WO2024009909A1 - Conducteur recouvert de résine, bobine et procédé de fabrication de conducteur recouvert de résine - Google Patents
Conducteur recouvert de résine, bobine et procédé de fabrication de conducteur recouvert de résine Download PDFInfo
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- WO2024009909A1 WO2024009909A1 PCT/JP2023/024432 JP2023024432W WO2024009909A1 WO 2024009909 A1 WO2024009909 A1 WO 2024009909A1 JP 2023024432 W JP2023024432 W JP 2023024432W WO 2024009909 A1 WO2024009909 A1 WO 2024009909A1
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- resin
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- coating
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- coated conductor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/06—Insulation of windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
Definitions
- the present disclosure relates to a resin-coated conductor, a coil, and a method for manufacturing a resin-coated conductor.
- Patent Document 1 discloses an insulated wire having an insulating film in which at least two insulating layers are laminated on a conductor having a rectangular cross section, the laminated insulating film having a thermosetting material on the outer periphery of the conductor. It is composed of an enamel insulating layer made of resin and an extruded insulating layer made of thermoplastic resin on the outside of the layer, the thickness of the enamel insulating layer is 50 ⁇ m or more, and the total thickness of the laminated insulating film ( T) and the relative permittivity ( ⁇ ) at 100°C, the maximum thickness (Tmax) of one layer in the laminated insulating layers, and the maximum value ( ⁇ max) and minimum value ( ⁇ min) of the relative permittivity at 100°C. , an insulated wire characterized by satisfying all of the following relationships is described. T ⁇ 100 ⁇ m (1.1) Tmax ⁇ 100 ⁇ m (1.2) 1.5 ⁇ 3.5 (2.1) 1.0 ⁇ max/ ⁇ min ⁇ 1.2 (2.2)
- Patent Document 2 discloses a heat-resistant electric wire comprising a core wire and a coating material coated on the core wire, the coating material irradiating the copolymer with radiation at a dose of 250 kGy or less. It is formed from a modified fluorine-containing copolymer obtained by irradiation at a temperature below the melting point, and the copolymer is a copolymer consisting of tetrafluoroethylene units and perfluoro(alkyl vinyl ether) units, and , a heat-resistant electric wire characterized by being made of at least one copolymer selected from the group consisting of copolymers consisting of tetrafluoroethylene units and hexafluoropropylene units.
- Patent Document 3 discloses a magnet wire comprising a conductor and an insulating coating formed on the outer periphery of the conductor, the insulating coating containing a copolymer containing tetrafluoroethylene units and fluoroalkyl vinyl ether units. and the melt flow rate of the copolymer is 10 to 60 g/10 minutes, and the content of fluoroalkyl vinyl ether units in the copolymer is 6.2 to 8.0% by mass with respect to all monomer units.
- the magnet wire is described.
- An object of the present disclosure is to provide a resin-coated conductor that is tightly adhered to the conductor without any gaps and is coated with a coating that is hard to be damaged.
- a resin-coated conductor comprising a conductor and a coating containing a resin and covering the conductor, the coating covering a surface of the coating.
- a coating irradiated with an electron beam, wherein the temperature of the electron beam irradiation is lower than the melting point of the resin forming the coating, and the electron beam acceleration voltage of the electron beam irradiation is 500 kV or less.
- a coated conductor is provided.
- FIG. 1 is a front view and a top view of a resin-coated conductor according to one embodiment.
- FIG. 2 is a cross-sectional view of a resin-coated conductor according to one embodiment.
- FIG. 3 is a cross-sectional view of a heat shrink tube according to one embodiment.
- Patent Document 1 describes that in order to improve the performance of rotating machines such as motors, it is required to accommodate a larger number of windings in the slots of the stator. Further, Patent Document 1 describes an insulated wire used in such a winding wire having an insulating film in which at least two insulating layers are laminated on a conductor having a rectangular cross section. It is described that the insulating film is composed of an enamel insulating layer made of a thermosetting resin on the outer periphery of the conductor and an extruded insulating layer made of a thermoplastic resin outside the layer.
- Patent Documents 2 and 3 describe the use of a material irradiated with radiation as a coating material for a heat-resistant electric wire or an insulating coating for a magnet wire.
- the resin-coated conductor of the present disclosure uses a coating whose surface is irradiated with an electron beam as a coating for covering the conductor, so the coating is formed of a resin with a low dielectric constant. Even in cases where a metal jig is used, the coating is less likely to be damaged when inserted into a slot in the core of a rotating electric machine or when bent in an edgewise direction. Therefore, the resin-coated conductor of the present disclosure can be easily deformed into a shape that can be easily accommodated in a slot without sacrificing good insulation properties, and furthermore, can be easily accommodated in a slot of a core. This makes it possible to downsize and improve the performance of rotating electrical machines such as motors.
- the resin-coated conductor of the present disclosure includes a conductor and a covering that covers the conductor, and the covering contains resin. Next, the structure of the conductor and the covering will be explained in more detail.
- the conductor may be a single wire, a grouped wire, a stranded wire, etc., but is preferably a single wire.
- the cross-sectional shape of the conductor may be circular, elliptical, rectangular, square, or polygonal.
- the conductor is not particularly limited as long as it is made of a conductive material, but it can be made of materials such as copper, copper alloy, aluminum, aluminum alloy, iron, silver, and nickel; It is preferable to use at least one member selected from the group consisting of aluminum alloys and aluminum alloys. Further, a conductor plated with silver plating, nickel plating, etc. can also be used. As the copper, oxygen-free copper, low-oxygen copper, copper alloy, etc. can be used.
- the width of the cross section of the conductor may be 1 to 75 mm, and the thickness of the cross section of the conductor may be 0.1 to 10 mm. .
