Classifications

• • 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
  • H01B3/002—Inhomogeneous material in general
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
  • C08L29/02—Homopolymers or copolymers of unsaturated alcohols
  • C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• • 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
  • H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
• • 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
  • H01B3/301—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen or carbon in the main chain of the macromolecule, not provided for in group H01B3/302
• • 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
  • H01B3/44—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 vinyl resins; acrylic resins
  • H01B3/447—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 vinyl resins; acrylic resins from acrylic compounds
• • 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
  • H01B3/44—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 vinyl resins; acrylic resins
  • H01B3/448—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 vinyl resins; acrylic resins from other vinyl compounds
• • 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
  • H01B3/47—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 fibre-reinforced plastics, e.g. glass-reinforced plastics
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F27/00—Details of transformers or inductances, in general
  • H01F27/28—Coils; Windings; Conductive connections
  • H01F27/32—Insulating of coils, windings, or parts thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/20—Applications use in electrical or conductive gadgets
  • C08L2203/206—Applications use in electrical or conductive gadgets use in coating or encapsulating of electronic parts
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
  • C08L2205/16—Fibres; Fibrils

Definitions

• This invention relates to an electrically insulating material suitable for electrical insulation applications.
• this invention relates to an electrically insulating conductor wrap material suitable for transformers, such as liquid filled transformers.
• a conventional insulating material is Kraft paper, which is a cellulose-based material that is often utilized in liquid filled transformers.
• cellulose paper suffers from several disadvantages such as high moisture absorption, water generation upon degradation, and limited thermal capabilities.
• Current liquid filled transformers require a moisture content of less than 0.5 wt% to operate reliably throughout its designed product lifetime. Water contamination in a liquid filled transformer results in reduced performance through increased electrical losses and electrical discharge activity. Because of its strong affinity for water (hygroscopic), cellulose paper forces liquid filled transformer manufacturers to spend extensive time and energy towards drying out these materials prior to final assembly into a liquid filled transformer. The presence of moisture can further accelerate cellulose degradation and results in additional release of water as a degradation product.
• Standard Kraft paper has a thermal class of 105°C and thermally upgraded Kraft has a thermal class of 120°C.
• the maximum operating temperature of the liquid filled transformer insulated with Kraft paper is limited by the thermal capabilities of the Kraft paper.
• the materials of the present invention are suitable for insulating electrical components in transformers, motors, generators, and other devices requiring insulation of electrical components.
• such materials are suitable as insulating conductor wrap for liquid filled transformers and other liquid filled electrical components.
• such materials can be utilized as conductor wrap for liquid filled transformers.
• At least some embodiments of the present invention provide an insulation article having lower moisture absorption. At least some embodiments of the present invention provide an electrically insulating saturated nonwoven sheet material having desirable thermal stability when compared to conventional cellulose-based Kraft paper. At least one embodiment of the present invention provides an article comprising an inorganic filler, fully hydrolyzed polyvinyl alcohol fibers, and a polymer binder. In another aspect, the article is formed as a saturated nonwoven sheet. In another aspect, the article can further include binder fibers that are resistant to hot oil. For example, the article can include polyphenylene sulfide (PPS) binder fibers.
• PPS polyphenylene sulfide
• the inorganic filler comprises at least one of kaolin clay, talc, mica, calcium carbonate, silica, alumina, alumina trihydrate, montmorillonite, smectite, bentonite, illite, chlorite, sepiolite, attapulgite, halloysite, vermiculite, laponite, rectorite, perlite, aluminum nitride, silicon carbide, boron nitride, and combinations thereof.
• the inorganic filler comprises kaolin clay.
• the kaolin clay comprises at least one of water-washed kaolin clay, delaminated kaolin clay, calcined kaolin clay, and surface-treated kaolin clay.
• the polymer binder comprises a latex-based material.
• the polymer binder comprises at least one of acrylic, nitrile, and styrene acrylic latex.
• the article comprises from about 20% to about 50% fully hydrolyzed polyvinyl alcohol fibers.
• the article comprises from about 40% to about 60% kaolin clay, and from about 5% to about 30% polymer binder.
• the article further comprises from about 0 % to about 20% PPS binder fibers. The percentages are by weight.
• the article is substantially cellulose free.
• the article is non-hygroscopic.
• Another embodiment of the present invention provides an insulating conductor wrap for electrical equipment, wherein the insulating conductor wrap comprises the aforementioned article.
• the electrical equipment comprises one of a transformer, a motor, and a generator.
• the electrical equipment comprises a liquid filled transformer.
• an oil filled transformer comprising electrically insulating conductor wrap having fully hydrolyzed polyvinyl alcohol fibers.
