TW201444903A - Fixing resin composition, rotor and motor vehicles, and method of producing rotor - Google Patents

Abstract

The invention provides a solid fixing resin composition with excellent filling properties and a rotor using the same. The rotor includes rotor core 110 which has a laminate obtained by laminating a plurality of plate member, and a plurality of holes 150 which are arranged along the periphery of the rotating shaft, wherein the holes 150 is provided in the laminate and the rotor core 110 is fixed to the rotating shaft. The rotor further includes a magnet 120 which is inserted into the hole 150, and a fixing member 130 which is formed by curing the fixing resin composition which is filled to the separated portion between the magnet 120 and the hole 150. The fixing resin composition for using in the fixing member 130 of the rotor, includes a thermosetting resin containing an epoxy resin (A), curing agent (B), inorganic filler (C), and ICI viscosity of the epoxy resin at 150 DEG C is 3 poise and below.

Description

Fixing resin composition, rotor, automobile, and rotor manufacturing method

The present invention relates to a method for producing a resin composition for a rotor, a rotor, an automobile, and a rotor.

In recent years, in the technical field of the rotor, a permanent magnet has been inserted into a hole portion provided in a rotor core, and a liquid resin is filled between the hole portion and the permanent magnet, thereby fixing the permanent magnet to the rotor core. technology. In the technical field, a liquid resin such as a urethane resin or an epoxy resin is usually used. Such a technique is described, for example, in Patent Document 1.

Further, Patent Document 2 describes an epoxy resin for sealing a motor for sealing a motor and a molded article obtained by curing the epoxy resin. According to the description, the molded article can obtain work environment, productivity, heat resistance, thermal conductivity, solvent resistance, high moisture resistance, and a low coefficient of linear expansion. Therefore, it is considered that the molded article described in Patent Document 2 can be used for the outer casing of the motor.

Further, the rotor described in Patent Document 3 has a configuration in which a second hole portion that communicates with the first hole portion and is along the rotation direction of the rotor is formed on the side surface of the first hole portion in which the permanent magnet is housed. The second hole portion is filled with a resin or a spring is disposed, thereby permanently magnetizing in the rotation direction of the rotor. The stress that the iron receives from the side wall of the first hole portion is alleviated. According to the description, it is possible to prevent the permanent magnet from being damaged. Further, as a method of filling the liquid resin between the hole portion of the rotor core and the magnet, there are two methods of pre-filling and coating. The prefill method includes the following steps. First, a liquid resin is filled into the hole portion of the rotor core by a dispenser. Then, a magnet is inserted into the hole portion filled with the liquid resin. The pre-filling method is described in Patent Documents 4 and 5. On the other hand, the coating method comprises the following steps. First, a liquid resin is applied to a magnet by a brush, and a magnet coated with a liquid resin is inserted into a hole of the rotor core. The coating method is described in Patent Document 6.

[Previous Technical Literature]

[Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2007-236020

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2009-13213

[Patent Document 3] Japanese Patent Laid-Open Publication No. 2002-359942

[Patent Document 4] Japanese Patent Laid-Open Publication No. 2005-304247

[Patent Document 5] Japanese Patent Laid-Open No. Hei 11-98735

[Patent Document 6] Japanese Patent Laid-Open Publication No. 2003-199303

It is difficult to apply the above-described technique of filling a liquid resin to a method of injecting a resin into a gap between a hole portion of a rotor core and a magnet previously inserted into the hole portion.

Further, the epoxy resin described in Patent Document 2 covers the entire horse. For the purpose. Therefore, it is difficult to use the resin described in Patent Document 2 for the purpose of fixing a permanent magnet.

As a result of research conducted by the inventors of the present invention, it has been found that by insert molding, the resin can be filled in the gap between the hole portion of the rotor core and the magnet previously inserted into the hole portion.

However, when the gap between the hole portion of the rotor core and the magnet is narrow, there is a possibility that the gap cannot be filled with the molten resin. Therefore, the inventors of the present invention thought that there is still room for improvement in the melt viscosity of the solid resin in order to improve the filling characteristics of the gap.

According to the present invention, there is provided a fixing resin composition for a fixing member constituting a rotor, the rotor comprising: a rotor core including a laminated body formed by laminating a plurality of plate members, fixed to the rotation a plurality of hole portions disposed along a peripheral edge portion of the rotating shaft, a magnet inserted into the hole portion, and a fixing member filled in the hole portion The fixing resin composition in the partition portion of the magnet is cured, and the fixing resin composition contains the thermosetting resin (A) in an amount of 5 mass% or more and 40 mass% or less, and the ICI contained in the ICI at 150 ° C. The epoxy resin (A1) having a viscosity of 3 poise or less is 70% by mass or more and 100% by mass or less; the curing agent (B) is 3% by mass or more and 35% by mass or less, and the ICI viscosity at 150 ° C is 2 poise or less; And the inorganic filler (C) is 50% by mass or more and 93% by mass or less; and the fixing resin composition is injected to have a width of 3 mm and a thickness under the conditions of a mold temperature of 175 ° C, a molding pressure of 6.9 MPa, and an injection time of 20 seconds. The slit flow length in the flow path of the cross-sectional shape of 80 μm is 75 mm or more and 300 mm or less.

According to the present invention, it is possible to provide a solid fixing resin composition excellent in filling characteristics and a rotor using the same.

100‧‧‧Rotor

110‧‧‧Rotor core

112‧‧‧ steel plate

114‧‧‧End board

116‧‧‧ slot department

118a‧‧‧End plate

118b‧‧‧End board

120‧‧‧ magnet

121‧‧‧ side wall

123‧‧‧ side wall

130‧‧‧Fixed components

140‧‧‧Filling Department

150‧‧‧ hole department

151‧‧‧ side wall

152‧‧‧ Hole Department

153‧‧‧ side wall

154a‧‧‧孔部

154b‧‧‧ Hole Department

156‧‧‧ Hole Department

160‧‧‧Riveting

170‧‧‧Axis

200‧‧‧上模

210‧‧‧ cans

220‧‧‧flow path

D1‧‧‧ interval width

The above and other objects, features and advantages of the present invention will become more apparent from

Fig. 1 is a plan view schematically showing a rotor according to an embodiment of the present invention.

Fig. 2 is a plan view schematically showing a mold for insert molding in an embodiment of the present invention.

Fig. 3 is a schematic enlarged view showing a part of a rotor according to an embodiment of the present invention.

Fig. 4 is a cross-sectional view showing a part of a rotor according to an embodiment of the present invention in a schematic manner.

Fig. 5 is a cross-sectional view showing the rotor of the embodiment of the present invention in a schematic manner.

Fig. 6 is a cross-sectional view showing a modification of the rotor according to the embodiment of the present invention.

Fig. 7 is a plan view showing a rotor of a modification in a schematic manner.

Fig. 8 is a plan view showing a rotor of a modification in a schematic manner.

Fig. 9 is a plan view showing a rotor of a modification in a schematic manner.

Hereinafter, embodiments of the present invention will be described using the drawings. In the drawings, the same components are denoted by the same reference numerals, and the description is omitted as appropriate.

Fig. 1 is a plan view of a rotor according to an embodiment of the present invention. Fig. 3 is an enlarged view of a portion of a rotor according to an embodiment of the present invention. Fig. 4 is a cross-sectional view showing a part of a rotor according to an embodiment of the present invention. Fig. 5 is a cross-sectional view showing the configuration of a rotor. The rotor 100 of the present embodiment includes a rotor core 110, a magnet 120, and a fixing member 130. The rotor core 110 includes a laminate in which a plurality of plate members (electromagnetic steel sheets) are laminated. The rotor core 110 is fixed to a rotating shaft (shaft 170). Further, in the rotor core 110, a plurality of holes 150 disposed along the peripheral edge portion of the rotating shaft are provided in the laminated body. The magnet 120 is inserted into the hole 150. The fixing member 130 is formed by curing the fixing resin composition filled in the space between the hole portion 150 and the magnet 120.

The rotor core 110 is configured by laminating a plurality of thin magnetic steel sheets (steel sheets 112). A through hole for inserting the shaft 170 is provided in the rotor core 110. The rotor core 110 can be formed, for example, in a cylindrical shape. The shape of the rotor core 110 in plan view is not particularly limited, and may be, for example, a circle, a polygon, or the like. Further, a plurality of electromagnetic steel sheets are coupled to each other by the caulking portion 160. Further, the electromagnetic steel sheet contains, for example, iron or an iron alloy. Further, an end plate 114 is provided at an end portion of the rotor core 110 in the axial direction. Further, in the end plate 114, a caulking portion 160 and a groove portion 116 for avoiding interference with the opening portion of the filling portion 140 may be provided.

The plurality of hole portions 150 (or the hole portion group including the plurality of hole portions) are disposed in the rotor core 110 such that the axis of the rotating shaft is center-symmetric. The number of the hole portions 150 is not particularly limited, and is, for example, 2 ⁿ or 3 ⁿ (n is a natural number, for example, 2 to 5). A magnet 120 is inserted into each of the hole portions 150. The hole portion 150 may be configured in accordance with the shape of the magnet 120. For example, a void (gap portion) may be formed around the corner portion of the magnet 120.

The arrangement of the holes 150 is not limited to the configuration shown in FIG. 1. For example, various layouts shown in FIGS. 7 to 9 may be employed. A group of holes having a pair of two or three hole portions 150 may be disposed along a peripheral portion of the rotating shaft. As shown in Fig. 1, each of the hole groups may include two holes that are spaced apart from each other and arranged in a V shape. Further, as shown in FIG. 9, the hole group may include hole portions 154a and 154b and a hole portion 156 formed between the hole portions 154a and 154b. Further, as shown in FIG. 8, the hole portions arranged in a V shape may communicate with each other to constitute one hole portion 152. Further, as shown in FIG. 7, the plurality of hole portions 150 may be disposed apart from each other so that the hole portion 150 is orthogonal to the direction perpendicular to the surface of the shaft.

Further, the magnet 120 may be fixed inside the hole portion 150. For example, as shown in FIGS. 3 and 4, the magnet 120 may be fixed to the side wall 151 on the outer circumference side of the rotor core 110 in the side wall of the hole portion 150. That is, the side wall 121 of the magnet 120 can be brought into contact with the side wall 151 of the hole portion 150. In other words, the fixing resin composition of the present invention can be filled in the space between the side wall other than the side wall 151 of the hole portion 150 and the magnet 120 (filling portion 140). The fixing resin composition is cured to form a fixing member 130. Fixed structure The member 130 may also be disposed between the corner portion of the hole portion 150 and the magnet 120. Here, as the magnet 120, for example, a permanent magnet such as a neodymium magnet can be used.

In FIGS. 3 and 4, the side wall 153 means that the side wall of the hole portion 150 is located on the inner circumference side of the rotor core 110. In addition, the side wall 123 refers to the side wall of the magnet 120 facing the side wall 153 of the hole portion 150.

In the present embodiment, as shown in FIG. 3 or FIG. 4, the interval width D1 of the gap between the hole portion 150 and the magnet 120 in the radial direction of the rotor core 110 is defined as the side wall 153 of the hole portion 150 to the side wall of the magnet 120. 123 distance. When the gap is present, the interval width D1 is preferably 20 μm or more and 500 μm or less. More preferably, it is 50 micrometers or more and 300 micrometers or less. By setting the interval width D1 within the above range, it is possible to impart good mechanical strength to the rotor.

As a result of research conducted by the inventors, it has been found that in a region having a narrow width, it is likely to be unfilled with a resin.

