JPH08126268A - Manufacture of rotary armature of stator motor, and rotary armature of stator motor - Google Patents

Abstract

PURPOSE: To improve the work efficiency at drop application enough and suppress the outflow at stay hardening enough, and secure the adhesion strength of a winding coil at high productivity and low cost by using one kind of thermosetting resin where the limitation of viscosity to cope with the time of drop application and stay hardening is limited. CONSTITUTION: Thermosetting resin 7 is prepared, which contains epoxy resin ingredients wherein bisphenol A-type epoxy resin and alicyclic epoxy resin are mixed at 1:3, and in which the glass transition temperature is 150 deg.C or over, and the viscosity of liquid is about 9Pa.sec and about 0.13Pa.sec, respectively, at temperatures of 25 deg.C and 100 deg.C. While rotating a preheated commutator 5 and a magnetic iron core 3, resin 7 is dropped and applied in normal temperature atmosphere of 10 deg.C-35 deg.C so as to stop the gaps, etc., between the winding coil 4 and a slot groove 3a. And, a very small quantity of resin which has leaked and adhered to the outside periphery of the magnetic iron core 3 is wiped away, and then it is passed through high-temperature atmosphere of 150 deg.C or over so as to harden harden the resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotary armature for a starter motor for starting an internal combustion engine, and more particularly to a rotary armature for a starter motor in which a winding coil is fixed to an object by using resin. The present invention relates to a manufacturing method and a rotating armature for a starter motor manufactured by this method.

[0002]

2. Description of the Related Art For example, the following are known techniques relating to the rotating armature of a conventional starter motor. JP, 58-39253, A In this publicly known art, when fixing the winding coil electrically connected to the conductor part of the outer circumference of the commutator by impregnating the preheated rotating armature with the resin powder, the glass is used. When the transition temperature is 100 ° C or higher, the melt viscosity at the rotor preheating temperature is 0.1 to 0.1
A first step of impregnating with a resin powder of 10 poise,
It is divided into a second step of impregnating with a resin powder having a glass transition temperature of 100 ° C. or higher and a melt viscosity at a rotor preheating temperature of 50 to 2000 poise. That is, two kinds of resin powders having different melt viscosities are impregnated stepwise to form two resin layers, thereby manufacturing a rotor capable of rotating at high speed while preventing the impregnated resin from flowing out.

In this known technique, a winding coil is fixed to a rotating armature by impregnating a resin (solvent-free varnish) mixed with a thermally conductive and electrically insulating inorganic filler. In this case, by using a resin having a viscosity of 20 to 20000 centipoise, preferably 50 to 1000 centipoise during impregnation, that is, at the time of drop coating, it is possible to prevent the workability from being deteriorated due to too high viscosity and to reduce the viscosity. It prevents the resin from dripping into the coil.

Japanese Patent Laid-Open No. 62-68054, Japanese Patent Laid-Open No. 63-95837, and Japanese Patent Laid-Open No. 63-114540 disclose these known techniques in which the ends of the winding coil projecting from both end surfaces of the magnetic core. The binding member is provided on the outer periphery of the coil portion, and the binding member and the winding coil, the winding coil and the winding coil, and the gap between the commutator and the winding coil are impregnated with resin, whereby a machine for the winding coil itself is provided. In addition to enhancing the mechanical strength, the mechanical coupling strength between the winding coil and the magnetic core is enhanced.

[0005]

However, the above-mentioned known techniques have the following problems. That is, in the known technique, two kinds of resins have to be prepared and impregnated in two steps, so that the number of manufacturing steps increases, the productivity deteriorates, and the cost increases. In general, a resin as a curing agent reaches a curing temperature by being applied dropwise to a preheated rotor, staying on the surface of the rotor and heated by the rotor, or by being introduced into a high temperature atmosphere. , Cure. At this time, the viscosity of the resin has a very strong temperature dependence, and the viscosity tends to decrease as the temperature rises. When dripping on the rotor and dripping on the rotor surface (hereinafter, appropriately referred to as “dripping application”), it is desirable that the viscosity be small to some extent from the viewpoint of improving workability and sufficiently penetrating into the winding coil. It is desirable that the viscosity be large to some extent so that the resin does not flow out when staying on the surface and hardening (hereinafter referred to as stay hardening). Here, in the known art, a viscosity limiting range based on the rotor preheating temperature is set in consideration of such temperature dependency of the resin powder viscosity. Here, since this rotor preheating temperature seems to have a constant relationship with the temperature at the time of residence hardening after dropping the resin powder (for example, both become almost equal), the outflow of resin powder at the time of residence hardening It seems to be appropriate as a reference temperature for suppressing However, on the other hand, when considering workability at the time of dripping application, the viscosity before adhering to the rotor becomes a problem, so the rotor preheating temperature is unsuitable as a reference temperature. In that case, the workability is poor and workability is insufficiently improved.

Further, in the known art, similarly to the above, in consideration of the temperature dependence of the viscosity of the resin (varnish), a limiting range of the viscosity based on the temperature at the time of impregnation (at the time of dripping application) is set, whereby the dripping application In addition to improving workability, the resin is suppressed from dripping at the time of drop coating. However, no consideration is given to the viscosity at the time of residence hardening where the resin tends to drip and flow out at a temperature much higher than that at the time of drop coating, and whether or not the resin sags at the time of residence curing has not been examined. Therefore, the viscosity setting based only on the temperature at the time of dripping application is poorly effective, and the resin outflow suppression during residence hardening becomes insufficient. In addition, the viscosity upon impregnation as described above is 20 to 20,000 centipoise (preferably 50 to
Although it is disclosed that 1000 centipoise) is desirable, the components and the mixing ratio thereof that realize the viscosity limiting range are not clearly shown, and the viability is poor.

