TWI737838B - Insulating component and its manufacturing method - Google Patents

Abstract

The present invention provides an insulating component, which is installed in a groove formed on the inner peripheral surface of a stator core, and is characterized by comprising: a base material, which is formed by one insulating sheet and has a groove covering the inside of the groove A groove portion, a bent portion provided at at least one end of the groove portion in the axial direction and slightly perpendicularly extending outward from the groove portion; and a resin molded body that is closely attached to the bent portion. This insulating member can achieve miniaturization, high efficiency, and large output of rotating electrical machines such as motors and motor generators.

Description

Insulating component and its manufacturing method

The present invention relates to an insulating component with excellent heat resistance and insulation and a manufacturing method thereof, and in particular to a groove embedded in the core material of motors, generators, and other rotating electrical machines to ensure electrical insulation between the core and the coil Insulating parts and manufacturing methods thereof.

The stator of a rotating electric machine such as a motor or a generator is composed of a ring-shaped stator core having a plurality of grooves in the circumferential direction of the inner peripheral surface and a coil wound around the grooves to ensure electrical insulation. , An insulating sheet is inserted between the stator core and the coil.

In the past, such insulating sheets used paper (trade name NOMEX (registered trademark)) composed of fibrids and fibers of polymeta-phenylene diamine (hereinafter referred to as meta-polyarylene diamine), and polymer A resin film such as ethylene phthalate, a polyaramide-resin film laminate formed by laminating the meta-polyaramide paper and the resin film, and the like.

Generally speaking, the insulating sheet, for example, as described in Figure 3 of Patent Document 1, is formed by folding both ends back, and then bending the back-folded part into a U-shape, and then inserting it into the groove. groove. At this time, the reverse-folded portion exists in a state protruding from the end surface of the core material in the axial direction, and the tip of the reversed-fold contact with the end surface of the core material prevents the insulating sheet from shifting in the axial direction of the groove.

However, if the insulating sheet is arranged in such a configuration, the length of the core material in the axial direction is increased due to the existence of the reflexed portion, so the coil wound on the groove portion must also be lengthened accordingly. This means that the use of copper wires for coils has increased, resulting in an increase in the size and weight of the rotating electrical machine, and the increase in the efficiency and output of the rotating electrical machine due to the lengthening of the coil, which is not suitable for use in, for example, automotive applications. Motor, etc. within the limited space.

As an insulating part to solve these problems, some people propose an insulating part formed in the following manner: in the insulating paper with the end of the core material folded back, a mold having both ends of the core material and protrusions embedded in the groove is used to form holes In the state where the folded portion of the insulating paper is arranged in the hole, molten resin is injected into the hole, and the molten resin embeds the folded portion of the insulating sheet and is in close contact with the end of the core material (Patent Document 2 ).

However, in this technology, the folded part of the insulating paper is arranged at an angle relative to the end surface of the core material, because the melted resin is injected when the folded part is not sufficiently fixed in the hole. This may be due to the injection of resin. The pressure deforms the insulating paper so that the resin cannot embed the insulating paper in the reversed part. In addition, there is no description about the types of insulating paper and molten resin. When selecting a material with poor adhesion between the molten resin and the insulating paper, if the insulating member is formed in a state of insufficient embedding like this, the rotating machine will operate There may be problems such as peeling of resin and insulating paper.

[Prior Art Document] [Patent Document] [Patent Document 1] Japanese Patent Publication No. 60-162951 [Patent Document 2] Japanese Patent No. 3921985

The object of the present invention is to provide a method for manufacturing an insulating component that can achieve the effects of miniaturization, high efficiency, and large output of rotating electrical machines such as motors, motor generators, and the like.

In view of this situation, the inventors of the present invention have made detailed studies in order to obtain an insulating member that can achieve the effects of miniaturization, high efficiency, and high output of rotating electric machines such as motors and generators, and completed the present invention.

That is, one embodiment of the present invention provides an insulating component which is installed in a groove formed on the inner peripheral surface of the stator core, and is characterized by including: a base material, which is formed by a piece of insulating sheet and has a covering A groove portion inside the groove, a bent portion provided at at least one end of the groove portion in the axial direction and slightly perpendicularly extending outward from the groove portion; and a resin molded body to be mounted in close contact with the bent portion .

Starting from the curved part of the groove viewed from the axial direction, cut the insulating sheet of the bent part.

The two ends of the insulating sheet can also be bent slightly perpendicular to the groove portion.

It is also possible to make the folded portion and the resin molded body adhere to each other without using an adhesive.

