JP3702279B2 - Carbon brush - Google Patents
Carbon brush Download PDFInfo
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- JP3702279B2 JP3702279B2 JP2003099561A JP2003099561A JP3702279B2 JP 3702279 B2 JP3702279 B2 JP 3702279B2 JP 2003099561 A JP2003099561 A JP 2003099561A JP 2003099561 A JP2003099561 A JP 2003099561A JP 3702279 B2 JP3702279 B2 JP 3702279B2
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- Prior art keywords
- carbon brush
- mass
- average particle
- resin
- talc
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Description
【0001】
【発明の属する技術分野】
本発明は、整流子を用いる小型モーターに組み込んで使用されるカーボンブラシに関する。
【0002】
【従来の技術】
従来、この種の樹脂硬化型カーボンブラシは、特許文献1に開示されるように、フィラーとなる天然黒鉛、人造黒鉛等の黒鉛粉末と、バインダーとなるフェノール樹脂、エポキシ樹脂等の熱硬化性樹脂を混練し、成形、硬化してカーボンブラシとしている。
【0003】
また、カーボンブラシに油及び/又は油化合物を含有する樹脂に無機質粉末を添加混合した樹脂の皮膜を形成してブラシの表面エネルギー及び固渋現象を防止することが特許文献2に提案されている。
【0004】
カーボンブラシ素子片を接着せしめる材料に蝋石または滑石粉末を混合したものを用い接着させ、カーボンブラシの電流経路を長くし、リアクタンス電圧を抑制することが特許文献3に提案されている。
【0005】
【特許文献1】
特公昭58−26156号公報
【特許文献2】
特開平3−178543号公報
【特許文献3】
特公昭28−6058号公報
【0006】
【発明が解決しようとする課題】
ところが、これらカーボンブラシは、長時間使用していると、カーボンブラシ自身が高温となり、これに伴って、ブラシ特性が低下する恐れがあった。また、特に樹脂硬化型カーボンブラシは、使用時に整流子表面に被膜を形成しやすく、カーボンブラシと整流子間における摩擦係数増大によりモーターの吸込仕事率及び寿命等のモーター特性が低下する要因の一つになっていた。
【0007】
また、カーボンブラシに油及び/又は油化合物を含有する樹脂に無機質粉末を添加混合した樹脂の皮膜を形成すると一時的にその効果は有するものの、長期間にわたってその効果を継続することはできない。また、添加する無機質粉末の種類によっては整流子表面が荒損し、モーター特性が低下する場合があった。
【0008】
これに加え、特許文献3に提案されている場合においても、これら粉末量が微量かつ整流子との接触面積がわずかであるため、粉末による皮膜形成までには至らず、タルク皮膜形成による長寿命化等の効果は薄いものであった。
【0009】
さらに、近年、特に樹脂硬化型カーボンブラシを使用したモーターの吸込仕事効率及び寿命の向上が強く要求されてきている。
【0010】
そこで本発明は、高い吸込仕事効率、長寿命化及び整流子表面の荒損防止が可能なカーボンブラシを提供することを目的とする。
【0011】
【課題を解決するための手段】
前記課題を解決するための本発明に係るカーボンブラシは、カーボンブラシにおいて、フィラーと、バインダーとなる熱硬化性樹脂またはピッチにタルクが含有されてなるカーボンブラシを要旨とする。さらに、前記タルクの含有量が0.1〜5.0質量%であることを要旨とする。
【0012】
本発明の請求項1に係るカーボンブラシについて以下に説明する。フィラーとしては、鱗状あるいは土状黒鉛等の天然黒鉛、あるいは、キッシュ黒鉛、熱分解炭素、膨張黒鉛等の人造黒鉛を平均粒子径が5〜500μmとなるように粉砕した黒鉛粉末が好適に使用できる。フィラーの平均粒子径が5μmよりも小さいと基材の強度低下となるため好ましくなく、500μmを越えると粒子離脱が発生する原因となるため好ましくない。また、黒鉛粉末以外に石油コークス、石炭コークス等もフィラーとして使用できる。
【0013】
バインダーとしては一般的に熱硬化性樹脂としては市販されている液状もしくは粉末状のフェノール樹脂、エポキシ樹脂、アルキッド樹脂、フラン樹脂、ユリア樹脂等が使用できる。また、樹脂以外にピッチ等もバインダーとして使用できる。
【0014】
タルクは市販されているものを好適に使用できるが、平均粒子径としては5〜100μmの粉末を使用することが好ましく、更に5〜70μmの粉末が好ましい。平均粒子径が5μmよりも小さいと強度低下となり、平均粒子径が100μmよりも大きいと、粒子離脱原因となるため好ましくない。
【0015】
