranded lay of each wire layer A ratio is required for the input of Sag10 software for the compressive stress calculation. Stress-strain coefficients are required for the input of the "Sag 10" software as a table (see Table 1 below).

Table 1

Initial wire A0 A1 A2 A3 A4 AF Final wire (10 year creep) B0 B1 B2 B3 B4 α (A1) Initial core C0 C1 C2 C3 C4 CF Final Core (10 year creep) D0 D1 D2 D3 D4 α (core)

The parameter TREF also defines the temperature at which the coefficients are referenced.

Definition of stress strain polynomial

The initial five numbers A0 through A4 are coefficients of the fourth order polynomial representing the product of the initial wire curve and the area ratio.

&Quot; (2) "

AF is the final elastic modulus of the wire.

&Quot; (3) "

Where ε is the conductor elongation in% and sigma is the stress in psi.

B0 through B4 are coefficients of the fourth order polynomial representing the product of the final 10 year creep curve of the wire and the area ratio.

&Quot; (4) "

Cα (A1) is the coefficient of thermal expansion of the wire.

C0 to C4 are coefficients of the fourth order polynomial representing the product of the area ratio and the initial curve for the composite core only.

CF is the final modulus of the composite core.

D0 to D4 are coefficients of the fourth order polynomial representing the product of the final 10-year creep curve and the area ratio of the composite core.

α (core) is the coefficient of thermal expansion of the composite core.

In fitting the calculation data and the measurement data, (i) the value of the stress parameter is changed so that the calculation curve corresponds to the measurement data so that the calculation curve and the measurement curve correspond at high temperatures (140 to 240 ° C.), and (ii) the measurement curve. Optimal fitting is performed by making the inflection point of close correspond to the calculation curve, and (i) the initial calculated deflection amount corresponds to the initial measurement deflection amount. Thus, the value of the stress parameter to achieve the best fit to the measurement data is calculated. This calculation is the "stress parameter" for the cable.

The cable according to the invention can be utilized in several applications, including overhead transmission cables.

Advantages and embodiments of the invention are illustrated in more detail by the following examples, but are not intended to limit the invention to the particular materials and quantities and other conditions and details described in these examples. All ratios and percentages are by weight unless otherwise stated.

Yes

Example

Example The cable of the example is prepared as follows. The wire is manufactured using the device 60 shown in FIG. Eleven tows of 10000 denier alpha alumina fibers (available under the trade name "NEXTEL 610" from 3M Company, St. Paul, USA) were supplied from a supply spool 62 and bound in a circular bundle. It is then thermally washed while passing through a 1.5 m (5 ft) long alumina tube 63 heated to 1100 ° C. at a rate of 305 cm / min (120 inches / min). The thermowashed fiber 61 then contains a melt (molten metal) 65 of a metallic aluminum (99.99% Al) matrix material (available from Beck Aluminum Co., Pittsburgh, Pa.). Exhaust from the vacuum chamber 64 before being introduced into the crucible 67 which is present. The fibers are pulled by the catalysis 70 from the feed spool 62. In order to infiltrate the melt 65 into the fiber tow 61, an ultrasonic probe 66 is placed in the melt 65 near the fiber. The molten metal of the wire 71 is cooled and cured after being discharged from the crucible 67 through the discharge die 68, where some cooling is performed before the wire 71 is completely discharged from the crucible 67. In addition, cooling of the wire 71 is promoted by a nitrogen gas stream that enters through the cooling device 69 and is injected into the wire 71. Wire 71 is collected on spool 72.

The fibers 61 are evacuated before they are introduced into the melt 67. The pressure in the vacuum chamber is about 20 torr. The vacuum system 64 has a 25 cm long alumina inlet tube sized to correspond to the diameter of the fiber 61 bundle. The vacuum chamber 64 is 21 cm in length and 10 cm in diameter. The capacity of the vacuum chamber is 0.37 m 3 / min. The evacuated fibers 61 are inserted into the melt 65 through the tubes of the vacuum system 64 through the metal bath (ie the evacuated fibers 61 are inserted into the melt 54 in a vacuum state). . The inner diameter of the discharge pipe corresponds to the diameter of the fiber bundle 61. Part of the outlet tube is immersed in the molten metal to a depth of 5 cm.

