JP2018201295A - Method for manufacturing rotor - Google Patents
Method for manufacturing rotor Download PDFInfo
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- JP2018201295A JP2018201295A JP2017104644A JP2017104644A JP2018201295A JP 2018201295 A JP2018201295 A JP 2018201295A JP 2017104644 A JP2017104644 A JP 2017104644A JP 2017104644 A JP2017104644 A JP 2017104644A JP 2018201295 A JP2018201295 A JP 2018201295A
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- field magnet
- shaft
- magnet
- core portion
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 title claims abstract description 12
- 229920005989 resin Polymers 0.000 claims abstract description 50
- 239000011347 resin Substances 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 43
- 230000015572 biosynthetic process Effects 0.000 claims description 17
- 238000000465 moulding Methods 0.000 claims description 16
- 239000000843 powder Substances 0.000 claims description 11
- 238000002347 injection Methods 0.000 description 12
- 239000007924 injection Substances 0.000 description 12
- 230000002093 peripheral effect Effects 0.000 description 12
- 239000011230 binding agent Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 239000004734 Polyphenylene sulfide Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229920000069 polyphenylene sulfide Polymers 0.000 description 3
- KPLQYGBQNPPQGA-UHFFFAOYSA-N cobalt samarium Chemical compound [Co].[Sm] KPLQYGBQNPPQGA-UHFFFAOYSA-N 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 229910000938 samarium–cobalt magnet Inorganic materials 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- PRQMIVBGRIUJHV-UHFFFAOYSA-N [N].[Fe].[Sm] Chemical compound [N].[Fe].[Sm] PRQMIVBGRIUJHV-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 229910001172 neodymium magnet Inorganic materials 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Landscapes
- Permanent Field Magnets Of Synchronous Machinery (AREA)
Abstract
Description
本発明は、ロータの製造方法に関する。 The present invention relates to a method for manufacturing a rotor.
従来、ブラシレスモータのロータは、シャフトと、シャフトの外周に設けられた環状の界磁磁石とを有している。界磁磁石は永久磁石であり、界磁磁石の内側とシャフトとの間に充填された樹脂によりシャフトと一体化される（例えば、特許文献１参照）。 Conventionally, a rotor of a brushless motor has a shaft and an annular field magnet provided on the outer periphery of the shaft. The field magnet is a permanent magnet, and is integrated with the shaft by a resin filled between the inside of the field magnet and the shaft (see, for example, Patent Document 1).
ところで、環状の界磁磁石の内側に樹脂を充填する場合、樹脂の注入圧力が低いと、磁樹脂が界磁磁石に密着せず、一体化されない虞がある。一方、樹脂の注入圧力が高いと、注入圧力が界磁磁石を広げる方向の応力となって界磁磁石が割れる虞がある。樹脂の注入圧力に耐えるように界磁磁石を厚くすると、磁石が高価となる。 By the way, when the resin is filled inside the annular field magnet, if the injection pressure of the resin is low, the magnetic resin may not adhere to the field magnet and may not be integrated. On the other hand, if the injection pressure of the resin is high, there is a risk that the injection pressure will become a stress in the direction of spreading the field magnet and the field magnet will break. If the field magnet is thickened to withstand the resin injection pressure, the magnet becomes expensive.
本発明は上記問題点を解決するためになされたものであって、その目的は、円筒形状の界磁磁石と、界磁磁石の内側の樹脂とを一体化できるロータの製造方法を提供することにある。 The present invention has been made to solve the above problems, and an object of the present invention is to provide a method for manufacturing a rotor capable of integrating a cylindrical field magnet and a resin inside the field magnet. It is in.
上記課題を解決するロータの製造方法は、シャフトと、前記シャフトの外周に配置され、樹脂材よりなる円筒形状のコア部と、前記コア部の外周に配置され、磁石粉と樹脂材を含み、極異方着磁された円筒形状の界磁磁石とからなるロータ構造の製造方法であって、前記コア部と前記界磁磁石のいずれか一方を第１形成物とし、前記コア部と前記界磁磁石のいずれか他方を第２形成物とし、前記第１形成物を金型内に配置し、前記第１形成物と前記金型とにより形成される空間に材料を充填して前記第２形成物を成型する。 A method of manufacturing a rotor that solves the above problems includes a shaft, a cylindrical core portion that is disposed on the outer periphery of the shaft, and is disposed on the outer periphery of the core portion, and includes magnet powder and a resin material, A method of manufacturing a rotor structure comprising a cylindrical field magnet having an anisotropically magnetized shape, wherein either one of the core part and the field magnet is a first formation, and the core part and the field Either one of the magnets is used as a second formed product, the first formed product is placed in a mold, and a space formed by the first formed product and the mold is filled with a material to form the second formed product. Mold the formation.
この構成によれば、一方を金型内に配置し、その金型に材料を注入してコア部と界磁磁石とを一体化するので、注入する材料の圧力によって２つの樹脂材の間の密着が高まり、確実な一体化が図れる。 According to this configuration, one is placed in the mold, and the core portion and the field magnet are integrated by injecting the material into the mold, so the pressure between the two resin materials is increased by the pressure of the injected material. Adhesion increases and reliable integration can be achieved.
上記のロータの製造方法において、前記第１形成物は前記界磁磁石であり、前記第２形成物は前記コア部であり、前記界磁磁石を前記金型内に配置し、前記界磁磁石の中心に前記シャフトを配置し、前記シャフトと前記界磁磁石との間の空間に前記材料を充填して前記コア部を成型することが好ましい。 In the method of manufacturing a rotor, the first formation is the field magnet, the second formation is the core, the field magnet is disposed in the mold, and the field magnet It is preferable that the core is formed by arranging the shaft at the center of the core and filling the space between the shaft and the field magnet with the material.
