Aluminum conductor composite core reinforced cable and method of manufacture

US 20050227067A1
Filed: 04/23/2003
Published: 10/13/2005
Est. Priority Date: 04/23/2002
Status: Active Grant

First Claim

Patent Images

1. (canceled)

View all claims

5 Assignments

Timeline View

Assignment View

0 Petitions

Accused Products

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 6×10⁻⁶m/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.

56 Citations

View as Search Results

176 Claims

1. (canceled)

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. (canceled)

43. (canceled)

44. (canceled)

45. (canceled)

46. (canceled)

47. (canceled)

48. (canceled)

49. (canceled)

50. (canceled)

51. (canceled)

52. (canceled)

53. (canceled)

54. (canceled)

55. (canceled)

56. (canceled)

57. (canceled)

58. (canceled)

59. (canceled)

60. (canceled)

61. (canceled)

62. (canceled)

63. (canceled)

64. (canceled)

65. (canceled)

66. (canceled)

67. (canceled)

68. (canceled)

69. (canceled)

70. (canceled)

71. (canceled)

72. (canceled)

73. (canceled)

74. (canceled)

75. (canceled)

76. (canceled)

77. (canceled)

78. (canceled)

79. (canceled)

80. (canceled)

81. (canceled)

82. (canceled)

83. (canceled)

84. (canceled)

85. (canceled)

86. (canceled)

87. (canceled)

88. (canceled)

89. (canceled)

90. (canceled)

91. (canceled)

92. (canceled)

93. (canceled)

94. (canceled)

95. (canceled)

96. (canceled)

97. (canceled)

98. (canceled)

99. (canceled)

100. (canceled)

101. (canceled)

102. (canceled)

103. A composite core for an electrical cable comprising:
- an inner core consisting of advanced composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin; and
  
  an outer core consisting of low modulus composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin;
  
  wherein, said composite core comprises a core tensile strength of at least about 160 Ksi (1103 MPa).
- View Dependent Claims (104, 105, 106, 107, 108, 109, 110, 111, 112, 113)
- - 104. A composite core as claimed in claim 103 wherein, the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
  - 105. A composite core as claimed in claim 103 comprising a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in (0.96 MPa·
    - m^1/2).
  - 106. A composite core as claimed in claim 103 wherein, at least one reinforced fiber type in the inner core comprises a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of about −
    - 0.7 to about 0 m/m/°
      
      C. and a tensile strength of at least about 350 Ksi (2413 MPa) and at least one reinforced fiber type in the outer core comprises a tensile strength in the range of at least about 180 Ksi (1241 MPa) coupled with a coefficient of thermal expansion in the range of about 5×
      
      10^−
      
      6to about 10×
      
      10^−
      
      6m/m/C.
  - 107. A composite core as claimed in claim 103 wherein, the composite material of the inner core and the outer core is selected to meet physical characteristics in the end composite core including a tensile strength of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 Msi (48 GPa) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient at least in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 108. A composite core as claimed in claim 103 comprising a fiber/resin volume fraction in the range of at least about 50%.
  - 109. A composite core as claimed in claim 103 comprising a fiber/resin ratio of at least about 62% by weight.
  - 110. A composite core as claimed in claim 103 wherein, said composite core comprises a hybridized concentric core having an inner carbon fiber/thermosetting resin core and an outer glass fiber/thermosetting resin core.
  - 111. A composite core as claimed in claim 103 wherein, said inner and outer cores form a concentric hybridized core.
  - 112. A composite core as set forth in claim 103 wherein, said outer core and said inner core form a segmented concentric core.
  - 113. A composite core as claimed in claim 103 wherein, at least one layer of a plurality of aluminum segments is wrapped around the core.

114. A composite core for an electrical cable comprising:
- two or more types of reinforced fiber types in a thermosetting resin matrix, said core-having at least 50% fiber volume fraction, wherein at least one fiber comprises a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of about −
  
  0.7 to about 0 m/m/C and a tensile strength at least about 350 Ksi (2413 MPa) and at least one fiber comprises a coefficient of thermal expansion in the range of about 5×
  
