CN112774959A - 用于涂覆转子用磁体的工艺 - Google Patents
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Abstract
本发明涉及一种用于涂覆待插入到转子的凹槽中的磁体的工艺,包括以下步骤:提供永磁体,并且施加干粉末涂层,所述干粉末涂层包括预聚物、固化剂、至少一种功能性填料和发泡剂,其特征在于,所述发泡剂是化学发泡剂。为了避免预聚物的过早的反应,发泡剂是化学发泡剂。此外,本发明涉及一种永磁体和包括永磁体的转子,对所述永磁体应用了根据本发明的工艺。
Description
技术领域
本发明涉及一种用于涂覆待插入到转子的凹槽中的磁体的工艺,包括以下步骤:提供永磁体,并且涂上干粉末涂层,所述干粉末涂层包括预聚物、固化剂、至少一种功能性填料和发泡剂,其特征在于,所述发泡剂是化学发泡剂。此外,本发明涉及一种永磁体和包括永磁体的转子,其中对所述永磁体应用了根据本发明的工艺。
背景技术
永磁体励磁电机的特征在于,定子携带电绕组并且转子相对于定子可转动地安装,所述转子携带多个永磁体,在电机运行过程中,所述定子绕组与所述永磁体的磁场相互作用。
在制造励磁电机的转子中存在的问题在于将永磁体固定在转子的叠片铁芯或叠层上。通常发生在转子本体的管状凹槽中的固定尤其必须切向和径向地非常精确地进行,以便避免转子的不平衡。这是因为特别是在高性能的机器中的不平衡可能是有害的。另一方面,叠片铁芯和永磁体的经济制造离不开相对较大的制造公差。
将磁体简单地胶粘在转子上不能满足这些需求。
因此,在现有技术中,例如专利文献EP 2462202 B1或DE 10 2014 214 381 A1描述了一种工艺,包括以下步骤:提供多个永磁体并且使用包含具有嵌入式可热膨胀的微球的基体的涂层来涂覆所述永磁体。该工艺还包括提供具有尺寸过大的凹空或凹槽的转子本体,所述凹空或凹槽用于容纳涂层永磁体,将涂层永磁体插入到转子本体的凹空中,将转子本体和涂层永磁体暂时加热到超过可热膨胀的微球的膨胀温度的工艺温度。
可热膨胀的微球在温度的影响下体积显著增大,且不可逆。当施加的温度超过所谓的微球的膨胀温度时尤其如此。若已经装配有涂层永磁体的转子加热到超过可热膨胀的微球的膨胀温度时,塑性基体开始熔化或软化。然后微球会膨胀。转而,软化的基体几乎不提供阻力。结果,永磁体的总涂层厚度增加并且可以填充永磁体和周围的凹槽壁之间的空隙。因此,永磁体在固定凹槽中自对中。冷却后,由于微球的膨胀的不可逆性,工艺停止。
但是,最近发现,即使在室温下微球也可以和预聚物发生反应。因此,环氧化物过早地消耗,并且因此在某些情况下,它不能填充永磁体之间的空隙以将永磁体粘附在固定凹槽上。此外,涂层的过早反应降低了涂覆的磁体在运输和存储过程中的整体结构稳定性。
发明内容
因此,本发明所要解决的问题可以在于,提供一种用于将永磁体粘附到转子上的改进了的工艺,尤其是避免预聚物的过早反应。
该问题通过权利要求的技术方案来解决。
根据第一方面,本发明描述一种用于涂覆待插入到转子的凹槽中的磁体的工艺,包括以下步骤:提供永磁体,并且涂上干粉末涂层,所述干粉末涂层包括预聚物、固化剂、至少一种功能性填料和发泡剂,其特征在于,所述发泡剂是化学发泡剂。
以这样的方式,尽管永磁体和转子本体的制造公差较大,仍可以实现永磁体的精确定位。
此外,功能性的填料改进了磁体和转子的叠片铁芯或叠层之间的热传导,并且还可以提高涂层在极高温度下、尤其超过150℃的稳定性。借助功能性填料磁体在高温下也不会移动(出于离心力的原因),即使涂层的部分可能在高温下软化。
发泡剂是能够通过发泡过程制造蜂窝结构的物质,从而使所述基体材料膨胀、例如使发泡剂嵌入其中的材料膨胀。由于根据本发明转子的膨胀涂层用于将磁体粘附在转子凹槽上,因此基体可称为“粘合”基体。
对于本发明,需要区分物理发泡剂和化学发泡剂。
根据本发明,物理发泡剂是在活化时基本上保持化学不变的发泡剂。物理发泡剂可以例如是CFC、HCFC、烃类,如戊烷、异戊烷、环戊烷、液体CO2。在这种情况下,无需发泡剂的化学反应就实现了需进行的膨胀工作。其他的物理发泡剂是微球。这些微球在活化时膨胀并且因此导致涂层的膨胀。尽管微球的膨胀在原则上可能是由化学反应引起的,但化学反应只会发生在微球内部-微球作为整体被认为是物理发泡剂。
