electric cable and electric cable production method

专利摘要:
ELECTRIC TRANSMISSION CABLES WITH COMPOSITE CORE. The present invention describes electrical cables containing a cable core and several conductive elements surrounding the cable core. The cable core contains a composite core, and each composite core contains a rod, which contains several unidirectionally aligned fiber shafts within a thermoplastic polymer matrix, and surrounded by a capping layer
公开号:BR112013026310B1
申请号:R112013026310-5
申请日:2012-04-11
公开日:2020-10-27
发明作者:Alan Daniel；Paul Springer；Yuhsin Hawig；Mark Lancaster；David W. Eastep；Sherri M. Nelson；Tim Tibor；Tim Regan；Michael L. Wesley
申请人:Southwire Company, Llc.；
IPC主号:

专利说明:

REFERENCE TO RELATED PATENTS APPLICATIONS
This patent application is being filed on April 11, 2012, as an international PCT patent application, in the name of Allan Daniel, a US citizen, Paul Springer, a US citizen, Yuhs in Hawig, a Chinese citizen , Mark Lancaster, an American citizen, David W. Eastep, an American citizen, Sherri M. Nelson, an American citizen, Tim Tibor, an American citizen, Tim Regan, an American citizen, and Michael L. Wesley, an American citizen, the applicants for nomination from all countries, and claims the priority of US patent application serial number 61 / 474,423, filed on April 12, 2011, and refers to US patent application serial number 61 / 474,458, filed on April 12, 2011, both of which are incorporated in their entirety by reference in this specification. BACKGROUND OF THE INVENTION
Composite wire structures are commonly used as transmission lines or cables for the transmission of electricity to users. Examples of composite transmission wire constructions include, for example, aluminum conductor steel reinforced cable (ACSR), aluminum conductor steel supported cable (ACSS), aluminum conductor composite reinforced cable (ACCR) and cable aluminum conductor composite core (ACCC). ACSR and ACSS cables include an outer conductive layer of aluminum surrounding an inner steel core. Transmission lines or cables are designed not only to efficiently transmit electricity, but also to be mechanically resistant and temperature resistant, especially when transmission lines are tied to towers and stretched over long distances.
It will be beneficial to produce cables with a composite core, which are capable of achieving the desired mechanical strength, durability and thermal performance required by applications such as overhead power cables. Consequently, it is for these purposes that the present invention is directed. SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts in a simplified form, which are further described below in the detailed description. This summary is not intended to identify necessary or essential aspects of the claimed object. Nor is this summary intended to be used to limit the scope of the claimed object.
Embodiments of the present invention may provide cables, for example, electrical transmission cables for overhead transmission of electricity, which may contain a cable core and conductive elements surrounding the cable core. The cable core can contain at least one composite core (the composite core can also be referred to as a composite filament or a polymeric composite filament). These core elements can serve as load-bearing elements for the cable for electrical transmission, and, in some embodiments, these core elements can be non-conductive.
According to an embodiment of the present invention, a composite core for the electrical cable is described. Generally, the cables and cores described in this specification can extend in a longitudinal direction. The composite core may comprise at least one stick, which comprises a continuous fiber component consisting of several consolidated thermoplastic impregnated rovings (the stick may also be referred to as a fiber core). Tangles can contain continuous fibers, oriented in the longitudinal direction, and a thermoplastic matrix that embeds the fibers. Fibers can have a tensile strength to mass limit ratio per unit length greater than about 1,000 megapascals per gram per meter (MPa / g / m). The continuous fibers can make up from about 25% by weight to about 80% by weight of the stick, and the thermoplastic matrix can make up from about 20% by weight to about 75% by weight of the stick. A capping layer may surround the rod, and this capping layer may be devoid of continuous fibers. The composite core can have a minimum flexural modulus of about 10 gigapascals (GPa).
According to another embodiment of the present invention, a process for forming a composite core, for an electrical transmission cable, is described. The process may comprise: impregnating several tangles with a thermoplastic matrix; and consolidating the tangles to form a ribbon, where the tangles can comprise continuous fibers oriented in the longitudinal direction. The fibers may have a tensile strength to mass limit per unit length greater than about 1,000 MPa / g / m. The continuous fibers can comprise from about 25% by weight to about 80% by weight of the tape, and the thermoplastic matrix can constitute from about 20% by weight to about 75% by weight of the tape. The tape can be heated to a temperature equal to or greater than the softening temperature (or melting temperature) of the thermoplastic matrix, and pulled by at least one stamping matrix, to compress and shape the tape on a stick. A capping layer can be applied to the stick to form a composite core.
In accordance with yet another embodiment of the present invention, a process for producing an electrical cable is described. This process may comprise: providing a cable core comprising at least one composite core; and surrounding the cable core with several conductive elements. The composite core may comprise at least one rod, consisting of several entangled entangled thermoplastic tangles. Tangles can comprise continuous fibers, oriented in the longitudinal direction, and a thermoplastic matrix that embeds the fibers. The fibers may have a tensile strength to mass limit per unit length greater than about 1,000 MPa / g / m. Typically, the stick can comprise from about 25% by weight to about 80% by weight of fibers, and from about 20% by weight to about 75% by weight of thermoplastic matrix. A capping layer can surround at least one rod, and this capping layer can generally be devoid of continuous fibers. In these and other embodiments, the composite core may have a flexural modulus greater than about 10 GPa.
Both the preceding summary and the detailed description below provide examples and are for explanation only. Consequently, the preceding summary as the detailed description below should not be considered as restrictive. In addition, aspects or variations can be provided in addition to those presented in this specification. For example, certain aspects and embodiments can be addressed to various combinations and subcombination of aspects, described in the detailed description. BRIEF DESCRIPTION OF THE DRAWINGS
The attached drawings, which are incorporated into and form part of the description, illustrate the various aspects and embodiments of the present invention. In the drawings: Figure 1 is a perspective view of an embodiment of a consolidated tape, for use in the present invention; Figure 2 is a cross-sectional view of another embodiment of a consolidated tape, for use in the present invention; Figure 3 is a schematic illustration of an embodiment of an impregnation system, for use in the present invention; Figure 4 is a cross-sectional view of the impregnation matrix shown in Figure 3; Figure 5 is a detailed view of an embodiment of a bypass assembly and an entry passage for an impregnation matrix, which can be employed in the present invention; Figure 6 is a perspective view of an embodiment of a plate, defining, at least partially, an impregnation zone, which can be used in the present invention; Figure 7 is a schematic illustration of an embodiment of a pultrusion system, which can be employed in the present invention; Figure 8 is a perspective view of an embodiment of a composite core of the present invention; Figure 9 is a perspective view of an embodiment of an electrical transmission cable of the present invention; Figure 10 is a perspective view of another embodiment of an electrical transmission cable of the present invention; Figure 11 is a cross-sectional view from the top of an embodiment of several calibration matrices, which can be used in accordance with the present invention; Figure 12 is a side cross-sectional view of an embodiment of a calibration matrix, which can be employed in accordance with the present invention; Figure 13 is a front view of part of an embodiment of a calibration matrix, which can be employed in accordance with the present invention; Figure 14 is a front view of an embodiment of forming cylinders, which can be used in accordance with the present invention; Figure 15 is a perspective view of the electrical cable in Examples 6 and 7; Figure 16 is a stress-strain diagram for the electrical cable in Example 7; and Figure 17 is a perspective view of the electrical cable of construction example 8. DETAILED DESCRIPTION OF THE INVENTION
The detailed description presented below refers to the attached drawings. As far as possible, the same or similar reference numbers are used in the drawings and in the description presented below, for reference to the same or similar elements or aspects. Although aspects and embodiments of the invention can be described, modifications, adaptations and other implementations are possible. For example, substitutions, additions or modifications can be made to the elements illustrated in the drawings, and the processes described in this specification can be modified by replacing, rearranging or adding stages to the described processes. Consequently, the detailed description presented below and its exemplary embodiments do not limit the scope of the invention.
The present invention is generally directed to electrical cables, such as overhead transmission lines, and to composite cores contained within these electrical cables. In certain embodiments of the invention, an electrical cable may comprise: a cable core consisting of at least one composite core (or composite filament); and a plurality of conductive elements surrounding the cable core. COMPOSITE CORE
The composite core may contain a rod (or fiber core) comprising a continuous fiber component, surrounded by a capping layer. The rod may comprise a plurality of fiber tangles aligned unidirectionally within a thermoplastic polymer matrix. Although they do not wish to be attached to the theory, applicants believe that the degree to which tangles are impregnated with the thermoplastic polymer matrix can be significantly improved by selective control in the impregnation process, and also by controlling the degree of compression conferred to the tangles. , during formation and molding of the rod, as well as the calibration of the final geometry of the rod. This well-impregnated stick can have a very small void fraction, which can promote excellent mechanical strength properties. Significantly, the desired mechanical strength properties can be achieved without the need for different types of fiber in the stick.
As used in this specification, the term "entangled" generally refers to an individual fiber bundle or tow. The fibers contained within the tangle can be twisted or straight. Although different fibers can be used in individual or different tangles, it can be beneficial that each tangle contains a single type of fiber, to minimize any adverse impact of the use of materials having different coefficients of thermal expansion. The continuous fibers used in the tangles can have a high degree of tensile strength in relation to their mass. For example, the fiber tensile strength limit can typically be in the range of about 1,000 to about 15,000 megapascals (MPa), in some embodiments, from about 2,000 MPa to about 10,000 MPa, and in some embodiments, from about 3,000 MPa to about 6,000 MPa. These tensile strengths can be obtained even though the fibers are of a relatively low weight, such as a mass per unit length of about 0.1 to about 2 grams per meter (g / m), in some embodiments of about from 0.4 to about 1.5 g / m. The tensile strength to mass ratio per unit length can therefore be about 1,000 megapascals per gram per meter (MPa / g / m) or higher, in some embodiments equal to or greater than about 4,000 MPa / g / m, and in some embodiments, from about 5,500 to about 20,000 MPa / g / m. These high mechanical strength fibers can be, for example, metal fibers, glass fibers (for example, E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1-glass, S2-glass, etc.), boron fibers, ceramic fibers (eg alumina or silica), aramid fibers (eg Kevlar® sold by El duPont de Nemours, Wilmington, Del.), synthetic organic fibers (eg example, polyamide, polyethylene, paraphenylene, terephthalamide, poly (ethylene terephthalate) and poly (phenylene sulfide)), and various other inorganic or organic fibrous materials, natural or synthetic, known for reinforcing thermoplastic and / or thermoset compositions. Carbon fibers can be particularly suitable for use as continuous fibers, which typically have a tensile strength to mass ratio per unit length in the range of about 5,000 to about 7,000 MPa / g / m. Often, continuous fibers can have a nominal diameter of about 4 to about 34 micrometers (jam), and, in some embodiments, from about 5 to about 35 µm. The number of fibers contained in each tangle can be constant or can vary from tangle to tangle. Typically, a tangle can contain from about 1,000 fibers to about 100,000 individual fibers, and, in some embodiments, from about 5,000 to about 50,000 fibers.
Any of several thermoplastic polymers can be used to form the polymeric matrix, in which the continuous fibers are embedded. Suitable thermoplastic polymers for use in the present invention can include, for example, polyolefins (for example, polypropylene, propylene-ethylene copolymers, etc.), polyesters (for example, poly (butylene terephthalate) - PBT), polycarbonates , polyamides (for example, Nylon®), poly (ethers - ketones) (for example, poly (ether - ether - ketone) - PEEK), poly (ethers - imides), poly (arylene ketones) (for example, poly ( phenylene diketone) - PDDK), liquid crystalline polymers, poly (arylene sulfides) (for example, poly (phenylene sulfide) - PPS, poly (biphenylene sulfide - ketone), poly (phenylene sulfide - diketone), poly ( biphenylene sulfide), etc.), fluoropolymers (for example, polytetrafluoroethylene polymer - perfluromethylvinyl ether, perfluoro - alkoxyalkane polymer, perfluroethylene polymer, ethylene polymer - tetrafluoroethylene, etc.), polyacetals, polyurethanes, polycarbonates, polyurethanes, polycarbonates (e.g. acrylonitrile - butadi eno - styrene) - ABS), and the like, or combinations thereof.
Generally, the properties of the thermoplastic matrix can be selected to obtain a desired combination of processability and end-use performance of the composite core. For example, the melt viscosity of the thermoplastic matrix can generally be low enough so that the polymer can adequately impregnate the fibers and be molded into the stick configuration. In this respect, the melt viscosity can typically range from about 25 to about 2,000 pascanos-seconds (Pa.s), in some embodiments, from 50 to about 500 Pa.s, and, in some embodiments, from about 60 to about 200 Pa.s, determined under the operating conditions used for the thermoplastic polymer (for example, about 360 ° C). Also, because the core can be used at high temperatures (for example, in high voltage transmission cables), a thermoplastic polymer, having a relatively high melting temperature, can be employed. For example, the melting temperature of these high temperature polymers can be in the range of about 200 ° C to about 500 ° C, in some embodiments, from about 225 ° C to about 400 ° C, and in some embodiments, from about 250 ° C to about 350 ° C.
In the particular embodiments considered in the present specification, poly (arylene sulfides) can be used in the present invention as a high temperature matrix with the desired melt viscosity. Poly (arylene sulfide) is, for example, a semicrystalline resin, which generally includes repetitive monomer units, represented by the following general formula:

