JP4092952B2 - Resin molding method and apparatus for compacting stator - Google Patents

Resin molding method and apparatus for compacting stator Download PDF

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Publication number
JP4092952B2
JP4092952B2 JP2002152085A JP2002152085A JP4092952B2 JP 4092952 B2 JP4092952 B2 JP 4092952B2 JP 2002152085 A JP2002152085 A JP 2002152085A JP 2002152085 A JP2002152085 A JP 2002152085A JP 4092952 B2 JP4092952 B2 JP 4092952B2
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Prior art keywords
end surface
resin
resin molding
stator body
stator
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JP2003347141A (en
Inventor
眞治 阿保
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Denso Corp
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Denso Corp
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  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Insulating Of Coils (AREA)
  • Electromagnets (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、ステータ本体の空洞部に挿入されたコイルの周囲を樹脂成型する樹脂成型装置及び樹脂成型方法に関する。
【０００２】
【従来の技術】
従来より、例えば電磁石に使用される圧粉ステータが知られている。この圧粉ステータは、鉄損を小さくするために、リン酸塩等の絶縁皮膜で表面を覆った鉄粉を圧縮成型したものである。
一方、振動や衝撃力などによるコイルの断線及びショートを防止するために、ステータにコイルを固定する方法がある。その固定方法としては、接着剤やポッティング、樹脂（エポキシ樹脂）による成型等が実施されている。特に、大量生産に向いているのは樹脂成型である。
【０００３】
【発明が解決しようとする課題】
ところが、樹脂成型による固定方法を上記の圧粉ステータに適用すると、樹脂の成型圧力により圧粉ステータが破壊される可能性がある。これに対し、成型圧力を低下させると、樹脂の充填不足が生じ、ステータ内部への樹脂のまわり込みが悪化してコイルを確実に固定できなくなる。このため、従来の樹脂成型方法では、成型条件を決めることが極めて困難であった。
本発明は、上記事情に基づいて成されたもので、その目的は、樹脂の充填不足を発生することなく、成型圧力によって圧粉ステータが破壊されることを防止できる圧粉ステータへの樹脂成型方法、及びこの樹脂成型方法を実施する樹脂成型装置を提供することにある。
【０００４】
【課題を解決するための手段】
（請求項１の発明）
金属粉を圧縮して固めた円筒型を有し、その円筒型の一端面側に環状の空洞部が凹設されたステータ本体と、空洞部に挿入されるコイルとを有する圧粉ステータに対し、空洞部に樹脂を注入してコイルの周囲を樹脂成型する樹脂成型方法であって、弾力を発生するとともに、ステータ本体の他端面を押圧する押圧手段を備え、押圧手段によって、ステータ本体の他端面に対しステータ本体の一端面側への押圧力が作用し、ステータ本体の一端面全体と他端面全体とが両側から挟み込まれた状態で樹脂成型を実施することを特徴とする。
この方法によれば、樹脂成型時にステータ本体の一端面が押さえ付けられることにより、樹脂の成型圧力でステータ本体が径方向に変形する（外側に広がる）ことを防止できる。
【０００５】
（請求項２の発明）
請求項１に記載した樹脂成型方法を実施する樹脂成型装置であって、
樹脂注入通路が設けられ、この樹脂注入通路の出口が自身の下端面に開口する上型を有し、空洞部が開口するステータ本体の一端面に上型の下端面を当接させ、両端面間に押さえ力を発生させた状態で、樹脂注入通路から空洞部へ樹脂を注入する。
この構成によれば、樹脂成型時にステータ本体の一端面と上型の下端面との間に摩擦力が働くため、樹脂の成型圧力でステータ本体が径方向に変形する（外側に広がる）ことを防止できる。
【０００６】
（請求項３の発明）
請求項２に記載した樹脂成型装置において、
