Conductive Laminate Water Barrier for Lightweight Subsea Cables

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Solution Overview

Problem

Current lead-based water barriers for subsea power cables are heavy, prone to fatigue, and environmentally hazardous, while existing laminate structures are not fully impervious and degrade in salt or hot water conditions.

Innovation Solution

A laminate tape comprising an adhesive polymer layer and a metallic layer with apertures, made from lightweight, corrosion-resistant metals like titanium or tin alloys, is used to create a waterproof and radially conductive barrier for subsea cables, which is applied helically around the cable core and sealed with additional polymer layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lead-based water barrier is used, then reliable water protection is achieved, but weight increases significantly

Engineering Contradiction:

Improvewater protection reliabilityVSAvoidcable weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs a composite laminate structure consisting of multiple layers including polymer adhesive layers and metallic barrier layers. This composite construction achieves reliable water protection through the synergistic combination of materials, where the polymer provides flexibility and adhesion while the metallic layers provide the water barrier function, collectively replacing the single-material lead-based solution with reduced weight.

Inventive Principle:

Principle #40Composite materials

2Strength

If lead-based water barrier is used, then sturdy protection is achieved, but fatigue resistance decreases

Engineering Contradiction:

Improveprotection strengthVSAvoidfatigue resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The laminate structure combines polymer and metallic layers, where the polymer adhesive layers provide flexibility and fatigue resistance while the metallic barrier layers provide structural strength and water protection. This composite approach allows the water barrier to withstand dynamic stresses and fatigue better than solid lead while maintaining protective strength.

Inventive Principle:

Principle #40Composite materials

3Reliability

If lead-based water barrier is used, then effective water protection is achieved, but environmental harm increases

Engineering Contradiction:

Improvewater protection effectivenessVSAvoidenvironmental pollution

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces toxic lead with environmentally friendly composite materials consisting of polymers and non-toxic metallic layers. This substitution maintains effective water protection functionality while eliminating the environmental pollution and health hazards associated with lead, aligning with modern environmental regulations and sustainability requirements.

Inventive Principle:

Principle #40Composite materials

4Weight of moving object

If laminate structure is used to replace lead, then weight is reduced, but water impermeability decreases

Engineering Contradiction:

Improvecable weightVSAvoidwater impermeability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The water barrier is segmented into multiple discrete layers including polymer adhesive layers and metallic barrier layers. Each layer performs a specific function, and the cumulative effect of the layered structure provides complete water impermeability while maintaining reduced weight compared to solid lead construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The laminate structure combines polymer and metallic materials in alternating layers, where the metallic layers provide the water barrier function and the polymer layers provide adhesion and flexibility. This composite arrangement achieves full water impermeability despite the lighter weight of individual layers.

Inventive Principle:

Principle #40Composite materials

5Object-generated harmful factors

If laminate structure is used to replace lead, then environmental friendliness is improved, but durability in salt water decreases

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoiddurability in salt water

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The laminate structure uses corrosion-resistant metallic layers combined with chemically stable polymer adhesive layers. This composite construction provides enhanced durability in salt water and hot water conditions compared to traditional materials, while maintaining environmental friendliness through the elimination of toxic substances.

Inventive Principle:

Principle #40Composite materials

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 lightweight, fully impervious, and durable water barrier that maintains conductivity, overcoming the limitations of lead-based systems and ensuring long-term performance in dynamic and corrosive environments.

Implementation Method 1

a first layer made of an adhesive polymer material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a metallic second layer wherein the tape comprises a plurality of apertures

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240363264A1Radially and longitudinally conductive water barrier assembly

Publication Date: 2024.10.31 NEXANS SA

AI summary

The present arrangement includes both a method of applying a non-lead sheathed radially and longitudinally conductive water barrier to a high voltage cable and a non-lead sheathed radially and longitudinally conductive water barrier and a laminate tape.