Further, in the known technique, there is no consideration for the temperature dependency of the resin viscosity as described above, and it is not possible to cope with the change of the ambient temperature of the rotor. Therefore, when a low-viscosity thermosetting resin is used for the purpose of improving workability during dripping application, the thermosetting resin will have a lower viscosity and flow out during retention curing, and the adhesion strength will be improved. There is a problem that it will be difficult to secure. At this time,
The thermosetting resin will flow out to the outer periphery of the magnetic core, but since the magnetic core requires high precision from the viewpoint of ensuring the performance of the starter motor, it is necessary to cut the resin after curing. There is also a problem that productivity will increase and it will be difficult to improve productivity. On the contrary, if a high-viscosity thermosetting resin is used in advance in order to suppress resin outflow during residence hardening and increase resin residence in the gap in the winding coil, the first drip coating work is difficult. There was a problem that Further, it is difficult to improve the workability of the rotating armature because the binding member is provided on the outer circumference of the end coil portion.

An object of the present invention is to improve workability during drop coating and to retain the resin sufficiently by using one type of thermosetting resin whose viscosity is restricted for both drop coating and retention hardening. To provide a method for manufacturing a rotating armature for a starter motor and a rotating armature for a starter motor capable of sufficiently suppressing the outflow during curing and ensuring the fixing strength of a winding coil with high productivity and low cost. is there.

[0009]

In order to achieve the above object, according to the present invention, a plurality of slots are formed and a plurality of winding coils are housed in the plurality of slots. The commutator having a plurality of conductors electrically connected to the winding coil and the rotating shaft to which the magnetic core and the commutator are fixed are preheated and rotated, and thermosetting in a room temperature atmosphere A first step of applying a resin by dropping and filling the thermosetting resin in at least the gap between the winding coil and the slot; the filled heat while rotating the magnetic core, the commutator, and the rotating shaft. A second procedure in which a curable resin is heated to a curing temperature of the thermosetting resin or higher to be cured, and at least the winding coil and the magnetic core are fixed with the cured thermosetting resin;
In the method for manufacturing a rotating armature of a starter motor having the above, the thermosetting resin has a viscosity of 5 Pa · sec or more and 20 Pa · sec or less at a liquid temperature of 25 ° C. and a viscosity of 0.08 Pa · at a liquid temperature of 100 ° C. sec or more 2
There is provided a method for manufacturing a rotating armature for a starter motor, which is characterized by using 0 Pa · sec or less.

Preferably, in the method of manufacturing a rotating armature for a starter motor, the thermosetting resin has a viscosity of 5 Pa · sec or more and 20 Pa · s at a liquid temperature of 25 ° C.
There is provided a method for manufacturing a rotating armature for a starter motor, characterized in that a material having a viscosity of not more than ec and a viscosity at a liquid temperature of 100 ° C. of not less than 0.08 Pa · sec and not more than 0.3 Pa · sec is used.

Further preferably, in the method of manufacturing a rotary armature for a starter motor, the thermosetting resin is a thermosetting liquid resin, and the first step is to set the thermosetting liquid resin in a liquid state. There is provided a method of manufacturing a rotating armature for a starter motor, which is a filling procedure.

More preferably, in the method for manufacturing a rotating armature for a starter motor, the thermosetting resin is
A method for manufacturing a rotating armature for a starter motor, comprising: an epoxy resin component in which a bisphenol A type epoxy resin and an alicyclic epoxy resin are mixed in a weight ratio of 1: 2 to 1: 4. It

Preferably, in the method for manufacturing a rotating armature for a starter motor, the thermosetting resin is a mixture of a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 3. There is provided a method of manufacturing a rotating armature for a starter motor, which comprises an epoxy resin component.

More preferably, in the method for manufacturing a rotating armature for a starter motor, a silica-based thixotropic agent is added to the thermosetting resin, and a method for manufacturing a rotating armature for a starter motor. Will be provided.

Further preferably, in the method of manufacturing a rotating armature for a starter motor, the first step is 10
A method of manufacturing a rotating armature for a starter motor, characterized in that the procedure is to apply the thermosetting resin by dropping at an ambient temperature of 35 ° C to 35 ° C.

More preferably, in the method of manufacturing a rotary armature for a starter motor, the first procedure includes a gap between the winding coil and the slot, a gap between the plurality of winding coils, and the gap. It is a procedure of filling the gap between the winding coil and the commutator with the thermosetting resin, and the second procedure is the winding coil and the magnetic core, the plurality of winding coils, and the winding coil. There is provided a method for manufacturing a starter motor, characterized in that the winding coil and the commutator are fixed to each other.

Further preferably, in the method of manufacturing a rotary armature for the starter motor, the starter motor is:
A rotating armature for a starter motor, characterized in that the thermosetting resin is configured to be usable even at a rotation speed of 8000 r / min or more, and the thermosetting resin is a resin having a glass transition temperature of 150 ° C. or more. A method is provided.

More preferably, in the method for manufacturing a rotating armature for a starter motor, the starter motor is constructed so that it can be used at an ambient temperature of about -40 ° C to 150 ° C, and the thermosetting resin is A method of manufacturing a rotating armature for a starter motor, characterized in that the resin has a glass transition temperature of 150 ° C. or higher.

