1. A polymer polyol comprising:
a castor oil-based polyol derived from polymerization by esterification of castor oil and a fatty acid comprising at least one hydroxyl group, the castor oil-based polyol having a molecular weight greater than 900 Da and a hydroxyl value below 130 mg KOHg; and
a hydrocarbon polyol selected from a compound having a two carbon to six carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups or a polymer consisting of from 1 to 100 monomeric units and at least two hydroxyl groups, where the monomeric unit is a two carbon to six carbon straight or branched chain hydrocarbon.
2. The polymer polyol of claim 1, wherein the castor oil-based polyol has a molecular weight selected from the group consisting of 900 to about 4000 Da, about 1300 to about 3500 Da, about 1700 to about 3000 Da, and about 2600 to about 3000 Da.
3. The polymer polyol of claim 1, wherein the hydroxyl value of the castor oil-based polyol is selected from the group consisting of about 25 to about 125 mg KOHg, about 30 to about 110 mg KOHg, about 40 to about 100 mg KOHg, about 50 to about 90 mg KOHg, about 50 to about 80 mg KOHg, about 60 to about 80 mg KOHg, about 52 mg KOHg, about 78 mg KOHg, and about 109 mg KOHg.
4. The polymer polyol of claim 1, wherein the hydrocarbon polyol is a four carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups.
5. The polymer polyol of claim 1, wherein the hydrocarbon polyol is a polybutadiene-based polyol.
6. The polymer polyol of claim 1, wherein the castor oil-based polyol has a viscosity of equal to or greater than about 400 cP at 25\xb0 C.
7. The polymer polyol of claim 1, wherein the castor oil-based polyol and the hydrocarbon polyol have relative concentrations selected from the group consisting of about 1% castor oil-based polyol to about 99% hydrocarbon polyol, about 5% castor oil-based polyol to about 95% hydrocarbon polyol, about 10% castor oil-based polyol to about 90% hydrocarbon polyol, about 15% castor oil-based polyol to about 85% hydrocarbon polyol, about 20% castor oil-based polyol to about 80% hydrocarbon polyol, about 25% castor oil-based polyol to about 75% hydrocarbon polyol, about 30% castor oil-based polyol to about 70% hydrocarbon polyol, about 40% castor oil-based polyol to about 60% hydrocarbon polyol, about 50% castor oil-based polyol to about 50% hydrocarbon polyol, about 60% castor oil-based polyol to about 40% hydrocarbon polyol, about 70% castor oil-based polyol to about 30% hydrocarbon polyol, about 80% castor oil-based polyol to about 20% hydrocarbon polyol, about 90% castor oil-based polyol to about 10% hydrocarbon polyol, about 95% castor oil-based polyol to about 5% hydrocarbon polyol, and about 99% castor oil-based polyol to about 1% hydrocarbon polyol.
8. A method of producing the polymer polyol of claim 1, the method comprising the steps of:
heating a mixture comprising a castor oil, a fatty acid, and an esterification catalyst;
reacting the mixture to produce a castor oil-based polyol having a molecular weight greater than 900 Da and a hydroxyl value below 130; and
combining the castor oil-based polyol with a hydrocarbon polyol selected from a compound having a two carbon to six carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups or a polymer consisting of from 1 to 100 monomeric units and at least two hydroxyl groups, where the monomeric unit is a two carbon to six carbon straight or branched chain hydrocarbon to produce a polymer polyol.
9. The method of claim 8, wherein the step of heating the mixture is conducted at about 180\xb0 C. or above.
10. The method of claim 8, wherein the fatty acid has at least one hydroxyl group.
11. The method of claim 8, wherein the castor oil-based polyol has a molecular weight selected from the group consisting of above 900 to about 4000 Da, about 1300 to about 3500 Da, about 1700 to about 3000, and about 2600 to about 3000.
12. The method of claim 8, wherein the hydroxyl value of the castor oil-based polyol is selected from the group consisting of about 25 to about 125, about 30 to about 110, about 40 to about 100, about 50 to about 90, about 50 to about 80, about 60 to about 80, about 52, about 78, and about 109 mg KOHg.
13. The method of claim 8, wherein the hydrocarbon polyol is a four carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups.
14. The method of claim 8, wherein the hydrocarbon polyol is a polybutadiene-based polyol.
15. The method of claim 8, wherein the castor oil-based polyol has a viscosity of equal to or greater than about 400 cP at 25\xb0 C.
