Insulation tape and rotary electric machine

Abstract

To satisfactorily impregnate an insulation tape with a resin, suppress occurrence of insulation failure associated with processing, and improve reliability.SOLUTION: An insulation tape according to an embodiment includes a glass substrate layer, a mica layer, and a film substrate layer, wherein the glass substrate layer, the mica layer and the film substrate layer are laminated through an adhesive layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] An embodiment of the present invention relates to an insulating tape and a rotating electric machine. [Background technology]

[0002] 2. Description of the Related Art Conventionally, coils used in rotating electrical machines such as electric motors and generators are provided with an insulating structure that prevents current flowing through a conductor inside the coil from leaking to the outside.

[0003] As an example of such an insulating structure, a structure in which insulating tape is wound around a conductor is known. Known insulating tape configurations include film-based mica tape, in which a mica material is bonded to a film substrate, and glass-based mica tape, in which a mica material is bonded to a glass substrate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] US Patent Application Publication No. 2013 / 0131218 Summary of the Invention [Problem to be solved by the invention]

[0005] However, when a film-based mica tape is used, the permeability of the impregnated resin deteriorates as the number of windings increases, which may result in poor resin impregnation of the main insulation. Furthermore, when a glass-based mica tape is used, there is a risk that the mica material may break along with the glass substrate during coil formation after taping, resulting in poor insulation.

[0006] The present invention has been made in consideration of the above, and aims to provide an insulating tape and a rotating electric machine that can perform resin impregnation in the insulating tape well and can suppress the occurrence of insulation defects due to processing, thereby improving reliability. [Means for solving the problem]

[0007] The insulating tape of the embodiment includes a glass substrate layer, a mica layer, and a film substrate layer, and the glass substrate layer, the mica layer, and the film substrate layer are laminated via an adhesive layer. [Effects of the Invention]

[0008] According to the embodiment of the present invention, resin impregnation in the insulating tape can be performed well, and the occurrence of insulation defects due to processing can be suppressed, thereby improving reliability. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic cross-sectional view illustrating the configuration of an insulating tape according to a first aspect of the embodiment. [Figure 2] FIG. 2 is a schematic cross-sectional view illustrating the configuration of an insulating tape according to a second aspect of the embodiment. [Figure 3] FIG. 3 is a cross-sectional view showing the general configuration of the rotating electric machine according to the embodiment. [Figure 4] FIG. 4 is a perspective view showing the configuration of the insulated coil according to the embodiment. [Figure 5] FIG. 5 is a cross-sectional view showing the configuration of an insulated coil according to an embodiment. [Figure 6] FIG. 6 is a schematic explanatory view of the state in which the insulating tape of the first embodiment is wound around the laminated conductor. [Figure 7] FIG. 7 is an enlarged cross-sectional view of an overlapping portion when the insulating tape of the first embodiment is wound around the laminated conductor. [Figure 8] FIG. 8 is a schematic explanatory view of the wound state of the insulating tape in the laminated conductor of the second embodiment. [Figure 9] FIG. 9 is an enlarged cross-sectional view of an overlapping portion when the insulating tape of the second embodiment is wound around the laminated conductor. [Figure 10] FIG. 10 is a schematic explanatory diagram of a wound state of a laminated conductor of a conventional insulating tape (film-based mica tape). [Figure 11]FIG. 11 is an enlarged cross-sectional view of an overlapping portion when a conventional insulating tape (film-based mica tape) is wound around a laminated conductor. [Figure 12] FIG. 12 is an explanatory diagram of the test results of the resin permeability test. DETAILED DESCRIPTION OF THE INVENTION

[0010] Here, the embodiments will be described in detail with reference to the drawings. [1] First embodiment of insulating tape FIG. 1 is a schematic cross-sectional view illustrating the configuration of an insulating tape according to a first aspect of the embodiment. The insulating tape 10 of the first embodiment includes a glass substrate layer 11, a film substrate layer 12, a mica layer 13, and an adhesive layer 14.

