Sprayable Motor Insulation Formulation for Partial Discharge Resistance
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Solution Overview
Problem
High-voltage electrical machines face challenges in insulation systems due to partial discharges leading to local heating and breakdown of organic materials, requiring efficient and cost-effective solutions for high-power density applications.
Innovation Solution
A sprayable insulation formulation comprising a resin mixture with diepoxidic carbon-based components, alkyl-/arylpolysiloxane, and curing agents, which can be applied automatably, eliminating the need for mica platelets and reducing erosion volume through partial discharge-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mica tape windings are used for insulation systems, then partial discharge resistance is maintained, but production costs increase and automation is limited
Solution Approach 1:
The patent changes the physical state of the insulation material from solid mica platelets in tape form to a sprayable liquid formulation containing siloxane components. This parameter change enables automated application while maintaining the erosion pathway extension function, thereby reducing production costs and enabling automation simultaneously.
Solution Approach 2:
The invention uses spray application technology to apply the insulation formulation. The sprayable formulation can be applied using pneumatic or hydraulic spray systems, enabling automated production processes and reducing manual labor costs while maintaining insulation performance.
2Reliability
If traditional mica tape windings are used for insulation systems, then partial discharge resistance is maintained, but production automation is restricted
Solution Approach 1:
The patent transforms the insulation material from solid mica tapes requiring manual winding to a sprayable liquid formulation. This parameter change in physical state and application method enables full automation of the insulation application process while maintaining the functional properties of mica-based erosion pathway extension through siloxane components.
Solution Approach 2:
The invention replaces the mechanical winding process of mica tapes with a spray application process. This substitution eliminates the need for manual tape handling and winding operations, enabling automated production lines and significantly improving the extent of automation in insulation system manufacturing.
3Reliability
If insulation system volume is increased to handle partial discharges, then erosion pathway is extended, but power density decreases
Solution Approach 1:
The patent creates a composite material system where siloxane components mimic the erosion pathway extension function of mica platelets. This composite approach maintains the protective function against partial discharges without requiring increased insulation volume, thereby preserving power density while extending erosion pathways.
Solution Approach 2:
The invention changes the chemical composition and molecular structure of the insulation material to achieve erosion pathway extension at molecular level rather than requiring increased physical volume. The siloxane-based formulation provides enhanced partial discharge resistance without increasing the overall insulation system dimensions, maintaining high power density.
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 solution significantly increases the partial discharge resistance and mechanical properties of the insulation system, allowing for automated production and extending the lifetime of high-voltage electrical machines by reducing erosion volume and enabling higher power densities.
Implementation Method 1
a sprayable resin mixture comprising, as well as a monomeric and/or oligomeric, at least diepoxidic carbon-based resin component, also a monomeric and/or oligomeric resin component based on alkyl-/arylpolysiloxane with at least one glycidyl ester and/or glycidyl ether functionalities and optionally also one or more compounds that are usable as curing agent and are based on anhydride and/or (poly)amine
Implementation Method 2
The solution significantly increases the partial discharge resistance and mechanical properties of the insulation system, allowing for automated production and extending the lifetime of high-voltage electrical machines by reducing erosion volume
Data Source
AI summary
Various embodiments include a sprayable formulation for an insulation system of an electrical machine, the formulation comprising a sprayable resin mixture including: a monomeric and/or oligomeric, at least diepoxidic carbon-based first resin component; and a monomeric and/or oligomeric second resin component based on alkyl-/arylpolysiloxane with at least one glycidyl ester and/or glycidyl ether functionalities; and a curing agent and based on at least one of: anhydride, (poly)amine, and amino- and/or alkoxy-functional alkyl-/arylpolysiloxane.