Such monomer units may constitute at least 80 mol%, and, in some embodiments, at least 90 mol%, in the polymer. It should be understood, however, that poly (phenylene sulfide) may contain additional recurring units, as described in US patent 5,075,381 to Gotoh et al., Which is incorporated entirely by reference in this specification, for all thin them. When used, these additional recurring units can typically make up less than about 20 mol% of the polymer. The available high viscosity melting poly (phenylene sulfides) may include those available from Ticona, LLC (Florence, Kentucky) under the brand name FORTRON®. Such polymers can have a melting temperature of about 285 ° C (determined according to ISO 11357-1,2,3) and a melting viscosity of about 260 to about 320 Pa.sa310 ° C.
According to the present invention, an extrusion device can generally be employed to impregnate the tangles with the thermoplastic matrix. Among other things, the extrusion device can facilitate the application of the thermoplastic polymer to the entire surface of the fibers. Impregnated tangles can also have a very low void fraction, which can increase the mechanical strength resulting from the stick. For example, in some embodiments, about 3% or less, in some embodiments, about 2% or less, in some embodiments, about 1% or less, and in some embodiments, about 0.5% or less . The void fraction can be measured using techniques well known to those skilled in the art. For example, the void fraction can be measured using a "resin burning" assay, in which the samples are placed in an oven (for example, at 600 ° C for 3 hours), to burn the resin. The mass of the remaining fibers can then be measured to calculate the weight and volumetric fractions. This "burning" test can be performed according to ASTM D 2584-08, to determine the weights of the fibers and the thermoplastic matrix, which can then be used to calculate the "void fraction", based on the following equations : Vf = 100 * (pt-pc) / pt where: Vt is the fraction of void as a percentage; pc is the density of the composite, measured using known techniques, such as a pycnometer for liquid or gas (eg helium pycnometer); pt is the theoretical density of the composite, determined by the following equation: Pt = 1 / [Wf / pf + Wm / Pm] where: Pm is the density of the thermoplastic matrix (for example, in the appropriate crystallinity); Pt is the density of the fibers; Wf is the weight fraction of the fibers; and Wm is the weight fraction of the thermoplastic matrix.
Alternatively, the void fraction can be determined by chemical dissolution of the resin, according to the ASTM D 3171-09 standard. The "burning" and "dissolving" methods may be particularly suitable for glass fibers, which are generally resistant to fusion and chemical dissolution. In other cases, however, the void fraction can be calculated indirectly based on the densities of the thermoplastic polymer, fibers and tape (or strip), according to ASTM D 2734-09 (Method A), in which the densities can be determined by method A of ASTM D792-08. Of course, the void fraction can also be estimated by using conventional microscopy equipment, or by using computed tomography (CT) scanning equipment, such as a Metrotom 1500 (2k x 2k) high resolution detector.
Referring to Figure 3, an embodiment of an extrusion device is shown. More particularly, the apparatus may include an extruder 120, containing a threaded shaft 124 mounted inside a drum 122. A heater 130 (for example, an electrical resistance heater) can be mounted outside the drum 122. During use, a load of Feed of thermoplastic polymer 127 can be supplied to extruder 120 through a feeder 126. The load of thermoplastic feed 127 can be transported inside the drum 122 by the threaded shaft 124, and heated by frictional forces inside the drum 122 and by the heater 130 After being heated, the feed charge can exit drum 122 through a drum flange 128 and enter a matrix flange 132 of an impregnation matrix 150.
A tangle of continuous fibers 142 or a plurality of tangle of continuous fibers 142 can be supplied from one or more spools 144 to the matrix 150. Generally, the tangles 142 can be held at a certain distance from each other before impregnation, such as at least at about 4 mm, and, in some embodiments, at least about 5 mm. The feed charge 127 can be further heated within the matrix by heaters 133, mounted on or around the matrix 150. The matrix can generally be operated at temperatures that are sufficient to cause melting and impregnation of the thermoplastic polymer. Typically, the operating temperatures of the matrix can be higher than the melting temperature of the thermoplastic polymer, such as at temperatures of about 200 ° C to about 450 ° C. When so processed, the tangles of continuous fibers 142 can be embedded in the polymeric matrix, which can be a resin 214 (Figure 4) processed from the feed charge 127. The mixture can then be extruded from the impregnation matrix 150 to create a extruded 152.
A pressure sensor 137 (Figure 3) can monitor the pressure near the impregnation matrix 150, so that extruder 120 can be operated to release a correct amount of resin 214, for interaction with the fiber tangles 142. The rate of The extrusion can be varied by controlling the rotation speed of the threaded shaft 124 and / or the feed rate of the feed load 127. Extruder 120 can be operated to produce extrudate 152 (tangles of impregnated fibers), which, after leaving the impregnation matrix 150, can enter an optional preform or guide section (not shown), before entering a nip formed between two adjacent cylinders 190. The cylinders 190 can help to consolidate the extrudate 152 in the form of a tape (or strip), as well as improving fiber impregnation and squeezing out any excess voids. In addition to cylinders 190, other molding devices can also be employed, such as a die system. The resulting consolidated tape 156 can be pulled by guides 162 and 164, mounted on the cylinders. The guides 162 and 164 also pull the extrudate 152 from the impregnation matrix 150 and the cylinders 190. If desired, the consolidated tape 156 can be wound in a section 171. In general, the tapes can be relatively thin and can have a thickness of about 0.05 to about 1 millimeter (mm), in some embodiments, from about 0.1 to about 0.8 mm, and, in some embodiments, from about 0.2 to about 0.4 mm.
Within the impregnation matrix, it can be beneficial for the tangles 142 to be traversed by an impregnation zone 250, to impregnate the tangles with the polymeric resin 214. In the impregnation zone 250, the polymeric resin can generally be forced across the tangles by shear and pressure created in the impregnation zone 250, which can significantly improve the degree of impregnation. This can be particularly useful when forming a composite of tapes with a high fiber content, such as a fraction of% by weight (Wf) equal to or greater than 35%, and, in some embodiments, a Wf equal to or greater about 40 $. Typically, matrix 150 may include a plurality of contact surfaces 252, such as, for example, at least 2, at least 3, from 4 to 7, from 2 to 20, from 2 to 30, from 2 to 40, from 2 to 50, or more contact surfaces 252, to create a sufficient degree of penetration and pressure in the tangles 142. Although their particular shapes may vary, contact surfaces 252 can typically have a curved surface, such as a curved shoulder, a stick, etc. The contact surfaces 252 can typically be made of a metallic material.
Figure 4 shows a cross-sectional view of an impregnation matrix 150. As shown, the impregnation matrix 150 can include a bypass set 220, an inlet passage 270 and an impregnation zone 250. Bypass set 220 can be provided for flow of the polymeric resin 214 can it. For example, tap set 220 can include a channel 222 or a plurality of channels 222. Resin 214, provided to the impregnation matrix 150, can flow through channels 222.
As shown in Figure 5, some parts of channels 222 can be curvilinear, and, in exemplary embodiments, channels 222 can have a symmetrical orientation along a central axis 224. Still, in some embodiments, the channels can be a plurality of branched grooves 222, which can include a first group of branched grooves 232, a second group 234, a third group 236, and, if desired, more groups of branched grooves. Each group can include 2, 3, 4 or more grooves 222 branching from grooves 222 in the preceding group, or from an initial channel 222.
The branched grooves 222 and their symmetrical orientations can distribute the resin 214 evenly, so that the resin flow 214, which leaves the derivation set 220 and covers the tangles 142, can be substantially evenly distributed in the tangles 142. Beneficially, this can result in generally uniform impregnation of the tangles 142.
In addition, bypass set 220 may, in some embodiments, define an outlet region 242, which generally comprises at least a portion downstream of the channels or grooves 222, from which resin 214 exits. In some embodiments, at least a part of the channels or grooves 222, arranged in the outlet region 242, may have an increasing area in a flow direction 244 of resin 214. The increasing area may allow further diffusion and distribution of resin 214 , as the resin flows through the derivation set 220, which can still result in a substantially uniform distribution of the resin 214 in the tangles 142.
As further illustrated in Figures 4 and 5, after flowing through the bypass assembly 220, the resin can flow through the inlet passage 270. The inlet passage 270 can be positioned between the bypass assembly 220 and the impregnation zone 250, and can be configured to drain resin 214 from tap set 220, so that resin 214 sheaths the electric transmission cable 142. In this way, resin 214 exiting tap set 220, such as the discharge region 242, can enter entrance passage 270 and flow through it, as shown.
After leaving bypass set 220 and inlet passage 270 of matrix 250, as shown in Figure 4, resin 214 can come in contact with tangles 142, which pass through matrix 150. As discussed above, resin 214 can substantially uniformly coat tangles 142, due to the distribution of resin 213 in tap set 220 and inlet passage 270. Also, in some embodiments, resin 214 may collide on an upper surface of each of the tangles 142, or on a lower surface of each of the tangles 142, or on both the upper and lower surfaces of each of the tangles 142. The initial collision on the tangles 142 can prevent further impregnation of the tangles 142 with resin 214.
As shown in Figure 4, the coated tangles 142 can traverse, in a direction of travel 282, the impregnation zone 250, which is configured to impregnate the tangles 142 with resin 214. For example, as shown in Figures 4 and 6, tangles 142 can pass through contact surfaces 252 in the impregnation zone. The collision of the tangles 142 on the contact surface 252 can create sufficient shear and pressure to impregnate the tangles 142 with resin 214, thereby coating the tangles 142.
In some embodiments, as shown in Figure 4, the impregnation zone 250 can be defined between two opposite plates separated from each other 256 and 258. The first plate 256 can define a first inner surface 257, while the second plate 258 can define a second inner surface 259. Contact surfaces 252 can be defined on, or extend over, both the first and second inner surfaces 257 and 259, or just one of the first and second inner surfaces 257 and 259. Figure 6 illustrates the second plate 258 and the various contact surfaces on them, which can form at least part of the impregnation zone 250, according to these embodiments. In the exemplary embodiments 250, as shown in Figure 4, the contact surfaces 252 can be alternatively defined on the contact surfaces 252, on the first and second surfaces 257 and 259. In this way, the tangles 142 can pass through the contact surfaces 252 in one wave-shaped, tortuous or sinusoidal route, which improves shear.
The angle 254, at which the tangles 142 pass through the contact surfaces 252, can generally be high enough to improve shear, but not high enough to cause excessive forces that will break the fibers. Thus, for example, the angle 254 can be in the range between approximately 1 ° and approximately 30 °, and, in some embodiments, between approximately 5 ° and approximately 25 °.
In alternative embodiments, the impregnation zone 250 can include a plurality of pins (not shown), each pin having a contact surface 252. The pins can be static, freely rotating or rotationally driven. In other alternative embodiments, the contact surfaces 252 and the impregnation zone 250 may comprise any shapes and / or structures suitable for impregnating the tangles 142 with resin 214, as desired or necessary.
To further facilitate the impregnation of the tangles 142, they can also be kept under tension while present within the impregnation matrix. The voltage can, for example, vary from about 5 to about 300 newtons (N), in some embodiments, from about 50 to about 250 N, and, in some embodiments, from about 100 to about 200 N , by tangle 142 or fiber tow.
As shown in Figure 4, in some embodiments, a landing zone 280 can be positioned downstream of the impregnation zone 250, in the direction of travel 282 of the tangles 142. The tangles 142 can cross the landing zone 280, before leaving the matrix 150. As shown in Figure 4, in some embodiments, a flat plate 290 can join the impregnation zone 250. Flat plate 290 can generally be configured to measure excess resin 214 from tangles 142. Thus, the openings in the flat plate 290, through which the tangles 142 pass through, can be dimensioned so that, when the tangles 142 pass through them, the size of the openings can cause excess resin 214 to be removed from the tangles 142.
The impregnation matrix, shown and described above, is just one of several possible configurations that can be employed in the present invention. In alternative embodiments, for example, the tangles can be introduced into a crosshead matrix, which can be positioned at an angle relative to the flow direction of the liquid polymer bath. As the tangles move through the crosshead matrix and reach the point at which the polymer leaves an extruder drum, the polymer can be forced into contact with the tangles. Examples of such a crosshead die extruder are described, for example, in U.S. patents 3,993,726 to Moyer, 4,588,538 to Chung et al., 5,277,566 to August in et al. and 5,658,513 by Amaike et al., which are incorporated in this specification in their entirety by reference to them for all purposes. It should also be understood that any other extruder design can also be employed, such as a twin screw extruder. In addition, other components can be employed optionally to assist in impregnating the fibers. For example, a "gas jet" set can be employed in certain embodiments, to help spread a tangle of individual fibers, which can all contain as many as 24,000 fibers, evenly across the width of the joined tow. This set may include a source of compressed air or another gas, which may collide in a generally perpendicular way in moving tangles, which pass through the outlet holes. The movable tangles can then be introduced into an impregnation matrix, as described above.
Regardless of the technique used, continuous fibers can be oriented in the longitudinal direction (the machine direction "A" of the system in Figure 3), to improve the tensile strength. In addition to fiber orientation, other aspects of the pultrusion process can also be controlled to obtain the desired mechanical strength. For example, a relatively high percentage of continuous fibers can be used in the consolidated tape, to provide better mechanical strength properties. For example, continuous fibers can typically comprise from about 25% by weight to about 80% by weight, in some embodiments, from about 30% by weight to about 75% by weight, and in some embodiments , from about 35% by weight to about 60% by weight of the tape. Likewise, one or more thermoplastic polymers may comprise from about 20% by weight to about 75% by weight, in some embodiments, from about 25% by weight to about 70% by weight, and in some embodiments, from about 40% by weight to about 65% by weight of the tape. The percentage of fibers and the thermoplastic matrix in the final stick can also fall within the ranges mentioned above.
As mentioned above, the tangles can be consolidated in the form of one or more tapes, before being molded into the desired stick configuration. When this tape is subsequently compressed, the tangles can be distributed in a generally uniform manner, around a longitudinal center of the stick. This uniform distribution improves the consistency of the mechanical strength properties (for example, flexural modulus, tensile strength limit, etc.) over the entire length of the rod. When used, the number of consolidated tapes used to form the stick can vary based on the desired thickness and / or cross-sectional area and mechanical strength of the stick, as well as the nature of the tapes themselves. In most cases, however, the number of tapes can be from 1 to 20, and in some embodiments, from 2 to 10. The number of tangles employed on each tape can also vary. Typically, however, a ribbon can contain 2 to 10 tangles, and, in some embodiments, 3 to 5 tangles. To help obtain the symmetrical distribution of the tangles in the final stick, it may be beneficial that they are spaced approximately the same distance from each other within the ribbon. Referring to Figure 1, for example, an embodiment of a consolidated ribbon 4 is shown, which contains three (3) tangles 5 spaced equidistant from each other in the -x direction. In other embodiments, however, it may be desired that the tangles are combined, so that the fibers of the tangles are generally evenly distributed across the ribbon 4. In these embodiments, the tangles can generally be indistinguishable from each other. Referring to Figure 2, for example, an embodiment of a consolidated ribbon 4 is shown, which contains tangles that are combined so that the fibers are generally evenly distributed over them.
