WO2017168880A1 - 硬化性組成物およびその硬化物ならびに回転機 - Google Patents
硬化性組成物およびその硬化物ならびに回転機 Download PDFInfo
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- WO2017168880A1 WO2017168880A1 PCT/JP2016/088053 JP2016088053W WO2017168880A1 WO 2017168880 A1 WO2017168880 A1 WO 2017168880A1 JP 2016088053 W JP2016088053 W JP 2016088053W WO 2017168880 A1 WO2017168880 A1 WO 2017168880A1
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
- C08L63/10—Epoxy resins modified by unsaturated compounds
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/226—Mixtures of di-epoxy compounds
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/24—Di-epoxy compounds carbocyclic
- C08G59/245—Di-epoxy compounds carbocyclic aromatic
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/26—Di-epoxy compounds heterocyclic
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- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/42—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/34—Heterocyclic compounds having nitrogen in the ring
- C08K5/3442—Heterocyclic compounds having nitrogen in the ring having two nitrogen atoms in the ring
- C08K5/3445—Five-membered rings
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- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/30—Windings characterised by the insulating material
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/003—Additives being defined by their diameter
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2203/00—Applications
- C08L2203/20—Applications use in electrical or conductive gadgets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
Definitions
- the present invention relates to a curable composition, a cured product thereof, and a rotating machine.
- Patent Document 1 JP-A-2006-057017 discloses a resin composition containing an epoxy resin, a curing agent for epoxy resin, a coupling agent, and inorganic particles.
- a curable epoxy resin composition is used for insulation treatment of heavy electrical equipment. For example, in a rotating machine, a mica tape wound around a coil conductor is impregnated with a curable epoxy resin composition. The curable epoxy resin composition is heated to become a cured product. Thereby, an insulating layer covering the coil conductor is formed.
- inorganic particles are not easily compatible with epoxy resins (organic materials). Therefore, in the composite material, aggregation of inorganic particles tends to occur. Furthermore, when the particle size becomes nano-order, the tendency is more remarkable. When the inorganic particles are aggregated, the inorganic particles are likely to settle. In addition, voids are easily formed around the aggregate. A void can become a starting point of partial discharge in a cured product. Therefore, in consideration of partial discharge resistance and the like, the insulation performance is still not sufficient.
- Patent Document 1 inorganic particles and an epoxy resin are bonded with a coupling agent or the like. Thereby, it is supposed that the dispersibility of an inorganic particle improves.
- the coupling agent has lower heat resistance than the epoxy resin. For this reason, when a coupling agent is used in a large amount, the heat resistance of the cured product may be lowered.
- the coupling agent is inferior to epoxy resin because of its strength of dielectric breakdown. Insulation degradation paths tend to progress through weakly insulated parts. Therefore, when the coupling agent is dispersed inside the cured product, dielectric breakdown may occur through the coupling agent. That is, when a coupling agent is used, the effect of improving the strength of dielectric breakdown due to the dispersion of inorganic particles may be offset.
- an object of the present invention is to provide a curable composition having improved insulation performance while suppressing a decrease in heat resistance.
- the curable composition (X) of the present invention contains an epoxy resin (A), a curing agent (B), a curing accelerator (C), and hydrophilic inorganic particles (D).
- the epoxy resin (A) includes a first epoxy resin (a1) and a second epoxy resin (a2).
- the first epoxy resin (a1) is a chain aliphatic epoxy resin having a hydrophilic group, and has a water content of 20% by mass to 99% by mass.
- the second epoxy resin (a2) includes at least one selected from the group consisting of cycloaliphatic epoxy resins, aromatic epoxy resins, and heterocyclic epoxy resins.
- the first epoxy resin (a1) and the hydrophilic inorganic particles (D) are both hydrophilic. Due to these interactions, the hydrophilic inorganic particles (D) are surrounded by the first epoxy resin (a1), and thus aggregation of the hydrophilic inorganic particles (D) is suppressed. That is, hydrophilic inorganic particles (D) can be dispersed without depending on the coupling agent. Therefore, it is possible to suppress a decrease in heat resistance accompanying the addition of the coupling agent. In addition, the insulation performance can be improved by the dispersion of inorganic particles.
- 1st Embodiment of this invention is curable composition (X) and its hardened
- the curable composition (X) includes an epoxy resin (A), a curing agent (B), a curing accelerator (C), and hydrophilic inorganic particles (D).
- the curable composition (X) may be thermosetting. Alternatively, the curable composition may be photocurable.
- Epoxy resin (A) is preferably 46% by volume to 98% by volume (more preferably 50% by volume to 97% by volume, even more preferably 70% by volume to 95% by volume). Included. Within this range, the balance between the insulation performance of the cured product (Y) and the mechanical properties (for example, toughness) is good.
- the epoxy resin (A) includes a first epoxy resin (a1) and a second epoxy resin (a2).
- the first epoxy resin (a1) is a chain aliphatic epoxy resin having a hydrophilic group.
- the first epoxy resin (a1) exhibits specific water solubility. That is, the first epoxy resin (a1) has a water content of 20% by mass to 99% by mass (preferably 30% by mass to 90% by mass, more preferably 40% by mass to 80% by mass, and most preferably 50% by mass. Mass% to 70 mass%).
- Water solubility means the dissolution rate (unit: mass%) of the epoxy resin in water at room temperature. That is, when the epoxy resin is dissolved in water adjusted to 25 ° C. ⁇ 1 ° C., the proportion of the epoxy resin actually dissolved in water is the water solubility. Specifically, the water solubility is measured as follows. Prepare 100 g of water adjusted to 25 ⁇ 1 ° C. While stirring the water well, the epoxy resin is gradually dropped into the water. The percentage of the value obtained by dividing the dripping amount of the epoxy resin until the mixed solution reaches a saturated state by the mass of water (100 g) is the water solubility. Whether or not it is dissolved is determined by the fact that the mixed solution is not turbid and that separation does not occur after standing.
- the water content of the first epoxy resin (a1) is less than 20% by mass, it is difficult to sufficiently disperse the hydrophilic inorganic particles (D).
- the water solubility exceeds 99% by mass, the heat resistance of the cured product (Y) may be lowered.
- the first epoxy resin (a1) is a chain aliphatic compound.
- the first epoxy resin (a1) may be linear.
- the first epoxy resin (a1) may be branched.
- the first epoxy resin has a hydrophilic group.
- the hydrophilic group is, for example, a hydroxy group, an ether group, a carboxy group or the like.
- the first epoxy resin (a1) has one or more epoxy groups in one molecule. That is, the first epoxy resin (a1) is a monovalent or polyvalent glycidyl compound.
- the first epoxy resin (a1) is preferably a glycidyl ether compound.
- the first epoxy resin (a1) is more preferably a polyglycidyl ether compound having a glycerol skeleton. When the 1st epoxy resin (a1) is these compounds, it is easy to adjust a water content rate within the limits of 20 mass% or more and 99 mass% or less.
