JP2007318942A - Mold apparatus for injection molding of embedded magnet rotor and manufacturing method thereof - Google Patents

Abstract

[PROBLEMS] To fix a permanent magnet in a well-balanced manner, and to prevent damage to the laminated core even when resin molding pressure is applied to the laminated core when the resin member is filled, thereby improving reliability. An embedded magnet rotor is provided.
A magnet-embedded rotor in which a permanent magnet 6 is inserted into a plurality of holes of a laminated core 3 formed by laminating plate-like magnetic members and a resin member 8 is injected through the injection hole. The apparatus to be manufactured includes a slide member 11c that comes into contact with part or all of the outer periphery of the laminated iron core 3. The slide member 11c is sandwiched and fixed between the upper mold 10 and the lower mold 11 so that the holes and the permanent magnets are fixed. The resin member was filled in between.
[Selection] Figure 14

Description

  The present invention relates to an embedded magnet type rotor in which a plurality of permanent magnets are mounted in a hole provided in an outer peripheral portion of a laminated iron core and functions as a rotor of a rotating electrical machine, and in particular, the permanent magnet is fixed in the hole. The present invention relates to a manufacturing apparatus and a manufacturing method.

  Conventionally, as this type of magnet-embedded rotor, for example, as shown in Patent Document 1, a permanent magnet is laminated by placing an adhesive sheet impregnated or coated with an adhesive on the outer periphery of the permanent magnet. It has been proposed to fix in a punched hole provided in.

  However, since the embedded magnet rotor as described above has an adhesive sheet impregnated or coated with an adhesive on the outer periphery of the permanent magnet, the position of the permanent magnet in each punched hole is not constant, and the magnetic There was a problem that the balance of characteristics and weight deteriorated and the performance deteriorated.

  Therefore, according to Patent Document 2 and Patent Document 3 filed by the same applicant as this application, it penetrates in the axial direction along the center side of the laminated core of the hole portion into which the permanent magnet is inserted, and corresponds to the permanent magnet. By forming a hole for injection that communicates with the hole at the position where the hole is to be filled, and filling the resin member between the hole and the permanent magnet via this hole for injection, the permanent magnet can be securely fixed in a balanced manner. Has proposed.

JP-A-9-163649 JP 2001-157394 A JP 2002-34187 A

  As in Patent Document 2 and Patent Document 3 above, for injection that penetrates in the axial direction along the center side of the laminated core of the hole portion into which the permanent magnet is inserted and communicates with the hole portion at a position corresponding to the permanent magnet When a hole is formed and a thermoplastic resin member is filled between the hole and the permanent magnet through the hole for injection, the resin flows and fills between the hole and the permanent magnet. Need to apply a large pressure (about 50 MPa). When such a pressure is applied to the hole of the laminated core, there is a problem that the thin-walled portion of the laminated core may be damaged by the pressure of the resin.

  The present invention has been made to solve the above-described problems. The permanent magnet is securely fixed in a well-balanced manner, and the laminated iron core is applied even when resin molding pressure is applied to the laminated iron core during filling of the resin member. It is an object of the present invention to provide a stratified apparatus and a manufacturing method for an embedded magnet rotor capable of preventing damage to the rotor and improving reliability.

  A mold apparatus for injection molding of a magnet-embedded rotor according to the present invention has a laminated core formed by laminating plate-like magnetic members, and is disposed on the end surface of the laminated core at a predetermined interval in the circumferential direction. And a plurality of holes formed so as to penetrate in the axial direction, permanent magnets inserted into the holes, and positions corresponding to the permanent magnets extending along the center side of the laminated core of the holes. In order to manufacture a magnet-embedded rotor including an injection hole portion formed in communication with the hole portion and a resin member injected through the injection hole portion and filled between the hole portion and the permanent magnet In the injection mold apparatus, the injection mold apparatus is composed of an upper mold and a lower mold, and a contact member that contacts a part or all of the outer periphery of the laminated core (slide in the detailed description of the invention). Member), and the contact member is clamped and fixed by the upper die and the lower die It is intended to fill a resin member between the bore and the permanent magnet.

  A method for manufacturing a magnet-embedded rotor according to the present invention includes a laminated iron core formed by laminating plate-like magnetic members, and an end face of the laminated iron core disposed at a predetermined interval in the circumferential direction and in the axial direction. A plurality of holes formed so as to penetrate, permanent magnets that are respectively inserted into the holes, holes extending at the center side of the laminated iron core of the holes and holes corresponding to the permanent magnets A method of manufacturing a magnet-embedded rotor including an injection hole portion formed in communication and a resin member injected through the injection hole portion and filled between the hole portion and a permanent magnet, A resin member is filled between the hole and the permanent magnet in a state where a part or all of the outer periphery of the laminated iron core is in contact with the contact member.

  According to this invention, the contact member is sandwiched and fixed between the upper die and the lower die while being in contact with part or all of the outer periphery of the laminated core, and the resin member is filled between the hole and the permanent magnet. Therefore, even if molding pressure for filling the laminated core with the resin member is applied, the thin-walled portion of the laminated core is not damaged, and a highly reliable embedded magnet rotor is provided with high productivity. Can do.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

Embodiment 1 FIG.
1 is a cross-sectional view taken along a plane passing through the rotation center axis of an embedded magnet rotor according to Embodiment 1 of the present invention, FIG. 2 is a cross-sectional view taken along line AA of FIG. 1, and FIG. FIG. 4 is a diagram showing a section taken along line B-B in FIG. 1, FIG. 4 is a diagram showing a section taken along line CC in FIG. 1, FIG. 5 is a diagram showing a section taken along line DD in FIG. FIG. 2 is a view showing a cross section taken along line EE of FIG. 1. 7 is a plan view showing a first plate-like magnetic member constituting the magnet-embedded rotor of FIG. 1, and FIG. 8 is a diagram showing a second plate-like magnetic member constituting the magnet-embedded rotor of FIG. FIG. 9 is a plan view showing a laminated core constituting the magnet-embedded rotor of the present embodiment, and FIGS. 10 and 11 are cross-sectional views of the FF line and GG line of the laminated core of FIG. It is sectional drawing cut | disconnected by the plane which passes a rotation center axis | shaft. 12 and 13 are a plan view and a front view of the permanent magnet of the present embodiment.

