JP5737499B2 - DISK MOTOR, ELECTRIC WORKING MACHINE HAVING THE SAME, AND DISK MOTOR MANUFACTURING METHOD - Google Patents

Description

  The present invention relates to a disk motor having a structure in which at least two coil disks are bonded, an electric working machine including the disk motor, and a method of manufacturing the disk motor.

  The disk motor of Patent Document 1 below is opposed to an output shaft, a coil disk fixed to the output shaft and having a substantially disk shape and printed with a coil pattern, a commutator connected to the coil pattern, and the coil pattern. And a brush for supplying current to the commutator.

  The rotational speed of the disk motor is determined by the voltage supplied from the brush, the current of the disk motor, the coil pattern of the coil disk, the magnetic flux of the magnet, the number of brushes (number of poles), and the like. If the voltage supplied from the brush and the current of the disk motor are constant, the disk motor can be set to the desired number of revolutions by changing the coil pattern of the coil disk, the magnetic flux of the magnet, and the number of brushes. It becomes.

  The laminated coil substrate of Patent Document 2 below is a portion in which a dummy electrode is formed on the same surface as the coil electrode, and the distance between the coil electrode and the dummy electrode is closest by the reinforcing electrode laminated on the laminated coil substrate. Is a structure in which a region including a part of a coil electrode and a part of a dummy electrode are sandwiched in the stacking direction, thereby improving the mechanical strength. The laminated coil substrate is a sintered substrate obtained by laminating and sintering ceramic green sheets.

  The multilayer substrate of Patent Document 3 below prevents an epoxy resin of an adhesive prepreg that melts by heat at the time of lamination bonding from flowing out between the substrates by providing a surrounding pattern surrounding the coil pattern around the coil pattern. It is said.

  The thin laminated coil of the following Patent Document 4 has a structure in which a dummy pattern that is electrically disconnected from the coil pattern is provided on the upper and lower surfaces of at least two double-sided substrates that face each other among a plurality of double-sided substrates. According to this, the interlayer plate can be thinly formed by the dummy pattern originally formed in the portion where the interlayer plate (prepreg) should intervene, and the resin filling amount impregnated in the interlayer plate can be reduced. At the same time, the dummy pattern serves as a dam and prevents the resin impregnated in the interlayer plate from leaking to the surroundings.

Japanese Patent No. 3636700 JP 2006-157985 A JP-A-9-232162 JP-A-9-45531

  In the disk motor of Patent Document 1, the area of the non-pattern-formed portion where no conductor pattern exists on the coil disk surface is large. For this reason, when laminating a plurality of coil disks of Patent Document 1, since the pattern non-formed portion is low in height and has little contribution to adhesion (or no contribution), the substantial adhesion contribution area is small, There is a problem that the adhesive strength between the layers is low. On the other hand, since the dummy electrode, the surrounding pattern, or the dummy pattern disclosed in Patent Documents 2 to 4 must be provided outside the coil pattern, application to the coil disk for the motor leads to an increase in the radial direction. Is unrealistic.

  The present invention has been made in view of such a situation, and an object of the present invention is to have a structure having at least two coil disks bonded to each other, and to increase the adhesive strength of the two coil disks as compared with the prior art. It is an object of the present invention to provide a disc motor that can perform the above, an electric working machine including the disc motor, and a disc motor manufacturing method.

The first aspect of the present invention is a disk motor. This disc motor
An output shaft;
Coaxially fixed to the output shaft and at least two coil disks in which a coil pattern including a plurality of radial patterns or groups of radial patterns extending radially outward from the center side is formed on one side or both sides and bonded to each other When,
A current supply unit for supplying current to the coil pattern;
A magnetic flux generator facing the coil pattern,
A reinforcing pattern is formed between adjacent radial patterns or groups of radial patterns on at least one of the coil disks,
The forming surface of the reinforcing pattern is an adhesive surface with the other coil disk ,
The coil pattern is present on at least the mutually facing surfaces of the two coil disks, and the other radial pattern or radial pattern is disposed between one adjacent radial pattern or group of radial patterns on the mutually facing surface when viewed in the axial direction. pattern group is characterized that you position.

  In the disk motor, the reinforcing pattern may be a small pattern insulated from each other.