- the first epoxy resin (a1) include, for example, ethylene glycol diglycidyl ether, diethylene glycol diglycidyl ether, triethylene glycol diglycidyl ether; polyglycidyl ether; glycerol polyglycidyl ether, diglycerol polyglycidyl ether; trimethylol.
- One of the above compounds may be used alone as the first epoxy resin (a1).
- Two or more compounds may be used in combination as the first epoxy resin (a1). That is, the first epoxy resin (a1) may be at least one selected from the above compound group.
- products that can be used as the first epoxy resin (a1) include, for example, Denacol EX-121, Denacol EX-171, Denacol EX-192, Denacol EX-211, Denacol EX-212, Denacol EX-313 , Denacol EX-314, Denacol EX-321, Denacol EX-411, Denacol EX-421, Denacol EX-512, Denacol EX-521, Denacol EX-611, Denacol EX-612, Denacol EX-614, Denacol EX-622 , Denacol EX-810, Denacol EX-811, Denacol EX-850, Denacol EX-851, Denacol EX-821, Denacol EX-830, Denacol EX-832, Denacol EX-841, Denacol X-861, Denacol EX-911, Denacol EX-941, Denacol EX-920, Denacol E
- the first epoxy resin (a1) preferably has a viscosity of 20 mPa ⁇ s to 21200 mPa ⁇ s (more preferably 20 mPa ⁇ s to 5000 mPa ⁇ s, even more preferably 40 mPa ⁇ s to 650 mPa ⁇ s, most preferably 90 mPa ⁇ s to 200 mPa ⁇ s).
- a viscosity of 20 mPa ⁇ s to 21200 mPa ⁇ s (more preferably 20 mPa ⁇ s to 5000 mPa ⁇ s, even more preferably 40 mPa ⁇ s to 650 mPa ⁇ s, most preferably 90 mPa ⁇ s to 200 mPa ⁇ s).
- the balance between the dispersibility and the dispersion stability of the hydrophilic inorganic particles (D) is good.
- Viscosity is measured using an E-type viscometer.
- the measurement temperature is 25 ⁇ 1 ° C.
- the rotation speed of the viscometer is 40 rpm. However, the rotational speed of the viscometer may be changed within the range of 10 to 120 rpm depending on the viscosity of the measurement object.
- the second epoxy resin (a2) includes at least one selected from the group consisting of cycloaliphatic epoxy resins, aromatic epoxy resins, and heterocyclic epoxy resins.
- the second epoxy resin (a2) is a component that imparts heat resistance to the cured product (Y).
- the cycloaliphatic epoxy resin contains one or more epoxy groups and one or more aliphatic carbocycles (non-aromatic carbocycles) in one molecule.
- Specific examples of the cycloaliphatic epoxy resin include alicyclic diepoxy adipate, alicyclic diepoxy carboxylate, vinylcyclohexene dioxide, 4-vinylcyclohexene-1,2-epoxide, and the like.
- the aromatic epoxy resin contains one or more epoxy groups and one or more aromatic rings in one molecule.
- Specific examples of the aromatic epoxy resin include, for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol AD type epoxy resin, brominated bisphenol type epoxy resin, phenol novolac type epoxy resin, cresol novolac type epoxy resin, glycidyl. Examples thereof include ester type epoxy resins and glycidylamine type epoxy resins.
- the heterocyclic epoxy resin contains one or more epoxy groups and one or more heterocyclic rings in one molecule.
- Specific examples of the heterocyclic epoxy resin include, for example, an epoxy resin having a triazine ring, a hydantoin type epoxy resin, and the like.
- one compound is used alone as the second epoxy resin (a2). It may be used. Two or more compounds may be used in combination as the second epoxy resin (a2).
- the ratio of the first epoxy resin (a1) to the total of the first epoxy resin (a1) and the second epoxy resin (a2) is preferably 26% by volume to 54% by volume (more preferably 27% by volume to 46% by volume). The following). Within this range, the balance between insulation performance and heat resistance tends to be good.
- the curing agent (B) reacts with the epoxy resin (A) to cure the epoxy resin (A).
- the curing agent (for epoxy resin (A)) include an amine curing agent, an acid anhydride curing agent, an imidazole curing agent, a polymercaptan curing agent, a phenol curing agent, and a Lewis acid curing agent. Examples thereof include a curing agent and an isocyanate curing agent.
- amine curing agent examples include, for example, ethylenediamine, 1,3-diaminopropane, 1,4-diaminobutane, hexamethylenediamine, dipropylenediamine, polyether diamine, 2,5-dimethylhexamethylenediamine, trimethyl.
- acid anhydride curing agent examples include methyltetrahydrophthalic anhydride, methylhexahydrophthalic anhydride, and methylnadic anhydride.
- the use of other acid anhydride curing agents does not depart from the scope of the present invention.
- imidazole curing agent examples include, for example, 2-methylimidazole, 2-undecylimidazole, 1,2-dimethylimidazole, 2-ethyl-4-methylimidazole, 2-heptadecylimidazole, 2-phenylimidazole, Examples thereof include 2-phenyl-4-methylimidazole, 1-benzyl-2-methylimidazole, 1-benzyl-2-phenylimidazole and the like. However, these are merely examples. The use of imidazole curing agents other than these does not depart from the scope of the present invention.
- the blending amount of the curing agent (B) can be appropriately adjusted according to the type of the epoxy resin (A) and the type of the curing agent (B).
- the blending amount of the curing agent (B) is preferably about 0.5 equivalents or more and 2 equivalents or less with respect to the epoxy equivalent of the epoxy resin (A).
- the blending amount of the curing agent (B) is less than 0.5 equivalent, curing of the epoxy resin (A) may not sufficiently proceed.
- curing agent (B) exceeds 2 equivalent, the heat resistance of a hardened
- Curing Accelerator (C) >> A hardening accelerator (C) accelerates
- the curing accelerator (C) include tertiary amines and salts thereof, quaternary ammonium compounds, imidazoles, alkali metal alkoxides, and the like. However, these are merely examples. The use of other curing accelerators does not depart from the scope of the present invention.
- the blending amount of the curing accelerator (C) is preferably about 0.01 to 30% by mass (more preferably about 0.05 to 20% by mass) with respect to the mass of the epoxy resin (A). ). When the blending amount is less than 0.01% by mass, the promoting effect may be small. If the blending amount exceeds 30% by mass, the storage stability of the curable composition (X), the moldability of the cured product (Y), and the like may be lowered.
- the curable composition (X) is preferably 2% by volume to 54% by volume (more preferably 3% by volume or more and 50% by volume or less, still more preferably 5% by volume or more and 30% by volume) of the hydrophilic inorganic particles (D). % Or less).
- the volume content of the hydrophilic inorganic particles (D) indicates a percentage of a value obtained by dividing the volume of the hydrophilic inorganic particles (D) by the volume of the curable composition (X).
