Commutator material and brush material, clad composite and small-sized DC motor
Patent application of the present invention is to be on May 12nd, 2006 applying date, and application number is 200610081971.9, and name is called the dividing an application of application for a patent for invention of " commutator material and brush material, clad composite and small-sized DC motor ".
Technical field
The present invention relates to be undertaken the commutator and the brush of the small-sized DC motor of electricity conversion, relate in particular to the employed commutator material of small-sized DC motor and the brush material that in DVD player, are used to make the rotation of DVD video disc by the sliding action of machinery.
Background technology
In recent years, in above-mentioned technical field, along with use-pattern from the variation of CD to DVD, carried out in a large number about the researchs of the small-sized DC motor that is fit for various uses with material.In the initial CD Player of playing music, video disc rotate to be about 500rpm, be not very big for small-sized DC motor with the load of commutator material and brush material.
Afterwards, when CD Player is carried on the automobile as sound appliances, require the useful life longevity of the small-sized DC motor in-40 ℃~85 ℃ the temperature range, the applicant has developed the small-sized DC motor that can realize such weather resistance with commutator material (referring to patent documentation 1).
[patent documentation 1] Japanese patent laid-open 8-291349 communique
The small-sized DC motor that is disclosed in this patent documentation 1 can be used for the high speed rotatingization of 2 times of speed of CD Player, 4 times of speed and the DVD player of regeneration special use with the commutator material, becomes representational commutator material in the spindle drive motor now.
Yet the control method of the spindle drive motor that DVD uses is more complicated, and the small-sized DC motor that patent documentation 1 is put down in writing also can satisfy its characteristic requirement sometimes with the commutator material, needs further to improve performance at present.In addition,, not only wish exploitation small-sized DC motor commutator material at present, also wish the brush material that exploitation is corresponding with it in order further to improve performance.
Summary of the invention
In recent years, the control method of the spindle drive motor used of known DVD has multiple mode.For example, the rotating speed by pulsed current control electric motor in the advanced audio equipment, but the small-sized DC motor of above-mentioned patent documentation 1 with the commutator material by the situation of the characteristic of pointing out to meet the demands.
The present invention finishes under such background, small-sized DC motor commutator material and brush material that the life-span that its purpose is to provide the DVD that can make the type of controlling by pulsed current to use spindle drive motor prolongs.
The present inventor has finished the present invention after conscientiously studying in order to solve above-mentioned problem.The present invention is the employed commutator material of small-sized DC motor, it is characterized in that, ZnO, rest part by Cu, 1.0~5.0 weight % of 6.0~10.0 weight % are to constitute forming of Ag, and Cu metallics, ZnO particle are dispersed in the AgCu alloy substrate.
Small-sized DC motor of the present invention is that material is to make Cu metallics, ZnO particle be dispersed in the alloy in the AgCu alloy substrate with the feature of commutator material.In this AgCu alloy substrate, the Cu of solid solution and dispersive Cu particle are beneficial to the raising wearability, dispersive ZnO particle not only reduces the loss that electric arc causes in the AgCu alloy substrate, and the effect of the lubricant of the slipper when playing as commutator, has the effect that the frictional force of making lowers.
The commutator material of small-sized DC motor in the past, for example the Ag-Pd-Cu-Ni alloy by what is called fusion manufactured, suppresses wearing and tearing by disperse Cu metallics and Ni metallics in alloy substrate.On the other hand, small-sized DC motor of the present invention is with in the commutator material, in the AgCu alloy substrate, be dispersed with Cu metallics and ZnO particle, like this metallics and oxide particle are together disperseed, then, can realize fabulous wearability as small-sized DC motor commutator material.
In addition, by making the commutator material, can realize the ZnO particle being dispersed in the AgCu alloy substrate as small-sized DC motor of the present invention commutator material with so-called powder metallurgic method.If the employing powder metallurgic method, the oxide particle utmost point that then is present in the Ag matrix disperses equably, and can't make the commutator material of the small-sized DC motor with weave construction identical with the present invention by the fusion method.
Small-sized DC motor of the present invention is with in the commutator material, be solid-solubilized in Cu in the AgCu alloy substrate and Cu metallics and mainly play the effect that small-sized DC motor is improved with the wearability of commutator material, this Cu content better is at 6.0~10.0 weight %.If less than 6.0 weight %, then the raising effect of the wearability of the reinforcement of the matrix of AgCu alloying generation and the generation of Cu metallics reduces, if surpass 10.0 weight %, then the raising to wearability produces adverse effect, the brush (brush) corresponding with commutator that wear and tear, the result makes the endurance life of small-sized DC motor low.This Cu content being set in the compositing range of 7.0~9.0 weight %, can making small-sized DC motor of the present invention reach best with the commutator properties of materials, is unusual ideal in practicality.
