Aluminum conductor composite core reinforced cable and method of manufacture

• US 20060051580A1
• Filed: 08/23/2005
• Published: 03/09/2006
• Est. Priority Date: 10/22/2003
• Status: Active Grant

• Current Assignee: CTC Global Corporation
• Original Assignee: CTC Cable Corporation
• Inventors: Bryant, David, Hiel, Clement, Ferguson, William Clark
• Granted Patent: US 7,438,971 B2
• Time in Patent Office: Days
• US Class Current: 428/375
• CPC Class Codes: H01B 5/105 composed of synthetic filaments, e.g. glass-fibres
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249942 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249945 Carbon or carbonaceous fiber
• CPC Class Codes: Y10T 428/249946 Glass fiber
• CPC Class Codes: Y10T 428/249949 Two or more chemically different fibers
• CPC Class Codes: Y10T 428/24995 Two or more layers
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core

Abstract

This invention relates to an aluminum conductor composite core reinforced cable and method of manufacture. The composite core comprises a plurality of longitudinally extending fibers embedded in a resin matrix. The composite core comprises the following characteristics: tensile strength ranging from about 250 to about 350 Ksi; a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to about 6×10⁻⁶ cm/cm·° C. The composite core is further manufactured according to a one or more die pultrusion system, the system comprising tooling designed in accordance with the processing speed, selection of composite core fibers and resin and desired physical characteristics of the end composite core.

Claims

1. A composite core for an electrical transmission cable, the core comprising:

a plurality of longitudinally extending high strength glass fibers embedded in a resin matrix, forming a composite core member,

wherein, the composite core member comprises a tensile strength ranging from about 250 to about 350 Ksi;

a modulus of elasticity ranging from about 12 to about 16 Msi; and

a coefficient of thermal expansion less than or equal to 6×

10 <sup>−

6</sup> cm/cm°

C.

3. The composite core of claim 1, wherein the high strength glass fibers comprise S-2 glass.

4. The composite core of claim 1, wherein the high strength glass fibers comprise a tensile strength ranging from about 450 Ksi to about 650 Ksi;

a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and

a coefficient of thermal expansion ranging from about 1.6×

10<sup>−

6</sup> cm/cm·

°

C to about 0 cm/cm·

°

C.

5. The composite core of claim 1, wherein the core can operate at temperatures that exceed 230°

C.

6. The composite core of claim 1, wherein the core can operate at temperatures as low as about −

45°

C.

2. A method for manufacturing a composite core for an electrical transmission cable, comprising:

pulling a plurality of pre-processed fibers of a single type into a circular pattern;

wetting the plurality of fibers with a resin system;

separating and pulling a center section of wetted fibers through a small pre-heater;

pulling the wetted fibers through a conventional die; and

pulling the fibers through a heated tube.

14. The method for manufacturing a composite core of claim 2, wherein the center section of wetted fibers heats the core from the center outward.

15. The method for manufacturing a composite core of claim 2, wherein the circular pattern of fibers aligns the fibers to form a core configuration.

16. The method for manufacturing a composite core of claim 2, wherein the conventional die comprises a temperature to cure the core.

17. The method for manufacturing a composite core of claim 16, wherein the fibers are pulled from the conventional die to a heated tube that maintains the core at an elevated temperature.

18. The method for manufacturing a composite core of claim 2, wherein the pre-processed fibers comprise S-2 glass.

19. The method for manufacturing a composite core of claim 2, wherein the fibers form a uniform core.

7. A composite core for an electrical transmission cable, the core comprising:

a plurality of longitudinally extending high strength glass fibers embedded in a resin matrix, to form a composite core member; and

an outer protective coating adjacent to and surrounding the composite core member.

8. The composite core of claim 7, wherein the high strength glass fibers comprise S-2 glass.

9. The composite core of claim 7, wherein the high strength glass fibers comprise a tensile strength ranging from about 450 Ksi to about 650 Ksi;

a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and

a coefficient of thermal expansion ranging from about 1.6×

10<sup>−

6</sup> cm/cm·

°

C. to about 0 cm/cm·

°

C.

10. The composite core of claim 7, wherein the core can operate at temperatures that exceed 230°

C.

11. The composite core of claim 7, wherein the core can operate at temperatures as low as about 45°

C.

12. The composite core of claim 7, wherein the composite core member comprises a tensile strength ranging from about 250 to about 350 Ksi;

a modulus of elasticity ranging from about 12 to about 16 Msi; and

a coefficient of thermal expansion less than or equal to 6×

10<sup>−

6</sup> cm/cm°

C.

13. The composite core of claim 7, wherein the outer protective coating comprises a tape, coating or film.