  Each small pattern may be narrower than the radial pattern and may extend substantially parallel to the radial direction of the coil disk.

  Each small pattern may be narrower than the radial pattern and may extend substantially perpendicular to the radial direction of the coil disk.

  In the disk motor, the reinforcing pattern may be substantially the same in height from the substrate surface of the coil disk as the coil pattern.

  In the disk motor, the reinforcing pattern may be made of the same material as the coil pattern.

  In the disk motor, the at least two coil disks may be bonded to each other via a sheet-like adhesive layer covering substantially the entire surface.

  In the disk motor, the plurality of radial patterns or groups of radial patterns may be arranged and formed at a predetermined interval in the circumferential direction of the coil disk.

  In the disk motor, the coil patterns may be provided on both sides of the coil disk and connected to each other.

  Another aspect of the present invention is an electric working machine including the disk motor.

Another aspect of the present invention is a method for manufacturing a disk motor. This method
An output shaft;
A coil pattern including a plurality of radial patterns or a group of radial patterns fixed coaxially to the output shaft and extending radially outward from the center side, and at least two coil disks bonded together;
A current supply unit for supplying current to the coil pattern;
A method of manufacturing a disk motor comprising a magnetic flux generator facing the coil pattern,
In the etching process of the conductor layer for forming the coil pattern of at least one of the coil disks, a reinforcing pattern is formed together with the coil pattern between adjacent radial patterns or radial pattern groups,
In the bonding step of bonding the two coil disks, the reinforcing pattern forming surface is used as the bonding surface, and the surfaces of the two coil disks on which the coil patterns are formed are opposed to each other, and viewed in the axial direction. And covering the substantially entire surface of the coil disk so that the other radial pattern or group of radial patterns is located between one adjacent radial pattern or group of radial patterns on the mutually facing surfaces of the two coil disks. The two coil disks are bonded and fixed to each other with a sheet-like adhesive layer interposed therebetween.

  It should be noted that any combination of the above-described constituent elements, or a conversion of the expression of the present invention between systems or the like is also effective as an aspect of the present invention.

  According to the present invention, since the reinforcing pattern is formed between adjacent radial patterns or groups of radial patterns on at least one of the coil disks, the adhesive strength between the two coil disks can be increased as compared with the related art. It is possible to realize a possible disc motor, an electric working machine including the disc motor, and a disc motor manufacturing method.

The perspective view of the brush cutter as an electrically-driven working machine which concerns on embodiment of this invention. FIG. 2 is a front sectional view of a drive unit of the brush cutter shown in FIG. 1. FIG. 3 is a schematic plan view of the stator shown in FIG. 2. The front view which made the left half of the rotor shown in FIG. 2 the cross section. The top view of the commutator board | substrate shown in FIG. (A) is a top view of the 1st coil disk shown in FIG. (B) is a bottom view of the coil disk. The coil pattern explanatory drawing of a 1st coil disk. (A) is a lamination | stacking cross-section enlarged view of the 1st coil disk and 2nd coil disk which are shown in FIG. (B) is a lamination | stacking cross-section enlarged view of the comparative example which removed the reinforcement pattern from (A). FIG. 9A is a plan view of a coil disk according to a comparative example shown in FIG. (B) is a bottom view of a coil disk according to the comparative example. FIG. 7 is a plan view of a coil disk having a reinforcing pattern (part 1) different from the example of FIG. FIG. 7 is a plan view of a coil disk having a reinforcing pattern (part 2) different from the example of FIG. FIG. 7 is a plan view of a coil disk having a reinforcing pattern (part 3) different from the example of FIG. FIG. 7 is a plan view of a coil disk having a reinforcing pattern (part 4) different from the example of FIG.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. In addition, the same code | symbol is attached | subjected to the same or equivalent component, member, etc. which are shown by each drawing, and the overlapping description is abbreviate | omitted suitably. In addition, the embodiments do not limit the invention but are exemplifications, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

  FIG. 1 is a perspective view of a brush cutter 1 according to an embodiment of the present invention. A brush cutter 1, which is an example of an electric working machine, includes a power supply unit 3, a pipe unit 4, a handle unit 5, a drive unit 6, and a cutting blade 7.

