Molding material composition for motor

Abstract

The present invention relates to a molding material composition for a motor, and a vehicle component molded using same.

Description

Molding material composition for motors

[0001] The present invention relates to a molding material composition for a motor and a motor manufactured using the same.

[0002]

[0003] Epoxy resin compositions are widely used for the purpose of fixing components within a rotor, and as an example, Korean Patent Publication No. 10-2007-0114634 relates to a coreless motor having a multi-stage rotor, and discloses a configuration in which the coreless motor includes a rotor having a plurality of magnets and a stator coupled with a plurality of electric coils, and the electric coils are fixed by hardening with epoxy resin.

[0004] Recently, epoxy resin compositions have been widely used as molding materials or fixing materials for automotive parts, and for example, they can be used to fix permanent magnets to a rotor core in electric vehicle motors.

[0005] A motor rotates when the permanent magnets in the rotor interact with the magnetic field generated by the current flowing within the stator. Typically, the rotor contains permanent magnets, and the stator contains electromagnets using coils. The motor controls the polarity of the electromagnets, continuously changing the polarity of the magnets, causing the rotor's permanent magnets to rotate in response to these changes. Therefore, for this electromagnetic interaction to generate optimal efficiency, the magnetism of the surrounding materials, other than the permanent magnets and electromagnets, must be reduced.

[0006] However, in the case of a molding composition that secures a permanent magnet within a rotor, there is a problem in that the electromagnetic interaction between the rotor and stator within the motor is hindered due to the high content of magnetic components contained within the inorganic filler included in the composition, resulting in a decrease in motor efficiency. Therefore, there is a need for the development of a molding composition that can optimize motor efficiency by enhancing electromagnetic interaction due to its low magnetic content.

[0007]

[0008] The present invention provides a motor molding material composition having a low content of a magnetic material. The present invention also provides a vehicle part molded using the motor molding material composition.

[0009]

[0010] The present invention provides a molding material composition for a motor, which comprises an epoxy resin, a hardener, and a filler, and has a magnetic content of 40 ppm or less.

[0011]

[0012] The present invention provides a molding material composition for a motor having a low magnetic content. The molding material composition for a motor according to the present invention can be used as a molding material for vehicle parts, and for example, can be applied to secure a permanent magnet to a motor rotor. The molding material composition according to the present invention can optimize the magnetic field formation efficiency of the permanent magnet due to its low magnetic content, thereby increasing the efficiency of the motor.

[0013]

[0014] The present invention will be described in detail below. However, the scope of the present invention is not limited solely to the details described below, and each component may be modified or selectively mixed as needed. Therefore, it should be understood that all modifications, equivalents, and alternatives included within the spirit and technical scope of the present invention are encompassed.

[0015] As used herein, “viscosity” is measured by conventional methods known in the art, and can be measured, for example, using a Brookfield viscometer. “Particle size (D 50 )” is measured by a conventional method known in the art, and can be measured, for example, by laser light scattering (LLS).

[0016]

[0017] <Motor molding material composition>

[0018] The molding material composition for a motor of the present invention comprises an epoxy resin, a curing agent, and a filler, and the content of a magnetic substance contained in the composition is 40 ppm or less. Therefore, when the molding material composition for a motor according to the present invention is applied for the purpose of fixing a permanent magnet to a rotor of a motor, the content of the magnetic substance in the molding material composition for a motor is low, thereby having low magnetism, thereby optimizing the efficiency of forming a magnetic field of a permanent magnet contained in the motor, thereby increasing the efficiency of the motor.

[0019]

[0020] epoxy resin

[0021] In the present invention, epoxy resin is used as a main resin, and by reacting with a curing agent and curing, a three-dimensional network structure is formed, thereby imparting strong and solid adhesion properties and heat resistance to an adherend.

[0022] As the epoxy resin, an epoxy resin commonly used in the relevant technical field can be used, and for example, one containing two or more epoxy groups in the molecular structure can be used. Non-limiting examples of epoxy resins that can be used include bisphenol A type epoxy resin, alicyclic epoxy resin, cresol novolac type epoxy resin, dicyclopentadiene type epoxy resin, biphenyl type epoxy resin, naphthalene type epoxy resin, anthracene type epoxy resin, non-condensed ring type polycyclic structure epoxy resin, bisphenol fluorene modified epoxy, etc., and one or more of these can be included. For example, the epoxy resin can include a formaldehyde polymer with (chloromethyl)oxirane and 2-methylphenol.

