Electrical apparatus

Abstract

An electrical apparatus that includes a cable connected to a transmission optimizer and configured to conduct a current for matching a desired power output. The cable includes at least one insulated conductor core including an innermost insulating layer disposed around the outside of a conducting layer having carbon fiber or graphite fiber as a conductor core. The cable is a single core cable having a single insulated conductor core or a multi-core cable having multiple single insulated conductor cores.

Claims

1. An electrical apparatus for conducting a current for matching a desired power output, the electrical apparatus comprising: a cable including at least one insulated conductor core, the insulated conductor core including: a conductor core including a conducting layer including carbon fiber or graphite fiber, and an insulating polymeric material disposed around an outside of the conductor core; and a transmission optimizer connected to the cable, the transmission optimizer being a transformer device that provides an adjustable voltage and current to the cable so that the cable provides the desired power output.

2. The electrical apparatus according to claim 1, wherein the cable has an electro-resistance per unit length of below 40 ?/m.

3. The electrical apparatus according to claim 1, wherein the carbon fiber or graphite fiber have filaments arranged in a bundle, extending side-by-side.

4. The electrical apparatus according to claim 1, wherein the carbon fiber or graphite fiber has a specific gravity of 1.1 to 2.2 and a tensile strength of 690 MPa to 6.2 GPa, the carbon fiber or graphite fiber being derived from carbonization of man-made fiber, coal tar, and petroleum pitch.

5. The electrical apparatus according to claim 1, wherein the conductor core includes a combination of the carbon fibre or graphite fibre with metal wire, the metal wire having a specific gravity of 2.5 to 9 and a tensile strength of 89 MPa to 1.3 GPa.

6. The electrical apparatus according to claim 1, wherein the conductor core includes the carbon fibre or graphite fibre and fibre optics.

7. The electrical apparatus according to claim 1, wherein the conductor core includes the carbon fibre or graphite fibre, metal wire, and fibre optics.

8. The electrical apparatus according to claim 1, further comprising: a transmitter connected to a first end of the cable and configured to convert a coded electric or electronic pulse to an equivalent coded light pulse; and a conversion device connected to a second end of the cable and configured to convert the coded light pulse back to an equivalent coded electrical or electronic pulse, wherein the conductor core includes fibre optics for transmitting the coded light pulse.

9. The electrical apparatus according to claim 1, wherein the insulating polymeric material has a break down voltage of at least 18 KV/mm at 20? C.

10. The electrical apparatus according to claim 1, wherein the cable includes a shielding layer formed with metal tape or wire-braid disposed around an outside of the insulated conductor core.

11. The electrical apparatus according to claim 1, wherein the cable includes a shielding layer disposed around the outside of the conductor core, the shielding layer formed with a semi-conductive polymeric material having a resistivity in the range of 10 ?.Math.m to 100 M?.Math.m at 15? C.

12. The electrical apparatus according to claim 1, wherein the cable includes a shielding layer disposed around an outside of the insulated conductor core and formed by yarn-braid or tape derived from carbon fibre or graphite fibre.

13. The electrical apparatus according to claim 1, wherein the cable includes an outer insulating layer disposed around an outside of the insulated conductor core, the outer insulating layer being a flame retardant polymeric material having a breakdown voltage of at least 18 KV/mm at 20? C. to protect the cable against damage from weathering and mechanical exposures.

14. The electrical apparatus according to claim 1, wherein the cable includes a reinforcement layer disposed around an outside of the insulated conductor core, the reinforcement layer being yarn-braid or tape derived from man-made fibers and glass fibre.

15. The electrical apparatus according to claim 1, wherein the cable includes an outermost layer that forms a protecting and shielding layer, the outermost layer being metal wire-braid.

16. The electrical apparatus according to claim 1, wherein the insulated conductor core does not include a reinforcement layer, a protecting layer, and a shielding layer.

17. The electrical apparatus according to claim 1, wherein the cable is a single-core cable that includes a single insulated conductor core.

18. The electrical apparatus according to claim 1, wherein the cable is a multi-core cable that includes a plurality of the insulated conductor core, the multi-core cable including from 2 to 100 of the insulated conductor cores.

