KR102448234B1 - Insulation member and manufacturing method thereof - Google Patents

Abstract

An insulating member mounted on a slot formed on the inner circumferential surface of the stator core, formed of a single insulating sheet, a slot portion covering the inside of the slot, and at least one end in the axial direction of the slot portion provided at a substantially right angle from the slot portion An insulating member is provided, comprising: a base having a bent portion extending outward; and a resin molded body provided in close contact with the bent portion. According to this insulating member, it is possible to achieve miniaturization, high efficiency, and high output power of rotating electric machines such as motors and motor generators.

Description

Insulation member and manufacturing method thereof

The present invention relates to an insulating member having excellent heat resistance and insulating properties and a method for manufacturing the same, in particular, an insulating member inserted into a slot of a core material of a motor, a generator, and other rotating electric machine to secure electrical insulation between a core and a coil, and its manufacturing method It relates to a manufacturing method.

A stator of a rotating electric machine such as a motor or a generator is constituted by an annular stator core having a plurality of slots in a circumferential direction of an inner circumferential surface, and a coil wound around the slots, and between the stator core and the coil, electrical insulation is An insulating sheet is inserted to secure it.

Conventionally, in such an insulating sheet, a fibrid of polymetaphenylene isophthalamide (hereinafter referred to as meta-aramid) and paper (trade name: Nomex (registered trademark)) composed of fibers, polyethylene terephthalate, etc. A resin film, an aramid-resin film laminate in which the meta-aramid paper and the resin film are laminated are used.

In addition, in general, as described in Fig. 3 of Patent Document 1, for example, the insulating sheet is formed by folding both ends, bending the folded portion to the outside to form a substantially U-shape, and then inserting it into the slot. At this time, the folded portion is present in a state protruding from the end face of the core material in the axial direction, and the tip of the fold is in contact with the end face of the core material, so that the insulating sheet is configured so that there is no displacement in the slot axial direction.

However, when the insulating sheet is arranged in such a configuration, since the length in the axial direction of the core material becomes longer due to the existence of the folded portion, it is necessary to make the coil wound in the slot portion longer as well. That is, the amount of copper wire used for the coil increases, and as a result, the size and weight of the rotating electric machine increase, and the length of the coil leads to a decrease in the efficiency and output of the rotating electric machine. For example, it is not preferable for application to a motor arranged in a limited space, such as for vehicle mounting.

As an insulating member for solving these problems, a cavity is formed using a mold having both end faces of the core material and protrusions entering the slot on insulating paper folded at the end of the core material, and the folded portion of the insulating paper is arranged in the cavity. An insulating member in which molten resin is poured into a cavity, the molten resin embeds a folded portion of an insulating sheet, and is formed in close contact with an end of a core material has been proposed (Patent Document 2).

However, in this technology, the folded portion of the insulating paper is arranged at an angle with respect to the end face of the core material, and the molten resin is injected in a state where the folded portion is not sufficiently fixed in the cavity, so by the injection pressure of the resin There is a concern that the insulating paper is deformed, whereby the resin cannot embed the insulating paper in the folded portion. In addition, when there is no description regarding the type of insulating paper and molten resin, and when a material with insufficient adhesion between the molten resin and the insulating paper is selected, if the insulating member is formed in a state where embedding is insufficient as described above, when the rotating electric machine is operated There is a concern that the resin and insulating paper may peel off.

Japanese Utility Model Application Publication No. 60-162951 Japanese Patent Publication No. 3921985

It is an object of the present invention to provide an insulating member which causes miniaturization, high efficiency, and high output power of rotating electric machines such as motors and motor generators, and a method for manufacturing the same.

In view of this situation, the present inventors have completed the present invention as a result of earnest examination in order to obtain an insulating member which brings miniaturization, high efficiency, and high output of rotating electric machines such as motors and generators.

That is, one embodiment of the present invention is an insulating member mounted on a slot formed on the inner peripheral surface of a stator core, is formed of a single insulating sheet, and includes a slot part covering the inside of the slot, and at least in the axial direction of the slot part An insulating member is provided, comprising: a base having a bent portion provided at one end and extending outwardly at a substantially right angle from the slot portion; and a resin molded body provided in close contact with the bent portion.

