CN116532335A - Preparation method of low-stress composite coating of coiled iron core, coiled iron core and application - Google Patents
Preparation method of low-stress composite coating of coiled iron core, coiled iron core and application Download PDFInfo
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- CN116532335A CN116532335A CN202310494277.3A CN202310494277A CN116532335A CN 116532335 A CN116532335 A CN 116532335A CN 202310494277 A CN202310494277 A CN 202310494277A CN 116532335 A CN116532335 A CN 116532335A
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 207
- 238000000576 coating method Methods 0.000 title claims abstract description 201
- 239000011248 coating agent Substances 0.000 title claims abstract description 200
- 239000002131 composite material Substances 0.000 title claims abstract description 43
- 238000002360 preparation method Methods 0.000 title claims abstract description 19
- 238000005507 spraying Methods 0.000 claims abstract description 71
- 239000000843 powder Substances 0.000 claims abstract description 45
- 238000000137 annealing Methods 0.000 claims abstract description 42
- 238000004804 winding Methods 0.000 claims abstract description 36
- 238000007751 thermal spraying Methods 0.000 claims abstract description 32
- 238000007592 spray painting technique Methods 0.000 claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 239000012815 thermoplastic material Substances 0.000 claims description 54
- 239000004033 plastic Substances 0.000 claims description 53
- 229920003023 plastic Polymers 0.000 claims description 53
- 238000000034 method Methods 0.000 claims description 37
- 230000008569 process Effects 0.000 claims description 26
- 239000007921 spray Substances 0.000 claims description 18
- 238000002844 melting Methods 0.000 claims description 10
- 230000008018 melting Effects 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 10
- 239000004677 Nylon Substances 0.000 claims description 5
- 239000004698 Polyethylene Substances 0.000 claims description 5
- 229920001778 nylon Polymers 0.000 claims description 5
- -1 polyethylene Polymers 0.000 claims description 5
- 229920000573 polyethylene Polymers 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 238000005516 engineering process Methods 0.000 abstract description 5
- 229920001169 thermoplastic Polymers 0.000 abstract description 3
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 59
- 230000035699 permeability Effects 0.000 description 16
- LNSPFAOULBTYBI-UHFFFAOYSA-N [O].C#C Chemical group [O].C#C LNSPFAOULBTYBI-UHFFFAOYSA-N 0.000 description 8
- 238000001816 cooling Methods 0.000 description 8
- 238000007590 electrostatic spraying Methods 0.000 description 8
- 239000003208 petroleum Substances 0.000 description 8
- 239000011241 protective layer Substances 0.000 description 8
- 239000002344 surface layer Substances 0.000 description 8
- 230000003746 surface roughness Effects 0.000 description 8
- 239000003973 paint Substances 0.000 description 6
- 239000000463 material Substances 0.000 description 4
- 229910000976 Electrical steel Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000011247 coating layer Substances 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000007710 freezing Methods 0.000 description 2
- 230000008014 freezing Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229910000889 permalloy Inorganic materials 0.000 description 2
- 230000035945 sensitivity Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
- B05D1/06—Applying particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0218—Pretreatment, e.g. heating the substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/52—Two layers
- B05D7/54—No clear coat specified
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/25—Magnetic cores made from strips or ribbons
-
- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
Abstract
The invention discloses a preparation method of a low-stress composite coating of a coiled iron core, the coiled iron core and application thereof, belonging to the technical field of iron core manufacturing, and comprising the following steps: s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine; s2, annealing the iron core; s3, preheating the iron core; s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core; s5, continuously spraying a layer of surface coating on the functional coating of the iron core. By the mode, the low-stress functional coating is prepared by utilizing the principle that powder with thermoplastic characteristics of a thermal spraying technology can be quickly heated and melted and quickly solidified, and then a thin surface coating is covered on the surface by utilizing a common spray painting technology, so that the composite coating with larger thickness and low stress is formed.
Description
Technical Field
The invention relates to the technical field of iron core manufacturing, in particular to a preparation method of a low-stress composite coating of a wound iron core, the wound iron core and application.
