JP3782805B2 - Method for producing composite - Google Patents

Description

The present invention relates to the production how the complex can be applied for example in the fabrication of the motor.

  Conventionally, a slotless motor having a configuration in which a slot is omitted is widely used along with a motor having a configuration in which a coil is wound around a winding groove (slot) formed in a rotor or a stator.

  Here, FIGS. 19 (a) and 19 (b) show the configuration of the main part of such a conventional slotless motor (see, for example, Japanese Patent No. 2799395). However, Fig.19 (a) is typical sectional drawing, FIG.19 (b) is an end elevation. As shown in both figures, the slotless motor 1900 is provided with a permanent magnet 1910 protruding from the surface of the rotating shaft around the periphery, and houses a rotor 1920 and a rotor 1920, both ends of which are fixed by ball bearings 1911. A substantially cylindrical motor coil 1930 positioned coaxially with the rotation axis of the rotor, a substantially cylindrical stator yoke 1940 that houses the motor coil 1930, and a casing 1950 that houses these parts are provided. Although not shown, the end portion of the rotor 1920 is exposed to the outside from the housing portion 1950 and transmits the rotational force to the outside.

  In the illustrated rotor 1920, most of the shaft housed in the motor coil 1930 has a shape that is thinner than the other portions, and a permanent magnet 1910 is provided in the narrowed portion. The permanent magnet 1910 is opposed to the inner wall of the stator yoke 1940 with the motor coil 1930 interposed therebetween.

In the slotless motor having the above-described configuration, the motor coil 1930 is uniformly arranged along the rotation circumference of the rotor 1920, and the rotor 1920 receives a uniform magnetic attraction force regardless of the position. Cogging does not occur, torque unevenness and rotation unevenness characteristics are not adversely affected, and the characteristics are higher than a motor having a slot.
Japanese Patent No. 2799395

  However, such a conventional slotless motor has the following problems. That is, in order to rotate the rotor 1920, the rotor 1920 must be inserted into the motor coil 1930 together with the permanent magnet 1910. At this time, as shown in FIGS. 19 (a) and 19 (b), the permanent magnet A gap 1960 is generated between the rotor 1920 and the motor coil 1930 corresponding to the thickness of the motor.

  Furthermore, the motor coil 1930 is schematically described. As shown in FIG. 20 (a), a wire 2100 formed as a strip-like coil 2000 by flat spiral winding having folding at both ends is shown in FIG. 20 (b). As shown, it is created by rounding into a cylindrical shape as shown by the arrow in the figure. In the figure, for the sake of simplicity, the strip coil 2000 is wound only once, but in actuality, it is formed by winding a plurality of times.

  At this time, both ends of the motor coil 1930 correspond to the edge of the strip coil 2000, but the edge of the strip coil 2000 is formed by overlapping the folded portions of the wire 2100 as shown in FIG. Therefore, the thickness thereof is larger than that of other portions, and therefore both end portions of the motor coil 1930 are also larger than the central portion where the wire rod is not folded. For this reason, the inner diameter of the stator yoke 1940 into which the motor coil 1930 is inserted needs to be greater than or equal to the outer diameter of both ends of the motor coil 1930.

  Also in this case, as shown in FIG. 19A, a gap 1970 is generated between the outer wall at the center of the motor coil and the inner wall of the stator yoke.

  These gaps 1960 and 1970 have caused a reduction in the efficiency of the motor.

The present invention has been made in view of the above problem, for example, rotor and as much as possible eliminating unnecessary gaps between the coils as can be created motor of the high-efficiency, production how complex The purpose is to provide.

In order to achieve the above object, according to the first aspect of the present invention, the first member constituted by the wire and the second member cannot be separated without deforming at least one of the shapes. In the state of the combination, the method of manufacturing a composite in a state where the surface of the first member and the surface of the second member are not in contact with each other,
Covering all or part of the surface of the second member with a mold member made of a material having a lower melting point than the material of the first member and the second member;
Forming the first member around all or part of the second member by drawing the wire around the mold member ;
And a step of melting the mold member and removing it from the first member and the second member to complete the combined state .

