CN102812524A - 发泡电线及其制造方法 - Google Patents
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Abstract
本发明的目的在于提供绝缘破坏电压良好的发泡电线及其制造方法。本发明的发泡电线中,发泡绝缘层2由具有耐热性的热塑性树脂形成、且平均气泡径为5μm以下。发泡绝缘层2的有效相对介电常数可以为2.5以下,发泡绝缘层2优选由聚苯硫醚、聚萘二甲酸乙二醇酯、聚对苯二甲酸乙二醇酯、聚醚醚酮和热塑性聚酰亚胺的任意一种形成,更优选由结晶性热塑性树脂形成。进一步地,可以在相对于发泡绝缘层2为外侧处具有未发泡的外侧皮层、或在相对于发泡绝缘层2为内侧处具有未发泡的内侧皮层、或者可具有这两者。
Description
【技术领域】
本发明涉及发泡电线及其制造方法。
【背景技术】
逆变器(インバータ)作为有效的可变速控制装置已被安装于多种电气设备中。但是,其以数kHz~数十kHz进行切换,它们的每一次脉冲会产生冲击电压(サージ電圧)。这样的逆变器浪涌(インバータサージ)为如下现象:在传送体系内的阻抗不连续点、例如进行连接的配线的起始端或终止端等处产生反射,其结果最大施加逆变器输出功率电压的2倍的电压。特别是,由IGBT等高速开关装置所产生的输出功率脉冲的电压敏捷度(電圧俊度)高,从而即使连接电缆短,冲击电压也高,此外该连接电缆所产生的电压衰减也较小,其结果,产生逆变器输出功率电压的近2倍的电压。
在逆变器关联设备、例如高速开关装置、变频马达(インバータモーター)、变压器等电气设备线圈中,作为磁导线主要使用漆包线即绝缘线。因而,如上所述,逆变器关联设备由于要施加逆变器输出功率电压的近2倍的电压,因而绝缘线要求起因于变频浪涌的局部放电劣化为最小限。
一般来说,局部放电劣化为电气绝缘材料的局部放电所产生的荷电颗粒的碰撞所致的分子链断裂劣化、溅射劣化、局部温度上升所致的热熔融或热分解劣化、或放电产生的臭氧所致的化学劣化等复杂起因的现象。对于因实际的局部放电而劣化的电气绝缘材料发现了厚度的减少。
为了得到不会产生局部放电的绝缘线也即局部放电的起始电压高的绝缘线,以防止这样的局部放电所致的绝缘线的劣化,可考虑有使绝缘线绝缘层的厚度增厚、或在绝缘层中使用相对介电常数低的树脂的方法。
但是,若增厚绝缘层,则绝缘线变粗,其结果导致电气设备的大型化。该情况与近年来马达或变压器所代表的电气设备的小型化要求相悖。例如,具体地说,即使是说“根据在定子槽中放入多少根电线来确定马达等旋转机的性能”也并非言过其实,其结果,导体截面积相对于定子槽截面积的比例(占积率)在近年来变得非常高。从而,若绝缘层的厚度增厚,则占积率降低,因而不优选。
另一方面,对于绝缘层的相对介电常数来说,作为绝缘层材料通常使用的树脂大部分的相对介电常数为3~4之间,如此并没有相对介电常数特別低的材料。另外,在实际中,在考虑到绝缘层所要求的其它特性(耐热性、耐溶剂性、可挠性等)的情况下,不一定能够选择相对介电常数低的材料。
作为减小绝缘层的实质相对介电常数的手段,可考虑使绝缘层发泡,一直以来,将具有导体与发泡绝缘层的发泡电线作为通信电线广泛使用。以往熟知的例如有使聚乙烯等烯烃系树脂或氟树脂进行发泡而得到的发泡电线,作为这样的发泡电线,例如在专利文献1、2中记载了经发泡的聚乙烯绝缘电线,在专利文献3、4中记载了经发泡的氟树脂绝缘电线,在专利文献5中记载了这两者,在专利文献6中记载了经发泡的聚烯烃绝缘电线。
但是,这些现有的发泡电线中,发泡倍数越增大,则绝缘破坏电压越降低。
【现有技术文献】
【专利文献】
专利文献1:日本专利第2835472号公报
专利文献2:日本专利第3299552号公报
专利文献3:日本专利第3276665号公报
专利文献4:日本专利第3245209号公报
专利文献5:日本专利第3457543号公报
专利文献6:日本专利第3267228号公报
【发明内容】
【发明所要解决的课题】
本发明是为了解决上述课题而作出的,其课题在于提供一种发泡电线及其制造方法,该发泡电线即使增大发泡倍数,绝缘破坏电压也优异,发泡化所致的低介电常数特性使耐局部放电性也优异。
【解决课题的手段】
本发明的发泡电线具有导体与发泡绝缘层,其中,上述发泡绝缘层由作为结晶性热塑性树脂或非晶性热塑性树脂的热塑性树脂形成,该结晶性热塑性树脂的熔点或非晶性热塑性树脂的玻璃化转变点为150℃以上;且上述发泡绝缘层的平均气泡径为5μm以下。
