ALUMINUM ELECTRICAL WIRE AND METHOD FOR MANUFACTURING ALUMINUM ELECTRICAL WIRE

• US 20180350487A1
• Filed: 06/25/2018
• Published: 12/06/2018
• Est. Priority Date: 12/25/2015
• Status: Active Grant

• Current Assignee: Furukawa Automotive Systems Incorporated (Furukawa Electric Company Limited), Furukawa Electric Company Limited
• Original Assignee: Furukawa Automotive Systems Incorporated (Furukawa Electric Company Limited), Furukawa Electric Company Limited
• Inventors: UCHIYAMA, Yasuharu, SAKAKI, Akihiro
• Granted Patent: US 10,468,154 B2
• Time in Patent Office: Days
• CPC Class Codes: C22C 21/00 Alloys based on aluminium
• CPC Class Codes: C22F 1/04 of aluminium or alloys based thereon
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: H01B 13/06 Insulating conductors or cables H01B13/32 takes precedence
• CPC Class Codes: H01B 3/443 from vinylhalogenides or other halogenoethylenic compounds
• CPC Class Codes: H01B 7/0009 Details relating to the conductive cores
• CPC Class Codes: H01B 7/02 Disposition of insulation

Abstract

The purpose of the present invention is to provide an aluminum wire in which the electroconductivity is similar to that of an insulated wire having a copper conductor, and in which the wire outside diameter is not increased. An aluminum electrical wire (1, 1A) in which an aluminum conductor (10, 10A) comprising 37 or 19 aluminum-based core wires (20, 20A) containing at least 99 mass % of aluminum is coated by an insulating resin covering (30), wherein the aluminum conductor (10, 10A) is obtained by concentrically twisting the aluminum-based core wires (20, 20A) in a non-compressed state, the cross-sectional area of the aluminum conductor (10, 10A) is 2.5 mm² to less than 17 mm², and the insulating resin coating has a thickness equal to from 10 to 20% of the conductor outside diameter of the aluminum conductors (10, 10A).

Claims

1. An aluminum electrical wire wherein a conductor comprising a plurality of aluminum-based core wires containing not less than 99 mass % of aluminum is covered with an insulating resin covering;

the conductor being constructed by concentrically twisting 19 or 37 of the aluminum-based core wires in a non-compressed state and at a same pitch; and

a thickness deviation of the insulating resin covering being not less than 70%.

2. The aluminum electrical wire according to claim 1, wherein the aluminum-based core wires constituting the conductor are disposed in a cross-sectionally regular hexagonal form.

3. The aluminum electrical wire according to claim 1, wherein

core wire diameters of the 19 or 37 aluminum-based core wires constituting the conductor are identical.

4. The aluminum electrical wire according to claim 1, wherein

a cross-sectional area of the conductor is not less than 2.5 mm² and less than 17 mm².

5. The aluminum electrical wire according to claim 1, wherein

the insulating resin covering has a thickness of not less than 10% and not greater than 20% of the conductor outer diameter.

6. The aluminum electrical wire according to claim 1, wherein

the insulating resin covering is vinyl chloride resin.

14. The aluminum electrical wire according to claim 1, wherein

the conductor is configured by twisting 19 of the aluminum-based core wires, and the twisting pitch is not less than 6.4 times and not greater than 22.0 times the conductor outer diameter.

15. The aluminum electrical wire according to claim 1, wherein

the conductor is configured by twisting 37 of the aluminum-based core wires, and the twisting pitch is not less than 6.2 times and not greater than 15.7 times the conductor outer diameter.

7. A method for manufacturing an aluminum electrical wire wherein a conductor constructed by twisting one aluminum-based core wire containing not less than 99 mass % of aluminum disposed in a center and 6, 12, and 18 of the aluminum-based core wires disposed concentrically from the center is covered with an insulating resin covering, the method comprising:

a twisting step of constructing the conductor by twisting the aluminum-based core wires while setting a twisting pitch to not less than 6.2 times and not greater than 15.7 times a conductor outer diameter and applying to the aluminum-based core wires a tensile force so as to result in a tensile force per unit cross-sectional area of not less than 12.5 N/mm² and not greater than 56.3 N/mm²; and

a covering step of covering the constructed conductor with the insulating resin covering;

the steps being performed in that order.

8. The method for manufacturing an aluminum electrical wire according to claim 7, wherein,

prior to the twisting step, a softening treatment step of implementing a softening treatment on the aluminum-based core wires is performed.

13. The method for manufacturing an aluminum electrical wire according to claim 7, wherein,

after the twisting step and prior to the covering step, a softening treatment step of implementing a softening treatment is performed.

9. A method for manufacturing an aluminum electrical wire wherein a conductor constructed by twisting one aluminum-based core wire containing not less than 99 mass % of aluminum disposed in a center and a predetermined number of the aluminum-based core wires disposed concentrically from the center is covered with an insulating resin covering, the method comprising:

a twisting step of constructing the conductor by twisting 6 or 12 of the aluminum-based core wires disposed concentrically from the center; and

a covering step of covering the constructed conductor with the insulating resin covering;

the steps being performed in that order;

wherein,

in the twisting step,

a twisting pitch is set to not less than 6.4 times and not greater than 22.0 times a conductor outer diameter, and

a tensile force is applied to the aluminum-based core wires so as to result in a tensile force per unit cross-sectional area of not less than 12.5 N/mm² and not greater than 87.5 N/mm².

10. The method for manufacturing an aluminum electrical wire according to claim 9, wherein,

in the twisting step,

the twisting pitch is set to not less than 6.4 times and not greater than 16.9 times the conductor outer diameter, and

a tensile force is applied to the aluminum-based core wires so as to result in a tensile force per unit cross-sectional area of not less than 62.5 N/mm² and not greater than 87.5 N/mm²;

and

after the twisting step and prior to the covering step, a softening treatment step of implementing a softening treatment is performed.

11. The method for manufacturing an aluminum electrical wire according to claim 9, wherein,

prior to the twisting step, a softening treatment step of implementing a softening treatment on the aluminum-based core wires is performed;

and

in the twisting step,

the twisting pitch is set to not less than 8.6 times and not greater than 22.0 times the conductor outer diameter, and

a tensile force is applied to the aluminum-based core wires so as to result in a tensile force per unit cross-sectional area of not less than 12.5 N/mm² and not greater than 56.3 N/mm².

12. A method for manufacturing an aluminum electrical wire wherein

the twisted wire conductor described in claim 11 is used as an inner layer part;

the twisting step comprising;

an inner layer twisting step of twisting the inner layer part; and

an outer layer twisting step of twisting an outermost layer by 18 of the aluminum-based core wires disposed concentrically on an outer side of the inner layer part;

the steps being performed in that order;

wherein,

in the outer layer twisting step,

an outer layer twisting pitch at which the outermost layer is twisted is set to a same pitch as a twisting pitch of the inner layer part, and

a tensile force is applied to the aluminum-based core wires so as to result in a tensile force per unit cross-sectional area of not less than 12.5 N/mm² and not greater than 56.3 N/mm², and a tensile force is applied to the inner layer part so as to result in a tensile force per unit cross-sectional area of not less than 250.0 N/mm² and not greater than 1875.0 N/mm².