Patent Publication Number: US-2018048205-A1

Title: Insulation wire, rotary electric machine, and manufacturing method of insulation wire

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an insulation wire, a rotary electric machine, and a manufacturing method of the insulation wire. 
     2. Description of the Related Art 
     Presently, a miniaturization and an increasing output power of a rotary electric machine such as a driving motor which is used in household electric machines, industry electric machines, ships, railway vehicles, and electric vehicles are ongoing. Therefore, heat resistance tolerable against the increased heating caused along with the miniaturization and the increasing output power, and pressure resistance (voltage resistance) tolerable against an increasing voltage are requested for an insulation wire used as a winding of the rotary electric machine. 
     Conventionally, as a winding of the rotary electric machine, there is primarily used an enameled wire which is formed by coating and baking varnish obtained by dissolving an insulating resin into a solvent. For example, the enameled wire manufactured by coating and baking polyimide varnish belongs to the H or higher class in heat resistance, and has heat resistance and an insulation property enduring a high temperature environment for a long time. 
     However, a process of coating and baking the varnish is necessarily repeated many times in order to form a predetermined film thickness of the insulation film in such an enameled wire. In addition, the processes have a problem in that the solvent contained in the varnish is left out as a waste in every process. The number of processes of coating and baking the varnish is increased in order to obtain higher voltage resistance, so that the cost is increased. 
     Therefore, as a method of manufacturing the insulation wire, there is considered a method of manufacturing the wire in which a thermoplastic resin is employed as the insulating resin for forming the insulation film by using an extrusion molding without the solvent. It is considered that the method reduces an environmental load and also effective. Further, in the extrusion molding, it is necessary that the thermoplastic resin be heated to a glass transition temperature or higher and be dissolved to be a viscosity suitable to the molding. 
     A super engineering plastic (such as polyphenylene sulfide (PPS) or polyether ether ketone (PEEK)) and a resin alloy thereof are known as the thermoplastic resin belonging to the H-class heat resistance. These materials are chemically stable compared to the conventional thermoplastic resin, and JP-2013-33607-A and JP-04-073811-A disclose examples that these materials are applied to the insulation wire. 
     JP-2013-33607-A discloses an insulation wire which is provided with at least one of the PPS and the PEEK and polyethylene around a conductor, and includes a coating layer having an insulation property with a storage elastic modulus in a predetermined range. In addition, JP-04-073811-A discloses a self-fusing insulation wire which includes an outermost self-bonding layer and an inner insulating layer made of the PPS. 
     The techniques disclosed in JP-2013-33607-A and JP-04-073811-A can form arbitrarily the insulation film by a small number of processes compared to the enameled wire, and can provide the insulation wire having the heat resistance and the pressure resistance. In addition, a resin thin film (layer) made of the super engineering plastic such as the PPS or the PEEK disclosed in JP-2013-33607-A and JP-04-073811-A is formed around the conductor by the extrusion molding. The insulation wire thus manufactured is provided from a wire maker to a maker which produces a rotary electric machine. 
     In general, the rotary electric machine is configured to include a rotor and a stator, and a coil obtained by winding the insulation wire is provided in any one of them. The rotary electric machine generates a rotation force using an induction field caused by the current flowing to the coil so as to rotate the rotor. A centrifugal force, vibrations, and an electromagnetic force are applied to the winding provided in the rotor or the stator as the rotor rotates. 
     The windings rub each other by such a mechanical stress, and the windings rub a surrounding member. Therefore, in order to prevent the insulation film of the winding from being worn out, the maker of the rotary electric machine generally performs a fixing process on the coil using a resin varnish having a thermosetting property such as an epoxy resin and an unsaturated polyester resin. 
     The resin varnish used in the fixing process is used in a highly polarized liquid state in which an epoxy resin and an unsaturated polyester resin are dissolved. On one hand, the PPS or the PEEK is chemically stable, but on the other hand, it is low in affinity. Therefore, the PPS or the PEEK has a problem of a low wettability to an organic solvent, and the insulation wire formed with the PPS or the PEEK in the outermost layer also has a low wettability of the resin varnish. 
     When the wettability of the resin varnish is low with respect to the insulation wire, the resin varnish is also low in permeability between the insulation wires or and between the insulation wire and a surrounding member. Therefore, there is a concern that a fixing process of the coil after curing the resin varnish is not sufficient, or a long-term reliability in driving the rotary electric machine is degraded. From this point of view, the insulation wire is provided by molding the self-bonding layer in the outermost layer of the PPS without using the fixing process in the resin varnish in JP-04-073811-A. 
     SUMMARY OF THE INVENTION 
     The insulation wires disclosed in JP-2013-33607-A and JP-04-073811-A are produced such that the insulation film is peeled off by an arbitrary length from the end to expose the conductor after being processed into the coil, and the exposed end is connected to a power source or a peripheral circuit by welding. At this time, heat caused by welding is transferred through the conductor, and the insulation film (such as the PPS or the PEEK) and the self-bonding layer are heated. When the heat is transferred to the insulation film such as the PPS or the PEEK, the insulation film is lifted up and peeled from the conductor (hereinafter, referred to as “lifting-up and peeling”). In addition, in a case where the self-bonding layer is formed by a thermoplastic resin such as polyester and a phenoxy resin, there is a problem in that the self-bonding layer is melt and peeled off from the insulation film, or a layer thickness is uneven when the welding heat transferred through the conductor exceeds a glass transition temperature or a melting point of the resin. In addition, in a case where a thermosetting resin is used as a coating film of the conductor, the curing is progressed by the welding heat transferred through the conductor, but the self-bonding layer is melt when the temperature exceeds a monomer melting point. Therefore, the same peeling problem occurs. 
     Further, in the case of the rotary electric machine in which the insulation wire is bent near the end of the welding of the insulation wire obtained by processing the coil, a stress occurs due to the bending in a place where the bending is performed. When the welding heat is transferred through the conductor and reaches the place where the stress occurs, cracks are generated in the insulation film, and the insulation Property may be lowered. 
     The invention has been made in view of such a situation, and an object thereof is to provide an insulation wire, a rotary electric machine, and a manufacturing method of the insulation wire in which the insulation film is not subjected to the lifting-up and peeling even when the heat caused by welding is transferred through the conductor, and an insulation property is secured. 
     An insulation wire according to the invention for solving the problem includes: a conductor of any shape; an insulation film made of a first thermoplastic resin that is formed around the conductor; and a self-bonding layer made of a second thermoplastic resin that is formed around the insulation film and has a self-bonding property, wherein the first thermoplastic resin contains at least one of polyphenylene sulfide and polyether ether ketone, and wherein the second thermoplastic resin contains a thermosetting resin and an inorganic filler. 
     In addition, a rotary electric machine according to the invention includes: an insulation wire that includes a conductor of any shape, an insulation film made of a first thermoplastic resin that is formed around the conductor, and a self-bonding layer made of a second thermoplastic resin that is formed around the insulation film and has a self-bonding property, wherein the first thermoplastic resin contains at least one of polyphenylene sulfide and polyether ether ketone, and wherein the second thermoplastic resin contains a thermosetting resin and an inorganic filler; and a rotor or a stator to which the insulation wire is wound. 
     A manufacturing method of an insulation wire according to the invention is a manufacturing method of an insulation wire that includes a conductor of any shape, an insulation film made of a first thermoplastic resin that is formed around the conductor, and a self-bonding layer made of a second thermoplastic resin that is formed around the insulation film and has a self-bonding property, wherein the first thermoplastic resin contains at least one of polyphenylene sulfide and polyether ether ketone, and wherein the second thermoplastic resin contains a thermosetting resin and an inorganic filler, and the method includes: forming the insulation film around the conductor made of any shape by an extrusion molding; and forming the self-bonding layer around the insulation film. 
     According to the invention, it is possible to provide an insulation wire and a rotary electric machine in which an insulation film is not lifted up nor peeled, and an insulation property can be secured even when heat caused by welding is transferred through a conductor. The manufacturing method of the insulation wire according to the invention can manufacture the insulation wire in which the insulation film is not lifted up and peeled, and the insulation property can be secured even when the heat caused by welding is transferred the conductor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic cross-sectional view for describing a configuration of an insulation wire according to an embodiment; 
         FIG. 2  is a schematic cross-sectional view for describing a configuration of the insulation wire according to an embodiment; 
         FIG. 3  is a schematic cross-sectional view illustrating a state where part of a conductor is cut out together with an insulation film and the self-bonding layer from the end of the insulation wire using a tool so as to expose the conductor; 
         FIG. 4  is a schematic cross-sectional view for describing a state after the end of the exposed conductor is heated at a temperature as high as welding; 
         FIG. 5  is a schematic exploded view for describing an aspect of a rotary electric machine according to this embodiment; 
         FIG. 6  is a schematic cross-sectional view for describing a coil which is obtained by winding an insulation wire according to this embodiment around a stator illustrated in  FIG. 5 ; 
         FIG. 7  is a schematic exploded view for describing another aspect of the rotary electric machine according to this embodiment; 
         FIG. 8  is a schematic cross-sectional view for describing the coil which is obtained by winding the insulation wire according to this embodiment around the stator illustrated in  FIG. 7 ; 
         FIG. 9  is a flowchart for describing a manufacturing method of the insulation wire according to this embodiment; 
