WO2004107538A1 - 電磁部材の製造方法および電磁部材 - Google Patents
電磁部材の製造方法および電磁部材 Download PDFInfo
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- WO2004107538A1 WO2004107538A1 PCT/JP2004/007011 JP2004007011W WO2004107538A1 WO 2004107538 A1 WO2004107538 A1 WO 2004107538A1 JP 2004007011 W JP2004007011 W JP 2004007011W WO 2004107538 A1 WO2004107538 A1 WO 2004107538A1
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- WIPO (PCT)
- Prior art keywords
- resin
- coil
- inner peripheral
- peripheral portion
- mold
- Prior art date
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
Definitions
- the present invention relates to a method for manufacturing an electromagnetic member and an electromagnetic member.
- the present invention relates to a method for manufacturing an electromagnetic member capable of suppressing damage to an insulating coating of a conductive wire when obtaining an electromagnetic member in which an insulating coated conductive wire is wound around a core.
- the motor consists of a rotating rotor and a fixed stay. Then, a coil wound around the core is used in the mouth or the stay.
- a core obtained by stamping out an electromagnetic steel sheet into a predetermined shape and laminating the stamped sheets is used.
- a core having a plurality of teeth and having a slot between each tooth is used.
- the conductor used is a metal wire with an insulating coating formed on the surface. This wire is wound around the outer circumference of the core teeth, that is, in the slot.
- the above-described technology relating to the motor coil has a problem that the insulating coating of the conductive wire constituting the coil may be damaged.
- the core has a rectangular cross section instead of a circular cross section, and the conductor is pressed against the corner, and the insulation coating is easily damaged.
- the core has a rectangular cross-section, there was a problem that the length of the conductor was long.
- the conductor is wound after the core is manufactured, it is difficult to wind the conductor with the gap between the core and the slot, making it difficult to close the conductor sufficiently to the core and eliminate the gap. Product moment) cannot be improved.
- a copper wire with a circular cross section it is difficult to improve the space factor, and the upper limit of the conventional space factor is about 60%.
- a main object of the present invention is to provide an electromagnetic member having a high space factor.
- Another object of the present invention is to provide a method of manufacturing an electromagnetic member that can easily form a coil having a core wound with a conductor without damaging the insulation of the conductor.
- the present invention achieves the above object by using a resin-molded coil in press-molding a magnetic powder and a coil in a mold.
- the method for manufacturing an electromagnetic member of the present invention is characterized by including the following steps.
- This resin mold body is placed in a mold, magnetic powder is filled in the upper and lower portions and the inner periphery of the resin mold body, and the resin mold body is pressed to form a pressed body in which the core made of magnetic powder and the resin mold body are integrated.
- the molding resin prevents direct contact between the insulating coating of the conductor and the magnetic powder, and the insulating coating is damaged. Can be prevented.
- the resin molded body and the magnetic powder are integrated in a mold to form a pressed body, it is easy to make the core into a free shape, especially a circular shape, and the insulation coating on the conductive wire may be damaged. A difficult core shape can be easily realized. Further, there is no need to perform a complicated process of forming a core in advance and winding a conductor around the core.
- the electromagnetic member of the present invention is an electromagnetic member having a dust core obtained by pressing a magnetic powder, and an insulated conductor that is pressed together with the magnetic powder and is wound around the core.
- the space factor of the electromagnetic member is 70% or more.
- the conductor has a configuration in which an insulating coating is applied on a metal wire.
- the material of the metal wire copper, aluminum, silver-containing steel, nickel-plated copper and the like are suitable.
- Polyurethane, polyester, polyamide, ester imide, amide imide, epoxy resin and the like are used for the insulation coating.
- the conductor preferably has a fusion layer in addition to the insulating coating.
- the material of the fusion layer polyvinyl butyral, epoxy resin, polyamide resin and the like are preferable.
- the heating for melting the fusion layer may be performed after the coil is formed and before the resin molding.
- temporarily fixing a plurality of evenings with a tape which can easily remove the coil can be mentioned.
- a helical coil is formed using the above-described conductor.
- the helical shape here is not limited to a circular shape when viewed from the axial direction, but also includes an elliptical shape and a rectangular shape.
- the winding of the conductive wire may be either aligned winding or random winding. For example, when a rectangular wire is used, as shown in FIG. 22A and FIG. Can be used. In the case of an edgewise wound coil, the end of the conductor 21 is pulled out to the upper and lower ends of the coil.
- both ends of the conductor 21 can be pulled out to the outer periphery of the coil by folding the rectangular conductor into a double shape and winding the conductor with the folded end on the inner peripheral side. Furthermore, as shown in Fig. 22C, a coil with a round wire can be used. The turbulent coil is easy to wind the conductor 21 and the terminal can be pulled out from any position of the coil.