The action of penetration of the molten metal 65 into the fiber 61 is facilitated by using a vibrating horn 66 located in the molten metal 65 in proximity to the fiber 61. Horn 66 is driven to vibrate at an amplitude of 0.18 mm (0.007 inches) in the air at a frequency of 19.7 kHz. The horn is connected to a titanium waveguide connected to an ultrasonic transducer (available from Sonics & Materials, Danbury, Conn.).

The fiber 61 is within 2.5 mm of the horn tip. Horn tips are made from a niobium alloy, a composite of 91 wt% niobium and 9 wt% molybdenum (available from PMTI, Pittsburgh, Pa.). This alloy is formed into a cylinder that is 12.7 cm (5 inches) long and 2.5 cm (1 inch) in diameter. This cylinder is adjusted to the desired frequency of 19.7 kHz by changing its length.

Molten metal 65 is degassed prior to penetration (eg, by reducing the amount of gas (eg hydrogen) dissolved in molten metal). Portable rotary degassing units are available from Brumund Foundry Inc., Chicago, Illinois, USA. The gas used is argon, the flow rate of this argon is 1050 liters per minute, the flow rate is determined by the air flow rate for the motor set at 50 liters per minute, and the duration is 60 minutes.

Silicon nitride evacuation die 68 is configured to form the desired wire diameter. The inner diameter of the evacuation die is 2.67 mm (0.105 inch).

The stranded core is stranded by a twisted pair device from the Wire Rope Company, Montreal, Canada. The cable has one wire in the center and six wires twisted to the right in the first layer. Before being wound together in a spiral, the individual wires are provided in separate bobbins and placed in the motor drive carriage of the twisted pair arrangement. The carriage has six bobbins for the layer of completed twisted pair cable. This layer of wire is tied together at the outlet of the carriage and placed above the central wire. During the cable twisted pair process, the center wire is pulled through the center of the carriage, where the carriage adds one layer to the twisted pair cable. Individual wires added as one layer are rotated about the central axis of the cable by a motor driven carriage while being pulled simultaneously from their respective bobbins. As a result, a spiral stranded core is formed.

The stranded core is wrapped in adhesive using a conventional taping device (model 300 Concentric Taping Head from Watson Machine International, Paterson, NJ). The tape backing is an aluminum thin film tape with glass fibers, a pressure sensitive silicone adhesive [Foil / Glass Cloth Tape 363 from 3M Company, St. Paul, Minn., USA. Marketed under the trade name "." The total thickness of the tape 18 is 0.18 mm (0.0072 inches). The tape is 1.90 cm (0.75 in) wide.

The average diameter of the finished core is 8.23 mm (0.324 inches) and the strand length of the stranded layer is 54.1 cm (21.3 inches).

The first trapezoidal aluminum alloy wire has an aluminum / zirconium rod with a tensile strength of 153.95 MPa (22183 psi), an elongation of 13.3%, and a conductivity of 60.4% according to the IACS standard [9.53 mm (0.375 inch) in diameter, Commercially available under the trade name "ZTAL" from Lamifil NV. The second trapezoidal wire is an aluminum / zirconium rod with a tensile strength of 132.32 MPa (19191 psi), an elongation of 10.4%, and a conductivity of 60.5% according to the IACS standard [9.53 mm (0.375 inch) in diameter, La Commercially available under the trade name "ZTAL" from Lamifil NV. These rods are drawn at room temperature using five intermediate dies and finally a trapezoidal forming die as is known in the art. The drawing die is made of tungsten carbide. Looking at the geometry of the tungsten carbide die, the entry angle is 60 °, the reduction ratio is 16 to 18 °, the bearing length is 30% of the die diameter, and the rear clearance angle (back relief angle) is 60 °. The die surface is highly polished. The die is lubricated and cooled using drawing oil. The drawing system refuels oil at a rate set in the range of 60-100 liters / minute per die, with the temperature set in the range of 40-50 ° C. The final forming die comprises two horizontal hardened steel (hardness 60Rc) forming rolls with a highly polished working surface. Roll grooves are formed based on the trapezoidal profile required. The roll is installed on a rolling stand located between the drawbox and the outer drawblock. By rolling the final forming roll, the area of the wire is reduced by about 23.5%. This area reduction is sufficient to move the metal to the edge of the roll groove to adequately fill the space between the forming rolls. The forming rolls are arranged in alignment so that the caps of the trapezoidal wires face the surfaces of the drawing blocks and bobbin drums. After molding, the wire profile is inspected and verified using a template.

