CN104023933A - 线圈支撑构件 - Google Patents
线圈支撑构件 Download PDFInfo
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- CN104023933A CN104023933A CN201280052375.1A CN201280052375A CN104023933A CN 104023933 A CN104023933 A CN 104023933A CN 201280052375 A CN201280052375 A CN 201280052375A CN 104023933 A CN104023933 A CN 104023933A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/58—Applying the releasing agents
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- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
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- B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
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- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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Abstract
本发明公开一种线圈支撑构件(1)和一种制造所述线圈支撑构件(1)的方法,在所述方法中,将热固性或热塑性材料引入模具腔中并硬化。在制造过程中,一个或多个部件(12,14)在引入所述热固性或热塑性材料之前定位在所述模具腔内。这些部件随后嵌入所述热固性或热塑性材料中并形成所述线圈支撑构件(1)的整体部分。向所述热固性或热塑性材料中添加一种或多种功能填充材料,以改进所述整体部件与所述热固性或热塑性材料之间的热匹配。
Description
技术领域
本发明涉及线圈支撑构件(有时称为线圈架),并且具体来说涉及对可由常规的或超导的线或带材制成的线圈或对一个或多个超导材料块提供结构支撑的构件。所述线圈支撑构件可用于构造尤其是旋转电动机器(例如,电动机或发电机)、磁共振成像(MRI)扫描仪、电磁铁、研究光束线和粒子加速器、故障电流限制器以及磁铁能量存储装置。在旋转电动机器的情况下,则多个线圈支撑构件可安装在转子组件的圆周周围。
背景技术
用于卷绕线圈的支撑构件是已知的,并且对于低温应用来说,通常由难以加工并且加工成本昂贵的不锈钢制成。
发明内容
本发明提供一种制作改进的线圈支撑构件的方法。将热固性或热塑性材料引入模具腔中并硬化以产生线圈支撑构件。
任何合适的制造过程均可用于将热固性或热塑性材料引入模具腔中,但典型的选项可能包括:注射模塑,其中在压力下使用注射模塑设备迫使所述材料进入模具腔中;铸造过程,其中将所述材料(例如)从集管容器或类似物倾倒在模具腔中;以及压缩模塑过程,其中将所述材料倾倒在模具腔中并且使用另外的模塑模来在所述材料硬化形成线圈支撑构件之前向所述材料施加压力。使用模塑过程或铸造过程代替常规的机械加工过程来产生线圈支撑构件意味着线圈支撑构件可具有更加复杂的几何形状,尤其是在实际接触并提供对卷绕线圈的机械支撑的表面处。使用热固性或热塑性材料代替不锈钢意味着还可使得线圈支撑构件的热性质大致匹配线圈和任何整体部件(参见下文)的热性质,这显著减少了所述支撑构件的结构问题。使用热固性或热塑性材料形成的线圈支撑构件相对轻质并且生产成本效益好。所述线圈支撑构件还具有改进的热传递性质,而无通常在铜板或铝板或任何相关热总线中发现的与电涡流通路相关的问题,并且提供有用的电隔离。
