Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F10/14—Monomers containing five or more carbon atoms
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/18—Manufacture of films or sheets
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B17/00—Insulators or insulating bodies characterised by their form
  • H01B17/56—Insulating bodies
• • 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
• • 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 insulating films for motors, interphase insulating paper, slot paper, and wedge paper.
• the present invention aims to provide an insulating film for motors that has a low dielectric constant and a low dielectric tangent, as well as excellent voltage resistance and heat resistance, and an interphase insulating paper, slot paper, and wedge paper that include the insulating film for motors.
• the 3-methyl-1-butene polymer is a polymer containing at least a structural unit derived from 3-methyl-1-butene.
• the 3-methyl-1-butene polymer may be a 3-methyl-1-butene homopolymer, or may be a copolymer of 3-methyl-1-butene and an unsaturated hydrocarbon. Examples of the unsaturated hydrocarbon include ethylene and ⁇ -olefins.
• the ⁇ -olefin used in the 3-methyl-1-butene polymer means an ⁇ -olefin other than 3-methyl-1-butene.
• the content of the 3-methyl-1-butene polymer in 100% by mass of the resin composition is preferably 80.0 to 99.9% by mass, more preferably 85.0 to 99.9% by mass, and even more preferably 90.0 to 99.9% by mass, from the viewpoint of obtaining an insulating film for a motor that has a lower relative dielectric constant and a lower dielectric tangent, as well as excellent voltage resistance and heat resistance.
• the resin composition may contain an alkyl radical scavenger from the viewpoint of exhibiting better mechanical properties.
• alkyl radical scavenger refers to a compound that reacts with an alkyl radical derived from a 3-methyl-1-butene polymer and then has a function of stabilizing the radical, and serves to suppress a chain reaction of main chain scission initiated by the alkyl radical.
• the alkyl radical scavenger preferably contains at least one selected from the group consisting of an acrylphenol compound and a benzofuranone compound.
• the alkyl radical scavengers may be used alone or in combination of two or more kinds.
• alkyl group having 1 to 9 carbon atoms examples include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, an s-butyl group, a t-butyl group, a 1,1-dimethylpropyl group, a 1,2-dimethylpropyl group, a 2,2-dimethylpropyl group, a 1-methylbutyl group, a 2-methylbutyl group, a 3-methylbutyl group, an n-pentyl group, an n-hexyl group, an n-heptyl group, an n-octyl group, and an n-nonyl group.
• acrylic phenol compound represented by the general formula (I) examples include 2,4-di-t-amyl-6-[1-(3,5-di-t-amyl-2-hydroxyphenyl)ethyl]phenyl acrylate, 2,4-di-t-butyl-6-[1-(3,5-di-t-butyl-2-hydroxyphenyl)ethyl]phenyl acrylate, and 2-t-butyl-6-[(3-t-butyl-2-hydroxy-5-methylphenyl)methyl]-4-methylphenyl acrylate.
• alkyl radical scavenger a commercially available product may be used.
• acrylic phenol compound represented by the general formula (I) examples include products sold under the trade names "Sumilizer (registered trademark) GS” and “Sumilizer (registered trademark) GM” manufactured by Sumitomo Chemical Co., Ltd.
• the benzofuranone compound used in this embodiment can be represented, for example, by the following general formula (II).
• phenolic antioxidants such as the "Adekastab (registered trademark) AO series” manufactured by ADEKA Corporation and the “Irganox (registered trademark) series” manufactured by BASF Japan Ltd.
• sulfur-based antioxidant examples include dilauryl 3,3'-thiodipropionate, dimyristyl 3,3'-thiodipropionate, distearyl 3,3'-thiodipropionate, laurylstearyl 3,3'-thiodipropionate, pentaerythritol-tetrakis-( ⁇ -lauryl-thio-propionate), 3,9-bis(2-dodecylthioethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane, and the like.
• the content of the antioxidant in the resin composition relative to 100 parts by mass of the 3-methyl-1-butene polymer is preferably 0.01 parts by mass or more, more preferably 0.10 parts by mass or more, from the viewpoint of ensuring the stability of the 3-methyl-1-butene polymer, and is preferably 1.00 parts by mass or less, more preferably 0.80 parts by mass or less, from the viewpoint of the relative dielectric constant and the dielectric loss tangent. That is, the content is preferably 0.01 to 1.00 parts by mass, more preferably 0.10 to 0.80 parts by mass.
• the content of the antioxidants means the total content of the antioxidants.
• the resin composition has a reduced amount of metal elements, and therefore, from the viewpoint of facilitating the reduction of the amount of metal elements, the thermoplastic elastomer is preferably a copolymer of an aromatic vinyl monomer and a conjugated diene monomer, and more preferably a block copolymer thereof. From the viewpoint of improving weather resistance, hydrogenated products thereof are more preferred.
