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Application of epoxy resins for insulation in high-voltage electrical applicances
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Update： 2021-10-22 |
絕緣材料的應(yīng)用極為悠久，在二十世紀初期，歐洲國家就已經(jīng)開始著手研究這一材料了，當時主要是通過采用高壓定子線圈作為主要的原材料，隨后美國等國家也開始著手研究，使得絕緣材料層出不窮。而我國直至二十世紀六七十年代才開始研究這一技術(shù)，利用酸性聚酯合成了絕緣材料，這些絕緣材料的應(yīng)用可謂是打響了我國材料發(fā)展史上的第一槍。從此以后，我國還繼續(xù)開發(fā)出了許多絕緣性技術(shù)。環(huán)氧樹脂便是基于這一時代背景下產(chǎn)生的一種絕緣性技術(shù)，它的應(yīng)用對于整個電力行業(yè)發(fā)展有著重要的意義。
The application of insulating material has a long-standing history. In the early 20th century, European countries began to study this material. At that time, high-voltage stator coil was mainly used as raw material. Then the United States and other countries also began to study, which made insulating material emerge in endlessly. However, China did not begin to study this technology until the 1960s and 1970s, using acidic polyester to synthesize insulating material. The application of these insulating materials can be said to be the first shot in the history of material development in our country. Since then, China has continued to develop many insulation technologies. Epoxy resin is an insulating technology based on the background of this era. Its application is of great significance to the development of the entire power industry.
隨著社會經(jīng)濟的飛速發(fā)展和高壓電器的日益增多，高壓電器絕緣問題越來越受到人們的重視。環(huán)氧樹脂在目前的高壓電器絕緣系統(tǒng)中最為常見，它的應(yīng)用對于整個電力系統(tǒng)安全有著重要意義。隨著電壓的不斷增加，電氣絕緣系統(tǒng)要求越來越嚴格，大容量發(fā)電技術(shù)的發(fā)展促使著電力電壓的提升，也不斷使得絕緣材料進步與優(yōu)化。
With the rapid development of social economy and the increasing number of high-voltage electrical appliances, the insulation of high-voltage electrical appliances has attracted more and more attention. Epoxy resin is the most common in current high-voltage electrical insulation systems. Its application is of great significance to the safety of the entire power system. With the continuous increase of voltage, the requirements for electrical insulation systems have become more and more stringent. The development of large-capacity power generation technology has promoted the increase of power voltage. It has also continuously made progress and optimization of insulation materials.
伴隨著科學技術(shù)發(fā)展和化學工業(yè)的日益進步，環(huán)氧樹脂也越來越復(fù)雜，其構(gòu)成和組成方式日益繁瑣。按照其組成方式我們就可以將環(huán)氧樹脂分為縮水甘油酯類、縮水甘油醚類、脂肪族環(huán)氧化合物等。按照當前的工作狀態(tài)以及工作方法，我們可以將環(huán)氧樹脂分為液態(tài)環(huán)氧樹脂和固態(tài)環(huán)氧樹脂兩種。
With the development of science and technology as well as the increasing progress of chemical industry, epoxy resin is becoming more and more complex. Its composition and combination methods are becoming more and more complicated. According to their composition we can divide epoxy resins into glycidyl esters, glycidyl ethers and aliphatic epoxy compounds. According to the current working status and working methods, we can divide epoxy resins into liquid epoxy resins and solid epoxy resins.
