Electric Cable Sheath Impregnation With Phase-Change Thermal Buffer
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Solution Overview
Problem
Existing high and very high voltage cables face limitations in energy conveyance due to Joule-effect losses and maximum temperature restrictions imposed by polymer insulation materials, which limit current intensity and cable life.
Innovation Solution
Incorporation of a thermal energy absorbing material, such as a phase change material, into the cable structure through impregnation processes, utilizing its latent heat to manage temperature and reduce Joule-effect losses, thereby increasing current intensity and cable life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal energy absorbing material is applied as a coating on the surface of the cable, then fire protection is provided, but the cable structure becomes complex and manufacturing is cumbersome
Solution Approach 1:
The patent combines the thermal energy absorbing material with the cable structure by impregnating it into the cable sheath during manufacturing, merging the fire protection function with the structural component rather than applying it as a separate coating layer.
Solution Approach 2:
The thermal energy absorbing material is nested within the cable sheath structure during the extrusion process, with the material being incorporated into the wall structure of the sheath, creating a multi-functional integrated component.
2Reliability
If thermal energy absorbing material is applied as a coating on the surface of the cable, then fire protection is provided, but application is time-consuming and manufacturing efficiency is reduced
Solution Approach 1:
The thermal energy absorbing material is incorporated into the cable sheath during the extrusion process itself, performing the fire protection application in advance during manufacturing rather than as a subsequent separate step, thereby eliminating additional processing time.
Solution Approach 2:
The fire protection material application is merged with the cable sheath manufacturing process, combining two operations into one continuous extrusion process that produces both the structural sheath and the fire protective layer simultaneously.
3Reliability
If separate fire protection coating is applied, then fire safety is improved, but cost increases due to additional materials and processing
Solution Approach 1:
The patent merges the fire protection material with the cable sheath material, using a single extrusion process to produce both the structural and fire protective components in one operation, thereby eliminating the need for separate materials and processing steps.
Solution Approach 2:
The cable sheath is designed to serve multiple functions simultaneously: providing structural protection and containing thermal energy absorbing material for fire safety, making the sheath a multi-functional component that reduces overall system complexity and cost.
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 thermal energy absorbing material effectively reduces cable temperature and enhances current conveyance capacity, extending the cable's useful life by managing thermal energy storage and minimizing energy losses.
Implementation Method 1
the material is capable of absorbing thermal energy generated during a fire event so as to prevent a rapid increase in temperature of the insulation
Implementation Method 2
A process for impregnating a cable sheath with a fire protective material
Data Source
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AI summary
The present application is related to a process for impregnating thermal energy absorbing material into the structure of an electric cable and an respective electric cable compring energy absorbing material for maximizing the intensity of electric current conveyed thereby. The developed technology involves the inclusion of a material in the cable structure, capable of absorbing thermal energy from at least one of the constituent layers of the cable, thus reducing the temperature of the surrounding materials. In this way, the present technology is useful for conveying and delivering electricity (high and very high voltage) within insulated cables, to underground installations, for example, allowing gains in the conveying capacity, without significant increase of the cable section. Therefore, the thermal limitation imposed by the insulation material is overcome, making it possible to maximize the electric current intensity of the conductor while reducing Joule-effect losses over time to the surroundings, thus increasing the useful life thereof.