JP3697672B2 - Mold material, mold motor and method for disassembling mold material - Google Patents

Description

【００１３】
【化２】

【００１４】
【化３】

【００１５】
（上記の式において、ｎは１〜３０である。）
本発明のモールド材のバインダーに用いられる不飽和ポリエステルの架橋剤には、少なくともアクリル酸２−ヒドロキシエチルまたはメタクリル酸２−ヒドロキシエチルを含む付加重合性モノマーが用いられる。
付加重合性モノマーとして、好ましくはその他に、スチレン、酢酸ビニル、酢酸アリル、アセト酢酸アリル、アクリル酸、アクリル酸メチル、メタクリル酸、メタクリル酸メチルが用いられる。これらのモノマーは、後述の脂肪族ポリエステルに対して比較的高い溶解能を有する。
また、ビニルトルエン、α−メチルスチレン、ジアリルフタレート、ジアリルイソフタレート、ジアリルテトラブロムフタレート、フェノキシエチルアクリレートなど従来用いられる付加重合性モノマーを併用することもできる。
上記付加重合性モノマーは、上記不飽和ポリエステル１００重量部に対して好ましくは２５〜１５０重量部、さらに好ましくは４０〜１００重量部の範囲で含有される。
【００１６】
本発明のモールド材に用いられる低収縮剤は、ポリ酢酸ビニル、ブタジエン・スチレン・メチルメタクリレート共重合体（ＭＢＳ樹脂）、ポリヒドロキシエチルメタクリレート、またはケトン樹脂であることが好ましい。これらの低収縮剤は、前述の付加重合性モノマー、アクリル酸２−ヒドロキシエチルまたはメタクリル酸２−ヒドロキシエチルに可溶であるため、バインダー樹脂組成物の調製が容易である。
なお、ポリカプロラクトンは、後述の脂肪族ポリエステルに属するが、低収縮剤としても機能し得るポリマーである。
通常は、１種類の低収縮剤を用いるが、低収縮効果を高めるため、補助低収縮剤を加え、複数の低収縮剤を使用することができる。
上記低収縮剤は、上記不飽和ポリエステル１００重量部に対して好ましくは１〜１００重量部、さらに好ましくは２〜５０重量部含有される。
ポリエチレン、ポリプロピレン、ポリスチレン、ポリ（エチレンビニルアルコール）、アクリル系共重合体、メタクリル系共重合体、スチレンーブタジエンブロック共重合体、アクリロニトリル−ブタジエンースチレン共重合体などの熱可塑性樹脂が低収縮剤として知られており、これらを上記の低収縮剤と併用してもよい。
【００１７】
本発明のモールド材は、好ましくは、脂肪族ポリエステルを含有する。脂肪族ポリエステルとしては、式（４）で表されるポリカプロラクトン、ポリプロピオラクトンのようなラクトンの開環重合により得られる重合体；式（５）で表されるポリ乳酸、式（６）で表されるポリグリコール酸のようなヒドロキシ酸の重合体；ポリエチレンアジペート、ポリプロピレンアジペート、ポリブチレンアジペート、ポリテトラメチレンアジペート、ポリエチレンサクシネート、ポリプロピレンサクシネート、ポリブチレンサクシネートのような式（７）で表されるグリコールと脂肪族ジカルボン酸とからなる共重合体；式（８）で表されるポリカプロラクトンジオール、式（９）で表されるポリカプロラクトントリオールのような末端に官能基を有する重合体；式（１０）で表されるような末端アクリル変性ポリカプロラクトン；３−ヒドロキシプロピオナート、３−ヒドロキシブチレート、３−ヒドロキシバリレート、３−ヒドロキシオクタノエートのような微生物の発酵により得られるポリエステルなどを用いることが望ましい。これらポリエステルは、後述の分解溶液に対して非常に優れた分解性を有する。
【００１８】
【化４】

【００１９】
【化５】

【００２０】
【化６】

【００２１】
【化７】

【００２２】
（上記の式において、ｌ、ｍ、ｎ、Ｎは各々独立して１０〜２０００であり、Ｒは、各々独立して炭素数１〜２０の炭化水素基である。）
上記脂肪族ポリエステルは、上記不飽和ポリエステル１００重量部に対して好ましくは１〜１００重量部、さらに好ましくは２〜５０重量部含有される。
【００２３】
本発明のモールド材は、好ましくは、硬化剤を含有する。
硬化剤としては、過酸化ベンゾイル、ｔ−ブチルパーベンゾエート、ｔ−ブチルパーオキシベンゾエート、ｔ−ブチルパーオキシラウレート、ｔ-ブチルパーオキシ−２−エチルヘキサノエート、ｔ−ブチルパーオクトエート、１，１−ビス（ｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン、２，５−ジメチル−２，５−ジ（ｔ−ブチルパーオキシ）ヘキサンなどが挙げられる。
上記硬化剤は、上記不飽和ポリエステル１００重量部に対して好ましくは０．１〜５重量部、さらに好ましくは０．２〜４重量部の範囲で含有される。
【００２４】
本発明のモールド材は、必要に応じて、充填材、増粘剤、離型剤、ワックス、着色剤などを添加する。
充填材としては、炭酸カルシウム、炭酸マグネシウムのような炭酸塩、硫酸カルシウム、硫酸バリウム、亜硫酸カルシウムのような（亜）硫酸塩、クレー、マイカ、ガラスバルーン、モンモリロナイト、ケイ酸、カオリン、タルクのようなケイ酸塩類、シリカ、珪燥土、酸化鉄、軽石バルーン、酸化チタン、アルミナのような酸化物、水酸化アルミニウム、水酸化マグネシウムのような水酸化物、グラファイト、ガラス繊維、炭素繊維、アスベスト繊維などの無機充填材；ならびに、木粉、もみ殻、木綿、紙細片、ナイロン繊維、ポリエチレン繊維、木材、パルプ、セルロースなどの有機充填材などが挙げられる。
上記充填材は、熱硬化性組成物１００重量部に対して好ましくは５〜６００重量部、さらに好ましくは２０〜５００重量部の範囲で添加される。このような範囲で充填材を添加することにより、モールド材の機械的強度が向上する。
【００２５】
増粘剤としては、酸化ベリリウム、酸化マグネシウム、水酸化マグネシウム、酸化カルシウム、水酸化カルシウム、酸化亜鉛、安息香酸、無水フタル酸、テトラヒドロ無水フタル酸、無水マレイン酸などが挙げられる。
離型剤としては、ステアリン酸、ステアリン酸亜鉛、ステアリン酸カルシウムなどが挙げられる。
ワックスとしては、ヘキストワックス、カルナバワックス、パラフィンなどが挙げられる。
着色剤としては、チタンホワイト、酸化クロム、カーボンブラックなどが挙げられる。
【００２６】
本発明のモールド材は、ジエタノールアミンによって容易に分解処理することができるが、それ自体が求核剤となって置換反応を起こし得る加溶媒分解性溶媒によっても分解処理することができる。そのようなとは、加溶媒分解性溶媒としては、水、メタノール、エタノール、エチレングリコール、酢酸、チオール、ヒドラジンなどが挙げられる。
【００２７】
本発明のモールドステータは、上記のモールド材を用いて構成される。以下、図面を参照して、本発明のモールドステータの好適な実施態様を説明する。
図１を用いて、本発明のモールドステータの第一の好適な実施態様を説明する。図１は、本発明のモールドステータを有するモールドモータの一実施態様を示す断面図である。モールドモータは、モータ部１０と、モールドステータ１１とから構成される。モールドステータ１１は、絶縁体１２を介して巻線１３が巻装された鉄芯１４と、この鉄芯１４を覆い、かつ、モールドステータ全体を満たしてモールド材で一体成形したモールド部１５とを有する。モータ部１０は、モールド部１５の開口部に取り付けられ、少なくとも回転子シャフト１６と回転子シャフトに取り付けられた回転子１７とを備えており、ブラケット１８により支持されている。回転子１７は、開口部の上壁に取り付けられたベアリング１９とブラケットに取り付けられたベアリング２０とにより軸支されている。
図示していないが、巻線１３の端末部は、モールドステータのシャフトの上に位置する部分まで延び、そこでリード線と接続され、外部からの入力が可能となっている。さらに、モールドステータ１１は、複数の取付孔２１を有するフランジ部２２を備えていてもよい。モールド部１５の最大厚み部分の厚みは、通常、約１０ｍｍである。
【００２８】
モールド部１５を構成するのは、上述の本発明のモールド材である。
モールド部の最大厚み部分の厚みは、用途に応じて変化し得るが、本発明においては、好ましくは１〜１０ｍｍ、さらに好ましくは１〜８ｍｍ、最も好ましくは１〜５ｍｍである。
絶縁体１２としては、例えば、脂肪族ポリエステル、ポリエチレンテレフタレート、ポリエチレンのような熱可塑性樹脂が使用される。絶縁体１２には、モールド時の巻線１３の形状保存効果が要求されるので、モールド時に軟化しないように、軟化点または融点が、モールド時の温度、例えば約１００℃以上のものが好ましい。絶縁体１２に脂肪族ポリエステルを用いると、分解時に、巻線１３と鉄芯１４との分離が可能となるため、特に好ましい。融点が１００℃を超える脂肪族ポリエステルとしては、例えば、前記の式（７）に示す共重合樹脂が挙げられる。
本発明のモールドステータは、上述の好適な実施態様の構成を適宜組み合わせることにより、より容易に分解される。
本発明のモールドステータは、ブラシレス直流モータ、交流モータ、リニアモータなどに適用される。
【００２９】
【実施例】
以下、本発明の実施例を説明する。
《実施例１》
不飽和ポリエステル６０重量部に、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル４０重量部を混合し、窒素雰囲気中において１００℃で１０分間攪拌し、６０重量％不飽和ポリエステル液状樹脂を得た。また、低収縮剤であるポリ酢酸ビニル３０重量部を、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル７０重量部に加え、低収縮剤溶液を得た。先の不飽和ポリエステル液状樹脂１７．７１重量部に、この低収縮剤溶液５．０９重量部、及び硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）を０．２５重量部加えて良く混合してバインダー樹脂組成物を得た。このバインダー樹脂組成物における付加重合性モノマー中のメタクリル酸ー２ヒドロキシエチルのモル分率は１である。
【００３０】
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、及びポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。
【００３１】
《実施例２》
不飽和ポリエステル７５重量部に、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチルを２５重量部混合し、窒素雰囲気中において１００℃で１０分間攪拌し、７５重量％不飽和ポリエステル液状樹脂を得た。また、低収縮剤であるポリ酢酸ビニル３２．６重量部を、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル６７．４重量部に溶解させ、低収縮剤溶液を得た。先の不飽和ポリエステル液状樹脂１５．０６重量部に、この低収縮剤溶液４．９７重量部、及び付加重合性モノマーであるメタクリル酸メチルを２．６３重量部を加え、更に、硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）を０．２５重量部加えて良く混合し、バインダー樹脂組成物を得た。このバインダー樹脂組成物における付加重合性モノマー中のメタクリル酸ー２ヒドロキシエチルのモル分率は０．６７である。
【００３２】
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、及びポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。
【００３３】
《実施例３》
不飽和ポリエステル７５重量部に、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチルを２５重量部混合し、窒素雰囲気中において１００℃で１０分間攪拌し、７５重量％不飽和ポリエステル液状樹脂を得た。また、低収縮剤であるポリ酢酸ビニル３２．６重量部を、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル６７．４重量部に溶解させ、低収縮剤溶液を得た。さらに、脂肪族ポリエステルであるポリカプロラクトン３０重量部を、付加重合性モノマーであるメタクリル酸メチル７０重量部に溶解させ脂肪族ポリエステル溶液を得た。先の不飽和ポリエステル液状樹脂１４．３１重量部に、この低収縮剤溶液４．７２重量部、及び脂肪族ポリエステル溶液３．７６重量部を加え、更に、硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）を０．２５重量部加え、良く混合し、バインダー樹脂組成物を得た。このバインダー樹脂組成物における付加重合性モノマー中のメタクリル酸ー２ヒドロキシエチルのモル分率は０．６７である。
【００３４】
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、及びポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。
【００３５】
《比較例１》
不飽和ポリエステル（日本触媒（株）製、商品名：エポラック）１２．０２重量部に、付加重合性モノマーであるスチレン９．６４重量部、脂肪族ポリエステルであるポリカプロラクトン（分子量４万、ダイセル化学工業（株）製、商品名：プラクセル）１．１４重量部、及び硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）０．２５重量部を加えて良く混合し、バインダー樹脂組成物を得た。
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛を１．２４重量部、色素であるカーボン粉末０．３７重量部、及びポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー樹脂組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。
【００３６】
《比較例２》
不飽和ポリエステル（日本触媒（株）製、商品名：エポラック）１２．０２重量部に、付加重合性モノマーであるスチレン９．６４重量部、ポリスチレン（分子量４万）１．１４重量部、及び硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）０．２５重量部を加えて良く混合し、バインダー樹脂組成物を得た。
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、及びポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー樹脂組成物を徐々に加えて混練し、均一なペースト状のものを得た。更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。このモールド材は、従来組成のものである。
【００３７】
上記実施例１〜３および比較例１、２で得られたモールド材は、バルク状であるので、通常ＢＭＣ（Bulk Molding Compound）と呼ばれる成形材料の１種であり、付加重合性モノマーを含むにもかかわらず、非粘着状態である。
これらモールド材の組成のうち、互いに異なるモノマーと低収縮剤の成分を表１にまとめた。また、これらモールド材について測定した基本物性を表２に示す。
【００３８】
【表１】

