WO2024122623A1 - 絶縁シート - Google Patents
絶縁シート Download PDFInfo
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- WO2024122623A1 WO2024122623A1 PCT/JP2023/043905 JP2023043905W WO2024122623A1 WO 2024122623 A1 WO2024122623 A1 WO 2024122623A1 JP 2023043905 W JP2023043905 W JP 2023043905W WO 2024122623 A1 WO2024122623 A1 WO 2024122623A1
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- WIPO (PCT)
- Prior art keywords
- adhesive layer
- layer
- insulating
- insulating sheet
- resin
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
Definitions
- the present invention relates to an insulating sheet.
- the insulating sheet of the present invention relates to an insulating sheet for a motor used in a drive motor of an automobile.
- a drive motor for an automobile includes a rotor and a stator that generates a force to rotate the rotor.
- the stator includes multiple coils, and generates a Lorentz force by generating a magnetic field in the multiple coils, which then rotates the rotor.
- the coil has, for example, a number of segment conductors connected to each other.
- the coil is usually attached to a member made of laminated magnetic steel plates, called a stator core or rotor core.
- the magnetic steel plates usually contain iron, which has high magnetic properties, as its main component.
- the segment conductor is usually made of enamel wire, in which a copper wire serving as a conductor is covered with an insulating coating (for example, a polyurethane resin coating).
- a core such as a stator core or a rotor core has a plurality of slot grooves, and a coil is housed in each of the plurality of slot grooves.
- an insulating sheet is housed in each slot together with the coil to ensure insulation between the coil and the inner wall surface of the slot. More specifically, the insulating sheet is housed in the slot in a state where it is wrapped around the coil.
- the coil, which is wound with an insulating sheet is fixed in the slot groove by an insulating resin (e.g., epoxy varnish) in the slot groove.
- the insulating sheet has a five-layer structure including a polyester resin layer made of a polyester film, two paper-like sheet layers respectively disposed above and below the polyester resin layer, and two adhesive layers respectively disposed between the polyester resin layer and the paper-like sheet, as described in Patent Document 1. That is, the insulating sheet has a five-layer structure in which the paper-like sheet layer is disposed as a surface layer and the polyester resin layer is disposed as an innermost layer.
- the paper-like sheet layer is composed of a paper-like sheet as described in Patent Document 1. For example, so-called "aramid paper” made mainly of wholly aromatic polyamide fiber is used as the paper-like sheet.
- the adhesive layer is usually formed by an adhesive mainly composed of polyurethane resin or the like.
- the core such as the stator core or rotor core
- the coils housed in each of the multiple slot grooves of the core are crushed in an integrated state, and valuable metal materials are recovered from the integrated core and coils.
- the recovery of the metal material from the integrated product is usually carried out by crushing the integrated product with a shredder or the like to obtain crushed material, and then recovering the valuable metal material from the crushed material.
- the crushed materials include crushed pieces of a first insulating resin such as polyurethane resin used to form the insulating coating, crushed pieces of a second insulating resin such as epoxy resin in the slot grooves, crushed pieces of iron materials such as magnetic steel plates that form the core, and crushed pieces of copper materials contained in the segment conductors that form the coil.
- a first insulating resin such as polyurethane resin used to form the insulating coating
- crushed pieces of a second insulating resin such as epoxy resin in the slot grooves
- crushed pieces of iron materials such as magnetic steel plates that form the core
- crushed pieces of copper materials contained in the segment conductors that form the coil are crushed pieces of copper materials contained in the segment conductors that form the coil.
- the specific gravity of each of the first insulating resin and the second insulating resin is about 1 g/ cm3
- the specific gravity of iron is about 8 g/ cm3
- the specific gravity of copper is about 9 g/cm3. Therefore, the specific gravity of iron and copper is sufficiently larger than the specific gravity of the first insulating resin or the second insulating resin. Therefore, the crushed materials of the first insulating resin and the crushed materials of the second insulating resin, and the crushed materials of the iron material and the crushed materials of the copper material can be easily separated and recovered with high accuracy by utilizing the difference in specific gravity.
- the difference in specific gravity between copper and iron is not that large, so it is difficult to accurately separate crushed iron material and crushed copper material using the difference in specific gravity and recover them separately.
- the core and coil are integrated, so it is difficult to accurately separate and recover the metal material that makes up the core and the metal material that makes up the coil.
- the present invention aims to provide an insulating sheet that can accurately separate the metal material constituting the core and the metal material constituting the coil from used drive motors and recover them separately.
- the insulating sheet according to the present invention is An adhesive layer and an insulating layer that is laminated on at least one surface of the adhesive layer to form an outermost layer,
- the adhesive layer is composed of a resin composition,
- the resin composition contains thermally expandable graphite.
- FIG. 2 is a cross-sectional view showing a configuration of an insulating sheet according to an embodiment of the present invention.
- FIG. 2 is a schematic perspective view of a stator of a drive motor of an automobile.
- FIG. FIG. 4 is an enlarged view of part A in FIG. 3 .
- the insulating sheet according to the present embodiment includes an adhesive layer and an insulating layer that is laminated on one surface of the adhesive layer to form an outermost layer.
- the adhesive layer is made of a resin composition.
- the resin composition contains thermally expandable graphite.
- the resin composition may contain an organic solvent (e.g., methyl ethyl ketone (MEK) or the like) for suspending or dissolving the resin.
- MEK methyl ethyl ketone
- the resin composition may be a resin solution containing an organic solvent.
- the insulating sheet according to this embodiment will be described using an insulating sheet with a five-layer structure as shown in Figure 1 as an example.
- the insulating sheet 10 according to the present embodiment is configured by laminating a first insulating layer 3a and a second insulating layer 3b on both sides of a base layer 1a with a first adhesive layer 2a and a second adhesive layer 2b interposed therebetween. That is, the insulating sheet 10 according to the present embodiment has a five-layer structure in which the first insulating layer 3a, the first adhesive layer 2a, the base layer 1a, the second adhesive layer 2b, and the second insulating layer 3b are laminated in this order. In the insulating sheet 10 according to the present embodiment, the first insulating layer 3a and the second insulating layer 3b constitute the outermost layers.