19. The electrical apparatus according to claim 18, wherein the cable includes an insulating layer disposed around an outside of the plurality of the insulated conductor cores in a form of inner jacketing.

20. The electrical apparatus according to claim 18, wherein from two to eight of the plurality of the insulated conductor cores are loaded together with a wrapping layer to form a group, the wrapping layer including a screen material and a binder tape.

21. The electrical apparatus according to claim 1, wherein the cable includes a plurality of the insulated conductor core, the conductor cores of the plurality including the carbon fibre or graphite fibre and at least one of metal wire and fibre optics.

22. The electrical apparatus according to claim 1, wherein the carbon fibre is derived from the carbonization of the man-made fibers of cellulose, rayon, and homopolymer and copolymer of polyacrylonitrile.

23. The electrical apparatus according to claim 1, wherein the electrical apparatus is configured to conduct current ranging from 0.01 mA to 800 A at voltages ranging from 12V to 140 KV for matching the desired power output.

24. The electrical apparatus according to claim 1, wherein the desired power output includes transmissions of power, signal, and data.

25. A cable for conducting a current for matching a desired power output, the cable having a low electro-resistance of below 40 ?/m, the cable comprising: at least one insulated conductor core, and the insulated conductor core including: a conductor core including an electrically conducting material that includes carbon fibre or graphite fibre, an innermost insulating layer disposed around an outside of the conductor core, the innermost insulating layer including an insulating polymeric material having a breakdown voltage of at least 18 KV/mm at 20? C.; an inner insulating layer that forms an inner jacketing by including a polymeric material having a breakdown voltage of at least 18 KV/mm at (20? C.) and disposed around the outside of the insulated conductor core; and an outer insulating layer that forms an outer jacketing by being a flame retardant insulating polymeric material to protect the cable against damages from weathering and mechanical exposures, wherein the cable is configured to conduct current ranging from 0.01 mA to 800 A at voltages ranging from 12V to 140 KV.

26. The cable according to claim 25, wherein the inner insulating layer and the outer insulating layer to form a single insulating layer by insulating polymeric material having a breakdown voltage of at least 18 KV/mm at 20? C.

27. The cable according to claim 25, wherein the desirable power output is achieved by connecting one end of the cable to a transmission optimizer.

28. The cable according to claim 25, further comprising: a shielding layer disposed around the outside of the insulated conductor core, and the shielding layer is in a form of metal tape or metal wire-braid.

29. The cable according to claim 25, further comprising: a protecting and shielding layer disposed around the outside of the outer insulating layer, the protecting and shielding layer being a metal wire-braid.

30. The cable according to claim 25, further comprising: a protecting layer disposed around an outside of the outer insulating layer, the protecting layer being a yarn-braid derived from man-made fibers and glass fibre.

31. The cable according to claim 25, further comprising: a plurality of the insulated conductor core, an outside of the plurality of the insulated conductor cores being surrounded by the inner insulating layer.

32. The cable according to claim 31, further comprising: a central strength member in a form of a solid core; and a cable filling compound including polymeric material and filament yarns, the cable filling compound being disposed inside the inner insulating layer to fill gaps in between the plurality of the insulated conductor core to improve the dimension stability of the plurality of the insulated conductor core.

33. The electrical apparatus according to claim 25, wherein the desired power output includes transmissions of power, signal, and data.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Specific embodiments of the invention will now be described by way of examples only and with reference to the accompanying drawings and its modifications, in which:

(2) FIG. 1 is a schematic view of an electrical apparatus that embodies this invention.

(3) FIG. 2 is a diagrammatic view showing the composition of a first exemplary cable of the electrical apparatus; and

(4) FIG. 3 is a diagrammatic view showing the composition of a second exemplary cable; and

(5) FIG. 4 is a diagrammatic view showing the composition of a third exemplary cable; and

(6) FIG. 5 is a diagrammatic view showing the composition of a fourth exemplary cable; and

(7) FIG. 6 is a diagrammatic view showing the composition of a fifth exemplary cable; and

(8) FIG. 7 is a diagrammatic view showing the composition of a sixth exemplary cable; and

(9) FIG. 8 is a diagrammatic view showing the composition of a seventh exemplary cable; and

(10) FIG. 9 is a diagrammatic view showing the composition of a eighth exemplary cable; and

(11) FIG. 10 is a diagrammatic view showing the composition of a ninth exemplary cable; and

(12) FIG. 11 is a diagrammatic view showing the composition of a tenth exemplary cable.

