JP4942802B2 - Electric motor rotor, electric motor, air conditioner, and electric motor manufacturing method - Google Patents

Description

  The present invention relates to an electric motor rotor, an electric motor, an air conditioner, and an electric motor that are formed by integrally forming a resin magnet on the outer periphery of a back yoke obtained by molding a thermoplastic resin containing soft magnetic material or ferrite. It relates to a manufacturing method.

  Conventionally, a rotor using a bond magnet, in which a molded body has a laminated structure of at least two layers, and a rare earth layer made of a resin composite material containing rare earth magnetic powder is installed as an outermost layer, and the inner side of the rare earth layer An electric motor rotor is proposed in which an intermediate layer made of at least one ferromagnetic composite material or soft magnetic resin composite material is provided (see, for example, Patent Document 1).

  In addition, a rotor magnet having a shaft, a back yoke formed of a thermoplastic resin containing soft magnetic material or ferrite, a resin magnet portion disposed on the outer periphery of the back yoke, and a position detection magnet are thermoplastic. In a rotor of an electric motor formed integrally with resin, a back yoke has a plurality of recesses on one axial end face, and a pedestal that serves as a positioning magnet for position detection on the other axial end face. A rotor of an electric motor in which a rotor magnet and a position detection magnet are integrally formed of a thermoplastic resin so as to embed a recess and a base of a back yoke has been proposed (for example, see Patent Document 2). .

JP 2005-151757 A JP 2007-221866 A

  The portion that does not become a product between the resin magnet portion and the resin magnet injection portion of the mold is referred to as a “runner”.

  For example, a case is assumed in which only a resin magnet is used to form a positioning projection, a position detection magnet holding projection, and a pedestal for positioning in the circumferential direction when being molded integrally with the shaft.

  When the runner is cut off, the resin magnet portion formed on the outer periphery of the yoke is connected only by the resin injection portion to the resin magnet portion, which causes a problem that the strength is weak.

  The present invention has been made to solve the above problems, and is formed by integrally molding a resin magnet portion on the outer periphery of a yoke obtained by molding a thermoplastic resin containing a soft magnetic material or ferrite. The rotor of the motor, the motor, the air conditioner, and the motor that can manufacture the pedestal on which the position detection magnet is installed and the position detection magnet holding projection that holds the outer periphery of the position detection magnet to the rotor magnet with high quality. A manufacturing method is provided.

The rotor of the electric motor according to this invention is
A substantially cylindrical yoke molded from a thermoplastic resin containing soft magnetic material or ferrite;
A resin magnet part integrally formed by a resin magnet on the outer periphery of the yoke;
A position detection magnet provided in the vicinity of one end of the resin magnet in the axial direction;
The yoke is formed at the axial end of the position detection magnet, and has a pair of protrusions and an opening formed between the pair of protrusions, and the position detection magnet is installed at a predetermined distance. A pedestal, and
The resin magnet portion protrudes axially outward from the axial end surface on the yoke position detection magnet side, and is a donut-shaped runner positioned inside the yoke, and radially extends radially outward from the donut-shaped runner. From the rib-shaped runner extending in the circumferential width, resin magnets are supplied and molded,
The rib-shaped runner uses the opening of the pedestal as a path for supplying the resin magnet, and the rib-shaped runner is integrated with the pedestal to form the pedestal.

  In the rotor of the electric motor according to the present invention, the rib-shaped runner uses the opening of the pedestal as a path for supplying the resin magnet, and the rib-shaped runner is integrated with the pedestal to form the pedestal portion. By improving the strength of the integrated position detection magnet holding projection, it is possible to improve manufacturing quality.

It is a figure which shows Embodiment 1, and sectional drawing (AA sectional drawing of FIG. 2) of the rotor 100 of an electric motor. FIG. 4 is a diagram showing the first embodiment, and is a side view on the opposite side of the position detection magnet 11 of FIG. 1. FIG. 3 shows the first embodiment, and is a side view on the position detection magnet 11 side of FIG. 1. FIG. 5 shows the first embodiment, and is a perspective view of the rotor 100 of the electric motor as viewed from the position detection magnet 11 side. FIG. 6 is a diagram showing the first embodiment, and is an enlarged view of the vicinity of an end surface of the gate detection portion 32 on the position detection magnet 11 side. FIG. 5 is a diagram showing the first embodiment, and is an enlarged view in the vicinity of a gate protrusion 32 in FIG. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of a rotor 200 of a modified example when viewed from the position detection magnet 11 side. FIG. 5 shows the first embodiment, and is an enlarged view of the vicinity of an end surface of the gate convex portion 40 on the position detection magnet 11 side. 4A and 4B are diagrams showing the first embodiment; FIG. 4A is a side view of the yoke 4 as viewed from the concave portion 6 side, FIG. 4B is a sectional view taken along the line BB in FIG. 11 is a side view as seen from the 11 side). FIG. 5 shows the first embodiment, and shows a state in which the yoke 4 is anisotropically oriented with respect to the polar direction by an outer orientation magnetic field. FIG. 9 shows the first embodiment and is an enlarged view of FIG. FIG. 9 shows the first embodiment and is an enlarged view of FIG. FIG. 4 is a diagram showing the first embodiment, and is a perspective view of the yoke 4 viewed from a pedestal 34; FIG. 3 is a diagram showing the first embodiment, and is a perspective view of the yoke 4 as seen from a recess 6; FIG. 15 shows the first embodiment and is a partially enlarged view of FIG. 14. FIG. 9 shows the first embodiment, and is a partially enlarged view of FIG. FIG. 9 shows the first embodiment and is an enlarged view of FIG. The figure which shows Embodiment 1, The figure which shows the rotor magnet 3 before excising a runner ((a) is the side view seen from the recessed part 6 side, (b) is CC sectional drawing of (a), (C) is the side view seen from the position detection magnet 11 side). FIG. 5 shows the first embodiment, and shows a state in which the rotor magnet 3 is oriented anisotropically with respect to the polar direction by an outer orientation magnetic field. FIG. 18 shows the first embodiment and is an enlarged view of FIG. FIG. 18 shows the first embodiment and is an enlarged view of FIG. FIG. 5 shows the first embodiment, and is a perspective view of the rotor magnet 3 before the runner is cut from the runner side. FIG. 23 shows the first embodiment and is an enlarged perspective view near the rib-like runner 35 of FIG. 22. FIG. 5 shows the first embodiment, and is a partial plan view showing the flow of the resin magnet when the rotor magnet 3 is molded. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of the rotor magnet 3 with the runner cut away as viewed from the pedestal 50 side. FIG. 5 shows the first embodiment, and is a perspective view of the rotor magnet 3 as viewed from the concave portion 6 side. 5A and 5B are diagrams showing the first embodiment of the yoke 104 (a) is a side view seen from the concave portion 6 side, (b) is a sectional view taken along the line DD in FIG. 6 is a side view seen from the opposite side of FIG. FIG. 28 shows the first embodiment and is an enlarged view of FIG. FIG. 5 shows the first embodiment, and is a perspective view of the yoke 104 as viewed from the opposite side of the recess 6. FIG. 5 shows the first embodiment, and shows a rotor magnet 103 of a modified example before cutting off the runner ((a) is a side view seen from the concave portion 6 side, and (b) is an EE of (a). Sectional view, (c) is a side view seen from the opposite side of the recess 6). FIG. 32 shows the first embodiment and is an enlarged view of FIG. FIG. 32 shows the first embodiment and is an enlarged view of FIG. FIG. 10 is a partial plan view showing the flow of the resin magnet when the rotor magnet 103 according to the modification is molded, showing the first embodiment. FIG. 5 shows the first embodiment, and is a partial perspective view of a modified rotor magnet 103 before cutting off the runner from the runner side. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of a rotor magnet 103 of a modified example in which a runner is cut from the opposite side of the recess 6; FIG. 4 is a diagram showing the first embodiment, and is a perspective view of a position detection magnet 11. FIG. 3 is a diagram illustrating the first embodiment and is a diagram illustrating a position detection magnet 11 ((a) is a plan view and (b) is a cross-sectional view taken along line FF in (a)). FIG. 5 shows the first embodiment and is a partially enlarged view of the position detection magnet 11. FIG. 5 shows the first embodiment, and is a perspective view of a stator 300 of the electric motor. FIG. 5 shows the first embodiment, and is a perspective view showing a state where the stator 300 of the motor is reversely bent and wound. FIG. 5 shows the first embodiment, and is a perspective view of a stator core 301 (band shape). FIG. 5 shows the first embodiment, and is a perspective view showing a state in which an insulating portion 303 is applied to a stator core 301 (band shape) and terminals are attached. FIG. 3 shows the first embodiment, and is a cross-sectional view of a 12-slot / 10-pole synchronous motor using the stator 300 of the motor. FIG. 3 shows the first embodiment, and is a connection diagram of stator windings of a stator 300 of the electric motor. FIG. 5 shows the first embodiment and is a development view showing a method of connecting the stator windings of the stator 300 of the electric motor. FIG. 5 shows the first embodiment and shows the electric motor 400. FIG. 5 shows the first embodiment, and shows a manufacturing process of the electric motor 400. FIG. 5 shows the second embodiment and shows the configuration of an air conditioner 500. FIG.

Embodiment 1 FIG.
The present embodiment relates to a rotor of an electric motor formed by integrally molding a resin magnet part on the outer periphery of a yoke obtained by molding a thermoplastic resin (described later) containing a soft magnetic material or ferrite. It is.

