JP2017005906A - Commutator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a commutator reconciling excellent dimensional stability and excellent mechanical strength, under high temperature/high speed rotation conditions.SOLUTION: In a commutator 100 having a resin metal composite body consisting of an inner member 14 fixed to the rotating shaft of a motor, and composed of a cured thermosetting resin composition, and an outer member 12 composed of a metal member and adhering to the outer peripheral surface of the inner member 14, the thermosetting resin composition contains one or more kinds of thermosetting resin selected from a group consisting of phenol resin, epoxy resin and melamine resin. The adhesion face of the outer member 12 and inner member 14, in the outer member 12, has a plurality of recesses, and the profile of the recess has a cross-sectional width larger than that of the opening, at at least a part from the opening to the bottom of the recess.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a commutator.

A conventional commutator fixed to a rotating shaft of a motor is generally composed of a copper segment and a molded product of a thermosetting resin molding material as an insulator. Such a commutator is a device for switching the direction of current by making contact with a brush constituting a part of a rotor in a motor.
Examples of the technology related to such a commutator include the following.

  In Patent Document 1, in order to suppress wear and noise caused by contact with a brush (slider), a commutator resin portion fixed to a rotating shaft and formed of an insulating resin, and the commutator resin portion A commutator is disclosed that employs a configuration that is provided on the outer periphery and includes a commutator metal plate that slides in surface contact with the slider.

Japanese Patent Laid-Open No. 2005-6457

  In recent years, further miniaturization and high-speed rotation of motors are required. In view of these circumstances, the level of technology required for commutators is also increasing. Here, since the commutator is a component of the motor, it is used under high temperature and high speed rotation conditions. Therefore, in the commutator, the copper segment and the insulator are separated by a large centrifugal force applied when the motor is rotated at a high speed, and a step between adjacent copper segments is generated. Adhesiveness (dimensional stability) excellent enough to prevent the circularity from dropping, and stable commutator performance in the long term even when the motor is rotated at high speed for a long time at high temperatures There is a strong demand to achieve excellent mechanical strength.

  However, the conventional commutator has a possibility that the above-described dimensional stability and mechanical strength are gradually lowered by repeated use under high temperature and high speed rotation conditions.

  Accordingly, the present invention provides a commutator that achieves both excellent dimensional stability and excellent mechanical strength under high temperature and high speed rotation conditions.

According to the present invention, an inner member that is fixed to the rotating shaft of the motor and is constituted by a cured body of a thermosetting resin composition;
An outer member made of a metal member and in close contact with the outer peripheral surface of the inner member;
A commutator having a resin-metal composite comprising:
The thermosetting resin composition includes one or more thermosetting resins selected from the group consisting of phenol resins, epoxy resins, and melamine resins,
In the outer member, the close contact surface between the outer member and the inner member has a plurality of recesses,
A commutator is provided in which the cross-sectional shape of the concave portion is a shape having a cross-sectional width larger than the cross-sectional width of the opening portion in at least a part between the opening portion and the bottom portion of the concave portion.

  According to the present invention, it is possible to provide a commutator that achieves both excellent dimensional stability and excellent mechanical strength under high temperature and high speed rotation conditions.

It is a figure for demonstrating the commutator which concerns on this embodiment. It is a schematic diagram for demonstrating the example of the cross-sectional shape of the recessed part which comprises the roughening layer of the metal member surface which concerns on this embodiment. 3 is an enlarged view of a roughened layer present on the surface of the metal sheet obtained in Example 1. FIG. 2 is an electron micrograph showing an enlarged cross-sectional view of a joint portion in a test piece obtained in Example 1. FIG. It is a cross-sectional shape of the commutator for a test used for evaluation of an Example.

<Commutator>
FIG. 1 is a diagram for explaining a commutator 100 according to the present embodiment. Hereinafter, the outer member 12 is also referred to as a metal segment 12, and the inner member 14 is also referred to as a resin member 14 or a cured body 14 of a thermosetting resin composition.
As shown to Fig.1 (a), the commutator 100 which concerns on this embodiment is fixed to the rotating shaft of a motor, and is comprised by the inner member 14 comprised with the hardening body of a thermosetting resin composition, and a metal member. A commutator 100 having a resin-metal composite comprising an outer member (metal segment) 12 that is configured and is in close contact with the outer peripheral surface of the inner member 14, wherein the thermosetting resin composition is a phenol resin. In addition, the outer member (metal segment) 12 and the inner member 14 in the outer member (metal segment) 12 include one or more thermosetting resins selected from the group consisting of epoxy resin and melamine resin. The contact surface 103 has a plurality of recesses, and the cross-sectional shape of the recesses has a shape having a cross-sectional width larger than the cross-sectional width of the opening at least at a part from the opening to the bottom of the recess. To have. In this way, even when used repeatedly under high-temperature and high-speed rotation conditions, the performance is not degraded due to the large centrifugal force applied during high-speed rotation of the motor, which is excellent in terms of dimensional stability and mechanical strength. The commutator 100 can be realized. In other words, according to the present embodiment, the commutator 100 that achieves both excellent dimensional stability and excellent mechanical strength under high temperature and high speed rotation conditions can be realized.

  As described above, the commutator 100 according to the present embodiment is configured by the inner member 14 made of a cured body of the thermosetting resin composition and the metal member, and is in close contact with the outer peripheral surface of the inner member 14. And an outer member (metal segment) 12 and a resin-metal composite. That is, the commutator 100 according to the present embodiment is characterized in that it is formed by a member (resin metal composite) in which the bonding interface between the inner member 14 and the outer member (metal segment) 12 is firmly bonded. Is. Note that the resin-metal composite according to the present embodiment does not include the one in which the inner member is simply fitted to the separately manufactured outer member (metal segment) by assembling or the like. In this way, when the commutator is formed by simply fitting the inner member to the separately manufactured outer member (metal segment), the joint interface between the inner member and the outer member (metal segment) is large at the time of use. Centrifugal force is applied. When the above-described commutator simply fitted is used repeatedly, this centrifugal force is accumulated, peeling between the inner member and the outer member (metal segment) of the commutator, and mechanical of the commutator. It is thought that a decrease in strength will occur gradually.

  Here, the commutator 100 according to the present embodiment is not limited as long as the inner member 14 and the outer member (metal segment) 12 form the above-described adhesion structure, but the inner member 14 and the outer member (metal segment). 12 is preferably bonded without an adhesive, and more preferably, the inner member 14 and the outer member (metal segment) 12 are integrally formed. The inner member 14 and the outer member (metal segment) 12 have excellent bonding strength even without an adhesive. Therefore, the manufacturing process of the resin metal composite can be simplified. That is, the resin-metal composite according to the present embodiment is preferably such that the inner member 14 and the outer member (metal segment) 12 are physically joined by an anchor effect or the like. Moreover, it is preferable that the resin metal composite which concerns on this embodiment is the thing in which the inner member 14 and the outer member (metal segment) 12 were formed integrally.

