WO2021256538A1 - 電磁鋼板用コーティング組成物、電磁鋼板、積層コア及び回転電機 - Google Patents
電磁鋼板用コーティング組成物、電磁鋼板、積層コア及び回転電機 Download PDFInfo
- Publication number
- WO2021256538A1 WO2021256538A1 PCT/JP2021/023049 JP2021023049W WO2021256538A1 WO 2021256538 A1 WO2021256538 A1 WO 2021256538A1 JP 2021023049 W JP2021023049 W JP 2021023049W WO 2021256538 A1 WO2021256538 A1 WO 2021256538A1
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- WIPO (PCT)
- Prior art keywords
- steel sheets
- coating composition
- electromagnetic steel
- curing agent
- electrical steel
- Prior art date
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- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 4
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 4
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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
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
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- 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
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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
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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- 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
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- H01F3/02—Cores, Yokes, or armatures made from sheets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
-
- 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
-
- 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
-
- 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
-
- 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
-
- 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
- B32B2603/00—Vanes, blades, propellers, rotors with blades
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2312/00—Crosslinking
- C08L2312/04—Crosslinking with phenolic resin
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
Definitions
- the present invention relates to a coating composition for an electromagnetic steel sheet, an electromagnetic steel sheet, a laminated core, and a rotary electric machine.
- a core iron core
- a laminated core in which a plurality of electromagnetic steel sheets are joined to each other and laminated is known.
- Caulking and welding are known as methods for joining electrical steel sheets to each other.
- the magnetic properties (core iron loss) of electrical steel sheets tend to deteriorate due to mechanical strain and thermal strain during processing.
- Patent Document 1 a method of bonding electromagnetic steel sheets having an insulating film having an adhesive ability on the surface to each other is known (Patent Document 1). Adhesion using the insulating film does not give mechanical strain or thermal strain, so it is superior in core iron loss as compared with caulking and welding. Epoxy resin has little volume change, is excellent in heat resistance, oil resistance, and chemical resistance, and is excellent as an adhesive for adhering electromagnetic steel sheets to each other (Patent Documents 2 and 3).
- a method of improving heat resistance there is a method of blending a phenol resin.
- a resin having excellent heat resistance is hard at room temperature and applies a large stress to the laminated core, so that the magnetic properties deteriorate.
- a resin having an appropriate hardness near room temperature is inferior in heat resistance because it becomes soft at high temperatures. For these reasons, it is difficult to achieve both excellent magnetic properties and excellent heat resistance that can maintain sufficient adhesive strength even when exposed to high temperatures during driving.
- the present invention is a coating composition for electrical steel sheets that can achieve both the magnetic properties of a laminated core and heat resistance that can maintain the adhesive strength between electromagnetic steel sheets even in a high temperature state during driving, an electromagnetic steel sheet using the same, a laminated core, and rotation.
- the purpose is to provide electrical equipment.
- the coating composition for an electromagnetic steel plate according to one aspect of the present invention is a first curing agent composed of an epoxy resin and an alkylphenol, and a second curing agent composed of one or both of a phenol resol resin and a phenol novolac resin.
- the content of the first curing agent is 1.0 part by mass or more and 20.0 parts by mass or less with respect to 100 parts by mass of the epoxy resin.
- the alkylphenol is a monoalkylphenol having an alkyl group having 2 to 20 carbon atoms and an alkyl group having 2 to 20 carbon atoms. It may contain either one or both of the dialkylphenols.
- the coating composition for electrical steel sheets according to the above [1] or [2] has a content of the second curing agent of 5.0 parts by mass or more and 150.0 parts by mass with respect to 100 parts by mass of the epoxy resin. It may be less than or equal to a mass part.
- the coating composition for electrical steel sheets according to any one of the above [1] to [3] may have a curing shrinkage rate of 15% or less.
- the coating composition for an electromagnetic steel plate according to any one of the above [1] to [4] contains [content of the first curing agent (A)] / [containing of the second curing agent (B)].
- the mass ratio represented by [amount] may be 0.01 to 4.0.
- the electromagnetic steel sheet according to one aspect of the present invention has an insulating film on the surface containing the coating composition for electrical steel sheets according to any one of the above [1] to [5].
- a plurality of electrical steel sheets according to the above [6] are laminated and bonded to each other.
- the rotary electric machine according to one aspect of the present invention includes the laminated core according to the above [7].
- a coating composition for electrical steel sheets capable of achieving both the magnetic properties of a laminated core and heat resistance capable of maintaining the adhesive strength between electrical steel sheets even in a high temperature state during driving, and electromagnetic steel using the same.
- Steel sheets, laminated cores and rotary electric machines can be provided.
- FIG. 2 is a cross-sectional view taken along the line AA of FIG. It is a top view of the material for forming the laminated core shown in FIG. 1.
- FIG. 4 is a cross-sectional view taken along the line BB of FIG. It is an enlarged view of the part C of FIG. It is a side view of the manufacturing apparatus used for manufacturing the laminated core shown in FIG. 1.
- an electric motor as a rotary electric machine specifically an AC electric motor, more specifically a synchronous electric motor, and more specifically, a permanent magnet field type electric motor will be described as an example.
- This type of motor is suitably adopted for, for example, an electric vehicle.
- the rotary electric machine 10 includes a stator 20, a rotor 30, a case 50, and a rotary shaft 60.
- the stator 20 and the rotor 30 are housed in the case 50.
- the stator 20 is fixed in the case 50.
- the rotary electric machine 10 adopts an inner rotor type in which the rotor 30 is located inside the stator 20 in the radial direction.
- an outer rotor type in which the rotor 30 is located outside the stator 20 may be adopted.
- the rotary electric machine 10 is a 12-pole 18-slot three-phase AC motor.
- the rotary electric 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 an adhesive laminated core for a stator (hereinafter referred to as 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 central axis O direction of the stator core 21 (or core back portion 22) is referred to as an axial direction
- the radial direction of the stator core 21 (or core back portion 22) (direction orthogonal to the central axis O) is referred to as a radial direction
- the circumferential direction (direction that orbits around the central axis O) of the stator core 21 (or core back portion 22) is referred to as a circumferential direction.
- the core back portion 22 is formed in an annular shape in a plan view of the stator 20 when viewed from the axial direction.