  As shown in FIG. 1, the magnet-embedded rotor according to the present embodiment includes a permanent magnet 6 and a laminated iron core 3 formed by laminating a first plate-like magnetic member 1 and a second plate-like magnetic member 2. It is configured by mounting the rotor shaft 7. As shown in FIG. 7, the first plate-like magnetic member 1 has a plurality of holes 1 a arranged at predetermined intervals in the circumferential direction near the outer periphery, and a laminated core 3 of these holes 1 a. Injection hole 1b disposed at the center in the circumferential direction on the center side, shaft hole 1c disposed at the center of the laminated iron core 3, and regions between the injection hole 1b and the shaft hole 1c. Disposed caulking portions 1e and positioning hole portions 1f for forming molds to be described later are respectively formed. Further, as shown in FIG. 8, the second plate-like magnetic member 2 has holes 2a, injection holes similar to the respective portions 1a, 1b, 1c, 1e, and 1f of the first plate-like magnetic member 1. A portion 2b, a shaft hole portion 2c, a caulking portion 2e, and a positioning hole portion 2f are formed, and further, a slit portion 2d that communicates between the hole portion 2a and the injection hole portion 2b is formed.

  Moreover, as shown in FIGS. 1-11, the laminated iron core 3 of this Embodiment is the 2nd plate-shaped magnetic member in the position corresponding to the axial direction both ends and the axial direction substantially center part of the permanent magnet 6. As shown in FIG. 2 are stacked in a combination of, for example, about 3 to 4 sheets, and the first plate-like magnetic member 1 is disposed in the remaining positions, and the holes 1a and 2a, 1b and 2b, 1c and 2c, 1f and 2f are formed. They are configured to match each other, and are fixed and integrated with the crimping caulking 1e, 2e. And in the part by which the 2nd plate-shaped magnetic member 2 is arrange | positioned, by each slit part 2d, the communicating groove part which has the same width as a slit and the depth for 3-4 times the plate | board thickness of a plate-shaped magnetic member, for example 4 and the communication hole 5 are formed. Further, since the positioning holes 1f and 2f of the first and second plate-like magnetic members 1 and 2 are laminated so as to coincide with each other, as shown in FIGS. The positioning hole 12 is formed.

  Moreover, as shown in FIGS. 1-13, the some permanent magnet 6 is inserted in both the hole parts 1a and 2a of the 1st and 2nd plate-shaped magnetic members 1 and 2, respectively. The rotor shaft 7 is fitted into the shaft holes 1c and 2c of the first and second plate-like magnetic members 1 and 2. The resin member 8 is injected from the injection holes 1b and 2b of the first and second plate-like magnetic members 1 and 2, and is injected into the holes 1a and 2a via the communication groove 4 and the communication hole 5. The permanent magnets 6 are loaded while leaving a partial space on the axial center side.

  The magnet-embedded rotor according to the present embodiment is a rotor having six magnetic poles composed of six permanent magnets 6 as shown in the drawing, and the central part of each magnetic pole of the laminated core 3 has an outer diameter. It has a shape that is convex in the direction. The present invention is not limited to a 6-pole embedded magnet rotor, and can be applied without being limited to the number of poles, such as 4-pole, 8-pole, 10-pole, and 12-pole.

  FIG. 14 is a cross-sectional view showing the configuration of a molding die applied to the manufacture of the magnet-embedded rotor of the present embodiment, and is shown in a state in which the laminated core 3 is inserted. FIG. 15 shows a different cross section of the molding die in the same state as FIG. 14, and the positioning hole 12 of the laminated iron core 3 is shown. FIG. 16 is a cross-sectional view showing a state in which the laminated iron core 3 is inserted and moved and arranged so that a movable slide member of the molding die is in contact with the outer circumference of the laminated iron core. FIG. 17 is a cross-sectional view showing a state in which the laminated iron core 3 is inserted and clamped (sandwiched between the upper die and the lower die) in a state where the slide member is in contact with the outer peripheral portion of the laminated iron core. 18 is a plan view of a molding die into which the laminated core 3 shown in FIG. 14 is inserted. FIG. 19 is a plan view of the molding die in a state where the laminated core 3 shown in FIG. 16 is inserted and the slide member in which the molding die is movable is moved and arranged so as to contact the outer peripheral portion of the laminated core.

  As shown in the drawing, the molding die 9 is a die for injecting a resin member 8 into the laminated core 3, and includes an upper die 10 and a lower die 11. The upper mold 10 is opened at positions corresponding to the resin supply holes 10a, the branch holes 10b branched from the resin supply holes 10a, and the injection holes 1b and 2b of the laminated core 3 from the branch holes 10b. A plurality of injection holes 10c, and a protrusion 10d that can contact the upper end surface of the permanent magnet 6 disposed in each of the holes 1a and 2a of the laminated core 3. The lower mold 11 protrudes from the shaft 11a that can be inserted into the shaft holes 1c and 2c of the laminated core 3 and the positions corresponding to the holes 1a and 2a of the laminated core 3, respectively. 2a, a projecting part 11b capable of contacting the lower end surface of the permanent magnet 6 and a part having the same shape in contact with the outer peripheral part of the laminated core 3, and a slide member 11c movable in the radial direction of the laminated core 3, movable An air cylinder 11d for moving the sliding member 11c in the radial direction and a positioning projection (positioning pin) 11e provided at a position corresponding to the positioning hole 12 of the laminated iron core 3 are provided. As shown in FIGS. 18 and 19, the upper mold 10 and the lower mold 11 can be aligned by the guide pins 11f.

