JP2775149B2 - Manufacturing method of outer rotor motor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a method for manufacturing an outer rotor motor.

[0002]

2. Description of the Related Art Various types of outer rotor type motors have been conventionally known. Recently, for the purpose of simplifying the structure and reducing the number of manufacturing steps, an outer rotor cup is formed of a synthetic resin, and a metal frame is formed inside the outer rotor cup. (Hereinafter referred to as a back yoke) and a magnet integrally molded have been proposed by the present applicant.

FIG. 5 shows an example of such a resin-integrated outer rotor type motor.
And a stator 3 having an iron core 3b, a shaft 1 rotatably supported by the stator 3 via a bearing 2, and a stator 3 fixed to the shaft 1.
And a printed board mounted integrally with the stator 3 at an end of the stator 3 in an opening direction of the rotor cup 4 and provided at a predetermined interval around the stator 3 so as to cover the stator 3. Consists of seven.

[0004] The rotor cup 4 is molded integrally with the back yoke 5 and the magnet 6 by resin, and the center of the rotor cup 4 is fixed to a protruding portion of the shaft 1 from the stator 3. The magnet 6 is mounted via the back yoke 5 at a position on the inner peripheral surface of the rotor cup 4 corresponding to the stator coil 3a. Further, a field magnetic pole position detection sensor (hereinafter, referred to as a detection sensor) 8 such as a photo interrupter is attached to a part of the side edge of the printed circuit board 7.

[0005] Such a brushless motor comprises a stator coil 3a provided on a stator 3 and a rotor cup 4a.
The rotor 6 is rotated by a magnet 6 mounted on the inner peripheral surface of the rotor cup. The current is switched to the stator coil 3 a by the printed circuit board 7, and the rotation of the rotor cup 4 is controlled by the detection sensor 8.

Incidentally, the outer rotor motor as described above requires a member for protecting the printed circuit board 7 from external impact, dust and the like, and a member for attaching the motor to a fixed member. For this reason, a protection portion for covering and protecting the exposed portion of the printed circuit board 7 and fixing the motor to the fixing member is provided by resin. And such an outer rotor motor is manufactured by the following manufacturing method using a mold. That is, resin is poured into the lower die on which the stator coil 3a and the iron core 3b are mounted and the upper die on which the printed circuit board 7 on which the detection sensor 8 is mounted, and the upper die and the lower die are connected to each other. The stator 3 is integrally formed with the substrate 7 and the protection unit.

[0007] By forming a mounting hole at the side edge of the protection portion, the motor can be mounted on the fixing member by screws or the like.

[0008]

However, in order to integrally mold the stator 3 together with the printed circuit board 7 and the protection portion by using resin, it is necessary to apply heat at the time of molding.
This temperature is about 120-160 ° C. for a thermosetting resin and about 200 ° C. or more for a thermoplastic resin. That is, in the case where the protection portion is provided on the exposed portion of the printed circuit board 7 and integrally molded, the printed
Heat exceeding 0 ° C. will be applied. However, the detection sensor 8 such as a photointerrupter has a high possibility that its characteristics deteriorate at a high temperature exceeding 100 ° C. When the characteristics of the detection sensor 8 deteriorate, the operation and life of the detection sensor 8 are affected, and furthermore, there is a problem that defective products such as malfunctioning of the outer rotor motor occur.

An object of the present invention is to solve the above-mentioned problems in the prior art, and an object of the present invention is to provide an outer rotor motor capable of integrally molding a printed board having electronic components and a stator with a resin. Is to provide a method of manufacturing the same. More specifically, when integrally molded with resin, an outer rotor that can prevent the electronic components such as the position detection sensor from deteriorating in characteristics due to heat and produce a high-performance outer rotor motor with a reduced defective product occurrence rate can be manufactured. An object of the present invention is to provide a method for manufacturing a motor.

[0010]

According to a first aspect of the present invention, there is provided a method of manufacturing an outer rotor motor, comprising: a stator comprising a stator coil and an iron core; and a cup-shaped end surface and a circumferential surface covering the stator. A method of manufacturing an outer rotor motor, comprising: a rotor cup provided on a printed circuit board provided with electronic components on a surface thereof; and molding the stator and the printed board integrally with a resin using a mold. In molding the printed circuit board integrally, a space portion in which electronic components on the printed circuit board are accommodated and which has an opening communicating with the outside of the mold, and resin for integral molding is prevented from flowing into this space portion. Using a mold having a blocking portion, an electronic component is arranged in the space of the mold, and the stator and the printed circuit board are mounted. While cooling the electronic components through the opening by blowing cooling air into the space portion, characterized in that integrally molded with the printed circuit board and the stator by resin filled in the mold.