• the melting point of the resin composition of the present embodiment is preferably 260 to 310° C. When the melting point of the resin composition is within the above range, molding can be performed more easily, and reflow heat resistance can be further improved.
• the melting point of the resin composition means a peak temperature measured by a method similar to the method for measuring the melting point of a 3-methyl-1-butene polymer, and specifically, the melting point can be measured by the method for measuring the melting point of a 3-methyl-1-butene polymer described in the Examples.
• the thickness of the insulating film for a motor of this embodiment is preferably 50 ⁇ m or more, more preferably 100 ⁇ m or more, and even more preferably 120 ⁇ m or more from the viewpoint of insulation properties, and is preferably 1000 ⁇ m or less, more preferably 700 ⁇ m or less, and even more preferably 400 ⁇ m or less from the viewpoint of suppressing a decrease in motor output. That is, the thickness of the insulating film for a motor is preferably 50 to 1000 ⁇ m, more preferably 100 to 700 ⁇ m, and even more preferably 120 to 400 ⁇ m.
• the method for producing an insulating film for a motor includes a step of obtaining a 3-methyl-1-butene polymer, a step of obtaining a resin composition, and a step of forming the resin composition to obtain an insulating film for a motor.
• melt kneading are not particularly limited, but it is preferable to perform melt kneading by injecting an inert gas into the inside of a melt kneader, or by degassing the inside of the melt kneader under reduced pressure.
• melt and knead the resin composition in an inert atmosphere or in a low-oxygen state.
• the method of injecting an inert gas into the melt kneader to melt and knead may be, for example, to inject each component into the melt kneader while injecting an inert gas into the melt kneader to perform melt kneading, or to inject an inert gas into the melt kneader after injecting each component into the melt kneader to perform melt kneading.
• the inert gas may be continuously injected into the melt kneader during melt kneading. The method of injecting the inert gas can be carried out depending on the equipment provided in each melt kneader.
• the inert gas may be injected from a gas supply section such as an inert gas provided in the melt kneader, from a supply section for each component provided in the melt kneader, or from a gas vent vent provided in the melt kneader.
• a gas supply section such as an inert gas provided in the melt kneader
• the inert gas can be injected into the entire area from the inert gas supply section to the heating section where melting and kneading are performed, and melting and kneading can be performed.
• the inert gas include nitrogen gas, helium gas, neon gas, argon gas, krypton gas, and carbon dioxide gas. From the viewpoints of availability and versatility, nitrogen gas is preferred.
• the method of degassing the inside of the melt kneader under reduced pressure and melt kneading may be, for example, to feed each component into the melt kneader, and then degass the inside of the melt kneader under reduced pressure and melt kneading.
• degassing the inside of the melt kneader under reduced pressure may be performed intermittently or continuously.
• the method of degassing the inside of the melt kneader under reduced pressure can be carried out according to the equipment provided in each melt kneader, and may be carried out through a vacuum vent, for example.
• the inside of the melt kneader can be in a vacuum state of, for example, 0.1 kPa or more and 50 kPa or less.
• the melt kneader may be a single-screw extruder, multi-screw extruder, kneader, Banbury mixer, or the like, which is equipped with equipment capable of melt kneading by injecting an inert gas into the melt kneader, or equipment capable of melt kneading by depressurizing and degassing the inside of the melt kneader.
• the melt-kneading temperature is preferably 300 to 380°C.
• the melt kneading temperature is 300° C. or higher, the 3-methyl-1-butene polymer can be sufficiently melted, and additives can be easily dispersed.
• the melt kneading temperature is 380° C. or lower, thermal decomposition of the 3-methyl-1-butene polymer and additives can be suppressed.
• the melt kneading temperature is more preferably 300° C. or higher, and further preferably 310° C. or higher.
• the melt kneading temperature is more preferably 380° C. or lower, and further preferably 360° C. or lower.
• the melt-kneading time can be adjusted depending on the size of the kneading device, etc. For example, it may be 1 to 15 minutes, but is not limited to this numerical range of melt-kneading time.
• the "melt-kneading time” refers to the time the mixer is rotating in a batch kneader, and the residence time of the raw materials in the device in the case of a continuous extrusion kneader.
• the rotation speed of the mixer during melt kneading may be 80 rpm or more, or 100 rpm or more, and may be 300 rpm or less, or 250 rpm or less.
• the resin composition is removed from the melt-kneader and cooled.
• the step of obtaining an insulating film for a motor is a step of obtaining an insulating film for a motor by molding a resin composition.
