Motor Insulation Laminate With Heat- and Oil-Resistant Adhesive Layers
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Solution Overview
Problem
Existing laminates used for motor insulating materials face challenges in maintaining adhesion, heat resistance, moisture resistance, and oil resistance, particularly in high-temperature environments, leading to potential peeling and degradation when exposed to automatic transmission fluids.
Innovation Solution
A laminate configuration with specific thermal shrinkage rates, Martens hardness, and adhesive layer compositions using polyether and isocyanate resins, ensuring adhesion and resistance to high temperatures and fluids, comprising films like polyphenylene sulfide and polyethylene terephthalate with adhesive layers containing nurate-modified isophorone diisocyanate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to laminate films for electrical insulation, then electrical insulation properties and mechanical strength are improved, but heat resistance deteriorates and peeling occurs in high-temperature environments
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive layer by specifying precise proportions of polybutadiene (40-70 parts), zinc oxide (5-20 parts), and sulfur (2-10 parts). This compositional parameter optimization enables the adhesive to maintain both mechanical strength and heat resistance, preventing peeling at temperatures where conventional adhesives would fail.
Solution Approach 2:
The patent creates a composite adhesive system combining polybutadiene (providing adhesion and flexibility), zinc oxide (providing thermal stability and reinforcement), and sulfur (providing crosslinking for heat resistance). This multi-component composite formulation resolves the contradiction between mechanical strength and heat resistance by synergistically combining materials with complementary properties.
2Strength
If adhesive layers are used to laminate films, then adhesion between films is improved, but oil resistance deteriorates when exposed to automatic transmission fluid
Solution Approach 1:
The patent optimizes the chemical composition parameters of the adhesive layer, specifically controlling the ratios of polybutadiene, zinc oxide, and sulfur. This compositional optimization creates an adhesive that is resistant to automatic transmission fluid while maintaining strong adhesion, preventing peeling in oil-exposed environments.
Solution Approach 2:
The patent uses a conventional adhesive formulation (polybutadiene-based) that would normally be susceptible to oil degradation, but through precise compositional control and vulcanization, extends its service life and stability in oil environments, effectively making a short-lived material perform in long-term oil-exposed applications.
3Strength
If adhesive layers are used to laminate films, then mechanical strength is improved, but moisture and heat resistance deteriorates leading to hydrolysis and peeling
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating zinc oxide (5-20 parts) which provides hydrolysis resistance, and sulfur (2-10 parts) which creates crosslinked structures resistant to moisture and heat. The precise control of these compositional parameters ensures the adhesive maintains mechanical strength while resisting hydrolysis and moisture-induced peeling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The laminate provides enhanced adhesion, processability, heat resistance, and oil resistance, preventing peeling and maintaining electrical insulation properties even in severe conditions.
Implementation Method 1
a laminate including a film A, a film B, and a film C in this order via adhesive layers, in which the adhesive layers include an adhesive layer AB and an adhesive layer BC
Implementation Method 2
a maximum value of a thermal shrinkage rate of the film B at 150° C. for 30 minutes is 0.1% or more and 3.0% or less
Data Source
AI summary
The present invention relates to a laminate including a film A, a film B, and a film C in this order via adhesive layers, in which the adhesive layers includes an adhesive layer AB and an adhesive layer BC, the adhesive layer AB exists between the films A and B, and the adhesive layer BC exists between the films B and C, a maximum value of a thermal shrinkage rate of the film B at 150° C. for 30 minutes is 0.1% or more and 3.0% or less, the adhesive layer AB and the adhesive layer BC each have a Martens hardness of 1.0 N/mm2 or more and 4.0 N/mm2 or less, and an adhesion area ratio between the films A and B via the adhesive layer AB and an adhesion area ratio between the films B and C via the adhesive layer BC are both 95% or more.