JP2001061262A - Manufacture of resin-sealed armature - Google Patents

Abstract

PROBLEM TO BE SOLVED: To seal an armature into a prescribed form, in the space of a slot or the like so that the resin does not get out to the peripheral face or the like of an iron core. SOLUTION: In this manufacturing method, an elastic transformable surrounding member 5 is attached, in the condition that it pressure contacts a peripheral face 2a of a core 2, to the peripheral face 2a of the iron core 2, and a space 6 made by a surrounding member 5 is filled with sealing resin. In this case, it is desirable that the surrounding member 5 be a ring-shaped rubber member, which is made longer in the axial direction of a rotary shaft than a salient pole 2c of the iron core 2, and that the bore be smaller than the outside periphery of the salient pole 2c Moreover, it is possible to increase the quantity of bulge from the space of the iron core 2 by compressing the surrounding member 5 within a mold 7 at the time of injection of resin thereby sticking it fast more to the iron core 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a resin-sealed armature. More specifically, the present invention relates to an improvement in a method of sealing a resin in an armature in which a resin is sealed between iron cores.

[0002]

2. Description of the Related Art In a motor, in order to enhance insulation between windings (coils) and frames, or to improve water resistance, an armature having a winding wound around a motor core is molded by casting resin. A technique called so-called potting is performed. When a resin-sealed motor is manufactured in this manner, a resin such as polyurethane is injected including a slot inside the motor core, and then hardened by hardening.

For example, in a motor armature 101 shown in FIGS. 10 and 11, a salient pole portion 10 of an iron core around which a winding 105 is wound.
102 are sealed with a resin 104 together with the windings 105 to form an armature 101 with improved insulation and water resistance to the rotor. The armature 1 is thus sealed with the resin 104.
As a method of manufacturing 01, for example, there is a method using an outsert type.

[0004]

However, when the resin 104 is cast into the gap between the armatures 101 as described above,
The resin 104 may protrude from a predetermined range, and an appropriate air gap with the field magnet may not be secured. For example, as shown in FIG. 11, the resin 104 protrudes from the slots 103,.
The outer diameter at 4 exceeds the outer diameter at salient pole section 102. In addition, the inner diameter of the mold is formed slightly larger than the outer diameter of the core in order to make it easier to remove the mold for casting the resin 104. Therefore, the resin 104 in the upper and lower portions of the core also protrudes outward. . Further, the resin 104 may wrap around the core and adhere to the core. In this case, in order to prevent the resin 104 from coming into contact with the field magnet, an unnecessary portion had to be cut off, which required a lot of work. Also, in order to minimize the protruding portion, positioning in outsert was difficult.

Further, a resin 10 is provided on the peripheral surface of the salient pole portion 102.
4 may be attached, and even if unnecessary resin 104 is scraped off, there is a possibility that uncut portions are left on the outer peripheral portion. On the other hand, if it is cut too much, the iron core of the armature 101 may be damaged, and it is difficult to completely remove such uncut portions. In order to scrape off the resin 104 protruding from the armature 101, appropriate equipment is required.

Accordingly, the present invention provides a method for manufacturing a resin-sealed armature, in which an armature can be easily manufactured by sealing a resin into a predetermined shape in a gap such as a slot. With the goal.

[0007]

In order to achieve the above object, according to the first aspect of the present invention, an armature is formed by winding a coil around an iron core, and then the core and the coil are exposed. In a method of manufacturing a resin-sealed armature that is sealed with a resin, a surrounding member that can be elastically deformed is attached to the peripheral surface of the iron core while being pressed against the peripheral surface of the iron core, and is formed by the surrounding member. The space is filled with a sealing resin.

In this case, the surrounding member wound around the peripheral surface of the iron core forms a space to be filled with the resin.
The enclosing member presses the iron core from the surroundings, makes close contact with the peripheral surface without any gap, and protrudes inward from a slot or the like of the iron core by its elasticity.