  1 to 47 show the first embodiment. FIG. 1 is a sectional view of the rotor 100 of the electric motor (AA sectional view of FIG. 2), and FIG. 2 is the opposite of the position detecting magnet 11 of FIG. 3 is a side view of the position detection magnet 11 side of FIG. 1, FIG. 4 is a perspective view of the rotor 100 of the motor viewed from the position detection magnet 11 side, and FIG. FIG. 6 is an enlarged view of the vicinity of the end surface of the position detection magnet 11, FIG. 6 is an enlarged view of the vicinity of the gate protrusion 32 of FIG. 1, and FIG. 7 is a perspective view of the rotor 200 of the modified motor as viewed from the position detection magnet 11 side. 8 is an enlarged view of the vicinity of the end face of the position detection magnet 11 of the gate convex portion 40, FIG. 9 is a view showing the yoke 4 ((a) is a side view seen from the concave portion 6 side, and (b) is (a). FIG. 10 is a cross-sectional view taken along the line BB of FIG. FIG. 11 is a diagram showing a state in which the magnet 4 is anisotropically oriented with respect to the polar direction by the outer orientation magnetic field, FIG. 11 is an enlarged view of FIG. 9A, FIG. 12 is an enlarged view of FIG. FIG. 14 is a perspective view of the yoke 4 viewed from the recess 6, FIG. 15 is a partially enlarged view of FIG. 14, and FIG. 16 is a partially enlarged view of FIG. 17 is an enlarged view of FIG. 9 (b), FIG. 18 is a view showing the rotor magnet 3 before cutting off the runner ((a) is a side view as seen from the concave portion 6 side, and (b) is C in FIG. 9 (a)). -C sectional view, (c) is a side view seen from the position detecting magnet 11 side), and FIG. 19 is a diagram showing a state in which the rotor magnet 3 is anisotropically oriented with respect to the polar direction by the outer orientation magnetic field. 20 is an enlarged view of FIG. 18B, FIG. 21 is an enlarged view of FIG. 18C, and FIG. 22 is a rotor magnet before cutting off the runner. FIG. 23 is an enlarged perspective view of the vicinity of the rib-like runner 35 in FIG. 22, FIG. 24 is a partial plan view showing the flow of the resin magnet when the rotor magnet 3 is molded, and FIG. The perspective view which looked at the rotor magnet 3 which cut off the runner from the base part 50 side, FIG. 26 is the perspective view which looked at the rotor magnet 3 from the recessed part 6 side, FIG. 27 is the figure which shows the yoke 104 of a modification ((a ) Is a side view as viewed from the side of the recess 6, (b) is a sectional view taken along the line DD of (a), (c) is a side view as viewed from the opposite side of the recess 6), and FIG. FIG. 29 is an enlarged view, FIG. 29 is a perspective view of the yoke 104 as viewed from the opposite side of the recess 6, and FIG. 30 is a diagram showing a modified rotor magnet 103 before cutting off the runner ((a) is viewed from the recess 6 side. Side view, (b) is an EE cross-sectional view of (a), and (c) is viewed from the opposite side of the recess 6. 31 is an enlarged view of FIG. 30 (b), FIG. 32 is an enlarged view of FIG. 30 (c), and FIG. 33 is a partial plan view showing the flow of the resin magnet when the rotor magnet 103 of the modification is molded. 34 and FIG. 34 are partial perspective views of the modified rotor magnet 103 before the runner is cut from the runner side, and FIG. 35 is a view of the modified rotor magnet 103 with the runner removed from the opposite side of the recess 6. 36 is a perspective view of the position detecting magnet 11, FIG. 37 is a view showing the position detecting magnet 11 ((a) is a plan view, (b) is a cross-sectional view taken along line EE of (a)), 38 is a partially enlarged view of the position detection magnet 11, FIG. 39 is a perspective view of the stator 300 of the electric motor, FIG. 40 is a perspective view showing a state where the stator 300 of the electric motor is reversely bent and wound, and FIG. FIG. 42 is a perspective view of the stator core 301 (strip shape). FIG. 43 is a sectional view of a 12-slot / 10-pole synchronous motor using the stator 300 of the motor, and FIG. 44 is a sectional view of the motor. FIG. 45 is a development view showing a method of connecting the stator windings of the stator 300 of the motor, FIG. 46 is a diagram showing the motor 400, and FIG. 47 is a manufacturing process of the motor 400. FIG.

  The rotor 100 of the electric motor shown in FIGS. 1 to 3 has a shaft 1, a rotor magnet 3, and a position detection magnet 11 set in a resin mold, and is made of thermoplastic such as PBT (polybutylene terephthalate). The resin 17 is molded by being injected into a resin molding die.

  Thereafter, bearings 410 (see FIG. 46, for example, ball bearings) are assembled on both sides of the rotor magnet 3.

  The rotor 100 of the electric motor will be described as an example having 10 magnetic poles. The number of magnetic poles is not limited to 10 but may be any even number.

  The rotor 100 of the electric motor is combined with a stator, which will be described later, to constitute, for example, a brushless DC motor.

  The bearing 410 (refer to FIG. 46) abuts on a surface 19 that is formed on the outer periphery of the shaft 1 by the thermoplastic resin 17 and stops the bearing of the cylindrical shaft outer peripheral cylindrical resin portion 31.

  A knurled eye 2 is formed on a portion of the thermoplastic resin 17 of the shaft 1 that is inscribed in the cylindrical outer peripheral resin portion 31. Generally called knurling in Japan, it has a jagged groove shape mainly applied to the outer periphery of a round object (here, shaft 1), and functions as a slipper. For example, in an invisible part, the friction coefficient is mainly increased at the connection part of the press-fitting part (insert), or the jaggedness is eaten into the inner diameter, and the stopper is used as a detent.

  Details of the rotor magnet 3 and the position detection magnet 11 will be described later. Here, first, the molding of the rotor 100 of the electric motor by the thermoplastic resin 17 such as PBT (polybutylene terephthalate) will be described.

  On the lower mold (not shown) of the mold installed in the vertical molding machine, the rotor magnet 3 is placed on the side of the yoke 4 with the concave portion 6 on the axial end face (the axial end face on which the position detecting magnet 11 is attached). Inserted from the opposite axial end face (left side in FIG. 1), the rotor magnet 3 is incorporated into the lower mold of the mold.

  The lower mold of the mold is inserted into the mold of the shaft 1 fitted into a tapered notch 7 (see FIGS. 1, 2, and 9A) provided on the axial end surface of the yoke 4 on the recess 6 side. A convex portion that is coaxial with the portion. When the mold is tightened, the convex part of the lower mold (core part) of the mold is pressed against the tapered notch 7 so that the outer periphery of the resin magnet part 5 and the shaft 1 are coaxial.

  A tapered notch 7 provided on the end surface in the axial direction of the yoke 4 on the recess 6 side is provided corresponding to (opposite) the magnetic pole. Accordingly, ten notches 7 are formed at substantially equal intervals in the circumferential direction (see FIG. 9A). The reason why the notches 7 are provided so as to correspond to (be opposed to) the magnetic poles is to make the magnetic paths for the magnetic poles of the yoke 4 substantially the same.

  In this case, the convex part of the lower mold of the mold fitted in the tapered notch 7 (see FIGS. 1, 2 and 9A) provided on the axial end surface of the yoke 4 on the concave part 6 side is There are five. The yoke 4 is fitted into five of the ten tapered notches 7 provided on the axial end surface on the concave portion 6 side (substantially equidistant in the circumferential direction).

  When the rotor magnet 3 is inserted into the lower mold of the mold from the axial end surface of the yoke 4 on the side provided with the recess 6 and the rotor magnet 3 is assembled into the lower mold of the mold, the five protrusions of the lower mold Since any five of the ten notches 7 of the yoke 4 may be fitted into the part, there is an effect that the workability is improved as compared with the case of five notches 7.

  Further, the shaft 1 provided with a knurled eye 2 that serves as an anti-rotation of the shaft outer peripheral cylindrical resin portion 31 is set at the center of the lower rotor magnet 3 during molding in which the thermoplastic resin 17 is filled.

  Further, after the position detection magnet 11 (see FIGS. 36 to 38) is installed inside the pedestal 50 (see FIG. 25) of the rotor magnet 3, the mold is closed and the thermoplastic resin 17 such as PBT is closed. Is molded by injection.

  Although the position detection magnet 11 will be described in detail later, the position detection magnet 11 includes steps 12 (see FIGS. 36 to 38) at both axial end portions on the inner diameter side, and the thickness direction (see FIG. 38). It is symmetrical.

  When the position detection magnet 11 is attached to the rotor magnet 3, a thermoplastic resin 17 such as PBT is formed on the step 12 (see FIGS. 36 to 38) on the axial end side (outside) of the rotor magnet 3. To prevent the position detecting magnet from coming off in the axial direction.

  If the position detection magnet 11 is provided with steps 12 at both ends in the thickness direction, the position detection magnet 11 can be mounted without worrying about the front and back when the position detection magnet 11 is mounted on the rotor magnet 3. However, there may be a step 12 on one side in the thickness direction of the position detection magnet 11, and the step 12 side may be the axial end portion side (outside) of the rotor magnet 3.

  Further, as shown in FIGS. 36 to 38, the position detection magnet 11 includes a rib 13 that prevents rotation when the step 12 is embedded with the thermoplastic resin 17.

  Further, it is assumed that the position detection magnet 11 is set on the pedestal 50 (see FIG. 25) of the rotor magnet 3. The rotor magnet 3 is inserted into the lower mold of the mold from the axial end surface of the yoke 4 on the side provided with the recess 6, and the rotor magnet 3 is incorporated into the lower mold of the mold. The axial end surface on the side having the recess 6 is the lower surface, and the axial end surface on the side on which the position detecting magnet 11 is set on the opposite side is the upper surface.

  The position detection magnet 11 is disposed on the upper surface of the pedestal 34 and the rib-like runner 35 (the portion remaining as a product) inside the position detection magnet holding projection 35b of the pedestal portion 50 (see FIG. 25) of the rotor magnet 3. (Almost horizontal state).