On the other hand, by using the fixing resin composition of the present invention having excellent filling properties, it is possible to prevent the resin from being filled with a resin in a region having a narrow width. Thereby, the fixing member 130 can be well filled in the gap between the hole portion 150 and the magnet 120, so that the rigidity of the rotor 100 can be improved. Therefore, the noise generated by the rotor during spin rotation can be reduced.

As shown in FIG. 5, the end plate 114 is fixed to the shaft 170 and sandwiches the rotor core 110 in the axial direction. The end plate 114 is fixed to the shaft 170 by a rivet portion 160. However, the present invention is not limited to this embodiment. As shown in FIG. 6, the end plates 118a and 118b may be fixed to the shaft 170 by welding or the like. Further, in the hole portion 150, the solid portion may not be formed on the side wall on the peripheral side of the magnet 120. Although the member 130 is fixed, as shown in FIG. 6, the fixing member 130 may be formed on the both side walls on the outer peripheral side and the inner peripheral side of the magnet 120.

Hereinafter, each component constituting the fixing resin composition of the rotor 100 of the present invention will be described.

The fixing resin composition can be used to form a rotor and to form a vehicle including a rotor. That is, the fixing resin composition is used to fix a magnet disposed in a hole portion formed in a rotor core including an electromagnetic steel sheet.

(fixing resin composition)

The solid-state fixing resin composition of the present invention comprises a thermosetting resin (A) containing an epoxy resin, a curing agent (B), and an inorganic filler (C). The fixing resin composition is distinguished from other fixing resin compositions by the fact that the ICI viscosity at 150 ° C of the epoxy resin is 3 poise or less. In addition, the fixing resin composition was injected into a flow path having a cross-sectional shape having a width of 3 mm and a thickness of 80 μm under the conditions of a mold temperature of 175 ° C, a molding pressure of 6.9 MPa, and an injection time of 20 seconds. The slit flow length is 75 mm or more. Further, the slit flow length at this time is preferably 75 mm or more and 300 mm or less, more preferably 80 mm or more and 300 mm or less.

[thermosetting resin (A)]

First, the thermosetting resin (A) will be described.

The thermosetting resin (A) is not particularly limited, and an epoxy resin (A1), an oxetane resin, a (meth) acrylate resin, an unsaturated polyester resin, or a diene phthalate may be used. An ester resin, a maleimide resin, or the like. Among them, curability and preservability, and hardened materials can be preferably used. Epoxy resin (A1) excellent in heat resistance, moisture resistance and chemical resistance.

The thermosetting resin (A) of the present invention contains an epoxy resin (A1). The epoxy resin (A1) may be one having two or more epoxy groups in one molecule.

The molecular weight or structure of the epoxy resin is not particularly limited, and it is preferred to lower the viscosity of the fixing resin composition. The upper limit of the ICI viscosity at 150 ° C of the epoxy resin (A1) is 3 poise or less, preferably 1.5 poise or less. The lower limit is not particularly limited, but is preferably 0 poise or more, and more preferably 0.01 poise or more. Thereby, the filling property of the fixing resin composition can be improved, and even when the gap between the hole portion and the magnet is narrow, the contact area between the steel sheet and the magnet can be ensured to be sufficient, so that high mechanical strength can be imparted.

Further, examples of the epoxy resin (A1) include a biphenyl type epoxy resin, a phenol aralkyl type epoxy resin having a biphenyl skeleton, and a phenol aralkyl type epoxy resin having a pendant phenyl skeleton. A phenol aralkyl type epoxy resin having a phenylene aralkyl type epoxy resin having a phenylene skeleton, a phenol aralkyl type epoxy resin having a methoxynaphthalene skeleton, a phenol novolac epoxy resin, and an adjacent Phenolic novolac type epoxy resin, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, tetramethyl bisphenol type epoxy resin and other bisphenol type epoxy resin, Bisnaphthol type epoxy resin, dicyclopentadiene type epoxy resin, dihydrothylene glycol type epoxy resin, and triphenylmethane type epoxy resin.

Among them, the epoxy resin (A1) is preferably a phenol aralkyl type epoxy resin having a pendant phenyl skeleton, in addition to a crystalline epoxy resin such as a biphenyl type epoxy resin or a bisphenol type epoxy resin. A phenol aralkyl type epoxy resin having a biphenyl skeleton and a triphenylmethane type epoxy resin. The order It can be used alone or in combination of two or more.

The content of the thermosetting resin (A) of the present invention is not particularly limited, and is preferably 5% by mass or more and 40% by mass or less, and more preferably 7% by mass or more, based on 100% by mass of the total of the fixing resin composition. 20% by mass or less.

In a preferred embodiment of the epoxy resin (A1) of the present invention, the lower limit of the content of the epoxy resin is not particularly limited, and is preferably 70% by mass based on 100% by mass of the thermosetting resin (A). The above is 100% by mass or less, and more preferably 80% by mass or more and 100% by mass or less.

[hardener (B)]

Next, the hardener (B) will be described. The hardener (B) is used to produce a three-dimensional crosslinker of the epoxy resin (A1) contained in the thermosetting resin (A). The curing agent (B) is not particularly limited, and it is preferred to lower the viscosity of the fixing resin composition. The upper limit of the ICI viscosity of the curing agent (B) at 150 ° C is preferably 2 poise or less, more preferably 1.8 poise or less, still more preferably 1.7 poise or less. The lower limit is not particularly limited, but is preferably 0 poise or more, and more preferably 0.01 poise or more.

Further, the hardener (B) may be, for example, a novolac type phenol resin, a phenol aralkyl resin having a pendant phenyl skeleton, a phenol aralkyl resin having a pendant phenyl skeleton, and a naphthol having a pendant phenyl skeleton. A phenol resin such as a aralkyl resin, a phenol resin mainly composed of a reaction product of hydroxybenzaldehyde, formaldehyde, and phenol, and a copolymer of a triphenylmethane type phenol compound and a novolak type phenol compound. These may be used alone or in combination of two or more. By using the phenol resin-based hardener as described above, it is possible to impart flame resistance, moisture resistance, and electrical properties. The balance of sex, hardenability, storage stability, etc. is good. In particular, in terms of hardenability, for example, the hydroxyl group equivalent of the phenol resin-based curing agent can be 90 g/eq or more and 250 g/eq or less.

Further, examples of the curing agent that can be used in combination include a polyaddition hardening agent, a catalyst type curing agent, and a condensation type curing agent.

Examples of the polyaddition hardening agent include aliphatic polyamines such as diethylenetriamine (DETA), triethylenetetramine (TETA), and m-xylenediamine (MXDA), and diaminodiphenylmethane (diaminodiphenylmethane). DDM), an aromatic polyamine such as m-phenylenediamine (MPDA) or diaminodiphenyl hydrazine (DDS), a polyamine compound such as dicyandiamide (DICY) or an organic acid dioxane; Alicyclic anhydrides such as phthalic anhydride (HHPA), methyltetrahydrophthalic anhydride (MTHPA), trimellitic anhydride (TMA), pyromellitic dianhydride (PMDA), benzophenone IV An acid anhydride such as an aromatic acid anhydride such as carboxylic acid dianhydride (BTDA); a polyphenol compound such as a novolak type phenol resin or a phenol polymer; a polythiol compound such as a polysulfide, a thioester or a thioether; an isocyanate prepolymer and a seal An isocyanate compound such as a terminal isocyanate; an organic acid such as a carboxylic acid-containing polyester resin.

Examples of the catalyst-type hardener include a tertiary amine compound such as benzyldimethylamine (BDMA) or 2,4,6-tris-dimethylaminomethylphenol (DMP-30); An imidazole compound such as imidazole or 2-ethyl-4-methylimidazole (EMI24); a Lewis acid such as BF ₃ complex or the like.

Examples of the condensing-type hardening agent include a phenol resin having a methylol group such as a resol resin, a urea resin such as a hydroxymethyl group-containing urea resin, and a melamine resin such as a hydroxymethyl group-containing melamine resin.

When the other curing agent is used in combination, the lower limit of the content of the phenol resin-based curing agent is preferably 20% by mass or more, more preferably 30% by mass or more, and particularly preferably 50% based on the total amount of the curing agent (B). More than % by mass. If the blending ratio is within the above range, the flame resistance can be maintained and good fluidity can be exhibited. In addition, the upper limit of the content of the phenol resin-based curing agent is not particularly limited, and is preferably 100% by mass or less based on the total amount of the curing agent (B).

The total value of the content of the curing agent (B) is not particularly limited, and the lower limit of the fixing resin composition of the present invention is preferably 3% by mass or more based on 100% by mass of the total of the fixing resin composition. More preferably, it is 3.5% by mass or more. When the lower limit of the blending ratio is within the above range, good curability can be obtained. In addition, the total value of the content of the curing agent (B) is not particularly limited as long as the upper limit of the fixing resin composition of the present invention, and is preferably 35% by mass based on the total value of all the fixing resin compositions. The mass% or less is more preferably 15% by mass or less.

Further, the phenol resin and the epoxy resin as the curing agent (B) are preferably such that the number of epoxy groups (EP) in the entire thermosetting resin (A) and the number of phenolic hydroxyl groups in the entire phenol resin (OH) The equivalence ratio (EP) / (OH) is adjusted to be 0.8 or more and 1.3 or less. When the equivalent ratio is in the above range, sufficient curing properties can be obtained when the obtained fixing resin composition is molded.

[Inorganic Filling Material (C)]

As the inorganic filler (C) used in the fixing resin composition of the present invention, an inorganic filler which is generally used in the technical field of the fixing resin composition can be used. For example, melting cracked vermiculite and melting Melted vermiculite such as globular vermiculite, crystalline vermiculite, alumina, kaolin, talc, clay, mica, rock wool, ash stone, glass powder, glass flakes, glass beads, glass fiber, tantalum carbide, tantalum nitride , aluminum nitride, carbon black, graphite, titanium dioxide, calcium carbonate, calcium sulfate, barium carbonate, magnesium carbonate, magnesium sulfate, barium sulfate, cellulose, aromatic guanamine, wood, forming a phenol resin molding material or epoxy resin The pulverized powder obtained by pulverizing the cured product of the material or the like. Among them, a vermiculite such as a molten fragmented vermiculite, a molten spherical vermiculite, or a crystalline vermiculite is preferable, and a molten spherical vermiculite is more preferably used. Also, among them, calcium carbonate is preferred in terms of cost. One type of the inorganic filler (C) may be used, or two or more types may be used in combination.

The average particle diameter D _{50 of the} inorganic filler (C) is preferably 0.01 μm or more and 75 μm or less, more preferably 0.05 μm or more and 50 μm or less. When the average particle diameter of the inorganic filler (C) is within the above range, the filling property of the fixing resin composition of the present invention with respect to the partition portion (filling portion) between the hole portion and the magnet can be improved. In addition, by setting the upper limit of the average particle diameter of the inorganic filler (C) to 75 μm or less, the filling property can be further improved.

The average particle diameter D ₅₀ is a volume-converted average particle diameter measured by a RODOS SR-type laser diffraction type measuring device (SYMPATEC HEROS & RODOS).

Further, in the fixing resin composition of the present invention, the inorganic filler (C) may contain two or more kinds of globular vermiculite having different average particle diameters D ₅₀ . Thereby, it is possible to simultaneously improve fluidity and filling properties and suppress burrs.