【００３９】
【表２】

【００４０】
スパイラルフローは、細孔からの材料押し出し長さ（フロー長さ）を表すもので、主にトランスファー成形やインジェクション成形の成形性を判定するのに利用される。１５０℃、１００ｋｇｆ／ｃｍ²の条件で測定した。比較例は、従来用いられているモールド材の組成である。実施例のものは、スパイラルフローがほぼ比較例と同等であることから、比較例と同様の条件で成形して問題ないことが分かる。
成形時の寸法安定性を示す成形収縮率は、１５０℃、１００ｋｇｆ／ｃｍ²、１０分間の成形条件のもので測定した（ＪＩＳ Ｋ６９１１）。実施例のものは、成形収縮率が従来の量産品である比較例２と同等であった。ポリカプロラクトンの場合、脂肪族ポリエステルであって、さらに低収縮剤としても機能していることがわかる。
また、本発明のモールド材の硬化時間は、従来品よりも短い傾向にあるが、成形性において問題となるようなものではない。
【００４１】
最後に成形品の強度を測定した。各モールド材を用いて、１５０℃、５分間のトランスファー成形で幅１２．７ｍｍ、長さ１２７ｍｍ、高さ３．２ｍｍの平板状に成形し、曲げ試験試料とした。曲げ試験は、支点間距離５０ｍｍ、クロスヘッド速度１０ｍｍ／ｍｉｎ．で行った。実施例のものは、少し強度の小さいものもあるが、ほぼ従来品の比較例２と同等の強度であった。
以上より、本発明のモールド材の試作品は、通常工業的によく使用される不飽和ポリエステル樹脂からなるモールド材（繊維強化プラスチックなどと呼ばれる）と比較した場合、いずれも成形性、硬化性（硬化時間）、強度などに関してはほぼ同等であり、寸法安定性、スパイラルフロー長さについても問題になるような点はなかった。従って、本発明によるモールド材は、通常ＦＲＰ材料が使用されるような用途に十分応用できる。
【００４２】
次に、実施例１〜３、および比較例１、２のモールド材を、金型温度１５０℃、注入圧力３５ｋｇ／ｃｍ²ので圧縮成形を行い、φ１９ｍｍの円柱状成形品を試作した。そして、これら成形品の分解処理試験を行った。試験方法は、少なくとも塩基と加溶媒分解性溶媒からなる分解溶液に浸漬することによった。実施例１〜３については、５Ｎの水酸化ナトリウム水溶液を分解溶液として使用した。この溶液に、各モールド材成形体を９０℃で２４時間浸漬し、分解液浸透の速度、および分解液浸漬処理後の成形体の表面硬度を測定した。なお、硬度の測定は、処理後のモールド材成形体が非常に脆くなっていることを考え、ゴム硬度計を用いて行った。その結果を表３に示す。
【００４３】
【表３】

【００４４】
実施例１〜３のモールド材成形体は、比較例１、２に比べて、一様に分解溶液の浸透速度が速く、また浸透後の表面硬度が小さい。実施例１〜３のモールド材においては、分解液親和性の高い付加重合性モノマー、メタクリル酸２−ヒドロキシエチルの存在のために、分解溶液が組成物中に速やかに浸透すると共に、組成物骨格を構成する不飽和ポリエステル樹脂中のエステル結合が加溶媒分解を受け、バインダー樹脂は３次元構造を失い、モールド成形体は崩壊する、すなわち表面硬度も非常に小さくなる。従って、非常に分解処理性の高いモールド材である。
一方、比較例２のモールド材は、従来使用されている組成のモールド材であり、このような塩基と水を含む溶液によっても処理することはできない。比較例１のように、低収縮材としてポリカプロラクトンを使用することによって、分解液処理性を向上させることができるが、実施例３のように分解液親和性の高い付加重合性モノマーを導入することで、さらに大きな分解液処理性を得ることができる。
また、実施例２と実施例３の比較から分かるように、分解液親和性の高い付加重合性モノマー、メタクリル酸２−ヒドロキシエチルを用いた場合においても、脂肪族ポリエステルは、分解液浸透性を向上させると共に、自ら加溶媒分解を受けるため、脂肪族ポリエステルであるポリカプロラクトンを用いた方が、分解処理性が向上している。
【００４５】
以上のように、本発明のモールド材は、硬化成形後においては、不飽和ポリエステルと付加重合性モノマーとの共重合によって、主鎖にエステル結合を有し、架橋鎖に分解液親和性の高い２ーヒドロキシエチル基を有する３次元架橋構造が形成され、３次元構造中に低収縮剤が分散した状態にある。このため硬化成形後のモールド材を、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液に浸漬することによって、付加重合性モノマーの存在のために分解溶液が組成物中に速やかに浸透すると共に、組成物骨格を構成する不飽和ポリエステル樹脂中のエステル結合の中に加溶媒分解を受けるものが現れ、バインダー樹脂は３次元構造を失い、モールド成形体は崩壊する。
また、脂肪族ポリエステルであるポリカプロラクトンを含有することにより、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液に対する親和性、加溶媒分解性が高く、バインダーである不飽和ポリエステル樹脂架橋構造の加溶媒分解が、より効率良く効果的に進行する。
【００４６】
なお、脂肪族ポリエステルを含有させる場合、実施例３のように溶解能のあるモノマーに溶解して混入することにより、簡易に安定して分散させることができる。
なお、脂肪族ポリエステルを含有させる場合、粉体、繊維状、針状などの形状で混入させるのももちろん良い。
また、水での煮沸試験においては、実施例１〜３、比較例１、２において違いは観察されず、本発明の実施例においても耐水性は、従来品並であった。
また、水酸化ナトリウム水溶液の濃度は、実施例のように５Ｎに限ることなく、１０Ｎ以下に調製されれば良い。さらに、２〜５Ｎの範囲に調製されることがより好ましい。
【００４７】
なお、モールド材の構成および製造方法は、実施例に限定されることはなく、例えば、炭酸カルシウム、珪酸カルシウム、硫酸バリウム、水酸化アルミニウム、タルク、マイカなどのフィラーや、ガラス繊維、炭素繊維などの強化剤、その他、増粘剤、離型剤、着色剤などを混入していてももちろん良い。
なお、上記実施例では、モールド材成形時に圧縮成形を用いたが、トランスファー成形、射出成形などによっても良い。
また、実施例では、バルク状のモールド材について説明したが、バルク状以外にも、シート状のＳＭＣ（sheet molding compound）や、粒状のＰＭＣ（pelletized type molding compound）であってもよい。
なお、実施例では、円柱状に成形した例を用いたが、これに限定されることなく、その他の形状を有する成形体、および塗料、パテ、接着剤などであっても良い。
なお、分解処理時の温度も、もちろん実施例の値に限定されない。しかし、耐圧装置による分解処理を行わない場合は、分解溶液の沸点以下であることが好ましい。
【００４８】
《実施例４》
不飽和ポリエステル、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル、およびスチレンをそれぞれ異なる配合比で混合し、窒素雰囲気下において１００℃で１０分間攪拌し、７種類の不飽和ポリエステル液状樹脂を得た。また、低収縮剤であり脂肪族ポリエステルであるポリカプロラクトン（ダイセル化学工業（株）製、商品名：プラクセル）３０重量部を、付加重合性モノマーであるスチレンとメタクリル酸２−ヒドロキシエチルの１：１（重量）混合物７０重量部に加え、低収縮剤溶液を得た。先の不飽和ポリエステル液状樹脂１７．７１重量部に、この低収縮剤溶液５．０９重量部、および硬化剤１，１−ビス（ｔｅｒｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）０．２５重量部を加え、良く混合し、７種類のバインダーとなる樹脂組成物を得た。
この各不飽和ポリエステル液状樹脂における不飽和ポリエステル、メタクリル酸２−ヒドロキシエチル、スチレンの配合比、およびバインダー樹脂組成物における付加重合性モノマー中のメタクリル酸２−ヒドロキシエチルのモル分率をまとめて表４に示した。
【００４９】
【表４】

【００５０】
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、およびポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、それぞれバインダー樹脂成分の異なる７種類のモールド材を得た。
【００５１】
次に、これら７種類のモールド材を、金型温度１５０℃、注入圧力３５ｋｇ／ｃｍ²で圧縮成形を行い、φ１９ｍｍの円柱状成形品を試作した。そして、これら成形品の分解処理試験を行った。試験方法は、少なくとも塩基と加溶媒分解性溶媒からなる分解溶液に浸漬することによった。本実施例では、５Ｎの水酸化ナトリウム水溶液を分解溶液として使用した。この溶液に、各モールド材成形体を９０℃で２４時間浸漬し、分解液浸透の速度、および分解液浸漬処理後の成形体の表面硬度を測定した。なお、硬度の測定は、処理後のモールド材成形体が非常に脆くなっていることを考え、ゴム硬度計を用いて行った。その結果を表５に示す。
【００５２】
【表５】

