JPS63202009A - Manufacture of core - Google Patents

Abstract

PURPOSE:To improve efficiency and to prevent deterioration of working environment due to fine powder, by applying a coating agent of colloidal mixture comprising specified compositions on both surfaces of a strip shaped iron core material, heating and fixing the material, molding the core material into a core shape, and annealing the core. CONSTITUTION:A long Permalloy plate is wound in a roll shape so as to form an iron core material 20. The material 20 is loaded in a feeding unit 21 together with a reel. The material is unwound and made to pass in a sprayer box 22. Atomized coating agent is applied on both surfaces and both side surfaces of the iron core material 20 so as to form a thin layer. The coating agent is a colloidal mixture comprising boric acid, magnesium oxide, sodium silicate and water. The iron core material 20, on which the coating agent is applied, is supplied from the sprayer box 22, made to pass through a heating box, heated, burned and fixed. Countless minute projections are formed on the surface of the fixed coating agent. Therefore, the iron cores are not stuck to each other. Thus efficiency is improved, and detrioration in working environment due to fine powder can be prevented.

Description

Detailed Description of the Invention "Field of Industrial Application" This invention is applicable to transformer cores used as iron cores of small transformers, zero-phase current transformers, etc., and head cores used as iron cores of recording/playback heads of tape recorders. The present invention relates to a method of manufacturing a core for manufacturing such as.

"Conventional technology" Permalloy, an iron-nickel alloy magnetic material with a thickness of 12 to 0.55 m, is used for transformer cores such as small transformers and tape recorder cores using E type, F type, and U dust. These are punched out, annealed, and then laminated.

To illustrate the conventional method for manufacturing such a core 0.3ζ, the width is 300~45011! Plate thickness α2 with IK
~ While unwinding the long band-shaped permalloy plate wound into a roll, the width of the permalloy plate is 12 mm depending on the core size
The iron core material of the band-shaped permalloy plate, which has been cut and narrowed in width, is cut into a plurality of pieces with a size of ~24 shoulders using a roll cutter or the like, and then wound again into a raw shape.

As shown in FIG. 12, the permalloy iron core material 1 cut into a roll and wound up into a roll as described above is attached to the feeding machine 2 together with the reel, and then the press machine 3 is used to form E-type, F-type, U-type, etc. The strip-shaped permalloy plate remaining after punching is punched out into the desired shape and wound up with a winding machine 4.

15 is an enlarged cross-sectional view of the main parts of the press machine 3 shown in FIG. 12, in which 5 is a ram, 6 is an upper die, 7 is a lower die, and 8 is a guide rod attached to the lower die 7. When the upper die 6't- is raised and lowered by the ram 5 while passing the iron core material 1 between the upper die 6 and the lower die 7, an iron core 9 having a desired shape is stamped from the iron core material 1. 9 falls through the effective cutting edge 10 of the lower m7. FIG. 14 shows the E-shaped core 9 stamped and formed from the core material 1 in this way, overlapping each other.

The iron core 9 formed by punching in this manner is heated at 1.100° C. for about 4 hours in a hydrogen atmosphere to remove carbon, sulfur, etc. from the iron core 9 and remove processing distortion, and then slowly or rapidly cooled. However, as shown in Fig. 14, if high-temperature annealing is performed with the cores 9 still stacked on top of each other, many of the cores lined up in a row will break due to the fringing of the edges that occurs during punching. 9 will be welded. Moreover, if the overlapping iron cores 9 are peeled off one by one and the iron cores 9 are separated and annealed at a high temperature, the iron cores 9 will be deformed. Conventionally, when performing annealing, the punched cores 9 are peeled off one by one and separated, petroleum oil is sprayed onto the entire surface of each core 9, and then fine powder such as alumina or magnesia is deposited. Then, the iron core 9 to which the fine powder has been adhered is arranged in an annealing tray device 11 shown in FIG. 15, and annealed in an annealing furnace so that the iron core 9 is neither welded nor deformed. The annealing tray device 11 shown in FIG.
and an outer box 15, registered utility model No. 1.56.
This is disclosed in No. 4354 (Utility Model Publication No. 59-5838).

