Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K1/00—Details of the magnetic circuit
  • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/002—Inhomogeneous material in general
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
  • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
  • H01B3/40—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes epoxy resins
• • 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
• • 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
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/64—Electric machine technologies in electromobility

Definitions

• the present disclosure relates to an insulating material for a stator, a stator, and a method for manufacturing the stator.
• Patent Document 1 describes a stator configuration in which an insulating paper is provided between a coil and a tooth, and a varnish is impregnated between the insulating paper and the coil to cure the stator.
• Patent Document 2 discloses a stator manufactured by integrally molding a coil and a core by fitting a coil and a core and resin-molding the space between the coil and the core and the end face of the coil side. There is.
• Patent Document 3 describes a method of forming a stator by fixing a coil and a stator core with a synthetic resin such as an epoxy resin at a resin mold portion.
• Patent Document 4 discloses a stator composed of a cured product of a thermosetting resin composition. Further, the thermosetting resin composition includes one or more thermosetting resins selected from the group consisting of a phenol resin, an epoxy resin, and an unsaturated polyester resin, and an inorganic filler. Is disclosed.
• Japanese Unexamined Patent Publication No. 2019-170105 Japanese Unexamined Patent Publication No. 2009-261806 International Publication No. 2013/121590 Japanese Unexamined Patent Publication No. 2017-5870
• the present disclosure relates to an insulating material for a stator that is suitably applicable to a stator having a densified coil, and a stator having a coil insulated by the insulating material for the stator, and a method for manufacturing the same.
• Means for solving the above problems include the following aspects.
• An insulating material for a stator that contains an epoxy resin, a curing agent, and a spherical inorganic filler and is used for insulation between the coils of the stator.
• the curing agent contains a phenol curing agent.
• the inorganic filler contains at least one selected from the group consisting of silica, alumina, and magnesium oxide.
• ⁇ 4> The insulating material for a stator according to any one of ⁇ 1> to ⁇ 3>, wherein the content of the inorganic filler is 50% by mass or more with respect to the total mass of the insulating material for the stator.
• ⁇ 5> The insulating material for a stator according to ⁇ 4>, wherein the content of the inorganic filler is 70% by mass or more with respect to the total mass of the insulating material for a stator.
• ⁇ 6> The insulating material for a stator according to ⁇ 5>, wherein the content of the inorganic filler is 80% by mass or more with respect to the total mass of the insulating material for a stator.
• ⁇ 7> The insulating material for a stator according to any one of ⁇ 1> to ⁇ 6>, wherein the maximum particle size of the inorganic filler is 100 ⁇ m or less.
• ⁇ 8> The insulating material for a stator according to any one of ⁇ 1> to ⁇ 7>, wherein the inorganic filler has an average aspect ratio of 0.8 to 1.0 in observation with a scanning electron microscope.
• ⁇ 9> A stator having a coil insulated by the insulating material for a stator according to any one of ⁇ 1> to ⁇ 8>.
• ⁇ 10> A method for manufacturing a stator, which comprises insulating the coils with the insulating material for a stator according to any one of ⁇ 1> to ⁇ 8>.
• ⁇ 11> The method for manufacturing a stator according to ⁇ 10>, wherein the insulation between the coils is performed by transfer molding.
• ⁇ 12> A method of using an insulating material containing an epoxy resin, a curing agent, and a spherical inorganic filler for insulation between coils of a stator.
• an insulating material for a stator that is suitably applicable to a stator having a high-density coil, a stator having a coil insulated by the insulating material for the stator, and a method for manufacturing the same are provided.
• the term "process” includes, in addition to a process independent of other processes, the process as long as the purpose of the process is achieved even if it cannot be clearly distinguished from the other process. ..
• the numerical range indicated by using "-" includes the numerical values before and after "-" as the minimum value and the maximum value, respectively.
• the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of the numerical range described in another stepwise description. ..
• the upper limit value or the lower limit value of the numerical range may be replaced with the value shown in the examples.
• each component may contain a plurality of applicable substances.
• the content or content of each component is the total content or content of the plurality of substances present in the composition unless otherwise specified.
• a plurality of types of particles corresponding to each component may be contained.
• the particle size of each component means a value for a mixture of the plurality of particles present in the composition unless otherwise specified.
• the term "layer" refers to the case where the layer is formed in the entire region when the region is observed, and also when the layer is formed only in a part of the region. included.
• the insulating material for a stator of the present disclosure contains an epoxy resin, a curing agent, and a spherical inorganic filler, and is used for insulation between coils of the stator.
