JP2020171171A - Annular laminated core material and manufacturing method of the same - Google Patents

Abstract

To provide an annular laminated core material that eliminates iron loss due to eddy currents generated from a joint of each core material and does not require an additional step and a manufacturing method of the same.SOLUTION: An annular laminated core material 1 includes a core body 6 in which a plurality of annular core materials is formed by laminating into a cylindrical shape and a groove extending in an axial direction on an inner peripheral surface on an inner side in a radial direction or on an outer peripheral surface on an outer side in the radial direction is formed, a resin molded body 2 formed by integrally molding a pair of bodies 2a formed to cover at least a part of both axial end surfaces of the core body 7 and a connecting portion 2b connecting the pair of bodies 2a, and an insulating sheet 6 disposed on an inner surface of the groove. Both ends of the insulating sheet 6 in the axial direction are in contact with the bodies 2a of the resin molded body 2, respectively.SELECTED DRAWING: Figure 1

Description

The present invention relates to an annular laminated core material and a method for producing an annular laminated core material.

Conventionally, an annular laminated core material such as a motor core formed by bonding a predetermined number of annular core materials punched from a strip-shaped thin plate material in a laminated state has been known. As a method for producing an annular laminated core material, for example, an in-mold automatic lamination method is known. In the in-mold automatic laminating method, first, the strip-shaped thin plate material is intermittently transferred by the progressive die device, and the desired die-cutting process is sequentially performed on the core thin plate portion of the strip-shaped thin plate material. Next, the thin plate portion for the core material is punched out with an outer diameter punch, separated from the strip-shaped thin plate material, and sequentially removed into the die. Then, each of the removed core materials is bonded in a laminated state by a predetermined number of pieces by a caulking coupling means which is a kind of temporary fixing means provided in advance on the core material.

As a general caulking bonding means in the in-mold automatic laminating method, for example, as in Patent Document 1 (Japanese Unexamined Patent Publication No. 58-116033), each core material is provided with a cut-out portion in advance, or Patent Document 2 (Japanese Patent Laid-Open No. 49-37103) is provided with a punching protrusion (dowel), and in a laminated state, the vertically adjacent core materials are caulked and joined by a raised portion or a punching protrusion. The configuration is used.

Further, for example, a laminated core material in which each core material is adhered by an adhesive or a laser beam is also known.

Japanese Unexamined Patent Publication No. 58-116033 JP-A-49-37103

However, in the above-mentioned caulking coupling means, the coupling portion due to the cut-out portion or the embossed protrusion is left as it is even when assembled as a motor, so that an eddy current or the like is generated in this caulking coupling portion due to iron loss. There was a problem that the efficiency was reduced by several percent.

Further, in the method of adhering with a direct material or a laser beam, a resin molded body is laminated as a core material in order to secure electrical insulation with the winding after applying an adhesive or performing a laser beam irradiation process. An additional step was required to fit the.

Therefore, an object of the present invention is to provide an annular laminated core material which eliminates iron loss due to an eddy current generated from a joint portion of each core material and which does not require an additional step, and a method for producing the same. Is what you do.

The present invention is an annular laminated core material, in which a plurality of annular core materials are laminated to form a cylindrical shape, and a groove portion extending in the axial direction on the inner peripheral surface in the radial direction or the outer peripheral surface in the radial direction. A resin molded body in which a core main body formed of a core body, a pair of main body portions formed so as to cover at least a part of both axial end surfaces of the core main body, and a connecting portion connecting the pair of main body portions are integrally molded. The insulating sheet is provided on the inner surface of the groove portion, and both ends of the insulating sheet in the axial direction are in contact with the main body portion of the resin molded body.

According to the present invention having the above configuration, the pair of main body portions of the resin molded body are integrated by the connecting portion, and further, the insulating sheet and the resin molded body are connected by contacting each other, so that the laminated core material is crimped. It can be integrated without being temporarily fixed by or by bonding. As a result, it is not necessary to provide a caulking joint portion for caulking in the core material, iron loss can be suppressed, and additional steps such as application of an adhesive and a laser beam are not required.

In the present invention, preferably, the core main body is formed with through holes extending between both end faces in the axial direction, and the connecting portion connects the pair of main body portions through the through holes of the core main body.
According to the present invention having the above configuration, when the resin molded body is molded, the molten resin is filled in the space corresponding to the pair of main body portions and the connecting portion through the through holes, so that the main body portion and the connecting portion are connected. Can be integrated.

In the present invention, preferably, a groove portion extending between both end faces in the axial direction is formed on the inner peripheral surface or the outer peripheral surface of the core main body, and the connecting portion connects the pair of main body portions through the groove portion of the core main body. ..
According to the present invention having the above configuration, when the resin molded body is molded, the molten resin is filled in the space corresponding to the pair of main body portions and the connecting portion through the peripheral groove portion, so that the main body portion and the connecting portion Can be integrated.

In the present invention, preferably, the annular core material has flat surfaces on both sides in the axial direction, and each core material is in direct contact with the adjacent core material and the flat surfaces.
According to the present invention having the above configuration, iron loss can be further suppressed.

In the present invention, preferably, the insulating sheet and the resin molded body are connected without using an adhesive.
According to the present invention having the above configuration, the annular laminated core material can be manufactured without performing an additional step such as adhesion.

In the present invention, the axial length of the contact portion between the insulating sheet and the resin molded body is preferably 0.5 mm or more.
According to the present invention having the above configuration, if the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5 mm or more, a linear segment conductor is arranged in the groove portion of the annular laminated core material 1. However, there is no deviation between the core materials when bent, and it can withstand the load applied during bending.