         FIG. 10  is a schematic view illustrating a configuration of a manufacturing apparatus which implements the manufacturing method of the insulation wire according to this embodiment; 
         FIG. 11  is a schematic view for describing a test piece for simulating a welding portion of the insulation wire according to the example and the comparative example; and 
         FIG. 12  is a schematic view for describing a test piece for simulating the welding portion of the insulation wire according to the example and the comparative example. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Hereinafter, embodiments of an insulation wire and a rotary electric machine according to the invention will be appropriately described in detail with reference to the drawings. 
     (Insulation Wire) 
       FIGS. 1 and 2  are schematic cross-sectional views for describing the configuration of an insulation wire  10  according to an embodiment. As illustrated in  FIGS. 1 and 2 , the insulation wire  10  according to this embodiment includes a conductor  11 , an insulation film  12  which is formed around the conductor  11 , and a self-bonding layer  13  which is formed around the insulation film  12 . The insulation wire  10  according to this embodiment can be applied to a rotary electric machine such as a driving motor which is used in household electric machines, industry electric machines, ships, railway vehicles, and electric vehicles, but not limited thereto. The insulation wire may be applied to any machine as long as a conventional enameled wire can be used to the machine. In other words, the insulation wire  10  according to this embodiment may be used in place of the enameled wire. 
     (Conductor) 
     The conductor  11  may have any shape. The conductor  11  may use, for example, the conductor  11  having the same wire shape as that of a core wire of the typical insulation wire  10 , or may be formed by a copper wire, an aluminium wire, or an alloy wire made of an alloy containing at least one of copper and aluminium. As a copper wire, any one of tough pitch copper, oxygen free copper, and deoxidized copper may be used, or any one of an annealed copper wire and a hard-drawn copper wire may be used. In addition, a wire of which the surface is plated with tin, nickel, silver, or aluminium may be used. As an aluminium wire, a hard-drawn aluminium wire and a semihard-drawn aluminium wire may be used. In addition, as an alloy wire, for example, there may be exemplified a wire formed of a copper-tin alloy, a copper-silver alloy, a copper-zinc alloy, a copper-chromium alloy, a copper-zirconium alloy, an aluminium-copper alloy, an aluminium-silver alloy, an aluminium-zinc alloy, an aluminium-iron alloy, or an aldrey aluminium alloy. 
     The shape of the conductor  11  is desirably a circular wire of which the horizontal cross section is a circulate shape as illustrated in  FIG. 1  for example, and may be a rectangular wire of which the horizontal cross section is a rectangular shape as illustrated in  FIG. 2 . Further, the rectangular wire may have rounded corners. In addition, a single wire formed by one conductor  11  and a strand wire formed by twisting a plurality of conductors  11  may be used. The conductor  11  is desirably subjected to a surface treatment using an organometallic compound such as a silane coupling agent in order to improve adhesiveness to a first thermoplastic resin. The conductor  11  may be manufactured such that a raw material is dissolved to mold an ingot such as a billet or a wire bar, and the ingot may be molded by an extruding process or by an extending process after hot rolling is performed. Further, the conductor  11  may be replaced with one which currently comes into the market. 
     (Insulation Film) 
     The insulation film  12  is formed around the conductor  11  using the first thermoplastic resin. The first thermoplastic resin is made of any one of polyphenylene sulfide (PPS) and polyether ether ketone (PEEK). In other words, with the use of the PPS or the PEEK, the insulation film  12  becomes excellent in an insulation property, heat resistance, chemical resistance, fire retardance, dimension stability, and a mechanical property. 
     The first thermoplastic resin may be a resin alloy to which other resin material and inorganic material are added to the PPS or the PEEK according to required characteristics such as workability, the heat resistance, and the insulation property. As the other resin material and the inorganic material, for example, a thermoplastic resin such as polyamide or thermoplastic polyimide, an inorganic filler such as talc, and a glass fiber may be exemplified. In addition, the PPS or the PEEK may be a modified PPS or a modified PEEK which is partially deformed. Examples of the PPS may include Torelina (registered trademark) T1881 (made by Toray). An arbitrary amount of other resins may be added as needed, and adjusted by kneading. A layer thickness of the insulation film  12  can be arbitrarily selected in consideration of the insulation property and the workability, but it may be desirably equal to 100 μm or more and 200 μm or less in a trend of high output and miniaturization of the rotary electric machine in recent years. 
     (Self-Bonding Layer) 
     The self-bonding layer  13  is formed around the insulation film  12 . The self-bonding layer  13  is formed using a second thermoplastic resin, and has a self-bonding property. In other words, when being activated by heat or solvent, the self-bonding layer  13  is fused with the adjacent self-bonding layer  13 , and forms a larger structure. For example, a winding coil produced by winding the insulation wire  10  around magnetic pole teeth of the rotary electric machine may be used as a coil produced by self-fusing one fusion coil (that is, the self-bonding layer  13  of the winding coil). The second thermoplastic resin contains a thermosetting resin (a thermosetting monomer and a cross-linking agent) and an inorganic filler. In addition, the self-bonding layer  13  contains a curing agent. 
     The second thermoplastic resin contains at least one of a phenoxy resin and a polyamide resin, and these resins may be mixed together at an arbitrary ratio. In other words, a mixing ratio of the phenoxy resin and the polyamide resin as the second thermoplastic resin may be set such that the polyamide resin becomes 100 to 0 parts by weight with respect to 0 to 100 parts by weight of the phenoxy resin. Preferably, for example, the polyamide resin is set to 20 or more parts by weight with respect to a total 100 parts by weight of the phenoxy resin and the polyamide resin, and more preferably, the polyamide resin is set to 40 or more parts by weight with respect to a total 100 parts by weight of the phenoxy resin and the polyamide resin. 
     As an example of the phenoxy resin, YP-70 or ZX-1356-2 (a copolymer made of a bisphenol A epoxy resin and bisphenol F epoxy resin) made by Nippon Steel &amp; Sumikin Chemical Co., Ltd. may be used. In addition, as an example of the phenoxy resin, YP-50 or FX-316 (a bisphenol A phenoxy resin and a bisphenol F phenoxy resin) by Nippon Steel &amp; Sumikin Chemical Co., Ltd. may be used. As an example of the polyamide resin, CM3007 (PA66 excellent in flexibility) made by Toray and UBESTA XPA (registered trademark) made by Ube Industries, Ltd. may be used, and a resin composition produced by blending these resins into the phenoxy resin at an arbitrary ratio may be used. 
     For example, an epoxy compound may be suitably used as the thermosetting monomer. A content of the thermosetting monomer may be appropriately set and, for example, desirably 5 or more parts by weight and 30 or less parts by weight with respect to 100 parts by weight of the second thermoplastic resin. The epoxy compound may be, for example, produced by mixing one or two or more resins selected from an aromatic epoxy resin, an alicyclic epoxy resin, a novolac epoxy resin, an aliphatic epoxy resin, a glycidyl ester type epoxy resin, a glycidyl amine type epoxy resin, a glycidyl acrylic type epoxy resin, a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, and a polyester type epoxy resin. As the epoxy compound, it is desirable to use a multifunctional epoxy resin which can increase a cross-linking density in a case where an adhesive strength is improved and heat resistance is increased. 
     The curing agent is also called the cross-linking agent, and serves to cure (cross-link) the thermosetting monomer. A composition of the second thermoplastic resin desirably contains a curing catalyst which accelerates a reaction between the thermosetting monomer and the curing catalyst at an arbitrary ratio. A content of the curing agent can be appropriately set in accordance with an equivalent ratio of the cross-linking agent and, for example, desirably 5 or more parts by weight and 30 or less parts by weight with respect to 100 parts by weight of the second thermoplastic resin. As the curing agent, a phenol resin or an acid anhydride can be used for example. As the phenol resin, a phenol aralkyl resin (having a phenol skeleton, or a dephenylene skeleton), a naphthol aralkyl resin, and a polyoxystyrene resin may be used for example. In addition, as the phenol resin, a resol type phenol resin such as an aniline modified resol resin, a demethyl ether resol resin, a novolac type phenol resin such as a phenol novolac resin, a cresol novolac resin, a tert-butyl phenol novolac resin, and a nonyl phenol novolac resin, and a specific phenol resin such as a dicyclopentadiene modified phenol resin, a terpene modified phenol resin, and a triphenolmethane type resin may be used for example. In addition, as a polyoxystyrene resin, a poly (p-oxystyrene) phenol novolac-based resin may be used. As the acid anhydride, a tetrahydro phthalic anhydride and a hexahydro phthalic anhydride may be used for example. 
     As the curing catalyst, for example, in a case where the self-bonding layer  13  is subjected to the extrusion molding, a high temperature type of imidazoles are desirably used which do not progress in a cross-linking reaction by the extrusion molding. The content of the curing catalyst can be appropriately set and, for example, desirably 0.1 or more parts by weight and 5 or less parts by weight with respect to 100 parts by weight of the second thermoplastic resin. 
     Since the self-bonding layer  13  contains the inorganic filler (not illustrated), the pressure resistance and the insulation property of a place to be bent in the insulation wire  10  can be improved. In addition, since the self-bonding layer  13  contains the inorganic filler, thixotropy can be obtained, and it is possible to suppress deformation and sagging at the time of thermal curing. 
     The inorganic filler is desirably formed in at least one of a plate shape and a squamous shape. Therefore, the pressure resistance and the insulation property are more securely improved, and the deformation at the time of thermal curing and the thermal sagging caused by heat transferred at the time of welding can be more securely suppressed. As the inorganic filler, any material may be used as long as the material is an inorganic material such as mica, glass flake, and aluminium hydroxide for example. As the inorganic filler, glass flake made by Nippon Sheet Glass Co., Ltd. and mica made by Yamaguchi Mica Co., Ltd. may be used for example. The content of the inorganic filler is not particularly limited as long as the workability and the insulation property are satisfied, and roughly 10 or more parts by weight and 30 or less parts by weight are practical. 
     A layer thickness of the self-bonding layer  13  is not Particularly limited as long as the adhesiveness between the insulation wires  10 , the adhesiveness between the insulation wire  10  and the other member (not illustrated), and the adhesiveness between the insulation wire  10  and insulating varnish are obtained by the fusion, and desirably roughly 5 μm or more and 50 μm or less. 