此处,所谓“结晶性”指的是高分子为有规则排列的状态。另外,“非晶性”指的是高分子例如为线球状或缠结这样的无定形状态。
【发明的效果】
根据本发明的发泡电线,即使增大发泡倍数,绝缘破坏电压也优异,发泡化所致的低介电常数特性使耐局部放电性也优异。
具体地说,利用下述本发明的发泡电线,得到了不会降低绝缘破坏电压的效果,本发明发泡电线中,发泡绝缘层由作为结晶性热塑性树脂或非晶性热塑性树脂的热塑性树脂形成,该结晶性热塑性树脂的熔点或非晶性热塑性树脂的玻璃化转变点为150℃以上;且上述发泡绝缘层的平均气泡径为5μm以下。上述结晶性热塑性树脂的熔点或非晶性热塑性树脂的玻璃化转变点的上限值没有特别限制,但通常为400℃以下。上述发泡绝缘层的平均气泡径的下限值没有特别限制,但通常为0.01μm以上。
进一步地,通过利用有效相对介电常数为2.5以下、更优选为2.0以下的发泡绝缘层,或者通过使用相对介电常数为4.0以下、更优选为3.5以下的热塑性树脂,可得到局部放电起始电压的提高效果较大这样的效果,发泡绝缘层由结晶性热塑性树脂形成的本发明的发泡电线可得到耐溶剂性和耐化学药品性良好这样的效果。上述发泡绝缘层的有效相对介电常数的下限值没有特别限制,但通常为1.1以上。上述热塑性树脂的相对介电常数的下限值没有特别限制,但通常为2.0以上。
另外,通过在上述发泡绝缘层的外侧具有未发泡的外侧皮层、或在上述发泡绝缘层的内侧具有未发泡的内侧皮层、或者具有这两者,从而得到了可良好地保持耐磨耗性和拉伸强度等机械特性这样的效果。皮层可在发泡工序中生成。内侧皮层可通过在气体饱和前进行发泡来形成。这种情况下,也可在发泡绝缘层的厚度方向使气泡数呈梯度。另外,也可通过多层挤出包覆等方法来设置。这种情况下,可通过在内侧包覆不易发泡的树脂来形成内侧皮层。
利用本发明的发泡电线的制造方法可制造这些发泡电线。
可适宜参照所付的附图,由下述记载更为明确本发明的上述和其它特征及优点。
【附图说明】
图1中,图1(a)为示出本发明的发泡电线的一个实施方式的截面图,图1(b)为示出本发明的发泡电线的其它实施方式的截面图。
图2中,图2(a)为示出本发明发泡电线的另一实施方式的截面图,图2(b)为示出本发明发泡电线的另一实施方式的截面图,图2(c)为示出本发明的发泡电线的另一实施方式的截面图。
图3为示出实施例1~8和比较例1~6中的绝缘破坏电压相对于发泡电线的气泡径的图表。
【具体实施方式】
下面参照附图对本发明发泡电线的实施方式进行说明。
图1(a)中示出截面图的本发明发泡电线的一实施方式具有导体1与包覆导体1的发泡绝缘层2;图1(b)中示出截面图的本发明发泡电线的其它实施方式的导体的截面为矩形。图2(a)中示出截面图的本发明的发泡电线的另一实施方式在发泡绝缘层2的外侧具有外侧皮层4;在图2(b)中所示的本发明发泡电线的另一实施方式在发泡绝缘层2的内侧具有内侧皮层3;图2(c)中示出截面图的本发明发泡电线的另一实施方式在发泡绝缘层2的外侧具有外侧皮层4,且在发泡绝缘层2的内侧具有内侧皮层3。
导体1例如由铜、铜合金、铝、铝合金或它们的组合等来制作。导体1的截面形状并无限定,可适用圆形、矩形(扁平)等。
发泡绝缘层2中,平均气泡径为5μm以下、优选为1μm以下。若超过5μm,则绝缘破坏电压降低;通过设为5μm以下,则可良好地维持绝缘破坏电压。进一步地,通过设为1μm以下,可更为确实地保持绝缘破坏电压。平均气泡径的下限并无限制,但实际上为1nm以上,为优选的。发泡树脂层2的厚度并无限制,但实际上为30μm~200μm,为优选的。
另外,发泡绝缘层2优选为具有耐热性的热塑性树脂,例如可以使用聚苯硫醚(PPS)、聚对苯二甲酸乙二醇酯(PET)、聚萘二甲酸乙二醇酯(PEN)、聚对苯二甲酸丁二醇酯(PBT)、聚醚醚酮(PEEK)、聚碳酸酯(PC)、聚醚砜(PES)、聚醚酰亚胺(PEI)、热塑性聚酰亚胺(PI)等。本说明书中的“具有耐热性”是指结晶性热塑性树脂的熔点或非晶性热塑性树脂的玻璃化转变点为150℃以上。此处,熔点指的是利用差示扫描量热计(Differential Scanning Calorimetry:DSC)测定的值。另外,玻璃化转变点指的是利用差示扫描量热计(DSC)测定的值。进一步地,更优选结晶性热塑性树脂。例如为聚苯硫醚(PPS)、聚对苯二甲酸乙二醇酯(PET)、聚萘二甲酸乙二醇酯(PEN)、聚对苯二甲酸丁二醇酯(PBT)、聚醚醚酮(PEEK)等。
