TW201447931A - 表面改造之高架導體 - Google Patents

表面改造之高架導體 Download PDF

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TW201447931A
TW201447931A TW102138290A TW102138290A TW201447931A TW 201447931 A TW201447931 A TW 201447931A TW 102138290 A TW102138290 A TW 102138290A TW 102138290 A TW102138290 A TW 102138290A TW 201447931 A TW201447931 A TW 201447931A
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conductor
coating
elevated
aluminum
engineered
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TWI633564B (zh
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Cody R Davis
Sathish K Ranganathan
Ryan Andersen
Vijay Mhetar
William S Temple
Srinivas Siripurapu
Gordon Baker
James Freestone
Dennis L Doss
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Gen Cable Technologies Corp
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00Power cables
    • H01B9/006Constructional features relating to the conductors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/30Drying; Impregnating
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/008Other insulating material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/02Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/02Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
    • H01B3/10Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances metallic oxides
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators 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
    • H01B3/46Insulators 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 silicones
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/002Auxiliary arrangements
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29Protection against damage caused by extremes of temperature or by flame
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29Protection against damage caused by extremes of temperature or by flame
    • H01B7/292Protection against damage caused by extremes of temperature or by flame using material resistant to heat
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00Power cables
    • H01B9/008Power cables for overhead application
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/42Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction
    • H01B7/421Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Paints Or Removers (AREA)
  • Insulated Conductors (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
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  • Non-Insulated Conductors (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)

Abstract

本發明係關於一種表面改造之高架導體,其具有容許該導體以較低溫操作之一塗層。該塗層為具有耐熱及潮濕老化特性之一無機非白色塗層。該塗層較佳包含具有所需性質之一熱輻射劑及一適當的黏結/懸浮劑。在一較佳實施例中,該塗層具有小於80之L*值,大於或等於0.5之一熱發射率,及/或大於0.3之一太陽能吸收係數。

Description

表面改造之高架導體
本申請案主張於2012年8月10日申請之美國臨時申請案第61/681,926號;於2012年9月17日申請之美國臨時申請案第61/702,120號;於2013年2月26日申請之美國臨時申請案第61/769,492號及2013年3月15日申請之美國臨時申請案第61/800,608號之優先權;該等案以引用方式併入本文中。
本發明係關於一種表面改造之高架導體,其具有容許該導體以較低溫操作之一塗層。
隨著對電力需求的持續增長,對較高容量傳輸及分佈線之需求亦增長。一傳輸線可遞送之功率量取決於該線之載流容量(安培容量)。一線之安培容量受限於載送電流之裸露導體之最大安全操作溫度。超過此溫度可導致導體或線之附件之損壞。此外,導體藉由歐姆損耗及太陽能熱量而加熱且其藉由傳導、對流及輻射而冷卻。歸因於歐姆損耗而產生之熱量因歐姆損耗=I2R之關係而取決於通過其之電流(I)及其之電阻(R)。電阻(R)自身取決於溫度。較高電流及溫度引起較高電阻,繼而引起導體中更多的電損耗。
已在此項技術中提出若干解決方案。Simic之WO 2007/034248揭示塗敷有一光譜選擇表面塗層之高架導體。該塗層具有高於0.7之一熱發射率(E)係數及小於0.3之太陽能吸收(A)係數。Simic亦要求表面 色彩為白色以具有低的太陽能吸收。
DE 3824608揭示一種具有一發射率大於0.6(較佳大於0.9)之一黑漆塗層之高架纜線。該漆係由一塑膠(例如聚胺酯)及黑色顏料製成。
FR 2971617揭示一種塗敷有其之發射率係數為0.7或更大及太陽能吸收係數為0.3或更小之一聚合層之電導體。該聚合層係由聚偏二氟乙烯(PVDF)及一白色顏料添加劑製造。
FR 2971617及WO 2007/034248兩者皆需要不期望因隨時間推移發生眩光及變色之白色塗層。DE 3824608及FR 2971617兩者皆需要不期望歸因於其等之可疑熱量及潮濕老化特性之聚合塗層。
因此,高架導體仍需要一耐用、無機、非白色塗層,以容許該等導體以降低之溫度操作。
導體之溫度取決於包含導體之電性質、導體之物理性質及當地天氣條件之諸多因素。升高導體溫度之一方法係通過因太陽能輻射自太陽吸收熱量。所吸收之熱量取決於導體之表面,即,表面之吸收率係數(「吸收率」)。一低吸收率指示導體因太陽能輻射僅吸收少量熱量。
降低導體溫度之一方式係透過輻射發射熱。所輻射之熱量取決於導體表面之發射率係數(「發射率」)。高發射率指示導體比具有低發射率之一導體輻射更多熱量。
相應地,本發明之一目的在於提供包含一發射劑之一高架導體,當根據ANSI C119.4-2004測試時,包含一發射劑之導體之操作溫度降低至比相同導體在不具有發射劑之情況下之溫度更低。該發射劑可直接併入至導體中或塗敷於導體上。較佳地,操作溫度降低達至少5℃。
本發明之一進一步目的提供用於具有耐熱及潮濕老化特性之高 架導體之一無機、非白色塗層。該塗層較佳包含具有所需性質之一熱輻射劑及一適當黏結/懸浮劑。在一較佳實施例中,該塗層具有大於或等於0.5之一熱發射率及/或大於0.3之一太陽能吸收係數。在較佳實施例中,該塗層具有類似於導體之熱膨脹之一熱膨脹,在0℃至250℃之一溫度範圍內之約10×10-6/℃至約100×10-6/℃。
本發明之又一目的提供用於以一無機、非白色、撓性塗層塗敷一高架導體之方法,相較於相同導體在不具有熱輻射劑之情況下之溫度,該塗層降低該導體之操作溫度。
100‧‧‧高架導體
102‧‧‧入口繞線筒
104‧‧‧預處理單元
106‧‧‧塗敷單元
108‧‧‧乾燥/固化單元
110‧‧‧金屬線之核心/滾筒
112‧‧‧導體
120‧‧‧導線
130‧‧‧光譜選擇表面
200‧‧‧高架導體/環形液泛式鑄模
202‧‧‧內表面
204‧‧‧中心開口
206‧‧‧管
210‧‧‧導線
220‧‧‧光譜選擇表面層
300‧‧‧高架導體
310‧‧‧金屬線之核心
320‧‧‧導線
330‧‧‧光譜選擇表面層
400‧‧‧高架導體
410‧‧‧導線
420‧‧‧光譜選擇表面層
