JP2008178163A - Method of manufacturing stator, mold device, and structure of stator - Google Patents

Method of manufacturing stator, mold device, and structure of stator Download PDF

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Publication number
JP2008178163A
JP2008178163A JP2007006826A JP2007006826A JP2008178163A JP 2008178163 A JP2008178163 A JP 2008178163A JP 2007006826 A JP2007006826 A JP 2007006826A JP 2007006826 A JP2007006826 A JP 2007006826A JP 2008178163 A JP2008178163 A JP 2008178163A
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Japan
Prior art keywords
stator
gates
molding
stator core
cavity
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Pending
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JP2007006826A
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Japanese (ja)
Inventor
Katsunari Matsumoto
克成 松本
Original Assignee
Toyota Motor Corp
トヨタ自動車株式会社
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Priority to JP2007006826A priority Critical patent/JP2008178163A/en
Publication of JP2008178163A publication Critical patent/JP2008178163A/en
Pending legal-status Critical Current

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Abstract

A stator manufacturing method capable of improving the strength of a weld portion is provided.
A stator core and a coil mounted on the stator core are set in a mold cavity, and a molding material is injected into the cavity from a plurality of gates. In the manufacturing method in which the stator 25 is manufactured by integrally molding the two, the molding is performed so that the weld formed by the joining of the molding materials 30 injected from the plurality of gates 12 is curved.
[Selection] Figure 1

