JP5951049B2 - Mold stator, pump, pump manufacturing method, and refrigeration cycle apparatus - Google Patents

Description

The present invention relates to a mold stator, a pump , a pump manufacturing method, and a refrigeration cycle apparatus.

  As a conventional motor, for example, in a molded motor disclosed in Patent Document 1 below, a wiring board is disposed on the upper surface of a mold stator, and a driving element for supplying a driving current to the stator winding is mounted on the wiring board. The stator and the wiring board are molded with an electrically insulating resin material. And in this prior art, the heat sink which radiates the heat which a drive element emits is embed | buried under mold resin, or it is comprised so that a part of heat sink may be exposed outside.

  In addition, the motor shown in Patent Document 2 below is configured to detect a temperature from a lead leg having good thermal conductivity by fixing a temperature detection element in the vicinity of the drive element by soldering. According to this prior art, the temperature followability can be improved, and the temperature detection element can be attached only by the soldering operation, so that the temperature detection element has good followability and productivity. Is obtained.

JP 2007-267568 A JP 2000-188850 A

  However, in the mold motor disclosed in Patent Document 1, the detection temperature of the temperature detection element that detects the temperature of the drive element has poor followability with respect to the temperature of the drive element, and the drive element is thermally destroyed before the protection circuit is operated. There was a possibility.

  In addition, in the motor shown in Patent Document 2, when the drive circuit is composed of a plurality of discrete elements, each drive element is provided with a temperature detection element so that it can cope with any of the drive elements becoming hot. There is a possibility that the cost increases. In addition, in this motor, there is a possibility that the layout of electronic components may be restricted when the board is downsized or the number of components is increased.

This invention is made in view of the above, Comprising: The mold stator which can detect the temperature of a drive element accurately without incurring a cost increase, a pump, the manufacturing method of a pump, and a refrigeration cycle apparatus are obtained. With the goal.

In order to solve the above-described problems and achieve the object, the molded stator of the present invention is mounted with a stator formed by winding a coil around a plurality of teeth provided with an insulating portion of a stator core, and a driving element. a substrate that has been found in the thermosetting resin a molded stator comprising integrally formed, the substrate includes a temperature detecting element which is mounted on the same surface as the substrate surface on which the driving element is mounted, wherein A comb-shaped thin metal plate that covers the side surfaces of the drive element and the temperature detection element, and a thin metal formed in a size that covers a surface opposite to the surface of the drive element and the temperature detection element that faces the substrate. made a flat plate, a laminated, is provided on the opposite side of the driving element and the temperature sensing element, and the heat transfer plate to connect these elements thermally, the heat transfer plate is the drive element and Thermally connected to the temperature sensing element Obtain Bei and a heat transfer plate holder for holding said heat transfer plates in condition.

  According to the present invention, the temperature of the drive element and the temperature of the temperature detection element are detected by detecting the temperature of the drive element via the heat transfer plate disposed so as to cover the one or more drive elements and the temperature detection element. As a result, the temperature of the drive element can be accurately detected without increasing the cost.

FIG. 1 is a configuration diagram of a heat pump hot water supply apparatus using a pump according to an embodiment of the present invention. FIG. 2 is an exploded perspective view of the pump. FIG. 3 is a perspective view of the mold stator. FIG. 4 is a cross-sectional view of the mold stator. FIG. 5 is an exploded perspective view of the stator assembly. FIG. 6 is a block diagram of the heat transfer plate assembly. FIG. 7 is a view of the heat transfer plate assembly as viewed from the side opposite to the stator. FIG. 8 is a perspective view of the heat transfer plate assembly as viewed from the side opposite to the stator. FIG. 9 is a perspective view of the stator before the heat transfer plate assembly is assembled. FIG. 10 is a perspective view of the stator assembled with the heat transfer plate assembly. FIG. 11 is a perspective view of a substantially comb-shaped heat transfer plate viewed from the side opposite to the stator. FIG. 12 is a perspective view of the substantially uneven heat transfer plate as viewed from the side opposite to the stator. FIG. 13 is a perspective view of the heat transfer plate holder as seen from the side opposite to the stator. FIG. 14 is a perspective view of the heat transfer plate holder as seen from the stator side. FIG. 15 is an exploded perspective view of the pump unit. FIG. 16 is a sectional view of the pump. FIG. 17 is a perspective view of the casing as seen from the shaft support portion side. FIG. 18 is a cross-sectional view (A-A cross-sectional view of FIG. 20) of the rotor portion. FIG. 19 is a side view of the rotor portion viewed from the impeller mounting portion side. FIG. 20 is a side view of the rotor portion viewed from the side opposite to the impeller mounting portion. FIG. 21 is an enlarged sectional view of the sleeve bearing. FIG. 22 is a sectional view of the resin magnet (a sectional view taken along line BB in FIG. 23). FIG. 23 is a sectional view of the resin magnet ( a sectional view taken along the line CC in FIG . 22) . FIG. 24 is a side view of the resin magnet as viewed from the impeller mounting portion side. FIG. 25 is a perspective view of the rotor portion viewed from the impeller mounting portion side. FIG. 26 is a perspective view of the rotor portion viewed from the side opposite to the impeller mounting portion. FIG. 27 is a diagram showing a manufacturing process of the pump. FIG. 28 is a conceptual diagram showing a circuit of a refrigeration cycle apparatus using a refrigerant-water heat exchanger.

Hereinafter, embodiments of a mold stator, a pump , a pump manufacturing method, and a refrigeration cycle apparatus according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

Embodiment.
Before describing the pump 10 according to the embodiment of the present invention, first, an outline of a heat pump type hot water supply apparatus 300 that is an example of an apparatus in which the pump 10 is used will be described.

  FIG. 1 is a configuration diagram of a heat pump type hot water supply apparatus 300 using a pump 10 according to an embodiment of the present invention. As shown in FIG. 1, the heat pump hot water supply apparatus 300 includes a heat pump unit 100, a tank unit 200, and an operation unit 11 on which a user performs a driving operation and the like.

  In FIG. 1, a heat pump unit 100 includes a compressor 1 that compresses a refrigerant (for example, a rotary compressor, a scroll compressor, etc.), a refrigerant-water heat exchanger 2 that exchanges heat between the refrigerant and water, and a high-pressure unit. A decompression device 3 for decompressing and expanding the refrigerant, an evaporator 4 for evaporating the low-pressure two-phase refrigerant, a refrigerant pipe that connects the compressor 1, the refrigerant-water heat exchanger 2, the decompression device 3, and the evaporator 4 in an annular shape. 15, a pressure detection device 5 that detects the discharge pressure of the compressor 1, a fan 7 that blows air to the evaporator 4, and a fan motor 6 that drives the fan 7. A refrigerant circuit is comprised by the compressor 1, the refrigerant | coolant-water heat exchanger 2, the decompression device 3, the evaporator 4, and the refrigerant | coolant piping 15 which connects these cyclically | annularly.

  Further, the heat pump unit 100 includes, as temperature detection units, a boiling temperature detection unit 8 of the refrigerant-water heat exchanger 2, a feed water temperature detection unit 9 of the refrigerant-water heat exchanger 2, and an outside air temperature detection unit 17. I have.

  The heat pump unit 100 includes a heat pump unit control unit 13. The heat pump unit control unit 13 receives signals from the pressure detection device 5, the boiling temperature detection unit 8, the feed water temperature detection unit 9, and the outside air temperature detection unit 17, and controls the rotation speed of the compressor 1 and the decompression device 3. The opening degree control and the rotational speed control of the fan motor 6 are performed.