  In the commutator 100 according to the present embodiment, as described above, the contact surface 103 of the outer member (metal segment) 12 and the inner member 14 in the outer member (metal segment) 12 has a plurality of recesses. In addition, the recess has a close-contact structure in which the cross-sectional shape of the recess has a shape having a cross-sectional width larger than the cross-sectional width of the opening at least at a part between the opening and the bottom of the recess. In other words, the commutator 100 according to the present embodiment is an outer member in which a plurality of convex portions formed on the outer peripheral surface of the inner member 14 made of a cured body of a thermosetting resin composition are made of a metal member ( The metal segment) 12 is fitted to a plurality of recesses formed on the inner peripheral surface of the metal segment 12, and employs a close contact structure having a structure in which the protrusions and the recesses are alternately continued. Therefore, according to the commutator 100 which concerns on this embodiment, it is possible to improve the adhesiveness of the inner member 14 and the outer member (metal segment) 12 drastically compared with the conventional commutator. Specifically, the commutator 100 according to the present embodiment employs the above-described contact structure, so that the inner member 14 and the outer member (metal segment) 12 can be connected to each other when repeatedly used under high temperature and high speed rotation conditions. Misalignment and peeling can be prevented. In other words, according to the commutator 100 according to the present embodiment, even when used under high-temperature and high-speed rotation conditions, there is a step between the adjacent outer members (metal segments) 12 (inter-segment step). Further, it is possible to suppress the roundness of the commutator 100 from being lowered.

  Furthermore, since the commutator 100 according to the present embodiment employs the above-described close-contact structure, a commutator having a relatively small commutator with a diameter of less than φ18 mm and a relatively small centrifugal force due to rotation has a conventional commutator. There is no need to process nails or reinforcing rings to improve the dimensional stability and strength of the commutator, and it can be expected that man-hours and costs can be reduced. Further, in a commutator having a relatively large commutator of φ18 mm or more and having a relatively large centrifugal force due to rotation, there is a one-step difference (inter-segment step) between adjacent outer members (metal segments) 12. It is possible to reliably suppress the occurrence or the roundness of the commutator 100 from being lowered. Therefore, according to the present embodiment, it is possible to realize the commutator 100 that is superior to the prior art in terms of cost or life.

In addition, the commutator 100 according to the present embodiment is more excellent in terms of reliability under high temperature and high speed rotation conditions by appropriately controlling various factors related to the following two conditions, for example. can do.
(1) Composition of thermosetting resin composition (combination of thermosetting resin, its curing agent and additives, etc.)
(2) Selection of metal material (setting of various conditions related to metal type, surface treatment, etc.)

(Outer member (metal segment) 12)
Examples of the metal material constituting the outer member (metal segment) 12 include iron, stainless steel, aluminum, aluminum alloy, magnesium, magnesium alloy, copper, and copper alloy from the viewpoint of availability and price. These may be used alone or in combination of two or more. Among these, it is preferable that copper or a copper alloy is included from the viewpoint of being lightweight and high in strength and capable of exhibiting excellent conductive properties. The metal segment 12 has fine irregularities on the contact surface 103 between the metal segment 12 and the inner member (resin member) 14 from the viewpoint of improving the bonding strength with the cured body of the thermosetting resin composition constituting the inner member 14. It is preferable to have a roughened layer made of

FIG. 2 is a schematic diagram for explaining an example of the cross-sectional shape of the recess 201 constituting the roughened layer 104 on the surface of the metal segment 12 according to the present embodiment. Here, the roughened layer 104 refers to a region having a plurality of recesses 201 provided on the surface of the metal segment 12.
The thickness of the roughened layer 104 is preferably 3 μm or more and 40 μm or less, more preferably 4 μm or more and 32 μm or less, and particularly preferably 4 μm or more and 30 μm or less. When the thickness of the roughened layer 104 is within the above range, the bonding strength and bonding durability between the resin member 14 and the metal segment 12 can be further improved. Here, in this embodiment, the thickness of the roughened layer 104 represents the depth D3 of the largest depth among the plurality of recesses 201, and can be calculated from a scanning electron microscope (SEM) photograph. .

It is preferable that the cross section of the recess 201 has a shape having a cross section width D2 larger than the cross section width D1 of the opening 203 in at least a part between the opening 203 and the bottom 205 of the recess 201.
As shown in FIG. 2, the cross-sectional shape of the recess 201 is not particularly limited as long as D2 is larger than D1, and can take various shapes. The cross-sectional shape of the recess 201 can be observed with, for example, a scanning electron microscope (SEM).

When the cross-sectional shape of the recess 201 is the above-described shape, the reason why a resin-metal composite having a more excellent bonding strength is not always clear, but the surface of the contact surface 103 is between the resin member 14 and the metal segment 12. This is thought to be due to the structure in which the anchor effect of can be expressed even more strongly.
When the cross-sectional shape of the concave portion 201 is the above shape, the resin member 14 is caught between the opening 203 and the bottom portion 205 of the concave portion 201, so that the anchor effect is effective. Therefore, it is considered that the bonding strength and bonding durability between the resin member 14 and the metal segment 12 are improved.

  The average depth of the recess 201 is preferably 0.5 μm or more and 40 μm or less, and more preferably 1 μm or more and 30 μm or less. When the average depth of the recess 201 is equal to or less than the above upper limit value, the thermosetting resin composition (P) can sufficiently enter the depth of the recess 201, so that the resin member 14 and the metal segment 12 enter each other. It is possible to further improve the mechanical strength and joining durability of the region. When the average depth of the recesses 201 is equal to or greater than the above lower limit, the proportion of the filler (B) present inside the recesses 201 is increased when the thermosetting resin composition (P) contains the filler (B). Therefore, it is possible to improve the mechanical strength and the durability of joining in the region where the resin member 14 and the metal segment 12 penetrate each other. Therefore, when the average depth of the recess 201 is within the above range, the bonding strength between the resin member 14 and the metal segment 12 and the durability of the bonding can be further improved.

  The average depth of the recess 201 can be measured from a scanning electron microscope (SEM) photograph as follows, for example. First, a cross section of the roughened layer 104 is photographed with a scanning electron microscope. From the observation image, 50 concave portions 201 are arbitrarily selected and their depths are measured. The average depth is obtained by integrating all the depths of the recesses 201 and dividing the sum by the number.