由于環(huán)氧樹脂的絕緣性能高、結(jié)構(gòu)強度大和密封性能好等許多獨特的優(yōu)點，已在高低壓電器、電機和電子元器件的絕緣及封裝上得到廣泛應(yīng)用。主要用于電器、電機絕緣封裝件的澆注，如電磁鐵、接觸器線圈、互感器、干式變壓器等高低壓電器的整體全密封絕緣封裝件的制造。特別在電器工業(yè)中得到了快速發(fā)展，從常壓澆注、真空澆注已發(fā)展到自動壓力凝膠成型。
Due to its many unique advantages, such as high insulation performance, high structural strength and good sealing performance, epoxy resin has been widely used in the insulation and packaging of high and low voltage electrical appliances, motors and electronic components. It is mainly used for casting of electrical equipment and motor insulation packaging, including the manufacturing of integrally sealed insulating packages for high and low voltage electrical appliances such as electromagnets, contactor coils, mutual inductors and dry-type transformers. It has developed rapidly in the electrical industry from normal pressure casting and vacuum casting to automatic pressure gel forming.
南通新納希新材料有限公司可以提供三款脂環(huán)族縮水甘油酯類環(huán)氧樹脂，牌號分別為S-182、S-184和S-186。本文將重點介紹S-182和S-184在戶外高壓電器絕緣中的具體應(yīng)用分析。新納希環(huán)氧樹脂憑借著優(yōu)異的機械、熱以及介電性能，廣泛用于戶外絕緣的電氣設(shè)備。
Nantong Synasia New Material Co., Ltd. can provide three different types of cycloaliphatic glycidyl ester epoxy resins, including S-182, S-184 and S-186. In this post, we will introduce the specific application analysis of S-182 and S-184 in outdoor high-voltage electrical insulation. Due to excellent mechanical, thermal and dielectric properties, Synasia epoxy resins are widely used for insulation in outdoor electrical equipment.
01. 新納希產(chǎn)品介紹/Synasia product introduction
Syna S-182
CAS no. 21544-03-6
化學品名：四氫鄰苯二甲酸二縮水甘油酯
Chemical name: tetrahydrophthalic acid diglycidyl ester
S-182作為一款低粘度基礎(chǔ)樹脂，耐低溫性能極佳?？梢赃x用酸酐和胺類作為固化劑，用于絕緣材料澆筑體。
As a low-viscosity base resin, S-182 is best known for its excellent resistance to low temperature. This product can be cured with either amines or anhydrides. Itis suitable for insulating materials in casting bodies.
對于高壓電器來說，環(huán)氧澆注絕緣體的出現(xiàn)不僅會使高壓電器介電性能、機械強度等得到提高，而且還能使電子器件體積減少，質(zhì)量減輕等。在生產(chǎn)環(huán)氧澆注絕緣體時，不僅需要保證其工藝性，比如流動性、澆注溫度、凝膠化速度、固化速度等等，而且也要保證膠在固化過程中有良好的裂開性和較高的耐熱性。這就需要在生產(chǎn)過程中，化學反應(yīng)放熱量及其體積收縮率要小，熱膨脹系數(shù)與嵌入固體件的熱膨脹系數(shù)要接近，固化物要有較高的機械強度等。
The appearance of epoxy cast insulators will not only improve the dielectric properties and mechanical strength of high-voltage electrical appliances, but also reduce the volume and quality of electronic devices. In the production of epoxy cast insulators, it is not only necessary to ensure its manufacturability, such as fluidity, casting temperature, gelation speed, curing speed, etc., but also to ensure that the glue has good cracking and high resistance during the curing process. This requires that in the production process, the heat of chemical reaction and its volume shrinkage should be small. Its thermal expansion coefficient should be close to that of the embedded solid part and the cured product should have higher mechanical strength.
Syna S-184
CAS no. 5493-45-8
化學品名：六氫鄰苯二甲酸二縮水甘油酯
Chemical name: hexahydrophthalic acid diglycidyl ester
S-184 是基于六氫鄰苯二甲酸酐的低粘度雙官能脂環(huán)族縮水甘油酯環(huán)氧樹脂。它可以用胺或酸酐固化。由于它是完全脂肪族的，因此該產(chǎn)品非常適合在戶外使用時承受陽光和紫外線照射。用加速酸酐固化劑固化時，可達到110℃以上的玻璃化轉(zhuǎn)變溫度。
S-184 is low-viscosity difunctional cycloaliphatic glycidyl ester epoxy resin based on hexahydrophthallic anhydride. It can be cured with either amines or anhydrides. Because it is fully aliphatic, this product is well suited to withstand sun and uv exposure in outdoor use. When cured with accelerated anhydride curing agents, glass transition temperature in excess of 110℃ can be attained.