通过使用结晶性热塑性树脂,得到了耐溶剂性、耐化学药品性优异的发泡电线。进一步地,通过使用结晶性热塑性树脂,可使皮层变薄,使所得到的发泡电线的低介电特性良好。本说明书中,皮层是指未发泡的层。
另外,优选使用相对介电常数为4.0以下的热塑性树脂,该相对介电常数更优选为3.5以下。
其理由在于,在所得到的发泡电线中,为了得到局部放电起始电压的提高效果,发泡绝缘层的实效相对介电常数优选为2.5以下、进一步优选为2.0以下,这些发泡绝缘层通过使用上述相对介电常数的热塑性树脂而易于得到。
相对介电常数可使用市售的测定器进行测定。关于测定温度和测定频率,可根据需要进行变更,但在本说明书中,只要没有特别记载,以测定温度为25℃、测定频率为50Hz进行测定。
另外,所使用的热塑性树脂可以单独使用一种、也可以2种以上混合使用。
本发明中,在不会对特性造成影响的范围内,也可在获得发泡绝缘层的原料中掺合结晶成核剂、结晶化促进剂、气泡化成核剂、抗氧化剂、抗静电剂、紫外线防止剂、光稳定剂、荧光增白剂、颜料、染料、增容剂、润滑剂、增强剂、阻燃剂、交联剂、交联助剂、增塑剂、增稠剂、减粘剂和弹性体等各种添加剂。并且可在所得到的发泡电线中层积含有这些添加剂的树脂形成的层,也可涂布含有这些添加剂的涂料。
另外,优选在发泡绝缘层的外侧处具有未发泡的外侧皮层、或在发泡绝缘层的内侧具有未发泡的内侧皮层、或者具有这两者。其中,在该情况下,为了不妨碍使相对介电常数降低的效果,相对于内侧皮层的厚度、外侧皮层的厚度与发泡绝缘层的厚度的合计,内侧皮层的厚度与外侧皮层的厚度的合计优选为20%以下、更优选为10%以下。上述内侧皮层的厚度与外侧皮层的厚度的合计相对于内侧皮层的厚度与外侧皮层的厚度以及发泡绝缘层的厚度的合计的比例的下限值没有特别限制,但通常为1%以上。通过具有内侧皮层或外侧皮层,表面的平滑性良好,因而绝缘性良好。进一步地,可保持耐磨耗性和拉伸强度等机械强度。
发泡倍数优选为1.2倍以上、更优选为1.4倍以上。因而易于实现为得到局部放电起始电压的提高效果所必要的相对介电常数。发泡倍数的上限没有限制,但通常优选为5.0倍以下。
对于发泡倍数,通过水中置换法来测定为了发泡而包覆的树脂的密度(ρf)和发泡前的密度(ρs),由(ρs/ρf)计算出发泡倍数。
对于本发明的发泡电线,使热塑性树脂发泡的方法没有特别限定,可以在挤出成型时混入发泡剂、可通过填充氮气或二氧化碳等的发泡挤出进行包覆、或者可以在挤出成型为电线后通过填充气体来使其发泡。
对于在挤出成型为电线后通过填充气体来使其发泡的方法进行更具体的说明。本方法包括下述工序:使用挤出模头将树脂挤出包覆在导体的外周后,通过保持在加压惰性气体气氛中而使其含有惰性气体的工序;以及通过在常压下进行加热来发泡的工序。
这种情况下,若考虑大量生产性,则优选例如如下进行制造。即,成型为电线后,与间隔件(セパレータ)交错地进行重叠,卷绕在卷线轴上形成辊,将所得到的辊保持在加压惰性气体气氛中从而使之含有惰性气体,进一步在常压下加热至包覆材料的原料——热塑性树脂的软化温度以上,由此使其发泡。此时所使用的间隔件没有特别限定,可以使用透过气体的无纺布。由于尺寸为配合卷线轴的宽度,因而可根据需要适当进行调整。
另外,也可在使电线中含有惰性气体后,设于输送机中,在卷取机之间、在常压下使其通过加热至热塑性树脂的软化温度以上的热风炉中,从而进行连续发泡。
作为惰性气体,可以举出氦气、氮气、二氧化碳或氩气等。直至发泡呈饱和状态为止的惰性气体渗透时间和惰性气体渗透量根据进行发泡的热塑性树脂的种类、惰性气体的种类、渗透压力和发泡绝缘层的厚度的不同而不同。作为惰性气体,若考虑气体向热塑性树脂的渗透性——速度和溶解度,则更优选二氧化碳。
【实施例】
下面基于实施例更详细地说明本发明,但本发明并不限定于此。
本发明人进行了对于利用PEN树脂以平均气泡径为0.1μm~5μm的情况下(实施例1~8)、气泡径为7μm~31μm的情况下(比较例1~6)、未发泡的情况下(比较例7~8)的绝缘破坏电压、有效相对介电常数和局部放电起始电压(PDIV:Partial DischargeInception Voltage)进行比较的实验。
[实施例1]
