TWI795924B - Manufacturing method of laminated iron core - Google Patents

Abstract

一種積層鐵芯的製造方法，包含一前置步驟、一堆疊步驟、一塗覆步驟、一加熱步驟、一壓合步驟，及一分離步驟。該前置步驟是準備數個具有二塗料層的母材。該堆疊步驟將該等母材疊置於模具形成數個結構件。該塗覆步驟在該等結構件間塗覆一離型劑層。該加熱步驟是對該等結構件加熱而形成一半成品。該離型劑層受熱形成一與該等塗料層不相黏結的隔離膜。該壓合步驟是施加沖壓力使半成品固結成積層鐵芯。該分離步驟是將該等積層鐵芯自模具取出從而得到數個成品。藉由所述隔離膜能減少應力集中而產生的形變問題，以提升製程的良率。A method for manufacturing a laminated iron core, comprising a pre-step, a stacking step, a coating step, a heating step, a pressing step, and a separation step. The pre-step is to prepare several base materials with two coating layers. In the stacking step, the base materials are stacked on the mold to form several structural parts. In the coating step, a release agent layer is coated between the structural parts. The heating step is to heat the structural parts to form a semi-finished product. The release agent layer is heated to form an isolation film that is not bonded to the paint layers. The pressing step is to apply stamping force to consolidate the semi-finished product into a laminated iron core. In this separation step, the laminated iron cores are taken out from the mold to obtain several finished products. The isolation film can reduce the deformation problem caused by stress concentration, so as to improve the yield of the manufacturing process.

Description

積層鐵芯的製造方法Manufacturing method of laminated iron core

本發明是有關於一種製造方法，特別是指一種積層鐵芯的製造方法。The invention relates to a manufacturing method, in particular to a manufacturing method of a laminated iron core.

參閱圖1、2，說明現有的一種鐵芯的製造方法，適用於同時製成數個鐵芯8，每一鐵芯8包括多個自黏鋼片81，該鐵芯的製造方法包含一準備步驟S1、一疊片步驟S2、一壓合步驟S3，及一分離步驟S4。在該準備步驟S1中，是提供該等自黏鋼片81，且每一自黏鋼片81表面上具有二分別位於相反兩側的黏性塗層。在該疊片步驟S2中，先設定每一鐵芯8所需堆疊的該等自黏鋼片81之數量後開始進行堆疊，且每當該等自黏鋼片81之堆疊數量達到每一鐵芯8所預設之堆疊數量時，會在位於最上方之該自黏鋼片81個別放置一分隔片7。在該壓合步驟S3中，則是對該等自黏鋼片81進行加壓與加熱，製成彼此相堆疊之鐵芯8。最後，該分離步驟S4是施加一外力將每兩兩上下相鄰之鐵芯8進行分離，從而製得多個所述鐵芯8。Referring to Fig. 1, 2, illustrate the manufacturing method of a kind of existing iron core, be applicable to making several iron cores 8 simultaneously, each iron core 8 comprises a plurality of self-adhesive steel sheets 81, the manufacturing method of this iron core comprises a preparation Step S1, a lamination step S2, a pressing step S3, and a separation step S4. In the preparation step S1, the self-adhesive steel sheets 81 are provided, and each self-adhesive steel sheet 81 has two adhesive coatings located on opposite sides on the surface. In the stacking step S2, first set the number of self-adhesive steel sheets 81 to be stacked for each iron core 8 and then start stacking, and whenever the stacked quantity of these self-adhesive steel sheets 81 reaches the When the stacking quantity of the core 8 is preset, a separator 7 will be placed on the self-adhesive steel sheet 81 located at the top. In the pressing step S3, the self-adhesive steel sheets 81 are pressurized and heated to form the stacked iron core 8 . Finally, the separation step S4 is to apply an external force to separate every pair of iron cores 8 adjacent up and down, so as to produce a plurality of iron cores 8 .

