WO2026024902A1 - Procédés et appareils pour coupler des conducteurs composites à l'aide d'explosifs - Google Patents

Procédés et appareils pour coupler des conducteurs composites à l'aide d'explosifs

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Publication number
WO2026024902A1
WO2026024902A1 PCT/US2025/038955 US2025038955W WO2026024902A1 WO 2026024902 A1 WO2026024902 A1 WO 2026024902A1 US 2025038955 W US2025038955 W US 2025038955W WO 2026024902 A1 WO2026024902 A1 WO 2026024902A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductor
coupler
optical fiber
strength member
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/038955
Other languages
English (en)
Inventor
Jianzhong Jason HUANG
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ts Conductor Corp
Original Assignee
Ts Conductor Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ts Conductor Corp filed Critical Ts Conductor Corp
Publication of WO2026024902A1 publication Critical patent/WO2026024902A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/08—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected by an explosion
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G7/00—Overhead installations of electric lines or cables
    • H02G7/05—Suspension arrangements or devices for electric cables or lines
    • H02G7/053—Suspension clamps and clips for electric overhead lines not suspended to a supporting wire
    • H02G7/056—Dead-end clamps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/32—Insulated conductors or cables characterised by their form with arrangements for indicating defects, e.g. breaks or leaks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/005—Power cables including optical transmission elements

Definitions

  • the electrical grid is a major contributor to greenhouse emissions and global warming.
  • the US electrical grid is more than 25 years old and globally about 2,000 TWh electricity is wasted annually, and about 1 Billion Metric Ton of GHG emission is associated with just compensatory generation.
  • Numerous distribution lines are coupled to each other via couplers and to dead ends to span over long distances. Coupling the distribution lines to couplers can take significant amount of time and manpower which can increase installation costs.
  • Embodiments described herein relate generally to methods and apparatuses for coupling electrical conductors to couplers using explosives.
  • a coupler includes a body defining a channel therethrough, and an explosive material disposed around the body. The coupler is movable between a first Attorney Docket No.
  • TSCD-006/01WO 346332-2078 configuration in which an end of a conductor is removably disposed in the channel defined by the coupler, the conductor including a strength member including: a core formed from a composite material and an encapsulation layer disposed around the core, and a conductor layer disposed around the strength member, and a second configuration in which the explosive material is detonated to cause the coupler to be fixedly coupled to the end of the conductor.
  • a sleeve is disposed around the body, the explosive material disposed around the sleeve.
  • a method includes: removing a portion of a first conductor layer from an end of a first conductor to expose a portion of a first strength member; inserting the end of the first strength member into a channel defined by a coupler; removing a portion of a second conductor layer from an end of a second conductor to expose a portion of a second strength member; inserting the end of the second strength member into the channel defined by the coupler; and detonating explosive material coupled to the coupler to cause the coupler to be coupled to the first and the second conductor.
  • a method includes: removing a portion of a conductor layer from an end of a conductor to expose a portion of a strength member; inserting the end of the first strength member into a channel defined by a coupler; and detonating explosive material coupled to the coupler to cause the coupler to be coupled to the conductor.
  • FIG. 1 is a schematic illustration of an assembly including a conductor and a coupler configured to be coupled to the coupler, according to an embodiment.
  • FIG.2 is front cross-section view of a conductor, according to an embodiment.
  • FIG.3 is a front cross-section view of a conductor, according to an embodiment.
  • FIG.4 is a front cross-section view of a conductor, according to an embodiment.
  • FIG. 5A is a schematic illustration of a first conductor and a second conductors having axial ends thereof disposed in a coupler that has an explosive material disposed on an outer surface of the coupler, in an uncoupled configuration, according to an embodiment;
  • FIG. 5B is a schematic illustration of the coupler and first and second conductors of FIG. 5A in coupled configuration in which the first and second conductors coupled to each other via the coupler after detonating the explosive material.
  • FIG. 5A is a schematic illustration of a first conductor and a second conductors having axial ends thereof disposed in a coupler that has an explosive material disposed on an outer surface of the coupler, in an uncoupled configuration, according to an embodiment
  • FIG. 5B is a schematic illustration of the coupler and first and second conductors of FIG.
  • FIG. 6 is a schematic flow chart of a method for coupling a first conductor to a second conductor via a coupler using explosives disposed on the coupler, according to an embodiment.
  • FIG. 7A is a schematic illustration of a conductor having an axial end thereof disposed in a coupler that has an explosive material disposed on an outer surface of the coupler, in an uncoupled configuration, according to an embodiment;
  • FIG.7B is a schematic illustration of the coupler and the coupler of FIG.7A in a coupled configuration in which the conductor is coupled to the coupler after detonating the explosive material.
  • FIG.8 is a schematic flow chart of a method for coupling a conductor to a coupler using explosives disposed on the coupler, according to an embodiment.
  • Embodiments described herein relate generally to methods and apparatuses for coupling electrical conductors to couplers using explosives.
  • embodiments described herein relate to methods and apparatuses for coupling conductors that include a strength member including a composite core and an encapsulation layer disposed around the composite core, and a conductor layer disposed on the strength member, to dead-end couplers, splicing couplers, or any other couplers using explosives.
  • TSCD-006/01WO 346332-2078 One way to improve electrical transmission is to provide conductors that are lighter than traditional conductors, have higher strength, provide high electrical transmission, and can be easily integrated in the current electrical grid system, as well as underground transmission systems. Another way is to integrate sensors within the conductors such that various operating parameters of the conductors such as, for example, sag, fault location, temperature sensing, tension load, etc., can be measured passively and/or in real time. This can lead to awareness of the conductor and circuit condition for in system reliability and resiliency, operational flexibility, and optimization of the PowerGrid performance at all times, including much needed accurate situational awareness during extreme weather events. [0022] Conventional conductors, however, fail to provide such benefits.
  • Another challenge to modernizing the electrical grid is the time and cost associated with installing, mounting, or laying down new electrical conductors, particularly the time and manpower conventionally used for coupling conductors to each other via splicing couplers or to dead end couplers for terminating the conductor at an electrical pole or tower.
  • coupling conductors to couplers can involve using special tools for crimping or coupling the couplers to the conductors, difficult crimp placement, output calibration, extensive conductor preparation, use of oxide inhibitors to protect surfaces of the conductors, generation of coronas when hydraulic joints are used that can create hotspots on the conductors leading to breakdown over time, high splice resistance that can be as much as 95% of the conductor’s resistance, and spending as much as 4-6 hours for manual crimping of a small number of conductors.
  • embodiments of the methods and apparatus described herein for coupling conductors that include a strength member and a conductor layer disposed around the strength member, to couplers via explosives may provide one or more benefits including, for example: 1) providing a strength member that has a gap free encapsulation layer around a Attorney Docket No.
  • TSCD-006/01WO 346332-2078 composite core that inhibits presence of air, oxygen, and/or electrolytes at the interface between the encapsulation layer and the core, thereby protecting encapsulation layer and core interface from corrosion, and the core from oxidation, moisture plasticization, ultraviolet (“UV”) light, corrosion, and environmental degradation; 2) protecting the composite core from compression and bending failures via the encapsulation layer; 3) providing cushioning via the encapsulation layer to protect the composite core during coupling of the conductor with couplers by implosion force exerted by exploding explosive materials disposed on the coupler, thereby reducing installation cost by obviating the use of special tools, special training, or custom couplers; 4) increase conductor strength and preserve residual tension in the composite core during manufacturing of the strength member such that any compressive stress in the conductor has to first overcome the pre-existing tension in the composite core, thereby delaying buildup of compressive stress and inhibiting compression buckling failure that is associated with conventional conductors, as well
  • FIG. 1 is a schematic illustration of an assembly 100 including at least one conductor 102 coupleable to a coupler 140, according to an embodiment.
  • the coupler 140 may include a splice coupler configured to couple two conductors to each other (e.g., couple a first conductor 102 to a second conductor 102), a dead end couple, configured to couple the conductor 102 to a pole or tower, or any other suitable coupler as described herein.
  • the conductor 102 includes a strength member 110 including a composite core 112 (also referred to herein as “core 112”) and an encapsulation layer 114 disposed around Attorney Docket No. TSCD-006/01WO 346332-2078 the core 112.
  • An optical fiber assembly 150 disposed in the core.
  • a conductor layer 120 is disposed around the strength member 110, and optionally, an insulating layer 122 is disposed on the conductor layer 120.
  • an outer coating may be 130 disposed on the insulating layer 122 or the conductor layer 120, and/or an inner coating may be 116 disposed around strength member 110 i.e., between the conductor layer 120 and the strength member 110.
  • the encapsulation layer 114 is disposed circumferentially around the core 112.
  • the core 112 may be formed from a composite material.
  • the composite material may include nonmetallic fiber reinforced metal matrix composite, carbon fiber reinforced composite of either thermoplastic or thermoset matrix, or composites reinforced with other types of fibers such as quartz, AR-Glass, E-Glass, S-Glass, H-Glass, silicon carbide, silicon nitride, alumina, basalt fibers, especially formulated silica fibers, any other suitable composite material, or any combination thereof.
  • the composite material includes a carbon fiber reinforced composite of a thermoplastic or thermoset resin.
  • the reinforcement in the composite strength member(s) can be discontinuous, for example, include whiskers or chopped fibers, or continuous fibers in substantially aligned configurations (e.g., parallel to axial direction) or randomly dispersed (including helically wind or woven configurations).
  • the composite material may include a continuous or discontinuous polymeric matrix composites reinforced by carbon fibers, glass fibers, quartz, or other reinforcement materials, and may further include fillers or additives (e.g., nanoadditives).
  • the core 112 may include a carbon composite including a polymeric matrix of epoxy resin cured with anhydride hardeners. [0028] The core 112 may have any suitable cross-sectional width (e.g., diameter).
  • the core 112 has a diameter in a range of about 3 mm to about 15 mm, inclusive (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 mm, inclusive). In some embodiments, the core 112 may have a diameter in a range of about 5 mm to about 10 mm, inclusive. In some embodiments, the core 112 may have a diameter in a range of about 10 mm to about 15 mm, inclusive. In some embodiments, the core 112 may have a diameter in a range of about 7 mm to about 12 mm, inclusive. In some embodiments, the core 112 may have a diameter of about 9 mm. Attorney Docket No.
  • the core 112 may have a first glass transition temperature (e.g., for thermoset composites), or melting temperature (e.g., for thermoplastic composites).
  • the first glass transition temperature or melting temperature is in a range of about 100 degrees Celsius to about 350 degrees Celsius, inclusive (e.g., about 100, about 110, about 120, about 130, about 140, about 150, about 160, about 170, about 180, about 190, about 200, about, 210, about 220, about 230, about 240, about 250, about 260, about 270, about 280, about 290, about 300, about 310, about 320, about 330, about 340, or about 350 degrees Celsius, inclusive).
  • the first glass transition temperature or melting temperature may be at least about 70 degrees Celsius (e.g., at least 100, at least 120, at least 140, at least 150, at least 160, at least 180, at least 200, at least 220, at least 240, at least 250 , at least 260, at least 270, at least 280, at least 290, or at least 300, degrees Celsius, inclusive).
  • the glass transition temperature or melting temperature of the core 112 may correspond to a threshold operating temperature of the conductor 102, which may limit the ampacity of the conductor 102.
  • a maximum amount of current that can be delivered through the conductor 102 is the current at which the operating temperature of the conductor 102, or at least the temperature of the core 112 is less than the glass transition temperature or melting temperature of the composite core 112.
  • the core 112 defines a circular cross-section.
  • the core 112 may define an ovoid, elliptical, polygonal, or asymmetrical cross- section.
  • the strength member 110 may include a single core 112. In other embodiments, the strength member 110 may include multiple cores, for example, 2, 3, 4, or even more, with the encapsulation layer 114 being disposed around the multiple cores or around each individual core.
  • each of the multiple cores may be substantially similar to each other, or at least one of the multiple cores may be different from the other cores (e.g., have a different size, different shape, formed from a different material, have components such as the optical fiber assembly 150 embedded therein, etc.).
  • an optical fiber assembly 150 e.g., one or more optical fiber assemblies
  • the optical fiber assembly 150 may be disposed axially along or Attorney Docket No.
  • the optical fiber assembly 150 includes a fiber core 152 and a fiber encapsulation layer 154 disposed around the fiber core 152.
  • the fiber core 152 may include an optical fiber (e.g., a single-mode optical fiber, a multi-mode optical fiber, a graded index fiber, a step index fiber, a glass optical fiber, a plastic optical fiber, any other suitable optical fiber or combination thereof) that is capable of transmitting optical energy or light having a wavelength in a range of about 100 nm to about 1 mm, inclusive (e.g., from the ultraviolet to the infrared range).
