HK1088991B - Iron core exhibiting excellent insulating property at end face, and method for coating end face of iron core - Google Patents

Description

Iron core with excellent end face insulation and method for treating end face of iron core to obtain insulation coating

Technical Field

The present invention relates to an iron core having an end face which is produced by cutting, stamping, etc. of the iron core in the process of producing the iron core using a magnetic steel sheet and which is covered with an insulating coating which is extremely excellent in insulation, adhesion, corrosion resistance, etc. after treatment, and to a method of insulation treatment of the iron core.

Further, the present invention relates to a core of an electric device on which a silicon compound having Si — O bonds is coated and deposited in order to improve various properties and prevent short circuits, and to a method of producing the same, and to a high-temperature operating electric device and a method of producing the same.

Here, the "transformer" is an electric device, which is a motor core, a generator, and a transformer in a broad sense generated by stacking or winding a magnetic material and including a stationary device for changing a high frequency band of voltage. "magnetic material" refers to oriented magnetic steel sheets, non-oriented magnetic steel sheets, amorphous metals, alloys of angstrom, and other known soft magnetic materials having ferromagnetic properties for use in transformers ranging from large to small.

Background

When a non-oriented magnetic steel sheet is used for a motor core or a stationary device, the core is finally manufactured by cutting a coil of the magnetic steel sheet, punching it into predetermined formed bodies, stacking a predetermined number of these formed bodies, and then clamping them by welding, caulking, bolting, pipe hooping, casting, bonding, or the like. In the case of using a transformer core made of oriented silicon steel sheets, a bar-shaped coil is cut, cut or stamped into a predetermined formed body, and then these formed sheets are made into a stacked core or a wire-wound core. Transformers are roughly divided into three types:

1) mainly medium to large-sized 'stacked transformer' with iron core formed by stacking oriented magnetic steel sheets "

2) Miniature wound transformer having an iron core formed by winding an oriented magnetic steel sheet or amorphous metal "

3) "miniature transformers" include switching power supply accessories attached to the equipment, which have primarily non-oriented magnetic steel sheets, amorphous metals, and alloys of angstrom as stacked and wound cores (EI cores, etc.).

1) The medium to large-sized transformer referred to as a "stacked transformer" is a transformer used in an ultra-high voltage substation and a primary to intermediate substation. They are produced by stacking oriented magnetic steel sheets and fastening them with nuts and bolts or special adhesive tape or annealing or varnishing and attaching the windings if necessary.

2) Small transformers referred to as "wound transformers" are small transformers for power distribution located downstream of the intermediate substation. They are assembled by winding a cut oriented magnetic steel sheet and an amorphous metal into a predetermined size, shaping it, then strain annealing, reshaping, and then winding the conductor.

3) The EI core and other small transformers attached to the electric apparatus of (1) are not limited to the oriented magnetic steel sheet and non-oriented magnetic steel sheets may also be used. They are formed by cutting or punching sheets into a predetermined size and then stacking them. Sometimes they are also produced by winding.

Note that the above distinguishing features are limited to japan only. In other countries, in particular in europe, there is no classification of 2). This is considered to be a small one of class 1).

All transformers basically mainly use magnetic steel sheets or amorphous metals as the material of the core to ensure efficiency.

Among these, magnetic steel sheets are produced by steel manufacturers. The final form at the steel manufacturer is usually a coil wound steel sheet with a thickness of 0.20-0.70 mm. It is cut to the desired width, then further cut to the desired length and cut to the final size.

The surface of the magnetic steel sheet is usually treated to provide it with an insulating coating. The varnish and bluing are for improving corrosion resistance and insulating properties of the end face (surface formed by punching, cutting, etc.) of the core. The surface insulating coating of the magnetic steel sheet used in this way has an influence on corrosion resistance, punching property, weldability and insulating property. In particular, in order to improve the insulation performance between steel sheets at the time of stacking to suppress an increase in iron loss due to eddy current loss, many studies on the improvement of the insulation performance have been made.

In the past, as an insulating coating agent for the surface of a steel sheet, an organic type coating agent has been used for an oriented silicon steel sheet, and inorganic type, organic type and composite inorganic-organic type coating agents have been used for a non-oriented silicon steel sheet according to applications or purposes. An excellent heat-resistant insulating film is required for the oriented silicon steel sheet because a forsterite film is formed on the surface of the steel sheet during the secondary recrystallization annealing, and thus a thermal flattening treatment at 800-. In addition, the grain-oriented silicon steel sheet is considerably improved in iron loss and magnetic strain by using the film tension effect. As described above, the organic type coating agent as the insulating coating layer is not suitable for the grain-oriented silicon steel sheet. Generally, inorganic type coatings are excellent in heat resistance and solderability, but poor in punching property. On the other hand, the organic coating layer is excellent in punching property and adhesion, but poor in heat resistance and solderability. In recent years, in order to eliminate defects in both, composite inorganic-organic type coatings capable of exhibiting properties between the two have been commonly used. However, for the insulating coating formed only when producing the steel sheet, the insulating property is insufficient, or in the case where an annealing step is included, the insulating property is significantly degraded, and thus varnishing or other insulating measures become necessary.

In particular, it has been found in recent years that the insulation performance on the end faces of the core formed by punching or cutting has a large influence on the core efficiency. There is still a need to develop an industrially advantageous technique for treating the end faces of the core. However, with the method of insulation treatment of the end faces of the core, which has been conventionally used, although improvement of corrosion resistance or insulation performance is effective, adhesion, coating strength and insulation performance are insufficient.

For example, bluing not only results in poor insulation and corrosion resistance, but also results in poor stability and causes a great increase in expenses in the heat treatment step.

Further, the treatment with an organic compound or a varnish mainly composed of an organic compound is effective for corrosion resistance and insulation on its own, but is insufficient for adhesion, coating strength, insulation, and heat resistance. In particular, the problem of poor wettability means that cleaning or annealing is required as a pretreatment. Further, also with respect to heat resistance, when the core forming process includes aluminum die casting or other heat treatment, it is not appropriate.

In addition, the treatment with phosphate or another inorganic type insulating coating requires pretreatment and high temperature drying as the treatment with organic type and semi-organic type coatings. There are also problems in coating properties: thick coating is difficult, adhesion is poor, the insulating coating is peeled off due to annealing, and the like. These prior arts have many problems in view of working environment and efficiency, and thus further improvement is required.

Further, phenolic resin laminates, silicone resin laminates, molded phenol products and other synthetic resin insulating materials are used as insulators, but these are not directly coated on the end faces of the cores but wound or adhered as products, and therefore the problem of the insulation performance of the end faces being lowered due to burrs or the like cannot be prevented.

In addition, in recent years, transformers using amorphous metal as a core material have also been produced, but in the production of transformers, temporary fastening is required due to "weak stiffness" at the time of "core insertion (tightening)" because amorphous foil "tears". Measures to prevent "tearing" are necessary. The core of the finished transformer is mainly immersed in oil, but the temporary fastening and fixing solution for preventing "tearing" requires oil resistance. This has inherent limitations on the various properties sought from the standpoint of work efficiency and labor hygiene.

As the electric devices, there are motors, exciters, generators, transformers, reactors, and other electromagnetic instruments or heaters, and the like. Electromagnetic instruments are generally composed of a conductor carrying an electric current and a magnetic circuit carrying a magnetic flux.

A large amount of current is passed through the conductor to achieve a high output of the electromagnetic instrument. However, if a large current passes through the conductor, the conductor or the surrounding material is heated, destroying the electrical insulation properties of the conductor or the magnetic material, and causing problems in fastening the various elements of the apparatus.

The magnetic circuit uses a core and a yoke. Most of the cores used are stacks of magnetic steel sheets. To bundle the stacked cores, caulking, welding, bolting, etc. are often employed. For caulking and soldering, an electrical short occurs between the stacked layers. For ac excitation, short circuit current is generated and causes degradation of the device performance. Therefore, molding or bonding is sometimes used for binding between the magnetic steel sheets. However, for molding or bonding, the use of high temperatures is not possible.

In the heater, the heating element is fastened and insulated by ceramic or other elements that can withstand high temperatures. These fastenings are partial. Time and labor are required for the assembly process, and sometimes noise and vibration are problematic because of partial fastening. For gluing etc., a complete fastening is possible. It is also possible that the process becomes simple and automated if insulation can be ensured, but there is no bonding method that can be used at high temperatures.

Disclosure of the invention

The object of the present invention is to provide an extremely quick and easy coating method of covering end faces as a new technique for treating the end faces of a core to obtain an insulating coating, replacing the usual varnishing, bluing and other heat treatments, due to the fact that: after baking in a conventional process for obtaining an insulating coating based on bluing and varnishing to improve corrosion resistance and insulating properties of the end faces of a core, there are many problems in adhesion, insulating properties, corrosion resistance, heat resistance and working efficiency of the insulating coating.

Another object of the invention is to provide an electrical apparatus and a method for producing the apparatus that can be operated at high temperatures.

It is a further object of the present invention to provide an electrical device component that is inhibited in electrical shorting and stress and strain associated with the packaging and is superficially improved, and a simple packaging method for the component.

(1) Iron core with excellent end face insulation, characterized in that the end faces of the core are treated to obtain a material containing at least 30% by weight of converted SiO₂And an insulating coating having an average film thickness of at least 0.5 μm.

(2) The iron core having excellent end-face insulation as recited in (1), characterized in that the average film thickness of the insulating coating is at least 2 μm and the breakdown voltage is at least 30V.

(3) The iron core having excellent end face insulation described in (1) or (2), characterized in that the insulating coating has a heat resistance of at least 400 ℃ x 1 hour in air.

(4) The iron core having excellent end surface insulation as recited in any one of (1) to (3), characterized in that the silicon compound is a dry coating containing one or more ofLayer (b): silicone resin, alkali metal silicate, colloidal silica, low melting glass frit, consisting of¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of a compound produced by hydrolysis and dehydration condensation of one or more substances represented by (R)³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, and when n is 2 or 3, a plurality of R³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, and when n is 0, 1 or 2, a plurality of R⁴May be different), and a modified silicone polymer composed of a compound produced by a hydrolysis reaction and a dehydration condensation reaction of one or more species represented by (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) and one or more types of compounds represented by (R)³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, and when n is 2 or 3, a plurality of R³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, when n is 0, 1 or 2, a plurality of R⁴May be different) of the one or more substances represented by (a) a hydrolysis reaction and a dehydration condensation reaction.

(5) The iron core having excellent end surface insulation according to (4), characterized in that the pure silicone polymer is a compound in whichAt R¹And R²A compound having not more than 4 carbon atoms in the alkyl group and produced by a hydrolysis reaction and partial dehydration condensation reaction of one or more substances selected from tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, tetrabutoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriisopropoxysilane, monomethyltributoxysilane, monoethyltrimethoxysilane, monoethyltriethoxysilane, monoethyltriisopropoxysilane, monoethyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, and diphenyldiethoxysilane, and the modified silicone polymer is an acryl-modified silicone polymer, a silicone polymer having a hydroxyl group and a silicone oil group, a silicone oil, one or more of alkyd-modified silicone polymer, polyester acryl-modified silicone polymer, epoxy-modified silicone polymer, amino-modified silicone polymer, vinyl-modified silicone polymer, and fluorine-modified silicone polymer.

(6) The iron core having excellent end surface insulation according to any one of (1) to (5), characterized in that a metallic element or semimetallic element M other than oxygen (O), carbon (C), hydrogen (H), nitrogen (N), sulfur (S) and fluorine (F) in the insulating coating is mainly silicon (Si), and the Si is mainly present in a form having Si-O bonds, and the M other than Si is one or more elements selected from Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb and Bi.

(7) The core having excellent end face insulation according to any one of (1) to (6), characterized in that the total weight ratio of Si, Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb and Bi with respect to the total weight of those elements other than oxygen (O), carbon (C), hydrogen (H), nitrogen (N), sulfur (S) and fluorine (F) in the insulating coating is at least 90 parts by weight, and in that the weight ratio of Si with respect to the total weight of those elements other than O, C, H, N and S in the insulating coating is at least 50 parts by weight.

(8) The iron core having excellent end surface insulation according to any one of (1) to (7), characterized in that the core body is composed of a non-oriented magnetic steel sheet.

(9) A transformer core extremely excellent in insulation and corrosion resistance, characterized by having an insulating coating composed of a pure silicone polymer on the end faces and surfaces of stacked steel sheets of a magnetic material.

(10) A transformer core extremely excellent in insulation and corrosion resistance, characterized by having a conductor in a core composed of stacked magnetic materials, and having an insulating coating composed of a pure silicone polymer on the surfaces of and between the magnetic materials and the conductor.

(11) The transformer core extremely excellent in insulation and corrosion resistance as recited in (9) or (10), characterized in that the insulating coating has an average film thickness of 0.5 to 100 μm and a breakdown voltage of at least 30V.