Background
Soft magnetic materials have stress sensitivity, i.e. the magnetic permeability decreases when subjected to stress, and in general the higher the magnetic permeability the greater the stress sensitivity of the material. Therefore, it is particularly important to find a low stress coating for high permeability materials in some special applications.
The conventional wound iron core is generally manufactured by winding silicon steel, permalloy and amorphous and nanocrystalline strips, and the latter two are used in occasions requiring high magnetic permeability except silicon steel. Because the thickness of the material is very thin, and the strip material can become brittle after annealing, in order to protect the stable application of the iron core in various occasions, the finished iron core is generally protected on the surface of the bare iron core by a coating, so that the iron core has certain mechanical strength and insulating property.
In the iron core manufacturing industry, the traditional coating spraying process mainly adopts two processes of spray painting or electrostatic powder spraying. The two processes are suitable for mass production due to the advantages of good appearance quality, high efficiency and the like. The paint spraying process forms a coating layer by directly spraying liquid paint on the surface of the coiled iron core, and the paint liquid permeates between sheets of the coiled strip, so that the phenomenon of overlarge internal stress of the coating layer is easily caused in the curing process. The electrostatic powder spraying technology is that thermosetting powder is attached to the surface of an iron core through electrostatic action and then baked for a long time at high temperature, so that the powder is solidified to form a coating, and the magnetic permeability of the wound iron core is reduced due to the long-time high-temperature baking in the process and the dynamic characteristic that the powder is easy to flow at high temperature and the high internal stress generated by the solidified coating.
Therefore, for wound cores made from permalloy, particularly amorphous and nanocrystalline tapes (thickness less than 30 microns), in high permeability applications, it is necessary to develop a low stress coating that is lower than conventional paint and electrostatic powder coatings and is specific to wound core protection.
Based on the above, the invention designs a preparation method of a low-stress composite coating of a wound iron core, the wound iron core and application to solve the problems.
Disclosure of Invention
Aiming at the defects existing in the prior art, the invention provides a preparation method of a low-stress composite coating of a wound iron core, the wound iron core and application.
In order to achieve the above purpose, the invention is realized by the following technical scheme:
the preparation method of the low-stress composite coating of the coiled iron core comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
s2, annealing the iron core;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core.
Further, S2 is specifically: annealing the iron core coiled in the step S1, wherein the temperature of the annealing treatment is controlled to be 520-590 ℃; the annealing treatment time is controlled to be 1-2 h.
Further, the method also comprises the step S3 of preheating the iron core; step S3 is located between step S2 and step S4;
s3 specifically comprises the following steps: preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled to be 60-110 ℃; the preheating treatment time is controlled to be 25-35 min.
Further, S4 is specifically: and spraying plastics on the preheated iron core by using thermal spraying equipment and spraying plastics powder.
Further, the plastic spraying powder is selected from thermoplastic materials with the particle size of 60-120 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃.
Further, the thermoplastic material is selected from nylon, polyethylene, epoxy resin or the like.
Furthermore, the thickness of the functional coating can reach between 0.1 and 1.5 mm.
Further, S5 is specifically: and on the basis of taking the functional coating as a bottom layer, adopting a spray painting process to continuously spray a surface coating with the thickness of 120-300 mu m.
The invention also provides the coiled iron core prepared by the preparation method.
The invention also provides application of the winding iron core in preparation of an inductor, a reactor or a transformer product.
Advantageous effects
The invention utilizes the principle that powder with thermoplastic characteristics of a thermal spraying technology can be quickly heated and melted and quickly solidified to form instant freezing flow to prepare the low-stress functional coating; then the common paint spraying process is utilized to cover a thinner surface coating on the surface decoration; thereby forming a composite coating with a large thickness and low stress.