【００５３】
付加重合性モノマー中におけるメタクリル酸２−ヒドロキシエチルのモル分率が大きいほど、分解液の浸透性は高く、分解処理後の表面硬度もより大きく低下する。メタクリル酸２−ヒドロキシエチルの存在が、モールド材の分解性を向上させる。特に、メタクリル酸２−ヒドロキシエチルのモル分率が０．４以上のものでは、分解処理後の表面硬度が低く、手作業などによっても破砕、粉砕、減容化、剥離など、いずれの処理も施し易い状態であった。
また、従来、不飽和ポリエステル液状樹脂は、不飽和ポリエステルのスチレン溶液であるため、不飽和ポリエステルに対する全モノマー量を増やすことなしに、付加重合性モノマー中のメタクリル酸２−ヒドロキシエチルの含有率を上げるのが困難であったが、本実施例のように、不飽和ポリエステルを、メタクリル酸２−ヒドロキシエチルまたはスチレンとメタクリル酸２−ヒドロキシエチルの混合溶液に溶解させた液状樹脂を用いることによって、全付加重合性モノマー中のメタクリル酸２−ヒドロキシエチルのモル分率が０．４以上である分解性の高いバインダー樹脂を作成することができる。
【００５４】
以上のように、本発明のモールド材は、硬化成形後においては、不飽和ポリエステルと付加重合性モノマーとの共重合によって、主鎖にエステル結合を有し、架橋鎖に分解液親和性の高い２ーヒドロキシエチル基の多い３次元架橋構造が形成され、３次元構造中に低収縮剤が分散した状態にある。このため硬化成形後のモールド材を、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液に浸漬することによって、２ーヒドロキシエチル基の置換率が高いため、分解溶液が組成物中に速やかに浸透すると共に、組成物骨格を構成する不飽和ポリエステル樹脂中のエステル結合の中に加溶媒分解を受けるものが現れ、バインダー樹脂は３次元構造を失い、モールド成形体は速やかに崩壊する。
なお、上記実施例では、メタクリル酸２−ヒドロキシエチルを例に説明したが、アクリル酸２−ヒドロキシエチルによっても全く同様の傾向が得られる。
また、メタクリル酸２−ヒドロキシエチルとアクリル酸２−ヒドロキシエチルが同時に混入されていて、付加重合性モノマー中に占める両者のモル分率の和が０．４以上であっても当然よい。
また、水酸化ナトリウム水溶液の濃度は、実施例のように５Ｎに限ることなく、１０Ｎ以下に調製されれば良い。さらに、２〜５Ｎの範囲に調製されることがより好ましい。
【００５５】
《実施例５》
不飽和ポリエステル６０重量部に、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル４０重量部を混合し、窒素雰囲気下において１００℃で１０分間攪拌し、６０重量％不飽和ポリエステル液状樹脂を得た。また、脂肪族ポリエステルであるポリカプロラクトン（ダイセル化学工業（株）製、商品名：プラクセル）３０重量部を、付加重合性モノマーであるアクリル酸７０重量部に溶解させ、脂肪族ポリエステル溶液を得た。先の不飽和ポリエステル液状樹脂１７．７１重量部に、この脂肪族ポリエステル溶液５．０９重量部、および硬化剤１，１−ビス（tert−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）０．２５重量部を加え、良く混合し、バインダーとなる樹脂組成物を得た。このバインダー樹脂組成物における付加重合性モノマー中のメタクリル酸２−ヒドロキシエチルのモル分率は０．５である。
【００５６】
次に、充填材である炭酸カルシウム５７重量部、離型剤であるステアリン酸亜鉛２重量部、および増粘剤酸化マグネシウム１重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
ガラス繊維をカッターで切断したチョップドストランドを、ポリエチレンフィルム上に散布し、先のペースト状物を含浸させることによってモールド材を得た。含浸を終えたモールド材は、必要長さを巻き取って熟成させ、必要な稠度にまで増粘させた。この結果、ペースト状物１００重量部に対して、約３０重量部のガラス繊維が配合されたことになる。
【００５７】
《実施例６》
不飽和ポリエステル６０重量部に、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチルを４０重量部混合し、窒素雰囲気下において１００℃で１０分間攪拌し、６０重量％不飽和ポリエステル液状樹脂を得た。また、低収縮剤であるメチルメタクリレート・ブタジエン・スチレン共重合体（ＭＢＳ樹脂）３０重量部を、付加重合性モノマーであるアクリル酸２−ヒドロキシエチル７０重量部に溶解させ、低収縮剤溶液を得た。先の不飽和ポリエステル液状樹脂１３．８３重量部に、この低収縮剤溶液３．９７重量部、および脂肪族ポリエステルであるポリ乳酸（島津製作所製、商品名：ラクティ）５重量部を２５０〜５００μｍの粒子状で混入し、最後に硬化剤１，１−ビス（tert−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）を０．２５重量部加えて良く混合し、バインダーとなる樹脂組成物を得た。
【００５８】
次に、充填材である炭酸カルシウム５７重量部、離型剤であるステアリン酸亜鉛２重量部、および増粘剤酸化マグネシウム１重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
ガラス繊維をカッターで切断したチョップドストランドを、ポリエチレンフィルム上に散布し、先のペースト状物を含浸させることによってモールド材を得た。含浸を終えたモールド材は、必要長さを巻き取って熟成させ、必要な稠度にまで増粘させた。この結果、ペースト状物１００重量部に対して、約３０重量部のガラス繊維が配合されたことになる。
【００５９】
実施例５および６のモールド材は、シート状であるので、通常ＳＭＣ（sheet molding compound）と呼ばれる成形材料の１種であり、スチレンを含むにもかかわらず、非粘着状態である。
実施例５および６のモールド材は、通常工業的によく使用される不飽和ポリエステル樹脂からなるＦＲＰ（繊維強化プラスチック）と比較した場合、いずれも成形性、硬化性（硬化時間、ゲル化時間）、強度などに関してはほぼ同等であり、寸法安定性、スパイラルフロー長さについても問題になるような点はなかった。成形時の収縮性においても問題はなく、ＭＢＳ樹脂あるいは脂肪族ポリエステルであるポリカプロラクトンが低収縮剤として機能していることがわかる。従って本発明によるモールド材は、通常ＦＲＰ材料が使用されるような用途へは、十分応用できる。
【００６０】
次に、この実施例５および６のモールド材を、金型温度１５０℃、注入圧力３５ｋｇ／ｃｍ²で圧縮成形を行い、φ１９ｍｍの円柱状成形品を試作した。そして、この試作品材成形体の分解処理試験を行った。試験方法は、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液に浸漬することによった。ここでは、４Ｎの水酸化ナトリウム水溶液を分解溶液として使用した。また、比較として塩基を含まない水だけの分解溶液にも同時に浸漬した。モールド材成形体を、各分解溶液に９０℃で浸漬し、分解液浸透の速度、および分解液浸漬処理後の成形体の表面硬度を測定した。なお、硬度の測定は、ゴム硬度計によった。その結果を表６に示す。
【００６１】
【表６】

