WO2015174546A1 - 磁気エンコーダの製造方法 - Google Patents
磁気エンコーダの製造方法 Download PDFInfo
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- WO2015174546A1 WO2015174546A1 PCT/JP2015/064243 JP2015064243W WO2015174546A1 WO 2015174546 A1 WO2015174546 A1 WO 2015174546A1 JP 2015064243 W JP2015064243 W JP 2015064243W WO 2015174546 A1 WO2015174546 A1 WO 2015174546A1
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- magnetic
- rubber
- ferrite
- magnetic powder
- powder
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/14—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
- G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
- G01D5/245—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains using a variable number of pulses in a train
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/10—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials non-metallic substances, e.g. ferrites, e.g. [(Ba,Sr)O(Fe2O3)6] ferrites with hexagonal structure
- H01F1/11—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials non-metallic substances, e.g. ferrites, e.g. [(Ba,Sr)O(Fe2O3)6] ferrites with hexagonal structure in the form of particles
- H01F1/113—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials non-metallic substances, e.g. ferrites, e.g. [(Ba,Sr)O(Fe2O3)6] ferrites with hexagonal structure in the form of particles in a bonding agent
- H01F1/117—Flexible bodies
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0273—Imparting anisotropy
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/02—Permanent magnets [PM]
- H01F7/0205—Magnetic circuits with PM in general
- H01F7/021—Construction of PM
- H01F7/0215—Flexible forms, sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2019/00—Use of rubber not provided for in a single one of main groups B29K2007/00 - B29K2011/00, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2509/00—Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
- B29K2995/0008—Magnetic or paramagnetic
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D2205/00—Indexing scheme relating to details of means for transferring or converting the output of a sensing member
- G01D2205/80—Manufacturing details of magnetic targets for magnetic encoders
Definitions
- the present invention relates to a method of manufacturing a magnetic encoder provided with a magnetic body made of a magnetic rubber molded product obtained by vulcanizing a magnetic rubber composition containing nitrile rubber and ferrite magnetic powder.
- Magnetic rubber molded products obtained by vulcanizing a magnetic rubber composition containing rubber and magnetic powder are used in various applications.
- one suitable application of the magnetic rubber molded product is a magnetic encoder, which is manufactured by magnetizing the magnetic rubber molded product.
- various rubbers are used corresponding to the required performance of the product, but nitrile rubber is preferably used from the balance of oil resistance, heat resistance, price, and the like.
- As the magnetic powder, ferrite magnetic powder, rare earth magnetic powder and the like are properly used according to the required performance, but ferrite magnetic powder is preferably used from the viewpoint of cost and durability (for example, Patent Documents 1 to 4). 3).
- Patent Document 4 discloses a ferrite powder having a plurality of peaks in the particle size distribution, a compression density (CD) of 3.5 g / cm 3 or more, and a coercive force (p-iHc) of the green compact of 2100 Oe or more.
- An anisotropic bonded magnet using is described. Specifically, it describes that an anisotropic bonded magnet is produced by injection-molding a composition containing the ferrite powder and 6-nylon in a magnetic field. Thereby, it is said that a bonded magnet having a high magnetic force excellent in filling property and orientation can be produced while maintaining the coercive force.
- the polyamide (6-nylon) used in Patent Document 4 has a low viscosity at a high temperature exceeding the melting point, and can be injection-molded at a high speed even if it contains a large amount of ferrite magnetic powder.
- a magnetic rubber molded product is produced by kneading a magnetic rubber composition having a high viscosity at a low temperature for a long time and then vulcanizing it.
- a high-viscosity magnetic rubber composition containing a large amount of ferrite magnetic powder is kneaded for a long time, the contained ferrite magnetic powder is subjected to intense shearing force for a long time. It has been found that the coercive force of is greatly reduced.
- the present invention has been made to solve the above-mentioned problems, and a magnetic encoder having a magnetic material having a high coercive force and a high residual magnetic flux density is manufactured by vulcanizing a magnetic rubber composition having good moldability. It is an object to provide a method for doing this.
- the above problem is a method of manufacturing a magnetic encoder including a magnetic body made of a magnetic rubber molded product, A mixing step of mixing a nitrile rubber (A), a ferrite magnetic powder (B), and a vulcanizing agent (C) and then kneading, and a magnetic field applied with the magnetic rubber composition.