Description

  The present invention relates to a stator manufacturing method, a molding apparatus, and a stator structure.
  There is a stator of a molded motor in which a stator core and a coil mounted on the stator core are integrally molded (see, for example, Patent Documents 1 to 4).
JP 2000-125524 A JP-A-9-121515 Japanese Patent Laid-Open No. 5-207711 JP-A-6-113508
  By the way, when a stator core and a coil attached to the stator core are set in a cavity of a mold, and resin (mold material) is injected into the cavity from a plurality of gates, molding is performed from the plurality of gates. The weld material is formed by the joining of the molding materials. If the weld is linear, the strength of the stator is weakened. For example, as shown in FIG. 8, in the weld portion 81, fibrous fillers 82 for reinforcing the resin material are arranged in the direction of the weld line, and against the tensile force in the direction perpendicular to the weld line (the arrow X direction in FIG. 8). Since the fibrous filler 82 is difficult to exert its effect, the strength is weaker than that of other parts.
  Therefore, the present invention provides a stator manufacturing method, a molding apparatus, and a stator structure capable of improving the strength of the weld portion.
  In the stator manufacturing method according to the present invention, a stator core and a coil attached to the stator core are set in a cavity of a mold, and a molding material is injected into the cavity from a plurality of gates. A stator manufacturing method for manufacturing a stator by integrally molding a mold, wherein the mold is formed such that a weld formed by joining of molding materials injected from the plurality of gates has a curved shape. It is characterized by performing.
  In one aspect of the present invention, a flow velocity distribution in which the weld has a curved shape is generated in the flow of the molding material in the cavity.
  In the first aspect of the above aspect, the shape of the cavity is set to a shape that causes the flow velocity distribution.
  In one example of the first aspect, the stator core is annular, the plurality of coils are arranged substantially equally in the circumferential direction of the stator core, and the gates face the gaps between the adjacent coils. The mold is provided with projections protruding into the cavity at positions facing the gates, and the projections are arranged at different positions in the radial direction of the stator core.
  In the second aspect of the above aspect, the arrangement of the gates and the injection amount of the molding material from the gates are set so as to cause the flow velocity distribution.
  In one example of the second aspect, the stator core is annular, and a plurality of the coils are arranged substantially equally in the circumferential direction of the stator core, and the plurality of gates includes a plurality of first gates and the first gates. A plurality of second gates having a smaller injection amount of molding material than one gate, and each of the first gates is disposed at a position facing each gap between adjacent coils. These gates are arranged at intermediate positions of the first gates adjacent to each other.
  In the third aspect of the above aspect, the shape of the stator core or the coil is set to a shape that causes the flow velocity distribution.
  In an example in the third aspect, the stator core is annular, the plurality of coils are arranged substantially equally in the circumferential direction of the stator core, and the gates face gaps between adjacent coils. It arrange | positions in a position and each said clearance gap is set to a mutually different magnitude | size.
  In the above example, for example, the sizes of the gaps are made different from each other by making the shapes of the coils different from each other.
  A molding apparatus according to the present invention is a molding apparatus that integrally molds a stator core and a coil attached to the stator core, the cavity in which the stator core and the coil are set, and a molding material in the cavity. And a mold die provided with a plurality of gates for injecting, wherein the weld formed by joining the mold materials injected from the plurality of gates is configured to be curved. And
  In one aspect of the present invention, a flow velocity distribution in which the weld has a curved shape is generated in the flow of the molding material in the cavity.
  In the first aspect of the above aspect, the shape of the cavity is set to a shape that causes the flow velocity distribution.
  In one example of the first aspect, the stator core is annular, the plurality of coils are arranged substantially equally in the circumferential direction of the stator core, and the gates face the gaps between the adjacent coils. The mold is provided with projections protruding into the cavity at positions facing the gates, and the projections are arranged at different positions in the radial direction of the stator core.
  In the second aspect of the above aspect, the arrangement of the gates and the injection amount of the molding material from the gates are set so as to cause the flow velocity distribution.
  In one example of the second aspect, the stator core is annular, and a plurality of the coils are arranged substantially equally in the circumferential direction of the stator core, and the plurality of gates includes a plurality of first gates and the first gates. A plurality of second gates having a smaller injection amount of molding material than one gate, and each of the first gates is disposed at a position facing each gap between adjacent coils. These gates are arranged at intermediate positions of the first gates adjacent to each other.
  A stator structure according to the present invention includes a stator core and a coil attached to the stator core, is set in a cavity of a mold, and is molded integrally by injecting a molding material from a plurality of gates into the cavity. A stator structure to be molded, wherein a weld formed by joining of molding materials injected from the plurality of gates is configured to have a curved shape.