【００６２】
浸漬して２４時間後までに分解液は成形品に完全浸透しており、いずれも高い分解性を示している。また、２４時間後では各試料とも、成形品は非常に柔らかすぎて表面硬度は測定不可能であった。破砕、粉砕、減容化など、いずれの処理も施し易い状態であった。分解液親和性の高いアクリル酸２−ヒドロキシエチルまたはメタクリル酸２−ヒドロキシエチルを含むモールド材は、少なくとも塩基と水を含む加溶媒分解性溶液である分解溶液に対して優れた分解性を発揮する。一方、水による処理では、成形品は全く侵されず、表面の硬度も依然として堅いままであった。
【００６３】
以上の実施例５および６から明らかなように、本発明のモールド材は、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液によって非常に柔らかい状態にまでできるので、その後ほとんど力をかけずに減容化なり、粉砕なり、また、その他の部品を包接している場合は、簡単に剥離・分離することができる。一方、塩基を含まない水などによっては全く侵されない。従って、通常の使用環境下においては、湿気が多い、水に濡れるなどの状況であっても、侵されることはない。しかし、常に、非常な高温高湿に曝され続けるような環境下では、安全のために表面をコーティングしておくことが望ましい。この場合、コーティングは、ポリエチレン、ポリプロピレン、ポリスチレン、ポリビニルアセタールなどの樹脂を溶解した溶液、または分散させた懸濁液を塗布・乾燥することによって設けることができる。コート層の厚みは、約０．１〜０．５ｍｍなので、コーティングしたモールド材成形体の分解処理は、表面をヤスリなどで削ったあと、分解液に浸漬すれば良い。
【００６４】
なお、アクリル酸は鉄によってゲル化作用を受けることがあるので、アクリル酸を含むモールド材の成形時の金型まわりには、純鉄を使用しないことが好ましい。
また、分解性を促進する脂肪族ポリエステルは、実施例５のようにモノマーに溶解した状態で混入することもできるし、実施例６のように粒子状で混入することもできる。
また、実施例５および６では、脂肪族ポリエステルであるポリ乳酸を粒子状で含有したが、繊維状あるいは針状であっても良い。
【００６５】
なお、モールド材の構成および製造方法は、上記実施例１〜６に限定されることはなく、例えば、炭酸カルシウム、珪酸カルシウム、硫酸バリウム、水酸化アルミニウム、タルク、マイカなどのフィラーや、ガラス繊維、炭素繊維などの強化剤、その他、増粘剤、離型剤、着色剤などを混入していてももちろん良い。
なお、実施例１〜６ではモールド材成形時に圧縮成形を用いたが、トランスファー成形、射出成形などによっても良い。
また、実施例１〜４ではバルク状のモールド材について、また実施例５、６ではシート状のＳＭＣ（sheet molding compound）について説明したが、これら以外にも粒状のＰＭＣ（petletized type molding compound）であってもよい。
実施例１〜６では、円柱状に成形した例を用いたが、これに限定されることなく、その他の形状を有する成形体、および塗料、パテ、接着剤などであっても良い。
なお、分解処理時の温度も、もちろん実施例の値に限定されない。
なお、本発明のモールド材から得られる最終成形品は、浴槽、便槽、貯水槽、洗面台のような建設資材；椅子、机、家具のような家庭用品；タイル、人工大理石、パイプのような土木資材；船舶、自動車、鉄道、航空機のような輸送機器のボディや部品；住宅機器；化粧板；装飾品などの様々な分野で使用され得る。
【００６６】
なお、本発明のモールド材成形体を浸漬し、分解処理した溶液は、以上の実施例の組成、配合比に限定されず、少なくとも塩基と、加溶媒分解性溶媒を含んでいればよい。塩基としては、本実施例で示した水酸化ナトリウム以外にも、水酸化カルシウム、水酸化カリウムのような金属水酸化物、酸化ナトリウム、酸化カルシウムのような金属酸化物、ナトリウムエトキシド、カリウムｔ−ブトキシドのような金属アルコキシドなどが挙げられる。これらは単独で、あるいは２種以上を混合して使用され得る。また、加溶媒分解性溶媒としては、本実施例使用の水以外にも、エタノール、メタノール、エチレングリコール、アンモニア、酢酸、ヒドラジンなどを混入することができる。
また、分解溶液中には、加溶媒分解性溶媒以外にも、ジエチルエーテル、ジオキサン、テトラヒドロフラン、アセトン、ジメチルホルムアミド、ジメチルアミンなどの溶媒を、１種、あるいは２種以上が混合しても使用され得る。
【００６７】
《実施例７》
モールドモータの実施例について説明する。
不飽和ポリエステル６１重量部、付加重合性モノマーであるメタクリル酸２−ヒドロキシエチル３４重量部、およびスチレン５重量部を混合し、窒素雰囲気下、１００℃で１０分間攪拌し、不飽和ポリエステル液状樹脂を得た。また、低収縮剤であり脂肪族ポリエステルであるポリカプロラクトン（ダイセル化学工業（株）製、商品名：プラクセル）３０重量部を、付加重合性モノマーであるスチレンとメタクリル酸２−ヒドロキシエチルの１：１（重量）混合物７０重量部に加え、低収縮剤溶液を得た。先の不飽和ポリエステル液状樹脂１７．７１重量部に、この低収縮剤溶液５．０９重量部、および硬化剤１，１−ビス（tert−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン（日本油脂（株）製、商品名：パーヘキサ３Ｍ）０．２５重量部を加えて良く混合し、バインダーとなる樹脂組成物を得た。
【００６８】
次に、充填材である炭酸カルシウム９．９１重量部、水酸化アルミニウム５０．８重量部、離型剤であるステアリン酸亜鉛１．２４重量部、色素であるカーボン粉末０．３７重量部、およびポリエチレン０．９９重量部をニーダに移し、乾式混合を行った。約５分後、均一に混ったこの乾式混合物に、先に混合しておいたバインダー組成物を徐々に加えて混練し、均一なペースト状のものを得た。
更に、このペースト状物に、１３．６３重量部のガラス繊維をまんべんなく分散させながら、極力短時間で添加し、ガラス繊維が濡れて均一に分散したところで混練を終了して、モールド材を得た。
このモールド材と絶縁体を介して巻線が巻装された鉄芯とを１５０℃で一体成形し、図１に示すようなモールドステータを作成した。このモールドステータを、５Ｎの水酸化ナトリウム水溶液に９０℃に２４時間浸漬した後、モールド材の除去を試みたところ、素手でモールド材を除去し、巻線および鉄芯を分離することができた。
さらに、８時間浸漬することにより、巻線に一部残留していたモールド材を完全に除去することができた。
【００６９】
以上のように、本発明のモールド材を用い、鉄芯と巻線を覆いモールドしてなるモールドモータは、塩基と加溶媒分解性溶媒からなる分解液に浸漬することによって、モールド部分が分解され、崩壊するため、剥離が容易な状態にあり、簡易にモールド部分と、鉄芯、巻線を分離できる。すなわち、有価物である金属の回収性の非常に高いモールドモータである。
なお、モータのモールドに使われるモールド材は、もちろん本実施例の組成に限定されない。また、分解処理時の温度も、もちろん本実施例の値に限定されない。
【００７０】
なお、本発明のモールドモータを浸漬し、分解処理した溶液は、以上の実施例の組成、配合比に限定されず、少なくとも塩基と、加溶媒分解性溶媒を含んでいればよい。塩基としては、本実施例で示した水酸化ナトリウム以外にも、水酸化カルシウム、水酸化カリウムのような金属水酸化物、酸化ナトリウム、酸化カルシウムのような金属酸化物、ナトリウムエトキシド、カリウムｔ−ブトキシドのような金属アルコキシドなどが挙げられる。これらは単独で、あるいは２種以上を混合して使用され得る。また、加溶媒分解性溶媒としては、本実施例使用の水以外にも、エタノール、メタノール、エチレングリコール、アンモニア、酢酸、ヒドラジンなどを混入することができる。
また、分解溶液中には、加溶媒分解性溶媒以外にも、ジエチルエーテル、ジオキサン、テトラヒドロフラン、アセトン、ジメチルホルムアミド、ジメチルアミンなどの溶媒を、１種、あるいは２種以上が混合しても使用され得る。
【００７１】
《実施例８》
モールド材の分解処理方法の実施例について説明する。
実施例１、実施例３、および比較例２のモールド材を、金型温度１５０℃、注入圧力３５ｋｇ／ｃｍ²で圧縮成形を行い、φ１９ｍｍの円柱状成形品を試作した。そして、この試作品を対象に分解処理試験を行った。試験は、ジエタノールアミンに２００℃で浸漬することによった。
各試料とも、分解液浸透部分は完全分解し、分解液中に溶出していた。特に実施例１および３の分解性は高く、２４時間後までにモールド材成形体は消失し、分解液中に完全溶出していた。一方、従来のモールド材である比較例２の成形体に対しては、分解液浸透部分の崩壊性は大きいものの、分解速度が非常に遅い。少なくともモールド材中に脂肪族ポリエステルを含有することにより、その分解性は向上する。また、少なくとも塩基と加溶媒分解性溶媒からなる分解溶液に対して優れた分解性を示す、本発明のモールド材に対しては、同じく優れた分解性を示す分解処理方法である。
【００７２】
以上のように、少なくとも不飽和ポリエステルと、付加重合性モノマーと、低収縮剤からなる熱硬化性組成物をバインダーとして含むモールド材の成形体を、ジエタノールアミンに浸漬することによって、完全に溶解分解することができる。また、特に本発明のモールド材に対する分解処理性が高い。
なお、分解処理時の温度も、もちろん本実施例の値に限定されない。しかし、耐圧装置による分解処理を行わない場合は、分解溶液の沸点以下であることが好ましい。
なお、ジエタノールアミンを含む分解溶液には、以上の実施例の配合に限定されず、その他の溶媒や塩基などを含んでいても良い。塩基としては、水酸化ナトリウム、水酸化カルシウム、水酸化カリウムのような金属水酸化物、酸化ナトリウム、酸化カルシウムのような金属酸化物、ナトリウムエトキシド、カリウムｔ−ブトキシドのような金属アルコキシドなどが挙げられる。これらは加溶媒分解の触媒として働くため、分解性は加速される。その他、加溶媒分解性溶媒の水、エタノール、メタノール、エチレングリコール、アンモニア、酢酸、ヒドラジンなどを混入することができる。また、加溶媒分解性溶媒以外にも、ジエチルエーテル、ジオキサン、テトラヒドロフラン、アセトン、ジメチルホルムアミド、ジメチルアミンなどの親水性有機溶媒などを混合しても使用できる。しかし、これらの場合、沸点などの影響で使用可能な温度領域が異なるので注意しなければならない。
また、分解処理後のモールド材は、分別などの手段により、各充填剤および樹脂合成材料として再利用することができる。
【００７３】
【発明の効果】
以上のように、本発明によれば、使用後において、少なくとも塩基と加溶媒分解性溶媒を含む分解溶液によって、簡単に分解処理できるモールド材およびモールドモータを提供することができる。
本発明の分解処理方法によれば、モールド材を容易に分解溶解することができる。
【図面の簡単な説明】
【図１】本発明によるモールドステータを有するモールドモータの一実施態様を示す断面図である。
【図２】従来のモールドモータの外観を示す斜視図である。
【図３】従来のモールドモータのステータ部の外観を示す斜視図である。
【符号の説明】
１０ モータ部
１１ モールドステータ
１２ 絶縁体
１３ 巻線
１４ 鉄芯
１５ モールド部
１６ 回転子シャフト
１７ 回転子
１８ ブラケット
１９、２０ ベアリング
２１ 取付孔
２２ フランジ部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold material that is excellent in strength and heat resistance and that can be easily disposed of after use, a mold motor using the mold material, and a method for disassembling them.
[0002]
[Prior art]
A thermosetting resin having an unsaturated polyester and an addition polymerizable monomer as a skeleton may be used alone, but many are used as composite materials, and about 80% of the production amount is as fiber reinforced plastic (FRP). It is used. And since it is easy to mix with fillers such as inorganic substances, additives, and fibers, it is applied to molding materials, laminates, adhesives, paints, and the like.
On the other hand, these resins are three-dimensionalized by a curing reaction and generally become insoluble and infusible solids. Therefore, decomposition treatment has been difficult conventionally, and it is difficult to adapt to recycling treatment and reuse. There was no choice but to discard.
The molding material is a molding material in which a resin as a binder is filled with an inorganic material such as glass fiber, calcium carbonate, talc or silica, or an organic material such as pulp or wood. Such filling makes the material high in specific strength and specific rigidity, and thus is applied to various uses in the industrial and consumer fields.
[0003]
Since this type of molding material is a composite material, it is generally difficult to recycle after use. Furthermore, if the binder resin is a thermosetting resin, it becomes three-dimensional by a curing reaction and generally becomes an insoluble and infusible solid. There was no choice but to discard it as something that was difficult to fit. However, as the problem of waste has attracted attention, the development of recycling and recycling technologies is required, and the use of raw materials by thermal decomposition has begun to be considered. However, the advantages of the thermosetting resin or mold material, such as hardness, strength, heat resistance, flame resistance, and chemical resistance, make waste disposal difficult from a technical standpoint.
[0004]
On the other hand, in recent years, equipment using a molding material having a thermosetting resin as a binder, for example, a mold motor, is used in consumer equipment, industrial equipment, office equipment, and the like. Since such a molded motor is excellent in silence, vibration damping, insulation, and maintainability, and is compact and easy to automate at the time of manufacture, its demand is rapidly expanding.
Conventionally, a molded stator of a molded motor used as an AC motor, a brushless DC motor or the like generally has a configuration disclosed in, for example, Japanese Patent Application Laid-Open No. 61-214740. The configuration will be described with reference to FIGS. FIG. 2 shows an external appearance of a molded motor having a conventional molded stator 201, and FIG. 3 is a perspective view showing a configuration of a stator portion before being molded. As shown in FIG. 2, the molded motor includes a motor unit 220 and a molded stator 201 that is integrally molded so as to cover the stator unit of FIG. 3 with a molding material 202. As shown in FIG. 3, the stator portion has an iron core 204 around which a winding 203 is wound via a cylindrical insulator 207, and the insulator 207 is formed on a part of one circumferential portion thereof. A printed circuit board 211 having a wiring pattern 210 is provided. On the printed circuit board 211, the terminal portion of the winding and the lead wire 212 are connected, and an external signal is input.
This mold material is made of a thermoplastic resin such as polyethylene terephthalate, polyethylene, polypropylene, or nylon, or a thermosetting resin such as unsaturated polyester, vinyl ester resin, or phenol resin as a binder material, and calcium carbonate, Contains talc and carbon black.
[0005]
The waste problem is becoming more serious, and development of a technology for reducing the volume of a discarded thermosetting composition or a molded product and a processing technology for reuse is urgently required. In particular, unsaturated polyester resins reinforced with fibers are frequently used in the manufacture of large products such as fishing boats, tanks, and housing equipment, and therefore, decomposition and recycling of waste are serious. In addition, many molding materials using thermosetting resins as binders are often used as structural materials because of their strength and the like, and often include other materials such as metals. Metals and the like are valuable resources that are more expensive than resin materials, and the possibility of their recycling and reuse is a bigger problem. That is, the current situation is that the conventional configuration and processing method for the molded product cannot solve the waste problem.
[0006]
On the other hand, when disposing of the mold motor, it is desirable to remove the mold material and recycle the valuable iron core and winding metal. In the conventional general waste treatment, the molding material is first crushed by a shredder, and then valuable materials such as iron cores and windings are selected from the crushed material, thereby recycling the valuable materials. However, in the mold motor configured as described above, since the teeth of the shredder are easily damaged by the iron core and the winding, the crushing process is avoided, and the valuable material is discarded without being recycled and is buried together with other waste. . Mold materials such as the above are not naturally decomposed by landfill, so silicon steel plates and copper wires used for iron cores and windings are highly valuable as materials even after use as a motor. Regardless, it is left as it is without being recycled. Furthermore, a conventional decomposition method such as volume reduction by thermal decomposition described above cannot be applied to a thermosetting resin used as a molding material. Therefore, the conventional mold motor cannot be crushed or disassembled, and has a problem that valuable materials such as iron cores and windings are difficult to reuse at the time of disposal.
[0007]
[Problems to be solved by the invention]
In view of the above, an object of the present invention is to provide a mold material that can be easily disposed of when discarded and a simple decomposition method of the molded material molded body.
Another object of the present invention is to provide a molded motor that can be easily disassembled and can reuse valuable materials such as iron cores and windings.
[0008]
[Means for Solving the Problems]
The molding material of the present invention contains a thermosetting resin composition comprising at least an unsaturated polyester, an addition polymerizable monomer, and a low shrinkage agent as a binder, and the addition polymerizable monomer is at least 2-hydroxyethyl acrylate or methacrylic acid. It contains acid 2-hydroxyethyl.
In the mold material, the low shrinkage agent is preferably at least one selected from the group consisting of polyvinyl acetate, butadiene / styrene / methyl methacrylate copolymer, polyhydroxyethyl methacrylate, and ketone resin.
The addition polymerizable monomer preferably contains at least one selected from the group consisting of styrene, vinyl acetate, allyl acetate, allyl acetoacetate, acrylic acid, methyl acrylate, methacrylic acid, and methyl methacrylate.
[0009]
Further, the molding material of the present invention includes a thermosetting resin composition comprising at least an unsaturated polyester, an addition polymerizable monomer, and a low shrinkage agent as a binder, the low shrinkage agent is polycaprolactone, and the addition polymerizable monomer is At least one of 2-hydroxyethyl acrylate and 2-hydroxyethyl methacrylate and styrene, and the molar fraction of 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate in the total addition polymerizable monomer is 0.00. 4 or more.
The mold material preferably further contains at least one selected from the group consisting of polyvinyl acetate, butadiene / styrene / methyl methacrylate copolymer, polyhydroxyethyl methacrylate, and ketone resin as an auxiliary low shrinkage agent. .
In addition, polycaprolactone, polypropiolactone, polylactic acid, polyglycolic acid, polyethylene adipate, polypropylene adipate, polybutylene adipate, polytetramethylene adipate, polyethylene succinate, polypropylene succinate, polybutylene succinate, polycaprolactone diol, polycaprolactone It is desirable to contain at least one aliphatic polyester selected from the group consisting of triols and 3-hydroxyalkanoate copolymers.
[0010]
The molded motor of the present invention has a configuration in which the molding material is molded so as to cover the iron core and the winding.
The method for decomposing a molding material molded body according to the present invention includes at least diethanolamine as a molding material molding material including, as a binder, a thermosetting resin composition comprising at least an unsaturated polyester, an addition polymerizable monomer, and a low shrinkage agent. Has a structure to be immersed in the decomposition solution The addition polymerizable monomer contains at least 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate. To do.
In the above decomposition method, the binder of the target molding material is further polycaprolactone, polypropiolactone, polylactic acid, polyglycolic acid, polyethylene adipate, polypropylene adipate, polybutylene adipate, polytetramethylene adipate, polyethylene succinate, polypropylene It is desirable to contain at least one aliphatic polyester selected from the group consisting of succinate, polybutylene succinate, polycaprolactone diol, polycaprolactone triol, and 3-hydroxyalkanoate copolymer.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
The unsaturated polyester used for the binder of the molding material of the present invention can be obtained by polycondensation of unsaturated polybasic acid, saturated polybasic acid and glycols by a known method. Examples of the unsaturated polybasic acid include maleic anhydride, fumaric acid, itaconic acid, citraconic acid and the like. Saturated polybasic acids include phthalic anhydride, isophthalic acid, terephthalic acid, adipic acid, sebacic acid, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, endomethylenetetrahydrophthalic anhydride, het acid, tetrabromophthalic anhydride, etc. Can be mentioned. As glycols, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, 1,3-butanediol, 1,6-hexanediol, hydrogenated bisphenol A, bisphenol A propylene oxide compound, dibromoneopentyl And glycols.
Suitable unsaturated polyesters include copolymers of isophthalic acid and fumaric acid represented by formula (1) and neopentyl glycol, and phthalic anhydride and fumaric anhydride represented by formula (2). And a copolymer of propylene glycol and a copolymer of isophthalic acid and maleic anhydride and propylene glycol represented by the formula (3).
[0012]
[Chemical 1]