[0011] The glass substrate layer 11 is also called a fiber-reinforced layer and contains, for example, glass fibers as a main component, and the glass fibers are usually woven in a mesh shape. The thickness of this glass substrate layer 11 is, for example, about 30 μm.

[0012] The film substrate layer 12 is made of a polymer film such as polyester, polyimide, etc. The thickness of this film substrate layer 12 is, for example, about 6 μm.

[0013] The mica layer 13, also referred to as the main insulating layer, is made of a non-conductive material and is the main component for realizing the insulating function of the insulating tape 10. For example, it contains inorganic substances such as mica, such as laminated mica or uncalcined laminated mica, asbestos, or porcelain powder as its main components. The thickness of the mica layer 13 is, for example, about 100 μm.

[0014] The adhesive layer 14 contains, as an adhesive, for example, unsaturated polyester resin, epoxy resin, or the like as a main component.

[0015] In the example of Figure 1, the insulating tape 10 of the first embodiment is laminated from top to bottom in the order of glass substrate layer 11 → adhesive layer 14 (second adhesive layer 14-2) → film substrate layer 12 → adhesive layer 14 (first adhesive layer 14-1) → mica layer 13. Therefore, the mica layer 13 is supported by the film substrate layer 12 via the first adhesive layer 14-1, so that even when the insulating tape 10 is actually used to wind around a coil or the like, the mica layer 13 is less likely to crack.

[0016] [2] Second embodiment of insulating tape Next, the insulating tape of the second embodiment will be described. FIG. 2 is a schematic cross-sectional view illustrating the configuration of an insulating tape according to a second aspect of the embodiment. In FIG. 2, the same parts as those in the insulating tape of FIG. 1 are denoted by the same reference numerals, and the detailed description thereof is incorporated herein. The insulating tape 10A of the second embodiment includes a glass substrate layer 11, a film substrate layer 12, a mica layer 13, and an adhesive layer 14, similar to the insulating tape 10 of the first embodiment. However, the layering order is different from that of the insulating tape 10 of the first embodiment. In the example of Figure 2, the insulating tape 10A of the second embodiment is layered from top to bottom in the order of film substrate layer 12 → adhesive layer 14 (first adhesive layer 14-1) → mica layer 13 → adhesive layer 14 (second adhesive layer 14-2) → glass substrate layer 11. Therefore, even in this embodiment, the mica layer 13 is supported by the film substrate layer 12 via the first adhesive layer 14-1, so that even when the insulating tape 10 is actually used to wind around a coil or the like, the mica layer 13 is less likely to crack.

[0017] Next, a rotating electrical machine according to an embodiment will be described. FIG. 3 is a cross-sectional view showing the general configuration of the rotating electric machine according to the embodiment. The rotating electrical machine 20 is a component of, for example, an electric motor, a generator, or the like, and includes a rotor 30 and a stator 40.

[0018] The rotor 30 includes a rotor shaft 31 and a rotor core 32 . The rotor shaft 31 is rotatably supported by bearings 21 near both ends thereof. Here, the bearing 21 is fixed to a bearing bracket 23 provided integrally with a frame 22 serving as a housing of the rotating electrical machine 20 . Furthermore, the rotor core 32 is fixed to the outer peripheral surface of the rotor shaft 31 and rotates together with the rotor shaft 31 .

[0019] The stator 40 includes a stator core 41 and an insulated coil 42 . The stator core 41 is arranged radially outward from the rotor core 32 with a gap therebetween. The insulating coil 42 is a member that is incorporated into the stator core 41 and generates a magnetic field that is essential for the rotating electric machine 20. An insulating structure, which will be described later, is provided on the outer periphery of the insulating coil 42. The insulated coil 42 is assembled so as to penetrate through the stator core 41. The insulated coil 42 is an example of a coil.

[0020] FIG. 4 is a perspective view showing the configuration of the insulated coil according to the embodiment. FIG. 5 is a cross-sectional view showing the configuration of an insulated coil according to an embodiment.