• the inventors have attempted to develop an insulating material capable of obtaining excellent insulating properties between coils, and an insulating material containing an epoxy resin, a curing agent, and a spherical inorganic filler has a filling property and a filling property. It has been found that it can be suitably used for insulation between the coils of a stator because it has excellent performance in dimensional stability.
• insulation means electrical insulation.
• the insulating material for the stator of the present disclosure may contain a resin material other than the epoxy resin and the curing agent (that is, the curing agent of the epoxy resin), but from the viewpoint of exhibiting effects such as dimensional stability particularly well.
• the total content of the epoxy resin and the curing agent (that is, the curing agent of the epoxy resin) in the components excluding the inorganic filler in the insulating material for the stator is preferably 50% by mass or more, preferably 70% by mass or more. It is more preferably present, and more preferably 90% by mass or more.
• the total content of the epoxy resin and the phenol curing agent in the components other than the inorganic filler in the insulating material for the stator is preferably 50% by mass or more. , 70% by mass or more, more preferably 90% by mass or more.
• the components of the insulating material for the stator, excluding the inorganic filler may be referred to as "resin components" for convenience.
• each component of the insulating material for the stator of the present disclosure will be described in detail.
• the insulating material for the stator of the present disclosure includes an epoxy resin.
• the type of epoxy resin is not particularly limited as long as it has an epoxy group in the molecule.
• the epoxy resin may be solid or liquid under normal temperature and pressure (for example, 25 ° C. and atmospheric pressure), and is preferably solid.
• the epoxy resin is at least one selected from the group consisting of phenol compounds such as phenol, cresol, xylenol, resorcin, catechol, bisphenol A and bisphenol F, and naphthol compounds such as ⁇ -naphthol, ⁇ -naphthol and dihydroxynaphthalene.
• a novolak type epoxy resin which is an epoxidation of a novolak resin obtained by condensing or cocondensing a kind of phenolic compound and an aliphatic aldehyde compound such as formaldehyde, acetaldehyde, and propionaldehyde under an acidic catalyst.
• Epoxide resin, orthocresol novolak type epoxy resin, etc. A triphenylmethane type phenol resin obtained by condensing or cocondensing the above phenolic compound with an aromatic aldehyde compound such as benzaldehyde or salicylaldehyde under an acidic catalyst.
• Triphenylmethane type epoxidized resin a copolymerized epoxy resin obtained by epoxidizing a novolak resin obtained by cocondensing the above phenol compound, naphthol compound, and aldehyde compound under an acidic catalyst.
• Diphenylmethane type epoxy resin which is a diglycidyl ether such as bisphenol A and bisphenol F;
• Biphenyl type epoxy resin which is an alkyl-substituted or unsubstituted biphenol diglycidyl ether;
• Stilben-type epoxy resin which is a diglycidyl ether of a stilben-based phenol compound.
• Sulfur atom-containing epoxy resin that is a diglycidyl ether such as bisphenol S; Epoxide resin that is an alcoholic glycidyl ether such as butanediol, polyethylene glycol, polypropylene glycol; A glycidyl ester type epoxy resin that is a glycidyl ester of an acid compound; a glycidylamine type epoxy resin in which an active hydrogen bonded to a nitrogen atom such as aniline, diaminodiphenylmethane, or isocyanuric acid is replaced with a glycidyl group; a dicyclopentadiene and a phenol compound.
• diglycidyl ether such as bisphenol S
• Epoxide resin that is an alcoholic glycidyl ether such as butanediol, polyethylene glycol, polypropylene glycol
• a glycidyl ester type epoxy resin that is a glycidyl ester of an
• Dicyclopentadiene-type epoxy resin which is an epoxide of the cocondensation resin of Rate, 2- (3,4-epoxide) cyclohexyl-
• An alicyclic epoxy resin such as 5,5-spiro (3,4-epoxy) cyclohexane-m-dioxane; paraxylylene-modified epoxy resin which is a glycidyl ether of a paraxylylene-modified phenol formaldehyde; metaxylylene-modified which is a glycidyl ether of a metaxylylene-modified phenol resin.
• Epoxy resin Terpen-modified epoxy resin that is a glycidyl ether of a terpene-modified phenol form; Dicyclopentadiene-modified epoxy resin that is a glycidyl ether of a dicyclopentadiene-modified phenol resin; Cyclopentadiene-modified epoxy resin that is a glycidyl ether of a cyclopentadiene-modified phenol resin.
• a polycyclic aromatic ring-modified epoxy resin which is a glycidyl ether of a polycyclic aromatic ring-modified phenol resin; a naphthalene-type epoxy resin which is a glycidyl ether of a naphthalene ring-containing phenol resin; a halogenated phenol novolac-type epoxy resin; a hydroquinone-type epoxy resin; Methylol propane type epoxy resin; Linear aliphatic epoxy resin obtained by oxidizing an olefin bond with a peracid such as peracetic acid; Aralkyl type which is an epoxy of an aralkyl type phenol resin such as phenol aralkyl resin and naphthol aralkyl resin.