- the volume of the hydrophilic inorganic particles (D) is determined by dividing the mass of the powder by the true density of the hydrophilic inorganic particles (D).
- the insulation performance (eg, initial breakdown voltage, partial discharge resistance) of the cured product (Y) is greatly improved.
- the dispersibility of the hydrophilic inorganic particles (D) is good, and the mechanical properties of the cured product (Y) are also good.
- the viscosity of curable composition (X) will become high and application to an impregnation use may be difficult.
- Hydrophilic inorganic particles (D) are inorganic compound particles.
- the hydrophilic inorganic particles (D) have the property of being easily adapted to water.
- Examples of the hydrophilic inorganic particles include metal oxides such as silicon oxide, magnesium oxide, aluminum oxide, zinc oxide, beryllium oxide, copper oxide, and cuprous oxide.
- the hydrophilic inorganic particles (D) preferably have a hydrophilic group on the surface.
- the hydrophilic group include a hydroxy group, a carboxy group, an amino group, a silanol group, and a siloxane group.
- the hydrophilic group may be introduced by a surface modifier.
- the surface modifier include ⁇ -glycidoxy-propyltrimethoxysilane, ⁇ -aminopropyl-trimethoxysilane, vinyltriethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-glycidyloxypropyl-trimethoxysilane.
- Silane coupling agents such as: titanate coupling agents, aluminate coupling agents; aluminum laurate, aluminum stearate, iron stearate; aluminum hydroxide; alumina, silica, zirconia; silicone;
- the hydrophilic inorganic particles (D) more preferably have a silanol group on the surface.
- the hydrophilic inorganic particles (D) are more preferably silicon oxide (silica) having a silanol group on the surface.
- Silica may be crystalline.
- Silica may be amorphous.
- Amorphous silica can be synthesized by, for example, a wet method, a dry method, a melting method, or the like. Examples of the wet method include a sedimentation method and a gel method. Examples of the dry method include a flame hydrolysis method, an arc method, a plasma method, and the like. Among these, fumed silica synthesized by a flame hydrolysis method in particular can have a suitable amount of silanol groups on the surface.
- the amount of the hydrophilic group bonded to the surface of the hydrophilic inorganic particle (D) can be represented by the hydrophilic group density on the particle surface.
- “Hydrophilic group density” indicates the number of hydrophilic groups per unit area.
- the hydrophilic group density is preferably 0.1 / nm 2 to 10 / nm 2 (more preferably 2 / nm 2 to 5 / nm 2 ). Within this range, the dispersibility of the hydrophilic inorganic particles (D) is good.
- S i represents a hydrophilic group density [unit: number / nm 2 ].
- S b represents the amount of the powder sample [unit: g].
- S m represents the specific surface area [unit: m 2 / g] of the powder.
- T represents an absolute temperature [unit: K].
- H represents the amount of hydrogen [unit: ml] generated when the dried powder [S b [g]] is reacted with LiAlH 4 (Lithium Aluminum Hydride; LAH) in diethylene glycol dimethyl ether.
- LiAlH 4 Lithium Aluminum Hydride
- the hydrophilic inorganic particles (D) preferably have an average primary particle size of 0.5 nm to 1200 nm (more preferably 1 nm to 1000 nm, still more preferably 5 nm to 100 nm, most preferably 10 nm to 50 nm). It is. Within this range, the partial discharge resistance tends to be improved.
- the average value of the primary particle diameter is measured by an image analysis method using a scanning electron microscope (SEM).
- the primary particle size indicates the particle size of the primary particles.
- the particle size indicates the ferret diameter. Measure the particle size of at least 5 primary particles.
- the average value is an arithmetic average value.
- the hydrophilic inorganic particles (D) preferably have a specific surface area of 10 m 2 / g or more and 350 m 2 / g or less (more preferably 20 m 2 / g or more and 250 m 2 / g or less, even more preferably 30 m 2 / g or more and 200 m 2 or less. / G or less). Within this range, the dispersibility of the hydrophilic inorganic particles (D) is good. “Specific surface area” indicates a value measured by a gas adsorption method (BET method).
- the surface of the hydrophilic inorganic particles (D) may be coated with a hydrophilic polymer. It may have a shell structure made of a hydrophilic organic substance.
- hydrophilic inorganic particles (D) include core-shell type inorganic particles comprising a metal oxide core and a hydrophilic organic substance shell (coating layer).
- the metal oxide to be the core include zinc oxide, cerium oxide, aluminum oxide, zirconium oxide, cobalt oxide and the like, but are not particularly limited thereto.
- those that can be used as the core-shell type hydrophilic inorganic particles include core-shell type cerium particles (manufactured by Hokuko Chemical Co., Ltd.).
- Unsaturated polyester resin (a3) The curable composition (X) is unsaturated as a resin other than the first epoxy resin (a1) and the second epoxy resin (a2) or as at least one resin contained in the first epoxy resin (a1).
- the polyester resin (a3) may be included.
- the unsaturated polyester resin (a3) contains two or more (meth) acryloyl groups in one molecule and has a hydrophilic group.
- the hydrophilic group include a hydroxy group, an ether group, and a carboxy group. Since the unsaturated polyester resin (a3) has a hydrophilic group, the dispersibility of the hydrophilic inorganic particles (D) is the same as that of the first epoxy resin (a1) due to the interaction with the hydrophilic inorganic particles (D). Can be improved.
- the unsaturated polyester resin (a3) may be unsaturated via a free radical generated from an organic peroxide.
- An addition reaction of a saturated binding site (including a (meth) acryloyl group) occurs. Therefore, the first epoxy resin (a1) and the second epoxy resin (a2) are obtained by adding an unsaturated polyester resin (a3) via a free radical in addition to the ring-opening addition polymerization of an epoxy group due to the presence of the epoxy resin curing catalyst. The addition reaction proceeds simultaneously.
- the first epoxy resin (a1), the second epoxy resin (a2) and the unsaturated polyester resin (a3) are polymerized with each other, and the three-dimensional crosslinking proceeds efficiently, so that the crosslinking density increases in a short time. To do. Therefore, the curing time of the curable composition (X) is shortened.
- the unsaturated polyester resin (a3) include, for example, epoxy (meth) acrylate resin (vinyl ester resin), urethane (meth) acrylate resin, polyether (meth) acrylate resin, polyester (meth) acrylate resin, and the like. Is mentioned. These may be used singly or in combination of two or more.
- the epoxy (meth) acrylate resin means a resin obtained by an addition reaction between (meth) acrylic acid and an epoxy compound, and by changing the kind of the epoxy compound, the ratio of (meth) acrylic acid addition, and the like. Resins with different physical properties can be obtained.
- the epoxy compound include compounds having a skeleton such as bisphenol A, bisphenol E, bisphenol F, hydrogenated phthalic acid, cresol novolac, phenol novolac, resorcin, and techmore polyphenylene ether. .
