JPH10256031A - Magnet, manufacture thereof and small-sized motor using the magnet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To contrive weight reduction and cutting down the cost of production of a magnet. SOLUTION: An armature coil 12d is wound around the stator core 12 which is fitted to a stator frame 11, and a shaft 13 is rotatably retained by the stator frame 11. A rotor 14, having a cylindrical part 14a covering the stator core 12, is fixed to the shaft 13, and a rotor magnet 16, which is opposing to the external circumferential surface of the stator core providing the prescribed gap, is attached to the cylindrical inner circumferential surface of the rotor. The magnet supporting part 26 of the rotor magnet 16, having flexibility and spring-like property, is attached to the main circumferential surface of the cylindrical part, and a plurality of magnet main bodies 27, which are formed by dispersing magnetic powder on resin, are magnetized respectively in the prescribed direction. These magnet main bodies 27 are adhered to the magnet supporting part 26 in the state wherein they are opposing to the outer circumferential surface of the stator core 12 and arranged leaving the prescribed intervals, and a magnet holding part 28 of resin is filled in between a plurailty of magnet main bodies 22.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a magnet having a plurality of magnet functions having different directions of magnetic poles, a method of manufacturing the same, and a miniaturized external or internal type in which the magnet is used as a rotor magnet or a stator magnet. It relates to a motor.

[0002]

2. Description of the Related Art Conventionally, as an epimotor, an armature coil 2d is wound around a stator core 2 fitted to a stator frame 1 as shown in FIG. 3 is rotatably held by the stator frame 1, and a rotor 4 having a cylindrical portion 4 a covering the stator core 2 is fixed to the shaft 3,
Furthermore, a rotor magnet 6 is mounted on the inner peripheral surface of the cylindrical portion 4a of the rotor 4 facing the outer peripheral surface of the stator core 2 and leaving a predetermined gap from the outer peripheral surface of the stator core 2. In this motor, a single cylindrical sintered magnet, a single cylindrical plastic magnet, a plurality of arc-shaped sintered magnets, or the like is used as the rotor magnet 6.

[0003] A cylindrical sintered magnet is obtained by compressing magnetic powder into a cylindrical shape with a predetermined mold, sintering at a high temperature, and grinding the inner and outer diameters.
It is made by magnetizing. This magnetizing is performed by rotating the sintered magnet in the circumferential direction so that adjacent magnetic moments are directed in opposite directions at predetermined arc lengths (the circumferential length divided by the number of magnet poles). Is carried out. The cylindrical plastic magnet is produced by pouring magnetic powder dispersed in a resin into a predetermined mold, solidifying it, molding it into a predetermined cylindrical shape, and magnetizing it in the same manner as the above-mentioned cylindrical sintered magnet. Further, the arc-shaped sintered magnet is cut at predetermined arc lengths after grinding the inner and outer diameters in the same manner as the cylindrical sintered magnet, and magnetized by applying a radial external magnetic field at each cut length. It is made by things. The cylindrical sintered magnet and the cylindrical plastic magnet are fixed by press-fitting or bonding to the inner peripheral surface of the cylindrical portion 4a of the rotor 4. The plurality of arc-shaped sintered magnets are fixed to the inner peripheral surface of the cylindrical portion 4a of the rotor 4 by bonding or screwing them at predetermined intervals.

[0004]

However, in the above-mentioned conventional external rotation type motor, if a cylindrical sintered magnet or a cylindrical plastic magnet is used as the rotor magnet, a magnetic force is required on the inner peripheral surface of the cylindrical portion of the rotor. Since the magnets are also arranged between the magnetic poles, which are the parts not to be used, the rotor becomes heavy and there is a problem that a relatively large amount of magnetic powder is required. As a result, it takes a relatively long time for the moment of inertia of the rotor to increase and the rotor to reach a predetermined rotation speed. If expensive rare-earth magnetic powder is used as the magnetic powder, there is a problem that the production cost is greatly affected. Was. In addition, since the magnetic poles of the cylindrical sintered magnet or the cylindrical plastic magnet are continuous, it is difficult to control the magnetic flux distribution of each magnetic pole. On the other hand, when a plurality of arc-shaped sintered magnets are used as the rotor magnet, the problem of the cylindrical sintered magnet or the cylindrical plastic magnet is solved, but the plurality of arc-shaped sintered magnets are connected to the inner periphery of the cylindrical portion of the rotor. If these magnets are adhered to each other, there is a problem that the adhesive strength of these magnets is unreliable. There is a problem that screwing becomes difficult when the size is reduced.

A first object of the present invention is to reduce the weight and the manufacturing cost, to control each magnetic flux distribution of a plurality of magnet bodies reliably, and to assemble a cylindrical inner peripheral surface. Another object of the present invention is to provide a magnet and a method for manufacturing the same that can be securely fixed even on a columnar outer peripheral surface. A second object of the present invention is to reduce the weight and manufacturing cost of a rotor magnet or a stator magnet, to reliably control the magnetic flux distribution of a plurality of magnet bodies, and to further improve the rotor magnet or the stator magnet. Is to provide a small motor that can securely fix the motor to the cylindrical inner peripheral surface of the rotor or the outer peripheral surface of the stator frame. Further, a third object of the present invention is to prevent the rust of the magnet main body by covering the magnet main body with the cover body, and to form the magnet support portion by using a ferromagnetic material to form the magnet main body. An object of the present invention is to provide a magnet, a method of manufacturing the same, and a small motor using the magnet, which can improve characteristics.

[0006]

The invention according to claim 1 is
As shown in FIG. 1, a magnet 16 made of a resin member having a function as a plurality of magnets having different magnetic pole directions. In the magnet according to the first aspect, since the magnet 16 is made of a resin member, the magnet 16
Can be reduced in weight and manufacturing cost can be reduced. The invention according to claim 2 is the invention according to claim 1, and further has a function as a plurality of magnets having different magnetic pole directions at predetermined intervals in the resin member as shown in FIG. It is characterized by having been done. In the magnet according to the second aspect, the functions as a plurality of magnets are provided in the resin member of the magnet 16 at predetermined intervals, so that these magnet functions are magnetically separated, respectively. Each magnetic flux distribution of the magnet function can be reliably controlled.

The invention according to claim 3 is the invention according to claim 1 or 2, wherein the resin member is formed by dispersing magnetic powder in the resin, as shown in FIG. I do. In the magnet according to the third aspect,
Since the resin component is formed by dispersing the magnetic component in the resin, it is possible to further reduce the weight and manufacturing cost of the magnet 16. The invention according to claim 4 is the invention according to claim 1 or 2, and further as shown in FIG.
The resin member is formed by rolling a flexible resin into a ring shape. In the magnet according to the fourth aspect, since the resin member is formed by rolling the flexible resin into a ring shape, even if the mounting portion of the magnet 16 is a cylindrical inner peripheral surface or a columnar outer peripheral surface, This magnet can be fixed securely.

The invention according to claim 5 is the invention according to claim 4, wherein as shown in FIG. 1, the resin member is formed by molding a flexible resin into a tape or a film. Features. In the magnet according to the fifth aspect, since the resin member is formed by molding a flexible resin into a tape or a film, a large number of magnets 16 can be manufactured simply by cutting into a strip shape, further reducing the manufacturing cost. Can be reduced.