  At this time, a predetermined gap exists between the outer peripheral surface of the position detection magnet 11 and the inner peripheral surface of the position detection magnet holding projection 35b.

  Although not described in detail, the lower mold installed on the turntable rotates at a predetermined rotation speed of, for example, 180 ° at the time of molding.

  When the position detection magnet 11 is placed on the pedestal 50 (see FIG. 25) of the rotor magnet 3 before resin molding, for example, when the position detection magnet 11 rotates at a predetermined rotation speed of 180 °, the position detection magnet 11 Centrifugal force acts.

  However, since the position detection magnet holding projection 35b exists around the position detection magnet 11, the position detection magnet holding projection 35b prevents the positional displacement in the radial direction and is less likely to fall off the rotor magnet 3. . Thereby, productivity is improved.

  From the outer periphery of the shaft outer peripheral cylindrical resin portion 31 to the outer periphery of the shaft outer peripheral cylindrical resin portion 31 (see FIG. 1, FIG. 3 to FIG. 5) in which the thermoplastic resin 17 is cylindrically formed on the outer periphery of the shaft 1 by resin molding. Radially, gate protrusions 32 for injecting the thermoplastic resin 17 are formed.

  The thermoplastic resin 17 is injected from the axial end surface of the gate protrusion 32 on the position detection magnet 11 side. Therefore, as shown in FIG. 5, the gate processing trace 32a remains on the axial end surface of the gate convex portion 32 on the position detecting magnet 11 side.

  For example, the number of the gate protrusions 32 is half of the number of magnetic poles (here, five of the half of 10 poles) (see FIG. 4).

  The gate convex portion 32 extends from the shaft outer peripheral cylindrical resin portion 31 with a predetermined length r (see FIG. 5) in the radial direction. The inner circumferential surface of the yoke inner circumferential cylindrical resin portion 37 (see FIGS. 4 and 5) is separated from the radial tip of the gate convex portion 32 by a predetermined distance.

  The direction extending in the radial direction of the gate convex portion 32 is substantially the magnetic pole center direction of the resin magnet portion 5.

  One axial end face (position detection magnet 11 side) of the gate protrusion 32 is a predetermined dimension d1 (see FIG. 6, for example, about 1 mm) from the axial end face on which the position detection magnet 11 of the rotor magnet 3 is provided. ) Only inside.

  As shown in FIG. 1, the other axial end surface of the gate protrusion 32 is positioned on a mold alignment surface mark 38 between the upper mold and the lower mold of the resin mold.

  Accordingly, the axial length of the gate protrusion 32 is approximately half the axial length of the rotor magnet 3.

  The reason why one axial end face (position detection magnet 11 side) of the gate protrusion 32 is located on the inner side by a predetermined dimension d1 from the axial end face on which the position detection magnet 11 of the rotor magnet 3 is provided. To do.

  As already described, the thermoplastic resin 17 is injected from the axial end surface of the gate convex portion 32 on the position detecting magnet 11 side, and as shown in FIG. 5, the gate convex portion 32 on the position detecting magnet 11 side is injected. A gate processing trace 32a remains on the end surface in the axial direction.

  The gate processing trace 32a may protrude to the outside from the end surface in the axial direction on the position detection magnet 11 side of the gate protrusion 32 to an arbitrary length. When there is a thing that interferes with the protrusion of the gate processing trace 32a, it is preferable that the protrusion of the gate processing trace 32a is located inside the axial end surface of the rotor magnet 3 on the position detecting magnet 11 side.

  For example, when the outer diameter of the bearing 410 (see FIG. 46, for example, a ball bearing) is smaller than the inner diameter of the yoke inner peripheral cylindrical resin portion 37 (see FIGS. 1 and 3 to 5), the mold stator 350 (see FIG. 46), the protrusion of the gate processing trace 32a may interfere with the mold.

  Therefore, one axial end surface (position detection magnet 11 side) of the gate protrusion 32 is positioned inward by a predetermined dimension d1 from the axial end surface on which the position detection magnet 11 of the rotor magnet 3 is provided. The gate processing trace is made smaller than d1. Since it is possible to take only the range of the gate processing trace d1, productivity can be improved.

  As shown in FIGS. 1 to 5, a plurality of ribs 18 are formed radially between the shaft outer peripheral cylindrical resin portion 31 and the yoke inner peripheral cylindrical resin portion 37.

  In the case shown in FIGS. 1 to 5, ten ribs 18 are formed radially between the shaft outer peripheral cylindrical resin portion 31 and the yoke inner peripheral cylindrical resin portion 37 at substantially equal intervals in the circumferential direction.

  The rib 18 extends in the inter-pole direction of the resin magnet part 5.

  Two ribs 18 are formed on both sides of one gate protrusion 32 into which the thermoplastic resin 17 is injected. The radial thickness of the rib 18 is smaller than the radial thickness of the gate protrusion 32.

  The thermoplastic resin 17 reaches the resin magnet portion 5 and the position detection magnet 11 through the ribs 18 and is integrated into the rotor magnet 3.

  The thermoplastic resin 17 such as PBT is directly injected from the gate convex portion 32 to the shaft outer peripheral cylindrical resin portion 31 on the outer periphery of the shaft 1 and can be filled earliest. Therefore, it is possible to improve the weld strength of the shaft outer peripheral cylindrical resin portion 31 of the cylindrical resin portion.

  Conventionally, resin is injected into the yoke inner peripheral cylindrical resin portion 37 and the shaft outer peripheral cylindrical resin portion 31 is filled with the resin via the ribs 18.

  The number, thickness (circumferential direction), and length (axial direction, radial direction) of the ribs 18 extending radially from the shaft outer peripheral cylindrical resin portion 31 are within a range that has the strength to withstand the torque generated by the motor and the repeated stress caused by intermittent operation. Thus, the cost may be reduced by making it as thin, thin and short as possible.

  Further, by changing the number, thickness (circumferential direction), and length (axial direction, radial direction) of the ribs 18 and adjusting the rigidity in the circumferential direction, the transmission excitation force from the resin magnet portion 5 to the shaft 1 is adjusted. Since the motor can be reduced in noise, the quality of the product is improved.

  A modified example of the electric motor rotor 200 will be described with reference to FIGS.

  The electric motor rotor 200 according to the modified example is different from the electric motor rotor 100 shown in FIGS.

  In the rotor 200 of the electric motor of the modification, the rib 41 is formed from the radial tip of the gate convex portion 40 toward the yoke inner circumferential cylindrical resin portion 37.

  That is, the ribs 41 are formed on the five gate protrusions 40 formed at substantially equal intervals in the circumferential direction.

  The thermoplastic resin 17 is injected from the axial end face of the gate protrusion 40 on the position detection magnet 11 side. Therefore, as shown in FIG. 8, the gate processing trace 40a remains on the axial end surface of the gate convex portion 40 on the position detecting magnet 11 side. Gate processing traces 40a remain on all five gate protrusions 40.

  In this way, by forming the rib 41 from the radial tip of the gate convex portion 40 toward the yoke inner peripheral cylindrical resin portion 37, the thermoplastic resin is also provided on the resin magnet portion 5 and the position detection magnet 11 side. Since 17 is filled quickly, the quality in manufacturing can be improved.

  When molding the rotors 100 and 200 of the electric motor using the thermoplastic resin 17, the resin magnet portion is filled with the thermoplastic resin 17 by pressing both axial end surfaces near the outer periphery of the resin magnet portion 5 with a mold. 5. Productivity and quality can be improved by preventing burrs from occurring on the outer periphery and preventing deburring.

  Further, a part of the notch 7 of the yoke 4 (here, five, the notch 7 in which the convex part of the lower mold of the mold is not fitted) and the concave part 6 (10, for example, FIG. 9) and the pedestal portion 50 (see FIG. 25) are filled with the thermoplastic resin 17 so as to stop torque transmission and rotation.

  By completely filling the concave portion 6 of the yoke 4 and the pedestal portion 50 with the thermoplastic resin 17, the outer periphery of the concave portion 6 of the yoke 4 and the pedestal portion 50 when the thermoplastic resin 17 is molded and contracted in the inner diameter direction. The thermoplastic resin 17 is caught on the surface, so that a gap between the thermoplastic resin and the rotor magnet can be prevented, and a reduction in bonding force can be prevented.

  That is, by using the recess 6 for preventing the protrusion of the gate processing trace 6a (see FIG. 15) from protruding from the axial end surface of the yoke 4 and the pedestal 50 for positioning the position detection magnet 11. In addition, since it is not necessary to add a structure for preventing a decrease in the bonding force, cost and noise can be reduced.

  Next, the yoke 4 constituting the rotor magnet 3 will be described in detail with reference to FIGS.

  The yoke 4 provided inside the rotor magnet 3 is obtained by injection molding a thermoplastic resin containing soft magnetic material or ferrite.

  When the yoke 4 is formed, a soft magnet or ferrite contained in the yoke 4 can be obtained by disposing a strong magnet outside the portion that forms the outer periphery of the yoke 4 and providing an orientation magnetic field. Oriented anisotropically with respect to the polar direction.

  As shown in FIG. 10, the yoke 4 is oriented anisotropically with respect to the polar direction by an orientation magnetic field outside the portion forming the outer periphery of the yoke 4 of the mold.

  In FIG. 10, the pedestal 34 (or the recess 6 and the notch 7) is omitted for easy viewing.

  As shown in FIG. 9, the yoke 4 is formed in a substantially cylindrical shape. On the outer periphery of the yoke 4, as shown in FIG. 11, the concave portions 47 and the convex portions 48 are alternately arranged. Here, the number of the concave portions 47 and the convex portions 48 is ten, respectively.

  The concave portion 47 on the outer periphery of the yoke 4 corresponds (opposites) to the magnetic pole of the resin magnet portion 5.

  Further, the convex portion 48 on the outer periphery of the yoke 4 corresponds (opposites) between the poles of the resin magnet portion 5.

