WO2020129948A1 - 積層コア、その製造方法及び回転電機 - Google Patents
積層コア、その製造方法及び回転電機 Download PDFInfo
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- WO2020129948A1 WO2020129948A1 PCT/JP2019/049312 JP2019049312W WO2020129948A1 WO 2020129948 A1 WO2020129948 A1 WO 2020129948A1 JP 2019049312 W JP2019049312 W JP 2019049312W WO 2020129948 A1 WO2020129948 A1 WO 2020129948A1
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- adhesive
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- laminated core
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/02—Cores, Yokes, or armatures made from sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/18—Layered products comprising a layer of metal comprising iron or steel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
- B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
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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
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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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0233—Manufacturing of magnetic circuits made from sheets
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/05—5 or more layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/06—Coating on the layer surface on metal layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/20—Inorganic coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/28—Multiple coating on one surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/202—Conductive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/208—Magnetic, paramagnetic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
- C09J2203/326—Applications of adhesives in processes or use of adhesives in the form of films or foils for bonding electronic components such as wafers, chips or semiconductors
Definitions
- the present invention relates to a laminated core, a manufacturing method thereof, and a rotating electric machine.
- the present application claims priority based on Japanese Patent Application No. 2018-235868 filed in Japan on December 17, 2018, the contents of which are incorporated herein by reference.
- Patent Document 1 Conventionally, a laminated core as described in Patent Document 1 below is known. In this laminated core, electromagnetic steel sheets adjacent to each other in the laminating direction are bonded.
- the conventional laminated core has room for improvement in improving magnetic properties.
- the present invention has been made in view of the above-mentioned circumstances, and an object thereof is to improve the magnetic characteristics of a laminated core.
- a first aspect of the present invention is provided between a plurality of electromagnetic steel sheets laminated on each other and coated with insulating coatings on both sides, and the electromagnetic steel sheets adjacent to each other in the laminating direction.
- Adhesives that adhere to each other, and the adhesive forming the adhesives includes a first phase and a second phase, and the adhesives are the first phase that is a sea structure and the island structure. Which has a sea-island structure with the second phase, the first phase contains an epoxy resin, an acrylic resin, and a curing agent, and the first phase has an SP value of 8.5 to 10.7 (cal).
- the second phase includes an elastomer, and the second phase is a laminated core having an SP value of 7.5 to 8.4 (cal/cm 3 ) 1/2. is there.
- the difference between the SP value of the first phase and the SP value of the second phase is 0.1 to 3.0 (cal/cm 3 ) 1/. It may be 2 .
- the content of the first phase may be 50% by volume or more based on the total volume of the adhesive portion.
- the content of the epoxy resin is 50% by volume or more based on the total volume of the first phase. Good.
- the content of the acrylic resin is 5 to 45% by volume with respect to the total volume of the first phase. May be. (6)
- the content of the curing agent is 1 to 40% by volume based on the total volume of the first phase. May be.
- the curing agent may be a novolac type phenol resin.
- the laminated core according to any one of (1) to (7) may be for a stator.
- an adhesive containing a first phase containing an epoxy resin, an acrylic resin, and a curing agent, and a second phase containing an elastomer is applied to the surface of a magnetic steel sheet to form a plurality of The method for producing a laminated core according to any one of (1) to (8) above, wherein the electromagnetic steel sheets are stacked and the adhesive is cured to form an adhesive portion.
- a third aspect of the present invention is a rotary electric machine including the laminated core according to any one of (1) to (8).
- the magnetic characteristics of the laminated core can be improved.
- FIG. 3 is a sectional view taken along line AA of FIG. 2. It is a side view which shows the schematic structure of the manufacturing apparatus of a laminated core.
- an electric motor specifically, an AC motor, more specifically, a synchronous motor, and more specifically, a permanent magnet field type electric motor will be described as an example of the rotating electric machine.
- This type of electric motor is preferably used in, for example, an electric vehicle.
- the rotary electric machine 10 includes a stator 20, a rotor 30, a case 50, and a rotating shaft 60.
- the stator 20 and the rotor 30 are housed in the case 50.
- the stator 20 is fixed to the case 50.
- an inner rotor type in which the rotor 30 is located inside the stator 20 is adopted.
- the rotating electric machine 10 may be an outer rotor type in which the rotor 30 is located outside the stator 20.
- the rotary electric machine 10 is a 12-pole 18-slot three-phase AC motor. However, the number of poles, the number of slots, the number of phases, etc. can be changed appropriately.
- the rotating electrical machine 10 can rotate at a rotation speed of 1000 rpm, for example, by applying an exciting current having an effective value of 10 A and a frequency of 100 Hz to each phase.
- the stator 20 includes a stator core 21 and a winding (not shown).
- the stator core 21 includes an annular core back portion 22 and a plurality of teeth portions 23.
- the direction of the central axis O of the stator core 21 (or the core back portion 22) is referred to as the axial direction
- the radial direction of the stator core 21 (or the core back portion 22) (the direction orthogonal to the central axis O) is referred to as the radial direction
- the circumferential direction of the stator core 21 (or the core back portion 22) (direction around the central axis O thereof) is called the circumferential direction.
- the core back portion 22 is formed in an annular shape in a plan view when the stator 20 is viewed in the axial direction.
- the plurality of teeth portions 23 project from the core back portion 22 inward in the radial direction (toward the central axis O of the core back portion 22 along the radial direction).
- the plurality of tooth portions 23 are arranged at equal intervals in the circumferential direction.
- 18 teeth portions 23 are provided at a central angle of 20 degrees about the central axis O.
- the plurality of teeth portions 23 have the same shape and the same size.
- the winding is wound around the tooth portion 23.
- the winding may be concentrated winding or distributed winding.
- the rotor 30 is arranged radially inward of the stator 20 (stator core 21).
- the rotor 30 includes a rotor core 31 and a plurality of permanent magnets 32.
- the rotor core 31 is formed in an annular shape (annular shape) arranged coaxially with the stator 20.
- the rotating shaft 60 is arranged in the rotor core 31.
- the rotating shaft 60 is fixed to the rotor core 31.
- the plurality of permanent magnets 32 are fixed to the rotor core 31. In the present embodiment, two pairs of permanent magnets 32 form one magnetic pole.
- the plurality of sets of permanent magnets 32 are arranged at equal intervals in the circumferential direction. In the present embodiment, 12 sets (24 in total) of permanent magnets 32 are provided at a central angle of 30 degrees about the central axis O.
- an embedded magnet type motor is adopted as the permanent magnet field type electric motor.
- the rotor core 31 is formed with a plurality of through holes 33 that penetrate the rotor core 31 in the axial direction.
- the plurality of through holes 33 are provided corresponding to the plurality of permanent magnets 32.
- Each permanent magnet 32 is fixed to the rotor core 31 while being arranged in the corresponding through hole 33.
- the fixing of each permanent magnet 32 to the rotor core 31 can be realized by, for example, bonding the outer surface of the permanent magnet 32 and the inner surface of the through hole 33 with an adhesive agent.
- a surface magnet type motor may be adopted as the permanent magnet field type electric motor instead of the embedded magnet type motor.
- the stator core 21 and the rotor core 31 are both laminated cores. As shown in FIG. 2, the stator 20 is formed by stacking a plurality of electromagnetic steel plates 40.
- the laminated thickness of each of the stator core 21 and the rotor core 31 is, for example, 50.0 mm.
- the outer diameter of the stator core 21 is, for example, 250.0 mm.
- the inner diameter of the stator core 21 is, for example, 165.0 mm.
- the outer diameter of the rotor core 31 is, for example, 163.0 mm.
- the inner diameter of the rotor core 31 is, for example, 30.0 mm.
- the product thickness, outer diameter, and inner diameter of the stator core 21, and the product thickness, outer diameter, and inner diameter of the rotor core 31 are not limited to these values.
- the inner diameter of the stator core 21 is based on the tip of the tooth portion 23 of the stator core 21.
- the inner diameter of the stator core 21 is the diameter of an imaginary circle inscribed in the tips of all the teeth 23.
- Each electromagnetic steel plate 40 forming the stator core 21 and the rotor core 31 is formed, for example, by punching an electromagnetic steel plate serving as a base material.
- the electromagnetic steel plate 40 a known electromagnetic steel plate can be used.
- the chemical composition of the electromagnetic steel sheet 40 is not particularly limited.
- a non-oriented electrical steel sheet is used as the electrical steel sheet 40.
- a non-oriented electrical steel sheet for example, a non-oriented electrical steel strip according to JIS C2552:2014 can be adopted.
- the grain-oriented electrical steel sheet for example, a grain-oriented electrical steel strip according to JIS C2553:2012 can be adopted.
- both surfaces of the electromagnetic steel sheet 40 are covered with insulating coatings.
- the substance forming the insulating coating for example, (1) an inorganic compound, (2) an organic resin, (3) a mixture of an inorganic compound and an organic resin, or the like can be applied.
- the inorganic compound include (1) a complex of dichromate and boric acid, (2) a complex of phosphate and silica, and the like.
- the organic resin include epoxy resin, acrylic resin, acrylic styrene resin, polyester resin, silicone resin, and fluororesin. The organic resin may be the same as or different from the organic resin contained in the adhesive described later.
- the thickness of the insulating coating is preferably 0.1 ⁇ m or more.
- the insulating effect becomes saturated as the insulating coating becomes thicker.
