Rotor, method of manufacturing a rotor, and motor

Abstract

The present invention is to provide a rotor which reduces the number of components, reduces manufacturing costs, and realizes weight reduction. As a solution, a plurality of plate-shaped magnets (6) are partially bonded by a first adhesive (8a) at a prescribed interval via a positioning member (10) positioned on the inner circumferential surface (5a) of the rotor yoke (5) in the radial and axial directions, the positioning member (10) is removed, a second adhesive (8b) is heat-cured, and the plurality of plate-shaped magnets (6) are bonded and fixed to each other at a prescribed interval with a gap in the circumferential direction.

Description

Technical Field

[0001] This invention relates to a motor rotor, a method for manufacturing the rotor, and a motor. Background Technology

[0002] For example, in high-output motors, rare-earth magnets, such as those primarily composed of neodymium, are used as rotor magnets. When using rare-earth magnets to manufacture multi-pole magnets, to achieve lightweight and low-cost operation, segmented magnets, divided into sections for each pole, are used instead of toroidal magnets. However, it is difficult to arrange and fix these segmented magnets circumferentially along the rotor yoke in a specified position. Rare-earth magnets have stronger magnetic force than ferrite magnets, but they are also prone to rusting; therefore, nickel plating is applied to the surface for rust prevention to improve corrosion resistance. Furthermore, the friction of the adhesive surface decreases when wetted with adhesive, making the magnets prone to movement. Especially if epoxy resin adhesives are used, the viscosity of the adhesive temporarily decreases during the heat curing process, easily causing the magnets to shift position. If the magnets shift position, motor characteristics deteriorate, potentially causing motor vibration or noise.

[0003] Therefore, for example, in the rotor of an external rotor motor, such as Figure 6A As shown, a positioning member 53, which positions and holds multiple segment magnets 52 relative to a cylindrical rotor yoke 51, positions and bonds each segment magnet 52 radially and axially. Comb-shaped separating members 53b are formed at predetermined intervals from the annular connecting portion 53a of the positioning member 53. The annular connecting portion 53a defines the axial position of the segment magnets 52, and the separating members 53b define the radial position. After the positioning member 53 is inserted along the inner circumferential surface 51a from one end opening of the rotor yoke 51, the segment magnets 52 coated with adhesive 54 are inserted and bonded between the separating members 53b from the other end opening of the rotor yoke 51 (see reference). Figure 6A Then, the adhesive 54 is heated and cured to bond and fix the section magnet 52 together with the positioning member 53 to the inner peripheral surface 51a of the rotor yoke 51 (see reference). Figure 6B Next, the rotor hub 56, which is integrally assembled with the rotor shaft 55, is pressed into and fixed to the rotor yoke 51 (see reference). Figure 6C This forms an outer rotor type rotor 57 capable of rotating around the rotor shaft 55 (see reference). Figure 6D ).

[0004] Similarly, in the rotor of an internal rotor type motor, after the positioning member 53 is mounted from one axial side to the outer peripheral surface 51b of the cylindrical rotor yoke 51 centered on the rotor shaft 55, the segment magnet 52 coated with adhesive 54 is inserted from the other axial side between the separating members 53b and bonded (see reference). Figure 7AThen, an inner rotor type rotor 57 is formed, and the adhesive 54 is heated and cured to bond and fix the segment magnet 52 together with the positioning member 53 to the outer peripheral surface 51b of the rotor yoke 51 (see reference). Figure 7B ).

[0005] In addition, a technique has been proposed to enhance the retaining force of magnets installed in the rotor yoke of an external rotor motor to prevent the magnets from tipping over during assembly, thereby improving workability. A cylindrical inner shell is embedded into the inner surface of a cylindrical rotor outer shell, and a resin retaining ring is integrally assembled between the rotor outer shell and the inner shell. The resin retaining ring is used to arrange multiple magnets circumferentially with spacers (see Patent Document 1: Japanese Patent Application Publication No. 2003-304660).

[0006] Existing technical documents

[0007] Patent documents

[0008] Patent Document 1: Japanese Patent Application Publication No. 2003-304660 Summary of the Invention

[0009] The technical problem that the invention aims to solve

[0010] However, in Figure 6D and Figure 7B In Patent Document 1, since the segment magnet 52 is bonded and fixed together with the positioning member 53 to the inner circumferential surface 51a or outer circumferential surface 51b of the rotor yoke 51, if the adhesive is heated and cured, the originally unnecessary positioning member 53 will be bonded together with the segment magnet 52 to the rotor yoke 51, making it impossible to remove the positioning member 53. Furthermore, the resin retaining ring in Patent Document 1 is used as an essential component for fixing the magnet.

[0011] In this way, assembling the originally unnecessary positioning component 53 or resin retaining ring onto the rotor 57 will not only increase the number of parts and thus increase the manufacturing cost, but also increase the weight of the motor.

[0012] Furthermore, if the segment magnet 52 is glued and fixed to the rotor yoke 51 without using the positioning member 53, then as Figure 8A As shown, in order to position the segment magnet 52 on the inner circumferential surface of the rotor yoke 51, it is necessary to alternately form concave portions 51a and convex portions 51b in the circumferential direction. Or as... Figure 8B As shown, a comb-shaped positioning member 56a needs to be provided on the outer periphery of the rotor hub 56 pressed into the rotor yoke 51. In either case, the machining time of the component will increase, thereby increasing the manufacturing cost.

