JP2002184241A - Composite reinforced electrical transmission conductor - Google Patents

Abstract

(57) [Summary] (Modified) [PROBLEMS] To provide a novel, composite material reinforced component for providing load-bearing performance, and to introduce a Hikari fiber filament as an integral component of a transmission cable as an option Provide an electrical transmission cable that enables A current carrying component and a load bearing component comprising a reinforced plastic, wherein the load bearing component is an outer sheath surrounding the current carrying component. In this way, the sheath provides the required strength and the inner core provides for the transmission of electrical signals. In yet another embodiment, a strip of reinforced plastic composite is embedded in a cylindrically shaped current carrying component.
A fiber optic cable is received in a hole formed in the power carrying component.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

FIELD OF THE INVENTION This invention relates generally to certain novel and useful improvements in electrical transmission cables, and more particularly to composite reinforced components to provide load bearing performance. Has,
The present invention relates to an electrical transmission cable that allows an optical fiber filament to be optionally introduced as an integral component of the transmission cable.

[0002]

BACKGROUND OF THE INVENTION A cable structure having an inner core as a current carrying component formed of wrought aluminum or other highly conductive material such as copper, silver, or the like. That turned out to be desirable. Although the cores of these metals have excellent electrical conductivity, they do not have good load-bearing properties, so when used with an outer composite shell that provides load-bearing components, improved conductivity is achieved. Taking advantage of the degree, the use of such an inner core material becomes possible. By using this structure, and since the amount of composite material can be the same as or greater than that used in the central core cable structure, equal or improved strength performance is provided.

[0003] Not only is the conductivity utilized with the cable of the present invention improved, but there is also a substantial advantage of lower weight for a given cable diameter. This is due to the fact that it is possible to distribute the same weight of composite material as the outer shell, which will have a relatively thin cross-section as compared to a composite with a central core. It is caused. Furthermore, this construction also reduces the sag as well as the temperature rise as occurs with stranded steel cable members, and consequently energy loss. In addition, the use of aluminum core composites can take advantage of the greater conductivity that results from using refined aluminum instead of alloyed aluminum.

[0004] Another significant problem with the transmission and distribution of communication signals is when transmitting fiber optic signals. The transmission and distribution of fiber optic signals is relatively new, and as a result, road use rights for posts that hold fiber optic cables are very limited, if not virtually nonexistent. At present, most fiber optic cables are used entangled with electrical transmission conductors in a rather rudimentary manner. This system eliminates the need for land declaration, convenience and construction of new telecommunications posts. Furthermore, underground cables pose environmental concerns as well. As a result, fiber optic cables are used, albeit rudimentary, over electrical transmission cables.

[0005] When laid with optical fiber cables carried on electrical transmission conductors, there are concerns about climate, ultraviolet radiation, and similar environmental effects. Of course, in order to effectively combine a transmission network with a transmission-communication network, it is desirable to combine optical fiber signal transmission and electrical signal transmission.

[0006]

SUMMARY OF THE INVENTION The present invention generally comprises an outer load-bearing component formed of a reinforced plastic composite material, and a central portion formed of a highly conductive current-carrying material that acts as a current-carrying conductor. The present invention relates to a current carrying conductor using a core. The cable of the present invention
It has an elongated and continuous central hole for passing fiber optic cables or other types of communication cables extending therethrough. In this way, the cables of the present invention not only provide power transmission and distribution, but also
It also provides for the transmission and distribution of communications, thereby forming a combined transmission network of power and communication signals.

As indicated above, in its simplest form:
One of the main objects of the present invention was to provide a current carrying cable that takes advantage of the fact that pure wrought aluminum has at least 10% higher conductivity than alloyed aluminum. The cable of the present invention also adds the advantage that it can carry communication signals like a fiber optic bundle for telecommunications. With or without the present invention, it is no longer necessary to use aluminum as a major part of the load-bearing performance in the final cable, and therefore it is no longer necessary to alloy aluminum to enhance tensile properties . Since aluminum is not used for load bearing performance in the present invention,
Except for the physical properties for that purpose, smelted aluminum will remain. Load bearing performance is provided by a reinforced plastic composite in a sheath outside the cable. The higher conductivity of smelted aluminum allows it to be used to its fullest advantage.