- a mixing step of mixing a nitrile rubber (A), a ferrite magnetic powder (B), and a vulcanizing agent (C) and then kneading, and a magnetic field applied with the magnetic rubber composition.
- Content of ferrite magnetic powder (B) with respect to 100 parts by mass of nitrile rubber (A) is 700 to 1500 parts by mass
- compression density of ferrite magnetic powder (B) is 3.5 g / cm 3 or more.
- the ferrite magnetic powder (B) has a plurality of peaks in its particle size distribution. It is also preferred that the ferrite magnetic powder (B) is an anisotropic magnetic powder.
- the minimum value ML of the torque when the vulcanization curve of the magnetic rubber composition at 180 ° C. is measured is preferably 3 to 8 kgf ⁇ cm.
- a magnetic rubber composition is obtained by mixing nitrile rubber (A), ferrite magnetic powder (B) and vulcanizing agent (C) and then kneading at 60 to 130 ° C. for 10 to 60 minutes. Is also preferable. Furthermore, it is also preferable to vulcanize at 140 to 250 ° C. for 1 to 30 minutes in the mold to which the magnetic field is applied.
- the manufactured encoder includes a support member that can be attached to the rotating body, and an annular magnetic rubber molded product that is attached to the support member.
- the magnetic rubber molded product has an N-pole and an S-pole in the circumferential direction. It is preferable that they are alternately magnetized.
- a magnetic encoder provided with a magnetic material having a high coercive force and residual magnetic flux density can be produced by vulcanizing a magnetic rubber composition having good moldability.
- the high-performance magnetic encoder manufactured by the method of the present invention can contribute to improvement in accuracy and miniaturization of various sensors using the encoder.
- the magnetic encoder in the present invention includes a magnetic body made of a magnetic rubber molded product.
- the magnetic rubber molded article is obtained by vulcanizing a magnetic rubber composition containing nitrile rubber (A) and ferrite magnetic powder (B).
- the content of the ferrite magnetic powder (B) with respect to 100 parts by mass of the nitrile rubber (A) is 700 to 1500 parts by mass
- the compression density of the ferrite magnetic powder (B) is 3.5 g / cm 3 or more. is there.
- the magnetic rubber composition used in the present invention is characterized by blending magnetic powder having a high compression density at a high concentration.
- the present inventors molded and vulcanized a magnetic rubber composition in which various magnetic powders were blended in a large amount with nitrile rubber in a mold to which a magnetic field was applied. The magnetic properties of were measured. As a result, when magnetic powder having a high compression density was used, the moldability of the magnetic rubber composition was good while containing a high concentration of magnetic powder, and the high viscosity magnetic rubber composition was kneaded for a long time. Nevertheless, it has been found that a magnetic rubber molded product having a high coercive force can be obtained.
- the residual magnetic flux density of the magnetic rubber molded article could be increased by molding and vulcanizing in a mold to which a magnetic field was applied.
- a magnetic rubber molded product having a high residual magnetic flux density and a high coercive force at the same time is required for a high-performance magnetic encoder.
- the magnetic rubber composition of the present invention contains nitrile rubber (A).
- the nitrile rubber (A) used in the present invention is not particularly limited, and a copolymer of acrylonitrile and 1,3-butadiene can be used. Hydrogenation to the double bond remaining in the 1,3-butadiene unit after polymerization is optional.
- a non-hydrogenated product (NBR) and a hydrogenated product (HNBR) can be selectively used depending on the application. If it is a range which does not inhibit the effect of this invention, you may contain the structural unit derived from the other copolymerizable monomer. Such a structural unit may contain a functional group such as a carboxyl group or a carboxylic anhydride group.
- the content of acrylonitrile units in the nitrile rubber (A) is preferably 15 to 50% by mass. In addition, the content of 1,3-butadiene units is preferably 50 to 85% by mass including hydrogenated ones.
- the nitrile rubber (A) may be unhydrogenated (NBR) or hydrogenated (HNBR).
- the Mooney viscosity (ML 1 + 10 , 100 ° C.) of the nitrile rubber (A) is preferably 20-100. In order to maintain moldability while containing a large amount of magnetic powder, it is preferable that the Mooney viscosity is low. Therefore, it is more preferably 70 or less, and further preferably 55 or less.
- nitrile rubber that is liquid at room temperature (25 ° C.) may be used in combination, it is preferable to use only nitrile rubber that is solid at room temperature in terms of operability.