  In one aspect of the present invention, the shape of the stator core or the coil is a shape that generates a flow velocity distribution in which the weld has a curved shape in the flow of the molding material in the cavity.
  In one example of the above aspect, the stator core is annular, the plurality of coils are arranged substantially equally in the circumferential direction of the stator core, and the gaps between adjacent coils are different in size.
  In the above example, for example, the shapes of the coils are different from each other, so that the sizes of the gaps are different from each other.
  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of a stator which can improve the intensity | strength of a weld part, a molding apparatus, and a stator structure can be provided.
  Hereinafter, embodiments of the present invention will be described with reference to the drawings.
  FIG. 1 is a schematic view showing an example of a stator manufacturing method and a molding apparatus 10.
  First, the configuration of the molding apparatus 10 will be described with reference to FIG. The molding apparatus 10 is an apparatus that integrally molds a stator core 21 and a coil (specifically, a concentrated winding coil) 22 attached to the stator core 21, and is a cavity 11 in which the stator core 21 and the coil 22 are set. And a mold die provided with a plurality of gates 12 for injecting a molding material into the cavity 11. Specifically, the molding apparatus 10 includes an upper mold 13 and a lower mold 14, and a cavity 11 is formed between the upper mold 13 and the lower mold 14, and the upper mold 13 or the lower mold 14 (the upper mold 13 in FIG. 1). ) Is provided with a plurality of gates 12.
  Next, with reference to FIG. 1, the procedure of the stator manufacturing method will be described.
  First, the stator core 21 and the coil 22 attached to the stator core 21 are set in the mold cavity 11 (S1).
  Next, a resin 30 as a molding material is put into a pot 15 provided in the upper mold 13 and communicating with the plurality of gates 12 (S2). In a preferred embodiment, the resin 30 includes a fibrous filler for reinforcing a resin material such as glass fiber or carbon fiber.
  Next, the resin 30 in the pot 15 is pressurized with the plunger 16 while being melted at a high temperature, whereby the molten resin 30 is injected into the cavity 11 from the plurality of gates 12 (S3, S4).
  Next, after the resin 30 in the cavity 11 is cured, the upper mold 13 and the lower mold 14 are separated, and the molded product 23 is taken out (S5).
  Next, the unnecessary portion 24 formed by the gate 12 is removed from the molded product 23 to obtain the stator 25 in which the stator core 21 and the coil 22 are molded (S6).
  FIG. 2 is a plan view showing an example of a stator molded by the manufacturing method shown in FIG. 3 is a cross-sectional view taken along the line BB in FIG. 2 and 3, the stator 25 includes a stator core 21, a coil 22, and a mold part 26. The stator core 21 has an annular shape, and includes a substantially cylindrical yoke 21a and a plurality of (here, 12) teeth 21b extending toward the central axis at predetermined intervals inside the yoke 21a. ing. Coils 22 are wound around the plurality of teeth 21b via insulating bobbins. The stator core 21 and the plurality of coils 22 are covered with a mold portion 26.
  As described above, welds are formed by the joining of the resin 30 injected from the plurality of gates 12. However, if the welds are linear, the strength of the stator becomes very weak.
  FIG. 4 shows how a linear weld is formed. In FIG. 4, the direction of the arrow indicates the direction of the resin flow, and the length of the arrow indicates the speed of the resin flow. In FIG. 4, unlike FIG. 1, the gate 12 is provided in the lower mold 14 and is connected to the lower end of the cavity 11. These are the same for FIGS. 5 to 7 described later.
  In FIG. 4, a plurality of coils 22 are equally arranged in the circumferential direction of the annular stator core 21. And the gate 12 is arrange | positioned in the position facing each clearance gap between the mutually adjacent coils 22, and the resin 30 is inject | poured from each gate 12 equally. In this case, the resin 30 passes through a gap having an equal cross-sectional area between the coils. In addition, the inflow speed of the resin 30 is set to be low from the viewpoint of avoiding the generation of voids and the position of the coil 22 from being displaced. For these reasons, the flow of the resin 30 is hardly disturbed, and a linear weld 27 is formed in the radial direction of the stator 25.
  Therefore, in the present embodiment, from the viewpoint of improving the strength of the mold portion 26 of the stator 25, the molding is performed so that the weld formed by the joining of the molding materials injected from the plurality of gates is curved. Do. Here, “the weld has a curved shape” includes that the weld line on the surface or cross section of the stator 25 has a curved shape, and the bonding surface (weld surface) of the mold material has a curved shape. . In a preferred embodiment, the molding is performed such that the weld line on the surface or cross section viewed from the axial direction of the stator 25 is curved. The weld line may be at least partially curved, but is preferably curved overall. In a preferred embodiment, the weld line has a wave shape such as an S shape.
  More specifically, in the present embodiment, a flow velocity distribution in which the weld has a curved shape is generated in the flow of the molding material in the cavity 11.
  Hereinafter, two modes for performing molding so that the weld has a curved shape will be described.
(First aspect)
In the first aspect, the molding apparatus is configured such that the weld has a curved shape. For example, the molding apparatus is configured to generate a flow velocity distribution in which the weld has a curved shape in the flow of the molding material in the cavity.