When the composite material surrounds the central aluminum core, it is possible to use the same amount of composite material as the composite material constitutes the central core. Can be used with much thinner cross sections. In this way, the weight is substantially lower for any given cable diameter. This, combined with a reduction in heat generation and the resulting energy loss, tends to result in a highly efficient cable. Furthermore, since the weight is reduced, the slack as occurs with standard steel cables is reduced.

[0009] By using the outer composite jacket as part of the current carrying cable, the envelope provides waterproofing of the central aluminum core, and furthermore, this aluminum core can be used for other weather and environmental conditions. Both reduce exposure to conditions. Further, it isolates communication cables, such as fiber optic cables, from exposure to environmental conditions. In addition, the cable of the present invention is effective in achieving security for messages transmitted over fiber optic cable, where the location of the cable makes access difficult.

From the foregoing, it can be seen that some particular advantages of the composite reinforced aluminum cable of the present invention are as follows. 1. The cost of this composite reinforced conductor is less than the cost of conventional steel cable conductors of the same diameter. 2. The cable of the present invention is capable of passing communication conductors, particularly fiber optic cables, whereby the conductor system of the present invention allows for a combination of power distribution and communication distribution networks. 3. The composite material used as the outer sheath has a 50% lower coefficient of thermal expansion than the steel core reinforced version. 4. Tensile strength (breaking strength) is about 1 times that of carbon steel core wire (about 210 ksi for HC steel).
50% higher. 5. The conductivity of the composite reinforced conductor is at least 40% higher than the steel reinforced aluminum conductor of the same outer diameter (ACSR conductor) and the target value is 200% higher. 6. The conductor cable can also use T & D accessories and other accessories that are provided in a similar manner to traditional cables. 7. The conductor cable has the capability to be used in minimally modified site laying equipment and procedures. 8. The composite is compatible with conventional wire and cable processing techniques. 9. The cable of the present invention eliminates temperature rise due to eddy currents. 10. A uniform aluminum core has a radial temperature difference on the order of 1/100 when compared to twisted wire. 11. The cable has no attenuation of strength and no resulting increase in slack due to annealing of the taut member. 12. The cable of the present invention has simplified manufacturing requirements because it does not require multiple layers of stranded aluminum to cancel self-inductance. 13. Excludes non-uniform current flow due to self-inductance when used as an instant conductor cable.

[0011] In addition to other advantages, the novel conductors of the present invention have at least twice the recycling effectiveness of ACSR. When this new type of cable is combined with a commercial manufacturing process, it will be possible to use a combination of core extrusion and composite extrusion processes in a continuous, high speed, low cost production assembly line. The process also transforms aluminum into a high value-added product by manufacturing and integrating lightweight composite strength members and optical fibers for data communication and information monitoring. --- Brief Description of the Drawings-- The invention has been described so far generally and will now be described with reference to the accompanying drawings. FIG. 1 is a partial perspective view of a composite reinforced current carrying conductor having a conductive inner core structure therein according to and in accordance with the present invention. FIG. 2 is a partial perspective view similar to FIG. 1 but showing the outer composite reinforced load-bearing conductor and the inner conductive core according to the present invention in a fully cured state. FIG.
FIG. 4 is a partial perspective view showing a further modification of the composite reinforced current carrying conductor with an internal conductive split core according to the present invention. FIG. 4 is a partial perspective view of yet another variation of a composite reinforced current carrying conductor according to the present invention, including through an optical fiber bundle. FIG. 5 is a partial perspective view similar to FIG. 4 but showing the core portion separated and spread to receive the fiber optic cable.
FIG. 6 is a partial perspective view showing another modification of the composite-reinforced current carrying conductor according to the present invention. FIG. 7 is a partial perspective view of yet another variation having an inner conductive core and an outer composite load-bearing sheath, with the exception that the sheath is formed with a coolant duct. FIG. 8 is a partial perspective view showing still another modification of the current-carrying conductor in which the current-carrying material also includes a helical streak-shaped load-bearing composite material. FIG. 9 is a partial sectional view showing a first step in splicing a cable according to the present invention.
FIG. 10 is a partial cross-sectional view similar to FIG. 15 and showing a second step in splicing a cable. FIG. 11 is a partial sectional view similar to FIGS. 9 and 10 and showing the steps of splicing an optical fiber cable in splicing a cable of the type shown in FIGS. FIG. 12 is a partial cross-sectional view similar to FIG. 11 and showing the cable after the splicing is completed. FIG.
FIG. 13 is a sectional view taken along lines 13-13 of FIG. FIG.
FIG. 4 is a partial perspective view showing still another modification of the current carrying conductor according to the present invention. FIG. 15 is an end cross-sectional view diametrically crossing another variant of the current carrying conductor of the structure according to the invention and of the embodiment. FIG. 16 is a partial perspective view of a cable according to the invention and similar to that of FIG. 8, but also carrying a fiber optic bundle therein.

