Technical field of the Invention

[001] The present invention generally relates to the field of electric power transmission elements. More particularly the present invention relates to a flat twisted composite core aluminum alloy conductor (FTCCAAC) for efficient electrical power transmission

Background of the Invention

[002] Generally, the growing populations and industrializing countries create huge needs for electrical energy. The electricity is not only used in one particular location, it needs to be transmitted to different locations through long distance transmission lines. But transmitting electricity over long distances via networks involves energy loss. The growing demand of electricity provides the need for minimizing the transmission loss to reduce the resources consumed while delivering the large amount of power to the users.

[003] Mainly, the electricity loss is incorporated in transformers and transmission cable. For reducing the transmission loss there is a need to provide loss less transmission for the distribution of electrical energy. The transmission loss of the cable depends on the type of conductor and thermal limit of the conductors.

[004] Building new lines are often very difficult due to the lack of available lands and environmental concerns, especially in the developed countries. The transportation of transmission cable from one place to another place is very difficult because of high weight of transmission cables corresponding to the conductors and the core materiel. The transmission lines between towers countenance a high sag, low strength, reliability and transmission loss.

[005] In the light of aforementioned discussion, there exists a need for an efficient electrical power transmission cables.

Brief Summary of the Invention

[006] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

[007] A more complete appreciation of the present invention and the scope thereof can be obtained from the accompanying drawings which are briefly summarized below and the following detailed description of the presently preferred embodiments.

[008] An exemplary objective of the present invention is to develop the transmission of electric power with higher ampacity, better insulation and thermal characteristics through a flat twisted composite core aluminum alloy conductor (FTCCAAC).

[009] An exemplary objective of the present invention is to minimize the reactive power loss due to the inductive and capacitive parameters associated with the transmission cables and to provide deploy-able structure for emergency restoration.

[0010] An exemplary objective of the present invention is to provide low weight composite flat conductor with carbon composite flat core for increasing the strength of the conductor by minimizing the weight. Thus the transmission cable structure is optimized.

[0011] An exemplary objective of the present invention is to provide high voltage insulation for corona breakdown by using the advanced insulation with the nano materials and structures of the transmission cables.

[0012] An exemplary objective of the present invention is to provide required ampacity by layering the kapton corona resistant (kapton CR) tape over the flat twisted composite core aluminum alloy conductors (FTCCAAC).

[0013] An exemplary objective of the present invention is to secure the greatest clearance between the conductor and the ground level and also to increase the power transmission capacity and reduce the conductor sag by utilizing a special fiber core having a lighter weight and less liner expansion.

[0014] An exemplary objective of the present invention is to provide a very low thermal expansion coefficient and also offers larger surface area across the cross section for better heat dissipation along the length of the conductor.

[0015] An exemplary objective of the present invention is to virtually eliminate the thermal sag by incorporating the high strength carbon and glass fibers with special polymers to create a cable.

[0016] An exemplary objective of the present invention is to provide larger surface area with thermal dissipation, minimize the residual magnetic fields and eddy current effects, reduce the elevated temperature sag, exhibit excellent self-dampening characteristics, reduce the sag and high-strength core allowing greater spans and eliminating the bi-metallic corrosion by the non metallic core.

[0017] An exemplary embodiment of an electric power transmission cable is disclosed. According to a first aspect, a plurality of flat twisted composite core aluminum alloy conductors enclosed with a taping material comprising a flat conductor profile and a thin insulation to provide a better heat dissipation and a conductor gauge reduction.

[0018] According to the first aspect, a plurality of flat twisted composite core aluminum alloy conductors enclosed with a taping material comprising a transmission cable circuit pattern configured to control an electromagnetic interference of a plurality of electric signals.

[0019] According to the first aspect, a plurality of flat twisted composite core aluminum alloy conductors enclosed with a taping material comprising a design to provide a terminal less connection system, modularity and a multiplexing.

[0020] According to the first aspect, the electric power transmission cable includes a plurality of round edges and a low edge width mounted over the taping material for providing a lower profile harness. The tapping material comprises a kapton corona resistant tape, zirconium tapping and mica tapping. Thus the kapton corona resistance tape is formed by wrapping it over and heat sealing it to a plurality of flat twisted composite core aluminum alloy conductors.

[0021] According to the first aspect, the electric power transmission cable includes the plurality of flat twisted composite core aluminum alloy conductors are packed as a spool to reduce the packing space of the transmission cable.