This wire is then wound onto the bobbin. Several properties of the wire thus formed are shown in Table 2 below. The "effective diameter" of the trapezoidal shape refers to the diameter of a circle having the same cross-sectional area as that of the trapezoidal shape. The twisted pair device is equipped with 20 bobbins (of which 8 bobbins are for the first wire for twisting the first inner layer and 12 bobbins are for the second wire for twisting the second outer layer). The wire is taken out from a subset of the test bobbin, which is a "sample bobbin" of these.

[Table 2]

Effective diameter
mm (inches) The tensile strength
MPa (psi) Elongation
% Conductivity (IACS)
% Inner layer Wire first bobbin 4.54 (0.1788) 168.92 (24,499) 5.1 59.92 Wire fourth bobbin 4.54 (0.1788) 159.23 (23,095) 4.3 60.09 Wire eighth bobbin 4.54 (0.1788) 163.39 (23,697) 4.7 60.18 Outer layer Wire first bobbin 4.70 (0.1851) 188.32 (27,314) 4.7 60.02 Wire fourth bobbin 4.70 (0.1851) 186.27 (27,016) 4.3 60.09 Wire eighth bobbin 4.70 (0.1851) 184.73 (26,793) 4.3 60.31 Wire 12th bobbin 4.70 (0.1851) 185.50 (26,905) 4.7 59.96

The cables are manufactured by Nexans, Weiburn, using the core and wires (internal and external) described above for the comparative examples and conventional planetary twisted pair devices. Cable manufacturing apparatus 80 is schematically illustrated in FIGS. 7, 7A, and 7B.

The spool 81 of the core is provided in the head of the conventional planetary twisted pair device 80, and the spool 81 is freely rotated by a tension force applied through the braking system. The tension applied to the core at the time of feeding is 45 kg (100 lbs). The core is charged at room temperature [about 23 ° C. (73 ° F.). The core is conveyed through the center of the bobbin carriages 82 and 83 and through the closing dies 84 and 85 and transported around the capstan wheel 86 and attached to the winding spool 87 (60 inches in diameter 152 cm).

Prior to attaching the outer stranded wire layer 89, individual wires are provided in separate bobbins 88 located in the plurality of motor drive carriages 82, 83 of the twisted pair device. The range of tensile forces required to pull wire 89 from bobbin 88 is set to 11 to 14 kg (25 to 30 pounds). The twisted pair station consists of a carriage and a sealed die. In each stranded station, the wires 89 of each layer are tied together at the outlet of each carriage of the closing dies 84 and 85 and are disposed over the center wire or over the previous layer. Thus, the core passes through two twisted pair stations. In the first station 8, the wire is stranded over the core in a left twisted state. At the second station 12, the wire is stranded over the previous layer in a right twisted state.

Depending on the application, the core material and wire for a given layer are contacted through hermetic dies 84 and 85. The closed die is a cylinder (see FIGS. 7A and 7B), which is held in place using bolts. This die is made of hardened tool steel and can be completely sealed.

The finished cable is conveyed through the capstan wheel 86 and wound onto a winding spool 87 (diameter 91 cm (36 inches)). The finished cable is conveyed through a straightening device consisting of rollers (each roller is 12.5 cm (5 inches) and arranged linearly in two banks, each row having seven rollers). . The spacing between the two rows of rollers is chosen so that the rollers can act directly on the cable. Two rows of rollers are located on opposite sides of the cable, where a row of rollers corresponds to the space formed by the rollers of the other row opposite. Thus, the two rows are biased from each other. When the cable is conveyed through the straightening device, the cable is bent back and forth on the rollers, allowing the stranded wire to extend the same length in the conductor, thus eliminating the loose stranded wire.

