Patent Number: 041683943
Section: description

DETAILED DESCRIPTION OF THE DRAWING Referring to FIG. 1, there is shown one embodiment of electrical penetration assembly 11 employing my novel features, as would be typically installed in a penetration nozzle 15, piercing a concrete wall 16 enclosing a nuclear reactor (not shown) which would be located to the right of FIG. 1. The nozzle 15 is preferably made of an alloy steel and has an annular steel flange 17 fixed to the end thereof. The nozzle 15 is normally cylindrical and the flange 17 has its exposed surface perpendicular to the nozzle axis. Suitably bolted by bolts 19 to flange 17 is a steel header plate 18 having internal bores or passageways 21 suitably placed in a manner that will be made more apparent hereinafter, and having at least one transverse bore 20. Between the flange 17 and plate 18 is disposed an annular gasket 22 having novel features, as will be explained hereinafter. Into each transverse bore is inserted an electrical penetration assembly 11. The passageways 21 are made to communicate with each transverse bore 20 and to a pressure gauge 25 in a manner such as is taught in U.S. Pat. No. 3,828,118. One will note that the transverse bore 20 consists of two cylindrical outer bore sections 20a and 20b connected by a conical section 20c so that the assembly 11 can be removed from the outside of the reactor containment vessel represented by wall 16. The embodiment of the electrical penetration assembly 11 shown in FIG. 1 has a central conductor 31 preferably made of copper surrounded by ceramic insulator 32 preferably shaped as shown. The insulator 32 has the necessary annular ribs 33 to provide a high resistance to electrical leakage patterns. Between the ribs 33 the insulator has two cylindrical portions or sections 20a' and 20b' disposed on each side of a tapered portion or section 20c' to match the respective cylindrical sections 20a and 20b and the tapered section 20c on the transverse bore in the header plate 18. Within the tapered section 20c' of the insulator 32, a gas pervious means, in the form of a porous ceramic section 35, is placed between non-porous ceramic sections 36 and 37. The porous section 35 is, for example, made of equal amounts of alumina and silica with 100 micron-sized pores and is disc shaped. The sections 36 and 37 are, for example, made of alumina which is formed dense and rigid and with a glazed surface. Section 35 is bonded to sections 36 and 37 with a suitable glaze and the bonding is preferably done in the green state before firing of the ceramic to achieve uniform bonding strength. The ends of the conductor 31 are provided with suitable terminals such as terminal 38 which is called a NEMA type lug terminal. Since the bonding between the copper conductor 31 and the insulator 32 is inherently poor, I have provided a flexible metal apertured cap 41 at each end of the insulator 32, the cap 41 is shaped as shown to provide a lateral or axial movement between the conductor and insulator. The cap 41 is made of, for example, Monel, which is brazed to the copper conductor 31 and brazed to an annular metallized surface 42 on the insulator 32, which surface is made in a well known manner. To prevent relatively large axial movements, a copper ring 43 is brazed on the conductor 31 adjacent to each end of the insulator 32. These rings 43 are located on the copper when the copper is at ambient temperature and then bonded thereto. The electrical penetration assembly 11 is installed as shown, with a pair of suitable O-ring seals 45 and 46 disposed in suitable grooves in the header 18 and a retaining ring 47 bolted to the outside of the header and holding the assembly 11 in place. As in the prior art, the passageway 21 is filled with nitrogen. The nitrogen communicates with a pair of opposing circumferential grooves 51 in gasket 22 through a passageway 52. The gasket 22 has aperture 53 between grooves 51. Therefore, if any leaks develop, the nitrogen would pass through the porous ceramic 35 and through the space between the gasket 22 and header 18 or flange 17 and the pressure read on the gauge 25 would drop. Referring to FIG. 2, another embodiment of my electrical penetration assembly is shown, wherein like numbered items refer to the same functional thing. This embodiment also has the electrical conductor 31, the ceramic insulator 32 with ribs 33, cylindrical sections 20a' and 20b' and tapered section 20c', flexible end caps 41, metallized surfaces 42 and rings 43. Since no porous section 35 is provided, as this insulator 32 is made of a dense alumina, I have provided a T-shaped leakage path or ducts 61 and 62 with path 61 parallel to the conductor 31 and opening at opposite ends of the insulator 32 within the end caps and with path 62 communicating with path 61 and opening at the tapered section 20c'. Now, when this embodiment is installed, such as the embodiment shown in FIG. 1, path 62 communicates with the passageway 21 to perform a like function. Referring to FIG. 3 there is shown another embodiment wherein like numbered items refer to the same functional thing. This embodiment also has the electrical conductor 31, insulator 32 with ribs 33, cylindrical sections 20a', 20b' and tapered section 20c', flexible end caps 41, metallized surfaces 42 and rings 43. This embodiment also eliminates the porous section 35, but includes a zigzag duct 63 which terminates against the conductor 31, as shown, and opens at the tapered section 20c'. Also, when this embodiment is installed, such as in the embodiment of FIG. 1, path 63 communicates with path passageway 21 to perform a like function. Referring to FIG. 4, there is shown still another embodiment which has utility for low voltage application. This embodiment has a plurality of conductors 71, preferably seven conductors, arranged with six conductors evenly disposed around a central conductor. The conductors 71 are covered by a suitable insulator shaped similar to the insulator of the embodiment in FIG. 1, but made simpler. The insulator has two outer cylindrical sections 72 and 73 of different diameters connected by a conical section 74. At the conical section is placed a wafer-shaped porous insulator 75 while on each side there is disposed a dense insulation material as will be further described. This electrical penetration assembly can also be installed in a system shown in FIG. 1 so that the porous