WO2003050825A1 - High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement - Google Patents

High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement Download PDF

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Publication number
WO2003050825A1
WO2003050825A1 PCT/US2001/048758 US0148758W WO03050825A1 WO 2003050825 A1 WO2003050825 A1 WO 2003050825A1 US 0148758 W US0148758 W US 0148758W WO 03050825 A1 WO03050825 A1 WO 03050825A1
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WO
WIPO (PCT)
Prior art keywords
cable
composite
core wire
composite core
jacket
Prior art date
Application number
PCT/US2001/048758
Other languages
French (fr)
Inventor
Joseph T. Blucher
Original Assignee
Northeastern University
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Northeastern University filed Critical Northeastern University
Priority to US10/498,687 priority Critical patent/US20050061538A1/en
Priority to PCT/US2001/048758 priority patent/WO2003050825A1/en
Publication of WO2003050825A1 publication Critical patent/WO2003050825A1/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00Power cables
    • H01B9/006Constructional features relating to the conductors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00Power cables
    • H01B9/008Power cables for overhead application

Definitions

  • High power electrical transmission cables are required for transmission of electrical power between power generating stations.
  • Such cables typically have a reinforcing or supporting core wire made of steel.
  • the steel core carries the load of the cable.
  • Strands of an electrically conducting material are wound around the steel core.
  • the strands are typically formed from aluminum or copper.
  • the steel In cables having a steel core f the steel has a relatively high specific weight (7.8 gm/cc) . Also, steel has a large coefficient of thermal expansion that can result in sagging of the cable. In extreme cases, thermal expansion can cause the cable to break. Another disadvantage arises from the use of a single load-carrying cable; failure of this single cable can be catastrophic to the entire cable.
  • a high power transmission cable having a composite material core.
  • This cable is stronger, more lightweight, and has a lower thermal expansion coefficient than cables using a steel core.
  • the core material however, has an elongation of only 1 to 1.5% and is relatively brittle, leading to possible breakage and failure of the cable .
  • the present invention provides a high power electrical power transmission cable that is strong, lightweight and has a lower coefficient of thermal expansion.
  • the cable is formed from
  • composite-composite wires that comprise individual strands of a conducting material such as aluminum or copper in concentric or random arrangement with one or more cores of ceramic or carbon fiber reinforced composite wire.
  • the composite core wire comprises aligned reinforcing fibers of carbon or ceramic embedded within a matrix material.
  • the matrix material is also a conducting material, such as aluminum or copper, although other materials can be used.
  • the composite core wire may be formed by a continuous pressure infiltration process such as that disclosed in U.S. Patent No. 5,736,199, the disclosure of which is incorporated by reference herein.
  • the concentric jacketing of the composite core wire(s) with the conducting material can be carried out in a number of ways.
  • the jacketing materials may be coextruded over the composite core wire(s).
  • the jacketing material may be cold rolled longitudinally around and along the composite core wire(s).
  • the composite core wire(s) may be inserted in a tube of the jacketing material, which may be drawn down over the composite core wire(s). Other methods of jacketing the composite core wire are possible.
  • Fig. 1 is a copy of a micrograph at 1000 X illustrating the composite core wire of the present invention
  • Fig. 2 is a copy of a micrograph at 30 X illustrating a composite-composite wire comprising the composite core wire of Fig. 1 jacketed with a copper jacket;
  • Fig. 3 is a copy of a micrograph at 450 X more closely depicting the interface between the composite core wire and the copper jacket of Fig. 2;
  • Fig. 4 is a schematic illustration of a plurality of composite core wires within a jacket.
  • a high power electrical transmission cable is formed from composite-composite wires, each composite-composite wire comprising individual strands of a conducting material such as aluminum or copper in concentric, even, or random arrangement with one or a plurality of cores of ceramic or carbon fiber reinforced composite wire.
