CA2480271A1 - Aluminum conductor composite core reinforced cable and method of manufacture - Google Patents

Aluminum conductor composite core reinforced cable and method of manufacture Download PDF

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Publication number
CA2480271A1
CA2480271A1 CA002480271A CA2480271A CA2480271A1 CA 2480271 A1 CA2480271 A1 CA 2480271A1 CA 002480271 A CA002480271 A CA 002480271A CA 2480271 A CA2480271 A CA 2480271A CA 2480271 A1 CA2480271 A1 CA 2480271A1
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Prior art keywords
set forth
composite core
range
core
composite
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CA002480271A
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French (fr)
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CA2480271C (en
Inventor
George Korzeniowski
Clem Hiel
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CTC Global Corp
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Priority to CA2682116A priority Critical patent/CA2682116C/en
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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G7/00—Overhead installations of electric lines or cables
    • H02G7/04—Arrangements or devices for relieving mechanical tension
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D22/00—Producing hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/08—Several wires or the like stranded in the form of a rope
    • H01B5/10—Several wires or the like stranded in the form of a rope stranded around a space, insulating material, or dissimilar conducting material
    • H01B5/102—Several wires or the like stranded in the form of a rope stranded around a space, insulating material, or dissimilar conducting material stranded around a high tensile strength core
    • H01B5/105—Several wires or the like stranded in the form of a rope stranded around a space, insulating material, or dissimilar conducting material stranded around a high tensile strength core composed of synthetic filaments, e.g. glass-fibres
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/182—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments
    • H01B7/1825—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments forming part of a high tensile strength core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/006—Constructional features relating to the conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/02—Cable terminations
    • H02G15/06—Cable terminating boxes, frames or other structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions
    • H02G15/18—Cable junctions protected by sleeves, e.g. for communication cable
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G7/00—Overhead installations of electric lines or cables
    • H02G7/05—Suspension arrangements or devices for electric cables or lines
    • H02G7/053—Suspension clamps and clips for electric overhead lines not suspended to a supporting wire
    • H02G7/056—Dead-end clamps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249945—Carbon or carbonaceous fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249946—Glass fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249949—Two or more chemically different fibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2938—Coating on discrete and individual rods, strands or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/172—Coated or impregnated

Abstract

This invention relates to an aluminum conductor composite core reinforced cable (ACCC) (300) and method of manufacture. An ACCC cable having a composite core (302, 304) surrounded by at least one layer of aluminum conductor (306, 308). The composite core comprises at least one longitudinally oriented substantially continuous reinforced fiber type in a thermosetting resin matrix having an operating temperature capability within the range of about 90 to about 230 ~C, at least 50% fiber volume fraction, a tensile strength in the range of about 160 to about 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi and a thermal expansion coefficient in the range of about 0 to about 6 x 10-6 m/m/C.

Claims (101)

