Epoxy Resin Composition for Transformer Insulation
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Solution Overview
Problem
Conventional epoxy resin compositions used in transformers face issues with crack resistance and heat resistance due to rapid curing reactions, which lead to increased curing time and difficulties in mold processing, and require plasticizers for crack suppression.
Innovation Solution
An epoxy resin composition incorporating a glycol-based functional group in the main chain, a filler for electrical insulation and thermal conduction, and an imidazole-based catalyst, which allows for rapid curing without the need for increased temperature or catalyst amounts, thereby reducing curing time and enhancing crack resistance without using plasticizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the curing temperature is increased to shorten the curing process, then the curing time is reduced, but a crack can be generated in the transformer due to rapid curing reaction
Solution Approach 1:
The patent changes the chemical composition parameters of the epoxy resin by incorporating glycol-based functional groups in the main chain, which fundamentally alters the curing characteristics to achieve both short curing time and crack resistance without temperature increase
Solution Approach 2:
The patent creates a composite epoxy resin system combining glycol-based functional groups with specific curing agents and imidazole-based catalysts, where the synergistic interaction enables rapid curing without the harmful effects of high temperature curing
2Loss of time
If the amount of catalyst is increased to accelerate the curing rate, then the curing time is reduced, but the gelation time is shortened causing difficulty in mold process
Solution Approach 1:
The patent changes the catalyst type parameter from conventional catalysts to imidazole-based catalysts, which provides controlled acceleration of curing rate while maintaining adequate gelation time for proper mold processing
Solution Approach 2:
The imidazole-based catalyst acts as an intermediary that mediates between the epoxy resin and curing agent, enabling controlled reaction kinetics that balance curing speed with mold processability
3Reliability
If plasticizer is added to suppress crack, then the crack resistance is improved, but the process complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for plasticizers by incorporating crack-resistance functionality directly into the epoxy resin main chain through glycol-based functional groups, simplifying the composition while maintaining or improving crack resistance
Solution Approach 2:
The glycol-based functional groups in the epoxy resin main chain serve multiple functions simultaneously: providing flexibility for crack resistance, enabling rapid curing, and maintaining heat resistance, eliminating the need for separate plasticizer additives
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 significantly shortens curing time, improves crack resistance, and maintains heat resistance, allowing for increased production efficiency and cost-effectiveness by eliminating the need for plasticizers while maintaining formability and heat resistance.
Implementation Method 1
an imidazole-based catalyst, and includes a flexible (plasticized) functional group such as a glycol-based functional group in the epoxy main chain and has a resistance to stress generated during curing, and after the temperature is increased by using the imidazole-based catalyst, a reaction rate is rapid, thereby significantly shortening the curing time
Implementation Method 2
a flexible (plasticized) functional group such as a glycol-based functional group in the epoxy main chain and has a resistance to stress generated during curing
Implementation Method 3
a filler for an electrical insulation and a thermal conduction
Data Source
AI summary
The disclosure describes an epoxy resin composition and a transformer including the same. The epoxy resin composition according to an embodiment of the present invention includes an epoxy resin having a glycol-based functional group in a main chain, a filler, a curing agent, and an imidazole-based catalyst, and the transformer according to an embodiment includes an insulated conductor wound in multiple layers in a vertical direction; a semi-conductive layer which is provided on the insulated conductor and disperses a concentrated electric field; and an insulator which is casted on the insulated conductor and the semi-conductive layer and forms an outer shape of the transformer, and the insulator consists of the epoxy resin composition including the epoxy resin having the glycol-based functional group in the main chain, the filler, the curing agent, and the imidazole-based catalyst.