- the cross-sectional shape of the conductor may be rectangular.
- the outer diameter of the conductor may be 6.5 mm or more and 200 mm or less. Further, the ratio of width to thickness may be greater than 1 and less than or equal to 30.
- the diameter of the conductor is preferably 0.1 to 10 mm, more preferably 0.3 to 3 mm.
- the surface roughness Sz of the conductor is preferably 0.2 to 12 ⁇ m, more preferably 1 ⁇ m or more, still more preferably 5 ⁇ m or more, and more preferably is 10 ⁇ m or less.
- the surface roughness of the conductor can be adjusted by surface treating the conductor using a surface treatment method such as etching treatment, blasting treatment, laser treatment, or the like. Further, the surface of the conductor may be provided with irregularities by surface treatment.
- the distance between the convex and convex portions is preferably as small as possible, for example, 0.5 ⁇ m or less. Further, the size of the unevenness is such that, for example, the area of each concave portion when cutting the convex portions on the unprocessed surface is 0.5 ⁇ m 2 or less.
- the uneven shape may be a single crater-shaped uneven shape, or may be branched like an ant nest.
- the covering covers the conductor and is in direct contact with the conductor. Furthermore, the surface of the coating is irradiated with an electron beam at a relatively low temperature and a relatively low electron beam acceleration voltage, thereby maintaining the uniformity of the thickness of the coating and making it possible to bond with the conductor. It is possible to form a coating that adheres strongly without gaps, and moreover, a coating that is less likely to be scratched can be obtained.
- the temperature of electron beam irradiation is lower than the melting point of the resin forming the coating, preferably 20°C lower than the melting point of the resin, more preferably 40°C lower, and even more preferably 60°C lower. below temperature. Further, the lower limit of the temperature of electron beam irradiation is preferably at least 150° C. lower, more preferably at least 130° C. lower.
- Adjustment of the irradiation temperature is not particularly limited, and can be performed by a known method. Specifically, the resin-coated conductor is held in a heating furnace maintained at a predetermined temperature, the resin-coated conductor is placed on a hot plate, and a heater built into the hot plate is energized, or Examples of methods include heating a hot plate using external heating means.
- the electron beam acceleration voltage for electron beam irradiation is 500 kV or less, preferably 400 kV, more preferably 300 kV or less, still more preferably 200 kV or less, even more preferably 150 kV or less, and particularly preferably 100 kV. or less, most preferably 70 kV or less, preferably 30 kV or more, and more preferably 50 kV or more.
- the electron beam irradiation amount is preferably 40 to 200 kGy, more preferably 50 kGy or more, and even more preferably 150 kGy or less.
- the thickness of the coating is preferably 40 to 300 ⁇ m, more preferably 50 ⁇ m or more, still more preferably 60 ⁇ m or more, and even more preferably 250 ⁇ m or less, from the viewpoint of insulation properties and adhesion between the conductor and the coating. and more preferably 200 ⁇ m or less.
- the entire coating can be exposed to the electron beam. Only the surface of the coating (an area of a certain depth) is modified without being modified. This maintains the inherent properties of the resin that forms the coating (e.g., the elongation rate of the resin), and also improves the scratch resistance of the surface of the coating while maintaining the adhesion between the conductor and the coating. can be improved.
- the coating is composed of a crystalline inner layer that adheres to the conductor and an amorphous surface layer that forms the surface of the coating.
- the amorphous surface layer is formed by irradiating the surface of the coating with an electron beam at a relatively low temperature and a relatively low electron beam acceleration voltage.
- the resin-coated conductor is placed on a hot stage, and while the temperature of the hot stage is raised, the cross section of the resin-coated conductor is observed using a polarizing microscope.
- the coating When the coating is in a molten state, it becomes a dark field under a crossed Nicols polarizing microscope.
- the resin in the molten part When cooled at a rate of 50°C/min to below the melting point, the resin in the molten part recrystallizes and the crystal layer becomes brighter due to polarized light, but the surface layer modified by the electron beam has a crosslinked structure that is difficult to recrystallize. Therefore, it becomes a dark field.
- the modified part and the non-modified part are distinguished by differences in brightness and color change. With this method, the presence or absence of modification of the coated conductor is confirmed.
- the method of irradiating the electron beam is not particularly limited, and examples thereof include a method using a conventionally known electron irradiation device.
- the number of times the electrons are irradiated is not particularly limited, and may be one time or multiple times. After the electron beam is irradiated from one side of the resin-coated conductor, the electron beam may be further irradiated from the opposite direction.
- the electron beam irradiation environment is not particularly limited, but it is preferable that the oxygen concentration is 1000 ppm or less, more preferably in the absence of oxygen, in a vacuum, or in an inert gas such as nitrogen, helium, or argon. More preferably, it is carried out in an atmosphere.
- the covering is made of resin.
- the relative dielectric constant of the resin is preferably 4.0 or less, more preferably 3.4 or less, still more preferably 2.9 or less, and even more preferably 2.4 or less. It is particularly preferably 2.2 or less, and preferably 1.80 or more.
- the relative permittivity of the resin can be determined by measuring changes in resonance frequency and electric field strength at a temperature of 20 to 25°C using a network analyzer HP8510C (manufactured by Hewlett-Packard) and a cavity resonator for the resin before irradiation with an electron beam. This is a value obtained by measurement.
- thermoplastic resins examples include fluororesin, polyaryletherketone (PAEK) resin, thermoplastic polyimide resin, thermoplastic polyamideimide resin, polyamide resin, polyolefin resin, modified polyolefin resin, polyvinyl resin, polyester, and ethylene/vinyl alcohol copolymer.