The arithmetic average roughness (surface roughness) Ra of the adhesion surface 103 of the metal segment 12 is preferably 0.5 μm or more and 40.0 μm or less, more preferably 1.0 μm or more and 20.0 μm or less, particularly preferably. 1.0 μm or more and 10.0 μm or less. When the arithmetic average roughness (surface roughness) Ra is within the above range, the bonding strength between the resin member 14 and the metal segment 12 can be further improved.
Further, the surface 10 point average roughness (maximum height) Rz of the adhesion surface 103 of the metal segment 12 is preferably 1.0 μm or more and 40.0 μm or less, more preferably 3.0 μm or more and 30.0 μm or less. . When the surface 10-point average roughness (maximum height) Rz is within the above range, the bonding strength and bonding durability between the resin member 14 and the metal segment 12 can be further improved. Ra and Rz can be measured according to JIS-B0601.

  In the metal segment 12, the ratio of the actual surface area by the nitrogen adsorption BET method to the apparent surface area of the adhesion surface 103 to be bonded to the resin member 14 (hereinafter also simply referred to as the specific surface area) is preferably 100 or more, more preferably. 150 or more. When the specific surface area is equal to or greater than the lower limit, the bonding strength and bonding durability between the resin member 14 and the metal segment 12 can be further improved. The specific surface area is preferably 400 or less, more preferably 380 or less, and particularly preferably 300 or less. When the specific surface area is not more than the upper limit, the bonding strength between the resin member 14 and the metal segment 12 and the durability of the bonding can be further improved.

  Here, the apparent surface area in the present embodiment means a surface area when it is assumed that the surface of the metal segment 12 is smooth without unevenness. For example, when the surface shape is a rectangle, it is represented by vertical length × horizontal length. On the other hand, the actual surface area by the nitrogen adsorption BET method in the present embodiment means the BET surface area obtained from the adsorption amount of nitrogen gas. For example, using a specific surface area / pore distribution measuring device (BELSORPmini II, manufactured by Nippon Bell Co., Ltd.) for a vacuum dried sample to be measured, the nitrogen adsorption / desorption amount at liquid nitrogen temperature is measured, and based on the nitrogen adsorption / desorption amount Can be calculated.

When the specific surface area is within the above range, the reason why a resin-metal composite that is further excellent in bonding strength and bonding durability is not always clear, but the surface of the contact surface 103 with the resin member 14 is This is probably because the anchor effect between the resin member 14 and the metal segment 12 can be further enhanced.
When the specific surface area is equal to or greater than the lower limit, the contact area between the resin member 14 and the metal segment 12 is increased, and the region where the resin member 14 and the metal segment 12 enter each other increases. As a result, the area where the anchor effect works increases, and it is considered that the bonding strength and bonding durability between the resin member 14 and the metal segment 12 are further improved.

On the other hand, if the specific surface area is too large, the proportion of the metal segment 12 in the region where the resin member 14 and the metal segment 12 have entered each other decreases, so that the mechanical strength and the durability of bonding in this region are reduced. . Therefore, when the specific surface area is equal to or less than the upper limit, the mechanical strength and the durability of bonding of the region where the resin member 14 and the metal segment 12 have entered each other are further improved. It is considered that the bonding strength with the metal segment 12 and the durability of the bonding can be further improved.
From the above, when the specific surface area is within the above range, the surface of the contact surface 103 with the resin member 14 can exhibit the anchor effect between the resin member 14 and the metal segment 12 more strongly and has a well-balanced structure. It is inferred that

In the metal segment 12, the glossiness of at least the adhesion surface 103 bonded to the resin member 14 is preferably 0.1 or more, more preferably 0.5 or more, and further preferably 1 or more. When the glossiness is not less than the lower limit, the bonding strength between the resin member 14 and the metal segment 12 can be further improved. Further, the glossiness is preferably 30 or less, more preferably 20 or less. When the glossiness is not more than the above upper limit value, the bonding strength between the resin member 14 and the metal segment 12 can be further improved. Here, the glossiness in the present embodiment indicates a value at a measurement angle of 60 ° (incident angle of 60 °, reflection angle of 60 °) measured in accordance with ASTM-D523. The glossiness can be measured using, for example, a digital glossiness meter (20 °, 60 °) (GM-26 type, manufactured by Murakami Color Research Laboratory Co., Ltd.).
When the gloss is within the above range, the reason why a resin-metal composite that is more excellent in bonding strength is not necessarily clear, but the surface of the contact surface 103 with the resin member 14 has a more messy structure, This is probably because the anchor effect between the resin member 14 and the metal segment 12 can be further enhanced.

Next, a method for forming the roughened layer 104 by roughening the surface of the metal segment 12 will be described.
The roughened layer 104 can be formed, for example, by chemically treating the surface of the metal segment 12 or a metal member that is a material thereof using a surface treatment agent.
Here, the chemical treatment of the surface of the metal segment 12 or the metal member that is the material of the metal segment 12 using the surface treatment agent itself has been performed in the prior art. However, in the present embodiment, (1) a combination of the metal segment 12 or a metal member serving as a material thereof and a chemical treatment agent (surface treatment agent), (2) temperature and time of chemical treatment, and (3) chemical treatment. Factors such as post-treatment of the subsequent metal segment 12 or the surface of the metal member that is the material thereof are highly controlled. In order to obtain a resin metal composite, it is particularly important to highly control these factors.
Hereinafter, an example of a method for forming the roughened layer 104 on the surface of the metal segment 12 will be described. However, the method for forming the roughened layer 104 according to the present embodiment is not limited to the following example.

First, (1) a combination of a metal segment 12 or a metal member that is a material thereof and a surface treatment agent is selected.
When using the metal segment 12 composed of iron or stainless steel or a metal member that is a material thereof, an inorganic acid, a chlorine ion source, a cupric ion source, and a thiol compound are combined as necessary as a surface treatment agent. It is preferred to select an aqueous solution.
When using the metal segment 12 composed of aluminum or an aluminum alloy or a metal member as the material, an aqueous solution in which an alkali source, an amphoteric metal ion source, a nitrate ion source, and a thio compound are combined as necessary as a surface treatment agent Is preferably selected.
When using the metal segment 12 composed of magnesium or a magnesium alloy or a metal member serving as a material thereof, an alkali source is used as the surface treatment agent, and it is particularly preferable to select an aqueous solution of sodium hydroxide.
When using the metal segment 12 composed of copper or a copper alloy or a metal member as a material thereof, as a surface treatment agent, an inorganic acid such as nitric acid or sulfuric acid, an organic acid such as an unsaturated carboxylic acid, a persulfate, a persulfate Hydrogen oxide, imidazole and its derivatives, tetrazole and its derivatives, aminotetrazole and its derivatives, azoles such as aminotriazole and its derivatives, pyridine derivatives, triazine, triazine derivatives, alkanolamines, alkylamine derivatives, polyalkylene glycols, sugar alcohols Selecting an aqueous solution using at least one selected from a cupric ion source, a chlorine ion source, a phosphonic acid chelating agent, an oxidant, and N, N-bis (2-hydroxyethyl) -N-cyclohexylamine. preferable.