- the insulating sheet 10 according to the present embodiment is used, for example, as an insulating sheet for a drive motor of an automobile.
- An example of a drive motor of an automobile is an oil-cooled drive motor.
- the oil-cooled drive motor is a drive motor that is cooled by cooling oil such as ATF.
- Examples of the automobile include a hybrid automobile (HEV) and an electric vehicle (EV).
- Examples of the drive motor include an HV motor, a motor generator, an alternator, a 4WD motor, an oil pump motor, an EPS motor, a compressor motor, and an in-wheel motor.
- the first insulating layer 3a and the second insulating layer 3b are made of, for example, a paper-like sheet formed using fibers.
- fibers used to form the paper-like sheet include organic fibers such as aromatic polyamide fibers, polyether sulfide fibers, polyphenylene sulfide fibers, polypropylene fibers, polyether ether ketone fibers, polyethylene terephthalate fibers, acrylate fibers, and polyethylene naphthalate fibers, and inorganic fibers such as glass fibers, rock wool, asbestos, boron fibers, alumina fibers, and carbon fibers, as well as natural fibers such as silk and cotton, and semi-synthetic fibers such as cellulose.
- the paper-like sheet may be made of only one of these fibers, or may be made of a mixture of two or more of these fibers.
- the paper-like sheet is preferably formed using wholly aromatic polyamide fibers as a main raw material among the above-mentioned fibers.
- the paper-like sheet is preferably a wholly aromatic polyamide paper containing wholly aromatic polyamide fibers.
- the fully aromatic polyamide paper has good heat resistance, and since the first insulating layer 3a and the second insulating layer 3b are made of fully aromatic polyamide paper, the insulating sheet 10 of this embodiment can have good heat resistance.
- the wholly aromatic polyamide paper is preferably produced by a wet papermaking method using wholly aromatic polyamide fibers.
- the wholly aromatic polyamide paper may be, for example, one made by fiberizing a condensation polymer of phenylenediamine and phthalic acid (wholly aromatic polyamide), in which all groups other than the amide group are composed of benzene rings, and using this fiberized wholly aromatic polyamide fiber as the main constituent material.
- the wholly aromatic polyamide paper for example, one commercially available from DuPont under the trade name "Nomex (registered trademark)" can be used.
- the wholly aromatic polyamide paper may have a surface coating treatment with a coating agent, or may not have a surface coating treatment.
- the coating agent may contain a polyamide resin.
- a polyamide resin a methoxymethylated polyamide resin in which at least a portion of the amide group sites are methoxymethylated is preferably used.
- the first insulating layer 3a and the second insulating layer 3b may be made of, for example, a polyester-based film. That is, the first insulating layer 3a and the second insulating layer 3b may be a resin film layer made of a polyester-based film or the like.
- polyester film examples include a polyethylene terephthalate (PET) film and a polyethylene naphthalate (PEN) film.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- the first insulating layer 3a and the second insulating layer 3b are made of a polyester-based film, it is preferable that the first insulating layer 3a and the second insulating layer 3b are made of a polyethylene naphthalate (PEN) film, from the viewpoint of having better hydrolysis resistance.
- the resin film constituting the resin film layer may have higher heat resistance than a polyester-based film.
- resin films examples include polyimide (PI) films, polyamide films, polyphenylene sulfide (PPS) films, polyether ether ketone (PEEK) films, and ethylene-tetrafluoroethylene copolymer (ETFE) films.
- PI polyimide
- PPS polyphenylene sulfide
- PEEK polyether ether ketone
- ETFE ethylene-tetrafluoroethylene copolymer
- each of the first insulating layer 3a and the second insulating layer 3b may be 20 ⁇ m or more, 25 ⁇ m or more, or 30 ⁇ m or more. Also, the thickness of each of the first insulating layer 3a and the second insulating layer may be 250 ⁇ m or less, 100 ⁇ m or less, or 70 ⁇ m or less. In particular, when the first insulating layer 3a and the second insulating layer 3b are made of wholly aromatic polyamide paper, having a thickness within the above-mentioned numerical range can impart high mechanical properties to the insulating sheet 10.
- first insulating layer 3a and the second insulating layer 3b are made of wholly aromatic polyamide paper, having a thickness within the above-mentioned numerical range can improve the shape retention of the insulating sheet 10 that has been subjected to bending processing.
- the first insulating layer 3a and the second insulating layer 3b may have the same thickness or may have different thicknesses.
- each of the first insulating layer 3a and the second insulating layer 3b can be determined by measuring the thickness at 10 randomly selected locations using a digital micrometer and taking the arithmetic average of these measurements.
- the first adhesive layer 2a can be formed, for example, by applying a resin composition to one surface of the base layer 1a.
- the second adhesive layer 2b can be formed by applying a resin composition to the other surface of the base layer 1a.
- the first adhesive layer 2a can also be formed by applying a resin composition to one surface of the first insulating layer 3a (the surface facing the base layer 1a).
- the second adhesive layer 2b can also be formed by applying a resin composition to one surface of the second insulating layer 3b (the surface facing the base layer 1a).
- the amount of the resin composition applied is preferably 10 g/m 2 or more and 100 g/m 2 or less.
- the first adhesive layer 2a and the second adhesive layer 2b can have more sufficient bonding strength.
- the first adhesive layer 2a and the second adhesive layer 2b can be formed thinner.
- the thickness of the insulating sheet 10 according to the present embodiment can be made relatively thin. As a result, the insulating sheet 10 according to the present embodiment can be easily inserted into a narrow and small space.
- the first adhesive layer 2a and the second adhesive layer 2b may have the same thickness or different thicknesses, but it is preferable that they have the same thickness.
- the resin composition preferably contains, as a resin, an acrylic resin, a polyurethane resin, an epoxy resin, an epoxy ester resin, a polyester resin, a silicone resin, or the like.
- the resin composition more preferably contains an acrylic resin, a polyurethane resin, or an epoxy resin as a resin, and particularly preferably contains an acrylic resin. That is, the resin composition is particularly preferably an alkyl resin composition containing an acrylic resin.
- the acrylic resin is, for example, a homopolymer of a monomer represented by the following formula (1), or a copolymer having at least a constituent unit based on the monomer.
