CN103109328B - 用于制造绝缘材料的层压的层状结构 - Google Patents

用于制造绝缘材料的层压的层状结构 Download PDF

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CN103109328B
CN103109328B CN201180045806.7A CN201180045806A CN103109328B CN 103109328 B CN103109328 B CN 103109328B CN 201180045806 A CN201180045806 A CN 201180045806A CN 103109328 B CN103109328 B CN 103109328B
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J.内尔格斯
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Abstract

本发明涉及用于制造片状绝缘层压体的层状结构（10,30），包括下列顺序的片状和相互叠加设置的单层：-乙阶树脂（12,34）-玻璃织物（14,36）-由聚酯薄膜形成的芯层（38,16a+16b）-玻璃织物（18,40）-乙阶树脂（42,20）。在固化的状态下，由此制造的绝缘材料例如适合于在变压器绕组的低压绕组和高压绕组之间作为绝缘阻隔层使用。

Description

用于制造绝缘材料的层压的层状结构
本发明涉及用于制造片状绝缘材料的层压的层状结构以及由此制造的绝缘材料。
普遍已知的是，在构造高电压（Hochspannung）技术的组件时，例如干式变压器，需要使用绝缘材料。例如，当两个按照运行要求在不同的电压水平上运转的组件，如变压器的高压（Oberspannung）和低压绕组，彼此间具有太小的距离时，可能导致电击穿。为了防止这种情况，通常使用所谓的绝缘阻隔层，其会延长需要电克服的火花放电间隙，并因此保证了组件的安全运转。在高电压干式变压器中空心圆柱形地相互交叉的低压和高压绕组的情况下，例如对于6kV-30kV的电压水平，这样的一个阻隔层设计成薄壁的绝缘的空心圆柱，其设置在通常位于径向内部的低压绕组和位于径向外部的高压绕组之间的径向边界区域。
例如，这样的圆柱体由薄壁多层的层压体组成。层压体是指一种材料或者一种产品，其由两个或更多个平面状相互粘结的或者另外结合在一起的层组成。这些层可以由相同的或者不同的材料组成。适合于前面提到的绝缘目的的层压体例如具有下列示例性的层状结构，其中电压强度基本上由聚酯薄膜来确定：
-8μm的固化的聚酯酰亚胺树脂或者环氧树脂
-50μm的聚酯非织造织物
-350μm的聚酯薄膜
-50μm的聚酯非织造织物
-350μm的聚酯薄膜
-50μm的聚酯非织造织物
-8μm的固化的聚酯酰亚胺树脂或者环氧树脂。
但是，也可以考虑使用多层的粘结的聚酯薄膜，例如每个层厚度为350μm的最多四层。
这种条带状的层压体借助相应的层压装置制造成卷状。为了使其转化成为所想要的用于高电压变压器的绝缘阻隔层的空心圆柱形状，把具有所想要的长度和宽度的条带片段手工弯曲成空心圆柱形状和用耐热的胶带在重叠处固定。正如对于干式变压器在高电压区域所常见的，就整个结构而言优选希望的方式为温度等级F即155℃的耐热性。
这里的缺点在于，开始提到整个层厚度为大约1mm的层压体结构具有有限的稳定性，这样的稳定性不适合制造例如功率为5MW或者更高的较大型变压器的绝缘空心圆柱。添加具有由此产生的更厚的整个层厚度的其它层需要更高的消耗和材料使用，这被证明是不利的。同样被证明不利的是，这样的绝缘阻隔层会造成变压器的燃烧负荷。
另外描述的四层聚酯薄膜尽管具有稍微高点的机械稳定性，但由于缺少薄膜复合体外侧的涂层仅适用于温度等级B即130℃。
基于这些现有技术，本发明的任务在于，提供一种绝缘材料或合适的初级产品，其特点在于提高的稳定性和/或降低的可燃材料含量。
该任务通过用于制造开始提到类型的片状绝缘材料的层压的层状结构来解决。其特点在于下列片状和相互叠加设置的单层：
-乙阶树脂
-玻璃织物
-由聚酯薄膜构成的芯层
-玻璃织物
-乙阶树脂。
本发明的基本想法是，使用由聚酯薄膜构成的芯层代替交替顺序的聚酯薄膜和聚酯非织造织物，该芯层的两面被具有一个邻界乙阶树脂层的玻璃织物层包围。
树脂的乙阶是指，树脂的固化过程已经开始，但是随后故意地被中断，以至于树脂处于没有完全聚合的状态。但是，树脂的乙阶也是指，通过相应的加热到例如80℃的熔化温度和随后的冷却使树脂在本身的聚合化学反应没有引发的情况下转化为固态。在这样的状态中，树脂在相应的温度下再次熔化，其中本身的聚合反应在高于熔化温度的温度下进行。
按照本发明，在层压时处于液体甲阶状态的树脂例如借助具有相应表面结构的轧辊来施涂，其中在接下来的干燥过程中例如使其通过具有合适高的温度的烤炉，以便树脂接下来尽管转化为乙阶状态，但是基本上避免了聚合反应的发生。
多层状结构的层压可以在单独一个层压过程中包含多个层，但也可以仅仅是分别把两个层层压成一个中间产品，该中间产品接下来再次在滚筒上被卷绕起来。接下来，把该中间产品和其它层一起进行层压。
完成层压的层状结构还不具有所想要的最终稳定性，这里其还需要加热到烘焙温度，以便使树脂从其乙阶状态开始再次液化，和通过毛细管作用至少部分吸收在玻璃织物的间隙中而与玻璃织物层相结合。通过相应高的烘焙温度引发聚合反应过程，和在接下来的冷却过程之后进行树脂的完全聚合反应，和形成具有相应高的稳定性的绝缘材料。通过在片状绝缘材料的两个外层上设置之后产生的玻璃织物复合体层，在低的总层厚度的情况下也保证了高的总体结构稳定性。此外，因为玻璃织物与现在不再使用的聚酯非织造织物相反不会造成燃烧负荷，所以以有利的方式降低了层压体层中可燃材料的比例。
在层压的层状结构的优选实施方案中，树脂层的厚度和与此邻界的玻璃织物层的厚度的比例大约为3：20。在液态，树脂的量以有利的方式与玻璃织物中待填充的空隙体积相匹配。
