Aluminum conductor composite core reinforced cable and method of manufacture

Abstract

This invention relates to an aluminum conductor composite core reinforced cable and method of manufacture. The composite core comprises a plurality of longitudinally extending fibers embedded in a resin matrix. The composite core comprises the following characteristics: tensile strength ranging from about 250 to about 350 Ksi; a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to about 6×10 −6 cm/cm·° C. The composite core is further manufactured according to a two die pultrusion system, the system comprising tooling designed in accordance with the processing speed, selection of composite core fibers and resin and desired physical characteristics of the end composite core.

1 . A composite core for an electrical transmission cable, the core comprising: 
 a plurality of longitudinally extending fibers embedded in a resin matrix, the fibers further comprising: 
 a tensile strength ranging from about 450 Ksi to about 650 Ksi;  
 a tensile modulus of elasticity ranging from about 12 to about 16 Msi; and  
 a coefficient of thermal expansion ranging from about 1.6×10 −6  cm/cm·° C. to about 0 cm/cm·° C.;  
 wherein, the composite core is processed via a two die processing system.  
   
   
   
       2 . A composite core according to  claim 1 , wherein the fibers are S-2 glass fibers.  
   
   
       3 . A composite core according to  claim 1 , wherein the composite core further comprises a tensile strength ranging from about 250 to about 350 Ksi; a modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to 6×10 −6  cm/cm° C.  
   
   
       4 . A composite core according to  claim 1 , wherein the two die system comprises at least a first die, a second die and a gap between the first die and the second die.  
   
   
       5 . A composite core according to  claim 4 , wherein the length of the first die, the second die and the gap is determined by the processing speed.  
   
   
       6 . A composite core according to  claim 1 , wherein the two die processing system operates at a speed of about 48 inches/min.  
   
   
       7 . A composite core according to  claim 6 , wherein the two die processing system comprises a first die having a length in the range of about 10 to about 14 inches, a second die having a length ranging from about 34 to about 38 inches and a gap between the first and second die ranging from about 4 to about 8 inches.  
   
   
       8 . A composite core according to  claim 1 , wherein the composite core is manufactured by a two die process system the steps comprising: 
 pulling the plurality of fibers through a resin wet-out system to form a fiber/resin matrix;    removing the excess resin from the fiber/resin matrix;    pulling the fibers through a first die comprising a temperature within the range of about 200 to about 240° F.;    pulling the fibers through a gap at about ambient temperature; and    pulling the fibers through a second die, the second die having a first and second end, wherein the temperature within the second die ramps from about 220° F. at the first end to about 400° F. towards the second end.    
   
   
       9 . A composite core for an electrical transmission cable, comprising a plurality of longitudinally extending S-2 glass fibers embedded in a resin to form a fiber/resin matrix, wherein the fiber/resin matrix forms a concentric core and wherein the composite core comprises a tensile strength ranging from about 250 to about 350 Ksi; a modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to 6×10 1−6  cm/cm·° C.  
   
   
       10 . A composite core according to  claim 9 , wherein the core is manufactured using a two die processing system comprising at least a first die, a second die and a gap between the first die and the second die.  
   
   
       11 . A composite core according to  claim 10 , wherein the core is processed at a speed of about 48 inches/min and wherein the first die comprises a length in the range of about 10 to about 14 inches, the second die comprises a length in the range of about 34 to about 38 inches, and a gap comprises a length in the range of about 4 to about 8 inches.  
   
   
       12 . A composite core according to  claim 9 , wherein the core is manufactured by a process, the steps comprising: 
 pulling the plurality of fibers through a resin wet-out system to form a fiber/resin matrix;    removing the excess resin from the fiber/resin matrix;    pulling the fibers through a first die comprising a temperature ranging from about 200 to about 240° F.;    pulling the fibers through a gap at about ambient temperature; and    pulling the fibers through a second die, the second die having a first and second end, wherein the temperature within the second die ramps from about 220° F. at the first end to about 400° F. towards the second end.    
   
   
       13 . A composite core for an electrical transmission cable, the core comprising a plurality of longitudinally extending fibers embedded in a resin to form a fiber/resin matrix, wherein the fiber/resin matrix is processed through a first die at about 220° F., a gap at about ambient temperature and cured in a second die comprising a ramped temperature range from about 240° F. to about 400° F.  
   
   
       14 . A composite core according to  claim 13 , wherein the composite core further comprises a tensile strength ranging from about 250 to about 350 Ksi; a modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to 6×10 −6  cm/cm·° C.  
   
   
       15 . A composite core for an electrical cable comprising a plurality of longitudinally extending fibers embedded in a resin matrix, wherein the resin matrix further comprises a mold release element and wherein the composite core comprises a tensile strength ranging from about 250 to about 350 Ksi; a modulus of elasticity ranging from about 12 to about 16 Msi; and a coefficient of thermal expansion less than or equal to 6×10 −6  cm/cm·° C.  
   
   
       16 . A composite core according to  claim 15 , wherein the core is manufactured by a process, the steps comprising: 
 pulling the plurality of fibers through a resin wet-out system forming a fiber/resin matrix;    removing the excess resin from the fiber/resin matrix;    pulling the fibers through a first die comprising a temperature ranging from about 200 to about 240° F.;    pulling the fibers through a gap at about ambient temperature; and    pulling the fibers through a second die, the second die having a first and second end, wherein the temperature within the second die ramps from about 220° F. at the first end to about 400° F. towards the second end.    
   
   
       17 . A composite core according to  claim 15 , wherein the fibers are S-2 glass fibers.  
   
   
       18 . A method for manufacturing a composite core for an electrical transmission cable, comprising: 
 pulling the plurality of fibers through a resin wet-out system forming a fiber/resin matrix;    removing the excess resin from the fiber/resin matrix;    pulling the fibers through a first die comprising a temperature ranging from about 200 to about 240° F.;    pulling the fibers through a gap at about ambient temperature; and    pulling the fibers through a second die, the second die having a first and second end, wherein the temperature within the second die ramps from about 220° F. at the first end to about 400° F. towards the second end.    
   
   
       19 . A method for manufacturing a composite core for an electrical transmission cable according to  claim 18 , the method further comprising the step of wrapping the core with a coating.  
   
   
       20 . A composite core comprising a plurality of fibers embedded in a resin matrix manufactured according to the process in  claim 18 .  
   
   
       21 . A method for manufacturing a composite core according to  claim 18 , the first die comprising a length in the range of about 10 to about 14 inches for a processing speed of about 48 inches/min.  
   
   
       22 . A method for manufacturing a composite core according to  claim 18 , the second die comprising a length in the range of about 34 to about 38 inches for a processing speed of about 48 inches/min.  
   
   
       23 . A method for manufacturing a composite core according to  claim 18 , the gap between the first die and the second die comprising a length in the range of about 4 to about 8 inches for a processing speed of about 48 inches/min.