Title of Invention

B-STAGE POLYESTER RESIN IMPREGNATED POLYESTER-FIBREGLASS FABRIC TAPE AND THE PROCESS OF MANUFACTURING THE SAME

Abstract A polyester resin impregnated polyester - fiberglass fabric tape comprises of a woven fabric with polyester fiber as warp yarn and fiber glass as fill yarn coated on both side with formulated thermosetting polyester resin and laminated with both side silicone coated polyester film interliner. The tape is in semicured B-stage and is having, sufficient tack at normal temperature which helps layer to layer sticking without any air entrapment when applied in a spiral fashion with a 50% overlap on conductor and on thermal curing the polyester yarn in warp shrinks and provides a firm grip on the conductor, cures and forms a good bond with copper and fabric as well as between fabric and fabric even without pressure.
Full Text FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
COMPLETE SPECIFICATION
(See Section 10)
B-STAGE POLYESTER RESIN IMPREGNATED POLYESTER -FIBREGLASS FABRIC TAPE AND THE PROCESS OF MANUFACTURING THE SAME


PRS Solutions Private Limited, a Company incorporated under the Companies Act, 1956 and having its office at 63, Bombay Samachar Marg, Mumbai - 400 001 Maharashtra State, India.
The following specification particularly describes the nature of this invention and the manner in which it is to be performed


FIELD OF THE INVENTION:
This invention Telates to manufacturing of B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape and the process of manufacturing the same. The said tape is sufficiently tacky at normal temperature to form interlayer bond when wrapped around on a conductor and shrinks, cures and forms a good bond with copper and fabric as well as between fabric and fabric when thermally cured even without pressure. The said tape is used as insulating and binding materials for manufacturing and repairing in the fields of electrical machinery, transformer, Armature & Stator coils etc.
DESCRIPTION OF THE PRIOR-ART:
It is common practice in the manufacture of electrical windings, like those used in electrical motors, to insulate the respective turns of the coil by placing insulating material above the winding turns. Such insulation system generally comprises of sleeves of materials like cotton, fiberglass etc. and insulating varnishes where said insulating material absorbs varnish & thus provides reinforcement to the insulating varnishes. The purpose of the insulation system is to protect such windings from mechanical damage as well as provide required electrical insulation. A good insulation system should have high tensile strength, flexibility, and firm grip on the coil, good mechanical and chemical resistance

properties. Glass fiber is commonly used as one of the preferred insulating material. Although it provides good mechanical strength it has very low elongation thereby making a tight winding difficult. Such coils are subsequently varnished where varnish is used as a low viscosity liquid and is applied by different methods such as Dip or flood impregnation, Vacuum-Pressure Impregnation (VPI), Trickle Impregnation etc. In all these techniques the dripping of extra varnish makes the entire process messy and workers are exposed to toxic and harmful liquids.
To overcome the above problems an insulating material is required where the substrate provides the mechanical strength and tight winding and is available with sufficient varnish.
Accordingly one objective of the present invention is to supply varnish in the semi cured (B-stage) form that gets cured on heating.
Another objective of the present invention is to use a substrate that provides good mechanical strength as well as shrinks in the longitudinal direction to form a tight grip on the coil.
Yet another objective of this invention is to provide the said shrinkable substrate and said B-stage varnish in the form of a tape for easy winding.

SUMMARY OF THE INVENTION:
Present invention deals with a B-stage electrical insulation tape made out of a woven fabric where the fabric comprises of polyester fiber as warp yarn and glass fiber as fill yarn. Such combination fabric shows perfect property of heat-resistance, insulation and heat shrink. The B-stage tape made by impregnating the said fabric with B-stage cured polyester resin becomes excellent electrical insulating and binding material for manufacturing and repairing in the fields of electrical machinery, transformer, Armature & Stator coils etc. simply by winding and thermosetting and this eliminates the messy operations of varnishing.
B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape is manufactured by coating the said fabric with thermosetting resinous material which is a formulated saturated polyester resin on one side with a desirable deposition followed by drying with conventional methods. Thereafter, the opposite side of the said fabric is coated with the said material with a desirable deposition. As an alternative technique, the said fabric is coated with the said formulated saturated polyester resin on both the sides of the fabric together in one pass with desirable deposition followed by drying with conventional method. Thereafter, the insulating product thus obtained is further slit and/or cut to desired size and shapes by conventional cutting techniques along with the siliconised polyester film liner used during the