16. The method of claim 8, wherein the castor oil-based polyol and the hydrocarbon polyol have relative concentrations selected from the group consisting of about 1% castor oil-based polyol to about 99% hydrocarbon polyol, about 5% castor oil-based polyol to about 95% hydrocarbon polyol, about 10% castor oil-based polyol to about 90% hydrocarbon polyol, about 15% castor oil-based polyol to about 85% hydrocarbon polyol, about 20% castor oil-based polyol to about 80% hydrocarbon polyol, about 25% castor oil-based polyol to about 75% hydrocarbon polyol, about 30% castor oil-based polyol to about 70% hydrocarbon polyol, about 40% castor oil-based polyol to about 60% hydrocarbon polyol, about 50% castor oil-based polyol to about 50% hydrocarbon polyol, about 60% castor oil-based polyol to about 40% hydrocarbon polyol, about 70% castor oil-based polyol to about 30% hydrocarbon polyol, about 80% castor oil-based polyol to about 20% hydrocarbon polyol, about 90% castor oil-based polyol to about 10% hydrocarbon polyol, about 95% castor oil-based polyol to about 5% hydrocarbon polyol, and about 99% castor oil-based polyol to about 1% hydrocarbon polyol.
17. A polyurethane comprising the reaction product of:
an isocyanate; and
the polymer polyol of claim 1.
18. The polyurethane of claim 17, wherein the polyurethane is capable of maintaining at least about 70% of an initial hardness when exposed to at least about 100\xb0 C. and at least about 95% relative humidity for at least 28 days.
19. The polyurethane of claim 17, wherein the polyurethane is capable of maintaining at least about 40% of an initial hardness when exposed to at least about 100\xb0 C. and at least about 95% relative humidity for at least 28 days.
20. The polyurethane of claim 17, wherein the polyurethane has a hardness level less than or equal to about 50 Shore A.
21. The polyurethane of claim 17, wherein the tensile strength of the polyurethane is selected from the group consisting of about 90 to about 300 psi, about 100 to about 250 psi, about 110 to about 220 psi, about 117 to about 211 psi, and about 153 to about 181 psi.
22. The polyurethane of claim 17, wherein the elongation property of the polyurethane is selected from the group consisting of between about 55 to about 90%, about 60 to about 89%, about 67% to about 83%, and about 67 to about 77%.
23. The polyurethane of claim 17, wherein the modulus of the polyurethane is selected from the group consisting of about 200 to about 370 psi, about 210 to about 358 psi, about 250 to about 340 psi, and about 290 to about 310 psi.
24. The polyurethane of claim 17, wherein the isocyanate is selected from the group consisting of diphenylmethane diisocyanate (MDI), modified MDI, polymeric MDI, toluene diisocyanate, hexamethylene diisocyanate, methylene bis(cyclohexyl isocyanate) and isophorone diisocyanate.
25. The polyurethane of claim 17, wherein the castor oil-based polyol has a molecular weight selected from the group consisting of above 900 to about 4000 Da, about 1300 to about 3500 Da, about 1700 to about 3000, and about 2600 to about 3000 Da.
26. The polyurethane of claim 17, wherein the hydroxyl value of the castor oil-based polyol is selected from the group consisting of about 25 to about 125, about 30 to about 110, about 40 to about 100, about 50 to about 90, about 50 to about 80, about 60 to about 80, about 52, about 78, and about 109 mg KOHg.
27. The polyurethane of claim 17, wherein the hydrocarbon polyol is a four carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups.
28. The polyurethane of claim 17, wherein the hydrocarbon polyol is a polybutadiene-based polyol.
29. The polyurethane of claim 17, wherein the castor oil-based polyol and the hydrocarbon polyol have relative concentrations selected from the group consisting of about 1% castor oil-based polyol to about 99% hydrocarbon polyol, about 5% castor oil-based polyol to about 95% hydrocarbon polyol, about 10% castor oil-based polyol to about 90% hydrocarbon polyol, about 15% castor oil-based polyol to about 85% hydrocarbon polyol, about 20% castor oil-based polyol to about 80% hydrocarbon polyol, about 25% castor oil-based polyol to about 75% hydrocarbon polyol, about 30% castor oil-based polyol to about 70% hydrocarbon polyol, about 40% castor oil-based polyol to about 60% hydrocarbon polyol, about 50% castor oil-based polyol to about 50% hydrocarbon polyol, about 60% castor oil-based polyol to about 40% hydrocarbon polyol, about 70% castor oil-based polyol to about 30% hydrocarbon polyol, about 80% castor oil-based polyol to about 20% hydrocarbon polyol, about 90% castor oil-based polyol to about 10% hydrocarbon polyol, about 95% castor oil-based polyol to about 5% hydrocarbon polyol, and about 99% castor oil-based polyol to about 1% hydrocarbon polyol.