- the magnetic rubber composition of the present invention contains a ferrite magnetic powder (B).
- the ferrite magnetic powder (B) is not particularly limited, and strontium ferrite magnetic powder and barium ferrite magnetic powder are preferably used.
- Compressed density of the ferrite magnetic powder (B) of the present invention must be at 3.5 g / cm 3 or more, preferably 3.55 g / cm 3 or more. Thereby, it is possible to obtain a magnetic rubber molded article having good moldability and excellent magnetic properties.
- the compression density is usually 4 g / cm 3 or less.
- the compression density (g / cm 3 ) of the ferrite magnetic powder (B) was compressed at a pressure of 1 ton / cm 2 after filling a cylindrical mold having an inner diameter of 2.54 cm with 10 g of ferrite magnetic powder. It is the density of the sample. In order to have such a compression density, it is preferable to have a plurality of peaks in the particle size distribution.
- the particle size distribution of the ferrite magnetic powder (B) can be measured using a dry laser diffraction particle size distribution measuring apparatus.
- the average particle size of the ferrite magnetic powder (B) is preferably 0.5 to 2 ⁇ m.
- the ferrite magnetic powder (B) is preferably an anisotropic magnetic powder.
- Anisotropic magnetic powder suitable for such a vulcanization method is generally marketed as “for magnetic field orientation”.
- the magnetic powder for magnetic field orientation has a small aspect ratio ((diameter / thickness) ratio in the plate-like body) so that it can be easily rotated in the rubber composition when a magnetic field is applied.
- a method of aligning with mechanical deformation without applying a magnetic field a method having a large aspect ratio generally marketed as “for mechanical alignment” is used.
- the content of the ferrite magnetic powder (B) with respect to 100 parts by mass of the nitrile rubber (A) is 700 to 1500 parts by mass.
- the content of the ferrite magnetic powder (B) is preferably 850 parts by mass or more, and more preferably 1000 parts by mass or more.
- the magnetic rubber composition of the present invention may contain rubbers other than nitrile rubber as long as the effects of the present invention are not impaired.
- the content is usually 10% by mass or less of the total amount of rubber components, preferably 5% by mass or less, and more preferably substantially free of rubber other than nitrile rubber.
- the magnetic rubber composition of the present invention may contain magnetic powder other than ferrite magnetic powder, for example, rare earth magnetic powder, as long as the effects of the present invention are not impaired.
- the content is usually 10% by mass or less of the total amount of magnetic powder, preferably 5% by mass or less, and more preferably substantially free of magnetic powder other than ferrite magnetic powder.
- the magnetic rubber composition of the present invention contains a vulcanizing agent (C).
- a vulcanizing agent (C) those usually used for vulcanizing the nitrile rubber (A) such as sulfur, peroxide, polyamine compound and the like can be adopted.
- the content of the vulcanizing agent (C) is usually 0.1 to 10 parts by mass with respect to 100 parts by mass of the nitrile rubber (A).
- the magnetic rubber composition of the present invention may contain components other than the nitrile rubber (A), the ferrite magnetic powder (B), and the vulcanizing agent (C) as long as the effects of the present invention are not impaired. .
- Various additives such as a vulcanization accelerator, a vulcanization aid, an acid acceptor, a colorant, a filler, and a plasticizer that are usually used in the magnetic rubber composition can be contained.
- the method for producing a magnetic encoder of the present invention comprises a mixing step of mixing a nitrile rubber (A), a ferrite magnetic powder (B), and a vulcanizing agent (C) and then kneading, and the magnetic step.
- a rubber composition is molded in a mold to which a magnetic field is applied and vulcanized to obtain a magnetic rubber molded product.
- a magnetic rubber composition is produced by mixing the components described above.
- the mixing method is not particularly limited, and a kneading method using an open roll, a kneader, a Banbury mixer, an intermixer, an extruder, or the like is employed. Especially, it is preferable to knead
- the temperature of the magnetic rubber composition during kneading is preferably 60 to 130 ° C.
- the kneading time is preferably 10 to 60 minutes.
- kneading a composition having a relatively low temperature and high viscosity for a relatively long time and then subjecting it to vulcanization is the usual method for producing a rubber molded article.
- a magnetic rubber composition containing a large amount of ferrite magnetic powder is kneaded for a long time with a high viscosity, the magnetic force of the ferrite magnetic powder is subject to a strong shearing force for a long time, so the coercive force of the obtained magnetic rubber molded product decreases. I understood it.
