EP2372725B1 - Production d'une isolation électrique et produits isolés - Google Patents

Production d'une isolation électrique et produits isolés Download PDF

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Publication number
EP2372725B1
EP2372725B1 EP10157948.0A EP10157948A EP2372725B1 EP 2372725 B1 EP2372725 B1 EP 2372725B1 EP 10157948 A EP10157948 A EP 10157948A EP 2372725 B1 EP2372725 B1 EP 2372725B1
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Prior art keywords
components
filler
mould
electrical insulator
final mixture
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EP10157948.0A
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German (de)
English (en)
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EP2372725A1 (fr
Inventor
Ho Chau Hon
Cherif Ghoul
Lars E. Schmidt
Marco Schneider
Willi Gerig
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ABB Research Ltd Switzerland
ABB Research Ltd Sweden
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ABB Research Ltd Switzerland
ABB Research Ltd Sweden
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Priority to EP10157948.0A priority Critical patent/EP2372725B1/fr
Priority to KR1020110025868A priority patent/KR101252593B1/ko
Priority to CN201110084796XA priority patent/CN102254648B/zh
Publication of EP2372725A1 publication Critical patent/EP2372725A1/fr
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Publication of EP2372725B1 publication Critical patent/EP2372725B1/fr
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/40—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes epoxy resins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B17/00—Insulators or insulating bodies characterised by their form
    • H01B17/56—Insulating bodies