其中，所述分隔片7包括一用於接觸每一鐵芯8的最下方之自黏鋼片81的第一表面71、一位於相反側的第二表面72，及數個圍繞設置於該第二表面72且用於接觸每一鐵芯8之位於最上方之自黏鋼片81的凸起部73。藉由該等凸起部73能減少每兩兩上下相鄰之鐵芯8彼此之間的接觸面積，以降低該等鐵芯8彼此之間的黏著力，有利於減輕在該分離步驟S4所施加之外力，而使所述鐵芯8於分離後能有較好的品質。Wherein, the separator 7 includes a first surface 71 for contacting the lowermost self-adhesive steel sheet 81 of each iron core 8, a second surface 72 on the opposite side, and several The two surfaces 72 are used to contact the protrusion 73 of the uppermost self-adhesive steel sheet 81 of each iron core 8 . The contact area between every pair of up and down adjacent iron cores 8 can be reduced by the protruding parts 73, so as to reduce the adhesion between the iron cores 8, which is beneficial to alleviate the separation process in the separation step S4. External force is applied so that the iron core 8 can have better quality after separation.

然而，在該壓合步驟S3中，會提供一衝壓力對該等自黏鋼片81進行加壓，以利於提升每一鐵芯8的結構強度。惟因所述分隔片7之該等凸起部73是以多點相間隔分布的方式，設置在每一鐵芯8位於最上方之自黏鋼片81，所以在加壓的過程中，容易有應力集中在每一分隔片7之該等凸起部73與最上方之自黏鋼片81的所接觸部分，甚至可能使每一鐵芯8變形損壞，造成生產成本不必要的提高，故現有之鐵芯的製造方法仍有待改善。However, in the pressing step S3 , a stamping force is provided to press the self-adhesive steel sheets 81 , so as to improve the structural strength of each iron core 8 . But because these protrusions 73 of the separator 7 are arranged in the manner of multi-point spaced distribution, each iron core 8 is positioned at the self-adhesive steel sheet 81 at the top, so in the process of pressing, it is easy to Stress concentrates on the contact portion between the protrusions 73 of each separator 7 and the uppermost self-adhesive steel sheet 81, which may even deform and damage each iron core 8, resulting in an unnecessary increase in production cost. The manufacturing method of the existing iron core still needs to be improved.

因此，本發明之目的，即在提供一種能減少生產不良的積層鐵芯的製造方法。Therefore, it is an object of the present invention to provide a method of manufacturing a laminated iron core capable of reducing defective production.

於是，本發明積層鐵芯的製造方法，包含一前置步驟、一堆疊步驟、一塗覆步驟、一加熱步驟、一壓合步驟，及一分離步驟。Therefore, the manufacturing method of the laminated iron core of the present invention includes a pre-step, a stacking step, a coating step, a heating step, a pressing step, and a separation step.

該前置步驟是準備數個具有二分別位於相反側之表面的母材，且在每一母材的該等表面分別塗佈二塗料層。The preceding step is to prepare several base materials with two surfaces located on opposite sides respectively, and apply two coating layers on the surfaces of each base material respectively.

該堆疊步驟是先設定使多個所述母材相互堆疊而形成一結構件的堆疊數量，並據以將該等母材疊置於一模具中而形成數個結構件。In the stacking step, the stacking quantity of a plurality of base materials to be stacked to form a structural part is firstly set, and accordingly the base materials are stacked in a mold to form several structural parts.

該塗覆步驟在該等結構件之相鄰的塗料層間均勻塗覆一離型劑層。In the coating step, a release agent layer is evenly coated between the adjacent coating layers of the structural parts.

該加熱步驟是對該等結構件進行加熱，使該等塗料層產生黏性而讓每一結構件的該等母材彼此定位，形成一半成品，其中，該離型劑層受熱會形成一與該等塗料層彼此不相黏結而介於相鄰之所述半成品間的隔離膜。The heating step is to heat the structural parts to make the coating layers viscous and position the parent materials of each structural part to form a semi-finished product, wherein the release agent layer will form a molded part when heated. These paint layers are not bonded to each other but interposed between adjacent semi-finished products.

該壓合步驟是對該等半成品施加一沖壓力，使每一半成品的該等母材固結形成個別的積層鐵芯。The pressing step is to apply a stamping force to the semi-finished products, so that the parent materials of each semi-finished product are consolidated to form individual laminated iron cores.

該分離步驟是將該等積層鐵芯自該模具中依序取出從而得到數個成品。In the separating step, the laminated iron cores are sequentially taken out from the mold to obtain several finished products.

