JP7339918B2 - Armature core for axial gap type rotating electric machine, method for manufacturing armature core for axial gap type rotating electric machine - Google Patents

Description

The present invention relates to an armature and the like used in an axial gap type rotary electric machine that serves as an electric motor and a generator.

2. Description of the Related Art In an axial gap type rotary electric machine, which serves as a generator or an electric motor, a rotor and a stator are arranged facing each other in the axial direction of a rotating shaft. One of the rotor and stator serves as an armature having windings (coils), and a rotating magnetic field is generated by applying a current to the armature. The other of the rotor and stator serves as a counter element (field element) that faces the armature, and is configured with, for example, a permanent magnet, and generates rotational force (torque) through interaction with the rotating magnetic field of the armature. . In the case of an axial gap type rotary electric machine, the stator side often serves as the armature.

In the armature, the armature core and the windings are integrated with resin by insert molding. The armature core (iron core) consists of a disk body (yoke) configured in a disk shape (the disk shape includes the concept of a ring) and protruding bodies (teeth) arranged to protrude from the disk body (yoke) ). A plurality of protrusions are arranged in the circumferential direction with respect to the disc body. A winding is wrapped around each projection of the core.

The armature core is mainly configured by laminating soft magnetic steel plates (electromagnetic steel plates). This soft magnetic steel sheet has the property of easily forming a magnetic path in the surface direction of the sheet. In order to effectively transmit the magnetic field generated by the windings to the counter element, the disk body (yoke) is a disk-shaped soft magnetic steel plate that spreads in the direction perpendicular to the rotation axis of the armature (radial direction and circumferential direction). are stacked in the axial direction of the armature. The projecting body is configured in a block shape by stacking rectangular soft magnetic steel plates extending in the axial direction and the circumferential direction of the armature in the radial direction of the armature.

As described above, if an attempt is made to manufacture the armature core of the axial gap type rotating electrical machine from soft magnetic steel sheets, the structure will be complicated and the manufacturing cost will increase. Therefore, the powder core is used as the armature core. Specifically, an insulating film is formed on a magnetic metal powder to form a single magnetic domain, and a lubricating agent or the like is mixed with the metal powder and press-molded using a mold. By annealing this molded product, an armature core of a dust core is manufactured.

If the entire armature core is integrally formed with a dust core, the large size of the powder core results in a large forming load, which is likely to be restricted by the press machine. Therefore, an attempt has been made to divide the armature core into split cores in the circumferential direction and form the split cores with powder cores (see Patent Document 1).

JP 2017-229191 A

If an armature core is formed by combining a plurality of split cores into an integrated unit, the rigidity of the entire armature is lowered. In particular, since an axial reaction force (thrust reaction force) acts on the armature core of an axial gap type rotating electric machine, the armature core is easily deformed. If the armature core is deformed, it may interfere with the counterpart, so a large air gap must be ensured, resulting in an increase in the size of the rotating electric machine.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an armature core or the like for an axial gap type rotary electric machine, which can reasonably achieve both rigidity and ease of manufacture. .

The present invention, which achieves the above objects, provides an armature core used in an axial gap type rotating electrical machine, wherein the radial direction (hereinafter referred to as the a disk extending in the armature radial direction) and in the circumferential direction (hereinafter referred to as the armature circumferential direction); and a protruding body, wherein the protruding body is a dust core obtained by compressing iron powder.

In relation to the armature core, the disk body is a laminated steel plate obtained by laminating disk-shaped soft magnetic steel plates in the armature axial direction.

In relation to the armature core, the protruding body is characterized in that it has a substantially trapezoidal shape when viewed from the armature axial direction.

In relation to the armature core, the protruding body includes a distal end surface facing the distal end side in the armature axial direction, a proximal end surface facing the proximal end side in the armature axial direction, and connecting the distal end surface and the proximal end surface. and a peripheral wall.

In relation to the armature core, the peripheral wall has an inner wall surface facing inward in the armature radial direction, an outer wall surface facing outward in the armature radial direction, and a pair of side wall surfaces facing in the armature circumferential direction. characterized by

In relation to the armature core, the projecting body is characterized in that a tip-side retraction surface retracting toward the base end side of the tip surface is formed on the periphery of the tip surface of the projecting body.

