Manufacturing device of motor iron core and manufacturing method of motor iron core

Abstract

The apparatus for manufacturing a motor core according to the present disclosure comprises: a mold for holding a motor core including a resin filling part; a chamber formed in the mold, one end portion of the chamber communicating with the resin composition filling passage, and the resin composition filling passage communicating with the resin filling part; a plunger that conveys the thermosetting resin composition conveyed to the chamber toward the resin composition filling path; a heater disposed in the mold, or disposed in the mold and around the chamber; and an extruder that kneads the resin composition and conveys the kneaded resin composition to the chamber so as to introduce the resin composition into the chamber, the extruder being provided with: an extrusion conveyance path that conveys the resin composition therein; a screw disposed in the extrusion conveyance path and configured to knead and convey the resin composition; and a first temperature adjustment mechanism, at least a part of which is disposed inside the screw.

Description

Technical Field

[0001] The present disclosure relates to a manufacturing device and a manufacturing method of a motor core. Background Art

[0002] Among rotating electrical machines, there are rotating electrical machines in which permanent magnets are mounted on a motor core, such as a rotor core. When mounting permanent magnets on a motor core in this manner, a method is known in which a permanent magnet is inserted into a slot provided in the motor core, and then a resin composition is filled around the slot and cured (see, for example, Japanese Patent Application Publication No. 2013-009453).

[0003] Japanese Patent Application Laid-Open No. 2013-009453 describes that when a thermosetting resin composition is to be filled into slots of a rotor core, a resin sheet of a predetermined size in consideration of a required filling amount is placed in a pot and heated in the pot to soften and melt the resin sheet before filling. Summary of the invention

[0004] Problems to be solved by the invention

[0005] In the device described in Japanese Patent Gazette No. 2013-009453, it is usually necessary to prepare in advance more resin than the prescribed filling amount in consideration of the dimensional tolerance of the product, so as to avoid insufficient resin, such as thermosetting resin, to be filled in the groove. However, in this case, the thermosetting resin cannot be reused after curing, so when the resin filling portion is small due to the dimensional tolerance, there is a lot of waste of resin. In addition, the motor core adopts various shapes, and thus the shape of the slot for inserting the magnet also adopts various shapes, so there is basically no situation where the slot shape is the same in different vehicle models. Therefore, if you want to prepare a resin sheet of the best size for each motor core, you need to ensure storage space, etc., and the management cost will increase. In addition, there is also the problem that the management of multiple resin sheets becomes complicated.

[0006] In addition, as the development of rotating motors for driving / generating electricity mounted on electric vehicles is getting faster and faster, due to the diversification of the size and groove shape of the rotating motors themselves, the amount of resin used also tends to increase, so it is necessary to make the resin sheet larger. When the amount of filled resin increases, the temperature management of the resin tends to become difficult compared to the case where the amount of resin is small, and it is easy to produce temperature unevenness such as local overheating or insufficient heating. In the case of using a thermosetting resin composition, such temperature unevenness may become the main cause of the deviation of the timing of curing, so as a result, it may become the cause of poor filling of the resin composition.

[0007] In view of the above problems, an object of the present disclosure is to provide a motor core manufacturing apparatus and a motor core manufacturing method capable of suppressing loss of a resin composition and suppressing poor filling of the resin composition.

[0008] Solutions for solving problems

[0009] In order to achieve the above-mentioned purpose, the manufacturing device of the motor core of the first scheme of the present disclosure includes: a mold, which holds the motor core including a resin filling portion; a cavity, which is formed in the mold, and one end of the cavity is connected to a resin composition filling path, wherein the resin composition filling path is connected to the resin filling portion; a plunger, which transports the thermosetting resin composition delivered to the cavity toward the resin composition filling path; a heater, which is arranged in the mold, or in the mold and around the cavity; and an extruder, which mixes the resin composition and transports it to the cavity to put the resin composition into the cavity, the extruder including: an extrusion conveying path, which conveys the resin composition inside; a screw, which is arranged in the extrusion conveying path, mixes and conveys the resin composition; and a first temperature control mechanism, at least a part of which is arranged inside the screw.

