JP2011212841A - Molding machine, method for producing mold motor using molding machine, and mold motor produced by the method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the following problem: in a thermosetting resin molding machine, since a thermosetting resin is packed in a mold while being directly contacted/pressurized by a sub-upper mold, the thermosetting resin directly contacted with the sub-upper mold does not flow, and a defective appearance or a void occurs in part of a product formed by the sub-upper mold.SOLUTION: A process (a) shows a preceding stage in which a divided plunger 9 and the divided sub-upper mold 10 are connected mechanically to each other, and the thermosetting resin 6 is pressurized/packed into the mold in which a stator winding 4 and a stator core 5 are arranged in a concave state different from a form to form a mold motor finally. A process (b) shows a process in which the thermosetting resin is pressurized/packed into the mold and in this case, shows a process in which a part where the divided plunger 9 and the divided sub-upper mold 10 are connected mechanically to each other is pressurized/packed in the concave state different from the form to form the mold motor finally.

Description

  The present invention relates to a thermosetting resin molding machine and a mold used for manufacturing a mold motor particularly used in an air conditioner, a water heater, and a washing machine.

  In recent years, as shown in FIG. 3, it has been widely used to form the entire stator with a thermosetting resin that takes advantage of vibration damping, shape flexibility, and reliability.

  Further, a thermosetting resin molding machine for molding a conventionally used mold motor will be described with reference to FIG. FIG. 2 is a schematic diagram showing a thermosetting resin molding machine and its mold. The thermosetting resin 6 is inserted into the pot 16, and the upper die 11, the lower die 12, and the inner die of the finished motor winding are provided with the finished motor windings 4 and 5. The mold 15 is pressurized by the plunger 13 and the sub-mold 14 is filled with the thermosetting resin while being in direct contact and pressure. After filling, the thermosetting resin 6 is cured by the heat energy of the mold to become an insoluble and infusible resin, and forms a stator of the molded motor. This molding method is generally called transfer molding. (For example, patent document 1).

JP 2005-178232 A

  However, in the thermosetting resin molding machine that has been used in the past, the thermosetting resin is filled in the mold while being directly contacted and pressurized with the sub-upper mold. There was no flow in the thermosetting resin, and the appearance defects and voids of some products formed by the sub-upper mold were problematic. In addition, the dimensional accuracy of the bearing housing is deteriorated, and it is difficult to cope with the recent reduction in vibration and noise, and further reduction of vibration and noise is strongly demanded.

  In order to solve the above-described conventional problems, the present invention has a pot for inserting a thermosetting resin, and has a plunger that is operated to press-fill the thermosetting resin into a mold. The upper mold of the mold is provided with a movable sub upper mold, and the thermosetting resin inserted into the pot by the movable sub mold is the The mold is pressed and filled, and a part of the thermosetting resin molded product is formed by the movable sub mold, and the mold is molded from the molded resin product. In the molding machine having a configuration in which the runner portion generated in the surface does not occur, the surface of the plunger that pressurizes the thermosetting resin is divided into two or more surfaces, and the surface of the divided plunger that pressurizes the thermosetting resin is respectively A plunger configured to be controlled by a pressurizer, and Serial sub upper mold is divided similarly to the plunger, it is obtained by a molding machine having a configuration in which movable in conjunction with the control of the plunger. According to the present invention, runners that have occurred during molding do not occur, appearance defects and voids that have occurred during molding can be reduced, and vibration and noise of the molded motor can be reduced.

  This will be specifically described below. First, the first invention of the present application has a pot for inserting a thermosetting resin, and a molding machine having a plunger that is operated to pressurize and fill the thermosetting resin into a mold. The surface of the plunger that pressurizes the thermosetting resin is divided into two or more surfaces, and the surface of the divided plunger that pressurizes the thermosetting resin can be controlled by a pressurizer. Therefore, when the thermosetting resin is pressure-filled in the mold, there is an effect that the thermosetting resin flowing in the mold can be accurately controlled. Here, it is preferable that the surfaces of the divided plungers are circular, and the areas of the respective surfaces of the divided plungers are approximately the same. This is because when the thermosetting resin is pressure-filled in the mold, the greater the difference in the area of each of the divided plungers, the more accurately the thermosetting resin that flows in the mold is controlled. The air in the thermosetting resin that is filled under pressure cannot easily escape, and voids are likely to occur in the molded product. Moreover, it is preferable to control the surface of each divided plunger with a pressurizer such as a hydraulic pressure, a spring, or an electric motor.