In relation to the armature core, the projecting body is characterized in that a proximal side retracting surface retracting to the distal side from the proximal end surface is formed on the peripheral edge of the proximal end surface of the protruding body.

In relation to the armature core, the peripheral wall of the protruding body is formed with an engagement stepped portion that can be engaged in the armature axial direction.

In relation to the armature core, the peripheral wall of the projecting body is formed with a peripheral wall-side groove portion or a peripheral wall-side protrusion extending in the armature axial direction.

In relation to the armature core, the base end surface of the protruding body is formed with a base-end-side convex portion that protrudes in the armature axial direction.

In relation to the armature core, a plurality of the base-end-side protrusions are formed along the radial direction of the armature.

In relation to the armature core, the peripheral wall includes an inclined surface displaced in the armature radial direction and/or the armature circumferential direction along the armature axial direction.

In relation to the armature core, the protruding body is characterized by having a through hole penetrating in the armature axial direction.

In relation to the armature core, the disk body has a housing portion that houses at least a part of the base end side of the projecting body.

The present invention for achieving the above objects includes the above armature core, a winding portion arranged to surround the projecting body, and a resin portion collectively covering the armature core and the winding portion. An armature for an axial gap type rotary electric machine characterized by

The present invention for achieving the above object is an axial gap type rotating electric machine comprising the above-described armature and a counterpiece arranged to face the armature in the armature axial direction.

The present invention, which achieves the above object, is an insert molding mold for the armature, wherein the cavity is formed with a reference surface for holding the tip surfaces of the plurality of protrusions so as to be in the same position. A metal mold for insert molding of an armature characterized by:

In relation to the above-described insert molding die, the cavity is characterized by forming a disk body holding portion that holds the disk body in the vicinity of the base end of the protrusion.

According to the present invention, it is possible to obtain an armature core or the like for an axial gap type rotary electric machine that can rationally achieve both rigidity and ease of manufacture.

It is (A) a top view of the armature core of the armature in embodiment of this invention, (B) is a front view. It is a top view of the disk body of the same armature core. (A) is a plan view of a protruding body of the armature core, and (B) is a six-sided view of the single protruding body. (A) is a plan view of the same protrusion, and (B) and (C) are a cross-sectional view and a partially enlarged view for explaining a state of press-molding the same protrusion. (A) is a plan view of the same armature, (B) is a front view of the same armature, and (C) shows the state of the mold when insert molding the same armature (A ) is a cross-sectional view taken along line CC. (A) is a plan view showing an enlarged part of the same armature, (B) is a cross-sectional view taken along line BB of (A), and (C) is CC of (A). It is an arrow sectional view. (A) is a hexahedral view of a single projecting body of an armature that is a modification of the present embodiment, and (B) to (E) are partially enlarged views of the same armature as viewed from the radially outer peripheral side. is a cross-sectional view. (A) is a six-sided view of a single protruding body of the armature, which is a modified example of the present embodiment, and (B) and (C) are partially enlarged views showing a process of engaging the same protruding body with a disk body. It is sectional drawing and a top view, (D) is sectional drawing which expanded a part of the same armature, and was seen from the circumferential direction. (A) is a six-sided view of a single projecting body of an armature that is a modification of the present embodiment, and (B) is a cross-sectional view of a part of the same armature that is enlarged and viewed from the radially outer peripheral side. (C) is a front view and a side view of the single protrusion. (A) is a six-sided view of a single protruding body of an armature that is a modification of the present embodiment, and (B) and (C) are partially enlarged views of the same armature as viewed from the side in the circumferential direction. is a cross-sectional view. (A) is a six-sided view of a single projecting body of an armature that is a modified example of the present embodiment, and (B) is an enlarged view of a part of the same armature from the direction of arrows BB in (A). (C) is a cross-sectional view of (A) and (B) taken along line CC, and (D) is a cross-sectional view of (A) and (B) taken along line D- It is a D arrow sectional view. (A) is a six-sided view of a single protruding body of an armature that is a modification of the present embodiment, and (B) is a cross-sectional view of a part of the same armature that is enlarged and viewed from the side in the circumferential direction. be. (A) is a six-sided view of a single projecting body of an armature that is a modification of the present embodiment, and (B) is a cross-sectional view of a part of the same armature that is enlarged and viewed from the radially outer peripheral side. be. (A) is a six-sided view of a single projecting body of an armature that is a modification of the present embodiment, and (B) is a cross-sectional view of a part of the same armature that is enlarged and viewed from the radially outer peripheral side. be. (A) is a plan view of a disk body of an armature core that is a modification of the present embodiment, (B) is a cross-sectional view of (A) taken along line BB, and (C) is the same disk body. is a cross-sectional view of an armature core using .