The content of the inorganic filler (C) is preferably 50% by mass or more, and more preferably 60%, based on 100% by mass of the total of the fixing resin composition. The mass% or more is more preferably 65% by mass or more, and particularly preferably 75% by mass or more. When the lower limit is within the above range, the increase in the moisture absorption amount or the decrease in the strength due to the curing of the obtained fixing resin composition can be reduced. In addition, the amount of the inorganic filler (C) is preferably 93% by mass or less, more preferably 91% by mass or less, and still more preferably 90% by mass or less based on 100% by mass of the total of the fixing resin composition. When the upper limit is within the above range, the obtained fixing resin composition has good fluidity and good formability. Therefore, the manufacturing stability of the rotor is improved, and a rotor excellent in balance between the yield and the durability can be obtained.

In addition, as a result of the investigation by the inventors of the present invention, it has been found that by setting the content of the inorganic filler (C) to 50% by mass or more, the difference in linear expansion coefficient between the fixing member and the electromagnetic steel sheet can be reduced, and the electromagnetic steel sheet can be suppressed. The deformation of the temperature changes to cause the rotation characteristics of the rotor to decrease. Thereby, it is possible to realize a rotor excellent in durability, particularly in the durability of the rotation characteristics.

In addition, in the case of using a vermiculite such as molten crushed vermiculite, molten globular vermiculite or crystalline vermiculite as the inorganic filler (C), the content of the vermiculite is 100 masses with respect to the total value of the fixing resin composition. % is preferably 40% by mass or more, and more preferably 60% by mass or more. When the lower limit is within the above range, the balance between fluidity and thermal expansion coefficient is good.

In addition, when the inorganic filler (C) is used in combination with a metal hydroxide such as aluminum hydroxide or magnesium hydroxide described later, or an inorganic flame retardant such as zinc borate, zinc molybdate or antimony trioxide, It is preferable that the total amount of the inorganic flame retardant and the inorganic filler is in the inorganic filler Within the range of the content of (C).

In the embodiment of the present invention, the total amount of the inorganic fillers and the inorganic flame retardant such as aluminum hydroxide is 80% by mass or more based on 100% by mass of the total of the fixing resin compositions. However, in the present invention, in order to appropriately adjust the fluidity and the coefficient of linear expansion according to the member used for the rotor, it is also possible to reduce the content of the inorganic filler and increase the content of the resin material.

[Other ingredients]

The fixing resin composition of the present invention may further contain a curing accelerator (D). The curing accelerator (D) may be any one that promotes the reaction of the epoxy group of the epoxy resin with the hydroxyl group of the phenol resin-based curing agent (B), and a curing accelerator (D) which is usually used may be used.

Specific examples of the curing accelerator (D) include an organic phosphine, a tetra-substituted fluorene compound, a phosphobetaine compound, an addition product of a phosphine compound and a hydrazine compound, and an addition of a hydrazine compound and a decane compound. a compound containing a phosphorus atom; a ruthenium compound such as 1,8-diazabicyclo(5,4,0)undecene-7, imidazole or the like, a tertiary amine such as benzyldimethylamine or the like A compound containing a nitrogen atom represented by an amidinium salt, an ammonium salt or the like. In the above, from the viewpoint of curability, a compound containing a phosphorus atom is preferred, and a tetrasubstituted fluorene compound, a phosphoric acid betaine compound, or a phosphine compound is more preferable from the viewpoint of balance between fluidity and hardenability. A latent hardening accelerator such as an adduct of a ruthenium compound, an adduct of a ruthenium compound and a decane compound. If considering the fluidity, it is especially a tetra-substituted ruthenium compound. From the viewpoint of weldability, a phosphate ester betaine compound, an addition product of a phosphine compound and a ruthenium compound, and an adduct of a ruthenium compound and a decane compound are particularly preferable in view of latent hardenability. Further, from the viewpoint of continuous moldability, a tetra-substituted fluorene compound is preferred. Further, in view of cost, an organic phosphine or a compound containing a nitrogen atom can also be preferably used.

Examples of the organophosphine which can be used in the resin composition for fixing of the present invention include a primary phosphine such as ethylphosphine or phenylphosphine; a secondary phosphine such as dimethylphosphine or diphenylphosphine; and trimethylphosphine. A tertiary phosphine such as triethylphosphine, tributylphosphine or triphenylphosphine.

The tetrasubstituted fluorene compound which can be used in the resin composition for fixing of the present invention is, for example, a compound represented by the following formula (1).

In the formula (1), P represents a phosphorus atom, and R1, R2, R3 and R4 each independently represent an aromatic group or an alkyl group, and A represents at least one member selected from the group consisting of a hydroxyl group, a carboxyl group and a thiol group in the aromatic ring. An anion of an aromatic organic acid of any of the functional groups, AH represents an aromatic organic acid having at least one functional group selected from the group consisting of a hydroxyl group, a carboxyl group and a thiol group on the aromatic ring, and x and y are 1~ An integer of 3, z is an integer from 0 to 3, and x = y.

The compound represented by the formula (1) can be obtained, for example, by the following means, but is not limited thereto. First, a tetrasubstituted phosphonium halide, an aromatic organic acid, and a base are uniformly mixed in an organic solvent to prepare the solution system. An aromatic organic acid anion is produced internally. Then, the compound represented by the formula (1) can be precipitated by adding water. In view of the fact that the compound represented by the formula (1) is excellent in the balance between the yield at the time of synthesis and the curing acceleration effect, R1, R2, R3 and R4 bonded to the phosphorus atom are preferably a phenyl group, and AH is a compound having a hydroxyl group on an aromatic ring, that is, a phenol compound, and A is an anion of the phenol compound. Furthermore, the concept of phenolic compounds includes monocyclic phenol, cresol, catechol, resorcinol or condensed polycyclic naphthol, dihydroxynaphthalene, and multiple aromatic rings (multicyclic Bisphenol A, bisphenol F, bisphenol S, biphenol, phenylphenol, phenol novolac, and the like. Among them, a phenol compound having two hydroxyl groups is preferably used.

The phosphate betained compound which can be used in the resin composition for fixing of the present invention is, for example, a compound represented by the following formula (2).

In the formula (2), X1 represents an alkyl group having 1 to 3 carbon atoms, Y1 represents a hydroxyl group, a is an integer of 0 to 5, and b is an integer of 0 to 4.

The compound represented by the formula (2) can be obtained, for example, by the following method. First, a triarylphosphine triaryl substituted phosphine is contacted with a diazonium salt, and a hydroxy group is substituted by a triaromatic substituted phosphine with a diazonium group of a diazonium salt to obtain a formula (2). ) the compound represented. However, it is not limited to this.

The adduct of the phosphine compound and the hydrazine compound which can be used for the fixing resin composition of the present invention is, for example, a compound represented by the following formula (3).

In the formula (3), P represents a phosphorus atom, and R5, R6 and R7 independently of each other represent an alkyl group having 1 to 12 carbon atoms or an aryl group having 6 to 12 carbon atoms, and R8, R9 and R10 independently represent a hydrogen atom. Or a hydrocarbon group having 1 to 12 carbon atoms, and R8 and R9 may be bonded to each other to form a ring.

As the phosphine compound used in the adduct of the phosphine compound and the hydrazine compound, for example, triphenylphosphine, tris(alkylphenyl)phosphine, tris(alkoxyphenyl)phosphine, trinaphthylphosphine, The aromatic ring such as tris(benzyl)phosphine is not hydroxy-substituted or a substituent such as an alkyl group or an alkoxy group is present, and examples of the substituent such as an alkyl group or an alkoxy group include those having a carbon number of 1 to 6. From the viewpoint of availability, triphenylphosphine is preferred.

Further, examples of the ruthenium compound used in the adduct of the phosphine compound and the ruthenium compound include o-benzoquinone, p-benzoquinone, and anthracene. Among them, p-benzoquinone is preferred in terms of storage stability.

As a method for producing an adduct of a phosphine compound and a hydrazine compound, an adduct can be obtained by contacting and mixing the organic trisphosphine and a benzoquinone in a solvent which can be dissolved. As a solvent, it is preferred to dissolve the adduct A ketone such as acetone or methyl ethyl ketone with low solubility. However, it is not limited to this.

In the compound represented by the formula (3), in terms of lowering the thermal modulus of elasticity of the cured product of the fixing resin composition, R5, R6 and R7 which are preferably bonded to the phosphorus atom are phenyl groups, and A compound in which R8, R9 and R10 are a hydrogen atom, that is, a compound obtained by adding 1,4-benzoquinone and triphenylphosphine.

The adduct of the oxime compound and the decane compound which can be used for the fixing resin composition of the present invention is, for example, a compound represented by the following formula (4).

In the formula (4), P represents a phosphorus atom, and Si represents a germanium atom. R11, R12, R13 and R14 each independently represent an organic group having an aromatic ring or a heterocyclic ring or an aliphatic group, and X2 is an organic group bonded to the groups Y2 and Y3. X3 is an organic group bonded to the groups Y4 and Y5. Y2 and Y3 represent a group in which protons are released by protons, and groups Y2 and Y3 in the same molecule are bonded to a ruthenium atom to form a chelate structure. Y4 and Y5 represent a group in which a proton group is released, and a group Y4 and Y5 in the same molecule are bonded to a ruthenium atom to form a chelate structure. X2 and X3 may be the same or different from each other, and Y2, Y3, Y4, and Y5 may be the same or different from each other. Z1 is an organic group having an aromatic ring or a heterocyclic ring, or an aliphatic group.

In the formula (4), R11, R12, R13 and R14 are, for example, benzene. Base, methylphenyl, methoxyphenyl, hydroxyphenyl, naphthyl, hydroxynaphthyl, benzyl, methyl, ethyl, n-butyl, n-octyl and cyclohexyl, among others, More preferably, it is a substituted aromatic group or an unsubstituted aromatic group such as a phenyl group, a methylphenyl group, a methoxyphenyl group, a hydroxyphenyl group or a hydroxynaphthyl group.

Further, in the formula (4), X2 is an organic group bonded to Y2 and Y3. Similarly, X3 is an organic group bonded to the groups Y4 and Y5. Y2 and Y3 are groups formed by proton-releasing protons, and the groups Y2 and Y3 in the same molecule are bonded to the ruthenium atom to form a chelate structure. Similarly, Y4 and Y5 are groups in which a proton is released to protons, and groups Y4 and Y5 in the same molecule are bonded to a ruthenium atom to form a chelate structure. The groups X2 and X3 may be the same or different from each other, and the groups Y2, Y3, Y4, and Y5 may be the same or different from each other. The group represented by -Y2-X2-Y3- and -Y4-X3-Y5- in the above formula (4) contains a group in which a proton donor releases two protons. The proton donor is preferably an organic acid having at least two carboxyl groups or hydroxyl groups in the molecule, more preferably an aromatic compound having at least two carboxyl groups or hydroxyl groups on the carbon constituting the aromatic ring, and more preferably forming an aromatic ring. An aromatic compound having at least two hydroxyl groups on the adjacent carbon. For example, catechol, pyrogallol, 1,2-dihydroxynaphthalene, 2,3-dihydroxynaphthalene, 2,2'-biphenol, 1,1'-bi-2-naphthol , salicylic acid, 1-hydroxy-2-naphthoic acid, 3-hydroxy-2-naphthoic acid, chlorodecanoic acid, tannic acid, 2-hydroxybenzyl alcohol, 1,2-cyclohexanediol, 1,2 - Propylene glycol and glycerin, etc. Among these, catechol, 1,2-dihydroxynaphthalene, and 2,3-dihydroxynaphthalene are more preferable from the viewpoint of obtaining a balance between the ease of the raw material and the hardening promoting effect.

