JP2014192941A - Rotor manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device for manufacturing a gate cut rotor by separating a sealing material filling a housing recess accurately at a gate without missing, with simple configuration.SOLUTION: A rotor manufacturing device comprises: a molding 1 forming a runner 30 constituting a gate G, closing the opening of the housing recess H of a rotor core C where a magnet M is arranged, opening to the periphery of the housing recess H on the surface Ca of the rotor core C, and communicating with the housing recess H to constitute a gate G; sealing material filling means 4 for filling the housing recess H with a plasticized sealing material P via the runner 30 of the molding 1; and gate cut means for separating the sealing material P in solidified state at the gate G between the runner 30 and the housing recess H. Corner 31 of the runner 30 of the molding 1 is formed into C plane shape 32, so that a separation start point SP occurring in the sealing material P at the time of gate cut is located on the reverse side of the rotor core C side.

Description

  The present invention relates to a rotor manufacturing apparatus, and more particularly to a rotor manufacturing apparatus for manufacturing a rotor of an electric motor formed by sealing a magnet disposed in a housing recess of a rotor core with a sealing material. .

  In the case of manufacturing a rotor in which a magnet is disposed in a housing recess of the rotor core and sealed with a sealing material, the magnet M is disposed in the housing recess H of the rotor core C as shown in FIGS. (FIG. 5 (a)), for example, a thermosetting resin is filled in the housing recess H as the sealing material P by transfer molding or the like (FIG. 5 (b)), and the solidified sealing material P is molded. A gate cut is performed at the gate portion G between the runner 30 ′ of the mold 1 ′ and the accommodating recess H to remove unnecessary sealing material P from the rotor core C (FIG. 5 (c)). It is generally done.

For example, Patent Literature 1 is known as a conventional technique for manufacturing such a rotor. In Patent Document 1, a permanent magnet piece is inserted into a magnet insertion hole formed in a rotor laminated iron core in which a plurality of iron core pieces are caulked and laminated via caulking dowels, and sandwiched between an upper die and a lower die, In the method of manufacturing a rotor in which the magnet insertion hole is filled with resin from a resin reservoir pot formed in the upper mold or the lower mold, the caulking dowel is arranged at the center of the resin reservoir pot and enters the magnet insertion hole. And a method of manufacturing a rotor, characterized in that the resin reservoir pot and the magnet insertion hole are connected via a runner (hereinafter referred to as a runner). Yes.
Further, in Patent Document 1, individual iron core pieces are caulked and laminated via caulking dowels, and a rotor laminated iron core in which a permanent magnet piece is inserted in each magnet insertion hole is sandwiched between an upper die and a lower die, In a rotor manufacturing apparatus that fills the magnet insertion hole through a runner from a resin reservoir pot formed in the upper mold or the lower mold, the center of the caulking dowel is aligned with the center of the resin reservoir pot. Thus, a rotor manufacturing apparatus is disclosed in which the resin insertion into the magnet insertion hole is performed, and the resin reservoir pot is provided in the upper mold.

  And in paragraph 0017 of patent document 1, in the state where the rotor lamination iron core (rotor core) formed by laminating a plurality of iron core pieces is resin-sealed, it is sandwiched between the upper mold and the lower mold, It is described that a magnet insertion hole is filled with a sealing resin through a runner formed from the upper mold pod to the upper mold. Further, in FIGS. 1 and 4 of Patent Document 1, the pod is formed so as to penetrate the upper mold (that is, opened directly above the caulking dowel of the iron core piece), and the pod and the magnet insertion hole. The runner that communicates with the upper die opens to the lower surface of the upper die (that is, the runner opening faces the surface of the rotor core), and the cross section gradually decreases from the pod toward the magnet insertion hole. Is formed.

  As another mold 1 'in the prior art for manufacturing a rotor, there is a mold having a runner plate 3' below an upper mold 2 'as shown in FIG. The molding die 1 ′ performs transfer molding, and the upper die 2 ′ is formed so that the pod 10 ′ penetrates, as in Patent Document 1. However, the mold 1 ′ shown in FIG. 6 has a runner plate 3 ′ disposed below the upper mold 2 ′ (between the upper mold 2 ′ and the rotor core C). The runner plate 3 ′ 30 'is formed to penetrate. The runner 30 ′ is arranged so that its upper end opens into the pod 10 ′, and its lower end is the surface Ca of the rotor core C and opens around the housing recess H and at the end of the housing recess H. J is substantially vertical and is formed in a tapered shape so that the diameter gradually increases from the upper end toward the lower end. A gate portion G is formed between the end of the housing recess H and the corner portion 31 ′ of the runner 30 ′ (the portion that opens to the housing recess H of the runner 30 ′). The opening of the receiving recess H of the rotor core C is covered and closed by the lower surface 3a 'of the runner plate 3' except for the gate portion G.