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The attached drawings are an example of the embodiment of the invention, and in the drawings, the same parts are denoted by the same reference numerals. Also, the shape and dimensional ratio of each part in each drawing are not necessarily accurate.

FIG. 1 shows the overall structure of an armature core 1 of this embodiment. The armature core 1 is used in an armature of an axial gap type rotary electric machine (generator or motor), and here, a stator is exemplified. The armature core 1 has a disk body (yoke) 10 and protrusions (teeth) 30 . The disk body 10 has a plate shape perpendicular to the axial direction of the armature (hereinafter referred to as the armature axial direction Z), and extends in the radial direction (hereinafter referred to as the armature radial direction K) and the circumferential direction (hereinafter referred to as the armature circumferential direction). extending in direction S). The disc body 10 of this embodiment has a ring shape, and a circular opening 12 is formed on the axial center side. The rotary shaft of the rotary electric machine is accommodated in this circular opening 12 .

The disc body 10 is a laminated steel plate in which disc-shaped soft magnetic steel plates having the same outer shape when viewed from above (viewed in the axial direction) are laminated in the armature axial direction Z. As shown in FIG. The disc body 10 is secured with high rigidity against thrust force by the laminated steel plates.

A plurality (here, 12 pieces) of protrusions 30 having the same shape are combined with this disc body 10 . As shown in FIG. 1B, the protruding body 30 is arranged to protrude in the armature axial direction Z from the surface 10A of the disk body 10 . The plurality of protrusions 30 are arranged at equal intervals (here, at intervals of 15 degrees) in the circumferential direction.

The projecting body 30 is a dust core obtained by compressing iron powder. Specifically, it is manufactured by using a raw material in which the surface of magnetic metal particles (powder) is coated with an insulating coating, molding this powder by a mold compression process (pressing process), and performing heat treatment (annealing). In addition, resin can be included in a part of raw materials.

As shown in FIG. 2, the disk body 10 has a plurality of housing portions 14 for housing the projecting bodies 30 at regular intervals in the circumferential direction. In the present embodiment, the accommodating portion 14 is an opening penetrating in the axial direction, and has a shape similar to the outer shape of the projecting body 30 . The disk body 10 has an inner ring portion 20 that is a circular arc or a partial circular arc, an outer ring portion 21 that is a circular arc or a partial circular arc, and a radially extending portion 22 so as to surround the housing portion 14 . The inner ring portion 20 serves as an annular member forming the radially inner edge of the housing portion 14 , and the outer ring portion 21 serves as an annular member forming the radially outer edge of the housing portion 14 . The radially extending portion 22 is a belt-like member extending radially to connect the inner ring portion 20 and the outer ring portion 21 and forms both side edges of the accommodating portion 14 .

An isolation slit 24 is formed in the outer ring portion 21 . The isolation slit 24 serves as a gap penetrating the inner edge of the disc body 10 and the housing portion 14 . The isolation slits 24 serve to suppress the generation of eddy currents circulating around the housing portion 14 (the inner ring portion 20, the outer ring portion 21, and the radially extending portion 22). It should be noted that the separation slit 24 can be placed anywhere as long as it is formed along the periphery of the housing portion 14 . For example, it may be formed in the radially extending portion 22 .

Furthermore, the isolation slits 24 also play a role of fixing the projecting bodies 30 with resin by pouring resin into the isolation slits 24 during insert molding, which will be described later.