- the plurality of tooth portions 23 project radially inward from the inner circumference of the core back portion 22 (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 angular intervals in the circumferential direction. In the present embodiment, 18 tooth portions 23 are provided at every 20 degrees of the central angle centered on the central axis O.
- the plurality of tooth portions 23 are formed to have the same shape and the same size as each other. Therefore, the plurality of tooth portions 23 have the same thickness dimension as each other.
- the winding is wound around the teeth portion 23.
- the winding may be a centralized winding or a distributed winding.
- the rotor 30 is arranged radially inside 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 ring) 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.
- a set of two permanent magnets 32 form one magnetic pole.
- the plurality of sets of permanent magnets 32 are arranged at equal angular intervals in the circumferential direction. In this embodiment, 12 sets (24 in total) of permanent magnets 32 are provided at every 30 degrees of the central angle centered on the central axis O.
- an embedded magnet type motor is adopted as a permanent magnet field type 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 arrangement of the plurality of permanent magnets 32.
- Each permanent magnet 32 is fixed to the rotor core 31 in a state of being arranged in the corresponding through hole 33.
- the fixing of each permanent magnet 32 to the rotor core 31 can be realized, for example, by adhering the outer surface of the permanent magnet 32 and the inner surface of the through hole 33 with an adhesive.
- a surface magnet type motor may be adopted instead of the embedded magnet type.
- both the stator core 21 and the rotor core 31 are laminated cores.
- the stator core 21 is formed by laminating a plurality of electromagnetic steel sheets 40 in the laminating direction.
- the product thickness (total length along the central axis O) 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 end portion of the teeth portion 23 in the stator core 21. That is, the inner diameter of the stator core 21 is the diameter of a virtual circle inscribed in the tips of all the teeth portions 23.
- Each of the electrical steel sheets 40 forming the stator core 21 and the rotor core 31 is formed, for example, by punching the material 1 as shown in FIGS. 4 to 6.
- Material 1 is an electromagnetic steel sheet that is a base material of the electromagnetic steel sheet 40. Examples of the material 1 include strip-shaped steel plates and cut plates.
- the strip-shaped steel sheet that is the base material of the electromagnetic steel sheet 40 may be referred to as material 1.
- a steel sheet having a shape used for a laminated core by punching the material 1 may be referred to as an electromagnetic steel sheet 40.
- the material 1 is handled, for example, in a state of being wound around the coil 1A shown in FIG. 7.
- non-oriented electrical steel sheets are used as the material 1.
- JIS C 2552: 2014 non-oriented electrical steel sheet can be adopted.
- a grain-oriented electrical steel sheet may be used instead of the non-oriented electrical steel sheet.
- JIS C 2553: 2019 grain-oriented electrical steel sheet can be adopted.
- a non-oriented thin electromagnetic steel strip or a directional thin electromagnetic steel strip of JIS C 2558: 2015 can be adopted.
- the upper and lower limit values of the average plate thickness t0 of the material 1 are set as follows, for example, in consideration of the case where the material 1 is used as the electromagnetic steel sheet 40. As the material 1 becomes thinner, the manufacturing cost of the material 1 increases. Therefore, in consideration of the manufacturing cost, the lower limit of the average plate thickness t0 of the material 1 is 0.10 mm, preferably 0.15 mm, and more preferably 0.18 mm. On the other hand, if the material 1 is too thick, the manufacturing cost becomes good, but when the material 1 is used as the electromagnetic steel sheet 40, the eddy current loss increases and the core iron loss deteriorates.
- the upper limit of the average plate thickness t0 of the material 1 is 0.65 mm, preferably 0.35 mm, and more preferably 0.30 mm.
- 0.20 mm can be exemplified as a material that satisfies the above range of the average plate thickness t0 of the material 1.
- the average plate thickness t0 of the material 1 includes not only the thickness of the base steel plate 2 described later but also the thickness of the insulating film 3. Further, the method for measuring the average plate thickness t0 of the material 1 is, for example, the following measuring method. For example, when the material 1 is wound into the shape of the coil 1A, at least a part of the material 1 is unwound into a flat plate shape. In the material 1 unraveled into a flat plate shape, a predetermined position in the longitudinal direction of the material 1 (for example, a position 10% of the total length of the material 1 away from the longitudinal edge of the material 1) is selected. do. At this selected position, the material 1 is divided into five regions along the width direction thereof. The plate thickness of the material 1 is measured at four locations that are boundaries of these five regions. The average value of the plate thicknesses at the four locations can be set to the average plate thickness t0 of the material 1.
- a predetermined position in the longitudinal direction of the material 1 for example, a position 10% of the total length of the material
- the upper and lower limit values of the average plate thickness t0 of the material 1 can be naturally adopted as the upper and lower limit values of the average plate thickness t0 of the electrical steel sheet 40.
- the method for measuring the average plate thickness t0 of the electrical steel sheet 40 is, for example, the following measuring method.
- the thickness of the laminated core is measured at four locations (that is, every 90 degrees around the central axis O) at equal intervals in the circumferential direction.
- Each of the measured product thicknesses at the four locations is divided by the number of laminated electromagnetic steel sheets 40 to calculate the plate thickness per sheet.
- the average value of the plate thicknesses at the four locations can be set to the average plate thickness t0 of the electromagnetic steel sheet 40.
- the material 1 includes a base steel plate 2 and an insulating coating 3.
- the material 1 is formed by covering both sides of a strip-shaped base steel plate 2 with an insulating coating 3.
- most of the material 1 is formed of the base steel plate 2, and the insulating film 3 thinner than the base steel plate 2 is laminated on the surface of the base steel plate 2.
- the chemical composition of the base steel sheet 2 contains 2.5% to 4.5% Si in mass%.
- the yield strength of the material 1 can be set to, for example, 380 MPa or more and 540 MPa or less.
- the insulating film 3 When the material 1 is used as the electromagnetic steel sheet 40, the insulating film 3 exhibits insulation performance between the electromagnetic steel sheets 40 adjacent to each other in the stacking direction. Further, in the present embodiment, the insulating coating 3 has an adhesive ability and adheres the electromagnetic steel sheets 40 adjacent to each other in the laminating direction.
- the insulating coating 3 may have a single-layer structure or a multi-layer structure. More specifically, for example, the insulating coating 3 may have a single-layer structure having both insulating performance and adhesive ability, and may include a base insulating coating having excellent insulating performance and a ground insulating coating having excellent adhesive performance. It may have a multi-layer structure including.