[0013] Technical solutions adopted to solve technical problems

[0014] The present invention was made to solve the above-mentioned technical problems. Its purpose is to provide a rotor that reduces the number of parts, lowers manufacturing costs, and achieves lightweight design; to provide a method for manufacturing a rotor with good assemblability that can be assembled to a rotor yoke by radial and axial positioning of plate magnets; and to provide a motor that uses a rotor, is inexpensive, has good assemblability, and can maintain motor characteristics.

[0015] To solve the above-mentioned technical problems, the present invention includes at least the following structure.

[0016] A rotor comprising, at predetermined intervals, a plurality of plate-shaped magnets divided circumferentially on the circumferential surface of a rotor yoke, characterized in that the plate-shaped magnets are flat plate magnets, and a first adhesive portion and a second adhesive portion are formed adjacently or partially overlapping on the adhesive surfaces of the magnets using a plurality of adhesives with different curing conditions. The first adhesive portion is coated with a first adhesive that cures for a predetermined time, and the second adhesive portion is coated with a thermosetting second adhesive that requires a longer curing time but has a higher adhesive strength than the first adhesive. An adhesive layer is formed in the gap between the curved surface of the rotor yoke and the flat surface of the plate-shaped magnets as an adhesive accumulation portion for the first adhesive and the second adhesive. The plurality of plate-shaped magnets, positioned radially and axially on the circumferential surface of the rotor yoke, are partially bonded to the first adhesive portion by curing the first adhesive and then bonded and fixed to each other at the first adhesive portion and the second adhesive portion by thermosetting the second adhesive.

[0017] Therefore, since a first adhesive that cures for a specified time is applied to the bonding surface of the plate magnet, the plate magnet can be positioned radially and axially on the rotor yoke and partially bonded at the first bonding portion. Since a thermosetting second adhesive that requires a longer curing time but has a higher bonding strength than the first adhesive is thermosetting, multiple plate magnets are bonded and fixed to each other in the circumferential direction at the first bonding portion and the second bonding portion with a specified gap. Therefore, it is possible to reduce the number of positioning components that were originally unnecessary, reduce manufacturing costs, and achieve rotor weight reduction.

[0018] In addition, since multiple plate-shaped magnets are bonded and fixed to the rotor yoke at specified intervals, cost reduction can be achieved compared with ring magnets. Furthermore, the radial and axial positioning accuracy of the plate magnets relative to the rotor yoke is high, and assembly can be performed without positional misalignment.

[0019] In particular, since the bonding of the flat magnet requires no special processing, not only can manufacturing costs be reduced, but the gap formed between the flat magnet and the curved surface that serves as the bonding surface for the rotor yoke can be used as an adhesive accumulation area for both the first and second adhesives, thus maintaining the bonding strength between the first and second bonding portions. Furthermore, when ultraviolet irradiation is applied while the flat magnet portion is bonded to the first bonding portion, sufficient space can be ensured for ultraviolet light to irradiate from the gap between the curved surface and the flat surface.

[0020] Ideally, the plate magnet is a rare-earth magnet with a rust-proof surface treatment, and the first adhesive and the second adhesive are sandwiched in the gap between the rotor yoke and the plate magnet.

[0021] Therefore, it is possible to use adhesives with different curing conditions to bond and fix high-output plate magnets relative to the rotor yoke without causing positional displacement.

[0022] Ideally, regarding the bonding surface of the aforementioned plate magnet, the area of ​​the first bonding portion coated with the first adhesive and the area of ​​the second bonding portion coated with the second adhesive, the second bonding portion has the same area as or a larger area than the first bonding portion.

[0023] This allows the final bonding strength of the plate magnet relative to the rotor yoke to be maintained.

[0024] The first adhesive mentioned above can also be any one of ultraviolet curing adhesives, anaerobic curing adhesives, and instant adhesives.

[0025] Therefore, by irradiating the first adhesive layer sandwiched between the plate magnet and the rotor yoke with ultraviolet light or making it anaerobic, or by bringing it into contact with an instant adhesive, or by a combination of the above methods, the plate magnet can be easily bonded to the rotor yoke portion due to the curing of the first adhesive. Furthermore, when the thermosetting second adhesive is heated and cured, the plate magnet is partially bonded by the first adhesive, thus preventing positional shift.

[0026] It can also be a rotor of an external rotor type motor in which multiple plate-shaped magnets divided circumferentially are fixed at predetermined intervals on the inner circumferential surface of the rotor yoke, which is formed in a cup shape, or a rotor of an internal rotor type motor in which multiple plate-shaped magnets divided circumferentially are fixed at predetermined intervals on the outer circumferential surface of the rotor yoke, which is formed in a cylindrical shape.

[0027] Compared to ring magnets, it can achieve cost reduction and weight reduction, and both the outer rotor type and the inner rotor type can be assembled with high radial and axial positioning accuracy of the plate magnet relative to the rotor yoke.

[0028] In a motor, by including any of the rotors described above; and a stator having stator pole teeth opposite to the plate magnets of the rotor, it is possible to provide an inexpensive, lightweight, easily assemblable external rotor motor or an internal rotor motor that can maintain motor characteristics.