- R 1 is a hydrogen atom or a lower alkyl group
- R 2 is an alkyl group having 1 to 12 carbon atoms.
- the acrylic resin may be a polyacrylic ester such as polymethyl acrylate, polyethyl acrylate, or polybutyl acrylate (PAB); a polymethacrylic ester such as polymethyl methacrylate, polyethyl methacrylate, or polybutyl methacrylate; or a copolymer such as an ethylene-acrylic ester copolymer, an ethylene-acrylic ester-acrylic acid copolymer, a styrene-methacrylic ester-acrylic acid copolymer, an acrylic ester-vinyl chloride copolymer, an acrylic ester-acrylic acid copolymer, a methacrylic ester-vinyl chloride copolymer, a styrene-methacrylic ester-butadiene copolymer, or a methacrylic ester-acrylonitrile copolymer.
- PAB polybutyl acrylate
- PAB polybutyl acryl
- polybutyl acrylate is preferred as the acrylic resin.
- the resin composition contains polybutyl acrylate as the acrylic resin, the resin composition preferably contains polyisocyanate in addition to polybutyl acrylate.
- the polybutyl acrylate is preferably crosslinked with the polyisocyanate.
- the resin composition containing polybutyl acrylate and polyisocyanate preferably contains 3 parts by mass or more, and more preferably 10 parts by mass or more, of the polyisocyanate per 100 parts by mass of the polybutyl acrylate.
- the resin composition containing polybutyl acrylate and polyisocyanate preferably contains 25 parts by mass or less, and more preferably 20 parts by mass or less, of the polyisocyanate per 100 parts by mass of the polybutyl acrylate.
- the polybutyl acrylate (PAB) may have a carboxy group.
- the resin composition containing polybutyl acrylate and polyisocyanate preferably further contains a terpene phenol.
- the polyacrylic acid and the terpene phenol are preferably crosslinked with a polyisocyanate.
- the resin composition containing polybutyl acrylate, polyisocyanate, and terpene phenol preferably contains 1 part by mass or more and 30 parts by mass or less of terpene phenol per 100 parts by mass of polybutyl acrylate.
- the resin composition may contain an alkylphenol instead of the terpene phenol.
- the above-mentioned resin composition containing an alkylphenol preferably contains 1 part by mass or more and 30 parts by mass or less of the alkylphenol per 100 parts by mass of the polybutyl acrylate.
- the polyurethane resin is, for example, a urethane reaction product between a polyol component having two or more hydroxyl groups in one molecule and a polyisocyanate component having two or more isocyanate groups in one molecule.
- polyurethane resin does not refer to a "polyurethane resin” in the broad sense including a “polyurethane-urea resin”, but refers to a "polyurethane resin” that does not substantially contain urea bonds.
- the polyol component may be a conventional polyol component used for synthesizing polyurethane resins.
- Specific examples of the polyol component include polyester polyol, polyether polyol, polycarbonate polyol, and other polyols.
- polyester polyol examples include polyethylene adipate diol, polybutylene adipate diol, polyhexamethylene adipate diol, polyneopentyl adipate diol, polyethylene/butylene adipate diol, polyneopentyl/hexyl adipate diol, poly-3-methylpentane adipate diol, polybutylene isophthalate diol, polycaprolactone diol, and poly-3-methylvalerolactone diol.
- the polyester polyol has good heat resistance. Therefore, when the resin composition contains a polyurethane resin and the polyol component of the polyurethane resin is a polyester polyol, the adhesive layer formed by the resin composition can have good heat resistance.
- polyether polyol examples include polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and random/block copolymers thereof.
- the polyether polyol has good hydrolysis resistance. Therefore, when the resin composition contains a polyurethane resin and the polyol component of the polyurethane resin is a polyether polyol, the adhesive layer formed by the resin composition can have good hydrolysis resistance.
- polycarbonate polyol examples include polytetramethylene carbonate diol, polypentamethylene carbonate diol, polyneopentyl carbonate diol, polyhexamethylene carbonate diol, poly(1,4-cyclohexanedimethylene carbonate) diol, and random/block copolymers thereof.
- the polycarbonate polyol has both good heat resistance and good hydrolysis resistance. Therefore, when the resin composition contains a polyurethane resin and the polyol component of the polyurethane resin is a polycarbonate polyol, the adhesive layer formed by the resin composition can have both good heat resistance and good hydrolysis resistance.
- the other polyols include dimer diol or a hydrogenated product thereof, polybutadiene polyol or a hydrogenated product thereof, polyisoprene polyol or a hydrogenated product thereof, acrylic polyol, epoxy polyol, polyether ester polyol, siloxane-modified polyol, ⁇ , ⁇ -polymethyl methacrylate diol, and ⁇ , ⁇ -polybutyl methacrylate diol.
- the hydrogenated product of dimer diol and the hydrogenated product of polybutadiene polyol have both good heat resistance and good hydrolysis resistance, similar to the polycarbonate polyol.
- the adhesive layer formed by the resin composition can have both good heat resistance and good hydrolysis resistance.
- the polyisocyanate component may be any of the conventional polyisocyanate components used in the synthesis of polyurethane resins.
- polyisocyanate component examples include toluene-2,4-diisocyanate, toluene-2,6-diisocyanate, 4-methoxy-1,3-phenylene diisocyanate, 4-isopropyl-1,3-phenylene diisocyanate, 4-chloro-1,3-phenylene diisocyanate, 4-butoxy-1,3-phenylene diisocyanate, 2,4-diisocyanate diphenyl ether, 4,4'-methylenebis(phenylene isocyanate) (MDI), crude or polymeric MDI, jurylene diisocyanate, xylylene diisocyanate (XDI), 1,5-naphthalene diisocyanate, benzidine diisocyanate, aromatic diisocyanates such as 4,4'-diisocyanate dibenzyl socyanate, o-nitrobenzidine diisocyanate, and 4,4'-diisocyanate dibenzyl;
- the polyurethane resin can be produced by a conventionally known general production method.
- the polyurethane resin can be produced by reacting the polyol component and the polyisocyanate component by a one-shot method or a multi-stage method.
- the one-shot method or the multi-stage method can be carried out at a temperature in the range of, for example, 20° C. to 150° C., preferably 60° C. to 110° C.
