Polymer Transformer Spacer Structure for Moisture and Noise Control
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Solution Overview
Problem
Pressboard spacers in transformers suffer from water adsorption, deformation, and inadequate noise reduction, which affect electrical properties and operational noise levels, posing challenges in transformer design and manufacturing.
Innovation Solution
Development of spacers made from polymers with varying moduli of elasticity, incorporating regions with different mechanical properties to enhance mechanical stability, noise damping, and dielectric performance, manufactured using methods like co-extrusion, injection molding, and 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressboard spacers are used in transformers, then electrical insulation is provided, but water adsorption causes deformation and reduces reliability
Solution Approach 1:
The spacer is constructed as a composite material consisting of a pressboard core layer combined with polymer material layers (such as epoxy resin, polyimide, or PTFE). This composite structure combines the excellent electrical insulation properties of pressboard with the low water adsorption and high dimensional stability of polymers, thereby resolving the contradiction between providing electrical insulation and preventing water adsorption-induced deformation.
Solution Approach 2:
Different regions of the spacer are assigned different materials with specific properties: the pressboard core provides structural support and electrical insulation, while the polymer layers on the surfaces provide resistance to water adsorption and mechanical stability. This local differentiation of material properties allows each region to perform its specific function optimally, preventing water adsorption from causing deformation while maintaining overall spacer reliability.
2Object-generated harmful factors
If pressboard spacers are used, then mechanical support is provided, but noise reduction is inadequate
Solution Approach 1:
The composite structure of pressboard core with polymer layers creates a material with both high mechanical strength and excellent noise damping properties. The polymer materials (such as epoxy resin or polyimide) have inherent noise reduction capabilities while maintaining structural integrity, thus reducing transformer noise without compromising mechanical support strength.
Solution Approach 2:
The spacer utilizes materials with different mechanical parameters - the pressboard provides high compressive strength while the polymer layers provide damping characteristics. By changing the material parameters (selecting polymers with appropriate damping coefficients) while maintaining the overall structural strength, the spacer achieves both mechanical support and noise reduction functions simultaneously.
3Object-generated harmful factors
If polymer spacers with varying moduli are used, then noise damping is improved, but manufacturing complexity increases
Solution Approach 1:
The spacer is segmented into distinct functional layers: a pressboard core layer and outer polymer material layers. Each layer has a specific modulus of elasticity optimized for its function - the pressboard core provides structural support while the polymer layers provide noise damping. This segmentation allows for optimized noise damping performance while maintaining a relatively simple laminated structure that is manufacturable using conventional composite material techniques.
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 polymer spacers provide improved mechanical stability, reduced noise levels, and enhanced dielectric properties, eliminating the need for lengthy drying processes and improving transformer performance.
Implementation Method 1
the at least one first region and the at least one second region differ in their mechanical properties, like elasticity, hardness and/or damping against vibrations
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
In at least one embodiment, the spacer (1) is for a highvoltage transformer (10) and comprises a first material (41) which is a polymer. The spacer (1) is, for example, of sheetshape, and comprises a first region (21) and a second region (22), the first region (21) has a higher modulus of elasticity than the second region (22).