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EP3018772B1 - Multi-layer carbon brush and method for producing same - Google Patents

Multi-layer carbon brush and method for producing same Download PDF

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Publication number
EP3018772B1
EP3018772B1 EP15192874.4A EP15192874A EP3018772B1 EP 3018772 B1 EP3018772 B1 EP 3018772B1 EP 15192874 A EP15192874 A EP 15192874A EP 3018772 B1 EP3018772 B1 EP 3018772B1
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EP
European Patent Office
Prior art keywords
boron nitride
layer
bonding agent
mixture
carbon brush
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP15192874.4A
Other languages
German (de)
French (fr)
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EP3018772A1 (en
Inventor
Rainer Sperling
Klaus-Georg Tontsch
Stefan Günther
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schunk Kohlenstofftechnik GmbH
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Schunk Kohlenstofftechnik GmbH
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Publication of EP3018772A1 publication Critical patent/EP3018772A1/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/18—Contacts for co-operation with commutator or slip-ring, e.g. contact brush
    • H01R39/20—Contacts for co-operation with commutator or slip-ring, e.g. contact brush characterised by the material thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/18—Contacts for co-operation with commutator or slip-ring, e.g. contact brush
    • H01R39/26—Solid sliding contacts, e.g. carbon brush
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/12—Manufacture of brushes