  In the mold 1 ′ configured as described above, when the rotor R is manufactured, the magnet M is first accommodated in the accommodating recess H of the rotor core C, and the upper mold 2 ′ is inserted into the rotor core C via the runner plate 3 ′. On the other hand, it is relatively pressed and clamped. At this time, the lower surface 3 a ′ of the runner plate 3 ′ closes the opening of the accommodating recess H of the rotor core C except for the gate portion G, and the lower end of the runner 30 ′ is the surface Ca of the rotor core C and the accommodating recess H The gate portion G is configured so as to be open to the periphery of the housing and to communicate with the housing recess H. In this state, the sealing material P that has been put into the pod 10 ′ and plasticized is pressed by the plunger 4 ′ to fill the accommodating recess H from the pod 10 ′ through the runner 30 ′, and the sealing material H is solidified. Let The volume of the sealing material P that is inserted into the pod 10 ′ and pressed by the plunger 4 ′ fills the housing recess H and the runner 30 ′ in which the magnet M is accommodated, and the pod 10 ′. It is set so that only a fixed amount remains. When the sealing material P is solidified, the sealing material P filled in the runner 30 ′ is fixed to the surface of the rotor core C, and the sealing material P filled in the housing recess H is the lower surface 3a ′ of the runner plate 3 ′. It is in the state which adhered to.

  After the sealing material P is solidified, the plunger 4 ′ and the upper mold 2 ′ are raised, and then the runner plate 3 ′ is raised so as to be separated from the rotor core C. When the runner plate 3 ′ is raised, the sealing material P filled in the runner 30 ′ and fixed to the surface Ca of the rotor core C is peeled off from the surface of the rotor core C, and filled in the receiving recess H to be filled with the runner. The sealing material P fixed to the lower surface 3a ′ of the plate 3 ′ is peeled off from the lower surface 3a ′ of the runner plate 3 ′, and is filled into the sealing material P filled in the runner 30 ′ and the accommodating recess H. The encapsulating material P is separated at the gate portion G and gate-cut. The rotor R is manufactured with the goal that the sealing material P filled in the accommodation recess H forms the same plane as the surface of the rotor core C. The gate cut is not limited to transfer molding, and can be performed even in the case of other molding techniques such as injection molding as long as the molding die 1 'having the runner 30' is used.

JP 2011-125116 A

  Among the conventional techniques described above, in Patent Document 1, as described above, the pod is formed so as to penetrate the upper mold, and the runner opens to the lower surface of the upper mold continuously with the pod. Therefore, when the plunger is filled with the sealing resin in the magnet insertion hole and solidified, the sealing resin remaining in the pod and the sealing resin filled in the runner are applied to the surface of the rotor laminated core. It is in a fixed state. Thus, the sealing resin fixed to the rotor laminated core of the pod and the runner is generally peeled off from the surface of the rotor laminated core, and the sealing resin filled in the runner and the magnet insertion hole are filled. The sealing resin is separated at the gate portion that becomes the boundary between the runner and the magnet insertion hole (gate cut). However, Patent Document 1 does not describe anything about gate cut.

  Further, among the conventional techniques described above, in the mold 1 ′ configured as shown in FIG. 6, when the gate is cut, the lower surface of the runner plate 3 ′ and the surface Ca of the rotor core C are sealed as described above. Since the stopper P is fixed, stress concentrates on the corner 31 ′ of the runner 30 ′ that constitutes the gate portion G of the mold 1 ′, and the corner 31 ′ serves as a separation starting point SP in FIG. As shown, the separation boundary line SL enters the housing recess H side, the sealing material P filled in the housing recess H is lost, and the same plane as the surface Ca of the rotor core C cannot be formed. Thus, the rotor R from which the sealing material P is missing becomes eccentric and the rotation balance is deteriorated. As a result, vibration is generated when the electric motor is driven, the rotor R is damaged, and the life is shortened. A problem will occur.

  The present invention was made in order to solve the above-mentioned problems, and with a simple configuration, the gate part is accurately separated without losing the sealing material filled in the accommodating recess, and the gate is cut. The sealing material filled in the housing recess forms the same plane as the surface of the rotor core, thus providing a device capable of producing a rotor having a good rotation balance, suppressing vibration during driving, and having a long life. The purpose is to do.

