JP2008245344A - Molded motor, blower, air conditioner, and water heater, and water heater - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cost-effective, small, and highly reliable molded motor. <P>SOLUTION: The molded motor includes a molded stator 20 and a rotor assembly 30. The molded stator has a stator portion 10, which includes a stator core 1 structured by stacking magnetic steel sheets having a plurality of slots, an insulation member 8 attached to stator core, a winding 2 provided on the stator core, and a substrate 5, on which a drive circuit is mounted, attached to one axial end of the insulation member 8, and which is formed by a molding resin 3. The rotor assembly has a rotor 4, a shaft 11 which is fitted into the axial holes formed at substantially central part of the rotor 4, and two bearings 7 fixed to the shaft 11 and positioned outside both axial ends of the rotor 4. The substrate 5 is arranged outside the bearing 7 at the substrate 5 side of the rotor assembly 30 and inside the molding resin 3 constituting an enclosure of the axial end of the molded stator 20. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molded electric motor, and particularly to the position of a substrate of the molded electric motor.

In the conventional mold motor, the protrusion of the insulating member applied to the stator winding is inserted into the substrate and welded, so that the substrate is attached to the stator portion. The stator is formed by encapsulating the stator with mold resin. A rotor is built into the stator to complete the motor. At this time, the position of the board in the motor in the axial direction is between the outer end face of the board-side bearing and the end face of the stator. Therefore, it is necessary to set a hole shape larger than the size of the bearing in the substrate (for example, see Patent Document 1).
JP 2003-259614 A

However, the mold motor disclosed in Patent Document 1 has the following problems.
(1) The hole-shaped part of the substrate is a part to be discarded and is wasted. Moreover, drilling is required. Therefore, the manufacturing cost increases.
(2) Since there is a hole in the substantially central portion of the substrate, circuit wiring of the substrate becomes complicated.
(3) The circuit wiring of the substrate generally needs to be divided into a high voltage portion and a low voltage portion. By providing a hole shape in the substrate, wiring that should be originally distinguished from a high voltage portion and a low voltage portion becomes impossible, and there is a risk that reliability may be lowered by becoming weak against noise.
(4) During the process of molding the stator portion with the mold resin, when the stator portion is inserted into the mold, it must be inserted so that the bearing portion of the mold does not contact the hole portion of the substrate. This complicates the work.

  The present invention has been made to solve the above-described problems, and an object thereof is to provide a mold motor, a blower, an air conditioner, and a water heater that are inexpensive, small, and highly reliable. .

  The mold motor according to the present invention is configured by attaching an insulating member to a stator core having a plurality of slots, which is configured by laminating electromagnetic steel plates, and is provided with a winding, and further, a drive circuit is provided at one axial end of the insulating member. It has a stator part to which the mounted substrate is attached, and this stator part is fitted into a mold stator formed by molding resin, a rotor, and a shaft hole formed in a substantially central part of this rotor. A rotor assembly having a shaft and two bearings fixed to the shaft and positioned outside both ends of the rotor in the axial direction, and the substrate is mold-fixed outside the bearing on the substrate side of the rotor assembly. It arrange | positions in the mold resin which comprises the outline of the axial direction edge part of a child.

  In the mold motor according to the present invention, since the substrate is disposed outside the bearing on the substrate side of the rotor assembly and in the mold resin at the axial end portion of the mold stator, the substrate escapes from the bearing as in the prior art. There is no need to make a hole, and there is no restriction on the shape of the substrate. Since the hole shape is eliminated from the substrate, the strength of the substrate is improved. As a result, the deformation of the substrate at the time of mounting the electronic component on the substrate and molding is reduced, the long-term reliability is improved, and a long-life mold motor can be provided.

Embodiment 1 FIG.
FIGS. 1 to 3 are diagrams showing the first embodiment. FIG. 1 is a partial cross-sectional view of the molded motor 100. FIG. 2 is a perspective view before the stator portion 10 is assembled. FIG.

  As shown in FIG. 1, the mold motor 100 includes a mold stator 20, a rotor assembly 30, and a bracket 6.

  The mold stator 20 is integrally formed by applying the mold resin 3 to the stator portion 10.

