Electroceramic coating of a wire for use in a bundled power transmission cable

• US 9,953,747 B2
• Filed: 02/06/2017
• Issued: 04/24/2018
• Est. Priority Date: 08/07/2014
• Status: Active Grant

• Current Assignee: Henkel AG & Co KGaA
• Original Assignee: Henkel AG & Co KGaA
• Inventors: Dolan, Shawn E., Ziehm, Mark W., Kuhns, Eric C., Lombardo, Jr., Michael
• Primary Examiner(s): Thompson, Timothy
• Assistant Examiner(s): McAllister, Michael F
• Application Number:
  US15/425,123
• Publication Number:
  US 20170148548A1
• Time in Patent Office: 442 Days
• Field of Search: 174113 R
• CPC Class Codes: C25D 17/08 Supporting racks , i.e. not for suspending
• CPC Class Codes: C25D 9/12 on light metals
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: H01B 13/0891 After-treatment
• CPC Class Codes: H01B 13/16 by passing through or dipping in a liquid bath; by spraying
• CPC Class Codes: H01B 3/105 Wires with oxides
• CPC Class Codes: H01B 5/002 Auxiliary arrangements
• CPC Class Codes: H01B 7/0045 Cable-harnesses
• CPC Class Codes: H01B 7/02 Disposition of insulation
• CPC Class Codes: H01B 7/28 Protection against damage caused by moisture, corrosion, chemical attack or weather
• CPC Class Codes: H01B 7/292 using material resistant to heat
• CPC Class Codes: H01B 7/421 for heat dissipation
• CPC Class Codes: H01B 9/006 Constructional features relating to the conductors
• CPC Class Codes: H02K 3/02 Windings characterised by the conductor material
• CPC Class Codes: H02K 3/30 Windings characterised by the insulating material
• CPC Class Codes: Y02A 30/14 Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables

Abstract

A cable for power distribution applications includes a plurality of wires bundled into the cable. The plurality of wires typically is comprised of interior wires and peripheral wires with the peripheral wires surrounding the interior wires. At least one wire is coated with a high emissivity coating that includes at least 10 weight percent aluminum oxide and a metal oxide other than aluminum oxide. Characteristically, the wire coated with the high emissivity coating has an emissivity greater than about 0.5 in the infrared region of the electromagnetic spectrum and a surface area at least 50 times greater than the surface area of a bare wire prior to being coated with the high emissivity coating.

Claims

1. A cable for power distribution applications, the cable comprising:

a plurality of wires bundled into a cable and extending along a central longitudinal axis of the cable;

the plurality of wires comprised of interior wires and peripheral wires with the peripheral wires surrounding the interior wires, at least one peripheral wire being a coated wire having deposited thereon a high emissivity coating, the high emissivity coating comprising at least one metal oxide other than aluminum oxide and at least 10 weight percent aluminum oxide, the coated wire having an emissivity greater than or equal to 0.5 and a surface area at least 20 times greater than the surface area of a bare peripheral wire prior to being coated with the high emissivity coating.

2. The cable of claim 1 wherein the interior wires and the peripheral wires comprise aluminum or an aluminum alloy.

3. The cable of claim 1 wherein the interior wires comprise a first set of interior wires and a second set of interior wires such that the second set of interior wires surrounds the first set of interior wires.

4. The cable of claim 1 wherein the high emissivity coating is homogenous.

5. The cable of claim 1 wherein the at least one metal oxide other than aluminum oxide comprises a mixture of metal oxides.

6. The cable of claim 1 wherein the coated wire coated with the high emissivity coating has an emissivity from about 0.5 to about 0.96.

7. The cable of claim 1 wherein each peripheral wire is coated with the high emissivity coating.

8. The cable of claim 1 wherein the high emissivity coating has a thickness from about 1 to 20 microns.

9. The cable of claim 1 wherein the high emissivity coating has a surface area of about 100 times greater than the surface area of the bare peripheral wire prior to being coated with the high emissivity coating.