  • the fiber core 152 may also include a cladding (not shown) disposed around a central core (e.g., a glass cladding) and configured to inhibit transmission of optical energy therethrough to prevent transmission losses.
  • the fiber encapsulation layer 154 may include one or more layers, for example, a protective layer, a thermal resistant layer, an external jacket, and/or a moisture exclusion layer.
  • a protective layer for example, a thermal resistant layer, an external jacket, and/or a moisture exclusion layer.
  • the optical fiber assembly 150 may be configured to transmit optical communication signals (e.g., internet signals, cable signals, telecom signals, etc.), and may be configured as fiber-to-home cables.
  • the optical fiber sensing assembly 150 may be configured to measure various operating parameters of the conductor 102, for example, mechanical parameters such as strain (e.g., distributed strain), stress, sag, change in length, etc., or temperature (e.g., distribute temperature), or electrical operating parameters (e.g., detect line faults or breaks).
  • a signal generator may be used to communicate optical energy (e.g., a continuous or pulsed laser light) with wavelength ( ⁇ o) into the fiber core 152, and analyze the returning optical energy (e.g., Raman back scattering light or Brillouin back scattering light) from the same fiber core 152 to obtain precise temperature (T) and strain ( ⁇ ) profile along the conductor 102 in real-time.
  • time of flight measurements may be used to determine the conductor length for precise line sag information or line fault location real time.
  • optical energy e.g., laser light
  • the power intensity of anti-stock Raman Back Scattering light is sensitive only to fiber's Attorney Docket No. TSCD-006/01WO 346332-2078 temperature change, therefore the intensity ratio between anti-stokes and stokes peaks is used to calculate the temperature (T) variation.
  • the optical fiber assembly 150 may be able to sense various parameters of the conductor 102 or surroundings thereof using optical time domain reflectometry (OTDR), distributed temperature sensing (DTS), distributed strain sensing (DSS), and/or distributed acoustic sensing (DSS). [0035] In some embodiments, the optical fiber assembly 150 may be configured to sense or monitor vibration in the conductor 102 or in the air surrounding the conductor 102.
  • OTDR optical time domain reflectometry
  • DTS distributed temperature sensing
  • DSS distributed strain sensing
  • DSS distributed acoustic sensing
  • the optical fiber assembly 150 may be configured to sense aeolian vibrations that are high frequency and low amplitude vibrations, and/or sense galloping vibrations that are low frequency and high amplitude vibrations.
  • Aeolian vibrations may correspond to wind speeds of less than about 8 m/s, and ability to sense aeolian vibrations may enable the optical fiber assembly 150 to sense wind speed.
  • galloping vibrations may correspond to wind speeds of equal to or greater than about 10 m/s, and ability to sense these vibrations may allow determination of high winds around the conductor 102, which can damage the conductor 102 or may be indicators of a hazardous weather.
  • the optical fiber assembly 150 may be configured to monitor vibrations in the range of about 8 m/s to about 20 m/s range, that may enable monitoring vibrations in a portion or sub-span of the conductor 102. In some embodiments, 5 or more optical fiber assemblies 150 may be included in the conductor 102 that are collectively used for vibration monitoring.
  • conventional conductors include optical fiber sensors that may be stranded on the conductor or disposed within a separate tube (e.g., a hollow stainless steel or aluminum tube) that is co-located with various conductor layers of such conventional conductors.
  • optical fiber assembly 150 may be disposed in the core 112 such that the optical fiber assembly 150 is in intimate contact with the core 112. Because of this intimate contact, any mechanical stress, strain, sag, and/or change in length of the conductor 102 is also experienced by the optical fiber assembly 150, thus allowing the optical fiber Attorney Docket No. TSCD-006/01WO 346332-2078 assembly 150 to accurately measure changes in mechanical operating parameters.
  • the intimate contact also allows accurate measurement of conductor temperature (e.g., to allow detection and inhibit overheating of the core 112 above the first glass temperature) and/or to environmental temperature, for example, to enable monitoring of temperature anomalies in the environment around the conductor, for example, to detect hot spots, cold spots, heatwaves, wildfires, winter storms, etc.
  • FIG.1 shows the core 112 including a single optical fiber assembly 150
  • a plurality of optical fiber assemblies 150 may be disposed in the core 112.
  • the one or more optical fiber assemblies 150 may be loosely packed inside the composite core 112 such that it is strongly bonded to the composite material of the core 112, but the loose packing beneficially reduces micro-bending of optical fibers.
  • the composite core 112 may have a first color and the fiber encapsulation layer 154 may have a second color different from the first color.
  • the composite material used to form the core 112 may include carbon fibers, graphene, graphite, or some other reinforcing material that has a dark color such that the first color may be a dark color (e.g., black or nearly black color).
  • the second color of the fiber encapsulation layer 154 may have a high contrast relative to the core 112.
  • the fiber encapsulation layer 154 may have a bright color such as white, bright pink, bright green, bright orange, bright blue, or any other suitable color that has a substantially high contrast with the color of the core 112.
  • the fiber encapsulation layer 154 may include a fluorescent material or include a fluorescent dye (e.g., nanoparticles, quantum dots, Eosin yellow, luminol, fluorescein, coumarin, cyanine, rhodamine, acridine orange, malachite green, zinc sulfide, any other suitable fluorescent material or a combination thereof) that may allow a user to visually differentiate the optical fiber assembly 150 from the core 112 (e.g., by shining a suitable excitation light on the core 112 so as to cause the fiber encapsulation layer 154 to fluoresce).
  • the fiber encapsulation layer 14 may include a phosphorescent material (e.g., phosphorous).
  • the optical fiber assembly 150 may be disposed at any suitable location in the core 112. In some embodiments, the optical fiber assembly 150 may be disposed approximately along a central axis of the strength member 110, or a central axis of the conductor 102 in embodiments in which the conductor 102 has a single strength member 110. In some instances, it may be desirable to enable a user to easily access the optical fiber assembly 150 disposed or embedded in the core 112.
  • the optical fiber assembly 150 may be disposed proximate to a radially outer edge of the core 112. In other words, the optical fiber assembly 150 may be disposed parallel to the central axis of the core 112 proximate to an outer peripheral edge of the core 112.
  • a shortest radial distance from an outer edge of optical fiber assembly 150 to a proximate radial outer edge of the core 112 may be in a range of about 0.1 mm to about 3 mm, inclusive (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.2, 2.4, 2.6, 2.8, or 3.0 mm, inclusive).
  • the shortest radial distance may be at least 0.1 mm. In some embodiments, the shortest radial distance may be at least 0.2 mm. In some embodiments, the shortest radial distance may be at least 0.3 mm. In some embodiments, the shortest radial distance may be at least 0.4 mm. In some embodiments, the shortest radial distance may be at least 0.5 mm. In some embodiments, the shortest radial distance may be at least 0.6 mm. In some embodiments, the shortest radial distance may be at least 0.7 mm. In some embodiments, the shortest radial distance may be at least 0.8 mm. In some embodiments, the shortest radial distance may be at least 0.9 mm.
  • the shortest radial distance may be at least 1.0 mm. In some embodiments, the shortest radial distance may be at least 1.2 mm. In some embodiments, the shortest radial distance may be at least 1.4 mm. In some embodiments, the shortest radial distance may be at least 1.6 mm. In some embodiments, the shortest radial Attorney Docket No. TSCD-006/01WO 346332-2078 distance may be at least 1.8 mm. In some embodiments, the shortest radial distance may be at least 2.0 mm. In some embodiments, the shortest radial distance may be at least 2.2 mm. In some embodiments, the shortest radial distance may be at least 2.4 mm.
  • the shortest radial distance may be at least 2.6 mm. In some embodiments, the shortest radial distance may be at least 2.8 mm. In some embodiments, the shortest radial distance may be at least 3.0 mm. [0040] In some embodiments, the shortest radial distance may be at most 3 mm. In some embodiments, the shortest radial distance may be at most 2.8 mm. In some embodiments, the shortest radial distance may be at most 2.6 mm. In some embodiments, the shortest radial distance may be at most 2.4 mm. In some embodiments, the shortest radial distance may be at most 2.2 mm. In some embodiments, the shortest radial distance may be at most 2.0 mm.
  • the shortest radial distance may be at most 1.9 mm. In some embodiments, the shortest radial distance may be at most 1.8 mm. In some embodiments, the shortest radial distance may be at most 1.7 mm. In some embodiments, the shortest radial distance may be at most 1.6 mm. In some embodiments, the shortest radial distance may be at most 1.5 mm. In some embodiments, the shortest radial distance may be at most 1.4 mm. In some embodiments, the shortest radial distance may be at most 1.3 mm. In some embodiments, the shortest radial distance may be at most 1.2 mm. In some embodiments, the shortest radial distance may be at most 1.1 mm.
  • the shortest radial distance may be at most 1.0 mm.
  • the optical fiber assembly 150 may thus be used to measure conductor length of the conductor 102 for measuring precise sag in the monitored circuit real time accuracy. The sag determination may be independent of environmental condition. The conductor length may also be useful to determine a fault location in the conductor 102 when necessary for prompt dispatch of crew to the exact fault location. Accurate distributed temperature sensing may allow for monitoring of surrounding areas such as wildfires or winter storm, as well as hot spots (e.g., partial conductor damage from broken strands) and cold spots (e.g., vegetation accidents with tree onto the conductor).
  • hot spots e.g., partial conductor damage from broken strands
  • cold spots e.g., vegetation accidents with tree onto the conductor.
  • Determination of the strain profile along conductor length of the conductor 102 may allow for accurate monitoring of snow or ice accumulation to enable proactive remediation (e.g., ice melting) and storm restoration. Such information may allow a controller (e.g., a power grid control room) to monitor the conductor 102 operation in real time with confidence and reliability.
  • a controller e.g., a power grid control room
  • the encapsulation layer 114 is disposed around the core 112, for example, circumferentially around the core 112.
  • an inner insulation layer may optionally be interposed between the core 112 and the encapsulation layer 114.
  • the inner insulation layer may be formed from any suitable insulative material, for example, glass fibers (disposed either substantially parallel to axial direction or woven or braided glass), a resin layer, an insulative coating, any other suitable insulative material or a combination thereof.
  • the inner insulation layer may also be disposed on axial ends of the core 112, for example, to protect the axial ends of the core 112 from corrosive chemicals, environmental damage, etc.
  • the encapsulation layer 114 may be formed from any suitable electrically conductive or non-conductive material.
  • the encapsulation layer 114 may be formed from a conductive material including, but not limited to aluminum (e.g., 1350- H19), annealed aluminum (e.g., 1350-0), aluminum alloys (e.g., Al-Zr alloys, 6000 series Al alloys such 6201-TSl, -T82, -T83, 7000 series Al alloys, 8000 series Al alloys, etc.), copper, copper alloys (e.g., copper magnesium alloys, copper tin alloys, copper micro-alloys, etc.), any other suitable conductive material, or any combination thereof.
  • aluminum e.g., 1350- H19
  • annealed aluminum e.g., 1350-0
  • aluminum alloys e.g., Al-Zr alloys, 6000 series Al alloys such 6201-TSl, -T82, -T83, 7000 series Al alloys, 8000 series Al alloys, etc.
  • copper copper alloys (e.g., copper magnesium
  • the encapsulation layer 114 is formed from Al and is pretensioned, i.e., is under tensile stress after being disposed on the core 112.
  • the encapsulation layer 114 may be formed from a non-conductive material, e.g., polymers, carbon fiber, glass fiber, ceramics, silicone, rubber, polyurethane, any other suitable non-conductive material, or a combination thereof.
  • the encapsulation layer 114 may be disposed on the core 112 using any suitable process.
  • the encapsulation process for disposing the encapsulation layer 114 around the core 112 may employ a conforming machine.
  • the encapsulation process may be performed with a similarly functional machine other than a conforming machine, and be optionally further drawn to achieve target characteristics of the encapsulation layer 114 (e.g., a desired geometry or stress state).
  • the conforming machines or the similar machines used for disposing the encapsulation layer 114 may allow quenching of the encapsulation layer 114.
  • the conforming machine may be integrated with stranding machine, or with pultrusion machines used in making fiber reinforced composite strength members. While FIG.1 shows a single encapsulation layer 114 disposed around the core 112, in some embodiments, multiple encapsulation layers 114 may be disposed around the core Attorney Docket No. TSCD-006/01WO 346332-2078 112.
  • each of the multiple encapsulation layers 114 may be substantially similar to each other, or may be different from each other (e.g., formed from different materials, have different thicknesses, have different tensile strengths, etc.).
  • core 112 may include a carbon fiber reinforced composite
  • the encapsulation layer 114 may include aluminum, for example, pretensioned or precompressed aluminum.
  • the interface between the core 112 and the encapsulation layer 114 may include surface features, for example, grooves, slots, notches, indents, detents, etc.
