JP4942806B2 - 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

  In a conventional rotor of a motor in which a resin magnet portion is formed on the outer periphery of a yoke, the yoke is set in a mold and a resin magnet is injected into the outer periphery of the yoke to form the resin magnet portion. At this time, not all of the injected resin magnet becomes a product (resin magnet part), and the part from the injection part of the mold to the product (resin magnet part) often does not become a product.

  If the number of magnetic poles (for example, 10 poles) outside the outer periphery of the yoke is the number of magnetic poles (for example, 10 poles) that are injected into the product (resin magnet part), The ratio of the amount of the resin magnet in the portion that does not become a product between the resin magnet injection portion of the mold (hereinafter referred to as “runner”) becomes so large that it cannot be ignored.

  When the amount of runners increases, the material cost increases when the runners are discarded. Further, when all runners are reused as resin magnets, there is a problem that physical properties (mechanical strength) are lowered.

The present invention has been made to solve the above-described problems, and provides a rotor for an electric motor, an electric motor, an air conditioner, and a method for manufacturing the electric motor rotor that can achieve the following objects.
(1) Cost reduction by reducing the amount of runners for the resin magnet part;
(2) When reusing all runners, lower the runner reuse ratio to suppress the decrease in physical properties (strength) of the resin magnet;
(3) A pedestal on which the position detection magnet is installed is formed on the resin magnet portion by a runner.

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 plurality of grooves provided on one axial end face of the yoke, extending radially in a radial direction, having a predetermined depth and a predetermined circumferential width;
A resin magnet part integrally formed by a resin magnet on the outer periphery of the yoke;
A pedestal formed to protrude from the resin magnet portion a predetermined distance outward in the axial direction;
A magnet for position detection installed on the pedestal,
The resin magnet part is molded by supplying a resin magnet from a donut-like runner located inside the yoke and a rib-like runner extending radially outward from the donut-like runner to the outer periphery of the yoke,
The rib-shaped runner uses the groove of the yoke as a path to which the resin magnet is supplied,
The pedestal is formed on the rib-like runner.

  Since the rotor of the electric motor according to the present invention reduces the amount of runners relative to the product, the cost can be reduced. Further, when all runners are reused, the product quality can be improved by lowering the runner reuse ratio and suppressing the decrease in physical properties (strength) of the resin magnet. Further, the pedestal on which the position detection magnet is installed can be formed integrally with the resin magnet portion by the rib-like runner.