- PAEK polyaryletherketone
- Coalescence polyacetal resin, polyurethane resin, polyphenylene oxide resin, polycarbonate resin, acrylic resin, styrene resin, acrylonitrile/butadiene/styrene resin (ABS), vinyl chloride resin, cellulose resin, polysulfone resin, polyethersulfone resin ( PES), polyetherimide resin, polyphenylene sulfide resin, etc.
- fluororesin is preferable from the viewpoint of electrical properties.
- fluororesins examples include polytetrafluoroethylene, tetrafluoroethylene (TFE)/fluoroalkyl vinyl ether (FAVE) copolymer, tetrafluoroethylene (TFE)/hexafluoropropylene (HFP) copolymer, and TFE/ethylene copolymer.
- EFE TFE/ethylene/HFP copolymer
- ECTFE ethylene/chlorotrifluoroethylene
- PCTFE polychlorotrifluoroethylene
- CTFE/TFE copolymer polyvinylidene fluoride [ PVdF]
- PVdF polyvinylidene fluoride
- VdF polyvinylidene fluoride copolymer
- PVTC polyvinyl fluoride
- TFE/VdF/CTFE copolymer VTC]
- melt-processable fluororesin As the fluororesin, a melt-processable fluororesin is preferable because a coating or a heat-shrinkable tube can be easily produced by extrusion molding, and a coating that adheres more closely to the conductor can be formed.
- melt processable means that the polymer can be melted and processed using conventional processing equipment such as extruders and injection molding machines. Therefore, melt-processable fluororesins usually have a melt flow rate of 0.01 to 500 g/10 minutes as measured by the measuring method described below.
- the melt flow rate of the fluororesin is preferably 0.1 to 100 g/10 minutes, more preferably 70 g/10 minutes or less, even more preferably 60 g/10 minutes or less, and even more preferably 50 g/10 minutes. /10 minutes or less, particularly preferably 40 g/10 minutes or less, and most preferably 30 g/10 minutes or less.
- a coating with uniform thickness and excellent mechanical strength can be easily obtained.
- the melt flow rate of the fluororesin was determined using a melt indexer (manufactured by Yasuda Seiki Seisakusho Co., Ltd.) in accordance with ASTM D1238 at 372°C under a 5 kg load for 10 minutes from a nozzle with an inner diameter of 2.1 mm and a length of 8 mm. This is the value obtained as the mass of polymer flowing out per minute (g/10 min).
- the dielectric constant of the fluororesin is preferably 2.4 or less, more preferably 2.2 or less, and even more preferably 2.1 or less, from the viewpoint of electrical properties, and the lower limit is not particularly limited, but Preferably it is 1.8 or more.
- the relative dielectric constant of fluororesin is determined by measuring changes in resonance frequency and electric field strength at a temperature of 20 to 25°C using a network analyzer HP8510C (manufactured by Hewlett-Packard) and a cavity resonator for fluororesin before irradiation with an electron beam. This is the value obtained by measuring below.
- the melting point of the fluororesin is preferably 200 to 322°C, more preferably 220°C or higher, even more preferably 240°C or higher, even more preferably 260°C or higher, particularly preferably 280°C or higher.
- the temperature is more preferably 320°C or lower.
- the melting point can be measured using a differential scanning calorimeter (DSC).
- DSC differential scanning calorimeter
- the fluororesin is preferably at least one selected from the group consisting of TFE/FAVE copolymers and TFE/HFP copolymers; Combination is more preferred.
- a TFE/FAVE copolymer is a copolymer containing tetrafluoroethylene (TFE) units and fluoroalkyl vinyl ether (FAVE) units.
- Y 1 represents F or CF 3
- Rf represents a perfluoroalkyl group having 1 to 5 carbon atoms
- p represents an integer of 0 to 5
- q represents an integer of 0 to 5.
- a monomer represented by and general formula (2): CFX CXOCF 2 OR 1 (2) (wherein, X is the same or different and represents H, F or CF3 , and R1 represents at least one linear or branched atom selected from the group consisting of H, Cl, Br and I.
- a fluoroalkyl group having 1 to 6 carbon atoms which may contain 1 to 2 atoms, or 1 to 2 atoms of at least one selected from the group consisting of H, Cl, Br and I
- At least one type selected from the group consisting of monomers represented by can be mentioned.
- FAVE is preferably a monomer represented by the general formula (1), consisting of perfluoro(methyl vinyl ether), perfluoro(ethyl vinyl ether) (PEVE), and perfluoro(propyl vinyl ether) (PPVE). At least one selected from the group consisting of PEVE and PPVE is more preferable, at least one selected from the group consisting of PEVE and PPVE is even more preferable, and PPVE is particularly preferable.
- the content of FAVE units in the TFE/FAVE copolymer is such that the modification of the fluororesin by electron beam irradiation progresses more smoothly, thereby creating a coating that adheres more tightly to the conductor and is more scratch-resistant. Since it can be formed, it is preferably 0.4 to 4.0 mol%, more preferably 1.1 mol% or more, still more preferably 1.3 mol% or more, based on the total monomer units. More preferably 1.4 mol% or more, particularly preferably 1.5 mol% or more, most preferably 1.8 mol% or more, more preferably 3.2 mol% or less, even more preferably is 2.8 mol% or less, particularly preferably 2.5 mol% or less, particularly preferably 2.4 mol% or less.
- the content of TFE units in the TFE/FAVE copolymer is preferably 96.0 to 99.6 mol based on the total monomer units, since it adheres more strongly to the conductor and provides a coating that is more scratch resistant.
- % more preferably 96.8 mol% or more, still more preferably 97.2 mol% or more, even more preferably 97.5 mol% or more, particularly preferably 97.6 mol% or more It is more preferably 98.9 mol% or less, still more preferably 98.7 mol% or less, even more preferably 98.6 mol% or less, particularly preferably 98.5 mol% or less. Most preferably, it is 98.2 mol% or less.
