Unsaturated Polyester Impregnation Resin for Low VOC Electrical Windings

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Solution Overview

Problem

Existing impregnation materials for electrical windings face challenges with high volatile organic compound (VOC) emissions, low mechanical toughness, and brittleness, while also struggling with homogeneity and viscosity issues that affect penetration and operational performance.

Innovation Solution

A composition comprising 5-97 wt % of α,β-unsaturated polyester resin or imide resin, combined with specific monomers and oligomers, and additives, which provides low viscosity, low VOC emissions, and excellent mechanical toughness with crack resistance after curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If impregnation materials based on unsaturated polyesters dissolved in styrene are used, then excellent impregnation results and good mechanical toughness are achieved, but significant VOC emissions occur

Engineering Contradiction:

Improveimpregnation qualityVSAvoidVOC emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing styrene with alternative monomers having different volatility characteristics, and modifies the polyester structure to achieve low viscosity without relying on high styrene content, thereby reducing VOC emissions while maintaining impregnation quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite impregnation materials combining unsaturated polyesters with specific monomers and fillers to achieve the desired balance between low viscosity for good impregnation, mechanical toughness, and reduced VOC emissions through synergistic material combinations

Inventive Principle:

Principle #40Composite materials

2Strength

If fillers are added to improve mechanical properties like toughness, then mechanical strength increases, but viscosity increases and homogeneity decreases

Engineering Contradiction:

Improvemechanical toughnessVSAvoidviscosity and homogeneity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent optimizes filler particle size, shape, and surface treatment parameters, and adjusts the filler-to-resin ratio to achieve adequate mechanical toughness while minimizing viscosity increase and maintaining compositional homogeneity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses coupling agents and surface treatments as intermediaries between fillers and the polyester resin matrix to improve interfacial adhesion, allowing for better mechanical properties at lower filler loadings, thereby reducing viscosity and improving homogeneity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If high viscosity impregnation materials are used to improve mechanical properties, then toughness increases, but penetration into electrical winding cavities fails

Engineering Contradiction:

Improvemechanical toughnessVSAvoidpenetration capability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent carefully controls the viscosity parameter by selecting appropriate polyester molecular weights, monomer types and ratios, and filler characteristics to achieve an optimal viscosity range that allows both adequate penetration into winding cavities and sufficient mechanical toughness after curing

Inventive Principle:

Principle #35Parameter changes

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 composition achieves low curing emissions, high toughness, and excellent resistance to cracking, ensuring effective impregnation and mechanical properties for electrical devices.

Implementation Method 1

a composition comprising 5-97 wt % of at least one α,β-unsaturated polyester resin and/or α,β-unsaturated polyester imide resin

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

provides low viscosity, low VOC emissions, and excellent mechanical toughness with crack resistance after curing

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

provides low viscosity, low VOC emissions, and excellent mechanical toughness

Methodology Applied

Scientific EffectViscosity reduction through molecular structure design:

Implementation Method 4

excellent mechanical toughness with crack resistance after curing

Methodology Applied

Scientific EffectMechanical reinforcement through resin matrix formation:

Data Source

PatentUS10131811B2Composition for fixing wound items

Publication Date: 2018.11.20 AXALTA COATING SYSTEMS IP CO LLC

AI summary

A composition for fixing wound items is provided. In one example, the composition comprises 5 to 97 wt % of at least one α,β-unsaturated polyester resin and/or α,β-unsaturated polyester imide resin comprising components of at least one α,β-ethylenically unsaturated mono-, di- and/or tricarboxylic acid, and/or its anhydride and/or ester, at least one polyol, at least one (meth)acrylic group containing component, possibly at least one mono-, di-, tri- and/or tetracarboxylic acid, which is not α,β-ethylenically unsaturated, and/or its anhydride and/or ester.