- epoxy resin various known epoxy resins such as phenol novolac type epoxy resins, triphenylmethane type epoxy resins, cresol novolac type epoxy resins, bisphenol A type epoxy resins, modified bisphenol A type epoxy resins, bisphenol F type epoxy resins, modified bisphenol F type epoxy resins, bisphenol AD type epoxy resins, modified bisphenol AD type epoxy resins, dicyclopentadiene type epoxy resins, or biphenyl type epoxy resins can be used.
- the epoxy resin is preferably a phenol novolac type epoxy resin.
- the epoxy equivalent of the phenol novolac type epoxy resin is preferably 150 g/eq or more, more preferably 160 g/eq or more, and even more preferably 170 g/eq or more.
- the epoxy equivalent of the phenol novolac type epoxy resin is preferably 200 g/eq or less, more preferably 190 g/eq or less, and even more preferably 180 g/eq or less.
- the epoxy equivalent can be determined according to JIS K 7236.
- the resin composition contains an epoxy resin
- the resin composition further contains a curing agent for the epoxy resin.
- the curing agent for the epoxy resin include a phenol-based curing agent, an amine-based curing agent, and an acid anhydride-based curing agent.
- the phenol-based curing agent, the amine-based curing agent, and the acid anhydride-based curing agent may be used alone or in combination of two or more. Among these, the phenol-based curing agent is preferable.
- phenol-based hardener examples include phenol novolac resin, aralkyl-type phenol resin, dicyclopentadiene-modified phenol resin, naphthalene-type phenol resin, bisphenol-type phenol resin, and triphenylmethane-type phenol resin.
- amine-based curing agent examples include diaminodiphenylsulfone, dicyandiamide, diaminophenylmethane, and triethylenetetramine.
- acid anhydride curing agent examples include phthalic anhydride, trimellitic anhydride, and maleic anhydride.
- the resin composition may contain 10 parts by mass or more, 20 parts by mass or more, 30 parts by mass or more, or 40 parts by mass or more of an epoxy resin hardener per 100 parts by mass of epoxy resin.
- the resin composition may contain 70 parts by mass or less, 60 parts by mass or less, or 50 parts by mass or less of an epoxy resin hardener per 100 parts by mass of epoxy resin.
- the resin composition may further include a curing accelerator in addition to the curing agent for the epoxy resin.
- a curing accelerator examples include tetraphenylphosphonium tetraphenylborate, imidazoles, triphenyl phosphate (TPP), and amine-based curing accelerators.
- TPP triphenyl phosphate
- amine-based curing accelerator examples include boron trifluoride monoethylamine.
- the resin composition containing the curing accelerator may contain 0.1 parts by mass or more, 0.5 parts by mass or more, 1 part by mass or more, or 2 parts by mass or more of the curing accelerator per 100 parts by mass of the epoxy resin.
- the resin composition containing the curing accelerator may contain 10 parts by mass or less, 7 parts by mass or less, or 4 parts by mass or less of the curing accelerator per 100 parts by mass of the epoxy resin.
- the resin composition may contain an acrylic resin in addition to the epoxy resin.
- the resin composition preferably contains a phenol novolac type epoxy resin as the epoxy resin, and further contains polybutyl acrylate (PAB) as the acrylic resin.
- PAB polybutyl acrylate
- Such a resin composition may contain 100 parts by mass or more, 150 parts by mass or more, or 200 parts by mass or more of the acrylic resin relative to 100 parts by mass of the epoxy resin.
- the resin composition may contain 300 parts by mass or less, or 250 parts by mass or less of the acrylic resin relative to 100 parts by mass of the epoxy resin.
- the resin composition for forming the first adhesive layer 2a and the second adhesive layer 2b contains thermally expandable graphite.
- the expansion start temperature of the thermally expandable graphite is preferably higher than 200° C., more preferably 205° C. or higher, and even more preferably 210° C. or higher.
- the expansion start temperature of the thermally expandable graphite is preferably lower than 300° C., more preferably 250° C. or lower, even more preferably 230° C. or lower, and particularly preferably 220° C. or lower. Since the expansion start temperature of the thermally expandable graphite is within the above numerical range, when the insulating sheet 10 of this embodiment is used as an insulating sheet for a drive motor, the thermally expandable graphite can be prevented from starting to expand at the temperature during operation of the drive motor (up to approximately 200°C). Furthermore, when the drive motor is no longer in use, the thermal expansion of the thermally expandable graphite can be started at a relatively low temperature of about 300°C.
- the expansion start temperature of the thermally expandable graphite is the temperature at which the thermally expandable graphite expands to at least 1.1 times its volume before the start of heating when the temperature is increased from 150°C at a rate of 5°C/min.
- the temperature intervals at which the volume of the thermally expandable graphite is measured There are no particular limitations on the temperature intervals at which the volume of the thermally expandable graphite is measured. For example, the volume of the thermally expandable graphite can be measured every time the temperature is increased by 5°C.
- the volume average particle diameter D50 of the thermally expandable graphite is preferably 50 ⁇ m or more, more preferably 60 ⁇ m or more, even more preferably 70 ⁇ m or more, and particularly preferably 80 ⁇ m or more.
- the volume average particle diameter D50 of the thermally expandable graphite is preferably 250 ⁇ m or less, more preferably 200 ⁇ m or less, even more preferably 150 ⁇ m or less, and particularly preferably 100 ⁇ m or less.
- the thermally expandable graphite can be dispersed relatively uniformly in each of the first adhesive layer 2a and the second adhesive layer 2b, and therefore, a sufficient space for the thermal expansion of the thermally expandable graphite can be secured in each of the first adhesive layer 2a and the second adhesive layer 2b.
- the volume average particle diameter D50 of the thermally expandable graphite can be measured on a volume basis, for example, by using a laser diffraction/scattering type particle size measuring device (Microtrac MT3000II series, manufactured by Microtrac Bell).
- the thermally expandable graphite is produced by treating various graphites, such as natural graphite, pyrolytic graphite, or kish graphite, with sulfuric acid and sodium nitrate, potassium permanganate, bromine, or a halide, to produce an intercalation compound between the layers of the graphite.