first layer coating to prevent tacky B-stage Polyester resin impregnated Polyester - Fiberglass fabric layers sticking with each other.
The polyester - fiberglass fabric used comprises of polyester fiber as warp yarn and glass fiber as fill yarn. The thickness of the said fabric used depends on the requirement of the application and preferably will be 0.05 mm to 0.125 mm thick. However, fabric of other thickness can also be used.
The said formulated saturated Polyester resin is blended with melamine resins such as hexa methoxy methyl melamine, partially methylated melamine and Benzoguanamine resin and an acid catalyst.
For optimum performance with respect to level of cure, flexibility, hardness and impact resistance a combination of saturated Polyester resin with hexa methoxy methyl melamine at ratio 70:30 to 85:15 on solid resin content is preffered. Use of acid catalyst such as para Toluene sulphonic acid between 1% and 5% helps promoting cure. The polyester resin used for the purpose is formulated to achieve the desirable properties such that it cures to form bond with conducting component of the winding at a temperature of 175°C or higher. Part methylated amino resin can be used in place of hexa methoxy methyl melamine and will develop very good hardness & solvent resistance but at the expense of flexibility. Benzoguanamine resin can also be used to increase cure response & retortability.

The formulated thermosetting polyester resin is evenly deposited on a both side silicone resin coated polyester film interliner by conventional coating techniques such as reverse roll coating or clearance coating or knife over roll coating. The most optimum deposition of the said resin is about 60 to 100 gram per square meter, however any other deposition can also be used depending on the end application. The formulated thermosetting polyester resin coated interliner is passed through the drier at a temperature between 60° to 90°C and at a suitable speed to keep the resin in tacky condition followed by lamination of the said fabric on the resin coated side. The product of this pass is then given another layer of coating of the said formulated thermosetting polyester resin on the opposite surface of the said fabric by conventional coating techniques such as reverse roll coating or clearance coating or knife over roll coating with an optimum deposition of 60 to 80 gram per square meter or any other suitable deposition followed by drying at temperatures below 90°C in order to achieve tacky B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape. The insulating product thus obtained is further slit and/or cut to desired size and shapes by conventional cutting techniques along with the siliconised polyester film interliner used during the first layer coating to prevent tacky B-stage Polyester resin impregnated Polyester - Fiberglass fabric layers sticking with each other.
In an alternate method of manufacturing B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape the fabric

is coated with the said formulated thermosetting polyester resin evenly on both surfaces of the said fabric in the same coating pass by preferably giving a total resin deposition of 120 to 160 gram peT square meter or any other suitable deposition using dip-squeeze coating technique followed by drying at a temperature below 90°C and at a suitable speed to keep the resin in tacky B-stage condition. Both side Silicone resin coated polyester film is then laminated as interlayer separator to prevent layers of the said tape sticking with each other. The insulating product thus obtained is further slit and/or cut to desired size and shapes by conventional cutting techniques along with the said both side coated siliconised polyester film interliner.
B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape thus obtained can be cured at 175°C ± 10°C for 4 hour to obtain a good bond with copper and fabric as well as between fabric and fabric. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape thus obtained provides many advantages over the conventional insulation tapes commonly used. Some of the benefits of using the said tape as insulating and binding materials for manufacturing and repairing in the fields of electrical machinery, transformer, Armature & Stator coils etc. are:
1. Tape is in B-stage form with sufficient resin impregnation which eliminates the need for dipping the conductors in varnish,

2. Tape has retained tack at normal temperatures which
helps layer to layer sticking with no entrapped air when
applied in a spiral fashion with a 50% overlap on conductors,
3. On thermal curing the polyester yarns in warp shrinks and provide a firm grip on the conductor without application of pressure,
4. On curing it forms very good bond between copper and fabric as well as between fabric and fabric.
The Figure 1 is the schematic representation of the construction of the B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape.

WE CLAIM:
1. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape and the process of manufacturing the same comprises of the following steps:
(a) (i) evenly depositing thermosetting formulated polyester
resin, which is a blend of saturated polyester resin with
melamine resins and acid catalysts, on one side of silicone
resin coated polyester film with a desirable deposition by
use of conventional coating methods followed by lamination of
one surface of Polyester - Fiberglass fabric;
(ii) coating the other side of the said polyester resin coated Polyester - Fiberglass fabric with a desirable deposition by use of conventional coating methods followed by drying with conventional methods;
(b) alternatively coating both sides of a Polyester - Fiberglass fabric in one pass with the said thermosetting formulated polyester resin with a desirable deposition by use of conventional coating methods followed by drying with conventional methods;
(c) The insulating product thus obtained is further slit and/or cut to desired size and shapes by conventional cutting techniques along with the said both side silicone resin coated polyester film interliner.

2. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in Claim 1 wherein Polyester -Fiberglass fabric is a woven fabric having polyester fiber as warp yarn and glass fibers as fill yarn and is having thickness of 0.05 mm to 0.125 mm;
3. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in Claim 1 wherein the said melamine resins is hexarnethoxymethyl melamine, partially methylated melamine and/or Benzoguanamine resin.
4. B-stage Polyester resin impregnated polyester - Fiberglass fabric tape as claimed in Claim 1 wherein acid catalyst is para Toluene sulphonic acid;
5. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in Claim 1(a) wherein the resin coating on one side is 60 to 100 gram per square meter and on the other side is 60 to 80 gram per square meter;
6. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in Claim l{b) wherein total resin deposition is 120 to 160 gram per square meter;
7. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in claim 1 wherein the release liner used is both side silicone resin coated polyester film;

8. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape as claimed in Claim 1 wherein saturated Polyester resin is formulated to achieve good bond with conducting component of the winding at 175 ± 10°C.
9. B-stage Polyester resin impregnated Polyester - Fiberglass fabric tape manufactured by the method as claimed in Claims 1 to 9.
Dated this 30th day of December, 2008


Documents:

3-mum-2009-abstract.doc

3-mum-2009-abstract.pdf

3-MUM-2009-CLAIMS(AMENDED)-(17-5-2012).pdf

3-MUM-2009-CLAIMS(AMENDED)-(21-3-2013).pdf

3-MUM-2009-CLAIMS(AMENDED)-(23-11-2012).pdf

3-MUM-2009-CLAIMS(GRANTED)-(25-3-2013).pdf

3-MUM-2009-CLAIMS(MARKED COPY)-(17-5-2012).pdf

3-MUM-2009-CLAIMS(MARKED COPY)-(23-11-2012).pdf

3-mum-2009-claims.doc

3-mum-2009-claims.pdf

3-mum-2009-correspondence(12-1-2009).pdf

3-MUM-2009-CORRESPONDENCE(21-1-2013).pdf

3-MUM-2009-CORRESPONDENCE(21-3-2013).pdf

3-MUM-2009-CORRESPONDENCE(23-11-2012).pdf

3-MUM-2009-CORRESPONDENCE(3-3-2009).pdf

3-MUM-2009-CORRESPONDENCE(31-7-2012).pdf

3-MUM-2009-CORRESPONDENCE(IPO)-(25-3-2013).pdf

3-mum-2009-correspondence.pdf

3-mum-2009-description(complete).doc

3-mum-2009-description(complete).pdf

3-MUM-2009-DESCRIPTION(GRANTED)-(25-3-2013).pdf

3-mum-2009-drawing.pdf

3-mum-2009-form 1.pdf

3-MUM-2009-FORM 18(3-3-2009).pdf

3-MUM-2009-FORM 2(GRANTED)-(25-3-2013).pdf

3-MUM-2009-FORM 2(TITLE PAGE)-(GRANTED)-(25-3-2013).pdf

3-mum-2009-form 2(title page).pdf

3-mum-2009-form 2.doc

3-mum-2009-form 2.pdf

3-MUM-2009-FORM 26(17-5-2012).pdf

3-mum-2009-form 3.pdf

3-mum-2009-form 5.pdf

3-mum-2009-form 9(12-1-2009).pdf

3-MUM-2009-OTHER DOCUMENT(21-1-2013).pdf

3-mum-2009-power attorney.pdf

3-MUM-2009-REPLY TO EXAMINATION REPORT(17-5-2012).pdf

3-MUM-2009-REPLY TO HEARING(27-8-2012).pdf

abstract1.jpg

FORM9.TIF


Patent Number 255804
Indian Patent Application Number 3/MUM/2009
PG Journal Number 13/2013
Publication Date 29-Mar-2013
Grant Date 25-Mar-2013
Date of Filing 01-Jan-2009
Name of Patentee PRS SOLUTIONS PRIVATE LIMITED
Applicant Address 63, BOMBAY SAMACHAR MARG, MUMBAI-400001,
Inventors:
# Inventor's Name Inventor's Address
1 BISWAS ASHOK 1204 ASTER, 12TH FLOOR, DOSTI ACRES, WADALA (EAST), MUMBAI-400037, MAHARASHTRA STATE, INDIA.
2 SHROFF PRADIP HIRALAL 1802, WALLACE APARTMENTS, SLATER ROAD, MUMBAI-400007, MAHARASHTRA STATE, INDIA.
3 BHATTACHARYA SOMNATH A-5, VYAS CO-OPERATIVE HOUSING SOCIETY LIMITED, 131, MODEL TOWN, SEVEN BUNGLOWS, ANDHERI (WEST), MUMBAI-400053, MAHARASHTRA STATE, INDIA.
4 DIWADKAR NAYAN NARAYAN 81A/14, ON RADHAKRISHNA CHS, BRINDABAN COMPLEX, THANE (WEST)-400601, MAHARASHTRA STATE, INDIA.
PCT International Classification Number H01B7/17
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA