Ceramic Insulator Assembly With Equipotential Layers for High Proof Voltage

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Solution Overview

Problem

Ceramic insulators for high-voltage applications face challenges in achieving required proof voltage due to the finite electric strength and buildup of discharge, particularly at voltages above 100 kV, which is addressed by using multiple short components connected with complex and costly solder methods.

Innovation Solution

A method involving axially symmetrical ceramic structural elements joined with an electrically conductive equipotential layer, where the base material for the equipotential layer is incorporated between the ceramic structural elements prior to sintering, allowing for a monolithic connection and simplified production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple short ceramic components are connected by brazing solder to achieve required proof voltage above 100 kV, then the dielectric strength is improved, but the production cost and technical complexity increase significantly

Engineering Contradiction:

Improveproof voltageVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the joining process and sintering process into a single integrated step. The green bodies of ceramic components are stacked with equipotential layers between them, and both the joining and sintering occur simultaneously in one furnace cycle, eliminating the need for separate brazing operations and reducing production complexity while maintaining vacuum tightness and electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The equipotential layers are placed between the green bodies (unsintered ceramic components) before the sintering process begins. This preliminary positioning allows the layers to be automatically integrated into the final structure during sintering, ensuring proper alignment and eliminating the need for post-assembly adjustments or complex vacuum sealing procedures.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple short ceramic components are connected by brazing solder to achieve required proof voltage, then the dielectric strength is improved, but the production cost increases

Engineering Contradiction:

Improveproof voltageVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the joining operation and sintering operation into a single process step. By stacking green bodies with equipotential layers and sintering them together in one furnace cycle, the patent eliminates the need for separate brazing equipment, materials, and quality control procedures, significantly reducing production costs while achieving the required vacuum tightness and mechanical strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The equipotential layers are made from inexpensive materials such as metal foils, metal powders, or conductive ceramics that are applied directly to the green bodies. These layers serve their purpose during sintering and become permanently integrated into the final product, eliminating the need for expensive brazing materials and complex vacuum sealing components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If a single long cylindrical insulator component is used, then the structure is simple, but the proof voltage is insufficient for high-voltage applications above 100 kV

Engineering Contradiction:

Improvestructure simplicityVSAvoidproof voltage

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent divides the insulator into multiple short ceramic components (green bodies) stacked axially, with equipotential layers between them. This segmentation allows each component to maintain adequate dielectric strength while the series arrangement of multiple components achieves the required total proof voltage for high-voltage applications above 100 kV.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces equipotential layers between the ceramic components to create equipotential surfaces that prevent electric field concentration at the joints. These conductive layers ensure uniform voltage distribution across the stacked components, allowing the insulator to withstand high voltages without breakdown at the connection points.

Inventive Principle:

Principle #12Equipotentiality

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

This approach enhances the dielectric strength and breakdown voltage of ceramic insulators while reducing production costs and technical complexity, enabling a more cost-effective and efficient high-voltage switching system.

Implementation Method 1

prior to a sintering process of said ceramic structural elements (6)

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11760068B2Ceramic insulator

Publication Date: 2023.09.19 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

Various embodiments include a method for producing a ceramic insulator for a high-voltage or medium-voltage switching system comprising: attaching a base material for an equipotential layer between two axially symmetrical ceramic structural elements; disposing the electrically conductive equipotential layer between the two ceramic structural elements; and joining the two ceramic structural elements to form a unitary body along a symmetry axis of a first of the two elements.