The present invention relates generally to dielectric materials used as parts of insulation systems utilized in transformers. The present invention also relates generally to methods of fabrication of dielectric materials used in transformers.
Currently available high-voltage power transformers utilize cellulose-based insulation materials that are impregnated with dielectric fluids. The insulation systems for currently available power transformers include insulation between turns, insulation between disc and sections, layer insulation, insulation between windings and insulation between components at high voltage and ground potential parts such as cores, structural members and tanks.
The above-mentioned dielectric-fluid-impregnated cellulosic insulation components have certain performance issues over the life of the transformer. As such, these require special processes, design considerations and application considerations for use in power transformers. For example, cellulose, being a natural fiber, is subject to variations in certain properties that are important in proper functioning of the transformer during a long, trouble-free operational life. More specifically, the use of cellulose based insulation materials limits maximum operating temperature. Further, such materials require special processes for stabilization and dry out to reduce moisture content of the insulation system.
In actual operation, all insulation systems age and degrade. Degradation of the insulation system results in the reduced life of a transformer. Also, ageing of the insulation system degrades the performance of the power transformer over time. The rate of degradation is a complex function of the operating temperature, moisture content and oxygen content of the insulation system.
At least in view of the above, it would be desirable to have dielectric materials that are more consistent. It would also be desirable for such materials to have more predictable and improved performance with respect to ageing as result of the effects of temperature, moisture and oxygen. It would be further desirable to have dielectric materials that provide better mechanical properties and dimensional stability under pressure over the life of a power transformer without requiring special processes.
In addition to the above, it would also be desirable to provide novel dielectric materials that could be either used for or incorporated into insulation for power transformers. It would be particularly useful for these novel dielectric materials to be resistant to deterioration by being particularly designed to withstand relatively high operating voltages and operating temperatures. It would also be desirable to provide novel methods of forming such dielectric materials and insulations.
The foregoing needs are met, to a great extent, by one or more embodiments of the present invention. According to one such embodiment, a dielectric material is provided. The dielectric material includes an epoxy matrix having a porosity of at least 20% by volume. The dielectric material also includes a high-voltage dielectric insulating fluid, wherein at least 90% of the porosity is filled with the insulating fluid.
In accordance with another embodiment of the present invention, a method of forming a dielectric material is provided. The method includes mixing an epoxy resin with an epoxy-curing agent, a foaming agent and a solvent to form a mixture. The method also includes curing the mixture to form a matrix having at least 20% porosity by volume. The method further includes back-filling at least 90% of the porosity with a high-voltage dielectric insulating fluid.
In accordance with yet another embodiment of the present invention, another dielectric material is provided. The dielectric material includes means for mixing an epoxy resin with an epoxy-curing agent, a foaming agent and a solvent to form a mixture. The dielectric material also includes means for curing the mixture to form a matrix having at least 20% porosity by volume. The dielectric material further includes means for back-filling at least 90% of the porosity with a high-voltage dielectric insulating fluid.
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Embodiments of the present invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout.
According to certain embodiments of the present invention, the chemical components are added individually. According to other embodiments of the present invention, two or more of the chemical components are added to the mixture 20 at substantially the same time. The stirring mechanism 22 may be operated either continuously as chemical components are added or may be operated intermittently. Also, as will be described below in conjunction with the discussion of methods according to the present invention, the mixture 20 may be heated, either continuously or intermittently as and after one or more chemical components are added.
Within the pores 28 illustrated in
In order to promote accessibility of the pores 28, relatively brittle sponge materials are used as the matrix 26 according to certain embodiments of the present invention. These types of materials allow for relatively easy rupture of portions of walls between pores 28 that would otherwise isolate the pores if not ruptured.
According to certain embodiments of the present invention, the epoxy matrix 26 illustrated in
No particular restrictions are made upon the epoxy resin 10 used to form the epoxy matrix 26. However, according to certain embodiments of the present invention, the epoxy resin 10 includes one or more of a polyglycidyl compound and a phenol novolac epoxy.
According to certain embodiments of the present invention, the epoxy matrix 26 illustrated in
As mentioned above, the selection of the curing agent 18 depends on the selection of the epoxy resin 10. More specifically, the curing agent 18 is chosen based upon its ability to cure the resin 10. According to certain embodiments of the present invention, the curing agent 18 includes one or more of an aliphatic amine, an aromatic amine and a fatty polyamide. However, other curing agents 18 are also within the scope of the present invention.
