Painting mold for horizontal enameled flat wire and preparation method of painting mold

Abstract

The invention provides a lacquering mold for a horizontal enameled flat wire and a preparation method of the lacquering mold, and relates to the technical field of mold material processing. The material used by the painting mold is an aluminum-based or magnesium-based composite material reinforced by ceramic particles, and the ceramic technology is one or more of SiC, TiC, TiB2, Al2O3 particles or whiskers. The mold is manufactured by adopting a powder injection molding process. The lacquering mold for the horizontal type enameled flat wire has the advantages of being low in thermal expansion coefficient, high in hardness and elasticity modulus and good in abrasion resistance, can stably float at the design position in a paint box, and solves the problem that due to the fact that a traditional mold is large in weight and deviates from the center, the thicknesses of paint films on the upper side and the lower side of the enameled flat wire are not consistent.

Description

A coating mold for horizontal enameled flat wire and its preparation method Technical Field

[0001] This invention relates to a painting mold for horizontal enameled flat wire and its manufacturing method, belonging to the field of mold material processing technology. Background Technology

[0002] Magnetizing wire is an insulated wire used to manufacture coils or windings in electrical products. It is an important raw material for transformers, new energy motors, and various electrical appliances. Enameled wire is the main type of magnetizing wire, consisting of a conductor and an insulation layer. The bare wire is annealed, then coated with enamel multiple times and baked. In recent years, the rapid development of the power industry, new energy vehicles, and wind power has brought a broader market for magnetizing wire applications and also placed higher demands on its performance.

[0003] Enameled wire comes in two types: round and flat. With the increasing demand for miniaturization in transformers and electrodes, the use of enameled flat wire is constantly increasing. For enameled flat wire, a key parameter affecting its performance is the uniformity of the enamel film thickness on both sides. Currently, most enameled flat wires are produced using vertical enameling machines. Due to the limitations of this production method, the difference in enamel film thickness on both sides of the produced flat wire is significant; according to incomplete statistics, the enamel film thickness ratio is mostly between 2:8 and 3:7. Using a horizontal enameling machine to produce enameled flat wire can effectively improve the uniformity of the enamel film thickness, increasing the enamel film thickness ratio on both sides of the flat wire to approximately 4:6, but this still falls short of the ideal thickness ratio of 4.5:5.5.

[0004] The consistency of paint film thickness on both sides of enameled flat wire is affected by a variety of factors, among which the painting mold is a key component. Because horizontal enameling machines are designed for parallel wire routing, ensuring consistent paint film thickness requires not only high hardness, elastic modulus, and a low coefficient of thermal expansion in the painting mold material, but also low density to guarantee a lightweight mold that can stably float in its designed position within the paint box. Currently, the primary material for painting molds in horizontal enameling machines is mold steel, which has a high density, resulting in a heavy mold and causing a shift in the mold's center, thus affecting the consistency of paint film thickness on both sides of the enameled flat wire. Summary of the Invention

[0005] Based on the existing problems of the current horizontal enameling machine coating mold, the present invention provides a horizontal enameling machine coating mold and its manufacturing method, which realizes the coating mold's wear resistance, high elastic modulus, low thermal expansion coefficient and lightweight performance, and improves the consistency of the coating film thickness on both sides of the produced enameled flat wire.

[0006] This invention provides a coating mold for horizontal enameled flat wire. The coating mold is made of a ceramic particle-reinforced aluminum-based or ceramic particle-reinforced magnesium-based composite material. The ceramic particles are one or more of SiC, TiC, TiB2, and Al2O3 particles, and the ceramic particle content in the composite material is 15wt%-50wt%.

[0007] The present invention also provides a method for preparing a coating mold for horizontal enameled flat wire, comprising the following steps: (1) weighing metal powder and ceramic particles in proportion, wherein the metal powder is aluminum powder or magnesium powder with a particle size of 50-200μm, and the ceramic particles have a particle size of 1-100μm; (2) first cleaning the ceramic particles, and then depositing a portion of the metal powder on the surface of the ceramic particles to form a core-shell structure reinforcement particle; (3) mixing the remaining metal powder with the core-shell structure reinforcement particle, and then adding an adhesive in a high-shear mixer. (3) Mix the ingredients evenly to form granular feed, wherein the amount of binder added accounts for 10% to 40% of the total weight of the metal powder and the core-shell structure reinforcing particles; (4) Inject the granular feed into the mold using an injection molding machine to obtain a blank of a horizontal enameled flat wire painting mold; (5) Degrease the blank by heat, wherein the degreasing temperature is 50-200℃ and the degreasing time is 5-15h; (6) Sinter the degreased blank in a vacuum hot pressing sintering furnace, and after sintering, perform fine processing to obtain a horizontal enameled flat wire painting mold of the required size.