The magnetic permeability mu of the wound iron core prepared by the invention reaches 150000 at the highest at the frequency of 1 KHz; at the frequency of 10KHz, the magnetic permeability mu of the iron core reaches 100000 at most; and under the frequency of 10KHz, compared with the iron core with a common coating, the magnetic permeability mu of the iron core can be obviously improved by 10% -28%, and the method can be well applied to the production of the high magnetic permeability winding iron core; the method is beneficial to being applied to the fields of manufacturing inductors, reactors, transformers and the like used under high power.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. It will be apparent that the described embodiments are some, but not all, embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention is further described below with reference to examples.
Example 1
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled at 550 ℃; the time of annealing treatment is controlled to be 2 hours;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled to be 60 ℃; the preheating treatment time is controlled at 35min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 60 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is nylon and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 0.1mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 120um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 2
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled at 590 ℃; the time of annealing treatment is controlled to be 1h;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled at 110 ℃; the time of the preheating treatment is controlled to be 25min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 70 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is polyethylene, and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 1.5mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 300um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 3
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled at 550 ℃; the time of the annealing treatment is controlled to be 1.6 hours;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled at 85 ℃; the time of the preheating treatment is controlled to be 30min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is made of thermoplastic materials with the particle size of 80 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is epoxy resin, and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 0.6mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 150um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 4
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled to be 540 ℃; the time of the annealing treatment is controlled to be 1.2 hours;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled at 105 ℃; the time of the preheating treatment is controlled at 29min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 90 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is nylon and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 0.5mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 180um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 5
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled at 555 ℃; the time of annealing treatment is controlled to be 1.3 hours;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled to be 100 ℃; the time of the preheating treatment is controlled to be 31min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 100 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is epoxy resin, and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 1mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 200um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 6
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled at 560 ℃; the time of the annealing treatment is controlled to be 1.4 hours;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled to be 90 ℃; the time of the preheating treatment is controlled to be 26min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 110 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is polyethylene, and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 1.2mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 230um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 7
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled to be 570 ℃; the time of the annealing treatment is controlled to be 1.7h;
s3, preheating the iron core;
specifically, preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled at 80 ℃; the time of the preheating treatment is controlled to be 28min;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is made of thermoplastic materials with the particle size of 80 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is nylon and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 1.4mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 260um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Example 8
The embodiment provides a preparation method of a low-stress composite coating of a coiled iron core, which comprises the following steps:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
specifically, the amorphous and nanocrystalline strips are coiled into iron cores with required sizes by an automatic coiling machine or a manual coiling machine;
s2, annealing the iron core;
specifically, annealing the iron core wound in the step S1, wherein the temperature of the annealing treatment is controlled to be 585 ℃; the time of the annealing treatment is controlled to be 1.8 hours;
s3, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
specifically, the iron core after the preheating treatment is subjected to plastic spraying by using thermal spraying equipment and plastic spraying powder; the plastic spraying powder is selected from thermoplastic materials with the particle size of 90 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃; the thermoplastic material is polyethylene, and can be selected according to the thickness of the coating and the surface roughness requirement; the thickness of the functional coating is 0.8mm;
wherein, the thermal spraying plastic process principle is as follows: the spraying plastic powder is quickly and continuously sent into the spray gun by means of compressed air, and the spraying plastic powder is fully melted by oxygen-acetylene high-temperature flame or liquefied petroleum gas-air high-temperature flame (both are about 2000 ℃) at the front end of the spray gun and sprayed onto the preheated iron core along with flame airflow, so that a layer of coating can be adhered on the surface of the iron core; the coating is cooled and then is not required to be baked, so that a thicker tough coating is obtained, the coating is a functional coating and can be used as a bottom layer of a low-stress composite coating, and the thickness range of a common electrostatic spraying coating is generally below 200 mu m;
the functional coating is formed by directly spraying thermoplastic materials on the surface of the iron core after being heated and melted by flame and rapidly cooling and solidifying the thermoplastic materials on the surface of the iron core, so that the thermoplastic materials only stay on the shallow surface layer between the strip sheets of the coiled iron core when being cooled, and the internal stress is lower;
s4, continuously spraying a layer of surface coating on the functional coating of the iron core;
specifically, on the basis of taking the functional coating as a bottom layer, a layer of surface coating is continuously sprayed by adopting a spray painting process; the thickness of the surface coating is 280um; the surface coating has the function of the decorative layer and the protective layer in the composite coating.