  As shown in FIGS. 2 and 3, the stator portion 10 is configured by stacking electromagnetic steel plates, attaching an insulating member 8 to a stator core 1 having a plurality of slots (not shown), and winding 2 is applied. Is done. Furthermore, a substrate 5 on which electronic components for driving the mold motor 100 are mounted is attached to one axial end surface of the stator portion 10. The substrate 5 is fixed to the protrusion 18 of the insulating member that extends outward in the axial direction from one axial end of the insulating member 8.

  The rotor assembly 30 includes a rotor 4, a shaft 11 that fits into a shaft hole formed at a substantially central portion of the rotor 4, and outer sides of both axial ends of the rotor 4 that are fixed to the shaft 11. Two bearings 7 are provided. The rotor 4 is a permanent magnet type rotor using a permanent magnet, for example.

  The axial end of the mold stator 20 on the substrate 5 side is closed with the mold resin 3. Since the other axial end of the mold stator 20 is open, the rotor assembly 30 is inserted into the mold stator 20 from this opening side. Further, the bracket 6 is attached to the mold stator 20. The bracket 6 is attached so that the rotor assembly 30 is sandwiched between the bracket 6 and the mold resin 3, and the mold electric motor 100 is completed.

  The substrate 5 is disposed outside the bearing 7 on the substrate 5 side of the rotor assembly 30 and in the mold resin 3 constituting the outline of the axial end portion of the mold stator 20. The mold electric motor 100 is based on a method of detecting the position of the rotor 4 without a sensor. However, a position detection sensor that detects the position of the rotor 4 may be provided on the substrate 5.

  With this configuration, since there is no substrate 5 in the portion of the mold resin 3 that receives the bearing 7 in the radial direction, the influence on the dimensional accuracy due to the difference in the linear expansion coefficient between the substrate 5 and the mold resin 3 is eliminated. It is possible to improve the dimensional accuracy of the part of the mold resin 3 that receives the resin. The length in the axial direction of the portion of the mold resin 3 was made substantially thicker than the axial length of the bearing 7.

  Moreover, since the axial length of the portion of the mold resin 3 that supports the bearing 7 in the radial direction is substantially the same as the axial length of the bearing 7, the strength is improved, and sound vibration can be suppressed. Noise reduction is possible.

  Since the substrate 5 is disposed outside the bearing 7 on the substrate 5 side of the rotor assembly 30 and in the mold resin 3 at the axial end portion of the mold stator 20, a hole through which the bearing 7 escapes is formed in the substrate 5 as in the prior art. There is no need to open it. Therefore, there is no restriction on the shape of the substrate 5. For example, as shown in FIGS. 2 and 3, the substrate 5 can be made semicircular and the number of substrates can be reduced, thereby reducing the cost.

  Since the substrate 5 has no hole shape, the strength of the substrate 5 is improved. As a result, the deformation of the substrate 5 when the electronic component is mounted on the substrate 5 and the molding is reduced, the long-term reliability is improved, and the long-life mold motor 100 can be provided.

  One bearing 7 is positioned inside the mold resin 3 in which the substrate 5 is housed. Therefore, it is possible to realize dustproof and contamination prevention for the bearing 7 and to provide a long-life molded motor 100.

  One bearing 7 is positioned inside the mold resin 3 in which the substrate 5 is housed. Therefore, noise leaking to the outside of the bearing 7 can be reduced, and the noise of the molded motor 100 can be reduced.

Embodiment 2. FIG.
4 and 5 are diagrams showing the second embodiment. FIG. 4 is a partial cross-sectional view of the mold motor 100, and FIG. 5 is a partial cross-sectional view of a modified mold motor 100. FIG.

  As shown in FIG. 4, the mold electric motor 100 of the present embodiment specifies the position of the electronic component 13 to be mounted on the substrate 5. In addition, a copper through hole 17 is provided in the portion of the substrate 5 facing the electronic component 13. Others are the same as in FIG.

  When a drive circuit for driving the molded motor 100 is mounted on the substrate 5, some of the electronic components 13 constituting the drive circuit generate heat and require heat dissipation. As for the electronic component 13 that needs to be radiated, it may be insufficient to radiate heat from the mold resin 3 surrounding the electronic component 13 to the outside.

