Molding method of high-thermal-conductivity whole-immersion generator stator insulation system

Abstract

The invention discloses a forming method of a high-thermal-conductivity whole-immersion generator stator insulation system. The forming method comprises the following steps: after a copper material is drawn into an electromagnetic wire with a designed cross section, carrying out insulation coating treatment; carrying out gelling treatment on the electromagnetic wire after blanking and splicing; after a stator gelling coil is formed, a plurality of layers of high-heat-conduction mica tapes are wrapped; after the binding is finished, embedding the lower-layer soft stator coil into a stator core slot, and assembling an interlayer filler strip, an upper-layer soft stator coil, an expansion felt, an under-wedge filler strip and a slot wedge; a supporting ring, a support and a binding fastening structure are arranged on the end portion of the coil, expansion felts and insulation cushion blocks are arranged between the end portion coil and an insulation structural part in a cushioned mode, the end portion of the coil is bound through a binding band, and after the generator stator is assembled, the stator is subjected to overall pre-drying treatment and then is subjected to the overall vacuum pressure impregnation process. And finally, the high-thermal-conductivity generator stator insulation system is formed. The high-thermal-conductivity filler is introduced into a generator insulation system, so that the thermal conductivity coefficient of the generator insulation material is greatly improved.

Description

Technical Field

[0001] The invention relates to a molding method of a high-thermal-conductivity integrally impregnated generator stator insulation system, belonging to the technical field of generator stator insulation. Background Art

[0002] With the continuous development of large surface-cooled generators, the temperature rise level is an important factor in measuring the design and manufacturing level of motors. The heat of the stator coil copper wire needs to be conducted to the stator core on the slot side through the electromagnetic wire insulation, main insulation, side pads, and air gaps in turn, and then conducted to the outside of the generator. Excellent heat dissipation capacity is an important indicator affecting the service life of large surface-cooled high-voltage generators. At present, the generator stator insulation material widely uses a combination of several components such as mica powder, glass fiber, polyester fiber, and polyester fiber, and then composites with resin adhesives to form generator insulation materials. The existing generator insulation material has a low thermal conductivity (≈0.26W / (m·K)), which is not conducive to the heat dissipation inside the generator stator, becomes a blockage point in the heat conduction link of the generator, and cannot effectively reduce the temperature rise of the generator. At the same time, the current conventional generator stator uses hard coil embedding when embedding the wire, and the slot is filled and fixed with semiconductor pads and semiconductor corrugated plates to ensure the effective electrical connection between the stator coil and the core. However, the filling structure inevitably causes a gap between the wire bar and the slot wall, which will cause electrical corrosion in the stator wire bar slot and affect the main insulation performance. In addition, the thermal conductivity of air is extremely low (≈0.02W / m·K). The larger air gaps further hinder the heat dissipation of the wire rods and increase the difficulty of heat conduction to the iron core, resulting in the comprehensive thermal conductivity of the generator insulation being reduced to (about 0.20~0.23W / (m·K)). The accumulated heat also seriously affects the insulation life of the generator stator coil.

[0003] Therefore, in order to ensure the efficient and stable operation of the generator, it is urgently necessary to research and develop insulating materials and insulating structures with high thermal conductivity (comprehensive thermal conductivity coefficient > 0.35W / (m·K)) to meet the needs of modern large-capacity surface-cooled generators for efficient heat dissipation. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a high thermal conductivity integral immersion generator stator insulation system to meet the heat dissipation and temperature rise requirements of large surface-cooled generators.

