High Voltage Bushing Solid Dielectric Structure
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Solution Overview
Problem
Conventional high voltage bushings require time-consuming and costly impregnation processes using oil or resin, which can lead to voids and increase the risk of partial discharge and treeing, affecting the electrical and mechanical properties of the device.
Innovation Solution
The use of non-impregnatable electrically insulating films bonded together to form a solid dielectric part, eliminating the need for impregnation and reducing voids, with electrodes bonded to the films during the manufacturing process to enhance field grading and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impregnation processes using oil or resin are used, then the dielectric part achieves electrical insulation, but the manufacturing time increases and voids are formed
Solution Approach 1:
The patent extracts and eliminates the impregnation process entirely from the manufacturing method. Instead of using oil or resin impregnation to achieve electrical insulation, the invention uses pre-formed turns of non-impregnatable insulating film that inherently provide the necessary insulation properties, thereby removing the time-consuming impregnation step while maintaining electrical insulation reliability
Solution Approach 2:
The insulating film is prepared and formed into turns before being applied to the electrodes. This preliminary formation of the dielectric structure with pre-defined insulation properties eliminates the need for subsequent impregnation processes, reducing manufacturing time while ensuring reliable electrical insulation from the outset
2Reliability
If impregnation processes using oil or resin are used, then the dielectric part achieves electrical insulation, but voids are formed increasing the risk of partial discharge and treeing
Solution Approach 1:
The invention extracts and removes the source of void formation by eliminating the impregnation process. The non-impregnatable insulating film is applied in a controlled manner that prevents void formation, thereby maintaining electrical insulation reliability while eliminating the harmful effects of voids, partial discharge, and treeing associated with traditional impregnation methods
Solution Approach 2:
The patent changes the fundamental parameter of the insulating material from impregnatable (oil or resin) to non-impregnatable insulating film. This parameter change fundamentally alters the manufacturing process, eliminating void formation while maintaining the necessary electrical insulation properties and preventing partial discharge and treeing
3Productivity
If non-impregnatable insulating film is used, then manufacturing time is reduced, but bonding strength between turns must be ensured
Solution Approach 1:
The bonding process is initiated during the formation of each turn, before the next turn is applied. This preliminary bonding action ensures that each turn is securely attached to the previous turn and electrodes, maintaining structural integrity while enabling continuous manufacturing without time-consuming post-bonding operations
Solution Approach 2:
The manufacturing process maintains continuous useful action by performing bonding operations during the turn formation process itself. This eliminates idle time between steps and ensures continuous production flow while maintaining adequate bonding strength through ongoing bonding operations as each turn is applied
4Stability of the object's composition
If electrodes are bonded to turns during manufacturing, then mechanical stability is enhanced, but process complexity increases
Solution Approach 1:
The patent merges multiple operations into a single integrated process: turn formation, electrode positioning, and bonding are combined into one continuous manufacturing step. This consolidation enhances mechanical stability through proper electrode-turn bonding while avoiding the increased complexity that would result from separate sequential operations
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
This approach reduces manufacturing time and costs, improves the precision of field grading, and enhances the dielectric strength and mechanical properties of the device, allowing for smaller diameter designs that are more efficient and environmentally friendly.
Implementation Method 1
the bonding can for example be performed by use of surface plasma activation
Data Source
AI summary
The method relates to an electric device comprising at least two electrodes which are separated by dielectric part. At least one of said electrodes is arranged to be at a floating potential. The dielectric part comprises at least one turn of at least one non-impregnatable electrically insulating film between two neighboring electrodes. The electrodes are bonded to adjacent turns of non-impregnatable insulating film, and adjacent turns of non-impregnatable insulating film, if any, are bonded to each other, so that the turns of non-impregnatable insulating film and the electrodes form a solid body. The invention further relates to a method of manufacturing an electric device, where bonding of at least one turn is performed upon forming of said turn, so that the bonding of said turn to the turn/electrode underneath will commence before said turn has been completely covered by the next turn.