• the electrically insulating conductor wrap further comprises an inorganic filler and a polymer binder.
• the oil filled transformer comprises about 20% to about 50%> fully hydrolyzed polyvinyl alcohol fibers, from about 40% to about 60% kaolin clay and from about 5% to about 30% polymer binder, wherein the percentages are by weight.
• the electrical insulating saturated nonwoven material is substantially cellulose free.
• substantially cellulose free means containing less than 10 wt% cellulose-based material, preferably containing less than 5 wt% cellulose-based material, more preferably containing only trace amounts of cellulose-based material, and most preferably containing no cellulose-based material.
• non-hygroscopic means containing less than 5 wt% water content at a relative humidity of 50%, more preferably containing less than 1.5 wt% water content at a relative humidity of 50%, and even more preferably less than 1 wt% water content at a relative humidity of 50%.
• Fig. 1 is schematic diagram of a wrapped conductor having a conductor wrap comprising a saturated nonwoven sheet according to an aspect of the invention.
• At least one embodiment of the present invention provides an article comprising fully hydrolyzed polyvinyl alcohol fibers, an inorganic filler, and a polymer binder.
• the article can be formed as an insulating saturated nonwoven sheet for electrical equipment, such as transformers, motors, generators. Electrical equipment is sometimes filled with an insulating (dielectric) liquid or fluid. Typical fluids used in liquid filled electrical equipment can include mineral oil, natural ester oils, synthetic ester oils, silicone oils, and the like.
• the article can be formed as an insulating saturated nonwoven sheet for liquid filled electrical equipment, such as liquid filled transformers, liquid filled cable, and liquid filled switchgear. As a result, the liquid-filled electrical equipment can be substantially cellulose free.
• At least some embodiments of the present invention provide an electrically insulating conductor wrap having decreased moisture absorption, higher thermal stability and higher thermal conductivity as compared to conventional cellulose-based Kraft paper.
• At least some of the embodiments provide an insulating material that can be formed using a carding process then saturated with a coating.
• the insulating saturated sheet can have acceptable thickness/thinness, strength, flexibility, and elongation for electrical equipment applications.
• cellulose-based Kraft paper has been used in the liquid filled transformer industry for many years, the high moisture absorption, susceptibility to hydrolysis, and limited high temperature capabilities are known disadvantages.
• fully hydrolyzed polyvinyl alcohol fibers more particularly a combination of an inorganic filler, such as kaolin clay, and fully hydrolyzed polyvinyl alcohol fibers in the article, an electrically insulating saturated nonwoven sheet with lower moisture absorption, higher thermal stability, and higher thermal conductivity has been
• the article and electrically insulating material described herein can provide a transformer manufacturer with the ability to reduce current extensive time and energy- consuming dry out cycles that are typically performed to dry out a transformer unit insulated with traditional Kraft paper prior to oil impregnation. These dry out cycles may last from between 12 hours to several days depending on design and size of unit. Further, not only is Kraft cellulose paper hygroscopic, the aging and actual degradation of cellulose generates water as a by-product which can further reduce the insulation qualities of the transformer oil.
• the electrically insulating saturated nonwoven material comprises polyvinyl alcohol (PVOH) fibers.
• the electrically insulating saturated nonwoven material comprises from about 20% to about 50% fully hydrolyzed polyvinyl alcohol fibers by weight.
• fully hydrolyzed it is meant that the fibers contain less than 5% unhydrolyzed vinyl acetate units and therefore have a degree of hydrolysis of at least 95%.
• Fully hydrolyzed polyvinyl alcohol typically has a melting point ranging between 230°C-245 °C. More preferably, the fully hydrolyzed fibers possess high tenacity (> 6g/denier).
• Fully hydrolyzed, high tenacity polyvinyl alcohol fibers are typically insoluble in water at room temperature.
• polyvinyl alcohol fibers with a low degree of hydrolysis typically have a melting point ranging from 180-190°C and are soluble in water at room temperature.
• These partially hydrolyzed PVOH fibers are usually used as binder fibers.
• the electrically insulating saturated nonwoven sheet comprises an inorganic filler.
• suitable inorganic fillers include, but are not limited to, kaolin clay, talc, mica, calcium carbonate, silica, alumina, alumina trihydrate,
• the electrically insulating material comprises from about 0% to about 60% kaolin clay by weight. More preferably, the electrically insulating material comprises from about 40% to about 60% kaolin clay by weight.
• the electrically insulating saturated nonwoven sheet comprises a polymer binder.
• a suitable polymer binder may include a latex-based material.
