Method for the manufacture of a composite core for an electrical cable

Abstract

A method for the manufacture of a composite core for an electrical cable. The method may include pulling carbon fiber tows and glass fiber tows through a composite core processing system. The carbon fiber tows and the glass fiber tows are contacted with a resin, such as a thermosetting resin, to impregnate the fiber tows with the resin. The glass fiber tows are disposed on the outside of the carbon fiber tows to form a glass fiber layer around the carbon. The resin is then cured to form the composite core, which is adapted for use in an electrical transmission and distribution cable.

1 . A method for the manufacture of a composite core adapted for use in an electrical transmission and distribution cable, comprising the steps of:
 pulling a plurality of carbon fiber tows;   pulling a plurality of glass fiber tows;   contacting the plurality of carbon fiber tows and the plurality glass fiber tows with a resin to impregnate the carbon fiber tows and the glass fiber tows with the resin;   disposing the glass fiber tows as an outer layer surrounding the carbon fiber tows; and   curing the resin to form a cured composite core that is adapted for use in an electrical transmission and distribution cable.   
     
     
         2 . A method as recited in  claim 1 , wherein the resin is a thermosetting resin. 
     
     
         3 . A method as recited in  claim 1 , wherein the resin has a viscosity within the range of about 200 centipoise to about 1500 centipoise at 20° C. 
     
     
         4 . A method as recited in  claim 1 , wherein the contacting step comprises pulling the carbon fiber tows through a wet-out tank. 
     
     
         5 . A method as recited in  claim 1 , wherein the contacting step comprises pulling the glass fiber tows through a wet-out tank. 
     
     
         6 . A method as recited in  claim 1 , wherein the contacting step comprises injecting the resin into the carbon fiber tows. 
     
     
         7 . A method as recited in  claim 1 , wherein the contacting step comprises injecting the resin into the glass fiber tows. 
     
     
         8 . A method as recited in  claim 1 , further comprising the step of compacting the carbon fiber tows and the glass fiber tows after the contacting step. 
     
     
         9 . A method as recited in  claim 8 , wherein the compacting step removes excess resin from the fiber tows. 
     
     
         10 . A method as recited in  claim 1 , wherein the curing step comprises curing the resin at a temperature of from about 350° F. to about 400° F. 
     
     
         11 . A method as recited in  claim 1 , further comprising the step of winding the cured composite core on a wheel for storage. 
     
     
         12 . A method as recited in  claim 11 , wherein the cured composite core has a length of at least about 6000 feet. 
     
     
         13 . A method as recited in  claim 1 , further comprising the step of heating the resin before the curing step. 
     
     
         14 . A method as recited in  claim 1 , wherein the pulling steps comprise pulling the fiber tows at processing speeds in the range of about 9 ft/min to about 50 ft/min. 
     
     
         15 . A method for the manufacture of a composite core adapted for use in an electrical transmission and distribution cable, comprising the steps of:
 pulling a plurality of carbon fiber tows;   contacting the plurality of carbon fiber tows with a resin;   pulling a plurality of glass fiber tows;   contacting the plurality of glass fiber tows with a resin;   disposing the glass fiber tows as an outer layer surrounding the carbon fiber tows;   compacting the carbon fiber tows and the glass fiber tows after the disposing step to form a compacted fiber bundle; and   curing the resin in the compacted fiber bundle to form a cured composite core that is adapted for use in an electrical transmission and distribution cable.