[0005] In order to solve the above problems, the present invention provides a molding method of a high thermal conductivity integrally impregnated generator stator insulation system, comprising the following steps:

[0006] Step 1): After the copper material is drawn into an electromagnetic wire of a designed cross-section, the electromagnetic wire is subjected to an insulation coating treatment;

[0007] Step 2): the electromagnetic wire is subjected to a gelling treatment after blanking, splicing and replacement to obtain a stator gelling coil;

[0008] Step 3): After the stator gelled coil is formed, multiple layers of high thermal conductivity mica tape are wrapped according to the size requirements of the generator drawing to obtain a soft coil, which includes a lower soft stator coil and an upper soft stator coil;

[0009] Step 4): After wrapping, the lower soft stator coil is embedded in the stator core slot, and each stator core slot is then assembled with interlayer gaskets, upper soft stator coils, expansion felt, wedge under-gaskets, and slot wedges in sequence;

[0010] Step 5): The coil end of the soft coil is pre-fixed on the stator core through an insulating support fixing structure, and an expansion felt and an insulating spacer are provided between the insulating support structure and the coil end, and a generator stator preform is obtained after assembly;

[0011] Step 6): After the generator stator preform is subjected to overall pre-baking treatment, it is subjected to overall vacuum pressure impregnation (GVPI). After the GVPI process is completed, it is baked and cured to obtain a generator stator with a gapless structure. The gapless structure can eliminate the air thermal resistance between the stator coil in the slot and the stator core slot, thereby improving the comprehensive thermal conductivity of the generator stator; the overall vacuum pressure impregnation (GVPI) technology realizes the complete infiltration and filling of all insulating materials and tiny air gaps in the generator stator. The impregnation process is carried out in a strict vacuum environment to ensure the comprehensive infiltration and tight bonding of the resin to the insulating material without leaving any gaps. Subsequently, after a strictly temperature-controlled baking and curing process, these insulating materials are integrated into the stator structure to form a generator stator insulation system with high thermal conductivity, which effectively promotes the efficient conduction of heat inside the stator and lays a solid foundation for the long-term stable operation of the generator.

[0012] Step 7): The stator winding end and all the insulating support structures form a whole, ensuring that the generator stator has sufficient mechanical strength in both the circumferential and radial directions, and ultimately forming a safe and reliable high thermal conductivity generator stator insulation system.

[0013] Preferably, in the step 1), the coating insulation material used for the electromagnetic wire insulation coating treatment includes glass fiber, polyester fiber and high thermal conductivity paint film; wherein the high thermal conductivity paint film is any one of polyimide, polyesterimide, polyetheretherketone or modified epoxy resin added with high thermal conductivity inorganic powder; the high thermal conductivity inorganic powder is a compound of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity inorganic powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

[0014] Preferably, in the step 2), the gelling material used for the gelling treatment includes inter-row insulating material and transposition filling material; the inter-row insulating material is composed of glass fiber cloth, glass fiber felt, high thermal conductivity inorganic powder and B-stage epoxy resin; the transposition filling material is composed of mica powder, high thermal conductivity inorganic powder and B-stage epoxy resin, the high thermal conductivity inorganic powder is a compound of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity inorganic powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

[0015] Preferably, in the step 3), the high thermal conductivity mica tape includes a mica powder layer, an alkali-free glass fiber reinforcement layer and a high thermal conductivity resin adhesive layer located in the middle, the high thermal conductivity resin adhesive layer includes a modified epoxy resin, a zinc salt accelerator and a high thermal conductivity inorganic powder, the high thermal conductivity powder is a compound of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

[0016] Preferably, in step 4), the interlayer pads, wedge under pads and slot wedges are epoxy laminate materials with added high thermal conductivity inorganic powder, and the high thermal conductivity inorganic powder is a compound of any one or more of alumina, boron nitride and aluminum nitride. The specification of the high thermal conductivity inorganic powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

[0017] Preferably, in step 5), the insulating support fixing structure includes a bracket and a strap, the bracket and the insulating spacer are epoxy glass cloth laminated composite materials, the strap is a hollow tube belt woven with glass fiber with a tetraethylammonium bromide promoter, and the outside of the hollow tube belt is coated with a polyvinyl alcohol protective film.

[0018] Preferably, in step 6), the overall vacuum pressure impregnation process includes vacuum drying, resin impregnation, nitrogen pressurization, resin back painting, stator paint dripping, and stator baking and curing process steps.

[0019] More preferably, the impregnation resin used in the impregnation process is an epoxy anhydride two-component resin, component A is a low molecular weight bisphenol A glycidyl ether obtained by molecular distillation technology, and its appearance is a colorless transparent liquid, the molecular weight is 340, and the epoxy value is 0.58 mol / 100g; the component B curing agent is a high-purity methyl hexahydrophthalic anhydride, which has an appearance of a colorless transparent liquid, a molecular weight of 168, an acid value of 660 mg / g, and no solvent or active diluent.