The insulating sheet of the bent portion may be cut with the bent portion of the slot viewed from the axial direction as a starting point.

Both ends of the insulating sheet may be bent at a substantially right angle with respect to the slot portion.

The bent portion and the resin molded body may be in close contact with each other without using an adhesive.

The insulating sheet is an aramid paper containing aramid fibrid and short aramid fibers, an aramid-resin film laminate in which the aramid paper and a resin film are laminated, or a sheet formed by melt-extruding a resin on the aramid paper may be selected from

The resin molded body may be a resin molded body formed using a polymer having an amide bond, and the surface of the insulating sheet in contact with the resin molded body may be an aramid paper containing aramid fibrids and short aramid fibers.

Another embodiment of the present invention is a method for manufacturing an insulating member mounted on a slot formed on the inner peripheral surface of a stator core, wherein a portion corresponding to a bent portion of the insulating sheet is cut in the axial direction at the position of the bent portion of the slot viewed from the axial direction Then, the insulation sheet is folded so as to be substantially at right angles to the slot portion of the insulation sheet, and after bending along the slot shape, the bent portion of the insulation sheet is filled with a molten resin composition by injection molding to form a flange-shaped core. An object of the present invention is to provide a method for manufacturing an insulating member comprising forming an end face portion.

Another embodiment of the present invention is a method for manufacturing an insulating member mounted on a slot formed on the inner peripheral surface of a stator core, wherein a portion corresponding to a bent portion of the insulating sheet is cut in the axial direction at the position of the bent portion of the slot viewed from the axial direction Then, after making a mountain fold so as to be substantially perpendicular to the slot portion of the insulating sheet, and bending along the slot shape, the molten resin composition on the sheet surface facing the slot portion of the bent portion of the insulation sheet is injected by injection molding. A method for manufacturing an insulating member, wherein the bent portion of the insulating sheet is filled to form a flange-shaped core end face portion, the insulating sheet is exposed on the surface of the core end face portion as viewed from the side of the sheet surface not facing the slot portion will be.

Another embodiment of the present invention is a method for manufacturing an insulating member mounted on a slot formed on the inner peripheral surface of a stator core, wherein a portion corresponding to a bent portion of the insulating sheet is cut in the axial direction at the position of the bent portion of the slot viewed from the axial direction Then, after making a mountain fold so as to be substantially perpendicular to the slot portion of the insulating sheet, and bending along the slot shape, the molten resin composition on the sheet surface facing the slot portion of the bent portion of the insulation sheet is injected by injection molding. Filling to form a flange-shaped core end face portion, the bent portion of the insulating sheet, viewed from the side of the sheet surface not facing the slot portion, forms a core end face portion on which the insulating sheet is exposed, after which the insulating sheet is exposed To provide a method for manufacturing an insulating member, wherein the core end face portion is filled with a molten resin composition by injection molding, and an insulating sheet forms a flange-shaped core end face portion completely covered with a resin molded body.

Another aspect of the present invention is to provide a motor having a core in which a coil is wound in a slot in which the insulating member is mounted on an inner circumferential surface.

Another embodiment of the present invention is to provide a generator, characterized in that the insulating member has a core wound in a slot mounted on the inner peripheral surface, the coil.

Another aspect of the present invention is to provide a rotating electric machine, characterized in that the insulating member has a core wound in a slot mounted on the inner peripheral surface, the coil is wound.

BRIEF DESCRIPTION OF THE DRAWINGS It is a perspective view which shows the insulating member of one Embodiment of this invention.
2 is a perspective view showing an insulating member according to another embodiment of the present invention.
It is a front view of the insulating sheet used for one Embodiment of this invention.
Fig. 4 is a perspective view of the insulating sheet of Fig. 3 being bent (before the resin molded body is adhered).

Hereinafter, although the insulating member of a preferable embodiment of this invention is demonstrated in detail with reference to drawings, it is not specifically limited to this. 1 is a perspective view of an insulating member 1 according to a preferred embodiment of the present invention.

The insulating member 1 is formed of one insulating sheet, and has a slot portion 2 having a substantially U-shape in cross section that covers the inner surface of the slot of the stator core, and is provided at both ends in the axial direction of the slot portion having a substantially U shape. It has a base (4) having a bend (3) extending outwardly outwardly approximately perpendicularly from the . In addition, in this specification, the axial direction of a slot part means the direction toward the other core end face part from one core end face part in the surface of the slot part opposing to a stator core.

