3D-Printed Electrical Insulators With Graded Field and Strength
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Solution Overview
Problem
Electrical power devices, such as those used in gas insulated switchgear, face challenges in achieving suitable electrical insulation and mechanical support while withstanding mechanical stresses and pressure differences, particularly in high voltage and current applications, where conventional manufacturing methods limit the complexity and effectiveness of field control and mechanical strength.
Innovation Solution
The method employs additive manufacturing techniques to create electrical power devices with tailored electrical and mechanical properties by determining target spatial distributions of physical properties through simulation and forming subsequent parts with varying materials to achieve desired electrical field patterns and mechanical strengths, using techniques like 3D printing to create parts that are at least partially in contact with initial parts or formed independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing methods (molding, vacuum casting, APG) are used to produce electrical power devices, then the production process is relatively simple and cost-effective, but the ability to achieve complex spatial distributions of electrical and mechanical properties is limited
Solution Approach 1:
The patent applies local quality by enabling different regions of the electrical power device to have different material compositions and properties. Through additive manufacturing, the system can vary the compounding ratio of insulating materials locally to achieve specific electrical field grading patterns and mechanical strength distributions in different spatial zones, rather than using uniform materials throughout the entire device.
Solution Approach 2:
The patent utilizes composite materials by combining multiple insulating materials with different properties in varying ratios. The additive manufacturing process allows for the creation of multi-material composites where the compounding ratio can be adjusted during fabrication to achieve desired electrical and mechanical property distributions within the same component.
2Strength
If the electrical power device is designed to withstand great mechanical stresses and provide gas-tight mechanical support, then the mechanical strength is improved, but the electrical insulation performance may be compromised due to material and design constraints
Solution Approach 1:
The patent applies local quality by assigning different material properties to different regions of the device. Areas requiring high mechanical strength (such as load-bearing structures) use materials optimized for mechanical performance, while areas requiring electrical insulation use materials with superior dielectric properties. This spatial differentiation allows both mechanical and electrical requirements to be satisfied simultaneously in their respective zones.
Solution Approach 2:
The patent uses composite materials to combine the advantages of different insulating materials. By creating composite structures with materials having complementary properties (one optimized for mechanical strength, another for electrical insulation), the device achieves both high mechanical strength for gas-tight support and reliable electrical insulation performance.
3Reliability
If additive manufacturing is used to create parts with tailored physical properties, then the electrical field grading and mechanical strength are enhanced, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent applies preliminary action by performing simulation and determination of target spatial distributions of physical properties before the actual additive manufacturing process. This pre-planning allows for optimization of the manufacturing path and material deposition strategy, reducing unnecessary iterations and improving manufacturing efficiency while maintaining the enhanced electrical field grading and mechanical strength benefits.
Data Source
AI summary
A method for producing an electrical power device from subsequently manufactured parts by an additive manufacturing technique includes determining a target spatial distribution of a physical property of the electrical power device, the physical property being an electrical property and/or a mechanical property; forming a part of the electrical power device; selecting a physical property of a subsequent part of the electrical power device corresponding to the determined spatial distribution of the physical property such as to be different from a corresponding physical property of the part; and by means of the additive manufacturing technique, forming the subsequent part such that it is at least partially in contact with the part.An electrical power device is obtainable by the method, and the electrical power device may be used as an AC or DC insulator in an HVAC or HVDC apparatus.