US20070031646A1 - Molded product and manufacturing method thereof - Google Patents

Molded product and manufacturing method thereof Download PDF

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Publication number
US20070031646A1
US20070031646A1 US11/497,338 US49733806A US2007031646A1 US 20070031646 A1 US20070031646 A1 US 20070031646A1 US 49733806 A US49733806 A US 49733806A US 2007031646 A1 US2007031646 A1 US 2007031646A1
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United States
Prior art keywords
metal plates
melting point
sheet material
polymer
molded product
Prior art date
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Abandoned
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US11/497,338
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English (en)
Inventor
Takanori Yamazaki
Naofumi Chiwata
Takenori Taki
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Hitachi Cable Ltd
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Hitachi Cable Ltd
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Publication date
Application filed by Hitachi Cable Ltd filed Critical Hitachi Cable Ltd
Assigned to HITACHI CABLE, LTD. reassignment HITACHI CABLE, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHIWATA, NAOFUMI, TAKI, TAKENORI, YAMAZAKI, TAKANORI
Publication of US20070031646A1 publication Critical patent/US20070031646A1/en
Priority to US12/768,794 priority Critical patent/US8568547B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14221—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure by tools, e.g. cutting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/206—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly
    • Y10T156/1044—Subsequent to assembly of parallel stacked sheets only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/239—Complete cover or casing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • the present invention relates to a molded product and a method of manufacturing the same, in which surroundings of each of metal bodies spaced at a constant interval is covered with insulating polymer to insulate plural metal plates electrically.
  • the technique by which metal bodies are covered with a molded part comprised of insulating polymer is generally used to secure the reliability over the long term when insulating between metal bodies of relatively high average electric field strength of hundreds of V/mm or more with insulating polymer.
  • the technique by which insulating polymer is injection-molded or extrusion-molded to obtain a target shape with the part to be exposed of metal bodies held is most frequently used.
  • metal plates 101 , 102 which have plural terminal parts 101 a , 102 a are coated with molded part 103 in usual molded product 100 .
  • Terminal parts 101 a and 102 a of metal bodies 101 , 102 can be exposed from molded part 103 .
  • metal bodies 101 , 102 are spaced at specified intervals and insulated to each other.
  • Metal bodies 101 , 102 are set in cavity 113 of injection molding die 110 as shown in FIG. 11 , and fixed in cavity 113 with terminal part 101 a , 102 a placed between upper dies 111 and lower dies 112 . Afterwards, molten resin 116 is supplied to cavity 113 from at least one shooting head 115 connected fluidly thereto. After the supply of molten resin 116 is completed, molded part 103 is formed by cooling molten resin 116 to solidify, and molded product 100 shown in FIG. 10 is obtained.
  • metal bodies 101 , 102 are difficult to hold metal bodies 101 , 102 when tried to insulate relatively thin metal plates 101 , 102 spaced at specified intervals, and cover the outside of metal bodies 101 , 102 with molded part 103 .
  • metal bodies 101 , 102 are transformed by the pressure of injected molten resin 116 , and the homogeneity of clearance 105 is lost.
  • the homogeneity of clearance 105 is lost, the electric field concentrates on the part with a narrow interval, the defect part of the insulation structure when the voltage is applied to metal bodies 101 , 102 . As a result, long-term reliability of the article is spoiled
  • an object of the present invention is to provide a molded product and a method of manufacturing the same, in which the insulating layer of uniform thickness is formed in a narrow clearance between plural metal bodies.
  • the present invention in one aspect resides in a molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically comprises a spacer polymer arranged between said metal plates, which consists of insulating polymer whose melting point is T 1 , and a molded part, which covers surroundings of said metal plates and said spacer polymer, and consists of insulating polymer whose melting point is T 2 ( ⁇ T 1 ).
  • the principal ingredient of said insulating polymer of melting point T 1 is aromatic polymer, and the principal ingredient of said insulating polymer of melting point T 2 is polyolefine.
  • the bonding layer composed of the adhesive that melting point T 3 is in the relation of T 3 ⁇ T 1 is provided between said metal plates and said spacer polymer, and between said metal plates and said molded part.
  • the first and second bonding layers composed of the adhesive that melting point T 3 is in the relation of T 3 ⁇ T 1 are provided between said metal plates and said spacer polymer, and between said metal plates and said molded part, respectively, and each adhesive which composes said first and second bonding layers has high compatibility.