  The power supply unit 3 has a battery 301 as a power source detachable. The pipe unit 4 mechanically connects (links) the power supply unit 3 and the drive unit 6. A wiring (not shown) for electrically connecting the power supply unit 3 and the drive unit 6 is inserted into the pipe unit 4. Power is supplied from the power supply unit 3 to the drive unit 6 by this wiring. The drive unit 6 accommodates a disk motor inside the head housing 61, and rotationally drives the cutting blade 7 with power supplied from the power supply unit 3. The configuration of the disk motor will be described later.

  The handle portion 5 is attached and fixed in the middle of the pipe portion 4, that is, between the power source portion 3 and the drive portion 6. The handle portion 5 is formed by attaching grips 52 to the tips of a pair of arms 51. One grip 52 is provided with a throttle 53. The operator can adjust the power supplied to the drive unit 6 by operating the throttle 53, that is, the rotation speed of the cutting blade 7 can be adjusted. The cutting blade 7 has a substantially disk shape, and a sawtooth is formed on the periphery thereof. In addition, a hole (not shown) is formed at the center of the cutting blade 7 to be attached to an output shaft of a disk motor described later.

  FIG. 2 is a front sectional view of the drive unit 6 of the brush cutter 1 shown in FIG. In addition, as shown in FIG. 2, the extending direction of the output shaft 31 is defined as the up-down direction. The drive unit 6 has a disk motor 80 inside the head housing 61. The head housing 61 is formed by fitting and integrating a cover portion 62 and a base portion 63. The disk motor 80 includes a stator 81, a rotor 82, and a pair of brushes 83. The pair of brushes 83 are provided symmetrically with respect to the rotating shaft (output shaft 31) of the disk motor 80 and are supported by the brush holder 65 of the cover portion 62. Each brush 83 is urged toward the commutator substrate 35 (lower side) by a spring 83A so that the lower surface abuts a commutator pattern of a conductor such as copper on the commutator substrate 35 described later. The brush 83 is connected to the power supply unit 3 in FIG. 1 and functions as a current supply unit that supplies a current to a coil pattern (to be described later) of the rotor 82.

  The stator 81 includes a magnet 41 as a magnetic flux generator, and an upper yoke 42 and a lower yoke 43 that are soft magnetic bodies. The ring-shaped upper yoke 42 is fixed to the lower surface of the cover portion 62 with, for example, screws 622. The ring-shaped lower yoke 43 having substantially the same diameter as the upper yoke 42 is fixed to the ring-shaped groove 631 formed on the lower surface of the base portion 63 with, for example, a screw 632. The magnet 41 is fitted and fixed in a hole 633 formed on the upper surface of the base portion 63.

  FIG. 3 is a schematic plan view of the stator 81 shown in FIG. As shown in the figure, for example, ten disk-shaped magnets 41 are arranged at an equal angular pitch on the circumference (the holes 633 in FIG. 2 accommodating the magnets 41 are also located on the circumference. The same number exists side by side). The center of the circumference substantially coincides with the rotation center of the disk motor 80. Adjacent magnets 41 have different top magnetic poles. As the magnet 41, a rare earth magnet such as a neodymium magnet is preferable, but a sintered magnet such as a ferrite magnet may be used. The upper yoke 42 and the lower yoke 43 increase the magnetic flux density applied to the coil pattern of the rotor 82 described later.

  As shown in FIG. 2, the rotor 82 includes an output shaft 31 (rotor shaft), a commutator substrate 35, a coil portion 36, and a flange 37. The output shaft 31 is rotatably supported by an upper bearing 311 fixed to the cover portion 62 and a lower bearing 312 fixed to the base portion 63. A male screw 31A is formed at the lower end of the output shaft 31, and the cutting blade 7 of FIG. 1 is fixed by a fastener (not shown). The upper surface of the commutator substrate 35 is a sliding surface of the brush 83. A current is supplied from the power supply unit 3 shown in FIG. 1 to the coil unit 36 via the brush 83 and the commutator substrate 35.

