U.S. patent number 3,692,924 [Application Number 05/122,940] was granted by the patent office on 1972-09-19 for nonflammable electrical cable.
This patent grant is currently assigned to La Barge, Inc.. Invention is credited to Eugene A. Nye.
United States Patent |
3,692,924 |
Nye |
September 19, 1972 |
NONFLAMMABLE ELECTRICAL CABLE
Abstract
Nonflammable electrical cable resistant to combustion under
current overload conditions. The cable conductor is constituted by
one or more composite metal strands. Each strand has an aluminum
base core clad with copper and has an outer layer of silver, nickel
or tin. The conductor is wrapped with flexible fire-resistant
insulating material and the facing areas of the wrapping are sealed
with an adhesive which is kept out of contact with the conductor.
When subjected to a current overload in an oxygen atmosphere the
strand fuses, thereby interrupting the current, before either the
insulating material or the adhesive can ignite.
Inventors: |
Nye; Eugene A. (Yorba Linda,
CA) |
Assignee: |
La Barge, Inc. (St. Louis,
MO)
|
Family
ID: |
22405781 |
Appl.
No.: |
05/122,940 |
Filed: |
March 10, 1971 |
Current U.S.
Class: |
174/120SR;
337/142; 174/121A; 174/110N; 174/126.2 |
Current CPC
Class: |
H01B
7/295 (20130101); H01B 7/428 (20130101); H01H
85/0241 (20130101) |
Current International
Class: |
H01H
85/00 (20060101); H01B 7/42 (20060101); H01B
7/00 (20060101); H01B 7/295 (20060101); H01B
7/17 (20060101); H01H 85/02 (20060101); H01b
007/02 () |
Field of
Search: |
;174/12R,12C,12SR,121A,11N,126CP |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Goldberg; E. A.
Claims
What is claimed is:
1. Nonflammable electrical cable, resistant to combustion under
current overload conditions in an oxygen atmosphere, comprising a
composite metal strand comprising an aluminum base conductor core,
an annular cladding of copper metallurgically bonded to the surface
of the aluminum base core, an annular coating of a metal selected
from the group consisting of silver, nickel and tin overlying the
outside surface of the copper cladding, and an outer wrapping of
flexible fire-resistant insulating material on said composite
strand, said wrapping having facing areas with adhesive
therebetween for sealing purposes, said adhesive being entirely out
of contact with said composite strand, said cable being resistant
to combustion when subjected to a current overload in an oxygen
atmosphere with said strand being fused and the current being
interrupted before ignition of said insulating material or
adhesive.
2. A cable as set forth in claim 1 wherein the insulating material
is selected from the group consisting of polyimide and
amide-modified polyimide film.
3. A cable as set forth in claim 1 wherein said adhesive has a
softening point of between about 300.degree. F. and about
600.degree. F.
4. A cable as set forth in claim 1 having a plurality of said
strands within said wrapping.
5. A cable as set forth in claim 4 wherein the aluminum base core
is an alloy having an ultimate tensile strength of not less than
about 9,000 psi, an elongation of not less than about 8 percent,
and a conductivity of not less than about 60 percent I.A.C.S.
6. A cable as set forth in claim 5 wherein the aluminum base core
is constituted by an alloy containing between about 0.07 percent
and about 0.65 percent by weight iron, up to about 0.12 percent by
weight silicon, up to about 0.03 percent by weight magnesium,
between about 0.01 percent and about 0.03 percent by weight
manganese, between about 0.02 percent and about 0.04 percent by
weight copper, and between about 0.006 percent and about 0.011
percent by weight boron, the balance essentially aluminum with no
more than 0.001 percent by weight each of titanium, vanadium nickel
or chromium.
7. A cable as set forth in claim 6 wherein said adhesive material
is fluorinated ethylene propylene resin.
8. A cable as set forth in claim 4 wherein said wrapping has a
substantially uniform thickness of at least about 2 mils.
9. A cable as set forth in claim 4 wherein said wrapping includes
at least two individual layers of helically wrapped polyimide
tape.