Here, the height Hs of the slide member 11 c is set to be larger than the substantial height Ht of the laminated core 3. The actual height of the laminated iron core means that the thickness of the first and second plate-like magnetic members is t, and the number of laminated layers is n, Ht = nt
It is a dimension expressed by. Usually, the laminated core 3 is formed by laminating a plurality of plate-like magnetic members, but a laminate gap (space) G1 exists between the plate-like magnetic members and the plate-like magnetic members as shown in FIG. . The height excluding the dimension of the laminated gap is defined as the substantial height of the laminated core 3. Here, FIG. 20 shows the lamination gap G1 between the laminated cores before compression (clamping) according to the present embodiment, and FIG. 21 shows the lamination gap G2 between the laminated cores after compression (die clamping) according to the present embodiment. Indicates.

  In the case of the present embodiment, since the thickness t = 0.35 mm of the plate-like magnetic member and the number of stacked layers n = 114, the substantial height is Ht = 39.9 mm. The height of the slide member 11c is set to Hs = 40 mm.

  As shown in FIGS. 18 and 19, the slide member 11c has a shape in contact with the outer periphery of the two magnetic poles of the magnet-embedded rotor, and an air cylinder 11d is connected to the outside of the slide member 11c. It is configured to move in the radial direction by the driving force of the cylinder 11d. Although not shown, a linear guide mechanism is provided in the sliding direction of the slide member 11c, and the outer peripheral portion of the slide member 11c and the laminated iron core 3 can be in contact with each other without a gap. As shown in FIG. 19, when the slide member 11c is pressed against the laminated core 3 by the air cylinder 11d, the pressure of the air cylinder 11d is adjusted to about 200 N, and the laminated core 3 is adjusted by the pressure of the air cylinder 11d. The outer peripheral portion of the is not deformed.

  Next, a method for manufacturing the embedded magnet rotor according to the first embodiment will be described. First, as shown in FIG. 7, a hole 1a, an injection hole 1b, a shaft hole 1c, and a positioning hole 1f are formed in the first plate-like magnetic member 1 by punching. Further, as shown in FIG. 8, a hole 2a, an injection hole 2b, a shaft hole 2c, a slit 2d, and a positioning hole 2f are formed in the second plate-like magnetic member 2 by punching. . Next, as shown in FIGS. 10 and 11, the second plate-like magnetic member 2 is positioned corresponding to both axial ends of the laminated iron core 3, and the position corresponding to the substantially axial center of each permanent magnet 6. For example, 3 to 4 sheets are respectively disposed in the first plate-like magnetic member 1 and the remaining portions are disposed with the first plate-like magnetic member 1, and the respective hole portions 1a, 2a, injection hole portions 1b, 2b, shaft hole portion 1c 2c and the positioning holes 1f and 2f are laminated so as to coincide with each other. Then, the laminated first and second plate-like magnetic members 1 and 2 are fixedly integrated with the crimping caulking 1e and 2e to form the laminated iron core 3.

  As shown in FIGS. 14 and 15, the laminated core 3 formed as described above is laminated on the shaft portion 11a of the lower mold 11 so that each hole 2a coincides with each projection 11b. The shaft holes 1c and 2c are inserted and the positioning holes 12 formed by the positioning holes 1f and 2f are inserted into the positioning protrusions 11e of the lower mold 11. In this case, when the slide member 11c moves to the center side of the molding die 9, the laminated core 3 is arranged such that the portion of the slide member 11c that contacts the laminated core 3 can be in contact with the outer peripheral portion of the laminated core 3 without a gap. And the angle of the lower mold 11 are matched.

  When the laminated core 3 is inserted into the lower mold 11, the slide member 11 c mounted on the lower mold 11 has moved outward from the center of the molding die 9 due to the drive unit of the air cylinder 11 d retreating. Since it is in a state, the laminated core 3 can be easily inserted into the lower mold 11.

  Next, a predetermined number of permanent magnets 6 are inserted into the holes 1a and 2a of the laminated iron core 3, respectively. In the present embodiment, the number of permanent magnets 6 inserted into each of the holes 1a and 2a is one, but when the axial length of the magnet-embedded rotor is long, a plurality of permanent magnets 6 are inserted. To do. For example, when manufacturing a magnet-embedded rotor using the same permanent magnet 6 as in this embodiment and a laminated iron core having an axial length of 80 mm, two permanent magnets are provided in each hole as shown in FIG. insert. In this case, two communicating hole portions 5 of the laminated core 3 formed at positions corresponding to the permanent magnets 6 are formed in the same number as the number of permanent magnets.

  Next, the slide member 11c mounted on the lower die 11 moves to the center side of the molding die 9 by the advance of the drive portion of the air cylinder 11d, and is pressed in a state where it is in contact with the outer peripheral portion of the laminated iron core 3 without a gap. . However, since the pressing force of the air cylinder 11d is adjusted to about 200 N as described above, the laminated iron core 3 is not deformed or damaged by the pressing force.

  Then, the lower mold 11 is arranged such that the upper mold 10 is aligned with the position of each injection hole 2b of the laminated core 3 with each injection hole 10c and the position of each hole 2a with each projection 10d. Place on top of the.

  Next, the upper mold 10 and the lower mold 11 are clamped with a required force by a mold clamping mechanism (not shown) of the injection molding machine, and the laminated iron core 3 and the slide member 11c are compressed by the upper mold 10 and the lower mold 11. Fixed. As described above, since the height of the slide member 11 c is set to be larger than the substantial height of the laminated core 3, the slide member 11 c is compressed with a greater force than the laminated core 3.

