Method for manufacturing a motor core

Abstract

The manufacturing method of the motor core includes: a laminate manufacturing process, which involves stacking multiple iron chips 11 to manufacture a magnet housing portion MHb extending along its stacking direction. 10 The laminate 10; the magnet placement process, in which a permanent magnet 30 extending along the lamination direction of the iron chip 11 is placed in the magnet storage section MHb. 10 Inside; and, in the fixing process, using a synthetic resin material Y that is softened at a first temperature T1 and cured at a second temperature T2 higher than the first temperature T1, the permanent magnet 30 is fixed to the magnet storage part MHb. 10 The fixing process includes: an injection process in which the temperature of the synthetic resin material Y is set to a first temperature T1, and the softened synthetic resin material Y is injected into the magnet receiving part MHb using an injection device X having a container capable of keeping the synthetic resin material Y in a softened state. 10 ; and, in the curing process, while the injection device X is removed from the laminate 10, the temperature of the synthetic resin material Y injected into the laminate 10 is raised to a second temperature T2, thereby curing the synthetic resin material Y.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a motor core. In particular, it relates to a method for forming a laminated body by stacking multiple thin plates (steel plates), forming a laminated body having a magnet housing portion extending along its stacking direction, inserting a permanent magnet into the magnet housing portion, and fixing (sealing) the permanent magnet within the laminated body (magnet housing portion). Background Technology

[0002] For example, as described in Patent Document 1 below, a method is known for fixing (sealing) a permanent magnet inserted into a magnet storage portion of a laminate to the laminate using a thermoplastic resin material. Furthermore, as described in Patent Documents 2 and 3, a method is known for fixing (sealing) a permanent magnet inserted into a magnet storage portion of a laminate to the laminate using a thermosetting resin material.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2008-245405

[0006] Patent Document 2: Japanese Patent No. 5357217

[0007] Patent Document 3: Japanese Patent No. 4414417 Summary of the Invention

[0008] In the method described in Patent Document 1, a heated and softened thermoplastic resin material is injected from an injection device into the magnet housing. As it diffuses within the magnet housing, it cools and begins to solidify. Therefore, a relatively high injection pressure is required to fill the magnet housing orifice with the thermoplastic resin material in a short time, and pressure is maintained to prevent backflow until the thermoplastic resin material solidifies. Consequently, the injection device cannot be removed from the laminate until the thermoplastic resin material has solidified within the magnet housing. In other words, the injection device is occupied from the start of the injection until the curing process is complete. Therefore, the productivity of the motor core is low.

[0009] As mentioned above, thermoplastic resin materials have high injection and holding pressures. Therefore, if the wall thickness of the portion forming the magnet housing in the laminate is small, there is a risk of deformation of the aforementioned peripheral portion during the injection or curing process of the thermoplastic resin material.

[0010] Furthermore, when using the methods of Patent Document 2 or Patent Document 3, the thermosetting resin material, softened by heating, is injected from the injection device into the magnet receiving section. Here, the thermosetting resin material is generally in a solid state (small flakes) before use, and begins to cure immediately upon softening by heating. Therefore, similar to the case when using thermoplastic resin materials, a high injection pressure and holding pressure are required to maintain the thermosetting resin material. Thus, the same problems arise as with the method of Patent Document 1.

[0011] Furthermore, due to the manufacturing precision (dimensional accuracy in the thickness direction, flatness, etc.) of each sheet (steel plate), the height dimension (dimension in the stacking direction of multiple sheets) of each laminate varies to some extent. That is, the volume of the magnet housing in each laminate varies to some extent. Therefore, even when the volume of the magnet housing is large, a slightly larger amount of thermosetting resin material (small pieces) than the assumed volume (maximum volume) of the magnet housing is used, in a way that allows it to be filled with thermosetting resin material. That is, during softening, an amount of thermosetting resin material is used that slightly overflows from the magnet housing. The thermosetting resin material overflowing from the magnet housing remains in the injection device. That is, it cures within the injection device. Therefore, after the permanent magnet is fixed to the laminate, the synthetic resin material cured in the injection device needs to be removed.

[0012] This invention addresses the aforementioned problems and aims to provide a method for manufacturing motor cores that can improve the productivity of motor cores. It should be noted that in the following description of the various components of this invention, for ease of understanding, symbols for corresponding portions of the embodiments are shown in parentheses; however, the various components of this invention should not be construed as limited to the configuration of the corresponding portions indicated by the symbols of the embodiments.

[0013] To achieve the above objectives, the manufacturing method of the motor core (1) of the present invention includes: a laminate manufacturing process, which involves laminating multiple steel plates (11) and manufacturing a magnet housing portion (MHb) extending along the lamination direction of the steel plates. 10 MHc 10 MHd 10 The process includes: a stacked body (10) of steel plates; a magnet placement process in which permanent magnets (30) extending along the stacking direction of the plurality of steel plates are placed in the magnet storage section; and a fixing process in which the permanent magnets are fixed in the magnet storage section using a synthetic resin material (Y) that is softened at a first temperature (T1) and cured at a second temperature (T2) higher than the first temperature; the fixing process includes: an injection process in which the temperature of the synthetic resin material is set to the first temperature, and the softened synthetic resin material is injected into the magnet storage section MHb using an injection device (X) having a container capable of keeping the synthetic resin material in a softened state.10 ; and, in the curing process, while the injection device is removed from the laminate, the temperature of the synthetic resin material injected into the laminate is raised to the second temperature, thereby curing the synthetic resin material.

