Components used as electrical insulating barriers based on polyaryletherketone (PAEK) and polyphenylsulfone (PPSU)

Abstract

The present invention relates to the field of electric motors or generators and to components, such as slot liners and slot wedges, used as electrical insulating barriers in slots of a stator configured to receive electrical windings, respectively, which are manufactured from a composition based on polyaryletherketone (PAEK) and polyphenylsulfone (PPSU) and which exhibit a combination of chemical and mechanical properties.

Description

[Technical field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 308525, filed February 10, 2022, and European Patent Application No. 22186074.5, filed July 20, 2022, the contents of which are incorporated herein by reference in their entirety for all purposes. In the event of any discrepancy between this application and this PCT application that would affect the clarity of the terms or wording, only this application should be referenced.

[0002] The present invention relates to the field of electric motors or generators, and more particularly to components, such as slot liners or slot wedges, used as electrical insulating barriers in slots of a stator configured to receive respective electrical windings, the components being manufactured from a composition based on polyaryletherketone (PAEK) and polyphenylsulfone (PPSU) and exhibiting a combination of chemical and mechanical properties. [Background technology]

[0003] Electric motors and generators are used in a wide range of applications. Electric motors convert electrical energy into mechanical energy in the form of motion. Generators convert mechanical energy into electrical energy. Although the two machines have different functions, they both have a stationary part of the machine, the stator, which contains conductors, usually in the form of copper wire coils, inserted into slots.

[0004] In a motor, the stator generates a magnetic field and interacts magnetically with the rotor or other moving element. The stator in an electric motor remains stationary but provides the driving force that rotates the rotor. Stators can have a variety of configurations depending on the motor's application, but typically have a "core" made from laminations of steel or other magnetic material. The core provides a path for the magnetic flux passing through the stator. The core has slots formed in it for placement of coils of electrical conductor. Current passing through the conductive coils creates the magnetic field used to operate the motor.

[0005] To avoid damage and improve the performance of the electric machine, an electrical insulating barrier must exist between the windings and the stator in the stator slots. For this purpose, two components are typically inserted into the slots: slot liners and slot wedges.

[0006] A slot liner is a component in an electric machine, such as a motor or generator, that provides an electrical insulating barrier between the windings and the stator. The component is cut from a film and shaped to fit within the slot of the motor or generator.

[0007] A slot wedge is a slot closure that holds the stator windings in the slot.

[0008] EP 2738219 (D1) discloses ternary compositions comprising at least one poly(aryl ether ketone) (PAEK), at least one polyphenylsulfone (PPSU), at least one other poly(aryl ether sulfone) polymer, and optional specific reinforcing fillers. D1 also discloses the use of these compositions as insulating coatings for electrical and electromagnetic wires (§0151). WO 2020 / 011814 (D2) relates to articles comprising a polymer component and a metal coating. US 2020 / 009785 (D3) relates to a method for producing three-dimensional (3D) objects using an additive manufacturing system. WO 2016 / 034624 (D4) relates to sulfone polymer compositions. Examples CE-12, CE-13, and CE-14 disclose polymer compositions with a lower proportion of PAEK (PEEK) than in claim 1. WO 2007 / 107519 (D5) relates to reinforced polyaryletherketone compositions having a lower proportion of PAEK (PEEK) than in claim 1. None of these documents discloses the subject matter of claim 1.

[0009] US 2011 / 0095641 A1 (D6) discloses a slot liner, but does not disclose the claimed polymer composition. Summary of the Invention [Problem to be solved by the invention]

[0010] Slot liners and slot wedges are commonly made from polymer-based materials because they can be molded easily and at low cost. However, the polymer-based materials currently used are either very expensive aramids (also known as Nomex®) or low performance polymers that must be used in bulk to achieve sufficient electrical insulation or the required mechanical integrity. DK7-0953M, commercialized by SolEpoxy, is an epoxy-based thermosetting coating powder that has been used in the field as an insulating material, but epoxy-based thermosetting resins are known to be difficult to recycle.

[0011] Additionally, for slot liners or slot wedges, the thicker the film, the less flexible it typically is.

[0012] Polymer-based materials used for electrical insulation must exhibit a good combination of chemical resistance (particularly in the motor environment, where components must exhibit good folding resistance) and mechanical properties (high stiffness with mechanical ductility, high temperature resistance).As the electric vehicle industry is expected to move from 400 volt systems to 800 volts and above, improved components are likely to be required.

[0013] Additionally, the polymer-based material used for insulation should be easily converted into the components of the present invention. For example, the polymer-based material should be easily converted into a film, especially at a thin thickness (e.g., 2-5 mils). In this regard, a slot liner with a thin thickness allows for a higher conductor density in the cavity, which helps to increase the power output of the motor. Alternatively, in another aspect, the higher density allows for a smaller motor size without affecting the power output.

[0014] Therefore, there is a need for recyclable parts with low thickness and a good combination of chemical and mechanical properties for use as an efficient electrical insulating barrier in the slots of stators. In particular, the parts should exhibit high tensile elongation at break while maintaining thermal (load deflection temperature) and electrical insulating properties. [Means for solving the problem]

[0015] The invention is set out in the accompanying set of claims.

[0016] The invention thus relates to a component according to any one of claims 1 to 41, in particular a slot liner or slot wedge, for use as an electrical insulating barrier in a slot of a stator, comprising or made from composition (C), said component being designed to be inserted into a slot of a stator.

[0017] The invention also relates to the use of the composition (C) for the manufacture of a slot liner or a slot wedge according to claim 42.

[0018] The invention also relates to an electric motor according to any one of claims 43-44.

[0019] The invention also relates to a generator according to any one of claims 45-46.

[0020] The invention also relates to compositions (C) and (C*) as defined hereinafter and according to claim 47, which exhibit in particular the physicochemical and / or insulating properties defined hereinafter.

[0021] These themes are defined in more detail below. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 shows a stator (1) containing slots (2), each of which contains a slot liner (3). [Diagram 2] FIG. 2 shows a stator (1) containing slots (2), each of which is closed by a slot wedge (4).