In addition, small-sized DC motor of the present invention is with in the commutator material, the ZnO particle at slipper, be the effect that solid lubricant is played on the contact surface.The content of this ZnO better is 1.0~5.0 weight %.The content of this ZnO then can't be brought into play the function as lubricant less than 1.0 weight %, if surpass 5.0 weight %, then processibility descends, and is difficult to be processed into the small-sized DC motor commutator.This ZnO being set in the compositing range of 2.0~4.0 weight %, can making the self-cleaning contact characteristic reach best, is unusual ideal in practicality.
When above-mentioned small-sized DC motor of the present invention is used as the commutator of electric motor with the commutator material, in order to make the constituent material of better commutator, better be to use the base material that adopts Cu or Cu alloy, part on this base material is buried small-sized DC motor of the present invention commutator material underground, makes clad composite.Thus, with commutator and outside conducting the time, for example tin-welding is good, and the processibility when being configured as the high shape of the desired circularity of commutator shape also improves.In addition, by adopting the form of so-called clad composite, can be corresponding to employed small-sized DC motor, control the small-sized DC motor of the present invention that is embedded in the base material thickness of commutator material, so can only use expensive small-sized DC motor commutator material, also ideal aspect cost in the part of necessity.
The small-sized DC motor of being buried underground of the clad composite of the base material of use Cu or Cu alloy is with being exposed to surperficial part in the commutator material owing to be exposed in the atmosphere, so cure easily.Therefore, bury the clad composite of small-sized DC motor of the present invention underground for the part on the base material of Cu or Cu alloy, be more preferably the small-sized DC motor that this quilt is buried underground and be covered with Au or Au alloy with at least a portion on the commutator material with the commutator material.Known Au or Au alloy are that erosion resistance is good and can realize the good commutator material of low contact resistance, but since very expensive, be disadvantageous on manufacturing cost so use in a large number.Therefore,, not only can suppress the increase of cost, and can prevent the sulfation of small-sized DC motor of the present invention effectively the part of Au or the necessary part of Au alloy lining by only with the commutator material.If such clad composite is used for the commutator of small-sized DC motor, the excellent contact resistance characteristic of Au or Au alloy during then owing to the initial stage of use, can realize good motor drive, even Au or Au alloy are damaged because of wearing and tearing, because there is small-sized DC motor of the present invention commutator material in its private side, can continue again to use.
Above-mentioned of the present invention so-called two layers or three layers of clad composite are used for can significantly prolonging the life-span of this small-sized DC motor self under the situation of DVD with the commutator of spindle drive motor.
The present inventor has found 2 kinds of brush materials following explanation, that be suitable for small-sized DC motor after the brush material corresponding with it conscientiously studied in exploitation above-mentioned small-sized DC motor employed commutator material.
First kind of small-sized DC motor of the present invention be characterised in that with brush material, is to constitute forming of Ag by MgO, the rest part of 0.1~5.0 weight %, and the MgO particle is dispersed in the matrix of Ag.
Another kind of small-sized DC motor of the present invention is characterised in that with brush material, is to constitute forming of Pt by Ni, the rest part of 5.0~15.0 weight %, and Ni is solid-solubilized in the Pt matrix.
Small-sized DC motor of the present invention is with in the brush material, the MgO particle is dispersed in the material in the Ag matrix, the MgO particle that is dispersed in the Ag matrix not only reduces the loss that electric arc causes, and the effect of the lubricant of the slipper when playing as brush, have the effect that the frictional force of making lowers.
The small-sized DC motor that is dispersed with the MgO particle in this Ag matrix is with in the brush material, the MgO particle at slipper, be the effect that solid lubricant is played on the contact surface, the content of this MgO better is 0.1~5.0 weight %.The content of this MgO then can't be brought into play the function as lubricant less than 0.1 weight %, if surpass 5.0 weight %, then processibility descends, and is difficult to be processed into the small-sized DC motor brush.This MgO being set in the compositing range of 1.5~4.0 weight %, can making the self-cleaning contact characteristic reach best, is unusual ideal in practicality.
In addition, by making brush material, can realize being dispersed with in the Ag matrix small-sized DC motor brush material of MgO particle with so-called powder metallurgic method.If the employing powder metallurgic method, the oxide particle utmost point that then is present in the Ag matrix disperses equably.The material of such particle dispersion-type can't be made the small-sized DC motor brush material with identical weave construction by so-called fusion method described later.
