JP6479392B2 - Laminated iron core and method for manufacturing the same - Google Patents

Description

  The present invention relates to a laminated core and a method for manufacturing the same.

  A laminated iron core is a component of a motor, and is formed by stacking a plurality of electromagnetic steel sheets processed into a predetermined shape and fastening them. The motor includes a rotor (rotor) and a stator (stator) made of laminated iron cores, and is completed through a process of winding a coil around the stator, a process of attaching a shaft to the rotor, and the like. A motor employing a laminated core is conventionally used as a drive source for a refrigerator, an air conditioner, a hard disk drive, an electric tool, and the like, and in recent years is also used as a drive source for a hybrid car.

  Caulking and welding are known as means for fastening electromagnetic steel plates adjacent in the vertical direction. These fastening means are excellent in terms of cost and work efficiency, and have been widely adopted conventionally. On the other hand, when priority is given to the high torque and low iron loss of the motor, the electromagnetic steel sheets may be fastened using a resin material or an adhesive instead of caulking or welding.

  Patent Document 1 discloses a method of fastening a plurality of thin metal plates 11 with a resin material. That is, in the method described in Patent Document 1, a plurality of thin metal plates 11 provided with a plurality of orifices 14 are used, and the orifices 14 are filled with a resin material in a state where these thin metal plates 11 are stacked, and the insert is inserted. The thin metal plates 11 are fastened together by forming 20 (see FIGS. 5 and 6 of Patent Document 1).

  Patent Document 2 discloses a method of manufacturing a laminated core 110 by temporarily binding a plurality of core sheets 50 with a fixing jig 120 having caulking, and then binding them using a resin material. That is, the method described in Patent Document 2 includes a step of temporarily binding core sheets 50 with a fixing jig 120 disposed outside the laminated core 110 and a laminated core made of an insulating resin 13 formed by, for example, die-cast molding. The split-type stator 200 is manufactured through a process of binding the core 110 and a process of removing the fixing jig 120 from the stack core 110 after the stacking of the stacked core 110 (FIGS. 2 and 3 of Patent Document 2). reference). The stator 200 having no caulking is finally obtained by removing the fixing jig 120 having caulking from the laminated core 110 in the manufacturing process.

Special table 2003-529309 gazette Japanese Patent No. 5357187

  As described above, Patent Document 1 discloses that metal thin plates are fastened together by filling a resin material into an orifice provided in the metal thin plate. However, according to the study by the present inventors, there is a problem that depending on the shape of the hole for filling the resin material (orifice 14 in Patent Document 1), the residue is likely to rise in the process of forming the hole by punching. . “Left-up” means a phenomenon in which a material punched into a punch included in a mold (referred to as “scrap” or “slip-out”) adheres. If an indentation is generated in the product due to debris adhering to the punch, a product defect is caused. When the shape of the residue is a simple shape such as a circle or an ellipse, the residue rises easily.

  In addition to the shape of the orifice 14, the method described in Patent Document 1 has room for improvement in terms of the position where the orifice 14 is provided and the size of the so-called yoke portion. That is, the laminated core for the stator includes an annular yoke portion and a teeth portion extending in the center direction from the inner peripheral side of the yoke portion. In the method described in Patent Document 1, a thin metal plate 11 which is square and has an opening 12 for mounting a rotor (motor shaft) in the center is used, and orifices 14 are formed near the four corners, respectively. . On the other hand, in recent years, in order to cope with the demand for miniaturization of the motor and the demand for reduction of the manufacturing cost, the yoke portion is designed with the minimum necessary size (see FIGS. 1 to 3 of Patent Document 2). When providing holes for resin filling in a laminated iron core for a stator with a narrow yoke part, the shape of the hole and the position of the hole are devised, thereby further increasing both the high torque and low iron loss of the motor. Achieving standards is required. The same performance as the above-described laminated core for the stator is also required for the laminated core for the rotor.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a laminated core that can sufficiently suppress the occurrence of residue rise in the manufacturing process and that can achieve both high torque and low iron loss of a motor at a sufficiently high level, and a method for manufacturing the same. .

  The present invention provides a laminated iron core for a stator including a laminated body formed by laminating a plurality of electromagnetic steel sheets and having an annular yoke portion and a teeth portion extending in the center direction from the inner peripheral side of the yoke portion. . The laminated core for the stator is a plurality of through-holes that penetrate from the upper surface to the lower surface of the laminate, and is on the extension of the center line extending in the radial direction of the teeth portion in plan view and along the outer periphery of the yoke portion. The plurality of first through holes provided and resin filling portions formed in the plurality of first through holes, respectively. The first through-hole has at least two side surfaces extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion, and one side surface extending along the outer periphery of the yoke portion. And it has the convex part or recessed part extended from the upper surface of a laminated body to a lower surface on the said one side surface.

  The laminated iron core for the stator has a plurality of electromagnetic steel plates fastened with a resin material (resin filling portion). The first through hole for forming the resin-filled portion is formed in a region where the magnetic flux is sparse (position on the extension line of the center line extending in the radial direction of the tooth portion in plan view and along the outer periphery of the yoke portion). Yes. Further, the first through hole has a specific shape, that is, two side surfaces extending in a direction in which the first through hole is away from the inner peripheral side to the outer peripheral side of the yoke portion, and one extending along the outer periphery of the yoke portion. By having at least the side surface, it is possible to sufficiently suppress the flow of magnetic flux from being inhibited by the resin filling portion. The two side surfaces of the first through hole and the convex portion or the concave portion of the one side surface contribute to suppression of residue rise in the step of punching the opening serving as the first through hole with a mold.

  The laminated iron core for the stator further includes a cylindrical member accommodated in the first through hole, and a resin filling portion is formed between the inner surface of the first through hole and the outer surface of the cylindrical member. Good. By adopting such a configuration, there is an advantage that a sufficiently high fastening force can be secured and the amount of resin used can be reduced even when the cross-sectional area of the first through hole is relatively large.

