Aluminum conductor composite core reinforced cable and method of manufacture
DCFirst Claim
1. A composite core for an electricity transmission cable comprising:
- a. an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type having a modulus of elasticity that exceeds the modulus of elasticity of glass fibers;
b. an outer core surrounding the inner core comprising a plurality of substantially continuous reforcing fibers of at least a second type, the fibers having a modulus of elasticity of or similar to glass fibers; and
c. a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded in said resin matrix;
wherein, the fibers of the outer core are different from the fibers of the inner core and wherein, the fibers of theinner and the outer cores are oriented substantially parallel to the longitudinal axis.
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Abstract
This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable has a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises a plurality of fibers from at least one fiber type in one or more matrix materials. The composite core can have a maximum operating temperature capability above 100° C. or within the range of about 45° C. to about 230° C., at least 50% fiber to resin volume fraction, a tensile strength in the range of about 160 Ksi to about 370 Ksi, a modulus of elasticity in the range of about 7 Msi to about 37 Msi and a coefficient of thermal expansion in the range of about −0.7×10−6 m/m/° C. to about 6×10−6 m/m/° C. According to the invention, a B-stage forming process may be used to form the composite core at improved speeds over pultrusion processes wherein the speeds ranges from about 9 ft/min to about 60 ft/min.
70 Citations
29 Claims
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1. A composite core for an electricity transmission cable comprising:
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a. an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type having a modulus of elasticity that exceeds the modulus of elasticity of glass fibers; b. an outer core surrounding the inner core comprising a plurality of substantially continuous reforcing fibers of at least a second type, the fibers having a modulus of elasticity of or similar to glass fibers; and c. a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded in said resin matrix; wherein, the fibers of the outer core are different from the fibers of the inner core and wherein, the fibers of theinner and the outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A composite core for an electrical cable comprising:
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a. a first section comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type comprising a modulus of elasticity that exceeds the modulus of elasticity of glass fibers; b. one or more other sections that surround the first section comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the fibers comprising a modulus of elasticity of or similar to glass fibers; and c. a cured resin matrix, wherein the fibers of the first second and the one or more other sections are embedded within the resin matrix; wherein, the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis and wherein, the fibers of the first section are different from the fibers of the one or more other sections. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A composite core for an electrical cable comprising:
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a. an inner core comprising a plurality of substantially continuous reinforcing carbon fibers; b. an outer core surrounding the inner core comprising a plurality of substantially continuous reinfocing glass fibers; and c. a cured resin matrix wherein, the fibers of the inner and the outer cores are embedded in said resin matrix; wherein the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis, and wherein the composite core comprises a set of mechanical properties. - View Dependent Claims (24, 25, 26)
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27. A composite core for an electrical cable comprising:
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a. a first section comprising a plurality of substantially continuous reinforcing carbon fibers; and b. at least one other section surrounding the first section comprising a plurality of substantially continuous reinforcing glass fibers; and c. a cured resin matrix, wherein the fibers of the first section and the at least one other section are embedded within the resin matrix; wherein the fibers of the first section and the at least one other section are oriented substantially parallel to the longitudinal axis and wherein, the core comprises a set of mechanical properties. - View Dependent Claims (28, 29)
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Specification