JP2008289268A - Thin stator, axial gap brushless vibrating motor equipped with this stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance torque by disposing a detent torque producing member so that the thickness thereof can be completely disregarded and deleting the coil disposition area portion of a stator base to ensure the thickness of a coil. <P>SOLUTION: Multiple air-core armature coils 5 are disposed on the upper face of a nonmagnetic or a weakly magnetic bracket 1 with insulating coating 1g in-between. The bracket has a shaft supporting portion disposed in the center thereof. A stator base 4 is added so that it is not overlaid on the air-core armature coils 5. A drive circuit member D is placed on the stator base 4. A detent torque producing member 3 is buried in the bracket 1 so that it is not protruded from the insulating coating 1g. The detent torque producing member is formed in at least one pair so that an angle equal to the open angle between the magnetic poles of a rotor to be combined is formed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  TECHNICAL FIELD The present invention relates to a thin stator and an axial gap type brushless vibration motor that is suitable for use as a silence notification means or the like of a mobile communication device.

As an axial air gap type brushless vibration motor, a coreless slotless type motor having one bearing has been proposed. (See Patent Document 1 and Patent Document 2)
As a brushless vibration motor with a drive circuit, a non-circular type in which a drive circuit member is arranged on the side of a stator is known which is a cored type in which armature coils are wound around a plurality of equally arranged salient poles. Yes. (See Patent Document 3)
However, such a device has a large lateral size, and the SMD method arranged on the printed wiring board of the set has poor mounting efficiency, and the cored type has to increase the thickness. There is no practicality.
Further, there has been proposed a structure including a cored and a coreless slotless type in which a part of a plurality of armature coils is deleted to provide a space, and a drive circuit member is disposed in this space. (See Patent Document 4)
Japanese Utility Model Publication No. 4-137463 JP 2002-143767 A JP 2000-245103 A JP 2002-142427 A (FIGS. 8 to 11)

By the way, in the single-phase type driven by one Hall sensor, a detent torque generating member that stops at a specific position is necessary in order to reliably start the magnetic pole position of the rotor magnet combined with the stator side next time.
Since this detent torque generating member has a thickness conventionally, if it is arranged on the bracket, the arrangement space is not easily obtained, and this causes a problem that goes against the thinning of the motor itself. On the other hand, it has also been proposed that the detent torque generating member is housed in the inner diameter portion of the air-core armature coil so that the thickness of the detent torque generating member can be substantially ignored. Therefore, there is a problem that the number of turns cannot be increased if the coil inner diameter is increased. When the coil is arranged on the outer diameter of the coil, the optimal position depends on the magnetic pole of the axial gap magnet to be combined. It may not be.

That is, the arrangement position of the detent torque generating member must be deliberately shifted from the center of the coil so that it may stop at either the center of the magnetic pole or the neutral position of the magnetic pole in order to avoid starting errors. If the inner diameter is small, this shift angle cannot be increased.
Further, if the predetermined shift angle cannot be maintained, the position of the effective conductor portion contributing to the torque is sacrificed and the starting torque is reduced. In such a stator, an air-core armature coil is generally arranged on a printed wiring board, but in an axial gap type motor, if the reduction in thickness is pursued, the thickness of the stator base cannot be ignored, The thickness of the air-core armature coil is sacrificed and the torque is reduced.

  Therefore, the present invention makes it possible to completely ignore the arrangement thickness of the detent torque generating member so as to obtain the optimum position (shift angle) of the detent torque generating member regardless of the inner diameter of the coil. The thickness of the coil is made negligible and the amount is increased as the coil thickness to increase the torque.

  In order to solve the above problem, as shown in claim 1, a bracket made of a non-magnetic or weak magnetic material having a shaft support portion disposed at the center and at least one air-core armature disposed on the upper surface of the bracket. A stator base comprising a coil and a printed wiring board that is attached to the bracket so as not to overlap with the air-core armature coil, the terminal of the air-core armature coil is connected and a drive circuit member is disposed, and the bracket This can be achieved with the detent torque generating member embedded so as not to protrude from the upper surface.

  Specifically, as shown in claim 2, the means for preventing the air-core armature coil and the stator base from overlapping is a coil mounting guide hole formed in the stator base, and is continuous with the coil mounting guide hole. Then, it is preferable that the stator base and the bracket have a recess for leading out the terminal of the air-core armature coil.

  According to a third aspect of the present invention, it is preferable that the bracket is formed with an insulating film in an arrangement area of the air-core armature coil including at least the detent torque generating member.

  According to a fourth aspect of the present invention, the detent torque generating member is formed in at least a pair so as to have an opening angle substantially equal to or an integral multiple of a magnetic pole opening angle of a rotor to be combined, and a through hole formed in the bracket The one that is fitted in is good.

  According to a fifth aspect of the present invention, the stator base, the air-core armature coil, the detent torque generating member, and the drive circuit member are preferably integrated with the bracket with resin.