  • the composite core wire comprises aligned reinforcing fibers of carbon or ceramic embedded within a matrix material.
  • Carbon fibers are preferred, because carbon is conductive and generally less expensive than ceramics.
  • any suitable ceramic fiber such as aluminum oxide, may be used if desired.
  • the matrix material is also a conducting material, such as aluminum or copper, although other materials can be used.
  • a polymer or epoxy material can be used for the matrix.
  • Such a material is less conductive than, for example, aluminum or copper, but provides the same or similar strength and may be less expensive to manufacture.
  • the composite core wire may be formed by a continuous pressure infiltration process such as that disclosed in U.S. Patent No. 5,736,199, the disclosure of which is incorporated by reference herein.
  • strands of carbon or ceramic fibers are introduced into a pressurized bath of molten matrix material through a lower orifice which provides a gradient such that the matrix material is liquid adjacent to the bath and solid farthest from the bath, thereby preventing the pressurized molten matrix material from blowing out of the bath.
  • the matrix material infiltrates the fibers.
  • the infiltrated fibers are drawn upwardly out of the bath into a pressurized environment in which the molten matrix material solidifies.
  • Fig. 1 illustrates a composite core wire 10 of carbon fibers 12 in an aluminum matrix 14.
  • the composite core wire comprises approximately 12,000 individual strands of carbon or ceramic fiber.
  • the solidified, infiltrated core wire has a diameter of approximately 1/16 inch.
  • the number of strands of the fiber material and the finished diameter of the composite core wire may be chosen depending on the desired finished composite-composite wire, which depends on the power, voltage, and distance of the desired power transmission cable. Over long distances, power is usually transmitted at high voltages, at least 22 kV and often much greater.
  • the same continuous pressure infiltration process may be used, although the pressure required to cause the polymer matrix material to infiltrate the fibers may be lower than is required for a metal such as aluminum or copper.
  • the jacketing of the composite core wire or wires with the conducting material can be carried out in a number of ways .
  • the jacketing material may be coextruded over the composite core wire or wires.
  • the jacketing material may be cold rolled longitudinally around and along the composite core wire or wires and welded to seal the longitudinal joint.
  • the composite core wire or wires may be inserted in a tube of the jacketing material, which may be drawn down over the composite core wire or wires . It will be appreciated that other methods of jacketing the composite core wire are possible.
  • the core wire or wires may be concentrically or evenly or randomly distributed within the jacketing material.
  • the jacketed core wire may then be covered with any suitable insulating material and any other desired sheathing, as known in the art.
  • Fig. 2 illustrates one composite core wire 10 of Fig. 1 jacketed in a copper wire 16.
  • Fig. 3 illustrates the interface between the composite core wire and the copper jacket of Fig. 2.
  • Fig. 4 illustrates a plurality of composite core wires 10 in a random distribution within a jacket 14.
  • Strands of copper cable having carbon fibers and strands having aluminum oxide fibers were produced using the above- described high pressure, continuous infiltration process.
  • the tensile strengths of the strands were above 50,000 psi, which is about 2.5 times that of pure copper.
  • the weight of the reinforced strands was about 20 percent lower than that of pure copper.
  • a number of composite-composite reinforced wires formed in this manner can be assembled into a suitably sized power transmission cable in any desired manner.
  • the composite-composite reinforced wires are relatively light in weight, having a specific weight ranging from 2.1 to 2.7 gm/cc, thereby leading to considerable weight savings over existing power transmission cables.
  • the composite-composite reinforced wires also have relatively high strength and a low coefficient of thermal expansion.

Abstract

A high power electrical transmission cable having composite wires (10), wherein the wires have aligned reinforcing fibers (12) of carbon or ceramic embedded within a matrix material (14). A jacket of an electrically conductive material surrounds the core wire (10). The reinforcing fibers and the matrix material may be also electrically conducting materials. The matrix material may be aluminum, copper, a polymer, or an epoxy material.

