JPS61210608A - Manufacture of magnetic material - Google Patents

Abstract

PURPOSE:To increase the permeability along a magnetic circuit and to restrain the eddy-current loss in a vertical plane by making a magnetic field in the same shape with the magnetic circuit of an electric apparatus in which a magnetic material is used. CONSTITUTION:For example, soft magnetic powder such as iron powder, etc. is injection-molded using a pellet previously kneaded with nylon, etc. When plastic is melted in a cavity 3 and a magnetic field is formed in the cavity 3 applying a current in a coil 4, the soft magnetic powder in the plastic is orientated in the direction of a magnetic path and fixed in the plastic in the orientated state by cooling. A coil 4 with the core material manufactured in this way for a transformer and a primary winding 5 constitute a magnetic circuit which has the same shape for each of the cavity 3 and a core 7. This reduces the magnetic reluctance in the direction of a magnetic path in the core 7 of the transformer and can restrain the eddy-current loss generated in a vertical plane.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method of manufacturing a magnetic member used in a magnetic circuit of an electrical device such as a motor or a transformer.

[Prior Art] Conventionally, magnetic members such as motor and armature cores that form the motor's magnetic circuit have generally been made of materials with high magnetic permeability such as iron or silicon steel plates. There is.

On the other hand, the inventor of the present application, for example,
As shown in No. 35, because of the ability to select any shape and the ease of processing, there are methods in which soft magnetic powder or soft magnetic fibers are mixed into plastic, etc. and injection molded, and soft magnetic powder or soft magnetic fibers are mixed with a binder. We devised a method for manufacturing magnetic members using a molding and sintering method.

[Problem to be solved by the invention] The magnetic properties of magnetic members manufactured by injection molding or mold sintering are lower than the inherent magnetic permeability of soft magnetic powder or soft magnetic fiber due to the presence of a binder such as plastic. I can't keep track of things.

[Means for Solving the Problems] In the present invention, when manufacturing a magnetic member by injection molding or molding sintering using a magnetic material such as soft magnetic S fiber and a binder such as plastic, the 11 field is It is molded and solidified in a magnetic field configured in the same shape as the magnetic circuit of the electrical equipment in which it is used.

[Function] When the above method is carried out, the 11 bamboo materials are arranged in the direction along the magnetic path of the magnetic circuit of the electrical equipment, with high density in the direction of the magnetic path, and binder in the direction perpendicular to the magnetic path. The structure has an intervening structure. When assimilation is completed in this state, the magnetic permeability in the direction of the magnetic path is high, and eddy currents in the plane perpendicular to the magnetic path are blocked by the binder, so generation is suppressed and a magnetic member with low loss can be obtained. Can be done.

[Example 1] Next, the present invention will be explained in more detail with reference to an example shown in the drawings.

Fig. 1 shows an example of manufacturing a core member of a transformer according to the present invention, and 1 shows an injection molding machine that mixes and injects soft magnetic powder and plastic by melting, and 2 shows a mold for manufacturing the transformer core. It is. However, the mold is made of a non-magnetic material such as copper or porcelain.

3 is a cavity portion of the mold 2, and 4 is a coil for forming a magnetic path.

For injection, first, a pellet is prepared in which soft magnetic powder such as iron powder is kneaded with nylon 12 or the like, and normal injection molding is performed. Then, when the plastic is in a molten state in the cavity 3, when a current is passed through the coil 4 and a magnetic field is applied to the cavity, the soft magnetic powder in the plastic is oriented in the direction of the magnetic path, and as it cools, it melts into the plastic. It is fixed in the oriented state. FIG. 2 shows the transformer core member manufactured in this manner taken out and assembled as a transformer FE. In FIG. 2, 5 is the primary winding of the transformer, 6 is the secondary winding, and 7 is the core. In this case, the coil shown at 4 in FIG. 1 and the primary winding shown at 5 in FIG. A feature of the present invention is that the core 7 of the transformer made in this manner has low magnetic resistance in the direction of the magnetic path, and suppresses eddy current loss occurring in a plane perpendicular to the magnetic path.

``Example 2'' Next, an example of manufacturing a core and a yoke portion constituting a magnetic circuit of a flat type two-phase four-pole brushless motor will be described.

3 to 5 show the principle configuration diagram of the motor 8. FIG.

