Aluminum conductor composite core reinforced cable and method of manufacture
First Claim
Patent Images
1. 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;
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
an outer film surrounding the composite core;
wherein, the composite core comprises a tensile strength of at least 160 Ksi.
0 Assignments
0 Petitions
Accused Products
Abstract
This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC 303 cable (300) has a composite core surrounded by an outer film (305) and at least one layer of aluminum conductor (306). The composite core (303) comprises a plurality of fibers from at least one fiber type in one or more matrix materials. According to the invention, unique processing techniques such a B-Staging and/or film-coating techniques can be used to increase production rates from a few feet per minute to sixty or more feet per minute.
-
Citations
15 Claims
-
1. 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;
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
an outer film surrounding the composite core;
wherein, the composite core comprises a tensile strength of at least 160 Ksi. - View Dependent Claims (2, 3, 4, 5, 6, 7)
-
-
8. A composite core for an electrical cable comprising:
-
two or more types of reinforced fiber types in a resin matrix, said core further comprising;
at least 50% fiber volume fraction, wherein at least one fiber comprises a modulus of elasticity at least about 15 (151 GPa) to 45 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of at least about −
0.6×
1010−
6/°
C. to about 1.0×
1010−
5/°
C. and a tensile strength at least about 250 ksi (2413 MPa) and at least one fiber comprising a modulus of elasticity of at least about 9 Msi, a coefficient of thermal expansion in the range of about 5×
10−
6/°
C. to about 10×
10 −
6/°
C. and a tensile strength of at least about 180 Ksi (1241 MPa); and
an outer film surrounding the composite core. - View Dependent Claims (9, 10, 11)
-
-
12. A method of processing a composite core for an electrical cable comprising:
-
pulling one or more types of longitudinally oriented and substantially continuous fiber types through a resin to form a fiber resin matrix;
removing excess resin from the fiber resin matrix;
processing the fiber resin matrix through at least one first die type to compress the fibers into a geometric shape determined by the at least one die;
introducing an outer film;
wrapping the outer film around the composite core;
processing the fiber resin matrix through at least one second die type to compress the composite core and coating; and
curing the composite core and coating. - View Dependent Claims (13, 14, 15)
-
Specification