In order to achieve the above object, the rotor manufacturing apparatus of the present invention closes the opening of the receiving recess of the rotor core on which the magnet is disposed, and opens to the periphery of the receiving recess of the rotor core and communicates with the receiving recess. Forming mold, sealing material filling means for filling the accommodating recess with the plasticized sealing material through the runner of the molding mold, and the solidified sealing material between the runner and the accommodating recess A rotor cutting device for manufacturing a rotor of an electric motor comprising a magnet arranged in a receiving recess of a rotor core and sealed with a sealing material. And the corner | angular part of the runner which comprises the gate part of the said shaping | molding die is shape | molded in the shape which can position the isolation | separation starting point which generate | occur | produces in a sealing material at the time of a gate cut on the non-rotor core side.
In order to achieve the above object, the rotor manufacturing apparatus of the present invention closes the opening of the receiving recess of the rotor core in which the magnet is disposed, and opens around the receiving recess of the rotor core and communicates with the receiving recess. A molding die for forming the runner, sealing material filling means for filling the housing recess with the plasticized sealing material via the runner of the molding die, and the runner and the housing recess for the solidified sealing material. A rotor for manufacturing a rotor for an electric motor comprising a magnet disposed in a housing recess of a rotor core and sealed with a sealing material. In the apparatus, the runner of the mold is formed so that a separation starting point generated in the sealing material when the gate is cut can be positioned at a corner of the accommodating recess constituting the gate portion. To do.

According to the present invention, the corner of the runner that constitutes the gate portion of the mold has the separation starting point generated in the sealing material at the time of gate cut as the anti-rotor core side (that is, the anti-containment recess side or the upstream side of the runner). The separation boundary line is prevented from entering the housing recess, and the sealing material protrudes slightly from the opening of the housing recess in the rotor core with high accuracy. Gate cut can be performed. Therefore, the sealing material filled in the housing recess forms substantially the same plane as the surface of the rotor core without losing the sealing material filled in the housing recess, so that the rotation balance is good and vibration during driving is suppressed. And a device capable of manufacturing a rotor having a long lifetime can be provided.
In addition, according to the present invention, the runner of the mold is molded so that the separation starting point generated in the sealing material when the gate is cut can be positioned at the corner of the accommodating recess that constitutes the gate portion. The separation boundary line can be prevented from entering the housing recess, and gate cutting can be performed with high accuracy to the extent that the sealing material slightly protrudes from the opening of the housing recess of the rotor core. Therefore, the sealing material filled in the housing recess forms substantially the same plane as the surface of the rotor core without losing the sealing material filled in the housing recess, so that the rotation balance is good and vibration during driving is suppressed. And a device capable of manufacturing a rotor having a long lifetime can be provided.

(Aspect of the Invention)
In the following, the invention that is claimed to be claimable in the present application (hereinafter referred to as “claimable invention”. The claimable invention is at least the “present invention” to the invention described in the claims. Some aspects of the present invention, including subordinate concept inventions of the present invention, superordinate concepts of the present invention, or inventions of different concepts) will be illustrated and described. As with the claims, each aspect is divided into sections, each section is numbered, and is described in a form that cites the numbers of other sections as necessary. This is for the purpose of facilitating the understanding of the claimable invention, and is not intended to limit the combinations of the constituent elements constituting the claimable invention to those described in the following sections. In other words, the claimable invention should be construed in consideration of the description accompanying each section, the description of the embodiments, etc., and as long as the interpretation is followed, another aspect is added to the form of each section. In addition, an aspect in which constituent elements are deleted from the aspect of each item can be an aspect of the claimable invention.

