Insulation Tape Spacer Particles Impregnation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electrical insulation systems in high-voltage machines are prone to defects during the impregnation process, leading to partial discharges and reduced service life due to incomplete resin saturation, which can cause 'treeing' channels and electrical breakdowns.
Innovation Solution
An electrical insulation tape with increased porosity, achieved by incorporating spacer particles that enhance impregnation, ensuring complete resin saturation and reducing defects, thereby extending the service life of high-voltage machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical insulation tape is impregnated with impregnating resin in a trough, then the electrical conductor is insulated, but defects form that are not saturated with resin leading to partial discharges
Solution Approach 1:
The electrical insulation tape is designed with controlled porosity to enable capillary absorption of impregnating resin. The porous structure allows the resin to penetrate deeply and uniformly into the tape material, ensuring complete saturation and eliminating voids that would otherwise cause partial discharges and insulation failures.
Solution Approach 2:
The porosity parameter of the electrical insulation tape is optimized to balance resin absorption efficiency and electrical insulation performance. By controlling the pore size distribution and total porosity, the tape achieves optimal impregnation while maintaining its dielectric properties and mechanical strength.
2Strength
If the electrical insulation tape has low porosity, then mechanical strength is maintained, but impregnation with resin is incomplete leading to defects
Solution Approach 1:
The tape utilizes a porous structure with carefully controlled characteristics that facilitate resin penetration while preserving mechanical integrity. The pore network allows efficient impregnation without creating weak points, and the pore walls provide structural support that maintains strength despite the increased porosity.
Solution Approach 2:
The electrical insulation tape is constructed as a composite material system combining porous substrate material with impregnating resin. This composite structure leverages the porous framework for resin absorption and distribution, while the resin fills the pores to create a unified structure that achieves both good impregnation and maintained mechanical strength.
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 increased porosity of the insulation tape allows for efficient impregnation, reducing personnel and process costs, preventing partial discharges, and enhancing the durability of the electrical insulation system by eliminating defects and potential delamination sites.
Implementation Method 1
The electrical insulation tape according to the invention has an increased porosity in the area of the spacer particles
Implementation Method 2
the electrical insulation tape is first wound around the electrical conductor and then impregnated with an impregnating resin. For impregnation, the electrical conductor wrapped with the electrical insulation tape is, for example, saturated with the impregnating resin in a trough
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electrical insulation tape (9) for a high-voltage electrical machine (10), comprising a particle composite (13b) that can be impregnated, which has a plurality of platelet-shaped electrical insulation particles (8), and comprising first spacing particles (7a), which are applied to the surface of the electrical insulation tape (9) such that the porosity of the electrical insulation tape (9) is higher in the region of the first spacing particles (7a) than in the region of the particle composite (13b) that can be impregnated.