[0014] The curing process of one embodiment of the present invention includes: removing the injection device from the laminate, transferring the laminate to a heating furnace or induction heating device located at a different position from the injection device, using the heating furnace or induction heating device to raise the temperature of the synthetic resin material injected into the laminate to the second temperature, and curing the synthetic resin material.

[0015] Another aspect of the present invention provides a method for manufacturing a motor core, comprising: a laminate manufacturing step, wherein multiple steel plates are laminated to manufacture a laminate having a magnet housing portion extending along the lamination direction of the steel plates; a magnet placement step, wherein permanent magnets extending along the lamination direction of the multiple steel plates are placed within the magnet housing portion; and a fixing step, wherein the permanent magnets are fixed within the magnet housing portion using a synthetic resin material that is softened at a first temperature and cured at a second temperature higher than the first temperature; the fixing step comprising: an injection step, wherein the temperature of the synthetic resin material is set to the first temperature, and the softened synthetic resin material is injected into the magnet housing portion using an injection device having a container capable of maintaining the synthetic resin material in a softened state; and a curing step, wherein the laminate is transferred to a heating furnace or induction heating device located at a different position from the injection device, and the temperature of the synthetic resin material injected into the laminate is raised to the second temperature using the heating furnace or the induction heating device, thereby curing the synthetic resin material.

[0016] In one embodiment of the invention, the injection device has a heating device to maintain the synthetic resin material at the first temperature.

[0017] In another embodiment of the present invention, the injection device includes a drive device for discharging the synthetic resin material from the container. In the injection process, after the softened synthetic resin material is filled into the magnet receiving portion, the drive direction of the drive device of the injection device is reversed, and then the injection device is removed from the laminate.

[0018] As described above, the synthetic resin material used in this invention does not cure when its temperature is maintained at a first temperature, but cures when a second temperature higher than the first temperature is reached. Therefore, even when the synthetic resin material is injected into the magnet housing, it does not cure within the magnet housing in this state. Therefore, unlike the manufacturing method of the motor core using Patent Documents 1 to 3, the injection pressure of the synthetic resin material can be set at a lower level. Furthermore, pressure holding to prevent backflow of the synthetic resin material is not required. Therefore, the following curing process can be implemented: immediately after filling all magnet housings with synthetic resin material, the injection device is released, the laminate is transferred to another location (downstream of the production line), and the synthetic resin material is heated and cured at that location. That is, according to this invention, once the filling of a laminate with synthetic resin material is completed, the injection device can be released immediately without waiting for the synthetic resin material to cure completely, and the work of filling the next laminate with synthetic resin material can begin.

[0019] In the fixing process of one embodiment of the present invention, before the injection process, the laminate is heated in such a way that the temperature of the laminate is higher than the first temperature and lower than the second temperature. In the injection process, the nozzle of the injection device is brought into contact with the opening end of the magnet receiving portion of the laminate, so that the temperature of the laminate into which the softened synthetic resin material is injected is higher than the first temperature and lower than the second temperature.

[0020] Therefore, during the injection process, the temperature of the laminate is higher than the melting temperature of the synthetic resin material, thus maintaining the synthetic resin material in a molten state. Furthermore, the temperature is lower than the curing temperature of the synthetic resin material, thereby suppressing curing. In other words, the synthetic resin material maintains good flowability during the injection process.

[0021] In the injection process of one embodiment of the present invention, when the injection pressure of the synthetic resin material is greater than a predetermined pressure, the injection of the synthetic resin material into the through hole of the laminate is stopped.

[0022] Therefore, an amount of synthetic resin material approximately the same as the volume of the space (gap) within each magnet housing (the necessary and sufficient amount to fill the aforementioned space) can be injected from the injection device into each magnet housing. Then, after filling the magnet housing with the synthetic resin material, the laminate is heated to cure the synthetic resin material; however, during this curing process, the injection device is released (removed) from the laminate. Therefore, the heat from the laminate heated during the curing process is not transferred to the injection device. Therefore, unlike the manufacturing methods used in Patent Documents 2 and 3, the synthetic resin material does not cure inside the container and the injection device. Therefore, the work of removing the synthetic resin material from the injection device is unnecessary.

[0023] As described above, the productivity of motor cores can be improved according to the present invention.

[0024] Another aspect of the present invention provides a method for manufacturing a motor core, comprising: a laminate manufacturing step, wherein multiple steel plates are laminated to manufacture a laminate having a magnet housing portion extending along the lamination direction of the steel plates; a magnet placement step, wherein permanent magnets extending along the lamination direction of the multiple steel plates are placed within the magnet housing portion; and a fixing step, wherein a synthetic resin material that is solid at room temperature, softened at a first temperature higher than the room temperature, and cured at a second temperature higher than the first temperature is used to fix the permanent magnets within the magnet housing portion; the fixing step comprising: an injection step, wherein the temperature of the synthetic resin material is raised from the room temperature to the first temperature to soften the synthetic resin material, and the softened synthetic resin material is injected into the magnet housing portion; and a curing step, wherein the temperature of the synthetic resin material injected into the laminate is raised to the second temperature to cure the synthetic resin material.

[0025] Another aspect of the present invention includes the following steps in the injection process: feeding the solid synthetic resin material into an injection device, raising the temperature of the fed synthetic resin material to the first temperature, softening the synthetic resin material, and injecting the softened synthetic resin material into the magnet receiving portion.