1. A composite core for an aluminum conductor composite core reinforced cable comprising:
two or more longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix, said core having at least 50% fiber volume fraction and an operating capability in the range of about 90 to about 230°C.
2. A composite core as set forth in claim 1 wherein the reinforced fiber types of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
3. A composite core as set forth in claim 1 comprising a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in.
4. A composite core as set forth in claim 1 comprising a thermosetting resin having a tensile strength at least about 160 to about 240 Ksi.
5. A composite core as set forth in claim 1 comprising a thermosetting resin having the ability to withstand operating temperatures in the range of about 90 to about 230°C.
6. A composite core as set forth in claim 1 wherein at least one reinforced fiber type comprises a modulus of elasticity in the range of about 22 to 37 Msi coupled with a coefficient of thermal expansion in the range of about -0.7 to about 0 m/m/C.
7. A composite core as set forth in claim 1 wherein at least one reinforced fiber type comprises a modulus of elasticity in the range of about 6 to about 7 Msi coupled with a coefficient of thermal expansion in the range of about 5 x 10 -6 to about 10 x 10 -6 m/m/C.
8. A composite core as set forth in claim 1 comprising a fiber/resin volume fraction in the range of about 50 to about 57%.
9. A composite core as set forth in claim 1 comprising a fiber/resin ratio in the range of about 62 to about 75% by weight.
10. A composite core as set forth in claim 1 comprising an ambient temperature capability in the range of about -40 to about 90 C.
11. A composite core as set forth in claim 1 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
12. A composite core for an aluminum conductor composite core reinforced cable comprising:
at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin matrix, said core having at least 50%
fiber volume fraction, an operating capability in the range of about 90 to about 230 C, a modulus of elasticity in the range of about 22 to 37 Msi, a coefficient of thermal expansion in the range of about -0.7 to about 0 m/m/C and a tensile strength in the range of about 160 to about 240 Ksi.
13. A composite core as set forth in claim 12 wherein the reinforced fiber of the composite core is selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
14. A composite core as set forth in claim 12 comprising a thermosetting resin having a neat resin fracture toughness at least about 0.87 INS-lb/in.
15. A composite core as set forth in claim 12 comprising a thermosetting resin having a tensile strength at least about 160 to about 240 Ksi.
16. A composite core as set forth in claim 12 comprising a thermosetting resin having the ability to withstand ambient temperatures in the range of about -40 to about 90 C.
17. A composite core as set forth in claim 12 comprising a fiber/resin volume fraction in the range of about 50 to about 57%.
18. A composite core as set forth in claim 12 comprising a fiber/resin ratio in the range of about 62 to about 75% by weight.
19. A composite core as set forth in claim 12 comprising an operating temperature capability in the range of about 170 to about 220 C.
20. A composite core as set forth in Claim 12 comprising an ambient temperature capability in the range of about -40 to about 90C.
21. A composite core as set forth in claim 12 wherein the core comprises two or more longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix.
22. A composite core as set forth in claim 12 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
23. A composite core for an aluminum conductor composite core reinforced cable comprising:
an inner core comprising an advanced composite; and an outer core comprising a low modulus composite.
24. A composite core as set forth in claim 23 wherein said inner and outer layers form a uniform concentric hybridized core.
25. A composite core as set forth in claim 23 having a total fiber volume fraction in the range of about 50 to about 57%.
26. A composite core as set forth in claim 23 having a total fiber/thermosetting resin ratio in the range of about 62 to about 75% by weight.
27. A composite core as set forth in claim 23 wherein the core comprises a tensile strength in the range of about 160 to about 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi, an operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C.
28. A composite core as set forth in claim 23 wherein the physical characteristics of said outer layer accommodates splicing.
29. A composite core as set forth in claim 23 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
30. A composite core as set forth in claim 23 wherein the core comprises a tensile strength in the range of about 160 to about 240 Ksi.
31. A composite core as set forth in claim 23 wherein the core comprises a modulus of elasticity in the range of about 7 to about 30 Msi.
32. A composite core as set forth in claim 23 wherein the core comprises an operating temperature in the range of about 90 to about 230 C.
33. A composite core as set forth in claim 23 wherein the core comprises a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C.
34. A composite core for an aluminum conductor composite core reinforced cable comprising:
An inner core comprising a carbon/epoxy composite; and An outer core comprising a glass fiber/epoxy composite.
35. A composite core as set forth in claim 34 wherein said inner and outer layers form a uniform concentric hybridized core.
36. A composite core as set forth in claim 34 wherein said inner and outer layers form a segmented concentric core.
37. A composite core as set forth in claim 34 having a total fiber fraction volume in the range of about 50 to about 57%.
38. A composite core as set forth in claim 34 having a fiber/resin ratio in the range of about 62 to 75% by weight.
39. A composite core as set forth in claim 34 wherein the core comprises a tensile strength in the range of about 160 to about 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi, an operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C.
40. A composite core as set forth in claim 34 wherein the core comprises a tensile strength in the range of about 160 to about 240 Ksi.
41. A composite core as set forth in claim 34 wherein the core comprises a modulus of elasticity in the range of about 7 to about 30 Msi.
42. A composite core as set forth in claim 34 wherein the core comprises an operating temperature in the range of about 90 to about 230 C.
43. A composite core as set forth in claim 34 wherein the core comprises a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C.
44. A composite core as set forth in claim 34 wherein the physical characteristics of said outer layer accommodates splicing.
45. An aluminum conductor composite core reinforced cable comprising:
a composite core having at least one longitudinally oriented and substantially continuous reinforced fiber type in a thermosetting resin matrix, said core having at least 50% fiber volume fraction, an operating temperature capability in the range of about 90 to about 230 C; a tensile strength in the range of about 160 to about 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi and a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C; and at least one layer of aluminum conductor surrounding the composite core.
46. A cable as set forth in claim 45 wherein said at least one layer of aluminum surrounding the composite core comprises a plurality of trapezoidal shaped aluminum segments wrapped around the core.
47. A cable as set forth in claim 45 wherein a second layer of a plurality of trapezoidal shaped aluminum segments is wrapped around the core.
48. A composite core as set forth in claim 45 wherein the composite core comprises two or more longitudinally oriented and substantially continuous reinforced fiber types.
49. A composite core as set forth in claim 45 wherein the composite core permits splicing.
50. A composite core as set forth in claim 45 comprising a fiber/resin volume fraction in the range of about 50 to about 57%.
51. A composite core as set forth in claim 45 comprising a fiber/resin ratio in the range of about 62 to about 75% by weight.
52. A cable of claim 45 wherein the reinforced fiber types of the composite core are selected from the group consisting, of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
53. A composite core as set forth in claim 45 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.

