WO1997012377A1 - An insulated conductor and process for making an insulated conductor - Google Patents
An insulated conductor and process for making an insulated conductor Download PDFInfo
- Publication number
- WO1997012377A1 WO1997012377A1 PCT/US1996/013466 US9613466W WO9712377A1 WO 1997012377 A1 WO1997012377 A1 WO 1997012377A1 US 9613466 W US9613466 W US 9613466W WO 9712377 A1 WO9712377 A1 WO 9712377A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- conductor
- thickness
- inch
- electrical conductor
- recited
- Prior art date
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/145—Pretreatment or after-treatment
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/323—Insulation between winding turns, between winding layers
Definitions
- the present invention relates generally to an insulated conductor and processes for making an insulated conductor, and more particularly to processes for making a high voltage insulated electrical conductor for use in electrical transformers. Still more particularly, the invention relates to an insulated conductor and a process for making an electrical conductor having an insulation coating disposed thereon of thickness of about 0.00125 to about 0.00315 inch.
- Rectangular conductors with high dielectric strength insulation such as polyphenylsulfone are coated using thermoplastic extruders equipped with crossheads tooled to coat rectangular conductors.
- the extruded insulation coating thickness range is about 0.0025 inch (the minimum obtainable) to about 0.0035 inch (easily obtainable) .
- One of the shortcomings of the extrusion crosshead is that the coating thickness cannot be controlled to thin coatings of less than 0.0025 inch.
- a goal of the present invention is to provide a process for making electrical conductors in which the thickness of the extruded coating can be reduced by about 10% to about 50% to provide a reduced insulation thickness range of about 0.00125 inch to about 0.00315 inch depending on the extruded starting thickness and the percent reduction utilized.
- the process in accordance with the invention provides a coating of insulative material which can have a prescribed thickness less than that produced by the presently available extrusion process (es) .
- An insulated conductor comprising an electrical conductor and an insulative coating disposed on the conductor.
- the coating has a thickness of about 0.00125 inch to about 0.00315 inch, and preferably about 0.00125 to about 0.00175 inch.
- a process for making an insulated conductor in accordance with the present invention includes extruding an insulative material onto a conductor and subsequently roll reducing the coated conductor so that the insulative material on the conductor is reduced by about 10% to about 50% to a prescribed thickness and the conductor assumes a prescribed thickness and width.
- the extruding step preferably comprising extruding the insulative material to a thickness of about 0.0025 inch to about 0.0035 inch and more preferably to a thickness of at least about 0.0025 inch
- the rolling step preferably comprises rolling the insulative material to a thickness of about 0.00125 to 0.00315 inch and preferably to a thickness of about 0.00125 to 0.00175 inch.
- the insulative material is a thermoplastic polymer, such as polyphenylsulfone.
- the conductor is generally rectangular in cross-section.
- the preferred embodiment of the invention also includes rolling the conductor to a reduced thickness and increased surface area, i.e., the rolling step includes rolling the insulative material to a prescribed thickness and at the same time rolling the conductor to a reduced thickness.
- the rolling step includes rolling the insulative material to a prescribed thickness and at the same time rolling the conductor to a reduced thickness.
- Fig. 1 schematically depicts an extruder and the process of extruding an insulative material onto the surface of a rectangular conductor.
- the product of the extrusion process is a conductor 10 comprising an electrical conductor 12 and an insulative coating 14.
- Fig. 2 schematically depicts the rolling step in accordance with the present invention, wherein up to four rolls 16a-16d are employed to roll the insulative coating to a desired thickness, and at same time alter the shape
- Fig. 3 illustrates one form of transformer; a transformer 20 comprising a pair of coils 10' (i.e., coils composed of an insulated conductor in accordance with the present invention) and a core 18.
- a transformer 20 comprising a pair of coils 10' (i.e., coils composed of an insulated conductor in accordance with the present invention) and a core 18.
- the present invention employs developed sizes of conductor that can be reduced to the desired dimensions with the desired thickness of insulation.
- Presently preferred embodiments of the invention employ reducing rolls.
- This invention when applied in conjunction with the thermoplastic extruder, allows rectangular conductors (e.g., aluminum or copper) to be produced with the desired dimensions of conductor and insulation thickness.
- This invention can be employed to control the insulation thickness of either of the two opposing sides of the conductor, or of all four sides, depending on the roller configuration.
