Patent Grant
6847514
The invention relates to surge arresters and other types of electrical power distribution equipment.
Electrical transmission and distribution equipment is subject to voltages within a fairly narrow range under normal operating conditions. However, system disturbances, such as lightning strikes and switching surges, may produce momentary or extended voltage levels that greatly exceed the levels experienced by the equipment during normal operating conditions. These voltage variations often are referred to as over-voltage conditions.
If not protected from over-voltage conditions, critical and expensive equipment, such as transformers, switching devices, computer equipment, and electrical machinery, may be damaged or destroyed by over-voltage conditions and associated current surges. Accordingly, it is routine practice for system designers to use surge arresters to protect system components from dangerous over-voltage conditions.
A surge arrester is a protective device that is commonly connected in parallel with a comparatively expensive piece of electrical equipment so as to shunt or divert over-voltage-induced current surges safely around the equipment, thereby protecting the equipment and its internal circuitry from damage. When exposed to an over-voltage condition, the surge arrester operates in a low impedance mode that provides a current path to electrical ground having a relatively low impedance. The surge arrester otherwise operates in a high impedance mode that provides a current path to ground having a relatively high impedance. The impedance of the current path is substantially lower than the impedance of the equipment being protected by the surge arrester when the surge arrester is operating in the low-impedance mode, and is otherwise substantially higher than the impedance of the protected equipment.
Upon completion of the over-voltage condition, the surge arrester returns to operation in the high impedance mode. This prevents normal current at the system frequency from following the surge current to ground along the current path through the surge arrester.
Conventional surge arresters typically include an elongated outer enclosure or housing made of an electrically insulating material, a pair of electrical terminals at opposite ends of the enclosure for connecting the arrester between a line-potential conductor and electrical ground, and an array of other electrical components that form a series electrical path between the terminals. These components typically include a stack of voltage-dependent, nonlinear resistive elements, referred to as varistors. A varistor is characterized by having a relatively high resistance when exposed to a normal operating voltage, and a much lower resistance when exposed to a larger voltage, such as is associated with over-voltage conditions. In addition to varistors, a surge arrester also may include one or more spark gap assemblies housed within the insulative enclosure and electrically connected in series with the varistors. Some arresters also include electrically conductive spacer elements coaxially aligned with the varistors and gap assemblies.
For proper arrester operation, contact must be maintained between the components of the stack. To accomplish this, it is known to apply an axial load to the elements of the stack. Good axial contact is important to ensure a relatively low contact resistance between the adjacent faces of the elements, to ensure a relatively uniform current distribution through the elements, and to provide good heat transfer between the elements and the end terminals.
One way to apply this load is to employ springs within the housing to urge the stacked elements into engagement with one another. Another way to apply the load is to wrap the stack of arrester elements with glass fibers so as to axially-compress the elements within the stack.
In one general aspect, the invention features a surge arrester or surge arrester module having a stack of components including at least one active electrical element, such as a varistor. Each component has end faces, at least one of which is mechanically bonded to an end face of another component such that the combined components of the stack define a single, monolithic structure that serves as both an electrically-active element and a mechanical support element of the surge arrester. The surge arrester also includes an insulative housing surrounding the stack of components. The stack of components is capable of withstanding current pulses having magnitudes of 65 kA and durations of {fraction (4/10)} microseconds, where {fraction (4/10)} indicates that a pulse takes 4 microseconds to reach 90% of its peak value and 10 microseconds more to get back down to 50% of its peak value, without significant degradation in operating performance of the stack of components.
Embodiments may include one or more of the following features. For example, the stack of components may be capable of withstanding current pulses having magnitudes of 100 kA and durations of {fraction (4/10)} microseconds without significant degradation in operating performance of the stack of components.