53. An aluminum conductor composite core reinforced cable comprising:
a composite core having two or more longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix, said core having at least 50% fiber volume fraction and an operating capability in the range of about 90 to about 230 C; and at least one layer of aluminum conductor surrounding the composite core.
54. A composite core as set forth in claim 53 having a tensile strength in the range of about 160 to 240 Ksi.
55. A composite core as set forth in claim 53 having a modulus of elasticity in the range of about 7 to 30 Msi.
56. A composite core as set forth in claim 53 having a thermal expansion coefficient range of about 0 to 6 × 10 -6 m/m/C.
57 57. A cable as set forth in claim 53 wherein said at least one layer of aluminum surrounding the composite core comprises a plurality of trapezoidal shaped aluminum segments wrapped around the core.
58. A cable as set forth in claim 53 wherein a second layer of a plurality of trapezoidal shaped aluminum segments is wrapped around the core.
59. A cable as set forth in claim 53 wherein the composite core permits splicing.
60. A composite core as set forth in claim 53 comprising a fiber/resin volume fraction in the range of about 50 to 57%.
61. A composite core as set forth in claim 53 comprising a fiber/resin ratio in the range of about 62 to 75% by weight.
62. A composite core as set forth in claim 53 wherein the fibers of the composite core are selected from the group consisting of carbon, Kevlar, basalt, glass, aramid, boron, liquid crystal fibers, high performance polyethylene and carbon nanofibers.
63. A composite core as set forth in claim 53 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
64. An aluminum conductor composite core reinforced cable comprising:
a carbon/epoxy inner core;
a glassfiber/epoxy outer core; and at least one layer of aluminum conductor surround the composite core.
65. A composite core as set forth in claim 64 wherein said inner core comprises a tensile strength at least about 370 Ksi, a tensile modulus of at least 20 Msi and tensile strain at least about 1.7%.
66. A composite core as set forth in claim 64 wherein said outer core comprises a tensile strength at least 298,103 psi and a tensile modulus at least 11.2 x 10 6 psi.
67. A composite core as set forth in claim 64 wherein said outer core and said inner core form a uniform concentric hybridized core.
68. A composite core as set forth in claim 64 wherein said outer core and said inner core form a segmented concentric core.
69. A composite core as set forth in claim 64 wherein said outer core and said inner core have a total fiber volume fraction in the range of about 50 to about 57%.
70. A composite core as set forth in claim 64 wherein said outer core and said inner core have a total fiber/resin ratio in the range of 62 to 75% by weight.
71. A composite core as set forth in claim 64 wherein said cone comprises a tensile strength in the range of about 160 to 240 Ksi, modulus of elasticity in the range of about 7 to 30 Msi, operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 x 10 -6 m/m/C.
72. A method of providing electrical power using an aluminum conductor composite core reinforced cable the steps comprising:
using a cable having a composite core comprising at least one longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix said core having at least 50% by fiber volume fraction and an operating capability in the range of about 90 to about 230 C surrounded by at least one layer of aluminum conductor surrounding the composite core; and transmitting power across the composite cable.
73. A method as set forth in claim 72 wherein said cable replaces at least a portion of existing cable.
74. A method as set forth in claim 72 wherein the composite core comprises a fiber/resin ratio in the range of about 62 to about 75% by weight.
75. A method as set forth in claim 72 wherein said cable comprises tensile strength in the range of about 160 to 240 Ksi, modulus of elasticity in the range of about 7 to 30 Msi, operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 × 10 -6 m/m/C.
76. A method as set forth in claim 72 wherein said cable comprises an ambient temperature range of about -40C to about 90 C.
77. Method of processing a composite core comprising the steps of:
providing a predetermined number of fiber tows;
guiding the fiber tows through a wet-out tank filled with resin;
using a B-stage oven and a plurality of bushings spaced apart to shape and compress said fiber tows; and curing the composite core member;
78. A method as set forth in claim 77 wherein said guide is a plate having a plurality of passageways wherein the orientation of passageways is.