     In addition, the insulation wire  10  according to this embodiment desirably is subjected to atmospheric pressure plasma treatment after the insulation film  12  is formed, and then the self-bonding layer  13  is formed. By performing the atmospheric pressure plasma treatment, the wettability of the insulation film  12  is improved, and the adhesiveness to the self-bonding layer  13  can be improved. 
     Further, the effect of improving the adhesiveness between the insulation film  12  and the self-bonding layer  13  obtained by the atmospheric pressure plasma treatment is vanished within a period from several hours to several days. Therefore, it can be said that it is not possible to determine whether the process is performed through analysis on the surface of the insulation film  12  of the insulation wire  10  using an analysis machine after the wire is commercialized and some periods elapse. However, a reference of whether the process is performed may be determined as follows. For example, part of the conductor  11  is cut out together with the insulation film  12  and the self-bonding layer  13  from the end of the insulation wire  10  using a tool such as an electric wire stripper so as to expose the conductor  11  (see  FIG. 3 , and  FIG. 3  will be described below). Then, it is possible to make a determination by observing the presence/absence of the lifting-up and peeling of the insulation film  12  after the exposed conductor  11  is welded on a condition that the insulation film  12  and the self-bonding layer  13  are not carbonized. In this case, when the atmospheric pressure plasma treatment is performed, the adhesiveness between the insulation film  12  and the self-bonding layer  13  is improved, and the insulation film  12  is coated with the self-bonding layer  13 , so that the lifting-up and peeling does not occur (mostly). On the contrary, in a case where the atmospheric pressure plasma treatment is not performed, the adhesiveness between the insulation film  12  and the self-bonding layer  13  is not improved, so that the self-bonding layer  13  is shrunk more than the insulation film  12 . Therefore, an uncoated portion of the insulation film  12  is increased, and the lifting-up and peeling occurs. In other words, whether the atmospheric pressure plasma treatment is performed can be determined in this embodiment by performing such an observation test. 
     As described above, the self-bonding layer  13  is activated by heat and solvent and thus shows the self-bonding property. In other words, the self-bonding layer  13  of the unwelded insulation wire  10  contains an uncured thermosetting monomer (not used in the self-bonding). Therefore, when the heat caused by welding is transferred through the conductor  11  to heat the self-bonding layer  13 , the self-bonding layer  13  is activated by the heat, and the resin is cured and shrunk. On the contrary, since the insulation film  12  does not contain the thermosetting monomer, the curing and shrinking of the resin caused by the thermosetting monomer does not occur. Therefore, a thermal shrinkage of the insulation film  12  is smaller than that of the self-bonding layer  13 , and the insulation film  12  is hardly shrunk. Further, in the case of the insulation wire  10  according to this embodiment, the self-bonding layer  13  contains the inorganic filler, so that the curing and shrinking is reduced compared to the self-bonding layer which does not contain the inorganic filler. Furthermore, in the case of the insulation wire  10  according to this embodiment, when the surface of the insulation film  12  is subjected to the surface treatment such as the atmospheric pressure plasma treatment to increase the adhesive strength of the self-bonding layer  13 , the adhesiveness between the insulation film  12  and the self-bonding layer  13  can be improved. Therefore, the curing and shrinking of the self-bonding layer  13  can be reduced still more. 
     Accordingly, when the welding is performed using the insulation wire  10  according to this embodiment and the rotary electric machine is manufactured, the insulation film  12  and the self-bonding layer  13  enter the states as illustrated in  FIGS. 3  and  4 . Further,  FIG. 3  is a schematic cross-sectional view for describing a state where part of the conductor  11  is cut out together with the insulation film  12  and the self-bonding layer  13  from the end of the insulation wire  10  using a tool (not illustrated) so as to expose the conductor  11 .  FIG. 4  is a schematic cross-sectional view for describing a state after the end of the exposed conductor  11  is heated at a temperature as high as the welding. 
     First, as illustrated in  FIG. 3 , part of the conductor  11  is cut out together with the insulation film  12  and the self-bonding layer  13  from the end of the insulation wire  10  using a tool such as an electric wire stripper so as to expose the conductor  11 . Therefore, a diameter of the exposed portion of the conductor  11  becomes narrow. In addition, at this time, the ends of the insulation film  12  and the self-bonding layer  13  are placed at the same position P. Next, when the exposed conductor  11  is welded, the insulation film  12  and the self-bonding layer  13  are shrunk by the heat as illustrated in  FIG. 4 . However, as described above, the insulation film  12  is hardly shrunk since the thermosetting monomer is not contained. In addition, since the self-bonding layer  13  contains the inorganic filler in this embodiment, the shrinkage can be reduced more than the self-bonding layer which does not contain the inorganic filler. Further, since the self-bonding layer  13  in this embodiment contains the inorganic filler, the insulation property is improved, and the thermal sagging can also be suppressed. 
     Therefore, when the welding is performed using the insulation wire  10  according to this embodiment, the welding portion is formed such that a difference between a distance (a distance where the conductor  11  is exposed) W 1  from the position P where the insulation film  12  and the self-bonding layer  13  are removed before welding to the end of the insulation film  12  after welding, and a distance W 2  from the position P where the insulation film  12  and the self-bonding layer  13  are removed before welding to the end of the self-bonding layer  13  after welding is reduced as illustrated in  FIG. 4 . In other words, even when the insulation wire  10  according to this embodiment is welded, the self-bonding layer  13  can coat the insulation film  12 . Further, in the case of the self-bonding layer which does not contain the inorganic filler, a distance W 3  (illustrated by a broken line in  FIG. 4 ) from the position P where the insulation film is removed before welding to the end of the self-bonding layer after welding is increased more than the distance W 2 . In other words, in this case, the self-bonding layer cannot coat the insulation film when the welding is performed. Therefore, the lifting-up and peeling occur, and the insulation property cannot be secured. 
     As described above, when the welding is performed using the insulation wire  10  according to this embodiment, the insulation film  12  and the self-bonding layer  13  are hardly shrunk in a connection point of the welding between the insulation wires  10  or the welding to another conductive member. Therefore, the insulation property can be improved. In addition, since the insulation film  12  is coated with the self-bonding layer  13  which contains the inorganic filler, the lifting-up and peeling of the insulation film  12  can be prevented even when the welding heat is transferred through the conductor  11 . Further, in a case where there is a bent place in the insulation wire  10 , the pressure resistance and the insulation property of the bent place can be improved since the insulation film  12  is coated with the self-bonding layer  13  which contains the inorganic filler. 
     (Rotary Electric Machine) 
     Next, the rotary electric machine according to this embodiment will be described with reference to  FIGS. 5 to 8 . Further,  FIG. 5  is a schematic exploded view for describing an aspect of a rotary electric machine  20  according to this embodiment.  FIG. 6  is a schematic cross-sectional view for describing the coil  22  which is obtained by winding the insulation wire  10  according to this embodiment around the stator illustrated in  FIG. 5 .  FIG. 7  is a schematic exploded view for describing another aspect of the rotary electric machine  20  according to this embodiment.  FIG. 8  is a schematic cross-sectional view for describing the coil which is obtained by winding the insulation wire  10  according to this embodiment around the stator illustrated in  FIG. 7 . 
     As illustrated in  FIG. 5 , a rotary electric machine  20 A according to this embodiment includes a stator  21 , a rotor  22 A, a first housing  23 , and a second housing  24 . The rotary electric machine  20 A according to this embodiment includes the rotor  22 A on the outside of the stator  21 , and is generally called an outer rotor type of rotary electric machine. The insulation wire  10  is wound around magnetic pole teeth  21 A of the stator  21  to form the coil  22  as illustrated in  FIG. 6 . Then, the insulation wire  10  is welded to another insulation wire  10  or the other conductive member at an arbitrary place of the stator  21 . The welded place is coated by the insulating varnish (not illustrated) not to make the conductor  11  exposed together with the insulation film  12  and the self-bonding layer  13 , and cured. Further, as the insulating varnish, for example, powder varnish F-219 (made by Somar Co., Ltd.) may be used, but not limited thereto. Any insulating varnish may be used as long as the exposed portion of the conductor  11 , the insulation film  12 , and the self-bonding layer  13  can be coated. 
     The first housing  23  and the second housing  24  each are made of metal (desirably nonmagnetic metal) in a bottomed cylindrical shape. The first housing  23  and the second housing  24  are provided with the stator  21  and the rotor  22 A inside the cylinder, and connected by an arbitrary fitting structure such as a welding and a screw. 
     The rotor  22 A is provided on the outside of the stator  21 , and includes a permanent magnet (not illustrated) which generates a magnetic field. The rotor  22 A is supported by a bearing which is provided in the first housing  23  and the second housing  24  to be rotatable on the outside of the stator  21 . Since the rotary electric machine  20 A with such a configuration includes the rotor  22 A on the outside of the stator  21 , a large torque is easily obtained. There is an advantage that the rotation is stable in the case of a constant rotation. 
     In addition, as illustrated in  FIG. 7 , a rotary electric machine  20 B according to this embodiment includes the stator  21 , a rotor  22 B, the first housing  23 , and the second housing  24 . The rotary electric machine  20 B according to this embodiment includes the rotor  22 B in the inside of the stator  21 , and is generally called an inner rotor type of rotary electric machine. The insulation wire  10  is wound around magnetic pole teeth  21 B of the stator  21  to form the coil  22  as illustrated in  FIG. 8 . Then, the insulation wire  10  is welded to another insulation wire  10  or the other conductive member at an arbitrary place of the stator  21 . Further, the stator  21 , the first housing  23 , and the second housing  24  are the same as described above, and thus the description thereof will be omitted. 
     The rotor  22 B is provided on the inside of the stator  21 , and includes a permanent magnet (not illustrated) which generates a magnetic field. The rotor  22 B is supported by a bearing which is provided in the first housing  23  and the second housing  24  to be rotatable on the inside of the stator  21 . Since the rotary electric machine  20 B with such a configuration includes the rotor  22 B on the inside of the stator  21 , responsiveness is excellent. Since the coil is provided on the outside, heat radiation is excellent. 