[0010] In the manufacturing device of the motor core as described above, as the resin composition to be put into the cavity, there is no need to use a resin composition that is previously formed into a sheet, and the supply amount of the resin composition to the cavity can be easily changed, so the loss of the resin composition can be suppressed. In addition, the resin composition conveyed by the screw can be cooled or heated by the first temperature control mechanism. Therefore, for example, if the first temperature control mechanism is used to cool the resin composition, the temperature rise caused by the shear heat generated when the resin composition is conveyed can be suppressed. Thereby, the progress of the unintentional curing reaction during the conveyance of the resin composition can be suppressed, and the poor filling of the resin composition can be avoided. In addition, if the first temperature control mechanism is used to heat the resin composition, it can assist in rapid temperature rise when the resin composition in the extruder is heated. In addition, the shear heat generated when conveying the resin composition is mostly generated locally, which may become the cause of temperature unevenness, but if the resin composition is heated by the first temperature control mechanism, the effect of suppressing the temperature unevenness can also be expected.

[0011] A motor core manufacturing device according to a second aspect of the present disclosure is the motor core manufacturing device according to the first aspect of the present disclosure, wherein the extruder further includes a second temperature regulating mechanism disposed in the extrusion conveying path surrounding a portion of the screw.

[0012] In the manufacturing device of the motor core as described above, in addition to the first temperature regulating mechanism disposed inside the screw, a second temperature regulating mechanism disposed in the extrusion conveying path is also included, thereby cooling or heating the resin composition conveyed in the extrusion conveying path from both the inside and the outside. As a result, the temperature control of the resin composition during conveying can be implemented more reliably.

[0013] The manufacturing device of the motor core of the third embodiment of the present disclosure is in the manufacturing device of the motor core of the first or second embodiment of the present disclosure, wherein the first temperature control mechanism includes: an inlet path, having a heat medium supply port at one end of the inlet path, and extending from the base end side of the screw along the central axis of the screw; and an outflow path, one end of the outflow path is connected to the other end of the inflow path, and the outflow path extends toward the base end side of the screw.

[0014] In the above-described motor core manufacturing apparatus, a passage is formed through which a heat medium can pass through the inside of the screw, and thus the screw and the resin composition around the screw can be cooled or heated by supplying the heat medium into the screw.

[0015] A motor core manufacturing apparatus according to a fourth aspect of the present disclosure is the motor core manufacturing apparatus according to the third aspect of the present disclosure, wherein the heat medium used in the first temperature regulating mechanism is gas.

[0016] In the above-described motor core manufacturing apparatus, since gas is used as the heat medium used for the first temperature control means, the heat medium can be easily handled compared to the case of using a liquid heat medium.

[0017] The manufacturing device of the motor core of the fifth scheme of the present disclosure is any one of the manufacturing devices of the motor core of the first to fourth schemes of the present disclosure, wherein the screw includes: a first cylindrical screw body, on the periphery of which fins for conveying the resin composition are formed, and the top end of the first screw body is blocked; and a first flow path forming member, which is composed of a cylindrical body having a through hole extending in the long dimension direction at its center, and a plurality of grooves extending in the long dimension direction are formed on the periphery of the first flow path forming member, and the first flow path forming member is embedded in the first screw body in a manner that a gap is formed between the top end thereof and the bottom inside the first screw body.

[0018] In the above-described motor core manufacturing apparatus, the inflow path and the outflow path can be formed inside the screw by assembling the two members, and processing of the parts for the screw becomes easy.

[0019] The manufacturing device of the motor core of the sixth scheme of the present disclosure In the manufacturing device of the motor core of any one of the first to fourth schemes of the present disclosure, the screw includes: a second screw body, a fin for conveying the resin composition is formed on the periphery of the second screw body, and a plurality of through holes extending along the long dimension direction are formed inside the second screw body; and a second flow path forming member, connected to the top end of the second screw body so that the ends of the plurality of through holes are connected to each other.

[0020] In the above-described motor core manufacturing apparatus, the inflow path and the outflow path can be formed inside the screw by assembling two members, and processing of parts for the screw becomes easy.

[0021] The manufacturing device of the motor core of the seventh embodiment of the present disclosure is a manufacturing device of the motor core of the sixth embodiment of the present disclosure, wherein the second screw body is formed by connecting a plurality of split bodies having the fins formed on the periphery and a plurality of through holes extending in the long dimension direction formed on the inside in such a manner that the plurality of through holes are connected to each other.

[0022] In the above-described motor core manufacturing apparatus, since the screw body can be formed by connecting a plurality of split bodies, the length of the screw body can be easily made variable.

[0023] The manufacturing method of the motor core of the eighth scheme of the present disclosure includes the following steps: holding the motor core in a mold formed with a resin composition filling path in a manner that the resin composition filling path is connected to the resin filling part of the motor core; using an extruder capable of conveying the resin composition, adjusting the temperature of the resin composition and conveying the resin composition toward a cavity connected to the resin composition filling path, wherein the extruder comprises: an extrusion conveying path for conveying the resin composition inside; a screw arranged in the extrusion conveying path for kneading and conveying the resin composition; and a first temperature regulating mechanism, at least a part of which is arranged inside the screw; actuating a plunger capable of moving in the cavity to fill the softened resin composition in the cavity into the resin filling part; and solidifying the softened resin composition filled in the resin filling part.

