CN115036092A - Composite magnetic ring and preparation method thereof - Google Patents
Composite magnetic ring and preparation method thereof Download PDFInfo
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- CN115036092A CN115036092A CN202210866658.5A CN202210866658A CN115036092A CN 115036092 A CN115036092 A CN 115036092A CN 202210866658 A CN202210866658 A CN 202210866658A CN 115036092 A CN115036092 A CN 115036092A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
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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
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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
- H01F41/0253—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 permanent magnets
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F2003/103—Magnetic circuits with permanent magnets
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F2003/106—Magnetic circuits using combinations of different magnetic materials
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Abstract
The invention provides a composite magnetic ring and a preparation method thereof, wherein the composite magnetic ring comprises an inner ring magnetic ring and an outer ring magnetic ring which are coaxial; the outer wall of the inner ring magnetic ring is provided with axial trapezoidal ribs; the inner wall of the outer ring magnetic ring is provided with a groove matched with the trapezoidal ribs of the inner ring magnetic ring; a magnetic field is arranged between every two adjacent grooves, and the adjacent magnetic fields are in different orientations; the material of the inner ring magnetic ring comprises a soft magnetic composite material; the material of the outer ring magnetic ring comprises a permanent magnet composite material; the composite magnetic ring fully utilizes the characteristics of two different magnetic materials, couples the two magnetic materials, optimizes the structure of the magnetic ring, and greatly improves the surface magnetic field of the composite magnetic ring by further designing a magnetic circuit; the composite magnetic ring has the advantages of light weight, high surface magnetism and good strength, has excellent dynamic balance characteristic and is suitable for various micro and special motors.
Description
Technical Field
The invention belongs to the technical field of permanent magnet motors, and particularly relates to a composite magnetic ring and a preparation method thereof.
Background
The permanent magnet motor generates a magnetic field of the motor through the permanent magnet, so that an exciting current is not needed, and compared with the traditional induction motor, the permanent magnet motor has the remarkable advantages of simpler structure, more reliable operation, small size, light weight, small loss, high efficiency and the like, and is widely applied to various fields of traffic, aviation, national defense, industry and daily life. In recent years, with increasing importance placed on environmental problems caused by the greenhouse effect in various countries around the world, people have increasingly high requirements for energy efficiency of various motors, and the motors are promoted to be miniaturized, lightened and high in efficiency. In a permanent magnet motor, the influence of the performance of a magnetic material on the structural design and final performance of the motor is very critical, and under the same winding parameters and test conditions, the higher the performance of the magnetic material is, the higher the maximum torque of the motor is, and the higher the efficiency of the highest efficiency point is. Meanwhile, for the permanent magnet motor with specified power, the magnetic material with higher performance is adopted, so that the number of turns of the winding can be reduced, and the size of the motor is reduced.
On the other hand, the size of the air-gap magnetic field of the permanent magnet motor is closely related to the shape, size (surface area and thickness), magnetizing method, magnetic coupling structure and the like of the adopted permanent magnet. Even if magnetic materials with the same performance are adopted, the sizes of the obtained air gap magnetic fields are completely different by adopting different magnetic circuit designs, so that how to adopt a proper magnetic circuit structure and fully utilize the performance of the magnetic materials is also a hot point of research in the field of motors.
CN107959361A discloses a stator of a permanent magnet torque motor, which is characterized in that notches between stator teeth are sealed by a sealing material, so that the stator teeth are in an annular integral structure, the stator yoke is in another integral structure, and the stator teeth and the stator yoke can be separated from each other, therefore, in the stator assembly process, after each armature winding is assembled on the corresponding stator tooth, the armature winding and the stator tooth can be directly connected together through the insertion or buckling of a slot. In addition, when the stator core is made of a nanocrystalline soft magnetic alloy material or a high-grade silicon steel material, the loss of the motor is favorably reduced; when the rotor permanent magnet is supported by the iron core and the tangential magnetizing permanent magnet and the radial magnetizing permanent magnet are alternately arranged on the surface of the working air gap side of the iron core, the torque density of the motor is improved.
CN111164867A discloses a permanent magnet carrier (which may be a rotor or a stator of an electrical machine) comprising a first non-magnetic ring and a second non-magnetic ring. Between the rings are soft magnetic pole elements. The soft magnetic pole elements are each connected to the first and second non-magnetic rings, and the soft magnetic pole elements are separated from each other by the first and second non-magnetic rings. A permanent magnet is disposed between the soft magnetic pole elements.
