Electric Insulation System of an Electric Motor, and Associated Manufacturing Process
Various embodiments of the teachings herein include an electrical insulation system for an electric motor comprising a conductor with wire winding in a slot of a laminated core of a stator. The wire winding is embedded in an encapsulation. The encapsulation includes volume-increasing particles.
1 . An electrical insulation system for an electric motor, the system comprising:
a conductor with wire winding in a slot of a laminated core of a stator;
wherein the wire winding is embedded in an encapsulation; and
the encapsulation includes volume-increasing particles.
2 . The insulation system as claimed in claim 1 , wherein the conductor comprises a carrier with an impregnating resin.
3 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises a filler.
4 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises mica particles.
5 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises aluminum oxide particles.
6 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises boron nitride particles.
7 . The insulation system as claimed in claim 1 , wherein the carrier comprises fibers.
8 . The insulation system as claimed in claim 1 , wherein the volume-increasing particles comprise gas-filled particles.
9 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises additives.
10 . The insulation system as claimed in claim 1 , wherein the encapsulation comprises an epoxy resin.
11 . The insulation system as claimed claim 1 , wherein the encapsulation does not comprise macropores.
12 . A method for producing an electrical insulation system for an electric motor, the method comprising:
forming a conductor from winding wire and a carrier medium loaded with filled impregnating resin;
drawing the formed conductor into the slots of a laminated core of a stator of the electric motor;
heating the laminated core such that gas-filled particles present in the impregnating resin expand with an increase in volume and thereby increase the volume of the not yet cured impregnating resin; and
curing the impregnated winding wire carrier insulation.
13 . The method as claimed in claim 12 , wherein the carrier medium comprises prepreg fibers.