In the illustrated embodiment, the cross section of the slot portion 2 is approximately U-shaped, but the cross section of the slot portion is not limited to the U-shape, and depending on the shape of the slot of the stator core and the strength required for the insulating member 1, etc. It may have a cross section of a rectangle, a square, a pentagon, a V-shape, and the like.

The bent portion 3 includes a pair of rectangular side bent portions 3a and 3a extending outwardly from each long side of which the U-shaped edge of the slot portion 2 opposes, and the U-shaped bottom side to the outside. It is provided with a rectangular bottom bent part 3b extending to .

The insulating member 1 is further provided with the resin molded body 5 provided in the bending part 3 . The resin molded body 5 has a substantially horseshoe shape made of resin, as shown in FIG. 1 . Specifically, the resin molded body 5 covers the back surface of the side bent portions 3a and 3a, and also covers the back surface and the periphery of the bottom bent portion 3b. Around the bottom bent portion 3b, it has a semicircular shape and is flush with the surface of the bottom bent portion 3b. In this embodiment, the core end face part 6 is comprised by the bent part 3 and the resin molded object 5. As shown in FIG. By employing such a structure for forming the core end face portion 6, the length in the axial direction of the core material of the insulating member can be shortened as compared with the case of forming the folded portion. In addition, in this specification, "approximately perpendicular/approximately right angle" means that it is 90 ° ± 15 °, preferably 90 ° ± 10 °, more preferably 90 ° ± 5 °.

When the insulating member 1 is fitted into the slot of the stator core, the entire surface of the end portion outside in the axial tip direction of the slot cannot be covered by the bent portion 3 alone. However, in the insulating member 1 of the present embodiment, the resin molded body 5 can cover a portion (approximately U-shaped side bottom) that is not covered by the bent portion 3 . The height of the insulating member from the axial end is preferably equal over the entire surface of the core end face portion 6 . In addition, at this time, it is preferable that the resin molded body 5 and the insulating sheet 7 are joined without an adhesive agent.

2 : has shown the perspective view of the insulating member 10 of one Embodiment of this invention different from FIG. As shown in FIG. 2 , in the insulating member 10 , the resin molded body 50 has the same horseshoe shape as the insulating member 1 shown in FIG. 1 , but the side bent portions 3a and 3a and the bottom portion It has a shape which covers the bent part 3b from top and bottom. In the aspect shown in FIG. 2, since the front and back surfaces of an insulating sheet are coat|covered with resin, close_contact|adherence of an insulating sheet and a resin molded object can be made more firmly.

In addition, as an aspect in which the resin molded body and the insulating sheet are joined without an adhesive agent, any of the following five aspects is preferable.

Insulation sheet: resin molded body

Aramid paper: molded article of polyamide resin composition

3-layer laminate of aramid paper/resin film/aramid paper: molded body of polyamide resin composition

3-layer laminate of aramid paper/sheet-like polyamide resin composition/aramid paper: molded body of polyamide resin composition

Two-layer laminate of aramid paper/resin film: molded body of polyamide resin composition

Two-layer laminate of aramid paper/sheet-like polyamide resin composition: molded article of polyamide resin composition

Here, when using a two-layer laminate of an aramid paper / resin film or a sheet-like polyamide resin composition as an insulating sheet, the resin molded body may be provided on any surface of the two-layer laminate, but providing on the aramid paper side desirable. Moreover, it is preferable to form the sheet-like polyamide resin composition by melt extrusion.

The manufacturing method of the base 4 which comprises the insulating member 1 is demonstrated. Fig. 3 is a front view of the insulating sheet 7 used to form the base 4 of the insulating members 1 and 10 according to the preferred embodiment of the present invention. The region between the dashed-dotted line portion 7a shown at both ends of the rectangular insulating sheet 7 in the longitudinal direction and the end 7b of the insulating sheet 7 is a location to be later processed into the bent portion 3 . The distance between the two dashed-dotted lines 7a and 7a of the insulating sheet 7 is the axial length of the insulating member 1, and this axial length corresponds to the axial length of the stator core. First, the dotted line portion between (7c) to (7d) is cut, and then, the dashed-dotted line portion 7a is viewed from the front to form a mountain fold at a substantially right angle. After that, the base 4 constituting the insulating member is formed by further bending the broken line portions (between the upper and lower 7d) along the slot shape, that is, by performing bone folds when viewed from the front (FIG. 4). After bending the insulating sheet into the shape shown in FIG. 4 , the resin molded body 5 is formed so as to cover the bent portion 3 .