  As shown in claim 6, these are provided with the stator according to any one of claims 1 to 5 and a rotor combined with the stator via an axial gap, the rotor including a rotor yoke, An axial gap type magnet having a plurality of magnetic poles fixed to a rotor yoke and an arc-shaped eccentric weight fixed to the rotor case at the outer periphery of the magnet are provided, and an outer case covers the stator outer periphery so as to cover the rotor It is good that it is assembled to.

  According to a seventh aspect of the present invention, the rotor case is provided with a bearing at the center thereof, and a base end of a shaft that is rotatably supported via the bearing is fixed to the bracket by welding, and a tip end of the shaft is externally attached. What is supported by the case and fixed by welding from the outside is good.

  In the first aspect of the present invention, since the detent torque generating member is within the thickness of the bracket, the thickness can be substantially ignored. As a result, the detent torque generating member is set at a position unrelated to the inner diameter of the air-core armature coil. Since the number of turns is sufficiently secured and there is no stator base in the area where the air-core armature coil is disposed, the coil can be made thick so that a sufficient amount of torque can be obtained.

  In the invention shown in claim 2, since the means for not overlapping the air-core armature coil and the stator base is the guide hole, the position of each coil is constant even when there are two or more coils, and the winding start terminal of the air-core armature coil The lead-out recess can be led out without disconnection at the beginning of winding.

  In the invention according to the third aspect, the winding start terminal can be led out without being disconnected by the winding start terminal leading recess of the air-core armature coil.

  In the invention according to claim 4, since the detent torque generating members are formed at least in pairs so as to have an opening angle substantially equal to or an integral multiple of the magnetic pole opening angle of the rotor to be combined, magnetic balance can be easily obtained. Since the thickness of the detent torque generating member is included in the bracket, the thickness can be completely ignored.

  In the invention shown in claim 5, since the thin stator is integrated with resin, each member functions as a skeleton, so that the rigidity is improved and the impact resistance is high.

  In the invention shown in claim 6, since the thickness of the detent torque generating member can be ignored as the axial gap type motor, and the thickness of the air-core armature coil can be increased by the amount of the stator base, a thin axial gap type capable of obtaining sufficient torque A vibration motor is obtained.

  In the invention shown in claim 7, since it is assembled by welding via the shaft, the rigidity is good.

  1 is a plan view of a bracket as a main member constituting the stator of the present invention, FIG. 2 is a plan view of a detent torque generating member attached to the bracket, and FIG. 3 is a plan view of a stator base attached to the bracket of FIG. FIG. 4 is an assembly diagram of a stator including these members, and FIG. 5 is a longitudinal sectional view of an axial air gap type brushless vibration motor including such a stator.

(First embodiment)
1 and 2, the bracket 1 constituting the stator of the present invention is a stainless steel plate made of nonmagnetic or weak magnet, and is formed of a thin plate having a thickness of about 0.2 mm. In addition, the bracket 1 is fixed to the shaft support portion 1a at the center by the laser welding L1 (see FIG. 5 described later) from the outside (the back side of the sheet of FIG. 1) of the shaft 2 from the outside. Further, the bracket 1 has a central side connected to the outer side in the radial direction of the shaft 2 and is expanded in a V shape toward the radial direction, and is equal to the opening angle of the magnetic pole of the axial gap type magnet 10 to be described later. The through hole 1b is opened. The bracket 1 may be a conductive or non-conductive material.

  The position of the through-hole 1b is set to 60 °, which is the same as the opening angle of the magnetic poles of the axial gap magnet 10 to be described later, and will be described later so that the center can be stopped and started at any position. It is set at a position of 15 ° from the center of each air-core armature coil 5 to be arranged. The through hole 1b is connected on the center side. Since this air-core armature coil 5 is composed of an insulated wire, it can be bonded as it is.

  If it does in this way, the four through-holes 1b connected by the center side of the bracket 1 and extending in radial direction equal to the opening angle of a magnetic pole will be obtained. Next, on the opposite side of the through hole 1b through the shaft 2, a rectangular through hole 1c is opened at a position of a drive circuit member D disposed on a stator base 4 described later. A feeding terminal arrangement portion 1d is formed so as to protrude from the outer periphery of the radial direction, and resin passage holes 1e are formed on both sides of the rectangular through hole 1c. Each 1f is a recess provided to release a winding start terminal of an air-core armature coil 5 described later, and is pressed by press molding. It may be a long hole penetrating. In the bracket 1 thus configured, in order to more reliably insulate each air-core armature coil 5, a resist insulating film 1g having a thickness of, for example, about 0.02 mm is provided at least with a detent torque generating member 3 and the bracket 1 described later. The air-core armature coil 5 is applied to the mounting area. The insulating film 1g can also be applied to the entire surface of the bracket 1 from the work. The insulating film 1g may be an insulating thin sheet or film.