- the "adhesive ability of the insulating coating 3" in the present embodiment means that the laminated body composed of a plurality of electromagnetic steel sheets 40 laminated with the insulating coating 3 sandwiched thereof has an adhesive strength of a predetermined value or more under a predetermined temperature condition. It means the ability that can be expressed.
- the insulating coating 3 covers both sides of the base steel plate 2 without gaps over the entire surface.
- a part of the layers of the insulating coating 3 may not cover both sides of the base steel plate 2 without gaps.
- a part of the layer of the insulating coating 3 may be intermittently provided on the surface of the base steel plate 2.
- both sides of the base steel plate 2 need to be covered with the insulating film 3 so that the entire surface is not exposed.
- the insulating coating 3 does not have a base insulating coating having excellent insulating performance and has a single-layer structure having both insulating performance and adhesive ability, the insulating coating 3 has no gap over the entire surface of the base steel plate 2. Must be formed.
- the insulating film 3 has a multi-layer structure including a base insulating film having excellent insulating performance and a ground insulating film having excellent adhesiveness, both the base insulating film and the ground insulating film are made of a base steel sheet. In addition to forming the base insulating film without gaps over the entire surface of No. 2, even if the underlying insulating film is formed without gaps over the entire surface of the base steel sheet and the upper ground insulating film is intermittently provided, both insulation performance and adhesive ability can be achieved. ..
- the coating composition constituting the underlying insulating film is not particularly limited, and for example, a general treatment agent such as a chromic acid-containing treatment agent or a phosphate-containing treatment agent can be used.
- the insulating coating 3 having an adhesive ability is coated with a coating composition for an electromagnetic steel sheet containing an epoxy resin, a first curing agent (A), and a second curing agent (B).
- the insulating film made of the coating composition for electrical steel sheets is in an uncured or semi-cured state (B stage) before heat crimping at the time of manufacturing a laminated core, and the curing reaction proceeds by heating during heat crimping to adhere. Noh develops.
- the coating composition for electrical steel sheets may be used for forming an insulating film having a single layer structure, or may be used for forming an underlying insulating film provided on an underlying insulating film.
- epoxy resin a general epoxy resin can be used, and specifically, any epoxy resin having two or more epoxy groups in one molecule can be used without particular limitation.
- epoxy resins include bisphenol A type epoxy resin, bisphenol F type epoxy resin, phenol novolac type epoxy resin, cresol novolac type epoxy resin, triphenylmethane type epoxy resin, alicyclic epoxy resin, and glycidyl ester type.
- Epoxy resin, glycidylamine type epoxy resin, hidden toin type epoxy resin, isocyanurate type epoxy resin, acrylic acid modified epoxy resin (epoxy acrylate), phosphorus-containing epoxy resin, their halides (bromination epoxy resin, etc.) and hydrogenation Things etc. can be mentioned.
- the epoxy resin one type may be used alone, or two or more types may be used in combination.
- the content of the epoxy resin is, for example, preferably 30 to 90% by mass, more preferably 40 to 80% by mass, still more preferably 50 to 70% by mass, based on the total mass of the coating composition for electrical steel sheets.
- the content of the epoxy resin is at least the above lower limit value, the adhesive strength of the electrical steel sheet 40 can be further increased.
- the content of the epoxy resin is not more than the above upper limit value, the stress strain of the electromagnetic steel sheet 40 can be further suppressed.
- the first curing agent consists of an alkylphenol.
- the alkylphenol is not particularly limited, and is, for example, cresol (o-cresol, etc.), ethylphenol (o-ethylphenol, etc.), propylphenol (p-propylphenol, p-isopropylphenol, etc.), butylphenol (p-butylphenol, etc.).
- p-sec-butylphenol, etc. nonylphenol (p-nonylphenol, etc.), dodecylphenol (p-dodecylphenol, etc.), dimethylphenol (2,3-dimethylphenol, etc.), diethylphenol (2,3-diethylphenol, etc.), Examples thereof include dibutylphenol (2,6-di-sec-butylphenol and the like), trimethylphenol (2,3,4-trimethylphenol and the like) and the like.
- the alkylphenol one kind may be used alone, or two or more kinds may be used in combination.
- the alkylphenol is either a monoalkylphenol having an alkyl group having 2 to 20 carbon atoms or a dialkylphenol having an alkyl group having 2 to 20 carbon atoms. Or both are preferably included.
- the number of carbon atoms of the alkyl group of the monoalkylphenol is more preferably 3 to 16, and even more preferably 4 to 12.
- the number of carbon atoms of the two alkyl groups of the dialkylphenol is more preferably 3 to 20 and even more preferably 4 to 12, respectively.
- the content of the first curing agent (A) in the coating composition for electrical steel sheets is 1.0 part by mass or more and 20.0 parts by mass or less with respect to 100 parts by mass of the epoxy resin.
- the content of the first curing agent (A) is at least the above lower limit value, a laminated core having excellent heat resistance can be obtained.
- the content of the first curing agent is not more than the upper limit, a laminated core having excellent magnetic properties can be obtained.
- the lower limit of the content of the first curing agent (A) is preferably 2.0 parts by mass or more, more preferably 3.0 parts by mass or more.
- the upper limit of the content of the first curing agent (A) is preferably 18.0, more preferably 16.0 parts by mass or less, and further preferably 15.0 parts by mass or less.
- the second curing agent (B) is at least one selected from a phenol resol resin and a phenol novolac resin.
- the phenol resol resin and the phenol novolak resin as the second curing agent have neither an alkyl group nor an alkoxy group in the phenol skeleton.
- the phenol resol resin may be used alone, the phenol novolac resin may be used alone, or the phenol resol resin and the phenol novolac resin may be used in combination.
- the total content of the second curing agent (B) in the coating composition for electrical steel sheets is preferably 5.0 parts by mass or more and 150.0 parts by mass or less with respect to 100 parts by mass of the epoxy resin.
- the lower limit of the content of the second curing agent (B) is preferably 5.0 parts by mass or more, more preferably 10.0 parts by mass or more, and further preferably 20.0 parts by mass or more.
- the upper limit of the content of the second curing agent (B) is preferably 150.0 parts by mass or less, more preferably 100.0 parts by mass or less, and further preferably 70.0 parts by mass or less.