按照特别优选的发明变型，树脂层的厚度分别为大约15μm和玻璃织物层的厚度分别为大约100μm。考虑到前面提到的比例，这里要实现与片状绝缘材料的总厚度为大约1mm相匹配的两个外层厚度。其中，分别为15μm的树脂层厚度被认为是下限，它和各个玻璃织物层一起产生足够的稳定性。当然，更高的层厚度，例如50μm也是可以和有意义的。在这种情况下，树脂层将没有完全地被吸收在玻璃织物中，表面将相应地更光滑。
只有在增加的总层厚度的情况下，玻璃织物层还要进一步增加的厚度才被证明是有意义的，在这种情况下当然也不会造成燃烧负荷。按照顾客的要求，也可以考虑，在接受提高的总层厚度的情况下对于减小的燃烧负荷进一步减小聚酯薄膜的厚度和通过相应提高的玻璃织物层的厚度进行平衡。这样的话，提高的总层厚度是由玻璃织物相对于聚酯薄膜较低的绝缘能力而产生的。
就此而论，当芯层具有两层大约350μm厚的聚酯薄膜时被证明是有利的。350μm是商业上常用的层厚度，其中具有提高的层厚度例如500μm的薄膜明显更难制造。因此，最有利的是制造由两层350μm厚的薄膜组成的绝缘芯。这样，和两个外层的层厚度一起产生将近1mm的总层厚度。对于更高的总层厚度，可以相应地按比例增加每个层厚度，和/或通过相应提高的单层数目仿制。按照相应的层压装置的存在与否，制造一个这样的层压结构有利地首先以聚酯薄膜、玻璃织物层和乙阶树脂的层状结构形式进行，其中随后将两层这样的中间产品以聚酯薄膜面相互粘结和/或层压。
已经显示，苯酚-环氧预缩合物或者双酚A树脂特别适合于作为乙阶树脂使用。其可以特别好地被涂覆和也具有合适的温度特性。这里可以明确参考两种产品：HexionEpenol9968-LG作为合适的苯酚-环氧预缩合物和Albesiano8045/A作为合适双酚A树脂。在烘焙和固化的状态下，一方面必须产生对应于温度等级F即大于155℃的耐热性，另一方面出于制造的原因没有超过耐热性太多的烘焙温度是可取的，例如在120℃到180℃的范围，通常大约140℃。
优选地，层压的层状结构具有空心圆柱形状，其此外与待制造的变压器中低压和高压绕组之间形成的内部空间相匹配。提供这样的空心圆柱形状是通过例如从送到的卷筒中剪切一段相应宽度和长度的按照本发明的层压体，和首先用夹子固定成相应的形状，其中出于随后绝缘的原因提供两个端点在它们的结合处例如几个厘米的相互重叠。以这种方式，空心圆柱体可以在制造相应的变压器绕组时容易地作为绝缘阻隔层集成在其中。按照变压器的额定功率和绕组结构，圆柱体直径为例如0.5m-2m。
在使用所述层压的层材料作为绝缘材料之前，其仍然要短时间加热到至少烘焙温度，以便通过形成外部的玻璃织物复合体层和/或树脂的完全聚合反应来制造具有所想要的强度的最终绝缘材料。
被证明特别适合于短时间加热的是在120℃-180℃的温度范围和至少30min的时间。
在本发明的范围内，也提供高电压绕组，其具有一个空心圆柱形地围绕着绕组轴设置的低压绕组，和一个以径向距离空心圆柱形地围绕着同一绕组轴设置的高压绕组。该高电压绕组的特点在于，在通过径向距离形成的空隙内设置一个按照权利要求1到6之一的形状上相匹配的层压的层状结构。
所述层压的层状结构用作低压和高压绕组之间的绝缘阻隔层。基于这种绕组主要径向对称的结构，在两个绕组之间也类似圆柱形地形成了间隙。由此层压的层状结构的空心圆柱形状是一个适于简单地可集成在整个绕组中的形状。当然也可以考虑，由多个壳状的部分组合成这种空心圆柱的形状。
这种绕组最终的电学功能只有当其或者作为单个绕组或者在完整安装的变压器中一起短时间加热到至少烘焙温度，以便完全聚合的玻璃织物复合材料在空心圆柱的外侧形成时才会出现。在制造变压器时这样短时间的加热任选总是必要的，例如当对于低压绕组的导体绝缘同样使用乙阶树脂时，例如本领域的专业人员已知的预浸料坯。以这种方式，对于作为绝缘阻隔层使用的空心圆柱不需要额外的加热过程。以同样有利的方式也不用使用耐热的胶带来固定空心圆柱，其原因在于在加热后通过开始时再次变为液体的树脂也会产生以圆柱形卷起来的层压体的结合，该层压体在固化后具有高的强度。
其它有利的实施可能性可以从其他的从属权利要求中得到。
借助在附图中展示的实施例，详细描述本发明、其它实施方案和其它优点。
其中：
图1示例性的第一个层压的层状结构以及
图2示例性的第二个层压的层状结构。
图1显示了示例性的和非按规定比例的第一个层压的层状结构10，其具有按照本发明顺序的分别带有附图标记的单层：
12:15μm乙阶树脂，例如HexionEpenol9968-LG
14:100μm玻璃织物
16a:350μm聚酯薄膜，由此形成芯层的第一部分层
16b:350μm聚酯薄膜，由此形成芯层的第二部分层
18:100μm玻璃织物
20:15μm乙阶树脂，例如HexionEpenol9968-LG。
在每个加热过程之后，树脂层12、20至少部分吸收到邻界的玻璃织物层14、18的空隙中和与之形成固体复合材料，该材料是通过树脂的完全聚合反应产生的。
图2显示了示例性的第二个层压的层状结构30，其具有围绕绕组轴44设置的空心圆柱形状32。这个图示也不是按照比例的，但这里也显示了按照本发明的分别带有附图标记的层顺序：
34:15μm乙阶树脂，例如Albesiano8045/A
36:100μm玻璃织物
38:700μm由聚酯薄膜形成的芯层
40:100μm玻璃织物
42:15μm乙阶树脂，例如Albesiano8045/A。
当然，所述的层厚度仅作为参考值来理解，其本身服从通常的制造公差。
附图标记列表
10示例性的第一个层压的层状结构
12第一单层乙阶树脂
14第一单层玻璃织物
16a芯层的第一聚酯薄膜层
16b芯层的第二聚酯薄膜层
18第二单层玻璃织物
20第二单层乙阶树脂
30示例性的第二个层压的层状结构
32空心圆柱的形状
34第一单层乙阶树脂
36第一单层玻璃织物
38芯层
40第二单层玻璃织物
42第二单层乙阶树脂
44绕组轴