[0023] The epoxy resin may be one having an epoxy equivalent weight (EEW) of 100 to 300 g / eq, for example, 180 to 230 g / eq, and a viscosity (150°C) of 300 to 600 cps, for example, 400 to 500 cps. If the epoxy equivalent is less than the above-mentioned range, the cured density may increase, resulting in poor moisture resistance reliability, and if it exceeds the above-mentioned range, the curing property may be poor. If the viscosity is less than the above-mentioned range, excessive B / F may occur during molding due to the low viscosity, and if it exceeds the above-mentioned range, the high viscosity may cause a decrease in flowability, resulting in an underfilling phenomenon during molding. An epoxy resin satisfying the above-mentioned properties has relatively low viscosity characteristics, and thus can secure flowability and be easy to mix even when a high content of filler is included.

[0024] Based on the total weight of the molding material composition for the motor, the content of the epoxy resin may be 5 to 30 wt%, for example 5 to 20 wt%. If the content of the epoxy resin is less than the above-mentioned range, adhesion, flowability, and moldability may be reduced, and if it exceeds the above-mentioned range, the reliability of the molding material may be deteriorated due to increased moisture absorption, and the strength may be reduced due to a relative decrease in the filler content.

[0025]

[0026] hardener

[0027] The molding material composition for a motor according to the present invention includes a curing agent. The curing agent reacts with the epoxy resin to promote curing of the composition, thereby improving adhesion.

[0028] The curing agent may be any curing agent known in the art that undergoes a curing reaction with an epoxy resin. For example, the curing agent may be a phenol-based compound having two or more phenolic hydroxyl groups in one molecule. For example, the curing agent may include at least one selected from the group consisting of a phenol novolac resin, a cresol novolac resin, a phenol aralkyl resin, and a polyfunctional phenol compound. For example, the curing agent may include a phenol polymer with formaldehyde.

[0029] The above curing agent may be one having a hydroxyl equivalent of 50 to 200 g / eq, for example, 90 to 120 g / eq, and a viscosity (150°C) of 0.1 to 20 poise, for example, 1 to 5 poise. If the hydroxyl equivalent of the curing agent exceeds the above-mentioned range, the curing property may be poor, and if it is less than the above-mentioned range, the moisture resistance reliability may be poor. If the viscosity exceeds the above-mentioned range, the high viscosity may cause a decrease in flowability, which may result in a non-filling phenomenon during molding, and if it is less than the above-mentioned range, the low viscosity may cause excessive B / F during molding.

[0030] Based on the total weight of the molding material composition for motors, the content of the curing agent may be 1 to 20 wt%, for example, 1 to 10 wt%. If the content of the curing agent is less than the above-mentioned range, curability and moldability may be reduced, and if it exceeds the above-mentioned range, the reliability of the molding material may be deteriorated and the strength may be reduced due to increased moisture absorption.

[0031]

[0032] filler

[0033] The molding material composition for a motor according to the present invention comprises a filler. The filler imparts strength to the molding material composition for a motor, thereby providing excellent durability, supports a permanent magnet under high-speed rotation, and improves moldability by controlling flowability.

[0034] As the filler, any filler commonly used in the relevant technical field can be used without limitation. For example, inorganic fillers such as silica, silica nitride, alumina, aluminum nitride, and boron nitride can be used, and these can be used alone or in combination of two or more. For example, the filler may include silica.

[0035] The shape of the above filler is not particularly limited, and both angular and spherical shapes can be used. The particle size (D) of the above filler 50 ) may be 1 to 30 μm, for example 5 to 15 μm.

[0036] The above filler may include a magnetic material such as iron, nickel, cobalt, or a metal oxide such as iron oxide (Fe2O3), chromium oxide (Cr2O3), or ferrite. When a motor molding material composition including such a filler is applied for the purpose of fixing a permanent magnet to a motor rotor, there is a problem in that the formation of a magnetic field of the permanent magnet and electromagnetic interaction with the stator coil are hindered, thereby reducing the magnetic flux of the rotor and lowering the efficiency of the motor.

[0037] In the present invention, by controlling the content of a magnetic material in a molding material composition to 40 ppm or less, when the molding material composition is applied for the purpose of fixing a permanent magnet to a rotor of a motor, the efficiency of the motor can be increased by optimizing the efficiency of forming a magnetic field of the permanent magnet.

[0038] For example, in the present invention, by controlling the content of a magnetic material in a filler, a motor molding material composition having a magnetic content of 40 ppm or less can be provided. The filler may have a magnetic content of 0.1 to 40 ppm, for example, 0.2 to 30 ppm.

[0039] As another example, the present invention provides a motor molding material composition having a magnetic content of 40 ppm or less by de-metalizing a motor molding material composition including a filler containing a magnetic material. The de-metalizing process may be performed by a method of removing a metal component in the motor molding material composition through a metal separator. The de-metalizing process may be performed in one or more steps selected from the group consisting of before dispersion of the motor molding material composition, after pulverization, before compression, and after compression, and the de-metalizing process may be performed one or more times.

[0040] Based on the total weight of the molding material composition for motors, the content of the filler may be 40 to 90 wt%, for example, 50 to 90 wt%. If the content of the filler is less than the aforementioned range, the moisture absorption in the cured product of the molding material composition may increase, which may lower the reliability of the molding material. If the content of the filler exceeds the aforementioned range, the fluidity may decrease, resulting in poor moldability.

[0041]

[0042] additives

[0043] The motor molding material composition according to the present invention may further include additives commonly used in the relevant technical field, such as an adhesion enhancer, a release agent, a colorant, a catalyst, a flame retardant, etc., as needed, within a range that does not deteriorate the physical properties of the motor molding material composition according to the present invention.

[0044] As an adhesion enhancer to improve the bonding between organic and inorganic substances and adhesion to a metal substrate, epoxy silane, amino silane, mercapto silane, acrylic silane, vinyl silane, etc. can be used, and as a release agent to improve the releasability between the epoxy molding compound (EMC) and the external mold, long-chain fatty acids, metal salts of long-chain fatty acids, paraffin wax, carnauba wax, polyethylene wax, silicone oil, etc. can be used. In addition, additives such as a coloring agent (e.g., carbon black, Bengala, etc.) to provide color to the resin composition, a catalyst (e.g., imidazole compound, amine compound, organic phosphine compound, etc.) to improve the curing speed and workability, and a flame retardant (e.g., metal hydroxide, etc.) can be further included.

[0045] The above additives may be added within a content range known in the relevant technical field, and for example, may be included in an amount of 0.01 to 10 wt%, respectively, based on the total weight of the molding material composition for motors, but is not limited thereto.

[0046]

[0047] <Vehicle Parts>

[0048] The present invention provides a vehicle component molded using the aforementioned motor molding material composition. For example, the aforementioned motor molding material composition can be used as a molding material to fix and seal components within a vehicle component driven by electromagnetic interaction, particularly components within a vehicle component requiring excellent vibration resistance, heat resistance, dimensional stability, and deformation resistance.

[0049] For example, a permanent magnet can be inserted into a hollow space formed in a rotor of a motor, and the molding material composition for a motor of the present invention can be filled between the hollow space and the permanent magnet to fix the permanent magnet in the rotor.

[0050] In particular, the molding material composition according to the present invention has a low magnetic content of 40 ppm or less, so that when applied for the purpose of fixing a permanent magnet to a motor rotor, it does not interfere with the electromagnetic interaction between the rotor and the stator when the motor is driven, thereby optimizing the efficiency of forming a magnetic field of the permanent magnet, thereby increasing the efficiency of the motor.

[0051]

[0052] Hereinafter, the present invention will be described in more detail through examples. However, the following examples are intended only to aid understanding of the present invention and are not intended to limit the scope of the present invention in any way.