  • the present invention resides in a method of manufacturing a molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically, comprises the steps of arranging a first sheet material composed of insulating polymer whose melting point is T 1 between said metal plates spaced at specified intervals, arranging a second sheet material composed of insulating polymer whose melting point is T 2 ( ⁇ T 1 ) outside of the outermost metal plates, hot-pressing molding a laminate of the metal plates, the first sheet material, and the second sheet material at a temperature higher than T 2 but lower than T 1 , melting the second sheet material while securing the interval between the metal plates by the first sheet material, and covering the surroundings of the metal plates and the first sheet material with the molded part composed of insulating polymer whose melting point is T 2 .
  • the present invention resides in a method of manufacturing a molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically, comprises the steps of arranging a first sheet material composed of insulating polymer whose melting point is T 1 between said metal plates spaced at specified intervals, arranging a laminate of the metal plates and the first sheet material in the cavity of the injection mold, injecting insulating polymer whose melting point is T 2 ( ⁇ T 1 ) heated and melted at a temperature higher than T 2 but lower than T 1 into the cavity, and covering the surroundings of the metal plates and the first sheet material with the molded part composed of insulating polymer whose melting point is T 2 while securing the interval between the metal plates by the first sheet material.
  • a plurality of said first sheet materials are arranged between the metal plates.
  • the method of manufacturing a molded product further comprises the steps of providing as one first bonding layers and second bonding layers which consist of adhesive whose melting point T 3 is in the relation of T 3 ⁇ T 1 on surfaces of the first sheet material and surfaces on the metal body sides of the second sheet materials, respectively, and after hot-pressing molding, bonding the first sheet material to said metal plates by the first bonding layers, and said molded part to said metal plates by the second bonding layers.
  • each adhesive which composes the first bonding layer and the second bonding layer has compatibility, and the first bonding layer are bonded to the second bonding layer.
  • the method of manufacturing a molded product further comprises the steps of providing as one first bonding layers which consist of adhesive whose melting point T 3 is in the relation of T 3 ⁇ T 1 on surfaces of the first sheet material, and after hot-pressing molding, bonding the first sheet material to said metal plates by the first bonding layers.
  • Plural metal plates can be coated with insulating polymer according to the present invention. Moreover, it is possible to insulate between plural metal plates by a thin and uniform insulating layer.
  • FIG. 1 is a sectional view of the spacer polymer sheet used for a manufacturing method of the molded product according to a preferred embodiment of the present invention.
  • FIG. 2 is a sectional view of mold polymer sheet used for a manufacturing method of the molded product according to a preferred embodiment of the present invention.
  • FIG. 3A and FIG. 3B are structural drawings of the molded product according to a preferred embodiment of the present invention.
  • FIG. 3A is a plan view
  • FIG. 3B is a sectional view taken along the line 3 B- 3 B of FIG. 3A .
  • FIG. 4 is a view showing the lamination state of a laminate used to manufacture the molded product according to a preferred embodiment of the present invention.
  • FIG. 5 is a view showing the state where the laminate of FIG. 4 is arranged between hot pressing plates of a hot pressing machine.
  • FIG. 6 is a view showing the state where the hot pressing mold was performed to the laminate of FIG. 5 .
  • FIG. 7 is a sectional view of a first modification of FIG. 6 .
  • FIG. 8A and FIG. 8B are views showing the modification of the frame body used for a manufacturing method of the molded product according to a preferred embodiment of the present invention.
  • FIG. 8A is a plan view
  • FIG. 8B is a view seen from a direction of arrow 8 B of FIG. 8A .
  • FIG. 9 is an explanatory drawing of a manufacturing method of the molded product according to another preferred embodiment of the present invention.
  • FIG. 10A , FIG. 10B and FIG. 10C are structural drawings of a general bus bar.
  • FIG. 10A is a plan view
  • FIG. 10B is a view seen from a direction of arrow 10 B of FIG. 10A
  • FIG. 10C are a sectional view taken along the line 10 C- 10 C of FIG. 10A .
  • FIG. 11 is an explanatory drawing of the conventional manufacturing method of a molded product.
  • FIG. 3 is structural drawing of the molded product according to a preferred embodiment of the present invention.
  • FIG. 3A is a plan view
  • FIG. 3B is a sectional view taken along the line 3 B- 3 B of FIG. 3A .