10. A cable as set forth in claim 4 wherein the strands are woven.
Description
BACKGROUND OF THE INVENTION
In the design of high performance aircraft and space vehicles, one
of the more difficult problems is the provision of electrical
systems which present minimum hazard when the vehicle is in
operation. Electrical systems for both power and signal purposes
are essential to each of the various vital functions of the
vehicle, including propulsion, directional control and guidance. As
a consequence, electrical energy must be transmitted from the
electrical power sources to a multitude of points located
throughout the vehicle.
To insure the safety of the vehicle during operation, the
electrical transmission equipment must be secure against
short-circuiting or other misdirection of electrical energy and
against fire hazards under both normal and current overload
conditions. Thus the electrical conductor of the transmission
equipment must be insulated in a manner which prevents current
leakage to the surroundings and exposure of the surroundings to
excess temperatures, even when the conductor is seriously
overloaded. Moreover, the insulating material itself must be
resistant to combustion even when exposed to the temperatures to
which the conductor rises when overloaded.
Electrical cable which has been available heretofore has not proved
to be flame resistant under all the conditions to which it is
exposed in modern aircraft or spacecraft. The atmosphere in a space
vehicle normally consists of 95 percent or more by volume oxygen.
The combustibility of almost all materials is much greater in such
an atmosphere than it is in air, which contains only about 20
percent oxygen. Thus, even the most flame-resistant cable
insulation materials known will burn when exposed to such an
atmosphere at the temperatures to which conventional electrical
cable rises during an overload.
Among the best flexible cable insulation materials presently
available are fluorinated ethylene propylene resin (sold under the
trade designation "FEP Teflon" by E. I. DuPont de Nemours and
Company) and a polyimide resin (sold under the trade designation
"Kapton" by E. I DuPont de Nemours and Company). A high performance
cable which has been commercially available and which has been used
in the electrical systems of spacecraft consists of a copper
conductor surrounded by an insulating sheath of "FEP Teflon," the
latter in turn being surrounded by a dip coating of polyimide film.
Though quite satisfactory under normal service conditions, this
cable has not proved to be flame resistant when exposed to an
oxygen-rich atmosphere under electrical current overload
conditions. The inability of this cable to withstand such
conditions has been demonstrated by a standard test developed by
the National Aeronautics and Space Administration at the George C.
Marshall Spaceflight Center (Specification 101A, Jan. 12, 1970). In
this test, a sample of insulated wire or cable is placed in a
chamber whose atmosphere contains 95 percent by volume oxygen at
the operating pressure of a spacecraft, i.e., about 6.5 psia. After
the cable sample has been allowed to "soak" in the oxygen
atmosphere for a period of 10 minutes, a current is applied to the
sample by means of an external d.c. electrical power supply. The
initial test current is 5-20 amps. below the nominal fusion current
of the cable conductor, depending on the size of the wire tested.
If ignition is not obtained within one minute of the application of
current, the current is raised in 5-amp. steps at one minute
intervals until the conductor fails or ignition occurs. When
subjected to this test, the aforementioned cable has burned, as
evidenced by the emission of fumes and smoke, before the fusion
temperature of the conductor has been reached, despite the presence
of the external sheathing of polyimide material.
A substantial amount of research has been conducted by numerous
workers in the art in an effort to provide a nonflammable
electrical cable for use in aircraft and spacecraft which can
survive the NASA tests. Prior to the present invention, however, it
is believed that none of these efforts have been successful.
Numerous insulating materials and combinations thereof have been
tried with uniformly unsatisfactory results. The various insulating
materials which have been unsuccessfully tested on copper
conductors include all types of fluorocarbon tapes and extrusions,
including fluorinated ethylene propylene resin (sold under the
trade designation "FEP Teflon" by E. I. DuPont de Nemours and
Company), tetrafluoroethylene resin (sold under the trade
designation "TFE Teflon" by E. I. DuPont de Nemours and Company)
and poly vinylidene fluoride (sold under the trade designation
"Kynar" by the Pennwalt Corporation); tapes and braids of glass
wool fibers and "Kapton"; and various combinations of these
insulators including combinations of "Kapton" and glass fibers.