[0020] More preferably, the impregnation process uses a method of vacuuming and applying pressure to improve the fluidity and wettability of the resin to fill the gap inside the generator stator preform to obtain a generator stator with a gap-free structure.

[0021] Preferably, in step 7), the comprehensive thermal conductivity of the stator insulation system of the high thermal conductivity generator is greater than 0.35 W / (m·K).

[0022] The present invention introduces high thermal conductivity fillers (thermal conductivity of 30-300W / (m·K)) into the generator insulation system, thereby greatly improving the thermal conductivity of the generator insulation material. In addition, the overall vacuum pressure impregnation (GVPI) technology is used to fill all insulation air gaps, and all insulation materials are integrally formed on the stator structure, forming a stable and reliable generator stator insulation system with high thermal conductivity (comprehensive thermal conductivity>0.35W / (m·K)).

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1) The thermal conductivity of the generator insulation material is greatly increased by more than 30% by introducing high thermal conductivity fillers;

[0025] 2) The soft coil is assembled after wire embedding. Compared with the traditional single coil thermosetting and then wire embedding, the influence of the molding die on the coil performance is eliminated, and the damage to the coil insulation during the manufacturing process is also reduced, which improves the uniformity and stability of the coil insulation quality;

[0026] 3) The Global Vacuum Pressure Impregnation (GVPI) technology is used to fill all air gaps inside the insulating material, between insulating parts and in the core slots with resin, ensuring the comprehensive thermal conductivity of the generator insulation system (>0.35W / (m·K)). BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 A process flow chart of the molding method provided by the present invention;

[0028] Figure 2 It is a structure for assembling in the stator slot; Figure 2 In the figure, 100 is the lower stator coil, 110 is the electromagnetic wire coating insulation material, 120 is the inter-row insulation material; 130 is the high thermal conductivity mica tape; 200 is the inter-layer pad; 300 is the upper stator coil; 400 is the stator core; 500 is the expansion felt; 500 is the wedge under-pad; 600 is the slot wedge;

[0029] Figure 3 Assembling the structure for the stator end; Figure 3 In the figure, 810 is the end of the lower stator coil, 820 is the end of the upper stator coil, 910 is the support ring, 920 is the bracket, and 930 is the insulating spacer. DETAILED DESCRIPTION

[0030] In order to make the present invention more clearly understood, preferred embodiments are described in detail below with reference to the accompanying drawings.

[0031] Example

[0032] The invention provides a method for forming a high thermal conductivity integrally impregnated generator stator insulation system. Figure 1 A method 1000 for forming a high thermal conductivity integrally impregnated generator stator insulation system according to some embodiments of the present disclosure is shown. Figure 2 and Figure 3 FIG. 1 is a schematic diagram showing a high thermal conductivity type integrally immersed generator stator insulation system according to some embodiments of the present disclosure. Figure 1 As shown, the forming method 1000 includes the following steps. In step 1: after the copper material is drawn into the electromagnetic wire of the designed cross section, the electromagnetic wire is subjected to insulation coating treatment. It should be understood that according to actual needs, the copper material is drawn into the electromagnetic wire of the designed cross section, for example, the cross section may include but is not limited to, circular, rectangular, elliptical, polygonal, irregular shape, etc. In some embodiments, as Figure 2 As shown, the magnet wire insulation coating process may include coating the outer circumference of the magnet wire with an insulating material 110 to facilitate subsequent processing steps.

