Thermoplastic applications for pulse power alternators

The field coil is the primary component of the rotor assembly that provides the rotating magnetic field for the pulse power alternator. The design of the field coil is optimized so that it will produce the required magnetic field with minimum transient losses. The high currents required to produce the correct amp-turns, along with the mechanical loads due to high rotational speeds, present further design requirements for selection of field coil material, insulation, and surrounding material that completes the matrix of the field coil sub-assembly. With the addition of active cooling requirements in the field coil design, surrounding materials must be selected that retain electrically insulative properties and are thermally conductive to allow sufficient heat removal from the field coil. Thermoplastics are now being reviewed to replace traditional glass-epoxy potting compounds (thermosets) that have been used extensively in pulsed alternator designs. Fillers can be added to tailor properties of the thermoplastic, such as ceramics to increase thermal conductivity at the cost of an increase in density. Thermal analyses have been performed that show the benefits of using thermally conductive potting compounds. In addition, subscale field coil mockups (motorettes) have been encapsulated and tested to demonstrate encapsulation of current field coil geometries