According to a sixth aspect of the present invention, as shown in FIG. 7, a plurality of magnet bodies 27 arranged in a line at a predetermined interval and magnetized in a predetermined direction, respectively, And a magnet holding portion 28 having a spring property and filled between a plurality of magnet main bodies 27. In the magnet according to the sixth aspect, if the mounting portion of the magnet 66 is a cylindrical inner peripheral surface, when the magnet 66 is rolled into a ring shape and inserted, the magnet 66 becomes the magnet holding portion 2.
Due to the resiliency of 8, it comes into close contact with the cylindrical inner peripheral surface. Further, since the relatively expensive magnetic powder of the magnet main body 27 can be used in a minimum necessary amount, the weight of the magnet 66 can be reduced, and
Can be manufactured at relatively low cost. Further, since the plurality of magnet bodies 27 are magnetically separated from each other, it is possible to reliably control each magnetic flux distribution of these magnet bodies 27.

According to a seventh aspect of the present invention, as shown in FIG. 9, a plate-shaped magnet support portion 26 made of a ferromagnetic material and having flexibility and spring properties, and a predetermined space on the magnet support portion 26 are provided. A plurality of magnet main bodies 27 bonded and magnetized in a predetermined direction in a state where they are spaced apart from each other, and a magnet holding portion 28 filled between the plurality of magnet main bodies 27 having flexibility and resilience. It is a magnet provided. This claim 7
In the magnet described in (1), since the magnetic flux emitted from each magnet main body 27 reaches the adjacent magnet main body 27 through the magnet support portion 26 having a high magnetic permeability, the magnetic flux density between each magnet main body 27 increases, The magnetic characteristics of the main body 27 can be improved. If the assembly portion of the magnet 76 is a cylindrical inner peripheral surface, when the magnet 76 is rolled into a ring shape and inserted, the magnet 76 is resilient to the cylindrical inner peripheral surface due to the spring properties of the magnet support portion 26 and the magnet holding portion 28. Adhere to The operation other than the above is the same as that of the magnet described in claim 6.

The invention according to claim 8 is the invention according to claim 7, further comprising a cover body 29 formed of resin and adhered to the upper surfaces of the magnet main body 27 and the magnet holding portion 28, as shown in FIG. It is characterized by having. Claim 8
In the magnet described in (1), since the entire surface of the magnet main body 27 is covered with the magnet support portion 26, the magnet holding portion 28, and the cover body 29, the magnet main body 27 is shut off from the air. The operation other than the above is the same as that of the magnet according to the seventh aspect.

According to a ninth aspect of the present invention, as shown in FIG. 11, a cover body 29 made of resin and a cover body 2 are provided.
A plurality of magnet bodies 27 that are adhered in a state of being arranged at predetermined intervals on the magnet 9 and magnetized in a predetermined direction, respectively, and are filled between the plurality of magnet bodies 27 having flexibility and spring properties. This is a magnet including a magnet holding unit 28. In the magnet according to the ninth aspect, one surface of the magnet main body 27 is in close contact with the mounting surface of the magnet 86, and
Of the magnet holding portion 28 and the cover body 29
The magnet main body 27 is substantially blocked from the air because it is covered with. The operation other than the above is the same as that of the magnet described in claim 6.

As shown in FIG. 8, the invention according to claim 10 is a step of kneading the magnetic powder and the first resin paste at a predetermined weight ratio, and a method of kneading the kneaded material 40 at predetermined intervals. A step of pouring into the first mold 41 in which one recess 41a is formed in a row, and a step of magnetizing by applying a magnetic field of a predetermined strength in a vertical direction to each kneaded material 40 in the plurality of first recesses 41a; A step of forming a plurality of magnet main bodies 27 by heat-treating and curing a plurality of magnetized kneaded materials 40; and a step of forming a single positioning member 67 made of resin into a plurality of first concave portions 41.
a) temporarily attaching the plurality of magnet bodies 27 together with the positioning member 67 from the first mold 41 to the upper surface of all of the plurality of magnet bodies 27 in the first mold 41; And a step of pouring the second resin paste 43 between the plurality of magnet bodies 27 in the second recess 42a.
Forming the magnet holding portion 28 by heat-treating and hardening the magnet holding member 3;
7 and a step of peeling and removing the magnet from the magnet holding unit 28. According to the manufacturing method of the tenth aspect, the magnet 66 of the sixth aspect is obtained.

According to an eleventh aspect of the present invention, as shown in FIG. 11, a step of kneading a magnetic powder and a first resin paste at a predetermined weight ratio, and a step of mixing a plurality of kneaded materials 40 at predetermined intervals. A step of pouring into the first mold 41 in which one recess 41a is formed in a line, a step of applying a magnetic field of a predetermined strength vertically to each kneaded material 40 in each first recess 41a, A step of forming a plurality of magnet main bodies 27 by heat-treating and hardening the plurality of magnetized kneaded materials 40; and a step of forming a single magnet support portion 26 formed of a ferromagnetic material into a plurality of first recesses 41a. Bonding the plurality of magnet bodies 27 together with the magnet support portions 26 from the first mold 41 to the second concave portions 42 of the second mold 42.
a, the step of accommodating the magnet support portion 26 in the lower side, the step of flowing the second resin paste 43 between the plurality of magnet bodies 27 in the second recess 42a, and the heat treatment of the second resin paste 43. And forming the magnet holding portion 28 by curing the magnet. According to the manufacturing method of the eleventh aspect, the magnet 76 according to the seventh aspect is obtained.

A twelfth aspect of the present invention is the invention according to the eleventh aspect, further comprising a step of heat-treating and curing the second resin paste 43 to form the magnet holding portion 28, as shown in FIG. A cover 29 formed of resin is adhered to the upper surfaces of the holding portion 28 and the magnet main body 27. According to the manufacturing method of the twelfth aspect, the eighth aspect is provided.
Is obtained.

According to a thirteenth aspect of the present invention, as shown in FIG. 12, the step of kneading the magnetic powder and the first resin paste 43 at a predetermined weight ratio, and the step of A step of pouring into the first mold 41 in which the first concave portions 41a are formed in a line, and a step of magnetizing by applying a magnetic field of a predetermined strength vertically to each of the kneaded materials 40 in the plurality of first concave portions 41a. A step of forming a plurality of magnet main bodies 27 by heat-treating and curing a plurality of magnetized kneaded materials 40, and a step of forming a single cover body 29 formed of resin into a plurality of first recesses 41a. A step of bonding the magnet bodies 27 to the entire upper surface, removing the plurality of magnet bodies 27 together with the cover body 29 from the first mold 41, and housing the plurality of magnet bodies 27 in the second recess 42a of the second mold 42 so that the cover body 29 faces down. Process and the second resin paste 43 A step Komu flow between the plurality of magnets body 27 of the recess 42a, a manufacturing method of a magnet comprising the step of forming a second resin paste 43 magnet retaining portion 28 is cured by heat-treating. According to the manufacturing method of the thirteenth aspect, the magnet 86 according to the ninth aspect is obtained.

FIG. 2 or FIG.
The rotor magnet 16 or the stator magnet 96 is an abduction type small motor 10 or 90 in which the rotor magnet 16 or the stator magnet 96 is the magnet according to any one of claims 1 to 9. In the small motor according to the present invention, the magnetic powder of the magnet body 27, which is relatively expensive, can be used in the minimum necessary amount. Therefore, the weight of the rotor magnet 16 or the stator magnet 96 is reduced to reduce the rotor 14 or the stator frame 11. The weight can be reduced, and the rotor magnet 16 or the stator magnet 96 can be manufactured at a relatively low cost. Also, a plurality of magnet bodies 2
Since each of the magnets 7 is magnetically separated, each magnetic flux distribution of these magnet main bodies 27 can be reliably controlled. Further, the entire surface of the magnet main body 27 is covered with the magnet support portion 26 and the magnet holding portion 28.
If the magnet body 27 is covered with the cover body 29, the magnet body 27 can be shielded from air. Further, since the magnetic flux emitted from each magnet main body 27 reaches the adjacent magnet main body 27 through the magnet support portion 26 having a high magnetic permeability, the magnetic flux density between each magnet main body 27 increases, and the magnetic characteristics of each magnet main body 27 are reduced. Can be improved.