• Epoxy resin etc. Further, epoxies of silicone resin, epoxies of acrylic resin and the like can also be mentioned as epoxy resins.
• the epoxy resin may be used alone or in combination of two or more. Among them, a polyfunctional epoxy resin such as a triphenylmethane type epoxy resin is mentioned as a preferable epoxy resin from the viewpoint of mechanical strength.
• the epoxy equivalent (molecular weight / number of epoxy groups) of the epoxy resin is not particularly limited. From the viewpoint of mechanical strength, the epoxy equivalent of the epoxy resin is preferably 100 g / eq to 1000 g / eq, and more preferably 150 g / eq to 500 g / eq.
• the epoxy equivalent of the epoxy resin shall be a value measured by a method according to JIS K 7236: 2009.
• the softening point or melting point of the epoxy resin is preferably 40 ° C to 180 ° C, and from the viewpoint of handleability when preparing the insulating material for the stator, it is preferably 50 ° C to 130 ° C. More preferred.
• the melting point of the epoxy resin is a value measured by differential scanning calorimetry (DSC), and the softening point of the epoxy resin is a value measured by a method (ring ball method) according to JIS K 7234: 1986.
• the epoxy resin content is not particularly limited. From the viewpoint of fluidity, filling property, etc., the content of the epoxy resin is preferably 5% by mass or more, and preferably 8% by mass or more, based on the total mass of the insulating material for the stator. Further, from the viewpoint of mechanical strength and the like, the content of the epoxy resin is preferably 20% by mass or less, more preferably 15% by mass or less, based on the total mass of the insulating material for the stator. From this point of view, the content of the epoxy resin is preferably 5% by mass to 20% by mass, more preferably 8% by mass to 15% by mass, and 8% by mass, based on the total mass of the insulating material for the stator. It may be 10% by mass to 12% by mass, or 10% by mass to 15% by mass.
• the insulating material for the stator contains a curing agent.
• the curing agent is not particularly limited as long as it can react with the epoxy group of the epoxy resin to cure the epoxy resin.
• the curing agent include a phenol curing agent (a compound having a phenolic hydroxyl group in the molecule), an amine curing agent, an acid anhydride curing agent, a polypeptide curing agent, a polyaminoamide curing agent, an isocyanate curing agent, a blocked isocyanate curing agent, and the like. Can be mentioned.
• the curing agent is preferably a phenol curing agent.
• the curing agent may be solid or liquid at 25 ° C. and atmospheric pressure, and is preferably solid.
• phenol curing agent examples include polyvalent phenol compounds such as resorsin, catecol, bisphenol A, bisphenol F, substituted or unsubstituted biphenol; phenol, cresol, xylenol, resorsin, catecol, bisphenol A, bisphenol F, and phenylphenol. , Aminophenol and other phenolic compounds and at least one phenolic compound selected from the group consisting of ⁇ -naphthol, ⁇ -naphthol, dihydroxynaphthalene and other naphthol compounds, and aldehyde compounds such as formaldehyde, acetaldehyde and propionaldehyde are acidic.
• polyvalent phenol compounds such as resorsin, catecol, bisphenol A, bisphenol F, substituted or unsubstituted biphenol
• phenol cresol, xylenol, resorsin, catecol, bisphenol A, bisphenol F, and phenyl
• Novorac-type phenolic resin obtained by condensation or cocondensification under a catalyst; phenol-aralkyl resin, naphthol-aralkyl resin, etc., which are synthesized from the above-mentioned phenolic compound, dimethoxyparaxylene, bis (methoxymethyl) biphenyl, etc. Phenol formaldehyde; paraxylylene and / or metaxylylene-modified phenolic resin; melamine-modified phenolic resin; terpen-modified phenolic resin; dicyclopentadiene-type phenolic resin and dicyclopentadiene synthesized from the above phenolic compound and dicyclopentadiene by copolymerization.
• Type naphthol resin cyclopentadiene-modified phenolic resin; polycyclic aromatic ring-modified phenolic resin; biphenyl-type phenolic resin; Examples thereof include a triphenylmethane-type phenol resin obtained by subjecting them to the above; a phenol resin obtained by copolymerizing two or more of these types.
• the phenolic curing agent may be used alone or in combination of two or more.
• a novolak type phenol resin is mentioned as a preferable phenol resin from the viewpoint of curability, mechanical strength and the like.