In addition, small-sized DC motor of the present invention is with in the brush material, and for for solid solution in the Pt matrix has the alloy of Ni, the drain performance that the original anti-electric arc of Pt metal causes is just excellent, and by Ni is solid-solubilized in the Pt matrix, it is smooth that surface of the electric brush becomes again.That is, the effect of the lubricant of the slipper when solid solution Ni plays as brush has the effect that the frictional force of making lowers.
In addition, used in the brush material by the small-sized DC motor of the present invention that solid solution in Pt matrix has the alloy of Ni to constitute, the metal Ni of solid solution improves the oilness of Pt, and this Ni content better is to be 5.0~15.0 weight %.This Ni content is less than 5.0 weight %, and then the oilness of Ni raising function can't be brought into play, if surpass 15.0 weight %, then contact resistance increases because Ni is oxidized to nickel oxide.This Ni being set in the compositing range of 8.0~12.0 weight %, can making the self-cleaning contact characteristic reach best, is unusual ideal in practicality.
In addition, make, can be implemented in the small-sized DC motor brush material of the present invention that solid solution has the alloy of Ni to constitute in the Pt matrix by what is called fusion method.Known in the past small-sized DC motor brush material, for example the Ag50wt%-Pd50wt% alloy is made by what is called fusion method, suppresses wearing and tearing by the solid solution alloy of making AgPd.For the small-sized DC motor brush material that solid solution has the alloy of Ni to constitute in Pt matrix of the present invention, can similarly make with the Ag50wt%-Pd50wt% alloy by the fusion method, by Ni is solid-solubilized in the Pt matrix, can realize for the wear-resistant of electric arc and the coexistence of oilness, as the small-sized DC motor brush material, can realize fabulous wearability.
When above-mentioned small-sized DC motor of the present invention is used as the brush of electric motor with brush material, in order to make the constituent material of better brush, better be to use the base material that adopts rubber-like Cu alloy, part on this base material is buried small-sized DC motor brush material of the present invention underground, makes clad composite.Thus, utilize the elasticity of base material, brush is contacted with commutator with the suitableeest loading.In addition, by adopting the form of so-called clad composite, can be corresponding to employed small-sized DC motor, control the small-sized DC motor of the present invention that is embedded in the base material thickness of brush material, so can only use expensive small-sized DC motor brush material, also ideal aspect cost in the part of necessity.
Research according to the present inventor is confirmed, if make up above-mentioned small-sized DC motor of the present invention commutator material and brush material, be used for the employed small-sized DC spindle drive motor of DVD player, then can realize low contact resistance characteristic and low voltage starting characteristic etc. reliably.
As mentioned above, if small-sized DC motor of the present invention is used for the employed small-sized DC spindle drive motor of DVD player with the combination of commutator material or brush material or these materials, then can the long term maintenance low contact resistance, for a long time with the low start voltage drivingmotor.Therefore, if adopt the present invention, can realize the small-sized DC motor life-time dilatation that commutator material by in the past or brush material can't be realized.
Description of drawings
The stereographic map of [Fig. 1] two layers of clad composite.
The stereographic map of [Fig. 2] three layers of clad composite.
[Fig. 3] pulse controlled waveform sketch.
Embodiment
To the preferred embodiment of the present invention based on the embodiment of following record and in the past example describe.At first, to describing about the result of small-sized DC motor of the present invention with the wearing character evaluation of commutator material and brush material.Represented in the table 1, related to small-sized DC motor of the present invention with the composition of the embodiment 1 of commutator material with carry out and the small-sized DC motor of the correlated example in the past 1 of the characteristic of this embodiment 1 composition with the commutator material.
[table 1]
(weight %)
For the small-sized DC motor of embodiment 1 commutator material, at first the Cu powder of 8.0 weight %, the ZnO powder of 3.0 weight % and the Ag powder of rest part were stirred 4 hours with ball mill, make each powder homogeneous dispersive powdered mixture.Then, this powdered mixture is inserted in the cylindrical vessel, axially applied 4.9 * 10 from cylinder
5The pressure of N (50tf) carries out compression process and handles, and forms the cylindrical blank of diameter 50mm.Then, this cylindrical blank is carried out 4 hours sintering processes (5.0Pa) under the temperature of 973K (700 ℃).These compression process are handled, sintering processes repeats 3 times.
