Polymer-Coated Active Components for Clean-Air High-Voltage Insulation
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Solution Overview
Problem
High-voltage devices using SF6 as an insulating gas face environmental harm and high costs, while clean air alternatives require costly configurations for high dielectric strength and compact designs.
Innovation Solution
Coating active components in high-voltage devices with polymers such as PTFE, PCTFE, or polyolefins to provide electrical insulation, allowing the use of clean air or synthetic air at low gas pressures and compact structures without arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If SF6 gas is used as insulating medium, then dielectric strength is improved, but environmental harm and cost increase
Solution Approach 1:
A polymer coating layer is introduced as an intermediary between the active component and the insulating gas. This coating has high dielectric strength and prevents electric arcing, allowing the use of environmentally friendly insulating gases (clean air, synthetic air, or low-GWP gases) instead of SF6, thereby resolving the contradiction between dielectric strength and environmental harm
Solution Approach 2:
The invention uses a composite structure combining polymer coating material with alternative insulating gas. The polymer coating (such as PTFE, PCTFE, or polyolefin) provides enhanced dielectric strength at the component surface, while the alternative gas provides bulk insulation, together achieving SF6-level performance without environmental damage
2Object-affected harmful factors
If clean air is used as insulating gas, then environmental friendliness is improved, but dielectric strength deteriorates
Solution Approach 1:
The polymer coating acts as an intermediary that enhances the dielectric strength of clean air. By providing a surface layer with high breakdown voltage resistance, it compensates for the lower dielectric strength of clean air compared to SF6, enabling safe operation at high voltages with environmentally friendly gas
3Reliability
If polymer coating is applied to active components, then dielectric strength is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes the surface parameter of active components by applying a polymer coating. This modification is achieved through established coating techniques (dip coating, spray coating, or extrusion) that are relatively simple and cost-effective, adding minimal manufacturing complexity while dramatically improving dielectric strength and preventing arcing
4Volume of moving object
If high voltage levels are achieved with alternative gases, then compact design is improved, but risk of electric arcing increases
Solution Approach 1:
The polymer coating serves as a protective intermediary on active components, preventing electric arcing in compact high-voltage devices using alternative gases. It creates a high-dielectric-strength surface that eliminates arcing risks, enabling compact designs with clean air or synthetic air at high voltage levels
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
Prevents electric arcing and component damage, enabling cost-effective high voltage operation with environmentally friendly gases and reducing material usage.
Implementation Method 1
The at least one active component is coated with at least one polymer... allows for electrical insulation of the at least one active component with respect to other components... prevents electric arcing during operation
Data Source
AI summary
The invention relates to a high-voltage device (1), in particular a measuring transducer, with an encapsulating housing (2) and with at least one active component (3), which is arranged in the encapsulating housing (2). The at least one active component (3) is coated with at least one polymer (4). A method according to the invention for increasing the dielectric strength in a high-voltage device (1) involves at least one active component (3), which is arranged in an encapsulating housing (2), in particular filled with clean air (6), being coated with at least one polymer (4), in particular by shrink-fitting a shrink tube and/or by immersion-bath coating and/or by spray coating, wherein the polymer (4) is applied in particular as polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), polyolefin and/or an ethylenetetrafluoroethylene copolymer (ETFE).