[0023] As can be seen, both parts, shown in darker shade, are located in different locations in the stator slot.

[0024] general definition For clarity, the following definitions and precision are used throughout this application.

[0025] Unless otherwise indicated, percentages are given by weight (wt%). Furthermore, the proportions of components of a composition are given as wt% relative to the total weight of the composition.

[0026] Unless otherwise indicated, the percentages of repeat units in the polymers disclosed herein are given in mole % based on the total amount of repeat units.

[0027] Melting temperature T of PAEK m is the temperature determined as the peak temperature of the melting endotherm in the second heating scan in a differential scanning calorimeter (DSC) according to ASTM D3418-03, E1356-03, E793-06, E794-06 using heating and cooling rates of 20° C. / min. For purposes of this description, if a melting endotherm is detected in the second heating scan, the polymer is crystalline.

[0028] Heat of fusion means the heat of fusion measured by DSC according to ASTM D3418-03 using the second heating scan. The area is taken between the melting endotherm and the baseline, which is drawn from the point T=Tg+50° C. to the end of the defined melting peak where the peak returns to the baseline. Tg represents the glass transition and is determined according to ASTM D3418.

[0029] Where numerical ranges are given, the endpoints of the range are included.

[0030] The term "halogen", unless otherwise specified, includes fluorine, chlorine, bromine, and iodine.

[0031] The term "aromatic" means any mononuclear or polynuclear cyclic group (or cyclic moiety) having a number of pi electrons equal to 4n+2, where n is 0 or any positive integer, and the aromatic group (or moiety) may be an aryl or arylene group (or aryl or arylene moiety).

[0032] An "aryl group" is a monovalent hydrocarbon group consisting of a core, which may be composed of a benzene ring or of multiple benzene rings fused together by sharing two or more adjacent ring carbon atoms, and an end. Non-limiting examples of aryl groups are phenyl, naphthyl, anthryl, phenanthryl, tetracenyl, triphenylyl, pyrenyl, and perylenyl groups. The end of an aryl group is the free electron of a carbon atom contained in the benzene ring of the aryl group, with the hydrogen atom bonded to said carbon atom removed. The end of an aryl group can form a bond with another chemical group.

[0033] An "arylene group" is a divalent hydrocarbon group consisting of a core composed of a benzene ring or of multiple benzene rings fused together by sharing two or more adjacent ring carbon atoms, and two ends. Non-limiting examples of arylene groups are phenylene, naphthylene, anthrylene, phenanthrylene, tetracenylene, triphenylylene, pyrenylene, and perylenylene. The ends of an arylene group are the free electrons of the carbon atoms contained in the benzene ring of the arylene group, and the hydrogen atoms bonded to the carbon atoms are removed. Each end of an arylene group can form a bond with another chemical group. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] The present invention relates to a component, such as a slot liner or slot wedge, for use as an electrical insulating barrier in slots of a stator of an electric motor or generator, the slots being configured to receive electrical windings, the component comprising or made from a polymer composition (C) as defined in more detail below.

[0035] Slot Liner The component of the present invention may be a slot liner. Since the slot liner needs to be cut and shaped to fit into the slot of the stator, it is generally in the form of a film having a thickness of less than 1.0 mm, preferably less than 0.50 mm, and more preferably less than 0.20 mm. The thickness of the slot liner is usually at least 0.02 mm.

[0036] The thickness of the slot liner may be 0.02 to 0.18 mm, in particular 0.05 to 0.15 mm. The composition of the present invention allows the thickness of the slot liner to be reduced in order to obtain space within the slot, while still maintaining an excellent combination of properties.

[0037] According to one embodiment, the slot liner is manufactured from composition (C).

[0038] According to another embodiment, the slot liner comprises the composition (C). For example, the slot liner may be multi-layered. This means that it has two layers (L) made of or containing the composition (C). 1 ) and (L 1 *) and layer (L 1 ) and (L 1 It is possible for the layer to comprise a composition (C) between the first and second layers (L1) and (L2) made of a polymer composition different from the composition (C*).

[0039] The present invention also relates to a stator assembly for use in an electric machine that includes a stator core having a plurality of slots, each slot configured to receive an electrical winding, and at least one slot liner of the present invention.

[0040] The invention also relates to an electric machine, such as a motor or generator, comprising at least one slot liner according to the invention.

[0041] Electric machines generally include a stator and a rotor, the stator including a number of slots within which windings are disposed, and at least one slot liner, as defined herein, disposed within one slot between the stator core and the windings to insulate the stator core from the windings.

[0042] The slot liner can be manufactured using conventional techniques for converting polymer-based materials, such as (co)extrusion.

[0043] For example, a convenient method of manufacturing a slot liner is to extrude the polymer composition (C) into a film, usually at the thickness desired for the slot liner. The slot liner is then formed from a section cut from the film and contoured to fit the space within the slot. For multi-layer slot liners, a coextrusion process is used in a similar manner.

[0044] The slot liner can be formed in different configurations and sizes. For example, the slot liner can be as depicted in FIG. 7 of U.S. Pat. No. 4,151,436, FIG. 7 of U.S. Pat. No. 4,247,978, FIG. 1 of U.S. Pat. No. 3,943,392, FIG. 3 of U.S. Pat. No. 5,306,976, FIG. 3 of U.S. Pat. No. 1,058,975,172, FIG. 6 of U.S. Pat. App. Pub. No. 2010 / 0141079 A1, FIG. 2 of U.S. Pat. App. Pub. No. 2011 / 0095641 A1, or FIG. 1 of U.S. Pat. App. Pub. No. 2016 / 0065025.

[0045] Typically, the slot liner is substantially U-shaped.

[0046] Typically, the slot liner is designed to fold upon itself, for example to facilitate axial insertion into or along the slot.

[0047] Slot Wedge The component of the present invention may be a slot wedge.

[0048] According to one embodiment, the slot wedge is manufactured from composition (C).

[0049] According to another embodiment, the slot wedge comprises the composition (C).