  • Spacer polymer part 34 composed of insulating polymer of melting point T 1 and adhesive of melting point T 3 (T 3 ⁇ T 1 ) is provided between metal plates 31 and 32 . Surroundings of spacer polymer part 34 and metal plates 31 and 32 are covered with molded part 33 composed of insulating polymer of melting point (or softening point) T 2 ( ⁇ T 1 ). Projection parts (terminal part) 31 a and 32 a projects from molded part 33 .
  • first bonding layers 12 a , 12 b composed of the adhesive whose melting point T 3 is in the relation of T 3 ⁇ T 1 are provided as one on the surface (upper and lower sides in FIG. 1 ) of first sheet material 11 composed of insulating polymer whose melting point is T 1 to make spacer polymer sheet 10 .
  • first bonding layer can be provided only on one side of first sheet material 11 . Further, first bonding layer need not necessarily provide.
  • second bonding layer 22 composed of the adhesive whose melting point T 3 is in the relation of T 3 ⁇ T 1 is provided as one on the surface on metal body side (under face in FIG. 2 ) of second sheet material 21 composed of insulating polymer whose melting point is T 2 ( ⁇ T 1 ) to make mold polymer sheet 20 . Further, the second bonding layer need not necessarily provide.
  • laminate 40 is formed by placing spacer polymer sheet 10 between metal plates 31 and 32 , and laminating mold polymer sheet 20 on metal plates 31 and 32 so that the surface of the side of second bonding layer 22 may contact the metal sheet. At this time, the lamination is performed so that a part of metal plates 31 and 32 may protrude beyond laminate 40 .
  • the points of metal plates 31 and 32 which protrude from laminate 40 become terminal parts 31 a and 32 a .
  • a plurality of spacer polymer sheets 10 can be placed between metal plates 31 and 32 .
  • the clearance between metal plates 31 , 32 of molded product 30 described later can be freely adjusted by adjusting the number of spacer polymer sheets 10 . When the number of metal plates is three sheets or more, mold polymer sheets 20 are arranged only outside of two outermost metal plates.
  • Laminate 40 is arranged between hot pressing plates 41 and 42 of the hot pressing machine.
  • Terminal part 31 a is supported by upper dies 43 and lower dies 44 as shown in the FIG. 5 , and positioned on step part 44 a of lower dies 44 .
  • terminal part 32 a is supported by upper dies 45 and lower dies 46 , and positioned on step part 45 a of upper dies 45 .
  • At least one of hot pressing plates 41 and 42 is connected with a cylinder etc. (not shown) of an oil pressure piston, and can move freely in directions of arrows A 1 and A 2 , that is, in a direction where laminate 40 is compressed.
  • the hot pressing mold is carried out to laminate 40 at a temperature higher than T 2 , but lower than T 1 .
  • the pressure when the hot pressing mold is carried out is the pressure by which molten polymer 63 (described later), second sheet material 21 melted, can be transformed and drifted sufficiently, and is not limited to the specified value.
  • first sheet material 11 of spacer polymer sheet 10 is not melted when the hot pressing mold is carried out, and the shape is maintained. Therefore, the interval (clearance) corresponding to the thickness of first sheet material 11 can be almost secured between metal plates 31 and 32 . Moreover, this clearance becomes uniform over the direction of the surface of metal plates 31 and 32 . Further, second sheet material 21 of each mold polymer sheet 20 is melted by the hot pressing processing, and becomes molten polymer 63 . This molten polymer 63 flows so as to bury space 61 formed by hot pressing plates 41 , 42 , dies 43 , 44 , and dies 45 , 46 .
  • each adhesive which composes first bonding layers 12 a , 12 b , and second bonding layers 22 is melted partially by the hot pressing processing because melting point T 3 is less than T 1 as well as T 2 , and flowed along with molten polymer 63 .
  • Temperature T 3 can be either one of T 3 ⁇ T 2 and T 3 ⁇ T 2 .
  • Metal plate article 30 shown in FIG. 7 is obtained by molten polymer 63 spread in space 61 being cooled, and being solidified.
  • First sheet material 11 and each of metal plates 31 , 32 are bonded through remaining first bonding layers 12 a and 12 b .
  • the major part of molding sides (under face in FIG. 7 ) of metal plate 31 and molded part 33 , and the major part of molding sides (top face in FIG. 7 ) of metal plate 32 and molded part 33 are bonded through remaining second bonding layers 22 .
