Molded product and manufacturing method thereof

Abstract

A molded product and a method of manufacturing the same are disclosed, in which the insulating layer of uniform thickness is formed in a narrow clearance between plural metal bodies. Surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically. A spacer polymer which consists of insulating polymer whose melting point is T 1 is arranged between the metal plates, and a molded part which consists of insulating polymer whose melting point is T 2 (<T 1 ) covers surroundings of the metal plates and the spacer polymer.

1 . A molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically, comprising: 
 a spacer polymer arranged between said metal plates, which consists of insulating polymer whose melting point is T 1 , and    a molded part, which covers surroundings of said metal plates and said spacer polymer, and consists of insulating polymer whose melting point is T 2 (<T 1 ).    
   
   
       2 . The molded product according to  claim 1 , wherein the principal ingredient of said insulating polymer of melting point T 1  is aromatic polymer, and the principal ingredient of said insulating polymer of melting point T 2  is polyolefine.  
   
   
       3 . The molded product according to  claim 1 , wherein the bonding layer composed of the adhesive melting point T 3  is in the relation of T 3 <T 1  is provided between said metal plates and said spacer polymer, and between said metal plates and said molded part.  
   
   
       4 . The molded product according to  claim 3 , 
 wherein the first and second bonding layers composed of the adhesive that melting point T 3  is in the relation of T 3 <T 1  are provided between said metal plates and said spacer polymer, and between said metal plates and said molded part, respectively, and    wherein each adhesive which composes said first and second bonding layers has high compatibility.    
   
   
       5 . A method of manufacturing a molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically, comprising the steps of: 
 arranging a first sheet material composed of insulating polymer whose melting point is T 1  between said metal plates spaced at specified intervals,    arranging a first sheet material composed of insulating polymer whose melting point is T 2 (<T 1 ) outside of the outermost metal plates,    hot-pressing molding a laminate of the metal plates, the first sheet material, and the second sheet material at a temperature higher than T 2  but lower than T 1 ,    melting the second sheet material while securing the interval between the metal plates by the first sheet material, and    covering the surroundings of the metal plates and the first sheet material with the molded part composed of insulating polymer whose melting point is T 2 .    
   
   
       6 . A method of manufacturing a molded product, in which surroundings of metal plates spaced at specified intervals are covered with insulating polymer to insulate them electrically, comprising the steps of: 
 arranging a first sheet material composed of insulating polymer whose melting point is T 1  between said metal plates spaced at specified intervals,    arranging a laminate of the metal plates and the first sheet material in the cavity of the injection mold,    injecting insulating polymer whose melting point is T 2  (<T 1 ) heated and melted at a temperature higher than T 2  but lower than T 1  into the cavity, and    covering the surroundings of the metal plates and the first sheet material with the molded part composed of insulating polymer whose melting point is T 2  while securing the interval between the metal plates by the first sheet material.    
   
   
       7 . The method of manufacturing a molded product according to  claim 5 , wherein a plurality of said first sheet materials are arranged between the metal plates.  
   
   
       8 . The method of manufacturing a molded product according to  claim 5 , further comprising the steps of: 
 providing as one first bonding layers and second layers which consist of adhesive whose melting point T 3  is in the relation T 3 <T 1  on surfaces of the first sheet material and surfaces of the metal body sides of the second sheet materials, respectively, and    after hot-pressing molding, bonding the first sheet material to said metal plates by the first bonding layers, and said molded part to said metal plates by the second bonding layers.    
   
   
       9 . The method of manufacturing a molded product according to  claim 8 , 
 wherein each adhesive which composes the first bonding layer and the second bonding layer has compatibility, and the first bonding layer are bonded to the second bonding layer.    
   
   
       10 . The method of manufacturing a molded product according to  claim 6 , further comprising the steps of: 
 providing as one first bonding layers which consist of adhesives whose melting point T 3  is in the relation of T 3 −T 1  on surfaces of the first sheet material, and    after hot-pressing molding, bonding the first sheet material to said metal plates by the first bonding layers.