- the coil formed in a spiral shape is resin-molded in order to maintain its shape.
- a resin having the following characteristics is preferable.
- the melting point of the mold resin is preferably 100 ° C. or less.
- the resin has flexibility enough to be simply peeled off at the resin temperature after molding of the pressed body or that the resin can be melted and removed by heating the dryer. It is.
- This mold resin may be any of a soft resin having a penetration of 1 or more and a hard resin having a penetration of less than 1 stipulated in JISK 2235-5.4 at 25 ° C. Can also be used.
- the soft resin examples include hydrocarbon wax, fatty acid / higher alcohol wax, amide wax, ester wax and metal soap.
- Specific examples of the soft resin include solid esters composed of higher fatty acids and higher monohydric alcohols, spermaceti (hexadecyl palmitate), beeswax (mixture of cerotic acid, esters of palmitate, etc.), cinnamon wax and stone wax. (Paraffin), wood wax, etc.
- spermaceti hexadecyl palmitate
- beeswax mixture of cerotic acid, esters of palmitate, etc.
- cracks may occur in the core when the pressed body is extracted from the mold, depending on the size of the pressed body and the composition of the magnetic powder.
- the thickness of the magnetic powder disposed on the outer periphery of the mold body is such that cracks in the core can be suppressed and that the core can easily break through and be removed in a later step. For example, it is preferably about 0.05 to 1.0 mm.
- the resin used for the mold is made of a different material from the insulating coating constituting the conductive wire. This makes it possible to easily remove the mold resin from the coil in a later step.
- the shape of the resin mold body is a cylindrical body in which the entire coil can be embedded with mold resin.
- the inner peripheral hole of the coil is not filled with the molding resin, but is molded while leaving the inner peripheral hole to form a hollow cylindrical body.
- the cross-sectional shape of the cylindrical body is preferably circular, but may be non-circular such as rectangular.
- the thickness of the mold resin on the inner peripheral side of the coil be thin and the thickness of the mold resin on the outer peripheral side of the coil be large.
- the clearance between the core and the coil can be made substantially negligible when the core is formed on the inner circumference of the resin mold later.
- the outer diameter of the resin mold be substantially the same as the inner diameter of the mold when the pressed body is formed in a later step, or that the thickness of the magnetic powder on the outer periphery of the resin mold be minimized. With this configuration, the shape of the coil is not disturbed when the pressed body is formed.
- the axial distance of the inner peripheral side of the resin mold body is larger than the axial distance of the outer peripheral side. Is also preferably reduced.
- the shrinkage when pressurized may be “Mold resin> Magnetic powder or conducting wire”.
- the upper and lower punches having projections may be used to sufficiently press the magnetic powder filled in the inner periphery of the resin mold body. In that case, a larger pressing force is applied in the axial direction on the inner peripheral portion of the resin mold body. Even in such a case, if the resin mold body has a hollow cylindrical shape with both end surfaces being flat, the inner peripheral side where the coil is disposed and the amount of resin is relatively small has a small degree of compression, and the coil does not exist.
- the degree of compression increases on the outer peripheral side where the amount of resin is large.
- the resin mold body after the press body is formed has a shape in which the axial distance on the outer peripheral side is smaller than the axial distance on the inner peripheral side, and the coil relatively protrudes in the axial direction.
- the press body including the resin mold body having such a shape has a problem that it is difficult to draw out the ends of the conductive wires constituting the coil.
- the outer peripheral side of the resin mold body with no coil and high compression ratio is projected in the axial direction from the inner peripheral side in advance, so that after molding the pressed body, a resin mold body with both end surfaces substantially flat is obtained. And the ease of pulling out the wire terminal can be improved.
- both ends of the conductive wire constituting the coil are arranged on the outer peripheral side of the coil turn. Both ends of the conductor are embedded inside the resin mold when molded.
- this terminal needs to be pulled out to be connected to the conductor of another coil or the power supply side. If both ends of the conductor are arranged in advance on the outer circumference side of the coil turn, if the mold resin is removed after molding of the pressed body, the end of the conductor is already drawn out, and it will go to the power supply side Can be easily performed.
- This resin mold is preferably a molding method in which a coil is loaded into a mold having a core fitted into the inner peripheral hole of the coil and resin is injected. According to this molding method, the molten resin is simply poured into the mold and cured, and no special manufacturing equipment is required. ) Molding)
- any magnetic powder can be applied to the present invention as long as it is a magnetic substance powder.
- a soft magnetic material is preferable.