Fig. 5 shows the first embodiment, and is a front view of a rotor 100 of the electric motor. FIG. 5 shows the first embodiment and is a side view of the position detecting magnet 11 side of the rotor 100 of the electric motor. FIG. 5 shows the first embodiment, and is a side view of the opposite side of the position detection magnet 11 of the rotor 100 of the electric motor. FIG. 3 shows the first embodiment, and is a WW sectional view of FIG. 2. FIG. 3 shows the first embodiment and is a TT cross-sectional view of FIG. 2. 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. 3 shows the first embodiment and is a front view of the shaft 1; 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. 11 shows the first embodiment, and is an enlarged view of the vicinity of the end surface of the position detection magnet 11 of the gate protrusion 40 of FIG. 10. 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. 12 shows the first embodiment and is an enlarged view of FIG. FIG. 12 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 as viewed from the groove 33 side. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of the yoke 4 as viewed from the concave portion 6 side. FIG. 18 shows the first embodiment and is a partially enlarged view of FIG. 17. FIG. 12 shows the first embodiment and is a partially enlarged view of FIG. FIG. 12 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 a side view seen from the runner 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. 22 shows the first embodiment and is an enlarged view of FIG. FIG. 22 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. 26 shows the first embodiment, and is an enlarged perspective view near the rib-like runner 35 of FIG. 25. 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. 2 is a diagram showing the first embodiment, and is a diagram showing a rotor magnet 3 with a runner cut away ((a) is a side view seen from the concave portion 6 side, (b) is a sectional view taken along line DD in (a), and (c) ) Side view from the runner side). FIG. 5 shows the first embodiment, and is a perspective view of the rotor magnet 3 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. 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 42 show the first embodiment. FIG. 1 is a front view of the rotor 100 of the electric motor, FIG. 2 is a side view of the position detection magnet 11 side of the rotor 100 of the electric motor, and FIG. 4 is a side view of the rotor 100 opposite to the position detecting magnet 11, FIG. 4 is a cross-sectional view taken along the line WW in FIG. 2, FIG. 5 is a cross-sectional view taken along the line TT in FIG. 7 is a perspective view as seen from the position detecting magnet 11 side, FIG. 7 is an enlarged view of the vicinity of the end face of the position detecting magnet 11 of the gate convex portion 32, FIG. 8 is an enlarged view of the vicinity of the gate convex portion 32 of FIG. 10 is a front view of the shaft 1, FIG. 10 is a perspective view of the rotor 200 of the modified motor as viewed from the position detection magnet 11 side, and FIG. 11 is a view of the vicinity of the position detection magnet 11 side end surface of the gate protrusion 40 of FIG. FIG. 12 is an enlarged view, and FIG. 12 is a view showing the yoke 4 ((a) is a side seen from the recess 6 side (B) is a cross-sectional view taken along the line B-B of (a), (c) is a side view seen from the position detecting magnet 11 side), and FIG. 14 is an enlarged view of FIG. 12 (a), FIG. 15 is an enlarged view of FIG. 12 (c), and FIG. 16 is a perspective view of the yoke 4 as viewed from the groove 33 side. 17 is a perspective view of the yoke 4 as viewed from the concave portion 6 side, FIG. 18 is a partially enlarged view of FIG. 17, FIG. 19 is a partially enlarged view of FIG. 12 (b), and FIG. 20 is an enlarged view of FIG. 21 is a view showing the rotor magnet 3 before cutting off the runner ((a) is a side view seen from the recess 6 side, (b) is a cross-sectional view taken along the line CC in (a), and (c) is from the runner side. FIG. 22 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, and FIG. FIG. 24 is an enlarged view of FIG. 21C, FIG. 25 is a perspective view of the rotor magnet 3 before the runner is cut from the runner side, and FIG. 26 is a rib-like runner of FIG. FIG. 27 is a partial plan view showing the flow of the resin magnet when the rotor magnet 3 is molded, and FIG. 28 is a view showing the rotor magnet 3 with the runner removed ((a) is the side of the recess 6). (B) is a sectional view taken along DD of (a), (c) is a side view seen from the runner side), FIG. 29 is a perspective view of the rotor magnet 3 seen from the pedestal 50 side, 30 is a perspective view of the rotor magnet 3 viewed from the concave portion 6 side, FIG. 31 is a perspective view of the position detection magnet 11, FIG. 32 is a view showing the position detection magnet 11 ((a) is a plan view, (b) ) Is a sectional view taken along line FF in FIG. FIG. 34 is a perspective view of the stator 300 of the motor, FIG. 35 is a perspective view showing a state where the stator 300 of the motor is reversely bent and wound, and FIG. 36 is a stator core 301 (band-shaped). 37 is a perspective view showing a state in which a terminal is attached with an insulating portion 303 applied to a stator core 301 (strip shape). FIG. 38 is a cross section of a 12-slot / 10-pole synchronous motor using the stator 300 of the motor. 39 is a connection diagram of the stator windings of the stator 300 of the motor, FIG. 40 is a development view showing a method of connecting the stator windings of the stator 300 of the motor, and FIG. 41 is a diagram showing the motor 400. Reference numeral 42 denotes a manufacturing process of the electric motor 400.

  1 to 8, a shaft 100, a rotor magnet 3, and a position detection magnet 11 are set in a resin molding die, and thermoplastic such as PBT (polybutylene terephthalate). The resin 17 is molded by being injected into a resin molding die.

  Thereafter, bearings 410 (see FIG. 41, 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 (see FIG. 41) contacts the surface 19 (see FIGS. 4 and 5) formed on the outer periphery of the shaft 1 by the thermoplastic resin 17 and holding the bearing of the cylindrical shaft outer peripheral cylindrical resin portion 31. Touch.

