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Xinova is looking for your ideas

REQUEST FOR APPLICATION (RFA)

Electrical Insulation Key words: Electrical Insulation, insulator, high voltage, high current, power electronics, thermal resistance, corona, coronal discharge, electrical systems, electronics, electricity, partial discharge, high frequency, polymer, engineering polymer, alumina, nanoparticle, polyimide nanocomposite insulation, mica, silicone, PEEK, mica tape, generator.

Request for Application

Circulation Date: November 10, 2017

RFA-170121 Electrical Insulation

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation

SUMMARY Xinova seeks the development of commercialization plans for the application of innovations to new industries and markets. Specifically, Xinova seeks the disclosure of applications for electrical insulation composed of alumina-polyimide or mica-silicone. Desired application characteristics and format for submission are described on page 6.

Description of Request for Application With this RFA, Xinova is seeking new applications where the technology solves a current problem, or substantially improves a product, process or experience. These electrical insulation technologies have been developed by General Electric (GE) for specific needs in avionics and defense markets. The goal of this RFA is to elucidate other application opportunities where these technologies can be exploited outside of avionics and defense industries.

Description of Current Innovation General Electric would like to identify new applications for two different types of electrical insulation: • Alumina-polyimide (AP) nanocomposite • Mica-silicone (MS) Alumina is another name for aluminum oxide (Al2O3) and, in this case, is in nanoparticulate form (<100nm). It is combined with a polymer called polyimide to form a polymer nanocomposite. MS is a reinforced polymer where mica is combined with silicone. Mica is part of a group of silicate minerals, a major component of rocks in the earth's crust, and has the general formula: X2Y4–6Z8O20(OH, F)4, in which • • •

X is K, Na, or Ca or less commonly Ba, Rb, or Cs; Y is Al, Mg, or Fe or less commonly Mn, Cr, Ti, Li, etc.; Z is chiefly Si or Al, but also may include Fe3+ or Ti.

AP has very good thermal and coronal resistance and is a strong dielectric. Thus, it can withstand heat exceeding 250oC, plasma discharges, and high voltage along

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation with high frequencies (up to 2,000 kHz), which are stressful on insulation. Thermal resistance is critical because of the high-heat environments some electric components operate in. There are insulators that have high coronal resistance and are strong dielectrics, but none exist that have the same combination of characteristics of AP. The insulation is 10% alumina by weight. Polyimides suffer from some processing difficulties, which have limited their growth. Most of them have a high glass transition temperature (Tg) that requires special processing. Polyimides tend to have poor UV stability. MS is not as thermally resistant as AP but does has good thermal (<330oC) resistance. It withstands coronas well and is also resistant to oil and water. This is very advantageous for use in the oil or marine industries or any application exposed to the environment. It is 20-40% mica by weight. However, with this application, a ceramic coating is first applied to the wire, then the MS coating is applied. Because of their use in windings, AP and MS must be sufficiently flexible such that the insulation does not delaminate or crack or otherwise suffer damage during winding operations. AP and MS must also be sufficiently abrasion resistant, so that the outer surface of the system can survive the friction, scraping, and abrading forces that can be encountered during winding operations. In addition, AP and MS must be sufficiently durable and resistive to degradation, so that dielectric properties are maintained over a long period of time. The relevant patents are •

14/268260 – High-Temperature, High-Frequency Magnet Wire (polyimide plus alumina nanoparticles), and

US20170011820 – Insulated Windings (ceramic coated with silicone that has filler particles)

Current Market Applications for Technology AP is currently used in aviation equipment, specifically generators, motors and actuators.

Current Economics According to MarketsAndMarkets, the electrical insulation materials market will be worth almost USD$10B by 2021 and growing at a CAGR of 5.82% from 2016. This market includes thermoplastics, epoxy resin and ceramic materials. Applications include power systems, electronics, cables and transmission lines, and domestic portable applications. According to Future Market Insights, 4,700 KT were produces in 2016 with that figure projected to reach 8,800 KT by the end of 20217 expanding at a CAGR of 5.8%.

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Thermoplastics and ceramics are the major types in the electrical insulation materials market. Power system application represents the bulk of the demand for electrical insulating materials. Asia-Pacific is estimated to account for the highest CAGR during the forecast period. Asia-Pacific is the largest market for electrical insulation materials market, followed by North America and Europe. China, the U.S., Japan, and Korea are the largest consumers of electrical insulating materials. Factors, such as augmentation & modernization of transmission & distribution network, increased global demand for electricity, upgrading of ageing technology, and growth of renewable energy have all led to the increasing demand of electrical insulating materials in the Asia-Pacific region. Thermoplastic insulation is the largest component and comprises about 40% of the total revenue because they are cheaper to produce than conventional insulation materials such as glass or ceramics, and provide a highly effective insulation performance. The high insulation capability of thermoplastics is also unaffected by harsh environmental conditions. The electrical insulation market is highly competitive due to the presence of a large numbers of local players who supply low-quality products at comparatively inexpensive pricing.