- a soft magnetic material is a ferromagnetic material that is magnetized by an external magnetic field and then loses its magnetization and returns to its original state when the external magnetic field is removed.
- a material having a large magnetic permeability in other words, a material having a small coercive force Hc can be said to be a soft magnetic material. More specifically, pure iron, steel (Fe-N system, Fe-C system, 6-?
- a magnetic powder in which an insulating thin film is coated on a soft magnetic powder is preferable.
- a powder having such a coating iron loss of the obtained electromagnetic member in a high frequency range can be suppressed, and magnetic characteristics such as a magnetic flux density can be improved.
- the insulating thin film is preferably made of a material containing an oxide. More specifically, examples include iron phosphate, manganese phosphate, zinc phosphate, calcium phosphate, silicon oxide, titanium oxide, aluminum oxide, zirconium oxide, and the like.
- a lubricant may be added to the magnetic powder.
- a lubricant for example, fatty acids such as stearic acid and oleic acid can be used.
- the amount of the lubricant to be added is preferably 0.15% by mass or less based on the mixed material with the magnetic powder.
- a binder may be added to the magnetic powder.
- the binder may be a thermoplastic resin, a thermosetting resin, a non-thermoplastic resin, or the like.
- the press body is formed by placing the resin mold body and the magnetic powder in a mold and applying pressure.
- a cylindrical mold and upper and lower punches that move up and down in the mold inner hole.
- the cross-sectional shape of the mold is not limited to a circle.
- Press bodies are formed by using known techniques such as warm forming and mold lubrication. As a result, the density of the pressed body can be increased and the space factor can be improved, leading to improved magnetic properties.
- the powder temperature during warm compaction is preferably from 100 to 180 ° C.
- the pressing conditions depend on the material of the mold resin, the material and particle size of the magnetic powder, the size and shape of the object to be pressed, etc., but the pressing force when forming the pressed body is 7.0 to 15.0 ton Z cm. 2 is preferred.
- the pressing force when forming the pressed body is 7.0 to 15.0 ton Z cm. 2 is preferred.
- the magnetic powder is filled into the hollow holes of the resin mold body, but it is difficult to apply sufficient pressure to the magnetic powder at this location with a flat upper and lower punch.
- the magnetic powder filled in the hollow hole of the resin mold body can be sufficiently pressurized, and high powder filling can be achieved. Density can be achieved.
- the shape of the projection is not particularly limited as long as it can project toward the inner peripheral side of the resin mold body. Various shapes such as truncated cone, column, truncated pyramid, and prism can be used.
- At least one of the upper and lower punches pressing from the upper and lower end surfaces of the resin mold body is disposed on the inner peripheral portion on the inner peripheral side and on the outer peripheral portion of the inner peripheral portion, and is independent of the inner peripheral portion. It is preferable to configure the outer peripheral portion that operates. In this case, a first pressurization for simultaneously pressing the inner and outer peripheral portions and a second pressurizing for pressing only the inner peripheral portion are performed. By performing such multi-stage pressing, a core having a high filling density can be formed.
- the inner peripheral portion When performing the first and second pressurization, the inner peripheral portion may be made to protrude from the surface of the outer peripheral portion in the pressurizing direction from the stage of the first pressurization so that the inner peripheral portion has the function of a protrusion. good. With this configuration, a core having a higher filling density can be formed.
- the first pressurization is such that the surfaces of the inner peripheral portion and the outer peripheral portion of the upper punch are flush with each other, and the inner peripheral portion of the lower punch is retracted from the outer peripheral portion.
- the second pressing may be performed such that the inner peripheral portion of the upper punch protrudes from the outer peripheral surface and the inner peripheral portion and the outer peripheral surface of the lower punch are flush with each other.
- a press body or a multi-stage press obtained by a punch having a projection by the above method The pressed body obtained by performing the above process has a shape in which at least one of the upper and lower end surfaces of the core is concave on the inner peripheral side and the outer peripheral side is annularly protruded.
- the unevenness on the inner and outer circumferences can be used for fitting when assembling the stay or the mouth, and contributes to improving the ease of assembling the stay or the rotor.
- the mold resin After pressing, the mold resin is removed. By this removal, the wire terminal of the coil can be pulled out. It is preferable to use a simple means for removing the mold resin, such as simply extruding with a spatula or melting and removing by heating with a drier.
- the electromagnetic member of the present invention includes a dust core and a coil wound around the dust core.
- the pressure-dividing core is, for example, a magnetic core formed by pressing powder by the above-described manufacturing method.
- As a typical form of the dust core there is a force having a rod-shaped or pipe-shaped body and flanges provided at both ends of the body.