  • Spacer polymer part 34 comprises first sheet material 11 and remaining first bonding layers 12 a and 12 b . When the first bonding layer is not provided on first sheet material 11 , the first sheet material itself becomes spacer polymer part 34 .
  • the manufacturing of molded product 30 comes to be easy and to stabilize as the difference between the melting point of insulating polymer whose melting point is T 2 which composes first bonding layers 12 a , 12 b and that of insulating polymer whose melting point is T 1 which composes second bonding layers 22 becomes large.
  • Polymer material which contains aromatic polymer as a principal ingredient is suitable for insulating polymer whose melting point is T 1 .
  • polymer material or various elastomers which contains polyolefine as a principal ingredient is suitable for insulating polymer whose melting point is T 2 .
  • the first polymer which has first adhesion mechanism by which strong bonding for the aromatic polymer material is obtained is used for insulating polymer whose melting point is T 1 .
  • the second polymer which has second adhesion mechanism by which strong bonding for the metallic material is obtained is used for insulating polymer whose melting point is T 2 . It is more desirable that each polymer has high compatibility.
  • first bonding layers 12 a , 12 b , and second bonding layers 22 are adjacent. At this time, first bonding layers 12 a , 12 b , and second bonding layers 22 are strongly bonded when first polymer and second polymer have high compatibility, and metal plates 31 , 32 , and first sheet material 11 can be bonded more strongly consequently.
  • styrenic elastomer which has styren block with high compatibility with aromatic polymer is used as an adhesive.
  • the styren block part and the aromatic polymer in the adhesive are melted into each other when the adhesive and the aromatic polymer material are heated and pressurized.
  • the aromatic polymer means polymer which has an aromatic ring in the principal chain.
  • PPE polyphenylene ether
  • PEI polyetherimide
  • PC polycarbonate
  • polyether sulphone polyimide
  • polyphenylene sulfide polysulfone
  • polyether ketone polyether ketone
  • styrenic elastomer which has the styren block styrene ethylene butylene styrene copolymer (SEBS), styrene ethylene propylene styrene copolymer (SEPS), diblock copolymer such as styrene butylene styrene copolymer (SBS), diblock copolymer such as styrene butadiene rubber hydrogenised can be used.
  • SEBS styrene ethylene butylene styrene copolymer
  • SEPS styrene ethylene propylene styrene copolymer
  • diblock copolymer such as styrene butylene styrene copolymer (SBS)
  • diblock copolymer such as styrene butadiene rubber hydrogenised
  • the epoxy radical part or the acid radical part of polymer produces hydrogen bond with the water molecule or the oxide of the metal surface by using the acid-modified or epoxy-modified polymer as an adhesive.
  • Maleic acid modification in the acid modification of polymer is typical acid -modification.
  • elastomer polyethylene (PE) such as SBS, SEBS, polyisobutylene (PIB), etc.
  • polymer of olefinic system such as polypropylene as acid-denaturated polymer.
  • Spacer polymer part 34 which is a thin insulating layer can be uniformly formed by coating molded part 33 with spacer polymer sheet 10 arranged between metal plates 31 and 32 according to a manufactu ring method of a molded product according to this embodiment.
  • the formation of this spacer polymer 34 is influenced by neither the size of the areas of metal plates 31 and 32 nor the size of the clearance between metal plates 31 and 32 .
  • the thickness of spacer polymer 34 that is, the clearance between metal plates 31 and 32 is uniform in a direction of the surface of the metal plates.
  • molded part 33 and spacer polymer part 34 of the molded product according to this embodiment are formed not by the injection molding like the conventional manufacturing method shown in the FIG. 11 but by the hot pressing mold.
  • molded part 33 and spacer polymer part 34 can be manufactured by using simple frame body composed of dies 43 , 44 , dies 45 , 46 and hot pressing plates 41 , 42 shown in FIG. 6 . Namely, an expensive dies for an injection molding need not be used. Therefore, molded product 30 can be manufactured cheaply.
  • the shape and the thickness of second sheet material 21 used to manufacture molded product 30 according to this embodiment are adjusted for the volume to increase more than at least necessary amounts of the volume only by 10-40% in consideration of the volume of final molded part 33 .
  • the shape and the thickness of second sheet material 21 are adjusted so that the amount of the overflow of molten polymer 63 may be 10% to 40% of the actual amount of volume of molded part 33 .
  • the shape reproducibility of molded part 33 can be improved by taking the amount of the overflow of molten polymer 63 enough.