Based on the above background, how to provide a magnetic ring device and a material thereof, which can provide a high surface under the condition of a smaller size, and promote the miniaturization and high-efficiency development of a motor, is a problem to be solved at present.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a composite magnetic ring and a preparation method thereof, wherein the composite magnetic ring is made of two different magnetic materials, and the structure of the magnetic ring is optimized, so that the surface magnetic field of the magnetic ring is effectively improved, the air gap magnetic field of a motor can be improved when the composite magnetic ring is applied to the motor, and the miniaturization and the high efficiency of the motor are facilitated; the preparation method is simple in process flow and suitable for industrial production.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the invention provides a composite magnetic ring, comprising an inner ring magnetic ring and an outer ring magnetic ring which are coaxial;
the outer wall of the inner ring magnetic ring is provided with axial trapezoidal ribs;
the inner wall of the outer ring magnetic ring is provided with a groove matched with the trapezoidal ribs of the inner ring magnetic ring; a magnetic field is arranged between every two adjacent grooves, and the adjacent magnetic fields are in different orientations;
the material of the inner ring magnetic ring comprises a soft magnetic composite material; the material of the outer ring magnetic ring comprises a permanent magnet composite material.
According to the invention, the composite magnetic ring fully utilizes the magnetic characteristics of the soft magnetic composite material and the permanent magnetic composite material, designs a novel structure of the soft magnetic composite material inner ring and the permanent magnetic composite material outer ring, and greatly improves the surface magnetic field of the composite magnetic ring by further designing a magnetic circuit; the composite magnetic ring has the advantages of light weight, high surface magnetism and good strength, has excellent dynamic balance characteristic and is suitable for various micro and special motors.
The following technical solutions are preferred technical solutions of the present invention, but not limited to the technical solutions provided by the present invention, and technical objects and advantageous effects of the present invention can be better achieved and achieved by the following technical solutions.
As a preferable technical solution of the present invention, the outer diameter of the inner ring magnetic ring is 35-45mm, for example, 35mm, 37mm, 39mm, 41mm, 43mm or 45 mm; the internal diameter is 30 to 38mm, for example 30mm, 32mm, 34mm, 36mm or 38mm, and the above-mentioned values are not limited to the values listed, but other values not listed in the respective numerical ranges are also applicable.
Preferably, the thickness of the inner ring magnetic ring is 2.5-3.5mm, such as 2.5mm, 2.7mm, 2.9mm, 3.1mm, 3.3mm or 3.5mm, but not limited to the recited values, and other values not recited in the numerical range are also applicable.
Preferably, the outer diameter of the outer ring magnetic ring is 40-50mm, such as 40mm, 42mm, 44mm, 46mm, 48mm or 50 mm; the internal diameter is 30 to 45mm, for example 30mm, 32mm, 34mm, 36mm, 38mm, 40mm, 43mm or 45mm, and the selection of the above-mentioned values is not limited to the values listed, and other values not listed in the respective numerical ranges are also applicable.
Preferably, the thickness of the outer ring magnetic ring is 2.5-7.5mm, such as 2.5mm, 3.0mm, 4.5mm, 5.0mm, 5.5mm, 6.0mm, 6.5mm, 7.0mm or 7.5mm, but not limited to the recited values, and other values not recited in the numerical range are also applicable.
In the invention, the size and thickness of the inner and outer ring magnetic rings have certain influence on the performance of the finally obtained composite magnetic ring. If the thickness is proper, but the sizes of the inner ring magnetic ring and the outer ring magnetic ring are too large, namely the size of the integral composite magnetic ring is too large, the surface magnetic waveform of the magnetic ring is changed, collapse occurs in the middle of a peak, and the peak value of the surface magnetic is reduced; if the thickness is proper, but the sizes of the inner and outer ring magnetic rings are too small, namely the size of the integral composite magnetic ring is too small, the total magnetic flux of the magnetic ring is reduced; if the overall size of the composite magnetic ring is proper, but the thickness of the inner ring magnetic ring is too thick, the waste of soft magnetic materials can be caused, and the total weight of the magnetic ring is increased; if the overall size of the composite magnetic ring is proper, but the thickness of the inner ring magnetic ring is too thin, the magnetic flux on the surface of the composite magnetic ring is reduced; if the overall size of the composite magnetic ring is proper, but the thickness of the outer ring magnetic ring is too thick, the waste of permanent magnet materials is caused; if the overall size of the composite magnetic ring is appropriate, but the thickness of the outer ring magnetic ring is too thin, the magnetic flux on the surface of the composite magnetic ring is reduced.
