JP2011188701A - Rotor of motor for pump, pump, air conditioner, floor heating device, hot water supply device, and method of manufacturing the pump - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rotor of a motor for pumps that improves pump performance by reducing a friction loss and a circulating loss. <P>SOLUTION: In the rotor of the motor for pumps, a rotor unit is formed by integrally molding a magnet and a sleeve bearing disposed inside the magnet with a thermoplastic resin, and has an impeller attachment unit formed by the thermoplastic resin. The magnet includes: a plurality of cutouts that are formed at substantially equal intervals in a peripheral direction at an inner peripheral side of an end face on a side facing a magnetic pole position detection element, and have a substantially rectangular cross-sectional shape; and a plurality of projections having a substantially rectangular cross-sectional shape formed at substantially equal intervals in a circumferential direction so that the projections project inward on an inner peripheral side at a predetermined depth from the end face on a side of the impeller attachment unit. In the integral molding by the thermoplastic resin, the cutout of the magnet is set to a lower die of a molding die to secure coaxiality, and an upper die of the molding die is pressed against the projections, thus positioning the magnet. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a rotor of a pump motor. The present invention also relates to a pump using the rotor of the pump motor and a method for manufacturing the pump. Furthermore, the present invention relates to an air conditioner, a floor heating device, and a hot water supply device using the pump.

  In the rotor of the pump motor manufactured by integrally molding the magnet and the sleeve bearing with the thermoplastic resin, the sleeve bearing and the magnet are set in the lower mold when the rotor of the pump motor is integrally molded with the thermoplastic resin, Furthermore, in a state where the notch holding portion of the left and right slide mechanism provided in the upper die is pressed from the radial direction to the substantially rectangular notch formed on the outer peripheral portion of the end surface of the magnet on the impeller mounting side. There has been proposed a rotor for a pump motor in which a magnet and a sleeve bearing are integrally formed of a thermoplastic resin (see, for example, Patent Document 1 (Embodiment 1, etc.)).

  In addition, in a rotor for a pump motor manufactured by integrally molding a magnet and a sleeve bearing with a thermoplastic resin, a rotor balancing hole provided on the upper die is provided on the bottom surface of a semicircular groove provided on the inner diameter of the magnet. There is also proposed a rotor for a pump motor in which a magnet and a sleeve bearing are integrally formed of a thermoplastic resin in a state where a pin for forming a roller is pressed (see, for example, Patent Document 1 (Embodiment 2). etc)).

JP 2009-197729 A

  However, the rotor of the pump motor according to the first embodiment in Patent Document 1 has a concave portion formed by a substantially square cutout provided on the outer periphery of the magnet. This recess serves as a fluid resistance when the rotor of the pump motor rotates in water. Therefore, the friction loss when the rotor of the pump electric motor rotates in water increases, and the pump efficiency may decrease.

  Further, in the rotor of the pump motor according to the second embodiment of Patent Document 1, the circulation loss due to the circulation flow using the balance hole as a route increases. Therefore, when the pressure difference between the front and back of the impeller is relatively small and it is not necessary to provide a countersunk hole, an unnecessary circulation path is provided, which may reduce pump efficiency. Moreover, there was a possibility that the life of the pin for forming the counter hole of the rotor provided in the mold may be reduced by being pressed against the magnet.

  The present invention has been made in order to solve the above-described problems, and it is possible to reduce the friction loss and the circulation loss of the rotor of the pump motor, and to improve the pump performance. A rotor, a pump, and a method for manufacturing the pump are provided.

  Furthermore, an air conditioner, a floor heating device, and a hot water supply device equipped with the pump are provided.

A rotor of a pump motor according to the present invention is mounted on a pump that partitions a water circuit and a mold stator including a substrate on which a magnetic pole position detection element is mounted, with a bowl-shaped partition wall part, In the rotor of the pump motor, which is rotatably housed, one end faces the magnetic pole position detection element, and the other end has a rotor part having an impeller mounting part for attaching the impeller.
The rotor is
A magnet and a sleeve bearing disposed inside the magnet are integrally formed of thermoplastic resin, and at the same time, the impeller mounting portion is formed of thermoplastic resin,
The magnet
A plurality of notches having a substantially square shape in cross section are formed on the inner peripheral side of the end face on the side opposite to the magnetic pole position detection element at a substantially equal interval in the circumferential direction.
A plurality of protrusions that are formed at substantially equal intervals in the circumferential direction so as to protrude inward from the end surface on the impeller mounting portion side to the inner peripheral side of a predetermined depth,
At the time of integral molding with thermoplastic resin, a magnet notch is set in the lower mold of the molding die to ensure coaxiality, and the upper mold for molding is pressed against the projection to position the magnet. is there.

  The rotor of the pump electric motor according to the present invention, when integrally molding the sleeve bearing and the magnet with the thermoplastic resin, to set the notch of the magnet in the lower mold of the molding die, to ensure the coaxial, The upper die of the molding die is pressed against the protrusion provided on the inner periphery of the magnet to position the magnet, so that the positional relationship and coaxiality between the sleeve bearing and the magnet can be secured, and the rotor of the pump motor The quality of the product can be improved.

FIG. 3 shows the first embodiment and is a configuration diagram of a heat pump hot water supply apparatus 300. FIG. FIG. 3 is an exploded perspective view of the pump 10 showing the first embodiment. FIG. 5 shows the first embodiment and is a perspective view of a mold stator 50. FIG. 5 shows the first embodiment and is a cross-sectional view of a mold stator 50. FIG. 5 shows the first embodiment and is an exploded perspective view of the stator assembly 49; FIG. 4 is a diagram showing the first embodiment and a diagram showing a pilot hole part 81 ((a) is a side view, (b) is a plan view)). FIG. 5 shows the first embodiment, and is a perspective view of a stator assembly 49; FIG. 5 shows the first embodiment, and is an exploded perspective view of the pump unit 40; FIG. 3 shows the first embodiment, and is a cross-sectional view of the pump 10. FIG. 5 shows the first embodiment, and is a perspective view of the casing 41 as seen from the shaft support portion 46 side. It is a figure which shows Embodiment 1, and sectional drawing (AA sectional drawing of FIG. 13) of the rotor part 60a. FIG. 5 shows the first embodiment, and is a side view of the rotor portion 60a viewed from the impeller attachment portion 67a side. The side view which looked at the rotor part 60a from the opposite side of the impeller attachment part 67a in the figure which shows Embodiment 1. FIG. FIG. 5 shows the first embodiment, and is an enlarged sectional view of a sleeve bearing 66. FIG. 5 shows the first embodiment, and is a cross-sectional view of a resin magnet 68 (cross-sectional view taken along line BB in FIG. 17). FIG. 5 shows the first embodiment, and is a side view of the resin magnet 68 viewed from the protrusion 68a side. FIG. 5 shows the first embodiment, and is a side view of the resin magnet 68 viewed from the opposite side of the protrusion 68a. It is a figure which shows Embodiment 1, and sectional drawing (CC sectional drawing of FIG. 20) of the resin magnet 468 of the modification 1. As shown in FIG. FIG. 5 shows the first embodiment, and is a side view of the resin magnet 468 of the first modification viewed from the protrusion 468a side. FIG. 9 shows the first embodiment, and is a side view of the resin magnet 468 of the first modification viewed from the opposite side of the protrusion 468a. It is a figure which shows Embodiment 1, and sectional drawing of the resin magnet 568 of the modification 2 (DD sectional drawing of FIG. 23). FIG. 5 shows the first embodiment, and is a side view of a resin magnet 568 according to Modification 2 as viewed from the projection 568a side. FIG. 5 shows the first embodiment, and is a side view of a resin magnet 568 according to Modification 2 as viewed from the opposite side of the protrusion 568a. FIG. 5 shows the first embodiment and shows the manufacturing process of the pump 10. FIG. 3 is a diagram illustrating the first embodiment and is a conceptual diagram illustrating a circuit of an apparatus using the refrigerant-water heat exchanger 2. It is a figure shown for a comparison and is sectional drawing of the rotor part 760 of the prior art example 1 (XX sectional drawing of FIG. 27). It is a figure shown for a comparison and the side view which looked at the rotor part 760a of the prior art example 1 from the impeller attachment part 767a side. It is a figure shown for a comparison and sectional drawing of the resin magnet 768 of the prior art example 1 (YY sectional drawing of FIG. 30). It is a figure shown for the comparison, The side view which looked at the resin magnet 768 of the prior art example 1 from the notch 768f side. It is a figure shown for a comparison and is the side view which looked at the resin magnet 768 of the prior art example 1 from the notch 768f opposite side. It is a figure shown for a comparison and is sectional drawing of the rotor part 860a of the prior art example 2 (ZZ sectional drawing of FIG. 32). It is a figure shown for a comparison and the side view which looked at the rotor part 860a of the prior art example 2 from the impeller attachment part 867a side. It is a figure shown for a comparison and sectional drawing of the resin magnet 868 of the prior art example 2 (FF sectional drawing of FIG. 35). It is a figure shown for a comparison and the side view which looked at the resin magnet 868 of the prior art example 2 from the notch 868b opposite side. It is a figure shown for a comparison and is the side view which looked at the resin magnet 868 of the prior art example 2 from the notch 868b side.