Next, (2) the metal segment 12 or a metal member serving as the material thereof is immersed in a surface treatment agent, and the metal segment 12 or the metal member surface serving as the material is subjected to chemical treatment. At this time, the processing temperature is, for example, 30 ° C. The processing time is appropriately determined depending on the material and surface state of the metal segment 12 to be selected or the metal member used as the material, the type and concentration of the surface treatment agent, the processing temperature, etc., and is, for example, 30 to 300 seconds. At this time, it is important that the etching amount in the depth direction of the metal segment 12 or the metal member as the material thereof is preferably 3 μm or more, more preferably 5 μm or more. The etching amount in the depth direction of the metal segment 12 or the metal member serving as the material thereof can be evaluated by calculating from the weight, specific gravity, and surface area of the dissolved metal segment 12 or the metal member serving as the material. The etching amount in the depth direction can be adjusted by the type and concentration of the surface treatment agent, the treatment temperature, the treatment time, and the like.
In the present embodiment, by adjusting the etching amount in the depth direction, the thickness of the roughened layer 104, the average depth of the recesses 201, Ra, Rz, and the like described above can be adjusted.

Finally, (3) post-treatment is performed on the metal segment 12 after chemical treatment or the surface of the metal member that is the material thereof. First, the metal segment 12 or the surface of the metal member that is the material thereof is washed with water and dried. Next, the chemically treated metal segment 12 or the surface of the metal member serving as the material thereof is treated with an aqueous nitric acid solution or the like.
The metal segment 12 which has the roughening layer 104 which concerns on this embodiment, or the metal member used as the raw material by the above procedure can be obtained.

(Resin member 14)
Next, the resin member 14 according to the present embodiment will be described.
The resin member 14 is formed by curing the thermosetting resin composition (P).

The thermosetting resin composition (P) includes a thermosetting resin (A), and examples of the thermosetting resin (A) include a phenol resin, an epoxy resin, an unsaturated polyester resin, a diallyl phthalate resin, and a melamine resin. Oxetane resin, maleimide resin, urea (urea) resin, polyurethane resin, silicone resin, resin having a benzoxazine ring, cyanate ester resin, and the like are used. These may be used alone or in combination of two or more.
Among these, the group consisting of phenolic resin, epoxy resin and melamine resin from the point of being able to bring the features of the resin material itself such as heat resistance, workability, mechanical properties, adhesion and rust prevention to the commutator The thermosetting resin composition containing 1 or more selected more is used suitably, and a glass fiber reinforced phenol resin and a melamine resin are especially preferable.
The content of the thermosetting resin (A) is preferably 10 parts by mass or more and 60 parts by mass or less, more preferably 15 parts by mass or more and 40 parts by mass or less, when the entire resin member 14 is 100 parts by mass. is there.

  Examples of the phenolic resin include novolak-type phenolic resins such as phenol novolak resin, cresol novolak resin, and bisphenol A type novolak resin; Examples thereof include resol type phenol resins such as oil-melted resol phenol resin; aryl alkylene type phenol resins and the like. These may be used alone or in combination of two or more.

  Among the phenol resins, it is preferable to use a novolac type phenol resin or a resol type phenol resin, and more preferably a resol type phenol resin, for reasons such as availability, low cost, and good workability by roll kneading. Moreover, a resol type phenol resin and a novolac type phenol resin can be used in combination. Thereby, while being able to raise the intensity | strength of the resin member 14, toughness can also be improved.

The thermosetting resin composition (P) includes the filler (B) from the viewpoint of improving the mechanical strength of the resin member 14. However, in this embodiment, the elastomer (D) described later is excluded from the filler (B).
The content of the filler (B) is preferably 30 parts by mass or more and 85 parts by mass or less, and more preferably 50 parts by mass or more and 80 parts by mass or less when the entire resin member 14 is 100 parts by mass. By making the content of the filler (B) within the above range, it is possible to further improve the mechanical strength of the resulting resin member 14 while improving the workability of the thermosetting resin composition (P). it can. Thereby, a resin-metal composite that is more excellent in the bonding strength between the resin member 14 and the metal segment 12 can be obtained. Moreover, the value of the linear expansion coefficient (alpha) _R of the resin member 14 obtained can be adjusted by adjusting the kind and content of a filler (B).

  Examples of the filler (B) include a fibrous filler, a granular filler, and a plate-like filler. Here, the fibrous filler is a filler whose shape is fibrous. The plate-like filler is a filler whose shape is plate-like. The granular filler is a filler having a shape other than a fiber or plate including an indefinite shape.

Examples of the fibrous filler include glass fiber, carbon fiber, asbestos fiber, metal fiber, wollastonite, attapulgite, sepiolite, rock wool, aluminum borate whisker, potassium titanate fiber, calcium carbonate whisker, and titanium oxide whisker. And fibrous inorganic fillers such as ceramic fibers; aramid fibers, polyimide fibers, and poly (fibrous organic fillers such as paraphenylene benzobisoxazole fibers). These may be used alone or in two kinds. You may use it in combination.
In addition, in this embodiment, it is preferable that glass fiber is contained as a thermosetting resin composition (P).

  Examples of the plate-like filler and granular filler include talc, kaolin clay, calcium carbonate, zinc oxide, calcium silicate hydrate, mica, glass flakes, glass powder, magnesium carbonate, silica, titanium oxide, Alumina, aluminum hydroxide, magnesium hydroxide, barium sulfate, calcium sulfate, calcium sulfite, zinc borate, barium metaborate, aluminum borate, calcium borate, sodium borate, aluminum nitride, boron nitride, silicon nitride, the above fibers For example, a pulverized product of a filler. These may be used alone or in combination of two or more.