[0013]
[Chemical formula 2]

[0014]
[Chemical 3]

[0015]
(In the above formula, n is 1 to 30.)
An addition polymerizable monomer containing at least 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate is used as the crosslinking agent for the unsaturated polyester used in the binder of the molding material of the present invention.
As addition-polymerizable monomers, styrene, vinyl acetate, allyl acetate, allyl acetoacetate, acrylic acid, methyl acrylate, methacrylic acid, and methyl methacrylate are preferably used. These monomers have a relatively high solubility in the aliphatic polyester described later.
Moreover, conventionally used addition polymerizable monomers such as vinyltoluene, α-methylstyrene, diallyl phthalate, diallyl isophthalate, diallyl tetrabromophthalate, and phenoxyethyl acrylate may be used in combination.
The addition polymerizable monomer is contained in an amount of preferably 25 to 150 parts by weight, more preferably 40 to 100 parts by weight with respect to 100 parts by weight of the unsaturated polyester.
[0016]
The low shrinkage agent used in the molding material of the present invention is preferably polyvinyl acetate, butadiene / styrene / methyl methacrylate copolymer (MBS resin), polyhydroxyethyl methacrylate, or ketone resin. Since these low shrinkage agents are soluble in the aforementioned addition polymerizable monomer, 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate, the binder resin composition can be easily prepared.
Polycaprolactone belongs to the aliphatic polyester described later, but is a polymer that can also function as a low shrinkage agent.
Usually, one type of low shrinkage agent is used, but in order to enhance the low shrinkage effect, an auxiliary low shrinkage agent can be added and a plurality of low shrinkage agents can be used.
The low shrinkage agent is preferably contained in an amount of 1 to 100 parts by weight, more preferably 2 to 50 parts by weight, based on 100 parts by weight of the unsaturated polyester.
Thermoplastic resins such as polyethylene, polypropylene, polystyrene, poly (ethylene vinyl alcohol), acrylic copolymer, methacrylic copolymer, styrene-butadiene block copolymer, acrylonitrile-butadiene-styrene copolymer are low shrinkage agents. These may be used in combination with the above-mentioned low shrinkage agent.
[0017]
The molding material of the present invention preferably contains an aliphatic polyester. Examples of aliphatic polyesters include polymers obtained by ring-opening polymerization of lactones such as polycaprolactone and polypropiolactone represented by formula (4); polylactic acid represented by formula (5), and formula (6) Polymers of hydroxy acids such as polyglycolic acid represented by formula (7) such as polyethylene adipate, polypropylene adipate, polybutylene adipate, polytetramethylene adipate, polyethylene succinate, polypropylene succinate, polybutylene succinate A copolymer comprising a glycol and an aliphatic dicarboxylic acid; a polymer having a functional group at the end, such as a polycaprolactone diol represented by the formula (8) and a polycaprolactone triol represented by the formula (9) Terminal acrylic modified polycaprola as represented by formula (10) Ton; 3- hydroxypropionate, 3-hydroxybutyrate, 3-hydroxyvalerate, it is used as the polyester obtained by fermentation of microorganisms such as 3-hydroxy-octanoate desirable. These polyesters have very excellent degradability with respect to the decomposition solution described later.
[0018]
[Formula 4]

[0019]
[Chemical formula 5]

[0020]
[Chemical 6]

[0021]
[Chemical 7]