[0024] In the manufacturing method of the motor core as described above, as the resin composition to be put into the cavity, there is no need to use a resin composition that has been pre-formed into a sheet, and the supply amount of the resin composition to the cavity can be easily changed, so the loss of the resin composition can be suppressed. In addition, for example, the first temperature control mechanism can be used to adjust the temperature of the resin composition and convey it to the cavity. Therefore, for example, the first temperature control mechanism can be used to cool the resin composition to suppress the temperature rise caused by the shear heat generated when conveying the resin composition. Thereby, the progress of the unintentional curing reaction during the conveyance of the resin composition can be suppressed, and the poor filling of the resin composition can be avoided. In addition, if the first temperature control mechanism is used to heat the resin composition, it can assist in rapid temperature increase when the temperature of the resin composition in the extruder is raised. In addition, the shear heat generated when conveying the resin composition is mostly generated locally, which may become the cause of temperature unevenness, but if the resin composition is heated by the first temperature control mechanism, the effect of suppressing the temperature unevenness can also be expected.

[0025] Effects of the Invention

[0026] According to the motor core manufacturing apparatus and the motor core manufacturing method disclosed in the present disclosure, it is possible to suppress loss of the resin composition and suppress poor filling of the resin composition. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic explanatory diagram showing an example of a motor core manufacturing apparatus according to an embodiment of the present disclosure.

[0028] Figure 2A Yes means Figure 1 The explanatory diagram of a part of the first temperature regulating mechanism of the motor core manufacturing device shown is a cross-sectional view and a side view showing one state of the screw manufacturing process.

[0029] Figure 2B Yes means Figure 1 The explanatory diagram of a part of the first temperature regulating mechanism of the motor core manufacturing device shown is a cross-sectional view and a side view showing one state of the screw manufacturing process.

[0030] Figure 2C Yes means Figure 1 The explanatory diagram of a part of the first temperature regulating mechanism of the motor core manufacturing apparatus shown is a cross-sectional view and a side view showing a manufactured screw.

[0031] Figure 3A It is an explanatory diagram showing a first modified example of the screw shown in FIG. 2 , and is a cross-sectional view and a side view showing a first screw body.

[0032] Figure 3BIt is an explanatory diagram showing a first modified example of the screw shown in FIG. 2 , and is a cross-sectional view and a side view showing a first flow path forming member.

[0033] Figure 3C It is an explanatory diagram showing a first modified example of the screw shown in FIG. 2 , and is a cross-sectional view and a side view of the screw of the first modified example.

[0034] Figure 4A It is an explanatory diagram showing a second modification of the screw shown in FIG. 2 , and is a cross-sectional view and a side view showing a state before a second screw body and a second flow path forming member are assembled.

[0035] Figure 4B It is an explanatory diagram showing a second modification of the screw shown in FIG. 2 , and is a cross-sectional view and a side view showing a state after a second screw body and a second flow path forming member are assembled.

[0036] Figure 5 This is a flowchart showing an example of a method for manufacturing a motor core according to an embodiment of the present disclosure.

[0037] Fig. 6A It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown.

[0038] Figure 6B It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown.

[0039] Fig. 7A It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown.

[0040] Figure 7B It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown.

[0041] Fig. 8A It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown.

[0042] Figure 8B It means executing Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 An operation explanatory diagram showing an example of the operation state of the motor core manufacturing device shown. DETAILED DESCRIPTION

[0043] This application is based on Japanese Patent Application No. 2022-092469 filed in Japan on June 7, 2022, and the contents thereof constitute a part of this application as the contents of this application.

[0044] In addition, the present disclosure should be more fully understood through the following detailed description. Through the following detailed description, the further application scope of the present application should become apparent. However, the detailed description and specific examples are preferred embodiments of the present disclosure, which are recorded only for the purpose of illustration. This is because, according to the detailed description, various changes and modifications are apparent to those skilled in the art within the spirit and scope of the present disclosure.

[0045] The applicant does not intend to dedicate any of the described embodiments to the public, and disclosed changes and alternatives that may not be literally included in the claims are also intended to be part of the invention under the doctrine of equivalents.

