Nanostructured insulation for electric machines

Patent metadata

Field	Value
Publication number	US-11569701-B2
Application number	US-201916539526-A
Country	US
Kind code	B2
Filing date	Aug 13, 2019
Priority date	Aug 13, 2018
Publication date	Jan 31, 2023
Grant date	Jan 31, 2023

Abstract

An insulating composition having a polymer resin, a nanoclay, and one or more nanofillers. The insulating composition has a thermal conductivity of greater than about 0.8 W/mK, a dielectric constant of less than about 5, a dissipation factor of less than about 3%, and a breakdown strength of greater than about 1,000V/mil. The insulating composition has an endurance life of at least 400 hours at 310 volts per mil.

First claim

What is claimed is:

1. An insulating composition comprising:
a) a polymer resin;
b) a nanoclay; and
c) one or more nanofillers, the one or more nanofillers including zinc oxide and wherein the composition comprises greater than about 5% zinc oxide by weight,
wherein the insulating composition has a dielectric constant of less than about 5, a dissipation factor of less than about 3%, and a breakdown strength of greater than about 1,000V/mil, and
wherein the insulating composition has an endurance life of at least 400 hours at 310 volts per mil.

2. The insulating composition of claim 1 , wherein the polymer resin is selected from the group consisting of: epoxy resin, silicone rubber, polyester resin, polyimides, polyamide-imides, polyetherimides, polysulfones, polyether ether keton, polycarbonates, and polyamide-imides.

3. The insulating composition of claim 1 , wherein the nanoclay is selected from the group consisting of: montmorillonite, kaolin, and talc.

4. The insulating composition of claim 1 , wherein the composition comprises about 7% zinc oxide to about 10% zinc oxide by weight.

5. The insulating composition of claim 1 , wherein the composition comprises about 60% to about 70% polymer resin by weight.

6. The insulating composition of claim 1 , wherein the composition comprises about 60% to about 70% polymer resin, about 20% to about 30% nanoclay, about 5% to about 20% boron nitride, and greater than about 5% zinc oxide about 0% to about 15% zinc oxide by weight.

7. The insulating composition of claim 1 , wherein the insulating composition has an endurance life of at least 3000 hours at 310 volts per mil.

8. The insulating composition of claim 1 , wherein the insulating composition has a thermal conductivity of greater than about 0.8 W/mK.

9. A motor comprising,
a rotor;
a stator;
at least one winding associated with the rotor or the stator; and
a nanostructured insulating composition applied to the at least one winding, wherein the nanostructured insulating composition comprises:
a) a polymer resin;
b) a nanoclay; and
c) one or more nanofillers, the one or more nanofillers including zinc oxide and wherein the composition comprises greater than about 5% zinc oxide by weight.

10. The motor of claim 9 ,
wherein the nanostructured insulating composition has a dielectric constant of less than about 5, a dissipation factor of less than about 3%, and a breakdown strength of greater than about 1,000V/mil.

11. The motor of claim 10 , wherein the nanostructured insulating composition has a thermal conductivity of greater than about 0.8 W/mK.

12. The motor of claim 10 , wherein the nanostructured insulating composition has an endurance life of at least 400 hours at 310 volts per mil.

13. The motor of claim 12 , wherein the nanostructured insulating composition has an endurance life of at least 3000 hours at 310 volts per mil.

14. The motor of claim 10 , wherein the nanoclay is selected from the group consisting of: montmorillonite, kaolin, and talc.

15. The motor of claim 10 , wherein the composition comprises about 7% zinc oxide to about 10% zinc oxide by weight.

16. The motor of claim 10 , wherein the composition comprises about 60% to about 70% polymer resin by weight.

17. The motor of claim 10 , wherein the composition comprises about 60% to about 70% polymer resin, about 20% to about 30% nanoclay, about 5% to about 20% boron nitride, and greater than about 5% zinc oxide to about 15% zinc oxide by weight.

18. A method of insulating a motor, the motor including a rotor, a stator, and at least one winding associated with the rotor or the stator, the method comprising:
wrapping a winding around a lamination of the motor, and
applying a nanostructured insulating composition to the winding, wherein the nanostructured insulating composition comprises:
a) a polymer resin;
b) a nanoclay; and
c) one or more nanofillers, the one or more nanofillers including zinc oxide and wherein the composition comprises greater than about 5% zinc oxide by weight.

19. The method of claim 18 ,
wherein the nanostructured insulating composition has a dielectric constant of less than about 5, a dissipation factor of less than about 3%, and a breakdown strength of greater than about 1,000V/mil.

20. The method of claim 19 , wherein the nanostructured insulating composition has a thermal conductivity of greater than about 0.8 W/mK.

21. The method of claim 19 , wherein the nano structured insulating composition has an endurance life of at least 400 hours at 310 volts per mil.

22. The method of claim 19 , wherein the nano structured insulating composition has an endurance life of at least 3000 hours at 310 volts per mil.

23. The method of claim 19 , wherein the nanoclay is selected from the group consisting of: montmorillonite, kaolin, and talc.

24. The method of claim 19 , wherein the composition comprises about 7% zinc oxide to about 10% zinc oxide by weight.

25. The method of claim 19 , wherein the composition comprises about 60% to about 70% polymer resin by weight.

26. The method of claim 19 , wherein the composition comprises about 60% to about 70% polymer resin, about 20% to about 30% nanoclay, about 5% to about 20% boron nitride, and greater than about 5% zinc oxide to about 15% zinc oxide by weight.

Assignees

• Univ Connecticut

Inventors

• Cao Yang

Classifications

• H02K3/50

  Fastening of winding heads, equalising connectors, or connections thereto · CPC title

• H01B3/46

  silicones · CPC title

• H01B3/12

  ceramics · CPC title

• H01B3/306

  Polyimides or polyesterimides · CPC title

• H02K3/30 Primary

  Windings characterised by the insulating material · CPC title