Definitions

  • the invention relates to electrical insulation products in general and to high or medium voltage products in particular.
  • the present document concerns particularities in the manufacturing process of insulated products, such as barrier insulators, for example.
  • the present invention is based on a method for manufacturing an electrical insulator and to an electrical insulator manufactured by the method according to the independent claims.
  • thermosetting insulation material is used e.g. for producing dry type distribution transformers, medium voltage (MV) embedded poles and other insulation.
  • the mixing of highly filled insulation material takes considerable time, often above 1 hour.
  • the standard process includes mixing of resin with filler and hardener with filler separately in two pots equipped with an impeller mixer, in order to prevent premature reaction. After good filler dispersion is achieved in the two components, they are simultaneously forced through a so-called static mixer and injected into a mould.
  • the moulding principle is either traditional vacuum casting or automatic pressure gelation; a process which can also be vacuum assisted.
  • This object is achieved by accelerating the production process by employing a different mixing process for treating the insulation material.
  • the inventive system is based on a fast rotating conveying screw.
  • a method for manufacturing an electrical insulator for medium or high voltage equipment comprising the steps of forcing all liquid components of an insulating material of the electrical insulator through a static mixer, adding at least one filler to the components, forcing the components with the at least one filler through a tube comprising a fast-turning screw mixing device mixing the components with the at least one filler to a final mixture of the insulating material, leading the final mixture to a mould through an outlet of the mixing device that is fluidly connected to the mould, forming an electrical insulator by at least partially curing the final mixture, and moulding the electrical insulator.
  • a method for manufacturing an electrical insulator for medium or high voltage equipment comprising the steps of forcing all liquid components of an insulating material of the electrical insulator through a static mixer, adding at least one filler to the components, forcing the components with the at least one filler through a tube comprising a fast-turning screw mixing device mixing the components with the at least one filler to a final mixture of the insulating material, leading the final mixture to a mould for vacuum casting, the mould being located in a vacuum chamber the inlet of the vacuum chamber connected to an outlet of the mixing device that is fluidly connected to the mould, forming an electrical insulator by at least partly curing the final mixture, and moulding the electrical insulator.
  • the Fuller sieve curve describes the optimized filler composite of a mixture providing optimized characteristics of the mixture such as an optimized strength and porosity or cavity of the mixture.
  • the compactness of the manufactured insulator may be optimized providing an ideal relation between the fillers and the components/the matrix.
  • the components may comprise a hardener and a resin.
  • a continuous mixer with very high shear is used instead of using a batch mixer.
  • the high shear reduces mixing time considerably compared to a conventional impeller mixer that mixes the dispersion of filler in resin and hardener typically with a low shear resulting in a rather lengthy procedure.
  • Insulating materials may be standard filled epoxy, for example with one filler size, typically silica, with a filler content of around 65 wt.-%, corresponding to around 44 vol.-%.
  • the insulating material my comprise polymer concrete.
  • At least two fillers may be used, with a filler content between 70 and 96 wt.-%, corresponding to around 49 to 91 vol.-%, and typically between 83 and 85 wt.-%, corresponding to around 60 to 70 vol.-%).
  • Polymer concrete may be used for each of the fillers.
  • the time required for mixing a dispersion of filler in resin and hardener by applying a higher shear may be reduced by at least a factor 10 compared to prior art devices such as impeller mixers because the mixing efficiency is significantly increased.
  • Filler, resin, and hardener may be seen as components of an insulating material of an electrical insulator.
  • a method for manufacturing an insulator for medium or high voltage equipment wherein the material is forced through a tube, such as a cylindrical tube, with a fast turning screw inside, which causes high shear, resulting in a good dispersion of filler in a matrix of the material.
  • the components pass the mixing screw in less than one minute, including a thin-film degassing unit.
  • the high shear forces produced by the system allow for a higher filler content, which can be reached by applying more than one filler.
  • inventive method contributes to the following advantages:
  • Reference 1 denotes a large silica filler particle with a typical average diameter of 0.3 mm
  • 2 denotes a void
  • 3 denotes a an area with small silica filler particles with a typical average diameter of 0.016 mm, and an epoxy matrix.
  • the particles 1 and voids 2 have rather large dimensions.
  • the large void dimensions might lead to partial discharge if the insulation material is subjected to high electric fields which might cause degradation of the material during lifetime of the insulated products.
  • the insulation formulation consists of epoxy resin, hardener, catalyst, filler, and other liquid or solid additives.
  • a typical filler content may be 65 wt.-%.
  • the situation in figure 2 displaying an optical micrograph of a second sample of a polymer concrete produced by blending of the constituents by conventional production methods employing an impeller-type mixing device.
  • the difference of the second sample compared to the first sample shown in figure 1 resides in that the void content could be greatly reduced by applying a combination of vacuum degassing and vibration. Again, essentially three distinguishable areas can be identified.
  • Reference 4 denotes a resin-rich area with very low filler content whereas 5 denotes a large filler particle (comparable to reference 1 in figure 1 ) and 6 denotes an area with small silica filler particles and epoxy matrix (comparable to reference 3 in figure 1 ). Especially the particles 4 and 5 have rather large dimensions. Again the inhomogeneous compound might undergo a long-term degradation if subjected to a high electric field.
  • FIG 3 A scanning electron micrograph of a first sample of a polymer concrete blended with the inventive production method according to the present invention is shown in figure 3 .
  • the scale of the micrograph is 500 ⁇ m (Micrometers) the comparatively large silica particles 1 are easily identified (comparable to reference 1 in figure 1 ).
  • Reference 3 denotes an area with small silica filler particles and epoxy matrix (comparable to reference 3 in figure 1 ).
  • a region pointed out by an arrow IV is contained in figure 3 . Said region IV is a close-up of reference 3 and will be explained by figure 4 .
  • the step of forcing the mixture through a cylinder comprising a fast-turning screw mixing device to produce a final mixture causes a Shear modulus (Young's modulus) in flexion being in a range of about 20 to about 30 GPa and a Young's modulus in compression of about 30 to about 40 GPa.