The stack of components may include a first end component, a second end component, and at least one intermediate component. The first end component may include a first end face mechanically bonded to an end face of an intermediate component, and the second end component may include a first end face mechanically bonded to an end face of an intermediate component. The stack of components may also include a pair of conductive end terminals, with a first terminal being mechanically bonded to a second end face of the first end component and a second terminal being mechanically bonded to a second end face of the second end component.
The stack of components may include two or more varistors, and the varistors may be metal oxide varistors (MOVs). At least a first end face of a first varistor and at least a second end face of a second varistor may be covered with metal coatings. The metal coatings may be coatings of aluminum or brass having thicknesses between 0.002 and 0.010 inches.
The varistors may be formed from ceramic material and mechanical bonding between end faces of two adjacent varistors may be provided by stacking the varistors and heating them together such that the mechanical bond is formed by interaction between the adjacent ceramic end faces. The varistors may be unfired, partially fired, or fully fired before they are stacked and heated together.
Mechanical bonding between end faces of two adjacent varistors may be provided by covering a varistor end face with a bond promoting material. The bond promoting material helps to produce a strong, electrically-conductive bond between the varistors. The bond promoting material may be, for example, a slurry of the ceramic material, an organic adhesive, an inorganic adhesive, a metal-filled glass frit, a solder, or a brazing material.
Mechanical bonding between an end face of a varistor and an adjacent component may be provided by applying a metal layer to the end face and attaching the metal layer to a metal surface of the adjacent component. The metal layer and the metal surface may be attached by soldering or brazing. For example, a solder or brazing material having a melting temperature less than 50° C. more than an expected operating temperature of the surge arrester may be used.
The metal layer and the metal surface may be attached by stacking the varistor and the adjacent component with a preform element between the metal layer of the varistor and the metal surface of the adjacent component, applying pressure to the varistor and the adjacent component, heating the varistor, the adjacent component, and the preform element to melt the preform element, cooling the varistor and the adjacent component, and removing the applied pressure. The preform element may be formed from a solder composition.
The metal layer and the metal surface also may be attached by coating at least one of the metal layer and the metal surface with an epoxy, stacking the varistor and the adjacent component with the epoxy between the metal layer and the metal surface, applying pressure to the varistor and the adjacent component, heating the varistor and the adjacent component to cure the epoxy, cooling the varistor and the adjacent component, and removing the applied pressure.
Another way of attaching the metal layer and the metal surface includes coating the metal layer and the metal surface with a silver-filled glass matrix, stacking the varistor and the adjacent component with the silver-filled glass matrix between the metal layer and the metal surface, and heating the components.
The adjacent component may be a second varistor and the metal surface may be a surface of a metal layer applied to an end face of the second varistor. The adjacent component also may be a conductive metal terminal and the metal surface may be an end face of the conductive metal terminal.
The surge arrester may satisfy the IEEE Standard for Metal-Oxide Surge Arresters (IEEE Std. C62.11-1999), including the standards applicable to distribution surge arresters.
In another general aspect, the invention features joining end faces of two ceramic varistors by applying a metal layer to an end face of a first varistor, applying a metal layer to an end face of a second varistor, and attaching the metal layers. The metal layers may be attached using soldering or brazing. For example, a solder or brazing material having a melting temperature less than 50° C. more than an expected operating temperature of the varistors may be used.
The metal layers may be attached by stacking the varistors with a preform element between the metal layers, applying pressure to the varistors and the preform element, heating the varistors and the preform element to melt the preform element, cooling the varistors and the preform element, and removing the applied pressure. Similarly, they may be attached by coating at least one of the metal layers with an epoxy, stacking the varistors with the epoxy between the metal layers, applying pressure to the varistors, heating the varistors to cure the epoxy, cooling the varistors, and removing the applied pressure. In yet another approach, the metal layers may be attached by coating the metal layers with a silver-filled glass matrix, stacking the varistors with the silver-filled glass matrix between the metal layers, and heating the components.
Other features and advantages will be apparent from the following description, including the drawings and the claims.