この構成によれば、割れ易い界磁磁石を先に加工し金型と接触させることでインサート時の圧力を受けたときの界磁磁石の割れが抑制される。
上記のロータの製造方法において、金型入子を第２の金型内に配置し、前記金型入子の内面と前記第２の金型とにより形成される空間に前記磁石粉と前記樹脂材を含む磁石材料を充填して前記界磁磁石を成型し、前記第１形成物としての前記界磁磁石と前記金型入子とを前記金型内に配置することが好ましい。
According to this configuration, the field magnet is easily cracked when it is subjected to pressure during insertion by first processing the easily breakable field magnet and bringing it into contact with the mold.
In the rotor manufacturing method, a mold insert is disposed in a second mold, and the magnet powder and the resin are formed in a space formed by an inner surface of the mold insert and the second mold. It is preferable that the field magnet is molded by filling a magnet material including a material, and the field magnet as the first formed product and the mold insert are disposed in the mold.
この構成によれば、金型入子の内面の側に界磁磁石を形成し、コア部を成型する金型に金型入子及び界磁磁石を配置（インサート）することにより、割れ易い界磁磁石のインサートが容易となる。 According to this configuration, a field magnet is formed on the inner surface side of the mold insert, and the mold insert and the field magnet are arranged (inserted) in the mold for molding the core portion, thereby easily breaking the field. Magnet magnet insertion is facilitated.
上記のロータの製造方法において、前記第１形成物は前記コア部であり、前記第２形成物は前記界磁磁石であり、中心に前記シャフトが一体化された前記コア部を前記金型内に配置し、前記コア部と前記金型との間の空間に前記材料を充填して前記界磁磁石を成型することが好ましい。 In the above-described rotor manufacturing method, the first formation is the core portion, the second formation is the field magnet, and the core portion integrated with the shaft at the center is placed in the mold. Preferably, the field magnet is molded by filling the material in a space between the core portion and the mold.
この構成によれば、割れ易い界磁磁石を後に成型することで、界磁磁石がコア部材を成型する樹脂の圧力を受けないので、界磁磁石に割れの発生が抑制される。
上記のロータの製造方法において、前記シャフトを第２の金型内に配置し、前記シャフトと前記第２の金型との間の空間に樹脂を充填し、中心に前記シャフトが一体化された前記コア部を成型し、前記第１形成物としてのコア部材と前記シャフトとを前記金型内に配置することが好ましい。
According to this configuration, since the field magnet is not subjected to the pressure of the resin for molding the core member by forming the field magnet that is easily cracked later, occurrence of cracks in the field magnet is suppressed.
In the above rotor manufacturing method, the shaft is disposed in a second mold, a space between the shaft and the second mold is filled with resin, and the shaft is integrated in the center. Preferably, the core part is molded, and the core member as the first formed product and the shaft are disposed in the mold.
この構成によれば、金型を基準としてシャフト及びコア部を配置し、コア部の外周に界磁磁石を成型することで、シャフト及びコア部と界磁磁石とが容易に同軸状となる。 According to this configuration, the shaft and the core portion are arranged on the basis of the mold, and the field magnet is molded on the outer periphery of the core portion, so that the shaft, the core portion, and the field magnet are easily coaxial.
本発明のロータの製造方法によれば、円筒形状の界磁磁石と、界磁磁石の内側の樹脂とを一体化できるロータの製造方法を提供できる。 According to the method for manufacturing a rotor of the present invention, it is possible to provide a method for manufacturing a rotor capable of integrating a cylindrical field magnet and a resin inside the field magnet.
以下、各形態を説明する。
なお、添付図面は、理解を容易にするために構成要素を拡大して示している場合がある。構成要素の寸法比率は実際のものと、または別の図面中のものと異なる場合がある。また、断面図では、理解を容易にするために、一部の構成要素のハッチングを省略している場合がある。
Hereinafter, each embodiment will be described.
In the accompanying drawings, components may be shown in an enlarged manner for easy understanding. The dimensional ratios of the components may be different from the actual ones or in other drawings. Further, in the cross-sectional view, some components may not be hatched for easy understanding.
図１（ｂ）に示すように、モータ１０は、環状のステータ１１と、ステータ１１の内側に配置されたロータ１２とを有している。
図１（ａ）に示すように、ロータ１２は、シャフト２１と、コア部２２と、界磁磁石２３とを有している。
As shown in FIG. 1B, the motor 10 includes an annular stator 11 and a rotor 12 disposed inside the stator 11.
As shown in FIG. 1A, the rotor 12 has a shaft 21, a core portion 22, and a field magnet 23.
シャフト２１は円柱状に形成されている。シャフト２１は金属製である。
コア部２２は、円環状に形成されている。コア部２２は、例えば熱可塑性の樹脂よりなる。この樹脂は、例えばＰＰＳ（ポリフェニレンサルファイド）樹脂、ポリアミド樹脂（例えば、ナイロン１２）、等である。
The shaft 21 is formed in a cylindrical shape. The shaft 21 is made of metal.
The core part 22 is formed in an annular shape. The core part 22 is made of, for example, a thermoplastic resin. This resin is, for example, a PPS (polyphenylene sulfide) resin, a polyamide resin (for example, nylon 12), or the like.
界磁磁石２３は、円環状に形成されている。
図１（ｂ）に示すように、界磁磁石２３は、外周面２３ａにおいて、周方向にＮ極とＳ極とが交互に並ぶ極異方性に着磁されている。つまり、本実施形態の界磁磁石２３は、「外周極異方」に着磁されている。図１（ｂ）に示す矢印は、磁力の方向を示す。
The field magnet 23 is formed in an annular shape.
As shown in FIG. 1B, the field magnet 23 is magnetized on the outer peripheral surface 23a with polar anisotropy in which N poles and S poles are alternately arranged in the circumferential direction. In other words, the field magnet 23 of the present embodiment is magnetized in “peripheral pole anisotropic”. The arrow shown in FIG. 1B indicates the direction of magnetic force.