After annealing the iron core 9, take out the outer box 15 and the inner box 12, spray air to remove fine powder such as alumina and magnesia adhering to the surface of the iron core 9, and then remove the inner box 12 from the outer box 15.
The required number of sheets were stacked to form the core.

In addition, as a type of transformer core that has been conventionally used, a toroidal core 1 is made by spirally winding a band-shaped permalloy iron core material 1 cut to a predetermined width as shown in FIG.
There is one called 4. In annealing the toroidal core 14, conventionally, as shown in FIG. 17, the iron core material 1 cut into a predetermined width and wound into a roll is fed out while applying pack tension to the fine powder tank 15. Fine powder such as alumina or magnesia is adhered to the surface of the iron core material 1 through the iron core material 1, and the cutting blade 17 is operated every predetermined length while measuring the length with the weight counter 16 which measures the length corresponding to the required weight. The core material 1 is cut to a predetermined length and is wound up by a winding machine 4.

As shown in FIG. 18, the core material 1 wound up in this manner has fine powder 18 of alumina, magnesia, etc. interposed between the core materials 1 constituting the toroidal core 14.

As shown in FIG. 19, the toroidal cores 14 in this state are arranged in the inner box 12 of the annealing tray assembly f11 while sprinkling fine powder 18 such as alumina or magnesia so that the toroidal cores 14 do not come into contact with each other. The box 12 is placed inside the outer box 13 and annealed. The annealed toroidal core 14 is taken out from the annealing tray device 11 and the fine powder 18 is removed.

"Problems to be Solved by the Invention" Conventional core manufacturing methods have the following drawbacks.

(1) When punching the core 2 from the core material 1 with the press @3 shown in Fig. 12, the core 9 is
As shown in Figure @14, they were firmly stuck to each other, so it took some time to peel them off one by one.

(2) After spraying petroleum-based oil onto the entire surface of the iron core 9 that was peeled off one by one, it was a troublesome task to apply fine powder of alumina, magnesia, or the like.

(3) After annealing, it is time-consuming to remove the fine powder adhering to the iron core 9 or the toroidal core 14 by jetting air, and the fine powder remaining without being completely removed may be removed. The powder peeled off during the manufacture of transformers and recording/playback heads, causing problems in winding work, etc.

(4) In the case of the toroidal core 14 shown in FIG.
The distribution of the fine powder 18 interposed between the spirally shaped core materials 1 becomes uneven, and local welding between the core materials 1 occurs during annealing, so the core materials 1 are formed into a loose spiral shape. This has the disadvantage of deteriorating magnetic properties.

This invention solves the above-mentioned conventional drawbacks, prevents iron cores formed from iron core materials from sticking, and eliminates the need for spraying petroleum oil, adhesion of fine powder, and removal of fine powder after annealing. The purpose of this invention is to provide an efficient core manufacturing method with good workability.

"Means for Solving the Problems" This invention involves applying a coating agent of a colloidal mixture consisting of boric acid, magnesium oxide, sodium silicate, and water to both sides of a strip-shaped core material, and then heating the core material. In this method, a coating agent is adhered to both sides of an iron core, and the iron core material with the coating agent adhered to both sides is formed into a core shape and annealed to make a core.

Examples of its implementation include punching and forming an iron core material with a coating agent adhered to both sides into the shape of a core, and forming an iron core material with a coating agent adhered to both sides into the shape of a spiral toroidal core. It will be done.

``Operation'' Countless fine protrusions are formed on the surface of the coating agent applied and fixed to both sides of the core material, and the cores no longer stick to each other.

"Example" Next, embodiments of the invention will be described with reference to the drawings.