Further preferably, in the method for manufacturing a rotating armature for a starter motor, the thermosetting resin is a resin having a glass transition temperature of 150 ° C. or higher, and the first procedure is the magnetic iron core, There is provided a method of manufacturing a rotating armature for a starter motor, which is characterized in that the commutator and the rotating shaft are heated to 150 ° C. or higher in advance and the thermosetting resin is applied dropwise.

More preferably, in the method of manufacturing a rotating armature for a starter motor, the thermosetting resin is
It is a resin having a glass transition temperature of 150 ° C. or higher, and the second step is a step of charging the magnetic iron core, the commutator and the rotating shaft into a high temperature atmosphere of 150 ° C. or higher. A method of manufacturing a rotating armature for a starter motor is provided.

Further preferably, in the method for manufacturing a rotating armature for a starter motor, a small amount of resin leaked out of the thermosetting resin filled in the first procedure and adhered to the outer peripheral surface of the magnetic core. The method for manufacturing a rotating armature for a starter motor, further comprising: a third step of wiping and removing the same before the second step.

To further achieve the above object, according to the present invention, a magnetic iron core having a plurality of slots formed therein, and a plurality of winding coils housed in the plurality of slots, and the plurality of winding coils and an electric coil Including a commutator having a plurality of electrically connected conductors, a rotating shaft to which the magnetic core and the commutator are fixed, and the thermosetting resin at least in the gap between the winding coil and the slot. In a rotary armature of a starter motor in which the winding coil and the magnetic iron core are fixed by being filled and hardened, the thermosetting resin has a viscosity of 5 Pa · sec or more at a liquid temperature of 25 ° C. 20
Provided is a rotating armature for a starter motor, which has a viscosity of 0.08 Pa · sec or more and 20 Pa · sec or less at a liquid temperature of 100 ° C.

Preferably, in the rotating armature of the starter motor, the thermosetting resin has a viscosity at a liquid temperature of 25 ° C. of 5 Pa · sec or more and 20 Pa · sec or less,
Provided is a rotating armature for a starter motor, which has a viscosity at a liquid temperature of 100 ° C. of 0.08 Pa · sec or more and 0.3 Pa · sec or less.

Further preferably, in the rotating armature of the starter motor, the thermosetting resin is a mixture of a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 2 to 1: 4. There is provided a rotating armature for a starter motor, which comprises the above epoxy resin component.

More preferably, in the rotary armature of the starter motor, the thermosetting resin is an epoxy resin component in which a bisphenol A type epoxy resin and an alicyclic epoxy resin are mixed in a weight ratio of 1: 3. There is provided a rotating armature for a starter motor, comprising:

Further preferably, in the rotating armature for a starter motor, there is provided a rotating armature for a starter motor, characterized in that a silica-based thixotropic agent is added to the thermosetting resin.

[0027]

In the present invention configured as described above, the viscosity of the thermosetting resin at the liquid temperature of 25 ° C. is not less than 5 Pa · sec and not more than 20 Pa · sec.
The viscosity corresponding to room temperature such as 5 ° C, that is, the viscosity corresponding to the temperature at the time of dripping is about 1 / about that of the conventional thermosetting resin.
It becomes 5 or less and becomes extremely small. Therefore, in the first procedure, when the thermosetting resin is applied by drop coating to the magnetic iron core, the commutator, and the rotating shaft to fill at least the gap between the winding coil and the slot, the workability is improved and the depth of the gap is increased. It is possible to sufficiently permeate a wide range up to or from the dropping position. Further, since the viscosity at a liquid temperature of 100 ° C. is 0.08 Pa · sec or more and 20 Pa · sec or less, for example, the viscosity at around 80 to 120 ° C., that is, the viscosity corresponding to the temperature at the time of residence hardening is about 5 times that of the conventional one. The above is extremely large. Therefore, in the second procedure,
When the filled thermosetting resin is heated to the curing temperature or higher to be cured and at least the winding coil and the magnetic core are fixed with the cured thermosetting resin, the resin is sufficiently prevented from dripping and flowing out. It can be cured while staying. Therefore, since the filling and adhesion of the thermosetting resin in the gap is sufficient (the retention rate is high), it is possible to sufficiently secure the fixing strength between the winding coil and the fixed object (for example, magnetic iron core). Then, at this time, since one kind of resin is dropped and applied in one process, the manufacturing process is not increased and the productivity is not deteriorated as in the prior art, and the cost can be reduced. In addition, since the filled resin can be hardened while staying without sagging, the cutting process of the outer peripheral portion of the magnetic iron core after hardening can be reduced or omitted. Therefore, also in this sense, productivity can be improved.

