Twisted Superconductor Wire Insulation for Coil Winding Separation
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Solution Overview
Problem
Existing methods for insulating superconductors, such as using insulating lacquer or woven fabrics, are cumbersome and time-consuming, particularly when applied in a batch process, and do not efficiently allow for physical and electrical separation while maintaining thermal conductivity.
Innovation Solution
A twisted structure of superconductor wires with elongated electrical insulation elements, twisted in the same direction and step as the superconductor wires, to create a continuous separation distance between windings, facilitating resin impregnation and heat treatment without forming brittle material contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating lacquer or woven fabrics are used to insulate superconductors, then electrical insulation is achieved, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The patent combines the superconductor wire and insulation elements into a single twisted structure. The insulation elements are integrated directly with the superconductor wires through twisting, eliminating the need for separate insulation application steps and significantly reducing production time while maintaining electrical insulation reliability
Solution Approach 2:
The insulation elements are prepared and positioned around the superconductor wires before the winding process. By pre-assembling the insulated superconductor structure, the patent avoids time-consuming insulation application during or after coil winding, thereby improving productivity without compromising insulation quality
2Reliability
If insulation is applied around superconductors, then physical and electrical separation is achieved, but the process becomes cumbersome
Solution Approach 1:
The patent merges the insulation function with the structural configuration by twisting insulation elements together with superconductor wires. This integrated approach achieves physical and electrical separation while simplifying the manufacturing process, as the insulation is inherently incorporated into the superconductor structure rather than being applied as a separate component
Solution Approach 2:
The patent uses homogeneous twisting of insulation elements and superconductor wires throughout the entire length of the superconducting coil. This uniform twisted structure ensures consistent physical and electrical separation along all windings, achieving reliable insulation while maintaining manufacturing simplicity through a standardized, repeatable process
3Reliability
If elongated insulation elements are twisted with superconductor wires, then continuous separation distance is created, but the structure becomes more complex
Solution Approach 1:
The patent employs a twisted helical structure for both superconductor wires and insulation elements. This curved, spiral configuration naturally creates continuous separation distance between adjacent windings through the geometry of the twist itself, achieving reliable insulation without requiring additional complex structural components
Solution Approach 2:
The patent maintains homogeneous twisting parameters throughout the superconducting coil, using consistent twist pitch and insulation element dimensions. This uniformity ensures continuous separation distance is achieved reliably while keeping the structure relatively simple and easy to manufacture through standardized twisting processes
Data Source
Figure 1~2
Figure 3
AI summary
A superconductor (10, 30) has a twisted structure and is adapted to form windings in a superconducting coil. The superconductor (10, 30) comprises at least one superconductor wire. The superconductor further comprises at least one elongated electrical insulation element (18, 37). The elongated electrical insulation element(s) (18, 37) is/are twisted with or around the superconductor wire(s) in order to create a separation distance with an adjacent superconductor wire in a neighbouring winding, The elongated electrical insulation element(s) (18, 37) and the superconductor wire(s) may be twisted in one and the same twisting operation.