Annular laminated core material and method for manufacturing the same

Abstract

Provided are an annular laminated core material and a manufacturing method thereof that eliminates iron loss caused by eddy currents and the like generated from the joints of the core materials and does not require additional steps. The annular laminated core material (1) comprises: a core body (4) formed into a cylindrical shape by laminating a plurality of annular core materials, wherein a groove extending in the axial direction is formed on the inner peripheral surface inward in the radial direction or the outer peripheral surface inward in the radial direction; a resin molded body (2) integrally formed with a pair of main body parts (2a) formed in a manner covering at least a portion of the axial end surfaces of the core body (4) and a connecting part (2b) connecting the pair of main body parts (2a); and an insulating sheet (6) disposed on the inner surface of the groove; the axial ends of the insulating sheet (6) are respectively in contact with the main body part (2a) of the resin molded body (2).

Description

Technical Field

[0001] The present invention relates to an annular laminated core material and a method for manufacturing the annular laminated core material. Background Art

[0002] In the past, it has been known that there are annular stacked core materials such as motor cores, which are formed by combining a predetermined number of annular core materials punched out from a strip-shaped thin plate in a stacked state. As a method for manufacturing annular stacked core materials, for example, an in-mold automatic stacking method is known. In the in-mold automatic stacking method, first, while the strip-shaped thin plate is intermittently transferred in a forward-feeding metal mold device, the core material thin plate portion of the strip-shaped thin plate is sequentially subjected to the desired die punching processing. Next, the core material thin plate portion is punched out with an outer shape punching punch, separated from the strip-shaped thin plate and punched out into the mold in sequence. Then, each of the punched out core materials is combined in a stacked state with a predetermined number of pieces each time using a caulking connection mechanism that is pre-set on the core material as a kind of temporary fixing mechanism.

[0003] As a general caulking and joining mechanism in the in-mold automatic lamination method, for example, a structure is adopted in which a cut-and-raised portion is pre-arranged on each core material as in Patent Document 1 (Japanese Patent Publication No. 58-116033), or a punched-out protrusion (pin) is provided as in Patent Document 2 (Japanese Patent Publication No. 49-37103), and the upper and lower adjacent core materials are caulked and joined by the cut-and-raised portion or the punched-out protrusion in the stacked state.

[0004] In addition, a laminated core material in which each core material is bonded together by, for example, an adhesive or a laser beam is also known.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 58-116033

[0008] Patent document 2: Japanese Patent Application Laid-Open No. 49-37103. Summary of the invention

[0009] Problems to be solved by the invention

[0010] However, in the above-mentioned caulking joint mechanism, since the joint portion formed by the cut-and-raised portion, the punched-out protrusion, etc. is also retained as it is when assembled into a motor, there is a problem that eddy currents etc. are generated in the caulking joint portion, resulting in a drop in efficiency of several percentage points due to iron loss.

[0011] Furthermore, in the method of bonding using an adhesive material or a laser beam, an additional step of fitting the resin molded body to the laminated core material is required after the adhesive application or laser beam irradiation step in order to ensure electrical insulation from the winding.

[0012] Therefore, an object of the present invention is to provide an annular laminated core material and a method for producing the same which eliminates iron loss caused by eddy currents etc. generated from the joining portions of the core materials and does not require an additional step.

[0013] Means used to solve problems

[0014] The present invention is an annular stacked core material, characterized in that it comprises: a core body, which is formed into a cylindrical shape by stacking multiple annular core materials, and a groove portion extending in the axial direction is formed on the inner circumferential surface on the inner side of the radial direction or the outer circumferential surface on the outer side of the radial direction; a resin molded body, which is integrally formed with a pair of main body portions formed in a manner of covering at least a portion of the axial end surfaces of the core body and a connecting portion connecting the pair of main body portions; and an insulating sheet, which is arranged on the inner surface of the groove portion; the axial end portions of the insulating sheet are respectively in contact with the main body portion of the resin molded body.

[0015] According to the present invention having the above structure, since the pair of main body parts of the resin molded body are integrated by the connecting part, and further, the insulating sheet and the resin molded body are connected by abutting, the laminated core materials can be integrated without temporary fixation by caulking, bonding, etc. Thus, it is not necessary to provide a caulking joint part for caulking on the core material, so that iron loss can be suppressed, and additional processes such as application of adhesive and laser beam are not required.

[0016] In the present invention, preferably, a through hole extending across both end surfaces in the axial direction is formed in the core body; and the connecting portion passes through the through hole of the core body to connect the pair of main body portions.

[0017] According to the present invention having the above configuration, when the resin molded body is molded, the molten resin passes through the through hole and is filled into the space corresponding to the pair of main body parts and the connecting part, so that the main body part and the connecting part can be integrated.

[0018] In the present invention, preferably, a groove extending between both end surfaces in the axial direction is formed on the inner circumferential surface or the outer circumferential surface of the core body; and the connecting portion passes through the groove of the core body to connect the pair of main body portions.

[0019] According to the present invention having the above configuration, when the resin molded body is molded, the molten resin passes through the peripheral surface groove and is filled into the space corresponding to the pair of main body parts and the connecting part, so that the main body part and the connecting part can be integrated.

[0020] In the present invention, it is preferred that both axial surfaces of the annular core material are flat surfaces, and that the flat surfaces of each core material and the adjacent core material are in direct contact with each other.

[0021] According to the present invention having the above configuration, iron loss can be further suppressed.

[0022] In the present invention, it is preferable that the insulating sheet and the resin molded body are connected without using an adhesive.

[0023] According to the present invention having the above configuration, the annular laminated core material can be manufactured without performing an additional step such as bonding.

[0024] In the present invention, it is preferable that the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5 mm or more.

[0025] According to the present invention having the above structure, since the axial length of the contact portion between the insulating sheet and the resin molded body is greater than 0.5 mm, when the linear segmented conductor is arranged in the groove portion of the annular laminated core material and bent, there is no deviation between the core materials and the load acting during bending can be withstood.