[0012]

DETAILED DESCRIPTION OF THE INVENTION A more detailed and drawings figures where the (These preferred illustrate embodiments. Of the invention) viewed by reference number assigned to, C ₁ is reinforced plastic composite material 1 illustrates an electrical transmission cable having a load-bearing outer sheath 10 and a centrally located conductive aluminum core 12 extending therethrough. Still referring to FIG. 1, it can be seen that the load-bearing sheath 10 is a tubular reinforced plastic composite member.
Also, in the embodiment shown in FIG. 1 and the embodiments shown and described subsequently, there is a single core material, but the core can be formed of multiple separate aluminum layers. It should also be understood that the aluminum core can be formed of stranded wire. In this structure, the cable C ₁
Is apparently similar to a conventional steel core cable. Thus, it can be laid or suspended in the same manner and with the same equipment as used for steel core cables.

The outer sheath 10 initially consists of a separate winding or roving of reinforcing material, as will also be explained hereinafter. As shown, a helically wound stranded wire consisting of both a clockwise stranded wire and a counterclockwise stranded wire; otherwise, a stranded wire in a combination of other patterns A wire is applied to the central core at the desired thickness.

[0014] The winding of the individual strands of reinforcing material can be performed by any of several known winding systems, for example, William Brandt.
Goldsworthy et al., US Pat. No. 3,579,
No. 401, William Brandt Goldsw
Orthy et al., US Pat. No. 3,769,127, Wi.
U.S. Pat. No. 3,810,805 to lliam Brandt Goldsworthy et al., William.
U.S. Pat. No. 3,576,705 to Brandt Goldsworthy et al., William Brandt.
Goldworthy, US Patent 3,654,0
No. 28, as well as the devices described in Goldsworthy's numerous other patents.

The embodiment of FIG. 1 is only effective for cables with a fundamentally short length. This is because the core 10 cannot be bent too much. It will be appreciated that the entire cable must be capable of being wound on a drum and transported to a remote location, where it is unwound and suspended or laid at the point of use. For this purpose, the central unit core 10 is a one it is preferably made of a plurality of core portion 20 which is shaped to separate, which is shown most successfully to the cable C ₂ in FIG. In this case, the separate parts 20, when assembled together, create a cylindrical core 22. Wrapping the strand in one direction around the central core allows the strands to slide somewhat over each other, thereby facilitating winding this cable around a drum or other cylindrically-shaped member.

In the embodiment of the invention shown in FIG. 2, there are six separate parts in the shape of a pie. However, the number of parts can be any number. For the present invention, five separate parts have been found to be preferred. This is because this number allows the cable to be folded and wound on a bobbin, while not making the number of parts forming the cable too large.

It has also been found in the present invention that it is desirable to have an odd number of distinct parts, for example 5, 7 or 9 distinct parts. This odd number of separate parts facilitates winding on a truck or other, or winding a cable around a storage drum or the like for transport.