  The tank unit 200 includes a hot water tank 14 that stores hot water heated by exchanging heat with a high-temperature and high-pressure refrigerant in the refrigerant-water heat exchanger 2, and a bath water reheating heat exchanger that replenishes the bath water. 31, a bath water circulation device 32 connected to the bath water reheating heat exchanger 31, a pump 10 that is a hot water circulation device disposed between the refrigerant-water heat exchanger 2 and the hot water tank 14, and a refrigerant A hot water circulation pipe 16 connecting the water heat exchanger 2 and the hot water tank 14, a mixing valve 33 connected to the refrigerant-water heat exchanger 2, the hot water tank 14 and the bath water reheating heat exchanger 31; And a bath water recirculation pipe 37 for connecting the hot water tank 14 and the mixing valve 33. The refrigerant-water heat exchanger 2, the hot water tank 14, the pump 10, and the hot water circulation pipe 16 constitute a water circuit.

  In addition, the tank unit 200 includes a tank water temperature detection unit 34, a post-reheating water temperature detection unit 35 that detects the water temperature after passing through the bath water reheating heat exchanger 31, and a mixing valve 33 as temperature detection units. And a post-mixing water temperature detection unit for detecting the water temperature after passing through.

  The tank unit 200 includes a tank unit control unit 12. The tank unit controller 12 receives signals from the in-tank water temperature detector 34, the reheated water temperature detector 35, and the mixed water temperature detector 36, and controls the rotational speed of the pump 10 and the opening / closing control of the mixing valve 33. I do. Furthermore, the tank unit 200 transmits and receives signals to and from the heat pump unit control unit 13 and the operation unit 11.

  The operation unit 11 is a remote controller, an operation panel, or the like provided with a switch or the like for the user to perform hot water temperature setting, hot water instruction, and the like.

  In FIG. 1, a normal boiling operation operation in the heat pump type hot water supply apparatus 300 configured as described above will be described. When the boiling operation instruction from the operation unit 11 or the tank unit 200 is transmitted to the heat pump unit control unit 13, the heat pump unit 100 performs the boiling operation.

  The heat pump unit controller 13 controls the rotational speed of the compressor 1, the opening degree of the decompressor 3, and the fan based on the detected values of the pressure detector 5, the boiling temperature detector 8, and the feed water temperature detector 9. The number of revolutions of the motor 6 is controlled.

  Moreover, the detection value of the boiling temperature detection part 8 is transmitted / received between the heat pump unit control part 13 and the tank unit control part 12, and the tank unit control part 12 is the temperature detected by the boiling temperature detection part 8. The number of rotations of the pump 10 is controlled so as to reach the target boiling temperature.

  In the heat pump type hot water supply apparatus 300 controlled as described above, the temperature of the high-temperature and high-pressure refrigerant discharged from the compressor 1 decreases while dissipating heat to the water supply circuit side in the refrigerant-water heat exchanger 2. The high-pressure and low-temperature refrigerant that has radiated heat and passed through the refrigerant-water heat exchanger 2 is decompressed by the decompression device 3. The refrigerant that has passed through the decompression device 3 flows into the evaporator 4 where it absorbs heat from outside air. The low-pressure refrigerant exiting the evaporator 4 is sucked into the compressor 1 and circulates to form a refrigeration cycle.

  On the other hand, the water in the lower part of the hot water tank 14 is guided to the refrigerant-water heat exchanger 2 by driving the pump 10 which is a hot water circulation device. Here, water is heated by the heat radiation from the refrigerant-water heat exchanger 2, and the heated hot water is returned to the upper part of the hot water tank 14 through the hot water circulation pipe 16 and stored.

  As described above, in the heat pump hot water supply apparatus 300, the pump 10 is used as a hot water circulation apparatus that circulates hot water in the hot water circulation pipe 16 between the hot water tank 14 and the refrigerant-water heat exchanger 2.

  Next, the pump 10 according to the present embodiment will be described. FIG. 2 is an exploded perspective view of the pump 10.

  As shown in FIG. 2, the pump 10 includes a pump unit 40 that absorbs and discharges water by rotation of a rotor (described later), a mold stator 50 that drives the rotor, a pump unit 40, and a mold stator. And a tapping screw 160 that is a fastening screw that fastens the screw 50. In the illustrated example, the number of tapping screws 160 is five, for example, but is not limited thereto.

  The pump 10 includes five tapping screws 160 of pilot hole parts 81 (see FIG. 5 described later for details) embedded in the mold stator 50 through screw holes 44a formed in the boss portions 44 of the pump portion 40. It is assembled by fastening to the pilot hole 84.

  In addition to the configuration described above, in FIG. 2, the casing 41, the suction port 42, the discharge port 43, the bowl-shaped partition wall component 90, the lead wire 52, the mold resin 53, the stator core 54, and the pump unit installation surface 63. Are described below.

  3 is a perspective view of the mold stator 50, FIG. 4 is a sectional view of the mold stator 50, FIG. 5 is an exploded perspective view of the stator assembly 49, FIG. 6 is a configuration diagram of the heat transfer plate assembly 120, and FIG. FIG. 8 is a perspective view of the heat transfer plate assembly 120 as viewed from the anti-stator side, and FIG. 9 is a perspective view of the stator 47 before the heat transfer plate assembly 120 is assembled. FIG. 10, FIG. 10 is a perspective view of the stator 47 assembled with the heat transfer plate assembly 120, FIG. 11 is a perspective view of the substantially comb-shaped heat transfer plate 110b seen from the side opposite to the stator, and FIG. FIG. 13 is a perspective view of the heat transfer plate holder 112 as seen from the stator side, FIG. 13 is a perspective view of the heat transfer plate holder 112 as seen from the stator side, and FIG. 14 is a perspective view of the heat transfer plate holder 112 as seen from the stator side. 15 is an exploded perspective view of the pump unit 40, FIG. 16 is a sectional view of the pump 10, and FIG. The ring 41 is a perspective view of the shaft support portion 46 side.

  First, the configuration of the mold stator 50 will be described. The mold stator 50 shown in FIGS. 3 and 4 is obtained by molding the stator assembly 49 (see FIG. 5) with the mold resin 53.

  On one end surface in the axial direction of the mold stator 50, specifically, on the end surface on the casing 41 side (see FIG. 2), a flat pump portion installation surface 63 is provided along the outer peripheral edge.

  In the pump portion installation surface 63, feet 85 (see FIG. 5) of pilot hole parts 81 are embedded in the axial direction at five locations. The foot 85 is, for example, a substantially cylindrical resin molded part. At the time of molding with the mold resin 53, one end surface (end surface on the pump unit 40 side) of the foot portion 85 becomes a mold pressing portion 82 (see FIG. 4) of the molding die. Therefore, the pilot hole part 81 is exposed in a form embedded inside the pump part installation surface 63 by a predetermined distance. What is exposed is a mold retainer 82 and a pilot hole 84 for the tapping screw 160.

  The lead wire 52 drawn out from the stator assembly 49 is drawn out from the vicinity of the axial end surface of the mold stator 50 opposite to the pump part 40 side.

  The axial positioning of the mold stator 50 during molding with the mold resin 53 (thermosetting resin) is performed by a plurality of heat transfer plate pressing pins 112a (see FIG. 8) formed on the heat transfer plate holder 112. The axial end surface serves as an upper mold pressing part. Therefore, the axial end surface (mold pressing surface) of the heat transfer plate pressing pin 112a is exposed from the axial end surface on the substrate 58 side of the mold stator 50 (not shown).

  Further, the axial end surface of the insulating portion 56 on the anti-connection side (pump portion 40 side) serves as a lower mold pressing portion. Therefore, the end surface of the insulating portion 56 on the anti-connection side is exposed from the axial end surface of the mold stator 50 opposite to the substrate 58 side (not shown).