  • the composite core 112 may have a glass fiber tow disposed around its outer surface to create a screw shape or twisted surface.
  • a braided or woven fiber layer is applied in the outer layer of the core 112 to promote interlocking or bonding between the core 112 and the encapsulation layer 114.
  • the encapsulation layer 114 may have a thickness in a range of about 0.3 mm to about 5 mm, inclusive, or even higher (e.g., 0.3, 0.5, 1, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 mm, inclusive, or even higher).
  • a ratio of an outer diameter of the encapsulation layer 114 to an outer diameter of the core 112 is in range of about 1.2:1 to about 5:1, inclusive (e.g., 1.2:1, 1.5:1, 2:1, 2.5:1, 3:1, 3.5:1, 4:1, 4.5:1, or 5:1, inclusive).
  • the encapsulation layer 114 may be excluded.
  • the strength member 110 may have a minimum level of tensile strength, for example, at least 600 MPa (e.g., at least 600, at least 700, at least 800, at least 1,000, at least 1,200, at least 1,400, at least 1,600, at least 1,800, or at least 2,000 MPa).
  • at least 600 MPa e.g., at least 600, at least 700, at least 800, at least 1,000, at least 1,200, at least 1,400, at least 1,600, at least 1,800, or at least 2,000 MPa.
  • the elongation during pretension of the strength member 110 may include elongation by at least 0.01% strain (e.g., at least 0.01%, at least 0.05%, at least 0.1%, at least 0.15%, at least 0.2%, at least 0.25%, at least 0.3%, at least 0.35%, at least 0.4%, at least 0.45%, or at least 0.5% strain, inclusive) depending on the type of strength members and the degree of knee point reduction, and the strength member 110 may be pre-tensioned before or after entering the conforming machine.
  • the strength member 110 may be configured to endure radial compression from crimping of conventional fittings as well as Attorney Docket No.
  • the encapsulation layer 114 may have an outer surface that is configured to be smooth and shiny (e.g., surface treated) so as to reduce absorptivity (i.e., enhance solar reflectivity) so as to reduce an operating temperature of the core 112 and to prevent the temperature of the core 112 from exceeding its glass transition temperature or melting temperature.
  • the outer coating 130 may be formulated to have high radiative emissivity in the 2.5 microns to 15 microns wavelength, inclusive of the solar radiation. While this may cause cooling of the conductor layer 120, the radiated heat will also travel towards the strength member 110 and cause heating of the core 112, for example, cause the core 112 to be at a higher operating temperature than the conductor layer 120, which is undesirable.
  • the outer surface of the encapsulation layer 114 may be sufficiently reflective so as to have solar absorptivity of less than 0.6 (e.g., less than 0.55, less than 0.5, less than 0.45, less than 0.4, less than 0.35, less than 0.3, less than 0.25, less than 0.2, less than 0.15, or less than 0.1, inclusive) at a wavelength in a range of 2.5 microns to 15 microns, inclusive (e.g., 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 11, 12, 13, 14, or 15 microns, inclusive), at an operating temperature of the conductor 102 in a range of 90 degrees Celsius to 250 degrees Celsius, inclusive (e.g., 90, 100, 120, 140, 160, 180, 200, 220, 240, or 250 degrees Celsius, inclusive).
  • the outer surface of the encapsulation layer 114 is optionally, at least one of treated or coated with a coating (e.g., the inner coating 116) so as to have a reflectivity of greater than about 50% (e.g., greater than 50%, greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, or greater than 95%, inclusive) at thermal radiative wavelengths corresponding to an operating temperature of greater than about 90 degrees Celsius.
  • the outer surface of the encapsulation layer 114 may be surface treated (e.g., plasma treated, texturized, etc.) to have the solar absorptivity as described above. Attorney Docket No.
  • the strength member 110 i.e., the outer surface of the encapsulation layer 114 may be optionally coated with an inner coating 116 to reduce solar absorptivity.
  • the inner coating 116 may be disposed between the encapsulation layer 114 and the conductor layer 120.
  • the inner coating 116 may be formulated to have an absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5, less than 0.45, less than 0.4, less than 0.35, less than 0.3, less than 0.25, less than 0.2, less than 015, or less than 0.1, inclusive) at a wavelength in a range of 2.5 microns to 15 microns, inclusive (e.g., 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 11.0, 12.0, 13.0, 14.0, or 15.0 microns, inclusive), at an operating temperature of the conductor 102 in a range of 90 degrees Celsius to 250 degrees Celsius, inclusive (e.g., 90, 100, 120, 140, 160, 180, 200, 220, 240, or 250 degrees Celsius, inclusive).
  • an operating temperature of the conductor 102 in a range of 90
  • the inner coating 116 may be configured to reflect a substantial amount of solar radiation in the wavelength of equal to or less than 2.5 microns (e.g., at least 50% of solar radiation in a wavelength of equal to or less than 2.5 microns that is incident on the encapsulation layer 114).
  • a thickness of the inner coating 116 may be in a range of about 1 micron to about 500 microns, inclusive (e.g., 1, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, or 500 microns, inclusive).
  • the inner coating 116 may have a reflectivity of greater than about 50% (e.g., greater than 50%, greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, or greater than 95%, inclusive) at thermal radiative wavelengths corresponding to an operating temperature of greater than about 90 degrees Celsius.
  • the strength member 110 may include a composite core 112 that may be black in color (e.g., includes a carbon composite). The core 112 may therefore, act as a black body absorbing radiation causing the core 112 to have a higher temperature relative to the conductor layer 120 or otherwise, the encapsulation layer 114.
  • the encapsulation layer 114 having the highly reflective outer surface, and/or the inner coating 116 having low solar absorptivity reflect a substantial portion of the heat emitted by the conductor layer 120 back into the environment.
  • This may facilitate lowering an operating temperature of core 112, therefore protecting the core 112 and allowing the conductor 102 to operate at a higher temperature relative to the core 112 so as to inhibit Attorney Docket No. TSCD-006/01WO 346332-2078 the temperature of the core 112 from exceeding a threshold temperature (e.g., its glass transition temperature or melting point).
  • a threshold temperature e.g., its glass transition temperature or melting point
  • the inner coating 116 may include any inner coating having any suitable structure and function as described in detail in U.S. Patent No. 11,854,721 (the “’721 patent”), issued December 26, 2023, and entitled “Composite Conductors Including Radiative and/or Hard Coatings and Methods of Manufacture Thereof,” the entire disclosure of which is incorporated herein by reference.
  • the conductor layer 120 is disposed around the strength member 110 and configured to transmit electrical signals therethrough at an operating temperature, for example, in a range of 60 degrees to 250 degrees Celsius, inclusive.
  • the conductor layer 120 may include a plurality of strands of a conductive material disposed around the strength member 110.
  • the conductor layer 120 may include a first set of conductive strands disposed around the strength member 110 in a first wound direction (e.g., wound helically around the strength member 110 in a first rotational direction), a second set of conductive strands disposed around the first set of strands in a second wound direction (e.g., wound helically around the first set of conducive strands in a second rotational direction opposite the first rotational direction), and may also include a third set of strands wound around the second set of strands in the first wound direction, and may further include any number of additional strands as desired.
  • a first wound direction e.g., wound helically around the strength member 110 in a first rotational direction
  • a second set of conductive strands disposed around the first set of strands in a second wound direction e.g., wound helically around the first set of conducive strands in a second rotational direction opposite the first rotational direction
  • the conductor layer 120 may include, for example, aluminum, aluminum alloy, copper or copper alloy including micro alloy as conductive media, etc.
  • the conductor layer 120 may include conductive strands including Z, C or S wires to keep the outer strands in place.
  • the conductor layer 120 may have any suitable cross-sectional shape, for example, circular, triangular, trapezoidal, etc.
  • the conductor layer 120 may include a stranded aluminum layer that may be round or trapezoidal.
  • the conductor layer 120 may include Z shaped aluminum strands.
  • the conductor layer 120 may include S shaped aluminum strands.
  • the conductor 102 may include any of the conductors described in U.S. Patent No.9,633,766 (the “’766 patent”), filed September 23, 2015, and entitled “Energy Efficient Conductors with Reduced Thermal Knee Points and the Method of Manufacture Thereof,” the entire disclosure of which is incorporated herein by reference.
  • Attorney Docket No. TSCD-006/01WO 346332-2078 [0054]
  • the strength member 110 may be adequately tensioned while the conductor layer 120 of aluminum or copper or their respective alloys disposed around the strength member 110 may be applied to cause the conductor 102 to form a cohesive conductive hybrid rod that is spoolable onto a conductor reel.
  • the conductor 102 may be optionally configured to be non-round (e.g., elliptical) such that the shorter axis (in conductor 102) is subjected to bending around a spool (or a sheaves wheel during conductor installation) to facilitate a smaller bend or spool radius, while the strength members 110 may be configured to have a longer axis to facilitate spring back for installation.
  • non-round e.g., elliptical
  • the overall conductor 102 may be round with non-round strength member 110 or multiple strength members 110 arranged to be non-round, and the spooling bending direction may be along the long axis of the strength member 110 to facilitate spring back while not overly subjecting the conductor layer 120 with additional compressive force from spooling bending.
  • the conductor layer 120 may include multiple segments, for example, strands or sets of strands or wires of conductive material (e.g., 2, 3, 4 etc.), and each segment bonded to strength member 110 while retaining compressive stress, and the segments rotates one full rotation or more along the conductor 102 length (equal to one full spool in a reel) to facilitate easy spooling.
  • segments for example, strands or sets of strands or wires of conductive material (e.g., 2, 3, 4 etc.), and each segment bonded to strength member 110 while retaining compressive stress, and the segments rotates one full rotation or more along the conductor 102 length (equal to one full spool in a reel) to facilitate easy spooling.
  • the conductor 102 may be configured to have negligible skin effect (i.e., conducting layer thickness is less than the skin depth required at AC circuit frequency), with the strength member 110 may be under sufficient residual tensile stress, and the conductor layer 120 (e.g., each of the strands of the conductive material) are mostly free of tension or under compressive stress.
  • the strands of the conductive material may be formed from a conforming machine, for example, by extruding hot deformable (e.g., semi solid) conductive material (e.g., aluminum) from a mold. The strands can be molded to be round or trapezoidal.
  • the extrusion mold or die may have a stranding lay ratio defined therein so that during the stranding operation of the conductive strands, no shaping may be needed (e.g., removing of sharp corners or edges of the conductive strands to avoid corona as is performed in conventional stranding operations).
  • the conductive media may be extruded out of the mold or die at an angle so as to form conductive strands that wrap around the strength member 110 at an angle, as described herein.
  • the conductor layer 120 may include a plurality of layers of conductive strands disposed concentrically around the strength member 110, with each layer being of finite thickness to maximize skin effect for lowest AC resistance at minimal conductor content.
  • the conductor layer 120 may be optionally stranded to facilitate conductor spooling around a reasonably sized spool and facilitate conductor stringing.
  • the outer most strands included in the conductor layer 120 may be TW, C, Z, S, or round strands if more aluminum or copper are used, as it will not cause permanent bird caging problem (i.e., the inner strands of the conductor layer 120 may not be deformed such that they prevent the outer strands from proper resettlement after tension is released or reduced). Accordingly, the smooth outer surface and the compact configuration can effectively reduce the wind load and ice accumulation on the conductor 102, resulting in less sag from ice or wind related weather events.
  • the conductor 102 may be pre-stressed, for example, by subjecting the conformed conductor 102 to a paired tensioner approach or trimming the predetermined core 112 length before dead-ending, all accomplished without exerting the high tensile stress to the pole arms to pre-tension conventional conductors in the electric poles.
  • the conductor 102 may be subjected to pre-tensioning treatment using sets of bull wheels prior to the first sheave wheel during stringing operation, without exerting additional load to the electric towers.
  • the conductor 102 may be subjected to the pre-tensioning stress between the first and second tensioners, for example, about 2 times of the average conductor every day tensile load to ensure that the pre-tensioning is driving its knee point below the normal operating temperature so that conductor layer 120 is not in tension for optimal self-damping and the conductor 102 substantially does not change its sag with temperature.
  • the conductor layer 120 (e.g., each strand of conductive material included in the conductor layer 120) may include aluminum having electrical conductivity of at least 50% ICAS, at least 55% ICAS, at least 60% ICAS, or at least 65% ICAS, or may include copper having electrical conductivity of at least 65% ICAS, at least 75% ICAS, or even at least 95% ICAS.
  • the conductor 102 may combine pre-tensioning with strength member 110 that may include an encapsulation layer 114 formed of a conductive material of sufficient compressive strength and thickness to substantially preserve the pre-tensioning stress in the strength member 110, while rendering the conductor layer 120 disposed around the strength member 110 mostly tension free or in compression after conductor field installation, and preserving the low thermal expansion characteristics of the strength member 110.
