Eccentric Coaxial Cable Layout for Easier Outer Conductor Contacting
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Solution Overview
Problem
Existing coaxial cables in high-voltage systems face challenges in contacting the outer conductor, heat dissipation, and ease of installation, particularly with large nominal cross-sections, and are not cost-effective.
Innovation Solution
The inner conductor is arranged eccentrically within the cable by dividing the outer conductor into sector bundles with varying dimensions, allowing for easy separation and improved heat dissipation, and the inner conductor is stranded with these bundles to facilitate manufacturing and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the outer conductor is designed as a continuous ring surrounding the inner conductor, then electromagnetic shielding is improved, but contacting the outer conductor becomes difficult and requires separating it from the inner conductor
Solution Approach 1:
The outer conductor is segmented into at least three sector bundles arranged around the inner conductor. This segmentation allows the outer conductor to maintain its electromagnetic shielding function while enabling easier contacting by accessing individual sector bundles without requiring complete separation from the inner conductor.
Solution Approach 2:
The sector bundles are designed with asymmetric dimensional distribution around the inner conductor, creating an eccentric arrangement. This asymmetry provides at least one access direction where the outer conductor can be contacted more easily, resolving the contradiction between maintaining continuous shielding and enabling convenient contacting.
2Power
If the nominal cross-section of the cable is increased to transmit higher power, then power transmission capability is improved, but heat dissipation from the inner conductor becomes more difficult
Solution Approach 1:
The sector bundles are designed with varying dimensions and wire configurations in different radial positions. Sector bundles closer to the inner conductor have different characteristics than those farther away, optimizing local heat dissipation pathways while maintaining overall high power transmission capability through the increased nominal cross-section.
3Power
If the nominal cross-section of the cable is increased to transmit higher power, then power transmission capability is improved, but ease of cable installation and laying becomes more difficult
Solution Approach 1:
The outer conductor is divided into multiple sector bundles that can be independently handled during installation. This segmentation reduces the bending resistance and flexibility requirements for the entire cable, making installation and laying easier even when the overall nominal cross-section is large for high power transmission.
4Ease of manufacture
If the inner conductor is positioned coaxially with the outer conductor, then manufacturing simplicity is improved, but heat dissipation and ease of contacting the outer conductor are worsened
Solution Approach 1:
The inner conductor is deliberately positioned eccentrically relative to the outer conductor by designing sector bundles with varying dimensions. This asymmetric arrangement improves heat dissipation by creating optimal thermal pathways and facilitates easier contacting of the outer conductor, while the manufacturing process remains feasible through standardized stranding techniques.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a coaxial cable (1) for transmitting electric current in a high-voltage system of a motor vehicle comprising: - an inner conductor (2); - an outer conductor (4); - an inner insulating layer (3) arranged between the inner conductor (2) and the outer conductor (4); - and an insulating cable sheath (7); wherein the outer conductor (4) is designed to be able to transmit essentially the same electrical power as the inner conductor (2).In order to enable simplified contacting of the outer conductor (4), the invention provides that the individual wires of the outer conductor (4), viewed in a cross-sectional area of the coaxial cable (1) normal to a cable axis (9) of the coaxial cable (1), are divided into at least three sector bundles (5), wherein the sector bundles (5) are dimensioned such that the inner conductor (2) is positioned eccentrically to the cable axis (9) in the cross-sectional area and wherein the inner conductor (2) and the sector bundles (5) of the outer conductor (4) are stranded together.