[0029] The method for manufacturing a rotor is characterized by comprising: a step of applying a first adhesive (UV-curable type) to the bonding surfaces of multiple plate-shaped magnets, with the gaps formed between the curved surface of the rotor yoke and the plane of the plate-shaped magnets serving as adhesive accumulation portions; a step of applying a second thermosetting adhesive (requiring a longer curing time but with higher bonding strength than the first adhesive) to the bonding surfaces of the plate-shaped magnets, with the gaps formed between the curved surface of the rotor yoke and the flat surface of the plate-shaped magnets serving as adhesive accumulation portions; and a step of installing a positioning member on the circumferential surface of the rotor yoke, wherein the positioning member is formed by radially and axially positioning the plate-shaped magnets. The process comprises: a process in which comb-shaped partition members for positioning are connected in a ring; a process in which the plate-shaped magnet is positioned between the partition members of the rotor yoke on which the positioning members are mounted and disposed at a predetermined interval on the circumferential surface of the rotor yoke via the first adhesive and the second adhesive; a process in which the first adhesive applied to the plate-shaped magnet is cured and the plate-shaped magnet is positioned radially and axially relative to the rotor yoke and partially bonded at the first bonding portion; a process in which the positioning members are removed from the rotor yoke; and a process in which the second adhesive is heat-cured and the plate-shaped magnet is bonded and fixed relative to the rotor yoke at the first bonding portion and the second bonding portion.

[0030] Furthermore, the first and second adhesives applied to the bonding surfaces of the plate magnet include two cases: direct application to the bonding surfaces and pre-supply to the bonding surfaces for indirect application. Additionally, when referring to a plate magnet, it can be any sheet material with a certain thickness, and is not limited to flat plates; it also includes various forms such as curved plates.

[0031] According to the rotor manufacturing method described above, by installing a positioning member consisting of comb-shaped partition members that are positioned radially and axially connected in a ring on the rotor yoke, plate-shaped magnets can be positioned and arranged radially and axially between the partition members.

[0032] In addition, after the first adhesive applied to the plate magnet has cured and the plate magnet has been bonded to the rotor yoke at the first bonding portion, the positioning member can be removed from the rotor yoke. By omitting the originally unnecessary positioning member, the number of parts can be reduced, manufacturing costs can be lowered, and the rotor can be made lighter.

[0033] In addition, after removing the positioning member from the rotor yoke, the thermosetting second adhesive applied to the plate magnet is thermosetting and bonded to the rotor yoke at the first and second bonding portions, thus enabling the plate magnet to be bonded and fixed with high positional accuracy.

[0034] In particular, since the gap formed between the flat surface of the plate magnet and the curved surface that serves as the bonding surface of the rotor yoke can be used as an adhesive storage area for the first adhesive and the second adhesive, the bonding strength of the first bonding part and the second bonding part can be maintained.

[0035] Alternatively, it can be a method for manufacturing the rotor of an external rotor type motor, comprising: a step of mounting a positioning member, which is formed by connecting comb-shaped partition members that position the plate-shaped magnets radially and axially to an annular connecting portion, onto the inner peripheral surface of the cylindrical rotor yoke; a step of inserting a plurality of the plate-shaped magnets between the partition members and positioning them on the inner peripheral surface of the rotor yoke at predetermined intervals via the first adhesive and the second adhesive; and a step of integrally assembling the rotor hub and the rotor shaft onto the rotor yoke.

[0036] Alternatively, it can be a method for manufacturing the rotor of an internal rotor type motor, comprising: a step of mounting a positioning member, which is formed by connecting comb-shaped partition members that position the plate magnets in the radial and axial directions to an annular connecting portion, onto the outer peripheral surface of the rotor yoke centered on the rotor shaft; and a step of inserting a plurality of the plate magnets between the partition members and positioning them on the outer peripheral surface of the rotor yoke at predetermined intervals via the first adhesive and the second adhesive.

[0037] The first adhesive may also be at least one of ultraviolet curing adhesive, anaerobic curing adhesive and instant adhesive, and is used to bond the plate magnet relative to the rotor yoke portion.

[0038] Thus, by irradiating the first adhesive layer sandwiched between the plate magnet and the rotor yoke with ultraviolet light, or by placing it in an anaerobic state, or by contacting it with the bonding surface of the magnet, or by a combination of the above methods, the first adhesive is cured, and therefore the plate magnet can be easily bonded to the rotor yoke portion.

[0039] Alternatively, the multiple plate magnets may be magnetized before being bonded to the rotor yoke, or after being bonded to the rotor yoke.

[0040] If the plate magnets are pre-magnetized, they may attract and stick to each other when inserted into the rotor yoke, but this will not happen by using positioning members.

[0041] In addition, if the plate magnets are magnetized after being bonded to the rotor yoke, the assembly of the plate magnets becomes easier and less susceptible to thermal demagnetization.

[0042] Invention Effects

[0043] As described above, it is possible to provide a rotor that reduces the number of parts, lowers manufacturing costs, and achieves lightweight design.

[0044] In addition, a method for manufacturing a well-assembled rotor is provided, which can perform radial and axial positioning of multiple plate magnets and bond them to the rotor yoke with high positional accuracy.

[0045] In addition, it is possible to provide a motor that uses the aforementioned rotor, is inexpensive, has good assemblability, and can maintain motor characteristics. Attached Figure Description

[0046] Figures 1A to 1E This is an explanatory diagram showing the manufacturing process of the rotor of an external rotor type motor.

[0047] Figures 2A to 2D This is an explanatory diagram showing the manufacturing process of the external rotor type motor following Figure 1.

[0048] Figures 3A1 to 3B3 This is an explanatory diagram showing the form of a plate-shaped magnet that is bonded and fixed to the rotor yoke.

[0049] Figures 4A to 4C This is an explanatory diagram showing the manufacturing process of the rotor of an internal rotor type motor.

[0050] Figure 5A and Figure 5B This is an explanatory diagram showing the bonding area of ​​the first and second bonding parts of a plate magnet.

[0051] Figures 6A to 6D This is a process diagram showing the manufacturing method of the rotor of an existing external rotor type motor.

