JP2023099969A - Stator unit, manufacturing method of stator unit and manufacturing apparatus of stator unit - Google Patents

Abstract

To reduce compression stress when bonding a stator and a housing.SOLUTION: A stator unit comprises a cylindrical housing and a stator inserted to an inside of the housing. The housing and the stator are bonded by a thermoplastic adhesive including a thermoplastic resin and ceramic particles. The thermoplastic resin preferably includes a polyamide imide. The ceramic particles preferably include at least one of a silicon dioxide or an aluminum oxide.SELECTED DRAWING: Figure 3

Description

The present invention relates to a stator unit, a stator unit manufacturing method, and a stator unit manufacturing apparatus.

In the structure of a motor, there is a case where a housing having a function such as promoting heat dissipation is joined to the outer peripheral surface of a stator that holds windings. As a method for joining the stator and the housing, shrink fitting, metal-to-metal joining by aluminum plating (aluminum plating method), and the like are used. For example, as a structure for suppressing deformation of the stator during joining by shrink fitting or press fitting, a structure is disclosed in which a weld provided on the stator and a flange provided on the housing are arranged at positions corresponding to each other. (Patent document 1).

JP 2014-82935 A

When the stator and housing are joined by shrink fitting, aluminum plating, or the like, compressive stress is generated in the stator due to the stress load due to the interference fit and the difference in coefficient of thermal expansion between the stator and the housing. Such compressive stress should be reduced as much as possible, since it may become a cause of deterioration of the performance of the motor.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a stator unit, a stator unit manufacturing method, and a stator unit manufacturing apparatus capable of reducing compressive stress when the stator and housing are joined together.

A stator unit as one aspect of the present invention includes a cylindrical housing and a stator inserted inside the housing, and the housing and the stator are bonded by a thermoplastic adhesive containing a thermoplastic resin and ceramic particles. It is characterized by having

Further, a method for manufacturing a stator unit as one aspect of the present invention is a method for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing, wherein the stator is inserted inside the housing. a filling step of filling the space between the housing and the stator with a thermoplastic adhesive containing a thermoplastic resin and ceramic particles; and a curing step of heating and hardening the thermoplastic adhesive filled in the space. and

Further, a method for manufacturing a stator unit as one aspect of the present invention is a method for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing, wherein thermoplastic resin is applied to the outer peripheral surface of the stator. An applying step of applying a thermoplastic adhesive containing resin and ceramic particles, an inserting step of inserting the stator coated with the thermoplastic adhesive into the interior of the housing, and a heat filled space between the housing and the stator. and a curing step of heating and curing the plastic adhesive.

Further, a stator unit manufacturing apparatus as one aspect of the present invention is an apparatus for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing, wherein the stator is inserted inside the housing. a filling mechanism that fills the space between the housing and the stator with a thermoplastic adhesive containing thermoplastic resin and ceramic particles; and a curing mechanism that heats and hardens the thermoplastic adhesive that fills the space. and

Further, a stator unit manufacturing apparatus according to one aspect of the present invention is an apparatus for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing, wherein the outer peripheral surface of the stator is made of thermoplastic resin. An application mechanism for applying a thermoplastic adhesive containing resin and ceramic particles, an insertion mechanism for inserting the stator coated with the thermoplastic adhesive into the interior of the housing, and heat filled in the space between the housing and the stator. and a curing mechanism for heating and curing the plastic adhesive.

