High Voltage Cable Thermal Management via Metallic Heat Conductor
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Solution Overview
Problem
High voltage electric cables face challenges in maintaining conductor temperature within defined limits due to heat generation, leading to insulation deterioration, and existing cooling solutions are either costly or inefficient in heat transfer.
Innovation Solution
Incorporating a heat conducting metallic layer around the cable core and cooling pipe, made of materials like aluminium, copper, or steel, to facilitate efficient thermal transfer from the conductor to the cooling medium, along with a flexible polymer cooling pipe and metal braiding for enhanced heat management and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the conductor area is increased to maintain temperature within defined limits, then the temperature control is improved, but the material cost and insulation material requirement increase
Solution Approach 1:
A heat conducting metallic layer is introduced as an intermediary between the cable core and the cooling pipe. This metallic layer facilitates more efficient heat transfer from the conductor to the cooling medium, allowing better temperature control without increasing conductor or insulation material
Solution Approach 2:
The thermal conductivity parameter is enhanced by introducing the metallic layer with high thermal conductivity between the conductor and cooling pipe, changing the heat transfer characteristics of the cable system to achieve better temperature management
2Temperature
If external cooling pipes are used around the cable, then the cooling effect is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The cooling pipe is merged with the cable structure itself, forming an integrated cooling cable where the cooling pipe becomes part of the cable cross-section. This integration reduces device complexity compared to external cooling systems while maintaining effective cooling
Solution Approach 2:
The metallic layer serves multiple functions: it acts as both a heat conducting element for the cooling system and provides structural support and thermal equalization within the cable, reducing the need for separate components
3Temperature
If cooling pipes are integrated into the cable structure, then the cooling efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The cooling pipe is constructed as a flexible polymer tube that can be easily formed and integrated during the cable extrusion process. The flexibility of the polymer material allows it to conform to the cable structure without requiring complex rigid piping installation
Solution Approach 2:
The cable structure becomes a composite system combining the conductor, insulation, flexible polymer cooling pipe, and metallic heat conducting layer. This composite structure integrates multiple functions within a unified manufacturing process
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 solution enables effective thermal equalization and heat transfer, allowing for longer cable installations with reduced material usage and cost, while maintaining efficient cooling performance, thus extending cable length and current ratings without significant increases in conductor size or material.
Implementation Method 1
a heat conducting element, in particular a heat conducting metallic layer, arranged in contact with the outer surface of the at least two cable cores so as to conduct heat to the cooling medium arranged in the cooling pipes
Implementation Method 2
Cooling air or water is arranged in the cooling pipe to absorb the heat generated in the conductor of the cable core
Data Source
Figure 1
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AI summary
A high voltage electric cable (1) comprising at least one cable core (2a, 2b, 2c), at least one cooling pipe (7a, 7b, 7c) for cooling the cable core comprising a polymer and adapted for carrying a cooling fluid, and a cable covering (6) enclosing the at least one cable core and the at least one cooling pipe. The electric cable further comprises at least one heat conducting element (5a, 5b.5c) surrounding the at least one cable core (2a, 2b.2c), and being arranged in thermal contact with the at least one cable core (2a, 2b, 2c) and the at least one cooling pipe (7a, 7b, 7c)