[0026] Here, Patent Documents 2 and 3 disclose a method for fixing a permanent magnet within a magnet housing using a thermosetting synthetic resin material. However, this thermosetting synthetic resin material is solid (sheet-like) before use and begins to cure immediately upon heating and softening. Therefore, there is a risk that the thermosetting synthetic resin material may cure before being fully filled into the magnet housing, thus failing to achieve sufficient fixing strength for the permanent magnet. In contrast, the thermosetting synthetic resin material used in this invention is heated from room temperature (its state before use), softens upon reaching a first temperature, but remains in a softened state until a second temperature higher than the first temperature is reached. Therefore, the softened thermosetting synthetic resin material can be filled into the magnet housing relatively easily, resulting in sufficient fixing strength for the permanent magnet. Furthermore, the thermosetting resin material can be kept in a softened state within the injection device, allowing any surplus from the manufacture of one motor core to be used in the manufacture of the next motor core. Attached Figure Description

[0027] Figure 1 This is a perspective view of a rotor core manufactured using a manufacturing method according to one embodiment of the present invention.

[0028] Figure 2 yes Figure 1 The diagram shown is an exploded perspective view of the rotor core.

[0029] Figure 3 It is a 3D diagram of an iron chip.

[0030] Figure 4A This is a top view of the iron chip.

[0031] Figure 4B It is an enlarged image obtained by magnifying a portion of the outer periphery of the iron chip.

[0032] Figure 5 It is a cross-sectional view of the magnet storage section perpendicular to the long side direction (depth direction).

[0033] Figure 6 It is a cross-sectional view of a permanent magnet perpendicular to its long side.

[0034] Figure 7 It is an enlarged view obtained by magnifying the outer periphery of the cross section of the rotor core perpendicular to the central axis.

[0035] Figure 8 It is an enlarged view obtained by magnifying the outer periphery of the end face of the magnet storage part on the side of the opening end of the central axis of the intermediate component.

[0036] Figure 9 It is a three-dimensional diagram that roughly represents the injection and curing processes.

[0037] Figure 10 It is a cross-sectional view of the injection device and intermediate components along the central axis of the nozzle in the injection process.

[0038] Figure 11A This is a top view obtained by enlarging the outer periphery of the upper end plate in the injection process of the first modified example of the present invention.

[0039] Figure 11B This is a cross-sectional view of the injection device and intermediate components along the central axis of the nozzle in the injection process of the first modified example.

[0040] Figure 12 This is a top view obtained by enlarging the outer periphery of the upper end plate in the injection process of the second modified example of the present invention.

[0041] Figure 13 This is a top view obtained by enlarging the outer periphery of the upper end plate in the injection process of the third modified example of the present invention.

[0042] Figure 14 This is a top view obtained by enlarging the outer periphery of the upper end plate in the injection process of the fourth modified example of the present invention.

[0043] Figure 15 This is a top view showing the positional relationship between the magnet housing and the nozzle in the injection process of the fifth modified example of the present invention.

[0044] Figure 16 This is a top view showing the positional relationship between the magnet housing and the nozzle in the injection process of the sixth modified example of the present invention.

[0045] Figure 17 This is a top view showing the positional relationship between the magnet housing and the nozzle in the injection process of the seventh modified example of the present invention.

[0046] Figure 18 This is a top view showing the positional relationship between the magnet housing and the nozzle in the injection process of the eighth modified example of the present invention. Detailed Implementation

[0047] The following describes a method for manufacturing a motor core according to one embodiment of the present invention. Figure 1 and Figure 2 The steps of the rotor core 1 shown will be explained. It should be noted that the rotor core 1 is used in the rotor of a known IPM motor. The rotor core 1 includes a laminate 10, an end plate 20, a plurality of permanent magnets 30, and an end plate 40.

[0048] (Laminated body manufacturing process)

[0049] The laminate 10 is a stack of iron chips 11 made of silicon steel plates (see reference). Figure 3as well as Figure 4A and Figure 4B The iron chip 11 is formed by punching the base material. A circular through hole THa is formed in the center of the iron chip 11. 11 In addition, through holes THb are provided on the outer periphery of each region A obtained by dividing the iron chip 11 into 8 equal parts along the circumference. 11 THc 11 THd 11 Through hole THb 11 THc 11 THd 11 Adjacent to each other in the circumferential direction of the iron chip 11. Through hole THb 11 Configured in the through hole THc 11 With through hole THd 11 Between. Through hole THb 11 It is a roughly rectangular (isosceles trapezoid) shape extending in a direction perpendicular to the radial direction of the iron chip 11 and perpendicular to the thickness direction. Through-hole THc 11 THd 11 It presents an approximate pentagon extending in a direction that is radially perpendicular to the iron chip 11 and in a direction perpendicular to the thickness of the plate.

[0050] In the through hole THb 11 In the edge S on the outer periphery of the iron chip 11 THb A pair of protrusions P are formed on the upper part, protruding towards the inner periphery. THb P THb Protrusion P THb Formed on edge S respectively THb Both ends in the extending direction. Additionally, in the through hole THc 11 THd 11 In the edge, the outer periphery of the iron chip 11 is edge S THc S THd One end side in the extension direction and located in the through hole THb 11 Side part S1 THc S1 THd Compared to THb with through holes 11 opposite side part S2 THc S2 THd It is located radially outward of the iron chip 11. That is, in a top view of the iron chip 11, at part S1 THc With part S2 THc Boundary section S12 THc and part S1 THd With part S2 THd Boundary section S12 THd There are stepped differences at each location. At location S1 THcS1 THd Each of these locations has a protrusion P that extends inward to the circumference. THc P THd Protrusion P THc P THd Formed respectively at part S1 THc S1 THd Through hole THb in the extension direction 11 The end of the side.

