Multi-Material High-Voltage Insulator Threaded Interface

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Solution Overview

Problem

High-voltage insulators face conflicting requirements such as withstanding high voltages, mechanical stresses, and temperature cycling while maintaining vacuum compatibility, and existing solutions like epoxy or brazing introduce weaknesses or stress, leading to potential electrical breakdowns.

Innovation Solution

The design of high-voltage insulators using multiple sections of different materials, such as PEEK and MACOR, that are threaded together without epoxy or brazing, leveraging the strengths of each material to achieve high standoff voltages and flexural strength while minimizing gaps and electrical tracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If epoxy or brazing is used to join insulator sections, then the insulator can be assembled from different materials, but the joint introduces weaknesses and stress leading to potential electrical breakdowns

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidelectrical breakdown resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent removes the epoxy or brazing material from the joint interface, extracting the harmful element that caused electrical breakdowns. The sections are joined mechanically through interference fits and threaded connections alone, eliminating the weak intermediate layer that previously compromised reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces precision-machined mechanical interfaces (interference fits, threads, keyways) as intermediaries to join the insulator sections. These mechanical features serve as the mediating structure that replaces epoxy/brazing, providing both structural support and electrical isolation without creating weak points.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If a single material is used for the entire insulator, then manufacturing is simpler, but the insulator cannot simultaneously optimize for both flexural strength and electric field standoff

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidflexural strength and electric field standoff

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The insulator is divided into multiple sections, each made from materials optimized for specific functions. The first section uses material with high flexural strength for mechanical support, while the second section uses material with high electric field standoff for electrical isolation. This segmentation allows each material to be selected and manufactured independently for its optimal performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the insulator have different material properties tailored to local requirements. The region subject to mechanical loads uses high-strength material, while the region exposed to high electric fields uses high-breakdown material. This local optimization resolves the contradiction between manufacturing simplicity and performance optimization.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If multiple materials are joined together, then the insulator can satisfy conflicting requirements, but the interface between materials creates potential breakdown paths

Engineering Contradiction:

Improverequirements satisfactionVSAvoidelectrical tracking at interface

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harm of material interfaces into a benefit by designing the interface with precision mechanical features that create continuous, gap-free contact. The interference fits and threaded connections transform what could be discontinuous breakdown paths into continuous, controlled transitions between materials, eliminating the harmful effect while preserving the beneficial multi-material configuration.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent replaces the chemical bonding system (epoxy/brazing) with a mechanical bonding system (interference fits, threads, keyways). This substitution eliminates the need for intermediate bonding materials that created electrical tracking paths, using purely mechanical contact to join sections while maintaining electrical isolation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11651874B2High-voltage insulators having multiple materials

Publication Date: 2023.05.16 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

High-voltage insulators are disclosed that are capable of handling diverse requirements, such as providing high standoff voltages, high temperature cycling, and the ability to withstand flexural stress. One high-voltage insulator includes a first piece formed from a first material, a second piece formed from a second material, and an interface section where the first piece contacts with and forms a seal with the second piece. The interface includes a first groove located that accommodates a first gasket, sets of matching threads on the first and second pieces. The interface section further accommodates a second gasket. In this multi-piece high-voltage insulator, the first material can have a first set of flexural, heat resistance, and electrical standoff characteristics suitable for a first environment, and the second material can have a second set of flexural, heat resistance and electrical standoff characteristics suitable for a second environment.