Embodiment 1 FIG.
The rotor of the pump motor according to the present embodiment is mounted on a pump that partitions water and a mold stator having a substrate on which a magnetic pole position detecting element is mounted by a bowl-shaped partition wall component, and is freely rotatable within the bowl-shaped partition wall component. A rotor of a pump motor that includes an impeller mounting portion that has one end facing the magnetic pole position detection element and the other end to which the impeller is attached,
A ring-shaped magnet and a sleeve bearing disposed inside the magnet are integrally formed of thermoplastic resin, and at the same time, an impeller mounting portion is formed of thermoplastic resin.
The magnet includes a plurality of notches having a substantially square cross-sectional shape extending in the axial direction on the inner peripheral side opposite to the magnetic pole position detection element.
A plurality of protrusions with a substantially square cross section extending in the axial direction are provided on the inner peripheral side of a predetermined depth from the end surface on the impeller mounting portion side, and are integrated with thermoplastic resin at substantially equal intervals. At the time of molding, the positional relationship between the sleeve bearing and the magnet and the coaxiality can be ensured, and the quality of the rotor of the pump motor can be improved.

  The present embodiment is characterized by the rotor of the pump motor. First, an outline of a heat pump type hot water supply apparatus that is an example of an apparatus in which a pump is used will be briefly described.

  FIG. 1 is a diagram showing the first embodiment and is a configuration diagram of a heat pump type hot water supply apparatus 300. As shown in FIG. 1, the heat pump hot water supply apparatus 300 includes a heat pump unit 100, a tank unit 200, and an operation unit 11 on which a user performs a driving operation and the like.

  In FIG. 1, a heat pump unit 100 includes a compressor 1 that compresses refrigerant, a refrigerant-water heat exchanger 2 that exchanges heat between the refrigerant and water, a decompression device 3 that decompresses and expands high-pressure refrigerant, and a low-pressure two-phase refrigerant. A refrigerant circuit in which the evaporator 4 for evaporating the refrigerant is annularly connected by a refrigerant pipe 15, a pressure detection device 5 that detects the discharge pressure of the compressor 1, a fan 7 that blows air to the evaporator 4, and the fan 7 are driven. And a fan motor 6.

  Further, as temperature detecting means, a boiling temperature detecting means 8 of the refrigerant-water heat exchanger 2, a feed water temperature detecting means 9 of the refrigerant-water heat exchanger 2, and an outside air temperature detecting means 17 are provided.

  Moreover, the heat pump unit control part 13 is provided. The heat pump unit controller 13 receives signals from the pressure detector 5, the boiling temperature detector 8, the feed water temperature detector 9, and the outside air temperature detector 17, and controls the rotation speed of the compressor 1 and the decompressor 3. The opening degree control and the rotation speed control of the fan motor 6 are performed.

  The tank unit 200 includes a hot water tank 14 that stores hot water heated by exchanging heat with a high-temperature and high-pressure refrigerant in the refrigerant-water heat exchanger 2, and a bath water reheating heat exchanger that replenishes the bath water. 31, bath water circulation device 32, pump 10 which is a hot water circulation device arranged between refrigerant-water heat exchanger 2 and hot water tank 14, hot water circulation pipe 16, refrigerant-water heat exchanger 2 and hot water. A mixing valve 33 connected to the tank 14 and the bath water reheating heat exchanger 31 and a bath water retreating pipe 37 for connecting the hot water tank 14 and the mixing valve 33 are provided.

  Further, as temperature detection means, a tank water temperature detection device 34, a water temperature detection device 35 for detecting the water temperature after passing through the bath water reheating heat exchanger, and a water temperature after passing through the mixing valve 33 are detected. A post-mixing water temperature detector 36 is provided.

  A tank unit controller 12 is also provided. The tank unit controller 12 receives signals from the in-tank water temperature detection device 34, the reheating water temperature detection device 35, and the mixed water temperature detection device 36, and controls the rotational speed of the pump 10, the opening and closing control of the mixing valve 33, In addition, signals are transmitted to and received from the operation unit 11.

  The operation unit 11 is a remote controller, an operation panel, or the like provided with a switch or the like for the user to perform hot water temperature setting, hot water instruction, and the like.

  In FIG. 1, a normal boiling operation operation in the heat pump type hot water supply apparatus configured as described above will be described. When the boiling operation instruction from the operation unit 11 or the tank unit 200 is transmitted to the heat pump unit control unit 13, the heat pump unit 100 performs the boiling operation.

  The heat pump unit controller 13 provided in the heat pump unit 100 controls the rotational speed of the compressor 1 and the decompression device 3 based on the detection values of the pressure detection device 5, the boiling temperature detection means 8, the feed water temperature detection means 9, and the like. The opening degree control and the rotation speed control of the fan motor 6 are performed.

  Further, the detection value of the boiling temperature detection means 8 is transmitted and received between the heat pump unit control unit 13 and the tank unit control unit 12, and the tank unit control unit 12 sets the temperature detected by the boiling temperature detection means 8 as the target. The rotation speed of the pump 10 is controlled so as to reach the boiling temperature.

  In the heat pump type hot water supply apparatus 300 controlled as described above, the temperature of the high-temperature and high-pressure refrigerant discharged from the compressor 1 decreases while dissipating heat to the water supply circuit side in the refrigerant-water heat exchanger 2. The high-pressure and low-temperature refrigerant that has radiated heat and passed through the refrigerant-water heat exchanger 2 is decompressed by the decompression device 3. The refrigerant that has passed through the decompression device 3 flows into the evaporator 4 where it absorbs heat from outside air. The low-pressure refrigerant exiting the evaporator 4 is sucked into the compressor 1 and circulates to form a refrigeration cycle.

  On the other hand, the water in the lower part of the hot water tank 14 is guided to the refrigerant-water heat exchanger 2 by driving the pump 10 which is a hot water circulation device. Here, water is heated by the heat radiation from the refrigerant-water heat exchanger 2, and the heated hot water is returned to the upper part of the hot water tank 14 through the hot water circulation pipe 16 and stored.

  As described above, in the heat pump hot water supply apparatus 300, the pump 10 is used as a hot water circulation apparatus that circulates hot water in the hot water circulation pipe 16 between the hot water tank 14 and the refrigerant-water heat exchanger 2.

  FIG. 2 is a diagram showing the first embodiment, and FIG. 2 is an exploded perspective view of the pump 10.

