JP2012170190A - Rotor laminate iron core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor laminate iron core which prevents peeling of iron core pieces at upper and lower end parts of the rotor laminate iron core and improves the reliability and the quality of the rotor laminate iron core.SOLUTION: In a rotor laminate iron core 10, permanent magnets 16 are inserted into multiple magnet insertion holes 15 formed in a circumferential direction and are sealed with a resin. In the rotor laminate iron core 10, tongue pieces 19, 20 are respectively formed on iron core pieces 11, 12 located at axial end parts of the rotor laminate iron core 10 and fit into resin sealing space parts 18, each of which is formed extending at longitudinal one side or both sides of each magnet insertion hole 15 in a plain view.

Description

The present invention relates to a rotor laminated core (including an inner rotor type and an outer rotor type) formed by laminating a plurality of iron core pieces and having a plurality of permanent magnets (including non-magnetized magnets) disposed therein.

As a rotor of an electric motor mounted on a hybrid vehicle or the like, a magnet mold method has been proposed in which a permanent magnet is fixed to a rotor (specifically, a rotor laminated iron core) with a mold resin (see Patent Documents 1 and 2). This will be schematically described with reference to FIGS. 6A to 6C. Permanent magnets 62 (two in this example) are respectively inserted into the plurality of magnet insertion holes 61 formed around the rotor laminated core 60. Inserted between the upper die 63 and the lower die 64 and tightened, the mold resin 66 put in the resin pot 65 provided in the upper die 63 is pushed out by the plunger 67, and each magnet insertion hole is inserted through the runner 68. The permanent magnet 62 was fixed to the magnet insertion hole 61.

Japanese Patent No. 3786946 JP 2007-236020 A

However, in the magnet molding method described above, as shown in FIGS. 7A to 7C, the outer peripheral portions (particularly magnet insertion holes) of the iron core pieces 71 and 72 located on the uppermost surface and the lowermost surface of the rotor laminated iron core 60 are used. The portion between 61 and the outer edge of the laminated rotor core 60) is weak against the load in the axial direction, and there is a problem that the resin peels off easily.

The problem of peeling off of these iron core pieces 71 and 72 is common in that they occur in the iron core pieces at the upper and lower end portions of the rotor laminated iron core having the most weak adhesive force with the mold resin. It has been found that the occurrence is significant in a region where the distance from the outer peripheral edge of the rotor laminated core is small when viewed from the outside in the radial direction.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and a rotor laminated core intended to improve the reliability and quality of the rotor laminated iron core by preventing the peeling of the iron core pieces at the upper and lower ends of the rotor laminated iron core. The purpose is to provide.

The rotor laminated core according to the first invention that meets the above-mentioned object is a rotor laminated iron core in which permanent magnets are inserted into a plurality of magnet insertion holes formed in the circumferential direction and sealed with resin.
A tongue piece formed on the core piece at the axial end of the rotor laminated core in a resin-sealed space formed by extending to one side or both sides in the longitudinal direction in plan view of each magnet insertion hole Is inserted. In this case, the insertion depth of the tongue piece portion is preferably about 2 to 5 times the thickness of the iron core piece.
In addition, the shape of the tongue piece portion may be a linear shape, a bowl shape, or an arrow shape.

Further, the rotor laminated core according to the second invention is the rotor laminated iron core according to the first invention, wherein the tongue piece portion is bent and a portion excluding the base portion is fitted into the resin-encapsulated space portion. Yes. In this case, the tongue piece portion may be bent around its base portion or may be bent and bent.

A rotor laminated core according to a third aspect of the present invention is the rotor laminated core according to the second aspect of the present invention, wherein the tongue piece before bending is formed with a length such that the tip thereof is in contact with the permanent magnet.
According to a fourth aspect of the rotor laminated iron core of the present invention, in the second rotor laminated iron core, the tongue piece before bending is formed with a length such that the tip thereof does not contact the permanent magnet.
In addition, in 3rd, 4th invention, it can also apply individually to the iron core piece currently formed in the axial direction both ends.