  In this through hole 1b, a detent torque generating member 3 made of a magnetic stainless steel plate such as SUS430 having a thickness of about 0.15 mm and connected to the center side is buried by press fitting or the like, and the upper surface thereof is equal to or less than the upper surface of the bracket 1. Is set to be The detent torque generating member 3 is arranged with an air core armature coil 5 described later superimposed thereon. Since the detent torque generating member 3 has an opening angle of each portion extending in the radial direction equal to the magnetic pole opening angle of the axial gap magnet 10 combined therewith, a pair of N and S poles appear alternately. Therefore, the magnetic balance is good.

  Further, if the bracket 1 is allowed to be slightly thick, a recess instead of the through hole 1b may be press-molded, and the detent torque generating member 3 may be embedded in the recess. Further, the structure of the detent torque generating member 3 does not need to exactly match the opening angle of the magnetic poles of the axial gap magnet 10 to be combined as long as it has a detent torque generating function.

  3 and 4, the stator base 4 made of a flexible substrate (printed wiring board) having a thickness of about 0.12 mm has a central hole 4 a at the center thereof in accordance with the shaft support portion 1 a of the bracket 1. A connection type coil mounting guide hole 4b partially matched with the outer shape of the air-core armature coil 5 is formed on the outer periphery in the radial direction. Here, four air-core armature coils 5 can be mounted at an arrangement pitch of 60 °. It has a structure.

  Accordingly, the four air-core armature coils 5 are respectively attached to the bracket 1 via the coil attachment guide holes 4b so as not to overlap with the stator base 4. The air-core armature coils 5 all have the same thickness and are fixed to the bracket 1 with an adhesive.

  The coil mounting guide hole 4b is formed with a cut 4bb in a part so that the winding start terminal of the air-core armature coil 5 is led out. Further, a connection land 4c for single-phase connection is formed by printed wiring in the middle of each outer diameter side of the coil mounting guide hole 4b, and on the opposite side of the coil mounting guide hole 4b via the shaft 2, Two single-phase connection termination connection lands 4d are formed, and a solder implantation land 4e of the drive circuit member D is formed so as to be sandwiched between the land lands, and a power supply terminal land 4f is formed at the tip.

  On both sides of the solder planting land 4e of the drive circuit member D, elongated slits 4g are formed so that the stator base 4 in this portion can be easily bent and deformed. Further, at least a portion of the stator base 4 where the solder planting land 4e of the drive circuit member D is formed is dropped into the square through hole 1c, and the substantial thickness of the stator base 4 at this portion can be ignored. ing. Further, the stator base 4 is formed with a similar resin passage hole 4h at the same position in the plane as the resin passage hole 1e formed in the bracket 1. In the solder planting land 4e, a single-phase full-wave motor drive circuit member D having a built-in Hall sensor is solder-planted at a position indicated by an imaginary line, and power is supplied from the power feeding terminal land 4f. The drive circuit member D has a size of about 2 mm to 2.2 mm square and a thickness of about 0.5 mm. Besides the 4-terminal pin such as a PWM drive type as necessary, the drive circuit member D can be used at start-up and steady-state. A multi-terminal pin type capable of two-stage drive can also be adopted. Since the air-core armature coil 5 is formed slightly smaller than the coil mounting guide hole 4b and is bonded to the bracket 1 with the UV curable anaerobic adhesive so as to align the direction toward the center, each air-core armature The position of the coil 5 is constant.

  The stator base 4 configured as described above is accurately aligned using the feed terminal land 4f, the feed terminal arrangement portion 1d, the outer periphery, and the like, and fixed with a UV curable anaerobic adhesive. That is, such a stator S is assembled as shown in FIG. 4 when the above is summarized, but each connection land is omitted because it is complicated.

  Then, as shown in FIG. 5 described later, here, the injection molding resin 6 having relatively heat resistance is integrally molded so that the upper surface of the air-core armature coil 5 and the upper surface of the drive circuit member D are exposed. Since the resin passes through the resin passage holes 1e and 4h, the stator base 4 and each member are fixed to the bracket 1 with sufficient strength. The resin passage holes 1e and 4h may be used as a gate in resin molding from the bottom surface of the bracket 1. If formed in this way, each air-core armature coil 5 side is set in a mold, so there is no risk of damaging each coil when the molds are aligned. Thus, since all the members are fixed by resin molding as the stator S, sufficient strength is ensured while being thin.

  On the other hand, the eccentric rotor R combined with such a stator S is as shown in FIG. That is, the rotor case 7 is made of magnetic stainless steel having a thickness of about 0.2 mm, and is formed with a flat portion 7a, an outer peripheral side hanging portion 7b, and an inner diameter side hanging portion 7c, and the outer circumferential side hanging portion 7b is made of arcuate tungsten. An eccentric weight 8 is fixed by soldering or laser welding, and a sintered oil-impregnated bearing 9 is fastened to the inner diameter side hanging portion 7c by laser welding, soldering, or the like. Inside the flat portion 7a, the axial gap magnet 10 magnetized to 6 poles is fixed by adhesion or the like.

