Additive Manufacturing Power Bushing Condenser Core

The patent applies parameter changes by subjecting the additively manufactured insulator to elevated temperature and pressure conditions. This transforms the physical state of the material, causing the polymeric insulating material to soften and flow, which fills the porous structure and eliminates voids. The parameter change from ambient to elevated temperature and pressure resolves the contradiction by maintaining production flexibility while achieving dense, reliable insulation suitable for high-voltage applications.

The patent utilizes phase transitions of the polymeric insulating material. At elevated temperature, the polymer transitions from a rigid solid state to a softened, more fluid state, allowing it to consolidate and fill pores. This phase transition enables the insulator to achieve dense, void-free structure suitable for high-voltage insulation while retaining the manufacturing advantages of additive manufacturing.

The patent applies segmentation by dividing the manufacturing process into two distinct stages: first, additive manufacturing creates the basic insulator structure with necessary thickness; second, consolidation treatment densifies the material. This segmentation allows each process to optimize for its specific function, enabling production of thick insulators that would be difficult with single-step injection moulding.

The patent uses composite materials approach by combining additively manufactured polymeric insulating material with conducting sheets to create a condenser core. This composite structure allows the insulator to achieve both the thickness required for high-voltage applications and the manufacturing simplicity of additive manufacturing, while the consolidation process ensures adequate density.

The patent merges multiple traditional process steps into a simplified workflow. Instead of separate winding, drying, vacuum impregnation, and curing steps, the patent combines additive manufacturing with a single consolidation treatment. This merging maintains insulation quality by achieving void-free dense structure while significantly reducing production time and process complexity.

The patent extracts and eliminates unnecessary intermediate steps from the traditional manufacturing process. By using additive manufacturing to directly create the insulator structure followed by consolidation treatment, the patent removes the need for winding, drying, and vacuum impregnation steps, thereby reducing production time while maintaining insulation quality.

The patent applies this principle by using cost-effective polymeric insulating material through additive manufacturing instead of expensive polymer film. The additively manufactured insulator, when consolidated, achieves adequate density and insulation quality, providing a more economical alternative to traditional polymer film winding while maintaining necessary reliability.

The patent uses parameter changes in the consolidation process to achieve dense structure from relatively inexpensive polymeric material. By applying elevated temperature and pressure, the material properties change to achieve void-free dense insulation, making the process cost-effective compared to expensive polymer film while maintaining insulation quality.