When the filler (B) is 100 parts by mass as a whole, the filler (B) is a filler (B1) having an average particle diameter of more than 5 μm in the weight-based particle size distribution measured by the laser diffraction scattering particle size distribution measurement method. It is preferably contained in an amount of not less than 99 parts by mass and more preferably not less than 85 parts by mass and not more than 98 parts by mass. Thereby, the mechanical strength of the resin member 14 obtained can be further improved while improving the workability of the thermosetting resin composition (P). Although the upper limit of the average particle diameter of a filler (B1) is not specifically limited, For example, it is 100 micrometers or less.
More preferably, the filler (B1) includes a fibrous filler or a plate-like filler having an average major axis of 5 μm to 50 mm and an average aspect ratio of 1 to 1000.
The average major axis and average aspect ratio of the filler (B1) can be measured from an SEM photograph as follows, for example. First, a plurality of fibrous fillers or plate-like fillers are photographed with a scanning electron microscope. From the observation image, 50 fibrous fillers or plate-like fillers are arbitrarily selected, and their major diameters (fiber length in the case of fibrous fillers, planar major dimension in the case of plate-like fillers) and The short diameter (in the case of a fibrous filler, the fiber diameter, in the case of a plate-like filler, the dimension in the thickness direction) is measured. The average major axis is obtained by integrating all major axes and dividing by the number. Similarly, the average minor axis is obtained by integrating all minor axes and dividing by the number. The average major axis with respect to the average minor axis is defined as the average aspect ratio.

  The filler (B1) is preferably one or more selected from glass fiber, rock wool, wollastonite and the like. When such a filler (B1) is used, the mechanical strength of the resin member 14 can be particularly improved.

The filler (B) has an average particle size of 0.1 μm or more and 5 μm or less in a weight-based particle size distribution measured by a laser diffraction / scattering particle size distribution measurement method when the entire filler (B) is 100 parts by mass. The filler (B2) is preferably contained in an amount of 1 part by mass or more and 30 parts by mass or less, and more preferably 2 parts by mass or more and 15 parts by mass or less. Thereby, the filler (B) can be sufficiently present inside the recess 201. As a result, the mechanical strength of the region where the resin member 14 and the metal segment 12 have entered each other can be further improved.
As the filler (B2), the average major axis is preferably 0.1 μm or more and 100 μm or less, more preferably 0.2 μm or more and 50 μm or less, and the average aspect ratio is preferably 1 or more and 50 or less, more preferably 1 or more and 40 or less. It is more preferable to include a fibrous filler or a plate-like filler.
The average major axis and average aspect ratio of the filler (B2) can be measured from an SEM photograph as follows, for example. First, a plurality of fibrous fillers or plate-like fillers are photographed with a scanning electron microscope. From the observation image, 50 fibrous fillers or plate-like fillers are arbitrarily selected, and their major diameters (fiber length in the case of fibrous fillers, planar major dimension in the case of plate-like fillers) and The short diameter (in the case of a fibrous filler, the fiber diameter, in the case of a plate-like filler, the dimension in the thickness direction) is measured. The average major axis is obtained by integrating all major axes and dividing by the number. Similarly, the average minor axis is obtained by integrating all minor axes and dividing by the number. The average major axis with respect to the average minor axis is defined as the average aspect ratio.

  As such a filler (B2), one or two selected from wollastonite, kaolin clay, talc, calcium carbonate, rock wool, glass beads, silica, aluminum hydroxide, and calcium silicate hydrate More than species are preferred.

  Moreover, the thermosetting resin composition (P) can also contain a solid lubricant as a filler (B). As the solid lubricant, for example, one or more selected from Teflon (registered trademark), boron nitride, molybdenum disulfide, and melamine cyanurate are preferable. By including the solid lubricant, the friction coefficient of the resin member 14 is lowered.

  Further, the filler (B) may be subjected to a surface treatment with a coupling agent such as a silane coupling agent (C) described later.

  The thermosetting resin composition (P) may further contain a silane coupling agent (C). By including the silane coupling agent (C), the adhesion between the resin member 14 and the metal segment 12 can be improved. Further, by including the silane coupling agent (C), the affinity between the thermosetting resin (A) and the filler (B) is improved, and as a result, the mechanical strength of the resin member 14 is further improved. be able to.

  The content of the silane coupling agent (C) is not particularly limited because it depends on the specific surface area of the filler (B), but is preferably 0.01 parts by mass or more and 4 parts by mass with respect to 100 parts by mass of the filler (B). 0.0 part by mass or less, and more preferably 0.1 part by mass or more and 1.0 part by mass or less. When the content of the silane coupling agent (C) is within the above range, the mechanical strength of the resin member 14 can be further improved while sufficiently covering the filler (B).

Examples of the silane coupling agent (C) include epoxy groups such as γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, and β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane. -Containing alkoxysilane compounds; mercapto group-containing alkoxysilane compounds such as γ-mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane; γ-ureidopropyltriethoxysilane, γ-ureidopropyltrimethoxysilane, γ- (2- Ureido group-containing alkoxysilane compounds such as ureidoethyl) aminopropyltrimethoxysilane; γ-isocyanatopropyltriethoxysilane, γ-isocyanatopropyltrimethoxysilane, γ-isocyanatopropylmethyldimethoxy Isocyanato group-containing alkoxysilane compounds such as silane, γ-isocyanatopropylmethyldiethoxysilane, γ-isocyanatopropylethyldimethoxysilane, γ-isocyanatopropylethyldiethoxysilane, γ-isocyanatopropyltrichlorosilane; γ-amino Amino group-containing alkoxysilane compounds such as propyltriethoxysilane, γ- (2-aminoethyl) aminopropylmethyldimethoxysilane, γ- (2-aminoethyl) aminopropyltrimethoxysilane, γ-aminopropyltrimethoxysilane; Examples thereof include hydroxyl group-containing alkoxysilane compounds such as -hydroxypropyltrimethoxysilane and γ-hydroxypropyltriethoxysilane.
These may be used alone or in combination of two or more.

From the viewpoint of improving the toughness of the resin member 14, the thermosetting resin composition (P) according to the present embodiment may further include an elastomer (D). However, in this embodiment, the filler (B) described above is excluded from the elastomer (D).
The content of the elastomer (D) is preferably 1 part by mass or more and 10 parts by mass or less, and more preferably 1.5 parts by mass or more and 7 parts by mass or less when the entire resin member 14 is 100 parts by mass. . By setting the content of the elastomer (D) within the above range, the toughness of the resin member 14 can be further improved while maintaining the mechanical strength of the resin member 14. Thereby, a resin-metal composite that is more excellent in the bonding strength between the resin member 14 and the metal segment 12 can be obtained.

  Examples of the elastomer (D) include unmodified polyvinyl acetate, carboxylic acid-modified polyvinyl acetate, polyvinyl butyral, natural rubber, isoprene rubber, styrene / butadiene rubber, butadiene rubber, chloroprene rubber, butyl rubber, ethylene / propylene rubber Acrylic rubber, styrene / isoprene rubber, acrylonitrile / budadiene rubber, urethane rubber, silicon rubber, fluorine rubber and the like. These may be used alone or in combination of two or more. Among these, unmodified polyvinyl acetate, carboxylic acid-modified polyvinyl acetate, acrylic rubber, acrylonitrile / budadiene rubber, and polyvinyl butyral are preferable. When these elastomers (D) are used, the toughness of the resin member 14 can be particularly improved.