[0018] FIG. 4 cable C, which is similar to the cable _{C 2
3} , wherein in this particular case the individual pie-shaped portion 20 of the core 22 is configured with an arched recess 34 formed at its innermost end. Are different. In this particular embodiment,
As shown in FIGS. 5 and 6, the innermost end 34 is generally trapezoidal in shape. The fact that there are separate parts as shown allows the cable to be wound onto a winch or similar structure.

The innermost end 34 defines a central opening 36, which can also be seen to receive a fiber optic bundle 38 having a separate fiber optic cable 40.

FIG. 6 shows two semicircular sections 52 and 5
4 it is one which illustrate embodiments C ₄ with, each of which defines a hole in the center for receiving the fiber optic cable 38 has a semi-circular opening 56. One portion 52 has an elongated protrusion 60 which is configured to be incorporated into an elongated groove 62 of the other half conductor 54.

FIG. 7 has a plurality of coolant ducts 72 for receiving a coolant such as water or oil or the like, which removes heat generated by the flow of current through the current carrying conductors. it is intended to illustrate embodiments C ₅ having a cable 70 that is designed.

FIG. 8 illustrates an embodiment without an outer cylindrical core formed of a reinforced plastic material. Rather, a plurality of spirally wound grooves 76 are formed in the surface of the metal core 74 and are designed to receive a reinforced plastic composite wire 78.

FIG. 16 illustrates an embodiment that also uses a linear body 160 separate from the central core 74. Still further, this embodiment is in the form C ₇ holes provided at the center portion, the bundle 162 of fiber optic cable therethrough extends.

[0024] Figure 14, embodiments of the cable _{C 8} is shown in the form a separate optical fiber cables 174
There are a plurality of optical fiber bundles 172 which have the same and are surrounded by a metal current carrying conductor 166. The conductor 166 has a space 168 to receive the fiber optic cable 170. It also has a separate outer helical strip 176 which is a reinforced composite load bearing member forming the outer sheath 180. In addition, a further outer sheath 18 is provided around the sheath 176.
2 are arranged.

FIG. 15 shows aluminum or the like.
A separate material made of highly conductive material such as quality
An embodiment having a split core 190 formed by a portion 192
State C ₉FIG. In addition, this core
Separate preformed composite material around the perimeter as shown
It is surrounded by a portion 194. These parts
Not interlocked but close to adjacent parts
In contact with and spaced apart. They can be linked if necessary
However, in the illustrated embodiment, the separate parts are
Can slide relatively easily,
Cable can be easily wound.

In the embodiment of the present invention shown in FIG.
Such a composite portion 194 is similar to the embodiment C ₈Sheath 1 in
82 and covered by an outer sheath 196.
You. This embodiment of the invention is also equally effective.
Where the outer sheath 196 is
To protect cables from environmental and other environmental degradation
I can. The inner core 190 may also be
Or to receive other communication cables (not shown)
A core hole 198 is provided.

FIGS. 9 to 13 illustrate an embodiment in which any _{one of} the current carrying cables C _{1 to} C ₉ described above is spliced.

In the splicing technique shown in FIGS. 9-13, the current carrying conductor 120 (which is similar to any of the previously described current carrying cables is similar to the current carrying conductors which are aligned so that similar axes are coincident). Spliced to 122, the latter also being similar to any of the current-carrying cables described above, each of these current-carrying cables 120 and 122 having a high Are provided with inner cores 124 and 126 respectively formed of a conductive material, and furthermore, each of the inner cores 124 and 126 carries optical fiber cables 128 and 130, respectively.
Finally, each of the electrical cables 120 and 122
Outer reinforced plastic composite load bearing sheaths 134 and 136 are provided, respectively.

As described above, each of the electrical cables 120 and 122 is wound on a cable bobbin at a manufacturing location and transported to a use location, which may be remote. At that point, the individual cables would be unwound and spliced to different lengths. As also mentioned above, splicing of fiber optic cables would be performed at separate fiber optic cable splicing locations, as schematically illustrated at 138 in FIG. Splicing techniques for fiber optic cables are conventional and are not shown or described in further detail here.