Further, Z1 in the formula (4) means having an aromatic ring or a heterocyclic ring Examples of the organic group or the aliphatic group include an aliphatic hydrocarbon group such as a methyl group, an ethyl group, a propyl group, a butyl group, a hexyl group or an octyl group, or an aromatic group such as a phenyl group, a benzyl group, a naphthyl group or a biphenyl group. a reactive substituent such as a hydrocarbon group, a glycidoxypropyl group, a mercaptopropyl group, an aminopropyl group or a vinyl group, etc., among which, in terms of thermal stability, a methyl group, an ethyl group, and more preferably Phenyl, naphthyl and biphenyl.

The method for producing an adduct of a ruthenium compound and a decane compound is as follows. In a flask containing methanol, a proton donor such as phenyltrimethoxydecane or a proton donor such as 2,3-dihydroxynaphthalene is added and dissolved, and then dissolved in a chamber. A sodium methoxide-methanol solution was added dropwise with stirring. Further, a solution prepared by dissolving a tetrasubstituted phosphonium halide such as tetraphenylphosphonium bromide in methanol, which was prepared in advance, was added dropwise thereto under stirring at room temperature, at which time crystals were precipitated. The precipitated crystals were filtered, washed with water, and vacuum dried to obtain an adduct of a hydrazine compound and a decane compound. However, it is not limited to this.

The lower limit of the content of the curing accelerator (D) which can be used in the fixing resin composition of the present invention is preferably 0.1% by mass or more based on 100% by mass of the total of all the fixing resin compositions. When the lower limit of the content of the hardening accelerator (D) is within the above range, sufficient curability can be obtained. In addition, the upper limit of the content of the curing accelerator (D) is preferably 3% or less, and more preferably 1% by mass or less based on 100% by mass of the total of all the fixing resin compositions. When the upper limit of the content of the hardening accelerator (D) is within the above range, sufficient fluidity can be obtained.

Further, the fixing resin composition of the present invention may further contain a compound (E) in which a hydroxyl group is bonded to two or more adjacent carbon atoms constituting the aromatic ring (hereinafter, simply referred to as "compound (E)" ). By making The compound (E) having a hydroxyl group bonded to two or more adjacent carbon atoms constituting the aromatic ring, even if a curing accelerator containing no latent phosphorus atom is used as the promoting epoxy resin (A1) In the case of the curing accelerator (D) of the crosslinking reaction of the phenol resin-based curing agent (B), the reaction resin composition can be prevented from reacting during the melt-kneading, and the fixing resin composition can be stably obtained. Further, the compound (E) also has an effect of lowering the melt viscosity of the fixing resin composition and improving fluidity. The compound (E) may be a monocyclic compound represented by the following formula (5) or a polycyclic compound represented by the following formula (6), and the compounds may have a substituent other than a hydroxyl group. .

In the formula (5), any of R15 and R19 is a hydroxyl group, and when one of them is a hydroxyl group, the other is a substituent other than a hydrogen atom, a hydroxyl group or a hydroxyl group, and R16, R17 and R18 are a hydrogen atom and a hydroxyl group. Or a substituent other than a hydroxyl group.

In the formula (6), any one of R20 and R26 is a hydroxyl group, and when one of them is a hydroxyl group, the other is a substituent other than a hydrogen atom, a hydroxyl group or a hydroxyl group, and R21, R22, R23, R24 and R25 are a substituent other than a hydrogen atom, a hydroxyl group or a hydroxyl group.

Specific examples of the monocyclic compound represented by the formula (5) include catechol, pyrogallol, gallic acid, gallic acid ester, and the like. Further, specific examples of the polycyclic compound represented by the formula (6) include 1,2-dihydroxynaphthalene, 2,3-dihydroxynaphthalene, and the like. Among these, in terms of the ease of control of fluidity and hardenability, a compound in which a hydroxyl group is bonded to each of two adjacent carbon atoms constituting the aromatic ring is preferable. Further, in consideration of the volatilization in the kneading step, it is more preferable that the mother nucleus is a compound having a low volatility and a high stability of the naphthalene ring. In this case, specifically, the compound (E) can be, for example, a compound having a naphthalene ring such as 1,2-dihydroxynaphthalene or 2,3-dihydroxynaphthalene or a derivative thereof. These compounds (E) may be used alone or in combination of two or more.

The lower limit of the content of the compound (E) is preferably 0.01% by mass or more, more preferably 0.03% by mass or more, and particularly preferably 0.05% by mass or more based on 100% by mass of the total of all the fixing resin compositions. When the lower limit of the content of the compound (E) is within the above range, the resin group for fixation can be obtained. The viscosity of the product is sufficiently reduced and the effect of improving the fluidity. In addition, the upper limit of the content of the compound (E) is preferably 2% by mass or less, more preferably 0.8% by mass or less, and particularly preferably 0.5% by mass or less based on 100% by mass of the total of all the fixing resin compositions. When the upper limit of the content of the compound (E) is within the above range, the curing property of the fixing resin composition is lowered, and the physical properties of the cured product are less likely to decrease.

In the fixing resin composition of the present invention, a coupling agent (F) such as a decane coupling agent may be added to improve the adhesion between the epoxy resin (A1) and the inorganic filler (C). The coupling agent (F) may be a reaction between the epoxy resin (A1) and the inorganic filler (C) to improve the interface strength between the epoxy resin (A1) and the inorganic filler (C). The epoxy decane, amino decane, ureido decane, decyl decane, and the like are exemplified. Further, by using the coupling agent (F) in combination with the above-mentioned compound (E), the effect of the compound (E), that is, the effect of lowering the melt viscosity of the fixing resin composition and improving the fluidity can be improved.

Examples of the epoxy decane include γ-glycidoxypropyl triethoxy decane, γ-glycidoxypropyl trimethoxy decane, and γ-glycidoxy propyl methyl dimethyl oxide. Basear, β-(3,4-epoxycyclohexyl)ethyltrimethoxydecane, and the like. Further, examples of the aminodecane include γ-aminopropyltriethoxydecane, γ-aminopropyltrimethoxydecane, and N-β(aminoethyl)γ-aminopropyltrimethyl. Oxydecane, N-β(aminoethyl)γ-aminopropylmethyldimethoxydecane, N-phenyl-γ-aminopropyltriethoxydecane, N-phenyl-γ -Aminopropyltrimethoxydecane, N-β(aminoethyl)γ-aminopropyltriethoxydecane, N-6-(aminohexyl)3-aminopropyltrimethoxy Pyridinium, N-(3-(trimethoxydecylpropyl)-1,3-xylylenediamine, etc. Further, as the ureido decane, for example, γ-ureidopropyltriethoxydecane may be mentioned. And hexamethyldiazepine or the like. It may also be used in the form of a latent amine decane coupling agent which is protected by reacting a primary amine moiety of an amino decane with a ketone or an aldehyde. Further, the amino decane may have two Further, examples of the mercaptodecane include γ-mercaptopropyltrimethoxydecane and 3-mercaptopropylmethyldimethoxydecane, and examples thereof include bis(3-triethoxydecylalkyl). a decane coupling agent which exhibits the same function as a mercaptodecane coupling agent by thermal decomposition, such as a tetrasulfide or a bis(3-triethoxydecylpropyl) disulfide, etc. The decane coupling agent may be subjected to a hydrolysis reaction in advance. The decane coupling agents may be used alone or in combination of two or more.

From the viewpoint of continuous moldability, decyl decane is preferred, and from the viewpoint of fluidity, amino decane is preferred, and from the viewpoint of adhesion, epoxy decane is preferred.

The lower limit of the content of the coupling agent (F) such as a decane coupling agent which can be used in the resin composition for fixing of the present invention is preferably 0.01% by mass or more based on 100% by mass of the total of all the fixing resin compositions. More preferably, it is 0.05% by mass or more, and particularly preferably 0.1% by mass or more. When the lower limit of the content of the coupling agent (F) such as a decane coupling agent is within the above range, the interface strength between the epoxy resin (A1) and the inorganic filler (C) is not lowered, and good vibration resistance can be obtained. In addition, the upper limit of the content of the coupling agent (F) such as a decane coupling agent is preferably 1% by mass or less, and more preferably 0.8% by mass or less based on 100% by mass of the total of all the fixing resin compositions. It is particularly preferably 0.6% by mass or less. When the upper limit of the content of the coupling agent (F) such as a decane coupling agent is within the above range, the interface strength between the epoxy resin (A1) and the inorganic filler (C) is not lowered, and good vibration resistance can be obtained. In addition, when the content of the coupling agent (F) such as a decane coupling agent is within the above range, the water absorbing property of the cured product of the fixing resin composition does not increase, and good rust resistance can be obtained.

In the fixing resin composition of the present invention, an inorganic flame retardant (G) may be added to improve flame retardancy. Among them, the metal hydroxide or the composite metal hydroxide which hinders the combustion reaction due to dehydration and heat absorption at the time of combustion is preferable in terms of shortening the burning time. Examples of the metal hydroxide include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, and zirconium hydroxide. The composite metal hydroxide is a hydrotalcite compound containing two or more metal elements, at least one metal element is magnesium, and the other metal elements are selected from the group consisting of calcium, aluminum, tin, titanium, iron, cobalt, nickel, copper, or As the metal hydroxide in the zinc, a magnesium hydroxide-zinc solid solution can be easily obtained as a commercial metal hydroxide. Among them, from the viewpoint of continuous moldability, aluminum hydroxide or magnesium hydroxide-zinc solid solution is preferred. The inorganic flame retardant (G) may be used singly or in combination of two or more. In addition, for the purpose of reducing the influence on the continuous formability, it may be used after surface treatment with an antimony compound such as a decane coupling agent or an aliphatic compound such as a wax.

The content of the inorganic flame retardant (G) of the present invention is preferably 1% by mass or more and 20% by mass or less, more preferably 3% by mass or more, based on 100% by mass of the total of the fixing resin composition of the present invention. Below mass%.

The concentration of the ionic impurities in the fixing resin composition of the present invention The upper limit is preferably 500 ppm or less, more preferably 300 ppm or less, still more preferably 200 ppm or less, based on the fixing resin composition. The lower limit of the concentration of the ionic impurities is not particularly limited, and is, for example, 0 ppb or more, more preferably 10 ppb or more, and still more preferably 100 ppb or more with respect to the fixing resin composition of the present invention. Therefore, when the cured product of the fixing resin composition of the present invention is used in a fixing member, it is possible to maintain high rust resistance even when it is treated under high temperature and high humidity conditions.

The ionic impurities of the present invention are not particularly limited, and examples thereof include an alkali metal ion, an alkaline earth metal ion, and a halogen ion, and more specifically, a sodium ion or a chloride ion. The upper limit of the concentration of the sodium ion is preferably 100 ppm or less, more preferably 70 ppm or less, still more preferably 50 ppm or less, based on the fixing resin composition of the present invention. In addition, the upper limit of the concentration of the chloride ion is preferably 100 ppm or less, more preferably 50 ppm or less, and still more preferably 30 ppm or less, based on the fixing resin composition of the present invention. By setting it within the above range, it is possible to suppress corrosion of the electromagnetic steel sheet or the magnet.

In the present embodiment, for example, ionic impurities can be reduced by using an epoxy resin having a high purity. According to the above, a rotor excellent in durability can be obtained.

The concentration of the ionic impurities can be determined as follows. First, the fixing resin composition of the present invention is subjected to shape curing at 175 ° C for 180 seconds, and then pulverized by a pulverizer to obtain a powder of a cured product. The obtained cured product powder was treated in pure water at 120 ° C for 24 hours, and the ions were extracted into pure water, and then measured by ICP-MS (inductively coupled plasma ion source mass spectrometer).

