US2014178661A1PendingUtilityA1

Electrical insulation paper, methods of manufacture, and articles manufactured therefrom

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Assignee: SABIC INNOVATIVE PLASTICS IPPriority: Dec 21, 2012Filed: Dec 21, 2012Published: Jun 26, 2014
Est. expiryDec 21, 2032(~6.4 yrs left)· nominal 20-yr term from priority
Inventors:Thomas AdjeiBenny Ezekiel DavidJohn Raymond KrahnDennis LockyerPaul LockyerDavid K. SmithErich Otto TeutschPeter James Zuber
H01B 3/48D21H 17/72H01B 3/52D21H 13/20D21H 13/26
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Claims

Abstract

A fibrous substrate comprising a consolidated product of a fiber composition is provided comprising polyimide fibers; fibers selected from aromatic polyamide fibrids or polycarbonate fibers; aromatic polyamide fibers. A process of preparing a fibrous substrate is disclosed, comprising forming a layer from a slurry comprising a suspension solvent; and fiber composition comprising a combination of polyimide fibers; aromatic polyamide fibers; aromatic polyamide fibrids; each based on the total weight of the fibers in the fiber composition; dewatering the layer; and consolidating the layer to form the fibrous substrate; wherein a layer of polyimide fiber aromatic polyamide fibrid is applied to each surface of the fibrous substrate either before or after said consolidating step, and the substrate and polyimide layers are together subjected to a consolidating step. In another embodiment, articles comprising the above fibrous substrates are provided.

Claims

exact text as granted — not AI-modified
1 . A fibrous substrate comprising a consolidated product of a fiber composition comprising, based on the total weight of fibers in the fiber composition:
 from about 10 to about 65 wt. % of polyimide fibers;   from about 10 to about 30 wt. % of fibers selected from aromatic polyamide fibrids or polycarbonate fibers;   from about 25 to about 70 wt. % aromatic polyamide fibers;   wherein the consolidated product has a thickness of from more than 0 to less than 8 mils.   
     
     
         2 . An electrical paper comprising the fibrous substrate of  claim 1 . 
     
     
         3 . The electrical paper of  claim 2 , wherein the polyimide fibers are selected from polyetherimide fibers, polyetherimidesulfone fibers, polyetheramideimide fibers, and combinations thereof. 
     
     
         4 . The electrical paper of  claim 2 , wherein the polyimide fibers are polyetherimides having a polydispersity index ranging from 2.2 to 2.5. 
     
     
         5 . The electrical paper of  claim 2 , wherein at least one of the aromatic polyamide fibrid and aromatic polyamide fiber is an aromatic para-polyamide. 
     
     
         6 . The electrical paper of  claim 5 , wherein the aromatic para-polyamide is selected from poly(p-phenylene terephthalamide), poly(p-phenylene terephthalamide-co-3′4′-oxydiphenylene terephthalamide), and combinations thereof. 
     
     
         7 . The electrical paper of  claim 2 , wherein the thickness of the substrate is from about 1.0 to 5 mils. 
     
     
         8 . The electrical paper of  claim 2 , wherein the thickness of the substrate is from 2 to 4 mils. 
     
     
         9 . The electrical paper of  claim 2 , further comprising a thermosetting or thermoplastic polymer impregnated in the fibrous substrate. 
     
     
         10 . An article comprising the electrical paper of  claim 2 . 
     
     
         11 . The article of  claim 10 , wherein the article is a phase separator, primary insulation in a motor, generator, or transformer, secondary insulation in a motor, generator, or transformer. 
     
     
         12 . An electrical paper comprising
 a fibrous substrate having a first side and a second side opposite the first side, and comprising a consolidated product of a fiber composition comprising:   about 20 to 65 wt. % of polyimide fibers;   about 30 to 70 wt. % of aromatic polyamide fibers;   about 10 to 30 wt. % aromatic polyamide fibrids;   each based on the total weight of these fibers in the fiber composition; and having   a first layer comprising about 75 to 95 wt. % polyimide fibers and about 5 to 25 wt. % aromatic polyamide fibrids disposed on the first side of the fibrous substrate; and   a second layer comprising about 75 to 95 wt. % polyimide fibers and about 5 to 25 wt. % aromatic polyamide fibrids disposed on the second side of the fibrous substrate,   wherein the electrical paper has a thickness of from more than 0 to less than 8 mil.   
     
     
         13 . The electrical paper of  claim 12 , wherein the fibrous substrate comprises about 40 wt. % polyimide fibers, about 40 wt. % aromatic polyamide fibers and about 20 wt. % aromatic polyamide fibrids and the first and second layers comprise about 90 wt. % polyimide fibers and about 10 wt. % aromatic polyamide fibrids. 
     