FIG. 1 is an exploded perspective view showing an example of the configuration of the motor according to the first embodiment. FIG. 2 is a perspective view showing an example of the configuration of the stator unit according to the first embodiment. 3 is a perspective view showing an example of the configuration of the stator according to the first embodiment. FIG. FIG. 4 is a perspective view showing an example of the configuration of the housing according to the first embodiment; FIG. 5 is a cross-sectional view taken along line VV in FIG. 2, showing an example of the configuration of the stator unit according to the first embodiment. FIG. 6 is a partially enlarged cross-sectional view showing an example of the configuration of the joint portion between the stator and the housing according to the first embodiment. FIG. 7 is a flowchart showing an example of steps in the stator unit manufacturing method according to the first embodiment. FIG. 8 is a cross-sectional view showing the configuration of a mechanism according to a first example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 9 is a partially enlarged cross-sectional view showing the configuration of a mechanism according to a first example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 10 is a cross-sectional view showing the configuration of a mechanism according to a second example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 11 is a partially enlarged cross-sectional view showing the configuration of a mechanism according to a second example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 12 is a cross-sectional view showing the configuration of a mechanism according to a third example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 13 is a top view showing the configuration of a seal jig in a mechanism according to a third example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 14 is a partially enlarged cross-sectional view showing the configuration of a mechanism according to a third example for executing the filling step of the stator unit manufacturing method according to the first embodiment. FIG. 15 is a block diagram showing an example of the configuration of the stator unit manufacturing apparatus according to the first embodiment. FIG. 16 is a flow chart showing an example of steps in a stator unit manufacturing method according to the second embodiment. FIG. 17 is a cross-sectional view showing an example of the configuration of a mechanism that performs the application step and the insertion step of the stator unit manufacturing method according to the second embodiment. FIG. 18 is a partially enlarged cross-sectional view showing an example of the configuration of a mechanism for executing the application process and the insertion process of the stator unit manufacturing method according to the second embodiment. FIG. 19 is a block diagram showing an example of the configuration of a stator unit manufacturing apparatus according to the second embodiment.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. The configurations of the embodiments described below and the actions and effects brought about by the configurations are examples, and the present invention is not limited to the following descriptions.

(First embodiment)
FIG. 1 is an exploded perspective view showing an example of the configuration of the motor 1 according to the first embodiment. A motor 1 according to this embodiment has a stator unit 11 , windings 12 , a rotor 13 , bearings 14 and 15 and a shaft 16 .

The stator unit 11 is a member that holds the windings 12 . The stator unit 11 has a cylindrical shape, and the windings 12 are fixed to the inner circumference of the stator unit 11 . The winding 12 is connected to a power supply via wiring, and generates a magnetic field according to power (current) supplied from the power supply. The rotor 13 is a cylindrical member made of a conductor and contains permanent magnets. The rotor 13 is inserted inside the stator unit 11 along the insertion direction D, is rotatably supported by bearings 14 and 15 , and rotates according to the magnetic field generated by the windings 12 . The shaft 16 is a cylindrical member extending along the insertion direction D, rotates together with the rotor 13, and transmits rotational force to a predetermined mechanism. The configuration shown in FIG. 1 is an example, and the configuration of the motor 1 is not limited to this.

FIG. 2 is a perspective view showing an example of the configuration of the stator unit 11 according to the first embodiment. FIG. 3 is a perspective view showing an example of the configuration of the stator 21 according to the first embodiment. FIG. 4 is a perspective view showing an example of the configuration of the housing 22 according to the first embodiment. FIG. 5 is a cross-sectional view taken along line VV in FIG. 2, showing an example of the configuration of the stator unit 11 according to the first embodiment.

The stator unit 11 includes a stator 21 and a housing 22 , and is constructed by joining the housing 22 to the outer peripheral surface of the stator 21 .

The stator 21 is a cylindrical member made of a highly conductive material such as electromagnetic steel. Windings 12 (see FIG. 1) are arranged on the upper and lower end surfaces of the stator 21 , and when current flows through the windings 12 , a magnetic field is generated from the stator 21 to rotate the rotor 13 . The inner peripheral surface of the stator 21 exemplified here is formed into folds to hold the windings 12 . The stator 21 may be configured by stacking a plurality of plate-like members.

The housing 22 is a cylindrical member made of a material having high thermal conductivity such as aluminum. The inner diameter of housing 22 is slightly larger than the outer diameter of stator 21 so that a predetermined space is formed between stator 21 and housing 22 . The housing 22 has effects such as protection of the stator 21 and the windings 12 and cooling of the stator 21 (promotion of heat dissipation).

FIG. 6 is a partially enlarged cross-sectional view showing an example of the configuration of the joint portion between the stator 21 and the housing 22 according to the first embodiment. FIG. 6 conceptually shows the configuration of the part indicated by the one-dot chain line in FIG.

The stator 21 and the housing 22 according to this embodiment are joined together by a thermoplastic adhesive 31 filling a space 25 between the stator 21 and the housing 22 . The width of space 25 (the distance between stator 21 and housing 22) is preferably in the range of 0.01 mm to 0.5 mm.

Thermoplastic adhesive 31 includes thermoplastic resin 35 and ceramic particles 36 . The thermoplastic resin 35 may be, for example, polyamideimide or the like. Ceramic particles 36 can be, for example, silicon dioxide, aluminum oxide, and the like. The thermoplastic adhesive 31 may further contain a solvent such as N-ethyl-pyrrolidone, but the solvent is eventually removed.

