JP2018115615A - Fan device and its process of manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate assembling of a lead wire having a connector at a fan device.SOLUTION: When a motor 10 provided with a stator part 100 and a rotor part 200 actually installed at a circuit board 300 is stored and assembled in a casing 400 having an air outlet 410 at one end side in an axial direction and an inlet port 420 at the other end side, the circuit board 300 is constituted to have a main body part 310 where the stator part 100 is actually installed and several arm parts 320 extending from the main body part 310 outwardly and then a lead line 500 having a connector is soldered in advance to the circuit board 300. Then, the stator part 100 is stored from the inlet port 420 into the casing 400 and each of the arm parts 320 at the circuit board 300 is connected to an end surface 411 of the air outlet 410 of the casing 400 to cause the lead line 500 having the connector to be drawn out to the side of the air outlet 410.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a fan device such as an axial fan, a centrifugal fan, and a sirocco fan, and a manufacturing method thereof.

  This type of fan device is widely used for cooling, ventilation, air conditioning, vehicle air conditioning, air blowing, and the like for electronic devices, home appliances, OA devices, industrial devices, and the like. The structure known as 1 is common. In the axial fan shown in the document, an outer rotor type motor having a rotor part and a stator part is accommodated in a casing (housing), the rotor part has a plurality of moving blades, and the casing is a plurality of stationary blades. The stator portion has a structure in which the base portion of the central portion is integrally provided at the end portion on the inner peripheral side of each stationary blade so as to be fixed to the casing. And the circuit board which controls operation | movement of a motor is arrange | positioned at the base part of the stator part.

JP 2008-175158 A

  By the way, when assembling the axial fan having the structure shown in the above-mentioned patent document, a lead wire with a connector is soldered in advance to a circuit board on which a stator part constituting the motor is mounted, and the stator part is placed in the casing. However, the accommodation is performed from the opening on the side where there is no stationary blade. At that time, a process is usually employed in which the connector is passed from the inner side of the casing through the gap between the stationary blades and the lead wire with the connector is pulled out of the casing. FIG. 9 shows an example of an axial fan assembled in such a manner, and a connector 903 and a lead wire 904 are inserted into a gap between a plurality of stationary blades 902 formed on the end surface on one end side in the axial direction of the casing 901. Yes. An impeller 906 that is rotationally driven by a motor 905 is accommodated in the casing 901, and the lead wire 904 is connected to a circuit board provided on a stator portion of the motor 905 by soldering.

  However, in such a structure, depending on the size of the connector, it may not be possible to pass through the gap between the stationary blades. In this case, the end of the lead wire opposite to the connector from the outside of the casing is fixed to the stationary blade. The gap is inserted into the casing and the end thereof is soldered to the circuit board. However, when the lead wire is short, the space for soldering becomes narrow and the work becomes very difficult, which causes a problem that workability is deteriorated.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a fan device and a method of manufacturing the same that can facilitate assembly work more effectively than in the past.

  The present invention is a fan device including a motor including a stator portion and a rotor portion, a circuit board on which the stator portion is mounted, and a casing for housing the motor, wherein the casing is at least in the axial direction. An opening is formed on one end side, and the circuit board has a main body part on which the stator part is mounted, and a plurality of arm parts extending outward from the main body part, and at least of the arm parts of the circuit board A part of the fan device is joined to an end face of the opening on the one end side of the casing by a joining means, and the motor is housed in the casing in that state.

  In the present invention, a mode in which a connector is connected to the circuit board via a lead wire drawn to the one end side in the axial direction can be mentioned.

  In the present invention, an embodiment in which a plurality of the arm portions are provided at circumferentially equally divided portions can be mentioned.

  In the present invention, there is an embodiment in which the arm portion is formed in a wing shape.

  In this invention, the aspect by which the stationary blade part was provided between the said several arm parts is mentioned.

  In the present invention, there is an embodiment in which the arm portion is reinforced by a reinforcing means.

  In this invention, the aspect by which the surface of the said axial direction one end side in the said main-body part of the said circuit board is coat | covered with the coating | covering material is mentioned.

  In the present invention, an embodiment in which a part or the whole of the stator portion is covered with the covering material is exemplified.

