JP2017011998A - Method for manufacturing magnet and method for resin-molding motor core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a magnet capable of positioning a magnet inserted into an insertion hole of a motor core in a simple method.SOLUTION: A method for manufacturing a magnet includes the steps of: preparing a magnet 3 of a rectangular cross section; superposing a metal mask 12 in which a pattern 12a is formed on one side surface of the magnet 3; supplying a curable resin onto the metal mask 12 and performing screen printing; and forming a plurality of resin protrusions 4 by curing the formed resin pattern by removing the metal mask 12 from the magnet 3 after the screen printing.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method of manufacturing a magnet that is inserted into an insertion hole of a motor core and molded integrally with a mold resin, for example, and a resin core molding method of resin molding a motor core using the magnet.

  2. Description of the Related Art There is known an embedded magnet type motor that includes a magnet inside a rotor and rotates the rotor by an electromagnetic action that acts between a rotating magnetic field generated in the stator and the rotor. The rotor of this embedded magnet type motor has a shaft, a rotor core supported by the shaft, and a magnet fixed to the rotor core. As the rotor core, a laminated core configured by laminating electromagnetic steel plates in the axial direction is used, and a plurality of insertion holes into which magnets are inserted are formed in the laminated core. Since the magnet inserted and fixed in the insertion hole of the rotor core has a clearance with respect to the insertion hole, it may be difficult to fix the magnet at an arbitrary position in the hole after the insertion. On the other hand, for example, when assembled close to either the outer side or the inner side in the radial direction, it is possible to suppress the bias and eccentricity of the magnetic flux balance, which can contribute to the improvement of the motor output. Further, in order to prevent the magnet from being damaged by centrifugal force or vibration, the magnet is protected by filling a gap between the magnet and the hole wall surface. In this case, the magnet inserted into the insertion hole is usually fixed using an adhesive, a thermosetting resin, or the like, but it is difficult to fix the magnet while the magnet is positioned in the insertion hole.

  Therefore, a method for manufacturing a rotor is proposed in which a hemispherical projection member made of a resin material is formed on the inner wall of the insertion hole of the rotor core to form a gap around the magnet, and then the entire circumference of the magnet is covered with resin. (See Patent Document 1 and FIG. 9).

JP 2007-159223 A

However, there is no disclosure of a specific method for previously forming the protruding member with a resin material on the inner wall surface of the insertion hole of the rotor core on which the magnetic steel sheet shown in Patent Document 1 described above is laminated and pressed. It is not practical to form a protruding member made of resin by potting because it is difficult to manage the height. If the magnet inserted into the insertion hole of the rotor core cannot be positioned, it will contribute to the variation in motor output.
In addition, in rare earth magnets containing neodymium magnets and dysprosium, there is a demand for shortening the number of heating times and the heating time as much as possible because a phenomenon of demagnetization occurs when heat histories overlap in the manufacturing process.

  An object of the present invention is to solve the above-described problems of the prior art, and to improve the motor characteristics by using a magnet manufacturing method capable of positioning a magnet inserted into the insertion hole of the motor core by a simple method. It is an object of the present invention to provide a resin mold method for a possible motor core.

  A magnet manufacturing method according to the present invention is a method of manufacturing a magnet that is inserted into an insertion hole of a motor core and is integrally molded with a mold resin, the step of preparing a magnet having a rectangular cross section, and one side of the magnet A step of superimposing a metal mask on which a pattern is formed, a step of supplying a curable resin onto the metal mask and performing screen printing, and a resin formed by removing the metal mask from the magnet after screen printing Curing a pattern to form a plurality of resin protrusions, and positioning at least one side surface of the magnet having a rectangular cross section with the hole wall surface of the insertion hole of the motor core while maintaining a predetermined clearance A resin protrusion having a uniform height is formed.

According to the magnet manufacturing method, a plurality of resin protrusions having a uniform height can be formed on the magnet with a simple method by screen printing.
Therefore, the magnet can be positioned by providing a predetermined clearance with the resin protrusion to the insertion hole of the motor core.

  The resin protrusion may be one obtained by curing an ultraviolet curable resin as a curable resin by irradiation with ultraviolet rays, or one obtained by heating and curing a thermosetting resin as a curable resin. Well, the resin protrusion for positioning can be formed with these curable resins.

