TECHNICAL FIELD

The invention relates to an electrical water-based insulation varnish with reduced curing time and increased mechanical strength to provide electrical insulation of components used in motor and transformer construction such as electric motors, coils, rotors, and stators.

BACKGROUND

In order to provide the necessary insulation in all electrical machines from small transformers to large generators in the relevant technical field, many different insulation materials with their characteristics and effectiveness are required. The purpose of electrical insulation is to ensure the passage of electrical current in such a way that the efficiency of electrical current in conductors is maximized. The insulation varnishes used for this purpose provide mechanical support to the conductors.

Due to the structure of the insulation varnishes used in the art, the curing time is approximately 6 hours at 160°C. The long duration of this period causes the insulation varnish to be unable to fully bind the windings due to its structure and application viscosity. Studies have shown that this situation does not provide sufficient mechanical strength. In addition, a bad odor is emitted during the curing of the insulation varnish. Varnish is applied in an open boiler by immersion method. While the spread of uncomfortable odor in the environment during the application causes air pollution, it negatively affects the health of the people in the environment. In addition, stability problems such as phase separation and precipitation are encountered in thinned varnishes.

All the problems mentioned above have made it necessary to make an innovation in the relevant technical field as a result.

BRIEF DESCRIPTION OF THE INVENTION The present invention relates to an electrical water-based insulation varnish with reduced curing time and increased mechanical strength to provide electrical insulation of components used in motor and transformer construction such as electric motors, coils, rotors, and stators.

The main object of the invention is to obtain a water-based electrical insulation varnish that provides electrical insulation of components used in the construction of motors and transformers such as electric motors, coils, rotors, and stators.

Another object of the invention is to obtain a water-based electrical insulation varnish to reduce varnish curing time.

Another object of the invention is to obtain a water-based electrical insulation varnish that enables the bonding of windings of components used in motor and transformer construction such as electric motors, coils, rotors, and stators.

Another object of the invention is to provide a water-based electrical insulation varnish that provides superior mechanical strength.

Another object of the invention is to provide a water-based electrical insulation varnish that does not cause stability problems in use.

To achieve all this, the invention is an electrical insulation varnish suitable for use in providing the electrical insulation of components used in motor and transformer construction, such as electric motors, coils, rotors, and stators, for coating the said components on the parts where they are used as substrates, characterized in that it is formed by combining components A and B and

- wherein the said component A comprises a mixture of melamine and epoxy ester resins in predetermined amounts, at least one catalyst, at least one solvent, and at least one amine-based component,

- the said component A comprises epoxy resin in the range of 70% to 85% by weight and melamine resin in the range of 10% to 25% by weight,

- wherein the said component B is water.

The possible embodiment of the invention is that the varnish comprises the amine component in a range of 3% to 5% by weight in component A. The possible embodiment of the invention is that the mixture of melamine/epoxy resin is 1/4 by weight in component A.

The possible embodiment of the invention is that the said solvent in component A is butyl glycol.

The possible embodiment of the invention is that the varnish comprises the solvent in the range of 3% to 6% by weight in component A.

The possible embodiment of the invention is that the varnish comprises sulfonic acid as the said catalyst.

The possible embodiment of the invention is that the varnish comprises the catalyst in the range of 0.01% to 0.2% by weight in component A.

The possible embodiment of the invention is that the varnish comprises at least one biocide, at least one surface modifier, and at least one anti-foam in component A.

The possible embodiment of the invention is that the varnish comprises an anti-foam in the range of 0.1% to 1% by weight, a surface modifier in the range of 0.1% to 1% by weight, and a biocide component in the range of 0.01% to 0.3% by weight in component A.

The possible embodiment of the invention is that the varnish comprises components A and B with a value of 100/115 (%/%) as A/B%.

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the subject of the invention is a water-based electrical insulation varnish with reduced curing time and increased mechanical strength to provide electrical insulation of the components used in motor and transformer construction such as electric motors, coils, rotors, and stators, and it is explained with examples that do not have any limiting effect only for a better understanding of the subject. In the invention, the term "providing electrical insulation" is meant to ensure the passage of electrical current in such a way as to maximize the efficiency of electrical current in conductors.

In the invention, the term "curing" refers to the application of varnish to convert from a liquid to a solid state. With this application, the process of transforming the film formed by the fluid organic coating on the surface into a thermoset hard film as a result of polymerization reactions takes place. The term "curing time" refers to the time elapsed for this process.

In the invention, the term "mechanical strength" refers to the behavior patterns of the materials under mechanical loads. The electronic components of the machines used must be strong enough to withstand the loads they are exposed to under weather conditions, forces applied by people, and working conditions. Otherwise, the life of the machine remains very limited.

One of the innovative aspects of the invention is that the water-based insulation varnish of the invention can provide the electrical insulation of the components used in the construction of motors and transformers such as electric motors, coils, rotors, and stators by reducing the curing time and increasing the mechanical strength.