S-184主要用于為中高壓設(shè)計的戶外電氣絕緣應(yīng)用。由于它是不含雙酚A的環(huán)氧樹脂，因此該產(chǎn)品非常適合用于不黃變的涂料、電絕緣部件，特別是鑄造體中的絕緣材料，例如變壓器填料。
S-184 is used mostly in applications for outdoor electrical insulation designed for medium and high voltage. Because it is bisphenol-A free epoxy resin, this product is excellent for non-yellowing coatings, electrical insulating components, especially the insulating materials in casting bodies, e.g., transformer fillers.
就當今的環(huán)氧樹脂的應(yīng)用實踐進行分析，環(huán)氧樹脂在應(yīng)用的過程中不僅具備著粘結(jié)性良好、固化過程較為科學、耐熱性與耐久性高的特點，同時其抗腐蝕性、抗機械強度也較高，能夠滿足各種不同高壓配線施工要求。
Based on the application analysis of today’s epoxy resin, epoxy resin not only has the characteristics of good adhesion, scientific curing process, good heat resistance and high durability, but it also provides excellent resistance to corrosion and mechanical strength. It can meet various high-voltage wiring requirements in construction.
對于絕大部分高壓電器來說，通常采用露天的方式進行運作。所以耐氣候變化的環(huán)氧絕緣漆的研發(fā)勢在必行。S-184因其耐候性極佳，特別適合戶外高壓電器絕緣材料中的應(yīng)用。
Most high-voltage electrical appliances usually operate in the open air. Therefore, the research and development of weather-resistant epoxy insulating paint is imperative. S-184 is especially suitable for the application of outdoor high-voltage electrical insulation materials due to its excellent weatherability.
隨著我國智能電網(wǎng)體系的建設(shè)以及對輸變電的安全與可靠性要求的不斷提高，作為輸配電重要設(shè)備的開關(guān)、絕緣子、變壓器及互感器等戶外高壓電器產(chǎn)品，其絕緣的無油化、無瓷化已成為電力部門迫切需要解決的問題。目前，以脂環(huán)族環(huán)氧樹脂為代表的戶外環(huán)氧樹脂澆注料已逐步代替硅橡膠，在10～110 kV電壓等級絕緣中占主導地位。
With the construction of China's smart grid system and the continuously increased safety and reliability requirements of power transmission and transformation, outdoor high-voltage electrical products such as switches, insulators, transformers, mutual inductors and so on, which are important equipment for transmission and distribution. Oil-free and porcelain-free insulation has become an urgent issue in the power sector. At present, outdoor epoxy resin castables especially cycloaliphatic epoxy resins have gradually replaced silicone rubber. They have taken a leading role in the insulation of voltage levels of 10 to 110 kV.
02. 環(huán)氧樹脂澆注工藝/Epoxy resin casting technology
環(huán)氧樹脂澆注的工藝方法，從不同的工藝條件去理解有不同的區(qū)分方法。從物料進入模具的方式來區(qū)分可分為澆注和壓注；澆注指物料自流進入模具。它又分常壓澆注和真空澆注；壓注指物料在外界壓力下進入模具，并且為了強制補縮 , 在物料固化過程中，仍保持著一定的外壓，它由過去的簡單加壓凝膠法發(fā)展成現(xiàn)在成熟的自動壓力凝膠法。從物料固化溫度來區(qū)分，可分為常溫澆注法和高溫澆注法。
Epoxy resin casting method varies with different technical conditions. According to the way the material enters the mold, it can be divided into casting and injection molding. Casting refers to the self-flowing of the material into the mold. It is divided into normal pressure casting and vacuum casting. Injection molding means that the material enters the mold under external pressure, and in order to force the feeding, the material still maintains a certain external pressure during the curing process. It has developed from the simple pressure gel method in the past to the mature automatic pressure gel method. According to the solidification temperature of the material, it can be divided into normal temperature casting method and high temperature casting method.
