JP3432380B2 - Manufacturing method of brushless fan motor - Google Patents

Description

BACKGROUND OF THE INVENTION [0001] [Technical Field of the Invention The present invention is a stator side to a method of manufacturing a brushless fan <br/> motor that waterproof a mold of a silicone rubber. 2. Description of the Related Art An ordinary brushless fan motor includes a stator, a circuit board having a control circuit for controlling a current flowing through each winding of the stator, and a plurality of rotors each including a permanent magnet. A rotor having a magnetic pole on the inner peripheral side and a plurality of blades on the outer peripheral side, a bearing supporting tubular portion housing therein a bearing for rotatably supporting a rotating shaft of the rotor, and surrounding the outer periphery of the blade. A housing portion, a board housing portion for housing a circuit board, and a stator side case having a plurality of webs for connecting the board housing portion and the housing portion, wherein one web has a control circuit for the circuit board. Has a structure in which a plurality of lead wires extending from the housing are housed and a lead wire housing groove for guiding the housing toward the housing is formed. [0003] Such a brushless fan motor is sometimes installed in a ventilation opening of an outdoor hut and used for cooling an internal power supply and electronic equipment. In brushless fan motors used in such applications, if rain that enters from the ventilation openings of the shed enters the case on the stator side, a short circuit may occur in the control circuit, or rust may occur on the bearings. However, in the worst case, the rotation of the motor stops and the power supply and the electronic device cannot be cooled. In order to avoid this, most of the stator in the stator side case is molded with silicone rubber, and then the silicone rubber is filled in the lead wire accommodating groove in the web accommodating the lead wire. There has been proposed a brushless fan motor in which the stator side is waterproofed by molding a lead wire. [0005] However, in the conventional waterproof brushless fan motor having such a structure, the second molding of the lead wire is performed manually, which reduces the manufacturing cost. There was a problem that became expensive. Further, in the above-described structure, there is a problem that water may enter when an interface is formed at two mold portions and peeling occurs at those portions. Further, in the above-described structure, the stator is molded in a state where the magnetic pole surface is exposed, and the magnetic pole surface is later covered with another material, which also has a problem of increasing the number of working steps. Further, if the magnetic pole surface is covered with another material, there is a problem that an interface is formed and water easily enters the inside. An object of the present invention is to provide a method for producing a highly waterproof brushless fan motor. Another object of the present invention is to provide a manufacturing <br/> production method of a brushless fan motor that allows the mold without creating an interface mold layer. Another object of the present invention is to provide a method for manufacturing a waterproof effect is high brushless fan motor. Another object of the present invention, brushless fan motor capable of preventing water from entering the interior core from the pole face
It is to provide a manufacturing method of. It is another object of the present invention to provide a method of manufacturing a brushless fan motor which can effectively inject silicone rubber in one operation. According to the present invention, there is provided a stator having a plurality of salient poles, and a stator having a plurality of stator magnetic poles having windings wound around the salient poles, A circuit board on which electronic components constituting a control circuit for controlling a current flowing through windings constituting a plurality of stator magnetic poles of the stator fixed to the stator, and a plurality of rotors comprising permanent magnets; A rotor having a magnetic pole on the inner peripheral side and a plurality of blades on the outer peripheral side, a bearing supporting cylinder part in which a bearing rotatably supporting a rotating shaft of the rotor is housed, and a blade of the rotor. A housing portion surrounding the outer periphery, a board housing portion in which the circuit board is housed and fixed, and a stator-side case including a plurality of webs connecting the board housing portion and the housing portion; The web has multiple wires extending from the control circuit on the circuit board. A lead wire storage groove for housing the lead wire and guiding it to the housing side is formed, and a communication path communicating between the lead wire storage groove and the board storage portion is formed between the lead wire storage groove and the board storage portion, and a circuit including a stator and electronic components is provided. The object of the present invention is to improve a brushless fan motor in which a plurality of lead wires accommodated in a substrate and a lead wire accommodating groove are molded with silicone rubber. In the present invention, the stator, the circuit board including the electronic components, and the plurality of lead wires are integrally molded by a single injection of silicone rubber while being housed in the stator side case. With such a structure, the molding operation using silicone rubber is performed once, and the number of operation steps is reduced. In addition, since the interface between the two molded portions does not exist in the silicone rubber mold layer as in the related art, the waterproof effect is high. In the present invention, it is preferable that the magnetic pole surface of the stator magnetic pole of the stator is also covered with silicone rubber. This can prevent water from entering the core from the pole face. In addition, the number of working steps is reduced as compared with the conventional method in which the magnetic pole surface is covered with another material in another process. Further, according to the present invention, the rotor has a rotor side case in which blades are arranged on the outer peripheral side and rotor magnetic poles are arranged on the inner peripheral side, and a rotating shaft for fixing the rotor side case to the rotating shaft. And a bush fixed to the