界磁磁石２３は、例えばボンド磁石（プラスチックマグネット、ゴムマグネット等）よりなる。ボンド磁石は、磁石粉をバインダで固めて成形した複合材料磁石である。磁石粉は、例えば、フェライト磁石、サマリウム鉄窒素（Ｓｍ−Ｆｅ−Ｎ）系磁石、サマリウムコバルト（Ｓｍ−Ｃｏ）系磁石、ネオジム磁石等の磁石粉である。バインダは、例えば熱可塑性樹脂（例えばＰＰＳ）、等の樹脂材である。 The field magnet 23 is made of, for example, a bond magnet (plastic magnet, rubber magnet, etc.). The bond magnet is a composite magnet formed by solidifying magnet powder with a binder. The magnet powder is, for example, a magnet powder such as a ferrite magnet, a samarium iron nitrogen (Sm—Fe—N) magnet, a samarium cobalt (Sm—Co) magnet, or a neodymium magnet. The binder is a resin material such as a thermoplastic resin (for example, PPS).
つまり、ロータ１２は、シャフト２１と、樹脂を含む材料からなるコア部２２及び界磁磁石２３とにより構成されている。従って、金型を用い、コア部２２と界磁磁石２３とを成形することにより、コア部２２と界磁磁石２３とを密着させて一体とすることができる。例えば、金型内にコア部２２を配設（インサート）し、界磁磁石２３の材料を金型内に射出して成形する。また、金型内に界磁磁石２３を配設し、コア部２２の材料を金型内に射出して成形する。この金型内にシャフト２１を配設（インサート）することにより、シャフト２１とコア部２２と界磁磁石２３とを一体化したロータ１２が得られる。 That is, the rotor 12 includes the shaft 21, the core portion 22 and the field magnet 23 made of a material containing resin. Therefore, the core 22 and the field magnet 23 can be brought into close contact with each other by molding the core 22 and the field magnet 23 using a mold. For example, the core portion 22 is disposed (inserted) in the mold, and the material of the field magnet 23 is injected into the mold and molded. Further, the field magnet 23 is disposed in the mold, and the material of the core portion 22 is injected into the mold and molded. By disposing (inserting) the shaft 21 in the mold, the rotor 12 in which the shaft 21, the core portion 22, and the field magnet 23 are integrated is obtained.
（第１実施形態）
上記のロータ１２の製造方法の第１実施形態を説明する。
図２に示すように、先ず磁石材料を磁場配向成形して図１（ａ）に示す界磁磁石２３を成型する。次に、界磁磁石２３とシャフト２１を金型内に配置（インサート）し、その金型に樹脂を充填して図１（ａ）に示すコア部２２を成型する。これにより、シャフト２１とコア部２２と界磁磁石２３とを一体化する。
(First embodiment)
1st Embodiment of the manufacturing method of said rotor 12 is described.
As shown in FIG. 2, the magnet material is first subjected to magnetic field orientation molding to form the field magnet 23 shown in FIG. Next, the field magnet 23 and the shaft 21 are disposed (inserted) in the mold, and the mold is filled with a resin to mold the core portion 22 shown in FIG. Thereby, the shaft 21, the core part 22, and the field magnet 23 are integrated.
この製造方法を順次説明する。
図３（ａ）に示すように、金型３０内に金型入子４１を配置する。金型３０は、第１金型３１（例えば可動金型）と第２金型３２（例えば固定金型）とを含む。図３（ａ）は、第１金型３１と第２金型３２とを型閉めした状態を示す。金型入子４１は、円筒状の内周面を有している。この金型入子４１は、例えば円環状に形成されている。第１金型３１を第２金型３２（例えば固定金型）に対して型閉めする。そして、図３（ｂ）に示すように、第１金型３１と金型入子４１との間の空間３０ａ、つまり第１金型３１と第２金型３２と金型入子４１とにより形成される空間３０ａに、磁石材料４３を充填する。磁石材料４３は、磁石粉とバインダを含む。そして、配向用磁石３５により金型３０内の磁石材料４３に磁場をかけ、界磁磁石２３を成形する。配向用磁石３５は、例えば電磁石や永久磁石である。図３（ｃ）に示すように、界磁磁石２３と金型入子４１を図３（ｂ）に示す第１金型３１から取り出す。
This manufacturing method will be described sequentially.
As shown in FIG. 3A, a mold insert 41 is disposed in the mold 30. The mold 30 includes a first mold 31 (for example, a movable mold) and a second mold 32 (for example, a fixed mold). FIG. 3A shows a state where the first mold 31 and the second mold 32 are closed. The mold insert 41 has a cylindrical inner peripheral surface. The mold insert 41 is formed in an annular shape, for example. The first mold 31 is closed with respect to the second mold 32 (for example, a fixed mold). Then, as shown in FIG. 3B, a space 30a between the first mold 31 and the mold insert 41, that is, the first mold 31, the second mold 32, and the mold insert 41. The space 30a to be formed is filled with the magnet material 43. The magnet material 43 includes magnet powder and a binder. A magnetic field is applied to the magnet material 43 in the mold 30 by the orientation magnet 35 to form the field magnet 23. The orientation magnet 35 is, for example, an electromagnet or a permanent magnet. As shown in FIG. 3C, the field magnet 23 and the mold insert 41 are taken out from the first mold 31 shown in FIG.