- the ferrite magnetic powder (B) having a compression density of 3.5 g / cm 3 or more This is a problem unique to magnetic rubber compositions that is not observed when a polyamide-containing bonded magnet is manufactured by injection molding.
- the minimum value ML of the torque when the vulcanization curve at 180 ° C. of the magnetic rubber composition thus obtained is measured is preferably 3 to 8 kgf ⁇ cm.
- ML is less than 3 kgf ⁇ cm, air may remain in the molded product.
- ML exceeds 8 kgf ⁇ cm, the moldability may be insufficient and the filling may be insufficient.
- the step of molding the magnetic rubber composition in a mold to which a magnetic field is applied and vulcanizing it to obtain a magnetic rubber molded product is the molding step.
- the magnetic rubber composition is usually molded into a desired shape and vulcanized by heating.
- the molding method of the magnetic rubber composition include extrusion molding and compression molding. Of these, compression molding is preferred.
- the vulcanization temperature is preferably 140 to 250 ° C.
- the vulcanization time is preferably 1 to 30 minutes.
- secondary vulcanization may be performed by further heating.
- a heating method for vulcanization general methods used for rubber vulcanization such as compression heating, steam heating, oven heating, hot air heating and the like are used, and compression heating is preferable.
- vulcanization is performed in a mold to which a magnetic field is applied. Thereby, the residual magnetic flux density of the magnetic rubber molded product can be increased. At this time, when compression molding, it is preferable to apply a magnetic field in a direction perpendicular to the surface of the molded product.
- the magnetic encoder manufactured by the method of the present invention includes a magnetic body formed by magnetizing the magnetic rubber molded product obtained as described above.
- the magnetic body may have only one set of S pole and N pole, but in many cases, it is a multipolar magnetic body in which magnetic poles are alternately arranged.
- the magnetization mode is not limited to these.
- the shape of the magnetic body is not particularly limited, but it is preferably an annular shape such as a disk shape or a cylindrical shape when detecting a rotational motion.
- the S pole and the N pole are alternately arranged in the circumferential direction and the angle can be detected, which is the most important aspect in practical use.
- a flat belt-like magnetic material may be used.
- the magnetic encoder manufactured by the method of the present invention includes a support member that supports the magnetic body as necessary.
- the support member is preferably a metal member, particularly a metal plate.
- the bonding method between the magnetic rubber molded product and the support member is not particularly limited, and both may be directly bonded when the magnetic rubber molded product is vulcanized.
- the thermosetting adhesive may be cured, and the magnetic rubber molded product may be fixed to the support member with the thermosetting adhesive.
- thermosetting adhesive may be cured at the same time that the product is molded and vulcanized, and the magnetic rubber molded article may be fixed to the support member with the thermosetting adhesive.
- the thermosetting adhesive used here is not particularly limited as long as it is a type of adhesive that cures by a crosslinking reaction caused by heat.
- a phenol resin, an epoxy resin, a urethane resin, a rubber paste in which an unvulcanized rubber is dissolved in a solvent, a silane coupling agent, or the like can be used.
- a preferred embodiment of the magnetic encoder manufactured by the method of the present invention includes a support member that can be attached to a rotating body, and an annular magnetic rubber molded product mounted on the support member, and the magnetic rubber molded product is N
- This is a magnetic encoder in which poles and S poles are alternately magnetized in the circumferential direction. This is useful as a magnetic encoder that detects rotational motion.
- the application of the magnetic encoder manufactured by the method of the present invention is not particularly limited.
- magnetic encoders one that includes an annular or disk-shaped multipolar magnetic body in which magnetic poles are alternately arranged in the circumferential direction is used for a sensor that detects rotational motion.
- a sensor that detects rotational motion.
- it is used for an axle rotation speed detection device, a crank angle detection device, a motor rotation angle detection device, and the like.
- positioned in a linear direction is used for the sensor which detects a linear motion.
- it is used for a linear guide device, a power window, a power seat, a brake depression amount detection device, office equipment, and the like.
- a magnetic encoder for a sensor rotor of a vehicle anti-lock brake system is most useful for a magnetic encoder manufactured by the method of the present invention, which has excellent flexibility and magnetic characteristics, and high residual magnetic flux density and coercive force. It is a use.