- the urethane (meth) acrylate resin means a resin obtained by urethanizing an isocyanate compound, a polyol compound, and a hydroxyl group-containing (meth) acrylic acid monomer, the type of compound to be combined, the number of functional groups of the (meth) acrylic acid monomer, etc. By changing the value, resins having different physical properties can be obtained.
- the polyether (meth) acrylate resin means a chain polymer having an ether bond (—O—) in the main chain and a (meth) acryloyl group at the terminal.
- the polyester (meth) acrylate resin is a saturated polyester obtained by condensation reaction of a saturated dibasic acid and a polyhydric alcohol, and has a (meth) acryloyl group at the terminal, or ⁇ , ⁇ -Means an unsaturated polyester obtained by condensation reaction of an unsaturated dibasic acid and a polyhydric alcohol, having a (meth) acryloyl group at the terminal.
- the unsaturated polyester resin (a3) is preferably a hydrophilic group obtained by introducing a meth (acryloyl) group into an epoxy resin having a hydrophilic group (including an epoxy resin similar to the first epoxy resin (a1)).
- an epoxy acrylate resin which has this it is not limited to this.
- examples of such an epoxy acrylate resin having a hydrophilic group include a polymer of a monomer compound obtained by introducing a meta (acryloyl) group into a monoepoxy compound, diepoxy compound or polyepoxy compound having a hydrophilic group. Can do.
- the unsaturated polyester resin (a3) include, for example, an epoxy acrylate resin having a glycerin skeleton, a propylene glycol skeleton, or a polypropylene glycol skeleton.
- products that can be used as the unsaturated polyester resin (a3) include Denacol acrylate DA-212, DA-314, DA-314-90M, DA-910, DA-911M, DA-920, DA- 931 (both manufactured by Nagase ChemteX Corporation).
- the ratio of the content of the unsaturated polyester resin (a3) to the total amount of the curable composition containing the unsaturated polyester resin (a3) is preferably 5% by volume or more.
- the upper limit of content ratio of said unsaturated polyester resin (a3) is not specifically limited, For example, it is 54 volume% or less.
- the curable composition (X) contains the unsaturated polyester resin (a3)
- the curable composition (X) is usually a curing agent for the unsaturated polyester resin (a3), and the unsaturated polyester resin (a3). It further contains a curing accelerator for the polyester resin (a3).
- reaction initiator for the unsaturated polyester resin (a3)
- organic peroxide for example, an organic peroxide can be used.
- organic peroxide is not particularly limited, and those known in the technical field can be used.
- organic peroxides include ketone peroxides, peroxyketals, hydroperoxides, dialkyl peroxides, diacyl peroxides, peroxyesters, and peroxydicarbonates Can be used. These organic peroxides may be used alone or in combination of two or more.
- organic peroxide examples include, for example, 1,1-di (t-butylperoxy) cyclohexane, 1,1-di (t-hexylperoxy) cyclohexane, 1,1-di (t-hexylperper).
- Examples of the curing accelerator for the unsaturated polyester resin (a3) include metal soaps, metal chelates, and amines.
- metal soaps include zinc octylate, vanadium octylate, copper naphthenate, cobalt naphthenate, and barium naphthenate.
- metal chelates examples include vanadium acetyl acetate, cobalt acetyl acetate, and iron acetylacetonate.
- amines include: Aniline, diethanolaniline, N, N-substituted anilines [N, N-dimethylaniline, N, N-diethylaniline, N, N-bis (hydroxyethyl) aniline, etc.], p-toluidine, m-toluidine, N-ethyl-m-toluidine, N, N-substituted-p-toluidine [N, N-dimethyl-p-toluidine, N, N-bis (2-hydroxyethyl) -p-toluidine, N, N-bis (2-hydroxypropyl) -p- Toluidine etc.), 4- (N, N-substituted amino) benzaldehyde [4- (N, N-dimethylamino) benzaldehyde, 4- [N, N-bis (2-hydroxyethyl) amino] benzaldehyde, 4- (N-methyl-N -Hydr
- FIG. 3 is a flowchart showing an outline of a method for producing the curable composition (X).
- the manufacturing method includes a preliminary dispersion step (S01), a shear dispersion step (S02), and a curable composition preparation step (S03).
- S01 preliminary dispersion step
- S02 shear dispersion step
- S03 curable composition preparation step
- Preliminary dispersion step (S01) In the preliminary dispersion step (S01), the first dispersion is prepared by dispersing the hydrophilic inorganic particles (D) in the first epoxy resin (a1).
- the distribution method in this step is not particularly limited.
- the hydrophilic inorganic particles (D) can be dispersed in the first epoxy resin (a1) by means usually used in the technical field.
- a general rotation / revolution stirrer or the like can be used.
- Shear dispersion step (S02) In the shear dispersion step (S02), the first dispersion and the second epoxy resin (a2) are sprayed into a predetermined nozzle at a high pressure. The hydrophilic inorganic particles are crushed and dispersed in the liquid by the shearing force generated in the jet. In this way, a second dispersion is prepared.
- a wet high pressure shear disperser is preferably used.
- the hydrophilic inorganic particles (D) are usually in the form of aggregates such as secondary particles and tertiary particles.
- the aggregation is crushed by applying a strong shearing force to the hydrophilic inorganic particles (D).
- the hydrophilic inorganic particles (D) are crushed to such an extent that they have a nano-order primary particle size.
- the crushed hydrophilic inorganic particles (D) are dispersed in a medium. Thereby, the 2nd dispersion liquid is prepared.
- the hydrophilic inorganic particles (D) have hydrophilic groups (for example, silanol groups) and hydrophilic groups (for example, hydroxy groups, ether groups, etc.) of the first epoxy resin (a1), so that the hydrophilic inorganic particles (D) have hydrophilic inorganic particles (D).
- the particles (D) are surrounded by the first epoxy resin (a1). For this reason, re-aggregation and sedimentation of the hydrophilic inorganic particles (D) are suppressed. That is, a uniform dispersed state is formed, and the state can be stably maintained.
- the pressure applied to the dispersion is preferably 100 MPa or more and 200 MPa or less (more preferably 150 MPa or more and 200 MPa or less). If the pressure is too high, the primary particles are crushed and the active surface is exposed. Therefore, reaggregation may occur easily. If the pressure is too low, the hydrophilic inorganic particles (D) may not be sufficiently crushed and dispersed.
- Curable Composition Preparation Step (S03) In the curable composition preparation step (S03), the curing agent (B) and the curing accelerator (C) are added to the second dispersion and stirred. Thereby, curable composition (X) is prepared.
- the stirring method in this step is not particularly limited.
- stirring can be performed by means commonly used in the art.
- a general stirrer or the like can be used.
- vacuum deaeration treatment or the like may be performed as necessary. From the above, the curable composition (X) can be produced.
- additives that can be usually blended in the technical field may be used in combination.
- Such an additive may be added in the shear dispersion step (S02).
- the cured product (Y) is a cured product of the curable composition (X).