  In this invention, the aspect by which the part by the side of the said main-body part side of the said arm part is coat | covered with the said coating | covering material is mentioned.

  In the present invention, there is an embodiment in which the covering material covered on the arm portion is formed in a wing shape.

  The present invention can also be understood as an invention of a manufacturing method. The invention relating to the manufacturing method is the above-described fan device invention, wherein the stator portion housing step of inserting and housing the stator portion in the casing from the opening on the one axial end side of the casing, and the stator portion housing step Thereafter, at least a part of the arm part of the circuit board is joined to an end face of the opening on the one end side of the casing.

  In the invention of the above manufacturing method, a mode in which a connector is connected to the circuit board via a lead wire can be mentioned.

  Advantageous Effects of Invention According to the present invention, an effect is provided that a fan device and a method for manufacturing the same that can facilitate assembly work more effectively than before are provided.

It is a longitudinal cross-sectional view of the axial fan which concerns on one Embodiment of this invention. It is a perspective view of a coaxial flow fan. It is a disassembled perspective view of a coaxial flow fan. It is a perspective view of the stator assembly which comprises a coaxial flow fan, Comprising: (A) The state before potting, (B) The state after potting. (A) The perspective view of the stator assembly of other embodiment by which the arm part of the circuit board was made, (B) The perspective view of the axial flow fan which comprises the stator assembly. (A) Perspective view of stator assembly of another embodiment in which vane-shaped potting is made on arm part of circuit board and stator vane part is further provided between arm parts, (B) Axial flow including the stator assembly It is a perspective view of a fan. It is the perspective view of the form which exposed the outer peripheral surface of the stator part which is another form of potting to a stator assembly. FIG. 10 is a perspective view of another form of potting on the stator assembly, potted only on the main body of the circuit board. It is a perspective view which shows the prior art example of an axial flow fan.

Hereinafter, an embodiment in which the present invention is applied to an axial fan will be described with reference to the drawings.
(1) Basic structure of axial fan FIG. 1: has shown the longitudinal cross-section of the axial fan 1 (an example of a fan apparatus) which concerns on one Embodiment. The axial fan 1 includes an impeller 210 that is rotationally driven by a motor 10, and a casing 400 that houses the motor 10 and the impeller 210. The casing 400 is formed in a substantially square hollow rectangular tube shape when viewed from the axial direction (the axial direction of the motor 10).

  In FIG. 1, the lower opening that is one axial end side of the casing 400 forms an exhaust port (opening on one axial end side) 410, and the upper opening that is the other axial end side forms an intake port 420. Yes. That is, when the impeller 210 rotates, air is sucked into the casing 400 from the upper intake port 420 of the casing 400 and exhausted from the lower exhaust port 410. 2 is a perspective view of the axial fan 1 viewed from the exhaust port 410 side, FIG. 3 is an exploded perspective view of the axial fan 1, and FIG. 4A is a perspective view of a stator assembly 20 described later. Mounting holes 430 penetrating in the axial direction are formed in the four corner portions of the casing 400. The axial fan 1 is attached to the target device by a fixture such as a bolt passed through the attachment hole 430.

  The motor 10 includes a stator unit 100 and a rotor unit 200. As shown in FIG. 1 and FIG. 4A, the stator unit 100 includes a stator core 110, an insulator 120 attached to the stator core 110, and a coil 130 in which a winding is wound around the insulator 120. The stator core 110 is formed by laminating thin sheet core materials made of a plurality of electromagnetic steel plates, and a plurality of pole teeth 112 extend radially from the outer periphery of the central cylindrical portion 111. The winding is wound around each pole tooth 112 via an insulator 120, thereby forming a coil 130. A circuit board 300 that controls the rotational drive of the rotor unit 200 is disposed on one end side in the axial direction of the stator unit 100 (lower side in FIG. 1). Although details will be described later, the circuit board 300 includes a main body portion 310 on which the stator portion 100 is mounted, and a plurality of arm portions 320 extending outward from the main body portion 310, and at least a part of the plurality of arm portions 320 is formed. The end face 411 of the exhaust port 410 in the casing 400 is joined by joining means, and the motor 10 is accommodated in the casing 400 in that state.