线圈支撑构件可通过单级制造过程或多级制造过程形成。在单级过程中,模具腔的形状将大致限定成品线圈支撑构件的形状。将热固性或热塑性材料引入模具腔中、硬化并从所述模具腔中移除线圈支撑构件。线圈支撑构件可能需要经受一个或多个最终精加工过程、机械加工过程或后期生产过程,如下文更详细描述。然而,线圈支撑构件的形状大致由模具腔的形状限定,这意味着可以快速且成本效益好的方式制造具有复杂几何形状的结构。
在多级过程中,只有最终模具腔的形状才实质限定成品线圈支撑构件的形状。其他模具腔将限定线圈支撑构件的层或部分,所述层或部分可任选地设计来为成品支撑构件提供不同性质,或者允许制造特定支撑构件,如果这在使用单级过程的情况下是不可能的话。在典型的多级过程中,允许第一级过程中所产生的层或部分硬化,然后从模具腔中移除,并放置在用于下一级的模具腔中,诸如此类。因此每一级都将限定成品线圈支撑构件的不同的层或部分。可使用任何数量的级。
先前形成的层或部分可使用一个或多个定位构件定位在用于下一级的模具腔中。每个层或部分可包括结构特征(例如,‘键控(keying)’特征),所述结构特征允许将热固性或热塑性材料引入制造过程的随后一级中以便机械地结合至所述层或部分。除了所述机械结合之外,还将发生任意化学结合,所述化学结合通常会发生在线圈支撑构件的不同层或部分之间,即,当引入模具腔中的热固性或热塑性材料与前一级过程中所产生的下面层或相邻部分结合时。
热固性或热塑性材料的选择将取决于线圈支撑构件的预期应用和所需性质。所述热固性或热塑性材料可包括经活化以使所述材料硬化或固化的硬化剂。例如,适用于形成线圈支撑构件的材料可能是合成树脂或环氧化物和硬化剂,连同任选组分来调节所述材料的粘性。可向热固性或热塑性材料添加功能填充材料以改进或改变所述材料的热性质、机械性质、电性质和磁性质中的一种或多种。例如,可添加诸如尤其是玻璃、硅石、石英、氧化铝、氮化铝、氮化硼和氧化钛、云母、粘土、金属、超导材料、玻璃或基于聚合物的中空填充剂的填充材料来改进或改变热固性或热塑性材料的基本物理性质。还可添加磁性填充材料来使穿过使用中的线圈支撑构件的磁通量转向或者引导穿过使用中的线圈支撑构件的磁通量,并且所述磁性填充材料可相应地分布。所述填充材料可改进热固性或热塑性材料与任何整体部件的热匹配(见下文),即,以便改变热固性或热塑性材料的热膨胀系数,从而使得所述热膨胀系数与任何一个或多个整体部件的热膨胀系数更密切匹配。所述热匹配将优选涵盖在从室温(或环境温度)到线圈支撑构件的操作温度的温度范围,并且足够密切以便防止沿硬化的热固性或热塑性材料与整体部件之间的界面出现剥离和开裂。可添加不同填充材料的组合(或不同类型或大小的相同填充材料,很容易理解,很多材料可以具有不同颗粒大小的粉末、薄片、纤维、管等获得,材料的这些不同形态可为热固性或热塑性材料提供不同的性质)。所述填充材料可遍及热固性或热塑性材料大致均匀分布,或者不均匀分布以使得所述填充材料集中在成品线圈支撑构件的某些部分或区域处或者与成品线圈支撑构件的某些部分或区域隔离。填充材料可减少或消除诸如硬化或固化过程中热固性或热塑性材料的收缩和开裂之类的已知问题。
功能填充材料可在将其引入模具腔之前或正在将其引入模具腔时添加到热固性或热塑性材料中。如果填充材料是大致均匀分布的,那么与热固性或热塑性材料的某种形式的预混合可能是所需的。在合适的粉末在被送入注射模塑设备中之前与粘合剂(例如,热塑性聚合物材料)预混合的情况下可使用粉末注射模塑(PIM)过程。功能填充材料还可在引入热固性或热塑性材料之后但在所述热固性或热塑性材料完全硬化或固化之前添加到模具腔中。这可允许线圈支撑构件的特定部分或区域以更受控的方式掺杂填充材料。不同的填充材料可在制造过程中的不同时间添加,包括在固化过程中添加。
在多级制造过程中,则在线圈支撑构件的不同的层或部分中可使用不同的热固性或热塑性材料,和/或不同的填充材料、填充材料的组合或不使用填充材料。填充材料或填充材料的组合可谨慎选择,以便在每个层或部分中实现不同的特性或性质,如改进的热导率、机械强度或刚度。很多填充材料是昂贵的,因此如果它们仅仅用于线圈支撑构件中所述填充材料实际提供技术改进的部分或层中,那么制造过程通常将更具成本效益。在制造过程的一些级中,将仅使用热固性或热塑性材料,即,没有必要使用任何填充材料。
