Secondary Electrical Insulation Coatings Containing Nanomaterials

Abstract

Use of the barrier property effect of nanomaterials to improve the electrical insulation resistance and corrosion protection strength properties of electromagnetic devices. The beneficial effects are realized with nanomaterial loadings of 1-20%, and preferably between 1-5%, parts by weight of coating resins. Nanomaterials include, but are not limited to, silica, alumina, zirconia, and antimony pentoxide, which are dispersed either directly into a coating, or pre-dispersed in a carrier appropriate to the solvent of the resin system. The rheology of the resin system is not significantly altered which would otherwise affect processing of the resins for their intended applications.

1 . A coating composition for an electromagnetic device to improve the electrical insulation resistance and corrosion protection properties of the device, the coating composition comprising a substantially homogenous mixture of a commercially available coating resin material and an inorganic nanomaterial; the nanomaterial being added to the resin material by between approximately 1-20% part by weight of the composition.  
     
     
         2 . The coating composition of  claim 1  in which the nanomaterial is an inorganic material in the range of 1-150 nanometers.  
     
     
         3 . The coating composition of  claim 2  in which the nanomaterial is chosen from the group consisting of silica, alumina, zirconia, antimony pentoxide and combinations thereof.  
     
     
         4 . The coating composition of  claim 1  in which the nanomaterial comprises between approximately 1-5% part by weight of the composition.  
     
     
         5 . The coating composition of  claim 1  in which the resin material is a standard filled unsaturated polyester (UPE) coating material.  
     
     
         6 . The coating composition of  claim 1  in which the resin material is a water borne polyester (WBPE) coating material.  
     
     
         7 . The coating composition of  claim 1  in which the nanomaterial is dispersed directly into the resin material.  
     
     
         8 . The coating composition of  claim 1  in which the nanomaterial is pre-dispersed into a carrier appropriate for the resin material with which the nanomaterial is mixed.  
     
     
         9 . The coating composition of  claim 1  in which the barrier effect resulting from use of the nanomaterial improves electrical and corrosion resistance properties of the coating using lower amounts of the nanomaterial than a coating produced using a standard inorganic filler material.  
     
     
         10 . The coating composition of  claim 9  in which the barrier effect resulting from use of the nanomaterial further improves the abrasion resistance of the coating.  
     
     
         11 . The coating composition of  claim 10  in which the barrier effect resulting from use of the nanomaterial produces a coating having a low viscosity relative to systems where fumed silica is used to prevent settling of fillers, thereby providing flexibility in processing options for the coating.  
     
     
         12 . The coating composition of  claim 11  in which the coating has a viscosity of less than 1000 centipoise.  
     
     
         13 . A coating composition for an electromagnetic device to improve the electrical insulation resistance and corrosion protection properties of the device, the coating composition consisting of a substantially homogenous mixture of a commercially available coating resin material and an inorganic nanomaterial; the nanomaterial being added to the resin material by between approximately 1-20% part by weight of the composition; the nanomaterial being chosen from the group consisting of silica, alumina, zirconia, antimony pentoxide and combinations thereof; and the resin material being chosen from the group consisting of unsaturated polyesters, epoxies, urethanes, waterborne polyesters, epoxy emulsions, organic solvent borne alkyds, acrylated and methacrylated urethanes, acrylated and methacrylated epoxies, acrylated and methacrylated polyols, acrylated and methacrylated vegetable oils, and combinations thereof.  
     
     
         14 . The coating composition of  claim 13  in which the nanomaterial is an inorganic material in the range of 1-150 nanometers.  
     
     
         15 . The coating composition of  claim 13  in which the nanomaterial comprises between approximately 1-5% part by weight of the composition.  
     
     
         16 . A process for producing a coating composition for an electromagnetic device to improve the electrical insulation resistance and corrosion protection properties of the device; the process comprising: 
 formulating a coating resin using a commercially available resin material;    adding to the resin material between approximately 1-20% part by weight of a nanomaterial;    mixing the resin material and nanomaterial together until a homogeneous composition is achieved.    
     
     
         17 . The process of  claim 16  in which between approximately 1-5% part by weight of the nanomaterial is added to the resin material.  
     
     
         18 . The process of  claim 16  in which the nanomaterial is an inorganic material in the range of 1-150 nanometers.  
     
     
         19 . The process of  claim 16  wherein the nanomaterial is chosen from the group consisting of silica, alumina, zirconia, antimony pentoxide and combinations thereof.  
     
     
         20 . The process of  claim 16  in which the resin material is a standard filled unsaturated polyester (UPE) coating material.  
     
     
         21 . The process of  claim 16  in which the resin material is a water borne polyester (WBPE) coating material.  
     
     
         22 . The process of  claim 16  wherein the step of adding the nanomaterial to the resin comprises dispersing the nanomaterial directly into the resin.  
     
     
         23 . The process of  claim 16  wherein the step of adding the nanomaterial to the resin comprises pre-dispersing the nanomaterial into a carrier appropriate for the resin material with which the nanomaterial is mixed and mixing the pre-dispersed nanomaterial with the resin.