CAPACITOR, CAPACITIVE VOLTAGE SENSOR AND METHOD FOR MANUFACTURING A CAPACITOR

Abstract

A capacitor comprises an electrically conductive cylinder, an electrically conductive or semi-conductive cylindrical shell or shell segment arranged concentrically around the electrically conductive cylinder, and a dielectric arranged between the electrically conductive cylinder and the electrically conductive or semi-conductive cylindrical shell or shell segment. The dielectric comprises a particulate composite including a matrix material having a non-zero (e.g. negative) thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having an opposite (e.g. positive thermal) coefficient of relative permittivity. The positive thermal coefficient of relative permittivity is thereby selected such that the capacitance value of the capacitor is constant within a stability margin over a predefined temperature interval.

Claims

1. Capacitor comprising: an electrically conductive cylinder; an electrically conductive or semi-conductive cylindrical shell or shell segment arranged concentrically around the electrically conductive cylinder; and a dielectric arranged between the electrically conductive cylinder and the electrically conductive or semi-conductive cylindrical shell or shell segment, the dielectric comprising: a particulate composite including a matrix material having a non-zero thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having an opposite thermal coefficient of relative permittivity, wherein the coefficients of relative permittivity are selected such that the capacitance value of the capacitor is constant within a stability margin over a predefined temperature interval.

2. Capacitor according to claim 1, wherein dielectric comprises a particulate composition including a matrix material having a negative thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having a positive thermal coefficient of relative permittivity.

3. Capacitor according to claim 1, wherein the matrix material comprises a plastic or rubber material, such as silicone rubber or a silicone elastomer.

4. Capacitor according to claim 1, wherein the matrix material comprises one or a combination of ethylene propylene diene monomer (EPDM) and high module ethylene propylene rubber (HEPR).

5. Capacitor according to claim 1, wherein the particulate filler material comprises one or a combination of an epoxy, a polyurethane resin, polyvinylidenefluoride and polyvinylidenefluoride co-polymers.

6. Capacitor according to claim 1, wherein the particulate filler material is included in the matrix material an amount between 0 vol % and 30 vol % of particulate filler material.

7. Capacitor according to claim 1, wherein the electrically conductive cylinder forms part of a high-voltage or medium-voltage power conductor in a high-voltage or medium-voltage power network.

8. Capacitor according to claim 1, wherein the electrically conductive or semi-conductive cylindrical shell or shell segment comprises a mechanically rigid metal component, in particular an aluminium, steel and/or copper annulus.

9. Capacitor according to claim 1, wherein the electrically conductive or semi-conductive cylindrical shell or shell segment comprises a flexible member, in particular a conductive silicone tube or a silicone pad covered with an electrically conductive ink or coating.

10. Capacitive voltage sensor, comprising: a capacitor according to claim 1 as voltage sensing capacitor; a reference impedance coupled in series between the voltage sensing capacitor and a reference potential; and a voltage measurement circuit configured to measure a voltage drop across the reference impedance.

11. Method for manufacturing a capacitor, comprising the steps of: applying a dielectric to an electrically conductive cylinder; and arranging an electrically conductive or semi-conductive cylindrical shell or shell segment concentrically around the electrically conductive cylinder over the dielectric, wherein the dielectric comprises a particulate composite including a matrix material having a negative thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having a positive thermal coefficient of relative permittivity.

12. Method according to claim 11, wherein applying the dielectric comprises: mixing the particulate filler material to the liquid silicone rubber or silicone elastomer composition in a static or dynamic mixer of an injection moulding machine; and injection moulding the mixed silicone composition over the electrically conductive cylinder.

13. Method according to claim 12, further comprising: blending additional particulate filler material with the liquid silicone rubber or silicone elastomer composition prior to filling the composition into the injection moulding machine.

14. Method for manufacturing a capacitor, comprising the steps of: applying a dielectric between an electrically conductive cylinder and an electrically conductive or semi-conductive cylindrical shell or shell segment comprising a mechanically rigid metal component, in particular an aluminium, steel and/or copper annulus, wherein the dielectric comprises a particulate composite including a matrix material having a negative thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having a positive thermal coefficient of relative permittivity.

Description

[0032] The invention will be explained in greater detail with reference to exemplary embodiments depicted in the drawings as appended.

[0033] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification.

[0034] The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.

[0035] FIG. 1 schematically illustrates a perspective view of a voltage sensing capacitor according to an embodiment of the invention.

[0036] FIG. 2 schematically illustrates an axial cross section view through the voltage sensing capacitor of FIG. 1 along the line A-A according to a further embodiment of the invention.