[0051] To make the through holes THa of each iron chip 11 11 Coaxial configuration and through holes THb of each iron chip 11 11 THc 11 THd 11 Multiple iron chips 11 are stacked in a coaxial configuration. The iron chips 11 are pressed together. In the stack 10, the through holes THa of each iron chip 11 are... 11 and through hole THb 11 THc 11 THd 11 They are connected in directions parallel to the extension direction of the central axis C of the laminate 10 (the lamination direction of the iron chip 11) (see reference). Figure 1 In other words, the laminate 10 has a through hole THa coaxially arranged with the central axis C. 10 (Through holes THa of each iron chip 11) 11 (Connected portions). Furthermore, the laminate 10 has a plurality of magnet storage portions MHb extending parallel to the central axis C at its outer periphery. 10 MHc 10 MHd 10 (Through holes THb of each iron chip 11) 11 THc 11 THd 11 (Connected parts). Magnet storage section MHb 10 With the protrusion P THb P THb The convex part P formed by overlapping MHb P MHb (Refer to Figure 5 Magnet storage section MHc 10 MHd 10 Having protrusions P respectively THc P THd The convex part P formed by overlapping MHc P MHd Additionally, the magnet storage section MHc 10 MHd 10 Having the boundary part S12 THc S12 THd The wall S12 formed by overlappingMHc S12 MHd .

[0052] MHb Magnetic Storage Unit 10 MHc 10 MHd 10 The cross section CS perpendicular to the extension direction (the stacking direction of the iron chip 11) b CS c CS d The widths Wb, Wc, and Wd are roughly the same (see reference). Figure 5 ). Cross section CS c CS d The lengths Lc and Ld of the laminate 10 are greater than the cross section CS. b The length Lb.

[0053] (First end plate installation process)

[0054] An end plate 20 is mounted on one end face (below) in the direction extending from the central axis C of the laminate 10 constructed as described above (see reference). Figure 2 End plate 20 is made of synthetic resin. End plate 20 is a plate-shaped component with approximately the same shape as iron chip 11. The thickness of end plate 20 is slightly greater than that of iron chip 11. End plate 20 has a through hole THa with the laminate 10. 10 Circular through holes of approximately the same diameter THa 20 However, it does not have a magnet storage section MHb 10 MHc 10 MHd 10 The corresponding through hole.

[0055] To make the through hole THa 20 With through hole THa 10 The end plate 20 is mounted on one end face (bottom) of the laminate 10 in a coaxial configuration. The end plate 20 blocks the magnet storage section MHb. 10 MHc 10 MHd 10 One end (bottom side) in the extending direction. It should be noted that the magnet storage section MHb... 10 MHc 10 MHd 10 The other end (upper side) is open in the direction of extension.

[0056] (Magnet preparation process)

[0057] Then, from the magnet storage section MHb 10 MHc 10 MHd 10 The other end (upper side) of the extension direction faces the magnet storage part MHb 10 MHc10 MHd 10 A permanent magnet 30 is inserted inside. The permanent magnet 30 is prism-shaped. The length of the permanent magnet 30 is slightly smaller than that of the magnet storage part MHb. 10 MHc 10 MHd 10 The depth. For example... Figure 6 As shown, the cross-section CS of the permanent magnet 30 perpendicular to the long side direction 30 It is rectangular in shape. Cross-section CS 30 Length L 30 Less than the cross section CS b Length Lb (refer to) Figure 5 Additionally, the cross-section CS 30 Width W 20 Less than the cross section CS b Width Wb (refer to) Figure 5 ).

[0058] MHb in the magnet storage section 10 In the middle, permanent magnet 30 is arranged in the magnet storage section MHb 10 Central part (refer to) Figure 7 That is, each magnet storage section MHb 10 The central axis of the permanent magnet 30 is aligned with the central axis of the convex part P. MHb P MHb Between. In the magnet storage section MHb 10 In the middle, the cross section S of the permanent magnet 30 30 The permanent magnet 30 is arranged such that the extension direction of the short side is aligned with the radial direction of the laminate 10. As described above, the magnet storage section MHb 10 The inner dimensions are smaller than the outer dimensions of the permanent magnet 30 (refer to...). Figure 5 and Figure 6 Therefore, the outer peripheral surface of the permanent magnet 30 and the magnet storage part MHb 10 A gap is formed between the inner circumferential surfaces.

[0059] In the magnet storage section HMC 10 MHd 10 In the middle, permanent magnet 30 is from the magnet storage section MHc 10 MHd 10 Looking at the central part near the magnet storage section MHb 10 Side configuration (refer to) Figure 7 That is, in the magnet storage section MHc 10 In the middle, the permanent magnet 30 is disposed on the protrusion P. MHc With wall S12 MHc Between. In the magnet storage section MHd 10 In the middle, the permanent magnet 30 is disposed on the protrusion P. MHdWith wall S12 MHd Between. In the magnet storage section MHc 10 MHd 10 In the middle, the cross section S of permanent magnet 30, 30 30 S 30 The permanent magnet 30 is arranged such that the extension direction of the short side is consistent with the radial direction of the laminate 10. The permanent magnet 30 is positioned on the outer peripheral surface of the magnet housing portion MHc. 10 MHd 10 A gap is formed between the inner circumferential surfaces.