[0008] Preferably, the shell thickness in the core-shell structure reinforcing particles is 0.1-1 μm.

[0009] Preferably, the adhesive is a paraffin-based adhesive.

[0010] Preferably, in step (4), the injection temperature is 150-200 ℃, the injection pressure is 10-15 MPa, and the mold temperature is 50-90 ℃.

[0011] Preferably, the sintering temperature in step (6) is 550-650℃, the pressure is 50-150MPa, and the sintering time is 1-3h.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: The horizontal enameled flat wire coating mold prepared by the present invention has the characteristics of wear resistance, low elastic modulus, low coefficient of expansion, and light weight, overcoming the problem that the traditional mold is heavy, causing the mold center to shift, which in turn affects the consistency of the coating thickness on the upper and lower sides of the enameled flat wire. At the same time, the present invention uses powder injection molding process to achieve near-form manufacturing of the mold, ensuring the dimensional accuracy of the mold. Attached Figure Description

[0013] Figure 1 is a physical image of the horizontal enameled flat wire coating mold manufactured according to Embodiment 1 of the present invention; Figure 2 is a microscopic morphology image of the enameled flat wire coating mold material manufactured according to Embodiment 1 of the present invention.

[0014] Figure 3 shows an application scenario of the horizontal enameled flat wire painting mold manufactured according to Embodiment 1 of the present invention. Detailed Implementation

[0015] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The paraffin-based adhesive used in the present invention contains 70 wt% paraffin, 20 wt% high-density polyethylene, and 10 wt% stearic acid; the purity of the aluminum powder and magnesium powder used is greater than 99.0%. Example 1 A method for preparing a coating mold for a horizontal enameled flat wire, the specific steps are as follows: (1) Weigh 80 parts by weight of aluminum powder (average particle size of 125 μm, purity of 99.5%) and 20 parts by weight of SiC ceramic particles (average particle size of 7.5 μm); (2) Clean the SiC ceramic particles using an ultrasonic cleaning device. Cleaning is performed, and then some aluminum powder is deposited on the surface of SiC ceramic particles by chemical plating to form an aluminum coating, forming core-shell structure reinforcement particles, wherein the aluminum coating (i.e., the shell layer) has a thickness of 0.2 μm; (3) the core-shell structure reinforcement particles and the remaining aluminum powder are mixed, and 35 parts by weight of paraffin-based binder are added, and then they are mixed evenly in a high-shear mixer to form granular feed; (4) the mixed powder obtained in (3) above is injected into the molded material using an injection molding machine, wherein the injection temperature is 150°C and the injection pressure is 12 (5) The green blank of the horizontal enameled flat wire is obtained by hot degreasing the green blank at a temperature of 70°C and a time of 7h. (6) The degreased green blank is sintered in a vacuum hot pressing sintering furnace at a temperature of 630°C, a pressure of 100MPa, and a time of 2h. After sintering, a near-formed enameled mold is obtained. (7) The near-formed enameled mold is precision machined to obtain a horizontal enameled flat wire enameled mold of the required size.

[0016] Example 2: A method for preparing a horizontal enameled flat wire coating mold, the specific steps are as follows: (1) Weigh 60 parts by weight of aluminum powder (average particle size of 125 μm, purity of 99.5%) and 40 parts by weight of SiC ceramic particles (average particle size of 7.5 μm); (2) Clean the SiC ceramic particles using an ultrasonic cleaning device, and then deposit some of the aluminum powder on the surface of the SiC ceramic particles by chemical plating to form an aluminum coating layer, forming core-shell structure reinforcement particles, wherein the aluminum coating layer (i.e., the shell layer) thickness is 0.2 μm; (3) Mix the core-shell structure reinforcement particles and the remaining aluminum powder, add 40 parts by weight of paraffin-based binder, and then mix evenly in a high-shear mixer to form granular feed; (4) Inject the mixed powder obtained in (3) above into a molding machine, wherein the injection temperature is 150°C, the injection pressure is 15 MPa, and the mold temperature is 70°C. (5) The green blank of the horizontal enameled flat wire is obtained at ℃; (6) The green blank is degreased at 70℃ for 10h; (7) The degreased green blank is sintered in a vacuum hot pressing sintering furnace at 630℃, 120MPa for 3h for sintering, and a near-formed enameled mold is obtained after sintering; (8) The near-formed enameled mold is finished to obtain a horizontal enameled flat wire enameled mold of the required size.