図４（ａ）に示すように、金型５０に、界磁磁石２３及び金型入子４１を配置（インサート）するとともに、シャフト２１を界磁磁石２３の軸中心と同軸上に配置（インサート）する。金型５０は、第１金型５１（例えば可動金型）と第２金型５２（例えば固定金型）とを含む。図４（ａ）は、第１金型５１と第２金型５２とを型閉めした状態を示す。シャフト２１と界磁磁石２３及び金型入子４１は、金型５０を基準として配置（インサート）される。従って、シャフト２１は、金型５０により界磁磁石２３の軸中心に精度よく配置される。 As shown in FIG. 4A, the field magnet 23 and the mold insert 41 are disposed (inserted) in the mold 50, and the shaft 21 is disposed coaxially with the axial center of the field magnet 23 (inserted). ) The mold 50 includes a first mold 51 (for example, a movable mold) and a second mold 52 (for example, a fixed mold). FIG. 4A shows a state where the first mold 51 and the second mold 52 are closed. The shaft 21, the field magnet 23, and the mold insert 41 are arranged (inserted) with reference to the mold 50. Therefore, the shaft 21 is accurately placed at the axial center of the field magnet 23 by the mold 50.
次に、図４（ｂ）に示すように、シャフト２１と界磁磁石２３との間の空間５０ａ、つまり、第１金型５１と第２金型５２とシャフト２１と界磁磁石２３とにより形成される空間５０ａに、樹脂４２を充填し、樹脂４２を硬化してコア部２２を成形する。そして、図４（ｃ）に示すように、金型入子４１からロータ１２を取り外す。 Next, as shown in FIG. 4B, a space 50 a between the shaft 21 and the field magnet 23, that is, the first mold 51, the second mold 52, the shaft 21, and the field magnet 23. The space 42 to be formed is filled with the resin 42 and the resin 42 is cured to form the core portion 22. Then, the rotor 12 is removed from the mold insert 41 as shown in FIG.
（作用）
図４（ａ）に示すように、第１金型５１に、界磁磁石２３及び金型入子４１を配置する。このため、割れ易い界磁磁石２３を容易に第１金型５１に配置（インサート）することができる。
(Function)
As shown in FIG. 4A, the field magnet 23 and the mold insert 41 are arranged in the first mold 51. For this reason, the field magnet 23 that is easily broken can be easily placed (inserted) in the first mold 51.
また、金型入子４１の内側に界磁磁石２３が成型されている。このため、界磁磁石２３と金型入子４１との間に隙間が生じない。そして、図４（ｂ）に示すように、界磁磁石２３とシャフト２１との間に樹脂４２を充填する。 A field magnet 23 is molded inside the mold insert 41. For this reason, there is no gap between the field magnet 23 and the mold insert 41. Then, as shown in FIG. 4B, a resin 42 is filled between the field magnet 23 and the shaft 21.
この工程により、シャフト２１と界磁磁石２３とに対してコア部２２が一体的に成形される。この工程において、コア部２２を成形する樹脂４２を金型５０内に注入（射出）する。樹脂４２の注入圧力によって、注入する樹脂４２と界磁磁石２３の内周面との間と、注入する樹脂４２とシャフト２１の外周面との間の密着性が高く、シャフト２１とコア部２２と界磁磁石２３とが一体的となる。 Through this process, the core portion 22 is integrally formed with the shaft 21 and the field magnet 23. In this step, a resin 42 for molding the core portion 22 is injected (injected) into the mold 50. Due to the injection pressure of the resin 42, the adhesiveness between the resin 42 to be injected and the inner peripheral surface of the field magnet 23 and between the resin 42 to be injected and the outer peripheral surface of the shaft 21 is high. And the field magnet 23 are integrated.
コア部２２を成型する樹脂４２を充填する際の注入圧力は、界磁磁石２３の外周に配置された金型入子４１により受け止められる。このため、界磁磁石２３が注入圧力によって拡径することが抑制される、つまりコア部２２の成型時における界磁磁石２３の割れが抑制される。 The injection pressure when filling the resin 42 for molding the core portion 22 is received by the mold insert 41 disposed on the outer periphery of the field magnet 23. For this reason, the diameter of the field magnet 23 is suppressed from being increased by the injection pressure, that is, cracking of the field magnet 23 during the molding of the core portion 22 is suppressed.
図４（ａ）に示すように、シャフト２１と界磁磁石２３及び金型入子４１は、金型５０を基準としてその金型５０内に配置される。従って、シャフト２１と界磁磁石２３とを同軸状に精度よく配置される。 As shown in FIG. 4A, the shaft 21, the field magnet 23, and the mold insert 41 are disposed in the mold 50 with respect to the mold 50. Therefore, the shaft 21 and the field magnet 23 are accurately arranged coaxially.
このようにして得られるロータ１２は、シャフト２１に対して樹脂製のコア部２２と、樹脂材のバインダと磁石粉とを含む界磁磁石２３とからなる。従って、このロータ１２は、金属製のカバーや金属製のコア部を有していないため、イナーシャが小さい。また、このロータ１２は、金属製のカバーを必要としないため、図１（ｂ）に示すステータ１１に対して磁気ギャップが小さいロータ１２とすることができる。このため、安価で軽量であり、高い応答性のモータを提供できる。また、金属製のカバーを用いた場合、ロータとステータとの間の磁気ギャップが大きく、磁気損失となる。一方、本実施形態では、図１（ｂ）に示すロータ１２の界磁磁石２３とステータ１１との間の磁気ギャップが小さく、磁気損失の増加を抑制することができる。 The rotor 12 thus obtained includes a resin core portion 22 with respect to the shaft 21, and a field magnet 23 including a resin binder and magnet powder. Accordingly, since the rotor 12 does not have a metal cover or a metal core, inertia is small. In addition, since the rotor 12 does not require a metal cover, the rotor 12 can have a smaller magnetic gap than the stator 11 shown in FIG. For this reason, an inexpensive, lightweight, and highly responsive motor can be provided. Further, when a metal cover is used, the magnetic gap between the rotor and the stator is large, resulting in magnetic loss. On the other hand, in this embodiment, the magnetic gap between the field magnet 23 of the rotor 12 and the stator 11 shown in FIG. 1B is small, and an increase in magnetic loss can be suppressed.