To insure against the possibility of fire generated by a current
overload on any of the cables which have been commercially
available heretofore, elaborate precautions are necessary if the
cable is used in an oxygen atmosphere. One accepted approach is to
encase the cable in ablative material and house the resulting
structure in aluminum channels partitioned at frequent intervals to
isolate various sections of the cable from one another. These two
measures serve to isolate a portion of cable whose insulation has
started burning and to impede access of oxygen to a site of
combustion. Though reasonably effective, these measures are not
only expensive in themselves but, more seriously, occupy space and
add a substantial amount of weight to a spacecraft or aircraft,
thus severely reducing its payload. A critical need has existed in
the art, therefore, for an electrical cable which is nonflammable
under overload conditions in an oxygen atmosphere and which,
consequently, does not require the use of elaborate space-wasting
and weight-wasting measures to avoid the serious hazards which
flammable-type cables otherwise present.
SUMMARY OF THE INVENTION
It is an object of the present invention, therefore, to provide a
high performance electrical cable which is nonflammable under
overload conditions even in an oxygen environment. It is a
particular object of this invention to provide such a cable which
can be subjected to the sever NASA test conditions without burning,
fuming or smoking. A further object of the invention is to provide
such a cable which possesses advantageous mechanical and electrical
properties. Other objects will be in part apparent and in part
pointed out hereinafter.
In substance, the present invention is directed to nonflammable
electrical cable, resistant to combustion under current overload
conditions in an oxygen atmosphere, comprising a composite metal
strand and an outer wrapping constituted by a flexible
fire-resistant insulating material. The composite strand comprises
an aluminum base conductor core, an annular cladding of copper
metallurgically bonded to the surface of the aluminum base core,
and an annular coating of a metal selected from the group
consisting of silver, nickel and tin overlying the outside surface
of the copper cladding. The wrapping of film insulation has facing
areas with adhesive therebetween for sealing purposes, but the
adhesive is entirely out of contact with the composite strand. The
cable is resistant to combustion when subjected to a current
overload in an oxygen atmosphere with the composite strand being
fused and the current being interrupted before ignition of the
insulating material or the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged transverse cross-sectional view of the cable
of the invention;
FIG. 2 is a plan view illustrating a preferred form of the film
insulation wrapping; and
FIG. 3 is a plan view showing another alternative form of the
wrapping.
Corresponding reference characters indicate corresponding parts
throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unlike the electrical cables which have hitherto been employed in
the electrical systems of high performance aircraft and spacecraft,
the cable of the present invention is resistant to combustion even
under current overload conditions in an oxygen atmosphere. More
particularly, the cable of this invention does not support
combustion when tested to failure in accordance with NASA's George
C. Marshall Spaceflight Center test (Specification 101A, dated Jan.
12, 1970). Thus, the cable may be used in oxygen atmospheres
without the elaborate and expensive precautions and resultant
reduction in payload which are required when prior art cables are
used. In its preferred embodiment, the cable of the invention
possesses advantageous mechanical properties which satisfy the
requirements for utilization of the cable in high performance
aircraft and spacecraft. These properties are preserved during
sealing of the insulation by careful control of temperature
conditions in the sealing oven. The cable also possesses
outstanding electrical properties and may be utilized in
essentially any power or signal service without short circuiting,
current leakage or excessive power consumption. Among particular
applications in which this cable has been found highly useful is
shielding against radio frequency interference and electromagnetic
interference.
The novel and unique combination of four essential design
principles provides the flame resistance of the cable of this
invention in an oxygen atmosphere. First, an insulating material
such as polyimide or an amide-modified polyimide is used which is
resistant to combustion at very high temperatures. Second, the
aluminum core conductor, which is used instead of conventional
copper fuses at a temperature on the order of 660.degree. C., far
below the 1,083.degree. C. fusion temperature of copper. The
resultant interruption of current, which takes place very quickly
once the fusion current is reached or exceeded, prevents the
insulation from reaching a temperature at which it can ignite. The
thermal insulating properties of the insulation contribute to rapid
fuse action by impeding dissipation of the heat generated on
overload. Third, the adhesive material, which normally has an
ignition point well below that of the insulation, is kept out of
contact with the conductor strand, being separated therefrom by at
least one layer of the insulation. In conjection with the quick
fuse action of the core, this prevents combustion from arising with
the adhesive. By contrast, conventional cables heretofore available
have commonly included a sheathing of polytetrafluoroethylene, or
similar materials having softening points and ignition temperatures
in the range of the adhesives, in direct contact with the
conductor. Fourth, the use of a wrapping of insulation instead of
an extruded sheathing provides a more uniform thickness of
insulation, free from holidays or other defects which occasionally
allow moisture leakage or current leadage in conventional cable.