The inner layer, with an outer diameter of 15.4 mm (0.608 inches), a mass per unit length of 353 kg / km (237 pounds / 1000 feet) and a left twist length of 20.3 cm (8 inches), consists of eight trapezoidal wires. The sealing block for the inner layer (made of hardened tool steel, with a hardness of 60 Rc) is set to an inner diameter of 15.4 mm (0.608 inch). Thus, the diameter of the closure block is set to be exactly the same as the cable diameter.

The outer layer consists of twelve trapezoidal wires with an outer diameter of 22.9 mm (0.9015 inches), a mass per unit length of 507.6 kg / km (341.2 pounds / 1000 feet), and a right twist length of 25.9 cm (10.2 inches). The total mass per unit length of the aluminum alloy wire is 928.8 kg / km (624.3 lbs / 1000 ft), the total mass per unit length of the core is 136.4 kg / km (91.7 lbs / 1000 ft), and the total per unit length of the conductor The mass is 1065 kg / km (716.0 lbs / 1000 ft). The sealing block for the outer layer (made of hardened tool steel, with a hardness of 60 Rc) is set to an internal diameter of 22.9 mm (0.9015 inches). Thus, the diameter of the closure block is set exactly the same as the final cable diameter.

Tensile force (as in the feed bobbin) of the inner and outer wires is measured using a handheld force gauge (available from McMaster-Card, Chicago, Illinois, USA) and measures 13.5 to 15 kg (29 to 33 kg). Pounds), and the core feed tension is set to about 90 kg (198 lb) by the brake using the same method as in the bobbin. In addition, no straightening device is used, and the cable is not wound on the spool but extends straight and lies on the floor. The core is charged at room temperature [about 23 ° C. (73 ° F.).

The twisted pair device operates at a speed of 15 m / min (49 ft / min) and is driven using a conventional capstan wheel, standard straightener and a conventional winding spool of 152 cm (60 inches) in diameter.

The conductors formed are tested using the following "Cut-end Test Method". The conductor area under test lies straight on the floor, and sub-sections of lengths of 3.1 to 4.6 m (10 to 15 feet) are fixed at both ends. Subsequently, the conductor is cut to separate the region where both ends are fixed. Then, one clamp was released, at which time the motion of the layer was not detected. The motion of the layers relative to each other is then detected for the area of the conductor. The motion of each layer is measured using a ruler to determine the range of motion for the core. The outer aluminum layer is retracted with respect to the composite core, with the core being the reference zero, the inner aluminum layer is retracted by 0.16 inches (4 mm) and the outer layer is retracted by 0.31 inches (8 mm).

Example Cables are also measured using Kinecttrics, Inc., Toronto, Ontario, Canada, using the following "Sag Test Method I". Conductors of certain lengths are finished with conventional epoxy fittings, allowing the layers to maintain the same relative position as in the manufactured state. At this time, the aluminum / zirconium wire extends through the epoxy fitting and outward to the other side, and is then reconfigured to form a connection for AC power using conventional terminal connectors. Epoxy fittings are injected into aluminum spell sockets connected to the tension-bearing turnbuckles. On one side, the load cell (5000kg capacity) is connected to the turnbuckle, which is attached to the traction eye at both ends. The eye is connected to a large concrete pillar that is large enough to minimize the end deformation of the system when the system is under tension. For the test, the tensile force is raised to 20% of the conductor's rated breaking strength. Thus, 2082 kg (4590 lbs) is applied to the cable. Temperature is used at three points along the length of the conductor (one quarter, one half, and three quarters of the total span spacing from the towing eye to the towing eye) and nine thermocouples (three at each point). And J type available from Omega Corporation, Stamford, Connecticut. At each point, three thermocouples are positioned in three different radial positions within the conductor, i.e. between the outer aluminum strands, between the inner aluminum strands, and adjacent (i.e., adjacent to) the outer core wire. do. The amount of deflection is three points along the length of the conductor (1/4 of span spacing, using a traction wire potentiometer (available from SpaceAge Control Inc., Palmdale, CA)). 1/2 point and 3/4 point). The traction wire potentiometer is positioned to measure the vertical motion of three points. AC current is applied to the conductor to raise the temperature to the desired value. The temperature of the conductor is raised from room temperature (about 20 ° C. (68 ° F.)) to about 240 ° C. (464 ° F.) at a rate of 60 to 120 ° C./minute (140 to 248 ° F.). The highest temperature of all thermocouples is used as a control. It takes about 1200 amps of current to form a temperature of 240 ° C. (464 ° F.).