Background There are numerous applications for mica explained in the figure below.

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Polymers There are a variety of polymers, but electrical insulators are comparable to engineering plastics, often called engineering thermoplastics (ETPs), which are thermoplastics that maintain dimensional stability and many mechanical properties at temperatures greater than 100°C and less than 0°C. However, of these, only hightemperature polymers offer competition to the insulators in this RFA. • • • • • • • • • • • • • • • • • • •

Acrylonitrile butadiene styrene (ABS) Nylon 6 Nylon 6-6 Polyamides (PA) Polyaryletherketone (PAEK) Polybenzimidazole Polybutylene terephthalate (PBT) Polycarbonates (PC) Polyetheretherketone (PEEK) Polyetherketone (PEK) Polyethylene terephthalate (PET) Polyimides o Polyamide-imide (PAI) o Polyetherimide Poly(naphthodithiophene) Polyoxymethylene plastic (POM / Acetal) Polyphenylene sulfide (PPS) Polyphenylene oxide (PPO) Polyphenylquinoxalines Polyquinoxaline Polysulphone (PSU) o Polyethersulfone (PES) o Polysulfone o Polyphenylsulfone Polytetrafluoroethylene (PTFE / Teflon)

Reinforced Engineered Thermoplastics A subset of engineering thermoplastics are reinforced plastics, which are made by compounding a resin with one or more reinforcements, which are inert materials in the form of fibers, spheres and powders. Choices are typically based on the required mechanical or physical property enhancements. Most thermosets are compounded with some type of reinforcement, but different resins react to reinforcements in different ways. Combinations of reinforcements include glass; glass/mineral filler; glass/mineral filler/carbon fiber; and mineral filler/carbon fiber and stainless steel in combination with glass, minerals and carbon fibers; along with non-fibrous materials, such as mica and wollastonite.

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Application Suggestions Out-of-Scope Aviation, drone, and submersible pumps for oil and gas applications are out-ofscope. General Electric is well aware of these applications. Electronic Components This insulation could be used on the irregularly shaped, individual components found in electronics. The three main classes of electronic components include: •

Active components

Passive components

Interconnecting components

Active components can control current by means of another electrical signal. Transistors and oscillators are examples of active components. Passive components are incapable of controlling current by means of another electrical signal. Examples include capacitors and resistors. Interconnecting components connect components. Active and passive components are usually configured into subsystems that are then further assembled into complete electronic systems. The most common type of subsystem is the printed circuit board. Electromechanical components such as connectors are then used to link many boards into larger systems. The three classes of components direct the operation of electronic products. Within each main category, there are subdivisions, often classified by the technology and/or materials used or the circuit function performed. Active Electronic Components Active components in can be divided into two fundamental groups: •

Semiconductor or solid-state devices

Display devices

Insulation could apply to semi-conductor technology, but more at the macro-level (i.e. PCB), as opposed to coating a micro-chip or transistor. Passive and Interconnecting Electronic Components Products include capacitors, resistors, microprocessors, bare and loaded printed circuit boards, electron tubes, electronic connectors, and computer modems. Related industries include electron tube manufacturing, printed circuit boards, electronic capacitors, electronic resistors, light-emitting diodes, parametric diodes, integrated circuits, transistors, and many other electronic components. More data on specific types of capacitors, resistors, etc. can be obtained if further pursuit of this topic is of interest. Interconnecting Components

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation These include printed circuits, connectors, relays, and switches that connect other components. AP used as a conformal coating may be useful for these components. Conformal Coatings Conformal coatings are coatings that conform to the shape of the substrate, in this case, electronic parts. They protect electronic circuitry from moisture, fungus, dust, chemicals, other contaminations, abrasion, and corrosion caused by extreme environments, preventing short circuits and corrosion of conductors and solder joints. Conformal coating materials fall into two broad categories: polymeric coatings and inorganic hard coatings. Polymeric coatings can be further divided into two broad process categories: liquid-deposited coatings and vapor-deposited coatings. The selection of a conformal coating material depends on the required properties of the coating material, the substrate to be coated, the specific function of the coating, and constraints regarding process type and costs. Electrical Power Generation and Distribution There are three main components to electrical power: generation, transmission, and distribution. This equipment can be found in terrestrial or marine environments, both offering different types of environmental abuse. Also, these components are not only part of national power grids, but also are present in large ships, factories, and other industries requiring significant infrastructure, such as offshore drilling rigs and mines. Generators are made up of two main components. The rotor is the rotating part that has wires, while the stator is the stationary part that surrounds the motor, both of which are enclosed in a housing. Generators in protected (e.g. indoor) locations may be candidates for AP. Those in outdoor locations that are subject to environmental abuse may be candidates for MS. The electricity is usually sent to a step-up transformer, essentially a couple of wires in an oil-based coolant enclosed in a housing, that increases the voltage of the current. Transformers experience high voltage and heat, and are often exposed to the elements. AP or MS, especially because of its resistance to oil, would be useful in this application. In the case of national electric grids and large infrastructure, the high-voltage current is transmitted through power lines that are encased in various layers of polymeric coatings and metal, and are either buried or suspended above ground. Although they do not experience high heat, they do experience high voltage and are exposed to the elements. AP or MS may be useful considering their high dielectric and coronal resistance. At this point, there is often another series of step-down transformers at a substation that decrease the voltage and send the current to the end-user. These transformers are similar to step-up transformers. Marine