  FIG. 4 is a front view of the rotor 82 shown in FIG. As shown in the figure, a flange 37 made of metal such as aluminum, which is coaxially fixed to the output shaft 31, is composed of a substantially cylindrical cylindrical portion 37A and a substantially circular disc portion 37B. The The disc portion 37B protrudes outward from the side surface of the cylindrical portion 37A perpendicularly to the output shaft 31. The insulating plates 38 and 39 having the same shape as the disc portion 37B in the axial direction are bonded and fixed to the upper and lower surfaces of the disc portion 37B by sheet-like adhesive layers 502 and 503 (insulating properties) having the same shape. The commutator substrate 35 is bonded and fixed to the upper surface of the insulating plate 38 via a sheet-like adhesive layer 501 (insulating). The coil portion 36 is bonded and fixed to the lower surface of the insulating plate 39 via a sheet-like adhesive layer 505 (insulating).

  The coil portion 36 is formed by laminating a first coil disk 361 to a fourth coil disk 364 with a sheet-like adhesive layer 507 (insulating property) interposed therebetween. The sheet-like adhesive layer 507 has the same shape as each coil disk when viewed in the axial direction, and covers substantially the entire surface of each coil disk. The first coil disk 361 to the fourth coil disk 364 have a larger diameter than the disk portion 37B, and a coil pattern described later is formed on both surfaces. The conductor pins 40 extending from the commutator substrate 35 to the fourth coil disk 364 electrically connect the commutator pattern of the commutator substrate 35 and at least one of the coil patterns of the first coil disk 361 to the fourth coil disk 364. Connect to. An insulating pipe 401 is fitted into the through hole (the insertion hole for the pin 40) of the disc portion 37B to ensure insulation between the pin 40 and the flange 37.

  FIG. 5 is a plan view of the commutator substrate 35 shown in FIG. A through-hole 35A at the center of the disc-shaped commutator substrate 35 (commutator disk) is for inserting the cylindrical portion 37A of FIG. A predetermined number of pin insertion holes 35B are provided at equal distances from the center of the commutator substrate 35, and the pins 40 shown in FIG. 4 are selectively inserted into some of the pin insertion holes 35B. The commutator pattern 351 formed on the commutator substrate 35 is radially divided into 40 segments. Two segments (first, ninth, second, tenth, etc.) with seven segments in between are connected to each other by a connection pattern (not shown) formed on the opposite side of the connection pattern 352 formed on the inside. It is connected.

  FIG. 6A is a plan view of the first coil disk 361 shown in FIG. FIG. 6B is a bottom view of the coil disk. Since the other coil disks have the same structure as the first coil disk 361 and have the same coil pattern, only the first coil disk 361 will be described here.

  The first coil disk 361 has a coil pattern 92 and a reinforcing pattern 93 on both surfaces of a disk-shaped insulating substrate 90 (for example, an insulating resin substrate such as a glass fiber reinforced epoxy resin substrate). The through hole 91 at the center of the insulating substrate 90 is for inserting the cylindrical portion 37A of FIG. A total of 16 pin insertion holes 94 are formed, four each at an angle of 90 ° from the center of the insulating substrate 90. The distances from the pin insertion holes 94 to the center of the insulating substrate 90 are equal to each other. Each pin insertion hole 94 communicates with one of the pin insertion holes 35 </ b> B formed in the commutator substrate 35.

  The coil pattern 92 made of copper or other conductive material has 20 partial coil pattern groups 920 each made up of two rows of patterns having substantially the same width close to each other. The partial coil pattern group 920 is formed by sequentially connecting the inner communication pattern group 92A, the radial pattern group 92B, and the outer communication pattern group 92C. The inner side connection pattern groups 92A on both sides are electrically connected to each other through through holes 921 formed in the vicinity of the end portions. The outside contact pattern groups 92C on both sides are electrically connected to each other through through holes 922 formed in the vicinity of the end portions. The radial pattern group 92B extends radially outward from the center side of the insulating substrate 90 and passes the inner contact pattern group 92A and the outer contact pattern group 92C. The radial pattern groups 92B on both sides exist at substantially the same position when viewed in the axial direction. The radial pattern group 92B of each coil disk is located immediately above the arrangement circumference of the magnets 41 (the circumference around which the centers of the magnets 41 are arranged). That is, the radial pattern group 92 </ b> B passes just above the magnet 41 as each coil disk rotates. A rotational force is obtained by an electromagnetic force between the current flowing through the radial pattern group 92B and the magnetic field generated by the magnet 41.