In the resin composition for fixing of the present invention, the upper limit of the content of the alumina is preferably 10% by mass or less, more preferably 7% by mass or less, more preferably 7% by mass or less, more preferably the total value of the fixing resin composition. 5 mass% or less. The lower limit of the content of the alumina is not particularly limited. For example, the total value of the resin composition for fixing of the present invention is preferably 100% by mass or more, more preferably 0.01% by mass or more, and even more preferably 0.01% by mass or more. 0.1% by mass or more. By setting the content of the alumina to be equal to or less than the above upper limit value, the fluidity of the fixing resin composition of the present invention can be improved, and weight reduction can be achieved. Further, in the present embodiment, 0% by mass is allowed to include the value of the detection limit.

In addition to the above-mentioned components, the fixing resin composition of the present invention may be suitably formulated with a hydrotalcite or a hydrated oxide ion scavenger of an element selected from the group consisting of magnesium, aluminum, lanthanum, titanium, and zirconium; carbon black, Colorants such as iron oxide and titanium oxide; natural waxes such as carnauba wax; synthetic waxes such as polyethylene wax; high-grade fatty acids such as stearic acid or zinc stearate, metal salts or paraffin wax release agents; polybutadiene A low stress agent such as a polyoxonium compound such as a compound, an acrylonitrile-butadiene copolymer compound, a polyoxyxene oil or a polyoxyxene rubber.

The content of the coloring agent of the present invention is preferably 0.01% by mass or more and 1% by mass or less, more preferably 0.05% by mass or more and 0.8% by mass or less based on 100% by mass of the total of the fixing resin composition of the present invention. By setting the content of the coloring agent within the above range, it is not necessary to carry out the step of removing the colored impurities, and the workability is improved. Therefore, a rotor excellent in yield can be achieved.

The content of the release agent of the present invention is not particularly limited as long as the total value of the fixing resin composition of the present invention is 100% by mass, and the content of the releasing agent of the present invention is, for example, preferably 0.01% by mass. More than %, more The upper limit is preferably, for example, 1% by mass or less, more preferably 0.5% by mass or less, still more preferably 0.2% by mass or less, and particularly preferably 0.1% by mass or less. As is well known, when a semiconductor wafer is subjected to transfer molding, a certain amount of a release agent is added to ensure a release property of the fixing member from the mold. However, if the amount of the releasing agent added is too high, the adhesion between the fixing member and the electromagnetic steel sheet may be lowered. Therefore, in the present invention, the content of the releasing agent is preferably as small as possible, and particularly preferably 0.2% by mass or less. Thereby, the adhesion between the fixing member and the electromagnetic steel sheet can be improved, so that the rotor excellent in durability can be realized.

The content of the low stress agent of the present invention is preferably 0.01% by mass or more and 3% by mass or less, more preferably 0.05% by mass or more and 2% by mass or less based on 100% by mass of the total of the fixing resin composition of the present invention.

By setting the fixing resin composition of the present invention to the above-described configuration, the filling characteristics of the fixing resin composition can be improved. Further, even when the gap between the hole portion and the magnet is narrow, the contact area between the steel sheet and the magnet can be ensured to be sufficient. As a result, a high mechanical strength can be imparted to the rotor.

Further, even if the resin composition for fixing of the present invention is immersed in an automatic transmission fluid (ATF), the weight change rate and the volume change rate before and after the immersion can be suppressed to be small, so that it can be used for automotive applications. The rotor is extremely suitable for its characteristics. The molded article of the fixing resin composition of the present invention is immersed in ATF at 150 ° C for 1,000 hours, and the weight change ratio before and after ATF immersion is preferably 0.5% or less, more preferably 0.35% or less. The volume change rate before and after ATF impregnation is preferably 1.0%. Next, it is preferably 0.90%. The weight change rate and the volume change rate before and after the ATF immersion can be obtained, for example, by the following method. First, the fixing resin composition of the present invention was injection-molded at a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds to obtain a molded article having a length of 80 mm, a width of 10 mm, and a thickness of 4 mm (hardening). ()). The obtained molded article was subjected to heat treatment at 175 ° C for 4 hours as post-hardening, and the obtained product was used as a test piece, and the weight X1 and volume Y1 before the ATF immersion were measured. Then, the test piece was placed in a pressure-resistant container, and immersed at 150 ° C for 1,000 hours in a state filled with ATF. Then, the test piece was taken out from the pressure-resistant container, and the surface-attached ATF was wiped off, and the weight X2 after the ATF immersion was measured, and the volume Y2 was measured, and the weight change rate and the volume change rate before and after the ATF immersion were calculated according to the following formula.

Weight change rate before and after ATF impregnation [%]=(X2-X1)/X1×100

Volume change rate before and after ATF impregnation [%]=(Y2-Y1)/Y1×100

With respect to the fixing resin composition of the present invention, the fixing resin composition was injected into a section having a width of 3 mm and a thickness of 80 μm under the conditions of a mold temperature of 175 ° C, a molding pressure of 6.9 MPa, an injection time of 20 seconds, and a curing time of 90 seconds. The lower limit of the slit flow length in the flow path of the shape is preferably 75 mm or more, more preferably 80 mm or more, still more preferably 85 mm or more, and on the other hand, the upper limit is preferably 300 mm or less. By setting the slit length of 80 μm or more to the lower limit or more, the filling characteristics of the gap in the region having a narrow width can be improved. In addition, by setting the slit length of 80 μm or less to the upper limit or less, it is possible to suppress a large amount of burrs from adhering to the rotor, and the burrs are detached when the rotor is rotated to hinder the rotation of the rotor.

Further, in the present embodiment, for example, the slit flow length can be increased by making the particle diameter of the filler fine, reducing the softening point of the epoxy resin and/or the curing agent, and reducing the amount of the curing accelerator.

In the fixing resin composition of the present invention, the lower limit of the high-viscosity viscosity when the measurement is performed at a measurement temperature of 175 ° C and a load of 10 kg using a high-viscosity viscosity measuring device is not particularly limited, and is preferably 3 Pa ‧ s or more. The upper limit is not particularly limited, but is preferably 50 Pa‧s or less, more preferably 30 Pa‧s or less, and further preferably 15 Pa‧s or less. . When it is at least the above lower limit value, it is possible to suppress the occurrence of voids due to indentation or the like during molding. When it is at least the above upper limit value, good filling properties can be obtained. Thereby, a rotor excellent in manufacturing stability can be realized.

Further, in the present embodiment, for example, the high-viscosity viscosity can be lowered by reducing the softening point of the epoxy resin or the curing agent, using a latent hardening accelerator, and using a molten spherical vermiculite as a filler. .

The gel time of the fixing resin composition of the present invention at 175 ° C is preferably 10 seconds or more and 50 seconds or less, more preferably 15 seconds or more and 45 seconds or less. When it is more than the above lower limit value, the filling property can be improved. If it is less than or equal to the above upper limit, the molding cycle can be accelerated.

Further, in the present embodiment, for example, the gel time can be lowered by increasing the amount of the curing accelerator. Thereby, a rotor excellent in manufacturing stability can be realized.

The spiral flow of the fixing resin composition of the present invention is preferably 50 cm or more, more preferably 60 cm or more, still more preferably 80 cm or more. If it is at least the above lower limit value, the filling property can be improved, especially Fillability in the vertical direction. The upper limit of the spiral flow is not particularly limited, but is preferably 250 cm or less, and more preferably 220 cm or less. Thereby, a rotor excellent in manufacturing stability can be realized.

Further, in the present embodiment, for example, the spiral flow can be increased by using a molten spherical vermiculite as a filler, reducing the softening point of the epoxy resin or the curing agent, and reducing the amount of the curing accelerator.

When the curing resin composition of the present invention is subjected to measurement of the curing torque at a measurement temperature of 175 ° C using a vulcanizer, the curing torque value after 60 seconds from the start of the measurement is T ₆₀ , and the maximum hardening torque is 300 seconds after the start of the measurement. When the value is T _max , the ratio T ₆₀ /T _max (%) of the hardening torque value after 60 seconds from the start of the measurement to the maximum hardening torque value up to 300 seconds after the start of the measurement is preferably 40% or more, more preferably 45% or more, further preferably 50% or more. The upper limit of the hardening torque value is not particularly limited, but is preferably 100% or less, and more preferably 95% or less. If it is more than the above lower limit value, productivity is expected to be improved.

Further, in the present embodiment, for example, the ratio of the hardening torque value can be increased by increasing the amount of the curing accelerator. Thereby, a rotor excellent in manufacturing stability can be realized.

The fixing resin composition of the present invention is first produced in a dumbbell-shaped fixing resin composition obtained in accordance with JIS K7162 under a curing condition of a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds. . The cured product of the above-mentioned dumbbell-shaped fixing resin composition was further cured at 175 ° C for 4 hours to prepare a test piece. For the above test piece at a temperature of 25 ° C, a load speed of 1.0 mm / min The tensile test was carried out under the test to obtain the fracture energy. Further, in ISO 527-2, the shape similar to the dumbbell shape described in JIS K7162 is described.

Hereinafter, the fracture energy obtained by performing the tensile test under the conditions of a temperature of 25 ° C and a load speed of 1.0 mm/min is defined as the fracture energy a. Further, the fracture energy obtained by performing the tensile test under the conditions of a temperature of 150 ° C and a load speed of 1.0 mm/min was defined as the fracture energy b. In addition, the breaking strength under the measurement condition of the breaking energy a is the breaking strength a, and the breaking strength under the measurement condition of the breaking energy b is the breaking strength b.

The fracture energy is calculated by plotting the relationship between the stress and the forward strain at the time of the tensile test as a curve (stress-strain curve).

Specifically, the integral value of the stress from the start point of the tensile test to the breaking point calculated by using the strain as a variable. The larger the fracture energy, the higher the hardness and the adhesion strength of the obtained rotor core, and the more excellent the durability. Further, the unit of the fracture energy is ×10 ^-4 J/mm ³ .

The breaking energy a of the cured product (fixing member) of the fixing resin composition of the present invention is preferably 1.5 × 10 ^-4 J/mm ³ or more. By having the fracture energy a in this range, a rotor core excellent in durability and hardness and adhesion strength can be obtained.

Further, the breaking energy a is more preferably 1.9 × 10 ^-4 J/mm ³ or more. By setting the fracture energy a within this range, it is possible to realize a rotor core which exhibits sufficient durability even in an environment of high-speed rotation at a high temperature for a long period of time. In addition, the upper limit is not particularly limited, and it is sufficient as long as it is about 15.0 × 10 ^-4 J/mm ³ .

Further, the breaking energy b is preferably 1.2 × 10 ^-4 J/mm ³ or more. When the fracture energy b measured at a temperature higher than the fracture energy a is within the above range, a rotor excellent in durability and hardness and adhesion strength can be obtained. Further, the breaking energy b is more preferably 1.5 × 10 ^-4 J/mm ³ or more. When the fracture energy b is within this range, the durability at the time of high-speed rotation is further improved. Similarly to the fracture energy a, the upper limit of the fracture energy b is not particularly limited, and is sufficient as long as it is about 8.0 × 10 ^-4 J/mm ³ .

In order to increase the fracture energy a and b, the following methods are effective.