- the electromagnetic member of the present invention has a space factor of 70% or more.
- the “occupancy ratio” is, in principle, the ratio of the cross-sectional area of the metal wire to the cross-sectional area of the dust core in the conductor wound in the slot.
- the slot cross-sectional area is defined as the area surrounded by a straight line connecting the trunk, the collar, and the flanges at both ends in the longitudinal cross section of the core in the case of a magnetic core that has flanges with equal outer diameters at both ends of the trunk. I do.
- the cross section of the magnetic core usually has a body and an arc-shaped flange integrated on both sides of the body.
- the slot cross-sectional area is a range surrounded by a radial extension of the arcuate flange on the side continuous in the circumferential direction, and the arcuate flange and the trunk.
- the bulging part that extends beyond the slot is not considered as the space factor, and the ratio of the cross-sectional area of the metal wire inside the slot to the cross-sectional area of the slot.
- a more preferable space factor is 75% or more, and a still more preferable space factor is 80% or more.
- This electromagnetic member can be used in various fields utilizing the action as an electromagnet.
- it can be used for motor coils, solenoids, solenoid valves, and electromagnetic switches.
- FIG. 1 is a longitudinal sectional view of a motor coil obtained by the method of the present invention.
- FIG. 2 is an explanatory view showing a process of manufacturing a molded body.
- FIG. 3 is a longitudinal sectional view of the resin mold body.
- FIG. 4 is a schematic explanatory view showing a state where a resin mold body is arranged in a mold in a press body forming step.
- FIG. 5 is a schematic explanatory view showing a state in which the magnetic hole is filled also in the hollow hole and the upper part of the resin mold body in the press body forming step.
- FIG. 6 is a schematic explanatory view showing a pressurized state at the time of pressing in a press body forming step.
- FIG. 7 is a longitudinal sectional view of the press body.
- FIG. 8 is a vertical cross-sectional view of the pressed body in a state where the wire ends are pulled out to the outer peripheral side of the coil.
- FIG. 9 is an explanatory view showing a state where the resin is removed from the press body of FIG. 8 and the wire ends are extended.
- FIG. 10 is a longitudinal sectional view of a resin mold body having a step between the inner peripheral side and the outer peripheral side.
- FIG. 11 is a vertical cross-sectional view of the pressed body in a state where the coil is recessed into the core.
- FIG. 12 is a schematic explanatory view of an embodiment of the present invention in which two-stage pressing is performed.
- FIG. 13 is a schematic explanatory view of an embodiment of the present invention in which a magnetic powder is filled also between a resin mold and a mold.
- FIG. 14 shows a sixth embodiment in which only the upper punch performs two-stage pressurization.
- FIG. 14A is an explanatory view showing a first pressurized state
- FIG. 14B is an explanatory view showing a second pressurized state.
- FIG. FIG. 15 shows a sixth embodiment in which two-stage pressing is performed by upper and lower punches.
- FIG. 15A is an explanatory diagram showing a state of a first pressing
- FIG. 15B is an explanatory diagram showing a state of a second pressing.
- FIG. FIG. 16 is a partial cross-sectional view of a motor showing a state in which a motor coil obtained from a pressed body constitutes a stay of an inner single-mouth type motor.
- FIG. 17 is a partial cross-sectional view of a motor showing a state in which a motor coil obtained from a press body constitutes a stay of an outer-opening overnight motor.
- FIG. 18 is a schematic sectional view of the electromagnetic member of the present invention in the seventh embodiment.
- FIG. 19 is a schematic sectional view of the electromagnetic member of the present invention in the eighth embodiment.
- FIG. 20 is a schematic sectional view of the electromagnetic member of the present invention in the ninth embodiment.
- FIG. 21 is a schematic sectional view of the electromagnetic member of the present invention in the tenth embodiment.
- FIG. 22A is a perspective view of an edgewise wound coil
- FIG. 22B is a perspective view of a flatwise wound coil
- FIG. 22C is a perspective view of a randomly wound coil.
- This motor coil has a coil 20 in which a conductive wire 21 is spirally wound around an outer periphery of a core 10.
- the core 10 has a disk-shaped flange portion 11 at both ends, and has a configuration in which both flange portions 11 are connected by a cylindrical body portion 12.
- the conducting wire 21 is wound around the outer periphery of the body 12 of the core so that both ends can be pulled out to the outer peripheral side of the core.
- the conductor 21 has an insulating coating 23 formed on the metal wire 22.
- Such a motor coil is manufactured as follows.
- a coil is used in which a conductor with a circular cross section in which a polyurethane insulating coating is provided on a copper wire is spirally aligned and wound.
- the outer diameter of the conductor is about 1-2 mm.
