Mechanism of influence of different flight altitudes on insulation breakdown performance of ETFE aviation cables

LI Lili; LI Yuzhe; LI Xiaokun; FU Lei; WANG Yulong; HAN Shuang; GAO Junguo

doi:10.7498/aps.74.20250932

Abstract

By studying the breakdown performance of ethylene-tetrafluoroethylene (ETFE) copolymer under low pressure via molecular dynamics simulations, and verifying the simulation results through low-pressure breakdown experiments, the insulation failure mechanism of ETFE materials under low pressure can be revealed on an atomic scale. First, molecular dynamics simulations are performed on ETFE. As the flight altitude gradually increases from 0 km to 24 km, the simulated pressure decreases from 101.300 kPa to 2.951 kPa. Correspondingly, the intermolecular distance increases by 9.692%, the interchain interaction energy decreases by 8.383%, the free volume fraction of ETFE increases by 62.586%, and the density of ETFE decreases by 7.737%. Subsequently, based on the electromechanical breakdown theory, it is deduced that the breakdown field strength of ETFE decreases by 17.626%. Finally, the low-pressure breakdown experiment shows that the breakdown field strength decreases by 40.078%, and the density measurement test indicates that the density decreases by 1.574%. Both simulation and experimental results confirm that the breakdown field strength of ETFE decreases with the reduction of pressure. This is because under low-pressure conditions, the increase in free volume fraction and the decrease in density provide a longer mean free path for free electrons. And the decrease in charge trap level weakens the charge trapping capability, leading to a higher concentration of free electrons. All these factors contribute to the reduction of the breakdown field strength of ETFE. This study provides performance prediction and failure mechanism analysis for the application of ETFE in aerospace and high-altitude extreme environments, and has guiding significance for the optimal design of aerospace insulation ETFE materials.

Keywords:

Authors and contacts

1.
Key Laboratory of Engineering Dielectrics and its Applications, Ministry of Education, State Key Laboratory of High-Efficiency Special Cable Technology, College of Electrical and Electronic Engineering, Harbin University of Science and Technology, Harbin 150080, China
2.
Shenfei Wire Harness Technology Co., Ltd., Shenyang 110035, China
3.
Shenyang Aircraft Design and Research Institute, Aviation Industry Corporation of China, Ltd., Shenyang 110035, China

Corresponding author: WANG Yulong, wangyulong@hrbust.edu.cn

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References

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[2]	Ahmad J, Niasar M J 2025 J. Appl. Polym. Sci. 142 27 Google Scholar
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[4]	Shahsavarian T, Li C, Baferani M A, Ronzello J, Cao Y, Wu X, Zhang D 2021 IEEE Trans. Dielectr. Electr. Insul. 28 231 Google Scholar
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Cited By

图 1 ETFE不同飞行高度下的性能研究

Figure 1. Performance study of ETFE at different flight altitudes.

DownLoad: Full-Size Img PowerPoint

图 2 ETFE模型　(a) ETFE单体模型; (b) 分子链模型; (c) ETFE聚合物模型

Figure 2. ETFE model: (a) ETFE monomer model; (b) molecular chain model; (c) ETFE polymer model.

DownLoad: Full-Size Img PowerPoint

图 3 ETFE分子动力学模拟的温度变化曲线

Figure 3. Temperature variation curve of ETFE molecular dynamics simulation.

DownLoad: Full-Size Img PowerPoint

图 4 ETFE分子动力学模拟的能量变化曲线

Figure 4. Energy variation curves of ETFE molecular dynamics simulation.

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图 5 ETFE分子动力学模拟的密度变化曲线

Figure 5. Density variation curve of ETFE molecular dynamics simulation.

DownLoad: Full-Size Img PowerPoint

图 6 不同飞行高度下ETFE分子动力学模拟平衡状态模型　(a) 0 km; (b) 7 km; (c) 10 km; (d) 14 km; (e) 17 km; (f) 24 km

Figure 6. Equilibrium state model of ETFE molecular dynamics simulation at different flight altitudes: (a) 0 km; (b) 7 km; (c) 10 km; (d) 14 km; (e) 17 km; (f) 24 km.

DownLoad: Full-Size Img PowerPoint

图 7 在ETFE中通过标记不同链H和F测量分子间距离

Figure 7. Intermolecular distances are measured in ETFE by labeling different chains H and F.

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图 8 ETFE分子间距离对应的RDF图

Figure 8. RDF graph corresponding to intermolecular distance of ETFE.

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图 9 ETFE的分子间相互作用能随飞行高度的变化

Figure 9. Variation of intermolecular interaction energy of ETFE with flight altitude.

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图 10 ETFE的相对介电常数随飞行高度的变化

Figure 10. Variation of the relative dielectric constant of ETFE with flight altitude.

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图 11 ETFE的自由体积分数随飞行高度的变化

Figure 11. Variation of the free volume fraction of ETFE with flight altitude.