  In addition to the above, the fixing means for the eccentric weight 8 may be a means such as extending the outer periphery of the rotor case 7 and tightening the concave / convex joint or welding the concave / convex joint. The axial gap type magnet 10 is set so as to ensure the adhesive strength by deliberately reducing the inner diameter side and bringing it closer to the inner diameter side hanging part 7c so that the adhesive wraps around. Although an area that is not magnetized appears on the inner diameter side, it is convenient in terms of setting the detent torque generating member 3.

  The eccentric rotor R configured as described above is rotatably mounted on the shaft 2 via a thrust washer SW and a bearing 9, covered with an outer case 11, and incorporated in the outer periphery of the bracket 1 at the opening of the outer case 11. Then, a part is laser welded L2 from the outside, the tip of the shaft 2 is fitted into the shallow burring hole 11a of the outer case 11, and laser welding L3 is performed from the outside to complete the axial gap type brushless vibration motor. To do. If it does in this way, it will become a monocoque structure as a whole, and can fully endure the impacts, such as dropping.

  By adopting each of these embodiments, an extremely thin axial gap type brushless vibration motor having a diameter of 10 mm and a thickness of 2 mm or less can be realized, and the air-core armature coil 5 that requires the most thickness as the stator S has a thickness of the stator. The torque can be increased by increasing by 25% from the base, that is, from 0.35 mm to 0.45 mm.

The stator of the present invention can be applied not only to a vibration motor but also to a normal rotation type single-phase brushless motor such as a general fan motor if it is a shaft rotation type.
The present invention can take various other embodiments without departing from the technical idea and characteristics thereof. Therefore, the above-described embodiment is merely an example and should not be interpreted in a limited manner. The technical scope of the present invention is indicated by the claims, and is not restricted by the text of the specification.

It is a top view of a bracket as a main member which comprises the stator of this invention. It is a top view of the detent torque generation member with which the bracket of FIG. 1 is mounted. It is a top view of the stator base attached to the bracket of FIG. It is an assembly drawing of the stator provided with these members. It is a longitudinal cross-sectional view of the axial direction air gap type brushless vibration motor provided with such a stator.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Bracket 1a Shaft support part 1b Through-hole 1c Through-hole 1d Feeding terminal arrangement | positioning part 1e Resin passage hole 1f Recessed part 1g Insulation film 2 Shaft 3 Detent torque generating member 4 Stator base 4a Center hole 4b Coil mounting guide hole 4bb Cut 4c Connection land 4d Single-phase termination terminal land 4e Solder planting land 4f Feeding terminal land 4g Notch 4h Resin passage hole 5 Air core armature coil 6 Resin 7 Rotor case 7a Flat portion 7b Outer peripheral side drooping 7c Inner diameter side drooping 8 Eccentric weight 9 Burning Oil impregnated bearing 10 Axial gap type magnet 11 Outer case 11a Burring hole D Drive circuit member L1 Laser welding L2 Laser welding L3 Laser welding S Stator R Eccentric rotor SW Thrust washer

  TECHNICAL FIELD The present invention relates to a thin stator and an axial gap type brushless vibration motor that is suitable for use as a silence notification means or the like of a mobile communication device.

As an axial air gap type brushless vibration motor, a coreless slotless type motor composed of one bearing has been proposed. (See Patent Document 1 and Patent Document 2)
As a brushless vibration motor with a drive circuit, a non-circular type in which a drive circuit member is arranged on the side of a stator is known which is a cored type in which armature coils are wound around a plurality of equally arranged salient poles. Yes. (See Patent Document 3)
However, such a device has a large lateral size, and the SMD method arranged on the printed wiring board of the set has poor mounting efficiency, and the cored type has to increase the thickness. There is no practicality.
Further, there has been proposed a structure including a cored and a coreless slotless type in which a part of a plurality of armature coils is deleted to provide a space, and a drive circuit member is disposed in this space. (See Patent Document 4)
Japanese Utility Model Publication No. 4-137463 JP 2002-143767 A JP 2000-245103 A JP 2002-142427 A (FIGS. 8 to 11)

By the way, in the single-phase type driven by one Hall sensor, a detent torque generating member that stops at a specific position is necessary in order to reliably start the magnetic pole position of the rotor magnet combined with the stator side next time.
Since this detent torque generating member has a thickness conventionally, if it is arranged on the bracket, the arrangement space is not easily obtained, and this causes a problem that goes against the thinning of the motor itself. On the other hand, it has also been proposed that the detent torque generating member is housed in the inner diameter portion of the air-core armature coil so that the thickness of the detent torque generating member can be substantially ignored. Therefore, there is a problem that the number of turns cannot be increased if the coil inner diameter is increased. When the coil is arranged on the outer diameter of the coil, the optimal position depends on the magnetic pole of the axial gap magnet to be combined. It may not be.