FIG. 14 or FIG.
As shown in FIG. 5, the rotor magnet 106 or the stator magnet 116 is an inverting small motor 100 or 110 in which the rotor magnet 106 or the stator magnet 116 is a magnet according to any one of claims 1 to 9. The operation of the small motor according to the fifteenth aspect is substantially the same as that of the small motor according to the fourteenth aspect.

[0019]

Next, a first embodiment of the present invention will be described in detail with reference to the drawings. As shown in FIGS. 1 and 2, the small motor 10 of the present invention is an abduction type slotless brushless DC motor. The motor 10 includes a stator core 12 fitted on a stator frame 11 and a shaft 13 rotatably held on the stator frame 11.
A rotor 14 having a cylindrical portion 14a covering the stator core 12 and fixed to the shaft 13; and a rotor magnet 16 mounted on the inner peripheral surface of the cylindrical portion 14a of the rotor 14.
And The stator frame 11 has a base portion 11a.
A projection 11b extending upward from the center of the base 11a, and an insertion hole 11c extending vertically from the projection 11b to the base 11a. Stator core 12 is formed by laminating a number of silicon steel plates having insulated surfaces. A through hole 12a is formed at the center of the stator core 12 so as to be pressed into the protrusion 11b of the stator frame 11, and, for example, ten slots 12b are formed at the outer periphery of the stator core 12. Correspondingly, ten teeth 12c are formed between each of the slots 12b, and an armature coil 12d coated with insulation is wound around each of the teeth 12c.

The shaft 13 is inserted into an insertion hole 11c of the stator frame 11, and is rotatably held by the stay frame 11 via two bearings 17, 18. Also, a first and a second male screw portion 13 are provided at an upper end and a lower end of the shaft 13.
a and 13b are respectively formed. The rotor 14 is formed by bending a steel plate, and has the cylindrical portion 14a,
A disk-shaped portion 14b connected to the upper edge of the cylindrical portion 14a and having a center fitted into an upper portion of the shaft 13; Rotor 1
4 is fixed to the shaft 13 by screwing a nut 19 to the first male screw portion 13a of the shaft 13, and is configured to be rotatable integrally with the shaft 13. Also shaft 1
3 and the nut 22 through the washer 21 to the second external thread portion 13b.
Are screwed into each other so that the shaft 13 cannot move up and down with respect to the inner ring of the bearing 18, and the outer ring of the bearing 18 is held down by the outer ring of the bearing 18 from the lower surface by the bearing holding plate 23 attached to the stator frame 11. It is configured to be unable to move up and down with respect to the stator frame 11.

The rotor magnet 16 is formed by dispersing magnetic powder into a resin, and is formed in a predetermined direction by dispersing a magnetic powder in a resin. A plurality of magnet bodies 27 which are respectively magnetized and further adhered to the magnet support portion 26 in a state facing the outer peripheral surface of the stator core 12 at predetermined intervals, and a resin filled between the plurality of magnet bodies 27 And a magnet holding portion 28 made of a metal. The magnet support portion 26 is formed of a ferromagnetic material in a plate shape having a thickness of 0.005 to 2.0 mm. As ferromagnetic materials, amorphous alloys,
It is preferable to use soft magnetic materials such as permalloy, electromagnetic soft iron and silicon steel plate, that is, materials having high magnetic permeability, but iron-based materials such as spring steel (JIS SUP3) and ferrite / martensitic stainless steel (JIS SUS430, SUS440A) Materials may be used. Further, if the magnet support portion 26 can be formed to have flexibility and spring properties, it may be formed in a plate or film shape by dispersing ferromagnetic powder in a resin such as vinyl chloride, natural or synthetic rubber. Good.

The amorphous alloy contains Co, Fe, and Ni in a total amount of 70 to 98% by weight, B, Si, and P in a total amount of 2 to 30% by weight, and also contains Al, Mn, Zr, Nb, and the like. A specific example of an iron-based amorphous alloy is Fe-95.4.
% Alloy containing B-4.6% by weight, Fe-91.
There is an alloy comprising 4% by weight, Si-5.9% by weight, and B-2.7% by weight. As a specific example of the Ni-based amorphous alloy, there is an alloy composed of Ni-94.5% by weight and P-5.5% by weight. Specific examples of the cobalt-based amorphous alloy include an alloy composed of Co-84% by weight, Fe-5.3% by weight, Si-8.5% by weight and B-2.2% by weight, and Co-84% by weight. Fe-3.3% by weight and B-1.
Alloy consisting of 3% by weight, P-9.8% by weight and Al-1.6% by weight, Co-89% by weight, Fe-5.3% by weight and S
i-an alloy consisting of 2.3% by weight and B-3.4% by weight, C
o-81.9% by weight, Fe-5.1% by weight and Si-10
% Alloy with B-3% by weight, Co-80% by weight
, Fe-10% by weight, Si-6% by weight and B-4% by weight, Co-78.8% by weight, Fe-5.1% by weight, Si-6.1% by weight and B-4. 7% by weight and Ni-
There is an alloy composed of 5.3% by weight.

As permalloy, 78-Permalloy, 45-P
ermalloy, Hipernik, Monimax, Sinimax, Radiometal,
1040 Alloy, Mumetal, Cr-Permalloy, Mo-Permalloy, S
upermalloy, Hardperm, 36-Permalloy, Deltamax, square hysteresis permalloy, JIS PB class 1 and 2, JIS PC
One to three, JIS PD one and two, JIS PE one and two are used. As the electromagnetic soft iron, industrial pure iron, armco iron, Cioffi pure iron, low carbon steel sheet, or the like is used. As the silicon steel sheet, a non-oriented silicon steel sheet, a directional silicon steel sheet, or the like is used. Further, as the ferromagnetic powder to be dispersed in the resin, an atomized powder or a crushed powder such as the above-mentioned materials and sendust, or a ferrite powder such as a Mn-Zn type is used.

The above "having flexibility and spring property" means that
This means that the magnet support portion 26 has such flexibility and resilience that the magnet support portion 26 comes into close contact with the inner peripheral surface of the cylindrical portion 14a of the rotor 14 and does not easily come off the inner peripheral surface of the cylindrical portion 14a. It is preferable to use a soft magnetic material as the magnet support 26 because the magnetic flux emitted from each magnet main body 27 reaches the adjacent magnet main body 27 through the magnet support 26 having high magnetic permeability. This is because the magnetic flux density between them increases, and the magnetic characteristics of each magnet main body 27 can be improved.

It is preferable that the proportions of the magnetic powder and the resin constituting the magnet main body 27 are in the range of 50 to 98% by weight and 50 to 2% by weight, respectively. This magnetic powder has a maximum particle size of 250 μm or less, and an average particle size of 1 to 1.
Preferably it is in the range of 100 μm. Magnet body 2
As the magnetic powder of No. 7, a material having large residual magnetic flux density and coercive force, such as magnetic powder such as Alnico 5 and Alnico 8, ferrite magnet powder, and rare earth cobalt magnet powder is used. As the resin of the magnet body 27, vinyl chloride, urethane-
A vinyl chloride graft copolymer, natural or synthetic rubber, epoxy resin or the like is used. The magnet main body 27 is formed in a column shape having a relatively low height, and the number thereof is one in this embodiment.
There are two. It is preferable to use the same resin as the resin forming the magnet main body 27 as the magnet holding portion 28. This is to improve the adhesion between the magnet holding portion 28 and the magnet main body 27.