[0033] In some embodiments, Figure 2 As shown, the coating insulating material 110 used for the insulation coating of the electromagnetic wire may include glass filaments, polyester filaments and high thermal conductivity paint films. For example, the coating insulating material 110 may be a ribbon-like material composited with glass filaments and polyester filaments, by wrapping the ribbon-like material around the surface of the electromagnetic wire, and then coating or impregnating the high thermal conductivity paint film on the outside after the wrapping is completed. In some embodiments, the high thermal conductivity paint film may be any one of polyimide, polyesterimide, polyetheretherketone or modified epoxy resin with added high thermal conductivity inorganic powder. In some embodiments, the high thermal conductivity inorganic powder may be a compound of any one or more of alumina, boron nitride and aluminum nitride. The specification of the high thermal conductivity inorganic powder is micron-level, and the thermal conductivity is 30 to 300W / (m·K). By providing a high thermal conductivity paint film in the coating insulating material 110, the insulation of the electromagnetic wire can be achieved, and the heat dissipation of the electromagnetic wire can be accelerated.

[0034] In step 2: the electromagnetic wire is subjected to a gelling treatment after blanking, splicing and weaving to obtain a stator gelled coil. Those skilled in the art will understand that the drawn electromagnetic wire is a continuous and relatively long electromagnetic wire, which needs to be blanked, spliced ​​and weaved according to the process and use requirements to obtain a stator coil of a set length and woven into shape. The woven stator coil is subjected to a gelling treatment to obtain a stator gelled coil. It should be understood that the gelling treatment can be a process of high-temperature curing and bonding treatment of a resin (such as epoxy resin) to obtain a hard stator gelled coil to facilitate the subsequent mica tape wrapping.

[0035] In some embodiments, Figure 2 As shown, the gelling material used in the gelling treatment may include inter-row insulation material 120 and transposition filling material 140. In some embodiments, the inter-row insulation material 120 may be composed of glass fiber cloth, glass fiber felt, high thermal conductivity inorganic powder and B-stage epoxy resin. It should be understood by those skilled in the art that B-stage epoxy resin is a semi-cured epoxy resin. For example, the inter-row insulation material 120 may be a B-stage (semi-cured) sheet material formed by composite pressing of glass fiber cloth, glass fiber felt, high thermal conductivity inorganic powder and B-stage epoxy resin, and placed between multiple rows of electromagnetic wires of the stator gelling coil, such as Figure 2 Those skilled in the art should understand that the B-stage resin in the inter-row insulation material has fluidity at high temperature and can be filled into the gaps between the strands of the electromagnetic wires to bond the multiple strands of electromagnetic wires into a hard stator gelled coil.

[0036] In some embodiments, the transposition filling material 140 may be composed of mica powder, high thermal conductivity inorganic powder and B-stage epoxy resin. For example, the transposition filling material 140 may be a strip material formed by composite pressing of mica powder, high thermal conductivity inorganic powder and B-stage epoxy resin, and is disposed on the top and bottom of the multiple rows of electromagnetic wires of the stator gelled coil, such as Figure 2 The transposition filling material 140 can be used to fill the transposition pits at the top and bottom of the stator gelled coil, so that the surface of the stator gelled coil is continuous and smooth, which is convenient for the subsequent mica tape wrapping.

[0037] It should be understood that the high thermal conductivity inorganic powder in the present invention can be a compound of any one or more of aluminum oxide, boron nitride, and aluminum nitride. The specification of the high thermal conductivity inorganic powder is micron-level, and the thermal conductivity coefficient is 30 to 300 W / (m·K), which will not be elaborated in the following text.

[0038] In step 3: after the stator gelled coil is formed, multiple layers of high thermal conductivity mica tape 130 are wrapped according to the drawing size requirements of the generator to obtain a soft coil. It should be understood that multiple layers of high thermal conductivity mica tape can be wrapped on the surface of multiple stator gelled coils to form multiple soft coils. In some embodiments, the multiple soft coils can be divided into a lower soft stator coil 100 and an upper soft stator coil 300. Each soft coil may include a coil body and a coil end. By wrapping multiple layers of high thermal conductivity mica tape 130 on the periphery of the stator gelled coil, the stator gelled coil can be insulated and the thermal conductivity of the insulating material can be improved.