  As shown in FIG. 2, the pump 10 includes a pump unit 40 that absorbs and discharges water by rotation of a rotor (described later), a mold stator 50 that drives the rotor, a pump unit 40, and a mold stator. And tapping screws 160 (four in the example of FIG. 2) that are fastening screws that fasten 50.

  In the pump 10 according to the present embodiment, four tapping screws 160 are prepared through the screw holes 44 a formed in the boss portion 44 of the pump portion 40, and the pilot holes 84 of the pilot hole component 81 embedded in the mold stator 50. The pump 10 is assembled by fastening to (refer FIG. 4).

  First, the configuration of the mold stator 50 will be described. 3 to 7 are diagrams showing the first embodiment. FIG. 3 is a perspective view of the mold stator 50. FIG. 4 is a cross-sectional view of the mold stator 50. FIG. 5 is an exploded perspective view of the stator assembly 49. 6 is a view showing a pilot hole part 81 ((a) is a side view, (b) is a plan view)), and FIG. 7 is a perspective view of a stator assembly 49. FIG.

  As shown in FIGS. 3 and 4, the mold stator 50 is obtained by molding a stator assembly 49 (described later) with a mold resin 53.

  One end face (on the pump part 40 side) in the axial direction of the mold stator 50 is a flat pump part installation surface 63 along the outer peripheral edge part.

  A plurality of second grooves 64 are formed radially on the pump portion installation surface 63 in the radial direction. The second groove 64 is a relief groove for a reinforcing rib of a flange portion 90b (see FIG. 8) of the flange-shaped partition wall component 90 described later. In the example of FIG. 3, six second grooves 64 are formed at substantially equal intervals in the circumferential direction corresponding to reinforcing ribs of the flange portion 90 b of the flange-shaped partition wall component 90 described later.

  The pump portion installation surface 63 is provided with an annular third groove 65 that connects the outer end portions of the six second grooves 64. The annular third groove 65 corresponds to an annular rib formed in the flange portion 90 b of the flange-shaped partition wall component 90.

  Furthermore, foot portions 85 (see FIG. 6) of pilot hole parts 81 of substantially cylindrical resin molded products are embedded in the four corners of the pump portion installation surface 63 in the axial direction. At the time of molding with the mold resin 53, one end face (the pump part 40 side) of the foot part 85 of the pilot hole part 81 becomes a mold pressing part 82 (see FIG. 4) of the molding die. Therefore, the pilot hole part 81 is exposed in a form embedded inside the pump part installation surface 63 by a predetermined distance. What is exposed is a mold retainer 82 and a pilot hole 84 for the tapping screw 160.

  A lead wire 52 drawn from a stator assembly 49 to be described later is drawn to the outside from the vicinity of the axial end surface on the opposite side of the pump portion 40 of the mold stator 50.

  The axial positioning of the mold stator 50 during molding with the mold resin 53 (thermosetting resin) is performed on the axially outer end faces of the plurality of protrusions 95a formed on the substrate pressing component 95 (see FIG. 7). However, it becomes the upper mold holder. Therefore, the axially outer end surfaces (die pressing surfaces) of the plurality of protrusions 95a are exposed on the axial end surface of the mold stator 50 on the substrate 58 side (not shown).

  Further, a protrusion 56a (see FIGS. 5 and 7) extending further outward (in the axial direction) than the axial end face of the insulating portion 56 on the anti-connection side is a lower mold pressing portion. Therefore, a plurality of protrusions 56a are exposed on the axial end surface of the mold stator 50 opposite to the substrate 58 (not shown).

  The radial positioning of the mold stator 50 at the time of molding is performed by fitting the inner peripheral surface of the stator core 54 to the mold. Therefore, the tips of the teeth of the stator core 54 are exposed at the inner peripheral portion of the mold stator 50 shown in FIGS.

  Regarding the internal structure of the mold stator 50, that is, the stator assembly 49 (lead wire 52, stator core 54, insulating portion 56, coil 57, substrate 58, terminal 59, etc. shown in FIG. 4) and pilot hole component 81. Will be described later.

  Next, the stator assembly 49 will be described. As shown in FIGS. 5 and 7, the stator assembly 49 includes a stator 47 and a pilot hole part 81.

The stator assembly 49 is manufactured by the following procedure.
(1) An electromagnetic steel sheet having a thickness of about 0.1 to 0.7 mm is punched into a band shape, and a band-shaped stator core 54 laminated by caulking, welding, bonding or the like is manufactured. The strip-shaped stator core 54 includes a plurality of teeth. The tips of the teeth of the stator core 54 are exposed at the inner periphery of the mold stator 50 shown in FIG. Since the stator core 54 shown here has six teeth connected by thin-walled connecting portions, the tips of the teeth of the stator core are exposed at six locations also in FIG. However, only two locations are visible in FIG.
(2) An insulating portion 56 is applied to the teeth of the stator core 54. The insulating portion 56 is formed integrally with or separately from the stator core 54 using, for example, a thermoplastic resin such as PBT (polybutylene terephthalate).
(3) A concentrated coil is wound around the teeth provided with the insulating portion 56. Six concentrated winding coils 57 are connected to form a three-phase single Y-connection winding.
(4) Since it is a three-phase single Y connection, a terminal 59 (power supply) to which a coil 57 (see FIG. 4) of each phase (U phase, V phase, W phase) is connected on the connection side of the insulating portion 56 Power supply terminal and neutral point terminal) are assembled. There are three power terminals and one neutral point terminal.
(5) The board | substrate 58 is attached to the insulation part 56 (side in which the terminal 59 is assembled | attached) on the connection side. The substrate 58 is sandwiched between the insulating portion 56 by the substrate pressing component 95. On the substrate 58, an IC 58a (driving element) for driving an electric motor (brushless DC motor), a Hall element (position detecting element) for detecting the position of the rotor 60, and the like are mounted. The IC 58a and the Hall element are defined as electronic components. In addition, a lead wire lead-out component 61 that leads out the lead wire 52 to a notch near the outer peripheral edge portion is attached to the substrate 58.
(6) The board 58 to which the lead wire lead-out part 61 is attached is fixed to the insulating portion 56 by the board pressing part 95, and the pilot hole part 81 is assembled to the stator 47 to which the terminal 59 and the board 58 are soldered. Thus, the stator assembly 49 is completed.

  The configuration of the pilot hole part 81 will be described with reference to FIGS. The pilot hole part 81 is formed by molding a thermoplastic resin such as PBT (polybutylene terephthalate).

  As shown in FIG. 6, a plurality of substantially cylindrical foot portions 85 each having a pilot hole 84 for the tapping screw 160 are connected by a thin connecting portion 87. After the pilot hole part 81 is molded together with the stator 47, the substantially cylindrical leg part 85 is formed so that the pilot hole part 81 is prevented from coming off, and the exposed end surface (the mold presser part 82 and the protrusion) 83 end portion) is a taper shape that becomes thicker.

  In addition, the pilot hole part 81 includes a plurality of protrusions 85 a for preventing rotation of the pilot hole part 81 on the outer peripheral part of the foot part 85. The pilot hole part 81 can be set in a mold at once by connecting the substantially cylindrical foot 85 with a thin connecting part 87, so that the processing cost can be reduced.

  As shown in FIGS. 5 and 7, the connecting portion 87 of the pilot hole component 81 is provided with a plurality of claws 86 for assembling the pilot hole component 81 to the stator 47. In the example of FIG. 5, two claws 86 are provided.

  By fixing the claw 86 of the pilot hole part 81 in the groove 54a formed in the outer peripheral portion of the stator core 54 of the stator 47, the stator 47 and the pilot hole part 81 are set in the mold once. If possible, the processing cost can be reduced.

  When the stator assembly 49, in which the pilot hole part 81 is locked to the stator 47, is molded by the mold resin 53, the end face on the opening side of the pilot hole 84 for the tapping screw 160 of the pilot hole part 81 (die holding part 82) And the protrusion 83 (refer FIG. 4) with which the other end surface of the pilot hole part 81 is clamped with a molding die, and the axial direction positioning of the pilot hole part 81 is performed.