  The radial positioning of the mold stator 50 at the time of molding is performed by fitting the inner peripheral surface of the stator core 54 to the mold. Therefore, the tip end portion (inner peripheral portion) of the teeth of the stator core 54 is exposed on the inner peripheral portion of the mold stator 50 shown in FIG.

  Next, the internal configuration of the mold stator 50, that is, the configuration of the stator assembly 49 will be described.

  As shown in FIG. 5, the stator assembly 49 includes a stator 47 and a pilot hole part 81. 4 and 5, the stator 47 includes a lead wire 52, a stator core 54 provided with a groove 54a, an insulating portion 56, a coil 57, an IC 58a, a Hall element 58b, a substrate 58, a terminal 59, A lead wire lead part 61 and a heat transfer plate assembly 120 are provided. The pilot hole component 81 includes a foot portion 85, protrusions 83 and 85 a provided on the foot portion 85, and a connecting portion 87.

The stator assembly 49 is manufactured by the following procedure.
(1) An electromagnetic steel sheet having a thickness of, for example, about 0.1 to 0.7 mm is punched into a band shape, and an annular stator core 54 is manufactured by laminating the electromagnetic steel sheet by caulking, welding, adhesion, or the like. The stator core 54 includes a plurality of teeth. The tips of the teeth of the stator core 54 are exposed on the inner periphery of the mold stator 50 shown in FIG. Since the stator core 54 shown here has, for example, twelve teeth connected by the thin-walled connecting portion, the tips of the teeth of the stator core 54 are exposed at 12 locations in FIG. However, the teeth visible in FIG. 3 are five of the twelve teeth.
(2) An insulating portion 56 is applied to the teeth of the stator core 54. The insulating portion 56 is molded integrally with the stator core 54 or separately from the stator core 54 using a thermoplastic resin such as PBT (polybutylene terephthalate).
(3) Concentrated winding coil 57 (see FIG. 4) is wound around the teeth provided with insulating portion 56. Twelve concentrated winding coils 57 are connected to form a three-phase single Y-connection winding.
(4) Since it is a three-phase single Y connection, a terminal 59 (see FIG. 4) to which a coil 57 (see FIG. 4) of each phase (U phase, V phase, W phase) is connected on the connection side of the insulating portion 56. 4, a power supply terminal to which power is supplied and a neutral point terminal) are assembled. There are three power terminals and one neutral point terminal.
(5) The heat transfer plate assembly 120 is manufactured in parallel. Details of the heat transfer plate assembly 120 will be described later.
(6) The substrate 58 is attached to the insulating portion 56 on the connection side (side on which the terminal 59 is assembled). A substrate fixing protrusion 130 is formed on the insulating portion 56 of the stator 47, and the substrate 58 has an insertion hole (not shown) into which the protrusion 130 is inserted. By inserting the protrusion 130 into the insertion hole, the substrate 58 is placed on the insulating portion 56, and the substrate 58 is sandwiched between the insulating portion 56 and the heat transfer plate holder 112. As shown in FIG. 4, the substrate 58 includes an IC 58a (driving element) that drives an electric motor (for example, a brushless DC motor), a temperature detecting element 111 that detects the temperature of the driving element that suddenly generates heat when there is an abnormality such as a lock, and the rotation. Electronic equipment such as a Hall element 58b (for example, a magnetic pole position detecting element) for detecting the position of the child 60 is mounted. Since the IC 58a and the temperature detection element 111 are mounted on the anti-stator side of the substrate 58, they can also be seen in FIG. 5 (or FIG. 9). However, since the Hall element 58b is mounted on the opposite side to the IC 58a, it is not visible in FIG. The IC 58a and the Hall element 58b are defined as electronic components. In addition, a lead wire lead-out component 61 and a heat transfer plate assembly 120 that lead out the lead wire 52 are attached to the substrate 58 at a notch near the outer peripheral edge thereof.
(7) The substrate 58 to which the lead wire lead-out component 61 and the heat transfer plate assembly 120 are attached is fixed to the insulating portion 56 by the heat transfer plate holder 112, and the terminal 59 and the substrate 58 are soldered to the stator 47. The stator assembly 49 is completed by assembling the pilot hole part 81.

  Next, the configuration of the heat transfer plate assembly 120 will be described with reference to FIGS. A heat transfer plate assembly 120 shown in FIG. 6 includes a heat transfer plate 110 formed by laminating a substantially uneven heat transfer plate 110a and a substantially comb-shaped heat transfer plate 110b, and the heat transfer plate 110 is locked. And a heat transfer plate holder 112 that performs. The substantially uneven heat transfer plate 110a and the substantially comb-shaped heat transfer plate 110b are manufactured by punching, milling, etching, or the like from a thin metal plate having excellent thermal conductivity such as copper. The heat transfer plate holder 112 is formed by injection molding a thermoplastic resin such as PBT (polybutylene terephthalate).

  The heat transfer plate 110a having a substantially concave and convex shape and the heat transfer plate 110b having a substantially comb shape are stacked so as to cover the opposite end surface of the drive element and the side surface of the drive element, thereby efficiently generating heat of the drive element. This can be transmitted to the detection element 111.

  The heat transfer plate 110 shown in FIG. 6 is composed of three thin metal flat plates as an example. However, by changing the shape of the thin metal flat plates and the number of stacked layers, the heat transfer plate 110 can correspond to a drive element having an arbitrary shape. It is possible.

  In addition, when there are a plurality of driving elements, the shape of the substantially uneven heat transfer plate 110a and the shape of the substantially comb-shaped heat transfer plate 110b are formed so as to cover only the driving elements that generate a large amount of heat. It is possible to reduce the amount of use of the thin metal flat plate, and to reduce the processing cost of the thin metal flat plate.

  As shown in FIG. 11, the substantially comb-shaped heat transfer plate 110 b has a substantially U-shape disposed around the drive element and the temperature detection element 111. When there are a plurality of drive elements, the substantially comb-shaped heat transfer plate 110b is configured to include a plurality of substantially U-shaped members so that the side surfaces of the drive elements and the temperature detection element 111 can be enclosed. Are formed in a substantially comb shape. By forming it in a substantially comb shape, it is possible to surround a plurality of drive elements with a single thin flat plate, thereby reducing processing costs.

  As shown in FIG. 12, the substantially uneven heat transfer plate 110a is formed in an uneven shape so as to cover the entire end surface on the opposite side of the driving element and the end surface on the opposite side of the temperature detecting element 111. . By forming the projections and depressions, it is possible to efficiently transmit the heat generated by the drive element to the temperature detection element 111. In addition, since the substantially uneven heat transfer plate 110a is formed so as to cover the entire end surface on the side opposite to the substrate of the drive element, the substantially uneven heat transfer plate 110a also serves as a heat radiating plate. It is possible to suppress the temperature rise of the drive element.

  As shown in FIGS. 11 and 12, the substantially uneven heat transfer plate 110 a and the substantially comb-shaped heat transfer plate 110 b are located at positions corresponding to the claws 112 c (see FIG. 14) provided on the heat transfer plate holder 112. In addition, a substantially square notch (110a-1, 110b-1) may be provided. By locking the claw 112c provided on the heat transfer plate holder 112 to the notches (110a-1, 110b-1), it is possible to prevent the positional deviation of the laminated thin metal flat plates.

  Next, the configuration of the heat transfer plate holder 112 will be described with reference to FIGS. The heat transfer plate holder 112 has a thin connection shape formed by injection molding of a thermoplastic resin such as PBT (polybutylene terephthalate). The heat transfer plate holder 112 is provided with a plurality of protrusion insertion holes 112b (two in the example of FIG. 13) corresponding to the protrusions 130 (see FIG. 5). The heat transfer plate holder 112 is fixed to the stator 47 together with the substrate 58 by inserting the protrusions 130 into the protrusion insertion holes 112b. Therefore, it is not necessary to use a separate part for fixing the substrate 58 to the heat transfer plate assembly 120, and the processing cost can be reduced.