[0039] In some embodiments, the high thermal conductivity mica tape 130 may include a powdered mica layer, an alkali-free glass fiber reinforcement layer, and a high thermal conductivity resin adhesive layer located in the middle. For example, a strip material may be composited by powdered mica, alkali-free glass fiber, and a high thermal conductivity resin. In some embodiments, the high thermal conductivity resin adhesive layer may include a modified epoxy resin, a zinc salt accelerator, and a high thermal conductivity inorganic powder. For example, the powdered mica layer and the alkali-free glass fiber reinforcement layer may be bonded by a high thermal conductivity resin adhesive layer to form a strip of high thermal conductivity mica tape, so as to facilitate subsequent wrapping and improve the thermal conductivity of the mica tape insulation material.

[0040] In step 4: after wrapping, the lower soft stator coil 100 is embedded in the stator core slot 400, and each stator core slot is then assembled with interlayer spacers 200, upper soft stator coil 300, expansion felt 500, wedge under spacers 600, and slot wedges 700 in sequence. Figure 2 As shown, each lower soft stator coil 100 wrapped with high thermal conductivity mica tape 130 is respectively embedded in each stator core slot, for example, embedded in the bottom of the stator core slot. Then, the interlayer pad 200, the upper soft stator coil 300, the expansion felt 500, the wedge pad 600, and the slot wedge 700 can be assembled in order from bottom to top. It should be understood that the number of stator core slots can be multiple, and the number of lower soft stator coils 100 and the number of upper soft stator coils 300 are consistent with the number of stator core slots. It should be understood that the expansion felt 500, the wedge pad 600, and the slot wedge 700 are all insulating materials to fill the gap between the soft coil and the stator core slot, and to achieve insulation and fixation between the soft coil and the stator core slot.

[0041] By adopting the method of soft coil embedding and then assembling, compared with the traditional method of thermosetting a single coil and then embedding the wire, the influence of the molding die on the coil performance is eliminated, while the damage to the coil insulation during the manufacturing process is reduced, and the uniformity and stability of the coil insulation quality is improved.

[0042] In step 5: the coil end of the soft coil is pre-fixed on the stator core through an insulating support fixing structure, and an expansion felt and an insulating spacer are provided between the insulating support structure and the coil end, thereby obtaining a generator stator preform. It should be understood that the generator stator preform can be an assembly of the soft coil and the stator core after assembly. In some embodiments, the coil end of each soft coil (e.g. Figure 3The lower coil end 810 and the upper coil end 820 shown are pre-fixed on the stator core, for example, on the end face of the stator core, respectively, through an insulating support fixing structure. It should be understood that the pre-fixation can be direct or indirect, or pre-fixed in a certain direction. The coil end of the soft coil is pre-fixed on the stator core to prevent the soft coil from moving during the subsequent impregnation process, which affects the assembly of the power generation stator. Insulating spacers are provided to space multiple soft coils apart. The soft coil is made to conform to the insulating support structure by expanding the felt, and the coil is expanded and tightened in the subsequent GVPI process to ensure that the coil end is firmly fixed.

[0043] In some embodiments, the insulating support fixing structure may include a support ring 910, a bracket 920 and a bandage. The support ring 910 and the bracket 920 are used to fix the coil end on the stator core, and the bandage is used to tie and fasten the soft coils, and the soft coils and the support ring 910 and the bracket 920. In some embodiments, the support ring 910, the bracket 920, and the insulating pad 930 can be an epoxy glass cloth laminated composite material. In some embodiments, the bandage is a hollow tube belt woven with glass fiber with a tetraethylammonium bromide promoter, and the outside of the hollow tube belt is coated with a polyvinyl alcohol protective film. The mechanical strength after binding can be increased by the hollow tube belt. The bandage with a tetraethylammonium bromide promoter can promote curing in the subsequent baking and curing process (for example, in step 6) to shorten the curing time. A polyvinyl alcohol protective film is provided outside the hollow tube belt to prevent the promoter from absorbing moisture and prevent the loss of the promoter during impregnation.

[0044] In step 6: the generator stator preform is subjected to overall pre-baking treatment, and then subjected to overall vacuum pressure impregnation (GVPI), and after the GVPI process is completed, it is baked and cured to obtain a generator stator with a gap-free structure. It should be understood that the generator stator preform is subjected to overall pre-baking treatment to facilitate drying of the moisture therein to avoid affecting the subsequent impregnation process.

