CN103608157B - 磁负载的复合材料转子和制备磁负载的预浸渍带的方法 - Google Patents

磁负载的复合材料转子和制备磁负载的预浸渍带的方法 Download PDF

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CN103608157B
CN103608157B CN201280029583.XA CN201280029583A CN103608157B CN 103608157 B CN103608157 B CN 103608157B CN 201280029583 A CN201280029583 A CN 201280029583A CN 103608157 B CN103608157 B CN 103608157B
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band
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magnetic loading
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C·D·塔兰特
G·M·D·戴
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Abstract

一种制备磁负载的预浸渍的带的方法,使用加热的并与加热的熔池(2)相关联的鼓(1),所述熔池(2)含有热塑性树脂溶液。将纤维带材料(4)进料至鼓(1)上,并且恰好在纤维带材料接触鼓的外围之前,将所述纤维带材料(4)用各向异性的磁颗粒材料(6)浸渍以形成预浸渍的带(8)。所述预浸渍的带进料至加热站,在所述加热站将所述预浸渍的带与热塑性树脂浸渍的纤维丝束粘合以产生磁负载的复合材料带。所述加热站包括转动驱动的加热的心轴(20),所述心轴(20)具有嵌入其中的磁场(41、42)以向预浸渍的带(8)提供所需的磁位形。

