Aluminum conductor composite core reinforced cable and method of manufacture
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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 6×10−6 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.
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Citations
176 Claims
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103. A composite core for an electrical cable comprising:
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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)
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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−
6 m/m/C to about 10×
10−
6 m/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)
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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)
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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)
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143. A composite core for an electrical cable comprising:
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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)
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148. A composite core for an electrical cable comprising:
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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)
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154. An electrical cable comprising:
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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)
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164. 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 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)
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165. Method of processing a composite core member comprising the steps of:
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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.
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Specification