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Method for the manufacture of a composite core for an electrical cable

a technology of aluminum conductors and composite cores, which is applied in the direction of power cables, insulated conductors, cables, etc., can solve the problems of cable sag, many problems, and component limitations of traditional cables

Inactive Publication Date: 2010-07-22
CTC GLOBAL CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a composite core for an electrical cable that includes a center region, an interface region, and an outer region. The center region has a plurality of longitudinally extending reinforcing fibers of at least a first fiber type embedded in a resin matrix. The fibers are oriented substantially parallel to the longitudinal axis. The interface region has a random mixture of fibers from the center region and the outer region, creating a transition between fiber types. The outer region has a plurality of longitudinally extending reinforcing fibers of at least a second fiber type embedded in a resin matrix, the fibers being oriented substantially parallel to the longitudinal axis. The composite core provides improved strength and flexibility for electrical cables.

Problems solved by technology

The inherent physical characteristics of the components of these traditional cables limit ampacity.
However, increasing conductor weight causes numerous problems.
Weight increases due to increased conductor area cause the cable to sag.
In addition, large load increases relate to increased tension placed on the cable infrastructure which, depending on the load, may require structure reinforcement or replacement, wherein such infrastructure modifications are typically not financially feasible.

Method used

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  • Method for the manufacture of a composite core for an electrical cable
  • Method for the manufacture of a composite core for an electrical cable
  • Method for the manufacture of a composite core for an electrical cable

Examples

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example

[0109]In accordance with another embodiment of the invention, a multi-phase B-stage forming process produces a composite core member from substantially continuous lengths of suitable fiber tows and heat processable resins. In a further step, the composite core member is wrapped with high conductivity aluminum.

[0110]A process for making composite cores for ACCC cables according to the invention is described as follows. Referring to FIG. 1, the conductor core B-stage forming process of the present invention is shown and designated generally by reference number 10. The B-stage forming process 10 is employed to make continuous lengths of composite core members from suitable fiber tows or rovings and heat processable resins. The resulting composite core member comprises a hybridized concentric core having an inner and outer layer of uniformly distributed substantially parallel fibers.

[0111]In starting the operation, the pulling and winding spool mechanism is activated to commence pulling...

example one

Composite Core

[0173]A particular embodiment of the invention is now described wherein the composite strength member comprises boron free E-glass and carbon with type 13 sizing. E-glass combines the desirable properties of good chemical and heat stability, and good electrical resistance with high strength. The cross-sectional shape or profile is illustrated in FIG. 8 wherein the composite strength member comprises a concentric carbon core encapsulated by a uniform layer of glass fiber composite. In a preferred embodiment the process produces a hybridized core member comprising two different materials.

[0174]The fiber structures in this particular embodiment are 54 ends of E-glass product, 220 yield Veterotex Amer and 28 ends of carbon Torayca T7DOS yield 24K. The resin used is Araldite MY 721 from Vantico.

[0175]In operation, the ends of E-glass and carbon are threaded through a fiber tow guide comprising two rows of 32 passageways, two rows inner of 31 passageways and two innermost ro...

example two

Composite Core

[0179]An example of an ACCC reinforced cable in accordance with the present invention follows. An ACCC reinforced cable comprising four layers of components consisting of an inner carbon / epoxy layer, a next glassfiber / epoxy layer and two layers of tetrahedral shaped aluminum strands. The strength member consists of an advanced composite T700S carbon / epoxy having a diameter of about 0.2165 inches, surrounded by an outer layer of R099-688 glassfiber / epoxy having a layer diameter of about 0.375 inches. The glassfiber / epoxy layer is surrounded by an inner layer of nine trapezoidal shaped aluminum strands having a diameter of about 0.7415 inches and an outer layer of thirteen trapezoidal shaped aluminum strands having a diameter of about 1.1080 inches. The total area of carbon is about 0.037 in2, of glass is about 0.074 in2, of inner aluminum is about 0.315 in2 and outer aluminum is about 0.5226 in2. The fiber to resin ratio in the inner carbon strength member is 70 / 30 by w...

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Abstract

A method for the manufacture of a composite core for an electrical cable. The method may include pulling carbon fiber tows and glass fiber tows through a composite core processing system. The carbon fiber tows and the glass fiber tows are contacted with a resin, such as a thermosetting resin, to impregnate the fiber tows with the resin. The glass fiber tows are disposed on the outside of the carbon fiber tows to form a glass fiber layer around the carbon. The resin is then cured to form the composite core, which is adapted for use in an electrical transmission and distribution cable.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional application of U.S. patent application Ser. No. 12 / 074,996, filed Mar. 6, 2008, which is a continuation in part of U.S. patent application Ser. No. 10 / 511,881, now U.S. Pat. No. 7,368,162, which is an application under 35 USC §371 of PCT / US03 / 12520, filed Apr. 23, 2003, which claims the benefit of U.S. Provisional Application No. 60 / 374,879, filed Apr. 23, 2002. In relation to this Application, applicants claim priority of earlier U.S. provisional application Ser. No. 60 / 374,879 filed in the United States Patent and Trademark Office on Apr. 23, 2002. The entire disclosure of each of the foregoing is incorporated by reference herein.FIELD OF THE INVENTION[0002]The present invention relates to an aluminum conductor composite core (ACCC) reinforced cable and method of manufacture. More particularly, to a cable for providing electrical power having a reinforced fiber thermosetting resin composite core surround...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H3/12
CPCB32B15/04B32B27/04H01B5/105H01B7/1825H01B9/006H01B13/0016Y10T428/2938H02G7/056H02G15/06H02G15/18Y10T428/2933Y10T428/294H02G7/04Y10T428/249946Y10T428/24995
Inventor HIEL, CLEMENTKORZENIOWSKI, GEORGE
Owner CTC GLOBAL CORP
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