在結合附圖考慮時參考下列詳細描述而變得更好瞭解且將輕易獲得本發明及其諸多隨附優點之一更完全理解:圖1係根據本發明之一實施例之一導體的一橫截面圖;圖2係根據本發明之一實施例之一導體的一橫截面圖;圖3係根據本發明之一實施例之一導體的一橫截面圖;圖4係根據本發明之一實施例之一導體的一橫截面圖;圖5係展示針對一給定施加電流量測金屬基板之溫度之測試配置的一圖式;圖6係展示塗敷及未塗敷導體之溫度的一圖表;圖7係展示針對一給定施加電流量測串聯迴路系統中的金屬基板之溫度差異之測試配置的一圖式;圖8係展示2/0 AWG實心鋁導體之溫度的一圖表;圖9係展示795 kcmil愛彼特(Arbutus)全鋁導體之溫度的一圖表。
圖10係展示本發明之一連續程序的一圖式;圖11係展示液泛式鑄模之一橫截面的圖式;圖12係展示液泛式鑄模之一平面圖的一圖式;及圖13係展示液泛式鑄模之一剖視圖的一圖式。
本發明提供一種包含一外部塗層之高架導體,當根據ANSI C119.4-2004測試時,相較於相同導體在不具有熱輻射劑之情況下之溫度,該外部塗層降低該導體之操作溫度。該熱輻射劑可直接併入至導體中或塗敷於導體上。較佳地,操作溫度降低達至少5℃。
在一實施例中,本發明提供一種裸露高架導體,其具有一表面塗層以降低導體之操作溫度且未明顯改變任意電氣或機械性質(諸如,(例如)電阻、電暈、斷裂伸長率、抗張強度及彈性係數)。本發明之塗層較佳為非白色。CIE出版物15.2(1986)第4.2節推薦使用CIE L*、a*、b*色標。色彩空間被組織為一立方體。L*軸自頂部蔓延至底部。L*之最大值為100,其表示一極佳的反射擴散體或白色。L*之最小值為0,其表示黑色。如本文所使用,「白色」意謂L*值為80或更大。
在一較佳實施例中,塗層之熱發射率係數為大於或等於0.5,更佳大於0.7,最佳大於約0.8。在又一較佳實施例中,塗層之吸收率係數大於約0.3,較佳大於約0.4,及最佳大於約0.5。由於導體塗層因金屬線在加熱及冷卻期間之熱膨脹而破裂,所以表面塗層之膨脹係數較佳與纜線導體之膨脹係數匹配。對於本發明,該塗層之膨脹係數在0℃至250℃之一溫度範圍內較佳在10×10-6/℃至約100×10-6/℃之範圍內。該塗層較佳亦通過熱老化特性。由於高架導體經設計以75℃至250℃之最大溫度(取決於高架導體之設計)操作,所以加速熱老化較佳係藉由將樣本置於維持在325℃之一空氣循環烘箱中達1天及7天之一時期而實施。在完成熱老化之後,將樣本置於21℃的室溫下達24小時之一時期。接著使該等樣本彎向於自較高直徑至較低直徑定尺寸之不同圓柱心軸;及該等塗層觀察到心軸尺寸之各者處之任意肉眼可見的裂縫。將結果與在熱老化之前之塗層之撓性進行比較。
在另一實施例中,本發明之塗層(塗層組合物)包含一黏結劑及一熱輻射劑。該組合物在塗敷於一裸露導體線上作為一表面層時容許該導體更好地驅散該導體在操作期間所產生之熱。該組合物亦可包含其他任選成分,諸如,填料、穩定劑、著色劑、界面活性劑及紅外線(IR)反射添加劑。該組合物較佳僅包含無機成分。若使用任意有機成分,則有機成分應小於約10%(按乾燥塗層組合物之重量計),較佳小於5重量百分比。一旦塗層塗敷於一導體上且使該塗層變乾,該塗層較佳小於200微米,更佳小於100微米,最佳小於30微米。但無論何種情況,該厚度為至少5微米。根據本發明所產生之塗層較佳為非白色。更特定言之,該等塗層為非白色(L*<80)及/或具有大於約0.3較佳約0.5最佳約0.7之一吸收率。該等塗層可為非導電性、半導電性或導電性。
一或多種黏結劑可用於塗層組合物中,較佳具有約20%至60%(按總乾燥組合物之重量計)之一濃度。該黏結劑可包含一官能基,諸如,羥基、環氧基、胺、酸、氰酸鹽、矽酸鹽、矽酸酯、醚、碳酸酯、馬來酸等等。無機黏結劑可為(但不限於)金屬矽酸鹽,諸如,矽酸鉀、矽酸鈉、矽酸鋰及矽酸鎂鋁;膠溶氧化鋁一水合物;膠體氧化矽;膠體氧化鋁;磷酸鋁及其組合。
一或多種熱輻射劑可用於塗層組合物中,較佳具有約1%至20%(按總乾燥組合物之重量計)之一濃度。熱輻射劑包含(但不限於)氧化鎵、氧化鈰、氧化鋯、六硼化矽、四硼化碳、四硼化矽、碳化矽、二矽化鉬、二矽化鎢、二硼化鋯、氧化鋅、亞鉻酸銅、氧化鎂、二氧化矽、氧化錳、氧化鉻、氧化鐵、碳化硼、矽化硼、銅鉻氧化物,磷酸三鈣、二氧化鈦、氮化鋁、氮化硼、氧化鋁、氧化鎂、氧化鈣及其組合。
一或多種IR反射添加劑可用於塗層組合物中。一般而言,IR反 射添加劑可包含(但不限於)鈷、鋁、鉍、鑭、鋰、鎂、釹、鈮、釩、鐵、鉻、鋅、鈦、錳,及基於鎳之金屬氧化物及陶瓷。通常,單獨使用0.1%至5%(按總乾燥組合物之重量計)之IR反射添加劑或與著色劑混合使用。
一或多種穩定劑可用於塗層組合物中,較佳具有約0.1%至2%(按總乾燥組合物之重量計)之一濃度。穩定劑之實例包含(但不限於)分散穩定劑(諸如膨潤土)。
一或多種著色劑可用於塗層組合物中,較佳具有約0.02%至0.2%(按總乾燥組合物之重量計)之一濃度。著色劑可為有機或無機顏料,其包含(但不限於)二氧化鈦、金紅石、鈦、鴨類、板鈦礦、鎘黃、鎘紅、鎘綠、橙鈷、鈷藍、天藍、鈷亞硝酸鉀、鈷黃、銅顏料、藍銅礦、漢紫、漢藍、埃及藍、孔雀石、巴黎綠、酞菁藍BN、酞菁綠G、鉻綠、鮮綠色、氧化鐵顏料、血紅色、鐵丹、氧化物紅、赭紅、威尼斯紅、普魯士藍、粘土顏料、黃赭、生赭石、燒赭石、生褐、焦赭,海洋顏料(深藍、深藍綠蔭)、鋅顏料(鋅白、鋅鐵氧體)及其組合。
一或多種界面活性劑亦可用於塗層組合物中,較佳具有約0.05%至0.5%(按總乾燥組合物之重量計)之一濃度。合適界面活性劑包含(但不限於)陽離子、陰離子或非離子界面活性劑及脂肪酸鹽。