  The manufacturing method of a thermosetting resin composition (P) is not specifically limited, Generally, it can manufacture by a well-known method. For example, the following method is mentioned. First, the thermosetting resin (A), if necessary, a filler (B), a silane coupling agent (C), an elastomer (D), a curing agent, a curing aid, a release agent, a pigment, a flame retardant, A weathering agent, an antioxidant, a plasticizer, a lubricant, a sliding agent, a foaming agent, and the like are blended and mixed uniformly. Subsequently, the obtained mixture is heated, melted and kneaded by a kneading apparatus such as a roll, a kneader, or a twin screw extruder alone or in combination with a plurality of kneading apparatuses. Finally, the obtained mixture is granulated or pulverized to obtain a pellet-shaped or granular thermosetting resin composition (P).

The linear expansion coefficient α _R in the range from 25 ° C. to the glass transition temperature of the resin member 14 is preferably 10 ppm / ° C. or more and 50 ppm / ° C. or less, more preferably 15 ppm / ° C. or more and 45 ppm / ° C. or less. When the linear expansion coefficient α _R is within the above range, the reliability of the temperature cycle of the resin-metal composite can be further improved.

  The cured body of the thermosetting resin composition (P) of the present embodiment, that is, the glass transition temperature (Tg) of the resin member 14 is preferably 150 ° C. or higher, more preferably 180 ° C. or higher, and further preferably. Is 200 ° C. or higher. About the hardening body of a thermosetting resin composition (P), the reliability of the commutator 100 can be improved further by setting a glass transition temperature (Tg) as mentioned above.

The density of the resin member 14 is preferably 2.5 g / cm ³ or less, and more preferably 2.0 g / cm ³ or less, from the viewpoint of weight reduction.

  In addition, the resin member 14 preferably has a moisture-proof dielectric breakdown strength of 5 MV / m or more, more preferably 7 MV / m or more, after being subjected to a moisture resistance treatment at 40 ° C. and 90% RH for 1000 hours. By carrying out like this, the electrical insulation reliability of a resin metal composite can be improved further.

  When the thermosetting resin composition (P) containing the filler (B) is used, the filler (B) is present inside the recess 201, and the scanning electron microscope of the filler (B) present in the recess 201 is used. The average major axis by image analysis of photographs is preferably 0.1 μm or more and 5.0 μm or less, and more preferably 0.2 μm or more and 4 μm or less. Thereby, the mechanical strength of the area | region where the resin member 14 and the metal segment 12 penetrate | invaded mutually can be improved further.

  Moreover, the average aspect ratio of the filler (B) existing inside the recess 201 is preferably 1 or more and 50 or less, and more preferably 1 or more and 40 or less.

  The average major axis and average aspect ratio of the filler (B) present inside the recess 201 can be measured from the SEM photograph as follows. First, a cross section of the roughened layer 104 is photographed with a scanning electron microscope. From the observation image, 50 fillers (B) existing inside the recess 201 are arbitrarily selected, and their major diameters (fiber length in the case of fibrous fillers, and major axis in the planar direction in the case of plate-like fillers). Dimension) and a short diameter (in the case of a fibrous filler, the fiber diameter, in the case of a plate-like filler, the dimension in the thickness direction) are measured. The average major axis is obtained by integrating all major axes and dividing by the number. Similarly, the average minor axis is obtained by integrating all minor axes and dividing by the number. The average major axis with respect to the average minor axis is defined as the average aspect ratio.

  Further, the filler (B) present in the recess 201 is from the group consisting of wollastonite, kaolin clay, talc, calcium carbonate, rock wool, glass beads, silica, aluminum hydroxide, and calcium silicate hydrate. It is preferable that it is 1 type, or 2 or more types selected.

Moreover, when the resin member 14 contains an elastomer (D), the resin member 14 preferably has a sea-island structure, and the elastomer (D) is preferably present in the island phase.
With such a structure, the toughness of the resin member 14 can be improved and the impact resistance of the resin-metal composite can be improved. Therefore, the bonding strength between the resin member 14 and the metal segment 12 can be maintained even when an external impact is applied to the resin-metal composite.
The sea-island structure can be observed by scanning electron micrographs.

The average diameter by image analysis of the scanning electron micrograph of the island phase is preferably 0.1 μm or more and 100 μm or less, and more preferably 0.2 μm or more and 30 μm or less. When the average diameter of the island phase is within the above range, the toughness of the resin member 14 can be further improved and the impact resistance of the resin-metal composite can be further improved.
The average diameter of the island phase can be measured from a scanning electron microscope (SEM) photograph as follows. First, a cross section of the resin member 14 is photographed with a scanning electron microscope. From the observation image, 50 island phases existing in the resin member 14 are arbitrarily selected and their diameters are measured. The average diameter is the sum of the island phase diameters divided by the number.

<Manufacturing method of commutator>
The method for manufacturing the commutator 100 according to the present embodiment is not particularly limited as long as the resin metal composite can be molded so that the resin member 14 and the metal segment 12 are integrally adhered. Examples of a method capable of molding such a resin-metal composite include a transfer molding method, an injection molding method, a compression molding method, and an injection compression molding method. Moreover, although an example of the manufacturing method of the commutator of this embodiment is specifically mentioned later in an Example, the following processes are included, for example.
(A) The process which installs the metal segment 12 which has the roughening layer 104 in the joint surface closely_contact | adhered to a resin member at least, or the metal member used as the raw material in a metal mold | die.
(B) The thermosetting resin composition (P) is injected into the mold, and at least a part of the thermosetting resin composition (P) is in contact with the bonding surface, the thermosetting resin composition (P). Is a step of joining the resin member 14 made of the thermosetting resin composition (P) and the metal segment 12 or a metal member serving as a material thereof to obtain a resin-metal composite.
(C) A step of processing or polishing the outer periphery of the obtained resin-metal composite to obtain a commutator that has a roundness conforming to the standard and a step difference between the pieces.
In addition, when using the non-segmented integral metal member used as the raw material of the metal segment 12, the process of segmenting a metal member by carrying out an outer periphery process or a slit process after a (B) process as needed. Need to do.

  As mentioned above, although embodiment of this invention was described with reference to drawings, these are the illustrations of this invention, Various structures other than the above are also employable.

  Hereinafter, the present embodiment will be described in detail with reference to examples and comparative examples. In addition, this embodiment is not limited to description of these Examples at all.