本発明の請求項2,3に係る樹脂硬化および炭化型カーボンブラシの製造方法としては、(1)所定量のフィラーと熱硬化性樹脂またはピッチとタルクを混合した混合物を成形、熱処理して熱硬化性樹脂結合型カーボンブラシを得る方法や、(2)フィラーと熱硬化性樹脂とを混合、成形、熱処理したカーボンブラシ基材にタルクを分散させた溶液を含浸させる方法等が例示できる。
【0016】
具体的に本発明に係る樹脂硬化および炭化型カーボンブラシの製造方法を例示すると下記のようになる。フィラーとして平均粒子径が50μmの人造黒鉛70〜90質量%と、バインダーとして熱硬化性樹脂及び/またはピッチを10〜30質量%の用意する。さらに、これらの総量に対して平均粒子径が50μmのタルクを0.1〜5質量%、好ましくは、0.3〜3質量%、さらに好ましくは、0.5〜2質量%添加し、室温〜200℃で混練する。この混練物を所定の粒子径になるように粉砕後、50〜300MPaで成形し、熱処理して本発明に係る樹脂結合型カーボンブラシとする。
【0017】
本発明では、フィラーと熱硬化性樹脂にタルクを0.1〜5質量%添加したカーボンブラシとしたので潤滑性および整流性能が向上し、高吸込仕事効率および長寿命化となる。
【0018】
【実施例】
以下に、本発明を具体例に基づき説明するが本発明はこれらの実施例に限定されるものではない。
【0019】
(実施例1)
(人造黒鉛+熱硬化性樹脂+タルク0.5質量%添加)
平均粒子径が50μmの人造黒鉛83質量%に、熱硬化性樹脂としてエポキシ樹脂を17質量%、及びこの総量に対して平均粒子径が50μmのタルクを0.5質量%添加し、これを100℃で混練した。この混練物を粉砕、100MPaで成形後、180℃で熱処理させてカーボンブラシを得た。
【0020】
(実施例2)
(人造黒鉛+熱硬化性樹脂+タルク1.0質量%添加)
平均粒子径が50μmの人造黒鉛83質量%に、熱硬化性樹脂としてエポキシ樹脂を17質量%、及びこの総量に対して平均粒子径が50μmのタルクを1.0質量%添加し、これを100℃で混練した。この混練物を粉砕、100MPaで成形後、180℃で熱処理させたカーボンブラシを得た。
【0021】
(実施例3)
(人造黒鉛+熱硬化性樹脂+タルク2.0質量%添加)
平均粒子径が50μmの人造黒鉛83質量%に、熱硬化性樹脂としてエポキシ樹脂を17質量%、及びこの総量に対して平均粒子径が50μmのタルクを2.0質量%添加し、これを100℃で混練した。この混練物を粉砕、100MPaで成形後、180℃で熱処理させてカーボンブラシを得た。
【0022】
(実施例4)
(人造黒鉛+ピッチ+タルク0.5質量%添加)
平均粒子径が50μmの人造黒鉛70質量%に、バインダーとしてピッチを30質量%、及びこの総量に対して平均粒子径が50μmのタルクを0.5質量%添加し、これを200℃で混練した。この混練物を粉砕、100MPaで成形後、650℃で熱処理させてカーボンブラシを得た。
【0023】
(比較例1)
(人造黒鉛+熱硬化性樹脂)
平均粒子径が50μmの人造黒鉛83質量%に、熱硬化性樹脂としてエポキシ樹脂を17質量%、これを100℃で混練した。この混練物を粉砕、100MPaで成形後、180℃で熱処理させてカーボンブラシを得た。
【0024】
(比較例2)
(人造黒鉛+ピッチ)
平均粒子径が50μmの人造黒鉛70質量%に、バインダーとしてピッチを30質量%、これを200℃で混練した。この混練物を粉砕、100MPaで成形後、650℃で熱処理させてカーボンブラシを得た。
【0025】
上記実施例1から3と、比較例1のカーボンブラシの物理特性を表1に示す。
【0026】
【表1】
【0027】
また、上記実施例1から3と、比較例1のカーボンブラシを、以下に示す試験モーター及び試験条件でカーボンブラシの性能試験を行った。
電圧:AC100V 60Hz
運転条件:連続運転
圧力:35kPa
試験環境:室温40〜45℃、湿度30%以下
【0028】
上記条件におけるカーボンブラシの特性試験の結果をまとめて表2に示す。
【0029】
【表2】
【0030】
実施例4と比較例2のカーボンブラシの物理特性を表3に示す。
【0031】
【表3】
【0032】
電圧:AC230V 60Hz
運転条件:断続運転
圧力:50kPa
試験環境:室温20〜45℃、湿度30%以下
【0033】
上記条件におけるカーボンブラシの特性試験の結果をまとめて表4に示す。
【0034】
【表4】
【0035】
表2より、実施例1から実施例3に係るカーボンブラシは、高い吸込仕事効率及び寿命が大幅に向上していることがわかる。また、表4より、実施例4に係るカーボンブラシは、寿命が向上しかつ整流火花が抑制されていることがわかる。また、表2および表4の整流子摩耗率からタルクを含有することにより整流子に荒損が発生していないこともわかる。
【0036】
【発明の効果】
フィラーとバインダーにタルク粉末を添加し混練、粉砕、成形、熱処理したカーボンブラシとすることによってタルクの有する潤滑性及び整流性能向上によって吸込仕事率が向上し、かつ長寿命のカーボンブラシとすることができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a carbon brush used by being incorporated into a small motor using a commutator.
