Transformer Electric Shields Divert High Electric Fields
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Solution Overview
Problem
High frequency and high power density applications in transformer structures face challenges with electric field stress and insulation material failure due to increased switching frequencies and higher power handling, leading to dielectric losses, partial discharges, and catastrophic device failure, exacerbated by voids in the insulation material.
Innovation Solution
Incorporating electric shields with a laminate structure comprising metal and dielectric layers, such as printed circuit boards, between the primary and secondary windings to concentrate and redirect high electric fields away from insulation material prone to failure, thereby reducing void formation and enhancing insulation material viscosity for improved encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If increased switching frequencies and higher power handling are implemented, then power density and efficiency are improved, but electric field stress and insulation material failure increase
Solution Approach 1:
An electric shield comprising a laminate structure with metal layers and dielectric layers is introduced as an intermediary component between primary and secondary windings. The shield redirects high strength electric fields away from insulation material, preventing failure mechanisms while allowing high power density operation. The shield acts as a mediator that protects the insulation material from the harmful effects of increased switching frequencies and power handling.
2Productivity
If electric fields are concentrated in insulation material areas, then power transfer efficiency is improved, but dielectric losses and partial discharges increase
Solution Approach 1:
The harmful electric field concentration is extracted from the insulation material by introducing the electric shield. The shield takes out the high strength electric fields from areas where they cause dielectric losses and partial discharges, redirecting them through the shield structure instead. This allows power transfer efficiency to be maintained while eliminating the harmful effects.
3Device complexity
If conventional insulation material arrangements are used, then device complexity is reduced, but failure mechanisms due to voids and electric field stress increase
Solution Approach 1:
The electric shield uses a composite laminate structure combining metal layers and dielectric layers. This composite material approach provides both electrical shielding functionality and structural integrity, protecting against failure mechanisms while maintaining reasonable device complexity. The composite structure allows the shield to handle high electric fields effectively.
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 electric shields effectively divert high electric fields within the shielding planes, reducing failure mechanisms like dielectric losses and partial discharges, allowing the use of higher viscosity insulation materials and enhancing the reliability of transformer structures.
Implementation Method 1
electric shields may be incorporated within transformers of solid state transformer devices to shield and/or redirect high strength electric fields away from areas of insulation material that may be prone to failure mechanisms
Data Source
AI summary
Shielding arrangements for transformer structures capable for operation in high frequency and high power density applications are disclosed. Electric shields may be incorporated within transformers to shield and/or redirect high strength electric fields away from areas of insulation material that may be prone to failure mechanisms. Such electric shields may be positioned between primary and secondary windings in order to be coupled with electric potentials of the windings. The electric shield may comprise a laminate structure that includes one or more metal layers and one or more dielectric layers, for example a printed circuit board. By positioning the electric shields in this manner, high electric fields associated with solid state transformer applications may be concentrated within planes of the electric shields and diverted away from potential problem areas, for example areas that are close to the windings where voids in the insulation material may otherwise promote failure mechanisms.