  As shown in FIG. 1, the rotor unit 200 includes an impeller 210 and a shaft 220 in the impeller 210. In the impeller 210, a plurality of blades 215 are formed on the outer peripheral surface of a covered cylindrical hub 211 at equal intervals in the circumferential direction. The hub 211 and the plurality of blades 215 are formed by, for example, integral molding using a resin mold. ing. The shaft 220 is suspended from the center of the hub 211, and the upper end portion is fixed to the lid portion 212 of the hub 211. The blades 215 are integrally formed on the outer peripheral surface of the cylindrical body portion 213 of the hub 211, and a magnet 240 is attached to the inner peripheral surface of the body portion 213 via the yoke 230.

  As shown in FIG. 1, the rotor part 200 is rotatable with respect to the stator part 100 by the shaft 220 being supported in the cylindrical part 111 of the stator part 100 via a pair of bearings 250 and a bearing liner 260. Built in. In this assembled state, the outer peripheral surfaces of the magnet 240 and the stator core 110 face each other with a minute gap therebetween, whereby the motor 10 is configured. An annular gap between the shaft 220 and the bearing liner 260 on the front end side of the shaft 220 is closed by a retainer 271 mounted on the shaft 220 and a shim 272 on the outer peripheral side thereof.

(2) Stator assembly The stator unit 100 and the circuit board 300 constitute the stator assembly 20 shown in FIG. In addition to the stator unit 100 and the circuit board 300, the stator assembly 20 is connected to a plurality of connectors (in this case, two cables) in which a connector 520 connected to a power source or the like is connected to one end and the other end is connected to the circuit board 300 by soldering ) Lead wire 510.

  As shown in FIG. 4 (B), the stator assembly 100 and the circuit board 300 are potted with a potting material (an example of a covering material, an example of a reinforcing means). 1 to 3, the stator unit 100 and the circuit board 300 are potted with a potting material 30. Potting is a generally well-known coating processing technique in which a potting material made of, for example, urethane resin or epoxy resin is coated on the surface of a product such as a substrate for the purpose of moisture proofing / waterproofing, antifouling, insulation, reinforcement and the like. In addition, the kind of potting material 30 of this embodiment is not limited, It selects suitably.

  As shown in FIG. 4A, the circuit board 300 has a shape in which a plurality of arm portions 320 extend outward from the outer peripheral edge of the disk-shaped main body portion 310. In this case, four arm portions 320 are formed at equally spaced locations in the circumferential direction. The extending direction of the arm part 320 is not particularly limited. In the present embodiment, every other one formed in the circumferential direction is parallel to each other, and those adjacent in the circumferential direction are orthogonal to each other. It has an extended form. The main body portion 310 and the arm portion 320 are integrally formed of the same substrate material, and the main body portion 310 is provided with a control circuit, connection terminals, and the like. The main body portion 310 is larger than the diameter of the stator portion 100, and the stator portion 100 is mounted concentrically on the main body portion 310. A lead wire 510 to which the connector 520 is connected (hereinafter referred to as a lead wire with connector 500) is soldered and connected to a connection terminal of the main body 310 in advance.

  The potting region in the stator assembly 20 is substantially the entire stator portion 100 and the entire main body portion 310 of the circuit board 300. As shown in FIG. 1, the lower portion of the inner peripheral surface of the stator core 110 is potted with the potting material 30, but the portion in contact with the bearing liner 260 above it is not potted. The lead wire 500 with a connector is drawn out from the potting portion to the outer peripheral surface of the main body 310.

  In the stator assembly 20 in which the predetermined region is potted with the potting material 30 as described above, the distal end portion of each arm portion 320 of the circuit board 300 is on the end surface (end surface of the opening on one end side) 411 of the casing 400. The motor 10 is accommodated in the casing 400 in this state. Moreover, the lead wire 500 with a connector is drawn out to the exhaust port 410 side (lower side in FIG. 1). That is, the connector 520 is connected to the circuit board 300 via the lead wire 510 drawn to one end side in the axial direction. Each arm portion 320 is fitted in an attachment groove 412 formed on one side of each attachment hole 430 of the end surface 411 of the exhaust port 410. A pin 415 protruding to the exhaust side is provided on the bottom surface of the mounting groove 412 by means such as press fitting, and a pin hole 325 formed in the arm portion 320 is fitted into the pin 415. Then, the arm part 320 is joined to the end surface 411 of the exhaust port 410, that is, the casing 400 by soldering the pin 415 and the arm part 320.