Wrapped insulation is also generally more flexible than extruded
sheathing and is thus more resistant to cracking under conditions
of flexure.
Referring to FIG. 1 of the drawings, the novel cable of this
invention has an aluminum base conductor core 1 which is clad with
an annular layer of copper 3. The copper cladding is in turn coated
with an annular layer 5 of either silver, nickel or tin. The copper
cladding provides desirable termination properties not otherwise
possessed by aluminum conductors and the outer coating of silver,
nickel or tin further enhances the termination properties and
provides corrosion resistance. As FIG. 1 shows, the cable
preferably includes a plurality of composite metal strands bundled
together inside the insulation. The insulation is constituted by a
wrapping 7 of an insulation material such as polyimide or
amide-modified polyimide tape, with an adhesive 9 lying between
facing areas of the insulation wrapping for purposes of sealing the
insulation.
Different arrangements of the insulation are shown in FIGS. 2 and
3. FIG. 2 shows a preferred embodiment of the invention in which
two or more individual layers of insulation tape are helically
wrapped around the conductor with a layer of adhesive lying between
the two layers of insulation. Such an arrangement is also indicated
in FIG. 1. Alternatively, of course, a single layer of tape may be
helically wrapped around the conductor, with the trailing edge of
each wrap lapping the leading edge of the preceding wrap and a
layer of adhesive material lying between the facing areas thus
presented to form a helical seam. FIG. 3 shows another embodiment
in which the longitudinal center line of the tape is oriented
parallel to the longitudinal center line of the conductor with one
edge of the tape lapping the opposite edge in a single longitudinal
seam which is also parallel to the center line of the conductor.
The seam of FIG. 3 is formed by a layer of adhesive lying between
facing areas of the tape. In each embodiment, the adhesive material
is kept out of contact with the conductor, being separated
therefrom by at least one layer of the film insulation tape.
The composition of the aluminum base core is not critical insofar
as the nonflammability characteristics of the cable are concerned.
Thus, essentially any aluminum base alloy whose melting point is on
the order of that of aluminum will provide the fuse action which
protects against combustion of insulation materials such as
polyimide or amide-modified polyimide. However, because of the
mechanical and electrical properties which are desirable in an
electrical cable adapted for use in high performance aircraft or
spacecraft, it is preferable that the aluminum base core be
constituted by an alloy containing between about 0.07 percent and
about 0.65 percent by weight iron, up to about 0.12 percent by
weight silicon, up to about 0.03 percent by weight magnesium,
between about 0.01 percent and about 0.03 percent by weight
manganese, between about 0.02 percent and 0.04 percent by weight
copper, and between about 0.006 percent and about 0.011 percent by
weight boron with no more than 0.001 percent by weight each of
titanium, vanadium, nickel or chromium. The presence of the
indicated proportions of iron is especially important in increasing
the tensile strength of the aluminum alloy. Among the aluminum
alloys whose compositions fall within the above indicated ranges
may be mentioned the alloys sold under the trade designations "EC
Aluminum No. 1," "EC Aluminum No. 2," "CK-76" and "EC Aluminum No.
3" by the Aluminum Company of America, and the alloy sold under the
trade designation "Triple E" by the Southwire Company. The
compositions of these alloys and their associated physical
properties are shown in Table I. "CK-76" and "Triple E" are
particularly preferred alloys for the conductor core.
TABLE
I Chemical Composition - Percent Physical Properties Ti, elon- V,
ga- Conduct- Ni, Uts ti- ivity % Fe Si Mg Mn Cu B Cr KSI on
I.A.C.S.