In the present invention, the insulating sheet and the resin molded body are preferably connected by impregnating the surface of the insulating sheet in contact with the resin molded body with the resin constituting the resin molded body.
According to the present invention having the above configuration, the insulating sheet and the resin molded body can be more firmly connected.

In the present invention, preferably, the resin molded body is formed by using a polymer having an amide bond, and the surface of the insulating sheet in contact with the resin molded body is composed of the polymer having an amide bond.
According to the present invention having the above configuration, the polymer and the insulating sheet are entangled at the molecular level, and the insulating sheet and the resin molded body can be more firmly connected.

In the present invention, preferably, the resin molded body is formed by using a polymer having an amide bond, and the surface of the insulating sheet in contact with the resin molded body is composed of aramid paper composed of aramid fibrid and aramid short fibers. Has been done.
According to the present invention having the above configuration, the polymer and the insulating sheet are entangled at the molecular level, and the insulating sheet and the resin molded body can be more firmly connected.

The motor of the present invention uses a stator in which a winding is wound around the above-mentioned annular laminated core material.
According to the motor having the above configuration, the above-mentioned effects are achieved.

The motor generator of the present invention uses a stator in which a winding is wound around the above-mentioned annular laminated core material.
According to the motor generator having the above configuration, the above-mentioned effects are achieved.

The generator of the present invention uses a stator in which a winding is wound around an annular laminated core material.
According to the generator having the above configuration, the above-mentioned effects are exhibited.

The present invention is a method for manufacturing an annular laminated core material, in which a plurality of annular core blocks are laminated to form a cylindrical shape, and axially on an inner peripheral surface inward in the radial direction or an outer peripheral surface inward in the radial direction. A placement step of arranging the core body on which the extending groove is formed in the molding die so that the insulating sheet is placed in the groove, and at least the axial end faces of the core body by injecting resin into the molding die. It is characterized by including a pair of main body portions formed so as to cover a part thereof, and a resin molding step for integrally molding a resin molded body including a connecting portion connecting the pair of main body portions.

According to the present invention having the above configuration, the main body portion and the connecting portion can be integrally formed, and the laminated core materials can be integrated without temporary fixing such as caulking or adhesion.

According to the present invention, it is possible to provide an annular laminated core material which eliminates iron loss due to an eddy current generated from a joint portion of each core material and which does not require an additional step, and a method for producing the same.

It is a schematic perspective view which shows the structure of the annular laminated core material of one Embodiment of this invention. It is a perspective view which shows the core body of the annular laminated core material shown in FIG. It is a perspective view which shows the core material which comprises the core body shown in FIG. It is a perspective view which shows the insulation sheet of the annular laminated core material shown in FIG. It is a perspective view which shows the core body of the annular laminated core material by another embodiment.

Hereinafter, the cyclic laminated core material according to one embodiment of the present invention and the method for producing the same will be described with reference to the drawings, but the present invention is not particularly limited thereto.

(Circular laminated core material)
FIG. 1 is a schematic perspective view showing the configuration of an annular laminated core material according to an embodiment of the present invention. As shown in FIG. 1, the annular laminated core material has a cylindrical shape, has a shape in which a plurality of arms extending inward in the radial direction are formed on the inner peripheral surface, and a groove is formed between the arms. The annular laminated core material 1 preferably has an axial length of a contact portion between the insulating sheet and the resin molded body of 0.5 mm or more. The annular laminated core material of the present embodiment is used, for example, as a stator for a motor, a motor generator, and a generator by winding a winding around each arm.

(Core body)
FIG. 2 is a perspective view showing a core body of the annular laminated core material shown in FIG. As shown in FIG. 2, the core main body 4 is a cylindrical member in which a plurality of annular core members 8 are laminated, and a plurality of openings on the inner peripheral surface are formed so as to extend in the axial direction. The boundaries of the laminated core materials 8 forming the core body 4 are not always visible, but are shown in FIGS. 1, 2 and 5 for the sake of explanation.

FIG. 3 is a perspective view showing a core material constituting the core body shown in FIG. As shown in FIG. 3, the core material 8 is a plate-shaped member formed as flat surfaces on both sides in the axial direction, and has a cross section in which substantially H-shaped portions on the outer peripheral side in the radial direction are connected in a circular shape. are doing. The core material 8 includes an annular ring portion 8a, a plurality of arm portions 8b extending inward in the circumferential direction from the ring portion 8a, and protrusions 8c extending from the tip end portion of the arm portion 8b to both sides in the circumferential direction. , Equipped with. Between each arm portion 8b, a substantially trapezoidal groove portion 8d surrounded by an adjacent arm portion 8b, an annular portion 8a, and a protruding portion 8c is formed. Further, on the outer peripheral surface of the annular portion 8a, six outer peripheral groove portions 8e are formed at equal angular intervals in the circumferential direction. As the material of the core material 8, a metal such as a silicon steel plate can be used.