  • Shear modulus Young's modulus
  • region 3 comprises a comparatively large amount of small filler particles in the range of 0.004 mm diameter 7 surround larger particles in the range of 0.016 mm diameter 8 and particles in the range of 0.06 mm diameter 9.
  • the high shear applied to the mixture during the mixing step causes the homogeneous distribution of particles.
  • the mixture is forced through a cylinder comprising a continuous fast-turning screw mixing device in order to produce a final mixture and a thin-film degassing unit leading to a material with very low void content.
  • the dark portions 10 of figure 4 denote the epoxy matrix.
  • Fig. 5 schematically shows a Fuller sieve curve.
  • the Fuller sieve curve describes the optimized filler composite of a mixture providing optimized characteristics of the mixture such as an optimized strength and porosity or cavity of the mixture.
  • Fig. 6A shows a flow chart of a method 100 for manufacturing an electrical insulator for medium or high voltage equipment comprising the steps of forcing all liquid components of an insulating material of the electrical insulator through a static mixer 101, adding at least one filler to the components 102, forcing the components with the at least one filler through a tube comprising a fast-turning screw mixing device mixing the components with the at least one filler to a final mixture of the insulating material 103, leading the final mixture to a mould through an outlet of the mixing device that is fluidly connected to the mould 104a, forming an electrical insulator by at least partially curing the final mixture 105, moulding the electrical insulator 106, degassing the final mixture by a degassing unit 107, and post-curing the final mixture at least partly outside the mould 108.
  • Fig. 6B shows a flow chart of a method 100 for manufacturing an electrical insulator for medium or high voltage equipment comprising the steps of forcing all liquid components of an insulating material of the electrical insulator through a static mixer 101, adding at least one filler to the components 102, forcing the components with the at least one filler through a tube comprising a fast-turning screw mixing device mixing the components with the at least one filler to a final mixture of the insulating material 103, leading the final mixture to a mould for vacuum casting, the mould being located in a vacuum chamber the inlet of the vacuum chamber connected to an outlet of the mixing device that is fluidly connected to the mould 104b, forming an electrical insulator by at least partly curing the final mixture 105, moulding the electrical insulator 106, degassing the final mixture by a degassing unit 107, and post-curing the final mixture at least partly outside the mould 108.
  • the epoxy resin compositions are made from components as given in Table 1.
  • the components were mixed with different mixing devices (2 different production-size impeller mixers, and a production-size continuous screw mixer). The mixing times were recorded and about 4 mm thick quadratic plates (150 x 150 mm) were cast and cured for about 8 hours at about 80 °C and post-cured for about 4 h at about 140 °C. Samples for mechanical testing were machined out of these plates and tested according to the standards given in Table 2. Five samples were tested per listed property.
  • the production-size impeller mixers comprised two separate mixing containers equipped with an impeller for epoxy resin and anhydride hardener. In these containers the filler is dispersed into resin and hardener respectively. These two components are forced thereafter through a static mixer.
  • the epoxy composition is prepared by volumetric dosage of the liquid components through a static mixer. Thereafter the fillers are added and dispersed by forcing all components through a cylindrical tube equipped with a fast turning screw, also containing a thin-film degassing unit.
  • Table 1 Raw material formulation for an aromatic epoxy composition (ingredients are given in phr: parts per hundred of epoxy resin)
  • impeller mixer A led to better results after about 240 min of mixing compared to impeller mixer B after about 480 min of mixing. A slight increase in mechanical properties with mixing time was observed for impeller mixer B.
  • the continuous screw mixer leads to superior mechanical properties compared to both impeller mixers. Even with a very long mixing time of about 480 min, the mechanical properties of the continuous screw mixer can not be reached. Mechanical properties are a function of filler dispersion in the matrix material, which is again dependent on the mixing efficiency. The mixing efficiency depends on both mixing time and mixing geometry.
  • the continuous screw mixer creates a very high shear, compared to the impeller mixers and hence, even the very short mixing time, which is in the range of about 1 minute, leads to good dispersion.
  • the epoxy resin compositions (Table 3) are made from components as given in Table 4.
  • the epoxy composition is prepared by volumetric dosage of the liquid components through a static mixer. Thereafter the fillers are added and dispersed by forcing all components through a cylindrical tube containing a fast turning screw, also containing a thin-film degassing unit. The resting time of the material in the screw is in the range of minutes, typically below 1 minute.
  • the exit of the mixing tube is directly connected by a hose to a heated steel mould mounted on a hot-press.
  • the steel mould was for an medium voltage outdoor insulator.
  • the mould on the hot-press is at a temperature of 125 °C. After injection and further two hours of curing the part is demoulded.
  • Example compositions (ingredients are given in phr: parts per hundred of epoxy resin) Ingredient Example 2 Example 3 Example 4 Araldite CY184 100 100 100 Aradur HY1235 90 90 90 DY062 0.54 0.54 0.54 Silbond W12 EST 354 354 Sihelco 30 576 726 Filler content (wt.-%) 65 83 85 Table 4 Raw materials for cycloaliphatic epoxy compositions.
  • the polymer concrete composition (Table 5) is made from components as given in Table 6.
  • This example evaluates the filler dispersion for two dispersing methods: a lab-scale impeller mixer and a production-size continuous screw mixer.
  • a lab-scale impeller mixer the components were mixed until a homogeneous mixture was obtained (typically 30 - 60 min). The mix was degassed thereafter at 5 mbar and cast into plate moulds giving 6 mm thick plates. The plates were cured for 2 h at 90 °C and 10 h at 140 °C.
  • the mixing process for the continuous screw mixer was as described in examples 2-4. Small samples were cut out of the plates and prepared for microscopy. The samples were characterized with optical and scanning electron microscopy.
  • Example composition (ingredients are given in phr: parts per hundred of epoxy resin) Ingredient Example 5 Araldite CY184 100 Aradur HY1102 90 DY070 0.3 Silbond 600 EST 66 Silbond W12 EST 131 Millisil W3 312 Sihelco 30 569 Filler content (wt.-%) 65 Table 6 Raw materials for cycloaliphatic epoxy compositions: Type Trade name Producer Cycloaliphatic epoxy resin Araldite CY184 Huntsman Advanced Materials (CH) Anhydride hardener Aradur HY1135 Huntsman Advanced Materials (CH) Accelerator DY070 Huntsman Advanced Materials (CH) Silica flour Millisil W3 Quarzwerke (DE) Silica flour Silbond W12 EST Quarzwerke (DE) Silica flour 600 EST Quarzwerke (DE) Silica sand Sihelco 30 Sihelco (CH)