• suitable polymer binders can include, but are not limited to, acrylic latex, nitrile latex, styrene acrylic latex, and natural rubber latex.
• the electrically insulating material comprises from about 5% to about 30% polymer binder by weight. In some preferable embodiments, the electrically insulating material comprises from about 5%> to about 20%) polymer binder by weight.
• the electrically insulating material may further comprise an additional fiber.
• the additional fiber comprises an amorphous, undrawn fiber.
• the additional fiber comprises a binder fiber resistant to hot oil.
• the electrically insulating materials comprise polyphenylene sulfide (PPS) fiber.
• the electrically insulating materials comprise bicomponent fibers such as PPS/polyethylene terephthalate (PET) bicomponent fibers.
• the electrically insulating material comprises from about 0% to about 30% PPS fiber by weight. In other embodiments, the electrically insulating material comprises from about 0% to about 20% PPS fiber by weight.
• the electrically insulating material is formed as a saturated nonwoven sheet or mat.
• a carded polyvinyl alcohol fiber based nonwoven material is subsequently saturated with a slurry coating that includes an inorganic filler and a latex binder.
• a carded nonwoven mat comprising a combination of polyvinyl alcohol fibers and PPS fibers is subsequently saturated with a slurry coating that comprises an inorganic filler and a latex binder.
• carding/saturation process allows the resulting sheet to be thin (e.g. less than 5 mils (0.13 mm), in some aspects about 2 - 3 mils (0.05-0.08 mm)).
• the carding and coating steps can be performed using conventional processes.
• chopped polyvinyl alcohol fibers are conveyed to a blower, then to a carding machine which combs the fibers into a nonwoven mat or batting.
• the mat is then calendered with heat (e.g., using thermal bonding) to provide strength.
• Other conventional nonwoven forming processes can also be employed.
• a slurry comprising inorganic clay in a polymer latex is then applied to the nonwoven mat using conventional coating techniques such as with a wire-wound rods (e.g., Meyer rods) or curtain coating.
• a nonwoven, non-hygroscopic insulating material can comprise an inorganic filler, fully hydro lyzed polyvinyl alcohol fibers, a polymer binder, and additionally, high surface area fibers.
• This material can be prepared using a wet-laid process, such as is described in U.S. Provisional Patent Application No. 61/931,792, incorporated by reference herein in its entirety.
• nonwoven, non-hygroscopic insulating material suitable for use in electrical equipment.
• the nonwoven, non-hygroscopic insulating material can be utilized as conductor wrapping within a liquid filled transformer.
• the electrically insulating material is resistant to high temperature fluids, including high temperature oil.
• Fig. 1 shows another aspect of the present invention, an insulating conductor wrap suitable for use in electrical equipment, such as a liquid filled transformer.
• the transformer comprises an oil filled transformer.
• a wrapped conductor 100 includes a conductor, such as rectangular conductor 110, wrapped by a sheet 120.
• Conductor 110 can comprise any conventional conductor material.
• the conductor 110 is electrically isolated from adjacent conductors by sheet 120, which is wrapped around the conductor 110.
• Sheet 120 can comprise the saturated nonwoven sheet described above.
• the wrapped conductor 100 can then be utilized in liquid (e.g., oil) filled distribution or power transformers. Further, one or more of additional transformer components may also be formed from the electrically insulating material described herein, as would be understood by one of skill in the art given the present description.
• transformers can be approved for a higher operating class, and can be designed to meet, e.g., IEEE Std. C57.154-2012.
• the removal of cellulose and cellulose-based transformer components can lead to much shorter dry out times.
• the transformers themselves can be less susceptible to water degradation.
• the exemplary electrically insulating saturated nonwoven materials were made using methods known in the art, as follows:
• the carded nonwoven mats used to prepare Examples 1-10 utilized a mixture of the fibers shown in Table 1. Compositions of each mat in percentage by weight (wt%) are provided in Table 2. The fiber mixtures were passed through a carding machine to yield nonwoven battings with basis weights shown in Table 2. Each nonwoven batting was then calendered through a steel cotton nip at a line speed of 32 feet/min (9.8 m/min), with the steel roll heated to a temperature of approximately 300°F (149 °C) and a nip pressure around 800 pli (143 kg/cm).
• Example 10 was calendered through 2 steel cotton nips at a line speed of 75 feet/min (22.9 m/min), with the steel roll heated to a temperature of approximately 410°F (210°C) and a nip pressure around 800 pli (143 kg/cm).