According to the first aspect of the present invention, since a mold having a blocking portion for preventing the resin for integral molding from flowing into the space of the mold is used, the resin is not used during molding. Does not flow into In addition, a mold having an opening formed so as to communicate with the outside of the mold in this space is used, and cooling air is blown into the space from the opening to cool the electronic components and integrally mold them. Even if it is sometimes heated, the heat transmitted from the resin near the electronic component such as near the blocking portion is cooled by the cooling air blown from the opening.

The second aspect of the present invention is the first aspect of the present invention.
In the method for manufacturing an outer rotor motor according to the aspect, the blocking portion includes a convex portion formed at a peripheral portion of the space of the mold at a position where the electronic component is arranged, and the opening portion is provided in the blocking portion. A method for manufacturing an outer rotor motor, comprising:

According to the second aspect of the present invention, since the opening is provided in the blocking portion formed by the convex portion, the resin does not flow into the electronic component during molding, and the resin does not flow during molding. Even when heating is performed, the electronic component is cooled by the cooling air blown from the opening.

The third aspect of the present invention is the second aspect of the present invention.
In the method for manufacturing an outer rotor motor described above, the protrusion is formed of a member different from the mold.

According to the third aspect of the present invention, since the projection is formed of a member different from the mold, the projection can be provided on the printed circuit board.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment corresponding to the inventions according to claims 1 to 3 and an outer rotor motor manufactured based on the invention will be described below with reference to FIGS. In this embodiment, the same members as those in the related art are denoted by the same reference numerals, and description thereof will be omitted.

(1) Configuration of Embodiment An outer rotor motor manufactured by a method for manufacturing an outer rotor motor according to the present invention includes, as shown in FIG. A shaft 1 rotatably supported by the stator 3; and a rotor cup 4 fixed to the shaft 1 and fitted to the outer periphery of the stator 3. A field pole detection sensor 8 such as a photo interrupter and a connector 9 are provided on a part of the side of the surface of the printed circuit board 7. The molded part includes a protective part 10 for protecting the printed circuit board 7 and a stator-side molded part. The upper surface of the protective part 10 is open on the surface on the stator 3 side, and the concave part 7a communicates with the outer peripheral end face. Is provided. Further, as shown in FIG. 2, a mounting hole 13 for fixing the outer rotor motor to a fixing member with a screw or the like is formed in a peripheral portion of the protection portion 10.

The method of manufacturing the outer rotor motor according to the present embodiment for manufacturing the outer rotor motor as described above is as follows. That is, the rotor cup 4 is integrally molded with the back yoke 5 and the magnet 6 by resin. The stator 3 and the printed circuit board 7
Is integrally molded with a resin using upper and lower dies 14, which are upper and lower dies as shown in FIG. That is, the lower mold 14 corresponds to the formation of the stator-side mold section, and the upper mold 15 corresponds to the formation of the protection section 10. The upper die 15 has a space in which the detection sensor 8 and the connector 9 on the printed circuit board 7 are accommodated, and a bushing 12 (corresponding to a blocking portion) separate from the die is formed in this space. ) Are provided so as to surround the periphery of the position where the back yoke 5 and the magnet 6 are arranged. further,
As shown in FIGS. 2 and 3, the bushing 12 is formed with an opening 11 that communicates with the outside of the mold in a freely permeable manner. The mold also has a portion corresponding to the mounting hole 13 formed in the protection portion 10.

A stator coil 3a and an iron core 3b are mounted on the lower mold 14 of such a mold. The printed circuit board 7 is mounted in the space of the upper die 15 so that the detection sensor 8 and the connector 9 are located on the side of the stator-side mold portion during integral molding. Then, resin flows into and connects to the lower mold 14 and the upper mold 15 of the mold, and the stator 3 and the printed board 7 are integrally molded. Further, in the vicinity of the opening 11 of the mold, cooling air is blown from the opening 11 to the detection sensor 8 and the connector 9 in the space from the opening 11 by an arbitrary blowing means.

(2) Operation of the Embodiment The operation of this embodiment as described above is as follows. That is, even if the resin flows into the mold, the detection sensor 8
Around the printed circuit board 7 and the bushing 12
And the mold does not flow the resin. In addition, the detection sensor 8 and the connector 9 are kept in a state of communicating with the outside at the opening 11 even when heat exceeding 100 ° C. is applied during the integral molding, so that air can flow. Further, cooling air is blown from the blower provided near the corresponding portion of the opening 11 in the mold toward the detection sensor 8 and the connector 9 through the opening 11.
The heat energy at the time of integral molding is transmitted to the blown cooling air and moves to the outside of the mold.