  The second aspect of the present invention is the method for producing a composite according to the first aspect of the present invention, wherein the mold member is made of a material having a rigidity that does not deform due to a force when forming the first member. It is.

  Moreover, 3rd this invention is a manufacturing method of the composite_body | complex of 1st this invention whose material of the said mold member is a metal.

  Moreover, 4th this invention is a manufacturing method of the composite_body | complex of 3rd this invention whose said metal is Senjualloy (trademark).

In the fifth aspect of the present invention, in the composite, only the first part which is a part of the second member is covered with the first member.
The second part of the second member that is not covered by the first member is exposed to the outside,
The shape of the first portion of the second member is substantially cylindrical, and the shape of the second portion is substantially cylindrical having a smaller outer diameter formed coaxially with the first portion. Is a shape,
The shape of the first member is the manufacturing method of the composite according to the first aspect of the present invention, which is substantially cylindrical corresponding to the first portion of the second member.

Further, the present invention of the sixth, the second member is a rotor of the motor,
The first portion of the second member is a rotary shaft of said rotor, a second portion of said second member is a permanent magnet provided on the rotary shaft and the rotational axis of the rotor,
It said first member is a coil of the motor,
The composite is the composite manufacturing method according to the first aspect of the present invention, which is a motor assembly in which the rotor and the coil are combined.

According to the present invention, it is possible to provide a manufacturing how applications complexes motor assembly Hinto capable of realizing example of the high-efficiency motor.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment)
FIGS. 1A and 1B are diagrams showing the configuration of a slotless type motor configured by the motor assembly of the first embodiment of the composite of the present invention. 1A is a sectional view, and FIG. 1B is an end view.

  As shown in FIGS. 1A and 1B, in the motor 1000, the same or corresponding parts as those in FIG. 19 are denoted by the same reference numerals, and detailed description thereof is omitted. In the motor of the present embodiment, the rotor 1920, the bearing 1911, and the casing 1950 are the same as the conventional example, but the shapes of the motor coil 1010 and the stator yoke 1020 are different as will be described later.

  First, the general shape of the motor coil 1010 of this embodiment is a cylindrical shape as in the case of the conventional motor coil 1930, but the shape of both ends and the size of the outer diameter are different. That is, the inner diameter of the motor coil 1010 corresponding to the outer diameter of the permanent magnet 1910 is the same as that of the conventional example, but the winding of the coil goes around to the end face side of the permanent magnet 1910 at both ends of the motor coil 1010. An end face 1030 is formed. As shown in FIG. 1A, the permanent magnet 1910 has an orthogonal surface corresponding to the wall portion of the present invention that is orthogonal to the surface of the rotor 1920, and an end surface 1030 that is a part of the inner wall of the motor coil 1010. The back surface is opposed to this orthogonal surface. Further, as shown in FIG. 1B, the permanent magnet 1910 is hidden by the end face 1030 so that a part of the permanent magnet 1910 cannot be directly seen. That is, the part including the permanent magnet 1910 of the rotor 1920 is covered with the side surface and the end surface 1030 of the cylindrical motor coil 1010.

  Secondly, unlike the conventional example, both end portions of the motor coil 1010 have the same thickness as the central portion on the outer diameter side. Therefore, the inner surface of the stator yoke 1020 and the outer surface of the motor coil 1010 are in close contact with each other.

  By having such a configuration, the motor coil 1010 in the present embodiment has no useless gap between the permanent magnet 1910 and the motor coil 1010, and is also used between the motor coil 1010 and the stator yoke 1020. The gap can be eliminated, and higher efficiency can be obtained than in the conventional example.

  Next, a method for manufacturing the motor coil 1010 as described above will be described, and an embodiment of the method for manufacturing the composite of the present invention will be described.