Experimental example
The iron core prepared in the embodiment 3 of the invention is subjected to iron core magnetic permeability detection, and the detection results are shown in the following table:
| project | Example 3 |
| Magnetic permeability mu of iron core (1 KHz frequency) | ＞80000 |
| Magnetic permeability mu of iron core (10 KHz frequency) | ＞60000 |
It can be seen that the wound iron core with the low-stress composite coating provided by the invention has the magnetic permeability mu of up to 150000 at the frequency of 1 KHz; at the frequency of 10KHz, the magnetic permeability mu of the iron core reaches 100000 at most; and under the frequency of 10KHz, compared with the iron core with a common coating, the magnetic permeability mu of the iron core can be obviously improved by 10% -28%, and the method can be well applied to the production of high-magnetic-permeability coiled iron cores, such as the production of high-power amorphous and nanocrystalline coated iron cores; is beneficial to be applied to the fields of manufacturing inductors, reactors, presses and the like used under high power.
The invention utilizes the principle that powder with thermoplastic characteristics of a thermal spraying technology can be quickly heated and melted and quickly solidified to form instant freezing flow to prepare the low-stress functional coating; then the common paint spraying process is utilized to cover a thinner surface coating on the surface decoration; thereby forming a composite coating with a large thickness and low stress.
The above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. The preparation method of the low-stress composite coating of the coiled iron core is characterized by comprising the following steps of:
s1, winding an iron core: winding the strip into an iron core with a required size by adopting a winding machine;
s2, annealing the iron core;
s4, performing thermal spraying on the iron core to form a layer of functional coating on the surface of the iron core;
s5, continuously spraying a layer of surface coating on the functional coating of the iron core.
2. The method for preparing a low-stress composite coating for a wound iron core according to claim 1, wherein S2 is specifically: annealing the iron core coiled in the step S1, wherein the temperature of the annealing treatment is controlled to be 520-590 ℃; the time of the post-annealing treatment is controlled to be 0.5-2 h.
3. The method for preparing a low-stress composite coating for a wound iron core according to claim 1, further comprising the step of S3 of preheating the iron core; step S3 is located between step S2 and step S4;
s3 specifically comprises the following steps: preheating the annealed iron core in the step S2, wherein the temperature of the preheating is controlled to be 60-110 ℃; the preheating treatment time is controlled to be 25-35 min.
4. The method for preparing a low-stress composite coating for a wound core according to claim 3, wherein S4 is specifically: and spraying plastics on the preheated iron core by using thermal spraying equipment and spraying plastics powder.
5. The method for preparing a low-stress composite coating for a wound iron core according to claim 4, wherein the plastic-sprayed powder is a thermoplastic material with a particle size of 60-120 meshes; the melting point range of the thermoplastic material is controlled between 180 ℃ and 280 ℃.
6. The method for preparing a low-stress composite coating for a wound core according to claim 5, wherein the thermoplastic material is nylon, polyethylene, epoxy resin or the like.
7. The method for preparing a low-stress composite coating for a wound core according to claim 1, wherein the functional coating has a thickness of 0.1-1.5 mm.
8. The method for preparing a low-stress composite coating for a wound iron core according to claim 1, wherein S5 specifically comprises: and on the basis of taking the functional coating as a bottom layer, adopting a spray painting process to continuously spray a surface coating with the thickness of 120-300 mu m.
9. A wound core prepared according to the preparation method of any one of claims 1 to 8.
10. Use of a wound core according to claim 9 for the manufacture of an inductor, reactor or transformer product.
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| US4615106A (en) * | 1985-03-26 | 1986-10-07 | Westinghouse Electric Corp. | Methods of consolidating a magnetic core |
| WO2008060405A2 (en) * | 2006-11-09 | 2008-05-22 | Xiom Corporation | Epoxy and thermoplastic powdered thermal spray compositions |
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