9 is a case, 10 is a rotor using a 4-pole magnet, and 11 is a drive on the stator side, which is made of ultra-thin steel plates and insulating plates wound in a circular or elliptical shape. Coil, 12 is a core and yoke part for forming a magnetic path, 1
3 is a drive circuit board a14 is a rotating shaft. The magnetic path 15 of the core and yoke portion 12 of the motor 8 has the shape shown in FIG.

Therefore, in order to produce an anisotropic magnetic member having a small magnetic resistance along the magnetic path 15 and suppressing eddy current loss in a plane perpendicular to the magnetic path 15 by the method according to the present invention, the motor as shown in FIG. It may be molded and solidified in a magnetic field configured in the same shape as the magnetic circuit.

In FIG. 7, 16 is an electromagnet that forms Ils, 2
numeral 3 is a mold made of non-magnetic material, numeral 3 is a cavity for molding and solidifying the core and yoke, and numeral 1 is an injection molding machine for injecting a molten mixture of soft magnetic powder and plastic. The orientation of the core-yoke member 12 made in this way is as shown in FIGS. 8 and 9, and it is a member that has high magnetic permeability along the magnetic circuit and suppresses eddy current loss perpendicular to it. . 1
5 shows no magnetic path. Also, each part of the desired magnetic path can be magnetic, and the other parts can be non-magnetic parts made of only plastic.

Furthermore, if this idea is expanded further, a so-called plastic magnet, in which hard magnetic powder that can form a magnet is mixed into plastic, is compositely molded at the same time as the soft magnetic member of the present invention is molded, and at that time, it is possible to create a magnet that is the same as the magnetic circuit of an electrical device. By molding and solidifying while applying a magnetic field from the outside, it is possible to simplify the process by simultaneously making the plastic magnets 1 to anisotropic and the soft magnetic member anisotropic and molding them at the same time.

Figure 10 shows the magnetic path 1 in the core and yoke member 12 in Figure 8.9.
This figure shows the electromagnet 16 and the coil 4 when making the 5. 17 indicates a north pole, and 18 indicates a south pole.

In the electromagnet 16 shown in FIG.
A member 16C with a coil 4 provided on the outer periphery from the center part of 6b
This member 16C is connected to the connecting parts 16a and 16.
If it is difficult to stand up from each center part of b,
As shown in Figure 11, shift its position and instead,
In order to make the state of the magnetic path 15 that can be formed uniform with this,
It is also possible to make one of the N poles 17 and S poles 18 larger and the other smaller. In this case, the distances from one rising position of the member 16C to the heads such as the N poles 17 are a and b.
Then, it is preferable to set the size of both heads to be inversely proportional to the distance [a, b].

[Results] As is clear from the above description, according to the present invention, magnetic materials such as soft magnetic powder or soft magnetic fibers are mixed with a binder such as plastic, and electrical equipment is manufactured by injection molding or mold sintering. By making a soft magnetic member oriented in the same shape as the magnetic circuit, it is possible to have characteristics that have high magnetic permeability in the direction along the magnetic circuit and suppress eddy current loss in the direction perpendicular to it.

[Brief explanation of the drawing]

The drawings show an embodiment of the apparatus for carrying out method h of the present invention, and FIG. 1 is a front view (partial sectional view) of the manufacturing apparatus, FIG. 2 is a front view of the transformer, and FIG. 3 is a front view of the transformer. The figure is a longitudinal cross-sectional view of a flat brushless motor, Figure 4 is a cross-sectional view taken along the line IV-Vl in Figure 3, Figure 5 is a cross-sectional view taken along the v-v line in Figure 3, and Figure 6 is shown in Figure 3. Fig. 7 is a front view (partial sectional view) of another manufacturing device;
The figure is a plan view showing the orientation of the core-yoke member formed according to the present invention, FIG. 9 is a longitudinal cross-sectional view of the one in FIG.
FIG. 0 and FIG. 11 are perspective views and explanatory views showing different examples of electromagnets used in carrying out the present invention. DESCRIPTION OF SYMBOLS 1... Injection molding machine, 2... Mold, 3... KiVity, 4... Coil, 7... Core, 8... Motor,
10... Rotor, 11... Drive coil, 12...
Core and yoke portion, 15...Magnetic path, 16...Electromagnetic V [Applicant: Ube Industries, Ltd.! 11m Condolence 1tJ Figuya 11 Kyo

Claims (1)

[Claims] Magnetic manufacturing involves forming and solidifying a soft magnetic material using a binder in a magnetic field configured in the same shape as the magnetic circuit of an electrical device to produce a magnetic member with anisotropic characteristics suitable for the electrical device. Manufacturing method of parts