(1) A molding die that closes the opening of the receiving recess of the rotor core in which the magnet is disposed, and that forms a runner that opens around the receiving recess of the rotor core and communicates with the receiving recess, and plasticized sealing A sealing material filling means for filling the material into the housing recess through the runner of the mold, and a gate cutting means for separating the solidified sealing material at the gate portion between the runner and the housing recess. A rotor manufacturing apparatus for manufacturing a rotor of an electric motor formed by sealing a magnet disposed in a housing recess of a rotor core with a sealing material,
The rotor manufacturing apparatus, wherein a corner portion of the runner constituting the gate portion of the molding die is molded into a shape that allows the separation starting point generated in the sealing material when the gate is cut to be located on the side opposite to the rotor core.
Item (1) corresponds to claim 1. In the invention of the item (1), when manufacturing the rotor, the magnet is first accommodated in the accommodating recess of the rotor core, and the mold is relatively pressed against the rotor core and clamped. At this time, the molding die is positioned so as to close the opening of the housing recess of the rotor core, and the runner of the molding die is opened around the housing recess of the rotor core and communicates with the housing recess. A gate portion is formed between the runner and the accommodating recess. In this state, the encapsulating material plasticized by the encapsulating material filling means is filled into the housing recess through the runner and solidified. At this time, the sealing material filled in the runner is fixed to the surface of the rotor core, and the sealing material filled in the housing recess is fixed to the surface of the mold. Then, while releasing from a rotor core shaping | molding die, the sealing material solidified by the gate cut means is isolate | separated by the gate part between a runner and an accommodation recessed part. At this time, the corner portion of the runner that constitutes the gate portion of the molding die is molded into a shape that allows the separation starting point generated in the sealing material at the time of gate cutting to be located on the side opposite to the rotor core, thereby separating the sealing material. Is the corner of the runner constituting the gate portion of the mold, starting from the position on the side opposite to the rotor core, reaching the corner of the receiving recess across the gate portion, and then filling the gate portion onto the surface of the rotor core. Peeling of the sealing material that has been fixed is started from the corner of the housing recess, and peeling of the sealing material that has been filled in the housing recess from the corner of the housing recess and stuck to the surface of the mold is started. The Therefore, it is possible to prevent the separation boundary line from entering the housing recess and to perform the gate cutting with high accuracy so that the sealing material slightly protrudes from the opening of the housing recess of the rotor core. Therefore, the sealing material filled in the housing recess forms a substantially same plane as the surface of the rotor core without losing the sealing material filled in the housing recess, so that the rotation balance is good and vibration during driving is achieved. It is possible to provide a device that can suppress the rotation and manufacture a rotor having a long life.

(2) The rotor manufacturing apparatus according to (1), wherein a corner portion of the runner constituting the gate portion of the mold is formed in a C-plane shape.
Item (2) corresponds to claim 2. In the invention of the item (2), in the invention described in the item (1), the corner portion of the runner constituting the gate portion of the mold is formed in a C-surface shape, so that sealing is performed at the time of gate cutting. It is possible to realize a shape in which the separation starting point generated in the material can be positioned on the side opposite to the rotor core.

(3) The rotation according to (2), characterized in that corner portions of the runner constituting the gate portion of the mold are formed in a C-surface shape with a uniform width with respect to adjacent surfaces. Child manufacturing equipment.
In the invention described in the item (3), in the invention described in the item (2), the corners of the runner are molded into a C-surface shape with a uniform width with respect to the surfaces adjacent to each other, thereby sealing at the time of gate cutting. It is possible to realize a shape in which the separation starting point generated in the material can be positioned on the side opposite to the rotor core.

(4) The corner portion of the runner constituting the gate portion of the molding die is formed in a C-surface shape with a wider width on the opening side of the housing recess of the rotor core than the inner peripheral surface side of the runner. The rotor manufacturing apparatus according to item (2).
In the invention of the item (4), in the invention described in the item (2), the corner portion of the runner is formed in a C-surface shape with a wider width on the opening side of the accommodating recess of the rotor core than the inner peripheral surface side of the runner. By molding, it is possible to embody a shape that can position the separation starting point generated in the sealing material at the time of gate cutting on the side opposite to the rotor core.

(5) A mold that closes the opening of the receiving recess of the rotor core in which the magnet is disposed, and that forms a runner that opens around the receiving recess of the rotor core and communicates with the receiving recess, and plasticized sealing A sealing material filling means for filling the material into the housing recess through the runner of the mold, and a gate cutting means for separating the solidified sealing material at the gate portion between the runner and the housing recess. A rotor manufacturing apparatus for manufacturing a rotor of an electric motor formed by sealing a magnet disposed in a housing recess of a rotor core with a sealing material,
A rotor manufacturing apparatus, wherein the runner of the molding die is shaped so that a separation starting point generated in a sealing material at the time of gate cutting can be positioned at a corner of the housing recess constituting the gate portion. .
Item (5) corresponds to claim 3. In the invention of the item (5), when manufacturing the rotor, the magnet is first accommodated in the accommodating recess of the rotor core, and the mold is relatively pressed against the rotor core and clamped. At this time, the molding die is positioned so as to close the opening of the housing recess of the rotor core, and the runner of the molding die is opened around the housing recess of the rotor core and communicates with the housing recess. A gate portion is formed between the runner and the accommodating recess. In this state, the encapsulating material plasticized by the encapsulating material filling means is filled into the housing recess through the runner and solidified. At this time, the sealing material filled in the runner is fixed to the surface of the rotor core, and the sealing material filled in the housing recess is fixed to the surface of the mold. Then, while releasing from a rotor core shaping | molding die, the sealing material solidified by the gate cut means is isolate | separated by the gate part between a runner and an accommodation recessed part. At this time, the runner of the mold is molded so that the separation starting point generated in the sealing material at the time of gate cutting can be positioned at the corner of the housing recess constituting the gate portion. Separation starts from the corner of the housing recess, crosses the gate and reaches from the corner of the housing recess to the side opposite the rotor core (runner inner wall), and then fills the housing recess from the corner of the housing recess. Peeling of the sealing material fixed to the surface of the rotor is started, and peeling of the sealing material filled in the gate portion and fixed to the surface of the rotor core is started from the corner portion of the housing recess. Therefore, it is possible to prevent the separation boundary line from entering the housing recess and to perform the gate cutting with high accuracy so that the sealing material slightly protrudes from the opening of the housing recess of the rotor core. Therefore, the sealing material filled in the housing recess forms a substantially same plane as the surface of the rotor core without losing the sealing material filled in the housing recess, so that the rotation balance is good and vibration during driving is achieved. It is possible to provide a device that can suppress the rotation and manufacture a rotor having a long life.