本發明之功效在於：透過將所述離型劑層能平整地附著於該等結構件之間，且經熱處理後能形成具有承受面積大與厚度均勻之特性的所述隔離膜，除了能隔離於該等半成品之間而防止該等半成品之間難以分離，在該等半成品受該沖壓力沖壓時，還可避免因應力集中而產生的形變問題，能提升後續製程的生產良率，以克服上述習知之問題。The effect of the present invention lies in that the release agent layer can be evenly attached between the structural members, and after heat treatment, the isolation film with the characteristics of large bearing area and uniform thickness can be formed. Prevent the semi-finished products from being difficult to separate between the semi-finished products. When the semi-finished products are stamped by the stamping force, the deformation problem caused by stress concentration can be avoided, and the production yield of the subsequent process can be improved to overcome The above known problems.

參閱圖3，為本發明積層鐵芯的製造方法的一實施例，本實施例包含一前置步驟101、一堆疊步驟102、一塗覆步驟103、一加熱步驟104、一壓合步驟105，及一分離步驟106。要先行說明的是，本實施例中是以使用數個自黏鋼片，而於衝壓設備中製成所述積層鐵芯的情況為例而進行說明。Referring to Fig. 3, it is an embodiment of the manufacturing method of the laminated iron core of the present invention, this embodiment includes a pre-step 101, a stacking step 102, a coating step 103, a heating step 104, a pressing step 105, And a separation step 106. It should be explained first that in this embodiment, the case of using several self-adhesive steel sheets to manufacture the laminated iron core in a punching equipment is taken as an example for illustration.

參閱圖4、5並配合圖3，該前置步驟101是先以一裁切機將原料1裁切成數個具有二分別位於相反側之表面111的母材11，且在每一母材11的該等表面111分別塗佈二塗料層12，其中，每一塗料層12是由環氧樹脂、壓克力樹脂或是聚酯樹酯所組成。具體而言，每一母材11為一種自黏鋼片，而每一塗料層12則是以環氧樹脂為例，但並不以此為限制。Referring to Figures 4 and 5 and in conjunction with Figure 3, the pre-step 101 is to cut the raw material 1 into several base materials 11 with two surfaces 111 respectively located on opposite sides with a cutting machine, and in each base material The surfaces 111 of 11 are respectively coated with two coating layers 12, wherein each coating layer 12 is composed of epoxy resin, acrylic resin or polyester resin. Specifically, each base material 11 is a self-adhesive steel sheet, and each paint layer 12 is an example of epoxy resin, but it is not limited thereto.

該堆疊步驟102是先設定使多個所述母材11相互堆疊而形成一結構件31的堆疊數量，並據以將該等母材11疊置於一模具2中而形成數個結構件31(於圖5中僅繪示出一個)。於該實施例中，該模具2內部設有一定位件22與一感測器21，該定位件22為設置在該模具2底部的擋片且會提供一限位力，使該等母材11能穩定地疊置於該模具2內，而不會在後續加工的工程中產生位移甚至是錯位。該感測器21是一種光學測距器，主要是用於偵測該等母材11相互堆疊之高度H，以便於後續該塗覆步驟103的實施。The stacking step 102 is to first set the number of stacks for stacking a plurality of the base materials 11 to form a structural member 31, and accordingly stack the base materials 11 in a mold 2 to form a plurality of structural members 31 (Only one is shown in FIG. 5). In this embodiment, a positioning member 22 and a sensor 21 are provided inside the mold 2. The positioning member 22 is a stopper arranged at the bottom of the mold 2 and provides a limiting force so that the base materials 11 It can be stably stacked in the mold 2 without displacement or even dislocation in subsequent processing. The sensor 21 is an optical range finder, which is mainly used to detect the stacking height H of the base materials 11 , so as to facilitate the subsequent implementation of the coating step 103 .

要特別說明的是，該模具2為了避免該等母材11於後續在高溫環境下會產生沾黏之現象，及需要避免與該等母材11一同被加熱的問題，該模具2較佳是以工程塑膠、陶瓷，或是鐵氟龍的其中一者所製成。It should be noted that the mold 2 is preferably a Made of engineering plastics, ceramics, or Teflon.