The viscosity of the thermosetting resin at a liquid temperature of 25 ° C. is 5 Pa · sec or more and 20 Pa · sec or less, and the viscosity at a liquid temperature of 100 ° C. is 0.08 Pa · sec or more and 0.3 Pa · sec or less. As a result, it is possible to improve the workability at the time of dripping application and to realize the viscosity characteristic capable of sufficiently suppressing the outflow of the resin at the time of stay hardening. Further, the thermosetting resin is a thermosetting liquid resin, and by filling the thermosetting liquid resin in a liquid state in the first procedure, workability is improved during dripping application and resin outflow during stagnation curing. A thermosetting resin that can be sufficiently suppressed can be realized. In addition, since the thermosetting resin contains an epoxy resin component in which a bisphenol A type epoxy resin and an alicyclic epoxy resin are mixed in a weight ratio of 1: 2 to 1: 4, workability during dripping application is improved. It is possible to surely realize the component blending of the thermosetting resin which can be improved and sufficiently suppress the outflow of the resin at the time of residence hardening. Furthermore, since the thermosetting resin contains an epoxy resin component in which a bisphenol A type epoxy resin and an alicyclic epoxy resin are mixed at a weight ratio of 1: 3, the workability at the time of drop coating is improved and retention is achieved. It is possible to reliably realize the component combination of the thermosetting resin that can most effectively achieve the resin outflow suppression during curing. In addition, since the silica-type thixotropic agent is added to the thermosetting resin, the viscosity at a liquid temperature of 100 ° C. can be further increased, and the resin outflow at the time of residence curing can be more reliably suppressed. Further, the first procedure is 10 ° C to
The procedure of dropping and applying the thermosetting resin at the ambient temperature of 35 ° C. can realize the procedure of dropping and applying the thermosetting resin in the ambient temperature atmosphere. The first procedure is a procedure of filling thermosetting resin in the gap between the winding coil and the slot, the gap between the plurality of winding coils, and the gap between the winding coil and the commutator, respectively. The second procedure is to fix the winding coil and the magnetic iron core, the plurality of winding coils to each other, and the winding coil and the commutator, respectively, thereby increasing the mechanical strength of the winding coil itself. The mechanical fixing strength between the winding coil, the magnetic core and the commutator can be increased. Further, the starter motor can be applied to a starter motor of an ordinary passenger car engine by being configured so that it can be used even at a rotation speed of 8000 r / min or more, and at this time, the thermosetting resin has a glass transition temperature. Is 150 ° C or higher and is equal to or higher than 150 ° C, which is the upper limit of the ambient temperature when applied to this ordinary passenger car, so that an elastic rubber state can always be maintained even during use. Can withstand loads. Further, the starter motor is adapted to be used at an ambient temperature of about −40 ° C. to 150 ° C., so that the starter motor can be applied to a starter motor of a normal passenger car engine, and at this time, it is thermosetting. The resin is a resin having a glass transition temperature of 150 ° C. or higher, which is the upper limit of the ambient temperature of 150.
When the temperature is equal to or higher than ℃, it is possible to always maintain an elastic rubber state even during use and withstand a high load. Further, the thermosetting resin has a glass transition temperature of 1
It is a resin having a temperature of 50 ° C. or higher, and the first procedure is a procedure in which the magnetic iron core, the commutator, and the rotary shaft are heated to 150 ° C. or higher in advance and the thermosetting resin is dropped and applied.
Since the procedure is to put the magnetic iron core, the commutator and the rotating shaft in a high temperature atmosphere of 150 ° C or more while rotating, it ensures that the resin is not brittle when it is thermoset and that it is in an elastic rubber state. Can be changed to. In addition, a third procedure is further included in which, before the second procedure, a small amount of resin leaking out of the thermosetting resin filled in the first procedure and adhering to the outer peripheral surface of the magnetic core is wiped off and removed. Thus, when the thermosetting resin filled in the second procedure is cured, it is possible to completely prevent the resin from being cured in a spilled state. Therefore, the outer peripheral surface of the magnetic core can be processed without cutting. Therefore, the number of steps is reduced and productivity can be improved.

[0029]

Embodiments of the present invention will be described below with reference to FIGS. A first embodiment of the present invention will be described with reference to FIGS. This embodiment is an embodiment of a method for manufacturing a rotating armature for a starter motor. The rotating armature manufactured by the manufacturing method of the present embodiment is a starter motor for ordinary passenger cars, that is, a rotation speed of 8000 r / min or more, about -40 ° C. to 150, as shown in FIGS. A rectifier that is attached to a starter motor that can be used at an ambient temperature of ° C, and has a magnetic core 3 having a plurality of winding coils 4 wound in a plurality of slot grooves 3a and a conductor portion 5a on the outer periphery. The coil 5 and the rotating shaft 2 to which the magnetic core 3 and the commutator 5 are fixed, and the gap between the winding coil 4 and the conductor portion 5a (see FIG. 5) and the gap between the winding coils 4 (see FIG. 6), and the gap between the winding coil 4 and the slot groove 3a (see FIG. 7) is filled with resin 7 and cured, so that the winding coil 4, the commutator 5, and the winding coil 4 are connected to each other. Winding coil 4 A fixed iron core 3 is fixed.

The essential part of the manufacturing method of this embodiment is the resin 7
And the method of filling and curing the same. Hereinafter, the procedure of this method will be described in detail.

First, the thermosetting resin 7 contains an epoxy resin component in which a bisphenol A type epoxy resin and an alicyclic epoxy resin are mixed at a weight ratio of 1: 3.
A thermosetting liquid resin having a glass transition temperature of 150 ° C. or higher is prepared. The temperature-dependent characteristic of the viscosity of the resin 7 is as shown in FIG. 2. For example, the viscosity at a liquid temperature of 25 ° C. is about 9 Pa · sec, and the viscosity at a liquid temperature of 100 ° C. is about 0.13 Pa · sec. . Then, the commutator 5 and the magnetic iron core 3 which are already fixed to the rotary shaft 2 and electrically connected to the conductor portion 5a and the winding coil 4 are heated in advance (for example, to 150 ° C.) and rotated to 10 ° C. 35
The resin 7 is dropped and applied in a normal temperature atmosphere of ℃, and the gap between the winding coil 4 and the conductor portion 5a described above, the gap between the winding coils 4 and the gap between the winding coil 4 and the slot groove 3a, respectively. Fill with resin 7. At this time, the dropping may be performed in an appropriate order in the gap between the winding coil 4 and the conductor portion 5a, the gap between the winding coils 4 and the gap between the winding coil 4 and the slot groove 3a. In addition, drop at least one place among these three gaps,
It is also possible to sequentially infiltrate the dusty portion from the dropping portion and fill it.