     In the rotary electric machine  20  ( 20 A and  20 B) according to this embodiment described above, the insulation wire  10  according to this embodiment is used for the coil  22 , so that the insulation film  12  and the self-bonding layer  13  are hardly shrunk at the welded place between the insulation wires  10  or to the other conductive member, so that the insulation property can be improved. In addition, since the insulation film  12  is coated with the self-bonding layer  13  which contains the inorganic filler, the lifting-up and peeling of the insulation film  12  can be prevented even when the welding heat is transferred through the conductor  11 . Further, in a case where there is a bent place in the insulation wire  10 , the pressure resistance and the insulation property of the bent place can be improved since the insulation film  12  is coated with the self-bonding layer  13  which contains the inorganic filler. 
     (Manufacturing Method of Insulation Wire) 
     Next, a manufacturing method of the insulation wire according to this embodiment will be described with reference to  FIGS. 9 and 10 . Further,  FIG. 9  is a flowchart for describing the manufacturing method of the insulation wire according to this embodiment.  FIG. 10  is a schematic view illustrating a configuration of a manufacturing apparatus which implements the manufacturing method of the insulation wire according to this embodiment. 
     As illustrated in  FIG. 9 , the manufacturing method of the insulation wire  10  according to this embodiment includes an insulation film forming process S 2  and a self-bonding layer forming process S 4 , and performs these processes in this order. The manufacturing method of the insulation wire  10  according to this embodiment illustrated in  FIG. 9  may be performed according to the manufacturing method of the insulation wire  10  by a typical extrusion molding illustrated in  FIG. 10 . Hereinafter, the manufacturing method of the insulation wire  10  according to this embodiment will be described in detail. 
     (Insulation Film Forming Process) 
     The insulation film forming process S 2  is a process of forming the insulation film  12  by the extrusion molding around the conductor  11  produced in a predetermined arbitrary shape. The conductor  11  and the insulation film  12  used in the insulation film forming process S 2  are equal to those described above, and the description thereof will be omitted. The insulation film forming process S 2  is mainly performed using a first kneading extrusion molding machine  41  illustrated in  FIG. 10 . The first kneading extrusion molding machine  41  includes a cross-head die  42  which is provided with a mouse piece corresponding to the shape of the conductor  11 . 
     A first thermoplastic resin  43  prepared in a pelletized state is inserted to a hopper/input port  44  of the first kneading extrusion molding machine  41 , and supplied to a cylinder (not illustrated). The first thermoplastic resin  43  is kneaded in a melt state in the cylinder, and then supplied to the cross-head die  42 . 
     Further, in a case where the first thermoplastic resin  43  is the resin composition, each component of the resin composition may be inserted to the hopper/input port  44  of the first kneading extrusion molding machine  41  in place of Pelletizing. In this case, each component is melt and kneaded in the cylinder to make the resin composition, and supplied to the cross-head die  42 . 
     In the cross-head die  42 , the streak conductor  11  to be the core wire passes through. The conductor  11  is obtained by the extending process in which a wire diameter is gradually reduced to a predetermined level by passing through the die. It is desirable that the conductor  11  be heated in a heating furnace  30  provided before the first kneading extrusion molding machine  41  in order to help the extending process. A heating temperature of the conductor  11  in the heating furnace  30  is desirably 300° C. for example. When passing through the cross-head die  42 , the resin composition of the melt first thermoplastic resin  43  is coated to form a thin film around the conductor  11 . Thereafter, the conductor  11  formed with the thin film is crystallized after passing through an electric furnace  45  and cooled down in a water bath (not illustrated) so as to form the insulation film  12  around the conductor  11 . Further, in the explanation of the manufacturing method, the conductor  11  formed with the insulation film  12  so far may be called a “coated wire  46 ”. 
     (Self-Bonding Layer Forming Process) 
     The self-bonding layer forming process S 4  is a process of forming the self-bonding layer  13  around the insulation film  12  which is formed in the insulation film forming process S 2 . The self-bonding layer  13  used in the self-bonding layer forming process S 4  is the same as described, and the description thereof will be omitted. The self-bonding layer forming process S 4  is performed mainly using a second kneading extrusion molding machine  61  illustrated in  FIG. 10 . The second kneading extrusion molding machine  61  includes a cross-head die  62  which is provided with a mouse piece corresponding to the shape of the coated wire  46 . 
     A second thermoplastic resin  63  prepared in a pelletized state is inserted to a hopper/input port  64  of the second kneading extrusion molding machine  61 , and supplied to a cylinder (not illustrated). The second thermoplastic resin  63  is kneaded in a melt state in the cylinder, and then supplied to the cross-head die  62 . 
     Further, in a case where the second thermoplastic resin  63  is the resin composition, each component of the resin composition may be inserted to the hopper/input port  64  of the second kneading extrusion molding machine  61  in place of pelletizing. In this case, each component is melt and kneaded in the cylinder to make the resin composition, and supplied to the cross-head die  62 . 
     In the cross-head die  62 , the coated wire  46  passes through. The coated wire  46  is obtained by the extending process in which a wire diameter is gradually reduced to a predetermined level by passing through the die. When passing through the cross-head die  62 , the resin composition of the melt second thermoplastic resin  63  is coated to form a thin film around the coated wire  46 . Thereafter, the coated wire  46  formed with the thin film is cooled down in the water bath so as to form the insulation wire  10  in which the self-bonding layer  13  is formed around the insulation film  12 . 
     As Illustrated in  FIGS. 1 and 2 , the cross section of the insulation wire  10  manufactured as described above is formed such that the insulation film  12  made of the first thermoplastic resin is formed around the conductor  11  and the self-bonding layer  13  is formed around the insulation film  12 . 
     (Desirable Aspect of Manufacturing Method) 
     As a desirable aspect of the manufacturing method of the insulation wire  10  according to this embodiment, a conductor surface treatment process S 1  is provided before the insulation film forming process S 2  as illustrated in  FIG. 9 . In addition, as a desirable aspect of the manufacturing method of the insulation wire  10  according to this embodiment, an insulation film surface treatment process S 3  is provided between the insulation film forming process S 2  and the self-bonding layer forming process S 4  as illustrated in  FIG. 9 . It is desirable that the conductor surface treatment process S 1  and the insulation film surface treatment process S 3  are performed rather than performing only any one of them. Hereinafter, a desirable aspect of these processes will be described. 
     (Conductor Surface Treatment Process) 
     The conductor surface treatment process S 1  is a process of performing a surface treatment on the surface of the conductor  11  to increase the adhesive strength of the insulation film  12 . In the conductor surface treatment process S 1 , the surface of the conductor  11  is desirably treated using the organometallic compound for example. Therefore, the organometallic compound interposed between the surface of the conductor  11  of an inorganic material and the surface of the insulation film  12  of an organic material serves to strongly bond the two. Therefore, since the conductor  11  and the insulation film  12  are strongly bonded, the insulation film  12  is more hardly lifted up and peeled off even when the heat caused by welding is transferred through the conductor  11 . As an example of such an organometallic compound, there is the silane coupling agent. When the silane coupling agent is used as the organometallic compound, the conductor  11  and the insulation film  12  can be more securely and strongly bonded. Therefore, the insulation film  12  is more hardly lifted up and peeled off even when the heat caused by welding is transferred through the conductor  11 . The conductor surface treatment process S 1  may be performed by a medical coating apparatus (not illustrated) in  FIG. 10 . As an example of the medical coating apparatus, there are a dip coater, a roll coater, a die coater, and a spray coater. 
     (Insulation Film Surface Treatment Process) 
     The insulation film surface treatment process S 3  is a process of performing a surface treatment on the surface of the insulation film  12  to increase the adhesive strength of the self-bonding layer  13 . As an example of such a surface treatment, a physical roughening treatment such as oxidation treatment in which the surface of the insulation film  12  is treated using ozone or a strong acid, a chemical coupling treatment, atmospheric pressure plasma treatment, and sand blast treatment may be arbitrarily selected. As the surface treatment in the insulation film surface treatment process S 3 , it is desirable that the atmospheric pressure plasma treatment among these treatments be applied. In a case where the atmospheric pressure plasma treatment is applied, a plasma atmosphere may be arbitrarily selected from nitride gas, oxygen gas, and argon gas. 
     The insulation film surface treatment process S 3  is desirably performed by a surface treatment apparatus  51  provided between the electric furnace  45  and the second kneading extrusion molding machine  61  (desirably between the water bath (not illustrated in  FIG. 10 ) disposed after the electric furnace  45  and the second kneading extrusion molding machine  61 ). Further, in  FIG. 10 , the surface treatment apparatuses  51  are provided one by one to interpose the coated wire  46  in a vertical direction to irradiate an atmosphere pressure plasma  52 , but not limited thereto. A plurality of surface treatment apparatuses  51  may be provided in parallel with the coated wire  46  to irradiate the atmosphere pressure plasma  52 . In addition, the number of surface treatment apparatuses  51  may be one, or three or more. In a case where an atmospheric pressure plasma apparatus is used as the surface treatment apparatus  51 , a cross-sectional shape of the nozzle which irradiates the plasma may be a circular shape or a rectangular shape. 
     As described above, the manufacturing method of the insulation wire  10  according to this embodiment sequentially performs at least the insulation film forming process S 2  and the self-bonding layer forming process S 4 , so that the insulation wire  10  according to this embodiment can be manufactured. 
     EXAMPLES 
     Next, the insulation wire according to the invention will be specifically described using examples and comparative examples, but the technical scope of the invention is not limited thereto. 
     The materials used in the examples and the comparative examples are as follows. 
     [Materials] 
     First thermoplastic resin: PPS (Torelina T1881 made by Toray)
 