ステータ本体の他端面に対向して可動し、上型との間にステータ本体を挟み込む押さえ型と、この押さえ型を押圧して、上型の下端面とステータ本体の一端面との間に押さえ力を発生させる押圧手段とを有していることを特徴とする。
この構成では、押さえ型が可動するので、ステータ本体の寸法バラツキを吸収でき、上型の下端面とステータ本体の一端面との間に過大な押さえ力が発生することを防止できる。
【０００７】
（請求項４の発明）
請求項２に記載した樹脂成型装置において、
上型との間にステータ本体を挟み込む下型を有し、この下型に対し上型を所定量だけ押し込んで、ステータ本体を押さえ付けた状態で樹脂成型を実施することを特徴とする。
この構成によれば、上型を押し込んでステータ本体を押さえ付けることにより、樹脂成型時にステータ本体の一端面と上型の下端面との間に摩擦力が働くため、樹脂の成型圧力でステータ本体が径方向に変形する（外側に広がる）ことを防止できる。
【０００９】
【発明の実施の形態】
次に、本発明の実施形態を図面に基づいて説明する。
（第１実施例）
図１は樹脂成型装置の断面図、図２はステータ本体の断面図である。
本実施例の圧粉ステータ１は、例えば電磁石に使用されるもので、ステータ本体２に設けられる空洞部２ａにコイル３を挿入し、そのコイル３を樹脂成型したものである。
ステータ本体２は、図２に示す様に、鉄粉をリン酸塩等の絶縁材料と混合して円筒型に圧縮成型したもので、その円筒型の一端面２ｂ側に環状の空洞部２ａが凹設され、その空洞部２ａより内周側に内側磁極部２ｃが形成され、空洞部２ａより外周側に外側磁極部２ｄが形成される。
【００１０】
以下に、ステータ本体２の空洞部２ａに挿入したコイル３を樹脂成型するための樹脂成型装置と樹脂成型方法について説明する。
樹脂成型装置は、図１に示す様に、下型４と上型５、及び下型４に格納された押さえ型６とバネ７（本発明の押圧手段）等より構成される。
下型４は、円筒形に凹設された挿入空間４ａを有し、この挿入空間４ａの内部に押さえ型６とバネ７を格納している。
【００１１】
上型５には、樹脂注入通路５ａが設けられ、この樹脂注入通路５ａの出口が自身の下端面５ｂに開口している。
押さえ型６は、挿入空間４ａに挿入されるステータ本体２の他端面２ｅを受けて、上型５との間にステータ本体２を挟み込んでいる。この押さえ型６は、挿入空間４ａを上下方向に可動する。
バネ７は、押さえ型６を上方へ押圧して、上型５の下端面５ｂとステータ本体２の一端面２ｂとの間に押さえ力を発生させる。なお、本発明の押圧手段は、バネ７以外にも、弾力を発生する弾性材料（例えばゴム材）を使用することもできる。
【００１２】
次に、樹脂成型方法について説明する。
先ず、ステータ本体２（空洞部２ａにコイル３が挿入されている）を下型４の挿入空間４ａに挿入する。この時、ステータ本体２は、自身の一端面２ｂ（空洞部２ａを有する端面）側を挿入空間４ａの上方へ向けて挿入し、その一端面２ｂが下型４の上端面４ｂより若干上方へ突き出た状態で押さえ型６に支持される。
【００１３】
続いて、下型４の上に上型５をセットして、下型４の上端面４ｂと上型５の下端面５ｂとを密着させる。この時、上型５のセット荷重により、ステータ本体２が挿入空間４ａの内部へ押し込まれ、ステータ本体２の一端面２ｂと下型４の上端面４ｂとが同一高さとなる。これにより、バネ７の押圧力が押さえ型６を介してステータ本体２に働くため、ステータ本体２の一端面２ｂと上型５の下端面５ｂとの間に押さえ力が発生する。
続いて、上型５の樹脂注入通路５ａよりステータ本体２の空洞部２ａに樹脂８を注入して、コイル３の周囲に充填する。この時、空洞部２ａの深部まで樹脂８が流れ込む様に、所定の成型圧力が付与される。
【００１４】
（第１実施例の効果）
本実施例の樹脂成型方法では、バネ７の押圧力によってステータ本体２の一端面２ｂと上型５の下端面５ｂとの間に押さえ力が発生し、その押さえ力によって両端面２ｂ、５ｂ間に摩擦力が働くため、樹脂８の成型圧力でステータ本体２が径方向に変形する（特にステータ本体２の外側磁極部２ｄが径方向外側に広がる）ことを防止できる。その結果、樹脂成型時に所定の成型圧力を付与してもステータ本体２が変形して破壊されることはなく、且つ空洞部２ａの深部まで樹脂８が流れ込んでコイル３の周囲に充填されるので、確実にコイル３を樹脂成型することができる。
【００１５】
（参考例）
図３は樹脂成型装置の断面図である。
本参考例の樹脂成型装置は、下型４と上型５だけで構成される（第１実施例で説明した押さえ型６とバネ７を使用しない）場合の一例である。
下型４は、図３に示す様に、挿入空間４ａの深さＤがステータ本体２の高さＨより若干小さく設計されている。従って、ステータ本体２は、挿入空間４ａに挿入されると、自身の他端面２ｅが挿入空間４ａの底面に支持され、且つ自身の一端面２ｂ側が挿入空間４ａの開口面（下型４の上端面４ｂ）より若干突き出ている。
【００１６】
上型５は、第１実施例と同じく樹脂注入通路５ａを有し、この樹脂注入通路５ａの出口が自身の下端面５ｂに開口している。