Definitions

  • the invention relates to a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between these insulating layer of electrically insulating material. Also, the invention relates to a method for producing a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one insulating layer of electrically insulating material extending between successive functional layers, wherein the layer of electrically conductive material or a this material containing the filler and the electrically insulating material are introduced into a mold in an order corresponding to the course of the layer of the multilayer carbon brush to be produced, then pressed and subsequently heat-treated.
  • a multi-layer carbon brush which has a plurality of electrically insulating glued together functional layers of particular carbon material.
  • the electrically insulating bond is an insulating layer.
  • multi-layer carbon brush carbon brushes known in which the layers are each electrically conductive, but optionally have different mechanical properties.
  • a corresponding carbon brush is the DE 91 06 977 U1 refer to.
  • the various layers - also called zones - which have different material compositions can be formed by successively introducing two starting layers with different material compositions into a mold before pressing the carbon brushes together and pressing them together. In this case, one zone may have a higher copper content than the other.
  • a designated as multilayer sliding contact carbon brush after the DE 44 30 745 A1 has layers, each consisting of conductive powder.
  • two conductive powders are simultaneously introduced into a mold in order to carry out a heat treatment after a compression step.
  • additional layers can be formed by supplying electrically conductive powder to the mold in succession.
  • a method for producing a laminate of carbon is the DE 33 07 090 A1 refer to.
  • sheets of a thermoplastic material are placed by pressing and heat treatment between stackable carbon layers, such as carbon fiber felt layers, to be exposed to desired pressures and temperatures.
  • the DE 199 02 938 A1 refers to a carbon brush, which consists of sections of different compositions.
  • the carbon brush is produced in a pressing process.
  • a starter carbon brush which consists of a first layer of a low-resistance material and an edge layer of a high-resistance material, which terminates from the running surface of the carbon brush at a distance from the opposite rear side surface.
  • the first and second layers are made together in a mold by filling powder into them, pressing, and then sintering.
  • Multilayer carbon brushes which consist of Kohleriegeln and running between these insulating layers are often used for smaller reversible motors such.
  • the insulating layer may consist of a film or of insulating adhesive or synthetic resin, one or more powder resins. Due to the higher transverse resistance, the current flowing between the two blades of a commutator covered by the carbon brush is reduced, thus improving the commutation.
  • the known multilayer carbon brushes of the type described above are usually produced in such a way that initially temperature-treated carbon plates are aligned with one another in order to then introduce a film between them. Then there is a mechanical processing, a custom machining and introduction of the ropes or strands.
  • a carbon brush which consists of a low-resistance layer and a high-resistance layer.
  • the latter consists of carbon material, binder and boron nitride.
  • Subject of the DE 195 49 195 A1 is a carbon brush for electric motors, which may be mixed as a lubricant molybdenum sulfide or boron nitride.
  • a corresponding carbon brush is also the EP 1 662 638 A1 refer to.
  • a multilayer carbon brush and a method for their preparation of the type mentioned is the EP 1 481 449 B1 refer to.
  • powder materials are layered in a mold, pressed and then heat treated.
  • powder materials come for the electric conductive functional layers mixtures of natural graphite, synthetic graphite, resin in question.
  • insulating materials phenolic resin powders are proposed.
  • the present invention is based on the object, a multi-layer carbon brush of the type mentioned in such a way that the insulating layer consisting of electrically insulating material has a desired uniform thickness over the entire height or length of the carbon brush. Also, a method is to be provided, with which the materials used to make the insulating layer are sufficiently flowable, so that introduced to form the electrically insulating layers in the mold, which is used for the production of the carbon brush, a good filling material can be so that the insulating layer of the finished carbon brush has the desired uniform thickness.
  • a multi-layer carbon brush of the type mentioned is proposed, which is characterized essentially by the fact that the electrically insulating material consists of a mixture of binder and boron nitride.
  • the binder is a resin, in particular phenolic resin.
  • pitch or a mixture of resin and pitch come into question.
  • the boron nitride is in particular boron nitride in the graphite-like hexagonal modification, which has good lubricant properties.
  • hexagonal boron nitride is to be specified as being particularly preferred, cubic boron nitride may optionally also be used.
  • a fine-grained mixture consisting of a binder, in particular phenolic resin, and boron nitride, or a granulate consisting of these materials, is sufficiently flowable, so that a shape in which the carbon brush is produced to the desired extent and evenly filled in height.
  • the insulating layer is formed from a compressed granules of a homogenized mixture, which consists of binder, in particular phenolic resin, and boron nitride, in particular hexagonal boron nitride, or contains.
  • the invention is also characterized by a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between them insulating layer of electrically insulating material, wherein the insulating layer consists of a compressed granules of a homogenized mixture, the Binder and boron nitride is.
  • the granules consist of grains of an average diameter between 1 .mu.m and 300 .mu.m.
  • the binder should be finer grained than the boron nitride, wherein for the binder 45 microns ⁇ d 90 ⁇ 50 microns, 15 microns ⁇ d 50 ⁇ 20 microns and 1 micron ⁇ d 10 ⁇ 5 microns should apply.
  • the mixture to be introduced into the mold is sufficiently fluid, on the one hand, when 3 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and 30 ⁇ m ⁇ d 50 ⁇ 40 ⁇ m and on the other hand if 30 ⁇ m ⁇ d 10 ⁇ 70 ⁇ m and 170 ⁇ m ⁇ d 50 ⁇ 220 ⁇ m.
  • the invention is therefore also characterized by a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between these insulating layer of electrically insulating material, wherein the insulating layer consists of a compressed granules of a homogenized mixture, the consisting of binder and boron nitride or binder and boron nitride, wherein the granules of grains having an average diameter between 1 .mu.m and 350 .mu.m, wherein in particular the boron nitride is in granular form and grain size values on the one hand 3 microns ⁇ d 10 ⁇ 5 microns and 30 microns ⁇ d 50 ⁇ 40 ⁇ m or, on the other hand, 30 ⁇ m ⁇ d 10 ⁇ 70 ⁇ m and 170 ⁇ m ⁇ d 50 ⁇ 220 ⁇ m and the grain size values for the binder are 1 ⁇ m ⁇ d 10
  • Powder form means that the starting product has a starting grain without the additional method of grain size change apply, as is the case in the production of granules, wherein in the manufacture of the granules in particular degrading processes are used as pressing and grinding.
  • the insulating layer is composed such that the proportion of the binder, in particular the phenolic resin, behaves to the proportion of boron nitride such as 2: 1 to 0.8: 1.
  • the binder which is, as mentioned, a resin and / or pitch, should have a maximum weight fraction of 60% by weight and a minimum weight fraction of 20% by weight of the electrically insulating material.
  • the weight ratios of boron nitride: binder should be 65% by weight: 35% by weight or 50% by weight: 50% by weight. In both ratio ranges, a flowable mixture is obtained which meets the requirements for producing an insulating layer.
  • a method for producing a multi-layer carbon brush is characterized in that as the electrically insulating material, a fine-grained powder and / or granules of a homogenized mixture is introduced into the mold, wherein the fine-grained powder or granules consists of a binder and boron nitride or contains a binder and boron nitride.
  • the binder should be phenolic resin and the boron tride hexagonal boron nitride.
  • the mixture does not contain carbon material.
  • the carbon material present in the binder is disregarded.
  • boron nitride that is to say in particular the hexagonal boron nitride, and binder powder are likewise preferred Phenolic resin powder, are homogenized and then, for example, by a constructive process, in particular fluidized bed process, the granules is produced.
  • a degrading process can also be used.
  • one or more bodies are first prepared by pressing from the homogenized mixture of the particular hexagonal boron nitride powder and the binder, such as phenolic resin, to then produce the granules of desired particle size, in particular by grinding the body or bodies.
  • the binder such as phenolic resin
  • cubic boron nitride could possibly also be used, although hexagonal boron nitride is particularly suitable and should be emphasized, which is used as constituent for the electrically insulating material together with a binder such as resin and / or pitch.
  • the invention is therefore also characterized by a method for producing a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one insulating layer of electrically insulating material extending between successive functional layers, wherein the electrically conductive material in layers or a material containing the electrical conductive material as a filler and the electrically insulating material in a sequence corresponding to the course of the multilayer carbon brush to be produced, then pressed and then heat treated, wherein as the electrically insulating material, a granulate consisting of a binder and boron nitride or Binder nitride and boron nitride is introduced into the mold, wherein previously boron nitride powder and binder powder are homogenized and either from so prepared mixture by a building process or mixture thus prepared is compressed to one or more bodies and then in a degrading process from the or the granules are produced to the bodies.
  • electrically conductive material such as carbon material
  • the binder powder used is in particular a powder having a particle size distribution of 1 to 100 ⁇ m. These values apply in particular to phenolic resin powders.
  • boron nitride powder one having a grain size distribution of 1 ⁇ m ⁇ d 50 ⁇ 10 ⁇ m can be used.
  • the binder should have a particle size of 1 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and / or 15 ⁇ m ⁇ d 50 ⁇ 20 ⁇ m and / or 45 ⁇ m ⁇ d 90 ⁇ 50 ⁇ m, in particular 1 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and 15 ⁇ m ⁇ d 50 ⁇ 20 ⁇ m and 45 ⁇ m ⁇ d 90 ⁇ 50 ⁇ m.
  • the pregranulated boron nitride has a particle size of 3 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and / or 30 ⁇ m ⁇ d 50 ⁇ 40 ⁇ m, in particular 3 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and 30 ⁇ m ⁇ d 50 ⁇ 40 ⁇ m, or the pregranulated boron nitride has a particle size of 30 ⁇ m ⁇ d 10 ⁇ 70 ⁇ m and / or 170 ⁇ m ⁇ d 50 ⁇ 220 ⁇ m, in particular 30 ⁇ m ⁇ d 10 ⁇ 70 ⁇ m and 170 ⁇ m ⁇ d 50 ⁇ 220 ⁇ m.
  • d 10 , d 50 or d 90 means that 10%, 50% or 90% of the particles present are smaller than the specified value for the diameter.
  • Pre-granulated means that the starting product is in granular form. Then, from the pre-granules and the binder, it is preferable to prepare the mixture by the above-described procedures, which is filled in the mold for producing the carbon brush.
  • the mixture can be prepared by an anabolic, but in particular by a degrading process.
  • the mixture of boron nitride and binder should be homogenized at room temperature.
  • the binder powder is mixed with the boron nitride powder in the ratio of 1: 2 to 1: 0.8, wherein preferably the proportion of phenolic resin powder can be equal to that of the boron nitride powder.
  • the proportions in each case relate to the weight of the mixture.
  • a mixture with 50 wt .-% boron nitride and 50 wt .-% of binder, in particular phenolic resin, is used.
  • binder such as phenolic resin powder and 65% by weight of boron nitride are mixed.
  • a resin is preferably used as the binder, it is also possible to completely or partially replace the resin by pitch.
  • the granules used according to the invention which are used for the insulating layer, can preferably be produced by the following methods.
  • an alternative hexagonal boron nitride and phenolic resin can be homogenized and the mixture thus produced is compressed and then roughly mined by crushing.
  • pre-granulated boron nitride and phenolic resin powder can be mixed. The relevant mixture is then used to produce the insulating layer. It is provided in particular that the pre-granulated boron nitride is coarse-grained than the phenolic resin.
  • the mean diameter of the boron nitride between 30 .mu.m and 50 .mu.m may be, wherein 3 microns ⁇ d 10 ⁇ 5 microns and 30 microns ⁇ d ⁇ 90 should be 40 microns.
  • the phenolic resin powder should have a particle size distribution of 1 ⁇ m ⁇ d 10 ⁇ 5 ⁇ m and / or 5 ⁇ m ⁇ d 50 ⁇ 20 ⁇ m and / or 45 ⁇ m ⁇ d 90 ⁇ 50 ⁇ m, wherein preferably all three value ranges should be fulfilled.
  • the electrically conductive material used is preferably a mixture of natural graphite and synthetic graphite. Based on its total weight fraction, about 25% by weight of resin, such as phenolic resin, and about 40% by weight of pitch can then be added to exemplify numerical values. h., a total of 100 weight units of natural graphite and synthetic graphite, 25 weight units of resin and 40 weight units of pitch, the latter based on the 100 weight units.
  • the invention relates to a method for producing a multi-layer carbon brush.
  • a multilayer carbon brush is understood to be one in which a functional layer of carbon material or an insulating layer which contains two electrically conductive material layers, also referred to as a carbon barrier, runs.
  • the teaching according to the invention comprises the production of multi-layer carbon brushes with two or more functional layers.
  • Fig. 1 is purely in principle a multi-layer carbon brush 10 with three carbon bars 12, 14, 16 shown, which are electrically isolated from each other via insulating layers 18.
  • the carbon bars 12, 14, 16 and the insulating layers 18 are perpendicular to the tread 20 of the carbon brush. From the running surface 20 opposite surface 22 is a tamping contact 24 with rope or stranded wire 26 from.
  • a tamping contact 24 with rope or stranded wire 26 from.
  • the materials forming the individual layers 12, 14, 16, 18 be introduced successively in the desired layer sequence into a die 28 of a pressing device 30.
  • a punch 32 is adjustably arranged to fill the die 28 with various materials to the desired extent. After filling the respective material forming a layer, excess material is removed by means of a slide 34. Then there is a pre-compression of the introduced material - after each filling of the material of each layer.
  • the desired materials - on the one hand from carbon and on the other hand electrically insulating material - have been introduced and after each introduction of the material for a layer precompressed, after filling the space of the die 28 with the material for the top layer performed a final compaction. Pre-compression and final compression takes place via a stamp 36.
  • the cross section of the die 28 is such that a multi-layer plate 38 results, which is divided after removal from the die 28 and heat treatment in the usual way in sections 40, 42, 44, the dimensions of which the produced multilayer Carbon brushes correspond. Then, a custom machining of the sections 40, 42, 44 and insertion of the rope in the usual manner.
  • plate 38 consists of the existing carbon material functional layers 46, 48, between which the existing electrically insulating material layer 50 extends, which has been prepared from a homogenized granular mixture of phenolic resin and hexagonal boron nitride.
  • the proportion by weight of phenolic resin should be between 60% and 30% and that of boron nitride between 40% and 70%.
  • the boron nitride is in particular hexagonal boron nitride, although cubic boron nitride could also be used.
  • the thickness of the layer 50 consisting of the electrically insulating material may be in the range between 30 ⁇ m and 400 ⁇ m, in particular in the range between 100 ⁇ m and 200 ⁇ m. Accordingly, the average diameters of the granules forming grains should be selected.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Description