適於本發明之其他塗層發現於Holcombe Jr.等人之美國專利第6,007,873號,Simmons等人之美國專利第7,105,047號及Kourtides等人之美國專利第5,296,288號中,該等案以引用方式併入本文中。
一較佳塗層組合物包含51.6重量百分比氧化鈰粉末及48.4重量百分比磷酸鋁黏結劑溶液。磷酸鋁黏結劑溶液較佳包含57重量百分比三水合磷酸單鋁(Al(H2PO4)3)、2重量百分比磷酸及41重量百分比水。
另一較佳塗層組合物包含碳化硼或矽化硼作為一發射劑及一黏結劑溶液。黏結劑溶液包含矽酸鈉及二氧化矽在水中的混合物,其中 塗層中的矽酸鈉與二氧化矽之乾燥重量比為約1:5。碳化硼之含量使得其組成總塗層乾燥重量之2.5重量百分比至7.5重量百分比。
又一較佳塗層組合物包含膠狀二氧化矽作為黏結劑及六硼化矽粉末作為發射劑。六硼化矽之含量使得其組成總塗層乾燥重量之2.5重量百分比至7.5重量百分比。
在本發明之一實施例中,塗層組合物可包含小於約5%之有機材料。在該情況中,塗層組合物較佳包含矽酸鈉、氮化鋁及胺基官能矽氧烷(經改造以包含胺基官能基之聚矽氧)。矽酸鈉較佳存在有約60重量百分比至90重量百分比乾燥塗層組合物,更佳約67.5重量百分比至82.5重量百分比;氮化鋁較佳存在有約10重量百分比至35重量百分比乾燥塗層組合物,更佳15重量百分比至30重量百分比;及胺基官能矽氧烷較佳存在有約小於約5重量百分比乾燥塗層組合物,更佳約2重量百分比至3重量百分比。氮化鋁較佳具有小於2m2/g之一特定表面面積及/或下列顆粒尺寸分佈:D 10%-0.4至1.4微米、D 50%-7至11微米及D 90% 17至32微米。較佳胺基官能矽氧烷為胺基二甲基聚矽氧烷。更佳地,二甲基聚矽氧烷在25℃時具有約10至50厘拖之一黏度及/或0.48毫當量鹼基/克之一胺當量。
一旦塗層被固化,則該塗層提供當彎向於具有10英吋或更小的直徑之一心軸時無肉眼可見的裂縫之一撓性塗層。該固化塗層亦具耐熱性且在325℃的熱老化達1天及7天之一時期之後通過相同的心軸彎曲測試。
圖1、圖2、圖3及圖4繪示根據本發明之各種實施例之併入一光譜選擇表面之各種裸露高架導體。
如圖1中可見,本發明之裸露高架導體100一般包含一或多根金屬線之一核心110、圍繞該核心之圓形橫截面導線120及光譜選擇表面層130。核心110可為鋼、恆範鋼、碳纖維複合物或對導體提供強度之 任意其他材料。導線120為銅或銅合金,或鋁或鋁合金,其包含鋁型號1350、6000系列之合金鋁或鋁鋯合金,或任意其他導電金屬。如圖2中可見,裸露高架導體200一般包含圓形導線210及光譜選擇表面層220。導線210為銅或銅合金,或鋁或鋁合金,其包含鋁型號1350、6000系列合金鋁或鋁鋯合金,或任意其他導電金屬。如圖3中可見,本發明之裸露高架導體300一般包含一或多根金屬線之一核心310,圍繞該核心之梯形導線320及光譜選擇表面層330。核心310可為鋼、恆範鋼、碳纖維複合物或對導體提供強度之任意其他材料。導線320為銅或銅合金,或鋁或鋁合金,其包含鋁型號1350、6000系列合金鋁或鋁鋯合金,或任意其他導電金屬。
如圖4中可見,裸露高架導體400一般包含梯形導線410及光譜選擇表面層420。導線410為銅或銅合金,或鋁或鋁合金,其包含鋁型號1350、6000系列合金鋁或鋁鋯合金,或任意其他導電金屬。
塗層組合物可在一高速分散機(HSD)、球磨機或珠磨機中製成或使用此項技術中已知的其他技術而製成。在一較佳實施例中,一HSD用於製成塗層組合物。為製成塗層組合物,在一高速分散機中採用黏結劑、分散介質及界面活性劑(若使用)且製備一溶液。將熱輻射劑、填料、穩定劑、著色劑及其他添加劑緩慢添加至該溶液中。最初,使用一較低攪拌速度以移除殘存空氣且隨後將速度逐步增大高達3000rpm。執行高速混合直至在塗層中達成填料及其他添加劑之所要分散。任意多孔填料亦可在其等添加至混合物中之前預塗敷有黏結劑溶液。分散介質可為水或一有機溶劑。有機溶劑之實例包含(但不限於)酒精、酮、酯、烴或其組合。較佳的分散介質為水。所得塗層混合物為具有總固體量之約40%至80%之一懸浮液。在儲存此混合物之後,固體顆粒可沉澱,及因此該塗層混合物需要攪拌且可經進一步稀釋以在轉移至塗層施加器中之前達成所需粘度。
在本發明之一實施例中,在施加塗層組合物之前製備高架導體之表面。製備程序可為化學處理、加壓空氣清洗、熱水或蒸汽清洗、毛刷清洗、熱處理、噴砂處理、超音波、抗眩光、溶劑擦拭、電漿處理及類似者。在一較佳程序中,高架導體之表面係藉由噴砂處理而抗眩光。
塗層混合物組合物可藉由透過氣壓控制之噴槍(較佳以10psi至45psi壓力)而施加。該噴槍噴嘴較佳垂直於導體之方向(以約90°角)而放置以在導體產品上達到一均勻塗層。在特定情況中,兩個或兩個以上的槍可用於達到更有效率的塗層。塗層厚度及密度受控於混合物粘度、槍壓及導體線速度。在塗層施加期間,高架導體之溫度較佳維持在10℃至90℃之間,其取決於導體之材料。
替代地,塗層混合物可藉由浸塗或使用一毛刷或使用一滾筒而施加至高架導體。因此,將乾淨及乾燥導體浸至塗層混合物中以容許該混合物完全塗敷該導體。接著將該導體自塗層混合物移除且容許將其烘乾。
在應用之後,容許藉由在室溫或在高達325℃之高溫時的蒸鍍將高架導體上的塗層烘乾。在一實施例中,藉由使塗層完全暴露但短暫(約0.1秒至2秒,較佳約0.5秒至1秒)加熱之直接火焰暴露而將塗層烘乾。