下型４の挿入空間４ａにステータ本体２を挿入した後、上型５をセットする時に、上型５の下端面５ｂが下型４の上端面４ｂに密着するまでステータ本体２を押し込む。つまり、上型５の押し込み量は、下型４の上端面４ｂ（本発明の規制面）によって規制される。
その後、第１実施例と同様に、樹脂注入通路５ａを通じて空洞部２ａに樹脂８を注入し、コイル３の周囲に充填する。
【００１７】
本参考例の方法においても、上型５を押し込んで下型４との間にステータ本体２を挟み込み、ステータ本体２の一端面２ｂと上型５の下端面５ｂとの間に所定の押さえ力を発生させることにより、樹脂の成型圧力でステータ本体２が径方向に変形する（特に外側磁極部２ｄが径方向外側に広がる）ことを防止できる。
なお、ステータ本体２の高さＨは、上型５を押し付けた時に、その圧縮力で破壊しないように、寸法公差が設定されることは言うまでもない。
【図面の簡単な説明】
【図１】樹脂成型装置の断面図(a) とＡ−Ａ断面図(b) である（第１実施例）。
【図２】ステータ本体の断面図である。
【図３】 樹脂成型装置の断面図である（参考例）。
【符号の説明】
１ 圧粉ステータ
２ ステータ本体
２ａ 空洞部
２ｂ ステータ本体の一端面
３ コイル
４ 下型
４ｂ 下型の上端面（規制面）
５ 上型
５ａ 樹脂注入通路
６ 押さえ型
７ バネ（押圧手段）
８ 樹脂[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a resin molding apparatus and a resin molding method for resin molding around a coil inserted in a cavity of a stator body.
[0002]
[Prior art]
Conventionally, for example, a dust stator used for an electromagnet is known. This dust stator is formed by compression molding iron powder whose surface is covered with an insulating film such as phosphate in order to reduce iron loss.
On the other hand, there is a method of fixing the coil to the stator in order to prevent the coil from being disconnected or short-circuited due to vibration or impact force. As the fixing method, an adhesive, potting, molding with a resin (epoxy resin), or the like is performed. In particular, resin molding is suitable for mass production.
[0003]
[Problems to be solved by the invention]
However, if the fixing method by resin molding is applied to the above-mentioned dust stator, the dust stator may be broken by the molding pressure of the resin. On the other hand, if the molding pressure is reduced, insufficient filling of the resin occurs, and the wrapping of the resin into the stator deteriorates, so that the coil cannot be reliably fixed. For this reason, it has been extremely difficult to determine the molding conditions in the conventional resin molding method.
The present invention has been made on the basis of the above circumstances, and its purpose is to form a resin in a dust stator that can prevent the dust stator from being destroyed by molding pressure without causing insufficient resin filling. The present invention provides a method and a resin molding apparatus for performing the resin molding method.