[0050] The slot wedge may be in the form of a film having a thickness of less than 1.0 mm, preferably less than 0.50 mm, and more preferably less than 0.20 mm. The thickness of the slot wedge is typically at least 0.02 mm.

[0051] The thickness of the slot wedge may be 0.02 to 0.18 mm, more specifically 0.05 to 0.15 mm. The compositions of the present invention allow the thickness of the slot wedge to be reduced to gain space within the slot while still maintaining an excellent combination of properties.

[0052] The slot wedge can be manufactured using conventional conversion techniques of polymer-based materials, such as extrusion or injection molding.

[0053] For example, a convenient method of manufacturing a slot wedge is to injection mold the slot wedge.

[0054] Composition (C) The composition (C) is · at least 50.0% by weight of at least one polyaryletherketone (PAEK); · 15.0-42.0 wt. % of at least one polyphenylsulfone (PPSU); 8.0-25.0% by weight of at least one inorganic filler; · optionally up to 3.0 wt. % of at least one nucleating agent other than inorganic fillers; · optionally at least one plastic additive; comprises, consists essentially of, or consists of.

[0055] P.A.E.K. Composition (C) comprises at least 50.0% by weight of at least one polyaryletherketone (PAEK). The proportion of PAEK may be more specifically 50.0 to 65.0% by weight, more specifically 50.0 to 60.0% by weight. This proportion may be preferably 53.0 to 60.0% by weight, more specifically 55.0 to 60.0% by weight.

[0056] Composition (C) may comprise only one PAEK.

[0057] Composition (C) may contain two or more PAEKs, in which case each PAEK has a different repeat unit and / or a different weight average molecular weight (M w For the avoidance of doubt, it is emphasized that in that case the percentages indicated above correspond to the total percentages of PAEK.

[0058] The at least one PAEK preferably exhibits a heat of fusion of at least 35.0 J / g, preferably at least 40.0 J / g, more preferably at least 45.0 J / g as measured from the second heat of a Differential Scanning Calorimetry test according to ASTM D3418-03.

[0059] The PAEK preferably exhibits a melt viscosity of at least 200 Pa·s, measured according to ASTM D3835 at 400° C. and a shear rate of 1000 1 / s. This melt viscosity is usually at most 600 Pa·s. The melt viscosity of the PAEK, measured according to ASTM D3835 at 400° C. and a shear rate of 1000 1 / s, is between 200 and 600 Pa·s, preferably between 250 and 600 Pa·s.

[0060] The PAEK preferably exhibits a melting temperature of at least 300°C, preferably at least 320°C.

[0061] "Poly(aryl ether ketone) (PAEK)" means a polymer comprising arylene groups linked by oxygen atoms and / or carbonyl groups, the polymer having repeat units (R PAEK ) in an amount of more than 50.0 mol %: -Ar'-C(=O)-Ar''-(I) wherein Ar' and Ar'' are the same or different and are optionally substituted arylene groups. Each substituent that may be present on each aromatic group is selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali metal or alkaline earth metal sulfonate, alkyl sulfonate, alkali metal or alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium. The number of substituents that may be present on each aromatic group is j', which may be zero or an integer from 1 to 4. j' is preferably 0. Ar' and Ar'' are more specifically selected independently from the group consisting of phenylene and biphenylene.

[0062] Repeating unit (R PAEK ) is selected from the group consisting of units of formula (JA) to formula (JQ): [ka] (R' in these formulas j’ each R' is the same or different from the others and is selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium; j' is zero or an integer from 1 to 4. Preferably, j' is zero.

[0063] More specifically, the PAEK is selected from the group consisting of PEEK, PEKK, PEK, PEEKK, PEKEKK, and combinations thereof. According to a preferred embodiment, the PAEK is selected from the group consisting of PEEK, PEKK, and combinations thereof. According to another preferred embodiment, the PAEK is PEEK.

[0064] PEEK More specifically, PAEK is poly(ether ether ketone) (PEEK). As used herein, "poly(ether ether ketone) (PEEK)" refers to a polymer having more than 50.0 mol% of repeat units of the formula (J'-A): [ka] The repeating unit of the polymer is represented by the formula:

[0065] Preferably, at least 60.0 mol %, preferably at least 70.0 mol %, preferably 80.0 mol %, preferably at least 90.0 mol %, preferably at least 95.0 mol %, preferably at least 99.0 mol %, and most preferably all, of the repeat units of the PEEK are repeat units (J'-A).

[0066] PEKK More specifically, PAEK is poly(ether ketone ketone) (PEKK). As used herein, "poly(ether ketone ketone) (PEKK)" refers to a polymer having greater than 50.0 mol% of repeat units of the formula (J'-B) and the formula (J''-B): [ka] The term "polymer" refers to a combination of repeating units of the above formula.

[0067] Preferably, at least 60.0 mol %, preferably at least 70.0 mol %, preferably 80.0 mol %, preferably at least 90.0 mol %, preferably at least 95.0 mol %, preferably at least 99.0 mol %, and most preferably all, of the PEKK repeat units are a combination of repeat units (J'-B) and (J''-B).

[0068] P.E.K. More specifically, the PAEK may be a poly(ether ketone) (PEK). As used herein, "poly(ether ketone) (PEK)" refers to a polymer having greater than 50.0 mol% of repeat units of the formula (J'-C): [ka] The repeating unit of the polymer is represented by the formula:

[0069] Preferably, at least 60.0 mol %, preferably at least 70.0 mol %, preferably 80.0 mol %, preferably at least 90.0 mol %, preferably at least 95.0 mol %, preferably at least 99.0 mol %, and most preferably all, of the PEK repeat units are repeat units (J'-C).

[0070] PEEKK More specifically, PAEK is poly(ether ether ketone ketone) (PEEKK). As used herein, "poly(ether ether ketone ketone) (PEEKK)" refers to a polymer having greater than 50.0 mol% of the repeat units of the formula (J'-M): [ka] The repeating unit of the polymer is represented by the formula:

[0071] Preferably, at least 60.0 mol %, preferably at least 70.0 mol %, preferably 80.0 mol %, preferably at least 90.0 mol %, preferably at least 95.0 mol %, preferably at least 99.0 mol %, and most preferably all, of the repeat units of the PEEKK are repeat units (J'-M).