  First, as shown in FIGS. 2A and 2B, a rotor 1920 having the same permanent magnet 1910 as the conventional example is prepared. 2A is a front view, and FIG. 2B is an end view.

  Next, as shown in FIGS. 3 (a) and 3 (b), a molding composed of a pair of symmetrical molds 1300a and 1300b made of a material that does not adhere to at least the material of the mold member, such as resin or aluminum. Prepare a mold. However, FIG. 3A is a perspective view of the entire mold, and FIG. 3B is a plan view of the mold 1300b. As shown in the drawing, the mold corresponds to the thickness of the shaft of the rotor 1920 and is formed continuously with the first groove portion 1310 and the first groove portion 1310 which are in close contact with the first groove portion 1310. It has the 2nd groove part 1320 and the 3rd groove part 1330 in which the dent slightly wider than the groove part 1310 was formed. In the third groove portion 1330, a minute convex portion 1331 having a size corresponding to the thickness of the wire of the motor coil 1010 is formed at the boundary with the second groove portion 1320. The shape of the molding die 1300a is the same as that of the molding die 1300b, except that a filling port 1340 for communicating the third groove portion with the outside is opened as shown in FIG. 3 (a). The manufacturing method of the mold itself is a known technique and will not be described in detail. For example, it may be performed by shaping a member in which the shape of the mold is reversed.

  As shown in FIG. 4A, the rotor 1920 is arranged in such a mold 1300. FIG. 4B is a view showing a state where the rotor 1920 is disposed in the mold 1300b. As shown in the drawing, the shaft of the rotor 1920 and the first groove portion 1310 are in close contact with each other, and a minute gap is provided between the inner wall of the second groove portion 1320 and the surface of the rotor 1920 so as to contact each other. There is nothing. Also in the third groove 1330, the shaft surfaces of the permanent magnet 1910 and the rotor 1920 are arranged in the space without contacting the inner wall of the mold 1300b.

  Next, as shown in FIG. 5, the rotor 1920 is sandwiched from above and below so that the mold 1300b on which the rotor 1920 is disposed is covered with the mold 1300a. Since the mold 1300a has the same shape as the mold 1300b, the intermediate portion of the rotor 1920 including the permanent magnet 1910 does not contact any part of the inner wall of the mold, and the second groove 1320 of each of the molds 1300a and 1300b. And it is fixed in the space formed by the third groove 1330.

  Here, the filling port 1340 of the mold 1300a is filled with a low-melting-point metal that has been melted into a liquid state. The low melting point metal is not particularly limited to a specific type, but Senju Alloy (registered trademark) is used here. Senjualloy has the property of melting and liquefying at 70 ° C., and was melted in a hot water bath and filled. The low melting point metal is filled in the space in the mold and is fixed to the permanent magnet 1910 and the rotor 1920 in the space.

  Next, the mold is removed when the mold and the rotor 1920 are sufficiently lowered to the curing temperature of the low melting point metal.

  FIG. 6 shows the state of the rotor 1920 from which the mold has been removed. The central portion of the rotor 1920 has two thin shaft portions 1620 that are coaxial with the thick shaft portion 1610 and the thick shaft portion 1610 formed by transferring the shape of the space in the mold and have a thinner outer diameter. It is covered with a cylindrical mold member having a coaxial stage. That is, the rotor 1920 and the mold member are integrated. On both edges of the thick shaft portion 1610 of the mold member, concave portions 1611 formed by transferring the pattern of the convex portion 1331 of the third groove portion 1330 are formed. In the figure, the low melting point metal gate 1612 poured from the filling port 1340 remains, but this is removed and the surface is processed to be flat. The state where the mold member is completed is shown in FIGS. 7A is a front view, and FIG. 7B is an end view.

  Next, a process of manufacturing a coil by winding a wire around a mold member integrated with the rotor 1920 will be described.