[0046] Hereinafter, various embodiments for implementing the present disclosure will be described with reference to the accompanying drawings. It should be noted that, below, the scope required for the description to achieve the purpose of the present disclosure is schematically shown, and the scope required for the description of the corresponding part of the present disclosure is mainly described, and the parts where the description is omitted are set as the content based on the known technology. In addition, the same or similar reference numerals are marked for the components that are identical or equivalent to each other in the figures, and repeated descriptions are omitted. Moreover, in the case where a plurality of components that are identical or equivalent to each other are included in one figure, sometimes only a few of them are marked with reference numerals for the convenience of the view.

[0047] <Motor core manufacturing equipment>

[0048] Figure 1: is a schematic diagram showing an example of a motor core manufacturing device according to an embodiment of the present disclosure. The motor core manufacturing device 1 according to the present embodiment may be a device for assembling permanent magnets 3 to a motor core, such as an inner rotor type rotor core 2. Furthermore, the assembly of the permanent magnets 3 may be achieved by resin molding. It should be noted that in the present embodiment, the rotor core 2 is illustrated as an example of a motor core, and the groove portion 4 (more strictly speaking, the filling space 6) of the rotor core 2 is illustrated as an example of a resin-filled portion of the motor core, but the present disclosure is not limited thereto. Specifically, the motor core manufacturing device 1 may be used, for example, to resin mold a portion of a stator core as a motor core on which a coil is wound, or the motor core manufacturing device 1 may be used to fill resin into through holes provided in the axial direction of an unriveted laminated core to fix the laminated core as a whole. In addition, in the following description, for ease of understanding, sometimes “ / ” is used. Figure 1 The description will be given with the X direction shown in the figure being the left-right direction, the Y direction being the front-back direction, and the Z direction being the height direction (or the up-down direction).

[0049] The resin composition P used in the motor core manufacturing device 1 of the present embodiment is a thermosetting resin composition. More specifically, it may mainly contain a thermosetting resin such as an epoxy resin, a phenolic resin, an unsaturated polyester resin, or a cyanate resin. In addition to the thermosetting resin, a curing agent, a filler, etc. may be added to the resin composition P.

[0050] like Figure 1 As shown, the manufacturing device 1 of the motor core of this embodiment includes at least: a manufacturing device body 10; a mold 20 for holding the rotor core 2; a chamber 30 that can accommodate a resin composition P; a plunger 35 that transports the resin composition P in the chamber 30; a heater 40, as an example of a heater that can heat the mold 20 and the chamber 30; and an extruder 50 for injecting the resin composition P into the chamber 30.

[0051] The manufacturing device body 10 may include: a base 11; a plurality of (e.g., four) pillars 12 three-dimensionally arranged on the surface of the base 11; and a top plate 13 supported by the top end of the pillar 12. The top plate 13 may have an upper mold 21 of a mold 20 described later fixed to the lower surface of the top plate 13, and an actuator (not shown) may be used to enable the top plate 13 to be raised and lowered in the vertical direction together with the pillar 12 and the upper mold 21.

[0052] The mold 20 is a member for holding the rotor core 2. Specifically, the mold 20 may include: an upper mold 21, which abuts against the upper part of the rotor core 2, more specifically, the upper surface of the rotor core 2, and supports it; and a lower mold 22, which abuts against the lower part of the rotor core 2, more specifically, the lower surface of the rotor core 2, and supports it. The lower mold 22 may include: a lower mold body 23; and a stage 24, which is provided on the lower mold body 23 and is used to place the rotor core 2. The rotor core 2 may be placed on the stage 24 or transported from the stage 24 by a robot arm (not shown) or the like.

[0053] In addition, a resin composition filling path 25 may be provided inside the carrier 24, and the resin composition filling path 25 is used to supply the resin composition P to the appropriate part of the rotor core 2 placed on the carrier 24. The path structure of the resin composition filling path 25 is preferably changed to match the structure of the rotor core 2 to be placed on the carrier 24. Regarding the carrier 24, a plurality of carriers with different structures of the resin composition filling path 25 are prepared in advance, and it is better to change and use them appropriately to match the size of the rotor core 2 to be maintained in the mold 20, the position of the groove portion 4, etc. In addition, the lower mold 22 may also include an elevator 26 for raising and lowering the carrier 24 to clean the resin composition filling path 25. It should be noted that, in this embodiment, an example is shown in which the resin composition filling path 25 is provided in the lower mold 22 and the resin composition P is filled from the bottom, but it is not limited to this. For example, a solution in which a resin composition filling path is provided in the upper mold 21 and the resin composition P is filled from the top can also be adopted.