In a preferred embodiment of the present invention, the height of the trapezoidal ribs of the inner ring magnetic ring is 1/2-2/3, such as 1/2, 7/12, or 2/3, which is equal to the thickness of the outer ring magnetic ring.
In the present invention, it is also important to control the height of the trapezoidal ribs. If the height of the trapezoidal ribs is too small, the size and distribution of surface magnetic flux can be changed, the peak value is reduced, and if the height of the trapezoidal ribs is too large, the strength of an outer ring magnetic ring can be poor, and in actual use, the outer magnetic ring is cracked due to external factors such as cold and hot temperature difference and vibration.
Preferably, the angle between the side of the trapezoidal section of the trapezoidal rib and the horizontal plane is 45-60 °, such as 45 °, 50 °, 55 ° or 60 °, but not limited to the values listed, and other values not listed in the range of the values are also applicable.
In the invention, the included angle between the side edge of the trapezoidal section of the trapezoidal rib and the horizontal plane also influences the performance of the composite magnetic ring. If the angle is too small. Apparent magnetic peak value reduction occurs; if the angle is too large, the strength of the outer ring magnetic ring is deteriorated.
Preferably, the number of trapezoidal ribs is 6-10, such as 6, 7, 8, 9 or 10, but not limited to the recited values, and other values not recited in the range of values are equally applicable.
As the preferable technical scheme of the invention, the surface magnetic curve of the composite magnetic ring is in a sine wave shape.
Preferably, the average secondary peak value of the composite magnetic ring is not less than 2500Gs, such as 2500Gs, 2550Gs, 2600Gs, 2650Gs, 2700Gs, 2750Gs, 2800Gs, 2850Gs, 2900Gs, 2950Gs or 3000Gs, but is not limited to the recited values, and other values not recited in the numerical range are also applicable.
In a second aspect, the invention provides a preparation method of the above composite magnetic ring, and the preparation method comprises the following steps:
(1) preparing an inner ring magnetic ring by adopting a soft magnetic composite material through an injection process;
(2) preparing an outer ring magnetic ring by an injection process on the basis of the obtained inner ring magnetic ring, thereby obtaining a composite magnetic ring;
wherein, a magnetic field is arranged in a mould used for preparing the outer ring magnetic ring.
According to the invention, when the inner ring magnetic ring is prepared, the magnetic field does not need to be additionally arranged in the mold, only the required magnetic field needs to be arranged in the mold when the outer ring magnetic ring is prepared, and a mature injection process is adopted, so that the process is simple, the production efficiency is high, and the large-scale production is facilitated.
As a preferable technical scheme of the invention, the preparation of the soft magnetic composite material in the step (1) comprises the following steps:
preparing a surface treatment solution: mixing phosphoric acid, an alcohol solution, a zinc source and a water-soluble resin to obtain a surface treatment solution;
and secondly, mixing the obtained surface treatment solution with iron powder, a silane coupling agent and a high polymer material in sequence, mixing, and then mixing and granulating to obtain the soft magnetic composite material.
In the invention, the permanent magnet composite material of the outer ring magnetic ring can be prepared by the method of patent 202111363515.4. The soft magnetic composite material prepared by the method has good strength and injectability on the premise of ensuring enough soft magnetic performance, and compared with the existing soft magnetic composite material, the soft magnetic composite material can be integrally injection-molded with the permanent magnetic ring in an injection molding mode, and finally the composite magnetic ring with excellent performance is obtained.
As a preferable embodiment of the present invention, the preparation of the surface treatment solution according to step (i) more specifically includes: phosphoric acid, absolute ethyl alcohol, water, a zinc source and water-soluble resin are sequentially mixed and heated to obtain a surface treatment solution.
Preferably, the zinc source comprises zinc oxide.
Preferably, the water-soluble resin comprises any one of polypropylene, polyamide or polyethylene glycol or a combination of at least two thereof.
Preferably, the temperature of the mixing in step (i) is 70 to 90 ℃, for example 70 ℃, 75 ℃, 80 ℃, 85 ℃ or 90 ℃, but is not limited to the recited values, and other values not recited in the range of the values are also applicable.
