LOW BUCKLE COPPER WIRE

Abstract

This document describes a copper wire and the method for preparing it. The copper wire described herein has improved ampacity compared to conventional ACSR copper wire, as well as reduced buckling or bending compared to conventional bare ACSR conductor and / or ACSR copper wire.

Description

LOW BUCKLE COPPER WIRE Cross-reference to related applications This application is filed on October 30, 2020, as an international PCT application and claims the benefit of priority of United States of America provisional patent application No. 62 / 929,516, filed on November 1, 2019, the subject matter of which is incorporated herein in its entirety by reference. Brief description of the invention This document describes a copper wire and the method for preparing it. The copper wire described herein has improved ampacity compared to conventional ACSR copper wire, as well as reduced sag or bending compared to conventional bare ACSR conductor and / or ACSR copper wire. Background of the invention Over the past several years, both the frequency and intensity of wildfires in the western United States have been increasing. Often, these fires are started by intermittent contact between overhead power lines and surrounding vegetation. Less frequently, wildfires are started by contact between overhead power lines and wildlife. Wildfires started in this way have led to the loss of hundreds of lives, thousands of homes, and billions of dollars in economic value. Electric utility companies are routinely blamed for these losses, and the resulting reliability issues have led to the financial ruin of numerous companies. To prevent wildfires started by electrical power infrastructure, electric utilities have adopted two general procedures: First, when weather conditions increase the likelihood of a wildfire, the utilities begin decommissioning their system, cutting power to millions of people for an extended period. The second mitigation procedure involves hardening electrical transmission and distribution systems through extensive vegetation management and the use of materials that are less likely to start wildfires. The most common procedure used by electric utilities is to replace bare overhead distribution conductors with an insulated conductor, referred to as copper wire. The insulating material used in copper wire significantly reduces the potential for wildfire initiation when there is intermittent contact between the electrical conductors and surrounding vegetation. Electric utilities are actively replacing bare distribution conductors with copper wire to improve their wildfire initiation posture, although a critical drawback of conventional copper wire makes the effectiveness of this procedure questionable. Specifically, the added weight of the covering material on traditional copper wire causes the product to sag or flex more than the bare conductor it is replacing.Additional buckling or bending leads to reduced clearance in the vegetation. MA / E / ZUZZ / UOSOZO most scenarios. While the ability to withstand intermittent contact is improved with the use of copper wire, the probability of contact is also increased due to additional buckling or bending. The modality described herein eliminates the need for the previously mentioned exchange; that is, the additional weight of the covering material is more than offset by the improved performance of the core material used. When the steel core wire used in conventional copper wire is replaced with a carbon fiber composite core, the resulting buckling is the same as, or less than, the buckling observed with the original bare conductor. Because of this, the modality described herein is able to withstand intermittent contact with vegetation in the same way as conventional copper wire and, at the same time, is less likely to come into contact with vegetation due to its improved buckling performance. Brief description of the drawings The above and other objectives, characteristics, and advantages of the modality and methods described herein will become clear from the following description of its particular modalities, as illustrated in the accompanying drawings. The drawings are not necessarily to scale; instead, the emphasis is on illustrating the principles of the modalities and methods described herein. Figure 1 shows a cross-sectional view of a copper wire. Figure 2 shows a view of a length of copper wire. Figure 3 identifies the characteristics of the exemplified copper wire types (see examples Nos. 3.1-3.48) that have a nominal voltage of 15 kV. Figure 4 identifies the characteristics of the exemplified copper wire types (see Examples Nos. 4.1-4.44) that have a nominal voltage of 25 kV. Figure 5 identifies the characteristics of the exemplified copper wire types (see Examples Nos. 5.1-5.41) that have a nominal voltage of 35 kV. Figure 6 identifies the characteristics of the exemplified copper wire types (see Examples Nos. 6.1-6.32) that have a nominal voltage of 46 kV. Figure 7 identifies the characteristics of the exemplified copper wire types (see Examples Nos. 7.1-7.29) that have a nominal voltage of 69 kV. Figure 8 identifies the characteristics of the exemplified copper wire types (see Examples Nos. 8.1-8.24) that have a nominal voltage of 115 kV. Figure 9 represents a performance map showing buckling or bending as a function of linear current for an ACSR copper wire, an ACSR bare conductor, and a copper wire described herein (e.g., Example No. 3.3). Detailed description The information that follows describes the modalities with reference to the accompanying figures, which show the preferred modalities. However, the above could be included in many different ways and should not be interpreted as being limited to the modalities illustrated herein. The phrase “a” or “an” entity as used herein refers to one or more of this entity. The terms “optional” or “optionally” as used herein mean that a subsequently described item, event, or circumstance could not be required to occur and that the description includes instances where the event or circumstance occurs and instances where it does not. References to singular items should be understood to include plural items and vice versa, unless otherwise explicitly indicated or made clear from the context. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of clauses, sentences, words, and the like joined together, unless otherwise indicated or made clear from the context. Thus, unless otherwise indicated or made clear from the context, the term “or” should generally be understood to mean “and / or,” and similarly, the term “and” should generally be understood to mean “and / or.” The designation of value ranges herein is not intended to be limiting, referring instead, individually, to any and all values ​​that fall within the range, unless otherwise indicated herein, and each separate value within this range is incorporated into the specification as if it were individually designated herein. The words “around,” “approximately,” or similar expressions, when accompanying a numerical value, shall be construed as indicating the deviation as would be appreciated by a person of ordinary experience in the art to operate satisfactorily for an intended purpose. The ranges of values ​​and / or numerical values ​​provided herein are provided only as examples and do not constitute a limitation on the scope of the described embodiments. The use of any or all of the examples or example language (“for example,” “such as,” or similar expressions) provided herein is intended only to further illuminate the embodiments and does not constitute a limitation on the scope of the embodiments claimed. Nothing in the specification shall be construed as indicating any unclaimed element that is essential to the practice of the embodiments. In the following description, terms such as “first”, “second”, “third”, “superior”, “inferior”, “below”, and the like are understood to be words of convenience and shall not be interpreted as implying a positional or chronological order or otherwise limiting any corresponding element unless otherwise expressly indicated. The information that follows details various modes of disclosure. Specifically, to avoid any doubt, it is intended that any of the particular characteristics described individually in each of these paragraphs (or parts thereof) could be combined with one or more of the other characteristics described in one or more of the remaining paragraphs (or parts thereof). In other words, it is explicitly intended that the characteristics described below individually in each paragraph (or part thereof) represent aspects of disclosure that could be taken alone and / or in combination with other aspects of disclosure. The person skilled in the art will appreciate that the subject matter claimed extends to these combinations of characteristics and that these have not been detailed here for the sake of brevity. A copper wire is described herein, comprising: (a) a composite core comprising at least one coated filament including a first resin supporting a carbon fiber matrix and a coating layer including a second resin located on the surface of the first resin; (b) a plurality of aluminum filaments located on the periphery of the composite core; and (c) a covering system comprising (c-1) optionally, a conductor lining or shielding including a third resin and an ionic substance dispersed therein, wherein the conductor shielding is located on the periphery of the plurality of aluminum filaments;and (c-2) a covering layer comprising a fourth resin, a fifth resin, or a combination thereof, wherein the covering layer is located on the periphery of the plurality of aluminum filaments (b), or, if present, the periphery of the conductor shielding (c-1), wherein the copper wire has a voltage rating of about 15-115 kV and a resistance rating of about 1043.262-24947.58 kg (2,300-55,000 lb).; Figure 1 shows a cross-sectional view of an example copper wire 1. From this view, it can be seen that the example copper wire comprises: (a) a composite core 2, (b) a plurality of aluminum strands 3 located on the periphery of the composite core, and (c) a covering system comprising (c-1) optionally, a conductor shield 4 located on the periphery of the plurality of conductors 3; (c-2) a covering layer, comprising an inner covering layer 5 located on the periphery of the conductor shield 4; and (c) an outer covering layer 6 located on the periphery of the inner covering layer 5. Figure 2 shows a view of a length of copper wire 1 with the same numbered elements as shown in Figure 1. As noted below, the copper wire described herein exhibits improved buckling or bending properties when compared to an ACSR copper wire, as well as to a bare ACSR conductor. Another unexpected aspect concerns the increased ampacity compared to ACSR copper wire, because hysteresis losses (also called magnetic losses) in the steel core no longer need to be considered. It was found that the copper wire described herein (when compared to a comparable ACSR copper wire) has an increased ampacity ranging from approximately 8–12%, including all intermediate values ​​such as approximately 9%, 10%, and 11%. Accordingly, one aspect refers to a copper wire that has an ampacity that could be around 1.08-1.12 times an ampacity of an ACSR copper wire, where each copper wire has the same size, twist, and coating thickness. In one aspect, the composite core comprises one coated filament or seven coated filaments. In another aspect, the composite core has an outside diameter that fluctuates from approximately 1.78 to 12.7 mm (0.07 to 0.50 in). In one specific embodiment, the composite core has an outside diameter of 2.03. MA / 2.29, 2.54, 2.79 3.05, 3.3, 3.56, 3.81,4.06, 4.32, 4.57, 4.83, 5.08, 5.33, 5.59, 5.84, 6.1,6.35, 6.6, 6.86, 7.11, 7.37, 7.62, 7.87, 8.38, 8.64, 8.89, 9.14, 9.4, 9.65, 9.91, 10.2, 10.4, 10.7, 10.9, 11.2, 11.4, 11.7, 12.2, or 12.4 mm (0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, or 0.49 inches). In one particular embodiment, the composite web has an outside diameter of 2.12, 2.6, 2.67, 3, 3.17, 3.3, 3.37, 3.47, 3.78, 4.17, 4.23, 4.47, 4.75, 4.79, 5.3, 6.06, 6.36, 6.78, 6.8, 7.3, 7.8, 7.81, 8.01, 8.5, 9, 9.5, 10.4, 11.2 or 12.5 mm (0.0835, 0.1024, 0.1051, 0.1181, 0.1247, 0.1299, 0.1327, 0.1366, 0.1488, 0.1640, 0.1667, 0.1759, 0.1870, 0.1886, 0.2088, 0.2385, 0.2505, 0.2676, 0.2677, 0.2874, 0.3071, 0.3072, 0.3153, 0.3345, 0.3543, 0.3741, 0.4086, 0.4410, or 0.4920 inches). In one respect, the composite core comprises substantially continuous carbon fibers. See, for example, Honda, Kimura, Ushijima, and Sato. In another respect, the carbon fibers comprise polyacrylonitrile, aramid fiber, rayon, petroleum fish, or another suitable carbon-based material. Examples of carbon fibers include, but are not limited to, carbon fiber (graphite, graphene, or nanotubes), Kevlar fibers, aramid