DETAIL DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(13) FIG. 1 shows an electrical apparatus (100) that is a first embodiment of this invention. The electrical apparatus (100) is used for the transmission of power, data and signal under a voltage ranges from 12V to 140 KV. There are several components that go to make up the electrical apparatus (100). These include at least a transmission optimizer (20) and a cable (500). In general the electrical apparatus (100) is arranged with an input end of the transmission optimizer (20) being connected to a source of power supply (18) using a conventional electric cable (19), and the output end and/or the cable (19) being connected to a cable (500). The cable (500) includes a single insulated conductor core to form a single-core cable (300). The cable (500) includes multiple numbers of insulated conductor core to form a multi-core cable (400). The cable (500) conducts a current in the range of 0.01 mA to 800 A under the electrical voltage ranges from 12V to 140 KV and or matching a desirable power output for the transmission of power (P), data (D) and signal (S). The transmission optimizer (20) is an electrical device to provide an adjustable electrical voltage and or current for the cable (500) to conduct the required determinable electric current so as to match the desirable power output from the source of power supply (18) for the transmission of power, data and signal. The cable (500) has an end connected to a transmitter (22, and the other end connecting to conversion device (24). The transmitter (22) is used to convert the coded electrical or electronic pulse to an equivalent coded light pulse, and the conversion unit (24) is used to convert the coded light pulse back to an equivalent coded electrical or electronic pulse. The transmitter (22) and the conversion device (24) are optional components of the electrical apparatus (100). The transmitter (22) and conversion device (24) are incorporated when the cable (500) having a conductor core composition that requires light pulse for the transmission of data and signal.

(14) The cable (500) includes a single conductor core to form a single-core cable (300).

(15) The cable (500) includes multiple numbers of single conductor core to form a multi-core cable (400).

(16) FIG. 2 to FIG. 8 shows the exemplary cables of the cable (500) having a single insulated conductor core in forms of a single-core cable (300).

(17) FIG. 9 to FIG. 11 shows the exemplary cables of the cable (500) having multiple numbers of single insulated conductor core in forms of a multi-core cable (400).

(18) FIG. 2 shows the first exemplary cable (310) of the cable (500) or (300). The cable (310) includes an innermost insulating layer (220) disposed around the outside of the conductor core (210). An outer insulating layer (240) disposes around the outside of the innermost insulating layer (220). The conductor core (210) includes carbon fibre or graphite fibre having filaments arranged in a bundle extending side-by-side. The conductor core has a low electro-resistance of below 40 ?/m. Depending on the cable specification requirement, metal wire and fibre optics can be added to modify the composition of the conductor core (210). The innermost insulating layer (220) and the outer insulating layer (240) are formed with insulating polymeric material having a breakdown voltage (20? C.) of at least 18 KV/mm, for example, with composition being derived from polyvinyl, polyolefins, EPR and silicone rubber. The choice of the insulating composition depends on the cable application requirement including electrical voltage, temperature, and environmental condition.

(19) FIG. 3 shows the second exemplary cable (320) of the cable (500) or (300). The cable (320) includes a single insulating layer (220) or (240) disposed around the outside of the conductor core (210), formed by a single extrusion.

(20) FIG. 4 shows the third exemplary cable (330) of the cable (500) or (300). The cable (330) has a similar composition as the cable (320), and with an addition of a shielding layer of a semi-conductive polymeric material (232) disposed in between the conductor core (210) and the insulating layer (220) or (240). The shielding layer (232) includes a semi-conductive polymeric material having a resistivity in the range of 10 ?.Math.m to 100 M?.Math.m at 15? C., for example, with semi-conductive composition being derived from polyolefins and silicone rubber.

(21) The structural design of the cable (330) can be modified with the outer insulating layer (240) disposed around the outside of the innermost insulating layer (220), formed by a double extrusion.