The insulating sheet can be selected from polyaramide paper composed of polyaramide fibrids and polyaramide short fibers, and a polyaramide-resin film laminate formed by laminating the polyaramide paper and a resin film , Or melt and press the resin out of any of the sheets formed on the polyaramide paper.

The resin molded body may be a resin molded body formed by using a polymer with an amide bond; the surface of the insulating sheet contacting the resin molded body may also be composed of polyaramide fibrids and polyaramide staple fibers. Composition of polyaramide paper.

Another aspect of the present invention is to provide a method of manufacturing an insulating component, wherein the insulating component is installed in a groove formed on the inner peripheral surface of the stator core, and the feature is: When viewed from the axial direction, it is the position of the bend of the groove. After cutting it in the axial direction, fold it so that it is slightly perpendicular to the groove of the insulating sheet, and then bend it along the shape of the groove. The melted resin composition is filled into the folded part of the insulating sheet by injection molding to form a flange-shaped core end face.

Another aspect of the present invention is to provide a method for manufacturing an insulating component, wherein the insulating component is installed in a groove formed on the inner peripheral surface of the stator core, and the feature is: When viewed from the axial direction, it is the position of the curved part of the groove. After cutting it in the axial direction, fold it so that it is slightly perpendicular to the groove part of the insulating sheet, and then bend along the shape of the groove. The melted resin composition is filled by injection molding on the surface of the sheet facing the groove in the folded part of the insulating sheet to form a flange-like core end face. If the folded part of the insulating sheet is not facing Observing from one side of the sheet surface of the groove part, the insulating sheet is exposed on the surface of the end face of the core part.

Another aspect of the present invention is to provide a method for manufacturing an insulating component. The insulating component is installed in a groove formed on the inner peripheral surface of the stator core. When viewed from the axial direction, it is the position of the curved part of the groove. After cutting it in the axial direction, fold it so that it is slightly perpendicular to the groove part of the insulating sheet, and then bend it along the shape of the groove. The melted resin composition is filled by injection molding on the surface of the sheet facing the groove in the folded portion of the insulating sheet to form a flange-like core end surface. After observing the end face of the core part with the insulating sheet exposed from the surface side of the sheet facing the groove part, the molten resin composition is filled by injection molding to the end face of the core part where the insulating sheet is exposed to form a complete insulating sheet. The flange-shaped core end surface covered by the resin molded body.

Another aspect of the present invention is to provide a motor, which is characterized in that the groove in which the above-mentioned insulating member is installed on the inner peripheral surface has a core part around which a coil is wound.

Another aspect of the present invention is to provide a generator, which is characterized in that the groove in which the above-mentioned insulating member is installed on the inner peripheral surface has a core part around which a coil is wound.

Another aspect of the present invention is to provide a rotating electric machine, which is characterized in that the groove in which the above-mentioned insulating member is installed on the inner peripheral surface has a core around which a coil is wound.

Although the insulating member of the preferred embodiment of the present invention will be described in detail below with reference to the drawings, it is not particularly limited thereto. The first figure is a perspective view of an insulating member 1 according to a preferred embodiment of the present invention.

The insulating component 1 includes: a base material 4, which is formed by a single insulating sheet, has a groove portion covering the inner surface of the groove of the stator core and a cross-section of a U-shaped groove 2. It is provided in a U-shaped groove The bent portions 3 extending outward from the groove portion 2 at both ends in the axial direction of the groove portion slightly perpendicularly. In addition, in this specification, the axial direction of the groove means the direction from the end face of the core on one side to the end of the core on the other side of the face of the groove facing the stator core.

In the embodiment shown in the figure, the cross section of the groove part 2 is slightly U-shaped, but the cross-section of the groove part is not limited to the U-shape, and it can also be adapted to the shape of the groove in the stator core and the strength required by the insulating member 1 It has a rectangular, square, pentagonal, V-shaped cross section, etc.

The folded portion 3 includes: a pair of rectangular side folded portions 3a, 3a, which extend outward from the opposite long sides on the U-shaped end edge of the groove portion 2; and a rectangular bottom folded portion 3b, which extends outward from the bottom edge of the U-shape.