  As another example of the magnet manufacturing method, a step of preparing a magnet having a rectangular cross section, a step of forming a resin pattern by dropping or applying an ultraviolet curable resin on at least one side surface of the magnet, Irradiating the formed resin pattern with ultraviolet rays to cure the resin pattern to form a plurality of resin protrusions, and the hole wall surface of the insertion hole of the motor core on at least one side surface of the magnet having a rectangular cross section It is also possible to form resin protrusions of uniform height that are positioned in contact with each other while maintaining a predetermined clearance. According to this, even when a rare earth magnet is used, for example, the time and number of times of applying the thermal history in the manufacturing process can be reduced, so that the thermal demagnetization phenomenon does not occur and the performance of the magnet is not deteriorated.

  If the resin protrusion is formed not only on one side surface of the magnet but also on the end surface in the longitudinal direction, not only the periphery of the magnet but also the end surface in the longitudinal direction can be sealed with the mold resin. It can be sealed and protected.

  Further, in the resin molding method of the motor core, a step of preparing a magnet manufactured using any one of the above-described magnet manufacturing methods and having a plurality of resin protrusions having a uniform height on at least one side surface is formed on the motor core. Inserting the magnet into the insertion hole, positioning the magnet with the resin protrusion abutting against the hole wall surface of the insertion hole and maintaining a predetermined amount of clearance between the hole wall surface and one side of the magnet; And heat-curing a mold resin filled in the insertion hole to mold the magnet integrally with the motor core.

Thus, by inserting the magnet into the insertion hole of the motor core, the resin protrusion is brought into contact with the hole wall surface of the insertion hole, and the clearance between the hole wall surface and one side surface of the magnet is maintained at a predetermined amount and positioned. The mold resin filled in the insertion hole can be heat-cured to integrally mold the magnet with the motor core.
Therefore, the resin can be molded by moving the magnet toward the inside or the outside in the radial direction of the insertion hole, or can be resin-molded by providing a predetermined clearance between the hole wall surface around the magnet. Can be improved.

If the magnet manufacturing method described above is used, the magnet inserted into the insertion hole of the motor core can be positioned by a simple method.
Moreover, if the resin molding method of a motor core is used, the resin molding method of the motor core which can improve a motor characteristic can be provided.

It is explanatory drawing which shows the process of forming the resin protrusion on a magnet. It is explanatory drawing which shows the process of inserting the magnet of FIG. 1 in a motor core. It is explanatory drawing which shows the resin mold process following FIG. It is explanatory drawing which shows the resin mold process following FIG. It is sectional explanatory drawing which shows the other example of positioning of the magnet with respect to the insertion hole of a motor core. It is a perspective view which shows the form of the resin protrusion formed in a magnet.

  Hereinafter, a preferred embodiment of a resin molding method for a motor core according to the present invention will be described in detail with reference to the accompanying drawings. In the following, a permanent magnet type rotor (rotor) core will be described as a motor core. The motor core is not limited to the rotor core, and may be a stator (stator) core.

  The rotor includes a shaft (not shown), a motor core 1 supported by the shaft, and a magnet 3 inserted into the insertion hole 2 of the motor core 1 (see FIG. 2B). The magnet 3 inserted into the insertion hole 2 is inserted with two magnets 3 of the same size arranged in series, but a single magnet 3 may be used. The motor core 1 is provided with a central through hole 1a into which a shaft (not shown) is inserted. The magnet 3 is, for example, a magnetic block before magnetization, and a rare earth sintered magnet such as a neodymium magnet or a ferrite sintered magnet is used. As the motor core 1, for example, a laminated core (laminated iron core) in which plate-like magnetic bodies such as electromagnetic steel plates punched by press working are laminated is used.

  In FIG. 2B, a resin protrusion 4 is formed on at least one side surface 3a of a rectangular parallelepiped magnet 3 having a rectangular cross section. In this embodiment, the resin protrusion 4 is provided with a clearance between the side surface 3 a of the magnet 3 and the hole wall surface 2 b on the radially outer side of the insertion hole 2. It is preferably formed so as not to tilt. In this embodiment, the resin protrusion 4 is formed on the radially outer side surface 3a of the magnet 3, and the magnet 3 is positioned near the radially inner hole wall surface 2a.

For example, as shown in FIG. 6A, resin protrusions 4 formed in a columnar shape (disk shape) may be formed at a plurality of locations including the four corners of the side surface 3 a of the magnet 3. The resin protrusions 4 do not have to be arranged in a line, for example, they may be arranged in a zigzag pattern or in a dotted pattern.
Further, as shown in FIG. 6B, the resin protrusions 4 may be provided on ridges that are continuous along the longitudinal direction on both sides of the side surface 3a of the magnet 3. In any case, the magnet 3 may be formed so as not to tilt in the direction of arrow P centered on the vertical axis and in the direction of arrow Q centered on the horizontal axis.