In order to obtain the desired porosity in the epoxy matrix 26 illustrated in
The insulating fluid 14 illustrated in
Regardless of whether or not they include substantially the same material(s), several differences nonetheless exist between the insulating fluid 14 illustrated in
For example, according to certain embodiments of the present invention, once the epoxy matrix 26 is mechanically stable, the dielectric material 24 is submerged in a bath of insulating fluid. The, the insulating fluid 30 flows into the interconnected pores 28 illustrated in
Another representative manner in which the insulating fluid 14 illustrated in
As will be discussed below, a mixture of an epoxy resin, an epoxy curing agent, a foaming agent and a solvent is dispersed under controlled conditions into a polymer fiber matrix. The process is repeated until desired dimensions are realized and is typically carried out under controlled temperature, pressure and duration to promote uniformity, open pore structure and a porosity of at least 20% by volume. This open pore structure facilitates uniform impregnation of a dielectric fluid in the dielectric material.
More specifically, in
In addition to the components mentioned above, a set of shims 40 are also illustrated in
As will be discussed in more detail below, when forming a dielectric material according to certain embodiments of the present invention, some of the mixture 20 illustrated in
According to certain embodiments of the present invention, not all of the components listed in step 44 are added to the mixture. However, when present, the curing agent typically promotes solidification of the epoxy resin into the epoxy matrix 26 and the foaming agent typically promotes formation of the pores 28, 28′ illustrated in
According to step 46, a polymeric layer is pre-heated. According to certain embodiments of the present invention, this pre-heating step 46 may be used to accelerate the rate of curing of the epoxy matrix, to promote homogeneity of the epoxy matrix and/or to control the amount of porosity in the dielectric material that will ultimately be formed as the polymeric layer is cured.
Step 48 follows step 46 and specifies coating a portion of a first surface of the polymeric layer with the mixture. This coating step 48 may be performed, for example, by coating one side (e.g., either the top or bottom) of the polymeric layer 32 illustrated in
Step 50 then specifies coating a portion of a second surface of the polymeric layer with the mixture, thereby forming a layered structure having the polymeric layer positioned between two layers of the mixture. Referring to
Pursuant to the coating steps 48, 50, step 52 specifies pressing the mixture against the first surface and the second surface, thereby forming a layered structure having the polymeric layer positioned between two layers of the mixture. However, according to certain embodiments of the present invention, the pressing step 52 may be performed pursuant to only one surface being coated. Also, the pressing step 52 may be performed on the mixture only and without a polymeric layer ever being introduced into the process at all.
Step 54 of the flowchart 42 specifies placing a release layer adjacent to the mixture during the pressing step 52. With reference to
Step 56 next specifies placing a spacer adjacent to the polymeric layer. The placing step 56 may be implemented, for example, using one or more of the shims 40 illustrated in
As illustrated in step 58, at any point after the mixing step 44, the mixture may be cured to form an epoxy matrix having at least 20% porosity by volume (e.g., epoxy matrix 26 illustrated in
Step 60 of the flowchart 42 specifies back-filling at least 90% of the porosity with high-voltage dielectric insulating fluid. In order to implement step 60, a small amount of insulating fluid (e.g., insulating fluid 14 illustrated in
According to step 62, a vacuum may be pulled upon the epoxy matrix during the back-filling step 60. According to some such embodiments, the vacuum may be pulled on one side of the dielectric material and insulating fluid on one or more other sides of the dielectric material is effectively “sucked into” the dielectric material.
The present invention will be further understood upon reference to the following non-limiting examples:
Mix 100 g of an epoxy resin together with 20 g of MIBK, 2 g of a foaming agent and 28 g of a hardener. Allow the mixture to stand for approximately four minutes, then apply the mixture evenly onto a 50 g polymer mat that has been pre-heated to 80° C. Position the coated polymer mat and shims between two platen and press the platen together. Cure for approximately twenty minutes at a platen temperature of 95° C.
Mix 100 g of an epoxy resin together with 20 g of MIBK, 2 g of an insulating fluid, 2 g of a foaming agent and 28 g of a hardener. Allow the mixture to stand for approximately four minutes, then apply the mixture evenly onto a 50 g polymer mat. Position the coated polymer mat and shims between two platen and press the platen together. Cure for approximately twenty minutes at a platen temperature of 100° C.
Upon practicing one or more embodiments of the present invention, one of skill in the art will appreciate that the devices and components within the scope of the present invention may readily be utilized as insulation systems or components of insulation systems for all dielectric-fluid-impregnated high-voltage power system apparatuses. Such apparatuses may include, for example, power transformers, shunt reactors, phase shifting transformers, circuit breakers, instrument transformers, bushings and other high-voltage devices. Materials according to certain embodiments of the present invention may also be used as insulation systems or components for, for example, gas-insulated, vacuum-insulated and cryogenic-fluid-filled power system apparatuses.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.