The insulating member 1 further includes a resin molded body 5 attached to the bent portion 3. As shown in the first figure, the resin molded body 5 is formed of resin and has a horseshoe shape. Specifically, the resin molded body 5 covers the back surfaces of the side folded portions 3a and 3a, and further covers the back surface and peripheral edges of the bottom folded portions 3b. The circumference of the bottom bent portion 3b has a semicircular shape, which forms a plane with the surface of the bottom bent portion 3b. In this embodiment, the fold portion 3 and the resin molded body 5 constitute the core end surface portion 6. By adopting such a structure for forming the end face portion 6 of the core, the length of the core material of the insulating member in the axial direction can be shortened compared with the case of forming the reflexed portion. In addition, in this specification, "slightly vertical/slightly right angle" means 90°±15°, preferably 90°±10°, more preferably 90°±5°.

When the insulating member 1 is fitted into the groove of the stator core, only the bent portion 3 cannot completely cover the outer end of the groove in the axial end direction. However, in the insulating member 1 of the present embodiment, the resin molded body 5 can cover the portion that cannot be covered by the folded portion 3 (the bottom portion of the U-shaped side is abbreviated). The height of the insulating member at the end in the axial direction is preferably the same over the entire surface of the end face 6 of the core. In addition, at this time, it is preferable to join the resin molded body 5 and the insulating sheet 7 without passing through the adhesive.

The second figure is a perspective view showing an insulating member 10 according to an embodiment of the present invention which is different from the first figure. As shown in the second figure, in the insulating member 10, although the resin molded body 50 has the same horseshoe shape as the insulating member 1 shown in the first figure, it has the side folded portions 3a, 3a and the bottom folded from the top and bottom. The shape of part 3b. In the aspect shown in the second figure, the surface and the back surface of the insulating sheet are covered with resin, so the insulating sheet can be more firmly adhered to the resin molded body.

In addition, as an aspect of bonding the resin molded body and the insulating sheet impermeable to the adhesive, any one of the following five aspects is preferable.

Insulation sheet: resin molded body

Polyaramide paper: molded body of polyamide resin composition

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

A 3-layer laminate of polyaramide paper/sheet-like polyaramide resin composition/polyaramide paper: molded body of polyaramide resin composition

A two-layer laminate of polyaramide paper/resin film: a molded body of a polyaramide resin composition

Two-layer laminate of polyaramide paper/sheet-like polyamide resin composition: molded body of polyamide resin composition

Here, when a two-layer laminate of polyaramide paper/resin film or sheet-like polyamide resin composition is used as an insulating sheet, the resin molded body can be provided on any surface of the two-layer laminate, but It is better on the polyaramide paper side. Furthermore, it is preferable to form a sheet-shaped polyamide resin composition by melt extrusion.

The manufacturing method of the base material 4 which comprises the insulating member 1 is demonstrated. The third figure is a front view of the insulating sheet 7 used to form the base material 4 of the insulating components 1, 10 of the preferred embodiment of the present invention. The area between the chain portion 7a at both ends of the long-side direction of the rectangular insulating sheet 7 and the end 7b of the insulating sheet 7 is the area where the bend portion 3 is subsequently processed. The distance between the two chain wires 7a, 7a of the insulating sheet 7 is the length of the insulating member 1 in the axial direction, and the length in the axial direction corresponds to the length of the stator core in the axial direction. First, after cutting the dotted line portion between 7c to 7d, the chain line portion 7a is mountain-folded so that it becomes slightly vertical when viewed from the front. After that, the dotted line (between 7d and upper and lower) is folded along the shape of the groove, which means that the valley folding is performed when viewed from the front, thereby forming the base material 4 that constitutes the insulating member (Figure 4). After the insulating sheet is folded into the shape shown in the fourth figure, the resin molded body 5 is formed to cover the folded portion 3.

The insulating members shown in the first and second figures are used to fit into the grooves on the inner peripheral surface of the core material. At this time, the core end surface 6 formed by the bent portion 3 and the resin molded body 5 (50 in the second figure) is in contact with the core end surface, so the coil is wound in the groove When grooved, the position of the insulating parts can be prevented from deviating.

(Polyaramide)

In the present invention, polyaramide refers to a linear polymer compound in which 60% or more of the amide bond is directly bonded to an aromatic ring. As such polyarylene amines, for example, poly(m-xylylenediamine) and its copolymers, poly(p-xylylenediamine) and its copolymers, copolymerized p-phenylene 3, 4'-Diphenyl ether, p-xylylenedimethamide, etc. These polyaramides can be manufactured industrially by, for example, a solution polymerization method using a condensation reaction with an aromatic acid dichloride and an aromatic diamine, a two-stage interfacial polymerization method, etc., and they are commercially available. Product acquisition, but not limited to this. Among these polyaramides, polymeta-phenylene diamine has good molding processability, flame retardancy, heat resistance and other characteristics, so from this point of view, it is better to use poly-metaphenylene diamine. M-Phenylenediamine.

