UV and Thermal Curing Epoxy Resin for Electrical Insulation

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Solution Overview

Problem

Thermally curable epoxy resin compositions for high voltage electrical insulations require long curing times, result in material losses, and emit harmful substances, while UV-curable systems struggle to cure thick or highly filled resin systems effectively.

Innovation Solution

A UV and thermally curable epoxy resin composition using a one-component cationically curable epoxy resin system with cationic photo- and thermal-initiators, allowing for simultaneous UV and heat curing to achieve complete curing without dripping or emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermally curable epoxy resin compositions are used, then high voltage electrical insulations can be produced, but curing times are long and material losses occur

Engineering Contradiction:

Improvequality of electrical insulationVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines two curing mechanisms (thermal and UV) into a single epoxy resin system. The composition contains both thermal hardening components and UV-curable components, allowing the material to be cured by either or both methods, thereby resolving the contradiction between reliable curing and production efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention changes the curing parameters by introducing UV irradiation as an additional curing parameter alongside thermal curing. This allows for rapid curing when UV is applied, while maintaining the option for thermal curing for thick sections, thus improving productivity without compromising insulation quality

Inventive Principle:

Principle #35Parameter changes

2Reliability

If thermally curable compositions are used in wet filament winding, then electrical insulations can be produced, but material losses due to dripping amount up to 10%

Engineering Contradiction:

Improveelectrical insulation performanceVSAvoidmaterial loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies UV irradiation preliminarily during or immediately after the winding process to initiate curing before the resin can drip. This preliminary action solidifies the resin in place, preventing material loss while ensuring complete curing through subsequent thermal treatment

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By merging UV-curable components with thermal hardening components, the system enables rapid initial setting via UV to prevent dripping, while the thermal component ensures complete curing for electrical insulation performance

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If UV-curable systems are used, then curing times are reduced, but thick or highly filled resin systems cannot be cured homogenously

Engineering Contradiction:

Improvecuring speedVSAvoidcuring homogeneity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent segments the curing process into two stages: UV irradiation for rapid surface and near-surface curing, and thermal curing for deep penetration and complete homogenization. This segmentation allows each method to address its optimal depth range, ensuring both speed and uniformity

Inventive Principle:

Principle #1Segmentation

4Reliability

If thermally curable compositions are used, then electrical insulations can be produced, but harmful emissions are generated

Engineering Contradiction:

Improveelectrical insulation qualityVSAvoidharmful emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention changes the curing parameter from purely thermal to include UV irradiation. This parameter change enables curing at lower temperatures or with reduced thermal input, minimizing the generation of harmful emissions while maintaining electrical insulation quality

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

This method reduces curing and cooling times, eliminates material waste, and produces high-quality, thick electrical insulators with minimal environmental impact, simplifying production processes and eliminating the need for continuous mandrel rotation.

Implementation Method 1

at least one cationic photo-initiator... UV-curable and thermally curable epoxy resin... ultra-violet radiation (UV) and thermally curable composition

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

at least one cationic thermal-initiator... thermally curable epoxy resin... heat-curable one-component epoxy resin system

Methodology Applied

Scientific EffectThermal polymerization:

Data Source

PatentUS10332659B2Method of producing high voltage electrical insulation

Publication Date: 2019.06.25 ABB (SCHWEIZ) AG

AI summary

Method of producing a high voltage electrical insulation, in that (i) an ultra-violet radiation as well as thermally curable composition, comprising at least one UV-curable and heat-curable epoxy resin, at least one cationic photo-initiator and at least one cationic thermal-initiator, is provided, and that (ii) ultraviolet radiation as well as heat is applied to the curable composition in any desired sequence for a time long enough until complete curing of the curable composition is obtained and products obtained.