COMPOSITE CORE FOR AN ELECTRICAL CABLE
This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable ( 300 ) has a composite core and at least one layer of aluminum conductor ( 306 ). The composite core (303) comprises a plurality of fibers from at least one fiber type in one or more matrix materials. 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.
1 . A composite core for an electrical cable, the composite core comprising:
a plurality of substantially continuous reinforcing fibers of a first type embedded in a resin; and
a layer surrounding the reinforcing fibers of a first type, the layer comprising fibers of a second type that are different than the first type fibers, the second type fibers of the layer being laid at least a first angle relative to a longitudinal axis of the composite core, and
wherein the composite core is adapted for use as a strength member in an electrical distribution and transmission cable.
2 . A composite core as recited in claim 1 , wherein the first type fibers are carbon fibers.
3 . A composite core as recited in claim 1 , wherein the second type fibers are glass fibers.
4 . A composite core as recited in claim 1 , wherein the first type fibers are carbon fibers and the second type fibers are glass fibers.
5 . A composite core as recited in claim 1 , wherein the second type fibers have a lower modulus of elasticity than the first type fibers.
6 . A composite core as recited in claim 1 , wherein the first type fibers have a modulus of elasticity of at least about 22 Msi and the second type fibers are glass fibers.
7 . A composite core as recited in claim 1 , wherein the first type fibers are carbon fibers and the second type fibers have a modulus of elasticity of from about 6 Msi to about 15 Msi.
8 . A composite core as recited in claim 1 , wherein the resin comprises a thermosetting resin.
9 . A composite core as recited in claim 1 , wherein the resin comprises a thermoplastic resin.
10 . A composite core as recited in claim 1 , wherein the first type fibers have a tensile strength of at least about 250 Ksi.
11 . A composite core as recited in claim 1 , wherein the second type fibers are helically wound around the plurality of substantially continuous reinforcing fibers of a first type.
12 . A composite core as recited in claim 1 , wherein the second type fibers of the layer are interlaced.
13 . A composite core as recited in claim 1 , wherein the second type fibers of the layer are woven.
14 . A composite core as recited in claim 1 , wherein the layer comprises a braided sleeve of the second type fibers.
15 . A composite core as recited in claim 1 , wherein the layer is nonconductive and insulating.
16 . A composite core as recited in claim 1 , wherein the second type fibers of the layer comprise a first group of fibers having a first orientation at the first angle and a second group of fibers having a second orientation at a second angle relative to the longitudinal axis of the composite core.
17 . A composite core as recited in claim 1 , wherein the composite core has a modulus of elasticity within the range of about 7 Msi to about 37 Msi.
18 . A composite core as recited in claim 1 , wherein the composite core has a tensile strength above 200 Ksi.
19 . A composite core as recited in claim 1 , wherein the composite core is fabricated by pulling a plurality of substantially continuous fiber tows of the first fiber type and the second fiber type through a composite core processing system.
20 . A composite core for an electrical cable, the composite core comprising:
a plurality of substantially continuous reinforcing carbon fibers embedded in a resin; and
a layer surrounding and insulating the reinforcing carbon fibers, the surrounding layer comprising glass fibers wherein the glass fibers are laid at least a first angle relative to a longitudinal axis of the composite core,
wherein the composite core is adapted for use as a strength member in an electrical distribution and transmission cable.
21 . A composite core as recited in claim 20 , wherein the glass fibers have a lower modulus of elasticity than the carbon fibers.
22 . A composite core as recited in claim 20 , wherein the resin comprises a thermosetting resin.
23 . A composite core as recited in claim 20 , wherein the resin comprises a thermoplastic resin.
24 . A composite core as recited in claim 20 , wherein the glass fibers comprise substantially continuous glass fibers that are helically wound around the plurality of substantially continuous reinforcing carbon fibers.
25 . A composite core as recited in claim 20 , wherein the glass fibers of the surrounding layer are interlaced.
26 . A composite core as recited in claim 20 , wherein the glass fibers of the surrounding layer are woven.
27 . A composite core as recited in claim 20 , wherein the surrounding layer comprises a braided sleeve of the glass fibers.
28 . A composite core as recited in claim 20 , wherein the glass fibers of the surrounding layer comprise a first group of glass fibers having a first orientation and a second group of glass fibers having a second orientation relative to the longitudinal axis of the composite core.