(12) A magnetic element for electromagnetic apparatus composed of a plurality of pieces of magnetic material that have been punched into substantially the same shape, stacked and bonded together with a silicone polymer, characterized in that it is bonded without locally applying strain and/or stress to the pieces of magnetic material.

(13) The magnetic element for an electromagnetic device as set forth in (12), wherein the armature core is composed of a plurality of divided core pieces.

(14) Electrical apparatus operating at high temperatures, characterized by having a conductor or conductors and a magnetic material bonded together while ensuring electrical insulation between adjacent elements of the same or different types using a pure silicone polymer as a solution having the ability to fasten and hold adjacent elements to each other after application and drying between adjacent elements and to fasten even at high temperatures exceeding 200 ℃And bandaging, the pure silicone polymer being formed by (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of one or more pure silicone polymers, and the composition of the compounds resulting from the hydrolysis and partial dehydration condensation reactions of one or more pure silicone polymers.

(15) A method of processing a core and treating end faces of the core to obtain an insulating coating, the method comprising, when producing the core, punching or cutting a material into predetermined formed bodies, stacking and clamping them, annealing or not, treating the end faces of the core to obtain the insulating coating, and then drying and/or baking, the method of treating the end faces of the core to obtain the insulating coating being characterized in that one or more of the following substances can be used as an insulating coating treating agent: silicone resins, alkali metal silicates, colloidal silica, low melting glass frits, made of a mixture of (R) and (B)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of a solution containing a compound produced by a hydrolysis reaction and a dehydration condensation reaction of one or more substances represented by (R)³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, and when n is 2 or 3, a plurality of R³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, and when n is 0, 1 or 2, a plurality of R⁴May be different) of a solution of a compound produced by a hydrolysis reaction and a dehydration condensation reaction of one or more species represented by (R), and a modified silicone polymer sol composed of (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) and (R) is³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, and when n is 2 or 3, a plurality of R³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, and when n is 0, 1 or 2, a plurality of R⁴Which may be different) of a compound produced by hydrolysis and dehydration condensation of one or more substances represented by (a) a mixed silicone polymer sol to be dipped and/or sprayed and/or brushed so as to have an average film thickness of 0.5 to 20 μm after drying and/or baking.

(16) The method for treating an end face of a core to obtain an insulating coating as recited in (15), characterized in that the pure silicone polymer sol is one wherein R is¹And R²A compound having not more than 4 carbon atoms in the alkyl group, which comprises a compound produced by a hydrolysis reaction and a partial dehydration condensation reaction of one or more substances selected from tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, tetrabutoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriisopropoxysilane, monomethyltributoxysilane, monoethyltriethoxysilane, monoethyltriisopropoxysilane, monoethyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, and diphenyldiethoxysilane, and which is characterized in that the modified silicone polymer sol is a silicone polymer containing an acryloyl group, Alkyd-modified silicone polymerizationA solution of one or more of a polyester acryl-modified silicone polymer, an epoxy-modified silicone polymer, an amino-modified silicone polymer, a vinyl-modified silicone polymer, and a fluorine-modified silicone polymer.

(17) The method of treating an end face of a core to obtain an insulating coating as recited in (15) or (16), characterized in that a metal element or semimetal element M other than oxygen (O), carbon (C), hydrogen (H), nitrogen (N), sulfur (S) and fluorine (F) is mainly silicon (Si) in the insulating coating, and said Si is mainly present in a form having Si-O bonds, and M other than silicon is one or more elements selected from the group consisting of Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb and Bi.

(18) The method of treating an end face of a core to obtain an insulating coating according to any one of (15) to (17), characterized in that a total weight ratio of Si, Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb, and Bi with respect to a total weight of those elements other than oxygen (O), carbon (C), hydrogen (H), nitrogen (N), sulfur (S), and fluorine (F) in the insulating coating is at least 90%, and in that a weight ratio of Si with respect to a total weight of those elements other than O, C, H, N and S in the insulating coating is at least 50% by weight.

(19) The method of treating end faces of a core to obtain an insulating coating according to any one of (15) to (18), characterized in that 0.1 to 50 parts by weight, in terms of solid content, of one or more of inorganic oxide powder particles, inorganic oxide colloidal substances, organic resin powder particles and organic resin latex solutions, relative to 100 parts by weight of SiO of pure silicone polymer sol, modified silicone polymer sol and/or mixed silicone polymer sol, as a filler, is further added to the insulating coating treatment agent₂And (6) counting.

(20) The method for treating an end face of a core to obtain an insulating coating as described in (19), characterized in that as the inorganic powder particles or colloidal substanceWith SiO having a primary particle size of 7-5000nm₂、Al₂O₃、TiO₂、ZrO₂And/or one or more of their complexes.

(21) The method for treating an end face of a core to obtain an insulating coating as described in (19), characterized in that one or more substances selected from the group consisting of polyacrylate, polystyrene, polyethylene, polypropylene, polyamide, polycarbonate, polyurethane, melamine resin, phenol resin, epoxy resin and/or copolymer thereof having a particle size of 50 to 10000nm are used as the organic resin powder particles or latex solution substance.

(22) The method of treating end faces of a core to obtain an insulating coating according to any one of (15) to (21), characterized in that when the end faces of the core are treated, they are treated with at least two repeated applications with drying at room temperature to 300 ℃ for at least 30 seconds.

(23) The method of treating an end face of a core to obtain an insulating coating according to any one of (15) to (22), characterized in that, when an insulating coating agent to which the filler described in any one of (19) to (20) has been added and blended is applied by at least one coating treatment in order to obtain a repeated coating, the thickness of the coating layer containing the filler after drying is 0.2 to 10 μm, and the average film thickness of the total insulating coating agent obtained by applying the insulating coating agent without adding and blending the filler in at least the last coating treatment is 0.5 to 20 μm.

(24) The method for treating an end face of a core to obtain an insulating coating according to any one of (15) to (23), characterized in that the core is composed of a non-oriented magnetic steel sheet.

(25) A method for producing a transformer core extremely excellent in insulation and corrosion resistance, characterized by coating an end face or surface of a transformer core composed of a stack of magnetic materials with a pure silicone polymer and then drying it to form an insulating coating.

(26) A method of producing a transformer core extremely excellent in insulation and corrosion resistance, characterized in that a magnetic material is stacked, a conductor is attached, then an insulating coating of an organosilicon compound is applied and dried to fasten the magnetic material and the conductor.

(27) The method for producing a transformer core extremely excellent in insulation and corrosion resistance according to the items (25) to (26), characterized in that the applied and dried insulating coating has an average film thickness of 2 to 100 μm and a breakdown voltage of at least 30V.

(28) The method for producing a transformer core extremely excellent in insulation and corrosion resistance according to any one of (25) to (27), characterized by using a heat-curable compound as the pure silicone polymer.

(29) The method for producing a transformer core extremely excellent in insulation and corrosion resistance according to any one of (25) to (28), characterized by using a steel sheet obtained by preparing a steel sheet represented by the general formula (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²Which may be different) as a pure silicone polymer, is coated and dried one or more times by at least one of dipping, spraying, and brushing.

(30) The method for producing a transformer core extremely excellent in insulation and corrosion resistance as recited in (29), characterized in that the pure silicone polymer contains at least 50% of Si (OX)¹)₄And R¹Si(OX²)₃。

(31) The method for producing a transformer core extremely excellent in insulation and corrosion resistance according to any one of (25) to (30), characterized by adding and blending 0.1 to 50 parts by weight of SiO as inorganic powder particles or colloidal substances₂、Al₂O₃、TiO₂、ZrO₂And/or one of its complexesOne or more kinds, relative to 100 weight parts of SiO contained as additive in the pure organic silicon polymer₂And (6) counting.

(32) The method for producing a transformer core extremely excellent in insulation and corrosion resistance according to any one of (25) to (31), characterized in that the drying temperature of the pure silicone polymer is not more than 200 ℃.

(33) A simple packing method of a magnetic member for an electromagnetic apparatus composed of a plurality of pieces of magnetic material, characterized in that the plurality of pieces of magnetic material are arranged and assembled, and then a solution capable of packing the pieces of magnetic material by drying or immersing the pieces of magnetic material in the solution is applied, and then dried to bond them together.

(34) A simple packing method for a magnetic member used in an electromagnetic device is characterized in that a plurality of magnetic material pieces punched out into substantially the same shape are stacked, and then a solution capable of packing the magnetic material pieces by drying or immersing the magnetic material pieces in the solution is applied, and then dried to bond them together.

(35) The simple packing method for a magnetic element for an electromagnetic device according to (33) or (34), characterized in that as the solution capable of packing pieces of the magnetic material together by drying, a solution mainly composed of at least one of a pure silicone polymer and a modified silicone polymer is used.

(36) The simple wrapping method for a magnetic element for an electromagnetic device according to any one of (33) to (35), characterized by using, as the pure silicone polymer, a silicone polymer obtained by polymerizing (R) with (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of one or more substancesAnd an organosilicon compound produced by a partial dehydration condensation reaction.

(37) The simple wrapping method for a magnetic element for an electromagnetic device according to any one of (33) to (35), characterized in that as the modified silicone polymer, one or more of an acryl-modified silicone polymer, an alkyd-modified silicone polymer, a polyester acryl-modified silicone polymer, an epoxy-modified silicone polymer, an amino-modified silicone polymer, a vinyl-modified silicone polymer, and a fluorine-modified silicone polymer are used.

(38) The production method for an electric device operating at high temperature according to any one of (28) to (42), characterized in that as one solution having the ability to fasten and hold adjacent members to each other between the adjacent members after coating and drying and to fasten and bind them even at high temperatures exceeding 200 ℃, a solution of (R) is used¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²Which may be different), is coated on or immersed in a conductor or conductors and magnetic materials, and then dried to bond the conductor or conductors and magnetic materials together while ensuring electrical insulation between adjacent elements of the same or different types.

(39) The method for producing an electric apparatus operating at high temperature according to (38), characterized in that¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) The alkoxy group represented by (a) is,wherein R is²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of a pure silicone polymer composed of organosilicon compounds represented by (a) containing at least 80% of organosilicon compounds of at least n-0, 1 and a composition ratio of organosilicon compounds having n-0 to n-1 of from 1:20 to 4: 1.

(40) The production method for an electric device operating at high temperature as recited in any one of (38) or (39), characterized in that a heat-curable pure silicone polymer is used as the pure silicone polymer (compound).

(41) The production method for an electric device operating at high temperature according to any one of (38) to (40), characterized in that 0.1 to 10 parts by weight of SiO having an initial particle size of 7 to 5000nm is added as an additive to a pure silicone polymer₂、Al₂O₃And TiO₂One or more of (a).

(42) The production method for an electric device operating at high temperature according to any one of (38) to (41), characterized in that the thickness after drying is 2 to 100 μm.

(43) The production method for an electric device operated at high temperature according to any one of (38) to (42), characterized in that the drying temperature does not exceed 200 ℃.

Brief description of the drawings

Fig. 1 is a view showing the relationship between the film thickness and the breakdown voltage in the case where the solutions of inventive example 3 and inventive example 6 were baked while varying the deposition thickness after drying in the examples;

fig. 2 is a view of a divided core piece;

fig. 3 is a view of the state of those stacked divided core pieces being held and fastened;

figure 4 is a partial detail view of a stacked separate core segment formed with a binder film;

FIG. 5 is a perspective view of a stacked divided core sheet with wound wire on the wrapping film;

figure 6 is a view of the condition of those stacked separate core pieces with wound wire immersed in the wrapping solution;

fig. 7 is a view of the state of those stacked divided core pieces wrapped in the case;

fig. 8 is a sectional view (a) and a plan view (b) of the IPM rotor; and

fig. 9 is a cross-sectional view of a reactor formed with a wrapping film.

Best mode for carrying out the invention

The core in the present invention is a core of a motor, an exciter, a generator, a transformer, a reactor, or other energy conversion device, that is, a stacked core (including mesh-type, rod-type, block-type, and other cores, cast powder cores, etc.) of magnetic steel sheets (including stainless steel sheets and iron sheets used as magnetic materials).

The machined end faces and a part of the surface of the core are free of any insulating coating or no more coating at all. For cores having no or poor insulation on the end surfaces or surfaces of the core, elements that sometimes contact the core, such as the secondary conductor of an induction machine, the case for fastening the core in a motor, generator, or the like, bolts and other fastening elements, windings and magnets, can short-circuit the core and cause an increase in losses due to the short-circuit current and a reduction in torque, thrust or output.

Further, when the corrosion resistance of the end face or surface of the core is low, the end face or surface is easily rusted. The rust may damage the media and the encoder and other precision sensors of the recording apparatus or cause various mechanical failures, and therefore improvement of the corrosion resistance is important.