  As shown in FIGS. 1 and 2, in this joined state, the potting surface 30a that covers the main body 310 of the circuit board 300 and faces the exhaust side is parallel to the end surface 411 of the exhaust port 410 and has no step, and Each arm part 320 is located on the inner side (upper side in FIG. 1) of the casing 400 than the potting surface 30a. The exhaust port 410 is partitioned by each arm portion 320, and a gap between each arm portion 320 becomes a substantial exhaust port. The arm part 320 corresponds to the stationary blade 902 of the axial fan shown in FIG.

  Soldering is an example of a joining means for joining the arm part 320 to the casing 400. In addition, the pin 415 and the arm part 320 are welded or welded, or the tip part of the pin 415 protruding from the pin hole 325 is used. Various joining means can be appropriately employed as long as the joining strength can be ensured by crushing or screwing, adhesive, or the like.

(3) Manufacturing method of axial fan Next, one Embodiment of the manufacturing method which assembles the axial fan 1 of the said structure is described.
The axial fan 1 is assembled by housing the stator assembly 20 in the casing 400 from the exhaust port 410 side and mounting it, and incorporating the rotor unit 200 in the stator unit 100 while housing it in the casing 400 from the intake port 420 side. Is called. The bearing 250, the bearing liner 260, the retainer 271 and the shim 272 are mounted on the shaft 220 of the rotor unit 200 in advance. The bearing 250 is fixed (for example, press-fitted) in the bearing liner 260, and the shaft 220 is fixed in the bearing liner 260.

  As a method for manufacturing the axial fan 1, a stator part housing step in which the stator part 100 is inserted and housed in the casing 400 from the opening on one end side in the axial direction of the casing 400, and after the stator part housing step, An arm part joining step for joining at least a part of the arm part 320 to the end face of the opening on one end side of the casing 400. The following are specific examples.

  In order to attach the stator assembly 20 to the casing 400, the stator assembly 20 is disposed on the exhaust port 410 side of the casing 400, and the stator portion 100 potted by the potting material 30 is inserted into the casing 400 from the exhaust port 410 and accommodated. (Stator part 100 accommodation process). Then, at the same time that the tip of each arm 320 of the circuit board 300 is fitted into the mounting groove 412, the pin hole 325 is fitted into the pin 415, and the arm 320 is brought into contact with the bottom surface of the mounting groove 412. Next, the pin 415 and the arm part 320 are joined by a joining means such as soldering, and each arm part 320 is joined to the end surface 411 of the exhaust port 410 (arm part joining step).

  Subsequently, the rotor unit 200 is disposed on the intake port 420 side, the tip of the shaft 220 is directed to the casing 400 side, and the bearing liner 260 attached to the shaft 220 is adhered in the cylindrical unit 111 of the stator unit 100 to The rotor unit 200 is inserted into the casing 400 through the port 420 and accommodated. Thereafter, the stator portion 100 potted by the potting material 30 is accommodated in the hub 211 of the impeller 210, and the assembly of the axial flow fan 1 is completed.

  Note that the above assembly procedure is an example. For example, after the stator unit 100 is accommodated in the casing 400, the rotor unit 200 is connected to the exhaust port 410 before the arm unit 320 is joined to the end surface 411 of the exhaust port 410 of the casing 400. The arm portion 320 may be joined to the end surface 411 of the exhaust port 410. Further, if the rotor part 200 is large enough to pass through the exhaust port 410, the rotor unit 200 is assembled into the stator unit 100 to assemble the motor 10, and the motor 10 is accommodated in the casing 400 from the exhaust port 410, Finally, the arm portion 320 may be joined to the end surface 411 of the exhaust port 410. Furthermore, although the lead wire with connector 500 is soldered in advance to the connection terminal of the main body 310 of the circuit board 300, the connection terminal is exposed to the surface on the exhaust port 410 side (the potting surface 30a). After joining the arm part 320 to the casing 400, the lead wire 510 may be soldered to the connection terminal.