- the outer diameter of the coil is 26 mm, the inner diameter is 16 mm, and the height is 10 mm.
- the coil is resin-molded.
- a cylindrical mold 30 having a bottomed container shape with an open top and a rod-shaped core 31 in the center is used (see FIG. 2).
- Ready The coil 20 is fitted around the core 31.
- the outer diameter of the core 31 is slightly smaller than the inner diameter of the coil 20, and the coil 20 is disposed close to the core 31 and away from the inner peripheral wall.
- the molten resin 40 is injected into the mold. At this time, the mold 30 does not have a part, and the surface of the molten resin remains in a natural surface state.
- the resin 40 paraffin wax 125 manufactured by Nippon Seimitsu Co., Ltd. was used. The penetration of this resin at 25 ° C specified by JISK223 5-5.4 is 1 or more.
- the resin mold body 50 is extracted from the mold. Thereby, as shown in FIG. 3, a resin molded body 50 in which the coil 20 is embedded in the hollow cylindrical resin 40 can be obtained.
- a pressed body is formed.
- a mold 60 having a cylindrical filling portion and upper and lower punches 61 and 62 for pressing the filling portion from above and below are used for forming the press body.
- the upper and lower punches 61 and 62 those having projections 61A and 62A at the center thereof were used.
- the projections 61A and 62A (FIGS. 4 and 5) are frustoconical.
- the resin mold 50 (coil) is arranged coaxially with the mold 60. Further, as shown in FIG. 5, the inside and the upper portion of the hollow of the resin mold body 50 are also filled with the magnetic powder 70.
- somayloy 500 manufactured by Hoganas, Sweden, was used as the magnetic powder 70.
- Soma Ioy 500 is a magnetic powder having a phosphate insulating coating on a soft magnetic powder.
- the upper punch 61 When the magnetic powder 70 is filled, the upper punch 61 is lowered to compress the pressurized object in the mold between the lower punch 62 and the room temperature (see FIG. 6). The applied pressure was 9 ton / cm 2 . The density of the obtained core was 7.5 g / cm 3 .
- the upper punch 61 is pulled up, and the lower punch 62 is pushed up to remove the press body 80 from the mold 60.
- the obtained pressed body 80 is a cylindrical body having concave portions corresponding to the protrusions 61A and 62A of the upper and lower punches at the center of the upper and lower ends, and the magnetic powder is compressed.
- the molded core 10 and the resin mold body 50 are integrated.
- the mold resin 40 is removed from the obtained pressed body 80. Here, removal was performed by extracting mold resin 40 with a spatula. By removing the resin 40, the coil 20 is exposed as shown in FIG. By pulling out the exposed terminal of the coil 20, a motor coil can be obtained.
- FIG. 8 is a cross-sectional view of a press body according to the second embodiment
- FIG. 9 is a cross-sectional view of the obtained coil. Except for the configuration of the coil 20 used, the method of forming the resin mold body 50 and the pressed body 80 and the method of removing the mold resin 40 are the same as in the first embodiment. Focus on differences from the state.
- a coil 20 is prepared in which the terminal of the conductive wire is not wound spirally but is drawn to the outer peripheral side from the spirally wound evening.
- This coil is resin-molded as in the first embodiment.
- the terminal 21 A of the conductive wire is bent so as to fit within the inner diameter of the resin mold.
- a pressed body 80 is produced in the same manner as in the first embodiment.
- the obtained pressed body 80 had a columnar shape in which the core 10 and the resin molded body were integrated, and the wire terminal 21 A was drawn out and bent inside the resin molded body. It is in a state.
- a motor coil can be obtained as shown in FIG.
- the use of the coil in which the wire terminal is not wound in advance allows the wire terminal to be taken out immediately after the resin is removed from the press body, further improving the manufacturability.
- This embodiment is a method of the present invention in which resin can be easily removed from a molded body, and a terminal of a conductive wire can be easily pulled out.
- a resin mold body 8OA whose axial distance on the center side is smaller than axial distance on the outer peripheral side is used.
- the resin mold body 8OA having a small axial length over a width slightly larger than the conductor wire width of the coil 20 from the inner periphery of the resin mold body 8OA is used.
- the end surface of the resin mold body 8OA is formed in a stepped shape on the inner peripheral side and higher on the outer peripheral side. This step was set at 2.0 mm.
- the step size is used to correct a dimension that is excessively shrunk when a resin corresponding to the coil height is molded under pressure, and an optimum step size is set for each coil shape.
- Such a resin molded body 8OA can be easily obtained by changing the shape of the core of the resin mold in FIG.