Die Erfindung bezieht sich auf eine Mehrschicht-Kohlebürste mit zumindest zwei Funktionsschichten aus elektrisch leitendem Material, wie Kohlenstoffmaterial, und zumindest einer zwischen diesen vorhandenen Isolierschicht aus elektrisch isolierendem Material. Auch nimmt die Erfindung Bezug auf ein Verfahren zur Herstellung einer Mehrschicht-Kohlebürste mit zumindest zwei Funktionsschichten aus elektrisch leitendem Material, wie Kohlenstoffmaterial, und zumindest einer Isolierschicht aus elektrisch isolierendem Material, die zwischen aufeinander folgenden Funktionsschichten verläuft, wobei schichtweise das elektrisch leitende Material oder ein dieses als Füllstoff enthaltendes Material und das elektrisch isolierende Material in einer dem Schichtverlauf der herzustellenden Mehrschicht-Kohlebürste entsprechenden Reihenfolge in eine Form eingebracht, sodann verpresst und anschließend wärmebehandelt werden.
Der DE 199 13 599 A1 ist eine Mehrschicht-Kohlebürste zu entnehmen, die mehrere untereinander elektrisch isolierend verklebte Funktionsschichten aus insbesondere Kohlenstoffmaterial aufweist. Die elektrisch isolierende Verklebung stellt eine Isolierschicht dar.
Es sind auch als Mehrschicht-Kohlebürste bezeichnete Kohlebürsten bekannt, bei denen die Schichten jeweils elektrisch leitend sind, jedoch gegebenenfalls unterschiedliche mechanische Eigenschaften aufweisen. Eine entsprechende Kohlebürste ist der DE 91 06 977 U1 zu entnehmen. Die verschiedenen Schichten - auch Zonen genannt -, die unterschiedliche Materialzusammensetzungen aufweisen, können dadurch ausgebildet werden, dass vor dem Pressen der Kohlebürsten nacheinander zwei Ausgangsschichten mit unterschiedlichen Materialzusammensetzungen in eine Pressform eingebracht und zusammen miteinander verpresst werden. Dabei kann eine Zone einen höheren Kupferanteil als die andere aufweisen.The invention relates to a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between these insulating layer of electrically insulating material. Also, the invention relates to a method for producing a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one insulating layer of electrically insulating material extending between successive functional layers, wherein the layer of electrically conductive material or a this material containing the filler and the electrically insulating material are introduced into a mold in an order corresponding to the course of the layer of the multilayer carbon brush to be produced, then pressed and subsequently heat-treated.
Of the DE 199 13 599 A1 shows a multi-layer carbon brush, which has a plurality of electrically insulating glued together functional layers of particular carbon material. The electrically insulating bond is an insulating layer.
There are also known as multi-layer carbon brush carbon brushes known in which the layers are each electrically conductive, but optionally have different mechanical properties. A corresponding carbon brush is the DE 91 06 977 U1 refer to. The various layers - also called zones - which have different material compositions can be formed by successively introducing two starting layers with different material compositions into a mold before pressing the carbon brushes together and pressing them together. In this case, one zone may have a higher copper content than the other.

Eine als Vielschicht-Schleifkontakt bezeichnete Kohlebürste nach der DE 44 30 745 A1 weist Schichten auf, die jeweils aus leitendem Pulver bestehen. Zur Herstellung des Vielschicht-Schleifkontaktes werden in eine Form gleichzeitig zwei leitende Pulver eingefüllt, um nach einem Kompressionsschritt eine Wärmebehandlung durchzuführen. Neben dem Ausbilden von Schichten durch gleichzeitiges Einbringen von Pulver in eine Form können zusätzlich Schichten dadurch ausgebildet werden, dass elektrisch leitendes Pulver nacheinander der Form zugeführt wird.A designated as multilayer sliding contact carbon brush after the DE 44 30 745 A1 has layers, each consisting of conductive powder. In order to produce the multilayer sliding contact, two conductive powders are simultaneously introduced into a mold in order to carry out a heat treatment after a compression step. In addition to the formation of layers by simultaneous introduction of powder into a mold, additional layers can be formed by supplying electrically conductive powder to the mold in succession.

Aus der DE 636 540 C ist ein Verfahren zur Herstellung mehrschichtiger Kohlebürsten bekannt. Fertige Kohleschichten werden glatt geschliffen und zwischen zwei fertige Kohleschichten dickflüssiges Kunstharz mit Isolierstoff angeordnet, um sodann die Kohleschichten in einem geeigneten Presswerkzeug einzuspannen, um eine Trocknung in einem Ofen zu ermöglichen.From the DE 636 540 C a method for producing multilayer carbon brushes is known. Finished carbon layers are smoothed and placed between two finished carbon layers thick resin with insulating material, then to clamp the coal layers in a suitable pressing tool to allow drying in an oven.

Ein Verfahren zum Herstellen eines Schichtstoffes aus Kohlenstoff ist der DE 33 07 090 A1 zu entnehmen. Zur Erzielung gewünschter Endkörper werden durch Pressen und Wärmebehandlung zwischen übereinander anordbaren Kohlenstoffschichten, wie Kohlestofffilzschichten, Folien aus einem thermoplastischen Kunststoff angeordnet, um sodann gewünschten Drücken und Temperaturen ausgesetzt zu werden.A method for producing a laminate of carbon is the DE 33 07 090 A1 refer to. In order to obtain desired end bodies, sheets of a thermoplastic material are placed by pressing and heat treatment between stackable carbon layers, such as carbon fiber felt layers, to be exposed to desired pressures and temperatures.

Die DE 199 02 938 A1 bezieht sich auf eine Kohlebürste, die aus Abschnitten unterschiedlicher Stoffzusammensetzungen besteht. Die Kohlebürste wird dabei in einem Pressvorgang hergestellt.The DE 199 02 938 A1 refers to a carbon brush, which consists of sections of different compositions. The carbon brush is produced in a pressing process.

Aus der EP 1 128 496 A1 ist eine Starter-Kohlebürste bekannt, die aus einer ersten Schicht aus einem Material niedrigen Widerstands und einer Randschicht aus einem Material hohen Widerstandes besteht, die von der Lauffläche der Kohlebürste ausgehend im Abstand zur gegenüberliegenden Rückseitenfläche endet. Die erste und zweite Schicht werden gemeinsam in einer Form durch Einfüllen von Pulver in diese, Pressen und anschließendes Sintern hergestellt.From the EP 1 128 496 A1 is known a starter carbon brush, which consists of a first layer of a low-resistance material and an edge layer of a high-resistance material, which terminates from the running surface of the carbon brush at a distance from the opposite rear side surface. The first and second layers are made together in a mold by filling powder into them, pressing, and then sintering.

Mehrschicht-Kohlebürsten, die aus Kohleriegeln und zwischen diesen verlaufenden Isolierschichten bestehen, werden häufig für kleinere reversierbare Motoren wie z. B. Waschmaschinenmotoren eingesetzt. Die Isolierschicht kann dabei aus einer Folie oder aus isolierendem Klebstoff bzw. synthetischem Harz, einem oder mehreren Pulverharzen bestehen. Durch den höheren Querwiderstand wird der Strom, der zwischen den beiden von der Kohlebürste überdeckten Lamellen eines Kommutators fließt, reduziert und somit die Kommutierung verbessert.Multilayer carbon brushes, which consist of Kohleriegeln and running between these insulating layers are often used for smaller reversible motors such. B. used washing machine motors. The insulating layer may consist of a film or of insulating adhesive or synthetic resin, one or more powder resins. Due to the higher transverse resistance, the current flowing between the two blades of a commutator covered by the carbon brush is reduced, thus improving the commutation.

Die bekannten Mehrschicht-Kohlebürsten zuvor beschriebener Art werden üblicherweise derart hergestellt, dass zunächst temperaturbehandelte Kohlenstoffplatten zueinander ausgerichtet werden, um zwischen diesen sodann eine Folie einzubringen. Anschließend erfolgt eine mechanische Bearbeitung, eine Maßbearbeitung und Einbringen der Seile oder Litzen.The known multilayer carbon brushes of the type described above are usually produced in such a way that initially temperature-treated carbon plates are aligned with one another in order to then introduce a film between them. Then there is a mechanical processing, a custom machining and introduction of the ropes or strands.

Aus der DE 10 2005 057 063 A1 ist eine Kohlebürste bekannt, die aus einer Niedrigwiderstandsschicht und einer Hochwiderstandsschicht besteht. Letztere besteht aus Kohlenstoffmaterial, Bindemittel und Bornitrid.From the DE 10 2005 057 063 A1 is known a carbon brush, which consists of a low-resistance layer and a high-resistance layer. The latter consists of carbon material, binder and boron nitride.

