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Application of Epoxy Resins in Electrical Apparatus
Application of Epoxy Resins in Electrical Apparatus
Application of Epoxy Resins in Electrical Apparatus
Application
of
Epoxy
Resins in Electrical
THOMAS W. DAKIN,
FELLOW, IEEE
Appar
t
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122
or stresses. After the resin starts to "gel" or form a threedimensional network, then internal stress may develop
and lead to cracks. Thermal contraction shrinkage also
occurs after curing or polymerization of the resin. The
magnitude of this is dependent on the curing temperature
Silica
Filled
Density, gins/cc
1.11-1.40
1.6-2.0
4-10
1.2-4.0
Thermal conductivity
4.0-5.0
10-20
10-5 (cm/cm/C)
(10-4 cal/sec/cm2/C/cm
Tensile strength,
(psi)
Elongation, (%)
Compressive strength, (psi)
Heat distortion temperature,
(C)
4000-13,000
7-13,000
3.6-6.0
1.0-3.0
15-25,000
15-35,000
<25-290
123
40
Fig. 1.
Temperature _
Typical temperature variation of tan 5 of epoxy resins.
related with a softening temperature of the resin. Flexibilizing the resin shifts the high-temperature peak toward
lower temperatures. Further curing of the resin, (if it is
not sufficiently cured), will shift the peak toward higher
temperatures. Increasing the test frequency will also shift
the curve to higher temperatures. Increasing the polarity
and ionic content of the resin can raise the whole curve
upward. The lower temperature peak, which is not always
observed with all resins, is attributed to small polar side
groups in the solid three-dimensional molecular network.
These can sometimes rotate or oscillate, as in a cage,
independently of the whole structure. With proper attention to resin formulation, it is possible to achieve
low-dissipation factors at elevated temperatures. Values
of 0.01 to 0.02 tan 8 at 150C have been achieved.
DIELECTRIC STRENGTH
Data on the dielectric strength of epoxy resins and
laminates when tested in a conventional ASTM D149
test manner, using a plate between electrodes (immersed
in oil to prevent flashover) is not remarkably different
from many other resin sheets and laminates, showing
values in V/mils which vary about as the inverse square
root of the thickness, being for 1/8-in thickness about
400 V/mils. Tests of sheet materials in oil or other insulating fluids usually occur with prebreakdown discharges in
the fluid at the electrode edges. These discharge streamers
have high-electric stresses at their termination on the
resin surface and result in lower breakdown voltages, and
declining breakdown stresses with increasing thickness.
Of particular interest is the dielectric strength of cast
epoxy resins with embedded electrodes, a condition which
can be readily achieved with these vacuum castable
materials. Furthermore, this condition of embedded
conductors is typical of many cast resin applications.
With embedded conductors or electrodes, predischarges
in the immersion medium are avoided and strengths more
representative of the resin itself are achieved. Fig. 2(a)
and 2(b) are cast epoxy breakdown values published by
Professor Kind's Laboratory at the Technical University
of Braunschweig [4]. These figures show several points.
1) The low-frequency 50- (or 60-) Hz breakdown volt-
124
INSULATION)
DECEMBER 1974
SURFACE TRACKING
Surface tracking of resins is of primary concern in
outdoor applications or where moisture condenisation is
a part of the environment. Epoxy resins incorporating
benzene ring (aromatic) chemical structures usually track
under moderate wet tracking conditions, but cycloaliphatic
epoxy compounds seldom track. The difference is due to
the fact that benzene rings are more readily converted
to graphitic structures under the high arc temperatures.
Several severe laboratory wet tracking tests, starting
with the dust and fog test [10], followed by the inclined
plane [11] and differential wet track test [12], which
were successively more rapid in operation, showed that
resins could be formulated to be essentially nontracking
under the most severe conditions. Aluminum oxide trihydrate fillers in sufficient percentages upgrade the track
resistance of these resins. Outdoor applications under wet
polluted conditions require a nontracking system, (including resin, filler, and shed design), not just in degree,
but absolutely. Such systems are now available. Under
severe environmental conditions, however, it may be
possible to use reliably, resin systems which have improved track resistance, but which will track, if unfilled,
under the most severe levels of the previously mentioned
tests.
Glass fibers incorporated into resins for improving
mechanical strength, if they are not adequately protected,
may lead to development of low-resistance paths along
125
(b)
(a)
Fig. 3. (a) Cast epoxy condenser-type bushings with porcelain
weather sheds (Westinghouse), 25 kV, 1200 and 400 A; 34.5
kV, 400 A. (b) Comparison of paper-Micarta and cast epoxy
condenser bushings, with porcelain weather sheds, 34.5-kV rating
(Westinghouse).
126
INSULATION,
DECEMBER 1974
(a)
Fig. 5.
(b)
Fig. 4. (a) Outdoor insulation test station (Westinghouse, Pittsburgh), for 23 and 11.5 kV. (b) Outdoor insulator test strips
under stress (Westinghouse, Pittsburgh).
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CONCLUSION
The development of epoxy resins which meet the stringent requirements of many types of insulation applications
127
(a)
(b)
(c)
Fig. 6. (a) Wall mounted cast epoxy current transformer (Messwandlerbau). (b) 20-kV cast epoxy transformer in North Germany
(Messwandlerbau). (c) 60-kV cast epoxy current transformer in
an outdoor application (Messwandlerbau).
Fig. 9. Cast epoxy power transformers, 5 MVA, 30 kV, Transformatoren Union, West Germany (Araldite F).
128
1974
Fig. 10. Cast epoxy foil wound coil for 15-kV, 50-kVA (listribution
transformer (used in oil) (Westinghouse).
(a)
(b)
porcelain indicates they will find an impressive increase
in outdoor use.
Fig. 13. Stand off insulators for outdoor service (A. B. Chance
Co.). (a) 15 kV. (b) 26 kV.
REFERENCES
[1] Mod. Plast., Jan. 1974.
[21 T. W. Dakin et al., CIGRE Rep. 15-04, 1972 Session.
[31 a) H. L. Lee and K. 0. Neville, Handbook of Epoxy Resins.
New York: McGraw-Hill, 1967.
b) P. F. Bruins, Ed., Epoxy Resin Technology. New York:
Interscience, 1968.
[4] D. Kind, Electrotech. Z., vol. A91, p. 134, 1970; also 1969 Anni.
Rep. NRC Conf. on Electrical Insulationi, p. 128.
[5] B. Dittmer, Arch. Electrotech. (Berlin), vol. 48, pp. 150, 287,
387, 1963.
[6] F. Y. Tse, M. J. Mulcahey, and W. R. Bell, in Proc. Inst. Elec.
Eng. Conf. on Dielectric Materials, Measurements, and ApplicaAuthorized licensd use limted to: IE Xplore. Downlade on May 10,2 at 19:087 UTC from IE Xplore. Restricon aply.
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]