Photovoltaic Cable With Diffusion Barrier
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Solution Overview
Problem
Cables used for connecting photovoltaic modules face challenges in maintaining long-term stability and resistance to moisture and fire in damp environments, with existing solutions either being costly, bulky, or failing to prevent water diffusion and flame retardancy effectively.
Innovation Solution
A cable design featuring a diffusion barrier layer between the outer jacket and insulation layer, made of non-polar and hydrophobic polymers, which significantly reduces water and moisture ingress, combined with a flame-retardant outer sheath containing halogen-free additives, and a high-quality additive in the inner layers for enhanced fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin external fire protection layer is applied to a thick polyethylene layer, then the cable achieves flame retardancy, but the underlying polyethylene layer can catch fire quickly if the external layer is damaged
Solution Approach 1:
The patent applies different flame retardant properties to different layers of the cable. The outer sheath contains flame retardant additives for initial fire resistance, while the inner diffusion barrier layer provides a secondary protective function. This local differentiation of protective qualities ensures that if one layer fails, another layer provides backup protection, resolving the contradiction between achieving flame retardancy and preventing rapid fire spread.
Solution Approach 2:
The cable employs a composite structure with multiple layers having different material properties. The outer sheath and diffusion barrier layer are composed of different materials with complementary functions - the outer layer provides flame retardancy while the inner layer acts as a diffusion barrier. This composite approach allows the cable to maintain both flame retardancy and reduced fire spread risk simultaneously.
2Reliability
If flame retardant additives are added to the outer jacket to improve fire resistance, then the cable achieves desired flame retardant properties, but the additives are washed out over time in moist environments
Solution Approach 1:
The patent divides the protective function into separate layers. The outer sheath contains flame retardant additives for fire resistance, while the inner diffusion barrier layer is specifically designed to prevent moisture ingress. This segmentation allows each layer to specialize in one protective function, preventing the wash-out problem while maintaining flame retardancy.
Solution Approach 2:
The diffusion barrier layer acts as an intermediary between the moist external environment and the inner cable components. It prevents moisture from reaching and washing out the flame retardant additives in the outer sheath, thereby preserving the fire resistance properties over the long term while allowing the cable to function in damp environments.
3Object-affected harmful factors
If a very thick layer of polyethylene is used for moisture protection, then the cable resists moisture and water, but the cable becomes bulky and the non-flame-retardant material increases fire spread risk
Solution Approach 1:
The patent changes the material parameters of the diffusion barrier layer, specifically using crosslinked polyolefin material with specific density and crystallinity characteristics. This allows the layer to provide effective moisture diffusion protection at reduced thickness compared to conventional polyethylene, thereby reducing cable volume while maintaining moisture resistance.
Solution Approach 2:
The cable uses a composite structure where the diffusion barrier layer is made of crosslinked polyolefin material with specific properties optimized for moisture protection. This specialized material provides superior moisture barrier performance at thinner cross-sections compared to conventional polyethylene, reducing overall cable volume while maintaining effective moisture resistance.
4Adaptability or versatility
If the cable is laid underground in moist soil, then the cable is exposed to high humidity and moisture, but moisture damages the cable by washing out additives and impairing insulation properties
Solution Approach 1:
The diffusion barrier layer serves as an intermediary protective layer between the moist external environment and the inner insulation components. It specifically prevents moisture diffusion into the cable interior, thereby protecting the insulation properties and additive content from moisture-related degradation while enabling underground installation.
Solution Approach 2:
The patent implements preliminary protection by placing the diffusion barrier layer in advance to prevent moisture ingress before it can reach and damage the inner cable components. This preemptive barrier action stops the harmful process of moisture diffusion at the interface, preserving insulation properties and additive integrity throughout the cable's service life.
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 achieves long-term moisture resistance, reduced risk of fire spread, and improved operational reliability, while minimizing production costs and effort, by preventing water diffusion and maintaining flame retardancy even after exposure to moisture and fire.
Implementation Method 1
a diffusion barrier layer (3) arranged between the outer jacket (4) and the insulation layer (2), which is designed in such a way that the cross-diffusion of water and moisture into the interior of the cable is prevented or at least significantly reduced
Implementation Method 2
made of non-polar and hydrophobic polymers, which significantly reduces water and moisture ingress
Data Source
Figure 1~2
AI summary
The invention relates to a cable (10) for the electrical connection of photovoltaic modules to a power grid, comprising: - at least one electrical and/or at least one optical conductor (1); - an insulating layer (2) enclosing the conductor (1); - an outer sheath (4) enclosing the aforementioned components. According to the invention, a diffusion barrier (3) is arranged between the outer sheath (4) and the insulating layer (2).