[0021] The insulated coil 42 has a laminated conductor 51 (electrical conductor), a turn insulating portion 53, and a main insulating portion 55. The turn insulating portion 53 and the main insulating portion 55 form the insulating structure of the insulated coil 42.

[0022] The laminated conductor 51 is configured by stacking a plurality of conductive wires 51A. The laminated conductor 51 according to this embodiment is configured by bundling 14 conductive wires 51A (7 layers, 2 columns). However, the configuration of the laminated conductor 51 is not limited to this, and should be designed appropriately depending on the usage situation. For example, the laminated conductor 51 may be configured by stacking more than 14 conductive wires 51A, or may be configured by stacking only one conductive wire 51A.

[0023] A turn insulation portion 53 is provided on the outer surface of each conductor 51A. As a result, the outer surface of the laminated conductor 51 is covered with the turn insulation portion 53. A main insulation portion 55 is provided on the outside of the turn insulation portion 53. The main insulation portion 55 includes the wound insulating tape 10 (tape-shaped member) of the first embodiment.

[0024] The insulating tape 10 according to this embodiment is spirally wound around the laminated conductor 51 using a half-wrap method. When the width of the insulating tape 10 is W, the spiral pitch is W / 2. In other words, the insulating tape 10 is wound so as to overlap half of the insulating tape 10 wound in the previous turn.

[0025] After the winding of the laminated conductor 51 has been completed over the entire length, the insulating tape 10 may be wound a plurality of times (for example, 10 times) on top of the laminated conductor 51. This allows the insulating tape 10 to be formed in multiple layers. The more layers of the insulating tape 10, the more improved the insulating performance. The number of turns of the insulating tape 10 may be selected appropriately depending on the required insulating performance, etc.

[0026] The above description has been given using the insulating tape 10 of the first embodiment as an example, but the same applies to the insulating tape 10A of the second embodiment.

[0027] Next, the resin permeability test for insulating tape will be explained. The following describes the case where a resin permeability test was carried out on the insulating tape 10 of the first embodiment, the insulating tape 10A of the second embodiment, and a conventional insulating tape (film-based mica tape).

[0028] First, the wound state of the insulating tape 10 of the first embodiment will be described. FIG. 6 is a schematic explanatory view of the state in which the insulating tape of the first embodiment is wound around the laminated conductor. FIG. 7 is an enlarged cross-sectional view of an overlapping portion when the insulating tape of the first embodiment is wound around the laminated conductor.

[0029] As shown in FIG. 6, the insulating tape 10 of the first embodiment is spirally wound around a laminated conductor 51 by a half-wrap method. As shown in the dashed line frame B1 in FIG. 6, the insulating tape 10 is wound so as to overlap half of the insulating tape 10 wound in the previous turn.

[0030] As shown by the solid arrows RSN in FIG. 6, when the resin is permeated using the vacuum pressure method, the resin permeates from the side surfaces of the insulating tape 10 in the width direction. Then, in the overlapping portion when the insulating tape 10 is wound around the laminated conductor, as shown in Figure 7, the water penetrates into the tape interface portion of the overlapping portion, and gradually penetrates in the direction indicated by the dashed arrow AR1 in Figure 6.

[0031] Here, in the insulating tape 10 of the first embodiment, the tape interface portion is a position where the glass substrate layer 11 and the mica layer 13 face each other.

[0032] In other words, in Figure 6, the resin does not penetrate directly along the radial direction of the laminated conductor 51, but rather gradually penetrates along the radial direction of the laminated conductor 51 from the widthwise side of the insulating tape 10 through the tape interface portion, mainly the glass substrate layer 11, and secondarily through the mica layer 13.

[0033] Next, the wound state of the insulating tape 10A of the second embodiment will be described. FIG. 8 is a schematic explanatory view of the wound state of the insulating tape in the laminated conductor of the second embodiment. FIG. 9 is an enlarged cross-sectional view of an overlapping portion when the insulating tape of the second embodiment is wound around the laminated conductor.