The surface of the magnet main body 27 facing the outer peripheral surface of the stator core 12 is covered with a film-like cover body 29 formed of resin. In this embodiment, the entire surface of the rotor magnet 16 facing the outer peripheral surface of the stator core 12 is covered with the cover body 29. Thereby, the magnet main body 27 can be prevented from being rusted on the magnet main body 27 by being cut off from the air. As the cover body 29, a surface-treated polyethylene terephthalate (PET) film, polybutylene terephthalate (PBT), polyethylene (PE), or the like is used. The reason why the film such as polyethylene terephthalate (PET) is subjected to the PVC treatment is to enhance the adhesiveness between the magnet body 27 and the magnet holding portion 28 of the cover body 29.

Reference numeral 31 in FIG. 2 is a rotor position sensor for detecting the rotational position of the rotor 14. As the sensor 31, a Hall element or the like that detects the strength of the magnetic flux of the magnet main body 27 and the determination of the magnetic pole is used. Although not shown, the detection output of the rotor position sensor 31 is connected to a control input of a controller, and the control output of the controller is connected to each amateur coil 12d via a drive circuit. The controller switches the phase to each armature coil 12d based on the detection output of the rotor position sensor 31 and energizes the armature coil 12d, whereby the rotation speed of the rotor 14 is controlled.

In this embodiment, an external rotation type slotless brushless DC motor is described as a small motor. However, an external rotation type motor in which a rotor magnet is attached to an inner peripheral surface of a cylindrical portion of a rotor is used. , A slotless brushless DC motor or other motor. Further, in this embodiment, the magnet main body is formed in a columnar shape having a relatively low height, but may be formed in an elliptical shape or another shape in cross section. The number of magnet bodies may be 11 or less or 13 or more. In this case, it is necessary to change the number of slots of the stator core in order to improve the motor characteristics.
Further, if the magnet support portion and the cover portion are formed in different colors, there is no danger that the rotor magnet will be turned upside down and mounted on the rotor, and if either the magnet support portion or the cover portion is made transparent, the internal magnet The position of the main body can be visually recognized, which is preferable in terms of quality control and the like.

A method for manufacturing the rotor magnet of the small motor configured as described above will be described with reference to FIGS. First, the magnetic powder and a first resin paste of a resin such as vinyl chloride are kneaded at a ratio of, for example, 85% by weight of the magnetic powder and 15% by weight of the first resin paste. (FIG. 3)
(A)). The plurality of first recesses 41a are formed at predetermined intervals in the first mold 41, and the upper surface of the first mold 41 is squeezed with a spatula to remove the upper surface of the kneaded material 40 in the first recess 41a. It is made to match the upper surface of the first mold 41. In this state, a magnetic field of a predetermined strength is applied vertically to each kneaded material 40 in each first concave portion 41a to be magnetized. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. Next, after heat-treating at a predetermined temperature to cure the kneaded material 40 to form the magnet main body 27, it is formed in the same shape as the upper surface of the first mold 41 with a ferromagnetic material such as an amorphous alloy, and one surface is formed of vinyl chloride. The strip-shaped magnet support portion 26 coated with an adhesive such as a system is overlapped on the upper surface of the first mold 41. In this state, a predetermined heat and pressure are applied between the first mold 41 and the magnet support portion 26 to thermocompression-bond the plurality of magnet main bodies 27 to the magnet support portion 26 (FIG. 3B).

Next, the magnet support 26 to which the plurality of magnet main bodies 27 are adhered is taken out of the first mold 41, and the second mold 42 is removed.
Is accommodated in the long second concave portion 42a such that the magnet support portion 26 is on the lower side. In this state, a second resin paste 43 of a resin such as vinyl chloride is poured between the plurality of magnet bodies 27 (FIG. 3C), and the upper surface of the second mold 42 is squeezed with a spatula or the like. The magnet holder 28 is formed by heat treatment at a temperature and curing. Further, a cover body 29 formed in the same shape as the magnet support portion 26 with a resin such as a PET film subjected to a PVC treatment is overlaid on the upper surface of the second mold 42,
By applying a predetermined heat and pressure between the mold 42 and the cover body 29, the cover body 29 is thermocompression-bonded to the upper surfaces of the magnet main body 27 and the magnet holding portion 28 (FIG. 3D), and the second concave portion of the second mold 42 is formed. 42
A strip member 44 having a three-layer structure is obtained by taking it out of FIG. 3A (FIG. 3E). When the band-shaped member 44 is cut at a predetermined length and at a predetermined angle with respect to the longitudinal direction, a parallelogram rotor magnet 16 is obtained (FIG. 4).
(A)). Although the magnetic powder is magnetized when the kneaded material of the magnetic powder and the resin is poured into the first concave portion of the first mold, the magnetic powder may be magnetized in a state where the magnetic powder is molded into a belt-shaped member.

One example of a procedure for assembling the rotor magnet thus manufactured to the rotor is shown in FIGS. 1, 2 and 4 (b).
It will be described based on. The cylindrical portion 14a of the rotor 14 is
An adhesive is applied to the inner peripheral surface, and the rotor magnet 16 is
(B) As shown in FIG.
Insert into a. Due to the spring properties of the magnet support portion 26 and the magnet holding portion 28, the rotor magnet 16 is
a, the rotor magnet 26 is in close contact with the inner peripheral surface (FIGS. 1 and 2).
a is fixed to the inner peripheral surface by an adhesive, that is, the cylindrical portion 14
a is attached to the inner peripheral surface. As a result, the rotor magnet 1
6 can be securely fixed to the inner peripheral surface of the cylindrical portion 14a of the rotor 14. Further, since the magnetic powder of the magnet main body 27 requires a minimum necessary amount and the magnet support portion 26 is extremely thin, the weight of the rotor magnet 16 can be reduced. As a result, the rotor 14 to which the rotor magnet 16 is attached becomes lighter and the moment of inertia becomes smaller, so that the performance of the motor 10, especially the performance when the motor 10 is downsized, can be improved.

Since the amount of magnetic powder in the relatively expensive magnet main body 27 can be minimized, the rotor magnet 16 can be manufactured at a relatively low price, and the manufacturing cost of the motor 10 can be reduced. Further, since the plurality of magnet bodies 27 are magnetically separated from each other, it is possible to reliably control each magnetic flux distribution of these magnet bodies 27. Furthermore, even if there is a dimensional error in the inner diameter of the cylindrical portion 14a or the length of the rotor magnet 16, for example, even if the length of the rotor magnet 16 is longer than the inner peripheral length of the cylindrical portion 14a, Is inclined and cut, and if the both ends of the rotor magnet 16 are slightly displaced from each other along the inclined surface, the error can be absorbed. As a result, the rotor magnet 16 does not separate from the inner peripheral surface of the cylindrical portion 14a of the rotor 14. In addition, if a protrusion is provided on the inner peripheral surface of the cylindrical portion of the rotor and a hole is formed in the rotor magnet so as to face the protrusion, and the hole is fitted into the protrusion when the rotor magnet is inserted into the cylindrical portion, the rotor magnet is Since the magnet support portion is kept in close contact by the resiliency, and cannot be rotated by the fitting of the hole into the projection, no adhesive is required.