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  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Claims (12)

  1. Procédé (100) pour fabriquer un isolateur électrique pour un équipement à moyenne ou haute tension, le procédé (100) comprenant les étapes de :
    forcer tous les composants liquides d'un matériau isolant de l'isolateur électrique à travers un mélangeur statique (101) ;
    ajouter au moins une charge aux composants (102) ;
    forcer les composants avec la au moins une charge à travers un tube comprenant un dispositif de mélange à vis à rotation rapide mélangeant les composants avec la au moins une charge jusqu'à un mélange final du matériau isolant (103) ;
    conduire le mélange final jusqu'à un moule à travers une sortie du dispositif de mélange qui est fluidiquement reliée au moule (104a) ;
    former un isolateur électrique en durcissant au moins partiellement le mélange final (105) ; et
    mouler l'isolateur électrique (106).
  2. Procédé (100) pour fabriquer un isolateur électrique pour un équipement à moyenne ou haute tension, le procédé (100) comprenant les étapes de :
    forcer tous les composants liquides d'un matériau isolant de l'isolateur électrique à travers un mélangeur statique (101) ;
    ajouter au moins une charge aux composants (102) ;
    forcer les composants avec la au moins une charge à travers un tube comprenant un dispositif de mélange à vis à rotation rapide mélangeant les composants avec la au moins une charge jusqu'à un mélange final du matériau isolant (103) ;
    conduire le mélange final jusqu'à un moule pour une coulée sous vide, le moule étant situé dans une chambre à vide, l'entrée de la chambre à vide étant reliée à une sortie du dispositif de mélange qui est fluidiquement relié au moule (104b) ;
    former un isolateur électrique en durcissant au moins partiellement le mélange final (105) ; et
    mouler l'isolateur électrique (106).
  3. Procédé (100) selon la revendication 1, dans lequel le moule est une partie d'une chambre à vide.
  4. Procédé (100) selon la revendication 1 ou 2, comprenant en outre l'étape de :
    dégazer le mélange final par une unité de dégazage (107) ;
    dans lequel le dispositif de mélange à vis à rotation rapide comprend l'unité de dégazage.
  5. Procédé (100) selon la revendication 1 ou 2, dans lequel le durcissement est réalisé au moins partiellement dans le moule.
  6. Procédé (100) selon la revendication 1 ou 2, dans lequel le durcissement est réalisé entièrement dans le moule.
  7. Procédé (100) selon l'une quelconque des revendications 1 à 6, comprenant en outre l'étape de :
    post-durcir le mélange final au moins partiellement en dehors du moule (108), de préférence dans un four à convection forcée.
  8. Procédé (100) selon l'une quelconque des revendications 1 à 7,
    dans lequel au moins deux charges sont ajoutées aux composants ; et
    dans lequel les charges sont sélectionnées de telle sorte qu'une proportion de mélange des charges du matériau isolant suit une courbe granulométrique de Fuller avec une distribution de Fuller de P = d D n
    Figure imgb0004
    dans lequel d est la taille de particules des charges, D est la taille de particules maximale, P est le taux de particules de taille inférieure ou égale à d, et n est le coefficient de calibrage.
  9. Procédé (100) selon l'une quelconque des revendications 1 à 8, dans lequel l'étape de forçage du mélange à travers le tube comprend un dispositif de mélange à vis à rotation rapide mélangeant les composants avec la au moins une charge jusqu'à un mélange final entraînant un module de Young en flexion qui est dans un intervalle d'environ 2 à environ 40 GPa, de préférence dans un intervalle d'environ 10 à environ 30 GPa.
  10. Procédé (100) selon l'une quelconque des revendications 1 à 9, dans lequel le volume des au moins deux charges comprend au moins 49 pour cent du volume du matériau isolant de l'isolateur électrique.
  11. Procédé (100) selon l'une quelconque des revendications 8 et 9 à 10, dans la mesure où elles dépendent de la revendication 8, dans lequel la proportion des charges est déterminée en fonction du coefficient de calibrage n étant de 0,5.
  12. Procédé (100) selon l'une quelconque des revendications 8 et 9 à 10, dans la mesure où elles dépendent de la revendication 8, dans lequel la proportion des charges est déterminée en fonction du coefficient de calibrage n étant de 0,37.
EP10157948.0A 2010-03-26 2010-03-26 Production d'une isolation électrique et produits isolés Active EP2372725B1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP10157948.0A EP2372725B1 (fr) 2010-03-26 2010-03-26 Production d'une isolation électrique et produits isolés
KR1020110025868A KR101252593B1 (ko) 2010-03-26 2011-03-23 전기 절연의 생성 및 절연된 제품
CN201110084796XA CN102254648B (zh) 2010-03-26 2011-03-24 电绝缘和绝缘产品的生产