- the content of each monomer unit in the copolymer is measured by 19 F-NMR method.
- the TFE/FAVE copolymer can also contain monomer units derived from monomers copolymerizable with TFE and FAVE.
- the content of the monomer copolymerizable with TFE and FAVE is preferably from 0 to 3.6 mol%, more preferably from 0 to 3.6 mol%, based on the total monomer units of the TFE/FAVE copolymer. It is 1 to 2.2 mol%, more preferably 0.2 to 1.0 mol%.
- the TFE/FAVE copolymer is preferably at least one selected from the group consisting of a copolymer consisting only of TFE units and FAVE units, and the above-mentioned TFE/HFP/FAVE copolymer. More preferred is a copolymer consisting only of the following.
- the melting point of the TFE/FAVE copolymer is preferably 280 to 322°C, more preferably 285°C or higher, more preferably 315°C or lower, and even more preferably is below 310°C.
- the melting point can be measured using a differential scanning calorimeter (DSC).
- the glass transition temperature (Tg) of the TFE/FAVE copolymer is preferably 70 to 110°C, more preferably 80°C or higher, and even more preferably 100°C or lower. Glass transition temperature can be measured by dynamic viscoelasticity measurement.
- the relative dielectric constant of the TFE/FAVE copolymer is preferably 2.4 or less, more preferably 2.2 or less, and even more preferably 2.1 or less, and the lower limit is particularly Although not limited, it is preferably 1.8 or more.
- the relative dielectric constant of the TFE/FAVE copolymer was determined by measuring the resonant frequency and electric field strength of the TFE/FAVE copolymer before irradiation with an electron beam using a network analyzer HP8510C (manufactured by Hewlett-Packard) and a cavity resonator. This is a value obtained by measuring changes at a temperature of 20 to 25°C.
- a TFE/HFP copolymer is a copolymer containing tetrafluoroethylene (TFE) units and hexafluoropropylene (HFP) units.
- the content of HFP units in the TFE/HFP copolymer is preferably 0.1 mol% or more, more preferably 0.1% by mole or more based on the total monomer units, since it can form a coating that adheres more firmly to the conductor. It is .7 mol% or more, more preferably 1.3 mol% or more, preferably 22 mol% or less, and more preferably 11 mol% or less.
- the content of TFE units in the TFE/HFP copolymer is preferably 78 mol% or more, more preferably 89 mol% based on the total monomer units, since it can form a coating that adheres more firmly to the conductor. or more, preferably 99.9 mol% or less, more preferably 99.3 mol% or less, still more preferably 98.7 mol% or less.
- the TFE/HFP copolymer can also contain monomer units derived from monomers copolymerizable with TFE and HFP.
- the content of the monomer copolymerizable with TFE and HFP is preferably 0 to 21.9 mol%, more preferably 0.9 mol%, based on the total monomer units of the TFE/HFP copolymer.
- the content is 1 to 5.0 mol%, more preferably 0.1 to 1.0 mol%.
- the melting point of the TFE/HFP copolymer is preferably 200 to 322°C, more preferably 210°C or higher, even more preferably 220°C or higher, more preferably less than 300°C, and even more preferably 280°C or higher. below °C.
- the glass transition temperature (Tg) of the TFE/HFP copolymer is preferably 60 to 110°C, more preferably 65°C or higher, and even more preferably 100°C or lower.
- the fluororesin has a functional group. Because the fluororesin has functional groups, it is possible to form a coating that adheres more firmly to the conductor, and the modification of the coating progresses smoothly through electron beam irradiation, making it easier to form a coating that is even more resistant to scratches. can do.
- the functional group is preferably at least one selected from the group consisting of a carbonyl group-containing group, an amino group, a hydroxy group, a -CF 2 H group, an olefin group, an epoxy group, and an isocyanate group.
- R 6 is an alkyl group having 1 to 20 carbon atoms or an alkyl group having 2 to 20 carbon atoms containing an ether-bonding oxygen atom
- R 3 examples include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, and the like.
- R 4 examples include a methylene group, -CF 2 - group, -C 6 H 4 - group, etc.
- R 5 examples include a methyl group, an ethyl group, a propyl group, an isopropyl group, Examples include butyl group.
- R 7 include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, and the like.
- R 8 and R 9 include a hydrogen atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a phenyl group, and the like.
- the hydroxy group is a group represented by -OH or a group containing a group represented by -OH.
- -OH constituting a carboxyl group is not included in a hydroxy group.
- Examples of the hydroxy group include -OH, methylol group, and ethylol group.
- An olefinic group is a group having a carbon-carbon double bond.
- -CR 10 CR 11 R 12
- R 10 , R 11 and R 12 may be the same or different and are a hydrogen atom, a fluorine atom, or a monovalent organic group having 1 to 20 carbon atoms.
- the number of functional groups in the fluororesin is preferably 100 to 1300 per 10 6 carbon atoms.
- the number of functional groups per 10 6 carbon atoms is more preferably 50 or more, still more preferably 100 or more, particularly preferably 200 or more, more preferably 1000 or less, and Preferably it is 800 or less, particularly preferably 700 or less.
- the number of functional groups mentioned above is the number of functional groups of the fluororesin contained in the coating before electron beam irradiation.
- an insulating coating containing a fluororesin By irradiating an insulating coating containing a fluororesin with the number of functional groups within the above range with an electron beam, a crosslinking reaction between the functional groups of each polymer molecule of the fluororesin progresses, and the fluororesin is modified. It is assumed that this will be questioned.
