Nickel-Coated Copper Cable Insulation for Extreme Conditions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high voltage electrical cables fail to meet the extreme requirements of aerospace, nuclear, and petroleum sectors due to limitations in temperature resistance, radiation resistance, degassing standards, and mechanical flexibility, particularly at high temperatures and high voltages.
Innovation Solution
A high voltage electrical cable design featuring a nickel-coated copper or copper alloy central conductor with a multilayer insulation system using extruded thermoplastic materials like polyetherketones and polyetherketoneetherketoneketones, combined with additional thermosetting polymer layers for enhanced thermal and mechanical stability, and a metallic shielding layer for radiation protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polymer insulating materials are used to withstand high temperatures, then temperature resistance is improved, but outgassing increases and low-temperature flexibility deteriorates
Solution Approach 1:
The patent employs a composite insulating structure combining polyimide ribbon (providing high-temperature resistance and low outgassing) with thermoplastic coating (providing low-temperature flexibility and processing ease). This composite approach allows the cable to withstand temperatures up to 280°C while meeting space sector outgassing standards (CVCM < 0.1%, RML < 1%) and maintaining flexibility at cryogenic temperatures.
2Temperature
If polyimide thermosetting resins are used for high-temperature resistance, then temperature resistance is improved, but manufacturing difficulty increases due to processing constraints
Solution Approach 1:
The insulating system is segmented into two functional layers: a polyimide ribbon layer (providing high-temperature resistance) and a thermoplastic coating layer (providing ease of manufacture through extrusion). This segmentation allows each layer to be optimized for its specific function while simplifying the overall manufacturing process.
Solution Approach 2:
The thermoplastic coating acts as an intermediary layer that facilitates manufacturing by providing good extrudability and adhesion to the central conductor, while the polyimide ribbon serves as the primary high-temperature barrier. This intermediary approach resolves the conflict between high-temperature performance and manufacturing ease.
3Reliability
If insulating material thickness is increased to withstand high voltages, then voltage resistance is improved, but cable flexibility deteriorates
Solution Approach 1:
The patent uses a composite insulating structure with optimized layer thicknesses: the polyimide ribbon provides high-voltage resistance with minimal thickness due to its superior dielectric properties, while the thermoplastic coating adds necessary flexibility. This composite approach achieves 5,000V withstand capability while maintaining cable flexibility for mechanical bending operations.
Data Source
Figure 1~4
AI summary
The present invention relates to a high-voltage electrical cable including a central conductor (1) made of copper or a copper alloy coated with nickel, and at least one main insulating material layer (2) arranged around the central conductor (1), said insulating material layer consisting of an extruded thermoplastic material selected from among poly(ether-ketone), poly(ether-ketone-ether-ketone-ketone), and the mixtures thereof. The invention also relates to the use of the cable in the aerospace and/or nuclear and/or scientific research and/or oil research fields.