Applications Claiming Priority (1)

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EP10157948.0A EP2372725B1 (fr) 2010-03-26 2010-03-26 Production d'une isolation électrique et produits isolés

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EP2372725B1 true EP2372725B1 (fr) 2013-09-11

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CN109256245A (zh) * 2017-07-14 2019-01-22 泰科电子(上海)有限公司 绝缘子及其制造方法
JP7308799B2 (ja) * 2020-08-31 2023-07-14 東芝三菱電機産業システム株式会社 レジン製造方法及び絶縁構造製造方法

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ATE420445T1 (de) * 2000-12-06 2009-01-15 Prysmian Spa Verfahren zum herstellen eines kabels mit einer wiederverwertbaren beschichtung
AU2002217054B2 (en) * 2000-12-06 2006-10-12 Prysmian Cavi E Sistemi Energia S.R.L. Process for producing a cable with a recyclable coating
DE10208644A1 (de) * 2002-02-28 2003-09-11 Bakelite Ag Verfahren zur Herstellung und Verarbeitung von Epoxidharz-Formmassen
EP1491566B1 (fr) * 2003-06-16 2007-02-28 ABB Technology Ltd Composition de résine de époxy et procédé de moulage d'un article moulé et article moulé par ce procédé
EP1878027A4 (fr) * 2005-05-04 2012-04-11 Abb Research Ltd Materiau d' isolation electrique, dispositif electrique et procede de fabrication de materiau d' isolation electrique
WO2009043376A1 (fr) * 2007-10-03 2009-04-09 Abb Research Ltd Système d'isolation électrique à résistance accrue au claquage électrique
EP2326679A1 (fr) * 2008-09-19 2011-06-01 ABB Research Ltd. Composition de résine époxy

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CN102254648B (zh) 2013-08-14
CN102254648A (zh) 2011-11-23
EP2372725A1 (fr) 2011-10-05
KR101252593B1 (ko) 2013-04-10
KR20110108279A (ko) 2011-10-05

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