[0053]

[0054] [Experimental Example 1-13]

[0055] According to Tables 1 and 2 below, each component was mixed to prepare a molding material composition for each experimental example. After the molding material composition for each experimental example was pulverized into a powder state (particle size of 3 mm or less), a sample (50-100 g) was placed in a magnetic analyzer sample holder preheated for 30 minutes to measure the content of magnetic substances, and the results are shown in Tables 1 and 2 below. In the case of the experimental examples in which de-ironization was performed, the molding material composition was pulverized, the metal component was removed using a metal separator, and then the content of magnetic substances was measured using the above method.

[0056]

[0057]

[0058]

[0059]

[0060]

[0061] Epoxy resin: formaldehyde polymer with (chloromethyl)oxirane and 2-methylphenol (Cas No. 29690-82-2, epoxy equivalent 203 g / eq)

[0062] Curing agent: phenol resin, phenol polymer with formaldehyde (Cas No. 9003-35-4, hydroxyl equivalent 107 g / eq)

[0063] Filler 1: Spherical silica (D50 9 ㎛, Magnetic content 10 ppm)

[0064] Filler 2: Spherical silica (D50 15 ㎛, Magnetic content 50 ppm)

[0065] Filler 3: angular silica (D50 10 ㎛, magnetic content 80 ppm)

[0066] Silane: Trimethoxy[3-(phenylamino)propyl]silane

[0067] Wax: Carnauba wax

[0068] Colorant: Carbon black

[0069] Catalyst: 2-phenyl-4-methyl-5-hydroxymethylimidazole

[0070] Flame retardant: Magnesium hydroxide

[0071]

[0072] [Physical property evaluation]

[0073] The physical properties of the molding material composition manufactured in each experimental example were measured as follows, and the results are shown in Tables 3 and 4 below.

[0074]

[0075] Spiral flow

[0076] The flowability was measured using a transfer molding press (175 ℃, 70 kgf / ㎠).

[0077]

[0078] Gel Time (G / T)

[0079] After setting the temperature to the same temperature as the mold press (175 ℃) using a hot plate, the time from the melting point of each specimen to the gelation point was measured.

[0080]

[0081] permanent magnet flux

[0082] A permanent magnet was placed in the rotor of a motor sample and molded using the molding material composition of each experimental example to produce a specimen. Each rotor was analyzed using a rotor scanner to measure the magnetic flux.

[0083]

[0084]

[0085]

[0086]

[0087]

[0088] As shown in Tables 3 and 4 above, the motor molding material compositions of Experimental Examples 1-5 according to the present invention exhibited excellent physical properties across all measured items. On the other hand, the motor molding material compositions of Experimental Examples 6-13, in which the content of magnetic material was outside the range of the present invention, were found to have inferior magnetic flux compared to Experimental Examples 1-5.

[0089]

[0090] The present invention provides a molding material composition for a motor having a low magnetic content.

[0091]

Claims

1. A molding material composition for a motor, comprising an epoxy resin, a hardener, and a filler, and having a magnetic content of 40 ppm or less.

2. In the first paragraph, the epoxy resin has an epoxy equivalent weight (EEW) of 100 to 300 g / eq and a viscosity (150°C) of 300 to 600 cps, A molding material composition for a motor, wherein the hydroxyl equivalent of the above-mentioned curing agent is 50 to 200 g / eq and the viscosity (150°C) is 0.1 to 20 poise.

3. In the first paragraph, the content of the magnetic material in the filler (magnetic content) is 0.1 to 40 ppm, and the particle size (D 50 ) A molding material composition for a motor having a diameter of 1 to 30 μm.

4. A motor molding material composition manufactured by mixing the epoxy resin, the hardener, and the filler in the first paragraph, and then removing the iron.

5. A motor molding material composition according to claim 1, comprising 5 to 30 wt% of the epoxy resin, 1 to 20 wt% of the hardener, and 40 to 90 wt% of the filler, based on the total weight of the motor molding material composition.

6. A vehicle part molded using a motor molding material composition according to any one of claims 1 to 5.

7. A vehicle component in accordance with claim 6, wherein the permanent magnet flux of the motor molded using the molding material composition is 0.44 or more.

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