High-Voltage Component With Integrated Control Electrode
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Solution Overview
Problem
Existing high-voltage electrical components, such as bushings and partitioning insulators, face challenges in manufacturing ease and operational reliability due to complex designs and susceptibility to mechanical damage, particularly during transport, assembly, and maintenance.
Innovation Solution
A coaxial electrical component with a solid polymer insulating body and a hood-shaped control electrode made from dimensionally stable solid polymer material, where the control electrode is non-detachably connected and coated with hardened electrically conductive paint, simplifying manufacturing and assembly while enhancing dielectric strength and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the control electrode is made detachable for ease of assembly, then ease of manufacture and assembly is improved, but mechanical stability and reliability deteriorate due to susceptibility to mechanical damage during transport and assembly
Solution Approach 1:
The control electrode is permanently integrated into the insulating body through co-molding, eliminating detachable connections. The insulating body and control electrode are formed as a single unified component using identical polymer material, ensuring mechanical stability while maintaining ease of manufacture through integrated production.
Solution Approach 2:
The control electrode and insulating body are made from identical polymer material with matching physical and chemical properties. This homogeneity ensures uniform mechanical behavior, thermal expansion characteristics, and electrical performance throughout the integrated structure, preventing interface failures.
2Reliability
If the control electrode is made from rigid material for dimensional stability, then operational reliability is improved, but susceptibility to mechanical damage during transport and assembly increases
Solution Approach 1:
The polymer material parameters are optimized to achieve a balance between rigidity and toughness. The material exhibits appropriate stiffness for dimensional stability during operation while maintaining sufficient ductility to absorb mechanical impacts during transport and assembly without catastrophic failure.
Solution Approach 2:
The polymer material incorporates reinforcing fillers and plasticizers to create a composite structure that provides both the dimensional stability of rigid materials and the damage resistance of tougher polymers, achieving optimal mechanical properties for both manufacturing and operation.
3Ease of manufacture
If the insulating body and control electrode are made from identical polymer material, then manufacturing simplicity is improved, but dielectric strength may be compromised
Solution Approach 1:
While the base polymer material is identical throughout, the insulating body receives an additional conductive coating on its outer surface. This creates local differentiation where the bulk material provides uniform dielectric properties and manufacturing simplicity, while the surface coating enhances electrical performance and controls electric field distribution.
4Reliability
If the control electrode is permanently integrated into the insulating body, then mechanical stability is improved, but ease of repair and replacement deteriorates
Solution Approach 1:
The entire insulating body with integrated control electrode is designed as an economical, non-critical component that can be replaced as a complete unit rather than repaired. The low cost of the polymer material and simple molding process enable replacement rather than repair, maintaining mechanical stability while accepting reduced replaceability.
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 simplifies manufacturing and assembly, increases operational reliability by preventing mechanical damage to the control electrode, and enhances dielectric strength through identical material properties of the insulating body and control electrode, ensuring high operational reliability and reduced electron escape.
Implementation Method 1
containing a solid polymer mass formed by curing a pre-formed, flowable polymer mass
Implementation Method 2
a hood-shaped control electrode electrically connected to and attached to one end of the current conductor, which controls the electric field between the current conductor and the mounting flange during operation of the system
Implementation Method 3
a coating of a hardened, electrically conductive lacquer is applied at least to the outwardly facing surface of the cap
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The electric component is designed for a high-voltage system. Said component has, in a coaxial arrangement, a conductor (10) which extends along an axis (A) and which can be maintained at high-voltage potential, a rigid insulating body (20) which is fixed to the conductor (10) and which surrounds the conductor, a mounting flange (30) which is fixed to the insulating body (20) and which can be maintained at ground potential, and a control electrode (50) which is connected to the conductor (10) in an electrically conductive manner, which is fixed to an end (12) of the conductor (10), and which is designed in the form of a hub. The insulating body (20) contains a solid polymer material (21) which is made by curing a preformed flowable polymer material. During the operation of the system, the control electrode (50) controls the electric field between the conductor (10) and the mounting flange (30). The aim of the invention is to produce the electric component in a simple manner and to increase the operating reliability of the component. This is achieved in that control electrode (50) is connected to the conductor (10) in an undetachable manner, and the control electrode has a hub (51), which is produced during the preforming and curing of the flowable polymer material, which is dimensionally stable, which is coated at least on the outside with a conductive lacquer (52), and which is made of the solid polymer material (21), or in that the control electrode (50) is designed so as to be elastically deformable and has a hub (51) which is coated with a conductive or non-conductive lacquer (52) and which is made of an elastomer plastic.