已開發之塗層可用於已安裝及當前使用之高架導體。現有導體可塗敷有一機器人系統以進行自動或半自動塗敷。自動系統以三個步驟運作:1.清洗導體表面;2.將塗層施加於導體表面上;及3.烘乾塗層。
該塗層可以若干方式施加至導體。該塗層可藉由在個別金屬線在裸露高架導體中組裝之前塗敷該等個別金屬線而施加。此處,可塗敷該導體之全部金屬線,或更經濟,僅塗敷該導體之最外部金屬線。 替代地,該塗層可僅施加至裸露高架導體之外部表面。此處,可塗敷完整的外部表面或其之一部分。
可在一分批程序、一半批程序或一連續程序中施加塗層。連續程序為較佳。圖10繪示本發明之一較佳連續程序。在入口繞線筒102之後,導體112在將塗層施加於塗敷單元106中之前經由一預處理單元104而通過一表面製備程序。在施加塗層之後,該導體可經由一乾燥/固化單元108而烘乾。一旦被烘乾,將纜線纏繞於一滾筒110上。
在預處理單元104中,較佳藉由噴砂除漆而製備導體112之表面。較佳介質為沙,然而,亦可使用玻璃珠子、鈦鐵礦、鋼丸。噴砂除漆係繼空氣擦拭之後以使微粒材料自該導體112吹落。一空氣擦拭由以一角度且沿與導體112之行進方向相反之一方向吹至該導體112上之空氣噴射組成。空氣噴射產生附接至導體112之周邊之一360°氣環且以高空氣速度擦拭表面。在此情況中,當導體退出預處理單元104時,導體112上的任意顆粒被擦拭且吹回至預處理單元104中。空氣噴射通常以約60PSI至約100PSI較佳為70PSI至90PSI更佳約80PSI操作。空氣噴射較佳具有約125mph至約500mph更佳約150mph至約400mph及最佳約250mph至約350mph之一速度(來自噴嘴)。在空氣擦拭之後,每平方英尺導體表面之導體表面上的尺寸大於10微米之顆粒數目低於1000,較佳每平方英尺表面小於100。在空氣擦拭之後,該導體較佳藉由(例如)一加熱烘箱、UV、IR、E光束、明火及類似者而加熱。該加熱可藉由單一或多個單元而完成。在一較佳實施例中,乾燥/固化藉由直接火焰應用而發生。此處,使纜線直接通過一火焰以將該纜線表面加熱至高於周圍溫度之一溫度。預處理中的高加熱溫度容許稍後在乾燥/固化單元中的較低加熱溫度。然而,加熱不應太強烈以影響塗層之品質(例如,黏著性、均勻性、皰腫性等等)。此處加熱導體不高於約140℃為較佳,更佳不大於約120℃。
一旦導體112之表面已製備,則其已製備用於塗敷。塗敷程序發生於塗敷單元中,其中纜線通過一液泛式鑄模,將塗層之一液體懸浮液沈積至已製備表面。圖11至圖13展示一環形液泛式鑄模200之一描繪。經由一管206將塗層懸浮液饋送至鑄模200。當導體112通過液泛式鑄模200之中心開口204時,塗層懸浮液經由該鑄模200之內表面202中的開口埠而塗敷該導體112。較佳地,液泛式鑄模200包含圍繞內表面202之周邊均勻間隔之兩個或兩個以上(較佳四個,更佳六個)開口埠。一旦導體112退出液泛式鑄模,則其通過另一空氣擦拭以移除過量的塗層懸浮液且圍繞該導體均勻散佈塗層。在一絞合導體之情況中,空氣擦拭容許塗層穿透該導體之表面上的絞合線之間的凹槽。此空氣擦拭較佳在相同於預處理單元104中的空氣擦拭之條件之條件下操作。
一旦導體112被塗敷,其通過乾燥/固化單元108。乾燥/固化可藉由空氣或藉由使用溫度高達1000℃及/或線速度介於約9英尺/分鐘至約500英尺/分鐘之間(較佳約10英尺/分鐘至約400英尺/分鐘)的熱氣而完成,其取決於用於導體中的金屬合金。乾燥程序可為逐步乾燥、快速乾燥或直接火焰應用。乾燥或固化亦可藉由其他技術(如一加熱烘箱、UV、IR、E光束、化學製品或液體噴霧及類似者)而完成。乾燥可藉由單一或多個單元而完成。其亦可為垂直或水平或呈一特定角度。在一較佳實施例中,乾燥/固化藉由直接火焰應用而發生。此處,纜線較佳直接通過一火焰以將纜線表面加熱至高達約150℃較佳高達約120℃之一溫度。一旦被烘乾/固化,將經塗敷之導體纏繞於一滾筒110上以用於儲存。
若對一個別絞合線(代替整個纜線)進行操作,則連續程序較佳以高達約2500ft/min最佳約9ft/min至約2000ft/min更佳約10ft/min至約500ft/min最佳約30ft/min至約300ft/min之一線速度操作。
本發明之高架導體塗層可用於複合核心導體設計中。在較高操作溫度及較高強度對重量比率下因複合核心導體之較低垂陷而使用複合核心導體。因塗層而降低導體操作溫度可進一步降低導體之垂陷且減少複合物中的聚合物樹脂之降級。複合核心之實例可發現於(例如)美國專利第7,015,395號、第7,438,971號及第7,752,754號中,該等案以引用方式併入本文中。
經塗敷之導體展現經改良之熱消散。發射率為一表面藉由輻射而發射熱之相對功率,及由一表面發射之輻射能量對相同溫度下由一黑體發射之輻射能量之比率。發射度為由每單位面積之一主體之表面輻射之能量。發射率可(例如)藉由揭示於Lawry等人之U.S.專利申請公開案第2010/0076719號中的方法而量測,該案以引用方式併入本文中。
在沒有進一步描述之情況下,據信,一般技術者可使用先前描述及下列繪示性實例而製造且利用本發明之化合物且實踐所主張之方法。給定下列實例以繪示本發明。應瞭解,本發明不限於此實例中所描述之特定條件或細節。
實例1
使用不同E/A(發射率對吸收率比率)值執行電腦模擬研究,以針對相同峰值電流量測導體之操作溫度之降低。E/A比率被視為藉由塗敷改造之導體之表面性質。表1列出高架導體之各種設計之模擬結果:
