Importance

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Abstract

An insulating material (10) for an electrical generator rotor and method of forming the same. An insulating substrate (12) is formed from a single layer of woven glass fabric (16) having a necessary thickness and coated with a thermosetting resin (18). A first side of the substrate (12) is adhered to a first layer of copper winding material (20) of an electrical generator. A second side of the substrate (12) is covered with a layer of contacting material (14), such as plastic film, paper, treated felt or coated glass fabric, to cover the rough as-formed surface of the substrate (12) resulting from the coating of the necessarily thick layer of fabric (16). The contacting material (14) provides a desired coefficient of friction to form a slip surface permitting relative movement between the first layer of copper winding material (20) and a second layer of copper winding material (24) disposed over the insulating material (10). The addition of a separate contacting layer eliminates the prior art step of laminating three relatively thin layers of prepreg composite material to achieve a desired thickness and surface finish. Sanding to maintain adequate thickness control is also eliminated, thereby significantly reducing the cost of the insulating material (10) when compared to prior art insulation.

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First Claim