- the mass ratio represented by [content of first curing agent (A)] / [content of second curing agent (B)] (hereinafter, also referred to as "A / B ratio") is 0.01 to. 4.0 is preferable.
- the A / B ratio is more preferably 0.1 or more, still more preferably 0.25 or more.
- the A / B ratio is more preferably 3.8 or less, still more preferably 3.5 or less.
- the coating composition for electrical steel sheets may contain components other than the epoxy resin, the first curing agent (A) and the second curing agent (B).
- examples of other components include an acrylic resin, a curing agent other than the first curing agent (A) and the second curing agent (B), a curing accelerator (curing catalyst), an emulsifier, an antifoaming agent, and the like. ..
- the coating composition for electrical steel sheets does not contain inorganic fillers such as silica, alumina, and glass.
- inorganic fillers such as silica, alumina, and glass.
- only one kind may be used, or two or more kinds may be used in combination.
- the acrylic resin is not particularly limited.
- the monomer used for the acrylic resin include unsaturated carboxylic acids such as acrylic acid and methacrylic acid, methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, and cyclohexyl (meth).
- unsaturated carboxylic acids such as acrylic acid and methacrylic acid
- (meth) acrylates such as meta) acrylate, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, and hydroxypropyl (meth) acrylate can be mentioned.
- the acrylic resin may have a structural unit derived from a monomer other than the acrylic monomer.
- examples of other monomers include ethylene, propylene, styrene and the like.
- the other monomer one type may be used alone, or two or more types may be used in combination.
- the glass transition point (Tg point) of the acrylic resin is not particularly limited, but the lower limit is preferably ⁇ 40 ° C., more preferably ⁇ 20 ° C.
- the upper limit of the Tg point of the acrylic resin is preferably 80 ° C., more preferably 50 ° C.
- the content of the acrylic resin is not particularly limited, and is, for example, 1% by mass or more and 50% by mass or less with respect to the total amount of the epoxy resin and the acrylic resin. be able to. The same applies to the content when it is contained as an acrylic-modified epoxy resin or an acrylic monomer.
- an acrylic resin when used, it may be used as an acrylic modified epoxy resin obtained by grafting an acrylic resin onto an epoxy resin.
- the coating composition for electrical steel sheets it may be contained as a monomer forming an acrylic resin.
- curing agents examples include latent epoxy resin curing agents that initiate a curing reaction by heating. Specific examples thereof include aromatic polyamines, acid anhydrides, dicyandiamides, boron trifluoride-amine complexes, and organic acid hydrazides. As other curing agents, one type may be used alone, or two or more types may be used in combination.
- the content of the other curing agent in the coating composition for electrical steel sheets is preferably 20 parts by mass or less, more preferably 10 parts by mass or less, based on 100 parts by mass of the epoxy resin.
- an epoxy resin adhesive having excellent heat resistance has a large Young's modulus near room temperature when the adhesive strength at a high temperature is guaranteed, and stresses the steel plate to deteriorate the magnetic properties (core iron loss).
- the resin composition has an appropriate strength near room temperature, the heat resistance is lowered.
- the cured product has a structure having an alkyl group as a side chain. Therefore, the elastic modulus of the cured product is appropriately lowered, the stress applied to the steel sheet is reduced, and a laminated core having excellent magnetic properties can be obtained.
- the phenol resin has excellent heat resistance, the heat resistance is also improved by using the first curing agent (A) and the second curing agent (B) in combination. From these things, it is possible to achieve both magnetic properties and heat resistance.
- the curing shrinkage of the coating composition for electrical steel sheets is preferably 15% or less, more preferably 12% or less, further preferably 10% or less, and particularly preferably 8% or less.
- the curing shrinkage rate is measured by a method according to JIS K 6941.
- the insulating film 3 can be formed, for example, by applying a coating composition for an electromagnetic steel sheet to the surface of a base steel sheet, drying it, and baking it.
- the lower limit of the reached temperature at the time of baking is preferably 120 ° C. or higher, more preferably 140 ° C. or higher.
- the upper limit of the reached temperature at the time of baking is preferably 200 ° C. or lower, more preferably 180 ° C. or lower.
- the coating composition for electrical steel sheets is sufficiently adhered to the electrical steel sheets, and peeling is suppressed.
- the ultimate temperature is not more than the above upper limit value, the curing of the epoxy resin can be suppressed, and the adhesive ability of the coating composition for electrical steel sheets can be maintained.
- the lower limit of the baking time is preferably 5 seconds or longer, more preferably 10 seconds or longer.
- the upper limit of the baking time is preferably 60 seconds or less, more preferably 30 seconds or less.
- the baking time is equal to or longer than the above lower limit, the coating composition for electrical steel sheets is sufficiently adhered to the electrical steel sheets and peeling is suppressed.
- the baking time is not more than the above upper limit, the curing of the epoxy resin can be suppressed, and the adhesive ability of the coating composition for electrical steel sheets can be maintained.
- the upper and lower limit values of the average thickness t1 of the insulating film 3 may be set as follows, for example, in consideration of the case where the material 1 is used as the electromagnetic steel sheet 40.
- the average thickness t1 of the insulating film 3 is the insulation performance and adhesive ability between the electrical steel sheets 40 laminated with each other. Adjust so that can be secured.
- the average thickness t1 (thickness per one side of the electromagnetic steel sheet 40 (material 1)) of the insulating coating 3 can be, for example, 1.5 ⁇ m or more and 8.0 ⁇ m or less. ..
- the average thickness of the underlying insulating coating can be, for example, 0.3 ⁇ m or more and 2.5 ⁇ m or less, preferably 0.5 ⁇ m or more and 1.5 ⁇ m or less.
- the average thickness of the upper insulating film can be, for example, 1.5 ⁇ m or more and 8.0 ⁇ m or less.
- the method of measuring the average thickness t1 of the insulating coating 3 in the material 1 is the same as that of the average plate thickness t0 of the material 1, and the thicknesses of the insulating coatings 3 at a plurality of locations can be obtained and obtained as the average of those thicknesses. can.
- the upper and lower limit values of the average thickness t1 of the insulating film 3 in the material 1 can be naturally adopted as the upper and lower limit values of the average thickness t1 of the insulating film 3 in the electrical steel sheet 40.
