Abstract: A system and method for forming electrical devices via additive manufacturing processes that utilize starting materials that are in a solid state at least prior to, as well as after, the formation of the electrical device. A first solid starting material can be configured to form one or more insulator layers of the electrical device, while another solid starting material can be applied to form one or more electrically conductive layers. The starting materials canbe applied layer-by-layer during formation of the electrical device such that the electrically conductive layers can become automatically embedded within the insulating layers, and vice versa. The additive manufacturing process(es) utilized to form the electrically conductive layers from solid starting materials can be different than the additive manufacturing process(es) utilized to form the insulator layers.

Abstract: An epoxy formulation is provided with improved properties for electrical components exposed to a voltage differential. The improved electrical properties include increased glass transition temperature, increased breakdown strength and/or lower loss factor. Electrical components may be formed from the epoxy formulation by 3D printing the epoxy formulation and curing the formulation with UV radiation. The epoxy formulation includes epoxy, a photoinitiator and an accelerator.

Abstract: A method for forming an article of manufacture using additive manufacturing, includes: a processor executing program instructions to: (a) rotate an object continuously about a horizontal axis using a first rotational stage, wherein the object is partially submerged in a bath of energy curable liquid formulation during the rotation; (b) control a rate of rotation of the object to achieve a desired radial thickness of a sub layer of uncured liquid formulation at a desired rotational location on the object; (c) direct an energy source to provide an energy dose onto the object at a desired rotational location, wherein the energy dose is configured to cure and solidify the sub layer; and repeat (a), (b) and (c) until a desired radial thickness of a cured liquid formulation layer is a achieved.

Abstract: A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.

Abstract: The present invention relates to a polymer composition suitable for the manufacture of an electrical insulation layer for cables having superior mechanical and electrical properties and being environmentally friendly, to a cable comprising said polymer composition as well as to the use of the polymer composition as an electrical insulation layer in cables.

Abstract: A method for manufacturing for an electrical machine includes: stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each lamination having a plurality of openings therein, the openings forming a plurality of rotor poles in the rotor segment, each pole having a plurality of passages formed from the openings; rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; injecting into the passages of the first pole a polymer bonded permanent magnet (PBM) material in molten form, wherein the (PBM) material includes magnetic particles suspended within a polymeric matrix; subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the (PBM) material; and solidifying the (PBM) material to form permanent magnets within the passages of the first pole.

Abstract: A method for forming an article of manufacture using additive manufacturing, includes: a processor executing program instructions to: (a) rotate an object continuously about a horizontal axis using a first rotational stage, wherein the object is partially submerged in a bath of energy curable liquid formulation during the rotation; (b) control a rate of rotation of the object to achieve a desired radial thickness of a sub layer of uncured liquid formulation at a desired rotational location on the object; (c) direct an energy source to provide an energy dose onto the object at a desired rotational location, wherein the energy dose is configured to cure and solidify the sub layer; and repeat (a), (b) and (c) until a desired radial thickness of a cured liquid formulation layer is a achieved.

Abstract: A method for manufacturing for an electrical machine includes: stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each lamination having a plurality of openings therein, the openings forming a plurality of rotor poles in the rotor segment, each pole having a plurality of passages formed from the openings; rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; injecting into the passages of the first pole a polymer bonded permanent magnet (PBM) material in molten form, wherein the (PBM) material includes magnetic particles suspended within a polymeric matrix; subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the (PBM) material; and solidifying the (PBM) material to form permanent magnets within the passages of the first pole.

Abstract: A cable tie having a strain sensing device incorporated therein. In one embodiment, the strain sensing device is a fiber Bragg grating (FBG), which is preferably molded within the strap. In this case, the cable tie further includes a socket in optical communication with the fiber Bragg grating for coupling of the cable tie to an external light source. In another embodiment, the strain sensing device is a mechanical fuse that activates in the presence of a predetermined amount of strain on the cable tie. The mechanical fuse is preferably disposed on the strap and is made of a fuse material having a mechanical strength lower than a mechanical strength of the material of the strap so that the mechanical fuse will fracture or deform earlier than the material of the underlying strap when both the fuse and the strap experience the same increasing strain.

Abstract: A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.

Abstract: A high voltage or medium voltage transmission power cable includes a metallic conductor and an insulation system including an electrical insulation layer including a first composite material, and a semiconducting layer including a second composite material. The insulation layer and the semiconducting layer are arranged to surround the conductor. The first composite material in the insulation layer includes a polymer matrix and first inorganic conductive filler particles, wherein the amount of the first inorganic conductive filler particles is from 0.1 to 10 wt-%, based on the total weight of the first composite material, and wherein the first inorganic conductive filler particles are other than carbon black. A method of manufacturing the cable is also disclosed.

