Strip Conductor Layer Layout for AC Loss Reduction
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Solution Overview
Problem
Existing strip conductor devices for AC-fed devices suffer from high electrical losses due to hysteresis and coupling effects, and are mechanically weakened by excessive stress in overlapping sections, leading to low total current density and high production costs.
Innovation Solution
The strip conductor device comprises two elongated strip conductor elements with substrate layers and conductor layers featuring barrier elements that extend from the edges towards the center line, arranged alternately and mirror-inverted. This configuration allows for a twisting of the current path, reducing electrical losses and maintaining mechanical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If strip conductors are woven together in a meandering shape to improve efficiency and increase performance, then electrical losses are reduced, but the strip conductors are mechanically weakened by excessive stress in overlapping sections
Solution Approach 1:
The strip conductor is divided into multiple individual strands that are woven together to form a braid structure. Each strand maintains its structural integrity while the collective braid achieves the desired meandering current path, distributing mechanical stress across multiple segments rather than concentrating it in overlapping sections of a single continuous strip.
Solution Approach 2:
The solution transitions from a two-dimensional planar strip conductor to a three-dimensional braided structure. By adding the dimensional complexity of weaving multiple strands together, the design achieves the necessary current path meandering without creating problematic overlapping sections, as the strands interlace through space rather than lying flat against each other.
2Reliability
If thick insulation layers or large interspacing are used to insulate individual conductors, then insulation reliability is improved, but the cables have a low total current density
Solution Approach 1:
Multiple individual conductor strands are merged into a single braided cable structure. The insulation is applied to the individual strands before braiding, and the braiding process brings these insulated strands into close proximity without requiring additional interspacing or thick insulation layers, thereby maintaining high current density while preserving insulation reliability through the combined structure.
3Shape
If plastic deformation or punching-out is used to produce the meander structure, then the desired current path is achieved, but production costs increase and material degradation risk increases
Solution Approach 1:
Instead deforming a single continuous strip conductor through expensive plastic deformation or punching processes, the invention segments the conductor into multiple simple strands that are braided together. This segmentation allows the meander structure to emerge naturally from the braiding process itself, eliminating the need for costly deformation operations and associated material degradation risks.
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 solution reduces electrical losses in AC-fed devices by neutralizing induced electric fields, maintains mechanical robustness, and achieves high total current density without the need for deformation or punching, thus lowering production costs.
Implementation Method 1
Such strip conductors with layer structures very often show high losses when used in the alternating current range. In the case of standard conductors, these are so-called eddy currents flowing over width and length
Implementation Method 2
in the case of superconductors, these are mainly hysteresis and coupling effects, as well as dynamic electrical losses
Data Source
AI summary
A strip conductor device includes first and second elongated strip conductor elements, each configured to be coupled at a coupling-in end to a contact device for coupling-in electric current and at a coupling-out end to a contact device for coupling-out electric current. The first elongated strip conductor element is a first strip conductor that has a substrate layer that carries a conductor layer that has barrier elements along a length of the conductor layer. The second elongated strip conductor element is a second strip conductor that has a substrate layer that carries a conductor layer that has barrier elements along a length of the conductor layer. The first strip conductor element forms a layer arrangement with the second strip conductor element and the coupling-in ends and the coupling-out ends of the first and second strip conductor elements lie one above the other.