Example 1
<Preparation of thermosetting resin composition (P1)>
34.0% by mass of novolac type phenolic resin (PR-51305, manufactured by Sumitomo Bakelite Co., Ltd.), 6.0% by mass of hexamethylenetetramine, glass fiber (CS3E479, manufactured by Nittobo Co., Ltd., average particle size: 11 μm, average major axis: 32.0 mm (average aspect ratio: 270) 52.0% by mass, wollastonite (manufactured by NYCO Minerals, NYAD5000, average particle size: 3 μm, average major axis: 9 μm) 6.0% by mass, γ-aminopropyltriethoxy Silane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) 0.2% by mass, magnesium oxide (manufactured by Kamishima Chemical Industry Co., Ltd.) 0.5% by mass, other components such as a lubricant 1.3% by mass, each dry-type The mixture is melted and kneaded with a heating roll at 90 ° C., cooled into a sheet, and pulverized to form a granular thermosetting resin composition P1) was obtained.

<Preparation of metal parts>
As a metal sheet not subjected to surface treatment, an oxygen-free copper C1020 metal sheet A (80 mm × 10 mm, thickness 1.0 mm, density 8.94 g / cm ³⁾ whose surface was sufficiently polished with # 4000 polishing paper. ) Was prepared. Separately, an aqueous solution of sulfuric acid (130 parts by mass), hydrogen peroxide (25 parts by mass), toluenesulfonic acid (5 parts by mass), and 5-phenyltetrazole (0.5 parts by mass) was prepared. In the obtained aqueous solution (30 ° C.), the metal sheet A was immersed and swung, and dissolved in the depth direction by 15 μm (calculated from the reduced weight of copper). Then, it washed with water and dried and obtained the metal sheet 1 (metal member).
In addition, about this metal sheet 1, the cross section of the recessed part was a shape which has a cross-sectional width larger than the cross-sectional width of an opening part in at least one part between the opening part of a recessed part and a bottom part.

<Production of metal resin composite>
A metal resin composite 1 was prepared using the obtained thermosetting resin composition (P1) and the metal sheet 1. Specifically, it was produced by the following procedure.
First, the metal sheet 1 having a thickness of 1 mm was placed in the mold without being fixed. Next, the thermosetting resin composition (P1) was heated so that the thickness after curing was 3 mm, and a predetermined amount was injected into the mold. At this time, the metal sheet 1 was pressed against the inner wall of the mold by the fluid pressure of the thermosetting resin composition (P1). Finally, the thermosetting resin composition (P1) was cured by compression molding to obtain a metal resin composite 1 that was a two-layer sheet of a resin member sheet having a thickness of 3 mm and a metal sheet 1 having a thickness of 1 mm. This metal resin composite 1 was used as a test piece 1. The compression molding conditions were an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes.

<Production of commutator>
A commutator made of a resin-metal composite was produced under the same conditions as those for producing the test piece 1. Specifically, a commutator 1 was obtained by preparing a cylindrical metal member, forming a thermosetting resin composition (P1) by transfer molding, and then segmenting the metal member. . The transfer molding conditions were an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes.

(Example 2)
Instead of wollastonite used in the thermosetting resin composition (P1), calcium silicate hydrate (manufactured by Ube Materials, Zonoheidi, average particle size: 0.1 to 0.5 μm, average major axis: A test piece 2 and a commutator 2 were produced in the same manner as in Example 1 except that the thermosetting resin composition (P2) was prepared using 6.0% by mass of 1 to 5 μm). About these, the measurement and evaluation which are mentioned later were performed.

(Example 3)
Instead of the thermosetting resin composition (P1), the following thermosetting resin composition (P3) was used, and a metal sheet 2 made of oxygen-free copper containing 0.03% silver was used as the metal sheet. Except for the above, a test piece 3 and a commutator 3 were produced in the same manner as in Example 1. About these, the measurement and evaluation which are mentioned later were performed.

<Preparation of thermosetting resin composition (P3)>
25.5% by mass of novolac-type phenolic resin (PR-51305, manufactured by Sumitomo Bakelite Co., Ltd.), 4.5% by mass of hexamethylenetetramine, glass fiber (CS3E479, manufactured by Nittobo Co., Ltd., average particle size: 11 μm, average major axis: 3 mm, average aspect ratio: 270) 61.0% by mass, wollastonite (manufactured by NYCO Minerals, NYAD5000, average particle size: 3 μm, average major axis: 9 μm) 7.0% by mass, γ-aminopropyltriethoxy Silane (manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903) 0.2% by mass, magnesium oxide (manufactured by Kamishima Chemical Industry Co., Ltd.) 0.5% by mass, other components such as a lubricant 1.3% by mass, each dry-type The mixture is melted and kneaded with a heating roll at 90 ° C., cooled into a sheet, and pulverized to form a granular thermosetting resin composition P3) was obtained.

(Comparative Example 1)
Instead of the metal sheet 1, a test piece 4 and a commutator 4 were produced by the same method as in Example 1 except that the metal sheet A that was not roughened was used. About these, the measurement and evaluation which are mentioned later were performed.

  The used thermosetting resin composition, metal member, test piece, and commutator were evaluated according to the following contents.

<Evaluation of thermosetting resin composition>
-Linear expansion coefficient (alpha) _M : The test piece used for a measurement was produced by performing transfer molding of the thermosetting resin composition on conditions with an effective pressure of 20 MPa, a mold temperature of 175 ° C, and a curing time of 3 minutes. About the obtained test piece, linear expansion in the range from 25 degreeC to the glass transition temperature of a resin member on the compression conditions of 5 degreeC / min using thermomechanical analyzer TMA (TA Instruments company make, EXSTAR6000). The coefficient α _M was measured. The unit is ppm.

-Electrical insulation resistance: The thermosetting resin composition was subjected to transfer molding under the conditions of an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes to prepare a test piece. Using the obtained test piece, the electrical insulation resistance of the test piece was measured in an atmosphere of 25 ° C. according to JIS K 6911. The unit is Ω.

Specific gravity: The thermosetting resin composition was subjected to transfer molding under the conditions of an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes to prepare a test piece. Using the obtained test piece, the specific gravity of the test piece was measured according to JIS K 6911 under an atmosphere of 25 ° C. The unit is g / cm ³ .

Bending strength: The thermosetting resin composition was subjected to transfer molding under the conditions of an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes to prepare a test piece. Using the obtained test piece, the bending strength of the test piece was measured in accordance with JIS K 6911 in an atmosphere of 25 ° C. The unit is MPa.