(Polyaramid fibrids)

In the present invention, polyaramide fibrids are thin film-like particles composed of polyaramide, and are also called polyaramide slurry. Examples of the manufacturing method include methods described in Japanese Patent Publication No. 35-11851 and Japanese Patent Publication No. 37-5732. Polyaramide fibrids have the same papermaking properties as general wood pulp, so after being dispersed in water, they can be formed into flakes in a paper machine. In this case, for the purpose of ensuring the quality suitable for papermaking, a so-called beating treatment can be implemented. The beating process can be implemented by a dish-shaped refiner, a beating machine, or other paper-making raw material processing machines with a mechanical cutting function. In this operation, the morphological changes of fibrids can be monitored by the degree of drainage (freeness) specified in JIS P8121. In the present invention, the drainage degree of the polyaramide fibrids after the beating treatment is preferably in the range of 10 to 300 cm ³ (Canadian standard freeness). The fibrids having a water drainage degree larger than this range may have lower strength of the subsequently formed sheet. On the other hand, if it is ^{desired to obtain a water filtration degree of less than 10cm 3} , the utilization efficiency of many input mechanical power will be reduced and the processing volume per unit time will be reduced. Furthermore, because of excessive fineness of fibrids It is easy to cause the so-called bonding function to decrease.

(Polyaramide staple fiber)

In the present invention, polyaramide staple fibers are those obtained by cutting polyaramide as a raw material to a predetermined length. Examples of such fibers include "CONEX (registered trademark)" manufactured by Teijin Co., Ltd. , "TECHNORA (registered trademark)", "NOMEX (registered trademark)", "KEVLAR (registered trademark)" of DuPont, "TOWARON (registered trademark)" of Teijin ARAMID, etc., but not limited to these.

The polyaramide staple fiber may preferably have a fineness in the range of 0.05 dtex or more and less than 25 dtex. Fibers with a fineness of less than 0.05 dtex tend to cause agglomeration in the wet process (described later). In addition, for fibers with a fineness of 25 dtex or more, the fiber diameter becomes too large, which reduces the aspect ratio and strengthens the mechanics. The effect is reduced, and poor uniformity of the polyaramide paper may occur.

The length of the polyaramide staple fiber can be selected from the range of 1 mm or more but less than 25 mm, preferably 2-12 mm. If the length of the short fiber is less than 1mm, the mechanical properties of the polyaramide paper will be reduced. On the other hand, if the length is 25mm or more, when the polyaramide paper is produced by the wet method described later, "interlacing" is likely to occur. "End" and so on, and easily become the cause of the defect.

(Polyaramide paper)

In the present invention, the polyaramide paper is a sheet mainly composed of the polyaramide fibrids and polyaramide short fibers, and generally has a thickness in the range of 20 μm to 1000 μm. Preferably it is 25 to 500 μm. Furthermore, polyaramide paper generally has a weight per unit area in 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 polyaramide fibrids and polyaramide staple fibers can be arbitrarily determined, and it is preferable to set the ratio (mass ratio) of polyaramide fibrids/polyaramide staple fibers to 1 /9-9/1, more preferably 2/8-8/2, but not limited to this range.

The polyaramide paper is generally manufactured by a method of mixing the above-mentioned polyaramide fibrids and polyaramide short fibers to form a sheet. Specifically, it is possible to use, for example, a method of forming a sheet using airflow after the above-mentioned polyaramide fibrids and polyaramide staple fibers are dry mixed; After the amine short fibers are dispersed and mixed in a liquid medium, they are spit out to a liquid-penetrating support, such as a net or a ribbon, to form a sheet, and then remove the liquid to dry it. However, these methods are Among them, it is preferable to select the so-called wet papermaking method using water as a medium.

In the wet papermaking method, an aqueous slurry containing at least a single or a mixture of polyaramide fibrids and polyaramide staple fibers is generally sent to a paper machine and dispersed, followed by dehydration, squeezing and drying. Rewind as a sheet method. As the paper machine, a Fourdrinier paper machine, a cylinder paper machine, an inclined paper machine, a hybrid paper machine combining these, and the like can be used. In the case of manufacturing with a composite paper machine, by forming a sheet of slurries with different blending ratios and combining them into one, a composite sheet composed of a plurality of paper layers can be obtained. In papermaking, additives such as dispersibility enhancers, defoamers, and paper strength enhancers can be used according to the needs.