Here, taking the case where the resin 7 is dropped and applied in the gap between the winding coils 4 as an example, the dropping and applying procedure is shown in FIGS. 3 and 4. As shown in FIG. 3, while the fixed iron core 3 is rotated in the direction B in the drawing, the resin 7
Is dripped from the drip application nozzle 9 into the gap between the winding coils 4. Thus, the thermosetting resin 7 can be uniformly applied to the entire circumference by dropping and applying while rotating. Then, the resin 7 is sequentially filled and penetrated into all the gaps, and the state shown in FIG. 4 is obtained. The same applies when the resin 7 is dropped in the gap between the winding coil 4 and the conductor portion 5a or when the resin 7 is dropped in the gap between the winding coil 4a and the slot groove 3a.

Next, while maintaining the rotation of the rotating shaft 2, the commutator 5, and the fixed iron core 3, the resin 7 filled in the previous procedure leaked and adhered to the outer peripheral surface of the magnetic iron core 3. Wipe off a small amount of resin and remove.

Further, while maintaining the rotation, the commutator 5 and the magnetic core 3 fixed to the rotary shaft 2 are fixed to 15
The resin 7 is cured by passing through a high temperature atmosphere of 0 ° C. or higher. The resin 7 does not harden immediately after being placed in a high temperature atmosphere, but hardens when the liquid temperature reaches a hardening temperature of 150 ° C. or higher. At this time, the resin 7 has a glass transition temperature of 1% or less.
By heating to 50 ° C. or higher, when the resin is subsequently thermoset, the resin does not become brittle and can be changed into an elastic rubber state without fail. In addition, at this time, the thermosetting resin 7 can be uniformly filled all around by passing through the high temperature atmosphere while rotating after the resin application and curing.

By the above process, the winding coil 4, the commutator 5, the winding coils 4 and the winding coil 4 and the fixed iron core 3 are fixed to each other through the cured resin 7.

By the way, in the method for manufacturing a rotary armature according to this embodiment, the viscosity characteristics of the resin are changed by optimizing the components of the thermosetting resin. Hereinafter, this will be described in detail with reference to FIG. The inventors of the present application
In a thermosetting resin containing an epoxy resin component obtained by mixing a bisphenol A type epoxy resin and an alicyclic epoxy resin, the temperature dependence of the viscosity of the thermosetting resin was examined, and the results shown in FIG. 1 were obtained. . In FIG. 1, the horizontal axis represents the temperature of the resin [° C.] and the vertical axis represents the viscosity of the resin [Pa · sec]. The bisphenol A type epoxy in the epoxy resin component contained in the thermosetting resin. This is a change in the temperature dependence of the viscosity when the mixing ratio (weight ratio) of the resin and the alicyclic epoxy resin is changed. In the figure, the straight line contains the epoxy resin component mixed with bisphenol A type epoxy resin: alicyclic epoxy resin = 4: 1, and corresponds to the conventional thermosetting resin. Further, the straight line, the straight line, and the straight line are respectively bisphenol A type epoxy resin: alicyclic epoxy resin = 1: 2,
It corresponds to the one containing the epoxy resin component mixed at 1: 3 and 1: 4.

In FIG. 1, comparing straight lines ~,
A straight line has a viscosity of about 100 Pa at a liquid temperature of 25 ° C.
・ Sec, viscosity at liquid temperature 100 ℃ is about 0.035P
a · sec was about 20 Pa · s for each straight line
ec and about 0.08Pa ・ sec, about 9Pa for each straight line
・ Sec is about 0.13 Pa ・ sec, and the straight line is about 5 Pa ・ sec and about 0.3 Pa ・ sec. That is, the higher the mixing ratio of the alicyclic epoxy resin to the bisphenol A type epoxy resin, the lower the temperature side (for example, 10 ° C to 35 ° C).
℃) viscosity decreases, high temperature side (eg 80 ℃ ~ 120
It can be seen that the viscosity of (° C.) increases. That is, as compared with the straight line of the conventional thermosetting resin, the linear to thermosetting resins have a viscosity at 10 to 35 ° C., which corresponds to the temperature at the time of dripping application, to about 1/5 or less, and the temperature at the time of residence curing is almost the same. The corresponding viscosity at 80 to 120 ° C. is about twice or more.

From the above, as the mixing ratio of the alicyclic epoxy resin to the bisphenol A type epoxy resin is increased, the viscosity at the time of drop coating becomes smaller, the workability is improved, and the viscosity at the residence hardening temperature is increased. It can be seen that outflow due to dripping is suppressed. However,
When the mixing ratio of the bisphenol A type epoxy resin represented by a straight line: alicyclic epoxy resin = 1: 4 is further increased, the viscosity at the time of drop coating becomes too small, and the viscosity drops at the same time as the coating. There is a risk that If the mixing ratio of the bisphenol A type epoxy resin: alicyclic epoxy resin = 1: 2, which is represented by a straight line, is smaller than the above, the effects of improving workability and suppressing outflow are insufficient. Therefore, the inventors of the present application
In order to improve the workability at the time of dripping and to suppress the outflow due to sagging at the time of stay hardening, bisphenol A type epoxy resin contained in the epoxy resin component: alicyclic epoxy resin = 1: 2
In the range of 1: 4, in other words, the viscosity at a liquid temperature of 25 ° C. is about 5 Pa · sec to 20 Pa · sec, and the liquid temperature is 100 ° C.
It was judged to be effective if a resin having a viscosity of about 0.08 Pa · sec to 0.3 Pa · sec was used.