參閱圖6、7並配合圖3，該塗覆步驟103是利用一噴塗工具4在該等結構件31之相鄰的塗料層12間均勻塗覆一離型劑層5，且該噴塗工具4資訊連接該感測器21，以利於判斷該等母材11的堆疊數量是否正確。當該等母材11的堆疊數量到達每一結構件31的預設之高度H時，該感測器21會發出一控制訊號至該噴塗工具4，使該噴塗工具4對要進行下一結構件31的該堆疊步驟102之第一個母材11，且是所述母材11朝向下方的塗料層12之表面噴塗所述離型劑層5，而使所述離型劑層5能均勻地附著。其中，所述離型劑層5是選自複合基脂或是複合鋰基脂的其中一者，所述離型劑層5較佳是以複合鋰基脂為例，但不以上述所限制。Referring to Fig. 6, 7 and cooperate Fig. 3, this coating step 103 is to utilize a spraying tool 4 to evenly coat a release agent layer 5 between the adjacent paint layers 12 of these structures 31, and the spraying tool 4 The sensor 21 is connected with information to facilitate judging whether the stacking quantity of the base materials 11 is correct. When the stacking quantity of these base materials 11 reaches the preset height H of each structural member 31, the sensor 21 will send a control signal to the spraying tool 4, so that the spraying tool 4 will carry out the next structure The first base material 11 of the stacking step 102 of the piece 31, and the surface of the base material 11 facing the lower coating layer 12 is sprayed with the release agent layer 5, so that the release agent layer 5 can be uniform attached. Wherein, the release agent layer 5 is one of them selected from complex base grease or lithium complex base grease, and the release agent layer 5 is preferably an example of lithium complex base grease, but not limited by the above .

該加熱步驟104是利用圍繞於該模具2且採用周波加熱的感應線圈，來對該等結構件31進行熱處理。其加熱原理是利用是感應線圈通電而產生感應電流，使感應電流通過該等結構件31來產生熱能，進而產生加熱效果。其中，藉由加熱處理會使該等塗料層12產生黏性，使每一結構件31的該等母材11彼此黏合定位形成一半成品32(繪示於圖8)，而所述離型劑層5會受熱會形成一與該等塗料層12彼此不相黏結，且介於相鄰之所述半成品32之間的隔離膜51。於該實施例中，加熱溫度範圍介於70°C至350°C之間，而加熱頻率介於0.1kHz至1kHz之間。In the heating step 104 , heat treatment is performed on the structural components 31 by using an induction coil surrounding the mold 2 and adopting cycle heating. The heating principle is to generate an induced current by electrifying the induction coil, and make the induced current pass through the structural parts 31 to generate heat energy, thereby generating a heating effect. Among them, the coating layers 12 will be viscous by heat treatment, so that the parent materials 11 of each structural member 31 are bonded and positioned to form a semi-finished product 32 (shown in FIG. 8 ), and the release agent The layer 5 is heated to form a separation film 51 that is not bonded to the paint layers 12 and is interposed between the adjacent semi-finished products 32 . In this embodiment, the heating temperature ranges from 70°C to 350°C, and the heating frequency ranges from 0.1kHz to 1kHz.

參閱圖8、9並配合圖3，在該壓合步驟105中，是將一施壓件6與該模具2進行合模，且該施壓件6會對該等半成品32施加一向下的沖壓力，使每一半成品32的該等母材11之間具有良好的密實度，以形成個別的積層鐵芯91。在此過程中，因所述隔離膜51是具有厚度均勻與較大的承受面積之特性，可有效地使作用於所述隔離膜51的應力分散，以至於讓該等半成品32於該壓合步驟105中，能避免發生因應力集中進而導致該等半成品32有變形或毀壞的問題。Referring to Figures 8 and 9 in conjunction with Figure 3, in the pressing step 105, a pressing member 6 is molded with the mold 2, and the pressing member 6 will apply a downward punch to the semi-finished products 32. The pressure makes the base materials 11 of each semi-finished product 32 have good compactness, so as to form individual laminated iron cores 91 . During this process, because the isolation film 51 has the characteristics of uniform thickness and large bearing area, the stress acting on the isolation film 51 can be effectively dispersed, so that the semi-finished products 32 can be pressed together. In step 105 , the deformation or damage of the semi-finished products 32 due to stress concentration can be avoided.