[0072] PEKEKK More specifically, the PAEK is a PEKEKK polymer. As used herein, "PEKEKK" refers to a polymer in which greater than 50.0 mole percent of the repeating units are of the formula (J'-Q): [ka] The repeating unit of the polymer is represented by the formula:

[0073] Preferably, at least 60.0 mol % of the repeat units are repeat units (J'-Q), preferably at least 70.0 mol %, preferably 80.0 mol %, preferably at least 90.0 mol %, preferably at least 95.0 mol %, preferably at least 99.0 mol %, and most preferably all.

[0074] Preparation of PAEK PAEKs are prepared by polycondensation techniques well known in the art, particularly by nucleophilic or electrophilic routes.

[0075] More precisely, PAEKs can be prepared by aromatic nucleophilic substitution leading to diaryl ether bonds. Polycondensation is generally 2 CO 3 The reaction is carried out in a solvent such as diphenyl sulfone at temperatures above 300° C. with the aid of a base such as

[0076] More specifically, PAEK can be obtained by polycondensation of a mixture of at least one aromatic compound having two hydroxy groups and at least one aromatic compound having two halogens, such as fluorine. For example, PEEK is generally prepared by reacting hydroquinone with 4,4'-difluorobenzophenone in diphenylsulfone in the presence of at least one alkali metal carbonate under an inert atmosphere at high temperature, such as >300°C.

[0077] Details regarding polycondensations involving nucleophilic substitution can be found, for example, in US Pat. No. 4,176,222.

[0078] More precisely, PAEKs can be prepared by Friedel-Crafts electrophilic substitution leading to diaryl ketone bonds. Polycondensation is generally carried out using AlCl 3 This is carried out in a solvent at a temperature below 150° C. with the aid of a Lewis acid such as

[0079] Details on polycondensations involving Friedel-Crafts electrophilic substitution can be found, for example, in U.S. Pat. No. 4,841,013, U.S. Pat. No. 4,816,556, WO 2011 / 004164 and WO 2014 / 013202.

[0080] PPSU Composition (C) contains 15.0 to 42.0% by weight of at least one polyphenylsulfone. The proportion of PPSU may be more specifically 20.0 to 40.0% by weight, more specifically 20.0 to 35.0% by weight. This proportion is preferably 25.0 to 32.0% by weight.

[0081] Composition (C) may contain only one type of PPSU.

[0082] Composition (C) may also contain two or more types of PPSU, in which case each PPSU may have different repeat units and / or different weight average molecular weights (M wFor the avoidance of doubt, it is emphasized that in that case the percentages indicated above correspond to the total percentages of PPSU.

[0083] As used herein, "polyphenylsulfone (PPSU)" means a polymer in which at least 90.0 mole % of the repeating units are repeating units of formula (II) (RPPSU): [ka] wherein each R is the same or different and is selected from halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium, and each h is the same or different and is an integer ranging from 0 to 4.

[0084] PPSU is typically amorphous.

[0085] Preferably, at least 95.0 mol %, most preferably at least 99.0 mol % of the repeat units of the PPSU are repeat units (R PPSU More preferably, all the repeating units of the PPSU are the repeating units (R PPSU ).

[0086] Repeating unit (R PPSU ) can more specifically conform to the following formula (IIa): [ka] (wherein R and h are as defined above).

[0087] More specifically, each h is zero.

[0088] More preferably, the PPSU has at least 90.0 mol % of the repeat units, preferably at least 95.0 mol % of the repeat units, and even more preferably all of the repeat units have the formula: [ka] The polymer represented by the formula:

[0089] The melt flow rate (MFR) of PPSU, measured according to ASTM D1238 at 365° C. under a load of 5.0 kg, is in the range of 5.0 to 60.0 g / 10 min, preferably 10.0 g / 10 min to 40.0 g / 10 min, and most preferably 10 to 30 g / 10 min.

[0090] Preparation of PPSU PPSU is usually produced by polycondensation based on nucleophilic aromatic substitution.

[0091] Thus, PPSU can be prepared by polycondensation of 4,4'-dihydroxybiphenyl (biphenol) with 4,4'-dichlorodiphenylsulfone in the presence of a base. The reaction of the monomer units occurs by nucleophilic aromatic substitution with the elimination of one unit of hydrogen halide as the leaving group.

[0092] Inorganic Filler The composition (C) contains 8.0 to 25.0% by weight of at least one inorganic filler. The proportion of the inorganic filler may be more specifically 10.0 to 25.0% by weight, more specifically 10.0 to 20.0% by weight.

[0093] According to one embodiment, the proportion of inorganic filler is at least 12.0% by weight, or even at least 14.0% by weight, this proportion being preferably between 14.0 and 20.0% by weight.

[0094] According to another embodiment, the proportion of the inorganic filler is 10.0 to 15.0% by weight.

[0095] The function of the inorganic filler is to increase the elastic modulus while maintaining the ductility of the composition.

[0096] The inorganic filler can be, for example, selected from the group consisting of talc, mica, and combinations thereof. Preferably, the inorganic filler is talc.

[0097] Preferably, the inorganic filler exhibits an aspect ratio, defined as the average ratio between the length and the minimum of the width and thickness, of at least 5. Preferably, the aspect ratio is at least 10, more preferably at least 20.

[0098] Preferably, the inorganic filler exhibits a D50 of less than 20.0 microns, preferably less than 10.0 microns, most preferably less than 5.0 microns, where D50 is the median of the size distribution in volume obtained by laser diffraction measurement. Typically, D50 is at least 0.5 microns.

[0099] Nucleating Agent Composition (C) may optionally contain up to 3.0% by weight of at least one nucleating agent. If present, the proportion of nucleating agent may be 0.1 to 3.0% by weight, or 0.1 to 1.5% by weight.

[0100] The nucleating agent may be selected from the group consisting of graphite, graphene, boron nitride, and combinations thereof. Preferably, the nucleating agent is boron nitride, which does not blacken the slot liner, making defects easier to detect.