[0004]
[Means for Solving the Problems]
(Invention of Claim 1)
For a dust compact stator having a cylindrical shape in which metal powder is compressed and hardened, and having a stator body in which an annular cavity is recessed on one end face side of the cylinder, and a coil inserted into the cavity A resin molding method in which resin is injected into the cavity and resin is molded around the coil, and includes a pressing means that generates elasticity and presses the other end surface of the stator body. A pressing force to one end surface side of the stator body acts on the end surface, and resin molding is performed in a state where the entire one end surface and the other end surface of the stator body are sandwiched from both sides.
According to this method, it is possible to prevent the stator body from being deformed in the radial direction (spread outward) by the molding pressure of the resin by pressing one end surface of the stator body during resin molding.
[0005]
(Invention of Claim 2)
A resin molding apparatus for performing the resin molding method according to claim 1,
A resin injection passage is provided, and the outlet of the resin injection passage has an upper die that opens to its lower end surface. The lower end surface of the upper die is brought into contact with one end surface of the stator body where the cavity portion opens, and both end surfaces The resin is injected into the cavity from the resin injection passage with a pressing force generated therebetween.
According to this configuration, since a frictional force acts between one end surface of the stator body and the lower end surface of the upper mold during resin molding, the stator body is deformed in the radial direction (spread outward) by the resin molding pressure. Can be prevented.
[0006]
(Invention of Claim 3)
In the resin molding apparatus according to claim 2,
A pressing mold that moves opposite to the other end surface of the stator body and sandwiches the stator body with the upper mold, and presses the pressing mold between the lower end surface of the upper mold and one end surface of the stator main body. And pressing means for generating a force.
In this configuration, since the pressing die is movable, the dimensional variation of the stator body can be absorbed, and an excessive pressing force can be prevented from being generated between the lower end surface of the upper die and the one end surface of the stator body.
[0007]
(Invention of Claim 4)
In the resin molding apparatus according to claim 2,
A lower mold sandwiching the stator main body between the upper mold and the upper mold is pushed into the lower mold by a predetermined amount, and the resin molding is performed with the stator main body pressed.
According to this configuration, by pressing the upper die and pressing the stator body, a frictional force acts between the one end surface of the stator body and the lower end surface of the upper die during resin molding. Can be prevented from deforming in the radial direction (spreading outward).
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
FIG. 1 is a sectional view of a resin molding apparatus, and FIG. 2 is a sectional view of a stator body.
The dust stator 1 according to the present embodiment is used for an electromagnet, for example. The coil 3 is inserted into a cavity 2a provided in the stator body 2, and the coil 3 is resin-molded.
As shown in FIG. 2, the stator main body 2 is formed by mixing iron powder with an insulating material such as phosphate and compression-molding it into a cylindrical shape. An annular hollow portion 2a is formed on one end surface 2b side of the cylindrical shape. The inner magnetic pole portion 2c is formed on the inner peripheral side of the hollow portion 2a, and the outer magnetic pole portion 2d is formed on the outer peripheral side of the hollow portion 2a.
[0010]
Below, the resin molding apparatus and resin molding method for resin-molding the coil 3 inserted in the cavity 2a of the stator body 2 will be described.
As shown in FIG. 1, the resin molding apparatus includes a lower mold 4 and an upper mold 5, a pressing mold 6 stored in the lower mold 4, a spring 7 (pressing means of the present invention), and the like.
The lower mold 4 has an insertion space 4a recessed in a cylindrical shape, and a pressing mold 6 and a spring 7 are stored in the insertion space 4a.
[0011]
The upper mold 5 is provided with a resin injection passage 5a, and an outlet of the resin injection passage 5a is opened to the lower end surface 5b of itself.
The holding die 6 receives the other end surface 2e of the stator body 2 inserted into the insertion space 4a and sandwiches the stator body 2 between the upper die 5 and the holding die 6. The presser mold 6 is movable in the insertion space 4a in the vertical direction.
The spring 7 presses the pressing die 6 upward to generate a pressing force between the lower end surface 5 b of the upper die 5 and the one end surface 2 b of the stator body 2. The pressing means of the present invention can use an elastic material (for example, a rubber material) that generates elasticity in addition to the spring 7.