[0034] As shown in FIG. 8, the insulating tape 10A of the second embodiment is spirally wound around a laminated conductor 51 by the half-wrap method.

[0035] As shown in the dashed line frame B2 in FIG. 8, the insulating tape 10A is wound so as to overlap half of the insulating tape 10 wound in the previous turn. As shown by the solid arrows RSN in FIG. 8, when the resin is permeated using the vacuum pressure method, the resin permeates from the side surfaces in the width direction of the insulating tape 10A.

[0036] Then, in the overlapping portion when insulating tape 10A is wound around the laminated conductor, as shown in FIG. 9, the adhesive permeates into the tape interface portion of the overlapping portion, and gradually permeates in the direction indicated by the dashed arrow AR2 in FIG. Here, in the insulating tape 10 of the second embodiment, the tape interface portion is a position where the glass substrate layer 11 and the film substrate layer 12 face each other.

[0037] In other words, the resin does not penetrate directly along the radial direction of the laminated conductor 51, but rather gradually penetrates along the radial direction of the laminated conductor 51 from the widthwise side of the insulating tape 10A through the tape interface portion, mainly through the glass substrate layer 11.

[0038] Next, the winding state of a conventional insulating tape (film-based mica tape) will be described. 10 is a schematic explanatory diagram of the wound state of a laminated conductor of a conventional insulating tape (film-based mica tape). In FIG. 10, the same parts as in FIG. 6 are denoted by the same reference numerals.

[0039] FIG. 11 is an enlarged cross-sectional view of an overlapping portion when a conventional insulating tape (film-based mica tape) is wound around a laminated conductor.

[0040] As shown in FIG. 10, a conventional insulating tape 60 includes a film substrate layer 12, a mica layer 13, and an adhesive layer .

[0041] In the example of FIG. 2, the conventional insulating tape 60 is formed by laminating the film substrate layer 12, the adhesive layer 14, and the mica layer 13 in this order from top to bottom. The conventional insulating tape 60 is also spirally wound around the laminated conductor 51 by the half-wrap method.

[0042] As shown in the dashed line frame B3 in FIG. 10, the conventional insulating tape 60 is also wound so as to overlap half of the insulating tape 60 wound in the previous turn. As shown by the solid arrows RSN in FIG. 10, when the resin is permeated using the vacuum pressure method, the resin permeates from the side surfaces in the width direction of the insulating tape 10A.

[0043] Then, in the overlapping portion when the insulating tape 60 is wound around the laminated conductor 51, as shown in Figure 11, the air permeates into the tape interface portion of the overlapping portion, and gradually permeates in the direction indicated by the dashed arrow AR3 in Figure 10. Here, the tape interface portion is a position in the insulating tape 60 where the film substrate layer 12 and the mica layer 13 face each other.

[0044] In other words, the resin does not penetrate directly along the radial direction of the laminated conductor 51, but rather gradually penetrates along the radial direction of the laminated conductor 51 from the widthwise side of the insulating tape 60 through the tape interface portion, mainly through the mica layer 13.

[0045] Next, the results of the resin penetration test will be explained. FIG. 12 is an explanatory diagram of the test results of the resin permeability test. In the resin penetration test shown in Figure 12, the insulating tape was wrapped 10 times (10 layers) for each test piece, and resin penetration was performed using the vacuum pressure method under the same insulating tape wrapping conditions and resin penetration conditions (resin material, pressurized pressure, vacuum decompression state, temperature, etc.).

[0046] In this case, the resin penetration treatment was performed on each of the first embodiment of the insulating tape 10, the second embodiment of the insulating tape 10A, and the conventional insulating tape 60 until a sufficient amount of time had passed for the resin penetration rate of the eighth layer (third layer from the surface) of the first embodiment of the insulating tape 10, which had been measured in advance, to reach 100%.

[0047] As a result, as shown in the left column of Figure 12, after sufficient time had passed for the resin permeability of the eighth layer of the first embodiment of insulating tape 10 to reach 100%, the seventh layer, which is the layer below the eighth layer, had a resin permeability of 95%, and the sixth layer, which is the layer below the seventh layer, had a resin permeability of 40%.

