Polyimide Insulation on Laminated Structures for Electric Machines
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Solution Overview
Problem
Conventional electric machines with powder-coated epoxy insulation are limited by temperature ratings of up to 180°C, leading to increased cooling requirements and larger geometries, while slot liners result in manufacturing complexities and larger machine sizes, necessitating improved insulation solutions for laminated structures within electric machines.
Innovation Solution
An insulation layer is formed directly on laminated structures within electric machines using thermoset polymeric materials like polyimide, with optional filler materials such as titanium oxide and silica oxide, and applied via various techniques like spraying or extrusion, providing enhanced thermal and electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional powder coat epoxy insulation is used, then manufacturing is simplified, but temperature rating is limited to 180°C
Solution Approach 1:
The patent changes the material parameters by transitioning from epoxy-based powder coats to polyimide-based insulation materials, enabling temperature ratings to increase from 180°C to 260°C while maintaining manufacturability through adapted application processes
Solution Approach 2:
The patent employs composite material structures by combining polyimide insulation materials with specific filler materials and adhesives, creating a multi-component system that achieves high temperature resistance while ensuring proper adhesion and electrical insulation properties
2Temperature
If slot liners are used for insulation, then electrical insulation is provided, but machine geometry increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the slot liner function with the laminated structure by forming insulation material directly on the laminated structure surface, eliminating the need for separate slot liner components and reducing overall machine volume
Solution Approach 2:
The patent extracts and eliminates the separate slot liner component from the insulation system, integrating the insulation function directly into the laminated structure through surface-formed insulation material
3Temperature
If conventional powder coats are used, then application is simple, but heat transfer capability is reduced
Solution Approach 1:
The patent utilizes porous or filled insulation material structures that enhance heat transfer capabilities while maintaining electrical insulation properties, allowing improved thermal management without excessive system complexity
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
This solution allows for improved heat transfer and higher temperature ratings, reducing machine size and enhancing efficiency, particularly beneficial for compact applications like unmanned aerial vehicles, while eliminating the need for conventional powder coats and slot liners.
Implementation Method 1
applied via various techniques like spraying or extrusion
Implementation Method 2
applied via various techniques like spraying or extrusion
Implementation Method 3
providing enhanced thermal and electrical performance
Data Source
AI summary
Electric machines, such as motors, may include an armature and a field component, and at least one of the armature or the field component may include a laminated structure having a plurality of slots into which a plurality of conductive elements are positioned. Additionally, a polymeric insulation layer may be formed directly on the laminated structure at least within the plurality of slots.