FIG. 5 shows a second embodiment of the present invention.
5, the same reference numerals as those in FIG. 4 indicate the same parts. In this embodiment, a single protrusion 46a is formed at one end of the rotor magnet 46, and a single recess 46b into which the single protrusion 46a can be inserted is formed at the other end. In the rotor magnet 46 configured as described above, the rotor magnet 46
When the is rounded into a ring shape, the protrusions 46a and the recesses 46b at both ends thereof can be fitted to each other, so that both ends of the rotor magnet 46 can be butted without any gap.

FIG. 6 shows a third embodiment of the present invention.
6, the same reference numerals as those in FIG. 4 indicate the same parts. In this embodiment, two protrusions 56a, 56a are formed at one end of the rotor magnet 56, and two protrusions 56a are formed at the other end.
a, 56a into which two recesses 56b, 5 can be inserted respectively.
6b is formed. In the rotor magnet 56 thus configured, when the rotor magnet 56 is rolled into a ring shape, the protrusions 56a, 56a and the recess 56 at both ends thereof are formed.
Since b and 56b can be fitted with each other, both ends of the rotor magnet 56 can be butted against each other without a gap.

FIG. 7 shows a fourth embodiment of the present invention.
7, the same reference numerals as those in FIG. 1 indicate the same parts. In this embodiment, the rotor magnet 66 does not have the cover body and the magnet support portion, and the magnet holding portion 28 and the magnet main body 27 having flexibility and spring property are formed on the inner peripheral surface of the cylindrical portion 14 a of the rotor 14. , Except that it is attached to the rotor magnet of the first embodiment. However, the rotor magnet 66 of the present embodiment is
8 is used when rust does not occur or hardly occurs even when exposed to air.

The rotor magnet 6 constructed as described above
6 will be described with reference to FIG. 8, the same reference numerals as those in FIG. 3 indicate the same parts. First, similarly to the first embodiment, the kneaded material 40 is divided into the plurality of first concave portions 4 of the first mold 41.
1a, and the upper surface of the kneaded material 40 in the first concave portion 41a is made to coincide with the upper surface of the first mold 41 (FIG. 8A). In this state, a magnetic field of a predetermined strength is applied vertically to each kneaded material 40 in each first concave portion 41a to be magnetized. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. Next, after heat-treating at a predetermined temperature to cure the kneaded material 40 to form the magnet main body 27, an adhesive such as an acrylic rubber-based adhesive is formed to have the same shape as the upper surface of the first mold 41 and to one surface. The positioning member 67 in the form of a strip
It overlaps on the upper surface of the mold 41. In this state, a predetermined heat and pressure are applied between the first die 41 and the positioning member 67 to temporarily adhere the plurality of magnet bodies 27 to the positioning member 67 (FIG. 8).
(B)). The positioning member 67 is made of polyethylene terephthalate (PET), polybutylene terephthalate (P
BT) or the like.

Next, the positioning member 67 to which the plurality of magnet bodies 27 are adhered is removed from the first mold 41, and is housed in the long second concave portion 42a of the second mold 42 such that the positioning member 67 is located on the lower side. I do. In this state, the second resin such as vinyl chloride
The resin paste 43 is poured between the plurality of magnet main bodies 27 (FIG. 8 (c)), and the upper surface of the second mold 42 is squeezed with a spatula or the like, and then heat-treated at a predetermined temperature to be hardened and cured. Is molded. Further, after the magnet main body 27 and the magnet holding portion 28 adhered to the positioning member 67 are taken out from the second concave portion 42a of the second die 42 (FIG. 8D), the positioning member 67 is peeled off and removed. The band-shaped member 64 having a layer structure is obtained (FIG. 8E). When this band-shaped member 64 is cut into a predetermined length and rounded into a ring shape, a rotor magnet 66 is obtained (FIG. 7). The procedure for assembling the rotor magnet 66 manufactured in this manner to the rotor 14 is substantially the same as that of the first embodiment, and a description thereof will not be repeated.

FIG. 9 shows a fifth embodiment of the present invention.
9, the same reference numerals as those in FIG. 1 indicate the same parts. This embodiment is configured the same as the rotor magnet of the first embodiment except that the rotor magnet 76 does not have a cover. However, the rotor magnet 76 of the present embodiment is used when rust does not or hardly occurs even when the magnet main body 27 is exposed to air.

The rotor magnet 7 thus configured
6 will be described with reference to FIG. 10, the same reference numerals as those in FIG. 3 indicate the same parts. First, similarly to the first embodiment, the kneaded material 40 flows into the plurality of first concave portions 41a of the first mold 41, and the upper surface of the kneaded material 40 in the first concave portion 41a is made to coincide with the upper surface of the first mold 41. (FIG. 10 (a)).
In this state, a magnetic field of a predetermined strength is applied vertically to each kneaded material 40 in each first concave portion 41a to be magnetized. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. Next, a heat treatment is performed at a predetermined temperature to cure the kneaded material 40 and
After molding 7, the strip-shaped magnet support portion 26 is overlaid on the upper surface of the first mold 41 in the same manner as in the first embodiment. In this state, predetermined heat and pressure are applied between the first mold 41 and the magnet support portion 26 to apply a plurality of magnet main bodies 2 to the magnet support portion 26.
7 is thermocompression-bonded (FIG. 10B).

Next, the magnet support portion 26 to which the plurality of magnet main bodies 27 are adhered is taken out of the first mold 41 and the second mold 42 is removed.
Is accommodated in the long second concave portion 42a such that the magnet support portion 26 is on the lower side. In this state, a second resin paste 43 of a resin such as vinyl chloride is poured between the plurality of magnet bodies 27 (FIG. 10C), and the upper surface of the second mold 42 is squeezed with a spatula or the like. The magnet holder 28 is formed by heat treatment at a temperature and curing. Further, the magnet support 26
When the magnet main body 27 and the magnet holding portion 28 adhered to the second mold 42 are taken out from the second concave portion 42a of the second mold 42, a band-shaped member 74 having a two-layer structure is obtained (FIG. 8D). When the band-shaped member 74 is cut into a predetermined length and rounded into a ring, a rotor magnet 76 is obtained (FIG. 9).

The rotor magnet 7 manufactured as described above
In No. 6, the number of manufacturing steps can be reduced as compared with the rotor magnet of the first embodiment by the amount of no cover. Also, the procedure for assembling the rotor magnet 76 to the rotor 14 is substantially the same as that of the first embodiment, and a description thereof will not be repeated.

FIG. 11 shows a sixth embodiment of the present invention. 11, the same symbols as those in FIG. 1 indicate the same parts.
In this embodiment, the rotor magnet 86 does not have a magnet support portion, and the magnet holding portion 28 and the magnet main body 27 having flexibility and spring property are connected to the cylindrical portion 14 of the rotor 14.
a Except that it is attached to the inner peripheral surface, it is configured the same as the rotor magnet of the first embodiment.

The rotor magnet 8 constructed as described above
6 will be described with reference to FIG. 12, the same reference numerals as those in FIG. 3 indicate the same parts. First, similarly to the first embodiment, the kneaded material 40 flows into the plurality of first concave portions 41a of the first mold 41, and the upper surface of the kneaded material 40 in the first concave portion 41a is made to coincide with the upper surface of the first mold 41. (FIG. 12 (a)).
In this state, a magnetic field of a predetermined strength is applied vertically to each kneaded material 40 in each first concave portion 41a to be magnetized. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. At this time, the magnetic powder in the kneaded material 40 adjacent to each other is magnetized so that the magnetic poles thereof are in opposite directions. Next, a heat treatment is performed at a predetermined temperature to cure the kneaded material 40 and
After molding 7, a belt-shaped cover body 29 formed of a resin such as a PVC-treated PET film into the same shape as the upper surface of the first mold 41 and having one surface coated with an adhesive such as a vinyl chloride-based adhesive is removed. It overlaps on the upper surface of the first mold 41. In this state, a predetermined heat and pressure are applied between the first mold 41 and the cover body 29, and the plurality of magnet main bodies 27 are thermocompression-bonded to the cover body 29 (FIG. 12B).