[0022]
(In the above formula, l, m, n and N are each independently 10 to 2000, and R is each independently a hydrocarbon group having 1 to 20 carbon atoms.)
The aliphatic polyester is preferably contained in an amount of 1 to 100 parts by weight, more preferably 2 to 50 parts by weight, based on 100 parts by weight of the unsaturated polyester.
[0023]
The molding material of the present invention preferably contains a curing agent.
Curing agents include benzoyl peroxide, t-butyl perbenzoate, t-butyl peroxybenzoate, t-butyl peroxylaurate, t-butyl peroxy-2-ethylhexanoate, t-butyl peroctoate, Examples include 1,1-bis (t-butylperoxy) 3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, and the like.
The curing agent is contained in an amount of preferably 0.1 to 5 parts by weight, more preferably 0.2 to 4 parts by weight with respect to 100 parts by weight of the unsaturated polyester.
[0024]
The mold material of the present invention is added with a filler, a thickener, a release agent, a wax, a colorant, and the like as necessary.
Fillers include carbonates such as calcium carbonate and magnesium carbonate, (sulfur) sulfates such as calcium sulfate, barium sulfate and calcium sulfite, clay, mica, glass balloons, montmorillonite, silicic acid, kaolin and talc. Silicates, silica, siliceous earth, iron oxide, pumice balloon, oxides such as titanium oxide and alumina, hydroxides such as aluminum hydroxide and magnesium hydroxide, graphite, glass fiber, carbon fiber, asbestos And inorganic fillers such as fibers; and organic fillers such as wood flour, rice husk, cotton, paper strips, nylon fibers, polyethylene fibers, wood, pulp, and cellulose.
The filler is added in an amount of preferably 5 to 600 parts by weight, more preferably 20 to 500 parts by weight with respect to 100 parts by weight of the thermosetting composition. By adding the filler in such a range, the mechanical strength of the molding material is improved.
[0025]
Examples of the thickener include beryllium oxide, magnesium oxide, magnesium hydroxide, calcium oxide, calcium hydroxide, zinc oxide, benzoic acid, phthalic anhydride, tetrahydrophthalic anhydride, and maleic anhydride.
Examples of the mold release agent include stearic acid, zinc stearate, calcium stearate and the like.
Examples of the wax include Hoechst wax, carnauba wax, and paraffin.
Examples of the colorant include titanium white, chromium oxide, and carbon black.
[0026]
The molding material of the present invention can be easily decomposed with diethanolamine, but can also be decomposed with a solvolytic solvent which itself can be a nucleophile and cause a substitution reaction. Examples of such solvolytic solvents include water, methanol, ethanol, ethylene glycol, acetic acid, thiol, and hydrazine.
[0027]
The mold stator of this invention is comprised using said mold material. Hereinafter, preferred embodiments of the molded stator of the present invention will be described with reference to the drawings.
A first preferred embodiment of the molded stator of the present invention will be described with reference to FIG. FIG. 1 is a cross-sectional view showing an embodiment of a molded motor having a molded stator of the present invention. The molded motor includes a motor unit 10 and a molded stator 11. The mold stator 11 includes an iron core 14 around which a winding 13 is wound via an insulator 12, and a mold part 15 that covers the iron core 14 and that is integrally formed with a molding material so as to fill the entire mold stator. Have. The motor unit 10 is attached to the opening of the mold unit 15 and includes at least a rotor shaft 16 and a rotor 17 attached to the rotor shaft, and is supported by a bracket 18. The rotor 17 is pivotally supported by a bearing 19 attached to the upper wall of the opening and a bearing 20 attached to the bracket.
Although not shown, the end portion of the winding 13 extends to a portion located on the shaft of the molded stator, where it is connected to a lead wire and input from the outside is possible. Further, the molded stator 11 may include a flange portion 22 having a plurality of mounting holes 21. The thickness of the maximum thickness part of the mold part 15 is usually about 10 mm.
[0028]
It is the above-described molding material of the present invention that constitutes the mold part 15.
Although the thickness of the maximum thickness part of a mold part may change according to a use, In this invention, Preferably it is 1-10 mm, More preferably, it is 1-8 mm, Most preferably, it is 1-5 mm.
As the insulator 12, for example, a thermoplastic resin such as aliphatic polyester, polyethylene terephthalate, or polyethylene is used. Since the insulator 12 is required to preserve the shape of the winding 13 during molding, the insulator 12 preferably has a softening point or a melting point of, for example, about 100 ° C. or higher so as not to be softened during molding. Use of aliphatic polyester for the insulator 12 is particularly preferable because the winding 13 and the iron core 14 can be separated at the time of decomposition. As an aliphatic polyester whose melting | fusing point exceeds 100 degreeC, the copolymer resin shown to said Formula (7) is mentioned, for example.
The molded stator of the present invention is more easily disassembled by appropriately combining the configurations of the preferred embodiments described above.
The molded stator of the present invention is applied to brushless DC motors, AC motors, linear motors, and the like.
[0029]
【Example】
Examples of the present invention will be described below.
Example 1
60 parts by weight of unsaturated polyester was mixed with 40 parts by weight of 2-hydroxyethyl methacrylate as an addition polymerizable monomer, and the mixture was stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain a 60% by weight unsaturated polyester liquid resin. . Further, 30 parts by weight of polyvinyl acetate as a low shrinkage agent was added to 70 parts by weight of 2-hydroxyethyl methacrylate as an addition polymerizable monomer to obtain a low shrinkage solution. In addition to 17.71 parts by weight of the above unsaturated polyester liquid resin, 5.09 parts by weight of this low shrinkage agent solution and a curing agent 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Japan) A binder resin composition was obtained by adding 0.25 parts by weight of Oil and Fat Co., Ltd., trade name: Perhexa 3M, and mixing well. The molar fraction of methacrylic acid-2-hydroxyethyl in the addition polymerizable monomer in this binder resin composition is 1.
[0030]
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. .
[0031]
Example 2
25 parts by weight of 2-hydroxyethyl methacrylate, which is an addition polymerizable monomer, was mixed with 75 parts by weight of unsaturated polyester and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain a 75% by weight unsaturated polyester liquid resin. . Further, 32.6 parts by weight of polyvinyl acetate as a low shrinkage agent was dissolved in 67.4 parts by weight of 2-hydroxyethyl methacrylate as an addition polymerizable monomer to obtain a low shrinkage solution. To 15.06 parts by weight of the above unsaturated polyester liquid resin, 4.97 parts by weight of this low shrinkage agent solution and 2.63 parts by weight of methyl methacrylate which is an addition polymerizable monomer are added. 0.25 parts by weight of 1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Nippon Yushi Co., Ltd., trade name: Perhexa 3M) was added and mixed well to obtain a binder resin composition. It was. The molar fraction of methacrylic acid-2-hydroxyethyl in the addition polymerizable monomer in this binder resin composition is 0.67.
[0032]
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. .
[0033]
Example 3
25 parts by weight of 2-hydroxyethyl methacrylate, which is an addition polymerizable monomer, was mixed with 75 parts by weight of unsaturated polyester and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain a 75% by weight unsaturated polyester liquid resin. . Further, 32.6 parts by weight of polyvinyl acetate as a low shrinkage agent was dissolved in 67.4 parts by weight of 2-hydroxyethyl methacrylate as an addition polymerizable monomer to obtain a low shrinkage solution. Further, an aliphatic polyester solution was obtained by dissolving 30 parts by weight of polycaprolactone, which is an aliphatic polyester, in 70 parts by weight of methyl methacrylate, which is an addition polymerizable monomer. 4.72 parts by weight of this low shrinkage agent solution and 3.76 parts by weight of an aliphatic polyester solution are added to 14.31 parts by weight of the above unsaturated polyester liquid resin, and further, a curing agent 1,1-bis (tert- (Butylperoxy) 3,3,5-trimethylcyclohexane (Nippon Yushi Co., Ltd., trade name: Perhexa 3M) was added in an amount of 0.25 parts by weight and mixed well to obtain a binder resin composition. The molar fraction of methacrylic acid-2-hydroxyethyl in the addition polymerizable monomer in this binder resin composition is 0.67.
[0034]
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. .
[0035]
<< Comparative Example 1 >>
Unsaturated polyester (manufactured by Nippon Shokubai Co., Ltd., trade name: Epolak), 12.02 parts by weight, 9.64 parts by weight of styrene as an addition polymerizable monomer, polycaprolactone as an aliphatic polyester (molecular weight 40,000, Daicel Chemical 1.14 parts by weight manufactured by Kogyo Co., Ltd., trade name: Plaxel, and 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (manufactured by NOF Corporation, trade name) : Perhexa 3M) 0.25 part by weight was added and mixed well to obtain a binder resin composition.
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, And 0.99 weight part of polyethylene was moved to the kneader, and dry mixing was performed. After about 5 minutes, the binder resin composition previously mixed was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. .
[0036]
<< Comparative Example 2 >>
Unsaturated polyester (manufactured by Nippon Shokubai Co., Ltd., trade name: Epolak) 12.02 parts by weight, 9.64 parts by weight of styrene as an addition polymerizable monomer, 1.14 parts by weight of polystyrene (molecular weight 40,000), and curing 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Nippon Yushi Co., Ltd., trade name: Perhexa 3M) 0.25 parts by weight and mixed well, binder resin composition I got a thing.
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the binder resin composition previously mixed was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste. Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. . This mold material has a conventional composition.
[0037]
Since the molding materials obtained in Examples 1 to 3 and Comparative Examples 1 and 2 are bulky, they are usually one type of molding material called BMC (Bulk Molding Compound) and contain an addition polymerizable monomer. Nevertheless, it is non-sticky.
Among the compositions of these molding materials, different monomers and low shrinkage components are summarized in Table 1. Table 2 shows the basic physical properties measured for these molding materials.
[0038]
[Table 1]

[0039]
[Table 2]

[0040]
The spiral flow represents the material extrusion length (flow length) from the pores, and is mainly used to determine the formability of transfer molding or injection molding. 150 ° C, 100 kgf / cm ² It measured on condition of this. A comparative example is a composition of the molding material used conventionally. Since the spiral flow of the example is almost the same as that of the comparative example, it can be seen that there is no problem in molding under the same conditions as in the comparative example.
Mold shrinkage, which indicates dimensional stability during molding, is 150 ° C., 100 kgf / cm. ² The measurement was performed under molding conditions for 10 minutes (JIS K6911). The thing of an Example was equivalent to the comparative example 2 whose molding shrinkage rate is a conventional mass-produced product. In the case of polycaprolactone, it can be seen that it is an aliphatic polyester and also functions as a low shrinkage agent.
Further, the curing time of the molding material of the present invention tends to be shorter than that of the conventional product, but it does not cause a problem in moldability.
[0041]
Finally, the strength of the molded product was measured. Each mold material was formed into a flat plate shape having a width of 12.7 mm, a length of 127 mm, and a height of 3.2 mm by transfer molding at 150 ° C. for 5 minutes, and used as a bending test sample. The bending test was performed at a fulcrum distance of 50 mm and a crosshead speed of 10 mm / min. I went there. Although the thing of an Example has a little small intensity | strength, it was the intensity | strength substantially equivalent to the comparative example 2 of a conventional product.
From the above, the prototypes of the mold material of the present invention are both moldability and curability when compared with a mold material (called a fiber reinforced plastic, etc.) made of an unsaturated polyester resin that is usually used industrially. Curing time) and strength were almost the same, and there was no problem with respect to dimensional stability and spiral flow length. Therefore, the molding material according to the present invention can be sufficiently applied to applications in which an FRP material is usually used.
[0042]
Next, the molding materials of Examples 1 to 3 and Comparative Examples 1 and 2 were subjected to a mold temperature of 150 ° C. and an injection pressure of 35 kg / cm. ² Therefore, compression molding was performed, and a cylindrical molded product having a diameter of 19 mm was manufactured as a prototype. And the decomposition processing test of these molded products was done. The test method was based on immersion in a decomposition solution consisting of at least a base and a solvolytic solvent. For Examples 1 to 3, a 5N aqueous sodium hydroxide solution was used as the decomposition solution. Each molding material molded body was immersed in this solution at 90 ° C. for 24 hours, and the rate of decomposition solution penetration and the surface hardness of the molded body after the decomposition solution immersion treatment were measured. The hardness was measured using a rubber hardness meter in consideration of the fact that the molded material after processing was very brittle. The results are shown in Table 3.
[0043]
[Table 3]

[0044]
Compared with Comparative Examples 1 and 2, the molded material molded bodies of Examples 1 to 3 have a uniformly high penetration rate of the decomposition solution and a small surface hardness after the penetration. In the molding materials of Examples 1 to 3, the decomposition solution quickly penetrates into the composition due to the presence of the addition polymerizable monomer having high decomposition solution affinity, 2-hydroxyethyl methacrylate, and the composition skeleton. The ester bond in the unsaturated polyester resin constituting the resin undergoes solvolysis, the binder resin loses the three-dimensional structure, and the molded product collapses, that is, the surface hardness becomes very small. Therefore, it is a mold material with extremely high decomposability.
On the other hand, the molding material of Comparative Example 2 is a molding material having a conventionally used composition, and cannot be treated with a solution containing such a base and water. As in Comparative Example 1, the use of polycaprolactone as a low shrinkage material can improve the processability of the decomposition solution, but an addition polymerizable monomer having a high affinity for the decomposition solution is introduced as in Example 3. As a result, it is possible to obtain an even greater decomposition liquid processability.
Further, as can be seen from the comparison between Example 2 and Example 3, even when an addition polymerizable monomer having high decomposition solution affinity, 2-hydroxyethyl methacrylate, is used, the aliphatic polyester has decomposition solution permeability. In addition to improving the solvolysis by itself, the use of polycaprolactone, which is an aliphatic polyester, improves the decomposition processability.
[0045]
As described above, the mold material of the present invention has an ester bond in the main chain and a high affinity for the decomposition liquid in the cross-linked chain by copolymerization of the unsaturated polyester and the addition polymerizable monomer after curing. A three-dimensional crosslinked structure having a 2-hydroxyethyl group is formed, and the low shrinkage agent is dispersed in the three-dimensional structure. For this reason, by immersing the molding material after curing molding in a decomposition solution containing at least a base and a solvolytic solvent, the decomposition solution quickly penetrates into the composition due to the presence of the addition polymerizable monomer, Some of the ester bonds in the unsaturated polyester resin constituting the composition skeleton appear to undergo solvolysis, the binder resin loses the three-dimensional structure, and the molded article collapses.
In addition, by containing polycaprolactone, which is an aliphatic polyester, it has a high affinity for a decomposition solution containing at least a base and a solvolytic solvent, a high solvolytic property, and a solvated solvent of an unsaturated polyester resin crosslinked structure as a binder. Decomposition proceeds more efficiently and effectively.
[0046]
When aliphatic polyester is contained, it can be easily and stably dispersed by dissolving and mixing in a soluble monomer as in Example 3.
In addition, when aliphatic polyester is contained, it is of course good to mix in the form of powder, fiber, needle or the like.
Moreover, in the boiling test in water, a difference was not observed in Examples 1 to 3 and Comparative Examples 1 and 2, and the water resistance in the Examples of the present invention was comparable to the conventional products.
Moreover, the density | concentration of sodium hydroxide aqueous solution should just be adjusted to 10N or less, without restricting to 5N like an Example. Furthermore, it is more preferable to prepare in the range of 2-5N.
[0047]
In addition, the structure of the molding material and the manufacturing method are not limited to the examples. For example, fillers such as calcium carbonate, calcium silicate, barium sulfate, aluminum hydroxide, talc, and mica, glass fibers, carbon fibers, and the like. Of course, a thickener, a release agent, a colorant and the like may be mixed.
In the above embodiment, compression molding is used at the time of molding the molding material, but transfer molding, injection molding, or the like may be used.
Moreover, although the bulk-shaped molding material was demonstrated in the Example, sheet-like SMC (sheet molding compound) and granular PMC (pelletized type molding compound) may be used besides a bulk shape.
In addition, although the example shape | molded in the column shape was used in the Example, it is not limited to this, The molded object which has another shape, a coating material, a putty, an adhesive agent, etc. may be sufficient.
Of course, the temperature during the decomposition treatment is not limited to the values in the examples. However, when the decomposition treatment by the pressure device is not performed, the boiling point of the decomposition solution is preferable.
[0048]
Example 4
Unsaturated polyester, addition-polymerizable monomer 2-hydroxyethyl methacrylate, and styrene are mixed at different blending ratios and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain seven types of unsaturated polyester liquid resins. It was. Further, 30 parts by weight of polycaprolactone (trade name: Plaxel, manufactured by Daicel Chemical Industries, Ltd.), which is a low-shrinkage agent and aliphatic polyester, is added to 1: 2 of styrene and 2-hydroxyethyl methacrylate as an addition polymerizable monomer. In addition to 70 parts by weight of 1 (weight) mixture, a low shrinkage agent solution was obtained. In addition to 17.71 parts by weight of the above unsaturated polyester liquid resin, 5.09 parts by weight of this low shrinkage agent solution and a curing agent 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Japan) 0.25 part by weight, manufactured by Yushi Co., Ltd., trade name: Perhexa 3M) was added and mixed well to obtain a resin composition serving as 7 types of binders.
The blending ratio of unsaturated polyester, 2-hydroxyethyl methacrylate and styrene in each unsaturated polyester liquid resin, and the molar fraction of 2-hydroxyethyl methacrylate in the addition polymerizable monomer in the binder resin composition are collectively shown. This is shown in FIG.
[0049]
[Table 4]