In a preferred embodiment of the present invention, the particle size of the iron powder in step (ii) is 50 to 100. mu.m, for example, 50. mu.m, 60. mu.m, 70. mu.m, 80. mu.m, 90. mu.m, or 100. mu.m, but the particle size is not limited to the above-mentioned values, and other values not shown in the above-mentioned range are also applicable.
Preferably, the magnetic permeability of the iron powder in step (c) is 600-800H/m, such as 600H/m, 650H/m, 700H/m, 750H/m or 800H/m, but not limited to the values listed, and other values not listed in the range of the values are also applicable.
Preferably, the iron powder of step (ii) has a saturation magnetization of 1.4-1.8T, such as 1.4T, 1.5T, 1.6T, 1.7T, or 1.8T, but not limited to the recited values, and other values not recited in this range are also applicable.
Preferably, the mass ratio of the surface treatment solution to the iron powder in step (ii) is 1 (9-11), such as 1:9, 1:9.5, 1:10, 1:10.5 or 1:11, but not limited to the recited values, and other values not recited in the range of the values are also applicable.
As a preferable technical scheme of the invention, the adding amount of the silane coupling agent in the step (II) is 0.5-1.5% of the mass of the iron powder, for example.
Preferably, step (c) the polymeric material comprises any one of PP, PA6, PA12, POM or PPs or a combination of at least two of these, typical but non-limiting examples being: combinations of PP and PA6, PA6 and PA12, POM and PPs, and the like.
Preferably, the temperature of the mixing in step (c) is 130-160 ℃, such as 130 ℃, 140 ℃, 150 ℃ or 160 ℃, but not limited to the recited values, and other unrecited values within the range of values are equally applicable.
As a preferable technical solution of the present invention, in the mold described in the step (2), the set magnetic field waveform is a sine waveform.
Preferably, in the mold of step (2), the magnetic field strength is set to 0.8-1.0T, such as 0.8T, 0.85T, 0.9T, 0.92T or 1.0T, but not limited to the values listed, and other values not listed in the range of values are also applicable.
In the invention, if the orientation magnetic field in the die is less than 0.8T, the magnetic material in the outer ring magnetic ring can not obtain sufficient orientation, and the high surface magnetism of the invention can not be achieved; the magnetic field strength in the mold also need not exceed 1.0T because the magnetic material is already sufficiently oriented at 1.0T without the need for further increases.
Compared with the prior art, the invention has the following beneficial effects:
(1) the composite magnetic ring disclosed by the invention fully utilizes the magnetic characteristics of the soft magnetic composite material and the permanent magnetic composite material, the soft magnetic composite material and the permanent magnetic composite material are coupled, a novel structure of a soft magnetic composite material inner ring and a permanent magnetic composite material outer ring is designed, a magnetic circuit is further designed, the surface magnetic field of the composite magnetic ring is greatly improved, and the average surface magnetic strength of the composite magnetic ring can reach more than 2510Gs by further controlling the conditions of the size, the thickness and the like of each magnetic ring in the design process;
(2) the composite magnetic ring has the advantages of light weight, high surface magnetism and good strength, and has excellent dynamic balance characteristic because the composite magnetic ring is formed by the permanent magnetic ring and the soft magnetic ring which are integrally formed by an injection process, thereby being suitable for various micro-special motors
(3) The preparation method of the composite magnetic ring has the advantages of simple process flow, high production efficiency and better industrial application prospect.
Drawings
Fig. 1 is a schematic structural diagram of a composite magnetic ring provided in embodiment 1 of the present invention.
The magnetic field generator comprises 1-inner ring magnetic ring, 11-trapezoidal ribs, 2-outer ring magnetic ring, N-N pole magnetic field and S-S pole magnetic field.
Detailed Description
In order to better illustrate the present invention and facilitate the understanding of the technical solutions of the present invention, the present invention is further described in detail below. However, the following examples are only simple examples of the present invention and do not represent or limit the scope of the present invention, which is defined by the claims.