As shown in FIG. 2, in the core body 4, a plurality of core materials 8 are laminated without a temporary fixing means. That is, the surface of each core material 8 is not formed with a raised portion or a punched protrusion for caulking. Further, the flat surfaces of the core materials 8 adjacent to each other in the axial direction are in direct contact with each other, there is no adhesive between the core materials 8, and there is no welding mark by the laser beam. The core body 4 has the same cross-sectional shape over the entire length in the axial direction, and has a cylindrical cylindrical portion 4a, a plurality of arm portions 4b extending inward in the circumferential direction from the cylindrical portion 4a, and a circumferential direction from the tip of the arm portion 4b. It includes protrusions 4c extending on both sides. The axial thickness of the core main body 4 is equal to the thickness of the annular laminated core material 1 excluding the pair of main body portions 2a of the resin molded body 2. The cylindrical portion 4a of the core main body 4 is configured by laminating the annular portion 8a of the core material 8, and the arm portion 4b of the core main body 4 is configured by laminating the arm portion 8b of the core material 8 so that the core main body 4 protrudes. The protruding portion 8c of the core material 8 is laminated in the portion 4c.

Between each arm portion 4b, a substantially trapezoidal groove portion 4d that is surrounded by an adjacent arm portion 4b, a cylindrical portion 4a, and a protruding portion 4c and extends in the axial direction is formed. The groove portion 4d of the core main body 4 is formed by the groove portions 8d of the laminated core material 8 being continuous in the axial direction. Further, on the outer peripheral surface of the cylindrical portion 4a, six outer peripheral groove portions 4e formed at equal angular intervals in the circumferential direction and extending in the axial direction are formed. The outer peripheral groove portion 4e of the core main body 4 is formed by laminating a plurality of outer peripheral groove portions 8e of the core material 8.

In the present embodiment, the outer peripheral groove portion 4e is formed on the outer peripheral surface of the core main body 4, and the connecting portion 2b is formed in the outer peripheral groove portion 4e. However, the present invention is not limited to this, and for example, as shown in FIG. A through hole 104b that penetrates in the axial direction may be formed in the core main body 104. In this case, the outer peripheral groove portion 4e is unnecessary. When the core main body 104 having such a configuration is used, a connecting portion is formed in the through hole 104b, and the main bodies 2a can be connected to each other through the through hole 104b. When forming such a through hole, it is preferable to form it in the cylindrical portion 104a. Further, in the present embodiment, the groove portion 4d is formed on the inner peripheral surface in the radial direction of the core main body 4, but the groove portion may be formed on the outer peripheral surface on the outer peripheral surface in the radial direction of the core main body 4. In this case, instead of the outer peripheral groove portion 4e, an inner peripheral groove portion extending in the axial direction may be formed on the inner peripheral surface inward in the radial direction, and a connecting portion of the resin molded body may be formed in the inner peripheral groove portion. A through hole may be formed in the cylindrical portion, and a connecting portion of the resin molded body may be formed in the through hole.

(Insulating sheet)
FIG. 4 is a perspective view showing an insulating sheet of the annular laminated core material shown in FIG. As shown in FIG. 4, the insulating sheet 6 has the same substantially U-shaped cross-sectional shape in the axial direction, and has the same axial length as the axial length of the annular laminated core material 1. The insulating sheet 6 is formed by bending a long strip-shaped sheet material, and has a central portion 6a, a left bending portion 6b, and a right bending portion 6c. The central portion 6a has a width equal to the width of the bottom portion of the groove portion 4d of the core main body 4. The left-turned portion 6b and the right-turned portion 6c have a width equal to the radial surface of the groove portion 4d of the core main body 4. The inner edges of the left-turned portion 6b and the right-turned portion 6c in the radial direction are bent toward each other to form the tip bent portions 6d and 6e.

As shown in FIG. 1, the insulating sheet 6 is arranged on the inner surface of each groove portion 4d of the core main body 4. The central portion 6a of the insulating sheet 6 is arranged on the bottom portion (radial outer surface) of the groove portion 4d, and the left bending portion 6b and the right bending portion 6c are arranged on the surface extending in the radial direction of the groove portion 4d. ing. The tip bending portions 6d and 6e are arranged on the radial outer surface of the protruding portion 8c. Further, both ends of the insulating sheet 6 in the axial direction protrude outward from both ends in the axial direction of the core main body 4 by a length equal to the thickness of the main body 2a of the resin molded body 2. The insulating sheet 6 is provided to insulate between the winding and the inner peripheral surface of the groove 4d of the core body 4 when the winding of the motor is wound around the arm 4b of the core body 4. ..

In the present embodiment, as the insulating sheet, a paper, a non-woven fabric, a film having an insulating property, a composite thereof, or a laminated sheet can be used. For example, insulating paper such as aramid paper composed of aramid fibrid and aramid short fibers, plastic film such as polyphenylene sulfide film, polyimide film, polyetheretherketone film, polyethylene terephthalate film, polyethylene naphthalate film, and laminated sheets thereof. Can be mentioned. In particular, a laminated sheet containing aramid paper composed of aramid fibrid and aramid short fibers is preferable on at least one side. Here, as the adhesive used for laminating the aramid paper, a suitable adhesive usually used in the art can be used, for example, epoxies, acrylics, phenols, polyurethanes, silicon. Examples include, but are not limited to, adhesives such as polyesters and amides. Further, when the above films are laminated with an adhesive, the films are usually stretched, and when a bobbin for a motor is manufactured by the melt injection molding method of the present invention described later, the laminated sheet is likely to be deformed due to shrinkage. .. For this reason, a laminated sheet in which the polymer is melt-impregnated in the aramid paper by superimposing the filem obtained by melt-forming the polymer and the above-mentioned aramid paper and heating and pressurizing the polymer, and a polymer extract (web) and the aramid paper are extracted. Laminated sheets that can be combined or laminated, heated and pressed, and melt-impregnated with resin in aramid paper, and heat-sealed by melt-extruding resin onto aramid paper are preferably used.