The present invention provides a laminated iron core for a stator having the same configuration as the laminated iron core for the stator except that it has a notch instead of the first through hole. That is, the laminated iron core for the stator includes a laminated body that is formed by laminating a plurality of electromagnetic steel plates and includes an annular yoke portion and a tooth portion extending in the center direction from the inner peripheral side of the yoke portion, A plurality of cutouts provided on the outer periphery of the yoke portion, extending from the upper surface to the lower surface of the laminated body, extending along the center line extending in the radial direction of the teeth portion in plan view and along the outer periphery of the yoke portion It has the some notch provided and the resin filling part each formed in the some notch. These notches have at least two side surfaces extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion, and have convex portions or concave portions extending from the upper surface to the lower surface of the laminate on the two side surfaces. . A region between two adjacent resin filling portions on the outer periphery of the laminated core is not covered with resin, and a side surface of the tooth portion is not covered with resin .

  The laminated iron core for the stator is also fastened with a plurality of electromagnetic steel plates with a resin material (resin filling portion). The notch for forming the resin filling portion is formed in a region where the magnetic flux is sparse (position on the extension of the center line extending in the radial direction of the tooth portion in plan view and along the outer periphery of the yoke portion). In addition, since the notch has at least two side surfaces extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke part, the flow of magnetic flux is inhibited by the resin filling part. Can be sufficiently suppressed. The protrusions or recesses on the two side surfaces of the notch contribute to the suppression of dregs rise in the process of punching out the opening to be the notch with a mold.

  The laminated iron core for a stator according to the present invention includes a plurality of second through holes provided on a center line extending in the radial direction of the teeth portion in a plan view, the plurality of through holes penetrating from the upper surface to the lower surface of the laminated body. You may further have a hole and the resin filling part each formed in the several 2nd through-hole. The second through hole has at least two side surfaces extending along the center line, and has a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces.

  By providing the second through hole, the teeth portion can be securely fastened by the resin material. By providing the second through hole on the center line extending in the radial direction of the tooth portion, the flow of magnetic flux can be inhibited by the resin filling portion and the magnetic imbalance can be minimized. The convex portions or concave portions on the two side surfaces of the second through hole contribute to the suppression of dregs rise in the step of punching out the opening serving as the second through hole with a mold.

  The present invention includes an annular laminate formed by laminating a plurality of electromagnetic steel plates, a plurality of magnet fixing openings provided side by side in the circumferential direction of the laminate, and a plurality of magnets accommodated in the magnet fixing openings. A laminated core for a rotor including a magnet is provided. The laminated iron core for a rotor is a plurality of through-holes penetrating from the upper surface to the lower surface of the laminated body, and is on a straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view. And a plurality of first through holes provided along the inner peripheral side of each of the first through holes and a resin filling portion formed in each of the plurality of first through holes. The first through-hole has at least two side surfaces extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the laminate, and one side surface extending along the inner periphery of the laminate. The side surface and the one side surface have a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate.

  The laminated iron core for the rotor is also fastened with a plurality of electromagnetic steel plates with a resin material (resin filling portion). The first through-hole for forming the resin-filled portion is a region in which magnetic flux is sparse (on a straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view and along the inner peripheral side of the laminated body Formed). Further, the first through-hole has a specific shape, that is, two side surfaces extending in a direction in which the first through-hole moves away from the outer peripheral side to the inner peripheral side of the laminate, and 1 extending along the inner periphery of the laminate. By having at least one side surface, it is possible to sufficiently suppress the flow of magnetic flux from being inhibited by the resin filling portion. The two side surfaces of the first through hole and the convex portion or the concave portion of the one side surface contribute to suppression of residue rise in the step of punching the opening serving as the first through hole with a mold.

  The laminated iron core for a rotor further includes a cylindrical member accommodated in the first through hole, and a resin filling portion is formed between the inner surface of the first through hole and the outer surface of the cylindrical member. Good. By adopting such a configuration, there is an advantage that the amount of resin used can be reduced and a sufficiently high fastening force can be secured even when the cross-sectional area of the first through hole is relatively large.

The present invention provides a laminated iron core for a rotor having the same structure as the laminated iron core for a rotor except that a cutout is provided instead of the first through hole. That is, the laminated iron core for the rotor includes an annular laminate formed by laminating a plurality of electromagnetic steel plates, a plurality of magnet fixing openings provided side by side in the circumferential direction of the laminate, and a magnet fixing A plurality of magnets housed in the opening and extending from the upper surface to the lower surface of the multilayer body, and a plurality of cutouts provided on the inner periphery of the multilayer body, and laminated between two adjacent magnets in plan view It has a plurality of notches provided on the straight line extending in the radial direction of the body and along the inner periphery of the laminated body, and resin filling portions respectively formed in the plurality of notches . These notches have at least two side surfaces extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the laminated body, and have convex portions or concave portions extending from the upper surface to the lower surface of the laminated body on the two side surfaces. .

  The laminated iron core for the rotor is also fastened with a plurality of electromagnetic steel plates with a resin material (resin filling portion). The notch for forming the resin-filled portion is a region where the magnetic flux is sparse (position on the straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view and along the inner periphery of the laminated body) Is formed. In addition, since the notch has at least two side surfaces extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the laminate, the flow of magnetic flux is inhibited by the resin filling portion. Can be sufficiently suppressed. The protrusions or recesses on the two side surfaces of the notch contribute to the suppression of dregs rise in the process of punching out the opening to be the notch with a mold.

  The laminated core for a rotor according to the present invention is a plurality of through-holes penetrating from the upper surface to the lower surface of the laminated body, and on a straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view. You may further have the some 2nd through-hole provided, and the resin filling part each formed in the some 2nd through-hole. The second through hole has at least two side surfaces extending along the straight line, and has a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces.

  By providing the second through hole, the outer peripheral side of the laminate can be securely fastened by the resin material. By providing the second through hole on a straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view, the flow of magnetic flux is obstructed by the resin filling portion and a magnetic imbalance is required. It can be minimized. The convex portions or concave portions on the two side surfaces of the second through hole contribute to the suppression of dregs rise in the step of punching out the opening serving as the second through hole with a mold.

