Compact Superconducting Cable Connector Assembly
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Solution Overview
Problem
Existing low temperature superconducting cable joints in magnetic confinement fusion devices have large dimensions, complex structures, lower maximum operational current, unstable resistance, and inadequate high voltage insulation, which hinder efficient energy confinement and plasma stabilization.
Innovation Solution
A compact connector assembly using a saddle-shaped copper block with a clamp mechanism, sealed inner and outer shells for helium flow, and Teflon shims to reduce AC loss, along with a single heat soldering process and resin-based high-voltage insulation, replacing the complex twin-box type joint structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the twin-box type joint structure is used for connecting low temperature superconducting cables, then the connection can be achieved, but the joint has large dimension (overall length about 1m), complex structure, and requires large quantity of glass fiber reinforced epoxy fillers
Solution Approach 1:
The joint structure is divided into two separate half-joints, each containing one superconducting cable terminal. These half-joints are compressed into a connector assembly and connected through a common copper block, eliminating the need for extensive fillers and reducing overall complexity while maintaining connection functionality.
Solution Approach 2:
The two half-joints are nested together within a single connector assembly, with the superconducting cable terminals positioned on opposite sides of a common copper block. This nested configuration reduces the overall joint length from 1m to a compact size while integrating multiple functions into a unified structure.
2Ease of manufacture
If the twin-box type joint structure is used, then connection is achieved, but there are 3 different connecting interfaces requiring individual soldering heating processes
Solution Approach 1:
Multiple connecting interfaces are merged into a single integrated copper block that contacts both superconducting cable terminals simultaneously. This allows all soldering operations to be performed in one heating process rather than requiring three separate soldering steps, significantly simplifying manufacturing.
3Reliability
If the twin-box type joint structure is used, then connection is achieved, but high voltage insulation layer cannot be directly wrapped and requires large quantity of glass fiber reinforced epoxy fillers to form regular shape
Solution Approach 1:
A flexible insulation layer is directly wrapped around the compact connector assembly, forming a smooth outer surface without requiring rigid fillers. The flexible wrapping conformally follows the compact geometry, providing effective high voltage insulation while eliminating the need for complex glass fiber reinforced epoxy filler structures.
4Reliability
If the joint structure with copper tubes and inner copper block is used (EAST superconducting Tokamak), then connection is achieved, but joint resistance has high deviation and AC loss is not reduced
Solution Approach 1:
Teflon shims are strategically placed at specific locations within the copper block to create localized non-conductive barriers. This local quality modification interrupts eddy current paths precisely where they would otherwise form, reducing AC loss while maintaining stable electrical contact and low joint resistance through the remaining copper contact areas.
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 results in a reduced AC loss, lower resistance, and improved high voltage insulation, enabling higher operational currents and more compact designs that enhance the mechanical strength and voltage withstand capabilities of the superconducting cable connections.
Implementation Method 1
a clip mechanism wrapped around the outer surface of the two low temperature superconducting cable terminals to tightly clamp the copper layer, the two welding material layers and the two low temperature superconducting cable terminals from the inside to the outside of the connecting assembly
Implementation Method 2
two welding material layers, each is provided between the copper layer and either of the two low temperature superconducting cable terminals
Implementation Method 3
an inner shell which is sealedly welded for communicating with a helium flowing pass for cooling the helium
Data Source
AI summary
A connector assembly of two low temperature superconducting cable terminals and manufacturing method thereof. A connector assembly comprises a copper layer having one side which is conducted with one low temperature superconducting cable and another side which is conducted with another low temperature superconducting cable, two welding material layers, wherein each the welding material layer is provided between the copper layer and either of the two low temperature superconducting cable, and a clip mechanism covered the outer surface of either of the low temperature superconducting cable to tightly clamp the copper layer, the two welding material layers and the two low temperature superconducting cable form the inside to the outside of the connector assembly. The connector assembly of the present invention has compact structure. The saddle-shaped copper block is compressed by a clamp mechanism is use to weld with two low temperature superconducting terminals.