[0060] (Second end plate installation process)

[0061] Then, an end plate 40 is installed on the other end face in the direction of extension of the central axis C of the laminate 10 (see reference). Figure 2 End plate 40 is made of synthetic resin. End plate 40 is a plate-shaped component with approximately the same shape as iron chip 11. The thickness of end plate 40 is slightly greater than that of iron chip 11. End plate 40 has a through hole THa with the laminate 10. 10 Circular through holes of approximately the same diameter THa 40 Additionally, the end plate 40 has sections corresponding to the magnet storage section MHb. 10 MHc 10 MHd 10 Multiple circular through holes THb 40 THc 40 THd 40 It should be noted that the through hole THb 40 THc 40 THd 40 Perform tapered machining. That is, through hole THb 40 THc 40 THd 40 As the end plate 40 moves from one side toward the other, its inner diameter gradually decreases.

[0062] To make the through hole THa 40 With through hole THa 10 Coaxial configuration, with the central axis of each permanent magnet 30 connected to multiple through holes THb. 40 THc 40 THd 40 The end plate 40 is configured in a coaxial manner with the central axis (refer to...). Figure 8 It should be noted that the other side of the end plate 40 contacts the end face of the laminate 10. This forms the intermediate assembly SA (see reference). Figure 9 In the intermediate component SA, the through hole THa 20 Through hole THa 10 and through hole THa 40It is connected along the extension direction of the central axis C. Furthermore, the magnet storage section MHb... 10 MHc 10 MHd 10 and through hole THb 40 THc 40 THd 40 They are connected in directions parallel to the extension direction of the central axis C. Magnet storage section MHb 10 MHc 10 MHd 10 One end (bottom) in the direction of extension (depth) is blocked, but the other end (top) is open.

[0063] Then, the permanent magnets 30 are fixed (sealed) to each magnet storage section MHb. 10 MHc 10 MHd 10 The following describes the internal process. First, the intermediate component SA is placed on a rotary table (not shown). The intermediate component SA is coaxially aligned with the rotary table. End plate 40 is located on the upper side of the laminate 10, and end plate 20 is located on the lower side of the laminate 10 (see reference). Figure 9 (See the left side of the figure). Then, using a heating device not shown, the intermediate component SA (laminate 10) is heated in such a way that the temperature of the laminate 10 is higher than a first temperature T1 (e.g., 80°C) and lower than a second temperature T2 (e.g., 120°C) as described later.

[0064] In order to fix (seal) the permanent magnets 30 to each magnet storage section MHb 10 MHc 10 MHd 10 In this embodiment, for example, a synthetic resin material Y as described in Japanese Patent Application Publication No. 2000-239642 is used. That is, the synthetic resin material Y is solid (sheet-like) before use (at room temperature), and softens when heated from this state to a first temperature T1. The synthetic resin material Y does not solidify while remaining at the first temperature, but solidifies at a second temperature T2, which is higher than the first temperature T1.

[0065] Using the injection device X, the synthetic resin material Y described above is filled into each magnet storage section MHb. 10 MHc 10 MHd 10 .like Figure 9 and Figure 10 As shown, the injection device X includes a material cylinder Xa, a heating device Xb, and a delivery device Xc. The material cylinder Xa is cylindrical, and a nozzle Xa1 is provided at its front end. The outer diameter of the front end of the nozzle Xa1 is slightly smaller than that of the through hole THb. 40 THc 40 THd40 The inner diameter. A through hole TH is provided on the side of the barrel Xa. Xa From the through hole TH Xa Unused (flake-like) synthetic resin material Y is fed into the barrel Xa. A heating device Xb is installed on the side of the barrel Xa, setting the temperature of the synthetic resin material Y inside the barrel Xa to a first temperature T1, thus maintaining the synthetic resin material Y in a softened state. The delivery device Xc includes a screw Xc1, a drive device Xc2, etc. The screw Xc1 is housed inside the barrel Xa. The screw Xc1 is coaxially arranged with the barrel Xa. One end of the screw Xc1 along its long side (the end on the nozzle Xa1 side) is formed into a sharp point. The other end of the screw Xc1 along its long side is connected to the drive device Xc2. The drive device Xc2 includes an electric motor and a reduction gear. The drive device Xc2 rotates the screw Xc1 around its central axis.

[0066] (Injection process)

[0067] First, above the intermediate component SA, align the central axis of nozzle Xa1 with the through hole THb. 40 The injection device X is configured in a manner consistent with the central axis. It should be noted that the injection device X is supported by an actuator (robotic arm) not shown, by which it moves in the vertical direction.