(6) The rotor manufacturing apparatus according to item (5), wherein the runner of the mold is formed so as to be inclined with respect to a direction in which the gate portion is separated by the gate cutting means.
Item (6) corresponds to claim 4. In the invention of the item (6), in the invention described in the item (5), the runner is formed so as to be inclined with respect to the direction of separation of the gate portion by the gate cutting means, thereby generating the sealing material at the time of gate cutting. It is possible to embody that the separation starting point to be positioned can be positioned at the corner of the accommodating recess that constitutes the gate portion.

It is the elements on larger scale which were shown in order to demonstrate 1st Embodiment of the shaping | molding die by this invention. It is the elements on larger scale which were shown in order to demonstrate the modification of 1st Embodiment of the shaping | molding die by this invention. It is the fragmentary sectional view shown in order to demonstrate 2nd Embodiment of the shaping | molding die by this invention. FIG. 4 is a partially enlarged view of FIG. 3. It is the perspective view partially shown in order to demonstrate the general process which manufactures a rotor. It is a fragmentary sectional view of the shaping | molding die in a prior art. It is the elements on larger scale of FIG.

First, a first embodiment of a rotor manufacturing apparatus according to the present invention will be described based on FIG. 1 with reference to FIG.
The rotor manufacturing apparatus of the present invention is generally for manufacturing a rotor R of an electric motor formed by sealing a magnet M arranged in a housing recess H of a rotor core C with a sealing material P. The opening of the accommodating recess H of the rotor core C where the magnet M is disposed is closed, and the gate portion G is configured to open around the accommodating recess H on the surface Ca of the rotor core C and communicate with the accommodating recess H. The molding die 1 for forming the runner 30, the sealing material filling means 4 for filling the housing recess H with the plasticized sealing material P through the runner 30 of the molding die 1, and the solidified sealing material P Gate cutting means (to be described later) for separating the gate portion G between the runner 30 and the accommodating recess H, and the corner portion 31 of the runner 30 constituting the gate portion G of the mold 1 is gate cut. Sometimes the separation starting point SP generated in the sealing material P Is molded on the C surface shape 32 such that the stator core C side may be positioned on the opposite side.

  The mold 1 in this embodiment includes an upper mold 2 and a runner plate 3 disposed below the upper mold 2 as shown in FIG. The upper mold 2 is formed so that the pod 10 penetrates. The bottom of the pod 10 is constituted by the runner plate 3 with the upper mold 2 and the runner plate 3 being in close contact with each other. The sealing material filling means 4 includes a plunger. The plunger 4 moves up and down relatively with respect to the upper die 2, and is supported so as to rise together with the upper die 2 when the upper die 2 is lifted away from the rotor core C. The plunger 4 moves downward relative to the upper mold 2 to enter the pod 10 and pressurizes the plasticized sealing material P. When the plunger 4 moves upward relative to the upper mold 2, the plunger 4 comes out of the pod 10. Thus, a tablet of the sealing material P having a predetermined volume can be put into the pod 10.