[0054] In addition, the upper mold 21 may be movable in the vertical direction together with the top plate 13 as described above. And, by lowering the upper mold 21 when the rotor core 2 is placed on the stage 24 and pressing the upper surface of the rotor core 2 with a predetermined pressing force, the rotor core 2 can be held in a manner such that the rotor core 2 is sandwiched between the upper mold 21 and the lower mold 22. The shape, material, etc. of the surface of the upper mold 21 and the stage 24 that abuts against the rotor core 2 are preferably adjusted so that the resin composition P does not leak out of the rotor core 2 during the filling of the resin composition P described later. In other words, the shape, material, etc. of the surface of the upper mold 21 and the stage 24 that abuts against the rotor core 2 are adjusted so that the contact surface becomes a sealed state when the rotor core 2 is sandwiched. In addition, in the present embodiment, as described above, a structure is adopted in which the upper mold 21 moves up and down together with the top plate 13, but other structures may be adopted as long as the upper mold 21 and the lower mold 22 can be relatively changed in the vertical direction. Specifically, for example, instead of moving the upper mold 21 in the vertical direction, the lower mold 22 may be moved in the vertical direction, or both the upper mold 21 and the lower mold 22 may be moved.

[0055] In the present embodiment, as the groove portion 4 of the rotor core 2, a rectangular parallelepiped structure having substantially no gap in the front-back direction and the left-right direction is exemplified. Therefore, the upper mold 21 and the lower mold 22 adopt a structure having a substantially flat abutting surface, but the shape of the abutting surface of the upper mold 21 and the lower mold 22 can also be appropriately changed to match the shape of the rotor core 2 to be maintained. For example, when the motor core manufacturing device 1 of the present embodiment is used for resin molding of an inner rotor type stator core, it is preferable to adopt a structure including a protrusion inserted into the space formed in the center of the stator core as the upper mold 21 and the lower mold 22.

[0056] The rotor core 2 held in the above-mentioned mold 20 can be composed of, for example, a substantially cylindrical magnetic body formed by laminating a plurality of thin electromagnetic steel plates. A through hole 5 for inserting a shaft constituting a rotating shaft when assembled into a motor can be provided in the axial portion of the rotor core 2. In addition, one or more grooves 4 extending along the axial direction of the rotor core 2 can be provided in a manner surrounding the through hole 5. The groove 4 can be formed, for example, in a rectangular parallelepiped shape, but the specific shape is not particularly limited as long as it is a shape into which the permanent magnet 3 described later can be inserted.

[0057] The groove portion 4 of the rotor core 2 can be used for the permanent magnet 3 to be inserted and fixed therein. The permanent magnet 3 can be configured as a rectangular parallelepiped slightly smaller than the groove portion 4, for example. In addition, the permanent magnet 3 may be magnetized or not. When the permanent magnet 3 is inserted into the groove portion 4, a gap is at least partially formed between the outer peripheral surface of the permanent magnet 3 and the inner peripheral surface of the groove portion 4. The gap can function as a filling space 6, and the filling space 6 is an example of a resin filling portion. When the rotor core 2 is placed on the carrier 24, a portion of each of the multiple filling spaces 6 can be connected to the end of the resin composition filling path 25.

[0058] The cavity 30 may form a space into which a predetermined amount of the resin composition P to be filled in the filling space 6 is put. The cavity 30 may be formed in a manner extending in the up-down direction inside a support table 31 provided on the base 11. The upper end of the cavity 30 may be connected to the resin composition filling path 25 of the carrier 24 included in the lower mold 22 disposed on the support table 31.

[0059] The plunger 35 may be a member for conveying the resin composition P conveyed into the cavity 30 toward the resin composition filling path 25. The plunger 35 of this embodiment may form the lower surface of the cavity 30 and may be connected to an actuator (not shown) to freely move vertically in the cavity 30.

[0060] The heater 40 may be composed of a known heater or the like, and heats an appropriate portion of the manufacturing apparatus 1. The heater 40 of this embodiment may include: a mold heater 41, which is disposed in the mold 20, specifically, in the upper mold 21 and the lower mold body 23; and a cavity heater 42, which is disposed around the cavity 30 in the support table 31 in a manner close to the outer periphery of the cavity 30. As the mold heater 41 and the cavity heater 42, a known heater such as an infrared heater or a sheath heater may be used.