  As shown in FIG. 9, a knurled eye 2 is applied to a portion of the thermoplastic resin 17 of the shaft 1 that is inscribed in the shaft outer peripheral cylindrical 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. 5), the rotor magnet 3 is assembled into the lower mold of the mold.

  The lower mold of the mold is fitted with a tapered notch 7 (see FIGS. 3 to 5, 12) provided on the axial end surface of the yoke 4 on the recess 6 side, Convex part with coaxial secured. 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. 12A). 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, there are five convex portions of the lower mold that are fitted into a tapered notch 7 provided on the axial end surface of the yoke 4 on the concave portion 6 side. 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 workability is improved.

  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 detecting magnet 11 (see FIGS. 31 to 33) is installed inside the base 50 (see FIG. 29) of the rotor magnet 3, the mold is closed and the thermoplastic resin 17 such as PBT is placed. Injection and molding.

  Although the position detection magnet 11 will be described in detail later, the position detection magnet 11 includes steps 12 (see FIGS. 31 to 33) at both axial end portions on the inner diameter side, and the thickness direction (see FIG. 33). 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. 31 to 33) on the end side (outside) of the rotor magnet 3 in the axial direction. 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. 31 to 33, the position detecting 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 base 50 (see FIG. 29) 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 rib-like runner 35 (the part remaining as a product) inside the position detection magnet holding projection 50b of the base 50 (see FIG. 29) of the rotor magnet 3 (substantially horizontal). Status).

  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 50b.

  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. 29) 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 is centrifuged. Force acts.

  However, since the position detection magnet holding projection 50b exists around the position detection magnet 11, the position detection magnet holding projection 50b prevents the positional displacement in the radial direction and is less likely to fall off the rotor magnet 3. . Thereby, productivity is improved.

  By resin molding, on the outer periphery of the shaft outer peripheral cylindrical resin portion 31 (see FIGS. 4 and 5) in which the thermoplastic resin 17 is cylindrically formed on the outer periphery of the shaft 1, radially from the outer periphery of the shaft outer peripheral cylindrical resin portion 31, 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. 7, the gate processing trace 32 a 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 the number of magnetic poles (here, five half of 10 poles) (see FIG. 2).

  The gate protrusion 32 extends from the shaft outer peripheral cylindrical resin portion 31 in the radial direction with a predetermined length r (see FIG. 7). The inner circumferential surface of the yoke inner circumferential cylindrical resin portion 37 (see FIGS. 6 and 7) and the radial tip of the gate convex portion 32 are separated from each other 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 surface (position detection magnet 11 side) of the gate convex portion 32 has a predetermined dimension d1 (see FIG. 8, for example, about 1 mm) from the axial end surface on which the position detection magnet 11 of the rotor magnet 3 is provided. ) Only inside.

  As shown in FIGS. 4 and 5, 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. 7, 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. 41, for example, a ball bearing) is smaller than the inner diameter of the yoke inner circumferential cylindrical resin portion 37 (see FIGS. 6 and 7), the mold stator 350 (see FIG. 41). There is a possibility that the protrusion of the gate processing trace 32a interferes 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. 2, 3, and 6, 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. 2, 3, and 6, ten ribs 18 are radially formed 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. Yes.

  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 rotor 200 of the electric motor according to the modification is different from the rotor 100 of the electric motor 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. 11, a gate processing trace 40 a remains on the axial end surface of the gate convex portion 40 on the position detection 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. 12) and the pedestal 50 (see FIG. 29) are filled so that the thermoplastic resin 17 is embedded, and serves as a torque stop and a rotation stop in the rotation direction.

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

  That is, by using the recess 6 for preventing the protrusion of the gate processing trace 6a (see FIG. 18) from protruding from the end surface in the axial direction of the yoke 4, and the pedestal 50 for positioning the position detecting magnet 11, 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. 13, 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. 13, the grooves 33 (or the recesses 6 and the cutouts 7) are omitted for the sake of clarity.