- the number of functional groups of the fluororesin is within the above range, even when the surface is irradiated with an electron beam at a relatively low temperature and a relatively low electron beam acceleration voltage, the fluororesin on the surface can be smoothly modified. This process progresses to easily form a coating that is even more resistant to scratches.
- the above-mentioned functional groups are functional groups present at the main chain end or side chain end of the copolymer (fluororesin), and functional groups present in the main chain or side chain, preferably at the main chain end. exist.
- -COOH includes a dicarboxylic acid anhydride group (-CO-O-CO-) formed by bonding two -COOHs.
- Infrared spectroscopy can be used to identify the type of functional group and measure the number of functional groups.
- the absorption frequencies of -CH 2 CF 2 H, -CH 2 COF, -CH 2 COOH, -CH 2 COOCH 3 and -CH 2 CONH 2 are shown in the table, respectively.
- the absorption frequency is several tens of Kaiser (cm -1 ) lower than that of COOH free, -COOH bonded, -COOCH 3 , and -CONH 2 . Therefore, for example, the number of functional groups in -COF is the number of functional groups determined from the absorption peak at absorption frequency 1883 cm -1 due to -CF 2 COF and the absorption peak at absorption frequency 1840 cm -1 due to -CH 2 COF. This is the sum of the calculated number of functional groups.
- the above-mentioned functional group is introduced into the fluororesin (copolymer) by, for example, a chain transfer agent or a polymerization initiator used when producing the fluororesin.
- a chain transfer agent or a polymerization initiator used when producing the fluororesin.
- -CH 2 OH is introduced at the end of the main chain of the copolymer.
- the functional group is introduced into the end of the side chain of the copolymer.
- the fluororesin may contain units derived from a monomer having a functional group.
- a cyclic hydrocarbon having a dicarboxylic acid anhydride group (-CO-O-CO-) and having a polymerizable unsaturated group in the ring as described in JP-A-2006-152234;
- Examples include monomers and monomers having a functional group (f) described in International Publication No. 2017/122743.
- Examples of monomers having a functional group include monomers having a carboxy group (maleic acid, itaconic acid, citraconic acid, undecylenic acid, etc.); monomers having an acid anhydride group (itaconic anhydride, anhydride, etc.); citraconic acid, 5-norbornene-2,3-dicarboxylic anhydride, maleic anhydride, etc.), monomers having a hydroxyl group or an epoxy group (hydroxybutyl vinyl ether, glycidyl vinyl ether, etc.), and the like.
- the fluororesin can be produced by conventionally known methods such as, for example, appropriately mixing monomers serving as its constituent units and additives such as a polymerization initiator, and performing emulsion polymerization or suspension polymerization.
- the coating may contain other components as necessary.
- Other ingredients include crosslinking agents, antistatic agents, heat stabilizers, foaming agents, foaming nucleating agents, antioxidants, surfactants, photopolymerization initiators, antiwear agents, surface modifiers, pigments, etc. Agents, etc. can be mentioned.
- the content of other components in the coating is preferably less than 1% by mass, more preferably 0.5% by mass or less, and even more preferably 0.5% by mass, based on the mass of the resin in the coating. It is 1% by mass or less, and the lower limit is not particularly limited, but it may be 0% by mass or more. That is, the coating may not contain other components.
- the resin-coated conductor of the present disclosure includes, for example, (1) Using an extruder, heat the resin to melt it, extrude the molten resin onto the conductor to form a coating, and irradiate the surface of the resulting coating with an electron beam. A manufacturing method of irradiating; (2) Cover the conductor with a heat-shrinkable tube containing resin, shrink the heat-shrinkable tube to form a covering (shrinkable material), and apply electrons to the surface of the resulting covering (shrinkable material).
- the obtained coating may be heat treated.
- the adhesion between the conductor and the covering can be further improved.
- the heat treatment is preferably performed after the coating is irradiated with an electron beam, since the uniformity of the thickness of the coating is maintained well.
- the heat treatment can be performed by heating the resin-coated conductor batchwise or continuously using a hot air circulation furnace or a heating furnace that utilizes high-frequency induction heating. It can also be carried out by a salt bath method.
- a resin-coated conductor is passed through molten salt and heated.
- Molten salts include mixtures of potassium nitrate and sodium nitrate.
- the temperature of the heat treatment is usually at least the melting point of the resin, preferably at least 15° C. above the melting point of the resin, and preferably at most 100° C. above the melting point of the resin.
- the heat treatment time is preferably 0.1 to 15 minutes, more preferably 0.5 minutes or more, since it can further improve the adhesion between the conductor and the coating and suppress oxidation of the conductor. , more preferably 10 minutes or less. If heated at high temperatures for a long time, copper core wires may become oxidized and discolored.
- the conditions for irradiating the surface of the coating with an electron beam in the method for manufacturing a resin-coated conductor are as described above.
- a method for forming a coating to be irradiated with an electron beam will be described in detail.
- a resin-coated conductor including a conductor and a covering can be obtained by extruding a molten resin onto the conductor.
- the extrusion molding machine is not particularly limited, but an extrusion molding machine equipped with a cylinder, a die, and a nipple having a passage port through which the conductor is sent out can be used.
- the temperature of the resin in a molten state is usually at least the melting point of the resin, preferably at least 15°C higher than the melting point of the resin, more preferably at least 20°C higher than the melting point of the resin, and even more preferably at least 20°C higher than the melting point of the resin.
- the temperature is 25°C or more higher than the melting point of .
- the upper limit of the temperature of the resin in a molten state is not limited, but is, for example, lower than the thermal decomposition temperature of the resin.
- the line speed during extrusion molding may be 0.1 to 50 m/min, preferably 20 m/min or less.
- the resin-coated conductor After forming the coating, the resin-coated conductor can be cooled.
- the cooling method is not particularly limited, and may be water cooling, air cooling, or the like.