- various graphites such as natural graphite, pyrolytic graphite, or kish graphite
- sulfuric acid and sodium nitrate, potassium permanganate, bromine, or a halide to produce an intercalation compound between the layers of the graphite.
- the above-mentioned various graphites have a structure in which a plurality of hexagonal rings each consisting of six carbon atoms are connected in the plane direction to form a network plane, which is laminated at a predetermined interval (3.354 ⁇ ) in the height direction. That is, in the thermally expandable graphite, an intercalation compound is generated between adjacent network planes.
- thermally expandable graphite When the thermally expandable graphite is heat-treated at a temperature equal to or higher than the thermal expansion starting temperature (e.g., 280° C.), gas is generated from the intercalation compound, and the generated gas widens the spacing between the mesh planes, causing the thermally expandable graphite to expand in a direction perpendicular to the plane direction of the mesh planes.
- the thermal expansion starting temperature e.g., 280° C.
- the insulating sheet 10 of this embodiment is used, for example, in a drive motor including a rotor having a rotor core, a stator having a stator core in which a plurality of slot grooves are formed, and a plurality of coils housed in the plurality of slot grooves, to ensure insulation between the stator core and the multiple coils.
- the insulating sheet 10 of this embodiment is used to ensure insulation between the stator and multiple coils by being wound around multiple coils and accommodated in multiple slot grooves, as described below.
- the coils wound with the insulating sheet 10 are fixed to the slots by insulating resin (e.g., epoxy varnish) placed inside the slots.
- the stator core and the coils are integrated with each other by the insulating resin. Thereafter, when the drive motor is no longer in use, the integrated assembly of the stator core and the coils is heated at a temperature equal to or higher than the thermal expansion starting temperature (e.g., 280° C.), thereby expanding the thermally expandable graphite inside each of the first adhesive layer 2 a and the second adhesive layer 2 b.
- the expansion of the thermally expandable graphite inside each of the first adhesive layer 2 a and the second adhesive layer 2 b can cause cohesive failure in each of the first adhesive layer 2 a and the second adhesive layer 2 b.
- the integrated state between the stator core and the coils can be released by causing cohesive failure in the first adhesive layer 2 a and the second adhesive layer 2 b, and the metal material (e.g., iron material, etc.) constituting the stator core and the metal material (e.g., copper material, etc.) constituting the coils can be separated and recovered separately.
- the rotor core has a plurality of slot grooves for accommodating a plurality of coils in the same manner as the stator core, and the plurality of coils are accommodated in the slot grooves while being wound with the insulating sheet 10 according to this embodiment, the rotor core can be released from the integrated state with the plurality of coils in the same manner as described above.
- different types of metal materials can be accurately separated and recovered from the integrated product of the core (stator core and rotor core) and the plurality of coils.
- the resin composition preferably contains 1% by mass or more of thermally expandable graphite, more preferably 5% by mass or more, and even more preferably 15% by mass or more.
- the resin composition preferably contains 40% by mass or less of thermally expandable graphite, more preferably 30% by mass or less, and even more preferably 25% by mass or less.
- the thermally expandable graphite in the resin composition within the above-mentioned numerical range, it becomes easier to disperse the thermally expandable graphite relatively uniformly inside each of the first adhesive layer 2 a and the second adhesive layer 2 b. In other words, it is possible to suppress uneven distribution of the thermally expandable graphite inside each of the first adhesive layer 2 a and the second adhesive layer 2 b. Therefore, when the insulating sheet 10 according to this embodiment is used as an insulating sheet for a drive motor, the adhesive strength of the first adhesive layer 2a and the second adhesive layer 2b to the first insulating layer 3a and the second insulating layer 3b can be suppressed from decreasing due to uneven distribution of the thermally expandable graphite during operation of the drive motor.
- the first adhesive layer 2a and the second adhesive layer 2b can have good adhesiveness to the first insulating layer 3a and the second insulating layer 3b, respectively. Furthermore, by suppressing uneven distribution of the thermally expandable graphite inside each of the first adhesive layer 2a and the second adhesive layer 2b, sufficient space can be secured inside each of the first adhesive layer 2a and the second adhesive layer 2b for the thermal expansion of the thermally expandable graphite.
- the thermally expandable graphite can be sufficiently expanded inside the first adhesive layer 2a and the second adhesive layer 2b, and sufficient cohesive failure can be caused in the first adhesive layer 2a and the second adhesive layer 2b.
- the integrated state of the stator core and the coils can be released, and the stator core and the coils can be separated.
- the metal material constituting the stator core e.g., iron material, etc.
- the metal material constituting the coils e.g., copper material, etc.
- the thickness of each of the first adhesive layer 2a and the second adhesive layer 2b is preferably 5 ⁇ m or more, more preferably 10 ⁇ m or more, and even more preferably 20 ⁇ m or more. Also, the thickness of each of the first adhesive layer 2a and the second adhesive layer 2b is preferably 40 ⁇ m or less.
- the thickness of each of the first adhesive layer 2a and the second adhesive layer 2b can be measured using a digital microscope (for example, Model VHX-8000 manufactured by Keyence Corporation). Specifically, the thickness can be measured as follows. (1) An image of the side surface of the insulating sheet 10 is obtained using a camera provided in a digital microscope. (2) The image is displayed on the monitor of the digital microscope.
- the thickness is measured at 10 randomly selected locations for each of the first adhesive layer 2a and the second adhesive layer 2b, and the arithmetic average of the thickness values measured for each of the first adhesive layer 2a and the second adhesive layer 2b is calculated.
- the adhesive strength of each of the first adhesive layer 2a and the second adhesive layer 2b to the first insulating layer 3a and the second insulating layer 3b is preferably 10 N/25 mm or less, more preferably 5 N/25 mm or less, even more preferably 3 N/25 mm or less, and particularly preferably 1 N/25 mm or less.
- the first adhesive layer 2a and the second adhesive layer 2b can be relatively easily peeled off from the first insulating layer 3a and the second insulating layer 3b, respectively. That is, after the first adhesive layer 2a and the second adhesive layer 2b are peeled off from the first insulating layer 3a and the second insulating layer 3b, respectively, as described above, cohesive failure can be caused inside the first adhesive layer 2a and the second adhesive layer 2b. This makes it easier to release the integrated state of the stator core and the multiple coils, which in turn makes it easier to separate and recover different types of metal materials from the integrated assembly of the core and the multiple coils in a used drive motor.