As described above, according to this embodiment, the stator 21 and the housing 22 are joined together by the thermoplastic adhesive 31 containing the thermoplastic resin 35 and the ceramic particles 36 . Since the thermoplastic adhesive 31 contains the ceramic particles 36 with a relatively small linear expansion and a relatively large Young's modulus, the residual stress during solidification shrinkage of the thermoplastic resin 35 can be relaxed. can reduce the compressive stress applied to In addition, heat dissipation (the ability to cool the stator 21) can be improved by the action of the ceramic particles 36 having relatively high thermal conductivity.

Moreover, by using polyamide-imide as the thermoplastic resin 35, the stator unit 11 having excellent heat resistance, chemical resistance, etc. can be manufactured. Also, the maximum particle size of the ceramic particles 36 is preferably 1 μm or less. As a result, agglomeration of the ceramic particles 36 can be avoided, and the effect of reducing the compressive stress and the effect of improving the heat dissipation by the ceramic particles 36 can be realized at a high level. Also, the content of the ceramic particles 36 is preferably in the range of 40 wt % to 60 wt %. As a result, it is possible to achieve high levels of bonding strength, reduction of compressive stress, and improvement of heat dissipation.

A method of manufacturing the stator unit 11 as described above will be described below. FIG. 7 is a flow chart showing an example of steps in the method of manufacturing the stator unit 11 according to the first embodiment.

First, an insertion step (S11) is performed to insert the stator 21 into the interior of the housing 22 (the space inside the inner peripheral surface). Thereafter, a filling step (S12) of filling the space 25 between the stator 21 and the housing 22 with the thermoplastic adhesive 31 is performed. After that, a curing step (S13) is performed in which the thermoplastic adhesive 31 filled in the space 25 is heated and cured.

In addition, before the insertion step, an expansion step may be performed to expand the inner diameter of the housing 22 by heating the housing 22 for thermal expansion. This simplifies the insertion process. The heating temperature, heating time, etc. in the curing step should be appropriately determined according to the type, amount, etc. of the thermoplastic resin 35 to be used. C. to 200.degree. C., and the heating time is preferably 2 hours or longer.

FIG. 8 is a cross-sectional view showing the configuration of a mechanism 50 according to a first example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. FIG. 9 is a partially enlarged cross-sectional view showing the configuration of a mechanism 50 according to a first example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. In FIG. 9, the configuration of the portion indicated by the dashed-dotted line in FIG. 8 is enlarged.

The mechanism 50 according to this example includes a base jig 51 and a supply table 52 . The base jig 51 is a member that is fixed to the lower end of the stator 21 and used to adjust the positional relationship between the stator 21 and the housing 22 . The supply table 52 has a recess 53 shaped to receive the base jig 51 . A thermoplastic adhesive 31 is stored in the recess 53 . When the filling process is executed, the base jig 51 to which the stator 21 is fixed is advanced into the recess 53 , thereby pressurizing the thermoplastic adhesive 31 accumulated in the recess 53 and separating the stator 21 and the housing 22 . is filled in the space 25 between

FIG. 10 is a cross-sectional view showing the configuration of a mechanism 60 according to a second example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. FIG. 11 is a partially enlarged cross-sectional view showing the configuration of a mechanism 60 according to a second example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. In FIG. 11, the portion indicated by the dashed-dotted line in FIG. 10 is enlarged.

A mechanism 60 according to this example includes a seal jig 61 , a hopper 62 and a pusher 63 . The seal jig 61 is a member that seals the upper end of the stator 21 . A lower end of the stator 21 is sealed by a base jig 51 . The hopper 62 is a funnel-shaped member installed above the sealing jig 61, and the thermoplastic adhesive 31 is stored therein. The pusher 63 is a member that is vertically displaced inside the hopper 62 by a predetermined drive mechanism, and presses the thermoplastic adhesive 31 downward. During the filling process, the pusher 63 is gradually moved downward to pressurize the thermoplastic adhesive 31 stored in the hopper 62 and fill the space 25 between the stator 21 and the housing 22. be filled.

FIG. 12 is a cross-sectional view showing the configuration of a mechanism 70 according to a third example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. FIG. 13 is a top view showing the configuration of the seal jig 61 in the mechanism 70 according to the third example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. FIG. 14 is a partially enlarged cross-sectional view showing the configuration of a mechanism 70 according to a third example for executing the filling step of the method for manufacturing the stator unit 11 according to the first embodiment. In FIG. 14, the portion indicated by the dashed-dotted line in FIG. 12 is enlarged.

