JP2018182993A - ボンド磁石の射出成形装置及びボンド磁石の射出成形方法 - Google Patents
ボンド磁石の射出成形装置及びボンド磁石の射出成形方法 Download PDFInfo
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 47
- 230000005291 magnetic effect Effects 0.000 claims abstract description 107
- 230000004907 flux Effects 0.000 claims abstract description 83
- 239000000463 material Substances 0.000 claims abstract description 44
- 238000002347 injection Methods 0.000 claims abstract description 43
- 239000007924 injection Substances 0.000 claims abstract description 43
- 238000003780 insertion Methods 0.000 claims abstract description 34
- 230000037431 insertion Effects 0.000 claims abstract description 34
- 230000005415 magnetization Effects 0.000 claims abstract description 24
- 230000002093 peripheral effect Effects 0.000 claims abstract description 24
- 239000003302 ferromagnetic material Substances 0.000 claims abstract description 7
- 239000000155 melt Substances 0.000 abstract 1
- 239000000243 solution Substances 0.000 abstract 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 10
- 230000004323 axial length Effects 0.000 description 5
- 230000007423 decrease Effects 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000013459 approach Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000000696 magnetic material Substances 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004308 accommodation Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2701—Details not specific to hot or cold runner channels
- B29C45/2703—Means for controlling the runner flow, e.g. runner switches, adjustable runners or gates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2701—Details not specific to hot or cold runner channels
- B29C45/2708—Gates
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0273—Imparting anisotropy
- H01F41/028—Radial anisotropy
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
- H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
- H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
- H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
- H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
- H02K1/2773—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect consisting of tangentially magnetized radial magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
- B29K2995/0008—Magnetic or paramagnetic
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Permanent Field Magnets Of Synchronous Machinery (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Permanent Magnet Type Synchronous Machine (AREA)
Abstract
Description
上記構成によれば、ロータコアに着磁率の高いボンド磁石を成形できるため、モータの出力トルク向上を図ることができる。
上記構成によれば、着磁機構によりロータコアに磁束が付与されるため、ロータコアの磁石挿入孔に射出された後のボンド磁石材料を配向・着磁できる。
図1及び図2に示すロータ1は、図示しないステータの内周側に回転可能に配置されるものであり、例えば電動パワーステアリング装置の駆動源となるモータ(回転電機)を構成する。
図3に示すように、ボンド磁石13の射出成形装置21は、ロータコア12を支持する下型22と、円環状の着磁機構23を有する中間型24と、溶融した樹脂材料に粉末の磁性材料を混合したボンド磁石材料の供給源25に接続される上型26とを備えている。なお、下型22及び中間型24は、上型26に対して一体的に移動可能な可動型として構成されている。
別の工程で製造されたロータコア12を着磁機構23内に挿入し、軸孔14に位置決め棒32が挿入されるようにして台座部31上にロータコア12を載置する。続いて、図3に示すように、下型22及び中間型24を移動させて上型26に組み付ける。これにより、射出金型63の突出部72が着磁機構23内に挿入され、磁束付与部材73がヨーク41と径方向に対向する。この状態では、上記のように磁束付与部材73からゲート77内に磁束が付与される(図8参照)。
(1)射出金型63に、ゲート77内に磁束を付与する磁束付与部材73を設け、ボンド磁石13を射出成形する際に、ゲート77内に磁束を付与しながら溶融状態のボンド磁石材料をロータコア12の磁石挿入孔15に射出するようにした。磁石挿入孔15に射出される前のゲート77内に存在するボンド磁石材料は、温度が高く流動性も高いため、ゲート内に磁束を付与することで効果的にボンド磁石を着磁できる。これにより、ロータコア12に配向率及び着磁率の高いボンド磁石13を成形できるため、モータの出力トルク向上を図ることができる。