30. A method of producing a polyurethane, the method comprising the steps of:
forming the polymer polyol of claim 1; and
curing the polymer polyol with isocyanate to produce a polyurethane.
31. The method of claim 30, wherein the polyurethane is capable of maintaining at least about 70% of an initial hardness when exposed to at least about 100\xb0 C. and at least about 95% relative humidity for at least 28 days.
32. The method of claim 30, wherein the polyurethane is capable of maintaining at least about 40% of an initial hardness when exposed to at least about 100\xb0 C. and at least about 95% relative humidity for at least 28 days.
33. The method of claim 30, wherein the polyurethane has a hardness level less than or equal to about 50 Shore A.
34. The method of claim 30, wherein the tensile strength of the polyurethane is selected from the group consisting of about 90 to about 300 psi, about 100 to about 250 psi, about 110 to about 220 psi, about 117 to about 211 psi, and about 153 to about 181 psi.
35. The method of claim 30, wherein the elongation property of the polyurethane is selected from the group consisting of between about 55 to about 90%, about 60 to about 89%, about 67% to about 83%, and about 67 to about 77%.
36. The method of claim 30, wherein the modulus of the polyurethane is selected from the group consisting of about 200 to about 370 psi, about 210 to about 358 psi, about 250 to about 340 psi, and about 290 to about 310 psi.
37. The method of claim 30, wherein the isocyanate is selected from the group consisting of diphenylmethane diisocyanate (MDI), modified MDI, polymeric MDI, toluene diisocyanate, hexamethylene diisocyanate, methylene bis(cyclohexyl isocyanate) and isophorone diisocyanate.
38. The method of claim 30, wherein the castor oil-based polyol has a molecular weight selected from the group consisting of above 900 to about 4000 Da, about 1300 to about 3500 Da, about 1700 to about 3000, and about 2600 to about 3000 Da.
39. The method of claim 30, wherein the hydroxyl value of the castor oil-based polyol is selected from the group consisting of about 25 to about 125, about 30 to about 110, about 40 to about 100, about 50 to about 90, about 50 to about 80, about 60 to about 80, about 52, about 78, and about 109 mg KOHg.
40. The method of claim 30, wherein the hydrocarbon polyol is a four carbon straight or branched chain aliphatic hydrocarbon with at least two hydroxyl groups.
41. The method of claim 30, wherein the hydrocarbon polyol is a polybutadiene-based polyol.
42. The method of claim 30, wherein the castor oil-based polyol and the hydrocarbon polyol have relative concentrations selected from the group consisting of about 1% castor oil-based polyol to about 99% hydrocarbon polyol, about 5% castor oil-based polyol to about 95% hydrocarbon polyol, about 10% castor oil-based polyol to about 90% hydrocarbon polyol, about 15% castor oil-based polyol to about 85% hydrocarbon polyol, about 20% castor oil-based polyol to about 80% hydrocarbon polyol, about 25% castor oil-based polyol to about 75% hydrocarbon polyol, about 30% castor oil-based polyol to about 70% hydrocarbon polyol, about 40% castor oil-based polyol to about 60% hydrocarbon polyol, about 50% castor oil-based polyol to about 50% hydrocarbon polyol, about 60% castor oil-based polyol to about 40% hydrocarbon polyol, about 70% castor oil-based polyol to about 30% hydrocarbon polyol, about 80% castor oil-based polyol to about 20% hydrocarbon polyol, about 90% castor oil-based polyol to about 10% hydrocarbon polyol, about 95% castor oil-based polyol to about 5% hydrocarbon polyol, and about 99% castor oil-based polyol to about 1% hydrocarbon polyol.
43. The polymer polyol of claim 1, wherein the castor oil-based polyol has a molecular weight of about 1300 to about 3500 Da and a hydroxyl value of about 25 to about 125 mg KOHg.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
What is claimed is:
1. Apparatus for detecting whether wire leads were properly terminated to tang terminals of dynamo-electric machine components, comprising:
a wire gripper configured to (a) hold an excess portion of a first wire lead that extends from a first tang terminal of a dynamo-electric machine component to a first side of the wire gripper and (b) move away from the first tang terminal to tear the excess portion of the first wire lead; and
a detecting unit configured to detect whether the excess portion of the first wire lead is extending from the first side of the wire gripper after the excess portion of the first wire lead was torn.
