Submarine Power Cable Sheath Bonding for Dynamic Friction Control
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Solution Overview
Problem
Dynamic submarine power cables face reduced life expectancy due to movement restrictions between the insulation system and the metallic sheath, especially under dynamic loads and varying thermal conditions.
Innovation Solution
A method of manufacturing dynamic submarine power cables involves providing an insulation system, a semiconducting polymeric layer, and a longitudinally welded metallic radial water blocking layer. The polymeric layer forms an adhesive layer when heated, adhering to the inner surface of the metallic radial water blocking layer, thereby controlling movement and friction between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high friction materials are used between the insulation system and metallic sheath, then the life expectancy of the cable is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The patent applies a polymeric layer that changes its friction characteristics dynamically: during manufacturing handling, the layer remains in a low-friction state allowing free movement between layers; after manufacturing, heating transforms it into a high-friction adhesive layer that restrains movement. This dynamic property resolution resolves the contradiction between ease of manufacture and reliability.
Solution Approach 2:
The patent changes the physical parameter of the polymeric layer from a low-friction state during manufacturing to a high-friction adhesive state through heating. This parameter change allows the same material to satisfy both manufacturing ease (low friction) and operational reliability (high friction) requirements at different stages.
2Reliability
If high friction materials are used between the insulation system and metallic sheath, then the life expectancy of the cable is improved, but the device complexity increases
Solution Approach 1:
The patent utilizes the phase transition of the polymeric layer from a non-adhesive to an adhesive state through heating. This phase transition enables the material to provide high friction only when needed (after manufacturing), while maintaining low friction during manufacturing, thereby improving reliability without significantly increasing device complexity.
Solution Approach 2:
The patent applies the polymeric layer in advance in a low-friction form that facilitates manufacturing, then activates its high-friction adhesive property after manufacturing is complete. This preliminary action in a controlled state resolves the contradiction by separating the manufacturing phase from the operational phase requirements.
3Ease of manufacture
If the layers are allowed to move freely during manufacturing, then the ease of manufacture is improved, but the life expectancy deteriorates
Solution Approach 1:
The polymeric layer provides dynamic friction control: low friction during manufacturing allows free movement between layers for ease of handling, while heating after manufacturing transforms it to high friction to restrain movement and improve life expectancy. This temporal separation of properties resolves the contradiction.
Solution Approach 2:
The friction parameter of the polymeric layer is changed from low to high through heating after the manufacturing process. This parameter change ensures that during manufacturing the layers can move freely (improving ease of manufacture), while in operation the high friction restrains movement (improving life expectancy).
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 enhances the life expectancy of dynamic submarine power cables by allowing controlled movement between components while maintaining high friction when necessary, facilitating easier handling during manufacturing and improving mechanical stress distribution.
Implementation Method 1
heating the metallic radial water blocking layer after step c) such that the polymeric layer melts and forms an adhesive layer that adheres to an inner surface of the metallic radial water blocking layer
Implementation Method 2
the polymeric layer melts and forms an adhesive layer that adheres to an inner surface of the metallic radial water blocking layer
Implementation Method 3
By having a bedding layer that provides high friction between the metallic water-blocking layer and the outer semiconducting layer, movement between the metallic water-blocking layer and the outer semiconducting layer may be restricted
Data Source
AI summary
A method of manufacturing a dynamic submarine power cable, the method including: a) providing an insulation system around a conductor, the insulation system including an inner semiconducting layer, an insulation layer arranged around the inner semiconducting layer, and an outer semiconducting layer arranged around the insulation layer, b) providing a semiconducting polymeric layer around the outer semiconducting layer, c) providing a longitudinally welded metallic radial water blocking layer around the polymeric layer, the metallic radial water blocking layer being in contact with the polymeric layer, and d) heating the metallic radial water blocking layer after step c) such that the polymeric layer melts and forms an adhesive layer that adheres to an inner surface of the metallic radial water blocking layer.