Dry HV Instrument Transformer Insulation With PES-Epoxy Composite
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Solution Overview
Problem
Existing dry high voltage instrument transformers require a large volume of expensive compressible silicone gel for insulation, increasing production costs and the risk of defects due to the extensive use of insulating material.
Innovation Solution
The use of an insulating composite made of PES nonwoven impregnated with low viscosity epoxy reduces the need for compressible silicone insulation, enhancing insulation reliability and dielectric strength while minimizing material costs and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large volume of compressible silicone gel is used for insulation, then the dielectric insulation between high potential and ground potential elements is improved, but the production cost increases and the risk of defects formation increases
Solution Approach 1:
The patent changes the physical and chemical parameters of the insulating material by using PES nonwoven fabric impregnated with epoxy resin instead of compressible silicone gel. This material substitution fundamentally alters the insulation approach, providing equivalent or superior dielectric strength while requiring significantly less material volume, thereby reducing both quantity and cost.
Solution Approach 2:
The patent employs a composite insulating structure consisting of PES nonwoven fabric combined with epoxy resin. This composite material provides enhanced mechanical strength, void-free construction, and superior dielectric properties compared to homogeneous silicone gel insulation, allowing reduced material quantity while maintaining or improving insulation reliability.
2Strength
If the surfaces of metallic elements are coated with high dielectric strength coating, then the dielectric strength of the insulation system is improved, but the production cost and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the need for separate high dielectric strength coatings on metallic elements by using the PES nonwoven fabric impregnated with epoxy resin as the primary insulation barrier. This material inherently provides sufficient dielectric strength, making additional coatings unnecessary and thereby reducing device complexity and production cost.
3Reliability
If compressible silicone gel insulation is used, then electrical insulation is provided, but the amount of material needed is large and expensive
Solution Approach 1:
The patent changes the material parameters by substituting compressible silicone gel with PES nonwoven fabric impregnated with epoxy resin. This material change enables achieving the same electrical insulation performance with significantly reduced material volume, directly addressing the contradiction between insulation reliability and material quantity.
Solution Approach 2:
The use of composite PES nonwoven fabric and epoxy resin creates a structurally efficient insulation system that provides equivalent electrical insulation with reduced volume compared to compressible silicone gel, thereby resolving the contradiction between maintaining insulation reliability and reducing material quantity.
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 PES nonwoven composite insulation provides reliable, void-free, and crack-free insulation with higher dielectric strength, reducing the amount of compressible silicone material needed, thus lowering production costs and dimensions of the transformers.
Implementation Method 1
The insulation comprises an insulating composite containing an electrically insulating material made of PES nonwoven impregnated and cured with low viscosity epoxy
Data Source
AI summary
A dry high voltage (HV) instrument transformer in the form of a HV current transformer includes a core casing having a secondary winding, a top housing, a primary winding, and a dry bushing, wherein the core casing comprises an insulation containing an electrically insulating material made of PES nonwoven impregnated and cured with low viscosity epoxy. The dry HV instrument transformer in the form of a HV voltage transformer includes a bottom tank housing, a cast of a primary winding module with an embedded screen surrounding the primary winding, a field grading disc, and a core, wherein the cast of the primary winding module is made of an insulating composite containing an electrically insulating material made of PES nonwoven impregnated and cured with low viscosity epoxy.