- the space factor decreases and the performance as a laminated core decreases. Therefore, the insulating coating is preferably thin as long as the insulating performance can be secured.
- the thickness of the insulating coating is preferably 0.1 ⁇ m or more and 5 ⁇ m or less, and more preferably 0.1 ⁇ m or more and 2 ⁇ m or less. The thickness of the insulating coating can be measured, for example, by observing a cut surface obtained by cutting the electromagnetic steel plate 40 in the thickness direction with a microscope or the like.
- the thickness of the electromagnetic steel sheet 40 is preferably 0.10 mm or more.
- the thickness of the electromagnetic steel plate 40 is preferably 0.65 mm or less. Further, as the electromagnetic steel plate 40 becomes thicker, iron loss increases.
- the thickness of the electromagnetic steel plate 40 is preferably 0.35 mm or less, more preferably 0.25 mm or less, and further preferably 0.20 mm or less.
- the thickness of each electromagnetic steel plate 40 is, for example, preferably 0.10 mm or more and 0.65 mm or less, more preferably 0.10 mm or more and 0.35 mm or less, and 0.10 mm or more and 0.25 mm or less. More preferably, 0.10 mm or more and 0.20 mm or less are particularly preferable.
- the thickness of the electromagnetic steel plate 40 also includes the thickness of the insulating coating. The thickness of the electromagnetic steel plate 40 can be measured by, for example, a micrometer or the like.
- a plurality of electromagnetic steel plates 40 forming the stator core 21 are laminated with an adhesive portion 41 interposed therebetween.
- the adhesive portion 41 is formed on the core back portion 22 and the tooth portion 23 of the stator core 21.
- the adhesive portion 41 is formed radially inward from the inner periphery of the core back portion 22 (toward the central axis O of the core back portion 22 along the radial direction) like 41 a, 41 b, and 41 c. ..
- Adhesive portions 41b and 41c are formed on the plurality of tooth portions 23, respectively.
- An adhesive portion 41a is formed on the core back portion 22 at a position corresponding to the plurality of teeth portions 23.
- the adhesive part 41 is formed of an adhesive containing a first phase and a second phase.
- the adhesion part 41 has a sea-island structure of a first phase and a second phase.
- the “sea-island structure” means a phase-separated structure in which a phase composed of one component (island structure part) is dispersed in a phase composed of the other component (sea structure part).
- the adhesive portion 41 has a sea-island structure, so that the strain generated in the electromagnetic steel plate 40 can be eased.
- the hysteresis loss can be easily reduced, and as a result, the magnetic characteristics of the laminated core can be improved. It is considered that the sea-island structure of the hard first phase hardened material and the soft second phase easily absorbs the strain generated in the magnetic steel sheet 40, and thus the strain generated in the magnetic steel sheet 40 can be relaxed.
- the hysteresis loss is an energy loss caused by a change in the magnetic field direction of the laminated core.
- Hysteresis loss is a type of iron loss.
- the first phase forms a sea structure part that is a continuous phase
- the second phase forms an island structure part that is a dispersed phase.
- the first phase which has a lower viscosity and a larger amount than the second phase, forms a sea structure part that is a continuous phase.
- the adhesive forming the adhesive portion 41 includes a first phase and a second phase.
- the first phase contains an epoxy resin, an acrylic resin, and a curing agent.
- an acrylic-modified epoxy resin obtained by graft-polymerizing an acrylic resin with an epoxy resin is preferable from the viewpoint of easily increasing the adhesive strength of the adhesive portion 41.
- the adhesive is cured, for example, by being heated to 80° C. or higher under normal pressure to be a cured product.
- the “normal pressure” means a pressure when neither depressurization nor pressurization is performed, and is usually about 1 atm (0.1 MPa).
- the content of the first phase is preferably 50% by volume or more, more preferably 50 to 95% by volume, further preferably 60 to 90% by volume, particularly preferably 70 to 80% by volume, based on the total volume of the adhesive. ..
- the adhesive strength of the adhesive portion 41 is likely to be increased.
- the strain generated in the electrical steel sheet 40 is easily relaxed.
- the content of the first phase is the ratio of the volume of the first phase to the total volume of the adhesive at 25°C.
- the SP value (solubility parameter) of the first phase is 8.5 to 10.7 (cal/cm 3 ) 1/2 , preferably 8.7 to 10.5 (cal/cm 3 ) 1/2 , It is more preferably 9.0 to 10.0 (cal/cm 3 ) 1/2 .
- the adhesive portion 41 easily forms a sea-island structure with the second phase.
- the SP value of the first phase is equal to or less than the above upper limit value, the adhesive is easily applied to the surface of the electromagnetic steel plate 40.
- SP value means the solubility parameter of Hildebrand.
- the SP value of the first phase can be measured, for example, by the following method.
- the resin composition constituting the first phase is applied to the surface of the non-oriented electrical steel sheet and heated to 120° C. to cure.
- the obtained cured product was rubbed with various solvents having known SP values and the cured product of the first phase was dissolved in the solvent to cause discoloration of the solvent, the SP value of the solvent was changed to the SP value of the first phase.
- Examples of various solvents having known SP values include n-pentane (SP value: 7.0 (cal/cm 3 ) 1/2 ) and n-hexane (SP value: 7.3 (cal/cm 3 ). 1/2 ), diethyl ether (SP value: 7.4 (cal/cm 3 ) 1/2 ), n-octane (SP value: 7.6 (cal/cm 3 ) 1/2 ), vinyl chloride (SP Value: 7.8 (cal/cm 3 ) 1/2 ), cyclohexane (SP value: 8.2 (cal/cm 3 ) 1/2 ), isobutyl acetate (SP value: 8.3 (cal/cm 3 ).
- the SP value of the first phase can be adjusted by the type and content of the epoxy resin that constitutes the first phase, the type and content of the acrylic resin, and the type and content of the curing agent.
- the number average molecular weight of the epoxy resin in the first phase is preferably 1200 to 20000, more preferably 2000 to 18000, and even more preferably 2500 to 16000.
- the number average molecular weight of the epoxy resin can be measured by size exclusion chromatography (SEC: Size-Exclusion Chromatography) described in JIS K7252-1:2008 using polystyrene as a standard substance.
- the epoxy resin for example, those obtained by condensing epichlorohydrin and bisphenol in the presence of an alkali catalyst, epichlorohydrin and bisphenol are condensed into a low molecular weight epoxy resin in the presence of an alkali catalyst, Examples thereof include those obtained by polyaddition reaction of a low molecular weight epoxy resin and bisphenol.
- the "low molecular weight epoxy resin” means an epoxy resin having a number average molecular weight of less than 1200.
- the epoxy resin may be an epoxy ester resin in which a divalent carboxylic acid is combined.
- Examples of the divalent carboxylic acid include succinic acid, adipic acid, himelic acid, azelaic acid, sebacic acid, dodecanedioic acid, and hexahydrophthalic acid.
- Examples of the bisphenol include bisphenol A, bisphenol F, bisphenol AD and the like, and bisphenol A and bisphenol F are preferable.
- Examples of the alkali catalyst include sodium hydroxide and potassium hydroxide. These epoxy resins may be used alone or in combination of two or more.
- the content of the epoxy resin is preferably 50% by volume or more, more preferably 50 to 94% by volume, further preferably 55 to 90% by volume, particularly preferably 60 to 80% by volume, based on the total volume of the first phase. ..
- the adhesive strength of the adhesive portion 41 is likely to be increased.
- the strain generated in the electrical steel sheet 40 is easily relaxed.
- the content of the epoxy resin is the ratio of the volume of the epoxy resin to the total volume of the first phase before curing at 25°C.
- the number average molecular weight of the acrylic resin in the first phase is preferably 5,000 to 100,000, more preferably 6,000 to 80,000, and further preferably 7,000 to 60,000.
- the adhesive strength of the adhesive portion 41 is likely to be increased.
- the number average molecular weight of the acrylic resin is not more than the above upper limit value, it is easy to suppress the viscosity of the adhesive from becoming high, and it is easy to apply the adhesive to the surface of the electromagnetic steel sheet 40.
- the number average molecular weight of the acrylic resin can be measured by the same method as the number average molecular weight of the epoxy resin.
- acrylic resin examples include acrylic resins obtained by polymerizing or copolymerizing at least one kind selected from unsaturated carboxylic acids such as acrylic acid, methacrylic acid, maleic acid, itaconic acid, crotonic acid, and the above unsaturated carboxylic acids.
- unsaturated carboxylic acids such as acrylic acid, methacrylic acid, maleic acid, itaconic acid, crotonic acid, and the above unsaturated carboxylic acids.
- An acrylic resin obtained by copolymerizing at least one kind of monomer selected from the following and at least one kind selected from the following radically polymerizable unsaturated monomers is mentioned.
- radical-polymerizable unsaturated monomer include (1) the number of carbon atoms of acrylic acid or methacrylic acid such as 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, hydroxypropyl acrylate and hydroxypropyl methacrylate.
- hydroxyalkyl esters (2) methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, isobutyl methacrylate, acrylic acid tert-butyl, tert-butyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, lauryl acrylate, lauryl methacrylate, stearyl acrylate, stearyl methacrylate, decyl acrylate, etc.