- the core 31 of FIG. 2 which was simply a round bar is changed to a dumbbell-type core having a disk-shaped flange at both ends of the round bar.
- One of the flanges of the core is fixed to the bottom of the mold, and the other is detachably attached to the free end of the round bar.
- the resin is injected into the mold up to the upper surface of the other flange. After the resin is cured, the flange portion on the free end side is removed, and the mold filling is extracted to obtain the resin mold body 80A shown in FIG.
- the shrinkage ratio of the mold resin, magnetic powder, and conductive wire under pressure is almost the same, they all shrink in the same way during press molding.
- this shrinkage rate is "mold resin> magnetic
- the resin mold body is deformed before and after the press body is formed based on the difference in shrinkage.
- a coil is arranged on the outer peripheral side where the amount is large, and is compressed more than the inner peripheral side where the resin amount is relatively small.
- the shape of the resin mold body 50 after forming the pressed body is such that the axial distance on the outer peripheral side is smaller than the axial distance on the inner peripheral side, 20 has a shape protruding in the axial direction.
- the press body 80 including the resin mold body 50 having such a shape has a state in which the turns of the coil 20 at both ends are sunk into the core 10, so that it is difficult to remove the resin 40 and the coil 2 It may be difficult to pull out 0 terminals. This problem becomes more remarkable when using a coil in which a conductive wire is wound up to the terminal as in the first embodiment.
- the outer peripheral side of the resin mold body is formed high in advance, so that the height of the resin mold body after pressing is increased from the inner peripheral side. It can be made substantially uniform over the outer peripheral side. As a result, it is possible to easily remove the resin from the pressed body and easily draw out the terminal of the conductor.
- the method of forming the resin, magnetic powder or pressed body to be used is the same as in the first embodiment, and a description thereof will be omitted.
- the upper punch 61 and the lower punch 62 are arranged on the inner peripheral portions 61B, 62B on the inner peripheral side and the outer periphery of the inner peripheral portions 61B, 62B.
- Annular outer peripheral portions 61C and 62C are arranged on the inner peripheral portions 61B, 62B on the inner peripheral side and the outer periphery of the inner peripheral portions 61B, 62B.
- Annular outer peripheral portions 61C and 62C are arranged on the inner peripheral portions 61B, 62B on the inner peripheral side and the outer periphery of the inner peripheral portions 61B, 62B.
- Annular outer peripheral portions 61C and 62C Annular outer peripheral portions 61C and 62C.
- the cross-sectional shape of the combination of the inner peripheral portions 61B, 62B and the outer peripheral portions 61C, 62C is the same as the upper and lower punches used in the first embodiment, and the inner peripheral surface is the outer peripheral surface. It protrudes like
- the method of forming the resin mold body and the press body is the same as that of the first embodiment, and therefore the description is omitted.
- TSE38026 manufactured by GE Toshiba Silicone Co., Ltd. is used as the resin 40 forming the resin mold body.
- This product reacts with moisture in the air to cure into a rubber-like elastic body at room temperature, and easily adheres to metal'plastic.
- the penetration of the resin at 25 ° C. specified by JISK 2 235-5.4 is less than 1.
- a resin mold body 50 having an outer diameter of 29 mm is coaxially loaded into a mold 60 having an inner diameter of 30 mm, and the resin mold body 50 is also provided on the outer periphery of the resin mold body 50.
- the magnetic powder 70 was wrapped around.
- the obtained pressed body has a columnar shape whose entire circumference is covered with a compact of magnetic powder 70.
- the outer peripheral portion of the resin mold body in the press body has a very small thickness of the green compact and can be easily pierced and removed, and further, the resin inside can be removed.
- only the magnetic powder rubs with the mold during the production of the pressed body, so that the pressing and the removal of the pressed body can be easily performed. There was no crack in the core when removing the pressed body.
- FIG. 14A is an explanatory diagram showing a first pressurized state in this example
- FIG. 14B is an explanatory diagram showing a second pressurized state.
- the method of molding the resin mold body and the point of removing the resin after the molding of the pressed body are the same as those in the above-described embodiments, and therefore the description thereof is omitted.
- the upper punch 61 is arranged on the cylindrical inner peripheral portion 61B and the outer periphery of the inner peripheral portion. And an annular outer peripheral portion 61C.
- the inner peripheral portion 61B and the outer peripheral portion 61C can be pressurized independently.
- the surface of the lower punch 62 is formed of a cylindrical surface protruding toward the upper punch when the inside of the mold is viewed in a longitudinal section.
- one end surface of the obtained pressed body is also formed of a cylindrical surface, and when the pressed body is used as a motor coil for the stay, Is the surface that faces the mouth.
- the method shown in FIG. 15 is also suitable.
