MXPA98003858A - Automotive electric conductor flexible high mechanical resistance, based on copper alloys and process for your obtenc - Google Patents

Abstract

It involves the fabrication of a symmetrical 7 wire hybrid conductor (1 hard copper alloy wire to the center - 6 hard ETP copper wires in the periphery) in 24 gauge and 26 AWG that meets Ford SAEJ1678 specifications as regards electrical resistance and load to rupture, in order to have an outer diameter that forms a tubular wall with very slight undulation

Description

AUTOMATIC ELECTRIC CONDUCTOR FLEXIBLE ALTA MECHANICAL RESISTANCE, BASED ON COPPER ALLOYS AND PROCESS FOR ITS OBTAINING BACKGROUND OF THE INVENTION Among the technological developments of the automotive industry is the processes focused on the manufacture of primary low voltage cable for use in automotive vehicles.

The requirements of the automotive industry worldwide for materials which will be employed in the short term (year 2000), are based on the following: • Trends in the automotive market worldwide • Alternatives to meet the demands of the automotive industry.

• Standards and specifications, present and future of the automotive industry.

• Commercially available materials that, according to your properties, can meet the requirements of the automotive cable. • Trends in the automotive industry have focused on the reduction of weight to have a lower demand for fuel. On the other hand, the demand for vehicles that offer greater safety, luxury and comfort, and the consequent need for cables for the different additional circuits, has been multiplied in a short time and will continue to multiply during the coming years.

The reduction in the diameter of the conductor with the same mechanical characteristics of the conductors used in the harnesses for automobiles, is the alternative by which the designers have opted and will continue being the tendency of greater application during the next years. This forces the driver to consider materials of greater mechanical strength than copper, while maintaining an adequate balance of mechanical strength / electrical conductivity that meets the specifications.

Currently there are two proposals for automotive cable specifications that cover the characteristics described above, these being: Standard SAEJ1678- "Low Voltage, Ultra Thin Wall Primary Cable" (primary low voltage, ultra-thin wall cable) Engineering specification of the FORD- "Cable, Primary Low voltage 0.25 mm and 0.15 mm Wall" (primary low voltage cable 0.25 mm and 0.15 mm wall).

These specifications do not describe the materials with which the conductors must be manufactured, but they establish a minimum breaking load, as well as a maximum electrical resistance; in this case, the present invention covers the conductors of gauge 24 and 26 AWG, which present as a condition of design a symmetrical formation of 7 threads.

Currently, conductors used for sizes below 22 AWG are manufactured from 100% copper alloys, which must cover a mechanical and electrical resistance that meets the above specifications.

It is therefore an object of the invention to produce: Hybrid conductors with a symmetrical construction of 7 wires, that is to say, to use a wire of high resistance to the center and 6 wires of copper ETP hard in the periphery, for the case of the conductor in caliber 24 AWG, the 7 wires are of caliber 32 AWG , while in the case of the conductor in 26 AWG caliber, the central wire is of 33 AWG caliber, while the 6 wires of the periphery are of 34 AWG caliber.

DESCRIPTION OF THE INVENTION The invention is described below in more detail in order to better illustrate it, where: Figure 1 shows the cross section and longitudinal section of the 24 gauge conductor and in fig. 2 also shows the cross section and longitudinal of a conductor but with caliber 26 AWG, and its main characteristic is that it is a hybrid conductor, that is to say the central wire must be of high resistance which must have a mechanical resistance superior to that of electrolytic copper in hard state, while the peripheral wires must be electrolytic copper in hard state.

The automotive electrical conductor 10 is a symmetrical hybrid conductor 15 consisting of a 7 wire assembly 11 both in FIG. 1 as in 2, for the case of the conductor in 24 AWG caliber, the 7 wires are in 32 AWG caliber, while for the 26 AWG caliber conductor the central wire 12 is in 33 AWG caliber and the 6 peripheral wires 16 in 34 AWG caliber. for both conductors the central wire 12 is copper alloy in hard state and must have a mechanical strength greater than 90 kg / mm2 with a minimum elongation of 1%, while the peripheral wires in both conductors are hard copper ETP and must have a mechanical strength greater than 50 kg / mm2 with a minimum elongation of 1%.

The high strength materials are Copper Ciad Steel with 40% conductivity, C23000 brass and C27000 brass.

The step is the straight length at which the same conductor wire appears at an analogous point having traveled helically to the conductor, this variable must be such that the central wire is always located at the center of the conductor, so for the conductor in 24 AWG gauge must have a step 13 less than 15 mm and for the conductor in 26 AWG gauge, step 14 must be less than 10 mm In the following table 1 the characteristic properties of the conductor such as physical, mechanical and electrical that each one of the conductors must cover are indicated.

TABLE I Next, the procedure for manufacturing said flexible rope type electric conductor with high mechanical resistance based on high resistance materials with copper content useful for automotive service is described.

The procedure comprises the steps of: Coarse stretching; Final stretch, (Copper and high strength materials); The 24 AWG gauge, or 26 AWG high resistance, gauge 33 AWG is then assembled. According to the previous stages; ETP Copper Coarse Thickness Beginning with 8 mm diameter ETP copper wire in the annealed state, which is stretched to obtain a 13 AWG gauge wire in the annealed state.