In the present embodiment, the laminated core 3 is formed by laminating 114 plate-like magnetic members having a plate thickness t = 0.35 mm. Since the height Hs of the slide member 11c is 40 mm, the height of the laminated core 3 is compressed to 40 mm by clamping. The average stacking gap G after being compressed is 0.9 μm. The average laminated gap G is G = (Hc−t × n) / (n−1) where Hc is the height of the laminated laminated core when compressed.
It is a numerical value shown by and shows the average value of the stacking gap.

  The relationship between the force for compressing the laminated iron core 3 and the average laminated gap is as shown in FIG. Therefore, in order to compress the laminated iron core until the average laminated gap G becomes 0.9 μm, a pressing force of 200 KN is required, and the slide member 11 c is compressed by a force obtained by subtracting the force of 200 KN from the clamping force. Become.

  When the mold clamping force is set to 800 KN, the entire slide member is compressed with a force of 600 KN, so the compression force received by one slide member is 200 KN. Assuming that the slide member 11c, the lower die 11, and the upper die 10 are all steel, and the friction coefficient is 0.07, the slide member 11c is pressurized by the upper die 10 and the lower die 11 by the clamping force, so that the slide member 11c is held by the upper die 10 and the lower die 11 which are rigid bodies with a frictional force of 14KN.

  After the slide member 11c is fixed to the upper mold 10 and the lower mold 11 in this way, the resin member 8 is injected from the resin supply hole 10a of the upper mold 10 with a predetermined pressure.

  The injected resin member 8 flows in order through the branch hole 10b, each injection hole 10c, and each injection hole 1b, 2b of the laminated iron core 3, and passes through each communication hole 5 formed by the slit 2d. Through the holes 1a and 2a, pressing the permanent magnets 6 to the outer peripheral side, leaving some space on the axial center side, and forming the slits 2d at both ends of the laminated core 3. Then, it is guided into each of the holes 1a and 2a through the respective communicating groove portions 4 and filled with the permanent magnet 6 pressed from the upper and lower end surfaces of the laminated core 3 and from both side surfaces of the permanent magnet 6.

  At this time, the pressure applied for resin filling acts on the laminated core 3 as shown by the arrows in FIG. FIG. 23A is a detailed partial plan view showing the vicinity of the holes 1a and 2a of the laminated core 3 in the present embodiment, and FIG. 23B is a cross-sectional view taken along the line JJ in FIG. Since the inner diameter side of the holes 1a and 2a of the laminated core 3 has large dimensions (thickness from the holes 1a and 2a to the shaft holes 1c and 2c) and high rigidity, the resin molding pressure 13a acts in the inner diameter direction. However, there is no worry that the laminated iron core 3 is damaged. Also, since the resin filled in the holes 1a, 2a of the laminated core 3 receives molding pressure from the resin filled in the adjacent holes, and the force of both balances, the resin molding pressure 13b acting in the circumferential direction, There is no concern that the laminated iron core 3 is damaged by 13c.

  When the resin molding pressure 13d toward the outer diameter of the molding pressure of the resin filling the holes 1a and 2a of the laminated core 3 is applied, a large stress is generated in the thin-walled portions 1g, 1h, 2g and 2h of the laminated core 3. The laminated iron core 3 may be damaged.

  However, the molding die 9 of the present embodiment is equipped with a slide member 11c, which is held and fixed by the upper die 10 and the lower die 11 in contact with the outer peripheral portion of the laminated iron core 3 at the time of resin filling. Since the outer peripheral portion of the laminated core 3 is supported by the slide member 11c in the outer diameter direction, the thin-walled portions 1g, 1h, 2g, and 2h of the laminated core 3 are not damaged by the molding pressure at the time of resin filling.

  When the thickness of the plate-like magnetic member is t, the circumferential width dimension of the holes 1a and 2a is L (see FIG. 24), and the molding pressure of the resin is P (MPa), the holes 1a and 2a are filled. The force acting on the outer diameter side from the holes 1a and 2a of the laminated core 3 by the molding pressure by the resin to be applied is PLt. This force acts on the thin-walled portions 1g, 1h, 2g, and 2h. As described above, when the resin is filled, the sliding member 11c is in contact with the outer peripheral portion of the laminated iron core 3 due to the frictional force generated by the clamping force. Since it is held and fixed to the upper mold 10 and the lower mold 11, it does not deform even when a resin molding pressure is applied.

  Here, the force which the outer peripheral part of the laminated iron core 3 receives by the molding pressure at the time of resin filling is estimated. In the portion of the pressure range A shown in FIG. 24, the resin 8 is filled in the entire hole portion of the laminated core 3, but in the pressure range B portion, the resin-filled portion is a gap between both end portions of the permanent magnet 6 and each hole portion. Only part 13 is present. However, to be precise, the resin is filled in the gaps between the communicating holes 5 and the permanent magnets 6 around the communicating holes 5 and the respective holes, but since the area is small, the influence on the force applied to the outer peripheral portion of the laminated core 3 is not affected. It is small and will be ignored in this calculation.

With reference to FIG. 24, the dimensions of each part of the magnet-embedded rotor of this example are as follows. The circumferential width Lm of the magnet is 45 mm, the axial length Hm of the permanent magnet is 38.6 mm, the maximum outer diameter of the laminated core 3 is 75 mm, the height of the laminated core H is 40 mm, and the shaft diameter is φ25 mm. LCP resin (liquid crystal polymer) was used as the resin. Here, when the molding pressure of the resin in the hole 2a is P = 40 MPa, the force F1 acting on the outer diameter side due to the molding pressure of the resin filling the hole 2a (molding pressure range A) is F1 = P × L × (H-Hm)
^{= 40 × 10 6 × 50 ×} 10 -3 × (40-38.6) × 10 -3
= 1400N
It becomes.

