JP2005268589A - Simple manufacturing method of magnetic member for energy converter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a simple manufacturing method of a member for a high-performance energy converter. <P>SOLUTION: In manufacture of the magnetic member in which machined strips of a magnetic steel plate are laminated, the machined strips are laminated and temporarily fixed beforehand, after binding liquid the function of which is binding through drying is applied or the strips are dipped in the binding liquid, and then the strips are dried, laminated and bound. Processes from machining of the electromagnetic steel plate to completion of a drying/binding method are made simple by applying temporary fixation to the drying/binding method. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  TECHNICAL FIELD The present invention relates to a laminated iron core and a laminated yoke, a laminated bundle manufacturing method, and a laminated iron core and laminated yoke manufactured by lamination.

  Examples of energy conversion devices include electric motors, actuators, generators, transformers, and reactors. For these, an iron core forming a magnetic circuit is generally used. Many of the iron cores are made by laminating electromagnetic steel sheets, and caulking, welding, bolting, etc. are often used for binding the laminated iron cores. However, these bundling methods do not bind all over the layers, so the mechanical rigidity and strength of the iron core and the like are not perfect, so there is a problem in heat removal for removing heat generated by vibration noise or loss. Yes, in caulking, welding causes an electrical short circuit between the layers, and in alternating current excitation, a short circuit current is generated, resulting in a decrease in device performance. Moreover, in these bindings, local stress / strain is added to the electrical steel sheet as it is fixed or integrated, and magnetic property deterioration due to this stress / strain cannot be ignored. In particular, in order to ensure the lamination strength, welding and caulking are applied with sufficient strength to the teeth where the main magnetic flux on the magnetic circuit of the iron core passes a lot. It is a problem. Accordingly, there is a demand for avoiding and reducing these problems in the stacking.

  In order to avoid such a problem, instead of caulking, welding, and bolting, adhesion, molding, or the like is employed, and interlayer short circuit and local stress distortion are avoided and reduced. Recently, the inventors have developed a simple binding method (hereinafter referred to as a dry binding method) using a liquid containing a silicon compound disclosed in Patent Document 1, but the present invention applies the dry binding method to a mass production process. The present invention proposes a method for maintaining a laminated state before bonding as a problem at the time.

The dry bundling method means that when a magnetic member used in an electromagnetic device is composed of a plurality of magnetic materials, the plurality of magnetic material pieces are arranged and assembled, and if they are kept in that state, they are magnetic. In this method, a liquid having an ability to bind material pieces is applied or immersed in the liquid, and then dried to bind the plurality of magnetic material pieces.
JP 2003-193263 A

  The present invention provides a method for simplifying the laminating process in bonding and binding a magnetic member in which workpieces of magnetic steel sheets are laminated.

The feature of the present invention is that
(1) In the manufacture of a magnetic member in which workpieces of magnetic steel sheets are laminated, after the workpieces are previously laminated and temporarily fixed, a binding solution having a function of binding by drying is applied or the binding solution is applied to the binding solution A simple manufacturing method of a magnetic member for energy conversion equipment, characterized by drying and bundling after dipping,
(2) The simple manufacturing method of the magnetic member for energy conversion devices according to (1) above, wherein the temporary fixing force is 1/10 or less of the binding force after drying the binding liquid,
(3) A magnetic member for an energy conversion device, characterized by being laminated and bound by a simple method for producing a magnetic member for an energy conversion device according to (1) or (2) above,
It is in.

  When temporary fixing is applied to the dry bundling method as in the present invention, the process from the processing of the electrical steel sheet to the completion of the dry bundling method is simplified. When temporary fixing is not performed, it is necessary to use a manufacturing process that can maintain the laminated state or use a jig, which increases the manufacturing cost or requires time. Conventionally, when interlaminar bundling is performed by caulking or welding, the performance of the iron core and yoke due to stress strain due to interlaminar short circuit or interlaminar bundling has deteriorated, but in the present invention, the interlaminar bundling strength necessary for the final device performance is dry. Since it is carried out by the bundling method, caulking and welding as temporary tacks are light, so that it is possible to reduce the deterioration of the performance of the iron core and the yoke due to stress distortion due to interlayer short circuit and interlayer bundling.

  The magnetic member for energy conversion device of the present invention is a magnetic member used for energy conversion device in electric energy or mechanical energy, for example, an armature in a motor, an actuator or a generator, a field iron core, a relay, a transformer , Reactors, ignitions, choke coils, iron cores for filters and inductors, regardless of application or model. Electric motors, actuators, and generators include induction machine types, synchronous machine types, DC machine types, reluctance types, and combinations of two or more types, including large to micro motors. In addition, transformers include winding transformers, product transformers, etc., and various types of iron cores. Reactors are inverters, converters, choppers, devices used for power factor improvement by adjusting the phase of voltage and current, harmonics, etc. These are used for filters, ignition, etc., except for winding type and stacking type, those with and without air gaps, those with saturable type and without saturation, and those with cut iron core.

