Mesh Electrode Insulation Plug to Prevent Voids and Delamination
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Solution Overview
Problem
Existing voltage sensing devices in high-voltage and medium-voltage power distribution networks face issues with electrode delamination and void formation due to shrinkage of insulating material during solidification, leading to reduced reliability and increased risk of electrical discharges.
Innovation Solution
A sensored insulation plug with a deformable mesh electrode embedded in a solidified insulating material, allowing the mesh to adapt to the flow of insulating material during casting, reducing the risk of voids and delamination, and ensuring reliable voltage sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating material is solidified around the electrode, then the electrical insulation is improved, but the electrode delamination occurs due to shrinkage
Solution Approach 1:
The electrode surface is covered with a flexible conformal coating layer that can accommodate the shrinkage of the insulating material during solidification. This coating layer flexes with the shrinking material, preventing delamination between the electrode and insulating material while maintaining electrical insulation integrity.
Solution Approach 2:
A conformal coating layer is introduced as an intermediary between the electrode and the insulating material. This intermediate layer acts as a buffer that absorbs the stress caused by differential shrinkage, preventing direct delamination between the rigid electrode and the shrinking insulating material.
2Manufacturing precision
If the insulating material flows around the electrode during casting, then the void formation is reduced, but the electrode structure may be distorted
Solution Approach 1:
The conformal coating on the electrode acts as a flexible shell that allows the insulating material to flow around and under it during casting, ensuring complete filling and void-free insulation. The flexibility of the coating prevents resistance to material flow while maintaining electrode structural integrity.
Solution Approach 2:
The electrode surface is made dynamically adaptable through the conformal coating, which can deform during the casting process to accommodate material flow. This dynamic flexibility ensures the insulating material can fully surround the electrode without creating voids, while the coating returns to its original configuration after casting.
3Strength
If the mesh is made rigid for structural stability, then the mechanical strength is improved, but the void formation increases due to material flow restriction
Solution Approach 1:
The mesh structure is covered with a flexible conformal coating that allows the insulating material to flow freely around and through the mesh during casting. The coating acts as a flexible shell that prevents void formation by ensuring complete material infiltration, while the rigid mesh underneath provides the necessary mechanical strength.
Solution Approach 2:
The electrode is constructed as a composite structure combining a rigid mesh framework for mechanical strength with a flexible conformal coating layer for manufacturing adaptability. This composite design allows the rigid mesh to provide structural integrity while the flexible coating ensures complete filling during casting without void formation.
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 deformable mesh design enhances the reliability and durability of voltage sensing devices by minimizing voids and electrical discharges, maintaining accurate voltage measurement over time.
Implementation Method 1
Upon solidification and curing of the casting material, the casting material shrinks, while the embedded electrodes maintain their size
Implementation Method 2
the mesh is a deformable mesh, adapted to be deformed by insulating material in liquid state flowing around the mesh before solidification of the insulating material
Data Source
AI summary
Sensored insulation plug (1) for being inserted into a separable connector in a power distribution network comprises a plug body (140) formed by a solidified insulating material (610), and a primary capacitor (150), operable as a high-voltage capacitor in a voltage divider for sensing the elevated voltage. The primary capacitor includes a high-voltage electrode (160) for direct electrical connection to the elevated voltage. A sensing electrode (170) of a tubular shape, embedded in the plug body (140), arranged around the high-voltage electrode, comprises a deformable mesh of conductive wires forming a plurality of apertures between the wires to allow portions of the insulating material (610) on opposite sides of the mesh to be mechanically connected with each other by insulating material in the apertures while the insulating material solidifies and thereafter. A dielectric formed by a portion (180) of the insulating material (610) is arranged between the sensing electrode (170) and the high-voltage electrode (160).