Description

磁负载的复合材料转子和制备磁负载的预浸渍带的方法
本发明涉及磁负载复合材料(MLC)转子,涉及用于其制备的带,以及涉及用于制造所述转子和带的设备。
MLC转子,有时称为飞轮,可以用于以超过30,000r.p.m的高速旋转的电动发动机/发电机中充当能量存储和/或发动机。转子能够根据能量是否应用于通电线圈或从通电线圈提取而充当发动机或发电机,所述通电线圈在与转子共同使用的定子上。MLC转子的使用具有不需要离散磁性的优点,所述离散磁性在高速下会突然消失。
通过使用嵌入热固性树脂(例如环氧树脂)、基质中的纤维丝束形成的复合材料飞轮在US-A-2002/0083791、EP-A-1199493、US-A-4080845和WO-A-94/06193中描述,所述纤维丝束即未缠绕的人造纤维的连续的丝束,所述人造纤维例如玻璃纤维或碳纤维。
制备MLC转子的已知的方法是缠绕干玻璃纤维丝束和由粉末状的磁性材料(例如各向异性的NdFeB)和热固性树脂制成的浆体。该方法是逐渐将浆体进料至心轴以产生浆体层,同时以开放结构将干玻璃纤维丝束层缠绕在浆体层上。开放结构的开口用浆体填充,使得玻璃纤维丝束捕获MLC浆体层,将其挤压以产生所需的树脂级别。在MLC浆体中的过量的树脂用于浸渍玻璃纤维丝束以产生所需的结构。然后在旋转心轴的同时将所述缠绕结构胶凝并固化。所述方法描述于WO-A-94/06193中。
制造MLC转子的已知方法依赖于树脂和NdFeB粉末浆体的流动性来流动以产生所需的结构。流动能力阻止了采用实现与电流的各向异性的NdFeB颗粒相关的剩磁通量的增益所需的程序,因为所述颗粒倾向于在定向磁体的极周围集聚。这种集聚引起不利于高速转子/飞轮的不平衡并可能导致转子和定子组件的破坏。
US-A-5650220公开了一种具有加固的热塑性材料体的加固条(reinforcementbar),所述加固的热塑性材料通过层压多层纤维加固的热塑性塑料的条制备,所述热塑性塑料可以包括磁性材料,使得所述热塑性塑料加热更快。然而,这个参考文献不涉及MLC转子和与其制造有关的问题。
本发明试图提供制备磁负载的复合材料带和包含所述磁负载的复合材料带的转子的改进的方法。
根据本发明,提供了制备磁负载的复合材料带的方法,所述方法包括向加热站(29)进料热塑性树脂浸渍的纤维丝束(24),向所述加热站进料各向异性的磁负载的预浸渍的带(8),施加在所述加热站的热以粘合所述丝束和带从而制备磁负载的复合材料带的步骤,所述加热站(29)包括转动驱动的心轴(20)和压紧辊(28),所述心轴设置成被加热,所述压紧辊与心轴相关联,所述丝束和带被进料通过压紧辊和心轴之间,其特征在于所述心轴具有嵌入其中的磁场(41、42)以向各向异性的磁负载的预浸渍的带提供所需的磁位形。
适宜地,所述心轴配置有偶数个磁体以产生例如包含12个磁体的6个极对(polepairs)。
有利地,以弧形设置磁体使得带的半径围绕心轴增加,在磁负载的预浸渍的带中的极大体上对齐。
有利地,所述带缠绕在心轴周围用于后续应用。
优选地,在加热站的热由激光装置和热氮装置中的一种提供。
适宜地,所述激光装置是脉冲驱动或连续驱动中的一种以提供足以粘合丝束和带的温度,在例如350℃-400℃的温度下粘合。
有利地,进料丝束和带的速度为0.1-1m/s的范围。
优选地,所述加热的心轴被设置成将复合材料带成形为所需的形状。
有利地,加热所述心轴至温度为120℃-200℃。
优选地,所述心轴具有嵌入其中的磁场以向各向异性的磁负载的预浸渍的带提供所需的磁位形。
热塑性树脂是当加热时转变为液体并且当充分冷却时凝固成玻璃态的聚合物。热塑性聚合物带与现有技术中用于MLC转子结构中的热固性聚合物不同在于它们可以再熔化和重塑。使用热塑性基质比现有技术中的热固性基质的一个优点是在制造过程中限制了磁性颗粒材料的流动性使得由于颗粒移动并集中在场极的聚集效应大大降低。这是由于在制造过程中基质在加热站在非常小的位置和非常短的时间为液体。
优选地,所述心轴大体上为圆柱体,具有设置在所述圆柱体的相邻径向内表面和外表面的交替的极对。
有利地,所述心轴被设置成通过加热装置例如热空气加热。
适宜地,所述心轴被设置成通过卷切机旋转。
根据本发明的一个特征,提供了根据本发明的方法制备的磁负载的复合材料带。
在另外的特征中,提供了根据本发明的方法制备的转子。
本发明的心轴被设计成具有嵌入其中的磁场,所述心轴具有与所需的最终组件相同的位形。通过采用这样的具有各向异性的磁性颗粒材料的设备,当转子随后被磁化用于应用时,颗粒的磁区(magneticregimes)产生更强的磁象(megneticpattern)。
本发明现在将通过实例参照附图进行描述,其中:
图1显示了用于本发明的用于制备磁负载的预浸渍的带的设备;
图2显示了根据本发明的制造磁负载复合材料带的设备,以及
图3显示了用于本发明的心轴。
在图中,相同的参考数字表示相同的部分。