As described above, the obtained polyaramide paper is heated and pressurized between a pair of rollers at high temperature and high pressure, thereby improving the density and mechanical strength. The conditions of the heating and pressing process, when a metal roll is used, for example, a temperature of 100°C to 400°C and a linear pressure of 50 to 400 kg/cm can be exemplified, but are not limited to these conditions. During hot pressing, multiple polyaramide papers can also be laminated. In addition, the above-mentioned heating and pressing processing may be performed multiple times in any order.

(Insulation sheet)

In the present invention, the insulating sheet refers to a sheet having electrical insulation. The insulating sheet preferably has ^{a volume resistivity of 1×10 10} to 1×10 ²⁰ Ω·cm, and more preferably has a volume resistivity of 1×10 ¹² to 1×10 ²⁰ Ω·cm. The polyaramide paper monomer may include, for example, a polyaramide-resin film laminate formed by laminating the polyaramide paper and a resin film, and then using an adhesive or the like, or by melting and pressing the resin out The sheet formed on the polyaramide paper.

Examples of the resin film used in the polyaramide-resin film laminate include: polyethylene terephthalate, polyethylene naphthalate, polyamide, aromatic polyamide, and polyamide Amine, polytetrafluoroethylene, polyphenylene sulfide, etc. These can be used alone, and resins or copolymers in which two or more kinds are mixed can also be used. In addition, as an adhesive used to laminate polyaramide paper, any adhesive commonly used in this technical field can be used, and examples include epoxy-based, acrylic-based, phenol-based, urethane-based, and silicone-based adhesives. Adhesives such as resin-based, polyester-based, and amide-based adhesives, but are not limited to these.

In the case of laminating the polyaramide paper with the above-mentioned film using an adhesive, the film is generally stretched. However, in the case of manufacturing insulating parts by the method described later, the polyaramide-resin film laminate is likely to be caused by shrinkage. Therefore, when the deformation must be suppressed as much as possible, it is better to use the film made by melting the polymer in advance and the polyaramide paper to overlap, then heat and press, and then melt and impregnate the polymer in The method in the polyaramide paper, or the method of melting and pressing the resin onto the polyaramide paper to heat it, etc., directly laminate the resin on the polyaramide paper sheet without passing through the adhesive.

The number of layers of the laminate can be appropriately selected according to the use and purpose of the laminate. However, if the polyaramide paper is arranged on at least one side of the surface layer, its smoothness becomes better, and it is easy to insert the above-mentioned insulating member in the motor. The effect of the groove of the core material is therefore better. For example, the method described in JP 2006-321183, the resin is melted and pressed onto the polyaramide paper, and the method is made by heat fusion. It is made of an aromatic polyamide resin and an epoxy resin in the molecule. A two-layer laminated sheet of polymer and polyaramide paper, or polyarylene, composed of epoxy group-containing phenoxy resin, and the ratio of the epoxy group-containing phenoxy resin is 30-50% by mass Amine paper, a 3-layer laminated sheet of the polymer and polyaramide paper, but not limited to these.

The thickness, weight per unit area (basis weight) and density of the insulating sheet can be appropriately selected according to the size of the core material, groove shape, application, and purpose. Any thickness can be selected as long as there is no problem with the folding processability. Generally speaking, from the viewpoint of workability, it is 50 μm to 1000 μm, preferably 50 μm to 500 μm, more preferably 70 to 300 μm, but it is not limited to this. In addition, the weight per unit area is preferably 30 to 1000 g/m ² , more preferably 50 to 750 g/m ² . The density is preferably 0.1 to 2.5 g/cm ³ , more preferably 0.5 to 2.0 g/cm ³ .

(Resin molded body)

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

The resin composition used in the resin molded body of the present invention is preferably a resin having an amide bond alone or containing the resin. Examples of resins having an amide bond include: polyamide 6, polyamide 66, polyamide 612, polyamide 11, polyamide 12, copolymerized polyamide, polyamide MXD6, polyamide 46. Polyamide resins such as methoxymethylated polyamide, semi-aromatic polyamide, etc., alone or a mixture of these. Here, as the semi-aromatic polyamide, a polyamide composed of an aromatic dicarboxylic acid component and a diamine component having a linear aliphatic diamine having 4 to 10 carbon atoms is exemplified. Examples of such semi-aromatic polyamides include: "ZYTEL (registered trademark) HTN501" manufactured by DuPont, a polyamide resin produced by the ternary polymerization of hexamethylene diamine, 2-methylpentane diamine, and terephthalic acid. Etc., but not limited to this. Or a polymer containing a polyamide resin composition shown in JP 2006-321951, or a mixture of these, or a mixture of the polymer and an inorganic substance such as glass fiber. Here, as the polymer, it is composed of an aromatic polyamide resin and an epoxy-containing phenoxy resin having an epoxy group in the molecule, and contains 30-50% by mass of the epoxy-containing benzene Polyamide resin composition made of oxy resin. In particular, a molded body of a mixture of a semi-aromatic polyamide and glass fiber has high heat resistance and is therefore preferable. Examples of such a mixture include "ZYTEL (registered trademark) HTN51G, 52G" of DuPont, but it is not limited to these.