[0048] Furthermore, with regard to the insulating tape 10A of the second embodiment, after a sufficient amount of time had passed for the resin permeability of the eighth layer of the insulating tape 10 of the first embodiment to reach 100%, the resin permeability of the eighth layer of the insulating tape 10A of the second embodiment also reached 100%, but the seventh layer, which was the layer below the eighth layer, had a resin permeability of 85%, and the sixth layer, which was the layer below the seventh layer, had a resin permeability of 20%.

[0049] Furthermore, with regard to the conventional insulating tape 60, after sufficient time had passed for the resin permeability of the eighth layer of the first embodiment of the insulating tape 10 to reach 100%, the resin permeability of the eighth layer of the conventional insulating tape 60 was 95%, but the seventh layer, which was the layer below the eighth layer, had a resin permeability of 30%, and the sixth layer, which was the layer below the seventh layer, had a resin permeability of 0%.

[0050] Based on the above results, it can be seen that the resin permeability is significantly higher for both the first embodiment of the insulating tape 10 and the second embodiment of the insulating tape 10A compared to the conventional insulating tape 60, and that when manufacturing coils to be used in actual rotating electric machines, the time required to achieve a resin permeability of 100% in all layers of the insulating tape can be significantly reduced, significantly shortening the manufacturing time for insulated coils and improving manufacturing efficiency.

[0051] As described above, the insulating tape having a three-layer structure according to the embodiment can improve the resin permeability, thereby improving reliability and dielectric strength. Furthermore, according to the insulating tape having a three-layer structure of the embodiment, the occurrence of cracks in the mica layer can be suppressed, so that the decrease in dielectric strength can be more reliably suppressed.

[0052] Although the coil manufacturing method has not been described in detail in the above explanation, it is possible to create an insulated coil using the insulating tape of the embodiment and construct a rotating electric machine using either the so-called shuttle coil method or the so-called flat coil method.

[0053] More specifically, in the so-called shuttle coil type coil production method in which insulating tape is wound around a coil by molding the coil after coil winding and heat pressing, and then mechanically and manually winding insulating tape around the molded coil, the three-layer insulating tape of the embodiment can suppress the occurrence of cracks in the mica layer, thereby further improving productivity, as well as in the flat coil type coil production method in which insulating tape is mechanically wound around a coil after coil winding and heat pressing, and then intermediate molding and final molding are performed.

[0054] In the above explanation, an insulating tape with a three-layer structure is described, but it is also possible to construct an insulating tape with a multi-layer structure of four or more layers by laminating a film substrate layer on a mica layer via an adhesive layer, and then laminating a glass substrate layer on top of that.

[0055] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]

[0056] 10, 10A insulating tape 11 Glass substrate layer 12 Film base layer 13 Mica layer 14 Adhesive layer 14-1 1st adhesive layer 14-2 Second adhesive layer 20 Rotating Electric Machine 21 Bearings 22 frames 23 Bearing bracket 30 rotor 31 rotor shaft 32 Rotor core 40 Stator 41 Stator core 42 Insulated coil 51 Laminated conductor 51A conductor 53 Turn insulation section 55 Main insulation section

Claims

1. a glass substrate layer; A mica layer; a film substrate layer, the glass substrate layer, the mica layer, and the film substrate layer are laminated via an adhesive layer; Insulating tape.

2. the mica layer is laminated on the film substrate layer via the first adhesive layer; The insulating tape of claim 1 .

3. the glass substrate layer is laminated on the film substrate layer via the second adhesive layer; The insulating tape of claim 2 .

4. the glass substrate layer is laminated on the mica layer via the second adhesive layer; The insulating tape of claim 2 .

5. A stator; a rotor rotatable relative to the stator; a coil provided on at least the stator of the stator and the rotor, The coil includes a conductor and the insulating tape according to any one of claims 1 to 4, covering the conductor. Rotating electric motor.

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