- Example 1 Preparation of unvulcanized rubber sheet
- the raw materials shown below were kneaded for 35 minutes using an 8-inch diameter open roll while maintaining the temperature of the composition at 60 to 100 ° C., and unvulcanized rubber sheets having thicknesses of 1 mm, 1.5 mm and 2 mm were obtained. Produced.
- Nitrile rubber 100 parts by mass Acrylonitrile content 34%, Mooney viscosity (ML 1 + 10 , 100 ° C.) 45 Strontium ferrite magnetic powder A (for magnetic field orientation): 1100 parts by mass Average particle diameter: 1.2 ⁇ m (having a plurality of peaks in the particle size distribution) Compression density 3.6 g / cm 3 Residual magnetic flux density of compressed body 196mT Coercive force of compressed body 236 kA / m Plasticizer TOTM [trimellitic acid tris (2-ethylhexyl)]: 3 parts by mass Zinc flower: 4 parts by mass Stearic acid: 3 parts by mass Anti-aging agent [4,4'-bis ( ⁇ , ⁇ -Dimethylbenzyl) diphenylamine]: 5 parts by mass, solid paraffin: 2 parts by mass, sulfur: 0.4 parts by mass, vulcanization accelerator MBTS (2,2'-dibenzothiazo
- the support member As the support member (slinger), an annular member having an L-shaped cross section made of SUS430 having a plate thickness of 0.6 mm was used. Regarding the dimensions of the support member, the inner diameter of the inner cylindrical portion was 55 mm, the outer diameter of the outer ring portion was 67 mm, and the axial length of the inner cylindrical portion was 4.0 mm. On the other hand, the obtained unvulcanized rubber sheet having a thickness of 1.5 mm was punched out into a donut shape having an inner diameter of 56 mm and an outer diameter of 67 mm, and placed on a support member pre-applied with an adhesive made of phenol resin as a raw material. .
- Example 2 In Example 1, an unvulcanized rubber sheet was prepared in the same manner as in Example 1 except that stron ferrite magnetic powder B was used instead of strontium ferrite magnetic powder A.
- the characteristics of the strontium ferrite magnetic powder B are as follows. Using the obtained unvulcanized rubber sheet, vulcanization characteristics, magnetic characteristics, and adhesion to the support member were measured in the same manner as in Example 1. The results are summarized in Table 1. Average particle size 1.14 ⁇ m (has one peak in the particle size distribution) Compression density 3.5 g / cm 3 185mT residual magnetic flux density of the compact Holding force of compressed body 273 kA / m
- Example 3 In Example 1, hydrogenated nitrile rubber (HNBR) was used instead of nitrile rubber (NBR), the amount of stearic acid was 2 parts by mass, and the amount of sulfur was 0.5 parts by mass. In the same manner as in Example 1, an unvulcanized rubber sheet was produced.
- the characteristics of the hydrogenated nitrile rubber used here are as follows. Using the obtained unvulcanized rubber sheet, vulcanization characteristics, magnetic characteristics, and adhesion to the support member were measured in the same manner as in Example 1. The results are summarized in Table 1. Acrylonitrile content 36% Mooney viscosity (ML 1 + 10 , 100 ° C.) 57 Iodine number 28g / 100g
- Example 1 an unvulcanized rubber sheet was prepared in the same manner as in Example 1 except that strontium ferrite magnetic powder C (for magnetic field orientation) was used instead of strontium ferrite magnetic powder A.
- strontium ferrite magnetic powder C for magnetic field orientation
- the characteristics of the strontium ferrite magnetic powder C are as follows.
- the vulcanization characteristics, magnetic characteristics, and adhesion to the support member were measured in the same manner as in Example 1. The results are summarized in Table 1.
- Average particle size 1.4 ⁇ m (has one peak in the particle size distribution)
- Compression density 3.4 g / cm 3 185mT residual magnetic flux density of the compact Compressive body coercive force 207 kA / m
- Example 1 in which the magnetic powder having a compression density of 3.5 g / cm 3 or more was vulcanized while applying a magnetic field, a magnetic material having a high residual magnetic flux density and coercive force was obtained. I was able to.
- the ML value in the vulcanization curve was small, and the fluidity during molding was good.
- Example 1 having a plurality of peaks in the particle size distribution of the magnetic powder, it can be seen that the ML value is particularly low and the fluidity is greatly improved.