To splice the respective lengths of cables 120 and 122, the outer composite sheath surrounding the central current carrying conductors 124 and 126 is cut off from the rest of the outer sheath and 9 is removed to expose the ends of conductors 124 and 126, as best shown in FIG. Thereafter, a conductive crimp sleeve 140, also formed of the same material as both cores 124 and 126, is attached to cable 122.
The cable 126 is slid over one end, such as the core 126 of FIG. In addition, the outermost reinforced plastic composite coupling sleeve 142 is also slid over the end of the cable 122 prior to separating the reinforced plastic composite outer load bearing layer 136. At this point, the two cables 120 and 122 are in a spliced configuration.

In actual splicing, the two cables 120 and 122 are brought together so that the cores 124 and 126 are in contact and meshing positions. Thereafter, the crimp sleeve 140 is actually moved to extend and cover the end regions of each of the two cores 124 and 126 in the manner shown in FIGS. At this point, the crimp sleeve can be physically secured to the ends of the two cores 124 and 126 in the manner shown in FIGS. At this point in the splicing process, the outer sheath 134 and 136 of the reinforced plastic composite that has been removed at that time is replaced by an outer reinforced plastic composite sleeve 142. This outer coupling sleeve 142 is moved axially over or contacts the end of each of the outer sheaths 134 and 136. At this point, a heater (not shown) is used to heat the reinforced plastic composite and pressure is applied, thereby partially melting the outer connecting sleeve 142 and the ends of the sheaths 134 and 136. And re-merge to form their integral bond. This pressure can be applied by a hand-operated tool, such as a tool of the pliers nature. The pressure itself is used to consolidate the material and expel any entrained air while curing the resin matrix material. In this way, one cable 2
It can be seen that one main component is easily spliced to the corresponding component of the opposite cable.

FIGS. 12 and 13 also illustrate the individual components of the spliced cross-section, and complete splicing to allow splicing of any of the current carrying cables C ₅ -C _9. Is shown.

[0033] The electrical transmission cable of the present invention is adapted to carry more current than an equivalent sized steel core conductor. This allows a highly conductive metal such as aluminum to be supported by a reinforced plastic sheath to support a greater amount than a similarly sized steel cable, even with some weight reduction without increasing weight This is because you can do it.

[Brief description of the drawings]

FIG. 1 is a partial perspective view of a composite reinforced current carrying conductor having a conductive inner core structure therein and according to an embodiment of the present invention.

FIG. 2 is a partial perspective view similar to FIG. 1 but showing the outer composite reinforced load-bearing conductor and the inner conductive core according to the present invention in a fully cured state.

FIG. 3 has an internal conductive split core according to the invention;
FIG. 9 is a partial perspective view showing a further modification of the composite-reinforced current carrying conductor.

FIG. 4 is a partial perspective view of yet another variation of a composite reinforced current carrying conductor according to the present invention, including through a fiber optic bundle.

5 is a partial perspective view similar to FIG. 4, but showing the core portion separated and expanded to receive the fiber optic cable.

FIG. 6 is a partial perspective view showing another modification of the composite-reinforced current carrying conductor according to the present invention.

FIG. 7 is a partial perspective view of yet another variation having an inner conductive core and an outer composite load-bearing sheath, with the exception that the sheath has a cooling fluid duct formed therein.

FIG. 8 is a partial perspective view showing still another modification of the current-carrying conductor in which the current-carrying material also includes a reinforced spiral-shaped load-bearing composite material.

FIG. 9 is a partial cross-sectional view showing a first step in splicing a cable according to the present invention.

FIG. 10 is a partial sectional view similar to FIG. 15, but showing a second step in splicing the cable.

FIG. 11 is a partial sectional view similar to FIGS. 9 and 10 and showing the steps of splicing an optical fiber cable in splicing a cable of the type shown in FIGS.

FIG. 12 is a partial cross-sectional view similar to FIG. 11, showing the cable after the splicing is completed.

FIG. 13 is a sectional view taken along lines 13-13 of FIG.