[0017] Example 3: A method for preparing a horizontal enameled flat wire coating mold, the specific steps are as follows: (1) Weigh 85 parts by weight of magnesium powder (average particle size of 130 μm, purity of 99.0%) and 15 parts by weight of Al2O3 ceramic particles (average particle size of 3.0 μm); (2) Clean the Al2O3 ceramic particles using an ultrasonic cleaning device, and then deposit a portion of the magnesium powder on the surface of the Al2O3 ceramic particles by chemical plating to form a magnesium coating layer, forming core-shell structure reinforcement particles, wherein the thickness of the magnesium coating layer (i.e., the shell layer) is 0.1 μm; (3) Mix the core-shell structure reinforcement particles and the remaining magnesium powder, add 40 parts by weight of paraffin-based binder, and then mix evenly in a high-shear mixer to form granular feed; (4) Inject the mixed powder obtained in (3) above into a molding machine, wherein the injection temperature is 100℃, the injection pressure is 15 MPa, and the mold temperature is 50℃. (5) The green blank of the horizontal enameled flat wire is obtained at 50°C and the degreasing time is 10h. (6) The degreased green blank is sintered in a vacuum hot pressing sintering furnace at 600°C, 100MPa, and 2h. After sintering, a near-formed enameled mold is obtained. (7) The near-formed enameled mold is finely processed to obtain a horizontal enameled flat wire enameled mold of the required size.

[0018] It should be noted that the above examples are merely some specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments and other modifications are possible. All modifications directly or indirectly derived by those skilled in the art from the disclosure of the present invention should be considered within the scope of protection of the present invention.

[0019] The embodiments described above are some, but not all, embodiments of the present invention. The detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

Claims

1. A painting mold for horizontal enameled flat wire, characterized in that, The coating mold is made of a ceramic particle reinforced aluminum matrix or ceramic particle reinforced magnesium matrix composite material. The ceramic particles are one or more of SiC, TiC, TiB2, and Al2O3 particles, and the ceramic particle content in the composite material is 15wt%-50wt%.

2. The method for preparing a coating mold for horizontal enameled flat wire according to claim 1, characterized in that, The process includes the following steps: (1) Weighing metal powder and ceramic particles according to a ratio, wherein the metal powder is aluminum or magnesium powder with a particle size of 50-200 μm, and the ceramic particles have a particle size of 1-100 μm; (2) Cleaning the ceramic particles first, and then depositing a portion of the metal powder onto the surface of the ceramic particles to form core-shell structure reinforced particles; (3) Mixing the remaining metal powder with the core-shell structure reinforced particles, adding a binder, mixing evenly in a high-shear mixer, and forming granular feed. The amount of adhesive added accounts for 10% to 40% of the total weight of the metal powder and the core-shell structure reinforcing particles; (4) the granular feed is injected into the injection molding machine to obtain a blank of a horizontal enameled flat wire painting mold; (5) the blank is hot degreased, wherein the degreasing temperature is 50-200℃ and the degreasing time is 5-15h; (6) the degreased blank is sintered in a vacuum hot pressing sintering furnace, and after sintering, it is finely processed to obtain a horizontal enameled flat wire painting mold of the required size.

3. The preparation method according to claim 2, characterized in that: The shell thickness in the core-shell structure reinforcing particles is 0.1-1 μm.

4. The preparation method according to claim 2, characterized in that: The adhesive is a paraffin-based adhesive.

5. The preparation method according to claim 2, characterized in that: In step (4), the injection temperature is 150-200 ℃, the injection pressure is 10-15 MPa, and the mold temperature is 50-90 ℃.

6. The preparation method according to claim 2, characterized in that: The sintering temperature in step (6) is 550-650℃, the pressure is 50-150MPa, and the sintering time is 1-3h.

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