In other words, the enclosing member surrounds the periphery of the iron core in an annular shape, and the slot forms a space in the slot portion slightly protruding inward due to its elasticity, so that the resin filled in the space becomes larger than the outer diameter of the iron core. Never.
In addition, the filled resin does not leak around from the gap between the iron core and the surrounding member, and does not protrude higher than the peripheral surface even after being formed. For this reason, this resin-sealed armature has no trouble of shaving off the resin that has protruded after casting of the resin, and after molding, if combined with the stator yoke, an appropriate air gap is formed between the armature and the field magnet. .

According to a second aspect of the present invention, in the method of manufacturing a resin-sealed armature according to the first aspect, the iron core includes a central ring portion and a salient pole portion formed to project outward from the central ring portion. An armature that is a stator or a rotor of a motor in which a coil is wound around a salient pole portion is configured, and the surrounding member is longer in the rotation axis direction than the salient pole portion around which the coil is wound. A ring-shaped rubber member formed, while pressing the inner peripheral surface of the rubber member against the outer peripheral surface of the salient pole portion,
The inner peripheral surface side of the rubber member is set as a resin injection space.

Therefore, when the periphery of the salient pole portion of the iron core is covered with the surrounding member, a resin injection space is set. In this case, the surrounding member is a rubber member having elasticity, and by pressing against the outer peripheral surface of the salient pole portion, a portion not in contact with the salient pole portion protrudes inside the peripheral surface. Therefore, the resin cast in the resin injection space does not protrude outside the peripheral surface of the salient pole portion. Further, the surrounding member is formed to be sufficiently long also in the rotation axis direction, and can seal the resin without protruding beyond the core outer diameter even in the axial direction above and below the salient pole portion.

According to a third aspect of the present invention, in the method for manufacturing a resin-sealed armature according to the second aspect, the inner diameter of the ring-shaped rubber member is formed smaller than the outer circumference of the salient pole portion. For this reason, when the ring-shaped rubber member as the surrounding member is covered so as to cover the outer periphery of the salient pole portion, the rubber member comes into pressure contact with the salient pole portion due to its own elasticity. Therefore, a resin injection space covered by the ring-shaped rubber member is formed, and by filling the resin with the resin injection space, it is possible to mold the resin according to the mold.

The invention according to claim 4 is the invention according to claim 2 or 3.
In the method for manufacturing a resin-sealed armature according to the above, when the resin is injected, the resin is compressed in the mold and enters the inner peripheral side from the outer peripheral surface of the salient pole portion, and the resin is injected in this state. It is. In this case, the ring-shaped rubber member, which is the surrounding member, receives a pressing force from a mold provided outside, and is elastically deformed so as to protrude further inward from the gap between the salient pole portions. For this reason, the resin injection space is further reduced by the amount of the protrusion, and the rubber member is sealed more tightly with the iron core so that the resin does not leak.

According to a fifth aspect of the present invention, in the method for manufacturing a resin-sealed armature according to the fourth aspect, the inner periphery of the mold is formed on an inclined surface, and the outer periphery of the rubber member is also inclined corresponding to the inclined surface. And an inner peripheral surface of the rubber member on the side opposite to the compressed side is formed as an inclined portion. In this case, an axial pressure or a radial pressure is generated as a component force of the pressing force from the inclined surface of the mold to the rubber member. According to this, the enclosing member can be placed under an effective triaxial stress state, so that the enclosing member can be more closely adhered to the peripheral surface of the iron core and the amount of protrusion between the iron cores can be increased. Further, by devising the shape of the rubber member or the like, the amount of protrusion of the rubber member at the upper and lower portions of the core can be increased.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The configuration of the present invention will be described below in detail based on an example of an embodiment shown in the drawings.

1 to 8 show one embodiment of a method of manufacturing the resin-sealed armature 1 of the present invention. This resin-sealed armature 1 forms an armature by winding a coil 3 around an iron core 2, and then seals the iron core 2 and the coil 3 with a resin 4 so that a peripheral surface 2 a of the iron core 2 is exposed. It is formed. The method of manufacturing the resin-sealed armature 1 of the present invention is applicable to various armatures 1. Hereinafter, the armature 1 of a slotted motor as shown in FIG. 4 will be described as an example.