Second thermoplastic resin (1): Phenoxy resin (YP-70 made by Nippon Steel &amp; Sumikin Chemical Co., Ltd.)
 
Second thermoplastic resin (2): Polyamide resin (XPA-9063X made by Ube Industries)
 
Cross-linking agent: Epoxy resin (EP-1011 made by Mitsubishi Chemical Corporation)
 
Curing agent: Phenol-based curing agent (H-4 made by Meiwa Plastic Industries Ltd.)
 
Curing catalyst: imidazole-based curing accelerator (2PHZ-PW made by Shikoku Chemicals Corporation)
 
Inorganic filler: Mica powder (A-11 made by Yamaguchi Mica Co., Ltd.)
 
     The composition of the self-bonding layer used in the examples and the comparative examples are listed in Table 1. Further, a unit of numerical values listed in Table 1 is “part by weight”. In Table 1, “-” indicates “No containing”. 
     
       
         
           
               
               
               
               
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                   
                   
                   
                 First 
                 Second 
               
               
                   
                 First 
                 Second 
                 Third 
                 comparative 
                 comparative 
               
               
                   
                 example 
                 example 
                 example 
                 example 
                 example 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Second 
                 100 
                 — 
                 60 
                 100 
                 100 
               
               
                 thermoplastic 
               
               
                 resin (1) 
               
               
                 Second 
                 — 
                 100 
                 40 
                 — 
                 — 
               
               
                 thermoplastic 
               
               
                 resin (2) 
               
               
                 Cross-linking 
                 12.5 
                 12.5 
                 12.5 
                 — 
                 12.5 
               
               
                 agent 
               
               
                 Curing agent 
                 9.4 
                 12.5 
                 12.5 
                 — 
                 12.5 
               
               
                 Curing catalyst 
                 1.3 
                 1.3 
                 1.3 
                 — 
                 0.63 
               
               
                 Inorganic filler 
                 25 
                 25 
                 25 
                 — 
                 — 
               
               
                   
               
            
           
         
       
     