The number of layers of the laminated sheet can be appropriately selected according to the use and purpose of the laminated body. For example, from an aromatic polyamide resin produced by a method of melt-extruding a resin onto aramid paper as described in JP-A-2006-321183 and heat-sealing, and an epoxy group-containing phenoxy resin having an epoxy group in the molecule. Therefore, examples thereof include a two-layer laminated sheet of polymer and aramid paper in which the ratio of the epoxy group-containing phenoxy resin is 30 to 50% by mass, and a three-layer laminated sheet of aramid paper, polymer and aramid paper, but the present invention is limited thereto. It's not a thing.

When the adhesiveness between the insulating sheet and the resin molded body described later is not sufficient and the winding is peeled off, it is preferable to surface-treat the surface of the insulating sheet in contact with the resin molded body to improve the adhesiveness. .. Here, the surface treatment includes plasma surface treatment, corona surface treatment, surface treatment by liquid immersion and the like. By carrying out such a surface treatment, the surface energy of the surface of the insulating paper is improved and the interface energy with the resin molded body is lowered, and as a result, the adhesiveness with the resin molded body is improved. Plasma surface treatment is particularly preferable because of the simplicity of treatment.

The thickness of the insulating sheet can be appropriately selected according to the application and purpose of the insulating sheet, and can be selected as long as there is no problem in workability such as bending and winding. Generally, from the viewpoint of workability, a thickness within the range of 50 μm to 1000 μm (particularly preferably 70 to 200 μm) is preferable, but the thickness is not limited to this.

(Aramid)
In the present embodiment, the aramid means a linear polymer compound (aromatic polyamide) in which 60% or more of the amide bonds are directly bonded to the aromatic ring. Examples of such aramids include polymetaphenylene isophthalamide and its copolymer, polyparaphenylene terephthalamide and its copolymer, poly (paraphenylene) -copoly (3,4'-diphenyl ether) terephthalamide and the like. Can be mentioned. These aramids are industrially produced by, for example, conventionally known interfacial polymerization methods and solution polymerization methods using isophthalated products and metaphenylenediamine, and can be obtained as commercial products, but the present invention is limited thereto. It is not something that is done. Among these aramids, polymetaphenylene isophthalamide is preferably used because it has properties such as good molding processability, heat adhesion, flame retardancy, and heat resistance.

(Aramid Five Brid)
In the present embodiment, the aramid fibrid is a film-like aramid particle having a papermaking property, and is also called an aramid pulp (see Japanese Patent Publication No. 35-11851, Japanese Patent Publication No. 37-5732, etc.).

It is widely known that aramid fibrid is subjected to disintegration and beating treatments and used as a papermaking raw material in the same manner as ordinary wood pulp, and so-called beating treatments can be performed for the purpose of maintaining quality suitable for papermaking. This beating process can be carried out by a discriminator, beater or other papermaking raw material processing device that exerts a mechanical cutting action. In this operation, the morphological change of the fibrid can be monitored by the drainage test method (freeness) specified in Japanese Industrial Standards P8121. In the present embodiment, the drainage degree of the aramid fibrid after the beating treatment is preferably in the range of 10 cm ^{3 to} 300 cm ³ (Canadian Freeness (JISP8121)). Fibrids with a drainage level greater than this range may reduce the strength of the aramid paper formed from it. On the other hand, if it is attempted to obtain a drainage degree smaller than 10 cm ³ , the utilization efficiency of the mechanical power to be input becomes small, the processing amount per unit time is often small, and the binder becomes finer. Since it progresses too much, it tends to cause a deterioration of the so-called binder function. Therefore, even if an attempt is made to obtain a drainage degree smaller than 10 cm ³ in this way, no significant advantage is recognized.

(Aramid short fiber)
Aramid short fibers are obtained by cutting fibers made of aramid, and examples of such fibers include Teijin Limited's "Teijin Cornex (registered trademark)" and DuPont's "Nomex (registered trademark)". , But not limited to these, although they can be obtained under product names such as.

The length of the aramid short fibers is generally selectable from 1 mm or more and less than 50 mm, preferably in the range of 2 to 10 mm. If the length of the short fibers is smaller than 1 mm, the mechanical properties of the sheet material deteriorate, while if the length of the short fibers is 50 mm or more, "entanglement" and "binding" are likely to occur in the production of aramid paper by the wet method. Prone to cause defects.

(Aramid paper)
In the present embodiment, the aramid paper is a sheet-like material mainly composed of the above-mentioned aramid fibrid and aramid short fibers, and generally has a thickness in the range of 20 μm to 1000 μm, preferably 25 to 200 μm. There is. Furthermore, aramid paper is generally ^{10g / m 2 ~1000g / m 2} , preferably has a basis weight in the range of 15~200g / m ^2. Here, the mixing ratio of the aramid fibrid and the aramid short fiber can be arbitrary, but the ratio (mass ratio) of the aramid fibrid / aramid short fiber is preferably 1/9 to 9/1. It is preferably 2/8 to 8/2, particularly 3/7 to 7/3, but is not limited to this range.

