Mass Impregnated Cable Insulation Weight Reduction
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Solution Overview
Problem
The use of lead in mass-impregnated paper-insulated power transmission cables is heavy, environmentally detrimental, and poses health risks, particularly for submarine and terrestrial applications, while existing alternatives like aluminum and copper do not adequately address mechanical strength and weight reduction.
Innovation Solution
Incorporating a transverse reinforcing layer of steel or fiberglass tape around a copper or aluminum metal layer, which is laminated with a layer of insulating material, provides mechanical reinforcement and reduces weight by allowing for thinner metal layers, thereby replacing lead and enhancing cable durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If lead is used as the metallic layer in mass-impregnated paper insulation cables, then mechanical strength and protection are improved, but weight increases and environmental harm worsens
Solution Approach 1:
The patent changes the material parameter from lead to copper or aluminum, which have different density and mechanical properties. This substitution reduces weight while maintaining protective function through optimized layer configuration and thickness parameters
Solution Approach 2:
The patent creates a composite structure with multiple layers including copper or aluminum metallic layer, insulating material layer, and transverse reinforcing layer. This composite design distributes mechanical strength across different materials, allowing lead to be replaced without sacrificing overall cable strength
2Weight of moving object
If copper or aluminum replaces lead in the metallic layer, then weight is reduced, but mechanical strength and durability worsen
Solution Approach 1:
The patent compensates for the lower mechanical strength of copper or aluminum by introducing a transverse reinforcing layer made of steel wire or fiberglass tape. This composite structure combines the lightweight advantage of copper/aluminum with the high strength of steel/fiberglass, achieving both weight reduction and strength maintenance
Solution Approach 2:
The patent divides the protective function into separate layers: the copper or aluminum metallic layer provides basic protection and electrical continuity, while the dedicated transverse reinforcing layer provides enhanced mechanical strength. This segmentation allows each layer to optimize its specific function without compromise
3Weight of moving object
If the metallic layer thickness is reduced to achieve weight loss, then weight improves, but mechanical protection worsens
Solution Approach 1:
The patent uses a composite structure where a thin copper or aluminum metallic layer is combined with a transverse reinforcing layer. The reinforcing layer compensates for the reduced thickness of the metallic layer, maintaining mechanical protection while enabling overall weight reduction through the lighter material composition
4Strength
If lead is used for environmental safety, then protection is improved, but environmental harm and health risks worsen
Solution Approach 1:
The patent changes the material parameter from lead to copper or aluminum, which are environmentally benign materials. This substitution eliminates the toxicological and environmental problems associated with lead while maintaining the protective and mechanical functions through optimized structural parameters
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
This configuration significantly reduces cable weight by up to 10 kg per linear meter, improves mechanical strength through elastic reinforcement, and is suitable for high DC voltages and underwater use.
Implementation Method 1
The transverse reinforcement layer ensures a spring effect due to its elasticity, in order to reinforce the mechanical strength during the expansion or contraction of the layer of impregnated paper
Implementation Method 2
said layer of insulating material is laminated to said metal layer
Data Source
Figure 1
AI summary
The invention relates to an electricity transport cable with mass impregnated paper insulation comprising around at least one conductor (1), a layer of impregnated paper (2) and a metallic layer (3) adjacent to said layer of impregnated paper, this metallic layer (3) being constituted of copper or of aluminium. According to the invention, the cable comprises, directly around said metallic layer (3), a layer of insulating material (4), and directly around said layer of insulating material (4), a transverse strengthening layer (5) exhibiting an elastic limit of between 20.106 N to 100.106 N per metre of cable length.