  10^−
  
  6m/m/C to about 10×
  
  10^−
  
  6m/m/C and a tensile strength of at least about 180 Ksi (1241 MPa).
- View Dependent Claims (115, 116, 117, 118, 119, 120, 121, 122, 123)
- - 115. A composite core as claimed in claim 114 wherein, the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
  - 116. A composite core as claimed in claim 114 comprising a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in (0.96 MPa·
    - m^1/2).
  - 117. A composite core as claimed in claim 114 wherein, a proportion and type of fibers are selected to meet physical characteristics in the end composite core including a tensile strength in the range of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 (48 GPa) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient at least in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 118. A composite core as claimed in claim 114 comprising a fiber/resin volume fraction in the range of at least about 50%.
  - 119. A composite core as claimed in claim 114 comprising a fiber resin ratio of at least about 62% by weight.
  - 120. A composite core as claimed in claim 114 wherein said composite core comprises a hybridized concentric core having an inner carbon/thermosetting resin layer and an outer glass fiber/thermosetting resin layer.
  - 121. A composite core as claimed in claim 114 wherein, the core comprises an outer layer and an inner layer that form a concentric hybridized core.
  - 122. A composite core as set forth in claim 114 wherein, the core comprises an outer layer and an inner layer that form a segmented concentric core.
  - 123. A composite core as claimed in claim 114 wherein, at least one layer of a plurality of aluminum segments is wrapped around the core.

124. A composite core for an electrical cable comprising:
- one or more types of longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix, said core having a tensile strength of at least about 160 Ksi (1103 MPa) and a modulus of elasticity in the range of about 7 to about 30 Msi.
- View Dependent Claims (125, 126, 127, 128, 129, 130, 131, 132, 133)
- - 125. A composite core as claimed in claim 124 wherein, the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
  - 126. A composite core as claimed in claim 124 comprising a thermosetting resin having a neat resin fracture toughness at-least about 0.87 INS-lb/in (0.96 MPa·
    - m^1/2).
  - 127. A composite core as claimed in claim 124 wherein, the composite core comprises two or more fiber types wherein, at least one reinforced fiber type comprises a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of about −
    - 0.7 to about 0 m/m/C and a tensile strength in the range of at least about 350 Ksi (2413 MPa) and at least one reinforced fiber type comprises a tensile strength in the range of at least about 180 Ksi (1241 MPa) coupled with a coefficient of thermal expansion in the range of about 5×
      
      10^−
      
      6to about 10×
      
      10^−
      
      6m/m/C.
  - 128. A composite core as claimed in claim 124 comprising a fiber/resin volume fraction in the range of at least about 50%.
  - 129. A composite core as claimed in claim 124 comprising a fiber resin ratio of at least about 62% by weight.
  - 130. A composite core as claimed in claim 124 wherein said composite core comprises a hybridized concentric core having an inner carbon/thermosetting resin layer and an outer glass fiber/thermosetting resin layer.
  - 131. A composite core as claimed in claim 124 wherein, said composite core comprises an inner layer and an outer layer wherein, said layers form a concentric hybridized core.
  - 132. A composite core as set forth in claim 130 wherein, said composite core comprises an inner and an outer layer wherein, said layers form a segmented concentric core.
  - 133. A composite core as claimed in claim 124 wherein, at least one layer of a plurality of aluminum segments is wrapped around the core.

134. A composite core for an electrical cable comprising a composite material, said core having a tensile strength of at least about 160 Ksi (1103 MPa) and an operating temperature of at least about 90°
- C. wherein, said core is sufficiently flexible to wind around at least a seven foot wheel diameter for transportation.
- View Dependent Claims (135, 136, 137, 138, 139, 140, 141, 142)
- - 135. A composite core as claimed in claim 134 wherein, the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
  - 136. A composite core as claimed in claim 134 comprising a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in (0.96 MPa·
    - m^1/2).
  - 137. A composite core as claimed in claim 134 wherein, said composite material further comprises at least one reinforced fiber type comprising a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of about −
    - 0.7 to about 0 m/m/°
      
      C. and a tensile strength in the range of at least about 350 Ksi (2413 MPa) and at least one reinforced fiber type comprising a tensile strength in the range of at least about 180 Ksi (1241 MPa) coupled with a coefficient of thermal expansion in the range of about 5×
      
      10^−
      
      6to about 10×
      
      10^−
      
      6m/m/PC.
  - 138. A composite core as claimed in claim 134 wherein, the composite material comprises a number and type of fibers selected to meet physical characteristics in the end composite core including a tensile strength in the range of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 (48) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient at least in the range of about 0 to about 6×
    - 10^−
      
      6m/m/C.
  - 139. A composite core as claimed in claim 134 wherein, said composite core comprises a hybridized concentric core having an inner carbon/thermosetting resin layer and an outer glass fiber/thermosetting resin layer.
  - 140. A composite core as claimed in claim 134 wherein, said composite core comprises an inner layer and an outer layer wherein, said layers form a concentric hybridized core.
  - 141. A composite core as set forth in claim 134 wherein said composite core comprises an outer layer and an inner layer that form a segmented concentric core.
  - 142. A composite core as claimed in claim 134 wherein at least one layer of a plurality of aluminum segments is wrapped around the core.

