Optimization of insulating tapes for high power conductors

The integrity and performance of high-voltage electrical systems depend critically on the quality and reliability of their insulation. Insulating tapes are a vital component in the construction of high-power conductors, serving to prevent electrical faults and ensure safety and efficiency. This thesis explores the characterization and production performance of a broad spectrum of insulation tapes utilized in electrical engineering, focusing on their physical, thermal, electrical, and mechanical properties. These types include Natural Kraft, Kraft thermally upgraded and calendered, Kraft micro crepe, aramid tapes (such as Nomex), Polyester film, Polyimide, Mica tapes, coupled tapes, and dotted papers. Each material is evaluated for its specific attributes and suitability in various electrical insulation applications, such as in transformers, motors, and other high-power electrical apparatus. A comprehensive analysis was conducted using a combination of laboratory testing and industrial application assessments to evaluate each type of tape. Physical properties measured include thickness, tensile strength, and elongation at break, while thermal properties such as thermal stability are assessed under controlled conditions. Electrical properties, including dielectric strength, dielectric constant and dissipation factor, are also evaluated, alongside mechanical properties like tensile energy absorption and fracture toughness. Experimental results demonstrate significant variations in performance based on material composition and manufacturing processes. Natural Kraft tapes, for example, showed good mechanical strength but lower thermal and electrical performance compared to thermally upgraded Kraft and Kraft micro crepe tapes. Aramid tapes like Nomex exhibited excellent thermal stability and strength, making them ideal for high-temperature applications. Polyester film and Polyimide tapes provided outstanding electrical insulation properties but varied in their mechanical strength. Mica tapes emerged as superior in both thermal and electrical insulation, particularly in fire-resistant applications. Coupled tapes and dotted papers showed unique properties tailored for specific niche applications, offering improvements in ease of application and cost-effectiveness. The thesis further explores the implications of these findings for the manufacturing processes, highlighting how adjustments in material processing, such as calendering and creping, significantly impact the performance characteristics of the insulation tapes. Recommendations are provided for optimizing production techniques to enhance the desirable properties of each tape type. In conclusion, this thesis offers a detailed comparative analysis of various insulation tapes, providing valuable insights that can aid manufacturers in selecting the appropriate material for specific electrical insulation needs. It also lays the groundwork for future research in material science aimed at developing advanced insulation tapes with enhanced performance attributes. Keywords: Insulation Tapes, Electrical Insulation, Natural Kraft, Kraft Paper, Aramid Tape, Polyester Film, Polyimide, Mica Tape, Coupled Tapes, Dotted Paper, Material Characterization and selection.