Overmolded Probe Power Cable for Non-Thermal Plasma Reactors
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Solution Overview
Problem
Conventional high voltage cables adapted for direct transfer of power to non-thermal plasma reactors in diesel engines have a low survival rate in harsh conditions, often requiring external connections that lead to arcing and inefficiencies in soot reduction.
Innovation Solution
A high voltage power cable design that directly inserts into the reactor, using a conducting core and insulation layer capable of withstanding extreme temperatures and pressures, with an epoxy coating and gasket seals to prevent arcing and ensure reliable power transfer up to 35 kV.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional high voltage cables are used for direct power transfer to non-thermal plasma reactors, then power transfer capability is achieved, but survival rate in harsh conditions deteriorates
Solution Approach 1:
The patent employs a composite cable structure consisting of multiple material layers: conducting core, insulation layer, metallic braid shield, and outer jacket. Each layer provides specific protective functions, collectively enabling the cable to withstand harsh plasma reactor conditions while maintaining power transfer capability
Solution Approach 2:
The cable incorporates pre-installed protective elements including heat-resistant materials, corrosion-resistant coatings, and mechanical protection layers before exposure to harsh conditions. These preemptive protective measures cushion the cable against thermal, chemical, and mechanical stresses encountered in plasma reactors
2Ease of operation
If external connections are used for power transfer, then installation flexibility is improved, but arcing and inefficiencies increase
Solution Approach 1:
The patent extracts the connection interface from the external environment by providing a sealed feedthrough that penetrates the reactor wall. This eliminates exposed external connections and their associated arcing problems while maintaining installation flexibility through standardized feedthrough designs
Solution Approach 2:
The sealed feedthrough acts as an intermediary element between the external power source and the internal plasma reactor environment. It provides a controlled transition point that prevents direct exposure of connections to harsh conditions, thereby eliminating arcing while maintaining connection flexibility
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 cable effectively transfers high voltage power within non-thermal plasma reactors, enhancing soot reduction and emission treatment by maintaining a sealed environment and preventing electrical leakage, thus improving the durability and efficiency of the power transfer process.
Implementation Method 1
an epoxy coating and gasket seals to prevent arcing and ensure reliable power transfer
Implementation Method 2
a conducting core and insulation layer capable of withstanding extreme temperatures and pressures
Data Source
AI summary
A transfer module for transferring power to a non-thermal plasma generator includes a power cable; a first epoxy; a second epoxy; an interface between the first epoxy and the second epoxy; and a well; the power cable including a conductor for conducting electrical power and an insulation layer for surrounding a portion of the conductor; the first epoxy being located within the well to surround the insulation layer; the second epoxy being located within the well to surround the conductor located within the well; the second epoxy being located outside the well to surround the conductor located outside the well.