143. A composite core for an electrical cable comprising:
- an inner core comprising a high grade carbon fiber comprising a tensile strength of at least 700 Ksi and a tensile modulus of at least 30 Msi in a thermosetting resin comprising a viscosity range of at least about 200 to about 1500 Centipoise at 20°
  
  C.; and
  
  an outer core comprising an E-glass fiber in a thermosetting resin comprising a viscosity range of at least about 200 to about 1500 Centipoise at 20°
  
  C.;
  
  wherein, the composite core comprises a tensile strength in the range of about 160 to 240 Ksi and a modulus of elasticity in the range of about 7 to about 30 Msi.
- View Dependent Claims (144, 145, 146, 147)
- - 144. A composite core as claimed in claim 143 wherein the inner core and the outer core comprise a number and type of fibers selected to meet physical characteristics in the end composite core including a tensile strength in the range of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 (48) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient at least in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 145. A composite core as claimed in claim 143 wherein, said inner and outer cores form a concentric hybridized core.
  - 146. A composite core as set forth in claim 143 wherein, said outer core and said inner core form a segmented concentric core.
  - 147. A composite core as claimed in claim 143 wherein at least one layer of a plurality of aluminum segments is wrapped around the core.

148. A composite core for an electrical cable comprising:
- an inner core comprising a carbon fiber and at least a portion of one or more fibers having mechanical properties in excess of glass fiber in a thermosetting resin; and
  
  an outer core comprising a glass fiber in a thermosetting resin.
- View Dependent Claims (149, 150, 151, 152, 153)
- - 149. The composite core as claimed in claim 148, wherein the fiber having mechanical properties in excess of glass fiber is basalt.
  - 150. A composite core as claimed in claim 148 wherein, the inner and outer cores comprise a proportion and type of fibers selected to meet physical characteristics in the end composite core including a tensile strength in the range of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 (48 GPa) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient at least in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 151. A composite core as claimed in claim 148 wherein, said inner and outer cores form a concentric hybridized core.
  - 152. A composite core as set forth in claim 148 wherein, said outer core and said inner core form a segmented concentric core.
  - 153. A composite core as claimed in claim 148 wherein, at least one layer of a plurality of aluminum segments is wrapped around the core.

154. An electrical cable comprising:
- a composite core further comprising;
  
  an inner core consisting of advanced composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin;
  
  an outer core consisting of low modulus composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin; and
  
  at least one layer of conductor surrounding said outer core;
  
  wherein, said composite core comprises a core tensile strength of at least about 166 Ksi (1103 MPa).
- View Dependent Claims (155, 156, 157, 158, 159, 160, 161, 162, 163)
- - 155. An electrical cable as claimed in claim 154 wherein, the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
  - 156. An electrical cable as claimed in claim 154 wherein the composite core further comprises a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in (0.96 MPa·
    - m^1/2).
  - 157. An electrical cable as claimed in claim 154 wherein, the composite core comprises at least one reinforced fiber type in the inner core comprising a modulus of elasticity in the range of about 22 (151 GPa) to 37 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of about −
    - 0.7 to about 0 m/m/°
      
      C. and a tensile strength of at least about 350 Ksi (2413 MPa) and at least one reinforced fiber type in the outer core comprising a tensile strength in the range of at least about 180 Ksi (1241 MPa) coupled with a coefficient of thermal expansion in the range of about 5×
      
      10^−
      
      6to about 10×
      
      10^−
      
      6m/m/C.
  - 158. An electrical cable as claimed in claim 154 wherein, the composite material of the inner core and the outer core is selected to meet physical characteristics in the end composite core including a tensile strength of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 Msi (48 GPa) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient at least in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 159. An electrical cable as claimed in claim 154 wherein, the composite core comprises a fiber/resin volume fraction in the range of at least about 50%.
  - 160. An electrical cable as claimed in claim 154 wherein, the composite core comprises a fiber/resin ratio of at least about 62% by weight.
  - 161. An electrical cable as claimed in claim 154 wherein, said composite core comprises a hybridized concentric core having an inner carbon fiber/thermosetting resin core and an outer glass fiber/thermosetting resin core.
  - 162. An electrical cable as claimed in claim 154 wherein, said inner and outer cores form a concentric hybridized core.
  - 163. An electrical cable as set forth in claim 154 wherein, said outer core and said inner core form a segmented concentric core.