- alkyl ester or cycloalkyl ester of acrylic acid or methacrylic acid having 1 to 24 carbon atoms (3) acrylamide, methacrylamide, N-methyl acrylamide, N-ethyl acrylamide, diacetone acrylamide, N-methylol acrylamide
- Aromatic vinyl monomer such as functional acrylamide or functional methacrylamide such as N, methylol methacrylamide, N-methoxymethyl acrylamide and N-butoxymethyl acrylamide, and (4) styrene, vinyltoluene, ⁇ -methylstyrene And (5) vinyl acetate, vinyl propionate, acrylonitrile, methacrylonitrile, and other aliphatic vinyl monomers.
- Preferred combinations of the above unsaturated monomers include, for example, a combination of methyl methacrylate, 2-ethylhexyl acrylate and acrylic acid, a combination of styrene, methyl methacrylate, ethyl acrylate and methacrylic acid, styrene and acrylic.
- examples include a combination of ethyl acid and methacrylic acid, a combination of methyl methacrylate, ethyl acrylate, and acrylic acid.
- An acrylic-modified epoxy resin obtained by graft-polymerizing an acrylic resin with an epoxy resin is, for example, a high molecular weight epoxy resin in an organic solvent solution in the presence of a radical generator such as benzoyl peroxide. It is obtained by carrying out a graft polymerization reaction of the above radically polymerizable unsaturated monomer on a resin.
- the "high molecular weight epoxy resin” means an epoxy resin having a number average molecular weight of 1200 or more.
- the radical generator used in the graft polymerization reaction is preferably 3 to 15 parts by mass with respect to 100 parts by mass of the solid content of the radically polymerizable unsaturated monomer.
- the above graft polymerization reaction requires, for example, 1 to 3 hours with a radically polymerizable unsaturated monomer obtained by uniformly mixing a radical generator with an organic solvent solution of a high molecular weight epoxy resin heated to 80 to 150° C. And the same temperature is maintained for 1 to 3 hours.
- the organic solvent used in the graft polymerization reaction may be any organic solvent that dissolves the high molecular weight epoxy resin and the radically polymerizable unsaturated monomer and is miscible with water.
- organic solvent include isopropanol, butyl alcohol, 2-hydroxy-4-methylpentane, 2-ethylhexyl alcohol, cyclohexanol, ethylene glycol, diethylene glycol, 1,3-butylene glycol, ethylene glycol monoethyl ether, Examples thereof include alcohol solvents such as ethylene glycol monobutyl ether and diethylene glycol monomethyl ether, ketone solvents such as acetone and methyl ethyl ketone, cellosolve solvents and carbitol solvents.
- an inert organic solvent which is immiscible with water
- examples of such an organic solvent include aromatic hydrocarbons such as toluene and xylene, and esters such as ethyl acetate and butyl acetate. ..
- the content of the acrylic resin is preferably 5 to 45% by volume, more preferably 10 to 40% by volume, and further preferably 15 to 30% by volume, based on the total volume of the first phase.
- the content of the acrylic resin is the ratio of the volume of the acrylic resin to the total volume of the first phase before curing at 25°C.
- the curing agent in the first phase a commonly used epoxy resin curing agent can be used.
- the curing agent in the first phase include polyamine curing agents such as aliphatic polyamines, alicyclic polyamines, aromatic polyamines, polyamide polyamines and modified polyamines; monofunctional acid anhydrides (phthalic anhydride, hexahydrophthalic anhydride).
- Bifunctional acid anhydrides pyromellitic anhydride, benzophenonetetracarboxylic acid anhydride, ethylene glycol bis) (Anhydrotrimate), methylcyclohexene tetracarboxylic acid anhydride, etc.), free acid acid anhydride (trimellitic anhydride, polyazelainic acid anhydride, etc.), etc.
- latent curing agent for example, dicyandiamide, melamine, organic acid dihydrazide, amine imide, ketimine, tertiary amine, imidazole salt, boron trifluoride amine salt, microcapsule type curing agent (the curing agent is formed with casein etc.
- a microcapsule which breaks the microcapsule when heated and pressed to cause a curing reaction with the resin
- a molecular sieve type curing agent a curing agent adsorbed on the surface of an adsorptive compound, an adsorption molecule by heating. And the like which react with the resin to cure).
- a novolac type phenol resin (phenol novolac resin) is preferable from the viewpoint of easily increasing the adhesive strength of the adhesive portion 41.
- the "novolak type phenolic resin” means a resin obtained by subjecting phenols and aldehydes to a condensation reaction using an acid catalyst.
- phenols include phenol.
- Formaldehyde is mentioned as an aldehyde.
- the acid catalyst include oxalic acid and divalent metal salts.
- the novolac type phenol resin is a solid at room temperature (25° C.) and is classified as a thermoplastic resin. In the novolac type phenol resin, the --CH 2 OH group is hardly bonded to the phenol nucleus (aromatic ring) that constitutes the phenol resin.
- the content of the curing agent is preferably 1 to 40% by volume, more preferably 5 to 30% by volume, still more preferably 10 to 20% by volume, based on the total volume of the first phase.
- the content of the curing agent is equal to or more than the above lower limit value, it is easy to increase the adhesive strength of the adhesive portion 41.
- the content of the curing agent is less than or equal to the above upper limit value, the stability of the adhesive portion 41 is likely to be increased.
- the content of the curing agent is the ratio of the volume of the curing agent to the total volume of the first phase before curing at 25°C.
- the second phase comprises an elastomer.
- the elastomer include natural rubber and synthetic rubber, and synthetic rubber is preferable.
- the synthetic rubber include polybutadiene synthetic rubber, nitrile synthetic rubber, chloroprene synthetic rubber and the like.
- the polybutadiene-based synthetic rubber include isoprene rubber (IR, SP value: 7.9 to 8.4 (cal/cm 3 ) 1/2 ) and butadiene rubber (BR, SP value: 8.1 to 8.6). (Cal/cm 3 ) 1/2 ), styrene-butadiene rubber (SBR, SP value: 8.1 to 8.7 (cal/cm 3 ) 1/2 ), polyisobutylene (butyl rubber, IIR, SP value: 7.
- nitrile synthetic rubber examples include acrylonitrile butadiene rubber (NBR, SP value: 8.7 to 10.5 (cal/cm 3 ) 1/2 ), acrylic rubber (ACM, SP value: 9.4 (cal/ cm 3 ) 1/2 ) and the like.
- chloroprene synthetic rubber examples include chloroprene rubber (CR, SP value: 8.2 to 9.4 (cal/cm 3 ) 1/2 ).
- urethane rubber (SP value: 10.0 (cal/cm 3 ) 1/2 ) and silicone rubber (SP value: 7.3 to 7.6 (cal/cm 3 ) 1/ 2 ), fluororubber (FKM, SP value: 8.6 (cal/cm 3 ) 1/2 ), chlorosulfonated polyethylene (CSM, SP value: 8.1 to 10.6 (cal/cm 3 ) 1 / 2 ), epichlorohydrin rubber (ECO, SP value: 9.6 to 9.8 (cal/cm 3 ) 1/2 ) and the like may be used.
- SBR, EPDM, and NBR are preferable because they have excellent heat resistance and can easily alleviate the strain generated in the electromagnetic steel plate 40.
- the elastomer may be used alone or in combination of two or more.
- the second phase may contain a compound other than the elastomer.
- the compound other than the elastomer include the above-mentioned acrylic resin and the like.
- the content of the elastomer is preferably 50% by volume or more, more preferably 70% by volume or more, further preferably 90% by volume or more, particularly preferably 100% by volume, based on the total volume of the second phase.
- the adhesive portion 41 easily forms the sea-island structure of the first phase and the second phase, and the strain generated in the electrical steel sheet 40 is easily relaxed.
- the content of the elastomer is the ratio of the volume of the elastomer to the total volume of the second phase at 25°C.
- the content of the second phase is preferably 5 to 50% by volume, more preferably 10 to 40% by volume, and further preferably 20 to 30% by volume, based on the total volume of the adhesive.
- the content of the second phase is equal to or more than the above lower limit value, the strain generated in the electrical steel sheet 40 is easily relaxed.
- the content of the second phase is equal to or less than the above upper limit value, the adhesive strength of the adhesive portion 41 is likely to be increased.
- the content of the second phase is the ratio of the volume of the second phase to the total volume of the adhesive at 25°C.
- the volume of the second phase is determined by immersing the second phase in water at 25° C. and increasing the volume of water.
- the SP value of the second phase is 7.5 to 8.4 (cal/cm 3 ) 1/2 , preferably 7.7 to 8.2 (cal/cm 3 ) 1/2 , and 7.9 to 8.0 (cal/cm 3 ) 1/2 is more preferable.
- the SP value of the second phase is equal to or more than the above lower limit value, it is easy to apply the adhesive to the surface of the electromagnetic steel plate 40.
- the adhesive portion 41 easily forms the sea-island structure of the first phase and the second phase.
- the SP value of the second phase can be measured, for example, by the following method.
- the resin composition that constitutes the second phase is applied to the surface of the non-oriented electrical steel sheet and heated to 120° C. to cure.
- the SP value of the solvent is changed to the SP value of the second phase.
- various solvents having a known SP value include the same solvents as those having a known SP value when the SP value of the first phase is measured.
- the SP value of the second phase can be adjusted by the type and content of the elastomer in the resin composition constituting the second phase, the type and content of the compound other than the elastomer contained in the second phase, and combinations thereof.
- the difference between the SP value of the first phase and the SP value of the second phase is preferably 0.1 to 3.0 (cal/cm 3 ) 1/2 , and 1.0 to 3.0 (cal/cm 3 ) 1/2 is more preferable, and 1.5 to 2.5 (cal/cm 3 ) 1/2 is further preferable.