__________________________________________________________________________
"EC .09 .054 .002 .001 .003 .007 less 14.2 12% 62.6 Al- than no. 1"
"EC .10 .052 .002 .001 .003 .006 .00170 15.7 9% 62.2 Al- no. 2" "EC
.14 .053 .002 .001 .002 .011 each 10.0 37% 63.6 Al no. 3" "Trip-
.60 .050 .002 .002.004 .006 17.0 18.002 .002 60.5 le E" "CK- .10
.12 .003 .003 .003 .003 17.0 16% 61.0 76"
__________________________________________________________________________
the copper cladding constitutes between about 12 percent and about
20 percent by volume of the composite metal conductor strand and is
metallurgically bonded to the aluminum base core. A number of
conventional methods may be employed to provide a metallurgical
bond of cladding to the aluminum conductor core. Among such methods
may be noted hot-dipping, flame-spraying, electroplating, or
solid-phase bonding (as described in U.S. Pat. Nos. 2,691,815 and
2,753,623).
Copper-clad aluminum alloy rod stock, from which the conductor may
be produced by conventional wire-drawing techniques, is
commercially available. Such stock having a diameter of
approximately five-sixteenths inch, for example, is available from
Texas Instruments Incorporated. By a series of conventional drawing
and annealing steps the rod stock may be drawn to any convenient
gauge. Preferably the stock is drawn to a diameter corresponding to
between 8 and 40 A.W.G. Strands of this size may be conveniently
woven into a cable bundle having a relatively high degree of
flexibility. Where there are no narrow radius bends in the cable as
installed or where no significant flexure in use is anticipated,
larger diameter strands may be used. In the latter case a bundle of
strands may be unnecessary, and the conductor may be constituted by
a single composite metal strand.
As indicated above, size reduction of copper-clad rod stock may be
accomplished by conventional techniques to produce a finished
strand having the desired mechanical and electrical properties. For
use in high performance aircraft and spacecraft, the finished
strand should have a tensile strength of at least about 9,000 psi,
an elongation of not less than about 8 percent and a conductivity
of not less than about 60 percent I.A.C.S. (conductivity relative
to conductivity of copper conductor of same cross section). As
indicated in Table I, the preferred aluminum base conductor core
materials have properties which are substantially superior to these
minimums. During size reduction of the copper-clad rod stock, the
ratio of copper volume to total volume remains substantially
constant. Thus the volume of copper produced on the finished
conductor strand can be predetermined by cladding the rod stock
with that proportionate volume of copper.
The annular layer of nickel, silver or tin is preferably applied to
the copper-clad aluminum base stock prior to the drawing operation,
though silver or tin may be applied after drawing if desired. A
silver or tin layer may be provided by hot-dipping, while a layer
of nickel must be applied by extrusion. Copper-clad aluminum rod
having an annular outer layer of nickel is commercially available
from Texas Instruments Incorporated and is sold by it under the
trade designation "DFE3."
Regardless of which metal is used for it, the outer layer should
have a thickness of at least about 40 microinches after drawing. As
with the copper cladding, the annular cross-sectional area of the
silver or nickel coating is reduced proportionately to the
reduction of the core area during drawing. The thickness of the
outer coating may then be similarly predetermined.
The wrapping of insulation is preferably constituted by a film of
polyimide resin (sold under the trade designation "Kapton" by E. I.
DuPont de Nemours and Company) or amide-modified polyimide resin
(sold under the trade designation "AI" by Westinghouse Electric
Corporation). These resins are described in U.S. Pat. Nos.
3,179,634 and 3,179,635, respectively. As will be apparent to
anyone skilled in the art, however, other flexible fire-resistant
insulating materials which will survive the failure of the
conductor under overload conditions in an oxygen atmosphere, as
demonstrated by the NASA test conditions, can also be utilized.
Very few such materials are known in the present state of the art.
None has been found which survives failure of a copper conductor.
By use of a copper-clad aluminum conductor and by keeping the
adhesive out of contact with the conductor, polyimide and
amide-modified polyimide film insulations survive the fusion of the
conductor on overload. Thus, any flexible insulation material which
resists combustion at the temperatures to which it is exposed under
such circumstances would serve equally well.
The thickness of the insulation wrapping should be at least about
0.5 mil. Desirably, the wrapping is constituted by two or more
layers of 1-2 mils thick polyimide film having a backing of 0.1-0.5
mil "FEP." Thus the insulation as a whole has a total thickness of
3-10 mils, depending in part on the extent of lapping. Greater
thicknesses can be utilized but are not normally necessary.
