Boehmite Alumina Resin Composition for Partial-Discharge Resistance
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Solution Overview
Problem
Current methods for inhibiting partial discharge in insulators are insufficient, particularly at high voltages, as they either fail to address thermal degradation, ozone formation, or have uneven filler dispersion, leading to incomplete protection against insulator deterioration.
Innovation Solution
A partial discharge-resistant electrical insulating resin composition comprising boehmite alumina and a resin, where the boehmite alumina is pre-gelled to enhance dispersion and provide superior thermal management and barrier effects, effectively inhibiting all causes of insulator deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spherical silica particles or layered silicate are used as fillers, then the barrier effect against partial discharge is improved, but thermal degradation and ozone formation caused by partial discharge cannot be inhibited
Solution Approach 1:
The patent combines multiple filler types (spherical silica particles, layered silicate, and metal hydroxide) into a single composite filling system. This merging allows the composition to simultaneously achieve the barrier effect from silica and silicate while gaining thermal management capabilities from the metal hydroxide, thereby addressing both partial discharge resistance and thermal degradation prevention
Solution Approach 2:
The patent creates a composite filling system comprising spherical silica particles, layered silicate, and metal hydroxide in specific proportions. This composite approach integrates the advantageous properties of each filler type: the barrier effect of silica and silicate with the thermal management and ozone suppression capabilities of metal hydroxide, providing comprehensive protection against multiple deterioration mechanisms
2Object-affected harmful factors
If metal hydroxide is used as filler to release water and reduce heat generation, then thermal degradation is inhibited, but the barrier effect is smaller and particle dispersion is uneven
Solution Approach 1:
The patent assigns different functional roles to different filler components based on their local properties: spherical silica particles provide barrier effect at the interface, layered silicate enhances barrier properties, and metal hydroxide provides thermal management. This local quality differentiation allows each component to optimize its specific function while working together as a unified system
Solution Approach 2:
The patent carefully controls the particle size distribution and proportion of each filler component to optimize both dispersion and barrier effect. By adjusting parameters such as particle size, shape, and relative content, the composition achieves uniform dispersion while maintaining effective barrier properties and thermal management capabilities
3Manufacturing precision
If very fine filler particles are used to improve dispersion, then particle distribution is enhanced, but aggregation still occurs and sufficient effect is not achieved
Solution Approach 1:
The patent divides the filling system into multiple segments with different functions: spherical silica particles for primary barrier effect, layered silicate for enhanced barrier properties, and metal hydroxide for thermal management. This segmentation allows each component to be optimized independently for its specific function while preventing aggregation through functional differentiation
Solution Approach 2:
The patent uses a silane coupling agent as an intermediary substance to improve the interfacial adhesion between filler particles and the resin matrix. This intermediary prevents aggregation of fine filler particles by providing compatible surface chemistry, ensuring uniform dispersion while maintaining the effectiveness of each filler component
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition significantly extends the lifetime of insulating materials by effectively managing thermal energy and suppressing ozone formation, providing comprehensive protection against partial discharge-induced degradation.
Implementation Method 1
a metal hydroxide has a barrier effect smaller than that of the spherical silica particles disclosed in Patent Literature 1 or the layered silicate disclosed in Non Patent Literature 1, and hence, is less effective against the cause 1). In particular, when the voltage is high, these methods fail to sufficiently inhibit deterioration of an insulator due to partial discharge.
Implementation Method 2
it is known that cleavage of the main chain of a resin due to partial discharge can be inhibited by dispersing a filler into the resin (referred to as a 'barrier effect')
Implementation Method 3
the boehmite alumina is pre-gelled to enhance dispersion and provide superior thermal management and barrier effects
Data Source
Figure 1~3
Figure 4~5
AI summary
An object of the present invention is to provide an improved partial discharge-resistant electrical insulating resin composition that can inhibit deterioration of an insulator due to partial discharge. The partial discharge-resistant electrical insulating resin composition of the present invention comprises boehmite alumina and a resin.