  8 and 9 are diagrams showing the configuration of a winding device for winding a wire around a mold member. In the winding apparatus 1800, the connecting means 1810 is a means for connecting the rotor 1920 and the driving mechanism 1820, and the driving mechanism 1820 is realized by a motor or the like, and has a driving force for rotating the rotor 1920 together with the connecting means 1810 in the direction of arrow a in the figure. The feeding means and the wire fixing means 1830 are means for fixing the end of the wire, which will be described later, and are fixed immediately below the rotor 1920 and interlock with the rotation of the rotor 1920.

  The crank pipe 1840 is a hollow pipe bent in a key shape, and is a means for feeding the wire to the rotor 1920 side. The crank pipe 1840 is fixed at a fixed position by the crank pipe position fixing means 1850. Further, the crank pipe position fixing means 1850 incorporates a rotation mechanism realized by a ball bearing or the like, and the crank pipe 1840 can be rotated in the direction of arrow b in the figure (a drive mechanism for rotation is not shown). Further, the crank pipe position fixing means 1850 can be linearly moved in the direction of arrow c in the figure on a plane including the pedestal 1860 by a sliding mechanism 1870 provided on the pedestal 1860. Note that the rotation of the crank pipe 1840 and the movement of the sliding mechanism 1870 are performed by the driving force from the motor 1875.

  By explaining the operation of the winding apparatus as described above, the step of winding the wire around the mold member will be described. First, as shown in FIG. 10A, the tip of the wire 1880 introduced from the crank pipe 1840 is fixed to the wire rod fixing means 1830 with the tip of the crank pipe 1840 and the wire rod fixing means 1830 facing each other. . Next, as shown in FIG. 10B, the drive mechanism 1820 is driven to rotate the rotor 1920 and the wire rod fixing means 1830 in the 90 ° clockwise direction (arrow a in the figure). At this time, while being pulled by the wire fixed to the wire fixing means 1830, the sliding mechanism 1870 slides with the driving force of the motor 1875, so that the tip of the crank pipe 1840 also moves together with the wire fixing means 1830.

  As the wire 1880, a copper wire having a round cross section is used in the present embodiment. However, the present invention is not limited to this, and any conductive material that can be energized may be used and does not depend on the cross-sectional shape, side surface shape, or the like. A flat wire, foil wire or the like may be used.

  Next, as shown in FIG. 10C, the wire 1880 is fed out while rotating the crank pipe 1840 in the clockwise direction (arrow b in the figure). Then, the wire 1880 drawn from the tip of the crank pipe 1840 is extended upward along the height direction of the mold member. At this time, the crank pipe 1840 is rotated at an angle substantially larger than 180 ° so that the side surface of the wire 1880 fits into the lower concave portion 1612a and the upper concave portion 1612b of the thick shaft portion 1610 of the mold member. . By this operation, the side surface of the wire 1880 drawn from the crank pipe 1840 and the side surface of the thick shaft portion 1610 of the mold member are in contact with each other.

  Also, the copper alloy which is the material of the wire 1880 and the send alloy which is the material of the mold member have higher hardness than the send alloy, so that the thick shaft portion 1610 is not deformed by the printing pressure of the wire 1880.

  Next, as shown in FIG. 10 (d), the wire rod is sent out while the rotor 1920 and the wire rod fixing means 1830 are further rotated by 90 ° in the clockwise direction (arrow c in the drawing). Then, a new wire 1881 is pulled out from the crank pipe 1840 from a position where it is fitted in the concave portion 1612b on the upper side of the thick shaft portion 1610 of the mold member, so that the side surface of the thin shaft portion 1620 is wound away from the surface of the thick shaft portion 1610. To be extended to.

  Next, as shown in FIG. 11A, the wire 1881 is fed out while rotating the crank pipe 1840 in the clockwise direction (arrow a in the figure). Then, the wire 1881 drawn from the tip of the crank pipe 1840 is extended downward along the height direction of the thick shaft portion 1610 of the mold member. Also at this time, the crank pipe 1840 is rotated at an angle substantially larger than 180 ° so that the side surface of the wire 1881 is fitted into the lower concave portion 1613b and the upper concave portion 1613a of the thick shaft portion 1610. By this operation, the side surface of the wire 1881 drawn from the crank pipe 1840 and the side surface and end surface of the thick shaft portion 1610 of the mold member are in contact with each other.