The present invention provides a method for manufacturing a laminated core for a stator and a rotor having the first through hole. That is, method of manufacturing a laminated core according to the present invention, electrical steel plate and supplying to the mold, a step of punching an opening as a first through-hole from the electromagnetic steel plates in the mold, electrical steel plate in the mold The step of advancing in the step, the step of obtaining a plurality of electromagnetic steel sheets to be laminated by punching out the region including the opening to be the first through hole in the mold, and the first through hole in a state where the plurality of electromagnetic steel plates are laminated The process of fastening the electromagnetic steel plates adjacent in the up-down direction by forming the resin filling portion in this order.

  According to the manufacturing method, it is possible to efficiently manufacture a laminated core that can achieve both a high torque and a low iron loss of the motor at a sufficiently high level. In particular, it is possible to sufficiently suppress the occurrence of residue rise in the process of punching the opening that becomes the first through hole.

The present invention provides a method for manufacturing a laminated core for a stator and a rotor having the above-described notches. That is, method of manufacturing a laminated core according to the present invention is advanced, electrical steel plate comprising the steps of supplying to the mold, a step of punching out the opening Naru O by notches from the electromagnetic steel sheets in the mold, the electrical steel plate in the mold A step of obtaining a plurality of electromagnetic steel sheets to be laminated by punching a region including a part of the opening to be cut out in the mold, and a resin filling portion in the notch in a state in which the plurality of electromagnetic steel sheets are laminated. And the step of fastening electromagnetic steel sheets adjacent in the up-down direction in this order.

  According to the manufacturing method, it is possible to efficiently manufacture a laminated core that can achieve both a high torque and a low iron loss of the motor at a sufficiently high level. In particular, it is possible to sufficiently suppress the occurrence of residue rise in the process of punching out the opening that becomes a notch.

  The method for manufacturing a laminated core according to the present invention includes a step of punching an opening serving as a second through hole from an electromagnetic steel sheet in a mold, and forming a resin filling portion in the second through hole in a state where a plurality of electromagnetic steel sheets are laminated. You may further provide a process. By employ | adopting this structure, a some electromagnetic steel plate can be fastened more reliably.

  According to the present invention, it is possible to sufficiently suppress the occurrence of waste during the manufacturing process, and it is possible to achieve both a high motor torque and a low iron loss at a sufficiently high level.

It is a perspective view which shows an example of the stator (stator) which consists of a laminated iron core. It is sectional drawing which follows the II-II line | wire in FIG. It is a top view which expands and shows the area | region in which the 1st through-hole and the 2nd through-hole were formed. It is a top view which shows an example of a 1st through-hole. It is a perspective view which shows an example of a 1st through-hole. It is a top view which shows the other example of a 1st through-hole. (A)-(e) is a top view which shows the modification of a 1st through-hole, respectively. (A)-(c) is a top view which shows the modification of a 1st through-hole, respectively. It is sectional drawing which shows the 1st through-hole by which the cylindrical member is arrange | positioned inside. It is a top view which expands and shows the 2nd through-hole shown in FIG. It is a top view which shows the other example of a 2nd through-hole. It is a schematic diagram which shows an example of the apparatus for manufacturing a laminated iron core. (A)-(c) is a top view which shows the electromagnetic steel plate in which various opening was formed, (d) is a top view which shows the electromagnetic steel plate which has an opening used as a 1st through-hole. (A)-(c) is a top view which shows the electromagnetic steel plate in which various opening was formed, (d) is a top view which shows the electromagnetic steel plate which has a notch. It is a top view which shows the laminated iron core for stators in which the resin filling part was formed in the notch. It is a top view which shows a division type laminated iron core for stators. It is a perspective view which shows an example of the rotor (rotor) which consists of a laminated iron core. It is a top view which expands and shows the area | region in which the 1st through-hole and the 2nd through-hole were formed. It is a top view which shows an example of a 1st through-hole. It is sectional drawing which shows the notch in which the resin filling part was formed.

  Embodiments of the present invention will be described in detail with reference to the drawings. In the following description, the same reference numerals are used for the same elements or elements having the same functions, and redundant description is omitted. Here, the position of the configuration is described based on the orientation of the laminate when the fastening resin is injected into the through hole. For example, the surface of the laminate facing upward when the fastening resin is injected is referred to as “upper surface”, and the opening of the through hole located on this upper surface is referred to as “upper opening”.

<Laminated iron core constituting the stator>
FIG. 1 is a perspective view of a laminated iron core S constituting a stator. The shape of the laminated core S is substantially cylindrical, and the opening Sa located in the center is for arranging the laminated core (rotor) R shown in FIG. The laminated iron core S has a substantially annular yoke portion Sy and a teeth portion St extending in the center direction from the inner peripheral side of the yoke portion Sy. Depending on the application and performance of the motor, the width of the yoke portion Sy (W in FIG. 1) is about 2 to 40 mm. The laminated iron core S shown in FIG. 1 has 12 teeth portions St. The number of teeth portions St is not limited to twelve.

  As shown in FIGS. 1 and 2, the laminated iron core S is provided so as to be arranged at equal intervals along the outer periphery of the laminated body 10 made of a plurality of electromagnetic steel plates M processed into a predetermined shape and the yoke portion Sy. Twelve first through holes 1 and resin filling portions 11 formed by filling each first through hole 1 with resin are provided. The laminated iron core S is further provided with a total of twelve second through-holes 2 provided one by one in each tooth portion St, and a resin-filled portion formed by filling each second through-hole 2 with resin. 12. Both the first through hole 1 and the second through hole 2 extend from the upper surface 10 a to the lower surface 10 b of the laminate 10.