2. The apparatus defined in claim 1 wherein the detecting unit comprises a single sensor and wherein the detecting unit is configured to move the single sensor to scan a predetermined area about the first side of the wire gripper in order to detect whether the excess portion of the first wire lead is extending from the first side of the wire gripper.
3. The apparatus defined in claim 1 wherein the detecting unit comprises a single sensor selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor.
4. The apparatus defined in claim 1 wherein the first wire lead is an initial wire lead, wherein the wire gripper is further configured to (a) hold an excess portion of a final wire lead that extends from a second tang terminal of the dynamo-electric machine component to a second side of the wire gripper and (b) move away from the second tang terminal to tear the excess portion of the final wire lead, and wherein the detecting unit is further configured to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper after the excess portion of the final wire lead was torn.
5. The apparatus defined in claim 4 wherein the detecting unit comprises a first sensor and a second sensor, wherein the first sensor detects whether the excess portion of the initial wire lead is extending from the first side of the wire gripper after the excess portion of the initial wire lead was torn and wherein the second sensor detects whether the excess portion of the final wire lead is extending from the second side of the wire gripper after the excess portion of the final wire lead was torn.
6. The apparatus defined in claim 5 wherein the first and second sensors are stationary with respect to the wire gripper, wherein the first sensor is positioned to detect within a first area where the initial wire lead is expected to be after a successful wire termination of the initial wire lead, and wherein the second sensor is positioned to detect within a second area where the final wire lead is expected to be after a successful wire termination of the final wire lead.
7. The apparatus defined in claim 5 wherein the detecting unit moves the first and second sensors to scan respective predetermined areas about the first and second sides of the wire gripper in order to detect whether the excess portions of the initial and final wire leads are extending from the respective first and second sides of the wire gripper.
8. The apparatus defined in claim 5 wherein the first and second sensors are selected from the group consisting of beam sensors, vision sensors, and tactile sensors.
9. The apparatus defined in claim 4 wherein the detecting unit comprises a single sensor, wherein the single sensor is moved to a first position to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper, and wherein the single sensor is moved to a second position to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
10. The apparatus defined in claim 9 wherein the single sensor is selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor.
11. The apparatus defined in claim 4 wherein the detecting unit comprises a single sensor, wherein the single sensor is moved to scan a first area about the first side of the wire gripper to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper, and wherein the single sensor is moved to scan a second area about the second side of the wire gripper to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
12. The apparatus defined in claim 11 wherein the single sensor is selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor.
13. The apparatus defined in claim 4 wherein the first and second tang terminals are the same tang terminal.
14. A method for detecting whether wire leads were properly terminated to tang terminals of dynamo-electric machine components, comprising:
tearing an excess portion of a first wire lead by stretching the excess portion of the first wire lead between a first side of a wire gripper and a first tang terminal; and
detecting whether the excess portion of the first wire lead is extending from the first side of the wire gripper after the excess portion of the first wire lead was torn.
15. The method defined in claim 14 wherein a single sensor is used to detect whether the excess portion of the first wire lead is extending form the first side of the wire gripper, the method further comprising moving the single sensor to scan a predetermined area about the first side of the wire gripper in order to detect whether the excess portion of the first wire lead is extending from the first side of the wire gripper.
16. The method defined in claim 14 wherein a single sensor selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor is used to detect whether the excess portion of the first wire lead is extending from the first side of the wire gripper.
17. The method defined in claim 14 wherein the first wire lead is an initial wire lead, the method further comprising:
tearing an excess portion of a final wire lead by stretching the excess portion of the final wire lead between a second side of the wire gripper and a second tang terminal; and
detecting whether the excess portion of the final wire lead is extending from the second side of the wire gripper after the excess portion of the second wire lead was torn.
18. The method defined in claim 17 wherein a first sensor is used to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper and wherein a second sensor is used to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
19. The method defined in claim 18 wherein the first and second sensors are stationary with respect to the wire gripper, wherein the first sensor is positioned to detect within a first area where the initial wire lead is expected to be after a successful wire termination of the initial wire lead, and wherein the second sensor is positioned to detect within a second area where the final wire lead is expected to be after a successful wire termination of the final wire lead.