- the lower punch 62 also includes an inner peripheral portion 62B and an outer peripheral portion 62C, and is configured to be able to press each independently.
- the operation of the upper punch 61 is the same as the method shown in FIG. 14 in the first and second pressurizations, but the operation of the lower punch 62 is different. That is, the first pressurization is performed with the inner peripheral portion 6 2B of the lower punch 62 retracted from the outer peripheral portion 62C, and the second pressurization is performed on the inner peripheral portion 62 of the lower punch 62. It is performed so that the surfaces of B and the outer peripheral portion 62C are flush with each other.
- the filling height of the magnetic powder in the inner peripheral portion on the lower punch side during the first pressurization can be increased.
- the inner peripheral portion 62B of the lower punch is further pressurized by the second pressurization, it is possible to obtain a sufficient pressurizing distance for the magnetic powder disposed in the hollow hole of the resin mold body, A core having a high packing density can be formed.
- FIG. a partial cross-sectional view of an inner rotor type motor is shown.
- the unevenness provided on one end surface of the core 10 is fitted into the inner peripheral surface of the ring member 110, so that the connection between the core 10 and the ring member 110 is easily and reliably performed.
- the other end face of the core 10 is formed of a cylindrical surface, and faces the rotor 130 (indicated by a broken line) disposed on the inner periphery of the stay 100.
- the circular arc of the cylindrical surface and the outer circular arc of the rotor 130 are concentrically arranged, so that the distance between the stay 100 and the rotor 130 can be kept uniform.
- motor coils 120 Although only two motor coils 120 are shown in FIG. 16 for convenience of explanation, in practice, a large number of motor coils 120 are arranged at equal intervals on the inner circumference of the ring member. Are arranged.
- the motor coil according to the present invention can also be used for a motor with a single rotor type.
- the inner side is the stay 100 and the outer side is the rotor 130.
- a plurality of motor coils 120 are radially fixed to the shaft 100 O A of the stay 100.
- Each motor coil 120 is composed of a core 10 and a coil 20 wound around the core 10 as in the motor of FIG.
- FIG. 18 shows a partial cross-sectional view of the station.
- the motor coil constituting a part of the stay is composed of a core 10 formed by compressing magnetic powder and a conductor 21 compressed together with the magnetic powder.
- the core 10 has a body 12 having a rectangular cross section, and one end of the body 12, that is, an arc-shaped outer flange 11 A formed on the outer periphery of the body when viewed from the rotating shaft of the motor. It comprises the other end of the body 11, that is, an arc-shaped inner circumferential flange 11 B formed on the inner circumferential side of the body.
- the body 11 and the inner flange 11 B constitute one tooth, and the diameter of the body 12, the outer flange 11 A, the inner flange 11 B, and the outer flange 11 A
- the area surrounded by the direction extension line is the slot in which the conductor is stored.
- a plurality of such motor coils are By arranging and integrating, a stay is formed.
- a conductor 21 is wound around the body 12 in an edgewise manner.
- the conductor 21 has an insulating coating on the surface of a metal wire (copper wire) having a substantially rectangular cross section.
- conductive wires 21 having a constant thickness and a different width were used.
- a conductor may be used which has a larger thickness but a smaller width on the inner peripheral side and a smaller thickness but a larger width on the outer peripheral side. With this configuration, the conductors are arranged so that they are not laminated in the circumferential direction (in the depth direction of the slot), and the cross-sectional area is substantially constant and the electric resistance is constant.
- a defined coil can be formed.
- Thickness of insulation coating on metal wire 0.12 mm
- Thickness of wax when forming resin mold 0.2 mm
- the space factor of the above-mentioned motor coil was 76%, and even a motor coil having a different slot depth in the radial direction of the motor could secure a space factor of 75% or more.
- a space factor of 75% or more could be secured even in a motor that forms a stay by combining multiple motor coils.
- the space factor of a comparative example in which a 0.96 mm diameter conductor (0.9 mm conductor diameter) was wound around a core made of laminated steel sheets and having the same shape and dimensions was also determined. As a result, the space factor of the comparative example was only about 60%. (Eighth embodiment)
- FIG. 19 shows the cross section.
- This electromagnetic member includes a core 10 and a conductive wire 21 wound around the core 10.
- the core 10 includes a round bar-shaped body 12 and a disc-shaped flange 11 integrated with both ends of the body 12.
- each flange 11 has the same diameter, and as a result, the slot surrounded by the trunk 12 and the two flanges 11 is configured to have the same depth in the trunk axial direction.
- a conductor 21 is wound around the body 12 of the core in an edgewise winding.