The cylindrical blank of having carried out these compression process and vacuum sintering processing is processed to form the wire rod of diameter 6.0mm by hot extrusion.Then, by Wire Drawing, make the wire rod of diameter 1.6mm.
The small-sized DC motor of example 1 was made by the fusion method with the commutator material in the past, the composition of putting down in writing according to table 1, with each metal fusion, then by cast, extrusion processing, Wire Drawing, make the wire rod of diameter 1.6mm.This routine in the past small-sized DC motor has detailed description with the manufacture method of commutator material in patent documentation 1.
[patent documentation 1] Japanese patent laid-open 8-291349 communique
Each wire rod of Xing Chenging is processed into band shape by rolling press as mentioned above, and its embedding is joined in the Cu material as stratum basale, obtains clad composite.Then, this clad composite is heat-treated under 1023K (750 ℃), roll repeatedly, make two layers of clad composite of total thickness 0.3mm, wide 19mm.
Here, the form to clad composite of the present invention describes.The stereographic map of Fig. 1 is represented to have buried the form that be known as two layer clad composite of the small-sized DC motor shown in the present embodiment with the commutator material underground in the part of the base material that is made of the Cu alloy.In addition, the stereographic map of Fig. 2 represent to have buried underground in the part of the base material that constitutes by the Cu alloy small-sized DC motor that the small-sized DC motor shown in the present embodiment buried this underground with the commutator material, again with the part of commutator material with Au or Au alloy form that be covered, that be known as three layers of clad composite.In addition, Fig. 1 a and Fig. 2 a, 2b represent the clad composite of single filler rod, and Fig. 1 b represents the clad composite of two filler rods.Among the figure, symbol 1 expression small-sized DC motor of the present invention commutator material, the exposed division of the part that the small-sized DC motor that the representative of the symbol 1 of Fig. 2 ' expression is buried underground has exposed with the part of commutator material 1, symbol 2 expression Cu alloy base materials, symbol 3 is represented Au or Au alloys.
Then, to carry out the foregoing description 1 and when the wearing character of the commutator material of example 1 was estimated in the past the corresponding brush material of employed commutator describe.This small-sized DC motor of expression composition of brush material in the table 2.
[table 2]
(weight %)
The manufacture method of each small-sized DC motor shown in the employing table 2 with the brush of brush material described.In embodiment 2, embodiment 3, will stir 4 hours with ball mill with each Ag powder of forming suitable MgO powder, rest part, make each powder homogeneous dispersive powdered mixture.Then, this powdered mixture is inserted in the cylindrical vessel, axially applied 4.9 * 10 from cylinder
5The pressure of N (50tf) carries out compression process and handles, and forms the cylindrical blank of diameter 50mm.Then, this cylindrical blank is carried out 4 hours sintering processes (5.0Pa) under the temperature of 1123K (850 ℃).These compression process are handled, sintering processes repeats 3 times.
The cylindrical blank of having carried out these compression process and vacuum sintering processing is processed to form the wire rod of diameter 6.0mm by hot extrusion.Then, by Wire Drawing, make the wire rod of diameter 1.6mm.
Then, to the embodiment 4 shown in the employing table 2 and in the past the small-sized DC motor of example 2 describe with the manufacture method of the brush of brush material.For the embodiment 4 and the brush material of example 2 in the past, use the fusion method, each is formed according to table 2 is put down in writing, with each metal fusion, then by cast, extrusion processing, Wire Drawing, make the wire rod of diameter 1.6mm.
Each brush of Xing Chenging is processed into band shape with wire rod by rolling press as mentioned above, and its embedding is joined in the Cu material as stratum basale, obtains clad composite.Then, this clad composite is heat-treated under 1073K (800 ℃), roll repeatedly, make two layers of clad composite of total thickness 70 μ m, wide 19mm.These two layers of clad composites are form same as shown in Figure 1, are to have buried the form of the small-sized DC motor shown in the present embodiment with brush material underground in the part of the base material that is made of the Cu alloy.For this brush with two layers of clad composite, small-sized DC motor brush material shown in the symbol 1 expression table 2 among Fig. 1, the exposed division of the part that the small-sized DC motor that the representative of the symbol 1 of Fig. 2 ' expression is buried underground has exposed with the part of brush material 1, symbol 2 represents the Cu alloy base materials.