- the method for measuring the average thickness t1 of the insulating coating 3 on the electrical steel sheet 40 is, for example, the following measuring method. For example, among a plurality of electrical steel sheets forming a laminated core, the electrical steel sheet 40 located on the outermost side in the laminated direction (the electrical steel sheet 40 whose surface is exposed in the laminated direction) is selected. On the surface of the selected electrical steel sheet 40, a predetermined position in the radial direction (for example, a position just intermediate (center) between the inner peripheral edge and the outer peripheral edge of the electrical steel sheet 40) is selected.
- the thickness of the insulating coating 3 of the electrical steel sheet 40 is measured at four locations (that is, every 90 degrees around the central axis O) at equal intervals in the circumferential direction.
- the average value of the measured thicknesses at the four locations can be taken as the average thickness t1 of the insulating coating 3.
- the reason why the average thickness t1 of the insulating coating 3 was measured on the outermost electromagnetic steel sheet 40 in the laminating direction is that the thickness of the insulating coating 3 is the laminating position along the laminating direction of the electromagnetic steel sheet 40. This is because the insulating film 3 is built so that it hardly changes.
- the electromagnetic steel sheet 40 is manufactured by punching the material 1 as described above, and the laminated core (stator core 21 and rotor core 31) is manufactured by the electromagnetic steel sheet 40.
- the description of the laminated core will be returned.
- the plurality of electrical steel sheets 40 forming the stator core 21 are laminated via the insulating coating 3.
- the electromagnetic steel sheets 40 adjacent to each other in the stacking direction are adhered over the entire surface by the insulating film 3.
- the surface of the electromagnetic steel sheet 40 facing the stacking direction (hereinafter referred to as the first surface) is the bonding region 41a over the entire surface.
- the electromagnetic steel sheets 40 adjacent to each other in the stacking direction may not be adhered over the entire surface.
- the adhesive region 41a and the non-adhesive region (not shown) may coexist on the first surface of the electrical steel sheet 40.
- the plurality of electrical steel sheets forming the rotor core 31 are fixed to each other by the caulking 42 (dowel) shown in FIG.
- the plurality of electrical steel sheets forming the rotor core 31 may also have a laminated structure fixed by the insulating coating 3 as in the stator core 21.
- the laminated core such as the stator core 21 and the rotor core 31 may be formed by so-called rotating stacking.
- the stator core 21 is manufactured, for example, by using the manufacturing apparatus 100 shown in FIG. 7.
- the manufacturing apparatus 100 the laminated core manufacturing apparatus 100 (hereinafter, simply referred to as the manufacturing apparatus 100) will be described.
- the material 1 is sent out from the coil 1A (hoop) in the direction of the arrow F, the material 1 is punched a plurality of times by the dies arranged on each stage to gradually form the shape of the electromagnetic steel sheet 40. go. Then, the punched electrical steel sheets 40 are laminated and pressurized while raising the temperature. As a result, the electromagnetic steel sheets 40 adjacent to each other in the laminating direction are adhered by the insulating coating 3 (that is, the portion of the insulating coating 3 located in the adhesive region 41a exerts an adhesive ability), and the adhesion is completed.
- the insulating coating 3 that is, the portion of the insulating coating 3 located in the adhesive region 41a exerts an adhesive ability
- the manufacturing apparatus 100 includes a plurality of stages of punching stations 110.
- the punching station 110 may have two stages or three or more stages.
- the punching station 110 of each stage includes a female die 111 arranged below the material 1 and a male die 112 arranged above the material 1.
- the manufacturing apparatus 100 further includes a stacking station 140 at a position downstream of the most downstream punching station 110.
- the laminating station 140 includes a heating device 141, an outer peripheral punching female die 142, a heat insulating member 143, an outer peripheral punching male die 144, and a spring 145.
- the heating device 141, the outer peripheral punched female die 142, and the heat insulating member 143 are arranged below the material 1.
- the outer peripheral punching die 144 and the spring 145 are arranged above the material 1.
- Reference numeral 21 indicates a stator core.
- the material 1 is sequentially sent out from the coil 1A in the direction of the arrow F in FIG. Then, the material 1 is sequentially punched by a plurality of punching stations 110. By these punching processes, the shape of the electromagnetic steel sheet 40 having the core back portion 22 and the plurality of tooth portions 23 shown in FIG. 3 is obtained on the material 1. However, since it is not completely punched at this point, the process proceeds to the next step along the arrow F direction.
- the material 1 is sent to the laminating station 140, punched out by the outer peripheral punching die 144, and laminated with high accuracy.
- the electromagnetic steel sheet 40 receives a constant pressing force by the spring 145.
- the laminated core formed by stacking the electromagnetic steel sheets 40 in this way is heated to, for example, a temperature of 200 ° C. by the heating device 141. By this heating, the insulating coatings 3 of the adjacent electromagnetic steel sheets 40 are adhered to each other (adhesion step).
- the heating temperature in the bonding step for example, 120 to 250 ° C. is preferable, 150 to 230 ° C. is more preferable, and 200 to 220 ° C. is further preferable.
- the heating temperature is at least the above lower limit value, the insulating coating 3 is sufficiently cured and the adhesive strength of the laminated core can be further enhanced.
- the heating temperature is not more than the above upper limit value, the thermal deterioration of the insulating coating 3 can be suppressed, and the adhesive strength of the laminated core can be further enhanced.
- the heating time in the bonding step is affected by the size of the laminated core and the heating method, but is preferably 30 to 120 minutes, more preferably 45 to 100 minutes, still more preferably 60 to 80 minutes, for example.
- the heating time is equal to or longer than the above lower limit, the insulating coating 3 is sufficiently cured and the adhesive strength of the laminated core can be further enhanced.
- the heating time is not more than the above upper limit value, the thermal deterioration of the insulating coating 3 can be suppressed, and the adhesive strength of the laminated core can be further enhanced.
- the pressure for pressurizing the laminate is, for example, preferably 2 to 50 MPa, more preferably 3 to 30 MPa, and even more preferably 4 to 20 MPa.
- the insulating coating 3 is sufficiently adhered and the adhesive strength of the laminated core can be further enhanced.
- the pressure at the time of pressurizing the laminated body is not more than the above upper limit value, the protrusion from the end portion of the insulating coating 3 can be suppressed, and the stacking accuracy of the laminated core can be further improved.