  Further, as shown in FIG. 11B, when this state is viewed from above, the wire 1881 is stretched from the lower side to the upper side of the thick shaft portion 1610 and is then in contact with the thin shaft portion 1620 while being thick. After traversing the end face 1614 of the shaft portion 1610, it is folded back again from the upper side to the lower side of the thick shaft portion 1610. At this time, the wire on the end face 1614 is curved or linear depending on the strength of the wire. The figure shows a curved example.

  Next, as shown in FIG. 11C, the wire rod is sent out while rotating the rotor 1920 and the wire rod fixing means 1830 by about 90 ° in the counterclockwise direction (arrow b in the drawing). Then, a new wire 1882 is pulled out from the crank pipe 1840 from the position fitted in the lower recess 1613a, and is stretched so as to wind the side surface of the lower thin shaft portion 1620.

  Next, as shown in FIG. 11D, the wire 1882 is fed out while rotating the crank pipe 1840 in the clockwise direction (arrow c in the figure). Then, the wire 1882 drawn from the tip of the crank pipe 1840 is extended upward along the height direction of the mold member. At this time, the lower concave portion 1615b and the upper concave portion of the thick shaft portion 1610 of the mold member are adjacent to the concave portion into which the wire rod 1880 already arranged on the side surface of the thick shaft portion 1610 is fitted. The crank pipe 1840 is rotated at an angle substantially greater than 180 ° so as to fit into 1615a. By this operation, the side surface of the wire 1882 drawn out from the crank pipe 1840 and the side surface of the thick shaft portion 1610 of the mold member come into contact with each other, and the wire 1880 and the wire 1882 are in close contact with each other.

  By repeatedly performing the operations of FIG. 10B to FIG. 11D, it is possible to cover part of the side surface and part of both end surfaces of the thick shaft portion 1610 of the mold member with the wire material.

  12 (a) and 12 (b) show a state of a part of the motor coil created by the above process. However, FIG. 12A is a front view and FIG. 12B is an end view. As shown in FIG. 12B, the winding along the long side direction of the thick shaft portion 1610 is placed on the side surface of the thick shaft portion 1610 of the mold member so as to face the rotor 1920 in between. When a pair is formed over two layers, windings are formed so as to connect the pair of windings at the end face of the thick shaft portion 1610, thereby forming one coil 120. The coil 120 occupies 1/3 of the side area of the thick shaft portion 1610. A coil having the same dimensions as the coil 120 is formed on the periphery of the thick shaft portion 1610. As shown in (b), a three-phase motor coil 1010 comprising three coils 120 covering the side surface and both end surfaces of the thick shaft portion 1610 is completed.

  Next, the mold member is removed from the rotor 1920 integrated with the mold member, around which the motor coil 1010 is completed. As already described, since the mold member uses Senju Alloy (registered trademark), which is a low melting point metal, it is melted by being immersed in warm water of about 80 ° C. and separated from the motor coil 1010 and the rotor 1920, for example. The motor coil 1010 and the rotor 1920 after the mold member is removed form a motor assembly corresponding to the motor assembly of the present invention. FIG. 14 shows a partial state of the motor assembly 1400 created by the above process. 14A is a front view, and FIG. 14B is an end view. Compared to FIG. 13, it can be seen that the thin shaft portion 1620 is removed. FIG. 15 is a cross-sectional view taken along the line AA ′ in FIG. It can be seen that the motor coil 1010 is a three-phase motor coil composed of three coils of R phase, S phase, and T phase.