相比之下,根据本发明,化学发泡剂是在活化时发生化学变化的发泡剂并且直接浸没在涂层基体中,即,化学发泡剂不位于微球内部。例如,由于气体逸出和气体膨胀,化学活化的发泡剂在活化时增加涂层基体的体积(固化后不可逆)。因此,转子的膨胀涂层导致磁体固定在转子凹槽上。相对于物理发泡剂、例如微球,化学发泡剂与涂层基体混合,并且化学发泡剂在活化时发生反应,例如使得释放出充当气体的部分,并且因此使涂层基体膨胀。优选地,化学发泡剂受热分解。发现这样的化学发泡剂不会过早地与涂层基体发生反应。因此,预聚物不会过早地消耗,并且因此仍可用于填充永磁体之间的空隙并且将永磁体粘附在固定凹槽上。此外,由于涂层、尤其预聚物不会发生过早的反应,因此涂覆的磁体在运输和存储过程中的整体结构稳定性得以保持。
化学发泡剂包括例如异氰酸酯、偶氮二甲酰胺、联氨和其他氮基材料以及碳酸氢钠。通过化学发泡剂的化学反应形成了气态产物和其他的副产品,通过泡沫生产过程的热量或者反应聚合物的放热促进了所述化学反应。由于发生发泡反应形成低分子量化合物充当发泡气体,因此可能释放出额外的放热。低分子量化合物一旦形成就永远不会还原为最初的发泡剂。因此,反应优选是不可逆的。
根据本发明可以使用混合的物理/化学发泡剂。这里协力使用化学的和物理的发泡使得相对于释放和吸收的热能彼此抵消,使升温最小化。否则,由于物理发泡剂的高加载而产生的过高的放热可以导致热降解和结构不稳定性。然而,优选仅使用化学发泡剂,尤其是在没有微球作为物理发泡剂的情况下并且尤其在没有任何物理发泡剂的情况下。
“化学发泡剂的活化”应理解为通过引发化学发泡剂的反应而诱发膨胀工艺的操作。这可以是利用高能辐射的照射,例如电子照射、电磁感应、超声波、激光或UV辐射、可见光或化学发泡剂加热到发泡剂发生化学反应的温度。根据优选的实施例,诱发过程、例如具有高能辐射的照射和/或加热导致化学发泡的分解。在特别的实施例中,诱发过程、例如具有高能辐射的照射和/或加热导致化学发泡剂的分解。在特别的实施例中,诱发过程、例如具有高能辐射的照射和/或加热导致化学发泡剂的分解,其中,分解导致气体的形成,其至少部分地导致基体的膨胀。
功能性的填料可以例如是碳酸钙和/或硫酸钡和/或玻璃纤维和/或金属颗粒。
总而言之,上述工艺即使当存在相对较大的制造公差的情况下也允许将磁体精确定位在转子凹槽的中心。上述工艺不需要额外的粘合剂并且在使用中可以提供较好的防振动保护。由于粉末涂层基体膨胀均匀,磁体被精确并且充分地粘附,即,固定在转子的凹槽中。
粉末涂覆系统通常是本领域技术人员已知的。它们可以包括粘合剂和添加剂,可向其添加着色剂和填料。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,预聚物是环氧预聚物。环氧树脂是相对低分子量的预聚物,通常含有至少两个环氧基团。环氧基团可指定为缩水甘油基或环氧乙烷基团。
很多种环氧树脂是工业化生产的。由预聚物反应得到的环氧聚合物是高分子或半高分子材料。不同的链长由聚合反应引起。生产环氧树脂的原材料主要来自石油。环氧树脂的一个重要标准是环氧基团含量或者说环氧值。这表示为有关材料中环氧基团的特定的物质的量。它计算为该材料中环氧基团的物质的量除以所考虑的材料的质量(在这种情况下为树脂的质量)的比例。环氧值的倒数称为“环氧当量”,它是环氧树脂样品的质量与该材料中存在的环氧基团的数量之比。原则上,根据本发明可以使用多种环氧预聚物和经聚合后的环氧聚合物。通常利用化学计量或接近化学计量的固化剂(也称为硬化剂)的量使环氧树脂固化,以便达到最大的物理性能。可以混合不同级的环氧树脂并且加入添加剂、增塑剂和/或填料用以达到所需的加工性能和最终性能。混合物、添加物和填料的使用被称为配制。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,固化剂是非潜伏性固化剂。它也通过一定的温度实现,但不像在潜伏性固化剂的情形那样通过与化学基团分离来实现。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,添加有至少一种功能性填料。
