Selective 3D Printed Insulation for High Voltage Components
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Solution Overview
Problem
The existing methods for producing high-voltage insulation for electrical components, particularly for use in space, require excessive amounts of insulating material and result in heavy, thermomechanically stressed components with potential insulation degradation over time.
Innovation Solution
A method utilizing 3D printing to apply layers of insulating material selectively around electrical components, allowing for precise application of insulating material based on component contours, reducing material usage and weight, and eliminating the need for casting molds, with the option for vacuum insulation between insulating sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complete casting with insulating material is used to encapsulate electrical components, then high-voltage insulation and safety are improved, but the amount of insulating material required increases and weight increases
Solution Approach 1:
The patent applies insulating material selectively only in areas where high-voltage insulation is actually needed, rather than completely encapsulating all components. The insulating material is applied to specific regions around high-voltage components based on their electrical stress requirements, reducing overall material usage while maintaining necessary insulation performance.
Solution Approach 2:
The patent divides the insulation structure into multiple layers (first layer and second layer) with different orientations and coverage areas. The first layer is applied in a first direction and the second layer is applied in a second direction perpendicular to the first, creating a segmented insulation structure that provides comprehensive coverage with reduced material quantity compared to a single thick layer.
2Reliability
If complete casting with insulating material is used to encapsulate electrical components, then high-voltage insulation and safety are improved, but the weight of the component assembly increases
Solution Approach 1:
The patent applies insulating material selectively only in areas where high-voltage insulation is actually needed, rather than completely encapsulating all components. The insulating material is applied to specific regions around high-voltage components based on their electrical stress requirements, reducing overall material usage and consequently reducing the weight of the assembly.
Solution Approach 2:
The patent divides the insulation structure into multiple layers (first layer and second layer) with different orientations and coverage areas. The first layer is applied in a first direction and the second layer is applied in a second direction perpendicular to the first, creating a segmented insulation structure that provides comprehensive coverage with reduced material quantity and weight compared to a single thick encapsulating layer.
3Reliability
If complete casting with insulating material is used to encapsulate electrical components, then insulation is provided, but thermomechanical stress on components increases and may cause insulation degradation
Solution Approach 1:
The patent applies insulating material selectively only in areas where high-voltage insulation is actually needed, rather than completely encapsulating all components. This localized approach reduces the constraining force exerted on components, minimizing thermomechanical stress while maintaining necessary insulation protection in critical areas.
Solution Approach 2:
The patent divides the insulation structure into multiple layers (first layer and second layer) with different orientations and coverage areas. The first layer is applied in a first direction and the second layer is applied in a second direction perpendicular to the first, creating a segmented insulation structure that provides comprehensive coverage with reduced material quantity and weight compared to a single thick encapsulating layer.
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
This approach reduces the weight and thermomechanical load on electrical components while maintaining effective insulation, preventing insulation degradation and enabling efficient high-voltage protection for space applications.
Implementation Method 1
The insulating material is applied to the electrical component by means of a 3D printing process
Data Source
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AI summary
A method for producing high-voltage insulation for electrical components (10) is described. The method comprises the following steps: applying a first layer (305) of insulating material (300) to the electrical component (10) and applying a second layer (310) of insulating material (300) to the electrical component. The second layer (310) is applied at least section by section to the first layer (305), such that the first layer (305) is positioned at least section by section between the second layer (310) and the electrical component (10). This method enables the on-demand electrical insulation of electrical components while simultaneously reducing the amount of insulating material required.