In the past, as a measure for improving insulation and corrosion resistance of an end face or surface of a core when the core is formed using a magnet steel sheet, after a coil material is stamped into the core, varnish, painting, bluing, or other heat treatment is employed.

However, in the prior art, in the case of varnishing, as a pretreatment, cleaning, annealing, etc. are necessary in order to remove stamping oil deposited at the time of stamping, and therefore, there are many problems in terms of equipment, time, and cost. Further, the adhesion, insulation and corrosion resistance of the formed varnish layer are unstable, and it is difficult to obtain sufficient effects, so that there is a problem in that it is impossible to obtain a necessary thick coating or more in the case of varnishing.

Further, even for bluing, there are many problems in stability and corrosion resistance of the oxide film and in insulating effect in addition to the problems of time and cost taken for annealing.

The inventors held the improvements of the insulating coating to the different compositions of the solution, the coating conditions and the drying or baking conditions. As a result, it was found that an iron core having extremely excellent insulating properties can be obtained by using a solution mainly composed of a silicon compound as an end face treatment agent.

From at least 30 parts by weight of converted SiO₂The coating composition is excellent in insulating properties. In particular, the inventors have succeeded in developing a coating method for an iron core end face coating and for obtaining excellent appearance, adhesion, heat resistance, corrosion resistance, wear resistance and insulation properties without pretreatment or high-temperature drying or the like in a short time, using an insulating coating composed of a pure silicone polymer, a modified silicone polymer and/or a mixed silicone polymer formed by dip-coating or spray-coating a sol mainly composed of an organosilicon compound.

Here, "SiO is converted₂The "weight of (b)" represents the total Si present in the silicon compound in the form of siloxane (Si-O-Si) bonds in terms of SiO₂The case of the form.

Furthermore, "neat silicone polymer" means a polymer obtained by the reaction of (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of the compound produced by the hydrolysis reaction and dehydration condensation reaction of one or more species represented by (R) modified silicone polymer³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, R being more than one when n is 2 or 3³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, and when n is 0, 1 or 2, a plurality of R⁴May be different), and "hybrid silicone polymer" means a compound produced by a hydrolysis reaction and a dehydration condensation reaction of one or more species represented by (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) and (R) is³)_nSi(X²)_4-n(wherein n is an integer of 0 to 3, R³Is an organic functional group other than alkyl or phenyl, and when n is 2 or 3, a plurality of R³May be different, X²Is made of Cl or O (R)⁴) Alkoxy of the formula (I), wherein R⁴Is alkyl, and when n is 0, 1 or 2, a plurality of R⁴May be different) of the compound produced by the hydrolysis reaction and dehydration condensation reaction of one or more substances represented by (a) or (b).

In addition, the solution state of these silicone polymers is made with pure silicone polymers, modified silicone polymers and mixed silicone polymers.

The present invention is explained in detail below.

The invention is characterized by a treatment method for obtaining an insulating coating on the end faces of a core. The composition of the solution is characterized by using one or more of a silicone resin, an alkali metal silicate, colloidal silica, a low melting glass frit, a pure silicone polymer sol, a modified silicone polymer sol, and a mixed silicone polymer sol as the composition of the solution. By dipping the core material into the solution or coating it by spraying, a uniform and dense coating can be formed on the exposed surface of the iron (i.e., the core end face or the groove portion) formed at the time of stamping.

In particular, when the silicon compound used is one or more of a pure silicone polymer sol, a modified silicone polymer sol, and a mixed silicone polymer sol, drying is completed at a low temperature in a short time, and a dense film having good adhesion and insulation properties is formed on the end face of the core.

It is well known that among silicone polymers formed from these sols, particularly a film of a pure silicone polymer can obtain more excellent heat resistance and is optimal for a core production process including an annealing step.

Further, as a method for forming a coating layer at a lower temperature and in a shorter time, it is effective to introduce other metals or semimetals having a crosslinking action, i.e., Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb or Bi, in the form of alkoxide or chloride dissolved in a solvent and to cause dehydration condensation reaction together with a silicon compound, thereby accelerating the formation of a siloxane (Si-O-Si) bond network.

When attempting to obtain high insulation resistance or voltage resistance, corrosion resistance or heat resistance, SiO per 100 parts by weight of the total silicone polymer₂0.1 to 50 parts by weight (in terms of solid content) of one or more of inorganic oxide powder particles, inorganic oxide colloidal substances, organic resin powder particles and organic resin latex solutions may be added as fillers to the above-described inorganic oxide powder particles, inorganic oxide colloidal substances, organic resin powder particles and organic resin latex solutionsAmong the silicone polymers in the silicon compound, an extremely significant effect in terms of improvement in insulation and breakdown voltage is thus obtained, and as a composite effect, the wettability to the end face of the core or the surface of the steel sheet is further improved.

In the treatment by the coating agent, pretreatment such as cleaning or annealing is unnecessary, which is necessary in the ordinary case of using an organic varnish or an inorganic insulating agent. This brings the advantage that the stamped core material can be directly processed to obtain an insulating coating after clamping.

When an insulating agent solution is applied, the ability of the solution to deposit on the end faces of the core can be controlled by controlling the type of solvent and the ratio, concentration and viscosity of the solvent. The solution can be applied to a predetermined thickness by controlling the extraction speed for the case of dip coating and the nozzle shape, ejection speed, etc. for the case of spray coating, in combination with the conditions of the solution. At this time, when a desired thickness cannot be obtained by a single process, the thickness may be obtained by coating once, drying at a low temperature, and then dip-coating or spray-coating again.

In the case of the silicon compound of the present invention, the drying conditions are drying and baking at a low temperature of less than 300 ℃ and in a short time.

In particular, when a pure silicone polymer, a modified silicone polymer, or a mixed silicone polymer obtained by using silane as a raw material is used, drying at room temperature to around 120 ℃ is sufficient. In particular, when a modified silicone polymer or a mixed silicone polymer is used, low-temperature and short-time drying is possible by the action of the modifying functional group. When short-time drying is required, extremely rapid treatment of the end faces of the core can be made possible by drying at temperatures as high as around 300 ℃ in the same manner as when a silicon compound is used.

Next, the reasons for these limitations of the present invention are explained.

First, the reason for the limitation of the core material having high insulation performance will be explained.

The iron core of the invention is characterized by a coating having an average film thickness of at least 0.5 [ mu ] m and containing at least 30 parts by weight of SiO in the coating in terms of SiO₂The silicon compound of (1).

The reason why the average film thickness of the coating layer of the end face of the core is to be at least 0.5 μm is that it is necessary to obtain the effect of improving the insulation and corrosion resistance. For an average film thickness of less than 0.5 μm, sufficient insulation and corrosion resistance cannot be obtained if a thin portion of the coating is locally present.

Furthermore, why it is necessary to include at least 30 parts by weight of a silicon compound (in terms of SiO) in the coating₂Meter) is that this is important for the density, insulating properties and heat resistance of the coating. In particular, it is preferable to contain at least 50 parts by weight, more preferably at least 75 parts by weight of the compound in order to improve insulation and heat resistance.

Another feature is that the silicon compound comprises one or more of alkali metal silicates, colloidal silica, low melting glass frits, neat silicone polymers, modified silicone polymers, and mixed silicone polymers.

When the surface is treated with these silicon compounds and they are dried, the insulating coating is dense and forms a uniform coating. The alkali metal silicate used is a mixture of M₂O nSiO₂ mH₂O (M: LiNa, K, n:1-4), such as sodium silicate.

Cores having a coating of an organosilicon compound called a pure organosilicon polymer, a modified organosilicon polymer or a mixed organosilicon polymer among these silicon compounds are characterized by a dense coating with sufficient uniformity and excellent properties in terms of corrosion resistance and insulating properties. In particular, in the case of a core having a pure silicone polymer coating, there is an advantage of excellent heat resistance at a relatively high temperature.

As the most preferable condition of the insulating coating, there is an insulating coating composed of a dried film of a pure silicone polymer, a modified silicone polymer and/or a mixed silicone polymer among the above silicon compounds having an average thickness of at least 2.0 μm, preferably 2.5 to 20 μm, and having a breakdown voltage of at least 30V on the end face of the core.

The core variation in the shape and roughness of the core end faces depends on the cutting or stamping conditions of the material. If there is a thickness of at least 2.0 μm, any change is absorbed and stable insulation properties are obtained. If the thickness is too thick, a cost problem or a problem such as a decrease in adhesion of the insulating coating may occur.

Another feature of the core of the present invention is that the core has a heat resistance of at least 400 ℃. "Heat resistance" as used in the present invention means that the adhesion and insulation properties are not impaired when annealed at this temperature. When a pure silicone polymer sol belonging to the treating agents used in the present invention is used in particular, the heat resistance is excellent. This makes it suitable for Al die casting or Cu die casting of the core.

Further, as the silicone polymer sol, a heat-curable silicone polymer sol is more preferable as the treating agent. This is because, in the case of the thermosetting type, there is an advantage in that: the solution that seeps between the steel sheets during dip coating or other coating processes can be dried in a short time while heating and drying.

The present inventors studied insulation of a motor core and efficiency of the core, and found that an improvement effect of electrical insulation can be obtained for an element contacting the core by improvement of insulation properties of an end face of the core, a short-circuit current between pieces which causes an increase in loss and a decrease in output is suppressed, and motor torque (thrust) and output power are improved.

For example, for a high-speed induction motor (180,000rpm, two poles) having a secondary conductor interval of 2cm in a rotating core, a core height (stacking height of magnetic steel sheets) of 50cm, and a 1T core excitation flux amount, a breakdown voltage of at least 34V (reference:180,000rpm/60s＝3kHz，√2ǒ × 3,000 × 0.02m × 0.5m/2 × 1T × two end faces 33.3V) are necessary. Thus, in practice, at least 50V is necessary.

The coating layer obtained from the pure silicone polymer, modified silicon polymer and mixed silicone polymer of the present invention can be made to be mainly composed of SiO by curing in a layered or three-dimensional shape by drying at low temperature in a short time in the process of removing alcohol or other solvent contained in the solution₂A dense insulating coating having excellent adhesion.

Since a breakdown voltage of at least 30V is obtained if the film thickness after drying reaches at least 0.5 μm with the insulating coating formed in this way, the lower limit of the average film thickness is 0.5 μm.

However, if the film thickness is more than 20 μm, the adhesion of the coating after the treatment may be degraded and cracks may occur according to the drying or baking conditions. Particularly when heat treatment is performed, adhesion defects sometimes occur. Further, the drying takes a long time, resulting in an increase in cost, and thus the thickness is limited.

The insulating coating used is one or more pure silicone polymers, modified silicone polymers, or hybrid silicone polymers. For example, by reaction of a compound of formula (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) in the absence of a solvent or in an inorganic solvent, and partial dehydration condensation reaction to produce a pure silicone polymer sol.

At this time, the type of the raw silane monomer used may be changed to provide various properties to the coating layer formed from the sol.

Furthermore, the present inventors have used pure silicone polymers for repeated large-scale experiments and have conducted studies on the conditions required to obtain a thick film having good insulation and heat resistance, and as a result, have found that the use of a so-called tetrafunctional or trifunctional silicone polymer having a composition of the above general formula in which n ═ 0 or 1 is very advantageous when a heat treatment step is involved.

In particular, by combining the component of n-1 in the range of 20 to 80% in the combination of n-0 and 1, a thick insulating coating extremely excellent in appearance, insulation, heat resistance and adhesion becomes possible.

The modified silicone polymer is a raw material monomer of a pure silicone polymer modified with an organic resin other than an alkyl group or a phenyl group. As a method of modification, the polymer is modified by known cold blending or condensation reaction or the like.

The hybrid silicone polymer is produced by hydrolysis and dehydration condensation reactions of raw monomers capable of forming a neat silicone polymer and raw monomers capable of forming a modified silicone polymer in the desired proportions. The pure silicone polymer component and the modified silicone polymer component are networked at the molecular level.

The raw material for obtaining the sol of pure silicone polymer is one or more of tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, tetrabutoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriisopropoxysilane, monomethyltributoxysilane, monoethyltrimethoxysilane, monoethyltriethoxysilane, monoethyltriisopropoxysilane, monoethyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, and diphenyldiethoxysilane of C4 or C4 alkyl type or less, and silane tetrachloride as silane chloride, titanium methyltrichloride, and the like.

The introduction of alkyl or phenyl groups provides flexibility and processability to the coating and allows it to exhibit better heat resistance compared to other organic functional groups.

However, as the number of carbon atoms of the alkyl group increases, heat resistance decreases, film formability decreases, drying temperature becomes higher, and other problems arise, and therefore, it is desirable that not more than four carbon atoms are present. Especially when heat resistance around 500-600 ℃ is considered, not more than one carbon atom is desirable.