  As shown in FIG. 12, the yoke 4 is formed in a substantially cylindrical shape. On the outer periphery of the yoke 4, as shown in FIG. 14, concave portions 47 and convex portions 48 are alternately arranged. Here, the number of the concave portions 47 and the convex portions 48 is 10 (since the rotor 100 of the electric motor has 10 poles).

  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.

  On one end face in the axial direction of the yoke 4, a plurality of recesses 6 (for example, circular shapes) having an axial depth d2 (see FIG. 19) are formed at substantially equal intervals in the circumferential direction (the number of magnetic poles). 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. 18) 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. 18) does not protrude from the end surface of the yoke 4 in the axial direction. Accordingly, the axial depth d2 (see FIG. 19) 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. 14, by providing a gate opening (remaining as a gate processing trace 6a) in a portion where the thickness is 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. 19))) 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. 20) of the yoke 4 is a tapered portion from the axial end surface on the side provided with the concave portion 6 to a substantially central position in the axial direction (the mold matching surface mark 46 (see FIG. 20) when the yoke 4 is formed). 45 (see FIG. 20). 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. 20) having a constant diameter is formed from the mold matching surface trace 46 of the tapered portion 45 to the axial end surface on the groove 33 side.

  The tapered portion 45 (see FIG. 20) of the hollow portion of the yoke 4 is formed with a fixed mold. Further, the straight portion 44 (see FIG. 20) of the hollow portion of the yoke 4 is formed by a movable mold.

  By forming the tapered portion 45 (see FIG. 20) of the hollow portion of the yoke 4 with a fixed mold, the resistance of the product (yoke 4) sticking to the fixed mold when the mold is opened is reduced.

  Further, by forming the straight portion 44 (see FIG. 20) 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. 12A and 14, the axial end surface of the yoke 4 on the side provided with the recess 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 recesses 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. 20) 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.

  As shown in FIGS. 12 (c), 15 and 16, a plurality of radial grooves 33 are formed on the axial end surface opposite to the axial end surface provided with the recess 6 of the yoke 4, which is the same as the number of poles in this case. This is provided so as to penetrate from the inner peripheral side to the outer peripheral side. The groove 33 serves as a path for supplying a resin magnet when a resin magnet portion 5 described later is formed integrally with the yoke 4.

  The groove 33 has a predetermined depth and width (circumferential direction), and can sufficiently secure the fluidity of the resin magnet while suppressing the influence on the magnetic characteristics to the resin magnet portion 5 as much as possible. Further, the groove 33 is arranged at the position of the magnetic pole, and is optimally arranged so that the magnetic characteristics of the resin magnet portion 5 can be drawn to the maximum.

  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. 22).

  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 a state where the yoke 4 is incorporated in the mold, the core end surface of the lower mold for molding the resin magnet portion 5 is located at the end surface (end surface opposite to the notch 7) provided with the groove 33 of the yoke 4. (See FIG. 23).

  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 half of the magnetic pole on the donut-shaped runner 36 (see FIG. 24) 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 molding the resin magnet part 5 remains as a resin injection part trace 36a in the donut-shaped runner 36 (see FIG. 24).

  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 doughnut-shaped runner 36 is formed at the height of the end surface including the groove 33 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-shaped runner 35 is formed at substantially the same height as the donut-shaped runner 36 (the height of the end surface including the groove 33 of the yoke 4).

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

  See FIG. 23 for the tapered shape that decreases inward in the axial direction from the end face of the core (lower mold) of the donut-shaped runner 36.

  Further, the taper shape that decreases inward in the axial direction from the end face of the core portion (lower mold) of the rib-like runner 35 is not shown.

  A rib-like runner 35 extending radially from the donut-like runner 36 has a groove 33 of the yoke 4 as a path from the axial end surface of the core (lower mold) of the mold for molding the resin magnet portion 5. It extends from the inner peripheral side to the outer peripheral side of the end face provided.