A belt-shaped iron core material 20 made of a long permalloy plate of @300 to 450 mm and a plate thickness of α2 to α35 is wound into a roll as shown in FIG.
The core material 20 is unwound and passed through the spray box 22, where the coating agent is sprayed onto the core material using a spray gun (not shown) or ultrasonic waves. Apply in a thin layer to both sides and both sides of 20.

The coating agent applied to the iron core material 20 in the spray box 22 is boric acid (BzOs), magnesium oxide (M0
), sodium silicate (NaO5i03 and its hydrates in various proportions. Na4SiO4°Na1stos, N
It can be obtained by melting a45i04 under appropriate conditions. )
, water (HsO).

The coated core material 20 is fed out of the spray box 22 and then passed through a heating box 23 where it is heated in a temperature range up to 600°C. This heating evaporates the moisture in the coating agent, and the coating agent is baked and fixed on the entire surface of the iron core material 20. The coating agent adhered to the iron core material 20 forms a colorless and transparent thin layer, and countless fine protrusions that can be observed under a microscope are formed on its surface.

The iron core material 20 with the coating agent fixed by baking is placed in the heating box 2.
From 3 to 12 to 2 depending on the dimensions of the transformer core.
Cutting is performed using a plurality of cutting machines 24 having a width of about 41 mm.

The cut end surface produced by this cutting exposes the skin of the permalloy. The coated core material 25, which has the coating agent adhered to both surfaces and is cut into a width corresponding to the dimensions of the transformer core to be manufactured, is wound into a roll by an automatic winder 26.

The coated iron core material 25, which is coated with coating agent on both sides and wound into a roll, is placed in a feeder together with a reel as shown in FIG. 27 and punched into a desired shape such as B-type, E-type, U-type, etc. using a press machine 28.
Roll it up at 9.

The press machine 28 has a ram 5 as shown in FIGS.
0, there are an upper die 31, a lower die 52, and a guide rod 55 attached to the lower die 52, and a press screw &) 34 is attached below the lower die 52.

The press screw s-) 34 has a bolt 5 attached to the bottom surface of the lower fi 32.
5, a plurality of guide rods 37 fixed vertically to the lower surface of the mounting plate 56, and a connecting plate 3 fixed horizontally to the lower end of the guide rods 37.
8, a coupling plate 40 which is coupled to the lower surface of the coupling plate 38 with bolts 39, and whose upper end is fixed to the lower surface of the coupling plate 40, extends vertically below the coupling plate 40, and then bends toward the front. The plurality of guide rods 41 and the tip KXiu of the guide rod 41) and the stop plate 42 and K
Therefore, it is configured.

The embodiment shown in FIGS. 5 and 6 has an EW iron core 43 (
This shows an example in which a coated iron core material 25 (see FIG. 5) is punched out from a coated iron core material 25 (see FIG. 5). When the mold 31 is raised and lowered, an E-shaped core 43 is punched out from the coated core material 25. Then, the punched E-shaped iron core 43 falls through the effective cutting edge 44 of the lower die 32, passes through the mounting plate 56, is guided by the guide rod 57, and is passed through the connecting plate 58.40t. After coming out, they are guided by the guide rod 41 and are lined up in sequence on the back side of the stop plate 42 as shown in FIG. Since a coating agent 45 (see FIG. 4) in which numerous fine protrusions are formed is fixed to both sides of the iron core 45, the stopper plate 4
The iron cores 43 arranged in sequence on the back surface of the iron cores 2 do not stick together tightly because the minute protrusions maintain minute gaps.

Fig. 7 shows the press shade 54 when punching a U-shaped core 45, the connecting plate 38.40 has a hole U5j, and the guide rod 37.41 punches a U-shaped core 45. The number and arrangement of the pieces are suitable for arranging them sequentially on the back side of the 45-karat gold stopper plate 42.

