Hollow Conductor Cable With Supercritical CO2 Cooling

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Solution Overview

Problem

Existing electrical cables and systems are heavy and have thermal limitations that restrict the amount of electric power they can transmit, and their insulation properties degrade at high altitudes, leading to increased risks of partial discharge.

Innovation Solution

Incorporating a fluid, such as supercritical CO2, within the cable to absorb heat and a pressurized gas as an electrical insulator to maintain insulation properties, reducing cable weight and increasing power transmission capacity while minimizing altitude effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If traditional electrical cables are used for power transmission, then the cable structure is simple and easy to manufacture, but the cable weight is high and power transmission capacity is limited

Engineering Contradiction:

Improvepower transmission capacityVSAvoidcable weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent changes the physical state of the filling medium to supercritical fluid (by controlling temperature and pressure parameters), which fundamentally alters the thermal properties of the cable. This enables significantly higher power transmission capacity while the lightweight conductor materials reduce cable weight, resolving the contradiction between power capacity and weight.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite structure with multiple conductor materials (such as aluminum and copper combinations) and composite insulation systems. This allows optimization of both weight and electrical properties, achieving high power transmission capacity with reduced weight compared to traditional single-material cables.

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional cable insulation is used, then the cable structure is simple, but insulation properties degrade at high altitudes leading to partial discharge

Engineering Contradiction:

Improveinsulation integrityVSAvoidaltitude adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent fills the cable with inert gas (such as nitrogen or sulfur hexafluoride) or supercritical fluid that provides excellent electrical insulation properties. This inert filling medium prevents partial discharge and maintains insulation integrity at high altitudes where traditional air-insulated cables would fail, thereby improving reliability and altitude adaptability simultaneously.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Power

If cable cross-section is increased to transmit more power, then power transmission capacity increases, but cable weight increases

Engineering Contradiction:

Improvepower transmission capacityVSAvoidcable weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent utilizes supercritical fluid filling to dramatically improve heat dissipation efficiency. This allows the cable to operate at higher temperatures and current densities without overheating, enabling high power transmission through a smaller cross-section, thus avoiding the weight increase that would result from enlarging the cable dimensions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the traditional mechanical approach of increasing cable size for higher power capacity with a thermal management approach using supercritical fluid cooling. This substitution allows achieving higher power transmission through improved heat dissipation rather than increased conductor cross-section, thereby maintaining lower cable weight.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution reduces cable weight, enhances power transmission capacity, and maintains insulation integrity at high altitudes by using supercritical CO2 for heat absorption and pressurized gases as insulators, thereby improving the reliability and efficiency of electric power transmission.

Implementation Method 1

Incorporating a fluid, such as supercritical CO2, within the cable to absorb heat

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

a fluid positioned within the hollow interior of the conductor

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 3

a pressurized gas as an electrical insulator to maintain insulation properties

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS12590557B2Cable for electric power transmission

Publication Date: 2026.03.31 GENERAL ELECTRIC CO

AI summary

A cable that includes a conductor defining a hollow interior, a casing surrounding the conductor, an electrical insulator positioned between the conductor and the casing, and a fluid positioned within the hollow interior of the conductor.