  The runner plate 3 is supported so as to move downward with the upper die 2 so as to be close to the rotor core C, and to move upward so as to be separated from the rotor core C independently of the upper die 2. As described above, the runner plate 3 can be moved upward after the upper mold 2 is moved upward, whereby the gate cut means is configured. A runner 30 is formed in a portion of the runner plate 3 constituting the bottom of the pod 10 so as to penetrate therethrough. The runner 30 in this embodiment is formed in a taper shape in which the central axis J is substantially vertical and gradually increases in diameter from an upper opening communicating with the pod 10 toward a lower opening partially communicating with the housing recess H. . The lower opening of the runner 30 is substantially open to the surface Ca of the rotor core C in a state where the runner plate 3 is in close contact with the surface Ca of the rotor core C, and partially opens to the housing recess H. A portion of the runner 30 that opens to the housing recess H constitutes a gate portion G. The opening of the accommodating recess H in the surface Ca of the rotor core C is covered with the lower surface 3a of the runner plate 3 except for the gate portion G communicating with the runner 30 by bringing the runner plate 3 into close contact with the surface Ca of the rotor core C. Blocked.

  In the case of the embodiment shown in FIG. 1, the corner portion 31 (refer to the phantom line shown by a two-dot chain line) that constitutes the gate portion G of the runner 30 The C surface shape 32 is formed by chamfering to the lower surface 3a side closing the H with equal widths W30 and W3a.

  In the manufacturing apparatus configured as described above, when the rotor R is manufactured, the magnet M is first disposed in the housing recess H of the rotor core C, and the rotor core C is disposed in the lower mold (described later). The plate 3 and the upper die 2 are clamped by being relatively close to the rotor core C. Thereby, the bottom part of the pod 10 is constituted by the runner plate 3, and the runner 30 has a lower opening facing the surface Ca of the rotor core C except for a part constituting the gate part G, and the magnet M of the rotor core C is The disposed accommodation recess H is covered and closed by the lower surface 3 a of the runner plate 3 except for the portion constituting the gate portion G. The lower mold has substantially the same depth as the thickness of the rotor core C as long as the receiving recess H of the rotor core C is positioned and fixed so that the gate portion G can be formed between the rotor core C and the runner 30. Thus, the rotor core C can be provided with a recess (cavity), or the rotor core C can be sandwiched between the upper mold 2 and the runner plate 3.

  Subsequently, in a state where the plunger 4 is lifted so as to be extracted from the pod 10, a tablet of the sealing material P formed so as to have a predetermined volume is put into the pod 10. The tablet is plasticized by being heated by a heater disposed around the pod 10. From this state, the plunger 4 is moved downward relative to the upper mold 2 to enter the pod 10 to pressurize the plasticized sealing material P. As a result, the plasticized sealing material P is filled into the accommodation recess H from the pod 10 via the runner 30 and the gate portion G. After that, when the sealing material P is solidified, the sealing material P filled in the runner 30 is fixed to the surface Ca of the rotor core C, and the sealing material P filled in the housing recess H is The plate 3 is fixed to the lower surface 3 a of the plate 3.

  In this state, the upper die 2 is first moved up together with the plunger 4 without moving up the runner plate 3, and then the runner plate 3 is moved up to move the sealing material P filled in the runner 30 and the housing recess. A gate cut for separating the sealing material P accommodated in H by the gate portion G is performed.

  At this time, as described above, the sealing material P of the runner 30 is fixed to the surface Ca of the rotor core C, and the sealing material P of the housing recess H is fixed to the lower surface 3 a of the runner plate 3. The runner plate 3 is moved upward and separated from the rotor core C. Therefore, as indicated by arrows in FIG. 1, separation of the sealing material P is performed on the inner peripheral surface side of the C surface shape 32 of the runner 30 (on the side away from the surface Ca of the rotor core C, that is, opposite to the rotor core C). One corner located on the side) is started as the starting point SP. Then, the sealing material P is separated from the separation starting point SP at the gate portion G by the separation boundary line SL shown by a one-dot chain line in FIG. 1, and then peeled off from the surface Ca of the rotor core C and formed into the runner 30. The lower surface 3 a of the runner plate 3 is peeled off from the C surface shape 32.

  As a result, the manufactured rotor R has a state in which the sealing material P filled in the runner 30 is formed with a slight protrusion corresponding to the C-surface shape 32 on only a part of the gate portion G. Become. Therefore, it is possible to reliably prevent the separation boundary line SL from entering the accommodation recess H side as in the prior art (see FIG. 7), and thus the sealing material P filled in the accommodation recess H is lost. The rotor R can be manufactured without any problems.

  Next, a modification of the first embodiment of the present invention will be described with reference to FIG. In the description of this modification, the same or corresponding parts as those in the embodiment described with reference to FIG. 1 are denoted by the same reference numerals, the description thereof will be omitted, and only different parts will be described.