[0052] Figure 7A and Figure 7B This is a process diagram showing the manufacturing method of the rotor of an existing internal rotor type motor.

[0053] Figure 8A and Figure 8B This is an explanatory diagram showing the necessary structures of the rotor yoke and rotating hub. Detailed Implementation

[0054] Hereinafter, with reference to the accompanying drawings, an embodiment of the rotor, the rotor manufacturing method, and the motor of the present invention will be described. First, the schematic structure of the motor will be described with reference to FIG1. ​​In this embodiment, as an example of a motor, an external rotor type or an internal rotor type DC brushless motor described later is used.

[0055] like Figure 2C , Figure 2D As shown, the DC brushless motor uses an external rotor type motor M, comprising a rotor 1 and a stator 2. The rotor 1 is cup-shaped by being embedded in a rotor hub 4 connected to the rotor shaft 3, thereby closing one end opening of a cylindrical rotor yoke 5 (made of magnetic material such as iron or SUS). On the inner circumferential surface 5a of the rotor yoke 5 (refer to...) Figure 2A )A multi-plate magnet 6 (rotor magnet) is bonded and fixed together, which is alternately magnetized into N or S poles along the circumference (see reference). Figure 2B Each plate magnet 6 is arranged opposite to the stator pole teeth 7b of the stator core 7, which will be described later. Furthermore, when referred to as a plate magnet 6, it can be any magnetic plate material with a certain thickness, and is not limited to a flat plate (see [reference]). Figure 3B1 It also includes bent plates (see reference). Figure 3A1 (and other forms)

[0056] like Figure 2C As shown, the stator 2 has a stator core 7 assembled on the outer periphery of the bearing housing 2a. Multiple stator pole teeth 7b of the stator core 7 protrude radially outward from the annular core back 7a. The stator core 7 can be either a laminated core formed by stacking and stamping electromagnetic steel plates or a block core composed of magnetic metal blocks. The stator pole teeth 7b of the stator core 7 are surrounded by an insulator (insulated winding tube) 7c, and coils 7d are wound around the insulator 7c. The rotor 1 inserts the rotor shaft 3 into the bearing housing 2a of the stator 2, and the plate magnet 6 is assembled with the stator pole teeth 7b of the stator core 7 in a rotatable configuration (see reference). Figure 2D ).

[0057] Here, the structure of rotor 1 will be described in detail.

[0058] like Figure 3A3 , Figure 3B3 As shown, multiple plate-shaped magnets 6, circumferentially divided into multiple plates, are arranged with predetermined intervals on the inner circumferential surface 5a of the cylindrical rotor yoke 5. The plate-shaped magnets 6 are made of rare-earth magnets (e.g., neodymium magnets) with rust-proof surfaces. A first adhesive 8a and a second adhesive 8b are sandwiched between the rotor yoke 5 and the plate-shaped magnets 6 for bonding. Thus, as will be described later, different types of adhesives can be used to bond and fix the high-output plate-shaped magnets 6 relative to the rotor yoke 5 without causing positional displacement.

[0059] like Figure 5A , 5BAs shown, a first adhesive portion 6a and a second adhesive portion 6b are formed adjacent to each other on the bonding surface 6c of each plate magnet 6. The first adhesive portion 6a is coated with a first adhesive 8a that cures for a predetermined time, and the second adhesive portion 6b is coated with a second adhesive 8b for main fixation that requires a longer curing time than the first adhesive 6a but has a higher bonding strength. The first adhesive 8a can be, for example, an ultraviolet-curing adhesive, or an adhesive composed of an ultraviolet-curing adhesive and an anaerobic-curing adhesive, and the second adhesive 8b can be, for example, a thermosetting epoxy resin adhesive. Thus, by irradiating the first adhesive 8a sandwiched between the plate magnet 6 and the rotor yoke 5 with ultraviolet light, the first adhesive 8a can be cured in a relatively short time to form the separating portion (first adhesive cured portion) 8c that separates the plate magnets 6. Therefore, the plate magnets 6 can be easily bonded to the rotor yoke 5. Furthermore, when the second adhesive 8b is heated and cured, the plate magnet 6 is positioned circumferentially by the partition 8c and partially bonded by the first adhesive portion 8a, thus preventing positional displacement. The state in which the plate magnet 6 is bonded to the inner circumferential surface 5a of the rotor yoke 5 is shown in... Figure 3B3 In addition, the first adhesive 8a applied to the first bonding portion 6a of the plate magnet 6 and the second adhesive 8b applied to the second bonding portion 6b include two cases: one is applied directly to the bonding surface 6c, and the other is applied indirectly by pre-supplying the adhesive to the bonding surface (the inner circumferential surface 5a of the rotor yoke 5).

[0060] Plate magnet 6 is plate-shaped, such as Figure 3B2 As shown, an adhesive storage portion for the first adhesive 8a and the second adhesive 8b is formed in the gap 9 formed between the curved inner circumferential surface 5a of the rotor yoke 5 and the bonding surface 6c of the flat plate magnet 6. In this case, since no special processing of the plate magnet 6 is required, not only can the manufacturing cost be reduced, but the gap 9 formed between the inner circumferential surface 5a (curved surface) which serves as the bonding surface of the rotor yoke 5 can also be used as an adhesive storage portion for the first adhesive 8a and the second adhesive 8b, thereby maintaining the strength of partial or fixed bonding. In particular, when irradiating ultraviolet light during partial bonding, sufficient space can be ensured for ultraviolet light to be irradiated from the gap between the inner circumferential surface 5a (curved surface) and the end face of the flat plate magnet 6.