determined by the desired cross section configuration of the composite core.
79. A method as set forth in claim 77 wherein the number and type of fiber tows is determined to meet physical characteristics in the end composite core including a tensile strength in the range of,160 to 240 Ksi, a modulus of elasticity in the range of about 7 to about 30 Msi, an operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 × 10 -6 m/m/C.
80. A method as set forth in claim 77 wherein the step of guiding the fiber tows through a wet-out tank filled with resin further comprises a pre-heating step prior to wet-out to evaporate moisture in the fiber tows.
81. A method as set forth in claim 77 wherein the wet out tank filled with resin comprises a device to aid in wetting the fibers.
82. A method as set forth in claim 77 wherein the wet out tank filled with resin comprises a series of wipers to remove excess resin from the fibers.
83. A method as set forth in claim 77 wherein the step of shaping and compressing the fiber tows further comprises:
guiding the fiber tows into a first B-stage temperature oven;
guiding the fiber tows into a second B-stage temperature oven comprising a series of bushings wherein each bushing in the series comprises a plurality of passageways;
guiding the fiber tows through the consecutive series of bushings and passageways; and using the bushings to form the composite core.
84. A method as set forth in claim 77 wherein the size of at least a portion of the passageways diminishes with consecutive bushings.
85. A method as set forth in claim 77 wherein at least a portion of the position of the passageways changes with consecutive bushings.
86. A method as set forth in claim 77 wherein the first B-stage temperature oven is in the range of about 200 to about 250 F.
87. A method as set forth in claim 77 wherein the second B-stage temperature oven is in the range of about 200 to about 250 F.
88. A method as set forth in claim 77 wherein the step of curing the composite core further comprises:
guiding the composite core from the second B-stage temperature oven to a curing oven wherein the curing oven temperature is in the range of about 330 to about 370 F;
guiding the composite core from the curing oven to a cooling zone wherein the cooling zone is in the range of about 34 to about 100 F;
guiding the composite core from the cooling zone to a post-cure oven wherein the temperature of the post-cure oven is in the range of about 330 to about 370 F; and guiding the composite core from the post-cure oven through a cooling zone wherein the core is cooled by air in the range of about 170 to. about 180 F.
89. A method as set forth in claim 77 wherein the fibers of the composite core are selected from the group consisting of carbon, Kevlar; basalt, glass, aramid, boron, liquid crystal fibers; high performance polyethylene and carbon nanofibers.
90. A method as set forth in claim 77 wherein the method of processing comprises processing speeds in the range of about 9 ft/min to about 50 ft/min.
91. A method of improving the efficiency of an electrical power distribution system the steps comprising:
forming an aluminum conductor composite core reinforced cable comprising a composite core having at least one longitudinally oriented and substantially continuous reinforced fiber types in a thermosetting resin matrix said core having at least 50% fiber volume fraction and an operating capability in the range of about 90 to about 230 C surrounded by at least one layer of aluminum conductor; and replacing at least a portion of existing distribution lines with said cable.
92. A method as set forth in claim 91 wherein said composite core comprises a fiber/resin ratio in the range of 62 to 75% by weight.
93. A method as set forth in claim 91 wherein said composite core comprises a fiber volume fraction in the range of about 50 to about 57%.
94. A method as set forth in claim 91 wherein said composite core comprises a hybridized concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
95. A composite core for an aluminum conductor composite core reinforced cable comprising:
a segmented inner core comprising advanced composite; and a segmented outer core comprising low modulus composite.
96. A composite core as set forth in claim 95 wherein the total fiber fraction is in the range of about 50 to about 57%.
97. A composite core as set forth in claim 95 wherein the total fiber/resin ratio is in the range of about 62 to 75% by weight.
98. A composite core as set forth in claim 95 wherein the core comprises a tensile strength in the range of about 160 to about 240 Ksi, modulus of elasticity in the range of about 7 to about 30 Msi, operating temperature in the range of about 90 to about 230 C and a thermal expansion coefficient in the range of about 0 to about 6 × 106 m/m/C.
99. A composite core as set forth in claim 95 wherein the physical characteristics of said outer layer accommodates splicing.
100. A composite core as set forth in claim 95 wherein the segments are formed separately.
101. A composite core as set forth in claim 95 wherein said composite core comprises a segmented concentric core having an inner carbon/epoxy layer and an outer glass fiber/epoxy layer.
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