[0050]
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated, Seven different mold materials were obtained.
[0051]
Next, these seven kinds of mold materials are molded at a mold temperature of 150 ° C. and injection pressure of 35 kg / cm. ² Was subjected to compression molding to produce a cylindrical molded product having a diameter of 19 mm. And the decomposition processing test of these molded products was done. The test method was based on immersion in a decomposition solution consisting of at least a base and a solvolytic solvent. In this example, a 5N aqueous sodium hydroxide solution was used as the decomposition solution. Each molding material molded body was immersed in this solution at 90 ° C. for 24 hours, and the rate of decomposition solution penetration and the surface hardness of the molded body after the decomposition solution immersion treatment were measured. The hardness was measured using a rubber hardness meter in consideration of the fact that the molded material after processing was very brittle. The results are shown in Table 5.
[0052]
[Table 5]

[0053]
The greater the molar fraction of 2-hydroxyethyl methacrylate in the addition polymerizable monomer, the higher the permeability of the decomposition solution, and the lower the surface hardness after the decomposition treatment. The presence of 2-hydroxyethyl methacrylate improves the decomposability of the molding material. In particular, when the molar fraction of 2-hydroxyethyl methacrylate is 0.4 or more, the surface hardness after the decomposition treatment is low, and any treatment such as crushing, crushing, volume reduction, peeling, etc. can be performed manually. It was easy to apply.
Moreover, conventionally, since the unsaturated polyester liquid resin is a styrene solution of unsaturated polyester, the content of 2-hydroxyethyl methacrylate in the addition-polymerizable monomer can be increased without increasing the total monomer amount relative to the unsaturated polyester. Although it was difficult to raise, by using a liquid resin in which unsaturated polyester was dissolved in 2-hydroxyethyl methacrylate or a mixed solution of styrene and 2-hydroxyethyl methacrylate, as in this example, A highly decomposable binder resin having a molar fraction of 2-hydroxyethyl methacrylate in the total addition polymerizable monomer of 0.4 or more can be prepared.
[0054]
As described above, the mold material of the present invention has an ester bond in the main chain and a high affinity for the decomposition liquid in the cross-linked chain by copolymerization of the unsaturated polyester and the addition polymerizable monomer after curing. A three-dimensional cross-linked structure with many 2-hydroxyethyl groups is formed, and the low shrinkage agent is dispersed in the three-dimensional structure. For this reason, since the mold material after curing molding is immersed in a decomposition solution containing at least a base and a solvolytic solvent, the substitution rate of 2-hydroxyethyl groups is high, so that the decomposition solution quickly penetrates into the composition. At the same time, some of the ester bonds in the unsaturated polyester resin constituting the composition skeleton appear to undergo solvolysis, the binder resin loses its three-dimensional structure, and the molded product rapidly disintegrates.
In the above embodiment, 2-hydroxyethyl methacrylate was described as an example, but the same tendency can be obtained with 2-hydroxyethyl acrylate.
Further, it is naturally possible that 2-hydroxyethyl methacrylate and 2-hydroxyethyl acrylate are mixed at the same time, and the sum of the molar fractions of both in the addition polymerizable monomer is 0.4 or more.
Moreover, the density | concentration of sodium hydroxide aqueous solution should just be adjusted to 10N or less, without restricting to 5N like an Example. Furthermore, it is more preferable to prepare in the range of 2-5N.
[0055]
Example 5
60 parts by weight of unsaturated polyester was mixed with 40 parts by weight of 2-hydroxyethyl methacrylate as an addition polymerizable monomer, and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain a 60% by weight unsaturated polyester liquid resin. . Also, 30 parts by weight of polycaprolactone (trade name: Plaxel, manufactured by Daicel Chemical Industries, Ltd.), which is an aliphatic polyester, was dissolved in 70 parts by weight of acrylic acid, which is an addition polymerizable monomer, to obtain an aliphatic polyester solution. . In addition to 17.71 parts by weight of the above unsaturated polyester liquid resin, 5.09 parts by weight of this aliphatic polyester solution and a curing agent 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Japan) 0.25 part by weight, manufactured by Yushi Co., Ltd., trade name: Perhexa 3M, was added and mixed well to obtain a resin composition serving as a binder. The molar fraction of 2-hydroxyethyl methacrylate in the addition polymerizable monomer in this binder resin composition is 0.5.
[0056]
Next, 57 parts by weight of calcium carbonate as a filler, 2 parts by weight of zinc stearate as a release agent, and 1 part by weight of a thickener magnesium oxide were transferred to a kneader, and dry mixing was performed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
A chopped strand obtained by cutting glass fibers with a cutter was sprayed onto a polyethylene film, and a mold material was obtained by impregnating the previous paste. The mold material that had been impregnated was wound up and aged for the required length to increase the viscosity to the required consistency. As a result, about 30 parts by weight of glass fiber is blended with 100 parts by weight of the paste.
[0057]
Example 6
40 parts by weight of 2-hydroxyethyl methacrylate, which is an addition polymerizable monomer, was mixed with 60 parts by weight of the unsaturated polyester and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain a 60% by weight unsaturated polyester liquid resin. . Also, 30 parts by weight of a methyl methacrylate / butadiene / styrene copolymer (MBS resin), which is a low shrinkage agent, is dissolved in 70 parts by weight of 2-hydroxyethyl acrylate, which is an addition polymerizable monomer, to obtain a low shrinkage agent solution. It was. 250-500 μm of 13.83 parts by weight of the above-mentioned unsaturated polyester liquid resin and 5.97 parts by weight of this low shrinkage agent solution and 5 parts by weight of polylactic acid (trade name: Lacti, manufactured by Shimadzu Corporation) as an aliphatic polyester Finally, the curing agent 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (manufactured by NOF Corporation, trade name: Perhexa 3M) is 0.25 weight. Part of the mixture was added and mixed well to obtain a resin composition serving as a binder.
[0058]
Next, 57 parts by weight of calcium carbonate as a filler, 2 parts by weight of zinc stearate as a release agent, and 1 part by weight of a thickener magnesium oxide were transferred to a kneader, and dry mixing was performed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
A chopped strand obtained by cutting glass fibers with a cutter was sprayed onto a polyethylene film, and a mold material was obtained by impregnating the previous paste. The mold material that had been impregnated was wound up and aged for the required length to increase the viscosity to the required consistency. As a result, about 30 parts by weight of glass fiber is blended with 100 parts by weight of the paste.
[0059]
Since the molding materials of Examples 5 and 6 are in sheet form, they are one type of molding material generally called SMC (sheet molding compound) and are in a non-adhesive state despite containing styrene.
The molding materials of Examples 5 and 6 are both moldability and curability (curing time, gelation time) when compared with FRP (fiber reinforced plastic) made of unsaturated polyester resin, which is usually used industrially. The strength and the like were almost the same, and there was no problem with respect to dimensional stability and spiral flow length. There is no problem in shrinkability at the time of molding, and it can be seen that MBS resin or aliphatic polyester polycaprolactone functions as a low shrinkage agent. Therefore, the molding material according to the present invention can be sufficiently applied to applications in which FRP materials are usually used.
[0060]
Next, the molding materials of Examples 5 and 6 were molded at a mold temperature of 150 ° C. and injection pressure of 35 kg / cm. ² Was subjected to compression molding to produce a cylindrical molded product having a diameter of 19 mm. And the decomposition processing test of this prototype material molded object was done. The test method was based on immersion in a decomposition solution containing at least a base and a solvolytic solvent. Here, 4N sodium hydroxide aqueous solution was used as a decomposition solution. For comparison, the sample was also immersed in a water-only decomposition solution containing no base. The molding material molded body was immersed in each decomposition solution at 90 ° C., and the rate of decomposition solution penetration and the surface hardness of the molded body after the decomposition solution immersion treatment were measured. The hardness was measured with a rubber hardness meter. The results are shown in Table 6.
[0061]
[Table 6]

