Thermoplastic Cable Joint Insulation With Pre-Moulded Cylindrical Layers
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Solution Overview
Problem
Traditional methods for jointing high voltage conductors using thermoplastic insulation face challenges such as material deformation during the melting process due to lack of cross-linking, requiring specialized equipment and a two-step procedure to account for density/volume changes.
Innovation Solution
A method involving pre-moulded thermoplastic insulation elements with inner and outer semiconducting layers, and an insulating layer, which are assembled and heated above the crystalline melting point with applied pressure to form a cylindrical joint, reducing material deformation and labor intensity while minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional lapping method is used for thermoplastic insulation jointing, then the process is simple, but material deformation occurs during melting due to lack of cross-linking
Solution Approach 1:
The patent applies preliminary action by pre-cross-linking the thermoplastic material before the jointing process. The insulation layers are pre-cross-linked to form a stable network structure that prevents material deformation during subsequent melting and jointing operations, thereby resolving the contradiction between process simplicity and manufacturing precision
2Manufacturing precision
If direct injection moulding procedure is used, then material deformation is reduced, but highly specialized equipment is required and the process becomes more complex
Solution Approach 1:
The patent segments the jointing process into distinct sequential steps: preparing insulation layers, forming semiconducting layers, and final jointing. This segmentation allows each step to be performed with simpler, more conventional equipment rather than requiring a single complex injection moulding system, thereby reducing device complexity while maintaining manufacturing precision
3Manufacturing precision
If direct injection moulding is used, then material deformation is controlled, but the jointing process requires two steps to account for density/volume change
Solution Approach 1:
The patent applies parameter changes by controlling the density and volume of the thermoplastic material through pre-cross-linking and controlled heating processes. By adjusting these parameters in advance and during the jointing process, the patent achieves proper density control without requiring multiple separate steps, thereby maintaining manufacturing precision while improving productivity
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
This approach enhances the uniformity and homogeneity of the joint, reduces material interfaces, and simplifies the jointing process, resulting in a more reliable and efficient high voltage conductor insulation system.
Implementation Method 1
The material is heated above its crystalline melting point and shaped into a cylinder
Implementation Method 2
pressure is applied to shape each layer into a cylinder after any of the steps c), d), and e)
Data Source
AI summary
The present invention relates to a thermoplastic insulation system for jointing of high voltage conductors, comprising at least one joint element, wherein each joint element comprises an insulating layer made of a thermoplastic insulating material, and wherein the at least one joint element is adapted for surrounding the electric conductor joint and wherein the pre-moulded thermoplastic insulation constitutes a cylindrical layer around the electric conductor joint. The invention also relates to a method to produce such an insulation system.