20. The method defined in claim 18 further comprising:
moving the first sensor to scan a first predetermined area about the first side of the wire gripper in order to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper; and
moving the second sensor to scan a second predetermined area about the second side of the wire gripper in order to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
21. The method defined in claim 18 wherein the first and second sensors are selected from the group consisting of beam sensors, vision sensors, and tactile sensors.
22. The method defined in claim 17 further comprising:
moving a single sensor to a first position to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper; and
moving the single sensor to a second position to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
23. The method defined in claim 22 wherein the single sensor is selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor.
24. The method defined in claim 17 further comprising:
moving a single sensor to scan a first area about the first side of the wire gripper to detect whether the excess portion of the initial wire lead is extending from the first side of the wire gripper; and
moving the single sensor to scan a second area about the second side of the wire gripper to detect whether the excess portion of the final wire lead is extending from the second side of the wire gripper.
25. The method defined in claim 24 wherein the single sensor is selected from the group consisting of a beam sensor, a vision sensor, and a tactile sensor.
26. The method defined in claim 17 wherein the first and second tang terminals are the same tang terminal.
27. Apparatus for terminating thin wire leads to tang terminals of dynamo-electric machine components, comprising:
a wire gripper configured to hold an excess portion of a thin wire lead that extends from a tang terminal, wherein the thin wire lead is attached to the tang terminal; and
a plunger device configured to (a) contact the excess portion of the thin wire lead at a location between the wire gripper and the tang terminal and (b) move the excess portion of the thin wire lead to tear the excess portion of the thin wire lead at the tang terminal.
28. The apparatus defined in claim 27 wherein the excess portion undergoes tension when the plunger device moves the excess portion.
29. The apparatus defined in claim 27 wherein the plunger device comprises a plunger head configured to capture the excess portion of the thin wire lead.
30. The apparatus defined in claim 29 wherein the plunger device further comprises an air cylinder, wherein a portion of the plunger head (a) is positioned within the air cylinder and (b) is configured to operate as a piston, and wherein by applying pressurized gas within the air cylinder, the plunger head can be extended and retracted within the air cylinder in directions substantially parallel to the longitudinal axis of the air cylinder.
31. The apparatus defined in claim 27 wherein the plunger device is adjustable to contact the excess portion of the thin wire lead at a desired location.
32. The apparatus defined in claim 27 wherein the plunger device is configured to move the excess portion of the thin wire lead in a desired direction.
33. The apparatus defined in claim 27 wherein when the excess portion of the thin wire lead is moved by the plunger device, the portion of the excess portion of the thin wire lead that interacts with the tang terminal is torn by moving along an edge of the tang terminal.
34. The apparatus defined in claim 33 wherein the portion of the excess portion that interacts with the tang terminal is torn by moving along an edge of the tang terminal towards the bottom portion of the tang terminal.
35. The apparatus defined in claim 33 wherein the portion of the excess portion that interacts with the tang terminal is torn at a bottom edge of the tang terminal.
36. A method for terminating thin wire leads to tang terminals of dynamo-electric machine components, comprising:
gripping an excess portion of a thin wire lead that extends from a tang terminal, wherein the thin wire lead is attached to the tang terminal; and
moving the excess portion of the thin wire lead at a location between the wire gripper and the tang terminal to tear the excess portion of the thin wire lead at the tang terminal.
37. The method defined in claim 36 wherein the excess portion undergoes tension when the excess portion is moved.
38. The method defined in claim 36 wherein the excess portion of the thin wire lead is moved with a plunger device.
39. The method defined in claim 36 further comprising applying pressurized air to an air cylinder to move a plunger head, wherein the plunger head contacts and moves the excess portion of the thin wire lead at the location between the wire gripper and the tang terminal to tear the excess portion of the thin wire lead at the tang terminal.
40. The method defined in claim 36 further comprising adjusting the plunger device to contact the excess portion of the thin wire lead at a desired location.
41. The method defined in claim 36 further comprising moving the excess portion of the thin wire lead in a desired direction.
42. The method defined in claim 36 wherein moving the excess portion of the thin wire lead at the location between the wire gripper and the tang terminal causes a portion of the excess portion of the thin wire lead that interacts with the tang terminal to tear by moving along an edge of the tang terminal.
43. The method defined in claim 42 wherein the portion of the excess portion moves along the edge of the tang terminal towards the bottom portion of the tang terminal.
44. The method defined in claim 42 wherein the portion of the excess portion that interacts with the tang terminal is torn at a bottom edge of the tang terminal.