     
         14 . The electrical paper of  claim 12 , wherein the polyimide fibers are selected from polyetherimide fibers, polyetherimidesulfone fibers, polyetheramideimide, and combinations thereof. 
     
     
         15 . The electrical paper of  claim 12 , wherein the polyimide fibers are polyetherimides having a polydispersity index ranging from 2.2 to 2.5. 
     
     
         16 . The electrical paper of  claim 12 , wherein the aromatic polyamide is an aromatic para-polyamide. 
     
     
         17 . The electrical paper of  claim 12 , wherein the aromatic polyamide is selected from poly(p-phenylene terephthalamide), poly(p-phenylene terephthalamide-co-3′4′-oxydiphenylene terephthalamide), and combinations thereof. 
     
     
         18 . The electrical paper of  claim 12 , wherein the thickness of the substrate is from about 2.5 mils to 40 mils. 
     
     
         19 . The electrical paper of  claim 12 , wherein the thickness of the substrate is from 3 mils to 20 mils. 
     
     
         20 . The electrical paper of  claim 12 , further comprising a thermosetting or thermoplastic polymer impregnated in the fibrous substrate. 
     
     
         21 . An article comprising the electrical paper of  claim 12 . 
     
     
         22 . The article of  claim 21 , wherein the article is a phase separator, primary insulation in a motor, generator, or transformer, secondary insulation in a motor, generator, or transformer. 
     
     
         23 . An electrical paper comprising
 a fibrous substrate having a first side and a second side opposite the first side, and comprising a consolidated product of a fiber composition comprising:   about 75 to 95 wt. % polyimide fibers and about 5 to 25 wt. % aromatic polyamide fibrids each based on the total weight of these fibers in the fiber composition;   a first layer comprising:   about 35 to 45 wt. % of polyimide fibers;   about 35 to 45 wt. % of aromatic polyamide fibers;   about 10 to 30 wt. % aromatic polyamide fibrids;   disposed on the first side of the fibrous substrate; and   a second layer comprising:   about 35 to 45 wt. % of polyimide fibers;   about 35 to 45 wt. % of aromatic polyamide fibers;   about 10 to 30 wt. % aromatic polyamide fibrids;   disposed on the second side of the fibrous substrate,   wherein the electrical paper has a thickness of from more than 0 to less than 80 mil.   
     
     
         24 . The electrical paper of  claim 23 , wherein the polyimide fibers are selected from polyetherimide fibers, polyetherimidesulfone fibers, and combinations thereof. 
     
     
         25 . The electrical paper of  claim 23 , wherein the polyimide fibers are polyetherimides having a polydispersity index ranging from 2.2 to 2.5. 
     
     
         26 . The electrical paper of  claim 23 , wherein the aromatic polyamide is an aromatic para-polyamide. 
     
     
         27 . The electrical paper of  claim 23 , wherein the aromatic polyamide is selected from poly(p-phenylene terephthalamide), poly(p-phenylene terephthalamide-co-3′4′-oxydiphenylene terephthalamide), and combinations thereof. 
     
     
         28 . The electrical paper of  claim 23 , wherein the thickness of the substrate is from about 2.5 mils to 40 mils. 
     
     
         29 . The electrical paper of  claim 23 , wherein the thickness of the substrate is from 3 mils to 20 mils. 
     
     
         30 . The electrical paper of  claim 23 , further comprising a thermosetting or thermoplastic polymer impregnated in the fibrous substrate. 
     
     
         31 . An article comprising the electrical paper of  claim 23 . 
     
     
         32 . The article of  claim 31 , wherein the article is a phase separator, primary insulation in a motor, generator, or transformer, secondary insulation in a motor, generator, or transformer. 
     
     
         33 . A process of preparing a fibrous substrate, comprising
 forming a layer from a slurry comprising   a suspension solvent; and fiber composition comprising a combination of   about 20 to 65 wt. % of polyimide fibers;   about 30 to 70 wt. % of aromatic polyamide fibers;   about 10 to 30 wt. % aromatic polyamide fibrids;   each based on the total weight of the fibers in the fiber composition;   dewatering the layer; and   consolidating the layer to form the fibrous substrate;   wherein a layer of about 75 to 95 wt. % polyimide fiber and 5 to 25 wt. % aromatic polyamide fibrid is applied to each surface of the fibrous substrate either before or after said consolidating step, and the substrate and polyimide layers are together subjected to a consolidating step.   
     
     
         34 . The process of  claim 33 , wherein the consolidating step comprises calendering. 
     
     
         35 . The process of  claim 33 , wherein the layer is exposed to subatmospheric pressure during at least a portion of the process. 
     
     
         36 . The process of  claim 33 , wherein the consolidating is conducted in a continuous roll press. 
     
     
         37 . The fibrous substrate produced by the process of  claim 33 . 
     
     
         38 . An article comprising the fibrous substrate of  claim 37 .

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