Next, the cover body 29 to which the plurality of magnet bodies 27 are adhered is removed from the first mold 41, and is housed in the long second concave portion 42a of the second mold 42 such that the cover body 29 is on the lower side. I do. In this state, a second resin paste 43 of a resin such as vinyl chloride is poured between the plurality of magnet bodies 27 (FIG. 12).
(C)) After the upper surface of the second mold 42 is squeezed with a spatula or the like, it is heat-treated at a predetermined temperature to be hardened and hardened.
Is molded. Further, the magnet main body 27 and the magnet holding portion 28 bonded to the cover body 29 are attached to the second concave portion 42 of the second mold 42.
A strip member 84 having a two-layer structure is obtained by taking it out of FIG. 12A (FIG. 12D). When this band-shaped member 84 is cut into a predetermined length and rounded into a ring shape, a rotor magnet 86 is obtained (FIG. 11).

The rotor magnet 8 manufactured as described above
In No. 6, the number of manufacturing steps can be reduced as compared with the rotor magnet of the first embodiment by the absence of the magnet support portion. Also, the procedure for assembling the rotor magnet 86 to the rotor 14 is substantially the same as that of the first embodiment, and a description thereof will not be repeated. Further, in the small motor 10 incorporating the rotor magnet 86, one surface of the magnet main body 27 has the cylindrical portion 1.
4a, the magnet body 27 is almost insulated from air because the magnet body 27 is covered with the magnet holding portion 28 and the cover body 29 because the magnet body 27 and the other surface are covered with the magnet body 27. Does not occur.

FIG. 13 shows a seventh embodiment of the present invention. 13, the same reference numerals as those in FIG. 2 indicate the same parts.
In this embodiment, the small motor 90 is an abduction type brushed DC motor, and the stator magnet 96 wound around the stator frame 11 is rotated by the stator frame 11 so as to coincide with the center line of the stator magnet 96. A shaft 13 held so as to be able to rotate, a rotor 14 having a cylindrical portion 14a covering the stator magnet 96,
A rotor core 92 is provided on the inner peripheral surface of the cylindrical portion 14a of the rotor 14 so as to face the outer peripheral surface of the stator magnet 96 and to be attached with a predetermined gap from the outer peripheral surface of the stator magnet 96.

The stator magnet 96 is formed by cutting the band-shaped member of the first embodiment to a predetermined length, and the magnet support portion 26 and the magnet main body 27 are formed similarly to the rotor magnet of the first embodiment. It has a magnet holding part 28 and a cover body 29. The rotor 14 is fixed to the shaft 13, and an armature coil 92 a is wound around the rotor core 92. A commutator 91 electrically connected to the armature coil 92a is attached to a lower end of the cylindrical portion 14a of the rotor 14, and a pair of brush holders 93, 93 are provided near the periphery of the base 11a of the stator frame 11. It is inserted toward the commutator 91. A pair of brushes 94, 94 are slidably inserted into the pair of brush holders 93, 93, and these brushes 94, 94 are springs 97, 97.
As a result, it is pressed against the commutator 91.

The method of manufacturing the stator magnet 96 thus configured is substantially the same as the method of manufacturing the rotor magnet of the first embodiment, and therefore, the description thereof will not be repeated. To assemble the stator magnet 96 to the stator frame 11, first, an adhesive (not shown) is applied to an outer peripheral surface of the protrusion 11 b of the stator frame 11, and the stator magnet 96 is rolled into a ring shape to form the protrusion 1.
1b, and the protrusion 11b is inserted into a jig (not shown). As a result, the stator magnet 96 is temporarily fixed in a state wound around the outer peripheral surface of the protruding portion 11b. When heat treatment is performed at a predetermined temperature in this state, the stator magnet 96 is fixed to the outer peripheral surface of the protrusion 11b with an adhesive. After the fixing of the stator magnet 96 with the adhesive is completed, the protrusion 11b is pulled out from the jig.

In the small motor 90 using such a stator magnet 96, as in the small motor using the rotor magnet of the first embodiment, the magnetic powder of the magnet main body 27 requires a minimum necessary amount. And the magnet support 26
Is extremely thin, the stator magnet 16 can be reduced in weight. Further, since the amount of the magnetic powder of the relatively expensive magnet body 27 can be minimized, the stator magnet 96 can be manufactured at a relatively low price, and the manufacturing cost of the motor 90 can be reduced. Further, since the plurality of magnet bodies 27 are magnetically separated from each other, it is possible to reliably control each magnetic flux distribution of these magnet bodies 27. Further, the protrusion 1 of the stator frame 11
Even if there is a dimensional error in the outer diameter of the stator magnet 96 or the length of the stator magnet 96, since both ends of the stator magnet 96 are cut off at an angle, the both ends of the stator magnet 96 are slightly displaced from each other along the inclined surface. If that error can be absorbed.

FIG. 14 shows an eighth embodiment of the present invention. In this embodiment, a cylindrical stator frame 101 having both ends closed, a shaft 103 inserted through the stator frame 101 and rotatably held,
A rotor magnet 106 wound around the shaft 103 so as to be positioned within the stator frame 101 is fitted to the stator frame 101 so as to face the outer peripheral surface of the rotor magnet 106 and leave a predetermined gap from the outer peripheral surface of the rotor magnet 106. And a stator core 102 attached thereto. The shaft 103 is rotatably held on the stator frame 101 via bearings 103a and 103b. A rotor yoke 104 is fitted to the shaft 103, and the rotor magnet 10
6 is wound. The rotor magnet 106 is formed by cutting the band-shaped member of the first embodiment to a predetermined length, and the magnet support 26, the magnet main body 27, and the magnet holding portion are formed in the same manner as the rotor magnet of the first embodiment. 28
And a cover body 29. An armature coil 102a is wound around the stator core 102. Reference numeral 107 in FIG. 14 is a rotor position sensor that detects the rotational position of the rotor yoke 104, and reference numeral 108 is a bearing holding plate that prevents the bearing 103b from moving in the longitudinal direction of the shaft 103.

The rotor magnet 1 constructed as described above
Since the manufacturing method of No. 06 is substantially the same as the manufacturing method of the rotor magnet of the first embodiment, repeated description is omitted. The shaft 10 of the rotor magnet 106
The procedure for assembling the stator magnet into the stator frame according to the seventh embodiment is substantially the same as the procedure for assembling the stator magnet to the stator frame according to the seventh embodiment.

FIG. 15 shows a ninth embodiment of the present invention. 15, the same reference numerals as those in FIG. 14 indicate the same parts. In this embodiment, the small motor 110 is an inverting type brushed DC motor, and has a cylindrical stator frame 111 having both ends closed.
Shaft 113 inserted through and held rotatably
And a rotor core 112 fitted on the shaft 113 so as to be located in the stator frame 111, and a stator magnet 11 inserted on the stator frame 111.
6 is provided. An armature coil 112a is wound around the rotor core 112, and a stator magnet 116 faces the outer peripheral surface of the rotor core 112 and is spaced from the outer peripheral surface of the rotor core 112 by a predetermined gap.
11 is inserted.