The following are typical but non-limiting examples of the invention:
example 1:
the embodiment provides a composite magnetic ring and a preparation method thereof, wherein the preparation method comprises the following steps:
firstly, preparing a soft magnetic composite material required by an inner ring magnetic ring 1:
preparing a surface treatment solution: a. adding 1 kg of 85 wt% phosphoric acid solution into 10 kg of absolute ethyl alcohol, then adding 200g of deionized water, and fully stirring; b. adding 200g of zinc oxide, and fully stirring; c. then 300g of polyethylene glycol was added; d. heating the solution to 80 ℃, and fully stirring until the water-soluble resin is completely dissolved;
adding the obtained surface treatment solution into iron powder with D50 of 50 mu m, magnetic conductivity of 800H/m and saturation magnetization of 1.8T, stirring for 30min in a high-speed mixer, heating to 150 ℃, and continuing stirring for 1H, wherein the mass ratio of the surface treatment solution to the iron powder is 1: 10; then adding a silane coupling agent (KH550) into the iron powder, and stirring for 30min, wherein the adding amount of the silane coupling agent is 1% of the mass of the iron powder; then adding PA12 powder, continuously stirring for 1h at a high speed, mixing uniformly, and then placing the mixture into a double-screw mixing roll for mixing and granulating to obtain the soft magnetic composite material.
Next, a permanent magnet composite material was prepared, and the preparation method thereof is referred to example 1 in patent 202111363515.4.
Preparing a composite magnetic ring:
(1) preparing an inner ring magnetic ring 1 by using the obtained soft magnetic composite material and adopting an injection molding process, wherein the injection temperature is 260 ℃; wherein, the outer diameter of the inner ring magnetic ring 1 is 35mm, the inner diameter is 30mm, and the thickness is 2.5 mm; the outer wall of the inner ring magnetic ring 1 is provided with 8 trapezoid ribs 11, the height of each trapezoid rib 11 is 1/2 of the thickness of the outer ring magnetic ring 2, and the included angle between the side edge of the trapezoid section and the horizontal plane is 45 degrees;
(2) preparing an outer ring magnetic ring 2 by using the obtained permanent magnet composite material through an injection process on the basis of the obtained inner ring magnetic ring 1, wherein a magnetic field in a die cavity is of an 8-pole structure with alternating N poles and S poles, the waveform is a sine wave, and the magnetic field intensity is 1.0T; the outer diameter of the outer ring magnetic ring 2 is 40mm, the inner diameter is 35mm, and the thickness is 2.5 mm.
The schematic structural diagram of the composite magnetic ring prepared by the preparation method is shown in fig. 1.
Example 2:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when preparing the soft magnetic composite material, iron powder with D50 of 50 mu m, magnetic conductivity of 800H/m and saturation magnetization of 1.4T is selected in the step II.
Example 3:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when preparing the soft magnetic composite material, iron powder with the D50 of 75 mu m, the magnetic permeability mu of 700H/m and the saturation magnetization of 1.6T is selected in the step II.
Example 4:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when preparing the soft magnetic composite material, PPS powder is used as the polymer material selected in the step II; correspondingly, due to the difference of high polymer materials, the injection temperature in the step (1) is 300 ℃ when the composite magnetic ring is prepared.
Example 5:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: and (3) when the composite magnetic ring is prepared, the magnetic field intensity in the die cavity in the step (2) is 0.8T.
Example 6:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which are different from the method in embodiment 1 only in that: when the composite magnetic ring is prepared, the outer diameter of the inner ring magnetic ring 1 in the step (1) is 45mm, the inner diameter is 38mm, and the thickness is 3.5 mm; correspondingly, in the step (2), the outer diameter of the outer ring magnetic ring 2 is 50mm, the inner diameter is 45mm, and the thickness is 2.5 mm.
Example 7:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when the composite magnetic ring is prepared, the outer diameter of the inner ring magnetic ring 1 in the step (1) is 40mm, the inner diameter is 33mm, and the thickness is 3.5 mm; correspondingly, in the step (2), the outer diameter of the outer ring magnetic ring 2 is 50mm, the inner diameter is 40mm, and the thickness is 5 mm.
Example 8:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when the composite magnetic ring is prepared, the height of the trapezoidal ribs 11 of the inner ring magnetic ring 1 in the step (1) is 2/3 of the thickness of the outer ring magnetic ring 2.
Example 9:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which are different from the method in embodiment 1 only in that: when the composite magnetic ring is prepared, in the step (1), the included angle between the side edge of the trapezoidal section of the inner ring magnetic ring 1 and the trapezoidal ribs 11 and the horizontal plane is 60 degrees.
Example 10:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, in the step (1), the outer diameter of the inner ring magnetic ring 1 is 45mm, the inner diameter is 35mm, and the thickness is 5 mm.