fiber, high-performance polyethylene fiber, carbon nanofibers, or nanotubes. Several types of fibers are commercially available. Polyacrylonitrile (“PAN”) fibers could be obtained from a PAN carbon fiber or a PAN precursor. Other carbon fibers would include PAN-IM, PAN-HM, PAN-UHM, PITCH, or rayon-derived products, among others. In another aspect, the first resin comprises a thermoset resin, a thermoplastic resin, or a combination thereof. In yet another respect, the first resin comprises a thermoset resin. Examples of thermoset resins include, but are not limited to, an epoxy resin, an unsaturated polyester resin, a polyurethane resin, and a bismaleic amide resin. See, for example, Sato, Mehdi, and Ushijima. When a cable is required to have a heat resistance greater than 200°C, a bismaleic amide resin is preferably used. In another aspect, the first resin comprises a thermoplastic resin. Examples of thermoplastic resins include, but are not limited to, a polyolefin (e.g., polypropylene, propylene-ethylene copolymer, etc.), a polyester (e.g., polybutylene terephthalate (PBT)), a polycarbonate, a polyamide (e.g., NYLON), a polyether ketone (e.g., polyetheretherketone (PEEK)), a polyetherimide, a polyarylene ketone (e.g., polyphenyleneditone (PPDK)), a liquid crystal polymer, a polyarylene sulfide (e.g., polyphenylene sulfide (PPS), poly(biphenyl sulfide ketone), poly(phenylene sulfide diketone), poly(biphenylene sulfide), etc.), a fluoropolymer (e.g., polytetrafluoroethylene-perfluoromethyl vinyl ether polymer, perfluoro-alkoxyalkane polymer, petrafluoroethylene polymer, an ethylene-tetrafluoroethylene polymer, etc.), a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer (for example, acrylonitrile butadiene styrene (ABS)) and the like, or a combination thereof. See, for example, Daniel. In a further aspect, the second resin comprises a thermoplastic resin. A suitable thermoplastic for use as the second resin includes, but is not limited to, a polyolefin (e.g., a polypropylene, a propylene-ethylene copolymer, etc.), a polyester (e.g., a polyethylene terephthalate (PET), a polybutylene terephthalate (PBT)), a polycarbonate, a polyamide (e.g., NYLON), a polyether ketone (e.g., a polyetheretherketone (PEEK)), a polyetherimide, a polyarylene ketone (e.g., a polyphenyleneditone (PPDK)), a liquid crystal polymer, a polyarylene sulfide (e.g., a polyphenylene sulfide (PPS), a poly(biphenylene sulfide ketone), a poly(phenylene sulfide diketone), a poly(biphenylene sulfide), etc.A particularly suitable high dielectric strength resin could include a fluoropolymer (e.g., a polytetrafluoroethylene-perfluoromethyl vinyl ether polymer, a perfluoro-alkoxyalkane polymer, a petrafluoroethylene polymer, an ethylene-tetrafluoroethylene polymer, etc.), a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer (e.g., acrylonitrile butadiene styrene (ABS)), an acrylic polymer, polyvinyl chloride (PVC), and the like, or a combination thereof. A second particularly suitable high dielectric strength resin could include a polyester (e.g., polyethylene terephthalate (PET)), a polyketone (e.g., polyetheretherketone (PEEK)), a polysulfide (e.g., polyarylene sulfide), or a combination thereof. Another particularly suitable second dielectric strength resin could include polyethylene terephthalate. In one aspect, the copper wire described herein comprises a plurality of aluminum filaments (“AL wires or filaments”) comprising 1350-H19, 1350-0, or an aluminum-zirconium alloy (hereafter “AlZr”), wherein the AlZr contains aluminum (e.g., 1350-H19 aluminum) and about 0.2–0.33% by weight of zirconium. In another aspect, each of the AL filaments has an outside diameter ranging from about 1.778–10.16 mm (0.07–0.40 in). In yet another aspect, each of the AL filaments has a diameter of 2.03, 2.29, 2.54, 2.79, 3.05, 3.3, 3.56, 3.81, 4.06, 4.32, 4.57, 4.83, 5.08, 5.33, 5.59, 5.84, 6.1, 6.35, 6.6, 6.86, 7.11, 7.37, 7.62, 7.87, 8.38, 8.64, 8.89, 9.14, 9.4, 9.65, 9.91, 10.2, 10.4, 10.7, 10.9, 11.2, 11.4, 11.7, 12.2, or 12.4mm (0.08, 0.09, 0.10, 0.11,0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21,0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, or 0.49 inches). In one particular aspect, each of the AL filaments has a diameter of 1.96, 2.12, 2.4, 2.47, 2.57, 2.67, 2.69, 2.89, 2.92, 3, 3.01, 3.09, 3.14, 3.2, 3.27, 3.37, 3.38, 3.44, 3.46, 3.47, 3.58, 3.7, 3.72, 3.77, 3.78, 3.87, 3.97, 4.14, 4.25, 4.44, 4.47, 4.62, 4.77 or 4.78 mm (0.0772, 0.0834, 0.0943, 0.0974, 0.1013, 0.1052, 0.1059, 0.1137, 0.1151, 0.1181, 0.1184, 0.1217, 0.1236, 0.1261, 0.1287, 0.1327, 0.1329, 0.1354, 0.1362, 0.1367, 0.1410, 0.1456, 0.1463, 0.1486, 0.1489, 0.1523, 0.1564, 0.1628, 0.1672, 0.1749, 0.1758, 0.1820, 0.1878, or 0.1880 inches). In one respect, the copper wire described herein comprises a plurality of AlZr filaments. Data show that AlZr exhibits increased thermal stability. According to published standards, an ACSR copper wire using 1350-H19 aluminum could operate at around 90°C, provided the ACSR copper wire has an XLPE (cross-linked polyethylene) coating. Since 1350-H19 aluminum is annealed at around 93°C, a long-term loss of strength could occur from routine operation. MA / IZ / ZUZZ / U óyozo ML / around 90°C. The use of AlZr eliminates the possibility of long-term strength loss because the annealing temperature of AlZr is around 100°C higher than the emergency operating temperature. As shown in Figure 1, aluminum filaments generally have a circular (or round) cross-section. Specifically, aluminum filaments with a round cross-section have a filament configuration (e.g., the number of AL filaments and the number of coated filaments) selected from 6 / 1, 7 / 1, 18 / 1, 20 / 7, 22 / 7, 24 / 7, 26 / 7, 30 / 7, 36 / 1, 42 / 7, and 45 / 7. Furthermore, a 6 / 1 and 7 / 1 filament has a single conductive layer. Additionally, a strand of 18 / 1, 26 / 7, 18 / 1, 20 / 7, 22 / 7, 24 / 7, 26 / 7, and 30 / 7 has a double conductive layer. Furthermore, a 36 / 1, 42 / 7, and 45 / 7 strand has a triple conductive layer. It is contemplated that different configurations could be used in the copper wire described herein, including, but not limited to, wire trap, full / partial compression, soft body, aerial, and similar configurations. One might notice that Figures 1-2 show an empty space between a portion of the covering system (e.g., a conductor shield 4) and the plurality of aluminum filaments 3. In practice, there is no empty space between