# US 2021/0242759 A1 · Electric Insulation System of an Electric Motor, and Associated Manufacturing Process

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- Number: US 2021/0242759 A1
- Document ID: US20210242759A1
- Status: Published application
- Kind: A1
- Application number: 17/052,770
- Filed: 2019-05-03
- Published: 2021-08-05
- Earliest claimed: 2018-05-04
- Assignees: Siemens Aktiengesellschaft
- Applicants: Siemens Aktiengesellschaft
- Inventors: Tobias Katzenberger; Bastian Plochmann
- Web page: https://patentgrep.com/patent/US20210242759A1

## CPC

- H02K 15/12: Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines
- B29C 44/1209: {by impregnating a preformed part, e.g. a porous lining}
- H02K 3/30: Windings characterised by the insulating material
- H02K 3/34: between conductors or between conductor and core, e.g. slot insulation
- H02K 15/105: {to the windings}
- B29K 2067/00: Use of polyesters {or derivatives thereof}, as moulding material
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2105/046: {with closed cells}
- B29K 2105/0872: {Prepregs}
- B29L 2031/7498: {Rotors (with blades B29L2031/08)}
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

The insulation system as claimed in claim 1, wherein the conductor comprises a carrier with an impregnating resin.

### Claim 3 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises a filler.

### Claim 4 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises mica particles.

### Claim 5 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises aluminum oxide particles.

### Claim 6 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises boron nitride particles.

### Claim 7 (depends on 1)

The insulation system as claimed in claim 1, wherein the carrier comprises fibers.

### Claim 8 (depends on 1)

The insulation system as claimed in claim 1, wherein the volume-increasing particles comprise gas-filled particles.

### Claim 9 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises additives.

### Claim 10 (depends on 1)

The insulation system as claimed in claim 1, wherein the encapsulation comprises an epoxy resin.

### Claim 11 (depends on 1)

The insulation system as claimed claim 1, wherein the encapsulation does not comprise macropores.

### Claim 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.

### Claim 13 (depends on 12)

The method as claimed in claim 12, wherein the carrier medium comprises prepreg fibers.