[0061] like Figure 5A , Figure 5B As shown, ideally, in the bonding region of the bonding surface 6c of the plate magnet 6, the second bonding portion 6b has the same area as the first bonding portion 6a (see reference). Figure 5A (or an area larger than the first adhesive portion 6a (the second adhesive portion 6b > the first adhesive portion 6a)) (see reference) Figure 5BTherefore, the bonding strength between the plate magnet 6 and the rotor yoke 5 can be maintained.

[0062] As described above, the first adhesive 8a uses at least one of ultraviolet-curing adhesive, anaerobic-curing adhesive, and instant adhesive, while the second adhesive 8b uses a thermosetting epoxy resin adhesive. Therefore, by irradiating the first adhesive 8a sandwiched between the plate magnet 6 and the rotor yoke 5 with ultraviolet light, placing it in an anaerobic state, contacting it with an instant adhesive, or a combination of the above methods, the plate magnet 6 can be easily partially bonded to the rotor yoke 5 after the first adhesive 8a cures. Furthermore, when the second adhesive 8b is heated and cured, the plate magnet 6 is positioned circumferentially by the partition 8c and partially bonded by the first adhesive 8a, thus preventing positional shift.

[0063] In addition, the case where the plate magnet 6 is flat has been explained, but it can also be like... Figure 3A1 As shown, the bonding surface 6c is a curved plate with the same curvature as the rotor yoke 5. At this time, as... Figure 3A2 As shown, adhesive layers 8a and 8b are formed uniformly in the circumferential direction of the adhesive surface 6c between the curved inner circumferential surface 5a of the rotor yoke 5 and the bonding surface 6c of the plate magnet 6.

[0064] like Figure 5A , 5B As shown, a first adhesive portion 6a coated with a first adhesive 8a for partial bonding and a second adhesive portion 6b coated with a second adhesive 8b for bonding and fixing, which is heat-cured, are formed adjacent to the bonding surface 6c of the plate magnet 6. This is the same as in the case of the flat magnet. The state in which the plate magnet 6 is bonded to the inner circumferential surface 5a of the rotor yoke 5 is shown in... Figure 3A3 middle.

[0065] In addition, such as Figure 1C , Figure 1C As shown, a resin positioning member 10 is used to position and bond multiple plate-shaped magnets 6 to the inner circumferential surface 5a of the rotor yoke 5. The positioning member 10, made of resin molding material, includes an annular connecting portion 10a connected in a ring shape and multiple separating members 10b formed in a comb-like manner from the annular connecting portion 10a. The spacing between the separating members 10b is equal to or slightly wider than the width of the plate-shaped magnets 6. Furthermore, a flange portion 10c is provided extending radially outward from the annular connecting portion 10a for abutting against and positioning the open end of the rotor yoke 5.

[0066] like Figure 1DAs shown, the positioning member 10 (separating member 10b) is inserted into the inner circumferential surface 5a from one end opening of the rotor yoke 5, and the plate magnet 6 is inserted into the space between the separating members 10b from the other end opening to be positioned on the inner circumferential surface 5a in the radial and axial directions.

[0067] At this time, since the plate magnet 6 is coated with the first adhesive 8a at the first bonding portion 6a, the plate magnet 6 can be positioned in the radial and axial directions on the rotor yoke 5 and the first adhesive 8a can be cured (e.g., by irradiating with ultraviolet light) to partially bond it.

[0068] In addition, such as Figure 1E As shown, with the plate magnet 6 partially bonded to the inner circumferential surface 5a of the rotor yoke 5, the unnecessary positioning member 10 can be pulled out and removed from the rotor yoke 5. After removing the positioning member 10 from the rotor yoke 5, the plate magnet 6 is bonded and fixed at the second bonding portion 6b by heating and curing an epoxy resin-based second adhesive 8b at, for example, 100° to 180°. During the heating and curing process, the viscosity of the second adhesive 8b temporarily decreases, but because it is partially bonded by the first adhesive 8a, the plate magnet 6 does not shift in position.

[0069] This reduces the number of unnecessary positioning components 10, lowers manufacturing costs, and makes the rotor 1 lighter.

[0070] Furthermore, since multiple plate magnets 6 are bonded and fixed to the rotor yoke 5 at specified intervals using positioning members 10, cost reduction can be achieved compared to annular magnets, and assembly can be performed with high radial and axial positioning accuracy of the plate magnets 6 relative to the rotor yoke 5 without positional shift.

[0071] In this way, a rotor 1 of an external rotor type motor can also be formed, in which multiple plate-shaped magnets 6 divided circumferentially are fixed at specified intervals on the inner circumferential surface 5a of the rotor yoke 5.

[0072] Alternatively, it can be like Figure 4A , Figure 4A As shown, a positioning member 10 is used to position and bond multiple plate-shaped magnets 6 (bent plates) to the outer peripheral surface 5b of the rotor yoke 5 of the inner rotor type motor. The positioning member 10 is made of resin molding material and includes an annular connecting portion 10a connected in a ring and multiple separating members 10b formed in a comb-like manner from the annular connecting portion 10a. The flange portion 10c may also be omitted.

[0073] like Figure 4A , Figure 4AAs shown, the partition member 10b of the positioning member 10 is fitted into the outer peripheral surface 5b from one axial end of the rotor yoke 5, and the annular connecting portion 10a abuts against and is installed with one end face of the rotor yoke 5. Positioning is achieved radially and axially by inserting a plurality of plate magnets 6 from the other end face of the rotor yoke 5 between the partition members 10b.

