Electrical Bushing Molded Conductive Polymer Screen
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Solution Overview
Problem
Existing electrical bushings experience voltage stress and partial discharge when power lines pass through grounded planes, which prior art solutions have not adequately addressed, leading to suboptimal performance below the extinction levels specified in industry standards.
Innovation Solution
An electrical bushing design featuring a conductive polymer screen with a molded insulating body, where the screen's first region is embedded within the insulating body and its second region extends outward as an exterior flange, mitigating voltage stress and partial discharge by shaping the electrical field and providing external grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power lines pass through grounded planes at the bushing, then connection and disconnection of power lines is enabled, but voltage stress and partial discharge occur in the bushing
Solution Approach 1:
A conductive screen is introduced as an intermediary element between the power line and the grounded plane. The screen is embedded in the insulating body and extends beyond it, creating a gradual transition zone that mediates the electric field distribution. This intermediary structure prevents direct contact between high voltage and ground, thereby reducing voltage stress and partial discharge while maintaining connection capability.
Solution Approach 2:
The conductive screen extends in multiple dimensions - it is embedded within the insulating body in the internal dimension and protrudes outward in the external dimension. This multi-dimensional configuration allows the screen to influence the electric field in both internal and external regions, effectively managing voltage stress without compromising the connection function.
2Reliability
If conductive coatings and insulating geometries are added to prevent voltage stress and partial discharge, then electrical performance improves, but device complexity increases
Solution Approach 1:
The conductive screen and insulating body are merged into a single integrated structure through injection molding. The screen is embedded within the insulating body during the molding process, creating a unified component that combines both conductive and insulating functions. This merging eliminates the need for separate coatings or additional insulating layers, thereby improving electrical performance without significantly increasing device complexity.
Solution Approach 2:
The bushing employs a composite structure combining conductive material (screen) and insulating material (insulating body) in a single component. This composite approach allows the structure to simultaneously provide electrical conductivity for field management and electrical insulation for protection, achieving improved reliability without the complexity of multiple separate components or layers.
3Object-affected harmful factors
If a conductive screen is embedded in the insulating body to shape the electrical field, then voltage stress is reduced, but manufacturing complexity increases
Solution Approach 1:
The conductive screen is prepared and positioned in advance within the mold cavity before the insulating body material is injected. This preliminary placement ensures the screen is correctly positioned to shape the electrical field, and the subsequent injection molding process automatically embeds it in the correct location, reducing the need for post-manufacturing assembly steps.
Solution Approach 2:
The traditional mechanical assembly of embedding a conductive screen into an insulating body is replaced by an injection molding process. The liquid insulating material is injected around the pre-positioned screen and cures to form the integrated structure, eliminating the need for separate mechanical embedding operations and reducing manufacturing complexity.
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 proposed bushing design significantly reduces voltage stress and partial discharge, achieving a 400% improvement in partial discharge extinction voltage, exceeding industry standards and ensuring reliable performance under higher voltage conditions.
Implementation Method 1
the screen's first region is embedded within the insulating body and its second region extends outward as an exterior flange, mitigating voltage stress and partial discharge by shaping the electrical field
Implementation Method 2
the conductive polymer screen with a molded insulating body, where the screen's first region is embedded within the insulating body and its second region extends outward as an exterior flange, mitigating voltage stress and partial discharge
Data Source
AI summary
An electrical bushing is provided that includes a conductor, a conductive polymer screen, and an insulating body. The conductive polymer screen has a first region and a second region. The insulating body is molded over at least a portion of the conductor and is molded over the first region of the screen. The second region of the screen extends outward from the insulating body to define an exterior flange.