在直径1mm的铜线的外侧以厚度100μm形成由PEN树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在-25℃于1.7MPa进行168小时的加压处理,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于100℃的热风循环式发泡炉1分钟以使之发泡,得到在图2(a)中示出了截面图的实施例1的发泡电线。对于所得到的实施例1的发泡电线,通过后述方法进行测定。结果示于表1-1中。
[实施例2]
在二氧化碳气氛下在0℃于3.6MPa进行240小时加压处理;投入到设定于120℃的热风循环式发泡炉中;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例2的发泡电线。对于所得到的实施例2的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例3]
在二氧化碳气氛下在-30℃于1.3MPa进行456小时加压处理;投入到设定于120℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例3的发泡电线。对所得到的实施例3的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例4]
在二氧化碳气氛下在0℃于3.6MPa进行240小时加压处理;投入到设定于100℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例4的发泡电线。对所得到的实施例4的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例5]
在二氧化碳气氛下在0℃于3.6MPa进行96小时加压处理;投入到设定于120℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例5的发泡电线。对所得到的实施例5的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例6]
在二氧化碳气氛下在0℃于3.6MPa进行96小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例6的发泡电线。对所得到的实施例6的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例7]
在二氧化碳气氛下在0℃于3.6MPa进行96小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例7的发泡电线。对所得到的实施例7的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[实施例8]
在二氧化碳气氛下在17℃于4.7MPa进行16小时加压处理;投入到设定于90℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到在图2(a)中示出了截面图的实施例8的发泡电线。对所得到的实施例8的发泡电线进行与实施例1相同的测定。结果示于表1-1中。
[比较例1]
在二氧化碳气氛下在17℃于5.0MPa进行16小时加压处理;投入到设定于100℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例1的发泡电线。对所得到的比较例1的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例2]
在二氧化碳气氛下在17℃于4.7MPa进行16小时加压处理;投入到设定于120℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例2的发泡电线。对所得到的比较例2的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例3]
在二氧化碳气氛下在17℃于5.0MPa进行24小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例3的发泡电线。对所得到的比较例3的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例4]