- a resin-coated conductor When cooled by air cooling, it can be cooled at an appropriate rate, so the thickness of the coating tends to be uniform.
- the conductor may be deformed into a desired shape before being covered with a heat shrinkable tube.
- a heat shrinkable tube For example, if the conductor is a rectangular conductor, bend the rectangular conductor in the edgewise direction to form a rectangular conductor with a bent part, cover the rectangular conductor with the bent part with a heat shrink tube, and shrink the heat shrink tube.
- the coating can be suitably manufactured using a manufacturing method for forming a covering.
- the heat-shrinkable tube shrinks along the shape of the bent portion bent in the edgewise direction, and as a result, the formed coating adheres tightly to the bent portion of the rectangular conductor without any gaps. Become. Therefore, although the resin-coated conductor obtained by such a manufacturing method has one or more bent portions bent in the edgewise direction, there is no gap between the rectangular conductor and the coating.
- a heat-shrinkable tube can be heat-shrinked by heating it.
- the heating temperature for heat shrinking is preferably 150 to 290°C, more preferably 180°C or higher, even more preferably 200°C or higher, and even more preferably 250°C or lower.
- the heating time for heat shrinking is preferably 2 to 20 minutes, more preferably 5 minutes or more, and even more preferably 15 minutes or less.
- the substantially U-shaped rectangular conductor is covered with a heat shrink tube, and the rectangular conductor covered with the heat shrink tube is suspended from the top of the rectangular conductor.
- the gas existing between the rectangular conductor and the heat-shrinkable tube is smoothly discharged to the outside.
- the heat-shrinkable tube can be shrunk, the rectangular conductor and the heat-shrinkable tube can be more smoothly brought into close contact with each other without any gaps.
- a resin-coated conductor includes a rectangular conductor having one or more bent portions bent in an edgewise direction, and a covering covering the rectangular conductor, wherein the covering is a rectangular conductor having one or more bent portions. It is formed by covering a conductor with a heat shrink tube and shrinking the heat shrink tube.
- a resin-coated conductor according to one embodiment will be described in detail using figures.
- FIG. 1 is a front view and a top view of a resin-coated conductor according to one embodiment.
- FIG. 2 is a cross-sectional view of a resin-coated conductor according to one embodiment.
- a resin-coated conductor 100 shown in FIG. 1 is a resin-coated conductor (segment coil) for forming a coil by being inserted into each slot of a core of a rotating electric machine.
- the resin-coated conductor 100 is constructed by bending a resin-coated conductor of a predetermined length into a U-shape in the flatwise direction.
- the resin-coated conductor 100 includes a rectangular conductor 21 and a covering 22 formed around the outer periphery of the rectangular conductor 21.
- the resin-coated conductor 100 has a substantially U-shape and is composed of a curved portion 11 and slot insertion portions 12 extending from both ends of the curved portion 11.
- Shoulders 13a and 13b are formed by bending a rectangular conductor in the edgewise direction at a portion connecting the curved portion 11 and the slot insertion portion 12.
- the curved portion 11 has a convex portion 14 formed by bending the rectangular conductor in the edgewise direction, and a crank-shaped portion 15 formed by bending the rectangular conductor in the flatwise direction.
- the rectangular conductor 21 and the coating 22 are in complete contact with each other without any gaps at both the shoulder portions 13a and 13b, and also at the convex portion 14.
- FIG. 3 is a cross-sectional view of a heat shrink tube according to one embodiment.
- the heat shrink tube 30 includes a hollow portion 31.
- a rectangular conductor (not shown) having a bent part can be smoothly inserted into the hollow part 31, and the heat shrink tube 30 can be inserted into the rectangular conductor. can be covered.
- heat-shrinking the heat-shrinkable tube 30 placed over the rectangular conductor it is possible to manufacture the resin-coated conductor 100 in which the rectangular conductor 21 and the covering 22 are completely adhered to each other without any gaps.
- a heat-shrinkable tube can be manufactured by extrusion molding a resin.
- a heat-shrinkable tube can be manufactured by extruding a resin to obtain a tube and then expanding the tube.
- An extruder can be used for extrusion molding.
- the extruder may be a single screw extruder or a twin screw extruder.
- Conventionally known conditions can be employed as the molding conditions during extrusion molding. For example, a method can be used in which the resin is heated above its melting point to melt it and then extruded.
- a heat-shrinkable tube can be manufactured, for example, by referring to the method described in the following literature.
- (a) A method described in JP-A-11-080387 in which an unstretched tube is expanded by applying internal pressure in a stretching tube that regulates the stretching ratio in the radial direction.
- (b) A heat-shrinkable tube manufacturing apparatus that includes two pinch rollers, an air supply section, and a control section that controls tube expansion by changing the distance between the two pinch rollers, as described in JP-A-2011-183800.
- a manufacturing method using (c) A method described in International Publication No.
- a simple method for manufacturing a heat-shrinkable tube includes, for example, the following method. First, a tube is formed by extrusion molding at a resin temperature of 380° C., and then the obtained tube is inserted into a metal tube having a predetermined inner diameter. This is heated to 170° C. in an electric furnace and then expanded by applying internal pressure with air. At this time, the outer diameter can be kept constant because the diameter is regulated by the metal tube. Take it out and cool it to obtain a heat shrink tube.
- the shape of the metal tube may be cylindrical or quadrangular prism.
- the expansion ratio is preferably more than 1.0 times, more preferably 1.1 times or more, and even more preferably It is 1.2 times or more, preferably 50 times or less, more preferably 10 times or less, and still more preferably 5 times or less.
- the expansion magnification can be calculated by dividing the inner diameter of the tube after expansion by the inner diameter of the tube before expansion.