“预聚物的活化”应理解为引发预聚物聚合反应的操作。这可以是利用高能辐射的照射,例如电子照射、电磁感应、超声波、激光或UV辐射、可见光或将化学发泡剂加热到固化剂的化学反应诱发聚合反应的温度。根据优选的实施例,诱发过程、例如具有高能辐射的照射和/或加热导致固化剂活化,进而引发聚合过程。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,粉末饰面涂层不含弹性体。
通过气体逸出和气体膨胀,化学活化的发泡剂在活化时增加涂层基体的体积(固化后不可逆)。与物理发泡剂、例如微球不同,即使没有额外的弹性体聚合物,化学发泡剂也为转子凹槽中的磁体提供均质稳定的基体。总而言之,尤其由于使用了化学发泡剂,因此得到了具有良好密封性和粘附力的均质基体。不需要其他的弹性体来稳定基体。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,粉末饰面涂层不含物理发泡剂。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺还包括以下步骤:优选通过施加至少80℃的温度将粉末涂层熔化用以在永磁体上形成涂层。有利地,这允许涂覆的磁体插入到转子的凹槽中。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺包括以下步骤:将永磁体插入到转子的凹槽中。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺包括以下步骤:加热被插入到转子的凹槽中的永磁体,以便引起预聚物的固化。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺包括以下步骤:加热被插入到转子的凹槽中的永磁体,以便诱发化学发泡剂分解以膨胀涂层。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺还包括以下步骤:加热被插入到转子的凹槽中的永磁体,以便诱发预聚物的固化并且同时诱发化学发泡剂的分解以膨胀涂层。
根据前述方法的实施例,用粉末涂覆磁体可以在空间和时间上与将磁体结合在转子的凹槽中分开地进行。因此,磁体可以被涂覆并且随后插入到转子和/或定子中、优选为转子。因此,用粘合剂涂覆磁体可以在特别配备的部门中完成,或者通过磁体制造商或磁体供应商完成。因此,能够灵活并且成本高效地应用上述方法。粉末可以被喷射、挤压或者压模在磁体上。粉末优选喷射在磁体上。此外,粉末可以作为薄膜层压在磁体上。因此,涂覆的磁体可以暂时存储和/或从涂层位置运输到结合位置。在安装磁体的装配操作中不需要使用粘合剂。节省了在生产转子的地方处理粉末。因此,以此可以避免由于不当使用粉末而造成的污染。此外,上述方法是高度灵活的。
根据一个实施例,本发明描述用于涂覆磁体的工艺,其中,所述工艺还包括以下步骤:使永磁体上的涂层薄膜膨胀并且使预聚物固化,优选通过施加180℃至260℃之间的温度。优选地,预聚物的固化和化学发泡剂引起的膨胀通过加热、优选通过施加180℃至260℃之间的温度同时完成。将温度保持低于260℃降低了预聚物降解的风险,这会降低涂层的功能性。
根据本发明的另一方面,描述了一种对其应用了根据本发明的工艺的永磁体。
根据本发明的另一方面,描述了一种包括对其应用了根据本发明的工艺的永磁体的转子。
粘合剂可以是环氧树脂、含羧基和羟基的聚酯、丙烯酸树脂以及特殊用途的改性树脂。
添加剂会影响例如表面结构、表面光泽度、表面硬度和加工条件等重要参数。聚丙烯酸酯可以用作均化剂。同样还可用作粉末涂覆系统中的添加剂。使用的着色剂可以是颜料或染料。
最后,填料用于增加体积和用于调整堆积密度。碳酸钙、滑石或硫酸钡均可以用作填料。在混合上述成分或者混合部分上述成分之后,在加热下挤压混合物、冷却并且研磨成粉末。
附图说明
图1示出根据本发明的方法的示意图。
附图中的附图标记表示相同或相似的元件。附图以五个示意性的分步骤示出根据本发明的用于电机的转子的制造方法。