[0045] In some embodiments, the overall vacuum pressure impregnation process may include vacuum drying, resin impregnation, nitrogen pressurization, resin back painting, stator dripping painting, and stator baking and curing process steps. In some embodiments, the impregnation resin used in the GVPI impregnation process is an epoxy anhydride two-component resin, for example, including component A and component B curing agent. Component A is a low molecular weight bisphenol A glycidyl ether obtained by molecular distillation technology, which has an appearance of a colorless transparent liquid, a molecular weight of 340, and an epoxy value of 0.58 mol / 100g. Component B curing agent uses high-purity methyl hexahydrophthalic anhydride, which has an appearance of a colorless transparent liquid, a molecular weight of 168, an acid value of 660 mg / g, no solvent or active diluent, good storage stability, and safety and environmental protection.

[0046] In some embodiments, the impregnation process uses a vacuum and pressure-applying method to greatly improve the fluidity and wettability of the resin, so as to fill the gap inside the generator stator preform to obtain a generator stator with a non-gap structure. It should be understood by those skilled in the art that the gap inside the generator stator preform can include the gap inside all soft insulating materials and the gap between it and all insulating structures. For example, the gap inside the soft insulating material, the gap between the soft insulating material and the stator core slot, the gap between the coil end and the bracket, the gap between the strap and other insulating parts, etc. It should be understood that the soft insulating material can include high thermal conductivity mica tape 130, expansion felt 500, straps and other filling, coating and binding insulating materials. The insulating structure can include a bracket, an insulating pad, a wedge under-pad 600, a slot wedge 700 and other hard fixed support structures. By completely filling all the gaps in the soft insulating material and the insulating structure, a generator stator with a non-gap structure is obtained.

[0047] By adopting advanced integral vacuum pressure impregnation (GVPI) technology, all insulating materials and tiny air gaps of the generator stator are completely infiltrated and filled. This process is carried out in a strict vacuum environment, ensuring the comprehensive infiltration and tight bonding of the resin to the insulating material without leaving any gaps. Subsequently, after a strictly temperature-controlled baking and curing process, these insulating materials are integrally formed on the generator stator structure, forming a generator stator insulation system with high thermal conductivity, which effectively promotes the efficient conduction of heat inside the generator stator and lays a solid foundation for the long-term stable operation of the generator. It overcomes the problem that the thermal conductivity of existing generator insulation materials is relatively low, and the fixed insulation structure in the slot is not dense and there are air gaps, resulting in poor heat dissipation of the generator winding.

[0048] After GVPI treatment, the soft coil and the stator core can be fully contacted and solidified into one body. All the gaps or air gaps in the soft insulating materials and the insulation structure are completely filled by impregnation resin to obtain a generator stator with a gapless structure. The gapless structure can eliminate the air thermal resistance between the stator coil in the slot and the stator core slot, thereby greatly improving the comprehensive thermal conductivity of the generator stator. The coil end of the soft coil forms a whole with all the insulating support structures to ensure that the generator stator has sufficient mechanical strength in both the circumferential and radial directions, and finally form a safe and reliable high thermal conductivity generator stator insulation system. For example, the comprehensive thermal conductivity of the high thermal conductivity generator stator insulation system can be greater than 0.35W / (m·K).

[0049] By introducing high thermal conductivity inorganic powder into the insulating materials of the generator stator (for example, electromagnetic wire coating insulating material 110, inter-row insulating material 120, transposition filling material 140, high thermal conductivity mica tape 130, interlayer pads 200, expansion felt 500, wedge pads 600, slot wedges 700, etc.), the thermal conductivity of the generator insulating material is greatly improved, and the thermal conductivity of the insulating material can be increased by more than 30%.