- a commercially available heat shrink tube can also be used. It is preferable that the size is larger than that of the rectangular conductor so that it can be easily inserted, and that it has a shrinkage rate sufficient to shrink after heating and come into close contact with the rectangular conductor.
- a resin-coated conductor can be used as a coil.
- the coil include a stator coil and a rotor coil.
- a resin-coated conductor may be wound around a stator core or a rotor core to form a coil, or a resin-coated conductor may be wound and then attached to a stator core or rotor core.
- the resin-coated conductor has one or more bent portions bent in the edgewise direction, it can be suitably used as a segment coil inserted into a slot formed in a stator core or rotor core.
- a coil can be formed as a segment coil by inserting resin-coated conductors into slots and joining the ends of each resin-coated conductor.
- the resin-coated conductor and coil can be suitably used in electrical or electronic equipment such as motors, generators, and inductors. Furthermore, the resin-coated conductor and coil can be suitably used in on-vehicle electric equipment or on-vehicle electronic equipment, such as on-vehicle motors, on-vehicle generators, and on-vehicle inductors.
- a resin-coated conductor comprising a conductor and a coating containing a resin and covering the conductor, wherein the coating is a coating whose surface is irradiated with an electron beam. Accordingly, there is provided a resin-coated conductor in which the temperature of electron beam irradiation is lower than the melting point of the resin forming the coating, and the electron beam acceleration voltage of electron beam irradiation is 500 kV or less.
- a resin-coated conductor according to the first aspect is provided, in which the electron beam acceleration voltage is 200 kV or less and the electron beam irradiation amount is 40 to 200 kGy.
- a resin-coated conductor according to the first or second aspect in which the electron beam acceleration voltage is 70 kV or less and the electron beam irradiation amount is 40 to 150 kGy or less.
- the resin has a dielectric constant of 2.2 or less.
- the conductor is a rectangular conductor.
- the coating is a coating formed by extruding the resin onto the conductor using an extrusion molding method, or a coating formed by shrinking a heat-shrinkable tube containing the resin.
- a resin-coated conductor according to any of the fifth aspects is provided.
- the conductor is a rectangular conductor having one or more bent portions bent in an edgewise direction.
- a seventh method wherein the covering is a covering in which a heat-shrinkable tube is placed over the rectangular conductor having the bent portion, the heat-shrinkable tube is shrunk, and the surface of the resulting shrunken product is irradiated with an electron beam.
- a resin-coated conductor is provided according to this aspect.
- the ninth aspect of the present disclosure There is provided a resin-coated conductor according to any one of the first to eighth aspects, wherein the resin is a thermoplastic resin.
- a resin-coated conductor according to any one of the first to ninth aspects, wherein the resin is a fluororesin.
- the resin is a fluororesin.
- the fluororesin has a dielectric constant of 2.2 or less.
- the fluororesin has a melt flow rate of 0.1 to 100 g/10 minutes.
- the fluororesin is a copolymer containing tetrafluoroethylene units and fluoroalkyl vinyl ether units, and the content of fluoroalkyl vinyl ether units in the copolymer is 1.1 to 3.
- a resin-coated conductor according to any one of the tenth to twelfth aspects, wherein the resin-coated conductor has a content of 2 mol %.
- the fourteenth aspect of the present disclosure The resin-coated conductor according to any one of 10th to 13th, wherein the fluororesin has a functional group, and the number of functional groups of the fluororesin is 100 to 1300 per 10 6 carbon atoms.
- the coating is a coating that is further heat-treated at a temperature equal to or higher than the melting point of the resin forming the coating after being irradiated with an electron beam. A resin coated conductor is provided.
- a coil including a resin-coated conductor according to any one of the first to fifteenth aspects is provided.
- a method for manufacturing a resin-coated conductor according to any one of the first to fifteenth aspects comprising: forming a covering covering the conductor by coating the conductor with the resin; A manufacturing method is provided in which the surface of the coating is irradiated with an electron beam at a temperature lower than the melting point of the resin forming the coating and at an electron beam acceleration voltage of 500 kV or less.
- a manufacturing method in which, after irradiating with an electron beam, heat treatment is performed at a temperature equal to or higher than the melting point of the resin forming the coating.
- MFR Melt flow rate
- melting point It was determined as the temperature corresponding to the maximum value in the heat of fusion curve when the temperature was raised at a rate of 10° C./min using a differential scanning calorimeter (DSC).
- the fluororesin was melted at 330 to 340°C for 30 minutes and compression molded to produce a film with a thickness of 0.20 to 0.25 mm. This film was scanned 40 times using a Fourier transform infrared spectrometer [FT-IR (product name: Model 1760X, manufactured by PerkinElmer) and analyzed to obtain an infrared absorption spectrum. A difference spectrum was obtained from the base spectrum that does not exist. From the absorption peak of a specific functional group appearing in this difference spectrum, the number N of functional groups per 10 6 carbon atoms in the fluororesin was calculated according to the following formula (A).
- FT-IR product name: Model 1760X, manufactured by PerkinElmer
- N I ⁇ K/t (A) I: Absorbance K: Correction coefficient t: Film thickness (mm)
- Rate of change in thickness of coating [(maximum value of thickness - minimum value of thickness)/average thickness] x 100
- Adhesion between conductor and coating The adhesion between the conductor and the coating of the resin-coated conductor was evaluated according to the following criteria. ⁇ : The coating is peeled off from the conductor. ⁇ : The coating is destroyed when you try to peel it off from the conductor.