- the cured product (Y) is typically produced by heating the curable composition (X).
- the cured product (Y) is used in various forms and shapes depending on the application.
- the cured product (Y) can be molded into a desired shape by various molding methods such as impregnation, coating, casting, and sheet molding.
- the cured product (Y) is excellent in insulation performance and heat resistance. Therefore, the cured product (Y) is suitable for applications that require at least one of insulating performance and heat resistance.
- cured material (Y) is suitable for the insulating member of heavy electrical equipment, such as a rotary machine and a power transmission / transformation apparatus, for example. Examples of the insulating member include varnish, insulating paint, cable coating material, insulating sheet, sealing material, and the like.
- FIG. 2 is a conceptual diagram showing a cured product according to a reference form.
- inorganic particles are dispersed in an epoxy resin using a coupling agent.
- the cured product 20 includes an epoxy resin 16 and inorganic particles 13.
- a coating layer 15 derived from a coupling agent is formed on the surface of the inorganic particles 13.
- the coating layer 15 is inferior to the epoxy resin 16 due to the strength of dielectric breakdown. Therefore, when a high voltage is applied from the electrode 14, the insulation deterioration path 17 advances along the coating layer 15. Further, the coating layer 15 has lower heat resistance than the epoxy resin 16. Therefore, in the cured product 20, the overall heat resistance can be lowered.
- FIG. 1 is a conceptual diagram showing a cured product (Y) according to the first embodiment.
- the cured product 10 includes an epoxy resin 6 and hydrophilic inorganic particles 3.
- the epoxy resin 6 includes the first epoxy resin (a1) having high water solubility. Therefore, in the cured product 10, aggregation and sedimentation of the hydrophilic inorganic particles 3 are suppressed by the interaction between the epoxy resin 6 and the hydrophilic inorganic particles 3. As a result, the generation of voids as starting points for partial discharge is also suppressed.
- the cured product 10 achieves a uniform dispersed state without depending on the coupling agent. That is, the cured product 10 does not substantially contain a coupling agent. Therefore, even when a high voltage is applied from the electrode 4, the insulation degradation path 7 cannot progress long. Moreover, the heat resistance fall accompanying addition of a coupling agent can also be eliminated substantially.
- the second embodiment of the present invention is a rotating machine.
- the rotating machine may be a generator.
- the rotating machine may be an electric motor.
- the generator and the electric motor usually include a rotor and a stator.
- FIG. 4 is a schematic view illustrating a main part of the rotating machine according to the second embodiment. In FIG. 4, the slot exit part of the stator of a rotary machine is shown.
- the outline of the rotating machine according to the second embodiment is as follows.
- the rotating machine includes a rotor (not shown) and a stator 102.
- the stator 102 includes a coil conductor 103 and an insulating layer 104 that covers the coil conductor 103.
- the insulating layer 104 includes the cured product (Y) of the first embodiment.
- the rotating machine is excellent in insulation life and reliability based on the insulation performance and heat resistance of the cured product (Y).
- a slot 107 is provided in the stator core 101.
- the slot 107 is divided into an upper stage and a lower stage by a spacer 106.
- Stator 102 is arranged at the upper and lower stages of slot 107, respectively.
- the stator 102 is fixed in the slot 107 by a wedge 105.
- Stator 102 includes a coil conductor 103 and an insulating layer 104.
- the insulating layer 104 covers the coil conductor 103.
- the stator 102 is manufactured as follows. First, an insulated wire is prepared. The strand has conductivity. The material of the strand is, for example, copper, aluminum, silver or the like.
- the coil conductor 103 is composed of the strands.
- a mica tape is wound around the coil conductor 103. The mica tape is wound several times so that parts of the tape overlap each other. The width of the overlapping portion is, for example, about half the width of the mica tape.
- the coil conductor 103 around which the mica tape is wound is placed in a predetermined mold.
- the mold is impregnated with the curable composition (X) of the first embodiment. After impregnation, the inside of the mold is pressurized and the curable composition (X) is heated.
- the curable composition (X) may be heated by heating the mold.
- the curable composition (X) may be heated by heating the coil conductor 103.
- the heating temperature is, for example, about 100 ° C. or more and 250 ° C. or less.
- the pressure is, for example, about 5 kg / cm 2 or more and 100 kg / cm 2 or less.
- the pressurization time is, for example, about 0.5 hours to 24 hours.
- the stator 102 is removed from the mold.
- a mica tape is wound around the coil conductor 103 and then a mold release agent is applied to the surface thereof.
- the release agent may be one usually used in the technical field.
- the second epoxy resin (a2) was added to the first dispersion.
- the hydrophilic inorganic particles (D) were crushed and dispersed using a wet high-pressure shear dispersion apparatus.
- the treatment pressure was adjusted within the range of 150 MPa to 200 MPa. In this way, a second dispersion was prepared (S02).
- Comparative Example 1 According to the compounding amount shown in Table 1 below, a curable composition was prepared in the same manner as described above. As shown in Table 1 below, Comparative Example 1 is an example in which the water content of the first epoxy resin (a1) exceeds 99% by mass.
- curable compositions were prepared in the same manner as in Examples 1 to 15 except that hydrophobic inorganic particles were blended instead of the hydrophilic inorganic particles (D).
- Comparative Example 5 According to the composition shown in Table 1 below, a curable composition was prepared in the same manner as described above. Comparative Example 5 is an example in which the water content of the first epoxy resin (a1) is less than 20% by mass.
- viscosity The viscosity of the first epoxy resin (a1) was measured with an E-type viscometer. The results are shown in Table 1 above.
- the dispersibility of the curable composition was evaluated by a sedimentation method.
- the evaluation procedure is as follows.
- the curable composition was put in a glass container.
- the glass container was shaken well and then allowed to stand. After standing, light was irradiated from one side of the glass container, and the transparency of the curable composition was evaluated from the side not irradiated with light.
- Dispersibility was evaluated at three levels of A, B, and C. Based on the dispersibility of Example 1, A was better than the standard, B was equivalent to the standard, and C was worse than the standard. The results are shown in Table 1 above.
- ⁇ Average value of primary particle size> The curable composition was heated at 150 ° C. for 180 minutes. Thereby, a cured product was obtained. Using SEM, the average value of the primary particle diameter of the inorganic particles contained in the cured product was measured. The primary particle size was measured on 10 particles. Ten arithmetic average values were obtained. The results are shown in Table 1 above.
- the moldability of the cured product was evaluated by a mold release test.
- the evaluation procedure is as follows.
- a plate-shaped mold was prepared.
- the curable composition was poured into a plate-shaped mold.
- the curable composition was cured to obtain a plate-shaped cured product.
- the cured product was removed from the mold.
- the ease of removing the cured product was evaluated based on the following three levels.
- the case where the cured product could be easily removed was designated as A, the case where the cured product could be removed without causing damage, the case B, and the case where the cured product was brittle and caused damage when removed.
- the results are shown in Table 1 above.