(22) FIG. 5 shows the fourth exemplary cable (340) of the cable (500) or (300). The cable (340) includes an innermost insulating (220) disposed around the outside of the conductor core (210), and including a shielding layer (230) or (232) disposed in between the innermost insulating layer (220) and the outer insulating layer (240). The shielding layer (230) includes metal wire-braid and metal tape, for examples, steel wire-braid and copper tape, other metals can also be considered. The carbon fibre or graphite fibre can also be used as a shielding layer (230) in forms of yarn-braid and tape.

(23) FIG. 6 shows the fifth exemplary cable (350) of the cable (500) or (300). The cable (350) includes an innermost insulating layer (220) disposed around the outside of the conductor core (210), and including a reinforcement layer (250) disposed in between the innermost insulating layer (220) and the outer insulating layer (240). The reinforcement layer (250) is in a form of yarn-braid with those yarn filaments being derived from man-made fibres and glass fibre. Glass fibre is chosen for its incombustible property.

(24) The structural design of the cable (350) can be modified with incorporating a shielding layer (230) and or (232) disposed in between the innermost insulating layer (220) and the reinforcement layer (250).

(25) The structural design of the cable (350) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the reinforcement layer (250) and the outer insulating layer (240).

(26) FIG. 7 shows the sixth exemplary cable (360) of the cable (500) or (300). The cable (360) includes a shielding layer (232) disposed around the outside of the conductor core. An innermost insulating layer (220) disposes around the outside of the shielding layer (232), and including a reinforcement layer (250) disposed in between the innermost insulating layer (220) and the outer insulating layer (240).

(27) The structural design of the cable (360) can be modified by taking out the outer insulating layer (240).

(28) The structural design of the cable (360) can be modified by taking out the innermost insulating layer (220).

(29) The structural design of the cable (360) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the innermost insulating layer (220) and the reinforcement layer (250).

(30) The structural design of the cable (360) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the reinforcement layer (250) and the outer insulating layer (240).

(31) FIG. 8 shows the seventh exemplary cable (370) of the cable (500) or (300). The cable (370) has a similar composition as the cable (360) with the exception of using a shielding layer (230) and or (230) to replace the reinforcement layer (250).

(32) The structural design of the cable (370) can be modified by incorporating a reinforcement layer (250) disposed in between the shielding layer (232) and the innermost insulating layer (220).

(33) The structural design of the cable (370) can be modified by incorporating a reinforcement layer (250) disposed in between the shielding layer (230) or (232) and the outer insulating layer (240).

(34) FIG. 9 to FIG. 11 shows the exemplary cables of the cable (500) having multiple numbers (n) of insulated conductor core (305) to form a multi-core cable (400). The conductor cores of the multiple numbers (n) can have the same composition including carbon fibre or graphite fibre. The conductor cores of the multiple numbers (n) can have different compositions. The conductor cores of the multiple numbers (n) include carbon fibre or graphite fibre, metal wire, fibre optics, and combinations for the transmission of power, data and signal. The multiple numbers (n) are in the range of 2 (two) to 100 (one hundred), most preferably below 5 (five) for general purpose application, and most preferable below 60 (sixty) for heavy duty application. A certain number in the range of 2 (two) to 8 (eight) of the multiple numbers of the insulated conductor core can be loaded together to form as a group by a wrapping layer (260) with a screen material and or a binder tape. Most preferably below 5 (five) insulated conductor cores (305) form as a group. The wrapping layer (260) includes a screen material of aluminum-polyester in tape form, and or a binder tape being fabricated from thermoplastic material for example polyester. The wrapping layer (260) is optional depending on the cable specification requirement. The insulated conductor core (305) can have similar compositions as the exemplary cables of the cable (300). Most preferably the insulated conductor core (305) has similar composition as the cable (310), (320) and (330).

(35) FIG. 9 shows the eighth exemplary cable (410) of the cable (500) or (400). The cable (410) includes an insulating layer of inner jacketing (225) disposed around the outside of a wrapping layer (260) surrounding multiple numbers (n) of insulated conductor core (305), and including a reinforcement layer (250) disposed in between the inner jacketing (225) and an insulating layer of outer jacketing (240). The inner jacketing (225) and outer jacketing (240) form with insulating polymeric material having a breakdown voltage (20? C.) of at least 18 KV/mm, for example, with composition being derived from polyvinyl, polyolefins, EPR and silicone rubber.