Claims (8)

1.用于制造片状绝缘材料的层压的层状结构（10,30），其特征在于下列顺序的片状和相互叠加设置的单层：
-乙阶树脂(12,34)
-玻璃织物(14,36)
-由聚酯薄膜形成的芯层(38,16a+16b)
-玻璃织物(18,40)
-乙阶树脂(42,20),
其中芯层（38）具有两层（16a，16b）350μm厚的聚酯薄膜。
2.按照权利要求1的层压的层状结构，其特征在于，树脂层(12,20,34,42)的厚度和与之邻界的玻璃织物层(14,18,36,40)的厚度的比例为3:20。
3.按照权利要求2的层压的层状结构，其特征在于，树脂层(12,20,34,42)分别为15μm厚和玻璃织物层(14,18,36,40)分别为100μm厚。
4.按照权利要求1的层压的层状结构，其特征在于，乙阶树脂是苯酚-环氧预缩合物或者双酚A树脂。
5.按照权利要求1的层压的层状结构，其特征在于，其具有空心圆柱形状(32)。
6.绝缘材料，所述绝缘材料由权利要求1-5之一的层压的层状结构通过在140℃-180℃的温度范围内加热所述层压的层状结构经至少30min的时间而制造。
7.具有一个空心圆柱形地围绕着绕组轴（44）设置的低压绕组和一个以径向距离空心圆柱形地围绕着同一绕组轴设置的高压绕组的高电压绕组，其特征在于，在通过径向距离形成的空隙内设置一个按照权利要求1-5之一的在形状上相匹配的层压的层状结构（30）。
8.按照权利要求7的高电压绕组，其特征在于，在140℃-180℃的温度范围内加热所述层压的层状结构经至少30min的时间来制造绝缘材料。
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