- Tg glass transition temperature
- the partial discharge resistance was evaluated based on the partial discharge initiation voltage (PDIV). The measurement of PDIV was performed 10 times. The arithmetic average of 10 results was used as a representative value.
- the partial discharge resistance was evaluated based on three levels of A, B, and C. Based on the PDIV of Example 1, A was higher than the reference, B was equivalent to the reference, and C was lower than the reference. The results are shown in Table 1 above.
- Examples 1 to 15 have improved insulation performance (initial breakdown voltage and partial discharge resistance) compared to Comparative Examples 1 to 5. Moreover, the heat resistance fall accompanying it is suppressed. It is considered that the dispersibility of the hydrophilic inorganic particles (D) is improved by the interaction between the first epoxy resin (a1) having a water solubility of 20% by mass or more and 99% by mass or less and the hydrophilic inorganic particles (D). It is done.
- Example 1 water solubility: 64% by mass
- the ratio of saturated bonds and unsaturated bonds in the molecule is suitable, and it is considered that both the water content and heat resistance can be achieved.
- Comparative Example 1 water solubility: 100% by mass
- the ratio of unsaturated bonds is excessively low, which is considered to have caused a decrease in heat resistance.
- Example 1 since the first epoxy resin (a1) having a high water content surrounds the periphery of the hydrophilic inorganic particles (D), the dispersibility of the hydrophilic inorganic particles (D) is improved. Moreover, it is considered that the dispersion state is stable. In contrast, in Comparative Example 2 that does not include the first epoxy resin (a1), the hydrophilic inorganic particles (D) are likely to aggregate. Therefore, even if the hydrophilic inorganic particles (D) are once dispersed, they are re-aggregated thereafter. By the aggregation and sedimentation of the hydrophilic inorganic particles (D), voids that are the starting points of insulation deterioration and partial discharge are formed. As a result, it is considered that the initial breakdown voltage and the partial discharge resistance are reduced.
- Comparative Example 4 includes the first epoxy resin (a1) having a high water solubility. However, the inorganic particles are hydrophobic. Therefore, it is considered that the first epoxy resin (a1) and the inorganic particles are not compatible and the dispersibility is lowered. As a result, it is considered that the initial withstand voltage and the partial discharge property are lowered.
- Example 11 The superiority or inferiority of the initial withstand voltage and the partial discharge resistance among Example 3, Example 11 and Example 12 can be explained by the average value of the primary particle diameter of the hydrophilic inorganic particles (D).
- the primary particle size is larger than the insulation deterioration path, it is considered that the progress of the insulation deterioration path is likely to be hindered.
- the primary particle size becomes excessively large, it tends to settle, so that the dispersibility cannot be maintained and the insulation performance is lowered. Accordingly, it is considered that there is an appropriate range in which the average value of the primary particle diameters can be compatible. From this result, it is concluded that the range is 0.5 nm or more and 1200 nm or less.
- Example 16> A mixture of an unsaturated polyester resin (epoxy (meth) acrylate) having a hydrophilic group as an unsaturated polyester resin (a3) in each of 15 types of curable compositions (X) similar to those in Examples 1 to 15. 0, 10 or to the total amount of (the curable composition of this example) (that is, the total amount of the curable composition (X) and the unsaturated polyester resin (a3) as in Examples 1 to 15) 23% by volume was added. Furthermore, as a curing agent for the unsaturated polyester resin (a3), 1% by mass of alkyl ketone peroxide is added to the amount of the unsaturated polyester resin (a3) added, and as a curing accelerator for the unsaturated polyester resin (a3). A naphthenic acid metal soap was added in an amount of 0.5% by mass based on the added amount of the unsaturated polyester resin (a3).