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图 12 不同飞行高度下ETFE模型的自由体积变化　(a) 飞行高度0 km; (b) 飞行高度7 km; (c) 飞行高度10 km; (d) 飞行高度14 km; (e) 飞行高度17 km; (f) 飞行高度24 km

Figure 12. Variation of free volume of ETFE model at different flight altitudes: (a) 0 km; (b) 7 km; (c) 10 km; (d) 14 km; (e) 17 km; (f) 24 km.

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图 13 ETFE的密度随飞行高度的变化

Figure 13. Variation of the density of ETFE with flight altitude.

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图 14 ETFE的电荷陷阱能级随飞行高度的变化

Figure 14. Variation of the charge trap energy level of ETFE with flight altitude.

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图 15 不同气压下ETFE的击穿场强和杨氏模量

Figure 15. Breakdown field strength and Young’s modulus of ETFE at different air pressures.

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图 16 变气压击穿实验装置接线图

Figure 16. Wiring diagram of the variable pressure breakdown experimental setup.

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图 17 不同飞行高度下ETFE击穿场强的Weibull累积概率分布

Figure 17. Weibull cumulative probability distribution of ETFE breakdown field strength at different flight altitudes.

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表 1 不同飞行高度对应的气压值

Table 1. Barometric pressure values at different flight altitudes.

高度/km 气压值/kPa

0 101.300
7 41.150
10 26.520
14 14.190
17 8.857
24 2.951

DownLoad: CSV

表 2 不同飞行高度下ETFE平衡状态的动能和密度的变化率

Table 2. Rate of change of kinetic energy and density of ETFE in equilibrium state under different flight altitudes.

飞行高度/km 动能变化率/% 密度变化率/%

0 3.887 3.334
7 4.623 4.054
10 3.448 4.111
14 3.030 4.225
17 3.311 4.286
24 3.367 3.497

DownLoad: CSV

表 3 不同飞行高度下ETFE分子间距离

Table 3. Intermolecular distance of ETFE at different flight altitudes.

飞行高度/km 分子间距离/Å

0 5.675
7 5.775
10 5.825
14 5.975
17 6.075
24 6.225

DownLoad: CSV

表 4 不同飞行高度下ETFE的密度变化

Table 4. ETFE density measurement test at different flight altitudes.

高度/km 密度/(g·cm^–3)