  • the conductor 102 may have an inherently lower thermal knee point.
  • the conductor 102 may be easy to install and repair, while maintaining low sag, high capacity, and energy efficiency as a result of knee point shift.
  • metallurgical bonding may be provided between the strength member 110 and the conductor layer 120.
  • adhesives e.g., Chemlok 250 from Lord Corp
  • the conductor layer 120 may include aluminum, aluminum alloy, copper and copper alloys, lead, tin, indium tin oxide, silver, gold, nonmetallic materials with conductive particles, any other conductive material, conductive alloy, or conductive composite, or combination thereof.
  • the conductor layer 120 may be under no substantial tension while the strength member 110 may be pre-stretched/tensioned. After the pre-tension in the strength member 110 is released, the conductor layer 120 may be subjected to compression, which may minimize the shrinking back of the strength member 110.
  • the strength member 110 made with composite materials may have a strength above 80 ksi, and a modulus ranging from 5 msi to 40 msi, and a CTE of about 1x10 -6 /°C to about 8x10 -6 /°C, inclusive.
  • Attorney Docket No. TSCD-006/01WO 346332-2078 [0062]
  • the level of pre-tensioning in the conductor 102 may be dependent on conductor size, conductor configuration, conductor application environment and the desirable target thermal knee point.
  • the composite core 112 of the strength member 110 may include carbon fibers that are strong, light weight, and have low thermal sag.
  • the encapsulated strength member 110 using fiber reinforced composite materials may be particularly advantageous where the elastic strength member 110 facilitates spring back of the encapsulated strength member 110 from the reeled configuration for field installation.
  • the strength member 110 may be pre-strained by at least 0.05% (e.g., at least 0.05%, at least 0.1%, at least 0.15%, at least 0.2%, at least 0.25, or at least 0.3%, inclusive).
  • the skin depth may be in a range of about 9 mm to about 14 mm, inclusive at 25 Hz (e.g., 9, 10, 11, 12, 13, or 14 mm, inclusive) and in a range of about 14 mm to about 20 mm at 60 Hz (e.g., 14, 15, 16, 17, 18, 19, or 20 mm, inclusive).
  • a thickness of each strand of conductive media included in the conductor layer 120 may be less than the maximum allowable depth, for example, to achieve low A/C resistance.
  • each of the conductive strands included in the conductor layer 120 may include copper having a thickness of up to 12 mm (e.g., up to 12, up to 11, up to 10, up to 9, or up to 8 mm, inclusive).
  • each of the Attorney Docket No. TSCD-006/01WO 346332-2078 conductive strands included in the conductor layer 120 may include aluminum having a thickness of up to 16 mm (e.g., up to 16, up to 14, up to 13, up to 12, up to 11, or up to 10 mm, inclusive).
  • a dielectric coating may be interposed between the conductive strands to optimize for the skin effect.
  • lubricants may be provided between adjacent conductive strands to facilitate some relative motion of the conductive strands included in the conductor layer 120.
  • an interface between the strength member 110 and the conductor layer 120 may be further optimized with surface features in the strength member 110 enhancing interfacial locking and/or bonding between the strength member 110 and the conductor layer 120 to retain and preserve the stress from pretensioning.
  • Such features may include, but are not limited to protruded features on an outer surface of the strength member 110 (e.g., and outer surface of the encapsulation layer 114 of the inner coating 116) as well as rotation of the strength member 110 around the axial direction.
  • the same features can be incorporated into the interface between subsequent conductive strands included in the conductor layer 120.
  • the strength member 110 may include a glass fiber tow disposed around its surface to create a screw shape or twisted surface.
  • the insulating layer 122 may be formed from any suitable electrically insulative material, for example, rubber, plastics, or polymers (e.g., polyethylene, PTFE, high density polyethylene, cross-linked high density polyethylene, etc.).
  • the insulating layer 122 may be configured to electrically isolate or shield the conductor 102. In some embodiments, the insulating layer 122 may be excluded. [0066] In some embodiments, an outer surface of the conductor layer 120 (e.g., outer surface of the outermost conductive strands or an outer surface of each of the conductive Attorney Docket No.
  • the outer coating 130 is formulated to have a solar absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5, l less than 0.45, less than 0.40, less than 0.35, less than 0.30, less than 0.25, less than 0.20, less than 0.15, less than 0.1, inclusive or even lower) at a wavelength of less than 2.5 microns, and a radiative emissivity of greater than 0.5 (e.g., greater than 0.50, greater than 0.55, greater than 0.60, greater than 0.65, greater than 0.70, greater than 0.75, greater than 0.80, greater than 0.85, greater than 0.90, greater than 0.95, inclusive, or even higher) at a wavelength in a range of 2.5 microns to 15 microns, inclusive at an operating temperature in a range of 60 degrees C to 250 degrees Celsius, inclusive.
  • a solar absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5
  • the outer coating 130 is formulated to have radiative emissivity of greater than 0.55.
  • the coating 130 may be formulated to have a radiative emissivity of equal to or greater than 0.85 (e.g., 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, inclusive, or even higher) at a wavelength of about 6 microns, and a solar absorptivity of less than 0.3 (e.g., 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.20, 0.15, 0.10, inclusive, or even lower) at a wavelength of less than 2.5 microns at an operating temperature of about 200 degrees Celsius.
  • the low solar absorptivity of the outer coating 130 at a wavelength of less than 2.5 microns causes the outer coating 130 to reflect a substantial amount of solar radiation (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or even greater than 95% of the incident solar radiation) in the wavelength of less than 2.5 microns, thus reducing solar absorption and inhibiting increase in operating temperature of conductor 102.
  • a substantial amount of solar radiation e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or even greater than 95% of the incident solar radiation
  • the high radiative emissivity of the outer coating 130 at the wavelength in a range of 2.5 microns to 15 microns causes the outer coating 130 to emit heat being generated by the conductor 102 due to passage of current therethrough as photons, thus increasing radiation of heat away from the conductor 102 into the environment, further reducing the operating temperature of the conductor 102.
  • the outer Attorney Docket No. TSCD-006/01WO 346332-2078 coating 130 may cause a reduction in operating temperature of the conductor 102 at a particular current in a range of about 5 degrees Celsius to about 40 degrees Celsius, inclusive (e.g., 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, 30, 35, or 40 degrees Celsius, inclusive).
  • the conductor 102 can be operated at a lower temperature at the same ampacity. Conversely, the ampacity of the conductor 102 may be increased at the same operating temperature, relative to a conductor that does not include the outer coating 130.
  • the outer coating 130 may provide environmental protection that is configured to extend the operational lifespan of the conductor 102.
  • the outer coating 130 may act as a barrier against ultraviolet radiation, moisture ingress, airborne contaminants such as salt or industrial pollutants, and/or the like. These properties may reduce corrosion, mechanical wear, and the likelihood of insulation degradation, particularly in harsh environments.
  • an outer surface of at least a portion of the conductive strands forming the conductor layer 120 may be cleaned, for example, using surfactants or solvents to provide a clean surface for depositing the outer coating 130.
  • the outer surface of the conductor layer 120 e.g., each of the strands forming the conductor layer 120, the outer most strands, or an outer surface of the outer most strands
  • the insulating layer 122 may be roughened by sand blasting to provide a rough surface to facilitate adhesion of the outer coating 130 thereto.
  • the base coat and/or the outer coating 130 may be hydrophobic, for example, to inhibit ice formation, inhibit fouling, protect against UV radiation, and inhibit water born dirt.
  • the outer coating 130 may be applied in the form of a paint or slurry using any suitable method, for example, painting, dipping, spraying, evaporation, deposition follow by curing or cross-linking, or shrink wrapping.
  • the outer surface of the conductor layer 120 e.g., at least the outer most conductive strands included in the conductor layer 120
  • the outer surface of the conductive strands of the conductor layer 120 may be cleaned using any suitable method such as, for example, via acid, solvents or using a mechanical means (e.g., sand blasted) to facilitate adhesion of the outer coating 130 to the outer surface of the conductor layer 120.
  • a mechanical means e.g., sand blasted
  • the outer surface of the insulating layer 122 may be cleaned Attorney Docket No. TSCD-006/01WO 346332-2078 or texturized (e.g., via sand blasting) before depositing the outer coating 130 thereon.
  • the deposited outer coating 130 may be dried using hot air, infrared or naturally dried.
  • the outer coating 130 may provide one or more benefits such as, for example, being transparent, being electrically conductive, having less curing time during coating, having high thermal aging resistance, having reduced dust accumulation, having corrosion resistance, being hydrophobic, having ice accumulation resistance, having weather resistance, having scratch and abrasion resistance, having wear resistance, having flame resistance, having self-healing properties, having reduced surface friction, having better recoatability, having a reduction in conductor pull forces, or any combination thereof. Additionally, the outer coating 130 can impart improvements in conductor lifespan and performance. Hydrophobic properties can mean that a water droplet on a coating can have a contact angle of about 90° or more.
  • hydrophobic properties can mean that a water droplet on a coating can have a contact angle of about 130 degrees or more. Self- healing can be activated by exposure to one, or more conditions including normal atmospheric conditions, UV conditions, thermal conditions, or electric field conditions.
  • the outer coating 130 maybe hydrophilic, that minimizes formation of water droplets as the contact angle is substantially less than 90 degrees. Such implementations may be particularly useful for reducing corona, especially for extremely high voltage (EHV) and/or ultrahigh voltage (UHV) applications where the voltage of the circuit can be above 200 kV.
  • EHV extremely high voltage
  • UHV ultrahigh voltage
  • the outer coating 130 may be a “hard coating” configured to have a hardness, cutting resistance, or erosion resistance that is at least 5% greater than a hardness, cutting resistance, or erosion resistance of aluminum or aluminum alloys.
  • the outer coating 130 may advantageously protect the conductor layer 120 (e.g., each of a plurality of conductive strands of the conductor layer 120) from erosion, cutting, or otherwise mechanical damage (e.g., from accidental cutting by kite strings).
  • the outer coating 130 may have an erosion resistance that is at least 5% greater than an erosion resistance of aluminum or aluminum alloys.
  • the outer coating 130 has a Vickers hardness of greater than 200 MPa.
  • the outer coating 130 may include any of the outer coatings as described in detail in the ‘721 patent. Attorney Docket No. TSCD-006/01WO 346332-2078 [0074]
  • the coupler 140 may include a splice coupler, a dead end coupler or any other suitable coupler, and is configured to be coupled to an end of the conductor 102.
  • the coupler 140 may include a body 142 defining a channel therethrough.
  • the body 142 may include a cylindrical body.
  • the body 142 may be formed from a strong and rigid material.
  • the body 142 may be formed from a metal or metal alloy, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the coupler 140 may also include a sleeve 144 disposed around the body 142.
  • the sleeve 144 may include a cylindrical structure.
  • the sleeve 144 may have a length that is longer than a length of the body 142 of the coupler such that the sleeve 144 extends beyond at least one axial end of the body 142.
  • the coupler 140 is a splice coupler
  • the sleeve 144 may extend beyond both axial ends of the body 142.
  • the sleeve may extend beyond only one axial end of the body through which the conductor 102 is inserted into the coupler 140.
  • the sleeve 144 may be formed from an electrically conductive material, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the sleeve 144 may be configured to be physically and/electrically couple to the outer surfaces of the conductor layer 120 of the conductor layer 120 of the conductor 102, for example, only one conductor 102 (e.g., for a dead end coupler), or to outer surfaces of first and second conductor layers 120 of a first and a second conductor 102 to electrically couple the conductor layers of the first and second conductors, as described in further detail herein.
  • a mark or indicator may be provided or formed on an outer surface of the conductor layer 120 the mark aligned with an outer edge of a corresponding end of the sleeve 144 such that the conductor 102 is inserted only up to a predetermined length into the coupler 140.
  • the coupler 140 may include a connecting portion 146 defining a keyhole.
  • the connecting portion 146 may be coupled to the sleeve 144 and/or the body 142 at a second end of the coupler 140 opposite a first end of the coupler 140 through which the conductor 102 is disposed or inserted into the coupler 140.
  • the connecting portion 146 may be configured to be coupled to corresponding hooks or connectors located on poles (e.g., tension towers) from which the conductor 102 may be suspended.
  • a protective cap not Attorney Docket No.
  • the protective cap may include a strong and rigid material (e.g., metals, alloys, plastics, polymers, etc.) extending radially from the body 142 and/or sleeve 144 and may be configured to absorb explosive force or direct the explosive force due to the explosive material 162 being detonated away from the connecting portion 146.
  • an opening, a throughhole, or aperture may be defined on a wall of the connecting portion 146 adjacent to the body 142, sleeve 144, or any other portion of the coupler 140.
  • the optical fiber assembly 150 included in the conductor 102 may be routed out of the coupler 140 through the opening for coupling with a controller or receiver.