First, the iron core 2 is formed so as to have a central ring portion 2b and a salient pole portion 2c projecting outward from the central ring portion 2b as shown in FIG. An armature 1 in which a coil 3 is wound to be a stator or a rotor of a motor is configured. In the present embodiment, nine salient pole portions 2c,.
A 9-slot type armature 1 is constituted by 2c.
The salient pole portion 2c is provided in the radial direction as shown in the figure, and its tip is formed as a curved peripheral surface 2a along the inner surface of the yoke 13 of the rotor. Slots 8,..., 8 between adjacent salient pole portions 2c,.
It is. FIG. 1 shows the salient pole portion 2c of the layered iron core in which the illustration of the coil 3 is omitted.

The armature 1 is provided as shown in FIG. 4, FIG. 5, and FIG. The rotor of this motor has the shape shown in FIG. 7, and is rotatably mounted on the armature 1 to function as the yoke 13 of the rotor magnet 14. This yoke 1
A rotor magnet 14, which is a field magnet corresponding to the salient pole portions 2c,..., 2c of the iron core 2, is provided on the inner peripheral surface of the iron core 2. The rotor magnet 14 and the salient pole portions 2c of the iron core 2,
, 2c are arranged close to each other as shown in FIG. 7, and air gaps are formed at predetermined intervals between each other.

With respect to the armature 1 of the motor as described above, the surrounding member 5 is elastically deformed in order to seal the resin 4 in a predetermined shape by attaching the surrounding member 5 to the peripheral surface 2a,. The mold is formed as possible, and a gap formed when the iron core 2 is covered with the surrounding member 5 is used as a resin injection space 6 into which the sealing resin 4 is injected. In the present embodiment, the surrounding member 5 is formed as a salient pole portion 2c around which the coil 3 is wound.
It is formed in a ring shape by a ring-shaped rubber member formed longer in the rotation axis direction than the ring member. In this case, the inner peripheral surface 5a of the surrounding member 5 is replaced with the outer peripheral surface 2 of the salient pole portions 2c,.
a, ..., 2a.

The surrounding member 5 has an inner diameter of the salient pole portion 2c,
, 2c is preferably formed smaller than the outer circumference. In this case, the surrounding member 5 made of a rubber member covering the periphery of the iron core 2 presses the inner peripheral surface 5a thereof against the peripheral surfaces 2a,..., 2a by elastic force, and the slots 8,.
8 is formed. At this time,
Since the surrounding member 5 and the peripheral surfaces 2a,..., 2a of the iron core 2 are in contact with each other in a pressed state, no gap is formed between the two so that the resin 4 leaks out.

Further, since the surrounding member 5 in the present embodiment is formed of a rubber member, it has appropriate elasticity, and its inner peripheral surface 5a is pressed against the iron core 2, so that FIG. As shown, it protrudes inward so as to protrude into the slot 8 between the salient pole portions 2c.

The enclosing member 5 not only protrudes inward at the slot 8 as described above, but also protrudes inwardly above and below the salient pole portion 2c by its elasticity as shown in FIG. Therefore, the resin 4 injected into the resin injection space 6 is formed according to the shape of the space 4 formed by being covered with the deformed surrounding member 5 and protrudes from the upper and lower portions of the slot 8 and the salient pole portion 2c. Nothing. Therefore, the maximum diameter after filling the slot 8 with the resin 4 does not exceed the outer diameter of the iron core 2 on the peripheral surfaces 2a,..., 2a, and therefore the diameter on the peripheral surfaces 2a,. The diameter.