在該分離步驟106中，先確認該等半成品32受壓而被製成該等積層鐵芯91後，將該施壓件6移開使該沖壓力消失的同時，該感應線圈也不再產生熱能，以達成防止有過度加熱與過度加壓的問題發生。其次，利用所述隔離膜51具有離型的功能，來減少相鄰之該等積層鐵芯91間的黏合力，使操作者只要將該等積層鐵芯91自該模具2中依序一一取出，即可在不需要額外施加外力將相鄰之該等積層鐵芯91進行分離的情況下，即可得到數個成品92。要特別說明的是，所述隔離膜51還具有抗腐蝕的功能，而能保護所述成品較不易有生鏽的情形發生。In the separation step 106, after confirming that the semi-finished products 32 are pressurized and made into the laminated iron cores 91, the pressing member 6 is removed so that the pressing force disappears and the induction coil no longer generates Thermal energy to prevent overheating and overpressurization. Secondly, the separation film 51 has a release function to reduce the adhesive force between the adjacent laminated iron cores 91, so that the operator only needs to remove the laminated iron cores 91 from the mold 2 one by one. After taking out, several finished products 92 can be obtained without applying additional external force to separate the adjacent laminated iron cores 91 . It should be noted that the isolation film 51 also has the function of anti-corrosion, and can protect the finished product from rusting.

綜上所述，本發明積層鐵芯的製造方法，藉由於所述離型劑層5先區隔上下相鄰之該等結構件31，且經熱處理後能形成具有承受面積大與厚度均勻之特性的所述隔離膜51，使該等半成品32於壓合的過程中，不易有因應力集中而受壓變形或毀壞的問題發生。此外，藉由所述隔離膜51能降低相鄰之該等積層鐵芯91之間的黏合力，而能輕易地將該等積層鐵芯91分別分離成所述成品92。因此，確實能達成本發明之目的。To sum up, the manufacturing method of the laminated iron core of the present invention can form a structure with a large bearing area and a uniform thickness by first separating the upper and lower adjacent structural members 31 by the release agent layer 5 , and after heat treatment. The characteristic of the isolation film 51 makes it difficult for the semi-finished products 32 to be deformed or damaged due to stress concentration during the pressing process. In addition, the separation film 51 can reduce the adhesive force between the adjacent laminated iron cores 91 , so that the laminated iron cores 91 can be easily separated into the finished products 92 . Therefore, can really reach the purpose of the present invention.

惟以上所述者，僅為本發明之實施例而已，當不能以此限定本發明實施之範圍，凡是依本發明申請專利範圍及專利說明書內容所作之簡單的等效變化與修飾，皆仍屬本發明專利涵蓋之範圍內。But what is described above is only an embodiment of the present invention, and should not limit the scope of the present invention. All simple equivalent changes and modifications made according to the patent scope of the present invention and the content of the patent specification are still within the scope of the present invention. Within the scope covered by the patent of the present invention.

101:前置步驟 102:堆疊步驟 103:塗覆步驟 104:加熱步驟 105:壓合步驟 106:分離步驟 1:原料 11:母材 111:表面 12:塗料層 2:模具 21:感測器 22:定位件 31:結構件 32:半成品 4:噴塗工具 5:離型劑層 51:隔離膜 6:施壓件 91:積層鐵芯 92:成品 H:高度 101: Pre-steps 102:Stacking steps 103: Coating step 104: heating step 105: Pressing step 106: Separation step 1: raw material 11: Base material 111: surface 12: Paint layer 2: Mold 21: Sensor 22: Positioning parts 31: Structural parts 32: Semi-finished products 4: Spraying tools 5: Release agent layer 51: isolation film 6: Pressure parts 91:Laminated iron core 92: Finished product H: height

