Abstract: An insulated composite power cable having a wire core defining a common longitudinal axis, a multiplicity of composite wires around the wire core, and an insulative sheath surrounding the composite wires. In some embodiments, a first multiplicity of composite wires is helically stranded around the wire core in a first lay direction at a first lay angle defined relative to a center longitudinal axis over a first lay length, and a second multiplicity of composite wires is helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle over a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The insulated composite cables may be used for underground or underwater electrical power transmission. Methods of making and using the insulated composite cables are also described.

Abstract: Thermoset polymer composite wires including a multiplicity of substantially continuous fibers embedded in a solidified polymer composite matrix and forming a substantially continuous filament, the solidified polymer composite matrix further including a polymer formed by curing a polymer precursor from a liquid state and a multiplicity of nanoparticles having a median diameter of one micrometer or less substantially uniformly dispersed throughout the polymer composite matrix, and optionally, a corrosion resistant sheath surrounding the substantially continuous filament. In some embodiments, the multiplicity of particles includes surface-modified particles having a core and a surface modifying agent associated with the core and reacted with the polymer cured from a liquid state. Stranded cables including one or more such thermoset polymer composite wires, and methods of making and using such thermoset polymer composite wires and stranded cables are also described.

Abstract: An insulated composite power cable having a wire core defining a common longitudinal axis, a multiplicity of composite wires around the wire core, and an insulative sheath surrounding the composite wires. In some embodiments, a first multiplicity of composite wires is helically stranded around the wire core in a first lay direction at a first lay angle defined relative to a center longitudinal axis over a first lay length, and a second multiplicity of composite wires is helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle over a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The insulated composite cables may be used for underground or underwater electrical power transmission. Methods of making and using the insulated composite cables are also described.

Abstract: Embodiments of submersible composite cables include a non-composite electrically conductive core cable, a multiplicity of composite cables, including a multiplicity of composite wires, around the core cable, and an insulative sheath surrounding the composite cables. Other embodiments include an electrically conductive core cable; a multiplicity of elements selected from fluid transport, electrical power transmission, electrical signal transmission, light transmission, weight elements, buoyancy elements, filler elements, or armor elements, arranged around the core cable in at least one cylindrical layer defined about a center longitudinal axis of the core cable when viewed in a radial cross section; a multiplicity of composite wires surrounding the elements in at least one cylindrical layer about the center longitudinal axis; and an insulative sheath surrounding the composite wires. The composite wires may be metal matrix or polymer composite wires.

Abstract: An insulated composite power cable having a wire core defining a common longitudinal axis, a multiplicity of composite wires around the wire core, and an insulative sheath surrounding the composite wires. In some embodiments, a first multiplicity of composite wires is helically stranded around the wire core in a first lay direction at a first lay angle defined relative to a center longitudinal axis over a first lay length, and a second multiplicity of composite wires is helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle over a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The insulated composite cables may be used for underground or underwater electrical power transmission. Methods of making and using the insulated composite cables are also described.

Abstract: A compression connector and assembly include an elongated, interiorly hollow tube, and at least one tubular sleeve, the tube including a first material exhibiting a first axial extrusion rate and the sleeve including a second material exhibiting a second axial extrusion rate, wherein the sleeve wall thickness is selected such that, when inserted into the tube and subjected to mechanical compression in a direction substantially orthogonal to the tube's exterior surface, deforms so that the first and second materials extrude axially at substantially the same rate. In some exemplary embodiments, the sleeve wall thickness may be selected to be thin, or the sleeve may include a multiplicity of axially spaced-apart corrugations formed in at least one exterior or interior surface. The assembly may include stranded composite wires, optionally with a tape covering only a portion of the composite wires. A method of making the compression connector is also described.

Abstract: An insulated composite power cable having a wire core defining a common longitudinal axis, a multiplicity of composite wires around the wire core, and an insulative sheath surrounding the composite wires. In some embodiments, a first multiplicity of composite wires is helically stranded around the wire core in a first lay direction at a first lay angle defined relative to a center longitudinal axis over a first lay length, and a second multiplicity of composite wires is helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle over a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The insulated composite cables may be used for underground or underwater electrical power transmission. Methods of making and using the insulated composite cables are also described.

Abstract: Stranded composite cables include a single wire defining a center longitudinal axis, a first multiplicity of composite wires helically stranded around the single wire in a first lay direction at a first lay angle defined relative to the center longitudinal axis and having a first lay length, and a second multiplicity of composite wires helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle defined relative to the center longitudinal axis and having a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The stranded composite cables may be used as intermediate articles that are later incorporated into final articles, such as overhead electrical power transmission cables including a multiplicity of ductile wires stranded around the composite wires. Methods of making and using the stranded composite cables are also described.