  As will be described later, the electromagnetic steel sheet M supplies the unprocessed electromagnetic steel sheet (the electromagnetic steel sheet drawn from the wound body MC) to the mold, and the openings 1M and the second through holes that become the first through holes 1 by the punches of the mold. It is manufactured by punching out the opening 2M that becomes 2 (see FIG. 13). Hereinafter, the first through hole 1 and the second through hole will be described.

(First through hole)
The 1st through-hole 1 is comprised by laminating | stacking the some electromagnetic steel plate M each provided with the opening 1M. The 1st through-hole 1 is provided in the area | region where the magnetic flux in the laminated body 10 is sparse, and the shape is devised so that the flow of magnetic flux may not be inhibited as much as possible.

  First, regarding the position of the first through hole 1, as shown in FIG. 3, the first through hole 1 is on the extension line of the center line C <b> 1 extending in the radial direction of each tooth part St in plan view and on the outer periphery of the yoke part Sy. It is provided along. As shown in FIG. 3, this position is in a region where the magnetic flux MF flowing from the tooth portion St to the yoke portion Sy is divided in two directions in the circumferential direction of the yoke portion Sy, and the magnetic flux is sparse compared to other regions. .

  Next, regarding the shape of the first through hole 1, as shown in FIG. 3, the first through hole 1 has a substantially triangular cross-sectional shape. In other words, each of the plurality of electromagnetic steel plates M has a substantially triangular opening 1M (see FIG. 4). One vertex 1a of the substantially triangular shape faces the tooth portion St side, and a side 1cb that is the opposite side of the vertex 1a extends along the outer periphery of the yoke portion Sy. The side 1ba and the side 1ac constituting the vertex 1a extend in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion Sy. When the first through hole 1 is viewed in a three-dimensional view instead of in plan view, the two side surfaces Fba and Fac extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion Sy, and the outer periphery of the yoke portion Sy. It is comprised by one side Fcb extended (refer FIG. 5). According to the 1st through-hole 1 of the said shape, it can fully suppress that the flow of magnetic flux is disturbed resulting from the 1st through-hole 1.

  As shown in FIG. 5, the side surfaces Fba, Fac, Fcb constituting the first through hole 1 each have a convex portion Fd extending from the upper surface 10 a to the lower surface 10 b of the stacked body 10. In other words, the sides 1ba, 1ac, 1cb constituting the opening 1M of the electromagnetic steel sheet M have a convex portion 1d at the center of each side. The height of projection 1d (projection Fd) (D in FIG. 4) is preferably 0.01 mm or more, more preferably 0.02 to 0.20 mm, and even more preferably 0.02 to 0.10 mm. It is. The convex portion 1d is for suppressing the occurrence of dregling when the opening 1M is punched out of a roll-shaped electromagnetic steel sheet by punching. By providing the convex portions 1d having a height of 0.01 mm or more at a constant pitch (in this example, a pitch of about 120 ° as shown in FIG. 4) on the inner peripheral surface of the opening 1M, it is possible to effectively suppress the residue from rising.

  From the viewpoint of reducing wear of the punch (blade) of the mold, the apexes 1a, 1b, and 1c of the opening 1M are rounded not in an acute angle but in an arc shape. The radius of the roundness (curvature radius R) is preferably 0.2 mm or more, and more preferably 0.2 to 1.0 mm. Assuming that the shape of the opening 1M is a triangle (a triangle represented by a broken line in FIG. 4), the length of one side of the triangle is the length of the portion where the convex portion 1d is provided. From the viewpoint of prevention, the thickness is preferably about 0.4 to 10 mm, more preferably about 0.4 to 5 mm.

  Here, the case where the convex portions 1d are provided on the sides 1ba, 1ac, 1cb constituting the opening 1M is illustrated, but instead of the convex portion 1d, the concave portion 1e having the same size as the convex portion 1d is replaced with the sides 1ba, 1ac. , 1cb (see FIG. 6). Thereby, you may form the recessed part (not shown) extended from the upper surface 10a of the laminated body 10 to the lower surface 10b in side surface Fba, Fac, Fcb which comprises the 1st through-hole 1. FIG.

  The shape of the first through hole 1 is not limited to a substantially triangular shape. That is, as long as it has at least two side surfaces extending in a direction away from each other from the inner periphery side to the outer periphery side of the yoke portion Sy and one side surface extending along the outer periphery of the yoke portion Sy, the shape shown in FIG. May be. The first through hole 1 shown in FIG. 7A has a shape close to a trapezoid, and convex portions are provided on the inner peripheral surface of the first through hole 1 at a pitch of about 90 °. The first through hole 1 shown in FIG. 7B has a shape close to a pentagon combining a rectangle (rectangle or square) and a right-angled isosceles triangle, and a convex portion is formed on each side surface forming each side in a plan view. Is provided. The first through hole 1 shown in FIG. 7C has a shape close to a pentagon combining a rectangle and an equilateral triangle, and has a convex portion on each side surface forming one side of the rectangle and two sides of the equilateral triangle in plan view. Is provided. The first through hole 1 shown in FIG. 7D has a shape in which a part of three circles are arranged to overlap each other. By arranging the three circles so that the centers of the three circles form an equilateral triangle, a convex portion is formed by two adjacent arcs. The first through hole 1 shown in FIG. 7 (e) has a circular apex (corner portions) 1a, 1b, 1c and three sides (three side surfaces) formed so as to form a convex portion as a whole. It is constituted by. According to the first through hole 1 having the configuration shown in FIG. 7E, even if the resin shrinks in the process of hardening the resin in the first through hole 1, the resin peels off at the corners. Can be effectively prevented. First through-holes 1 shown in FIGS. 8A to 8C are the same as the first through-holes 1 shown in FIGS. 7A to 7C except that the first through-holes 1 shown in FIGS. It has the same configuration as.