在制造过程中,可将一个或多个部件定位在模具腔内,以使得所述部件与成品线圈支撑构件整体成形。换句话说,每个部件均正确地嵌入热固性或热塑性材料内来限定成品支撑构件的整体部分。在多级制造过程中,则不同部件可在每一级中定位。
每个部件均可使用将所述部件支撑在正确位置的一个或多个定位构件定位在模具腔内。所述定位构件可由任何合适的材料(例如,金属、陶瓷或玻璃纤维)制成,并且自身可嵌入热固性或热塑性材料内或在所述材料硬化之后移除。这可通过用合适的脱模剂涂覆每个定位构件以使得当将定位构件引入模具腔中时,其不会与热固性或热塑性材料结合来实现。在多级制造过程中,则由已移除的定位构件留下的任何空的空间或空隙可在随后一级中用热固性或热塑性材料填充。这提供了一种将部件完全嵌入线圈支撑构件的件体内的方式。
可与成品线圈支撑构件整体成形的部件实例将包括:尤其是电部件,如线圈的端部附接到其上的端子块;机械部件,如设计来提高线圈支撑构件的强度或刚度的支撑结构或支柱构件,和允许线圈支撑构件机械连接到外部设备(例如像电动机器的转子组件)的安装结构或固定结构;诊断部件,如温度传感器和应变仪;以及在线圈支撑构件在低温下(例如,作为用于超导电动机器的转子组件的一部分)操作的特别有用的热部件,如热传导总线、用于冷却流体循环的冷却剂管或外部冷却剂管可释放地或永久地连接到其上的连接器。所述部件可由金属、陶瓷等制成。一些部件可在制造过程的多个级内形成,其中单独的传导材料层和介电材料层整合到线圈支撑构件中以形成诸如热总线或电连接件的部件。
线圈可通过(例如)将线圈支撑构件放置在合适的线圈卷绕组件上而卷绕在成品线圈支撑构件周围。所述线圈可由任何常规的或超导的线或带材形成。线圈支撑构件可包括外部支撑表面,所述外部支撑表面在卷绕过程中并且当线圈支撑构件在使用中时接触线圈并支撑线圈使其呈所需形状。卷绕支撑构件随后可经受最终真空压力浸渍(VPI)过程以将线圈密封在合适的合成树脂中。还可能像任何其他部件一样在模具腔内定位预形成线圈,以使得所述线圈与线圈支撑构件整体成形并嵌入热固性或热塑性材料内。预形成线圈可使用任何常规的卷绕过程形成并且可在定位在模具腔内之前任选地经受VPI过程。在其他情况下,可在模具腔内定位一个或多个超导材料块而不是线圈。
线圈支撑构件的结构特征可在制造过程中形成,或者通过将部件定位在将随后被移除的模具腔内,例如,通过用合适的脱模剂来涂覆构件或在任何随后固化过程中构件熔化处以在线圈支撑构件的件体内留下空的空间或空隙的位置;或者使模具腔自身适当成形。可以这种方式很方便地形成的结构特征将包括用于冷却流体循环或用于允许形成到整体电部件的连接的电缆的内部导管。可在后期生产过程中使线圈支撑构件的结构特征金属化,以允许外部部件钎焊到所述结构特征上。例如,如果线圈支撑构件中形成了内部导管,那么所述结构可包括各自限定所述导管的端部的一个或多个突出部分,所述突出部分通过任何合适的过程(例如,沉积过程或电镀过程)金属化,以使得外部金属冷却剂管或用于冷却剂管的连接器可钎焊到连接部分上。线圈支撑构件的至少含有内部导管(或上文提及的嵌入冷却剂管部件)的那部分的热导率可通过使用合适的填充材料来改进,以使得有效地从线圈中移走热量。在实践中,这可去除对其中可能诱发问题涡流的金属热总线的需要。
可在引入热固性或热塑性材料之前向模具腔施加真空。所述真空也可在热固性或热塑性材料正引入模具腔中时维持真空。
用于在将热固性或热塑性材料引入模具腔中之后硬化或固化热固性或热塑性材料的‘固化时间表’将取决于所使用的特定材料和任何添加剂(如填充材料等)。固化可在室温下发生,或者如果需要升高的温度,那么可将整个模具放置在合适的炉或釜中。
本发明进一步提供由硬化的(或固化的)热固性或热塑性材料制成的模塑线圈支撑构件。
所述线圈支撑构件还可包括一种或多种功能填充材料,任选地用来改进或改变所述支撑构件的热性质、机械性质、电性质和磁性质中的一种或多种。填充材料的量将取决于具体应用,但按重量比小至约热固性或热塑性材料的5%的填充材料可提供有效的改进。
如上所述,不同的部件可在制造过程中与线圈支撑构件整体成形,即,嵌入在热固性或热塑性材料中。
线圈可卷绕在线圈支撑构件周围,或者预形成线圈可在线圈支撑构件的制造过程中与线圈支撑构件整体成形。线圈支撑构件还可用于支撑一个或多个超导材料块。