The lower edge of the surrounding member 5 is in contact with the substrate surface or the like without any gap. The shape of the lower edge is not particularly limited. For example, when a circular substrate is provided between the iron core 2 and the frame of the stator 9, the lower edge is cut obliquely so that the surrounding member 5 comes into close contact with the substrate. Doing so is one of the preferred modes. Enclosure member 5
Is pressed by receiving a pressing force in the axial direction, and the lower end edge of the surrounding member 5 is also pressed against the substrate. At this time, if the lower edge is formed so as to become thinner toward the lower end, it can be appropriately deformed, such as bent, and sufficiently adhere to the surface of the substrate.

The mold 7 functions as a means for closing the upper ends of the armature 1 and the stator 9 to form the space 4 and for applying an external pressure to the surrounding member 5 arranged around the armature 1. In this embodiment, the armature 1 and the surrounding member 5 are covered with a mold 7 having a U-shaped cross section as shown in FIG. 1, and a bolt 10 and a set of nuts 11, 11 generate a thrust load. It has been adopted as a means.

The mold 7 has a convex portion 7b at the center of the inner periphery, and positioning is performed by fitting the convex portion 7b into a concave portion 1a provided at the upper end of the armature 1. At this time, the armature 1 can slide in the axial direction with respect to the mold 7. For example, in the present embodiment, the protrusion height of the convex portion 7b and the depth of the concave portion 1a are substantially equal, and the mold 7 and the armature 1
A rubber O-ring 12 is interposed between the armature 1 and the sealant to improve the sealing performance and secure the sliding width of the armature 1. Although the sliding width is not particularly limited, it is preferable that the upper surface of the enclosing member 5 is small enough to come into contact with the inner upper surface of the mold 7 when receiving a thrust load.

The mold 7 has a through hole at the center of the shaft. A bolt 10 is passed through the through-hole, and both ends thereof are tightened by nuts 11 to apply a thrust load to the surrounding member 5. In this embodiment, the armature 1 is pushed up while the mold 7 having the feet 15,...
Conversely, a downward load may be applied to the mold 7 while the armature 1 is fixed. If the relative position between the mold 7 and the armature 1 can be changed along the axial direction, the bolt 10 and the nut 11 , 11 can be used as the pressurizing means.

Further, the mold 7 is provided with two substantially semicircular injection holes 7c, 7c as shown in FIG. 2, which function as holes for injecting the resin 4. It should be noted that the form of the injection holes 7c, 7c shown here is merely an example, and the injection hole 7c may be one, for example, or may be a smaller hole as long as resin injection into the space 6 is possible. Absent.

In the present embodiment, the inner diameter of the mold 7 is designed to be substantially equal to the outer diameter of the surrounding member 5.
Therefore, when a thrust load is applied to the enclosing member 5 in the vertical direction using the mold 7, the enclosing member 5 is distorted in the radial direction and is in a so-called triaxial stress state pressed by the inner periphery 7a. . For this reason, the surrounding member 5 protrudes further inward above and below the peripheral surface 2a of the iron core shown in FIG. 1, and further protrudes further inside the slot 8 shown in FIG. Note that the magnitude relationship between the inner diameter of the mold 7 and the outer diameter of the enclosing member 5 can be appropriately changed depending on the pressing mode when the enclosing member 5 is pressed by the mold 7.

When the resin-sealed armature 1 is manufactured by using the above-described enclosing member 5 and the mold 7, first, the armature 1 is encased by the enclosing member 5 that can elastically deform the periphery of the iron core 2. It is fitted into the mold 7 while being covered. Here, after the ring-shaped seal 12 is interposed, the armature 1 is fitted into the center of the shaft of the mold 7, and the bolt 10 is further penetrated. Nuts 11, 11 are attached to both ends of the bolt 10.

In such a state, the salient pole portion 2 of the iron core 2
Since c,..., 2c are sunk into the inner peripheral surface 5a of the enclosing member 5 as shown in FIGS. 1 and 3, the enclosing member 5 has salient pole portions 2c,
, 2c and the slots 8,..., 8 protrude inward from the peripheral surfaces 2a,. Therefore, it is possible to cast the resin 4 in this state, but it is preferable that the surrounding member 5 is further pressed.