The specific way in which the tangles are shaped can also be carefully controlled to ensure that the stick can be formed with an adequate degree of compression and mechanical strength properties. Referring to Figure 7, for example, a particular embodiment of a stick forming system and process is shown. In this embodiment, two tapes 12 can initially be provided in a wrapper wrapped in a basket 20. The basket 20 can be an unrolled basket, which includes a frame provided with horizontal axes 22, each supporting a packaging. A unwound basket can also be employed, particularly if desired to induce a twist in the fibers, such as when using raw fibers in a single step configuration. It should also be understood that the tapes can also be formed in line with the formation of the stick. In one embodiment, for example, the extrudate 152, leaving the impregnation matrix 150 of Figure 3, can be supplied directly to the system used to form a stick. A voltage regulating device 40 can also be employed to help control the degree of tension on the tapes 12. Device 40 can include an input plate 30, which extends in a vertical plane, parallel to the rotary axes 22 of the basket 20 and / or perpendicular to the incoming tapes. The voltage regulating device 40 may contain cylindrical bars 41, arranged in a staggered configuration, so that the rod 12 can pass over and under these bars, to define a wave pattern. The height of the bars can be adjusted to modify the amplitude of the waveform and voltage control.
The tapes 12 can be heated in an oven 45, before entering a consolidation matrix 50. Heating can be conducted using any known type of oven, such as an infrared oven, a convection oven, etc. During heating, the fibers in the ribbon can be oriented unidirectionally to optimize heat exposure and maintain uniform heating throughout the stick. The temperature at which the tapes 12 are heated can generally be high enough to soften the thermoplastic polymer to a point at which the tapes can bond together. However, the temperature may not be too high to destroy the integrity of the material. The temperature can vary, for example, from about 100 ° C to about 500 ° C, in some embodiments, from about 200 ° C to about 400 ° C, and, in some embodiments, from about 250 ° C at about 350 ° C. In a particular embodiment, for example, poly (phenylene sulfide) ("PPS) can be used as the polymer, and the tapes can be heated at or above the melting point of the PPS, which can be about 285 ° C.
After being heated, the tapes 12 can be provided to a consolidation matrix 50, which can compress them together into a preform 14, as well as can align and form the initial shape of the stick. As shown generically in Figure 7, for example, tapes 12 can be guided through a flow passage 51 of the matrix 50, in a direction "A" from an inlet 53 to an outlet 55. Passage 51 can have any of several shapes and / or sizes, to obtain the stick configuration. For example, the channel and stick configuration can be circular, elliptical, parabolic, trapezoidal, rectangular, etc. Within the matrix 50, the tapes can generally be maintained at a temperature at or above the melting point of the thermoplastic matrix used in the tape, to ensure adequate consolidation.
The desired heating, compression and molding of the tapes 12 can be done using a matrix 50, having one or multiple sections. For example, although not shown in detail in this specification, consolidation matrix 50 may have multiple sections, which work together to compress and shape tapes 12 in the desired configuration. For example, a first section of passage 51 can be a tapered zone, which can initially shape the material as it flows into matrix 50. The tapered zone can generally have a cross-sectional area, which is larger at its entrance than on your way out. For example, the cross-sectional area of passage 51, at the entrance to the tapered zone, can be about 2% or more, in some embodiments, about 5% or more, and in some embodiments, about 10% to about 20% larger than the cross-sectional area at the exit of the tapered zone. Regardless, the cross section of the flow passage can typically vary gradually and evenly within the tapered zone, so that a balanced flow of the composite material through the matrix can be maintained. A molding zone can follow the tapered zone, and can compress the material and provide a flow that is generally homogeneous through it. The molding zone can also precast the material in an intermediate shape, which is similar to that of the stick, but typically a larger cross-sectional area, to allow expansion of the thermoplastic polymer, while heated, to minimize the risk indentation within the matrix 50. The molding zone can also include one or more surface aspects, which give a directional variation to the preform. The directional variation can force the material to be redistributed, resulting in a more homogeneous distribution of the fiber / resin in the final form. This can also reduce the risk of dead spots in the matrix, which can cause the resin to burn. For example, the cross-sectional area of passage 51, in a molding zone, can be about 2% or more, in some embodiments, about 5% or more, in some embodiments, about 5% or more, and , in some embodiments, from about 10% to about 20% greater than the width of the preform 14. A matrix plateau can also follow the molding zone, to serve as an exit for passage 51. A molding zone, tapered zone and / or matrix plateau can be heated to a temperature at or above the glass transition temperature or melting point of the thermoplastic matrix.
If desired, a second matrix 60 (for example, a calibration matrix) can also be used to compress preform 14 into the final shape of the stick. When employed, it may be beneficial to allow preform 14 to be cooled briefly after leaving consolidation matrix 50, and before entering optional second matrix 60. This can allow the consolidated preform 14 to retain its original shape, before progressing further through the system. Typically, cooling can reduce the temperature of the outside of the stick below the melting point temperature of the thermoplastic matrix, to minimize and substantially prevent the occurrence of melting fractures on the outside surface of the stick. The inner section of the stick, however, remains in fusion to ensure compression when the stick enters the calibration matrix body. This cooling can be done by simply exposing the preform 14 to the ambient atmosphere (for example, room temperature) or by using active cooling techniques (for example, water bath or air cooling), as is known in the art. In one embodiment, for example, air can be blown in preform 14 (for example, with an air ring). Cooling between these stages, however, can generally occur for a short period of time, to ensure that preform 14 can be soft enough to be molded further. For example, after leaving the consolidation matrix 50, the preform 14 can be exposed to room temperature for only about 1 to about 20 seconds, and in some embodiments, about 2 to about 10 seconds, before entering the second matrix 60. Within the matrix 60, the preform can generally be maintained at a temperature below the melting point of the thermoplastic matrix used in the tape, so that the shape of the stick can be maintained. Although referred to above as single matrices, it should be understood that matrices 50 and 60 can, in fact, be formed from multiple individual matrices (for example, flat plate matrices).
Thus, in some embodiments, the multiple individual dies 60 can be used to gradually shape the material into the desired configuration. Dies 60 can be placed in series, and provide gradual decreases in material dimensions. These gradual decreases can provide retraction during and between the various stages.
For example, as shown in Figures 11 to 13, a first array 60 may include one or more corresponding inputs 62 and outputs 64, as shown. Any number of corresponding inputs 62 and outputs 64 can be included in a matrix 60, such as four, as shown, or one, two, three, five, six or more. An inlet 62, in some embodiments, can generally be oval or circular in shape. In other embodiments, the inlet 62 may have a curved rectangular shape, i.e., a rectangular shape with curved corners or a rectangular shape with longer straight side walls and shorter curved side walls. In addition, an outlet 64 may generally be oval or circular in shape, or it may have a curved rectangular shape. In some embodiments, in which an oval shaped inlet is used, the inlet 62 may have a ratio of major axis length 66 to minor axis length 68 in a range between approximately 3: 1 and approximately 5: 1. In some embodiments, in which an oval or circular inlet is used, the outlet 64 may have a ratio of major axis length 66 to minor axis length 68 in a range between approximately 1: 1 and approximately 3: 1. In embodiments in which a curved rectangular shape is used, the inlets and outlets may have ratios of greater axis length 66 to shorter axis length 66 (aspect ratios) in a range between approximately 2: 1 and approximately 7: 1, and the ratio of output 64 may be less than the ratio of input 62.
In other embodiments, the cross-sectional area of an inlet 62 and the cross-sectional area of a corresponding outlet 64 of the first array 60 may have a ratio in the range of approximately 1.5: 1 to 6: 1.
The first die 60 can therefore provide a generally uniform transformation of fiber material impregnated with polymer to a shape that is relatively similar to a final shape of the resulting stick, which, in the exemplary embodiments, has a circular cross-section or oval. Subsequent matrices, such as a second matrix 60 and a third matrix 60, as shown in Figure 11, can provide other gradual decreases and / or variations in the dimensions of the material, so that the shape of the material is converted into a section shape cross section of the stick. These subsequent dies 60 can both shape and cool the material. For example, in some embodiments, each subsequent matrix 60 can be maintained at a lower temperature than the previous matrices. In exemplary embodiments, all matrices 60 can be maintained at temperatures that are higher than a softening point temperature for the material.
In other exemplary embodiments, dies 60, having relatively long plateau lengths 69, may be desired, due to, for example, adequate cooling and solidification, which may be important in obtaining a desired shape and size. The relatively long plateau lengths 69 can reduce stresses and provide uniform transformations in the desired shapes and sizes, and with a fraction of void and minimal arching characteristics. In some embodiments, a plateau length ratio 69, at an output 64, to a long axis length 66, at output 64 for a matrix 60, can be in the range between 0 and approximately 20, such as between approximately 2 and approximately 6.
The use of calibration matrices 60, in accordance with the present invention, can provide gradual variations in the cross section of the material, as discussed. These gradual variations can, in the exemplary embodiments, ensure that the resulting product, such as a stick or other suitable product, has a generally uniform fiber distribution with a relatively minimal void fraction.
It should be understood that any suitable number of matrices 60 can be used to gradually form the material in a profile, having any shape of suitable cross section, as desired or necessary for various end-use applications.
In addition to the use of one or more dies, other mechanisms can also be used to help compress the preform 14 into a stick. For example, forming cylinders 90, as shown in Figure 14, can be used between the consolidation matrix 50 and the calibration matrix 60, between the various calibration matrices 60, and / or after the calibration matrices 60 further compress the preform 14, before it is converted into its final form. The cylinders can have any configuration, such as pull cylinders, overlap cylinders, etc., and can be vertical, as shown, or horizontal cylinders. Depending on the configuration of the cylinder 90, the surfaces of the cylinders 90 can be machined to check the dimensions of the final product, such as rod, core, profile, or other suitable product, to preform 14. In an exemplary embodiment, the pressure of the 90 cylinders can be adjustable, to optimize the quality of the final product.
The cylinders 90, in the exemplary embodiments, such as at least the parts in contact with the material, can generally have smooth surfaces. For example, relatively hard polished surfaces can be beneficial in many embodiments. For example, the surface of the cylinders can be formed of a chrome or other smooth material. This can allow cylinders 90 to manipulate preform 14, without damaging or undesirably altering preform 14. For example, these surfaces can prevent material from becoming trapped in the cylinders, and the cylinders can impart smooth surfaces to the materials.
In some embodiments, the temperature of the cylinders 90 can be controlled. This can be done by heating the cylinders 90 themselves, or by placing the cylinders 90 in a temperature-controlled environment.
Also, in some embodiments, surface aspects 92 can be provided on the cylinders 90. Surface aspects 92 can orient and / or control the preform 14 in one or more directions, as it passes through the cylinders. For example, surface aspects 92 can be provided to prevent preform 14 from bending on itself as it passes through cylinders 90. In this way, surface aspects 92 can guide and control deformation of preform 14 , in the transverse direction of the machine relative to a machine direction A, as well as in the vertical direction relative to machine direction A. Preform 14 can therefore be pushed together in the direction transverse to the machine, instead of being folded itself, as it passes through cylinders 90 towards machine A.
In some embodiments, pressure regulating devices can be provided in communication with the cylinders. These devices can be used with the cylinders to apply tension to the preform 14 in the machine direction, transverse to the machine and / or vertical direction, to orient and / or control the preform further.
As indicated above, the resulting stick can also be applied with a capping layer, to protect it from environmental conditions and / or to improve wear resistance. Referring again to Figure 7, for example, this capping layer can be applied using an extruder, oriented at any desired angle, to introduce a thermoplastic resin into a capping matrix 72. To help prevent a response galvanic, it may be beneficial for the capping material to have a dielectric strength of at least about 1 kV per millimeter (kV / mm), in some embodiments, at least about 2 kV / mm, in some embodiments of about 3 kV / mm to about 50 kV / mm, and, in some embodiments, from about 4 kV / mm to about 30 kV / mm, as determined according to ASTM D149-09. Thermoplastic polymers suitable for that purpose may include, for example, polyolefins (for example, polypropylene, propylene-ethylene copolymers, etc.), polyesters (for example, poly (ethylene terephthalate) - PBT, polycarbonates, polyamides (for example , Nylon®), poly (ethers - ketones) (eg poly (ether - ether - ketone) - PEEK), poly (ethers - imides), poly (arylene ketones (eg, poly (phenylene diketone) - PPDK) , liquid crystalline polymers, poly (arylene sulfides) (for example, poly (phenylene sulfide) - PPS), poly (biphenylene sulfide - ketone), poly (phenylene sulfide - diketone), poly (biphenylene sulfide), etc.), fluoropolymers (for example, polytetrafluoroethylene - perfluoromethylvinylether polymer, perfluoro - alkoxyalkane polymer, tetrafluoroethylene polymer, ethylene polymer - tetrafluoroethylene, etc.), polyacetals, polyurethanes, polycarbonates, for example, styrene polymers - trila - butadiene - styrene - ABS), acrylic polymers, poly (vinyl chloride - PVC), etc. Particularly suitable dielectric strength capping layer materials may include polyketone (eg, poly (ether - ether - ketone) - PEEK), polysulfide (eg, poly (arylene sulfide), or a mixture thereof.
The capping layer can generally be "stripped" of continuous fibers. That is, the capping layer may contain "less than about 10% by weight" of continuous fibers, in some embodiments, about 5% by weight or less of continuous fibers, and, in some embodiments, about 1% in continuous fibers. weight or less of continuous fibers (for example, 0% by weight). However, the capping layer may contain other additives to improve the final properties of the composite core. The additive materials employed at this stage may include those that are not suitable for incorporation into the continuous fiber material. For example, it may be beneficial to add pigments to reduce finishing work, or it may be beneficial to add flame retardant agents to improve the flame retardancy of the core. Because many additive materials can be thermally sensitive, an excessive amount of heat can cause them to decompose and produce volatile gases. Therefore, if a thermally sensitive additive material is extruded with an impregnating resin under conditions of high heating, the result can be a complete degradation of the additive material. Additive materials may include, for example, mineral reinforcing agents, lubricants, flame retardants, foaming agents, agents resistant to ultraviolet light, thermal stabilizers, pigments and combinations thereof. Suitable mineral reinforcing agents can include, for example, calcium carbonate, silica, mica, clays, talc, calcium silicate, graphite, calcium silicate, alumina trihydrate, barium ferrite and combinations thereof.