That is, the arrangement position of the detent torque generating member must be deliberately shifted from the center of the coil so that it may stop at either the center of the magnetic pole or the neutral position of the magnetic pole in order to avoid starting errors. If the inner diameter is small, this shift angle cannot be increased.
Further, if the predetermined shift angle cannot be maintained, the position of the effective conductor portion contributing to the torque is sacrificed and the starting torque is reduced. In such a stator, an air-core armature coil is generally arranged on a printed wiring board, but in an axial gap type motor, if the reduction in thickness is pursued, the thickness of the stator base cannot be ignored, The thickness of the air-core armature coil is sacrificed and the torque is reduced.

Therefore, the present invention makes it possible to completely ignore the arrangement thickness of the detent torque generating member so that the optimum position of the detent torque generating member (shift angle from the coil center ) can be obtained regardless of the inner diameter of the coil. At the same time, the thickness of the stator base is made negligible, and the corresponding portion is increased as the coil thickness to increase the torque.

To solve the above problem, as shown in Claim 1, a bracket made of a non-magnetic or weakly magnetic shaft support portion is arranged in the center, the air-core armature coils disposed towards on the bracket, A stator base which is attached to the bracket so as not to overlap with the air-core armature coil, and which is composed of a printed wiring board on which a terminal of the air-core armature coil is connected and a drive circuit member is disposed, and the bracket It can be achieved in that the detent torque generating member is padded on.

Specifically, as shown in claim 2, a shaft is supported by the shaft support portion, and a coil mounting guide hole is formed in the stator base as a means for preventing the air-core armature coil and the stator base from overlapping. A recess for leading the winding start of the air-core armature coil is formed in the stator base and the bracket continuously to the coil mounting guide hole , and the bracket includes an insulating film including at least the detent torque generating member. What is formed in the said air-core armature coil arrangement | positioning area is good.

According to a third aspect of the present invention, the detent torque generating member is formed in at least a pair so as to have an opening angle substantially equal to or an integral multiple of the magnetic pole opening angle of the rotor to be combined, and the through hole formed in the bracket The one that is fitted in is good.

According to a fourth aspect of the present invention, the bracket is formed with a through hole at a position where the drive circuit is disposed, the stator base is formed of a flexible substrate, and the drive circuit member is disposed on the stator base. that cuts the vicinity is formed, the stator base as said drive circuit member via the stator base is dropped into the through hole, the air-core armature coils,及 beauty said driving circuit member, said bracket What is integrated with resin is good.

As shown in claim 5 , the axial gap type brushless vibration motor includes the thin stator according to any one of claims 1 to 4 and a rotor combined with the stator via an axial gap. is, the rotor is a rotor yoke, an axial gap-type magnet having a plurality of magnetic poles fixed to the rotor yoke, eccentric weights and are provided, the outer case so as to cover the rotor is assembled to the stator outer periphery Things are good.

In the first aspect of the present invention, since the detent torque generating member is within the thickness of the bracket, the thickness can be substantially ignored. As a result, the detent torque generating member is set at a position unrelated to the inner diameter of the air-core armature coil. Since the air-core armature coil has a sufficient number of turns and there is no stator base in the area where the air-core armature coil is arranged, the coil can be sufficiently torqued accordingly. Can be thicker.

In the invention according to claim 2, since the insulating film is interposed between the coil and the bracket , the insulating film of the coil is damaged, and the insulation from the bracket is ensured. Further, since the means for preventing the air-core armature coil and the stator base from overlapping is a guide hole, the position of each coil is constant even when there are two or more coils, and the coil is wound by the terminal lead-out recess at the beginning of the air-core armature coil. First, the terminal can be derived without disconnection.

In the invention shown in claim 3, the detent torque generation or member is substantially equal to the magnetic pole opening angle of the rotor to be combined, or because it is formed at least a pair such that the opening angle of an integral multiple, magnetic adsorption balance easily As a result, since the thickness of the detent torque generating member is included in the bracket, the thickness can be completely ignored.

In the invention shown in claim 4, since the stator base bends facilitated by notches, the drive circuit members can be arranged substantially lower posture, stiffness because each member functions as a diaphyseal so are integrated with the resin while thin stator And the impact resistance is high.

In the invention shown in claim 5 , since the thickness of the detent torque generating member can be ignored as the axial gap type motor and the thickness of the air-core armature coil can be increased by the amount corresponding to the stator base, a thin axial gap type capable of obtaining sufficient torque. A vibration motor is obtained.

  1 is a plan view of a bracket as a main member constituting the stator of the present invention, FIG. 2 is a plan view of a detent torque generating member attached to the bracket, and FIG. 3 is a plan view of a stator base attached to the bracket of FIG. FIG. 4 is an assembly diagram of a stator including these members, and FIG. 5 is a longitudinal sectional view of an axial air gap type brushless vibration motor including such a stator.