其他條件 周圍溫度:25℃,風速2ft/s
實例2
一塗層係藉由混合矽酸鈉(20重量百分比)、具有碳化硼之二氧化矽(37重量百分比)作為一熱輻射劑(3重量百分比)及水(40重量百分比)而製備。將該塗層組合物施加至具有高於0.85之一發射率之一金屬基板。透過具有1mil塗層厚度之金屬基板及一未塗敷之金屬基板施加一電流以量測塗層之效能改良。測試裝置展示於圖5中且主要由一60Hz交流電流源、一真實RMS鉗形電流錶、一溫度資料記錄器件及一計時器組成。在68"寬×33"深的有窗安全圍封體內實行測試以控制圍繞樣本之空氣移動。一排風罩位於測試裝置之上64"處以進行通風。
待測試的樣本透過受控於一計時器之一繼電器觸點而與一交流電流源串聯連接。該計時器用於啟動電流源且控制測試之持續時間。流經樣本之60Hz交流電流藉由一真實RMS鉗形電流計而監測。一熱耦合用於量測樣本之表面溫度。使用一彈性夾,使熱耦合之尖端保持與樣本之中心表面牢固接觸。在經塗敷樣本上進行量測之情況下,移除熱耦合與樣本接觸之區域處之塗層以達到基板之溫度之準確量測。熱耦合溫度係藉由一資料記錄之記錄器件而監測以提供溫度變化之一連續記錄。
在相同實驗條件下對此測試設定之未塗敷及經塗敷之基板樣本兩者之溫度上升進行測試。將電流設定在一所要位準處且在測試期間 進行監測以確保一恆定電流流經樣本。將計時器設定為一所需值且設定溫度資料記錄之記錄器件以在每秒一個讀數之一記錄間隔時記錄溫度。
未塗敷及經塗敷樣本之金屬組分來自相同源材料且大部分為鋁1350。未塗敷樣本之成品尺寸為12.0"(L)×0.50"(W)×0.027"(T)。塗敷樣本之成品尺寸為12.0"(L)×0.50"(W)×0.29"(T)。厚度及寬度之增加歸因於所施加之塗層厚度。
未塗敷樣本被牢固置於測試設定中且熱耦合被固定至該樣本之中心部分。一旦完成,則接通電流源且將其調整至所要的安培容量加載位準。一旦達成該位準,則切斷電源。對於測試自身而言,一旦計時器及資料記錄器件全部經適當設定,則開啟計時器以啟動電流源,因此開始測試。所要電流流經樣本且溫度開始升高。樣本之表面溫度變化藉由資料記錄器件而自動記錄。一旦完成測試週期,則計時器自動關閉電流源,因此結束測試。
一旦測試未塗敷樣本,則自設定移除該未塗敷樣本且以經塗敷樣本代替。測試恢復,未對電源電流器件作調整。相同電流位準通過經塗敷樣本。
接著自資料記錄器件存取溫度測試資料且使用一電腦進行分析。比較來自未塗敷樣本測試之結果與來自經塗敷測試之結果係用於判定塗敷材料之比較發射率效益。測試結果展示於圖6中。
實例3
評估180 amp電流時風對兩個#4 AWG實心鋁塗敷導體之溫度升高之效應。具有三個排擋之一風扇係用於模擬風且使風直接吹向距離2英尺遠之導體以進行測試。測試方法電路圖展示於圖7中。經塗敷及未塗敷導體兩者皆在180 amp、太陽光及風的條件下進行測試;及測試結果展示於表2中。經塗敷導體在分別經受無風、低風及高風時比 未塗敷導體更快冷卻達35.6%、34.7%及26.1%。風速對經塗敷導體幾乎沒有影響,但對未塗敷導體具有13%的影響。
評估130 amp電流時風對兩個#4 AWG實心鋁導體之溫度升高之效應。分別在無風、低風及高風連同130 amp電流及太陽光的條件下測試未塗敷導體及經塗敷導體。測試結果總結於表3中。經塗敷導體在分別經受無風、低風及高風時比未塗敷導體更快冷卻達29.9%、13.3%及17.5%。
實例4
對經塗敷及未塗敷之2/0 AWG實心鋁及795 kcmil AAC Arbutus導體樣本執行測試。根據如本文所調適之ANSI C119.4-2004執行電流循環測試方法。
導體測試樣本
1)塗敷有實例2中所揭示之塗層組合物之2/0 AWG實心鋁導體。該塗層之厚度為1mil。
2)未塗敷之2/0 AWG實心鋁導體。
3)塗敷有實例2中所揭示之塗層組合物之795 kcmil Arbutus全鋁導體。該塗層之厚度為1mil。
4)未塗敷之795 kcmil Arbutus全鋁導體。
5)鋁板(電工級匯流排)。
測試迴路總成:一串聯迴路形成有六個相同尺寸的四腳導體樣品(三個未塗敷及三個被塗敷),及透過電流變壓器路由之一額外合適導體。該串聯迴路由兩個行程之三個相同尺寸的導體樣品組成,該等導體樣品在塗敷與未塗敷之間交替,與安裝於導體樣品之間的一等化器焊接在一起以提供等位平面進行電阻量測。等化器確保所有導體絞合線之間的永久接觸。等化器(2/0實心鋁之2"×3/8"×1.75"及795 AAC Arbutus之3"×3/8"×3.5")係由鋁匯流排製造。連接導體之尺寸的孔被鑽成等化器。將鄰近導體末端焊接至等化器以完成該串聯迴路。一端處之一較大等化器(2/0實心鋁之10"×3/8"×1.75"及795 AAC Arbutus之12"×3/8"×3.5")係用於連接兩個行程,而另一端處之等化器連接至透過電流變壓器路由之一額外導體。在圖7中描繪該迴路組態。
測試迴路總成距離任意壁至少1ft.而定位及距離地板及天花板至少2ft.而定位。鄰近迴路彼此距離至少1ft.而定位且單獨通電。
溫度量測:各導體樣品之溫度在測試過程中以指定時間間隔同時監測。使用T型熱耦合及一資料記錄器監測溫度。將一熱耦合附接至在12點鐘位置的樣品之中點處之各導體。各樣本之一樣品具有連接至3點鐘位置及6點鐘位置處之樣品之側之額外熱耦合。一熱耦合鄰近於該串聯迴路而定位以進行周圍溫度量測。