Sag _total of the conductor is calculated at various temperatures using the following equation.

here,

And Sag _1/2 is the deflection measured at the half-point of the span interval of the conductor,

Sag _1/4 is the deflection measured at a quarter of the span interval of the conductor,

Sag _3/4 is the deflection measured at the 3/4 point of the span interval of the conductor.

Table 3 below summarizes the defined input test parameters.

[Table 3]

parameter value Total span length 68.6 m (225 ft) Effective span length [m (feet)] 65.5 m (215 ft) The height of the north fixed point 2.36 m (93.06 in) Height of south fixed point 2.47 m (97.25 in) Conductor weight 1.083 kg / m (0.726 lbs / ft) Initial Tensile Force (at 20% RTS) 2082 kg (4590 lbs) Load cell capacity 5000 kg (1100 lb) load cell

The measured droop and temperature data (“result data” for the example) are shown graphically, and the resulting curve is shown as “SAG10” from Alcoa Fujikura Ltd., Greenville, SC, USA. The software is fitted using Alcoa Sag 10 graphics technology from a commercially available software program under the trade name "version 3.0, update 3.9.7". The stress parameter is a fitting parameter of "sag 10" called "built-in aluminum stress" and is a fitting parameter that can adjust the deflection point position in the prediction graph and the amount of deflection in the region behind the high temperature inflection point. A description of this stress parameter theory is described in the literature Theory of Compressive Stress in Aluminum of ACSR in the Alcoa Sag 10 User Manual (version 2.0). The conductor parameters for the 675 kilomil cables described in Tables 4-7 below are entered into Sag 10 software. Optimal fitting involves (i) changing the value of the stress parameter so that the output curve corresponds to the "result data" so that the output curve and the measurement curve correspond at high temperatures (140 to 240 ° C), and (ii) the "result data" curve The inflection point of the curve corresponds closely to the output curve, and (i) to the initial "result data" deflection (ie This is done by making the initial calculated deflection amount correspond. For this example, the best fit with the "result data" is achieved with a stress parameter value of 3.5 MPa (500 psi). Fig. 8 shows the amount of deflection (line 82) calculated by sag 10 and the amount of measurement deflection (data 83 shown).

The following conductor data is entered into the "sag 10" software.

Table 4

Sag 10's Conductor Parameters

Area 381.6 mm2 (0.5915 square inches)

2.3 cm (0.902 in)

Weight 1.083 kg / m (0.726 lb / ft)

RTS 10160 kg (22400 lbs)

[Table 5]

Line loading condition

Span length 65.5 m (215 ft)

Initial tensile force [at 22 ° C (72 ° F)] 2082 kg (4590 lbs)

[Table 6]

Options for Compressive Stress Calculation

Intrinsic Aluminum Stress 3.5 MPa (500 psi)

Aluminum area (ratio of total area) 0.8975

Number of aluminum layers 2

Number of stranded aluminum 20

Number of stranded cores 7

Stranded wire lay ratio

   Outer layer 11

   Inner layer 13

Stress Strain Parameters for Sag 10 TREF = 22 ° C (71 ° F)

Input parameters for software run (see table 7 below)

[Table 7]

Early aluminum A0 A1 A2 A3 A4 AF 17.7 56350.5 -10910.9 -155423 173179.9 79173.1 Final Aluminum (10 Year Creep) B0 B1 B2 B3 B4 α (A1) 0 27095.1 -3521.1 141800.8 -304875.5 0.00128 Initial core C0 C1 C2 C3 C4 CF -95.9 38999.8 -40433.3 87924.5 -62612.9 33746.7 Final Core (10 Year Creep) D0 D1 D2 D3 D4 α (core) -95.9 38999.8 -40433.3 87924.5 -62612.9 0.000353

Definition of stress strain polynomial

The initial five numbers A0 to A4 are coefficients of the fourth order polynomial representing the product of the initial aluminum curve and the area ratio.