- the heating device 141 may not be arranged on the outer peripheral punched female die 142. That is, before the electromagnetic steel sheets 40 laminated by the outer peripheral punched female die 142 are adhered, they may be taken out of the outer peripheral punched female die 142. In this case, the outer peripheral punched female die 142 may not have the heat insulating member 143. Further, in this case, the stacked electromagnetic steel sheets 40 before bonding may be sandwiched and held from both sides in the stacking direction by a jig (not shown), and then transported or heated. The stator core 21 is completed by each of the above steps.
- an insulating film is formed on the surface of an electromagnetic steel sheet by a coating composition for an electromagnetic steel sheet in which an epoxy resin, a first curing agent (A) and a second curing agent (B) are combined in a specific ratio.
- a coating composition for an electromagnetic steel sheet in which an epoxy resin, a first curing agent (A) and a second curing agent (B) are combined in a specific ratio.
- the shape of the stator core is not limited to the form shown in the above embodiment. Specifically, the dimensions of the outer diameter and inner diameter of the stator core, the product thickness, the number of slots, the dimensional ratio between the circumferential direction and the radial direction of the tooth portion, the dimensional ratio in the radial direction between the tooth portion and the core back portion, etc. are desired. It can be arbitrarily designed according to the characteristics of the rotary electric machine.
- a set of two permanent magnets 32 form one magnetic pole, but the present invention is not limited to this.
- one permanent magnet 32 may form one magnetic pole, or three or more permanent magnets 32 may form one magnetic pole.
- the permanent magnet field type electric machine has been described as an example of the rotary electric machine 10, but the structure of the rotary electric machine 10 is not limited to this as illustrated below, and is not further exemplified below. Various known structures can also be adopted.
- the permanent magnet field type motor has been described as an example of the rotary electric machine 10, but the present invention is not limited to this.
- the rotary electric machine 10 may be a reluctance type electric machine or an electromagnet field type electric machine (winding field type electric machine).
- the synchronous motor has been described as an example of the AC motor, but the present invention is not limited to this.
- the rotary electric machine 10 may be an induction motor.
- the AC electric machine has been described as an example of the rotary electric machine 10, but the present invention is not limited to this.
- the rotary electric machine 10 may be a DC motor.
- the rotary electric machine 10 has been described by taking an electric machine as an example, but the present invention is not limited to this.
- the rotary electric machine 10 may be a generator.
- ⁇ Curing shrinkage rate> The coating composition for electrical steel sheets was applied to the surface of the electrical steel strips of each example, and the curing shrinkage was measured.
- the curing shrinkage rate was measured by changing the film thickness according to JIS K 6941.
- Example 1 As a base steel sheet, non-directional electromagnetic steel having a mass% of Si: 3.0%, Mn: 0.2%, Al: 0.5%, a plate thickness of 0.25 mm and a width of 100 mm, the balance of which is composed of Fe and impurities. A steel plate was used. Each component shown in Table 1 was mixed to prepare a coating composition for electrical steel sheets. The obtained coating composition for an electromagnetic steel sheet was applied to the surface of a base steel sheet and baked at 160 ° C. for 15 seconds to obtain an electromagnetic steel strip having an insulating film having an average thickness of 3 ⁇ m.
- Examples 2 to 10 Comparative Examples 1 to 9