Claims

1. A molding method for a high thermal conductivity integrally impregnated generator stator insulation system, characterized in that: The following steps are involved: Step 1): After the copper material is drawn into an electromagnetic wire of a designed cross-section, the electromagnetic wire is subjected to an insulation coating treatment; Step 2): the electromagnetic wire is subjected to a gelling treatment after blanking, splicing and replacement to obtain a stator gelling coil; Step 3): After the stator gelled coil is formed, multiple layers of high thermal conductivity mica tape are wrapped according to the size requirements of the generator drawing to obtain a soft coil, which includes a lower soft stator coil and an upper soft stator coil; Step 4): After wrapping, the lower soft stator coil is embedded in the stator core slot, and each stator core slot is then assembled with interlayer gaskets, upper soft stator coils, expansion felt, wedge under-gaskets, and slot wedges in sequence; Step 5): The coil end of the soft coil is pre-fixed on the stator core through an insulating support fixing structure, and an expansion felt and an insulating spacer are provided between the insulating support structure and the coil end, and a generator stator preform is obtained after assembly; Step 6): After the generator stator preform is subjected to overall pre-baking treatment, the overall vacuum pressure impregnation is performed, and after the process is completed, it is baked and cured to obtain a generator stator with a gap-free structure.

2. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 1), the coating insulation material used for the electromagnetic wire insulation coating treatment includes glass fiber, polyester fiber and high thermal conductivity paint film; wherein the high thermal conductivity paint film is any one of polyimide, polyester imide, polyether ether ketone or modified epoxy resin added with high thermal conductivity inorganic powder; the high thermal conductivity inorganic powder is a compound of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity inorganic powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

3. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 2), the gelling material used in the gelling treatment includes inter-row insulation material and transposition filling material; the inter-row insulation material is composed of glass fiber cloth, glass fiber felt, high thermal conductivity inorganic powder and B-stage epoxy resin; the transposition filling material is composed of mica powder, high thermal conductivity inorganic powder and B-stage epoxy resin, the high thermal conductivity inorganic powder is a composite of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity inorganic powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

4. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 3), the high thermal conductivity mica tape includes a mica powder layer, an alkali-free glass fiber reinforcement layer and a high thermal conductivity resin adhesive layer located in the middle, the high thermal conductivity resin adhesive layer includes a modified epoxy resin, a zinc salt accelerator and a high thermal conductivity inorganic powder, the high thermal conductivity powder is a composite of any one or more of alumina, boron nitride and aluminum nitride, the specification of the high thermal conductivity powder is micron level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

5. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 4), the interlayer pads, wedge under pads, and slot wedges are epoxy laminated materials with high thermal conductivity inorganic powder added, and the high thermal conductivity inorganic powder is a compound of any one or more of alumina, boron nitride, and aluminum nitride. The specification of the high thermal conductivity inorganic powder is micron-level, and the thermal conductivity coefficient is 30 to 300 W / (m·K).

6. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 5), the insulating support fixing structure includes a bracket and a binding strap, the bracket and the insulating spacer are epoxy glass cloth laminated composite materials, the binding strap is a hollow tube belt woven with glass fiber with a tetraethylammonium bromide promoter, and the outside of the hollow tube belt is coated with a polyvinyl alcohol protective film.

7. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In step 6), the overall vacuum pressure impregnation process includes vacuum drying, resin impregnation, nitrogen pressurization, resin back painting, stator dripping paint, and stator baking and curing process steps.

8. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 7, characterized in that: The impregnation resin used in the impregnation process is an epoxy anhydride two-component resin, wherein the A component is a low molecular weight bisphenol A glycidyl ether obtained by molecular distillation technology, and has an appearance of a colorless transparent liquid, a molecular weight of 340, and an epoxy value of 0.58 mol / 100 g; the B component curing agent is a high-purity methyl hexahydrophthalic anhydride, and has an appearance of a colorless transparent liquid, a molecular weight of 168, an acid value of 660 mg / g, and no solvent or active diluent.

9. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 7, characterized in that: The impregnation process adopts a method of vacuuming and applying pressure to improve the fluidity and wettability of the resin so as to fill the gap inside the generator stator preform to obtain a generator stator with a gap-free structure.

10. The molding method of the high thermal conductivity integrally impregnated generator stator insulation system according to claim 1, characterized in that: In the step 7), the comprehensive thermal conductivity of the stator insulation system of the high thermal conductivity generator is greater than 0.35 W / (m·K).

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