[0101] The nucleating agent helps speed up the crystallization process when the composition is extruded into a film. Faster crystallization allows the film to reach a higher degree of crystallinity, which allows for better mechanical properties, especially a higher modulus.

[0102] Plastic Additives Composition (C) may also contain at least one plastic additive. By plastic additive is meant any additive that improves the stability, processability, or usability of an already formed polymer. More specifically, the plastic additive may be selected from the group consisting of colorants (e.g., dyes and / or pigments), UV stabilizers, heat stabilizers, antioxidants, internal and / or external lubricants, flame retardants, antistatic agents, antiblocking agents, and combinations thereof.

[0103] The proportion of plastic additives is usually less than 5.0% by weight, or even less than 2.0% by weight.

[0104] According to a preferred embodiment, composition (C) comprises only one or more PAEKs and one or more PPSUs as polymers present in the composition.

[0105] According to a preferred embodiment, composition (C) comprises only one PAEK and one PPSU as polymers present in the composition.

[0106] According to another preferred embodiment, the total proportion of PAEK and PPSU is at least 80.0% by weight, preferably at least 85.0% by weight.

[0107] According to another preferred embodiment, the weight ratio of PAEK / PPSU is between 60 / 40 and 70 / 30. This ratio may be between 62 / 38 and 68 / 32 or between 64 / 36 and 66 / 34.

[0108] Composition (C*) The composition (C) is more specifically at least 50.0% by weight of at least one polyaryletherketone (PAEK) selected from the group consisting of PEEK and PEKK; · 15.0-42.0 wt. % of at least one polyphenylsulfone (PPSU); 8.0 to 25.0% by weight of at least one inorganic filler, preferably talc; · optionally up to 3.0 wt. % of at least one boron nitride; · optionally at least one plastic additive; comprises, consists essentially of, or consists of.

[0109] The proportion, in particular, · 50.0 to 60.0 wt. % of at least one polyaryletherketone (PAEK) selected from the group consisting of PEEK and PEKK; · 25.0-32.0% by weight of at least one polyphenylsulfone (PPSU); 10.0 to 20.0% by weight of at least one inorganic filler, preferably talc; · optionally up to 3.0 wt. % of at least one boron nitride; · optionally at least one plastic additive; It is.

[0110] All the specifications and embodiments already disclosed for composition (C) apply to composition (C*).

[0111] Physicochemical properties of the components or compositions (C) and (C*) Ingredients and / or compositions (C) or (C*) exhibit a combination of properties.

[0112] According to one embodiment, compositions (C) and (C*) exhibit a tensile elongation at break of at least 10.0%, preferably at least 15.0%, more preferably at least 18.0%, measured according to ASTM D638 at a test speed of 50 mm / min.

[0113] According to one embodiment, compositions (C) and (C*) exhibit a tensile modulus of at least 4.82 GPa, measured according to ASTM D638 at a test speed of 50 mm / min.

[0114] According to one embodiment, compositions (C) and (C*) exhibit a deflection temperature under load of at least 180°C, preferably at least 190°C, measured on annealed 3.2 mm thick specimens (annealing conditions: 200°C for 2 hours) according to ASTM D648 at a stress of 1.82 MPa. The deflection temperature under load is preferably at least 195°C.

[0115] According to a preferred embodiment, compositions (C) and (C*) have - a tensile elongation at break of at least 10.0%, preferably at least 15.0%, preferably at least 18.0%, measured according to ASTM D638 at a test speed of 50 mm / min; and It exhibits a deflection temperature under load of at least 180°C, preferably at least 190°C, preferably at least 195°C, measured on annealed 3.2 mm thick test specimens (annealing conditions: 200°C for 2 hours) according to ASTM D648 at a stress of -1.82 MPa.

[0116] According to one embodiment, compositions (C) and (C*) are - a tensile modulus of at least 4.82 GPa (700 Kpsi) measured in accordance with ASTM D638 at a test speed of 50 mm / min (2 in / min); and - A tensile elongation at break of at least 10.0% measured in accordance with ASTM D638 at a test speed of 50 mm / min (2 in / min); and A deflection temperature under load of at least 180°C, preferably at least 190°C, measured on annealed 3.2 mm thick specimens (annealing conditions: 200°C for 2 hours) according to ASTM D648 at a stress of -1.82 MPa (264 psi) Shows.

[0117] The tensile modulus is typically up to 5.9 GPa (850 Kpsi), or even up to 5.2 GPa (750 Kpsi).

[0118] The tensile elongation at break is typically up to 25.0%.

[0119] The deflection temperature under load is typically up to 230°C.

[0120] The conditions for the measurement of physicochemical properties can be found in the experimental section.

[0121] Typically, compositions (C) and (C*) are semi-crystalline. Moreover, they preferably exhibit a heat of fusion of at least 20.0 J / g, more preferably at least 25.0 J / g, and most preferably at least 30.0 J / g, the heat of fusion being expressed as enthalpy of fusion relative to the polymer content of the composition. This level of crystallinity ensures that the composition, especially in the form of a film, will withstand the chemical environment encountered in the electric motor environment. Indeed, composition (C) must withstand environments such as automatic transmission fluids and impregnating resins used to seal motor windings.

[0122] Insulation properties The compositions (C) and (C*) and the parts also exhibit insulating properties: a partial discharge inception voltage (PDIV) of at least 900V, preferably at least 1000V, more preferably at least 1100V, per 100 microns thickness, measured according to ASTM D1868; and / or A breakdown voltage (BV) of at least 11 kV, preferably at least 12 kV, more preferably at least 13 kV for a thickness of 100 microns, measured according to ASTM D149.

[0123] Preparation of composition (C) / (C*) Typically, the components of composition (C) or (C*) are blended together, in particular by placing the components in a mixing device.

[0124] The ingredients are typically blended to form a homogeneous physical mixture.

[0125] Compositions (C) and (C*) are typically prepared by any known melt mixing process suitable for preparing thermoplastic compositions or compounds. The process can be carried out in a melt mixing device. Any melt mixing device known to those skilled in the art of preparing polymer compositions by melt mixing can be used.