Further, if the average resin molding pressure applied to the molding pressure range B is P2 = 10 MPa, the force F2 applied to the outer peripheral portion of the laminated core is F2 = (L−Lm) × Hm × P2.
^{= (50-45) × 10 -3 ×} 38.6 × 10 -3 × 10 × 10 6
= 1930N
It becomes.

Since the force F acting on the laminated iron core 3 due to the molding pressure of the resin is the sum of both, F = F1 + F2 = 3.33KN
It becomes. The above-described P1 and P2 were calculated using resin flow analysis.

  As described above, when the mold clamping force is 800 KN, the slide member 11 c is held by the upper mold 10 and the lower mold 11 with a frictional force of 14 KN. Therefore, a force 6.66KN of two poles of the force F acting on the laminated iron core 3 due to the molding pressure of the resin (more precisely, the sum of the component forces acting in the sliding direction of the slide member 11c of the force of one pole) Therefore, even if a force of 3.33 KN × COS 30 ° × 2 = approximately 5.77 KN is applied to the slide member 11c, the slide member 11c is held by the frictional force. Never move. Accordingly, the outer peripheral portion of the laminated core 3 in contact with the slide member 11c is not deformed, and the gap between the hole of the laminated core 3 and the permanent magnet 6 is filled with resin without damaging the laminated core 3, and the permanent magnet 6 Can be stably fixed to the laminated iron core 3 at a fixed position.

If there is no slide member 11c, in the pressure range A, the stress σ applied to the outer peripheral portion of the laminated core 3 is σ = Rc × P1 / Tc
Can be approximated by Tc is the thickness of the outer peripheral portion of the laminated core 3, Rc is the radius of curvature inside the outer peripheral portion of the laminated core 3, and Rc = 35 mm and Tc = 1 mm,
^{σ = 35 × 10 -3 × 30} × 10 6/1 × 10 -3
= 1050 × 10 ⁶ Pa = 1050 MPa
It becomes. Since the yield stress of the plate-like magnetic member is approximately 300 MPa, if the slide member 11c is not provided, the outer peripheral portion of the laminated core 3 is plastically deformed when a resin molding pressure is applied, resulting in breakage and resin leakage failure. Become.

  Next, the mold clamping mechanism (not shown) of the molding die 9 is loosened to remove the upper mold 10 and the slide member 11c is retracted. Then, the laminated iron core 3 is taken out from the lower mold 11 and the shaft hole 1c, By fitting and fixing the rotor shaft 7 to 2c, an embedded magnet type rotor is completed.

  As described above, according to the first embodiment, the resin member 8 is guided into the holes 1a and 2a via the communication grooves 4 and the communication holes 5 formed by the slits 2d, and the permanent magnet 6 is surrounded by the outer periphery. And the permanent magnet 6 is filled in the pressed state from the upper end surface side of the laminated core 3. Therefore, the permanent magnet 6 can be securely fixed in a balanced manner, and the reliability can be improved.

  Further, when the resin member 8 is filled, the slide member 11c mounted on the lower mold 11 is brought into contact with the outer peripheral portion of the laminated core and is sandwiched between the upper mold 10 and the lower mold 11 by the mold clamping mechanism. Since the resin member 8 is filled in a state in which the outer peripheral portion of the laminated core 3 is supported by the slide member 11c, the laminated core 3 is not damaged by the molding pressure at the time of resin filling, and is reliable. Improvements can be made.

  When the actual height Ht of the laminated core 3 is smaller than the specified value with respect to the height Hs of the slide member 11c, the average lamination gap after clamping is 4 μm or more, and the molding pressure at the time of resin filling As a result, the resin may enter the gap between the plate-like magnetic member and the plate-like magnetic member, resulting in burrs as described later. For example, when the number of stacked layers is 113 with the same setting as the present embodiment, the average stack gap is 4 μm, and burrs are generated.

  That is, when the lamination gap is 4 μm or more, the resin does not enter at a thickness (gap) of only the average lamination gap dimension, but the space (gap) of the plurality of lamination gaps is biased to one place as shown in FIG. Creates a large gap. We have discovered through experiments that the resin enters the large gap and that the gap further expands due to the molding pressure of the resin, resulting in large burrs and defects. Table 1 shows the experimental results of investigating the occurrence of burrs by making the substantial height Ht of the laminated iron core 3 constant and changing the height Hs of the slide member 11c to perform resin filling. In order to prevent burrs, it is necessary that the stacking gap is less than 4 μm, preferably 3 μm or less.

  Since the actual height Ht of the laminated iron core 3 varies depending on the thickness variation of the plate-like magnetic member, it is necessary to adjust the number of laminated sheets when the lot of steel sheet rolls for producing the laminated iron core 3 changes. For example, when the plate thickness of the plate-like magnetic member is 0.352 mm, if 114 sheets are laminated, the actual height of the laminated iron core is 40.128, which is larger than the height of the slide member 11c, and the slide member 11c is The upper mold 10 and the lower mold 11 cannot be sandwiched and fixed. If the resin member 8 is filled in this state, defects such as breakage of the outer peripheral portion of the laminated iron core 3 and resin leakage occur. In this case, if the number of laminated layers is 113, the actual height Ht of the laminated iron core 3 is 39.977 mm, the average laminated gap is 2 μm, an appropriate average laminated gap can be formed, and the outer peripheral portion of the laminated iron core is damaged. An embedded magnet rotor can be obtained without defects such as resin leakage.

  As described above, by manufacturing the laminated core 3 so that the substantial height Ht of the laminated core 3 is smaller than the height of the slide member 10c and the average laminated gap is 4 μm or less (adjusting the number of laminated layers). The resin is filled in the gap between the hole of the laminated iron core 3 and the permanent magnet 6 without causing defects such as damage to the outer peripheral portion of the laminated iron core 3 and resin leakage, and the permanent magnet 6 is stably positioned in the laminated iron core 3. Can be securely fixed.