  FIG. 5 is a diagram illustrating an example of the manufacturing method according to the first aspect. In this example, the shape of the cavity is set to a shape that causes the flow velocity distribution. Specifically, in FIG. 5, a plurality of coils 22 are arranged substantially equally in the circumferential direction of the annular stator core 21. And the gate 12 is arrange | positioned in the position facing each clearance gap between the coils 22 mutually adjacent. Further, the mold die is provided with a protrusion 17 protruding into the cavity 11 at a position facing each gate 12. Each protrusion 17 is arrange | positioned in a mutually different position about the radial direction of the stator core 21 so that the said flow velocity distribution may arise. Specifically, as the position of the protrusion 17 with respect to the gate 12, two kinds of positions, that is, a gate side close to the gate 12 and an anti-gate side far from the gate 12 are set, and one protrusion 17 is provided for each gate 12. Are alternately provided on the gate side and the opposite gate side.
  In the above configuration, the flow of the resin 30 that has entered between adjacent coils is hindered by the protrusions 17, and the flow speed of the resin 30 decreases. Thereby, the time for the resin 30 to reach the weld position is delayed. Since this phenomenon occurs alternately between the adjacent coils on the gate side and the opposite gate side, the weld 27 becomes a curve.
  FIG. 6 is a diagram illustrating another example of the manufacturing method according to the first aspect. In this example, the arrangement of each gate and the injection amount of the mold material from each gate are set so as to generate the flow velocity distribution. Specifically, in FIG. 6, a plurality of coils 22 are arranged substantially equally in the circumferential direction of the annular stator core 21. And the 1st gate (main gate) 12a is arrange | positioned in the position facing each clearance gap between the mutually adjacent coils 22. FIG. Further, the second gate (sub-gate) 12b in which the injection amount of the resin 30 is smaller than that of the first gate is arranged at each intermediate position (that is, a weld generation position) between the first gates 12a adjacent to each other. In FIG. 6, the second gate 12b is arranged at both the upper end and the lower end.
  In the above configuration, a portion of the weld 27 is divided by the resin 30 injected from the second gate 12b, and the weld 27 is prevented from being linear.
(Second aspect)
In the second aspect, the stator core and a coil attached to the stator core are included, set in a cavity of a mold, and molded integrally by injecting a molding material from a plurality of gates into the cavity. The stator structure is configured such that the weld is curved. That is, the stator structure that is the object of molding (molded object) is configured such that the weld has a curved shape. For example, the stator structure is configured to generate a flow velocity distribution in which the weld has a curved shape in the flow of the molding material in the cavity.
  FIG. 7 is a diagram illustrating an example of the manufacturing method according to the second aspect. In FIG. 7, the upper figure shows a state before resin injection, and the lower figure shows a state during resin injection. In this example, the shape of the stator core or coil is set to a shape that produces the flow velocity distribution. Specifically, in FIG. 7, a plurality of coils 22 are arranged substantially equally in the circumferential direction of the annular stator core 21. And the gate 12 is arrange | positioned in the position facing each clearance gap between the coils 22 mutually adjacent. Further, the sizes of the gaps (for example, the mold material inflow volume in the slot) are set to different sizes. In the example of FIG. 7, the sizes of the coils 22 are made different from each other, whereby the sizes of the gaps are made different. Specifically, every two coils 22b in which the outer diameter on the gate side is reduced as compared with the other coils 22a, that is, the coils 22b provided with the outer diameter reduction portions 22c are arranged. The outer diameter reduction part 22c may be provided on the side opposite to the gate, or a plurality of outer diameter reduction parts 22c may be provided.
  In the above configuration, a difference occurs in the speed at which the resin flows between adjacent coils, and the weld 27 becomes a curve.
  As described above, in the present embodiment, the stator core and the coil mounted on the stator core are set in the mold cavity, the molding material is injected into the cavity from a plurality of gates, and the stator core and the coil are integrated. When molding is performed, the molding is performed so that the weld formed by the joining of the molding materials injected from the plurality of gates has a curved shape. For this reason, according to the present embodiment, the strength of the weld portion can be improved as compared with the case where the weld is formed in a straight line.
  In this embodiment, the weld is formed in a curved shape by generating a flow velocity distribution in the flow of the molding material in the cavity. For this reason, it is possible to form the weld in a curved shape with a simple configuration.
  In addition, this invention is not limited to the said embodiment, It can change variously within the range which does not deviate from the summary of this invention.
It is the schematic which shows an example of the manufacturing method of a stator, and a molding apparatus. It is a top view which shows an example of the stator molded by the manufacturing method shown by FIG. It is BB sectional drawing of FIG. It is a figure which shows a mode that a linear weld is formed. It is a figure which shows an example of the manufacturing method which concerns on a 1st aspect. It is a figure which shows another example of the manufacturing method which concerns on a 1st aspect. It is a figure which shows an example of the manufacturing method which concerns on a 2nd aspect. It is a schematic diagram which shows the vicinity of a linear weld.
Explanation of symbols
  DESCRIPTION OF SYMBOLS 10 Mold apparatus, 11 Cavity, 12 Gate, 12a 1st gate, 12b 2nd gate, 13 Upper mold, 14 Lower mold, 15 Pot, 16 Plunger, 21 Stator core, 21a Yoke, 21b Teeth, 22 Coil, 23 Mold Molded product, 24 unnecessary part, 25 stator, 26 mold part, 27 weld, 30 resin (mold material).