Abstract: Thermoset polymer composite wires including a multiplicity of substantially continuous fibers embedded in a solidified polymer composite matrix and forming a substantially continuous filament, the solidified polymer composite matrix further including a polymer formed by curing a polymer precursor from a liquid state and a multiplicity of nanoparticles having a median diameter of one micrometer or less substantially uniformly dispersed throughout the polymer composite matrix, and optionally, a corrosion resistant sheath surrounding the substantially continuous filament. In some embodiments, the multiplicity of particles includes surface-modified particles having a core and a surface modifying agent associated with the core and reacted with the polymer cured from a liquid state. Stranded cables including one or more such thermoset polymer composite wires, and methods of making and using such thermoset polymer composite wires and stranded cables are also described.

Abstract: A compression connector and assembly include an elongated, interiorly hollow tube, and at least one tubular sleeve, the tube including a first material exhibiting a first axial extrusion rate and the sleeve including a second material exhibiting a second axial extrusion rate, wherein the sleeve wall thickness is selected such that, when inserted into the tube and subjected to mechanical compression in a direction substantially orthogonal to the tube's exterior surface, deforms so that the first and second materials extrude axially at substantially the same rate. In some exemplary embodiments, the sleeve wall thickness may be selected to be thin, or the sleeve may include a multiplicity of axially spaced-apart corrugations formed in at least one exterior or interior surface. The assembly may include stranded composite wires, optionally with a tape covering only a portion of the composite wires. A method of making the compression connector is also described.

Abstract: Helically stranded thermoplastic polymer composite cable (10) includes a single wire (2) defining a center longitudinal axis, a first multiplicity of thermoplastic polymer composite wire (4) helically stranded around the single wire (2), and a second multiplicity of polymer composite wire (6) helically stranded around the first multiplicity of thermoplastic polymer composite wire (4). The helically stranded thermoplastic polymer composite cable (10) may be used as intermediate articles that are later incorporated into final articles, such as electrical power transmission cables, including underwater tethers and underwater umbilicals. Methods of making and using the helically stranded thermoplastic polymer composite cables are also described.

Abstract: Embodiments of submersible composite cables include a non-composite electrically conductive core cable, a multiplicity of composite cables, including a multiplicity of composite wires, around the core cable, and an insulative sheath surrounding the composite cables. Other embodiments include an electrically conductive core cable; a multiplicity of elements selected from fluid transport, electrical power transmission, electrical signal transmission, light transmission, weight elements, buoyancy elements, filler elements, or armor elements, arranged around the core cable in at least one cylindrical layer defined about a center longitudinal axis of the core cable when viewed in a radial cross section; a multiplicity of composite wires surrounding the elements in at least one cylindrical layer about the center longitudinal axis; and an insulative sheath surrounding the composite wires. The composite wires may be metal matrix or polymer composite wires.

Abstract: An insulated composite power cable having a wire core defining a common longitudinal axis, a multiplicity of composite wires around the wire core, and an insulative sheath surrounding the composite wires. In some embodiments, a first multiplicity of composite wires is helically stranded around the wire core in a first lay direction at a first lay angle defined relative to a center longitudinal axis over a first lay length, and a second multiplicity of composite wires is helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle over a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The insulated composite cables may be used for underground or underwater electrical power transmission. Methods of making and using the insulated composite cables are also described.

Abstract: Stranded composite cables include a single wire defining a center longitudinal axis, a first multiplicity of composite wires helically stranded around the single wire in a first lay direction at a first lay angle defined relative to the center longitudinal axis and having a first lay length, and a second multiplicity of composite wires helically stranded around the first multiplicity of composite wires in the first lay direction at a second lay angle defined relative to the center longitudinal axis and having a second lay length, the relative difference between the first lay angle and the second lay angle being no greater than about 4°. The stranded composite cables may be used as intermediate articles that are later incorporated into final articles, such as overhead electrical power transmission cables including a multiplicity of ductile wires stranded around the composite wires. Methods of making and using the stranded composite cables are also described.

Abstract: A holder comprising an insert for reinforcing a metal matrix composite article and methods of making the same. In another aspect, the present invention provides metal matrix composite articles reinforced with an insert(s) and methods of making the same. Useful metal matrix composite articles comprising the inserts include brake calipers.