In the present invention, the resin composition used in the resin molded body has insulating properties, and the resin molded body formed from the resin composition preferably has a volume resistivity of ^{1×10 10} to 1×10 ^{20 Ω·cm} , And more preferably have a volume resistivity of ^{1×10 12} to 1×10 ^{20 Ω·cm.}

In the present invention, as the resin composition having such insulating properties, it is preferable to be the above-mentioned resin having an amide bond alone or to include the resin.

The thickness of the resin molded body is preferably 100 to 5000 μm, more preferably 500 to 2000 μm.

(Method of manufacturing insulating parts)

The manufacturing method of the insulating part of the present invention can use the following manufacturing method: use the above-mentioned insulating sheet to form the shape as shown in the fourth figure, and then arrange it in a mold so that the melted resin composition and the folded portion 3 The side of the center facing the groove portion is in contact with each other to perform injection molding, thereby forming a flange-shaped core end portion 6 where the bent portion 3 and the resin molded body 5 are bonded.

As shown in the first figure, in the case of forming a part of the end face of the core part exposed on the surface of the insulating sheet, it is arranged so that the folded part 3 is in contact with the mold to fix the insulating sheet 7, and then the resin is molded by injection molding. The composition is filled in the notch part (the bottom of the U-shaped side) of the folded part 3, and the folded part 3 and the resin molded body 5 can obtain a core end face 6 with a slightly U-shaped surface.

As shown in the second figure, in order to obtain the insulating part whose surface of the insulating sheet is completely covered by the resin molded body, the following method can be cited: after forming the insulating member 1 of the first figure, injection molding is additionally performed to obtain the resin molded body 50; Alternatively, a hole is formed so that the surface of the folded portion 3 of the insulating sheet 7 does not contact a mold, and the resin molded body 50 is formed by one-shot injection molding, but it is not limited to these methods. In the second figure, although a part of the side surface (front side) of the folded portion 3 is exposed, it may have a structure that completely covers the side surface. At this time, as a method of fixing the position of the bent portion 3 in the end face of the core, for example, a pluggable pin is pressed against the bent portion 3 in a mold to temporarily fix the bent portion 3, and then during injection molding ( In the process of filling the resin composition) the method of removing pins and the like, but it is not limited to this. The injection molding is performed as described above to form the end portion of the core portion where the insulating sheet and the resin molded body are bonded, and the insulating member of the present invention can be obtained.

Since only the insulating sheet constitutes the groove portion, the thickness of the groove portion in the insulating member of the present invention is the thickness of the insulating sheet. In addition, the thickness of the end portion of the core is preferably from 0.3 mm to 5 mm, more preferably from 0.4 mm to 3 mm, and still more preferably from 0.5 mm to 2 mm.

[Example]

The following examples illustrate the present invention in more detail. In addition, these examples are only examples, and do not limit the content of the present invention in any way.

[Example 1]

(Raw material preparation)

A slurry particle manufacturing apparatus (wet precipitator) composed of a combination of a stator and a roller described in JP-A-52-15621 was used to manufacture fibrids of polymetaphenylene diamine. Treat it with a crusher and a beater, and adjust the length-weighted average fiber length to 0.9mm. The filterability of the obtained fibrids was 90 cm ³ . On the other hand, meta-aramide fiber (NOMEX (registered trademark), single-thread fineness 2.2 dtex) manufactured by DuPont was cut to a length of 6 mm and used as a raw material for papermaking.

(Manufacturing of polyaramide paper)

The polyaramide fibrids and polyaramide short fibers prepared as described above were dispersed in water to prepare a slurry. After mixing these slurries with polyaramide fibrids and polyaramide staple fibers at a blending ratio (weight ratio) of 1/1, they are produced ^{with a TAPPI type hand machine (cross-sectional area of 625 cm 2)} Flakes. Then, it was heated and pressurized at a temperature of 330°C and a linear pressure of 300 kg/cm using a metal calender roll to obtain polyaramide paper.