- Comparative examples 1-2 A tetrafluoroethylene (TFE)/perfluoro(propyl vinyl ether) (PPVE) copolymer having the properties listed in Table 3 was molded into a rectangular copper wire (thickness: 1.95 mm, width: 3.36 mm) using an extrusion molding machine. ) was extruded at a die temperature of 390° C. and a take-off speed of 2 m/min to produce a rectangular wire provided with a coating layer. The thickness of the coating layer was 60 ⁇ m. In Comparative Example 1, the flat wires listed in Table 3 were evaluated as they were.
- TFE tetrafluoroethylene
- Comparative Example 2 the rectangular wire obtained in Comparative Example 1 was cut into 30 cm pieces and left in a hot air circulation oven set at a temperature of 330°C for 10 minutes for heat treatment.
- the flat wire described above was evaluated according to the evaluation method described above.
- Comparative example 3 As in Comparative Example 1, a tetrafluoroethylene (TFE)/perfluoro(propyl vinyl ether) (PPVE) copolymer having the properties shown in Table 3 was coated on a rectangular wire at the coating thickness shown in Table 3. Furthermore, similar to Comparative Example 2, heat treatment was performed under the heat treatment conditions listed in Table 3. Thereafter, the flat wires listed in Table 3 were evaluated according to the evaluation method described above.
- TFE tetrafluoroethylene
- Comparative Example 4 As in Comparative Example 1, a tetrafluoroethylene (TFE)/perfluoro(propyl vinyl ether) (PPVE) copolymer having the properties shown in Table 3 was coated on a rectangular wire at the coating thickness shown in Table 3. The flat wire was cut to a length of 30 cm. This was set on a hot plate in the chamber of an electron beam irradiation device so that the wide side of the rectangular wire faced the electron gun at the top of the chamber. The temperature of the heating plate was raised to a set temperature in advance, and the rectangular wire sample was set on the heating plate and then left for 30 minutes.
- TFE tetrafluoroethylene
- the flat wire was cut to a length of 30 cm. This was set on a hot plate in the chamber of an electron beam irradiation device so that the wide side of the
- electron beam irradiation was performed under the predetermined irradiation conditions listed in Table 3 (electron beam acceleration voltage 50 to 3000 kV, irradiation temperature 200 to 220° C., irradiation amount 40 to 200 kGy).
- the flat wire was turned over and the unirradiated back side was irradiated with the same amount. This irradiation amount was defined as the electron beam irradiation amount.
- heat treatment was performed under the heat treatment conditions listed in Table 3. Thereafter, the flat wires listed in Table 3 were evaluated according to the evaluation method described above.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Processes Specially Adapted For Manufacturing Cables (AREA)
- Coils Of Transformers For General Uses (AREA)
- Insulated Conductors (AREA)
- Insulating Of Coils (AREA)
Abstract
L'invention concerne un conducteur recouvert de résine qui comprend un conducteur et un matériau de revêtement qui contient une résine et recouvre le conducteur. La surface du matériau de revêtement est irradiée avec un faisceau d'électrons. La température d'irradiation par faisceau d'électrons est inférieure à un point de fusion de la résine formant le matériau de revêtement. La tension d'accélération de faisceau d'électrons de l'irradiation par faisceau d'électrons est inférieure ou égale à 500 kV.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2022108392 | 2022-07-05 | ||
| JP2022-108392 | 2022-07-05 |
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| WO2024009909A1 true WO2024009909A1 (fr) | 2024-01-11 |
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| Application Number | Title | Priority Date | Filing Date |
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| PCT/JP2023/024432 Ceased WO2024009909A1 (fr) | 2022-07-05 | 2023-06-30 | Conducteur recouvert de résine, bobine et procédé de fabrication de conducteur recouvert de résine |
Country Status (2)
| Country | Link |
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| JP (1) | JP7513931B2 (fr) |
| WO (1) | WO2024009909A1 (fr) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4792622B2 (ja) * | 2000-05-30 | 2011-10-12 | 旭硝子株式会社 | テトラフルオロエチレン/パーフルオロ(アルキルビニルエーテル)共重合体及びその製造方法 |
| JP2014093256A (ja) * | 2012-11-06 | 2014-05-19 | Dainippon Printing Co Ltd | フラットケーブルおよびその製造方法 |
| JP2015149274A (ja) * | 2014-01-08 | 2015-08-20 | ダイキン工業株式会社 | 耐熱電線 |
| JP6756413B1 (ja) * | 2019-04-26 | 2020-09-16 | ダイキン工業株式会社 | マグネット線およびコイル |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5483665B2 (ja) | 2008-03-10 | 2014-05-07 | 矢崎総業株式会社 | 電線の製造方法 |
| JP2012079641A (ja) * | 2010-10-06 | 2012-04-19 | Hitachi Cable Ltd | 電線・ケーブル |
| JP5928936B2 (ja) | 2012-01-23 | 2016-06-01 | 矢崎総業株式会社 | 表面架橋電線の製造方法 |
-
2023
- 2023-06-30 WO PCT/JP2023/024432 patent/WO2024009909A1/fr not_active Ceased
- 2023-06-30 JP JP2023108055A patent/JP7513931B2/ja active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4792622B2 (ja) * | 2000-05-30 | 2011-10-12 | 旭硝子株式会社 | テトラフルオロエチレン/パーフルオロ(アルキルビニルエーテル)共重合体及びその製造方法 |
| JP2014093256A (ja) * | 2012-11-06 | 2014-05-19 | Dainippon Printing Co Ltd | フラットケーブルおよびその製造方法 |
| JP2015149274A (ja) * | 2014-01-08 | 2015-08-20 | ダイキン工業株式会社 | 耐熱電線 |
| JP6756413B1 (ja) * | 2019-04-26 | 2020-09-16 | ダイキン工業株式会社 | マグネット線およびコイル |
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| JP2024007497A (ja) | 2024-01-18 |
| JP7513931B2 (ja) | 2024-07-10 |
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