When an appropriate number of cores 43 are lined up on the back of the stop plate 42, the stop plate 42 is removed and the cores 45 are removed from the guide rod 41 while they are lined up, and the cores 43 that are lined up are placed in the 15th position.
They are arranged in an annealing tray device 11 similar to the conventional one shown in the figure. At this time, the iron core 45 is not separated like in the past,
Since it is removed from the guide rod 41 in a lined up state, the iron core 45
The work of arranging them in the annealing tray device 11 can be done in a shorter time than conventionally.

After the iron cores 45 are arranged on the annealing tray device 11, they are placed in an annealing furnace and heated in a hydrogen atmosphere at 1,100° C. for about 4 hours. At this time, the fine protrusions of the coating agent 45 fixed to both sides of the iron core 45 maintain fine gaps between the iron cores 43, so that hydrogen, which is a reducing atmosphere, can easily pass through the fine gaps. , the electrical and magnetic properties of the iron core 45 can be improved. The iron core 43 heated in a hydrogen atmosphere completes annealing by slow cooling or rapid cooling, and is taken out from the annealing tray device 11. However, unlike the conventional method, fine powders such as alumina and magnesia are not attached to the iron core 43, so fine powders such as alumina and magnesia are not attached. There is no need to remove the powder, and the transformer core can be assembled by taking out the cores 43 from the annealing tray device 11 and stacking the cores 43 with the coating agent 45 adhered to both surfaces as they are. Since the coating agent 45 fixed to both sides of the iron core 430 is an extremely thin layer, it does not deteriorate the electric/magnetic characteristics of the transformer core.

In the above embodiments, the iron core 43 of the transformer core is formed by punching, but the tape rehood core also differs only in the shape of the core, and can be formed by punching in the same way as in the embodiments described above. can.

Next, to explain an example different from the order of FIGS. 1 and 2 described above, @300-450 m and plate thickness IIL2-
Band-shaped iron core material 2 made of long permalloy α35■
As shown in FIG. 8, the iron core material 20 is wound into a roll and is mounted on a feeding machine 21 together with a reel, and while the core material 20 is being rewound, it is first cut into a plurality of widths by a cutting machine 24. The cutting width in this case is as shown in Figure 10.
The dimensions should match the width 46 of No. 5.

The core material 20' cut into multiple strips with a width matching the width 46 of the core 43 by the cutting machine 24 as shown above is passed through the spray box 22 and the heating box 23, and is heated with boric acid, magnesium oxide, and sodium silicate. , water) is applied and fixed by baking to form a coated iron core material 25, which is then wound up by an automatic winding machine 26. In this case, the coated core material 25 has a coating agent fixed not only to the upper and lower surfaces but also to the cut end surfaces on both sides.

The coated core material 25, which has a width that matches the width 46 of the core 45 to be manufactured, is attached to the feeder 27 together with the reel as shown in FIG.
Then, an iron core 43 as shown in FIG. 10 is continuously punched and formed.

In this case, scattered punching scraps 47 as shown in FIG. 10 are generated, so a scrap container 48 is attached to the press 28 as shown in FIG. 9 to collect the punching scraps 47. Width 46 of the core 43 to be manufactured as shown in FIG.
The core 45 is punched and formed from the coated core material 25 having a width that matches that of the core 45, and has a coating agent adhered to both upper and lower surfaces as well as both end surfaces.

The iron core 43 punched and formed by the press machine 28 in FIG. 9 is shown in FIG. Annealing is performed using an annealing tray device 11.

Next, an embodiment of manufacturing a toroidal core 14 as shown in FIG. 16 according to the present invention will be described.

In this case, as in the embodiment explained in FIG. 8, the width of the toroidal core 14 to be manufactured by the cutting machine 24 is Matching multiple core materials 2
0' and cut the cut iron core material 20' into a spray box 22,
Passed through the heating box 25, boric acid, magnesium oxide,
Coating iron core material 25 is coated with a colloidal mixture of sodium silicate and water and fixed by baking.
Then, the automatic winder 26 winds it up.