[0061] The extruder (sometimes also referred to as an "extruder") 50 may be a mechanism that is connected to the chamber 30 at one end and can mix the resin composition P and convey it toward the chamber 30. The extruder 50 includes at least: a sleeve 51 as an example of an extrusion conveying path, in which the resin composition P is conveyed; and a screw 52, ​​which is arranged inside the sleeve 51 and mixes and conveys the resin composition P supplied to the sleeve 51, such as a powdered resin composition P1. It should be noted that in the present embodiment, an extruder 50 extending in the left-right direction is shown as an example, but the extension direction of the extruder 50 is not limited to this, for example, it may extend obliquely upward from the chamber 30, or it may extend in the up-down direction side by side with the chamber 30. In the case where the extruder 50 and the chamber 30 are arranged side by side, it is better to ensure a space for conveying the resin composition P between the extruder 50 and the chamber 30 in advance. In addition, in the present disclosure, an example is given of supplying a powdered resin composition P1 as the resin composition P supplied to the sleeve 51, but it is not limited to a powdered resin composition, and may be in other shapes, for example, at least a portion of which may be in a paste or granular form. Moreover, the powdered resin composition P1 in the present disclosure refers to a resin composition P1 formed of smaller particles such as granules or particles (the particles also include particles such as small pieces obtained by crushing / breaking a larger resin block).

[0062] The sleeve 51 may be a conveying path extending in one direction, for example, in the left-right direction, for kneading and conveying the resin composition P. A supply port 53 for supplying the powdered resin composition P1 may be formed at one end of the sleeve 51, and a conveying port 54 connected to the chamber 30 may be formed at the other end. A resin composition supply source 58 may be connected to the supply port 53 via a resin composition supply path 57. In addition, a shutter 56, for example, a sliding or rotating type, may be provided at the conveying port 54.

[0063] The screw 52 may be composed of a long strip member having a spiral fin 52F formed on the outer peripheral surface and rotated by a motor 59 connected to one end thereof. The screw 52 may be arranged in the sleeve 51 along the extension direction of the sleeve 51 so as to mix the powdered resin composition P1 supplied from the supply port 53 and convey it toward the transport port 54. In addition, if the powdered resin composition P1 is continuously supplied to the screw 52, ​​the resin composition P being conveyed can also be pressurized. Therefore, the powdered resin composition P1 conveyed in the sleeve 51 may be mixed and pressurized by the screw 52 during its conveying process, thereby gradually changing into a paste-like resin composition P2. It should be noted that the paste-like state mentioned here refers to the state in which the powdered resin composition P is integrated to form a block, thereby becoming a paste or clay-like state.

[0064] The motor 59 connected to the screw 52 can adjust the delivery amount of the resin composition P by its rotation speed. Therefore, the amount of the paste resin composition P2 fed from the extruder 50 into the cavity 30 can be adjusted with high precision by controlling the rotation speed of the motor 59. It should be noted that the paste resin composition P2 mentioned here may also be a mixture of the paste resin composition P2 and the powdered resin composition P1. In addition, in the present embodiment, an example is given of controlling the delivery amount of the paste resin composition P2 into the cavity 30 by the rotation speed of the motor 59, but the control of the delivery amount is not limited to such a method. For example, the delivery amount of the paste resin composition P2 into the cavity 30 may also be controlled according to the volume of the paste resin composition P2 in the sleeve 51, or according to the thrust required to deliver the paste resin composition P2.

[0065] The extruder 50 may also include a temperature sensor that detects the temperature of the powdered resin composition P1 or the paste resin composition P2 conveyed in the sleeve 51, or the room temperature in the sleeve 51. Furthermore, if the rotation speed of the motor 59 is controlled based on the detection result of the temperature sensor and the preset amount of the resin composition to be fed into the cavity 30, the amount of the paste resin composition P2 to be fed into the cavity 30 can be adjusted with higher accuracy. It should be noted that, with respect to the extruder 50 of the present embodiment, an extruder having one screw 52 is exemplified, but the number of screws 52 may be two or more.

[0066] In addition, the manufacturing device 1 of this embodiment may further include a control device 60 in order to control the above-mentioned motor 59 and other components. Figure 1 As shown by the dotted line, the control device 60 can be connected to each component in a communicative manner via wired or wireless communication. The control device 60 can be implemented using a sequencer (Programmable Logic Controller, PLC: Programmable Logic Controller) or a well-known computer.

[0067] The motor core manufacturing device 1 of the present embodiment adopts the extruder 50 mainly having the above-mentioned structure, thereby being able to supply an arbitrary amount of the resin composition P to the cavity 30 without using a previously formed sheet-shaped resin composition. As a result, the amount of the resin composition P delivered to the cavity 30 (i.e., the amount fed into the cavity 30) can be freely adjusted by controlling the rotation speed of the motor 59, so the amount fed into the cavity 30 can be freely changed, and the loss of the resin composition P generated during the manufacturing process can be reduced. In addition, it is not necessary to select the resin sheet in accordance with the amount of the resin composition to be filled into the motor core (resin composition filling amount).