  The radial pattern group 92 </ b> B on each surface exists at an equiangular pitch from the center of the insulating substrate 90. Therefore, on the surface of the insulating substrate 90, there is a region where the coil pattern 92 does not exist (hereinafter also referred to as “radial pattern group region”) between the adjacent radial pattern groups 92B. A reinforcing pattern 93 is provided in the region between the radial pattern groups. The reinforcing pattern 93 is made of the same material as the coil pattern 92, and the height from the insulating substrate 90 is substantially the same as the coil pattern 92. The reinforcing pattern 93 has a role of increasing the adhesive force between the laminated coil disks. This will be described later.

  7A and 7B are explanatory diagrams of the coil pattern of the first coil disk 361. FIG. Note that these drawings are the same as FIGS. 6A and 6B except for the reference numerals. The coil pattern 92 of the first coil disk 361 includes two coils. FIG. 7A shows the start point of one coil as A1-1 and the end point as A1-2. Further, the start point of the other coil is indicated by A2-1, and the end point thereof is indicated by A2-2 in the figure. One coil is connected to the points P11, P11 ′, P12 ′, P12, P13, P13 ′,... P19 ′, P20 ′ from the starting point A1-1. This makes one round clockwise from the starting point A1-1 when viewed from above. Further, the point P20 ′ is similarly connected to the points P20, P21, P21 ′, P22 ′, P22, P23, P23 ′,..., P29 ′, P30 ′. This makes two rounds clockwise from the starting point A1-1 as seen from above. Then, the point P30 ′ is similarly connected to the points P31 ′, P31, P32, P32 ′, and P33 ′ in the counterclockwise direction, and then goes around from the point P30 ′ to the end point A1-2. Similarly, the other coil is connected from the start point A2-1 to the end point A2-2.

  Then, the first coil disk 361 to the fourth coil disk 364 configured as described above are stacked in the axial direction (stacking direction) to form the coil unit 36. The coils of different coil disks are electrically connected by the pin 40 already described in FIG. Twelve pins 40 are required to connect the four coil disks. Here, in order to connect the coil patterns 92 formed on the two coil disks in series, for example, one of the through holes of one coil disk is positioned at the other of the through holes of the other coil disk. What is necessary is just to laminate | stack by shifting a phase. As a result, the two coil substrate coil sections 36 are displaced so that the four coil disks 361 to 364 coincide with each other in the coil pattern formed in the axial direction, or by a predetermined angle. In this way, they are stacked. When there is an angle shift, in the laminated state, the reinforcing pattern 93 of each coil disk faces the coil pattern 92 of the coil disk of the next layer as viewed in the axial direction.

  FIG. 8A is an enlarged cross-sectional view of the first coil disk 361 and the second coil disk 362 shown in FIG. In addition, since the lamination | stacking cross section of other coil disks is also the same, only the lamination | stacking cross section of the 1st coil disk 361 and the 2nd coil disk 362 is demonstrated here. FIG. 8B is a comparative example of FIG. 8A, and is an enlarged cross-sectional view of the laminated layer when the reinforcing pattern 93 is removed from FIG. 8A. FIG. 9A is a plan view of a coil disk according to the comparative example shown in FIG. FIG. 9B is a bottom view of the coil disk according to the comparative example.

  As shown in FIG. 8B, when the reinforcing pattern 93 is not present in the radial pattern group region 90B of the insulating substrate 90, the sheet-like adhesive layer 507 adheres to the radial pattern group 92B of the coil pattern 92. However, it does not reach the surface of the radial pattern group region 90B and does not adhere. Alternatively, even if the adhesive layer 507 is made sufficiently thick and the adhesive layer 507 reaches the surface of the radial pattern group region 90B by the pressing during lamination, the adhesive force is weak because the contact pressure is low. That is, the radial pattern inter-group region 90B has little or no contribution to adhesion. Therefore, the adhesive force between the laminated coil disks is weak, and it is difficult to ensure reliability. In addition, there is a problem of an increase in cost and an increase in thickness due to an increase in the thickness of the adhesive layer 507.