- the difference between the SP value of the first phase and the SP value of the second phase is equal to or more than the above lower limit value, the bonded portion easily forms a sea-island structure of the first phase and the second phase.
- the difference between the SP value of the first phase and the SP value of the second phase is not more than the above upper limit value, the second phase is uniformly dispersed, and the stability of the adhesive is likely to be increased.
- the difference between the SP value of the first phase and the SP value of the second phase is within the above numerical range, it is easy to alleviate the strain generated in the electrical steel sheet 40, improve the iron loss of the laminated core, and improve the laminated core. It is easy to improve the magnetic characteristics of.
- the difference between the SP value of the first phase and the SP value of the second phase is obtained from the SP value of the first phase obtained by measuring the SP value of the first phase and the SP value of the second phase, respectively. It is obtained by subtracting the SP value of the second phase.
- the adhesive of the present embodiment may contain optional components in addition to the above-mentioned first phase and second phase.
- a synthetic resin such as a polyolefin resin, a polyurethane resin, a polyamide resin, a polyimide resin, a polyester resin, a silicone resin, and a fluororesin; oxide fine particles such as silica and alumina; a conductive substance; a sparingly soluble chromate, etc.
- Anti-rust additive for example, condensed polycyclic organic pigment, phthalocyanine organic pigment, etc.); Coloring dye (for example, azo dye, azo metal complex salt dye, etc.); Film-forming aid; Dispersibility improving agent Defoaming agents and the like.
- These optional components may be used alone or in combination of two or more.
- the content of the optional components is preferably 1 to 40% by volume based on the total volume of the adhesive at 25°C.
- thermosetting adhesives in addition to thermosetting adhesives, radical polymerization adhesives and the like can also be used, and from the viewpoint of productivity, it is desirable to use room temperature curing adhesives. ..
- the room temperature curable adhesive cures at 20°C to 30°C.
- An acrylic adhesive is preferable as the room temperature curable adhesive.
- Typical acrylic adhesives include SGA (Second Generation Acrylic Adhesive. Second Generation Acrylic Adhesive). Any anaerobic adhesive, instant adhesive, or elastomer-containing acrylic adhesive can be used as long as the effects of the present invention are not impaired. It should be noted that the adhesive referred to here is in a state before being cured, and becomes an adhesive portion 41 after the adhesive is cured.
- the average tensile elastic modulus E of the adhesive portion 41 at room temperature (20° C. to 30° C.) is in the range of 1500 MPa to 4500 MPa. If the average tensile elastic modulus E of the adhesive portion 41 is less than 1500 MPa, the rigidity of the laminated core is reduced. Therefore, the lower limit of the average tensile elastic modulus E of the adhesive portion 41 is set to 1500 MPa, more preferably 1800 MPa. On the contrary, if the average tensile elastic modulus E of the adhesive portion 41 exceeds 4500 MPa, the insulating coating formed on the surface of the electromagnetic steel plate 40 may be peeled off.
- the upper limit value of the average tensile elastic modulus E of the adhesive portion 41 is set to 4500 MPa, more preferably 3650 MPa.
- the average tensile elastic modulus E is measured by the resonance method. Specifically, the tensile elastic modulus is measured according to JIS R 1602:1995. More specifically, first, a sample for measurement (not shown) is manufactured. This sample is obtained by bonding the two electromagnetic steel plates 40 together with an adhesive to be measured and curing it to form the bonding portion 41.
- the adhesive is a thermosetting type
- this curing is performed by heating and pressing under the heating and pressing conditions in actual operation.
- the adhesive is a room temperature curing type, it is performed by applying pressure at room temperature.
- the tensile elastic modulus of this sample is measured by the resonance method.
- the method of measuring the tensile elastic modulus by the resonance method is performed in accordance with JIS R 1602:1995, as described above.
- the tensile elastic modulus of the bonded portion 41 alone is obtained by calculating the influence of the electromagnetic steel plate 40 itself from the tensile elastic modulus (measured value) of the sample. Since the tensile modulus obtained from the sample in this way is equal to the average value of the laminated core as a whole, this value is regarded as the average tensile modulus E.
- the composition of the average tensile elastic modulus E is set so that the average tensile elastic modulus E hardly changes at the laminating position along the laminating direction or the circumferential position around the central axis of the laminated core. Therefore, the average tensile elastic modulus E can be set to the value obtained by measuring the cured adhesive portion 41 at the upper end position of the laminated core.
- a bonding method for example, a method of applying an adhesive to the electromagnetic steel plate 40 and then bonding by heating or pressure bonding or both can be adopted.
- the heating means may be any means such as heating in a high temperature tank or an electric furnace, or a method of directly energizing.
- the thickness of the adhesive portion 41 is preferably 1 ⁇ m or more.
- the thickness of the adhesive portion 41 exceeds 100 ⁇ m, the adhesive force is saturated. Further, as the adhesive portion 41 becomes thicker, the space factor decreases, and the magnetic characteristics such as iron loss of the laminated core deteriorate. Therefore, the thickness of the adhesive portion 41 is preferably 1 ⁇ m or more and 100 ⁇ m or less, and more preferably 1 ⁇ m or more and 10 ⁇ m or less. In the above, the thickness of the adhesive portion 41 means the average thickness of the adhesive portion 41.
- the average thickness of the adhesive portion 41 is more preferably 1.0 ⁇ m or more and 3.0 ⁇ m or less. If the average thickness of the adhesive portion 41 is less than 1.0 ⁇ m, sufficient adhesive force cannot be secured as described above. Therefore, the lower limit of the average thickness of the adhesive portion 41 is 1.0 ⁇ m, and more preferably 1.2 ⁇ m. On the contrary, if the average thickness of the adhesive portion 41 exceeds 3.0 ⁇ m and becomes thicker, a problem such as a large increase in the amount of distortion of the electrical steel sheet 40 due to shrinkage during thermosetting occurs. Therefore, the upper limit of the average thickness of the adhesive portion 41 is 3.0 ⁇ m, and more preferably 2.6 ⁇ m. The average thickness of the adhesive portion 41 is an average value of the entire laminated core.
- the average thickness of the adhesive portion 41 hardly changes at the stacking position along the stacking direction or the circumferential position around the central axis of the stacked core. Therefore, the average thickness of the adhesive portion 41 can be set to the average value of the numerical values measured at 10 or more positions in the circumferential direction at the upper end position of the laminated core.
- the average thickness of the adhesive portion 41 can be adjusted, for example, by changing the amount of adhesive applied. Also, the average tensile elastic modulus E of the adhesive portion 41, for example, in the case of a thermosetting adhesive, can be adjusted by changing one or both of the heating and pressurizing conditions and the type of curing agent applied at the time of adhesion. You can
- the plurality of electromagnetic steel plates 40 forming the rotor core 31 are fixed to each other by caulking C (dowel). However, the plurality of electromagnetic steel plates 40 forming the rotor core 31 may be bonded to each other by the bonding portion 41.
- the laminated cores such as the stator core 21 and the rotor core 31 may be formed by so-called rolling.
- a method for manufacturing a laminated core according to an embodiment of the present invention applies an adhesive containing a first phase containing an epoxy resin, an acrylic resin, and a curing agent, and a second phase containing an elastomer to the surface of a magnetic steel sheet.
- the method includes a step (application step), a step of laminating a plurality of electromagnetic steel sheets coated with an adhesive (laminating step), and a step of curing the adhesive to form an adhesive portion (curing step).
- the manufacturing apparatus 100 includes a first-stage punching station 110 at a position closest to the coil Q, and a second-stage punching station 120 disposed adjacent to the punching station 110 on the downstream side in the transport direction of the original steel sheet P. And an adhesive application station 130 disposed adjacent to the punching station 120 on the further downstream side.
- the punching station 110 includes a female die 111 arranged below the original steel plate P and a male die 112 arranged above the original steel plate P.
- the punching station 120 includes a female die 121 arranged below the original steel plate P and a male die 122 arranged above the original steel plate P.
- the adhesive application station 130 includes an applicator 131 including a plurality of injectors arranged according to the adhesive application pattern.
- the manufacturing apparatus 100 further includes a laminating station 140 at a position downstream of the adhesive application station 130.
- the laminating station 140 includes a heating device 141, an outer peripheral punching female mold 142, a heat insulating member 143, an outer peripheral punching male mold 144, and a spring 145.
- the heating device 141, the outer peripheral punching female die 142, and the heat insulating member 143 are arranged below the original steel plate P.
- the outer peripheral punching male die 144 and the spring 145 are arranged above the original steel plate P.
- the original steel plate P is sequentially sent out from the coil Q in the direction of arrow F in FIG. Then, the original steel sheet P is first punched by the punching station 110. Then, the original steel sheet P is punched by the punching station 120.
- the shape of the electromagnetic steel sheet 40 having the core back portion 22 and the plurality of teeth portions 23 shown in FIG. 3 is obtained on the original steel sheet P (punching step).
- the adhesive application station 130 in the next step the adhesive supplied from each injector of the applicator 131 is applied in a dot shape (application step).
- the original steel sheet P is sent to the laminating station 140, punched by the outer peripheral punching male die 144, and laminated accurately (laminating step).
- the electromagnetic steel plate 40 is subjected to a constant pressing force by the spring 145.
- the punching process, the coating process, and the laminating process as described above a predetermined number of electromagnetic steel plates 40 can be stacked.