本發明之其他的特徵及功效，將於參照圖式的實施方式中清楚地呈現，其中： 圖1是一方塊流程圖，說明現有的一種鐵芯製造方法； 圖2是一側視圖，說明二上下相鄰之鐵芯與一分隔片的連接關係； 圖3是一方塊流程圖，說明本發明積層鐵芯的製造方法的一實施例； 圖4是一流程示意圖，說明該實施例之一前置步驟的作業流程； 圖5是一示意圖，說明該實施例之一堆疊步驟的作業狀態； 圖6是一示意圖，說明該實施例之一塗覆步驟中一感測器、一噴塗工具與每一結構件所設定的高度之連動關係； 圖7是一示意圖，說明該實施例之一加熱步驟的作業狀態； 圖8是一示意圖，說明該實施例之一壓合步驟的作業狀態；及 圖9是一流程示意圖，說明該實施例之一分離步驟的作業流程。 Other features and effects of the present invention will be clearly presented in the implementation manner with reference to the drawings, wherein: Fig. 1 is a block flow chart, illustrates an existing a kind of iron core manufacturing method; Fig. 2 is a side view, illustrating the connection relationship between two adjacent iron cores up and down and a spacer; Fig. 3 is a block flow chart illustrating an embodiment of the manufacturing method of the laminated iron core of the present invention; Fig. 4 is a flow diagram illustrating the operation flow of one of the pre-steps of this embodiment; Fig. 5 is a schematic diagram illustrating the operation status of one of the stacking steps of this embodiment; Fig. 6 is a schematic diagram illustrating the interlocking relationship between a sensor, a spraying tool and the height set by each structural member in a coating step of this embodiment; Fig. 7 is a schematic diagram illustrating the operating state of one of the heating steps of this embodiment; Fig. 8 is a schematic diagram illustrating the working state of one pressing step of this embodiment; and Fig. 9 is a flow diagram illustrating the operation flow of one of the separation steps in this embodiment.

101:前置步驟 101: Pre-steps

102:堆疊步驟 102:Stacking steps

103:塗覆步驟 103: Coating step

104:加熱步驟 104: heating step

105:壓合步驟 105: Pressing step

106:分離步驟 106: Separation step

Claims (3)

一種積層鐵芯的製造方法，包含：一前置步驟，準備數個具有二分別位於相反側之表面的母材，且在每一母材的該等表面分別塗佈二塗料層；一堆疊步驟，設定使多個所述母材相互堆疊而形成一結構件的堆疊數量，並據以將該等母材疊置於一模具中而形成數個結構件；一塗覆步驟，在該等結構件之相鄰的塗料層間均勻塗覆一離型劑層，其中，該離型劑層是選自複合基脂或是複合鋰基脂的其中一者；一加熱步驟，對該等結構件進行加熱，使該等塗料層產生黏性而讓每一結構件的該等母材彼此定位，形成一半成品，其中，該離型劑層受熱會形成一與該等塗料層彼此不相黏結，並介於相鄰之所述半成品間的隔離膜；一壓合步驟，對該等半成品施加一沖壓力，使每一半成品的該等母材固結形成個別的積層鐵芯；及一分離步驟，將該等積層鐵芯自該模具中依序取出從而得到數個成品。 A method for manufacturing a laminated iron core, comprising: a preliminary step of preparing several base materials with two surfaces on opposite sides, and coating two paint layers on the surfaces of each base material; a stacking step , setting the number of stacks to make a plurality of base materials stacked on each other to form a structural member, and accordingly stacking the base materials in a mold to form several structural members; a coating step, in the structure A release agent layer is evenly coated between the adjacent paint layers of the parts, wherein the release agent layer is selected from one of complex base grease or lithium complex base grease; a heating step is carried out on these structural parts heating to make the paint layers viscous and position the parent materials of each structural part to form a semi-finished product. a separating film between adjacent semi-finished products; a pressing step, applying a stamping force to the semi-finished products to consolidate the base metals of each semi-finished product to form individual laminated cores; and a separating step, The laminated iron cores are sequentially taken out from the mold to obtain several finished products. 如請求項1所述的積層鐵芯的製造方法，其中，該加熱步驟的加熱溫度範圍介於70℃至350℃之間，而加熱頻率介於0.1kHz至1kHz之間。 The method for manufacturing a laminated iron core as claimed in Claim 1, wherein the heating temperature range of the heating step is between 70° C. and 350° C., and the heating frequency is between 0.1 kHz and 1 kHz. 如請求項1所述的積層鐵芯的製造方法，其中，每一塗料層是由環氧樹脂、壓克力樹脂或是聚酯樹酯所組成。 The method for manufacturing a laminated iron core according to claim 1, wherein each coating layer is composed of epoxy resin, acrylic resin or polyester resin.

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