The aramid paper is generally produced by the method of mixing the above-mentioned aramid fibrid and aramid short fibers and then forming a sheet. Specifically, for example, a method in which the above-mentioned aramid fibrid and aramid short fibers are dry-blended and then a sheet is formed using an air flow. After the aramid fibrid and aramid short fibers are dispersed and mixed in a liquid medium, the liquid permeates. A method of discharging onto a sex support, for example, a net or a belt to form a sheet, removing the liquid and drying, etc. can be applied, but among these, a so-called wet fabrication method using water as a medium is preferably selected. ..

In the wet papermaking method, an aqueous slurry of a single substance or a mixture containing at least aramid fibrid and aramid short fibers is sent to a paper machine to disperse the slurry, and then dehydrated, squeezed and dried to be wound up as a sheet. The method is common. As the paper machine, a long net paper machine, a circular net paper machine, an inclined paper machine and a combination paper machine combining these machines are used. In the case of production with a combination paper machine, a composite sheet composed of a plurality of paper layers can be obtained by forming a sheet of slurries having different mixing ratios and combining them. Additives such as dispersibility improvers, defoamers, and paper strength enhancers are used as needed during papermaking.

The density and mechanical strength of the aramid paper obtained as described above can be improved by heat-pressing the aramid paper between the pair of rolls at a high temperature and high pressure. For example, in the case of using a metal roll, the thermal pressure conditions can be exemplified in the range of a temperature of 100 to 400 ° C. and a linear pressure of 50 to 400 kg / cm, but are not limited thereto. It is also possible to stack multiple aramid papers during thermal pressure. The above thermal pressure processing can be performed a plurality of times in any order.

(Resin molded body)
The resin molded body 2 includes a pair of main body portions 2a formed along both end faces in the axial direction of the core main body 4, and six connecting portions 2b for connecting the outer peripheral edges of the pair of main body portions 2a. The main body 2a has a thickness corresponding to the distance between the axial end surface of the core main body 4 and the end of the insulating sheet 6, and has the same cross-sectional shape as the core main body 4 (core material 8). That is, the main body 2a includes an annular annular portion 2a1, a plurality of arm portions 2a2 extending inward in the circumferential direction from the annular portion 2a1, and protruding portions extending from the tip end portion of the arm portion 2a2 to both sides in the circumferential direction. 2a3 and. Between each arm portion 2a2, a substantially trapezoidal groove portion 2a4 surrounded by an adjacent arm portion 2a2, an annular portion 2a1, and a protruding portion 2a3 is formed. The radial outer peripheral surface of the central portion 6a of the insulating sheet 6 abuts on the bottom of the groove 2a4, and the left-turned portion 6b and the right-bent portion 6c of the insulating sheet 6 abut on the side surface of the arm portion 2a2, and the protruding portion 2a3 The tip bent portions 6d and 6e of the insulating sheet 6 are in contact with the outer peripheral surface in the radial direction. The main body 2a of the resin molded body 2 is used to insulate between the winding and the upper surface of the arm 4b of the core main body 4 when the winding of the motor is wound around the arm 4b of the core main body 4. It is provided. In the present embodiment, the main body 2a is formed so as to cover the entire axial end surface of the core main body 4, but at least it is in contact with the axial end of the insulating sheet 6 and the winding of the motor. It suffices to cover the arm portion 4b of the core main body 4 on which the is arranged. The resin constituting the resin molded body 2 is impregnated on the surface of the insulating sheet 6 that comes into contact with the resin molded body 2, whereby the resin molded body 2 and the insulating sheet 6 are connected to each other. In the present embodiment, the outer peripheral surfaces of the portions of both ends of the insulating sheet 6 protruding from the core main body 4 are in contact with the resin molded body 2.

The connecting portion 2b is formed in the outer peripheral groove portion 4e of the core main body 4, and connects the pair of main body portions 2a through the outer peripheral groove portion 4e. The connecting portions 2b are provided at equal angular intervals on the outer peripheral surface of the core main body 4.

In the present embodiment, examples of the material constituting the resin molded body 2 include PPS resin (polyphenylene sulfide resin), acrylic nitrile / butadiene / styrene copolymer resin, polyimide resin, polyethylene terephthalate resin, polyacetal resin, and amide. Polyamide 6, polyamide 66, polyamide 612, polyamide 11, polyamide 12, copolymerized polyamide, polyamide MXD6, polyamide 46, methoxymethylated polyamide, semi-aromatic polyamide and other polymers containing a bond, or JP-A-2006-321951 A polymer containing a polyamide resin composition as shown in the above, a mixture thereof, or a mixture of the above polymer and an inorganic substance such as glass fiber can be used. The resin molded body 2 is manufactured by a melt injection molding method in which the above material is injected (injected) into a desired mold in a molten state, cooled, and then removed from the mold. In particular, a molded product of a mixture of semi-aromatic polyamide and glass fiber is preferable because it has high heat resistance and good adhesion to a laminated sheet containing aramid paper. Examples of such a mixture include, but are not limited to, DuPont's Zytel® HTN51G, 52G and the like.

By forming a groove for positioning the winding in the portion of the resin molded body 2 in contact with the winding, the position of the winding is stabilized, highly accurate aligned winding is possible, and the efficiency of the motor generator and the like is improved. It is preferable because it produces an effect.