  As shown in FIG. 14, a plurality of heat transfer plate fixing claws 112 c extending toward the substrate side are provided on the substrate side surface (surface on the drive element side) of the heat transfer plate holder 112. In the example of FIG. 14, the heat transfer plate holder 112 is provided with six claws 112c. The nail | claw 112c latches in predetermined positions, such as the outer peripheral part of a heat transfer board (110a, 110b), and the heat transfer board 110 is hold | maintained.

  As shown in FIG. 13, a plurality of heat transfer plate pressing pins 112 a extending toward the outer side of the mold stator 50 are provided on the side opposite to the substrate (the surface opposite to the drive element side) of the heat transfer plate holder 112. Is provided. At least one heat transfer plate pressing pin 112 a is provided on the heat transfer plate holder 112. In the example of FIG. 13, nine heat transfer plate pressing pins 112 a are provided on the heat transfer plate holder 112. When the stator 47 is integrally formed with the mold, the heat transfer plate 110 can be brought into close contact with the drive element via the heat transfer plate holder 112 by pressing the mold die against the heat transfer plate pressing pin 112a.

  Next, the configuration of the pilot hole part 81 will be described with reference to FIG. The pilot hole part 81 is formed by molding a thermoplastic resin such as PBT (polybutylene terephthalate).

  As shown in FIG. 5, the pilot hole component 81 is configured by a plurality of (for example, five) foot portions 85 having a substantially cylindrical shape connected in a ring shape with thin connection portions 87. The foot portion 85 is provided with a pilot hole 84 into which the tapping screw 160 is screwed (see FIG. 2). The foot portion 85 has a tapered shape that becomes thicker from the exposed end surface (end surface of the mold pressing portion 82 and the protrusion 83) toward the central portion in the axial direction. By making the tapered shape in this way, after the pilot hole part 81 is molded together with the stator 47, there is an effect of preventing the pilot hole part 81 from coming off.

  The pilot hole component 81 includes a plurality of protrusions 85 a for preventing rotation on the outer peripheral portion of the foot portion 85. In the illustrated example, four protrusions 85 a are provided on the outer periphery of the foot 85. The protrusion 85a is formed to extend in the height direction (axial direction) of the foot 85 with a predetermined circumferential width. Further, the protrusion 85 a protrudes from the outer peripheral surface of the foot 85 by a predetermined dimension necessary for preventing the rotation of the pilot hole part 81. The pilot hole part 81 can be set in a mold once by connecting the substantially cylindrical foot part 85 with the thin connection part 87, and the processing cost can be reduced.

  A plurality of claws (not shown) for assembling the pilot hole part 81 to the stator 47 are provided in the connecting part 87 of the pilot hole part 81, and formed on the outer peripheral part of the stator core 54 of the stator 47. By locking the claw of the pilot hole part 81 in the groove 54a, the stator 47 and the pilot hole part 81 can be set in the mold at once, and the processing cost can be reduced.

  After the pilot hole part 81 is locked to the stator 47, when the stator assembly 49 is molded by the mold resin 53, the mold pressing portion 82 and the projection 83 of the pilot hole part 81 are formed by the mold. By pinching, the pilot hole part 81 is positioned in the axial direction.

  4 is made smaller than the outer diameter of the end surface on the opening side of the pilot hole part 81, the end surface of the pilot hole part 81 is formed on the mold press part 82. The part except for is covered with the mold resin 53. Therefore, since both end surfaces of the pilot hole part 81 are covered with the mold resin 53, it is possible to suppress the exposure of the pilot hole part 81 and improve the quality of the pump 10.

  The mold stator 50 is obtained by integrally molding a pilot hole part 81 assembled to the stator 47 with a mold resin 53. At this time, the pilot hole 84 is formed so as to be exposed. By tightening and assembling the pump unit 40 and the mold stator 50 to the pilot hole 84 with the tapping screw 160 through the screw holes 44a formed in the pump unit 40, the pump unit 40 and the mold stator 50 are firmly connected. Can be assembled (see FIG. 2).

Next, the configuration of the pump unit 40 will be described. As shown in FIG. 15, the pump unit 40 includes the following elements.
(1) Casing 41: The casing 41 has a fluid suction port 42 and a discharge port 43, and houses the impeller 60b of the rotor 60 therein. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide). On the outer periphery of the casing 41, the casing 41 is provided with five boss portions 44 having screw holes 44a used when the pump portion 40 and the mold stator 50 are assembled.
(2) Thrust bearing 71: The material of the thrust bearing 71 is ceramic such as alumina. Since the rotor 60 is pressed against the casing 41 via the thrust bearing 71 by the pressure difference acting on the front and back of the impeller 60b of the rotor 60 during operation of the pump 10, the thrust bearing 71 is made of ceramic. To ensure wear resistance and slidability.
(3) Rotor 60: The rotor 60 includes a rotor portion 60a and an impeller 60b. The rotor portion 60a is provided, for example, inside a ring-shaped (cylindrical or annular) resin magnet 68 (an example of a magnet) obtained by molding a pellet obtained by kneading magnetic powder such as ferrite and resin. A cylindrical sleeve bearing 66 (for example, made of carbon) is integrated with a resin portion 67 such as PPE (polyphenylene ether) (see FIG. 18 described later). The impeller 60b is a resin molded product such as PPE (polyphenylene ether). The rotor part 60a and the impeller 60b are joined together by, for example, ultrasonic welding. Details of the rotor 60a will be described later.
(4) Shaft 70: The material of the shaft 70 (rotating shaft) is, for example, ceramic such as alumina, SUS, or the like. Since the shaft 70 slides with a sleeve bearing 66 provided in the rotor 60, a material such as ceramic or SUS is selected to ensure wear resistance and slidability. One end of the shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, and the other end of the shaft 70 is inserted into the shaft support portion 46 (see FIG. 17) of the casing 41. One end of the shaft 70 inserted into the shaft support portion 94 (see FIG. 16) of the bowl-shaped partition wall component 90 is inserted so as not to rotate with respect to the shaft support portion 94. Therefore, one end of the shaft 70 is substantially D-shaped with a predetermined length (axial direction) cut out of a part of the circle, and the hole of the shaft support portion 94 is also shaped to match the shape of one end of the shaft 70. Yes. Further, the other end of the shaft 70 inserted into the shaft support portion 46 of the casing 41 is also substantially D-shaped by cutting out a part of a circle having a predetermined length (axial direction), and the shaft 70 extends in the length direction. It is symmetrical. However, the other end of the shaft 70 is rotatably inserted into the shaft support portion 46. The reason why the shaft 70 is symmetrical in the length direction is to allow assembly without being aware of the vertical direction when the shaft 70 is inserted into the shaft support portion 94 (see FIG. 15).
(5) O-ring 80: The material of the O-ring 80 is EPDM (ethylene-propylene-diene rubber) or the like. The O-ring 80 performs sealing between the casing 41 of the pump unit 40 and the bowl-shaped partition wall component 90. In pumps mounted on water heaters and the like, heat seals and long life are required for seals around water, so materials such as EPDM are used to ensure resistance.
(6) Cage-like partition wall component 90: Cage-like wall partition component 90 is formed using, for example, a thermoplastic resin such as PPE (polyphenylene ether). The bowl-shaped partition wall component 90 includes a bowl-shaped partition wall portion 90 a that is a fitting portion with the mold stator 50 and a flange portion 90 b. The bowl-shaped partition wall 90a is composed of a circular bottom and a cylindrical partition. A shaft support portion 94 into which one end of the shaft 70 is inserted is provided at a substantially central portion of the inner surface of the bottom portion of the bowl-shaped partition wall portion 90a (see FIG. 16). A plurality of ribs 92 are formed radially on the outer surface of the bottom of the bowl-shaped partition wall 90a in the radial direction. A plurality of reinforcing ribs (not shown) that reinforce the flange 90b are radially formed in the flange 90b. Further, the flange portion 90b is provided with an annular rib (not shown) that fits in the pump portion installation surface 63 (see FIG. 3) of the mold stator 50. In addition, holes 90d through which the tapping screw 160 (see FIG. 2) passes are formed in the flange portion 90b at five locations. Furthermore, an annular O-ring storage groove 90c for storing the O-ring 80 is formed on the surface of the flange portion 90b on the casing 41 side.