  The outer diameter of the mold pressing portion 82 on the opening side end face of the lower hole 84 for the tapping screw 160 of the lower hole part 81 is made smaller than the outer diameter of the end face on the opening side of the lower hole part 81. As a result, the end surface of the pilot hole part 81 is covered with the mold resin 53 except for the mold pressing portion 82. Therefore, since both end surfaces of the pilot hole component 81 are covered with the mold resin 53, it is possible to suppress the exposure of the pilot hole component 81 and improve the quality of the pump 10.

  In the mold stator 50, the pilot hole part 81 assembled to the stator 47 is integrally formed with the mold resin 53, and at this time, the pilot hole 84 for the tapping screw 160 of the foot portion 85 of the pilot hole part 81 is exposed. . By tightening and assembling the pump unit 40 and the mold stator 50 to the pilot hole 84 with the tapping screw 160 through the screw holes 44a formed in the pump unit 40, the pump unit 40 and the mold stator 50 are firmly connected. It becomes possible to assemble to.

  In addition, although not shown in the drawings, in order to firmly attach the pump unit 40 and the mold stator 50, as an alternative to the pilot hole part 81, a metal made of protrusions for preventing slipping and rotation prevention on the outer periphery is provided. It is also possible to use an insert nut having a screw hole. Changes in the type and mounting position of the pilot hole part 81 or the insert nut can be handled by changing the mounting part of the mold. When using an insert nut having a screw hole, a tightening screw is used.

Next, the configuration of the pump unit 40 will be described. 8 to 10 show the first embodiment, FIG. 8 is an exploded perspective view of the pump unit 40, FIG. 9 is a sectional view of the pump 10, and FIG. 10 is a perspective view of the casing 41 viewed from the shaft support unit 46 side. FIG. As shown in FIG. 8, the pump part 40 is comprised by the element shown below.
(1) Casing 41: It has a water suction port 42 (suction port) and a discharge port 43, and houses the impeller 60b of the rotor 60 therein. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide). The casing 41 is provided with four boss portions 44 having screw holes 44a used at the time of assembling the pump portion 40 and the mold stator 50 at the end on the water inlet 42 side. Moreover, the casing 41 is provided with the attachment leg 45 which has the hole 45a for fixing the pump 10 to the tank unit 200 of the heat pump type hot-water supply apparatus 300, for example in three places.
(2) Thrust bearing 71: The material of the thrust bearing 71 is ceramic such as alumina. Since the rotor 60 is pressed against the casing 41 via the thrust bearing 71 by the pressure difference of water acting on the front and back of the impeller 60b of the rotor 60 during the operation of the pump 10, the thrust bearing is made of ceramic. The product is used to ensure wear resistance and slidability.
(3) Rotor 60: The rotor 60 includes a rotor portion 60a and an impeller 60b. The rotor portion 60a includes a ring-shaped (cylindrical) resin magnet 68 (an example of a magnet) formed from pellets obtained by kneading magnetic powder such as ferrite and resin, and a cylindrical sleeve bearing provided inside the resin magnet 68. 66 (for example, made of carbon) is integrated with a resin portion 67 such as PPE (polyphenylene ether) (see FIG. 9). The impeller 60b is a resin molded product such as PPE (polyphenylene ether). The rotor part 60a and the impeller 60b are joined by ultrasonic welding or the like. Since this embodiment is characterized by the rotor portion 60a of the rotor 60, details thereof will be described later.
(4) Shaft 70: One end of the shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, and the other end of the shaft 70 is inserted into the shaft support portion 46 of the casing 41. One end of the shaft 70 inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90 is inserted so as not to rotate with respect to the shaft support portion 94. Therefore, one end of the shaft 70 is cut out of a part of a circle having a predetermined length (axial direction) (D-shape). The hole of the shaft support portion 94 is also shaped accordingly. The other end of the shaft 70 inserted into the shaft support portion 46 (see also FIG. 10) of the casing 41 is also cut out of a circular portion having a predetermined length (axial direction) (D-shape). That is, the axis 70 is symmetrical in the length direction. However, the other end of the shaft 70 is rotatably inserted into the shaft support portion 46 of the casing 41. The reason why the shaft 70 is symmetrical in the length direction is that when the shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, assembly is possible without being aware of the vertical direction.
(5) O-ring 80: The O-ring 80 seals the casing 41 of the pump unit 40 and the bowl-shaped partition wall component 90.
(6) Cage-like partition wall part 90: Cage-like partition wall part 90 is molded using a thermoplastic resin such as PPE (polyphenylene ether). The bowl-shaped partition wall component 90 includes a bowl-shaped partition wall portion 90 a that is a fitting portion with the mold stator 50 and a flange portion 90 b. The bowl-shaped partition wall 90a is composed of a circular bottom and a cylindrical partition. A shaft support portion 94 into which one end of the shaft 70 is inserted is erected at a substantially central portion of the inner surface of the circular bottom portion. Ribs 91 (not shown) extending in the axial direction are formed on the outer peripheral surface of the bowl-shaped partition wall 90a. The rib 91 (not shown) is formed to have a predetermined length in the axial direction from the base of the flange-shaped partition wall portion 90a (the connection portion with the flange portion 90b). And the dimension of the radial direction of the rib 91 (not shown) is a taper shape in which the base side of the bowl-shaped partition part 90a is large, and becomes small as it goes ahead. In the flange portion 90b, six reinforcing ribs (not shown) that reinforce the flange portion 90b are formed radially in the radial direction. The rib 91 of the bowl-shaped partition wall 90a is connected to any one of the reinforcing ribs. Thereby, manufacture of the shaping die of the bowl-shaped partition part 90 becomes easy. In addition, the flange portion 90 b includes an annular rib (not shown) that fits in an annular third groove 65 formed on the pump portion installation surface 63 of the pump portion 40 of the mold stator 50. In addition, holes 90d through which the tapping screw 160 passes are formed in the flange portion 90b at four locations. Furthermore, an annular O-ring storage groove 90c for storing the O-ring 80 is formed on the surface of the flange portion 90b on the casing 41 side.

  In the pump 10, the O-ring 80 is installed in the bowl-shaped partition wall part 90, the casing 41 is assembled to the bowl-shaped partition wall part 90, the pump part 40 is assembled, the pump part 40 is assembled to the mold stator 50, and the tapping screw 160 or the like. Fixed and assembled.

  When assembling the mold stator 50 and the pump unit 40, a first groove (not shown) formed in the axial direction on the inner peripheral portion of the mold stator 50, and the bowl-shaped partition wall of the bowl-shaped partition wall component 90 Positioning in the rotational direction (circumferential direction) is achieved by fitting an axially extending rib (not shown) to the outer peripheral surface of the portion 90a.

  The mold stator 50 and the pump unit 40 are fitted as follows. Since there is no rib (not shown) on the part of the outer peripheral surface of the bowl-shaped partition wall part 90 a opposite to the collar part 90 b, the bowl-shaped partition part 90 has a bowl-like shape of the pump part 40 on the inner circumference of the mold stator 50. The tip of the partition wall 90a (the portion without a rib (not shown)) can be inserted at an arbitrary position.

  When the insertion proceeds and the rib (not shown) of the bowl-shaped partition wall 90a of the pump unit 40 reaches the end on the opening side of the inner periphery of the mold stator 50, it is axially directed to the inner periphery of the mold stator 50. If the first groove (not shown) formed in the groove and the rib (not shown) extending in the axial direction are not aligned with the outer peripheral surface of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90, it is inserted further. However, since the bowl-shaped partition wall 90a of the pump unit 40 is inserted to some extent on the inner periphery of the mold stator 50, the first groove (not shown) and rib (not shown) can be easily rotated. And can be aligned.