  25 to 27 are cross-sectional views showing the configuration of another molding die applied to the manufacture of the magnet-embedded rotor according to the first embodiment of the present invention. FIG. 26 shows a state where the slide member 11c is in contact with the outer peripheral portion of the laminated iron core 3, and FIG. 27 shows a state where the upper die 10 and the lower die 11 are clamped. As shown in FIGS. 25 to 27, there is a case where the pedestal portion on which the laminated iron core 3 is mounted protrudes from the lower die main body, and the upper die 10 that is in contact with the upper end surface of the laminated iron core 3 during mold clamping. The part may protrude from the upper mold body. In such a case, in setting the height of the slide member 11c, the protruding dimension of the upper mold 10 and the protruding dimension of the lower mold 11 may be considered. That is, if the height of the actual slide member is set to the above-mentioned range by setting the height of the actual slide member as a dimension obtained by subtracting the projecting dimension of the upper mold 10 and the projecting dimension of the lower mold 11 from the height of the slide member. good. In the case of the present embodiment, from the results of Table 1, the substantial height of the slide member may be set to 40 to 40.25 mm. Then, without causing defects such as damage to the outer peripheral portion of the laminated core 3 and resin leakage, the gap between the hole of the laminated core 3 and the permanent magnet 6 is filled with resin, and the permanent magnet is stably positioned in the laminated core. Can be securely fixed.

  FIGS. 28 and 29 are plan views showing the configuration of another molding die applied to the manufacture of the magnet-embedded rotor according to the first embodiment of the present invention. FIG. FIG. 29 shows a state in which the slide member 11 c is in contact with the outer peripheral portion of the laminated core 3. 28 and 29, an example of the molding die 9 in which the number of the slide members 11c is six and arranged at positions corresponding to the magnetic poles of the permanent magnet 6 is described. Except for the difference in the number of slide members 11c, this is the same as the method for manufacturing the embedded magnet rotor of Embodiment 1 and the embedded magnet rotor using the same. Without causing defects such as breakage and resin leakage, the gap between the hole of the laminated core and the permanent magnet can be filled with resin, and the permanent magnet can be stably fixed to the laminated core in a fixed position. An embedded magnet rotor can be obtained with high productivity.

  Further, FIGS. 30 to 33 are plan views showing configurations of other molding dies applied to manufacture of the magnet-embedded rotor according to the first embodiment of the present invention. 30 and 31 are examples in which the slide member 11c is arranged corresponding to the two permanent magnets 6, FIG. 30 shows a state in which the laminated iron core 3 is mounted on the lower mold 11, and FIG. 31 shows a laminate of the slide member 11c. The state which contact | abutted to the outer peripheral part of the iron core 3 is shown. 32 and 33 are examples in which the slide member 11c is arranged corresponding to each permanent magnet 6, FIG. 32 shows a state in which the laminated iron core 3 is mounted on the lower mold 11, and FIG. 33 shows a laminate of the slide member 11c. The state which contact | abutted to the outer peripheral part of the iron core 3 is shown. 30-33, the convex part 50 and the convex part 60 are provided in the part which faces the outer periphery of the laminated core 3 of the slide member 11c. And the convex part 50 is contact | abutted to the position which hits the circumferential direction both ends of the permanent magnet 6 of the laminated iron core 3, and the convex part 60 is made to contact | abut the position which hits the circumferential direction center part of the permanent magnet 6 of the laminated iron core 3. In the case of a configuration in which the slide member 11c is in contact with the entire outer periphery of the laminated core 3 (FIGS. 18, 19, 28, and 29), if the contact surface of the slide member 11c is not accurately finished over the entire periphery, the contact is made. 30 to 33, there is no need to finish the contact surface of the slide member 11c with high accuracy over the entire circumference, and only the portion where the outer peripheral portion of the laminated iron core 3 may be damaged. By making contact, the permanent magnet can be stably fixed to the laminated iron core at a fixed position, and a magnet-embedded rotor can be obtained with higher productivity with higher quality.

  34 and 35 are cross-sectional views showing the configuration of another molding die applied to the manufacture of the magnet-embedded rotor according to the first embodiment of the present invention. FIG. FIG. 35 is a cross-sectional view showing a state in which the laminated iron core 3 is inserted, and FIG. 35 is a sectional view showing a state in which the slide member 11c is clamped in a state of being in contact with the outer peripheral portion of the laminated iron core 3. 34 and 35, the friction member 70 is disposed on the surface of the upper mold 10 or the lower mold 11 that contacts the slide member 11c, whereby the slide member 11c is more firmly clamped by the upper mold 10 and the lower mold 11. be able to. As the friction member 70, for example, a low steel material for automobiles is preferable because it has a high coefficient of friction (about 0.4). The low steel material for automobiles has a composition of 25% steel wool, 25% potassium titanate, 10% alumina, 25% calcium carbonate, and 15% phenol resin. In addition, a semi-metallic material, NAO material (non-asbestos organic material), or the like may be used.

Further, when manufacturing a magnet embedded rotor having a long axial length, a laminated core 3 having a long axial length is manufactured as shown in FIG. 37, and a plurality of permanent magnets 6 are arranged in accordance with the length. In addition to the method of inserting into each hole and filling the resin member 8 to fix the permanent magnet 6, there is the following method. That is, as shown in FIG. 38, the laminated core 3 taken out from the molding die 9 shown in the first embodiment (the permanent magnet 6 is inserted into each hole of the laminated core 3 to fix the permanent magnet 6). The laminated cores 3) filled with the resin member 8 are stacked in the axial direction so that the positions of the holes, shaft holes, and resin injection holes of the laminated cores 3 are aligned in the axial direction. By fitting and fixing the rotor shaft 7, a magnet-embedded rotor having a long shaft length can be obtained.
Further, the laminated cores 3 taken out from the molding die 9 are stacked while being shifted by a predetermined angle in the axial direction, and the rotor shaft 7 is fitted and fixed in that state, thereby the magnetic pole is skewed stepwise. A built-in rotor is obtained.