- the curable composition (X) and the cured product (Y) thereof were produced in the same manner as in Examples 1 to 15. At that time, the curing time of each curable composition (X) was measured. The curing time was determined based on the gelation time of the resin composition, and the time when gelation and fluidity were lost was defined as the curing time.
- FIG. 5 shows a graph plotting the relationship between the addition rate of the unsaturated polyester resin (a3) and the curing time of the curable composition (X).
- the addition of the unsaturated polyester resin (a3) shortens the curing time of the curable composition (X). This is presumably because the addition of the unsaturated polyester resin (a3) allows the three-dimensional crosslinking to proceed efficiently as described above, so that the crosslinking density increases in a short time.
- hydrophilic inorganic particles 4, 14 electrodes, 6, 16 epoxy resin, 7, 17 insulation degradation path, 10, 20 cured product, 13 inorganic particles, 15 coating layer, 101 stator core, 102 stator, 103 coil conductor 104 insulating layers, 105 wedges, 106 spacers, 107 slots.
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Abstract
Description
本発明の第1実施形態は、硬化性組成物(X)およびその硬化物(Y)である。
硬化性組成物(X)は、エポキシ樹脂(A)、硬化剤(B)、硬化促進剤(C)、および親水性無機粒子(D)を含む。硬化性組成物(X)は、熱硬化性であってもよい。あるいは硬化性組成物は、光硬化性であってもよい。
硬化性組成物(X)は、エポキシ樹脂(A)を好ましくは46体積%以上98体積%以下(より好ましくは50体積%以上97体積%以下、よりいっそう好ましくは70体積%以上95体積%以下)含む。この範囲で、硬化物(Y)の絶縁性能と、機械的特性(たとえば靭性等)とのバランスが良好である。
第1エポキシ樹脂(a1)は、親水基を有する鎖状脂肪族エポキシ樹脂である。第1エポキシ樹脂(a1)は、特定の水溶性を示す。すなわち、第1エポキシ樹脂(a1)は、水溶率が20質量%以上99質量%以下(好ましくは30質量%以上90質量%以下、より好ましくは40質量%以上80質量%以下、最も好ましくは50質量%以上70質量%以下)である。
第2エポキシ樹脂(a2)は、環状脂肪族エポキシ樹脂、芳香族エポキシ樹脂および複素環式エポキシ樹脂からなる群より選択される少なくとも1種を含む。第2エポキシ樹脂(a2)は、硬化物(Y)に耐熱性を付与する成分である。
硬化剤(B)は、エポキシ樹脂(A)と反応し、エポキシ樹脂(A)を硬化させる。(エポキシ樹脂(A)用の)硬化剤(B)としては、たとえば、アミン系硬化剤、酸無水物系硬化剤、イミダゾール系硬化剤、ポリメルカプタン系硬化剤、フェノール系硬化剤、ルイス酸系硬化剤、イソシアネート系硬化剤等が挙げられる。
硬化促進剤(C)は、エポキシ樹脂(A)の硬化を促進する。あるいは硬化促進剤(C)は、エポキシ樹脂(A)の硬化を制御する。硬化促進剤(C)としては、たとえば、第三級アミンおよびその塩、四級アンモニウム化合物、イミダゾール、アルカリ金属アルコキシド等が挙げられる。ただし、これらはあくまで例示に過ぎない。これら以外の硬化促進剤を用いたからといって、本発明の範囲を逸脱するわけではない。
硬化性組成物(X)は、親水性無機粒子(D)を好ましくは2体積%以上54体積%以下(より好ましくは3体積%以上50体積%以下、よりいっそう好ましくは5体積%以上30体積%以下)含む。親水性無機粒子(D)の体積含有率は、親水性無機粒子(D)の体積を、硬化性組成物(X)の体積で除した値の百分率を示す。親水性無機粒子(D)の体積は、粉末の質量を、親水性無機粒子(D)の真密度で除することにより求める。
Si=(H×7312.5)÷(Sb×Sm×T)・・・(1)
により求める。
硬化性組成物(X)は、第1エポキシ樹脂(a1)および第2エポキシ樹脂(a2)以外の樹脂として、または、第1エポキシ樹脂(a1)に含まれる少なくとも1種の樹脂として、不飽和ポリエステル樹脂(a3)を含んでいてもよい。
アニリン、ジエタノールアニリン、
N,N-置換アニリン〔N,N-ジメチルアニリン、N,N-ジエチルアニリン、N,N-ビス(ヒドロキシエチル)アニリン等〕、
p-トルイジン、m-トルイジン、N-エチル-m-トルイジン、
N,N-置換-p-トルイジン〔N,N-ジメチル-p-トルイジン、N,N-ビス(2-ヒドロキシエチル)-p-トルイジン、N,N-ビス(2-ヒドロキシプロピル)-p-トルイジン等〕、
4-(N,N-置換アミノ)ベンズアルデヒド〔4-(N,N-ジメチルアミノ)ベンズアルデヒド、4-[N,N-ビス(2-ヒドロキシエチル)アミノ]ベンズアルデヒド、4-(N-メチル-N-ヒドロキシエチルアミノ)ベンズアルデヒド等〕、
トリエタノールアミン、ジエチレントリアミン、ピリジン、フェニルモルホリン、ピペリジンなどが挙げられる。
硬化性組成物(X)は、以下の製造方法により製造することができる。図3は、硬化性組成物(X)の製造方法の概略を示すフローチャートである。当該製造方法は、予備分散ステップ(S01)、せん断分散ステップ(S02)、および、硬化性組成物調製ステップ(S03)を含む。以下、各ステップを説明する。
予備分散ステップ(S01)では、第1エポキシ樹脂(a1)に、親水性無機粒子(D)を分散させることにより、第1分散液を調製する。
せん断分散ステップ(S02)では、高圧で、第1分散液および第2エポキシ樹脂(a2)を所定のノズル内に噴射する。噴流内に発生するせん断力により、親水性無機粒子を破砕し、液中に分散させる。これにより第2分散液を調製する。
親水性無機粒子(D)は、通常、二次粒子、三次粒子等の凝集形態をとっている。本ステップでは、親水性無機粒子(D)に、強いせん断力を加えることにより、凝集を破砕する。親水性無機粒子(D)は、ナノオーダーの一次粒径を有する程度に、破砕される。同時に、破砕された親水性無機粒子(D)を媒質に分散させる。これにより、第2分散液が調製される。
硬化性組成物調製ステップ(S03)では、第2分散液に、硬化剤(B)および硬化促進剤(C)を加えて攪拌する。これにより硬化性組成物(X)が調製される。
硬化物(Y)は、硬化性組成物(X)の硬化物である。硬化物(Y)は、典型的には、硬化性組成物(X)を加熱することにより、生成される。硬化物(Y)は、用途に応じて、様々な形態、形状で使用される。硬化物(Y)は、たとえば、含浸、塗布、注型、シート成形等の各種成形方法により、所望の形状に成形され得る。
本発明の第2実施形態は、回転機である。
回転機は、発電機であってもよい。回転機は、電動機であってもよい。発電機および電動機は、通常、回転子および固定子を備える。図4は、第2実施形態の回転機の要部を示す概略図である。図4では、回転機の固定子のスロット出口部が示されている。
回転機は、回転子(図示せず)および固定子102を備える。固定子102は、コイル導体103と、コイル導体103を被覆する絶縁層104を含む。絶縁層104は、第1実施形態の硬化物(Y)を含む。回転機は、硬化物(Y)の絶縁性能および耐熱性に基づき、絶縁寿命、信頼性に優れる。
