Granted Patent B2

US 12,580,437 · App. 18/043,654 · Granted Mar 17, 2026

Inventors: Steffen Lang (Hallerndorf, DE); Marek Maleika (Fürth, DE); Jürgen Huber (Erlangen, DE); Lisa Sponsel (Bubenreuth, DE)

Assignee: INNOMOTICS GMBH

H02K3/40H01B3/002H02K3/30H02K15/105

Abstract

Claims (49)

1 . A powder coating formulation suitable for producing an insulation system of an electrical machine, the formulation comprising:

a curable resin mixture; and

spherical SiO2 filler particles having a maximum particle diameter of 100 μm;

wherein the spherical SiO2 filler particles are present with a mass fraction of between 5 wt % and 65 wt % based on the total mass of the powder coating formulation;

wherein the resin mixture is solid at room temperature and comprises:

a monomeric and/or oligomeric blend;

an epoxidized novolac blend with bisphenol A and/or bisphenol F diglycidyl etherb;

a chain-extended bisphenol A and/or F;

a diepoxidic or higher polyepoxidic carbon-based resin component; and/or

a monomeric and/or oligomeric resin blend based on alkyl- and/or aryl-polysiloxane; and

at least one further resin component comprising two or more glycidyl ester and/or glycidyl ether and/or hydroxyl functionalities; and/or

at least one compound acting as curing agent and based on dicyandiamide and/or on (poly)amine and/or on amino-functional and/or alkoxy-functional alkyl-/aryl-polysiloxane.

2 . The powder coating formulation of claim 1 , further comprising nonspherical SiO2 filler particles.

3 . The powder coating formulation of claim 1 , wherein the filler particles are crystalline and/or amorphous.

4 . The powder coating formulation of claim 1 , wherein the SiO2 filler particles comprise fused silica, quartz flour, and/or quartz glass.

5 . The powder coating formulation of claim 1 , wherein the filler particles have a particle size distribution D50 of between 1 μm and 50 μm, and/or a maximum particle diameter of 70 μm, and/or a thermal expansion coefficient of at most 20*10−6*K−1, and/or a relative permittivity of between 1 and 7 at 18° C. and 50 Hz.

6 . The powder coating formulation of claim 1 , wherein the filler particles are at least partly surface-modified.

7 . The powder coating formulation of claim 1 , comprising a sprayable powder coating material.

8 . The powder coating formulation of claim 1 , wherein, in the cured state it possesses a thermal expansion coefficient of at most 40*10−6*K−1.

9 . An electrical machine comprising:

a conductor; and

an insulation system comprising a resin mixture filled with spherical SiO2 particles having a maximum particle diameter of 100 μm;

wherein the spherical SiO2 filler particles are present with a mass fraction of between 5 wt % and 65 wt % based on the total mass of the powder coating formulation;

wherein the resin mixture is solid at room temperature and comprises:

a monomeric and/or oligomeric blend;

an epoxidized novolac blend with bisphenol A and/or bisphenol F diglycidyl etherb;

a chain-extended bisphenol A and/or F;

a diepoxidic or higher polyepoxidic carbon-based resin component; and/or

a monomeric and/or oligomeric resin blend based on alkyl- and/or aryl-polysiloxane; and

at least one further resin component comprising two or more glycidyl ester and/or glycidyl ether and/or hydroxyl functionalities; and/or

at least one compound acting as curing agent and based on dicyandiamide and/or on (poly)amine and/or on amino-functional and/or alkoxy-functional alkyl-/aryl-polysiloxane.

10 . A method for producing an insulation system of an electrical machine, the method comprising:

coating insulation components with a powder coating formulation including a curable resin mixture filled with spherical SiO2 particles having a maximum particle diameter of 100 μm; and

curing the formulation;

wherein the spherical SiO2 filler particles are present with a mass fraction of between 5 wt % and 65 wt % based on the total mass of the powder coating formulation;

wherein the resin mixture is solid at room temperature and comprises:

a monomeric and/or oligomeric blend;

an epoxidized novolac blend with bisphenol A and/or bisphenol F diglycidyl etherb;

a chain-extended bisphenol A and/or F;

a diepoxidic or higher polyepoxidic carbon-based resin component; and/or

a monomeric and/or oligomeric resin blend based on alkyl- and/or aryl-polysiloxane; and

at least one further resin component comprising two or more glycidyl ester and/or glycidyl ether and/or hydroxyl functionalities; and/or

at least one compound acting as curing agent and based on dicyandiamide and/or on (poly)amine and/or on amino-functional and/or alkoxy-functional alkyl-/aryl-polysiloxane.

11 . The method of claim 10 , wherein coating the insulation components includes:

preparing a substrate by heating and/or electrical contact;

applying the powder coating formulation to the prepared substrate; and

melting, drying, and/or partially gelling the powder coating formulation on the substrate.

12 . The method of claim 11 , wherein the powder coating formulation is applied and melted, dried, and/or partially gelled more than once.

13 . The method of claim 10 , carried out at least partly automatically.

Assignments (2)

Priority Claims (1)

Continuity (1)

References Cited (23)