Integrated power and data insulated electrical cable having a metallic outer jacket

• US 7,205,480 B2
• Filed: 12/13/2005
• Issued: 04/17/2007
• Est. Priority Date: 07/30/2004
• Status: Active Grant

• Current Assignee: Ulectra Corp.
• Original Assignee: Ulectra Corp.
• Inventors: Heuer, Arthur H., Donmoyer, William L., Planas, Alberto E. Jr., Planas, Alberto E. Sr., Fetterolf, James R. Sr., Blichasz, Charles S.
• Primary Examiner(s): Nguyen; Chau N.
• Application Number:
  US11/301,979
• Publication Number:
  US 20060090923A1
• Time in Patent Office: 490 Days
• Field of Search: 174/113.R, 174/120.R, 174/102.SC
• US Class Current: 174/113.00R
• CPC Class Codes: H01B 9/003 including electrical control or communication wires
• CPC Class Codes: H01B 9/02 with screens or conductive layers, e.g. for avoiding large potential gradients

Abstract

The present invention is directed to a hybrid electrical cable providing for power transmission or distribution and data and/or voice signal communications. In one preferred embodiment, the hybrid electrical cable includes a power cable having a group of one or more high voltage power conductors for conducting power and one or more groups of low power signal conductors for transmitting voice and/or data and/or control signals. The cable further includes a power cable insulation jacket overlying the group of one or more power conductors. The power cable insulation jacket includes a soft magnetic material, preferably a soft ferrite magnetic material, for RF absorption. The cable additionally includes an outer grounded metallic jacket or sheath overlying the power cable, the power cable insulation jacket and the one or more groups of low power conductors.

Claims

1. A hybrid electrical cable providing for power transmission or distribution and low power signal communications, the hybrid cable comprising:

a) a power cable including a first group of two or more conductors for conducting power;

b) a power cable insulation jacket overlying the first group of two or more power conductors, the power cable insulation jacket including a first layer comprising a soft magnetic material having a coercivity of 1 oersted or less;

c) a group of one or more low power signal conductors disposed exterior of the power cable insulation jacket; and

d) an outer jacket overlying the power cable, the power cable insulation jacket and the group of one or more low power signal conductors, wherein the outer jacket comprises a metallic material.

2. The hybrid electrical cable of claim 1 wherein the soft magnetic material of the power cable insulation jacket comprises a soft ferrite magnetic material.

3. The hybrid electrical cable of claim 2 wherein the soft ferrite magnetic material is embedded in an extrusible binder material and the power cable insulation jacket is extruded over the group of one or more power conductors to form the first layer.

4. The hybrid electrical cable of claim 3 wherein the extrusible binder material is selected from a polymer material and an elastomer material.

5. The hybrid electrical cable of claim 2 wherein the soft ferrite magnetic material of the power cable insulation jacket includes manganese zinc ferrite.

6. The hybrid electrical cable of claim 1 wherein the power cable insulation jacket further includes a second organic material insulation layer overlying the first layer.

7. The hybrid electrical cable of claim 1 wherein the outer jacket metallic material comprises aluminum.

8. The hybrid electrical cable of claim 1 wherein the outer jacket additionally includes a layer overlying the metallic material, the layer comprising a soft magnetic material having a coercivity of 1 oersted or less.

9. The hybrid electrical cable of claim 1 further including a binding jacket overlying the power cable insulation jacket and the group of one or more low power signal conductors to bind together the power cable and the group of one or more signal conductors, the outer jacket overlying the binding jacket.

10. The hybrid electrical cable of claim 1 wherein the group of one or more low power signal conductors is disposed exterior of the power cable.

11. The hybrid electrical cable of claim 1 wherein the outer jacket metallic material comprises steel.

12. The hybrid electrical cable of claim 1 wherein the power cable and the group of one or more low power signal conductors extend in parallel relationship within the outer jacket.

13. A hybrid electrical cable for high voltage power transmission or distribution and low power signal transmission, the hybrid electrical cable comprises:

a) a power cable including a group of one or more high voltage power conductors for conducting high voltage power;

b) the power cable further including a power cable insulation jacket overlying the group of one or more power conductors, the power cable insulation jacket having a first layer including a soft magnetic material having a coercivity of 1 oersted or less;

c) a group of one or more low power signal conductors disposed exterior of the power cable insulation jacket; and

d) an outer jacket overlying the power cable, the power cable insulation jacket and the group of one or more low power signal conductors, wherein the outer jacket comprises a grounded metallic material.

14. The hybrid electrical cable of claim 13 wherein the soft magnetic material of the power cable insulation jacket comprises a soft ferrite magnetic material.

15. The hybrid electrical cable of claim 14 wherein the soft ferrite magnetic material is embedded in an extrusible binder material and the power cable insulation jacket is extruded over the group of one or more power conductors to form the first layer.

16. The hybrid electrical cable of claim 15 wherein the extrusible binder material is selected from a polymer material and an elastomer material.

17. The hybrid electrical cable of claim 14 wherein the soft ferrite magnetic material of the power cable insulation jacket includes manganese zinc ferrite.

18. The hybrid electrical cable of claim 13 wherein the power conductor insulation jacket further includes a second organic material insulation layer overlying the first layer.

19. The hybrid electrical cable of claim 13 wherein the outer jacket metallic material comprises aluminum.

20. The hybrid electrical cable of claim 13 wherein the outer jacket includes a layer of soft magnetic material overlying the metallic material, the soft magnetic material having a coercivity of 1 oersted or less.

21. The hybrid electrical cable of claim 13 further including a binding jacket overlying the power cable insulation jacket and the group of one or more low power signal conductors to bind together the power cable and the group of one or more signal conductors, the outer jacket overlying the binding jacket.

22. The hybrid electrical cable of claim 13 wherein the outer jacket metallic material comprises steel.

23. The hybrid electrical cable of claim 13 wherein the power cable and the group of one or more low power signal conductors extend in parallel relationship within the outer jacket.