[0068] Then, as Figure 10 As shown, the injection device X descends, inserting the front end of nozzle Xa1 into the through hole THb. 40 Inside, the front end face of nozzle Xa1 contacts the upper end face of the laminate 10. Then, the control device of injection device X drives drive device Xc2, causing screw Xc1 to rotate forward, thus discharging softened synthetic resin material Y from nozzle Xa1. This fills the outer peripheral surface of permanent magnet 30 and magnet storage portion MHb with synthetic resin material Y. 10 The space (gap) between the inner circumferential surfaces. In the above-mentioned filling process of synthetic resin material Y, the control device of injection device X monitors the injection pressure of synthetic resin material Y. If the magnet housing part MHb 10 When the internal space (gap) is filled with synthetic resin material Y, the injection pressure rises sharply. If the control device detects a sharp increase in injection pressure, it stops the drive device Xc2. As a result, the synthetic resin material Y flows into the magnet housing MHb. 10 The injection amount and the MHb of each magnet storage section 10The volumes of the gaps within are approximately the same. It should be noted that by heating the laminate 10 as described above, during the injection process, the temperature of the laminate 10 is higher than the melting temperature of the synthetic resin material Y, thus maintaining the synthetic resin material Y in a molten state. Furthermore, the temperature of the laminate 10 is lower than the curing temperature of the synthetic resin material Y, thus suppressing the curing of the synthetic resin material Y. In other words, during the injection process, the synthetic resin material can maintain good flowability.

[0069] Then, the control device drives the drive device Xc2, causing the screw Xc1 to slightly reverse. Then, the injection device X rises and separates from the intermediate assembly SA (see Figure 11). In this way, by slightly reversing the screw Xc1, the dripping of synthetic resin material Y from the nozzle Xa1 can be suppressed when the injection device X rises.

[0070] Then, in the magnet storage section MHc 10 The injection device X is positioned above the rotating stage, which is rotated only by a predetermined angle. Then, in conjunction with the aforementioned magnet storage section MHb... 10 The same steps are followed in filling the synthetic resin material Y in the magnet housing section MHc. 10 The composite material Y is filled in. The above process is repeated in other magnet storage sections MHb. 10 Magnet storage section MHc 10 MHd magnetic storage unit 10 The middle is filled with synthetic resin material Y.

[0071] (Curing process)

[0072] MHb in all magnet storage sections 10 MHc 10 MHd 10 After the synthetic resin material Y is filled, it is removed (lifted) from the injection device X from the intermediate component SA. Then, the intermediate component SA is transferred to the electromagnetic induction heater IH, and the outer peripheral surface of the intermediate component SA is heated using the electromagnetic induction heater IH (see reference). Figure 9 (See the diagram on the right). Thus, all magnet storage sections MHb 10 MHc 10 MHd 10 The synthetic resin material Y inside is cured when it reaches the second temperature T2. In this way, each permanent magnet 30 is fixed (sealed) in the magnet housing MHb. 10 MHc 10 MHd 10 .

[0073] As described above, the synthetic resin material Y does not cure while its temperature is maintained at the first temperature T1. In this embodiment, the synthetic resin material Y is filled into the magnet housing portion MHb.10 MHc 10 MHd 10 In the process, the temperature of the laminate 10 is set to be the same as the first temperature T1. Therefore, even when the synthetic resin material Y is injected into the magnet housing part MHb 10 MHc 10 MHd 10 In this state, the synthetic resin material Y is in the magnet housing part MHb 10 MHc 10 MHd 10 The interior is also in a softened state. Therefore, unlike the manufacturing method of the motor core using Patent Documents 1 to 3, the injection pressure of the synthetic resin material Y can be set at a lower level. Furthermore, there is no need for a pressure holding device to prevent backflow of the synthetic resin material Y. Therefore, it is possible to achieve this in all magnet housing sections MHb. 10 MHc 10 MHd 10 After the synthetic resin material Y is filled, the injection device X is immediately released, and the intermediate component SA is transferred to another location (downstream of the production line), where the synthetic resin material Y is heated and cured. That is, according to this embodiment, if the filling of the synthetic resin material Y for one intermediate component SA is completed, the injection device X can be released immediately without waiting for the synthetic resin material Y to cure completely, and the filling of the synthetic resin material Y for the next intermediate component SA can begin.

[0074] Furthermore, based on the variation in injection pressure of synthetic resin material Y, the pressure on each magnet housing section MHb is controlled. 10 MHc 10 MHd 10 The injection of synthetic resin material Y. This will then connect with the magnet storage sections MHb. 10 MHc 10 MHd 10 A quantity of synthetic resin material Y, approximately equal in volume to the internal space (gap) (to meet the necessary and sufficient requirements of the aforementioned space), is injected from the injection device X into each magnet housing MHb. 10 MHc 10 MHd 10 Then, in all the magnet storage sections MHb 10 MHc 10 MHd 10After the synthetic resin material Y is filled, the intermediate component SA is heated by an electromagnetic induction heater IH to cure the synthetic resin material Y. However, during this curing process, the injection device X is released (removed) from the intermediate component SA. Therefore, the heat from the intermediate component SA heated by the electromagnetic induction heater IH is not transferred to the injection device X. Therefore, unlike the manufacturing methods used in Patent Documents 2 and 3, the synthetic resin material Y does not cure within the injection device X. Therefore, it is unnecessary to remove the synthetic resin material Y from the injection device X.

[0075] As described above, according to this embodiment, the productivity of rotor core 1 can be improved.

[0076] Furthermore, in the implementation of this invention, the embodiments are not limited to those described above, and various modifications can be made as long as they do not depart from the purpose of this invention.

