WO2014107112A1 - Aluminium single conductor cable - Google Patents

Aluminium single conductor cable Download PDF

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Publication number
WO2014107112A1
WO2014107112A1 PCT/NO2013/000058 NO2013000058W WO2014107112A1 WO 2014107112 A1 WO2014107112 A1 WO 2014107112A1 NO 2013000058 W NO2013000058 W NO 2013000058W WO 2014107112 A1 WO2014107112 A1 WO 2014107112A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
layer
cable
aluminium
extrusion
Prior art date
Application number
PCT/NO2013/000058
Other languages
French (fr)
Inventor
Klaus Jørgen Buur Winther SANDFELD
Jens Sandahl SØRENSEN
Torben Thomsen
Original Assignee
Norsk Hydro Asa
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Norsk Hydro Asa filed Critical Norsk Hydro Asa
Publication of WO2014107112A1 publication Critical patent/WO2014107112A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a general shape other than plane
    • B32B1/08—Tubular products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/088—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/023—Alloys based on aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/145—Pretreatment or after-treatment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/305—Polyamides or polyesteramides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1875—Multi-layer sheaths
    • H01B7/188—Inter-layer adherence promoting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/206—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00—Tubular articles, e.g. hoses, pipes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/36—Insulated conductors or cables characterised by their form with distinguishing or length marks
    • H01B7/365—Insulated conductors or cables characterised by their form with distinguishing or length marks being indicia imposed on the insulation or conductor

Abstract

Insulated single conductor grounding/earthling cable of aluminum comprising a core (3) of conductive aluminium and at least one outer electrical insulating layer or coating. The core (3) is provided with a first, inner polyamide (PA) layer (2) and a second, outer layer (1) of polyethylene (PE). A method for production of the insulated single conductor grounding/earthling cable includes the steps of producing the aluminium core in an extrusion or drawing station, calibrating the core through a sink die (6) and further drawing the core through a degreasing unit (5) to be degreased and etched in an alkaline bath. Then passing the core (3) through a surface pretreatment unit (8) where the aluminium surface of the core (4) is pretreated to ensure a strong bond between the PA (Polyamide) coating and the aluminum substrate and where after the core (3) is passed through a co-extrusion unit (9) where the PA and PE coatings are applied to the surface of the aluminum core in a co-extrusion process, one coating after the other.