Here, the thermosetting resin 7 used in the method for manufacturing the rotary armature of this embodiment is bisphenol A.
Type epoxy resin: Contains an alicyclic epoxy resin = 1: 3 epoxy resin component (corresponding to a straight line). Therefore, since the viscosity corresponding to the temperature at the time of drop coating is smaller than that of the straight line of the conventional thermosetting resin, the resin 7 is dropped and applied, and the gap between the winding coil 4 and the conductor portion 5a and the winding coil 4 are reduced. Improves workability when filling gaps between each other and the gap between the winding coil 4 and the slot groove 3a,
It can be penetrated deeply into the gap or in a wide range from the dropping position. Similarly, since the viscosity corresponding to the temperature at the time of residence hardening becomes larger than that of the straight line of the conventional thermosetting resin, the filled resin 7 is heated to a temperature not lower than the hardening temperature to be hardened, and the wound coil is wound. 4, the commutator 5, the winding coil 4 and the winding coil 4 and the magnetic core 3 are fixed to each other, resin can be sufficiently suppressed from flowing out and can be cured while staying. . Therefore, the resin 7 is sufficiently filled and bonded in the gap (the retention rate is high), so that the bonding strength between the winding coil 4, the commutator 5, the winding coils 4 and the winding coil and the magnetic core 3 is sufficiently secured. be able to. Therefore, the end coil portions 4a and 4b of the winding coil 4 protruding from both end surfaces of the magnetic core 3 (see FIG.
The binding member used in the prior art is not necessary to reinforce the end coil portions 4a and 4b, and only the resin 7 is present on the outer circumferences of the end coil portions 4a and 4b. That is, the process of attaching the binding member is not necessary, so that the productivity is improved.

Further, at this time, since one kind of resin 7 is dropped and applied in one step, the number of manufacturing steps is increased and the productivity is deteriorated as in the prior art in which two kinds of resins are dropped and applied in two steps. And the cost can be reduced. Also,
Since the outer peripheral portion of the magnetic iron core 3 is required to have high accuracy in order to ensure the performance of the starter motor, it is necessary to remove the thermosetting resin 7 attached to the outer peripheral portion as much as possible. A small amount of resin leaked out of the filled resin 7 and adhered to the outer peripheral surface of the magnetic iron core 3 is wiped and removed, so that the resin 7 drips and flows out when the filled resin 7 is cured later. It can be completely prevented from hardening in the state. Therefore, since the outer peripheral surface of the magnetic iron core 3 can be processed without cutting, the number of strokes can be reduced and productivity can be improved. Further, the resin 7 has a glass transition temperature of 15
It is a resin that is 0 ℃ or higher, and is the same as or higher than 150 ℃, which is the upper limit of the ambient temperature when applied to ordinary passenger cars, so that it can always maintain an elastic rubber state even when in use and can handle high loads. Can bear.

The effective mixing ratio of the epoxy resin components described in FIG. 1 is such that the weight ratio of the bisphenol A type epoxy resin and the alicyclic epoxy resin is 1: 2-1.
4 and the viscosity at a liquid temperature of 25 ° C. was about 5 at this time.
The viscosity at a liquid temperature of 100 ° C. was about 0.08 to 0.3 Pa · sec. Here, it was found that the viscosity at the liquid temperature of 100 ° C. can be improved by further adding a silica thixotropic agent to the thermosetting resin 7. Therefore, a proper amount of this silica-type thixotropic agent is added to the resin 7 having an epoxy resin component in which the mixing ratio, that is, the bisphenol A type epoxy resin and the alicyclic epoxy resin are mixed in a weight ratio of 1: 2 to 1.4. If the viscosity at a liquid temperature of 100 ° C. is improved to, for example, about 20 Pa · sec by adding it, a thermosetting resin more preferable in terms of viscosity characteristics can be realized. In this case, liquid temperature 1
Since the viscosity at 00 ° C. further increases, the resin outflow during retention hardening can be more reliably suppressed.

Further, in the above embodiment, the rotating shaft 2, the commutator 5, and the magnetic iron core 3 were heated to 150 ° C. in advance and then the resin 7 was dropped and applied, but it is not always necessary to heat at this time, and the final heating is not necessary. It is sufficient to once raise the temperature of the resin 7 to 150 ° C. or more before it is hardened. Therefore, for example, the temperature at the time of preheating may be lower than 150 ° C., if it is passed through a high temperature atmosphere of 150 ° C. or higher later. Further, in the above embodiment, the commutator 5 and the magnetic core 3 fixed to the rotating shaft 2 after being filled with the resin 7 were passed through a high temperature atmosphere of 150 ° C. or higher, but the present invention is not limited to this, and any means may be used. Resin 7 for 150
It suffices if the temperature is at least ℃, and the same effect is obtained in this case as well.