[0077] For example, such as Figure 11A As shown, the through hole THb 40 THc 40 THd 40 The inner diameter can also be smaller than the outer diameter of the front end of nozzle Xa1. In this case, such as Figure 11B As shown, nozzle Xa1 is pressed onto end plate 40 such that the front end face of nozzle Xa1 is in close contact with the upper surface of end plate 40. Additionally, as... Figure 12 As shown, the through hole THb 40 THc 40 THd 40 The central axis can also be offset from the center of the permanent magnet 30 towards the outer periphery of the laminate 10. Additionally, as... Figure 13 As shown, the through hole THb 40 THc 40 THd 40 The central axis can also be offset along the circumference of the laminate 10 when viewed from the center of the permanent magnet 30. That is, the outlet of the nozzle Xa1 may not be located above the permanent magnet 30 but in each magnet housing MHb. 10 MHc 10 MHd 10 Above the internal space (gap). It should be noted that... Figures 12-13 In the example shown, in order to insert the front end of nozzle Xa1 into the through hole THb 40 THc 40 THd 40 Alternatively, the through hole THb can be... 40 THc 40 THd 40 The inner diameter is set to be slightly larger than the outer diameter of the front end of nozzle Xa1.

[0078] In addition, such as Figure 14 As shown, the end plate 40 may also have an MHb disposed in the magnet storage section. 10 With magnet storage section MHc 10 THbc through hole at the boundary 40 In this case, the nozzle Xa1 simultaneously supplies power to the two magnet receiving sections MHb. 10 MHc 10 Inject synthetic resin material Y. It should be noted that, in Figure 14 In the example shown, in order to insert the front end of nozzle Xa1 into the through hole THbc 40 Alternatively, the through hole THbc can be... 40 The inner diameter is set to be slightly larger than the outer diameter of the front end of nozzle Xa1.

[0079] Alternatively, end plates 20 and 40 can also be removed (see reference). Figures 15-18 That is, the front end face of the nozzle Xa1 can be made to contact the end face of the laminate 10, and the synthetic resin material Y can be filled into the magnet housing part MHb. 10 MHc 10 MHd 10 In this case, the magnet housing MHb of synthetic resin material Y needs to be injected. 10 MHc 10 MHd 10 The opening end can be completely covered by the front face of nozzle Xa1. It should be noted that in these cases, a clamp is used to hold the magnet housing MHb. 10 MHc 10 MHd 10 The opening on the opposite side of the surface that contacts nozzle Xa1 is blocked. Figure 11A and Figure 11B Similarly, in the example shown, the central axis of nozzle Xa1 can be located above the center of permanent magnet 30 (see reference). Figure 15 It should be noted that, in Figures 15-18 The position of nozzle Xa is indicated by a double dashed circle. The inner circle represents the discharge hole Xa11 (the hole for discharging synthetic resin material Y) located at the front end of nozzle Xa1. The outer circle represents the shape Xa12 of the front end face of nozzle Xa. Additionally, with... Figure 12 Similarly, in the example shown, the central axis of nozzle Xa1 can be offset from the center of permanent magnet 30 towards the outer periphery of laminate 10 (see reference). Figure 16 Additionally, with Figure 13 Similarly, in the example shown, the central axis of nozzle Xa1 can be offset along the circumference of the laminate 10 when viewed from the center of the permanent magnet 30 (see reference). Figure 17 Additionally, with Figure 14 Similarly, in the example shown, the central axis of nozzle Xa1 can be located at the magnet housing MHb.10 With magnet storage section MHc 10 Above the boundary (refer to) Figure 18 ).

[0080] Alternatively, multiple injection devices X can be used simultaneously in multiple magnet storage sections MHb. 10 MHc 10 MHd 10 The intermediate component SA is filled with synthetic resin material Y. Alternatively, during the curing process, the intermediate component SA can be placed in a heating furnace to heat and cure the synthetic resin material Y. Furthermore, the above embodiment is an example of applying the manufacturing method of the motor core of the present invention to the manufacturing of the rotor core 1; however, the present invention can also be applied to the manufacturing of the stator core.

[0081] In addition, the end plates 20 and 40 in the above embodiments are made of synthetic resin, but metal end plates (such as stainless steel, aluminum alloy, etc.) can also be used.

[0082] Furthermore, in the above embodiment, the through hole THb of the end plate 40 40 THc 40 THd 40 Perform tapered machining. That is, through hole THb 40 THc 40 THd 40 The inner diameter gradually decreases from one side of the end plate 40 towards the other. Instead, the through hole THb... 40 THc 40 THd 40 The inner diameter can also gradually change from one side of the end plate 40 towards the other side. Additionally, the through hole THb... 40 THc 40 THd 40 The inner diameter can also be constant in the thickness direction of the end plate 40. Additionally, the through hole THb... 40 THc 40 THd 40 The shape is not limited to the above-described embodiments; for example, it can also be elliptical, polygonal, etc. In these cases, it can be based on the through hole THb. 40 THc 40 THd 40 The shape of the nozzle Xa1 is changed by changing its shape.

[0083] Furthermore, in the above embodiment, during the injection process, the front end face of nozzle Xa1 will inject the synthetic resin material Y into the hole (through hole THb). 40 THc 40 THd 40 MHb Magnet Storage Section10 MHc 10 MHd 10 The opening end of the nozzle Xa can be completely blocked, but it can also be configured to cover only a portion of the opening end. In this case, the shape of the nozzle tip face Xa12 can be changed according to the shape of the hole into which the synthetic resin material Y is to be injected. Furthermore, the shape and position of the discharge hole Xa11 on the nozzle tip face can also be changed according to the shape of the hole into which the synthetic resin material Y is to be injected. Alternatively, it can be configured to branch the flow path of the synthetic resin material Y at the tip end of the nozzle Xa and have multiple discharge holes Xa11. Alternatively, it can be configured to use a nozzle Xa with multiple discharge holes Xa11, while simultaneously using multiple holes (through holes THb)... 40 THc 40 THd 40 MHb Magnet Storage Section 10 MHc 10 MHd 10 The composition of the synthetic resin material Y injected into the )

