JPS5846946B2 - Manufacturing method of rotor for coreless motor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a method for manufacturing a coreless morph rotor, in which a coil pattern formed on a flexible film by etching is formed into a cylindrical shape to form a rotor coil, and a disk-shaped commutator is attached to the rotor coil. More specifically, the purpose is to facilitate the manufacture of rotors by making connections between the conductors of cylindrical coil patterns using the conductor portions on the circumferential surface of the commutator, and to improve the formation of the conductor portions of the commutator. The purpose is to simplify the manufacturing process by using punching and through-hole plating.

Conventionally, a coil pattern 1 formed by etching as shown in Fig. 1a is bent as shown in Fig. b, formed into a cylindrical shape as shown in Fig. C, and a cylindrical pattern is formed between the coil conductors as shown in Fig. d. Since the coils are electrically and mechanically connected and the work proceeds along a curved line, the work is troublesome and takes a long time.

To explain further according to the drawings, the parallelogram coil pattern 1 in FIG. 1a includes conductors A1B1°A2B2...
・, AnBn are formed, which are folded back at the center as shown in b, formed into a cylindrical shape as shown in C, and then formed into a cylindrical shape as shown in C.
As in, B1 is An, Bn is An, Bn-1
is An 2 to 1. , B2 was electrically connected to A1 by welding, soldering, etc., and this cylindrical coil block 2 was electrically connected to a commutator plate as many as the number of poles of the commutator segment S as shown in e to form a rotor.

Therefore, this electrical connection work is performed along the circumference, which is cumbersome, and requires a lot of processing time because it is necessary to remove the insulating material from the ends of the conductors.

The present invention aims to eliminate the above-mentioned drawbacks [Second
6 to 6 show an embodiment of the present invention, which will be explained according to the drawings.

FIG. 2 shows parallel conductors A1B1. A2B2°..., AnBn are formed, and a tongue piece is formed on the A side and a tongue piece is formed extending on the C1B side.

In this embodiment, the tongues C and D are located diagonally on the conductor AB and have a width smaller than 1/2 of the pitch P in the conductor.

When this coil pattern 1 is folded back to the back side, it becomes as shown in FIG. 3.

At this time, the base of the tongue piece C and the tip of the tongue piece should be aligned almost in a straight line.

This coil pattern 1 is further curved into a cylindrical shape to form a fourth coil pattern.
Do as shown.

At this time, Cn and Dl, Cn-1 and Dn, ,,,
, so that C1 and D2 are adjacent to each other.

However, the tongue piece C is bent inside the cylindrical coil 2,
In the state of coil 2, the tongues C and D of the conductor are all connected to coil 2.
exposed inside.

The commutator 3 shown in FIG. 5 is connected to the coil 2 in this state to complete the coil and commutator portion of the rotor.

FIG. 12 shows an example of a coil pattern having another shape.

In FIG. 5, the commutator disk 3 includes a flat segment S.
An electrode portion E is provided on the circumferential surface, and the electrode portion E is arranged so as to be electrically connected to the 81 portion and the CnDl portion of the coil, and to the B2 portion and the Cn□Dn portion of the coil.

The commutator 3 in FIG. 5 is an example in which the number of coil conductors is the same as the number of segments, and FIG. 6 is an example in which the number of coil conductors is three times the number of segments.

The number of connected conductors per segment is determined based on characteristics and cost, even if there are fallen trees.

To explain in more detail how to make the commutator 3 shown in FIG. 5 according to FIG. 7, the shaded area in FIG. Afterwards, through-hole plating is performed on the punching marks H.

The commutator segment S and this through-hole plated end surface E are electrically connected.

The commutator 3 is formed by punching out the connecting portion F of the through-hole plated commutator 3 in the next step.

The outline of the process is shown in the figure below.

[Copper laminated board (for example, board thickness 1.5, copper peel thickness 5
0μ)] → [Positioning hole punching] → [Commutator end face punching] →
[Segment etching] → [Through hole plating] →
(Ni plating] → CAu plating] → [Connection punching]
→ [Completed commutator product] The commutator 3 and cylindrical coil 2 made in this way are attached to the electrode portion E of the circumferential surface of the commutator disk 3, that is, the through-hole plated end surface of the coil 2, C1Dn, C2.
D1°C3D2. ... are electrically connected to each other, and the joint between the commutator and the coil section is connected to the eighth
As shown in the figure, the connection is made more completely using solder or conductive paint 4.

