Using bisphenol A and bisphenol F epoxy resin as main resin, aluminum hydroxide and spherical silicon micro powder as fillers, combined with anhydride curing agent and epoxy toughening agent, a film capacitor epoxy potting material for new energy vehicle was prepared, and the effects of each component on the properties of potting materials were analyzed. The results show that the film capacitor epoxy potting material for new energy vehicles prepared by optimized formula has high glass transition temperature, good mechanical properties, good adhesion performance, small linear expansion coefficient, and the performances of capacitors are excellent. The prepared potting material has comparable performance levels to similar potting materials abroad and is suitable for thin film capacitors used in new energy vehicles.

With the development of modern electrical equipment toward miniaturization, high-degree integration, and multi-functionalization, a large amount of heat accumulation will lead to insulation failure of electrical equipment. In order to develop a composite that can achieve high thermal conductivity even with low filler content (mass fraction<50%) and meet the strict requirement of current electrical equipment for heat dissipation, a composite insulating paper composed of aramid nanofibers and hydroxylated boron nitride nanotubes （BNNT-OH） was synthesized in this paper, and the effects of BNNT-OH content on the properties of composite insulating paper were studied. The results show that when the mass fraction of boron nitride nanotubes is 20%, the thermal conductivity of composite insulating paper is as high as 15.92 W/(m·K). The excellent thermal conductivity is due to the high intrinsic thermal conductivity of boron nitride nanotubes, and that the strong interaction between hydroxylated boron nitride nanotubes and aramid nanofibers reduces the interfacial thermal resistance.

Partial discharge inception voltage (PDIV) detection is an essential test method for evaluating the insulation performance of random wound inverter-fed motor stators. As an important parameter of pulse-width modulation voltage, the effects of pulse width on the PDIV of interturn insulation and interphase insulation in random wound inverter-fed motors are noteworthy. In this paper, the PDIV distribution laws of interturn insulation and interphase insulation in motor under different pulse widths were studied in the frequency of 50 Hz, rise time of 75 ns, and pulse widths within of 0.5-20 μs. The results show that when unipolar pulse square waves are input into random wound inverter-fed motors for PDIV testing, the overall trend of PDIV decreases as the input pulse width increases. Due to the combined effect of overvoltage from the rising and falling edges of short pulses, a turning point occurs in PDIV at a pulse width of 4 μs. It is necessary to consider the effects of pulse width and overvoltage and select appropriate pulse widths to obtain conservative values of stator insulation PDIV when conducting the PDIV test of interturn insulation and interphase insulation in random wound inverter-fed motor under unipolar pulse.

A new type of ceramifiable intumescent fire protection coating was prepared by using epoxy resin as the matrix, ammonium polyphosphate as the flame retardant, zinc borate as the flux, and raw vermiculite powder and wollastonite as the refractory fillers. The effects of the compound of four fillers on the properties of ceramifiable intumescent fire protection coating were studied by scanning electron microscope (SEM) and fire resistance test. The results show that ammonium polyphosphate can significantly improve the expansion multiplication rate and thermal insulation performance, zinc borate can effectively enhance the strength and density of the charcoal layer, and raw vermiculite powder and wollastonite can enhance the burn-resistant performance of the charcoal layer and increase the fire resistance time limit at high temperature. When the mass ratio of ammonium polyphosphate, raw vermiculite, zinc borate, and wollastonite is 11∶5∶6∶10, the tensile shear strength is 7.8 MPa, the refractory performance is the best, the fire resistance time limit reaches 10 min, the maximum backsheet temperature is 393℃, and the charcoal layer after burning can withstand a voltage of 1.0 kV.

High temperature vulcanized (HTV) silicone rubber insulators and liquid silicone rubber (LSR) insulators are widely used in power system transmission lines. In order to compare the performance differences of HTV silicone rubber and LSR material for external insulation under typical formulas, the mechanical properties, electrical properties, and hydrophobicity of the two materials were tested. The results show that LSR has better mechanical and electrical properties than HTV silicone rubber. The initial hydrophobicity characteristics of HTV silicone rubber and LSR are similar. The crystallization temperature of LSR is lower than that of HTV silicone rubber, and the thermal stability is higher than that of HTV silicone rubber, which indicates that LSR is more suitable for operation in low temperature or high temperature outdoor environment.

