CA2682116A1 - 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
CA2682116A1
CA2682116A1 CA002682116A CA2682116A CA2682116A1 CA 2682116 A1 CA2682116 A1 CA 2682116A1 CA 002682116 A CA002682116 A CA 002682116A CA 2682116 A CA2682116 A CA 2682116A CA 2682116 A1 CA2682116 A1 CA 2682116A1
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CA
Canada
Prior art keywords
composite core
electrical cable
recited
core reinforced
reinforced electrical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002682116A
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French (fr)
Other versions
CA2682116C (en
Inventor
George Korzeniowski
Clem Hiel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CTC Global Corp
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Individual
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Application filed by Individual filed Critical Individual
Publication of CA2682116A1 publication Critical patent/CA2682116A1/en
Application granted granted Critical
Publication of CA2682116C publication Critical patent/CA2682116C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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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
    • 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
    • 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
    • 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
    • Y10T428/249946—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
    • 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
    • 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) and method of manufacture. An ACCC cable having a composite core surrounded by at least one layer of aluminum conductor. 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. 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 50 ft/min.

Claims (15)

1. A composite core reinforced electrical cable, comprising:
a composite core, the composite core comprising a high strength inner core comprising carbon fibers and a non-conductive outer insulating layer surrounding the inner core, where the outer insulating layer has a lower modulus of elasticity than the inner core; and at least one layer of conductor surrounding the composite core.
2. A composite core reinforced electrical cable as recited in Claim 1, wherein the composite core has a tensile strength in the range of from about 160 ksi to about 240 ksi.
3. A composite core reinforced electrical cable as recited in Claim 1, wherein the composite core has a modulus of elasticity in the range of from about 7 Msi to about 30 Msi.
4. A composite core reinforced electrical cable as recited in Claim 1, wherein the outer insulating layer comprises glass fibers.
5. A composite core reinforced electrical cable as recited in Claim 4, wherein the glass fibers comprise glass fiber tows that are substantially continuous in length.
6. A composite core reinforced electrical cable as recited in Claim 5, wherein the outer insulating layer comprises a resin.
7. A composite core reinforced electrical cable as recited in Claim 6, wherein the outer insulating layer has a fiber/resin ratio of about 75/25 by weight.
8. A composite core reinforced electrical cable as recited in Claim 1, wherein the outer insulating layer comprises a resin.
9. A composite core reinforced electrical cable as recited in Claim 1, wherein the carbon fibers of the high strength inner core are dispersed in a resin.
10. A composite core reinforced electrical cable as recited in Claim 8, wherein the carbon fibers comprise carbon fiber tows that are substantially continuous in length.
11. A composite core reinforced electrical cable as recited in Claim 9, wherein the high strength inner core has a fiber/resin ratio of about 70/30 by weight.
12. A composite core reinforced electrical cable as recited in Claim 1, wherein the inner core of the composite core comprises substantially continuous carbon fiber tows disposed in a resin and the outer insulating layer comprises substantially continuous glass fiber tows disposed in a resin.
13. A composite core reinforced electrical cable as recited in Claim 1, wherein the at least one layer of conductor comprises an aluminum conductor helically wound about the composite core.
14. A composite core reinforced electrical cable as recited in Claim 1, wherein the electrical cable has a length of at least about 6000 feet.
15. A method of improving the efficiency of an electrical power distribution system comprising electrical distribution lines, comprising the step of replacing at least a portion of the electrical distribution lines with a composite core reinforced electrical cable as recited in Claim 1.
CA2682116A 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture Expired - Fee Related CA2682116C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US37487902P 2002-04-23 2002-04-23
US60/374,879 2002-04-23
CA002480271A CA2480271C (en) 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
CA002480271A Division CA2480271C (en) 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture

Publications (2)

Publication Number Publication Date
CA2682116A1 true CA2682116A1 (en) 2003-11-06
CA2682116C CA2682116C (en) 2012-04-10

Family

ID=29270561

Family Applications (2)

Application Number Title Priority Date Filing Date
CA2682116A Expired - Fee Related CA2682116C (en) 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture
CA002480271A Expired - Fee Related CA2480271C (en) 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture

Family Applications After (1)

Application Number Title Priority Date Filing Date
CA002480271A Expired - Fee Related CA2480271C (en) 2002-04-23 2003-04-23 Aluminum conductor composite core reinforced cable and method of manufacture

Country Status (26)

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US (4) US7368162B2 (en)
EP (1) EP1506085B1 (en)
JP (2) JP4589629B2 (en)
KR (1) KR101046215B1 (en)
CN (1) CN100450759C (en)
AP (1) AP1807A (en)
AU (1) AU2003221761B2 (en)
BR (2) BRPI0309535A8 (en)
CA (2) CA2682116C (en)
CO (1) CO5611183A2 (en)
DK (1) DK1506085T3 (en)
EA (1) EA007945B1 (en)
EG (1) EG25109A (en)
ES (1) ES2617051T3 (en)
HU (1) HUE031998T2 (en)
IL (1) IL164705A (en)
MA (1) MA27691A1 (en)
MX (1) MXPA04010513A (en)
NO (1) NO20044490L (en)
NZ (1) NZ535979A (en)
OA (1) OA12991A (en)
PL (1) PL208011B1 (en)
PT (1) PT1506085T (en)
TN (1) TNSN04187A1 (en)
WO (1) WO2003091008A1 (en)
ZA (1) ZA200408274B (en)

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CA2682116C (en) 2012-04-10
MA27691A1 (en) 2006-01-02
NZ535979A (en) 2007-11-30
US20040131834A1 (en) 2004-07-08
US7368162B2 (en) 2008-05-06
KR20050004150A (en) 2005-01-12
AP1807A (en) 2007-12-14
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