Solid Composite Transformer Insulation for High-Temperature Operation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-voltage, fluid-filled power transformers using cellulose-based insulation materials are limited by moisture absorption, aging, and operating temperature, which restricts their operational efficiency and requires costly heating processes, leading to lower maximum operating temperatures and reduced reliability.
Innovation Solution
A power transformer design incorporating a solid composite structure with base fibers and a binder material, where a cooling fluid is positioned between transformer components, and the composite structure is formed by heating the binder and fibers above the binder's melting temperature but below the fibers' melting temperature, allowing for improved insulation and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cellulose-based insulation materials are used in power transformers, then insulating properties are achieved, but moisture absorption occurs leading to aging and reduced reliability
Solution Approach 1:
The patent applies composite materials by combining cellulose fibers with synthetic polymer materials to create a hybrid insulation system. The synthetic polymer component provides moisture resistance while the cellulose provides structural integrity, thereby maintaining insulation reliability while reducing moisture absorption harmful effects.
Solution Approach 2:
The patent changes the chemical and physical parameters of the insulation material by treating cellulose with borax and other chemicals to reduce its moisture affinity. This parameter change allows the material to maintain its insulating properties while becoming less susceptible to moisture absorption and aging.
2Temperature
If cellulose-based insulation materials are used in power transformers, then insulating properties are achieved, but operating temperature is limited to 105°C or less
Solution Approach 1:
The patent uses composite materials combining cellulose with heat-resistant synthetic polymers that can withstand temperatures above 105°C. This composite structure maintains insulation stability while enabling higher operating temperatures, thus resolving the contradiction between temperature increase and reliability maintenance.
Solution Approach 2:
The patent modifies the thermal parameters of the insulation material through chemical treatment and composite formulation, raising the decomposition and degradation thresholds to accommodate higher operating temperatures while maintaining insulation stability through controlled material composition.
3Quantity of substance
If heating under vacuum is performed to reduce moisture content, then moisture content is reduced to less than 0.5%, but processing cost increases
Solution Approach 1:
The patent applies preliminary action by pre-treating the cellulose material with borax and other chemicals before transformer assembly to reduce moisture affinity. This preliminary treatment reduces the need for extensive post-assembly vacuum heating, thereby lowering processing costs while achieving the required moisture content levels.
Solution Approach 2:
The patent uses inexpensive chemical treatments and absorbent materials that can be applied during manufacturing to reduce moisture content, replacing the need for costly and time-consuming vacuum heating processes. These cheaper methods achieve sufficient moisture reduction without requiring expensive equipment or extended processing time.
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 design enables higher operating temperatures (up to 180°C), reduced transformer size, increased reliability, and enhanced insulating properties, allowing for more efficient electrical power transfer while minimizing the risk of thermal overload and maintaining structural integrity over time.
Implementation Method 1
a cooling fluid positioned between the first power transformer component and the second transformer component... the cooling fluid is in contact with the composite structure
Implementation Method 2
heating the binder material, the first base fiber and the second base fiber during the compressing step to a temperature above the first melting temperature but below the second melting temperature
Data Source
AI summary
An insulation system for a fluid-filled power transformer that allows for operation of the transformer at higher temperatures and with lowered susceptibility to aging. The insulation system includes a plurality of fibers that are bound together by a solid binding agent. The solid binding agent may, for example, for sheaths around the fibers or may be in the form of dispersed particles that bind the fibers to each other. Also, a method of fabricating such an insulation system.