AF is the final modulus of aluminum.

Where ε is the conductor elongation in% and sigma is the stress in psi.

B0 through B4 are coefficients of the fourth order polynomial representing the product of the final 10 year creep curve of aluminum and the area ratio.

Cα (A1) is the coefficient of thermal expansion of aluminum.

C0 to C4 are coefficients of the fourth order polynomial representing the product of the area ratio and the initial curve for the composite core only.

CF is the final modulus of the composite core.

D0 to D4 are coefficients of the fourth order polynomial representing the product of the final 10-year creep curve and the area ratio of the composite core.

α (core) is the coefficient of thermal expansion of the composite core.

Prophetic example1

The cable is manufactured as described in Example 1 by changing the twisted pair process as follows. Referring to Fig. 7, a second capstan 86A is further disposed between the supply reel 81 and the carriage 82. In order to make a cable with a stress parameter of about -3.5 MPa (-500 psi), the tension between the second capstan 86A and the carriage 82 is set to 240 kg (530 lb) using the capstan's tension adjustment mechanism. .

The cable is wrapped with adhesive tape using a conventional taping device (model 300 Concentric Taping Head of Watson Machine International, Paterson, NJ). Referring to Figure 7, a taping device 95 is disposed between the final hermetic die 85 and the capstan 86. The tape backing is an aluminum thin film tape with glass fibers, a pressure sensitive silicone adhesive [Foil / Glass Cloth Tape 363 from 3M Company, St. Paul, Minn., USA. Marketed under the trade name "." The total thickness of the tape 18 is 0.18 mm (0.0072 inches). The tape is 1.90 cm (0.75 in) wide.

Machining Example 2

The cable is manufactured as described in Example 1 by changing the twisted pair process as follows. In order to produce a cable with a stress parameter of about -34 MPa (-5000 psi), the tensile force between the second capstan 86A and the carriage 82 is set to 1202 kg (2650 pounds) using the capstan's tensile force adjustment mechanism.

Machining Example 3

The cable is manufactured as described in Example 1 by changing the twisted pair process as follows. The core is provided on the steel spool and placed in the oven for 8 hours so that the core temperature is formed as high as 44 ° C. above the ambient air temperature around the stranded apparatus (eg, if the ambient temperature is 24 ° C., the temperature of the core is oven Formed at 68 ° C.). The spool is then separated and placed on the supply spool 81 (see FIG. 7 where all functional members are shown) of the twisted pair apparatus 80, so that the core still remains hot at the beginning of the twisted pair operation (spool Because of this large size, the temperature of the core does not drop rapidly, but stranded work must be done within about 2 hours after the spool is removed from the furnace). In addition, the wire on the supply spool forming the outer layer of the cable should be maintained at ambient temperature (eg 24 ° C.). This process provides a cable with a stress parameter of -3.5 MPa (-500 psi).

Machining Example 4

The cable is manufactured as described in Working Example 3 by changing the twisted pair process as follows. At the start of the stranding operation, the temperature of the core is 131 ° C above the ambient air temperature. Therefore, if ambient temperature is 24 degreeC, core temperature will be 155 degreeC. This process provides a cable with a stress parameter of -17 MPa (-2500 psi).

Machining Example 5

The cable is manufactured as described in Working Example 3 by changing the twisted pair process as follows. At the beginning of stranded operation, the temperature of the core is 239 ° C. above the ambient air temperature. Therefore, if ambient temperature is 24 degreeC, core temperature will be 263 degreeC. This process provides a cable with a stress parameter of -34 MPa (-5000 psi).