the plurality of aluminum filaments 3 and the covering system (e.g., the conductor shield 4). Thus, one aspect refers to a copper wire where the covering system makes intimate contact with the outer portions of the aluminum filaments. As noted elsewhere, the covering system could comprise either a conductor shield and a covering layer or a covering layer alone. For a modality where no conductor shield is present, one might notice that the covering layer makes intimate contact with the outer portions of the aluminum filaments.Alternatively, for a modality where no conductor shielding is present and the covering layer comprises an inner and outer layer, a person might notice that the inner covering layer makes intimate contact with the outer portions of the aluminum filaments. In one aspect of the conductor shielding of the copper wire described herein, if present, the third resin comprises polyethylene and the ionic substance comprises carbon black, wherein the conductor shielding has a thickness of about 8-35 mils, including all intermediate values, such as, for example, about 9 mils, about 10 mils, about 11 mils, about 12 mils, about 13 mils, about 14 mils, about 15 mils, about 16 mils, about 17 mils, about 18 mils, about 19 mils, about 20 mils, about 21 mils, about 22 mils, about 23 mils, about 24 mils, about 25 mils, about of 26 thousandths, around 27 thousandths, around 28 thousandths, around 29 thousandths, around 30 thousandths, around 31 thousandths,around 32 thousandths, around 33 thousandths and around 34 thousandths. In one aspect of the copper wire coating layer described herein, each of the fourth and fifth resins comprises an optionally cross-linked polyethylene, such as, MA / HDPE or XLPE. Crosslinking, when present, could be achieved by a suitable method, such as crosslinking using a peroxide (e.g., dicumyl peroxide or di-tert-butyl peroxide), a silane (e.g., trimethoxyvinylsilane), irradiation, or by an azo-mediated crosslinking process. In one aspect of the copper wire described herein, the coating layer (c-2) comprises an inner coating layer and an outer coating layer, wherein the inner coating layer comprises the fourth resin, wherein the inner coating layer is located on the periphery of the plurality of aluminum strands (b), or if present, the periphery of the conductor shielding (c-1), and wherein the outer coating layer comprises the fifth resin and a colorant, wherein the outer coating layer is located on the periphery of the inner coating layer. In one aspect of the inner and outer covering layers of the copper wire described herein, each of the fourth and fifth resins comprises an optionally cross-linked polyethylene, such as HDPE or XLPE. The cross-linking, when present, could be achieved by a suitable method, such as, for example, cross-linking using a peroxide (e.g., dicumyl peroxide or di-tert-butyl peroxide), a silane (e.g., trimethoxyvinylsilane), irradiation, or by an azo-mediated cross-linking process. In one aspect of the copper wire coating described herein, the fifth resin comprises a polyethylene and the colorant comprises carbon black. In one aspect of the outer covering layer of the copper wire described herein, the fifth resin comprises a polyethylene and the colorant comprises carbon black. In another aspect of the copper wire described herein, each of the inner and outer covering layers independently has a thickness of approximately 70,320 thousandths, including all intermediate values, such as, for example, approximately 75 thousandths, approximately 80 thousandths, approximately 85 thousandths, approximately 90 thousandths, approximately 95 thousandths, approximately 100 thousandths, approximately 105 thousandths, approximately 110 thousandths, approximately 115 thousandths, approximately 120 thousandths, approximately 125 thousandths, approximately 130 thousandths, approximately 135 thousandths, approximately 140 thousandths, approximately 145 thousandths, approximately 150 thousandths, approximately 155 thousandths, approximately of 160 thousandths, around 165 thousandths, around 170 thousandths, around 175 thousandths, around 180 thousandths, around 185 thousandths, around 190 thousandths, around 195 thousandths,around 200 thousandths, around 205 thousandths, around 210 thousandths, around 215 thousandths, around 220 thousandths, around 225 thousandths, around 230 thousandths, around 235 thousandths, around 240 thousandths, around 245 thousandths, around 250 thousandths and around 255 thousandths, around 260 thousandths, around 265 thousandths, around 270 thousandths, around 275 thousandths, around 280 thousandths, around 285 thousandths, around 290 thousandths, around 295 thousandths, around 300 thousandths, around 305 thousandths, around 310 thousandths and around 315 thousandths. In one respect, copper wire has an outer diameter of approximately 15.2–63.5 mm (0.60–2.50 inches) and all intermediate values, including, for example, approximately 16.5 mm (0.65 inches), approximately 17.8 mm (0.70 inches), approximately 19.1 mm (0.75 inches), approximately 20.3 mm (0.80 inches), approximately 21.6 mm (0.85 inches), approximately 22.9 mm (0.90 inches), approximately 24.1 mm (0.95 inches), approximately 25.4 mm (1.00 inches), approximately 26.7 mm (1.05 inches), approximately 27.9 mm (1.10 inches), approximately 29.2 mm (1.15 inches), approximately 30.5 mm (1.20 inches), approximately 31.8 mm (1.25 inches), and so on. 33 mm (1.30 inches), about 34.3 mm (1.35 inches), about 35.6 mm (1.40 inches), about 36.8 mm (1.45 inches), about 38.1 mm (1.50 inches), about 39.4 mm (1.55 inches), about 40.6 mm (1.60 inches), about 41.9 mm (1.65 inches), about 43.2 mm (1.70 inches) and about 44.5 mm (1.75 inches), about 45.7 mm (1.80 inches), about 47 mm (1.85 inches), about 48.3 mm (1.90 inches), about 49.5 mm (1.95 inches), about 50.8 mm (2.00 inches), about 52.1 mm (2.05 inches), about 53.3 mm (2.10 inches), about 54.6 mm (2.15 inches), about 55.9 mm (2.20 inches), about 57.1 mm (2.25 inches), about 58.4 mm (2.30 inches), about 59.7 mm (2.35 inches), about 61 mm (2.40 inches) and about 62.2 mm (2.45 inches). In another aspect, copper wire has a nominal voltage of around 15 kV, around 25 kV, around 35 kV, around 46 kV, around 69 kV, or around 115 kV. In another aspect, copper wire has a nominal resistance of around 907.1847 kg (2,000 lb) to around 24947.58 kg (55,000 lb) and all intermediate values, including for example, 1043.262, 1111.301, 1501.391, 