Embodiment 2. FIG.
39 and 40 are cross-sectional views showing the configuration of a molding die applied to manufacture of the magnet-embedded rotor according to the second embodiment of the present invention. Note that the magnet-embedded rotor obtained by the molding die and the manufacturing method of the second embodiment has the same configuration as that of the first embodiment.

  As in the first embodiment, the molding die 9 of the present embodiment is equipped with a slide member 14 that can move to the lower mold 11. The slide member 14 is formed with a taper surface having the same angle as the taper surface of the taper block 15 attached to the upper mold 10. The slide member 14 is formed with an inclined hole 17 into which an inclined pin 16 attached to the upper mold 10 is fitted. The angle of the inclined pin 16 and the angle of the inclined hole 17 are also set to be the same.

  A spring member 18 is attached to the upper part of the taper block 15 mounted on the upper mold 10, and the contact surface 20 of the taper block 15 is pushed by the spring member 18 in the mold open state and is provided on the upper mold 10. It is pressed against the contact surface 19 of the mold.

  When the mold is opened, the slide member 14 is in a position retracted outward as in the first embodiment, and in this state, the laminated core 3 can be easily inserted.

  After the laminated core 3 is set on the lower mold 11, the upper mold 10 and the lower mold 11 are closed by a mold clamping mechanism (not shown) of an injection molding machine. When the taper surface hits the taper surface of the slide member 14 of the lower mold 11, the slide member 14 moves along the taper surface toward the center of the laminated iron core 3, and the outer peripheral portion of the laminated iron core 3 and the slide member 14 come into contact with each other. Similar to the first embodiment, the surface where the slide member 14 contacts the outer peripheral portion of the laminated core 3 has the same shape as the outer peripheral portion of the laminated core 3.

  When the slide member 14 comes into contact with the outer peripheral portion of the laminated iron core 3, the slide member 14 cannot move, and thereafter, the taper block 15 moves upward along the taper surface together with the mold clamping, the spring member 18 is compressed, and the mold Tightening is complete.

  When the mold clamping is completed, the outer peripheral surface of the laminated iron core 3 is subjected to a compressive force by the spring member 18 via the tapered surface of the slide member 14 and the tapered block 15, but the laminated iron core 3 is the same as in the first embodiment. The angle of the taper surface, the spring coefficient of the spring, and the amount of compression of the spring are adjusted so that the force to press the outer periphery of the steel core is about 200 N. Therefore, excessive force is applied to the outer periphery of the laminated core 3 by clamping. The problem that the laminated core 3 is broken does not occur.

  As in the first embodiment, the slide member 14 is sandwiched between the upper mold 10 and the lower mold 11 by mold clamping, and the resin can be filled into the gap between the hole of the laminated core 3 and the permanent magnet 6 in a fixed state. Therefore, the resin is filled in the gap between the hole of the laminated core 3 and the permanent magnet 6 without causing defects such as breakage of the outer peripheral portion of the laminated core 3 and resin leakage, and the permanent magnet 6 is stably positioned in the laminated core. Therefore, it is possible to obtain a rotor with built-in magnet with higher quality and higher productivity.

  When the upper mold 10 and the lower mold 11 are opened by the mold opening mechanism (not shown) of the injection molding machine after the resin filling is completed, the taper block 15 of the upper mold 10 is lowered by receiving the force of the spring member 18 (upper When the position of the mold is used as a reference, the lowering is performed, and when the position of the lower mold is used as a reference, the movement is stopped).

  After the mold opening is started, the upper mold 10 is slightly raised, and the inclined pin 16 of the upper mold 10 comes into contact with the outer portion of the inclined hole 17 of the lower mold 11. From this state, when the upper mold 10 is further raised, the slide member 14 moves backward (moves outward) along the inclination angle of the inclined pin 16 and the inclined hole 17, and then the inclined pin 16 is completely removed from the inclined hole 17. Get out.

  Thus, when the slide member 14 moves backward and a gap is formed between the outer periphery of the laminated iron core 3, the laminated iron core 3 after resin filling can be easily taken out from the molding die 9, and then the resin member. Can be easily inserted into the molding die, and the molding process can be repeated smoothly.

  Thereafter, the rotor shaft 7 is fitted and fixed in the shaft hole portion of the laminated iron core 3 taken out from the molding die 9 to complete the magnet-embedded rotor.