  A plurality of concave portions 6 (for example, circular shapes) having an axial depth d2 (see FIG. 16) are formed at substantially equal intervals in the circumferential direction on one axial end surface of the yoke 4. The concave portion 6 corresponds (opposites) to the convex portion 48 (between the poles of the resin magnet portion 5) on the outer periphery of the yoke 4.

  Here, since the rotor 100 of the electric motor has 10 poles, 10 recesses 6 are also formed.

  A soft magnetic material or a thermoplastic resin containing ferrite is injected into the yoke 4 from each recess 6. Therefore, the gate processing trace 6a (see FIG. 15) of the gate opening for injecting the thermoplastic resin remains in the yoke 4 after molding.

  The recess 6 is provided for one reason that the protrusion of the gate processing trace 6a (see FIG. 15) does not protrude from the end surface of the yoke 4 in the axial direction. Accordingly, the axial depth d2 (see FIG. 16) of the recess 6 is set such that the protrusion of the gate processing trace 6a does not protrude from the axial end surface of the yoke 4.

  By providing a gate port (remaining as the gate processing trace 6a) for injecting thermoplastic resin by the number of magnetic poles (here, 10 poles), when a thermoplastic resin containing soft magnetic material or ferrite is injected into the magnetic pole As a result, the quality of the yoke 4 can be improved.

  Furthermore, as shown in FIG. 11, by providing a gate opening (remaining as a gate processing trace 6a) in a portion that is thick between the electrodes, it is optimal for the flow of a soft magnetic material or a thermoplastic resin containing ferrite. Position and quality can be improved.

  Further, the gate opening (remaining as the gate processing trace 6a) has a round shape (circular shape) from one axial end face of the yoke 4, and has a predetermined length (axial depth d2 (FIG. 16))) is used as the center of the notched recess 6 to prevent burrs remaining on the gate processing trace 6a from appearing from the end face. For this reason, it is possible to improve the quality in manufacturing because it hinders positioning during the manufacturing process or suppresses the generation of dust.

  The hollow portion (see FIG. 17) of the yoke 4 is a taper portion from the axial end surface on the side including the concave portion 6 to the substantially central position in the axial direction (the mold matching surface trace 46 (see FIG. 17) when the yoke 4 is formed). 45 (see FIG. 17). The tapered portion 45 has a tapered shape that gradually narrows inward from the axial end surface on the side provided with the concave portion 6.

  Further, a straight portion 44 (see FIG. 17) having a constant diameter is formed from the mold matching surface trace 46 of the taper portion 45 to the axial end surface on the pedestal 34 side.

  The tapered portion 45 (see FIG. 17) of the hollow portion of the yoke 4 is formed by a fixed mold. Further, the straight portion 44 (see FIG. 17) of the hollow portion of the yoke 4 is formed by a movable mold.

  By forming the tapered portion 45 (see FIG. 17) of the hollow portion of the yoke 4 with a fixed mold, the force with which the product (yoke 4) sticks to the fixed mold when the mold is opened is reduced.

  Further, by forming the straight portion 44 (see FIG. 17) of the hollow portion of the yoke 4 with a movable mold, it becomes a resistance that the product (yoke 4) sticks to the fixed mold when the mold is opened. The fixed-side mold can be smoothly separated from the product (yoke 4), and the manufacturing quality can be improved.

  As shown in FIGS. 9A and 11, the axial end surface of the yoke 4 on the side provided with the concave portion 6 has a tapered shape that reaches the tapered portion 45 of the hollow portion with a predetermined width at the magnetic pole position between the concave portions 6. The notch 7 is formed. The number of tapered notches 7 is ten.

  Each tapered notch 7 is formed so as to be coaxial with the straight portion 44 of the hollow portion (see FIG. 17) and the outer periphery of the yoke 4.

  This taper-shaped notch 7 is used when a resin magnet portion 5 is integrally formed with a yoke 4 with a resin magnet, and when a rotor magnet 3 is integrally formed with a shaft 1 with a thermoplastic resin 17. However, by holding the notch 7 in such a way that the coaxiality is maintained, it is possible to ensure the coaxiality and the phase, and the manufacturing quality can be improved.

  A pedestal 34 for separating the position detecting magnet 11 (see FIGS. 36 to 38) from the end surface of the yoke 4 by a predetermined distance is provided on the axial end surface opposite to the axial end surface including the recess 6 of the yoke 4. (See FIGS. 9B, 9C, and 12).

  As shown in FIGS. 12 and 13, the circumferential position of the pedestal 34 corresponds (opposites) to the magnetic pole. That is, the pedestals 34 are formed at approximately equal intervals in the circumferential direction.

  Each pedestal 34 includes a projecting portion 34a projecting outward in the axial direction and an opening 34b formed between the two projecting portions 34a.

  The opening 34b formed between the two protrusions 34a included in the pedestal 34 serves as a path for supplying the resin magnet when the resin magnet portion 5 is formed integrally with the yoke 4. The width of the opening 34b is substantially the same as the runner width for supplying the resin magnet (see the rib-like runner 35 described later, FIG. 22).

  Next, the rotor magnet 3 will be described with reference to FIGS.

  In the rotor magnet 3 of the present embodiment, a yoke 4 is housed in a lower mold (not shown) of a mold installed in a vertical molding machine, and, for example, samarium (samarium iron), which is a rare earth, is disposed on the outer periphery of the yoke 4. ) Containing a resin magnet made of a thermoplastic resin and integrated with the resin magnet portion 5.

  Magnetic powder contained in the resin magnet part 5 by forming a strong magnet and providing an orientation magnetic field outside the part of the mold that forms the outer periphery of the resin magnet part 5 when the resin magnet part 5 is molded. Are oriented anisotropically with respect to the polar direction (see FIG. 19).

  A core part into which the hollow part of the yoke 4 of the mold for molding the resin magnet part 5 is inserted is formed in a lower mold (not shown). The yoke 4 is inserted into the core portion from the axial end surface provided with the recess 6 and is incorporated into the mold.

  In the state where the yoke 4 is incorporated in the mold, the end surface of the core portion of the lower mold for molding the resin magnet portion 5 is the end surface position including the base 34 of the yoke 4 (see FIG. 20).

  Further, by providing a convex part (not shown) fitted in the notch 7 provided on the axial end surface of the concave part 6 side of the yoke 4 on the core part (lower mold) of the mold for molding the resin magnet part 5, Positioning in the circumferential direction relative to the position of the magnet that creates the orientation magnetic field is performed.

  Moreover, the convex part fitted in the notch 7 of the core part ensures the coaxial with the outer periphery of the resin magnet part, and presses the taper-shaped notch 7 when the mold is tightened, so that the resin magnet part The outer periphery of 5 and the yoke 4 are coaxial.

  The resin injecting portion when the resin magnet portion 5 is formed is a magnetic pole on a donut-shaped runner 36 (see FIGS. 21 and 22) formed on the end surface of the core portion (lower die) of the mold for forming the resin magnet portion 5. Are provided at a substantially equal pitch in the circumferential direction.

  The resin injection part at the time of shaping | molding the resin magnet part 5 remains as the resin injection part trace 36a in the donut-shaped runner 36 (refer FIG. 21).

  The resin injection portion trace 36a is formed approximately in the middle of any two of the ten rib-like runners 35 formed.

  As shown in FIG. 20, the donut-shaped runner 36 protrudes from the end surface of the resin magnet portion 5 or the yoke 4 toward the pedestal side at approximately the height (axial direction) of the pedestal 34 of the yoke 4.

  Further, from the outer periphery of the donut-shaped runner 36, the rib-shaped runner 35 extends radially in the same number as the number of magnetic poles (here, 10). The rib-like runner 35 is formed at substantially the same height (axial direction) as the donut-like runner 36.

  As already described, the resin injection portion (resin injection portion trace 36a) when the resin magnet portion 5 is molded is provided at a substantially intermediate position between the two rib-like runners 35.

  Since the doughnut-shaped runner 36 and the rib-shaped runner 35 are formed by the upper mold, the donut-shaped runner to the upper mold when the mold is opened is formed by reducing the taper shape from the end surface of the core (lower mold) to the outside in the axial direction. The sticking of the runner 36 and the rib-like runner 35 is reduced.

  See FIG. 20 for the taper shape that decreases from the end surface of the core (upper mold) of the donut-shaped runner 36 to the outside in the axial direction.

  Also, refer to FIG. 23 for the tapered shape that decreases from the end face of the core portion (lower mold) of the rib-like runner 35 to the outside in the axial direction.

  Further, as shown in FIG. 20, the donut-shaped runner 36 has a predetermined depth (in the axial direction) dug into a concave shape straight from the end surface of the core (lower mold). The upper die is smoothly separated from the donut-shaped runner 36 by being a resistance to stick to the upper die 36.

  The rib-shaped runner 35 extending radially from the donut-shaped runner 36 crosses the axial end surface of the core (lower mold) of the mold for molding the resin magnet portion 5 and then the axial end surface of the yoke 4 on the pedestal 34 side. And reaches the opening 34b on the inner peripheral side of the pedestal 34. Furthermore, it extends from the outer periphery of the yoke 4 to a predetermined position on the axial end surface of the resin magnet unit 5 outside the opening 34b on the outer peripheral side of the base 34.

  As shown in FIG. 24, the resin magnet is injected into the resin injection portion (resin injection portion trace 36 a) of the donut-shaped runner 36. Up to this resin injection part (resin injection part trace 36a), the resin magnet flows in a runner (not shown) in the axial direction. Then, the flow direction is changed by 90 ° at the resin injection portion (resin injection portion trace 36a). That is, it is divided into two in the direction perpendicular to the axis. Thereafter, each of the resin magnets divided into two enters the rib-like runner 35 closest to the resin injection part (resin injection part trace 36a), and further flows into the resin magnet part 5 by changing the flow direction by 90 °.