The rotor laminated core according to a fifth aspect of the present invention is the rotor laminated core according to the first to fourth aspects of the invention, wherein the plurality of tongue pieces are provided with a gap with respect to one of the resin-sealed spaces. It has been.

The rotor laminated core according to a sixth aspect of the present invention is the rotor laminated core according to the first to fifth aspects, wherein the tongue piece is in addition to the core piece at the axial end of the rotor laminated core, A plurality of core pieces including the core pieces are formed.

And the rotor lamination | stacking iron core which concerns on 7th invention is a rotor lamination | stacking iron core which concerns on 1st-6th invention, The positioning protrusion in which the said permanent magnet is stored in a predetermined position is provided in the said magnet insertion hole. .

In the rotor laminated iron core according to the first to seventh inventions, the shaft of the rotor laminated iron core is formed in a resin-sealed space formed by extending in the longitudinal direction on one side or both sides in plan view of each magnet insertion hole. Since the tongue piece formed on the core piece at the end of the direction fits in, and the tongue piece adheres to the resin in the resin-sealed space and does not easily come out, it is at the axial end of the rotor laminated core. The core piece is difficult to peel off.
Thereby, the number of defective products of the rotor laminated core is reduced, and the quality of the electric motor using the rotor laminated core is further improved.

In particular, since the rotor laminated core according to the second invention is formed by bending the tongue piece, it can be easily manufactured with a constant size and shape using a mold.

In the rotor laminated iron core according to the fifth aspect of the present invention, a plurality of tongue pieces are provided with a gap with respect to one resin sealing space, so that the bonding strength with the sealing resin increases.

And since the rotor lamination | stacking iron core which concerns on 7th invention is provided with the positioning protrusion (positioning latching | locking part) in which a permanent magnet fits in a predetermined position in a magnet insertion hole, regardless of the shape and position of a tongue piece part The position of the permanent magnet with respect to the magnet insertion hole can be determined.

(A) is a top view of the rotor lamination | stacking iron core which concerns on the 1st Embodiment of this invention, (B) is PP 'sectional drawing of the same figure (A), (C) is the same figure (A). It is QQ 'sectional drawing. (A), (C) is the top view and side view of the iron core piece (core piece) located in the upper end of the same rotor lamination | stacking core, respectively, (B) is located in the center of the same rotor lamination | stacking iron core. It is a top view of an iron core piece. (A), (B) is a partial top view before and after inserting a permanent magnet in the magnet insertion hole of the rotor lamination | stacking iron core which concerns on the 2nd Embodiment of this invention, respectively, (C) is the same figure (B). It is SS 'sectional drawing. It is a graph which shows the relationship between the floating amount of an iron core piece, and a load. (A)-(E) are the partial top views of the tongue piece part which concerns on a modification. (A)-(C) are explanatory drawings of the magnet mold construction method which concerns on a prior art example. (A)-(C) are explanatory drawings of the rotor lamination | stacking iron core which concerns on a prior art example.

Subsequently, an embodiment in which the present invention is embodied will be described for the understanding of the present invention.
As shown in FIGS. 1 (A) to (C), the rotor laminated core 10 according to the first embodiment of the present invention has an iron core piece 11 disposed at axial ends (that is, an upper end and a lower end). , 12 and a plurality of iron core pieces 13 arranged in the middle thereof, and a rectangular parallelepiped arranged in a plurality of magnet insertion holes 15 formed in the circumferential direction of the iron core main body 14. A permanent magnet 16 having a shape and a mold resin 17 for sealing the permanent magnet 16 to the magnet insertion hole 15 are provided. The magnet insertion hole 15 is extended in the longitudinal direction in plan view, and a resin sealing space 18 is formed on both sides. Tongue pieces 19 and 20 formed in the core pieces 11 and 12 are fitted into the resin sealing space 18 in a state of being bent in the magnet insertion holes 15. These will be described in detail below.