In the case of large, high output, the thickness of the copper foil of this coil is also 5
In some cases, the thickness exceeds 00μ, in which case the connection may be made by welding.

Another embodiment will be described with reference to FIG.

FIG. 9 corresponds to the coil in FIG. 4, with the tongue C bent toward the outside of the cylindrical coil 2, and the commutator 3 in FIG. 5 or 6 in the same way. Combined to form a rotor.

FIG. 10 shows a different embodiment from the above-mentioned embodiment, in which the commutator segments are also formed of flexible films. and its extension piece S' are adhesively fixed to the top and side surfaces of the base, respectively.

As a result, a commutator 3 having the same function as that shown in FIG. 5 or 6 is obtained.

Alternatively, as shown in FIG. 10, a rotor can also be obtained by bonding only the segment portions S, and bending the extension portion S' upward and joining it to the coil 2 shown in FIG. 9.

In this case, the extension piece S' is connected, for example, to C1 and Dn in FIG.

FIG. 11 shows a state in which the etched patterns of the commutator and the coil are formed from an integrated flexible film, and only the coil portion 1 is bent.

This is assembled in the same process as when using the commutator SS' of FIG. 10 and the rotor coil 2 of FIG. 9.

However, it is assumed that the base 5 is bonded to the commutator segment S in the state shown in FIG. 11.

As described above, according to the method of the present invention, the conductors of the cylindrical coil can be connected on the commutator disk, making it easy to solder, etc. Also, the commutator can be connected by press punching, etching, plating, etc. All of this is done, and no manual work is required for the electrode portions on the peripheral surface, so the manufacturing process is simple and mass production is easy.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing a conventional example, a"e shows the manufacturing process of the rotor, FIGS. 2 to 5 are explanatory diagrams showing an embodiment of the present invention, and FIG. Top view, 3rd
The figure is a top view showing the above folded state, Fig. 4 is a perspective view showing the state where the above is curved into a cylindrical shape, Fig. 5 is a perspective view of the commutator disk, and Fig. 6 is another embodiment. FIG. 7 is an explanatory diagram showing the manufacturing process of the commutator disk of FIG. 5, where a is a top view before punching, b is a top view after punching, and C is a top view of b. A side view, FIG. 8 is a perspective view of the opening and closing completed according to FIGS. 2 to 5, FIG. 9 is a perspective view of another embodiment of the cylindrical coil, and FIG. 10 is a commutator disk. FIG. 11 is a top view of another embodiment of the coil pattern, and FIG. 12 is a top view of still another embodiment of the coil pattern. 1... Coil pattern, 2... Cylindrical coil, 3... Commutator disk, 4... Solder or conductive paint, 5... ...Commutator board, AB
...Conductor, C...Tongue, D...
・Tongue, S...Commutator segment, E...
... Commutator electrode part, H ... Annular hole or punching mark, F ... Connection part.

Claims (1)

[Scope of Claims] 1 A coil pattern formed by forming a plurality of inclined parallel conductors on a flexible film by etching, and extending and protruding narrow tongues from both ends of each conductor, with one end side facing the other end side. Fold the coil pattern so that it protrudes at a different level by approximately the length of the tongue piece on the extension line of .Furthermore, bend this coil pattern into a cylindrical shape, overlap the above-mentioned both end sides, and fold the tongue piece of the above-mentioned protruding end side to the other end side. The tongues on the sides are alternately adjacent to each other, a disc-shaped commutator is attached to the end of this cylindrical coil pattern, and the tongues are connected to a conductor section arranged around the commutator, thereby forming a coil. A method for manufacturing a rotor for coreless morph, characterized by simultaneously connecting conductors and connecting the coil commutator periphery. 2 Punch out an annular hole from the conductive foil laminate with a plurality of connecting parts left at equal angular positions, form commutator segments by etching inside the annular hole, apply through-hole plating to the annular hole, and further plate each part if necessary. Claim 1, characterized in that a tongue piece of a cylindrical coil pattern is connected to a plated portion of the annular hole of a disc-shaped commutator formed by cutting off the connecting portion after applying finish plating. A method for manufacturing a rotor for coreless morph. 3 Form a flat commutator segment on an insulating substrate, punch out an annular hole around the commutator segment leaving n times the number of connecting parts of the segments, apply through-hole plating to the annular hole, and then cut off the connecting parts. Claim 1, characterized in that every n local plated portions of the disc-shaped commutator are connected to the segment, and tongues of the cylindrical coil pattern are connected to these plated portions. A method for manufacturing a rotor for coreless morph as described in .