[0026] In the present invention, it is preferable that the insulating sheet and the resin molded body be connected by impregnating a resin constituting the resin molded body into a surface of the insulating sheet in contact with the resin molded body.

[0027] According to the present invention having the above configuration, the insulating sheet and the resin molded body can be more firmly connected.

[0028] In the present invention, it is preferred that the resin molded body is formed using a polymer having an amide bond, and the surface of the insulating sheet in contact with the resin molded body is composed of the polymer having an amide bond.

[0029] According to the present invention having the above configuration, the polymer and the insulating sheet are entangled with each other at a molecular level, and the insulating sheet and the resin molded body can be more firmly connected.

[0030] In the present invention, it is preferred that the resin molded body is formed using a polymer having an amide bond, and the surface of the insulating sheet in contact with the resin molded body is composed of aramid paper formed of aramid fibrids and aramid short fibers.

[0031] According to the present invention having the above configuration, the polymer and the insulating sheet are entangled with each other at a molecular level, and the insulating sheet and the resin molded body can be more firmly connected.

[0032] The motor of the present invention uses a stator in which windings are wound around the above-mentioned annular laminated core material.

[0033] According to the motor having the above structure, the above-mentioned effects are achieved.

[0034] The motor generator of the present invention uses a stator in which windings are wound around the above-mentioned annular laminated core material.

[0035] According to the motor generator having the above-described structure, the above-described effects are achieved.

[0036] The generator of the present invention uses a stator in which windings are wound around an annular laminated core material.

[0037] According to the generator having the above structure, the above-mentioned effects are achieved.

[0038] The present invention is a method for manufacturing an annular stacked core material, characterized in that it includes: a configuration step, in which a core body formed into a cylindrical shape by stacking a plurality of annular core blocks and having an axially extending groove formed on the inner circumferential surface inward in the radial direction or the outer circumferential surface outward in the radial direction is configured in a forming mold in such a manner that an insulating sheet is configured in the groove; and a resin molding step, in which resin is injected into the forming mold to integrally mold a resin molded body including a pair of main body portions formed in such a manner as to cover at least a portion of the axial end surfaces of the core body and a connecting portion connecting the pair of main body portions.

[0039] According to the present invention having the above configuration, the main body portion and the connecting portion can be formed integrally, and the laminated core materials can be integrated without temporary fixation such as caulking or bonding.

[0040] Effects of the Invention

[0041] According to the present invention, it is possible to provide an annular laminated core material and a method for manufacturing the same, which can eliminate iron loss caused by eddy currents or the like generated from the joining portions of the core materials and do not require an additional step. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 It is a schematic perspective view showing the structure of an annular laminated core material according to one embodiment of the present invention.

[0043] Figure 2 Yes means Figure 1 A perspective view of the core body of the annular laminated core material shown.

[0044] Figure 3 It means composition Figure 2 A perspective view of the core material of the core body shown.

[0045] Figure 4 Yes means Figure 1 A perspective view of an insulating sheet of an annular laminated core material is shown.

[0046] Figure 5 This is a perspective view showing a core body of an annular laminated core material according to another embodiment. DETAILED DESCRIPTION

[0047] Below, while referring to the attached Figure 1 Although the annular laminated core material and the manufacturing method thereof according to one embodiment of the present invention are described, the present invention is not particularly limited thereto.

[0048] (Ring-shaped laminated core)

[0049] Figure 1 1 is a schematic perspective view showing the structure of an annular laminated core material according to one embodiment of the present invention. Figure 1 As shown, the annular laminated core material is cylindrical, has a shape in which a plurality of arms extending radially inward are formed on the inner circumference, and a groove is formed between the arms. The annular laminated core material 1 preferably has an axial length of 0.5 mm or more of the contact portion between the insulating sheet and the aforementioned resin molded body. The annular laminated core material of this embodiment is used as a stator of a motor, a motor generator, or a generator, for example, by winding a winding around each arm.

[0050] (core body)

[0051] Figure 2 Yes means Figure 1 A three-dimensional view of the core body of the annular laminated core material shown in FIG. Figure 2 As shown in FIG. 1 , the core body 4 is a cylindrical component formed by stacking a plurality of annular core materials 8, and a plurality of grooves opening on the inner circumference are formed in an axially extending manner. In addition, the boundaries of the stacked core materials 8 forming the core body 4 are not necessarily visually recognizable, but are Figure 1 , Figure 2 , Figure 5 A diagram is provided for illustration purposes.

[0052] Figure 3 It means composition Figure 2 A three-dimensional view of the core material of the core body shown. Figure 3 As shown, the core material 8 is a plate-shaped component whose two axial surfaces are formed into flat surfaces, and has a roughly H-shaped portion whose radial outer peripheral side is connected to form a circular cross-section. The core material 8 has an annular ring portion 8a, a plurality of arm portions 8b extending from the annular portion 8a toward the inner side in the radial direction, and a protrusion 8c extending from the front end of the arm portion 8b to both sides in the circumferential direction. Between each arm portion 8b, a roughly trapezoidal groove portion 8d surrounded by adjacent arm portions 8b, annular portions 8a and protrusions 8c is formed. In addition, on the outer peripheral surface of the annular portion 8a, six peripheral groove portions 8e are formed at equal angles in the circumferential direction. As the material of the core material 8, metals such as silicon steel plates can be used.