For machining example 1 to example 5 Droopy  Calculation vs. Example

The Alcoa Sag 10 graphic technique described in the illustrative example is utilized to predict the temperature versus deflection behavior of the cables described in Processing Examples 1 and 2. The deflection curve is calculated using the Sag 10 model and the example technique. The conductor parameters described in Tables 8-11 are entered into Sag 10 software. The values of the compressive stress parameters are -3.5 MPa (-500 psi) and -34 MPa (-5000 psi). Figure 9 shows the temperature versus deflection curves of the illustrative examples and machining examples 1, 2, 3 and 5. The measurement data of the illustrative example is shown by data 93, and the calculation curve of the illustrative example is shown by line 98. The calculation curves for Machining Examples 1 and 3 using a stress parameter of −3.5 MPa (−500 psi) are shown by line 94. The calculation curves for Machining Examples 2 and 5 using a stress parameter of −34 MPa (−5000 psi) are shown by line 96.

The following conductor data is entered into the "sag 10" software.

[Table 8]

Sag 10's Conductor Parameters

Area 381.6 mm2 (0.5915 square inches)

2.3 cm (0.902 in)

Weight 1.083 kg / m (0.726 lb / ft)

RTS 10160 kg (22400 lbs)

Table 9

Line loading condition

Span length 65.5 m (215 ft)

Initial tensile force [at 22 ° C (72 ° F)] 2082 kg (4590 lbs)

Table 10

Options for Compressive Stress Calculation

Inherent aluminum stress +500 (fit to measurement data)

-500 (processing example 1)

-5000 (Example 2)

Aluminum area (ratio of total area) 0.8975

Number of aluminum layers: 2

Number of stranded aluminum 20

Number of stranded cores 7

Stranded wire lay ratio

   Outer layer 11

   Inner layer 13

Stress Strain Parameters for Sag 10 TREF = 22 ° C (71 ° F)

Input parameters of the software run (see Table 11 below)

Table 11

Early aluminum A0 A1 A2 A3 A4 AF 17.7 56350.5 -10910.9 -155423 173179.9 79173.1 Final Aluminum (10 Year Creep) B0 B1 B2 B3 B4 α (A1) 0 27095.1 -3521.1 141800.8 -304875.5 0.00128 Initial core C0 C1 C2 C3 C4 CF -95.9 38999.8 -40433.3 87924.5 -62612.9 33746.7 Final Core (10 Year Creep) D0 D1 D2 D3 D4 α (core) -95.9 38999.8 -40433.3 87924.5 -62612.9 0.000353

Comparative Example 1

Samples of 70m (230ft) of Steel Reinforced Cable ["3/0 ACSR 6/1 PIGEON" "were taken from King Wire, Inc., at Number One Cable Place, North Chicago, Illinois, USA. Inc.). The specifications of these samples are listed in Table 12 below.

Table 12

Codename 3/0 ACSR 6/1 PIGEON BARE AL Size (AWG) 3/0 Twisted pair ACSR (Al / Stl) 6/1 Aluminum wire diameter 4.2 mm (0.1672 in) Individual steel wire diameter 4.2 mm (0.1672 in) Completed cable outer diameter (OD) 12.8 mm (0.502 in) area Aluminum area 85 mm2 (0.1317 square inches) Steel area 14.2 mm2 (0.0220 square inches) Total area 99.2 mm2 (0.1537 square inches) weight 0.353 kg / m (0.237 lb / ft) Breaking strength 3003 kg (6620 lbs)

Example 1

The 45.7 cm (18 inch) long cable of Comparative Example 1 was formed in the following manner to obtain negative aluminum prestress. The aluminum wire is removed by 3 inches (7.6 cm) on both sides, exposing the center core wire. Using a # 10 die with 13 threads per cm (32 spirals per inch), a screw is formed about 2.5 cm (1 inch) of the ends of the central core wire. Spacers are further arranged to fill the gap between the aluminum wire and the screw area of the sample. A # 10 coupling nut with 13 spirals per cm (32 spirals per inch) is fastened to the threaded steel core wire and seated in the spacer. Samples are made by hand using a 2.5 cm (1 inch) wide, fiber-reinforced packaging tape sold under the trade name "SCOTCH 898" by 3M Company, St. Paul, Minn. Wrapped. The tape overlaps about one quarter of its width. One coupling nut is held fixed to the vise and the other nut is tightened with a torque of 0.29 kgf-m (25 inch-pounds) using a torque wrench. Upon completion of the tensioning of the steel, the diameter of the cable wrapped with tape was measured to be 13.7 mm (0.54 inch). The aluminum wire is held tightly wrapped around the central core wire. The relaxation of the aluminum wire was not detected. There is no gap formed between the aluminum wire and the central core wire. The aluminum wire does not spread or expand from the central core wire.