The insulating member shown in FIG. 1 and FIG. 2 is used by fitting into the slot of the inner peripheral surface of a core material. At this time, since the core end face portion 6 including the bent portion 3 and the resin molded body 5 (50 in the case of Fig. 2) exists in a state in contact with the core end face, the coil is inserted into the slot. It is possible to prevent displacement of the insulating member during winding.

(aramid)

In the present invention, aramid means a linear high molecular compound in which 60% or more of amide bonds are directly bonded to an aromatic ring. As such an aramid, polymetaphenylene isophthalamide and its copolymer, polyparaphenylene terephthalamide and its copolymer, copolyparaphenylene 3,4'-diphenyl ether terephthalamide, etc. are mentioned, for example. can These aramids are, for example, industrially produced by a solution polymerization method by a condensation reaction with an aromatic acid dichloride and an aromatic diamine, a two-step interfacial polymerization method, etc., and can be obtained as a commercial product, but is limited to this not. Among these aramids, polymetaphenylene isophthalamide is preferably used at the point provided with characteristics, such as favorable molding processability, a flame retardance, and heat resistance.

(aramid fibrid)

In the present invention, the aramid fibrid is a film-like microparticle containing aramid, and is also called aramid pulp. As a manufacturing method, the method of Unexamined-Japanese-Patent No. 35-11851, Japanese Unexamined-Japanese-Patent No. 37-5732, etc. is illustrated, for example. Since the aramid fibrid has papermaking properties similar to that of ordinary wood pulp, it can be dispersed in water and then molded into a sheet with a papermaking machine. In this case, a so-called beating treatment may be performed for the purpose of maintaining a quality suitable for papermaking. This beating process can be performed by a disc refiner, a beater, or other papermaking raw material processing equipment which exerts a mechanical cutting action. In this operation, the change in the shape of the fibrid can be monitored by the freeness (freeness) specified in JIS P8121. In the present invention, the freeness of the aramid fibrid after the beating treatment is preferably in the range of 10 to 300 cm ³ (Canadian Standard Freeness). In a fibrid having a freeness greater than this range, there is a possibility that the strength of a sheet formed therefrom may decrease. On the other hand, when it is desired to obtain a freeness smaller than 10 cm ³ , the efficiency of use of the input mechanical power decreases, and the throughput per unit time often decreases, and the refinement of the fibrid progresses too much. likely to cause deterioration.

(Aramid Short Fiber)

In the present invention, the short aramid fibers are cut to a predetermined length of fibers made from aramid as a raw material, and as such fibers, for example, "Conex (registered trademark)" of Teijin Co., Ltd., "Technora ( registered trademark)", "Nomex (registered trademark)" of DuPont, "Kevlar (registered trademark)", "Twaron (registered trademark)" of Teijin Aramid, etc., but are not limited thereto .

The short aramid fibers may preferably have a fineness within the range of 0.05 dtex or more and less than 25 dtex. Fibers having a fineness of less than 0.05 dtex are likely to cause agglomeration in the production (described later) by a wet method, and fibers having a fineness of 25 dtex or more, because the fiber diameter is too large, the aspect ratio is reduced, the reduction of the mechanical reinforcing effect, aramid There is a possibility that the uniformity of the paper may be poor.

The length of the short aramid fibers may be selected from the range of 1 mm or more and less than 25 mm, preferably 2 to 12 mm. If the length of the short fibers is less than 1 mm, the mechanical properties of the aramid paper are lowered, on the other hand, 25 mm or more, "entanglement" and "bonding", etc. are easy to occur during the production of the aramid paper by the wet method to be described later, and it is easy to cause defects .