164. A method of transmitting electrical power comprising:
- 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 consisting of advanced composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin; and
  
  an outer core consisting of low modulus composite material comprising at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin;
  
  wherein the composite core comprises a tensile strength in the range of at least about 160 Ksi (1103 MPa); and
  
  transmitting power across the composite cable.
- View Dependent Claims (166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176)
- - 166. A method as set forth in claim 164 wherein, using a B-stage oven and a series of a plurality of bushings to shape and compress said fiber tows further comprises using a plurality of bushings having a plurality of passageways wherein, the orientation of passageways is determined by the desired cross section configuration of the composite core.
  - 167. A method as set forth in claim 164 wherein the number and type of fiber tows are selected to meet physical characteristics in the end composite core including a tensile strength of at least 160 Ksi (1103 MPa), a modulus of elasticity in the range of at least about 7 (48) to about 30 Msi (206 GPa), an operating temperature in the range of about 90 to about 230°
    - C. and a thermal expansion coefficient in the range of about 0 to about 6×
      
      10^−
      
      6m/m/°
      
      C.
  - 168. A method as set forth in claim 164 wherein, the step of guiding the fiber tows through the wet-out process further comprises using a wet-out tank filled with resin and a pre-heating step prior to wet-out'"'"'to evaporate moisture in the fiber tows.
  - 169. A method as set forth in claim 164 wherein, the wet-out process further comprises a tank filled with resin and a device to aid in wetting the fibers.
  - 170. A method as set forth in claim 164 wherein, the wet out tank filled with resin comprises a series of wipers to remove excess resin from the fibers.
  - 171. A method as set forth in claim 164 wherein, the step of using a B-stage oven and a series of a plurality of bushings to shape and compress said fiber tows further comprises using bushings having a plurality of passageways wherein, at least a portion of the passageways diminishes with consecutive bushings.
  - 172. A method as set forth in claim 164 wherein, the step-of using a B-stage oven and a series of a plurality of bushings to shape and compress said fiber tows further comprises using bushings having a plurality of passageways wherein, at least a portion of the passageways diminishes with consecutive bushings and wherein, at least a portion of the position of the passageways changes with consecutive bushings.
  - 173. A method as set forth in claim 164 wherein the step of shaping and compressing the fiber tows further comprises:
    - guiding the fiber tows into a first B-stage temperature oven;
      
      guiding the fiber tows into a second B-stage temperature oven comprising a series of bushings wherein each bushing in the series comprises a plurality of passageways;
      
      guiding the fiber tows through the consecutive series of bushings and passageways; and
      
      using the bushings to form the composite core.
  - 174. A method as set forth in claim 164 wherein the step of curing the composite core further comprises:
    - guiding the composite core through a second B-stage temperature oven to a curing oven wherein the curing oven temperature is in the range of about 330 (165) to about 370 F (188 C);
      
      guiding the composite core from the curing oven to a cooling zone wherein the cooling zone is in the range of about 30 (−
      
      1) to about 100 F (37 C);
      
      guiding the composite core from the cooling zone to a post-cure oven wherein the temperature of the post-cure oven is in the range of about 330 (165) to about 370 F (188 C); and
      
      guiding the composite core from the post-cure oven through a cooling zone wherein the core is cooled by air in the range of about 170 (76) to about 180 F (82 C).
  - 175. A method as set forth in claim 164 wherein the step of using a B-stage oven and a series of a plurality of bushings to shape and compress the fiber tows further comprises forming one or more segments to make the composite core.
  - 176. A method as set forth in claim 164 wherein the step of guiding the fiber tows further comprises twisting the orientation of the fiber.

165. Method of processing a composite core member comprising the steps of:
- providing a predetermined number and type of fiber tows;
  
  guiding the fiber tows through a wet-out process;
  
  using a B-stage oven and a series of a plurality of bushings to shape and compress said fiber tows; and
  
  curing the composite core member.

Specification

Resources

Litigation Campaign Assessment

Current Assignee
CTC Global Corporation
Original Assignee
CTC Cable Corporation
Inventors
Korzienowski, George, Hiel, Clem

Granted Patent

US 7,368,162 B2
Time in Patent Office

Days
Field of Search
US Class Current

428/364
CPC Class Codes

B32B 15/04   comprising metal as the mai...

B32B 27/04   as impregnant, bonding, or ...

H01B 13/0016   for heat treatment

H01B 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 clamps

Y10T 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 fiber

Y10T 428/249946   Glass fiber

Y10T 428/249949   Two or more chemically diff...

Y10T 428/24995   Two or more layers

Y10T 428/2913   Rod, strand, filament or fiber

Y10T 428/2933   Coated or with bond, impreg...

Y10T 428/2938   Coating on discrete and ind...

Y10T 442/172 : Coated or impregnated

View All

Aluminum conductor composite core reinforced cable and method of manufacture

First Claim

5 Assignments

0 Petitions

Accused Products

Abstract

56 Citations

176 Claims

Specification

Solutions

Use Cases

Quick Links

Aluminum conductor composite core reinforced cable and method of manufacture

First Claim

5 Assignments

Subscription Required

Subscription Required

0 Petitions

Subscription Required

Accused Products

Subscription Required

Abstract

56 Citations

176 Claims

Specification

Subscription Required

Solutions

Use Cases

Quick Links