具体实施方式
第一步骤a提供永磁体10。
进一步的步骤b中,所提供的永磁体10借助粉末涂覆系统12利用干粉末涂层14进行喷涂,使得均匀的粉末涂层16沉积在永磁体10的表面上。
在进一步的步骤c中,使粉末涂覆的永磁体10经受涂覆温度TB的影响,使得粉末涂层16转化为涂层18。
在进一步的步骤d中,现在永久涂覆的永磁体10插入到叠片22的凹槽20中,所述叠片用作电机转子的基本主体。
在步骤e中,叠片22与永磁体10一起加热至工艺温度TP,使得涂层18转化为膨胀涂层24。根据本发明的方法使用化学发泡剂。与物理发泡剂、例如微球不同的是,化学发泡剂在活化时发生反应,例如使得释放出充当膨胀气体的部分,并且因此使涂层18膨胀以形成膨胀涂层24。在图1所示的实施例中,化学发泡剂加热后分解。化学发泡剂的活化和预聚物的活化、即由固化剂引起的预聚物的聚合反应基本上同时发生。化学发泡剂不会过早地与涂层18发生反应。因此,预聚物不会过早地消耗,并且因此仍可用于填充永磁体10之间的空隙并且将永磁体10粘附在固定凹槽20上。此外,由于粘合剂不会发生过早的反应,因此涂覆的磁体10在运输和存储过程中的整体结构稳定性得以保持。
附图标记列表
永磁体 10
粉末涂覆系统 12
干粉末涂层 14
粉末涂层 16
涂覆温度 TB
涂层 18
凹槽 20
叠片 22
工艺温度 TP
膨胀涂层 24
Claims (10)
1.一种用于涂覆待插入到转子的凹槽(20)中的磁体(10)的工艺,包括以下步骤:
提供永磁体(10),和
涂上干粉末涂层(14),所述干粉末涂层(14)包括预聚物、固化剂、至少一种功能性填料和发泡剂,其特征在于所述发泡剂是化学发泡剂。
2.根据权利要求1所述的工艺,其特征在于,所述预聚物是环氧预聚物。
3.根据权利要求1或2所述的工艺,其特征在于,所述固化剂是非潜伏性固化剂。
4.根据前述权利要求之一所述的工艺,其特征在于,所述干粉末涂层(14)不具有弹性体。
5.根据前述权利要求之一所述的工艺,其特征在于,所述干粉末涂层(14)不具有物理发泡剂。
6.根据前述权利要求之一所述的工艺,其特征在于,所述工艺还包括以下步骤:优选通过施加80℃至120℃之间的涂覆温度(TB),使存在于磁体上作为粉末涂层(16)的干粉末涂层(14)熔化,以便在永磁体上形成涂层(18)。
7.根据权利要求6所述的工艺,其特征在于,所述工艺还包括以下步骤:将永磁体(10)插入到转子的凹槽(20)中。
8.根据权利要求7所述的工艺,其特征在于,所述工艺还包括以下步骤:优选通过施加180℃至260℃之间的工艺温度(TP),使所述永磁体(10)上的涂层(16)膨胀并且固化所述预聚物,以便形成膨胀涂层(24)。
9.一种永磁体(10),对其应用了根据权利要求1至8任一项所述的工艺。
10.一种包括根据权利要求9所述的永磁体(10)的转子。
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EP4345139A1 (en) | 2022-09-27 | 2024-04-03 | Yantai Zhenghai Magnetic Material Co., Ltd. | Expanded coating, preparation method and use thereof, and permanent magnet comprising same |
WO2024130816A1 (zh) * | 2022-12-19 | 2024-06-27 | 天津三环乐喜新材料有限公司 | 一种粘结剂组合物和粘结涂层及其应用 |
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US20210138501A1 (en) | 2021-05-13 |
EP3819922A1 (en) | 2021-05-12 |
EP3819922B1 (en) | 2024-09-11 |
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