     First Example 
     In a first example, Torelina T1881 was used as the first thermoplastic resin, and YP-70 (phenoxy resin) was used as the second thermoplastic resin. EP-1011 was used as the cross-linking agent, H-4 was used as the curing agent, 2PHZ-PW was used as the curing catalyst, and A-11 was used as the inorganic filler. In addition, a 1.52 mm×3.19 mm rectangular copper wire (single wire) was used as a conductor serving as the core wire. 
     The insulation wire according to this example was manufactured as follows. First, a conductor preheated at 300° C. in the heating furnace was passed to the cross head of the kneading extrusion molding machine to which the PPS was inserted and a PPS insulation film was formed around the conductor. At this time, a cylinder supply speed of the extrusion molding machine and a sending speed of the conductor were adjusted to make a film thickness of the insulation film equal to or more than about 100 μm. Thereafter, the insulation film was cooled down to about 130° C. by the air to accelerate the crystallization of the insulation film, and passed through the electric furnace set to 130° C. 
     Next, the atmospheric pressure plasma treatment (the insulation film surface treatment) was performed on the surface (that is, the surface of the insulation film) of the wire formed with the insulation film. The atmospheric pressure plasma treatment was performed using the atmosphere pressure plasma the surface treatment apparatus (FG5001) made by Plasmatreat Gmbh. The treatment was performed such that a pair of plasma irradiation nozzles connected to the apparatus was disposed to face the wire formed with the insulation film to directly expose two wide surfaces of the rectangular wire to the plasma. The nitride gas was used as the plasma atmosphere. 
     Next, the resin composition containing the second thermoplastic resin (1) was made at a ratio according to the first example of Table 1, and kneaded and backed using a two-shaft mixer. Then, the obtained pellets were inserted to the kneading extrusion molding machine, and the wire subjected to the atmospheric pressure plasma treatment was passed to the pellet to form the self-bonding layer around the insulation film. At this time, the cylinder supply speed of the kneading extrusion molding machine was adjusted to make the film thickness of the self-bonding layer equal to or less than 50 μm. 
     The obtained wire was cooled by passing through the water bath, and the insulation wire was obtained. The film thickness of the PPS insulation film in the insulation wire thus obtained was about 110 μm, and the film thickness of the phenoxy resin self-bonding layer was about 40 μm. 
     Subsequently, the adhesiveness between the insulation film and the self-bonding layer was confirmed using the obtained insulation wire by the following scheme to simulate the welding at the time of processing the coil. The obtained insulation wire was cut out by about 10 cm, and the insulation film  12  and the self-bonding layer  13  on one of the ends of the insulation wire  10  were cut out by about 1 cm using the electric wire stripper so as to expose the conductor  11  as illustrated in  FIG. 3 . Further, any wire stripper may be used. However, in this example, the electric wire stripper was used to peel off the insulation film  12  and the self-bonding layer  13  while a wire bush wheel rotated. Herein, in a case where residues of the insulation film  12  or the self-bonding layer  13  are left in the surface of the conductor  11 , an adhesive failure may be caused when the sealing is performed using an insulating material again after welding. Therefore, the insulation film  12  was peeled off such that a small amount of the conductor  11  was cut out. For this reason, as illustrated in  FIG. 3 , the thickness of the conductor  11  in a peeled portion  14  is different from that in a portion (a non-peeled portion) where the conductor  11  is coated with the insulation film  12  and the self-bonding layer  13 . Further, in the surface of the conductor  11  of the peeled portion  14 , scrapes were visually confirmed which were generated by polishing when the insulation film  12  and the self-bonding layer  13  were peeled off. 
     Subsequently, as illustrated in  FIG. 11 , the insulation wires  10  and  10  of which the conductors  11  at the end were exposed were overlapped, and the exposed conductors  11  at the end were welded by a tungsten-inactive gas welding. In this example, the welding was performed while paying attention not to heat up the insulation film  12  and the self-bonding layer  13  by a pulse welding so as to achieve a strength of a welding portion  15 . 
     Further, when being excessively heated during the welding in the state illustrated in  FIG. 11 , the insulation film  12  and the self-bonding layer  13  are carbonized to be black or discolored. In such a welding condition, when the insulating varnish having a thermosetting property is coated in the exposed portion of the conductor  11  after welding, the conductor  11 , the insulation film  12 , and the self-bonding layer  13  are hardly bonded with the insulating varnish. Therefore, a current and a frequency at the time of welding were adjusted to perform the welding on an optimized conduction. In other words, the welding was performed on a condition that the insulation film  12  and the self-bonding layer  13  were carbonized to be black or discolored. 
     A state in an interface portion of the insulation wire  10  welded as described above with respect to the conductor  11 , the insulation film  12 , and the self-bonding layer  13  was observed. As a result, the insulation film  12  and the self-bonding layer  13  was slightly shrunk by the heat at the time of welding (see  FIG. 4 ), but the peeling of the insulation film  12  from the conductor  11  (the lifting-up and peeling), and the peeling of the self-bonding layer  13  from the insulation film  12  (the lifting-up and peeling) were not found. 
     In addition, the insulation wire  10  according to the first example was measured about the distances such as the distance W 1  (the distance of the exposed conductor  11 ) from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the insulation film  12 , and the distance W 2  from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the self-bonding layer  13  after welding (see  FIG. 4 ). The measurement was made on both side surfaces, the upper surface, and the lower surface, and an average value was taken. As a result, it was confirmed that W 1 &lt;W 2  was satisfied. This relation shows that the thermal shrinkage of the self-bonding layer  13  is larger than that of the insulation film  12 . As a reason, since the self-bonding layer  13  contains the curing agent having a thermosetting property and the cross-linking agent, the curing and shrinking occurs by the heat at the time of welding. However, since the self-bonding layer  13  contains the inorganic filler in this embodiment, it is considered that the distance of the curing and shrinking is shortened compared to the self-bonding layer not containing the inorganic filler. In addition, in this embodiment, the surface of the insulation film  12  is subjected to the atmospheric pressure plasma treatment to improve the adhesiveness between the insulation film  12  and the self-bonding layer  13 . Therefore, it is considered that the distance of the curing and shrinking is shortened compared to the self-bonding layer not subjected to the atmospheric pressure plasma treatment. Further, the distance W 1  of the exposed conductor  11  by the welding became longer than a distance W 4  of the exposed insulation film  12  by the welding (W 1 &gt;W 4 ). Therefore, it was confirmed that the insulation wire  10  according to the first example was in a desirable aspect from the viewpoint of coating the insulation film  12  with the self-bonding layer  13 . 
     Then, as illustrated in  FIG. 12 , insulating varnish  16  having the thermosetting property was coated and cured in the welding portion where the exposed conductor  11  (not illustrated in  FIG. 12 ) was exposed. In this embodiment, the powder varnish F-219 (made by Somar Co., Ltd.) was used as the insulating varnish  16 . The adhesiveness of the cured insulating varnish  16  with respect to the insulation film  12  and the self-bonding layer  13  (all not illustrated in  FIG. 12 ) was peeled out by a cutter (not illustrated) for the evaluation. As a result, the insulating varnish  16  was pulverized, and part of the insulating varnish  16  was strongly bonded and left onto the insulation film  12  and the self-bonding layer  13 . In other words, it was confirmed that the insulation wire  10  according to the first example was possible to strongly make the insulating varnish  16  adhere to the insulation film  12  and the self-bonding layer  13 . Since the phenoxy resin used in the self-bonding layer  13  includes a hydroxyl group having a polarity in a molecular structure, the phenoxy resin has a strong interaction between molecules. As a result, it is estimated that the phenoxy resin contributes to the improvement of the adhesiveness. 
     As described above, it was confirmed that the insulation wire  10  according to the first example had a good adhesiveness between the insulation film  12  and the self-bonding layer  13  in a welding process which was implemented when the rotary electric machine was manufactured, and an insulation sealing process which was performed on the exposed portion of the conductor  11  thereafter. In other words, it was confirmed that the insulation film  12  did not suffer the lifting-up and peeling in the insulation wire  10  according to this example even when the heat caused by welding was transferred to the conductor  11 , and the insulation property was secured. 
     Second Example 
     The insulation wire  10  according to a second example was manufactured similarly to that of the first example except that the second thermoplastic resin (2) was used in place of the second thermoplastic resin (1) (see Table 1). Then, the welding when the coil was processed was simulated similarly to the first example using the insulation wire  10  according to the second example, and the performance of the adhesiveness between the insulation film  12  and the self-bonding layer  13  was confirmed. 
