Carbon Fiber Composite Core Conductor

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Application

Carbon Fiber Composite Core Conductor is widely used in modern power transmission systems due to its high strength, low sag, light weight, and high current-carrying capacity.

Standard

ASTM B987 / B987M

GB/T 29324-2024

Construction

1. Composite Core (Inner Layer)

Material: Carbon fiber reinforced polymer (CFRP) combined with glass fiber reinforced polymer (GFRP).
Configuration: A solid single rod or a stranded composite core (depending on the design).
Function:

Provides high tensile strength (typically > 2400 MPa).
Very low coefficient of thermal expansion (CTE), minimizing sag at high operating temperatures.
Light weight (density ~1.9 g/cm³), much lighter than steel.
Non-metallic, thus immune to galvanic corrosion.

2. Conducting Layers (Outer Layers)

Material: Fully annealed (soft) aluminum wires, typically 1350-O or similar, with conductivity up to 63% IACS.
Shape of Wires: Trapezoidal (TW) – wires have a trapezoidal cross-section rather than round.
Arrangement: Concentrically stranded in one or two layers around the composite core. The trapezoidal shape allows tightly packed, gap-free stranding.
Benefits of trapezoidal design:

Increases aluminum cross-sectional area by ~28–29% compared to round-wire conductors of the same outer diameter.
Reduces electrical resistance and increases current-carrying capacity.
Improves surface smoothness and reduces wind drag.

Features

Product Data Sheet

TDS FOR TRAPEZOID WIRE STRUCTURE
Nominal Cross Section mm²	Nominal Diameter mm		Stranded Aluminium Wire		Section Area mm²			Weight kg/km	Rated Tension Fracture kN		DC Resistance (20℃) Ω/km	Elastic Modulus GPa		Expansion Coefficient (×10^-6/℃)
Nominal Cross Section mm²	Core Rod mm	Conductor mm	Layers	Nos.	Area of Aluminum Wire mm²	Area of Core Rod mm²	Total Area mm²	Weight kg/km	F1	F2		Below Inflection Temperature	Above Inflection Temperature	Below Inflection Temperature	Above Inflection Temperature
120/20	5	13.8	2	14	120.8	19.63	140.4	365.4	44.3	49.6	0.231	51.7	125	16.1	1.7
150/30	6	15.6	2	15	150	28.27	178.27	460.2	62.4	70	0.1861	50.8	125	16	1.7
185/30	6	17	2	15	185	28.27	213.27	566.5	64.5	72.2	0.151	60.8	125	13.9	1.7
240/30	6	19.1	2	16	240	28.27	268.27	718.1	67.8	75.5	0.1164	58.5	125	14.8	1.7
240/40	7	19.4	2	16	240	38.48	278.48	738.6	94.9	97.5	0.1164	61.3	125	13.7	1.7
300/25	5.5	21	2	16	300	23.76	323.76	874.5	62.9	69.3	0.0931	55.8	125	16	1.7
300/40	7	21.4	2	16	300	38.48	338.48	904	90.6	101	0.0931	59.2	125	14.5	1.7
300/50	8	21.8	2	16	300	50.26	350.26	927.5	113	126.6	0.0931	61.7	125	13.5	1.7
300/70	9.5	22.4	2	16	300	70.87	370.87	968.8	152	171.1	0.0931	65.9	125	12.2	1.7
400/25	5.5	24	2	19	400	23.76	423.76	1150.2	68.8	75.2	0.0699	54.3	125	16.6	1.7
400/50	8	24.7	2	19	400	50.26	450.26	1203.2	118.9	132.5	0.0699	59.1	125	14.6	1.7
450/50	8	26.1	2	19	450	50.26	500.26	1341	122	135.6	0.0621	58.1	125	15	1.7
500/35	6.5	27	2	22	500	33.18	533.18	1444.7	92.8	101.8	0.0559	54.8	125	16.4	1.7
500/45	7.5	27.2	2	22	500	44.17	544.17	1466.7	113.4	125.4	0.0559	56.4	125	15.6	1.7
500/65	9	27.7	2	22	500	63.61	563.61	1505.6	150.3	167.5	0.0559	59.1	125	14.5	1.7
630/45	7.5	30.3	3	36	630	44.17	674.17	1828.5	121.3	133.2	0.0444	55.1	125	16.3	1.7
630/55	8.5	30.6	3	36	630	56.74	686.74	1853.6	145.1	160.4	0.0444	56.5	125	15.6	1.7
630/70	9.5	30.7	3	36	630	70.85	700.85	1862.4	171.7	190.8	0.0444	58.1	125	14.9	1.7

TDS FOR TRAPEZOID WIRE STRUCTURE
Nominal Cross Section mm²	Stranded Aluminium Wire		Nominal Diameter mm		Section Area mm²			Total Area kg/km	Rated Tension Fracture kN	DC Resistance 20℃ Ω/km	Expansion Coefficient (×10^-6/℃)		Elastic Modulus (GPa)
Nominal Cross Section mm²	Layers	Nos.	Conductor mm	Core Rod mm	Area of Core Rod mm²	Area of Aluminum Wire mm²	Total Area mm²	Total Area kg/km	Rated Tension Fracture kN	DC Resistance 20℃ Ω/km	Below Inflection Temperature	Above Inflection Temperature	Below Inflection Temperature	Above Inflection Temperature
120/35	1	7	15.91	6.5	33.16	122.48	155.6	391	85.2	0.2385	12.6	1.9	65.1	118
150/35	2	26	17.27	6.5	33.16	148.86	182.02	464	88.6	0.1999	12.8	1.9	65.2	118
150/45	2	30	17.48	7.5	44.16	147.26	191.41	478	111.5	0.1995	11.3	1.9	66.3	118
185/35	2	24	19.07	6.5	33.16	187.04	220.2	570	93.4	0.1568	14.7	1.9	64.2	118
185/40	2	26	18.89	7	38.46	181.34	219.8	564	103.8	0.162	12.8	1.9	65.2	118
185/55	2	30	19.67	8.5	56.71	184.73	241.44	602	142.6	0.159	11.4	1.9	66.3	118
210/35	2	24	19.9	6.5	33.16	209.02	242.18	630	96.2	0.1403	14.8	1.9	64.4	118
210/45	2	26	20.35	7.5	44.16	211.73	255.89	656	119.7	0.1386	12.8	1.9	65.2	118
240/45	2	25	21.69	7.5	44.16	242.9	287.06	742	123.6	0.1209	14.1	1.9	64.5	118
240/70	2	48	22.27	9.5	70.85	241.27	312.12	900	179.5	0.1218	11.3	1.9	66.3	118
300/35	3	48	23.57	6.5	33.16	306.21	339.37	782	108.6	0.096	14.9	1.9	61.8	118
300/65	2	26	24.19	9	63.58	299.54	363.12	928	171.6	0.098	12.8	1.9	65.1	118
350/45	3	49	25.5	7.5	44.16	352.63	396.79	1045	137.6	0.0831	16.8	1.9	62	118
400/65	3	54	27.31	9	63.58	399.73	463.31	1206	184.4	0.0736	13.7	1.9	64.2	118
450/50	3	48	28	8	50.24	445.89	496.13	1313	163.5	0.0659	16	1.9	63.3	118
500/55	3	48	30	8.5	56.71	488.58	545.29	1442	181.2	0.0601	14.5	1.9	61.7	118
500/65	3	52	30.3	9	63.58	495.45	559.03	1471	196.5	0.0601	16	1.9	62.8	118
630/55	3	45	33.6	8.5	56.71	623.45	680.16	1815	198.4	0.0472	15.2	1.9	59.8	118

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