  • metal plates 31 and 32 are coated with molded part 33 , the bond strength between metal plates 31 , 32 and molded part 33 , that is, the magnitude of peel strength between metal plates 31 , 32 and molded part 33 becomes a main factor which determines the insulation performance of molded product 30 . Therefore, metal plates 31 , 32 and molded part 33 are bonded through the adhesive in molded product 30 according to this embodiment.
  • the bonding layers are formed on the surfaces of first sheet material 11 and second sheet material 21 , the surfaces of metal plates 31 , 32 or the surfaces of first sheet material 11 , second sheet material 21 , and metal plates 31 , 32 beforehand. As a result, metal plates 31 , 32 and molded part 33 can be bonded uniformly and strongly. It is possible to maintain excellently the insulation performance of molded product 30 over a long period of time.
  • the bond strength of adhesive of insulating polymer whose melting point is T 2 and metal plates 31 , 32 can be freely adjusted by adjusting an amount of the acid modification (or, epoxy modification) of acid modification (or, epoxy modification) polymer.
  • the bond strength of adhesive of insulating polymer whose melting point is T 1 and first sheet material 11 can be freely adjusted by adjusting an amount of the styrene in the styren block part of styrenic elastomer.
  • molded product 30 according to this embodiment is suitable for a mold type power supply bus bar.
  • molded part 33 is formed by using frame body composed by hot pressing plates 41 , 42 , dies 43 , 44 , and dies 45 , 46 in this embodiment as shown in FIG. 6
  • the present invention is not limited to such structure.
  • Lower metal frame 81 corresponds to the one that hot pressing plate 42 , and lower dies 44 , 46 are integrated, and mold polymer sheet 20 , metal plate 31 , and spacer polymer sheet 10 are accommodated in space part 82 of lower metal frame 81 .
  • upper metal frame corresponds to the one that hot pressing plate 41 and upper dies 43 , 45 are integrated, and metal plate 32 and mold polymer sheet 20 are accommodated in the space part of the upper metal frame.
  • the molded part is formed by the hot pressing process.
  • the molded part is formed by an injection molding process in the manufacturing method of a molded product according to this embodiment.
  • spacer polymer sheet 10 is made by providing first bonding layers 12 a , 12 b composed of the adhesive whose melting point T 3 is in the relation of T 3 ⁇ T 1 on the surfaces (upper and lower surfaces in FIG. 1 ) of first sheet material 11 composed of insulating polymer whose melting point is T 1 first shown in FIG. 1 .
  • laminate 97 shown in FIG. 9 is formed by placing spacer polymer sheet 10 between metal plated 31 and 32 and laminating them. At this time, the lamination is performed so that a part of metal plates 31 , 32 may protrude beyond the laminate 97 . Points of metal plates 31 , 32 which protrude beyond laminate 97 forms terminal parts 31 a , 32 a . Further, optionally, it is possible to place a plurality of spacer polymer sheets 10 between metal plates 31 and 32 . The clearance between metal plates 31 and 32 as described later can be freely adjusted by adjusting the number of spacer polymer sheets 10 to be placed.
  • first bonding layers 12 a , 12 b is melted, and metal plates 31 , 32 and first sheet material 11 are bonded through first bonding layers 12 a , 12 b .
  • bonded laminate 97 is set in cavity 93 of injection molding dies 90 .
  • Metal plates 31 and 32 are fixed in cavity 93 with terminal parts 31 a , 32 a placed between upper dies 92 and lower dies 91 .
  • molten polymer 96 is supplied to cavity 93 from at least one injection head 95 connected fluidly to cavity 93 .
  • Molten polymer 96 is the polymer made by heating insulating polymer whose melting point is T 2 ( ⁇ T 1 ) at a temperature higher than T 2 but lower than T 1 and melting it.
  • First sheet material 11 of spacer polymer sheet 10 does not melt at this injection molding processing, and thus its shape is maintained. Therefore, the interval (clearance) for the thickness of first sheet material 11 is almost secured between metal plates 31 and 32 . This clearance becomes uniform over a direction of the surfaces of metal plates 31 , 32 . Further, molten polymer 96 flows so as to fill in the space of cavity 93 . Moreover, a part of the adhesive which composes first bonding layers 12 a , 12 b melts by the temperature at the injection molding processing because melting point T 3 is in the relation of T 3 ⁇ T 1 , and flows along with molten polymer 96 .
