3D Printed Dielectric Structure for Dry-Type Transformer Insulation
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Solution Overview
Problem
Dry-type transformers face challenges in achieving efficient and cost-effective dielectric insulation due to the complexity and high cost of manufacturing parts with complex shapes, which can lead to gaps and reduced dielectric performance, increasing the risk of power failures.
Innovation Solution
A method involving 3D printing technology to create a single-piece dielectric structure that conforms to the shape of the electric field within the transformer, using polymers or composite materials, which reduces the number of parts, eliminates gaps, and integrates cooling and mechanical support, thereby enhancing dielectric behavior and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate insulating parts are manufactured to provide dielectric structure, then dielectric insulation is achieved, but manufacturing complexity increases and gaps may form between parts
Solution Approach 1:
The patent merges multiple separate insulating parts (support blocks, horizontal insulating screens, cylindrical insulating sheets) into a single monolithic insulating body. This eliminates gaps between parts and reduces manufacturing complexity while maintaining dielectric insulation performance. The single insulating body is formed by injecting insulating material into a mold cavity that defines the complete dielectric structure.
Solution Approach 2:
The single insulating body is designed with internally integrated functional elements that correspond to the traditional separate parts. The body includes embedded support blocks, horizontal screens, and cylindrical sheets as integral components, allowing the dielectric structure to provide multiple insulation functions simultaneously without requiring separate manufactured parts.
2Reliability
If parts with complex shapes are manufactured to fit component shapes and electric fields, then dielectric behavior improves, but manufacturing costs increase significantly
Solution Approach 1:
The patent combines multiple complex-shaped insulating components into a single monolithic insulating body with a complex external shape that fits the transformer components. This single complex part is manufactured in one injection molding process, eliminating the need to manufacture and assemble multiple separate complex parts, thereby reducing manufacturing costs while maintaining optimal dielectric behavior.
Solution Approach 2:
The injection molding process parameters are optimized to produce the complex-shaped monolithic insulating body in a single step. By controlling injection pressure, temperature, and mold design, the process efficiently creates the complex geometry required for optimal dielectric performance without requiring multiple manufacturing steps or expensive secondary operations.
3Ease of manufacture
If simple-shaped parts are manufactured to reduce costs, then manufacturing costs decrease, but gaps form between parts affecting dielectric performance
Solution Approach 1:
The patent merges all insulating functions into a single monolithic insulating body with a complex external shape designed to fit the transformer components. This eliminates gaps between parts while maintaining cost-effectiveness through single-step injection molding manufacturing, resolving the contradiction between simple part shapes and dielectric performance.
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 3D printed dielectric structure improves dielectric performance by closely fitting the electric field, reduces material costs, and enhances cooling efficiency, while providing mechanical support, thus minimizing the risk of dielectric failures and optimizing transformer design.
Implementation Method 1
3D printing is thus carried out based on said 3D dielectric simulation of the electric field from which 3D geometry for the dielectric structure is designed adapted to the shape of the electric field
Data Source
AI summary
A dry-type transformer, comprises a magnetic core, at least one high voltage (HV) winding, and at least one low voltage (LV) winding inductively coupled to the magnetic core. The transformer is made by determining a shape of an electric field that is generated, 3D printing a dielectric structure shaped to conform to the determined shape of the electric field, and mounting the dielectric structure between the HV and LV windings. A dielectric barrier arrangement for electrically isolating a coil of a transformer assembly from a further coil of the transformer assembly or from a core of the transformer assembly comprises a first dielectric structure having a first cylindrical dielectric structure extending along a longitudinal axis (L).