(aramid paper)

In the present invention, the aramid paper is a sheet-like article mainly composed of the above-described aramid fibrids and short aramid fibers, and generally has a thickness within the range of 20 µm to 1000 µm. Preferably it is 25-500 micrometers. In addition, the aramid paper generally has a weight per unit area within the range of 10 g/m ² to 1000 g/m ² . Preferably, it is 20 to 500 g/m ² . Here, the mixing ratio of aramid fibrid and short aramid fiber can be arbitrary, but it is preferable that the ratio (mass ratio) of aramid fibrid / short aramid fiber (mass ratio) is 1/9 to 9/1, more preferably 2/ 8 to 8/2, but is not limited to this range.

Aramid paper is generally produced by a method of mixing the aforementioned aramid fibrid and short aramid fibers into a sheet. Specifically, for example, after dry blending the aramid fibrids and short aramid fibers, a method of forming a sheet using an airflow, dispersion and mixing of aramid fibrids and short aramid fibers in a liquid medium, and then liquid permeability A method of discharging onto a support, for example, a net or a belt to form a sheet, and removing a liquid to dry it can be applied. Among them, a so-called wet sheet forming method using water as a medium is preferably selected.

In the wet papermaking method, a single or a mixture of aqueous slurry containing at least aramid fibrids and short aramid fibers is liquid fed to a paper machine and dispersed, and then dehydrated, impregnated and dried to form a sheet and wound up as a sheet. As the paper machine, a long-mesh paper machine, a round-mesh paper machine, an inclined paper machine, and a combination paper machine combining these machines are used. In the case of production in a combination paper machine, a composite sheet including a plurality of paper layers can be obtained by sheet-forming and uniting slurries having different mixing ratios. Additives such as a dispersibility improver, an antifoaming agent, and an intellectual strength enhancer are used when necessary.

The aramid paper obtained as mentioned above can improve a density and mechanical strength by heat-pressing processing at high temperature and high pressure between a pair of rolls. Although the conditions of heat press processing can illustrate the temperature of 100 degreeC - 400 degreeC, and the range of 50-400 kg/cm linear pressure, when using a metal roll, for example, it is not limited to these. A plurality of aramid papers may be laminated at the time of hot pressing. Moreover, you may perform the said heat-pressing process multiple times in arbitrary order.

(insulation sheet)

In the present invention, the insulating sheet means a sheet having electrical insulation properties. The insulating sheet preferably has a volume resistivity of 1×10 ¹⁰ to 1×10 ²⁰ Ω·cm, and more preferably a volume resistivity of 1×10 ¹² to 1×10 ²⁰ Ω·cm. The aramid paper alone, the aramid paper and the resin film are laminated, and the aramid-resin film laminate adhered with an adhesive or the like, or a sheet formed by melt-extruding the resin on the aramid paper.

Examples of the resin film used for the aramid-resin film laminate include polyethylene terephthalate, polyethylene naphthalate, polyamide, aromatic polyamide, polyimide, polytetrafluoroethylene, and polyphenylene sulfide. These may be used independently and may use resin and copolymer which blended 2 or more types. In addition, as an adhesive used for laminating the aramid paper, any adhesive commonly used in the technical field may be used, for example, epoxy-based, acrylic-based, phenol-based, urethane-based, silicone-based, polyester-based, amide-based adhesives, etc. adhesives, but are not limited thereto.

In the case of lamination of aramid paper and the film by an adhesive, the film is usually stretched, and when an insulating member is manufactured by the method described later, deformation of the aramid-resin film laminate is easy to occur due to shrinkage, so the deformation is slightly If it is necessary to suppress even if it is necessary, a method of superimposing and heat-pressing a film on which a polymer is melt-formed in advance and the aramid paper, melt-impregnating the polymer in an aramid paper, a method of melt-extruding the resin on the aramid paper to heat-seal it, etc. By this, the sheet which laminated|stacked the aramid paper directly with the resin without an adhesive agent is used preferably.