  At this time, the part that changes the flow direction of the resin magnet (the resin injection part (resin injection part trace 36a), the part that flows in the axial direction through the axial runner and splits in two directions perpendicular to the axis) is set in the mold. Can do. This is because the donut-shaped runner 36 having the resin injection portion (resin injection portion trace 36 a) is located inside the inner periphery of the yoke 4.

  For example, when the flow direction is changed at the end face in the axial direction of the yoke 4, there is a risk of causing damage such as a hole being formed in the end face of the yoke 4 due to the injection pressure of the resin magnet flowing in the axial direction through the axial runner.

  Since there is a part in the mold that changes the flow direction of the resin magnet (resin injection part (resin injection part trace 36a), part that flows in the axial direction through the axial runner and splits in two directions perpendicular to the axis), the axial direction The resin magnet that has flowed axially through the runner is less likely to damage the yoke 4 and the like. As a result, the manufacturing quality can be improved.

  Further, the hollow portion of the yoke 4 from the end surface on the pedestal 34 side to the die-matching surface mark 46 is a straight portion 44 (see FIG. 17) having a substantially constant circle diameter in cross section, and the hollow portion of the yoke 4 is Mold matching from the end face on the side of the pedestal 34 of the hollow part of the yoke 4 is made as small as possible by reducing the gap between the core part (lower mold) of the mold for molding the resin magnet part 5 fitted to the straight part 44 from the end face on the base 34 side. Resin magnet leakage into the gap between the straight portion 44 up to the surface mark 46 and the core portion (lower die) of the mold for molding the resin magnet portion 5 can be suppressed, and the manufacturing quality can be improved.

  When the rare earth resin magnet portion 5 is formed on the outer periphery of the yoke 4, the thickness of the resin magnet portion 5 is made as thin as possible because the material (rare earth resin magnet) is expensive. In that case, it is necessary to make the resin injection portion for directly injecting the resin magnet into the resin magnet portion 5 smaller in accordance with the thickness of the resin magnet portion 5. When the resin injection portion becomes small, the molding pressure increases.

  On the other hand, as in the present embodiment, a doughnut-like runner 36 and rib-like runners 35 extending radially from the outer periphery of the donut-like runner 36 in the same number as the number of magnetic poles are formed to form a donut shape. If the resin injection part (resin injection part trace 36a) is provided in the runner 36, the gate diameter of the resin injection part can be set arbitrarily, and the manufacturing quality can be improved.

  Moreover, the ratio of the runner amount to the product (resin magnet part 5) is reduced by reducing the number of resin injection parts (resin injection part trace 36a) of the resin magnet to half (5) the number of magnetic poles (10 poles). The number of resin injection portions of the resin magnet can be reduced as compared with the case where the number of magnetic poles is provided.

  The runner amount is the total amount of the donut-like runner 36, the rib-like runner 35, and other runners (not shown).

  “Runner” is defined as a portion that does not become a product (resin magnet portion 5) between the resin magnet portion 5 and the resin magnet injection portion of the mold. Specifically, the doughnut-like runner 36, the rib-like runner 35, And other runners not shown.

  However, in the case of the rotor magnet 3 shown in FIG. 18, as shown in FIG. 25, a part of the rib-like runner 35 (a portion from the inner peripheral surface of the base 34 of the yoke 4 to the tip (radial direction)) Become a product.

  In other words, the other runners (not shown), the doughnut-like runner 36, and the rib-like runner 35 (excluding a part, excluding the portion from the inner peripheral surface of the pedestal 34 of the yoke 4 to the tip (radial direction)) are rotor magnets. After completion of the molding of No. 3, it is cut out (see FIG. 25).

  In the case of the runners according to the present embodiment (other runners, donut-like runners 36, and rib-like runners 35 (excluding some)), the number of resin injection portions of resin magnets is the same as the number of magnetic poles (here, 10). Compared to the above, the amount of runners can be reduced by approximately 30%.

  Although the details are omitted, the ratio of the axial runner amount to the total runner amount is larger than the other donut-like runners 36 and the rib-like runners 35. Therefore, if the resin injection portion is reduced, the total runner amount is also reduced.

  In the present embodiment, the number of resin injection portions of the resin magnet is five, and the total amount of runners is reduced as compared with the case where the resin injection portions are provided by the number of magnetic poles (here, 10).

  Also, when reusing runners that do not become products, this embodiment recycles by reducing the amount of runners compared to the case where resin injection portions of resin magnets are provided by the number of magnetic poles (here, 10). By reducing the ratio and suppressing the decrease in physical properties (mainly mechanical strength) of the resin magnet, the quality of the product can be improved.

  Furthermore, the resin injection portion is half the number of magnetic poles, but the rib-like runner 35 has the same number of magnetic poles, so that the resin magnet injection condition is the same for each magnetic pole, and the orientation state is uniform. And the quality in manufacturing can be improved.

  As shown in FIG. 25, the other runners (not shown), the doughnut-like runner 36, and the rib-like runner 35 (except for a part) are cut off after the formation of the rotor magnet 3 is completed. The rib-like runner 35 is cut away from the donut-like runner 36 to the inner peripheral surface of the pedestal 34 of the yoke 4 extending radially.

  Therefore, as shown in FIG. 25, the pedestal portion 50 is constituted by a protruding portion 34 a of the pedestal 34 of the yoke 4 and a non-cut portion of the rib-like runner 35 extending radially outward from between the protruding portions 34 a. The non-cut portion of the rib-like runner 35 is provided with a position detection magnet holding projection 35b protruding outward in the axial direction at the radial tip.

  As already described, the position detection magnet 11 is configured such that the pedestal 34 and the rib-shaped runner 35 (the portion remaining as a product) are located inside the position detection magnet holding projection 35b (see FIG. 25) of the pedestal 50 of the rotor magnet 3. It is arrange | positioned on the upper surface of (a substantially horizontal state). When the position detection magnet 11 is placed on the pedestal 50 (see FIG. 25) of the rotor magnet 3 before resin molding, for example, when the position detection magnet 11 rotates at a predetermined rotational speed of 180 °, the position detection magnet 11 11 is subjected to centrifugal force. However, since the position detection magnet holding projection 35b exists around the position detection magnet 11, the position detection magnet holding projection 35b prevents the positional displacement in the radial direction and is less likely to fall off the rotor magnet 3. . Thereby, productivity is improved.

  Further, a portion outside the yoke 4 of the rib-like runner 35 formed on the resin magnet portion 5 is positioned to be positioned in the circumferential direction when the rotor magnet 3 is formed integrally with the shaft 1 with the thermoplastic resin 17. Used as a protrusion.

  For example, a positioning projection (a portion outside the yoke 4 of the rib-like runner 35), a position detection magnet holding projection 35b, and a pedestal that are positioned in the circumferential direction when molded integrally with the shaft 1 using only a resin magnet. 34, when the donut-like runner 36 and the rib-like runner 35 are cut off, the resin magnet portion 5 formed on the outer periphery of the yoke 4 is only the resin injection portion to the resin magnet portion 5. Since they are connected, there is a weak point that the strength is weak.

  However, the pedestal 34 is formed on the yoke 4, the central portion of the pedestal 34 is opened to provide the opening 34 b, and the rib-like runner 35 is integrated with the pedestal 34 to improve the strength. Quality can be improved.

  As described above, the doughnut-shaped runner 36 passes through the rib-shaped runner 35, the resin magnet is filled into the outer periphery of the yoke 4, and the yoke 4 and the resin magnet portion 5 are integrated, and then the inner peripheral side surface of the pedestal 34. By cutting out the rib-like runner 35 and the donut-like runner 36 on the inner side, the rotor magnet 3 of the present embodiment is obtained.

  A positioning projection (a portion outside the yoke 4 of the rib-like runner 35), a position detection magnet holding projection 35b, and a pedestal 34 that are positioned in the circumferential direction when molded integrally with the shaft 1 using only a resin magnet. When the doughnut-shaped runner 36 and the rib-shaped runner 35 are cut off, the resin magnet portion 5 formed on the outer periphery of the yoke 4 is connected only by the resin injection portion to the resin magnet portion 5. Therefore, there is a weak point that the strength is weak, but when the position detecting magnet 11 (see FIGS. 36 to 38) is not used, the pedestal 50 for the position detecting magnet 11 becomes unnecessary. The donut-shaped runner 36 and the rib-shaped runner 35 may be completely cut off.

  Next, the rotor magnet 103 when the position detection magnet 11 is not used will be described with reference to FIGS.

  The rotor magnet 103 includes a yoke 104 and a resin magnet portion 5 formed on the outer periphery of the yoke 104.

  The rotor magnet 103 also has 10 poles like the rotor magnet 3.

  First, the yoke 104 will be described. As shown in FIGS. 27 (a) and 27 (b), the configuration of the yoke 104 on the recess 6 side is the same as that of the yoke 4 of FIG.

  Since the position detecting magnet 11 (see FIGS. 36 to 38) is not used, the pedestal 34 that is the yoke 4 in FIG. 9 is not provided on the axial end surface of the yoke 104 opposite to the concave portion 6 (see FIG. 27-29).

  The yoke 104 provided inside the rotor magnet 103 is obtained by injection molding a soft magnetic material or a thermoplastic resin containing ferrite.

  Similar to the yoke 4, when forming the yoke 104, a strong magnet is disposed outside the portion forming the outer periphery of the die yoke 104 to provide an orientation magnetic field, thereby providing a soft magnetic material contained in the yoke 104. The magnetic material or ferrite is oriented anisotropically with respect to the polar direction.

  As shown in FIGS. 27A and 27C, the yoke 104 has a substantially cylindrical cross section. On the outer periphery of the yoke 104, as shown in FIG. 28, concave portions 47 and convex portions 48 are alternately arranged. Here, the number of the concave portions 47 and the convex portions 48 is ten, respectively.