在二氧化碳气氛下在17℃于4.8MPa进行3小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例4的发泡电线。对所得到的比较例4的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例5]
在二氧化碳气氛下在50℃于4.9MPa进行7小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例5的发泡电线。对所得到的比较例5的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例6]
在二氧化碳气氛下在50℃于4.9MPa进行3小时加压处理;投入到设定于140℃的热风循环式发泡炉中1分钟;除此以外,与实施例1同样地得到比较例6的发泡电线。对所得到的比较例6的发泡电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例7]
在直径1mm的铜线的外侧以厚度100μm形成由PEN树脂构成的挤出包覆层,得到比较例7的电线。对所得到的比较例7的电线进行与实施例1相同的测定。结果示于表1-2中。
[比较例8]
在直径1mm的铜线的外侧以厚度0.14μm形成由PEN树脂构成的挤出包覆层,得到比较例8的电线。对所得到的比较例8的电线进行与实施例1相同的测定。结果示于表1-2中。
[实施例9]
在直径1mm的铜线的外侧以厚度30μm形成由PPS树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在-32℃于1.2MPa进行24小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于200℃的热风循环式发泡炉中1分钟以使其发泡,得到在图2(c)中示出了截面图的实施例9的发泡电线。需要说明的是,所使用的PPS树脂中含有适度的弹性体成分及添加剂。对于所得到的实施例9的发泡电线,按后述方法进行测定。结果列于表2。
[实施例10]
在直径0.4mm的铜线的外侧以厚度40μm形成由PPS树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在-32℃于1.2MPa进行55小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于200℃的热风循环式发泡炉中1分钟以使其发泡,之后包覆表1-1中所示厚度的外侧皮层,得到在图2(c)中示出了截面图的实施例10的发泡电线。需要说明的是,所使用的PPS树脂中含有适度的弹性体成分及添加剂。对于所得到的实施例10的发泡电线,按后述方法进行测定。结果列于表2。
[实施例11]
在直径0.4mm的铜线的外侧以厚度40μm形成由PPS树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在17℃于4.9MPa进行55小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于120℃的热风循环式发泡炉中1分钟以使其发泡,得到在图2(c)中示出了截面图的实施例11的发泡电线。需要说明的是,所用的PPS树脂中含有适度的弹性体成分及添加剂。对于所得到的实施例11的发泡电线,按后述方法进行测定。结果列于表2。
[比较例9]
在直径1mm的铜线的外侧以厚度40μm形成由PPS树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在35℃于5.4MPa进行24小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于220℃的热风循环式发泡炉中1分钟以使其发泡,得到比较例9的发泡电线。需要说明的是,所用的PPS树脂中含有适度的弹性体成分及添加剂。对于所得到的比较例9的发泡电线,按后述方法进行测定。结果列于表2。
[比较例10]
在直径1mm的铜线的外侧以厚度30μm形成由PPS树脂构成的挤出包覆层,得到比较例10的电线。需要说明的是,所用的PPS树脂中含有适度的弹性体成分及添加剂。对所得到的比较例10的电线进行与实施例1相同的测定。结果列于表2。
[比较例11]