The number of layers of lamination can be appropriately selected depending on the use and purpose of the laminate, but if the aramid paper is disposed on the surface layer of at least one side, the slidability becomes good. There is an effect that it becomes easy to insert an insulating member, and it is preferable. For example, as described in Japanese Patent Laid-Open No. 2006-321183, an aromatic polyamide resin prepared by melt-extruding a resin on an aramid paper and thermally fusion-bonding, and an epoxy group-containing phenoxy having an epoxy group in the molecule A two-layer laminated sheet of a polymer and aramid paper containing a resin, wherein the ratio of the epoxy group-containing phenoxy resin is 30 to 50% by mass, and a three-layer laminated sheet of aramid paper and the polymer and aramid paper are mentioned, but are limited to these it's not going to be

The thickness, the weight per unit area (basis weight), and the density of the insulating sheet can be appropriately selected according to the size and slot shape of the core material, and the use or purpose, and any thickness can be selected as long as there is no problem in bending workability. Generally, it is 50 micrometers - 1000 micrometers, Preferably it is 50 micrometers - 500 micrometers, More preferably, it is 70-300 micrometers from a viewpoint of workability, but it is not limited to this. In addition, the weight per unit area is preferably 30 to 1000 g/m ² , and more preferably 50 to 750 g/m ² . The density is preferably 0.1 to 2.5 g/cm ³ , and more preferably 0.5 to 2.0 g/cm ³ .

(resin molded body)

In the present invention, the resin molded article refers to a molded article produced by an injection molding method in which a molten resin composition is filled in a desired mold and removed from the mold after cooling.

As a resin composition used for the resin molded object of this invention, it is preferable that the resin which has an amide bond alone or this resin is included. Examples of the resin having an amide bond include polyamide 6, polyamide 66, polyamide 612, polyamide 11, polyamide 12, copolyamide, polyamide MXD6, polyamide 46, methoxymethylated polyamide, semi-aromatic polyamide, etc. polyamide resin alone or a mixture thereof. Here, as a semi-aromatic polyamide, the polyamide containing an aromatic dicarboxylic acid component and the diamine component which has a C4-C10 linear aliphatic diamine is mentioned. Examples of such semi-aromatic polyamides include DuPont's "Zytel (registered trademark) HTN501", which is a polyamide resin obtained by tertiary polymerization of hexamethylenediamine, 2-methylpentamethylenediamine, and terephthalic acid. not. or a polymer or a mixture thereof containing a polyamide resin composition as shown in Japanese Patent Application Laid-Open No. 2006-321951, or a mixture of the polymer and an inorganic substance such as glass fiber. Here, the polymer is a polyamide resin composition comprising an aromatic polyamide resin and an epoxy group-containing phenoxy resin having an epoxy group in the molecule, and containing 30 to 50 mass% of the epoxy group-containing phenoxy resin. In particular, a molded article of a mixture of semi-aromatic polyamide and glass fiber is preferable because of its high heat resistance. Examples of such a mixture include, but are not limited to, "Zytel (registered trademark) HTN51G, 52G" manufactured by DuPont.

In the present invention, the resin composition used for the resin molded body has insulating properties, and the resin molded body molded from the resin composition preferably has a volume resistivity of 1×10 ¹⁰ to 1×10 ²⁰ Ω·cm, More preferably, it has a volume resistivity of 1×10 ¹² to 1×10 ²⁰ Ω·cm.

In the present invention, the resin composition having such an insulating property preferably contains the above-mentioned amide bond-containing resin alone or the resin.

It is preferable that the thickness of a resin molded object is 100-5000 micrometers, More preferably, it is 500-2000 micrometers.

(Manufacturing method of insulating member)

In the method for manufacturing an insulating member of the present invention, after forming a shape as shown in FIG. 4 using the above-described insulating sheet, it is placed in a mold and melted on the side facing the slot of the bent part 3 . A method of manufacturing by forming the flange-shaped core end face portion 6 to which the bent portion 3 and the resin molded body 5 are adhered by performing injection molding with the resin composition in contact can be used.

In the case where a part of the insulating sheet forms the core end face part exposed on the surface as shown in Fig. 1, the insulating sheet 7 is fixed by placing the bent part 3 and the mold in contact with the mold, and injection molding is performed, The cut-out portion (approximately U-shaped side bottom) of the bent portion 3 is filled with a resin composition to obtain a core end face portion 6 having an approximately U-shaped surface formed by the bent portion 3 and the resin molded body 5. can