  The concave portion 47 on the outer periphery of the yoke 104 corresponds to (opposes to) the magnetic pole of the resin magnet portion 5.

  Further, the convex portion 48 on the outer periphery of the yoke 104 corresponds (opposites) between the poles of the resin magnet portion 5.

  Next, the rotor magnet 103 will be described. As shown in FIGS. 30A and 30B, the configuration of the rotor magnet 103 on the recess 6 side is the same as that of the rotor magnet 3 shown in FIG.

  Since the position detection magnet 11 (see FIGS. 36 to 38) is not used, it is not necessary to form a pedestal on the axial end surface of the rotor magnet 103 opposite to the recess 6. Therefore, the rotor magnet 103 before cutting off the runner is formed with a donut-shaped runner 36 and a rib-shaped runner 135 on the axial end surface on the opposite side of the recess 6 as shown in FIGS. It has only been done.

  Similarly to the rotor magnet 3, the rotor magnet 103 also has a core part in which a hollow part of a mold yoke 104 for molding the resin magnet part 5 is inserted in a lower mold (not shown). The yoke 104 is inserted into the core portion from the axial end surface provided with the concave portion 6 and incorporated into the mold.

  In the state where the yoke 104 is incorporated in the mold, the end surface of the core portion of the lower mold for molding the resin magnet portion 5 is the axial end surface position on the opposite side of the concave portion 6 of the yoke 104 (see FIG. 31). .

  Further, by providing a convex part (not shown) fitted to the notch 7 provided on the axial end surface of the concave part 6 side of the yoke 104 on the core part (lower mold) of the mold for molding the resin magnet part 5, Positioning in the circumferential direction relative to the position of the magnet that creates the orientation magnetic field is performed.

  Moreover, the convex part fitted in the notch 7 of the core part ensures the coaxial with the outer periphery of the resin magnet part, and presses the taper-shaped notch 7 when the mold is tightened, so that the resin magnet part 5 is ensured to be coaxial with the yoke 104.

  The resin injection portion when the resin magnet portion 5 is formed is half of the magnetic pole on the donut-shaped runner 36 (see FIG. 32) formed on the end surface of the core portion (lower die) of the mold for forming the resin magnet portion 5. A quantity (here, 5 pieces of half of 10 poles) is provided at a substantially equal pitch in the circumferential direction.

  The resin injection part at the time of shaping | molding the resin magnet part 5 remains as the resin injection part trace 36a in the donut-shaped runner 36 (refer FIG. 32).

  The resin injection portion trace 36a is formed approximately in the middle of any two of the ten rib-like runners 135 formed.

  As shown in FIG. 31, the donut-shaped runner 36 protrudes outward (axial direction) from the end surface of the resin magnet portion 5 or the yoke 104 at the height (axial direction) of the substantially rib-shaped runner 135.

  Further, from the outer periphery of the donut-shaped runner 36, rib-shaped runners 135 extend radially in the same number (here, 10) as the number of magnetic poles. The rib-shaped runner 135 is formed at substantially the same height (axial direction) as the donut-shaped runner 36.

  As already described, the resin injection part (resin injection part trace 36a) when the resin magnet part 5 is molded is provided at a substantially intermediate position of the rib-like runner 135.

  Since the donut-shaped runner 36 and the rib-shaped runner 135 are formed by the upper mold, the donut to the upper mold when the mold is opened is formed by forming a tapered shape that decreases outward from the end surface of the core (lower mold) in the axial direction. The sticking of the runner 36 and the rib runner 135 is reduced.

  See FIG. 31 for the taper shape that decreases from the end surface of the core (lower mold) of the donut-shaped runner 36 to the outside in the axial direction.

  Also, refer to FIG. 34 for the taper shape that decreases from the end surface of the core portion (lower mold) of the rib-shaped runner 135 to the axially outer side.

  Further, as shown in FIG. 31, the donut-shaped runner 36 has a predetermined depth (axial direction) dug into a concave shape straight from the end surface of the core (lower mold), so that the donut-shaped runner at the time of mold opening The upper die is smoothly separated from the donut-shaped runner 36 by being a resistance to stick to the upper die 36.

  A rib-shaped runner 135 extending radially from the donut-shaped runner 36 crosses the axial end surface of the core portion (lower mold) of the mold for molding the resin magnet portion 5, then the end surface of the yoke 104, and extends from the outer periphery of the yoke 104. Extends into place.

  As shown in FIG. 33, the resin magnet is injected into the resin injection portion (resin injection portion trace 36a) of the donut-shaped runner 36. Up to this resin injection part (resin injection part trace 36a), the resin magnet flows in a runner (not shown) in the axial direction. Then, the flow direction is changed by 90 ° at the resin injection portion (resin injection portion trace 36a). That is, it is divided into two in the direction perpendicular to the axis. Thereafter, the resin magnets divided into two hands enter the rib-like runner 135 closest to the resin injection portion (resin injection portion trace 36 a) and further flow into the resin magnet portion 5.

  At this time, the part that changes the flow direction of the resin magnet (the resin injection part (resin injection part trace 36a), the part that flows in the axial direction through the axial runner and splits in two directions perpendicular to the axis) is set in the mold. Can do. This is because the donut-shaped runner 36 having the resin injection portion (resin injection portion trace 36 a) is located inside the inner periphery of the yoke 104.

  For example, when the flow direction is changed at the end face in the axial direction of the yoke 104, there is a risk of causing damage such as opening a hole in the end face of the yoke 104 by the injection pressure of the resin magnet flowing in the axial direction through the axial runner.

  Since there is a part in the mold that changes the flow direction of the resin magnet (resin injection part (resin injection part trace 36a), part that flows in the axial direction through the axial runner and splits in two directions perpendicular to the axis), the axial direction The resin magnet that has flowed axially through the runner is less likely to damage the yoke 104 and the like. As a result, the manufacturing quality can be improved.

  Further, the hollow portion of the yoke 104 is a straight portion 44 (see FIG. 35) having a substantially constant cross-sectional circle diameter from the opposite axial end surface of the concave portion 6 (notch 7) to the die-matching surface mark 46. Further, the gap between the core part (lower mold) of the mold for molding the resin magnet part 5 to be fitted with the straight part 44 from the opposite axial direction of the concave part 6 (notch 7) is made as small as possible. As a result, the straight portion 44 from the opposite axial end surface of the concave portion 6 (notch 7) of the hollow portion of the yoke 104 to the mold alignment surface mark 46, and the core portion (lower) of the mold for molding the resin magnet portion 5 It is possible to suppress the leakage of the resin magnet into the gap with the mold), and the quality in manufacturing can be improved.

  When the rare earth resin magnet portion 5 is formed on the outer periphery of the yoke 104, since the material (rare earth resin magnet) is expensive, the thickness of the resin magnet portion 5 is made as thin as possible. In that case, it is necessary to make the resin injection portion for directly injecting the resin magnet into the resin magnet portion 5 smaller in accordance with the thickness of the resin magnet portion 5. When the resin injection portion becomes small, the molding pressure increases.

  On the other hand, as in the present embodiment, a doughnut-shaped runner 36 and a rib-shaped runner 135 extending radially from the outer periphery of the donut-shaped runner 36 in the same number as the number of magnetic poles are formed to form a donut shape. If the resin injection part (resin injection part trace 36a) is provided in the runner 36, the gate diameter of the resin injection part can be set arbitrarily, and the manufacturing quality can be improved.

  Moreover, the ratio of the runner amount to the product (resin magnet part 5) is reduced by reducing the number of resin injection parts (resin injection part trace 36a) of the resin magnet to half (5) the number of magnetic poles (10 poles). The number of resin injection portions of the resin magnet can be reduced as compared with the case where the number of magnetic poles is provided.

  The runner amount is the total amount of the donut-like runner 36, the rib-like runner 135, and other runners (not shown).

  “Runner” is defined as a portion that does not become a product (resin magnet portion 5) between the resin magnet portion 5 and the resin magnet injection portion of the mold. Specifically, the doughnut-like runner 36, the rib-like runner 135, And other runners not shown.

  That is, the other runners not shown, the doughnut-like runner 36, and the rib-like runner 135 are cut off after the formation of the rotor magnet 103 is completed (see FIG. 35).

  The runners according to the present embodiment (the other runners, the donut-shaped runners 36, and the rib-shaped runners 135) are roughly 30 in comparison to the case where the number of resin injection portions of the resin magnet is the same as the number of magnetic poles (here, 10). % Of runners can be reduced.

  As already described, the ratio of the other runner amount to the total runner amount is larger than the other donut-like runners 36 and the rib-like runners 135. Therefore, if the resin injection portion is reduced, the total runner amount is also reduced.

  In the rotor magnet 103, the number of resin injection portions of the resin magnet is five, and the total runner amount is reduced as compared with the case where the resin injection portions of the resin magnet are provided by the number of magnetic poles (here, ten). Become.

  Also, when reusing runners that do not become products, the rotor magnet 103 is reused by reducing the amount of runners compared to the case where resin injection portions of resin magnets are provided by the number of magnetic poles (here, 10). By reducing the ratio and suppressing the decrease in physical properties (mainly mechanical strength) of the resin magnet, the quality of the product can be improved.

  Furthermore, the resin injection portion is half the number of magnetic poles, but the rib-like runner 135 is the same as the number of magnetic poles, so that the resin magnet injection is the same for each magnetic pole, and the orientation is uniform. The product quality can be improved.

  As shown in FIG. 35, the other runners, the doughnut-like runners 36, and the rib-like runners 135 (not shown) are all cut off after the formation of the rotor magnet 103 is completed.

  On the opposite axial end surface of the concave portion 6 (notch 7) of the resin magnet portion 5, the cut traces 51 obtained by cutting the rib-like runners 135 remain as many as the rib-like runners 135 (here, 10 pieces).