显示在图1中的用于制造磁负载的预浸渍的带的设备具有由发动机(未显示)驱动的鼓1,所述鼓通过任意合适的来源,例如电元件或热空气,被加热至温度为60℃至100℃。所述鼓1与熔池2相关联,所述熔池2通过任意合适的装置,例如电元件或热空气,被加热至温度为60℃至100℃。所述熔池被设置成含有得到用于应用的期望的树脂含量所需的比例的热塑性树脂溶液(例如环氧树脂)、溶剂和聚醚醚酮(PEEK)或聚醚酰亚胺(PEI)。
为了控制输送到鼓1周围的熔池2中的材料厚度,提供了径向设置在鼓的外周附近的刮板3。
纤维带材料4,例如玻璃纤维或碳纤维带、或KevlarTM(聚酰胺)、塑料或铝带、硼、尼龙、聚烯烃或其组合,或任意其它合适的已知纤维,恰好在鼓的外围位置之前从进料辊5周围的来源(未显示)进料至鼓1,所述鼓的外围位置是纳米尺寸的磁性颗粒(例如NdFeB颗粒)的浆体、溶剂和聚醚醚酮(PEEK)或聚醚酰亚胺(PEI)从进料喷嘴6提供的位置。所述浆体可以含有按体积计30%至45%的磁性颗粒材料。其它可以使用的磁性材料是铁、镍、钴或其合金。磁性材料可以,供选择地,由铁氧体例如钡铁氧体,或其它稀土元素例如钐钴制成。径向设置在鼓外围附近的浆体刮板7用于控制组合的树脂、纤维和磁性颗粒浆体的厚度,所述浆体粘附于热塑性带的一侧和边缘。离开鼓1后,由此形成磁负载的预浸渍的带8经过挤压辊9、10之间进入加热通道11,然后从通道的出口12离开。所述通道被加热至温度为100℃-150℃。所述通道11构成壳体13的一部分,组件1-10位于所述壳体13内部。所述壳体13具有连接到温度为100℃的热氮气15供给的入口14。设置位于通道周围与热氮气12结合的加热器16以从带8赶走过量的溶剂,并且所述过量的溶剂从壳体出口17去除,如箭头线18所示,供应给溶剂回收车间(未显示)。然后所述预浸渍的带8经过一组加热的压光辊(未显示)以产生平坦的带。
显示在图2中的设备用于使用热塑性带制造磁负载复合材料带。圆柱体心轴20由发动机(未显示)以0.5-1m/s的速度驱动以提供热塑性带(在下文中描述)并且由便利的来源(未显示)加热心轴,所述便利的来源可以为圆柱体内部部分提供热空气,由箭头线21显示。所述来源(未显示)可以是电加热的。心轴20连接到安装在卷切机(未显示)上,心轴被设置成在由箭头线22显示的方向上旋转。热塑性树脂浸渍的丝束24被进料通过预拉伸辊25、26、27至位于加热站29的压紧和导辊28。所述加热站29提供有来自激光30的热能,所述激光30可以是在加热站29在350℃至400℃的温度下提供脉冲或连续能量的2KW激光。同样提供给加热站29的是磁负载预浸渍的带8,所述磁负载预浸渍的带8进料通过拉伸辊31、32。尽管本发明被描述成使用仅一个热塑性树脂浸渍的纤维丝束24和一个各向异性的磁负载预浸渍的带8,但是应当理解的是本发明并不限于此,并且所使用的带的数量可以根据所需要的MLC复合材料带的结构而变化。
在加热站29通过粘合带8和24形成的磁负载复合材料带缠绕在心轴20上以形成发动机/发电机转子。通过激光加热也协助释放带中的应力。形成后,通过在炉中加热至300℃进行应力释放。尽管在图2的实施方案中描述的为在圆柱体心轴上形成,但是应当理解的是来自加热站的粘合带输出可以形成任何所需的形状/位形。
使用热塑性带比热固性带的优点在于:由于基质在加热站在非常小的位置和非常短的时间为液体,因此在制造过程中限制了磁性颗粒材料的流动性。因此由于磁性颗粒材料移动并集中在电场极,聚集效应大大降低。
所述复合材料带优选地具有在制造过程中对齐的各向异性的NdFeB颗粒材料磁区,从而当转子被磁化时产生更强的磁象。如图3所示,圆柱体形状的顺磁性材料(例如钛)的心轴40提供相对于圆柱体的周向表面在其中周向和径向设置的均布的电磁极对41、42。因此,交替的北41和南42极径向设置于心轴圆柱体,各极被垫片(spacer)隔开,并且所述极围绕圆柱体外周交替出现。可以有,例如12个极,即6个极对,围绕心轴外周设置,但是为了便于解释,仅有4个极对显示在图3中。尽管未显示,钛心轴形成外部圆柱体并且具有极对的径向内部铁氧体圆柱体位于内部和外部圆柱体之间的圆环域中。在使用中,当心轴被转动时,使电磁体41、42脉冲以对齐带中交替的北极和南极并且设置定时以使北极和南极与先前磁化的层交替出现。通过使用具有嵌入其中的磁场从而具有最终组件所需的相同位形的心轴,当向转子供能时,材料中各向异性的磁颗粒的磁区对齐以产生更强的磁体,并且通过使用磁化的心轴,实现了更均匀的磁场分布。此外,心轴中的磁场有助于在加热站29在激光熔化带之前稳固带。可以以弧形设置磁体41、42,使得当带的半径围绕心轴增加时,带中的极大体上对齐。
这样形成的转子然后经受应力降低/退火工艺,在所述工艺中转子被加热到大约250℃,然后允许在12小时期间冷却。
尽管当使用热塑性带时需要应力降低/退火工艺,但是没有当使用热固性树脂带时所需的胶凝或固化操作,使得制造时间进一步减少。
关于题述发明,对于所制备的转子的尺寸没有放热限制使得制备非常大直径的转子成为可能,而这对于当前的热固性法、湿法、绕制法是不可能的。

