Hot-Pressed Coil Insulation Tape for Void-Free High-Voltage Windings
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Solution Overview
Problem
Existing stator and rotor coils in electric machines suffer from insulation issues that limit their lifespan, voltage withstand, and are susceptible to environmental factors, with existing methods requiring complex vacuum pressure impregnation processes.
Innovation Solution
The use of improved insulation systems, including polyimide-coated copper strands, B-stage epoxy mica paper tape, and film back tape, along with optional conductive and stress grading tapes, which are applied and hot pressed to create void-free, high-voltage-resistant coils without the need for vacuum pressure impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulating materials and vacuum pressure impregnation processes are used, then coils can achieve adequate insulation, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The insulation tape is pre-impregnated with resin during manufacturing, creating a pre-prepared insulating structure that eliminates the need for post-winding vacuum pressure impregnation. This preliminary action embeds the resin within the tape layers before application to the coil, simplifying the overall manufacturing process while maintaining insulation reliability
Solution Approach 2:
The invention uses a composite insulating tape structure combining fabric reinforcement with resin impregnation. This composite material provides both mechanical strength and electrical insulation properties in a single integrated component, eliminating the need for separate impregnation steps and reducing manufacturing complexity
2Duration of action of stationary object
If traditional insulating tapes are used, then coils can be manufactured, but the insulation has voids and limited lifespan
Solution Approach 1:
The resin is pre-embedded in the tape during manufacturing, ensuring complete and uniform impregnation before the tape is applied to the coil. This preliminary impregnation action eliminates air voids and ensures consistent resin distribution, creating void-free insulation that extends lifespan without requiring complex post-processing
Solution Approach 2:
The multi-layer composite tape structure with fabric reinforcement and resin impregnation creates a dense, void-free insulation system. The fabric layers provide structural integrity while the resin fills gaps and creates a homogeneous insulating medium, eliminating voids that would otherwise limit insulation lifespan
3Reliability
If conventional insulation systems are used, then coils can operate, but they are susceptible to environmental factors and have limited voltage withstand
Solution Approach 1:
The composite insulating tape combines fabric reinforcement with environmentally resistant resin impregnation, creating a multi-functional insulating system. This composite structure provides both mechanical strength for voltage withstand and chemical resistance to environmental factors, achieving dual improvement in reliability and electrical strength
Solution Approach 2:
The resin impregnation changes the physical and chemical parameters of the insulating tape, enhancing its dielectric strength, moisture resistance, and thermal stability. These parameter changes in the insulating material directly improve both voltage withstand capability and environmental resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new insulation system enhances coil lifespan, improves voltage withstand, and provides protection against environmental factors while simplifying the manufacturing process, offering superior dielectric properties and flexibility.
Implementation Method 1
polyimide-coated copper strands
Implementation Method 2
B-stage epoxy mica paper tape, and film back tape
Implementation Method 3
applied and hot pressed to create void-free, high-voltage-resistant coils
Data Source
AI summary
Electric coils and a method of insulating electric coils comprises copper wire with insulation, turn tape (e.g., B stage), film tape, and armor tape. In a preferred embodiment, the tape is hot-pressed after application of the B stage turn tape and again just prior to the application of the armor tape.