Aluminum conductor composite core reinforced cable and method of manufacture

Abstract

This invention relates to an aluminum conductor composite core reinforced cable (ACCC) and method of manufacture. An ACCC cable has a composite core surrounded by at least one layer of aluminum conductor. The composite core comprises a plurality of fibers from at least one fiber type in one or more matrix materials. The composite core can have a maximum operating temperature capability above 100° C. or within the range of about −45° C. to about 230° C., at least 50% fiber to resin volume fraction, a tensile strength in the range of about 160 Ksi to about 370 Ksi, a modulus of elasticity in the range of about 7 Msi to about 37 Msi and a coefficient of thermal expansion in the range of about −0.7×10−6 m/m/° C. to about 6×10−6 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 60 ft/min.

Dependencies are inferred from the claim text.