  As shown in FIG. 24 to FIG. 27, by a resin magnet injected from the rib-like runner 35, a pedestal portion 50 a on which the position detection magnet 11 is placed and a position detection magnet that holds the position detection magnet 11 in the radial direction. A pedestal 50 having a magnet holding projection 50b is formed.

  As shown in FIG. 27, 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 is a straight portion 44 (see FIG. 20) in which the diameter of the circle of the cross section from the end surface including the groove 33 to the die-matching surface mark 46 is substantially constant, and the yoke 4 is hollow. The straight portion 44 of the hollow portion of the yoke 4 is made as small as possible by reducing the gap between the straight portion 44 of the portion and the core portion (lower die) of the mold for molding the resin magnet portion 5 fitted to the straight portion 44. In addition, it becomes possible to suppress the leakage of the resin magnet into the gap with the core portion (lower mold) of the mold for molding the resin magnet portion 5, 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 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. 21, as shown in FIG. 28, a part of the rib-like runner 35 (the part from the inner peripheral surface of the groove 33 of the yoke 4 to the tip (radial direction)) Product (pedestal 50).

  That is, other runners (not shown), donut-like runners 36, and rib-like runners 35 (excluding a part, excluding a portion from the inner circumferential surface of groove 33 of yoke 4 to the tip (radial direction)) are rotor magnets. After completion of the molding of No. 3, it is cut out (see FIG. 28).

  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 FIGS. 28 and 29, the other runners not shown, the donut-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 out from the donut-like runner 36 to the inner peripheral surface (straight portion 44) of the groove 33 of the yoke 4 extending radially. 28 and 29, the portion from the donut-shaped runner 36 of the rib-like runner 35 to the inner peripheral surface (straight portion 44) of the groove 33 of the yoke 4 extending radially is cut away, that is, the rib-like runner on the product is left. However, the rib-like runner from the inner peripheral surface to the inner peripheral side surface of the pedestal 50 may also be cut off.

  As shown in FIG. 29, the pedestal 50 includes a pedestal portion 50a on which the position detection magnet 11 is placed, and a position detection magnet holding projection 50b that holds the position detection magnet 11 in the radial direction.

  The doughnut-like runner 36 and the rib-like runner 35 are cut off inside the straight portion 44, but the portion formed in the groove 33 of the yoke 4 of the rib-like runner 35 is a non-cut portion 35a (see FIG. 29)).

  As already described, the position detection magnet 11 is disposed on the upper surface of the pedestal portion 50a inside the position detection magnet holding projection 50b (see FIG. 29) of the pedestal 50 of the rotor magnet 3.

  When the position detection magnet 11 is placed on the pedestal 50a (see FIG. 29) 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 50b is present in the surroundings, the position detection magnet holding projection 50b prevents the position detection magnet 11 from being displaced in the radial direction. There is little risk of falling off. Thereby, productivity is improved.

  Further, the position detection magnet holding projection 50b formed on the resin magnet portion 5 is used as a positioning projection for positioning in the circumferential direction when the rotor magnet 3 is molded integrally with the shaft 1 with the thermoplastic resin 17. Is also used.

  As described above, after 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, By cutting out the rib-like runner 35 and the donut-like runner 36, the rotor magnet 3 of the present embodiment is obtained.

  When the position detection magnet 11 (see FIGS. 31 to 33) is not used, the pedestal 50 for the position detection magnet 11 is not necessary, and the donut-shaped runner 36, the rib-shaped runner 35, and the pedestal 50 are completely removed. It may be excised. At this time, the donut-shaped runner 36, the rib-shaped runner 35, and the pedestal 50 are cut off inside the straight portion 44. The portion formed in the groove 33 of the yoke 4 of the rib-like runner 35 remains in the product. 28 and 29, the portion from the donut-shaped runner 36 of the rib-like runner 35 to the inner peripheral surface (straight portion 44) of the groove 33 of the yoke 4 extending radially is cut away, that is, the rib-like runner on the product is left. However, the rib-like runner from the inner peripheral surface to the inner peripheral side surface of the pedestal 50 may also be cut off.