Next, the coated core material 25 removed from the automatic winder 26 is molded into a spiral toroidal core 14 similar to that shown in FIG. 16 using a molding machine (not shown). As shown in the enlarged sectional view of FIG. 11, the toroidal core 14 formed by K in this way has the coating agent 45 fixed to the entire surface of the coated core material 25 wound in a spiral shape, so it cannot be annealed. Since local welding does not occur between the coated core materials 25 during this process, the coated core materials 25 can be tightly wound to form a toroidal core with good magnetic properties, and furthermore, they can be lined up in an annealing tray device and annealed. Since welding does not occur between the toroidal cores during the process, there is no need to sprinkle fine powder 18 as in the conventional method shown in Fig. 19. Therefore, many toroidal cores can be lined up in the annealing tray device and annealed at the same time.

"Effects of the Invention" This invention provides a coating agent 1r of a colloidal mixture consisting of boric acid, magnesium oxide, sodium silicate, and water on both sides of a strip-shaped iron core material. Since the core material is heated and fixed before being formed into the shape of the core and annealed, the coating agent prevents the punched cores from forming close contact with each other. There is no need to remove the fine powder by peeling it off and remove it after annealing, which simplifies the transformer manufacturing process, improves efficiency, and prevents deterioration of the working environment due to fine powder. can.

A coating agent that adheres to both sides of the core material formed into a masoa shape maintains minute gaps between the cores.
Therefore, during annealing, hydrogen, which is a reducing atmosphere, can circulate well between the iron cores, improving the electrical and magnetic properties of the iron cores.

[Brief explanation of the drawing]

1 and 2 are front views of an embodiment of the apparatus used in the method of the present invention, FIG. 3 is an enlarged front view showing a partially cut away main part of FIG. 2, and FIG. 4 is a perspective view of FIG. 3, FIG. 5 is an exploded perspective view of the main parts of FIG. 4, FIG. 6 is a partial side view of FIG. 4, and FIG. 7 is of an embodiment different from FIG. 4. FIGS. 8 and 9 are front views of other embodiments of the apparatus used in the method of the present invention, FIG. 10 is a plan view showing an example of forming a core, and FIG. FIG. 16 is an enlarged sectional view taken along line A-A of the toroidal core manufactured by the method of the invention; FIG. 12 is a front view of the apparatus used in the conventional method; FIG. 13 is an enlarged sectional view of the main parts in FIG. 12. , Fig. 14 is a perspective view showing an example of the iron core, Fig. 15 is a longitudinal sectional view of an annealing tray device showing a state in which the iron core is annealed by a conventional method, Fig. 16 is a plan view of the toroidal core, Fig. 17 18 is an enlarged sectional view taken along the line A-A in FIG. 16 of the toroidal core manufactured by the conventional method. FIG. 19 is the conventional method. FIG. 3 is a longitudinal cross-sectional view of the annealing tray device showing a state in which the toroidal core is annealed by the method shown in FIG. 11... Annealing tray device 14... Toroidal core 20, 20'... Iron core material 22... Spray box 23
... Heating box 25 ... Coating core material 43 ... Iron core 45 ... Coating agent patent applicant Nakano Permalloy Co., Ltd. Figure 16 Figure 18 Figure 17 b Figure 19

Claims (1)

[Claims] 1) After applying a coating agent of a colloidal mixture consisting of boric acid, magnesium oxide, sodium silicate, and water to both sides of a strip-shaped iron core material, the iron core material is heated to coat the coating agent. A method for producing a core, comprising: fixing the coating agent on both sides of the core material, forming the core material into a core shape, annealing the core material, and making the core. 2) A method for manufacturing a core according to claim 1, which comprises punching and molding an iron core material having a coating agent adhered to both surfaces into the shape of the core. 3) A method for manufacturing a core according to claim 1, characterized in that an iron core material having a coating agent adhered to both surfaces is formed into a spiral toroidal core shape.