1655.612, 1764.474, 2227.139, 2408.575, 2626.3, 2794.129, 3302.152, 3515.341, 3837.391, 4386.238, 4672.0014, 5170.953, 5216.3123, 5533.8269, 5805.9823, 6622.4486, 6939.9633, 7484.2741, 7665.7111, 8255.3811, 8391.4588, 8663.6143, 8708.9735, 9071.8474, 9344.0028, 9616.1582, 10115.11, 10704.78, 11067.654, 11657.324, 12110.916, 12292.353, 13743.849, 13789.208, 14288.16, 15603.578, 16646.84, 18415.85, 19821.987, 20139.501 and 24539.347 kg (2,300, 2,450, 3,310, 3,650, 3,890, 4,910, 5,310, 5,790, 6,160, 7,280, 7,750, 8,460, 9,670, 10,300, 11,400, 11,500, 12,200, 12,800, 14,600, 15,300, 16,500, 16,900, 18,200, 18,500, 19,100, 19,200, 20,000, 20,600, 21,200, 22,300, 23,600, 24,400, 25,700, 26,700, 27,100, 30,300, 30,400, 31,500, 34,400, 36,700, 40,600, 43.700, 44,400 and 54,100 pounds). The copper wire described herein shows marked improvements when compared to either an ACSR copper wire or a bare ACSR conductor. These improvements can be rationalized by evaluating the catenary constants of the example copper wire described herein and comparable ACSR copper wires and bare ACSR conductors. The catenary constant, also called the H / w constant, is the ratio of a conductor's horizontal tension (in pounds) to its weight per foot (lb / ft). The resulting ratio is in feet and is inversely proportional to the sag or bending of an overhead conductor. A higher catenary constant indicates less sag. As noted previously, Figure 9 presents a performance map showing sag as a function of linear current for an ACSR copper wire (top line), an ACSR bare conductor (middle line), and the copper wire described herein (bottom line), each with a voltage rating of 15 kV. It is noticeable that the copper wire described herein exhibits lower sag or bending (e.g., end or loaded) at a typical operating temperature of around 90–130°C than that of an ACSR copper wire or an ACSR bare conductor. Furthermore, higher catenary constants correlate with lower sag. Thus, the copper wire described herein has a higher catenary constant compared to a comparable ACSR copper wire or a comparable ACSR bare conductor. When considering the benefits of replacing a bare ACSR conductor with ACSR copper wire, the weight per foot will increase, which reduces the catenary constant, leading to greater sag. The surprising aspect of the copper wire described herein is that the horizontal tension remains at a higher percentage of its initial value as the operating temperature increases; this is without considering the initial tension at which the electric utility chooses to install the conductor.The weight reduction from replacing the steel core with a composite core, coupled with the material's ability to retain a higher percentage of horizontal tension across its operating range, means that the catenary constant of the copper wire described herein at the maximum operating temperature (e.g., around 130°C) is higher than the catenary constants of both the same-sized ACSR copper wire and the same-sized ACSR bare conductor. This latter aspect is an unexpected property of the copper wire described herein. The following table summarizes the aspects of the conductors (15 kV rated voltage) analyzed in Figure 9, including the estimated catenary constant (“H / w”) for each conductor at a maximum operating temperature of around 130°C. Coating thickness (thousandths) Conductor Size (AWG) Stranding Conductor shielding Inner layer 1'1 Outer layer b) H / v Meters (feet) Copper wire 1 / 0 6 / 1 25 75 75 1183.234 (3882) ACSR copper wire 1 / 0 6 / 1 25 75 75 438.912 (1440) ACSR bare conductor (“Raven”) 1 / 0 6 / 1 - - - 659.892 (2165) a)Ampacity assumptions: ambient temperature of 40°C, perpendicular wind of (4 ft / s) b)Using guide strength cross-linked polyethylene (TRXLPE). Based on this data, it could be observed that the H / w for a copper wire described 1 in the present (for example, Example No. 3.3) has a value of 1183.234 m (3882 ft) (“H / WTW”). This should be contrasted with a comparable ACSR copper wire, which has an H / w of 438.912 m (1440 ft). This should also be contrasted with a comparable ACSR bare conductor (see Raven), which has an H / w of 659.892 m (2165 ft) (“H / wacsr”). The data could also be evaluated as a ratio or proportion, for example, the H / wTw-with-H / wAcsR ratio (“CC-ratio”) could be calculated to be around 1.8 (i.e., 1183.234 / 659.892 m (3882 / 2165 ft)). Other H / w ratios could also be calculated so that comparable systems are around 1.10-1.90. In one respect, the copper wire being described has a catenary constant at a maximum operating temperature (“MOT”) of about 1.10-1.90 times a catenary constant for a bare ACSR having the same stranding, size, and voltage rating of copper wire. In one respect, the copper wire described herein has a CC ratio of about 1.10-1.90, which includes all values ​​in between, such as for example, 1.15, 1.20, 1.25, 1.30, 1.35, 1.40, 1.45, 1.50, 1.55, 1.60, 1.65, 1.70, 1.75, 1.80 and 1.85. One aspect relates to a copper wire manufacturing method described herein, which comprises: providing the composite core; braiding the plurality of aluminum conductor strands around the composite core; and successively coating the plurality of aluminum conductor strands around the composite core with the coating system and the outer coating layer; and rating the manufactured copper wire with a nominal resistance that is calculated by equation (1): nominal resistance (nConxSTRconxRFCon) + (nCorexSTRcorexRFCore) (1) where: nCOn is the number of strands in the plurality of aluminum strands; nCore is the number of coated strands in the composite core;STRCOn is the breaking strength (e.g., nominal, minimum, or average) of the aluminum filaments in the plurality of aluminum filaments at an elongation equal to the minimum of £con and Score; STRcore is the breaking strength (e.g., nominal, minimum, or average) of at least one of the coated filaments in the composite core at an elongation equal to the minimum of sCon and score; ε«>η is the amount of stretch at break of the aluminum filaments in the plurality of aluminum filaments; score is the amount of stretch at break of at least the coated filament in the composite core; RFCOn is the rating factor of the plurality of aluminum filaments; and RFcore is the rating factor of at least one of the coated filaments. As can be seen from Figures 3-9, the copper wires described herein could have numerous physical characteristics. In one respect, a copper wire described