0 1.715
7 1.703
10 1.707
14 1.703
17 1.692
24 1.688

DownLoad: CSV

map

[1]	Yuan L J, Zheng X, Zhu W B, Wang B, Chen Y Y, Xing Y Q 2024 Polymers 16 316 Google Scholar
[2]	Ahmad J, Niasar M J 2025 J. Appl. Polym. Sci. 142 27 Google Scholar
[3]	Riba J R, Moreno-Eguilaz M, Ibrayemov T, Boizieau M 2022 Materials 15 1677 Google Scholar
[4]	Shahsavarian T, Li C, Baferani M A, Ronzello J, Cao Y, Wu X, Zhang D 2021 IEEE Trans. Dielectr. Electr. Insul. 28 231 Google Scholar
[5]	Shahsavarian T, Li C, Baferani M A, Cao Y 2020 IEEE Conference on Electrical Insulation and Dielectric Phenomena East Rutherford, USA, October 18–30, 2020 p271
[6]	Bas-Calopa P, Riba J R, Moreno-Eguilaz M 2024 Proc. IEEE Int. Instrum. Meas. Technol. Conf. Glasgow, United Kingdom, May 20–23, 2024 p1
[7]	Anoy S, Mona G 2024 IEEE J. Emerg. Sel. Top. Power Electron. 13 4521 Google Scholar
[8]	Al Otmi M, Willmore F, Sampath J 2023 Macromolecules 56 9042 Google Scholar
[9]	Guo G, Zhang J, Chen X, Zhao X, Deng J, Zhang G 2022 Comput. Mater. Sci. 212 111571 Google Scholar
[10]	Tamir E, Sidess A, Srebnik S 2019 Chem. Eng. Sci. 205 332 Google Scholar
[11]	李丽丽, 韩爽, 王玉龙, 刘统江, 李育哲, 高俊国 2025 74 127702 Google Scholar Li L L, Han S, Wang Y L, Liu T J, Li Y Z, Gao J G 2025 Acta Phys. Sin. 74 127702 Google Scholar
[12]	Wang J M, Cieplak P, Li J, Wang J, Cai Q, Hsieh M, Lei H X, Luo R, Duan Y 2011 J. Phys. Chem. B 115 3100 Google Scholar
[13]	von Milczewski J, Tolsma J R 2021 Phys. Rev. B 104 125111 Google Scholar
[14]	Israelachvili J N 2011 Intermolecular and surface forces (Academic Press) p108
[15]	Mazo M, Balabaev N, Alentiev A, Yampolskii Y 2018 Macromolecules 51 1398 Google Scholar
[16]	Sharma S K, Pujari P K 2017 Prog. Polym. Sci. 75 31 Google Scholar
[17]	Wong C P J, Choi P 2024 Phys. Fluids 36 033120 Google Scholar
[18]	Pacułt J, Rams-Baron M, Chrząszcz B, Jachowicz R, Paluch M 2018 Mol. Pharm. 15 2807 Google Scholar
[19]	李亚莎, 夏宇, 刘世冲, 瞿聪 2022 71 052101 Google Scholar Li Y S, Xia Y, Liu S C, Qu C 2022 Acta Phys. Sin. 71 052101 Google Scholar
[20]	宋小凡, 闵道敏, 高梓巍, 王泊心, 郝予涛, 高景晖, 钟力生 2024 73 027301 Google Scholar Song X F, Min D M, Gao Z W, Wang P X, Hao Y T, Gao J H, Zhong L S 2024 Acta Phys. Sin. 73 027301 Google Scholar
[21]	Tang X X, Ding C L, Yu S Q, Zhong C, Luo H, Chen S 2024 Small 20 2306034 Google Scholar
[22]	Konstantinou K, Elliott S R 2023 Phys. Status Solidi RRL 17 8 Google Scholar
[23]	Welwang W, Takada T, Tanaka Y, Li S T 2017 IEEE Trans. Dielectr. Electr. Insul. 24 3144 Google Scholar
[24]	He G H, Luo H, Yan C F, Wan Y T, Wu D, Luo H, Liu Y, Chen S 2024 Energy Environ. Mater. 7 e12577 Google Scholar
[25]	Yang K R, Chen W J, Zhao Y S, He Y, Chen X, Du B, Yang W, Song Z, Fu Y F 2021 ACS Appl. Mater. Interfaces. 13 25850 Google Scholar
[26]	威廉H. 哈伊特著 (赵彦珍译) 2013 工程电磁场 (西安交通大学出版社) 第63页 Hayt W H (translated by Zhao Y Z) 2013 Engineering Electromagnetics (Xi’an Jiaotong University Press) p63
[27]	冯阳, 张硕, 周彬, 刘培焱, 杨心如, 李盛涛 2025 74 087701 Google Scholar Feng Y, Zhang S, Zhou B, Liu P Y, Yang X R, Li S T 2025 Acta Phys. Sin. 74 087701 Google Scholar
[28]	Paleti S H K, Kim Y, Kimpel J, Craighero M, Haraguchi S, Müller C 2024 Chem. Soc. Rev. 53 1702 Google Scholar
[29]	徐芝纶 2006 弹性力学(北京: 高等教育出版社) Xu Z L 2006 Theory of Elasticity (Beijing: Higher Education Press
[30]	Deng F K, Wei J H, Xu Y D, Lin Z Q, Lü X, Wan Y J, Sun R, Wong C P, Hu Y 2023 Nano-Micro Lett. 15 106 Google Scholar
[31]	虞健祥, 梁华琳, 杨轶钧, 明星 2025 74 077102 Google Scholar Yu J X, Liang H L, Yang Y J, Ming X 2025 Acta Phys. Sin. 74 077102 Google Scholar
[32]	韦昭召 2025 74 036201 Google Scholar Wei Z Z 2025 Acta Phys. Sin. 74 036201 Google Scholar
[33]	Hill A J, Thornton A W, Hannink R H J, Moon J D, Freeman B D 2020 Corros. Eng. Sci. Technol. 55 145 Google Scholar
[34]	Cao Y Y, Cao W H, Yang X, Liu C X, Qi X W 2021 Polym. Adv. Technol. 33 146 Google Scholar
[35]	陈季丹, 刘子玉 1982 电介质物理学 (北京: 机械工业出版社) 第312页 Chen J D, Liu Z Y 1982 Physics of Dielectrics (Beijing: China Machine Press) p312
[36]	Stark S 2022 J. Eur. Ceram. Soc. 42 462 Google Scholar
[37]	Xing Z L, Gu Z L, Zhang C, Guo S W, Cui H Z, Lei Q Q, Li G C 2022 Energies 15 4412 Google Scholar
[38]	Kantar E, Eie-Klusmeier K K, Ve T A, Ese M H, Hvidsten S 2024 IEEE Trans. Dielectr. Electr. Insul. 32 416 Google Scholar
[39]	Sima W, Yin Z, Sun P T, Li L C, Shao Q Q, Yuan T, Yang M 2020 IEEE Trans. Dielectr. Electr. Insul. 27 2014 Google Scholar
[40]	Fica-Contreras S M, Li Z, Alamri A, Charnay A P, Pan J, Wu C, Lockwood J R, Yassin O, Shukla S, Sotzing G A, Cao Y, Fayer M D 2023 Mater. Today. 67 57 Google Scholar
[41]	Zhang M R, Zhu B F, Zhang X, Liu Z X, Wei X Y, Zhang Z C 2023 Mater. Horiz. 10 2455 Google Scholar
[42]	Min D M, Yan C Y, Mi R, Cui H Z, Li Y W, Wang W W, Fréchette M F, Li S T 2018 IEEE Nanotechnol. Mag. 12 15 Google Scholar
[43]	Wang J, Shen Z H, Liu R L, Shen Y, Chen L Q, Liu H X, Chen N W 2023 Adv. Sci. 10 2300320 Google Scholar

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