(Manufacturing method of annular laminated core material)
The annular laminated core material 1 of the present embodiment can be manufactured as follows.
That is, first, the strip-shaped thin plate material is subjected to a desired die-cutting process, and then punched with an outer diameter punch to separate the core material. Then, the punched core material 8 is laminated in the cylindrical cavity of the injection molding die to form the core body 4. It should be noted that the core material 8 is not formed with a raised portion or a protrusion for fixing the caulking, and the core material 8 is not bonded with an adhesive or a laser beam. The core material 8 has no evidence of temporary fixing means. Next, the insulating sheet 6 is arranged in the groove 4d of the core body 4. At this time, the insulating sheet 6 is arranged so that both ends of the insulating sheet 6 protrude from both ends of the core main body 4 by a length corresponding to the thickness of the main body 2a of the resin molded body 2 (arrangement step). At this time, the distance between both axial end surfaces of the core body 4 and the inner surface of the cavity is the same as the protruding length of the insulating sheet 6, and the inner peripheral surface and the outer peripheral surface of the core body 4 are the inner surface of the cavity. Arrange so as to abut. As a result, a space corresponding to the main body portion 2a of the resin molded body 2 is formed between both end surfaces of the core main body 4 and the inner surface of the cavity, and between the outer peripheral groove portion 4e of the core main body 4 and the inner peripheral surface of the cavity. A space corresponding to the connecting portion 2b extending in the axial direction is formed. In the present embodiment, the core material 8 is laminated in the cavity to form the core body 4, and then the insulating sheet 6 is attached. However, the present invention is not limited to this, and the core body 4 with the insulating sheet 6 attached is not limited to this. May be placed in the cavity.

Next, by injecting the resin constituting the resin molded body 2 into the cavity, the resin is filled between the core main body 4 and the inner surface of the cavity. Then, when this resin is cured, the resin molded body 2 in which the main body portion 2a and the connecting portion 2b are integrated can be molded (resin molding step). By the above steps, the core material 8 constituting the laminated core main body 4 is fixed by the resin molded body 2 and the insulating sheet 6, and the annular laminated core material 1 can be manufactured as an integral body.

In the manufacturing method of the present embodiment, a plurality of core materials 8 are laminated in a cavity for injection molding without any evidence of temporary fixing means between the core materials 8, and at least a part of the insulating sheet 6 is preliminarily resin-molded. By arranging the resin molded body 2 so as to be in contact with the portion corresponding to 2, at least the surface portion of the insulating sheet 6 can be impregnated with the molten polymer forming the resin molded body 2. By producing the annular laminated core material 1 in which the portion of the resin molded body 2 and the insulating sheet 6 are connected and fixed in this manner, it is not necessary to use an adhesive and the resin molded body can be connected and fixed at the same time. .. Here, impregnation means that the molten polymer invades the surface of the insulating sheet. In particular, when the insulating sheet contains a polymer having an amide bond and / or aramid paper, the molten polymer invades the surface of the polymer having an amide bond and / or the aramid fibrid and / or the aramid short fibers constituting the aramid paper. That is. By impregnation, the polymer and the insulating sheet 6 are entangled at the molecular level, and the adhesion between the resin molded body 2 and the insulating sheet 6 becomes stronger. Further, the expansion of the resin and the core material 8 due to the temperature change during molding improves the adhesion between the insulating sheet 6 and the core material 8, so that the heat generated by the winding is efficiently transmitted to the core material 8 and the temperature rises excessively. It is prevented, the copper loss of the winding is reduced, and the output as a motor is improved.

In particular, when the resin molded body 2 is formed by using a polymer having an amide bond and the surface of the insulating sheet 6 in contact with the resin molded body 2 is made of a polymer having an amide bond, or when the resin molded body 2 is formed. Is formed by using a polymer having an amide bond, and when the surface of the insulating sheet 6 in contact with the resin molded body 2 is made of aramid paper composed of aramid fibrid and aramid short fibers, the resin molded body 2 is used. The constituent polymer having an amide bond and the insulating sheet 6 are entangled at the molecular level, and the adhesion between the resin molded body 2 and the insulating sheet 6 becomes stronger.

(Action effect)
According to this embodiment, the following effects are achieved.
According to the present embodiment, the pair of main body portions 2a of the resin molded body 2 are integrated by the connecting portion 2b, and further, the insulating sheet 6 and the resin molded body 2 are connected by abutting against each other. The material 8 can be integrated without being temporarily fixed by caulking or adhering. As a result, it is not necessary to provide a caulking joint portion for caulking in the core material 8, iron loss can be suppressed, and additional steps such as application of an adhesive and a laser beam are not required.

Further, according to the present embodiment, the resin melted when molding the resin molded body 2 is filled in the space corresponding to the pair of main body portions 2a and the connecting portion 2b through the outer peripheral groove portion 4e, the inner peripheral groove portion or the through hole. Therefore, the main body portion 2a and the connecting portion 2b can be integrated.

Further, according to the present embodiment, the annular core material 8 has flat surfaces on both sides in the axial direction, and each core material 8 is in direct contact with the adjacent core material 8 and the flat surfaces, so that iron loss is further increased. It can be suppressed.

Further, in the present embodiment, since the insulating sheet 6 and the resin molded body 2 are connected without using an adhesive, the annular laminated core material 1 is manufactured without performing an additional step such as adhesion. Can be done.

Further, in the present embodiment, since the axial length of the contact portion between the insulating sheet 6 and the resin molded body 2 is 0.5 mm or more, a linear segment conductor is arranged in the groove portion of the annular laminated core material 1. , There is no deviation between each core material when bent, and it can withstand the load applied at the time of bending.

Further, in the present embodiment, the surface of the insulating sheet 6 in contact with the resin molded body 2 is impregnated with the resin constituting the resin molded body 2, so that the insulating sheet 6 and the resin molded body 2 are connected to each other. The insulating sheet 6 and the resin molded body 2 can be more firmly connected.

