Flat Power Cable Swellable Fillers Geometry Stability
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Solution Overview
Problem
Existing flat power cables used in hostile environments, such as oil wells, face issues with weight, complexity, and geometry stability due to swelling polymeric sheaths and activated diffusion of gases, leading to cable failures and increased installation costs.
Innovation Solution
Incorporating swellable fillers with a polymeric material composition that swells to maintain the cable's flat configuration and protect against chemicals and high temperatures, while reducing weight and complexity during transportation and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a polymeric sheath is used to protect insulated conductors against heat, oil, chemicals and decompression, then protection against environmental factors is improved, but the sheath swells in high temperature and pressure environments causing cable geometry disarrangement and failure
Solution Approach 1:
The patent applies preliminary anti-action by placing inert fillers in the interstices before the cable is subjected to high temperature and pressure environments. These fillers preemptively occupy the space that would otherwise be available for polymeric sheath swelling, thereby preventing the swelling-induced geometry disarrangement and maintaining cable stability under adverse environmental conditions
Solution Approach 2:
The inert filler materials act as intermediaries between the polymeric sheath and the external environment. They serve as a physical barrier that restricts the expansion of the polymeric sheath in high temperature and pressure conditions, while also providing structural support to maintain the overall cable geometry and prevent conductor displacement
2Object-affected harmful factors
If lead sheath is used to protect insulated conductors against oil, chemicals and gases, then protection against corrosive environment is improved, but cable weight increases
Solution Approach 1:
The patent applies parameter changes by transitioning from dense lead sheathing to lighter polymeric sheath materials that provide equivalent or superior protection against oil, chemicals and gases. This material substitution maintains the protective function while significantly reducing the cable weight, making it more suitable for deep well applications where weight is a critical factor
Solution Approach 2:
The patent employs composite material structures combining polymeric sheaths with inert filler materials to achieve both protection and weight reduction. The composite design provides chemical resistance and mechanical protection while maintaining lower weight compared to traditional lead sheathing, addressing both the protection requirement and the weight constraint
3Stability of the object's composition
If swellable fillers are used to maintain cable geometry, then cable configuration stability is improved, but device complexity increases
Solution Approach 1:
The patent applies homogeneity by using inert filler materials that are chemically and physically compatible with the existing cable components. These fillers have uniform properties that match the surrounding polymeric materials, allowing them to be integrated into the cable structure without creating additional complexity or requiring special handling procedures during installation and operation
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 swellable fillers absorb fluids to maintain the cable's geometry and protect against environmental factors, reducing weight and installation time while ensuring effective protection and stability, thus enhancing the cable's performance and longevity.
Implementation Method 1
the swellable fillers absorb fluids to maintain the cable's geometry and protect against environmental factors
Data Source
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AI summary
A flat power cable comprises at least two cores (2) of which at least two comprise a power transmissive insulated element (3, 4) and a protective sheath (5) disposed in radially external position with respect to the power transmissive insulated element (3, 4). The cores (2) are disposed on a common transversal axis (X-X) and an outer armour (9) contains the cores (2). Inside said armour (9), adjacent cores (2) and an internal surface (12) of the armour (9) delimit empty interstitial spaces (10). The flat cable (1) comprises swellable fillers (13) disposed in said empty interstitial spaces (10). In a transversal section of the cable (1), each of the swellable fillers (13), in an unswelled configuration, presents a cross section area smaller' than a cross section area of the respective empty' interstitial space (10). The swellable fillers (13) swell by absorbing fluids the flat power cable (1) is submerged in and enlarge, filling all the interstices, pushing against the cores and the armour and constraining the cable in its flat configuration.