Laminated Insulation Structure for High-Voltage Transformers
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Solution Overview
Problem
The existing laminated layer structures for insulation materials in high-voltage transformers have limited stability and contribute to the fire load, making them unsuitable for larger transformers and requiring excessive material and effort for additional layers, while current alternatives offer only temperature resistance up to 130°C.
Innovation Solution
A laminated layer structure featuring a core layer of polyester film surrounded by glass fabric and B-stage resin, where the resin is applied in a liquid state and partially polymerized, then fully polymerized during heating to form a stable glass fabric composite with reduced combustible material content, achieving high stability and temperature resistance beyond 155°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of polyester film are used to increase insulation thickness, then electrical insulation performance is improved, but mechanical stability and fire resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining glass fabric layers with polyester film layers to create a laminated structure. The glass fabric provides mechanical stability and fire resistance, while the polyester film ensures electrical insulation performance. This composite approach resolves the contradiction by integrating materials with complementary properties rather than relying solely on multiple polyester film layers.
2Reliability
If additional layers are added to increase total layer thickness, then insulation performance is improved, but manufacturing complexity and material usage increase
Solution Approach 1:
The patent segments the insulation structure into alternating layers of glass fabric and polyester film, with each layer serving a specific function. This segmentation allows for optimized thickness of each component rather than requiring excessive thickness of a single material type, thereby improving insulation performance while controlling manufacturing complexity.
3Ease of operation
If polyester fleece is used in the laminate structure, then flexibility is improved, but fire load and combustible material content increase
Solution Approach 1:
The patent extracts the polyester fleece component from the laminate structure and replaces it with glass fabric layers. This removal eliminates the harmful fire load contribution while maintaining the necessary mechanical properties through the glass fabric's inherent characteristics, thereby reducing combustible material content without sacrificing structural integrity.
4Quantity of substance
If thin-walled laminate is used for insulation barriers, then material usage is reduced, but mechanical stability and suitability for larger transformers deteriorate
Solution Approach 1:
The patent employs composite materials with glass fabric providing high mechanical strength and stability, enabling the insulation barrier to withstand the demands of larger transformers. The glass fabric-reinforced structure achieves the necessary mechanical properties with optimized material thickness, avoiding excessive material usage while ensuring suitability for high-power applications.
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 provides enhanced stability and reduced fire load, enabling the use of insulation materials in larger transformers with improved temperature resistance and mechanical strength without the need for additional adhesive tapes, facilitating easier integration and manufacturing.
Implementation Method 1
it has to be heated to a baking temperature so that the resin liquefies again starting from its B state
Implementation Method 2
The polymerisation process is started by the correspondingly high baking temperature and after the subsequent cooling process the complete polymerisation of the resin has taken place
Implementation Method 3
forms a connection with the glass fabric layer by at least partially being connected by a capillary effect sucked into the interstices
Data Source
Figure 1~2
AI summary
Laminated layer structure (10) for producing a flat insulating material, comprises sequence-area and successively arranged single layers including first resin in B-stage (12), glass fiber, core layer (38) of polyester film, glass fabric and second resin in B-stage. Independent claims are also included for: (1) an insulating material, prepared by temporary heating of a laminated layer structure at a baking temperature such that the resin is completely polymerized; and (2) a high-voltage winding with a low-voltage winding, which is arranged around a hollow cylindrical winding axis (44), with a high-voltage winding, which is a hollow cylinder disposed at a radial distance about the same winding axis, where the laminated layer structure adapted in shape is arranged in the cavity formed by the radial distance.