  Next, an example of the mold 5 will be described with reference to FIG. In the following description, as an example of the mold 5, the upper mold 10 is a fixed mold and the lower mold 7 is a movable mold.

  The motor core 1 is carried into the mold 5 together with the intermediate mold 6. In the intermediate mold 6 on which the motor core 1 is placed, a cull 6 a is provided at a position facing the pot 8. A runner 6b (resin passage) formed between the cull 6a and the clamp surface of the lower mold 7 is communicated. The runner 6 b communicates with a gate 6 c that penetrates the intermediate mold 6 in the plate thickness direction. The motor core 1 is placed on the intermediate mold 6 so that the insertion hole 2 and the gate 6c of the intermediate mold 6 communicate with each other.

The lower mold 7 is provided with a plunger 9 in a cylindrical pot 8 and a pot hole 8a thereof that can be moved up and down. The plunger 9 is driven by a known transfer mechanism. Further, the lower mold 7 includes a heater 7a.
On the lower mold 7, the intermediate mold 6 is placed in alignment with the pot hole 8 a of the pot 8 and the cull 6 a facing each other. A resin path is formed between the runner 6b and the lower clamp surface. Further, the gate 6c communicates with the gap between the magnet 3 of the insertion hole 2 and the hole wall surface 2b on the radially outer side.

  A pressing block 11 is provided on the clamp surface side of the upper mold 10. When the mold 5 is clamped, the pressing block 11 is inserted into the central through hole 1a of the motor core 1 to hold the intermediate mold 6 (see FIG. 4B). The upper mold 10 has a heater 10a built therein.

Here, an example of the resin core molding method will be described with reference to FIGS.
In FIG. 1A, a magnet 3 having a rectangular cross section is prepared. As shown in FIG. 1B, a metal mask 12 (corresponding to a mask) on which a pattern 12a is formed is superposed on one side surface 3a of the magnet 3. The pattern 12a is a through hole, and is provided at a location where a resin to be described later is printed. Here, for the sake of explanation, the case where one magnet 3 is prepared is described. However, it is more efficient to print a resin by aligning a plurality of magnets 3 without gaps and overlaying a metal mask 12 thereon. Is.

  In FIG. 1C, a thermosetting resin is supplied onto the metal mask 12 to perform screen printing. Specifically, a liquid ultraviolet curable resin 13 is supplied onto the metal mask 12, and the squeegee unit 14 is scanned to uniformly apply the ultraviolet curable resin 13 to the mask surface. At this time, the ultraviolet curable resin 13 is applied to the side surface 3a of the magnet 3 with a uniform height and shape through the pattern 12a.

  Next, in FIG. 1D, the metal mask 12 is removed from the magnet 3. Next, the resin pattern (ultraviolet curable resin 13) formed on the exposed side surface 3 a of the magnet 3 is irradiated with ultraviolet rays from a UV light irradiation device (not shown). As a result, the resin pattern is cured to form a plurality of resin protrusions 4. In this way, by forming the resin protrusion 4 using the ultraviolet curable resin 13, even when a rare earth magnet is used, for example, the time and number of times of applying a thermal history in the manufacturing process can be reduced, so that the thermal demagnetization phenomenon is caused. It does not occur and the performance of the magnet 3 is not deteriorated.

  Next, in FIG. 2A, the motor core 1 is prepared. The motor core 1 is a laminated core formed by laminating and pressing electromagnetic steel sheets. The motor core 1 is formed with a central through hole 1a and an insertion hole 2 for a magnet 3 at the periphery thereof.

  Next, in FIG. 2B, the magnet 3 is inserted into the insertion hole 2 formed in the motor core 1. At this time, the magnet 3 is positioned with a predetermined clearance by the resin protrusion 4 with respect to the hole wall surface 2 b on the radially outer side of the insertion hole 2. Specifically, the magnet 3 is inserted into the insertion hole 2 with the resin protrusion 4 facing radially outward, and the magnet 3 is positioned by approaching the radially inner hole wall surface 2a. In this case, in order to insert the resin protrusions 4 in the same direction, the magnets 3 aligned in a predetermined direction are sequentially inserted into the insertion holes 2 so that the direction of the magnets 3 is surely aligned. can do. Furthermore, in order to insert the magnet 3 in the same direction, the magnet 3 may be inserted with the orientation of the magnet 3 more reliably by inserting after determining the presence or absence of the resin protrusion 4 by imaging or contact. . In addition, by measuring the position of the magnet 3 inserted into the insertion hole 2, the direction of the magnet 3 can be confirmed and passed to subsequent processing as a non-defective product.

