A scientific approach to coating motor windings with “heatless-cure” trickle coating

This paper describes the new “heatless-cure” trickle coating process for applying protective resin coatings to motor, generator and coil windings. The process cures the resin chemically with a catalyst instead of via the high-temperature baking process. It will save 90% of the energy consumed by ovens and will reduce the emission of volatile organic compounds into the atmosphere by 90%. All energy consumption creates heat, which increases global warming, adversely affecting the environment. Manufacturing is a major source of energy consumption, which also contributes to the release of carbon and sulfur dioxides caused by the use of coal and oil to generate electric power. Over 50% of all electrical energy is consumed by electric motors. In order to reduce the impact of energy consumption on the environment, governments will continue to require improvements in motor efficiency. The “heatless-cure” trickle coating process has many design and manufacturing opportunities not available to the high temperature baking processes. One of these is improved heat transfer, which can make a major contribution to improving motor efficiency. This paper presents the argument for more funding of the research necessary to take advantage of this new technology and describes the many very real benefits to motor design and manufacturing and to the protection of the environment for future generations