A glass fiber winding reinforced epoxy resin composite with high thermal conductivity was prepared by filling the bisphenol A type epoxy resin system with a mixture of alumina and silica powder fillers. The effects of filler content on the mechanical properties, electrical properties, and thermal conductivity of composite were studied. The results show that the addition of mixed fillers is beneficial for improving the thermal stability and thermal conductivity of the composite. When the mass fraction of the fillers is 62% (of which the mass fraction of silicon powder is 48% and the mass fraction of alumina is 14%), the tensile strength (0° and 90° directions), bending strength, and NOL ring tensile strength of the composite are 160.25, 24.50, 245.40, and 134.30 MPa, respectively. The dielectric constant is 1.889, the dielectric loss factor is 0.673×10^-2, the volume resistivity is 3.36×10¹⁶ Ω·cm, and the thermal conductivity is 1.257 W/(m·K), which is 155% higher than the thermal conductivity before addition.

A high heat resistant o-allylphenol-dicyclopentadiene epoxy resin was synthesized using dicyclopentadiene, o-allylphenol, and epichlorohydrin as raw materials, and its structure was characterized by infrared spectrum and gel chromatography. Then the epoxy resin was cured with bisphenol-A phenolic resin, benzoxazine resin, and active ester respectively, and a PCB substrate was pressed. The curing behavior of the system was studied by differential scanning calorimetry and thermogravimetric analysis. The mechanical properties, dielectric properties, and water absorption properties of the PCB substrate were tested, and compared with the curing system of phenol-dicyclopentadiene epoxy resin. The results show that compared with phenol-dicyclopentadiene epoxy resin, the o-allylphenol-dicyclopentadiene epoxy resin has higher heat resistance (glass transition temperature T_g and 5% thermogravimetric temperature T_d5% are higher), bending strength, impact strength, high temperature bending strength retention, and better dielectric properties, lower water absorption.

To address the issues of inadequate high-temperature insulation performance and thermal stability of wires, a high-temperature resistant ceramic coating was prepared using the nano alumina and a small quantity of nano silica as the primary raw materials by nanoparticle surface modification technology, then the ceramic coating was coated on quartz fiber braided layer to prepare a high-temperature composite insulating material. The structure, composition, and thermal stability of the coating were analyzed by X-ray diffraction (XRD), fourier-transform infrared spectroscopy (FTIR), and thermogravimetric-differential scanning calorimetry (TG-DSC). The morphology, volume resistivity, and electric strength of the high-temperature resistant ceramic coating-quartz fiber composite insulation layer before and after calcination were analyzed by scanning electron microscopy (SEM), high insulation resistance tester, and automatic voltage tester. The results show that the ceramic coating forms a ceramic protective layer on the quartz fiber braided layer after high temperature calcination, which can enhance the temperature resistance rating of the quartz fiber and improve its insulation performance. When the temperature exceeds 800℃, the insulation resistivity of the high-temperature resistant composite insulation layer still exceeds 2×10⁶ Ω·m, and the average electric strength at room temperature is as high as 400 kV/m, which has certain application prospects in the wires on specialized equipments such as aerospace engines, excitation coils, transformers.

To improve the insulating properties of machinable ceramic brush holders in high humidity environment, different types of organosilane film layers were formed on the surface of machinable ceramic, and their microstructure, contact angle, surface bonding strength, and moisture absorption rate were tested. The effects of the film layers containing KH-560, KH-570, and fluorosilane on the adhesion strength and moisture absorption of epoxy adhesive were studied. The mechanism of the films enhance the moisture resistance of machinable ceramic brush holder was concluded. The results show that the film layer thickness of KH-560 organosiliane on the surface of the machinable ceramic brush holder is about 40 μm. At the same time, the water contact angle of the brush holder product treated by KH-560 coupling agent increases from 9.2° to 42.8°, the moisture absorption rate reduces by more than 58.3%, and the hydrophobicity increases significantly. Even in the environment with relative humidity of 90%, the insulation resistance can still reach more than 220 MΩ, showing excellent insulation performance, which makes its insulation reliability improve significantly in high humidity environment.

The main insulation of large motor will produce many kinds of insulation defects during its operation process, and only used the phase resolved partial discharge (PRPD) pattern cannot reflect the characteristics of the defects fully. In this paper, four typical insulation defects such as internal air gap, coil wear in slot, overlapping part fault of end semiconductor coating and anti corona layer, and surface contamination were simulated in laboratory, their partial discharge (PD) information were collected in the electromagnetic shielding chamber, and the PRPD patterns and PSA patterns were drawn respectively. Combined with the characteristics of PRPD and PSA patterns under different voltage levels, the discharge characteristics of the typical insulation defects were analyzed. The results show that considering the symmetry, discharge amplitude, spectrum envelope shape of PRPD pattern and the discharge cluster number, discharge cluster distribution position, discharge cluster shape of PSA pattern, the four typical insulation defects can be identified accurately.