  In the pump 10, after the O-ring 80 is installed in the bowl-shaped partition wall component 90, the shaft 70, the rotor 60, and the thrust bearing 71 are installed in the bowl-shaped partition wall component 90. Then, the pump part 40 is assembled by assembling the casing 41 to the bowl-shaped partition wall part 90. As shown in FIG. 2, the pump unit 40 is assembled to the mold stator 50, and the pump 10 is assembled by fixing the pump unit 40 and the mold stator 50 with a tapping screw 160 or the like.

  Further, the rib 92 provided on the bottom of the bowl-shaped partition wall component 90 and the groove (not shown) of the mold stator 50 are fitted to each other, thereby positioning the pump unit 40 and the mold stator 50 in the circumferential direction. The

  The rotor 60 is accommodated inside the bowl-shaped partition wall 90a. A shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, and the rotor 60 is fitted on the shaft 70. Therefore, in order to ensure the coaxiality of the mold stator 50 and the rotor 60, the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall 90a is preferably as small as possible. For example, the gap is selected to be about 0.02 to 0.06 mm.

  However, if the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a is made too small, an air escape path may occur when the bowl-shaped partition wall portion 90a is inserted into the inner periphery of the mold stator 50. It becomes narrow and it becomes difficult to insert the bowl-shaped partition wall part 90.

18 is a sectional view of the rotor portion 60a (AA sectional view of FIG. 20), FIG. 19 is a side view of the rotor portion 60a viewed from the impeller mounting portion 67a side, and FIG. FIG. 21 is an enlarged cross-sectional view of the sleeve bearing 66, FIG. 22 is a cross-sectional view of the resin magnet 68 (BB cross-sectional view of FIG. 23), and FIG. sectional view (C-C sectional view of FIG. 22), FIG. 24 is a side view of the resin magnet 68 from the impeller mounting portion 67a side, FIG. 25 is viewed rotor portion 60a from the impeller mounting portion 67a side FIG. 26 is a perspective view of the rotor portion 60a viewed from the side opposite to the impeller mounting portion 67a.

The rotor section 60a will be described with reference to FIGS. As shown in FIGS. 18 to 26, the rotor section 60a includes at least the following elements.
(1) Resin magnet 68;
(2) sleeve bearing 66;
(3) Resin portion 67;
The resin portion 67 is a portion made of a thermoplastic resin such as PPE (polyphenylene ether). An impeller attachment portion 67 a for attaching the impeller 60 b is formed in the resin portion 67. The resin magnet 68 and the sleeve bearing 66 are integrally formed by the resin portion 67.

  The resin magnet 68 has a substantially ring shape (cylindrical shape) and is formed of pellets obtained by kneading a magnetic powder such as ferrite and a resin.

  The sleeve bearing 66 (for example, made of carbon) is provided inside the resin magnet 68. The sleeve bearing 66 has a cylindrical shape. Since the sleeve bearing 66 rotates by being fitted to the shaft 70 assembled in the bowl-shaped partition wall component 90 of the pump 10, for example, PPS (polyphenylene sulfide) added with sintered carbon or carbon fiber suitable for the material of the bearing is used. It is made of thermoplastic resin or ceramic. The sleeve bearing 66 includes a draft taper (not shown) whose outer diameter decreases from the center in the approximate axial direction toward both ends, and is, for example, a hemispherical protrusion 66a (see FIG. 21) that prevents rotation on the outer peripheral surface at the approximate center in the axial direction. A plurality of reference).

  A portion of the resin portion 67 formed in contact with the end surface of the resin magnet 68 on the impeller mounting portion 67a side is provided with a magnet pressing portion (not shown) provided on the upper mold of the resin molding die. Correspondingly, a recess 67b is formed. In the example of FIG. 18, the recess 67b is formed at a substantially central portion in the radial direction. The recess 67b is formed at a position substantially opposite to the protrusion 68a (see FIG. 19) of the resin magnet 68 in the axial direction.

  Further, as shown in FIG. 19, a plurality of impeller positioning holes 67c for attaching the impeller 60b are formed in the impeller attachment portion 67a. For example, three impeller positioning holes 67c are formed at substantially equal intervals in the circumferential direction. The impeller positioning hole 67c passes through the impeller attachment portion 67a. Each impeller positioning hole 67 c is formed on the intermediate radial extension line of two of the three protrusions 68 a of the resin magnet 68.

  Further, as shown in FIG. 19, the impeller mounting portion 67a has gates 67e (resin injection ports) used at the time of molding the rotor portion 60a with a thermoplastic resin (resin portion 67) at substantially equal intervals in the circumferential direction. For example, three are formed. Each gate 67e is formed on the radial extension of the projection 68a of the resin magnet 68 and inside the impeller positioning hole 67c.

18, of the resin portion 67, the portion you against the inner peripheral surface of the opposite side of the resin magnet 68 and impeller mounting portion 67a side, projections for positioning provided in the lower mold of the resin molding die ( notch is fitted in not shown) 67d is formed (see FIG. 18, FIG. 2 2). In the example of FIG. 20, the notches 67d are formed at four locations at approximately 90 ° intervals.

Next, the configuration of the resin magnet 68 will be described with reference to FIGS. The resin magnet 68 shown here has, for example, eight magnetic poles. The resin magnet 68 is provided with a plurality of tapered notches 68b at substantially equal intervals in the circumferential direction on the inner peripheral side of the end surface on the impeller mounting portion 67a side in a state where it is formed in the rotor 60. That is, the notch 68b is formed on the inner peripheral surface of the end face, and extends from the end face in a predetermined length axis direction. In the example of FIG. 24, there are eight notches 68b. The notch 68b has a tapered shape in which the diameter on the end face side is larger than the axial center side.

The resin magnet 68 has, for example, a substantially square shape from the end surface on the side where the notch 68b is formed ( the end surface on the impeller mounting portion 67a side) to a predetermined depth, and toward the impeller mounting portion 67a side. Thus, a plurality of protrusions 68a extending a predetermined length in the axial direction are provided at substantially equal intervals in the circumferential direction. In the example of FIG. 23, the number of protrusions 68a is three.

  As shown in FIG. 23, the protrusion 68a has a substantially square shape when viewed from the side surface, and includes a convex portion 68a-1 protruding toward the end surface. When the rotor part 60a is integrally formed, the convex part 68a-1 provided at the end part of the protrusion 68a is held by the thermoplastic resin (resin part 67) forming the rotor part 60a, so that the resin part 67 The rotational torque of the resin magnet 68 can be reliably transmitted even when a minute gap is formed between the resin magnet 68 and the resin magnet 68, and the quality of the rotor portion 60a can be improved. The shape of the protrusion 68a is not limited to a substantially square shape, and may be a triangle, trapezoid, semicircle, arc, polygon, or the like.