  If the positions of the first groove (not shown) and the rib (not shown) are aligned, the bowl-shaped partition wall 90a of the pump unit 40 can be completely inserted into the inner periphery of the mold stator 50.

  On the inner periphery of the bowl-shaped partition wall portion 90 a of the bowl-shaped partition wall component 90, the rotor 60 is fitted and accommodated on the shaft 70 inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90. Therefore, in order to ensure the coaxiality of the mold stator 50 and the rotor 60, the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 should be as small as possible. For example, the gap is selected to be about 0.02 to 0.06 mm.

  When the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is reduced, the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is inserted into the inner periphery of the mold stator 50. In some cases, insertion is difficult if there is no way for air to escape.

  Therefore, a first groove (not shown) formed in the axial direction is provided in the inner peripheral portion of the mold stator 50, and this first groove (not shown) serves as an air escape path.

  Further, circumferential positioning of the bowl-shaped partition wall component 90 and the mold stator 50 is necessary.

  In order to perform circumferential positioning of the bowl-shaped partition wall component 90 and the mold stator 50, a bowl-shaped partition wall is formed in a first groove (not shown) formed in the axial direction on the inner peripheral portion of the mold stator 50. A rib (not shown) of the portion 90a is fitted.

  If the rib (not shown) of the hook-shaped partition wall portion 90a blocks the first groove (not shown) of the mold stator 50 that is an air escape path, the mold stator 50 of the hook-shaped partition wall component 90 is closed. Insertion becomes difficult. Therefore, in a state where the bowl-shaped partition wall component 90 is completely inserted into the mold stator 50, the first groove (not shown) of the mold stator 50 and the rib (not shown) of the bowl-shaped partition wall 90a. There is a gap between them. The gap is set to about 1 mm at the narrowest place (where the radial dimension of the rib (not shown) is the largest).

  As described above, the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is made as small as possible (for example, about 0.02 to 0.06 mm), and the mold stator 50 rotates. A first groove (not shown) serving as an air escape path formed in the axial direction is provided in the inner peripheral portion of the mold stator 50 while ensuring the coaxiality with the child 60. It is easy to insert the bowl-shaped partition wall component 90 into the inner periphery. Further, a rib (not shown) having a predetermined length is formed in the bowl-shaped partition wall portion 90a in the axial direction from the base of the bowl-shaped partition wall portion 90a (connecting portion with the flange portion 90b), and the diameter of the rib (not shown) The dimension of the direction is a tapered shape in which the base side of the bowl-shaped partition wall portion 90a is large and decreases toward the front, and a rib (not shown) has a predetermined diameter in the first groove (not shown) of the mold stator 50. Since the fitting is performed with a gap in the direction (about 1 mm), the mold stator 50 and the bowl-shaped partition wall part 90 can be positioned, and the mold stator 50 and the bowl-shaped partition wall part 90 are assembled. Can be easily attached.

  11 to 14 are diagrams showing the first embodiment. FIG. 11 is a cross-sectional view of the rotor portion 60a (AA cross-sectional view of FIG. 13), and FIG. 12 shows the rotor portion 60a on the impeller mounting portion 67a side. 13 is a side view of the rotor portion 60a viewed from the side opposite to the impeller mounting portion 67a, and FIG. 14 is an enlarged cross-sectional view of the sleeve bearing 66.

The rotor section 60a will be described with reference to FIGS. As shown in FIGS. 11 to 13, the rotor section 60 a includes at least the following elements. For example, the resin magnet 68 and the sleeve bearing 66 are integrally formed of a thermoplastic resin (resin portion 67) such as PPE (polyphenylene ether).
(1) Resin magnet 68;
(2) sleeve bearing 66;
(3) Resin portion 67 (the portion made of thermoplastic resin, the impeller mounting portion 67a for attaching the impeller 60b is formed in the resin portion 67 made of thermoplastic resin).

  The resin magnet 68 has a substantially ring shape (cylindrical shape) and is formed of pellets obtained by kneading a magnetic powder such as ferrite and a resin.

  The sleeve bearing 66 (for example, made of carbon) is provided inside the resin magnet 68. The sleeve bearing 66 has a cylindrical shape. Since the sleeve bearing 66 rotates by being fitted to the shaft 70 assembled to the bowl-shaped partition wall component 90 of the pump 10, sintered carbon suitable for a bearing material, PPS (polyphenylene sulfide) added with carbon fiber, or the like. Manufactured with thermoplastic resin, ceramic, etc. The sleeve bearing 66 has a draft taper whose outer diameter decreases from the approximate axial center toward both ends, and includes a plurality of hemispherical protrusions 66a (see FIG. 14) that prevent rotation at the approximate axial center on the outer peripheral side.

  In the resin portion 67 formed on the end surface of the resin magnet 68 on the impeller mounting portion 67a side, a first recess 67b is formed at a location of a magnet pressing portion provided in the upper mold of the resin molding die. In the example of FIG. 11, the first concave portion 67b is formed in a substantially central portion (radial direction). The first recess 67 b is formed at a position facing the protrusion 68 a of the resin magnet 68.

  Further, the resin portion 67 formed on the inner peripheral surface of the resin magnet 68 on the side opposite to the impeller mounting portion 67a is fitted with a positioning projection (not shown) provided on the lower mold of the resin molding die. A notch 67d is formed (see FIGS. 11 and 13). In the example of FIG. 13, the notches 67d are formed at four locations at approximately 90 ° intervals. The notch 67d is formed at a position of a notch 68b (described later, FIG. 15) of the resin magnet 68.

  For example, the resin magnet 68 and the sleeve bearing 66 are integrally formed of a thermoplastic resin (resin portion 67) such as PPE (polyphenylene ether).

  15 to 17 show the first embodiment. FIG. 15 is a sectional view of the resin magnet 68 (BB sectional view of FIG. 17). FIG. 16 is a side view of the resin magnet 68 viewed from the protrusion 68a side. FIG. 17 is a side view of the resin magnet 68 as viewed from the opposite side of the protrusion 68a.

  Next, the configuration of the resin magnet 68 will be described with reference to FIGS. 15 to 17. The resin magnet 68 shown here has eight magnetic poles. The resin magnet 68 is provided with a plurality of tapered notches 68b at substantially equal intervals in the circumferential direction on the inner peripheral side of the end surface opposite to the impeller mounting portion 67a in a state of being molded in the rotor 60. In the example of FIG. 17, there are eight notches 68b. The notch 68b has a tapered shape in which the diameter on the end face side is larger than the inner side.

  The resin magnet 68 has substantially square (arc-shaped) protrusions 68a at substantially equal intervals in the circumferential direction from the end surface opposite to the end surface where the tapered notch 68b is formed to the inner peripheral side of a predetermined depth. Provide multiple. In the example of FIG. 16, there are four protrusions 68a.

  The protrusion 68a is formed so as to protrude toward the center of the resin magnet 68 in the same radial shape as the position of the gate 68c to which the plastic magnet (resin magnet material) is supplied.

  As shown in FIG. 16, the protrusion 68a has a substantially square shape (arc shape) when viewed from the side. Since the protrusion 68a is located in the same radial shape as the gate 68c, the formation of the protrusion 68a is facilitated, and the productivity of the resin magnet 68 is improved. That is, when the protrusion 68a is positioned between the gates 68c as in a resin magnet 468 (FIGS. 18 to 20) of Modification 1 described later, the protrusion 68a is welded (resin flow front (flow front end) is associated). ) And the resin is difficult to fill, and problems such as insufficient strength are likely to occur, and molding cannot be performed without increasing the molding pressure. By disposing the protrusion 68a at the position of the gate 68c, the above-described problems can be solved, and the quality of the magnet and the productivity can be improved. The shape of the protrusion 68a is not limited to a substantially square shape (arc shape). A shape such as a triangle, a trapezoid, a semicircle, or a polygon may be used.