Gegenstand der DE 195 49 195 A1 ist eine Kohlebürste für Elektromotoren, wobei als Schmiermittel Molybdänsulfid oder Bornitrid beigemischt sein kann. Eine entsprechende Kohlebürste ist auch der EP 1 662 638 A1 zu entnehmen.Subject of the DE 195 49 195 A1 is a carbon brush for electric motors, which may be mixed as a lubricant molybdenum sulfide or boron nitride. A corresponding carbon brush is also the EP 1 662 638 A1 refer to.

Eine Mehrschicht-Kohlebürste sowie ein Verfahren zu deren Herstellung der eingangs genannten Art ist der EP 1 481 449 B1 zu entnehmen. Zur Herstellung der Kohlebürste werden Pulvermaterialien schichtweise in eine Form eingebracht, verpresst und anschließend wärmebehandelt. Als Pulvermaterialien kommen für die elektrisch leitenden Funktionsschichten Mischungen aus Naturgraphit, synthetischem Graphit, Harz in Frage. Als isolierende Materialien werden Phenolharzpulver vorgeschlagen.A multilayer carbon brush and a method for their preparation of the type mentioned is the EP 1 481 449 B1 refer to. To produce the carbon brush, powder materials are layered in a mold, pressed and then heat treated. As powder materials come for the electric conductive functional layers mixtures of natural graphite, synthetic graphite, resin in question. As insulating materials, phenolic resin powders are proposed.

Beim Befüllen der Form hat sich jedoch gezeigt, dass die zur Herstellung der elektrisch isolierenden Schicht verwendeten Pulvermaterialien nicht im hinreichen Umfang fließfähig sind, um Schichten aufzubauen, die nach dem Verpressen die gewünschte gleichmäßige Dicke über die gesamte Höhe bzw. Länge der Kohlebürste aufweisen.When filling the mold, however, it has been shown that the powder materials used to produce the electrically insulating layer are not sufficiently flowable to build up layers having the desired uniform thickness over the entire height or length of the carbon brush after pressing.

Der vorliegenden Erfindung liegt die Aufgabe zu Grunde, eine Mehrschicht-Kohlebürste der eingangs genannten Art so weiterzubilden, dass die aus elektrisch isolierendem Material bestehende Isolierschicht eine gewünschte gleichmäßige Dicke über die gesamte Höhe bzw. Länge der Kohlebürste aufweist. Auch soll ein Verfahren zur Verfügung gestellt werden, mit dem die zur Herstellung der Isolierschicht verwendeten Materialien in hinreichendem Umfang fließfähig sind, so dass zur Bildung der elektrisch isolierenden Schichten in die Form, die für die Herstellung der Kohlebürste verwendet wird, ein gut füllendes Material eingebracht werden kann, so dass die Isolierschicht der fertigen Kohlebürste die gewünschte gleichmäßige Dicke aufweist.The present invention is based on the object, a multi-layer carbon brush of the type mentioned in such a way that the insulating layer consisting of electrically insulating material has a desired uniform thickness over the entire height or length of the carbon brush. Also, a method is to be provided, with which the materials used to make the insulating layer are sufficiently flowable, so that introduced to form the electrically insulating layers in the mold, which is used for the production of the carbon brush, a good filling material can be so that the insulating layer of the finished carbon brush has the desired uniform thickness.

Zur Lösung der Aufgabe wird eine Mehrschicht-Kohlebürste der eingangs genannten Art vorgeschlagen, die sich im Wesentlichen dadurch auszeichnet, dass das elektrisch isolierende Material aus einer Mischung aus Bindemittel und Bornitrid besteht. Insbesondere ist vorgesehen, dass das Bindemittel ein Harz, insbesondere Phenolharz, ist. Als Bindemittel kommen aber auch Pech oder eine Mischung aus Harz und Pech in Frage.To achieve the object, a multi-layer carbon brush of the type mentioned is proposed, which is characterized essentially by the fact that the electrically insulating material consists of a mixture of binder and boron nitride. In particular, it is provided that the binder is a resin, in particular phenolic resin. As a binder but also pitch or a mixture of resin and pitch come into question.

Bei dem Bornitrid handelt es sich insbesondere um Bornitrid in der graphitähnlichen hexagonalen Modifikation, das gute Schmiermitteleigenschaften aufweist.The boron nitride is in particular boron nitride in the graphite-like hexagonal modification, which has good lubricant properties.

Ist hexagonales Bornitrid als besonders bevorzugt anzugeben, so kann ggfs. auch kubisches Bornitrid verwendet werden.If hexagonal boron nitride is to be specified as being particularly preferred, cubic boron nitride may optionally also be used.

Überraschenderweise hat sich gezeigt, dass eine ein Bindemittel, insbesondere Phenolharz, und Bornitrid bestehende feinkörnige Mischung bzw. ein Granulat, das aus diesen Materialien besteht, hinreichend fließfähig ist, so dass sich eine Form, in der die Kohlebürste hergestellt wird, im gewünschten Umfang und in der Höhe gleichmäßig befüllen lässt.Surprisingly, it has been found that a fine-grained mixture consisting of a binder, in particular phenolic resin, and boron nitride, or a granulate consisting of these materials, is sufficiently flowable, so that a shape in which the carbon brush is produced to the desired extent and evenly filled in height.

In hervorzuhebender Ausgestaltung der Erfindung ist vorgesehen, dass die Isolierschicht aus einem verpressten Granulat aus einer homogenisierten Mischung gebildet ist, die aus Bindemittel, insbesondere Phenolharz, und Bornitrid, insbesondere hexagonalem Bornitrid, besteht oder diese enthält.In hervorzuhebender embodiment of the invention it is provided that the insulating layer is formed from a compressed granules of a homogenized mixture, which consists of binder, in particular phenolic resin, and boron nitride, in particular hexagonal boron nitride, or contains.

Die Erfindung zeichnet sich auch aus durch eine Mehrschicht-Kohlebürste mit zumindest zwei Funktionsschichten aus elektrisch leitendem Material, wie Kohlenstoffinaterial, und zumindest einer zwischen diesen vorhandenen Isolierschicht aus elektrisch isolierendem Material, wobei die Isolierschicht aus einem verpressten Granulat aus einer homogenisierten Mischung besteht, das aus Bindemittel und Bornitrid besteht.The invention is also characterized by a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between them insulating layer of electrically insulating material, wherein the insulating layer consists of a compressed granules of a homogenized mixture, the Binder and boron nitride is.

Insbesondere ist vorgesehen, dass das Granulat aus Körnern eines mittleren Durchmessers zwischen 1 µm und 300 µm besteht.In particular, it is provided that the granules consist of grains of an average diameter between 1 .mu.m and 300 .mu.m.

Das Bindemittel sollte feinkörniger als das Bornitrid sein, wobei für das Bindemittel 45 µm ≤ d90 ≤ 50 µm, 15 µm ≤ d50 ≤ 20 µm und 1 µm ≤ d10 ≤ 5 µm gelten sollte.The binder should be finer grained than the boron nitride, wherein for the binder 45 microns ≤ d 90 ≤ 50 microns, 15 microns ≤ d 50 ≤ 20 microns and 1 micron ≤ d 10 ≤ 5 microns should apply.

Hinsichtlich des Bornitrid hat sich überraschenderweise gezeigt, dass zwei bevorzugte Bereiche an Korngrößenverteilungen zu dem gewünschten Ergebnis führen, dass die in die Form einzufüllende Mischung hinreichend fließfähig ist, und zwar einerseits, wenn 3 µm ≤ d10 ≤ 5 µm und 30 µm ≤ d50 ≤ 40 µm und andererseits wenn 30 µm ≤ d10 ≤ 70 µm und 170 µm ≤ d50 ≤ 220 µm beträgt.With regard to the boron nitride, it has surprisingly been found that two preferred ranges of particle size distributions lead to the desired result that the mixture to be introduced into the mold is sufficiently fluid, on the one hand, when 3 μm ≦ d 10 ≦ 5 μm and 30 μm ≦ d 50 ≤ 40 μm and on the other hand if 30 μm ≤ d 10 ≤ 70 μm and 170 μm ≤ d 50 ≤ 220 μm.

Ferner kann das Granulat durch eine Korngrößenverteilung d90 = 250 µm und/oder 50 µm ≤ d50 ≤ 350 µm, insbesondere d50 = 100 µm, ausgezeichnet sein, insbesondere dann, wenn eine homogenisierte Mischung aus hexagonalem Bornitrid und Phenolharz verpresst und sodann grob abgebaut und zerkleinert wird.Furthermore, the granules can be distinguished by a particle size distribution d 90 = 250 μm and / or 50 μm ≦ d 50 ≦ 350 μm, in particular d 50 = 100 μm, in particular when a homogenized mixture of hexagonal boron nitride and phenolic resin is pressed and then roughly is mined and crushed.