電流設定:將導體電流設定為適當安培容量以在結束未塗敷之導體樣品之一加熱週期時產生高於周圍空氣溫度之100℃至105℃之一溫度。由於未塗敷導體及經塗敷導體在測試總成中為串聯放置,則相同電流通過兩個樣本。最初幾個熱循環係用於設定適當安培容量以產 生所要溫度升高。一熱循環由2/0 AWG實心鋁迴路之一個小時加熱繼而一個小時冷卻及795絞合鋁迴路之一個半小時加熱繼而一個半小時冷卻組成。
測試程序:除針對熱循環之減少量執行測試(執行至少50個循環)之外,根據電流循環測試方法(ANSI C119.4-2004)實行測試。將周圍溫度維持在±2℃。在熱循環期間連續記錄溫度量測。在導體返回至室溫之後,在結束加熱循環時及在下一加熱循環之前量測電阻。
測試結果:經塗敷之2/0 AWG實心鋁導體及795 kcmil Arbutus全鋁導體展示比未塗敷導體更低之溫度(大於20℃)。在圖8及圖9中分別擷取溫度差異資料。
實例5
一鋁基板塗敷有如下文所描述及表4中所總結之各種塗層組合物。該塗層組合物具有自白色至黑色之範圍之一色彩光譜。
鋁控制:由1350鋁合金製成之未塗敷鋁基板。
塗層2:具有56重量百分比固體量之基於聚胺酯之塗層,購自Lord公司作為等級Aeroglaze A276。
塗層3:具有70:30之含氟聚合物/丙烯酸樹脂比率之基於PVDF之塗層,購自Arkema作為Kynar ARC及10重量百分比二氧化鈦粉末。
塗層4:含75重量百分比矽酸鈉水溶液(含40%固體)及購自US Zinc之25重量百分比氧化鋅之塗層。
塗層5:含72.5重量百分比矽酸鈉水溶液(含40%固體)及購自H.C.Starck之12.5重量百分比氮化鋁AT粉末(具有D 10% 0.4微米至1.4微米、D 50% 7微米至11微米、D 90% 17微米至32微米之顆粒尺寸分佈)、購自Momentive效能材料控股公司之12.5重量百分比碳化矽及2.5重量百分比活性胺基聚矽氧樹脂(等級SF 1706)之塗層。
塗層6:含購自Dow corning之87.5重量百分比基於聚矽氧塗層(等 級236)及12.5重量百分比碳化矽之塗層。
塗層7:含矽酸鹽黏結劑(20重量百分比)、二氧化矽(37重量百分比)及碳化硼(3重量百分比)及水(40重量百分比)之塗層。
塗層8:含矽酸鉀(30重量百分比)、磷酸三鈣(20%重量百分比)、混合金屬氧化物顏料(5%)及水(45%)之塗層。
使用由美國BYK-Gardner製造之分光指南45/0光澤量測關於L*、a*、b*標度之樣本色彩。
按每ASTM E903測試樣本之太陽能反射率(R)及吸收率(A)。在300K溫度時按每ASTM E408量測樣本之發射率(E)。塗敷有1mil厚度塗層之50mm長度×50mm寬度×2mm厚度之鋁基板係用於量測太陽能反射率、吸收率、發射率。
測試經塗敷之樣本之能力以在相較於如實例2中所描述之使用95 amp之電流設定之一裸露鋁基板時降低導體之操作溫度。為研究太陽能對導體之操作溫度之效應,除了施加至測試樣本之電流之外,亦將模擬太陽能光譜之燈泡置於測試樣本之上,及記錄測試樣本溫度。使用標準金屬鹵化物400瓦燈泡(模型MH400/T15/HOR/4K)。使燈與燈泡之間的距離維持在1ft。該等結果被列為「電氣+太陽能」。關掉燈泡同時接通電流之結果被列為「電氣」。
塗層之熱老化效能係藉由將樣本置於維持在325℃之一空氣循環烘箱中達1天及7天之一時期而實施。在完成熱老化之後,將樣本置於21℃之室溫下達24小時之一時期。接著使該等樣本彎向於自較高直徑至較低直徑定尺寸之不同圓柱心軸及該等塗層觀察到心軸尺寸之各者處之任意肉眼可見的裂縫。若樣本在彎向於直徑為10英吋或更小之一心軸時並未展現肉眼可見的裂縫,則將樣本視為「合格」。
儘管已選定特定實施例來繪示本發明,然熟習此項技術者將瞭解,在不脫離如隨附申請專利範圍中所界定之本發明之範疇之情況下,可於其內作各種改變及修改。
102‧‧‧入口繞線筒
104‧‧‧預處理單元
106‧‧‧塗敷單元
108‧‧‧乾燥/固化單元
110‧‧‧滾筒
112‧‧‧導體

Claims (45)

  1. 一種表面改造之高架導體,其包括塗敷有一非白色無機塗層之一裸露導體,其中當根據ANSI C119.4-2004測試時,在一相同電流下,該表面改造之高架導體之操作溫度低於一未改造(不包含熱輻射劑)之高架導體之溫度。
  2. 如請求項1之表面改造之高架導體,其中當相較於該未改造之高架導體之該操作溫度時,該操作溫度降低達至少5℃。
  3. 如請求項1之表面改造之高架導體,其中該塗層之L*值小於80。
  4. 如請求項1之表面改造之高架導體,其中該塗層具有至少約0.75之一發射率係數。
  5. 如請求項1之表面改造之高架導體,其中該塗層具有大於0.5之一發射率係數及大於0.3之一太陽能吸收係數。
  6. 如請求項1之表面改造之高架導體,其中該塗層包括小於總乾燥塗層之5重量百分比之有機材料。
  7. 如請求項1之表面改造之高架導體,其中該塗層厚度小於約200微米。
  8. 如請求項1之表面改造之高架導體,其中該導體在以325℃熱老化達1天及7天之後通過心軸彎曲測試。
  9. 如請求項1之表面改造之高架導體,其中該塗層在0℃至250℃之溫度內具有在約10×10-6至約100×10-6/℃之範圍內的一熱膨脹係數。