  Further, when the position detection magnet 11 (see FIGS. 31 to 33) is not used, the base 50 may not be formed by the resin magnet when the resin magnet portion 5 is molded.

  Next, the position detection magnet 11 will be described with reference to FIGS. As shown in FIGS. 31 to 33, the ring-shaped position detecting magnet 11 is provided with steps 12 at both axial end portions on the inner diameter side and is symmetric in the thickness direction (see FIG. 35).

  The position detection magnet 11 is provided at one end of the motor rotor 100 in the axial direction (see FIGS. 4 and 5). The thermoplastic resin 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.

  In addition, although what has the level | step difference 12 in both ends was shown in FIGS. 31-33, there exists the level | step difference 12 in any one edge part, and it is located in the axial direction edge part side of the rotor 100 of an electric 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. 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. 41) 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. 35 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. 35) 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. 35) 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. 34 for the stator core butting portion 363 and the welded portion 364.

  As shown in FIG. 37, the insulating part 303 is formed in the strip-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 connection side (upper side in FIG. 37) of the insulating portion 303 to a band-shaped stator core 301 in which the insulating portion 303 is formed by integral molding.

  As shown in FIG. 38, 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. 39, 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 connection method of the stator winding 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 301a from the left (third 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 301a 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. 41, 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. 41, a connecting 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 doughnut-shaped runner 36, and the rib-shaped runner 35 (excluding the portion from the inner circumferential surface of the groove 33 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, the bracket 439, etc. 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. 43 is a diagram illustrating the second embodiment, and is a diagram illustrating a configuration of the air conditioner 500. As shown in FIG. 43, 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, 33 groove, 35 rib shaped runner, 35a non-removed part, 36 donut shaped runner, 36a resin injection part Trace, 37 Yoke inner circumference cylindrical resin part, 38 Mold mating surface trace, 40 Gate convex part, 40a Gate processing trace, 41 Rib, 44 Straight part, 45 Tapered part, 46 Mold mating surface trace, 47 Concave part, 48 Convex part, 50 pedestal, 50a pedestal, 50b magnet holding projection for position detection, 100 rotor of electric motor, 200 of electric motor Trochanter, 300 stator of motor, 301 stator core, 301a teeth, 301a-1 tip, 301b core back, 301c thin connector, 301d core end face, 302 coil, 303 insulation, 304 power supply terminal, 305 neutral Point terminal, 308 Projection, 341 Connection parts, 350 Mold stator, 363 Stator core butt, 364 Weld, 370 pin, 400 Electric motor, 410 Bearing, 439 Bracket, 500 Air conditioner, 542 Indoor unit, 543 Outdoor unit 544 Blower.

Claims (6)

A substantially cylindrical yoke molded from a thermoplastic resin containing soft magnetic material or ferrite;
A plurality of grooves provided on any one axial end face of the yoke, extending radially in a radial direction, having a predetermined depth and a predetermined circumferential width;
A resin magnet portion integrally formed with a resin magnet on the outer periphery of the yoke;
A pedestal formed to protrude from the resin magnet portion by a predetermined distance outward in the axial direction;
A position detecting magnet installed on the pedestal,
The resin magnet portion is molded by supplying the resin magnet from a donut-shaped runner positioned inside the yoke and a rib-shaped runner extending radially outward from the donut-shaped runner to the outer periphery of the yoke. ,
The rib-shaped runner has the groove of the yoke as a path through which the resin magnet is supplied,
The pedestal is formed on the rib-shaped runner, and the rotor of the electric motor is characterized in that the pedestal is formed on the rib-shaped runner.   The number of the said rib-like runner and the said base is made equal to the number of the magnetic poles formed in the said rotor, The rotor of the electric motor of Claim 1 characterized by the above-mentioned.   3. The electric motor rotor according to claim 1, wherein the pedestal includes a position detection magnet holding projection that holds an outer periphery of the position detection magnet. 4.   The electric motor using the rotor of the electric motor in any one of Claims 1-3.   An air conditioner equipped with the electric motor according to claim 4. A method of manufacturing an electric motor according to claim 4,
(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 the position detecting magnet, and 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:

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