KR101269688B1 - Method for manufacturing a soft magnetic core - Google Patents

Abstract

The present invention relates to a method for producing a soft magnetic core.

The present invention relates to a method of manufacturing a soft magnetic core which is a molded body by filling a soft magnetic powder into a die of a press machine and press molding the soft magnetic powder, wherein a soft coating material is inserted into the soft magnetic powder filled in the die and press molded together to form the soft magnetic core. It is characterized in that to produce a molded body of the soft magnetic core bonded to the coating material.

Therefore, the soft magnetic core molded body is bonded to the outer surface side and the inside of the soft coating material is produced, it is prevented from being damaged by external impact during the subsequent handling and use process, it is possible to improve the production yield Of course, there is an effect that can also improve the reliability of the product using the soft magnetic core.

Soft Magnetic, Powder, SMC, Pressurized, Forming, Die, Coating, Soft, Aluminum, Core, Motor, Rotor, Stator

Description

METHOD FOR MANUFACTURING A SOFT MAGNETIC CORE}

1 is a flow chart of a conventional method for manufacturing a soft magnetic core,

Figure 2 is a cross-sectional view showing an example of the structure of a press machine used for pressure molding of a conventional soft magnetic core,

3 is a flow chart of a method of manufacturing a soft magnetic core according to the present invention.

<Description of the symbols for the main parts of the drawings>

100: soft magnetic powder 110: die

120: upper punch 130: lower punch

140: mandrel

The present invention relates to a method of manufacturing a soft magnetic core, and more particularly, the outer surface side and the inside of the soft magnetic core molded body manufactured by placing a soft coating material on the outside or inside of the soft magnetic powder filled in the die and pressing together. The present invention relates to a method of manufacturing a soft magnetic core, which is to be integrally coupled to the soft coating material, thereby preventing the breakage of the soft magnetic core from being easily damaged by external impacts during the handling and use of the soft magnetic core.

In general, soft magnetic property materials include cores in inductors, stators and rotors of electrical devices such as motors, such as rotors, actuators, sensors, and transformer cores. It is used for various purposes.

Typically, soft magnetic cores, such as rotors and stators in electrical devices, have conventionally been manufactured by laminating a plurality of processed steel laminates in multiple layers and then welding them together to integrate them.

However, in the case of manufacturing the laminated steel sheet in this way, there is a problem in that it is difficult to produce a complicated shape of the product, and a large amount of scrap is generated.

In recent years, cores having high degrees of freedom in terms of shape have been fabricated by high-pressure molding soft magnetic powders.

In this case, the soft magnetic powder to be used is a powder that is magnetic when electric is applied, and is usually based on iron-based soft magnetic particles, and uses the soft magnetic powders to produce a soft magnetic core. This is done through conventional powder metallurgy processes.

Hereinafter, a manufacturing process of the soft magnetic core will be described in detail with reference to the flow chart of FIG. 1.

First of all, the powder is made through a spraying method or a pulverizing method, and then the powder is subjected to mechanical processing and heat treatment to prepare a soft magnetic powder that can be suitably used as a core material. S100).

Here, the soft magnetic powder may have various shapes such as round shape, flat shape, polygonal shape, and the like, and the size of the soft magnetic powder should be a size that can provide a good molding density. Ready to have

Subsequently, the soft magnetic core is manufactured using the soft magnetic powders prepared as described above. First, a mixed ceramic is added to the prepared soft magnetic powder to perform insulation coating (S102).

Here, the mixed ceramic added for the insulating coating refers to a ceramic mixture based on water silicate, and the ceramic coating reduces the eddy current loss of the core material by electrically separating the individual powders.

As the insulating coating is performed, the soft magnetic powders form conventional soft magnetic composites (SMC).

Subsequently, the soft magnetic powders prepared through the above process are press-molded by using a press machine, which is a compression molding machine, that is, the punched after filling the insulating coated soft magnetic powders into the molding space of the die of the press machine. By pressing to compress a predetermined molding pressure through a punch to form a soft magnetic core molded body having a predetermined shape (S106), at this time, prior to the press molding, the moldability of the core is improved while improving the moldability of the core. A small amount of binder and / or lubricant is added (S104) and then compacted together to reduce the frictional force and friction between the powder particles and to protect the molding die.

Here, the press machine used for pressure molding is classified into a single axial or a double axial according to the number of punches provided, and the like.

Referring to this, the upper punch 120, the lower punch 130 is provided on the upper side around the die 110, the soft magnetic powder 100 is filled therein, the mandrel 140 to penetrate through the center thereof. ) Will be provided.

Subsequently, the molded soft magnetic core is subjected to a heat treatment (annealing treatment) to remove internal residual stresses and deformations and to harden the added binder to improve the strength of the soft magnetic core while also improving its magnetic properties (S108). ).

Thereafter, in order to protect the characteristics of the soft magnetic core from moisture and the atmosphere, a surface of the polyester or epoxy resin is coated to a predetermined thickness to finally manufacture the soft magnetic core (S110).

However, conventionally, after making a soft magnetic core that is a molded body through a pressurization process, heat treatment is performed while the molded body is handled, and inspection or the like is performed, and the molded body is easily broken and broken in the process. It is a situation that a problem that is easily broken and broken even while using the magnetic core in the actual product assembly.

In other words, the molded product of the soft magnetic core in the pressure molded state is only a state in which the powders are concentrated due to the pressure, can be easily broken by an external impact and the like, but the bonding force is improved even when the heat treatment is completed, but similarly impact When this is applied, it is easily broken, and even when the soft magnetic core is applied to an actual product, it does not provide solid durability even during use, and thus is easily broken, causing various problems.