Then, use to adopt the commutator and the brush actual assembled small-sized DC motor of two layers of above-mentioned clad composite, to the specified time during drivingmotor state of wear of commutator and brush study.In the assembling of small-sized DC motor, use each small-sized DC motor commutator material of forming shown in the table 1, make two layers of clad composite shown in above-mentioned Fig. 1 a, this clad composite is processed into triodic rectifier of external diameter 3.3mm, long 2.4mm, the DVD main shaft small-sized DC motor of packing into.In addition,, make two layers of clad composite shown in above-mentioned Fig. 1 a, this clad composite is processed into the Brush Shapes of trident, the DVD main shaft small-sized DC motor of packing into for each small-sized DC motor brush material of forming shown in the table 2.The condition of comparison test is as shown in table 3, and pulse controlled roughly waveform at this moment is shown in Fig. 3.
[table 3]
Control |
Pulse control |
Maximum voltage |
7.2V |
The rotating speed of electric motor |
1800rpm |
Load |
12cm DVD video disc |
The test number |
5 |
Environment |
60 ℃, humidity do not have control |
Test period |
200 hours |
The small-sized DC motor that the wearing character is here estimated the combination of commutator material shown in the his-and-hers watches 4 and brush material carries out.Test temperature is 60 ℃, for the small-sized DC motors of 5 each combinations,, rotates after 200 hours as load with the DVD video disc of 12cm respectively, measures the wearing depth of the commutator and the brush of these 5 electric motor, calculates its mean value.It the results are shown in table 4.
[table 4]
Commutator |
Brush |
The wearing depth of commutator central part |
The wearing depth of commutator slit portion |
The wearing depth of+utmost point brush |
The wearing depth of-utmost point brush |
Embodiment |
1 |
Embodiment 4 |
9 |
19 |
3 |
1 |
Embodiment 1 |
Example 2 in the past |
10 |
15 |
9 |
5 |
Example 1 in the past |
Embodiment 4 |
20 |
38 |
4 |
2 |
Example 1 in the past |
Example 2 in the past |
31 |
48 |
31 |
27 |
(μm)
As shown in Table 4, in the electric motor of the combination of the commutator material of embodiment 1 and the brush material of embodiment 4, it is many that the commutator material of the wearing depth of commutator, the wearing depth of brush and example 1 in the past and the electric motor of the combination of the brush material of example 2 have in the past been compared all little.In addition, the either party of commutator material or brush material is under the situation of composition of the present invention, and the wearing depth of commutator, the wearing depth of brush also the commutator material than example 1 in the past are little with the electric motor of the combination of the brush material of example 2 in the past.Usually, in the pulse control of DVD main shaft with small-sized DC motor, owing to apply electric motor rotation control voltage continually, the rush current that therefore is equivalent to 10 times of nominal changes.Owing to the spark that at this moment produces, the rectification conversion portion of rectiblock fusion loss in the commutator, and if the conversion portion loss, then the transfer amount to brush also increases, the loss due to condensation grow.Find such loss due to condensation phenomenon in the electric motor of the commutator material of example 1 in the past and the combination of the brush material of example 2 in the past significantly, and in the electric motor of other combination, confirm that such loss phenomenon is inhibited.
Then, for using the commutator material shown in table 1 and the table 2 and the small-sized DC motor of brush material, describe with regard to the result who carries out after the long duration test.
The condition of this long duration test is identical with the condition shown in the table 3 except test period, and pulse controlled waveform also carries out in the same manner with Fig. 3.In addition, this long duration test is carried out 5 small-sized DC motors with the combination assembling of commutator material shown in the table 5 and brush material respectively.The time that electric motor breaks down is measured in this long duration test, stops long duration test but surpass 1300 hours electric motor endurance life at 1300 hours, with 1300 hours as the durable time.
[table 5]
Commutator |
Brush |
The 1st |
The 2nd |
The 3rd |
The 4th |
The 5th |
Embodiment |
1 |
Embodiment 2 |
760 |
1010 |
1140 |
1178 |
1200 |
Embodiment 1 |
Embodiment 3 |
1010 |
1280 |
1300 |
1300 |
1300 |
Embodiment 1 |
Embodiment 4 |
1008 |
1029 |
1300 |
1300 |
1300 |
Embodiment 1 |
Example 2 in the past |
775 |
818 |
914 |
928 |
1062 |
Example 1 in the past |
Embodiment 4 |
596 |
768 |
771 |
813 |
990 |
Example 1 in the past |
Example 2 in the past |
429 |
440 |
487 |
508 |
536 |
(hour)
As shown in Table 5, in the combination of the commutator material of embodiment 1 and the brush material of embodiment 2~4,5 electric motor all have the endurance life more than 1000 hours, satisfy market demands.