Die Erfindung zeichnet sich daher auch aus durch eine Mehrschicht-Kohlebürste mit zumindest zwei Funktionsschichten aus elektrisch leitendem Material, wie Kohlenstoffmaterial, und zumindest einer zwischen diesen vorhandenen Isolierschicht aus elektrisch isolierendem Material, wobei die Isolierschicht aus einem verpressten Granulat aus einer homogenisierten Mischung besteht, das aus Bindemittel und Bornitrid besteht oder Bindemittel und Bornitrid enthält, wobei das Granulat aus Körnern eines mittleren Durchmessers zwischen 1 µm und 350 µm besteht, wobei insbesondere das Bornitrid in Granulatform vorliegt und Korngrößenwerte einerseits 3 µm ≤ d10 ≤ 5 µm und 30 µm ≤ d50 ≤ 40 µm oder andererseits 30 µm ≤ d10 ≤ 70 µm und 170 µm ≤ d50 ≤ 220 µm aufweist sowie die Korngrößenwerte für das Bindemittel 1 µm ≤ d10 ≤ 5 µm und 15 µm ≤ d50 ≤ 20 µm und 45 µm ≤ d90 ≤ 50 µm betragen. Dabei sollte das Bindemittel in Pulverform vorliegen.The invention is therefore also characterized by a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one existing between these insulating layer of electrically insulating material, wherein the insulating layer consists of a compressed granules of a homogenized mixture, the consisting of binder and boron nitride or binder and boron nitride, wherein the granules of grains having an average diameter between 1 .mu.m and 350 .mu.m, wherein in particular the boron nitride is in granular form and grain size values on the one hand 3 microns ≤ d 10 ≤ 5 microns and 30 microns ≤ d 50 ≤ 40 μm or, on the other hand, 30 μm ≤ d 10 ≤ 70 μm and 170 μm ≤ d 50 ≤ 220 μm and the grain size values for the binder are 1 μm ≤ d 10 ≤ 5 μm and 15 μm ≤ d 50 ≤ 20 μm and 45 μm ≤ d 90 ≤ 50 μm. The binder should be in powder form.

Pulverform bedeutet, dass das Ausgangsprodukt eine Ausgangskörnung aufweist, ohne das zusätzliche Verfahren zur Korngrößenveränderung zur Anwendung gelangen, wie dies bei der Herstellung von Granulat der Fall ist, wobei bei der Herstellung des Granulats insbesondere abbauende Verfahren zum Einsatz gelangen wie Pressen und Mahlen.Powder form means that the starting product has a starting grain without the additional method of grain size change apply, as is the case in the production of granules, wherein in the manufacture of the granules in particular degrading processes are used as pressing and grinding.

Die Isolierschicht ist insbesondere derart zusammengesetzt, dass der Anteil von dem Bindemittel, insbesondere dem Phenolharz, sich zu dem Anteil von Bornitrid verhält wie 2 : 1 bis 0,8 : 1 .In particular, the insulating layer is composed such that the proportion of the binder, in particular the phenolic resin, behaves to the proportion of boron nitride such as 2: 1 to 0.8: 1.

Bevorzugterweise sollte das Bindemittel, das erwähntermaßen ein Harz und/oder Pech ist, einen maximalen Gewichtsanteil von 60 Gew.-% und einen minimalen Gewichtsanteil von 20 Gew.-% des elektrisch isolierenden Materials betragen. Insbesondere sollten die Gewichtsverhältnisse von Bornitrid : Bindemittel 65 Gew.-% : 35 Gew.-% oder 50 Gew.-% : 50 Gew.-% betragen. In beiden Verhältnisbereichen erhält man eine fließfähige Mischung, die den Anforderungen zur Herstellung einer Isolierschicht genügen.Preferably, the binder, which is, as mentioned, a resin and / or pitch, should have a maximum weight fraction of 60% by weight and a minimum weight fraction of 20% by weight of the electrically insulating material. In particular, the weight ratios of boron nitride: binder should be 65% by weight: 35% by weight or 50% by weight: 50% by weight. In both ratio ranges, a flowable mixture is obtained which meets the requirements for producing an insulating layer.

Ein Verfahren zur Herstellung einer Mehrschicht-Kohlebürste, insbesondere zuvor erfolgter Charakterisierung, zeichnet sich dadurch aus, dass als das elektrisch isolierende Material ein feinkörniges Pulver und/oder ein Granulat einer homogenisierten Mischung in die Form eingebracht wird, wobei das feinkörnige Pulver bzw. das Granulat aus einem Bindemittel und Bornitrid besteht oder ein Bindemittel und Bornitrid enthält. Dabei sollte insbesondere das Bindemittel Phenolharz und das Borntrid hexagonales Bornitrid sein.A method for producing a multi-layer carbon brush, in particular previous characterization, is characterized in that as the electrically insulating material, a fine-grained powder and / or granules of a homogenized mixture is introduced into the mold, wherein the fine-grained powder or granules consists of a binder and boron nitride or contains a binder and boron nitride. In particular, the binder should be phenolic resin and the boron tride hexagonal boron nitride.

Dabei ist insbesondere vorgesehen, dass die Mischung Kohlenstoffmaterial nicht enthält. Dabei bleibt das in dem Bindemittel vorhandene Kohlenstoffmaterial unberücksichtigt.It is provided in particular that the mixture does not contain carbon material. In this case, the carbon material present in the binder is disregarded.

Hervorzuheben ist des Weiteren, dass zur Herstellung der Mehrschicht-Kohlebürste nach Einbringen von dem jeweils eine Schicht bildenden Material, dieses zunächst vorverdichtet wird, bevor das Material der nachfolgenden Schicht eingebracht wird. Ist das Material der letzten Schicht eingebracht, so erfolgt die Endverdichtung.It should also be emphasized that for the production of the multi-layer carbon brush after the introduction of each of the one layer forming material, this is first precompressed before the material of the subsequent layer is introduced. If the material of the last layer is introduced, the final compaction takes place.

In hervorzuhebender Ausgestaltung der Erfindung ist vorgesehen, dass Bornitrid, also insbesondere das hexagonale Bornitrid, und Bindemittelpulver, gleichfalls bevorzugt Phenolharzpulver, homogenisiert werden und sodann z.B. durch ein aufbauendes Verfahren, insbesondere Wirbelschichtverfahren, das Granulat hergestellt wird.In an embodiment of the invention to be emphasized, it is provided that boron nitride, that is to say in particular the hexagonal boron nitride, and binder powder are likewise preferred Phenolic resin powder, are homogenized and then, for example, by a constructive process, in particular fluidized bed process, the granules is produced.

Alternativ kann auch ein abbauendes Verfahren zum Einsatz gelangen. Dabei werden aus der homogenisierten Mischung aus dem insbesondere hexagonalen Bornitridpulver und dem Bindemittel, wie Phenolharz, durch Pressen zunächst ein oder mehrere Körper hergestellt, um sodann insbesondere durch Mahlen des bzw. der Körper das Granulat gewünschter Korngröße herzustellen.Alternatively, a degrading process can also be used. In this case, one or more bodies are first prepared by pressing from the homogenized mixture of the particular hexagonal boron nitride powder and the binder, such as phenolic resin, to then produce the granules of desired particle size, in particular by grinding the body or bodies.

Das Homogenisieren sollte bei Raumtemperatur durchgeführt werden.Homogenization should be done at room temperature.

Auch ist zu erwähnen, dass ggfs. auch kubisches Bornitrid verwendet werden könnte, gleichwenn hexagonales Bornitrid besonders geeignet und hervorzuheben ist, das als Bestandteil für das elektrisch isolierende Material zusammen mit einem Bindemittel wie Harz und/oder Pech zum Einsatz gelangt.It should also be mentioned that cubic boron nitride could possibly also be used, although hexagonal boron nitride is particularly suitable and should be emphasized, which is used as constituent for the electrically insulating material together with a binder such as resin and / or pitch.

