Nanostructured insulation for electric machines
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.
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.