Description

High Voltage Electrical Power Transmission Cable Having Composite-Composite Wire With Carbon or Ceramic Fiber Reinforcement
CROSS REFERENCE TO RELATED APPLICATIONS
N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
BACKGROUND OF THE INVENTION High power electrical transmission cables are required for transmission of electrical power between power generating stations. Such cables typically have a reinforcing or supporting core wire made of steel. The steel core carries the load of the cable. Strands of an electrically conducting material are wound around the steel core. The strands are typically formed from aluminum or copper.
In cables having a steel coref the steel has a relatively high specific weight (7.8 gm/cc) . Also, steel has a large coefficient of thermal expansion that can result in sagging of the cable. In extreme cases, thermal expansion can cause the cable to break. Another disadvantage arises from the use of a single load-carrying cable; failure of this single cable can be catastrophic to the entire cable.
In PCT International Publication No. WO 97/00976, a high power transmission cable is disclosed having a composite material core. This cable is stronger, more lightweight, and has a lower thermal expansion coefficient than cables using a steel core. The core material, however, has an elongation of only 1 to 1.5% and is relatively brittle, leading to possible breakage and failure of the cable .
SUMMARY OF THE INVENTION The present invention provides a high power electrical power transmission cable that is strong, lightweight and has a lower coefficient of thermal expansion. The cable is formed from
composite-composite wires that comprise individual strands of a conducting material such as aluminum or copper in concentric or random arrangement with one or more cores of ceramic or carbon fiber reinforced composite wire. The composite core wire comprises aligned reinforcing fibers of carbon or ceramic embedded within a matrix material. Preferably, the matrix material is also a conducting material, such as aluminum or copper, although other materials can be used.
The composite core wire may be formed by a continuous pressure infiltration process such as that disclosed in U.S. Patent No. 5,736,199, the disclosure of which is incorporated by reference herein. The concentric jacketing of the composite core wire(s) with the conducting material can be carried out in a number of ways. For example, the jacketing materials may be coextruded over the composite core wire(s). The jacketing material may be cold rolled longitudinally around and along the composite core wire(s). Alternatively, the composite core wire(s) may be inserted in a tube of the jacketing material, which may be drawn down over the composite core wire(s). Other methods of jacketing the composite core wire are possible.
DESCRIPTION OF THE DRAWINGS The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
Fig. 1 is a copy of a micrograph at 1000 X illustrating the composite core wire of the present invention; Fig. 2 is a copy of a micrograph at 30 X illustrating a composite-composite wire comprising the composite core wire of Fig. 1 jacketed with a copper jacket;
Fig. 3 is a copy of a micrograph at 450 X more closely depicting the interface between the composite core wire and the copper jacket of Fig. 2; and
Fig. 4 is a schematic illustration of a plurality of composite core wires within a jacket.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, a high power electrical transmission cable is formed from composite-composite wires, each composite-composite wire comprising individual strands of a conducting material such as aluminum or copper in concentric, even, or random arrangement with one or a plurality of cores of ceramic or carbon fiber reinforced composite wire.
The composite core wire comprises aligned reinforcing fibers of carbon or ceramic embedded within a matrix material. Carbon fibers are preferred, because carbon is conductive and generally less expensive than ceramics. However, any suitable ceramic fiber, such as aluminum oxide, may be used if desired. Preferably, the matrix material is also a conducting material, such as aluminum or copper, although other materials can be used. For example, a polymer or epoxy material can be used for the matrix. Such a material is less conductive than, for example, aluminum or copper, but provides the same or similar strength and may be less expensive to manufacture.
The composite core wire may be formed by a continuous pressure infiltration process such as that disclosed in U.S. Patent No. 5,736,199, the disclosure of which is incorporated by reference herein. In this process, strands of carbon or ceramic fibers are introduced into a pressurized bath of molten matrix material through a lower orifice which provides a gradient such that the matrix material is liquid adjacent to the bath and solid farthest from the bath, thereby preventing the pressurized molten matrix material from blowing out of the bath. In the pressurized bath, the matrix material infiltrates the fibers. The infiltrated fibers are drawn upwardly out of the bath into a pressurized environment in which the molten matrix material solidifies. Then the infiltrated, solidified core wire is drawn through an exiting orifice to an ambient environment. Using this continuous process, great lengths of composite core wire, suitable for use in power transmission cables, can be manufactured. Fig. 1 illustrates a composite core wire 10 of carbon fibers 12 in an aluminum matrix 14. In this example, the composite core wire comprises approximately 12,000 individual strands of carbon or ceramic fiber. The solidified, infiltrated core wire has a diameter of approximately 1/16 inch. However, the number of strands of the fiber material and the finished diameter of the composite core wire may be chosen depending on the desired finished composite-composite wire, which depends on the power, voltage, and distance of the desired power transmission cable. Over long distances, power is usually transmitted at high voltages, at least 22 kV and often much greater.
If a polymer material is used for the matrix, the same continuous pressure infiltration process may be used, although the pressure required to cause the polymer matrix material to infiltrate the fibers may be lower than is required for a metal such as aluminum or copper.
The jacketing of the composite core wire or wires with the conducting material can be carried out in a number of ways . For example, the jacketing material may be coextruded over the composite core wire or wires. Alternatively, the jacketing material may be cold rolled longitudinally around and along the composite core wire or wires and welded to seal the longitudinal joint. In a further alternative, the composite core wire or wires may be inserted in a tube of the jacketing material, which may be drawn down over the composite core wire or wires . It will be appreciated that other methods of jacketing the composite core wire are possible. The core wire or wires may be concentrically or evenly or randomly distributed within the jacketing material. The jacketed core wire may then be covered with any suitable insulating material and any other desired sheathing, as known in the art.
Fig. 2 illustrates one composite core wire 10 of Fig. 1 jacketed in a copper wire 16. Fig. 3 illustrates the interface between the composite core wire and the copper jacket of Fig. 2. Fig. 4 illustrates a plurality of composite core wires 10 in a random distribution within a jacket 14.
Strands of copper cable having carbon fibers and strands having aluminum oxide fibers were produced using the above- described high pressure, continuous infiltration process. The tensile strengths of the strands were above 50,000 psi, which is about 2.5 times that of pure copper. The weight of the reinforced strands was about 20 percent lower than that of pure copper.
A number of composite-composite reinforced wires formed in this manner can be assembled into a suitably sized power transmission cable in any desired manner. The composite-composite reinforced wires are relatively light in weight, having a specific weight ranging from 2.1 to 2.7 gm/cc, thereby leading to considerable weight savings over existing power transmission cables. The composite-composite reinforced wires also have relatively high strength and a low coefficient of thermal expansion.
The invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims .

Claims

CLAIMSWhat is claimed is:
1. A high power electrical transmission cable comprising: a composite core wire comprising aligned reinforcing fibers of carbon or ceramic embedded within a matrix material; and a jacket of an electrically conductive material surrounding the core wire.
2. The cable of claim 1, wherein the reinforcing fibers comprise aluminum oxide.
3. The cable of claim 1, wherein the reinforcing fibers are electrically conductive.
4. The cable of claim 1, wherein the matrix material comprises an electrically conductive material.
5. The cable of claim 1, wherein the matrix material comprises aluminum or copper.
6. The cable of claim 1, wherein the matrix material comprises a polymer or an epoxy.
7. The cable of claim 1, wherein the tensile strength of the fibers is greater than 50,000 psi.
8. The cable of claim 1, wherein the cable has a specific weight ranging from 2.1 to 2.7 gm/ cc.
9. The cable of claim 1, further comprising a plurality of composite core wires, each composite core wire comprising aligned reinforcing fibers of carbon or ceramic embedded within a matrix material, the jacket surrounding the further composite core wire.
10. The cable of claim 9, wherein the plurality of composite core wires are evenly distributed within the jacket.
11. The cable of claim 9, wherein the plurality of composite core wires are randomly distributed within the jacket.
12. The cable of claim 1, wherein the composite core wire is concentric with the jacket.
13. The cable of claim 1, wherein the core wire is sized to transmit at least 22 kV.
14. The cable of claim 1, further comprising an insulating sheath concentrically surrounding the jacket.
PCT/US2001/048758 2001-12-12 2001-12-12 High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement WO2003050825A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/498,687 US20050061538A1 (en) 2001-12-12 2001-12-12 High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement
PCT/US2001/048758 WO2003050825A1 (en) 2001-12-12 2001-12-12 High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2001/048758 WO2003050825A1 (en) 2001-12-12 2001-12-12 High voltage electrical power transmission cable having composite-composite wire with carbon or ceramic fiber reinforcement