[0012]
Next, a resin molding method will be described.
First, the stator body 2 (the coil 3 is inserted into the cavity 2 a) is inserted into the insertion space 4 a of the lower mold 4. At this time, the stator body 2 is inserted with its one end face 2b (end face having the cavity 2a) side upward of the insertion space 4a, and its one end face 2b is slightly above the upper end face 4b of the lower mold 4. It is supported by the pressing die 6 in a protruding state.
[0013]
Subsequently, the upper mold 5 is set on the lower mold 4, and the upper end surface 4 b of the lower mold 4 and the lower end surface 5 b of the upper mold 5 are brought into close contact with each other. At this time, the stator body 2 is pushed into the insertion space 4a by the set load of the upper die 5, and the one end surface 2b of the stator body 2 and the upper end surface 4b of the lower die 4 have the same height. As a result, the pressing force of the spring 7 acts on the stator body 2 via the pressing die 6, and a pressing force is generated between the one end surface 2 b of the stator body 2 and the lower end surface 5 b of the upper die 5.
Subsequently, the resin 8 is injected into the cavity 2 a of the stator body 2 from the resin injection passage 5 a of the upper mold 5 and filled around the coil 3. At this time, a predetermined molding pressure is applied so that the resin 8 flows into the deep part of the cavity 2a.
[0014]
(Effects of the first embodiment)
In the resin molding method of the present embodiment, a pressing force is generated between the one end surface 2b of the stator body 2 and the lower end surface 5b of the upper mold 5 by the pressing force of the spring 7, and the pressing force between the both end surfaces 2b and 5b is generated. Therefore, the stator body 2 can be prevented from being deformed in the radial direction by the molding pressure of the resin 8 (particularly, the outer magnetic pole portion 2d of the stator body 2 spreads radially outward). As a result, even if a predetermined molding pressure is applied at the time of resin molding, the stator body 2 is not deformed and destroyed, and the resin 8 flows into the deep part of the cavity 2a and fills around the coil 3. The coil 3 can be surely resin-molded.
[0015]
( Reference example)
FIG. 3 is a sectional view of the resin molding apparatus.
The resin molding apparatus of this reference example is an example in the case of being configured only by the lower mold 4 and the upper mold 5 (without using the pressing mold 6 and the spring 7 described in the first embodiment).
As shown in FIG. 3, the lower mold 4 is designed such that the depth D of the insertion space 4 a is slightly smaller than the height H of the stator body 2. Therefore, when the stator body 2 is inserted into the insertion space 4a, the other end surface 2e of the stator body 2 is supported by the bottom surface of the insertion space 4a, and the one end surface 2b side of the stator body 2 is the opening surface of the insertion space 4a (the upper surface of the lower mold 4). It protrudes slightly from the end face 4b).
[0016]
The upper mold 5 has a resin injection passage 5a as in the first embodiment, and the outlet of the resin injection passage 5a is open to its lower end surface 5b.
After the stator body 2 is inserted into the insertion space 4 a of the lower mold 4, when the upper mold 5 is set, the stator body 2 is pushed in until the lower end surface 5 b of the upper mold 5 is in close contact with the upper end surface 4 b of the lower mold 4. That is, the pushing amount of the upper mold 5 is regulated by the upper end surface 4b of the lower mold 4 (regulation surface of the present invention).
Thereafter, as in the first embodiment, the resin 8 is injected into the cavity 2a through the resin injection passage 5a and filled around the coil 3.
[0017]
Also in the method of this reference example, the upper die 5 is pushed in and the stator body 2 is sandwiched between the lower die 4 and a predetermined pressing force is applied between the one end surface 2b of the stator body 2 and the lower end surface 5b of the upper die 5. By generating the above, it is possible to prevent the stator body 2 from being deformed in the radial direction by the molding pressure of the resin (particularly, the outer magnetic pole portion 2d spreads outward in the radial direction).