  The resin magnet 68 includes a gate 68c to which a plastic magnet (resin magnet material) is supplied on the side where the impeller mounting portion 67a is formed in a state where the resin magnet 68 is molded into the rotor 60, and the periphery of the gate has a predetermined depth. This is a substantially cylindrical recess 68d.

  The hollow portion of the resin magnet 68 is straight from the end face where the protrusion 68a is formed to the center position in the approximate axial direction, and is tapered from the end face opposite to the end face where the protrusion 68a is formed to the center position in the approximate axial direction. It is. Therefore, the productivity of the resin magnet 68 is improved, and the manufacturing cost can be reduced. That is, since the hollow portion of the magnet is tapered and tapered, it can be prevented from being taken into the mold (upper mold) and the productivity of the magnet can be improved. The mold for molding the magnet is divided into an upper mold and a lower mold of the protrusion 68a, and a part of the hollow portion formed by the lower mold is straight, thereby preventing the mold from being taken into the upper mold. , Magnet productivity can be improved. Remove from the lower mold by pushing it out with ejector pins.

  In the resin magnet 68 shown in FIGS. 15 to 17, the protrusion 68a is positioned in the same radial shape as the position of the gate 68c, thereby facilitating the formation of the protrusion 68a and improving the productivity of the resin magnet 68. As shown in FIG. 16, in the case where the number of magnetic poles and the number of protrusions are not the same, the magnetic poles having the protrusion 68a at the approximate center and the magnetic poles having the protrusion 68a not at the approximate center are alternately mixed. The magnetic pole with the protrusion 68a is thicker and has a higher magnetic force than the other magnetic poles. Therefore, when the protrusion 68a is at the pole center, the magnetic force is unbalanced unless the number is the same as the number of poles.

  18 to 20 show the first embodiment. FIG. 18 is a cross-sectional view of the resin magnet 468 of the first modification (C-C cross-sectional view of FIG. 20), and FIG. 19 shows the resin magnet 468 of the first modification. The side view seen from the processus | protrusion 468a side, FIG. 20 is the side view which looked at the resin magnet 468 of the modification 1 from the other side of the processus | protrusion 468a.

  In the resin magnet 468 of Modification 1 shown in FIGS. 18 to 20, four protrusions 468a are formed between the gates 468c (eight in total). That is, the four protrusions 468a are formed between the poles. The gate 468c and the protrusion 468a are formed at substantially equal intervals in the circumferential direction. Accordingly, between the eight poles, ones with projections 468a and ones without projections 468a are alternately arranged.

  The advantage of the resin magnet 468 of Modification 1 is that the magnetic force of each magnetic pole does not become unbalanced because the thickness of each magnetic pole is substantially uniform. On the other hand, since the weld position (where the resin flow front (flow front end) meets) is the position of the protrusion 468a, the protrusion 468a is not sufficiently filled with resin, and problems such as insufficient strength are likely to occur. .

  FIGS. 21 to 23 are diagrams showing the first embodiment, and a sectional view of the resin magnet 568 of the second modification (a sectional view taken along the line DD in FIG. 23). FIG. 22 shows the resin magnet 568 of the second modification on the protrusion 568a side. FIG. 23 is a side view of the resin magnet 568 of Modification 2 as viewed from the opposite side of the protrusion 568a.

  Like the resin magnet 568 of the modified example 2 shown in FIGS. 21 to 23, the center of the magnetic pole of the resin magnet 568 is set to the position of the gate 568c, and the number of protrusions 568a is the same as the number of magnetic poles (8 poles) of the resin magnet 568. Thus, the magnetic force of the resin magnet 568 is improved, and the performance of the pump motor can be improved. That is, since the resin magnet 568 is easily oriented at the position of the gate 568c, the orientation accuracy of the resin magnet 568 can be improved by setting the position of the gate 568c as the center of the magnetic pole.

  Further, since the protrusion 568a is located in the same radial shape as the position of the gate 568c, the formation of the protrusion 568a is facilitated, and the productivity of the resin magnet 568 can be improved.

  Next, integral molding of the rotor 60 of the pump motor with the thermoplastic resin will be described. The resin magnet 68 is taken as an example.

  A mold for integrally molding the resin magnet 68 and the sleeve bearing 66 includes an upper mold and a lower mold (not shown). First, the sleeve bearing 66 is set in the lower mold. Since the sleeve bearing 66 has a symmetrical cross-sectional shape, it can be set in the mold without matching the circumferential direction. The sleeve bearing 66 includes a plurality of protrusions 66a (see FIG. 14) on the outer peripheral portion, but the position of the protrusion 66a is not particularly limited. Therefore, the work process is simplified, the productivity is improved, and the manufacturing cost can be reduced.

  When the sleeve bearing 66 is set in the lower mold, the sleeve bearing 66 is set in a subsequent process by holding the inner diameter of the sleeve bearing 66 in a sleeve bearing insertion portion (not shown) provided in the lower mold. The accuracy of the coaxiality with the resin magnet 68 is ensured.

  The resin magnet 68 has an inner diameter of one end surface of the resin magnet 68 (the end surface opposite to the impeller mounting portion 67a in the state of the rotor 60 of the pump motor) after the sleeve bearing 66 is set in the lower mold. The taper-shaped notch 68b provided is fitted and set to a positioning projection (not shown) provided on the lower mold. In the example of FIG. 17, there are eight notches 68b, and four of them are fitted with lower positioning protrusions (not shown) at approximately 90 ° intervals. The eight cutouts 68b are provided in order to improve workability when the resin magnet 68 is set in the lower mold.

  Further, a magnet pressing portion (not shown) of the upper mold is formed on the inner peripheral portion of the other end surface of the resin magnet 68 (the end surface on the impeller mounting portion 67a side in the state of the rotor 60 of the pump motor). It presses against the substantially square-shaped protrusion 68a made from the axial direction. Thereby, the positional relationship and coaxiality of the sleeve bearing 66 and the resin magnet 68 are ensured.

  In the example of FIG. 16, there are a total of four substantially angular (arc-shaped) protrusions 68a on the inner periphery of the resin magnet 68, and the mold installation surface (the part pressed by the mold) of the protrusions 68a is formed after integral molding. Express. The four protrusions 68a ensure the positioning accuracy of the resin magnet 68 and at the same time secure the inflow path of the thermoplastic resin used for integral molding, thereby reducing the molding conditions during integral molding and producing. This is to improve the performance.

  Even when there is a gap between the insertion portion (not shown) of the lower mold resin magnet 68 and the outer diameter of the resin magnet 68, the protrusion holding portion (not shown) of the upper die is fixed to the inner diameter holding portion (positioning). By securing the coaxiality with the projections), the positional relationship and coaxiality between the sleeve bearing 66 and the resin magnet 68 can be secured, and the quality of the pump 10 can be improved.

  Conversely, by creating a gap between the insertion portion (not shown) of the lower mold resin magnet 68 and the outer diameter of the resin magnet 68, the workability of setting the resin magnet 68 in the mold is improved. Manufacturing costs are reduced.

  FIGS. 26 to 35 are views for comparison, FIG. 26 is a cross-sectional view of the rotor portion 760 of the conventional example 1 (XX cross-sectional view of FIG. 27), and FIG. FIG. 28 is a cross-sectional view of the resin magnet 768 of the conventional example 1 (YY cross-sectional view of FIG. 30), and FIG. 29 is a cutaway view of the resin magnet 768 of the conventional example 1. FIG. 30 is a side view of the conventional resin magnet 768 cut away from the notch 768f, and FIG. 31 is a cross-sectional view of the rotor portion 860a of the conventional example 2 (Z in FIG. 32). -Z cross-sectional view), FIG. 32 is a side view of the rotor portion 860a of the conventional example 2 as viewed from the impeller mounting portion 867a side, and FIG. 33 is a cross-sectional view of the resin magnet 868 of the conventional example 2 (FF of FIG. 34 is a cutaway view of the resin magnet 868 of the second conventional example. b side view from the opposite side of FIG. 35 is a side view of the resin magnet 868 in the conventional example 2 from the notch 868b side. In the following description, the description of all reference numerals for FIGS. 26 to 35 is omitted.

