MINERAL-INSULATED SHIELDED CABLE FOR ULTRA HIGH TEMPERATURES, HEATING ELEMENT AND TRANSMISSION CABLE, APPLICATION AND MANUFACTURING METHOD

Abstract

An ultra high temperature mineral-insulated shielded cabled is provided as a non-sintered compacted powder, where central conductors and/or a sheath are made of a conducting material selected from tantalum, tungsten, rhodium, rhenium, carbon, and a mixture of at least two of such materials. The mineral insulator is made of an insulating material selected from boron nitride, yttrium oxide, silicon nitride, aluminium nitride, and a mixture of such materials. The conductor is tantalum and the insulator is selected from hafnia, boron nitride, silicon nitride, and a mixture of such materials, in particular for a use at a temperature lower than 1 630° C. or 1 600° C.; or aluminium nitride, in particular at a temperature lower than 1 530° C. or 1 500° C. A device including this cable used below 1800° C., particularly under 1 600° C., in particular under vacuum, as a heating element or transmission cable.

Claims

1. A mineral-insulated shielded cable, comprising: one or more so-called central conductors, surrounded by at least one mineral insulator layer as a compacted powder, the assembly being enclosed into a ductile sheath of a sealed material; wherein said central conductors and said sheath are each made with at least 80%, in particular at least 90% and in particular at least 99%, of a material selected from tantalum, tungsten, rhodium, rhenium, carbon, and a mixture of at least two of these materials; and wherein said mineral insulator is made, with at least 80%, in particular at least 90% and in particular at least 99%, of a material selected from boron nitride, yttrium oxide, silicon nitride, aluminium nitride, and a mixture of at least two of these materials.

2. The cable of claim 1, wherein one or more of the central conductors and the sheath are made of metal obtained by melting, in particular vacuum melting.

3. The cable of claim 2, wherein one or more of the central conductors and the sheath are made of at least 99.95% pure metal.

4. The cable of claim 1, wherein the mineral insulator comprises at least 90%, in particular at least 99% and more particularly at least 99.9% by mass of boron nitride, and wherein the central conductors and the sheath of the cable each comprise at least 90%, in particular at least 99% and more particularly at least 99.9%, of a material selected from: tantalum, rhodium, tungsten, rhenium, carbon, and a mixture of at least two of these materials.

5. The cable of claim 1, wherein the mineral insulator comprises at least 90%, in particular at least 99% and more particularly at least 99.9% by mass of silicon nitride, and wherein the central conductors and the sheath of the cable each comprise at least 90%, in particular at least 99% and more particularly at least 99.9%, of a material selected from: tantalum, rhodium, tungsten, rhenium, carbon, and a mixture of at least two of these materials.

6. The cable of 1, wherein the central conductor of said cable comprises only one wire, in particular with a diameter higher than 0.1 mm, in particular higher than 0.5 mm, and with a diameter lower than 5 mm, in particular lower than 3 mm, and more particularly lower than 1 mm, and wherein the external diameter of the cable is lower than 5 mm, in particular lower than 3 mm and more particularly lower than 2.4 mm, and is higher than 0.5 mm, in particular higher than 1 mm and more particularly higher than 2 mm.

7. The cable of 1, characterised in that the central conductor comprises several wires, parallel to each other or coiled around a longitudinal axis of said cable.

8. A device comprising the cable of claim 1, wherein it is arranged to operate under conditions where said cable is brought to a so-called operational temperature which is higher than 1 200° C. and in particular higher than 1 300° C., and/or which is lower than 1 830° C., in particular lower than 1 800°, in particular lower than 1 630° C. and in particular lower than 1 600° C.

9. A device comprising the cable of claim 4, wherein said device is arranged to operate under conditions where the cable is brought to a so-called operational temperature which is higher than 1 470° C., and in particular higher than 1 500° C. and/or which is lower than 1630° C. and in particular lower than 1 600° C.

10. The device of claim 9, wherein said device is arranged to operate under conditions where the cable is likely to undergo a plurality of temperature variation cycles, between at least the operational temperature and at least a so-called standby temperature which is lower than 500° C. and more particularly lower than 250° C., during a so-called operational life service of said cable, defined by a number of cycles following which said cable has to remain operational, said life service being higher than 50 cycles, and in particular higher than 100 cycles, and for example higher than or equal to 180 cycles.

11. A device comprising the cable of claim 5, wherein said device is arranged to operate under conditions where the cable is brought to a so-called operational temperature which is lower than 1 530° C. and in particular lower than 1 500° C.