Twelve protrusions 30 are shown in FIG. As shown in FIG. 3B, each protrusion 30 has a substantially trapezoidal shape when viewed from the armature axial direction Z (see FIG. 1B). By forming the protrusions 30 into a trapezoidal shape, many protrusions 30 can be arranged as densely as possible within the limited space of the disc body 10 . In addition, although the case where 24 protrusions 30 are arranged is illustrated in this embodiment, the present invention is not limited to this. For example, it is preferable to arrange 6 or more projections 30, preferably 12 or more. More desirably, 18 or more are arranged.

By forming each projecting body 30 into a substantially trapezoidal shape, the winding angle of the winding wound around the projecting body 30 can be made loose, particularly on the inner peripheral side.

As shown in FIG. 3B, the projecting body 30 has a tip surface 32 facing the tip side in the armature axial direction Z, a base end surface 34 facing the base end side in the armature axial direction Z, and a tip face 32. It has a peripheral wall 36 that connects the proximal face 34 . The peripheral wall 36 has an inner wall surface 36A facing inward in the armature radial direction K, an outer wall surface 36B facing outward in the armature radial direction K, and a pair of side wall surfaces 36C facing in the armature circumferential direction S. As a result, the protrusion 30 has a hexahedral structure. Boundaries (corners) between the inner wall surface 36A and the pair of side wall surfaces 36C are curved surfaces that are partially arcuate in plan view. Similarly, the boundaries (corners) between the outer wall surface 36B and the pair of side wall surfaces 36C are curved surfaces that are partially arcuate in plan view. By forming a curved surface, it is possible to avoid damage to the winding wire. The radius of curvature of these curved surfaces is preferably 0.5 mm or more, more preferably 1.0 mm or more.

The inner wall surface 36A can be a curved plane that is recessed outward in the armature radial direction K, and the outer wall surface 36B can be a curved plane that is convex outward in the armature radial direction K. Also, the maximum width W1 of the inner wall surface 36A is set smaller than the maximum width W2 of the outer wall surface 36B. On the other hand, the width W1 is desirably as large as possible, and is set to 1/10 or more of the width W2. This is because the larger the width W1 of the inner wall surface 36A, the looser the winding angle of the winding wound thereon.

As shown in an enlarged view in FIG. 4A, a tip side retraction surface 32A retracting to the base end side of the tip surface 32 is formed on the peripheral edge of the tip surface 32 of the projecting body 30. As shown in FIG. As shown in FIG. 4B, when press-molding the projecting body 30, a die 300 for forming the peripheral wall 36 of the projecting body 30 and a punch 310 for forming the distal end surface 32 (or the proximal end surface 34) are used. The right side enlarged view of FIG. 4(B) is a schematic diagram showing the punch 310 (upper punch) immediately before coming into contact with the projecting body 30 (iron powder). After the iron powder is filled into the cavity, which is the internal space of the die 300 and the punch 310, the punch 310 is lowered to compress the iron powder as shown in FIG. 4(C). At that time, as shown in the right enlarged view, a burr 38 protruding in the axial direction is formed by the gap between the punch 310 and the die 300 . In the present embodiment, the tip-side withdrawal surface 32A is retracted from the tip surface 32 toward the base end by a distance L2 that is larger than the maximum protrusion amount (expected protrusion amount) L1 of the burr 38 . As a result, the tip of the burr 38 does not protrude beyond the tip surface 32 . Since the amount of protrusion of the burr 38 is, for example, 0.1 mm to 0.2 mm, the retraction distance of the tip side retraction surface 32A is preferably 0.2 mm or more, more preferably 0.5 mm or more. do. By the way, if the burr 38 protrudes in the armature axial direction Z beyond the tip surface 32, the positioning accuracy of the protruding body 30 deteriorates during insert molding, which will be described later, or contact with the counterpart (for example, the rotor) causes a problem. there's a possibility that.

For the same purpose as the distal side withdrawal surface 32A, as shown in the enlarged left side views of FIGS. It is preferable that a base-side retraction surface 34A that retracts toward the distal end side is formed.