  • the connecting portion 146 of the coupler 149 may be configured to be coupled to a pole (e.g., an electrical pole or tower).
  • a hook, rope, coil, or any other coupling mechanism may be interfaced with the keyhole defined in the connecting portion 146 to couple the coupler 140 to the pole.
  • An explosive material 162 is coupled to the coupler 140.
  • the explosive material 162 may be disposed around the body 142, or disposed around the sleeve 144 in embodiments in which the coupler 140 includes the sleeve 144.
  • any suitable explosive material 162 may be used such as, for example, trinitrotoluene (TNT), RDX, nitroglycerin, picric acid, lead azide, black powder, etc.
  • the explosive material 162 may be pressed or molded on an outer surface of the body 142 or sleeve 144.
  • the explosive material 162 may include a cord, string, rope, and/or the like including the explosive material 162.
  • the cord may be disposed (e.g., wrapped or wound) around the body 142 or sleeve 144.
  • a protective layer (not shown) may be disposed around the explosive material 162, for example, to protect the explosive material 162 from moisture or physical damage.
  • the coupler 140 is movable between a first configuration in which an end of a conductor 102 is removably disposed in the channel defined by the coupler 140, and a second configuration in which the explosive material 162 is detonated to cause the coupler 140 to be fixedly coupled to the end of the conductor 102.
  • a portion of the conductor layer 120 may be removed from the end of the conductor 102 to expose a portion of the Attorney Docket No.
  • a detonator 164 is operatively coupled to the explosive material 162. Any suitable detonator 164 may be used such as, for example, a wireless detonator, a blast cap, a non-electric detonator, or any other suitable detonator that can only be detonated by a special initiator or trigger to cause the explosive material 162 to explode, thus inhibiting accidental detonation.
  • a length of the conductor layer from first ends of each of the first conductor 102 and the second conductor 102 may be removed to expose a portion of the respective strength members 110 of the first and second conductors102 (e.g., removing a portion having a length in a range of about 150 mm to about 350 mm, inclusive, from the axial end of the conductors 102).
  • a circumcizer, a cutter or any other suitable equipment may be used to make slits or cuts in the conductor layer 120 of a pair of the conductors 102 proximate to axial ends of the conductors 102, and the portion of the conductor layers 120 of the conductors 102 removed or stripped off to expose a portion of their respective strength members 10. Examples of tools that may be used to remove the predetermined length of the conductor layers 120 are described in the ‘951 publication. [0081] At 16, the first axial end of the first conductor 102 is inserted into the channel defined by the coupler 140 through a first end of the coupler 140.
  • a first end of the second conductor 102 is inserted into the channel of the coupler 140 through a second end of the coupler 140 opposite the first end.
  • a mark or indicator may be provided or formed on an outer surface of the conductor layer 120 of the second conductor 102 and the mark aligned with an outer edge of the second end of the sleeve 144 such that the second conductor 102 is inserted only up to a predetermined length into the coupler 140, for example, about the same length that the first conductor 102 is inserted into the coupler 140.
  • an optical connector (not shown), for example, a LC connector, a SC connector, a ST connector, a MTP/MPO connector, FC connector, MT-RJ connector, E2000 connector, MU connector, SMA connector, DIN connector, D4 connector, opti-jack connector, LX.4 connector, fused-fiber optical coupler, a micro-optics optical coupler, a planar waveguide optical coupler, or any other suitable optical connector or coupler, or any Attorney Docket No. TSCD-006/01WO 346332-2078 suitable combination thereof, may be disposed into the channel defined by the coupler 140, for example, within the channel defined by the body 142.
  • First ends of the optical fiber assembly 150 of each of the first and second conductors 102 may be exposed and inserted into the optical connector to optically couple the optical fiber assembly 150 of the first conductor 102 to the optical fiber assembly 150 of the second conductor 102.
  • the optical connectors can include industry-standard connectors, including but not limited Lucent Connectors (LC), Subscriber Connectors (SC), Straight Tip connectors (ST), Ferrule Connectors (FC), and Multi-Fiber Push-On or Mechanical Transfer Push-On connectors (MPO/MTP), depending on the application and signal fidelity requirements. These connectors may be fusion-spliced or mechanically aligned within the coupler 140.
  • inserting the first ends of the first and second conductors 102 include positioning he exposed portions of the strength members 110 of the first and second conductor 102 within a portion of the channel defined by the body 142 of the coupler such that corresponding ends of the conductor layers 120 of each of the first and second conductors 102 are positioned in a portion of the coupler 140 that is outside the body 142, for example, within the sleeve 144 of the coupler 140.
  • the body 142 and the sleeve 144 have inner cross-sectional widths (e.g., diameters) that are larger than corresponding outer cross-sectional widths of the strength members 110 and the conductor layers 120 of the first and second conductors 102. This allows a gap to be present between inner surfaces of the body 142 and the sleeve 144 and corresponding outer surfaces of the strength member 110 and the conductor layer 120 when axial ends the first and second conductors 102 are inserted into the coupler 140. [0082] A number of couplers 140 may be used to splice multiple conductors 102 in series.
  • a length of the conductor layer 120 from a second end of the second conductor 102 that is opposite the first end of the second conductor 102, and a first end of a third conductor 102 may be removed.
  • the second end of the second conductor 102 is inserted into a channel of a second coupler 140 through a first end of the coupler 140, and a first end of a third conductor 102 is inserted into the channel through a second end of the second coupler 140 that is opposite the first end of the second coupler 140.
  • the explosive material 162 can be detonated, for example, by remotely triggering the detonator 164, to cause the Attorney Docket No.
  • TSCD-006/01WO 346332-2078 coupler 140 to be couped to the conductor 102, for example, coupled to the first and second conductor 102 and to physically and, optionally, electrically couple the first and the second conductor 102.
  • the detonation of the explosive material 162 causes the body 142 and optionally, the sleeve 144 to be compressed around the strength members 110 and the conductor layers 120 of the first and second conductors 102, respectively, such that there is substantially no gap between the body 142 and sleeve 144, and corresponding portions of the strength member 110 and conductor layer 120 of the first and second conductors 102.
  • the assembly 100 takes advantage of the energy contained in explosives to couple the conductor 102 to the coupler 140, or splice the first conductor 102 to the second conductor 102 via the coupler 140 by “implosive coupling” or “implosive splicing”. Compression is achieved by explosive force, obviating the need for any equipment and making coupling easier and faster. Moreover, the coupling or splice produced due to explosive couplings is mechanically and electrically superior to conventional hydraulically formed splices.
  • the layer of explosive material 162 disposed around the coupler 140 may be formulated with the right properties of detonation velocity, pressure and geometry to create desired compression for coupling the first and second conductors.
  • the geometry of the explosive material such as its thickness, placement pattern (e.g., helical winding, uniform wrap, or segmented charges), and/or proximity to the coupler body may influence the quality and uniformity of the coupling.
  • the explosive geometry may be tailored based on conductor size, coupler type (e.g., splice or dead-end), and material properties.
  • the body 142 and/or sleeve 144 implodes and a permanent compression of the body 142 and/or sleeve 144 on corresponding portions of the conductor(s) 102 is produced.
  • the protective layer may evaporate such that no flying debris is produced and a fully compressed, permanent, and smooth connection between Attorney Docket No.
  • the conductor(s) 102 and the coupler 140 is obtained.
  • the conductor(s) 102 and the coupler 140 can become one solid mass that appears as if it had been cold welded.
  • the explosive materials 162 disposed around the first coupler 140 and the second coupler 140 are detonated simultaneously.
  • any number of explosive materials 162 disposed with any suitable number of couplers 140 can be detonated simultaneously, allowing conductors 102 to be couped to each other via their respective couplers 140 simultaneously.
  • a work crew may prepare the conductors 102 and set up a desired number of couplers 140 for detonating simultaneously.
  • the coupler 140 offers a number of advantages over conventional hydraulic methods of joining conductors such as, for example, better connection quality, easier to installation, overall cost reduction and reduced project time.
  • An implosively coupled coupler 140 can have substantially all interstices between the sleeve 144 and the conductor layer 120 of the conductor 102 and between the strands of the conductor filled, thereby reducing moisture ingress and hence corrosion. There may be substantially no elongation of the sleeve 144 and only radial deformation may occur.
  • the implosive coupled coupler 140 can be corona free, thus inhibiting production of hotspots along the conductor(s) 102.
  • Use of mechanical equipment can be obviated, and the coupler 104 has better compression strength than a hydraulic coupler, while increasing consistency in compression quality.
  • the composite material from which the core 112 of the conductor(s) 102 is formed may be susceptible to crush force damage.
  • the encapsulation layer 114 disposed around the core 112 also serves as a protection layer to protect the core 112 from the compressing force exerted during implosive coupling of the body 142 around the strength member 110 of the conductor(s) 102.
  • a coating for example, the coating 130 may be disposed on the outer surface of the coupler 140.
  • the coating may be formulated to have a solar absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5, l less than 0.45, less than 0.40, less than 0.35, less than 0.30, less than 0.25, less than Attorney Docket No.
  • a radiative emissivity of greater than 0.5 (e.g., greater than 0.50, greater than 0.55, greater than 0.60, greater than 0.65, greater than 0.70, greater than 0.75, greater than 0.80, greater than 0.85, greater than 0.90, greater than 0.95, inclusive, or even higher) at a wavelength in a range of 2.5 microns to 15 microns,
  • the coupler 140 can heat up to a higher temperature than the portion of the coated conductor layer 120 disposed outside of the coupler 140. This can cause a local heating point that can heat up the core 112 of the conductor(s) 102 above their glass transition temperature and can lead to failure. Disposing the coating on the coupler 140 can keep the coupler 140 within a desired operating temperature as previously described, thus inhibiting operating temperature of portion of the core(s) 112 of the strength member(s) 110 disposed within the coupler 140 from exceeding its glass transition temperature or melting temperature. [0090] FIG.
  • the conductor 202 includes a strength member 210 including a core 212, an encapsulation layer 214 disposed around the core 212, and an optical fiber assembly 250 disposed in the core 212.
  • the conductor 202 also includes a conductor layer 220, an outer coating 230, and may optionally, also include an insulating layer 222 disposed between the conductor layer 220 and the outer coating 230.
  • the conductor 202 may be used in grid transmission applications to conduct electricity.
  • the core 212 may be formed from a composite material.
  • the composite material may include nonmetallic fiber reinforced metal matrix composite, carbon fiber reinforced composite of either thermoplastic or thermoset matrix, or composites reinforced with other types of fibers such as quartz, AR-Glass, E-Glass, S-Glass, H-Glass, silicon carbide, silicon nitride, alumina, basalt fibers, especially formulated silica fibers, any other suitable composite material, or any combination thereof.
  • the composite material may include a carbon fiber reinforced composite of a thermoplastic or thermoset resin.
  • the reinforcement in the composite strength member 210 can be discontinuous such as whiskers or chopped fibers; or continuous fibers in substantially aligned configurations (e.g., parallel to axial direction) or randomly dispersed (including helically wind or woven configurations).
  • the composite material may include Attorney Docket No. TSCD-006/01WO 346332-2078 a continuous or discontinuous polymeric matrix composites reinforced by carbon fibers, glass fibers, quartz, or other reinforcement materials, and may further include fillers or additives (e.g., nanoadditives).
  • the core 212 may include a carbon composite including a polymeric matrix of epoxy resin cured with anhydride hardeners.
  • the core 212 may be substantially similar to the core 112 formed using any suitable mechanism or method as described with respect to the core 112, and therefore not described in further detail herein.
  • the encapsulation layer 214 is disposed circumferentially around the core 212.
  • the encapsulation layer 214 may be formed from any suitable electrically conductive or non- conductive material.
  • the encapsulation layer 214 may be formed from a conductive material including, but not limited to aluminum (e.g., 1350-H19), annealed aluminum (e.g., 1350-0), aluminum alloys (e.g., Al-Zr alloys, 6000 series Al alloys such 6201-TSl, -T82, -T83, 7000 series Al alloys, 8000 series Al alloys, etc.), copper, copper alloys (e.g., copper magnesium alloys, copper tin alloys, copper micro-alloys, etc.), any other suitable conductive material, or any combination thereof, as described with respect to the encapsulation layer 114.
  • aluminum alloys e.g., Al-Zr alloys, 6000 series Al alloys such 6201-TSl, -T82, -T83, 7000 series Al alloys, 8000 series Al alloys, etc.
  • copper copper alloys (e.g., copper magnesium alloys, copper tin alloys, copper micro-alloy
  • the encapsulation layer 214 may be formed from a non-conductive material, e.g., polymers, carbon fiber, glass fiber, ceramics, silicone, rubber, polyurethane, any other suitable non-conductive material, or a combination thereof.