The resin magnet 68 is formed in the rotor 60, and a plurality of plastic magnets (material of the resin magnet 68) are supplied to the end face on the magnetic pole position detection element (Hall element 58b (see FIG. 4)) side. A gate 68c is provided (see FIG. 24). The end face on the magnetic pole position detection element side is the end face of the resin magnet 68 that faces the magnetic pole position detection element. The position of the gate 68c is, for example, between the electrodes (see FIG. 24). By providing the gate 68c between the poles , it is possible to improve the orientation accuracy of the resin magnet 68.

As shown in FIG. 22, the hollow portion of the resin magnet 68 from the end face on the side where the protrusion 68a is formed to outline axial center position (axial direction of the structural center position) is a straight shape, and the projections 68a are From the end surface on the opposite side of the end surface to be formed to the central position in the approximate axial direction, a tapered shape is formed. Thereby, since it becomes easy to take out the molded product from the mold, the productivity of the resin magnet 68 is improved, and the manufacturing cost can be reduced. In other words, the hollow portion of the resin magnet 68 has a tapered shape and prevents a part or all of the molded product from sticking to the mold and being unable to be taken out (taken into the mold). The productivity of the magnet 68 can be improved. The mold for molding the resin magnet 68 is divided into a fixed mold and a movable mold on the end taper-shaped end face of the protrusion 68a, and a part of the hollow portion formed by the movable mold is a straight shape. As a result, it is possible to prevent the resin magnet 68 from being taken into the stationary mold and to improve the productivity of the resin magnet 68. Remove from the movable mold by pushing it out with ejector pins.

  As shown in FIG. 24, a plurality of convex portions 68e are formed on the resin magnet 68 at substantially equal intervals on the same circumference on the end face on the magnetic pole position detection element (hall element 58b) side. In the example of FIG. 24, eight convex portions 68e are formed. The convex portion 68e has a cross-sectional shape, for example, a substantially long hole shape.

The convex portion 68e is formed at the pole center formed on the rotor 60, for example. That is, the convex portion 68e is disposed corresponding to the position of the gate 68c to which the material of the resin magnet 68 is supplied. Thus, by providing the convex part 68e at the pole center, the magnetic force is improved and the performance of the pump 10 can be improved.

  The convex portion 68 e is embedded with the thermoplastic resin (resin portion 67) when the rotor portion 60 a is integrally formed with the thermoplastic resin (resin portion 67), and the resin magnet 68 is held by the resin portion 67.

  The resin magnet 68 has a rotor position detecting magnetic pole portion 68f protruding in an annular shape having a predetermined width in the radial direction and a predetermined height in the axial direction on the outer peripheral portion of the end surface on the magnetic pole position detecting element (hall element 58b) side. (See FIGS. 22 and 24). In this way, a part of the resin magnet 68 is projected to the magnetic pole position detection element (Hall element 58b) side as the rotor position detection magnetic pole portion 68f, and the rotor position detection magnetic pole portion 68f of the resin magnet 68 and the substrate 58 are projected. The magnetic pole position detection accuracy can be improved by reducing the axial distance from the Hall element 58b mounted on the.

  The Hall element 58b, which is a magnetic sensor, is used as the magnetic pole position detection element. The Hall element 58b is packaged together with an IC that converts the output signal into a digital signal, and is configured as a Hall IC. Surface mounted on the substrate 58. A Hall IC mounted on the substrate 58 is used to detect the leakage flux of the resin magnet 68 from the axial end surface of the resin magnet 68 (the surface facing the magnetic pole position detection element). Compared to the case where the main magnetic flux of the resin magnet 68 is detected from the side surface of the resin magnet 68, the processing cost of the substrate 58 can be reduced, and the cost of the pump 10 can be reduced.

  Next, integral molding of the rotor 60 of the pump motor with the thermoplastic resin will be described. The resin magnet 68 is taken as an example of the magnet.

  A mold for integrally molding the resin magnet 68 and the sleeve bearing 66 includes an upper mold and a lower mold (not shown). First, the sleeve bearing 66 is set in the lower mold. Since the sleeve bearing 66 has a symmetrical cross-sectional shape, it can be set in the mold without matching the circumferential direction. The sleeve bearing 66 includes a plurality of protrusions 66a (see FIG. 22) on the outer peripheral portion, but the position of the protrusion 66a is not particularly limited. Therefore, the work process is simplified, the productivity is improved, and the manufacturing cost can be reduced.

  When the sleeve bearing 66 is set in the lower mold, the sleeve bearing 66 is set in a subsequent process by holding the inner diameter of the sleeve bearing 66 in a sleeve bearing insertion portion (not shown) provided in the lower mold. The accuracy of the coaxiality with the resin magnet 68 is ensured.

The resin magnet 68 is a taper provided on the inner peripheral edge of one end surface of the resin magnet 68 (the end surface on the impeller mounting portion 67a side in the state of the rotor 60) after the sleeve bearing 66 is set in the lower mold. A notch 68b is fitted into a positioning protrusion (not shown) provided on the lower mold and set. In the example of FIG. 24, there are eight notches 68b. Four of the notches 68b at intervals of approximately 90 ° are fitted into the positioning protrusions (not shown) of the lower mold, so that the sleeve bearing 66 and the resin magnet are fitted. The accuracy of the coaxiality with 68 is ensured. The eight cutouts 68b are provided in order to improve workability when the resin magnet 68 is set in the lower mold.

  Further, a magnet pressing portion (not shown) of the upper mold is formed in a substantially square shape formed on the inner peripheral edge of the other end surface of the resin magnet 68 (the end surface on the impeller mounting portion 67a side in the state of the rotor 60). The projection 68a is pressed from the axial direction. Thereby, the positional relationship between the sleeve bearing 66 and the resin magnet 68 is ensured.

  In the example of FIG. 23, there are a total of three substantially square (arc-shaped) protrusions 68a provided on the inner peripheral surface of the resin magnet 68, and the mold installation surface of the protrusion 68a (the part pressed by the mold). Appears after integral molding. The three protrusions 68a ensure the positioning accuracy of the resin magnet 68 and at the same time secure the flow path of the thermoplastic resin used for integral molding, thereby relaxing the molding conditions during integral molding and producing This is to improve the performance.

  Even when there is a gap between the insertion portion (not shown) of the lower mold resin magnet 68 and the outer diameter of the resin magnet 68, the inner diameter pressing portion (positioning protrusion) of the lower mold ensures coaxiality. By sandwiching between the upper mold and the lower mold, it is possible to secure the positional relationship and the coaxiality between the sleeve bearing 66 and the resin magnet 68, and it is possible to improve the quality of the pump 10.

  Conversely, by creating a gap between the insertion portion (not shown) of the lower mold resin magnet 68 and the outer diameter of the resin magnet 68, the workability of setting the resin magnet 68 in the mold is improved. Manufacturing costs are reduced.

  After the resin magnet 68 and the sleeve bearing 66 are set in a mold, a thermoplastic resin such as PPE (polyphenylene ether) is injection molded to form the rotor portion 60a. At this time, notches 68b (see FIG. 24) that cannot be pressed by the mold of the resin magnet 68, that is, four notches 68b, and a convex portion 68e provided on the end surface of the resin magnet 68 on the magnetic pole position detection element side, However, it is embedded in the resin part 67 of thermoplastic resin and becomes a transmission part of the rotational torque. Furthermore, the resin magnet 68 is firmly held by the convex portion 68e being embedded in the resin portion 67 of thermoplastic resin.

After the resin magnet 68 and the sleeve bearing 66 are integrally formed of a thermoplastic resin (resin portion 67), when the resin magnet 68 is magnetized, the inner peripheral surface of one end surface in the axial direction of the resin magnet 68 By using the notches 67d (four locations in FIG. 20 ) formed for the positioning at the time of magnetization, it is possible to perform magnetization with high accuracy.