  The resin filling portion 11 is formed by filling the first through hole 1 with resin. The resin filling part 11 consists of hardened | cured material of a thermosetting resin, for example. Specific examples of the thermosetting resin include a resin composition containing an epoxy resin, a curing initiator, and an additive. Examples of the additive include a filler, a flame retardant, and a stress reducing agent. As the filler, for example, a granular material obtained by crushing a cured product of a thermosetting resin may be used. By filling the first through hole 1 with resin, the electromagnetic steel plates M adjacent in the vertical direction can be fastened. By joining the electromagnetic steel sheets M with resin, it is possible to eliminate the need for caulking or welding that has been conventionally used to join the electromagnetic steel sheets M together. In addition, you may use not only a thermosetting resin but the other resin materials, such as a thermoplastic resin, for the resin filling part 11. FIG.

Here, the case where the entire first through hole 1 is filled with resin has been illustrated, but as shown in FIG. 9, a cylindrical member 1 f is disposed in the first through hole 1, and the inner surface of the first through hole 1. And the outer surface of the cylindrical member 1f may be filled with resin, while the inside of the cylindrical member 1f may be left hollow. That is, you may form the resin filling part 11 between the inner surface of the 1st through-hole 1, and the outer surface of the cylindrical member 1f. Thereby, even when the cross-sectional area of the 1st through-hole 1 is comparatively large (for example, 10-200 mm < ² >), there exists an advantage that sufficiently high fastening force can be ensured, reducing the usage-amount of resin. Examples of the material of the cylindrical member 1f include a thermosetting resin such as an epoxy resin and a non-magnetic metal such as stellen. In addition, the cross-sectional shape of the cylindrical member 1f does not need to correspond to the cross-sectional shape of the first through hole 1, and may be a cylindrical shape, an oval shape, a rectangular shape, or the like. Further, the cylindrical member 1f may be left in the first through hole 1 or removed after the first through hole 1 is filled with resin. Further, both ends of the cylindrical member 1f may be closed, or a solid columnar member may be employed instead of the hollow cylindrical member 1f.

(Second through hole)
The 2nd through-hole 2 is provided in order to fasten the teeth part St with resin (resin filling part 12). When a relatively thick electromagnetic steel sheet M (thickness of about 0.35 to 0.50 mm) is used, the laminate is formed only by the resin filling portion 11 provided in the first through hole 1 depending on the size of the laminate 10. The entire 10 can be fastened. On the other hand, when a relatively thin electromagnetic steel sheet M (thickness of about 0.10 to 0.30 mm) is used, the teeth portion St is deformed in the process of manufacturing the motor by fastening the teeth portion St with the resin filling portion 12. Can be sufficiently suppressed.

  The second through hole 2 is configured by laminating a plurality of electromagnetic steel plates M each provided with an opening (opening serving as a second through hole) 2M. The 2nd through-hole 2 is provided in the front end side of the teeth part St on the centerline C1 extended in the radial direction of each teeth part St. By providing the second through-hole 2 on the center line C1 extending in the radial direction of the tooth portion St, the flow of magnetic flux can be inhibited by the resin filling portion 12 and the magnetic imbalance can be suppressed to the minimum necessary ( (See FIG. 3).

  The shape of the second through hole 2 is devised so as not to obstruct the flow of magnetic flux as much as possible. That is, as shown in FIG. 10, the second through-hole 2 has an elongated shape and is arranged so that the major axis coincides with the center line C1. The ratio (A / B) between the length A of the major axis and the length B of the minor axis shown in FIG. 10 is preferably 2 to 5, and more preferably 3 to 4.

  As shown in FIG. 10, the 2nd through-hole 2 has the convex part Gc on the side surfaces Ga and Gb extended so that the center line C1 may be followed. The convex portion Gc extends from the upper surface 10a to the lower surface 10b of the laminate 10 (see FIG. 1). The height of the convex portion Gc (G in FIG. 10) is preferably 0.01 mm or more, more preferably 0.02 to 0.20 mm, and still more preferably 0.02 to 0.10 mm. The convex portion Gc is for suppressing the occurrence of residue rise when punching out the opening that becomes the second through hole 2 from the rolled electromagnetic steel plate. By providing the convex portions Gc having a height of 0.01 mm or more at a constant pitch (in this example, a pitch of about 180 °) on the inner peripheral surface of the opening, it is possible to effectively suppress the residue rise.

  Here, the case where the convex portions Gc are respectively provided in the second through holes 2 is illustrated, but a concave portion Gd having the same size as the convex portions Gc may be provided in the second through holes 2 instead of the convex portions Gc. FIG. 11).

  The resin filling portion 12 is formed by filling the second through hole 2 with resin. The resin filling portion 12 is made of, for example, a cured product of a thermosetting resin. Specific examples of the thermosetting resin include a resin composition containing an epoxy resin, a curing initiator, and an additive. Examples of the additive include a filler, a flame retardant, and a stress reducing agent. As the filler, for example, a granular material obtained by crushing a cured product of a thermosetting resin may be used. The resin constituting the resin filling portion 12 may be the same as or different from the resin constituting the resin filling portion 11.

  Here, the case where the entire second through-hole 2 is filled with resin is illustrated, but a cylindrical member (not shown) is disposed in the second through-hole 2 in the same manner as the first through-hole 1, and the second The resin may be filled between the inner surface of the through hole 2 and the outer surface of the tubular member, while the inside of the tubular member may be left hollow. That is, the resin filling portion 12 may be formed between the inner surface of the second through hole 2 and the outer surface of the cylindrical member.

<Manufacturing method of laminated iron core constituting the stator>
FIG. 12 is a schematic diagram showing a configuration of an apparatus for manufacturing the laminated iron core S. The manufacturing apparatus 100 shown in the figure includes an uncoiler 110 on which a wound body MC of electromagnetic steel sheets is mounted, a press machine 120, a feed device 130 provided in the press machine 120, and a progressive die 140 operated by the press machine 120. With.
A method for manufacturing the laminated core S constituting the stator will be described with reference to FIGS. The manufacturing method of the laminated iron core S includes the following steps in this order.
(A1) A step of preparing a wound body MC of an electromagnetic steel sheet.
(A2) A step of supplying the electromagnetic steel sheet drawn from the wound body MC to the mold 140.
(A3) A step of punching the opening 1M and the like to be the first through hole 1 from the electromagnetic steel plate in the mold 140.
(A4) A step of advancing the electromagnetic steel sheet drawn out from the wound body MC in the mold 140.
(A5) A step of obtaining a plurality of electromagnetic steel sheets M to be laminated by punching out the region R1 including the opening 1M in the mold 140.
(A6) A step of filling the first through hole 1 and the second through hole 2 with a resin in a state where a plurality of electromagnetic steel plates M are laminated.