  Next, in FIG. 3A, a mold resin 15 (for example, a resin tablet or a liquid resin) is supplied to the pot hole 8a of the pot 8 provided in the lower mold 7 of the mold mold 5 that has been opened. Further, the intermediate mold 6 is aligned and overlapped on the lower mold 7 so that the cal 6a faces the pot hole 8a. On the intermediate mold 6, the motor core 1 is placed in alignment so as to communicate with the insertion hole 2 and the gate 6c. The motor core 1 may be loaded into the lower mold 7 after being placed on the intermediate mold 6, or the motor core 1 and the intermediate mold 6 may be individually loaded into the lower mold 7 and overlapped.

  Next, in FIG. 4B, the mold 5 is closed. That is, the lower mold 7 is moved upward to clamp the intermediate mold 6 and the motor core 1 with the upper mold 10. At this time, the pressing block 11 is inserted into the central through hole 1 a of the motor core 1 to clamp the intermediate die 6 with the lower die 7.

  Next, in FIG. 4C, the transfer mechanism is operated to move the plunger 9 upward to feed the mold resin 15 melted in the pot 8 (the resin tablet 15 is melted). At this time, the mold resin 15 is filled in the insertion hole 2 through the cal 6a, the runner 6b formed between the intermediate mold 6 and the lower mold 7, and the gate 6c, and is cured by heating. As a result, the magnet 3 is integrally resin-molded with respect to the motor core 1 while being positioned so as to be aligned within the insertion hole 2 in a certain direction. Therefore, the motor characteristics can be improved by suppressing the deviation of the center of gravity without disturbing the magnetic flux balance of the motor core 1. Further, since the outer side in the radial direction of the magnet 3 is resin-molded with a certain thickness, it is possible to prevent the mold resin 15 from being pressed and damaged by the magnet 3 when centrifugal force or the like is applied.

  Further, the resin protrusion 4 having a uniform height is brought into contact with the hole wall surface 2a of the insertion hole 2 so that the clearance between the hole wall surface 2a and the one side surface 3a can be kept at a predetermined amount for positioning. For this reason, in the resin mold in which the height of the resin protrusion 4 is the same, uniform filling can be realized by causing the mold resin 15 to flow uniformly. As a result, it is possible to increase the strength of the mold resin 15 filled in the clearance and mass-produce the balanced high-quality motor core 1 with uniform quality.

  After the resin molding, the mold 5 is opened and the motor core 1 and the intermediate mold 6 are taken out. The intermediate mold 6 is integrally formed with an unnecessary resin including a molded product cal and a molded product runner gate. For example, the intermediate die 6 is pushed down with respect to the motor core 1 to be separated from the motor core 1. The motor core 1 is stored as a molded product, and the intermediate mold 6 is preferably reused after the unnecessary resin is separated and cleaned.

Next, another example of positioning of the magnet 3 with respect to the insertion hole 2 of the motor core 1 will be described with reference to FIG.
FIG. 5A shows a case where the resin protrusion 4 formed on the side surface 3 a of the magnet 3 is inserted toward the radially inner side of the insertion hole 2. At this time, the magnet 3 is positioned along the hole wall surface 2 b on the radially outer side of the insertion hole 2. The magnet 3 is resin-molded in the insertion hole 2 in the gap with the hole wall surface 2a on the radially inner side.

  FIG. 5B illustrates a case where the resin protrusion 4 of the magnet 3 is formed not only on the side surface 3a of the magnet but also on both end surfaces 3b in the longitudinal direction. As a result, gaps (clearances) are formed not only around the magnet 3 but also at both end surfaces in the longitudinal direction between the mold surfaces, so that the magnet 3 can be protected by being sealed with the mold resin 15. it can.

  FIG. 5C illustrates a case where the resin protrusions 4 are provided on the protrusions that are continuous in the longitudinal direction on both sides of the side surface 3a as shown in the magnet 3 in FIG. 6B. The magnet 3 is positioned along the hole wall surface 2 a on the radially inner side of the insertion hole 2. The magnet 3 is resin-molded in the gap between the insertion hole 2 and the hole wall surface 2b on the radially outer side.

In the mold 5 described above, the lower mold 7 is a movable mold and the upper mold 10 is a fixed mold. However, the upper mold 10 may be a movable mold and the lower mold 7 may be a fixed mold, and both are movable molds. There may be. The pot 8 is not limited to a single pot, and may be a multipot provided corresponding to the number of insertion holes 2.
The pot 8 is not limited to being provided in the lower mold 7 and may be provided in the upper mold 10. In this case, the intermediate die 6 is superimposed on the motor core 1 and clamped with the upper die 10. Further, the intermediate mold 6 may be used without being clamped only by the lower mold 7 and the upper mold 10.

