Graphene-Coated Electrical Cables for Lower Loss and Corrosion Resistance
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Solution Overview
Problem
Existing electrical cables face challenges with energy loss due to conductivity limitations, high material costs, corrosion, and tensile strength issues, particularly in high-voltage and subsea applications, where materials like copper and steel wires are expensive and prone to corrosion.
Innovation Solution
The integration of a continuous layer of two-dimensional materials, such as graphene, onto the surfaces of electrical cable components using mechanical exfoliation and wrapping or taping processes, enhancing conductivity, tensile strength, and corrosion resistance while reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If copper is used as the conductive core, then electrical conductivity is improved, but material cost increases
Solution Approach 1:
The patent applies composite materials by combining copper conductive core with graphene coating. The graphene layer enhances electrical conductivity and reduces energy loss while allowing reduction in copper quantity, thereby lowering material cost. This composite structure resolves the contradiction between improving conductivity and reducing material usage.
Solution Approach 2:
The patent changes the physical and chemical parameters of the cable by introducing graphene coating with superior electrical properties. The graphene layer has higher electron mobility and lower resistivity compared to copper, changing the overall electrical parameters of the conductive core to achieve reduced energy loss with less material.
2Reliability
If lead sheath is used to provide water barrier, then protection is improved, but cable mass increases
Solution Approach 1:
The patent extracts the water barrier function from the heavy lead sheath and implements it through alternative means such as corrosion-resistant alloy sheaths or protective coatings. This separation allows the cable to maintain water protection while eliminating the excessive mass contribution from lead, resolving the contradiction between protection and weight.
Solution Approach 2:
The patent changes the material composition of the sheath from lead-based to lighter corrosion-resistant alloys or composite materials that provide equivalent or superior water barrier protection. This parameter change in material density and protective properties achieves the same reliability function with reduced mass.
3Strength
If steel wire armour is used to provide tensile strength, then mechanical strength is improved, but corrosion resistance worsens
Solution Approach 1:
The patent applies composite materials by combining steel wire armour with corrosion-protective coatings such as galvanization, epoxy, or polymer coatings. This composite structure maintains the high tensile strength of steel while adding a protective layer that prevents corrosion, resolving the contradiction between strength and corrosion resistance.
Solution Approach 2:
The patent applies beforehand cushioning by pre-coating the steel wire armour with corrosion-protective materials before assembly into the cable structure. This protective layer is applied in advance to prevent corrosion from occurring, cushioning the steel against environmental damage while maintaining its mechanical strength properties.
4Loss of energy
If thicker materials are used to reduce voltage drop, then conductivity is improved, but cable mass increases
Solution Approach 1:
The patent uses composite materials with graphene coating on the conductive core to achieve superior electrical conductivity per unit cross-section. The graphene layer's exceptional electron mobility allows the cable to carry the same current with less voltage drop using thinner overall dimensions, thereby reducing cable mass while improving conductivity efficiency.
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
This approach results in electrical cables with improved conductivity, reduced mass and cost per unit length, increased tensile strength, and enhanced corrosion resistance, enabling the use of thinner materials and longer cable lengths with reduced voltage drop and increased durability.
Implementation Method 1
forming a continuous layer of two dimensional material by mechanical exfoliation
Implementation Method 2
enhancing conductivity, tensile strength, and corrosion resistance
Implementation Method 3
enhancing conductivity, tensile strength, and corrosion resistance
Data Source
AI summary
Electrical cables and methods of forming such cables are disclosed, comprising a layer of a two dimensional material. In some embodiments, the cable is a subsea cable. In other embodiments, the cable may be an overhead power cable or a cable for forming electrical windings in a motor, generator or transformer. In some embodiments, the cable comprises a conductive core for carrying an electric current, and the layer of two dimensional material is disposed on the conductive core. In some embodiments, the subsea cable is a subsea power cable, umbilical cable or telecommunications cable. In some embodiments, the two dimensional material is configured to be superconducting or near-superconducting.