  When the mold member is removed, a gap is generated between the motor coil 1010 formed on the mold member and the rotor 1920 covered with the mold member. This state is shown in the sectional view of FIG. In the drawing, a black portion 1600 is occupied by the mold member in the manufacturing process, and is a portion that becomes a void after completion. Since the motor coil 1010 and the rotor 1920 have an axisymmetric configuration, since the motor coil is formed to wrap around the end surface of the permanent magnet 1910, the permanent magnet 1910 is sealed in the motor coil 1010, so that the rotor 1920 and the motor The coil 1010 is combined with each other, and it is impossible to separate them unless both ends of the motor coil 1010 are deformed.

  The motor coil shown in FIG. 1 can be obtained by using the motor assembly thus obtained.

  As described above, according to the embodiment of the present invention, after molding the mold member so as to cover the entire permanent magnet 1910 attached to the rotor 1920 and molding the motor coil 1010 on the mold member, By removing the mold member and arranging the axes of the permanent magnet 1910 and the rotor 1920 in the gap generated in the motor coil 1010, the motor coil 1010 that wraps around the both end surfaces of the permanent magnet 1910 is formed. As a result, a highly efficient motor with a reduced excess gap as in the conventional example can be obtained.

  Further, according to the present embodiment, the motor coil 1010 straddles the end face of the permanent magnet 1910 corresponding to the wall portion of the present invention, as shown in FIG. 11B, FIG. 12, FIG. By being drawn and folded on a plane parallel to the end face of the permanent magnet 1910, the thickness due to the folding of the wire does not occur at both ends of the motor coil 1010. Therefore, since the thickness can be made the same at both end portions and the central portion of the motor coil 1010, the inner diameter of the stator yoke 1020 can be made smaller than that of the conventional example (the thickness of the stator yoke wall portion can be increased). As shown in FIG. 1 (a), the outer wall of the motor coil and the inner wall of the stator yoke can be brought into close contact with each other, and a high-efficiency motor without an extra gap can be obtained. Such a motor can also be applied to a motor for a gyroscope. A motor for a gyroscope is required to have a high rotational speed and rotational accuracy, but the motor according to the present embodiment is a portion where the gap between the motor coil 1010 and the permanent magnet 1910 is already seen as shown in FIG. Each part of 1600 can be created with high accuracy and is suitable for this application.

  In the above embodiment, the motor assembly 1400 corresponds to the motor assembly and the complex of the present invention, the rotor 1920 corresponds to the rotor and the second member of the present invention, and the motor coil 1010 corresponds to the coil of the present invention. Moreover, it corresponds to the first member, and the mold member corresponds to the mold member of the present invention. The stator yoke 1020 corresponds to the stator yoke of the present invention, and the housing portion 1950 corresponds to the housing portion of the present invention. The portion of the rotor 1920 excluding the permanent magnet 1910 corresponds to the rotating shaft of the rotor of the present invention.

  A part of the rotor 1920 and the permanent magnet 1910 covered by the thick shaft portion 1610 and the thin shaft portion 1620 of the mold member correspond to the first portion of the second member of the present invention. The uncovered portion corresponds to the second portion of the second member of the present invention.

  However, the present invention is not limited to the above embodiment. In the above description, a motor assembly composed of a motor coil and a rotor of a slotless motor has been described as an example of the composite of the present invention, but may be implemented in a motor assembly of a slotted motor. . In this case, the first member may be a substantially cylindrical rotor, and the second member may be a substantially cylindrical motor coil having an outer diameter smaller than that of the rotor.

  Also, as shown in the partial cross-sectional view of FIG. 17, the wire rod 1700 was disposed in a shell 17 shaped coil 1710 formed with a rough stitch with a gap, and an internal space 1730 of the coil 1710. A coil-magnet complex including a spherical magnet 1720 which is a spherical permanent magnet may be configured. In the coil-magnet composite, a magnetic field whose direction is changed is generated in the coil 1710 by flowing a current having a variable polarity and strength from a terminal (not shown) into the coil 1710, thereby causing the spherical magnet 1720 to behave randomly. It can be operated as a vibrating body by performing the above, and can be applied to a vibrator of a mobile phone or the like.