以上記述したように、本実施形態によれば、以下の効果を奏する。
（１−１）金型入子４１の内側に界磁磁石２３が成型されている。このため、界磁磁石２３と金型入子４１との間に隙間が生じない。そして、界磁磁石２３とシャフト２１との間に樹脂４２を充填し、コア部２２を成型する。樹脂４２を金型５０内に注入（射出）する。樹脂４２の注入圧力によって、注入する樹脂４２と界磁磁石２３の内周面との間と、注入する樹脂４２とシャフト２１の外周面との間の密着性が高く、シャフト２１とコア部２２と界磁磁石２３とを一体化できる。
As described above, according to the present embodiment, the following effects can be obtained.
(1-1) A field magnet 23 is molded inside the mold insert 41. For this reason, there is no gap between the field magnet 23 and the mold insert 41. Then, a resin 42 is filled between the field magnet 23 and the shaft 21 to mold the core portion 22. Resin 42 is injected (injected) into the mold 50. Due to the injection pressure of the resin 42, the adhesiveness between the resin 42 to be injected and the inner peripheral surface of the field magnet 23 and between the resin 42 to be injected and the outer peripheral surface of the shaft 21 is high. And the field magnet 23 can be integrated.
（１−２）金型入子４１の内側に界磁磁石２３が成型されている。コア部２２を成型する第１金型５１に、界磁磁石２３及び金型入子４１を配置する。このため、割れ易い界磁磁石２３を容易に第１金型５１に配置（インサート）することができる。 (1-2) A field magnet 23 is molded inside the mold insert 41. The field magnet 23 and the mold insert 41 are arranged in the first mold 51 for molding the core portion 22. For this reason, the field magnet 23 that is easily broken can be easily placed (inserted) in the first mold 51.
（１−３）コア部２２を成型する樹脂４２を充填する際の注入圧力は、界磁磁石２３の外周に配置された金型入子４１により受け止められる。このため、界磁磁石２３が注入圧力によって拡径することが抑制される、つまりコア部２２の成型時における界磁磁石２３の割れを抑制できる。 (1-3) The injection pressure when filling the resin 42 for molding the core portion 22 is received by the mold insert 41 arranged on the outer periphery of the field magnet 23. For this reason, it is possible to suppress the field magnet 23 from being expanded in diameter by the injection pressure, that is, it is possible to suppress cracking of the field magnet 23 when the core portion 22 is molded.
（１−４）シャフト２１と界磁磁石２３及び金型入子４１は、金型５０を基準としてその金型５０内に配置される。従って、シャフト２１と界磁磁石２３とを同軸状に精度よく配置できる。 (1-4) The shaft 21, the field magnet 23, and the mold insert 41 are arranged in the mold 50 with respect to the mold 50. Therefore, the shaft 21 and the field magnet 23 can be accurately arranged coaxially.
（１−５）ロータ１２は、シャフト２１に対して樹脂製のコア部２２と、樹脂材のバインダと磁石粉とを含む界磁磁石２３とからなる。従って、イナーシャの小さなロータ１２を得ることができる。 (1-5) The rotor 12 includes a resin core portion 22 with respect to the shaft 21, and a field magnet 23 including a resin binder and magnet powder. Therefore, the rotor 12 with small inertia can be obtained.
（第２実施形態）
次に、上記のロータ１２の製造方法の第２実施形態を説明する。
図５に示すように、先ずシャフトを配置（インサート）した金型に樹脂を充填して図１（ａ）に示すシャフト２１とコア部２２とを一体成形する。次いで、シャフト２１及びコア部２２を次の金型に配置し、コア部２２と金型との間に充填した磁石材料４３を磁場配向成形して図１（ａ）に示す界磁磁石をコア部２２と一体的に形成する。
(Second Embodiment)
Next, a second embodiment of the method for manufacturing the rotor 12 will be described.
As shown in FIG. 5, first, a mold having a shaft disposed (inserted) is filled with resin, and the shaft 21 and the core portion 22 shown in FIG. Next, the shaft 21 and the core portion 22 are arranged in the next mold, and the magnet material 43 filled between the core portion 22 and the mold is magnetically oriented and the field magnet shown in FIG. It is formed integrally with the part 22.
この製造方法を順次説明する。
図６（ａ）に示すように、金型６０内にシャフト２１を配置する。金型６０は、第１金型６１（例えば可動金型）と第２金型６２（例えば固定金型）とを含む。図６（ａ）は、第１金型６１と第２金型６２とを型閉めした状態を示す。そして、図６（ｂ）に示すように、第１金型６１とシャフト２１との間の空間６０ａ、つまり、第１金型６１と第２金型６２とシャフト２１とにより形成される円環状の空間６０ａに、樹脂４２を充填し、樹脂４２を硬化し、シャフト２１と一体的なコア部２２を成形する。そして、図６（ｃ）に示すように、シャフト２１及びコア部２２を図６（ｂ）に示す金型６０から取り出す。
This manufacturing method will be described sequentially.
As shown in FIG. 6A, the shaft 21 is disposed in the mold 60. The mold 60 includes a first mold 61 (for example, a movable mold) and a second mold 62 (for example, a fixed mold). FIG. 6A shows a state where the first mold 61 and the second mold 62 are closed. 6B, a space 60a between the first mold 61 and the shaft 21, that is, an annular shape formed by the first mold 61, the second mold 62, and the shaft 21 is formed. The space 42a is filled with the resin 42, the resin 42 is cured, and the core portion 22 integrated with the shaft 21 is formed. And as shown in FIG.6 (c), the shaft 21 and the core part 22 are taken out from the metal mold | die 60 shown in FIG.6 (b).