(4) Effects According to the above-described embodiment, after the stator assembly 20 in which the connector-attached lead wire 500 is connected to the circuit board 300 is completed, the stator portion 100 can be accommodated in the casing 400, and the accommodation thereof. In this state, the lead wire with connector 500 is drawn to the exhaust port 410 side. In the present embodiment, since no stationary blade is provided at the exhaust port 410 of the casing 400, the stator unit 100 can be inserted and accommodated in the casing 400 from the exhaust port 410 side.

  That is, since the stator portion 100 is not accommodated in the casing 400 from the intake port 420 side, the work of drawing the lead wire 500 with a connector from the inside side of the casing 400 through the gap between the stationary blades to the outside as in the prior art is required. No. If the connector 520 is of a size that cannot pass through the gap between the stationary blades, the lead wire 510 is passed through the gap from the outside (exhaust port side) and soldered to the circuit board. In this case, there is a problem that if the lead wire 510 is short, soldering work becomes difficult. However, in this embodiment, such work is not required. In this embodiment, the assembly of the lead wire 500 with a connector is also completed by incorporating the stator assembly 20 into the casing 400 and joining the arm portion 320 to the casing 400. For these reasons, according to the present embodiment, the assembly process becomes simpler than before, and the assembly work can be facilitated effectively.

  In addition, according to the present embodiment, the potting material 30 reinforces the stator portion 100 and the main body portion 310 of the circuit board 300 by potting, so that resistance to mechanical stress is improved and static electricity, temperature, humidity, The environmental resistance against water is improved.

(5) Other Embodiments Other embodiments of the present invention other than the above-described embodiment will be described below. In the case of referring to the drawings, the same components as those in the above-described embodiment are denoted by the same reference numerals and the description thereof is omitted.

(5-1) Potting With regard to potting (covering) with the potting material (covering material) 30, for example, a case in which at least the surface on one end side in the axial direction of the main body 310 of the circuit board 300 is potted with the potting material 30 ( 8), a case (FIGS. 5, 6, and 7) in which a part or the whole of the stator portion is covered with a covering material, and at least a portion of the arm portion 320 on the main body 310 side of the circuit board 300. There are cases that are potted in. A specific example will be described below.

  In FIG. 5A, potting with the potting material 30 on the stator portion 100 and the main body portion 310 of the circuit board 300 is extended to each arm portion 320. In this case, the main body part 310 side of the circuit board 300 in the arm part 320, that is, the root side is potted together with the main body part 310, leaving the tip part where the pin hole 325 is formed. FIG. 5B shows an axial fan incorporating the stator assembly 20 shown in FIG. The potting portion 31 to the arm portion 320 has a substantially pentagonal cross section (for example, a spoke shape) in the illustrated example, but the cross sectional shape is not limited. By potting on the arm part 320, the arm part 320 is reinforced to improve resistance to mechanical stress, and the environment resistance of the arm part 320 is improved.

  6A is the same as FIG. 5 in that potting by the potting material 30 is extended to each arm portion 320, but the potting portion 32 to the arm portion 320 smoothly rectifies the exhaust gas. Further, the stationary blade portion 33 having the same blade shape is integrally formed between the arm portions 320 by potting. The stationary blade portion 33 is formed in the center between the arm portions 320, and the plurality of alternately disposed stationary blade portions 33 and arm portions 320 are formed at equal intervals in the circumferential direction. Further, the length of the stationary blade portion 33 is set such that a slight gap is left between the tip of the stationary blade portion 33 and the inner peripheral surface of the exhaust port 410. FIG. 6B shows an axial fan incorporating the stator assembly 20 shown in FIG.

  Thus, the fan performance is improved by making the potting portion 32 and the stationary blade portion 33 of the arm portion 320 into a blade shape. In addition, although the stationary blade part 33 may be formed only by the potting material 30, it may be formed by providing a protruding part similar to the arm part 320 from the main body part 310 and potting the protruding part.

  In FIG. 7, the stator portion 100 and the main body portion 310 of the circuit board 300 are potted with the potting material 30, but the potting on the stator portion 100 is performed with the outer peripheral surface of the stator core 110 exposed, and the stator portion by potting. The increase in diameter of 100 is suppressed. FIG. 8 shows a form in which only potting 310 of the circuit board 300 is used for potting.