- An electromagnetic steel strip was obtained in the same manner as in Example 1 except that the composition and baking conditions of the coating composition for electrical steel sheets were changed as shown in Table 1.
- Table 1 shows the composition and baking conditions of the coating composition for electrical steel sheets of each example.
- Table 2 shows the evaluation results of the magnetic properties (magnetism) and the adhesive strength of each example.
- both the heat resistance and the magnetic characteristics of the laminated core can be achieved at the same time. Therefore, the industrial applicability is great.
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Abstract
Description
また、電気自動車の駆動モータ等では、駆動中に高温になるため、さらなる耐熱性が求められる。
[1]本発明の一態様に係る電磁鋼板用コーティング組成物は、エポキシ樹脂と、アルキルフェノールからなる第1硬化剤と、フェノールレゾール樹脂及びフェノールノボラック樹脂のいずれか一方又は両方からなる第2硬化剤と、を含有し、前記第1硬化剤の含有量が、前記エポキシ樹脂100質量部に対して、1.0質量部以上20.0質量部以下である。
[2]上記[1]に記載の電磁鋼板用コーティング組成物は、前記アルキルフェノールが、アルキル基の炭素原子数が2~20であるモノアルキルフェノール、及びアルキル基の炭素原子数が2~20であるジアルキルフェノールのいずれか一方又は両方を含んでもよい。
[3]上記[1]又は[2]に記載の電磁鋼板用コーティング組成物は、前記第2硬化剤の含有量が、エポキシ樹脂100質量部に対して、5.0質量部以上150.0質量部以下であってもよい。
[4]上記[1]~[3]のいずれかに記載の電磁鋼板用コーティング組成物は、硬化収縮率が15%以下であってもよい。
[5]上記[1]~[4]のいずれかに記載の電磁鋼板用コーティング組成物は、[前記第1硬化剤(A)の含有量]/[前記第2硬化剤(B)の含有量]で表される質量比が0.01~4.0であってもよい。
[6]本発明の一態様に係る電磁鋼板は、上記[1]~[5]のいずれかに記載の電磁鋼板用コーティング組成物を含む絶縁被膜を表面に有する。
[7]本発明の一態様に係る積層コアは、上記[6]に記載の電磁鋼板が複数積層され、互いに接着されている。
[8]本発明の一態様に係る回転電機は、上記[7]に記載の積層コアを備える。
図1に示すように、回転電機10は、ステータ20と、ロータ30と、ケース50と、回転軸60と、を備える。ステータ20及びロータ30は、ケース50内に収容される。
ステータ20は、ケース50内に固定される。
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の径方向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、スロット数、相数などは、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方向を軸方向と言い、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)を径方向と言い、ステータコア21(又はコアバック部22)の周方向(中心軸線O回りに周回する方向)を周方向と言う。
複数のティース部23は、コアバック部22の内周から径方向内側に向けて(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、周方向に同等の角度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。よって、複数のティース部23は、互いに同じ厚み寸法を有している。
前記巻線は、ティース部23に巻回されている。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、周方向に同等の角度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の配置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、実現できる。なお、永久磁石界磁型電動機として、埋込磁石型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(中心軸線Oに沿った全長)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、これらの値のみに限られない。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の先端部を基準とする。すなわち、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。
素材1は、例えば、図7に示すコイル1Aに巻き取られた状態で取り扱われる。本実施形態では、素材1として、無方向性電磁鋼板を採用している。無方向性電磁鋼板としては、JIS C 2552:2014の無方向性電磁鋼板を採用できる。しかしながら、素材1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してもよい。この場合の方向性電磁鋼板としては、JIS C 2553:2019の方向性電磁鋼板を採用できる。また、JIS C 2558:2015の無方向性薄電磁鋼帯や方向性薄電磁鋼帯を採用できる。
素材1が薄くなるに連れて素材1の製造コストは増す。そのため、製造コストを考慮すると、素材1の平均板厚t0の下限値は、0.10mm、好ましくは0.15mm、より好ましくは0.18mmとなる。
一方で素材1が厚すぎると、製造コストは良好になるが、素材1が電磁鋼板40として用いられた場合に、渦電流損が増加してコア鉄損が劣化する。そのため、コア鉄損と製造コストを考慮すると、素材1の平均板厚t0の上限値は、0.65mm、好ましくは0.35mm、より好ましくは0.30mmとなる。
素材1の平均板厚t0の上記範囲を満たすものとして、0.20mmを例示できる。
測定した4か所の積厚それぞれを、積層されている電磁鋼板40の枚数で割って、1枚当たりの板厚を算出する。4か所の板厚の平均値を、電磁鋼板40の平均板厚t0とすることができる。
素材1は、帯状の母材鋼板2の両面が絶縁被膜3によって被覆されてなる。本実施形態では、素材1の大部分が母材鋼板2によって形成され、母材鋼板2の表面に、母材鋼板2よりも薄い絶縁被膜3が積層されている。
Al:0.001%~3.0%
Mn:0.05%~5.0%
残部:Fe及び不純物
電磁鋼板用コーティング組成物からなる絶縁被膜は、積層コア製造時の加熱圧着前においては、未硬化状態又は半硬化状態(Bステージ)であり、加熱圧着時の加熱によって硬化反応が進行して接着能が発現する。電磁鋼板用コーティング組成物は、単層構成の絶縁被膜の形成に用いてもよく、下地絶縁被膜上に設ける上地絶縁被膜の形成に用いてもよい。
アルキルフェノールとしては、特に限定されず、例えば、クレゾール(o-クレゾール等)、エチルフェノール(o-エチルフェノール等)、プロピルフェノール(p-プロピルフェノール、p-イソプロピルフェノール等)、ブチルフェノール(p-ブチルフェノール、p-sec-ブチルフェノール等)、ノニルフェノール(p-ノニルフェノール等)、ドデシルフェノール(p-ドデシルフェノール等)、ジメチルフェノール(2,3-ジメチルフェノール等)、ジエチルフェノール(2,3-ジエチルフェノール等)、ジブチルフェノール(2,6-ジ-sec-ブチルフェノール等)、トリメチルフェノール(2,3,4-トリメチルフェノール等)等が挙げられる。アルキルフェノールとしては、1種を単独で使用してもよく、2種以上を併用してもよい。
モノアルキルフェノールのアルキル基の炭素原子数は、3~16がより好ましく、4~12がさらに好ましい。
ジアルキルフェノールの2つのアルキル基の炭素原子数はそれぞれ独立に、3~20がより好ましく、4~12がさらに好ましい。
第1硬化剤(A)の含有量の下限値は、好ましくは2.0質量部以上、より好ましくは3.0質量部以上である。第1硬化剤(A)の含有量の上限値は、好ましくは18.0、より好ましくは16.0質量部以下、さらに好ましくは15.0質量部以下である。
第2硬化剤(B)としては、フェノールレゾール樹脂を単独で使用してもよく、フェノールノボラック樹脂を単独で使用してもよく、フェノールレゾール樹脂とフェノールノボラック樹脂を併用してもよい。