The thermosetting resin referred to here is an unsaturated polyester resin molding material, an epoxy resin molding material, or the like, and a resin that is three-dimensionally cross-linked by curing and becomes an insoluble and infusible cured product. In addition, aluminum hydroxide, silica, clay, talc, etc. are molding materials that are used as reinforcing agents such as glass fiber, vinylon fiber, etc. In addition, the second invention provides a pot for inserting a thermosetting resin. And having a plunger that is operated to press-fill the thermosetting resin into the mold, and a sub-upper mold that can move at least a part of the upper mold among the molds. The thermosetting resin inserted into the pot with the movable sub mold is press-filled into the mold, and the heat is added with the movable sub mold. Part shape of curable resin molding And the mold has a configuration in which a runner portion that occurs in molding of the molded resin article does not occur, wherein the plunger is the same plunger as in the first invention, and the sub-upper The mold is divided in the same manner as the plunger of the first invention, and is a molding machine having a configuration that moves in conjunction with the control of the plunger and its mold, and does not produce a runner that occurs during molding. In addition, it is possible to accurately control the thermosetting resin that flows in the mold, and it is possible to reduce the appearance defects and the generation of voids that have occurred during molding. Here, it is preferable that the temperature of the sub-upper mold and the mold is the same. Moreover, it is preferable that the surface of the sub-upper mold to be divided is circular and the area of each surface of the divided sub-upper mold is substantially the same.

  3rd invention does not generate the runner which cannot be reused by making it the mold motor which molded the motor perimeter using the molding machine and metal mold | die of 2nd invention, and the runner part and the cut surface of a mold motor In addition, it is possible to realize molding that does not cause appearance defects and voids that occur during molding. Further, the dimensional accuracy of the bearing housing of the molded motor molded by this method can be improved, and vibration and noise generated from the molded motor can be reduced.

In a fourth aspect of the present invention, when pressure-filling a thermosetting resin into a mold,
(A) The divided sub-upper mold is divided into a shape different from the shape that forms a part of the molded motor, (b) The thermosetting resin is made into the metal in the shape of (a). After the step of pressurizing and filling the mold, (c) at the end of molding, the sub-mold is made to be a mold motor through a stepwise pressurization step that makes it the same as the shape that forms part of the mold motor. It is possible to realize molding that does not generate an unusable runner, does not have a cut surface of the runner portion and the mold motor, and does not generate appearance defects or voids that occur during molding. Further, the dimensional accuracy of the bearing housing of the molded motor molded by this method can be improved, and vibration and noise generated from the molded motor can be reduced.

  In the fifth aspect of the present invention, the shape of the upper mold is made concave in the step (a) of the fourth aspect of the invention, and it is easy to accurately control the thermosetting resin flowing in the mold. There is an effect.

  In a sixth aspect of the present invention, in the step (c) of the fourth aspect of the invention, before the thermosetting resin starts to be cured, the sub mold is made to have the same shape as that forming a part of the mold motor. And has the effect of enabling smooth molding. When the secondary mold is made to have the same shape as a part of the mold motor after the thermosetting resin is cured, a smooth molding operation becomes difficult.

  A seventh invention is a washing machine equipped with the molded motors of the second to sixth inventions, and provides a washing machine with low noise and vibration.

  The eighth invention is an air conditioner equipped with the molded motor of the second to sixth inventions, and provides an air conditioner with low noise and vibration.

  According to 1st invention of this application, in the molding machine which has the structure which does not produce the runner part which arises in shaping | molding, the effect that the molding machine which can reduce the external appearance defect and the generation | occurrence | production of the void which were produced at the time of shaping | molding can be acquired. .

  In addition, according to the second aspect of the invention, it is possible to reduce the appearance defects and the occurrence of voids that have occurred during molding.

  In addition, according to the third aspect of the invention, it is possible to reduce the appearance defects and the generation of voids that occur during the molding of the molded motor, and to reduce the vibration and noise of the molded motor.

  Further, according to the fourth aspect of the invention, it is possible to reduce the appearance defects and voids that occur during molding of the molded motor, and to reduce the vibration and noise of the molded motor.

