Fiber Mat Insulated Conductor for High Voltage Bus Bars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrical insulators for high-voltage bus bars and cables have limited temperature resistance, leading to potential internal short circuits and safety risks during thermal runaway events, and are difficult to produce and install effectively.
Innovation Solution
A method of manufacturing an electrically insulated conductor using a heat-resistant fiber mat, where the fiber mat is woven and welded to form a closed insulating sleeve around the conductor, providing a temperature-resistant enclosure that can withstand high temperatures and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical insulators are used for high-voltage bus bars and cables, then they provide basic electrical insulation, but they have limited temperature resistance leading to potential internal short circuits during thermal runaway events
Solution Approach 1:
The patent uses a composite structure consisting of a fiber mat (such as glass fiber, ceramic fiber, or basalt fiber) as the insulating material. These fibers are woven into a tubular form and welded to create a closed insulating sleeve that provides both electrical insulation and high-temperature resistance, preventing thermal runaway propagation and internal short circuits.
Solution Approach 2:
The patent changes the material parameters of the insulator by using heat-resistant fibers with melting points significantly higher than conventional insulators. The fiber mat is designed to maintain structural integrity at temperatures exceeding 1000°C, thereby providing reliable insulation during thermal events where conventional materials would fail.
2Ease of manufacture
If conventional insulators are used, then they provide electrical insulation, but they are difficult to produce and install effectively
Solution Approach 1:
The insulating cover is produced as a separate tubular component (insulating sleeve) that can be manufactured independently and then installed around the conductor. This segmentation allows for standardized production of the fiber mat sleeves, which can be easily wrapped around conductors of various shapes and sizes, simplifying both manufacturing and installation processes.
Solution Approach 2:
The patent replaces complex mechanical assembly processes with a welding process that joins the end portions of the fiber mat to form a closed sleeve. This welding method (using friction, ultrasonic, or other welding techniques) simplifies the production process compared to traditional mechanical assembly, while ensuring reliable installation effectiveness.
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 effectively prevents internal short circuits and ensures safety by providing a high-temperature-resistant insulation that can be easily and rapidly produced, suitable for various electrical conductor shapes, including high-voltage bus bars and cables, and maintains high electrical resistance.
Implementation Method 1
welding end portions of the at least one electrically insulating cover portion to form a closed insulating sleeve around the circumference of the electrical conductor
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
The present disclosure refers to a method of manufacturing an electrically insulated conductor (10) for a battery system, comprising the steps of providing an electrical conductor (20) for conducting an electrical current. The method further comprises the step of covering a circumference (22) of the electrical conductor (20) with at least one electrically insulating cover portion (30, 30'), wherein the electrically insulating cover portion (30, 30') is a fiber mat. The method further comprises the step of welding end portions (31, 31'; 33, 33') of the at least one electrically insulating cover portion (30, 30') to form a closed insulating sleeve around the circumference (22) of the electrical conductor (20).