As described above, according to the present embodiment, the following effects can be obtained.
(1) The substrate 58 is provided on the temperature detection element 111 mounted on the same surface as the substrate surface on which the drive element is mounted, and on the side opposite to the drive element and the temperature detection element 111, and these elements are thermally A heat transfer plate 110 to be connected and a heat transfer plate holder 112 that holds the heat transfer plate 110 in a state where the heat transfer plate 110 is thermally connected to the driving element and the temperature detection element 111 are provided. With this configuration, the temperature detection element 111 detects the temperature of the drive element via the heat transfer plate 110, so that the temperature difference between the temperature of the drive element and the temperature of the temperature detection element 111 can be reduced.
(2) Moreover, since the board | substrate 58 is provided with the heat transfer board 110, it can diffuse the heat | fever of a drive element to circumference | surroundings.
(3) The heat transfer plate assembly 120 includes a substantially comb-shaped thin metal flat plate (110b) in which a substantially U-shaped shape that covers the side surfaces of the drive element and the temperature detection element 111 is connected, and an end surface on the side opposite to the substrate of the drive element And the thin metal flat plate (110a) having a substantially uneven shape that covers the end surface on the side opposite to the substrate of the temperature detecting element 111 are laminated, so that heat generated from the end surface and side surface on the side opposite to the substrate of the drive element is It is possible to efficiently transmit the temperature detection element 111 via the transmission plate 110.
(4) Since the heat transfer plate holder 112 includes a plurality of thin metal flat plate fixing claws 112c extending toward the substrate side, heat transfer is achieved when the claws 112c are locked at a predetermined position of the heat transfer plate 110. The plate 110 can be held.
(5) The heat transfer plate holder 112 has a thin connection shape formed by injection molding, and corresponds to the substrate fixing protrusion 130 provided in the insulating portion 56 of the stator 47 and protruding in the axial direction toward the substrate 58. Since the plurality of projection insertion holes 112b are provided, the heat transfer plate holder 112 is fixed to the stator 47 together with the substrate 58 by inserting the projections 130 into the projection insertion holes 112b. Therefore, it is not necessary to use a separate part for fixing the substrate 58 to the heat transfer plate assembly 120, and the processing cost can be reduced.
(6) The heat transfer plate holder 112 includes a plurality of heat transfer plate pressing pins 112a extending from the side opposite to the substrate side of the heat transfer plate holder 112 (the side opposite to the drive element side) toward the outer side of the mold stator 50. Therefore, when the stator 47 is integrally molded with the mold, the heat transfer plate 110 is brought into close contact with the drive element via the heat transfer plate holder 112 by pressing the mold die against the heat transfer plate pressing pin 112a. Is possible.
(7) The substrate 58 is provided with a plurality of driving elements, and the heat transfer plate 110 is configured to thermally connect the plurality of driving elements and the temperature detection element 111. With this configuration, it is not necessary to arrange the temperature detecting element 111 in each driving element, and the manufacturing cost can be reduced as compared with the conventional technique.

Next, the manufacturing process of the pump 10 will be described. FIG. 27 is a diagram illustrating a manufacturing process of the pump 10.
(1) Step 1: An electromagnetic steel sheet having a thickness of about 0.1 to 0.7 mm is punched into a band shape, and a band-shaped stator core 54 is manufactured by laminating by caulking, welding, adhesion, or the like. In addition, the sleeve bearing 66 and the resin magnet 68 are manufactured. At the same time, the heat transfer plate holder 112 for retaining the heat transfer plate 110 is injection molded using a thermoplastic resin such as PBT (polybutylene terephthalate). In addition, a thin metal flat plate having excellent thermal conductivity such as copper is processed to manufacture the heat transfer plate 110.
(2) Step 2: Winding the stator core 54. An insulating portion 56 using a thermoplastic resin such as PBT (polybutylene terephthalate) is applied to the teeth of the band-shaped stator core 54 connected by the thin-walled connecting portion. A concentrated winding coil 57 is wound around the teeth provided with the insulating portion 56. For example, twelve concentrated winding coils 57 are connected to form a three-phase single Y-connection winding. Since it is a three-phase single Y connection, a terminal 59 (a power supply terminal to which power is supplied and a middle terminal) to which a coil 57 of each phase (U phase, V phase, W phase) is connected is connected to the connection side of the insulating portion 56. Sex point terminal) is assembled. In addition, the substrate 58 and a heat transfer plate having a substantially comb shape and a substantially uneven shape manufactured by flat plate processing of a thin metal are laminated, and the heat transfer plate 110 obtained by the lamination is formed by PBT (polybutylene terephthalate). The heat transfer plate assembly 120 is manufactured by engaging with a heat transfer plate holder 112 formed by injection molding of a thermoplastic resin such as the like. The substrate 58 is sandwiched between the insulating part 56 by the heat transfer plate holder 112. On the substrate 58, an IC for driving an electric motor (brushless DC motor), a Hall element for detecting the position of the rotor 60, and the like are mounted. The board 58 is attached with a lead wire lead-out component 61 and a heat transfer plate assembly 120 that lead out lead wires to a notch near the outer peripheral edge thereof. In addition, the rotor part 60a is manufactured. The rotor portion 60a includes a ring-shaped (cylindrical) resin magnet 68 formed by pelletizing a magnetic powder such as ferrite and a resin, and a cylindrical sleeve bearing 66 (for example, carbon) provided inside the resin magnet 68. For example, PPE (polyphenylene ether). At the same time, the impeller 60b is formed. The impeller 60b is molded using a thermoplastic resin such as PPE (polyphenylene ether).
(3) Step 3: Assemble the substrate 58 to the stator 47. The substrate 58 to which the lead wire lead-out component 61 and the heat transfer plate assembly 120 are attached is fixed to the insulating portion 56 by the heat transfer plate holder 112. At the same time, the impeller 60b is assembled to the rotor portion 60a by ultrasonic welding or the like. In addition, the bowl-shaped partition wall component 90 is formed. In addition, the shaft 70 and the thrust bearing 71 are manufactured. The shaft 70 is manufactured from SUS. The thrust bearing 71 is made of ceramic.
(4) Step 4: The substrate 58 is soldered. The terminals 59 (power supply terminals to which power is supplied and neutral point terminals) and the substrate 58 are soldered. At the same time, the pilot hole part 81 is formed. In addition, the casing 41 is formed. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide). In addition, the rotor 60 and the like are assembled to the bowl-shaped partition wall component 90.
(5) Step 5: The stator assembly 49 is manufactured by assembling the pilot hole part 81 to the stator 47.
(6) Step 6: The stator assembly 49 is molded to produce the mold stator 50. In addition, the pump 41 is assembled by fixing the casing 41 to the bowl-shaped partition wall component 90. In addition, a tapping screw 160 is also manufactured.
(7) Step 7: The pump unit 40 is assembled to the mold stator 50 and fixed with the tapping screw 160.

  FIG. 28 is a conceptual diagram showing a circuit of a refrigeration cycle apparatus using the refrigerant-water heat exchanger 2. The heat pump hot water supply apparatus 300 described at the beginning is an example of an apparatus that uses the refrigerant-water heat exchanger 2.

  The refrigeration cycle apparatus using the refrigerant-water heat exchanger 2 is, for example, an air conditioning apparatus, a floor heating apparatus, a hot water supply apparatus, or the like. The pump 10 of the present embodiment constitutes a water circuit of an apparatus using the refrigerant-water heat exchanger 2 and circulates water (hot water) cooled or heated by the refrigerant-water heat exchanger 2 in the water circuit. .

