Coated Conductor Jacket Using High-Aspect-Ratio Metal Hydroxide
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Solution Overview
Problem
Conventional high-density fillers, such as metal hydroxide with an aspect ratio less than 10, increase the density of cable jackets while decreasing the Alternating Current Breakdown Strength (ACBD) in all-dielectric self-supporting (ADSS) cables, making them unsuitable for self-supporting applications.
Innovation Solution
A composition comprising an ethylene-based polymer and 5-15 wt% of a metal hydroxide with an aspect ratio greater than or equal to 10, which maintains thermal conductivity above 0.52 W·m−1·K−1 and density below 1.02 g/cc, is used for the cable jacket, enhancing both thermal performance and ACBD.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional high density fillers (metal hydroxide with aspect ratio less than 10) are used in cable jacket, then thermal conductivity is improved, but density increases and ACBD decreases
Solution Approach 1:
The patent changes the aspect ratio parameter of metal hydroxide filler from less than 10 to greater than or equal to 10, while maintaining the filler content at 5-15 wt%. This parameter change resolves the contradiction by achieving thermal conductivity greater than 0.52 W·m−1·K−1 while keeping density less than or equal to 1.02 g/cc, preventing both density increase and ACBD decrease that occur with conventional fillers
2Temperature
If conventional high density fillers (metal hydroxide with aspect ratio less than 10) are used in cable jacket, then thermal conductivity is improved, but ACBD decreases
Solution Approach 1:
The patent changes the aspect ratio parameter of metal hydroxide filler to greater than or equal to 10, which resolves the contradiction between thermal conductivity and ACBD. The high aspect ratio filler geometry provides thermal conduction pathways while maintaining cable jacket integrity and electrical breakdown strength, achieving thermal conductivity greater than 0.52 W·m−1·K−1 without compromising ACBD
3Temperature
If metal hydroxide filler is added to ethylene-based polymer, then thermal conductivity increases, but density increases
Solution Approach 1:
The patent changes the aspect ratio parameter of metal hydroxide filler to greater than or equal to 10, which allows achieving thermal conductivity greater than 0.52 W·m−1·K−1 while maintaining density less than or equal to 1.02 g/cc. This resolves the contradiction by providing efficient thermal conduction pathways through the high aspect ratio geometry without proportionally increasing mass
Solution Approach 2:
The patent creates a composite material system combining ethylene-based polymer with metal hydroxide filler at 5-15 wt% content. The composite structure with high aspect ratio filler provides thermal conductivity greater than 0.52 W·m−1·K−1 while maintaining density less than or equal to 1.02 g/cc, resolving the contradiction between thermal performance and weight
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 solution provides a cable jacket with improved thermal conductivity and reduced density, addressing the issues of high density and low ACBD in ADSS cables, making it suitable for self-supporting applications.
Implementation Method 1
The composition has a thermal conductivity greater than 0.52 W·m−1·K−1
Data Source
AI summary
The present disclosure provides a composition. The composition includes (A) an ethylene-based polymer and (B) from 5 wt % to 15 wt % of a metal hydroxide component, based on the total weight of the composition. The metal hydroxide component includes a metal hydroxide having an aspect ratio greater than, or equal to, 10. The composition has a thermal conductivity greater than 0.52 W m−1 K−1 and a density less than, or equal to 1.02 g/cc. The present disclosure also provides a coated conductor including a non-metal conductor and a coating on the conductor, the coating containing the composition.