図７（ａ）に示すように、金型７０内にシャフト２１及びコア部２２を配置（インサート）する。金型７０は、第１金型７１（例えば可動金型）と第２金型７２（例えば固定金型）とを含む。図７（ａ）は、第１金型７１と第２金型７２とを型閉めした状態を示す。 As shown in FIG. 7A, the shaft 21 and the core portion 22 are arranged (inserted) in the mold 70. The mold 70 includes a first mold 71 (for example, a movable mold) and a second mold 72 (for example, a fixed mold). FIG. 7A shows a state in which the first mold 71 and the second mold 72 are closed.
図７（ｂ）に示すように、第１金型７１とコア部２２との間の空間７０ａ、つまり第１金型７１と第２金型７２とコア部２２とにより形成される空間７０ａに、磁石材料４３を充填する。磁石材料４３は、磁石粉とバインダを含む。そして、配向用磁石７５により金型７０内の磁石材料４３に磁場をかけ、界磁磁石２３を成形する。配向用磁石７５は、例えば電磁石や永久磁石である。 As shown in FIG. 7B, in the space 70a between the first mold 71 and the core part 22, that is, in the space 70a formed by the first mold 71, the second mold 72, and the core part 22. The magnet material 43 is filled. The magnet material 43 includes magnet powder and a binder. Then, a magnetic field is applied to the magnet material 43 in the mold 70 by the orientation magnet 75 to form the field magnet 23. The orientation magnet 75 is, for example, an electromagnet or a permanent magnet.
（作用）
図７（ａ）に示すように、シャフト２１と、シャフト２１と一体化したコア部２２とを金型７０に挿入（インサート）し、金型７０に磁石材料４３を充填して界磁磁石２３を成形する。従って、バインダとして樹脂材を含む磁石材料４３を金型７０に注入（射出）する際の注入圧力によって磁石材料４３とコア部２２との密着性が高く、コア部２２と界磁磁石２３とが確実に一体的となる。また、コア部２２の成形における応力は界磁磁石２３にかからないため、界磁磁石２３の割れ等の発生を抑制できる。
(Function)
As shown in FIG. 7A, the shaft 21 and the core portion 22 integrated with the shaft 21 are inserted (inserted) into the mold 70, and the magnet material 43 is filled into the mold 70 to fill the field magnet 23. Is molded. Therefore, the adhesion between the magnet material 43 and the core portion 22 is high due to the injection pressure when the magnet material 43 containing a resin material as a binder is injected (injected) into the mold 70, and the core portion 22 and the field magnet 23 are connected to each other. Be sure to be united. Further, since the stress in the molding of the core portion 22 is not applied to the field magnet 23, the occurrence of cracks and the like of the field magnet 23 can be suppressed.
図６（ａ）に示すように、シャフト２１は、金型６０を基準としてその金型６０内に配置される。そして、図６（ｂ）に示すように、金型６０とシャフト２１との間の空間６０ａに樹脂４２を充填してコア部２２を成形する。従って、シャフト２１とコア部２２は、金型６０により同軸状に精度よく配置される。 As shown in FIG. 6A, the shaft 21 is disposed in the mold 60 with respect to the mold 60. Then, as shown in FIG. 6B, the core portion 22 is formed by filling the resin 42 into the space 60 a between the mold 60 and the shaft 21. Accordingly, the shaft 21 and the core portion 22 are accurately arranged coaxially by the mold 60.
図７（ａ）に示すように、シャフト２１及びコア部２２は、金型７０を基準としてその金型７０内に配置される。そして、その金型７０とコア部２２との間の空間７０ａに磁石材料４３を充填して界磁磁石２３を成形する。従って、シャフト２１とコア部２２と界磁磁石２３は、金型７０により同軸状に精度よく配置される。 As shown in FIG. 7A, the shaft 21 and the core portion 22 are disposed in the mold 70 with reference to the mold 70. Then, the field material 23 is formed by filling the space 70 a between the mold 70 and the core portion 22 with the magnet material 43. Therefore, the shaft 21, the core portion 22, and the field magnet 23 are accurately arranged coaxially by the mold 70.
以上記述したように、本実施形態によれば、以下の効果を奏する。
（２−１）シャフト２１と、シャフト２１と一体化したコア部２２とを金型７０に挿入（インサート）し、金型７０に磁石材料４３を充填して界磁磁石２３を成形する。従って、バインダとして樹脂材を含む磁石材料４３を金型７０に注入（射出）する際の注入圧力によって磁石材料４３とコア部２２との密着性が高く、コア部２２と界磁磁石２３とが確実に一体的にできる。
As described above, according to the present embodiment, the following effects can be obtained.
(2-1) The shaft 21 and the core portion 22 integrated with the shaft 21 are inserted (inserted) into the mold 70, and the magnet material 43 is filled in the mold 70 to form the field magnet 23. Therefore, the adhesiveness between the magnet material 43 and the core portion 22 is high due to the injection pressure when the magnet material 43 containing a resin material as a binder is injected (injected) into the mold 70, and the core portion 22 and the field magnet 23 are Can be united reliably.
（２−２）シャフト２１と、シャフト２１と一体化したコア部２２とを金型７０に挿入（インサート）し、金型７０に磁石材料４３を充填して界磁磁石２３を成形する。コア部２２の成形における応力は界磁磁石２３にかからないため、界磁磁石２３の割れ等の発生を抑制できる。 (2-2) The shaft 21 and the core portion 22 integrated with the shaft 21 are inserted (inserted) into the mold 70, and the magnet material 43 is filled in the mold 70 to form the field magnet 23. Since the stress in the molding of the core portion 22 is not applied to the field magnet 23, the occurrence of cracks and the like of the field magnet 23 can be suppressed.
（２−３）シャフト２１は、金型６０を基準としてその金型６０内に配置される。金型６０とシャフト２１との間の空間６０ａに樹脂４２を充填してコア部２２を成形する。従って、シャフト２１とコア部２２を同軸状に精度よく配置できる。 (2-3) The shaft 21 is disposed in the mold 60 with reference to the mold 60. A space 60 a between the mold 60 and the shaft 21 is filled with a resin 42 to mold the core portion 22. Therefore, the shaft 21 and the core portion 22 can be accurately arranged coaxially.