  Further, the resin protrusion 4 provided on the magnet 3 may be formed not only on one side but also on both sides. In this case, the resin projections 4 provided on both side surfaces of the magnet 3 can be positioned with a predetermined clearance with respect to the hole wall surface 2a of the insertion hole 2 to which the magnet 3 is directed. And since it can position and arrange in arbitrary positions, it can carry out resin molding with sufficient balance. Also in this case, since the clearance with respect to the hole wall surface 2a can be set to an arbitrary amount, it becomes easy to control the flow of the mold resin 15, and the mold resin 15 is appropriately filled even for a finer clearance. Therefore, the high quality motor core 1 can be mass-produced with uniform quality.

  Also, the resin protrusion 4 can be formed only on one end surface of the magnet 3 in the longitudinal direction. Thereby, since a clearance gap between mold surfaces can be set to arbitrary values, it can also be used for resin flow control.

  Further, the resin protrusion 4 provided on the magnet 3 is not limited to the ultraviolet curable resin 13 but may be another curable resin, and as an example, a photo curable resin or a thermosetting resin may be used. In view of molding quality and productivity, it is preferable to form the resin protrusions 4 by the above-mentioned screen printing. Also good. Or the resin tape used as the resin protrusion 4, a resin sheet, etc. may be sufficient.

  Further, although the magnet 3 is positioned along the hole wall surface 2a on the radially inner side of the insertion hole 2 or the hole wall surface 2b on the radially outer side, the resin protrusion 4 is provided on the opposite side surface of the magnet 3. Thus, the magnet 3 may be positioned so as to form a clearance and sealed with the mold resin 15.

  DESCRIPTION OF SYMBOLS 1 Motor core 1a Center through-hole 2 Insertion hole 2a, 2b Hole wall surface 3 Magnet 3a Side surface 3b End surface 4 Resin protrusion 5 Mold metal mold 6 Intermediate mold 6a Cal 6b Runner 6c Gate 7 Lower mold 7a, 10a Heater 8 Pot 8a Pot hole 9 Plunger 10 Upper mold 11 Press block 12 Metal mask 12a Pattern 13 UV curable resin 14 Squeegee unit 15 Mold resin

Claims (5)

A method of manufacturing a magnet that is inserted into an insertion hole of a motor core and molded integrally with a mold resin,
A step of preparing a magnet having a rectangular cross section;
Overlaying a metal mask having a pattern formed on one side of the magnet;
Supplying a curable resin on the metal mask and performing screen printing;
A step of curing a resin pattern formed by removing the metal mask from the magnet after screen printing and forming a plurality of resin protrusions,
Manufacturing a magnet having a uniform height on a side wall of an insertion hole of the motor core and forming a resin protrusion having a uniform height for positioning with a predetermined clearance on at least one side of the magnet having a rectangular cross section Method.   2. The resin protrusion is obtained by curing an ultraviolet curable resin as the curable resin by irradiating ultraviolet rays, or by heating and curing a thermosetting resin as the curable resin. The manufacturing method of the magnet of description. A method of manufacturing a magnet that is inserted into an insertion hole of a motor core and molded integrally with a mold resin,
A step of preparing a magnet having a rectangular cross section;
Forming a resin pattern by dropping or applying an ultraviolet curable resin on at least one side of the magnet; and
Irradiating the resin pattern formed on the magnet with ultraviolet rays to cure the resin pattern to form a plurality of resin protrusions, and at least one side surface of the magnet having a rectangular cross section has an insertion hole of the motor core. A method of manufacturing a magnet, comprising: forming a resin protrusion having a uniform height that is positioned in contact with a hole wall surface while maintaining a predetermined clearance.   The method of manufacturing a magnet according to any one of claims 1 to 3, wherein the resin protrusion is formed not only on one side surface of the magnet but also on an end surface in a longitudinal direction. A step of preparing a magnet manufactured using the magnet manufacturing method according to claim 1 and having a plurality of resin protrusions having a uniform height on at least one side surface;
The magnet is inserted into an insertion hole formed in the motor core, and the resin protrusion is brought into contact with the hole wall surface of the insertion hole so that the clearance between the hole wall surface and one side surface of the magnet is maintained at a predetermined amount. Positioning, and
Heat-curing a mold resin filled in the insertion hole and integrally resin-molding the magnet with respect to the motor core;
A resin mold method for a motor core, comprising:

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