10. The cable of claim 1 wherein the high emissivity coating has a surface area from 30 to 250 times greater than a surface area of a bare wire.

11. The cable of claim 1 wherein at least one wire has a surface roughened by knurling or rifling.

12. The cable of claim 1 wherein the high emissivity coating comprises an oxide selected from the group consisting of titanium oxide, zirconium oxide, hafnium oxide, tin oxide, germanium oxide, boron oxide, iron oxides, copper oxides, manganese oxides, cobalt oxides, cerium oxides, molybdenum oxides, tungsten oxides, yttrium oxides, bismuth oxides, zinc oxide, vanadium oxides and combinations thereof.

13. The cable of claim 1 wherein the high emissivity coating is an electro-ceramic coating.

14. The cable of claim 13 wherein the high emissivity coating is formed by a method comprising:

contacting a bare wire with a bath containing an aqueous solution with a precursor for the electro-ceramic coating;

operating an electrification device in electrical communication with the bare wire to electrify the bare wire with a high voltage and a high current; and

electrochemically reacting the bare wire with the precursor in the bath to deposit the high emissivity coating on an outer surface of the wire thereby producing a coated wire.

15. The cable of claim 1 wherein the at least one metal oxide other than aluminum oxide an oxide mixture comprises a first oxide and a second oxide, the first oxide and the second oxide each independently selected from the group consisting of titanium oxide, zirconium oxide, hafnium oxide, tin oxide, germanium oxide, boron oxide, iron oxides, copper oxides, manganese oxides, cobalt oxides, cerium oxides, molybdenum oxides, tungsten oxides, yttrium oxides, bismuth oxides, zinc oxide, and vanadium oxides.

16. The cable of claim 15 wherein the high emissivity coating comprises domains of the first oxide and domains of the second oxide.

17. The cable of claim 1 wherein the high emissivity coating comprises a plurality of pores, at least some of the plurality of pores having high emissivity particles physically incorporated therein.

18. The cable of claim 17 wherein the high emissivity particles are selected from particles of carbon black, lamp black, graphite, graphene, graphene oxide, copper sulfide, MnO.

19. A cable for power distribution applications, the cable comprising:

a plurality of wires bundled into a cable and extending along a central longitudinal axis of the cable;

the plurality of wires comprised of interior wires and peripheral wires with the peripheral wires surrounding the interior wires, at least one peripheral wire being a coated wire having deposited thereon a high emissivity electro-ceramic coating comprising at least one of titanium oxide and zirconium oxide; and

at least 10 weight percent aluminum oxide, the coated wire having an emissivity greater than or equal to 0.5 and a surface area at least 100 times greater than the surface area of a bare peripheral wire prior to being coated with the high emissivity coating.

20. The cable of claim 19 wherein the coated wire coated with the high emissivity coating has an emissivity from about 0.5 to about 0.96.

21. The cable of claim 19 wherein the high emissivity coating has a thickness from 1 to 20 microns.

22. The cable of claim 21 wherein the high emissivity coating comprises a plurality of pores, the plurality of pores having graphite disposed therein.

23. The cable of claim 19 wherein the high emissivity electro-ceramic coating comprises titanium oxide and zirconium oxide.

24. The cable of claim 19 wherein the high emissivity coating has a surface area of about 700 times greater than the surface area of the bare peripheral wire prior to being coated with the high emissivity coating.

25. A coated wire comprising:

a metal wire; and

a coating chemically adhered directly on the metal wire, the coating comprising at least one metal oxide other than aluminum oxide and at least 10 weight percent aluminum oxide, the coating having an emissivity greater than or equal to 0.5 and a surface area at least 20 times greater than the surface area of a bare wire prior to being coated with the coating.

26. The coated wire of claim 25 wherein the coating is an electro-ceramic coating and the at least one metal oxide other than aluminum oxide is selected from titanium oxide, zirconium oxide and combinations thereof.