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Abstract
Description
ニトリルゴム(A)、フェライト磁性粉(B)及び加硫剤(C)を混合してから混練することによって磁性ゴム組成物を得る混合工程、及び該磁性ゴム組成物を磁場の印加された金型中で成形するとともに加硫して磁性ゴム成形品を得る成形工程を有し、
ニトリルゴム(A)100質量部に対するフェライト磁性粉(B)の含有量が700~1500質量部であり、かつ
フェライト磁性粉(B)の圧縮密度が3.5g/cm3以上であることを特徴とする磁気エンコーダの製造方法を提供することによって解決される。
[未加硫ゴムシートの作製]
以下に示す原料を、8インチ径のオープンロールを用いて、組成物の温度を60~100℃に維持して35分間混練し、厚さ1mm、1.5mm及び2mmの未加硫ゴムシートを作製した。
・ニトリルゴム(未水素添加:NBR):100質量部
アクリロニトリル含有量34%、ムーニー粘度(ML1+10、100℃)45
・ストロンチウムフェライト磁性粉A(磁場配向用):1100質量部
平均粒子径1.2μm(粒度分布において複数のピークを有する。)
圧縮密度3.6g/cm3
圧縮体の残留磁束密度196mT
圧縮体の保磁力236kA/m
・可塑剤TOTM[トリメリット酸トリス(2-エチルへキシル)]:3質量部
・亜鉛華:4質量部
・ステアリン酸:3質量部
・老化防止剤[4,4’-ビス(α,α-ジメチルベンジル)ジフェニルアミン]:5質量部
・固形パラフィン:2質量部
・硫黄:0.4質量部
・加硫促進剤MBTS(2,2’-ジベンゾチアゾリルジスルフィド):2質量部
・加硫促進剤TETD(テトラエチルチウラムジスルフィド):1.5質量部
得られた未加硫ゴムシートを試料とし、JIS K6300-2に準拠し、株式会社エー・アンド・デイ製の「キュラストメーター7」を用いて測定した。測定温度180℃で5分間の加硫曲線を測定し、縦軸をトルク、横軸を時間としたグラフのトルクの最小値ML(kgf・cm)、最大値MH(kgf・cm)、MHの10%のトルクになるまでの時間t10(分)及びMHの90%のトルクになるまでの時間t90(分)を求めた。
JIS K6251に準拠して引張試験を行った。得られた未加硫ゴムシートを用い170℃で10分間プレス加硫して厚さ1mmの加硫ゴムシートを得た。得られた加硫ゴムシートを打ち抜いて得られた、ダンベル状3号形の試験片を用い、23℃、相対湿度50%において、引張速度500mm/分の引張速度で、引張強さ(MPa)と伸び(%)を測定した。その結果、引張強さは4.0MPaであり、伸びは30%であった。
JIS K6253に準拠して測定した。引張試験と同様に作製した厚さ2mmの加硫ゴムシートを3枚重ね、タイプAデュロメータを用いて、23℃、相対湿度50%において測定を行い、ピーク値を読み取った。その結果、A硬度は90であった。
得られた未加硫ゴムシートを用い、直径18mm、厚さ6mmの円盤状試験片を作成し、試験片の厚み方向に磁場をかけながら、170℃で10分間プレス加硫して加硫ゴム試験片を得た。得られた成形品の残留磁束密度及び保磁力を、メトロン技研株式会社製の直流磁化特性試験装置「BHカーブトレーサー」によって測定した。その結果、残留磁束密度は300mTであり、保磁力は270kA/mであった。
支持部材(スリンガ)として、板厚0.6mmのSUS430からなる、断面L字型で円環状のものを用いた。当該支持部材の寸法は、内径側円筒部の内径が55mm、外側円輪部の外径が67mm、内径円筒部の軸方向長さが4.0mmであった。一方、得られた厚さ1.5mmの未加硫ゴムシートを、内径56mm、外径67mmのドーナツ状に打ち抜いて、フェノール樹脂を原料とする接着剤を予め塗布した支持部材上に載置した。引き続き、180℃で3分間プレス加硫して、内径56mm、外径67mm、厚さ1.0mmの磁性体を形成した。当該磁性体は支持部材に強固に接着しており、接着性は良好であった。以上の結果を表1にまとめて示す。
