Power conductor and system

Patent metadata

Field	Value
Publication number	US-12080449-B2
Application number	US-202117498347-A
Country	US
Kind code	B2
Filing date	Oct 11, 2021
Priority date	May 8, 2019
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

A power conductor can include a plurality of copper-clad aluminum wires that are braided together to form a power braid. The power conductor can include an insulating sheath configured to enclose at least a portion of the power braid. The power conductor can be configured for use a power distribution system, and can be configured to electrically connect a transformer with a power distribution modules. The power conductor can be configured to connect to a conductive palm of the transformer and to a conductive contact of the power distribution module.

First claim

What is claimed is:

1. A power conductor for a power distribution system, the power conductor comprising:
a plurality of copper-clad aluminum wires that are braided together to form a power braid, the power braid having an oblong cross-section with a cross-sectional area that is between 25 square millimeters and 3000 square millimeters, and the power braid being configured to carry an electrical current that is between 25 amperes and 5000 amperes; and
an insulating sheath enclosing at least a portion of the power braid.

2. The power conductor of claim 1 , wherein the power braid has a rectangular cross-section.

3. The power conductor of claim 1 , wherein at least one of the plurality of copper-clad aluminum wires are coated in a layer of tin.

4. The power conductor of claim 1 , wherein the power braid has at least one of a rounded cross-section, a rounded-rectangular cross-section, or an ovular cross section.

5. The power conductor of claim 1 , wherein each of the plurality of copper-clad aluminum wires has a diameter that is between 0.5 millimeters and 3 millimeters.

6. The power conductor of claim 1 , wherein the oblong cross-section has a cross-sectional area that is between 50 square millimeters and 1250 square millimeters.

7. The power conductor of claim 1 , wherein the power braid is configured to carry an electrical current that is at least one of: between 400 amperes and 5000 amperes; between 50 amperes and 2000 amperes; or between 100 amperes and 2000 amperes.

8. The power conductor of claim 1 , wherein the plurality of copper-clad aluminum wires are grouped together form at least one bundle, the at least one bundle being configured as a twisted bundle or braided bundle.

9. The power conductor of claim 8 , wherein the at least one bundle includes more than 200 copper-clad aluminum wires.

10. The power conductor of claim 1 , wherein the plurality of copper-clad aluminum wires are grouped together to form a plurality of bundles that are braided together.

11. The power conductor of claim 1 , wherein the insulating sheath is configured to withstand an operational voltage that is between 300 volts and 3000 volts.

12. A power distribution system comprising:
a transformer including a conductive palm;
a power distribution module including a conductive contact; and
a flexible power conductor being configured to electrically connect to the conductive palm of the transformer and to the conductive contact of the power distribution module, the flexible power conductor including a plurality of copper-clad aluminum wires that are braided together to form a power braid with an oblong cross-section with a cross-sectional area that is between 25 square millimeters and 3000 square millimeters, the power braid being configured to carry an electrical current that is between 25 amperes and 5000 amperes.

13. The power distribution system of claim 12 , further comprising:
a plurality of flexible power conductors that includes the flexible power conductor, each of the plurality of flexible power conductors being formed of braided copper-clad aluminum wires and being configured to connect between a corresponding conductive palm of the transformer and a corresponding conductive contact of the power distribution module.

14. The power distribution system of claim 12 , wherein the transformer is rated for between 2000 kVA and 2500 KVA; and
wherein one of:
the flexible power conductor is one of two flexible power conductors that are configured to collectively carry a current that is between 2816 amperes and 3520 amperes
the flexible power conductor is configured to collectively carry a current that is between 2816 amperes and 3520 amperes.

15. The power distribution system of claim 12 , wherein the power braid is configured to carry an electrical current that is between 900 amperes and 2253 amperes.

16. The power distribution system of claim 12 , wherein the flexible power conductor is secured to the conductive palm with a clamp.

17. The power distribution system of claim 12 , wherein the flexible power conductor includes an adapter that is secured the power braid.

18. The power distribution system of claim 17 , wherein the adapter is configured to secure the flexible power conductor to a distribution plate with at least one of a bolt-on or a crimped connection.

19. The power distribution system of claim 12 , wherein the flexible power conductor further includes an insulating sheath surrounding a portion of the power braid so that an exposed portion of the power braid can be secured to the conductive palm.

20. A method of installing a power conductor for use in a power distribution system at an operational site, the method comprising the steps of:
securing a first end of a power conductor to a conductive palm of a transformer, the power conductor including a plurality of copper-clad aluminum wires that are braided together to form a power braid with a cross-sectional area that is between 25 square millimeters and 3000 square millimeters;
bending the power conductor at the operational site to move a second end of the power conductor toward a power distribution module; and
securing the second end of the power conductor to a conductive contact of the power distribution module to electrically connect the transformer to the power distribution module.

Assignees

• Erico Int Corp

Inventors

• Godard Pascal
• Bizet Frederic

Classifications

• H01R13/5812

  the cable clamping being achieved by mounting the separate part on the housing of the coupling device · CPC title

• H01B1/023

  Alloys based on aluminium · CPC title

• H01B9/006

  Constructional features relating to the conductors · CPC title

• H01B7/228 Primary

  Metal braid · CPC title

• H01B7/08 Primary

  Flat or ribbon cables · CPC title