[0053] like Figure 2As shown, the core body 4 is stacked with multiple core materials 8 without a temporary fixing mechanism. That is, no cut-raised portion or punched protrusion for caulking and joining is formed on the surface of each core material 8. In addition, the flat surfaces of the core materials 8 adjacent to each other in the axial direction are directly in close contact with each other, and there is no adhesive between the core materials 8, and there is no welding mark caused by the laser beam. The core body 4 has the same cross-sectional shape throughout the entire axial length, and has a cylindrical cylindrical portion 4a, a plurality of arm portions 4b extending radially inward from the cylindrical portion 4a, and a protrusion 4c extending from the front end of the arm portion 4b to both sides of the circumference. The axial thickness of the core body 4 is equal to the thickness obtained by removing a pair of main body portions 2a of the resin molded body 2 from the axial direction of the annular stacked core material 1. The cylindrical portion 4a of the core body 4 is formed by laminating the annular portions 8a of the core material 8, the arm portion 4b of the core body 4 is formed by laminating the arm portions 8b of the core material 8, and the protruding portion 4c of the core body 4 is formed by laminating the protruding portions 8c of the core material 8.

[0054] Between each arm portion 4b, there is formed a roughly trapezoidal groove portion 4d which is surrounded by the adjacent arm portions 4b, the cylindrical portion 4a and the protruding portion 4c and extends in the axial direction. The groove portion 4d of the core body 4 is formed by the groove portion 8d of the stacked core material 8 being continuous in the axial direction. In addition, on the outer peripheral surface of the cylindrical portion 4a, there are formed 6 peripheral groove portions 4e which are formed at equal angles in the circumferential direction and extend in the axial direction. The peripheral groove portion 4e of the core body 4 is composed of the peripheral groove portions 8e of a plurality of core materials 8 stacked together.

[0055] In addition, in the present embodiment, the outer peripheral groove portion 4e is formed on the outer peripheral surface of the core body 4, and the connecting portion 2b is formed in the outer peripheral groove portion 4e, but it is not limited to this. For example, Figure 5 As shown, a through hole 104b is formed in the core body 104 so as to penetrate in the axial direction. In this case, the outer peripheral groove portion 4e is not required. In the case of using a core body 104 of such a structure, a connecting portion is formed in the through hole 104b, and the main body portions 2a can be connected to each other through the through hole 104b. In the case of forming such a through hole, it is preferably formed in the cylindrical portion 104a. In addition, in the present embodiment, the groove portion 4d is formed on the inner circumferential surface of the core body 4 in the radial direction, but the groove portion may also be formed on the outer circumferential surface of the core body 4 in the radial direction. In this case, an inner circumferential groove portion extending in the axial direction may be formed on the inner circumferential surface in the radial direction instead of the outer peripheral groove portion 4e, and a connecting portion of a resin molded body may be formed in the inner circumferential groove portion, or a through hole may be formed in the cylindrical portion, and a connecting portion of a resin molded body may be formed in the through hole.

[0056] (Insulation sheet)

[0057] Figure 4 Yes means Figure 1 A three-dimensional view of an insulating sheet of an annular laminated core material is shown. Figure 4 As shown, the insulating sheet 6 has the same substantially U-shaped cross-sectional shape in the axial direction, and has the same axial length as the axial length of the annular laminated core material 1. The insulating sheet 6 is formed by bending a long strip-shaped sheet, and has a central portion 6a, a left bent portion 6b, and a right bent portion 6c. The central portion 6a has a width equal to the width of the bottom of the groove portion 4d of the core body 4. The left bent portion 6b and the right bent portion 6c have a width equal to the width of the surface extending in the radial direction of the groove portion 4d of the core body 4. The radial inner end edges of the left bent portion 6b and the right bent portion 6c face each other and are bent, forming front end bent portions 6d and 6e.

[0058] like Figure 1 As shown, the insulating sheet 6 is arranged on the inner surface of each groove portion 4d of the core body 4. The central portion 6a of the insulating sheet 6 is arranged on the bottom (radially outer surface) of the groove portion 4d, and the left bent portion 6b and the right bent portion 6c are arranged on the surface of the groove portion 4d extending in the radial direction. The front end bent portions 6d and 6e are arranged on the radially outer surface of the protruding portion 8c. In addition, the insulating sheet 6 has both axial ends that protrude outward from the axial end surfaces of the core body 4 by a length equal to the thickness of the main body 2a of the resin molded body 2. The insulating sheet 6 is provided to insulate the winding from the inner circumferential surface of the groove portion 4d of the core body 4 when the motor winding is wound on the arm portion 4b of the core body 4.

[0059] In the present embodiment, as an insulating sheet, insulating paper, nonwoven fabric, film or a composite thereof, or a laminated sheet can be used. For example, insulating paper such as aramid paper composed of aramid fibrids and aramid staple fibers, plastic films such as polyphenylene sulfide film, polyimide film, polyetheretherketone film, polyethylene terephthalate film, and polyethylene naphthalate film, and laminated sheets thereof can be cited. In particular, it is preferred that at least one side of the laminated sheet contain aramid paper composed of aramid fibrids and aramid staple fibers. Here, as an adhesive used for laminating aramid paper, an appropriate adhesive commonly used in this technical field can be used, for example, epoxy, acrylic, phenolic, polyurethane, silicone, polyester, amide and the like adhesives can be cited, but are not limited to these. In addition, when the above-mentioned films are laminated with the aid of an adhesive, the films are usually stretched in many cases, and when a motor bobbin is manufactured by the melt injection molding method of the present invention described later, deformation of the laminated sheet due to shrinkage is likely to occur. Therefore, it is preferable to use a laminated sheet in which a film made by melting a polymer film is laminated with the above-mentioned aramid paper and heated and pressurized to melt-impregnate the aramid paper with the polymer, a laminated sheet in which a polymer papermaking product (web) is laminated or laminated with aramid paper and heated and pressurized to melt-impregnate the aramid paper with the resin, a laminated sheet in which a resin is melt-extruded onto the aramid paper and then heat-fused, etc.