Furthermore, polyaramide paper and polyethylene naphthalate film (manufactured by Teijin DuPont Film Co., Ltd., "TEONEX (registered trademark) Q51", thickness 100μm) were bonded together with an adhesive to obtain polyaramide A polyaramide-resin film laminate composed of a three-layer structure of polyaramide paper/polyethylene naphthalate film/polyaramide paper in which the paper is arranged on the outside.

(Manufacture of insulating parts)

Use the above-mentioned polyaramide-resin film laminate and cut it as shown in the third figure. After cutting the dotted line part of the third figure, fold the chain line part, which is slightly vertical when viewed from the front, and then follow the groove The shape of the groove folds the dotted line to obtain a three-dimensional insulating sheet. Using this insulating sheet and a semi-aromatic polyamide (“ZYTEL (registered trademark) HTN51G35EF” manufactured by DuPont Co., Ltd.) as a resin composition, injection molding was performed under the conditions shown in Table 1 to form a bond between the insulating sheet and the resin composition The end face of the core is obtained as an insulating part in the shape shown in the first figure. The distance from the junction of the groove part and the end face of the core to the edge of the end face of the core is 10mm, and the thickness of the end face of the core is 1mm. . The main characteristic values of the insulating parts thus obtained were evaluated by the following methods. The results are shown in Table 1. [test methods]

(1) Weight per unit area, thickness, density

It is implemented in accordance with JIS C 2300-2, and the density is calculated by (weight per unit area/thickness).

(2) Appearance of insulating sheet

Regarding the appearance of the insulating sheet, visually observe the degree of warpage caused by the heat during molding. Those with no warpage are judged as "good", those with a little warpage are judged as "substantially good", and those with obvious warping are judged Is "bad".

(3) Adhesion

With respect to the end face of the core of the insulating component, from the upper part of the U-shape, make a cut with a depth of 1 mm along the interface between the insulating sheet and the resin molded body, and peel off the insulating sheet and the resin molded body from the cut portion. The surface of the resin molded body after peeling was observed visually. If the paper layer on the surface of the insulating sheet remains on the surface of the resin molded body is judged as "good", the paper material on the surface of the insulating sheet is judged as "substantially good", and the paper material with no insulating sheet left at all is judged as " bad".

[Example 2]

Using the polyaramide paper obtained in Example 1, a semi-aromatic polyamide resin composition having 50% by weight of epoxy-containing phenoxy resin (using 50 parts by weight of ZYTEL (registered trademark) manufactured by DuPont) HTN501, 50 parts by weight of epoxy group-containing phenoxy resin, a semi-aromatic polyamide resin composition prepared by the method described in JP 2006-321183 A [0027], according to JP 2006- According to the method described in [0024] of 321183 Gazette, the polyaramide paper is arranged on the outside to obtain a laminated sheet having a three-layer structure of polyaramide paper/resin composition/polyaramide paper. Using this laminated sheet, in the same manner as in Example 1, an insulating member having the shape shown in the first figure was obtained. In the same manner as in Example 1, the main characteristic values of the insulating member thus obtained were evaluated. The results are shown in Table 1.

[Example 3]

Except changing the insulating sheet to polyaramide paper having the characteristics shown in Table 1, it was implemented in the same manner as in Example 1, and an insulating member having the shape shown in the first figure was obtained. In the same manner as in Example 1, the main characteristic values of the insulating member thus obtained were evaluated. The results are shown in Table 1.

Table 1

From the results of Table 1, the insulating member of the present invention also has a homogeneous appearance, and the thickness of the end face of the core is as small as 1 mm in the examples, that is, even if it is embedded in the stator core, the end protruding can be suppressed. Therefore, the insulating member of the present invention can suppress the length in the axial direction compared with a general rotating electric machine, and it is expected that the rotating electric machine using the insulating member can be reduced in size, efficiency, and output.

From the comparison of Examples 1 to 3, it can be seen that by using a polyaramide paper monomer composed of polyaramide fibrids and polyaramide staple fibers, and melting and pressing the resin out of the polyaramide paper monomer The group formed by the sheets formed on the polyaramide paper can suppress the warpage caused by heat during molding, and can present a better appearance.

1‧‧‧Insulation component 10‧‧‧Insulation component 2‧‧‧Groove 3‧‧‧Folding part 3a‧‧‧Side folding part 3b‧‧‧Bottom folding part4 ‧‧‧Resin molded body 50‧‧‧Resin molded body 6‧‧‧Core end face 7‧‧‧Insulation sheet 7a‧‧‧Insulation sheet chain part 7b‧‧‧Insulation sheet end 7c‧‧‧Insulation sheet end Intersection point with dotted line part 7d‧‧‧Intersection point of chain line part and dotted line part of insulating sheet

The first figure is a perspective view showing an insulating member according to an embodiment of the present invention.

