Polymer-Ceramic Composite for High-Voltage Cable Insulation
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Solution Overview
Problem
High-voltage electrical cables in aircraft require insulation materials that balance high thermal conductivity with low electrical conductivity, as existing polymer insulators have poor thermal conductivity and high electrical conductivity, leading to heat management issues.
Innovation Solution
A polymer-ceramic composite is developed with ceramic particles in a polymer matrix, where over 70% of ceramic particles are in contact with each other, achieving a dielectric strength of at least 300 kV/mm and thermal conductivity of at least 10 W/mK, using ceramic particles like boron nitride and a fluoropolymer matrix, processed by dispersing, drying, and compressing at specific temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer is used as insulation material, then electrical insulation performance is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent creates a composite material consisting of ceramic particles (with high thermal conductivity) dispersed within a polymer matrix (with good electrical insulation). This composite structure allows the material to simultaneously achieve high thermal conductivity from the ceramic phase and good electrical insulation from the polymer phase, directly resolving the contradiction between these two properties.
2Temperature
If ceramic particles are added to improve thermal conductivity, then thermal conductivity is improved, but electrical conductivity deteriorates
Solution Approach 1:
The patent applies local quality by creating distinct regions within the composite: ceramic particles provide high thermal conductivity in localized areas, while the polymer matrix maintains good electrical insulation throughout the bulk material. This spatial differentiation of functions allows simultaneous optimization of both thermal and electrical properties.
3Temperature
If ceramic particle concentration is increased to improve thermal conductivity, then thermal conductivity is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent optimizes the concentration of ceramic particles within the polymer matrix to achieve a balance between thermal conductivity and mechanical strength. By carefully controlling the volume fraction and distribution of ceramic particles, the composite achieves sufficient thermal conductivity while maintaining adequate mechanical properties for cable insulation applications.
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 composite provides robust mechanical and thermal properties while maintaining low electrical conductivity, effectively managing heat and preventing partial discharge failure in high-voltage electrical cables.
Implementation Method 1
a thermal conductivity of the composite is greater than or equal to about 10 watts per meter kelvin
Implementation Method 2
a dielectric strength of the composite is greater than or equal to about 300 kilovolts per millimeter
Data Source
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AI summary
Disclosed is a polymer-ceramic composite, comprising: ceramic particles (12) within a polymer matrix (14); wherein greater than or equal to about 70% of the ceramic particles by volume experience ceramic particle to ceramic particle contact; wherein a dielectric strength of the composite is greater than or equal to about 300 kilovolts per millimeter; and wherein a thermal conductivity of the composite is greater than or equal to about 10 watts per meter kelvin.