  The rotor portion 760a of the rotor 760 of the pump motor of Conventional Example 1 is provided on the upper die at two intervals of about 180 ° in the substantially rectangular notch 768f (see FIG. 28) of the resin magnet 768. Since the notch holding portion (not shown) of the left / right slide mechanism is pressed against, the resin portion 767 is formed with a recess 767g. The recess 767g contributes to friction loss when the rotor 760 of the pump motor rotates in water.

  Further, in the rotor portion 860a of the rotor 860 of the pump motor according to the conventional example 2, the circulation loss due to the circulating flow (water) through the balance hole 867e (see FIG. 31) increases. Therefore, when the pressure difference between the front and back of the impeller (not shown) is relatively small and it is not necessary to provide the countersunk hole 867e, an unnecessary circulation path is provided, which may reduce pump efficiency.

  The rotor portion 760a (see FIG. 26) of the rotor 760 of the pump motor of Conventional Example 1 may be eliminated if it is not necessary to provide the countersunk hole 767e. However, in the rotor portion 860a of the conventional example 2 (see FIG. 31), since the resin magnet 868 is pressed by a pin (not shown) for forming a balance hole, the balance hole 867a cannot be eliminated.

  On the other hand, in the case of the rotor 60 of the pump motor according to the present invention, there is no concave portion of the resin portion 67 by the notch holding portion (not shown) of the upper left and right slide mechanism on the outer peripheral surface. Therefore, the friction loss when the rotor 60 of the pump motor rotates in water can be reduced, and the performance of the pump 10 can be improved. Moreover, compared with the case where a countersink exists, the circulation loss by the circulation path | route via a counterhole can be reduced, and it becomes possible to aim at the performance improvement of the pump 10. FIG.

  After the resin magnet 68 and the sleeve bearing 66 are set in a mold, a thermoplastic resin such as PPE (polyphenylene ether) is injection molded to form the rotor portion 60a. At this time, notches 68b (FIG. 17) that cannot be pressed by the mold of the resin magnet 68, that is, the four notches 68b, and the gate 68c (FIG. 16) at the time of injection molding of the resin magnet 68 are provided. The recessed portion 68d (FIG. 16) is embedded in the resin portion 67 of thermoplastic resin and serves as a rotational torque transmission portion.

  After the resin magnet 68 and the sleeve bearing 66 are integrally formed of thermoplastic resin, when the resin magnet 68 is magnetized, the end surface of the resin magnet 68 opposite to the impeller mounting portion 67a of the rotor portion 60a is formed. By using the notches 67d (four locations in FIG. 13) formed on the inner peripheral surface for positioning during magnetization, accurate magnetization can be achieved.

As described above, according to the present embodiment, the following effects can be obtained.
(1) At the time of integral molding of the rotor 60 of the pump motor 60 with the thermoplastic resin (resin portion 67), the protrusion pressing portion (not shown) of the upper die is used as the rotor 60 of the pump motor of the resin magnet 68. In this state, the positional relationship and the coaxial relationship between the sleeve bearing 66 and the resin magnet 68 are ensured by pressing against the substantially square-shaped protrusion 68a formed on the inner peripheral portion of the end surface on the impeller mounting portion 67a side.
(2) Further, the rotor 60 of the pump electric motor of the present embodiment has a resin part recess (for example, FIG. 25) formed by a notch holding part (not shown) of the upper left and right slide mechanism on the outer peripheral surface thereof. In this case, the friction loss and the circulation loss when the rotor 60 of the pump motor rotates in water can be reduced. It is possible to improve the performance.
(3) After the resin magnet 68 and the sleeve bearing 66 are set in the mold, a thermoplastic resin such as PPS (polyphenylene sulfide) is injection-molded to form the rotor 60 of the pump motor. Notches 68b (see FIG. 17) that cannot be pressed by the mold of the resin magnet 68, that is, four notches 68b, and recesses 68d provided around the gate 68c during the injection molding of the resin magnet 68 (see FIG. 16). ) Is embedded in the resin portion 67 of the thermoplastic resin, the rotational torque can be reliably transmitted from the resin magnet 68 to the resin portion 67.
(4) When magnetizing the resin magnet 68, the notch 68b formed on the inner peripheral surface of the end surface of the resin magnet 68 opposite to the impeller mounting portion 67a of the rotor 60 of the pump motor is used for positioning at the time of magnetization. By using it, it is possible to magnetize with high accuracy.

FIG. 24 is a diagram illustrating the first embodiment, and is a diagram illustrating a manufacturing process of the pump 10. The manufacturing process of the pump 10 will be described with reference to FIG.
(1) Step 1: The stator 47 is manufactured. First, an electromagnetic steel plate having a thickness of about 0.1 to 0.7 mm is punched into a strip shape, laminated by caulking, welding, adhesion, or the like, and a strip-shaped stator core 54 connected by a thin connection portion is manufactured. The teeth are provided with an insulating portion 56 using a thermoplastic resin such as PBT (polybutylene terephthalate). A concentrated winding coil 57 is wound around the teeth provided with the insulating portion 56. For example, twelve concentrated winding coils 57 are connected to form a three-phase single Y-connection winding. Since it is a three-phase single Y connection, a terminal 59 (a power supply terminal to which power is supplied and a medium) Sex point terminal) is assembled. In addition, the sleeve bearing 66 is manufactured. In addition, the resin magnet 68 is formed.
(2) The substrate 58 is manufactured. The substrate 58 is sandwiched between the insulating portion 56 by the substrate pressing component 95. On the substrate 58, an IC for driving an electric motor (brushless DC motor), a Hall element for detecting the position of the rotor 60, and the like are mounted. In addition, a lead wire lead-out component 61 that feeds a lead wire into a notch portion near the outer peripheral edge portion is attached to the substrate 58. In addition, the rotor part 60a is manufactured. The rotor portion 60a includes a ring-shaped (cylindrical) resin magnet 68 formed by pelletizing a magnetic powder such as ferrite and a resin, and a cylindrical sleeve bearing 66 (for example, carbon) provided inside the resin magnet 68. For example, PPE (polyphenylene ether). At the same time, the impeller 60b is formed. The impeller 60b is molded using a thermoplastic resin such as PPE (polyphenylene ether).
(3) Step 2: The substrate 58 is fixed to the stator 47. The substrate 58 to which the lead wire lead-out component 61 is attached is fixed to the insulating portion 56 by the substrate holding component 95. At the same time, the impeller 60b is assembled to the rotor portion 60a by ultrasonic welding or the like. In addition, the bowl-shaped partition wall component 90 is formed. In addition, the shaft 70 and the thrust bearing 71 are manufactured. The shaft 70 is manufactured from SUS. The thrust bearing 71 is made of ceramic.
(4) Step 3: Solder the terminal 59 (the power supply terminal to which power is supplied and the neutral point terminal) and the substrate 58. By assembling the pilot hole part 81 to the stator 47, the stator assembly 49 is completed. The rotor 60 and the like are assembled to the bowl-shaped partition wall component 90. In addition, the casing 41 is molded together. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide).
(5) Step 4: The stator assembly 49 is molded to manufacture the mold stator 50. In addition, the pump 41 is assembled by fixing the casing 41 to the bowl-shaped partition wall component 90. In addition, a tapping screw 160 is also manufactured.
(6) Step 5: Assemble the pump 10. The pump unit 40 is assembled to the mold stator 50 and fixed with a tapping screw 160.