First, the strength and adhesion strength of the resin component can be improved by using the combination of the epoxy resin of the present invention and its hardener. In addition to this, it is more preferable to modify the surface of the inorganic filler by a decane coupling agent to improve the interface bonding strength between the resin and the inorganic filler. Further, it is more preferable to adjust the particle size distribution of the inorganic filler to form a structure in which microcracks generated inside the cured resin body are not easily developed.

The durability of the rotor of the present embodiment can be further improved by controlling the breaking strength a of the cured product (fixing member) of the fixing resin composition of the present invention to be within a range of 50 MPa or more. Specifically, by making the breaking strength a within this range, the durability at the time of high-speed rotation is further improved. Further, the breaking strength a is preferably 60 MPa or more. The upper limit is not particularly limited, and it is sufficient as long as it is about 200 MPa.

In the same manner as the breaking strength a, the breaking strength b of the cured product of the fixing resin composition of the present invention is controlled by the breaking strength b within a range of 15 MPa or more, and the durability at the time of high-speed rotation is further improved. Further, the breaking strength b is preferably 20 MPa or more. There is no special limit on the upper limit The system is sufficient as long as it is about 100 MPa.

By setting the breaking strengths a and b within the above specific range, it is possible to provide a rotor excellent in durability. In particular, it is possible to provide a rotor excellent in positional stability of a permanent magnet when the rotor is rotated at a high speed.

In the fixing resin composition of the present invention, the fixing resin composition was injection-molded at a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds to prepare a length of 80 mm and a width of 10 mm. A molded body of the above-mentioned fixing resin composition having a thickness of 4 mm. Further, the molded body was cured at 175 ° C for 4 hours to prepare a cured product. Then, the cured product was immersed in ATF at 150 ° C for 1,000 hours. The weight of the cured product before the ATF is immersed is X1, and when the weight of the cured product after the ATF is immersed is X2, the weight change rate [%] can be calculated by (X2-X1)/X1×100.

Here, the ATF is not particularly limited as long as it is a normal user, and various additives are added to the base oil. The base oil herein is typically a mineral oil based base oil, a synthetic oil based base oil, or a mixture of such. Examples of the additive component include a viscosity modifier, a friction modifier, and the like.

In the present embodiment, for the ATF for measuring the weight change rate, for example, Matic Fluid D (manufactured by Nissan Motor Co., Ltd.), Auto Fluid Type T-IV (manufactured by Toyota Motor Corporation), ATF DW-1 (manufactured by Honda Technik Co., Ltd.), or the like can be used. .

The fixing resin composition of the present invention preferably has a weight change ratio of 0.5% or less when the cured product (fixing member) is immersed in ATF at 150 ° C for 1,000 hours. More preferably, it is 0.2% or less. By impregnating ATF before When the weight change rate is less than or equal to the above upper limit value, even if the fixing member contacts the lubricating oil for a long period of time at a high temperature, the fixing member can be prevented from being largely swollen by the lubricating oil.

Moreover, it is preferable that the fixing resin composition of the present invention has a weight change ratio of -0.05% or more when the cured product is immersed in ATF at 150 ° C for 1,000 hours. More preferably -0.03% or more. When the weight change rate before and after the immersion of the ATF is equal to or higher than the above lower limit value, even if the fixing member contacts the lubricating oil for a long period of time at a high temperature, it is possible to suppress a part of the fixing member from flowing out into the lubricating oil. Further, by changing the weight change rate before and after the ATF immersion to the above lower limit value, it is possible to suppress a decrease in the characteristics of the lubricating oil.

Therefore, by setting the weight change rate before and after the ATF immersion within the above range, the size of the fixing member can be maintained constant even in an environment where the aluminum alloy is rotated at a high temperature for a long period of time. As a result, the position of the magnet can be maintained at a fixed position for a long period of time, so that a rotor excellent in long-term reliability can be obtained.

In addition, when the cured product of the fixing resin composition of the present invention is immersed in ATF at 150 ° C for 2,000 hours, the weight of the cured product after the ATF immersion is X3, by (X3-X1) / X1 × The weight change rate [%] calculated at 100 is preferably -0.1% or more and 0.6% or less. More preferably, it is -0.07% or more and 0.5% or less. By setting the weight change rate measured under the above conditions within the above range, it is possible to obtain a rotor excellent in long-term reliability even in an environment where high-speed rotation is performed at a high temperature for a long period of time.

Further, the cured product of the fixing resin composition of the present invention is immersed in ATF at 150 ° C for 1000 hours, and the above-mentioned hardening is performed before ATF immersion. When the volume of the object is Y1 and the volume of the cured product after the ATF is immersed is Y2, the volume change rate [%] calculated by (Y2-Y1)/Y1×100 is preferably -0.2% or more and 1.5% or less. . More preferably, it is -0.1% or more and 1% or less. By setting the volume change rate measured under the above conditions within the above range, it is possible to obtain a rotor excellent in long-term reliability even in an environment of high-speed rotation at a high temperature for a long period of time.

The fixing resin composition of the present invention can be uniformly mixed by using a mixer at room temperature, and then melt-kneaded by a kneading machine such as a heating roll, a kneader or an extruder, if necessary, and then cooled and pulverized as needed. Adjust to the required dispersion or fluidity, etc.

The method for producing the fixing resin composition of the present invention is not particularly limited, and it can be produced by the following method.

First, a thermosetting resin (A), a phenol resin-based curing agent (B), an inorganic filler (C), and preferably other additives are blended in a predetermined amount to obtain a fixing resin composition. Then, the blender is uniformly pulverized and mixed at a normal temperature using, for example, a mixer, a jet mill, or a ball mill, and then heated to a temperature of about 90 to 120 ° C using a kneading machine such as a heating roll, a kneader, or an extruder. Melt and knead. Then, the resin composition for fixing after kneading is cooled and pulverized to obtain a solid resin composition for fixing in the form of granules or powder. The particle size of the powder or granule of the fixing resin composition of the present invention is, for example, preferably 5 mm or less. When it is 5 mm or less, it is possible to suppress the occurrence of poor filling during the tableting and the unevenness in the quality of the tablet.

Then, the tablet is obtained by tableting the powder or granules of the obtained fixing resin composition. As a device for forming an ingot, a one-piece type or a plurality of rotary type ingot machines can be used. The shape of the tablet is not particularly limited, and is preferably a columnar shape. The temperature of the male mold, the female mold and the environment of the tableting machine is not particularly limited, and is preferably 35 ° C or less. When it is more than 35 ° C, the fixing resin composition reacts and the viscosity increases, and the fluidity is impaired. The tableting pressure is preferably in the range of 400 × 10 ⁴ Pa or more and 3000 × 10 ⁴ Pa or less. By setting the tableting pressure to be equal to or lower than the above upper limit value, it is possible to suppress the occurrence of cracking immediately after the tablet is pressed. On the other hand, by setting the tableting pressure to be equal to or higher than the above lower limit value, it is possible to suppress cracking of the tablet during conveyance due to insufficient cohesive force. The material and surface treatment of the mold of the male mold and the female mold of the tableting machine are not particularly limited, and a mold of a known material can be used. Examples of the surface treatment include, for example, electric discharge machining, coating release agent, and plating treatment. , grinding, etc.

Further, the glass transition temperature (Tg) of the fixing member of the present invention is preferably 130 ° C or higher, more preferably 140 ° C or higher. If it is more than the above lower limit value, reliability is expected to increase. The upper limit of the glass transition temperature (Tg) is not particularly limited, but is preferably 200 ° C or lower, more preferably 190 ° C or lower. Thereby, a rotor excellent in durability can be realized.

Further, in the present embodiment, for example, the glass transition temperature (Tg) can be increased by increasing the softening point of the epoxy resin or the curing agent.

The flexural strength of the fixing member of the present invention at 150 ° C is preferably 70 MPa or more, more preferably 100 MPa or more. When it is more than the above lower limit value, cracks and the like are less likely to occur, and reliability is expected to increase. The upper limit of the above bending strength is not particularly limited, but is preferably 300 MPa or less, more preferably 250. Below MPa. Thereby, a rotor excellent in durability can be realized.

Further, in the present embodiment, for example, the surface of the filler can be treated with a coupling agent to increase the bending strength.

The upper limit of the flexural modulus of the fixing member of the present invention at 150 ° C is preferably 1.6 × 10 ⁴ MPa or less, more preferably 1.3 × 10 ⁴ MPa or less. If it is less than or equal to the above upper limit value, it is expected that reliability is improved due to stress relaxation. The lower limit of the flexural modulus is not particularly limited, but is preferably 5,000 MPa or more, and more preferably 7,000 MPa or more. Thereby, a rotor excellent in durability can be realized.

Further, in the present embodiment, for example, the bending elastic modulus can be reduced by increasing the amount of the low stress agent added, reducing the amount of the filler to be added, and the like.

The linear expansion coefficient (α1) of the fixing member of the present invention in a region of 25 ° C or more and a glass transition temperature (Tg) or less is preferably 10 ppm / ° C or more, 25 ppm / ° C or less, more preferably 15 ppm / ° C or more, 20 ppm / Below °C. If it is in the above range, the difference in thermal expansion from the electromagnetic steel sheet is small and the magnet can be prevented from coming off. Thereby, a rotor excellent in durability can be realized.

Further, in the present embodiment, for example, the linear expansion coefficient (α1) can be reduced by increasing the amount of the filling material.

The linear expansion coefficient (α2) of the fixing member of the present invention in a region of 25 ° C or more and a glass transition temperature (Tg) or less is preferably 10 ppm / ° C or more, 100 ppm / ° C or less, more preferably 20 ppm / ° C or more, 80 ppm / Below °C. If it is in the above range, the difference in thermal expansion from the electromagnetic steel sheet is small and the magnet can be prevented from coming off. Thereby, a rotor excellent in durability can be realized.

Further, in the present embodiment, for example, the linear expansion coefficient (α2) can be reduced by increasing the amount of the filling material.

(Manufacturing method of the rotor)

The manufacturing method of the rotor 100 of the present embodiment includes the steps of preparing a rotor core 110 in which a plurality of holes arranged along a peripheral portion of a through hole through which a rotating shaft (shaft 170) is inserted is provided 150; inserting the magnet 120 into the hole portion 150; filling the fixing resin composition at a portion between the hole portion 150 and the magnet 120; curing the resin composition to obtain the fixing member 130; in the through hole of the rotor core 110 The shaft 170 is inserted and the shaft 170 is fixed to the rotor core.

The method of filling and fixing the resin composition in the present embodiment is preferably insert molding. The details will be described below.

First, the insert molding apparatus will be described.

Figure 2 is a cross-sectional view of the overmold 200 of the insert forming apparatus used for insert molding.

As an example of the method of forming the fixing member 130, a method of insert molding using a tablet-shaped fixing resin composition can be employed. An insert molding device is used in the insert molding. The molding apparatus includes an upper mold 200 including a tank 210 for supplying a fixing resin composition in the form of an ingot, and a flow path 220 for moving the fixing resin composition in a molten state; a lower mold; and a heating device. The upper mold and the lower mold are heated, and the extrusion mechanism is used to extrude the resin composition for fixing in a molten state. The insert molding apparatus may have, for example, a conveying function of conveying a rotor core or the like.

In this embodiment, the upper mold 200 and the lower mold are preferably connected to the rotor core 110. The upper surface and the lower surface (i.e., one surface of the electromagnetic steel sheet constituting the rotor core 110) are in close contact with each other, and are preferably plate-shaped, for example. In the present embodiment, the upper mold 200 and the lower mold do not cover the entirety of the rotor core 110, and do not cover one of the side portions, for example, which is different from the usual transfer forming mold used in the manufacturing method of the semiconductor device. . The mold for transfer molding is configured such that the entire semiconductor wafer is placed in a cavity formed by an upper mold and a lower mold.

