Power Cable Moisture Barrier: Plastic-Metal Composite
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High voltage power transmission cables face challenges with traditional lead-based moisture barriers, which are environmentally unfriendly and prone to mechanical fatigue, limiting the choice of alternative materials and methods for effective moisture protection.
Innovation Solution
A moisture barrier arrangement comprising a first extruded plastic layer and a second metallic layer, allowing for flexible application and adaptation, using environmentally friendly materials like copper, aluminum, or steel, which can be applied separately to provide permanent moisture protection without damaging the insulation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead is used as moisture barrier material, then ease of manufacture is improved, but environmental friendliness deteriorates and mechanical fatigue resistance worsens
Solution Approach 1:
The patent changes the material parameter from lead to alternative metals such as aluminum, copper, or steel. This substitution maintains the moisture barrier function while eliminating environmental hazards and improving mechanical fatigue resistance, directly resolving the contradiction between ease of manufacture and environmental friendliness.
Solution Approach 2:
The patent employs composite moisture barrier structures combining multiple metal layers or metal with other materials. This composite approach preserves the protective function while enabling use of environmentally friendly materials that resist mechanical fatigue, thereby resolving both the environmental and mechanical fatigue issues.
2Ease of manufacture
If lead is used as moisture barrier material, then ease of manufacture is improved, but mechanical fatigue resistance deteriorates
Solution Approach 1:
The patent changes the material parameter from lead to alternative metals such as aluminum, copper, or steel. These materials inherently possess superior mechanical fatigue resistance compared to lead, while remaining easy to manufacture and install, thus resolving the contradiction between ease of manufacture and mechanical fatigue resistance.
Solution Approach 2:
The patent promotes use of alternative metals that, while potentially requiring different manufacturing processes, offer extended service life and durability. This approach trades initial manufacturing simplicity for long-term reliability and reduced maintenance, resolving the mechanical fatigue issue.
3Object-affected harmful factors
If alternative materials are used as moisture barrier, then environmental friendliness is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent employs composite moisture barrier structures combining multiple metal layers or metal with other materials. This composite approach preserves the protective function while enabling use of environmentally friendly materials, and the layered structure facilitates manufacturing by allowing each layer to be applied using established processes, thus resolving the contradiction between environmental friendliness and ease of manufacture.
Solution Approach 2:
The patent divides the moisture barrier into multiple independent layers or segments. This segmentation allows each layer to be manufactured and applied separately using appropriate techniques for that material, making environmentally friendly materials as easy to manufacture as traditional lead barriers while achieving superior performance.
4Reliability
If moisture barrier is applied directly to insulation system, then protection effectiveness is improved, but risk of damaging insulation system increases
Solution Approach 1:
The patent introduces an intermediary layer between the moisture barrier and the insulation system. This intermediate layer acts as a buffer that provides mechanical protection to the sensitive insulation system during application of the moisture barrier, while still allowing the moisture barrier to perform its protective function, thus resolving the contradiction between protection effectiveness and risk of damage.
Solution Approach 2:
The patent applies a protective intermediary layer beforehand to cushion and protect the insulation system from potential damage during subsequent moisture barrier application. This prior cushioning ensures that the insulation system is protected from mechanical stresses, heat, or other harmful effects during the manufacturing process, while maintaining effective moisture protection.
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
This solution enhances mechanical properties, allows for the use of alternative materials, and provides effective moisture protection while maintaining electrical integrity, making the cable more adaptable and economical to produce.
Implementation Method 1
The first layer is an extruded plastic material layer and arranged in direct contact with the insulation system
Implementation Method 2
The second layer is a metallic material layer and arranged in contact with the first layer
Implementation Method 3
the insulation system is typically impregnated with a dielectric fluid, such as a low viscosity oil, to protect the insulation against moisture pick-up and to fill up all pores and voids
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The present invention relates to a power transmission cable (10; 20; 30) and a process for the production of the cable, which comprises a metal conductor (1; 21; 31), an electric insulation system (2; 22; 32) and a protection system surrounding the insulation system. The insulation system (2; 22; 32) comprises an inner semi-conducting layer (4; 24; 34) surrounded coaxially and radially outwards by an insulation layer (5; 25; 35), and the insulation layer is optionally surrounded coaxially and radially outwards by an outer semi-conducting layer (26; 36). The protection system comprises a moisture barrier arrangement (3; 23; 33) surrounding the insulation system coaxially and radially outwards of the insulation system. The moisture barrier arrangement (3; 23; 33) comprises an independently applicable first layer (7; 27; 37) and an independently applicable second layer (8; 28; 38), the first layer (7; 27; 37) being an extruded plastic material layer and arranged in direct contact with the insulation system (2; 22; 32), and the second layer (8; 28; 38) being a metallic material layer and arranged in contact with the first layer (7; 27; 37).