Dual-Layer Insulation Film for Partial Discharge Erosion
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Solution Overview
Problem
High-voltage electrical apparatuses face premature dielectric breakdown due to partial discharge caused by microvoids in insulating coatings and abrupt overvoltages from inverter surges, leading to erosion and failure, with existing solutions failing to adequately address the issue while maintaining cost-effectiveness.
Innovation Solution
A laminate comprising a conductor and a dual-layer insulating coating, where the second insulating coating contains 6 to 50 parts by mass of metal oxide hydrate within a resin composition, with a thickness of 5 μm or more and less than 75% of the total coating, forming an inorganic layer upon exposure to partial discharge, thereby enhancing electrical and physical characteristics while reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal oxide hydrate is filled in an insulating coating to suppress erosion from partial discharge, then erosion suppressing effect is improved, but manufacturing costs increase
Solution Approach 1:
The insulating coating is divided into two functional layers: a first insulating coating layer providing basic insulation, and a second insulating coating layer containing metal oxide hydrate for partial discharge erosion suppression. This segmentation allows the expensive metal oxide hydrate to be used only where needed (in the second layer), rather than throughout the entire coating, thus reducing overall material costs while maintaining erosion suppression effectiveness.
Solution Approach 2:
The metal oxide hydrate is concentrated in the second insulating coating layer where it is most needed for suppressing partial discharge erosion, rather than being uniformly distributed throughout the entire insulating coating. This local concentration optimizes the erosion suppressing effect at the critical interface while reducing the total amount of expensive filler material required.
2Reliability
If the thickness of the second insulating coating is increased to improve erosion suppression, then erosion suppressing effect is improved, but the ratio of the second layer thickness to total coating thickness increases, potentially affecting other performances
Solution Approach 1:
The invention optimizes the thickness parameters of the dual-layer coating system. The second insulating coating layer is designed with a thickness of 5 μm or more to ensure adequate erosion suppression, while its thickness ratio to the total coating thickness is controlled at less than 75% to maintain proper balance of electrical and physical characteristics. This parameter optimization ensures both erosion suppression effectiveness and overall performance stability.
3Reliability
If an insulating coating is applied to prevent partial discharge, then electrical insulation is improved, but microvoids in the coating can still cause concentration of electric field and partial discharge
Solution Approach 1:
The metal oxide hydrate in the second insulating coating layer serves as a sacrificial component that preferentially erodes when exposed to partial discharge. This conversion of the harmful partial discharge energy into controlled erosion of the filler material protects the resin matrix and the conductor, transforming the damaging effect into a self-protecting mechanism that extends insulation lifetime.
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 laminate effectively suppresses partial discharge erosion, improves electrical and physical characteristics, and reduces manufacturing costs by forming an inorganic insulating layer when exposed to inverter surges, thereby extending the insulation lifetime and preventing dielectric breakdown.
Implementation Method 1
when microvoids are present between adjacent insulated electric wires or in an insulating coating, concentration of electric field may occur at that region, resulting in partial discharge
Implementation Method 2
An inorganic insulating layer is formed on the insulating coating when the laminate is exposed to partial discharge caused by inverter surges
Data Source
AI summary
Provided is a layered body comprising a conductor and an insulation film containing a metal hydroxide hydrate, wherein properties such as electrical characteristics and physical characteristics can be improved while maintaining an erosion suppressing effect against partial discharge, and manufacturing costs can be reduced. The layered body comprises at least a conductor and an insulation film, wherein: the insulation film includes a first insulation film and a second insulation film; the second insulation film is constituted by a resin composition comprising a metal oxide hydrate; in the resin composition, the content of the metal oxide hydrate is 6-50 parts by mass with respect to 100 parts by mass of the resin; the thickness of the second insulation film is 5 μm or more; the ratio of the thickness of the second insulation film is less than 75% of the thickness of the entire insulation film; and in the insulation film, an inorganic insulation layer is formed when the layered body is exposed to a partial discharge generated by an inverter surge.