Aircraft Cable Insulation Reduces Weight and Partial Discharges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aircraft electrical cables face challenges with high voltage, humidity, temperature, and pressure, leading to partial discharges that degrade insulation and potentially cause electric arcs, while existing solutions do not optimize for reduced bulk and weight while maintaining resistance to partial discharges.
Innovation Solution
An electrical cable design featuring a central conductive element surrounded by a polyimide insulating layer and a fluorinated insulating layer with specific thicknesses, where the total thickness is optimized to minimize bulk and weight, and the fluorinated layer is less than 0.4 mm, ensuring resistance to partial discharges under high voltage and harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the thickness of the fluorinated insulating layer is reduced to decrease cable weight and bulk, then the cable becomes more compact and lighter, but the resistance to partial discharges deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the insulating materials, specifically using fluorinated polymers with high dielectric strength and optimized cross-linking density. This allows reducing the fluorinated layer thickness while maintaining PD resistance through superior material properties rather than relying solely on thickness
Solution Approach 2:
The patent employs a composite insulation structure combining polyimide and fluorinated polymer layers. The polyimide provides mechanical strength and thermal stability, while the fluorinated layer provides electrical insulation and PD resistance. This synergistic combination allows thickness optimization while maintaining reliability
2Weight of stationary object
If the operating voltage is increased to reduce cable cross-section and mass, then the cable mass is reduced by approximately half, but partial discharges are generated on the insulation surface and within defects
Solution Approach 1:
The patent modifies the electrical parameters of the insulation by using fluorinated polymers with high dielectric strength and optimized cross-linking density. This allows the cable to withstand higher operating voltages (230V or 400V) without generating partial discharges, enabling mass reduction while maintaining safety
Solution Approach 2:
The patent converts the potential harmful effect of high voltage into a benefit by using fluorinated polymers that resist partial discharges. The high voltage operation enables mass reduction, while the specialized material prevents the harmful partial discharge effects that would normally occur at such voltages
3Volume of stationary object
If the thickness of the polyimide and fluorinated layers is optimized to minimize cable size, then the cable bulk is reduced, but the resistance to partial discharges under high temperature and pressure conditions deteriorates
Solution Approach 1:
The patent optimizes the thermal and chemical parameters of the insulation materials, using fluorinated polymers with high thermal stability and optimized cross-linking density. This allows reducing layer thickness while maintaining PD resistance under high temperature (150°C) and pressure conditions through superior material properties
Solution Approach 2:
The patent applies different material properties to different layers: polyimide provides mechanical strength and thermal stability, while fluorinated polymer provides electrical insulation and PD resistance. This localized optimization allows thickness reduction while maintaining reliability under harsh conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cable achieves a reduced weight and bulk while maintaining a high threshold voltage for partial discharge inception, preventing degradation and ensuring safe operation at high temperatures and pressures.
Implementation Method 1
a fluorinated electrically insulating layer comprising a fluorinated polymer surrounding said electrically insulating layer comprising polyimide (PI)
Implementation Method 2
an electrically insulating layer comprising polyimide (PI) surrounding said elongated electrically conductive element
Data Source
Figure 1
AI summary
The present invention relates to an electrical cable comprising an elongated electrically conductive element, an electrically insulating layer comprising polyimide (PI) surrounding said elongated electrically conductive element, and a fluorinated electrically insulating layer comprising a fluorinated polymer surrounding said electrically insulating layer comprising polyimide (PI), said layers having specific thicknesses depending on the cross-section of the elongated electrically conductive element.