A labyrinth structure that opposes a small gap between the opening side end of the rotor side case and the opening side end of the substrate housing portion of the stator side case to prevent water from entering inside. To form In addition, it is preferable that a labyrinth structure is formed at the end of the cylindrical portion for supporting the bearing and the bush so as to oppose each other with a slight gap therebetween to prevent water from entering inside. Thus, a labyrinth structure is formed between the opening-side end of the rotor-side case and the opening-side end of the substrate housing portion of the stator-side case, and the end of the bearing support cylinder and the bush are formed. When a labyrinth structure is formed between them, it is possible to prevent water from entering the stator. In the manufacturing method according to the present invention, the stator, the circuit board including the electronic components, and the plurality of lead wires are housed in the stator side case, and are fitted to the board housing portion and the bearing supporting cylinder. The first mold is disposed so as to form a mold space including the stator and the electronic component, and the second mold is disposed to close the lead wire housing groove so as to leave an air vent on the housing side. Then, the posture of the stator side case in which the first and second molds are arranged is determined so that the air vent is located above. Then, silicone rubber is injected into the mold space from the silicone rubber injection port provided in the first mold, and the silicone rubber is injected into the lead wire accommodating groove through the communication passage to manufacture a brushless fan motor. When the silicone rubber is injected with the air vent opening positioned upward as described above, the silicone rubber enters the lead wire accommodating groove together with the discharge of air, and is easily molded by a single rubber injection. Can be. In addition, if the injection amount is limited, the rubber does not protrude from the lead wire housing groove, and the post-processing after cutting off the protruded rubber becomes unnecessary. FIG. 1 shows a first embodiment of a brushless fan motor according to the present invention. In FIG. 1, reference numeral 1 denotes a stator, and the stator 1 is configured by winding a winding 3 around each salient pole 2a of an iron core 2 having a plurality of salient poles 2a. These salient poles 2
a acts as a stator magnetic pole by exciting the winding 3.
Therefore, the tip of the salient pole portion 2a is the magnetic pole surface 2a 'of the stator magnetic pole.
It becomes. Reference numeral 4 denotes a circuit board fixed to the stator 1. The circuit board 4 includes an electronic circuit constituting a control circuit for controlling a current flowing through the windings 3 constituting a plurality of stator magnetic poles of the stator 1. Parts are mounted. The control circuit of the circuit board 4 and the winding 3 are connected to the terminal pins 4c which are passed through the through holes 4a of the circuit board 4 and are attached with the solder 4b.
a is wound, soldered and connected. 5
Is a rotor having a structure in which a plurality of rotor magnetic poles 6 made of permanent magnets are provided on the inner peripheral side and a plurality of blades 7 are provided on the outer peripheral side. Numeral 8 denotes a stator side case, a bearing supporting cylinder portion 11 in which a bearing 10 rotatably supporting a rotating shaft 9 of the rotor 5 is housed, and a housing portion surrounding the outer periphery of the blade 7 of the rotor 5. 12, a circuit board housing section 13 in which the circuit board 4 is housed and fixed, and a plurality of webs 14 connecting the board housing section 13 and the housing section 12 to each other. One of the plurality of webs 14 has a lead wire housing groove 16 for housing a plurality of lead wires 15 connected to a control circuit of the circuit board 4 and extending to guide the housing toward the housing 12. Is formed. Between the lead wire storing groove 16 and the board storing portion 13,
A communication path 17 that connects the two is formed. The rotor 5 has a rotor side case 1 in which a blade 7 is disposed on the outer peripheral side and a rotor magnetic pole 6 is disposed on the inner peripheral side.
8 and a bush 19 fixed to the rotating shaft 9 for fixing the rotor side case 8 to the rotating shaft. In particular, the rotor-side case 18 is formed of a flywheel 20 that supports the rotor magnetic pole 6 on the inner circumference and a blade mounting hub 21 that supports the blade 7 on the outer circumference. The flywheel 20 includes a cylindrical yoke portion 20a that supports the rotor magnetic pole 6 on the inner periphery thereof, and the yoke portion 20a.