     As a result, it was confirmed that the insulation film  12  and the self-bonding layer  13  of the insulation wire  10  according to the second example was slightly shrunk by the heat at the time of welding (see  FIG. 4 ). However, the peeling (the lifting-up and peeling) of the insulation film  12  from the conductor  11  and the peeling (the lifting-up and peeling) of the self-bonding layer  13  from the insulation film  12  were not found. 
     In addition, the insulation wire  10  according to the second example was measured about the distances such as the distance W 1  (the distance of the exposed conductor  11 ) from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the insulation film  12 , and the distance W 2  from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the self-bonding layer  13  after welding (see  FIG. 4 ). The measurement was made on both side surfaces, the upper surface, and the lower surface, and an average value was taken as described above. As a result, it was confirmed that the insulation wire  10  according to the second example satisfied W 1 &lt;W 2  similarly to the insulation wire  10  according to the first example. In addition, the distance W 1  of the exposed conductor  11  by the welding became longer than a distance W 4  of the exposed insulation film  12  by the welding (W 1  &gt;W 4 ). Therefore, it was confirmed that the insulation wire  10  according to the second example was in a desirable aspect from the viewpoint of coating the insulation film  12  with the self-bonding layer  13 . 
     Thereafter, similarly to the first example, the insulating varnish  16  was coated and cured in the welding portion where the conductor  11  was exposed (see  FIG. 12 ). The adhesiveness of the cured insulating varnish  16  with respect to the insulation film  12  and the self-bonding layer  13  (all not illustrated in  FIG. 12 ) was peeled out by a cutter (not illustrated) for the evaluation. As a result, the insulating varnish  16  was pulverized, and part of the insulating varnish  16  was strongly bonded and left onto the insulation film  12  and the self-bonding layer  13 . In other words, it was confirmed that the insulation wire  10  according to the second example was possible to strongly make the insulating varnish  16  adhere to the insulation film  12  and the self-bonding layer  13  similarly to the insulation wire  10  according to the first example. 
     As described above, it was confirmed that the insulation wire  10  according to the second example had a good adhesiveness between the insulation film  12  and the self-bonding layer  13  in a welding process implemented when the rotary electric machine was manufactured, and an insulation sealing process performed on the exposed portion of the conductor  11  thereafter. In other words, it was confirmed that the insulation film  12  did not suffer the lifting-up and peeling in the insulation wire  10  according to this example even when the heat caused by welding was transferred to the conductor  11 , and the insulation property was secured. 
     Third Example 
     The insulation wire  10  according a third example was manufactured similarly to that of the first example except that the second thermoplastic resin (1) and the second thermoplastic resin (2) each were used by a predetermined amount (see Table 1). Then, the welding when the coil was processed was simulated similarly to the first example using the insulation wire  10  according to the third example, and the performance of the adhesiveness between the insulation film  12  and the self-bonding layer  13  was confirmed. 
     As a result, it was confirmed that the insulation film  12  and the self-bonding layer  13  of the insulation wire  10  according to the third example was slightly shrunk by the heat at the time of welding (see  FIG. 4 ). However, the peeling (the lifting-up and peeling) of the insulation film  12  from the conductor  11  and the peeling (the lifting-up and peeling) of the self-bonding layer  13  from the insulation film  12  were not found. 
     In addition, the insulation wire  10  according to the third example was measured about the distances such as the distance W 1  (the distance of the exposed conductor  11 ) from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the insulation film  12 , and the distance W 2  from the position where the insulation film was removed before welding to the end of the self-bonding layer  13  after welding (see  FIG. 4 ). The measurement was made on both side surfaces, the upper surface, and the lower surface, and an average value was taken as described above. As a result, it was confirmed that the insulation wire  10  according to the third example satisfied W 1 &lt;W 2  similarly to the insulation wire  10  according to the first example. Further, the distance W 1  of the exposed conductor  11  by the welding became longer than a distance W 4  of the exposed insulation film  12  by the welding (W 1  &gt;W 4 ). Therefore, it was confirmed that the insulation wire  10  according to the third example was in a desirable aspect from the viewpoint of coating the insulation film  12  with the self-bonding layer  13 . 
     Thereafter, similarly to the first example, the insulating varnish  16  was coated and cured in the welding portion where the conductor  11  was exposed (see  FIG. 12 ). The adhesiveness of the cured insulating varnish  16  with respect to the insulation film  12  and the self-bonding layer  13  (all not illustrated in FIG.  12 ) was peeled out by a cutter (not illustrated) for the evaluation. As a result, the insulating varnish  16  was pulverized, and part of the insulating varnish  16  was strongly bonded and left onto the insulation film  12  and the self-bonding layer  13 . In other words, it was confirmed that the insulation wire  10  according to the third example was possible to strongly make the insulating varnish  16  adhere to the insulation film  12  and the self-bonding layer  13  similarly to the insulation wire  10  according to the first and second examples. 
     In addition, the insulation wire  10  according to the third example (a length of about 60 cm) was formed in a U shape by an edge wising. At this time, the insulation wire was bent by 180 degrees using a pin of 2.0 mmφ. An aluminium foil was wound in a bent portion of the U-shaped insulation wire  10 , and an electrode was provided. Further, an electrode was provided even on the other end of the U-shaped insulation wire  10 , and a breakdown voltage (BDV) was measured. As a result, the BDV of the bent portion of the insulation wire  10  was lowered by 12% compared to that before the bending, but it was confirmed that the BDV was equal to or more than 10 kV. Further, it was confirmed that a variation was less every sample, and the insulation property was good. 
     As described above, it was confirmed that the insulation wire  10  according to the third example had a good adhesiveness between the insulation film  12  and the self-bonding layer  13  in a welding process implemented when the rotary electric machine was manufactured, and an insulation sealing process performed on the exposed portion of the conductor  11  thereafter. In other words, it was confirmed that the insulation film  12  did not suffer the lifting-up and peeling in the insulation wire  10  according to this example even when the heat caused by welding was transferred to the conductor  11 , and the insulation property was secured. In addition, it was confirmed that the insulation wire  10  according to the third example had a good insulation property in the bent portion. It is considered that the good insulation property in the bent portion of the insulation wire  10  according to the third example is because that the self-bonding layer  13  contains the inorganic filler. Therefore, it is expected that the insulation property in the bent portion is good similarly even to the insulation wire  10  according to the first and second examples. 
     First Comparative Example 
     The insulation wire according to a first comparative example was manufactured similarly to that of the first example except that the second thermoplastic resin (1) did not contain the cross-linking agent, the curing agent, the curing catalyst, and the inorganic filler, and the atmospheric pressure plasma treatment was not performed (see Table 1). Then, the welding when the coil was processed was simulated similarly to the first example using the insulation wire according to the first comparative example, and the performance of the adhesiveness between the insulation film and the self-bonding layer was confirmed. 
     As a result, it was confirmed that the insulation film and the self-bonding layer of the insulation wire according to the first comparative example was shrunk by the heat at the time of welding similarly to the first to third examples (see  FIG. 4 ). However, the peeling (the lifting-up and peeling) of the insulation film from the conductor and the peeling (the lifting-up and peeling) of the self-bonding layer from the insulation film were not found. However, it was confirmed that the self-bonding layer of the insulation wire according to the first comparative example was cracked near the end, and the coating property (adhesiveness) to the insulation film was worsened. As a reason that the self-bonding layer of the insulation wire according to the first comparative example was cracked, a low strength of the thin film can be given since the self-bonding layer did not contain the inorganic filler. In addition, since the atmospheric pressure plasma treatment (the insulation film surface treatment) is not performed, a low adhesiveness between the insulation film and the self-bonding layer can be given. 