To calculate the compressive stresses formed in aluminum, the stresses of the steel core wires were determined by the Krone Socket Screw Selector (available from the Holo-Krome Company, West Hartford, Connecticut). It is calculated from the torque value using the data. For # 10 screws, 1.4 kgf-m (120 in-lb) of torque creates a tension load of 1270 kg (2800 lb) on the threaded steel wire. The tensile load produced on the steel core wire by fastening at 0.29 kgf-m (25 inch-pounds) is calculated at 264 kg (583 lbs: 25/120 x 2800 lbs). The tensile load of the steel is considered to be the same as the corresponding compressive load of aluminum but with the opposite sign. Therefore, the compressive load of aluminum is calculated to be -264 kg (-583 lb). From this, the compressive stress of aluminum is calculated to be -30.5 MPa (-4425 psi: 583 lbs / 1317 square inches).

For Comparative Example 1 and Example 1 Deflection  Calculation

In Tables 13 to 15, the calculated temperature vs. sag characteristics of the cable of Example 1 are compared with the calculated temperature vs. sag characteristics of the cable of Example 1. The Alcoa Sag 10 software model previously described in Example 1 is utilized to determine the temperature versus deflection behavior of the cable of Comparative Example 1 using a positive stress parameter of 17.2 MPa (2500 psi). Similarly, the Alcoa Sag 10 software model is used to determine the temperature versus deflection behavior of a cable of length 1 of Example 1 with an aluminum prestress of -30.5 MPa (-4425 psi). A temperature versus deflection curve is generated using the same span length parameter of 65.5 m (215 ft) as in Example 1. The initial tensile force of this model cable is 20% of the breaking strength. Line 101 in Fig. 10 is a curve calculated for the value of +17.2 MPa (+2500 psi) for the cable of the comparative example. Line 103 in FIG. 10 is a curve calculated for the value of -30.5 MPa (-4425 psi) for the cable of Example 1. FIG.

The following conductor data is entered into the "sag 10" software.

Table 13

Sag 10's Conductor Parameters

Codename Pigeon

Area 99.3 mm2 (0.1537 square inches)

12.8 cm (0.502 in)

Weight 0.353 kg / m (0.231 lb / ft)

RTS 3003 kg (6620 lbs)

Stress Strain Charts 1-938

Table 14

Line loading condition

Span length 65.5 m (215 ft)

Initial pull force [at 22 ° C (72 ° F)] 600 kg (1324 lb)

Table 15

Options for Compressive Stress Calculation

Intrinsic Aluminum Stress 17.2 MPa (2500 psi) (Example 2)

-30.5 MPa (-4425 psi) (Example 3)

Aluminum area (ratio of total area) 0.857

Number of aluminum layers 1

Number of stranded aluminum 6

Number of stranded cores 1

Stranded lay ratio, outer layer 13

Those skilled in the art can clearly understand that various changes and modifications can be made to the present invention without departing from the spirit and scope of the present invention, and the present invention is not limited to the embodiments described above.

Claims (32)

(a) steel; or (b) matrix composites comprising continuous fibers in a matrix material comprising a polymer, aluminum, an aluminum alloy or magnesium A longitudinal core having a thermal expansion coefficient comprising; And A plurality of wires collectively having a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the core Including, A cable having a stress parameter of less than 0 MPa wherein the plurality of wires comprises at least one of an aluminum wire, a copper wire, an aluminum alloy wire, or a copper alloy wire, wherein the plurality of wires are stranded around the core. The cable of claim 1 wherein the core comprises (b) and the continuous fiber comprises crystalline ceramics. The cable of claim 1 wherein the stress parameter of the cable ranges from less than 0 to -50 MPa. The method of claim 1 wherein the matrix material comprises a polymer and the continuous fiber is aramid, ceramic, boron, poly (p-phenylene-2,6-benzobisoxazole), graphite, carbon, titanium, tungsten and shape memory A cable comprising any one selected from the group consisting of alloys. delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete

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