Crosslinked Cable Accessory Layer for Thermal Management
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Solution Overview
Problem
High voltage cable junctions experience overheating issues due to inadequate thermal management, leading to polymer layer degradation and electrical failure, with existing thermal protection layers being inflexible and difficult to install around varying cable diameters, and lacking measured thermal conductivity.
Innovation Solution
A crosslinked electrically insulating layer composed of polymer material, boron nitride, and silicon carbide, providing improved thermal conductivity, flexibility, and electrical insulation, adaptable to varying cable diameters, and easy to manufacture and install.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal protection layer is applied around cable accessories, then thermal conductivity is improved, but flexibility and ease of installation deteriorate
Solution Approach 1:
The patent applies composite materials by combining polymer material with thermal conductive fillers (boron nitride and/or silicon carbide) to create a crosslinked layer that achieves both high thermal conductivity and flexibility. The polymer matrix provides flexibility while the embedded thermal conductive particles provide heat dissipation, resolving the contradiction between thermal performance and mechanical flexibility.
Solution Approach 2:
The patent changes the physical and chemical parameters of the protective layer by using a crosslinked polymer structure with specific filler content (5-50% by weight). The crosslinking process transforms the polymer from a linear structure to a network structure, enhancing both thermal stability and flexibility simultaneously, thus resolving the contradiction between thermal conductivity and ease of installation.
2Temperature
If a thermal protection layer is applied around cable accessories, then thermal conductivity is improved, but electrical insulation properties deteriorate
Solution Approach 1:
The patent uses composite materials where the polymer matrix maintains electrical insulation properties while embedded thermal conductive particles (boron nitride and silicon carbide) provide heat dissipation. The polymer base material inherently provides electrical insulation, and the filler particles are selected to not compromise this property, thus achieving both thermal conductivity improvement and electrical insulation maintenance.
Solution Approach 2:
The patent applies local quality by creating a heterogeneous structure where thermal conductive particles are distributed within the polymer matrix. The polymer regions maintain electrical insulation while the particle regions provide thermal conduction pathways, allowing the material to exhibit both insulating and thermally conductive properties in different locations within the same structure.
3Temperature
If existing thermal protection layers are used, then thermal protection is provided, but adaptability to varying cable diameters deteriorates
Solution Approach 1:
The patent employs a flexible crosslinked polymer layer that can conform to various cable diameters and accessory geometries. The polymer material's inherent flexibility allows it to be applied as a coating or wrap that adapts to the underlying cable structure, maintaining thermal protection while accommodating dimensional variations in different cable configurations.
Solution Approach 2:
The patent introduces dynamic adaptability through the flexible polymer matrix that can deform and conform to different cable diameters during installation. The material's viscoelastic properties allow it to adapt to the geometry of the cable accessory, providing consistent thermal protection across varying dimensions without requiring rigid structured designs.
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 crosslinked layer effectively evacuates heat from cable accessories, maintains electrical and mechanical integrity, and adapts to cable structures, reducing temperature at the hottest point by approximately 10°C while ensuring good sealing and insulation properties.
Implementation Method 1
the crosslinked layer has improved thermal conductivity, leading to better evacuation of the heat generated within the accessory
Implementation Method 2
at least one electrically insulating crosslinked layer comprising at least one polymer material, boron nitride and silicon carbide
Data Source
Figure 1~2
AI summary
The invention relates to a cable accessory, said accessory being surrounded by at least one electrically insulating cross-linked layer comprising at least one polymer material, boron nitride and silicon carbide, an electrical device comprising at least said cable accessory, a method for manufacturing said accessory and said device, the use of said cross-linked layer around an electrical cable accessory or in an electrical device, in particular to promote heat dissipation, an electrical cable connection kit, and a cable accessory, said accessory comprising two charges of different thermal conductivity.