(First embodiment)
1 and 2, the bracket 1 constituting the stator of the present invention is a stainless steel plate made of nonmagnetic or weak magnet, and is formed of a thin plate having a thickness of about 0.2 mm. The bracket 1 is fixed at the outside to the center of the shaft support portion 1a proximal end of the shaft 2 (see figure 5 below) from (behind the paper plane of FIG. 1) laser welding L1. Further, the bracket 1 has a central side connected to the outer side in the radial direction of the shaft 2 and is expanded in a V shape toward the radial direction, and is equal to the opening angle of the magnetic pole of the axial gap type magnet 10 to be described later. The through hole 1b is opened. The bracket 1 may be a conductive or non-conductive material.

  The position of the through-hole 1b is set to 60 °, which is the same as the opening angle of the magnetic poles of the axial gap magnet 10 to be described later, and will be described later so that the center can be stopped and started at any position. It is set at a position of 15 ° from the center of each air-core armature coil 5 to be arranged. The through hole 1b is connected on the center side. Since this air-core armature coil 5 is composed of an insulated wire, it can be bonded as it is.

In this way, four through-holes 1b are obtained which are connected on the center side of the bracket 1 and extend in the radial direction equal to the opening angle of the magnetic pole. Next, on the opposite side of the through hole 1b through the shaft 2, a rectangular through hole 1c is opened at a position of a drive circuit member D disposed on a stator base 4 described later. A feeding terminal arrangement portion 1d is formed so as to protrude from the outer periphery of the radial direction, and resin passage holes 1e are formed on both sides of the rectangular through hole 1c. Each 1f in the figure, a coreless winding start concave plant provided for releasing the terminal of the armature coil 5 will be described later, but is pressed formed by press molding, when integrally molded with resin 6 as described later resin Since it is closed with, it may be a long hole penetrating. Bracket 1 constituted in this way, the air-core to the insulation between the armature coil 5 more reliably, for example detent insulating coating 1g at least below by resist with a thickness of about 0.02mm torque generating member 3 and the bracket 1 The air-core armature coil 5 is applied to the mounting area. The insulating film 1g can also be applied to the entire surface of the bracket 1 from the work. The insulating film 1g may be an insulating thin sheet or film.

In this through hole 1b, a detent torque generating member 3 made of a magnetic stainless steel plate such as SUS430 having a thickness of about 0.15 mm and connected to the center side is buried by press fitting or the like, and the upper surface thereof is equal to or less than the upper surface of the bracket 1. Is set to be The detent torque generating member 3 is provided with an air core armature coil 5 which will be described later. Since the detent torque generating member 3 has an opening angle of each portion extending in the radial direction equal to the magnetic pole opening angle of the axial gap magnet 10 combined therewith, a pair of N and S poles appear alternately. Therefore, the magnetic balance is good.

  Further, if the bracket 1 is allowed to be slightly thick, a recess instead of the through hole 1b may be press-molded, and the detent torque generating member 3 may be embedded in the recess. Further, the structure of the detent torque generating member 3 does not need to exactly match the opening angle of the magnetic poles of the axial gap magnet 10 to be combined as long as it has a detent torque generating function.

3 and 4, the stator base 4 made of a flexible substrate (printed wiring board) having a thickness of about 0.12 mm has a central hole 4 a at the center thereof in accordance with the shaft support portion 1 a of the bracket 1. A connection type coil mounting guide hole 4b partially matched with the outer shape of the air-core armature coil 5 is formed in the outer periphery in the radial direction of the central hole 4a . Here, four air-core armature coils are arranged at a 60 ° arrangement pitch. 5 can be mounted.

  Accordingly, the four air-core armature coils 5 are respectively attached to the bracket 1 via the coil attachment guide holes 4b so as not to overlap with the stator base 4. The air-core armature coils 5 all have the same thickness and are fixed to the bracket 1 with an adhesive.

In this coil mounting guide hole 4b, a notch 4bb is formed in a part as a recess for starting the winding to lead out the winding starting terminal of the air-core armature coil 5. Further, a connection land 4c for single-phase connection is formed by printed wiring in the middle of each outer diameter side of the coil mounting guide hole 4b, and on the opposite side of the coil mounting guide hole 4b via the shaft 2, Two single-phase connection termination connection lands 4d are formed, and a solder implantation land 4e of the drive circuit member D is formed so as to be sandwiched between the land lands, and a power supply terminal land 4f is formed at the tip.