The stator magnet 116 is formed by cutting the belt-shaped member of the first embodiment to a predetermined length, and the magnet support 26 and the magnet main body 27 are formed in the same manner as the rotor magnet of the first embodiment. And magnet holder 28
And a cover body 29. The commutator 1 electrically connected to the amateur coil 112a is provided on the shaft 113.
17 are fitted, and a pair of brush holders 118, 118 are mounted on the outer peripheral surface of the stator frame 111.
It is inserted toward. A pair of brush holders 118, 11
8, a pair of brushes 119, 119 are slidably inserted into the brushes 119, 119.
0 is pressed against the commutator 117.

The method of manufacturing the stator magnet 116 thus configured is substantially the same as the method of manufacturing the rotor magnet of the first embodiment, and therefore, the description thereof will not be repeated. The procedure for assembling the stator magnets 116 to the stator frame 111 is substantially the same as the procedure for assembling the rotor magnets to the rotor according to the first embodiment, and a description thereof will not be repeated. As the rotor magnet or the stator magnet of the seventh to ninth embodiments, the rotor magnet of the fourth embodiment without a magnet support and a cover may be used. The rotor magnet of the fifth embodiment may be used, and the rotor magnet of the sixth embodiment having no magnet support may be used.

[0055]

As described above, according to the present invention, since the magnet is made of a resin member having a function as a plurality of magnets having different magnetic pole directions, the weight of the magnet is reduced and the manufacturing cost is reduced. Can be. If a plurality of magnets having different magnetic pole directions are provided at predetermined intervals in a resin member constituting the magnet, these magnet functions are magnetically separated from each other. Can be reliably controlled. Further, if the resin member constituting the magnet is formed by dispersing the magnetic powder in the resin, the weight of the magnet and the manufacturing cost can be further reduced. In addition, if the resin member constituting the magnet is formed by rolling the flexible resin into a ring shape, the magnet can be securely fixed even when the assembly portion of the magnet is the cylindrical inner peripheral surface or the column outer peripheral surface. . Further, if a resin member constituting the magnet is formed by molding a flexible resin into a tape or a film, a large number of magnets can be manufactured simply by cutting into a strip shape, and the manufacturing cost can be further reduced.

Also, a plurality of magnet bodies of magnets arranged in a state arranged at predetermined intervals are respectively magnetized in a predetermined direction, and a magnet holding portion having flexibility and spring property is provided with a plurality of magnet main bodies. If the magnet is filled in between, when this magnet is rolled into a ring shape and inserted into the cylindrical inner peripheral surface of the mounting portion, the magnet comes into close contact with the cylindrical inner peripheral surface due to the spring property of the magnet holding portion. As a result, the magnet can be securely fixed to the cylindrical inner peripheral surface by the adhesive or the like. In addition, since the magnetic powder of the relatively expensive magnet main body is required to be the minimum necessary, the weight of the magnet can be reduced and the magnet can be manufactured at a relatively low cost. Further, since the plurality of magnet bodies are magnetically separated from each other, it is possible to reliably control each magnetic flux distribution of these magnet bodies. Also, a plate-shaped magnet support portion having flexibility and spring properties is formed of a ferromagnetic material, and a plurality of magnet main bodies bonded in a state of being arranged at a predetermined interval on the magnet support portion in a predetermined direction. If the magnet holding portion having flexibility and spring property is filled between the plurality of magnet bodies, the magnetic flux emitted from each magnet body passes through the magnet support portion having a high magnetic permeability to the adjacent magnet. Since the magnetic flux reaches the main body, the magnetic flux density between the respective magnet main bodies increases, and the magnetic characteristics of each magnet main body can be improved. Further, if the assembly portion of the magnet is a cylindrical inner peripheral surface, when the magnet is rolled into a ring shape and inserted, the magnet comes into close contact with the cylindrical inner peripheral surface due to the spring properties of the magnet support portion and the magnet holding portion.

If the cover body made of resin is adhered to the upper surfaces of the magnet body and the magnet holding portion, the entire surface of the magnet body is covered with the magnet support portion, the magnet holding portion, and the cover body. Insulated from air. As a result, rust can be prevented from being generated on the magnet main body. Further, a plurality of magnet main bodies of magnets bonded in a state of being arranged at predetermined intervals on a cover body formed of resin are magnetized in predetermined directions, respectively, and a magnet holding portion having flexibility and spring property is provided. Is filled between the plurality of magnet bodies, one surface of the magnet body is in close contact with the mounting surface of the magnet, and the peripheral surface and the other surface of the magnet body are covered with the magnet holding portion and the cover body. The main body is almost isolated from the air.

On the other hand, a kneaded material obtained by kneading the magnetic powder and the first resin paste is poured into a plurality of first concave portions of the first mold, and a magnetic field is applied to each of the kneaded materials in the first concave portion to be magnetized. The plurality of magnet bodies are molded by curing the resin, and a single positioning member formed of resin is temporarily bonded to the upper surfaces of all of the plurality of magnet bodies in the plurality of first recesses. With the first mold and the second mold
The magnet holding portion is formed by housing the positioning member in the recess so that the positioning member is on the lower side, flowing the second resin paste between the plurality of magnet main bodies in the second recess, and curing the magnet, and further forming the plurality of positioning members. By peeling and removing the magnet from the magnet main body and the magnet holding portion, a magnet including the magnet main body and the magnet holding portion can be obtained.

In the same manner as described above, a plurality of magnet bodies are formed, and the magnet support portions are replaced with a plurality of first body members in place of the positioning members.
Adhering to the upper surface of all of the plurality of magnet bodies in the recess, taking out the plurality of magnet bodies together with the magnet support from the first mold, and housing the plurality of magnet bodies in the second recess of the second mold such that the magnet support is on the lower side; If the magnet holding part is molded in the same manner as described above, a magnet including the magnet main body, the magnet support part, and the magnet holding part can be obtained. Further, after the second resin paste is heat-treated and cured to form a magnet holding portion, a cover body made of resin is adhered to the upper surface of the magnet holding portion and the magnet main body, so that the magnet main body, the magnet support portion, and the magnet holding portion are formed. And a magnet comprising a cover part. Further, a plurality of magnet bodies are formed in the same manner as described above, and a cover body is bonded to the upper surfaces of all of the plurality of magnet bodies in the plurality of first recesses in place of the positioning member, and the plurality of magnet bodies are joined together with the cover body to the first mold. If the cover is placed in the second concave portion of the second mold so as to face down and the magnet holding portion is molded in the same manner as described above, a magnet including the cover portion, the magnet body, and the magnet holding portion can be obtained. .

In particular, if the magnet constructed or manufactured as described above is used as a rotor magnet or a stator magnet of an external or internal rotation type small motor, a relatively expensive magnetic powder of the magnet main body can be used in a minimum necessary amount. Since the amount is enough,
By reducing the weight of the rotor magnet or the stator magnet, the rotor or the stator frame can be made lighter, and the rotor magnet or the stator magnet can be manufactured at a relatively low cost. Further, since the plurality of magnet bodies are magnetically separated from each other, it is possible to reliably control each magnetic flux distribution of these magnet bodies. Further, if the entire surface of the magnet main body is covered with the magnet support portion, the magnet holding portion, and the cover body, the magnet main body is shut off from the air, so that rust can be prevented from being generated on the magnet main body. Further, the magnetic flux emitted from each magnet main body reaches the adjacent magnet main body through the magnet support portion having a high magnetic permeability, so that the magnetic flux density between each magnet main body is increased, and the magnetic characteristics of each magnet main body can be improved.

[Brief description of the drawings]

FIG. 1 is a diagram showing a small motor according to a first embodiment of the present invention;
Sectional view on the AA line of FIG.