  In the first embodiment described above, the C-plane shape 32 of the runner 30 is formed from the corner portion 31 with the uniform widths W30 and W3a, whereas the runner 30 in the embodiment of this modification example. The C surface shape 32 is formed such that the width W3a on the lower surface 3a side of the runner plate 3 is wider than the width W30 on the inner peripheral surface side of the runner 30. In the embodiment shown in FIG. 2, when the width W30 on the inner peripheral surface side of the runner 30 is 1, the width W3a on the lower surface 3a side of the runner plate 3 is formed into a C surface shape 32 so that the ratio is about 3. Has been.

  Since the C-surface shape 32 is configured in this way, the sealing material P is separated from the C-surface shape of the runner 30 as shown by arrows in FIG. 2, as in the embodiment shown in FIG. 1. One corner located on the inner peripheral surface side 32 (the side away from the surface Ca of the rotor core C, that is, the side opposite to the rotor core C) is started as a starting point SP. Then, the sealing material P is separated from the separation starting point SP in the gate portion G by a separation boundary line SL shown by a one-dot chain line in FIG. 2, and then peeled off from the surface Ca of the rotor core C and formed into the runner 30. The lower surface 3 a of the runner plate 3 is peeled off from the C surface shape 32. Here, the separation boundary line SL shown in FIG. 2 is closer to a straight line than the bending angle of the separation boundary line SL shown in FIG. In addition, the angle of the C surface shape 32 peeled from the separation starting point SP of the sealing material P in FIG. 2 is more gradual than the angle of the C surface shape 32 peeled from the separation starting point SP of the sealing material P in FIG. That is, the angle formed with the lower surface 3a of the runner plate 3 is close to a straight line. Therefore, the height of the protrusion formed on only a part of the gate portion corresponding to the C-surface shape 32 of the runner 30 can be further reduced. Since the separation boundary line SL can be prevented from entering the accommodation recess H side as in the conventional technique (see FIG. 7), the sealing material filled in the accommodation recess is not lost.

Next, a second embodiment of the mold in the rotor manufacturing apparatus of the present invention will be described with reference to FIGS. In addition, the same code | symbol is attached | subjected about the part which is the same as that of 1st Embodiment demonstrated based on FIG. 1 and FIG. 2, or an equivalent, and the description is abbreviate | omitted, and only a different part will be demonstrated.
The rotor manufacturing apparatus of the present invention is generally for manufacturing a rotor R of an electric motor formed by sealing a magnet M arranged in a housing recess H of a rotor core C with a sealing material P. The opening of the accommodating recess H of the rotor core C where the magnet M is disposed is closed, and the gate portion G is configured to open around the accommodating recess H on the surface Ca of the rotor core C and communicate with the accommodating recess H. The molding die 1 for forming the runner 30, the sealing material filling means 4 for filling the housing recess H with the plasticized sealing material P through the runner 30 of the molding die 1, and the solidified sealing material P And a gate cutting means for separating the gate portion G between the runner 30 and the accommodating recess H, and the runner 30 of the mold 1 separates the gate portion G by the gate cutting means (the runner plate as described above). 3 movement direction) It is molded with inclined allowed angle alpha, the separation starting point SP generated in the sealing material P at the time of gate cutting, and is configured so as to position the corner portion Ha of the accommodation recess H constituting the gate portion G.

  The runner 30 in the first embodiment is formed so that the central axis J is substantially vertical (that is, parallel to the movement direction of the runner plate 3), whereas the runner 30 in this embodiment is The central axis J is formed at a predetermined angle α with respect to the vertical (that is, inclined with respect to the moving direction of the runner plate 3). It is to be noted that the runner 30 is formed in a tapered shape in which the diameter of the runner 30 gradually increases from the pod 10 side toward the rotor core C, as in the above-described embodiment.

  The inclination angle α (FIG. 4) of the runner 30 is such that the inner peripheral surface (the inner peripheral surface on the left side in FIGS. 3 and 4) opposite to the housing recess H side of the runner 30 is the lower surface 3a of the runner plate 3 ( (Horizontal plane) is set in the range of 50 degrees to 70 degrees, more preferably in the range of 55 degrees to 65 degrees.

  In the manufacturing apparatus configured as described above, when the plasticized sealing material P is filled from the pod 10 through the runner 30 and the gate portion G into the receiving recess H and solidified by pressurization of the plunger 4, The sealing material P filled in 30 is fixed to the surface Ca of the rotor core C, and the sealing material P filled in the housing recess H is fixed to the lower surface 3 a of the runner plate 3. ing. In this state, the upper mold 2 is first moved upward together with the plunger 4, and then the runner plate 3 is moved upward to seal the sealing material P filled in the runner 30 and the sealing material P accommodated in the accommodating recess H. Is cut at the gate part G.