[0126] The mixing device used for preparing the composition can typically be selected from the list consisting of kneader, Banbury mixer, single screw extruder and twin screw extruder.The convenient mixing device that can be used for preparing the composition is a single screw extruder or a twin screw extruder.The convenient mixing device can be one of those disclosed in the experimental section.

[0127] The design of the kneading screws (e.g. flight pitch and width, clearance, length) and the operating conditions of the extruder are preferably and advantageously selected to provide sufficient heat and mechanical energy to fully melt the polymeric components and to obtain a homogeneous distribution of the various components. At the exit of the extruder, the strand extrudate of the composition can be chopped, for example by a rotating cutting knife, after a specific cooling time on a conveyor by water spray.

[0128] Compositions (C) and (C*) may be in the form of a powder or in the form of pellets, the latter form being preferred as it is more convenient to use. EXAMPLES

[0129] Experimental section Starting materials used: The polymers used in the examples are as follows:

[0130] PAEK: Polyetheretherketone (PEEK) - grade KetaSpire KT-880NT available from Solvay Specialty Polymers. This grade has a melt viscosity in the range of 120-180 Pa·s measured according to ASTM D3835 at 400°C and a shear rate of 1000 1 / s.

[0131] PAEK: Polyetheretherketone (PEEK) - grade KetaSpire KT-852NT available from Solvay Specialty Polymers. This grade has a melt viscosity in the range of 270-330 Pa·s measured according to ASTM D3835 at 400°C and a shear rate of 1000 1 / s.

[0132] PAEK: Polyetheretherketone (PEEK) - grade KetaSpire KT-820NT available from Solvay Specialty Polymers. This grade has a melt viscosity in the range of 380-500 Pa·s measured according to ASTM D3835 at 400°C and a shear rate of 1000 1 / s.

[0133] Polyphenylsulfone (PPSU): Grade R-5100NT available from Solvay Specialty Polymers. This grade exhibits an MFR of 14-20 g / 10 min measured according to ASTM D1238 using a temperature of 365° C. and a load of 5.0 kg.

[0134] Polyethersulfone (PES): Grade A-301NT available from Solvay Specialty Polymers.

[0135] The inorganic substances and other additives used were as follows:

[0136] Talc - Imerys Perfomance Additives grade Mistron®, D50 approximately 2 μm.

[0137] Boron nitride - grade Boronid® S1-SF available from 3M Corporation.

[0138] Zinc Oxide - Grade Activ® R-609 sourced from Lanxess Corporation.

[0139] Zinc stearate-Grade 2222 from Baerlocher Corporation.

[0140] Preparation of the compositions disclosed in Table II: All these compositions were prepared by first tumble blending the pellets or powders of the resins and additives to be blended in the desired composition ratio for about 20 minutes, followed by melt compounding of the resulting mixture using a 26 mm diameter Coperion ZSK-26 co-rotating partially intermeshing twin screw extruder having an L / D ratio of 48:1. The extruder had 12 barrel sections, with barrel sections 2 through 11 heated at a set temperature of 350°C. The die section was also set at a temperature of 350°C. A preblend of the raw material mixture was fed in barrel section 1 using a gravimetric feeder at a nominal throughput rate ranging from 17.5 to 28 lb / hr. The extruder was operated at a screw speed of about 200 rpm, and a vacuum was applied in barrel section 10 during compounding to strip out moisture and any possible residual volatiles from the compound. A single hole die was used for all compounds, and the molten polymer strands exiting the die were cooled in a water trough and then chopped in a pelletizer to form pellets approximately 3.0 mm in length and 2.7 mm in diameter.

[0141] Preparation of compositions CE3 and E5 in Table III: These two compositions were produced in a production scale setup using a Coperion ZSK-40 co-rotating partially intermeshing twin screw extruder with 12 barrel sections and an L / D ratio of 48. Feeding to the compounding extruder was done by metering the resin components (pre-blended if more than one) in one gravimetric feeder and the powdered additives (also pre-blended) in another gravimetric feeder. The feed rate ratio of the resin pre-blend to the additive pre-blend was adjusted to exactly achieve the proportions listed in Table III. The extruder operating parameters used during compounding are given in Table I below.

[0142] [Table 1]

[0143] injection molding Injection molding was used to produce test specimens for measuring mechanical properties and deflection temperature under load. Twenty-five tensile and twenty-five flexural specimens were made from each composition. The tensile specimens were Type I ASTM tensile bars with a thickness of 3.2 mm (0.125 inch) conforming to ASTM standard D638, and the flexural specimens had dimensions of 5 inches by 0.5 inches by 0.125 inches. The mechanical specimens were injection molded using the following approximate set temperature conditions conforming to supplier recommended injection molding guidelines for various polymers: rear barrel section: 710°F (376°C), mid barrel section: 710°F (376°C); front barrel section: 710°F (376°C); nozzle: 710°F (376°C); mold: 410°F (210°C).

[0144] test In evaluating all compositions, the following ASTM test methods were employed, which are considered in the context of the present invention: -D638: Tensile properties, measured at a test speed of 2 in / min (50 mm / min) -D648: Deflection temperature under load at 264 psi, measured on specimens annealed at 200°C for 2 hours -D149: Breakdown voltage (performed on film of nominal thickness 4 mils (100 microns))

[0145] All mechanical tests except deflection temperature under load were performed on molded test parts. Mechanical properties were measured on injection molded ASTM 3.2 mm thick specimens. Deflection temperature under load tests were performed on specimens annealed using annealing conditions of 200°C for 1 hour in a forced air oven.

[0146] [Table 2]

[0147] As can be seen, the compositions of Examples E1-E4 exhibit a superior combination of properties to the compositions of Comparative Examples CE1 and CE2. Composition CE1 exhibits a low deflection temperature under load. Composition CE2 exhibits a high deflection temperature (205° C.) but a low TEB.