herein has the following physical characteristics: a size of 1 / 0 AWG, a 6 / 1 twist, an AL filament diameter of about 3.3 mm (0.13 inches), a single core strand, a composite core outer diameter of about 3.3 mm (0.13 inches), a conductor diameter of about 10.2 mm (0.4 inches), a conductor shield having a thickness of about 25 mils, an inner covering layer having a thickness of about 75 mils, an outer covering layer having a thickness of about 75 mils, a copper wire (or cable) outer diameter of about 19.1 mm (0.75 inches), and a resistance rating of about 2630.836 kg (5.800 pounds). In another respect, a copper wire described herein has the following physical characteristics: a size of about 336 kcmil, a twist of 18 / 1, an AL filament diameter of about 3.56 mm (0.14 inches), a single core strand, a composite core outer diameter of about 3.56 mm (0.14 inches), a conductor diameter of about 17.8 mm (0.7 inches), a conductor shield having a thickness of about 25 mils, an inner covering layer having a thickness of about 75 mils, an outer covering layer having a thickness of about 75 mils, a copper wire (or cable) outer diameter of about 25.4 mm (1.0 inches), and a nominal resistance of 4399.846 kg (9,700 pounds). In yet another respect, a copper wire described herein has the following physical characteristics: a size of about 398 kcmil, a twist of 18 / 1, an AL filament diameter of about 3.81 mm (0.15 inches), a single core strand, a composite core outer diameter of about 3.81 mm (0.15 inches), a conductor diameter of about 17.8 mm (0.7 inches), a conductor shield having a thickness of about 25 mils, an inner covering layer having a thickness of about 75 mils, an outer covering layer having a thickness of about 75 mils, an outer copper wire (or cable) diameter of about 27.94 mm (1.1 inches), and a nominal resistance of 5216.3123 kg (11,500 pounds). In an additional aspect, a copper wire described herein has the following physical characteristics: a size of about 398 kcmil, a stranding of 26 / 7, an AL filament diameter of about 3.048 mm (0.12 inches), seven coated strands, a composite core outer diameter of about 7.62 mm (0.3 inches), a conductor diameter of about 20.32 mm (0.8 inches), a conductor shield having a thickness of about 25 mils, an inner covering layer having a thickness of about 75 mils, an outer covering layer having a thickness of about 75 mils, a copper wire (or cable) outer diameter of about 19.1 mm (0.75 inches), and a nominal resistance of 9525.4398 kg (21,000 pounds). Additional aspects of a copper wire described herein include physical characteristics, as described in each of the examples Nos. 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 3.10, 3.11, 3.12, 3.13, 3.14, 3.15, 3.16, 3.17, 3.18, 3.19, 3.20, 3.21, 3.22, 3.23, 3.24, 3.25, 3.26, 3.27, 3.28, 3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36, 3.37 3.38, 3.39, 3.40, 3.41, 3.42, 3.43, 3.44, 3.45, 3.46, 3.47, 3.48, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 4.10, 4.11, 4.12, 4.13, 4.14, 4.15, 4.16, 4.17, 4.18, 4.19, 4.20, 4.21, 4.22, 4.23, 4.24, 4.25, 4.26, 4.27, 4.28, 4.29, 4.30, 4.31, 4.32 4.33, 4.34, 4.35, 4.36, 4.37, 4.38, 4.39, 4.40, 4.41, 4.42, 4.43, 4.44, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 5.10, 5.11, 5.12, 5.13, 5.14, 5.15, 5.16, 5.17, 5.18, 5.19, 5.20, 5.21, 5.22, 5.23, 5.24, 5.25, 5.26, 5.27, 5.28, 5.29, 5.30, 5.31, 5.32, 5.33, 5.34, 5.35, 5.36, 5.37, 5.38, 5.39, 5.40, 5.41, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 6.10, 6.11, 6.12, 6.13 6.14, 6.15, 6.16, 6.17, 6.18, 6.19, 6.20, 6.21, 6.22, 6.23, 6.24, 6.25, 6.26, 6.27, 6.28, 6.29, 6.30, 6.31, 6.32, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 7.10, 7.11, 7.12, 7.13, 7.14, 7.15, 7.16, 7.17, 7.18, 7.19, 7.20, 7.21, MA / O» 7.22, 7.23, 7.24, 7.25, 7.26, 7.27, 7.28, 7.29, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 8.10, 8.11, 8.12, 8.13, 8.14, 8.15, 8.16, 8.17, 8.18, 8.19, 8.20, 8.21, 8.22, 8.23 ​​and 8.24. Aspects described Certain characteristics of low buckling copper wire described herein relate to the following aspects. Aspect 1. A copper wire, comprising: (a) a composite core comprising at least one coated filament including a first resin supporting a carbon fiber matrix and a coating layer including a second resin located on the surface of the first resin; (b) a plurality of aluminum filaments located on the periphery of the composite core; and (c) a covering system comprising (c-1) optionally, a conductor shield including a third resin and an ionic substance dispersed therein, wherein the conductor shield is located on the periphery of the plurality of aluminum filaments; and (c-2) a covering layer comprising a fourth resin, a fifth resin, or a combination thereof, wherein the covering layer is located on the periphery of the plurality of aluminum filaments (b), or if present, the periphery of the conductor shield (c-1);where the copper wire has a nominal voltage of around 15-115 kV and a nominal resistance of around 1043.262-24947.58 kg (2,300-55,000 lbs).; Aspect 2. The copper wire of aspect 1, wherein the composite core comprises one coated filament or seven coated filaments. Aspect 3. The copper wire of any one of aspects 1-2, wherein the composite core has an outside diameter of about 1.778-12.7 mm (0.07-0.5 inches). Aspect 4. The copper wire of any one of aspects 1-3, wherein the first resin comprises a thermosetting resin, a thermoplastic resin, or a combination thereof. Aspect 5. The copper wire of aspect 4, wherein the thermosetting resin comprises an epoxy series resin, an unsaturated polyester series resin, a polyurethane resin, and a bismaleic amide resin. Aspect 6. The copper wire of aspect 4, wherein the thermoplastic resin comprises a polyolefin, a polyester, a polycarbonate, a polyamide, a polyether ketone, a polyetherimide, a polyarylene ketone, a liquid crystal polymer, a polyarylene sulfide, a fluoropolymer, a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer, or a combination thereof. Aspect 7. The copper wire of any one of aspects 1-6, wherein the carbon fibers comprise a polyacrylonitrile, an aramid fiber, a rayon, a petroleum fish, or a combination thereof. Aspect 8. The copper wire of any one of aspects 1-7, wherein the second resin comprises a polyolefin, a polyester, a polycarbonate, a polyamide, a polyether ketone, a polyetherimide, a polyarylene ketone, a liquid crystal polymer, a polyarylene sulfide, a