- the thermal expansion starting temperature e.g., 280° C.
- the adhesive strength of each of the first adhesive layer 2a and the second adhesive layer 2b to the first insulating layer 3a and the second adhesive layer 2b is preferably 5 N/25 mm or more, more preferably 7 N/25 mm or more, and more preferably 10 N/25 mm or more.
- Such adhesive strength may be, for example, 50 N/25 mm or less.
- the above adhesive strength ensures sufficient adhesive strength of each of the first adhesive layer 2a and the second adhesive layer 2b to the wholly aromatic polyamide paper constituting the first insulating layer 3a and the second insulating layer 3b for the drive motor when in use.
- the adhesive strength of each of the first adhesive layer 2a and the second adhesive layer 2b to the first insulating layer 3a and the second insulating layer 3b is 1 N/25 mm or less after heating at 280°C for 30 minutes, and 5 N/25 mm or more before heating.
- the adhesive strength as described above it is possible to more easily release the integrated state between the stator core and the multiple coils in a used drive motor, while at the same time ensuring sufficient adhesive strength of each of the first adhesive layer 2a and the second adhesive layer 2b to the wholly aromatic polyamide paper that constitutes the first insulating layer 3a and the second insulating layer 3b in a drive motor in a used state.
- the adhesive strength of the first adhesive layer 2a to the first insulating layer 3a and the adhesive strength of the second adhesive layer 2b to the second insulating layer 3b can be determined as follows:
- the adhesive strength before heating and the adhesive strength after heating at 280° C. for 30 minutes can both be determined as follows. (1) A rectangular sample having a width of 25 mm is cut out from the insulating sheet 10.
- a 180-degree peel test is performed by pulling the first insulating layer 3a attached to the first adhesive layer 2a at a test speed of 100 mm/min in an environment of room temperature (23 ⁇ 2°C) and a relative humidity of 50% RH, to determine the peel strength (N/25 mm) of the first adhesive layer 2a to the first insulating layer 3a.
- a 180-degree peel test is performed by pulling the second insulating layer 3b attached to the second adhesive layer 2b to determine the peel strength (N/25 mm) of the second adhesive layer 2b to the second insulating layer 3b.
- At least one of the shear adhesive strength (S AF ) of the first adhesive layer 2 a to the first insulating layer 3 a and the shear adhesive strength (S AF ) of the second adhesive layer 2 b to the second insulating layer 3 b is preferably 1.4 MPa or more.
- Such a shear adhesive strength may be, for example, 10 MPa or less.
- At least one of the shear adhesive strength (S AF' ) of the first adhesive layer 2a to the first insulating layer 3a and the shear adhesive strength of the second adhesive layer 2b to the second insulating layer 3b is preferably 2.5 MPa or less, more preferably 2.0 MPa or less, and even more preferably 1.3 MPa or less.
- the difference ⁇ S AF (S AF -S AF' ) between the shear adhesive strength S AF and the shear adhesive strength S AF' is preferably 0.3 MPa or more, more preferably 0.4 MPa or more.
- Such ⁇ S AF (S AF -S AF' ) may be, for example, 0.1 MPa or less.
- the shear adhesive strength SAF before heating is determined as follows. (1) The insulating sheet 10 is sandwiched between two long pieces of SPCC (cold-rolled steel plate, 1 mm thick). The insulating sheet 10 is sandwiched between two pieces of SPCC such that only the end of one SPCC and the end of the other SPCC overlap each other. Specifically, a first insulating layer 3a is adhered to one surface of an end of one SPCC via an adhesive sheet (trade name "FB-ML634" manufactured by Nitto Shinko Corporation). A second insulating layer 3b is adhered to one surface of an end of the other SPCC via an adhesive sheet (same as above). Then, an insulating sheet 10 is sandwiched between the two SPCCs arranged as described above.
- the shear adhesive strength S AF' after heating at 280° C. for 30 minutes is determined as follows. (1') Without using an adhesive sheet, the insulating sheet 10 is sandwiched between two SPCC sheets (thickness 1 mm) in the thickness direction. Then, the insulating sheet 10 is fixed by sandwiching the two SPCC sheets with a double clip to obtain a specimen. The specimen is heated at 280°C for 30 minutes. (2') After the above heating, the insulating sheet 10 is taken out of the specimen that has been cooled to room temperature, and the above (1) is carried out on the taken-out insulating sheet 10. (3') The above (2) is carried out on the insulating sheet 10 taken out from the specimen.
- the first adhesive layer 2a and the second adhesive layer 2b may contain various known additives.
- additives include tackifiers, dispersants, antioxidants, antioxidants, processing aids, stabilizers, defoamers, flame retardants, thickeners, pigments, etc.
- the base layer 1a is preferably a polyester film made of a polyester resin, such as polybutylene terephthalate (PBT) resin, polyethylene terephthalate (PET) resin, polybutylene naphthalate (PBN) resin, or polyethylene naphthalate (PEN) resin.
- the polyester resin constituting the polyester film is preferably a polyethylene terephthalate (PET) resin or a polyethylene naphthalate (PEN) resin.
- the polyester film is preferably either a polyethylene terephthalate (PET) film or a polyethylene naphthalate (PEN) film, and more preferably a polyethylene naphthalate (PEN) film.
- the base layer 1a may be a polyimide (PI) film made of polyimide (PI) resin.
- the film may be a low-oligomer product having an oligomer content of 1% by mass or less.
- the base layer 1a can have better hydrolysis resistance.
- the oligomer content can be determined, for example, as follows. (I) A roughly square film sample with sides of about 5 cm is washed with methanol, and then the film sample is dried in a hot air oven at 160° C. for 1 hour to determine the initial mass (M 1 (g)). (II) The film sample is subjected to extraction treatment with boiling xylene (about 400 mL) using a Soxhlet extractor or the like for 48 hours.
- the film sample is washed with water, the xylene adhering to the surface is lightly wiped off, and then it is dried in a hot air oven at 160°C for 8 hours and allowed to cool in a desiccator before the above-mentioned ( M2 (g)) is measured.