The mechanism 70 according to this example includes a tank 71 , a pump 72 , a supply tube 73 , a supply nozzle 74 and a supply port 78 . Tank 71 stores thermoplastic adhesive 31 . Pump 72 pumps thermoplastic adhesive 31 stored in tank 71 to supply tube 73 . The supply tube 73 communicates between the pump 72 and the supply nozzle 74, and is branched into four on the supply nozzle 74 side in this example. The supply nozzle 74 is connected to the end of the supply tube 73 and discharges the thermoplastic adhesive 31 pressure-fed by the pump 72 . In this example, each of the four supply nozzles 74 is connected to each of the four branched ends of the supply tube 73 . As shown in FIG. 13, four supply ports 78 are formed in the sealing jig 61 according to this example. Each supply port 78 communicates with the space 25 and is configured to be connectable with the supply nozzle 74, as shown in FIGS. During the filling process, each supply nozzle 74 is connected to each supply port 78, and the thermoplastic adhesive 31 is pumped by the pump 72 so that the thermoplastic adhesive 31 fills the space between the stator 21 and the housing 22. 25 is filled.

The mechanisms 50, 60, and 70 are examples, and the method of filling the space 25 with the thermoplastic adhesive 31 is not limited to the above.

An apparatus for manufacturing the stator unit 11 as described above will be described below. FIG. 15 is a block diagram showing an example of the configuration of the stator unit 11 manufacturing apparatus 101 according to the first embodiment.

The manufacturing apparatus 101 according to this embodiment includes an insertion mechanism 111 that performs the insertion process, a filling mechanism 112 that performs the filling process, and a curing mechanism 113 that performs the curing process.

The insertion mechanism 111 includes, for example, a mechanism for fixing the base jig 51 to the stator 21, a mechanism for adjusting the positional relationship between the stator 21 and the housing 22 using the base jig 51, and a mechanism for connecting the stator 21 and the housing 22 relative to each other. It can be configured using a mechanism or the like that displaces the stator 21 to insert it into the housing 22 . Filling mechanism 112 may be configured utilizing, for example, mechanisms 50, 60, 70, etc., described above. The curing mechanism 113 can be configured using, for example, a temperature-controlled room that houses the stator unit 11 after completion of the filling process, a heating device that heats the inside of the temperature-controlled room, or the like.

The manufacturing method or manufacturing apparatus 101 as described above can manufacture the stator unit 11 in which the stator 21 and the housing 22 are bonded with the thermoplastic adhesive 31 containing the thermoplastic resin 35 and the ceramic particles 36 .

Other embodiments will be described below. Descriptions of portions that are the same as or similar to those of the first embodiment may be omitted.

(Second embodiment)
FIG. 16 is a flow chart showing an example of steps in the method of manufacturing the stator unit 11 according to the second embodiment.

In this embodiment, first, an application step (S21) of applying the thermoplastic adhesive 31 to the outer peripheral surface of the stator 21 is performed. Thereafter, an inserting step (S22) is performed for inserting the stator 21 coated with the thermoplastic adhesive 31 into the housing 22. As shown in FIG. After that, a curing step (S23) of heating and curing the thermoplastic adhesive 31 filled in the space 25 between the housing 22 and the stator 21 is performed. In addition, before the insertion step, an expansion step may be performed to expand the inner diameter of the housing 22 by heating the housing 22 for thermal expansion. This simplifies the insertion process.

FIG. 17 is a cross-sectional view showing an example of the configuration of a mechanism 80 that executes the application process and the insertion process of the manufacturing method of the stator unit 11 according to the second embodiment. FIG. 18 is a partially enlarged cross-sectional view showing an example of the configuration of a mechanism 80 that executes the application process and the insertion process of the manufacturing method of the stator unit 11 according to the second embodiment. In FIG. 18, the configuration of the portion indicated by the dashed line in FIG. 17 is enlarged.

The mechanism 80 according to this example includes a hopper 81 and rollers 82 . The hopper 81 is a funnel-shaped member installed at the upper end of the housing 22 and contains the thermoplastic adhesive 31 inside. The roller 82 is a member installed near the outer peripheral surface of the stator 21 in the hopper 81 and rotatable by a predetermined drive mechanism. The stator 21 can be inserted into the housing 22 while the thermoplastic adhesive 31 is applied to the outer peripheral surface of the stator 21 by rotating the roller 82 in accordance with the operation of inserting the stator 21 into the housing 22 . When the insertion of the stator 21 into the housing 22 is completed, the space 25 between the stator 21 and the housing 22 is filled with the thermoplastic adhesive 31 .