fluoropolymer, a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer, an acrylic polymer, a polyvinyl chloride, or a combination thereof. Aspect 9. The copper wire of any one of aspects 1-8, wherein the plurality of aluminum filaments comprises 1350-H19, 1350Ό, or an aluminum and zirconium alloy (0.2-0.33% zirconium) and wherein each aluminum filament has a diameter of 1.778-1.016 mm (0.07-0.40 inches). Aspect 10. The copper wire of any one of aspects 1-9, wherein the number of aluminum strands in the composite core (or braid) is selected from 6 / 1, 7 / 1, 18 / 1, 20 / 7, 22 / 7, 24 / 7, 26 / 7, 30 / 7, 36 / 1, 42 / 7 and 45 / 7. Aspect 11. The copper wire of any one of aspects 1-10, wherein the covering system comprises the conductor shield and wherein the third resin comprises polyethylene and the ionic substance comprises carbon black and wherein the conductor shield has a thickness of about 8-35 mils. Aspect 12. The copper wire of any one of aspects 1-11, wherein each of the fourth and fifth resins comprises an optionally cross-linked polyethylene, such as HDPE or XLPE. Aspect 13. The copper wire of any one of aspects 1-12, wherein the fifth resin comprises a polyethylene and the colorant comprises carbon black. Aspect 14. The copper wire of any one of aspects 1-13, wherein the covering layer (c-2) comprises an inner covering layer and an outer covering layer, wherein the inner covering layer comprises the fourth resin, wherein the inner covering layer is located on the periphery of the periphery of the plurality of aluminum strands (b), or if present, the periphery of the conductor shielding (c-1), wherein the outer covering layer comprises the fifth resin and a colorant, wherein the outer covering layer is located on the periphery of the inner covering layer and wherein each of the inner covering layer and the outer covering layer independently has a thickness of about 70-320 mils. Aspect 15. The copper wire of any one of aspects 1-14 having an outside diameter of about 1.524-6.35 cm (0.60-2.50 inches). Aspect 16. The copper wire of any one of aspects 1-15 having a nominal voltage of about 15, 25, 35, 46, 69 or 115 kV. Aspect 17. The copper wire of any one of aspects 1-16 having a nominal resistance of about 1043.262-24947.58 kg (2,300-55,000 pounds). Aspect 18. The copper wire of any one of aspects 1-17 having an ampacity of about 1.08-1.12 times an ampacity of an ACSR copper wire, wherein each copper wire has the same size, stranding, and coating thickness as the ACSR copper wire. Aspect 19. The copper wire of any one of aspects 1-18 having a catenary constant at a maximum operating temperature of about 1.10-1.90 times a catenary constant for a bare ACSR having the same stranding and size of copper wire. Aspect 20. A method of manufacturing copper wire of any one of aspects 1-19, comprising: providing the composite core; braiding the plurality of aluminum conductor strands around the composite core; successively covering the plurality of aluminum conductor strands around the composite core with the covering system; and rating the manufactured copper wire with a nominal resistance that is calculated by equation (1): nominal resistance (nconxSTRconxRFcon) + (ncorexSTRcorexRFcore) (1) where: nCOn is the number of filaments in the plurality of aluminum filaments; nCOre is the number of coated filaments in the composite core; STRcon is the breaking strength (e.g., nominal, minimum, or average) of the aluminum filaments in the plurality of aluminum filaments at an elongation equal to the minimum of £con and EcoreJ STRcore is the breaking strength (e.g., nominal, minimum, or average) of at least one of the coated strands in the composite core at an elongation equal to the minimum of £con and £core! econ is the amount of stretch at the break of the aluminum filaments in the plurality of aluminum filaments; Ecore is the amount of stretch at break of at least the coated filament in the composite core; RFcon is the rating factor for the plurality of aluminum filaments; and RFcore is the rating factor of at least one of the coated filaments. Information cited Daniel et al, Electrical Transmission Cables with Composite, United States Patent No. 9,012,781 B2, published on April 21, 2015 (“Alien”). Honda et al, Composite Patent and Manufacture Thereof, United States Patent No. 4,677,818A, published July 7, 1987 (“Honda”). Kimura et al., Fiber Composite Twisted Cable, United States Patent No. 8,250,845 B2, published on August 28, 2012 (“Kimura”). Mehdi et al., “X-Functional Phthalonitrile Monomers and Polymers”, chapter 3, In Plastics Design Library, Phthalonitrile Resins and Composites, Eds. Mehdi et al., William Andrew Publishing, 2018, pages 107-174 (“Mehdi”). Powers, WF, Rating an Enhanced Strength Conductor, United States Patent No. 9,847,152 B2, published on December 19, 2017 (“Powers”). Sato et al., Development of a Low Sag Aluminum Conductor Carbon Fiber Reinforced for Transmission Lines, Cigré Report 22-203, 2002 (“Sato”). Ushijima, K., Cable made of High Strength Fiber Composite Material, United States Patent No. 7,650,742, published on January 26, 2010 (“Ushijima”). The alternative methods, examples, and modifications that would still be included in the disclosure could be made by those experts in the technique, particularly those... MA / E / ZUZZ / UOSOZO in light of the previous teachings. Furthermore, it should be understood that the terminology used to describe disclosure is intended to be descriptive in nature rather than limiting. Those skilled in the technique will also appreciate that various adaptations and modifications of the preferred and alternative modalities described above can be implemented without departing from the scope and spirit of the disclosure. Therefore, it is understood that, within the scope of the modalities described herein, disclosure could be practiced differently than described herein. It will be understood that the expression “which includes” could be replaced with the expression “which consists of” for the modalities described herein. The subject matter of United States of America provisional patent application No. 62 / 929,516, filed on November 1, 2019, is incorporated herein by reference. All documents described herein are incorporated herein by reference in their entirety. Definitions and / or meanings of the subject matter described herein are subject to review in the event of any conflict between incorporated material and the subject matter described herein.