[0074] At this time, since the plate magnet 6 is coated with the first adhesive 8a on the bonding surface 6c, the plate magnet 6 can be positioned on the rotor yoke 5 and partially bonded by curing the first adhesive 8a (e.g., by irradiating with ultraviolet light). With the plate magnet 6 partially bonded, the unwanted positioning member 10 can be pulled out and removed from the rotor yoke 5. After removing the positioning member 10 from the rotor yoke 5, the plate magnet 6 is bonded and fixed at the first bonding portion 6a and the second bonding portion 6b by heating and curing the second adhesive 8b at, for example, 100° to 180°. During the heating and curing process, the viscosity of the second adhesive 8b temporarily decreases, but because it is partially bonded by the first adhesive 8a, the plate magnet 6 does not shift position.

[0075] Thus, as Figure 4B As shown, a rotor 1 of an inner rotor type motor is obtained in which multiple plate-shaped magnets 6, which are divided circumferentially, are fixed at predetermined intervals on the outer peripheral surface 5b of a rotor yoke 5 that is formed into a cylindrical shape.

[0076] Based on the structure of rotor 1 above, compared with the ring magnet, it is possible to reduce costs and reduce weight. Whether it is an outer rotor type or an inner rotor type, the plate magnet 6 can be assembled with high positional accuracy relative to the rotor yoke 5 in the radial and axial directions.

[0077] In addition, in motor M, by including any of the above-mentioned rotors 1 and stator 2 having stator pole teeth 7b opposite to the plate magnets 6 of the rotors 1, it is possible to provide an inexpensive, lightweight, easy-to-assemble external rotor type motor or an internal rotor type motor that can maintain motor characteristics.

[0078] Here, the manufacturing process of the rotor 1 of the external rotor type motor will be described with reference to Figures 1 and 2. Figure 1A In this process, the rotor shaft 3 is embedded into the center of the rotor hub 4 and assembled integrally. For example... Figure 1B As shown, a first adhesive 8a, which cures for a predetermined time, is applied to the first bonding portions 6a of the multiple plate-shaped magnets 6. The first adhesive 8a can be, for example, at least one of ultraviolet-curing adhesives, anaerobic-curing adhesives, and instant adhesives. Furthermore, a second adhesive 8b, which requires a longer curing time but has higher bonding strength than the first adhesive 8a, is applied to the second bonding portions 6b adjacent to the first bonding portions 6a of the plate-shaped magnets 6. The second adhesive 8b can be, for example, a thermosetting epoxy resin adhesive.

[0079] In addition, such as Figure 1B As shown, the process of applying the first adhesive 8a and the second adhesive 8b is not limited to the case of directly applying them to the bonding surface 6c of the plate magnet 6, but also includes the case of indirectly applying at least one of the adhesives to the bonding surface (inner circumferential surface 5a) of the rotor yoke 5. That is, in Figure 1B Alternatively, the first adhesive 8a can be applied around the inner circumferential surface corresponding to the first adhesive portion 6a from one open end of the rotor yoke 5, and the second adhesive 8b can be applied to the second adhesive portion 6b of the plate magnet 6.

[0080] Next, as Figure 1C , Figure 1C As shown, a positioning member 10 is installed on the inner circumferential surface 5a of the rotor yoke 5. The positioning member 10 is formed by connecting a comb-shaped partition member 10b, which positions the plate magnet 6 in the radial and axial directions, to the annular connecting portion 10a. The partition member 10b is inserted from the open side of the other end of the rotor yoke 5 until the flange portion 10c abuts against the open end.

[0081] Next, plate-shaped magnets 6 are inserted from one open side between the partition members 10b of the rotor yoke 5, which are equipped with positioning members 10, and are arranged at predetermined intervals on the inner circumferential surface 5a of the rotor yoke 5 via a first adhesive 8a and a second adhesive 8b. The state in which the plate-shaped magnets 6 are bonded to the rotor yoke 5 is shown in [the diagram]. Figure 1D middle.

[0082] exist Figure 1D In a certain state, the first adhesive 8a applied to the plate magnet 6 is cured, and the plate magnet 6 is partially bonded to the rotor yoke 5 at the first bonding portion 6a. Specifically, the plate magnet 6 is partially bonded to the rotor yoke 5 by irradiating the first adhesive 8a with ultraviolet light in the case of an ultraviolet-curing adhesive, by isolating it from the outside air in the case of an anaerobic adhesive, or by contacting it with the plate magnet 6 in the case of an instant adhesive.

[0083] Furthermore, the first adhesive 8a can be any one of ultraviolet-curing adhesives, anaerobic-curing adhesives, and instant adhesives; for example, it can also be an adhesive that is a mixture of ultraviolet-curing adhesives and anaerobic adhesives. In this case, the adhesive on the end face of the plate magnet 6 is cured by ultraviolet irradiation, thereby isolating it from the outside air, thus making the interior (the interior of the void 9: see reference) Figure 3B2 The adhesive becomes anaerobic and solidifies.

[0084] Next, as Figure 1E As shown, the unwanted positioning member 10 is removed from the other end opening of the rotor yoke 5, which is partially bonded with the plate-shaped magnet 6.

[0085] Next, as Figure 2A As shown, it will be Figure 1A The rotor hub 4 and rotor shaft 3, assembled in the middle, are embedded into one end opening of the rotor yoke 5 and assembled as a single unit, thus forming rotor 1. The assembled state of rotor 1 is shown in... Figure 2B .

[0086] Next, the epoxy resin-based second adhesive 8b is heated and cured at a specified temperature within the range of 100°C to 180°C, and the plate-shaped magnet 6 is bonded and fixed relative to the inner circumferential surface of the rotor yoke 5 at the first adhesive portion 6a and the second adhesive portion 6b.