- the thickness of the substrate layer 1a is preferably 10 ⁇ m or more, more preferably 15 ⁇ m or more, and even more preferably 25 ⁇ m or more.
- the thickness of the substrate layer 1a is preferably 250 ⁇ m or less, more preferably 100 ⁇ m or less, and even more preferably 75 ⁇ m or less.
- the thickness of the substrate layer 1a can be measured in the same manner as the thicknesses of the first insulating layer 3a and the second insulating layer 3b.
- the insulating sheet 10 according to the present embodiment preferably has a volume resistivity of 1 ⁇ 10 ⁇ cm or more, and more preferably has a volume resistivity of 1 ⁇ 10 ⁇ cm or more. By having such a volume resistivity, the insulating sheet 10 according to the present embodiment can have good electrical insulation properties.
- the drive motor includes a rotor with a permanent magnet and a stator with a coil, and the coil is formed by a segment conductor.
- the insulating sheet 10 according to this embodiment is used to insulate the coil from the core (stator core) in the stator.
- FIG. 2 is a perspective view of the drive motor 1.
- the stator 1 has a stator core 20 and a coil 30.
- Fig. 3 is a plan view of the stator 1 as seen from the direction of the rotation axis (arrow AD) of a rotor (not shown).
- Fig. 4 is a cross-sectional view showing a state in which the coil 30 is housed in the portion A of the stator core 20 shown in Fig. 3.
- a plurality of slot grooves 21 are formed on the inner peripheral surface side of a cylindrical stator core 20.
- the stator 1 has the stator core 20 and a plurality of coils 30 accommodated in the plurality of slot grooves 21 formed in the stator core 20.
- the plurality of slot grooves 21 each extend along the rotation axis direction (AD in FIG. 2) of the stator core 20, and are arranged at regular intervals from one another along the circumferential direction (RD in FIG. 2) of the stator core 20.
- the slot grooves 21 are formed over the entire length in the rotation axis direction AD of the stator core 20. Openings 21b (see FIG.
- the coil 30 is composed of multiple segment conductors 31 connected to each other.
- the segment conductor 31 is a rectangular enameled wire bent into a U-shape, as shown in the upper right of Figure 2, and has two legs 31b and a head 31a that connects the two legs 31b to each other.
- the segment conductor 31 has an exposed copper wire portion at a tip 31bx of the leg portion 31b on the opposite side to the head portion 31a, where the insulating coating is peeled off to expose the copper wire.
- the coil 30 is fabricated, for example, as follows.
- the legs 31b of the segment conductor 31 are inserted through the openings 21b of the slot grooves 21 in the upper end surface 20a of the stator core 20, and the tips 31bx of the legs 31b are exposed from the lower end surface 20b of the stator core 20.
- the legs 31b of one segment conductor 31 and the legs 31b of another segment conductor 31 are electrically connected at the exposed copper wire portion to form a connection portion 31x.
- an insulation process is performed on the connection portion 31x.
- the two legs 31b of one segment conductor 31 are inserted into the slot grooves 21 separately.
- the stator 1 Since the coil 30 is manufactured, for example, as described above, the stator 1 has an upper coil end portion on the upper end surface 20a side of the stator core 20, which is composed of the heads 31a of the segment conductors 31.
- the stator 1 also has a lower coil end portion on the lower end surface 20b side, which is composed of the connection portions 31x formed by connecting the legs 31b together.
- each slot groove 21 of the stator core 20 accommodates four legs 31b of the segment conductors 31 that form the coil 30 (one leg 31b of each of the four segment conductors 31 is accommodated).
- a total of four legs 31b are accommodated in each slot groove 21, lined up in a row from the inner circumferential surface side to the outer circumferential surface side of the stator core 20.
- the insulating sheet 10 according to this embodiment is interposed between the four leg portions 31 b and the inner wall surface of the slot groove 21 .
- the insulating sheet 10 according to this embodiment is attached longitudinally to the legs 31b of the segment conductor 31 and wound around the four legs 31b one or more times and disposed in the slot grooves 21.
- the insulating sheet 10 is disposed in the slot grooves 21 with both ends in the rotation axis direction AD protruding outward in the rotation axis direction AD from the upper end face 20a and the lower end face 20b of the stator core 20, respectively.
- the insulating sheet 10 according to this embodiment is disposed between the stator core 20 and the coil 30 with the first adhesive layer 2a and the second adhesive layer 2b interposed therebetween.
- the insulating sheet 10 is arranged in the slot groove 21 in a state where it is wound around the four legs 31b one or more times, so that both ends in the winding direction are overlapped. That is, in the stator 1, an overlapping portion 10d where both ends of the insulating sheet 10 overlap each other is present in the slot groove 21 (see FIG. 4). As shown in FIG. 4, the overlapping portion 10d is located on the outer side of the stator 1 in the radial direction DD.
- the protruding portions of the insulating sheet 10 protruding from the upper end surface 20a and the lower end surface 20b of the stator core 20 in the rotation axis direction AD may be folded. More specifically, the protruding portions may be folded so as to be hooked (engaged) on at least one of the upper end side and the lower end side of the slot groove 21.
- the coil 30 wound with the insulating sheet 10 in this embodiment is fixed in the slot groove 21 by the insulating resin (e.g., epoxy varnish) in the slot groove 21.
- the insulating resin e.g., epoxy varnish
- the insulating layer is made of a wholly aromatic polyamide paper containing wholly aromatic polyamide fibers, The insulating sheet according to any one of (1) to (3) above, wherein after heating at 280° C. for 30 minutes, the adhesive strength of the adhesive layer to the insulating layer is 10 N/25 mm or less.
- the thermally expandable graphite had a volume average particle diameter D50 of 90 ⁇ m, and the expansion starting temperature of the thermally expandable graphite was 210° C.
- the volume average particle diameter D50 of the thermally expandable graphite was determined by the method described in the embodiment section.
- the acrylic resin solution was applied to a polyethylene naphthalate (PEN) film using a roll coater with a coating gap of 250 ⁇ m.
- the viscosity of the acrylic resin solution was about 300 mPa ⁇ s.
- the acrylic resin layers, which were the first adhesive layer and the second adhesive layer, were subjected to aging treatment for 24 hours at a temperature of 130° C. That is, in the insulating sheet according to Example 1, the acrylic resin layer was heat-cured.