  At this time, as described above, the sealing material P filled in the runner 30 is pushed upward by the inner peripheral surface of the runner 30 formed to be inclined at the angle α as the runner plate 3 moves upward, The sealing material P fixed to the surface Ca of the rotor core C of the runner 30 starts to be peeled off, and the separation of the sealing material P starts from the corner portion Ha side of the housing recess H constituting the gate portion G. That is, the separation starting point SP is generated at the corner Ha of the housing recess H. Then, the sealing material P is indicated by an alternate long and short dash line in FIG. 4 from the separation starting point SP in the gate portion G toward the position slightly above the corner portion 31 of the runner 30 from the receiving recess H side corner portion Ha of the runner 30. And then separated from the intermediate position of the inner peripheral surface of the runner 30 on the housing recess H side, and then the lower surface 3 a of the runner plate 3 is filled into the housing recess H from the corner portion 31 of the runner 30. It will be peeled off from the sealing material P.

  As a result, the manufactured rotor R is in a state in which a small amount of the sealing material P of the gate portion G filled in the runner 30 remains in the sealing material P filled in the housing recess H. Therefore, the separation boundary line SL can be prevented from entering the housing recess H side as in the prior art (see FIG. 7), so that the sealing material P filled in the housing recess H is not lost. The rotor R can be manufactured.

  The present invention is not limited to the case where the molding die is configured to be separated into the upper die and the runner plate, and the sealing material filled in the runner is sealed in the accommodating recess. The upper die and the runner plate can be integrally formed as long as the material and the gate portion can be separated. Further, the present invention is not limited to communicating a single runner with one pod, and a plurality of one pod can be arranged according to the number of receiving recesses where the magnets of the rotor core are arranged and the arrangement of receiving recesses. The runners can be configured to communicate with each other, and a single or a plurality of runners can be configured to communicate with the plurality of pods. The sealing material is not limited to the thermosetting resin, and can be selected according to the conditions of the rotor to be manufactured as long as it is solidified after being plasticized and filled in the housing recess. Further, the present invention is not limited to transfer molding in which a tablet molded to have a predetermined volume as a sealing material is put into a pod of a molding die to be plasticized and filled. For example, a heating cylinder different from the molding die It is also possible to plasticize the sealing material and to inject a predetermined volume.

  R: Rotor, M: Magnet, C: Rotor core, Ca: Rotor core surface, H: Housing recess, Ha: Corner of housing recess, P: Sealing material, G: Gate part, 1: Mold, 2: Upper mold, 3: runner plate, 3a: back surface of runner plate, 4: plunger (sealing material filling means), 10: pod, 30: runner, 31: corner of runner, 32: C surface shape, SP: separation Starting point, SL: Separation boundary line, J: Center axis of runner

Claims (4)

A molding die that closes the opening of the receiving recess of the rotor core in which the magnet is disposed, and that forms a runner that opens around the receiving recess of the rotor core and communicates with the receiving recess, and a plasticized sealing material A rotor core comprising: a sealing material filling means for filling the receiving recess through the runner of the molding die; and a gate cutting means for separating the solidified sealing material at the gate portion between the runner and the receiving recess. A rotor manufacturing apparatus for manufacturing a rotor of an electric motor formed by sealing a magnet disposed in the housing recess with a sealing material,
The rotor manufacturing apparatus, wherein a corner portion of the runner constituting the gate portion of the molding die is molded into a shape that allows the separation starting point generated in the sealing material when the gate is cut to be located on the side opposite to the rotor core.   2. The rotor manufacturing apparatus according to claim 1, wherein corners of the runner constituting the gate portion of the mold are formed in a C-plane shape. 3. A molding die that closes the opening of the receiving recess of the rotor core in which the magnet is disposed, and that forms a runner that opens around the receiving recess of the rotor core and communicates with the receiving recess, and a plasticized sealing material A rotor core comprising: a sealing material filling means for filling the receiving recess through the runner of the molding die; and a gate cutting means for separating the solidified sealing material at the gate portion between the runner and the receiving recess. A rotor manufacturing apparatus for manufacturing a rotor of an electric motor formed by sealing a magnet disposed in the housing recess with a sealing material,
A rotor manufacturing apparatus, wherein the runner of the molding die is shaped so that a separation starting point generated in a sealing material at the time of gate cutting can be positioned at a corner of the housing recess constituting the gate portion. .   The rotor manufacturing apparatus according to claim 3, wherein the runner of the mold is formed so as to be inclined with respect to a direction in which the gate portion is separated by the gate cutting means.

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