固定子鉄心101には、スロット107が設けられている。スロット107は、スペーサ106によって、上段と下段とに分けられている。スロット107の上段および下段には、それぞれ固定子102が配置されている。固定子102は、ウェッジ105によって、スロット107内に固定されている。固定子102は、コイル導体103および絶縁層104を含む。絶縁層104は、コイル導体103を被覆している。
<硬化性組成物(X)およびその硬化物(Y)の製造>
以下のようにして、各種硬化性組成物(X)およびその硬化物(Y)を製造した。
以下の材料を準備した。
A種:ポリグリシジルエーテル
B種:ジグリセロールポリグリシジルエーテル
C種:ソルビトールポリグリシジルエーテル(高分子量)
D種:ソルビトールポリグリシジルエーテル
E種:ポリエチレングリセロールジグリシジルエーテル
F種:ポリエチレングリコールグリシジルエーテル
G種:ポリグリシジルエーテル
《第2エポキシ樹脂(a2)》
ビスフェノールA型エポキシ樹脂
《硬化剤(B)》
酸無水物系硬化剤
《硬化促進剤(C)》
イミダゾール系硬化促進剤
《親水性無機粒子(D)》
親水性フュームドシリカ
疎水性フュームドシリカ(比較例4に使用)
<実施例1~15>
下記表1に示す配合量に従って、第1エポキシ樹脂(a1)に親水性無機粒子(D)を分散させた。これにより第1分散液を調製した(S01)。分散操作には、自転公転式攪拌機を用いた。回転数は2000rpm、攪拌時間は2分間とした。
下記表1に示す配合量に従って、上記と同様にして、硬化性組成物を調製した。下記表1に示すように、比較例1は、第1エポキシ樹脂(a1)の水溶率が99質量%を超える例である。
下記表1に示すように、第1エポキシ樹脂(a1)を配合しないことを除いては、実施例1~15と同様にして、硬化性組成物を調製した。
下記表1に示すように、親水性無機粒子(D)を配合しないことを除いては、実施例1~15と同様にして、硬化性組成物を調製した。
下記表1に示すように、親水性無機粒子(D)に代えて、疎水性無機粒子を配合することを除いては、実施例1~15と同様にして、硬化性組成物を調製した。
下記表1に示す配合に従って、上記と同様にして、硬化性組成物を調製した。比較例5は、第1エポキシ樹脂(a1)の水溶率が20質量%未満の例である。
以下のようにして、材料および硬化性組成物を評価した。
前述の方法により、第1エポキシ樹脂(a1)の水溶率を測定した。結果を上記表1に示す。
E型粘度計により、第1エポキシ樹脂(a1)の粘度を測定した。結果を上記表1に示す。
沈降法により、硬化性組成物の分散性を評価した。評価手順は次のとおりである。ガラス容器に硬化性組成物を入れた。ガラス容器をよく振った後、静置した。静置後、ガラス容器の片側から光を照射し、光を照射していない側から硬化性組成物の透明性を評価した。分散性は、A、B、Cの3水準で評価した。実施例1の分散性を基準として、基準よりも良いものをA、基準と同等であるものをB、基準よりも悪いものをCとした。結果を上記表1に示す。
硬化性組成物を150℃で180分間加熱した。これにより硬化物を得た。SEMを用いて、硬化物に含まれる無機粒子の一次粒径の平均値を測定した。一次粒径は10個の粒子について測定した。10個の算術平均値を求めた。結果を上記表1に示す。
離型試験により、硬化物の成形性を評価した。評価手順は次のとおりである。板状の金型を準備した。板状の金型に硬化性組成物を注入した。硬化性組成物を加熱することにより、硬化性組成物を硬化させ、板状の硬化物を得た。硬化物を金型から取り外した。硬化物の取り外し易さを次の3水準で評価した。硬化物を容易に取り外すことが出来た場合をA、硬化物に破損が生じることなく取り外すことができた場合をB、硬化物が脆く、取り外す際に破損が生じた場合をCとした。結果を上記表1に示す。
ガラス転移温度(Tg)により、硬化物の耐熱性を評価した。Tgは、動的粘弾性測定により求めた。測定は引張モードで行った。損失正接(tanδ)の温度依存性を示すグラフにおいて、tanδがピークを示す温度をTgとした。実施例1のTgを基準として、基準よりも高いものをA、基準と同等であるものをB、基準よりも低いものをCとした。結果を上記表1に示す。Tgが高い程、耐熱性が良好である。
絶縁破壊試験によって、硬化物の初期耐圧を評価した。「JIS C 2110-1 固体電気絶縁材料-絶縁破壊の強さの試験方法-第1部:商用周波数交流電圧印加による試験」に準拠して、絶縁破壊の強さを測定した。測定は10回行った。10回の結果の算術平均値を代表値として採用した。初期耐圧は、A、B、Cの3水準で評価した。実施例1の絶縁破壊の強さを基準として、基準よりも強いものをA、基準と同等であるものをB、基準よりも弱いものをCとした。結果を上記表1に示す。
部分放電開始電圧(Partial Discharge Inception Voltage;PDIV)により、耐部分放電性を評価した。PDIVの測定は10回行った。10回の結果の算術平均値を代表値として採用した。耐部分放電性は、A、B、Cの3水準で評価した。実施例1のPDIVを基準として、基準よりも高いものをA、基準と同等であるものをB、基準よりも低いものをCとした。結果を上記表1に示す。
上記表1から分かるように、実施例1~15は、比較例1~5に比べて、絶縁性能(初期耐圧および耐部分放電性)が向上している。またそれに伴う耐熱性の低下が抑制されている。水溶率が20質量%以上99質量%以下である第1エポキシ樹脂(a1)と、親水性無機粒子(D)との相互作用により、親水性無機粒子(D)の分散性が向上したためと考えられる。
実施例1~15と同様の15種類の硬化性組成物(X)の各々に、不飽和ポリエステル樹脂(a3)として、親水性基を有する不飽和ポリエステル樹脂(エポキシ(メタ)アクリレート)を、混合物(本実施例の硬化性組成物)の全量(すなわち、実施例1~15と同様の硬化性組成物(X)および不飽和ポリエステル樹脂(a3)の合計量)に対して、0、10または23体積%添加した。さらに、不飽和ポリエステル樹脂(a3)の硬化剤として、アルキルケトンパーオキサイドを不飽和ポリエステル樹脂(a3)の添加量に対して1質量%添加し、不飽和ポリエステル樹脂(a3)の硬化促進剤としてナフテン酸金属石鹸を不飽和ポリエステル樹脂(a3)の添加量に対して0.5質量%添加した。
Claims (13)
- エポキシ樹脂、
硬化剤、
硬化促進剤および
親水性無機粒子
を含み、
前記エポキシ樹脂は、第1エポキシ樹脂および第2エポキシ樹脂を含み、
前記第1エポキシ樹脂は、親水基を有する鎖状脂肪族エポキシ樹脂であり、かつ水溶率が20質量%以上99質量%以下であり、
前記第2エポキシ樹脂は、環状脂肪族エポキシ樹脂、芳香族エポキシ樹脂および複素環式エポキシ樹脂からなる群より選択される少なくとも1種を含む、硬化性組成物。 - 前記第1エポキシ樹脂は、グリシジルエーテル化合物である、請求項1に記載の硬化性組成物。
- 前記第1エポキシ樹脂は、グリセロール骨格を有するポリグリシジルエーテル化合物である、請求項2に記載の硬化性組成物。
- 前記第1エポキシ樹脂および前記第2エポキシ樹脂の合計に対する前記第1エポキシ樹脂の割合は、26体積%以上54体積%以下である、請求項1~請求項3のいずれか1項に記載の硬化性組成物。
- 前記第1エポキシ樹脂は、粘度が20mPa・s以上21200mPa・s以下である、請求項1~請求項4のいずれか1項に記載の硬化性組成物。
- 1分子中に2個以上の(メタ)アクリロイル基を含み、親水性基を有する、不飽和ポリエステル樹脂を含む、請求項1~請求項5のいずれか1項に記載の硬化性組成物。
- 前記不飽和ポリエステル樹脂が、前記第1エポキシ樹脂にメタ(アクリロイル)基が導入されてなるエポキシアクリレート樹脂である、請求項6に記載の硬化性組成物。
- 前記親水性無機粒子は、表面に親水基を有する、請求項1~請求項7のいずれか1項に記載の硬化性組成物。
- 前記親水性無機粒子は、表面が親水性ポリマーで被覆されている、請求項1~8のいずれか1項に記載の樹脂硬化物。
- 前記親水性無機粒子は、一次粒径の平均値が0.5nm以上1200nm以下である、請求項1~請求項9のいずれか1項に記載の硬化性組成物。
- 前記硬化性組成物は、前記親水性無機粒子を2体積%以上54体積%以下含む、請求項1~請求項10のいずれか1項に記載の硬化性組成物。
- 請求項1~請求項11のいずれか1項に記載の硬化性組成物の硬化物。
- 回転子および固定子を備え、
前記固定子は、コイル導体と、前記コイル導体を被覆する絶縁層とを含み、
前記絶縁層は、請求項12に記載の硬化性組成物の硬化物を含む、回転機。
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CN201680082248.4A CN108884296B (zh) | 2016-03-31 | 2016-12-21 | 固化性组合物及其固化物以及旋转机 |
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US20200032046A1 (en) | 2020-01-30 |
CN108884296A (zh) | 2018-11-23 |
CN108884296B (zh) | 2021-04-09 |
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