• Carded nonwoven battings (Examples 1-9) were further calendered through a steel- steel nip at approximately the temperatures provided in Table 2 and a nip pressure of about 1000 pli (179 kg/cm) to provide a partially bonded nonwoven material, which was then saturated with a slurry of clay dispersed in a polymer latex binder.
• a butadiene acrylonitrile (BAN) latex (Emerald Performance Materials, USA) or an acrylic latex (HYCAR 26362, Lubrizol Corp) was used as the binder, and delaminated kaolin clay (HYDRAPRINT from KaMin, LLC, USA) was used as the clay, as indicated in Table 2.
• the final thickness (caliper) and basis weight of each example is provided in Table 3.
• Comparative examples CE1 and CE2 were commercially available thermally upgraded cellulose-based Kraft paper that were used as received.
• the thickness of CE 1 was 10 mil (254 microns [ ⁇ ]) and CE2 had a thickness of 3 mil (76 ⁇ ).
• Thermally upgraded Kraft paper is chemically modified to reduce the rate at which the paper decomposes.
• Machine Direction (MD) tensile strength and MD elongation were measured according to the procedures set forth in ASTM D-828-97 (2002), "Standard Test Method for Tensile Properties of Paper and Paperboard Using Constant-Rate-of-Elongation Apparatus.” Specimens of each sample were tested for initial tensile properties, then aged in mineral oil at 170°C for various lengths of time. Tensile properties were again measured, and the retained elongation and tensile strength were calculated as a percentage of the initial measurement before aging.
• Oil compatibility was evaluated by aging the solid insulation in mineral oil for 168 hours at 100°C and then measuring the dissipation factor of the mineral oil as described in ASTM D-924(2008), "Standard Test Method for Dissipation Factor (or Power Factor) and Relative Permittivity of Electrical Insulating Liquids)
• Thermal conductivity of the samples was measured using a modified ASTM D5470-06 Heat Flow Meter according to the following procedure.
• the hot and cold meter bars 2 in. (5 cm) in diameter and approximately 3 in. (7.6 cm) long, were instrumented with six evenly-spaced thermocouples, the first of which was 5.0 mm away from the interface between the bars.
• the bars were constructed from brass, with a reference thermal conductivity of 130 W/m-K.
• the contacting faces of the meter bars were parallel to within about 5 microns, and the force on the sample during testing was approximately 120N.
• the thickness of the sample was measured during testing by a digital displacement transducer with a nominal accuracy of 2 microns.
• the digital displacement transducer was zeroed.
• the saturated nonwoven material samples were submersed into insulation oil within a glass jar and then deaerated under vacuum in a vacuum oven at room temperature (25°C).
• the oil saturated samples were removed from the oil and placed onto the bottom meter bar.
• the oil served as the interfacial fluid to eliminate thermal contact resistance.
• the meter bars were closed and the normal force applied. Measurements of the heat flow through the meter bars, and the thickness of the sample were made throughout the duration of the test, typically about 30 minutes. Equilibrium was generally reached within about 10 minutes.
• the thermal conductivity of the sample, k was then calculated from the thickness of the sample (L), the thermal conductivity of the meter bars (k m ), the temperature gradient in the meter bars (dT/dx), and the extrapolated temperature difference across the sample
• Tables 4-6 show retained tensile strengths and % elongation of the electrically insulating saturated nonwoven materials and the thermally upgraded Kraft paper (CE1) as a function of aging time in mineral oil at 170°C.
• Examples 1-10 all showed tensile strengths high enough within the target range of approximately 24 lb/inch (4.2 N/mm). As shown in Table 4, Examples 1-3 all showed retained tensile strengths of greater than 50% after 12 weeks aging in mineral oil at 170°C. Satisfactory oil compatibility results were obtained when dissipation factor of the mineral oil aged with Example 10 at 100°C was measured. CEl, in contrast, lost nearly all of its MD tensile strength, retaining only 3% of its unaged tensile strength after 12 weeks aging in 170°C oil. In addition, the oil in which CEl was aged for 12 weeks was also noticeably darker and cloudier than the oil from Examples 1-3, indicating the presence of degradation products from the Kraft paper.
• Examples 1-10 all demonstrated an elongation greater than 5%, the typical minimum requirement for conductor wrap applications. (See Tables 5-6.)
• CEl shows an elongation of only 2.3%. It should be noted that typically, moisture needs to be added to Kraft paper to increase its elongation to about 5%.
• Example 10 The lower moisture absorption of Example 10 compared to CEl and CE2 at 50% relative humidity (RH) and 95% RH are evident from the results shown in Table 7.
• Example 10 has a higher thermal conductivity as compared to CEl and CE2, and the dielectric strength of Example 10 in both air and mineral oil is higher than CEl .

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