Abstract: A cable tie having a strain sensing device incorporated therein. In one embodiment, the strain sensing device is a fiber Bragg grating (FBG), which is preferably molded within the strap. In this case, the cable tie further includes a socket in optical communication with the fiber Bragg grating for coupling of the cable tie to an external light source. In another embodiment, the strain sensing device is a mechanical fuse that activates in the presence of a predetermined amount of strain on the cable tie. The mechanical fuse is preferably disposed on the strap and is made of a fuse material having a mechanical strength lower than a mechanical strength of the material of the strap so that the mechanical fuse will fracture or deform earlier than the material of the underlying strap when both the fuse and the strap experience the same increasing strain.

Abstract: It is proposed a wound conductor arrangement for an electrical machine: the wound conductor includes ma wound conductor comprising an electrically conductive material having an electrical conductivity value, and an insulation layer being at least partially provided around the wound conductor by a shrinkable tube comprising insulating material. The wound conductor arrangement further includes an intermediate layer provided between the wound conductor and the insulation layer. The intermediate layer has a conductivity value less than the conductivity value of the wound conductor. Further, an electric machine is proposed including the wound conductor arrangement. A method is described for insulating a wound conductor for an electrical machine.

Abstract: The present invention relates to an anhydride-free curable epoxy resin composition for use as high voltage (HV) insulation, to an anhydride-free curable epoxy resin mica composite or an anhydride-free curable epoxy resin cellulose composite comprising the same, to an insulating material obtained by curing the anhydride-free curable epoxy resin composition, the anhydride-free curable epoxy resin mica composite or the anhydride-free curable epoxy resin cellulose composite as well as to a process for producing the same.

Abstract: The present invention relates to a polymer composition suitable for the manufacture of an electrical insulation layer for cables having superior mechanical and electrical properties and being environmentally friendly, to a cable comprising said polymer composition as well as to the use of the polymer composition as an electrical insulation layer in cables.

Abstract: An insulator for a gas insulated device and method of making and/or producing the insulator are disclosed. The insulator includes an injection molded insulator disc and a conductor. The insulator disc includes a center opening encompassed by an inner bead inside which the conductor is arranged. The insulator disc includes, for example, a first material which is injection molded onto the conductor.

Abstract: An exemplary curable epoxy resin composition is disclosed which includes at least an epoxy resin component and a hardener component, and optionally further additives, wherein (a) at least a part of the hardener component is a chemically modified polycarbonic acid anhydride; (b) an optional glycol or polyglycol; (c) or a compound containing two carboxylic groups is included; and (d) the chemically modified acid anhydride hardener is present in an amount comprising at least 10% of reactive hardening groups calculated to all the reactive hardening groups contained in the total amount of hardener component present in the epoxy resin composition.

Abstract: Curable epoxy resin composition including an epoxy resin component and a filler component and optionally a hardener component and further additives, wherein (a) the curable epoxy resin composition has been produced by separately mixing together at least a part of the epoxy resin component and at least a part of the filler component and optionally some or all of the optional additives, prior to mixing theses components with the optional hardener component and with any remaining optional additives present in the curable epoxy resin composition, and that (b) the mixing together of at least a part of the epoxy resin component and at least a part of the filler component and optionally some or all of the optional additives has been carried out at a temperature higher than the casting temperature of the curable epoxy resin composition, and electrical insulation systems made therefrom.

Abstract: Curable epoxy resin composition, which is suitable for the production of electrical insulation systems for low, medium and high voltage applications, including at least an epoxy resin, a hardener, a mineral filler material, and optionally further additives, wherein (i) the epoxy resin component is a diglycidylether of bisphenol A (DGEBA); (ii) the hardener includes methyltetrahydrophthalic anhydride (MTHPA) and polypropylene glycol (PPG), wherein (iii) the average molecular weight of the polypropylene glycol (PPG) is within the range of about 300 to about 510 Dalton; and (iv) the molar ratio of methyltetrahydrophthalic anhydride (MTHPA) to polypropylene glycol (PPG) is within the range of about 9:1 to 19:1. A method of making the epoxy resin composition and electrical articles made therefrom are also provided.

Abstract: A curable epoxy resin composition is provided. The composition includes at least one diglycidyl ether of bisphenol A (DGEBA) and at least one diglycidyl ether of bisphenol F (DGEBF) as epoxy resins, in which the weight ratio of DGEBA:DGEBF is within the range of about 15:85 to 45:55; (ii) an anhydride hardener; (iii) and at least one plasticizer. The composition can additionally include a catalyst, at least one filler material and/or further additives. The dynamic complex viscosity value (?*) of the composition is within the range of 0.1 to 20 Pa·s. The present disclosure also provides a process for making the composition and electrical articles including an electrical insulation system made from the composition.