- the laminated body formed by stacking the electromagnetic steel plates 40 in this manner is heated to, for example, 60 to 200° C. by the heating device 141. This heating cures the adhesive and forms the adhesive portion 41 (curing step).
- the stator core 21 is completed through the above steps.
- the rotating electric machine and the laminated core according to the present embodiment a plurality of electromagnetic steel sheets whose both surfaces are covered with the insulating coating are laminated, and the electromagnetic steel sheets adjacent to each other in the laminating direction have the first phase and the first phase.
- the two are adhered at an adhesive portion formed of an adhesive containing two phases. Adhesion between the electromagnetic steel sheets makes it possible to obtain sufficient adhesive strength.
- each adhesive has a sea-island structure of a first phase and a second phase. Therefore, the rotary electric machine and the laminated core according to the present embodiment can easily alleviate the strain generated in the electromagnetic steel sheet. As a result, the hysteresis loss can be easily reduced, and the magnetic characteristics of the laminated core can be improved.
- the laminated core according to the present embodiment has improved magnetic characteristics. Therefore, the laminated core according to the present embodiment is suitable as a laminated core for a stator (stator core).
- the laminated core may be used as a rotor core.
- the shape of the stator core is not limited to the shape shown in the above embodiment. Specifically, the outer diameter and inner diameter of the stator core, the product thickness, the number of slots, the circumferential and radial dimension ratios of the teeth portion 23, the radial dimension ratios of the teeth portion 23 and the core back portion 22, and the like are It can be arbitrarily designed according to the desired characteristics of the rotary electric machine.
- the pair of permanent magnets 32 forms one magnetic pole, but the present invention is not limited to this.
- one permanent magnet 32 may form one magnetic pole, and three or more permanent magnets 32 may form one magnetic pole.
- the rotating electric machine has been described by taking a permanent magnet field type electric motor as an example, but the structure of the rotating electric machine is not limited to this as illustrated below, and further various publicly known not illustrated below. The structure of can also be adopted.
- the permanent magnet field type motor is described as an example of the synchronous motor, but the present invention is not limited to this.
- the rotating electric machine may be a reluctance type electric motor or an electromagnet field type electric motor (winding field type electric motor).
- the synchronous motor is described as an example of the AC motor, but the present invention is not limited to this.
- the rotating electric machine may be an induction motor.
- the AC motor is described as an example of the electric motor, but the present invention is not limited to this.
- the rotating electric machine may be a DC electric motor.
- an electric motor has been described as an example of the rotating electric machine, but the present invention is not limited to this.
- the rotating electric machine may be a generator.
- Examples 1 to 7, Comparative Examples 1 to 8 Prepare a hoop with a thickness of 0.25 mm, apply an insulating film treatment solution containing a metal phosphate and an acrylic resin emulsion on both sides of this hoop, and bake at 300°C to obtain an insulating film of 0.8 ⁇ m on one side. Formed. The hoop having the insulating coating formed thereon was wound up to form a coil Q. The coil Q was set in the above-described manufacturing apparatus 100, and the original steel plate P was sent out from the coil Q in the arrow F direction.
- a single plate core (electromagnetic steel plate 40) having a ring shape with an outer diameter of 300 mm and an inner diameter of 240 mm and provided with 18 rectangular teeth portions having a length of 30 mm and a width of 15 mm on the inner diameter side is provided. It was formed by punching (punching process). Subsequently, the punched veneer core was sequentially fed, and at each position shown in FIG. 3, 5 mg of the adhesive having the composition shown in Table 1 was applied in spots (application step), and laminated ( Lamination process). By repeating the same operation, a laminated body in which 130 veneer cores were laminated was obtained. While heating the obtained laminated body at a pressure of 10 MPa, it was heated at 120° C. to cure the adhesive (curing step), and the laminated core (stator core) of each example was manufactured. The average thickness of the adhesive portion was 1.5 ⁇ m.
- ⁇ Curing agent> Diethylaminopropylamine (DEAPA).
- C2 Novolac type phenol resin.
- C3 Methylhexahydrophthalic anhydride.
- the ratio of each component of the first phase represents the content (volume% (vol%)) of each component with respect to the total volume of the first phase.
- the ratio of the second phase represents the content (volume% (vol%)) with respect to the total volume of the adhesive.
- the second phase was 100% by volume of elastomer.
- the unit of SP value is (cal/cm 3 ) 1/2 .
- the SP value of the first phase was measured by the following method. The resin composition constituting the first phase was applied to the surface of the electromagnetic steel sheet and heated to 120° C. to cure.
- the obtained cured product was rubbed with various solvents having known SP values shown in Table 2, and when the solvent was discolored by dissolving the cured product of the first phase in the solvent, the SP value of the solvent was changed to The SP value for one phase was used.
- the SP value of the second phase was measured by the following method.
- the elastomer before being mixed with the resin composition constituting the first phase was heated to 120° C. to be cured.
- the obtained cured product was rubbed with various solvents having known SP values shown in Table 2, and when the solvent was discolored by dissolving the second phase cured product in the solvent, the SP value of the solvent was changed to Two-phase SP value was used.
- each solvent shown in Table 2 and a mixed solvent in which two or more kinds of these solvents are appropriately mixed to adjust the SP value are prepared. Then, it was made possible to measure the SP value in steps of 0.1 in the range of 7.0 to 11.4.
- "presence or absence of sea-island structure” is "present” if a phase-separated structure is observed by observing a cut surface obtained by cutting the laminated core in a radial direction so as to include an adhesive portion and a phase-separated structure is recognized. If none of them is recognized, it is set to “none”.
- the verification test was performed by simulation using software.
- the software finite element method electromagnetic field analysis software JMAG manufactured by JSOL Co., Ltd. was used.
- the iron loss of the laminated core of each example was obtained by the above simulation. Further, as a comparison target, the iron loss of the laminated core in which all the plurality of electromagnetic steel sheets were crimped was also obtained. A value (iron loss ratio) was obtained by dividing the iron loss of the laminated core of each example by the iron loss of the laminated core to be compared. When the iron loss of the laminated core of each example is equivalent to the iron loss of the laminated core to be compared, the iron loss ratio becomes 100%. The smaller the iron loss ratio, the smaller the iron loss of the laminated core of each example, and the more excellent the magnetic characteristics of the laminated core.
- the iron loss ratio of the laminated core of each example was calculated, and the magnetic characteristics of the laminated core of each example were evaluated based on the following evaluation criteria. The results are shown in Table 1. "Evaluation criteria" A: Iron loss ratio is less than 100%. B: Iron loss ratio is 100% or more.
- the iron loss ratio was less than 100%, and the magnetic characteristics could be improved.
- Comparative Examples 1 to 4 and 8 in which the SP value of the first phase was outside the range of the present invention the iron loss ratio was 100% or more.
- Comparative Examples 5 to 7 in which the content of the second phase was large and the bonded portion did not have a sea-island structure the iron loss ratio was 100% or more.
- the laminated core of the present invention can suppress the iron loss and improve the magnetic characteristics of the laminated core.
- the magnetic characteristics of the laminated core can be improved. Therefore, industrial availability is great.