[0022] According to the first aspect, the electric power transmission cable includes a low conductor thermal expansion coefficient of a plurality of flat twisted composite core aluminum alloy conductors configured to limit the performance of thermal sag of a transmission cable. The performance of thermal sag is increased proportionally with the temperature and mechanical properties of the transmission cable.

[0023] According to the first aspect, the electric power transmission cable includes a flat twisted composite core made by a plurality of fiber composite materials are utilized to cover the plurality of flat twisted composite core aluminum alloy conductors. The plurality of composite materials of a fiber exhibits an extraordinary mechanical and thermal property along the direction of the transmission cable. The plurality of composite materials of a fiber made by a kevlar based material; fiber yarns; and carbon composite materials.

Brief Description of the Drawings

[0024] Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein:

[0025] FIG.1 is a diagram depicting depicting an electric power transmission cable.

[0026] FIG. 2 is a diagram depicting a packing solution of a flat twisted composite core aluminum alloy conductor.

Detailed Description of the Invention

[0027] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0028] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. For a better understanding, components of the described embodiment are labeled with three digit component numbers. In general, the same first digit is used throughout the entire component numbers numbered and labeled within a figure. Like components are designated by like reference numerals throughout the various figures.

[0029] Referring to FIG. 1 is a block diagram 100 depicting an electric power transmission cable. According to a non limiting exemplary embodiment of the present invention, the electric power transmission cable includes of a flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d used for transmission of electrical power with higher ampacity, better insulation and thermal characteristics. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are covered with a taping material 104 made by a kapton corona resistance tape, zirconium tapping and mica tapping. The high dielectric constant insulating for kapton corona resistant (kapton CR) tape of tapping material 104 is formed by wrapping it over and heat sealing it to the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d. The tapping material 104 having a round edges 106 and low edge width 108 for providing lower profile harness to reduce the packing space of flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d.

[0030] In accordance with a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d having a flat conductor profile and thin insulation provides a better heat dissipation and allows a conductor gauge reduction. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d with the tapping material 104 minimizes the weight and increases the strength of the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d for resulting an optimization of a transmission cable structure. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are coated with high permeability of mew metal powder for shielding magnetic field.

[0031] According to a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d covered with a flat twisted composite core is made of carbon fiber composite materials. The carbon fiber composite materials having an exhibit mechanical and thermal property are along the direction of the transmission cable. The carbon fiber composite materials made by a kevlar based material, fiber yarns and carbon composite material allows the same mechanical strength of a steel with five times lower weight and a thermal expansion coefficient near to zero. The carbon fiber composite materials for the flat twisted composite core allows the production of the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d mainly for high voltage transmission cables.

[0032] In accordance with a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are of three types, first one is a whole series round thermal resistant flat twisted composite core aluminum alloy conductors (FTCCAAC), second is a whole series round soft flat twisted composite core aluminum alloy conductors (FTCCAAC) and third is a whole series shaped soft flat twisted composite core aluminum alloy conductors (FTCCAAC). These flat twisted composite core aluminum alloy conductors use a combination of aluminum clad Invar for the flat twisted composite core to provide a super thermal resistant Al-Zr alloy for a conductive layer of the transmission cable.

[0033] According to a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d provides a low thermal expansion coefficient for limiting sag of the transmission cable. The sag increased is proportional to the temperature and mechanical properties which may include but not limited to a diameter, strength and weight and the like of the transmission cable. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d maintain the mechanical strength with continuous operating temperature.

[0034] In accordance with a non limiting exemplary embodiment of the present invention, the three types of flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d have different voltage levels which includes a 220volts to 35kilovolts for series round thermal resistant flat twisted composite core aluminum alloy conductors, 35kilovolts to 500kilovolts of voltage for series round soft flat twisted composite core aluminum alloy conductors and 500kilovolts to 1000kilovolts for series shaped soft flat twisted composite core aluminum alloy conductors. The diameter of these three types of flat twisted composite core aluminum alloy conductors ranges from 2.5cmsquare to 250cmsquare and the thermal resistance level of three series of conductors is 160, 180 and 200.

[0035] According to a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are covered with the flat twisted composite core which provides a light weight for the transmission cable through the elimination of components by integrating and reducing the number of attachments, components and harness covering. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d is having a capacity of transmitting electric power up to a range of 1000amps to 500amps at 400kilovolts to 765kilovolts.