Although not shown in detail in the present specification, the cap matrix 72 can include various aspects known in the art to help achieve the desired cap layer application. For example, the cap matrix 72 may include an entry guide, which aligns the incoming rod. The capping matrix may also include a heating mechanism (for example, heated plate), which preheats the stick before applying the capping layer, to help ensure adequate agglutination. After capping, the molded part 15 can then be finally cooled using a cooling system 80, as is known in the art. The cooling system 80 can be, for example, a measuring system, which includes one or more blocks (for example, aluminum blocks), which can completely encapsulate the composite core, while a vacuum pulls the hot form against its walls as it cools. A cooling medium can be provided to the meter, such as air or water, to solidify the composite core in the correct way.
Even if a measuring system is not used, it can be beneficial to cool the composite core, after its exit from the capping matrix (or from the consolidation or calibration matrix, if capping is not applied). Cooling can occur by using any technique known in the art, such as a water tank, an air stream or a jet of cold air, a cooling jacket, an internal cooling channel, coolant circulation channels, etc. . Regardless, the temperature at which the material is cooled can be controlled to obtain certain mechanical properties, dimensional tolerances of parts, good processing and an aesthetically pleasing composite. For example, if the temperature of the cooling station is too high, the material can expand in the tool and interrupt the process. For semicrystalline materials, too low a temperature can also cause the material to cool very quickly and not provide complete crystallization, thereby adversely affecting the mechanical and chemical resistance properties of the composite. Multiple sections of cooling dies, with independent temperature control, can be used to provide a beneficial balance of processing and performance attributes. In a particular embodiment, for example, a water tank can be employed at a temperature of about 0 ° C to about 30 ° C, in some embodiments, from about 1 ° C to about 20 ° C, and, in some embodiments, from about 2 ° C to about 15 ° C.
If desired, one or more measuring blocks (not shown) can also be used, such as after capping. These blocks can contain openings, which are cut to the exact shape of the core, graduated in an oversized shape initially to the final shape of the core. As the composite passes through them, any tendency to move or bend can be counteracted, and they can be pushed back (repeatedly) into their correct shape. Once measured, the composite core can be cut to the desired length at a cutting station (not shown), such as with a cutting saw, capable of making cross-section cuts, or the composite core can be limited to the tow length fiber.
As will be considered, the temperature of the rod or composite core, as it advances through any section of the system of the present invention, can be controlled to produce final composite and manufacturing properties. Any or all of the assembly sections can be temperature controlled using electric cartridge heaters, fluid circulation cooling, etc., or any other temperature controlling device known to those skilled in the art.
With reference again to Figure 7, a pulling device 82 can be positioned downstream of the cooling system 80, to pull the finished composite core 16 through the system for final design of the composite. Pulling device 82 can be any device capable of pulling the core through the processing system at a desired rate. Typical pulling devices may include, for example, Cat handles and swing handles.
An embodiment of the composite core (or composite filament), formed from the process described above, is shown in more detail in Figure 8 as the element 516. As illustrated, the composite core 516 can have a substantially circular shape and can include a rod ( or fiber core) 514, comprising one or more consolidated tapes (a component of continuous fibers). By "substantially circular", it is generally meant that the aspect ratio of the core (height divided by width) is typically about 1.0 to about 1.5, and in some embodiments, about 1.0. Due to the selective control during the process used to impregnate the tangles and form a consolidated ribbon, as well as the process to compress and shape the ribbon, the composite core can comprise a relatively uniform distribution of the thermoplastic matrix over its entire length. This also means that the continuous fibers can be distributed in a generally uniform manner around a longitudinal central axis "L" of the composite core 516. As shown in Figure 8, for example, the rod 514 of the composite core 516 can include the fibers continuous 526, embedded within a thermoplastic matrix 528. The fibers 526 can generally be distributed uniformly around the longitudinal axis "L". It should be understood that only a few fibers are shown in Figure 8, and that the composite core can typically contain a substantially larger number of fibers distributed evenly.
A capping layer 519 can also extend around the perimeter of the rod 514 and define an outer surface of the composite core 516. The thickness of the cross section of the rod 514 can be strategically selected to help achieve a particular mechanical strength for the composite core. . For example, rod 514 may have a thickness (e.g., diameter) of about 0.1 to about 40 mm, in some embodiments, from about 0.5 to about 30 mm, and, in some embodiments, from about 1 to about 10 mm. The thickness of the capping layer 519 may depend on the desired function of the part, but it can typically be from about 0.01 to about 10 mm, and, in some embodiments, from about 0.02 to about 5 mm . The thickness of the total cross section, or height, of the composite core 516 can also vary from about 0.1 to about 50 mm, in some embodiments, from about 0.5 to about 40 mm, and, in some embodiments , from about 1 to about 20 mm (for example, diameter, if a circular cross section). Although the composite core may be substantially continuous in length, the length of the composite core may be limited in practice by the spool on which it is to be wound and stored, and / or by the length of the continuous fibers. For example, the length can often vary from about 1,000 m to about 5,000 m, although even longer lengths are certainly possible.
By controlling the various parameters mentioned above, cores having very high mechanical resistance can be formed. For example, composite cores can have a relatively high flexural modulus. The term "flexural modulus" generally refers to the stress to strain ratio in flexion strain (units of force per unit area), or the tendency for a material to bend. It is determined by the slope of a stress-strain curve, produced by a "three point bending" test (such as ASTM D790-10, Procedure A, room temperature). For example, the composite core of the present invention may have a flexural modulus of about 10 GPa or more, in some embodiments, from about 12 to about 400 GPa, in some embodiments, from about 15 to about 200 GPa , and, in some embodiments, from about 20 to about 150 GPa.
Composite cores, used to produce electrical cables consistent with certain embodiments described in this specification, may have tensile strength limits greater than about 300 MPa, such as, for example, in a range of about 400 MPa to about 5,000 MPa, or from about 500 MPa to about 3,500 MPa. In addition, suitable composite cores may have a tensile strength limit in the range of about 700 MPa to about 3,000 MPa; alternatively, from about 900 MPa to about 1,800 MPa, or, alternatively, from about 1,100 MPa to about 1,500 MPa. The term "tensile strength limit" generally refers to the maximum traction that a material can withstand while being stretched or pulled, before breaking, and is the maximum traction achieved in a stress - strain curve produced by a test traction (such as the standard
ASTM D3919-08) at room temperature.
Additionally, or alternatively, the composite core may have an elastic modulus under tension, or elastic modulus, in a range of about 50 GPa to about 500 GPa, from about 70 GPa to about 400 GPa, from about 70 GPa at about 300 GPa, or from about 70 GPa at about 250 GPa. In certain embodiments, the composite core may have an elastic modulus in a range of about 70 GPa at about 200 GPa; alternatively, from about 70 GPa to about 150 GPa; or alternatively, from about 70 GPa to about 130 GPa. The term "tensile modulus" or "elastic modulus" refers, in general, to the ratio of tensile strength limit to tensile strain and is the slope of a tensile - strain curve, produced by a tensile test (such as ASTM 3918-08) at room temperature.
The composite cores, produced in accordance with the present invention, can still have a relatively high flexion fatigue time, and can have a relatively high mechanical strength. Flexion fatigue time and residual flexural strength can be determined based on a "three point flexural fatigue" test (such as the ASTM D790 standard, typically at room temperature). For example, the cores of the present invention may exhibit residual flexural strength after one million cycles at 160 newtons ("N") or 180 N loads of about 414 MPa (megapascals) (60 kilograms per square inch - " ksi ") at about 793 MPa (115 ksi), in some embodiments, from about 483 MPa (70 ksi) to about 793 MPa (115 ksi), and, in some embodiments, from about 95 ksi to about 793 MPa (115 ksi). In addition, the cores may show relatively minimal reductions in flexural strength. For example, cores having void fractions equal to or less than about 4%, in some embodiments, equal to or less than about 3%, may show reductions in flexural strength after a three-point flexural fatigue test, from about 1% (for example, from a maximum primitive flexural strength of about 731 MPa - 106 ksi, to a maximum residual flexural strength of about 724 MPa - 105 ksi). Flexural strength can be tested before and after a fatigue test, using, for example, a three-point flexion test, as discussed above.
In some embodiments, the composite core may have a density or relative density less than about 2.5 g / cm3, less than about 2.2 g / cm3, less than about 2.0 g / cm3, or less than about 1.8 g / cm3. In other embodiments, the density of the composite core can be in the range of about 1.0 g / cm3 to about 2.5 g / cm3; alternatively, from about 1.1 g / cm3 to about 2.0 g / cm3; alternatively, from about 1.1 g / cm3 to about 1.9 g / cm3; alternatively, from about 1.2 g / cm3 to about 1.8 g / cm3; or alternatively, from about 1.3 g / cm3 to about 1.7 g / cm3;
In some cable applications, such as overhead transmission lines, the ratio of mechanical strength to weight of the composite core can be important. The ratio can be quantified by the ratio of the tensile strength of the core material to the density of the core material (in units of MPa / (g / cm3)). The mechanical strength to weight ratios can be in the range of about 400 to about 1,300, from about 400 to about 1,200, from about 500 to about 1,100, from about 600 to about 1,100, from about from 700 to about 1,100, from about 700 to about 1,000, or from about 750 to about 1,000. Again, the ratios are based on the tensile strength in MPa and the density of the composite core in g / cm3.
In some embodiments, the percentage elongation at break for the composite core may be less than 4%, less than 3% or less than 2%, while in other embodiments, the elongation at break may be in the range of about 0, 5% to about 2.5%, from about 1% to about 2.5% or from about 1% to about 2%.
The linear thermal expansion coefficient of the composite core can be less than about 3 x 10'6 / ° C or less than about 2 x 10'6 / ° C (or in units of m / m / ° C). Otherwise, the coefficient of linear thermal expansion can be, on a basis in ppm per ° C, less than about 5, less than about 4, less than about 3, or less than about 2. For example, the coefficient (ppm / ° C) can be in the range of about -0.4 to about 5; alternatively, from about -0.2 to about 4; alternatively, from about -0.4 to about 4 or; alternatively, from about -0.2 to about 2. The temperature range considered for this linear thermal expansion coefficient can generally be in the range of -50 ° C to 200 ° C, the range of 0 ° C to 200 ° C, the range of 0 ° C to 175 ° C, or the range of 25 ° C to 150 ° C. The coefficient of linear thermal expansion is measured in the longitudinal direction, that is, along the length of the fibers.
The composite core may also have a relatively small "bending radius", which is the minimum radius that the rod can be bent without damage, and is measured in the internal curvature of the composite core or composite filament. A smaller radius of curvature means that the composite core can be more flexible and can be wound around a smaller diameter coil. This property can also allow for easier replacement of the composite core on cables that currently use metal cores, and allows the use of tools and installation processes currently in use in conventional overhead cables. The radius of curvature for the composite core can, in some embodiments, be in a range of about 1 cm to about 60 cm, about 1 cm to about 50 cm, about 1 cm to about 50 cm , or from about 2 cm to about 45 cm, as determined at a temperature of about 25 ° C. The radius of curvature can be in a range of about 2 cm to about 40 cm, or about 3 cm to about 40 cm, in certain embodiments considered in this specification. In other embodiments, the radii of curvature that can be obtained are less than about 40 times the outer diameter of the composite core, in some embodiments, from about 1 to about 30 times the outer diameter of the composite core, and, in some embodiments, from about 2 to about 25 times the outer diameter of the composite core, determined at a temperature of about 25 ° C.
Significantly, the mechanical, physical and thermal resistance properties of the composite core, mentioned above, can also be maintained over a relatively wide temperature range, such as from about -50 ° C to about 300 ° C, from about 100 ° C to about 300 ° C, from about 110 ° C to about 250 ° C, from about 120 ° C to about 200 ° C, from about 150 ° C to about 200 ° C, or about 180 ° C to about 200 ° C.
The composite core may also have a low void fraction, such as about 6% or less, in some embodiments, about 3% or less, in some embodiments, about 2% or less in some embodiments some embodiments, about 1% or less, and, in some embodiments, about 0.5% or less. The void fraction can be determined in the manner described above, such as by using a "resin burning" assay, according to ASTM D 2584-08, or by using computed tomography (CT) scanning equipment. , such as a Metrotom 1500 (2k x 2k) high resolution detector.
In one embodiment, a composite core of the present invention can be characterized by the following properties: a limit of tensile strength in a range of about 700 MPa to about 3,500 MPa; an elastic modulus from about 70 GPa to about 300 GPa; and a coefficient of linear thermal expansion (in units of ppm per ° C) in a range of about -0.4 to about 5. Additionally, the composite core can have a density of less than about 2.5 g / cm3 , and / or a mechanical strength to weight ratio (in units of MPa / (g / cm3) in a range of about 500 to about 1,100. Also, in certain embodiments, the composite core may have a radius of curvature in a range of about 1 cm to about 50 cm. Furthermore, the composite core may have a percentage elongation at break of less than about 3%.
In another embodiment, a composite core of the present invention can be characterized by the following properties: a limit of tensile strength in a range of about 1,100 MPa to about 1,500 MPa; an elastic module in a range of about 70 GPa to about 130 GPa; and a coefficient of linear thermal expansion (in units of ppm per ° C) in a range of about 0.2 to about 2. Additionally, the composite core can have a density in a range of about 1.2 g / cm3 to about 1.8 g / cm3, and / or a mechanical strength to weight ratio (in units of MPa / (g / cm3) in a range of about 700 to about 1,100. Still, in certain embodiments, the composite core can have a radius of curvature in a range of about 2 cm to about 40 cm. Furthermore, the composite core can have a percentage elongation at break of about 1% to about 2.5%.
As will be seen, the embodiments of particular composite cores, described above, are merely exemplary of the various designs that may be within the scope of the present invention. Among the several possible composite core designs, it should be considered that other layers of material can be used in addition to those described above. In certain embodiments, for example, it may be beneficial to form a multicomponent core, in which one component comprises a material of greater mechanical resistance and the other component comprises a material of less mechanical resistance. These multicomponent cores can be particularly useful in increasing overall mechanical strength, without requiring more expensive high-strength materials for the entire core. The components of lower and / or higher mechanical strengths may comprise tape (s), which contain or contain continuous fibers embedded within a thermoplastic matrix.
In addition, it should be understood that the scope of the present invention is in no way limited to the embodiments described above. For example, composite cores can contain several other components, depending on the desired application and its required properties. Additional components can be formed from a continuous fiber tape, as described in this specification, as well as from other types of materials. In one embodiment, the composite core may contain a layer of staple fibers (for example, short fibers, long fibers, etc.), to improve its transversal mechanical strength. The staple fibers can be oriented so that at least a portion of these fibers can be positioned at an angle relative to the direction in which the continuous fibers extend. Eletric cable
Consistent with the embodiments described in this specification, the electrical cables of the present invention, such as overhead transmission lines, may comprise a cable core, consisting of at least one composite core, and a plurality of conductive elements surrounding the core of cable. The cable core can be a single composite core, incorporating any composite core design and the associated thermal and physical properties mentioned above. Alternatively, the cable core may comprise two or more composite cores, or composite filaments, having identical or different designs, and the same or different thermal and physical properties. These two composite cores can be mounted parallel to each other (straight) or twisted, for example, around a central composite core element.
Consequently, in some embodiments, an electrical cable may comprise a cable core, consisting of at least one composite core, surrounded by a plurality of conductive elements, whereas, in other embodiments, an electrical cable may comprise a cable core, consisting of of two or more composite cores, the cable core surrounded by a plurality of conductive elements. For example, the cable core may comprise, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 composite cores or more (for example, 37 composite cores), each of which can incorporate any composite core design and the associated thermal and physical properties mentioned above. The composite cores can be arranged, tied or oriented in any suitable way, as will be recognized by a person skilled in the art. For example, composite cores can be twisted, such as a cable core comprising 7 twisted composite cores or 19 twisted composite cores. Alternatively, the composite cores may be parallel, such as a cable core comprising a bundle of 7 composite cores aligned parallel to each other.
The electrical cable can comprise a plurality of conductive elements surrounding the cable core (for example, a single composite core, a plurality of twisted composite cores). The conducting elements can be of any geometric shape, and can be round / circular wires or trapezoidal wires, among others, and including their combinations. The conductive elements can be, in one layer, or 2 layers, or 3 layers, or 4 layers, and so on, around the cable core. The conductive elements can be configured parallel to the cable core, or helically wound, or in any other suitable arrangement. Any number of conductive elements (for example, wires) can be used, but a typical number of conductive elements in a cable can be up to 84 conductive elements, and often in the range of 2 to about 50. For example, in some common conductor arrangements, 7, 19, 26 or 37 wires can be used.
Exemplary transmission cable designs with composite cores, which can be employed in various embodiments of the present invention, are described in US patent 7,211,319 to Heil et al., Which is incorporated in its entirety in this specification by reference, for all purposes.
Referring then to Figure 9, an embodiment of an electrical cable 420 is shown. As illustrated, electrical cable 420 may include a plurality of conductive elements 422 (e.g., aluminum or an alloy thereof) arranged radially around a substantially cylindrical cable core 400, which is illustrated as a single composite core, but it can be of a plurality of twisted composite cores. The conductive elements can be arranged in a single layer or in multiple layers. In the illustrated embodiment, the conductive elements 422 are arranged to form a first concentric layer 426 and a second concentric layer 428. The shape of the conductive elements 422 can also be varied around the cable core 400.
In the illustrated embodiment, the conducting elements 422 have a generally trapezoidal cross-sectional shape. Other shapes can also be used, such as circular, elliptical, rectangular, square, etc. The conductive elements 422 can also be twisted or wound around the cable core 400 in any desired geometric configuration, such as in a helical manner.
Referring to Figure 10, for example, another embodiment of an electrical transmission cable 420 is shown. As illustrated, the electrical transmission cable 420 can include a plurality of conductive elements 422 (for example, aluminum or an alloy thereof) arranged radially around a substantially cylindrical cable core 400, which can be formed according to present invention. Figure 10 illustrates six composite cores 400 surrounding a single core 400, although any suitable number of composite cores 400, in any suitable arrangement, falls within the scope and spirit of the present invention and can be used in the cable core. A capping layer 519 can also extend around the perimeter and define an outer surface of each rod. The conductive elements can be arranged in a single layer or in multiple layers. In the illustrated embodiment, for example, conductive elements 422 are arranged to form a first concentric layer 426 and a second concentric layer 428. Naturally, any number of concentric layers can be employed. The shape of the conductive elements 422 can also be varied to optimize the number of elements that can be arranged around the cable core. In the illustrated embodiment, for example, the conducting elements 422 have a generally trapezoidal cross-sectional shape. Other shapes can also be used, such as circular, elliptical, rectangular, square, etc. The conductive elements 422 can also be twisted or wound around the cable core 400 in any desired geometric configuration, such as in a helical manner.
The cross-sectional area of the individual conducting elements can vary considerably, but, generally, the cross-sectional area of the individual elements can be in a range of about 10 to about 50 mm2, or from about 15 to about 45 mm2. The total conductive area can vary in square millimeters (in kcmil), for example, from about 84.62 to about 1773 square millimeters (about 167 to about 3,500 kcmil), from about 106, 4 to about 1368 square millimeters (about 210 to about 2,700 kcmil), from about 380 to about 1773 square millimeters (about 750 to about 3,500 kcmil) or from 380 to about 1520 square millimeters (about 750 to about 3,000 kcmil). The total conductive areas of about 402.8, about 453.5, about 486.4 and about 516.8 square millimeters (about 795, about 825, about 960 and about 1,020 kcmil) can be often used in many end uses in electrical cables, such as overhead power lines. For example, a cable reinforced with common aluminum conductor steel, known in the industry, is often referred to as a 402.8 mm (795 kcmil) ACSR "Drake" conductor cable.
The outside diameter of the cables according to the present invention is not limited to any particular range. However, typical cable outside diameters can be within a range, for example, from about 7 to about 50 mm, from about 10 to about 48 mm, from about 20 to about 40 mm, from about 25 to about 35 ml, or about 28 to about 30 mm. Likewise, the cross-sectional area of a composite core in the cable is not limited to any particular band. However, the typical cross-sectional areas of the composite core can be within a range of about 20 to about 140 mm2, or about 30 to about 120 mm2.
The conductive elements can be made of any suitable conductive or metallic material, including various alloys. The conducting elements may comprise copper, a copper alloy, aluminum, an aluminum alloy or combinations thereof. As used in this specification, the term "aluminum or an aluminum alloy" is mentioned for collective reference to grades of aluminum or aluminum alloys having at least 97% by weight of aluminum, at least 98% by weight of aluminum or at least 99% by weight of aluminum, including pure or substantially pure aluminum. Aluminum alloys or aluminum grades, having an IACS electrical conductivity of at least 57%, at least 58%, at least 59%, at least 60% or at least 61 (for example, 59% to 65%), can be employed in the embodiments described in this specification, and this includes any process that can produce these conductivities (for example, annealing, tempering, etc.). For example, aluminum alloy 1350 can be employed as aluminum or aluminum alloy in certain embodiments of this invention. Aluminum 1350, its composition and its minimum IACS are described in the ASTM B233 standard, the description of which is incorporated by reference in this specification in its entirety.
In some applications, such as overhead transmission lines, the bending of the electrical cable can be an important aspect. Bowing is generally considered to be the distance that a cable moves away from a straight line between the end points of a span. Arching a span of towers can affect the free span to the ground, and subsequently the height of the tower and / or the number of towers required. Bending can generally increase with the square of the span length, but it can be reduced by an increase in tensile strength and / or a decrease in cable weight. The electrical cables, in some embodiments of the present invention, can be bent (at a nominal temperature - 180 ° C - and for a span of 300 meters) with a light NESC load of about 3 to about 9.5 m, from about 4.5 to about 9.5 m, from about 5.5 to about 8 m, or from about 6 to about 7.5 m. Likewise, with a heavy NESC load, under similar conditions, the bowing can be in a range of about 3 to about 9.5, about 3 to about 7.5 m, about 4.5 to about 7.5 m, or from about 5 to about 7 m.
In some embodiments, the cable can also be characterized as having a tensile parameter equal to or greater than about 10 MPa, in some embodiments equal to or greater than about 15 MPa, and, in some embodiments, from about 20 to about 50 MPa. The method for determining the tensile parameter is described in more detail in U.S. Patent 7,093,416 to Johnson et al., Which is incorporated in this specification in its entirety by reference, for all purposes. For example, arching and temperature can be measured and graphed with arching versus temperature. A calculated curve can be adjusted to the measured data, using an Alcoa Sag 10 graphic method, available in a software program from the Southwire Company (Carrollton, GA) under the trademark indication SAG10 (version 3.0 update 3.10.10). The traction parameter is an adjustment parameter on the SAG10 marked as "built-in aluminum traction", which can be changed to adjust other parameters, if a material other than aluminum is used (for example, an aluminum alloy), and which adjusts the position of the junction point in the predicted graph and also the degree of arching at high temperature, in a regime after the junction point. A description of the traction parameter can also be provided in the Sag10 user manual (version 2.0), incorporated by reference in this specification by reference in its entirety.
In relation to the object described in this specification, creep is generally considered to be a permanent elongation of a cable, under load, for a long period of time. The degree of fluency of a cable length can be influenced by the length of time in use, cable load, cable pull, temperature conditions encountered, among other factors. It is considered that the cables described in this specification can have creep values of 10 years at a RBS (rated breaking voltage) less than about 0.25%, less than about 0.2% or less than about 0.175%. For example, the 10-year creep value at a 15% RBS may be less than about 0.25%, alternatively, less than about 0.2%, alternatively, less than about 0.15%, alternatively , less than about 0.1%, or, alternatively, less than about 0.075%. The 10-year creep value at a RBS of 305% may be less than about 0.25%, alternatively less than about 0.2%, or alternatively less than about 0.175%. These creep values are determined according to the 10-year ACSR driver creep test (Aluminum Association Fluency Test, rev. 1999), incorporated by reference in its entirety into this specification.
The electrical cables according to the embodiments of this invention can have a minimum operating temperature up to about 300 ° C, up to about 275 ° C or up to about 250 ° C. Certain cables provided in this specification can have maximum operating temperatures that can be up to about 225 ° C, alternatively up to about 200 ° C, alternatively up to 180 ° C, or alternatively up to 175 ° C. Maximum operating temperatures can be in the range of about 100 to about 300 ° C, about 100 to about 250 ° C, about 110 to about 250 ° C, about 120 to about 200 ° C, or from about 120 to about 180 ° C, in various embodiments of the present invention.
According to some embodiments, it may be beneficial for the electrical cable to have certain fatigue and / or vibration resistance properties. For example, the electrical cable can pass (satisfy or exceed) the Aeolian vibration test, specified in the IEED 1138 standard, incorporated in this specification by reference to 100 million cycles.
In some embodiments, the electrical cable may comprise a partial or complete layer of a material, between the cable core and the conductive elements. For example, the material can be conductive or non-conductive, and it can be a strip, which coils / covers partly or completely the cable core. The material can be configured to retain or hold the elements of individual composite cores of a cable core together.
In some embodiments, the material may comprise a foil or aluminum foil tape, a polymeric tape (for example, a polypropylene tape, a polyester tape, a Teflon tape, etc.), a glass-reinforced strip, and similar. Often, the thickness of the material (for example, the tape) can be in a range of about 0.025 mm to about 0.25 mm, although the thickness is not limited to that range.
In one embodiment, the tape or other material can be applied so that each winding overlaps the previous winding. In another embodiment, the tape or other material can be applied so that each subsequent winding leaves a gap with the previous winding. In yet another embodiment, the tape or other material can be applied so that it contacts the previous winding without any overlap and without any gap. In these and other embodiments, the tape or other material can be applied helically around the cable core.
In some embodiments, the electrical cable may comprise a partial or complete coating of a material between the cable core and the conductive elements. For example, the material can be, or can comprise, a polymer. Suitable polymers can include, but are not limited to, a polyolefin (for example, polyethylene and polypropylene homopolymers, copolymers, etc.), a polyester (for example, poly (butylene terephthalate) - PBT), a polycarbonate , a polyamide (eg Nylon®), a poly (ether - ketone) (PEEK), a poly (ether - imide), a poly (arylene ketone) (eg, poly (phenylene diketone) - PPDK), a polymer liquid crystalline, a poly (arylene sulfide) (for example, poly (phenylene sulfide) (PPS), a poly (biphenylene sulfide - ketone), poly (phenylene sulfide - diketone), poly (biphenylene sulfide), etc.), a fluoropolymer (for example, polytetrafluoroethylene - perfluoromethylvinylether polymer, perfluoro - alkoxyalkane polymer, tetrafluoroethylene polymer, ethylene - tetrafluoroethylene polymer, etc.), a polyacetal, a polyurethane, polycarbonates, for example a styrenic polymer , acrylonitrile - butadiene - styrene - ABS), an acrylic polymer co, poly (vinyl chloride - PVC) and the like, including their combinations. Furthermore, the polymer can be an elastomeric polymer. The coating can be conductive or non-conductive, and can contain various additives typically used in wire and cable applications. The sheath may, in some embodiments, serve as a protective coating for the cable core. Additionally, the coating can be used in cases where the composite core does not contain a capping layer, and the coating partially or completely covers the stick (or fiber core), for example, as a protective coating for the stick.
In circumstances where the cable core comprises two or more composite cores (e.g., composite filaments), the sheath may fill, partially or completely, the spaces between the individual core elements.
The present invention also encompasses processes for producing an electrical cable, consisting of a cable core and a plurality of conductive elements surrounding the cable core. Generally, electrical cables using various cable core configurations and conductive element configurations, described in this specification, can be produced by any suitable process known to those skilled in the art. For example, a rigid frame attachment device, which can rotate spools of composite cores or filaments to assemble a cable core, can be employed. In some embodiments, the rigid frame attachment device can impart a twist per machine revolution to all composite cores or filaments, except for the central composite core, which is not twisted. Each successive layer by the central composite core can be closed by a round matrix. After the final layer is applied, the cable core containing the composite cores or filaments can be fixed with tape or other material. If tape is used, it can be applied using a concentric tape knotting machine. The resulting cable core with the tape can be received on a spool. The cable core can then be fed back by the same rigid frame cable attachment device for applying a plurality of conductive elements around the cable core.
Consistent with the embodiments of the present invention, electricity transmission processes are provided in the present specification. One such electricity transmission process may comprise: (i) installing an electrical cable as described in this specification, for example, comprising a cable core and a plurality of conductive elements surrounding the cable core; and (ii) transmit electricity through the electric cable. Another method of transmitting electricity may comprise: (i) providing an electrical cable as described in the present specification, for example, comprising a cable core and a plurality of conductive elements surrounding the cable core; and (ii) transmit electricity through the electric cable. In these and other embodiments, the electrical cable, the cable core and the conductive elements can be any electrical cable, cable core and conductive elements described in this specification. For example, the cable core can comprise any composite core described in this specification, that is, one or more composite cores or filaments. Examples
