# US 8,771,566 B2 · Method of fabricating insulating resin material

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- Number: US 8,771,566 B2
- Document ID: US8771566B2
- Status: Granted
- Kind: B2
- Application number: 13/981,196
- Filed: 2012-01-04
- Published: 2013-11-14
- Granted: 2014-07-08
- Earliest claimed: 2011-02-01
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Hiroshi Yanagimoto
- Inventors: Hiroshi Yanagimoto
- Web page: https://patentgrep.com/patent/US8771566B2

## CPC

- H01B 3/441: {from alkenes}
- C08J 3/128: {Polymer particles coated by inorganic and non-macromolecular organic compounds}
- C08J 3/20: Compounding polymers with additives, e.g. colouring
- C08J 5/18: Manufacture of films or sheets
- C09D 1/00: Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
- C09D 7/20: Diluents or solvents
- H01B 3/442: {from aromatic vinyl compounds}
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

The present invention relates to a method of fabricating an insulating resin material (4) from a core/shell particle (3) having a core particle (2) containing a macromolecular compound and a shell layer (1) coating the core particle (2) and containing an inorganic compound. The method of fabrication includes mixing the core/shell particles (3) with a good solvent (10) for the macromolecular compound, infiltrating the good solvent (10) through the shell layer (1), impregnating the good solvent (10) into the macromolecular compound, molding a compact from the impregnated core/shell particles (3), and removing the good solvent from the compact by heating the molded compact.

## Claims

### Claim 1

A method of fabricating an insulating resin material from core/shell particles each having a core particle containing polystyrene and a shell layer coating the core particle and containing an inorganic compound, the method comprising:
a step of mixing the core/shell particles with benzene, toluene, or xylene, infiltrating the mixed benzene, toluene, or xylene into an inside of each of the core/shell particles through the shell layer, and impregnating the polystyrene with the mixed benzene, toluene, or xylene;
a step of molding a compact from the core/shell particles after the impregnation; and
a step of removing the impregnated benzene, toluene, or xylene from the compact by drying the molded compact.

### Claim 2 (depends on 1)

The method of fabricating an insulating resin material, the method according to claim 1, wherein the step of molding the compact is a step of forming an insulating film as the compact surface of a substrate by coating the surface of the substrate with the core/shell particles after the impregnation.

### Claim 3 (depends on 2)

The method of fabricating an insulating resin material, the method according to claim 2,
wherein the substrate is a plate-shaped substrate;
in the step of molding the compact, the insulating film which is the compact is formed by applying the core/shell particles after the impregnation on to the surface of the substrate; and
after the step of removing the impregnated benzene, toluene, or xylene from the compact, the insulating film which is the compact is peeled off from the surface of the substrate.

### Claim 4 (depends on 1)

The method of fabricating an insulating resin material, the method according to claim 1, wherein a thickness of the shell layer of each of the core/shell particles is at least 0.01 μm.