Energy Cable Zeolite Crosslinking By-Product Extraction
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Solution Overview
Problem
The existing processes for producing energy cables with crosslinked insulating layers require lengthy and high-temperature degassing to remove crosslinking by-products, leading to increased production time and costs, and potential space charge accumulation causing electrical discharges.
Innovation Solution
Incorporating zeolite particles within the cable core or on the semiconducting layer to absorb and irreversibly trap crosslinking by-products during heating, reducing the need for prolonged degassing and preventing space charge accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional degassing process is used to remove crosslinking by-products, then by-products are removed from the cable core, but the process requires prolonged high-temperature treatment (15 days to 2 months) and cannot be carried out continuously
Solution Approach 1:
A metallic screen layer is introduced as an intermediary component between the insulating layer and outer sheath. This screen layer acts as a collection medium for crosslinking by-products during the crosslinking process, enabling continuous removal of by-products without requiring prolonged post-processing degassing operations
Solution Approach 2:
The metallic screen layer is positioned and prepared in advance before crosslinking occurs. This preliminary arrangement allows by-products to be captured during the crosslinking process itself rather than requiring extended treatment afterward, effectively performing the removal action during the primary manufacturing step
2Reliability
If prolonged degassing process is used to remove heavy by-products like acetophenone and cumyl alcohol, then by-products are eliminated from the cable core, but production time and costs increase significantly
Solution Approach 1:
The metallic screen layer serves as a mediator that captures heavy by-products during crosslinking, eliminating the need for extended degassing operations and thereby maintaining high production efficiency while ensuring by-product removal
Solution Approach 2:
The metallic screen layer extracts and collects crosslinking by-products directly during the crosslinking process, separating them from the cable core structure without requiring prolonged post-processing treatment that would reduce production efficiency
3Strength
If crosslinking agent is added to achieve satisfactory mechanical and electrical properties, then material performance is improved, but crosslinking by-products are formed that cause space charge accumulation and electrical discharges
Solution Approach 1:
The metallic screen layer converts the harmful crosslinking by-products into a manageable form by collecting them during crosslinking. This transforms the harmful accumulation effect into a controlled collection process, maintaining the benefits of crosslinking while eliminating the harmful by-product accumulation
Solution Approach 2:
The metallic screen layer acts as an intermediary that intercepts crosslinking by-products before they can accumulate in the insulating material and cause space charge problems, allowing the crosslinking reaction to proceed while preventing the harmful effects of by-product accumulation
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 use of zeolite particles significantly shortens the degassing process, reduces manufacturing costs, and maintains cable performance by efficiently absorbing and trapping crosslinking by-products, thereby preventing electrical discharges and oxidative degradation.
Implementation Method 1
zeolite particles placed in the cable core... which are capable of extracting and absorbing, very efficiently and irreversibly, the by-products deriving from the cross-linking reaction
Implementation Method 2
heating the cable core up to a temperature causing migration of the crosslinking by-products from the crosslinked electrically insulating layer
Data Source
AI summary
An energy cable includes, at least one cable core including an electric conductor, a crosslinked electrically insulating layer, and zeolite particles placed in the cable core. The zeolite particles are able to extract and absorb, very efficiently and irreversibly, the by-products deriving from the cross-linking reaction, so as to avoid space charge accumulation in the insulating material during cable lifespan. A method for extracting crosslinking by-products from a cross-linked electrically insulating layer of an energy cable core, which includes manufacturing the energy cable core containing zeolite particles, heating the energy cable core up to a temperature causing migration of the crosslinking by-products from the crosslinked electrically insulating layer; and then placing a metal screen around the energy cable core.