[0087] Alternatively, it could be any one of multiple plate magnets 6 that are magnetized before being bonded to the rotor yoke 5 and after being bonded to the rotor yoke 5.

[0088] If the plate magnets 6 are pre-magnetized, they may attract and adhere to each other when inserted into the rotor yoke 5. However, this problem is prevented by using the positioning member 10. Furthermore, if the plate magnets 6 are magnetized after being bonded to the inner circumferential surface 5a of the rotor yoke 5, the assembly of the plate magnets 6 becomes easier and less susceptible to thermal demagnetization.

[0089] Through the above process, rotor 1 is manufactured and assembled onto stator 2, thereby producing motor M. Specifically, as follows... Figure 2C As shown, rotor 1 inserts rotor shaft 3 into bearing housing 2a of stator 2 and is rotatably supported by bearings (not shown). The plate magnet 6 of rotor yoke 5 is arranged opposite to and assembled with stator pole teeth 7b of stator core 7 to enable rotation. Motor M, with rotor 1 assembled to stator 2, is shown in [the diagram / image / description]. Figure 2D .

[0090] In addition, in the case of rotor 1 of the internal rotor type motor, such as Figure 4A , Figure 4A As shown, the rotor 1 can be manufactured through the same process simply by using different methods for applying the first adhesive 8a and the second adhesive 8b.

[0091] That is, such as Figure 4A , Figure 4A As shown, a positioning member 10 is installed on the outer peripheral surface 5b of the rotor yoke 5, which is assembled into a column shape around the rotor shaft 3. This positioning member 10 is formed by connecting comb-shaped separating members 10b, which position the plate-shaped magnet 6 radially and axially, to an annular connecting portion 10a. Alternatively, as shown... Figure 4A As shown, the first adhesive 8a is applied around the outer peripheral surface 5b of the rotor yoke 5 corresponding to the first adhesive portion 6a, and the second adhesive 8b is applied to the adhesive surface 6c corresponding to the second adhesive portion 6b of the plate magnet 6. Alternatively, it can be done as follows: Figure 4A As shown, a first adhesive 8a is applied to the bonding surface 6c of the plate magnet 6, and a second adhesive 8b is applied to the second bonding portion 6b.

[0092] Next, as Figure 4A , Figure 4A As shown, a positioning member 10 is installed on the outer peripheral surface 5b of the rotor yoke 5. The positioning member 10 is formed by connecting a comb-shaped partition member 10b, which positions the plate magnet 6 in the radial and axial directions, to the annular connecting portion 10a. The partition member 10b is inserted in such a way that it fits along the outer peripheral surface 5b of the rotor yoke 5 until the annular connecting portion 10a abuts against the end face of the rotor yoke 5.

[0093] Next, plate-shaped magnets 6 are inserted between the partition members 10b of the rotor yoke 5, where the positioning member 10 is installed, and positioned on the outer peripheral surface 5b of the rotor yoke 5 via a first adhesive 8a and a second adhesive 8b, arranged at predetermined intervals. The state in which the plate-shaped magnets 6 are bonded to the rotor yoke 5 is shown in... Figure 4B .

[0094] exist Figure 4B In a certain state, the first adhesive 8a applied to the plate magnet 6 is cured, and the plate magnet 6 is partially bonded to the rotor yoke 5 at the first bonding portion 6a. Specifically, the plate magnet 6 is partially bonded to the rotor yoke 5 by irradiating the first adhesive 8a with ultraviolet light in the case of an ultraviolet-curing adhesive, by isolating it from the outside air in the case of an anaerobic adhesive, or by contacting the plate magnet 6 with an instant adhesive to cure it.

[0095] Next, as Figure 4C As shown, the rotor 1 is assembled by removing the unwanted positioning member 10 from the other end of the rotor yoke 5, which is partially bonded with the plate magnet 6.

[0096] Finally, the epoxy resin-based second adhesive 8b is heated and cured at a specified temperature of 100°C to 180°C, and the plate-shaped magnet 6 is bonded and fixed to the outer peripheral surface 5b of the rotor yoke 5 at the first adhesive portion 6a and the second adhesive portion 6b. Through the above process, the rotor 1 of the internal rotor type motor is manufactured.

[0097] Alternatively, it could be any one of multiple plate magnets 6 that are magnetized before being bonded to the rotor yoke 5 and after being bonded to the rotor yoke 5.

[0098] According to the above-described manufacturing method of rotor 1, by installing a positioning member 10, which is formed by connecting comb-shaped partition members 10b that are positioned in the radial and axial directions to an annular connecting portion 10a, on rotor yoke 5, plate-shaped magnets 6 can be positioned and arranged in the radial and axial directions between partition members 10b.

[0099] Furthermore, after the first adhesive 8a applied to the plate magnet 6 is cured and the plate magnet 6 is partially bonded to the rotor yoke 5 at the first bonding portion 6a, the positioning member 10 can be removed from the rotor yoke 5. By omitting the originally unnecessary positioning member 10, the number of parts can be reduced, the manufacturing cost can be lowered, and the rotor 1 can be made lighter.

[0100] In addition, after removing the positioning member 10 from the rotor yoke 5, the second adhesive 8b applied to the plate magnet 6 is heated and cured and bonded to the rotor yoke 5, thus enabling the plate magnet 6 to be bonded and fixed with high positional accuracy.

