Non-porous Composite Transformer Insulation for Moisture Resistance
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Solution Overview
Problem
Cellulose-based insulating materials in electrical transformers are prone to moisture issues, leading to thermal degradation, axial imbalance, and unreliability at high temperatures, as they absorb moisture and cannot withstand continuous operation above 105°C.
Innovation Solution
A non-porous composite material comprising a resin matrix with up to 85% insulating fibers, which has a maximum moisture content of less than 0.5% and is resistant to high temperatures, providing mechanical strength and resilience through fiber reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cellulose-based insulating material is used, then the material is cheap and easy to handle, but it absorbs moisture and cannot withstand high temperatures above 105°C
Solution Approach 1:
The patent applies composite materials by combining cellulose fibers with synthetic polymer materials to create a hybrid insulating material. This composite structure allows the material to maintain the ease of handling properties of cellulose while gaining moisture resistance and high-temperature withstand capability from the synthetic polymer component, directly resolving the contradiction between ease of manufacture and reliability
2Reliability
If cellulose-based insulating material is used, then the material provides adequate insulation, but it undergoes thermal deterioration at high temperatures
Solution Approach 1:
The patent uses composite materials combining cellulose fibers with heat-resistant synthetic polymers. The cellulose provides insulation performance while the synthetic polymer matrix contributes thermal stability, allowing the composite to withstand temperatures above 105°C without thermal deterioration, thus resolving the contradiction between insulation performance and thermal stability
3Quantity of substance
If cellulose insulator absorbs moisture, then moisture content increases, but this leads to rapid ageing and dielectric problems
Solution Approach 1:
The patent applies the extraction principle by removing the moisture-absorbing characteristic from the insulating material through the use of hydrophobic synthetic polymer materials. These materials inherently resist moisture absorption, thereby extracting the harmful moisture uptake property from the traditional cellulose-based system while maintaining insulating functionality, thus resolving the contradiction between moisture content and operational reliability
4Stability of the object's composition
If spacers shrink due to moisture, then axial imbalance of windings occurs, but this leads to higher short circuit forces
Solution Approach 1:
The patent employs composite materials where hydrophobic synthetic polymers replace moisture-prone cellulose in spacer construction. This composite approach ensures dimensional stability by preventing moisture-induced shrinkage, thereby maintaining proper winding alignment and reducing short circuit forces, resolving the contradiction between dimensional stability and force reduction
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 composite material prevents moisture absorption, reduces thermal degradation, and maintains structural integrity at high temperatures, ensuring reliable operation and reduced compressibility, making it suitable for various transformer components like spacers and winding tables.
Implementation Method 1
an essentially non-porous composite material comprising a resin matrix and up to 85% by weight of insulating fibres surrounded by the resin matrix
Data Source
AI summary
The present invention relates to an electrical transformer comprising an electrical insulator and a winding of an electrical conductor around a core, said insulator being formed of an essentially non-porous composite material comprising a resin matrix and up to 85% by weight of insulating fibres surrounded by the resin matrix, the composite material having a maximum moisture content of less than 0.5% by weight at 23° C. and 50% relative humidity.