[0068] On the other hand, in an extruder that uses a screw 52 for kneading and conveying the resin composition P as in the above-mentioned extruder 50, the resin composition P is subjected to shear deformation by the screw 52 during its conveyance. Therefore, the temperature of the resin composition P may at least partially rise due to the shear heat generated during the deformation. When a thermosetting resin composition is used as the resin composition P as in the present embodiment, the curing reaction may proceed unintentionally due to the shear heat, and a part of it may be cured in the sleeve 51.

[0069] The unintentional progress of the curing reaction of the resin composition P in the sleeve 51 as described above may become a major cause of the deviation in the amount of the resin composition P supplied to the cavity 30, or may become a major cause of various problems when the rotation of the screw 52 is stopped due to the increase in the frequency of cleaning in the extruder 50 or the resin composition in the progress of the curing reaction being stuck. In addition, the unintentional progress of the curing reaction may also become a major cause of the uneven (melt) viscosity of the resin composition P supplied to the cavity 30. If the (melt) viscosity is too high, the fluidity inside the resin composition filling path 25, the groove 4, etc. may be impaired, and the resin composition P may not be filled into the filling space 6 in the rotor core 2. In view of this point, in the motor core manufacturing device 1 of the present embodiment, in order to suppress the unintentional temperature rise of the resin composition P, a first temperature control mechanism 70 is adopted. The first temperature control mechanism 70 is described below.

[0070] Figure 2 shows Figure 1 FIG. 1 is a diagram showing a portion of a first temperature control mechanism of a motor core manufacturing device, Figure 2A and Figure 2B It is a cross-sectional view and a side view showing a state of the screw manufacturing process. Figure 2CIt is a cross-sectional view and a side view showing the manufactured screw. It should be noted that in FIG2, the illustration of the fin 52F formed around the screw 52 is omitted. In addition, each cross-sectional view shown in FIG2 is a view obtained by cutting the screw 52 along a side extending in the long dimension direction passing through the central axis thereof, and a side view is a view showing the surface of the screw 52 connected to the base end side of the motor 59.

[0071] like Figure 2C As shown, at least a part of the first temperature control mechanism 70 of the motor core manufacturing device 1 of the present embodiment is arranged inside the screw 52, ​​thereby suppressing the temperature rise of the resin composition P kneaded and conveyed by the screw 52. The heat medium used in the first temperature control mechanism 70 may be a gas. Specifically, as the first temperature control mechanism 70 of the present embodiment, an air-cooling type cooling mechanism using air as a heat medium may be adopted, and a mechanism including an inflow path 74 and an outflow path 75 provided in the screw 52 may be adopted. As described above, when the heat medium of the first temperature control mechanism 70 is gas, its handling becomes easier than the case where a cooling mechanism using a liquid such as water as a heat medium is adopted.

[0072] It should be noted that, in the present embodiment, as the first temperature regulating mechanism 70, a mechanism for cooling the resin composition P is exemplified, but as long as the temperature of the heat medium is adjusted, the first temperature regulating mechanism 70 may be used to keep the resin composition P warm or to heat it. That is, the first temperature regulating mechanism 70 may be said to be a mechanism for adjusting the temperature of the resin composition P transported in the sleeve 51.

[0073] When the first temperature control mechanism 70 is used to heat the resin composition P, for example, when it is desired to raise the temperature of the resin composition P in the extruder 50, it can assist in rapid temperature rise. In addition, the shear heat generated when the resin composition P is transported in the extruder 50 is often generated locally in the sleeve 51, which may cause temperature unevenness. However, if the resin composition P in the sleeve 51 is heated by the first temperature control mechanism 70, the effect of suppressing the temperature unevenness can be expected.

[0074] More specifically, if Figure 1 and Figure 2C As shown, the first temperature adjustment mechanism 70 of this embodiment includes: a blower 71 as an example of a heat medium supply source; and a screw 52 having an inlet path 74 and an outlet path 75 through which the air supplied from the blower 71 passes.

[0075] The blower 71 is an example of a heat medium supply source, and the blower 71 can be connected to a heat medium supply port provided at the base end side of the inflow path 74 formed in the screw 52, ​​and can supply air as a heat medium into the inflow path 74. It should be noted that in the present embodiment, an air-cooling type cooling mechanism is adopted in the first temperature control mechanism 70, and therefore, an example is given of using air as a heat medium, but the heat medium is not limited thereto. Specifically, for example, water or other fluids can also be used as heat medium. In this case, it is sufficient to use other heat medium supply units instead of the blower 71.