• the molding method is not particularly limited, and a method suitable for the application may be used.
• the resin composition of the present embodiment is thermoplastic and can be melt molded. Therefore, injection molding, extrusion molding, compressed air molding, heat press molding, etc. can be used. Among these, extrusion molding is preferred from the viewpoint of obtaining a molded product with excellent ease of manufacture and dimensional accuracy.
• the motor insulating film can be suitably used as a motor insulating film for home appliances, audio equipment, IT equipment, communication equipment, office automation equipment, medical equipment, health care equipment, business equipment, industrial equipment, and transportation equipment such as automobiles, railways, and ships. Of these, it can be preferably used as a motor insulating film for vehicles, and more preferably as a motor insulating film for electric vehicles.
• the motor insulating film can be suitably used for interphase insulating paper that insulates between coil phases, insulators arranged in slots, i.e., slot paper, and wedge paper that closes the openings of the slot paper and slot grooves from the inside.
• the interphase insulating paper, slot paper, and wedge paper have a low relative dielectric constant and a low dielectric tangent, and are excellent in voltage resistance and heat resistance.
• the thickness and shape of the insulating film for a motor can be appropriately set depending on the application.
• the motor insulating film may have a folded portion with an angle of 50 to 150 degrees, for example, or may have a folded portion with an angle of 60 to 140 degrees. When the motor insulating film has multiple folded portions, these angles may be the same or different.
• a calibration curve was prepared from the ratio of the peak area of the deformation vibration at 1,461 cm ⁇ 1 originating from the main chain methylene group of the 3-methyl-1-butene homopolymer to the peak area of the deformation vibration at 727 cm ⁇ 1 originating from the side chain methylene group of the ⁇ -olefin homopolymer, and the addition ratio of each polymer.
• Test pieces (length: 60 mm, width: 60 mm, thickness: 0.2 mm) were prepared by cutting out each of the insulating films for motors obtained in Examples 1 to 5 and Comparative Examples 1 and 2. Using the test pieces and a precision LCR meter "Keysight E6980A" (manufactured by Agilent Technologies), the relative dielectric constant and dielectric loss tangent were measured at measurement frequencies of 1 kHz and 1 MHz by the capacitance method in accordance with JIS C 2138:2007.
• measurement solution A a solution prepared by dissolving about 0.1 mass% of analytical reagent grade anhydrous ammonium chloride (NH 4 Cl) having a purity of 99.8% or more in deionized water and preparing the resistivity at 23°C ⁇ 1°C to be 3.95 ⁇ m ⁇ 0.05 ⁇ m
• the voltage was changed from 400 to 900 V, and the maximum voltage at which no dielectric breakdown occurred (comparative tracking index) was measured.
• the tracking resistance was evaluated according to the following criteria. When the comparative tracking index is 800 V or more, the tracking resistance is good.
• B Comparative tracking index is 600V or more and less than 800V.
• C The maximum voltage at which no dielectric breakdown occurs is less than 600V.
• the test piece was fixed between a high-voltage side electrode (a bulb having a diameter of 20 mm) and a low-voltage side electrode (a bulb having a diameter of 20 mm), and an AC voltage of 50 Hz was increased at 150°C at a voltage increase rate of 3 kV/s to measure the dielectric breakdown strength.
• the obtained dielectric breakdown strength value was evaluated according to the following criteria. Note that if the dielectric breakdown strength is 150 kV/mm or more, the withstand voltage is good.
• C Conductive
• the composition of the obtained titanium catalyst component was 4.0 mass % titanium, 56.0 mass % chlorine, 17.0 mass % magnesium, 10.4 mass % ethyl benzoate, and 12.6 mass % of the hydrocarbon solvent consisting of decane and hexane.
• copolymer (A) which is a copolymer of 3-methyl-1-butene and 1-decene.
• the copolymer (A) thus obtained was subjected to the above-mentioned measurements, and the melting point was 286° C. and the melt viscosity was 104 Pa ⁇ s.
• the content of structural units derived from the comonomer 1-decene in the copolymer (A) was 1.1 mol %.
• Example 1 100 parts by mass of the copolymer (A) obtained in Production Example 1, 0.2 parts by mass of pentaerythritol tetrakis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate] ("AO-60", manufactured by ADEKA Corporation), 0.2 parts by mass of 3,9-bis(2,6-di-t-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane ("PEP-36", manufactured by ADEKA Corporation), 0.1 part by mass of 2,4-di-t-amyl-6-[1-(3,5-di-t-amyl-2-hydroxyphenyl)ethyl]phenyl acrylate ("Sumilizer (registered trademark) GS", manufactured by Sumitomo Chemical Co., Ltd.) and 0.25 part by mass of zinc stearate (antacid agent) were dry blended, and
• the resulting pellet-like resin composition (M1) was fed to a twin-screw kneading extruder "KZW15-45" (manufactured by Technobel Co., Ltd.), melt-kneaded at a cylinder temperature of 310°C, and melt-extruded into a film from a T-die.