Die Erfindung zeichnet sich daher auch aus durch ein Verfahren zur Herstellung einer Mehrschicht-Kohlebürste mit zumindest zwei Funktionsschichten aus elektrisch leitendem Material, wie Kohlenstoffmaterial, und zumindest einer Isolierschicht aus elektrisch isolierendem Material, die zwischen aufeinander folgenden Funktionsschichten verläuft, wobei schichtweise das elektrisch leitende Material oder ein das elektrische leitende Material als Füllstoff enthaltende Material und das elektrisch isolierende Material in einer dem Schichtverlauf der herzustellenden Mehrschicht-Kohlebürste entsprechenden Reihenfolge in eine Form eingebracht, sodann verpresst und anschließend wärmebehandelt werden, wobei als das elektrisch isolierende Material ein Granulat bestehend aus einem Bindemittel und Bornitrid oder Bindemittel und Bornitrid enthaltend in die Form eingebracht wird, wobei zuvor Bornitrid-Pulver und Bindemittelpulver homogenisiert werden und entweder aus so hergestellter Mischung durch ein aufbauendes Verfahren oder so hergestellte Mischung zu einem oder mehreren Körpern verpresst wird und sodann in einem abbauenden Verfahren aus dem bzw. den Körpern das Granulat hergestellt wird.The invention is therefore also characterized by a method for producing a multi-layer carbon brush with at least two functional layers of electrically conductive material, such as carbon material, and at least one insulating layer of electrically insulating material extending between successive functional layers, wherein the electrically conductive material in layers or a material containing the electrical conductive material as a filler and the electrically insulating material in a sequence corresponding to the course of the multilayer carbon brush to be produced, then pressed and then heat treated, wherein as the electrically insulating material, a granulate consisting of a binder and boron nitride or Binder nitride and boron nitride is introduced into the mold, wherein previously boron nitride powder and binder powder are homogenized and either from so prepared mixture by a building process or mixture thus prepared is compressed to one or more bodies and then in a degrading process from the or the granules are produced to the bodies.

Als Bindemittelpulver wird insbesondere ein Pulver einer Korngrößenverteilung 1 bis 100 µm verwendet. Diese Werte gelten insbesondere für Phenolharzpulver.The binder powder used is in particular a powder having a particle size distribution of 1 to 100 μm. These values apply in particular to phenolic resin powders.

Als Bornitridpulver kann ein solches verwendet werden, das eine Korngrößenverteilung 1 µm ≤ d50 ≤ 10 µm aufweist.As the boron nitride powder, one having a grain size distribution of 1 μm ≦ d 50 ≦ 10 μm can be used.

Insbesondere ist jedoch vorgesehen, dass eine homogenisierte Mischung aus Bornitrid, vorzugsweise vorgranuliertem Bornitrid, insbesondere hexagonales Bornitrid, und Bindemittel, insbesondere Phenolharz, verpresst, anschließend die verpresste Mischung zu einem Granulat aufgemahlen und sodann in die Form eingebracht wird, wobei die Korngröße des aufgemahlenen Granulats insbesondere beträgt d10 = 10 µm und /oder d50 = 180 µm und/oder d90 = 325 µm.In particular, however, it is provided that a homogenized mixture of boron nitride, preferably pregranulated boron nitride, in particular hexagonal boron nitride, and binder, in particular phenolic resin, pressed, then the pressed mixture is ground to a granulate and then introduced into the mold, wherein the grain size of the ground granules in particular, d 10 = 10 μm and / or d 50 = 180 μm and / or d 90 = 325 μm.

Hervorzuheben ist auch, dass das Bornitrid grobkörniger als das Bindemittel ist. Dabei sollte das Bindemittel eine Korngröße 1 µm ≤ d10 ≤ 5 µm und/oder 15 µm ≤ d50 ≤ 20 µm und/oder 45 µm ≤ d90 ≤ 50 µm, insbesondere 1 µm ≤ d10 ≤ 5 µm und 15 µm ≤ d50 ≤ 20 µm und 45 µm ≤ d90 ≤ 50 µm, aufweisen.It should also be emphasized that the boron nitride is coarser than the binder. The binder should have a particle size of 1 μm ≤ d 10 ≤ 5 μm and / or 15 μm ≤ d 50 ≤ 20 μm and / or 45 μm ≤ d 90 ≤ 50 μm, in particular 1 μm ≤ d 10 ≤ 5 μm and 15 μm ≤ d 50 ≤ 20 μm and 45 μm ≤ d 90 ≤ 50 μm.

Insbesondere ist vorgesehen, dass das vorgranulierte Bornitrid eine Korngröße 3 µm ≤ d10 ≤ 5 µm und/oder 30 µm ≤ d50 ≤ 40 µm, insbesondere 3 µm ≤ d10 ≤ 5 µm und 30 µm ≤ d50 ≤ 40 µm, oder das vorgranulierte Bornitrid eine Korngröße 30 µm ≤ d10 ≤ 70 µm und/oder 170 µm ≤ d50 ≤ 220 µm, insbesondere 30 µm ≤ d10 ≤ 70 µm und 170 µm ≤ d50 ≤ 220 µm aufweist.In particular, it is provided that the pregranulated boron nitride has a particle size of 3 μm ≦ d 10 ≦ 5 μm and / or 30 μm ≦ d 50 ≦ 40 μm, in particular 3 μm ≦ d 10 ≦ 5 μm and 30 μm ≦ d 50 ≦ 40 μm, or the pregranulated boron nitride has a particle size of 30 μm ≦ d 10 ≦ 70 μm and / or 170 μm ≦ d 50 ≦ 220 μm, in particular 30 μm ≦ d 10 ≦ 70 μm and 170 μm ≦ d 50 ≦ 220 μm.

d10, d50 bzw. d90 bedeutet, dass 10 %, 50 % bzw. 90 % der vorhandenen Partikel kleiner als der angegebene Wert für den Durchmesser sind.d 10 , d 50 or d 90 means that 10%, 50% or 90% of the particles present are smaller than the specified value for the diameter.

Vorgranuliert bedeutet, dass das Ausgangsprodukt in Granulatform vorliegt. Sodann wird aus dem Vorgranulat und dem Bindemittel bevorzugterweise nach zuvor beschriebenen Verfahrensweisen die Mischung hergestellt, die in die Form zur Herstellung der Kohlebürste gefüllt wird.Pre-granulated means that the starting product is in granular form. Then, from the pre-granules and the binder, it is preferable to prepare the mixture by the above-described procedures, which is filled in the mold for producing the carbon brush.

Dabei kann unmittelbar ein Homogenisieren mit dem Bindemittel erfolgen, um die Mischung zu erhalten. Alternativ kann durch ein aufbauendes, insbesondere jedoch durch ein abbauendes Verfahren die Mischung hergestellt werden.It can be done directly homogenizing with the binder to obtain the mixture. Alternatively, the mixture can be prepared by an anabolic, but in particular by a degrading process.

Insbesondere sollte die Mischung aus Bornitrid und Bindemittel bei Zimmertemperatur homogenisiert werden.In particular, the mixture of boron nitride and binder should be homogenized at room temperature.

Insbesondere ist vorgesehen, dass das Bindemittelpulver mit dem Bornitridpulver im Verhältnis von 1 : 2 bis 1 : 0.8 gemischt wird, wobei bevorzugterweise der Anteil von Phenolharzpulver gleich dem des Bornitridpulvers sein kann. Die Anteile beziehen sich dabei jeweils auf das Gewicht der Mischung.In particular, it is provided that the binder powder is mixed with the boron nitride powder in the ratio of 1: 2 to 1: 0.8, wherein preferably the proportion of phenolic resin powder can be equal to that of the boron nitride powder. The proportions in each case relate to the weight of the mixture.

Bevorzugterweise wird eine Mischung mit 50 Gew.-% Bornitrid und 50 Gew.-% Bindemittel, insbesondere Phenolharz, verwendet. Gute Ergebnisse lassen sich jedoch auch dann erreichen, wenn 35 Gew.-% Bindemittel, wie Phenolharzpulver, und 65 Gew.-% Bornitrid gemischt werden.Preferably, a mixture with 50 wt .-% boron nitride and 50 wt .-% of binder, in particular phenolic resin, is used. However, good results can be achieved even if 35% by weight of binder such as phenolic resin powder and 65% by weight of boron nitride are mixed.