[0060] The number of plies of the above-mentioned laminate can be suitably selected according to the purposes and purpose of laminate. For example, the aromatic polyamide resin produced by the method of hot-melt bonding and the epoxy-containing phenoxy resin having an epoxy group in the molecule can be recorded in Japanese Unexamined Patent Publication No. 2006-321183, which is composed of 2 layers of laminates, aramid paper, 3 layers of laminates of polymer and aramid paper, aramid paper, aramid paper, and aramid paper, but is not limited to these.

[0061] In the case where the insulating sheet is not sufficiently adhered to the resin molded body described later and peels off during winding, it is preferred to perform surface treatment on the surface of the insulating sheet that contacts the resin molded body to improve adhesion. The so-called surface treatment here includes plasma surface treatment, corona surface treatment, surface treatment by liquid immersion, etc. By implementing such surface treatments, the surface energy of the surface of the insulating paper is increased and the interfacial energy with the resin molded body is reduced, resulting in improved adhesion with the resin molded body. Because of the simplicity of treatment, plasma surface treatment is particularly preferred.

[0062] The thickness of the insulating sheet can be appropriately selected according to the use and purpose of the insulating sheet, and any thickness can be selected as long as there is no problem in processing such as bending and winding. Generally, from the viewpoint of processing, a thickness in the range of 50 μm to 1000 μm (particularly preferably 70 to 200 μm) is preferred, but it is not limited thereto.

[0063] (aramid)

[0064] In the present embodiment, the so-called aromatic polyamide refers to a linear polymer compound (aromatic polyamide) obtained by directly bonding more than 60% of the amide bonds to the aromatic ring. As such aromatic polyamides, for example, poly(m-phenylene isophthalamide) and its copolymers, poly(p-phenylene terephthalamide) and its copolymers, poly(p-phenylene)-co-(3,4'-diphenyl ether) terephthalamide, etc. can be cited. These aromatic polyamides can be obtained as commercial products by industrial production, such as the previously known interfacial polymerization method and solution polymerization method using isophthalic chloride and m-phenylenediamine, but are not limited to this. Among these aromatic polyamides, poly(m-phenylene isophthalamide) is preferably used in terms of having good molding processability, thermal adhesion, flame retardancy, heat resistance and other characteristics.

[0065] (aramid fibrids)

[0066] In the present embodiment, the aramid fibrids are film-like aramid particles having papermaking properties, and are also called aramid pulp (see Japanese Patent Publication Nos. 35-11851 and 37-5732, etc.).

[0067] It is widely known that aramid fibrids are subjected to dissociation and beating treatments as common wood pulp and used as papermaking raw materials, and the so-called beating treatment is applied for the purpose of maintaining a quality suitable for papermaking. The beating treatment can be carried out by a disc refiner, a beater, or other papermaking raw material processing equipment that has a mechanical cutting effect. During this operation, the morphological changes of the fibrids can be monitored by the freeness test method (freeness) specified in Japanese Industrial Standard P8121. In the present embodiment, the freeness of the aramid fibrids after the beating treatment is preferably at 10 cm 3 ~300cm 3 (Canadian freeness (JISP8121)). In the case of a fibrid with a water freeness greater than this range, the strength of the aramid paper formed thereafter may decrease. On the other hand, if a fiber with a water freeness greater than 10 cm is to be obtained, 3The smaller the filterability, the lower the efficiency of the mechanical power input, and the lower the processing volume per unit time. Furthermore, the excessive refinement of the fibrids easily leads to a decrease in the so-called binder function. 3 A small water filterability does not provide any significant advantages.

[0068] (aramid staple fiber)

[0069] Aramid staple fibers are obtained by cutting fibers made of aramid. Examples of such fibers include fibers available under trade names such as Teijinconex (registered trademark) from Teijin Co., Ltd. and Nomex (registered trademark) from DuPont, but are not limited to these.

[0070] The length of the aramid short fibers can be generally selected from a range of 1 mm or more and less than 50 mm, preferably 2 to 10 mm. If the length of the short fibers is less than 1 mm, the mechanical properties of the sheet material decrease. On the other hand, if the length is more than 50 mm, "entanglement" or "bundling" is likely to occur during the manufacture of aramid paper by a wet process, which is likely to cause defects.

[0071] (aramid paper)

[0072] In the present embodiment, the aramid paper is a sheet mainly composed of the above-mentioned aramid fibrids and aramid staple fibers, and generally has a thickness in the range of 20 μm to 1000 μm, preferably 25 to 200 μm. Furthermore, the aramid paper generally has a thickness of 10 g / m 2 ~1000g / m 2 , preferably 15 to 200 g / m 2 Here, the mixing ratio of the aramid fibrids and the aramid staple fibers may be any, but it is preferred that the ratio (mass ratio) of the aramid fibrids / aramid staple fibers be 1 / 9 to 9 / 1, more preferably 2 / 8 to 8 / 2, and particularly 3 / 7 to 7 / 3, but it is not limited to this range.

[0073] Aramid paper is generally produced by a method of mixing the aforementioned aramid fibrids with aramid staple fibers and then forming them into sheets. Specifically, for example, a method of dry-mixing the aforementioned aramid fibrids and aramid staple fibers and then forming a sheet using an air flow, a method of dispersing and mixing the aramid fibrids and aramid staple fibers in a liquid medium, spraying the aramid fibrids and aramid staple fibers onto a liquid-permeable support such as a net or a belt to form a sheet, and then removing the liquid to dry the sheet, etc., but among these, the so-called wet papermaking method using water as a medium is preferably selected.

[0074] In the wet papermaking method, generally, a single or mixed aqueous slurry containing at least aramid fibrids and aramid staple fibers is fed to a papermaking machine and dispersed, and then dehydrated, squeezed, and dried to be wound into sheets. As papermaking machines, fourdrinier papermaking machines, cylinder papermaking machines, inclined papermaking machines, and combination papermaking machines of these are used. In the case of manufacturing with a combination papermaking machine, a composite sheet consisting of multiple paper layers can be obtained by forming and combining slurries with different mixing ratios. During papermaking, additives such as dispersibility improvers, defoamers, and paper strength enhancers can be used as needed.