Further, in the present embodiment, the resin molded body 2 is formed by using a polymer having an amide bond, and the surface of the insulating sheet 6 in contact with the resin molded body 2 is formed of the polymer having an amide bond. , The polymer and the insulating sheet 6 are entangled at the molecular level, and the insulating sheet 6 and the resin molded body 2 can be more firmly connected.

Further, in the present embodiment, the resin molded body 2 is formed by using a polymer having an amide bond, and the surface of the insulating sheet 6 in contact with the resin molded body 2 is aramid composed of aramid fibrid and aramid short fibers. By being composed of paper, the polymer and the insulating sheet 6 are entangled at the molecular level, and the insulating sheet 6 and the resin molded body 2 can be more firmly connected.

Hereinafter, the present invention will be described with reference to examples. It should be noted that these examples are for explaining the contents of the present invention by way of examples, and do not limit the contents of the present invention at all.

(Ingredient preparation)
A fibrid of polymethaphenylene isophthalamide was produced using a pulp particle production apparatus (wet precipitator) composed of a combination of a stator and a rotor described in JP-A-52-15621. This was processed with a breaker and a beater to adjust the length-weighted average fiber length to 0.9 mm. The degree of drainage of the obtained aramid fibrid was 90 cm ³ .

On the other hand, a meta-aramid fiber manufactured by DuPont (Nomex (registered trademark), single yarn fineness of 2 denier) was cut into a length of 6 mm (hereinafter referred to as "aramid short fiber").

(Manufacturing of aramid paper)
The prepared aramid fibrid and aramid short fibers were each dispersed in water to prepare a slurry. These slurries were mixed so that the blending ratio (weight ratio) of fibrid and aramid short fibers was 1/1, and a sheet-like product was prepared by a tappy type hand-making machine (cross-sectional area 625 cm ² ). .. Next, this was hot-pressed with a metal calendar roll at a temperature of 330 ° C. and a linear pressure of 300 kg / cm to obtain the aramid papers shown in Examples 1 and 2 in Table 1.

(Manufacturing of laminated sheets)
Aramid paper (basis weight 37 g / m ² , thickness 51 μm, density 0.73 g / cm 3) and epoxy group-containing phenoxy produced in the same manner as described above by the method described in paragraph [0024] of JP-A-2006-321183. Aramid paper / resin composition / aramid paper (Aramid paper / resin composition / aramid paper) in which the aramid paper is arranged on the outside using a semi-aromatic polyamide resin composition containing 50% by weight of the resin (Formulation Example 6 of JP-A-2006-321183). The laminated sheets shown in Examples 3 and 4 of Table 1 containing the aramid paper having a three-layer structure of 37/54/37) by weight were obtained.

In addition, aramid paper (basis weight 37 g / m ² , thickness 51 μm, density 0.73 g / cm ³ ) and Toray polyethylene terephthalate film (S28 # 16, thickness 16 μm) are bonded together with an adhesive, and the aramid paper is placed on the outside. The laminated sheets shown in Examples 5 and 6 of Table 1 containing the arranged aramid paper having a three-layer structure of aramid paper / polyethylene terephthalate film / aramid paper (37/54/37 by weight) were obtained.

(Manufacturing of core material)
As shown in FIG. 2, a non-oriented electrical steel sheet (thickness 0.5 mm, thickness tolerance 0.04 mm) specified in JIS C 2552 was punched in an annular shape to produce a core material 8. The core material 8 has no evidence of temporary fixing means for caulking, bonding, or the like.

(Manufacturing of annular laminated core material)
Using the aramid paper or laminated sheet produced as described above as the insulating sheet, and further using the core material 8 produced as described above and the semi-aromatic polyamide (Zytel (registered trademark) HTN51G35EF) manufactured by DuPont as the polymer. Insertion molding was carried out under the conditions shown in Table 1 to obtain the annular laminated core material 1 shown in FIG. That is, (1) the core material 8 is laminated and inserted in advance into the cavity for injection molding, (2) the insulating sheet 6 is inserted into the groove of the laminated core material 8, and (3) a semi-fragrance manufactured by DuPont. Group polyamide is introduced and injection-molded by a melt injection molding method to integrally mold the resin molded body 2, the insulating sheet 6, and the laminated core material 8. At this time, at least the surface portion of the insulating sheet 6 is impregnated with the molten polymer, and the insulating sheet 6 is directly adhered to the surface of the resin molded body 2. Therefore, the annular lamination without evidence of the temporary fixing means shown in FIG. The core material 1 can be obtained. The measurement method for each condition is as follows.

(Measuring method)

(1) Measurement of basis weight and thickness The measurement was carried out according to JIS C2300-2.

(2) Calculation of density Calculated by basis weight ÷ thickness.

(3) Tensile strength and tensile elongation The test was carried out according to JIS C2300-2.

(4) Adhesiveness The adhesive portion between the insulating paper and the resin molded body was visually observed, and those having no wrinkles (swelling of the insulating paper) were judged to be "good" and those having wrinkles were judged to be "bad".

(5) Appearance of Insulating Sheet 6 The degree of warpage due to heat during molding of the insulating sheet was visually determined.