线圈支撑构件可包括一个或多个结构特征,如用于冷却流体循环或用于电缆的内部导管。线圈支撑构件的结构特征可在后期生产过程中金属化,以允许外部部件钎焊到所述结构特征上。
一个或多个线圈支撑构件可安装或固定到外部设备上。例如,多个线圈支撑构件可安装在用于旋转电动机器的转子组件的圆周周围。
附图说明
图1示出根据本发明的线圈支撑构件的透视图。
具体实施方式
虽然以下描述集中于用于超导线圈(即,由超导线或超导带材制成的线圈)的线圈支撑构件,所述线圈支撑构件预期安装在旋转电动机器(如电动机或发电机)的转子组件周围,但很容易理解,本发明具有更广泛的应用并且可与由常规材料如铜制成的线圈一起使用,并且用于安装到其他设备,例如像磁共振成像(MRI)扫描仪、电磁铁、研究光束线和粒子加速器、故障电流限制器以及磁铁能量存储装置。
线圈支撑构件1由引入模具腔中并固化的合成树脂材料(例如,环氧基树脂)制成。线圈支撑构件1包括外表面2,所述外表面2支撑超导线圈(未示出)并且具体来说具有弯曲的端部区域4,所述端部区域4经成形以提供对超导线圈的端部绕组的支撑。上板6和下板8悬伸出外表面2以使得线圈定位在所述上板与所述下板之间的空间10中。
管状突出部分12与下板8整体成形并且适配成连接到外部冷却剂管(未示出)。所述突出部分12与一个或多个内部冷却剂通道或导管流体连通,所述通道或导管在下板8内延伸并且低温冷却流体循环通过所述通道或导管以冷却线圈支撑构件1并维持超导线圈低于其超导温度。任何合适的安装块或固定块(未示出)可与下板8整体成形,以允许多个线圈支撑构件1安装到旋转电动机器的转子组件上。例如,所述固定块可能包括一个或多个内螺纹孔,所述内螺纹孔使得线圈支撑构件1能够螺栓连接到所述转子组件上。
一对端子块14与上板6整体成形。超导线圈的端部附接到所述端子块上以使得能够形成外部电连接。
线圈支撑构件1在单级过程中产生,这允许线圈支撑构件具有复杂的几何形状,特别是在外表面2的支撑超导线圈的区域中。然而,很容易理解,线圈支撑构件可在多级过程中形成,在所述多级过程中,至少热芯部分和机械刚性固定部分使用一系列模具腔顺序地形成,并且不同级可选使用不同合成树脂和/或功能填充剂。所述热芯部分可与内部冷却通道相邻并且包括外表面2并且可掺杂有改进其热导率的填充材料。安装块或固定块(未示出)可嵌入(例如)由下板8的至少一部分限定的机械刚性固定部分内。所述机械刚性固定部分可包括刚性支柱或支撑结构部件和/或可掺杂有改进其机械强度的填充材料。功能填充剂可用于改进合成树脂材料与各种嵌入部件之间的热匹配,,例如,以改变硬化的合成树脂的热膨胀系数,从而使得所述热膨胀系数与所述部件的热膨胀系数更密切匹配。所述热匹配将涵盖从室温到线圈支撑构件的操作温度的温度范围。这确保所述部件与所述合成树脂材料在冷却和操作阶段保持结合,并且防止当线圈支撑构件1在操作期间经历温度变化时沿界面出现开裂。
模具腔限定成品线圈支撑构件1的形状。端子块14可在将合成树脂引入模具腔中之前使用一个或多个定位构件定位在模具腔内合适位置处,以使得所述端子块在制造过程中嵌入形成上板6的合成树脂中。虽然未示出,但可通过将其他部件定位在模具腔内而类似地将其他部件嵌入合成树脂中。管状突出部分12可通过将金属冷却剂管嵌入形成下板8的合成树脂中使得每个管的端部分暴露来形成。内部冷却剂通道或导管同样可由嵌入下板8内的金属冷却剂管形成。外部冷却剂管可以常规方式可释放地或永久地连接到嵌入管的暴露端。管状突出部分12还可由合成树脂(即,作为下板8的整体部分)通过使用适当成形的模具腔和与每个部分的内部空间或空隙来形成,并且可选地还有下板8中的内部冷却剂通道或导管,通过使用定位在模具腔中的间隔物部件形成,并且所述间隔物部件预涂覆有脱模剂,以使得一旦环绕合成树脂固化并且线圈支撑构件从模具中移除,即可将所述间隔物部件从环绕合成树脂中移除以留下空的空间或空隙。如果管状突出部分12由合成树脂形成,那么可通过,例如,沉积过程或电镀过程使其金属化,从而使得外部金属冷却剂管或任何相关连接器可钎焊到所述突出部分12上。