As the modified silicone polymer, for example, one or more of acryl-modified silicone polymer, alkyd-modified silicone polymer, polyester acryl-modified silicone polymer, epoxy-modified silicone polymer, amino-modified silicone polymer, vinyl-modified silicone polymer, and fluorine-modified silicone polymer can be used. These modified organosilicon polymers also form bonds between organic functional groups other than Si-O-Si bonds, thus obtaining a dense insulating coating at low temperatures.

The hybrid silicone polymer is formed by using one or more of each of the raw material monomers for obtaining the above-described pure silicone polymer and the raw material monomers for obtaining the modified silicone polymer. The polymer enables to simultaneously realize heat resistance and the like of a pure silicone polymer and low-temperature curability, water repellency and other functions of a modified silicone polymer on a molecular level.

In addition, another metal oxide may be introduced to any of these silicone polymers as a catalyst or crosslinking point to promote the condensation reaction. Examples of the metal alkoxide as a raw material in this case include tetraethoxytitanium, isopropoxytitanium, and butoxyaluminum.

The insulating coating containing the silicone polymer is formed by an extremely rapid drying step in which desolvation and dehydration occur simultaneously₂The formed compact and firm coating. Thus, the insulating coating formed is dense, resistant to corrosion and to compressive stresses. When various steps are carried out in the following stepsThis is advantageous during processing.

Furthermore, when the organic group is an alkyl group such as methyl, phenyl or a fluorine-containing group such as CH₃When it is used, it is water repellent and more excellent corrosion resistance is obtained, and therefore it contributes to improvement of corrosion resistance.

Each of these silicone polymers can give a better coating than the prior art, but a denser coating having good insulating properties, heat resistance and adhesion is obtained in the case of pure silicone polymer, while in the case of modified silicone polymer or mixed silicone polymer, a tendency is shown to be slightly inferior in insulating properties, film strength, corrosion resistance, heat resistance and the like, compared with the former case, due to the organic resin component contained.

Further, in the case where the metal element or semimetal element M other than oxygen, carbon, hydrogen and nitrogen is mainly silicon (Si) which is mainly present in the form having Si — O bonds, and M other than silicon contains one or more elements selected from Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb and Bi as preferable conditions of the above insulating coating, the advantages should be attributed to the following reasons:

to impart insulating properties, the insulating coating is preferably a dense amorphous structure. Therefore, it is necessary to make the Si-O-Si network structure having an amorphous structure at a higher temperature a basic skeleton of the coating substrate.

However, in the method of forming a coating from a solution (sol), a problem of peeling of the coating occurs due to shrinkage occurring upon desolvation or condensation.

As a measure for solving this problem, there is a method of dispersing a stable oxide in a solvent and introducing it into a coating layer. The addition of oxides or composite oxides of metals or semimetals other than Si, suitable for the solvent, is advantageous.

Furthermore, the condensation reaction of Si-O-Si has the disadvantage of generally low reactivity. To improve this reactivity, a metal or semimetal catalyst is added, or the M-O bonds of the metal or semimetal (M) other than Si, constituting the crosslinking points of the Si-O-Si network, are introduced by using the alkoxide or acetoacetate complex or chloride of M. A dense film containing M was formed in a short time. As a result, the coating containing M gives a dense insulating coating with few cracks.

Next, the reason why the total weight ratio of Si, Li, Na, K, Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb, and Bi in the insulating coating relative to the total weight of those elements other than oxygen, carbon, hydrogen, nitrogen, sulfur, and fluorine in the insulating coating is at least 90 parts by weight and the weight ratio of Si relative to the total weight of those elements other than oxygen, carbon, hydrogen, nitrogen, sulfur, and fluorine in the insulating coating is at least 50 parts by weight is as follows:

the high insulating properties are substantially maintained by the insulating oxide in the coating. Therefore, the ratio of the metal components of the insulating oxide, i.e., Si, Li, Na, K, Mg, Ca, Y, Ti, Zr, Nb, B, Al, Ge, Sn, P, Sb and Bi, is preferably at least 90 parts by weight, more preferably at least 95 parts by weight, of all the components except oxygen, carbon, hydrogen, nitrogen, sulfur and fluorine contained in the organic functional groups introduced for imparting processability, water repellency, and the like, and additionally except oxygen for limiting the metal components.

Among these, as described above, the matrix structure of the coating greatly contributes to the Si-O-Si network. In the insulating coating, the weight ratio of the basic skeleton component, i.e., Si, must be at least 50 parts and preferably at least 75 parts by weight relative to the total weight of those elements other than oxygen, carbon, hydrogen, nitrogen, sulfur and fluorine, in view of improvement of insulating properties and improvement of coating strength.

In the application of the invention, it is advantageous to use, in particular, non-oriented magnetic steel sheets as core material and to use them for the insulation of the end faces during the assembly of the core. That is, in a core material of a motor core or the like, in almost all cases, the stacked core is treated to prevent rust or is subjected to an annealing treatment or is treated with an organic varnish to obtain an insulating property or both of them. The effect of this is enormous.

Next, in the method of producing an iron core using the present invention, in the step of processing the iron core, the non-oriented magnetic steel sheet iron core is punched, stacked, clamped, and processed as necessary to prevent rust or obtain insulating properties, etc. The technique of the present invention makes it possible to easily obtain a simple, low-cost and high-productivity non-oriented magnetic steel sheet core having excellent coating properties.

The core is treated with one or more of a silicone resin, an alkali metal silicate, colloidal silica, a low melting glass frit, a pure silicone polymer sol, a modified silicone polymer sol, and a mixed silicone polymer sol as a component of the insulating coating agent.

The core is characterized in that an average thickness of the insulating coating of 0.5 μm to 20 μm is obtained after production. The insulating coating layer densely and uniformly forms a coating layer when it is treated with a silicon compound and dried.

In particular, when a pure silicone polymer sol, a modified silicone polymer sol, and a mixed silicone polymer sol composed of an organosilicon compound are used, cleaning, annealing, or other pretreatment is not required in the treatment with the insulating coating agent, and thus it can effectively reduce the cost of industrial treatment.

Further, the insulating coating is dense and uniform and excellent in corrosion resistance and insulating properties. In addition, in the case of a pure silicone polymer, there is an advantage of excellent heat resistance at a higher temperature. This is advantageous for cases involving annealing, aluminum die casting or other heat treatment steps.

For the coating of the present invention, when the average film thickness is less than 0.5 μm, a sufficient effect of improvement of the insulation property and the corrosion resistance cannot be obtained. On the other hand, for a film thickness exceeding 20 μm, a locally thick portion occurs and the stacking thickness of the core increases or the adhesiveness deteriorates. In particular, this is set as a limit because local peeling or delamination of the insulating coating easily occurs when an annealing step is included.

For these applications, there are methods such as dip coating, spray coating, etc., but if the simplicity of the apparatus and the efficiency of use of the solution are taken into consideration, dip coating is advantageous.

Coating agents embodying features of the invention are characterized by the use of one or more of pure silicone polymer sol, modified silicone polymer sol, and mixed silicone polymer sol, depending on the composition of the solution.

The pure organic silicon polymer sol is prepared by the reaction of (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) is produced by performing hydrolysis and partial dehydration condensation reactions in the absence of a solvent or in an organic solvent, and is maintained in a sol state.

The modified silicone polymer sol is a solution of a compound obtained by hydrolysis and partial dehydration condensation reaction of raw material monomers of a pure silicone polymer sol modified with an organic resin other than an alkyl group or a phenyl group. The modification method is a known modification method utilizing cold blending, condensation reaction, or the like.

The mixed organic silicon polymer sol is produced by hydrolysis and dehydration condensation reaction of raw material monomers constituting the pure organic silicon polymer sol and raw material monomers constituting the modified organic silicon polymer sol in a desired ratio, and a structure is formed by using a pure organic silicon polymer sol component and a modified organic silicon polymer sol component which form a network at a molecular level.

Further, these coating agents are made into a sol by subjecting a metal or semimetal (M) other than Si as an alkoxide or chloride to hydrolysis and partial dehydration condensation reaction, to obtain an O-M-O-Si bond.

The raw material of the pure silicone polymer sol used is one or more of tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, tetrabutoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriisopropoxysilane, monomethyltributoxysilane, monoethyltrimethoxysilane, monoethyltriethoxysilane, monoethyltriisopropoxysilane, monoethyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, and diphenyldiethoxysilane of C4 or C4 alkyl type or less, and silane tetrachloride, titanium methyltrichloride, and the like as the silane.

The modified silicone polymer sol used is, for example, one or more of acryl-modified silicone polymer, alkyd-modified silicone polymer, polyester acryl-modified silicone polymer, epoxy-modified silicone polymer, amino-modified silicone polymer, vinyl-modified silicone polymer, and fluorine-modified silicone polymer. These are used by water and/or alcohol or another solvent, suitably diluted.

In particular, modified silicone polymers with polar functional groups are an effective mode of operation because no alcohol is required as a solvent. Also for the modified silicone polymer, there are bonds between the organofunctional groups other than Si-O-Si bonds. This is effective for forming a dense insulating coating at low temperature.

As the mixed silicone polymer, one or more of each of the raw material monomers for obtaining the above-mentioned pure silicone polymer and the raw material monomers for obtaining the modified silicone polymer may be used. As metal alkoxides used as crosslinking points of the matrix, tetraethoxytitanium, isopropoxytitanium, butoxyaluminum, and the like have been known.

Solutions for treating the end faces, surfaces, etc. of iron cores with these silicone polymers can be desolvated and dehydrated simultaneously, and thus dried extremely rapidly, forming a dense coating mainly composed of Si — O structures. Furthermore, the insulating coating formed is dense, resistant to corrosion and to compressive stresses. This is advantageous when various processing is performed in the subsequent steps.

When these silicone polymer sols are used and the film thickness after drying and/or baking is 0.5 to 20 μm, the adhesion is excellent and insulation treatment of the end face of the core excellent in insulation performance, breakdown voltage, corrosion resistance and heat resistance can be achieved. In particular, with the pure silicone polymer, an insulating coating superior in heat resistance is obtained.

In particular, when one or more of tetraethoxysilane, tetramethoxysilane, methyltriethoxysilane, methyltrimethoxysilane, and the like are used, excellent heat resistance is obtained. On the other hand, in the case of the modified silicone polymer or the mixed silicone polymer, a tendency of deterioration in heat resistance is exhibited, and therefore, this is suitable for an application in which annealing is not performed.

SiO by mixing with respect to 100 parts by weight of pure silicone polymer sol, modified silicone polymer sol and mixed silicone polymer sol₂Adding one or more inorganic powder particles, organic resin powder particles and/or latex solution or colloidal solution thereof as a filler to a coating solution using one or more of pure silicone polymer sol, modified silicone polymer sol and mixed silicone polymer sol in an amount of 0.1 to 50 parts by weight (in terms of solid content) can achieve an extremely significant effect of improvement in insulation property and breakdown voltage, and in addition, as a composite effect, improves the deposition force on the end face of the core or the surface of the steel sheet.

Further, by reducing the shrinkage upon drying, cracking can be easily suppressed and the thickness can be easily increased.

As the filler to be added at this time, 0.1 to 50 parts by weight of SiO having an initial particle size of 7 to 5000nm is added to the inorganic substance₂、Al₂O₃、TiO₂、ZrO₂And composites thereof, and blended as powder particles or colloidal materials.

As for the organic substance, the addition and blending of 0.1 to 50 parts by weight of one or more substances selected from the group consisting of acryl resin, polystyrene, polyethylene, polypropylene, polyamide, polycarbonate, polyurethane, melamine, phenol resin, epoxy resin and copolymers thereof having a particle size of 50 to 10,000nm as an emulsion substance can effectively improve the insulating property.

When SiO is contained in an amount of 100 parts by weight based on the whole silicone polymer₂When the amount is less than 0.1 part by weight, the effect of improving the insulation property and the adhesion is weak. On the other hand, if it exceeds 50 parts by weight, the improvement of the coating breakdown voltage is larger, but the density of the film is deteriorated or the life of the solution is decreased, so this is set as a limit.

As fillers, in the case of inorganic oxides, SiO₂、Al₂O₃、TiO₂、ZrO₂Or a powder or colloidal substance of a composite thereof is advantageous in that cost is reduced and an improvement effect of insulation properties is obtained due to good dispersion and addition.

In the case of the organic type, one or more powders or emulsions selected from acryl resin, polystyrene, polyethylene, polypropylene, polyamide, polycarbonate, polyurethane, melamine, phenol resin, and epoxy resin, or the like in a suitable combination may be used.

The inorganic additive is advantageous if the solution stability, hardness, insulating effect, heat resistance and the like are all considered together for the case of addition, because of lower cost and the possibility of obtaining excellent dispersion and stable improving effect of insulating property and adhesiveness. In particular, this effect is significant when strain annealing or another heat treatment step is performed.