The second figure is a perspective view of an insulating member according to another embodiment of the present invention.

The third figure is a front view of the insulating sheet used in one embodiment of the present invention.

The fourth figure is a perspective view when the insulating sheet of the third figure is folded (before adhering the resin molded body).

1‧‧‧Insulation parts

2‧‧‧Groove

3‧‧‧Folding part

3a‧‧‧Side bending part

3b‧‧‧Bottom fold

4‧‧‧Substrate

5‧‧‧Resin molding

6‧‧‧Core end face

Claims (11)

An insulating component, which is installed in a groove formed on the inner peripheral surface of a stator core, is characterized by comprising: a base material, which is formed by one insulating sheet, has a groove portion covering the inside of the groove, and is arranged in the groove At least one end of the groove portion in the axial direction and a bent portion extending slightly perpendicularly outward from the groove portion; and a resin molded body that is mounted in close contact with the bent portion; the resin molded body is provided in the bent portion Looking at the surface of the sheet material facing the groove portion, and viewing from the side of the folded portion of the insulating sheet that does not face the sheet surface of the groove portion, the insulating sheet is exposed on the surface of the end face of the core portion; or The resin molded body is provided to cover the folded portion from above and below. For example, the insulating component of claim 1 in the scope of the patent application, in which the insulating sheet of the bent portion is cut with the bent portion of the groove viewed from the axial direction as the starting point. For example, the insulating component of claim 1 or 2 in the scope of the patent application, wherein the two ends of the insulating sheet are bent slightly perpendicular to the groove portion. For example, the insulating component of any one of claims 1 or 2 in the scope of the patent application, wherein the folded portion and the resin molded body are closely adhered without using an adhesive. For example, the insulating component of claim 1 or 2 in the scope of patent application, wherein the insulating sheet is selected from polyaramide paper composed of polyaramide fibrids and polyaramide short fibers, the polyaramide paper and resin A polyaramide-resin film laminate formed by film lamination, and a group consisting of sheets formed on the polyaramide paper by melting and pressing the resin. For example, the insulating part of claim 1 or 2 in the scope of the patent application, wherein the resin molding system is formed by a polymer having an amide bond; the surface of the insulating sheet in contact with the resin molding is made of polyaramide fibrids and polyaramide Polyaramide paper composed of amine short fibers. A method of manufacturing an insulating component, wherein the insulating component is installed in a groove formed on the inner peripheral surface of the stator core, and is characterized in that the bent portion corresponding to the insulating sheet is viewed from the axial direction as one of the curved portions of the groove Position, cut in the axial direction, fold it to make it slightly perpendicular to the groove part of the insulating sheet, then fold it along the groove shape, and fill the insulation with the molten resin composition by injection molding In the folded part of the sheet, the surface of the sheet facing the groove part is formed, thereby forming a flange-like core end face. Viewed from the side of the folded part of the insulating sheet that does not face the sheet surface of the groove part, insulation The sheet is exposed on the surface of the end face of the core. A method of manufacturing an insulating component, wherein the insulating component is installed in a groove formed on the inner peripheral surface of the stator core, and is characterized in that the bent portion corresponding to the insulating sheet is viewed from the axial direction as one of the curved portions of the groove Position, cut in the axial direction, fold it to make it slightly perpendicular to the groove part of the insulating sheet, then fold it along the groove shape, and fill the insulation with the molten resin composition by injection molding The folded part of the sheet faces the surface of the sheet facing the groove part to form a flange-like core end face. When viewed from the side of the folded part of the insulating sheet that does not face the surface of the sheet facing the groove part, After the insulating sheet is the exposed core end surface, injection molding is used to fill the molten resin composition to the exposed core end surface of the insulating sheet to form a flange-shaped core in which the insulating sheet is completely covered by the resin molded body End face. A motor having a core part of a coil wound in a groove provided with an insulating member as in any one of claims 1 to 6 of the scope of the patent application on the inner peripheral surface. A generator with a core part of a winding coil in a groove provided with an insulating member as in any one of claims 1 to 6 in the scope of the patent application on the inner circumference. A rotary electric machine, which has a core part of a coil wound in a groove provided with an insulating member as in any one of claims 1 to 6 in the scope of the patent application.

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