High-Voltage Conductor Connection Element with Paper Insulation

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Solution Overview

Problem

In high-voltage electrical devices like transformers and choke coils, existing connection elements face challenges in minimizing space requirements while maintaining effective insulation and geometric compactness, especially with increasing operating voltages, such as from 500 kV to 750 kV in HVDC transformers.

Innovation Solution

A connection element with a metallic electrode having a hollow space for conductor alignment, surrounded by paper insulation, and additional pressboard insulation elements, which allows for compact design and enhanced insulation by subdividing the oil volume, reducing the risk of strong electric fields through rounded openings and smooth surfaces, and using shielding pipes for conductor stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional connection elements are used for connecting at least four electrical conductors, then the insulation capability is sufficient for lower voltages, but the space requirements become excessive and insulation capability is insufficient for high operating voltages (750 kV)

Engineering Contradiction:

Improveinsulation capabilityVSAvoidspace requirement

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent applies nesting by placing multiple conductors (at least four) inside a single hollow connection element, with each conductor surrounded by its own insulation layer. The conductors are arranged concentrically or radially within the hollow space, allowing compact integration of multiple electrical connections in one component while maintaining adequate insulation distances for high voltages up to 750 kV.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from planar/linear arrangement of conductors to a three-dimensional hollow spherical or cylindrical structure. Conductors are positioned in different spatial dimensions (radial directions) from a common center point, enabling compact space utilization while maintaining sufficient insulation distances through the third dimension (radial distance from center and angular separation).

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If the connection element is designed with sharp corners and edges to simplify manufacturing, then manufacturing is easier, but strong electric fields are generated requiring larger distances between components

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstrong electric fields

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent specifies that the connection element should have a hollow spherical or cylindrical shape with rounded surfaces and edges instead of sharp corners. This curvature eliminates concentration points for electric fields, reducing the risk of electrical breakdown and allowing more compact design while maintaining safety for high voltage operations up to 750 kV.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If additional insulation elements are added to improve insulation capability, then insulation capability increases, but device complexity increases

Engineering Contradiction:

Improveinsulation capabilityVSAvoidnumber of insulation elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple insulation functions into integrated insulation layers that surround each conductor and extend to the inner surface of the hollow connection element. The insulation structure is merged with the connection element itself, forming a unified component rather than separate assembled parts, thereby achieving high insulation capability while minimizing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hollow connection element serves multiple functions simultaneously: it provides mechanical support for multiple conductors, acts as a common insulation barrier, defines the geometric arrangement of conductors, and provides electrical isolation between conductors and surrounding components. This multi-functionality reduces the need for separate dedicated insulation elements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enables a space-saving, high-insulation-capability connection of multiple conductors, reducing the risk of electric field strong points and edges, and increasing the stability and insulation of the connection, allowing for efficient operation at higher voltages with minimal space usage.

Implementation Method 1

At least the outer surface of the electrode is surrounded by a paper insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

additional pressboard insulation elements, which allows for compact design and enhanced insulation by subdividing the oil volume

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9859701B2Connection of at least four electric conductors

Publication Date: 2018.01.02 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A connection element for electrically conductive connections of at least four electric conductors. The connection element has a metallic electrode which has a cavity for merging the conductors and an opening into the cavity for each conductor. At least the outer surface of the electrode is surrounded with a paper insulation.