In this embodiment, a thrust load is applied to the surrounding member 5 by tightening the nuts 11, 11, whereby the surrounding member 5 is further brought into close contact with the iron core 2 and the mold 7. In this case, the amount of protrusion of the enclosing member 5 further increases due to a triaxial stress state in which a radial load is applied in addition to a large thrust load. In addition, the surrounding member 5 is thereby connected to the peripheral surface 2 of the iron core.
a,..., 2a and the metal mold 7, so that the resin 4 does not leak from the gap when cast.

When the resin 4 is injected, a part of the surrounding member 5 is compressed in the mold 7 to form salient pole portions 2c,.
., 2a, and the resin 4 is injected in this state. The resin 4 injected into the resin injection space 6 is sealed according to the mold as shown by hatching in FIG.
Does not ooze out of the gap between the surrounding member 5 and
As shown in FIG. 8, the peripheral surfaces 2a,
.., 2a does not protrude. Therefore, a desired resin-sealed armature 1 is formed at the time when the resin 4 is sealed, and thereafter, an operation of cutting the resin 4 is unnecessary. Therefore, when the rotor 13 is put on the resin-sealed armature 1, the resin 4 does not contact the rotor magnet 14 or the like to hinder the rotation.

The above embodiment is an example of a preferred embodiment of the present invention, but the present invention is not limited to this, and various modifications can be made without departing from the gist of the present invention. For example, in the present embodiment, the inner peripheral surface 5a of the surrounding member 5
Is formed parallel to the axis, but it is preferable to form the inner peripheral surface 5a as an inclined surface as shown in FIG. Further, it is preferable that the outer periphery 5b of the enclosing member 5 is also an inclined surface corresponding to this inclined surface, and that the inner peripheral surface 5a of the enclosing member 5 on the side opposite to the compressed side is formed in the inclined portion.

In this case, even if a radial load is applied to the enclosing member 5, a component force for pressing in the axial direction acts in addition to the force inward in the radial direction, and simultaneously the pressing force in the axial direction is applied to the enclosing member 5. Can work. That is, if a pressing force is applied in the radial direction by the mold 7, the enclosing member 5 can be pressed in the axial direction without pressing in the axial direction to increase the amount of protrusion from the slots 8,. In this case, the amount of protrusion of the surrounding member 5 in the slot portion is appropriately increased, so that the resin 4 can be sealed in a state where the peripheral surfaces 2a,... Conversely, the mold 7
Also, in the case of compression in the axial direction, a load in the radial direction can be generated by using the inclined surface. Further, such an inclined surface also acts as a draft angle in the surrounding member 5, so that the surrounding member 5 can be easily released after casting the resin 4. Although FIG. 9 shows a case where a part of the inner peripheral surface 5a is an inclined surface, the inner peripheral surface 5a may be entirely inclined.

In this embodiment, a case where a so-called armature coil is fixed, that is, a brushless DC motor in which the armature 1 is provided on the stator 9 side has been described. Even when the resin 4 is provided on the rotor side, the resin 4 that does not protrude from the outer peripheral portion can be formed by pressing with a rubber-like member similar to the surrounding member 5.

[0036]

As is apparent from the above description, according to the method for manufacturing a resin-sealed armature according to the first aspect, the enclosing member surrounds the iron core and forms the space to be filled with the resin. , The resin can be sealed smaller than the outer diameter of the iron core. For this reason, post-processing such as shaving off the protruding portion after molding of the resin is unnecessary, and it is possible to obtain an ideal potting shape with a jig having a simple shape and combine it with the motor as it is.

According to the method for manufacturing a resin-sealed armature according to the second aspect, since the adhesion between the enclosing member and the iron core is ensured, the armature is formed in a sealed state while preventing leakage of the resin. can do. In addition, after potting, the resin can be peeled while being pulled by utilizing rubber elasticity, so that the mold can be easily removed and the resin can be easily separated.