[0062]
By 24 hours after immersion, the decomposition solution has completely penetrated into the molded product, and all show high decomposability. In addition, after 24 hours, in each sample, the molded product was too soft to measure the surface hardness. All treatments such as crushing, crushing and volume reduction were easy to apply. A molding material containing 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate having a high affinity for the decomposition solution exhibits excellent decomposability for a decomposition solution that is a solvolytic solution containing at least a base and water. . On the other hand, in the treatment with water, the molded product was not affected at all and the surface hardness was still hard.
[0063]
As is clear from Examples 5 and 6 above, the molding material of the present invention can be brought into a very soft state by a decomposition solution containing at least a base and a solvolytic solvent. When the container is packed, pulverized, or includes other parts, it can be easily peeled and separated. On the other hand, it is not affected at all by water which does not contain a base. Therefore, in a normal use environment, even if it is in a situation where it is wet or wet, it will not be attacked. However, it is always desirable to coat the surface for safety in environments where exposure to extremely high temperatures and high humidity continues. In this case, the coating can be provided by applying and drying a solution in which a resin such as polyethylene, polypropylene, polystyrene, or polyvinyl acetal is dissolved, or a dispersed suspension. Since the thickness of the coating layer is about 0.1 to 0.5 mm, the decomposition treatment of the coated molding material molded body may be carried out by immersing it in the decomposition solution after the surface is shaved with a file or the like.
[0064]
Since acrylic acid may be gelled by iron, it is preferable not to use pure iron around the mold when molding the molding material containing acrylic acid.
In addition, the aliphatic polyester that promotes degradability can be mixed in the state of being dissolved in the monomer as in Example 5, or can be mixed in the form of particles as in Example 6.
In Examples 5 and 6, polylactic acid, which is an aliphatic polyester, is contained in the form of particles, but it may be in the form of fibers or needles.
[0065]
In addition, the structure and manufacturing method of a molding material are not limited to the said Examples 1-6, For example, fillers, such as calcium carbonate, calcium silicate, barium sulfate, aluminum hydroxide, talc, mica, glass fiber Of course, a reinforcing agent such as carbon fiber, a thickener, a release agent, a colorant, and the like may be mixed therein.
In Examples 1 to 6, compression molding was used when molding the mold material, but transfer molding, injection molding, or the like may be used.
Further, in Examples 1 to 4, a bulk molding material was described, and in Examples 5 and 6, a sheet-shaped SMC (sheet molding compound) was described, but in addition to these, granular PMC (petletized type molding compound) was used. There may be.
In Examples 1-6, although the example shape | molded in the column shape was used, it is not limited to this, The molded object which has another shape, and a coating material, putty, an adhesive agent, etc. may be sufficient.
Of course, the temperature during the decomposition treatment is not limited to the values in the examples.
The final molded product obtained from the molding material of the present invention includes construction materials such as bathtubs, toilets, water tanks, and washbasins; household items such as chairs, desks, and furniture; tiles, artificial marble, and pipes. It can be used in various fields such as civil engineering materials; bodies and parts of transportation equipment such as ships, automobiles, railways, and aircraft; housing equipment; decorative panels;
[0066]
In addition, the solution which dipped and decomposed | disassembled the molding material molding of this invention is not limited to the composition and compounding ratio of the above Example, What is necessary is just to contain a base and a solvolytic solvent at least. As the base, in addition to sodium hydroxide shown in this example, metal hydroxides such as calcium hydroxide and potassium hydroxide, metal oxides such as sodium oxide and calcium oxide, sodium ethoxide, potassium t -Metal alkoxides such as butoxide. These may be used alone or in admixture of two or more. In addition to the water used in this example, ethanol, methanol, ethylene glycol, ammonia, acetic acid, hydrazine, and the like can be mixed as the solvolytic solvent.
Further, in the decomposition solution, in addition to the solvolytic solvent, a solvent such as diethyl ether, dioxane, tetrahydrofuran, acetone, dimethylformamide, dimethylamine or the like may be used even if one kind or two or more kinds are mixed. obtain.
[0067]
Example 7
An example of a molded motor will be described.
61 parts by weight of unsaturated polyester, 34 parts by weight of 2-hydroxyethyl methacrylate, which is an addition polymerizable monomer, and 5 parts by weight of styrene are mixed and stirred at 100 ° C. for 10 minutes in a nitrogen atmosphere to obtain an unsaturated polyester liquid resin. Obtained. Further, 30 parts by weight of polycaprolactone (trade name: Plaxel, manufactured by Daicel Chemical Industries, Ltd.), which is a low-shrinkage agent and aliphatic polyester, is added to 1: 2 of styrene and 2-hydroxyethyl methacrylate as an addition polymerizable monomer. In addition to 70 parts by weight of 1 (weight) mixture, a low shrinkage agent solution was obtained. In addition to 17.71 parts by weight of the above-mentioned unsaturated polyester liquid resin, 5.09 parts by weight of this low shrinkage agent solution and a curing agent 1,1-bis (tert-butylperoxy) 3,3,5-trimethylcyclohexane (Japan) 0.25 part by weight, manufactured by Yushi Co., Ltd., trade name: Perhexa 3M) was added and mixed well to obtain a resin composition serving as a binder.
[0068]
Next, 9.91 parts by weight of calcium carbonate as a filler, 50.8 parts by weight of aluminum hydroxide, 1.24 parts by weight of zinc stearate as a release agent, 0.37 parts by weight of carbon powder as a pigment, and 0.99 parts by weight of polyethylene was transferred to a kneader and dry mixed. After about 5 minutes, the previously mixed binder composition was gradually added to the uniformly mixed dry mixture and kneaded to obtain a uniform paste.
Further, 13.63 parts by weight of glass fibers were uniformly dispersed in this paste-like material, and added in a short time as much as possible. When the glass fibers were wet and uniformly dispersed, the kneading was terminated to obtain a molding material. .
This mold material and an iron core wound with a winding through an insulator were integrally formed at 150 ° C. to produce a molded stator as shown in FIG. This mold stator was immersed in a 5N aqueous sodium hydroxide solution at 90 ° C. for 24 hours, and then an attempt was made to remove the mold material. The mold material was removed with bare hands, and the winding and the iron core could be separated. .
Furthermore, by immersing for 8 hours, the molding material partially remaining in the winding could be completely removed.
[0069]
As described above, the mold motor using the mold material of the present invention and covering and molding the iron core and the windings is decomposed by immersing it in a decomposition solution consisting of a base and a solvolytic solvent. Since it collapses, it can be easily peeled off, and the mold part, iron core, and winding can be easily separated. That is, it is a molded motor with a very high recoverability of valuable metals.
Of course, the molding material used for the motor mold is not limited to the composition of this embodiment. Of course, the temperature during the decomposition treatment is not limited to the value of this embodiment.
[0070]
In addition, the solution which immersed the mold motor of this invention and decomposed | disassembled is not limited to the composition of the above Example, and a compounding ratio, What is necessary is just to contain a base and a solvolytic solvent at least. As the base, in addition to sodium hydroxide shown in this example, metal hydroxides such as calcium hydroxide and potassium hydroxide, metal oxides such as sodium oxide and calcium oxide, sodium ethoxide, potassium t -Metal alkoxides such as butoxide. These may be used alone or in admixture of two or more. In addition to the water used in this example, ethanol, methanol, ethylene glycol, ammonia, acetic acid, hydrazine, and the like can be mixed as the solvolytic solvent.
Further, in the decomposition solution, in addition to the solvolytic solvent, a solvent such as diethyl ether, dioxane, tetrahydrofuran, acetone, dimethylformamide, dimethylamine or the like may be used even if one kind or two or more kinds are mixed. obtain.
[0071]
Example 8
An embodiment of a method for disassembling the mold material will be described.
The mold materials of Example 1, Example 3, and Comparative Example 2 were molded at a mold temperature of 150 ° C. and injection pressure of 35 kg / cm. ² Was subjected to compression molding to produce a cylindrical molded product having a diameter of 19 mm. A disassembly treatment test was conducted on this prototype. The test was based on immersion in diethanolamine at 200 ° C.
In each sample, the decomposition solution permeation portion was completely decomposed and eluted in the decomposition solution. In particular, the degradability of Examples 1 and 3 was high, and the molding material molded body disappeared by 24 hours, and was completely dissolved in the decomposition solution. On the other hand, for the molded product of Comparative Example 2 which is a conventional mold material, the decomposition rate of the decomposition solution permeation portion is large, but the decomposition rate is very slow. By containing aliphatic polyester at least in the molding material, the degradability is improved. Moreover, it is the decomposition processing method which shows the outstanding decomposability | decomposability similarly with respect to the molding material of this invention which shows the outstanding decomposability | degradability with respect to the decomposition solution which consists of a base and a solvolytic solvent at least.
[0072]
As described above, a molded body of a molding material containing at least an unsaturated polyester, an addition polymerizable monomer, and a thermosetting composition comprising a low shrinkage agent as a binder is completely dissolved and decomposed by immersing it in diethanolamine. be able to. Moreover, the decomposition property with respect to the molding material of the present invention is particularly high.
Of course, the temperature during the decomposition treatment is not limited to the value of this embodiment. However, when the decomposition treatment by the pressure device is not performed, the boiling point of the decomposition solution is preferable.
In addition, the decomposition solution containing diethanolamine is not limited to the blending of the above examples, and may contain other solvents, bases, and the like. Examples of the base include metal hydroxides such as sodium hydroxide, calcium hydroxide and potassium hydroxide, metal oxides such as sodium oxide and calcium oxide, metal alkoxides such as sodium ethoxide and potassium t-butoxide. Can be mentioned. Since these act as catalysts for solvolysis, the degradability is accelerated. In addition, solvolytic solvents such as water, ethanol, methanol, ethylene glycol, ammonia, acetic acid, hydrazine and the like can be mixed. Further, in addition to the solvolytic solvent, a hydrophilic organic solvent such as diethyl ether, dioxane, tetrahydrofuran, acetone, dimethylformamide, dimethylamine or the like can be used by mixing. However, in these cases, care must be taken because the usable temperature range varies depending on the boiling point and the like.
Moreover, the mold material after the decomposition treatment can be reused as each filler and resin synthetic material by means such as separation.
[0073]
【The invention's effect】
As described above, according to the present invention, it is possible to provide a mold material and a mold motor that can be easily decomposed with a decomposition solution containing at least a base and a solvolytic solvent after use.
According to the decomposition treatment method of the present invention, the molding material can be easily decomposed and dissolved.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a molded motor having a molded stator according to the present invention.
FIG. 2 is a perspective view showing an external appearance of a conventional molded motor.
FIG. 3 is a perspective view showing an appearance of a stator portion of a conventional molded motor.
[Explanation of symbols]
10 Motor part
11 Molded stator
12 Insulator
13 Winding
14 Iron core
15 Mold part
16 Rotor shaft
17 Rotor
18 Bracket
19, 20 Bearing
21 Mounting hole
22 Flange

Claims (9)

 A thermosetting resin composition comprising at least an unsaturated polyester, an addition polymerizable monomer, and a low shrinkage agent is included as a binder, and the addition polymerizable monomer includes at least 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate. Mold material characterized by the above.  The molding material according to claim 1, wherein the low shrinkage agent is at least one selected from the group consisting of polyvinyl acetate, butadiene / styrene / methyl methacrylate copolymer, polyhydroxyethyl methacrylate, and ketone resin.   The addition polymerizable monomer includes at least one selected from the group consisting of styrene, vinyl acetate, allyl acetate, allyl acetoacetate, acrylic acid, methyl acrylate, methacrylic acid, and methyl methacrylate. The mold material as described.   A thermosetting resin composition comprising at least an unsaturated polyester, an addition polymerizable monomer, and a low shrinkage agent is included as a binder, the low shrinkage agent is polycaprolactone, and the addition polymerizable monomer is acrylic acid 2- It contains at least one of hydroxyethyl and 2-hydroxyethyl methacrylate and styrene, and the molar fraction of 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate in the total addition polymerizable monomer is 0.4 or more. Mold material characterized by   The mold according to claim 4, further comprising at least one selected from the group consisting of polyvinyl acetate, a butadiene / styrene / methyl methacrylate copolymer, polyhydroxyethyl methacrylate, and a ketone resin as an auxiliary low shrinkage agent. Wood.   In addition, polycaprolactone, polypropiolactone, polylactic acid, polyglycolic acid, polyethylene adipate, polypropylene adipate, polybutylene adipate, polytetramethylene adipate, polyethylene succinate, polypropylene succinate, polybutylene succinate, polycaprolactone diol, polycaprolactone The molding material according to any one of claims 1 to 5, comprising at least one aliphatic polyester selected from the group consisting of a triol and a copolymer of 3-hydroxyalkanoate.   A molded motor in which the molding material according to claim 1 covers at least part of an iron core and a winding. At least unsaturated polyester, an addition polymerizable monomer, and a molded article of a molding material including a low shrinkage agent thermosetting resin composition comprising as a binder, have a step of immersing the decomposition solution containing at least diethanolamine,
The method for decomposing a mold material, wherein the addition polymerizable monomer contains at least 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate . The binder further includes polycaprolactone, polypropiolactone, polylactic acid, polyglycolic acid, polyethylene adipate, polybutylene adipate, polytetramethylene adipate, polyethylene succinate, polybutylene succinate, polycaprolactone diol, polycaprolactone triol, 3 The method for decomposing a molding material according to claim 8, comprising at least one aliphatic polyester selected from the group consisting of copolymers of -hydroxyalkanoate .

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