  • the encapsulation layer 214 may be substantially similar to the encapsulation layer 114 and may be formed using any suitable mechanism or method as described with respect to the encapsulation layer 114, and therefore not described in further detail herein. While shown as including a single encapsulation layer 214, in some embodiments, multiple encapsulation layers 214 may be disposed on the core 212.
  • the interface between the core 212 and the encapsulation layer 214 may include surface features, for example, grooves, slots, notches, indents, detents, etc. to enhance adhesion, bonding and/or interfacial locking between a radially outer surface of the core 212 and a radially inner surface of the encapsulation layer 214. Such surface features may facilitate retention and preservation of the stress from pretensioning in the encapsulation layer 214.
  • the composite core 212 may have a glass fiber tow disposed around its outer surface to create a screw shape or twisted surface.
  • a braided or woven fiber layer is applied in the outer layer of the core 212 to promote interlocking or bonding between the core 212 and the encapsulation layer 214.
  • Attorney Docket No. TSCD-006/01WO 346332-2078 [0094]
  • the strength member 210 may have a minimum level of tensile strength, for example, at least 600 MPa (e.g., at least 600, at least 700, at least 800, at least 1,000, at least 1,200, at least 1,400, at least 1,600, at least 1,800, or at least 2,000 MPa, inclusive).
  • the elongation during pretension of the strength member 210 may include elongation by at least 0.005% strain (e.g., at least 0.005%, at least 0.01%, at least 0.1%, at least 0.2%, at least 0.25%, at least 0.3%, at least 0.35%, at least 0.4%, at least 0.45%, or at least 0.5% strain, inclusive) depending on the type of strength members and the degree of knee point reduction, and the strength member 210 may be pre-tensioned before or after entering the conforming machine.
  • at least 0.005% strain e.g., at least 0.005%, at least 0.01%, at least 0.1%, at least 0.2%, at least 0.25%, at least 0.3%, at least 0.35%, at least 0.4%, at least 0.45%, or at least 0.5% strain, inclusive
  • the strength member 210 may be configured to endure radial compression from crimping of conventional fittings as well as radial pressure during conforming of drawing down process or folding and molding of at least 3 kN (e.g., at least 3 kN, at least 4 kN, at least 5 kN, at least 10 kN, at least 15 kN, at least 20 kN, or at least 25 kN, inclusive).
  • the encapsulation layer 214 may have an outer surface that is smooth and shiny so as to maximize refractivity and reduce absorptivity (i.e., enhance reflectivity) for reducing an operating temperature of the core 212 and preventing the temperature of the core from exceeding its glass transition temperature or melting point.
  • the conductor 202 may include the outer coating 230 that is formulated to have a high radiative emissivity in the 2.5 microns to 15 microns wavelength, inclusive, of the solar radiation. While this may cause cooling of the conductor layer 220, the radiated heat will also travel towards the strength member 210 and cause heating of the core 212, for example, cause the core 212 to be at a higher operating temperature than the conductor layer 220, which is undesirable.
  • the outer surface of the encapsulation layer 214 may be configured for high radiative emissivity to remove heat from conductor 202 through thermal radiation.
  • the conductor layer 220 is disposed around the strength member 210 and configured to transmit electrical signals therethrough at an operating temperature in a range of about 60 degrees to about 250 degrees Celsius, inclusive.
  • the conductor layer 220 may be substantially similar to the conductor layer 120 and may be formed with any method or process as described with respect to the conductor 1ayer 120 and therefore, not described in further detail herein.
  • the conductor layer 220 may include a plurality of strands of a conductive material disposed around the strength member 210, as described with respect to the conductor layer 120.
  • the conductor layer 220 (e.g., a plurality of strands of conductive material) may include, for example, aluminum, aluminum alloy, copper or copper alloy including micro alloy as conductive media, etc.
  • the conductor layer 220 may include conductive strands including Z, C, or S wires to keep the outer strands in place.
  • the conductor layer 220 may have any suitable cross-sectional shape, for example, circular, triangular, trapezoidal, etc.
  • the conductor layer 220 may include stranded aluminum layer that may be round or trapezoidal. In some embodiments, the conductor layer 220 may include Z shaped aluminum strands. In some embodiments, the conductor layer 220 may include S shaped aluminum strands. In various embodiments, the conductor layer 220 may be formed from any suitable material, as described with respect to the conductor layer 120. [0098] In some embodiments, the conductor 202 may be pre-stressed, as previously described with respect to the conductor 102.
  • the conductor layer 220 (e.g., each strand of conductive material included in the conductor layer 220) may include aluminum having electrical conductivity of at least 50% ICAS, at least 55% ICAS, at least 60% ICAS, or at least 65% ICAS, or may include copper having electrical conductivity of at least 65% ICAS, at least 75% ICAS, or even at least 95% ICAS.
  • metallurgical bonding may be provided between the strength member 210 and the conductor layer 220, for example, via an adhesive.
  • an insulating layer 222 e.g., a jacket
  • the insulating layer 222 may be formed from any suitable electrically insulative material, for example, rubber, plastics, or polymers (e.g., polyethylene, high density polyethylene, cross-linked high density polyethylene, PTFE, etc.).
  • the insulating layer 222 may be configured to electrically isolate or shield the conductor 202. In some embodiments, the insulating layer 222 may be excluded.
  • the outer coating 230 is disposed on an outer surface of the conductor layer 220, for example, around individual strands that form the conductor layer 220, or only on outer surface of the outer most conductive strands of the conductor layer 220.
  • the coating 230 may be formulated to have a radiative emissivity of equal to or greater than 0.85 (e.g., 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, inclusive, or even higher) at a wavelength of about 6 microns, and a solar absorptivity of less than 0.3 (e.g., 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.20, 0.15, 0.10, inclusive, or even lower) at a wavelength of less than 2.5 microns at an operating temperature of about 200 degrees Celsius.
  • 0.85 e.g., 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, inclusive, or even higher
  • a solar absorptivity e.g., 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22
  • the outer coating 230 may be substantially similar to the outer coating 130 and therefore, not described in further detail herein.
  • the outer coating 230 may be a hard coating configured to have a hardness, cutting resistance, or erosion resistance that is at least 5% greater than a hardness, cutting resistance, or erosion resistance of aluminum or aluminum alloys. In this manner, the outer coating 230 may advantageously protect the conductor layer 220 (e.g., each of a plurality of conductive strands of the conductor layer 220) from erosion, cutting, or otherwise mechanical damage (e.g., from accidental cutting by kite strings).
  • the outer coating 230 may have an erosion resistance that is at least 5% greater than an erosion resistance of aluminum or aluminum alloys. In some embodiments, the outer coating 230 has a Vickers hardness of greater than 200 MPa. In some embodiments, the outer coating 230 may be substantially similar to the outer coating 130 described with respect to FIG. 1 and therefore, not described in further detail herein. [00102]
  • the optical fiber assembly 250 is disposed in the core 212 and includes a fiber core 252 and a fiber encapsulation layer disposed around the fiber core 252. The optical fiber assembly 250 may be substantially similar to optical fiber assembly 150.
  • the fiber encapsulation layer 254 may have a thickness T in a range of about 0.125 mm to about 0.5 mm, inclusive (e.g., 0.125, 0.15, 0.15, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, or 0.5 mm, inclusive).
  • the thickness T of the fiber encapsulation layer 254 and/or the thickness thereof may be sufficient to withstand the extrusion or pultrusion process used to form the core 252 or otherwise, the strength member 210.
  • the optical fiber assembly 250 is axially aligned with a central axis Attorney Docket No.
  • FIG. 3 is a side cross-section view of a conductor 302 that may be used as the conductors in the assembly 100, according to an embodiment.
  • the conductor 302 is similar to the conductor 202, for example, the conductor 302 includes a strength member 310 including a core 312 and an encapsulation layer 314, an optical fiber assembly 350, that may be substantially similar to the core 112, 212, the encapsulation layer 114, 214, and the optical fiber assembly 150, 250, respectively, as described, and therefore not described in further detail herein.
  • the conductor 302 also includes a conductor layer 320 disposed around strength member 310, and having an outer coating 330 disposed around the conductor layer 320.
  • the conductor layer 320 and the outer coating 330 may be substantially similar to the conductor layer 120, 220 and the outer coating 130, 230, previously described, and therefore not described in further detail herein.
  • an insulating layer e.g., the insulating layer 222 may be interposed between the outer coating 330 and the conductor layer 320, as previously described.
  • the conductor 302 also includes an inner coating 316 disposed on an outer surface of the encapsulation layer 314, for example, interposed between the encapsulation layer 314 and the conductor layer 320.
  • the inner coating 316 may be formulated to have a solar absorptivity of less than 0.5 (e.g., less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1) at a wavelength in a range of 2.5 microns to 15 microns, inclusive (e.g., 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 11.0, 12.0, 13.0, 14.0, or 15.0 microns, inclusive), at an operating temperature of the conductor 302 in a range of 90 degrees Celsius to 250 degrees Celsius, inclusive (e.g., 90, 100, 120, 140,
  • the inner coating 316 may be configured to reflect a substantial amount of solar radiation in the wavelength of equal to or less than 2.5 microns (e.g., at least 50% of solar radiation in a wavelength of equal to or less than 2.5 microns that is incident on the encapsulation layer 314).
  • a thickness of the inner coating 316 may be in a range of 1 micron to 500 microns, inclusive (e.g., 1, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, or 500 microns, inclusive).
  • Coating on core surface or on the encapsulation layer 314 surface might be thermally non-conductive or have poor thermal conductivity, for example, include ceramics, to minimize conductive heat transfer Attorney Docket No. TSCD-006/01WO 346332-2078 between the passively heated composite core 312 and the conductive encapsulation layer 314 metal with resistance heating.
  • a thickness of the inner coating 316 may be in a range of 50 microns to 300 microns, inclusive (e.g., 50, 100, 150, 200, 250, or 300 microns, inclusive).
  • a ratio of a thickness of the outer coating 330 to the thickness of the inner coating 316 may be in a range of about 1:1 to about 10:1, inclusive (e.g., 1:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, or 10:1, inclusive).
  • the inner coating 316 may be substantially similar to the inner coating 116 or may include any inner coating described in the ‘951 publication.
  • the optical fiber assembly 350 includes a fiber core 352 and a fiber encapsulation layer 354.
  • the thickness T of the fiber encapsulation layer 354 may be sufficient to withstand the extrusion or pultrusion process used to form the core 352 or otherwise, the strength member 310.
  • FIG. 4 is a side cross-section view of a conductor 402 that may be used as the conductors in the method 10, according to an embodiment.
  • the conductor 402 is similar to the conductor 202, for example, the conductor 402 includes a strength member 410 including a core 412, an encapsulation layer 414, and an optical fiber assembly 450, that may be substantially similar to the core 112, 212, the encapsulation layer 114, 214, and the optical fiber assembly 150, 250, respectively, as previously described herein.
  • the conductor 402 also includes a conductor layer 420 disposed around strength member 410 and an outer coating 430 disposed around the conductor layer 420.
  • the conductor layer 420 and the outer coating 430 may be substantially similar to the conductor layer 120, 220 and the outer coating 130, 230, previously described, and therefore not described in further detail herein.
  • an insulating layer (e.g., the insulating layer 222) may be interposed between the outer coating 430 and the conductor layer 420, as previously described.
  • an inner coating (e.g., the inner coating 116, 316) may optionally be disposed around the encapsulation layer 414 or otherwise interposed between the strength member 410 and the conductor layer 420, as previously described herein.
  • the optical fiber assembly 450 is disposed proximate to a radially outer edge of the core 412 such that the optical fiber assembly Attorney Docket No.
  • TSCD-006/01WO 346332-2078 450 is radially offset from the central axis (or longitudinal axis) of the core 412.
  • a shortest radial distance D from an outer edge of optical fiber assembly 450 to a radial outer edge of the core 412 may be in a range of about 0.1 mm to about 3 mm, inclusive (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.2, 2.4, 2.6, 2.8, or 3.0 mm, inclusive).
  • the shortest radial distance may be at least 0.1 mm. In some embodiments, the shortest radial distance may be at least 0.2 mm. In some embodiments, the shortest radial distance may be at least 0.3 mm. In some embodiments, the shortest radial distance may be at least 0.4 mm. In some embodiments, the shortest radial distance may be at least 0.5 mm. In some embodiments, the shortest radial distance may be at least 0.6 mm. In some embodiments, the shortest radial distance may be at least 0.7 mm. In some embodiments, the shortest radial distance may be at least 0.8 mm.