Referring to
Elements of the bonded element stack 105 are stacked in an end-to-end relationship and bonded together at their end surfaces. Since the elements of the stack 105 are affirmatively bound together, the arrester 110 does not need to include a mechanism or structure for applying an axial load to the elements.
The surge arrester 110 may be implemented as a distribution class surge arrester, such as a 10 kA heavy duty 10 kV (8.4 kV Maximum Continuous Operating Voltage) arrester. It should be understood, however, that the module 100 may be used in other types of surge arresters, and in other electrical protective equipment.
The bonded element stack 105 may include different numbers of elements, and elements of different sizes or types. Examples include varistors, capacitors, thyristors, thermistors, and resistors. For purposes of explanation, the stack is shown as including three metal oxide varistors (“MOVs”) 115 and a pair of terminals 120.
Referring also to
The MOVs may be sized according to the desired application. For example, in one set of implementations, the MOV may have a diameter between approximately 1 to 3 inches, such that the upper and lower faces 125, 130 each have surface areas of between about 0.785 and 7.07 square inches.
Given a particular metal oxide formulation and a uniform or consistent microstructure throughout the MOV, the thickness of the MOV determines the operating voltage level of the MOV. In one implementation, each MOV is about 0.75 inches thick. In some implementations, this thickness may be tripled.
It is desirable to minimize the cross-sectional areas of the MOVs so as to minimize the size, weight and cost of the arrester. However, the durability and recoverability of the MOVs tend to be directly related to the sizes of the MOVs. In view of these competing considerations, MOVs having diameters of approximately 1.6 inches have been used.
The upper and lower faces 125, 130 may be metallized using, for example, sprayed-on coatings of molten aluminum or brass. In some implementations, these coatings have thicknesses of approximately 0.002 to 0.010 inches. The outer cylindrical surface 135 is made up of the metal oxide formulation. In other implementations, the surface 135 may be covered by an insulative collar.
As shown in
A terminal 120 is disposed at each end of the stack 105. Each terminal 120 is a relatively short, cylindrical block formed from a conductive material, such as, for example, aluminum. Each terminal 120 has a diameter substantially equal to that of an MOV 115. In some implementations, each terminal may also include a threaded bore 150 in which may be positioned a threaded conductive stud 155. An outer cylindrical surface 160 of a terminal may be knurled, ribbed, or otherwise textured to improve adherence to the insulative coating 140.
In general, the terminals 120 may be thinner than terminals associated with modules that, for example, are wrapped with a structural layer to provide an axial load on the components of the module. This reduced thickness may result from changes in the geometry of the device, or simply because thicker metal is not needed for bonding with the structural layer.
As shown in
As noted above, elements of the bonded element stack 105 are bonded together at their end surfaces, such that the stack 105 serves as both the electrically-active component and the mechanical support structure of an electrical protective device such as the surge arrester 110. This bonding may involve ceramic-to-ceramic bonding between, for example, faces of adjacent MOVs; ceramic-to-metal bonding between, for example, an MOV and a terminal; and metal-to-metal bonding between, for example, a terminal and a component having a metal face, such as a spark gap assembly. The bonding must provide bonds that are both mechanically stable and electrically conductive.
Ceramic-to-ceramic bonding may include ceramic-to-bonding agent-to-ceramic bonding, cofiring, and refiring. Suitable bonding agents include, for example, organic adhesives, and inorganic adhesives. Cofiring includes firing two or more unfired MOVs together in a kiln to form a bond between the MOVs. This bond may be enhanced by providing a bond promoting material, such as, for example, an MOV slurry, between the unfired MOVs. Refiring includes firing two or more previously-fired MOVs together in a kiln, in the presence of a layer of bond promoting material between the MOVs. In both cofiring and refiring, heating of the layer of bond promoting material between the components helps to produce a strong, electrically-conductive bond between the components.