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Worse than water is seawater, which is significantly more corrosive. Even if electrical components are not directly exposed to it, the salt does get into the air. Electronics and power equipment in offshore oil rigs and ships need protection from this. The electronics necessary for operating a ship are similar to airplanes. Marine power-generating and transmitting equipment can be subjected to high voltages and frequencies. Parts need to be durable and to minimize failure, maintenance and inspection. MS would be particularly advantageous considering its water resistance, especially for offshore power generation. Railgun The United States Navy is seeking to install this type of gun on one of its Zumwaltclass destroyers. Railguns use an incredible amount of electrical energy, produce a significant amount of heat and must be protected from the environment. Either of the insulators may be applicable to this technology. Catapults The U.S. Navy is also experimenting with electric catapults which, like rail guns, require a significant amount of electrical energy. Portable Electric-Powered Equipment A trip to the local Home Depot will demonstrate a wide range of portable equipment from generators to welding equipment to hand-held power tools, such as drills and saws. Although hand-held equipment does not experience high heat, it does experience exposure to the elements. In addition, welding equipment can experience high voltages and current, while portable generators have the same problems as non-portable ones. MS may be applicable to these technologies. Wearable Electronics The shrinking of electronics has led to the development of wearable electronic devices beyond that of wrist watches. These devices include heart-rate monitors, activity trackers, navigation tools, and drug pumps. This technology could expand into clothing embedded with electronics. Environmental protection is paramount, so MS would be advantageous. Robots/Autonomous Technology Most robots lead sheltered lives, but more of these devices are venturing out of the factory and into uncontrolled environments. They are used for space exploration, underwater experiments, military applications, agricultural uses, and human support. These devices will need to be protected from the environment. MS may be of use. Batteries Consumers demand batteries that are energy dense and fast charging. Fastcharging batteries use high currents that generate heat, which can lead to thermal breakdown. Insulators that can withstand high heat and high currents may be of use in extending battery life. Battery Charges

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Not only do batteries experience high current and heat, but also the chargers themselves. With the advent of electric cars and consumer demands for batteries that charge more quickly, charging devices that can withstand high current and the environmental exposure may become more necessary. MS and AP may be applicable to these devices. Capacitors Various types of passive components are used in electrical and electronic systems. Among them, capacitors constitute a major type used in large quantities. The types of capacitors used in a system are of types such as ceramic, electrolytic (aluminum and tantalum), metallized film, mica, glass, porcelain, etc. Capacitors are used in electric circuits for applications such as timing, filtering, dc blocking, decoupling, suppression of voltage transients, etc. Both surface mount device (SMD) and normal leaded type of capacitors are used. Based on studies carried out on failed capacitors of all types, it has been found that major causes of failure of capacitors are heat, high voltage, humidity, chemical contamination, and moisture. AP and MS may be applicable.

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Competitive Landscape The key players in the global market include •

3M (U.S.),

DuPont (U.S.),

Elantas Electrical Insulation (Germany),

Haysite Reinforced Plastics (U.S.),

ITW Formex (U.S.),

Krempel GmbH (Germany),

Nitto Denko Corporation (Japan),

Tesa Se (Germany),

Teijin DuPont Films Japan (Japan),

Suzhou Jufeng (China),

Suzhou Taihu (China),

Vitar Insulation Manufacturer (Hong Kong), and

Zhenjiang Rongtai (China).

Key polyimide products and their respective producers include: •

Aurum olyimide: Mitsui Chemical (Japan), distributed by both DuPont and Ticona (U.S.).

Extem PEI: Sabic IP (Saudi Arabia).

Kapton polyimide: DuPont.

Torlon PAI: Solvay (Belgian).

Ultem PEI: Sabic IP.

Vespel polyimide: DuPont.