- thermoplastic coatings onto rectangular conductors is limited generally to a minimum thickness of 0.0025 inch. This is an inherent limitation due to the way presently available extruder crossheads, and their associated die components, apply the melted polymer to the conductor.
- This extrusion process is represented by the block bearing the same name in Fig. 1.
- a product of this process is a conductor 10 comprising the electrical conductor 12 and its associated insulative coating 14, wherein the coating has a minimum thickness of 0.0025 inch.
- the extruded insulation coating thickness can range from about 0.0025 inch (the minimum obtainable) to about 0.0035 inch (easily obtainable) .
- the polymers applicable to high voltage conductors used in transformers 20 must have performance characteristics that ensure functional life performance for up to 25 years. These polymers have dielectric strengths that allow them to be used with coating thicknesses of less than 0.0025 inch, i.e., in the range of about 0.00125 to about 0.00315 inch and preferably in the range of about 0.00125 to about 0.00175 inch.
- the product of the inventive process disclosed herein is a rectangular conductor 10' (see Fig. 2) having an insulation of a thickness which meets the dielectric needs of the transformer but does not exceed such need by an excessive amount.
- a set of reducing rolls is employed to reduce the insulation thickness.
- the reducing rolls can be configured in different ways, such as two flat rolls with parallel axes or one flat roll in combination with a slightly tapered, grooved roll, or four flat rolls (one on each side of the conductor 12) or four flat rolls as is configured in what is commonly known as a "Turks" head. These various configurations are represented generally in Fig. 2, which depicts four flat rolls 16a-16d.
- the final size of the conductor product i.e., the conductor and insulative coating
- the final size of the conductor product is produced by developing a starting size of conductor with an extrudable thickness of insulation that when rolled yields a conductor of the desired or predetermined dimensions with the desired or predetermined thickness of insulation.
- the conductor typically has a width no more than about ten times its thickness and the thickness of the insulation is about 0.00125 to 0.00175 inch.
- the thickness of the insulation is about 0.00125 to 0.00175 inch.
- coating thickness less than 0.00125 inch may be utilized for certain applications, as will be understood to those skilled in the art, and such reduced coating thicknesses may be obtained by the inventive process disclosed herein.
- the process involves the extrusion of a larger cross-section conductor than the desired final size.
- This conductor is then extrusion coated with thermoplastic insulation.
- the thickness of the coating for example, can be approximately 0.0025 inch, which is the minimum thickness possible by currently available extruders.
- the coated conductor is then rolled into a final desired cross- sectional thickness and width. During the rolling step, the ratio of the conductor surface to the volume of the conductor increases as the conductor cross-section changes from one rectangular shape to a different rectangular shape, i.e., as the thickness of the conductor is reduced. This means that the insulation thickness is reduced to below the original 0.0025 inch, resulting in a more efficient conductor.
- - rolled bare conductor size 0.0725 thickness x 0.2090 width.
- - rolled coated conductor size 0.0760 thickness x 0.2120 width.
- the present invention employs one or more roll means or apparatus to alter the shape of the coated conductor to achieve a desired or predetermined thickness of insulation.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Insulated Conductors (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP96929706A EP0850483A4 (en) | 1995-09-14 | 1996-08-20 | An insulated conductor and process for making an insulated conductor |
CA002231656A CA2231656A1 (en) | 1995-09-14 | 1996-08-20 | An insulated conductor and process for making an insulated conductor |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US52785995A | 1995-09-14 | 1995-09-14 | |
US08/527,859 | 1995-09-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1997012377A1 true WO1997012377A1 (en) | 1997-04-03 |
Family
ID=24103225
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/013466 WO1997012377A1 (en) | 1995-09-14 | 1996-08-20 | An insulated conductor and process for making an insulated conductor |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0850483A4 (en) |