Example 11:
the present embodiment provides a composite magnetic ring and a preparation method thereof, the preparation method is as described in embodiment 1, and the difference is only that: when the composite magnetic ring is prepared, in the step (1), the outer diameter of the inner ring magnetic ring 1 is 35mm, the inner diameter is 33mm, and the thickness is 1 mm.
Example 12:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, in the step (2), the outer diameter of the outer ring magnetic ring 2 is 65mm, the inner diameter is 45mm, and the thickness is 10 mm.
Example 13:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, in the step (2), the outer diameter of the outer ring magnetic ring 2 is 47mm, the inner diameter is 45mm, and the thickness is 1 mm.
Example 14:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, in the step (1), the height of the trapezoidal ribs 11 of the inner ring magnetic ring 1 is 1/3 of the thickness of the outer ring magnetic ring 2.
Example 15:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, the height of the trapezoidal ribs 11 of the inner ring magnetic ring 1 in the step (1) is 3/4 of the thickness of the outer ring magnetic ring 2.
Example 16:
the present embodiment provides a composite magnetic ring and a method for manufacturing the same, which is different from the method in embodiment 6 only in that: when the composite magnetic ring is prepared, the outer wall of the inner ring magnetic ring 1 in the step (1) is provided with square ribs, namely, the included angle between the side edge and the horizontal plane is 90 degrees.
Comparative example 1:
this comparative example provides a composite magnetic ring and a method of making the same, with reference to the method of example 1, except that: pure PA12 material was used instead of the soft magnetic composite material.
The average surface magnetic strength of the composite magnetic rings obtained in examples 1 to 16 and comparative example 1 was measured at 23 ℃ using a three-dimensional surface magnetic tester, and the results are shown in table 1.
TABLE 1
By adopting the preparation method disclosed by the embodiment 1-9 of the invention, the average surface magnetism of the prepared composite magnetic ring can reach more than 2510 Gs; compared with the embodiment 6, in the embodiment 10, the thickness of the inner ring magnetic ring is too thick, the surface magnetism of the composite magnetic ring is slightly increased, but the consumption of the soft magnetic composite material and the total weight of the composite magnetic ring are both increased more; compared with embodiment 1, in embodiment 11, the thickness of the inner magnetic ring is too thin, and the surface magnetism of the composite magnetic ring is reduced; compared with the embodiment 6, in the embodiment 12, the thickness of the outer ring magnetic ring is too thick, the surface magnetism of the composite magnetic ring is increased, but the using amount of the permanent magnet composite material and the total weight of the composite magnetic ring are increased, and the utilization efficiency of the permanent magnet composite material is obviously lower; compared with the embodiment 6, the thickness of the outer ring magnetic ring in the embodiment 13 is too thin, so that the surface magnetism of the composite magnetic ring is obviously reduced; compared with the embodiment 6, the height of the trapezoidal ribs of the inner ring magnetic ring in the embodiment 14 is too small, so that the surface magnetism of the composite magnetic ring is reduced; compared with the embodiment 6, in the embodiment 15, the height of the trapezoidal ribs of the inner ring magnetic ring is too large, the surface magnet is not obviously lifted, but the outer ring magnetic ring cracks in the cooling process after injection; compared with the embodiment 6, in the embodiment 16, the inner ring magnetic ring adopts the square ribs, the surface magnetism of the magnetic ring is slightly improved, but the composite magnetic ring cracks in the process of reliability test (such as cold and hot impact).
It can be seen from the above embodiments and comparative examples that the composite magnetic ring of the present invention fully utilizes the magnetic characteristics of the soft magnetic composite material and the permanent magnetic composite material, couples the two, designs the new structure of the inner ring of the soft magnetic composite material and the outer ring of the permanent magnetic composite material, and further designs the magnetic circuit, thereby greatly improving the average surface magnetic strength of the composite magnetic ring, and further controlling the size, thickness and other conditions of each magnetic ring in the design process, so that the surface magnetic field of the composite magnetic ring can reach over 2510 Gs; the composite magnetic ring has the advantages of light weight, high surface magnetism and good strength, has excellent dynamic balance characteristic, is suitable for various micro special motors, and has the advantages of simple process flow, high production efficiency and good industrial application prospect.