In addition, the tank 210 may have two separate flow paths 220, and may also have a Y-shaped flow path 220. Thereby, the fixing resin composition of the present invention can be filled into the two holes from one can 210. In addition, one tank may have one flow path for filling the fixing resin composition into one hole portion, or may have three flow paths for filling the fixing resin composition into three or more holes. Wherein, the plurality of flow paths can be independent of each other or continuous.

Next, the insert molding of this embodiment will be described.

First, the rotor core is preheated in an oven or a hot plate, and then fixed to a lower mold of a forming device (not shown). Then, a magnet is inserted into the hole portion of the rotor core. Then, the lower mold is raised to press the upper mold 200 against the upper surface of the rotor core. Thereby, the upper mold 200 and the lower mold sandwich the upper surface and the lower surface of the rotor core 110. At this time, the front end portion of the flow path 220 in the upper mold 200 is disposed on the space between the hole portion and the magnet. In addition, the rotor core is heated by the heat conduction from the lower mold of the forming apparatus and the upper mold 200. The temperature of the lower mold and the upper mold 200 of the forming apparatus is adjusted, for example, to about 150 ° C to 200 ° C so that the rotor core can reach a temperature suitable for forming and hardening the fixing resin composition. In this state, the tablet-shaped fixing resin composition is supplied into the can 210 of the upper mold 200. Supplied into the can 210 of the upper mold 200 The ingot-shaped fixing resin composition is heated in the can 210 to be in a molten state.

Then, the fixing resin composition in a molten state is extruded from the can 210 by a plunger (extrusion mechanism). In this manner, the fixing resin composition moves in the flow path 220 and is filled in the space between the hole portion and the magnet. During this period, the rotor core is heated by heat conduction from the mold (the lower mold and the upper mold 200), whereby the filled fixing resin composition is cured to form a fixing member. At this time, the temperature condition can be, for example, 150 ° C to 200 ° C. Further, the hardening time can be, for example, 30 seconds to 180 seconds. Thereby, the magnet 120 inserted inside the hole portion 150 is fixed by the fixing member 130. Then, the upper mold 200 is separated from the upper surface of the rotor core. Then, the shaft 170 is inserted into the through hole of the rotor core 110, and the shaft 170 is fixed to the rotor core.

According to the above, the rotor of this embodiment is obtained.

Here, the insert molding method of the present embodiment does not require mold removal, and this point is different from the transfer molding method used for manufacturing a semiconductor device.

In the insert molding method, the resin is filled into the hole portion of the rotor core 110 through the flow path of the upper mold 200 in a state where the upper surface of the rotor core 110 is in close contact with the upper mold 200. Therefore, a large amount of resin is not filled between the upper surface of the rotor core 110 and the upper mold 200, and the upper mold 200 and the upper surface are easily attached and detached.

On the other hand, in the transfer molding method, since the resin is filled in the cavity between the semiconductor wafer and the mold, it is necessary to skillfully remove the mold from the molded article. Therefore, the resin that seals the semiconductor wafer will specifically require the mold and The release property of the molded article.

The rotor 100 of the present embodiment can be mounted on a vehicle such as an electric vehicle such as a hybrid vehicle, a fuel cell vehicle, or an electric vehicle, or a train or a ship.

[Examples]

Hereinafter, the present invention will be described in detail with reference to examples but the present invention is not limited to the description of the examples. Unless otherwise stated, the "parts" described below indicate "parts by mass" and "%" means "mass%".

The raw material components used in the respective examples and comparative examples are shown below.

(thermosetting resin (A))

Epoxy resin 1: biphenyl type epoxy resin (manufactured by Mitsubishi Chemical Corporation, YX4000K, ICI viscosity at 150 ° C: 0.11 poise)

Epoxy Resin 2: Tetramethylbisphenol F-type epoxy resin (manufactured by Nippon Steel Chemical Co., Ltd., YSLV-80XY, ICI viscosity at 150 °C: 0.03 poise)

Epoxy Resin 3: o-cresol novolac type epoxy resin (manufactured by DIC, EPICLON N-665, ICI viscosity at 150 ° C: 3.06 poise)

Epoxy Resin 4: Phenol aralkyl type epoxy resin having a phenyl stretch structure (manufactured by Nippon Kayaku Co., Ltd., NC-2000, ICI viscosity at 150 ° C: 1.20 poise)

Epoxy Resin 5: Phenol aralkyl type epoxy resin having a biphenyl skeleton (manufactured by Nippon Kayaku Co., Ltd., NC3000, ICI viscosity at 150 ° C: 0.85 poise)

Epoxy resin 6: Triphenylmethane type epoxy resin (manufactured by Nippon Kayaku Co., Ltd., E-1032H-60, ICI viscosity at 150 ° C: 1.30 poise)

Epoxy Resin 7: o-cresol novolac type epoxy resin (manufactured by DIC, EPICLON N-670, ICI viscosity at 150 ° C: 4.28 poise)

Further, the melt viscosity (ICI viscosity) at 150 ° C was measured using a cone-plate type viscometer CV-1S (manufactured by Toayama Kogyo Co., Ltd.).

(hardener (B))

Phenolic resin-based hardener 1: Novolak-type phenol resin (manufactured by Sumitomo Bakelite, PR-HF-3, ICI viscosity at 150 ° C: 1.08 poise)

Phenolic resin-based hardener 2: Phenol aralkyl resin having a phenyl stretch structure (manufactured by Minghe Chemical Co., Ltd., MEH-7800-4S, ICI viscosity at 150 ° C: 0.73 poise)

Phenolic resin-based hardener 3: phenol aralkyl resin having a biphenyl skeleton (manufactured by Megumi Kasei, MEH-7851SS, ICI viscosity at 150 ° C: 0.68 poise)

Phenolic resin-based hardener 4: a phenol resin mainly composed of a reaction product of 2-hydroxybenzaldehyde, formaldehyde and phenol (manufactured by Air Water, HE910-20, ICI viscosity at 150 ° C: 1.5 poise)

Phenolic resin-based hardener 5: Novolak-type phenol resin (manufactured by Sumitomo Bakelite, PR-51714, ICI viscosity at 150 ° C: 1.64 poise)

(Inorganic Filling Material (C))

Spherical vermiculite 1 (manufactured by the electrical and chemical industry, FB-950, average particle diameter D ₅₀ is 23 μm)

Spherical vermiculite 2 (manufactured by the electrical and chemical industry, FB-35, average particle diameter D ₅₀ is 10 μm)

Spherical vermiculite 3 (manufactured by Admatechs, SO-25R, average particle diameter D ₅₀ is 0.5 μm)

Alumina (manufactured by the electrical and chemical industry, DAW-45, average particle diameter D ₅₀ is 43 μm)

(hardening accelerator (D))

Hardening accelerator 1: triphenylphosphine

Hardening accelerator 2: a hardening accelerator represented by the following formula (7)

Hardening accelerator 3: a hardening accelerator represented by the following formula (8)

Hardening accelerator 4: a hardening accelerator represented by the following formula (9)

Hardening accelerator 5: a hardening accelerator represented by the following formula (10)

(coupler (F))

Coupler 1: Phenylaminopropyltrimethoxydecane (manufactured by Dow Corning Toray Co., Ltd., CF4083)

Coupler 2: γ-glycidoxypropyltrimethoxydecane (manufactured by Shin-Etsu Chemical Co., Ltd., KBM-403)

(Inorganic flame retardant (G))

Aluminum hydroxide (manufactured by Sumitomo Chemical, CL-303)

(other additives)

Ion trapping agent: hydrotalcite (manufactured by Kyowa Chemical Industry, trade name DHT-4H)

Colorant: carbon black (Mitsubishi Chemical, MA600)

Release agent: montanic acid ester wax (Hoechst Wax E, Hoechst)

Low stress agent 1: Polyoxyl resin (manufactured by Shin-Etsu Chemical Co., Ltd., KMP-594)

Low stress agent 2: Polyoxygenated oil (manufactured by Dow Corning Toray Co., Ltd., TZ-8120)

(Example)

In the examples and the comparative examples, those obtained by blending the respective components according to the amounts shown in Tables 1 and 2 were mixed at room temperature using a mixer to obtain a powdery intermediate. Filling the obtained powdered intermediate in automatic supply In the feeding device (hopper), the heating roller which is quantitatively supplied to 80 ° C to 100 ° C is melt-kneaded. Then, it is cooled and then pulverized to obtain a fixing resin composition. The tablet was obtained by ingot forming the obtained fixing resin composition by using a molding device.

On the other hand, using the insert molding apparatus including the upper mold 200 shown in Fig. 2, the rotor was fabricated in accordance with the following procedure. First, the rotor core is fixed to the lower mold of the forming apparatus, and then the neodymium magnet is inserted into the hole portion of the rotor core, and the lower mold is raised to press the upper mold 200 against the upper surface of the rotor core. Then, the tablet-shaped fixing resin composition is supplied to the can 210 of the upper mold 200. Then, the fixing resin composition in a molten state is extruded from the can 210 by a plunger, and the fixing resin composition is filled in a portion where the hole portion and the neodymium magnet are separated. Then, the filled fixing resin composition is heat-cured to form a fixing member, and a rotor is obtained. The molding conditions at this time were set to rotor core temperature: 160 ° C, and hardening time: 120 seconds.

The measurement and evaluation of the obtained resin composition and the rotor described below were carried out. The results are shown in Tables 1 and 2. The rotor of the embodiment is excellent in strength.

(evaluation project)

Spiral flow: a low-pressure transfer molding machine (manufactured by Kohtaki Precision Machine Co., Ltd., KTS-15) was used for insert molding, and the fixing resin was composed at 175 ° C, an injection pressure of 6.9 MPa, and a dwell time of 120 seconds. The material was injected into a mold for spiral flow measurement according to ANSI/ASTM D 3123-72, and the flow length was measured. The spiral flow is a parameter of fluidity, and the larger the value, the better the fluidity. Single spiral flow in Tables 1, 2 The bit is cm.

Gel time: The fixing resin composition was placed on a hot plate controlled at 175 ° C, and punched with a spatula at about 1 time/sec. The time until the fixing resin composition was dissolved by heat and hardened was measured as the gel time. The unit of gel time in Tables 1 and 2 is seconds.

The high-viscosity viscosity is determined by a high-viscosity viscosity measuring device (manufactured by Shimadzu Corporation, CFT-500D), which is formed into a tablet shape (diameter: 11 mm, height: about 15 mm). The measurement was carried out using a nozzle (die) having a diameter of 0.5 mm and a length of 1.0 mm under the conditions of a temperature of 175 ° C and a load of 10 kg. The unit of the elevated viscosity in Tables 1 and 2 is Pa‧s.

Vulcanization torque ratio: The curing torque value after 60 seconds from the start of the measurement of the curing torque of the fixing resin composition at a measurement temperature of 175 ° C using a vulcanizer (manufactured by Orientec Co., Ltd., IVPS type JSR vulcanizer) When T _{60 is} set, the maximum hardening torque value up to 300 seconds after the start of measurement is set to T _max . The ratio T ₆₀ /T _max (%) of the hardening torque value after 60 seconds from the start of the measurement to the maximum hardening torque value up to 300 seconds after the start of the measurement was determined as the vulcanization torque ratio. The torque of the vulcanizer is a parameter of thermal rigidity. Therefore, the greater the vulcanization torque ratio, the better the hardenability.