     In addition, as illustrated in  FIG. 4 , the insulation wire according to the first example was measured about the distances such as the distance W 1  (the distance of the exposed conductor  11 ) from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the insulation film  12 , and the distance W 2  from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the self-bonding layer  13  after welding. The measurement was made on both side surfaces, the upper surface, and the lower surface, and an average value was taken. As a result, it was confirmed that the insulation wire according to the first comparative example satisfied W 1 &lt;W 2  similarly to the insulation wire  10  according to the first example. However, since the length of the distance W 2  became long compared to that of the first to third example, and there were many places in the insulation film  12  were not coated with the self-bonding layer  13 . As a reason, it is considered because the self-bonding layer  13  did not contain the inorganic filler. In addition, the fact that the atmospheric pressure plasma treatment was not performed on the surface of the insulation film  12  is also considered as an influence. Further, the distance W 1  of the conductor  11  exposed by the welding and the distance W 4  of the insulation film  12  exposed by the welding were substantially equal (W 1 ≠W 4 ). Therefore, it was confirmed that the insulation wire according to the first comparative example was an undesirable aspect from the viewpoint of coating the insulation film  12  with the self-bonding layer  13 . 
     In addition, thereafter, the insulating varnish  16  of the thermosetting property was coated and cured in the welding portion where the conductor was exposed similarly to the first example (see  FIG. 12 ). Then, the adhesiveness of the cured insulating varnish  16  with respect to the insulation film and the self-bonding layer of the insulation wire  10  (all not illustrated in  FIG. 12 ) was peeled out by a cutter for the evaluation. As a result, the insulating varnish  16  was pulverized, and part of the insulating varnish  16  was slightly left in the insulation film and the self-bonding layer. However, the slightly left insulating varnish  16  was also easily peeled off. As a primary reason, it is considered that the self-bonding layer did not contain the inorganic filler, and thus the heat caused by welding was transferred to cause the curing and shrinking and to expose the insulation film much. In other words, the adhesiveness between the insulation film and the insulating varnish is not good so much, and thus it is considered that the insulating varnish is easily peeled off from the insulation film and the self-bonding layer by increasing a contact surface between the insulation film and the insulating varnish. In addition, since the surface of the insulation film was not subjected to the atmospheric pressure plasma treatment, it is considered as one of causes that the adhesiveness between the self-bonding layer and the insulation film using the PPS was not good. In other words, the adhesiveness between the insulating varnish and the self-bonding layer using the phenoxy resin was good, and on the contrary the adhesiveness between the self-bonding layer and the insulation film of which the surface was not subjected to the atmospheric pressure plasma treatment was not good as described above, so that it is considered that the insulating varnish was not peeled off from the insulation film unlike the self-bonding layer. 
     Further, similarly to the third example, the insulation wire having a length of about 60 cm was made in the U shape by the edge wising. At this time, the insulation wire was bent by 180 degrees using a pin of 2.0 mmφ). An aluminium foil was wound in a bent portion of the U-shaped insulation wire, and an electrode was provided. Further, an electrode was provided even on the other end of the U-shaped insulation wire, and the BDV was measured. As a result, the BDV of the bent portion of the insulation wire was less than 10 kV, and it was confirmed that a variation for each sample was increased and the insulation property was not good. 
     As described above, it was confirmed that the insulation wire according to the first comparative example had a problem in adhesiveness between the insulation film and the self-bonding layer in the welding process which was implemented when the rotary electric machine was manufactured, and the insulation sealing process which was performed on the exposed portion of the conductor thereafter. In addition, it was confirmed that the insulation property of the insulation wire according to the first comparative example was not good. 
     Second Comparative Example 
     The insulation wire according to a second comparative example was manufactured similarly to that of the first example except that the second thermoplastic resin (1) did not contain the inorganic filler, and the atmospheric pressure plasma treatment was not performed (see Table 1). Then, the welding when the coil was processed was simulated similarly to the second example using the insulation wire according to the first comparative example, and the performance of the adhesiveness between the insulation film and the self-bonding layer was confirmed. 
     As a result, it was confirmed that the insulation film and the self-bonding layer of the insulation wire according to the second comparative example was shrunk by the heat at the time of welding similarly to the first to third examples (see  FIG. 4 ). However, the peeling (the lifting-up and peeling) of the insulation film from the conductor and the peeling (the lifting-up and peeling) of the self-bonding layer from the insulation film were not found. 
     In addition, as illustrated in  FIG. 4 , the insulation wire according to the second example was measured about the distances such as the distance W 1  (the distance of the exposed conductor  11 ) from the position P where the insulation film  12  and the self-bonding layer  13  were removed before welding to the end of the insulation film  12 , and the distance W 2  from the position P where the insulation film  12  and the self-bonding layer  13  are removed before welding to the end of the self-bonding layer  13  after welding. The measurement was made on both side surfaces, the upper surface, and the lower surface, and an average value was taken. As a result, it was confirmed that the insulation wire according to the second comparative example satisfied W 1 &lt;W 2  similarly to the insulation wire  10  according to the first example. However, since the length of the distance W 2  became long compared to that of the first to third example and the first comparative example, and there were many places in the insulation film  12  were not coated with the self-bonding layer  13 . As a reason, it is considered that the self-bonding layer  13  contained the cross-linking agent (the thermosetting resin, the thermosetting monomer) and the curing and shrinking occurred easily, but not contained the inorganic filler. In addition, the fact that the atmospheric pressure plasma treatment was not performed on the surface of the insulation film  12  is also considered as an influence. Further, the distance W 4  of the insulation film  12  exposed by the welding were longer than the distance W 1  of the conductor  11  exposed by the welding (W 1 &lt;W 4 ). Therefore, it was confirmed that the insulation wire according to the second comparative example was an undesirable aspect from the viewpoint of coating the insulation film  12  with the self-bonding layer  13 . 
     In addition, thereafter, the insulating varnish  16  of the thermosetting property was coated and cured in the welding portion where the conductor was exposed similarly to the first example (see  FIG. 12 ). Then, the adhesiveness of the cured insulating varnish  16  with respect to the insulation film and the self-bonding layer of the insulation wire  10  (all not illustrated in  FIG. 12 ) was peeled out by a cutter for the evaluation. As a result, the insulating varnish  16  was pulverized, and part of the insulating varnish  16  was slightly left in the insulation film and the self-bonding layer. However, the slightly left insulating varnish  16  was also easily peeled off. It is considered that the reason is the same as that of the first comparative example. 
     Further, similarly to the third example, the insulation wire having a length of about 60 cm was made in the U shape by the edge wising. At this time, the insulation wire was bent by 180 degrees using a pin of 2.0 mmφ. An aluminium foil was wound in a bent portion of the U-shaped insulation wire, and an electrode was provided. Further, an electrode was provided even on the other end of the U-shaped insulation wire, and the BDV was measured. As a result, the BDV of the bent portion of the insulation wire was less than 10 kV, and it was confirmed that a variation for each sample was increased and the insulation property was not good. 
     As described above, it was confirmed that the insulation wire according to the second comparative example had a problem in adhesiveness between the insulation film and the self-bonding layer in the welding process which was implemented when the rotary electric machine was manufactured, and the insulation sealing process which was performed on the exposed portion of the conductor thereafter. In addition, it was confirmed that the insulation property of the insulation wire according to the second comparative example was not good in the bent portion. 
     Hitherto, the manufacturing method of the insulation wire, the rotary electric machine, and the insulation wire have been described in detail using the embodiments and the example, but the invention is not limited to the embodiments to the examples. The various modification may be included. For example, the embodiments and the examples are described in a clearly understandable way for the invention, and thus the invention is not necessarily to provide all the configurations described above. In addition, some configurations of a certain embodiment or example may be replaced with the configurations of another embodiment or example, and the configuration of the other embodiment or example may also be added to the configuration of a certain embodiment or example. Furthermore, additions, omissions, and substitutions may be made on some configurations of each embodiment and example using other configurations.