• the resulting film was then cooled and solidified on a cooling roll at 110°C to obtain an insulating film for motors (P1) with a thickness of 200 ⁇ m.
• the evaluation results are shown in Table 1.
• Example 2 100 parts by mass of the copolymer (A) obtained in Production Example 1 was dry-blended with 0.2 parts by mass of pentaerythritol tetrakis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate] ("AO-60", manufactured by ADEKA Corporation) as a phenol-based antioxidant, 0.2 parts by mass of 3,9-bis(2,6-di-t-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane ("PEP-36", manufactured by ADEKA Corporation) as a phosphorus-based antioxidant, and 0.25 parts by mass of zinc stearate (antacid), and the mixture was melt-kneaded under a nitrogen atmosphere using a twin-screw kneading extruder "KZW15-45" (manufactured by Technovel Corporation) to obtain a pellet-shaped resin
• the resulting pellet-like resin composition (M2) was melt-kneaded in a nitrogen atmosphere at a cylinder temperature of 310°C using a twin-screw kneading extruder "KZW15-45" (manufactured by Technobel Co., Ltd.), and melt-extruded into a film from a T-die.
• the resulting film was then cooled and solidified on a cooling roll at 110°C, yielding an insulating film for motors (P2) with a thickness of 200 ⁇ m.
• the evaluation results are shown in Table 1.
• Example 3 100 parts by mass of the copolymer (A) obtained in Production Example 1 was dry-blended with 0.67 parts by mass of pentaerythritol tetrakis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate] ("AO-60", manufactured by ADEKA Corporation) as a phenol-based antioxidant, 1.33 parts by mass of 3,9-bis(2,6-di-t-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane ("PEP-36", manufactured by ADEKA Corporation) as a phosphorus-based antioxidant, and 0.25 parts by mass of zinc stearate (antacid), and then the mixture was melt-kneaded under an air atmosphere using a twin-screw kneading extruder "KZW15-45" (manufactured by Technovel Corporation) to obtain a pellet-shaped resin
• the resulting pellet-like resin composition (M3) was melt-kneaded in an air atmosphere at a cylinder temperature of 310°C using a twin-screw kneading extruder "KZW15-45" (manufactured by Technobel Co., Ltd.), and melt-extruded into a film from a T-die.
• the resulting film was then cooled and solidified on a cooling roll at 110°C, yielding an insulating film for motors (P3) with a thickness of 200 ⁇ m.
• the evaluation results are shown in Table 1.
• Example 4 A resin composition (M4) and an insulating film for motors (P4) were obtained in the same manner as in Example 1, except that the copolymer (B) obtained in Production Example 2 was used instead of the copolymer (A) in Example 1. The evaluation results are shown in Table 1.
• Example 5 A resin composition (M5) and an insulating film for motors (P5) were obtained in the same manner as in Example 1, except that the homopolymer (C) obtained in Production Example 3 was used instead of the copolymer (A) in Example 1. The evaluation results are shown in Table 1.
• Example 1 The evaluation was performed in the same manner as in Example 1, except that the motor insulating film (P1) was replaced with a PEEK film "APTIV1000" (manufactured by Victrex Japan Co., Ltd., thickness 200 ⁇ m, motor insulating film (Q1)). The evaluation results are shown in Table 2.
• an insulating film for a motor containing a resin composition containing a 3-methyl-1-butene polymer of the present invention is lightweight, has low water absorption, a low relative dielectric constant and a low dielectric loss tangent, and also has excellent heat resistance due to its voltage resistance and high melting point. In particular, since it has excellent heat resistance, it can be made smaller. Therefore, it is suitable for an insulating film for a motor. Furthermore, in Examples 1, 4, and 5, it can be seen that the mechanical properties of the insulating film are further improved by including an alkyl radical scavenger in the material.

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• Chemical & Material Sciences (AREA)
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• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
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• Insulation, Fastening Of Motor, Generator Windings (AREA)

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Citations (5)

• 2023
  • 2023-12-27 JP JP2024567916A patent/JPWO2024143450A1/ja active Pending
  • 2023-12-27 WO PCT/JP2023/046869 patent/WO2024143450A1/ja not_active Ceased
  • 2023-12-28 TW TW112151277A patent/TW202436388A/zh unknown

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