[0002]
[Prior art]
Conventionally, as disclosed in Patent Document 1, this type of resin-curing carbon brush is composed of graphite powder such as natural graphite and artificial graphite serving as a filler, and thermosetting resin such as phenol resin and epoxy resin serving as a binder. Are kneaded, molded and cured to form a carbon brush.
[0003]
Further, Patent Document 2 proposes to form a resin film obtained by adding and mixing an inorganic powder to a resin containing oil and / or an oil compound to a carbon brush to prevent the surface energy and solid astringency of the brush. .
[0004]
Patent Document 3 proposes that a material for adhering a carbon brush element piece is bonded using a mixture of wax stone or talc powder to lengthen the current path of the carbon brush and suppress the reactance voltage.
[0005]
[Patent Document 1]
Japanese Patent Publication No. 58-26156 [Patent Document 2]
Japanese Patent Laid-Open No. 3-178543 [Patent Document 3]
Japanese Patent Publication No. 28-6058 [0006]
[Problems to be solved by the invention]
However, when these carbon brushes are used for a long time, the carbon brush itself becomes a high temperature, and there is a risk that the brush characteristics may be lowered. In particular, resin-curing carbon brushes tend to form a coating on the surface of the commutator during use, and this is one of the factors that reduce motor characteristics such as motor suction work rate and life due to increased friction coefficient between the carbon brush and the commutator. I was tied up.
[0007]
In addition, when a resin film is formed by adding an inorganic powder to a resin containing oil and / or an oil compound in a carbon brush, the effect is temporarily achieved, but the effect cannot be continued for a long period of time. Further, depending on the kind of the inorganic powder to be added, the commutator surface may be damaged and the motor characteristics may be deteriorated.
[0008]
In addition to this, even in the case proposed in Patent Document 3, since the amount of these powders is very small and the contact area with the commutator is small, it does not lead to the formation of a film with powder, and it has a long life due to the formation of a talc film. The effect of the conversion was thin.
