High-Voltage Transformer Shielding Layer Grounding
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Solution Overview
Problem
Traditional high-voltage transformers face issues such as large size, heavy weight, significant no-load loss, lack of automatic fault isolation, and safety hazards due to high voltage potential on external surfaces, which hinder power density and safety in power distribution systems.
Innovation Solution
A high-voltage transformer design featuring a magnetic core, primary and secondary coil units with insulating portions, a shielding layer for safety grounding, and retaining walls to enhance insulation and safety, allowing for compact structure and improved power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air is used as main insulation against ground, then the transformer structure is simple, but larger insulation size is required and power density decreases
Solution Approach 1:
The patent changes the insulation medium from air to epoxy resin, fundamentally altering the insulation parameter. Epoxy resin provides significantly higher insulation strength per unit volume compared to air, allowing the transformer to achieve the required insulation level with a much more compact size, thereby resolving the contradiction between structural simplicity and insulation size.
Solution Approach 2:
The patent uses composite materials by combining epoxy resin with fiberglass reinforcement. This composite structure provides both the necessary electrical insulation properties and mechanical strength, allowing for a compact design that maintains structural integrity while achieving high power density.
2Reliability
If oil is used as main insulation against ground, then insulation performance is improved, but safety hazards increase due to flammable insulating oil
Solution Approach 1:
The patent replaces flammable insulating oil with epoxy resin, which is non-flammable and provides permanent, stable insulation. This substitution eliminates the safety hazard associated with fire while maintaining excellent insulation performance, effectively resolving the contradiction between reliability and safety.
Solution Approach 2:
Epoxy resin creates an inert, non-flammable environment that replaces the hazardous oil medium. The resin-cured structure provides inherent fire resistance while maintaining electrical insulation properties, thus eliminating safety hazards without compromising insulation performance.
3Ease of manufacture
If integrated epoxy resin cast transformer is manufactured, then manufacturing is simplified, but safety isolation is hard to make between high-voltage and low-voltage sides
Solution Approach 1:
The patent divides the transformer into distinct segmented sections: high-voltage winding section, low-voltage winding section, and shield layer section. The shield layer acts as an electrical barrier between high and low voltage sides, while the segmented structure allows for proper safety isolation. This segmentation maintains ease of manufacture through vacuum casting while ensuring reliable electrical isolation.
Solution Approach 2:
The shield layer serves as an intermediary element between the high-voltage and low-voltage windings. This intermediate conductive layer, properly grounded, provides the necessary safety isolation and electrical barrier, enabling safe operation while maintaining the integrated epoxy resin construction that simplifies manufacturing.
4Device complexity
If high voltage potential appears on external surface, then insulation is simplified, but safety distance is required and power density decreases
Solution Approach 1:
The patent changes the surface insulation parameter by using epoxy resin coating on the external surface. This resin coating provides high dielectric strength and prevents high voltage potential from appearing on the external surface, eliminating the need for additional safety distances while maintaining insulation simplicity.
Solution Approach 2:
The epoxy resin forms a flexible, conformal protective shell around the transformer components. This thin film provides excellent electrical insulation and surface protection, preventing voltage breakdown and eliminating the need for clearance distances, thereby achieving compact design without compromising insulation.
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 design achieves improved safety performance by reducing high voltage potential to zero volts on the surface, enabling a more compact and flexible structure with enhanced power density and reduced size compared to traditional transformers.
Implementation Method 1
a shielding layer 101, and the shielding layer 101 is used for connecting a safety ground
Implementation Method 2
the shielding layer 101 is used for connecting a safety ground
Implementation Method 3
at least a secondary coil unit, comprising at least one secondary winding; at least a primary coil unit, comprising at least one primary winding
Data Source
AI summary
A high-voltage transformer includes a magnetic core; at least a secondary coil unit including at least one secondary winding; at least a primary coil unit, comprising at least one primary winding and a first insulating portion, the first insulating portion forming at least one through hole, the primary winding encircling the through hole and being wrapped by the first insulating portion and fixed in the first insulating portion, the magnetic core passing through the through hole, a shielding layer being formed on a surface of the first insulating portion, and the shielding layer being used for connecting a safety ground; a second insulating portion formed by extending the first insulating portion; a first retaining wall presented in a closed ring shape, arranged on an end periphery of the second insulating portion; and a second retaining wall arranged in the first retaining wall.