The particle size of the filler is important. For the inorganic type filler, when the particle size is less than 7nm, when dispersed in a solution, the cohesion becomes stronger and the coating thickness becomes uneven or has an influence on the pH of the solution, and the stability of the solution is deteriorated, so this is set as a limit.

On the other hand, when the particle size exceeds 5000nm, the surface roughness becomes too large due to coarse particles, and the inorganic substance is liable to peel off from the end face of the core due to abrasion or the like, so that it is set as a limit. If in this range, the adhesion is good if there is a balance between the film thickness and the addition amount, and an insulating coating having a high breakdown voltage can be formed. This is set as a limit for the same reason as in the case of the organic filler.

When additives are added to the silicone polymer, a more uniform dispersion is desirable. If the powder material is added after dispersion in an alcohol or other solvent, an excellent dispersion effect is obtained. This is advantageous for obtaining a coating of uniform thickness. In particular, if the dispersing action of ultrasonic vibration or the dispersing action of another mixer or the like is used in conjunction, a uniform dispersion can be obtained.

When the iron core is dried after coating with the solution, drying at normal temperature is sufficient, but when it is attempted to dry in a short time or to improve the efficiency of the process, desolvation and dehydration condensation can sufficiently proceed and good coating properties are obtained if drying is performed in an oven at a temperature of not more than 300 ℃ for at least 30 seconds. As a preferred drying method, gradual heating can give good coating properties.

This is because if heated rapidly, water, alcohol or another solvent dries rapidly and bulk surface defects are easily generated.

When repeated coating with the solution of the invention to obtain thick coatings, it is advantageous, in order to obtain thicker coatings and good insulating properties, to first coat and dry the filler-containing solution at low temperatures of from room temperature to 120 ℃ and then coat and dry the filler-free solution.

In the case of repeated coating, it is sufficient to apply a coating agent containing a filler to obtain an average film thickness of 0.2 to 10 μm after drying, and then to apply a solution containing no filler to obtain an average film thickness of 0.5 to 20 μm after drying.

The treatment with reduced filler content is due to the fact that: the combined application of a large amount of a coating agent containing no filler can flatten the roughness caused by the filler, making it easy to obtain an insulating coating having high insulation, uniformity, adhesion, and corrosion resistance.

The reason for the limitation in the transformer core having high insulation performance is explained next.

The stacked sheets of the magnetic material in the present invention are treated with an insulating coating containing an organosilicon compound on their end faces and surfaces, thereby having excellent insulation and corrosion resistance. The coating component of the organosilicon compound used in the present invention has Si-O bonds and is formed mainly of SiO₂Extremely dense coatings of the components. Therefore, an insulating coating having extremely excellent insulating properties and corrosion resistance can be formed.

The thickness of the insulating coating of the invention reaches 2-100 μm. For a thickness exceeding 2 μm, the breakdown voltage becomes 40V, which is sufficient for a small transformer. If the thickness is less than 2 μm, there is a locally thin portion depending on the shape of the end face of the core and a stable breakdown voltage cannot be obtained. On the other hand, if the thickness exceeds 50 μm, the infinite breakdown voltage is approached. There is no problem even when a high breakdown voltage is required for the occasion of a large transformer. For the upper limit, the coating may be thick, but the limit of the maximum thickness is 100 μm in view of dryability, repeated application and adhesion of the insulating coating in actual operation. The most preferable range is 3 to 30 μm in view of easiness of coating treatment, coating property, cost, and the like.

Further, the transformer core of the present invention refers to a transformer core in which only the stacked core is treated to have an insulation property and a transformer core in which a conductor is attached to the stacked core, and then they are simultaneously subjected to an insulation coating. In the latter case, since the stacked core and the conductive material are simultaneously processed to obtain the insulating coating, not only insulation but also adhesion of the core and the conductor are simultaneously accomplished. The insulating coating penetrates the end faces of the core, the surfaces, between the steel sheets (foils), between the conductors and the interfaces between the core and the conductors. Not only extremely excellent insulating properties and corrosion resistance are obtained for the dried film, but also the stacked core material, the conductor itself, and the core and the conductor are strongly bonded. With the organosilicon compound coating of the present invention, a coating having excellent insulation and adhesion with hardness, strength, heat resistance, and the like is obtained depending on the composition thereof.

Next, as the composition of the solution of the organosilicon compound used in the present invention, a solution of the compound represented by the general formula (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different), the end face and the surface are coated and dried one or more times by at least one of dipping, spraying and brushing with drying being interposed. The organosilicon compounds are produced by hydrolysis and polymerization of known alkoxysilanes in the absence of solvents or in organic solvents. By varying the type or combination of silanes used at this time, coatings having various properties can be obtained.

When producing a partial hydrolysate of alkoxysilane as the organosilicon compound, it is possible to useOne or more of tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, tetrabutoxysilane, monomethyltrimethoxysilane, monomethyltriethoxysilane, monomethyltriisopropoxysilane, monomethyltributoxysilane, monoethyl-trimethoxysilane, monoethyltriethoxysilane, monoethyltriisopropoxysilane, monoethyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyldimethoxysilane, diethyldiethoxysilane, phenyltrimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, and diphenyldiethoxysilane. At this time, as a more preferable condition, if the raw materials are prepared so that the coating agent contains at least 50% of the compound (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different), excellent in insulating property, corrosion resistance, adhesion and heat resistance can be obtained. When the content is less than this value, heat resistance tends to decrease, and peeling of the film occurs according to heating conditions. Most preferably when the agent contains at least 50% R¹And at least 5% of X¹The case (1). In this case, a thick coating excellent in adhesion and heat resistance is obtained.

Depending on the production method, as the organosilicon compound, there are a heat-curing type treating agent which gives a partial hydrolysate of a silane compound as a reaction during curing and then can be used for treatment and curing by heating to evaporate alcohol or moisture of the solvent component, and a moisture-curing type treating agent which does not undergo partial hydrolysis during production of the organosilicon compound but can give a curing agent for treatment and then curing by hydrolysis and condensation reaction of moisture in the air. For the invention, the dielectric coating process, the wrapping and the adhesion are important not only on the sheet end faces but also between the sheets (foils), the spaces between the conductors and between the sheets (foils) and the conductors. As more preferable conditions, the use of the heat-curable solution is advantageous for obtaining a stable rapid drying and performance of the insulating coating.

By applying and drying one or more organosilicon compounds composed of partial condensates obtained from silanes at low temperatures, SiO excellent in coating properties can be formed₂A polymer film.

Further, when it is attempted to obtain high insulation resistance or breakdown voltage in a wrapping film, 0.1 to 50 parts by weight (in terms of solid content) of inorganic oxide powder particles or a colloidal solution as a filler is added to an organosilicon compound relative to 100 parts by weight of SiO contained in the organosilicon compound₂And (6) counting. As a combined effect of the added filler, the deposition ability on the core end face or steel sheet (foil) surface and the crack resistance and insulation properties of the coating are improved. As the inorganic powder particles or colloidal substances added, 0.1 to 50 parts by weight of a material selected from SiO having an initial particle size of 7 to 5000nm may be added₂、Al₂O₃、TiO₂、ZrO₂And/or one or more of its composite materials. If the amount is less than 0.1 part by weight, the effects of improving wettability, chipping resistance and insulating properties are not obtained. Further, if it exceeds 20 parts by weight, the wrapping property and adhesion are poor, and film unevenness is liable to occur. The optimum range of addition is 0.4 to 2 parts by weight.

The method of applying the above-mentioned organosilicon compound may be a general method of applying a surface coating, painting, or the like. Not only spray coating and dip coating methods but also brush coating methods may be used. General methods of suppressing unevenness of the coating amount and the like may also be used. Further, in order to improve the adhesion of the contact portion of the conductor, the magnetic material, or the like, if cleaning is performed once on the contact portion, the wrapping solution is impregnated in the contact portion, and then a predetermined contact state is established, it is possible to secure the wrapping force after drying.

The thickness of drying is easily controlled by changing the solvent type of the solution or the concentration or viscosity of the solvent. If the coating and drying steps are performed several times, the film thickness can be increased by this amount. The coating can be applied to a predetermined thickness by controlling the pull-out speed for the case of dip coating and the nozzle shape, spray speed, etc. for the case of spray coating, together with the above-described solution conditions. Further, the solution aggregation can be suppressed and the film thickness can be adjusted by blowing compressed air.

The electrically insulating coating formed in the present invention also has a wrapping function. In addition, it is also used as a rust preventive film. That is, only the end face of the core may be coated or the winding may be attached and then coated to secure it. The dry film of the present invention is mainly composed of SiO₂Composition, a dense film having Si-O bonds is formed, and thus extremely excellent insulating and rust preventing functions are exhibited.

When the organosilicon compound of the invention is used, the drying temperature should not exceed 200 ℃. This is because the solvent constituting a part of the organosilicon compound is mainly methanol, ethanol, butanol, propanol, water, or another low-temperature volatile solvent. The preferred drying temperature is 80-120 ℃. This drying temperature is made possible by the use of low boiling solvents. If within this temperature range, drying within a short time of several minutes becomes possible.

In large, medium and small transformers for electrical use, the flow of short-circuit current itself is a serious problem and therefore must not be allowed. The present invention also addresses the problems in terms of work efficiency, cost, and work environment caused by varnishing and other treatments that are typically performed after deburring, as well as other treatments of the end faces of the core material. If the organosilicon compounds according to the invention are used, better properties (functions) than those of the varnishes are ensured and these problems are reduced.

As the electric device in the present invention, there are an electromagnetic device and a heater. Electromagnetic devices include motors, exciters, generators, transformers, reactors, and the like. The heater uses induction heating, radiant heating using infrared or other light and electromagnetic waves, and heating using direct conduction. The application and model are irrelevant.

The motors, exciters and generators are classified as induction type motors, synchronous type motors, direct current type motors, reactance type motors or a combination of two or more types, and include large to micro motors. In addition, transformers include wound transformers, stacked transformers, and other types using various types of cores. Reactors are used for inverters, converters, vibration converters, devices for adjusting phases of voltage and current and improving power coefficients, filters for removing high frequencies and the like, ignition and the like. There are now a wound type, a stacked type, a type with cleaning and a type without cleaning, a saturable type, a type which does not allow saturation when used, a type which uses a cutting core, and the like. Both types with and without a core or yoke are possible. Furthermore, both types with permanent magnets and types without them are possible.

The core and yoke include magnetic steel sheets, metal alloys of the angstrom, iron-cobalt alloys, amorphous magnetic material cores, and other stacked cores, soft ferrite cores, cast cores, powder metallurgy cores, plastic formed cores of powder, and the like. The materials of the core and yoke include magnetic steel sheets, plates, and other ferrous metals or ferrous metal alloys, nickel, angstrom metals, and other nickel alloys, cobalt and cobalt alloys, and soft ferrites, amorphous materials, nanocrystalline materials, and the like. Such applications include armature cores, yokes, transformer cores, reactor cores, electrical cores, printed circuit boards, and the like. In particular, cores and yokes obtained by stamping and stacking magnetic steel sheets are largely used. The core includes, for example, a core used in a rotary machine obtained by punching and stacking individual pieces, a core using a combination of divided core pieces, and a wound core sometimes used in an axial gap type rotary machine, such as a plastically deformed core used in a transformer or a reactor, e.g., a claw pole core, a wound core, a stacked core, a sintered core, a powder molded core, a plastically formed core, or the like, a cut core, an El core, or the like. The present invention can be used in all of these.

The permanent magnet is not limited in type or shape, and is used not only in the fields of motors, exciters, and generators, but also for bias flux (magnetic field) used in a feedback transformer and a reactor.

Electromagnetic devices, as explained above, use a number of magnetic elements such as armature cores, permanent magnets, yokes, and the like. Even armature cores, yokes, etc. often comprise a plurality of pieces of magnetic material, as in a stack of magnetic steel pieces.

Electromagnetic devices are sometimes magnetically shielded or electromagnetically shielded to prevent magnetic flux from leaking to the outside or to prevent external magnetic flux from intruding into the device and adversely affecting the outside or inside of the equipment. The magnetic elements of the present invention include magnetic shields and electromagnetically shielded magnetic elements. In this case, the electromagnetic apparatus to which the present invention relates includes apparatuses, devices and facilities capable of generating magnetic flux and electromagnetic waves, and accordingly includes apparatuses, devices and facilities influenced by the magnetic flux and the electromagnetic waves. In addition, the present invention can also be applied to general magnetic shield materials and electromagnetic shield materials.