The invention is further illustrated by the examples presented below, which should not be considered in any way as imposing limitations on the scope of this invention. Various other aspects, embodiments, modifications and equivalents thereof, after reading the present specification, can be suggested by themselves to a person skilled in the art, without departing from the spirit of the present invention or the scope of the appended claims. Example 1
Two (2) strands of continuous fibers were formed initially using an extrusion system, as substantially described above. The carbon fiber tangles (Toray T700SC, which contained 12,000 carbon filaments having a tensile strength of 4,900 MPa and a mass per unit length of 0.8 g / m) were used in the continuous fibers, with each individual tape containing 4 tangles. The thermoplastic polymer used to impregnate the fibers was poly (phenylene sulfide) (PPS) (FORTRON® PPS 205, available from Ticona, LLC), which has a melting point of about 280 ° C. Each tape contained 50% by weight of carbon fibers and 50% by weight of PPS. The tapes had a thickness of about 0.18 mm and a fraction of void less than 1.0%. Once formed, the tapes were then fed to a pultrusion line, operating at a speed of 6.1 m / m in (20 ft / min). Before molding, the tapes were heated in an infrared oven (power setting 305). The heated tapes were then supplied to a consolidation matrix, having a circular shaped channel, which received the tapes and compressed them together, while forming the initial shape of the stick. Inside the matrix, the tapes were maintained at a temperature of about 177 ° C. After consolidation, the resulting preform was then succinctly cooled with an air ring / ducting device, which supplied air at room temperature, at a gauge pressure of 6.9 kPa (1 psig). The preform was then passed through a narrowing formed between two cylinders, and then to a calibration matrix for final molding. Within the calibration matrix, the preform was maintained at a temperature of around 140 ° C. After leaving this matrix, the profile was capped with a poly (ether - ether - ketone) (PEEK), which had a melting point of 350 ° C. The capping layer had an average thickness of about 0.1 - 0.15 mm. The resulting part was then cooled with an air stream. The resulting composite core had an average outside diameter of about 3.4 - 3.6 mm, and contained 45% by weight of carbon fibers, 50% by weight of PPS and 5% by weight of capping material.
To determine the mechanical strength properties of the composite core, the three-point bending test was performed according to the ASTM D790-10 standard, Procedure A. The support and nose radius was 0.63 cm (0.25 cm) inch), the support span was 30 mm, the length of the specimen was 5.08 centimeters (2 inches), and the test speed was 2 mm / min. The resulting flexural modulus was about 31 GPa and the flexural strength was about 410 MPa. The density of the piece was 1.48 g / cm3, and the void content was less than about 3%. The radius of curvature was 3.27 cm. Example 2
Two (2) strands of continuous fibers were formed initially using an extrusion system, as substantially described above. The carbon fiber tangles (Toray T700SC) were used in the continuous fibers, with each individual ribbon containing 4 tangles. The thermoplastic polymer used to impregnate the fibers was FORTRON® PPS 205. Each tape contained 50% by weight of carbon fibers and 50% by weight of PPS. The tapes had a thickness of about 0.18 mm and a fraction of void less than 1.0%. Once formed, the tapes were then fed to a pultrusion line, operating at a speed of 6.1 m / m in (20 ft / min). Before molding, the tapes were heated in an infrared oven (power setting 305). The heated tapes were then supplied to a consolidation matrix, having a circular shaped channel, which received the tapes and compressed them together, while forming the initial shape of the stick. Inside the matrix, the tapes were maintained at a temperature of about 343 ° C. After consolidation, the resulting preform was then cooled succinctly with an air ring / ducting device, which supplied air at room temperature, to a pressure gauge of 6.9 kPa (1 psig). The preform was then passed through a narrowing formed between two cylinders, and then to a calibration matrix for final molding. Within the calibration matrix, the preform was maintained at a temperature of around 140 ° C. After leaving this matrix, the profile was capped with FORTRON® PPS 205, which had a melting point of 280 ° C. The capping layer had an average thickness of about 0.1 - 0.15 mm. The resulting part was then cooled with an air stream. The resulting composite core had an average outside diameter of about 3.4 - 3.6 mm, and contained 45% by weight of carbon fibers, 50% by weight of PPS and 5% by weight of capping material.
To determine the mechanical strength properties of the composite core, the three-point bending test was performed according to the ASTM D790-10 standard, Procedure A. The support and nose radius was 0.63 cm (0.25 cm) inch), the support span was 30 mm, the length of the specimen was 5.08 centimeters (2 inches), and the test speed was 2 mm / min. The resulting flexural modulus was about 20.3 GPa and the flexural strength was about 410 MPa. The density of the piece was 1.48 g / cm3, and the void content was less than about 3%. The radius of curvature was 4.37 cm. Example 3
Two (2) strands of continuous fibers were formed initially using an extrusion system, as substantially described above. The glass fiber tangles (TUFRov® 4588 from PPG, which contained E glass filaments, having a tensile strength of 2,599 MPa and a mass per unit length of 0.0044 lb / yd (2.2 g / m) , were used for continuous fibers, with each individual tape containing 2 tangles.The thermoplastic polymer used to impregnate the fibers was poly (phenylene sulfide) (PPS) (FORTRON® 205, available from Ticona, LLC), which has a melting point of about 280 ° C. Each strip contained 56% by weight of carbon fibers and 44% by weight of PPS.The tapes had a thickness of about 0.18 mm and a fraction of void less than 1 , 0% Once formed, the tapes were then fed to a pultrusion line, operating at a speed of 6.1 m / m in (20 ft / min). Before molding, the tapes were heated in an oven infrared (330 power adjustment). The heated tapes were then supplied to a consolidation matrix, having a circular shaped channel, which received the f and compressed them together, forming the initial shape of the stick. After consolidation, the resulting preform was then cooled briefly with room air. The preform was then passed through a narrowing formed between two cylinders, and then to a calibration matrix for final molding. Within the calibration matrix, the preform was maintained at a temperature of around 275 ° C. After leaving this matrix, the profile was capped with FORTRON® 205. The capping layer had an average thickness of about 0.1 - 0.15 mm. The resulting part was then cooled with an air stream. The resulting composite core had an average outside diameter of about 3.4 - 3.6 mm, and contained 50% by weight of glass fibers and 50% by weight of PPS.
To determine the mechanical strength properties of the composite core, the three-point bending test was performed according to the ASTM D790-10 standard, Procedure A. The support and nose radius was 0.63 cm (0.25 cm) inch), the support span was 30 mm, the length of the specimen was 5.08 centimeters (2 inches), and the test speed was 2 mm / min. The resulting flexural modulus was about 18 GPa and the flexural strength was about 590 MPa. The void content was about 0% and the radius of curvature was 1.87 cm. Example 4
Two (2) strands of continuous fibers were formed initially using an extrusion system, as substantially described above. The glass fiber tangles (TlIFRov® 4588) were used in the continuous fibers, with each individual ribbon containing 2 tangles. The thermoplastic polymer used to impregnate the fibers was Nylon 66 (PA66), which has a melting point of around 250 ° C. Each tape contained 650% by weight of carbon fibers and 40% by weight of Nylon 66. The tapes had a thickness of about 0.18 mm and a fraction of void less than 1.0%. Once formed, the tapes were then fed to a pultrusion line, operating at a speed of 3.05 m / m in (10 ft / min). Before molding, the tapes were heated in an infrared oven (power setting 320). The heated tapes were then supplied to a consolidation matrix, having a circular shaped channel, which received the tapes and compressed them together, while forming the initial shape of the stick. After consolidation, the resulting preform was then cooled briefly with room air. The preform was then passed through a narrowing formed between two cylinders, and then to a calibration matrix for final molding. Within the calibration matrix, the preform was maintained at a temperature of about 170 ° C. After leaving this matrix, the profile was capped with Nylon 66. The capping layer had an average thickness of about 0.1 - 0.15 mm. The resulting part was then cooled with an air stream. The resulting composite core had an average outer diameter of about 3.4 - 3.6 mm, and contained 53% by weight of carbon fibers, 40% by weight of Nylon 66 and 7% by weight of capping material.
To determine the mechanical strength properties of the composite core, the three-point bending test was performed according to the ASTM D790-10 standard, Procedure A. The support and nose radius was 0.63 cm (0.25 cm) inch), the support span was 30 mm, the length of the specimen was 5.08 centimeters (2 inches), and the test speed was 2 mm / min. The resulting flexural modulus was about 19 GPa and the flexural strength was about 549 MPa. The void content was less than 0% and the radius of curvature was 2.34 cm. Example 5
Three (3) batches of eight (8) cores were formed, with different levels of void fractions. For each stick, two (2) continuous fiber strips were initially formed using an extrusion system, substantially as described above. The tangles of carbon fibers (Toray T700SC, which contained 12,000 carbon filaments having a tensile strength of 4,900 MPa and a mass per unit length of 0.8 g / m)) were used in the continuous fibers, with each individual tape containing 4 tangles. The thermoplastic polymer used to impregnate the fibers was poly (phenylene sulfide) (FORTRON® PPS 205, available from Ticona, LLC), which had a melting point of about 280 ° C. Each tape contained 50% by weight of carbon fibers and 50% by weight of PPS. The tapes had a thickness of about 0.18 mm and a fraction of void less than 1.0%. Once formed, the tapes were then fed to a pultrusion line, operating at a speed of 6.1 m / m in (20 ft / min). Before molding, the tapes were heated in an infrared oven (power setting 305). The heated tapes were then supplied to a consolidation matrix, having a circular shaped channel, which received the tapes and compressed them together, while forming the initial shape of the stick. Inside the matrix, the tapes were maintained at a temperature of about 177 ° C. After consolidation, the resulting preform was then succinctly cooled with an air ring / ducting device, which supplied air at room temperature, at a gauge pressure of 6.9 kPa (1 psig). The preform was then passed through a narrowing formed between two cylinders, and then to a calibration matrix for final molding. Within the calibration matrix, the preform was maintained at a temperature of around 140 ° C. After leaving this matrix, the profile was capped with poly (ether - ether - ketone) ("PEEK"), which had a melting point of 350 ° C. The capping layer had an average thickness of about 0.1 - 0.15 mm. The resulting composite core was then cooled with an air stream. The resulting composite core had an average outer diameter of about 3.5 mm, and contained 45% by weight of carbon fibers, 50% by weight of PPS and 5% by weight of capping material.
A first batch of composite cores had an average void fraction of 4.06%. A third batch of composite cores had an average void fraction of 8.74%. The void fraction measurements were made using a CT scan. A high resolution Metrotom 1500 detector (2k x 2k) was used to scan the core specimens. The detection was made using an optimized analysis mode, with a low probability threshold. Once the specimens were scanned for the void fraction, the Volume Graphics software was used to interpret the 3D scan data, and calculate the void levels in each specimen.
To determine the service life under flexion fatigue and the resistance to residual flexion of the rods, a three-point flexion fatigue test was performed according to the ASTM D790 standard. The support sweep was 5.59 cm (2.2 in) and the specimen length was 7.62 cm (3 in). Four (4) composite cores from each batch were tested at a load level of 160 newtons ("N") and four (4) composite cores from each batch were tested at a load level of 180N, respectively, representing about 50 % and 55% of the primitive (static) flexural (static) resistance of the cores. Each specimen was tested at one million cycles at a frequency of 10 hertz (Hz).
Before and after the fatigue test, to determine the respective properties of resistance to primitive and residual flexion of the rods, the three-point flexion test was conducted according to the ASTM D790-10 standard, Procedure A. The resistance to primitive flexion and residual mean of each batch, at each load level, were recorded. The resulting primitive flexural strength for the third batch was 734 MPa (107 ksi), and the resulting residual flexural strength for the third batch was 517 MPa (75 ksi), thus resulting in a reduction of about 29%. The resulting primitive flexural strength for the second batch was 745 MPa (108 ksi), and the resulting residual flexural strength for the second batch was 496 MPa (72 ksi), thus resulting in a reduction of about 33%. The resulting primitive flexural strength for the first batch was 731 MPa (106 ksi), and the resulting residual flexural strength for the first batch was 724 MPa (105 ksi), thus resulting in a reduction of about 1%. Example 6
Figure 15 illustrates the electrical cable 520 produced in Example 6. The 26 conductive elements 552 formed a first layer 526 and a second layer 528. The cable core 500 was a 7-core composite filament. A tape 530, between the cable core 500 and the conductive elements 522, partially covered the cable core 500 in a helical arrangement.
The electric cable was produced as follows. Seven (7) composite cores, having a diameter of about 3.5 mm, were twisted to form a twisted cable core with an array length of 508 mm. The composite cores were similar to those produced in Example 1 mentioned above. The cable core was fixed with aluminum foil tape laminated to a fiberglass fabric and a silicone based adhesive. 26 conductive wires were placed above and around the cable core and the strip in two layers, as shown in Figure 15. The conductive wires had a diameter of about 4.5 mm, and were made of fully annealed 1350 aluminum. The cable's tensile strength limit was approximately 136 MPa (19,760 psi). Example 7
Figure 15 illustrates the electrical cable 520 produced in Example 7. The 26 conductive elements 553 formed a first layer 526 and a second layer 528. The cable core 500 was a 7-core composite filament. A tape 530, between the cable core 500 and the conductive elements 522, partially covered the cable core 500 in a helical arrangement.
The electric cable was produced as follows. Seven (7) composite cores, having a diameter of about 3.5 mm, were twisted to form a twisted cable core with an array length of 508 mm. The composite cores were similar to those produced in Example 1 mentioned above. The cable core was fixed with aluminum foil tape laminated to a fiberglass fabric and a silicone based adhesive. 26 lead wires were placed above and around the cable core and the strip in two layers, as shown in Figure 15. The lead wires had a diameter of about 4.5 mm, and were made of an aluminum alloy containing zirconium (approximately 0.2 - 0.33% zirconium). Figure 16 illustrates the tensile - strain data for the electrical cable in Example 7.
The electrical cable of Example 7 was tested for its fatigue and / or vibration resistance properties, according to the Aeolian vibration test, specified in the IEED 1138 standard. The electrical cable of Example 7 passed the Aeolian vibration test at 100 million cycles.
Using a mathematical model based on aerial transmission cables, similar to that of Example 7, the 10-year creep values calculated at a RBS (Nominal Break Tensile) of 5%, 20%, 25% and 30% were approximately 0.054%, approximately 0.081%, approximately 0.119% and approximately 0.163%, respectively. Constructive example 8
Figure 17 illustrates electrical cable 620, which can be produced in Constructive Example 8. The 26 conducting elements 622 can form a first layer 626 and a second layer 628. The cable core 600 can be a 7-core composite filament. A tape 630, between the cable core 600 and the conductive elements 622, can partially cover the cable core 600 in a helical arrangement.
The electrical cable in Figure 17 can be produced as follows. Seven (7) composite cores, having a diameter of about 3.5 mm, were twisted to form a twisted cable core with an array length of 508 mm. The composite cores were similar to those produced in Example 1 mentioned above. The cable core was fixed with aluminum foil tape laminated to a fiberglass fabric and a silicone based adhesive. 26 conductor wires were placed above and around the cable core and the ribbon in two layers, as shown in Figure 17. The conductors can be trapezoidal wires having a cross-sectional area of about 15 - 17 mm2, and can be manufactured of annealed 1350 aluminum (or, alternatively, an aluminum alloy containing zirconium).

