High power, high frequency power cable

• US 9,449,739 B2
• Filed: 10/16/2012
• Issued: 09/20/2016
• Est. Priority Date: 10/16/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Gao, Lijun, Liu, Shengyi
• Primary Examiner(s): Nguyen, Hoa C
• Assistant Examiner(s): DEPEW, KEITH A
• Application Number:
  US13/652,959
• Publication Number:
  US 20140102781A1
• Time in Patent Office: 1,435 Days
• Field of Search: 174/70.R, 174/110.R, 174/110.SR, 174/102.R, 174/126.4, 174/107, 703/2
• US Class Current: 1/1
• CPC Class Codes: H01B 7/428 Heat conduction
• CPC Class Codes: H01B 9/04 Concentric cables

Abstract

The present disclosure provides a power cable apparatus that comprises an elongated thermal conductor, and an electrical conductor layer surrounding at least a portion of the elongated thermal conductor. In one or more embodiments, heat generated in the power cable is transferred via the elongated thermal conductor to at least one end of the power cable. In at least one embodiment, the apparatus further comprises an electric insulation layer surrounding at least a portion of the electrical conductor layer. In some embodiments, the apparatus further comprises a thermal insulation layer surrounding at least a portion of the electric insulation layer.

Claims

1. A power cable apparatus, the apparatus comprising:

an elongated thermal conductor core,

wherein the elongated thermal conductor core consists of one of pyrolytic graphite or a plurality of carbon nanotubes (CNTs); and

an electrical conductor layer surrounding and in direct contact with at least a portion of an outer surface of the elongated thermal conductor core,

wherein heat generated in the power cable is transferred via the elongated thermal conductor core to at least one end of the power cable.

2. The apparatus of claim 1, wherein the apparatus further comprises an electric insulation layer surrounding at least a portion of the electrical conductor layer.

3. The apparatus of claim 2, wherein the electric insulation layer is manufactured from one of polyvinylchloride (PVC), fluoroethylenepropylene (FEP), and polytetrafluorethylene (TFE) teflon.

4. The apparatus of claim 2, wherein the apparatus further comprises a thermal insulation layer surrounding at least a portion of the electric insulation layer.

5. The apparatus of claim 2, wherein the apparatus further comprises a shielding layer surrounding at least a portion of the electric insulation layer.

6. The apparatus of claim 5, wherein the apparatus further comprises a second electric insulation layer surrounding at least a portion of the shielding layer.

7. The apparatus of claim 1, wherein the apparatus further comprises a second thermal conductor layer surrounding at least a portion of the electrical conductor layer.

8. The apparatus of claim 7, wherein the apparatus further comprises an electric insulation layer surrounding at least a portion of the second thermal conductor layer.

9. The apparatus of claim 8, wherein the apparatus further comprises a thermal insulation layer surrounding at least a portion of the electric insulation layer.

10. The apparatus of claim 1, wherein a shape of a cross section of the elongated thermal conductor core is one of circular, rectangular, and polygonic.

11. The apparatus of claim 1, wherein the elongated thermal conductor core is manufactured from a material that is flexible, light weight, and has a very high thermal conductivity.

12. The apparatus of claim 1, wherein the electrical conductor layer comprises one of a single solid and multiple strands.

13. The apparatus of claim 1, wherein the electrical conductor layer is manufactured from one of copper alloys;

aluminum alloys; and

a combination of copper, iron, and silver alloys.

14. The apparatus of claim 1, wherein at least one of the ends of the power cable is connected to a cooling system.

15. A system to distribute power, the system comprising:

at least one power cable, comprising;

an elongated thermal conductor core,

wherein the elongated thermal conductor core consists of one of pyrolytic graphite or a plurality of carbon nanotubes (CNTs), and

an electrical conductor layer surrounding and in direct contact with at least a portion of an outer surface of the elongated thermal conductor core,

wherein heat generated in the power cable is transferred via the elongated thermal conductor core to at least one end of the at least one power cable; and

at least one cooling system connected to at least one of the ends of the at least one power cable.

16. The system of claim 15, wherein the at least one power cable further comprises an electric insulation layer surrounding at least a portion of the electrical conductor layer.

17. The system of claim 16, wherein the at least one power cable further comprises a thermal insulation layer surrounding at least a portion of the electric insulation layer.

18. The system of claim 16, wherein the at least one power cable further comprises a shielding layer surrounding at least a portion of the electric insulation layer.

19. The system of claim 18, wherein the at least one power cable further comprises a second electric insulation layer surrounding at least a portion of the shielding layer.

20. The system of claim 15, wherein the at least one power cable further comprises a second thermal conductor layer surrounding at least a portion of the electrical conductor layer.

21. The system of claim 20, wherein the at least one power cable further comprises an electric insulation layer surrounding at least a portion of the second thermal conductor layer.

22. The system of claim 21, wherein the at least one power cable further comprises a thermal insulation layer surrounding at least a portion of the electric insulation layer.

23. A method of cooling a power cable, the method comprising:

providing, for the power cable, an elongated thermal conductor core,

wherein the elongated thermal conductor core consists of one of pyrolytic graphite or a plurality of carbon nanotubes (CNTs);

providing, for the power cable, an electrical conductor layer surrounding and in direct contact with at least a portion of an outer surface of the elongated thermal conductor core; and

transferring heat generated in the power cable via the elongated thermal conductor core to at least one end of the power cable.