  In addition, according to the fifth aspect of the invention, it is possible to reduce the appearance defects and voids that occur during molding of the molded motor, and to reduce the vibration and noise of the molded motor.

  Further, according to the sixth aspect of the invention, it is possible to reduce the appearance defects and voids that occur when the molded motor is molded, and to reduce the vibration and noise of the molded motor.

  In addition, according to the seventh invention, a washing machine with low noise and vibration can be provided.

  In addition, according to the eighth invention, an air conditioner with low noise and vibration can be provided.

  As described above, the molding machine of the present invention, the method of manufacturing a mold motor using the molding machine, and the mold motor by the manufacturing method do not cause unnecessary runners, do not cause appearance defects, and have low noise. It is useful for a molding method of a low vibration mold motor.

(A) Explanatory drawing of process a of one embodiment of the present invention (b) Explanatory drawing of step b of one embodiment of the present invention (c) Explanatory drawing of step c of one embodiment of the present invention (A) Explanatory drawing showing a conventional thermosetting resin molding machine (b) Explanatory drawing showing a conventional thermosetting resin molding machine Explanatory drawing showing the configuration of the mold motor

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

  A present Example is described using FIG.1, FIG.2, FIG.3. FIG. 1 is a schematic diagram showing a stage of molding a thermosetting resin molding machine / mold and a mold motor according to an embodiment of the present invention, and a stator winding 4 of the mold motor as shown in FIG. And a step of integrally molding the stator iron core 5 with the thermosetting resin 6. In the molded motor, the bearing housing 1 is also made of a thermosetting resin, and its outer shape is formed by the divided sub-upper mold 10. In step (a), the divided plunger 9 and the divided upper die 10 are mechanically connected to each other, and finally the stator winding 4 has a concave shape different from the shape forming the molded motor. And a stage before pressurizing and filling the thermosetting resin 6 into the mold in which the stator core 5 is installed.

  At this time, the thermosetting resin is preheated to 30 ° C. to 80 ° C. so as to easily flow stably, and the upper mold 11, the lower mold 12, the sub upper mold 10, and the mold core 15 are 120 to 160. The temperature is adjusted to ℃. Further, the stator winding and the stator iron core are also in a state of 120 to 160 ° C. Step (b) shows the step of pressurizing and filling the thermosetting resin in the mold. At this time, the divided plunger 9 and the divided upper mold 10 are mechanically connected. The connected portion shows the stage of pressurizing and filling in a concave shape different from the shape that finally forms the molded motor. Step (c) shows the step of finishing pressurizing and filling the thermosetting resin into the mold, and the plunger 9 divided before the thermosetting resin begins to be cured and the sub-upper metal divided. A portion where the mold 10 is mechanically connected indicates a stage where a mold motor is finally formed.

  Thereafter, after the thermosetting resin is cured, the thermosetting resin is taken out from the mold, and a mold motor as shown in FIG. 3 is assembled. In the conventional method, there is no flow in the thermosetting resin 6 in contact with the sub-upper mold 10, and only a portion of the thermosetting resin 6 starts abrupt curing or gas in the resin appears on the surface. Due to this, appearance defects and voids occurred frequently. Further, in the conventional method, the thermosetting resin 6 in the vicinity in contact with the sub-upper mold 10 does not flow, and a uniform molding pressure is not applied, which causes vibration and noise of the mold motor. The dimensional accuracy of the bracket housing has deteriorated.

  FIG. 2 shows a thermosetting resin molding for molding a molded motor by a conventional method as a comparative example, and is a schematic diagram showing the process. The sub-upper mold 14 is mechanically connected to the plunger 13, and shows a process of pressurizing and filling the thermosetting resin 6 to the stator winding 4 and the stator core 5 installed in the mold. ing. Thereafter, after the thermosetting resin is cured, the thermosetting resin is taken out from the mold, and a mold motor as shown in FIG. 3 is assembled. At this time, the thermosetting resin is preheated to 30 ° C. to 80 ° C. so as to easily flow stably, and the upper mold 11, the lower mold 12, the sub upper mold 10, and the mold core 15 are 120 to 120 ° C. The temperature is adjusted to 160 ° C. Further, the stator winding and the stator iron core are also in a state of 120 to 160 ° C. In this method, there is no flow in the thermosetting resin 6 in the vicinity of contact with the sub-upper mold 14, and rapid curing is started only in that portion, or the gas in the resin appears on the surface. The appearance defect and the occurrence of voids occurred frequently. In addition, the thermosetting resin 6 in the vicinity of the sub-upper die 14 does not flow, and a uniform molding pressure is not applied. Therefore, the dimensional accuracy of the bracket housing that causes vibration and noise of the molded motor. Was getting worse.

