Aluminum conductor composite core reinforced cable and method of manufacture
First Claim
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.
5 Assignments
0 Petitions
Accused Products
Abstract
This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable has a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises a plurality of fibers from at least one fiber type in one or more matrix materials. The composite core can have a maximum operating temperature capability above 100° C. or within the range of about −45° C. to about 240° C. or higher, at least 50% fiber to resin volume fraction, a tensile strength in the range of about 160 Ksi to about 370 Ksi, a modulus of elasticity in the range of about 7 Msi to about 37 Msi and a coefficient of thermal expansion in the range of about −0.6×10−6 per deg. C. to about 1.0×10−5 per deg. C. 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.
77 Citations
22 Claims
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1. A composite core for an electrical cable comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6)
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7. An electrical cable comprising:
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a composite core further 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;
an outer film surrounding the composite core; and
at least one layer of conductor surrounding the composite core. - View Dependent Claims (8, 9, 10, 11, 12)
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13. An electrical cable comprising:
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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×
10−
6/°
C. to about 1.0×
10−
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);
an outer film surrounding the composite core; and
at least one layer of conductor surrounding the composite core and the outer film. - View Dependent Claims (14, 15, 16, 17, 18)
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19. A method of processing a composite core for an electrical cable comprising:
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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 (20, 21, 22)
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Specification