  On the other hand, when the reinforcing pattern 93 is present in the radial pattern group region 90B of the insulating substrate 90, in addition to the radial pattern group 92B of the coil pattern 92, the reinforcing pattern 93 is also sheet-like as shown in FIG. The adhesive layer 507 is adhered. For this reason, compared with the case where the reinforcing pattern 93 does not exist as shown in FIG. 8B, it is possible to secure a large adhesion area, and it is possible to enhance the adhesive force between the coil disks and increase the reliability. . Further, even if the adhesive layer 507 is thin, a strong adhesive force can be ensured, which is advantageous for thinning and cost reduction.

  As shown in FIG. 6A and the like, the reinforcing pattern 93 includes seven small patterns that are narrower than one radial pattern forming the radial pattern group 92B. Each small pattern extends radially outward from the center side of the insulating substrate 90. With respect to improving the adhesion between the coil disks, the reinforcing pattern 93 is effective even if it is not divided into small patterns as described above. However, if the reinforcing pattern 93 is, for example, one wide conductor layer, there is a problem that loss due to eddy current generated in the reinforcing pattern 93 with rotation of the insulating substrate 90 is large. Therefore, from the viewpoint of efficiency, the reinforcing pattern 93 is preferably divided as described above.

  Hereinafter, a method for manufacturing the disk motor 80 will be briefly described.

  Etching is performed by covering a disc-shaped insulating substrate with a conductive material such as a copper foil on both sides thereof with a mask (etching step). Necessary through holes and pin insertion holes are processed before or after the etching process. As a result, four coil disks 361 to 364 on which the coil pattern 92 and the reinforcing pattern 93 shown in FIG. Further, the commutator substrate 35 on which the commutator pattern 351 and the like shown in FIG.

  As shown in FIG. 4, prepreg-like sheet-like adhesive layers 501 to 503, 505, and 507 are passed between the pins 40 (for example, a thin sheet in which a glass cloth base material is impregnated with an epoxy resin to be semi-cured) Each member is laminated on the flange 37, and set in a mold and hot pressed (pressed in the laminating direction in a heated state) (adhesion step). Prior to hot pressing, the pin 40 and each coil disk are soldered in a state where the coil disks 361 to 364 are laminated. Further, after the hot pressing, the commutator substrate 35 and the pins 40 are soldered, and unnecessary portions of the protruding pins 40 are cut. 4 is combined with the stator 81 and the brush 83 as shown in FIG. 2 to complete the disk motor 80.

  According to the present embodiment, the following effects can be achieved.

(1) Since the reinforcing pattern 93 is formed between the adjacent radial pattern groups 92B, the adhesive force between the laminated coil disks can be improved as compared with the case where the reinforcing pattern 93 does not exist. it can. For this reason, high reliability can be ensured even for products with large vibrations or products that are subject to shock depending on how they are used.

(2) Since the reinforcing pattern 93 is made of the same material as the coil pattern 92 and has the same height from the substrate surface, both can be formed in a single etching process, which is easy to manufacture and inexpensive. That is, it is not necessary to increase the number of processes for forming the reinforcing pattern 93.

(3) Since the reinforcing pattern 93 is formed as a small pattern having a narrower width than one radial pattern forming the radial pattern group 92B, the eddy current loss is small and the efficiency is high. In other words, the magnetic flux that penetrates the region between the radial pattern groups constantly changes due to the characteristics of a product called a disk motor.For example, if a large conductor layer covering almost the entire region between the radial pattern groups is provided to secure the adhesive force, However, in this embodiment, such a problem can be preferably solved.

(4) Since the reinforcing pattern 93 is formed in the region between the radial patterns of the insulating substrate 90, it is not necessary to increase the area of the insulating substrate 90 in order to provide the reinforcing pattern 93.

  The present invention has been described above by taking the embodiment as an example. However, it is understood by those skilled in the art that various modifications can be made to each component and each processing process of the embodiment within the scope of the claims. By the way. Hereinafter, modifications will be described.

