Rotator coil and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9331536-B2
Application number	US-201214110993-A
Country	US
Kind code	B2
Filing date	Apr 9, 2012
Priority date	Apr 18, 2011
Publication date	May 3, 2016
Grant date	May 3, 2016

Abstract

A rotator coil is provided that includes a coil conductor and a mica tape wound a plurality of times around an outer periphery of the coil conductor. The mica tape includes mica paper and a reinforcing member, and has an adhesive resin layer containing an acryloyl-based component and a cyanate ester-based component between the mica paper and the reinforcing members. The reinforcing member, the mica paper, or both, are impregnated with a thermosetting resin composition, and hardened.

First claim

The invention claimed is:

1. A rotator coil comprising a coil conductor and a mica tape wound a plurality of times around an outer periphery of the coil conductor,
wherein the mica tape comprises
mica paper, a reinforcing member, and an adhesive resin layer comprising an acryloyl-based component and a cyanate ester-based component between the mica paper and the reinforcing member,
the reinforcing member, the mica paper, or both are impregnated with a thermosetting resin composition and hardened,
the thermosetting resin composition comprises an epoxy resin, a phenoxy resin and a polymaleimide compound, and
an amount of the phenoxy resin is from 0.1 to 5 parts by weight when a total weight of the epoxy resin and the polymaleimide compound is 100 parts by weight.

2. The rotator coil according to claim 1 , wherein the acryloyl-based component is made of a compound having 2 to 6 acryloyl groups in one molecule.

3. The rotator coil according to claim 1 , wherein the cyanate ester-based component is made of a compound having 2 to 6 cyanate ester groups in one molecule.

4. The rotator coil according to claim 1 , wherein a weight ratio between the acryloyl-based component and the cyanate ester-based component in the adhesive resin layer is from 25:75 to 70:30.

5. The rotator coil according to claim 1 , wherein the thermosetting resin composition is made of:
an epoxy resin having at least two epoxy groups in one molecule and having an average molecular weight of 1000 or less;
a phenoxy resin;
a polymaleimide compound having at least two or more maleimide groups in one molecule; and
acid anhydride.

6. The rotator coil according to claim 1 , wherein the rotator coil is suitable for a vehicle.

7. A method of manufacturing a rotator coil, comprising:
winding a mica tape comprising mica paper and a reinforcing member around a coil conductor;
impregnating the reinforcing member, the mica paper, or both of the mica tape with a thermosetting resin composition;
and hardening the thermosetting resin composition by heating,
wherein
the thermosetting resin composition is made of:
an epoxy resin comprising at least two epoxy groups in one molecule and having an average molecular weight of 1000 or less;
a phenoxy resin;
a polymaleimide compound comprising at least two or more maleimide groups in one molecule; and
acid anhydride, and

the mica tape is configured such that an adhesive resin layer comprising an acryloyl-based component made of a compound having 2 to 6 acryloyl groups in one molecule and a cyanate ester-based component made of a compound having 2 to 6 cyanate ester groups in one molecule is formed in advance between the mica paper and the reinforcing member.

8. The method according to claim 7 , wherein a total weight of the thermosetting resin composition is from 3 to 40 percent by weight with respect to a gross weight of the mica tape.

9. The rotator coil according to claim 1 , wherein an amount of the adhesive resin layer is from 4 to 40 parts by weight when an amount of the mica paper is 100 parts by weight.

Assignees

• Mabuchi Takahiro
• Yamamoto Shigeyuki
• Yoshioka Masahiro
• Kojiya Tomohiro
• Mitsubishi Electric Corp

Inventors

• Mabuchi Takahiro
• Yamamoto Shigeyuki
• Yoshioka Masahiro
• Kojiya Tomohiro

Classifications

• H02K3/345 Primary

  between conductor and core, e.g. slot insulation · CPC title

• H02K15/105

  to the windings · CPC title

• Y10T29/49009

  Dynamoelectric machine · CPC title

• H02K3/30 Primary

  Windings characterised by the insulating material · CPC title