[0009]
Furthermore, in recent years, there has been a strong demand for improvement in the suction work efficiency and life of a motor using a resin-cured carbon brush.
[0010]
Therefore, an object of the present invention is to provide a carbon brush capable of high suction work efficiency, long life, and prevention of commutation on the commutator surface.
[0011]
[Means for Solving the Problems]
The gist of a carbon brush according to the present invention for solving the above problems is a carbon brush in which talc is contained in a filler and a thermosetting resin or pitch as a binder. Furthermore, the gist is that the content of the talc is 0.1 to 5.0% by mass.
[0012]
The carbon brush according to claim 1 of the present invention will be described below. As the filler, graphite powder obtained by pulverizing natural graphite such as scale-like or earthy graphite, or artificial graphite such as quiche graphite, pyrolytic carbon, and expanded graphite so as to have an average particle size of 5 to 500 μm can be preferably used. . If the average particle diameter of the filler is smaller than 5 μm, the strength of the substrate is lowered, which is not preferable, and if it exceeds 500 μm, it is not preferable because it causes particle detachment. In addition to graphite powder, petroleum coke, coal coke and the like can also be used as fillers.
[0013]
As the binder, commercially available liquid or powdery phenol resins, epoxy resins, alkyd resins, furan resins, urea resins, etc. can be used as thermosetting resins. In addition to the resin, pitch or the like can be used as a binder.
[0014]
Commercially available talc can be suitably used, but the average particle size is preferably 5 to 100 μm, more preferably 5 to 70 μm. If the average particle size is smaller than 5 μm, the strength is lowered, and if the average particle size is larger than 100 μm, it causes particle detachment.
[0015]
The method for producing a resin-cured and carbonized carbon brush according to claims 2 and 3 of the present invention includes (1) molding, heat-treating a mixture of a predetermined amount of filler and thermosetting resin or pitch and talc, and heat-treating the mixture. Examples thereof include a method for obtaining a curable resin-bonded carbon brush, and (2) a method for impregnating a solution in which talc is dispersed in a carbon brush base material obtained by mixing, molding, and heat-treating a filler and a thermosetting resin.
[0016]
Specifically, the resin curing and carbonized carbon brush production method according to the present invention is exemplified as follows. 70 to 90% by mass of artificial graphite having an average particle diameter of 50 μm as a filler and 10 to 30% by mass of a thermosetting resin and / or pitch as a binder are prepared. Furthermore, 0.1 to 5% by mass, preferably 0.3 to 3% by mass, more preferably 0.5 to 2% by mass of talc having an average particle diameter of 50 μm is added to the total amount of these, and room temperature. Kneading at ~ 200 ° C. The kneaded product is pulverized so as to have a predetermined particle size, molded at 50 to 300 MPa, and heat-treated to obtain a resin-bonded carbon brush according to the present invention.
[0017]
In the present invention, since the carbon brush is obtained by adding 0.1 to 5% by mass of talc to the filler and the thermosetting resin, the lubricity and the rectifying performance are improved, and the high suction work efficiency and the long life are achieved.
[0018]
【Example】
Hereinafter, the present invention will be described based on specific examples, but the present invention is not limited to these examples.
[0019]
(Example 1)
(Artificial graphite + thermosetting resin + 0.5% by mass of talc added)
To 83% by mass of artificial graphite having an average particle size of 50 μm, 17% by mass of epoxy resin as a thermosetting resin, and 0.5% by mass of talc having an average particle size of 50 μm with respect to this total amount were added. Kneaded at a temperature of 0 ° C. The kneaded product was pulverized and molded at 100 MPa, and then heat treated at 180 ° C. to obtain a carbon brush.
[0020]
(Example 2)
(Artificial graphite + thermosetting resin + 1.0% by mass of talc added)
To 83% by mass of artificial graphite having an average particle size of 50 μm, 17% by mass of epoxy resin as a thermosetting resin, and 1.0% by mass of talc having an average particle size of 50 μm with respect to the total amount are added, and 100% Kneaded at a temperature of 0 ° C. The kneaded product was pulverized, molded at 100 MPa, and then heat treated at 180 ° C. to obtain a carbon brush.
