Aluminum electrical wire and method for manufacturing aluminum electrical wire

• US 10,468,154 B2
• Filed: 06/25/2018
• Issued: 11/05/2019
• 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 Electric Company Limited
• Inventors: Uchiyama, Yasuharu, Sakaki, Akihiro
• Primary Examiner(s): Mayo, III, William H.
• Application Number:
  US16/017,321
• Publication Number:
  US 20180350487A1
• Time in Patent Office: 498 Days
• Field of Search: 174 36, 1741251, 1741252, 174110 R
• 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

A conductor including multiple aluminum-based core wires, and an insulating resin covering directly covering the conductor such that the insulating resin covering is in contact with the aluminum-based core wires. The aluminum-based core wires includes one aluminum-based core wire containing not less than 99 mass % of aluminum in a center of the conductor and aluminum-based core wires positioned concentrically from the center of the conductor, and the conductor is constructed by concentrically twisting 19 or 37 of the aluminum-based core wires in a non-compressed state and at a same pitch such that a thickness deviation of the insulating resin covering is not less than 70%.

Claims

1. An aluminum electrical wire, comprising:

a conductor comprising a plurality of aluminum-based core wires; and

an insulating resin covering directly covering the conductor such that the insulating resin covering is in contact with the plurality of aluminum-based core wires,

wherein the plurality of aluminum-based core wires includes one aluminum-based core wire containing not less than 99 mass % of aluminum in a center of the conductor and aluminum-based core wires positioned concentrically from the center of the conductor, and the conductor is constructed by concentrically twisting 19 or 37 of the aluminum-based core wires in a non-compressed state and at a same pitch such that a thickness deviation of the insulating resin covering is not less than 70%.

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

3. The aluminum electrical wire according to claim 2, wherein the 19 or 37 of the aluminum-based core wires constituting the conductor have core wire diameters that are identical.

4. The aluminum electrical wire according to claim 2, 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 2, wherein the insulating resin covering has a thickness of not less than 10% and not greater than 20% of an outer diameter of the conductor.

6. The aluminum electrical wire according to claim 2, wherein the insulating resin covering is made of vinyl chloride resin.

7. The aluminum electrical wire according to claim 1, wherein the 19 or 37 of the aluminum-based core wires constituting the conductor have core wire diameters that are identical.

8. 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.

9. 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 an outer diameter of the conductor.

10. The aluminum electrical wire according to claim 1, wherein the insulating resin covering is made of vinyl chloride resin.

12. The aluminum electrical wire according to claim 1, wherein the conductor is constructed by concentrically twisting 37 of the aluminum-based core wires, and the twisting pitch is set not less than 6.2 times and not greater than 15.7 times the outer diameter of the conductor.

13. The aluminum electrical wire according to claim 1, wherein a cross-sectional area of the conductor is not less than 5.0 mm² and less than 17 mm².

11. The aluminum electrical wire according to claim wherein the conductor is constructed by concentrically twisting 19 of the aluminum-based core wires, and the twisting pitch is set not less than 6.4 times and not greater than 22.0 times an outer diameter of the conductor.

14. A method for manufacturing an aluminum electrical wire, comprising:

constructing a conductor by twisting a plurality of aluminum-based core wires; and

directly covering the conductor with an insulating resin covering such that the insulating resin covering is in contact with the plurality of aluminum-based core wires and that a thickness deviation of the insulating resin covering is not less than 70%,

wherein the constructing of the conductor comprises twisting 6, 12, and 18 of the aluminum-based core wires concentrically from one aluminum-based core wire containing not less than 99 mass % of aluminum in a center, while setting a twisting pitch to not less than 6.2 times and not greater than 15.7 times an outer diameter of the conductor, and applying to the aluminum-based core wires a tensile force such that a tensile force per unit cross-sectional area is not less than 12.5 N/mm² and not greater than 56.3 N/mm².

15. The method for manufacturing an aluminum electrical wire according to claim 14, further comprising:

applying a softening treatment on the aluminum-based core wires prior to the constructing of the conductor.

16. The method for manufacturing an aluminum electrical wire according to claim 14, further comprising:

applying a softening treatment on the aluminum-based core wires between the constructing of the conductor and the covering of the conductor.

17. A method for manufacturing an aluminum electrical wire, comprising:

constructing a conductor by twisting a plurality of aluminum-based core wires; and

directly covering the conductor with an insulating resin covering such that the insulating resin covering is in contact with the plurality of aluminum-based core wires and that a thickness deviation of the insulating resin covering is not less than 70%,

wherein the constructing of the conductor comprises twisting 6 or 12 of the aluminum-based core wires concentrically from one aluminum-based core wire containing not less than 99 mass % of aluminum in a center, setting a twisting pitch to not less than 6.4 times and not greater than 22.0 times an outer diameter of the conductor, and applying a tensile force to the aluminum-based core wires such that a tensile force per unit cross-sectional area is not less than 12.5 N/mm² and not greater than 87.5 N/mm².

18. The method for manufacturing an aluminum electrical wire according to claim 17, further comprising:

applying a softening treatment on the aluminum-based core wires between the constructing of the conductor and the covering of the conductor,

wherein the twisting pitch is set to not less than 6.4 times and not greater than 16.9 times the outer diameter of the conductor, and the tensile force is applied to the aluminum-based core wires such that the tensile force per unit cross-sectional area is not less than 62.5 N/mm² and not greater than 87.5 N/mm².

19. The method for manufacturing an aluminum electrical wire according to claim 17, further comprising:

applying a softening treatment on the aluminum-based core wires prior to the constructing of the conductor

wherein the twisting pitch is set to not less than 8.6 times and not greater than 22.0 times the conductor outer diameter, and the tensile force is applied to the aluminum-based core wires such that the tensile force per unit cross-sectional area is not less than 12.5 N/mm² and not greater than 56.3 N/mm².

20. The method for manufacturing an aluminum electrical wire according to claim 19, wherein the constructing of the conductor comprises twisting an inner layer part comprising the plurality of aluminum-based core wires, and forming an outermost layer by twisting 18 aluminum-based core wires concentrically on an outer side of the inner layer part, 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 18 aluminum-based core wires such that a tensile force per unit cross-sectional area is 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 such that a tensile force per unit cross-sectional area is not less than 250.0 N/mm² and not greater than 1875.0 N/mm².