CA (1) | CA2231656A1 (en) |
WO (1) | WO1997012377A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7989701B2 (en) | 2007-11-27 | 2011-08-02 | Sabic Innovative Plastics Ip B.V. | Multiconductor cable assembly and fabrication method therefor |
EP2533257A1 (en) * | 2011-06-09 | 2012-12-12 | ABB Technology AG | Transformer coil |
US9589703B2 (en) | 2013-11-11 | 2017-03-07 | General Cable Technologies Corporation | Data cables having an intumescent tape |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2291670A (en) * | 1939-08-31 | 1942-08-04 | Dow Chemical Co | Method of coating wire and the like |
US2949593A (en) * | 1957-05-09 | 1960-08-16 | Reynolds Metals Co | Electrical coil formed from multilayer strip conductor |
US3523362A (en) * | 1967-08-23 | 1970-08-11 | Gen Electric | Method of making electromagnetic cores |
US3626587A (en) * | 1970-04-06 | 1971-12-14 | Westinghouse Electric Corp | Methods of constructing electrical transformers |
US4082866A (en) * | 1975-07-28 | 1978-04-04 | Rte Corporation | Method of use and electrical equipment utilizing insulating oil consisting of a saturated hydrocarbon oil |
US4109375A (en) * | 1976-11-22 | 1978-08-29 | Westinghouse Electric Corp. | Method of making adhesive coated electrical conductors |
US4164619A (en) * | 1978-01-19 | 1979-08-14 | Westinghouse Electric Corp. | Porous encapsulating composition for electrical apparatus |
US4204087A (en) * | 1976-11-22 | 1980-05-20 | Westinghouse Electric Corp. | Adhesive coated electrical conductors |
US4882834A (en) * | 1987-04-27 | 1989-11-28 | Armco Advanced Materials Corporation | Forming a laminate by applying pressure to remove excess sealing liquid between facing surfaces laminations |
US4935302A (en) * | 1987-03-24 | 1990-06-19 | Asea Brown Boveri Ab | Electrical conductor provided with a surrounding insulation |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
NL7208610A (en) * | 1972-06-23 | 1973-12-27 | ||
US4521363A (en) * | 1984-01-23 | 1985-06-04 | Essex Group, Inc. | Extrusion of a plastic coating about a strand |
JPH0536315A (en) * | 1991-07-26 | 1993-02-12 | Showa Electric Wire & Cable Co Ltd | Manufacture of rectangular insulation cable |
-
1996
- 1996-08-20 WO PCT/US1996/013466 patent/WO1997012377A1/en not_active Application Discontinuation
- 1996-08-20 CA CA002231656A patent/CA2231656A1/en not_active Abandoned
- 1996-08-20 EP EP96929706A patent/EP0850483A4/en not_active Withdrawn
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2291670A (en) * | 1939-08-31 | 1942-08-04 | Dow Chemical Co | Method of coating wire and the like |
US2949593A (en) * | 1957-05-09 | 1960-08-16 | Reynolds Metals Co | Electrical coil formed from multilayer strip conductor |
US3523362A (en) * | 1967-08-23 | 1970-08-11 | Gen Electric | Method of making electromagnetic cores |
US3626587A (en) * | 1970-04-06 | 1971-12-14 | Westinghouse Electric Corp | Methods of constructing electrical transformers |
US4082866A (en) * | 1975-07-28 | 1978-04-04 | Rte Corporation | Method of use and electrical equipment utilizing insulating oil consisting of a saturated hydrocarbon oil |
US4109375A (en) * | 1976-11-22 | 1978-08-29 | Westinghouse Electric Corp. | Method of making adhesive coated electrical conductors |
US4204087A (en) * | 1976-11-22 | 1980-05-20 | Westinghouse Electric Corp. | Adhesive coated electrical conductors |
US4164619A (en) * | 1978-01-19 | 1979-08-14 | Westinghouse Electric Corp. | Porous encapsulating composition for electrical apparatus |
US4935302A (en) * | 1987-03-24 | 1990-06-19 | Asea Brown Boveri Ab | Electrical conductor provided with a surrounding insulation |
US4882834A (en) * | 1987-04-27 | 1989-11-28 | Armco Advanced Materials Corporation | Forming a laminate by applying pressure to remove excess sealing liquid between facing surfaces laminations |
Non-Patent Citations (1)
Title |
---|
See also references of EP0850483A4 * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7989701B2 (en) | 2007-11-27 | 2011-08-02 | Sabic Innovative Plastics Ip B.V. | Multiconductor cable assembly and fabrication method therefor |
EP2533257A1 (en) * | 2011-06-09 | 2012-12-12 | ABB Technology AG | Transformer coil |
US9589703B2 (en) | 2013-11-11 | 2017-03-07 | General Cable Technologies Corporation | Data cables having an intumescent tape |
Also Published As
Publication number | Publication date |
---|---|
EP0850483A4 (en) | 1998-11-04 |
CA2231656A1 (en) | 1997-04-03 |
EP0850483A1 (en) | 1998-07-01 |
MX9802036A (en) | 1998-08-30 |
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