[0075] By hot pressing the aramid paper obtained as described above between a pair of rollers at high temperature and high pressure, the density and mechanical strength can be increased. The conditions for hot pressing can be, for example, in the case of using metal rollers, a temperature of 100 to 400° C. and a linear pressure of 50 to 400 kg / cm, but are not limited thereto. A plurality of aramid papers may be stacked during hot pressing. The hot pressing process may be performed multiple times in any order.

[0076] (Resin molded body)

[0077] The resin molded body 2 includes a pair of main body portions 2a formed along the axial end faces of the core body 4 and six connecting portions 2b that connect the edges of the outer peripheral portions of the pair of main body portions 2a to each other. The main body portion 2a has a thickness equivalent to the distance between the axial end face of the core body 4 and the end of the insulating sheet 6, and has the same cross-sectional shape as the core body 4 (core material 8). That is, the main body portion 2a has an annular ring portion 2a1, a plurality of arm portions 2a2 extending radially inward from the annular portion 2a1, and a protrusion 2a3 extending from the front end of the arm portion 2a2 to both sides in the circumferential direction. Between each arm portion 2a2, a substantially trapezoidal groove portion 2a4 surrounded by adjacent arm portions 2a2, the annular portion 2a1 and the protrusion 2a3 is formed. The radial outer peripheral surface of the central portion 6a of the insulating sheet 6 abuts against the bottom of the groove portion 2a4, the left bent portion 6b and the right bent portion 6c of the insulating sheet 6 abut against the side surface of the arm portion 2a2, and the front end curved portions 6d and 6e of the insulating sheet 6 abut against the radial outer peripheral surface of the protruding portion 2a3. The main body 2a of the resin molded body 2 is provided to insulate the winding wire from the upper surface of the arm portion 4b of the core body 4 when the winding wire of the motor is wound on the arm portion 4b of the core body 4. In addition, in the present embodiment, the main body 2a is formed in a manner that covers the entire axial end surface of the core body 4, but it is sufficient as long as it abuts against at least the axial end portion of the insulating sheet 6 and covers the arm portion 4b of the core body 4 where the winding wire of the motor is arranged. The resin constituting the resin molded body 2 is impregnated into the surface of the insulating sheet 6 that abuts against the resin molded body 2, thereby connecting the resin molded body 2 and the insulating sheet 6. In the present embodiment, the outer peripheral surfaces of the portions of both end portions of the insulating sheet 6 that protrude from the core body 4 are in contact with the resin molded body 2 .

[0078] The connecting portion 2b is formed in the outer peripheral groove portion 4e of the core body 4, and connects the pair of body portions 2a through the outer peripheral groove portion 4e. The connecting portions 2b are provided on the outer peripheral surface of the core body 4 at equal angular intervals.

[0079] In the present embodiment, as the material constituting the resin molded body 2, for example, PPS resin (polyphenylene sulfide resin), acrylonitrile-butadiene-styrene copolymer resin, polyimide resin, polyethylene terephthalate resin, polyacetal resin, polyamide 6, polyamide 66, polyamide 612, polyamide 11, polyamide 12, copolymerized polyamide, polyamide MXD6, polyamide 46, methoxymethylated polyamide, semi-aromatic polyamide and other polymers, or polymers containing polyamide resin compositions as shown in Japanese Patent Application Laid-Open No. 2006-321951, or mixtures thereof, or mixtures of the above polymers with inorganic substances such as glass fibers can be used. The resin molded body 2 is manufactured by a melt injection molding method in which the above materials are injected into a desired metal mold in a molten state and removed from the mold after cooling. In particular, a molded body of a mixture of semi-aromatic polyamide and glass fibers is preferred because it has high heat resistance and good adhesion to a laminated sheet containing aramid paper. Examples of such a mixture include Zytel (registered trademark) HTN51G and 52G from DuPont, but the mixture is not limited to these.

[0080] By forming a winding positioning groove in the portion of the resin molded body 2 that contacts the winding, the position of the winding is stabilized, and the winding can be wound evenly with high accuracy, which has the effect of improving the efficiency of the motor generator, etc., and is therefore preferred.

[0081] (Method for manufacturing annular laminated core material)

[0082] The annular laminated core material 1 of the present embodiment can be produced as follows.

[0083] That is, first, the strip-shaped thin plate material is subjected to the desired die punching process, and then the core material is cut off by punching with a profile punch. Then, the punched core material 8 is stacked in the cylindrical cavity of the metal mold for injection molding to form the core body 4. In addition, no cut-raised portion or punched protrusion for caulking fixation is formed on the core material 8, and the core material 8 is not bonded by means of an adhesive, a laser beam, etc., and there is no trace of a temporary fixing mechanism on each core material 8. Next, an insulating sheet 6 is arranged in the groove portion 4d of the core body 4. At this time, the insulating sheet 6 is arranged in a manner that the two ends of the insulating sheet 6 protrude from the two end faces of the core body 4 by a length equivalent to the thickness of the main body 2a of the resin molded body 2 (arrangement step). At this time, the distance between the axial end faces of the core body 4 and the inner surface of the cavity becomes the same distance as the protruding length of the insulating sheet 6, and the inner circumferential surface and the outer circumferential surface of the core body 4 are arranged in a manner that abuts against the inner surface of the cavity. Thus, a space equivalent to the main body 2a of the resin molded body 2 is formed between the two end faces of the core body 4 and the inner surface of the cavity, and a space equivalent to the connecting portion 2b extending in the axial direction is formed between the outer peripheral groove portion 4e of the core body 4 and the inner peripheral surface of the cavity. In addition, in the present embodiment, the insulating sheet 6 is installed after the core material 8 is stacked in the cavity to form the core body 4, but it is not limited to this, and the core body 4 in a state where the insulating sheet 6 is installed can also be arranged in the cavity.