A second embodiment of the present invention will be described with reference to FIGS. This embodiment is an embodiment of the rotating armature of the starter motor manufactured by the manufacturing method of the first embodiment. The same members as those in the first embodiment are designated by the same reference numerals.
The structure of the rotating armature according to this embodiment is shown in FIGS.
5 is a side view showing a part of the rotary armature in a vertical cross section, FIG. 6 is a horizontal cross-sectional view taken along line VI-VI in FIG. 5, and FIG.
VII-VII is a cross-sectional view. 5 to 7, the rotary armature 1 of the present embodiment is a starter motor for an ordinary passenger car, that is, a rotation speed of 8000 r / min or more, about -40 ° C.
It is attached to a starter motor that can be used at an ambient temperature of 150 ° C., and has a laminated structure in which a plurality of slot grooves 3a are formed on the outer periphery and a plurality of winding coils 4 are wound in the slot grooves 3a. An iron core 3, a commutator 5 having a conductor portion 5a electrically connected to the winding coil 4 on its outer circumference, and a rotating shaft 2 to which the magnetic iron core 3 and the commutator 5 are fixed and both ends are rotatably supported. , Thermosetting resin 7 used for mechanically fixing the winding coil 4
And a field pole 8 arranged with a proper air gap at a position facing the outer peripheral surface of the magnetic iron core 3.

The resin 7 is filled in the gap between the winding coil 4 and the conductor portion 5a of the commutator 5 and hardened to fix the winding coil 4 and the commutator 5 to each other (see FIG. 5). Resin 7 that fixes the winding coils 4 by filling the gap between the winding coils 4 and hardening them (see FIG. 6)
And a resin 7 (see FIG. 7) that fills the gap between the winding coil 4 and the slot groove 3a and is hardened to fix the winding coil 4 and the fixed iron core 3 to each other.

According to the rotating armature 1 of this embodiment, the same effects as those of the first embodiment can be obtained during manufacturing, that is, the workability is improved during dripping and the outflow is suppressed during the retention effect. be able to.

[0046]

According to the present invention, since the viscosity corresponding to the temperature at the time of drop coating becomes extremely small, when the thermosetting resin is dropped and applied to the magnetic core, the commutator and the rotary shaft in the first procedure. The workability of can be improved. In addition, since the viscosity corresponding to the temperature at the time of residence hardening becomes extremely large, it is sufficient to prevent the resin from dripping and flowing out when the filled thermosetting resin is heated to the hardening temperature or higher and hardened in the second procedure. Can be suppressed. Therefore, it is possible to sufficiently secure the fixing strength between the winding coil and the object to be fixed (for example, the magnetic iron core). Therefore, it is necessary to use the binding member as in the prior art for the end coil portion protruding from both end surfaces of the magnetic iron core. Is eliminated, and only the thermosetting resin exists on the outer circumference of the end coil portion. That is, the process of attaching the binding member is not necessary, so that the productivity is improved. Further, at this time, since one kind of resin is dropped and applied in one process, productivity is not deteriorated, cost can be reduced, and the filled resin can be cured while staying without sagging. The cutting process of the outer periphery of the magnetic iron core afterwards may be less or can be omitted.
In this sense, productivity can be improved.

Further, since the silica type thixotropic agent is added to the thermosetting resin, the viscosity at the liquid temperature of 100 ° C. can be further increased and the resin outflow during the residence hardening can be more surely suppressed. Further, the method further has a third procedure of wiping off a small amount of the resin leaked from the thermosetting resin filled in the first procedure and adhering to the outer peripheral surface of the magnetic core before the second procedure. Therefore, it is possible to completely prevent the resin from dripping and flowing out and being cured by the second procedure. Therefore, the outer peripheral surface of the magnetic core can be processed without cutting.

[Brief description of drawings]

FIG. 1 is a diagram for explaining an effect of a thermosetting resin used in a method for manufacturing a rotary armature according to a first embodiment of the present invention.

FIG. 2 is a diagram for explaining the temperature dependence of a thermosetting resin.

FIG. 3 is a diagram showing a procedure of dropping and applying a resin in a gap between winding coils.

FIG. 4 is a diagram showing a state immediately after a resin is dropped and applied in a gap between winding coils.

FIG. 5 is a side view showing, in a vertical cross section, a part of a rotating armature according to a second embodiment of the present invention.

6 is a sectional view taken along line VI-VI in FIG.

7 is a sectional view taken along line VII-VII in FIG.

[Explanation of symbols]

 1 Rotating armature 2 Rotating shaft 3 Magnetic iron core 3a Slot groove 4 Winding coil 4a, b End coil part 5 Commutator 5a Conductor part 7 Resin

Front page continuation (72) Inventor Kenichi Sagaga 2520, Takaba, Katsuta-shi, Ibaraki Hitachi, Ltd. Automotive Equipment Division (72) Inventor Rikio Goto 2520, Takaba, Katsuta, Ibaraki Hitachi, Ltd. Automotive Equipment Co., Ltd. Within the business unit

Claims (18)