为了制造线圈支撑构件1,各种部件(例如,用于形成管状突出部分12和任何整体冷却剂通道的金属管,端子块14等)使用一个或多个定位构件合适地定位在模具腔内。随后,使用常规的注射模塑设备将合成树脂引入模具腔中并且可通过遵循适当的固化时间表来使所述合成树脂硬化,这可选地可能要求使用升高的温度。成品线圈支撑构件1随后从模具中移除并经受任何后期生产过程。如上文更详细描述,可向合成树脂中添加一种或多种功能填充剂来改进或改变线圈支撑构件1的性质。
超导线圈在单独的卷绕过程中卷绕到成品线圈支撑构件1上,所述卷绕过程是常规的并且不进行进一步描述。然而,应理解,预形成超导线圈可定位在模具腔内,以使得所述超导线圈嵌入线圈支撑构件1内上板6与下板8之间。
Claims (12)
1.一种将热固性或热塑性材料引入模具腔中并硬化来产生线圈支撑构件(1)的方法,其中在制造过程中,一个或多个部件(12,14)在引入所述热固性或热塑性材料之前定位在所述模具腔内,并且其中一种或多个功能填充材料在制造过程中添加到所述热固性或热塑性材料中,以改进所述热固性或热塑性材料与整体部件之间的热匹配。
2.根据权利要求1所述的方法,其中每个部件(12,14)使用一个或多个定位构件定位在所述模具腔内。
3.根据权利要求2所述的方法,其中部件和/或定位构件在定位在所述模具腔内之前用脱模剂进行涂覆。
4.根据以上任一项权利要求所述的方法,其中所述线圈支撑构件(1)通过多级制造过程形成,在所述多级制造过程中,每一级均形成所述线圈支撑构件(1)的层或部分。
5.根据权利要求4所述的方法,其中在所述多级制造过程的不同级中使用不同的热固性或热塑性材料和/或不同的填充材料、填充材料的组合或不使用填充材料。
6.根据以上任一项权利要求所述的方法,所述方法进一步包括将线圈卷绕在所述线圈支撑构件(1)周围的步骤。
7.根据权利要求1至5中任一项权利要求所述的方法,其中预形成线圈或一个或多个超导材料块在引入所述热固性或热塑性材料之前定位在所述模具腔内。
8.根据以上任一项权利要求所述的方法,其中所述线圈支撑构件(1)的一个或多个结构特征(12)在后期生产过程中金属化。
9.一种将热固性或热塑性材料引入模具腔中并硬化来产生线圈支撑构件(1)的方法,其中所述线圈支撑构件(1)通过多级制造过程形成,在所述多级制造过程中,每一级均形成所述线圈支撑构件(1)的层或部分,并且其中在所述多级制造过程的不同级中使用不同的热固性或热塑性材料和/或不同的填充材料、填充材料的组合或不使用填充材料,以使得所述线圈支撑构件的不同层或部分具有不同的特征或性质。
10.一种由硬化的热固性或热塑性材料制成的模塑线圈支撑构件,所述模塑线圈支撑构件(1)进一步包括所述模塑线圈支撑构件(1)内的一个或多个整体部件(12,14)和一种或多种功能填充材料,以改进所述热固性或热塑性材料与所述一个或多个整体部件之间的热匹配。
11.根据权利要求10所述的模塑线圈支撑构件(1),所述模塑线圈支撑构件(1)进一步包括整体卷绕线圈或一个或多个整体超导材料块。
12.根据权利要求10或权利要求11所述的模塑线圈支撑构件(1),所述模塑线圈支撑构件(1)进一步包括一个或多个内部导管。
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CN (1) | CN104023933A (zh) |
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WO2013060568A2 (en) | 2013-05-02 |
CA2851959A1 (en) | 2013-05-02 |
EP2771163A2 (en) | 2014-09-03 |
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US9613751B2 (en) | 2017-04-04 |
BR112014008290A2 (pt) | 2017-04-25 |
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US20140287927A1 (en) | 2014-09-25 |
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