[0036] In accordance with a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d cables are packed as a spool for reducing the packing space for the transmission cable. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are covered with the tapping material 104 for providing dimensional stability or repeatability to component level tolerance and repeatability from one harness to the next conductor. The flat twisted composite core aluminum alloy conductor (FTCCAAC) cable 102a, 102b, 102c, and 102d is packed as a custom three dimensional pack to provide a better fit to sub structure, flexibility and high ductility.

[0037] According to a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) cables 102a, 102b, 102c, and 102d having an adaptable design for providing terminal less connection system, multiplexing and modularity. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d are provided with a transmission cable circuit pattern to allow the control of electromagnetic interference and cross talk. The flat twisted composite core aluminum alloy conductor (FTCCAAC) 102a, 102b, 102c, and 102d transmission cables reduces the potential failure point in the building cables for power transmission. The adaptable integration design pattern of the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d also provides price reduction.

[0038] In accordance with a non limiting exemplary embodiment of the present invention, the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d transmission cable provides two times or more power flow with less transmission cost per kilometer. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d transmission cable having less weight provides the reduction of weight or height of a transmission power tower. The flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d cables reduce the installation time, storing and transportation.

[0039] According to a non limiting exemplary embodiment of the present invention, the sag of the flat twisted composite core aluminum alloy conductors (FTCCAAC) 102a, 102b, 102c, and 102d provides low slag to increase the power handling capacity with lower coefficient of thermal expansion.

[0040] Referring to FIG. 2 is a diagram 200 depicting a packing solution of a flat twisted composite core aluminum alloy conductors. According to a non limiting exemplary embodiment of the present invention, the packing solution includes a packing wheel 202 and a three conductor cable 204 including a white cable 204a, green cable 204b and black cable 204c.

[0041] In accordance with a non limiting exemplary embodiment of the present invention, the packing solution is utilized to pack the flat twisted composite core aluminum alloy conductors for transmitting an efficient electric power. The three conductor cables 204 includes a white cable 204a, green cable 204b and black cable 204c affixed in a single flat twisted composite core aluminum alloy conductor cables is winded to the packing wheel 202. The flat twisted composite core aluminum alloy conductor’s cables are packed as a spool for reducing the packing space for the transmission cable. The flat twisted composite core aluminum alloy conductors are covered with the tapping material for providing dimensional stability or repeatability to component level tolerance and repeatability from one harness to the next conductor. The flat twisted composite core aluminum alloy conductor is packed as a custom three dimensional pack to provide a better fit to sub structure, flexibility and high ductility.

[0042] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.

Claims:

What we claim is

1. An electric power transmission cable comprising:

a plurality of flat twisted composite core aluminum alloy conductors enclosed with a taping material comprising:

a flat conductor profile; and

a thin insulation to provide a better heat dissipation and a conductor gauge reduction;

a transmission cable circuit pattern configured to control an electromagnetic interference of a plurality of electric signals; and

a design to provide:
a terminal less connection system;
a modularity; and
a multiplexing.

2. The electric power transmission cable of claim 1, wherein a plurality of round edges and a low edge width mounted over the taping material for providing a lower profile harness.

3. The electric power transmission cable of claim 2, wherein a tapping material comprises a kapton corona resistant tape; zirconium tapping; and mica tapping.

4. The electric power transmission cable of claim 3, wherein kapton corona resistances tape formed by wrapping it over and heat sealing it to a plurality of flat twisted composite core aluminum alloy conductors.

5. The electric power transmission cable of claim 1, wherein packs the plurality of flat twisted composite core aluminum alloy conductors as a spool to reduce the packing space of the transmission cable.

6. The electric power transmission cable of claim 1, wherein a low conductor thermal expansion coefficient of the plurality of flat twisted composite core aluminum alloy conductors configured to limit the performance of thermal sag of the transmission cable.

7. The electric power transmission cable of claim 6, wherein the performance of thermal sag to be increased proportionally with the temperature and mechanical properties of the transmission cable.

8. The electric power transmission cable of claim 1, wherein a flat twisted composite core made by a plurality of fiber composite materials are utilized to cover the plurality of flat twisted composite core aluminum alloy conductors.

9. The electric power transmission cable of claim 8, wherein a plurality of composite materials of a fiber exhibit an extraordinary mechanical and thermal property along the direction of the transmission cable.

10. The electric power transmission cable of claim 9, wherein a plurality of composite materials of a fiber made by a kevlar based material; fiber yarns; and carbon composite materials.