Insulating material and electric machine winding and method for manufacturing the same

Abstract

In order to provide an electric machine winding having an insulating layer excellent in electric characteristics and an insulating layer of an electric machine winding excellent in electric characteristics, a high-thermal-conductivity insulating layer 11 is formed around the peripheral portion of a winding conductor 10 by the use of a high-thermal-conductivity insulating tape 1 having a mica layer 3 , a reinforcing material layer 5 , and a high-thermal-conductivity filler layer 7 , wherein the amount of resin of the mica layer 3 makes up 10 wt % to 25 wt % of the total weight of the insulating material and wherein the amount of resin of the high-thermal-conductivity filler layer 7 makes up 10 wt % to 25 wt % of the total weight of the insulating material.

What is claimed is:  
     
         1 . An insulating material shaped in a tape or a sheet, said insulating material made by laminating and bonding a dielectric layer made of a flake-shaped inorganic insulating material bonded with a thermosetting resin, a reinforcing material layer including a thermosetting resin, and a thermal-conductivity layer in which a high-thermal-conductivity inorganic fillers are dispersed in a thermosetting resin, wherein the amount of resin of the dielectric layer is 10 to 25 wt % of the weight of the insulating material, and wherein the amount of resin of the thermal-conductivity layer is 10 to 25 wt % of the weight of the insulating material, and wherein the difference between the amount of resin of the dielectric layer and the amount of resin of the thermal-conductivity layer is not more than 10 wt % by weight.  
     
     
         2 . An insulating material as claimed in  claim 1 , wherein the inorganic insulating material is flake-shaped mica.  
     
     
         3 . An insulating material as claimed in  claim 2 , wherein the difference between the amount of resin of the dielectric layer and the amount of resin of the thermal-conductivity layer is not more than 5 wt % by weight.  
     
     
         4 . An insulating material as claimed in  claim 1  or  claim 2 , wherein the total amount of resin of the insulating material makes up 20 wt % to 50 wt % of the total weight of the insulating material.  
     
     
         5 . An insulating material as claimed in  claim 1  or  claim 2 , wherein the filler of the thermal-conductivity layer is an inorganic material having a thermal conductivity of 5 W/m·k or more.  
     
     
         6 . An insulating material as claimed in  claim 1 , wherein the amount of resin of the dielectric layer is nearly equal to the amount of resin of the thermal-conductivity layer.  
     
     
         7 . An insulating material including a flake-shaped mica layer bonded with a thermosetting resin, a fiber-cloth-shaped or film-shaped reinforcing material layer bonded to the mica layer with a thermosetting resin, and a filler layer boded to the reinforcing material layer and including high-thermal-conductivity fillers dispersed in a thermosetting resin, wherein the thermosetting resin is half cured, and wherein the amount of resin of the mica layer is 10 to 25 wt % of the weight of the insulating material, and wherein the amount of resin of the filler layer is 10 to 25 wt % of the weight of the insulating material, and wherein the difference between the amount of resin of the mica layer and the amount of resin of the filler layer is not more than 10 wt % by weight, and wherein 1 wt % to 80 wt % by weight of the fillers are spherical.  
     
     
         8 . An insulating material as claimed in  claim 1 , wherein the dielectric layer, the reinforcing material layer, and the thermal-conductivity layer are laminated in this order.  
     
     
         9 . An insulating material as claimed in  claim 1 , wherein the reinforcing material layer, the thermal-conductivity layer, and the dielectric layer are laminated in this order.  
     
     
         10 . An electric machine winding having an insulating layer formed by a tape-shaped insulating material wound around a bunch of winding conductors thereof, wherein the tape-shaped insulating material is made by laminating and bonding a dielectric layer made of a flake-shaped inorganic insulating material arranged and bonded with a thermosetting resin, a reinforcing material layer including a thermosetting resin in a reinforcing material, and a thermal-conductivity layer in which high-thermal-conductivity inorganic fillers are dispersed in a thermosetting resin, and wherein the amount of resin of the dielectric layer is 10 to 25 wt % of the weight of the insulating material, and wherein the amount of resin of the thermal-conductivity layer is 10 to 25 wt % of the weight of the insulating material.  
     
     
         11 . An insulating material as claimed in  claim 10 , wherein the flake-shaped inorganic insulating material is flake-shaped mica.  
     
     
         12 . An insulating material as claimed in  claim 10 , wherein the difference between the amount of resin of the inorganic insulating material layer and the amount of resin of the thermal-conductivity layer is not more than 5 wt % by weight.  
     
     
         13 . An insulating material as claimed in  claim 10 , wherein the total amount of resin of the insulating material makes up 20 wt % to 50 wt % of the total weight of the insulating material.  
     
     
         14 . An insulating material as claimed in  claim 10 , wherein the filler in the thermal-conductivity layer is an inorganic material having a thermal conductivity of 5 W/m k or more.  
     
     
         15 . An insulating material as claimed in  claim 10 , wherein the amount of resin of the inorganic insulating material layer is nearly equal to the amount of resin of the thermal-conductivity layer.  
     
     
         16 . A method for manufacturing a rotary electric machine winding, said method comprising the steps of: 
 forming a tape-shaped or sheet-shaped insulating material by laminating and bonding a dielectric layer made of a flake-shaped inorganic insulating material bonded with a thermosetting resin, a reinforcing material layer including a thermosetting resin, and a thermal-conductivity layer in which high-thermal-conductivity inorganic fillers are dispersed in a thermosetting resin, wherein the inorganic, insulating material in the dielectric layer is arranged in nearly parallel to the direction of the face of the tape or sheet of the reinforcing material layer, and wherein the amount of resin of the dielectric layer is 10 to 25 wt % of the weight of the insulating material, and wherein the amount of resin of the thermal-conductivity layer is 10 to 25 wt % of the weight of the insulating material, and wherein the difference between the amount of resin of the dielectric layer and the amount of resin of the thermal-conductivity layer is not more than 10 wt % by weight;    densely winding the insulating material around a bunch of conductors;    placing the rotary electric machine winding into a forming die having a heating and pressing means; and    heating, pressing, and curing the thermosetting resin.    
     
     
         17 . An insulating material as claimed in  claim 16 , wherein the inorganic insulating material is flake-shaped mica.  
     
     
         18 . A method for manufacturing an insulating material as claimed in  claim 16 , wherein the difference between the amount of resin of the inorganic insulating material layer and the amount of resin of the thermal-conductivity layer is not more than 5 wt % by weight.  
     
     
         19 . A method for manufacturing an insulating material as claimed in  claim 16 , wherein the total amount of resin of the insulating material makes up 20 wt % to 50 wt % of the total weight of the insulating material.  
     
     
         20 . A method for manufacturing an insulating material as claimed in  claim 16 , wherein the filler in the thermal-conductivity layer is an inorganic material having a thermal conductivity of 5 W/m·k or more.  
     
     
         21 . A method for manufacturing an insulating material as claimed in  claim 16 , wherein the amount of resin of the inorganic insulating material layer is nearly equal to the amount of resin of the thermal-conductivity layer.