Conductor Part Air Void Elimination
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Solution Overview
Problem
Partial discharge at higher AC voltages between conductors and insulators in subsea connectors and penetrators is a reliability issue due to air voids formed during the manufacturing process, which can lead to dielectric failure.
Innovation Solution
A method for manufacturing a conductor part with a conductive core and an insulating sleeve, where at least one conductive layer is applied to the inner and outer surfaces of the sleeve, creating an air-tight interface that minimizes the risk of partial discharge by eliminating air voids and allowing for greater electrical stress without detrimental effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pre-formed insulator sleeve is engaged over the conductor, then the insulation structure is simple and easy to manufacture, but air voids are formed at the interface which cause partial discharge and reduce reliability
Solution Approach 1:
The harmful air voids are extracted/eliminated from the interface between conductor and insulator by applying conductive layers that create intimate contact, removing the source of partial discharge while maintaining the simple sleeve structure
Solution Approach 2:
Conductive layers are introduced as intermediary elements between the conductor and insulator sleeve, serving as a bonding interface that eliminates air voids while maintaining electrical conductivity and mechanical attachment
2Stability of the object's composition
If polymer insulation is over moulded onto metal substrate, then the insulation is integrated with the conductor, but air voids are formed due to shrinkage and thermal expansion differences which lead to partial discharge
Solution Approach 1:
The harmful air voids created by thermal shrinkage are extracted/eliminated by applying conductive layers that conform to the substrate and eliminate void spaces, preventing partial discharge while maintaining integrated construction
Solution Approach 2:
A composite structure is created combining metal substrate, conductive intermediate layers, and polymer insulation, where the conductive layers serve as a buffer that accommodates thermal expansion differences while maintaining intimate contact and eliminating air voids
3Device complexity
If air voids are present at the conductor-insulator interface, then the manufacturing process is simpler, but the electrical potential over-stresses the air voids causing ionization and partial discharges that lead to dielectric failure
Solution Approach 1:
The harmful air voids are extracted/removed from the interface by applying conductive layers that create continuous contact, eliminating the source of electrical stress concentration and partial discharge while adding only minimal process steps
Data Source
AI summary
A method for manufacturing a conductor part for a connector unit is provided. The conductor part includes a conductive core, an insulating sleeve, and at least a first conductive layer arranged between the conductive core and the insulating sleeve. The method includes equipping at least one section of a radially inner surface of the insulating sleeve with the first conductive layer, and equipping at least one section of a radially outer surface of the insulating sleeve with at least a second conductive layer. The second conductive layer is a metal layer or a conductive plastic layer. The method also includes inserting the conducting core in the insulating sleeve before or after equipping a surface of the insulating sleeve with a conductive layer.