在直径0.4mm的铜线的外侧以厚度40μm形成由PPS树脂构成的挤出包覆层,得到比较例11的电线。需要说明的是,所用的PPS树脂中含有适度的弹性体成分及添加剂。所得到的比较例11的电线进行与实施例1相同的测定。结果列于表2。
[实施例12]
在直径0.5mm的铜线的外侧以厚度32μm形成由PET树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在-30℃于1.7MPa进行42小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于200℃的热风循环式发泡炉中1分钟以使其发泡,得到在图2(a)中示出了截面图的实施例12的发泡电线。需要说明的是,所用的PET树脂中含有适度的弹性体成分。对于所得到的实施例12的发泡电线,按后述方法进行测定。结果列于表3。
[比较例12]
在直径0.5mm的铜线的外侧以厚度32μm形成由PET树脂构成的挤出包覆层,装入到压力容器中,在二氧化碳气氛下在17℃于5.0MPa进行42小时加压,由此使二氧化碳渗透直至饱和为止。接下来,从压力容器中取出,投入到设定于200℃的热风循环式发泡炉中1分钟以使其发泡,得到比较例12的发泡电线。需要说明的是,所用的PET树脂中含有适度的弹性体成分。对于所得到的比较例12的发泡电线,按后述方法进行测定。结果列于表3。
[比较例13]
在直径0.5mm的铜线的外侧以厚度32μm形成由PET树脂构成的挤出包覆层,得到比较例13的电线。需要说明的是,所用的PET树脂中含有适度的弹性体。对于所得到的比较例13的电线进行与实施例1相同的测定。结果列于表3。
评价方法如下。
[发泡绝缘层的厚度和平均气泡径]
发泡绝缘层的厚度和平均气泡径通过利用扫描电子显微镜(SEM)观察发泡电线的截面来求出。对平均气泡径进行更具体的说明。从利用SEM进行观察的截面中任意选取20个气泡,对20个气泡的直径进行测定,求出它们的平均值。
[发泡倍数]
对于发泡倍数,通过水中置换法来测定发泡电线的密度(ρf)和发泡前的密度(ρs),由(ρs/ρf)计算出发泡倍数。
[有效相对介电常数]
对于有效相对介电常数,测定发泡电线的静电容量,计算出由静电容量与发泡绝缘层的厚度得到的相对介电常数。静电容量的测定中使用LCR HiTESTER(日置电机株式会社制造、型号3532-50)。
[绝缘破坏电压]
有以下示出的铝箔法和双绞线(ツイストペア)法,选择铝箔法。
(铝箔法)
切出适当长度的电线,在中央附近卷缠10mm宽的铝箔,在铝箔与导体间施加50Hz的正弦波交流电压,一边连续升压一边测定发生绝缘破坏的电压(有效值)。测定温度为常温。
(双绞线法)
将2根电线捻合,在各导体间施加50Hz的正弦波交流电压,一边连续升压一边测定发生绝缘破坏的电压(有效值)。测定温度为常温。
[局部放电起始电压]
将2根电线捻合成扭转状(ツイスト状),制作试验片,向各导体间施加50Hz的正弦波交流电压,一边连续升压一边测定放电电荷量为10pC时的电压(有效值)。测定温度为常温。局部放电起始电压的测定中使用局部放电试验机(菊水电子工业制造、KPD2050)。
[熔点、玻璃化转变点]
熔点利用差示扫描量热计(Differential Scanning Calorimetry:DSC)进行测定。玻璃化转变点利用DSC进行测定。
将实施例1~12和比较例1~13中得到的发泡电线的评价结果列于表1-1、表1-2、表3中。图3中将实施例1~8和比较例1~6中的相对于发泡电线气泡径的绝缘破坏电压以图表示出。实施例1~8的结果以○表示,比较例1~6的结果以△表示。
【表1-1】
【表1-2】
如由表1-1、表1-2所知,实施例1~8中可良好地维持绝缘破坏电压、且确认到了发泡所致的有效相对介电常数的降低以及PDIV的提高。另一方面,在比较例1~6中,尽管确认到了有效相对介电常数的降低以及PDIV的提高,但其绝缘破坏电压降低。比较例1~6中,将相对于未发泡的比较例7、8中测定的绝缘破坏电压降低80%的情况视为降低。
【表2】
如由表2所示可知,实施例9~11中可良好地维持绝缘破坏电压、且确认到了发泡所致的有效相对介电常数的降低以及PDIV的提高。另一方面,在比较例9中,尽管确认到了有效相对介电常数的降低以及PDIV的提高,但绝缘破坏电压降低。比较例9中,将相对于未发泡的比较例10、11中测定的绝缘破坏电压低于80%的情况视为降低。
【表3】
