Gas Blocking Cable with High-Temperature Silicone Filling
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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 explosion scenarios, and existing water-blocked cables cannot withstand the high temperatures and pressures required for power generation turbine applications, which do not meet stringent IEC specifications.
Innovation Solution
A multi-conductor cable design that fills interstitial spaces with a high-temperature, inert, and non-flammable silicone compound, applied using various application devices during the cabling process, ensuring complete sealing between conductors, wires, and the jacket, and utilizing a combination of materials like polyimide tape, FEP jacket, and braids to maintain flexibility and withstand high temperatures.
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 hazardous gases can pass through interstitial spaces causing safety hazards
Solution Approach 1:
A filling compound is introduced as an intermediary substance to occupy and seal the interstitial spaces between conductors. This compound acts as a barrier that prevents gas passage while maintaining the existing cable structure, thus improving reliability without significantly increasing device complexity
Solution Approach 2:
The physical and chemical parameters of the filling compound are specifically selected to withstand high temperatures (up to 200°C) and high pressures of hazardous gases. By changing the parameters of the sealing material rather than the cable structure itself, the invention achieves gas blocking capability while keeping the overall design relatively simple
2Temperature
If water blocked cables are used, then fluid blocking is achieved, but the cables cannot withstand high temperatures up to 200°C in power generation turbine applications
Solution Approach 1:
The invention changes the temperature parameter tolerance by selecting a filling compound specifically designed to remain stable and effective at high temperatures up to 200°C. This high-temperature resistant compound maintains its sealing properties under thermal stress, unlike conventional water-blocking materials that would fail
Solution Approach 2:
The cable employs a composite structure combining the filling compound with the cable's existing components (conductors, insulation, jacket). This composite approach allows the filling compound to provide both high-temperature resistance and fluid blocking capability, achieving multiple functions through material composition rather than structural complexity
3Reliability
If gas blocking filling compound is applied to fill interstitial spaces, then gas passage is blocked at high pressure, but the manufacturing process becomes more complex
Solution Approach 1:
The filling compound is applied during the cable manufacturing process before the final jacketing step. This preliminary action allows the compound to be positioned and initially set while the cable structure is still being formed, making the overall manufacturing process more integrated rather than adding a separate post-manufacturing step
Solution Approach 2:
The filling compound is formulated to self-distribute and self-seal within the interstitial spaces through its own flow and curing properties. This self-service characteristic reduces the need for complex application equipment and manual intervention, thereby minimizing the impact on manufacturing simplicity while achieving reliable high-pressure gas blocking
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 gas passage at high pressures and temperatures up to 200°C, meeting IEC requirements and preventing leakage, while maintaining flexibility and compatibility with existing installation processes.
Implementation Method 1
A multi-conductor cable capable of blocking passage of high pressure gases and other fluids through the interstitial spaces of the cable
Implementation Method 2
the high cable operating temperature environment of a power generation turbine application (up to 200° C.)
Data Source
AI summary
A gas blocking cable includes cabled wires, where each wire includes cabled conductors 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 shield 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.