• the functional group equivalent of the curing agent (hydroxyl equivalent in the case of a phenol curing agent, active hydrogen equivalent in the case of an amine curing agent) is not particularly limited. From the viewpoint of mechanical strength, the functional group equivalent of the curing agent is preferably 70 g / eq to 1000 g / eq, and more preferably 80 g / eq to 500 g / eq.
• the hydroxyl group equivalent in the case of a phenol curing agent is a value calculated based on the hydroxyl group value measured in accordance with JIS K0070: 1992.
• the active hydrogen equivalent in the case of an amine-based curing agent is a value calculated based on the amine value measured in accordance with JIS K7237: 1995.
• the curing agent When the curing agent is a solid, its softening point or melting point is not particularly limited.
• the softening point or melting point of the curing agent is preferably 40 ° C. to 180 ° C. from the viewpoint of moldability, and more preferably 50 ° C. to 130 ° C. from the viewpoint of handleability of the insulating material for the stator. ..
• the melting point or softening point of the curing agent shall be a value measured in the same manner as the melting point or softening point of the epoxy resin.
• the equivalent ratio of the epoxy resin to the curing agent is not particularly limited. From the viewpoint of reducing the amount of each unreacted component, the equivalent ratio of the epoxy resin and the curing agent is preferably set in the range of 0.5 to 2.0, and is set in the range of 0.6 to 1.3. It is more preferable to be done. From the viewpoint of moldability, it is more preferable that the equivalent ratio of the epoxy resin and the curing agent is set in the range of 0.8 to 1.2.
• the insulating material for the stator contains a spherical inorganic filler.
• the "spherical shape" in the inorganic filler of the present disclosure includes not only a true spherical shape but also an elliptical spherical shape or a substantially spherical shape, and the surface may have irregularities or voids may be contained in the particles.
• particles having a circularity of 0.8 to 1.0 in scanning electron microscope (SEM) observation shall be included in the spherical inorganic filler.
• the average circularity of the spherical inorganic filler in SEM observation is preferably 0.8 to 1.0, and more preferably 0.9 to 1.0.
• the average circularity is the arithmetic mean value of the circularity of 100 particles arbitrarily selected in the SEM image.
• the circularity of the inorganic filler can be calculated by using a known image analysis means, if necessary.
• the insulating material for a stator of the present disclosure may contain an inorganic filler having a shape other than a spherical shape (plate shape, needle shape, fibrous shape, polygonal shape, etc.), but the filling property and mechanical strength are further improved.
• the content of the spherical inorganic filler in the entire inorganic filler is preferably 50% by number or more, more preferably 70% by number or more, and preferably 90% by number or more.
• the ratio based on the number of spherical inorganic fillers is the ratio of spherical particles in 1000 particles randomly selected from the SEM image of the inorganic filler.
• the average aspect ratio of the spherical inorganic filler in SEM observation is preferably 0.8 to 1.0, and more preferably 0.9 to 1.0.
• the "aspect ratio" of the inorganic filler represents a value (minor axis / major axis) obtained by dividing the length of the minor axis of the particles by the length of the major axis.
• the average aspect ratio of the inorganic filler is an arithmetic mean value of the aspect ratios of 100 particles randomly selected from the SEM image of the inorganic filler.
• the aspect ratio of the inorganic filler can be calculated from the image of the inorganic filler by using a known image analysis means, if necessary.
• the type of inorganic filler is not particularly limited.
• examples of the inorganic filler include silica such as molten silica and crystalline silica, glass, alumina, calcium carbonate, zirconium silicate, calcium silicate, silicon nitride, aluminum nitride, boron nitride, magnesium oxide, verilia, zirconia, and zirconium.
• examples thereof include fine powders such as fosterite, steatite, spinel, mulite, titania, talc, clay and mica, or spherical beads thereof.
• An inorganic filler having a flame-retardant effect may be used.
• examples of the inorganic filler having a flame-retardant effect include aluminum hydroxide, magnesium hydroxide, a composite metal hydroxide such as a composite hydroxide of magnesium and zinc, and zinc borate. It was
• the inorganic filler contains at least one selected from the group consisting of silica, alumina, and magnesium oxide.
• the inorganic filler contains at least one selected from the group consisting of silica, alumina, and magnesium oxide
• the total amount of at least one selected from the group consisting of silica, alumina, and magnesium oxide is the inorganic filler. It is preferably 70% by mass or more, more preferably 80% by mass or more, and further preferably 90% by mass or more with respect to the total mass of the above.
• the content of the inorganic filler is not particularly limited, and is preferably 50% by mass or more, more preferably 60% by mass or more, and 70% by mass or more with respect to the total mass of the insulating material for the stator. Is more preferable, and may be 80% by mass or more.
