Flexible Coaxial Cable for High-Power Transmission
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Solution Overview
Problem
High-performance coaxial cables face challenges in transmitting high power at high frequencies due to the skin effect, which requires large conductors and results in rigidity, limiting flexibility and efficiency.
Innovation Solution
A coaxial cable design featuring a flexible, tubular inner conductor screen with a filler that acts as a thermal energy store, using a braided or helical screen with a filler that absorbs and releases heat reversibly, and optionally includes a fiber bundle or extruded plastic strand for enhanced mechanical stability and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large conductor cross-section is used to transmit high power, then power transmission capability is improved, but cable rigidity increases and flexibility deteriorates
Solution Approach 1:
The inner conductor is segmented into multiple thin wire strands (7-19 strands per bundle, 3-5 bundles) rather than using a solid conductor. This segmentation maintains sufficient total cross-sectional area for high power transmission while allowing the cable to bend more easily, thus improving flexibility without sacrificing power capability.
Solution Approach 2:
The inner conductor uses thin wire strands (0.1-0.5 mm diameter) arranged in a flexible stranded structure rather than a rigid solid or tubular form. This thin-film-like approach enables the conductor to flex while maintaining electrical performance for high power transmission.
2Ease of operation
If a tubular inner conductor is used to improve flexibility, then cable flexibility is improved, but radial stability deteriorates due to compression at low pressures
Solution Approach 1:
The dielectric material is positioned locally between the inner conductor strands and the outer conductor, providing radial support exactly where needed. This localized dielectric support maintains the tubular structure's radial stability without requiring the entire structure to be rigid, preserving flexibility.
Solution Approach 2:
The cable uses a composite structure combining flexible stranded copper wires for the inner conductor with a dielectric material (such as polyethylene or polypropylene) that provides radial stability. This composite approach integrates flexibility from the stranded conductor with structural stability from the dielectric.
3Power
If solid inner conductors are used for high power transmission, then power transmission capability is improved, but material usage increases and flexibility deteriorates
Solution Approach 1:
The inner conductor is divided into multiple thin strands arranged in bundles rather than using a single solid conductor. This segmentation achieves the required current-carrying capacity through distributed thin wires, reducing the total amount of copper material needed compared to a solid conductor of equivalent cross-section.
Solution Approach 2:
The inner conductor uses thin wire strands (0.1-0.5 mm diameter) that provide sufficient electrical performance with minimal material thickness, reducing overall material usage while maintaining flexibility and power transmission capability.
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 design achieves high flexibility, efficient heat management, and reduced material usage, allowing for the transmission of high power at high frequencies without damage, while maintaining structural integrity and flexibility.
Implementation Method 1
a phase transformation generally takes place at a defined temperature, during which heat, for example heat of fusion, is absorbed and later given off again at a constant temperature
Implementation Method 2
the filler is designed as a latent heat store
Implementation Method 3
the so-called skin effect is known, which causes the current transported via the conductor to be displaced to the edge of the conductor. The skin effect is frequency dependent and increases with higher frequencies
Data Source
AI summary
The aim of the invention is to provide a flexible coaxial cable (2) for high-power applications. The coaxial cable has an inner conductor (4) which is made of a braided shield (4) and which is surrounded by a dielectricum (6) and an outer conductor (8) as usual. The braided shield (4) defines an inner cavity which is filled with a filler (12A, B). The filler (12A, B) is expediently a functional element and is designed as a thermal energy store for example or comprises a signal or data line.