Aluminum conductor composite core reinforced cable and method of manufacture
View Patent ↗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 230° C., 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 −0.7×10 −6 m/m/° C. to about 6×10 −6 m/m° C. According to the invention, a B-stage forming process may be used to form the composite core at improved speeds over pultrusion processes wherein the speeds ranges from about 9 ft/min to about 60 ft/min.
1. A method of high-speed processing a composite core comprising the steps of:
a. providing a plurality of fiber tows;
b. guiding the fiber tows through a wet-out system filled with resin to form resin impregnated fiber tows;
c. using a B stage oven and two or more dies spaced apart to shape and compact the resin impregnated fiber tows, wherein the B stage oven maintains the resin impregnated fiber tows in a semi-cure stage and wherein, the two or more dies shape and compact the resin impregnated fiber tows; and
d. curing the composite core member.
2. A method according to claim 1 , wherein at least one of the dies is a bushing.
3. A method according to claim 1 , wherein the wet-out system comprises a system to aid in wetting the fibers.
4. A method according to claim 1 , wherein the wet-out system is a wet-out tank.
5. A method according to claim 1 , wherein shaping and compacting the fiber tows further comprises:
a. guiding the fiber tows into a first B-stage temperature oven;
b. guiding the fiber tows into a second B-stage temperature oven comprising a plurality of bushings wherein each bushing comprises a plurality of passageways;
c. guiding the fiber tows through the bushings and the passageways; and
d. using the bushings to form the composite core.
6. A method according to claim 5 , wherein the first B-stage temperature oven is in the range of about 150° F. to about 350° F.
7. A method according to claim 5 , wherein the second B-stage temperature oven is in the range of about 150° F. to about 350° F.
8. A method according to claim 1 , wherein the step of curing the composite core further comprises:
a. guiding the composite core through a curing oven wherein a temperature of the curing oven is in the range of about 300° F. to about 400° F.;
b. guiding the composite core through a cooling zone wherein a temperature of the cooling zone is in the range of about 30° F. to about 100° F.;
c. guiding the composite core through a post-cure oven wherein a temperature of the post-cure oven is in the range of about 300° F. to about 400° F.; and
d. guiding the composite core through a cooling zone wherein the core is cooled by air to bring a temperature of the core into the range of about 120° F. to about 180° F.
9. A method according to claim 1 , wherein the method of processing has a maximum processing speed above 6 ft/mm.
10. A method according to claim 9 , wherein the maximum processing speed is within the range of about 9 ft/mm to about 60 ft/mm.
11. A method of high-speed processing a composite core comprising the steps of:
a. providing a plurality of fiber tows;
b. guiding the fiber tows through a wet-out system filled with resin;
c. using a B-stage oven and two or more dies spaced apart to shape and compact the fiber tows, wherein at least one of the dies is a plate having a plurality of passageways wherein the orientation of the passageways is determined by the desired cross section configuration of the composite core; and
d. curing the composite core member.