Claims

1. A copper wire, comprising: (a) a composite core comprising: at least one coated filament including; a first resin supporting a carbon fiber matrix; and a coating layer including a second resin located on the surface of the first resin; (b) a plurality of aluminum filaments located on the periphery of the composite core; and (c) a covering system comprising: (c-1) optionally, a conductor shield including a third resin and an ionic substance dispersed therein, wherein the conductor shield is located on the periphery of the plurality of aluminum filaments; and (c-2) a covering layer comprising a fourth resin, a fifth resin, or a combination thereof, wherein the covering layer is located on the periphery of the plurality of aluminum filaments (b), or if present, the periphery of the conductor shield (c-1);and where the copper wire has a nominal voltage of about 15-115 kV and a nominal resistance of about 1043.262-24947.58 kg (2,300-55,000 lbs).; 2. The copper wire according to claim 1, wherein the composite core comprises one coated filament or seven coated filaments.

3. The copper wire according to any of claims 1-2, wherein the composite core has an outside diameter of about 1.778-12.7 mm (0.07-0.5 inches).

4. The copper wire according to any one of claims 1-3, wherein the first resin comprises a thermoset resin, a thermoplastic resin, or a combination thereof.

5. The copper wire according to claim 4, wherein the thermosetting resin comprises an epoxy series resin, an unsaturated polyester series resin, a polyurethane resin, and a bismaleic amide resin.

6. The copper wire according to claim 4, wherein the thermoplastic resin comprises a polyolefin, a polyester, a polycarbonate, a polyamide, a polyether ketone, a polyetherimide, a polyarylene ketone, a liquid crystal polymer, a polyarylene sulfide, a fluoropolymer, a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer, or a combination thereof.

7. The copper wire according to any of claims 1-6, wherein the carbon fibers comprise a polyacrylonitrile, an aramid fiber, a rayon, a petroleum fish, or a combination thereof.

8. The copper wire according to any of claims 1-7, wherein the second resin comprises a polyolefin, a polyester, a polycarbonate, a polyamide, a polyether ketone, a polyetherimide, a polyarylene ketone, a liquid crystal polymer, a polyarylene sulfide, a fluoropolymer, a polyacetal, a polyurethane, a polycarbonate, a styrenic polymer, an acrylic polymer, a polyvinyl chloride, or a combination thereof.

9. The copper wire according to any of claims 1-8, wherein the plurality of aluminum filaments comprises 1350-H19, 1350-0, or an aluminum and zirconium alloy (0.2-0.33% zirconium) and wherein each aluminum filament has a diameter of 1.778-1.016 mm (0.07-0.40 inches).

10. The copper wire according to any of claims 1-9, wherein the number of aluminum filaments in the composite core (or braid) is selected from 6 / 1, 7 / 1, 18 / 1, 20 / 7, 22 / 7, 24 / 7, 26 / 7, 30 / 7, 36 / 1, 42 / 7 and 45 / 7.

11. The copper wire according to any of claims 1-10, wherein the covering system comprises the conductor shielding and wherein the third resin comprises polyethylene and the ionic substance comprises carbon black and wherein the conductor shielding has a thickness of about 8-35 mils.

12. The copper wire according to one of claims 1-11, wherein each of the fourth and fifth resins comprises an optionally cross-linked polyethylene, such as HDPE or XLPE.

13. The copper wire according to any of claims 1-12, wherein the fifth resin comprises a polyethylene and the colorant comprises carbon black.

14. The copper wire according to any of claims 1-13, wherein the coating layer (c-2) comprises an inner coating layer and an outer coating layer, wherein the inner coating layer comprises the fourth resin, wherein the inner coating layer is located on the periphery of the plurality of aluminum filaments (b), or if present, the periphery of the conductor shielding (c-1), wherein the outer coating layer comprises the fifth resin and a colorant, wherein the outer coating layer is located on the periphery of the inner coating layer, and wherein each of the inner coating layer and the outer coating layer independently have a thickness of about 70-320 mils.

15. The copper wire according to any of claims 1-14 having an outside diameter of about 1.524-6.35 cm (0.60-2.50 inches).

16. The copper wire according to any of claims 1-15 having a nominal voltage of about 15, 25, 35, 46, 69 or 115 kV.

17. The copper wire according to any of claims 1-16 having a nominal resistance of about 1043.262-24947.58 kg (2,300-55,000 lb).

18. The copper wire according to any of claims 1-17 having an ampacity of about 1.08-1.12 times an ampacity of an ACSR copper wire, wherein each copper wire has the same size, stranding and coating thickness as the ACSR copper wire.

19. The copper wire according to any of claims 1-18 having a catenary constant at a maximum operating temperature of about 1.10-1.90 times a catenary constant for a bare ACSR having the same stranding and size of copper wire.

20. A method of manufacturing copper wire according to any of claims 1-19, comprising: providing the composite core; braiding the plurality of aluminum conductor strands around the composite core; successively coating the plurality of aluminum conductor strands around the composite core with the coating system; and rating the manufactured copper wire with a nominal resistance that is calculated by equation (1): nominal resistance (nConxSTRConxRFcon) + (nCorexSTRcorexRFCore) (1) wherein: nCOn is the number of strands in the plurality of aluminum strands; nCore is the number of coated strands in the composite core;STRcon is the breaking strength (e.g., nominal, minimum, or average) of the aluminum filaments in the plurality of aluminum filaments at an elongation equal to the minimum of £con and ScoreJ. STRcore is the breaking strength (e.g., nominal, minimum, or average) of at least one of the coated filaments in the composite core at an elongation equal to the minimum of Scon and £core. scon is the amount of stretch at break of the aluminum filaments in the plurality of aluminum filaments; £core is the amount of stretch at break of at least the coated filament in the composite core; RFcon is the rating factor of the plurality of aluminum filaments; and RFcore is the rating factor of at least one of the coated filaments.