  • the shortest radial distance may be at least 0.9 mm. In some embodiments, the shortest radial distance may be at least 1.0 mm. In some embodiments, the shortest radial distance may be at least 1.2 mm. In some embodiments, the shortest radial distance may be at least 1.4 mm. In some embodiments, the shortest radial distance may be at least 1.6 mm. In some embodiments, the shortest radial distance may be at least 1.8 mm. In some embodiments, the shortest radial distance may be at least 2.0 mm. In some embodiments, the shortest radial distance may be at least 2.2 mm. In some embodiments, the shortest radial distance may be at least 2.4 mm.
  • the shortest radial distance may be at least 2.6 mm. In some embodiments, the shortest radial distance may be at least 2.8 mm. In some embodiments, the shortest radial distance may be at least 3.0 mm. [00109] In some embodiments, the shortest radial distance may be at most 3 mm. In some embodiments, the shortest radial distance may be at most 2.8 mm. In some embodiments, the shortest radial distance may be at most 2.6 mm. In some embodiments, the shortest radial distance may be at most 2.4 mm. In some embodiments, the shortest radial distance may be at most 2.2 mm. In some embodiments, the shortest radial distance may be at most 2.0 mm.
  • the shortest radial distance may be at most 1.9 mm. In some embodiments, the shortest radial distance may be at most 1.8 mm. In some embodiments, the shortest radial distance may be at most 1.7 mm. In some embodiments, the shortest radial distance may be at most 1.6 mm. In some embodiments, the shortest radial distance may be at most 1.5 mm. In some embodiments, the shortest radial distance may be at most 1.4 mm.
  • Attorney Docket No. TSCD-006/01WO 346332-2078 In some embodiments, the shortest radial distance may be at most 1.3 mm. In some embodiments, the shortest radial distance may be at most 1.2 mm.
  • the shortest radial distance may be at most 1.1 mm. In some embodiments, the shortest radial distance may be at most 1.0 mm. Positioning the optical fiber assembly 450 proximate to the radially outer edge of the core 412 may make it easier and/or faster for a user to access the optical fiber assembly 450 by removing or peeling only a portion of the core 412, thereby reducing installation, or repair time and cost.
  • FIG. 5A and 5B are side views of a coupler or fitting 540 that may be used to couple an axial end of a first conductor 502a to an axial end of the second conductor 502b using explosive force to form an assembly 500, according to an embodiment.
  • FIG.5A shows the coupler 540 in an uncoupled configuration in which the first and second conductors 502a, 502b are removably disposed in the coupler 540
  • FIG.5B shows the coupler 540 in a coupled configuration in which the first and second conductors 502a, 502b are fixedly coupled to the coupler 540
  • the conductors 502a, 502b can be substantially similar to each other, and include a strength member 510a, 510b and a conductor layer 520a, 520b disposed on the strength member.
  • the strength member 510a, 510b includes a core 512a, 512b having an encapsulation layer 514a, 514b disposed therearound.
  • An optical fiber assembly 550a, 550b may be disposed in the core 512a, 512b.
  • the core 512a, 512b, the encapsulation layer 514a, 514b, the optical fiber assembly 550a, 550b, and the conductor layer 520a, 520b may be substantially similar to the core 112, 212, 312, or 412, the encapsulation layer 114, 214, 314, or 414, the optical fiber assembly 150, 250, 350, or 450, and the conductor layer 120, 220, 320, 420, respectively, and therefore, not described in further detail herein. [00111] As shown in FIG.
  • the coupler or fitting 540 includes a body 542 (e.g., a cylindrical body) defining a channel configured to receive portions of corresponding axial ends of the first strength member 510a and the second strength member 510b.
  • a predetermined length of the conductor layers 520a, 520b of the conductors 502a, 502b may be removed (e.g., a portion having a length in a range of about 150 mm to about 350 mm, inclusive from the axial end of the conductors 502a, 502b).
  • the body 542 may be formed from a strong and rigid material.
  • the body 542 may be formed from a metal or metal alloy, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the cross-sectional width (e.g., diameter) of the inner volume of the body 542 may be slightly greater than the cross-sectional width (e.g., Attorney Docket No. TSCD-006/01WO 346332-2078 diameter) of the strength members 510a, 510b such that a first gap G1 exists between an inner surface of the body 542 and an outer surface of the strength members 510a. 510b in the uncoupled configuration.
  • an optical connector 552 (e.g., any of the optical connectors as described with respect to assembly 100) is disposed in the channel.
  • Each of the optical fiber assemblies 510a, 510b may be coupled to the optical connector 552 to optically couple the optical fiber assemblies 550a, 550b to each other.
  • the coupler 540 also includes a sleeve 544 disposed around the body 542 (e.g., circumferentially around the body 542) and has a length that is longer than a length of the body 542 such that the sleeve 544 extends axially outwards of the body 542.
  • the sleeve 544 may be formed from a conductive material, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the sleeve 544 may have a cross-sectional width (e.g., diameter) that is slightly larger than a cross-sectional width (e.g., diameter) of the conductor layers 520a, 520b such that second gap G2 exists between an inner surface of the sleeve 544 and outer surface of the conductor layers 520a, 520b in the uncoupled configuration.
  • An explosive material 562 is disposed on the sleeve 544.
  • any suitable explosive material may be used such as, for example, trinitrotoluene (TNT), RDX, nitroglycerin, picric acid, lead azide, black powder, etc.
  • the explosive material 562 may be pressed or molded on an outer surface of the sleeve 544.
  • the explosive material 562 may include a cord, string, or rope including the explosive material, which is wrapped or wound around the sleeve 544.
  • a protective layer (not shown) may be disposed around the explosive material 562, for example, to protect the explosive material 562 from moisture or physical damage.
  • a detonator 564 may be operatively coupled to the explosive material 562. Any suitable detonator 564 may be used such as, for example, a wireless detonator, a blast cap, a non-electric detonator, or any other suitable detonator that can only be detonated by a special initiator or trigger, thus inhibiting accidental detonation.
  • FIG. 5B shows the coupler 540 in a coupled configuration after detonating of the explosive material 562 by activating, initiating, or triggering the detonator 564.
  • detonating of the explosive material 562 creates an implosive force that compresses Attorney Docket No. TSCD-006/01WO 346332-2078 or crimps the sleeve 544 to corresponding portions of the conductor layers 520a, 520b, and the body 542 to strength members 510a, 510b.
  • the composite material from which the core 512a, 512b is formed may be susceptible to crush force damage.
  • the encapsulation layers 514a, 514b disposed around the cores 512a, 512b also serve as protection layers to protect the cores 512a, 512b from the compressive force exerted during implosive coupling of the body 542a, 542b around the strength members 510a, 510b.
  • the first optical fiber assembly 550a is coupled to the second optical fiber assembly 550b, for example, via the optical connector 552. In this manner, the first optical fiber assembly 550a may communicate sensing signals measured by the first optical fiber assembly 550a to the second optical fiber assembly 550b or vice versa for eventual communication to a controller.
  • a coating e.g., the outer coating 130
  • a coating may be disposed on an outer surface of the coupler 540 after the coupler 540 has been coupled to the conductors 502a, 502b to inhibit a temperature of the core 512a, 512b to exceed their glass transition temperature or melting temperature, and/or maintain operating temperature of the conductor layers 520a, 520b within a desired range (e.g., between 60 degrees Celsius and 250 degrees Celsius), as previously described herein.
  • a desired range e.g., between 60 degrees Celsius and 250 degrees Celsius
  • FIG. 6 is a schematic flow chart of a method 10 for coupling a first conductor (e.g., the conductor 102, 202, 302, 402, 502a) to a second conductor (e.g., the conductor 102, 202, 302, 402, 502a) via a coupler (e.g., the coupler 140, 540) using explosives (e.g., the explosive material 162, 562), according to an embodiment. While described with respect to the conductors 502a, 502b and the coupler 540, the operations of the method 10 can be used to couple or splice any conductors described herein via the coupler [00116]
  • the method 10 includes providing the first conductor 502a and the second conductor 502b, at 12.
  • the method 10 includes removing a portion or length of the conductor layer 520a, 520b from first ends of each of the first conductor 502a and the second conductor 502b to expose a portion of the respective strength members 510a, 510b of the first and second conductors 502a, 502b, at 14 (e.g., removing a portion having a length in a range of about 150 mm to about 350 mm, inclusive, from the axial end of the conductors 502a, 502b).
  • a circumcizer, a cutter or any other suitable equipment may be used to make slits or cuts in the conductor layers 520a, 520b proximate to axial ends of the conductors 502a, 502b, Attorney Docket No. TSCD-006/01WO 346332-2078 and the portion of the conductor layers 520a, 520b removed or stripped off to expose a portion of their respective strength members 510a, 510b.
  • the first end of the first conductor 502a is inserted into a channel defined by the body 542 of the coupler 540 through a first end of the coupler 540.
  • the sleeve 544 may be disposed around the body.
  • a mark or indicator may be provided or formed on an outer surface of the conductor layer 520a and the mark aligned with an outer edge of a first end of the sleeve 544 such that the first conductor 502a is inserted only up to a predetermined length into the coupler 540.
  • a first end of the second conductor 502b is inserted into the channel of the coupler 540 through a second end of the coupler 540 opposite the first end.
  • a mark or indicator may be provided or formed on an outer surface of the conductor layer 520b of the second conductor 502b and the mark aligned with an outer edge of the second end of the sleeve 544 such that the second conductor 502b is inserted only up to a predetermined length into the coupler 540, for example, about the same length that the first conductor 502a is inserted into the coupler 540.
  • the optical connector 552 may be disposed into the channel defined by the coupler 540, for example, within the channel defined by the body 542. First ends of the optical fiber assembly 550a, 550b of each of the first and second conductors 502a, 502b may be exposed and inserted into the optical connector 552 or otherwise communicatively coupled thereto, to optically couple the optical fiber assembly 550a of the first conductor 502a to the optical fiber assembly 550b of the second conductor 502b.
  • inserting the first ends of the first and second conductors 502a, 502b includes inserting the exposed portions of the first and second strength members 510a, 510b within a portion of the channel defined by the body 542 of the coupler 540 such that corresponding axial ends of the conductor layers 520a, 520b of each of the first and second conductors 502a, 502b are positioned in a portion of the coupler 540 that is outside the body 542, for example, but within the sleeve 544 of the coupler 540.
  • the body 542 and the sleeve 544 have inner cross-sectional widths (e.g., diameters) that are larger than corresponding outer cross-sectional widths of the strength members 510a, 510b and the conductor layers 520a, 520b of the first and second conductors Attorney Docket No. TSCD-006/01WO 346332-2078 502a, 502b. This allows a gap to be present between inner surfaces of the body 542 and the sleeve 544 and corresponding outer surfaces of the strength members 510a, 510b and the conductor layers 520a, 520b when ends of the first and second conductors 502a, 502b are inserted into the coupler 540.
  • inner cross-sectional widths e.g., diameters
  • the coupler 540 is a first coupler 540 and the method 10 also includes providing a third conductor and a second coupler.
  • the third conductor may also include a strength member including a core formed from a composite material and an encapsulation layer around the core, and a conductor layer disposed around the strength member, at 20.
  • the third conductor may also include the conductor 502a or 502b.
  • the method 10 includes removing a length of the conductor layer 520b from a second end of the second conductor 502b that is opposite the first end of the second conductor 502b, and a first end of the third conductor, at 22.
  • the second end of the second conductor 502b is inserted into a channel of a second coupler through a first end of the second coupler.
  • the second coupler may be substantially similar in structure and function to the first coupler 540, as previously described.
  • the first end of the third conductor is inserted into the channel through a second end of the second coupler that is opposite the first end of the second coupler.
  • a detonator 564 is operatively coupled to the explosive material 562, at 28.
  • any suitable detonator may be used such as, for example, a wireless detonator, a blast cap, a non-electric detonator, or any other suitable detonator that can only be detonated by a special initiator or trigger, thus inhibiting accidental detonation.
  • the explosive material 562 is detonated, for example, by remotely triggering the detonator 564, to cause the first coupler 540 to be couped to the first and second conductors 502a, 502b and to electrically couple the first and the second conductors 502a, 502b to each other, as previously described.
  • the explosive materials 562 disposed around the first coupler 540 and the second coupler are detonated simultaneously.
  • the method 10 may include performing a safety check prior to detonation to maintain a desired distance between the explosive material 562 and all personal.
  • Attorney Docket No. TSCD-006/01WO 346332-2078 [00123]
  • the method 10 may also include disposing a coating, for example, the coating 130 disposed on the outer surface of the coupler, at 32.
  • the coating may be formulated to have a solar absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5, l less than 0.45, less than 0.40, less than 0.35, less than 0.30, less than 0.25, less than 0.20, less than 0.15, less than 0.1, inclusive or even lower) at a wavelength of less than 2.5 microns, and a radiative emissivity of greater than 0.5 (e.g., greater than 0.50, greater than 0.55, greater than 0.60, greater than 0.65, greater than 0.70, greater than 0.75, greater than 0.80, greater than 0.85, greater than 0.90, greater than 0.95, inclusive, or even higher) at a wavelength in a range of 2.5 microns to 15 microns, inclusive at an operating temperature in a range of 60 degrees Celsius to 250 degrees Celsius, inclusive.