(6) Adhesion between the insulating sheet 6 and the core material 8 Regarding the degree of adhesion between the insulating sheet and the core material 8, the epoxy resin is impregnated with a bobbin for a motor containing the core material 8 and cured, and then the garnet fine particle-containing water is used. A jet (model 626 manufactured by Omax Co., Ltd.) was used to cut the annular laminated core material 1 perpendicularly in the axial direction at an axial intermediate point, and the average value of the distances between the insulating sheet 6 and the core material 8 was measured on the cut surface.

(7) Bending resistance When a linear segment conductor is placed in the groove of the annular laminated core material 1 and bent, the deviation between the core materials is visually observed, and the one without the deviation is "good". Those with a deviation were judged to be "defective".

From the results in Table 1, the annular laminated core material of the example can withstand the load applied when the segment conductor is bent when the segment conductor is used for the winding because the outer peripheral surface is supported by the resin molded body. Is. In addition, there is no evidence of temporary fixing means, iron loss does not occur due to the generation of eddy current due to the residue of the caulking joint, and the groove of the core material is covered with a thin insulating sheet, so the winding High efficiency can be expected by increasing the line product. In addition, since the adhesion between the insulating paper and the resin is sufficient, the insulation breakdown voltage is sufficiently high, and since the heat resistance of the used aramid paper and the polymer is high, it is considered that it can sufficiently withstand the heat generation of the winding. It can be seen that it is useful as a bobbin for motors that can withstand high efficiency and high output of motor generators and the like. In particular, in Examples 3 and 4, since the resin composition of the middle layer of the laminated sheet has a structure similar to that of the resin molded body, it is considered that the resin composition was softened at the time of molding and the adhesion between the insulating sheet and the core material was the best.
Further, as compared with Japanese Patent Application Laid-Open No. 55-13665, the entire unnecessary removed thin plate portion is formed into a half punched shape to form a caulking joint portion for temporary fixing, and the removed thin plate portion is later removed by press punching. High-quality laminated core material products can be manufactured with good workability because they are easily removed without requiring a large punching force and no post-processing is required without the occurrence of residual meat or burrs.
Furthermore, since the resin molded body and the insulating sheet are also mounted at the same time as molding, the steps of caulking and bonding and mounting the resin molded body can be omitted.

1 Circular laminated core material 2 Resin molded body 2a Main body 2a1 Ring 2a2 Arm 2a3 Protruding 2a4 Groove 2b Connecting part 4 Core main body 4a Cylindrical 4b Arm 4c Protruding 4d Groove 4e Outer groove 6 Insulation sheet 6a Central part 6b Left turn 6c Right turn 6d Tip bend 6e Tip bend 8 Core material 8a Ring 8b Arm 8c Protrusion 8d Groove 8e Outer groove

Claims (13)

It is an annular laminated core material
A core body in which a plurality of annular core materials are laminated to form a cylindrical shape, and a groove extending in the axial direction is formed on the inner peripheral surface in the radial direction or the outer peripheral surface in the radial direction.
A pair of main body portions formed so as to cover at least a part of both axial end surfaces of the core main body, and a resin molded body in which a connecting portion connecting the pair of main body portions is integrally molded.
An insulating sheet arranged on the inner surface of the groove portion is provided.
An annular laminated core material characterized in that both ends in the axial direction of the insulating sheet are in contact with the main body of the resin molded body. The core body is formed with through holes extending between both end faces in the axial direction.
The connecting portion connects the pair of main body portions through a through hole of the core main body.
The annular laminated core material according to claim 1. A peripheral groove portion extending between both end faces in the axial direction is formed on the inner peripheral surface or the outer peripheral surface of the core body.
The connecting portion connects the pair of main body portions through the peripheral groove portion of the core main body.
The annular laminated core material according to claim 1. The annular core material has flat surfaces on both sides in the axial direction, and each core material is in direct contact with the adjacent core material and the flat surfaces.
The annular laminated core material according to any one of claims 1 to 3. The annular laminated core material according to any one of claims 1 to 4, wherein the insulating sheet and the resin molded body are connected without using an adhesive. The annular laminated core material according to any one of claims 1 to 5, wherein the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5 mm or more. Any of claims 1 to 6, wherein the insulating sheet and the resin molded body are connected by impregnating the surface of the insulating sheet in contact with the resin molded body with the resin constituting the resin molded body. The annular laminated core material according to item 1. The resin molded body is formed by using a polymer having an amide bond.
The annular laminated core material according to any one of claims 1 to 7, wherein the surface of the insulating sheet in contact with the resin molded body is made of a polymer having an amide bond. The resin molded body is formed by using a polymer having an amide bond.
The annular laminated core material according to any one of claims 1 to 7, wherein the surface of the insulating sheet in contact with the resin molded body is made of aramid paper composed of aramid fibrid and aramid short fibers. .. A motor using a stator in which a winding is wound around the annular laminated core material according to any one of claims 1 to 9. A motor generator that uses a stator in which a winding is wound around the annular laminated core material according to any one of claims 1 to 9. A generator using a stator in which a winding is wound around the annular laminated core material according to any one of claims 1 to 9. It is a method for manufacturing an annular laminated core material.
A core body in which a plurality of annular core blocks are laminated to form a cylindrical shape and a groove portion extending in the axial direction is formed on the inner peripheral surface in the radial direction or the outer peripheral surface in the radial direction is insulated by the groove portion. The placement step of arranging the sheets in the molding mold so that the sheets are arranged, and
A resin molding step of injecting resin into a molding mold and integrally molding a resin molded body including a pair of main body portions formed so as to cover at least a part of both axial end surfaces of the core main body is included. A method for producing an annular laminated core material, which comprises.

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