Emulsions with improved stability

a technology of emulsion and stability, applied in the direction of plastic/resin/waxes insulators, transportation and packaging, coatings, etc., can solve the problems of environmental and safety concerns, acrylates carry unpleasant odor, and each of these monomers has significant use drawbacks

Inactive Publication Date: 2016-04-14
ELANTAS PDG
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0019]The present invention further provides a method of reducing or eliminating monomer content in electrical impregnating materials and at the same time reducing application viscosity to between 2000 mPas and 100 mPas, preferably between 200 mPas and 800 mPas, by employing as electrical impregnation material zero or low VOC emulsions comprising or consisting of
[0055]The present invention also provides a method of increasing the stability of aqueous emulsions of unsaturated polyesters comprising or consisting of

Problems solved by technology

Each of these monomers have significant drawbacks in use as electrical insulating varnishes.
Styrene and VT have high vapour pressure and low flashpoints leading to environmental and safety concerns.
Acrylates carry an unpleasant odor in addition to being expensive and having poor viscosity reduction of the unsaturated polyester resin.
UPE resins also have stability issues with only 6 months of shelf life before increases in viscosity are observed.
Aqueous epoxy emulsions are VOC and HAP free but are very expensive compared to the other chemistries.
Compositions with low levels of monomer or no monomer usually are very high viscosity materials (7000 cps / 7000 mPas) that are not suitable for impregnation of motors / stators.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0169]ELAN-Plus™ 71-0A01 (84 g of 35% surfactant in water) and 344 g of de-ionized water were added to a reactor and mixed for 30 minutes. In another reactor 336 g of unsaturated polyester Esterlite 605, 6 g of Dicumyl peroxide and 264 g of monomer DAP were heated to a temperature of 100° F. (38° C.) with continuous mixing. The unsaturated polyester solution was slowly added to the surfactant solution and mixed for half an hour. The pre-emulsion solution was then homogenised with an Eppenbach Homo-mixer until the particle size was less than one micron. Dynamic light scattering with a Malvern Mastersizer 3000 was used to measure the particle size. Viscosity was measured at 25° C. by Brookfield viscometer. The bond strength was measured on an Instron using the 3-point break method at 25° C. using ASTM D2519. Magnet wire (MW35) was formed into tight helical coils, dipped into the resin solution and cured in an oven for 2 hours at 150° C. Excellent bond strength of 23 lbs (10.43 kg) was...

examples 2 to 5

[0170]The same procedure as in Example 1 was repeated except that the amounts of the polyester and the monomer used were varied according to the formulation as shown in Table 1. The various (physical, mechanical, electrical properties) characteristic properties of these unsaturated polyester emulsion materials are presented in Table 2.

[0171]As can be seen in Examples 1-5, low levels of monomer can be used with an unsaturated polyester resin to achieve good film build and acceptable bond strength. The emulsion stability was checked after one year of room temperature ageing and found to be unchanged in emulsion particle size and physical bond strength characteristics.

TABLE 1Example 1Example 2Example 3Example 4Example 5Weights of raw materials charged (g)Surfactant8686868686De-ionized344344344344344waterPolyester336396456516576Esterlite605Monomer / 2642041448424oligomer

TABLE 2Example 1Example 2Example 3Example 4Example 5DAP:Resin44:5634:6624:7614:861:99Particle0.500.350.440.540.65sizeSol...

examples 6 and 7

[0172]The same procedure as in Example 1 was repeated except that the amounts of the polyester and the monomer used were varied according to the formulation as shown in Table 3.

[0173]The various (physical, mechanical, electrical properties) characteristic properties of these unsaturated polyester emulsion materials are presented in Table 4.

[0174]As was demonstrated in Examples 1-7, various commercially available unsaturated polyester resins (Esterlite 605 and Pedigree 70VT) can be utilised to make emulsions that are stable and achieve adequate film formation / bond strength. Different monomers were also successful including VT and DAP.

TABLE 3Example 6Example 7Weights of raw materials charged (g)Surfactant8686De-ionized water344344Polyester 70VT480540Monomer / oligomer12060

TABLE 4Example 6Example 7VT:Resin20:8010:90Particle size1.021.64Solids51.5255.2Viscosity (cP)290240Bond Strength (lbs)*27.2 / 3.5133.6 / 4.35(12.34 / 1.59)(15.24 / 1.97)*Bond strengths: HC, 25° C. / 150° C., curing: 2 h @ 150° C...

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Abstract

Disclosed are methods of lowering application viscosities of or of reducing or eliminating monomer content in electrical impregnating materials comprising or consisting of an emulsion of an unsaturated polyester or a mixture of unsaturated polyesters, water, at least one radical polymerisation initiator or radical polymerisation initiator / promoter mixture, at least one surfactant having an HLB-value of greater than 15, optionally at least one reactive diluent, and optionally further additives, a process for preparing zero or low VOC electrical impregnation materials, a method of impregnating electrical or electromechanical devices and a method of increasing the stability of aqueous emulsions of unsaturated polyesters.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The instant invention relates to compositions for insulating electrical machinery and more particularly to aqueous unsaturated polyester emulsion blends that are thermally or radiation cured.[0003]2. Discussion of Background Information[0004]Organic resin compositions are used as coatings for the mechanical, electrical and environmental-resistance they impart to electromagnetic devices. The coatings provide a mechanical strength, electrical insulation, and environmental protection for improved long-term durability of the devices, as well as increasing the quality of the final product.[0005]Suitable chemistries for the coating resin include, but are not limited to, unsaturated polyesters, epoxies, urethanes, waterborne polyesters, epoxy emulsions, silicones, organic solvent borne alkyds, acrylated and methacrylated urethanes, acrylated and methacrylated epoxies, acrylated and methacrylated polyols, and acrylated and meth...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): H01B3/42H01B19/04H01B19/02
CPCH01B3/425H01B19/04H01B19/02B05D1/02C08J3/095C08J2335/02C09D5/022C09D135/02
Inventor MURRAY, THOMAS J.BALAGAM, BHARATHI
Owner ELANTAS PDG
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