[0084] Next, the resin constituting the resin molded body 2 is injected into the cavity to fill the space between the core body 4 and the inner surface of the cavity. Then, the resin is hardened to form a resin molded body 2 in which the main body 2a and the connecting portion 2b are integrated (resin molding step). Through the above steps, the core material 8 constituting the core body 4 that is stacked is fixed by the resin molded body 2 and the insulating sheet 6, and an integrated annular stacked core material 1 can be manufactured.

[0085] The manufacturing method of this embodiment is to stack a plurality of core materials 8 in a cavity for injection molding in a state where there is no trace of a temporary fixing mechanism between the core materials 8, and to arrange the insulating sheet 6 in advance in such a manner that at least a portion thereof contacts a portion corresponding to the resin molded body 2, so that the molten polymer forming the resin molded body 2 can be impregnated into at least a portion of the surface of the insulating sheet 6. By making the annular stacked core material 1 in which a portion of the resin molded body 2 and the insulating sheet 6 are connected and fixed in this way, it is not necessary to use an adhesive, and the resin molded body can be connected and fixed at the same time when the resin molded body is made. The so-called impregnation here means that the molten polymer penetrates into the surface of the insulating sheet. In particular, when the insulating sheet contains a polymer having an amide bond and / or aramid paper, the molten polymer penetrates into the surface of the polymer having an amide bond and / or the aramid fibrid and / or aramid short fiber constituting the aramid paper. Through the impregnation, the polymer and the insulating sheet 6 are entangled with each other at the molecular level, and the bonding between the resin molded body 2 and the insulating sheet 6 becomes stronger. In addition, due to the expansion of the resin and the core material 8 caused by the temperature change during molding, the adhesion between the insulating sheet 6 and the core material 8 is improved, so the heat generation of the winding is efficiently transferred to the core material 8, preventing excessive temperature rise, reducing the copper loss of the winding, and improving the output of the motor.

[0086] In particular, when the resin molded body 2 is formed using a polymer having an amide bond and the surface of the insulating sheet 6 that contacts the resin molded body 2 is composed of a polymer having an amide bond, or when the resin molded body 2 is formed using a polymer having an amide bond and the surface of the insulating sheet 6 that contacts the resin molded body 2 is composed of an aromatic polyamide paper formed by aromatic polyamide fibrids and aromatic polyamide staple fibers, the polymer having an amide bond that constitutes the resin molded body 2 and the insulating sheet 6 are entangled with each other at the molecular level, and the bonding between the resin molded body 2 and the insulating sheet 6 becomes stronger.

[0087] (Effect)

[0088] According to this embodiment, the following effects are achieved.

[0089] According to the present embodiment, since the pair of main body portions 2a of the resin molded body 2 are integrated by the connecting portion 2b, and the insulating sheet 6 and the resin molded body 2 are connected by abutment, the laminated core material 8 can be integrated without temporarily fixing it by caulking, bonding, etc. Thus, it is not necessary to provide a caulking joint portion for caulking on the core material 8, iron loss can be suppressed, and additional processes such as application of adhesive and laser beam are not required.

[0090] In addition, according to this embodiment, since the molten resin passes through the outer peripheral groove portion 4e, the inner peripheral groove portion or the through hole and is filled into the space equivalent to a pair of main body portions 2a and the connecting portion 2b when the resin molded body 2 is molded, the main body portion 2a and the connecting portion 2b can be integrated.

[0091] Furthermore, according to the present embodiment, both axial surfaces of the annular core material 8 are flat surfaces, and the flat surfaces of each core material 8 and the adjacent core material 8 are in direct contact with each other, so that the iron loss can be further suppressed.

[0092] Furthermore, in the present embodiment, since the insulating sheet 6 and the resin molded body 2 are connected without using an adhesive, the annular laminated core material 1 can be manufactured without performing an additional step such as bonding.

[0093] Furthermore, in the present embodiment, since the axial length of the contact portion between the insulating sheet 6 and the resin molded body 2 is greater than 0.5 mm, a linear segment conductor is arranged in the groove portion of the annular laminated core material 1, and there is no deviation between the core materials during bending, and the load acting during bending can be withstood.

[0094] Furthermore, in the present embodiment, the resin constituting the resin molded body 2 is impregnated into the surface of the insulating sheet 6 that contacts the resin molded body 2 , thereby connecting the insulating sheet 6 and the resin molded body 2 . Therefore, the insulating sheet 6 and the resin molded body 2 can be connected more firmly.

[0095] In addition, in this embodiment, the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that abuts against the resin molded body 2 is formed using a polymer having an amide bond, so that the polymer and the insulating sheet 6 are entangled with each other at the molecular level, and the insulating sheet 6 and the resin molded body 2 can be more firmly connected.

[0096] In addition, in the present embodiment, the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that abuts against the resin molded body 2 is formed using aromatic polyamide paper formed by aromatic polyamide fibrids and aromatic polyamide staple fibers, so that the polymer and the insulating sheet 6 are entangled with each other at the molecular level, and the insulating sheet 6 can be more firmly connected to the resin molded body 2. Example

[0097] The present invention will be described below with reference to the following examples. In addition, these examples are provided to illustrate the content of the present invention and do not limit the content of the present invention in any way.

[0098] (Raw material preparation)

[0099] The pulp particle manufacturing device (wet settling machine) described in Japanese Patent Publication No. 52-15621, which is composed of a combination of a stator and a rotor, was used to manufacture the fibrids of polyisophthalamide metaphenylene diamine. The fibrids were treated with a disintegrator and a beater to adjust the length-weighted average fiber length to 0.9 mm. The filterability of the obtained aromatic polyamide fibrids was 90 cm 3 .