And a bottom plate portion 20b fixed to the bush 19 in a state of receiving one end of the bottom plate 20b. The yoke portion 20a is fixed to a blade mounting hub 21 with an adhesive 22, and the blade mounting hub 21 is fixed to the bottom plate portion 20b by a fixing means (not shown). Opening side end 18a of rotor side case 18
Further, the opening side end 13a of the substrate housing portion 13 of the stator side case 8 is configured so as to form a labyrinth structure in which both oppose each other via a slight gap 23 to prevent water from entering inside. Have been. The end 11a of the bearing support tube 11 and the bush 19 are configured to form a labyrinth structure that opposes each other through a slight gap 24 and prevents water from entering the inside. This prevents water from entering the case. The stator 1, the circuit board 4 including the electronic components, and the plurality of lead wires 15 are integrally molded by a single injection of the silicone rubber 25 while being housed in the stator-side case 8. . In the stator 1, the magnetic pole surface 2a 'of the stator magnetic pole is also thinly covered with the silicone rubber 25. With such a structure, the molding operation using the silicone rubber 25 is performed once, and the number of operation steps is reduced. In addition, since the interface between the two mold portions does not exist in the mold layer made of the silicone rubber 25, the waterproof effect is high. Furthermore, the pole face 2 of the stator pole of the stator 1
Since a 'is also covered with the silicone rubber 25, it is possible to prevent water from entering the core 2 from the magnetic pole surface 2a' of the stator magnetic pole. In another conventional process, the pole face 2a
The number of work steps is reduced as compared with the case where the 'is covered. FIG. 2 shows a second example of the embodiment of the brushless fan motor according to the present invention. In this brushless fan motor, the labyrinth structure is not provided between the opening-side end 18a of the rotor-side case 18 and the opening-side end 13a of the board housing portion 13 of the stator-side case 8. End 11 of Bearing Supporting Tube 11
It is provided only between a and the bush 19. Other configurations are the same as those of the first example. Even with such a structure, it is possible to prevent the water entering along the rotating shaft 9 from reaching the stator 1 by the labyrinth structure of the gap 24. FIGS. 3 and 4 are views showing a state in which a molded part for waterproofing the stator 1 side is formed in the brushless fan motor having the waterproof structure described above. Waterproofing of the stator 1 is performed before the rotor 5 is assembled. At this time, in a state where the stator 1, the circuit board 4 including the electronic components, and the plurality of lead wires 15 are stored in the stator side case 8,
The first mold 27 is arranged so as to form a mold space 26 including the stator 1 and the electronic components by being fitted with the substrate housing portion 13 and the bearing support tube portion 11. Further, a second mold 29 for closing the lead wire housing groove 16 so as to leave the air vent 28 on the housing 12 side is arranged. In this case, the lead wire 15 in the lead wire storage groove 16 is housed in the protection tube 15 ', but a structure in which the protection tube 15' is not covered may be used. As shown in FIG. 3, the attitude of the stator-side case 8 in which the first and second molds 27 and 29 are arranged is determined so that the air vent 28 is located upward. In this position, a silicone rubber injection port 30 is provided in advance in the first mold 27 so as to be located below the mold space 26. The silicone rubber 25 is injected into the mold space 26 from the silicone rubber injection port 30, and the silicone rubber 25 is inserted through the communication passage 17 into the lead wire accommodating groove 16.
The rubber 25 is injected. In this way, silicone
The rubber 25 is gradually filled from the lower part of the mold space 26 to the upper part.
Rises inside. When the silicone rubber 25 rises to a predetermined position in the lead wire accommodating groove 16, the injection of the silicone rubber 25 from the silicone rubber injection port 30 is stopped.