  • Molded product 30 in which surroundings of metal plates 31 , 32 and first sheet material 11 are covered with molded part 33 is obtained by molten polymer 96 spread in cavity 93 being cooled, and being solidified. First sheet material 11 and metal plates 31 , 32 are bonded through remaining first bonding layers 12 a , 12 b.
  • the molded part is formed by an injection molding process, an expensive injection molding dies is needed, differing from the manufacturing method of a molded product according to the above-mentioned embodiment.
  • the mold coating is performed to laminate 90 of at least three-layer structure, mold polymer sheet 20 shown in FIG. 2 is not needed. Therefore, the formation process of the laminate can be simplified compared with the manufacturing method of a molded product according to the previous embodiment in which laminate 40 of at least five layer-structure is coated with molding material.
  • Lap width L was 210 mm and the clearance between sheet coppers was 0.4 mm as shown in FIG. 3B , and the molding area (240 mm ⁇ 250 mm) which includes the lap area was coated with molding.
  • PPE sheet (Asahi Kasei Corporation, Zairon 540Z, and thickness t is 0.4 mm) where the heat-hardening bonding layer had been spread on both sides as shown in FIG. 1 was prepared.
  • the sheet was cut into the size (220 mm ⁇ 230 mm) whose length and breadth is 10 mm larger than the lap area of two sheet coppers.
  • flame-resistant PE resin sheet (UBE INDUSTRIES, LTD. Z555, and thickness t is 2.5 mm) which the hot melt adhesive layer was spread on one side as shown in FIG. 2 was prepared.
  • the flame-resistant PE resin sheet was cut (220 mm ⁇ 230 mm ⁇ 2.5 mm) so that the volume of two flame -resistant PE resin sheet may become more than the value obtained by subtracting the volume of the sheet copper and the PPE sheet from the volume of the molded product of 240 mm ⁇ 250 mm ⁇ 5 km. Further, a frame body composed of lower metal frame 81 shown in FIG. 8 and an upper metal frame which makes couple with lower metal frame 81 was prepared.
  • the laminate piled up in order of a flame-resistant PE resin sheet, a resin sheet, a PPE sheet, a sheet copper, and a flame-resistant PE resin sheet was arranged in this frame body.
  • This laminate was placed between hot pressing plates together with the frame body, and it was set in hot pressing molding machine heated to 130° C. The pressure of 0.5 MPa was applied after preheating enough, and the hot pressing processing was carried out. As a result, the molded product (sample 1 ) which has the structure shown in FIG. 7 was obtained.
  • the partial discharge generation disappearance voltage was measured again after heat cycle of ⁇ 25° C. to 105° C. was repeated 100 times to this sample 1 , and the same value of 8 kV or more as one before providing the heat cycle were obtained. In a word, it was confirmed that even if the heat cycle is added, the void and flaking off are not occurred on the interface of the sheet copper and the PPE sheet, and the sheet copper and the PPE sheet are strongly bonded.
  • the laminate piled up in order of a sheet copper, a PPE sheet and a sheet copper was placed between hot pressing plates of a hot pressing molding machine, and heated to 130° C.
  • the bonding layer in the PPE sheet melted by this heating processing, and the sheet copper and the PPE sheet were bonded through the bonding layer.
  • the injection molding processing was carried out by injecting the flame-resistant PE resin melted after having arranged this laminate in cavity 93 of injection molding dies 90 . Thereby, the molded product (sample 2 ) which has the structure shown in the FIG. 7 was produced.
  • the partial discharge generation disappearance voltage was measured again after heat cycle of ⁇ 25° C. to 105° C. was repeated 100 times to this sample 2 , and the same value of 8 kV or more as one before providing the heat cycle were obtained. In a word, it was confirmed that even if the heat cycle is added, the void and flaking off are not occurred on the interface of the sheet copper and the PPE sheet, and the sheet copper and the PPE sheet are strongly bonded.
  • injection molding dies 110 shown in FIG. 11 as a frame body was prepared.
  • the injection molding processing was carried out by injecting polyphenyl ether (PPE, Asahi Kasei Corporation, Zairon 540Z) melted after arranging the sheet copper in cavity 113 of injection mold 110 in cavity 113 , and the molded product (sample 3 ) was made.