FIGS. 5A and 5B show an armature 100 insert-molded in a state in which the armature core 1 and the winding 50 are combined with a resin 60. FIG. A winding 50 is wound around the protrusion 30 . The resin 60 wraps the winding wire 50 and the projecting body 30 to integrate the whole. For convenience of explanation, the outline of the resin 60 is indicated by dotted lines. As shown in FIG. 5A, in the disk body 10 of the armature core 1, a portion of the surface 10A of the outer ring portion 21 (see FIG. 2) is exposed without being covered with the resin 60. As shown in FIG. In other words, the resin 60 has an escape portion 60A, which partially exposes the surface 10A of the disc body 10. As shown in FIG. This is a portion used for positioning the disc body 10 in the cavity during insert molding.

FIG. 5(C) shows a mold 200 for insert molding the armature 100 . A reference surface 210 is formed on the bottom surface in the vertical direction of the cavity of the mold 200 to hold the tip surfaces 32 of the plurality of protrusions 30 at the same position. With this reference surface 210, the Z positions of the tip surfaces 32 of the plurality of projecting bodies 30 in the armature axis direction can be matched with each other with high accuracy. Furthermore, in the cavity, a disk body holding portion 220 is formed above the reference plane 210 in the vertical direction and holds the disk body 10 from the vertically lower side. The disk body holding portion 220 determines the position of the disk body 10 in the armature axial direction Z with respect to the reference surface 210 and the orthogonality to the armature axial direction Z with high accuracy. Since the resin does not flow into the contact portion between the disc body holding portion 220 and the disc body 10, the portion becomes an escape portion 60A for the resin 60 after molding. A gap is formed between the ceiling surface 230 of the cavity and the base end surface 34 of the protruding body 30 and between the ceiling surface 230 of the cavity and the back surface 10B of the disc body 10 . As a result, the resin 60 flows into this gap, so that all or part of the base end surface 34 of the protruding body 30 and the rear surface 10B of the disk body 10 after insert molding are covered with the resin 60 as shown in FIG. will be As a result, even if a thrust force directed toward the base end side in the armature axial direction Z acts on the disc body 10 and the projecting body 30, the resin 60 can receive the thrust force.

When the protruding body 30 is a dust core, it is likely to undergo dimensional changes during the molding process and the heat treatment process. That is, the dimension of the protruding body 30 in the armature axial direction Z is likely to have an error. Therefore, by providing the reference surface 210 that holds the distal end surfaces 32 of the plurality of projecting bodies 20 as in the mold 200 of the present embodiment, the dimensional errors of the projecting bodies 30 are concentrated on the proximal end surface 34 side. Further, positioning of the disc body 10 can be performed with high accuracy by using the disc body holding portion 220 without using the projecting body 30 . Note that, when insert molding is performed using this mold 200 , the front end surface 32 is exposed from the resin 60 .

As shown in FIG. 6A, an isolation slit 24 is formed in the disc body 10 . As a result, after insert molding, the resin 60 flows into the isolation slit 24 as shown in FIG. 6(B). As a result, since the resin 60 is also filled in the gap between the accommodating portion 14 of the disk body 10 and the projecting body 30, the relative movement between the disk body 10 and the projecting body 30 is suppressed after insert molding, and the rigidity of the whole is high. Become.

As described above, in the armature core 1 of the present embodiment, the disk body 10 and the protrusions 30 are separate members, and the disk body 10 is composed of laminated steel plates, while the protrusions 30 are dust cores. While the overall rigidity of the armature core 1 is increased by the disk body 10, the protruding body 30 can be freely formed into a desired shape.

As shown in FIG. 6(C), the protruding body 30 that becomes the dust core forms a magnetic path in no direction (freely). It can be bent toward the body 10 (here, in the armature circumferential direction S). On the other hand, the disk body 10 made of an electromagnetic steel sheet easily forms a magnetic path along the planar direction (here, the armature circumferential direction S). Therefore, by housing the projecting body 30 in the housing part 14, the direction of the magnetic path formed inside the base end side of the projecting body 30 and the direction of the magnetic path formed in the disk body 10 can be made continuous (matched). is possible, and a magnetic field with little loss can be generated.

Furthermore, the projecting body 30 of this embodiment has a substantially trapezoidal shape when viewed from the armature axial direction Z. As shown in FIG. In this way, as shown in FIG. 1, in the ring-shaped armature core 1, a large number of projections 30 can be densely arranged in the circumferential direction. As a result, it is possible to increase the total area of the tip surface 32 that can affect the torque. In addition, as compared with the fan shape having an acute angle on the shaft center side, the inner wall surface 36A can be secured on the inner peripheral side (the shaft center side). .