29 . A composite core as recited in claim 20 , wherein the composite core has a modulus of elasticity within the range of about 7 Msi to about 37 Msi.
30 . A composite core as recited in claim 20 , wherein the composite core has a tensile strength above 200 Ksi.
31 . A composite core as recited in claim 20 , wherein the composite core is fabricated by pulling a plurality of substantially continuous fiber tows of the first fiber type and the second fiber type through a composite core processing system.
32 . An electrical transmission and distribution cable, comprising:
a composite core strength member, the strength member comprising:
a plurality of substantially continuous reinforcing fibers of a first type embedded in a resin; and
a layer surrounding the reinforcing fibers of a first type, the surrounding layer comprising fibers of a second type that are different than the first type fibers, the second type fibers of the surrounding layer being laid at least a first angle relative to a longitudinal axis of the composite core, and
at least one layer of conductor surrounding the strength member.
33 . An electrical cable as recited in claim 32 , wherein the at least one layer of conductor comprises a plurality of aluminum conductor strands that are helically wrapped around the composite core strength member.
34 . An electrical cable as recited in claim 33 , wherein the aluminum conductor strands are trapezoidal shaped.
35 . An electrical cable as recited in claim 32 , wherein the first type fibers are carbon fibers.
36 . An electrical cable as recited in claim 32 , wherein the second type fibers are glass fibers.
37 . An electrical cable as recited in claim 32 , wherein the first type fibers are carbon fibers and the second type fibers are glass fibers.
38 . An electrical cable as recited in claim 32 , wherein the second type fibers have a lower modulus of elasticity than the first type fibers.
39 . An electrical cable as recited in claim 32 , wherein the first type fibers have a modulus of elasticity of at least about 22 Msi and the second type fibers are glass fibers.
40 . An electrical cable as recited in claim 32 , wherein the first type fibers are carbon fibers and the second type fibers have a modulus of elasticity of from about 6 Msi to about 15 Msi.
41 . An electrical cable as recited in claim 32 , wherein the resin comprises a thermosetting resin.
42 . An electrical cable as recited in claim 32 , wherein the resin comprises a thermoplastic resin.
43 . An electrical cable as recited in claim 32 , wherein the first type fibers have a tensile strength of at least about 250 Ksi.
44 . An electrical cable as recited in claim 32 , wherein the second type fibers are helically wound around the plurality of substantially continuous reinforcing fibers of a first type.
45 . An electrical cable as recited in claim 32 , wherein the second type fibers of the surrounding layer are interlaced.
46 . An electrical cable as recited in claim 45 , wherein the second type fibers are woven.
47 . An electrical cable as recited in claim 32 , wherein the surrounding layer comprises a braided sleeve of the second type fibers.
48 . An electrical cable as recited in claim 32 , wherein the surrounding layer is nonconductive and insulating.
49 . An electrical cable as recited in claim 32 , wherein the second type fibers of the s layer comprise a first group of fibers having a first orientation and a second group of fibers having a second orientation relative to the longitudinal axis of the composite core.
50 . An electrical cable as recited in claim 32 , wherein the composite core has a modulus of elasticity within the range of about 7 Msi to about 37 Msi.
51 . An electrical cable as recited in claim 32 , wherein the composite core has a tensile strength above 160 Ksi.
52 . An electrical cable as recited in claim 32 , wherein the composite core is fabricated by pulling a plurality of substantially continuous fiber tows of the first fiber type and the second fiber type through a composite core processing system.
53 . An electrical transmission and distribution cable, comprising:
a composite core strength member, the strength member comprising:
a plurality of substantially continuous reinforcing carbon fibers embedded in a resin; and
an layer surrounding and insulating the reinforcing carbon fibers, the surrounding layer comprising glass fibers wherein the glass fibers are laid at least a first angle relative to a longitudinal axis of the composite core, and
at least one layer of aluminum conductor strands surrounding the strength member, wherein the composite core has a modulus of elasticity within the range of about 7 Msi to about 37 Msi and a tensile strength above 160 Ksi.
54 . An electrical cable as recited in claim 53 , wherein the glass fibers comprise substantially continuous glass fibers that are helically wound around the plurality of reinforcing carbon fibers.