  • PPE polyphenyl ether
  • Partial discharge generation disappearance (10 pC) voltage in sample 3 was measured, and the very low value less than 1 kV or more was obtained. This molded product was cut, and the section was observed. As a result, it was confirmed that the void which affects negatively on electrical insulation had generated between sheet coppers.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
US11/497,338 2005-08-02 2006-08-02 Molded product and manufacturing method thereof Abandoned US20070031646A1 (en)

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US20110143111A1 (en) * 2009-12-16 2011-06-16 Hitachi Cable, Ltd. Insert molding method and insert molded product
EP2894731A4 (en) * 2012-09-04 2016-07-27 Nagase & Co Ltd PRODUCTION METHOD FOR RESIN FORMED MATERIALS AS BUSHING INSERT AND RESIN FORMATS AS BUSBAR INSERT
US10418730B2 (en) * 2015-03-23 2019-09-17 Furukawa Electric Co., Ltd. Cable connection structure and manufacturing method therefor
US20190331075A1 (en) * 2018-04-26 2019-10-31 Toyota Jidosha Kabushiki Kaisha Protector and method for manufacturing protector
US10907268B2 (en) 2015-05-18 2021-02-02 Suncall Corporation Method for producing multi-layer bus bar unit
DE102015208382B4 (de) 2014-05-07 2021-11-11 Kabushiki Kaisha Toyota Jidoshokki Elektrischer Kompressor

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JP5549491B2 (ja) * 2010-09-06 2014-07-16 日立金属株式会社 バスバーモジュールの製造方法、及びバスバーモジュール
KR101282627B1 (ko) * 2011-09-07 2013-07-12 현대자동차주식회사 휨 방지 플레이트를 갖는 연료전지용 엔드 플레이트
JP2019084740A (ja) * 2017-11-06 2019-06-06 株式会社デンソー 通電部材モジュール、及びその製造方法
US11646242B2 (en) 2018-11-29 2023-05-09 Qorvo Us, Inc. Thermally enhanced semiconductor package with at least one heat extractor and process for making the same
KR20210129658A (ko) 2019-01-23 2021-10-28 코르보 유에스, 인크. Rf 반도체 디바이스 및 이를 형성하는 방법
KR20210129656A (ko) 2019-01-23 2021-10-28 코르보 유에스, 인크. Rf 반도체 디바이스 및 이를 형성하는 방법
US11923238B2 (en) * 2019-12-12 2024-03-05 Qorvo Us, Inc. Method of forming RF devices with enhanced performance including attaching a wafer to a support carrier by a bonding technique without any polymer adhesive
JP7007512B1 (ja) 2021-05-31 2022-02-10 株式会社アテックス 導電部材及びその製造方法
CN115195158B (zh) * 2022-06-22 2024-04-12 北京玻钢院复合材料有限公司 制备复合材料与结构件界面压剪强度试样的模具及方法

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US20110143111A1 (en) * 2009-12-16 2011-06-16 Hitachi Cable, Ltd. Insert molding method and insert molded product
US8540917B2 (en) 2009-12-16 2013-09-24 Hitachi Cable, Ltd. Insert molding method and insert molded product
EP2894731A4 (en) * 2012-09-04 2016-07-27 Nagase & Co Ltd PRODUCTION METHOD FOR RESIN FORMED MATERIALS AS BUSHING INSERT AND RESIN FORMATS AS BUSBAR INSERT
US9843175B2 (en) 2012-09-04 2017-12-12 Atecs Corporation Method for manufacturing insert-molded bus bar, and insert-molded bus bar
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US10418730B2 (en) * 2015-03-23 2019-09-17 Furukawa Electric Co., Ltd. Cable connection structure and manufacturing method therefor
US10907268B2 (en) 2015-05-18 2021-02-02 Suncall Corporation Method for producing multi-layer bus bar unit
US20190331075A1 (en) * 2018-04-26 2019-10-31 Toyota Jidosha Kabushiki Kaisha Protector and method for manufacturing protector
CN110410253A (zh) * 2018-04-26 2019-11-05 丰田自动车株式会社 保护器及保护器的制造方法
US10907595B2 (en) * 2018-04-26 2021-02-02 Toyota Jidosha Kabushiki Kaisha Protector and method for manufacturing protector

Also Published As

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US8568547B2 (en) 2013-10-29
JP4815935B2 (ja) 2011-11-16
CN100581795C (zh) 2010-01-20
US20100206468A1 (en) 2010-08-19
JP2007038490A (ja) 2007-02-15
CN1907692A (zh) 2007-02-07

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