Bent High-Voltage Cable Insulation With Air Cavities for Heat Isolation
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Solution Overview
Problem
Existing high-power cables used in automobiles are prone to damage due to rubbing against the vehicle shell, leading to high-voltage discharge or short-circuit, and the solid cables experience excessive heating at bent positions, causing insulating layer softening or melting.
Innovation Solution
An electric energy transmission system featuring an electric connection skeleton with bent portions and cavities between the skeleton and the insulating layer, where the cavity contains a barrier breakdown dielectric with improved dielectric breakdown strength, and the system is designed with specific dimensions and materials to enhance heat dissipation and voltage breakdown resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid cables are used to replace flexible cables, then cable durability and resistance to rubbing damage are improved, but heat dissipation capability deteriorates due to excessive heating at bent positions
Solution Approach 1:
The patent introduces air as an intermediary cooling medium by creating cavities within the insulating layer at bent positions. These cavities allow air circulation to directly cool the cable surface at high-heat generation areas, effectively removing the thermal bottleneck without compromising the solid cable's durability advantages
Solution Approach 2:
The insulating layer is designed with a porous structure containing multiple cavities at bent positions. This porous design enables air penetration and circulation through the insulating layer, facilitating heat dissipation from the cable surface while maintaining the overall integrity and protective function of the insulating layer
2Strength
If solid cables are used to replace flexible cables, then cable strength is improved, but the risk of high-voltage discharge increases due to insulating layer softening or melting from excessive heat
Solution Approach 1:
Air is introduced as a cooling intermediary within cavities in the insulating layer, directly removing heat from bent cable positions. This prevents the insulating layer from reaching softening or melting temperatures, thereby eliminating the condition that would lead to high-voltage discharge while preserving the cable's strength
Solution Approach 2:
The patent changes the thermal parameter of the insulating layer by introducing air-filled cavities, which fundamentally alters the thermal management characteristics. This prevents temperature from reaching critical values that would compromise insulating properties and cause electrical breakdown
3Ease of operation
If multi-core flexible cables are used, then cable flexibility and ease of wiring are improved, but the risk of rubbing damage and insulating layer deterioration increases due to large cable diameters
Solution Approach 1:
The patent converts the harmful rubbing action into a beneficial cooling mechanism. By designing cavities in the insulating layer at positions where rubbing occurs (bent positions), the friction and pressure from rubbing are transformed into effective contact points for heat dissipation, turning a source of damage into a thermal management advantage
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 system effectively protects the insulating layer from softening or melting by isolating heat within the cavities, reduces the risk of high-voltage discharge, and enhances the safety of the electric energy transmission system through improved voltage breakdown resistance.
Implementation Method 1
the cavity contains air, and the thermal conductivity of the closed air is poor, so that when the bent portion of the electric connection skeleton generates a large amount of heat, it does not affect the insulating layer outside the cavity
Implementation Method 2
the closed air inside the cavity expands during heating of the bent portion of the electric connection skeleton, due to the existence of the insulating layer, the pressure in the cavity gradually increases, according to the Paschen's rule, the breakdown voltage increases as the air pressure increases
Data Source
AI summary
Disclosed in the present disclosure are an electric energy transmission system and an automobile. The electric energy transmission system includes at least one electric connection skeleton, an insulating layer sleeved on an outer wall of the electric connection skeleton, and connectors provided at two ends of the electric connection skeleton, and the electric connection skeleton is provided with at least one bent portion, and in at least a portion of the bent portion, at least one cavity is provided between an inner wall of the insulating layer and a periphery of the electric connection skeleton. The arrangement of this structure can ensure that the safety of the electric energy transmission system is greatly improved.