Off-axis fiber reinforced composite core for an aluminum conductor

• US 20080233380A1
• Filed: 03/06/2008
• Published: 09/25/2008
• Est. Priority Date: 04/23/2002
• Status: Active Grant

• Current Assignee: CTC Global Corporation
• Original Assignee: CTC Global Corporation
• Inventors: Bryant, David, Hiel, Clement, Korzeniowski, George, Ferguson, William, Bosze, Eric, Pilling, Douglas
• Granted Patent: US 9,093,191 B2
• Time in Patent Office: Days
• US Class Current: 428/299.4
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: H01B 13/0016 for heat treatment
• CPC Class Codes: H01B 5/105 composed of synthetic filaments, e.g. glass-fibres
• CPC Class Codes: H01B 7/1825 forming part of a high tensile strength core
• CPC Class Codes: H01B 9/006 Constructional features relating to the conductors
• CPC Class Codes: H02G 15/06 Cable terminating boxes, frames or other structures
• CPC Class Codes: H02G 15/18 protected by sleeves, e.g. for communication cable two-part covers H02G15/10 ; preforms having internal stresses B29C61/00
• CPC Class Codes: H02G 7/04 Arrangements or devices for relieving mechanical tension
• CPC Class Codes: H02G 7/056 Dead-end clamps
• CPC Class Codes: Y10T 428/249946 Glass fiber
• CPC Class Codes: Y10T 428/24995 Two or more layers
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2938 Coating on discrete and individual rods, strands or filaments
• CPC Class Codes: Y10T 428/294 including metal or compound thereof [excluding glass, ceramic and asbestos]

Abstract

A composite core for an electrical cable, the composite core defining a longitudinal axis that defines a center of the composite core, the core comprising a plurality of longitudinally extending reinforcing fibers embedded in a resin matrix, the fibers oriented substantially parallel to the longitudinal axis and a sheath surrounding the plurality of longitudinally oriented fibers. The sheath may further comprise a plurality of off-axis reinforcing fibers oriented at an angle relative to the longitudinal axis surrounding the longitudinally extending fibers. The sheath may comprise a type of resin, including for example, thermosetting resin or thermoplastic resin.

Claims

1. A composite core for an electrical cable, the composite core defining a longitudinal axis that defines a center of the composite core, the core comprising:

a plurality of longitudinally extending reinforcing fibers embedded in a resin matrix, the fibers comprising a tensile strength in excess of glass fibers, the fibers positioned towards the center of the composite core and the fibers oriented substantially parallel to the longitudinal axis; and

a plurality of off-axis reinforcing fibers oriented at an angle with respect to the longitudinal axis, the fibers embedded in a resin matrix and surrounding the longitudinally extending fibers.

2. The composite core as in claim 1, wherein the resin matrix embedding the longitudinally extending reinforcing fibers is the same as the resin matrix embedding the off-axis fibers.

3. The composite core as in claim 1, wherein the resin matrix embedding the longitudinally extending reinforcing fibers is different than the resin matrix embedding the plurality of off-axis reinforcing fibers.

4. The composite core of claim 2, wherein the resin matrix comprises a thermosetting resin.

5. The composite core of claim 2, wherein the resin matrix comprises a thermoplastic resin.

6. The composite core of claim 3, wherein the resin matrix that embeds the longitudinally extending fibers is a thermosetting resin and the resin matrix that embeds the plurality of off-axis reinforcing fibers is a thermoplastic resin.

7. The composite core of claim 1, wherein the off-axis fibers are oriented at an angle in the range of about 36°

to about 45°

, the angle measured relative to the longitudinal axis and an axis perpendicular to the longitudinal axis.

8. The composite core of claim 1, wherein the longitudinally extending fibers are carbon fibers.

9. The composite core of claim 1, wherein the off-axis fibers are glass fibers.

10. The composite core of claim 1, wherein the longitudinally extending fibers and the off-axis fibers are carbon.

11. The composite core of claim 1, wherein the longitudinally extending fibers and the off-axis fibers are glass.

12. A composite core for an electrical cable, the composite core defining a longitudinal axis that defines a center of the composite core, the core comprising:

a plurality of reinforcing fibers of one or more fiber types embedded in a resin matrix, the one or more reinforcing fiber types having a substantially parallel orientation with respect to the longitudinal axis; and

a sheath surrounding the plurality of one or more reinforcing fiber types.

13. The composite core of claim 12, wherein the plurality reinforcing fibers of one or more fiber types are embedded in a thermosetting resin.

14. The composite core of claim 12, wherein the sheath comprises a thermosetting or thermoplastic resin.

15. The composite core of claim 12, wherein the sheath is reinforced with a plurality of fibers.

16. The composite core of claim 15, wherein the sheath reinforcing fibers are oriented at an angle with respect to the longitudinal axis.

17. The composite core of claim 15, wherein the one or more reinforcing fiber types comprise a tensile strength in excess of glass fibers.

18. The composite core of claim 17, wherein the one or more reinforcing fiber types comprises carbon.

19. The composite core of claim 15, wherein the sheath is reinforced with a plurality of off-axis glass fibers.

20. A composite core for an electrical cable, the composite core defining a longitudinal axis that defines a center of the composite core, the core comprising:

a plurality of reinforcing carbon fibers embedded in a resin matrix, the carbon fibers positioned towards the center of the composite core and the carbon fibers having a substantially parallel orientation with respect to the longitudinal axis; and

a plurality of reinforcing glass fibers surrounding the carbon fibers, the glass fibers oriented at an off-axis angle relative to the longitudinal axis, the glass fibers embedded in a resin matrix.

21. The composite core in claim 20, wherein the resin matrix embedding the carbon fibers is a thermosetting resin matrix.

22. The composite core in claim 20, wherein the resin matrix embedding the glass fibers is a thermoplastic matrix.

23. The composite core in claim 20, wherein the off-axis glass fibers are oriented at an angle between about 1°

to about 90°

relative to the longitudinal axis, the angle measured in reference to the longitudinal axis and an axis perpendicular to the longitudinal axis.

24. The composite core in claim 20, wherein the resin matrix embedding the carbon and the glass fibers is a thermosetting resin matrix.

25. The composite core in claim 20, wherein the resin matrix embedding the carbon and the glass fibers is a thermoplastic matrix.

26. A composite core for an electrical cable, the composite core defining a longitudinal axis that defines a center of the composite core, the core comprising:

a central region, the central region comprising a plurality of longitudinally extending reinforcing fibers embedded in a resin matrix, the fibers comprising a tensile strength in excess of glass fibers, the fibers oriented substantially parallel to the longitudinal axis, the fibers arranged surrounding the center of the core;

an outer region defining an outer circumference of the core, the outer region comprising a plurality of longitudinally extending reinforcing fibers embedded in a resin matrix, the fibers comprising a tensile strength of or similar to glass fibers, the fibers oriented substantially parallel to the longitudinal axis; and

an interface region defining a transition between the central region and the outer region, the interface region comprising a transitional mixture of fibers from the central region and fibers from an outer region embedded in a resin matrix, the fibers oriented substantially parallel to the longitudinal axis.

27. The composite core of claim 26, wherein the fibers of the central region are carbon.

28. The composite core of claim 26, wherein the fibers of the outer region are glass.

29. The composite core of claim 26, wherein the fibers of the interface region comprise a transitional mixture of carbon and glass fibers.