第2硬化剤(B)の含有量の下限値は、好ましくは5.0質量部以上、より好ましくは10.0質量部以上、さらに好ましくは20.0質量部以上である。第2硬化剤(B)の含有量の上限は、好ましくは150.0質量部以下、より好ましくは100.0質量部以下、さらに好ましくは70.0質量部以下である。
本実施形態では、第1硬化剤(A)のアルキルフェノールを第2硬化剤(B)と組み合わせて用いることにより、硬化物がアルキル基を側鎖として持つ構造となる。そのため、硬化物の弾性率が適度に低下して鋼板に付与される応力が低減され、磁気特性に優れた積層コアが得られる。また、フェノール樹脂は優れた耐熱性を有しているため、第1硬化剤(A)と第2硬化剤(B)を組み合わせて用いることで、耐熱性も向上する。これらのことから、磁気特性と耐熱性を両立することができる。
なお、硬化収縮率は、JIS K 6941に準拠した方法により測定される。
焼き付ける際の到達温度の下限値は、好ましくは120℃以上、より好ましくは140℃以上である。焼き付ける際の到達温度の上限値は、好ましくは200℃以下、より好ましくは180℃以下である。到達温度が上記下限値以上であると、電磁鋼板用コーティング組成物が電磁鋼板と充分に接着し、剥離が抑制される。到達温度が上記上限値以下であると、エポキシ樹脂の硬化を抑制でき、電磁鋼板用コーティング組成物の接着能を維持できる。
素材1が電磁鋼板40として用いられる場合において、絶縁被膜3の平均厚みt1(電磁鋼板40(素材1)片面あたりの厚さ)は、互いに積層される電磁鋼板40間での絶縁性能及び接着能を確保できるように調整する。
複層構成の絶縁被膜3の場合、下地絶縁被膜の平均厚みは、例えば、0.3μm以上2.5μm以下とすることができ、0.5μm以上1.5μm以下が好ましい。上地絶縁被膜の平均厚みは、例えば、1.5μm以上8.0μm以下とすることができる。
なお、素材1における絶縁被膜3の平均厚みt1の測定方法は、素材1の平均板厚t0と同様の考え方で、複数箇所の絶縁被膜3の厚みを求め、それらの厚みの平均として求めることができる。
以下、積層コアの説明に戻る。
ステータコア21を形成する複数の電磁鋼板40は、図3に示すように、絶縁被膜3を介して積層されている。
また、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。
前記ステータコア21は、例えば、図7に示す製造装置100を用いて製造される。以下では、製造方法の説明にあたり、まず先に、積層コアの製造装置100(以下、単に製造装置100という)について説明する。
各段の打ち抜きステーション110は、素材1の下方に配置された雌金型111と、素材1の上方に配置された雄金型112とを備える。
加熱装置141、外周打ち抜き雌金型142、断熱部材143は、素材1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、素材1の上方に配置されている。なお、符号21は、ステータコアを示している。
以上の各工程により、ステータコア21が完成する。
上記実施形態では、回転電機10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、本発明はこれのみに限られない。例えば、回転電機10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。
上記実施形態では、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10が誘導電動機であってもよい。
上記実施形態では、回転電機10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10が直流電動機であってもよい。
上記実施形態では、回転電機10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10が発電機であってもよい。
実施例で使用した原料を以下に示す。
(エポキシ樹脂)
E1:ビスフェノールA型エポキシ樹脂
E2:ビスフェノールF型エポキシ樹脂
E3:トリフェニルメタン型エポキシ樹脂
A1:p-sec-ブチルフェノール
A2:p-ノニルフェノール
A3:p-ドデシルフェノール
A4:2,6-ジ-sec-ブチルフェノール
A5:p-プロピルフェノール
H1:フェノールレゾール樹脂
H2:フェノールノボラック樹脂
B1:ジアミノジフェニルメタン
B2:ジシアンジアミド
B3:4-メチルヘキサヒドロフタル酸無水物
M1:アクリル樹脂(メチルメタクリレート単位:イソプロピルアクリレート単位:スチレン単位:2-エチルヘキシルアクリレート単位(モル比)=40:30:20:10、ガラス転移温度:17℃)
M2:アクリル樹脂(メチルメタクリレート単位:n-ブチルアクリレート単位(モル比)=55:45、ガラス転移温度:10℃)
各例の電磁鋼帯から55mm×55mmサイズの矩形の電磁鋼板(単板)を切り出し、鋼板温度200℃、圧力10MPa、加圧時間1時間の条件で電磁鋼板10枚を積層接着して積層コアを作製した。得られた積層コアについて、JIS C2556(2015)に規定された単板磁気測定法により、圧延方向と圧延方向に対して直角方向の単板磁気特性を測定し、それらの値の平均値を磁気特性として求めた。なお、磁気特性(磁性)としては、鉄損として「W10/400(W/kg)」を評価した。「W10/400」は、周波数400Hz、最大磁束密度1.0Tのときの鉄損である。
各例の電磁鋼帯から、幅30mm×長さ60mmの長方形の電磁鋼板(単板)を2枚切り出した。次いで、表面に、電磁鋼板用コーティング組成物を塗布し、互いの幅30mm×長さ10mmの先端部分同士を重ね合わせ、加圧することで測定用のサンプルを作製した。加圧条件は、鋼板温度200℃、圧力10MPa、加圧時間1時間とした。
得られたサンプルに対し、雰囲気温度を25℃もしくは150℃のそれぞれ雰囲気下で、引張速度を2mm/分として引張り、剥離するまでの最大荷重(N)を測定し、この最大荷重(N)接着面積で除した数値を接着強度(MPa)とした。
各例の電磁鋼帯の表面に電磁鋼板用コーティング組成物を塗布し、、硬化収縮率を測定した。硬化収縮率は、JIS K 6941に準拠して膜厚の変化により測定した。
各例について、以下の基準で判定を行った。なお、鉄損が小さいほど、電磁鋼板に付与する応力歪が抑制されていることを意味する。測定結果及び判定結果を表2に示す。表において、発明範囲外の値には下線を付した。
「Good」:25℃の接着強度が5.0MPa以上、150℃の接着強度が1.0MPa以上、かつ磁気特性が12.0W/kg未満。
「Bad」:25℃の接着強度が5.0MPa未満、150℃の接着強度が1.0MPa未満、または、磁気特性が12.0W/kg以上。
母材鋼板として、質量%で、Si:3.0%、Mn:0.2%、Al:0.5%、残部がFe及び不純物からなる板厚0.25mm、幅100mmの無方向性電磁鋼板を用いた。
表1に示す各成分を混合して電磁鋼板用コーティング組成物を調製した。得られた電磁鋼板用コーティング組成物を母材鋼板の表面に塗布し、160℃で15秒間焼き付けることで、平均厚みが3μmの絶縁被膜を有する電磁鋼帯を得た。
電磁鋼板用コーティング組成物の組成及び焼き付け条件を表1に示すとおりに変更した以外は、実施例1と同様にして電磁鋼帯を得た。
一方、第1硬化剤の含有量が本発明の範囲外の比較例1~4、第1硬化剤を含まない比較例5~7および9、第2硬化剤を含まない比較例8では、耐熱性と磁気特性が両立できなかった。
Claims (8)
- エポキシ樹脂と、アルキルフェノールからなる第1硬化剤(A)と、フェノールレゾール樹脂及びフェノールノボラック樹脂のいずれか一方又は両方からなる第2硬化剤(B)と、を含有し、
前記第1硬化剤(A)の含有量が、前記エポキシ樹脂100質量部に対して、1.0質量部以上20.0質量部以下である、電磁鋼板用コーティング組成物。 - 前記アルキルフェノールが、アルキル基の炭素原子数が2~20であるモノアルキルフェノール、及びアルキル基の炭素原子数が2~20であるジアルキルフェノールのいずれか一方又は両方を含む、請求項1に記載の電磁鋼板用コーティング組成物。
- 前記第2硬化剤(B)の含有量が、エポキシ樹脂100質量部に対して、5.0質量部以上150.0質量部以下である、請求項1又は2に記載の電磁鋼板用コーティング組成物。
- 硬化収縮率が15%以下である、請求項1~3のいずれか一項に記載の電磁鋼板用コーティング組成物。
- [前記第1硬化剤(A)の含有量]/[前記第2硬化剤(B)の含有量]で表される質量比が0.01~4.0である、請求項1~4のいずれか一項に記載の電磁鋼板用コーティング組成物。
- 請求項1~5のいずれか一項に記載の電磁鋼板用コーティング組成物を含む絶縁被膜を表面に有する、電磁鋼板。
- 請求項6に記載の電磁鋼板が複数積層され、互いに接着されている、積層コア。
- 請求項7に記載の積層コアを備える回転電機。
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