Needless to say, a dimensional tolerance is set for the height H of the stator main body 2 so that the upper die 5 is not broken by the compressive force when the upper die 5 is pressed.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view (a) and a cross-sectional view AA (b) of a resin molding apparatus (first embodiment).
FIG. 2 is a cross-sectional view of a stator body.
FIG. 3 is a cross-sectional view of a resin molding apparatus ( reference example).
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Powder stator 2 Stator main body 2a Cavity part 2b One end surface of a stator main body 3 Coil 4 Lower mold | type 4b Upper end surface (regulation surface) of lower mold | type
5 Upper mold 5a Resin injection passage 6 Holding mold 7 Spring (pressing means)
8 Resin

Claims (4)

金属粉を圧縮して固めた円筒型を有し、その円筒型の一端面側に環状の空洞部が凹設されたステータ本体と、前記空洞部に挿入されるコイルとを有する圧粉ステータに対し、前記空洞部に樹脂を注入して前記コイルの周囲を樹脂成型する樹脂成型方法であって、
弾力を発生するとともに、前記ステータ本体の他端面を押圧する押圧手段を備え、
前記押圧手段によって、前記ステータ本体の他端面に対し前記ステータ本体の一端面側への押圧力が作用し、前記ステータ本体の一端面全体と他端面全体とが両側から挟み込まれた状態で樹脂成型を実施することを特徴とする圧粉ステータへの樹脂成型方法。A compacted stator having a cylindrical body in which metal powder is compressed and hardened, and having a stator body in which an annular cavity is recessed on one end surface side of the cylinder, and a coil inserted into the cavity. On the other hand, a resin molding method in which resin is injected into the hollow portion and resin is molded around the coil,
A pressing means for generating elasticity and pressing the other end surface of the stator body;
The pressing means applies a pressing force toward the one end surface side of the stator body to the other end surface of the stator body, and the resin molding is performed with the one end surface and the other end surface of the stator body being sandwiched from both sides. The resin molding method to the compacting stator characterized by implementing this. 請求項１に記載した樹脂成型方法を実施する樹脂成型装置であって、
樹脂注入通路が設けられ、この樹脂注入通路の出口が自身の下端面に開口する上型を有し、
前記空洞部が開口する前記ステータ本体の一端面に前記上型の下端面を当接させ、両端面間に押さえ力を発生させた状態で、前記樹脂注入通路から前記空洞部へ樹脂を注入する樹脂成型装置。A resin molding apparatus for performing the resin molding method according to claim 1,
A resin injection passage is provided, and the outlet of the resin injection passage has an upper mold that opens to its lower end surface.
The resin is injected from the resin injection passage into the cavity in a state where the lower end surface of the upper mold is brought into contact with one end surface of the stator main body where the cavity is open and a pressing force is generated between both end surfaces. Resin molding equipment. 請求項２に記載した樹脂成型装置において、
前記ステータ本体の他端面に対向して可動し、前記上型との間に前記ステータ本体を挟み込む押さえ型と、
この押さえ型を押圧して、前記上型の下端面と前記ステータ本体の一端面との間に押さえ力を発生させる前記押圧手段とを有していることを特徴とする樹脂成型装置。In the resin molding apparatus according to claim 2,
A pressing mold that is movable opposite to the other end surface of the stator body and sandwiches the stator body between the upper mold,
A resin molding apparatus comprising: a pressing unit that presses the pressing mold to generate a pressing force between a lower end surface of the upper mold and one end surface of the stator body. 請求項２に記載した樹脂成型装置において、
前記上型との間に前記ステータ本体を挟み込む下型を有し、
この下型に対し前記上型を所定量だけ押し込んで、前記ステータ本体を押さえ付けた状態で樹脂成型を実施することを特徴とする樹脂成型装置。 In the resin molding apparatus according to claim 2,
A lower mold sandwiching the stator body between the upper mold and the upper mold;
A resin molding apparatus, wherein the upper mold is pushed into the lower mold by a predetermined amount to perform resin molding in a state where the stator body is pressed .
JP2002152085A 2002-05-27 2002-05-27 Resin molding method and apparatus for compacting stator Expired - Fee Related JP4092952B2 (en)

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