  The refrigeration cycle apparatus using the refrigerant-water heat exchanger 2 shown in FIG. 28 includes a compressor 1 (for example, a scroll compressor, a rotary compressor, etc.) that compresses the refrigerant, and a refrigerant-water that exchanges heat between the refrigerant and water. A refrigerant circuit having a heat exchanger 2, an evaporator 4 (heat exchanger), and the like is provided. Further, this refrigeration cycle apparatus includes a water circuit having a pump 10, a refrigerant-water heat exchanger 2, a load 20, and the like.

  As described above, when the pump 10 according to the present embodiment is applied to a refrigeration cycle apparatus (an air conditioner, a floor heating apparatus, or a hot water supply apparatus) that uses the refrigerant-water heat exchanger 2, the performance of the pump 10 is improved. With the improvement of quality and productivity, the performance and quality of the refrigeration cycle apparatus can be improved, and the cost can be reduced.

The mold stator and pump according to the embodiment of the present invention show an example of the contents of the present invention, and can be combined with another known technique, and the gist of the present invention Of course, it is possible to change and configure such as omitting a part without departing from the scope.

As described above, the present invention can be applied to a mold stator, a pump, and a refrigeration cycle apparatus, and is particularly useful as an invention that can accurately detect the temperature of a drive element without causing an increase in cost.

1 compressor, 2 refrigerant-water heat exchanger, 3 decompression device, 4 evaporator, 5 pressure detection device, 6 fan motor, 7 fan, 8 boiling temperature detection unit, 9 feed water temperature detection unit, 10 pump, 11 operation Part, 12 tank unit control part, 13 heat pump unit control part, 14 hot water tank, 15 refrigerant pipe, 16 hot water circulation pipe, 17 outside air temperature detection part, 20 load, 31 bath water reheating heat exchanger, 32 bath water circulation apparatus, 33 Mixing valve, 34 Water temperature detection unit in tank, 35 Water temperature detection unit after reheating, 36 Water temperature detection unit after mixing, 37 Bath water replenishing piping, 40 Pump unit, 41 Casing, 42 Suction port, 43 Discharge port, 44 Boss parts, 44a screw hole, 46 the shaft support portion, 47 stator, 49 a stator assembly, 50 molded stator 52 leads, 53 molding resin, 54 stator core 5 a groove, 56 the insulating portion, 57 a coil, 58 a substrate, 58a IC, 58b Hall elements, 59 terminal, 60 a rotor, 60a rotor portion, 60b impeller 61 leads yarn end finding parts, 63 pump unit installation surface 66 sleeve Bearing, 66a protrusion, 67 resin part, 67a impeller mounting part, 67b recess, 67c impeller positioning hole, 67d notch, 67e gate, 68 resin magnet, 68a protrusion, 68a-1 convex part, 68b notch, 68c gate , 68d Concave part, 68e Convex part, 68f Rotor position detection magnetic pole part, 70 shaft, 71 Thrust bearing, 80 O-ring, 81 Pilot hole part, 82 Mold presser part, 83 Protrusion, 84 Pilot hole, 85 Foot part, 85a protrusion, 87 connecting portion, 90 hook-shaped partition wall part, 90a hook-shaped partition wall portion, 90b hook portion, 90c O-ring storage groove, 90d hole, 91 reinforcement Ribs, 92 ribs, 93 annular ribs, 94 shaft support parts, 95 substrate holding parts, 100 heat pump units, 110 heat transfer plates, 110a heat transfer plates with a substantially concave / convex shape, 110a-1 notches, 110b heats with a substantially comb shape Transmission plate, 110b-1 Notch, 111 Temperature detection element, 112 Heat transfer plate holder, 112a Heat transfer plate holding pin, 112b Projection insertion hole, 112c Claw, 120 Heat transfer plate assembly, 130 Projection, 160 Tapping screw, 200 Tank Unit, 300 Heat pump hot water supply device.

Claims (8)

A stator formed by winding a coil in a plurality of teeth insulating portion has been performed of the stator core, and the substrate on which the driving element is mounted is a a mold stator formed by integrally molded with a thermosetting resin And
The substrate is
A temperature detecting element mounted on the same surface as the substrate surface on which the driving element is mounted;
A thin comb-shaped metal flat plate that covers the side surfaces of the drive element and the temperature detection element, and a thin wall formed in a size that covers a surface opposite to the surface of the drive element and the temperature detection element that faces the substrate. A heat transfer plate that is formed by laminating a metal flat plate , provided on the opposite surface of the drive element and the temperature detection element, and thermally connecting these elements;
A heat transfer plate holder for holding the heat transfer plate in a state where the heat transfer plate is thermally connected to the drive element and the temperature detection element;
Mold stator with A stator in which a stator is formed by winding a coil around a plurality of teeth provided with an insulating portion of a stator core, and a substrate on which a drive element is mounted is a molded stator formed integrally with a thermosetting resin. And
The substrate is
A temperature detecting element mounted on the same surface as the substrate surface on which the driving element is mounted;
The drive element and the temperature detection element are provided on a surface opposite to the surface facing the substrate, and a heat transfer plate for thermally connecting these elements;
While holding the heat transfer plate in a state in which the heat transfer plate is thermally connected to the drive element and the temperature detecting element, the mold stator from a surface opposite to the surface facing the heat transfer plate A heat transfer plate holder provided with a plurality of heat transfer plate pressing pins extending toward the outer side of
A mold stator comprising: The substrate is provided with a plurality of the driving elements,
The heat transfer plate is molded stator according to a plurality of the driving element and the temperature sensing element 請 Motomeko 1 or claim 2 to connect thermally. To the heat transfer plate holder extends from the heat transfer plate holder and the surface facing toward the substrate side, any claim 3 請 Motomeko 1 more claws that provided for holding the heat transfer plate The mold stator according to claim 1 . The insulating portion is formed with a plurality of substrate fixing protrusions protruding in the direction of the substrate,
To the heat transfer plate holder is molded stator according to any one of claims 4 請 Motomeko 1 a plurality of protrusions insertion holes at positions that are provided corresponding to these projections. The pump provided with the mold stator of any one of Claims 1-5. A refrigerant circuit, a water circuit, and a refrigerant-water heat exchanger that connects the refrigerant circuit and the water circuit to exchange heat between the refrigerant and water, and
The said water circuit, refrigerating cycle apparatus in which the pump Ru contains according to claim 6. The stator core teeth are provided with an insulating portion, a coil is wound around the teeth provided with the insulating portion, a stator is manufactured, and a thin metal flat plate is processed to drive elements and temperature detection. Producing a heat transfer plate for thermally connecting the elements, and securing the heat transfer plate to a heat transfer holder formed by injection molding of a thermoplastic resin to produce a heat transfer plate assembly; A step of manufacturing a substrate on which an electronic component including a temperature detection element is mounted and a lead wire lead-out component for leading out a lead wire and the heat transfer plate assembly are attached;
An annular magnet and a sleeve bearing provided inside the magnet are integrally molded using a thermoplastic resin to produce a rotor part, and further to produce an impeller;
Assembling the substrate to the stator, assembling the impeller to the rotor part to produce a rotor, and further producing a bowl-shaped partition wall part, a shaft and a thrust bearing;
Soldering the terminal of the stator and the substrate, assembling the rotor to the bowl-shaped partition wall part, further forming a casing having a water inlet and a discharge port, and manufacturing a pilot hole part;
The stator and the pilot hole part are integrally molded with a mold resin to manufacture a mold stator, and the casing is fixed to the bowl-shaped partition wall part and has a plurality of screw holes on the outer periphery. Manufacturing a tapping screw together, and
Assembling the pump part to the mold stator, and fixing the pump part to the mold stator by the tapping screw through the screw hole of the pump part and the pilot hole of the pilot hole part;
Manufacturing method of a free Mupo pump.

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