  Magnetic members for energy conversion equipment are processed and laminated magnetic steel sheets, and are used as armatures, field iron cores and yokes, transformer iron cores, reactor iron cores, electromagnet iron cores and yokes, etc. .

  Magnetic steel plates as magnetic materials include iron or iron alloys such as electromagnetic steel plates and thick plates, nickel alloys such as nickel and permalloy, cobalt and cobalt alloys, amorphous materials, and nanocrystal materials. In particular, iron cores and yokes obtained by punching and laminating electromagnetic steel sheets are frequently used.

  Magnetic members include ones that are integrally punched and stacked, such as rotating machines, ones that are used in combination with split iron cores, wound iron cores that may be used in axial gap type rotating machines, or claw pole iron cores, etc. Such as a transformer, a reactor, etc., there are a wound iron core, a stacked iron core, a cut iron core, an EI iron core, etc., and the present invention can be applied to all.

  In the present invention, in the manufacturing process of the magnetic member obtained by laminating the work pieces of the magnetic steel sheet, when the work pieces are laminated and bound, a liquid that exhibits the ability to bind the magnetic steel sheet pieces by drying is applied, or A method of dipping in a liquid and then drying and integrating is applied.

  The bundling liquid used in the present invention is a liquid that has the ability to bind between magnetic steel sheets or between a magnetic member and another member by drying, and this bundling liquid is applied or immersed in the bundling liquid. The bundling liquid is attached to the outside of the magnetic steel plate or the magnetic member, or the bundling liquid is included in the contact portion of the magnetic steel plate or the magnetic member, and then the bundling liquid is dried to bind the magnetic steel plate or the magnetic member. Is.

  The bundling liquid has the above-mentioned bundling ability, and preferably has a pure silicon polymer and a liquid composition that can be easily dried and easily obtain a predetermined bundling force and can be expected to have a certain bundling force even at high temperatures. A liquid containing one or more modified silicone polymers as a main component is preferable.

  The pure silicon polymer is produced by hydrolyzing a known alkoxylane without solvent or in an organic solvent and polymerizing it. Under the present circumstances, the coating film which has various performance is obtained by changing the kind of silane to be used. The modified silicon polymer is obtained by modifying a pure silicon polymer with an organic resin. As a modification method, modification is performed by a known cold blend or condensation reaction.

  Tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriethoxysilane, monoethyltriethoxysilane when producing a partial hydrolyzate of alkoxylane as a pure silicon polymer Dimethyldimethoxysilane, diethyldiethoxysilane, monomethyltriisobupoxysilane, monoethyltributoxysilane, or monovinyltriethoxysilane is used.

  As the modified silicone polymer, one or more of acrylic modified silicone polymer, alkyd modified silicone polymer, polyester acrylic modified silicone polymer, and epoxy modified silicone polymer are used.

In addition, when it is intended to obtain a high insulation resistance or withstand voltage in the binding film, the inorganic oxide powder per 100 parts by mass of SiO _{2 of} pure silicon polymer or modified silicon polymer as a filler in the silicon polymer. 0.1 to 50 parts by mass of particles or colloidal solution, organic resin powder particles or one or more of these emulsion solutions as a solid content is added. As a combined effect of adding this filler, adhesion to the core end face and the steel sheet surface is improved. As an inorganic powder particle or colloidal substance to be added, one or more selected from SiO ₂ , Al ₂ O ₃ , TiO ₂ , ZrO ₂ and / or a composite material thereof having a primary particle diameter of 7 to 5000 nm Is added and blended in an amount of 0.1 to 50 parts by mass.

  The processed piece is a magnetic member piece obtained by punching a magnetic steel plate and processing it by shearing, laser cutting, or electric discharge machining, and includes a piece that has been bent or pulled after that.

  In the step of making a magnetic steel plate work piece or after the step, the laminated state is temporarily fixed and the dry binding method is performed. Temporary fixing is for caulking, welding, bonding, pinning, etc., to maintain the laminated state when performing the dry binding method, and the interlaminar binding strength of the temporary fixing is the same as during the dry binding method. The strength that can be maintained is sufficient, and it is not necessary that the strength is required when the device is driven. The interlaminar bond strength required when driving the device can be obtained after the dry bundling method has been implemented, thus reducing or avoiding the effects of interlaminar short-circuiting caused by caulking, welding, bonding, pinning, etc., and stress strain due to interlaminar bundling It is possible to reduce the caulking depth, welding depth, width and quantity, pinning strength and quantity, bonding strength and area, caulking, welding, bonding, pinning, etc. It can be applied where the influence is small.