[Claims] 1. A rectifier comprising: a magnetic iron core having a plurality of slots formed therein; and a plurality of winding coils housed in the plurality of slots; and a plurality of conductor portions electrically connected to the plurality of winding coils. Child and the rotating shaft to which the magnetic core and the commutator are fixed are preheated and rotated, and a thermosetting resin is dripped and applied in a normal temperature atmosphere while rotating, and at least in a gap between the winding coil and the slot. A first step of filling the thermosetting resin; heating the filled thermosetting resin to a temperature not lower than the curing temperature of the thermosetting resin while rotating the magnetic core, the commutator, and the rotating shaft to cure the thermosetting resin. A second step of fixing at least the winding coil and the magnetic core with the hardened thermosetting resin; and a method of manufacturing a rotating armature for a starter motor, comprising: Te, viscosity at liquidus temperature 25 ° C. is not more than 5 Pa · sec or higher 20 Pa · sec, and the viscosity at a liquid temperature of 100 ° C. is 0.08 Pa · sec or more 20P
A method of manufacturing a rotating armature for a starter motor, characterized in that a material having a-sec or less is used. 2. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the thermosetting resin has a viscosity of 5 Pa · sec or more and 20 Pa · s at a liquid temperature of 25 ° C.
A method of manufacturing a rotating armature for a starter motor, characterized in that the viscosity is 0.08 Pa · sec or more and 0.3 Pa · sec or less at a liquid temperature of 100 ° C. or less. 3. The method for manufacturing a rotary armature for a starter motor according to claim 1, wherein the thermosetting resin is a thermosetting liquid resin, and the first step is the thermosetting liquid in a liquid state. A method of manufacturing a rotating armature for a starter motor, which is a step of filling a resin. 4. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the thermosetting resin is a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 2 to 1: 1. 4. A method of manufacturing a rotating armature for a starter motor, which comprises an epoxy resin component mixed in a ratio of 4. 5. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the thermosetting resin is a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 3. A method of manufacturing a rotating armature for a starter motor, comprising a mixed epoxy resin component. 6. The rotating electric machine for a starter motor according to claim 4 or 5, wherein a silica-based thixotropic agent is added to the thermosetting resin. Child manufacturing method. 7. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the first step is 10 ° C.
A method of manufacturing a rotating armature for a starter motor, characterized in that the thermosetting resin is applied dropwise at an ambient temperature of 35 ° C. 8. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the first step includes: a gap between the winding coil and the slot; a gap between the plurality of winding coils; And a step of filling the gap between the winding coil and the commutator with the thermosetting resin, respectively, and the second step is the winding coil and the magnetic iron core, the plurality of winding coils, And a procedure of fixing the winding coil and the commutator, respectively. 9. The method of manufacturing a rotating armature for a starter motor according to claim 1, wherein the starter motor is configured to be usable even at a rotation speed of 8000 r / min or more, and the thermosetting resin is A method of manufacturing a rotating armature for a starter motor, which is a resin having a glass transition temperature of 150 ° C. or higher. 10. The method of manufacturing a rotating armature for a starter motor according to claim 1, wherein the starter motor is about −
The thermosetting resin is configured to be usable at an ambient temperature of 40 ° C to 150 ° C, and the thermosetting resin has a glass transition temperature of 150 ° C or higher. Production method. 11. The method for manufacturing a rotating armature for a starter motor according to claim 1, wherein the thermosetting resin is a resin having a glass transition temperature of 150 ° C. or higher,
Is a procedure of heating the magnetic iron core, the commutator, and the rotary shaft in advance to 150 ° C. or higher to apply the thermosetting resin by dripping, thereby producing a rotating armature for a starter motor. 12. The method of manufacturing a rotating armature for a starter motor according to claim 1, wherein the thermosetting resin is a resin having a glass transition temperature of 150 ° C. or higher,
The method of (1) is a procedure of introducing the magnetic iron core, the commutator and the rotating shaft into a high temperature atmosphere of 150 ° C. or higher while rotating the rotating armature. 13. The method of manufacturing a rotating armature for a starter motor according to claim 1, wherein a small amount of the thermosetting resin filled in the first procedure leaks and adheres to the outer peripheral surface of the magnetic core. A method for manufacturing a rotating armature for a starter motor, further comprising a third step of wiping off the resin of the above step before the second step. 14. A magnetic iron core having a plurality of slots formed therein, and a plurality of winding coils housed in the plurality of slots,
A commutator having a plurality of conductors electrically connected to the plurality of winding coils; and a rotating shaft to which the magnetic core and the commutator are fixed, at least the winding coil and the slot. In a rotating armature of a starter motor, in which the thermosetting resin is filled and hardened in a gap and the winding coil and the magnetic core are fixed, the thermosetting resin has a viscosity of 5 at a liquid temperature of 25 ° C.
Pa · sec or more and 20 Pa · sec or less, liquid temperature 100
A rotating armature for a starter motor, having a viscosity at 0 ° C of not less than 0.08 Pa · sec and not more than 20 Pa · sec. 15. The rotating armature for a starter motor according to claim 14, wherein the thermosetting resin has a liquid temperature of 25.
Viscosity at 5 ° C is 20 Pa · sec or less, and viscosity at liquid temperature 100 ° C is 0.08 Pa · sec.
A rotating armature for a starter motor, which is 0.3 Pa · sec or less. 16. The rotating armature for a starter motor according to claim 14, wherein the thermosetting resin comprises a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 2 to 1: 4. A rotating armature for a starter motor, which comprises an epoxy resin component mixed in 1. 17. The rotating armature for a starter motor according to claim 14, wherein the thermosetting resin is an epoxy obtained by mixing a bisphenol A type epoxy resin and an alicyclic epoxy resin in a weight ratio of 1: 3. A rotating armature for a starter motor, which comprises a resin component. 18. The rotating armature for a starter motor according to claim 16, wherein a silica-based thixotropic agent is added to the thermosetting resin.