Gas Blocking Cable with Interstitial Filling Materials
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Solution Overview
Problem
Conventional multi-conductor cables fail to prevent the passage of high-pressure hazardous gases through their interstitial spaces, posing a risk in power generation turbine environments, and existing water-blocking cables cannot withstand the high temperatures and pressures required for explosion-proof applications.
Innovation Solution
A multi-conductor cable design featuring a plurality of wires with insulation and filling materials, a shield, and a jacket, where each material is inert and non-flammable, capable of withstanding temperatures up to 200°C, and a method for applying these materials to prevent gas and fluid passage through interstitial areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-conductor cables are used, then the cable structure is simple and easy to manufacture, but high-pressure hazardous gases can pass through the interstitial spaces of the cable
Solution Approach 1:
The patent applies filling material specifically to the interstitial spaces between conductors and between wires to create gas-blocking properties in those specific locations, rather than requiring the entire cable structure to be complex. This localized approach blocks gas passage through interstitial areas while maintaining overall cable simplicity
Solution Approach 2:
The patent combines multiple materials including conductor filling material, wire filling material, insulation material, jacket material, and shield material to achieve gas blocking capability. Each material serves a specific function, and their composite structure creates effective gas barriers without requiring excessive structural complexity
2Temperature
If water blocking cables are used, then fluid blocking is achieved, but the cables cannot withstand high temperatures up to 200°C in power generation turbine environments
Solution Approach 1:
The patent changes the material parameters by selecting filling materials, insulation materials, and jacket materials specifically designed to withstand temperatures up to 200°C. This parameter change enables the cable to maintain its gas blocking capability in high-temperature power generation turbine environments where conventional water blocking cables would fail
3Reliability
If gas blocking is achieved only at the cable gland assembly connection, then the connection point is protected, but leak paths remain through the interstitial space in the cable
Solution Approach 1:
The patent applies filling material to the interstitial spaces between conductors and between wires during the cable manufacturing process, before the cable is installed. This preliminary action ensures that gas blocking is built into the cable structure itself, eliminating the need for complex additional manufacturing steps while preventing leak paths throughout the entire cable length
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 cable effectively blocks high-pressure gases and fluids, meeting stringent IEC requirements, and maintains flexibility and temperature resistance, preventing leakage and ensuring safety in turbine control rooms.
Implementation Method 1
a layer of filling material positioned in a space between the shield and the jacket... passage of a high pressure gas (at a pressure of approximately 3,000 kPa (435 psi)) or a high pressure fluid (at a pressure of approximately 3,000 kPa (435 psi)) through the first interstitial areas, the second areas, and the space between the shield and the jacket is prevented
Data Source
Figure 1
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Figure 3
AI summary
A gas blocking includes cabled wires, where wire includes cabled conductor having interstitial areas there between. An insulation material circumferentially surrounds the cabled conductors and a conductor filling material is positioned within the interstitial areas between conductors. A circumferentially surrounds the cabled wires so that a cable is formed with areas between the wires. A wire filling material is positioned within the areas between the wires. Each of the conductor filling material and wire filling material is inert, non-flammable and able to withstand a temperature of at least approximately 200°C.