• the content of the inorganic filler is 50% by mass or more with respect to the total mass of the insulating material for the stator, the insulating property between the coils tends to be further improved. In addition, there is a tendency that the water absorption rate can be lowered and the chemical resistance can be improved.
• the content of the inorganic filler is preferably 95% by mass or less with respect to the total mass of the insulating material for the stator, 90. It is more preferably 0% by mass or less, further preferably 85% by mass or less, and may be 80% by mass or less. From the above viewpoint, the content of the inorganic filler is preferably 50% by mass to 95% by mass, more preferably 60% by mass to 90% by mass, based on the total mass of the insulating material for the stator. It is more preferably 70% by mass to 90% by mass, particularly preferably 70% by mass to 85% by mass, and may be 70% by mass to 80% by mass, 80% by mass to 90% by mass. May be.
• the content of the inorganic filler in the cured product can be measured as follows. First, the total mass of the cured product is measured, and the thermosetting product is fired at 400 ° C. for 2 hours and then at 700 ° C. for 3 hours to evaporate the resin component, and the mass of the remaining inorganic filler is measured. The ratio of the mass of the inorganic filler to the total mass of the cured product is obtained and used as the content of the inorganic filler.
• the average particle size of the inorganic filler is not particularly limited. From the viewpoint of filling properties into narrow gaps, the average particle size of the inorganic filler is preferably 50 ⁇ m or less, more preferably 30 ⁇ m or less, and further preferably 20 ⁇ m or less. From the viewpoint of the mechanical strength of the cured product, the average particle size of the inorganic filler is preferably 5 ⁇ m or more, more preferably 10 ⁇ m or more, and further preferably 15 ⁇ m or more.
• the average particle size of the inorganic filler is preferably 5 ⁇ m to 50 ⁇ m, more preferably 10 ⁇ m to 30 ⁇ m, further preferably 10 ⁇ m to 20 ⁇ m, and particularly preferably 15 ⁇ m to 20 ⁇ m. preferable.
• the average particle size of the inorganic filler can be measured as the particle size (D50) when the accumulation from the small diameter side is 50% in the volume-based particle size distribution measured by the laser scattering diffraction method particle size distribution measuring device. can.
• the maximum particle size of the inorganic filler is preferably 100 ⁇ m or less, more preferably 80 ⁇ m or less, and more preferably 60 ⁇ m or less. Is more preferable, and may be 50 ⁇ m or less.
• the maximum particle size can be measured as the particle size (D99) when the accumulation from the small diameter side is 99% in the volume-based particle size distribution measured by the laser scattering diffraction method particle size distribution measuring device.
• the insulating material for the stator may contain various additives in addition to the epoxy resin, the curing agent, and the inorganic filler.
• the additive include a curing accelerator, a coupling agent, an ion exchanger, a mold release agent, a flame retardant, a colorant, a stress relaxation agent, an adhesion imparting agent and the like.
• the insulating material for the stator may contain a curing accelerator.
• the type of curing accelerator is not particularly limited, and imidazoles such as 2-ethyl-4-methylimidazole and 2-phenylimidazole; tertiary amines such as 1,8-diazabicyclo [5.4.0] -7-undecene. kind; phosphonium salts such as tetra-n-butylphosphonium tetraphenylborate; triphenylphosphine and the like.
• the curing accelerator may be used alone or in combination of two or more.
• the content of the curing accelerator is preferably 0.1 part by mass to 30 parts by mass with respect to 100 parts by mass of the resin component, and 1 part by mass to 15 parts by mass. It is more preferably by mass.
• the insulating material for the stator may contain a coupling agent from the viewpoint of improving the compatibility between the resin component and the inorganic filler, improving the adhesion to the substrate, and the like.
• the coupling agent include silane compounds such as epoxysilane, phenylsilane, mercaptosilane, aminosilane, phenylaminosilane, alkylsilane, ureidosilane and vinylsilane, titanium compounds, aluminum chelate compounds and aluminum / zirconium compounds.
• the coupling agent one type may be used alone or two or more types may be used in combination.
• the amount of the coupling agent is preferably 0.05 parts by mass to 5 parts by mass, and 0.1 parts by mass to 5 parts by mass with respect to 100 parts by mass of the inorganic filler. More preferably, it is 2.5 parts by mass.
• the insulating material for the stator may contain an ion exchanger from the viewpoint of improving moisture resistance, heat resistance and the like.
• the type of the ion exchanger is not particularly limited, and examples thereof include a hydrotalcite compound and a hydrous oxide of at least one element selected from the group consisting of magnesium, aluminum, titanium, zirconium and bismuth.