12. The device of claim 11, wherein said device is arranged to operate under conditions where the cable is likely to undergo a plurality of temperature variation cycles, between at least the operational temperature and at least a so-called standby temperature which is lower than 500° C. and more particularly lower than 250° C., during a so-called operational life service of said cable, defined by a number of cycles following which said cable has to remain operational to the minimum, said life service being higher than 200 cycles, and in particular higher than 300 cycles, and can also be higher than 400 cycles or even 450 cycles, and for example higher than or equal to 500 cycles.

13. The device of claim 8, wherein said device is arranged to operate under a vacuum being a pressure lower than 10.sup.−2 Pa, in particular lower than 10.sup.−3 Pa, and more particularly lower than 2.10.sup.−4 Pa.

14. The device of claim 8, wherein said device is arranged to make a heating element operated by flowing an electric intensity within the central element(s) of the cable.

15. The device of claim 14, wherein said device is arranged to produce a contact heating of an ionisation electrode within an electric type spatial or aeronautic thruster.

16. The device of claim 14, wherein the cable is wound around a hollow cathode and in that the device is arranged to preheat said cathode so as to allow gas ionisation, for example during the ignition of a self-heating spatial ion thruster.

17. The device of claim 8, wherein it is arranged to carry an electric or electromagnetic signal in a high temperature environment.

18. A method for manufacturing the mineral-insulated shielded cable of claim 1, wherein said method comprises the following steps of: preparing a blank having an initial external diameter, and comprising: the central conductor(s) as metal wires or pipes, the mineral insulator layer(s) as a powder surrounding said central conductors, and the sheath; one or more reduction passes by hammering or wire drawing, arranged to reduce the external diameter of said cable down to a final diameter lower than the initial diameter, and produce compacting of powders included in said cable.

19. The method of claim 18, further comprising at least one vacuum annealing step.

20. The of claim 18, further comprising at least one prior step of calcinating the powder material(s) making the mineral insulator, at a temperature higher than 500° C., in particular higher than 890° C., and for example at 900° C., during a time duration higher than 10 min and in particular between 15 min and 90 min.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0090] Further features and advantages of the invention will appear from the detailed description of an implementation in no way limiting, and the appended drawings in which:

[0091] FIG. 1 is a transverse and a longitudinal cross-section schematic views, which illustrate two exemplary structures of a mineral-insulated shielded cable according to the invention;

[0092] FIG. 2 is a perspective view of an ionising hollow cathode carrying a mineral-insulated shielded cable winding according to the invention, mounted as a heating cable; and

[0093] FIG. 3 is a longitudinal cross-section schematic view of the implementation of the heating cathode of FIG. 2, within a plasma ion thruster.

DETAILED DESCRIPTION

[0094] FIG. 1 illustrates two conventional exemplary structures of a mineral-insulated shielded cable in which the cable according to the invention can be implemented.

[0095] Such a cable 1, 1′ comprises one (cable 1) or several (cable 1′) so-called central conductors 14, surrounded by at least one mineral insulator layer 12 as a compacted powder, the assembly being enclosed into a ductile sheath 11 of a sealed material.

Insulation Resistance Tests, According to the Temperature

[0096] Numerous mineral-insulated shielded cables have been manufactured, and tested by mounting them as heating devices.

[0097] Tests performed are herein described, in a non-exhaustive way, which have been carried out with the following materials: [0098] Insulators: Alumina (Al2O3), Magnesia (MgO), Boron nitride (BN), Silicon nitride (Si3N4), Aluminium nitride (AlN), Hafnia, Spinel, Yttria; and [0099] Conducting material(s) and/or sheath(es): Tantalum, Tungsten, alloyed tungsten, Rhodium, Rhenium

[0100] Tantalum used in these tests is more than 99.95% pure, obtained by vacuum melting.

Manufacturing Procedure

[0101] Tests have been conducted with different combinations of these materials for the cable elements: insulator, conductors, sheath.

[0102] In a so-called “pearl” configuration, the conductor is a wire coiled around a solid insulator core, and surrounded by a solid insulator pipe. The solid insulator is in a so-called “pearl” form, that is solid but friable, generally obtained by extrusion or isostatic pressing, and machining. This kind of form is typically used to make the blank which will then be used to make the complete cable. The pearl then disintegrates through deformation during reduction passes, to transform into a compacted powder in the final cable.

[0103] In a so-called “cable” configuration, the mineral-insulated shielded cable is entirely mounted and brought to its final diameter.

[0104] The cable used here is a single-conductor cable. The blank is formed being assembled via a wire or pipe which will form the conductor, inserted into the hole of an insulator pearl or into the insulator powder, which insulator being itself surrounded by a pipe which will form the sheath. The blank subsequently undergoes several hammering or wire drawing passes followed or not by annealing passes, until the desired final diameter is obtained.

