Power Cable Thermal Conductor for Heat Dissipation
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Solution Overview
Problem
Conventional high power, high frequency power cables require bulky cooling systems due to inefficient heat dissipation, leading to increased weight, material usage, and reduced current capacity, which can be harmful to equipment and environmental control systems.
Innovation Solution
A power cable design featuring a multi-layer concentric structure with an elongated thermal conductor made from materials like pyrolytic graphite or carbon nanotubes, surrounded by an electrical conductor layer and insulation layers, allowing heat to be efficiently transferred to the ends of the cable for dissipation, reducing material usage and weight while maintaining high frequency power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional power cable designs are used with surface heat dissipation, then the cable structure is simple, but a bulky cooling system is required which increases weight and material usage
Solution Approach 1:
The patent embeds an elongated thermal conductor (made of pyrolytic graphite or carbon nanotubes) at the center of the cable, with the electrical conductor layer surrounding it. This nested configuration allows the thermal conductor to be integrated within the cable structure itself, eliminating the need for external bulky cooling systems while providing efficient heat dissipation through the cable's core to its surface.
2Device complexity
If conventional power cable designs are used with surface heat dissipation, then the cable structure is simple, but material usage increases due to bulky cooling systems
Solution Approach 1:
The patent embeds an elongated thermal conductor (made of pyrolytic graphite or carbon nanotubes) at the center of the cable, with the electrical conductor layer surrounding it. This nested configuration allows the thermal conductor to be integrated within the cable structure itself, eliminating the need for external bulky cooling systems while providing efficient heat dissipation through the cable's core to its surface.
3Ease of manufacture
If conventional power cable designs are used, then heat dissipation is simple, but current capacity is reduced due to heat generation harmful to equipment
Solution Approach 1:
The patent changes the thermal conductivity parameter of the cable by incorporating an elongated thermal conductor made of pyrolytic graphite or carbon nanotubes, which have ultra-high thermal conductivity. This parameter change enables more efficient heat dissipation along the cable's length, allowing the cable to sustain higher current capacities without generating harmful heat that would damage equipment or reduce reliability.
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 design reduces the overall weight by 30% and aluminum metal usage by 54% while maintaining current capacity, effectively lowering cable temperatures and alleviating heat load on environmental control systems, thus enhancing system efficiency.
Implementation Method 1
heat generated in the power cable is transferred via the elongated thermal conductor to at least one end of the power cable
Implementation Method 2
an electrical conductor layer surrounding at least a portion of the elongated thermal conductor
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
The present disclosure provides a power cable apparatus (100; 300; 400; 500; 600; 700) that comprises an elongated thermal conductor (110; 610; 710), and an electrical conductor layer (120; 620; 720) surrounding at least a portion of the elongated thermal conductor. In one or more embodiments, heat generated in the power cable is transferred via the elongated thermal conductor to at least one end of the power cable. In at least one embodiment, the apparatus further comprises an electric insulation layer (130; 640; 730) surrounding at least a portion of the electrical conductor layer. In some embodiments, the apparatus further comprises a thermal insulation layer (140; 650) surrounding at least a portion of the electric insulation layer. (Fig. 1A)