  • a solar absorptivity of less than 0.6 (e.g., less than 0.6, less than 0.55, less than 0.5,
  • the method 10 may further include incorporating one or more safety features associated with detonation of the explosive material 562.
  • one or more safety features may include tamper-resistant detonators, triggering mechanisms, or environmental sensors configured to prevent detonation under predefined conditions, such as elevated humidity or temperature.
  • the method 10 may further include maintaining a desired safe distance from the coupler 540, deploying protective barriers around the coupling site, and/or initiating detonation remotely.
  • the method 10 may further include verifying proper insertion and/or alignment of the conductor (e.g., the first conductor 502a and/or the second conductor 502b) within the coupler 540 using visual and/or electronic indicators disposed on or within the coupler prior to detonation.
  • FIGS.7A and 7B are side views of a coupler or fitting 640 that may be configured to be coupled to an axial end of a conductor 602 using explosive force, according to an embodiment.
  • FIG. 7A shows the coupler 640 in an uncoupled configuration in which the conductor 602 is removably disposed in the coupler 640
  • FIG.7B shows the coupler 640 in a coupled configuration in which the coupler 640 is fixedly coupled to the conductor 602.
  • the conductor 602 can include a strength member 610 and a conductor layer 620 disposed on the strength member 610.
  • the strength member 610 includes a core 612 having an encapsulation layer 614 disposed therearound.
  • An optical fiber assembly 650 is disposed in the core 612.
  • the core 612, the encapsulation layer 614, the optical fiber assembly 650, and the conductor layer 620 may be substantially similar to the core 112, 212, 312, 412, or 512a/b the encapsulation layer 114, 214, 314, 414, or 514a/b the optical fiber assembly 150, 250, 350, Attorney Docket No. TSCD-006/01WO 346332-2078 450, or 550a/b and the conductor layer 120, 220, 320, 420, or 520a/b respectively, and therefore, not described in further detail herein.
  • the coupler or fitting 640 includes a body 642 (e.g., a cylindrical body) defining a channel therethrough that is configured to receive a portion of an end of the strength member 610 conductor 602. For example, a portion or length of the conductor layer 620 of the conductor 602 may be removed (e.g., a portion having a length in a range of about 150 mm to about 350 mm, inclusive, from the axial end of the conductor 602).
  • the body 642 may be formed from a strong and rigid material.
  • the body 642 may be formed from a metal or metal alloy, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the cross-sectional width (e.g., diameter) of the inner volume of the body 642 may be slightly greater than the cross-sectional width (e.g., diameter) of the strength member 610 such that a first gap G1 exists between an inner surface of the body 642 and an outer surface of the strength member 610 in the uncoupled configuration.
  • the coupler 640 may also include a sleeve 644 disposed around the body 642 (e.g., circumferentially around the body 642) and has a length that is longer than a length of the body 642 such that the sleeve 644 extends axially outwards of a first axial end of the body 642 through which the strength member 610 is inserted into the channel defined by the body 642.
  • the sleeve 644 may be formed from a conductive material, for example, aluminum, alloys, copper, stainless steel, any other suitable material, or any suitable combination thereof.
  • the sleeve 644 may have a cross-sectional width (e.g., diameter) that is slightly larger than a cross-sectional width (e.g., diameter) of the conductor layer 620 such that a second gap G2 exists between an inner surface of the sleeve 644 and outer surface of the conductor layer 620 in the uncoupled configuration.
  • An explosive material 662 is disposed on the sleeve 644.
  • any suitable explosive material may be used such as, for example, trinitrotoluene (TNT), RDX, nitroglycerin, picric acid, lead azide, black powder, etc.
  • the explosive material 662 may be pressed or molded on an outer surface of the sleeve 644.
  • the explosive material 662 may include a cord, string, or rope including the explosive material, which is wrapped or wound around the sleeve 644.
  • a protective layer (not shown) may be disposed around the explosive material 662, for example, to protect the Attorney Docket No. TSCD-006/01WO 346332-2078 explosive material 662 from moisture or physical damage.
  • a detonator 664 may be operatively coupled to the explosive material 662. Any suitable detonator 664 may be used such as, for example, a wireless detonator, a blast cap, a non-electric detonator, or any other suitable detonator that can only be detonated by a special initiator or trigger, thus inhibiting accidental detonation.
  • the coupler 640 also includes a connecting portion 646 coupled to the sleeve 644 and/or the body 642 at a second end of the coupler 640 opposite the first end.
  • a wall 647 of the connecting portion 646 may be coupled to the sleeve 644 and/or the body 642.
  • the connecting portion 646 defines a keyhole 648 configured to couple to corresponding hooks or connectors located on poles (e.g., tension towers) from which the conductor 602 may be suspended.
  • a protective cap 666 may disposed at the second axial end, at an interface of the sleeve 644 and the connecting portion 646.
  • the protective cap 666 may include a strong and rigid material (e.g., metals, alloys, plastics, polymers, etc.) extending radially from the sleeve 644 and may be configured to absorb explosive force or direct the explosive force due to the explosive material being detonated away from the connecting portion 646.
  • an opening 645 may be defined on the wall 645 of the connecting portion 646 adjacent to the sleeve 644, or any other portion of the coupler 640.
  • the optical fiber assembly 650 included in the conductor 602 may be routed out of the coupler 640 through the opening 645 for coupling with a controller or receiver.
  • FIG.7B shows the coupler 640 in a coupled configuration after detonating of the explosive material 662 by activating, initiating, or triggering the detonator 664, as previously described with respect to coupler 540.
  • a coating e.g., the outer coating 130
  • FIG.8 is a schematic flow chart of a method 60 for coupling a conductor (e.g. the conductor 102, 202, 302, 402, 502a, 503b, or 602) to a coupler using explosives, according to an embodiment. While described with respect to the conductor 602 and the coupler 640, the Attorney Docket No. TSCD-006/01WO 346332-2078 operations of the method 60 can be used to couple any conductor to any coupler using explosives. All such implementations are envisioned and should be considered to be within the scope of the present disclosure. [00132] The method 60 includes providing the conductor 602, at 62.
  • a conductor e.g. the conductor 102, 202, 302, 402, 502a, 503b, or 602
  • the method 60 includes providing the conductor 602, at 62.
  • a portion or length of the conductor layer 620 is removed from an end of the conductor 602 to expose a portion of the strength member 610 of the conductor 602 (e.g., a portion having a length in a range of about 150 mm to about 350 mm, inclusive, from the end of the conductor 602).
  • a circumcizer, a cutter or any other suitable equipment may be used to make slits or cuts in the conductor layer 620 of the conductor 602 proximate to an end of the conductor 602, and the portion of the conductor layer 620 of the conductor 602 to expose a portion of the strength member 610 thereof, as previously described with respect to the method 10.
  • a mark or indicator may be provided or formed on an outer surface of the conductor layer 620 and the mark aligned with an outer edge of the first end of the sleeve 644 such that the conductor 602 is inserted only up to a predetermined length into the coupler 640.
  • the connecting portion 646 of the coupler 640 may be coupled to a pole (e.g., an electrical pole or tower), at 68.
  • a hook, rope, coil, or any other coupling mechanism may be interfaced with the keyhole 648 defined in the connecting portion 646 to couple the coupler 640 to the pole.
  • positioning the exposed portion of the strength member 610 of the conductor 602 within a portion of the channel defined by the body 642 of the coupler 640 disposes the conductor layer 620 of the conductor 602 in a portion of the coupler 640 that is outside the body 642 but within the sleeve 644 of the coupler 640.
  • the body 642 and the sleeve 644 have inner cross-sectional widths (e.g., diameters) that are larger than corresponding outer cross-sectional widths of the strength member 610 and the conductor layer 620 of the conductor 602. This allows a gap to be Attorney Docket No.
  • the detonator 664 is operatively coupled to the explosive material 662, at 72.
  • Any suitable detonator may be used such as, for example, a wireless detonator, a blast cap, a non-electric detonator, or any other suitable detonator that can only be detonated by a special initiator or trigger, thus inhibiting accidental detonation, as previously described.
  • the explosive material 662 is detonated, for example, by remotely triggering the detonator 664, to cause the coupler 640 to be couped to the conductor 602 and in some embodiments, electrically couple the conductor layer 620 of the conductor 602 to the coupler 640.
  • the detonation of the explosive material 662 causes the body 642 and the sleeve 644 to be compressed around the strength member 610 and the conductor layer 620 such that there is substantially no gap between the body 642 and the sleeve 644, and corresponding portions of the strength member 610 and conductor layer 620 of conductor 602.
  • the method 60 may also include disposing a coating, for example, the coating 130 on the outer surface of the coupler 640, as previously described with respect to the method 10.
  • a coating for example, the coating 130 on the outer surface of the coupler 640, as previously described with respect to the method 10.
  • the terms “about” and “approximately” generally mean plus or minus 10% of the stated value. For example, about 0.5 would include 0.45 and 0.55, about 10 would include 9 to 11, about 1000 would include 900 to 1100.
  • the terms “substantially’ and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains.
  • TSCD-006/01WO 346332-2078 The terms “coupled,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable, or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. [00140] It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only.

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Abstract

Un coupleur comprend un corps définissant un canal à travers celui-ci, et un matériau explosif disposé autour du corps. Le coupleur est mobile entre une première configuration dans laquelle une extrémité d'un conducteur est disposée de manière amovible dans le canal défini par le coupleur, le conducteur comprenant un élément de résistance comprenant : un noyau formé à partir d'un matériau composite et une couche d'encapsulation disposée autour du noyau, et une couche conductrice disposée autour de l'élément de résistance, et une seconde configuration dans laquelle le matériau explosif est détoné pour amener le coupleur à être couplé de manière fixe à l'extrémité du conducteur. Un manchon peut être disposé autour du corps, et le matériau explosif disposé autour du manchon. L'invention concerne également des procédés de couplage de coupleurs à des conducteurs à l'aide de matériaux explosifs.
PCT/US2025/038955 2024-07-25 2025-07-23 Procédés et appareils pour coupler des conducteurs composites à l'aide d'explosifs Pending WO2026024902A1 (fr)

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3668778A (en) * 1968-04-05 1972-06-13 Torleif Lindtveit Methods for joining ends of wires and the like
US3684820A (en) * 1969-12-02 1972-08-15 Raufoss Ammunisjonsfabrikker Joints for high tension lines, cables and the like
JPS5740256U (fr) * 1980-08-15 1982-03-04
US20110297441A1 (en) * 2008-04-16 2011-12-08 Afl Telecommunications Llc. Implosive joint and dead-end apparatus and method
US9633766B2 (en) 2014-09-26 2017-04-25 Jianping Huang Energy efficient conductors with reduced thermal knee points and the method of manufacture thereof
CN113363929A (zh) * 2021-05-21 2021-09-07 广州番禺电缆集团有限公司 一种电缆接头防爆隔离设备的联动防爆控制方法及装置
US20220385055A1 (en) * 2019-12-20 2022-12-01 Ctc Global Corporation Ported hardware for overhead electrical cables
US11854721B2 (en) 2022-03-28 2023-12-26 Ts Conductor Corp. Composite conductors including radiative and/or hard coatings and methods of manufacture thereof
WO2024091951A1 (fr) 2022-10-25 2024-05-02 Ts Conductor Corp. Conducteurs composites intelligents et leurs procédés de fabrication

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3668778A (en) * 1968-04-05 1972-06-13 Torleif Lindtveit Methods for joining ends of wires and the like
US3684820A (en) * 1969-12-02 1972-08-15 Raufoss Ammunisjonsfabrikker Joints for high tension lines, cables and the like
JPS5740256U (fr) * 1980-08-15 1982-03-04
US20110297441A1 (en) * 2008-04-16 2011-12-08 Afl Telecommunications Llc. Implosive joint and dead-end apparatus and method
US9633766B2 (en) 2014-09-26 2017-04-25 Jianping Huang Energy efficient conductors with reduced thermal knee points and the method of manufacture thereof
US20220385055A1 (en) * 2019-12-20 2022-12-01 Ctc Global Corporation Ported hardware for overhead electrical cables
CN113363929A (zh) * 2021-05-21 2021-09-07 广州番禺电缆集团有限公司 一种电缆接头防爆隔离设备的联动防爆控制方法及装置
US11854721B2 (en) 2022-03-28 2023-12-26 Ts Conductor Corp. Composite conductors including radiative and/or hard coatings and methods of manufacture thereof
WO2024091951A1 (fr) 2022-10-25 2024-05-02 Ts Conductor Corp. Conducteurs composites intelligents et leurs procédés de fabrication

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