[0100] On the other hand, meta-aramid fibers (Nomex (registered trademark), single-filament fineness 2 denier) manufactured by DuPont were cut into 6 mm lengths (hereinafter referred to as “aramid staple fibers”).

[0101] (Manufacture of aramid paper)

[0102] The prepared aramid fibrids and aramid short fibers were dispersed in water to prepare slurries. The slurries were mixed in a ratio (weight ratio) of 1:1 between the fibrids and the aramid short fibers and were spun on a TAPPI-type hand-coated machine (cross-sectional area 625 cm 2 ) to produce a sheet. Then, the sheet was hot-pressed at a temperature of 330° C. and a linear pressure of 300 kg / cm using a metal calender roll to obtain the aramid paper shown in Examples 1 and 2 in Table 1.

[0103] (Manufacturing of laminated sheets)

[0104] Aramid paper (basis weight 37 g / m2) produced in the same manner as described above by the method described in paragraph

[0024] of JP-A-2006-321183 was used. 2 , thickness 51 μm, density 0.73 g / cm3) and a semi-aromatic polyamide resin composition of an epoxy-containing phenoxy resin (combination example 6 of Japanese Patent Publication No. 2006-321183), to obtain a laminated sheet shown in Examples 3 and 4 of Table 1 comprising aramid paper having a three-layer structure of aramid paper / resin composition / aramid paper (weight ratio 37 / 54 / 37) with aramid paper arranged on the outside.

[0105] In addition, aramid paper (basis weight 37 g / m 2 , thickness 51μm, density 0.73g / cm 3 ) was bonded with a polyethylene terephthalate film (S28♯16, thickness 16 μm) manufactured by Toray Industries, Inc. with an adhesive to obtain a laminated sheet as shown in Examples 5 and 6 of Table 1 comprising aromatic polyamide paper having a three-layer structure of aromatic polyamide paper / polyethylene terephthalate film / aromatic polyamide paper (weight ratio 37 / 54 / 37) with the aromatic polyamide paper arranged on the outside.

[0106] (Manufacturing of core material)

[0107] The non-oriented electrical steel sheet (thickness 0.5 mm, thickness tolerance 0.04 mm) specified in JIS C 2552 is Figure 2 The core material 8 is produced by punching out in a ring shape. In addition, in the core material 8, there is no trace of a temporary fixing mechanism such as caulking or bonding.

[0108] (Manufacture of annular laminated core material)

[0109] The insulating sheet was made of aramid paper or laminated sheet produced as described above, the core material 8 produced as described above was also used, and the semi-aromatic polyamide (Zytel (registered trademark) HTN51G35EF manufactured by DuPont) was used as the polymer. Insert molding was performed under the conditions shown in Table 1 to obtain Figure 1 The annular laminated core material 1 shown in the figure. That is, (1) the core material 8 is laminated in advance and inserted into the cavity for injection molding, (2) the insulating sheet 6 is installed in the groove of the laminated core material 8, and (3) the semi-aromatic polyamide manufactured by DuPont is introduced and injection molded by melt injection molding to integrally mold the resin molded body 2, the insulating sheet 6 and the laminated core material 8. At this time, the molten polymer is impregnated into at least the surface portion of the insulating sheet 6, and the insulating sheet 6 is directly bonded to the surface of the resin molded body 2, so that Figure 1 The annular laminated core material 1 shown has no trace of the temporary fastening mechanism. The measurement method of each condition is as follows.

[0110] (Measurement method)

[0111] (1) Measurement of basis weight and thickness

[0112] Implemented in accordance with JIS C2300-2.

[0113] (2) Calculation of density

[0114] Calculated as basis weight ÷ thickness.

[0115] (3) Tensile strength and tensile elongation

[0116] Implemented in accordance with JIS C2300-2.

[0117] (4) Adhesion

[0118] The bonding portion between the insulating paper and the resin molded body was visually observed, and a portion without wrinkles (protrusions of the insulating paper) was judged as "good", and a portion with wrinkles was judged as "bad".

[0119] (5) Appearance of insulation sheet 6

[0120] The degree of warping of the insulating sheet portion due to heat during molding was determined visually.

[0121] (6) Adhesion between the insulation sheet 6 and the core material 8

[0122] Regarding the degree of adhesion between the insulating sheet portion and the core material 8, the motor winding bobbin containing the core material 8 was impregnated with epoxy resin. After hardening, a jet of water containing garnet particles (model 626 manufactured by OMAX Corporation) was used to cut the annular stacked core material 1 perpendicular to the axial direction at the axial midpoint, and the average value of the distance between the insulating sheet 6 and the core material 8 was measured on the cut surface.

[0123] (7) Bending resistance

[0124] Straight segment conductors were placed in the grooves of the annular laminated core material 1, and the deviation between the core materials when bent was visually observed. Those without deviation were judged as "good", and those with deviation were judged as "bad".

[0125] [Table 1]

[0126]

[0127] According to the results in Table 1, the annular laminated core material of the embodiment is supported by the resin molded body through the outer peripheral surface, and can also withstand the load acting on the segmented conductor when the segmented conductor is used in the winding. In addition, since there is no trace of a temporary fixing mechanism, iron loss will not occur due to the generation of eddy currents caused by the residue of the caulking joint, and the grooves of the core material are covered by an insulating sheet with a smaller thickness, so it is possible to expect high efficiency due to high concentration of winding. In addition, since the adhesion between the insulating paper and the resin is also sufficient, the insulation breakdown voltage is also sufficiently high. Furthermore, since the aromatic polyamide paper and the polymer used have high heat resistance, it can be expected that the heating of the winding can also be fully borne. Therefore, it can be known that the winding tube for motors that can withstand high efficiency and high output, such as motor generators, is useful. In particular, since the resin composition of the middle layer of the laminated sheet of Examples 3 and 4 is similar to the structure of the resin molded body, it softens during molding, and it can be expected that the adhesion between the insulating sheet and the core material becomes the best.