  10. 如請求項1之表面改造之高架導體,其中該導體包括銅或銅合金或鋁或鋁合金之一或多個導線,其包含鋁型號1350合金鋁、6000系列的合金鋁或鋁鋯合金或任意其他導電金屬。
  11. 如請求項9之表面改造之高架導體,其中該等金屬線為梯形。
  12. 如請求項1之表面改造之高架導體,其中該導體包括:一或多個鋼線、恆範鋼線或碳纖維複合線之一核心;及圍繞該核心之一或多個導線,該一或多個導線係由銅或銅合金或鋁或鋁合金製成,其包含鋁型號1350、6000系列之合金鋁或鋁鋯合金或任意其他導電金屬。
  13. 如請求項1之表面改造之高架導體,其中該導體包括一強化複合核心。
  14. 如請求項1之表面改造之高架導體,其中該導體包括一碳纖維強化複合核心。
  15. 如請求項1之表面改造之高架導體,其中該熱輻射劑包含於一表面塗層中。
  16. 如請求項1之表面改造之高架導體,其中該導體線之外層被塗敷。
  17. 如請求項1之表面改造之高架導體,其中該導體係由塗敷線構成。
  18. 如請求項1之表面改造之高架導體,其中該導體之該外層被塗敷。
  19. 如請求項1之表面改造之高架導體,其中該導體之一部分被塗敷。
  20. 如請求項1之表面改造之高架導體,其中該塗層包括小於約5%(按總乾燥塗層之重量計)之有機材料。
  21. 如請求項1之表面改造之高架導體,其中該塗層包括約1%至20%(按總塗層之重量計)之一熱輻射劑、約60%至90%之一黏結劑,及約10%至35%之氮化鋁,以及小於約5%胺基官能矽氧烷。
  22. 如請求項21之表面改造之高架導體,其中該黏結劑為矽酸鈉。
  23. 如請求項21之表面改造之高架導體,其中該胺基官能矽氧烷為 二甲基聚矽氧烷。
  24. 如請求項21之表面改造之高架導體,其中該二甲基聚矽氧烷在25℃時具有約10至50厘拖之一黏度及/或0.48毫當量鹼基/克之一胺當量。
  25. 如請求項21之表面改造之高架導體,其中該氮化鋁具有小於2m2/g之一特定表面面積及/或下列顆粒尺寸分佈:D 10%-0.4至1.4微米、D 50%-7至11微米及D 90% 17至32微米。
  26. 一種用於製造一表面改造之高架導體之方法,其包括如下步驟a.製備一裸露導體;b.將一液體塗層混合物施加於一導體之表面上以形成一塗敷導體;及c.烘乾該塗敷導體。
  27. 如請求項26之方法,其中步驟a包括如下步驟:噴砂處理該導體;及使該經噴砂處理之導體通過一空氣擦拭。
  28. 如請求項26之方法,其中在該空氣擦拭之後,每平方英尺之導體表面之該導體表面上之尺寸大於10微米之顆粒數目低於1000。
  29. 如請求項27之方法,其中步驟a進一步包括:在該空氣擦拭之後加熱該導體之步驟。
  30. 如請求項29之方法,其中該加熱係通過直接火焰曝露。
  31. 如請求項26之方法,其中步驟b包括:使該導體通過一液泛式鑄模及接著通過一空氣擦拭。
  32. 如請求項31之方法,其中該液泛式鑄模包括具有使該裸露導體通過其之一中心開口之一環形部分。
  33. 如請求項32之方法,其中該液泛式鑄模進一步包括用於將液體塗層混合物載送至該鑄模之一管。
  34. 如請求項32之方法,其中該液泛式鑄模包括該液體塗層混合物透過其沈積至該導體上之開口埠。
  35. 如請求項26之方法,其中步驟c包括:加熱該導體。
  36. 如請求項35之方法,其中該加熱係通過直接火焰曝露。
  37. 如請求項26之方法,其具有約10ft/min至約400ft/min之一線速度。
  38. 一種用於製造一表面改造之高架導體之方法,其包括使一導體塗敷有一非白色無機塗層之步驟,其中當根據ANSI C119.4-2004測試時,在一相同電流下,該表面改造之高架導體之操作溫度低於一未改造(不包含熱輻射劑)之高架導體之溫度。
  39. 如請求項38之方法,其中該塗層之L*值小於80。
  40. 如請求項38之方法,其中該塗層具有至少約0.75之一發射率係數。
  41. 如請求項38之方法,其中該塗層具有大於0.5之一發射率係數及大於0.3之一太陽能吸收係數。
  42. 如請求項38之方法,其中該塗層包括小於總乾燥塗層之5重量百分比之有機材料。
  43. 如請求項38之方法,其中該塗層厚度小於約200微米。
  44. 如請求項38之方法,其中該導體在以325℃熱老化達1天及7天之後通過心軸彎曲測試。
  45. 如請求項38之方法,其中該塗層在0℃至250℃之溫度內具有在約10×10-6至約100×10-6/℃之範圍內的一熱膨脹係數。
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JP6386459B2 (ja) 2018-09-05
BR112015002970B1 (pt) 2022-02-15
HUE054350T2 (hu) 2021-09-28
EP2883231A1 (en) 2015-06-17
MY189482A (en) 2022-02-16
AU2013300127B2 (en) 2017-07-13
TWI633564B (zh) 2018-08-21

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