從物料固化的速度來區(qū)分可分為普通固化法和快速固化法?，F(xiàn)代澆注工藝中，應(yīng)用比較成熟的澆注工藝方法主要是真空澆注法和自動壓力凝膠法。環(huán)氧樹脂澆注是將環(huán)氧樹脂、固化劑和其他配合料澆注到設(shè)定的模具內(nèi),由熱塑性流體交聯(lián)固化成熱固性制品的過程。目前常用的方法有真空澆注法、常壓澆注法以及環(huán)氧樹脂全密封的新工藝、新技術(shù)。
According to the curing speed of the material, it can be divided into ordinary curing method and fast curing method. In modern casting technology, mature casting methods mainly include vacuum casting method and automatic pressure gel method. Epoxy resin casting is the process of casting epoxy resin, curing agent and other materials into a set mold, and then cross-linking and curing by a thermoplastic fluid into a thermoset product. At present, commonly used methods include vacuum casting method, normal pressure casting method and innovative epoxy resin full sealing technology.
03. 環(huán)氧樹脂發(fā)展趨勢/Epoxy resin development trend
環(huán)氧樹脂電子電器封裝及絕緣材料的發(fā)展方向主要是：提高材料的耐熱性、介電性和阻燃性，降低吸水率、收縮率和內(nèi)應(yīng)力。改進的主要途徑是：合成新型環(huán)氧樹脂和固化劑；原材料的高純度化；環(huán)氧樹脂的改性，比如增韌、增柔、填充、增強、共混等；開發(fā)無溴阻燃體系；改進成型工藝方法、設(shè)備和技術(shù)。隨著半導體技術(shù)的飛速發(fā)展，對封裝材料的要求也越來越高，普通環(huán)氧樹脂已不能完全滿足技術(shù)要求。
The development direction of epoxy resin based electrical encapsulation and insulation materials is mainly to improve the heat resistance, dielectricity and flame retardancy of materials, and reduce water absorption, shrinkage rate and internal stress. The main ways of improvement include: synthesis of new epoxy resins and curing agents, higher purity of raw materials, modification of epoxy resins, such as toughening, softening, filling, strengthening, blending, etc., development of bromine-free flame retardant systems as well as the improvement of molding methods, equipment and technology. With the rapid development of semiconductor technology, the requirements for packaging materials are getting higher and higher. Ordinary epoxy resins can no longer fully meet the technical requirements.
目前國外對環(huán)氧樹脂技術(shù)改進主要集中在：
For the improvement of epoxy resin technology, overseas companies mainly focus on:
開發(fā)低粘度或熔融粘度低的二官能團型的環(huán)氧樹脂，通過填充高含量無機填充劑，大幅度降低封裝器件的內(nèi)應(yīng)力，減少鈍化開裂、配線松動和導線斷裂等不良缺陷。
Development of low-viscosity or low-melt-viscosity difunctional epoxy resins at present. With the use of high-content inorganic fillers, the internal stress of the packaged devices is greatly reduced, which helps minimize undesirable defects such as passivation cracking, loose wire, wire break, etc.
開發(fā)多官能團型的環(huán)氧樹脂，同時在環(huán)氧樹脂中導入耐熱和耐濕結(jié)構(gòu)的化合物，使封裝器件既具有高耐熱性，又具有低吸水率和低的內(nèi)應(yīng)力。
Development of multifunctional epoxy resins and at the same time introduce heat-resistant and moisture-resistant structural compounds into the epoxy resin, so that the packaged device can offer high heat resistance, low water absorption and low internal stress.
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