The use of an adhesive material is necessary to seal the insulation
wrapping in order to impede electrical current leakage or the
access of either moisture or oxygen to the conductor. The adhesive
material should be flame resistant under normal conditions and
should have a softening point of between about 300.degree. F. and
about 600.degree. F. If the softening point of the adhesive is
substantially less than 300.degree. F., it may melt prematurely on
overload and seep past the film insulation into contact with the
conductor, thus being exposed to high temperatures and raising the
hazard of fire. If the adhesive has a softening point substantially
greater than 600.degree. F., on the other hand, the mechanical and
electrical properties of the conductor may be adversely affected by
the excessive temperatures required in the process of sealing the
insulation with the adhesive. Among the adhesive materials which
possess the characteristics necessary for use in the cable of this
invention may be noted the epoxy adhesive films sold under the
trade designations "CMC 15" and "CMC 16" by the Circuit Materials
Co., the polyester adhesive sold under the trade designation "46950
Polyester Adhesive" by E. I. DuPont de Nemours and Company, the
polyamide-imide sold under the trade designation "TR 150-25" by
Thermo-Resist, Inc., the silicones sold under the trade
designations "SR-585" by the General Electric Company and "DC-280"
by Dow Corning Corporation, the epoxy sold under the trade
designation "D.E.N. 438" by the Dow Chemical Company, the nitrile
rubber phenolic sold under the trade designation "Plastilock 605"
by the B. F. Goodrich Company, and the fluorinated ethylene
propylene resin sold under the trade designation "FEP Teflon" by E.
I. DuPont de Nemours and Company. "FEP Teflon" is a preferred
adhesive since its softening point is at the upper end of the
300.degree. - 600.degree. F. range. It thus has a high degree of
stability during the subjection of the cable to a current overload,
without creating insuperable problems in the process of applying
the insulation to the conductor.
After the tape insulation has been wrapped around the conductor
strands the adhesive lying between facing areas of the insulation
is fused to seal said facing layers together. The adhesive is fused
by raising it to a temperature at or above its softening point for
a period sufficient for it to form a strong bond to each of the
facing areas of the tape between which it lies. This operation is
conveniently performed in an oven. Where an adhesive having a
relatively high softening point such as "FEP Teflon" is employed,
residence time in the oven is preferably held to a minimum to avoid
adverse effects on the mechanical properties of the conductor
strands. Exposure to sealing temperatures for excess periods of
time can also result in seepage of the adhesive past the tape
insulation and into contact with the conductor or can adversely
affect the silver or nickel plating.
A method has been developed for applying the film insulation
wrapping and sealing it with the adhesive which assures a high
integrity seal while protecting the other essential properties of
the cable. In this method, an insulation tape is used which has a
backing of adhesive material. The tape is wrapped around the
conductor with the backing facing outwardly. The wrapped cable is
then moved continuously through an oven having a temperature
profile which is a function of the nature of the adhesive. Thus,
the inlet temperature of the furnace should not be higher than
about 600.degree. F. while the outlet temperature should be between
the softening point temperature of the adhesive and about
850.degree. F.
To avoid overheating of the wire with consequent loss of mechanical
properties and also to avoid seepage of the adhesive or
deterioration of the outer layer of the composite conductor, the
cable is moved through the oven at a rate sufficient to raise the
adhesive temperature up to its softening point but not
substantially above it. Because the conductor strands not only act
as a heat sink but through axial heat transfer cause the loss of
heat from the furnace, the residence time required to bring the
adhesive to the desired temperature varies radically with the
cross-sectional area of the conductor strands contained in the
cable. Thus for "FEP Teflon" adhesive, where the inlet oven
temperature is 600.degree. .+-. 10.degree. F. and the exit oven
temperature is 850.degree. .+-. 10.degree. F., it has been
determined that the following residence times must be maintained
within .+-. 5 percent to insure a high integrity seal without
adversely affecting the properties of the cable.
TABLE II
Residence Cable Size Stranding Time (Min.)
__________________________________________________________________________
30 1 .times. 30 solid 0.33 26 19 .times. 38 ga. 0.40 24 19 .times.
