Stator Winding for an Electric Power System

Patent metadata

Field	Value
Publication number	US-2025141294-A1
Application number	US-202218688390-A
Country	US
Kind code	A1
Filing date	Jul 22, 2022
Priority date	Jul 22, 2022
Publication date	May 1, 2025
Grant date	—

Abstract

A stator winding comprising a protective member that overlies and surrounds at least a portion of a conductive member is provided. The protective member includes a polymer composition comprising a polymer matrix that includes a thermotropic liquid crystalline polymer. The polymer composition exhibits a melt viscosity of about 150 Pa-s or less and a deflection temperature under load of about 170° C. or more.

First claim

1 . A stator winding comprising a protective member that overlies and surrounds at least a portion of a conductive member, wherein the protective member includes a polymer composition, the polymer composition comprising a polymer matrix that includes a thermotropic liquid crystalline polymer, further wherein the polymer composition exhibits a melt viscosity of about 300 Pa-s or less as determined in accordance with ISO 11443:2021 at a shear rate of 1,000 s −1 and temperature of about 15° C. above the melting temperature of the composition, and a deflection temperature under load of about 170° C. or more as determined in accordance with ISO 75:2013 at a load of 1.8 MPa.

2 . The stator winding of claim 1 , wherein the polymer composition exhibits a melting temperature of about 250° C. to about 440° C.

3 . The stator winding of claim 1 , wherein the thermotropic liquid crystalline polymer contains repeating units derived from one or more aromatic dicarboxylic acids, one or more aromatic hydroxycarboxylic acids, or a combination thereof.

4 . The stator winding of claim 3 , wherein the aromatic hydroxycarboxylic acids include 4-hydroxybenzoic acid, 6-hydroxy-2-naphthoic acid, or a combination thereof.

5 . The stator winding of claim 4 , wherein the aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, or a combination thereof.

6 . The stator winding of claim 3 , wherein the liquid crystalline polymer further contains repeating units derived from one or more aromatic diols.

7 . The stator winding of claim 6 , wherein the aromatic diols include hydroquinone, 4,4′-biphenol, or a combination thereof.

8 . The stator winding of claim 1 , wherein the thermotropic liquid crystalline polymer is wholly aromatic.

9 . The stator winding of claim 1 , wherein the thermotropic liquid crystalline polymer includes repeating units derived from naphthenic hydroxycarboxylic and/or dicarboxylic acids in an amount of about 10 mol. % or more.

10 . The stator winding of claim 1 , wherein the polymer composition exhibits an in-plane thermal conductivity of about 2 W/m-K or more as determined in accordance with ASTM E1461-13(2022).

11 . The stator winding of claim 1 , wherein the polymer composition exhibits a cross-plane thermal conductivity of about 0.8 W/m-K or more as determined in accordance with ASTM E 1461-13(2022).

12 . The stator winding of claim 1 , wherein the polymer composition exhibits an in-plane thermal conductivity of from about 4 to about 8 W/m-K, as determined in accordance with ASTM E 1461-13(2022).

13 . The stator winding of claim 1 , wherein the polymer composition exhibits a dielectric strength of about 10 kilovolts per millimeter or more as determined in accordance with IEC 60234-1:2013.

14 . The stator winding of claim 1 , wherein the polymer composition further comprises a thermally conductive filler.

15 . The stator winding of claim 14 , wherein the thermally conductive filler includes mineral particles.

16 . The stator winding of claim 15 , wherein the mineral particles include talc.

17 . The stator winding of claim 15 , wherein the mineral particles constitute from about 70 to about 250 parts by weight per 100 parts by weight of the polymer matrix.

18 . The stator winding of claim 15 , wherein the mineral particles have a median diameter of from about 1 to about 25 micrometers, specific surface area of from about 1 to about 50 m 2 /g as determined in accordance with DIN 66131:1993, and/or moisture content of about 5% or less as determined in accordance with ISO 787-2:1981 at a temperature of 105° C.

19 . The stator winding of claim 14 , wherein the thermally conductive filler includes mineral fibers.

20 . The stator winding of claim 19 , wherein the mineral fibers include wollastonite.

21 . The stator winding of claim 19 , wherein the mineral fibers constitute from about 10 to about 150 parts by weight per 100 parts by weight of the polymer matrix.

22 . The stator winding of claim 1 , wherein the polymer composition is free of fillers having an intrinsic thermal conductivity of 100 W/m-K or more.

23 . The stator winding of claim 1 , wherein the polymer composition exhibits a comparative tracking index of about 170 volts or more as determined in accordance with IEC 60112:2003 at a thickness of 3 millimeters.

24 . The stator winding of claim 1 , wherein the protective layer includes a single layer formed from the polymer composition.

25 . The stator winding of claim 1 , wherein the conductive member includes a copper wire.

26 . The stator winding of claim 1 , wherein the winding has a substantially circular cross-sectional shape.

27 . The stator winding of claim 1 , wherein the protective member has a thickness of from about 0.01 to about 1 millimeter.

28 . A stator comprising a stator body from which extends a plurality of spaced apart slot segments between which intermediate slots are defined, wherein the stator winding of claim 1 is arranged on at least one of the slot segments.

29 . The stator of claim 28 , wherein the stator winding is wrapped around at least one of the slot segments.

30 . The stator of claim 28 , wherein the stator body has an annular shape and defines a central bore for receiving a rotor.

31 . The stator of claim 30 , wherein the slot segments are spaced apart in a circumferential direction and protrude radially toward the central bore.

32 . A power system comprising the stator of claim 28 and a rotor.

33 . An electric vehicle comprising a powertrain that includes the power system of claim 32 and a transmission that is connected to the propulsion source via at least one power electronics module.

Assignees

• Ticona Llc

Inventors

• Wang Rong

Classifications

• C08K2201/001

  Conductive additives · CPC title

• C08K2201/006

  Additives being defined by their surface area · CPC title

• C08K2201/005

  Additives being defined by their particle size in general · CPC title

• B60Y2200/91

  Electric vehicles · CPC title

• H01B3/423

  Linear aromatic polyesters · CPC title