The insulation varnish of the present invention is finally obtained by combining components A and B. Component B is water. Component A comprises at least one component to obtain the desired performance from the insulation varnish.

Component A preferably comprises more than one component.

The insulation varnish of the present invention contains a determined amount of epoxy ester resin as component A, as well as a determined amount of melamine resin. The melamine resin used is preferably in a partially methylated form. The insulation varnish of the present invention comprises component A, wherein the said component A comprises an epoxy ester resin in the range of 70% to 90% by weight if the ratio by weight of component A is considered to be 100%. Preferably, the epoxy ester constitutes 75% by weight of component A. The insulation varnish of the present invention comprises the melamine resin component as component A, while it constitutes a value in the range of 25% to 10% by weight. It is critical that the said components in the insulation varnish of the invention are in the determined weight ratios. The melamine and epoxy resin ratios obtained as a result of the research and development activities of the inventors must have the desired hardnesselasticity properties of the final product and have the said values to shorten the curing times. The most preferred embodiment is that the melamine/epoxy resin ratio is preferably 1/4 in the final product.

Component A of the insulation varnish of the present invention contains trace amounts of other components in addition to epoxy ester resin and melamine resin. One of these components is the solvent. Solvents directly affect the viscosity of the product. Therefore, the use of butyl glycol as a solvent was preferred. The solvent used is preferably used by mixing with water. Component A of the insulation varnish of the present invention comprises a value in the range of 3% to 6% by weight as the solvent/water mixture.

Component A of the insulation varnish of the present invention comprises at least one amine component. Component A of the insulation varnish comprises the amine component in a range of 3% to 5% by weight. The amine component is included as a pH regulator in component A of the insulation varnish. The specified amount of amine ensures that the pH value of the final product insulation varnish is in the range of 9-9.5.

Component A of the insulation varnish of the present invention comprises at least one antifoam component. It is preferred that the anti-foam used in the present invention has a gemini structure. The anti-foam contributes to preventing foam formation and reducing surface tension. Component A of the insulation varnish contains the anti-foam component in the range of 0.1% to 1% by weight.

Component A of the insulation varnish of the present invention comprises at least one surface smoother. It is preferred that the surface smoother used in the present invention has a gemini structure. Component A comprises a surface smoothing component in the range of 0.1% to 1% by weight.

Component A of the insulation varnish of the present invention comprises at least one biocide component. The biocide used in the present invention is preferred to be a combination of CMIT/MIT. Component A of the insulation varnish comprises a biocide component in the range of 0.01% to 0.3% by weight.

Component A of the insulation varnish of the present invention preferably comprises at least one catalyst component. The sulfonic acid compound is used as a catalyst in component A. The catalyst hydrophobic sulfonic acid structure provides acceleration of curing. Component A comprises a catalyst in the range of 0.01% to 0.2% by weight.

Table 1. A representation of the weight ratios of the raw materials contained in component A.

When Table 1 is examined, it is seen that component A of the insulation varnish of the present invention is obtained as a result of the mixture of epoxy ester resin, amine, melamine resin, solvent/water mixture, anti-foam, surface modifier, biocide and catalyst components in predetermined weight ratios. The ratio and sequence of components used for the production of the insulation varnish of the present invention are set to help provide electrical insulation.

The insulation varnish of the invention can be finally obtained by combining component A and component B. Accordingly, the inventors have determined that it is essential to combine the said components with certain weight ratios to have stably mixable and desired performance values. Accordingly, to obtain the final product insulation varnish, it comprises components A and B of 100/115 (%/% by weight) by weight as A/B%.

The insulation varnish with the configurations mentioned in the invention can be obtained by curing at a temperature of approximately 160°C for a maximum of 2.5 hours. The insulation varnishes in the present art can be obtained as a result of curing processes at much higher temperatures and for long periods.

The insulation varnish with the configurations mentioned in the invention has a viscosity value of 35-45 seconds/20°C in DINCUP4 standards. It is critical that the insulation varnish of the invention is at the said viscosity values. The present inventors have found that insulation varnishes with viscosity values in this range of values perform best because they directly affect the time and efficiency of the penetration within the components used in the construction of motors and transformers, such as electric motors, coils, rotors, and stator.

The insulation varnish with the configurations mentioned in the invention has a persistent hardness of 300-400.

The insulation varnish of the invention does not experience stability problems due to the synthesized polymer structure. The said polymer structure is thinned with water and there is no phase separation within it.

As a result of the insulation strength tests on the insulation varnishes obtained, the present inventors have determined that it provides strength up to 5000 V voltage. The tests were carried out using the "Ml 3394 CE MULTITesterXA device" on the wires containing the insulation varnish.

The scope of protection of the invention is specified in the attached claims and cannot be limited to those explained for sampling purposes in this detailed description. It is evident that a person skilled in the art may exhibit similar embodiments in light of the above-mentioned facts without drifting apart from the main theme of the invention.