36 ga. 0.45 22 19 .times. 34 ga. 0.50 20 19 .times. 32 ga. 0.55 16
19 .times. 29 ga. 0.71 12 19 .times. 27 ga. 0.91 128 .times. 38 1.8
162 .times. 40 2.0
__________________________________________________________________________
The following examples illustrate the invention.
EXAMPLE 1
A cable was prepared in accordance with the invention having 19
29-gauge woven composite metal strands. The copper cladding
constituted 15 percent by volume of each strand and was coated with
a 50 microinch thick layer of silver. Two individual layers of
"Kapton" film insulation tape were helically wound around the woven
strands. The inner layer was 2 mils thick and had a 0.5 mil thick
layer of "FEP" on its outer side. The outer layer was 1 mil thick,
and had a 0.1 mil thick layer of "FEP" on each side. The insulation
was sealed by passing the cable through an oven with an inlet
temperature of 600.degree. F. and an outlet temperature of
850.degree. F. with the residence time in the oven being about 43
seconds.
From the cable thus prepared, a number of lengths of cable samples
were cut. From these cable samples, a test bundle was prepared
consisting of seven lengths of cable, six of which were 12 inches
in length, and one of which was 13 inches in length. The bundle was
bound together in three places 4 inches apart using lacing tape.
The 13 -inch length of cable was positioned on the exterior of the
bundle and had a 1/2 -inch length of insulation stripped from each
of its ends. The lengths of cable which formed the bundle were
located parallel to each other and one end of the bundle was
twisted 180.degree. relative to the other end.
The exposed ends of the 13 -inch length of cable were connected to
two horizontally mounted electrical terminals in a test chamber
having a volume of 98 l. The chamber included a center support for
the cable sample spaced approximately half way between the two
electrical connections. The chamber was also provided with a
pressure gauge capable of measuring pressure to an accuracy of .+-.
0.1 psia, an oxygen supply and a window for observing and
photographing test results.
The electrical terminals inside the chamber were externally
connected to a d.c. electrical power supply capable of supplying a
250 amp. steady current.
The test chamber was evacuated to a total pressure of less than 5
torr. Oxygen gas containing less than 5 percent by volume of
nitrogen and other inert gases was then introduced into the chamber
until the pressure of the chamber reached 6.5 psia. The cable
sample bundle was allowed to "soak" in the oxygen atmosphere for 10
minutes, and then a current of 100 amp., 20 amp. below the nominal
fusion current, was applied to the 13 -inch cable by means of the
external d.c. power source. Twelve seconds following the
application of current, the cable failed. No evidence of
combustion, either smoke, fumes or darkening, was evident either
before or after cable failure. The sample bundle was removed from
the test chamber and examined. By cutting away a portion of the
insulation of the 13 -inch cable, it was determined that fusion of
the composite metal conductor strands had taken place and that the
conductor strands had consequently ruptured, causing an
interruption in current.
EXAMPLES 2-12
Additional sample lengths were cut from cable prepared in
accordance with the method described in Example 1. Eleven bundles
of cable samples, each containing six 12 -inch lengths and one 13
-inch length, were prepared and tested according to the method
described in Example 1. Each of these samples failed at 100 amp.
within the time set forth in Table III.
TABLE
III Example Current Time to Failure
__________________________________________________________________________
2 100 amp. 13 seconds 3 100 amp. 13 seconds 4 100 amp. 14 seconds 5
100 amp. 15 seconds 6 100 amp. 21 seconds 7 100 amp. 17 seconds 8
100 amp. 3 seconds 9 100 amp. 9 seconds 10 100 amp. 10 seconds 11
100 amp. 12 seconds 12 100 amp. 7 seconds
__________________________________________________________________________
No evidence of combustion was evident, either before or after cable
failure. Examination of the cable showed that fusion and rupture of
the composite metal conductor strands had taken place as in Example
1.
No other flexible electrical cable, either commercial or
experimental, is known to have passed this test.
In view of the above, it will be seen that the several objects of
the invention are achieved and other advantageous results
attained.
As various changes could be made in the above products without
departing from the scope of the invention, it is intended that all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
* * * * *