  First, a wound body MC of electromagnetic steel sheets is prepared (step (A1)) and mounted on the uncoiler 110. The length of the electrical steel sheet constituting the wound body MC is, for example, 500 to 10,000 m. In addition, when the remainder of the winding body MC in use decreases, a new winding body is prepared, and the start end part of the new winding body and the terminal end part of the winding body in use are joined by welding, for example.

  The electromagnetic steel sheet drawn out from the wound body MC is supplied to the mold 140 through the feeder 130 ((A2) step). By repeating the punching operation ((A3) step) by the punch (not shown) provided in the mold 140 and the feeding operation ((A4) step) of the electromagnetic steel sheet by the feeding device 130, (a) to (d) in FIG. ), Various predetermined openings are continuously formed in the electromagnetic steel sheet. First, a pilot hole P for alignment is formed (see FIG. 13A). Thereafter, an opening 1M to be the first through hole 1 and an opening 2M to be the second through hole 2 are formed (see FIG. 13B). Either the opening 1M or the opening 2M may be formed first, or may be formed simultaneously.

  As shown in FIGS. 13B to 13D, the electromagnetic steel sheets M to be laminated are obtained by punching out the region R1 including the opening 1M with a punch (step (A5)). A laminated core S shown in FIG. 1 is obtained by filling the first through hole 1 and the second through hole 2 with a resin in a state where a plurality of electromagnetic steel sheets M are laminated (step (A6)). The filling of the resin into the first through hole 1 and the second through hole 2 may be performed using a resin mold apparatus. The filling of the resin into the first through hole 1 and the filling of the resin into the second through hole 2 may be performed simultaneously or separately. Further, when the laminated core has a small thickness or the mechanical strength standard is not high, the resin filling time can be reduced by selectively filling only the minimum number of first through holes 1 with the resin. Costs can be reduced by reducing the amount of resin used.

  Here, the case where the electromagnetic steel plate M is obtained by punching the region R1 including the opening 1M by punching is illustrated, but the electromagnetic steel plate M may be obtained by punching the region R2 including a part of the opening 1M. In this case, the opening 1M is not a first through hole 1 but a notch. By laminating the electromagnetic steel sheets having the notches, the laminate 20 having the notches 3 extending from the upper surface 20a to the lower surface 20b of the laminate 20 is obtained. A laminated core is obtained by filling the notch 3 of the laminate 20 with the resin filling portion 13 (see FIG. 15). The laminated body 20 has the same configuration as that of the laminated body 10 except that the laminated body 20 has notches 3 for filling resin instead of the first through holes 1. In addition, what is necessary is just to implement resin filling operation in the state which has arrange | positioned the board, for example in the position where the notch 3 was formed in the outer periphery of the laminated body 20. FIG.

Furthermore, although the monolithic laminated core S and its manufacturing method are illustrated here, the present invention is not limited to the monolithic laminated core S, and may be applied to a split-type laminated core _SD and its manufacturing method. . As shown in FIG. 16, the laminated iron core _SD is constituted by a total of twelve laminated bodies 30 arranged in the circumferential direction. Each laminate 30 is provided with a dummy caulking portion 30a. The dummy caulking portion 30a is removed after the laminate 30 is fastened with a resin material.

<Laminated iron core constituting the rotor>
FIG. 17 is a perspective view of the laminated iron core R constituting the rotor. The shape of the laminated iron core R is substantially cylindrical, and the opening Ra located at the center is for mounting a shaft (not shown). A convex key Rc is provided on the inner peripheral surface Rb constituting the opening Ra.

  With respect to the laminated core R shown in FIG. 17, differences from the above-described laminated core S will be mainly described. The laminated iron core R includes a laminated body 50 made of a plurality of electromagnetic steel plates M, a plurality of magnet fixing openings 55, a first through hole 51 and a second through hole 52 that reinforce the fastening between the electromagnetic steel plates M, and each opening. 55, the gap between the inner surface of each opening 55 and the outer surface of the magnet 7, and the resin filled in the first through hole 51 and the second through hole 52 are provided. The opening 55, the first through hole 51, and the second through hole 52 all extend from the upper surface 50a to the lower surface 50b of the stacked body 50. In addition, the 1st through-hole 51, the 2nd through-hole 52, etc. were illustrated in FIG. 18, and illustration of these was abbreviate | omitted in FIG.

  The laminate 50 has a total of 16 openings 55 (see FIG. 17). Two adjacent openings 55 form a pair, and eight pairs of openings 55 are arranged at equal intervals along the outer periphery 50 c of the stacked body 50. The total number of openings 55 is not limited to 16, but may be determined according to the application of the motor, the required performance, and the like. Further, the shape and position of the opening 55 may be determined according to the use of the motor, the required performance, and the like.

  Two magnets are accommodated in the opening 55 side by side in the vertical direction. The magnet is a permanent magnet, and for example, a sintered magnet such as a neodymium magnet can be used. In addition, the number of magnets put in each opening 55 may be one or three or more. The type of magnet may be determined according to the application of the motor, the required performance, etc., for example, a bonded magnet may be used instead of a sintered magnet, or a magnet divided into multiple parts in the width direction may be used. Good.

  The 1st through-hole 51 is comprised by laminating | stacking the some electromagnetic steel plate M in which the opening 1M was each provided. The first through hole 51 is provided in a region where the magnetic flux in the stacked body 50 is sparse, and the shape is devised so as not to obstruct the flow of magnetic flux as much as possible.