  In such a coil-magnet composite, as shown in FIGS. 18A to 18C, a spherical magnet 1720 is prepared as a second member of the present invention, and this is used as a core. In addition, a sphere 1740 provided with a material made of senda alloy so as to include a rod member 1760 having a shape thinner than the diameter of the spherical magnet 1720 is molded as a mold member. At this time, both ends of the rod member 1760 are exposed from the surface of the sphere 1740. A wire rod is provided around the sphere 1740 in a mesh shape, and the coil 1710 as the first member of the present invention is formed so that the sphere magnet 1720 is indirectly covered with the sphere 1740. At this time, the exposed ends of the rod member 1760 are not covered with the coil 1710. Finally, the mold member is dissolved and removed using warm water or the like. At this time, when the rod member 1760 is pulled out of the coil 1710 at the stage where the mold member is softened, the melted mold member flows out from the hole 1770 formed thereafter, and only the spherical magnet 1720 is placed inside the coil 1710 on the spherical shell. Remains. That is, in this embodiment, the first member covers the entire second member in the completed composite. In the above configuration, the coil-magnet complex in which the spherical magnet 1720 is incorporated in the coil 1710 has been described. However, a steel ball having the same shape may be used instead of the spherical magnet 1720. In this case, the present invention constitutes a coil-steel ball composite in which the steel ball of the coil 1720 functions as an iron core, and this can be used as a spherical electromagnet.

  The present invention is not limited to the above configuration example, and the present invention is composed of a first member and a second member, which are combined so that they cannot be separated without deforming at least one of the shapes. In the production of the composite in which the surface of the first member and the surface of the second member are not in contact with each other, the second member can be combined with the first member without being deformed. This is useful for manufacturing parts.

  In the above embodiment, the wire of the coil that is the first member is copper and the mold member is a send alloy. However, the mold member of the present invention forms the first member. Any material may be used as long as it does not deform due to the force of the moment. Therefore, when the material of the mold member is send alloy, the material of the first member may be copper, gold, silver, steel, aluminum, nichrome, or the like. Moreover, a nonmetallic resin material and a ceramic material may be sufficient.

  In addition, since the material of the mold member may be a material having a lower melting point than the materials of the first member and the second member, a low melting point metal other than send alloy such as tin may be used, or a resin material or the like may be used. It may be used. In this case, the material of the first member may be a softer metal or resin material. In addition, about the hardness of a 2nd member, it is not necessary to consider the material of a type | mold member and a 1st member.

  The method for producing a composite according to the present invention has an effect capable of realizing, for example, a highly efficient motor and a coil-magnet composite, and is useful as, for example, a motor assembly, a method for producing a motor, and the like.