  The electronic component 13 that needs to be dissipated is disposed on the rotor 4 side of the substrate 5 and is disposed so as to be substantially opposed to the axial ends of the bearing 7 and the shaft 11. The thickness of the mold resin 3 surrounding the substrate 5 in the vicinity of the electronic component 13 is set to a minimum necessary thickness (for example, 1 mm or more). Since the bearing 7 and the mold resin 3 are in contact with each other, insulation is required between the bearing 7 and the electronic component 13.

  Heat of the electronic component 13 that needs to be dissipated is transmitted to the bearing 7 and the shaft 11 through the thin mold resin 3 and can be dissipated.

  In addition, by providing the copper through hole 17 in the portion of the substrate 5 facing the electronic component 13, the heat of the electronic component 13 that needs to be radiated is radiated from the copper through hole 17 to the outside through the mold resin 3. . Thereby, the temperature of the electronic component 13 which needs further heat dissipation can be lowered.

  A modification will be described with reference to FIG. In the case of FIG. 5, the electronic component 13 that needs to dissipate heat is disposed outside the substrate 5 on the side opposite to the rotor 4. Further, a copper through hole 17 is provided in the portion of the substrate 5 facing the electronic component 13. The copper through hole 17 of the substrate 5 is provided so as to substantially face the bearing 7 and the shaft 11.

  In the case of FIG. 5, the heat of the electronic component 13 that needs to be dissipated is radiated to the outside mainly through the mold resin 3. Further, heat is radiated from the copper through hole 17 of the substrate 5 to the bearing 7 and the shaft 11 through the mold resin 3. Thereby, the temperature of the electronic component 13 that requires heat dissipation can be lowered.

  As described above, the heat of the electronic component 13 that needs to be radiated is radiated to the bearing 7 and the shaft 11 or the outside, so that the temperature of the electronic component 13 that needs to be radiated can be lowered, and the output of the molded motor 100 can be increased. High efficiency can be achieved.

Embodiment 3 FIG.
FIG. 6 shows the third embodiment, and is a partial cross-sectional view of the molded electric motor 100.

  As shown in FIG. 6, the molded electric motor 100 of the present embodiment brings the substrate 5 into contact with the end surface of the bearing 7 on the substrate 5 side. A copper foil or a copper through hole is set on the surface of the substrate 5 to be contacted.

  Thus, the substrate 5 itself has a role of heat dissipation, realizes heat dissipation of the bearing 7, and a long-life molded motor 100 is obtained.

  By wiring the pattern on the portion of the substrate 5 that is in contact with the bearing 7, the temperature of the bearing 7 can be measured, and the molded motor 100 having a long life and high reliability can be provided. By monitoring the temperature of the bearing 7, the molded motor 100 capable of predicting the life can be realized.

  By bringing the pattern of the substrate 5 into contact with the bearing 7, the problem of electrolytic corrosion is solved. Electric corrosion is a phenomenon in which a potential difference is generated between the inner and outer rings of the bearing 7 of the rotor 4 due to high-frequency switching of the inverter, and a high-frequency current is generated in the meantime, so that the bearing 7 is damaged and abnormal noise is generated. It is.

  For the problem of electrolytic corrosion, the substrate 5 is brought into contact with the outer ring side end surface of the bearing 7, and a pattern wiring is set on the substrate 5, thereby measuring a potential difference generated between the inner and outer rings of the bearing 7. It becomes possible to monitor. Furthermore, if control for reducing the generated potential difference is performed on the substrate 5 using the measurement result, the occurrence of electrolytic corrosion can be suppressed.

Embodiment 4 FIG.
FIG. 7 is a diagram showing the fourth embodiment, and is a diagram showing a configuration of the air conditioner 200.

  As shown in FIG. 7, the air conditioner 200 includes an indoor unit 52 and an outdoor unit 53 connected to the indoor unit 52. The outdoor unit 53 has a blower 54. The mold motor 100 described in any of Embodiments 1 to 3 is mounted on the blower 54.