As shown in FIGS. 1 and 2A to 2C, the core pieces 11 to 13 are formed by pressing a magnetic steel plate having a thickness of, for example, 0.15 to 2 mm, and a shaft hole 23 is formed at the center. A plurality of punch holes 24, 25, and 26 that are stacked to become the magnet insertion holes 15 are formed along the radially outer region. Each of the holes 24, 25, and 26 has a portion 27 for forming the resin sealing space 18 on both sides.
At the center in the width direction of the longitudinal ends of the punch holes 24 and 25 of the core pieces 11 and 12 positioned at the upper end and the lower end (that is, the forming portion 27), the tongue piece portion 19 made of a rectangular plate material facing inward, 20 is provided.

The tongue pieces 19 and 20 are bent so as not to come into contact with the side end portions of the permanent magnets 16 disposed in the holes 24 and 25. Accordingly, the length of the tongue pieces 19 and 20 is, for example, about 0.5 to 2 times the width a of the holes 24 and 25, and the width of the tongue pieces 19 and 20 is about the width of the holes 24 and 25. For example, the width a is 0.3 to 0.6 times. When the iron core pieces 11 to 13 are laminated and the iron core main body 14 is caulked and laminated, the tongue pieces 19 and 20 are bent in advance within a range of 30 to 70 degrees, for example, based on the base. Note that the tongue pieces 19 and 20 may be bent inwardly in a curved shape.

In addition, the length of the tongue piece parts 19 and 20 may be a length that does not contact the side end parts of the permanent magnets 16 arranged in the punch holes 24 and 25 or a length that touches them without being bent. In addition, when the tongue pieces 19 and 20 are bent and are in contact with the side end portions of the permanent magnets 16 disposed in the extraction holes 24 and 25, the tongue pieces 19 and 20 are permanent when the permanent magnets 16 are inserted. The tongue pieces 19 and 20 may be bent while being applied to the side end of the magnet 16. In this case, it is preferable to bend by the permanent magnet 16 into which only one side of the tongue pieces 19 and 20 of the iron core pieces 11 and 12 located at both the upper end and the lower end is inserted.

In forming the rotor laminated core 10, a plurality of core pieces 13 are caulked and laminated on the core piece 12, and the iron core piece 11 is laminated on the top. In this case, when the tongue pieces 19 and 20 are bent in advance, the magnet insertion hole 15 formed with the tongue piece 20 of the iron core piece 12 facing upward and the tongue piece 19 of the iron core piece 11 facing downward. To fit within. Next, it is put between an upper mold and a lower mold (not shown) by a conventional method, clamped, and filled with a mold resin from a resin pot provided on the upper mold or the lower mold. As a result, the tongue pieces 19 and 20 are fitted (ie, pierced) into the cured mold resin, and the anchoring effect is exerted to prevent the upper and lower core pieces 11 and 12 from being peeled off.

Next, a rotor laminated core according to the second embodiment of the present invention will be described with reference to FIG. 3A shows the core body 31 in a state where the permanent magnet 16 is not inserted into the magnet insertion hole 30, and FIG. 3B shows the core body 31 in a state where the permanent magnet 16 is inserted into the magnet insertion hole 30. Indicates. FIG. 3C shows the rotor laminated iron core 33 in a state where the permanent magnet 16 is inserted into the magnet insertion hole 30 and fixed with the mold resin 32.

In this embodiment, a plurality of pairs (usually 4 to 8 pairs) of magnet insertion holes 30 are provided in the rotor laminated iron core 33 in the circumferential direction, and each magnet insertion hole 30 has a predetermined size (a rectangular parallelepiped shape). ) For determining the position of the permanent magnet 16. In this embodiment, one positioning protrusion 35 is provided, but a plurality of positioning protrusions 35 may be provided so that the permanent magnet 16 is accurately mounted at a predetermined position of the magnet insertion hole 30.

On one side of the magnet insertion hole 30, a resin sealing space 36 is provided by extending the magnet insertion hole 30 in the circumferential direction or in the longitudinal direction. It has the tongue piece part 37 bent in the back | inner side direction of the sealing space part 36. FIG. The tongue piece portion 37 is provided on the uppermost iron core piece 38 and the lowermost iron core piece (not shown), and the portion excluding the base portion which is a bending point is fitted into the inner side of the resin sealing space 36.