The present invention is illustrated in detail by the examples given above, but the present invention is not limited to the details given above, which means that the present invention is not limited to the details given above. It will be apparent to those skilled in the art that any modifications to the present invention, equivalents thereof, additions of additional operations, selection of specific ways, etc., are within the scope and disclosure of the present invention.
Claims (10)
1. A composite magnetic ring is characterized in that the composite magnetic ring comprises an inner ring magnetic ring and an outer ring magnetic ring which are coaxial;
the outer wall of the inner ring magnetic ring is provided with axial trapezoidal ribs;
the inner wall of the outer ring magnetic ring is provided with a groove matched with the trapezoidal ribs of the inner ring magnetic ring; a magnetic field is arranged between every two adjacent grooves, and the adjacent magnetic fields are in different orientations;
the material of the inner ring magnetic ring comprises a soft magnetic composite material; the material of the outer ring magnetic ring comprises a permanent magnet composite material.
2. The composite magnetic ring as claimed in claim 1, wherein the outer diameter of the inner ring magnetic ring is 35-45mm, and the inner diameter is 30-38 mm;
preferably, the thickness of the inner ring magnetic ring is 2.5-3.5 mm;
preferably, the outer diameter of the outer ring magnetic ring is 40-50mm, and the inner diameter of the outer ring magnetic ring is 30-45 mm;
preferably, the thickness of the outer ring magnetic ring is 2.5-7.5 mm.
3. The composite magnetic ring as claimed in claim 1 or 2, wherein the height of the trapezoidal ribs of the inner ring magnetic ring is 1/2-2/3 of the thickness of the outer ring magnetic ring;
preferably, the included angle between the side edge of the trapezoidal section of the trapezoidal rib and the horizontal plane is 45-60 degrees;
preferably, the number of the trapezoidal ribs is 6 to 10.
4. The composite magnetic ring as claimed in any one of claims 1 to 3 wherein the surface magnetic curve of the composite magnetic ring is sinusoidal;
preferably, the average surface magnetic peak value of the composite magnetic ring is not less than 2500 Gs.
5. A method of making a composite magnetic ring as claimed in any one of claims 1 to 4, said method comprising the steps of:
(1) preparing an inner ring magnetic ring by adopting a soft magnetic composite material through an injection process;
(2) preparing an outer ring magnetic ring by an injection process on the basis of the obtained inner ring magnetic ring, thereby obtaining a composite magnetic ring;
wherein, a magnetic field is arranged in a mould used for preparing the outer ring magnetic ring.
6. The method for preparing the composite magnetic ring as claimed in claim 5, wherein the step (1) of preparing the soft magnetic composite material comprises the following steps:
preparing a surface treatment solution: mixing phosphoric acid, an alcohol solution, a zinc source and a water-soluble resin to obtain a surface treatment solution;
and secondly, mixing the obtained surface treatment solution with iron powder, a silane coupling agent and a high polymer material in sequence, mixing, and then mixing and granulating to obtain the soft magnetic composite material.
7. The method for preparing a composite magnetic ring as claimed in claim 6, wherein the step of preparing the surface treatment solution more specifically comprises: sequentially mixing and heating phosphoric acid, absolute ethyl alcohol, water, a zinc source and water-soluble resin to obtain a surface treatment solution;
preferably, the zinc source comprises zinc oxide;
preferably, the water-soluble resin comprises any one of polypropylene, polyamide or polyethylene glycol or a combination of at least two of the foregoing;
preferably, the temperature of the mixing in step (i) is 70-90 ℃.
8. The preparation method of the composite magnetic ring as claimed in claim 6 or 7, wherein the particle size of the iron powder in the step (II) is 50-100 μm;
preferably, the magnetic permeability of the iron powder is 600-800H/m;
preferably, the saturation magnetization of the iron powder in the step (II) is 1.4-1.8T;
preferably, the mass ratio of the surface treatment solution to the iron powder is 1 (9-11).
9. The preparation method of the composite magnetic ring as claimed in any one of claims 6 to 8, wherein the addition amount of the silane coupling agent in the step (II) is 0.5 to 1.5 percent of the mass of the iron powder;
preferably, the polymer material comprises any one of or a combination of at least two of PP, PA6, PA12, POM and PPS;
preferably, the temperature for the mixing is 130-160 ℃.
10. The method as claimed in any one of claims 5 to 9, wherein in the mold in step (2), the waveform of the magnetic field is set to be sinusoidal;
preferably, in the mold in the step (2), the magnetic field intensity is set to be 0.8-1.0T.
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