When the molded silicone rubber 25 has hardened, the first and second molds 27 and 29 are removed. When the silicone rubber 25 is injected with the air vent 28 positioned upward as described above, the silicone rubber 25 enters the lead wire accommodating groove 16 together with the discharge of air, and the rubber is easily injected by one injection of rubber. Can be molded. If the injection amount is limited, the lead wire storage groove 1
The silicone rubber 25 does not protrude from the surface 6, and no post-processing is required after the protruded silicone rubber 25 is cut off. According to the present invention, the stator, the circuit board including the electronic components, and the plurality of lead wires are accommodated in the stator-side case by one injection of silicone rubber. Since the molding is performed integrally, the molding operation using the silicone rubber is performed once, and the number of operation steps can be reduced. Further, since the interface between the two mold portions does not exist in the silicone rubber mold layer, there is an advantage that the waterproof effect is high.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a vertical sectional view of a main part showing a first example of an embodiment of a brushless fan motor according to the present invention. FIG. 2 is a vertical sectional view of a main part showing a second example of the embodiment of the brushless fan motor according to the present invention. FIG. 3 is a longitudinal sectional view showing a state of one step of a method of manufacturing a brushless fan motor according to the present invention. FIG. 4 is a front view showing a mounted state of the mortar type as viewed from the right side in FIG. 3; [Description of Signs] 1 Stator 2 Iron core 2a Salient pole portion 2a 'Magnetic pole surface 3 Winding 4 Circuit board 4a Through hole 4b Solder 4c Terminal pin 5 Rotor 6 Rotor magnetic pole 7 Blade 8 Stator side case 9 Rotating shaft 10 Bearing 11 Bearing support cylinder 11a End 12 Housing 13 Substrate storage 13a Open end 14 Web 15 Lead wire 15 'Protective tube 16 Lead wire storage groove 17 Communication path 18 Rotor side case 18a Open end Part 19 Bush 20 Flywheel 20a Yoke part 20b Bottom plate part 21 Blade mounting hub 22 Adhesives 23, 24 Gap 25 Silicone rubber 26 Mold space 27 First mold 28 Air vent 29 Second mold 30 Silicone rubber Inlet

────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI H02K 15/12 H02K 15/12 E // H02K 7/14 7/14 A (72) Inventor Osamu Kawakami Osamu Kita-Otsuka, Toshima-ku, Tokyo 1-5-15-1 Sanyo Electric Co., Ltd. (56) References JP-A-48-8001 (JP, A) JP-A-6-31717 (JP, A) JP-A-4-105538 (JP, A) ) Japanese Utility Model Showa 63-96650 (JP, U) Japanese Utility Model Showa 62-26181 (JP, U) Japanese Utility Model 1991-91067 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) H02K 29/00 H02K 3/44 H02K 3/52 H02K 5/10 H02K 5/22 H02K 15/12 H02K 7/14 H02K 21/00

Claims (1)

(57) Claims 1. The salient pole portion of an iron core having a plurality of salient pole portions
With multiple stator poles with windings wound around
A stator and the plurality of stators of the stator fixed to the stator
A control for controlling a current flowing through the windings constituting the magnetic pole;
A circuit board on which electronic components constituting a control circuit are mounted, and a plurality of rotor magnetic poles comprising permanent magnets provided on the inner peripheral side; and
A rotor having a plurality of blades on an outer peripheral side, and a bearing rotatably supporting a rotating shaft of the rotor are internally provided.
The bearing support tubular portion to be stored, the blade of the rotor
A housing part surrounding the outer periphery of the circuit board is accommodated.
The substrate storage section to be fixed and the substrate storage section and the housing
Stator having a plurality of webs for connecting
And a side case , wherein one of the webs is provided from the control circuit of the circuit board.
A plurality of extended lead wires are housed on the housing side
A lead wire storage groove for guiding is formed, and both are provided between the lead wire storage groove and the substrate storage portion.
A communication path communicating with the circuit board, the circuit board including the stator, the electronic component, and the
The plurality of lead wires housed in the lead wire housing groove are
Brushless molded with silicone rubber
A method of manufacturing a fan motor, wherein the stator, the circuit board including the electronic component, and the
A state in which a plurality of lead wires are stored in the stator side case
In the above, it fits with the substrate storage part and the bearing support cylinder part.
Forming a mold space including the stator and the electronic component
The first mold so that the lead wire
Close the groove so as to leave an air vent on the housing side
A second mold is disposed, and the first and second molds are arranged such that the air vent is located upward.
Determine the posture of the stator side case where the molds 2 are placed
Because, silicone rubber injection port provided on the first mold
Inject the silicone rubber into the mold space from
And through the communication passage to the inside of the lead wire storage groove.
Brushless characterized by injecting silicone rubber
Manufacturing method of sfan motor.