Aluminum conductor composite core reinforced cable and method of manufacture
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First Claim
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1. A composite core for an electrical cable comprising:
- an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the first fiber type having a tensile strength that exceeds the tensile strength of glass fibers;
an outer core comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the second fiber type having a tensile strength of or similar to glass fibers; and
a resin matrix, wherein the fibers of the inner and the outer cores are embedded therein;
wherein, the fibers of the inner core are different from the fibers of the outer core, and wherein the fibers of the inner 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 having a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises at least one longitudinally oriented substantially continuous reinforced fiber type in a thermosetting resin matrix having an operating temperature capability within the range of about 90 to about 230° C., at least 50% fiber volume fraction, a tensile strength in the range of about 160 to about 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi and a thermal expansion coefficient in the range of about 0 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 50 ft/min.
73 Citations
36 Claims
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1. A composite core for an electrical cable comprising:
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an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the first fiber type having a tensile strength that exceeds the tensile strength of glass fibers; an outer core comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the second fiber type having a tensile strength of or similar to glass fibers; and a resin matrix, wherein the fibers of the inner and the outer cores are embedded therein; wherein, the fibers of the inner core are different from the fibers of the outer core, and wherein the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A composite core for an electrical cable comprising:
a plurality of reinforcing fibers in a thermosetting resin matrix to form the core, said core having at least 50% fiber volume fraction, the plurality of reinforcing fibers consisting of two or more different types of fibers, a first fiber type having a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) and a tensile strength at least about 350 Ksi (2413 MPa) and a second fiber type having a modulus of elasticity in the range of about 6 Msi to about 11.2 Msi and a tensile strength of at least about 180 Ksi (1241 MPa);
wherein, the fibers are arranged within the resin matrix having the higher tensile strength fibers in the center of the core.- View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19)
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20. A composite core for an electrical cable comprising:
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an inner core consisting of a plurality of substantially continuous reinforcing fibers, the fibers having a tensile strength that exceeds the tensile strength of glass fibers; an outer core surrounding the inner core consisting at least in part of a plurality of substantially continuous reinforcing glass fibers; and a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded therein; wherein, the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (21, 22, 23, 24, 25, 26)
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27. A composite core for an electrical cable comprising:
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an inner core comprising a plurality of reinforcing carbon fibers and at least a portion of a plurality of reinforcing fibers having a tensile strength in excess of glass fibers; an outer core surrounding the inner core comprising a plurality of glass fibers; and a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded therein; wherein, the fibers of the inner and outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (28)
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29. An electrical cable comprising:
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a composite core further comprising; an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the first type having a tensile strength that exceeds the tensile strength of glass fibers, wherein the fibers are substantially parallel to the longitudinal axis; an outer core comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the second type having a tensile strength of or similar to glass fibers, wherein the fibers are substantially parallel to the longitudinal axis; and a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded therein; and at least one layer of conductor surrounding said outer core. - View Dependent Claims (30, 31, 32, 33, 34, 35)
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36. A method of transmitting electrical power comprising:
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using a cable comprising a composite core and at least one layer of aluminum conductor surrounding the composite core, the composite core further comprising; an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the first type having a tensile strength that exceeds the tensile strength of glass fibers, wherein the fibers are substantially parallel to the longitudinal axis; an outer core comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the second type having a tensile strength of or similar to glass fibers, wherein the fibers are substantially parallel to the longitudinal axis; and a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded therein; and transmitting power across the composite cable.
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Specification
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Litigation Data
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Current AssigneeCTC Global Corporation
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Original AssigneeCTC Cable Corporation
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InventorsKorzienowski, George, Hiel, Clem
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Primary Examiner(s)GRAY, JILL M
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Application NumberUS10/511,881Publication NumberTime in Patent Office1,840 DaysField of Search428/291.4, 428/298.1, 428/299.4, 428/299.1, 428/300.4, 428/300.7, 428/301.4, 174/70.R, 174/102.R, 174/106.R, 174/113.C, 427/384, 427/372.2, 427/430.1, 427/434.2, 427/434.6US Class Current428/300.7CPC Class CodesB32B 15/04 comprising metal as the mai...B32B 27/04 as impregnant, bonding, or ...H01B 13/0016 for heat treatmentH01B 5/105 composed of synthetic filam...H01B 7/1825 forming part of a high tens...H01B 9/006 Constructional features rel...H02G 15/06 Cable terminating boxes, fr...H02G 15/18 protected by sleeves, e.g. ...H02G 7/04 Arrangements or devices for...H02G 7/056 Dead-end clampsY10T 428/249924 Noninterengaged fiber-conta...Y10T 428/24994 Fiber embedded in or on the...Y10T 428/249942 Fibers are aligned substant...Y10T 428/249945 Carbon or carbonaceous fiberY10T 428/249946 Glass fiberY10T 428/249949 Two or more chemically diff...Y10T 428/24995 Two or more layersY10T 428/2913 Rod, strand, filament or fiberY10T 428/2933 Coated or with bond, impreg...Y10T 428/2938 Coating on discrete and ind...View All
