Overhead Conductor Coated with Electrochemical Titanium Oxide

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Solution Overview

Problem

Overhead conductors face limitations in current-carrying capacity due to maximum safe operating temperature, leading to heat-related damage, as they generate heat through Ohmic losses and solar heat, and existing coatings do not effectively reduce operating temperatures.

Innovation Solution

A coated overhead conductor with an electrochemical deposition coating of titanium oxide or zirconium oxide is applied to the surface of conductive wires, reducing operating temperatures by forming a ceramic outer layer that can withstand higher temperatures and reduce heat generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the current-carrying capacity of the conductor is increased, then the power transmission capability is improved, but the operating temperature increases leading to heat-related damage

Engineering Contradiction:

Improvecurrent-carrying capacityVSAvoidoperating temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent converts the harmful thermal radiation into a beneficial cooling mechanism by applying a ceramic coating with high emissivity in the infrared spectrum. This coating transforms the conductor's heat radiation capability, turning the previously harmful heat accumulation into an active heat dissipation mechanism that lowers operating temperature while maintaining high current-carrying capacity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent uses composite material structure consisting of aluminum or aluminum alloy conductive wires coated with ceramic material. This composite structure combines the high electrical conductivity of aluminum with the high thermal emissivity and temperature resistance of ceramic, achieving both high current-carrying capacity and effective heat radiation

Inventive Principle:

Principle #40Composite materials

2Temperature

If a coating is applied to reduce operating temperature, then the heat radiation capability is improved, but the electrical resistance increases

Engineering Contradiction:

Improveoperating temperatureVSAvoidelectrical resistance

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent applies local quality by differentiating the functional properties of different layers: the bulk conductor material (aluminum) maintains high electrical conductivity for low electrical resistance, while the surface coating (ceramic) provides high thermal emissivity for heat radiation. This localized functional differentiation resolves the contradiction between temperature control and electrical performance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses a thin film ceramic coating on the conductor surface. This thin film structure provides the desired thermal radiation properties without significantly affecting the electrical conductivity of the underlying aluminum conductor, thus minimizing increase in electrical resistance while achieving effective heat dissipation

Inventive Principle:

Principle #30Flexible shells and thin films

3Productivity

If the conductor operating temperature is reduced, then the ampacity is improved, but the heat radiation efficiency is insufficient with conventional coatings

Engineering Contradiction:

ImproveampacityVSAvoidheat radiation efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent changes the key parameter of surface emissivity by applying ceramic coating with high infrared emissivity. This parameter change in the thermal radiation property dramatically improves heat radiation efficiency, enabling the conductor to dissipate heat more effectively and thereby increase ampacity without exceeding temperature limits

Inventive Principle:

Principle #35Parameter changes

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 coated conductors exhibit a reduced operating temperature of at least 5°C compared to uncoated conductors, with significant reductions at higher temperatures, thereby enhancing the conductor's performance and longevity by minimizing heat-related damage.

Implementation Method 1

performing electrochemical deposition of a first metal oxide on an outer surface of the bare conductor to form an outer layer on the bare conductor

Methodology Applied

Scientific EffectElectrochemical deposition: Electrodeposition

Implementation Method 2

a coated overhead conductor which better radiates heat away, thereby reducing operating temperature

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS10957468B2Coated overhead conductors and methods

Publication Date: 2021.03.23 GENERAL CABLE TECH CORP

AI summary

A coated overhead conductor having an assembly including one or more conductive wires, such that the assembly includes an outer surface coated with an electrochemical deposition coating forming an outer layer, wherein the electrochemical deposition coating includes a first metal oxide, such that the first metal oxide is not aluminum oxide. Methods for making the overhead conductor are also provided.