[0037] FIG. 3 schematically illustrates a radial cross section view through the voltage sensing capacitor of FIG. 1 along the line B-B according to a further embodiment of the invention.

[0038] FIG. 4 schematically illustrates a radial cross section view through a modified voltage sensing capacitor according to another embodiment of the invention.

[0039] FIG. 5 schematically illustrates a radial cross section view through a modified voltage sensing capacitor according to an even further embodiment of the invention.

[0040] FIG. 6 shows a measurement diagram illustrating the thermal dependence of capacitance value of a voltage sensing capacitor according to a further embodiment of the invention.

[0041] FIG. 7 shows a measurement diagram illustrating the thermal dependence of capacitance value of a further voltage sensing capacitor according to yet another embodiment of the invention.

[0042] FIG. 8 schematically illustrates a block diagram of capacitive voltage sensor circuitry according to another embodiment of the invention.

[0043] FIG. 9 schematically illustrates stages of a method for manufacturing a voltage sensing capacitor according to another embodiment of the invention.

[0044] In the figures, like reference numerals denote like or functionally like components, unless indicated otherwise. Any directional terminology like top, bottom, left, right, above, below, horizontal, vertical, back, front, and similar terms are merely used for explanatory purposes and are not intended to delimit the embodiments to the specific arrangements as shown in the drawings.

[0045] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

[0046] A perspective view of a voltage sensing capacitor 10 is schematically illustrated in FIG. 1. The two sectional view along the lines A-A and B-B of the voltage sensing capacitor 10 of FIG. 1 are shown in FIGS. 2 and 3, respectively. The voltage sensing capacitor 10 is generally of cylindrical or tubular shape having a central axis denoted with the reference sign X. Of course, the cylindrical shape does not necessarily need to be straight, but instead bent or curved cylindrical shapes may be equally possible. Particularly, when used for sensing a voltage of a current carrying conductor, the voltage sensing capacitor 10 may be manufactured from generally flexible or elastic materials, allowing the capacitor 10 to be bent at its central axis X to deviate from the purely straight cylindrical shape.

[0047] Along the central axis X an electrically conductive cylinder 2 is arranged to act as an inner electrode of the capacitor 10. The electrically conductive cylinder 2 may particularly form a part of a high-voltage or medium-voltage power conductor in a high-voltage or medium-voltage power network. An electrically conductive or semi-conductive cylindrical shell 1 is arranged concentrically around the electrically conductive cylinder 2, being spaced apart from the electrically conductive cylinder 2. The electrically conductive or semi-conductive cylindrical shell 1 acts as outer electrode or counter-electrode for the inner electrode of the capacitor 10. In between the two electrodes 1 and 2, a dielectric 3 is arranged.

[0048] As can be seen in the drawings of FIGS. 2 and 3, the dielectric 3 generally includes a particulate composite. The particulate composite is comprised of a matrix material having a negative thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having a positive thermal coefficient of relative permittivity. Therefore, upon an increase in temperature, the change in relative permittivity of the matrix material will be offset by the opposite change in relative permittivity of the particulate filler material.

[0049] The filler material is therefore chosen to have a positive thermal coefficient of relative permittivity. Exemplary filler materials may for example include epoxies such as Scotchcast Electrical Resin 8, or polyurethane resins such as Scotchcast Electrical Insulating Resin 40 or Scotchcast Electrical Insulating Resin 1402 FR, all available from 3M Company, U.S.A. Other filler materials may for example include polyvinylidenefluoride and polyvinylidenefluoride co-polymers such as Dyneon PVDF 31508 or Dyneon PVDF 11008, both available from 3M Company, U.S.A. The positive thermal coefficient of relative permittivity of the filler material is selected such that the capacitance value of the capacitor is constant within a stability margin over a predefined temperature interval. In other words, the positive thermal coefficient of relative permittivity of the filler material is used to compensate for the negative thermal coefficient of relative permittivity of the matrix material so that the effective relative permittivity of the dielectric 3 as a whole will remain stable with a change in temperature or will slightly increase within a predefined temperature interval. The desired effective relative permittivity may be adjusted by selecting appropriate filler material and by varying the amount of filler material in the particulate composite.

[0050] The stability margin may be predefined according to quality standards of the voltage sensing capacitor when used in a capacitive voltage sensor. Some quality standards like IEC 60044-7 (1999) define a stability margin equal to or less than +/3.0% or +1-0.5% or +1-0.2% of the capacitance value of the capacitor 10. The material, dimensions and positioning of the filler material and the matrix material may thus be selected to be able to keep the capacitance value within the desired stability margin.

