Capacitor Header Insulation Structure for Fast High-Voltage Discharge
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Solution Overview
Problem
High voltage capacitors face challenges in storing charge while discharging rapidly without experiencing dielectric breakdown, as reducing inductance to facilitate quick discharge increases the risk of dielectric breakdown due to high electric field gradients.
Innovation Solution
A capacitor header design featuring live and ground output plates with non-planar insulating members and additional insulating sheets that extend beyond the output plates, creating a non-linear path and reducing inductance while maintaining high dielectric strength through interleaving surfaces and seals to prevent surface tracking and corona breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the separation between capacitor header output plates is decreased to reduce inductance, then the discharge speed is improved, but the risk of dielectric breakdown increases due to high electric field gradient
Solution Approach 1:
The patent transforms the linear separation distance between output plates into a multi-dimensional insulation path by introducing interleaved insulating members with non-planar mating surfaces. This creates a three-dimensional tortuous path that increases the effective insulation length without increasing the linear separation distance, thereby reducing inductance while preventing dielectric breakdown.
Solution Approach 2:
The non-planar mating surfaces of the insulating members create a curved, tortuous path between the output plates. This curved geometry increases the electric field path length and distributes the electric field more evenly, reducing the electric field gradient and preventing dielectric breakdown while maintaining small plate separation.
2Reliability
If the amount of dielectric material is increased to prevent dielectric breakdown, then the insulation reliability is improved, but the inductance increases which reduces discharge speed
Solution Approach 1:
The patent divides the dielectric insulation into multiple segmented insulating members with interleaved structures. This segmentation allows the insulation to be distributed in a three-dimensional tortuous path rather than a single linear layer, increasing the effective insulation length without proportionally increasing the volume of dielectric material, thereby maintaining low inductance while ensuring high insulation reliability.
3Productivity
If the separation between output plates is decreased to reduce inductance, then the discharge rate is improved, but surface tracking and corona breakdown occur due to high electric field gradient
Solution Approach 1:
The non-planar mating surfaces create a curved, tortuous path that prevents direct line-of-sight electric field lines between the output plates. This curved geometry reduces the electric field gradient at the dielectric surface, preventing surface tracking and corona breakdown while maintaining small plate separation for high discharge rate.
Solution Approach 2:
The insulating members with non-planar mating surfaces act as intermediaries between the output plates, creating a tortuous path that mediates the electric field distribution. This intermediary structure reduces the electric field gradient and prevents harmful discharge phenomena while allowing rapid discharge.
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
Enables capacitors to store charge at high voltages for extended periods and discharge rapidly without dielectric breakdown, by increasing the path length between output plates and reducing inductance while maintaining structural integrity.
Implementation Method 1
storing a large amount of charge requires all the components of a capacitor (e.g. including the capacitor header) to be well insulated from each other to avoid dielectric breakdown
Implementation Method 2
Capacitors may be charged and then discharged to provide a high voltage pulse
Implementation Method 3
discharging a capacitor quickly requires a low inductance
Data Source
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AI summary
A capacitor header (101) for coupling a voltage output from a capacitor (100), which allows the capacitor to store a large amount of charge and then discharge this as a high voltage, while reducing the risk of dielectric breakdown. The capacitor header (101) includes a live output plate (120) connected to a central live conductor (106) of the capacitor and a ground output plate (117) connected to a ground conductor of the capacitor. The capacitor header also includes first and second insulating members (108), (124), which both have non-planar mating surfaces that interleave to form a non-linear path. An insulating seal (129) is included between the non-planar mating surfaces. The capacitor header (101) also includes two sets of insulating sheets (132), (134). The sets of insulating sheets extend beyond an outer perimeter of the live output plate and the ground output plate.