  Regarding the position of the first through hole 51, as shown in FIG. 18, the first through hole 51 is on a straight line C <b> 2 extending in the radial direction of the laminated body between two adjacent magnets in plan view, and the inner circumference of the laminated body It is provided along the side. As shown in FIG. 18, this position is the center of the magnetic pole (the center of the N pole and S pole), and the magnetic flux is sparse compared to other regions. However, the position of the first through hole 51 is not limited to this, and may be set between adjacent magnets having different phases. Regarding the shape of the first through hole 51, the first through hole 51 has a substantially triangular cross-sectional shape (see FIG. 19). The first through hole 51 has two side surfaces Fba and Fac extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the stacked body 50, and one side surface Fcb extending along the inner periphery of the stacked body 50. . According to the first through hole 51 having the above-described shape, it is possible to sufficiently suppress the magnetic flux flow from being disturbed due to the first through hole 1.

  As shown in FIG. 19, the 1st through-hole 51 has the convex part H on each side surface similarly to the above-mentioned 1st through-hole 1, respectively. The convex portion H extends from the upper surface to the lower surface of the stacked body 50. The height of the convex portion H is preferably 0.01 mm or more, more preferably 0.02 to 0.20 mm, and still more preferably 0.02 to 0.10 mm. The convex part H is for suppressing the occurrence of residue rise when punching out the opening that becomes the first through hole 51 from the magnetic steel sheet before processing. The shape of the first through hole 51 is not limited to a substantially triangular shape as in the case of the first through hole 1 described above, and may be the shape shown in FIG. A recess shown in FIG.

The resin filling portion 61 is formed by filling the first through hole 51 with resin. Similarly to the resin filling portions 11 and 12, the resin filling portion 61 is made of, for example, a cured product of a thermosetting resin. Here, the case where the entire first through hole 51 is filled with resin is illustrated, but as in the first through hole 1 described above, a cylindrical member is disposed in the first through hole 51 and the first through hole 51 is filled. The resin may be filled between the inner surface of the hole 51 and the outer surface of the cylindrical member, while the inside of the cylindrical member may be left hollow (see FIG. 9). Thereby, even when the cross-sectional area of the 1st through-hole 51 is comparatively large (for example, 10-200 mm < ² >), there exists an advantage that sufficiently high fastening force can be ensured, reducing the usage-amount of resin.

(Second through hole)
The 2nd through-hole 52 is provided in order to fasten the outer peripheral side of the laminated body 50 with resin (resin filling part 62). As shown in FIG. 18, it has an elongated shape and is arranged so that the major axis coincides with the straight line C2. The 2nd through-hole 52 has the same shape as the above-mentioned 2nd through-hole 2 (refer FIG. 10, 11). The position of the second through hole 52 is not necessarily set on the same straight line C <b> 2 as the first through hole 51, and may be set between adjacent magnets that are out of phase with the first through hole 51.

  A resin filling portion 62 is formed by filling the second through hole 52 with resin. Similarly to the resin filling portion 61, the resin filling portion 62 is made of, for example, a cured product of a thermosetting resin. The resin constituting the resin filling portion 62 may be the same as or different from the resin constituting the resin filling portion 61. Here, the case where the entire second through-hole 52 is filled with resin is illustrated, but a cylindrical member (not shown) is disposed in the second through-hole 52 in the same manner as the second through-hole 2, and the second The resin may be filled between the inner surface of the through hole 52 and the outer surface of the cylindrical member, while the inside of the cylindrical member may be left hollow. That is, the resin filling portion 62 may be formed between the inner surface of the second through hole 52 and the outer surface of the cylindrical member.

<Manufacturing method of laminated iron core constituting rotor>
The method for manufacturing the laminated core R constituting the rotor includes the following steps in this order.
(B1) A step of preparing a wound body MC of the electromagnetic steel sheet.
(B2) A step of supplying the electromagnetic steel sheet drawn from the wound body MC to the mold 140.
(B3) A step of punching an opening or the like that becomes the first through hole 51 from the electromagnetic steel plate in the mold 140.
(B4) A step of advancing the electrical steel sheet drawn out from the wound body MC in the mold.
(B5) A step of obtaining a plurality of electromagnetic steel sheets M to be laminated by punching out a region including the opening that becomes the first through hole 51 in the mold 140.
(B6) A step of filling the first through hole 51, the second through hole 52, and the magnet fixing opening 55 with a resin in a state where a plurality of electromagnetic steel plates M are laminated.

  By using a mold for manufacturing a magnetic steel sheet for a rotor, a laminated core R can be obtained through the same process as the above-described laminated core S (see FIGS. 12 to 14). As shown in FIG. 20, when the notch 63 extending from the upper surface to the lower surface is adopted on the inner peripheral surface of the laminate, the resin filling into the notch 63 is a state in which the shaft 200 is attached to the opening Ra at the center of the laminate. It can be done with.

  Furthermore, although the integrated laminated core R and the manufacturing method thereof have been illustrated here, the present invention is not limited to the integrated laminated core R, and may be applied to a split laminated core and a manufacturing method thereof. Further, similarly to the stator laminated body 30 shown in FIG. 16, the rotor laminated body may be temporarily fixed using a dummy caulking portion.

DESCRIPTION OF SYMBOLS 1,51 ... 1st through-hole, 1d ... convex part, 1e ... recessed part, 1f ... cylindrical member, 1M ... opening used as 1st through-hole, 2,52 ... 2nd through-hole, 2M ... 2nd through-hole and Opening, 3 ... notch, 7 ... magnet, 10, 20, 30, 50 ... laminated body, 10a, 20a, 50a ... upper surface of laminated body, 10b, 20b, 50b ... lower surface of laminated body, 11, 12, 13 , 61, 62 ... Resin filled portion, 30a ... Dummy caulking portion, 55 ... Magnet fixing opening, C1 ... Center line, C2 ... Straight line, Fba, Fac, Fcb ... Side, Fd, H ... Convex, Ga, Gb ... Side , Gd: concave portion, M: electromagnetic steel plate, MC: wound body, MF: magnetic flux, R: laminated iron core for rotor, R1, R2 ... region, Sy ... yoke portion, St ... teeth portion, S, _SD ... fixed Laminated iron core for child.