[0051] The predefined temperature interval is according to IEC 60044-7 (1999) between 25 C. and +40 C. or between 40 C. and +40 C. Depending on the desired application of the capacitor, other predefined temperature intervals may be chosen as well, such as between 20 C. and +60 C., or between 40 C. and +70 C.

[0052] FIGS. 4 and 5 each schematically illustrate modified voltage sensing capacitors 10 in radial cross section view similar to the view in FIG. 3. The voltage sensing capacitors 10 of the FIGS. 4 and 5 are each modified in different details and various features with respect to the voltage sensing capacitor 10 as shown and explained in conjunction with FIGS. 1, 2 and 3. Of course, the modification of the details for one of the voltage sensing capacitors 10 of the FIGS. 4 and 5 may equally be applied to respective other ones of the voltage sensing capacitors 10 and the modification possibilities are not limited to the ones explicitly and exemplarily depicted in those drawings.

[0053] The outer electrode in FIGS. 2 and 3 is depicted as closed ring structure, i.e. a shell 1 surrounding the full 360 of the circumference of the cylindrical capacitor shape. However, as exemplarily depicted in FIG. 4, it may be equally possible to use an electrically conductive or semi-conductive cylindrical shell segment 1 that only surrounds a fraction of the circumference of the cylindrical capacitor shape. The fraction may be chosen according to the intended application and may generally take on any value between 0 and 360. It may further be possible to use more than one electrically conductive or semi-conductive cylindrical shell segment 1 as outer electrode so that a plurality of electrically conductive or semi-conductive cylindrical shell segments 1 may be equidistantly spaced around the circumference of the cylindrical capacitor shape.

[0054] As shown in FIG. 5, it may be possible to provide a screening electrode 5b arranged concentrically with and around the electrically conductive or semi-conductive cylindrical shell 1. The screening electrode 5b may be connected to a reference potential, for example to ground G. A further dielectric 4, for example being made of the same material as the dielectric 3 may be provided between the electrically conductive cylindrical or semi-conductive shell 1 and the screening electrode 5b. The capacitor formed by the electrically conductive cylindrical or semi-conductive shell 1 as inner electrode, the dielectric 4 and the screening electrode 5b may also be used as reference capacitor in a series connection with the screened voltage sensing capacitor 10. That way, some of the thermal expansion effects affecting the screened voltage sensing capacitor 10 may apply equally to the reference capacitor as well, so that the dividing ratio of the voltage divider is kept approximately constant.

[0055] If the electrically conductive or semi-conductive cylindrical shell 1 or shell segment comprises a mechanically rigid metal component, for example an aluminium, steel and/or copper annulus, the dielectric 3 may at least partly be implemented as embedded dielectric in the inner wall of the rigid metal component.

[0056] The electrically conductive or semi-conductive cylindrical shell 1 may be shaped in ring form having a recessed trench extending circumferentially in its inner wall (not shown in the drawings). The dielectric 3 may then be at least partially implemented as mastic or sealant that is embedded within the recessed trench of the electrically conductive cylindrical shell 1 or shell segment.

[0057] FIG. 2 further shows the implementation of a laterally shifted grounding electrode 5a placed near the electrically conductive cylindrical or semi-conductive shell 1 or shell segment. The laterally shifted grounding electrode 5a of FIG. 2 may be connected to a reference potential, such as ground G.

[0058] FIG. 6 shows a measurement diagram illustrating the thermal dependence C1, C2, C3 of capacitance value C of a voltage sensing capacitor 10 for various combinations of materials of the matrix and the filler. The measurement curve C1 depicts the capacitance value C vs temperature for an Elastosil LR 3003/70 silicone as matrix loaded with 1.8 vol % of Scotchcast Electrical Resin 8 epoxy as particulate filler material. The measurement curve C2 depicts the capacitance value C vs temperature for an Elastosil LR 3003/70 silicone as matrix loaded with 8 vol % of Scotchcast Electrical Resin 2160 polyurethane as particulate filler material. The measurement curve C3 depicts the capacitance value C vs temperature for an Elastosil LR 3003/70 silicone as matrix loaded with 18 vol % of Dyneon PVDF 31508 as particulate filler material.

[0059] As can be seen, the composite material used as dielectric 3 compensates the oppositely changing relative permittivities with temperature of both matrix and filler material over a large temperature interval. As can be seen, the relative deviation C from a reference capacitance value for the curve C1 does not exceed 0.5% over a temperature interval of at least 5 C. to +65 C., C2 does not exceed 0.5% over a temperature interval of at least 0 C. to +70 C., C3 does not exceed 0.5% over a temperature interval of at least 20 C. to +70 C.