[0105] Powders are all calcinated at 600° C. Annealing passes are made under 100% Argon.

[0106] Blanks have been measured and weighed before reduction, which implies that compaction rates can be determined.

[0107] For tantalum cables, these cables are made with a grade of tantalum more than 99.95% pure, obtained by vacuum melting.

[0108] A blank is obtained which is therefore particularly ductile and conducive to hammering. The wire has a diameter of 0.508 mm, and the pipe a diameter of 3.175/2.413 mm). The tested cable has a final diameter of 2 mm.

[0109] Due to the large ductility of tantalum, it is contemplated to be able to go further below this diameter.

[0110] Ri=f(T) measurements have been made in an oven, for the temperature range from 600° C. to 1 000° C., with 3 m cables and more stable results are obtained.

Material Combination Tests

[0111] These Cables are Subsequently Tested as Heating Cables, by Rising the temperature thereof.

[0112] Test 3: Ta—MgO

[0113] A MgO and tantalum combination has been tested as a cable. Indeed, it is Magnesia which provides the highest hot insulation.

[0114] However, the test was not conclusive, the cable stopped operating whereas the temperature had not exceeded 1 300° C. An analysis of the out of service heating element showed that a eutectic type reaction occurred between tantalum and magnesia. This was confirmed by scanning electron microscope analyses.

Test 4: Ta—HfO2 Pearl

[0115] A test was carried out with a bare tantalum wire, wound around a perforated ø2.75 hafnia pearl. The assembly is brought to 1 600° C. with temperature gradients.

[0116] The test is raised up to 1 600° C., and the tantalum wire is still ductile at the end of the test. However, it was nearly no longer in contact with hafnia since the pearl was reduced in diameter to 0.5 mm, that is 18%, in all likelihood by sintering/melting or change of phase. After research, it would seem that hafnia has a change of phase from 1 650° C.

[0117] Thus, cables associating hafnia as an insulator with tantalum as a conductor and sheath have enabled an operational temperature of 1 500° C., or even 1 600° C.

Test 5: Ta—BN Cable: Maximum Temperature Rise Test.

[0118] A single-wire cable associating tantalum and BN (boron nitride). A heating test is performed under vacuum up to 1 900° C., but a short-circuit terminated the test, with a significant vacuum loss (degassing) occurring from 1 850° C.

[0119] A radiography is performed on the cable in proximity to the suspected fracture, which shows a sharp fracture of the core. The cable is actually highly breakable, with a typical pattern of a brittle fracture.

[0120] A resistance up to 1 800° C., or even 1 850° C. is observed, but with a short-circuit at 1 900° C.

Test 6: Ta—BN Pearl: Temperature Rise Test at 1 850° C.

[0121] A gradual temperature rise test is performed with a tantalum wire coiled around a BN pearl and then covered with another BN pearl.

[0122] At the end of this test, the BN chuck pearl is black and the turns are all grey and breakable. The pattern is still shiny, typical of a brittle fracture. It has been therefore demonstrated that there is a reaction with boron nitride at 1 900° C. and which is not related to the cable configuration.

[0123] It is furthermore noticed that the vacuum level is quite stable below 1 800° C. on the wire (cf. transition temperature) and highly disturbed beyond, without exceeding 5.10.sup.−4 m bar. There may be continuous micro degassing which happen during the tantalum/BN reaction. It does not seem to be here a sublimation or eutectic which would cause something abrupt and not gradual as here. May be a chemical reaction or diffusion.

[0124] It therefore seems that the Ta—BN combination is able to rise up to 1 800° C., or even 1 850° C., but it can have limits due to embrittlement of tantalum.

Test 7: Ta—BN Pearl: Temperature Resistance Test at 1 500° C. (1 h)

[0125] The test is repeated but this time at 1 500° C. during 1 h, and then the ductility of tantalum is manually observed.

[0126] At the end of the test, tantalum is still ductile. The association of tantalum with boron nitride is therefore operational up to 1 500° C.

[0127] Due to the ductility being kept, similar life service features to those known for usual heating temperatures, up to 1 500° C., can be reasonably expected.

Test 8 First Part: Ta—BN Pearl: Temperature Resistance Test at 1 600° C. (1 h)

[0128] The test repeated at 1 600° C. during 1 h. Quantified results are similar, but tantalum is brittle at the end of the test.

[0129] The maximum use temperature of tantalum with boron nitride is between 1 500° C. and 1 600° C. to keep a ductile state thereto.