ETP copper final drawing It is obtained starting from a 13 gauge wire in annealed state, which is stretched in a single step in a single line or multiline machine up to 32 AWG wire in the case of the conductor in 24 AWG and 34 AWG gauge, for the case of the conductor in 26 AWG caliber, both wires in hard state.

Stretched finish high strength materials.

The materials can be purchased in 20 AWG wire in annealed state and stretch them in a single step up to 32 AWG gauge, in the case of the driver in 24 AWG and 33 AWG in the case of the conductor in 26 AWG both in hard state.

Gathered 24 gauge conductor AWG In this stage a meeting machine is used in which, a symmetrical construction of 7 wires is made, the central wire is of high resistance in 32 AWG caliber and the 6 peripheral wires are hard copper ETP in caliber 32 AWG the conductor pitch must be less than 15 mm. to ensure the centering of the copper alloy wire; and Gathered conductor 26 gauge AWG In this stage a meeting machine is used in which, a symmetrical construction of 7 wires is made, the central wire is of high resistance in caliber 33 AWG and the 6 peripheral wires are hard copper ETP in caliber 34 AWG the conductor pitch must be less than 10 mm. to ensure the centering of the copper alloy wire.

Among the advantages offered by the hybrid driver are: Be a conductor with a hard high strength wire to the center and hard copper ETP in the periphery and not 100% copper alloy.

Be a driver smaller and lighter than current drivers but with a higher breaking load, as well as an electrical resistance within the automotive specifications for copper alloys.

This cable should be manufactured taking care that when assembled there is a voltage control such that the alloy wire is always in the center of the conductor to comply with the maximum electrical resistance specified and achieve an excellent surface finish.

Table I presents the physical, mechanical and electrical properties that each of the conductors must cover.

Table II describes the chemical composition of the wires used in the manufacture of hybrid conductors The CCS is composed of 1002 carbon steel coated with an ETP copper layer with a conductivity of 40%.

Having described the invention is considered a novelty and therefore the content is claimed in the following

Claims (1)

1. R E I V I N D I C A C I O N S Flexible automotive electrical conductor of high mechanical strength based on copper alloys, characterized by being of hybrid construction in 24 AWG caliber and 26 AWG, composed of a helical assembly of seven wires with a step less than 15 mm. Y 10 mm respectively; being the central wire based on a high strength material in hard state with a mechanical strength greater than 90 Kg / mm2 and minimum elongation of 1%; and being the six peripheral wires only of hard ETP copper with a mechanical resistance higher than 50 Kg / mm2 and minimum elongation of 1% that allow to obtain a smaller and lighter conductor than the conventional ones but with a higher breaking load and a higher resistance Electrical within the automotive specifications for copper alloys. Flexible automotive electrical conductor of high mechanical strength in accordance with clause 1, characterized in that the conductor in 24 AWG gauge, is constituted by a meeting of seven symmetrical wires one central and six peripherals all manufactured in 32 AWG gauge; while for a conductor in 26 AWG gauge, the central wire is manufactured in 33 AWG gauge and the six peripheral wires are manufactured in 34 AWG gauge, with the central wire in both gauges 24 and 26 of a high strength material in state hard and the six peripheral wires on both conductors are hard ETP copper. Flexible automotive electrical conductor of high mechanical strength, in accordance with clause 1, characterized in that the helical path for a conductor of 24 AWG gauge is less than 15 mm. and the passage for the conductor in 26 AWG gauge must be less than 10 mm. A method for manufacturing an automotive electrical conductor of clauses 1 to 3, characterized in that it comprises the steps of: coarse stretching, final drawing, copper and materials of high annealed mechanical strength; The 24 AWG gauge conductor assembly is then made with a 32 AWG heavy duty hard core core wire and joined with six 32 AWG hard ETP copper peripheral wires; If the 26 AWG gauge is required, part of a hard 33 AWG gauge wire and the assembled of the other six 34 AWG hard ETP copper peripheral wires. A copper alloy for manufacturing a flexible automotive electrical conductor of high mechanical strength of clauses 1 to 3, characterized in that it comprises a composition of 65-90% copper, (brass C 23000 and brass (27000); 35% of Zn. A copper alloy for manufacturing a flexible automotive electrical conductor of high mechanical strength in accordance with clause 5, characterized in that it preferably comprises a copper blend of 70 to 90% and Zn of 10 to 30%. A composite material with high strength for manufacturing a flexible automotive electrical conductor of high mechanical strength of clauses 1 to 3, characterized in that it comprises a copper-coated steel wire with a conductivity of 40%. E X T R A C T O It involves the fabrication of a symmetrical 7 wire hybrid conductor (1 hard copper alloy wire to the center - 6 hard ETP copper wires in the periphery) in 24 gauge and 26 AWG that meets Ford SAE J1678 specifications. to electrical resistance and load to the rupture, in order to have an outer diameter that forms a tubular wall with very slight undulations.