(3) Effects of the Embodiment The effects of the present embodiment as described above are as follows. That is, the resin, which becomes high in temperature when integrally molded with the detection sensor 8 and the connector 9, is separated from the resin via the bushing 12, and thus does not directly contact. Further, even if the thermal energy of the resin at the time of integral molding is transmitted in the direction of this space, the space in which the detection sensor 8 and the connector 9 are arranged is kept open to the opening 11. Is formed, and cooling air is blown into the opening 11, so that thermal energy is transmitted to the blown cooling air and moves to the outside of the mold. Temperature 100
Never exceed ℃. Therefore, it is possible to prevent the characteristic deterioration due to exposure of the detection sensor 8 and the connector 9 to a high temperature, and it is possible to reduce a defective product occurrence rate. Further, the outer rotor motor can be attached to the fixing member without damaging the printed circuit board 7 while sufficiently protecting the exposed portion of the printed circuit board 7 by the protection section 10.

(4) Other Embodiments The present invention is not limited to the above-described embodiments, and specific shapes of members, mounting positions and methods of each member can be appropriately changed. is there. For example, the protection unit 1
The openings 11 provided at 0 may be provided with different openings depending on the positions where the detection sensor 8 and the connector 9 are attached, and may be cooled separately.

Further, depending on the place where the outer rotor motor is installed, the mounting portion 11 is not formed in
It is also possible to separately provide a mounting member. Further, the blowing means is not limited to a means provided outside the mold as a separate member, and there is no problem as means provided on the outer wall of the mold. Further, it is not limited to blowing from outside the mold, but it is also possible to provide a blowing tube in the blowing means, insert this blowing port inside the opening, and directly blow the cooling air to the detection sensor or the like to cool the cooling device. is there. Thereby, cooling can be performed efficiently.

[0024]

As described above, according to the method of manufacturing the outer rotor motor of the present invention, when integrally molding the stator and the printed board, the electronic components on the printed board are housed and the outside of the mold is communicated. Using a mold having a space having an opening and a blocking portion for preventing resin for integral molding from flowing into this space, an electronic component is arranged in the space of the mold, and a stator is provided. By mounting the printed circuit board and the printed circuit board, and cooling the electronic components by blowing cooling air into the space from the opening, the stator and the printed circuit board are integrally molded with the resin filled in the mold, thereby forming an integrated body. By applying heat during molding, resin does not flow into the space during molding and air can flow from the opening to the electronic components in the space. Preventing sexual degradation, it is possible to reduce the defective products incidence. Therefore, it is possible to provide an outer rotor motor having a configuration in which a printed board having normal electronic components and a stator can be integrally molded with resin.

[Brief description of the drawings]

FIG. 1 is a side view showing an example of an outer rotor motor manufactured based on a method for manufacturing an outer rotor motor of the present invention.

FIG. 2 is a plan view showing a stator of the outer rotor motor of FIG.

FIG. 3 is an enlarged perspective view of a main part of the outer rotor motor of FIG. 1;

FIG. 4 is a side view showing one embodiment of a method for manufacturing an outer rotor motor of the present invention.

FIG. 5 is a side cross-sectional view of an outer rotor motor in a state where a conventional protection unit is not provided.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Shaft 2 ... Bearing 3 ... Stator 4 ... Rotor cup 5 ... Back yoke 6 ... Magnet 7 ... Printed circuit board 8 ... Detection sensor 9 ... Connector 10 ... Protection part 11 ... Opening 12 ... Bushing 13 ... Mounting hole 14 ... Bottom Mold 15… Upper mold

Claims (3)

(57) [Claims] 1. A stator comprising a stator coil and an iron core, a rotor cup which is formed in a cup shape by an end face and a circumferential surface and is provided so as to cover the stator, and a printed board provided with electronic components on the surface. In a method for manufacturing an outer rotor motor, wherein the stator and the printed board are integrally formed of resin using a mold, electronic parts on the printed board are housed when the stator and the printed board are integrally formed. A mold having a space having an opening communicating with the outside of the mold and a blocking portion for preventing resin for integral molding from flowing into the space is used. A component is arranged, the stator and the printed circuit board are mounted, and cooling air is blown from the opening into the space to cool the electronic component. A method of manufacturing the outer rotor motor, wherein the stator and the printed circuit board are integrally molded with the resin filled in the mold. 2. The method according to claim 1, wherein the blocking portion comprises a convex portion formed at a peripheral portion of the space of the mold where the electronic component is arranged, and the opening is provided in the blocking portion. The method for manufacturing an outer rotor motor according to claim 1, wherein: 3. The method for manufacturing an outer rotor motor according to claim 2, wherein said projection is formed of a member separate from said mold.