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Abstract
Description
本願は、2018年12月17日に、日本に出願された特願2018-235868号に基づき優先権を主張し、その内容をここに援用する。
(1)本発明の第一の態様は、互いに積層され、両面が絶縁被膜により被覆された複数の電磁鋼板と、積層方向に隣り合う前記電磁鋼板同士の間に設けられ、前記電磁鋼板同士をそれぞれ接着する接着部と、を備え、前記接着部を形成する接着剤が、第一相と第二相とを含み、前記接着部は、海構造部である前記第一相と、島構造部である前記第二相との海島構造を有し、前記第一相は、エポキシ樹脂とアクリル樹脂と硬化剤とを含み、前記第一相は、SP値が8.5~10.7(cal/cm3)1/2であり、前記第二相は、エラストマーを含み、前記第二相は、SP値が7.5~8.4(cal/cm3)1/2である積層コアである。
(2)前記(1)に記載の積層コアでは、前記第一相のSP値と、前記第二相のSP値との差が、0.1~3.0(cal/cm3)1/2であってもよい。
(3)前記(1)又は前記(2)に記載の積層コアでは、前記第一相の含有量が、前記接着部の総体積に対して、50体積%以上であってもよい。
(4)前記(1)から前記(3)のいずれか1つに記載の積層コアでは、前記エポキシ樹脂の含有量が、前記第一相の総体積に対して、50体積%以上であってもよい。
(5)前記(1)から前記(4)のいずれか1つに記載の積層コアでは、前記アクリル樹脂の含有量が、前記第一相の総体積に対して、5~45体積%であってもよい。
(6)前記(1)から前記(5)のいずれか1つに記載の積層コアでは、前記硬化剤の含有量が、前記第一相の総体積に対して、1~40体積%であってもよい。
(7)前記(1)から前記(6)のいずれか1つに記載の積層コアでは、前記硬化剤が、ノボラック型フェノール樹脂であってもよい。
(8)前記(1)から前記(7)のいずれか1つに記載の積層コアは、ステータ用であってもよい。
本実施形態では、回転電機10として、ロータ30がステータ20の内側に位置するインナーロータ型を採用している。しかしながら、回転電機10として、ロータ30がステータ20の外側に位置するアウターロータ型を採用してもよい。また、本実施形態では、回転電機10が、12極18スロットの三相交流モータである。しかしながら、極数やスロット数、相数等は適宜変更することができる。
回転電機10は、例えば、各相に実効値10A、周波数100Hzの励磁電流を印加することにより、回転数1000rpmで回転することができる。
ステータコア21は、環状のコアバック部22と、複数のティース部23と、を備える。以下では、ステータコア21(又はコアバック部22)の中心軸線O方向を軸方向といい、ステータコア21(又はコアバック部22)の径方向(中心軸線Oに直交する方向)を径方向といい、ステータコア21(又はコアバック部22)の周方向(の中心軸線O周りに周回する方向)を周方向という。
複数のティース部23は、コアバック部22から径方向の内側に向けて(径方向に沿ってコアバック部22の中心軸線Oに向けて)突出する。複数のティース部23は、周方向に同等の間隔をあけて配置されている。本実施形態では、中心軸線Oを中心とする中心角20度おきに18個のティース部23が設けられている。複数のティース部23は、互いに同等の形状で、かつ同等の大きさに形成されている。
前記巻線は、ティース部23に巻き回されている。前記巻線は、集中巻きされていてもよく、分布巻きされていてもよい。
ロータコア31は、ステータ20と同軸に配置される環状(円環状)に形成されている。ロータコア31内には、前記回転軸60が配置されている。回転軸60は、ロータコア31に固定されている。
複数の永久磁石32は、ロータコア31に固定されている。本実施形態では、2つ1組の永久磁石32が1つの磁極を形成している。複数組の永久磁石32は、周方向に同等の間隔をあけて配置されている。本実施形態では、中心軸線Oを中心とする中心角30度おきに12組(全体では24個)の永久磁石32が設けられている。
ロータコア31には、ロータコア31を軸方向に貫通する複数の貫通孔33が形成されている。複数の貫通孔33は、複数の永久磁石32に対応して設けられている。各永久磁石32は、対応する貫通孔33内に配置された状態でロータコア31に固定されている。各永久磁石32のロータコア31への固定は、例えば永久磁石32の外面と貫通孔33の内面とを接着剤により接着すること等により、実現することができる。なお、永久磁石界磁型電動機として、埋込磁石型モータに代えて表面磁石型モータを採用してもよい。
なおステータコア21及びロータコア31それぞれの積厚は、例えば、50.0mmとされる。ステータコア21の外径は、例えば、250.0mmとされる。ステータコア21の内径は、例えば、165.0mmとされる。ロータコア31の外径は、例えば、163.0mmとされる。ロータコア31の内径は、例えば、30.0mmとされる。ただし、これらの値は一例であり、ステータコア21の積厚、外径や内径、及びロータコア31の積厚、外径や内径はこれらの値に限られない。ここで、ステータコア21の内径は、ステータコア21におけるティース部23の先端部を基準としている。ステータコア21の内径は、全てのティース部23の先端部に内接する仮想円の直径である。
しかしながら、電磁鋼板40として、無方向性電磁鋼板に代えて方向性電磁鋼板を採用することも可能である。方向性電磁鋼板としては、例えば、JIS C2553:2012の方向性電鋼帯を採用することができる。
有機樹脂は、後述する接着剤に含まれる有機樹脂と同じでもよく、異なっていてもよい。
一方で、絶縁被膜が厚くなるに連れて絶縁効果が飽和する。また、絶縁被膜が厚くなるに連れて占積率が低下し、積層コアとしての性能が低下する。したがって、絶縁被膜は、絶縁性能が確保できる範囲で薄い方がよい。絶縁被膜の厚さ(電磁鋼板40片面あたりの厚さ)は、0.1μm以上5μm以下が好ましく、0.1μm以上2μm以下がより好ましい。
絶縁被膜の厚さは、例えば、電磁鋼板40を厚さ方向に切断した切断面を顕微鏡等により観察することで測定できる。
一方で、電磁鋼板40が厚すぎると、電磁鋼板40のプレス打ち抜き作業が困難になる。そのため、電磁鋼板40のプレス打ち抜き作業を考慮すると電磁鋼板40の厚さは0.65mm以下とすることが好ましい。
また、電磁鋼板40が厚くなると鉄損が増大する。そのため、電磁鋼板40の鉄損特性を考慮すると、電磁鋼板40の厚さは0.35mm以下が好ましく、0.25mm以下がより好ましく、0.20mm以下がさらに好ましい。
上記の点を考慮し、各電磁鋼板40の厚さは、例えば、0.10mm以上0.65mm以下が好ましく、0.10mm以上0.35mm以下がより好ましく、0.10mm以上0.25mm以下がさらに好ましく、0.10mm以上0.20mm以下が特に好ましい。なお電磁鋼板40の厚さには、絶縁被膜の厚さも含まれる。
電磁鋼板40の厚さは、例えば、マイクロメータ等により測定できる。
接着部41は、第一相と第二相との海島構造を有する。ここで、「海島構造」とは、一方の成分からなる相(島構造部)が、もう一方の成分からなる相(海構造部)中に分散した相分離構造を意味する。
本実施形態の電磁鋼板40は、接着部41が海島構造を有することで、電磁鋼板40に生じる歪を緩和しやすい。電磁鋼板40に生じる歪を緩和することで、ヒステリシス損が低減しやすく、その結果、積層コアの磁気特性を向上させることができる。硬い第一相の硬化物と柔らかい第二相との海島構造が、電磁鋼板40に生じる歪を吸収しやすいため、電磁鋼板40に生じる歪を緩和できるものと考えられる。
なお、ヒステリシス損とは、積層コアの磁界の方向が変化することによって生じるエネルギー損失のことをいう。ヒステリシス損は、鉄損の一種である。
本実施形態の接着部41では、第一相が連続相である海構造部を形成し、第二相が分散相である島構造部を形成している。第一相と第二相とのどちらが海構造部を形成するかは、その相の粘度や量によって決定される。本実施形態の接着部41では、第二相に比べて粘度が低く、かつ、量が多い第一相が、連続相である海構造部を形成している。
第一相は、エポキシ樹脂とアクリル樹脂と硬化剤とを含む。第一相の硬化物としては、接着部41の接着強度を高めやすい観点から、エポキシ樹脂にアクリル樹脂をグラフト重合させたアクリル変性エポキシ樹脂が好ましい。
第一相の含有量は、接着剤の総体積に対して、50体積%以上が好ましく、50~95体積%がより好ましく、60~90体積%がさらに好ましく、70~80体積%が特に好ましい。第一相の含有量が上記下限値以上であると、接着部41の接着強度を高めやすい。第一相の含有量が上記上限値以下であると、電磁鋼板40に生じる歪を緩和しやすい。
第一相の含有量は、25℃における接着剤の総体積に対する第一相の体積の割合である。
本明細書において、「SP値」は、ヒルデブラント(Hildebrand)の溶解度パラメータを意味する。
第一相のSP値は、例えば、下記の方法により測定することができる。無方向性電磁鋼板の表面に第一相を構成する樹脂組成物を塗布し、120℃に加熱して硬化させる。得られた硬化物に対してSP値が既知の種々の溶剤を擦り付け、第一相の硬化物が溶剤に溶解することにより溶剤が変色したとき、その溶剤のSP値を第一相のSP値とする。
エポキシ樹脂の数平均分子量は、標準物質としてポリスチレンを用い、JIS K7252-1:2008に記載のサイズ排除クロマトグラフィー(SEC:Size-Exclusion Chromatography)により測定できる。
エポキシ樹脂としては、2価のカルボン酸を組み合わせたエポキシエステル樹脂であってもよい。2価のカルボン酸としては、例えば、コハク酸、アジピン酸、ヒメリン酸、アゼライン酸、セバシン酸、ドデカン二酸、ヘキサヒドロフタル酸等が挙げられる。
ビスフェノールとしては、ビスフェノールA、ビスフェノールF、ビスフェノールAD等が挙げられ、ビスフェノールA、ビスフェノールFが好ましい。
アルカリ触媒としては、水酸化ナトリウム、水酸化カリウム等が挙げられる。
これらのエポキシ樹脂は、1種を単独で用いてもよく、2種以上を併用してもよい。
エポキシ樹脂の含有量は、25℃における硬化前の第一相の総体積に対するエポキシ樹脂の体積の割合である。