Slit flow length: in a mold in which a groove (slit) having a specific thickness opened at the front end is radially provided under the conditions of a mold temperature of 175 ° C, a molding pressure of 6.9 MPa, an injection time of 20 seconds, and a hardening time of 90 seconds. The fixing resin composition was subjected to injection molding, and the length of the resin flowing out into the slit having a width of 3 mm and a thickness of 80 μm was measured with a vernier caliper. unit Is mm.

Rotor formability: A metal piece (width 28 mm, thickness 3.8 mm, length 74 mm) which is regarded as a magnet is inserted into a mold which is regarded as an electromagnetic steel plate (the width of the hole portion is 30 mm, the thickness is 4 mm, and the depth is 75 mm). After being placed in a molding machine, the fixing resin composition was injection-molded at a temperature of 170 ° C, and the mold was taken out from the molding machine after a curing time of 120 seconds. The appearance of the molded article was visually observed to confirm whether or not there was an abnormality such as a void, and an abnormality such as no void was evaluated as ○, and an abnormality such as void was evaluated as ×.

Glass transfer temperature: A low-pressure transfer molding machine (manufactured by Kohtaki Precision Machine Co., Ltd., KTS-30) was used for insert molding, and the fixing resin was applied under the conditions of a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a hardening time of 2 minutes. The composition was subjected to injection molding to obtain a test piece of 4 mm × 4 mm × 15 mm. After the obtained test piece was hardened at 175 ° C for 4 hours, it was subjected to a thermomechanical analysis device (manufactured by Seiko Instruments Inc., TMA100) at a temperature increase rate in a temperature range of 0 ° C to 320 ° C. The measurement was performed at 5 ° C / min, and the linear expansion coefficient (α1) in the region below the glass transition temperature and the linear expansion coefficient (α2) in the rubber-like region were determined based on the graph obtained at this time. At this time, the intersection of the extension lines of α1 and α2 was taken as the glass transition temperature. In Tables 1 and 2, the unit of the glass transition temperature is °C, and the unit of the linear expansion coefficient (α1, α2) is ppm/°C.

Flame resistance: The low pressure transfer molding machine (manufactured by Kohtaki Precision Machine Co., Ltd., KTS-30) was used for insert molding. The fixing resin composition was injection molded under the conditions of a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, an injection time of 15 seconds, and a curing time of 120 seconds to prepare a flame resistant test piece of 127 mm × 12.7 mm × 3.2 mm thick. Using these test pieces, the fire resistance test was carried out in accordance with the standard of the UL94 vertical method to judge the flame resistance. The fire resistance rating and the like are shown. In the present invention, the flame retardancy is not a requirement, and therefore the flame retardancy may be appropriately adjusted.

The breaking energy a and b: a cured product (hereinafter referred to as a test piece) of a resin composition for fixing a rotor which is formed into a dumbbell shape according to JIS K7162, and is subjected to a condition of a load rate of 1.0 mm/min at 25 ° C or 150 ° C. Stretching test. In the tensile test, the Tensilon UCT-30T type manufactured by Orientec Co., Ltd. was used for the tensile tester, and the strain gauge was KFG-2-120-D16-11L1M2R type manufactured by Kyowa Electric Co., Ltd.

The relationship between the stress and the forward strain at the time of the tensile test is plotted as a curve (stress-strain curve). Then, using strain as a variable, the integral value of the stress from the start point of the tensile test to the breaking point was calculated. Furthermore, the unit is ×10 ^-4 J/mm ³ .

Oil resistance: The molding resin composition was injection-molded at a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds using a molding machine (manufactured by Kohtaki Precision Machine Co., Ltd.) to obtain a length. A molded article (cured product) of 80 mm, a width of 10 mm, and a thickness of 4 mm. The obtained molded article was subjected to heat treatment at 175 ° C for 4 hours for post-hardening, and the obtained product was used as a test piece, and the flexural strength and the flexural modulus were measured in an environment of 25 ° C in accordance with JIS K 6911. Then, the test piece is placed in a pressure-resistant container, and the pressure-resistant container is filled with After immersing for 1000 hours at a temperature of 150 ° C in the state of ATF oil (Nissan Matic Fluid D), the flexural strength and the flexural modulus were measured in the same manner as above. The initial value before the immersion of the ATF oil was evaluated as ○ within 10% of the change rate, and × when it was more than 10%.

ATF immersion test (1000 hours): The fixing resin composition was subjected to a molding machine (manufactured by Kohtaki Precision Machine Co., Ltd., KTS-30) at a mold temperature of 175 ° C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds. Injection molding was carried out to obtain a molded article (cured product) having a length of 80 mm, a width of 10 mm, and a thickness of 4 mm. The obtained molded article was subjected to heat treatment at 175 ° C for 4 hours as post-hardening, and the obtained product was used as a test piece, and the weight X1 and volume Y1 before the ATF immersion were measured. Then, the test piece was placed in a pressure-resistant container, and immersed at 150 ° C for 1,000 hours in a state filled with ATF. Then, the test piece was taken out from the pressure-resistant container, and the surface-attached ATF was wiped off, and the weight X2 after the ATF immersion was measured, and the volume Y2 was measured, and the weight change rate and the volume change rate before and after the ATF immersion were calculated according to the following formula.

Weight change rate before and after ATF impregnation [%]=(X2-X1)/X1×100

Volume change rate before and after ATF impregnation [%]=(Y2-Y1)/Y1×100

Further, the ATF system used Matic Fluid D (manufactured by Nissan Motor Co., Ltd.), Auto Fluid Type T-IV (manufactured by Toyota Motor Corporation), and ATF DW-1 (manufactured by Honda Technik Co., Ltd.).

ATF immersion test (2000 hours): The weight change rate and volume before and after ATF immersion were calculated in the same manner as the above ATF immersion test (1000 hours) except that the immersion time in ATF was changed to 2000 hours. Rate of change.

Detachment of the inorganic filler: After the ATF immersion test described above, the ATF oil was filtered, and the presence or absence of the inorganic filler on the filter paper was confirmed by a microscope.

According to the first to sixth embodiments, it is possible to obtain a fixing resin composition which is excellent in filling characteristics, mechanical properties, and oil resistance, and which exhibits excellent characteristics in the ATF immersion test.

Further, in Comparative Examples 1 to 2 in which the ICI viscosity of the epoxy resin was more than 3, the 80 μm slit flow length was less than 75. Thus, in Comparative Examples 1 and 2, the fixing resin composition having sufficient filling characteristics could not be obtained.

Furthermore, it is needless to say that the above-described embodiments and a plurality of modifications can be combined in a range in which the contents are not opposed to each other. In the above-described embodiments and modifications, the configuration of each unit and the like are specifically described. However, the configuration and the like can be variously modified within the scope of the present invention.

100‧‧‧Rotor

110‧‧‧Rotor core

120‧‧‧ magnet

130‧‧‧Fixed components

140‧‧‧Filling Department

150‧‧‧ hole department

160‧‧‧Riveting

Claims (13)

A solid resin composition for fixing a resin composition for fixing a fixing member for a rotor, the rotor comprising: a rotor core including a laminate body formed by stacking a plurality of plate members, and being fixed to the laminate a plurality of holes arranged along a peripheral edge portion of the rotating shaft; a magnet inserted into the hole portion; and the fixing member filling the hole in the laminated body; The fixing resin composition in the partition portion between the portion and the magnet is cured; and the solid resin composition for fixing the thermosetting resin (A) contains 5 mass% or more and 40 mass% or less, and contains 150 or less. The epoxy resin (A1) having an ICI viscosity of 3 poise or less at 70 C is 70% by mass or more and 100% by mass or less; the curing agent (B) is 3% by mass or more and 35% by mass or less, and the ICI viscosity at 150 ° C is 2 poise or less. And the inorganic filler (C) is 50% by mass or more and 93% by mass or less; and the fixing resin composition is injected to have a width of 3 mm under the conditions of a mold temperature of 175 ° C, a molding pressure of 6.9 MPa, and an injection time of 20 seconds. Sectional shape with a thickness of 80 μm The slit flow path when the flow length of 75mm or less than 300mm. The fixing resin composition according to claim 1, wherein the epoxy resin (A1) comprises at least one selected from the group consisting of a biphenyl type epoxy resin and a stretching phenyl skeleton. benzene Phenol aralkyl type epoxy resin, phenol aralkyl type epoxy resin having a phenyl group extending, phenol novolac type epoxy resin, o-cresol novolak type epoxy resin, bisphenol type epoxy resin, Binary naphthol type epoxy resin, dicyclopentadiene type epoxy resin, dihydrononanediol type epoxy resin, and triphenylmethane type epoxy resin. The fixing resin composition according to claim 1 or 2, wherein the curing agent (B) comprises at least one selected from the group consisting of a novolac type phenol resin and a phenyl group skeleton. A phenol aralkyl resin, a phenol aralkyl resin having a phenyl group extending, a naphthol aralkyl group having a phenyl group structure, and a phenol resin mainly comprising a reaction product of hydroxybenzaldehyde, formaldehyde and phenol. The fixing resin composition according to claim 1 or 2, wherein the epoxy resin is a crystalline epoxy resin. The fixing resin composition according to claim 1 or 2, wherein the high-viscosity viscosity of the fixing resin composition is 3 Pa‧ when the measurement is performed at a measurement temperature of 175 ° C and a load of 10 kg using a high-viscosity viscosity measuring device. s above 50Pa‧s. The fixing resin composition according to claim 1 or 2, wherein the fixing resin composition has a gel time at 175 ° C of 10 seconds or more and 50 seconds or less. The fixing resin composition according to claim 1 or 2, wherein the spiral flow of the fixing resin composition is 50 cm or more. The fixing resin composition according to claim 1 or 2, wherein the curing torque value after the measurement of the curing torque of the fixing resin composition is measured by using a vulcanizer at a measurement temperature of 175 ° C for 60 seconds. In the case of T ₆₀ , the maximum hardening torque value up to 300 seconds after the start of the measurement is T _max , and the ratio of the hardening torque value after 60 seconds from the start of measurement to the maximum hardening torque value up to 300 seconds after the start of the measurement is T ₆₀ / T _max (%) is 40% or more. The fixing resin composition according to claim 1 or 2, which is in the form of a powder, a granule or a tablet. The fixing resin composition according to claim 1 or 2, which is used in the fixing member constituting the rotor, wherein the rotor is in a plan view, the hole portion in the diameter direction of the rotor and the magnet The interval between the partition portions is 20 μm or more and 500 μm or less. A rotor comprising: a rotor core including a laminated body formed by stacking a plurality of plate members, fixed to a rotating shaft, and provided in the laminated body with a plurality of peripheral portions along the rotating shaft a hole portion; the magnet is inserted into the hole portion; and a fixing member that hardens the fixing resin composition filled in the space between the hole portion and the magnet; and the rotor is characterized in that The fixing resin composition used in the fixing member constituting the rotor is the fixing resin composition according to claim 1 or 2. An automobile comprising the rotor as recited in claim 11. A method for producing a rotor, which is produced by using the fixing resin composition according to claim 1 or 2, and the manufacturing method comprises the steps of: preparing a rotor core, the rotor core comprising a plurality of a laminated body formed by laminating a plate member, wherein the laminated body is provided with a plurality of holes arranged in a peripheral portion of a through hole penetrating through the rotating shaft; and a step of inserting a magnet into the hole portion; a step of filling the fixing resin composition between the hole portion and the magnet, and a step of inserting the rotating shaft into the through hole of the rotor core and fixing the rotating shaft to the rotor core.