Of course, this problem is not only limited to the production of the soft magnetic core, but can be said to be a problem commonly generated in the production of a molded body using all the metal powder.

The present invention has been made to solve the above-mentioned problems, the soft coating material is inserted into the outer surface and the inside of the soft powder during the press molding to be molded together by pressing the soft coating material on its outer surface and inside. The present invention provides a method of manufacturing a soft magnetic core, which enables the molded product of the soft magnetic core to be manufactured, thereby preventing the molded body of the soft magnetic core from being easily broken due to the presence of the soft coating material. There is this.

The method for producing a soft magnetic core of the present invention for achieving the above object is a method for manufacturing a soft magnetic core which is a molded body by filling a soft magnetic powder into a die of a press machine and press molding the soft magnetic core. The soft coating material is inserted into the magnetic powder and press-molded together to produce a molded body of the soft magnetic core to which the soft coating material is bonded.

The above objects and various advantages of the present invention will become more apparent from the preferred embodiments of the invention described below with reference to the accompanying drawings by those skilled in the art.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

3 is a flow chart of a method of manufacturing a soft magnetic core according to the present invention.

As is well known, soft magnetic core is prepared by first preparing soft magnetic powders (S200) which can be suitably used as a core material (S200), and then mixing the individual powders to be electrically insulated by adding mixed ceramics to the soft magnetic powders. After coating (S202), a small amount of binder and / or lubricant is added to the soft magnetic powders (S204), and then press-molded using a press machine (S208) to form a molded body of the soft magnetic core, and After heat-treating the molded body of the soft magnetic core (S210), and finally the protective coating on the surface of the molded body (S212), the production is completed.

According to the present invention, the soft coating material is inserted into the outer and / or inside of the soft magnetic powders 100 filled in the forming die 110 of the pressing machine before press molding using a press machine (S206), and then pressed together. By being molded (S208), a molded product of a soft magnetic core having a soft coating material bonded to the outer surface side and / or the inside thereof is obtained, thereby handling the soft magnetic core molded product and the actual product. The soft magnetic core molded body is prevented from being easily damaged by external impact due to the presence of the soft coating material in the process used and applied to the product.

That is, preferably, a soft coating material is inserted into the outside of the soft magnetic powders 100 filled in the die 110 (S206), and then pressure molded together (S208), so that the soft coating material is wrapped on the outer surface side. If a molded product of the combined soft magnetic core is obtained, the soft impact material on the outer surface side is applied when the impact is applied from the outside in the process of handling the soft magnetic core molded product or applying it to an actual product. By first receiving and mitigating, the molded body of the soft magnetic core therein can be protected without being damaged.

Here, as the soft coating material, a sheet-like soft sheet may be preferably used, and alternatively, soft metal powder may be used to be coupled to the outer surface side of the molded body according to pressure molding.

That is, first, the soft sheets are properly inserted into the inner surface side of the die 110 of FIG. 2, and the soft magnetic powders 100 are filled with the corresponding soft sheet inner spaces, and then the punches 120 and 130 are filled. By press molding using a soft magnetic core molded body coupled to wrap the soft sheets on the outer surface side can be produced.

At this time, the soft sheet is provided not only in the inner surface side of the die 110 but also in a portion that is in direct contact with the punches 120 and 130, and may be deformed while being in direct contact with the punches 120 and 130 being moved. Of course.

That is, the soft sheet should be provided so as to surround the outer surface side of the molded body to be manufactured as much as possible, which is intended to improve impact acceptability from the outside.

Of course, the soft coating material may be provided to suitably include not only the outer surface side of the molded body to be manufactured, but also inside thereof. If the soft coating material is provided therein, the magnetic properties of the soft magnetic core are not only in terms of impact water solubility. It may also be valid in terms of coordination.

In addition, since the property that the soft coating material should have essentially includes easy deformation property, easy bonding to the powder side, and excellent impact water solubility, aluminum (Al) may be preferably used as the material of the soft coating material.

Thus, according to the present invention, the problem of being easily broken in the subsequent handling and use process of the soft magnetic core molded body produced by pressure molding can be overcome, and in addition, the soft coating material is soft magnetic powder 100 and As it is provided between the dies 110, the soft magnetic powders 100 and the die 110 are in direct contact with each other during press molding so that the dies or soft magnetic powders may be prevented from being mutually damaged.

It will be appreciated by those skilled in the art that changes may be made to the present invention without departing from the spirit and scope of the invention as defined by the appended claims.

According to the present invention, since the soft coating material is manufactured in the soft magnetic core molded body bonded to the outer surface and the inside of the soft coating material, it is prevented from being damaged by external impact during the subsequent handling and use, thereby improving production yield. In addition, the effect of improving the reliability of the product using the soft magnetic core can be achieved.

Claims (6)

In the method for producing a soft magnetic core which is a molded body by filling the soft magnetic powder into the die of the press machine and pressure-molding, Inserting a soft sheet material in the form of a soft sheet to the outside and inside of the soft magnetic powder filled in the die and press-molded together, so that the soft coating material is coupled to the outer surface side and inside of the molded body of the soft magnetic core. Method for producing a soft magnetic core characterized in that. delete delete delete The method of claim 1, The soft coating material, Method for producing a soft magnetic core, characterized in that the soft metal powders. The method of claim 1, The soft coating material, A method for producing a soft magnetic core, comprising an aluminum material.

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