Claims (11)

A laminated iron core for a stator comprising a laminated body formed by laminating a plurality of electromagnetic steel plates and having an annular yoke portion and a tooth portion extending in the center direction from the inner peripheral side of the yoke portion,
A plurality of through-holes penetrating from the upper surface to the lower surface of the laminate, which are on an extension of the center line extending in the radial direction of the teeth portion in plan view and are provided along the outer periphery of the yoke portion. 1 through hole,
A resin filling portion formed in each of the plurality of first through holes;
Have
The first through hole has at least two side surfaces extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion, and one side surface extending along the outer periphery of the yoke portion. A laminated iron core for a stator having one side surface and a convex portion or a concave portion extending from the upper surface to the lower surface of the laminated body on one side surface. A cylindrical member housed in the first through hole;
The laminated iron core for a stator according to claim 1, wherein the resin filling portion is formed between an inner surface of the first through hole and an outer surface of the cylindrical member. A laminated iron core for a stator comprising a laminated body formed by laminating a plurality of electromagnetic steel plates and having an annular yoke portion and a tooth portion extending in the center direction from the inner peripheral side of the yoke portion,
A plurality of cutouts provided on the outer periphery of the yoke portion, extending from the upper surface to the lower surface of the laminated body, and extending on a center line extending in the radial direction of the teeth portion in plan view, and of the yoke portion A plurality of notches provided along the outer periphery;
A resin filling portion formed in each of the plurality of notches;
Have
The notch has at least two side surfaces extending in a direction away from each other from the inner peripheral side to the outer peripheral side of the yoke portion, and a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces. Have
A laminated core for a stator, wherein a region between two adjacent resin filling portions on the outer periphery of the laminated core is not covered with resin, and a side surface of the teeth portion is not covered with resin . A plurality of second through holes provided on the center line extending in the radial direction of the teeth portion in plan view, the plurality of through holes penetrating from the upper surface to the lower surface of the laminate;
A resin filling portion formed in each of the plurality of second through holes;
Further comprising
The second through hole has at least two side surfaces extending along the center line, and has a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces. A laminated iron core for a stator according to claim 1. An annular laminate formed by laminating a plurality of electromagnetic steel plates, a plurality of magnet fixing openings provided side by side in the circumferential direction on the laminate, and a plurality of magnets accommodated in the magnet fixing openings A laminated iron core for a rotor comprising:
A plurality of through-holes penetrating from the upper surface to the lower surface of the laminate, and are on a straight line extending in the radial direction of the laminate between the two adjacent magnets in plan view, and on the inner peripheral side of the laminate A plurality of first through holes provided at a position along the center of the magnetic pole and in a position where the magnetic flux is sparse compared to other regions ;
A resin filling portion formed in each of the plurality of first through holes;
Have
The first through hole has at least two side surfaces extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the laminate, and one side surface extending along the inner periphery of the laminate, A laminated core for a rotor having two side surfaces and a convex portion or a concave portion extending from the upper surface to the lower surface of the multilayer body on one side surface. A cylindrical member housed in the first through hole;
The laminated iron core for a rotor according to claim 5, wherein the resin filling portion is formed between an inner surface of the first through hole and an outer surface of the cylindrical member. An annular laminate formed by laminating a plurality of electromagnetic steel plates, a plurality of magnet fixing openings provided side by side in the circumferential direction on the laminate, and a plurality of magnets accommodated in the magnet fixing openings A laminated iron core for a rotor comprising:
A plurality of notches provided on the inner periphery of the multilayer body extending from the upper surface to the lower surface of the multilayer body, and extending between two adjacent magnets in plan view in a radial direction of the multilayer body And a plurality of notches provided along the inner periphery of the laminate,
A resin filling portion formed in each of the plurality of notches ;
Have
The notch has at least two side surfaces extending in a direction away from each other from the outer peripheral side to the inner peripheral side of the laminate, and has a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces. A laminated iron core for a rotor. A plurality of second through holes that are provided on a straight line extending in the radial direction of the laminated body between two adjacent magnets in plan view, the through holes penetrating from the upper surface to the lower surface of the laminated body. ,
A resin filling portion formed in each of the plurality of second through holes;
Further comprising
The second through hole has at least two side surfaces extending along the straight line, and has a convex portion or a concave portion extending from the upper surface to the lower surface of the laminate on the two side surfaces. A laminated iron core for a rotor according to one item. It is a manufacturing method of the lamination iron core according to any one of claims 1, 2, 5, and 6,
And supplying the electrical steel plate into a mold,
A step of punching an opening serving as the first through hole from an electromagnetic steel sheet in the mold;
A step of advancing in the electrical steel plate in the mold,
Obtaining a plurality of electrical steel sheets to be laminated by punching a region including an opening to be the first through hole in the mold; and
Fastening the electromagnetic steel sheets adjacent in the vertical direction by forming a resin filling portion in the first through hole in a state where a plurality of electromagnetic steel sheets are laminated;
In this order. It is a manufacturing method of the lamination iron core according to claim 3 or 7,
And supplying the electrical steel plate into a mold,
Punching out the opening to be cut out from the electromagnetic steel sheet in the mold,
A step of advancing in the electrical steel plate in the mold,
Obtaining a plurality of electrical steel sheets to be laminated by punching out a region including a part of the opening to be cut out in the mold;
Fastening the electromagnetic steel sheets adjacent in the vertical direction by forming a resin filling portion in the notch in a state where a plurality of electromagnetic steel sheets are laminated;
In this order. It is a manufacturing method of the lamination iron core according to claim 4 or 8,
A step of punching an opening serving as the second through hole from an electromagnetic steel sheet in the mold;
Forming a resin-filled portion in the second through hole in a state where a plurality of electromagnetic steel sheets are laminated;
The manufacturing method according to claim 9 or 10, further comprising:

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