Stator slot liners

Patent metadata

Field	Value
Publication number	US-9641037-B2
Application number	US-201414471488-A
Country	US
Kind code	B2
Filing date	Aug 28, 2014
Priority date	Aug 28, 2014
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

A slot liner for a stator assembly in one embodiment includes a mesh structural member and a coating. The coating is disposed on at least one side of the mesh structural member, and includes a mixture of a filler and a polyimide resin. The filler is a high thermal conductivity electrical insulating (HTCEI) filler, and includes particles of at least one of boron nitride, aluminum nitride, or a diamond material.

First claim

What is claimed is:

1. A slot liner for a stator assembly of a power system, the slot liner comprising:
a mesh structural member; and
a coating disposed on at least one side of the mesh structural member, the coating comprising a mixture of
a high thermal conductivity electrical insulating (HTCEI) filler, the HTCEI filler comprising particles of at least one of boron nitride, aluminum nitride, or a diamond material; and
a polyimide resin.

2. The slot liner of claim 1 , wherein the particles of the filler comprise boron nitride particles having a size between 100 nanometers and 300 nanometers, and the mesh structural member is configured to accept the size of the particles.

3. The slot liner of claim 1 , wherein the particles of the filler comprise boron nitride particles having a size between 10 nanometers and 100 microns, and the mesh structural member is configured to accept the size of the particles.

4. The slot liner of claim 1 , wherein the mesh structural member comprises a mesh formed with a polyether ether ketone (PEEK) material.

5. The slot liner of claim 1 , wherein the mesh structural member comprises a mesh formed with a yarn made of a NOMEX® material.

6. The slot liner of claim 1 , wherein the liner is generally U-shaped and includes at least one bend of about 90 degrees when positioned in the stator.

7. The slot liner of claim 1 , wherein the polyimide resin comprises between 50 and 65 percent of the coating by weight.

8. The slot liner of claim 1 , wherein the coating is disposed on two opposite sides of the mesh structural member.

9. A stator assembly for a power system, the stator assembly comprising:
an annular member defining a bore;
slots formed in the annular member having openings extending toward the bore;
windings passing through the slots; and
slot liners disposed in the slots and interposed between the windings and the annular member, wherein the slot liners comprise:
a mesh structural member; and
a coating disposed on at least one side of the mesh structural member, the coating comprising a mixture of
a high thermal conductivity electrical insulating (HTCEI) filler, the HTCEI filler comprising particles of at least one of boron nitride, aluminum nitride, or a diamond material; and
a polyimide resin.

10. The stator assembly of claim 9 , wherein the particles of the filler comprise boron nitride particles having a size between 10 nanometers and 100 microns and the mesh structural member is configured to accept the size of the particles.

11. The stator assembly of claim 9 , wherein the mesh structural member comprises a mesh formed with at least one of a polyether ether ketone (PEEK) material or a NOMEX® material, and wherein the liner is generally U-shaped and includes at least one bend of about 90 degrees when positioned in one of the slots of the stator.

12. The stator assembly of claim 9 , wherein the polyimide resin comprises between 50 and 65 percent of the coating by weight.

13. A method comprising:
providing a mesh structural member, a polyimide resin precursor, and a high thermal conductivity electrical insulating (HTCEI) filler, the HTCEI filler comprising particles of at least one of boron nitride, aluminum nitride, or a diamond material;
mixing the polyimide resin precursor and the HTCEI filler to provide a coating;
coating at least one side of the mesh structural member with the coating to provide a liner material;
curing the liner material; and
forming the liner material into a shape configured to be accepted by a slot of a stator assembly.

14. The method of claim 13 , wherein mixing the polyimide resin precursor and the HTCEI filler comprises using an amount of the polyimide resin precursor to provide a coating in which a polyimide resin comprises between 50 and 65 percent of the coating by weight.

15. The method of claim 13 , wherein the particles of the filler comprise boron nitride particles having a size between 10 nanometers and 100 microns, and the mesh structural member is configured to accept the size of the particles.

16. The method of claim 13 , wherein the particles of the filler comprise boron nitride particles having a size between 100 nanometers and 300 nanometers, and the mesh structural member is configured to accept the size of the particles.

17. The method of claim 13 , wherein forming the liner material comprises applying heat and pressure to the liner material.

18. The method of claim 17 , wherein the mesh structural member comprises a mesh formed with at least one of a polyether ether ketone (PEEK) material or a NOMEX®material, and wherein forming the liner material comprises forming the liner material into a generally U-shaped structure having at least one bend of about 90 degrees.

19. The method of claim 13 , further comprising pre-treating the mesh structural member before coating at least one side of the mesh structural member, wherein pre-treating comprises applying a hexane rinse and plasma treatment.

20. The method of claim 13 , wherein the coating at least one side of the mesh structural member comprises:
applying a first coat of the coating to a substrate;
applying the mesh structural member with a first surface oriented toward the first coat of the coating and a second surface opposite the first surface; and
applying a second coat of the coating to the second surface of the mesh structural member.

Assignees

• Gen Electric

Inventors

• Zhang Wei
• Zhao Rian
• Fang Xiaomei
• Littlejohn Matthew Hal

Classifications

• H02K15/10

  Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes · CPC title

• H02K3/345 Primary

  between conductor and core, e.g. slot insulation · CPC title

• H02K3/30

  Windings characterised by the insulating material · CPC title

• B29C70/88

  characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced · CPC title

• B29C70/688

  the inserts being meshes or lattices (B29C70/82, B29C70/683 take precedence) · CPC title