[0128] In addition, compared with the case where the unnecessary removed thin plate portion is half-punched as a caulking joint portion for temporary fixing as in Japanese Patent Laid-Open No. 55-13665, and then the removed thin plate portion is removed by pressure punching, it does not require a large punching force and can be easily removed, and there is no residual portion, burr formation, etc., and no post-processing is required, so high-quality laminated core products can be manufactured with good operability.

[0129] Furthermore, since the resin molded body and the insulating sheet are attached at the same time during molding, the steps of caulking and attaching the resin molded body can be omitted.

[0130] Description of Reference Numerals

[0131] 1 Ring-shaped laminated core

[0132] 2 Resin molding

[0133] 2a Main body

[0134] 2a1 Ring

[0135] 2a2 Arm

[0136] 2a3 Protrusion

[0137] 2a4 Groove

[0138] 2b Connection

[0139] 4 core body

[0140] 4a Cylinder

[0141] 4b Arm

[0142] 4c Protrusion

[0143] 4d slot

[0144] 4e Outer groove

[0145] 6 Insulation sheet

[0146] 6a Central

[0147] 6b Left bend

[0148] 6c Right bend

[0149] 6d Front bending part

[0150] 6e Front bend

[0151] 8 core material

[0152] 8a Ring

[0153] 8b Arm

[0154] 8c Protrusion

[0155] 8d Groove

[0156] 8e Peripheral groove.

Claims

1. A ring-shaped laminated core material, It is characterized in that have: The core body is formed into a cylindrical shape by stacking a plurality of annular core materials, and a groove extending in the axial direction is formed on the inner peripheral surface inward in the radial direction or the outer peripheral surface outward in the radial direction; A resin molded body integrally formed with a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body and a connecting portion connecting the pair of main body portions; as well as an insulating sheet disposed on the inner surface of the groove; The axial ends of the insulating sheet are in contact with the main body of the resin molded body. The core body is provided with a through hole extending between the two axial end surfaces; The connecting portion passes through the through hole of the core body to connect the pair of main body portions.

2. A ring-shaped laminated core material, It is characterized in that have: The core body is formed into a cylindrical shape by stacking a plurality of annular core materials, and a groove extending in the axial direction is formed on the inner peripheral surface inward in the radial direction or the outer peripheral surface outward in the radial direction; A resin molded body integrally formed with a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body and a connecting portion connecting the pair of main body portions; as well as an insulating sheet disposed on the inner surface of the groove; The axial ends of the insulating sheet are in contact with the main body of the resin molded body. A circumferential groove portion extending across the two axial end surfaces is formed on the inner circumferential surface or the outer circumferential surface of the core body; The connecting portion passes through the peripheral surface groove portion of the core body to connect the pair of main body portions.

3. The annular laminated core material according to claim 1 or 2, It is characterized in that The annular core material has two flat surfaces in the axial direction, and the flat surfaces of each core material and the adjacent core material are in direct contact with each other.

4. The annular laminated core material according to any one of claims 1 to 3, It is characterized in that The insulating sheet and the resin molded body are connected without using an adhesive.

5. The annular laminated core material according to any one of claims 1 to 4, It is characterized in that The axial length of the contact portion between the insulating sheet and the resin molded body is 0.5 mm or more.

6. The annular laminated core material according to any one of claims 1 to 5, It is characterized in that The insulating sheet and the resin molded body are connected to each other by impregnating a surface of the insulating sheet in contact with the resin molded body with a resin constituting the resin molded body.

7. The annular laminated core material according to any one of claims 1 to 6, It is characterized in that The resin molded body is formed using a polymer having an amide bond; The surface of the insulating sheet that contacts the resin molded body is composed of a polymer having an amide bond.

8. The annular laminated core material according to any one of claims 1 to 6, It is characterized in that The resin molded body is formed using a polymer having an amide bond; The surface of the insulating sheet that contacts the resin molded body is composed of aramid paper formed of aramid fibrids and aramid short fibers.

9. A motor, It is characterized in that A stator in which winding wires are wound around the annular laminated core material according to any one of claims 1 to 8 is used.

10. A motor generator, It is characterized in that A stator in which winding wires are wound around the annular laminated core material according to any one of claims 1 to 8 is used.

11. A generator, It is characterized in that A stator in which winding wires are wound around the annular laminated core material according to any one of claims 1 to 8 is used.

12. A method for manufacturing an annular laminated core material, It is characterized in that include: a step of placing a core body formed into a cylindrical shape by stacking a plurality of annular core blocks and having an axially extending groove formed on an inner circumferential surface inward in the radial direction or an outer circumferential surface outward in the radial direction, in a forming die so that an insulating sheet is placed in the groove; and a resin molding step of injecting resin into a molding die to integrally mold a resin molded body including a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body; The resin molded body is integrally formed with a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body and a connecting portion connecting the pair of main body portions. The core body is provided with a through hole extending between the two axial end surfaces. The connecting portion passes through the through hole of the core body to connect the pair of main body portions.

13. A method for manufacturing an annular laminated core material, It is characterized in that include: a step of placing a core body formed into a cylindrical shape by stacking a plurality of annular core blocks and having an axially extending groove formed on an inner circumferential surface inward in the radial direction or an outer circumferential surface outward in the radial direction, in a forming die so that an insulating sheet is placed in the groove; and a resin molding step of injecting resin into a molding die to integrally mold a resin molded body including a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body; The resin molded body is integrally formed with a pair of main body portions formed so as to cover at least a portion of both axial end surfaces of the core main body and a connecting portion connecting the pair of main body portions. A circumferential groove portion extending across the two axial end surfaces is formed on the inner circumferential surface or the outer circumferential surface of the core body; The connecting portion passes through the peripheral surface groove portion of the core body to connect the pair of main body portions.

Images