Insulating Paper Paint Immersion Process for Transformer Coils
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Solution Overview
Problem
Existing insulating paper used in transformer coils becomes damp during winding, leading to reduced electrical performance due to the lack of insulating paint, and applying multiple layers results in incomplete paint immersion.
Innovation Solution
A paint immersing process where insulating paper is dried and then immersed or sprayed with solvent-free epoxy or polyamide paint, ensuring uniform coverage and adhesion, allowing for direct use as an insulator without additional coating steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulating paper is used without insulating paint, then the production process is simpler, but the insulating paper becomes damp during winding resulting in reduced electrical performance
Solution Approach 1:
The insulating paper is pre-coated with insulating paint before the winding process. This preliminary action ensures that the paper maintains its insulating properties during coil winding, eliminating the need for post-winding paint application and avoiding dampness issues without complicating the overall production process.
Solution Approach 2:
The patent combines the insulating paper and insulating paint into a single integrated component. The paint is uniformly coated on the paper surface, creating a composite structure that functions as both structural support and electrical insulator, thereby maintaining reliability while simplifying the manufacturing process by eliminating separate painting steps.
2Reliability
If multiple layers of insulating paper are used to cover the conductor, then the insulation coverage is improved, but the insulating paint fails to completely immerse into each layer
Solution Approach 1:
Each layer of insulating paper is pre-coated with insulating paint before being wound around the conductor. This preliminary coating ensures that every layer, regardless of how many layers are stacked, has complete and uniform paint coverage from the outset, eliminating the immersion completeness issue that occurs when trying to paint stacked layers after winding.
Solution Approach 2:
The patent divides the coating process into separate stages for each layer. Instead of attempting to immerse paint through multiple stacked layers simultaneously, each layer is individually coated before assembly, ensuring complete paint penetration and uniform coverage on every layer while maintaining good electrical insulation performance.
3Reliability
If insulating paper is dried after winding the coil, then the paper can be painted, but additional paint application steps are required increasing process complexity
Solution Approach 1:
The insulating paper is coated with insulating paint before the drying and winding processes. This preliminary coating eliminates the need for subsequent paint application steps after coil assembly, reducing process complexity while ensuring the paper is protected from dampness and maintains its insulating properties throughout the winding and drying operations.
Solution Approach 2:
The patent merges the coating operation with the paper preparation stage, combining multiple functions (insulation protection, dampness prevention, and surface treatment) into a single pre-coating step. This integration eliminates the need for separate drying and painting operations after winding, thereby simplifying the overall manufacturing process while maintaining reliable insulation protection.
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 process simplifies the production by ensuring stable insulation and adhesion, maintaining electrical and mechanical properties without the need for additional paint application after winding, thus enhancing the insulating paper's performance and efficiency.
Implementation Method 1
taking out the base band of the insulating paper to dry at controlled temperature till solidifying the insulating paint and the base band of the insulating paper
Implementation Method 2
the insulating paint has a certain adhesive property, the structure of conductor with the insulating paper becomes more stable
Data Source
AI summary
The invention provides a paint immersing process for insulating paper, comprising the following steps: step 1, adding insulating paint in a container to blend paint; step 2, drying a base band of the insulating paper; step 3, entirely immersing the processed base band of the insulating paper into the insulating paint; or spraying the insulating paint onto the base band to cover the surface thereof; and step 4, taking out the base band to dry at controlled temperature till solidifying the insulating paint and the base band of the insulating paper. The paint immersing process is simple and practical to operate. The base band can directly cover a conductor as an insulator. As the insulating paint has a certain adhesive property, the structure of conductor with the insulating paper becomes more stable. After the conductor is wound into a coil, free of another immersing process, simplifying production.