(A) Front view of motor 1000 in the embodiment of the present invention (b) Side view of motor 1000 in the embodiment of the present invention (A) Front view of rotor 1920 in the embodiment of the present invention (b) Side view of rotor 1920 in the embodiment of the present invention (A) Perspective view showing molds 1300a and 1330b in the embodiment of the present invention (b) Plan view showing mold 1300b in the embodiment of the present invention (A) The figure for demonstrating the manufacturing method of the mold member in embodiment of this invention (b) The figure for demonstrating the manufacturing method of the mold member in embodiment of this invention The figure for demonstrating the manufacturing method of the type | mold member in embodiment of this invention The figure for demonstrating the manufacturing method of the type | mold member in embodiment of this invention (A) Front view of the rotor 1920 integrated with the mold member in the embodiment of the present invention (b) Side view of the rotor 1920 integrated with the mold member in the embodiment of the present invention The side view of the winding apparatus in embodiment of this invention The top view of the winding apparatus in embodiment of this invention (A) The figure for demonstrating the process of manufacturing a motor coil 1010 by winding a wire around a mold member in the embodiment of the present invention. (B) The motor coil 1010 by winding a wire around a mold member in the embodiment of the present invention. The figure for demonstrating the process of manufacturing (c) The figure for demonstrating the process of winding a wire around a type | mold member in embodiment of this invention, and manufacturing the motor coil 1010. (d) In embodiment of this invention The figure for demonstrating the process of winding a wire around a type | mold member and manufacturing the motor coil 1010 (A) The figure for demonstrating the process of manufacturing a motor coil 1010 by winding a wire around a mold member in the embodiment of the present invention. (B) The motor coil 1010 by winding a wire around a mold member in the embodiment of the present invention. The figure for demonstrating the process of manufacturing (c) The figure for demonstrating the process of winding a wire around a type | mold member in embodiment of this invention, and manufacturing the motor coil 1010. (d) In embodiment of this invention The figure for demonstrating the process of winding a wire around a type | mold member and manufacturing the motor coil 1010 (A) The figure for demonstrating the state by which the coil 120 was wound around a part of type | mold member in embodiment of this invention (b) The coil 120 in a part of type | mold member in embodiment of this invention The figure for demonstrating the wound state (A) The figure for demonstrating the state by which the motor coil 1010 was wound by the type | mold member in embodiment of this invention (b) The state by which the motor coil 1010 was wound by the type | mold member in embodiment of this invention Illustration for explaining (A) Front view of motor assembly 1400 in the embodiment of the present invention (b) Side view of motor assembly 1400 in the embodiment of the present invention Sectional drawing of the motor assembly 1400 in embodiment of this invention Sectional drawing of the motor assembly 1400 in embodiment of this invention The figure which shows the other structural example of the composite_body | complex in embodiment of this invention. (A) The figure for demonstrating the process of manufacturing the other structural example of the composite_body | complex in embodiment of this invention (b) The process of manufacturing the other structural example of the composite_body | complex in embodiment of this invention is demonstrated. (C) The figure for demonstrating the process of manufacturing the other structural example of the composite_body | complex in embodiment of this invention. (A) Front view of conventional slotless motor 1900 (b) Side view of conventional slotless motor 1900 (A) The figure for demonstrating the structure of the motor coil 1930 in the slotless motor 1900 by a prior art (b) The figure for demonstrating the structure of the motor coil 1930 in the slotless motor 1900 by a prior art

Explanation of symbols

1000 Motor 1010 Motor coil 1020 Stator yoke 1610 Thick shaft portion 1620 Thin shaft portion 1610 Recessed portion

Claims (6)

The first member composed of the wire and the second member are combined so that they cannot be separated without deforming at least one of the shapes, and in the state of the combination, the surface of the first member And the surface of the second member is a method of manufacturing a composite that is not in contact with the surface,
Covering all or part of the surface of the second member with a mold member made of a material having a lower melting point than the material of the first member and the second member;
Forming the first member around all or part of the second member by drawing the wire around the mold member ;
And a step of melting the mold member and removing it from the first member and the second member to complete the combined state .   The method of manufacturing a composite according to claim 1, wherein the mold member is made of a material having a rigidity that does not deform due to a force when forming the first member.   The manufacturing method of the composite_body | complex of Claim 1 whose material of the said mold member is a metal.   The method for producing a composite according to claim 3, wherein the metal is Senju Alloy (registered trademark). In the composite, only the first part which is a part of the second member is covered with the first member,
The second part of the second member that is not covered by the first member is exposed to the outside,
The shape of the first portion of the second member is substantially cylindrical, and the shape of the second portion is substantially cylindrical having a smaller outer diameter formed coaxially with the first portion. Is a shape,
2. The method of manufacturing a composite according to claim 1, wherein the shape of the first member is a substantially cylindrical shape corresponding to the first portion of the second member. It said second member is a rotor of the motor,
The first portion of the second member is a rotary shaft of said rotor, a second portion of said second part member is a permanent magnet provided on the rotary shaft and the rotational axis of the rotor,
The first member is a coil of a motor;
The method of manufacturing a composite according to claim 5 , wherein the composite is a motor assembly in which the rotor and the coil are combined.

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