[0021]
(Example 3)
(Artificial graphite + thermosetting resin + 2.0% talc added)
To 83% by mass of artificial graphite having an average particle size of 50 μm, 17% by mass of an epoxy resin as a thermosetting resin, and 2.0% by mass of talc having an average particle size of 50 μm with respect to the total amount were added. Kneaded at a temperature of 0 ° C. The kneaded product was pulverized and molded at 100 MPa, and then heat treated at 180 ° C. to obtain a carbon brush.
[0022]
(Example 4)
(Artificial graphite + pitch + talc 0.5 mass% addition)
70% by mass of artificial graphite having an average particle size of 50 μm, 30% by mass of pitch as a binder, and 0.5% by mass of talc having an average particle size of 50 μm with respect to this total amount were added and kneaded at 200 ° C. . The kneaded product was pulverized and molded at 100 MPa, and then heat treated at 650 ° C. to obtain a carbon brush.
[0023]
(Comparative Example 1)
(Artificial graphite + thermosetting resin)
17 mass% of epoxy resin as a thermosetting resin was kneaded with 83 mass% of artificial graphite having an average particle diameter of 50 μm at 100 ° C. The kneaded product was pulverized and molded at 100 MPa, and then heat treated at 180 ° C. to obtain a carbon brush.
[0024]
(Comparative Example 2)
(Artificial graphite + pitch)
70% by mass of artificial graphite having an average particle size of 50 μm was mixed with 30% by mass of a pitch as a binder at 200 ° C. The kneaded product was pulverized and molded at 100 MPa, and then heat treated at 650 ° C. to obtain a carbon brush.
[0025]
Table 1 shows the physical characteristics of the carbon brushes of Examples 1 to 3 and Comparative Example 1.
[0026]
[Table 1]
[0027]
Moreover, the carbon brush performance test was performed on the carbon brushes of Examples 1 to 3 and Comparative Example 1 using the test motor and test conditions described below.
Voltage: AC100V 60Hz
Operating conditions: Continuous operating pressure: 35 kPa
Test environment: room temperature 40-45 ° C, humidity 30% or less
The results of the carbon brush characteristic test under the above conditions are shown together in Table 2.
[0029]
[Table 2]
[0030]
Table 3 shows the physical characteristics of the carbon brushes of Example 4 and Comparative Example 2.
[0031]
[Table 3]
[0032]
Voltage: AC230V 60Hz
Operating conditions: Intermittent operating pressure: 50 kPa
Test environment: room temperature 20-45 ° C., humidity 30% or less
Table 4 summarizes the results of the carbon brush characteristic test under the above conditions.
[0034]
[Table 4]
[0035]
From Table 2, it can be seen that the carbon brushes according to Examples 1 to 3 have significantly improved high suction work efficiency and lifetime. Moreover, it can be seen from Table 4 that the carbon brush according to Example 4 has an improved life and suppresses rectifying sparks. It can also be seen from the commutator wear rates of Tables 2 and 4 that the commutator is free from rough damage by containing talc.
[0036]
【The invention's effect】
By adding talc powder to filler and binder and making a carbon brush kneaded, pulverized, molded, and heat treated, the suction work rate is improved by improving the lubricity and rectification performance of talc, and a long-life carbon brush can be obtained it can.
Claims (6)
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JP2003099561A JP3702279B2 (en) | 2003-04-02 | 2003-04-02 | Carbon brush |
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JP2003099561A JP3702279B2 (en) | 2003-04-02 | 2003-04-02 | Carbon brush |
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JP2004312803A JP2004312803A (en) | 2004-11-04 |
JP3702279B2 true JP3702279B2 (en) | 2005-10-05 |
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JP2003099561A Expired - Fee Related JP3702279B2 (en) | 2003-04-02 | 2003-04-02 | Carbon brush |
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JP (1) | JP3702279B2 (en) |
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2003
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