In beiden Verhältnisbereichen ist eine fließfähige Mischung erzielbar, die problemlos in die Form gefüllt werden kann, in der die Kohlebürste hergestellt wird.In both ratio ranges, a flowable mixture can be achieved, which can be easily filled into the mold in which the carbon brush is produced.

Wird als Bindemittel bevorzugterweise ein Harz verwendet, so besteht auch die Möglichkeit, das Harz ganz oder teilweise durch Pech zu ersetzen.If a resin is preferably used as the binder, it is also possible to completely or partially replace the resin by pitch.

Das erfindungsgemäß zum Einsatz gelangende Granulat, das für die Isolierschicht benutzt wird, ist bevorzugterweise durch nachstehende Verfahren herstellbar. So kann nach einer Alternative hexagonales Bornitrid und Phenolharz homogenisiert werden und die so hergestellte Mischung verspresst und anschließend durch Zerkleinern grob abgebaut werden. Dabei werden Granulatkörner eines mittleren Durchmessers zwischen 125 µm und 250 µm erzielt, wobei die Korngrößenverteilung d90 = 250 µm und d50 zwischen 50 µm und 350 µm betragen sollte.The granules used according to the invention, which are used for the insulating layer, can preferably be produced by the following methods. Thus, after an alternative hexagonal boron nitride and phenolic resin can be homogenized and the mixture thus produced is compressed and then roughly mined by crushing. In this case, granules of an average diameter between 125 microns and 250 microns are achieved, the grain size distribution d 90 = 250 microns and d 50 should be between 50 microns and 350 microns.

Alternativ kann bereits vorgranuliertes Bornitrid und Phenolharzpulver gemischt werden. Die diesbezügliche Mischung wird sodann zur Herstellung der Isolierschicht verwendet. Dabei ist insbesondere vorgesehen, dass das vorgranulierte Bornitrid grobkörniger als das Phenolharz ist. So kann der mittlere Durchmesser der Bornitridkörner zwischen 30 µm und 50 µm liegen, wobei 3 µm ≤ d10 ≤ 5 µm und 30 µm ≤ d90 ≤ 40 µm betragen sollte. Das Phenolharzpulver sollte eine Korngrößenverteilung 1 µm ≤ d10 ≤ 5 µm und/oder 5 µm ≤ d50 ≤ 20 µm und /oder 45 µm ≤ d90 ≤ 50 µm aufweisen, wobei bevorzugterweise alle drei Wertebereiche erfüllt sein sollten.Alternatively, pre-granulated boron nitride and phenolic resin powder can be mixed. The relevant mixture is then used to produce the insulating layer. It is provided in particular that the pre-granulated boron nitride is coarse-grained than the phenolic resin. Thus, the mean diameter of the boron nitride between 30 .mu.m and 50 .mu.m may be, wherein 3 microns ≤ d 10 ≤ 5 microns and 30 microns ≤ d ≤ 90 should be 40 microns. The phenolic resin powder should have a particle size distribution of 1 μm ≦ d 10 ≦ 5 μm and / or 5 μm ≦ d 50 ≦ 20 μm and / or 45 μm ≦ d 90 ≦ 50 μm, wherein preferably all three value ranges should be fulfilled.

Als elektrisch leitendes Material wird vorzugsweise eine Mischung aus Naturgraphit und synthetischem Graphit benutzt. Bezogen auf dessen Gesamtgewichtsanteil können sodann in etwa 25 Gew.-% Harz, wie Phenolharz, und in etwa 40 Gew.-% Pech hinzugegeben werden, um beispielhaft Zahlenwerte anzugeben, d. h., insgesamt 100 Gewichtseinheiten Naturgraphit und synthetisches Graphit, 25 Gewichtseinheiten Harz und 40 Gewichtseinheiten Pech, letztere bezogen jeweils auf die 100 Gewichtseinheiten.The electrically conductive material used is preferably a mixture of natural graphite and synthetic graphite. Based on its total weight fraction, about 25% by weight of resin, such as phenolic resin, and about 40% by weight of pitch can then be added to exemplify numerical values. h., a total of 100 weight units of natural graphite and synthetic graphite, 25 weight units of resin and 40 weight units of pitch, the latter based on the 100 weight units.

Weitere Einzelheiten, Vorteile und Merkmale der Erfindung ergeben sich nicht nur aus den Ansprüchen, den diesen zu entnehmenden Merkmalen - für sich und/oder in Kombination-, sondern auch aus der nachfolgenden Beschreibung von der Zeichnung zu entnehmenden bevorzugten Ausführungsbeispielen.For more details, advantages and features of the invention will become apparent not only from the claims, the features to be taken these features - alone and / or in combination, but also from the following description of the drawing to be taken preferred embodiments.

Es zeigen:

Fig. 1
eine Prinzipdarstellung einer Mehrschicht-Kohlebürste mit drei Funktions schichten,
Fig. 2
einen Teil der Kohlebürste nach Fig. 1,
Fig. 3
eine Prinzipdarstellung einer Form zur Herstellung von Platten und
Fig. 4
Mehrschicht-Platten zur Herstellung von Mehrschicht-Kohlebürsten.
Show it:
Fig. 1
a schematic diagram of a multi-layer carbon brush with three functional layers,
Fig. 2
a part of the carbon brush after Fig. 1 .
Fig. 3
a schematic diagram of a mold for the production of plates and
Fig. 4
Multi-layer boards for the production of multi-layer carbon brushes.

Die Erfindung bezieht sich auf ein Verfahren zur Herstellung einer Mehrschicht-Kohlebürste. Unter Mehrschicht-Kohlebürste wird dabei eine solche verstanden, bei der zwischen zwei aus elektrisch leitendem Material bestehenden auch als Kohleriegel bezeichneten Funktionsschichten aus Kohlenstoffmaterial oder dieses enthaltend eine Isolierschicht verläuft. Dabei umfasst die erfindungsgemäße Lehre die Herstellung von Mehrschicht-Kohlebürsten mit zwei oder mehr Funktionsschichten.The invention relates to a method for producing a multi-layer carbon brush. A multilayer carbon brush is understood to be one in which a functional layer of carbon material or an insulating layer which contains two electrically conductive material layers, also referred to as a carbon barrier, runs. The teaching according to the invention comprises the production of multi-layer carbon brushes with two or more functional layers.

In Fig. 1 ist rein prinzipiell eine Mehrschicht-Kohlebürste 10 mit drei Kohleriegeln 12, 14, 16 dargestellt, die gegeneinander über Isolierschichten 18 elektrisch isoliert sind.In Fig. 1 is purely in principle a multi-layer carbon brush 10 with three carbon bars 12, 14, 16 shown, which are electrically isolated from each other via insulating layers 18.

Die Kohleriegel 12, 14, 16 sowie die Isolierschichten 18 verlaufen senkrecht zur Lauffläche 20 der Kohlebürste. Von der der Lauffläche 20 gegenüberliegenden Fläche 22 geht ein Stampfkontakt 24 mit Seil bzw. Litze 26 aus. Insoweit wird jedoch auf hinlänglich bekannte Bauarten von Mehrschicht-Kohlebürsten zuvor beschriebener Art verwiesen.The carbon bars 12, 14, 16 and the insulating layers 18 are perpendicular to the tread 20 of the carbon brush. From the running surface 20 opposite surface 22 is a tamping contact 24 with rope or stranded wire 26 from. In that regard, however, reference is made to well-known types of multi-layer carbon brushes of the type described above.

Zur Herstellung von Mehrschicht-Kohlebürsten wird erfindungsgemäß vorgeschlagen, dass die die einzelnen Schichten 12, 14, 16, 18 bildenden Materialien nacheinander in der gewünschten Schichtreihenfolge in ein Gesenk 28 einer Pressvorrichtung 30 eingebracht werden. In dem Gesenk 28 ist ein Stempel 32 verstellbar angeordnet, um im gewünschten Umfang das Gesenk 28 mit verschiedenen Materialien zu füllen. Nach dem Einfüllen des jeweiligen eine Schicht bildenden Materials wird mittels eines Schiebers 34 überschüssiges Material entfernt. Sodann erfolgt ein Vorverdichten des eingebrachten Materials - und zwar nach jeweiligem Befüllen des Materials einer jeden Schicht.In order to produce multilayer carbon brushes, it is proposed according to the invention that the materials forming the individual layers 12, 14, 16, 18 be introduced successively in the desired layer sequence into a die 28 of a pressing device 30. In the die 28, a punch 32 is adjustably arranged to fill the die 28 with various materials to the desired extent. After filling the respective material forming a layer, excess material is removed by means of a slide 34. Then there is a pre-compression of the introduced material - after each filling of the material of each layer.