アクリル樹脂の数平均分子量が上記上限値以下であると、接着剤が高粘度になることを抑制しやすく、接着剤を電磁鋼板40の表面に塗布しやすい。
アクリル樹脂の数平均分子量は、エポキシ樹脂の数平均分子量と同様の方法により測定できる。
ラジカル重合性不飽和単量体としては、(1)アクリル酸2-ヒドロキシエチル、メタクリル酸2-ヒドロキシエチル、アクリル酸ヒドロキシプロピル、メタクリル酸ヒドロキシプロピル等の、アクリル酸又はメタクリル酸の炭素原子数が1~8個のヒドロキシアルキルエステル、(2)アクリル酸メチル、メタクリル酸メチル、アクリル酸エチル、メタクリル酸エチル、アクリル酸n-ブチル、メタクリル酸n-ブチル、アクリル酸イソブチル、メタクリル酸イソブチル、アクリル酸tert-ブチル、メタクリル酸tert-ブチル、アクリル酸シクロヘキシル、メタクリル酸シクロヘキシル、アクリル酸2-エチルヘキシル、メタクリル酸2-エチルヘキシル、アクリル酸ラウリル、メタクリル酸ラウリル、アクリル酸ステアリル、メタクリル酸ステアリル、アクリル酸デシル等の、アクリル酸又はメタクリル酸の炭素原子数が1~24個のアルキルエステル又はシクロアルキルエステル、(3)アクリルアミド、メタクリルアミド、N-メチルアクリルアミド、N-エチルアクリルアミド、ジアセトンアクリルアミド、N-メチロールアクリルアミド、N-メチロールメタクリルアミド、N-メトキシメチルアクリルアミド、N-ブトキシメチルアクリルアミド等の、官能性アクリルアミド又は官能性メタクリルアミド、(4)スチレン、ビニルトルエン、α-メチルスチレン等の、芳香族ビニル単量体、(5)酢酸ビニル、プロピオン酸ビニル、アクリロニトリル、メタクリロニトリル等の、脂肪族ビニル単量体等が挙げられる。
グラフト重合反応に用いられるラジカル発生剤は、ラジカル重合性不飽和単量体の固形分100質量部に対して、3~15質量部が好ましい。
このような有機溶剤としては、例えば、イソプロパノール、ブチルアルコール、2-ヒドロキシ-4-メチルペンタン、2-エチルヘキシルアルコール、シクロヘキサノール、エチレングリコール、ジエチレングリコール、1,3-ブチレングリコール、エチレングリコールモノエチルエーテル、エチレングリコールモノブチルエーテル、ジエチレングリコールモノメチルエーテル等のアルコール系溶剤、アセトン、メチルエチルケトン等のケトン系溶剤、セロソルブ系溶剤及びカルビトール系溶剤を挙げることができる。また、水と混和しない不活性有機溶剤も使用可能であり、このような有機溶剤としては、例えば、トルエン、キシレン等の芳香族系炭化水素類、酢酸エチル、酢酸ブチル等のエステル類が挙げられる。
アクリル樹脂の含有量は、25℃における硬化前の第一相の総体積に対するアクリル樹脂の体積の割合である。
潜在性硬化剤としては、例えば、ジシアンジアミド、メラミン、有機酸ジヒドラジド、アミンイミド、ケチミン、第3級アミン、イミダゾール塩、3フッ化ホウ素アミン塩、マイクロカプセル型硬化剤(硬化剤をカゼイン等で形成したマイクロカプセル中に封入し、加熱・加圧によりマイクロカプセルを破り、樹脂と硬化反応するもの)、モレキュラーシーブ型硬化剤(吸着性化合物の表面に硬化剤を吸着させたもので、加熱により吸着分子を放出し、樹脂と硬化反応するもの)等が挙げられる。
フェノール類としては、フェノールが挙げられる。
アルデヒド類としては、ホルムアルデヒドが挙げられる。
酸触媒としては、シュウ酸や2価の金属塩が挙げられる。
ノボラック型フェノール樹脂は、常温(25℃)で固体であり、熱可塑性樹脂に分類される。ノボラック型フェノール樹脂では、フェノール樹脂を構成するフェノール核(芳香環)に、-CH2OH基がほとんど結合していない。
硬化剤の含有量は、25℃における硬化前の第一相の総体積に対する硬化剤の体積の割合である。
合成ゴムとしては、ポリブタジエン系合成ゴム、ニトリル系合成ゴム、クロロプレン系合成ゴム等が挙げられる。
ポリブタジエン系合成ゴムとしては、例えば、イソプレンゴム(IR、SP値:7.9~8.4(cal/cm3)1/2)、ブタジエンゴム(BR、SP値:8.1~8.6(cal/cm3)1/2)、スチレンブタジエンゴム(SBR、SP値:8.1~8.7(cal/cm3)1/2)、ポリイソブチレン(ブチルゴム、IIR、SP値:7.7~8.1(cal/cm3)1/2)、エチレンプロピレンジエンゴム(EPDM、SP値:7.9~8.0(cal/cm3)1/2)等が挙げられる。
ニトリル系合成ゴムとしては、例えば、アクリロニトリルブタジエンゴム(NBR、SP値:8.7~10.5(cal/cm3)1/2)、アクリルゴム(ACM、SP値:9.4(cal/cm3)1/2)等が挙げられる。
クロロプレン系合成ゴムとしては、クロロプレンゴム(CR、SP値:8.2~9.4(cal/cm3)1/2)等が挙げられる。
合成ゴムとしては、上記のほか、ウレタンゴム(SP値:10.0(cal/cm3)1/2)、シリコーンゴム(SP値:7.3~7.6(cal/cm3)1/2)、フッ素ゴム(FKM、SP値:8.6(cal/cm3)1/2)、クロロスルホン化ポリエチレン(CSM、SP値:8.1~10.6(cal/cm3)1/2)、エピクロロヒドリンゴム(ECO、SP値:9.6~9.8(cal/cm3)1/2)等を用いてもよい。
エラストマーとしては、耐熱性に優れ、かつ、電磁鋼板40に生じる歪を緩和しやすい観点から、SBR、EPDM、NBRが好ましい。
エラストマーは、1種を単独で用いてもよく、2種以上を併用してもよい。
エラストマーの含有量は、第二相の総体積に対して、50体積%以上が好ましく、70体積%以上がより好ましく、90体積%以上がさらに好ましく、100体積%が特に好ましい。エラストマーの含有量が上記下限値以上であると、接着部41が第一相と第二相との海島構造を形成しやすく、電磁鋼板40に生じる歪を緩和しやすい。
エラストマーの含有量は、25℃における第二相の総体積に対するエラストマーの体積の割合である。
第二相の含有量は、25℃における接着剤の総体積に対する第二相の体積の割合である。第二相の体積は、第二相を25℃の水に浸漬し、増加した水の体積により求められる。
第二相のSP値は、例えば、下記の方法により測定することができる。無方向性電磁鋼板の表面に第二相を構成する樹脂組成物を塗布し、120℃に加熱して硬化させる。得られた硬化物に対してSP値が既知の種々の溶剤を擦り付け、第二相の硬化物が溶剤に溶解することにより溶剤が変色したとき、その溶剤のSP値を第二相のSP値とする。
SP値が既知の種々の溶剤としては、第一相のSP値を測定する際のSP値が既知の種々の溶剤と同様の溶剤が挙げられる。
第一相のSP値と第二相のSP値との差は、第一相のSP値と第二相のSP値とをそれぞれ測定し、得られた第一相のSP値から、得られた第二相のSP値を減じることによって求められる。
これら任意成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
なお、平均引張弾性率Eは、共振法により測定される。具体的には、JIS R 1602:1995に準拠して引張弾性率を測定する。
より具体的には、まず、測定用のサンプル(不図示)を製作する。このサンプルは、2枚の電磁鋼板40間を、測定対象の接着剤により接着し、硬化させて接着部41を形成することにより、得られる。この硬化は、接着剤が熱硬化型の場合には、実操業上の加熱加圧条件で加熱加圧することで行う。一方、接着剤が常温硬化型の場合には常温下で加圧することで行う。
そして、このサンプルについての引張弾性率を、共振法で測定する。共振法による引張弾性率の測定方法は、上述した通り、JIS R 1602:1995に準拠して行う。その後、サンプルの引張弾性率(測定値)から、電磁鋼板40自体の影響分を計算により除くことで、接着部41単体の引張弾性率が求められる。
このようにしてサンプルから求められた引張弾性率は、積層コア全体としての平均値に等しくなるので、この数値をもって平均引張弾性率Eとみなす。平均引張弾性率Eは、その積層方向に沿った積層位置や積層コアの中心軸線回りの周方向位置で殆ど変わらないよう、組成が設定されている。そのため、平均引張弾性率Eは、積層コアの上端位置にある、硬化後の接着部41を測定した数値をもってその値とすることもできる。
一方で、接着部41の厚さが100μmを超えると接着力が飽和する。また、接着部41が厚くなるに連れて占積率が低下し、積層コアの鉄損等の磁気特性が低下する。したがって、接着部41の厚さは1μm以上100μm以下が好ましく、1μm以上10μm以下がより好ましい。
なお、上記において接着部41の厚さは、接着部41の平均厚みを意味する。
接着部41の平均厚みは、積層コア全体としての平均値である。接着部41の平均厚みはその積層方向に沿った積層位置や積層コアの中心軸線回りの周方向位置で殆ど変わらない。そのため、接着部41の平均厚みは、積層コアの上端位置において、円周方向10箇所以上で測定した数値の平均値をもってその値とすることができる。
なお、ステータコア21やロータコア31などの積層コアは、いわゆる回し積みにより形成されていてもよい。
次に、本実施形態のステータコア21の製造方法について、図面を参照して説明する。
打ち抜きステーション110は、元鋼板Pの下方に配置された雌金型111と、元鋼板Pの上方に配置された雄金型112とを備える。
打ち抜きステーション120は、元鋼板Pの下方に配置された雌金型121と、元鋼板Pの上方に配置された雄金型122とを備える。
接着剤塗布ステーション130は、接着剤の塗布パターンに応じて配置された複数本のインジェクターを備える塗布器131を備える。
加熱装置141、外周打ち抜き雌金型142、断熱部材143は、元鋼板Pの下方に配置されている。一方、外周打ち抜き雄金型144及びスプリング145は、元鋼板Pの上方に配置されている。
以上の各工程により、ステータコア21が完成する。
加えて、それぞれの接着部は、第一相と第二相との海島構造を有する。このため、本実施形態に係る回転電機及び積層コアは、電磁鋼板に生じる歪を緩和しやすい。その結果、ヒステリシス損が低減しやすく、積層コアの磁気特性を向上させることができる。
本実施形態に係る積層コアは、磁気特性が向上されている。このため、本実施形態に係る積層コアは、ステータ用の積層コア(ステータコア)として好適である。積層コアは、ロータコアとして用いてもよい。