  On both sides of the solder planting land 4e of the drive circuit member D, elongated slits 4g are formed so that the stator base 4 in this portion can be easily bent and deformed. Further, at least a portion of the stator base 4 where the solder planting land 4e of the drive circuit member D is formed is dropped into the square through hole 1c, and the substantial thickness of the stator base 4 at this portion can be ignored. ing. Further, the stator base 4 is formed with a similar resin passage hole 4h at the same position in the plane as the resin passage hole 1e formed in the bracket 1. In the solder planting land 4e, a single-phase full-wave motor drive circuit member D having a built-in Hall sensor is solder-planted at a position indicated by an imaginary line, and power is supplied from the power feeding terminal land 4f. The drive circuit member D has a size of about 2 mm to 2.2 mm square and a thickness of about 0.5 mm. Besides the 4-terminal pin such as a PWM drive type as necessary, the drive circuit member D can be used at start-up and steady-state. A multi-terminal pin type capable of two-stage drive can also be adopted. Since the air-core armature coil 5 is formed slightly smaller than the coil mounting guide hole 4b and is bonded to the bracket 1 with the UV curable anaerobic adhesive so as to align the direction toward the center, each air-core armature The position of the coil 5 is constant.

  The stator base 4 configured as described above is accurately aligned using the feed terminal land 4f, the feed terminal arrangement portion 1d, the outer periphery, and the like, and fixed with a UV curable anaerobic adhesive. That is, such a stator S is assembled as shown in FIG. 4 when the above is summarized, but each connection land is omitted because it is complicated.

  Then, as shown in FIG. 5 described later, here, the injection molding resin 6 having relatively heat resistance is integrally molded so that the upper surface of the air-core armature coil 5 and the upper surface of the drive circuit member D are exposed. Since the resin passes through the resin passage holes 1e and 4h, the stator base 4 and each member are fixed to the bracket 1 with sufficient strength. The resin passage holes 1e and 4h may be used as a gate in resin molding from the bottom surface of the bracket 1. If formed in this way, each air-core armature coil 5 side is set in a mold, so there is no risk of damaging each coil when the molds are aligned. Thus, since all the members are fixed by resin molding as the stator S, sufficient strength is ensured while being thin.

  On the other hand, the eccentric rotor R combined with such a stator S is as shown in FIG. That is, the rotor case 7 is made of magnetic stainless steel having a thickness of about 0.2 mm, and is formed with a flat portion 7a, an outer peripheral side hanging portion 7b, and an inner diameter side hanging portion 7c. An eccentric weight 8 is fixed by soldering or laser welding, and a sintered oil-impregnated bearing 9 is fastened to the inner diameter side hanging portion 7c by laser welding, soldering, or the like. Inside the flat portion 7a, the axial gap magnet 10 magnetized to 6 poles is fixed by adhesion or the like.

  In addition to the above, the fixing means for the eccentric weight 8 may be a means such as extending the outer periphery of the rotor case 7 and tightening the concave / convex joint or welding the concave / convex joint. The axial gap type magnet 10 is set so as to ensure the adhesive strength by deliberately reducing the inner diameter side and bringing it closer to the inner diameter side hanging part 7c so that the adhesive wraps around. Although an area that is not magnetized appears on the inner diameter side, it is convenient in terms of setting the detent torque generating member 3.

  The eccentric rotor R configured as described above is rotatably mounted on the shaft 2 via a thrust washer SW and a bearing 9, covered with an outer case 11, and incorporated in the outer periphery of the bracket 1 at the opening of the outer case 11. Then, a part is laser welded L2 from the outside, the tip of the shaft 2 is fitted into the shallow burring hole 11a of the outer case 11, and laser welding L3 is performed from the outside to complete the axial gap type brushless vibration motor. To do. If it does in this way, it will become a monocoque structure as a whole, and can fully endure the impacts, such as dropping.

  By adopting each of these embodiments, an extremely thin axial gap type brushless vibration motor having a diameter of 10 mm and a thickness of 2 mm or less can be realized, and the air-core armature coil 5 that requires the most thickness as the stator S has a thickness of the stator. The torque can be increased by increasing by 25% from the base, that is, from 0.35 mm to 0.45 mm.

The stator of the present invention can be applied not only to a vibration motor but also to a normal rotation type single-phase brushless motor such as a general fan motor if it is a shaft rotation type.
The present invention can take various other embodiments without departing from the technical idea and characteristics thereof. Therefore, the above-described embodiment is merely an example and should not be interpreted in a limited manner. The technical scope of the present invention is indicated by the claims, and is not restricted by the text of the specification.

It is a top view of a bracket as a main member which comprises the stator of this invention. It is a top view of the detent torque generation member with which the bracket of FIG. 1 is mounted. It is a top view of the stator base attached to the bracket of FIG. It is an assembly drawing of the stator provided with these members. It is a longitudinal cross-sectional view of the axial direction air gap type brushless vibration motor provided with such a stator.