FIG. 4 shows an experimental example in which the effect of the present invention was confirmed using this rotor laminated iron core 33. In this experiment, the width of the tongue piece 37 was 0.5 mm, the length was 4 mm, and the thickness of the magnetic steel sheet was 0.3 mm. The end part of the upper iron core piece 38 was pulled, and the relationship between the load and the pulling amount (that is, the floating amount) was obtained. For comparison, the same experiment was also performed on an iron core piece without the tongue piece 38. As shown in FIG. 4, it can be seen that the rotor laminated iron core 33 provided with the tongue piece portion 38 is more difficult to peel off the uppermost or lowermost iron core piece.

FIG. 5 shows a modification of the tongue piece. (A) shows a straight tongue piece 40 as in the first and second embodiments, (B) shows a wedge-like tongue piece 41, ( C) shows a tongue piece portion 42 having a front-side bulge shape, (D) shows a tongue-like tongue piece portion 43, and (E) shows a tongue piece portion 44 having a plurality of plate pieces with gaps. The deformed tongue pieces 41 to 43 shown in (B), (C), and (D) are more difficult to be removed from the resin than the straight tongue pieces 40 and 44 of (A) and (E).

In the above-described embodiment, the tongue piece portion is provided only on the iron core piece at the axial end portion. However, the plurality of iron core pieces including the iron core piece at the axial end portion are provided with the tongue piece portion bent inward. The present invention also applies.
The present invention is also applied to a case where a rotor laminated iron core is configured by combining the first and second embodiments and modifications.
Moreover, although it is sufficient to apply the above-mentioned tongue piece part to only one piece of the core part of the upper end part and the lower end part of the core body, the second upper end part and the lower end part of the core body can be used as necessary. It can also be applied to core pieces. If the tongue piece (the tip) is not brought into contact with the permanent magnet inserted into the magnet insertion hole, the operation at the time of inserting the permanent magnet becomes easy.

DESCRIPTION OF SYMBOLS 10: Rotor laminated iron core, 11-13: Iron core piece, 14: Iron core main body, 15: Magnet insertion hole, 16: Permanent magnet, 17: Mold resin, 18: Resin sealing space part, 19, 20: Tongue piece part , 23: shaft hole, 24-26: punching hole, 27: formation site, 30: magnet insertion hole, 31: iron core body, 32: mold resin, 33: rotor laminated iron core, 35: positioning protrusion, 36: resin sealing Stop space part, 37: tongue piece part, 38: iron core piece, 40-44: tongue piece part

Claims (7)

In the rotor laminated iron core in which permanent magnets are inserted into a plurality of magnet insertion holes formed in the circumferential direction and sealed with resin,
A tongue piece formed on the core piece at the axial end of the rotor laminated core in a resin-sealed space formed by extending to one side or both sides in the longitudinal direction in plan view of each magnet insertion hole A rotor laminated iron core characterized in that is inserted. 2. The rotor laminated core according to claim 1, wherein the tongue piece portion is bent and a portion excluding the base portion is fitted into the resin-sealed space portion. 3. 3. The rotor laminated core according to claim 2, wherein the tongue piece before being bent is formed with a length such that a tip thereof is in contact with the permanent magnet. 4. 3. The rotor laminated core according to claim 2, wherein the tongue piece before bending is formed with a length that does not contact the permanent magnet. 5. The rotor laminated core according to claim 1, wherein a plurality of the tongue pieces are provided with a gap with respect to one of the resin-sealed spaces. Laminated iron core. 6. The rotor laminated core according to claim 1, wherein the tongue piece portion includes a plurality of iron core pieces including the iron core piece in addition to the iron core piece at the axial end portion of the rotor laminated iron core. The rotor laminated iron core is characterized by being formed in. The rotor laminated core according to any one of claims 1 to 6, wherein the magnet insertion hole is provided with a positioning projection for receiving the permanent magnet at a predetermined position.

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