(5-2) Others The shapes of the casing 400, the main body portion 310 of the circuit board 300, and the arm portion 320 are merely examples, and are not limited. For example, the casing 400 may be cylindrical, and the main body 310 of the circuit board 300 may be rectangular or polygonal. Moreover, although the arm part 320 is a board | substrate of the circuit board 300 and is thin plate shape, the arm part 320 itself may be formed in the wing | blade shape. Further, it is preferable that the arm portion 320 is reinforced by the reinforcing means because strength is improved. The potting material 30 potted on the arm portion 320 shown in FIGS. 5 and 6 is an example of the reinforcing means as described above. Further, the shape of potting formed on the arm part 320 is not limited. Further, in the above embodiment, the present invention is applied to an axial fan, but the present invention can also be applied to other types of fan devices such as a centrifugal fan and a sirocco fan.

  The present invention can be used for fan devices such as an axial fan, a centrifugal fan, and a sirocco fan.

  DESCRIPTION OF SYMBOLS 1 ... Axial fan (an example of a fan apparatus), 10 ... Motor, 20 ... Stator assembly, 30 ... Potting material (an example of a coating | covering material, an example of a reinforcement means), 30a ... Potting surface, 31 ... Potting part, 32 ... Potting , 33 ... Stator blade part, 100 ... Stator part, 110 ... Stator core, 111 ... Cylindrical part, 112 ... Polar teeth, 120 ... Insulator, 130 ... Coil, 200 ... Rotor part, 210 ... Impeller, 211 ... Hub, 212 ... Lid, 213 ... trunk, 215 ... blade, 220 ... shaft, 230 ... yoke, 240 ... magnet, 250 ... bearing, 260 ... bearing liner, 271 ... retainer, 272 ... shim, 300 ... circuit board, 310 ... main body , 320 ... arm part, 325 ... pin hole, 400 ... casing, 410 ... exhaust port (opening on one axial side) 411: End face of exhaust port (end face of opening on one end side), 412 ... Mounting groove, 415 ... Pin, 420 ... Intake port (opening on the other end side), 430 ... Mounting hole, 500 ... Lead wire with connector, 510 ... Lead wire, 520 ... Connector

Claims (12)

A motor having a stator portion and a rotor portion;
A circuit board on which the stator portion is mounted;
A casing for housing the motor;
A fan device comprising:
The casing is formed with an opening at least on one end side in the axial direction,
The circuit board has a main body portion on which the stator portion is mounted, and a plurality of arm portions extending outward from the main body portion,
At least a part of the arm portion of the circuit board is joined to an end face of the opening on the one end side of the casing by joining means, and the motor is housed in the casing in that state. apparatus.   2. The fan device according to claim 1, wherein a connector is connected to the circuit board via a lead wire drawn out to one end side in the axial direction.   The fan device according to claim 1, wherein the plurality of arm portions are provided at circumferentially equally divided locations.   The fan device according to claim 1, wherein the arm portion is formed in a wing shape.   The fan device according to any one of claims 1 to 4, wherein a stationary blade portion is provided between the plurality of arm portions.   The fan device according to claim 1, wherein the arm portion is reinforced by a reinforcing means.   The fan device according to claim 1, wherein at least a surface of the circuit board on the one end side in the axial direction of the main body is covered with a covering material.   The fan device according to claim 7, wherein a part or the whole of the stator portion is covered with the covering material.   The fan device according to claim 7 or 8, wherein at least a portion of the arm portion on the main body side of the circuit board is covered with the covering material.   The fan device according to claim 9, wherein the covering material covered on the arm portion is formed in a wing shape. It is a manufacturing method of the fan device according to any one of claims 1 to 10,
From the opening on the one end side in the axial direction of the casing, a stator part housing step for inserting and housing the stator part in the casing;
After the stator portion housing step, an arm portion joining step for joining at least a part of the arm portion of the circuit board to the end surface of the opening on the one end side in the casing;
A method for manufacturing a fan device, comprising:   12. The fan device manufacturing method according to claim 11, wherein a connector is connected to the circuit board via a lead wire.

Images