  As described above, as an example, the rotor magnet 3 in which the outer periphery of the yoke 4 has an uneven shape and the resin magnet portion 5 is integrally formed on the outer periphery is used. However, the outer periphery is circular and a concave or convex shape is provided in part. The resin magnet portion 5 may be formed on the outer periphery of the yoke 4 to form the rotor magnet 3.

  Alternatively, the rotor magnet 3 may be constituted by only a resin magnet.

  Alternatively, a sintered magnet or a molded resin magnet may be bonded to the yoke 4 to form the rotor magnet 3.

  Regardless of the outer peripheral shape of the yoke 4, the material of the magnet disposed on the outer periphery, and the fixing method, the gate processing trace 6a provided on one end surface of the yoke 4 formed of a thermoplastic resin containing a soft magnetic material protrudes from the end surface. It is possible to obtain the same effect by molding the shaft 1, the rotor magnet 3, and the position detection magnet 11 together by molding with a general-purpose thermoplastic resin so as to embed the recess 6 for preventing Needless to say.

  Next, the position detecting magnet 11 will be described with reference to FIGS. As shown in FIGS. 36 to 38, the ring-shaped position detecting magnet 11 has steps 12 at both axial end portions on the inner diameter side and is symmetric in the thickness direction (see FIG. 38).

  The position detection magnet 11 is provided at one end in the axial direction of the rotor 100 of the electric motor (see FIG. 1), but a thermoplastic resin such as PBT is formed on the step 12 at both ends in the axial direction on the inner diameter side of the position detection magnet 11. 17 is filled to prevent the position detecting magnet 11 from coming off in the axial direction.

  Since the position detection magnet 11 has a symmetrical shape in the thickness direction, it can be set in the mold without considering the direction, the working time can be shortened, and the productivity can be improved and the cost can be reduced.

  36 to 38 show the step 12 at both ends, but there is a step 12 at one end, which is located on the axial end of the rotor 100 of the motor. That's fine.

  Further, the position detection magnet 11 includes a rib 13 that prevents rotation when embedded in the thermoplastic resin 17.

  For example, the rotor 100 of the electric motor according to the first embodiment is combined with a stator of the electric motor to constitute a brushless DC motor (synchronous motor).

  Hereinafter, an example of the stator of the electric motor will be described with reference to FIGS. 39 to 44. A stator 300 of a 12 slot / 10 pole motor will be described.

This motor stator 300 is characterized in the following points.
(1) The number of slots of the stator core 301 is 12 (the stator core 301 has 12 teeth 301a);
(2) The coil 302 is a three-phase single Y connection and has 10 poles. The coil 302 is a concentrated winding method formed on each of the 12 teeth 301a;
(3) The stator core 301 is formed by punching electromagnetic steel sheets having a thickness of about 0.1 to 0.7 mm into a band shape, caulking them, and laminating them by welding, adhesion, or the like. The strip-shaped stator core 301 has twelve teeth 301a;
(4) The strip-shaped stator core 301 is provided with an insulating portion 303 that serves as an insulation between the coil 302 and the stator core 301. The insulating portion 303 is formed integrally with the stator core 301 using, for example, a thermoplastic resin such as PBT (polybutylene terephthalate). However, you may assemble | attach to the teeth 301a after shape | molding the insulation part 303. FIG. In that case, the insulating part 303 is divided into a connection side and an anti-connection side, and each is inserted from both ends in the axial direction of the teeth 301a to constitute the insulation part 303. The insulating part 303 is provided for each tooth 301a. Therefore, here, twelve insulating parts 303 are provided;
(5) After the insulating portion 303 is applied to the band-shaped stator core 301, three power terminals 304 and one piece are provided at a predetermined position on one axial end (connection side) of the outer wall of the insulating portion 303. A neutral point terminal 305 is inserted;
(6) The motor stator 300 is characterized in that rectangular wires are used for the power supply terminal 304 and the neutral point terminal 305;
(7) The belt-shaped stator iron core 301 is bent in the opposite direction to the stator 300 of the completed motor so that the opening between the teeth 301a is widened. Thereby, it becomes easy to wind the magnet wire around the teeth 301a;
(8) The first phase and the second phase are continuously wound (the connecting wire is not cut). The motor stator 300 is also characterized in this respect;
(9) Wind the third phase. The third phase is wound with a different magnet wire than the first and second phases;
(10) Positively bend the stator core 301 after winding so that the teeth 301a are on the inside (bent in a predetermined direction into a substantially donut shape);
(11) The stator core butt portion 363 of the stator core 301 is welded and fixed by the welded portion 364;
(12) Fusing of the power supply terminal 304 and the neutral point terminal 305;
(13) Further, a connection component 341 (see FIG. 46) connected to the outside is assembled to the stator 300 of the electric motor, and mechanically and electrically joined.

  The stator 300 of the electric motor shown in FIG. 40 shows a state where the winding is completed by reversely bending the stator core 301. And it is the figure which has seen the stator 300 of the electric motor from the diagonally upper side by the side of a connection. However, a winding start terminal, a winding end terminal, a crossover, and the like of the coil 302 are not shown.

  Since the stator core 301 is reversely bent, the teeth 301a face outward. Moreover, there is a wide space between adjacent teeth 301a, and a magnet wire can be easily wound around the teeth 301a.

  Three power supply terminals 304 are inserted into predetermined locations on the connection side (the upper side in the axial direction in FIG. 40) of the insulating portion 303 formed integrally with the stator core 301. Details will be described later.

  Further, one neutral point terminal 305 is inserted into a predetermined location on the connection side (the upper side in the axial direction in FIG. 40) of the insulating portion 303 integrally formed with the stator core 301.

  Furthermore, the insulating portion 303 includes a projection 308 on the connection side that holds the connecting wire of each phase at a predetermined position from the axial end surface of the stator core 301.

  The configuration of the band-shaped stator core 301 will be described with reference to FIG. Since stator 300 of the electric motor in the present embodiment has 12 slots, there are also 12 teeth 301a.

  The strip-shaped stator core 301 is formed by punching a magnetic steel sheet having a thickness of about 0.1 to 0.7 mm into a strip shape and laminating by caulking, welding, adhesion, or the like.

  The shape of each tooth 301a is substantially T-shaped in plan view. The teeth 301a extend substantially perpendicularly from the core back 301b.

  The tip portion 301a-1 of the teeth 301a (opposite side of the core back 301b) has a substantially square shape when viewed from the front. The tip portion 301a-1 of the tooth 301a is exposed even after the insulating portion 303 is integrally formed with the stator core 301. The gap between the rotor and the stator 300 of the electric motor needs to be a gap having a radial dimension of 1 mm or less. Therefore, the insulating portion 303 is not provided at the tip portion 301a-1 of the tooth 301a.

  Adjacent teeth 301a have core backs 301b connected by thin-walled connecting portions 301c. Therefore, the strip-shaped stator core 301 can be freely bent backward and forward.

  The core end surface 301d, which is the outer end surface of the core back 301b of the teeth 301a at both ends of the belt-shaped stator core 301, bends the stator core 301 after winding forward so that the teeth 301a are on the inside, and the stator core When the butt portion 363 is welded and fixed by the welded portion 364, they abut against each other. See FIG. 39 for the stator core butting portion 363 and the welded portion 364.

  As shown in FIG. 42, an insulating portion 303 is formed on the band-shaped stator core 301 by integral molding. However, it may not be integrally molded. It is possible to adopt a form in which the insulating part 303 as a separate part is inserted into each tooth 301a from both sides in the axial direction.

  A pin 370 for assembling a substrate (not shown) at the center is provided on the outer wall of the insulating portion 303 of the teeth 301a (three places).

  Three power supply terminals 304 and one neutral point terminal 305 are attached to the wire connection side (upper side in FIG. 41) of the insulation part 303 to a band-shaped stator core 301 in which the insulation part 303 is formed by integral molding.

  As shown in FIG. 43, the 12-slot / 10-pole synchronous motor (electric motor 400) is a synchronous motor (electric motor 400) in which the ratio of the number of teeth 301a to the number of magnetic poles of the rotor is 6: 5.

  The U phase includes a coil U1 +, a coil U2-, a coil U3-, and a coil U4 +. The winding start of the coil U1 + is connected to a U terminal which is one of the power terminals 304. The winding end of the coil U4 + is connected to a neutral point terminal 305 (neutral point).

  Coil U2- and coil U3- indicate that the coil U1 +, coil U4 + and the winding direction to the teeth 301a are different. Details will be described later. Hereinafter, the same applies to the V phase and the W phase.

  The V phase includes a coil V1-, a coil V2 +, a coil V3 +, and a coil V4-. The winding start of the coil V <b> 1-is connected to a V terminal which is one of the power supply terminals 304. The winding end of the coil V4- is connected to a neutral point terminal 305 (neutral point). The V terminal is provided on the outer wall of the insulating portion 303 of the tooth 301a in which one tooth 301a is blown counterclockwise from the tooth 301a provided with the U terminal.

  The W phase includes a coil W1 +, a coil W2-, a coil W3-, and a coil W4 +. The winding start of the coil W1 + is connected to a W terminal which is one of the power supply terminals 304. The winding end of the coil W4 + is connected to a neutral point terminal 305 (neutral point). The W terminal is provided on the outer wall of the insulating portion 303 of the tooth 301a in which one tooth 301a is blown counterclockwise from the tooth 301a provided with the V terminal.

  As shown in the connection diagram of the stator windings of the stator 300 of the electric motor in FIG. 44, the stator windings of the stator 300 of the electric motor are connected to a single Y. That is, the U-phase coil U1 +, the coil U2-, the coil U3-, and the coil U4 + are connected in series. Further, a V-phase coil V1-, a coil V2 +, a coil V3 +, and a coil V4- are connected in series. Further, a W-phase coil W1 +, a coil W2-, a coil W3-, and a coil W4 + are connected in series. Then, the winding ends of the coil U4 +, the coil V4-, and the coil W4 + are connected to the neutral point N.