References “Nanofiller Dispersion in Polymer Dielectric”; Daneil Tan, Yang Cao, Enis Tuncer, Patricia Irwin; Martials Sciences and Applications, 2013 6-15 “Mica/Epoxy-Composites in the Electrical Industry”; Natascha Andraschek, Andrea Johanna Wanner, Catharina Ebner, Gisbert Riess; Polymers 2016, 8, 201

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Awards for Applications We will conduct a global review of your opportunity report using a team of experts who will examine the technology, potential products, markets, future customers, existing landscape and overall commercialization potential. We will select the best proposed solutions gathered during the circulation period of this RFA. We will pay any awards in installments, as per your written and executed contract with us. Note the contract for RFAâ&#x20AC;&#x2122;s is different than the contract for RFIâ&#x20AC;&#x2122;s. Please see your Xinova representative for contract details.

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Notices Please contact: Xinova, LLC 701 Fifth Avenue, Suite 4100 Seattle, WA 98104 USA Xinova Asia Pte. Ltd. 150 Beach Road, # 08-06/08, Gateway West Singapore 189720 Copyright 2017. All rights reserved. Any distribution of this document is strictly prohibited. This document is the proprietary and confidential information of Xinova and any affiliate thereof. Inquiries: Doug Loy dloy@xinova.com

RFAtemplate version: 1.00

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REQUEST FOR APPLICATION

RFA-170121

Electrical Insulation Instructions for Submission Please read carefully before submitting Opportunity Reports 1. All opportunities must use the Opportunity Report form. This is different than Xinovaâ&#x20AC;&#x2122;s Solution Report form. Submissions to this RFA that do not use the Opportunity Report form will be rejected. 2. Terms and conditions of this RFA apply to anyone submitting proposed opportunities. 3. We accept only original, new and novel proposed opportunities. Proposed Opportunity Reports not satisfying these requirements will not be considered. 4. Please direct any questions you may have to your local Xinova office. Suggestions to refine, broaden or to include new information are welcome. Any suggestions you provide are given entirely voluntarily and shall not create any confidentiality obligation for us. We may use the suggestions without obligation or restriction of any kind. 5. You may submit one or more Opportunity Report during the circulation period of this RFA. Please see the first page for the circulation period. We will not accept any proposed Opportunity Reports after the RFA Closing Date. 6. Please contact your local Xinova office for the Opportunity Report form, or download following this link: (Opportunity Report Link). Please fill out the form accurately and completely. Incomplete forms may be returned to you for further action and may not be considered for acceptance. 7. Each proposed solution should be embodied in one Opportunity Report form. Do not include multiple proposed opportunities in one form. 8. We reserve the right to cancel or terminate this RFA at any time. 9. We may share information on select proposed opportunities and/or provide feedback to some or all of the inventors who submitted Opportunity Reports in response to this RFA. All information shared and/or feedback provided is our confidential information. 10.We will not retain any rights or obligations with respect to declined proposed Opportunity Reports.

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Opportunity Report â&#x20AC;&#x201C; Detailed Application Description TITLE OF PROPOSED APPLICATION 35T

I.

Executive Summary of Application

High level treatment of the entire business case, this introduces the opportunity and summarizes all the factors. Describe the proposed application and technical details making this application valuable and useful for companies and industries (i.e. technically feasible, commercially desirable, economically viable).

II.

Addressable Market Opportunity

Provide a full explanation of the application of the technology to a new market opportunity, specifically addressing the match of key features and benefits with market needs that are not addressed by existing commercial products or emerging technologies. -

Why is this a valuable opportunity that is addressed by the new technology?

-

What are the key shortcomings of existing technology solutions?

-

How will the new technology deliver value (eg revenue, cost savings, reduce working capital, etc).?

Beyond a vague measure of the overall market, provide a financial appraisal of costs of commercialization compared to expected revenue opportunities (or other value creation).

III.

Competitive Advantage

Outline the feasibility of the competitive advantage provided by the new technology to the new market application.

IV.

Scale

Describe a likely go to market strategy and explain how this scales over time.

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Opportunity Report â&#x20AC;&#x201C; Detailed Application Description

V.

Value Chain & Stakeholders

Outline the entire value chain necessary to exploit the new market opportunity. Where possible provide specific industry partners that would strengthen commercialization strategy, and indicate where specific contacts are personally known. Map key stakeholders for the business case, and where possible solicit feedback for this proposal.

VI.

Risks

Identify key commercialization risks and potential hurdles (for example regulatory) at both the microeconomic and macroeconomic scales and strategies for mitigation.

VII.

Resources

Outline key resources needed for the go to market strategy.

VIII. Background Information Provide background information (market reports, news, industry analysis, etc) in support of the business case.

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Electrical Insulation  
Electrical Insulation