It is sectional drawing cut | disconnected by the plane which passes along the rotation center axis | shaft of the magnet embedded rotor in Embodiment 1 of this invention. It is a figure which shows the cross section which follows the AA line of FIG. It is a figure which shows the cross section which follows the BB line of FIG. It is a figure which shows the cross section which follows the CC line | wire of FIG. It is a figure which shows the cross section which follows the DD line | wire of FIG. It is a figure which shows the cross section which follows the EE line | wire of FIG. It is a top view which shows the 1st plate-shaped magnetic member which comprises the magnet embedded type | mold rotor of FIG. It is a top view which shows the 2nd plate-shaped magnetic member which comprises the magnet embedded type | mold rotor of FIG. It is a top view which shows the laminated iron core which comprises the magnet embedded type | mold rotor of FIG. It is sectional drawing which follows the FF line | wire of the laminated core of FIG. 9, and is sectional drawing cut | disconnected by the plane which passes along the rotation center axis | shaft of a laminated core. It is sectional drawing which follows the GG line of the laminated iron core of FIG. 9, and is sectional drawing cut | disconnected by the plane which passes along the rotation center axis | shaft of a laminated iron core. It is a top view which shows the permanent magnet used for embodiment of this invention. It is a front view which shows the permanent magnet used for embodiment of this invention. It is sectional drawing which shows the structure of the shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a figure which shows the different cross section of the shaping die in the same state as FIG. It is sectional drawing which shows the state by which the laminated iron core was inserted by the shaping die, and the slide member moved and arrange | positioned so that the outer peripheral part of a laminated iron core may be contact | connected. It is sectional drawing which shows the state clamped in the state by which the laminated iron core was inserted by the shaping die, and the slide member contacted the outer peripheral part of the laminated iron core. It is a top view which shows the shaping | molding die with which the laminated iron core of FIG. 14 was inserted. FIG. 17 is a plan view of the molding die in a state in which the laminated core of FIG. 16 is inserted and the slide member is moved and arranged so as to be in contact with the outer periphery of the laminated core. It is a figure which shows the lamination | stacking clearance gap between the lamination | stacking iron cores before compression (die clamping) by Embodiment 1 of this invention. It is a figure which shows the lamination | stacking clearance gap between the laminated iron cores after compression (clamping) by Embodiment 1 of this invention. It is a figure which shows the bias | inclination of the lamination | stacking clearance gap between lamination | stacking iron cores after compression (die clamping). It is the detailed partial top view and J line sectional view which show the hole vicinity vicinity of the laminated iron core of Embodiment 1 of this invention. It is the detailed partial top view and J line sectional view which show the hole vicinity vicinity of the laminated iron core of Embodiment 1 of this invention. It is sectional drawing which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is sectional drawing which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is sectional drawing which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a top view which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is sectional drawing which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is sectional drawing which shows the structure of the other shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 1 of this invention. It is a figure which shows the relationship between the clamping force of a shaping die, and a lamination | stacking clearance gap. It is sectional drawing which shows the other magnet embedded type rotor in Embodiment 1 of this invention. It is sectional drawing which shows the other magnet embedded type rotor in Embodiment 1 of this invention. It is sectional drawing which shows the structure of the shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 2 of this invention. It is sectional drawing which shows the structure of the shaping die applied to manufacture of the magnet embedded type rotor of Embodiment 2 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 1st plate-shaped magnetic member, 2nd 2nd plate-shaped magnetic member, 3 laminated iron core, 4 communicating groove part,
5 communication hole, 6 permanent magnet, 7 rotor shaft, 8 resin member, 9 mold, 10 upper mold,
11 Lower mold, 11c Slide member, 14 Slide member, 15 Taper block,
16 inclined pin, 17 inclined hole, 18 spring member, 50, 60 convex part,
70 Friction member.

Claims (9)

A laminated core formed by laminating plate-like magnetic members, a plurality of holes formed in the end face of the laminated core at predetermined intervals in the circumferential direction and penetrating in the axial direction; and Permanent magnets that are respectively inserted into the holes, and injection holes that extend along the center side of the laminated iron core of the holes and that communicate with the holes at positions corresponding to the permanent magnets. In a mold apparatus for injection molding for manufacturing a magnet-embedded rotor including a portion and a resin member injected through the injection hole and filled between the hole and the permanent magnet,
The mold apparatus for injection molding includes an upper mold and a lower mold, and includes an abutting member that abuts a part or all of the outer periphery of the laminated core, and the abutting member is provided by the upper mold and the lower mold. A mold apparatus for injection molding of a magnet-embedded rotor, wherein a resin member is filled between the hole and the permanent magnet in a sandwiched and fixed state. The injection member for an embedded magnet rotor according to claim 1, wherein the contact member contacts a part or all of the outer peripheral portion of the laminated core corresponding to the magnetic poles of all permanent magnets. Mold equipment. 2. The mold apparatus for injection molding of a magnet-embedded rotor according to claim 1, wherein a plurality of the contact members are provided. 2. The injection of a magnet-embedded rotor according to claim 1, wherein a height of the contact member is larger than a substantial height of the laminated core (thickness of the plate-like magnetic member × number of laminated layers). Mold equipment for molding. The contact member is not fixed to the upper mold or the lower mold in a state where the upper mold and the lower mold are not closed, and is configured to be movable in the radial direction of the laminated core. The mold apparatus for injection molding of a magnet-embedded rotor according to claim 1. The contact member is in contact with at least the outer peripheral portion of the laminated core corresponding to both circumferential end portions of the permanent magnet and the outer peripheral portion of the laminated core corresponding to the circumferential central portion of the permanent magnet. The mold apparatus for injection molding of the magnet-embedded rotor according to claim 1. 2. The mold apparatus for injection molding of a magnet-embedded rotor according to claim 1, wherein a friction member is disposed on a surface of the upper die or the lower die that contacts the contact member. The contact member is formed with a taper surface having the same angle as the taper surface of the taper block provided on the upper mold, a spring member is attached to the taper block, and the contact member is attached to the upper mold. 2. The mold apparatus for injection molding of a magnet-embedded rotor according to claim 1, wherein an inclined hole into which the attached inclined pin is fitted is formed. A laminated core formed by laminating plate-like magnetic members, a plurality of holes formed in the end face of the laminated core at predetermined intervals in the circumferential direction and penetrating in the axial direction; and Permanent magnets that are respectively inserted into the holes, and injection holes that extend along the center side of the laminated iron core of the holes and that communicate with the holes at positions corresponding to the permanent magnets. And a method of manufacturing a magnet embedded rotor including a resin member injected through the injection hole and filled between the hole and the permanent magnet,
A method of manufacturing a magnet-embedded rotor, wherein a resin member is filled between the hole and the permanent magnet in a state where a part or all of the outer periphery of the laminated core is in contact with the contact member .

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