Dielectric insulation film
Dielectric films are provided. Such films can be used in electric submersible pump stators, for example, as slot liners, phase barriers, or housing barriers. The film includes a polymeric matrix combined with an inorganic filler or reinforcing system.
1 . A dielectric film comprising:
a polymeric matrix;
an inorganic, thermally conductive filler; and
a plurality of layers comprising:
one or more outer layers comprising a water resistant material; and
one or more inner layers comprising a high dielectric strength polyimide film or polyimide composite film, wherein:
each layer of the plurality of layers is a film, and
the one or more inner layers are sandwiched between the one or more outer layers such that the plurality of layers are configured to not physically or chemically bond together prior to insertion into an electric submersible pump motor stator.
2 . The dielectric film of claim 1 , wherein the plurality of layers are permanently bonded to a sheet comprising a reinforcing fabric.
3 . The dielectric film of claim 1 , wherein the inorganic, thermally conductive filler is present in an amount exceeding 15% total volume.
4 . The dielectric film of claim 1 , wherein the inorganic, thermally conductive filler comprises a mineral and/or a ceramic.
5 . The dielectric film of claim 1 , wherein the polymeric matrix comprises one or more of polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), or polyether ether ketone (PEEK).
6 . The dielectric film of claim 1 , wherein the plurality of layers are configured to be locked in place in the electric submersible pump motor stator during encapsulation of the electric submersible pump motor stator with a rigid thermoset resin.
7 . The dielectric film of claim 1 , wherein the one or more outer layers comprise a water resistant polytetrafluoroethylene (PTFE) or perfluoroalkoxy (PFA) composite.
8 . The dielectric film of claim 1 , wherein the one or more outer layers comprise a low modulus, high elongation film.
9 . The dielectric film of claim 1 , further comprising a surface treatment configured to improve compatibility with thermoset resin encapsulant of the electric submersible pump motor stator.
10 . The dielectric film of claim 1 , further comprising a surface treatment configured to improve compatibility with thermoset resin encapsulant of the electric submersible pump motor stator.
11 . A method of making a dielectric film, the method comprising:
forming one or more outer layers, wherein each outer layer comprises a water resistant material;
forming one or more inner layers, wherein each inner layer comprises a high dielectric strength polyimide film or polyimide composite film; and
sandwiching together the one or more inner layers with the one or more outer layers wherein the one or more inner layers and the one or more outer layers are not physically or chemically bonded together prior to insertion into an electric submersible pump motor stator.
12 . The method of claim 11 , further comprising:
inserting the dielectric film into the electric submersible pump motor stator,
and encapsulating the electric submersible pump motor stator with a rigid thermoset resin, such that the one or more outer layers and the one or more inner layers are mechanically locked in place.
13 . The method of claim 11 , further comprising:
incorporating an inorganic filler into a polymeric matrix of the dielectric film.
14 . The method of claim 13 , wherein the inorganic filler is incorporated into the polymeric matrix in an amount exceeding 15% total volume.
15 . The dielectric film of claim 1 , wherein the plurality of layers are permanently bonded to a sheet comprising glass.
16 . The method of claim 11 , further comprising applying a surface treatment to the dielectric film, the surface treatment configured to improve compatibility with a thermoset resin encapsulant of the electric submersible pump motor stator.