  Although not shown, the indoor unit 52 also uses a blower. The blower of the indoor unit 52 may be mounted with the molded electric motor 100 described in any of Embodiments 1 to 3.

  By incorporating the molded electric motor 100 described in any of Embodiments 1 to 3 into the blower 54, the air conditioner 200 with high reliability can be provided.

Embodiment 5. FIG.
FIG. 8 is a diagram illustrating the fifth embodiment and is a diagram illustrating a configuration of the water heater 300.

  As shown in FIG. 8, the water heater 300 is connected to an outdoor unit 55 of a water heater on which a refrigeration cycle having a refrigerant-water heat exchanger is mounted, and a refrigerant-water heat exchanger of the outdoor unit 55 of the water heater. A tank 56 and a bathtub 57 connected to the tank 56. The outdoor unit 55 of the water heater has a blower 54. By incorporating the molded electric motor 100 described in any of Embodiments 1 to 3 into the blower 54, a highly reliable hot water heater 300 can be provided.

FIG. 5 shows the first embodiment, and is a partial cross-sectional view of the molded electric motor 100. FIG. 5 shows the first embodiment, and is a perspective view before the stator part 10 is assembled. FIG. 5 shows the first embodiment, and is a perspective view after the stator part 10 is assembled. FIG. 5 shows the second embodiment, and is a partial cross-sectional view of the molded electric motor 100. It is a figure which shows Embodiment 2, and is a fragmentary sectional view of the mold motor 100 of a modification. FIG. 5 shows the third embodiment and is a partial cross-sectional view of the molded electric motor 100. FIG. 10 shows the fourth embodiment and shows the configuration of the air conditioner 200. FIG. FIG. 6 shows a fifth embodiment and shows a configuration of a water heater 300.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Stator iron core, 2 windings, 3 Mold resin, 4 Rotor, 5 Substrate, 6 Bracket, 7 Bearing, 8 Insulating member, 10 Stator part, 11 Shaft, 13 Electronic component, 17 Copper through hole, 18 Insulating member Projection, 20 mold stator, 30 rotor assembly, 52 indoor unit, 53 outdoor unit, 54 blower, 55 outdoor unit of water heater, 56 tank, 57 bathtub, 100 mold electric motor, 200 air conditioner, 300 water heater.

Claims (13)

A fixed structure in which an insulating member is attached to a stator core having a plurality of slots formed by laminating electromagnetic steel sheets, a winding is applied, and a substrate on which a drive circuit is mounted is attached to one axial end of the insulating member A mold stator having a child part and molding the stator part with a mold resin;
A rotor having a rotor, a shaft that fits into a shaft hole formed at a substantially central portion of the rotor, and two bearings that are fixed to the shaft and are located outside both ends in the axial direction of the rotor. And the board is disposed in the mold resin that forms an outline of an axial end of the mold stator outside the bearing on the board side of the rotor assembly. Mold electric motor.   The mold motor according to claim 1, wherein the substrate has a semicircular shape.   3. The mold according to claim 1, wherein an axial length of the portion of the mold resin that supports the bearing in a radial direction is made substantially thicker than an axial length of the bearing. Electric motor.   4. The electronic circuit according to claim 1, further comprising an electronic component that forms a driving circuit of the substrate and needs to dissipate heat, and is disposed so as to be substantially opposed to axial ends of the bearing and the shaft. 5. Mold electric motor.   The mold motor according to claim 4, wherein a copper through hole is provided in the portion of the substrate facing the electronic component.   6. The mold motor according to claim 4, wherein the electronic component is disposed on the rotor side of the substrate.   6. The mold motor according to claim 4, wherein the electronic component is disposed on the opposite side of the rotor of the substrate.   The mold motor according to claim 1, wherein the substrate is brought into contact with an end face of the bearing on the substrate side.   9. The mold motor according to claim 8, wherein a copper foil or a copper through hole is provided on the surface of the substrate in contact with the end face of the bearing.   The molded motor according to claim 9, wherein the bearing has an inner ring and an outer ring, and the substrate is brought into contact with the outer ring.   A blower comprising the molded electric motor according to any one of claims 1 to 10.   An air conditioner equipped with the blower according to claim 11.   A water heater equipped with the blower according to claim 11.