如由表3所示可知,实施例12中可良好地维持绝缘破坏电压、且确认到了发泡所致的有效相对介电常数的降低以及PDIV的提高。与此相对,在比较例12中,绝缘破坏电压降低。比较例12中,将相对于未发泡的比较例13中测定的绝缘破坏电压低于80%的情况视为降低。
本发明的发泡电线具有在图1(a)~1(b)和图2(a)~2(c)示出了截面图那样的截面。
实施例1~8、12中无内侧皮层3,为在图2(a)中示出了截面图的截面。另外,在实施例9~11中,由于设有内侧皮层3和外侧皮层4,因而为在图2(c)中示出了截面图的截面。
相对于此,本发明的发泡电线也可适用于如图1(a)中截面图所示那样的无内侧皮层3和外侧皮层4的情况,也可适用于如图1(b)中截面图所示那样的矩形导体1中。
【工业实用性】
本发明可利用在以汽车为代表的各种电气·电子设备等需要耐电压性、耐热性的领域中。
本发明并不限定于上述实施方式中,在本发明技术事项的范围内可进行各种变更。尽管已经结合本发明实施方式对本发明进行了说明,但只要申请人并未进行特别指定,则并不将本发明限定于所说明的任何细节中,申请人认为,只要不违反所附权利要求所示的发明精神与范围,则应宽泛地进行解释。
本申请以2010年3月25日在日本提出专利申请的日本特愿2010-070068为基础,主张其优先权,以参照的方式将其内容作为本说明书记载的一部分并入到本文中。
【符号说明】
1导体
2发泡绝缘层
3内侧皮层
4外侧皮层
Claims (8)
1.一种发泡电线,其为具有导体与发泡绝缘层的发泡电线,其中,上述发泡绝缘层由作为结晶性热塑性树脂或非晶性热塑性树脂的热塑性树脂形成,该结晶性热塑性树脂的熔点或非晶性热塑性树脂的玻璃化转变点为150℃以上;且该发泡绝缘层的平均气泡径为5μm以下。
2.如权利要求1所述的发泡电线,其中,所述发泡绝缘层的有效相对介电常数为2.5以下。
3.如权利要求1或2所述的发泡电线,其中,所述热塑性树脂的相对介电常数为4.0以下。
4.如权利要求1~3的任一项所述的发泡电线,其中,所述发泡绝缘层由聚苯硫醚、聚萘二甲酸乙二醇酯、聚对苯二甲酸乙二醇酯、聚醚醚酮和热塑性聚酰亚胺的任意一种形成。
5.如权利要求1~4的任一项所述的发泡电线,其中,在所述发泡绝缘层的外侧具有未发泡的外侧皮层,该外侧皮层的厚度相对于外侧皮层的厚度与所述发泡绝缘层的厚度的合计为20%以下。
6.如权利要求1~4的任一项所述的发泡电线,其中,在所述发泡绝缘层的内侧具有未发泡的内侧皮层,该内侧皮层的厚度相对于内侧皮层的厚度与所述发泡绝缘层的厚度的合计为20%以下。
7.如权利要求1~4的任一项所述的发泡电线,其中,在所述发泡绝缘层的外侧具有未发泡的外侧皮层,并且在所述发泡绝缘层的内侧具有未发泡的内侧皮层,该内侧皮层的厚度与该外侧皮层的厚度的合计相对于内侧皮层的厚度、外侧皮层的厚度与所述发泡绝缘层的厚度的合计为20%以下。
8.一种发泡电线的制造方法,其中,该制造方法具有如下工序:通过使包覆于导体的绝缘层以5μm以下的平均气泡径发泡,由此得到发泡绝缘层。
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Also Published As
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US9142334B2 (en) | 2015-09-22 |
WO2011118717A1 (ja) | 2011-09-29 |
EP2551858A1 (en) | 2013-01-30 |
JP5922571B2 (ja) | 2016-05-24 |
EP2551858B1 (en) | 2018-08-15 |
CN102812524B (zh) | 2015-05-27 |
US20130014971A1 (en) | 2013-01-17 |
JPWO2011118717A1 (ja) | 2013-07-04 |
KR101477878B1 (ko) | 2014-12-30 |
KR20130006617A (ko) | 2013-01-17 |
EP2551858A4 (en) | 2017-01-04 |
TW201140620A (en) | 2011-11-16 |
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