[0101] As explained above, a rotor 1 that reduces the number of parts, lowers manufacturing costs, and achieves lightweight design can be provided. Furthermore, a method for manufacturing a well-assembled rotor that allows for the radial and axial positioning of multiple plate magnets 6 and their high-precision bonding and fixation to the rotor yoke 5 can be provided.

[0102] In addition, it is possible to provide a motor M that uses the above-mentioned rotor 1, is inexpensive, has good assemblability, and can maintain motor characteristics.

Claims

1. A rotor comprising, at predetermined intervals, a plurality of circumferentially divided plate-shaped magnets on the circumferential surface of the rotor yoke, wherein the plate-shaped magnets are rare-earth magnets with rust-proof surfaces, characterized in that, A first adhesive portion and a second adhesive portion are formed adjacently or partially overlapping on the bonding surface of the flat magnet using multiple adhesives with different curing conditions. The first adhesive portion is coated with at least one of a first adhesive selected from UV-curable adhesive, anaerobic-curable adhesive, and instant adhesive, which cures for a specified time. The second adhesive portion is coated with a thermosetting second adhesive that requires a longer curing time but has a higher bonding strength than the first adhesive. An adhesive layer is formed by storing the gap between the curved surface of the rotor yoke and the flat surface of the flat magnet as an adhesive storage area for the first adhesive and the second adhesive. A plurality of plate-shaped magnets, which are positioned radially and axially on the circumferential surface of the rotor yoke, are bonded to the first bonding portion by the cured portion of the first adhesive included in the adhesive storage portion, and are then thermally cured by the second adhesive included in the adhesive storage portion. The plurality of plate-shaped magnets are bonded and fixed to each other at the first bonding portion and the second bonding portion with a predetermined gap in the circumferential direction.

2. The rotor as claimed in claim 1, characterized in that, Regarding the area of ​​the first adhesive portion coated with the first adhesive and the area of ​​the second adhesive portion coated with the second adhesive on the bonding surface of the flat magnet, the second adhesive portion has the same area as the first adhesive portion or an area larger than the first adhesive portion.

3. The rotor as described in claim 1 or 2, characterized in that, The rotor is the rotor of an external rotor type motor in which a plurality of flat plate magnets, divided circumferentially, are fixed at predetermined intervals on the inner circumferential surface of the rotor yoke, which is formed in a cup shape.

4. The rotor as described in claim 1 or 2, characterized in that, The rotor is the rotor of an internal rotor type motor in which a plurality of flat plate magnets, which are divided circumferentially, are fixed at predetermined intervals on the outer circumferential surface of the rotor yoke, which is formed into a cylindrical shape.

5. A motor, characterized in that, include: The rotor according to any one of claims 1 to 4; and the stator having stator pole teeth opposite to the plate-shaped magnet of the rotor.

6. A method for manufacturing a rotor, characterized in that, include: In a process of applying at least one of the following first adhesives to the bonding surface of a plate-shaped magnet divided into multiple rare earth magnets with rust-proofed surfaces, with the gap formed between the curved surface of the rotor yoke and the plate surface of the plate-shaped magnet serving as an adhesive accumulation area: a first bonding portion that is cured for a specified time, a UV-curable adhesive, an anaerobic curable adhesive, and an instant adhesive. In the bonding surface of the flat magnet, the gap formed between the curved surface of the rotor yoke and the flat surface of the flat magnet is used as an adhesive accumulation part, and a thermosetting second adhesive that requires a longer curing time but has a higher bonding strength than the first adhesive is applied to the second bonding part that is adjacent to or partially overlaps with the first bonding part. In the process of installing positioning members on the circumferential surface of the rotor yoke, the positioning members are formed by annularly connected comb-shaped separating members that position the flat magnet in the radial and axial directions. The process of positioning the flat magnet between the partition members of the rotor yoke on which the positioning member is installed and distributing it at a predetermined interval on the circumferential surface of the rotor yoke via the first adhesive and the second adhesive. The process of curing the first adhesive applied to the flat magnet and positioning and partially bonding the flat magnet relative to the rotor yoke in the radial and axial directions at the first bonding portion; The process of removing the positioning member from the rotor yoke; as well as The process of heat-curing the second adhesive, curing the first adhesive and the second adhesive in the bonding area including the adhesive accumulation portion, and bonding and fixing the flat magnet relative to the rotor yoke at the first bonding portion and the second bonding portion.

7. The method for manufacturing a rotor as described in claim 6, wherein the rotor is a rotor of an external rotor type motor, characterized in that, include: The process of installing a positioning member, which is formed by connecting a comb-shaped separating member that positions the flat magnet in the radial and axial directions to an annular connecting portion, onto the inner circumferential surface of the cylindrical rotor yoke. The process of inserting a plurality of the aforementioned flat magnets between the separating members, and positioning them on the inner circumferential surface of the rotor yoke at predetermined intervals via a first adhesive and a second adhesive; and The process of assembling the rotor hub and rotor shaft integrally onto the rotor yoke.

8. The method for manufacturing a rotor as described in claim 6, wherein the rotor is a rotor of an internal rotor type motor, characterized in that, include: The process of installing a positioning member, consisting of comb-shaped separating members that position the flat magnet radially and axially, connected to an annular connecting portion, onto the outer peripheral surface of the rotor yoke centered on the rotor shaft; and The process of inserting a plurality of the flat magnets between the separating members and positioning them on the outer peripheral surface of the rotor yoke at a predetermined interval via the first adhesive and the second adhesive.

9. The method for manufacturing a rotor as described in any one of claims 6 to 8, characterized in that, Its features are, The plurality of the plate-shaped magnets are magnetized before being bonded to the rotor yoke or after being bonded to the rotor yoke.

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