  FIG. 10 is a plan view of a coil disk having a reinforcing pattern (part 1) different from the example of FIG. The coil disk of FIG. 10 has the same configuration as the coil disk shown in FIG. 6A except for the shape of the reinforcing pattern. As shown in FIG. 10, the reinforcing pattern 93A of the modification is narrower than one radial pattern constituting the radial pattern group 92B, and is composed of 15 small patterns extending substantially perpendicular to the radial direction of the coil disk. Become. The reinforcing pattern on the opposite surface also has a similar small pattern (not shown). Even when the reinforcing pattern of this modification is provided, the eddy current loss can be kept small. In addition, by providing a small pattern along the moving direction of the magnet in this way, even if a minute eddy current is generated, the direction in which the eddy current is easily generated is orthogonal to the moving direction of the magnet, that is, the rotation direction Therefore, the influence on the rotation of the rotor can be further suppressed.

  FIG. 11 is a plan view of a coil disk having a reinforcing pattern (part 2) different from the example of FIG. The coil disk of FIG. 11 has the same configuration as the coil disk shown in FIG. 6A except for the shape of the reinforcing pattern. As shown in FIG. 11, the reinforcing pattern 93 </ b> B of the modification is formed by arranging a large number of small patterns vertically and horizontally. The shape of the small pattern is substantially square except for those at the ends. However, the shape of the small pattern may be a circle, an ellipse, a triangle, or another polygon. Similarly, the reinforcing pattern on the opposite surface is formed by arranging a large number of small patterns vertically and horizontally (not shown). Even when the reinforcing pattern of this modification is provided, the eddy current loss can be kept small.

  FIG. 12 is a plan view of a coil disk having a reinforcing pattern (part 3) different from the example of FIG. The coil disk of FIG. 12 has the same configuration as the coil disk shown in FIG. 6A except for the shape of the reinforcing pattern. As shown in FIG. 12, the reinforcing pattern 93 </ b> C of the modified example is formed by reciprocating small continuous patterns. The shape of the continuous small pattern may be a spiral reinforcing pattern 93D as shown in the reinforcing pattern (No. 4) shown in FIG. Even when the reinforcing pattern of this modification is provided, the eddy current loss can be kept small.

  The reinforcing patterns of the plurality of coil disks constituting the disk motor may have different shapes for each coil disk. Further, the shape of the reinforcing pattern may be different between one surface and the other surface of the same coil disk. Further, the reinforcing pattern on the same surface of the same coil disk may be different for each region between the radial pattern groups.

  The upper surface of the uppermost coil disk (first coil disk 361 in FIG. 4) and the lower surface of the lowermost coil disk (fourth coil disk 364 in FIG. 4) do not face the sheet-like adhesive layer. Since the surface of the disk has a uniform height, it is possible to produce an effect that it is easy to apply pressure evenly during pressing.

  The reinforcing pattern may be provided only on one of the two surfaces sandwiching the sheet-like adhesive layer. Also in this case, it is possible to increase the adhesive force between the coil disks as compared with the conventional case.

  The reinforcing pattern may be electrically insulated from the coil pattern as shown in the embodiment. However, the reinforcing pattern is insulated from the coil pattern unless it is a current path or a part of a closed circuit. It does not have to be.

  The reinforcing pattern may not be made into a small pattern. Even if the reinforcing pattern is one large conductive layer, although there is a problem of eddy current loss, it is possible to reinforce the adhesive force between the coil disks as compared with the conventional case.

  One or all of the coil disks may be single-sided substrates. Also in this case, it is preferable to sandwich the sheet-like adhesive layer 507 between the surfaces on which the reinforcing patterns 93 are formed.

  The plurality of coil disks may be stacked without any angular deviation from each other. That is, a stacked state in which the radial pattern groups 92B (and the reinforcing patterns 93) face each other with the sheet-like adhesive layer 507 interposed therebetween is also possible.

  The shape of the coil disk and the commutator substrate may not be a strict disk shape, but may be in a range that can be regarded as a substantial circle when viewed in the axial direction.

  In addition to the above, the number of magnets and their arrangement angle pitch, the number of coil pattern turns (the number of coil pattern rows), the number of coil disk stacks, the number of pin insertion holes and through holes, and other parameters are the required performance. It can be set appropriately according to the cost. Further, the number of turns of the coil pattern may be different for each coil disk. When the coil pattern is one row, the terms “partial coil pattern group”, “inner contact pattern group”, “radial pattern group”, and “outer contact pattern group” in the description of the embodiment are “ Replace with the exception of “group”.

