Interleaved Dielectric Leaves for Compact High Voltage Insulation

Solution Overview

Problem

Conventional protective covers for high voltage electrical conductors are bulky and heavy, making them difficult to handle and store, and they do not provide adequate isolation without relying on large air gaps.

Innovation Solution

The use of lightweight plastic materials combined with interleaving dielectric leaves to create a protective tube that maintains a large air gap while keeping the overall size small, along with a two-piece coupler for joining multiple covers in series, providing flexibility and enhanced insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional protective covers use large air gaps for insulation, then insulation effectiveness is improved, but the protective cover becomes bulky and heavy

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidprotective cover weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The protective cover is segmented into multiple thin dielectric leaves arranged in an interleaved configuration. This segmentation allows the creation of multiple smaller air gaps that collectively provide the necessary insulation effectiveness while keeping each individual leaf thin and lightweight, avoiding the need for a single large air gap that would increase weight and bulk.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a single-layer thick insulation structure to a multi-layer thin-leaf structure arranged in three-dimensional interleaved spaces. By utilizing the third dimension (radial arrangement of leaves around the conductor), the design achieves equivalent insulation performance with reduced overall dimensions and weight compared to conventional single-layer approaches.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If conventional protective covers use large air gaps for insulation, then insulation effectiveness is improved, but the protective cover becomes bulky

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidprotective cover size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The protective cover is segmented into multiple thin dielectric leaves arranged in an interleaved configuration. This segmentation allows the creation of multiple smaller air gaps that collectively provide the necessary insulation effectiveness while keeping each individual leaf thin and lightweight, avoiding the need for a single large air gap that would increase weight and bulk.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a single-layer thick insulation structure to a multi-layer thin-leaf structure arranged in three-dimensional interleaved spaces. By utilizing the third dimension (radial arrangement of leaves around the conductor), the design achieves equivalent insulation performance with reduced overall dimensions and weight compared to conventional single-layer approaches.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If protective covers are made from rubber material, then insulation effectiveness is improved, but the protective cover becomes heavy

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidprotective cover weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The protective cover uses composite construction combining multiple thin dielectric leaves (which can be made from lightweight materials like plastic or fiberglass) with air gaps between them. This composite structure replaces heavy solid rubber material while maintaining insulation effectiveness through the combined dielectric properties of the leaves and air spaces.

Inventive Principle:

Principle #40Composite materials

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 results in a compact, lightweight protective cover that is easy to store and handle, offering effective isolation at high voltages without the need for bulky or heavy materials, while maintaining the necessary air gap for safety.

Implementation Method 1

protective covers are typically formed of a dielectric material such as rubber, fiberglass, or plastic

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Implementation Method 2

The protective covers made of rubber are quite heavy because of their large size that is dictated by the need for a large air gap

Methodology Applied

Scientific EffectAir gap insulation: Electrical Resistance

Data Source

PatentUS7456363B2Electric wire protective tube and insulating coupler

Publication Date: 2008.11.25 HASTINGS FIBER GLASS PRODS

AI summary

A line guard is configured so as to have a very large air gap with a small overall physical size of the device. Opposed interleaved sets of plural insulating leaves are formed along a discontinuity extending along the length of the line guard so as to greatly extend the length of the air gap. This air gap structure allows the overall size of the line guard to be small thus providing advantages of reduced weight, ease of handling, and ease of storage. A two piece coupler apparatus is provided for joining adjacent line guards in a way that is both flexible and provides sufficient dielectric to operate at high voltages in a small package.