Electrical devices use conductors. The conductors of the electromagnetic device carry armature current or current that generates magnetic field flux. They may be provided on the stator side or on the rotor or moving plate side. Secondary conductors that carry induced currents, such as in an induction motor, short rings for a voice coil motor, and the like, are also included as conductors. The conductor of the heater is a heating element or the like. Furthermore, leads and lead systems for use in electrical equipment are included in the conductors of the present invention.

The high-temperature operating electrical apparatus of the present invention includes an apparatus used at a high temperature and used in a high-temperature environment, and an apparatus that becomes high in temperature because of heat generated due to a conductor or a magnetic material. Therefore, the electrical insulation and magnetic flux retention of the conductor or magnetic material must be able to withstand even high temperatures. The heat resistant temperature of the insulating coating or adhesive applied to the ordinary conductor is usually 180 ℃ maximum of type H of JIS (japanese industrial standards). In the present invention, "high temperature" refers to a temperature range of 200-. If the temperature is above 900 ℃, a mechanical failure occurs in the conductor itself. According to the present invention, it is possible to provide an electric apparatus capable of operating even at such a temperature.

In the present invention, a solution (hereinafter referred to as "dressing solution") having an ability to fasten and bind a conductor or a magnetic material and an ability to maintain the electrical insulating property of the conductor or the magnetic material at a high temperature after drying or a state of fastening and binding is applied or the dressing solution is impregnated, thereby depositing the dressing solution on the outside of the conductor or the magnetic material or impregnating the dressing solution between the conductors, between the magnetic materials, between the conductor and the magnetic material, and on the contact portions between the conductor, the magnetic material, and other elements. The binding solution is then dried at ambient or higher temperatures to bind the conductor and magnetic material or these and other components. The drying conditions in the present invention are sufficient drying at room temperature to around 120 ℃, but extremely rapid drying and curing becomes possible by drying at 80-200 ℃ for at least 30 seconds to obtain a sufficient coating effect.

In the present invention, the coating formed by drying the binding solution will cover the outer surface of the magnetic material or other components and bind them together. In addition, the binder solution penetrates into adjacent conductors, magnetic materials, etc., and binds them together when dry. (hereinafter, the coating or thin layer formed after the binding solution is dried is referred to as "binding film") therefore, since the binding capacity is determined by the type and thickness of the binding film, it is sufficient to determine the type and film thickness of the binding solution as needed. Further, the bundling ability varies depending on the shapes of the conductor and the magnetic material and the state of the surface or end face, so it is necessary to consider the shapes of the conductor and the magnetic material and the state of the surface or end face.

As a binding solution, a solution consisting essentially of one or more pure silicone polymers is used. The pure silicone polymer is prepared by polymerizing a monomer consisting of (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) of one or more organosilicon compounds represented by (a) a hydrolysis reaction and a dehydration condensation reaction. These are produced by hydrolysis and polymerization of known alkoxysilanes in the absence of solvents or in organic solvents. By varying the type of silane used at this time, coatings having various properties can be obtained.

Generally, pure silicone polymers include the types known as thermal and moisture curable. In the present invention, the former thermosetting type is preferably used. As explained above, the "thermosetting type" is composed of an organic silicon compound, methanol, ethanol, isopropanol, butanol, or other alcohols having a low boiling point and water. Therefore, during the curing process, the solvent component can be evaporated and expelled in a very short time by drying at a low temperature of about 120 ℃ or below 120 ℃, and a dense coating having Si — O bonds can be formed by drying for several minutes to several tens of minutes. In the latter moisture-curing type, a hydrolysis reaction is caused by the absorption of moisture in the air and the coating layer is cured and formed by the action of the added catalyst. Therefore, it sometimes takes several days to cure the coating. Further, in this case, the formation and curing of the coating is not completed unless moisture is supplied from the ambient atmosphere. When applied to a stack sheet, particularly a large-area material in the application of the present invention, curing proceeds on the end face, it becomes difficult to supply moisture to the inside, and therefore sometimes the inside coating cannot be cured even after several weeks, and therefore there is a problem that the curing time cannot be kept constant.

In the heat-curable type of the present invention, if heated to exceed the boiling point of the solvent, the solvent can be simply penetrated and expelled. This is an extremely large advantage in industrialization.

In addition to this, the present invention is,when attempting to achieve high insulation resistance and breakdown voltage in the pack coating, 0.1 to 50 parts by weight (as solids content) of one or more inorganic oxide powder particles or colloidal solutions, organic resin powder particles or their latex solutions are added as fillers to the silicone polymer, relative to 100 parts by weight of the SiO of the neat silicone polymer₂And (6) counting. As a composite effect of the filler addition, the deposition ability on the end face of the core or the surface of the steel sheet is improved. As the inorganic powder particles or colloidal substances added, 0.1 to 50 parts by weight of a material selected from SiO having an initial particle size of 7 to 5000nm may be added and blended₂、Al₂O₃、TiO₂、ZrO₂And/or one or more of its composite materials. Since the conditions used have an effect on the stability of the solution, it is more preferable to use a substance having an initial particle size of not more than 0.5 μm.

In the present invention, when it is attempted to obtain a wrapping film excellent in heat resistance, if the organosilicon compound contains at least 80% of the compound (R)¹)_nSi(X¹)_4-n(wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is made of Cl or O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, and when n is 0, 1 or 2, a plurality of R²May be different) and if the ratio of the case when n is 0 to the case when n is 1 is in the range of 1:20 to 4:1, the wrapping film achieves more excellent performance. In particular, the higher the ratio of the component of n ═ 0, the greater the hardness of the coating. In addition, the resulting wrap becomes crack resistant. This is advantageous for applications when used at high temperatures. Furthermore, the drying is generally rapid and the efficiency of the drying operation is improved. However, since the component where n-0 becomes too hard, there is a problem: thick coatings can no longer be obtained because of cracking problems during drying of the coating. That is, when the ratio of the case where n is 0/the case where n is 1 is less than 0.05(1:20), the heat resistance is deteriorated, and thus this is set as a limit. On the other hand, if the ratio isThe rate becomes more than 4(4:1), the heat resistance is improved, but problems of cracking of the coating and difficulty in obtaining a thick coating are also encountered, and this is set as a limit.

For improving the electrical insulating property, 0.1 to 10 parts by weight of a compound selected from SiO having an initial particle size of 7 to 5,000nm is added and blended as an additive₂、Al₂O₃、TiO₂And mixtures thereof, is sufficient.

The method of applying the dressing solution or the method of dip coating in the dressing solution may be a general method of surface coating or painting or the like. In addition to spraying and dipping, brushing or other methods may also be used. Unevenness in the amount of coating and the like can also be suppressed by a general method. Further, in order to improve the adhesion on the contact portion of the conductor, the magnetic material, or the like, the binding force after drying can also be improved by performing one cleaning of the contact portion, dipping the binding solution on the contact portion, and then establishing a predetermined contact state.

The dry thickness of the dressing is easily controlled by varying the type of solvent or the concentration or viscosity of the solvent of the dressing solution. If the coating and drying steps are performed several times, the film thickness can be increased by this amount. The coating can be applied to a predetermined thickness by controlling the pull-out speed for the case of dip coating and the nozzle shape, spray speed, etc. for the case of spray coating, together with the above-described solution conditions. Further, the solution aggregation can be suppressed and the film thickness can be adjusted by blowing compressed air.

The wrap formed in the present invention may also be used as an electrically insulating coating (when electrical insulating properties are sought) and may also be used as a coating for rust protection. The dry coating according to the invention consists essentially of SiO with a Si-O structure₂A dense film is formed and composed, and thus extremely excellent insulating and rust preventing functions are exhibited.

(example 1)

A cold-rolled coil comprising 0.35% of Si, 0.002% of Al and 0.25% of Mn and a non-oriented magnetic steel sheet having a thickness of 0.50mm was annealed on a continuous annealing line, and then a solution comprising 450 parts by weight of Mg, 120 parts by weight of boric acid and 5 parts by weight of acryl-styrene resin emulsion after baking in terms of solid content was baked thereon as an insulating coating agent at a steel sheet temperature of 350 ℃ on the line.

Next, by punching out a sheet from this coil and caulking, cores of rotors of 2.2kW, 200V, and 60Hz three-phase four-pole squirrel-cage induction motors (44 slots, semi-enclosed, with sweep bars (stator slots of 1.23 times pitch)) can be prepared.

The iron core was immersed in a coating agent to be deposited on the end face by using a solution having a composition shown in table 1 while varying the thickness of the film after drying, dried at normal temperature, and baked at 100 ℃ for 10 minutes. Next, the secondary conductor bar is formed by aluminum die casting on the inserted iron core and shaft, thereby manufacturing the rotor of the induction motor. The loss was found from the no-load characteristic of the motor, confirming the effect of the present invention.

Further, at this time, some of the annealed material was taken from the production line of non-oriented magnetic steel sheet (before being processed to obtain an insulating coating), a 10 × 30 cm sample was cut, and then the sample was coated with the above solution using a bar coater while varying the thickness of the coating after drying, and then similarly baked, and used for evaluation of breakdown voltage, coating density, corrosion resistance, and the like.

The coating state and magnetic characteristics of the core in this test and the evaluation results of the insulating coating before and after the material coated on the surface of the steel sheet was annealed are shown in tables 2 and 3.

As a result of this test, when the end faces of the core were treated with the insulating coating agent of the present invention, a transparent coating layer having good gloss was formed and extremely excellent corrosion resistance and heat resistance were exhibited. In contrast, in the case of treating the comparative material with a general varnish or an insulating coating agent, the oil deposited at the time of stamping has a large influence. The insulating coating is unevenly deposited, and thus corrosion resistance becomes extremely poor compared to the iron core coated with the coating agent of the present invention.

Furthermore, even when acetone was used as a pretreatment to remove the oil in comparative examples 1 and 2, the deposition state of the coating material on the end face became uneven, and results significantly inferior to the present invention were obtained even in coating properties.

Further, comparison of the iron loss reduction ratio of the iron core has shown that the loss of the motors treated in inventive examples 1 to 12 is reduced by 7 to 17%. Also for comparative examples 13 and 14, an improvement of about 4.5% was found. In contrast to this, little reduction in loss was found in the case of comparative example 1. Also for comparative example 1, the loss was reduced by 5%. Also in terms of motor performance, with the insulation treatment of the present invention, the loss is significantly reduced and high efficiency of the motor is achieved as compared with the ordinary non-insulation treatment or conventional treatment.

Further, looking at the coating properties when the coating test was performed by a bar coater using a cut piece, as shown in table 3, for the case of using the agent of the present invention, the corrosion resistance, the insulating property and the binder were all extremely excellent. In particular, in the case of coating with pure silicone polymers formed by hydrolysis of the alkoxysilanes of inventive examples 1 to 8, 10 and 11, it was confirmed that extremely good results in terms of breakdown voltage were obtained also after annealing.

Also in the example of the hybrid silicone polymer of invention example 12, significantly good breakdown voltage and coating properties were obtained. Further, with the alkali metal silicate, colloidal silica and silicone resin of inventive examples 13 and 14, although the breakdown voltage, corrosion resistance and adhesion were slightly inferior to those of the above pure silicone polymer, stable coating characteristics were obtained as compared with the comparative example.

In contrast, in the case of comparative examples 1 and 2, corrosion resistance and adhesion were extremely poor as compared with the present invention. In particular, with the conventional varnish, the coating layer is substantially completely burned off and blackened after annealing, and the corrosion resistance and the insulating property are extremely poor compared with the present invention.

(example 2)

Each of the agents of the present invention having a pure silicone polymer composition shown in Table 4 was used for baking an insulating coating in the same manner as in example 1 to obtain a film thickness after drying of 5 μm on the surface of a non-oriented magnetic steel sheet having a sheet thickness of 0.5 mm. Next, the steel sheets having this insulating coating were stacked, annealed at 400 ℃ x 1hr in air, and the heat resistance of the coating was examined. The results are shown in Table 4.

As a result of the tests, when these sheets were treated with solutions based on the pure silicone polymers of the invention, in each case a transparent glossy coating state was maintained even after annealing at 400 ℃ for 1 hour and no reduction in adhesion or insulation properties was observed. In contrast to this, in the case of the organic-type varnish of the comparative material, there were significant reductions in surface appearance, adhesion, and insulating properties due to annealing.

(example 3)

The stator (armature) core treated on its surface by the present invention is used for manufacturing a microturbine generator. The stator core is obtained by punching and caulking from a magnetic steel sheet, and has bolt holes to fasten the core.

Next, the stator core was treated by invention example 1 of example 1, the stator core was inserted into the case, and the cores were then bolted. In the past, since the core contacts the housing or the bolts or the caulking layers contact each other, a short-circuit current flows through the core, so that loss increases and the stator has a large degree of temperature rise. If the invention is applied, the above-mentioned short-circuit current can be reduced and avoided and it is possible to keep the magnitude of the temperature rise below 3 degrees on average.

