Sector Cable Solid Core Voids Reduction
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Solution Overview
Problem
High voltage electric cables have voids in the conductive core, reducing the cross-sectional conductive area and electric current density, and face flexibility issues with larger cross sections, especially in direct current applications, and require complex manufacturing processes and water-blocking materials.
Innovation Solution
A high voltage electric cable design featuring a solid central conductor with solid sector conductors of trapezoidal cross-section, arranged to minimize voids and increase conductive area, made from aluminium to enhance flexibility and reduce the need for water-blocking materials, allowing for higher current density and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sector cables are used with multiple strands and sheaths, then the cable structure provides insulation and mechanical strength, but voids form in the conductive core reducing the cross-sectional conductive area
Solution Approach 1:
The conductive core is segmented into multiple solid sector-shaped conductors (typically 3-6 sectors) arranged around a central conductor. Each sector maintains solid contact with adjacent sectors and the central conductor, eliminating voids while preserving mechanical strength and insulation properties through the modular sector structure.
Solution Approach 2:
Multiple solid sector conductors are merged into a unified conductive core structure where the sectors are tightly packed and in direct contact with each other and the central conductor. This merging eliminates air gaps and voids between strands, maximizing the effective cross-sectional conductive area while maintaining the structural integrity provided by the multi-component design.
2Power
If the cross section area of the cable core is increased to transport higher electric current, then the current carrying capacity increases, but the flexibility of the cable decreases
Solution Approach 1:
The large cross-sectional area is achieved through segmentation into multiple smaller solid sector conductors rather than a single large conductor. This segmentation allows the cable to maintain flexibility because each sector can slightly deform independently, while the overall current carrying capacity is maximized through the combined cross-sectional area of all sectors.
Solution Approach 2:
The cable employs a composite structure combining multiple solid sector conductors made of conductive material (such as aluminium or copper) with complementary metal reinforcement elements. This composite approach enables the cable to achieve both high current carrying capacity through the large total cross-sectional area and maintained flexibility through the specific arrangement and material properties of the sectors.
3Ease of manufacture
If voids are present in the conductive core, then the manufacturing process is simpler, but water-blocking materials are required to prevent moisture propagation
Solution Approach 1:
The invention extracts and eliminates voids from the conductive core by tightly packing solid sector conductors around a central conductor. By removing the voids that would otherwise require water-blocking materials, the design simplifies the overall cable structure and reduces the need for additional protective layers while maintaining manufacturing feasibility through the modular sector assembly process.
Data Source
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AI summary
It is disclosed a high voltage electric cable (1) having a longitudinal axis (X) and comprising a conductive core (1a) having a first cross section area. The conductive core (1a) comprises a solid, central conductor (2). It further comprises at least three solid, sector conductors (3) stranded around the central conductor (2). The central conductor (2) has a second cross section area and the ratio between the second and first cross section areas is of from 1/130 to 1/20.