[0084] Furthermore, in the injection process of the above embodiment (in the magnet housing section MHb) 10 MHc 10 MHd 10 In the process of filling synthetic resin material Y, the injection amount of synthetic resin material Y is controlled based on the change in the injection pressure of synthetic resin material Y. Alternatively, for example, the injection amount of synthetic resin material Y can also be controlled based on the rotation amount (number of rotations) of screw Xc1. Furthermore, as the injection device X, a device that pressurizes and delivers softened synthetic resin material Y can also be used. In this case, the injection amount of synthetic resin material Y can be controlled based on the pressure applied.

[0085] In the curing process of the above embodiment, the outer peripheral surface of the intermediate component SA is heated. Alternatively, the inner peripheral surface, one end face in the central axis direction, or the other end face of the intermediate component SA may also be heated.

[0086] Symbol Explanation

[0087] MHb 10 MHc 10 MHd 10 …Magnet storage section, T1…first temperature, T2…second temperature, X…injection device, Y…synthetic resin material, 1…rotor core, 10…laminated body, 11…iron chip, 20, 40…end plates, 30…permanent magnet

Claims

1. A method for manufacturing a motor core, comprising: The laminate manufacturing process involves stacking multiple steel plates to create a laminate having a magnet housing portion extending along the stacking direction of the steel plates. In the magnet arrangement process, permanent magnets extending along the stacking direction of the plurality of steel plates are arranged within the magnet receiving portion, and In the fixing process, a synthetic resin material that is solid at room temperature, softens at a first temperature higher than room temperature, remains uncured at the first temperature, and cures at a second temperature higher than the first temperature is used to fix the permanent magnet in the magnet housing. The fixed process includes: In the injection process, using an injection device having a container and a nozzle, a portion of the softened synthetic resin material in the container is injected from the nozzle into the magnet receiving part. The container has a heating device that sets the temperature of the synthetic resin material to the first temperature to maintain the synthetic resin material in a softened state. In the curing process, while the synthetic resin material remaining in the container and nozzle of the injection device is in a softened state, the nozzle is removed from the laminate, and the temperature of the synthetic resin material injected into the laminate is raised to the second temperature, thereby curing the synthetic resin material.

2. The method for manufacturing a motor core according to claim 1, wherein, The laminated body has multiple magnet storage sections. The injection process includes: injecting a portion of the softened synthetic resin material in the container into the first magnet receiving portion of the plurality of magnet receiving portions from the nozzle of the injection device; and after removing the nozzle from the first magnet receiving portion, injecting the synthetic resin material remaining in the container and the nozzle into the second magnet receiving portion from the nozzle of the injection device.

3. The method for manufacturing a motor core according to claim 1 or 2, wherein, Prior to the injection process, the laminate is heated in a manner that raises its temperature above the first temperature but lower than the second temperature. In the injection process, the nozzle of the injection device is brought into contact with the opening end of the magnet receiving portion of the laminate to inject the softened synthetic resin material.

4. The method for manufacturing a motor core according to any one of claims 1 to 3, wherein, During the injection process, when the injection pressure of the synthetic resin material exceeds a predetermined pressure, the injection of the synthetic resin material into the through-hole of the laminate is stopped.

5. The method for manufacturing a motor core according to any one of claims 1 to 4, wherein, The injection device includes a drive mechanism for discharging the synthetic resin material from the container. In the injection process, after the softened synthetic resin material is filled into the magnet receiving part, the driving direction of the driving device of the injection device is reversed, and then the injection device is removed from the laminate.

6. The method for manufacturing a motor core according to any one of claims 1 to 5, wherein, The curing process includes: removing the injection device from the laminate, transferring the laminate to a heating furnace or induction heating device located at a different position from the injection device, using the heating furnace or the induction heating device to raise the temperature of the synthetic resin material injected into the laminate to the second temperature, and curing the synthetic resin material.

7. A method for manufacturing a motor core, comprising: The laminate manufacturing process involves stacking multiple steel plates to create a laminate having a magnet housing portion extending along the stacking direction of the steel plates. In the magnet arrangement process, permanent magnets extending along the stacking direction of the plurality of steel plates are arranged within the magnet receiving portion, and In the fixing process, a synthetic resin material that is solid at room temperature, softens at a first temperature higher than room temperature, remains uncured at the first temperature, and cures at a second temperature higher than the first temperature is used to fix the permanent magnet in the magnet housing. The fixed process includes: In the injection process, using an injection device having a container and a nozzle, a portion of the softened synthetic resin material in the container is injected from the nozzle into the magnet receiving part. The container has a heating device that sets the temperature of the synthetic resin material to the first temperature to maintain the synthetic resin material in a softened state. In the curing process, while the synthetic resin material remaining in the container and nozzle of the injection device is in a softened state, the laminate is transferred to a heating furnace or induction heating device located at a different position from the injection device. The heating furnace or induction heating device is used to raise the temperature of the synthetic resin material injected into the laminate to the second temperature, thereby curing the synthetic resin material.

8. The method for manufacturing a motor core according to claim 7, wherein, In the injection process, the laminate is heated in such a way that the temperature of the laminate is higher than the first temperature and lower than the second temperature.

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