Claims (17)

1.一种制备磁负载的复合材料带的方法,所述方法包括以下步骤:向加热站(29)进料热塑性树脂浸渍的纤维丝束(24),向所述加热站进料各向异性的磁负载的预浸渍的带(8),在所述加热站施加热以粘合所述丝束和带从而制备磁负载的复合材料带,所述加热站(29)包括转动驱动的心轴(20)和压紧辊(28),所述心轴设置成被加热,所述压紧辊与心轴相关联,所述丝束和带被进料通过压紧辊和心轴之间,其特征在于,所述心轴具有嵌入其中的磁场(41、42)以向各向异性的磁负载的预浸渍的带提供所需的磁位形。
2.权利要求1所述的方法,其中所述心轴配置有偶数个磁体(41、42)以产生极对。
3.权利要求1所述的方法,其中所述心轴配置有偶数个磁体(41、42)以产生包含12个磁体的6个极对。
4.权利要求2或3所述的方法,其中以弧形设置磁体(41、42)使得带的半径围绕心轴增加,在磁负载的预浸渍的带中的极大体上对齐。
5.权利要求1所述的方法,其中所述带缠绕在心轴周围用于后续应用。
6.权利要求1所述的方法,其中在加热站的热由激光装置(30)和热氮装置中的一种提供。
7.权利要求6所述的方法,其中所述激光装置是脉冲驱动或连续驱动的一种以提供足以粘合丝束和带的温度。
8.权利要求7所述的方法,其中所述足以粘合丝束和带的温度为350℃-400℃。
9.权利要求1所述的方法,其中进料丝束和带的速度为0.1-1m/s。
10.权利要求1所述的方法,其中所述加热的心轴(20)被设置成将复合材料带成形为所需的形状。
11.权利要求1所述的方法,其中加热所述心轴至温度为120℃-200℃。
12.权利要求2或3所述的方法,其中所述心轴大体上为圆柱体,具有设置在所述圆柱体的相邻径向内表面和外表面的交替的极对(41、42)。
13.权利要求1所述的方法,其中所述心轴被设置成通过加热装置(21)加热。
14.权利要求1所述的方法,其中所述加热装置(21)为热空气。
15.权利要求1所述的方法,其中所述心轴被设置成通过卷切机旋转。
16.根据权利要求1的方法制备的磁负载的复合材料带。
17.由根据权利要求1的方法所得的带制备的转子。
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CN103608157A (zh) 2014-02-26
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JP6259030B2 (ja) 2018-01-10
WO2012172355A3 (en) 2013-04-25
GB201110233D0 (en) 2011-08-03
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JP2014523935A (ja) 2014-09-18
GB2491975A (en) 2012-12-19
GB2491975B (en) 2016-04-27
JP2017017986A (ja) 2017-01-19
WO2012172355A2 (en) 2012-12-20
US20140117803A1 (en) 2014-05-01
US10298079B2 (en) 2019-05-21
CA2837986C (en) 2019-01-22
EP2720843B1 (en) 2018-07-18

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