Next, modifications of the armature 100 and the armature core 1 of the present embodiment will be described with reference to FIG. 7 onward. 7 and subsequent figures, portions different from the present embodiment will be illustrated and described, and illustrations and descriptions of common portions will be omitted.

The projecting body 30 shown in FIG. 7A is formed with an engaging stepped portion 40 that can be engaged in the armature axial direction Z at the peripheral wall 36 . Here, the base end side of the projecting body 30 extends in the armature circumferential direction S, and the boundary thereof becomes the engagement stepped portion 40 . The engagement stepped portion 40 has an engagement surface facing the tip side in the armature axial direction Z. As shown in FIG. When insert molding is performed as shown in FIG. 7B, the engagement stepped portion 40 and the winding wire 50 (or the resin 60) are engaged in the armature axis direction Z, so that the protrusion 30 is moved by the magnetic force to the armature axis. Even if it is pulled toward the tip side in the direction Z, its movement is suppressed.

In addition, as shown in FIG. 7(C), it is preferable to engage the engaging surface of the engaging stepped portion 40 with the disc body 10 . In this way, even if the protruding body 30 is pulled toward the tip side in the armature axial direction Z by the magnetic force, the engaging stepped portion 40 engages with the disk body 10 to suppress its movement. In addition, as shown in FIG. 7(D), it is also possible to sandwich the engaging stepped portion 40 between a pair of disk bodies 10 and 11. In this way, the protruding body 30 can be moved in the armature axial direction Z. directional movement can be regulated. Furthermore, as shown in FIG. 7(E), it is also preferable to form an engagement stepped portion 40 (a portion extending from the main body) so as to protrude in the middle of the peripheral wall 36 in the armature axial direction Z. As shown in FIG. In this way, the tip side engaging surface 40A facing the tip side in the armature axial direction Z and the base end side engaging surface 40B facing the base end side can be formed. By engaging the proximal side engaging surface 40B with the disc body 10 (or the resin 60), it is also possible to restrict the movement of the projecting body 30 to the proximal side. Here, the case where the engaging stepped portion 40 is formed on the pair of side wall surfaces 36C of the peripheral wall 36 is shown, but it may be formed on the inner wall surface 36A or the outer wall surface 36B.

Further, as shown in FIG. 8A, on the peripheral wall 36 of the projecting body 30, a plurality of engaging stepped portions are provided at different positions along the armature axial direction Z and at positions not overlapping in the armature axial direction Z. Forming 40 is also preferred. Here, on the inner wall surface 36A, a first engaging stepped portion 41 is formed at a position close to the base end surface 34, and on the outer wall surface 36B, a second engaging stepped portion 41 is formed at a position shifted to the distal side from the first engaging stepped portion 41. A joint portion 42 is formed. At the same time, by setting the size of the accommodation portion 14 in the disk body 10 to be large, the projecting body 30 can be slid in the armature radial direction K. As shown in FIG. As shown in FIG. 8B, the projecting body 30 is inserted so that the first engaging stepped portion 41 does not interfere with the accommodating portion 14, and the second engaging stepped portion 42 and the surface 10A of the disk body 10 are aligned. After the engagement, as shown in FIG. 8C, by sliding the protruding body 30 inward (toward the shaft center) in the armature radial direction K, the first engaging stepped portion 41 is attached to the disk body 10. Engage. As a result, the protruding body 30 and the disk body 10 can be engaged in both directions in the armature axial direction Z. As shown in FIG. After that, as shown in FIG. 8(D), by integrally hardening with a resin 60 by insert molding, the sliding of the protruding body 30 in the armature radial direction K can be restricted. The reason why the plurality of engaging stepped portions 40 are arranged at positions that do not overlap in the armature axial direction Z is to allow the press-molded compact to be easily released from the die.