• the ion exchanger one type may be used alone or two or more types may be used in combination.
• the content of the ion exchanger is preferably 0.1 part by mass to 30 parts by mass, and more preferably 1 part by mass to 15 parts by mass with respect to 100 parts by mass of the resin component.
• the insulating material for the stator may contain a mold release agent from the viewpoint of obtaining good mold release property from the mold at the time of molding.
• the type of mold release agent is not particularly limited, and higher fatty acids such as carnauba wax, montanic acid, and stearic acid, ester waxes such as higher fatty acid metal salts and montanic acid esters, and polyolefin waxes such as polyethylene oxide and non-oxidized polyethylene. Can be mentioned.
• the release agent may be used alone or in combination of two or more.
• the content of the mold release agent is preferably 0.01 part by mass to 15 parts by mass, more preferably 0.1 part by mass to 10 parts by mass, and 0.1 part by mass to 5 parts by mass with respect to 100 parts by mass of the resin component. It may be a part by mass, or may be 0.1 part by mass to 3 parts by mass.
• the amount of the mold release agent is 0.01 part by mass or more with respect to 100 parts by mass of the resin component, the mold release property tends to be sufficiently obtained.
• the amount of the mold release agent is 15 parts by mass or less with respect to 100 parts by mass of the resin component, better adhesiveness tends to be obtained.
• the insulating material for the stator may contain a flame retardant.
• the type of the flame retardant is not particularly limited, and examples thereof include organic or inorganic compounds containing a halogen atom, an antimony atom, a nitrogen atom or a phosphorus atom, and a metal hydroxide.
• the flame retardant may be used alone or in combination of two or more.
• the content of the flame retardant is preferably 1 part by mass to 300 parts by mass, and more preferably 2 parts by mass to 150 parts by mass with respect to 100 parts by mass of the resin component.
• the insulating material for the stator may contain a colorant.
• the type of the colorant is not particularly limited, and examples thereof include carbon black, organic dyes, organic pigments, titanium oxide, lead tan, and red iron oxide.
• As the colorant one type may be used alone or two or more types may be used in combination.
• the content of the colorant may be appropriately selected depending on the purpose and the like.
• the insulating material for the stator may contain a stress relaxation agent.
• the type of stress relieving agent is not particularly limited, and thermoplastic elastomers such as silicone-based, styrene-based, olefin-based, urethane-based, polyester-based, polyether-based, polyamide-based, and polybutadiene-based, NR (natural rubber), and NBR (acrylonitrile).
• -Butadiene rubber acrylic rubber, urethane rubber, rubber particles such as silicone powder, methyl methacrylate-styrene-butadiene copolymer (MBS), methyl methacrylate-silicone copolymer, methyl methacrylate-butyl acrylate copolymer Examples thereof include rubber particles having a core-shell structure such as coalescence.
• the stress relaxation agent one type may be used alone or two or more types may be used in combination. The content of the stress relaxation agent may be appropriately selected depending on the purpose and the like.
• the insulating material for the stator may contain an adhesiveness-imparting agent from the viewpoint of improving the adhesion to the metal and the insulating property.
• the type of the adhesion-imparting agent is not particularly limited, and examples thereof include compounds having a carboxyl group, a hydroxyl group, an amino group, and the like.
• the adhesion-imparting agent may be used alone or in combination of two or more.
• the content thereof is not particularly limited, and is preferably 0.01 part by mass to 20.0 parts by mass with respect to 100 parts by mass of the resin component. It is more preferably 9.0 parts by mass to 10.0 parts by mass.
• the method for preparing the insulating material for the stator is not particularly limited.
• a method may be mentioned in which each component is sufficiently mixed by a mixer or the like, then melt-kneaded by a mixing roll, an extruder or the like, cooled and pulverized. More specifically, for example, a method of mixing and stirring each component, kneading with a preheated kneader, roll, extruder or the like, cooling and pulverizing can be mentioned.
• the insulating material for the stator may be solid or liquid at 25 ° C. and atmospheric pressure, and is preferably solid from the viewpoint of the mechanical strength of the cured product.
• the shape is not particularly limited, and examples thereof include powder, granules, and tablets.
• the insulating material for the stator is in the shape of a tablet, it is preferable that the dimensions and mass are suitable for the molding conditions from the viewpoint of handleability.
• the viscosity of the insulating material for the stator is not particularly limited. From the viewpoint of filling properties into narrow gaps, the viscosity of the insulating material for the stator is preferably 1000 Pa ⁇ s or less at 175 ° C., more preferably 500 Pa ⁇ s or less, and more preferably 200 Pa ⁇ s or less. More preferred.