Nachdem in das Gesenk 28 schichtweise die gewünschten Materialien - einerseits aus Kohlenstoff und andererseits aus elektrisch isolierendem Material - eingebracht worden sind und nach jedem Einbringen des Materials für eine Schicht ein Vorverdichten erfolgt ist, wird nach Befüllen des Freiraums des Gesenks 28 mit dem Material für die oberste Schicht eine Endverdichtung durchgeführt. Vorverdichten und Endverdichten erfolgt über einen Stempel 36.After layering in the die 28, the desired materials - on the one hand from carbon and on the other hand electrically insulating material - have been introduced and after each introduction of the material for a layer precompressed, after filling the space of the die 28 with the material for the top layer performed a final compaction. Pre-compression and final compression takes place via a stamp 36.

Dabei ist vorzugsweise vorgesehen, dass der Querschnitt des Gesenks 28 derart ist, dass sich eine Mehrschichtplatte 38 ergibt, die nach Entfernen aus dem Gesenk 28 und Wärmebehandlung in gewohnter Weise in Abschnitte 40, 42, 44 unterteilt wird, deren Abmessungen denen der herzustellenden Mehrschicht-Kohlebürsten entsprechen. Sodann erfolgt eine Maßbearbeitung der Abschnitte 40, 42, 44 und Einsetzen des Seils in gewohnter Weise.It is preferably provided that the cross section of the die 28 is such that a multi-layer plate 38 results, which is divided after removal from the die 28 and heat treatment in the usual way in sections 40, 42, 44, the dimensions of which the produced multilayer Carbon brushes correspond. Then, a custom machining of the sections 40, 42, 44 and insertion of the rope in the usual manner.

Die in Fig. 4 dargestellte Platte 38 besteht aus den aus Kohlenstoffmaterial bestehenden Funktionsschichten 46, 48, zwischen denen die aus elektrisch isolierendem Material bestehende Schicht 50 verläuft, die aus einem homogenisierten Granulatgemisch aus Phenolharz und hexagonalem Bornitrid hergestellt worden ist. Dabei sollte der Gewichtsanteil von Phenolharz zwischen 60 % und 30 % und der des Bornitrids zwischen 40 % und 70 % liegen.In the Fig. 4 shown plate 38 consists of the existing carbon material functional layers 46, 48, between which the existing electrically insulating material layer 50 extends, which has been prepared from a homogenized granular mixture of phenolic resin and hexagonal boron nitride. The proportion by weight of phenolic resin should be between 60% and 30% and that of boron nitride between 40% and 70%.

Bei dem Bornitrid handelt es sich insbesondere um hexagonales Bornitrid, gleichwenn auch kubisches Bornitrid verwendet werden könnte.The boron nitride is in particular hexagonal boron nitride, although cubic boron nitride could also be used.

Die Dicke der aus dem elektrisch isolierenden Material bestehenden Schicht 50 kann im Bereich zwischen 30 µm und 400 µm, insbesondere im Bereich zwischen 100 µm und 200 µm liegen. Entsprechend sind die mittleren Durchmesser der das Granulat bildenden Körner auszuwählen.The thickness of the layer 50 consisting of the electrically insulating material may be in the range between 30 μm and 400 μm, in particular in the range between 100 μm and 200 μm. Accordingly, the average diameters of the granules forming grains should be selected.

Claims (15)

  1. Method for the production of a multi-layer carbon brush (10) having at least two functional layers (12, 14, 16) made from electrically conducting material and at least one insulating layer (18) made from electrically insulating material which runs between successive functional layers, wherein the electrically conducting material, or a material containing the electrically conducting material as a filler, and the electrically insulating material are introduced layer-by-layer into a mould (28) in an order corresponding to the layer progression of the multi-layer carbon brush to be produced, then pressed and subsequently heat-treated,
    wherein a finely granulated powder and/or a granulate of a homogenised mixture is introduced into the mould (28) as the electrically insulating material,
    characterized in that
    the electrically insulating material consists of a bonding agent and boron nitride.
  2. Method according to Claim 1,
    characterized in that
    a homogenised mixture of pre-granulated boron nitride, in particular hexagonal boron nitride, and bonding agent, in particular phenolic resin, is introduced into the mould (28).
  3. Method according to Claim 1,
    characterized in that
    a homogenised mixture of boron nitride, preferably pre-granulated boron nitride, in particular hexagonal boron nitride, and bonding agent, in particular phenolic resin, is pressed and the pressed mixture is then ground to form a granulate and then introduced into the mould (28).
  4. Method according to Claim 1,
    characterized in that
    the grain size of the ground granulate is d10 = 10 µm and/or d50 = 180 µm and/or d90 = 325 µm.
  5. Method according to one of claims 1 to 4,
    characterized in that
    the boron nitride has coarser grains than the bonding agent.
  6. Method according to one of claims 1 to 5,
    characterized in that
    the bonding agent has a grain size 1 µm ≤ d10 ≤ 5 µm and/or 15 µm ≤ d50 ≤ 20 µm and/or 45 µm ≤ d90 ≤ 50 µm.
  7. Method according to Claim 5,
    characterized in that
    the pre-granulated boron nitride has a grain size 3 µm ≤ d10 ≤ 5 µm and/or 30 µm ≤ d50 ≤ 40 µm, in particular 3 µm ≤ d10 ≤ 5 µm and 30 µm ≤ d50 ≤ 40 µm, or the pre-granulated boron nitride has a grain size 30 µm ≤ d10 ≤ 70 µm and/or 170 µm ≤ d50 ≤ 220 µm, in particular 30 µm ≤ d10 ≤ 70 µm and 170 µm ≤ d50 ≤ 220 µm.
  8. Method according to one of claims 1 - 7,
    characterized in that
    the mixture of boron nitride and bonding agent is homogenised at room temperature.
  9. Method according to one of claims 1-8,
    characterized in that
    the granulate to be introduced into the mould (28) is produced from the homogenised mixture by an agglomeration process, in particular a fluidised bed process, or in that the homogenised mixture is pressed to form one or more bodies and the granulate to be introduced into the mould (28) is then produced in a reduction process, in particular by grinding.
  10. Method according to one of claims 1-9,
    characterized in that
    the bonding agent, such as phenolic resin, has a grain size distribution 1 µm ≤ d50 ≤ 100 µm and/or the boron nitride, in particular the hexagonal boron nitride, has a grain size distribution of 1 µm ≤ d50 ≤ 10 µm and/or 30 µm ≤ d90 ≤ 40 µm and/or 3 µm ≤ d10 ≤ 5 µm.
  11. Method according to one of claims 1-10,
    characterized in that
    in the mixture, the ratio of the proportion of bonding agent, in particular phenolic resin, to the proportion of boron nitride, in particular hexagonal boron nitride, is 2:1 to 0.8:1.
  12. Multi-layer carbon brush (10) having at least two functional layers (12, 14, 16) made from electrically conducting material and, between them, at least one insulating layer (18) made from electrically insulating material,
    characterized in that
    the electrically insulating material consists of a mixture of bonding agent and boron nitride.
  13. Multi-layer carbon brush according to Claim 12,
    characterized in that
    the bonding agent is a synthetic resin material, such as phenolic resin, and/or pitch, and/or the boron nitride is hexagonal boron nitride.
  14. Multi-layer carbon brush according to Claim 12 or 13,
    characterized in that
    in the mixture, the ratio of the proportion of bonding agent, in particular phenolic resin, to the proportion of boron nitride is 2:1 to 0.8:1.
  15. Multi-layer carbon brush according to Claim 12,
    characterized in that
    apart from the carbon material present in the bonding agent, the insulating layer does not contain any further carbon material.
EP15192874.4A 2014-11-05 2015-11-04 Multi-layer carbon brush and method for producing same Active EP3018772B1 (en)

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DE102014116114A1 (en) 2016-05-12
KR20160053813A (en) 2016-05-13
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CN105576471A (en) 2016-05-11
EP3018772A1 (en) 2016-05-11
CN105576471B (en) 2019-03-19

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