Aluminum conductor composite core reinforced cable and method of manufacture

• US 7,438,971 B2
• Filed: 08/23/2005
• Issued: 10/21/2008
• Est. Priority Date: 10/22/2003
• Status: Expired due to Term

• Current Assignee: CTC Global Corporation
• Original Assignee: CTC Cable Corporation
• Inventors: Bryant, David, Hiel, Clement, Ferguson, William Clark
• Primary Examiner(s): GRAY, JILL M
• Application Number:
  US11/210,052
• Publication Number:
  US 20060051580A1
• Time in Patent Office: 1,155 Days
• Field of Search: None
• US Class Current: 428/300.7
• 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 S-2 glass fibers embedded in resin matrix, to form a composite core member, the high strength glass fibers comprise tensile strength ranging from about 450 to about 650 Ksi, and 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×

10<sup>−

6</sup> cm/cm°

C.; and

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

2. The composite core of claim 1, wherein the outer protective coating comprises a protective tape or a film.

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

a plurality of longitudinally extending S-2 glass fibers embedded in a resin matrix, to form a composite core member, the composite core member comprising 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., the core capable of operating at temperatures that exceed 230°

C. and at temperatures as low as about −

45°

C.; and

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

4. The composite core of claim 3, wherein the outer protective coating comprises a tape, coating or film.