[0148] [Table 3]

[0149] As can be seen from the results in Table III, the composition of Example E5 exhibits a higher tensile elongation at break (TEB) and a higher deflection temperature under load than the composition of Comparative Example CE3.

[0150] Films of the two compositions CE3 and E5 were also extruded at four different nominal thicknesses (50, 100, 150, 200 microns) and widths of 36 inches. For this purpose, a single screw extruder was used. The extruder had a single stage non-vented screw with a diameter of 2.5 inches, an L / D ratio of 30, and a compression ratio of 3.0. It was equipped with a 46 inch wide film die, resulting in a final film width of 36 inches after trimming the outer edges. The operating conditions of the extruder, die, and take-up system are summarized in Table 4 below. The resin compositions were dried in a drying hopper at 300° F. for 4 hours before extrusion.

[0151] The film extrusion conditions were as follows:

[0152] [Table 4]

[0153] Extruded films of various thicknesses were tested for dielectric breakdown voltage and partial discharge inception voltage, and the test results are summarized in Table V.

[0154] [Table 5]

[0155] All these results show that the electrical insulating capabilities of the films prepared from the compositions of the present invention exhibit improved insulating properties over Comparative Example CE3.

Claims

1. A component for use as an electrical insulating barrier in a slot of a stator, comprising or consisting of composition (C), wherein composition (C) at least 50.0% by weight of at least one polyaryletherketone (PAEK); 15.0 to 42.0 wt. % of at least one polyphenylsulfone (PPSU); 8.0 to 25.0 wt. % of at least one inorganic filler; Optionally, up to 3.0% by weight of at least one nucleating agent other than inorganic fillers; - optionally at least one plastic additive; comprising, consisting essentially of, or consisting of The part is a slot liner or a slot wedge.

2. The composition (C) is only one PAEK; or - two or more PAEKs; The component of claim 1 , comprising:

3. 10. The part of claim 1, wherein composition (C) is in the form of a homogeneous physical mixture.

4. 2. The part according to claim 1, wherein the proportion of PAEK in composition (C) is 50.0 to 65.0% by weight.

5. 2. The part according to claim 1, wherein the proportion of PAEK in composition (C) is 53.0 to 60.0% by weight or 55.0 to 60.0% by weight.

6. 2. The part of claim 1, wherein the at least one PAEK exhibits a heat of fusion of at least 35.0 J / g, preferably at least 40.0 J / g, more preferably at least 45.0 J / g, as measured from the second heat of a Differential Scanning Calorimetry test according to ASTM D3418-03.

7. 10. The part of claim 1, wherein the at least one PAEK exhibits a melt viscosity of at least 200 Pa·s measured according to ASTM D3835 at 400°C and a shear rate of 1000 1 / sec.

8. 2. The part according to claim 1, wherein the at least one PAEK exhibits a melt viscosity of 200 to 600 Pa.s, preferably 250 to 600 Pa.s, measured according to ASTM D3835 at 400°C and a shear rate of 1000 1 / s.

9. 2. The part according to claim 1, wherein the PAEK exhibits a melting temperature of at least 300°C, preferably at least 320°C.

10. The PAEK comprises arylene groups linked by oxygen atoms and / or carbonyl groups, and the polymer comprises repeating units (R ＰＡＥＫ 2. The component of claim 1, comprising more than 50.0 mol% of: -Ar'-C(=O)-Ar''-(I) (wherein Ar′ and Ar″ are the same or different and are optionally substituted arylene groups, and the repeating unit (R ＰＡＥＫ ) are in particular units of the following formulae (JA) to (JQ): 【Chemistry 1】 and R' in these formulas is selected from the group consisting of ｊ’ each R' is the same as or different from one another and is selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine, and quaternary ammonium; and j' is zero or an integer from 1 to 4, with j' preferably being zero.

11. 2. The part of claim 1, wherein the PAEK is selected from the group consisting of PEEK, PEKK, PEK, PEEKK, PEKEKK, and combinations thereof.

12. 10. The part of claim 1, wherein the PAEK is selected from the group consisting of PEEK, PEKK, and combinations thereof.

13. PEEK is more than 50.0 mol % of the repeating units, preferably more than 95.0 mol % of the repeating units, preferably more than 99.0 mol % of the repeating units, most preferably all of the repeating units are of the formula (J'-A): 【Chemistry 2】 represents a polymer having a repeating unit of PEKK is more than 50.0 mol% of the repeating units, preferably more than 95.0 mol% of the repeating units, preferably more than 99.0 mol% of the repeating units, most preferably all of the repeating units are of the formula (J'-B) and the formula (J''-B): 【Transformation 3】 represents a polymer having a repeating unit of PEK is more than 50.0 mol% of the repeating units, preferably more than 95.0 mol% of the repeating units, preferably more than 99.0 mol% of the repeating units, and most preferably all of the repeating units are of the formula (J'-C): 【Chemistry 4】 represents a polymer having a repeating unit of PEEKK is more than 50.0 mol % of the repeating units, preferably more than 95.0 mol % of the repeating units, preferably more than 99.0 mol % of the repeating units, and most preferably all of the repeating units are of the formula (J'-M): 【Transformation 5】 represents a polymer having a repeating unit of PEKEKK is more than 50.0 mol % of the repeating units, preferably more than 95.0 mol % of the repeating units, preferably more than 99.0 mol % of the repeating units, and most preferably all of the repeating units are of the formula (J'-Q): 【Transformation 6】 represents a polymer having a repeating unit of 13. A component according to claim 11 or 12.

14. The PAEK has more than 95.0 mol %, preferably at least 99.0 mol %, of repeating units of the formula (J′-A): 【Transformation 7】 2. The part of claim 1, wherein the repeating unit is PEEK.

15. 10. The part of claim 1, wherein composition (C) comprises only one type of PPSU.

16. 10. The part of claim 1, wherein composition (C) comprises two or more types of PPSU.

17. 2. The part according to claim 1, wherein the proportion of PPSU in composition (C) is 20.0 to 40.0% by weight, preferably 25.0 to 32.0% by weight.