Description

Aluminium single conductor cable
The present invention relates to an insulated single conductor grounding/earthling cable of aluminum and a method of producing the same.
Electrical cables of the above kind are aimed at substituting copper cables used in railway applications as grounding connection. (Electrical potential equalization between the steel mast and high voltage overhead line in the event of a short-circuit fault).
The use of aluminium in electrical cables represents a light weight alternative that offers up to 45 % mass reduction compare to traditional copper core cables. Approximately one kilogram of aluminium can replace 2 kilograms of copper, provided equal conductivity. Since aluminium as such is much cheaper than copper and due to the fact that aluminium metal has lighter weight and therefore is easier to handle, cables made of such metal is definitely the cheapest and best choice.
It is further a fact that the increased world market price of copper has made this metal very attractive to looters who systematically remove copper cables from railway tracks on a large scale. Besides losing the direct cable value and labour costs associated with the restoration of the cabling connection, the railroad owner also loses revenue from the train service which is halted long periods of time..
The lower market value of aluminium in combination with an effective irremovable
"marking system" according to the present invention, the inventive cables as described and defined in the present application are less attractive to looters.
From US 3,441 ,660 is known a lightweight power cable of the above kind. The power cable is composed of a solid aluminium conductor with a semiconducting layer surrounding the aluminium conductor and with an electrical insulating layer on the outside which is further covered with an outer semi-conducting layer. The insulating layer according to the patent is preferably a cross-linked polyethylene, whereas the two semiconducting layers, the one inside and the other outside of the insulating layers, are made of polyethylene with added carbon.
The bonding between these layers and the bonding between the aluminium conductor and semiconducting inner layer is poor, whereby the layers are easily peeled off the conductor and the mechanical strength of the layers is poor. With the present invention is provided an electrical cable which substitutes copper cables used in railway applications as grounding connection. The cable is manufactured on the basis of a method and with a combination of insulating layers and pretreatment of the aluminium substrate which ensures supreme bonding to the solid aluminium conductor improved mechanical strength and good electrical insulation properties.
The cable according to the invention is characterized by the features as defined in the attached independent claim l and the method by which the cable is produced is defined in the dependent claim 4.
Preferred embodiments of the invention are further defined in the dependent claims 2 - 3 and 5 - 7.
The invention will be described in further detail in the following by means of examples and with reference to the attached figures, where: Fig. 1 shows in perspective view part of an electrical power cable according to the invention,
Fig. 2 shows a sketch of a production line for an electrical power cable according to the invention. Figure 1 shows a as stated above a perspective view part of an electrical power cable according to the invention where the layers of the cable are partly peeled off. The cable consists on an aluminum core 1 extruded in the present example from an AA 1370 alloy, a polyamide (PA) layer 2 covering the aluminum core and an outer layer 3 of polyethylene (PE).
Fig. 2 shows a sketch of a production line for a cable according to the invention. The aluminum core 3 is initially produced by extrusion in an extrusion plant (not shown) and preferably coiled, stored and transported on a reel 4 as shown in the figure. From the reel 4, the aluminium core 3 is straightened through a straightening section 5 and thereafter calibrated through a sink die 6. From the sink die the core 3 is further drawn through a degreasing unit 5 to be degreased and etched in an alkaline bath. The core is then further passed through chrome free surface pretreatment unit 8 where the aluminium surface of the core 4 is pre-treated to ensure a strong bond between the PA (Polyamide) coating and the aluminum substrate.
After the pretreatment unit 8, the core 4 is passed through a co-extrusion unit 9 where the PA and PE coatings are applied to the surface of the aluminum core in a co- extrusion process, one coating after the other. The co-extrusion unit may be a single unit with following , combined extrusion dies or two unit arrangement with separate dies (not further shown). The thickness of the coatings are controlled on the basis of the aluminium core speed, the viscosity of the coatings (depending on temperature) and pressure of the PA and PE mold sections.
The required thickness of the respective PA and PE coatings will depend on product application. Preferably the the first PA layer 2 preferably have a thickness of 60 microns, while the second, outer PE (layer 1 have a thickness of preferably 1000 microns.
In a further step the cable may be provided with printed text in a printing station 10 Preferrably the polyamide coating can be printed with predefined, irremovable text such as
"property of company..." which will have a preventive effect since it will make it more difficult for looters to sell cables that have been stolen. Text may in addition also be printed on the metal substrate and outer PE layer. In such case printing stations are provide prior to the co-extrusion unit, between the dies of the co-extruder and after the co-extruder (not further shown).
Finally the cable is cut to desired lengths in a cutting station 11 and the cut lengths of the cable are stored in a suitable stacking arrangement 12. Or the cable may be coiled and stored on suitable reels.
The decisive feature of this product in comparison to similar products in the market is the bond between the PA coating and the aluminum substrate. This strong bond between the aluminum core and the PA coating makes it almost impossible to remove unless it is done by by abrasion, machining or extreme heat (burned off).
The aluminium core may, as mentioned above can be an AA 1370 alloy with a composition as defined in the table below. However, other suitable Al alloys with good conductivity and mechanical properties such as AA8176 or AA1350 may also be used
Alloy 1370 Min Max
Si - 0,1
Fe - 0,25
Cu - 0,02
Mn - 0,01
Mg - 0,02
Cr - 0,01
Ni - -
Zn - 0,04
Ti - -
Ga - 0,03
Zr - -
Na - -
Pb - -
Others each - 0,02
Others total - 0,1
Rest AI As is stated above the present invention as described in the example is related to electrical cables of the kind that are preferably aimed at substituting copper cables used in railway applications as grounding connection. However, the invention as defined in the claims may of course be used for other applications where improved electrical insulation, good mechanical properties and extreme bonding of the outer coverings is important or required.