FIG. 2 is a sectional view taken along line BB of FIG. 1;

FIG. 3 is a process chart showing a method of manufacturing a magnet that will be a rotor magnet of the small motor.

FIG. 4A is a front view of a rotor magnet showing a state before a band member is cut into a predetermined length and rounded. (B) is a perspective view of the rotor magnet showing a state where the cut strip-shaped member is rounded into a ring shape with a predetermined radius of curvature.

FIG. 5 is a front view of a rotor magnet corresponding to FIG. 4A and showing a second embodiment of the present invention.

FIG. 6 is a front view of a rotor magnet corresponding to FIG. 4A showing a third embodiment of the present invention.

FIG. 7 is a sectional view illustrating a fourth embodiment of the present invention and corresponding to FIG. 1;

FIG. 8 is a process chart showing a method of manufacturing a magnet that will be a rotor magnet of the small motor.

FIG. 9 is a sectional view showing a fifth embodiment of the present invention and corresponding to FIG. 1;

FIG. 10 is a process chart showing a method of manufacturing a magnet to be a rotor magnet of the small motor.

FIG. 11 is a sectional view corresponding to FIG. 1, showing a sixth embodiment of the present invention.

FIG. 12 is a process chart showing a method of manufacturing a magnet to be a rotor magnet of the small motor.

FIG. 13 is a sectional view showing a seventh embodiment of the present invention and corresponding to FIG. 2;

FIG. 14 is a sectional view showing an eighth embodiment of the present invention and corresponding to FIG. 2;

FIG. 15 is a sectional view showing a ninth embodiment of the present invention and corresponding to FIG. 2;

FIG. 16 is a sectional view corresponding to FIG. 2 showing a conventional example.

[Description of Signs] 10, 90, 100, 110 Small motor 16, 46, 56, 66, 76, 86, 106 Rotor magnet (magnet) 26 Magnet support unit 27 Magnet main body 28 Magnet holding unit 29 Cover body 40 Kneaded material 41 First mold 41a First recess 42 Second mold 42a Second recess 43 Second resin paste 67 Positioning member 96, 116 Stator magnet (magnet)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI H02K 21/22 H02K 21/22 M (72) Inventor Toru Tsurumaki 3-7 Koganecho, Niigata City, Niigata Prefecture Inside

Claims (15)

[Claims] 1. A magnet made of a resin member having a function as a plurality of magnets having different magnetic pole directions. 2. The magnet according to claim 1, wherein a plurality of magnets having different directions of magnetic poles are provided at predetermined intervals in the resin member. 3. The magnet according to claim 1, wherein the resin member is formed by dispersing magnetic powder in the resin. 4. The magnet according to claim 1, wherein the resin member is formed by rolling a flexible resin into a ring shape. 5. The magnet according to claim 4, wherein the resin member is formed by molding a flexible resin into a tape or a film. 6. A plurality of magnet bodies (27) arranged in a state of being arranged at a predetermined interval and magnetized in a predetermined direction, respectively.
And a magnet holder (28) having flexibility and spring properties and filled between the plurality of magnet bodies (27). 7. A plate-shaped magnet support portion (26) formed of a ferromagnetic material and having flexibility and resilience, and bonded to the magnet support portion (26) in a state of being arranged at a predetermined interval. A plurality of magnet bodies (27), each of which is magnetized in a predetermined direction, and a magnet holder (28) having flexibility and spring properties and filled between the plurality of magnet bodies (27). Magnet. 8. The magnet according to claim 7, further comprising a cover body made of resin and adhered to upper surfaces of the magnet main body and the magnet holding portion. 9. A cover body (29) formed of a resin, and a plurality of magnet bodies that are bonded and arranged in a predetermined direction on the cover body (29) and magnetized in a predetermined direction, respectively. (27) A magnet comprising: a magnet holder (28) having flexibility and spring properties and filled between the plurality of magnet bodies (27). 10. A step of kneading a magnetic powder and a first resin paste at a predetermined weight ratio, and a step of mixing the kneaded material (40) with a plurality of first recesses (4) at predetermined intervals.
1a) flowing into a first mold (41) formed in a line, and applying a magnetic field of a predetermined strength in the vertical direction to each kneaded material (40) in the plurality of first recesses (41a). A step of magnetizing; a step of forming a plurality of magnet bodies (27) by heat-treating and curing the plurality of magnetized kneaded materials (40); and a single positioning member (67 ) Is temporarily bonded to all the upper surfaces of the plurality of magnet bodies (27) in the plurality of first recesses (41a); and the plurality of magnet bodies (27) are fixed to the first mold together with the positioning member (67). (41) and the second recess (42) of the second mold (42).
a) receiving the positioning member (67) in the lower side, and flowing a second resin paste (43) between the plurality of magnet bodies (27) in the second recess (42a). And a step of forming a magnet holding portion (28) by heat-treating and curing the second resin paste (43); and positioning the positioning member (67) with the plurality of magnet bodies (27) and the magnet. A step of peeling and removing the holding portion (28) from the holding portion (28). 11. A step of kneading a magnetic powder and a first resin paste at a predetermined weight ratio, and a step of mixing the kneaded material (40) with a plurality of first recesses (4) at predetermined intervals.
1a) flowing into a first mold (41) formed in a line, and applying a magnetic field of a predetermined strength vertically to each kneaded material (40) in each of the first recesses (41a). Magnetizing; forming a plurality of magnet bodies (27) by heat-treating and curing the plurality of magnetized kneaded materials (40); and a single magnet support portion formed of a ferromagnetic material. (26)
Bonding all the magnet bodies (27) in the plurality of first recesses (41a) to the upper surface of the plurality of magnet bodies (27); and attaching the plurality of magnet bodies (27) together with the magnet support portions (26) to the first mold ( 41) and removed from the second recess (4) of the second mold (42).
2a) accommodating the magnet support portion (26) so as to face down, and a second resin paste (43) between the plurality of magnet main bodies (27) in the second concave portion (42a). A method for manufacturing a magnet, comprising: a step of pouring; and a step of forming a magnet holding portion (28) by heat-treating and curing the second resin paste (43). 12. After the second resin paste (43) is heat-treated and cured to form a magnet holding portion (28), the second resin paste (43) is formed of a resin on the upper surfaces of the magnet holding portion (28) and the magnet main body (27). The method for manufacturing a magnet according to claim 11, wherein the cover body (29) is bonded. 13. A step of kneading a magnetic powder and a first resin paste at a predetermined weight ratio; and
1a) flowing into a first mold (41) formed in a row, and applying a magnetic field of a predetermined strength in the vertical direction to each kneaded material (40) in the plurality of first recesses (41a). A step of magnetizing, a step of forming a plurality of magnet bodies (27) by heat-treating and curing the plurality of magnetized kneaded materials (40), and a single cover body (29 ) To the entire upper surface of the plurality of magnet bodies (27) in the plurality of first recesses (41a); and attaching the plurality of magnet bodies (27) together with the cover body (29) to the first mold ( Taking out the second resin paste (43) into the second concave portion (42a) of the second mold (42) so that the cover body (29) is on the lower side; ), A step of forming a magnet holding portion (28) by heat-treating and curing the second resin paste (43). The method of production. 14. A rotor magnet (16, 46, 56, 66, 76, 8)
An abduction type small motor, wherein the stator magnet (96) is the magnet according to any one of claims 1 to 9. 15. An internal rotation type small motor, wherein the rotor magnet (106) or the stator magnet (116) is the magnet according to any one of claims 1 to 9.