A protruding body 30 shown in FIG. 9A has a protruding portion 43 protruding in the armature axial direction Z on the proximal end surface 34 . A plurality of base-end-side convex portions 43 are formed along the armature radial direction K and formed along the armature circumferential direction S. As shown in FIG. As a result, a so-called lattice-shaped or knurled projection is obtained as a whole. As shown in FIG. 9(B), insert molding of the protruding body 30 increases the contact area between the resin 60 and the base end surface 34, making it possible to increase the bonding force between the two. In addition, as shown in FIG. 9(C), it is preferable that the corners of the base-end-side convex portion 43 have an R shape (curved shape) in consideration of moldability.

The projecting body 30 of FIG. 10A has a plurality of proximal-side projections 43 projecting in the armature axial direction Z along the armature radial direction K on the proximal end surface 34 . As shown in FIG. 10(B), the housing portion 14 of the disc body 10 has a bottomed structure. can be fitted together. Further, for example, as shown in FIG. 10C, a plurality of through-holes corresponding to the proximal-side protrusions 43 are formed in the accommodating portion 14 of the disc body 10, and the through-holes and the proximal-side protrusions It is also possible to fit 43 together.

The projecting body 30 shown in FIG. 11A has a peripheral wall side groove portion 44 extending in the armature axial direction Z in the peripheral wall 36 . The peripheral wall side groove portion 44 starts in the middle of the peripheral wall 36 in the armature axial direction Z and reaches the base end surface 34 for ease of press molding and mold release. In this way, as shown in FIGS. 11B, 11C, and 11D, resin can be poured into the peripheral wall groove 44, so that the contact area between the resin 60 and the peripheral wall 36 is increased. It is possible to increase the bonding strength of Further, by terminating the peripheral wall side groove portion 44 in the middle of the peripheral wall 36, an axial stepped portion is also formed, and the resin 60 and the peripheral wall 36 can be engaged in the armature axial direction Z. FIG. In addition, although the case where the groove|channel is formed in the surrounding wall 36 was illustrated here, this invention is not limited to this. In the peripheral wall 36, rows of peripheral wall-side projections (protrusions) extending in the armature axial direction Z may be formed.

A through hole 45 penetrating in the armature axial direction Z is formed in the projecting body 30 of FIG. 12(A). As shown in FIG. 12(B), for example, by inserting a bolt into the through hole 45 and screwing the bolt into the disc body 10, the protruding body 30 can be fixed to the disc body 10. As shown in FIG. In addition, the present invention is not limited to the through hole 45, and by forming a female threaded hole on the base end surface 34 side, the projecting body 30 can be fixed by being screwed with a male screw.

The projecting body 30 of FIG. 13(A) is formed with an extended portion 46 on the distal end side. The extended portion 46 extends in the armature radial direction K and/or the armature circumferential direction S with respect to the main body. As a result, as shown in FIG. 13(B), it is possible to make the tip surface 32 of the projecting body 30 function as a yoke, and to increase the area facing the counterpart (for example, the rotor).

The projecting body 30 shown in FIG. 14A has a peripheral wall 36 formed with an inclined surface 47 that is displaced in the armature radial direction K and/or the armature circumferential direction S along the armature axial direction Z. As shown in FIG. Here, the pair of side wall surfaces 36</b>C itself forms a tapered inclined surface 47 extending in the armature circumferential direction S from the tip surface 32 toward the base end surface 34 . With this arrangement, as shown in FIG. 14B, even if the projecting body 30 is pulled toward the distal end side in the armature axial direction Z by the magnetic force, the resin 60 is engaged with the inclined surface 47 of the projecting body 30. and its movement is suppressed. The inclined surface 47 may be formed on the inner wall surface 36A or the outer wall surface 36B. Alternatively, the tapered inclined surface 47 that widens from the proximal end surface 34 toward the distal end surface 32 may be used.

In the disc body 10 shown in FIGS. 15A and 15B, the housing portion 14 is a bottomed concave portion having a bottom surface 14A. The isolation slit 24 communicates with the housing portion 14 . As shown in FIG. 15C, the projecting body 30 is accommodated in the accommodating portion 14 such that the base end surface 34 contacts the bottom surface 14A.

In the above-described embodiment, the disk body 10 of the armature core 1 is an annular ring that is completely connected in phases of 360 degrees, but the present invention is not limited to this. It also includes cases where the body has a partial circular arc (partial ring) shape. Moreover, although the armature 100 serves as a stator in this embodiment, it can also function as a rotor.