Claims

Claims
Insulated single conductor aluminium cable in particular grounding/earthling cable of aluminum comprising a core (3) of conductive aluminium and at least one outer electrical insulating layer or coating,
characterised in that
the core (3) is provided with a first, inner polyamide (PA) layer (2) and a second, outer layer (1 ) of polyethylene (PE).
Cable according to claim 1 ,
characterised in that
the first PA layer (2) preferably have a thickness of 60 microns, while the second, outer PE (layer (1 ) have a thickness of preferably 1000 microns
Cable according to claim 1 ,
characterised in that
the core (3) preferably is an AA 1370 aluminium alloy. Method for production of insulated cable, preferably single conductor grounding/earthling cable of aluminum as defined in the previous claims, characterised in that
the the aluminum core (3) is initially produced by extrusion or drawing in an extrusion or drawing plant, calibrated through a sink die (6) and further drawn through a degreasing unit (5) to be degreased and etched in an alkaline bath from which etching step, the core (3) is passed through a surface pretreatment unit (8) where the aluminium surface of the core (3) is pretreated to ensure a strong bond between the PA (Polyamide) layer and the aluminum substrate and where after the core (3) is passed through a co-extrusion unit (9) where the PA and PE layers are applied to the surface of the aluminum core in a co-extrusion process, one coating after the other.
Method for production of insulated single conductor cable according to claim 4, characterised in that,
the the pre-treatment is performed in a chrome free surface pretreatment unit (8).
Method for production of insulated single conductor cable according to claim 4, characterised in that,
the PA coating of the cable is provided with printed text in a printing station (10) between the extrusion dies of the co-extrusion unit (9).
Method for production of insulated single conductor cable according to claim 4, characterised in that,
each of the sufaces of the aluminium substrate, the PA layer and PE layer are provided with printed text.
PCT/NO2013/000058 2013-01-03 2013-12-18 Aluminium single conductor cable WO2014107112A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20130012 2013-01-03
NO20130012 2013-01-03

Publications (1)

Publication Number Publication Date
WO2014107112A1 true WO2014107112A1 (en) 2014-07-10

Family

ID=51062364

Family Applications (1)

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PCT/NO2013/000058 WO2014107112A1 (en) 2013-01-03 2013-12-18 Aluminium single conductor cable

Country Status (1)

Country Link
WO (1) WO2014107112A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105336453A (en) * 2015-11-24 2016-02-17 江苏永鼎盛达电缆有限公司 Double-layer co-extrusion and insulation irradiation crosslinking process method and low-smoke halogen-free flame-retardant wire
WO2019104183A1 (en) * 2017-11-22 2019-05-31 General Cable Technologies Corporation Wires formed from improved 8000-series aluminum alloy
WO2019175210A1 (en) 2018-03-13 2019-09-19 Hydro Extruded Solutions As Flat cable connection
US10633725B2 (en) 2015-10-14 2020-04-28 NaneAL LLC Aluminum-iron-zirconium alloys

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4546041A (en) * 1979-07-30 1985-10-08 General Electric Company Corona-resistant wire enamel compositions and conductors insulated therewith
JPH03152804A (en) * 1989-11-09 1991-06-28 Fujikura Ltd Insulated wire
WO1993018914A1 (en) * 1992-03-17 1993-09-30 Allied-Signal Inc. Improved flexible fire retardant multi-layer structures comprising polyolefin and polyamide layers and process for making the same
US5654095A (en) * 1995-06-08 1997-08-05 Phelps Dodge Industries, Inc. Pulsed voltage surge resistant magnet wire
WO1998033190A1 (en) * 1997-01-27 1998-07-30 Rea Magnet Wire Company, Inc. Electrical conductors coated with corona-resistant, multilayer insulation system

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4546041A (en) * 1979-07-30 1985-10-08 General Electric Company Corona-resistant wire enamel compositions and conductors insulated therewith
JPH03152804A (en) * 1989-11-09 1991-06-28 Fujikura Ltd Insulated wire
WO1993018914A1 (en) * 1992-03-17 1993-09-30 Allied-Signal Inc. Improved flexible fire retardant multi-layer structures comprising polyolefin and polyamide layers and process for making the same
US5654095A (en) * 1995-06-08 1997-08-05 Phelps Dodge Industries, Inc. Pulsed voltage surge resistant magnet wire
WO1998033190A1 (en) * 1997-01-27 1998-07-30 Rea Magnet Wire Company, Inc. Electrical conductors coated with corona-resistant, multilayer insulation system

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10633725B2 (en) 2015-10-14 2020-04-28 NaneAL LLC Aluminum-iron-zirconium alloys
CN105336453A (en) * 2015-11-24 2016-02-17 江苏永鼎盛达电缆有限公司 Double-layer co-extrusion and insulation irradiation crosslinking process method and low-smoke halogen-free flame-retardant wire
WO2019104183A1 (en) * 2017-11-22 2019-05-31 General Cable Technologies Corporation Wires formed from improved 8000-series aluminum alloy
WO2019175210A1 (en) 2018-03-13 2019-09-19 Hydro Extruded Solutions As Flat cable connection

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