<Evaluation of metal parts>
-Evaluation of metal member surface (roughness of roughened layer, cross-sectional shape of recess, average depth of recess and average cross-sectional width of opening): surface of metal member was photographed with an electron microscope (SEM), and the surface of the metal member The structure of the roughened layer existing in the metal surface was observed, and the thickness of the roughened layer formed on the metal surface, the cross-sectional shape of the recess, the average depth of the recess, and the average cross-sectional width of the opening were evaluated. In addition, in FIG. 3, the electron micrograph showing the enlarged view of the roughening layer which exists in the surface of the metal sheet 1 obtained in Example 1 is shown. As shown in FIG. 3, it can be seen that fine concave portions are formed on the surface of the metal sheet 1. Moreover, the metal sheet 2 according to Example 3 also had the same surface structure as FIG. On the other hand, the metal sheet A obtained in Comparative Example 1 was not formed with a recess as shown in FIG.

-Surface roughness (Ra and Rz): The surface shape of the joint surface with the resin member in the metal member at a magnification of 20 was measured using an ultra-deep shape measuring microscope (manufactured by Keyence Corporation, VK9700). From the obtained measurement results, the arithmetic average roughness (Ra) and the 10-point average roughness (Rz) of the joint surface of the metal member with the resin member were determined according to JIS-B0601. The unit is μm.

Specific surface area: After vacuum-drying a metal member, which is a sample to be measured, at 120 ° C. for 6 hours, using an automatic specific surface area / pore distribution measuring device (BELSORPmini II, manufactured by Nippon Bell Co., Ltd.), nitrogen absorption at liquid nitrogen temperature is performed. The desorption amount was measured. The actual surface area by the nitrogen adsorption BET method was calculated from the BET plot. The specific surface area was calculated by dividing the actual surface area measured by the nitrogen adsorption BET method in this way by the apparent surface area.

<Evaluation of specimen>
-Observation of joint part of test piece (presence / absence of filler inside concave part, average major axis of filler inside concave part and average aspect ratio of filler inside concave part): electron microscope (SEM) The cross-sectional structure of the joint was observed, and the presence / absence of the filler inside the recess, the average major axis and the average aspect ratio of the filler present inside the recess were evaluated. In addition, in FIG. 4, the electron micrograph showing the enlarged view of the cross section of the junction part of the test piece 1 obtained in Example 1 is shown. As shown in FIG. 4, it can be seen that the filler is present in the recess formed on the surface of the metal sheet 1 of the test piece 1 obtained in Example 1. Further, the test pieces 2 and 3 obtained in Examples 2 and 3 also had a filler as in FIG. Further, the presence or absence of a filler present in the recess formed on the surface of the metal sheet 1 was also confirmed from energy dispersive X-ray fluorescence analysis.

-Tensile shear strength: The surface of two metal sheets having a width of 4 cm, a length of 10 cm, and a thickness of 3 mm was uniformly polished with a paper having a roughness of 60 and degreased. The two metal sheets were heated to 165 ° C., and the test specimen was molded and pressure-bonded at a curing time of 60 seconds by placing the thermosetting resin composition in an area of 32 cm ² (4 cm × 8 cm) as the measurement sample area. Was made. Using the obtained test piece, the tensile shear strength of two metal sheets was measured under the condition of a peeling speed of 5 mm / min. The unit is kN.

-Bending strength: The bending strength of the said test piece was measured according to JISK6911 in 25 degreeC atmosphere using the obtained test piece. The unit is MPa. Moreover, the bending strength was measured with the metal sheet placed on the lower side.

<Evaluation of commutator>
Rotational fracture strength: A metal member was inserted into the mold, and the thermosetting resin composition was transfer molded under conditions of an effective pressure of 20 MPa, a mold temperature of 175 ° C., and a curing time of 3 minutes, and then at 180 ° C. for 4 hours. After the after-curing, after-curing was further performed at 210 ° C. for 4 hours. Next, while the metal member was segmented by outer peripheral processing, the roundness and the step difference between the pieces were adjusted, and the test commutator shown in FIG. 5 was produced. The obtained commutator was rotated in an atmosphere at 250 ° C., the rotational speed was increased at a speed of 1000 rpm / sec, and the rotational speed at the time of failure was defined as the rotational fracture strength. The unit is rpm.

Step difference between one piece: After producing the test commutator used for the measurement of the above-mentioned rotational fracture strength by the same method and rotating the test commutator in an atmosphere of 250 ° C. at 30000 rpm for 10 minutes, At the central portion of the commutator in the height direction, the step between adjacent metal segments was measured with an all-round roundness meter, and the maximum step was measured. The unit is μm.

  The evaluation results regarding the above evaluation items are shown in Table 1 below together with the blending ratio of each component.

  The commutators of the examples all achieved excellent dimensional stability and excellent mechanical strength under high temperature and high speed rotation conditions, whereas the commutators of the comparative examples had dimensions. The required level was not satisfied in terms of either stability or mechanical strength.

12 Outer member (metal segment)
14 Inner member (cured body of resin member or thermosetting resin composition)
100 Commutator 103 Contact surface 104 Roughening layer 201 Recess 203 Opening 205 Bottom

Claims (7)

An inner member that is fixed to the rotating shaft of the motor and is constituted by a cured body of a thermosetting resin composition;
An outer member made of a metal member and in close contact with the outer peripheral surface of the inner member;
A commutator having a resin-metal composite comprising:
The thermosetting resin composition includes one or more thermosetting resins selected from the group consisting of phenol resins, epoxy resins, and melamine resins,
In the outer member, the close contact surface between the outer member and the inner member has a plurality of recesses,
The commutator in which the cross-sectional shape of the concave portion is a shape having a cross-sectional width larger than the cross-sectional width of the opening portion in at least a part between the opening portion and the bottom portion of the concave portion. The thermosetting resin composition further includes a filler,
The commutator according to claim 1, wherein a part of the filler is present inside the recess.   The commutator according to claim 2, wherein an average aspect ratio of the filler present in the concave portion is 1 or more and 50 or less.   The filler present in the interior of the recess is a kind selected from the group consisting of wollastonite, kaolin clay, talc, calcium carbonate, rock wool, glass beads, silica, aluminum hydroxide, and calcium silicate hydrate The commutator according to claim 2 or 3 which is two or more kinds.   The commutator according to any one of claims 1 to 4, wherein the metal member includes copper or a copper alloy. The commutator according to any one of claims 1 to 5, wherein a density of the inner member is 2.5 g / cm ³ or less.   The roughening layer provided with the said several recessed part is formed in the contact | adherence surface which the said inner side member and the said outer side member closely_contact | adhere, The thickness of the said roughening layer is 3 micrometers or more and 40 micrometers or less. The commutator as described in any one of thru | or 6.

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