（２−４）シャフト２１及びコア部２２は、金型７０を基準としてその金型７０内に配置される。そして、その金型７０とコア部２２との間の空間７０ａに磁石材料４３を充填して界磁磁石２３を成形する。従って、シャフト２１とコア部２２と界磁磁石２３を同軸状に精度よく配置できる。 (2-4) The shaft 21 and the core portion 22 are disposed in the mold 70 with reference to the mold 70. Then, the field material 23 is formed by filling the space 70 a between the mold 70 and the core portion 22 with the magnet material 43. Therefore, the shaft 21, the core portion 22, and the field magnet 23 can be accurately arranged coaxially.
尚、上記各実施形態は、以下の態様で実施してもよい。
・上記実施形態に対し、コア部２２と界磁磁石２３とに回り止めを設けるようにしてもよい。
In addition, you may implement each said embodiment in the following aspects.
In contrast to the above embodiment, the core portion 22 and the field magnet 23 may be provided with a rotation stopper.
図８（ａ）及び図８（ｂ）に示すように、コア部２２には、外周面２２ａから径方向内側に向かう複数（図８（ａ）では４つ）の凹部２２ｂが、周方向に沿って等間隔に設けられている。界磁磁石２３には、内周面２３ｂから径方向内側に突出する複数（図８（ａ）では４つ）の凸部２３ｃが周方向に沿って等間隔に設けられている。コア部２２の凹部２２ｂと界磁磁石２３の凸部２３ｃにより、コア部２２と界磁磁石２３と互いの回り止めがなされる。コア部２２の凹部２２ｂと界磁磁石２３の凸部２３ｃは、それぞれを成型する金型により形成することができる。このため、製造工数は増加しない。 As shown in FIG. 8A and FIG. 8B, the core portion 22 has a plurality of (four in FIG. 8A) concave portions 22b extending radially inward from the outer peripheral surface 22a in the circumferential direction. It is provided at equal intervals along. In the field magnet 23, a plurality (four in FIG. 8A) of convex portions 23c projecting radially inward from the inner peripheral surface 23b are provided at equal intervals along the circumferential direction. The core portion 22 and the field magnet 23 are prevented from rotating together by the concave portion 22b of the core portion 22 and the convex portion 23c of the field magnet 23. The concave portion 22b of the core portion 22 and the convex portion 23c of the field magnet 23 can be formed by a mold for molding each. For this reason, the number of manufacturing steps does not increase.
図９（ａ）及び図９（ｂ）に示すように、コア部２２には、外周面２２ａから径方向外側に突出する複数（図９（ａ）では４つ）の凸部２２ｃが、周方向に沿って等間隔に設けられている。界磁磁石２３には、内周面２３ｂから径方向外側に向かう複数（図９（ａ）では４つ）の凹部２３ｄが周方向に沿って等間隔に設けられている。コア部２２の凸部２２ｃと界磁磁石２３の凹部２３ｄにより、コア部２２と界磁磁石２３と互いの回り止めがなされる。コア部２２の凸部２２ｃと界磁磁石２３の凹部２３ｄは、それぞれを成型する金型により形成することができる。このため、製造工数は増加しない。 As shown in FIGS. 9A and 9B, the core portion 22 has a plurality of (four in FIG. 9A) convex portions 22c protruding radially outward from the outer peripheral surface 22a. It is provided at equal intervals along the direction. The field magnet 23 is provided with a plurality (four in FIG. 9A) of recesses 23d that extend radially outward from the inner circumferential surface 23b at equal intervals along the circumferential direction. The core portion 22 and the field magnet 23 are prevented from rotating together by the convex portion 22 c of the core portion 22 and the concave portion 23 d of the field magnet 23. The convex part 22c of the core part 22 and the concave part 23d of the field magnet 23 can be formed by a mold for molding each of them. For this reason, the number of manufacturing steps does not increase.
図１０（ａ）及び図１０（ｂ）に示すように、コア部２２には、外周面２２ａから径方向内側に向かい、軸方向に沿って延びる複数（図１０（ａ）では４つ）の溝部２２ｄが、周方向に沿って等間隔に設けられている。界磁磁石２３には、内周面２３ｂから径方向内側に突出し、軸方向に沿って延びる複数（図１０（ａ）では４つ）の突条２３ｅが周方向に沿って等間隔に設けられている。コア部２２の溝部２２ｄと界磁磁石２３の突条２３ｅにより、コア部２２と界磁磁石２３と互いの回り止めがなされる。コア部２２の溝部２２ｄと界磁磁石２３の突条２３ｅは、それぞれを成型する金型により形成することができる。このため、製造工数は増加しない。 As shown in FIGS. 10A and 10B, the core portion 22 has a plurality of (four in FIG. 10A) extending radially inward from the outer peripheral surface 22a and extending along the axial direction. The groove portions 22d are provided at equal intervals along the circumferential direction. The field magnet 23 is provided with a plurality (four in FIG. 10A) of protrusions 23e that protrude radially inward from the inner peripheral surface 23b and extend in the axial direction at equal intervals along the circumferential direction. ing. The groove part 22d of the core part 22 and the protrusion 23e of the field magnet 23 prevent the core part 22 and the field magnet 23 from rotating together. The groove part 22d of the core part 22 and the protrusion 23e of the field magnet 23 can be formed by a mold for molding each of them. For this reason, the number of manufacturing steps does not increase.
１２…ロータ、２１…シャフト、２２…コア部、２３…界磁磁石、４１…金型入子、４２…樹脂、４３…磁石材料、５０，７０…金型、５０ａ，７０ａ…空間。
DESCRIPTION OF SYMBOLS 12 ... Rotor, 21 ... Shaft, 22 ... Core part, 23 ... Field magnet, 41 ... Mold insert, 42 ... Resin, 43 ... Magnet material, 50, 70 ... Mold, 50a, 70a ... Space.
