Thermoplastic Energy Cable With Dielectric Fluid
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Solution Overview
Problem
Conventional medium and high voltage cables with crosslinked polymer coatings are not recyclable, limiting their end-of-life disposal options and requiring incineration, while thermoplastic polyethylene materials have low operating temperature limits, and existing dielectric fluids either compromise thermomechanical properties or result in exudation.
Innovation Solution
A thermoplastic polymer-based energy cable with a dielectric fluid, specifically a compound with a formula X-A-X' where A is a totally aromatic condensed polycyclic moiety, is used to enhance electrical and thermomechanical properties, ensuring high reliability at temperatures above 90°C without exudation, by forming a homogeneous dispersion within the polymer matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crosslinked polymer coatings (XLPE, EPR, EPDM) are used to achieve satisfactory mechanical and electrical properties at high temperatures, then the cable provides good thermomechanical performance, but the material cannot be recycled and must be disposed of by incineration
Solution Approach 1:
The invention changes the fundamental parameter of polymer crosslinking state from crosslinked to thermoplastic, enabling the material to be processed and recycled while maintaining high temperature performance through the addition of specific dielectric fluids rather than relying on crosslinking for thermal stability
Solution Approach 2:
The invention creates a composite material system combining thermoplastic polymer base material with specific dielectric fluids (compounds of formula X-A-X' with aromatic condensed polycyclic moiety), where the dielectric fluid enhances both electrical properties and thermomechanical performance without compromising recyclability
2Ease of manufacture
If thermoplastic polyethylene (LDPE or HDPE) is used to enable recyclability, then the material can be processed and recycled, but the operating temperature is too low (generally about 70°C)
Solution Approach 1:
The invention modifies the thermoplastic polymer's performance parameters by incorporating specific dielectric fluids that raise the operating temperature capability from 70°C to above 90°C while preserving the thermoplastic nature and recyclability of the base material
Solution Approach 2:
The dielectric fluid acts as an intermediary substance that mediates between the thermoplastic polymer matrix and the high temperature operating conditions, allowing the polymer to withstand higher temperatures without compromising its thermoplastic characteristics
3Reliability
If polypropylene materials in admixture with dielectric fluid are used to achieve desired dielectric strength and processability, then electrical properties improve, but the dielectric liquid may exude and thermomechanical properties are compromised
Solution Approach 1:
The invention optimizes the molecular parameters of the dielectric fluid by selecting compounds with specific aromatic condensed polycyclic structures (formula X-A-X') that provide appropriate viscosity and molecular size to prevent exudation while maintaining dielectric strength enhancement
Solution Approach 2:
The invention creates a stable composite material system where the specific dielectric fluid compounds are compatible with the polypropylene matrix, forming a homogeneous dispersion that maintains both electrical and thermomechanical properties without phase separation or exudation
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 significantly increases the breakdown strength of the cable's coating layer, maintains thermomechanical properties, and allows for easy handling and recycling, enabling operation at high temperatures with improved reliability and reduced environmental impact.
Implementation Method 1
a thermoplastic polymer material in admixture with a dielectric fluid... forming a homogeneous dispersion within the polymer matrix
Implementation Method 2
the dielectric liquid should both determine a significant increase in its electrical properties (in particular the dielectric strength)... significantly increases the breakdown strength of the cable's coating layer
Data Source
AI summary
Energy cable comprising at least one electrical conductor and at least one extruded coating layer including a thermoplastic polymer material in admixture with a dielectric fluid, wherein said dielectric fluid comprises a compound of formula (I) X-A-X'; where A is a monocyclic aromatic moiety or an at least partially aromatic condensed polycyclic moiety; and at least one of X and X' is methyl or an aliphatic moiety, in both the cases optionally substituted with and/or interrupted by one or more of keto, alkoxy, alkylthio, mercapto, hydroxyalkyl, hydroxyl; the other being hydrogen; said compound having a ratio of number of aromatic carbon atoms to total number of carbon atoms greater than or equal to 0.6.