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WO2003050825A1 true WO2003050825A1 (en) 2003-06-19

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005091404A1 (en) * 2004-03-19 2005-09-29 Eaglepicher Horizon Batteries, Llc Composite wire having impervious core for use in an energy storage device
US7060326B2 (en) 2002-04-23 2006-06-13 Composite Technology Corporation Aluminum conductor composite core reinforced cable and method of manufacture
US7438971B2 (en) 2003-10-22 2008-10-21 Ctc Cable Corporation Aluminum conductor composite core reinforced cable and method of manufacture
AU2005255346B2 (en) * 2004-06-18 2011-03-03 Aker Kvaerner Subsea As Power umbilical comprising separate load carrying elements of composite material
WO2013164686A1 (en) 2012-05-02 2013-11-07 Nexans A light weight cable
US9093191B2 (en) 2002-04-23 2015-07-28 CTC Global Corp. Fiber reinforced composite core for an aluminum conductor cable

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3647939A (en) * 1970-05-15 1972-03-07 Southwire Co Reinforced composite aluminum alloy conductor cable
US5171941A (en) * 1990-03-30 1992-12-15 The Furukawa Electric Co., Ltd. Superconducting strand for alternating current
US5198621A (en) * 1991-12-31 1993-03-30 The Furukawa Electric Co., Ltd. Twisted cable
WO1995027991A1 (en) * 1994-04-11 1995-10-19 New England Electric Wire Corporation Superconductor cable and method of making
WO1997000976A1 (en) * 1995-06-21 1997-01-09 Minnesota Mining And Manufacturing Company Fiber reinforced aluminum matrix composite

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3647939A (en) * 1970-05-15 1972-03-07 Southwire Co Reinforced composite aluminum alloy conductor cable
US5171941A (en) * 1990-03-30 1992-12-15 The Furukawa Electric Co., Ltd. Superconducting strand for alternating current
US5198621A (en) * 1991-12-31 1993-03-30 The Furukawa Electric Co., Ltd. Twisted cable
WO1995027991A1 (en) * 1994-04-11 1995-10-19 New England Electric Wire Corporation Superconductor cable and method of making
WO1997000976A1 (en) * 1995-06-21 1997-01-09 Minnesota Mining And Manufacturing Company Fiber reinforced aluminum matrix composite
US6245425B1 (en) * 1995-06-21 2001-06-12 3M Innovative Properties Company Fiber reinforced aluminum matrix composite wire

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7060326B2 (en) 2002-04-23 2006-06-13 Composite Technology Corporation Aluminum conductor composite core reinforced cable and method of manufacture
US7368162B2 (en) 2002-04-23 2008-05-06 Ctc Cable Corporation Aluminum conductor composite core reinforced cable and method of manufacture
US9093191B2 (en) 2002-04-23 2015-07-28 CTC Global Corp. Fiber reinforced composite core for an aluminum conductor cable
US7438971B2 (en) 2003-10-22 2008-10-21 Ctc Cable Corporation Aluminum conductor composite core reinforced cable and method of manufacture
WO2005091404A1 (en) * 2004-03-19 2005-09-29 Eaglepicher Horizon Batteries, Llc Composite wire having impervious core for use in an energy storage device
AU2005255346B2 (en) * 2004-06-18 2011-03-03 Aker Kvaerner Subsea As Power umbilical comprising separate load carrying elements of composite material
WO2013164686A1 (en) 2012-05-02 2013-11-07 Nexans A light weight cable

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