Further, according to the method for manufacturing a resin-sealed armature according to the third aspect, the enclosing member can be elastically pressed into contact with the core when the enclosing member is put on the iron core. The resin can be molded as it is by casting.

In the method of manufacturing a resin-sealed armature according to the fourth aspect, the surrounding member is compressed in the mold and elastically deformed so as to protrude further inward from the gap between the salient pole portions. In addition, the resin injection space can be further reduced by the amount of the protrusion, and the enclosing member can be sealed more tightly with the iron core so that the resin does not leak out.

Further, in the method of manufacturing a resin-sealed armature according to the fifth aspect, the inner periphery of the mold and the outer periphery and the inner periphery of the enclosing member are formed in the inclined portion, so that they are separated from the inclined surface of the mold. An axial pressure or a radial pressure is generated as a force so that the enclosing member is brought into close contact with the peripheral surface of the iron core under an effective triaxial stress state, and the amount of protrusion between the iron cores can be increased.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of an armature, an enclosing member and a mold according to an embodiment of the present invention, taken along line II of FIG.

FIG. 2 is a plan view of a mold and the like.

FIG. 3 is a partial plan view showing a state where the periphery of an iron core is covered with a surrounding member.

FIG. 4 is a plan view of the armature according to the embodiment.

FIG. 5 is a side view of the armature shown in FIG. 4;

FIG. 6 is a bottom view of a stator configured by the armature of the present embodiment and the like.

FIG. 7 is a longitudinal sectional view of the motor according to the embodiment.

FIG. 8 is a partially enlarged view from the side showing the configuration of the armature.

FIG. 9 is a longitudinal sectional view when an inner periphery of a mold, an inner peripheral surface of a surrounding member and the like are inclined surfaces.

FIG. 10 is a partially enlarged view from the side showing an example of resin sealing in a conventional armature.

FIG. 11 is a partial plan view of an armature showing an example of conventional resin sealing.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Resin sealing type armature 2 Iron core 2a Peripheral surface 2b Central ring part 2c Salient pole part 3 Coil 4 Resin 5 Enclosure member 6 Resin injection space 7 Die 7a Inner circumference

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 5H615 AA01 BB01 BB14 PP01 PP02 PP08 PP10 PP13 QQ02 QQ19 SS10 SS13 SS20 SS44 TT05 TT26

Claims (5)

[Claims] 1. A resin-sealed armature wherein a coil is wound around an iron core to form an armature, and then the iron core and the coil are sealed with a resin so that a peripheral surface of the iron core is exposed. In the manufacturing method, the surrounding member elastically deformable on the peripheral surface of the iron core is attached in a state of being pressed against the peripheral surface of the iron core,
A method for manufacturing a resin-sealed armature, wherein a space formed by the surrounding member is filled with a sealing resin. 2. The motor according to claim 2, wherein the iron core has a central ring portion and a salient pole portion formed to protrude outward from the central ring portion, and a coil is wound around the salient pole portion so that a motor stator or The armature serving as a rotor is configured, and the enclosing member is a ring-shaped rubber member that is formed longer in the rotation axis direction than the salient pole portion around which a coil is wound, and the inner periphery of the rubber member is The method for manufacturing a resin-sealed armature according to claim 1, wherein a surface is pressed against an outer peripheral surface of the salient pole portion, and an inner peripheral surface side of the rubber member is set as a resin injection space. 3. The method according to claim 2, wherein an inner diameter of the ring-shaped rubber member is formed smaller than an outer circumference of the salient pole portion. 4. When the resin is injected, it is compressed in a mold and enters the inner peripheral side from the outer peripheral surface of the salient pole portion, and the resin is injected in this state. A method for manufacturing a resin-sealed armature according to claim 2. 5. An inner periphery of the mold is formed on an inclined surface, and an outer periphery of the rubber member is also an inclined surface corresponding to the inclined surface. Further, an inner periphery of the rubber member on a side opposite to a compression side. 5. The method for manufacturing a resin-sealed armature according to claim 4, wherein the surface is formed as an inclined portion.