In order to obtain an insulating member in which the entire surface of the insulating sheet is coated with a resin molded body as shown in Fig. 2, after forming the insulating member 1 in Fig. 1, injection molding is performed in another step to obtain a resin molded body 50, or A cavity is formed so that the surface of the bent portion 3 of the insulating sheet 7 does not come into contact with the mold, and a method of forming the resin molded body 50 by one injection molding, etc., but are limited to these not. In addition, although the side surface (front side) of the bent part 3 is partially exposed in FIG. 2, it is good also as a structure which covers all this side surface. At this time, as a method of fixing the position of the bent portion 3 in the core end surface portion, a pin that can be inserted and removed from the mold is inserted into the bent portion 3 to temporarily fix it, and thereafter, during injection molding (resin Although the method of removing a pin during filling of a composition) is mentioned, It is not limited to this. By performing injection molding as described above, the core end face portion to which the insulating sheet and the resin molded body are adhered can be formed to obtain the insulating member of the present invention.

The thickness of the slot part in the insulating member of this invention becomes the thickness of an insulating sheet, since a slot part is comprised only with the insulating sheet. Moreover, it is preferable that the thickness of a core end surface part is 0.3 mm - 5 mm, More preferably, it is 0.4 mm - 3 mm, More preferably, it is 0.5 mm - 2 mm.

Example

Hereinafter, the present invention will be described in more detail with reference to Examples. In addition, these examples are merely illustrative, and are not intended to limit the content of the present invention at all.

[Example 1]

(Preparation of raw materials)

A fibrid of polymetaphenylene isophthalamide was produced using an apparatus for producing pulp particles (wet sedimentation machine) comprising a combination of a stator and a rotor described in Japanese Patent Laid-Open No. 52-15621. This was treated with a grinding period and a beating stage to prepare a length-weighted average fiber length of 0.9 mm. The freeness of the obtained fibrid was 90 cm ³ . On the other hand, meta-aramid fibers manufactured by DuPont (Nomex (registered trademark), single yarn fineness of 2.2 dtex) were cut to 6 mm in length to be used as a raw material for papermaking.

(Production of aramid paper)

A slurry was prepared by dispersing the aramid fibrids and short aramid fibers prepared as described above in each water. After mixing these slurries so that the aramid fibrid and short aramid fibers are at a mixing ratio (weight ratio) of 1/1, a sheet-like article was prepared with a tapestry type weeding machine (cross-sectional area 625 cm ² ). Subsequently, this was heat-pressed with a metal calender roll at a temperature of 330°C and a linear pressure of 300 kg/cm to obtain an aramid paper.

In addition, aramid paper / polyethylene by bonding aramid paper and polyethylene naphthalate film (Teijin DuPont Film Co., Ltd., "Theonex (registered trademark) Q51", thickness 100 µm) with an adhesive, and placing aramid paper on the outside An aramid-resin film laminate comprising a three-layer structure of a naphthalate film/aramid paper was obtained.

(Manufacture of insulating member)

Using the aramid-resin film laminate, cut as shown in FIG. 3, cut the dotted line portion in FIG. 3, and then fold the dashed-dotted line portion at a substantially right angle when viewed from the front, and also bend the dashed line portion along the slot shape Thus, an insulating sheet formed in a three-dimensional shape was obtained. Using this insulating sheet and semi-aromatic polyamide (“Zytel (registered trademark) HTN51G35EF” manufactured by DuPont) as a resin composition, injection molding was performed under the conditions shown in Table 1, and the insulating sheet and the resin composition were adhered to the core end. The face portion was formed to obtain an insulating member having the shape shown in Fig. 1, in which the distance from the junction of the slot portion and the core end surface portion to the edge of the core end surface portion was 10 mm and the core end surface portion had a thickness of 1 mm. The following method evaluated the main characteristic values of the insulating member obtained in this way. A result is shown in Table 1.

[How to measure]

(1) Weight, thickness, and density per unit area

It implemented according to JISC2300-2, and the density was computed by (weight/thickness per unit area).

(2) Insulation sheet appearance

Regarding the appearance of the insulating sheet, visually observe the degree of warpage due to heat during molding, and if there is no warpage, it is called "good", if there is a slight warpage, it is "nearly good", and if there is remarkably warpage, it is called "bad". judged.

(3) Adhesiveness

With respect to the core end face of the insulating member, from the top of the substantially U shape, along the interface between the insulating sheet and the resin molded body, a cut of 1 mm was made with a cutter knife, and the insulating sheet and the resin molded body were peeled from this cut-out portion, and the resin after peeling The surface of the molded article was visually observed. When the paper layer on the surface of the insulating sheet remained on the surface of the resin molded body, it was judged as “good”, when the paper material on the surface of the insulating sheet remained “almost good”, and when the paper material of the insulating sheet did not completely remain was judged as “bad”. .