- Nomex (registered trademark) paper manufactured by DuPont was used as the wholly aromatic polyamide paper
- Teonex (registered trademark) Q51 manufactured by Toyobo Co., Ltd. was used as the polyethylene naphthalate (PEN) film.
- Example 2 As the insulating sheet according to the second embodiment, a five-layer laminate sheet was prepared in the same manner as in the first embodiment.
- the insulating sheet according to Example 2 had the same structure as the insulating sheet according to Example 1, except that the acrylic resin solution contained 10 mass % of thermally expandable graphite.
- the acrylic resin layers serving as the first adhesive layer and the second adhesive layer were subjected to aging treatment under the same conditions as in Example 1. That is, also in the insulating sheet according to Example 2, the acrylic resin layers were thermally cured.
- Example 4 As the insulating sheet according to Example 4, a five-layer laminate sheet was prepared in the same manner as in Example 1.
- the insulating sheet according to Example 4 had the same configuration as the insulating sheet according to Example 1, except that the acrylic resin solution contained 20 mass % of thermally expandable graphite.
- the acrylic resin layers serving as the first adhesive layer and the second adhesive layer were subjected to the aging treatment under the same conditions as in Example 1. That is, also in the insulating sheet according to Example 4, the acrylic resin layers were thermally cured.
- Example 5 As the insulating sheet according to Example 5, a five-layer laminate sheet was prepared in the same manner as in Example 1.
- the insulating sheet according to Example 5 had the same configuration as the insulating sheet according to Example 1, except that the acrylic resin solution contained 30 mass % of thermally expandable graphite.
- the acrylic resin layers serving as the first adhesive layer and the second adhesive layer were subjected to the aging treatment under the same conditions as in Example 1. That is, also in the insulating sheet according to Example 5, the acrylic resin layers were thermally cured.
- Example 6 As the insulating sheet according to Example 6, a five-layer laminate sheet was prepared in the same manner as in Example 1.
- the insulating sheet according to Example 6 had the same configuration as the insulating sheet according to Example 1, except that the acrylic resin solution contained 40 mass % of thermally expandable graphite.
- the acrylic resin layers serving as the first adhesive layer and the second adhesive layer were subjected to the aging treatment under the same conditions as in Example 1. That is, also in the insulating sheet according to Example 6, the acrylic resin layers were thermally cured.
- Comparative Example 1 As an insulating sheet according to Comparative Example 1, a five-layer laminate sheet was prepared in the same manner as in Example 1.
- the insulating sheet according to Comparative Example 1 had the same configuration as the insulating sheet according to Example 1, except that the acrylic resin solution did not contain thermally expandable graphite (the content was 0 mass %).
- the mixed resin layers serving as the first adhesive layer and the second adhesive layer were subjected to aging treatment at 130° C. for 24 hours. That is, also in the insulating sheet according to Comparative Example 1, the mixed resin layer was thermally cured.
- the insulating sheet of the present invention is suitable for use, for example, as an insulating sheet for motors used in automobile drive motors.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Laminated Bodies (AREA)
- Adhesives Or Adhesive Processes (AREA)
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2024563000A JPWO2024122623A1 (https=) | 2022-12-08 | 2023-12-07 | |
| CN202380081999.4A CN120266375A (zh) | 2022-12-08 | 2023-12-07 | 绝缘片 |
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| Application Number | Priority Date | Filing Date | Title |
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| JP2022-196283 | 2022-12-08 | ||
| JP2022196283 | 2022-12-08 |
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| Application Number | Title | Priority Date | Filing Date |
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| PCT/JP2023/043905 Ceased WO2024122623A1 (ja) | 2022-12-08 | 2023-12-07 | 絶縁シート |
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| Country | Link |
|---|---|
| JP (1) | JPWO2024122623A1 (https=) |
| CN (1) | CN120266375A (https=) |
| WO (1) | WO2024122623A1 (https=) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003284295A (ja) * | 2002-03-26 | 2003-10-03 | Okumura Shoten:Kk | モーターステータの解体装置 |
| JP2004189856A (ja) * | 2002-12-10 | 2004-07-08 | Tokai Rubber Ind Ltd | 接着体およびそれを用いたリサイクル方法 |
| WO2008145190A1 (en) * | 2007-05-31 | 2008-12-04 | Abb Research Ltd | Laminate for electrical machines |
| JP2014099999A (ja) * | 2012-11-14 | 2014-05-29 | Toyota Motor Corp | スロット絶縁紙 |
| JP2015163694A (ja) * | 2014-01-31 | 2015-09-10 | ソマール株式会社 | 接着シート |
| JP2019096410A (ja) * | 2017-11-20 | 2019-06-20 | タイガースポリマー株式会社 | 耐火積層体及びこれを用いた筒状積層体並びに電池隔離構造 |
-
2023
- 2023-12-07 CN CN202380081999.4A patent/CN120266375A/zh active Pending
- 2023-12-07 JP JP2024563000A patent/JPWO2024122623A1/ja active Pending
- 2023-12-07 WO PCT/JP2023/043905 patent/WO2024122623A1/ja not_active Ceased
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003284295A (ja) * | 2002-03-26 | 2003-10-03 | Okumura Shoten:Kk | モーターステータの解体装置 |
| JP2004189856A (ja) * | 2002-12-10 | 2004-07-08 | Tokai Rubber Ind Ltd | 接着体およびそれを用いたリサイクル方法 |
| WO2008145190A1 (en) * | 2007-05-31 | 2008-12-04 | Abb Research Ltd | Laminate for electrical machines |
| JP2014099999A (ja) * | 2012-11-14 | 2014-05-29 | Toyota Motor Corp | スロット絶縁紙 |
| JP2015163694A (ja) * | 2014-01-31 | 2015-09-10 | ソマール株式会社 | 接着シート |
| JP2019096410A (ja) * | 2017-11-20 | 2019-06-20 | タイガースポリマー株式会社 | 耐火積層体及びこれを用いた筒状積層体並びに電池隔離構造 |
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| CN120266375A (zh) | 2025-07-04 |
| JPWO2024122623A1 (https=) | 2024-06-13 |
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