  FIG. 25 shows the first embodiment and is a conceptual diagram showing a circuit of an apparatus using the refrigerant-water heat exchanger 2. The heat pump hot water supply apparatus 300 described at the beginning is an example of an apparatus that uses the refrigerant-water heat exchanger 2.

  The apparatus using the refrigerant-water heat exchanger 2 is, for example, an air conditioning apparatus, a floor heating apparatus, a hot water supply apparatus, or the like. The pump 10 according to the present embodiment is mounted in a water circuit of a device using the refrigerant-water heat exchanger 2 and circulates water (hot water) cooled or heated by the refrigerant-water heat exchanger 2 in the water circuit. Let

  The apparatus using the refrigerant-water heat exchanger 2 shown in FIG. 25 includes a compressor 1 that compresses refrigerant (for example, a scroll compressor, a rotary compressor, etc.), and refrigerant-water heat exchange in which heat is exchanged between the refrigerant and water. And a refrigerant circuit having an evaporator 2, an evaporator 4 (heat exchanger), and the like. Moreover, the water circuit which has the pump 10, the refrigerant | coolant-water heat exchanger 2, the load 20, etc. is provided.

  When the pump 10 equipped with the rotor 60 of the pump motor of the first embodiment is applied to a device (an air conditioner, a floor heating device, or a hot water supply device) that uses the refrigerant-water heat exchanger 2, the performance of the pump 10 And with quality improvement and productivity improvement, performance improvement, quality improvement, and cost reduction of the apparatus (air conditioning apparatus, floor heating apparatus, or hot water supply apparatus) using the refrigerant-water heat exchanger 2 can be achieved.

  In the above description, when the resin magnet 68 is molded, the plastic magnet (resin magnet material) is supplied from the gate 68c of the recess 68d of the resin magnet 68, but formed on the impeller mounting portion 67a side of the resin magnet 68. The protrusion 68a may be provided with a gate, and the resin magnet 68 may be injection molded. Thereby, the cost of the pump 10 can be reduced by reducing the amount of runners during injection molding of the resin magnet 68.

  1 compressor, 2 refrigerant-water heat exchanger, 3 decompression device, 4 evaporator, 5 pressure detection device, 6 fan motor, 7 fan, 8 boiling temperature detection means, 9 feed water temperature detection means, 10 pump, 11 operation Part, 12 tank unit control part, 13 heat pump unit control part, 14 hot water tank, 15 refrigerant pipe, 16 hot water circulation pipe, 17 outside air temperature detecting means, 20 load, 31 bath water reheating heat exchanger, 32 bath water circulation apparatus, 33 Mixing valve, 34 Water temperature detecting device in tank, 35 Water temperature detecting device after reheating, 36 Water temperature detecting device after mixing, 37 Bath water reheating piping, 40 Pump part, 41 Casing, 42 Water inlet, 43 Discharge port, 44 Boss Part, 44a screw hole, 45 mounting leg, 45a hole, 46 shaft support part, 47 stator, 49 stator assembly, 50 mold Stator, 52 Lead wire, 53 Mold resin, 54 Stator core, 56 Insulating part, 57 Coil, 58 Substrate, 58a IC, 59 terminal, 60 Rotor, 60a Rotor part, 60b Impeller, 61 Lead wire lead-out part, 63 Pump section installation surface, 66 Sleeve bearing, 67 Resin section, 67b First recess, 68 Resin magnet, 68a Protrusion, 68b Notch, 68c Gate, 68d Recess, 70 shaft, 71 Thrust bearing, 80 O-ring, 81 Bottom Hole part, 82 Mold holding part, 83 Protrusion, 84 Pilot hole, 85 Foot part, 85a Protrusion, 86 Claw, 87 Connecting part, 90 Rib-like partition part, 90a Rib-like partition part, 90b Rib part, 90c O-ring storage Groove, 90d hole, 91 rib, 93 annular rib, 94 shaft support, 95 substrate holding part, 100 heat pump unit , 160 tapping screw, 200 tank unit, 300 heat pump hot water supply device, 468 resin magnet, 468a protrusion, gate 468c, 568 resin magnet, 568a protrusion, 568c gate, 760 rotor, 760a rotor portion, 767a impeller mounting portion, 767e Balance hole, 768 Resin magnet, 768b Notch, 768f Notch, 767g Recess, 860 Rotor, 860a Rotor, 867a Impeller mounting, 867e Balance hole, 868 Resin magnet, 868f Mold retainer, 867g Notch Missing.

Claims (11)

A water circuit and a mold stator including a substrate on which a magnetic pole position detecting element is mounted are mounted on a pump that partitions the partition with a bowl-shaped partition wall part, and is rotatably accommodated in the bowl-shaped partition wall part, and one end of the pole position In the rotor of the electric motor for a pump provided with a rotor portion having an impeller mounting portion that faces the detection element and attaches the impeller at the other end,
The rotor part is
A magnet and a sleeve bearing disposed inside the magnet are integrally formed of a thermoplastic resin, and at the same time, the impeller mounting portion is formed of the thermoplastic resin,
The magnet
A plurality of notches having a substantially square shape in cross section are formed on the inner peripheral side of the end surface facing the magnetic pole position detection element at a substantially equal interval in the circumferential direction.
A plurality of protrusions that are formed at substantially equal intervals in the circumferential direction so as to protrude inwardly from the end surface on the impeller mounting portion side to the inner peripheral side of a predetermined depth,
At the time of integral molding with the thermoplastic resin, the notch of the magnet is set in the lower mold of the molding mold to ensure the coaxiality, and the upper mold of the molding mold is pressed against the protrusion, and the magnet The rotor of the motor for pumps characterized by performing positioning.   The protrusion formed on the impeller mounting portion side of the magnet coincides substantially with the center of the magnetic pole formed on the rotor, and substantially the same radial shape as the position of the gate to which the resin magnet is supplied. The rotor for a pump motor according to claim 1, wherein the rotor is formed so as to protrude toward the center of the magnet.   2. The pump according to claim 1, wherein the protrusion formed on the impeller mounting portion side of the magnet is positioned between magnetic poles formed on the rotor and between a gate to which the resin magnet is supplied. Electric motor rotor.   The rotor of a pump motor according to claim 1, wherein the number of the protrusions formed on the magnet on the side of the impeller mounting portion is the same as the number of magnetic poles formed on the rotor.   The rotor for a pump motor according to any one of claims 1 to 4, wherein a gate is provided on the protrusion formed on the impeller mounting portion side of the magnet, and the magnet is injection-molded.   The hollow portion of the magnet is straight from the end surface where the projection is formed to the center position in the approximate axial direction, and is tapered from the end surface opposite to the end surface where the projection is formed to the center position in the approximate axial direction. The rotor of the electric motor for pumps according to any one of claims 1 to 5 characterized by things.   A pump comprising the pump motor rotor according to any one of claims 1 to 6.   An air conditioner equipped with the pump according to claim 7.   A floor heating apparatus, wherein the pump according to claim 7 is mounted.   A hot water supply apparatus, wherein the pump according to claim 7 is mounted. It is a manufacturing method of the pump of Claim 7, Comprising:
A stator is manufactured, a magnet is molded together, and a sleeve bearing is manufactured together.
Winding around the stator, producing a substrate together, producing an impeller together, further producing a rotor part by integrally molding the magnet and the sleeve bearing,
Assembling the substrate to the stator, assembling the impeller and the rotor part together, and further producing a shaft, a thrust bearing, and a bowl-shaped partition wall part,
Soldering the terminal of the stator and the substrate, forming a pilot hole part together, forming a casing together, and further attaching a rotor or the like to the bowl-shaped partition part,
The stator and pilot hole parts are molded integrally with a mold to produce a mold stator, and a tapping screw is manufactured together.Furthermore, the casing is fixed to the bowl-shaped partition wall part and a pump part is assembled.
A pump manufacturing method, wherein the pump portion is assembled to the mold stator and fixed with the tapping screw.

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