权利要求:
Claims (19)
[0001]
1. Electric cable (420), comprising: (a) a cable core comprising at least one composite core (400); and (b) a plurality of conductive elements (422) surrounding the cable core; CHARACTERIZED by the fact that the composite core (400) comprises: (i) at least one rod (514) comprising a plurality of consolidated thermoplastic impregnated tangles (142), the tangles (142) comprising continuous fibers (526), oriented in the direction longitudinal, and a thermoplastic matrix (528), which embeds the fibers (526), the fibers (526) having a tensile strength to mass limit ratio per unit length greater than 1,000 MPa / g / m, in which the The stick (514) comprises a range from 25% by weight to 80% by weight of fibers (526) and a range from 20% by weight to 75% by weight of thermoplastic matrix (528), and in which the thermoplastic matrix (528) ) comprises a poly (arylene sulfide); and (ii) a capping layer (519) surrounding the at least one rod (514), wherein the capping layer (519) comprises a poly (ether-ether-ketone) and is free of continuous fibers or contains less than than 10% by weight of continuous fibers, where the composite core (400) has a flexural modulus of at least 10 GPa.
[0002]
2. Cable, according to claim 1, CHARACTERIZED by the fact that: the rod (514) comprises a range of 30% by weight to 75% by weight of fibers; the fibers (526) comprise carbon fibers; and the poly (arylene sulfide) comprises a poly (phenylene sulfide).
[0003]
3. Cable according to claim 1 or 2, CHARACTERIZED by the fact that the fibers (526) have a tensile strength to mass limit ratio per unit length in a range of 5,500 to 20,000 MPa / g / m.
[0004]
4. Cable according to any one of claims 1 to 3, CHARACTERIZED by the fact that the composite core (400) has: a bending module in a range of 15 to 200 GPa; and a limit of tensile strength in the range of 500 MPa to 3,500 MPa.
[0005]
5. Cable according to any one of claims 1 to 4, CHARACTERIZED by the fact that the composite core (400) has: an elastic module in a range of 70 GPa to 300 GPa; or a density of 1.2 g / cm3 to 1.8 g / cm3; or a resistance to weight ratio in the range of 500 MPa / (g / cm3) to 1,100 MPa / (g / cm3); or a percentage elongation at break in the range of 1% to 2.5%; or a coefficient of linear thermal expansion, in the longitudinal direction, in a range of -0.4 to 5 ppm per ° C; or a radius of curvature in a range from 1 cm to 50 cm; or a fraction of void below 6%; or any of its combinations.
[0006]
6. Cable according to any one of claims 1 to 5, CHARACTERIZED by the fact that: the rod (514) comprises from 2 to 20 tangles; and each tangle (142) comprises a range of 1,000 to 100,000 individual continuous fibers.
[0007]
Cable according to any one of claims 1 to 6, CHARACTERIZED by the fact that the cable core comprises two or more composite cores (400).
[0008]
8. Cable according to any one of claims 1 to 7, characterized by the fact that the cable core is a twisted core comprising from 2 to 37 composite cores (400), each composite core (400) having a sectional shape circular cross section.
[0009]
9. Cable according to any one of claims 1 to 8, CHARACTERIZED by the fact that the cable comprises up to 84 conductive elements (422, 426), and in which a total area of the conductive elements (422, 426) is in one range from 84.62 to 1773 square millimeters (167 to 3500 kcmil).
[0010]
10. Cable according to any one of claims 1 to 9, CHARACTERIZED by the fact that: the conductive elements (422, 426) comprise copper, a copper alloy, aluminum, an aluminum alloy or any combination thereof; or the conductive elements (422, 426) are arranged in 2, 3 or 4 layers around the cable core; or the conducting elements (422, 426) have a circular cross-sectional shape or a trapezoidal cross-sectional shape; or any of its combinations.
[0011]
11. Cable according to any one of claims 1 to 10, CHARACTERIZED by the fact that the conductive elements (422, 426) comprise aluminum or an aluminum alloy, having an IACS electrical conductivity in a range of 59% to 65% .
[0012]
12. Cable according to any one of claims 1 to 11, CHARACTERIZED by the fact that the cable has: a bend, at a nominal temperature of 180 ° C, to a level span of 300 meters with a light NESC load in a range from 3 to 9.5 m; and a bow, at a nominal temperature of 180 ° C, to a span of 300 meters with a heavy NESC load in a range of 3 to 7.5 m.
[0013]
13. Cable according to any one of claims 1 to 12, CHARACTERIZED by the fact that the cable has: a tensile parameter in a range of 20 MPa to 50 MPa; or a 10-year creep value at a RBS (Nominal Break Tensile) of 15% less than 0.2%; or a 10-year creep value at a RBS (rated rupture pull) of 30% less than 0.25%; or a maximum operating temperature in the range of 100 ° C to 250 ° C; or any of its combinations.
[0014]
14. Cable according to any one of claims 1 to 13, CHARACTERIZED by the fact that the cable passes an Aeolian vibration test at 100 million cycles.
[0015]
Cable according to any one of claims 1 to 14, characterized in that it further comprises a partial or complete strip layer (530), between the cable core (400) and the plurality of conductive elements (422, 426).
[0016]
16. Cable according to any one of claims 1 to 15, CHARACTERIZED by the fact that the cable is a high voltage overhead transmission cable.
[0017]
17. The electrical cable production method as defined in any one of claims 1 to 16, the method comprising: (A) providing a cable core comprising at least one composite core (400); and (B) surrounding the cable core with the plurality of conductive elements (422, 426); CHARACTERIZED by the fact that the composite core (400) comprises: (i) at least one rod (514) comprising a plurality of consolidated thermoplastic impregnated tangles (142), the tangles (142) comprising continuous fibers (526) , oriented in the longitudinal direction, and a thermoplastic matrix (528), which embeds the fibers (526), the fibers (526) having a tensile strength to mass limit ratio per unit length greater than 1,000 MPa / g / m , where the rod (514) comprises from 25% by weight to 80% by weight of fibers (526) and 20% by weight to 75% by weight of thermoplastic matrix (528), and where the thermoplastic matrix (528) ) comprises a poly (arylene sulfide); and (ii) a capping layer (519) surrounding the at least one rod (514), wherein the capping layer (519) comprises a poly (ether-ether-ketone) and is free of continuous fibers or contains less than than 10% by weight of continuous fibers, where the composite core (400) has a flexural modulus of at least 10 GPa.
[0018]
18. The method of claim 17, further comprising a step of partially or completely wrapping the cable core with a tape (530), prior to step (B).
[0019]
19. The method of claim 17, further comprising a step of partially or completely coating the cable core with a polymeric material, prior to step (B).