insulator 75 communicates with passageway 21. Since the bonding between conductor 71 and the insulator should prevent leakage at extreme conditions and after long life, the preferred process for making these electrical penetration assemblies, as shown in FIG. 4, will now be explained. The coefficient of thermal expansion for any conductor material such as copper is greater than most thermosetting dielectric materials. Further, shrinkage of the thermosetting dielectric materials after molding tends to move in the opposite direction from the conductors causing some leak paths between the conductors and the dielectric materials. The process described herein consists of applying a flexible coating between the conductors and the dielectric materials to produce a bonding in-between insuring a hermetically sealed thermosetting dielectric material on the conductors. The preferred process includes the following steps: 1. Each copper conductor is cleaned in an alkaline solution, rinsed and descaled in an ammonium persulfate solution (90 gms/liter), rinsed with de-ionized water and dried. 2. Each cleaned conductor is immersed in gamma-glycidoxypropyltrimethoxysilane and drained. Treated conductors are air dried for approximately 30 minutes. 3. A coating of solventless silicone resin is applied on each conductor, consisting of (a) a solventless liquid organosilicone resin containing 30 to 65 mol percent C.sub.6 H.sub.5 SiO.sub.3/2 units, 15 to 30 mol percent CH.sub.3 (CH.sub.2 .dbd.CH)SiO units, 20 to 40 mol percent (CH.sub.3).sub.2 SiO units, and 0 to 5 mol percent (CH.sub.3).sub.3 SiO.sub.1/2 units; (b) an organopolysiloxane fluid having at least two .tbd.SiH groups per molecule, the organopolysiloxane being of the formula ##STR1## in which n is an integer having a value of 2 or more, m is an integer having a value of 1 or more, n and m having a total value sufficient to result in a fluid having a viscosity of from 20 to 2000 cs. at 25.degree. ., the diphenylsiloxy units comprising from about 30 to 40 mol percent of said organopolysiloxane, which is present in the mixture in an amount sufficient to provide from 0.75 to 1.5 mol of .tbd.SiH per mol of vinyl substituent in (a); and (c) a platinum catalyst such as chloroplatinic acid containing approximately 10 p.p.m. by weight of platinum. 4. Each conductor is loaded into a mold retention insert, such as porous insulator 75, and preheated in an oven at 200.degree. C. The applied coating on the conductors is cured at 200.degree. C. for one hour. A complete cure of the coating is not necessary so that a maximum bonding may be obtained on the dielectric materials to be applied next. 5. The dielectric material consists of solventless silicone resin as described in (3) used in conjunction with filler materials of approximately 60 to 75 percent by weight of alumina powder or barium titanate or silica powder treated with gamma-glycidoxypropyltrimethoxysilane and between 1 to 3 percent of coarse-grain magnesium oxide to enhance the thermal conductivity. An example of the composition of the dielectric materials is as follows: (a) and (b): 34.5 gm PA1 (c): 3.5 gm PA1 Alumina Powder: 60 gm PA1 50-mesh Magnesium Oxide: 2 gm PA1 Dow Corning R-4-3157 Base: 34.5 gm PA1 Curing agent R-4-3157: 3.5 gm PA1 Tabular alumina: 60 gm PA1 350-mesh magnesium oxide: 2 gm PA1 Pyromellitic dianhydride: 8.5 gm PA1 N-glycidelphthalimide: 35 gm PA1 Tabular alumina: 60 gm 6. The above composition is cast into the mold and cured at 200.degree. C. for 16 hours. The electric feed-through module thus produced is hermetically sealed on each conductor. The dielectric material can withstand gamma irradiation to 2.times.10.sup.10 rads, thermal aging to 40 years design life, superheated steam at 600.degree. F. under pressure of 1200 psig without losing its hermeticity. Making the hermetically sealed electric penetration assembly feed-through modules, as shown in FIG. 4, by the standard vacuum cast method, ordinarily takes about 16 hours at 200.degree. C. This is not very suitable for high volume production. By the pressure gelation method on the other hand, it takes only about 30 minutes. Further, electric feed-through modules produced by the pressure gelation process are void free, more densely packed and better sealed with conductors because of the pressure exerted on the material during gel. As a result, considerable improvement can be achieved in the mechanical tensile strength, volume resistivity, insulation resistance and corona extinction level for high voltage applications. Referring to FIG. 5, the preferred apparatus and method of operation for making modules shown in FIG. 4 is now described: 1. After a coating of solventless silicone resin is applied on each conductor as described in (3) of the above mentioned process, each conductor is loaded into the mold 101 for pressure gelation molding. 2. The automatic pressure gelation system consists of a hydraulic press 102 to close the molds, a mold heating system 103 with thermostat control, a resin supply tank 104 with stirrer 105. The solventless silicone resin and the filler materials are first thoroughly mixed under vacuum drawn through tube 106. Then nitrogen pressure is applied through tube 106 so as to deliver the resin mixture into the mold 101. The mold is pre-heated to 200.degree. C. and material in the mold is held under a constant nitrogen pressure of approximately 15 psig during gel. 3. After about 30 minutes, the hermetically sealed electric feed-through module is cured and can be taken out of the mold. The module may be placed in an air-circulating oven preheated to a lower temperature to allow slower cooling rate to prevent any thermal shock during sudden cooling which may produce cracking of the molded parts. Examples of typical resin mixtures used to make insulators 72 and 73 of FIG. 4 are: 1. Solventless silicone resin Process: Pressure gelation molding at 200.degree. C. & 15 psig during gel for 30 minutes, followed by post-curing at 150.degree. C. for 4 hours. 2. PMDA Process: Compression molding at 400.degree. F. and 1,500 psig. Having described the preferred embodiments of my invention, one skilled in the art could devise other embodiments without departing from the spirit of my invention. Therefore, my invention is not to be considered as limited to the embodiments described but includes all embodiments which fall within the scope and breadth of my appended claims.