[0130] Tantalum thus seems to react with BN between 1 500° C. and 1 600° C., which causes its embrittlement, but remains operational from an electric point of view.

Test 8 Second Part: Ta—BN Cable: Temperature Resistance Test at 1 600° C. (1 h) and then Cycling

[0131] Tests are then resumed with the same cable type at a temperature lower than the initial 1 900° C., to assess its possibilities in terms of life service, under situations of use with several temperature rises.

[0132] A tantalum+BN single-wire cable with non-contiguous turns has been made with the previously tested BN powder. The cable was supplied to reach 1 600° C. during 1 h, with a prior 1 h-step at 1 000° C. At the end of this test, the cable proves ductile when handled.

[0133] This same cable has been subsequently cyclically supplied, between 1 600° C. and 200° C., to be ON during 7 min at 1 600° C. and OFF back to 200° C.

[0134] It is noticed that the cable has a life service higher than 180 cycles, between 200° C. and 1 600° C.

Test 9: Ta—Si3NO4 Cable: Temperature Rise Test

[0135] A test associating tantalum and silicon nitride Si3N4 has been performed. The cable made is coiled with 015 mm non-contiguous turns. The turns did not collapse at 1 600° C. and the temperature was homogeneous over the whole coiled part.

[0136] The heating element remained operational in its temperature rise up to 1 600° C., but could only operate during 30 min at this temperature. Upon examination, it is observed that the core melted over several mm inside the cable and created a discontinuity. While straightening the turn, it broke clean with a shiny pattern characteristic of tantalum embrittlement.

[0137] This combination is therefore capable of being possibly operational at a temperature lower than or equal to 1 600° C., but with a life service limited over time.

Test 10: Rhodium+BN Pearl: Temperature Rise Test

[0138] A test is performed with boron nitride (BN) associated with Rhodium, in a pearl type configuration.

[0139] The temperature rise halted at 1 650° C., due to a discontinuity. In the same time, the vacuum was broken, probably due to a sudden degassing. The continuity fault comes from the wire melting right in the middle with suspicions of vaporisation/sublimation at this vacuum rate (sudden vacuum loss).

[0140] Yet, on theoretical vaporisation curves, it can be seen that between 1 and 5.10.sup.−5 mbar rhodium is vaporised between 1 850° C. and 1 900° C.

[0141] It is therefore possible that the measurement at 1 650° C. within the BN pearls (via C-type bare wires) and at 1 625° C. at the surface of the outer BN pearl (via a pyrometer) substantially reduce temperature of the heating wire.

[0142] Thus, the discontinuity is probably produced by a real temperature of the conductor around 1 850° C., due to a temperature gradient and/or a contact fault.

[0143] This combination therefore seems operational below 1 600° C., or even above up to 1 800° C.

Example of Application: Preheating of Ionising Hollow Cathode for Producing Plasma on Spatial Thruster

[0144] FIG. 2 and FIG. 3 illustrate an exemplary embodiment of the invention, in which the cable is mounted as a heating element within an ion engine type thruster in a spatial system, for example of the ion engine type and in particular with grids or Hall effect.

[0145] In this example, the heating cable 1 is wound 93 around a hollow cathode 9C, and is controlled to preheat said cathode in order to enable gas ionisation under the effect of an electric field created between this cathode 9C and an anode 9A, for example the outside pipe which surrounds the cathode.

[0146] When ignited, the cathode is heated by the cable up to the temperature which will allow it to produce thermionic emission. The propelling gas 90 is injected through a supply, here on the left of the figure, and transforms into plasma 901 inside the cathode 9C. This plasma is then accelerated towards anode 9A, and escapes therefrom to outside through the central hole 99 as a propelling jet 909.

[0147] In continuous operation, the temperature of the cathode 9C is maintained by the plasma itself. The heating cable 1 is here used to preheat the cathode, which allows such a spatial thruster to be ignited. This cathode is for example of the BaO—W (for example “barium-oxide impregnated tungsten”), or LaB6 (“lanthanum-hexaboride”) insert 92 type.

[0148] By enabling a heating cable operating at higher temperatures and under vacuum to be made, the invention makes it possible to perform this preheating by a resistor made in the form of a mineral-insulated shielded cable 1. In comparison with a bare-wire resistor, this form enables an easier and more reliable implementation, as well as a better robustness to take-off constraints, and a better protection against contacts with the environment of the device or even with external elements which could penetrate thereinto.

[0149] Of course, the invention is not limited to the examples just described and numerous arrangements can be brought to these examples without departing from the scope of the invention.