[Example 2]

The aramid paper obtained in Example 1, 50 parts by weight of a semi-aromatic polyamide resin composition (Zytel (registered trademark) manufactured by DuPont) HTN501 containing 50% by weight of an epoxy group-containing phenoxy resin, and 50 parts by weight of an epoxy group-containing phenoxy resin Using the semi-aromatic polyamide resin composition prepared by the method described in [0027] of Japanese Unexamined Patent Application Publication No. 2006-321183 using the method described in [0024] of Japanese Unexamined Patent Application Publication No. 2006-321183, A lamination sheet containing a three-layer structure of aramid paper / resin composition / aramid paper was obtained, in which the aramid paper was arranged on the outside. Using this lamination sheet, it carried out similarly to Example 1, and obtained the insulating member of the shape shown in FIG. Thus, the main characteristic value of the obtained insulating member was carried out similarly to Example 1, and it evaluated. A result is shown in Table 1.

[Example 3]

Except having changed the insulating sheet with the aramid paper which has the characteristic shown in Table 1, it carried out similarly to Example 1, and obtained the insulating member of the shape shown in FIG. Thus, the main characteristic value of the obtained insulating member was carried out similarly to Example 1, and it evaluated. A result is shown in Table 1.

From the results in Table 1, the insulating member of the present invention has a homogeneous appearance, and the thickness of the end face of the core is also as small as 1 mm in the embodiment, that is, the protrusion of the end is suppressed even if it fits into the stator core. Accordingly, the insulating member of the present invention can suppress the length in the axial direction compared to a normal rotating electric machine, and can expect miniaturization, high efficiency, and high power of the rotating electric machine using the insulating member.

From the comparison of Examples 1 to 3, by using a selection from the group consisting of a sheet formed by melt-extruding a resin on an aramid paper single-piece, and the aramid paper comprising aramid fibrids and short aramid fibers, heat at the time of molding It turns out that the curvature caused by this is suppressed and shows a more favorable external appearance.

1 Insulation member
10 Insulation member
2 slots
3 bends
3a side bend
3b bottom bend
4 bass
5 Resin molded body
50 resin molded body
6 core end face
7 Insulation sheet
7a Insulation sheet dash-dotted line part
7b Insulation sheet end
7c Intersection of the end of the insulating sheet and the dotted line
7d Insulation sheet intersection point of dashed-dotted line and dotted line

Claims (12)

delete delete delete delete delete delete delete A method of manufacturing an insulating member mounted in a slot formed on an inner circumferential surface of a stator core,
After cutting a portion corresponding to the bent portion of the insulating sheet in the axial direction at the position of the bent portion of the slot viewed from the axial direction, mountain folds are made so as to be 90°±15° with respect to the slot portion of the insulating sheet, and the slot shape After bending to conform, the bent portion of the insulating sheet is filled with a molten resin composition on the sheet surface facing the slot portion by injection molding to form a flange-shaped core end surface portion, the bent portion of the insulation sheet not facing the slot portion A method for manufacturing an insulating member, wherein the insulating sheet is exposed on the surface of the core end face portion, as viewed from the side of the sheet surface. A method of manufacturing an insulating member mounted in a slot formed on an inner circumferential surface of a stator core,
After cutting a portion corresponding to the bent portion of the insulating sheet in the axial direction at the position of the bent portion of the slot viewed from the axial direction, mountain folds are made so as to be 90°±15° with respect to the slot portion of the insulating sheet, and the slot shape After the bent portion of the insulating sheet, the sheet surface facing the slot portion is filled with a molten resin composition by injection molding to form a flange-shaped core end face portion, and the bent portion of the insulating sheet faces the slot portion Viewed from the side of the uncoated sheet surface, after forming the core end face portion on which the insulation sheet is exposed, the molten resin composition is filled in the core end surface portion on which the insulation sheet is exposed by injection molding, and the insulation sheet is applied to the resin molded body. A method of manufacturing an insulating member forming a core end face portion on a flange completely covered by delete delete delete

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