  The present invention was applied to an armature core for a fan motor, thereby obtaining a fan motor with high efficiency and low noise. The armature core is an integrally punched iron core 11, and the temporary fixing is caulked 14 on the outer peripheral side of the yoke portion 13 of the iron core, which is less affected by the interlayer short circuit. As shown in FIG. 1, the iron core was immersed in a bundling solution [mixed solution in which 30 g of epoxy resin was added to 100 g of epoxy-modified polymer (concentration 50%, solvent toluene)] 16 and then dried and cured at 100 ° C. × 3 hours. Processed. The interlayer binding force (all surfaces) in the direction perpendicular to the laminated surface by the dry binding method of the present invention was about 30 times that of the case of caulking 14 alone. In FIG. 1, reference numeral 15 is an arm that sandwiches the iron core, and 17 is a bolt hole.

  Since the bundling liquid also enters between the layers, the rigidity of the iron core increased and the noise was reduced. Conventional fan motors have insufficient interlayer binding between the iron core teeth, causing noise generation. However, the present invention increases the binding of the teeth 12, so that noise generation can be avoided and the interlayer short circuit can be avoided. A reduction in efficiency could also be avoided.

  The present invention was applied to an armature core of a general-purpose motor whose efficiency is legally regulated, and a high-efficiency general-purpose motor was manufactured by suppressing deterioration of core characteristics due to caulking. The armature core was an integrally punched iron core, and the temporary fixing was caulked on the outer peripheral side of the yoke part of the iron core, where the effect of short circuit between the layers was small, and then the core was press-fitted into the case. Then, it was immersed in a binding solution [a silicone solution in which pure silicon polymer (R (SiOR) 3 composition) having a concentration of 60% was dissolved in toluene], and the whole was dried at 85 ° C. for 5 hours.

  A stator core in which 12 divided cores were combined with an 8-pole, 12-slot IPM motor for an electric vehicle was used. The laminated body was temporarily fixed to the outer periphery of the split core yoke portion by laser welding near both ends in the circumferential direction of the outer peripheral portion. Thereafter, the tooth part is sandwiched from both ends in the laminating direction, immersed in a binding solution [epoxy-modified silicone polymer solution (concentration 50%, solvent toluene)], taken out from the solution, and dried for 3 hours in a drying furnace at 80 ° C. for binding. .

  A step-up chopper iron core 41 shown in FIG. 2 was manufactured by the method of the present invention. A 0.2 mm thick magnetic steel sheet was punched into a strip shape and caulked. Caulking was performed at one place with a V caulking 43 at the center of the strips, and was performed for the purpose of stacking and binding the strips. The reason for using one caulking is to avoid performance degradation due to interlayer short circuit when a plurality of caulking is applied. In order to secure the stacking direction with a single caulking, V caulking was used. The caulking is not a plurality of conventional caulking, and the caulking depth is 3/4 of the plate thickness, which is smaller than 3/2 of the conventional plate thickness, and the iron core performance is deteriorated by caulking stress. Was suppressed. Thereafter, it is dipped into a binding solution [solution of 40% (solvent, isopropyl alcohol) as a pure silicon polymer], applied to a film thickness of 30 μm, dried and cured at 120 ° C. × 3 Hr, and iron core 41 for choppers. Was made.

Shown is an integrally punched iron core in the immersed state. An iron core for a boost chopper is shown.

Explanation of symbols

11: integrally punched iron core 12: tooth portion 13: yoke portion 14: V caulking 15: arm 16 sandwiching the iron core 16: binding liquid 17: bolt hole 41: iron core 43 for chopper 43: V caulking

Claims (3)

In the manufacture of a magnetic member in which workpieces of magnetic steel sheets are laminated, after the workpieces are laminated in advance and temporarily fixed, after being applied with a binding solution having a function of binding by drying or after being immersed in the binding solution A simple manufacturing method of a magnetic member for energy conversion equipment, characterized by drying and stacking. The simple manufacturing method of the magnetic member for energy conversion devices according to claim 1, wherein the temporary fixing force is 1/10 or less of the binding force after drying the binding liquid. A magnetic member for an energy conversion device, wherein the magnetic member is laminated and bound by the simple manufacturing method of the magnetic member for an energy conversion device according to claim 1 or 2.

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