[0060] FIG. 7 shows a measurement diagram illustrating the thermal dependence C1 of capacitance value C of a voltage sensing capacitor 10 including Elastosil LR3003/70 silicone as matrix material loaded with 8.5 vol % of Dyneon PVDF 11008 as particulate filler material. As can be seen, the relative deviation C from a reference capacitance value for this combination does not exceed 0.5% over a temperature interval of at least 20 C. to +70 C.

[0061] Typical axial lengths of the cylindrical capacitors 10 are at least 20 mm to 500 mm, preferably between 30 mm to 60 mm. Any other length is possible as well and strongly depends on the application. In particular, matrix materials having high shore hardness may be advantageously chosen to largely avoid thermal expansion problems.

[0062] FIG. 8 schematically illustrates a block diagram of capacitive voltage sensor circuitry 20 employing a capacitor 10 as a voltage sensing capacitor CS of a voltage divider. A reference impedance, such as for example a reference capacitor CM, is coupled in series between the voltage sensing capacitor CS and a reference potential such as for example ground G. A voltage measurement circuit 7 that is connected to a node NM between the two capacitors CS and CM on one hand and to a node NG connected to the reference potential on the other hand is configured to measure a voltage drop across the reference capacitor CM. The measured voltage drop may then be output to a control processor 8 that produces a corresponding voltage signal. The control processor 8 may for example be additionally equipped with electronic compensation means that further enhance the accuracy of the voltage signal, for example by taking into account temperature induced variations of the electric properties of the capacitors CS and CM. The reference capacitor CM may for example be installed on a PCB in the vicinity of the voltage sensing capacitor CS to provide for a compact voltage sensor assembly 20.

[0063] FIG. 9 schematically illustrates stages of a method M for manufacturing a capacitor, for example a voltage sensing capacitor 10 as explained in conjunction with FIGS. 1 to 5. The method M may be specifically used for manufacturing a capacitor that may be used as voltage sensing capacitor CS in a capacitive voltage sensor assembly 20 as illustrated in conjunction with FIG. 8.

[0064] In a first stage M1, a dielectric 3 is applied to an electrically conductive cylinder 2. The dielectric 3 is comprised of a particulate composite including a matrix material having a negative thermal coefficient of relative permittivity and a particulate filler material blended with the matrix material, the particulate filler material having a positive thermal coefficient of relative permittivity. The application in stage M1 may for example be performed by mixing the particulate material to the liquid silicone rubber or liquid silicone elastomer composition in a static or dynamic mixer of an injection moulding machine in a substage M1b. In order to mix the particulate filler material into the matrix material, the filler material should be pulverized to a powder as fine as possible. Such pulverization may be performed using a granular mill to obtain sub-millimeter particulate powder.

[0065] Typically, injection moulding machines may only allow for a maximum amount of 5 vol % of particulate material to be added in the mixer section due to restraints in the pumpability of the silicone oil component of the liquid silicone rubber or liquid silicone elastomer composition. If a higher amount of particulate material in the composite is desired, a previous optional substage M1a may be performed in which additional particulate material is blended with the liquid silicone rubber or liquid silicone elastomer composition prior to filling the composition into the injection moulding machine. The mixed silicone composition is then injection moulded in substage M1c over the electrically conductive cylinder 2. In a further option the electrically conductive or semi-conductive cylindrical shell 1 or shell segment in form of a mechanically rigid metal component may be inserted in the injection mold, so that the dielectric 3 fills the volume between cylinder 2 and conductive or semi-conductive cylindrical shell 1 or shell segment in one step. Step M2 can be omitted in this situation.

[0066] Then, in a stage M2, an electrically conductive cylindrical or semi-conductive shell 1 or shell segment is arranged concentrically around the electrically conductive cylinder 2 over the dielectric 3. This may for example be done by applying an electrically conductive ink or coating on the dielectric 3, or, alternatively, providing a flexible member such as an electrically conductive silicone pad or tube on the dielectric 3. For electrically contacting the electrically conductive cylindrical shell 1 or shell segment a copper tape may be applied on top of the electrode.

[0067] In the foregoing detailed description, various features are grouped together in one or more examples or examples with the purpose of streamlining the disclosure. It is to be understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents. Many other examples will be apparent to one skilled in the art upon reviewing the above specification.

[0068] The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. In the appended claims and throughout the specification, the terms including and in which are used as the plain-English equivalents of the respective terms comprising and wherein, respectively. Furthermore, a or one does not exclude a plurality in the present case.