• the lower limit of the viscosity of the insulating material for the stator is not particularly limited, and may be, for example, 100 Pa ⁇ s or more at 175 ° C.
• the viscosity of the insulating material for the stator can be measured by a high-grade flow tester (for example, manufactured by Shimadzu Corporation).
• the molding shrinkage of the cured product of the insulating material for the stator obtained by the following method is preferably 0.30% or less, more preferably 0.25% or less, and 0.20% or less. Is more preferable, and 0.15% or less is particularly preferable. The lower the molding shrinkage, the more preferable.
• the molding shrinkage is the molding shrinkage of a cured product obtained by molding an insulating material for a stator with a transfer molding machine under the conditions of a mold temperature of 175 ° C., a molding pressure of 6.9 MPa, and a curing time of 90 seconds.
• the glass transition temperature (Tg) of the cured product of the insulating material for the stator is preferably 130 ° C. or higher, more preferably 150 ° C. or higher, and 170 ° C. or higher from the viewpoint of heat resistance and mechanical strength. Is even more preferable.
• the glass transition temperature is, for example, a stator insulating material molded by a transfer molding machine under the conditions of a mold temperature of 175 ° C., a molding pressure of 6.9 MPa, and 90 seconds, and further, a condition of 175 ° C. for 5 hours.
• the glass transition temperature of the cured product post-cured in the above range is in the above range.
• the glass transition temperature can be measured, for example, as follows.
• the cured product is cut into strips to prepare a test piece, and the dynamic viscoelasticity is measured in the tensile mode for calculation.
• the measurement conditions are a frequency of 10 Hz, a heating rate of 5 ° C./min, and a strain of 0.1%, and in the obtained temperature-tan ⁇ relationship diagram, the temperature at which tan ⁇ is maximized is regarded as the glass transition temperature.
• RSA-G2 (TA Instruments) can be used as the evaluation device.
• the bending strength of the cured product measured by the following method is preferably 80 MPa or more, more preferably 100 MPa or more, and even more preferably 120 MPa or more.
• the upper limit of the bending strength is not particularly limited.
• a cured product of the insulating material is cut into a rectangular parallelepiped of 2.0 mm ⁇ 5.0 mm ⁇ 40 mm to prepare a test piece for evaluation of bending strength.
• a bending test is performed with a Tensilon universal material tester (for example, Instron 5948, Instron) under the conditions of a distance between fulcrums of 32 mm and a crosshead speed of 1 mm / min.
• a bending stress-displacement curve is created from the equation (A), and the maximum stress is taken as the bending strength.
• the bending strength is such that the insulating material for the stator is molded by a transfer molding machine under the conditions of a mold temperature of 175 ° C., a molding pressure of 6.9 MPa, and a curing time of 90 seconds, and then at 175 ° C. for 5 hours.
• the bending strength of the post-cured cured product is such that the insulating material for the stator is molded by a transfer molding machine under the conditions of a mold temperature of 175 ° C., a molding pressure of 6.9 MPa, and a curing time of 90 seconds, and then at 175 ° C. for 5 hours.
• the method of insulating the coils with an insulating material for a stator is not particularly limited, and examples thereof include a method of sealing the coils by transfer molding, injection molding, compression molding, or the like.
• a method of sealing the coils by transfer molding by sealing the coil under pressurized and heated conditions by transfer molding, it is possible to perform tight sealing while suppressing the entrainment of voids, and there is a tendency that the insulating property can be further improved.
• the insulating material for a stator of the present disclosure contains a spherical inorganic filler and has excellent fluidity as compared with the case where it contains a non-spherical inorganic filler, suitable molding by transfer molding is possible. ..
• the transfer molding temperature and time can be appropriately selected depending on the type of the insulating material for the stator. For example, molding may be performed under the conditions of a mold temperature of 170 ° C. to 180 ° C., a molding pressure of 5 MPa to 150 MPa, and a molding time of 1 minute to 3 minutes.
• the entire stator including the coil portion may be collectively sealed with the insulating material for the stator of the present disclosure by transfer molding.
• transfer molding it has been difficult to seal the stator by transfer molding mainly due to size restrictions.
• transfer molding is performed using the insulating material for the stator of the present disclosure, insulation between the coils can be easily performed.
• each member of the stator may be individually sealed.
• the insulating material for the stator of the present disclosure can be used for insulation between the coils of the stator.
• the stator of the present disclosure has a coil insulated by the above-mentioned insulating material for a stator.
• the insulating material for a stator of the present disclosure can be applied regardless of the winding method of the coil, such as distributed winding or centralized winding.
• the material of the coil is not particularly limited.
• the material of the coil includes conductors such as copper, aluminum, silver, and alloys thereof.