  In addition to the brush cutter shown in the embodiment, the electric working machine may be various electric tools having a rotary drive unit by a disk motor, such as a belt sander or a rotary band saw equipped with a disk motor.

DESCRIPTION OF SYMBOLS 1 Brush cutter 3 Power supply part 4 Pipe part 5 Handle part 6 Drive part 7 Cutting blade 301 Battery 31 Output shaft (rotor shaft)
35 Commutator board 36 Coil part 37 Flange 41 Magnet 42 Upper yoke 43 Lower yoke 51 Arm 52 Grip 53 Throttle 61 Head housing 62 Cover part 63 Base part 65 Brush holder 80 Disc motor 81 Stator 82 Rotor 83 Brush 92 Coil pattern 92A Inside communication Pattern group 92B Radial pattern group 92C Outer connection pattern group 920 Partial coil pattern groups 361-364 Coil disks 501-503, 505, 507 Adhesive layer

Claims (11)

An output shaft;
Coaxially fixed to the output shaft and at least two coil disks in which a coil pattern including a plurality of radial patterns or groups of radial patterns extending radially outward from the center side is formed on one side or both sides and bonded to each other When,
A current supply unit for supplying current to the coil pattern;
A magnetic flux generator facing the coil pattern,
A reinforcing pattern is formed between adjacent radial patterns or groups of radial patterns on at least one of the coil disks,
The forming surface of the reinforcing pattern is an adhesive surface with the other coil disk ,
The coil pattern is present on at least the mutually facing surfaces of the two coil disks, and the other radial pattern or radial pattern is disposed between one adjacent radial pattern or group of radial patterns on the mutually facing surface when viewed in the axial direction. disc motor, characterized that you position pattern group.   The disk motor according to claim 1, wherein the reinforcing pattern is a small pattern insulated from each other.   3. The disk motor according to claim 2, wherein each small pattern has a narrower width than the radial pattern and extends substantially parallel to the radial direction of the coil disk.   3. The disk motor according to claim 2, wherein each small pattern has a narrower width than the radial pattern and extends substantially perpendicular to the radial direction of the coil disk.   5. The disk motor according to claim 1, wherein the reinforcing pattern has a height from the substrate surface of the coil disk that is substantially the same as that of the coil pattern. 6.   The disk motor according to claim 1, wherein the reinforcing pattern is made of the same material as that of the coil pattern.   The disk motor according to any one of claims 1 to 6, wherein the at least two coil disks are bonded to each other via a sheet-like adhesive layer covering substantially the entire surface.   The disk motor according to any one of claims 1 to 7, wherein the plurality of radial patterns or groups of radial patterns are arranged and formed at a predetermined interval in a circumferential direction of the coil disk. The disk motor according to any one of claims 1 to 8 , wherein the coil patterns are provided on both surfaces of the coil disk and connected to each other. An electric working machine comprising the disk motor according to any one of claims 1 to 9 . An output shaft;
A coil pattern including a plurality of radial patterns or a group of radial patterns fixed coaxially to the output shaft and extending radially outward from the center side, and at least two coil disks bonded together;
A current supply unit for supplying current to the coil pattern;
A method of manufacturing a disk motor comprising a magnetic flux generator facing the coil pattern,
In the etching process of the conductor layer for forming the coil pattern of at least one of the coil disks, a reinforcing pattern is formed together with the coil pattern between adjacent radial patterns or radial pattern groups,
In the bonding step of bonding the two coil disks, the reinforcing pattern forming surface is used as the bonding surface, and the surfaces of the two coil disks on which the coil patterns are formed are opposed to each other, and viewed in the axial direction. And covering the substantially entire surface of the coil disk so that the other radial pattern or group of radial patterns is located between one adjacent radial pattern or group of radial patterns on the mutually facing surfaces of the two coil disks. A method of manufacturing a disk motor, wherein the two coil disks are bonded and fixed to each other with a sheet-like adhesive layer interposed therebetween.

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