Claims (5)
前記シャフトの外周に配置され、樹脂材よりなる円筒形状のコア部と、
前記コア部の外周に配置され、磁石粉と樹脂材を含み、極異方着磁された円筒形状の界磁磁石と
からなるロータ構造の製造方法であって、
前記コア部と前記界磁磁石のいずれか一方を第１形成物とし、前記コア部と前記界磁磁石のいずれか他方を第２形成物とし、
前記第１形成物を金型内に配置し、
前記第１形成物と前記金型とにより形成される空間に材料を充填して前記第２形成物を成型すること、
を特徴とするロータの製造方法。 A shaft,
A cylindrical core portion disposed on the outer periphery of the shaft and made of a resin material;
A method of manufacturing a rotor structure, which is arranged on the outer periphery of the core part, includes a magnet powder and a resin material, and is made of a pole-shaped magnetic field magnet,
Either one of the core part and the field magnet is a first formation, and the other part of the core part and the field magnet is a second formation,
Placing the first formation in a mold;
Filling the material formed in the space formed by the first formation and the mold and molding the second formation;
A method for manufacturing a rotor, characterized in that
前記第２形成物は前記コア部であり、
前記界磁磁石を前記金型内に配置し、前記界磁磁石の中心に前記シャフトを配置し、前記シャフトと前記界磁磁石との間の空間に前記材料を充填して前記コア部を成型すること、
を特徴とする請求項１に記載のロータの製造方法。 The first formation is the field magnet;
The second formation is the core;
The field magnet is disposed in the mold, the shaft is disposed in the center of the field magnet, and the core portion is molded by filling the space between the shaft and the field magnet with the material. To do,
The method of manufacturing a rotor according to claim 1.
前記第１形成物としての前記界磁磁石と前記金型入子とを前記金型内に配置すること、
を特徴とする請求項２に記載のロータの製造方法。 A mold insert is disposed in the second mold, and a space formed by the inner surface of the mold insert and the second mold is filled with a magnet material including the magnet powder and the resin material. Mold the field magnet,
Disposing the field magnet as the first formation and the mold insert in the mold;
The method for manufacturing a rotor according to claim 2.
前記第２形成物は前記界磁磁石であり、
中心に前記シャフトが一体化された前記コア部を前記金型内に配置し、前記コア部と前記金型との間の空間に前記材料を充填して前記界磁磁石を成型すること、
を特徴とする請求項１に記載のロータの製造方法。 The first formation is the core;
The second formation is the field magnet;
Placing the core part integrated with the shaft in the center in the mold, filling the space between the core part and the mold with the material, and molding the field magnet;
The method of manufacturing a rotor according to claim 1.
前記第１形成物としてのコア部材と前記シャフトとを前記金型内に配置すること、
を特徴とする請求項４に記載のロータの製造方法。
The shaft is disposed in a second mold, a resin is filled in a space between the shaft and the second mold, and the core part in which the shaft is integrated at the center is molded.
Disposing the core member as the first formation and the shaft in the mold;
The method of manufacturing a rotor according to claim 4.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2020156203A (en) * | 2019-03-20 | 2020-09-24 | 愛知製鋼株式会社 | Device and method for manufacturing magnet member |
| US11532960B2 (en) * | 2019-02-05 | 2022-12-20 | Fanuc Corporation | Device for manufacturing rotor core, method for manufacturing rotor core, and rotor structure |
| WO2023127084A1 (en) * | 2021-12-28 | 2023-07-06 | 三菱電機株式会社 | Rotor, motor, fan, ventilator, and air conditioner |
| JP7420327B1 (en) | 2022-10-24 | 2024-01-23 | 株式会社村田製作所 | Rotor member, rotor, rotating electric machine, brushless motor, and manufacturing method of rotor member |
| WO2024089933A1 (en) * | 2022-10-24 | 2024-05-02 | 株式会社村田製作所 | Rotor member, rotor, rotary electric mechanism, brushless motor, and method for manufacturing rotor member |
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| JP2008312284A (en) * | 2007-06-12 | 2008-12-25 | Aisin Seiki Co Ltd | Rotor for electric pump |
| WO2016203524A1 (en) * | 2015-06-15 | 2016-12-22 | 三菱電機株式会社 | Permanent magnet electric motor |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2008312284A (en) * | 2007-06-12 | 2008-12-25 | Aisin Seiki Co Ltd | Rotor for electric pump |
| WO2016203524A1 (en) * | 2015-06-15 | 2016-12-22 | 三菱電機株式会社 | Permanent magnet electric motor |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11532960B2 (en) * | 2019-02-05 | 2022-12-20 | Fanuc Corporation | Device for manufacturing rotor core, method for manufacturing rotor core, and rotor structure |
| JP2020156203A (en) * | 2019-03-20 | 2020-09-24 | 愛知製鋼株式会社 | Device and method for manufacturing magnet member |
| JP7275707B2 (en) | 2019-03-20 | 2023-05-18 | 愛知製鋼株式会社 | MAGNET MEMBER MANUFACTURING APPARATUS AND MANUFACTURING METHOD THEREOF |
| WO2023127084A1 (en) * | 2021-12-28 | 2023-07-06 | 三菱電機株式会社 | Rotor, motor, fan, ventilator, and air conditioner |
| JP7420327B1 (en) | 2022-10-24 | 2024-01-23 | 株式会社村田製作所 | Rotor member, rotor, rotating electric machine, brushless motor, and manufacturing method of rotor member |
| WO2024089933A1 (en) * | 2022-10-24 | 2024-05-02 | 株式会社村田製作所 | Rotor member, rotor, rotary electric mechanism, brushless motor, and method for manufacturing rotor member |
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