(example 4)

The cores treated with the present invention on the end surfaces thereof are combined with each other to produce an XY linear motor. In this XY linear motor, since the flow of magnetic flux is three-dimensional, cores punched from a common magnetic steel sheet are combined along a right angle.

Ordinary cores are in contact with each other at their end faces, but insulating paper is sandwiched between the cores, so that in the case where the cores are in contact, loss increases and there is a large variation in performance due to the contact of the end faces. On the other hand, if the insulating paper is inserted, the gap becomes relatively larger, the excitation current becomes larger, and an increase in the no-load resistance loss is caused.

If the insulation treatment method of the present invention is used to treat the end faces of the U-shaped core in combination with the two cores, the loss is reduced and the variation in performance is also reduced.

(example 5)

The core of the pump motor is protected from corrosion by encapsulating a stainless steel cover on the gap side between the rotor and the stator for the case where a magnetic steel sheet is used for the core material or by using a ferritic stainless steel for the core material.

In the former case, the structure is complex. Eddy current loss occurs on the stainless steel cover, the gap becomes larger, and the like, so that a drop in the output is inevitable. In the latter case, since the saturation magnetization of the ferritic stainless steel is low, a drop in the output is caused. Therefore, the motor is manufactured by processing the iron core composed of the magnetic steel sheet according to the present invention.

The iron core insulated by the present invention is also treated on the end face thereof. It is excellent in corrosion resistance, needless to say, and is simple in structure and can be manufactured using a highly saturated magnetized magnetic steel sheet, so that there is no problem in terms of reduction of the output. They do not rust even after 100 hours of operation, and the motor performance is the same as that of a normal motor except for the pump motor.

(example 6)

50H800 non-oriented magnetic steel sheets were die cut, strain annealed, and used to produce cores for small 48mm audio power transformers. The capacity was 100VA (100V/6V: 1A/16A).

In this case, condition 1 is to die cut it while caulking, and condition 2 is to die cut it without caulking.

The present invention is applicable to condition 2. That is, the surface (including the end faces) of the core was sprayed with a partial condensate obtained from diphenyldiethoxysilane, dimethylmonomethyltriethoxysilane, and tetraethoxysilane at a ratio of 1:4:5, and then dried to form a film. At this time, the coating treatment was carried out twice with hot air drying at 75 ℃ for 5 minutes to obtain an average film thickness of 7 μm. Then, the wire is attached to complete the assembly.

Condition 1 is for manufacturing a power transformer by a general method without using the present invention. The transformer of condition 1 has its core not completely fastened. Noise is generated and it is therefore necessary to provide a holder for the separate fastening. However, with the transformer according to the present invention, condition 2, noise is hardly generated from the core and an additional clamper is not required.

(example 7)

The invention is used for producing the brushless direct current motor of the four-pole motor. The binding solution used was a partial condensate (20% concentration) obtained from monomethyltrimethoxysilane and tetramethoxysilane in a 3:1 ratio, which was then dried to form a binding film. The stator is an armature composed of 12 separate core pieces (the core pieces 1 shown in fig. 2 are stacked together). The outer diameter of the assembled circular core is 120 mm. The divided core pieces 1A are punched out from the magnetic steel sheets and stacked. The centers of the magnetic steel sheets on the top and bottom of the stack are held by the bars 4a and 4b of fig. 3 to secure the stack. The dressing solution is applied only on the punched end faces-not the end faces of the teeth 2-corresponding to that clearance side of the rotor. The stack is then dried at room temperature to form a tight wrap. The dressing solution is applied by brushing, using a method that only adequately coats the working end face. In this case, the dressing solution was immersed in a brush and applied to obtain a dried average film thickness of 10 μm over a gap 5' (fig. 4) formed by a slit portion punched on the processed end face of the stacked core.

Next, the winding wire 6 is wound directly on the divided core sheet 1B with the wrapping film while drying the wrapping solution, as shown in fig. 5. Also as shown in fig. 6, the portions other than the gap side were immersed in the packing solution and dried. Due to this, the winding is fastened and the wrapping strength and rigidity of the core are improved. Next, the individual core pieces are assembled, and the shim plates 9a and 9b are placed on the top and bottom surfaces of the core stack of the core while the assembly is press-fitted into the case 10. When placing the shim, the dressing solution is applied to the surface that contacts the core, and then the shim is placed on the core. The assembly of the separate core pieces with the shim plate placed thereon is then coated on its outer circumference with a wrapping solution and then press-fitted into the housing as shown in fig. 6. Subsequently, it was completely dried.

If the method of the invention is used, electrical insulation and fastening and binding between the conductors, between the sheets of magnetic steel, between the conductors and the separate core sheets, between the separate core sheets and between the core and the housing are possible from ambient temperature to temperatures that can be tolerated by permanent magnets used in motors or temperatures above 500 ℃. Therefore, since this is higher than the ordinary winding temperature of 200 ℃ heat resistance, it is possible to let a larger current flow through the winding and obtain a high output. Furthermore, the rigidity of the motor as a whole becomes higher, thus becoming a way to resist noise and vibration. If the wrapping of the present invention is employed, it is possible to suppress short-circuit current which causes problems in caulking, welding, etc., and to reduce loss and improve controllability. Furthermore, it is possible to improve the escape of heat generated from the conductor and core through the wrap of the present invention. Also from this point of view, this can effectively increase the output of the motor and reduce the resistance loss (suppress the increase in resistance due to temperature rise).

(example 8)

A four-pole IPM (implanted magnet) motor was manufactured by the armature produced in example 7 and using the IPM rotor of the present invention. The motor is controlled in torque at low speed. Immersing the motor in a binding solution consisting of a partial condensate obtained from monomethyltriethoxysilane and tetraethoxysilane in a ratio of 1:3, converted to SiO in relation to 100 parts by weight₂The solution contains 2g of Al having a particle size of 10nm as filler₂O₃An average film thickness after drying of 5 μm was obtained. It is dried to form a wrapping film.

The magnetized SmCo sintered magnet was immersed in the binding solution and then dried. As shown in fig. 8, this magnet 12 is inserted into IPM rotor core 11. The rotor core with the inserted magnets is also immersed in the binding solution. Excess packing solution is removed while compressed gas is injected and the core is then press fit onto shaft 13. The assembly is then dried to form a wrapping 14 of the partial condensate. The invention can be used on the rotor to fasten the magnet and insulate the surface of the iron core at the temperature from normal temperature to the temperature (about 500 ℃) which the SmCo magnet can bear. Further, it is possible to improve the heat conductivity and the insulating property between the magnet and the core and to suppress the temperature rise of the magnet and to suppress the short-circuit current between the magnet and the core. The gap between the rotor and the shaft is filled with a wrapping film and serves to suppress the temperature rise of the rotor. SmCo magnets can be used at higher temperatures than FeNdB magnets, but the temperature rise of SmCo sintered magnets can also be suppressed, and the reduction in magnetization of the magnets can also be suppressed.

(example 9)

The invention is used for producing two-pole induction motors. The binding solution used was a partial condensate obtained from diphenylethoxysilane, dimethylmonomethyltriethoxysilane and tetraethoxysilane in a ratio of 1:5: 4. It is dried to form a wrapping film. The stator core is an integrally die-cut core on which caulking is provided for temporary fastening at three positions at the same distance of 2mm from the outer circumference in the circumferential direction. The binder solution is sprayed onto the slots of the entire core and dried to form a binder film. At this time, the coating treatment was carried out twice with intervening drying by warm air at 5 ℃ for 5 minutes to obtain an average film thickness of 7 μm. The wrapping solution is then deposited on the armature winding and the surface of the winding is dried. The dried wire is inserted into the slot of the stator core using an inserter. The entire armature is then immersed in the dressing solution. Hot air at 100 c was blown from that gap side of the rotor to blow off excess solution deposited on the tooth edges to reduce the film thickness of the gap surface to below 0.1 mm. The 100 deg.C hot air has the effect of accelerating drying. Finally, it is dried at 300 ℃ to form the final wrap.

If the present invention is used, it is possible to use temperatures up to 500 ℃. Bundling of stacked cores up to this temperature, suppression of short-circuit current, noise reduction with reduction of tooth edge vibration, increased output due to higher heat release, and low resistance loss (suppression of resistance increase due to temperature rise) can be expected.

(example 10)

An induction motor was produced by the armature core produced in example 9 and using the aluminum die-cast rotor of the present invention. The rotor is obtained by immersing the punched iron core in a binding solution and then drying to bind it, followed by aluminum die casting. The packing solution used was a mixed solution of monomethyltrimethoxysilane, tetramethoxysilane and dimethyldimethoxysilane in a ratio of 5:3: 2. It is dried to form a wrapping film.

The wrapping film formed by drying can withstand even aluminum die casting, so that short circuit between the secondary conductor aluminum conductor and the core can be suppressed. Therefore, the high output performance of the induction motor can be stabilized.

(example 11)

The wrapping solution is applied to the surface of the wire and dried. The windings are wound and the wound transformer core is then immersed in a wrapping solution and dried. The packing solution used was a partial condensate obtained from diphenyltriethoxysilane and monoethyltriethoxysilane in a 1:9 ratio. The coating treatment was carried out three times with intermediate intervention of drying by hot air at 80 ℃ for 15 minutes, after which the coating was dried to form a wrapping.

By applying the invention to the transformer core, it is possible to operate even at 200 ℃, improve the rigidity of the core, and reduce the noise by 3 db.

(example 12)

The invention is used for producing a core having a slit, which is used for a reactor of a step-up vibration converter. As shown in fig. 9, a wound core 21 is formed and immersed in a wrapping solution composed of a partial condensate obtained from diphenyldiethoxysilane and tetramethoxysilane at a ratio of 1.5:8.5, and dried in this state. The core stack is wrapped while maintaining its shape. Next, the slit 22 is formed by fastening and cutting in an area near the formation of the slit. On the other hand, the wire inserted into the cut wire-wound core is previously shaped by winding a wire and allowing a packing solution to be deposited on the surface thereof and dried, and then immersed in the packing solution again and dried, to be finally obtained. Next, the formed and wound wire is inserted into the cut core and two cut portions of the core facing each other on the cut portions to provide a slit. To maintain the slot, a non-magnetic insulator 23 is inserted and then a wire 24 is wound. In this state, the assembly is again inserted into the dressing solution to form dressing 25, and then dried.

The wrap may withstand temperatures of at least up to 500 ℃. The reactor can be sufficiently operated up to a temperature that can be withstood by other components than the reactor. The core itself is highly rigid. The slot is a noise and vibration barrier and is also comprised of a modular construction. Therefore, noise can be reduced.

(example 13)

Oriented magnetic steel sheets are die cut and the individual sheets are spirally formed to produce an integral circular armature core for an 8-pole motor. The helical core was stacked while rotating, the assembly was immersed in a wrapping solution consisting of a partial condensate obtained from monomethyltrimethoxysilane and tetramethoxysilane at a ratio of 1:1 to obtain a dried film thickness of 15 μm, and then dried for fastening, to produce an armature core. Subsequently, it was strain annealed at 800 ℃. After this, the wrapping solution is deposited on the surface of the wire, and then the wire is dried at room temperature and attached to an armature core to produce an armature. The wire wound core of the oriented magnetic steel sheet has a tooth tip in the rolling direction of the oriented magnetic steel sheet, and the magnetic properties of the tooth tip are extremely excellent, so that the motor iron loss can be reduced. For wound wires, the surface coating may peel off. However, with the treatment of the present invention, a surface coating is formed even on the peeled coating portion, and thus many problems can be avoided. Furthermore, the armature immersed in the wrapping solution and dried for fastening can be strain annealed at 800 ℃, so that the strain due to the winding can be eliminated and various properties of the oriented magnetic steel sheet material can be fully utilized.

(example 14)

The invention is used for producing simple small-sized 500 ℃ heating furnaces.

As a dressing solution, a partial condensate obtained from monomethyltrimethoxysilane and tetramethoxysilane in a ratio of 1:1 was used. This bundling solution is deposited on the surface of the heater wire. The heating wire is dried at room temperature and arranged on the inner wall surface of the heating furnace. The entire inner wall element is again immersed in the wrapping solution and dried to prepare the inner wall element with the heater. The inner wall element provided with the heater is used for producing a heating furnace. The wire faces the inside of the furnace, but the surface of the wire is formed with a dry coating of the binder solution, so that the effect of electrical insulation can be maintained to a high temperature. This furnace is simple in structure and suitable for a small-sized furnace.