Explanation of symbols

1 bracket 1a shaft support portion 1b through hole 1c through hole 1d feeding terminal arrangement portion 1e resin passing holes 1f concave plants 1g insulating film biaxially 3 detent torque generating member 4 stator base 4a central hole 4b coil mounting guide hole 4bb notch 4c connection land 4d Single-phase connection termination connection land 4e Solder planting land 4f Power supply terminal land 4g Notch 4h Resin passage hole 5 Air core armature coil 6 Resin 7 Rotor case 7a Flat part 7b Outer peripheral side hanging part 7c Inner diameter side hanging part 8 Eccentric weight 9 Sintered oil-impregnated bearing 10 Axial gap type magnet 11 Outer case 11a Burring hole D Drive circuit member L1 Laser welding L2 Laser welding L3 Laser welding S Stator R Eccentric rotor SW Thrust washer

In order to solve the above problem, as shown in claim 1, a bracket made of a non-magnetic or weak magnetic material having a shaft support portion disposed at the center, and an end of an air-core armature coil attached to the bracket. And a stator base made of a printed wiring board on which a drive circuit member is arranged. A coil mounting guide hole is formed in the stator base, and the air-core armature coil is formed through the coil mounting guide hole. Is arranged on the bracket so that the air-core armature coil and the stator base do not overlap with each other, and a detent torque generating member is embedded in the bracket.

Specifically, as shown in claim 2, the winding start terminal derivation recess of the air-core armature coils successively on the coil mounting guide hole in the stator base and the bracket are formed, insulated from the bracket good what film is formed on the air-core armature coils disposed area including at least the detent torque generation member.

As shown in claim 5, the axial gap type brushless vibration motor includes the thin stator according to any one of claims 1 to 4 and a rotor combined with the stator via an axial gap. The rotor is rotatably mounted on a shaft supported by the shaft support portion, and the rotor includes a rotor yoke, an axial gap type magnet having a plurality of magnetic poles fixed to the rotor yoke, and an eccentric weight. It is preferable that the outer case is assembled to the outer periphery of the stator so as to cover the rotor.

In order to solve the above problem, as shown in claim 1, a bracket made of a non-magnetic or weak magnetic material having a shaft support portion disposed at the center, and an end of an air-core armature coil attached to the bracket. And a stator base made of a printed wiring board on which a drive circuit member is arranged. A coil mounting guide hole is formed in the stator base, and the air-core armature coil is formed through the coil mounting guide hole. There is arranged on the bracket, the air-core armature coil and the stator base is configured so as not to overlap, the detent torque generating member is embedded in the through hole formed in the front Symbol bracket, the detent torque generating This can be achieved by setting the upper surface of the member to be equal to or less than the upper surface of the bracket .

According to a third aspect of the present invention, the bracket is formed with a through hole at a position where the drive circuit is disposed, the stator base is formed of a flexible substrate, and the drive circuit member is disposed on the stator base. The stator base, the air-core armature coil, and the drive circuit member are made of resin on the bracket so that the drive circuit member is dropped into the through hole through the stator base. It is good that they are integrated with each other.

As shown in claim 4 , the axial gap type brushless vibration motor includes the thin stator according to any one of claims 1 to 3 and a rotor combined with the stator via an axial gap. The rotor is rotatably mounted on a shaft supported by the shaft support portion, and the rotor includes a rotor yoke, an axial gap type magnet having a plurality of magnetic poles fixed to the rotor yoke, and an eccentric weight. It is preferable that the outer case is assembled to the outer periphery of the stator so as to cover the rotor.

Claims (7)

A bracket made of a non-magnetic or weak magnetic material with a shaft support portion arranged in the center;
An air-core armature coil arranged on the upper surface of the bracket;
A stator base made of a printed wiring board attached to the bracket so as not to overlap with the air-core armature coil, the terminal of the air-core armature coil being connected, and a drive circuit member being disposed;
A thin stator in which a detent torque generating member is embedded in the bracket so as not to protrude from the upper surface.   Means for preventing the air-core armature coil and the stator base from overlapping each other is a coil mounting guide hole formed in the stator base, and the air-core electric machine is connected to the stator base and the bracket continuously to the coil mounting guide hole. The thin stator according to claim 1, wherein a recess for leading out the terminal of winding of the child coil is formed.   The thin stator according to claim 1, wherein an insulating film is formed on the bracket in an arrangement area of the air-core armature coil including at least the detent torque generating member.   The detent torque generating member is formed in at least a pair so as to have an opening angle substantially equal to or an integral multiple of a magnetic pole opening angle of a rotor to be combined, and is fitted into a through hole formed in the bracket. Thin stator.   The thin stator according to any one of claims 1 to 4, wherein the stator base, the air-core armature coil, the detent torque generating member, and the drive circuit member are integrated with the bracket with resin.   A stator according to any one of claims 1 to 5 and a rotor combined with the stator via an axial gap are provided, the rotor having a rotor yoke and a plurality of magnetic poles fixed to the rotor yoke. An axial gap type brushless vibration comprising an axial gap type magnet and an arc-shaped eccentric weight fixed to the rotor case at the outer circumference of the magnet, and an outer case assembled to the outer circumference of the stator so as to cover the rotor motor.   The rotor case is provided with a bearing at the center, and the base end of a shaft that is rotatably supported via the bearing is fixed to the bracket by welding, and the tip end of the shaft is supported by an outer case, and is welded from the outside. The axial direction air gap type brushless vibration motor according to claim 6, which is fixed.

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