18. The PPSU has at least 90.0 mol %, preferably at least 95.0 mol %, more preferably at least 99.0 mol %, and most preferably all of the repeat units have the formula: 【Transformation 8】 10. The part of claim 1, wherein the polymer is:

19. 2. The part of claim 1, wherein the at least one PPSU in composition (C) exhibits a melt flow rate (MFR) in the range of 5.0 to 60.0 g / 10 min, preferably 10.0 g / 10 min to 40.0 g / 10 min, and most preferably 10 to 30 g / 10 min, measured according to ASTM D1238 at 365°C under a load of 5.0 kg.

20. 2. The part according to claim 1, wherein the proportion of inorganic filler in composition (C) is 10.0 to 25.0% by weight, preferably 10.0 to 20.0% by weight, preferably 14.0 to 20.0% by weight.

21. 2. The part according to claim 1, wherein the proportion of the inorganic filler in composition (C) is 10.0 to 15.0% by weight.

22. 2. The part of claim 1, wherein the inorganic filler in composition (C) is selected from the group consisting of talc, mica, and combinations thereof, preferably talc.

23. 2. The part according to claim 1, wherein the inorganic filler exhibits an aspect ratio, defined as the average ratio between the length and the smallest of the width and thickness, of at least 5, preferably at least 10, and more preferably at least 20.

24. 2. The part of claim 1, wherein the inorganic filler in composition (C) exhibits a D50 of less than 20.0 microns, preferably less than 10.0 microns, and most preferably less than 5.0 microns, where D50 is the median of the size distribution in volume obtained by laser diffraction measurement.

25. 10. The component of claim 1, wherein composition (C) comprises at least one nucleating agent, the nucleating agent preferably being boron nitride.

26. 2. The part according to claim 1, wherein the proportion of nucleating agent is 0.1 to 3.0% by weight or 0.1 to 1.5% by weight.

27. 10. The part of claim 1, wherein composition (C) comprises only one or more PAEKs and one or more PPSUs as polymers present in the composition.

28. 2. The part of claim 1, wherein composition (C) comprises, as polymers present in the composition, only one PAEK and only one PPSU.

29. 2. The part according to claim 1, wherein the total proportion of PAEK and PPSU is at least 80.0% by weight, preferably at least 85.0% by weight.

30. 2. The part of claim 1, wherein the weight ratio of PAEK / PPSU is between 60 / 40 and 70 / 30.

31. 2. The part of claim 1, wherein the weight ratio of PAEK / PPSU is from 62 / 38 to 68 / 32, or from 64 / 36 to 66 / 34.

32. 10. The part of claim 1, wherein composition (C) exhibits a heat of fusion of at least 20.0 J / g, more preferably at least 25.0 J / g, and most preferably at least 30.0 J / g, the heat of fusion being expressed as enthalpy of fusion relative to the polymer content of the composition.

33. The composition (C) is at least 50.0% by weight of at least one polyaryletherketone (PAEK) selected from the group consisting of PEEK and PEKK; 15.0 to 42.0 wt. % of at least one polyphenylsulfone (PPSU); 8.0 to 25.0% by weight of at least one inorganic filler, preferably talc; Optionally up to 3.0 wt. % of at least one boron nitride; - optionally at least one plastic additive; 2. The part of claim 1, wherein the composition (C*) comprises, consists essentially of, or consists of:

34. The composition (C) is 50.0 to 60.0 wt. % of at least one polyaryletherketone (PAEK) selected from the group consisting of PEEK and PEKK; 25.0 to 32.0 wt. % of at least one polyphenylsulfone (PPSU); 10.0 to 20.0% by weight of at least one inorganic filler, preferably talc; Optionally up to 3.0 wt. % of at least one boron nitride; - optionally at least one plastic additive; 2. The part of claim 1, wherein the composition (C*) comprises, consists essentially of, or consists of:

35. 2. The part of claim 1, wherein composition (C) exhibits a tensile elongation at break of at least 10.0%, preferably at least 15.0%, more preferably at least 18.0%, measured according to ASTM D638 at a test speed of 50 mm / min.

36. 10. The part of claim 1, wherein composition (C) exhibits a tensile modulus of at least 4.82 GPa measured according to ASTM D638 at a test speed of 50 mm / min.

37. 2. The part according to claim 1, wherein composition (C) exhibits a deflection temperature under load of at least 180°C, preferably at least 190°C, measured on annealed 3.2 mm thick test specimens according to ASTM D648 (annealing conditions: 200°C for 2 hours) at a stress of 1.82 MPa.

38. 10. The component of claim 1, exhibiting a partial discharge inception voltage (PDIV) of at least 900 V, preferably at least 1000 V, more preferably at least 1100 V per 100 micron thickness, measured according to ASTM D1868.

39. 10. The part of claim 1, exhibiting a breakdown voltage (BV) of at least 11 kV, preferably at least 12 kV, more preferably at least 13 kV per 100 micron thickness, measured according to ASTM D149.

40. The composition (C) has the following properties: a tensile modulus of at least 4.82 GPa measured according to ASTM D638 at a test speed of 50 mm / min; and a tensile elongation at break of at least 10.0%, preferably at least 15.0%, preferably at least 18.0%, measured according to ASTM D638 at a test speed of 50 mm / min; and a deflection temperature under load of at least 180°C, preferably at least 190°C, preferably at least 195°C, measured on annealed 3.2 mm thick specimens according to ASTM D648 (annealing conditions: 200°C for 2 hours) at a stress of 1.82 MPa; 2. The part of claim 1, wherein:

41. 10. The part of claim 1 in the form of a film having a thickness of less than 1.0 mm, preferably less than 0.50 mm, and more preferably less than 0.20 mm.

42. 10. Use of the composition according to claim 1 for the manufacture of slot liners or slot wedges.

43. An electric motor comprising the component of claim 1.

44. 44. The electric motor of claim 43, including a stator and a rotor, the components being inserted into slots in the stator.

45. A generator comprising the component of claim 1.

46. 46. ​​The generator of claim 45, including a stator and a rotor, the components being inserted into slots in the stator.

47. The composition (C) according to claim 1.

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