(example 15)

The present invention is used for producing a coil with less movement of a bobbin of a voice coil motor for HDD (hard disk drive). As packing solution, a partial condensate solution obtained from monomethyltrimethoxysilane and tetramethoxysilane in a ratio of 1:1 was used. This bundling solution is deposited on the surface of a rectangular aluminum conductor. The rectangular aluminum conductor was dried at room temperature and wound into a motor coil. Then, the entire formed coil was immersed in the wrapping solution again and dried to obtain a movable coil. The fastening and insulation by the binding solution used in this embodiment is not problematic even at the melting point of aluminum and is advantageous with respect to mechanical vibrations and strength, which can be problematic in the moving coil of a voice coil motor.

(example 16)

An IPM (magnet implanted) motor of four poles was manufactured by the armature core produced in example 16 and the IPM rotor using the present invention. The motor is controlled in torque at low speed. The packing solution used was a mixed solution obtained from tetramethoxysilane, monomethyltrimethoxysilane and diphenyldiethoxysilane in a ratio of 2:1: 1. It is dried to form a wrapping film.

The magnetized sintered FeNdB magnet was immersed in the wrapping solution and then dried. As shown in fig. 8, this magnet 12 is inserted into IPM rotor core 11. The rotor core with the inserted magnets is also immersed in the binding solution. Excess packing solution is removed while compressed gas is injected and the core is then press fit onto shaft 13. The assembly is then dried to form a wrapping 14 of the partial condensate. The present invention is used in an IPM rotor for the purpose of both fastening the magnet and treating the surface of the magnet, improving thermal conductivity and insulating properties between the magnet and the core, suppressing temperature rise of the magnet, and suppressing short-circuit current between the magnet and the core. The gap between the rotor and the shaft is filled with a wrapping film and serves to suppress the temperature rise of the rotor. The temperature rise of the sintered FeNdB magnet can be suppressed and the decrease in magnetization of the magnet can be suppressed.

(example 17)

The invention is used for producing two-pole induction motors. The binding solution used was monomethylmethoxysilane. It is dried to form a wrapping film. The stator core is an integrally die-cut core on which caulking is provided for temporary fastening at three positions at the same distance of 2mm from the outer circumference in the circumferential direction. The slots of the core are covered with insulating paper, the armature windings are attached, and the entire armature is then immersed in a wrapping solution. Then, hot air of 100 ℃ was blown from that clearance side of the rotor to blow off the excess solution deposited on the tooth tip portions, thereby reducing the film thickness of the clearance surface to less than 0.1 mm. It is then dried to form a wrap. The 100 deg.C hot air has the effect of accelerating drying.

If the present invention is used, it is possible to expect bundling of the stacked core, suppression of short-circuit current, reduction of noise due to reduction of vibration on the tooth tip portion, higher output due to high heat release, and lower resistance loss (suppression of increased resistance due to temperature rise).

(example 18)

The wound transformer core provided with the windings is immersed in a wrapping solution and dried. The binding solution used is a modified silicone polymer, i.e., an epoxy-modified polymer. It is dried to form a wrapping film.

By applying the present invention to the transformer core, the rigidity of the core is improved and the noise is reduced by 3 db.

(example 19)

In example 7, the stator was immersed in a wrapping solution and dried to perform stacking and wrapping, and then annealed at 750 ℃. This anneal reduces motor iron losses by 8%.

(example 20)

The invention is used for producing a core having a slit, which is used for a reactor of a step-up vibration converter. As shown in fig. 9, a wire-wound core 21 is formed and immersed in a wrapping solution, and then dried. The core stack is wrapped while maintaining its shape. The slot 22 is then formed by securing and cutting the slot in an area near where the slot is formed. To maintain the slot, a non-magnetic insulator 23 is inserted and then a wire 24 is wound. In this state, the assembly is again inserted into the dressing solution to form dressing 25, and then dried.

The reactor is characterized by high rigidity of the core itself. In addition, the slot is an obstacle to noise and vibration, and is also composed of a combined structure. Therefore, noise can be reduced.

(example 21)

Oriented magnetic steel sheets are die cut and the individual sheets are spirally formed to produce an integral circular armature core for an 8-pole motor. The helical core is stacked while rotating, the assembly is immersed in a wrapping solution, and dried to fasten it, thereby producing an armature core. The wire wound core of the oriented magnetic steel sheet has a tooth tip in the rolling direction of the oriented magnetic steel sheet. The magnetic properties of the tooth tip are extremely excellent, so that the motor iron loss can be reduced. For winding, peeling of the surface coating occurs, but by the treatment of the present invention, the surface coating is also formed on the peeled coating portion and thus many problems are avoided.

(example 22)

The polygon mirror motor for a laser beam printer is manufactured on a printed circuit board by using a magnetic steel sheet. The printed circuit board is a laminate of two magnetic steel sheets. The armature coil is fastened to it. The armature coil and the circuit board are fastened, and the magnetic steel sheet is bound by using the binding method of the invention. Two magnetic steel sheets are stacked, then the armature coil is fastened, and the assembly is then immersed in a wrapping solution and dried by hot air for fastening. The binding solution used maintains the binding force even in the event of an increase in the coil temperature and without problems of outgassing, so that the binding of the stack of two magnetic steel sheets of the printed circuit board and the fastening of the armature coil on the printed circuit board can be adequately maintained even if the motor operation causes a temperature increase. There is no problem of mirror fogging because there is no problem of outgassing.

(example 23)

The wire wound core of the transformer is produced as follows: the amorphous magnetic material is immersed in the packing solution and then dried while maintaining its shape. This core is used for producing a transformer, is fitted into a magnetically shielded enclosure, and is used while drying the transformer. For the case of magnetic shielding, an assembly of plates consisting of stacked nanocrystalline highly permeable materials can be used, immersed in the same packing solution and then dried to effect fastening. The amorphous material is extremely thin and thus the core or shield lacks rigidity, but the element can be simply bonded and enhanced in rigidity by the binding method of the present invention, the fastening of the core or shield becomes easy, and it is also highly unlikely that fragments of amorphous metal or nanocrystals are produced.

Industrial applicability

If there is a short circuit of a secondary conductor, a case, a bolt, or the like on an end face or surface of a core used for a motor or other energy conversion device, the loss of the device will increase, the torque, thrust, or output will decrease, and the performance will change. Therefore, the insulation treatment of the end faces and surfaces of the iron core is extremely important for improvement and stabilization of the performance of the apparatus. The ability to easily perform this insulation process in a short time is valuable in industry.

According to the present invention, it is possible to treat the end faces of the iron core, to obtain an insulating layer extremely excellent in the improving effects of insulating properties, corrosion resistance, adhesion, heat resistance and magnetism at low temperature and in a short time, without the need for cleaning to remove punching oil, annealing or other pretreatment.

Therefore, this method is effective for improvement and stabilization of the performance of the apparatus. The process is simple and therefore the cost can be reduced, and the technique is extremely valuable industrially. Improvements in efficiency and reduction in equipment losses are important for energy and environment. The use of the present invention is therefore also of value in society. A large number of applications such as home appliances, factory automation equipment, office automation equipment, automobiles, trains, and the like are contemplated.

Furthermore, the present invention is aware of the following facts: if there is a short circuit of a secondary conductor, a case, a bolt, etc. on an end face or a surface of a core used in various transformers, loss of equipment increases and damage occurs. Furthermore, this becomes a cause of performance fluctuation. Therefore, the insulation treatment of the end faces and surfaces of the iron core is extremely important for improvement and stabilization of the performance of the apparatus. The ability to easily perform this insulation process in a short time is valuable in industry. In addition, this may lead to improvements in various properties, such as heat resistance required at the time of annealing after processing.

In addition, the high temperature-operated electric apparatus according to the present invention can obtain a high heat-resistant temperature of the wire. The fastening and wrapping of the windings and the core and yoke of magnetic material is also not problematic at high temperatures. Therefore, it is possible to greatly increase the current flowing through the winding and to increase the output of the apparatus. In addition, the electric apparatus operating at high temperature can be used in high temperature occasions.

Claims (13)

1. A magnetic element for electromagnetic equipment, characterized in that a plurality of magnetic material sheets punched into substantially the same shape are stacked, and an insulating film having an average film thickness of 2 to 100 μm and a breakdown voltage of 30V or more is formed by coating an end portion of the magnetic material sheet with an organosilicon polymer and bonded thereto without locally applying strain and/or stress to the magnetic material sheet.

2. The magnetic element for an electromagnetic apparatus according to claim 1, wherein the armature core is composed of a plurality of divided core pieces.

3. An electric apparatus operating at high temperature, characterized by having a structure in which a conductor or a plurality of conductors and a magnetic material are bonded together while ensuring electrical insulation between adjacent members of the same or different types by using a pure silicone polymer as a liquid capable of fastening and holding the adjacent members to each other after coating and drying between the adjacent members and capable of fastening and binding at high temperature exceeding 200 ℃, and applying an insulating coating film having an average film thickness of 2 to 100 μm and a withstand voltage of 30V or more to the end portion, the pure silicone polymer being formed by passing (R) through¹)_nSi(X¹)_4-nThe composition of compounds resulting from the hydrolysis and partial dehydration condensation reaction of one or more neat silicone polymers represented by where n is an integer from 0 to 3 and R is¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is Cl or is formed from O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, when n is 0, 1 or 2, a plurality of R²May be different.

4. A simple binding method for a magnetic member used in an electromagnetic device, characterized in that a plurality of magnetic material pieces punched out into substantially the same shape are stacked, and then a solution capable of exerting the binding ability between the magnetic material pieces by drying is applied to the end portions, or the plurality of magnetic material pieces are immersed in the above solution and then dried to bond them together to form an insulating film having an average film thickness of 2 to 100 μm and a breakdown voltage of 30V or more.

5. The simple wrapping method for a magnetic element of an electromagnetic device according to claim 4, characterized in that as the solution capable of wrapping the pieces of magnetic material together by drying, a solution mainly composed of at least one of a pure silicone polymer and a modified silicone polymer is used.

6. Simple packing method for a magnetic element of an electromagnetic device, according to claim 5, characterized in that as pure silicone polymer a mixture of (R) and (II) is used¹)_nSi(X¹)_4-nAn organosilicon compound produced by hydrolysis and partial dehydration condensation reaction of one or more of the substances represented by (I), wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is Cl or is formed from O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, when n is 0, 1 or 2, a plurality of R²May be different.

7. The simple wrapping method for a magnetic element of an electromagnetic device according to claim 5, characterized in that as the modified silicone polymer, one or more of an acryl-modified silicone polymer, an alkyd-modified silicone polymer, a polyester acryl-modified silicone polymer, an epoxy-modified silicone polymer, an amino-modified silicone polymer, a vinyl-modified silicone polymer, and a fluorine-modified silicone polymer are used.

8. Method for producing an electrical apparatus operating at high temperatures, characterized in that as a solution between adjacent elements having the ability to fasten and hold adjacent elements to each other after coating and drying and to fasten and pack them at high temperatures exceeding 200 ℃, a solution is used which is composed of (R) and (R) a binder¹)_nSi(X¹)_4-nA pure organosilicon polymer of compounds produced by hydrolysis and partial dehydration condensation of one or more organosilicon compounds represented by (I), wherein n is an integer from 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is Cl or is formed from O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, when n is 0, 1 or 2, a plurality of R²The solution may be applied to the edge portions of the substrate to form a film having an average thickness of 2 to 100 μm and a breakdown voltage of 30V or moreAn insulating coating, and then applying or immersing the solution on or in the conductor or the conductors and the magnetic material, followed by drying to bond the conductor or the conductors and the magnetic material together while ensuring electrical insulation between adjacent members of the same or different types.

9. Method for producing an electrical installation operating at high temperatures according to claim 8, characterized in that use is made of (R) S¹)_nSi(X¹)_4-nA pure silicone polymer composed of an organosilicon compound represented by the formula (I) wherein n is an integer of 0 to 3, R¹Is alkyl or phenyl, when n is 2 or 3, a plurality of R¹May be different, X¹Is Cl or is formed from O (R)²) Alkoxy of the formula (I), wherein R²Is alkyl, when n is 0, 1 or 2, a plurality of R²It may be different, it contains at least 80% of at least n-0, 1 organosilicon compound and the composition ratio of organosilicon compound with n-0 to organosilicon compound with n-1 from 1:20 to 4: 1.

10. A method of producing an electrical device operating at high temperatures according to claim 9, characterized in that a heat-curable pure silicone polymer is used as the pure silicone polymer compound.

11. Method for producing an electrical device operating at high temperatures according to any of claims 8 to 10, characterized in that 0.1 to 10 parts by weight of SiO with an initial particle size of 7 to 5000nm are added as additive to the pure silicone polymer₂、Al₂O₃And TiO₂One or more of (a).

12. A method of producing an electrical device operating at high temperatures according to claim 11, characterized in that the thickness after drying is 2-100 μm.

13. Method for producing an electrical apparatus operating at high temperatures according to claim 12, characterized in that the drying temperature does not exceed 200 ℃.