Aluminum conductor composite core reinforced cable and method of manufacture
First Claim
1. A composite core for an electrical cable comprising:
- an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type having a modulus of elasticity that exceeds the modulus of elasticity of glass fibers;
an outer core surrounding the inner core comprising a plurality of substantially continuous reinforcing fibers of at least a second typethe fibers having a modulus of elasticity of or similar to glass fibers;
a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded in said resin matrix; and
a protective coating surrounding the outer composite core;
wherein, the fibers of the outer core are different from the fibers of the inner core and wherein, the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis.
5 Assignments
0 Petitions
Reexamination
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.
121 Citations
20 Claims
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1. A composite core for an electrical cable comprising:
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an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type having a modulus of elasticity that exceeds the modulus of elasticity of glass fibers; an outer core surrounding the inner core comprising a plurality of substantially continuous reinforcing fibers of at least a second type the fibers having a modulus of elasticity of or similar to glass fibers; a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded in said resin matrix; and a protective coating surrounding the outer composite core; wherein, the fibers of the outer core are different from the fibers of the inner core and wherein, the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (2, 3, 4)
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5. An electrical cable comprising:
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a composite core further comprising; an inner core comprising a plurality of substantially continuous reinforcing fibers of at least a first type, the fiber type having a modulus of elasticity that exceeds the modulus of elasticity of glass fibers; an outer core surrounding the inner core comprising a plurality of substantially continuous reinforcing fibers of at least a second type, the fibers having a modudul of elasticity of or similar to glass fibers; a cured resin matrix, wherein the fibers of the inner and the outer cores are embedded in said resin matrix; and a protective coating surrounding the outer core; and at least one layer of conductor surrounding the composite core; wherein, the fibers of the outer core are different from the fibers of the inner core and wherein, the fibers of the inner and the outer cores are oriented substantially parallel to the longitudinal axis. - View Dependent Claims (6, 7, 8)
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9. An electrical cable comprising:
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a composite core comprising two or more reinforcing fibers 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 about 45 Msi (255 GPa) coupled with a coefficient of thermal expansion in the range of at least about 31 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 comprises a modulus of elasticity of at least about 6 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);a protective coating surrounding the composite core; and at least one layer of conductor surrounding the protective coating. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A composite core for an electrical cable, the core comprising:
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a plurality of carbon fibers surrounded by a plurality of glass fibers; a cured resin matrix wherein, the carbon and glass fibers are embedded within said resin matrix to form the core; and a protective coating surrounding the core. - View Dependent Claims (16)
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17. A method of processing a composite core for an electrical cable comprising:
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pulling two or more longitudinally oriented and substantially continuous fibers 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 to compress the fibers to form the composite core, wherein the first die comprises one or more heating zones to begin catalyzation of the resin matrix; introducing a protective coating; applying the protective coating to the composite core; processing the fiber resin matrix through at least one second die to compress the composite core and coating, wherein the second die comprises a temperature to cure the fiber resin matrix; and curing the composite core and coating. - View Dependent Claims (18, 19, 20)
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Specification