Claims (19)

  1. A stator core and a coil attached to the stator core are set in a mold cavity, a molding material is injected into the cavity from a plurality of gates, and the stator core and the coil are integrally molded to manufacture a stator. A stator manufacturing method that comprises:
    A method of manufacturing a stator, wherein the molding is performed so that a weld formed by joining of molding materials injected from the plurality of gates has a curved shape.
  2. It is a manufacturing method of the stator according to claim 1,
    A stator manufacturing method, wherein a flow velocity distribution in which the weld has a curved shape is generated in a flow of a molding material in the cavity.
  3. It is a manufacturing method of the stator according to claim 2,
    The method for manufacturing a stator, wherein the shape of the cavity is set to a shape that causes the flow velocity distribution.
  4. It is a manufacturing method of the stator according to claim 3,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    Each of the gates is disposed at a position facing each gap between adjacent coils,
    The mold is provided with a protrusion protruding into the cavity at a position facing each gate.
    The protrusions are arranged at different positions in the radial direction of the stator core.
    A stator manufacturing method characterized by the above.
  5. It is a manufacturing method of the stator according to claim 2,
    The stator manufacturing method, wherein the arrangement of the gates and the injection amount of the molding material from the gates are set so as to generate the flow velocity distribution.
  6. It is a manufacturing method of the stator according to claim 5,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    The plurality of gates include a plurality of first gates and a plurality of second gates having a molding material injection amount smaller than that of the first gates,
    Each of the first gates is disposed at a position facing each gap between adjacent coils,
    Each of the second gates is disposed at each intermediate position of the first gates adjacent to each other.
    A stator manufacturing method characterized by the above.
  7. It is a manufacturing method of the stator according to claim 2,
    A stator manufacturing method, wherein the shape of the stator core or the coil is set to a shape that causes the flow velocity distribution.
  8. It is a manufacturing method of the stator according to claim 7,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    Each of the gates is disposed at a position facing each gap between adjacent coils,
    Each of the gaps is set to have a different size.
    A stator manufacturing method characterized by the above.
  9. A stator manufacturing method according to claim 8, comprising:
    A method of manufacturing a stator, characterized in that the sizes of the gaps are made different from each other by making the shapes of the coils different from each other.
  10. A molding apparatus for integrally molding a stator core and a coil attached to the stator core,
    A mold having a cavity in which the stator core and the coil are set, and a plurality of gates for injecting a mold material into the cavity;
    A molding apparatus characterized in that a weld formed by joining of molding materials injected from the plurality of gates has a curved shape.
  11. The molding apparatus according to claim 10,
    A molding apparatus characterized in that a flow velocity distribution in which the weld is curved is generated in the flow of the molding material in the cavity.
  12. The molding apparatus according to claim 11,
    The mold apparatus is characterized in that a shape of the cavity is set to a shape that generates the flow velocity distribution.
  13. The molding apparatus according to claim 12,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    Each of the gates is disposed at a position facing each gap between adjacent coils,
    The mold is provided with a protrusion protruding into the cavity at a position facing each gate.
    The protrusions are arranged at different positions in the radial direction of the stator core.
    A molding apparatus.
  14. The molding apparatus according to claim 11,
    The molding apparatus characterized in that the arrangement of the gates and the injection amount of the molding material from the gates are set so as to generate the flow velocity distribution.
  15. The molding apparatus according to claim 14,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    The plurality of gates include a plurality of first gates and a plurality of second gates having a molding material injection amount smaller than that of the first gates,
    Each of the first gates is disposed at a position facing each gap between adjacent coils,
    Each of the second gates is disposed at each intermediate position of the first gates adjacent to each other.
    A molding apparatus.
  16. A stator structure including a stator core and a coil attached to the stator core, set in a cavity of a mold, and molded integrally by injecting a molding material from a plurality of gates into the cavity. ,
    A stator structure, wherein a weld formed by joining mold materials injected from the plurality of gates is curved.
  17. The stator structure according to claim 16, wherein
    The stator structure according to claim 1, wherein the stator core or the coil has a shape that causes a flow velocity distribution in which the weld has a curved shape in the flow of the molding material in the cavity.
  18. The stator structure according to claim 17,
    The stator core is annular,
    A plurality of the coils are arranged substantially equally in the circumferential direction of the stator core,
    Each gap between adjacent coils is different in size,
    A stator structure characterized by that.
  19. The stator structure according to claim 18, wherein
    The stator structure according to claim 1, wherein the shapes of the coils are different from each other, whereby the sizes of the gaps are different from each other.
JP2007006826A 2007-01-16 2007-01-16 Method of manufacturing stator, mold device, and structure of stator Pending JP2008178163A (en)

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JP2007006826A JP2008178163A (en) 2007-01-16 2007-01-16 Method of manufacturing stator, mold device, and structure of stator

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Application Number Priority Date Filing Date Title
JP2007006826A JP2008178163A (en) 2007-01-16 2007-01-16 Method of manufacturing stator, mold device, and structure of stator

Publications (1)

Publication Number Publication Date
JP2008178163A true JP2008178163A (en) 2008-07-31

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014218063A (en) * 2013-05-10 2014-11-20 ファナック株式会社 Stator for motor for injecting resin by injection molding

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014218063A (en) * 2013-05-10 2014-11-20 ファナック株式会社 Stator for motor for injecting resin by injection molding
US9369010B2 (en) 2013-05-10 2016-06-14 Fanuc Corporation Stator of electric motor including resin injected by injection molding

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