- the conductor 21 has an insulating coating on the surface of a metal wire (copper wire) having a substantially rectangular cross section.
- all the conductors 21 having a constant thickness and different widths were used.
- such an electromagnetic member can also be obtained through coil preparation, formation of a resin mold body, molding of a press body, and removal of mold resin.
- Thickness of insulation coating on metal wire 0.12mm
- Wax thickness when forming resin mold 0.2 mm
- the space factor of the electromagnetic member was 85%, and the space factor of 75% or more could be secured by the electromagnetic member having the slots having the same depth in the axial direction of the core.
- the space factor of a comparative example in which a 0.96 mm diameter conductor (0.9 mm conductor diameter) was wound around a core composed of laminated steel sheets and having the same shape and dimensions was also determined. As a result, the space factor of the comparative example was only about 65%.
- This electromagnetic member also includes a pressure-dividing core (core 10) and a coil around which a conductor 21 is wound.
- the method of manufacturing this electromagnetic member is also performed according to the first embodiment.
- a dust core a pipe-shaped body 12 and both ends of the body The one having the formed annular flange 11 was used.
- the conductor 21 has a substantially rectangular cross section which is edgewise wound around the outer periphery of the body 12 between the two flanges 11.
- the pipe-shaped body 12 may be formed by using a core so that the magnetic powder is disposed in a hollow state.
- the magnet 140 is inserted into the interior of the magnetic core.
- the conducting wire 21 when the conducting wire 21 is energized, a magnetic field is generated in the axial direction of the coil, and the magnet 140 can be operated in the axial direction. Therefore, it can be used as a solenoid.
- the operation of the magnet 140 in the axial direction can be used for opening and closing a switch and opening and closing a solenoid valve (electromagnetic valve).
- This electromagnetic member also includes a pressure-dividing core (core 10) and a coil around which a conductor 21 is wound.
- the method of manufacturing this electromagnetic member is also performed according to the first embodiment.
- a powder magnetic core having a rod-shaped body 12 and disk-shaped flanges 11 formed at both ends of the body 12 is used.
- the conductor 21 used had an approximately rectangular cross section, which was edgewise wound around the outer periphery of the body 12 between the two flanges.
- a magnet 150 is arranged to face one end of the pressure-dividing core.
- the manufacturing method of the present invention can be used in the field of manufacturing an electromagnetic member including a dust core and a coil. Further, the electromagnetic component of the present invention can be used in various fields to which the action of an electromagnet is applied, such as a motor coil, a solenoid, an electromagnetic valve, and an electromagnetic switch.
- the electromagnetic member of the present invention by molding by pressing the coil together with the magnetic powder, The gap in the slot can be minimized, and a high space factor can be realized to form a high-power electromagnet. Therefore, it is possible to reduce the size and output of the motor.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Abstract
Description
Claims
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JP2003-155920 | 2003-05-30 | ||
JP2003155920 | 2003-05-30 | ||
JP2004-058198 | 2004-03-02 | ||
JP2004058198A JP2005020987A (ja) | 2003-05-30 | 2004-03-02 | 電磁部材の製造方法および電磁部材 |
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WO2004107538A1 true WO2004107538A1 (ja) | 2004-12-09 |
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JP4500649B2 (ja) * | 2004-11-02 | 2010-07-14 | 住友電気工業株式会社 | 電磁部材の製造方法 |
JP2007074860A (ja) * | 2005-09-08 | 2007-03-22 | Toyota Motor Corp | コアの製造方法 |
JP5563634B2 (ja) * | 2006-04-28 | 2014-07-30 | 三菱電線工業株式会社 | ステータ構造 |
JP2011199098A (ja) * | 2010-03-23 | 2011-10-06 | Yoshizumi Fukui | 巻き線一体型モールドコイルの巻き線方法 |
JP2012253922A (ja) | 2011-06-03 | 2012-12-20 | Seiko Epson Corp | コアレス電気機械装置、移動体、ロボット及びコアレス電気機械装置の製造方法 |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS4860008A (ja) * | 1971-12-02 | 1973-08-23 | ||
JP2000040626A (ja) * | 1998-07-24 | 2000-02-08 | Matsushita Electric Ind Co Ltd | チョークコイル |
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2004
- 2004-03-02 JP JP2004058198A patent/JP2005020987A/ja active Pending
- 2004-05-17 WO PCT/JP2004/007011 patent/WO2004107538A1/ja active Application Filing
Patent Citations (2)
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JPS4860008A (ja) * | 1971-12-02 | 1973-08-23 | ||
JP2000040626A (ja) * | 1998-07-24 | 2000-02-08 | Matsushita Electric Ind Co Ltd | チョークコイル |
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