Note that the mechanism 80 is merely an example, and the method of performing the application process and the insertion process is not limited to the above.

FIG. 19 is a block diagram showing an example of the configuration of a stator unit 11 manufacturing apparatus 201 according to the second embodiment. The manufacturing apparatus 201 according to this embodiment includes a coating mechanism 211 that performs the coating process, an insertion mechanism 212 that performs the insertion process, and a curing mechanism 213 that performs the curing process.

The coating mechanism 211 and the inserting mechanism 212 can be configured using, for example, the mechanism 80 described above. Note that the application mechanism 211 and the insertion mechanism 212 may be configured by mechanisms independent of each other. The curing mechanism 213 can be configured using, for example, a temperature-controlled room that accommodates the stator unit 11 after the coating process and the insertion process are completed, a heating device that heats the inside of the temperature-controlled room, or the like.

The stator unit 11 in which the stator 21 and the housing 22 are joined with the thermoplastic adhesive 31 containing the thermoplastic resin 35 and the ceramic particles 36 can also be manufactured by the manufacturing method or the manufacturing apparatus 201 as described above.

Although the embodiments of the present invention have been described above, the above-described embodiments and modifications thereof are merely examples, and are not intended to limit the scope of the invention. The novel embodiments and modifications described above can be embodied in various forms, and various omissions, replacements, and modifications can be made without departing from the spirit of the invention. The embodiments and modifications described above are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and equivalents thereof.

1 Motor 11 Stator Unit 12 Winding 13 Rotor 14, 15 Bearing 16 Shaft 21 Stator 22 Housing 25 Space 31 Thermoplastic Adhesive 35 Thermoplastic Resin 36 Ceramic Particles 51 Foundation Jig 52 Supply Base 53 Concave portion 61 Seal Jig 62, 81 Hopper 63 pusher 71 tank 72 pump 73 supply tube 74 supply nozzle 78 supply port 82 roller

Claims (9)

a cylindrical housing;
a stator inserted inside the housing;
with
wherein the housing and the stator are joined by a thermoplastic adhesive containing a thermoplastic resin and ceramic particles;
stator unit. The thermoplastic resin contains polyamideimide,
A stator unit according to claim 1 . the ceramic particles comprise at least one of silicon dioxide or aluminum oxide;
A stator unit according to claim 1 or 2. The maximum particle size of the ceramic particles is 1 μm or less.
A stator unit according to any one of claims 1 to 3. The content of the ceramic particles is in the range of 40 wt% to 60 wt%,
A stator unit according to any one of claims 1 to 4. A method for manufacturing a stator unit including a cylindrical housing and a stator inserted through the housing, comprising:
an inserting step of inserting the stator inside the housing;
a filling step of filling a space between the housing and the stator with a thermoplastic adhesive containing a thermoplastic resin and ceramic particles;
a curing step of heating and curing the thermoplastic adhesive filled in the space;
A method of manufacturing a stator unit comprising: A method for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing,
an application step of applying a thermoplastic adhesive containing a thermoplastic resin and ceramic particles to the outer peripheral surface of the stator;
an inserting step of inserting the stator coated with the thermoplastic adhesive into the interior of the housing;
a curing step of heating and curing the thermoplastic adhesive filled in the space between the housing and the stator;
A method of manufacturing a stator unit comprising: An apparatus for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing,
an insertion mechanism for inserting the stator inside the housing;
a filling mechanism for filling a space between the housing and the stator with a thermoplastic adhesive containing a thermoplastic resin and ceramic particles;
a curing mechanism that heats and cures the thermoplastic adhesive filled in the space;
A stator unit manufacturing apparatus comprising: An apparatus for manufacturing a stator unit including a cylindrical housing and a stator inserted inside the housing,
an application mechanism for applying a thermoplastic adhesive containing a thermoplastic resin and ceramic particles to the outer peripheral surface of the stator;
an insertion mechanism for inserting the stator coated with the thermoplastic adhesive into the interior of the housing;
a curing mechanism that heats and cures the thermoplastic adhesive filled in the space between the housing and the stator;
A stator unit manufacturing apparatus including:

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