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PL2697800T3|2017-07-31|

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AU2012242930B2|2016-03-31|

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法律状态:
2018-02-06| B25D| Requested change of name of applicant approved|Owner name: SOUTHWIRE COMPANY, LLC (US) |

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2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-02-11| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-05-12| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|

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2020-08-25| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-10-27| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/04/2012, OBSERVADAS AS CONDICOES LEGAIS. |

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2021-04-06| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 9A ANUIDADE. |

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2021-08-10| B24J| Lapse because of non-payment of annual fees (definitively: art 78 iv lpi, resolution 113/2013 art. 12)|Free format text: EM VIRTUDE DA EXTINCAO PUBLICADA NA RPI 2622 DE 06-04-2021 E CONSIDERANDO AUSENCIA DE MANIFESTACAO DENTRO DOS PRAZOS LEGAIS, INFORMO QUE CABE SER MANTIDA A EXTINCAO DA PATENTE E SEUS CERTIFICADOS, CONFORME O DISPOSTO NO ARTIGO 12, DA RESOLUCAO 113/2013. |

优先权:

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申请号 | 申请日 | 专利标题

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US201161474423P| true| 2011-04-12|2011-04-12|

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US61/474,423|2011-04-12|

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PCT/US2012/033077|WO2012142129A1|2011-04-12|2012-04-11|Electrical transmission cables with composite cores|

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