・上記実施形態において、上型26にヒータを設けることで、1つのロータコア12にボンド磁石13を射出成形する度に流路内に残留したボンド磁石を取り除かないようにすることが可能である。
・上記実施形態では、磁石挿入孔15の断面が径方向内側に向かって凸となる円弧状としたが、これに限らず、例えば径方向と直交する直線状やハ字状等でもよく、その形状は適宜変更可能である。
・上記実施形態では、ゲート痕16が複数のボンド磁石13(磁石挿入孔15)に跨るように射出金型63及びロータコア12を設計したが、これに限らず、ゲート痕16が単一のボンド磁石13に設けられるようにしてもよい。
(イ)前記ゲートは、前記突出部の端面における外周寄りの位置に開口されたボンド磁石の射出成形装置。上記構成によれば、ボンド磁石材料が着磁機構の内周面に近い磁場の強い範囲に射出され、強い磁束を受けて着磁されるため、成形されるボンド磁石の配向率及び着磁率を好適に向上できる。
Claims (6)
- 溶融状態のボンド磁石材料を対象物の空洞部に射出するゲートが形成された射出金型を備え、
前記射出金型には、前記ゲート内に磁束を付与する磁束付与部が設けられたボンド磁石の射出成形装置。 - 請求項1に記載のボンド磁石の射出成形装置において、
前記対象物の空洞部としてロータコアの磁石挿入孔にボンド磁石材料を射出するボンド磁石の射出成形装置。 - 請求項2に記載のボンド磁石の射出成形装置において、
前記ロータコアに磁束を付与して前記磁石挿入孔に射出されたボンド磁石材料を着磁する着磁機構を備えたボンド磁石の射出成形装置。 - 請求項3に記載のボンド磁石の射出成形装置において、
前記磁束付与部は強磁性材料からなり、前記着磁機構の磁束の磁路となるように該着磁機構の一部と対向することにより、該着磁機構の磁束を前記ゲート内に付与するボンド磁石の射出成形装置。 - 請求項4に記載のボンド磁石の射出成形装置において、
前記射出金型は、端面に前記ゲートが開口する突出部を有し、
前記突出部には、前記磁束付与部の側面が該突出部の外周面に露出するように設けられ、
前記着磁機構は、前記ロータコアとともに前記突出部の一部を内周側に収容可能な環状に形成され、前記側面と径方向において対向するボンド磁石の射出成形装置。 - 溶融状態のボンド磁石材料を射出金型のゲートから対象物の空洞部に射出してボンド磁石を成形するボンド磁石の射出成形方法において、
前記ゲート内に磁束を付与しながら溶融状態の前記ボンド磁石材料を前記空洞部に射出するボンド磁石の射出成形方法。
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JP2017083663A JP6939042B2 (ja) | 2017-04-20 | 2017-04-20 | ボンド磁石の射出成形装置及びボンド磁石の射出成形方法 |
US15/951,513 US10804776B2 (en) | 2017-04-20 | 2018-04-12 | Bonded-magnet injection molding device and bonded-magnet injection molding method |
EP18167505.9A EP3395532B1 (en) | 2017-04-20 | 2018-04-16 | Bonded-magnet injection molding device and bonded-magnet injection molding method |
CN201810353629.2A CN108736605B (zh) | 2017-04-20 | 2018-04-19 | 粘结磁铁的注射成型装置以及粘结磁铁的注射成型方法 |
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Cited By (2)
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WO2023007706A1 (ja) * | 2021-07-30 | 2023-02-02 | 川崎重工業株式会社 | ロータ、モータ、及びロータの製造方法 |
WO2023157131A1 (ja) * | 2022-02-16 | 2023-08-24 | 三菱電機株式会社 | 永久磁石回転子および永久磁石回転子の製造方法 |
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WO2018189822A1 (ja) * | 2017-04-12 | 2018-10-18 | 三菱電機株式会社 | Ipmロータ |
JP7099936B2 (ja) * | 2018-11-15 | 2022-07-12 | 株式会社三井ハイテック | 鉄心製品及び鉄心製品の製造方法 |
FR3113988B1 (fr) * | 2020-09-07 | 2023-04-28 | Commissariat Energie Atomique | Dispositif pour la formation de poles d’un rotor |
DE102021106222A1 (de) | 2021-03-15 | 2022-09-15 | Wirthwein Ag | Verbundmagnet-Spritzgussvorrichtung, Spritzgussmaschine sowie Verfahren zur Herstellung eines Verbundmagnet-Spritzgussteils |
CN113437843A (zh) * | 2021-07-09 | 2021-09-24 | 浙江盘毂动力科技有限公司 | 基于钕铁硼磁钢的转子结构及制造方法 |
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JP2017055491A (ja) * | 2015-09-07 | 2017-03-16 | 株式会社ジェイテクト | 埋込磁石型ロータユニットの製造方法、および埋込磁石型ロータの製造装置 |
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WO2023007706A1 (ja) * | 2021-07-30 | 2023-02-02 | 川崎重工業株式会社 | ロータ、モータ、及びロータの製造方法 |
WO2023157131A1 (ja) * | 2022-02-16 | 2023-08-24 | 三菱電機株式会社 | 永久磁石回転子および永久磁石回転子の製造方法 |
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US20180309351A1 (en) | 2018-10-25 |
EP3395532A1 (en) | 2018-10-31 |
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US10804776B2 (en) | 2020-10-13 |
CN108736605A (zh) | 2018-11-02 |
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