FIG. 14 is a partial perspective view showing still another modification of the current carrying conductor according to the present invention.

FIG. 15 is an end cross-sectional view diametrically across another variant of the current carrying conductor of the structure according to the invention and of the embodiment;

FIG. 16 is a partial perspective view of a cable according to the invention and similar to FIG. 8, but also carrying a fiber optic bundle therein.

 ──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor George Kosenowski, USA 90505, California, Trans, Madison Street 23920-40 F-term (reference) 2H001 FF02 5G307 EA02 EA06 EA08 EE02 EE03 EF10 5G309 KA02 5G319 HA10 HC01 HD01 HD07 HE19 HE23

Claims (13)

[Claims] 1. A current carrying conductor cable for the transmission of electric current, said current carrying conductor cable having a load bearing component and a current carrying component, the improvement comprising: a) the load bearing component is a reinforced composite material A current carrying conductor cable comprising: being formed; and b) said current carrying component is a highly conductive current carrying component. 2. The load-bearing component is an outer sheath made of a reinforced plastic composite and completely surrounding the other of the two components.
The current carrying conductor cable according to claim 1. 3. The highly conductive current carrying component comprises a plurality of separate parts, which are brought together in physical contact to enable the cable to be placed on a curved surface. 2. The current carrying conductor cable according to claim 1, wherein the separate portions are arranged concentrically to form a cylindrical conductor. 4. The current carrying conductor cable of claim 1, wherein a communication cable is threaded through a hole formed in said highly conductive current carrying component. 5. The current carrying component is a central core formed of a plurality of discrete portions, each of which is somewhat trapezoidal in shape and defines a central hole having a size for receiving a fiber optic cable. The current carrying conductor cable according to claim 4, wherein 6. The current carrying conductor cable according to claim 1, wherein said current carrying component is a core surrounded by said load-bearing component, and through which an optical fiber cable is passed. 7. The center core comprises a plurality of discrete portions arranged concentrically to form a cylindrical conductor, the discrete portions sized to receive a fiber optic cable. The current-carrying conductor cable according to claim 6, wherein the conductor cable is shaped so as to define a hole. 8. A method of making a long distance transmission current carrying cable, comprising: providing a generally cylindrical central core and disposing an outer cylindrical sheath around the core. The improvement comprises: a) one of the core or sheath comprising a highly conductive current carrying material and the other comprising a reinforced plastic composite material which provides load bearing performance to the cable. 9. The method according to claim 8, wherein the method includes forming the core of a plurality of discrete portions that together form a cylindrically shaped inner core. 10. The method of claim 9, further comprising providing a central hole in the current carrying conductor, and further comprising carrying the fiber optic cable in the central hole.
3. The method for producing a transmission current carrying cable according to claim 1. 11. The method further comprises: a) placing an inner sleeve generally formed of the same material as the core around the first cable of these cables; and b) generally forming the same material as the outer sheath. Disposing outer sleeves around a second cable of said cable; c) each substantially axially aligning an inner core end of the first cable with an inner core end of the second cable. D) crimping the sleeve around the contacted ends of the first and second cables such that the two cables are secured together in a conductive relationship; e) A) disposing a second sleeve around the contacted ends of the first and second cables; f) engaging the outer sleeve during connection with the outer sleeve engaging the end of the respective outer sheath. Sometimes heated, Partially dissolving and effectively flowing around the corresponding end impregnating the sheath and the outer sleeve; g) allowing the resin to cool, thereby allowing the outer sheath of the first cable to be permanently attached to the outer sheath of the second cable 11. The method of claim 10, comprising coupling together. 12. The method comprises the steps of: a) placing a second connecting outer sleeve, generally formed of the same material as the sheath, around a connected end of the cable when in contact with the end of the inner core; 12. The method of splicing a cable according to claim 11, comprising: b) heating the connecting sleeve to integrally connect it to the end of the sheath. 13. The method of claim 12, wherein the method also includes splicing both ends of a fiber optic cable carried in respective cores of the respective first and second cables.
The method for splicing a cable according to the above.