前記実施形態では、同期電動機として、永久磁石界磁型電動機を一例に挙げて説明したが、本発明はこれに限られない。例えば、回転電機がリラクタンス型電動機や電磁石界磁型電動機(巻線界磁型電動機)であってもよい。
前記実施形態では、交流電動機として、同期電動機を一例に挙げて説明したが、本発明はこれに限られない。例えば、回転電機が誘導電動機であってもよい。
前記実施形態では、電動機として、交流電動機を一例に挙げて説明したが、本発明はこれに限られない。例えば、回転電機が直流電動機であってもよい。
前記実施形態では、回転電機として、電動機を一例に挙げて説明したが、本発明はこれに限られない。例えば、回転電機が発電機であってもよい。
厚さ0.25mmのフープを用意し、このフープの両面にリン酸金属塩及びアクリル樹脂エマルジョンを含有する絶縁被膜処理液を塗布し、300℃で焼き付けを行い、片面で0.8μmの絶縁被膜を形成した。
絶縁被膜を形成したフープを巻き取り、コイルQとした。コイルQを上述した製造装置100にセットし、コイルQから元鋼板Pを矢印F方向に向かって送り出した。製造装置100を用いて、外径300mm及び内径240mmのリング状を有してかつ、内径側に長さ30mmで幅15mmの長方形のティース部を18箇所設けた単板コア(電磁鋼板40)を打ち抜きにより形成した(打ち抜き工程)。
続いて、打ち抜いた単板コアを順次送りながら、図3に示した各位置に、表1に示す組成の接着剤を1箇所当たり5mg、点状に塗布し(塗布工程)、そして積層した(積層工程)。同様の作業を繰り返し行うことにより、130枚の単板コアが積層された積層体を得た。得られた積層体を圧力10MPaで加圧しながら、120℃で加熱し、接着剤を硬化させて(硬化工程)、各例の積層コア(ステータコア)を製造した。接着部の平均厚さは、1.5μmであった。
<エポキシ樹脂>
A1:ビスフェノールF型。
A2:ビスフェノールA型。
A3:ビスフェノールAD型。
B1:アクリル酸。
B2:メタクリル酸。
B3:マレイン酸。
C1:ジエチルアミノプロピルアミン(DEAPA)。
C2:ノボラック型フェノール樹脂。
C3:メチルヘキサヒドロ無水フタル酸。
<エラストマー>
D1:EPDM(SP値:7.9~8.0(cal/cm3)1/2)。
D2:SBR(SP値:8.1~8.7(cal/cm3)1/2)。
D3:NBR(SP値:8.7~10.5(cal/cm3)1/2)。
表1中、第二相の比率は、接着剤の総体積に対する含有量(体積%(vol%))を表す。第二相は、エラストマー100体積%とした。
表1中、SP値の単位は、(cal/cm3)1/2である。第一相のSP値は、下記の方法により測定した。電磁鋼板の表面に第一相を構成する樹脂組成物を塗布し、120℃に加熱して硬化させた。得られた硬化物に対して、表2に示すSP値が既知の種々の溶剤を擦り付け、第一相の硬化物が溶剤に溶解することにより溶剤が変色したとき、その溶剤のSP値を第一相のSP値とした。
第二相のSP値は、下記の方法により測定した。第一相を構成する樹脂組成物と混合する前のエラストマーを120℃に加熱して硬化させた。得られた硬化物に対して、表2に示すSP値が既知の種々の溶剤を擦り付け、第二相の硬化物が溶剤に溶解することにより溶剤が変色したとき、その溶剤のSP値を第二相のSP値とした。
なお、第一相のSP値及び第二相のSP値の測定においては、表2に示す各溶剤と、これらの溶剤のうち2種以上を適宜混合してSP値を調整した混合溶剤を用意し、7.0~11.4の範囲の0.1刻みでSP値を測定できるようにした。
表1中、「海島構造有無」は、接着部を含むように、積層コアを径方向に切断した切断面を顕微鏡等により観察し、相分離構造が認められれば「有り」とし、相分離構造が認められなければ「無し」とした。
また、比較対象として、複数の電磁鋼板が全層かしめられている積層コアの鉄損も求めた。各例の積層コアの鉄損を、上記比較対象となる積層コアの鉄損で割った値(鉄損比)を求めた。各例の積層コアの鉄損が、上記比較対象となる積層コアの鉄損と同等であると、鉄損比が100%になる。鉄損比が小さいほど、各例の積層コアの鉄損が小さく、積層コアとしての磁気特性に優れる。
各例の積層コアの鉄損比を算出し、下記評価基準に基づいて各例の積層コアの磁気特性を評価した。結果を表1に示す。
《評価基準》
A:鉄損比が100%未満。
B:鉄損比が100%以上。
一方、第一相のSP値が本発明の範囲外である比較例1~4、8は、鉄損比が100%以上だった。
第二相の含有量が多く、接着部が海島構造を有しない比較例5~7は、鉄損比が100%以上だった。
20 ステータ
21 ステータコア(積層コア)
40 電磁鋼板
41 接着部
Claims (10)
- 互いに積層され、両面が絶縁被膜により被覆された複数の電磁鋼板と、
積層方向に隣り合う前記電磁鋼板同士の間に設けられ、前記電磁鋼板同士をそれぞれ接着する接着部と、を備え、
前記接着部を形成する接着剤が、第一相と第二相とを含み、
前記接着部は、海構造部である前記第一相と、島構造部である前記第二相との海島構造を有し、
前記第一相は、エポキシ樹脂とアクリル樹脂と硬化剤とを含み、
前記第一相は、SP値が8.5~10.7(cal/cm3)1/2であり、
前記第二相は、エラストマーを含み、
前記第二相は、SP値が7.5~8.4(cal/cm3)1/2である、積層コア。 - 前記第一相のSP値と、前記第二相のSP値との差が、0.1~3.0(cal/cm3)1/2である、請求項1に記載の積層コア。
- 前記第一相の含有量が、前記接着部の総体積に対して、50体積%以上である、請求項1又は2に記載の積層コア。
- 前記エポキシ樹脂の含有量が、前記第一相の総体積に対して、50体積%以上である、請求項1~3のいずれか一項に記載の積層コア。
- 前記アクリル樹脂の含有量が、前記第一相の総体積に対して、5~45体積%である、請求項1~4のいずれか一項に記載の積層コア。
- 前記硬化剤の含有量が、前記第一相の総体積に対して、1~40体積%である、請求項1~5のいずれか一項に記載の積層コア。
- 前記硬化剤が、ノボラック型フェノール樹脂である、請求項1~6のいずれか一項に記載の積層コア。
- ステータ用である、請求項1~7のいずれか一項に記載の積層コア。
- 請求項1~8のいずれか一項に記載の積層コアの製造方法であって、
エポキシ樹脂とアクリル樹脂と硬化剤とを含む第一相と、エラストマーを含む第二相とを含む接着剤を電磁鋼板の表面に塗布し、複数の前記電磁鋼板を重ねて前記接着剤を硬化させ、接着部を形成する、積層コアの製造方法。 - 請求項1~8のいずれか一項に記載の積層コアを備える回転電機。
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US11863017B2 (en) | 2018-12-17 | 2024-01-02 | Nippon Steel Corporation | Laminated core and electric motor |
US11915860B2 (en) | 2018-12-17 | 2024-02-27 | Nippon Steel Corporation | Laminated core and electric motor |
US11923130B2 (en) | 2018-12-17 | 2024-03-05 | Nippon Steel Corporation | Laminated core and electric motor |
US11973369B2 (en) | 2018-12-17 | 2024-04-30 | Nippon Steel Corporation | Laminated core with center electrical steel sheets adhered with adhesive and some electrical steel sheets fixed to each other on both ends of the center sheets |
US11979059B2 (en) | 2018-12-17 | 2024-05-07 | Nippon Steel Corporation | Laminated core and electric motor |
US11990795B2 (en) | 2018-12-17 | 2024-05-21 | Nippon Steel Corporation | Adhesively-laminated core for stator, method of manufacturing same, and electric motor |
US11996231B2 (en) | 2018-12-17 | 2024-05-28 | Nippon Steel Corporation | Laminated core and electric motor |
Also Published As
Publication number | Publication date |
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JP7180690B2 (ja) | 2022-11-30 |
KR102531969B1 (ko) | 2023-05-12 |
CN113196617A (zh) | 2021-07-30 |
JPWO2020129948A1 (ja) | 2021-11-04 |
CA3131673A1 (en) | 2020-06-25 |
KR20210091259A (ko) | 2021-07-21 |
TWI725670B (zh) | 2021-04-21 |
SG11202108989YA (en) | 2021-09-29 |
US20220029478A1 (en) | 2022-01-27 |
CA3131673C (en) | 2024-02-20 |
EP3902107A4 (en) | 2022-11-30 |
EP3902107A1 (en) | 2021-10-27 |
EA202192058A1 (ru) | 2021-11-24 |
TW202027984A (zh) | 2020-08-01 |
US11855485B2 (en) | 2023-12-26 |
BR112021009823A2 (pt) | 2021-08-17 |
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