Ceramic-to-metal bonding may include applying a metal layer to a ceramic surface (e.g., the face of an MOV) using, for example, arc spraying or silk screening. This metal layer then may be attached, for example, to the face of a terminal using, for example, solder. In some implementations, the face of the terminal is attached directly to the ceramic surface by, for example, soldering or brazing directly to the ceramic surface. Such direct soldering or brazing also may be used to attach two ceramic surfaces to each other.
When using solder, it is desirable to use low temperature solders, so as to avoid heating the MOV disks to temperatures that can damage the disks. This also tends to avoid the need for special fluxes, which can potentially attack the material from which the MOV disks are formed. In some circumstances, it also is useful to perform the soldering in a reducing atmosphere. However, this also has the potential to degrade the materials from which the disks are formed.
Another potential problem associated with using low temperature solders is that, in some cases, the solder temperature (e.g., 221° Celsius) can approach the operating temperature (e.g., 200° Celsius), which can lead to partial melting of the solder and potential device failure under extreme operating conditions. This problem may be avoided by selecting a solder having a solder temperature that differs sufficiently from the operating temperature, while not being too high.
Other techniques for attaching a metal to a ceramic surface include the use of an organic adhesive, such as a metal-filled epoxy; an inorganic adhesive; or brazes. Each of these techniques can be performed with or without metallized faces being deposited on the ceramic surfaces. When metallized faces are deposited on both ceramic surfaces, bonding of the metallized faces constitutes metal-to-metal bonding.
Referring to
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The procedures illustrated in
The standard also states that such arresters must endure environmental tests related to accelerated aging by exposure to electrical stresses and external contamination as set forth in sections 8.6.2 and 8.7 of the standard under the headings “Accelerated Aging Tests by Exposure to Electrical Stress” and “Contamination Test”. The described embodiments have demonstrated improved performance under these tests as indicated by required endurance with reduced overall electrical activity and surface currents (watts loss).
Other embodiments are within the scope of the following claims. For example, referring to
In some implementations, an insulative coating 835 may be bonded to the bonded element stack 800 to prevent the undesired entry of moisture or other contaminants into the module 805. The coating 835 also may provide increased tensile and mechanical strength to the module, as well as controlled venting of gases during an arrester failure.
Referring now to
Resin layers 860-870 may include a single resin formulation, or they may include two to four different resins. The resins used for layers 855-870 are selected so as to have similar cure temperatures and so as to be mutually compatible with the other resin layers making up the matrix 840. Further, the resin of matrix 840 must be stable at high temperatures and high voltages, meaning that the cured resins in matrix 840 must not depolymerize or lose bonding strength at the temperatures and voltages to which the components in the module 805 will be subjected during operation. Normal operating temperatures are typically between −60 and +60° Celsius. Failure mode temperatures can be as high as 350° Celsius. The material selected for layers 855-870 undergoes no thermal degradation at or below the failure temperature of the electrical equipment.
It is important that the insulative coating 835, when cured, have a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the electrical components of the stack 800. This will ensure that, at any temperature below its cure temperature, coating 835 will exert axially and radially compressive forces on the stack 800. The components in stack 800 typically have an average coefficient of thermal expansion in the range of 5*106 inches/° C. to 25*106 inches/° C., so it is desired that the coating 835 be formed from materials having a coefficient of thermal expansion of at least 50*106 inches/° C. to 250*106 inches/° C.
Details regarding formulation of an insulative coating, such as the insulative coating 835, are described in U.S. application Ser. No. 09/142,076, titled “Polymeric Weathershed Surge Arrester and Method” and filed Sep. 1, 1998, which is incorporated by reference.
Referring now to
As noted above, the various electrical component stacks may include other than three MOV devices. Examples of other arrangements of electrical components are illustrated in
This application is a divisional of application No. 09/432,147, filed Nov. 2, 1999 now U.S. Pat. No. 6,519,129, which is incorporated by reference.
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| Child | 10323677 | US |