It should be noted that the armature and the like of the present invention are not limited to the above-described embodiments, and it goes without saying that various modifications can be made without departing from the gist of the present invention.

1 armature core 10 disk body 10A front surface 10B rear surface 14 accommodating portion 24 isolation slit 30 projecting body 32 tip surface 32A tip side withdrawal surface 34 base end surface 34A base end side withdrawal surface 36 peripheral wall 36A inner wall surface 36B outer wall surface 36C side wall surface 38 burr 40 Engagement stepped portion 43 Base end side convex portion 44 Peripheral wall side groove portion 45 Through hole 46 Expansion portion 50 Winding wire 60 Resin 100 Armature 200 Mold 210 Reference surface 220 Disk body holding portion 230 Ceiling surface 300 Die 310 Punch K Armature Radial direction S Armature circumferential direction Z Armature axial direction

Claims (8)

An armature core used in an axial gap type rotating electric machine,
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
The protruding body is a dust core obtained by compressing iron powder,
The projecting body is
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
A tip-side retraction surface retracting to the proximal side from the tip surface is formed on the peripheral edge of the tip surface of the projecting body,
A burr projecting to the tip surface side is formed on the edge of the tip side retraction surface ,
Armature core for axial gap type rotating electric machine. A retraction distance in the armature axial direction of the tip side retraction surface with respect to the tip surface is set larger than the protrusion amount of the burr,
An armature core for an axial gap type rotary electric machine according to claim 1. An armature core used in an axial gap type rotating electric machine,
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
The projecting body is
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
A tip-side retraction surface that retracts toward the base end side of the tip surface at the peripheral edge of the tip surface is a powder iron core that is collectively formed by one-time compression from iron powder,
The retraction distance in the armature axial direction of the tip side retraction surface with respect to the tip surface is 0.2 mm or more,
Armature core for axial gap type rotating electric machine. An armature core used in an axial gap type rotating electric machine,
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
The protruding body is a dust core obtained by compressing iron powder,
The projecting body is
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
A proximal side retracting surface retracting to the distal side from the proximal surface is formed on the peripheral edge of the proximal surface of the projecting body,
A burr projecting toward the proximal surface is formed on the edge of the proximal side retraction surface,
Armature core for axial gap type rotating electric machine. A retraction distance in the armature axial direction of the base end side retraction surface with respect to the base end surface is set to be larger than the protrusion amount of the burr,
An armature core for an axial gap type rotary electric machine according to claim 4. An armature core used in an axial gap type rotating electric machine,
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
The projecting body is
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
A base-side withdrawal surface that retreats toward the tip side of the base-end surface at the peripheral edge of the base-end surface is a dust core formed by one-time compression from iron powder,
The retraction distance in the armature axial direction of the proximal retraction surface with respect to the proximal surface is 0.2 mm or more,
Armature core for axial gap type rotating electric machine. A method for manufacturing an armature core used in an axial gap type rotating electrical machine, comprising:
The core is
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
When the cavity of a mold having a die and a punch is filled with iron powder and compression-formed,
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
At the peripheral edge of the tip surface, a tip side retraction surface that retracts to the proximal side from the tip surface is collectively formed,
A method of manufacturing an armature core for an axial gap type rotating electric machine . A method for manufacturing an armature core used in an axial gap type rotating electrical machine, comprising:
The core is
a disk body extending in a radial direction (hereinafter referred to as an armature radial direction) and a circumferential direction (hereinafter referred to as an armature circumferential direction) with respect to a rotational axis direction of the armature (hereinafter referred to as an armature axial direction);
a plurality of projecting bodies arranged to be combined with the disk body and project from the surface of the disk body in the armature axial direction,
When the cavity of a mold having a die and a punch is filled with iron powder and compression-formed,
a tip surface facing the tip side in the armature axial direction;
a base end face facing the base end side in the armature axial direction;
a peripheral wall connecting the distal end surface and the proximal end surface;
At the peripheral edge of the proximal surface, a proximal side withdrawal surface that retreats to the distal side from the proximal surface is formed together,
A method of manufacturing an armature core for an axial gap type rotating electric machine .

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