  The stator winding connection method will be further described with reference to a development view showing the stator winding connection method of the stator 300 of the electric motor shown in FIG.

  Here, the first phase is called the U phase, the second phase is called the V phase, and the third phase is called the W phase. In the first U phase, the first coil U1 + is formed in the fifth tooth 301a from the left. The coil U2- is formed on the sixth tooth 301a from the adjacent left. The coil U3- is formed on the eleventh tooth 301a from the left. The coil U4 + is formed on the twelfth tooth 301a from the left (the first tooth 301a from the right). Both the coil U1 + and the coil U4 + are wound around the tooth 301a in the clockwise direction. Coil U2- and coil U3- are both wound around teeth 301a in a counterclockwise direction.

  In the second V phase, the first coil V1- is formed in the third tooth 301a from the left. The coil V2 + is formed in the fourth tooth 301a from the adjacent left. The coil V3 + is formed on the ninth tooth 301a from the left. The coil V4- is formed on the adjacent tenth tooth 1a from the left (second tooth 301a from the right). Coil V1- and coil V4- are both wound around teeth 301a in a counterclockwise direction. Both the coil V2 + and the coil V3 + are wound around the tooth 1a in the clockwise direction.

  In the third W phase, the first coil W1 + is formed on the first tooth 301a from the left. The coil W2- is formed on the second tooth 301a from the adjacent left. The coil W3- is formed on the seventh tooth 301a from the left. The coil W4 + is formed in the eighth tooth 301a from the left adjacent to the coil W4 +. Coil W1 + and coil W4 + are both wound around teeth 301a in the clockwise direction. Coil W2- and coil W3- are both wound around tooth 301a in a counterclockwise direction.

  As already described, the winding start of the coil U1 +, the coil V1-, and the coil W1 + is connected to the power supply terminal 304, respectively. Further, the winding ends of the coil U4 +, the coil V4-, and the coil W4 + are connected to the neutral point terminal 305, respectively.

  The motor stator 300 is characterized in that rectangular wires are used for the power supply terminal 304 and the neutral point terminal 305.

  As shown in FIG. 46, the electric motor 400 includes an electric motor rotor 100, a bracket 439, a mold stator 350 obtained by molding the electric motor stator 300, a connection component 341 (substrate), and the like.

  As shown in FIG. 46, a connection component 341 connected to the outside is assembled to the stator 300 of the electric motor, and after mechanically and electrically joining, a mold is applied to form a mold stator 350.

  Thereafter, the electric motor 400 is assembled by assembling components such as the rotor 100 (bearing 410) and the bracket 439 of the electric motor.

  By using the electric motor rotor 100 and the electric motor stator 300 that are good in quality and reduced in cost, the electric motor 400 of good quality and low cost can be obtained.

  Finally, the manufacturing process of the electric motor 400 will be described with reference to FIG. The electric motor 400 is a synchronous motor (for example, a brushless DC motor).

  (1) Step 1: The yoke 4 is formed. The yoke 4 is obtained by injection molding a soft magnetic material or a thermoplastic resin containing ferrite. When the yoke 4 is formed, a soft magnet or ferrite contained in the yoke 4 can be obtained by disposing a strong magnet outside the portion that forms the outer periphery of the yoke 4 and providing an orientation magnetic field. Oriented anisotropically with respect to the polar direction.

  (2) Step 2: The rotor magnet 3 is manufactured by integrally molding the resin magnet portion 5 on the outer periphery of the yoke 4. The rotor magnet 3 houses a yoke 4 in a mold, and a resin magnet made of a thermoplastic resin containing, for example, rare earth sama iron (samarium iron) is injection-molded on the outer periphery of the yoke 4 to integrate the resin magnet part 5. Can be obtained. Magnetic powder contained in the resin magnet part 5 by forming a strong magnet and providing an orientation magnetic field outside the part of the mold that forms the outer periphery of the resin magnet part 5 when the resin magnet part 5 is molded. Are oriented anisotropically with respect to the polar direction.

  (3) Step 3: Demagnetize the rotor magnet 3. In step 2, since the resin magnet part 5 is oriented anisotropically with respect to the polar direction, it has a magnetic force and is demagnetized in order to improve the subsequent workability.

  (4) Step 4: The runner of the rotor magnet 3 is excised. At the same time, the position detecting magnet 11 is formed. Further, the shaft 1 is processed. After the rotor magnet 3 is demagnetized, the axial runner (not shown), the donut-shaped runner 36, and the rib-shaped runner 35 (excluding the portion from the inner peripheral surface of the base 34 of the yoke 4 to the tip (radial direction)) are cut off. Is done.

  (5) Step 5: The rotor magnet 3, the position detecting magnet 11, and the shaft 1 are integrally molded with the thermoplastic resin 17.

  (6) Step 6: Magnetize the rotor magnet 3. In addition, the bearings 410 (two) are manufactured.

  (7) Step 7: Assemble the bearing 410 to the shaft 1 to manufacture the rotor 100 of the motor. In addition, the stator 300 and the bracket 439 of the electric motor are manufactured.

  (8) Step 8: The mold stator 350 is manufactured.

  (9) Step 9: The electric motor 400 is assembled.

Embodiment 2. FIG.
FIG. 48 is a diagram showing the second embodiment, and is a diagram showing a configuration of the air conditioner 500. As shown in FIG. 48, the air conditioner 500 includes an indoor unit 542 and an outdoor unit 543 connected to the indoor unit 542. The outdoor unit 543 includes a blower 544. The indoor unit 542 also includes a blower (not shown).

  The quality of the air conditioner 500 can be improved by using the high-quality motor 400 of Embodiment 1 as the blower motor that is the main part of the air conditioner 500 for the indoor unit 542 and the outdoor unit 543.

  1 axis, 2 knurled eyes, 3 rotor magnet, 4 yoke, 5 resin magnet part, 6 recess, 6a gate processing trace, 7 notch, 11 position detection magnet, 12 steps, 13 rib, 17 thermoplastic resin, 18 ribs, 19 bearing surface, 31 shaft outer peripheral cylindrical resin part, 32 gate convex part, 32a gate processing trace, 34 pedestal, 34a protruding part, 34b opening part, 35 rib-like runner, 35b position detection magnet holding Protrusion, 36 Donut-shaped runner, 36a Resin injection part trace, 37 Inner cylindrical resin part of the inner circumference of the yoke, 38 Type mating surface trace, 40 Gate convex part, 40a Gate treatment trace, 41 Rib, 44 Straight part, 45 Taper part, 46 type Mating surface trace, 47 concave part, 48 convex part, 50 pedestal part, 51 excision trace, 100 rotor of motor, 1 3 Rotor Magnet, 104 Yoke, 135 Rib Runner, 200 Motor Rotor, 300 Motor Stator, 301 Stator Core, 301a Teeth, 301a-1 Tip, 301b Core Back, 301c Thin Connection, 301d Core End face, 302 coil, 303 insulating part, 304 power supply terminal, 305 neutral point terminal, 308 protrusion, 341 connection parts, 350 mold stator, 363 stator core butting part, 364 welded part, 370 pin, 400 electric motor, 410 bearing 439 Bracket, 500 Air conditioner, 542 Indoor unit, 543 Outdoor unit, 544 Blower.

Claims (7)

A substantially cylindrical yoke molded from a thermoplastic resin containing soft magnetic material or ferrite;
A resin magnet portion integrally formed with a resin magnet on the outer periphery of the yoke;
A position detection magnet provided in the vicinity of one axial end of the resin magnet part;
The yoke is formed at an axial end of the yoke on the position detection magnet side, and has a pair of protrusions and an opening formed between the pair of protrusions, and the position detection magnet is separated by a predetermined distance. A pedestal that is installed separately,
The resin magnet portion protrudes outward in the axial direction from the axial end surface of the yoke on the position detection magnet side, radially from the donut-shaped runner located inside the yoke, radially outward from the donut-shaped runner, From the rib-like runner extending in the circumferential width of the opening of the yoke, the resin magnet is supplied and molded,
The rib-like runner uses the opening of the pedestal as a path for supplying the resin magnet, and the rib-like runner is integrated with the pedestal to form a pedestal portion. . The motor rotor according to claim 1, wherein a height of the rib-like runner is substantially equal to a height of the pedestal formed on the yoke. 3. The electric motor rotor according to claim 1, wherein the number of the rib-like runners and the pedestal formed on the yoke is equal to the number of magnetic poles of the resin magnet portion. 4.   The position detection magnet holding projection for holding the outer periphery of the position detection magnet is provided on the outer peripheral side of the pedestal formed on the yoke of the rib-like runner. The rotor of the electric motor described in 1.   An electric motor using the rotor of the electric motor according to claim 1.   An air conditioner equipped with the electric motor according to claim 5. A method of manufacturing an electric motor according to claim 5,
(1) a first step of forming the yoke;
(2) a second step of manufacturing a rotor magnet by integrally forming the resin magnet portion on the outer periphery of the yoke;
(3) a third step of demagnetizing the rotor magnet;
(4) a fourth step of cutting off the runner of the rotor magnet, forming a position detecting magnet, and further processing the shaft;
(5) a fifth step of integrally molding the rotor magnet, the position detecting magnet, and the shaft with a thermoplastic resin;
(6) a sixth step of magnetizing the rotor magnet and manufacturing a bearing together;
(7) a seventh step of manufacturing the rotor of the electric motor by assembling the bearing on the shaft, and manufacturing a stator and a bracket of the electric motor;
(8) an eighth step of producing a mold stator;
(9) a ninth step of assembling the electric motor;
A method for manufacturing an electric motor, comprising:

Images