実施例1において、ストロンチウムフェライト磁性粉Aの代わりにストロンフェライト磁性粉Bを用いた以外は実施例1と同様にして、未加硫ゴムシートを作製した。ストロンチウムフェライト磁性粉Bの特性は下記の通りである。得られた未加硫ゴムシートを用いて実施例1と同様にして、加硫特性、磁気特性、及び支持部材への接着性を測定した。結果を表1にまとめて示す。
平均粒子径1.14μm(粒度分布において1つのピークを有する。)
圧縮密度3.5g/cm3
圧縮体の残留磁束密度185mT
圧縮体の保持力273kA/m
実施例1において、ニトリルゴム(NBR)の代わりに水素添加ニトリルゴム(HNBR)を用い、ステアリン酸の配合量を2質量部とし、硫黄の配合量を0.5質量部とした以外は実施例1と同様にして、未加硫ゴムシートを作製した。ここで用いた水素添加ニトリルゴムの特性は下記の通りである。得られた未加硫ゴムシートを用いて実施例1と同様にして、加硫特性、磁気特性、及び支持部材への接着性を測定した。結果を表1にまとめて示す。
アクリロニトリル含有量36%
ムーニー粘度(ML1+10、100℃)57
ヨウ素価28g/100g
実施例1において、ストロンチウムフェライト磁性粉Aの代わりにストロンチウムフェライト磁性粉C(磁場配向用)を用いた以外は実施例1と同様にして、未加硫ゴムシートを作製した。ストロンチウムフェライト磁性粉Cの特性は下記の通りである。得られた未加硫ゴムシートを用いて、実施例1と同様にして、加硫特性、磁気特性、及び支持部材への接着性を測定した。結果を表1にまとめて示す。
平均粒子径1.4μm(粒度分布において1つのピークを有する。)
圧縮密度3.4g/cm3
圧縮体の残留磁束密度185mT
圧縮体の保磁力207kA/m
実施例1において、ストロンチウムフェライト磁性粉Aの代わりにストロンチウムフェライト磁性粉D(機械配向用)を用い、磁場を印加せずにプレス加硫した以外は実施例1と同様にして、未加硫ゴムシートを作製した。ストロンチウムフェライト磁性粉Dの特性は下記の通りである。得られた未加硫ゴムシートを用いて、実施例1と同様にして、加硫特性、磁気特性、及び支持部材への接着性を測定した。結果を表1にまとめて示す。
平均粒子径1.1μm(粒度分布において1つのピークを有する。)
圧縮密度3.2g/cm3
圧縮体の残留磁束密度193mT
圧縮体の保磁力235kA/m
Claims (7)
- 磁性ゴム成形品からなる磁性体を備えた磁気エンコーダの製造方法であって、
ニトリルゴム(A)、フェライト磁性粉(B)及び加硫剤(C)を混合してから混練することによって磁性ゴム組成物を得る混合工程、及び該磁性ゴム組成物を磁場の印加された金型中で成形するとともに加硫して磁性ゴム成形品を得る成形工程を有し、
ニトリルゴム(A)100質量部に対するフェライト磁性粉(B)の含有量が700~1500質量部であり、かつ
フェライト磁性粉(B)の圧縮密度が3.5g/cm3以上であることを特徴とする磁気エンコーダの製造方法。 - フェライト磁性粉(B)が、その粒度分布において複数のピークを有する請求項1に記載の磁気エンコーダの製造方法。
- フェライト磁性粉(B)が、異方性磁性粉である請求項1又は2に記載の磁気エンコーダの製造方法。
- 前記磁性ゴム組成物の180℃における加硫曲線を測定した際のトルクの最小値MLが、3~8kgf・cmである請求項1~3のいずれかに記載の磁気エンコーダの製造方法。
- 前記混合工程において、ニトリルゴム(A)、フェライト磁性粉(B)及び加硫剤(C)を混合してから、60~130℃で10~60分間混練することによって磁性ゴム組成物を得る、請求項1~4のいずれかに記載の磁気エンコーダの製造方法。
- 前記磁場の印加された金型中で140~250℃で1~30分間加硫する、請求項1~5のいずれかに記載の磁気エンコーダの製造方法。
- 回転体に取り付け可能な支持部材と、該支持部材に装着された環状の磁性ゴム成形品を備え、該磁性ゴム成形品がN極とS極とが円周方向に交互に着磁された磁気エンコーダを製造する、請求項1~6のいずれかに記載の磁気エンコーダの製造方法。
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