• a coil in which the conductor is covered with an insulating layer such as resin may be used.
• the stator of the present disclosure can be applied to various motors such as a motor for a hybrid vehicle, a motor for an electric vehicle, a motor for a hybrid diesel locomotive, a motor for an electric motorcycle, a motor for an elevator, and a motor used for a construction machine. ..
• the stator of the present disclosure is excellent in insulation between coils, it can be suitably applied even to a motor for a vehicle having a high output or a small size.
• the method of manufacturing a stator of the present disclosure includes insulating the coils with an insulating material for a stator.
• the details of the insulating material for the stator, the insulating method, and the stator are as described above.
• test data of the insulating material for the stator is described below.
• the present invention is not limited to the following test data.
• Epoxy resin Polyfunctional epoxy resin with epoxy equivalent of 163 g / eq to 175 g / eq and softening point of 57 ° C to 63 ° C.
• Curing agent Phenolic novolak resin with hydroxyl group equivalent of 106 g / eq and softening point of 68 ° C to 74 ° C.
• Filler 1 D50 is 19.9 ⁇ m (catalog value), molten silica particles with a maximum particle diameter of 55 ⁇ m or less (average circularity is in the range of 0.8 to 1.0, and average aspect ratio is 0.9 to 1). It is in the range of 0.0.)
• Phenol resin Resol type -Inorganic filler 2: Glass (fibrous inorganic filler)
• Each component shown in Table 1 was mixed in the amount shown in the same table, sufficiently mixed with a mixer, and then melt-kneaded at a temperature of 70 ° C to 100 ° C using a twin-screw kneader. Next, after cooling the melt, the solidified material was pulverized into a powder to prepare a target powder-like insulating material.
• the prepared insulating material was evaluated by various tests shown below. Unless otherwise specified, the insulating material was molded by a transfer molding machine under the conditions of a mold temperature of 175 ° C., a molding pressure of 6.9 MPa, and a curing time of 90 seconds. If necessary, post-curing was performed at 175 ° C. for 5 hours.
• Molding shrinkage rate (%) ⁇ (length of cured product before post-curing-length of cured product after post-curing) / (length of cured product before post-curing) ⁇ x 100
• the length of the cured product is the length of any one side of the rectangular cured product.
• Glass transition temperature (Tg) The glass transition temperature is measured by the following method, and the composition having a high Tg is made good.
• the cured product after post-curing is cut into strips to prepare test pieces, and the glass transition temperature is calculated by performing dynamic viscoelasticity measurement in the tensile mode.
• the measurement conditions are a frequency of 10 Hz, a heating rate of 5 ° C./min, and a strain of 0.1%, and in the obtained temperature-tan ⁇ relationship diagram, the temperature at which tan ⁇ is maximized is regarded as the glass transition temperature.
• RSA-G2 (TA Instruments) is used as the evaluation device.
• the bending strength is measured by the following method, and the composition showing high bending strength is made good.
• the cured product after curing of the insulating material is cut into a rectangular parallelepiped of 2.0 mm ⁇ 5.0 mm ⁇ 40 mm to prepare a test piece for evaluation of bending strength.
• a bending test is performed with a Tensilon universal material testing machine (Instron 5948, Instron) under the conditions of a distance between fulcrums of 32 mm and a crosshead speed of 1 mm / min.
• a bending stress-displacement curve is created from the equation (A), and the maximum stress is taken as the bending strength.
• Examples 1 and 2 since the fluidity of the insulating material is excellent, even if the content of the inorganic filler is increased to 85% by mass, excellent filling property is obtained without causing unfilled portions. In Examples 1 and 2, the liquidity equal to or higher than that in Comparative Example 1 is obtained. Further, it was found that the insulating materials of Examples 1 and 2 have a low molding shrinkage rate and can be suitably applied as an insulating material for a stator capable of high-precision sealing. On the other hand, in Comparative Example 1, the molding shrinkage rate is high, flow marks due to fiber orientation are seen, and the distribution of the filler tends to be uneven, so that it is applied to the insulating material for a stator that requires high accuracy. It turned out to be difficult.
• the Tg of the insulating material of Example 1, Example 2, and Comparative Example 1 was 175 ° C., 175 ° C., and 300 ° C., respectively, and good heat resistance was obtained in each case. It turned out to be.
• the bending strength it was found that the bending strengths of the insulating materials of Example 1, Example 2, and Comparative Example 1 were 100 MPa, 130 MPa, and 200 MPa, respectively, and good strength was obtained in each of them.
• the insulating material for the stator of the example has excellent filling property and dimensional stability as compared with the insulating material for the stator of the comparative example, and also has good mechanical strength and heat resistance. ..

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• 2021
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