(36) The structural design of the cable (410) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the inner jacketing (225) and the reinforcement layer (250).

(37) The structural design of the cable (410) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the wrapping layer (260) and the inner jacketing (225).

(38) The structural design of the cable (410) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the reinforcement layer (250) and the outer jacketing (240).

(39) The structural design of the cable (410) can be modified by replacing the inner jacketing (225) with a shielding layer (230) and or (232).

(40) The structural design of the cable (410) can be modified by taking out the outer jacketing (240).

(41) FIG. 10 shows the ninth exemplary cable (420) of the cable (500) or (400). The cable (420) includes an inner jacketing (225) disposed around the outside of a wrapping layer (260) surrounding the outside of multiple numbers of insulated conductor core (305), and including a shielding layer (230) and or (232) disposed in between the inner jacketing (225) and the outer jacketing (240).

(42) The structural design of the cable (420) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the wrapping layer (260) and the inner jacketing (225).

(43) The structural design of the cable (420) can be modified by taking out the inner jacketing (225).

(44) The structural design of the cable (420) can be modified by taking out the outer jacketing (240).

(45) FIG. 11 shows the tenth exemplary cable (430) of the cable (500) or (400). The cable (430) has similar composition as the cable (410) and the cable (420), but in the absence of the reinforcement layer and the shielding layer respectively.

(46) The structural design of the cable (430) can be modified by combining the inner jacketing (225) and the outer jacketing (240) to form a single insulating layer (225) or (240).

(47) The structural design of the cable (430) can be modified by incorporating a shielding layer (230) and or (232) disposed in between the wrapping layer (260) and the inner jacketing (225).

(48) The structural design of the cable (430) can be modified by replacing the inner jacketing (225) with a shielding layer (230) and or (232).

(49) The structural design of the cable (430) can be modified by incorporating a reinforcement layer (250) disposed in between the wrapping layer (260) and the inner jacketing (225).

(50) With continued reference to FIG. 9 to FIG. 11, an optional composition including a central strength member and cable filling compound can be considered for the multi-core cable (400). The optional composition disposes to fill the gaps in between the multiple numbers (n) of the insulated conductor core (305) to improve dimensional stability of the multiple numbers (n) of the insulated conductor core (305). The central strength member includes metal wire, thermoplastics and thermosetting rubber compound in a form of solid core. The cable filling compound includes thermoplastics, thermoplastic elastomers, thermosetting rubber and or filament yarns.

(51) With continued reference to FIG. 2 to FIG. 11, the conductor core (210) of the cable (500) forms from at least partly from an electrically conducting material that includes carbon fibre or graphite fibre having filaments being arranged in a bundle extending side-by-side. Metal wire and or fibre optics can be incorporated as an additional composition of the conductor core for the transmission of power, data and signal. Copper and aluminum are typical metal wire conductor. The shielding layer (230), (232) and the reinforcement layer (250) are optional depending on the cable specification requirement. Certain cable specification may require cable design having at least one shielding layer. Certain cable specification may require cable design having at least one reinforcement layer. Certain cable specification may require cable design having a combination of shielding layer and reinforcement layer. A further optional protecting layer disposes around the outside of the outer insulating layers (240) and (240) including a yarn-braid with yarn filaments being derived from man-made fibres and glass fibre. Glass fibre is chosen for its incombustible property. Another optional protecting and shielding layer disposes around the outside of the outer insulating layer in a form of metal wire-braid. Steel wire-braid is chosen for its high tensile property. The cable (400) includes a single insulating layer of (225) or (240) disposed around the outside of the multiple numbers of the insulated conductor core when the wrapping layer (260), the shielding layer (230), (232) and the reinforcement layer (250) are absent. The single insulating layer being formed by single extrusion of polymeric material having a voltage breakdown (20? C.) of at least 18 KV/mm.

(52) The cable (400) includes an outer jacketing (240) and an inner jacketing (225) disposed around the outside of the multiple numbers of the insulated conductor core when the wrapping layer (260), the shielding layer (230), (232) and the reinforcement layer (250) are absent.