  Table 1 shows the appearance defects and the measurement results of the dimensional accuracy of the voids and the inner diameter of the bearing housing of each of the 1000 molded motors produced by the method shown in the examples of the present invention and the conventional method shown in the comparative example. The thermosetting resin used here is a black unsaturated polyester resin molding material. In addition, the appearance defect was defined as an appearance defect when black unevenness occurred. Moreover, when the void of the magnitude | size of 1 mm or more had generate | occur | produced, it was set as the void. In addition, the bearing housing was measured at 100 units, and a portion having a mold size of φ20 mm at room temperature was measured.

From the results in Table 1, compared with the comparative example, the present invention can reduce appearance defects and voids, improve the dimensional accuracy, improve the gap accuracy between the rotor and the stator, and improve the mold motor. It can be confirmed that vibration and noise generated during rotation are reduced.

  Further, the present invention can be applied to a portion where a bracket or the like is inserted other than the bearing housing.

  Thus, according to the molding machine of the present invention, the mold motor manufacturing method using the molding machine, and the mold motor according to the manufacturing method, no runner is generated, and appearance defects and voids can be reduced, and Dimensional accuracy can be improved, gap accuracy between the rotor and stator can be improved, and noise and vibration generated during rotation of the mold motor can be reduced.

DESCRIPTION OF SYMBOLS 1 Bearing housing 2 Bracket 3 Rotor 4 Stator winding 5 Stator iron core 6 Thermosetting resin 7 Rotor shaft 8 Bearing 9 Divided plunger 10 Divided upper upper mold 11 Upper mold 12 Lower mold Mold 13 Plunger 14 Sub-upper mold 15 Mold core 16 Pot

Claims (8)

In a molding machine having a pot for inserting a thermosetting resin and having a plunger operated to press-fill the thermosetting resin into a mold, the thermosetting resin of the plunger is added. The molding machine has a configuration in which the surface to be pressed is divided into two or more surfaces, and the surfaces of the divided plungers that pressurize the thermosetting resin can be controlled by a pressurizer. The molding machine according to claim 1, further comprising:
A pot for inserting a thermosetting resin, a plunger that is operated to press-insert the thermosetting resin into the mold, and at least a part of the upper mold among the molds Is provided with a movable sub mold, and the thermosetting resin inserted into the pot with the movable sub mold is pressurized and filled into the mold, and the movable mold is movable. The molding machine has a configuration in which a part of the molded part of the thermosetting resin is formed with a flexible upper mold, and the runner part generated in the molding of the molded resin product does not occur. The molding machine has a structure in which the sub-upper mold has a divided structure and is movable in conjunction with the control of the plunger. A manufacturing method of a mold motor which molds the perimeter of a motor using the molding machine according to claim 2. In the manufacturing method of the mold motor according to claim 3,
When pressurizing and filling the thermosetting resin into the mold,
(A) the divided sub-upper mold is divided into a shape different from a shape forming a part of the mold motor;
(B) A step of pressure-filling a mold with a thermosetting resin in the shape of (a),
(C) A manufacturing method including a stepwise pressurizing step in which the upper mold is made to have the same shape as that forming a part of the molded motor at the end of molding. In the manufacturing method of the mold motor according to claim 4,
A method for manufacturing a molded motor, wherein when the thermosetting resin is pressure-filled in a mold, the shape of the sub-upper mold is a concave shape in the step (a). In the manufacturing method of the mold motor according to claim 5,
When pressurizing and filling the thermosetting resin into the mold, in step (c), before the thermosetting resin begins to be cured, the sub mold is formed into a part of the mold motor. The manufacturing method of the mold motor made the same. A washing machine equipped with a motor obtained by the method for producing a molded motor according to any one of claims 2 to 6. An air conditioner equipped with a motor obtained by the method for manufacturing a molded motor according to any one of claims 2 to 6.