[0076] The screw 52 may be formed with an inflow passage 74 at its center and a plurality of outflow passages 75 at positions close to its outer peripheral surface. One end of the inflow passage 74 located on the base end side of the screw 52 is opened at the end of the screw 52 to form a heat medium supply port, and the other end located on the top end side of the screw 52 is composed of a passage extending along the central axis of the screw 52 and connected to the outflow passage 75. In addition, the outflow passage 75 may be formed by a plurality of (two in FIG. 2 ) passages extending substantially parallel to the inflow passage 74 between the inflow passage 74 and the outer peripheral surface of the screw 52. The outflow passage 75 may be a passage in which one end located on the top end side of the screw 52 is connected to the other end of the inflow passage 74, and the other end located on the base end side of the screw 52 is connected to the outside of the sleeve 51.

[0077] As described above, when the inlet path 74 is formed along the central axis of the screw 52, ​​it is preferred to simplify the connection structure between the inlet path 74 formed in the rotating screw 52 and the blower 71. In connection therewith, in the first temperature control mechanism 70 of the present embodiment, air is used as the heat medium, and therefore, it is not necessary to recover the air flowing out of the outflow path 75. Therefore, the other end of the outflow path 75 only needs to be connected to the outside of the sleeve 51. It should be noted that, in the present embodiment, an example is given of setting two outflow paths 75 in a manner of clamping the inflow path 74 from the upper and lower directions, but the configuration and number of the outflow paths 75 can be appropriately changed. For example, four outflow paths 75 can be set in a manner of clamping the inflow path 74 from both the upper and lower directions and the left and right directions.

[0078] The other end of the inflow path 74 and one end of the outflow path 75 are connected via a communication path 76. Figure 2C As shown, the communication passage 76 can be formed by a passage extending in a direction intersecting the extension direction of the screw 52. The first temperature control mechanism 70 mainly allows air as a heat medium to pass through the inside of the communication passage 76 and the above-mentioned outflow passage 75, thereby cooling the screw 52 and the resin composition P transported around the screw 52. Therefore, it is better to arrange the communication passage 76 and the outflow passage 75 at a position close to the outer peripheral surface of the screw 52.

[0079] Hereinafter, an example of a method for manufacturing the screw 52 having the above-mentioned structure will be briefly described. Figure 2A As shown in FIG. 1 , three bottomed holes are formed along the long dimension direction of the screw 52 from the base end side of the long screw 52. The bottomed holes can form an inflow path 74 and an outflow path 75, respectively. Figure 2B As shown in the figure, a through hole is formed from the outer peripheral surface of the screw 52 in a manner that crosses the bottoms of the three bottomed holes. The through hole can form a communication path 76. Then, the two openings of the through hole are finally blocked by a sealing member 76S, thereby providing a screw 52 including an inlet path 74 and an outlet path 75 whose ends are connected to each other through the communication path 76.

[0080] In the motor core manufacturing device 1 of the present embodiment, when the screw 52 is operated to convey the resin composition P to the chamber 30, the first temperature regulating mechanism 70 including the above-mentioned structure is operated. Thus, the screw 52 and the resin composition P kneaded and conveyed around the screw 52 can be cooled. Thus, the unintentional temperature rise caused by the shear heat generated when conveying by the screw 52 can be suppressed, and the filling failure caused by the progress of the curing reaction of the resin composition P before filling can be effectively suppressed. More specifically, the poor conveying of the resin composition P in the sleeve 51 and the increase in the frequency of the cleaning work in the sleeve 51 can be effectively suppressed.

[0081] In order to more reliably suppress the temperature rise caused by the shear heat generated in the resin composition P, the motor core manufacturing device 1 of this embodiment may be provided with a second temperature control mechanism 80 on the sleeve 51 side in addition to the first temperature control mechanism 70 described above. Figure 1 As shown, the second temperature control mechanism 80 is preferably provided at least in the portion of the screw 52 surrounding the sleeve 51. The second temperature control mechanism 80 may be, for example, a heat medium passage passing through the inside of the sleeve 51. The heat medium supplied to the heat medium passage is not particularly limited, and water, air, etc. may be used.

[0082] If the second temperature control mechanism 80 is used in addition to the first temperature control mechanism 70, the resin composition P kneaded and conveyed by the screw 52 can be cooled or heated from both the inside and the outside. Therefore, if these temperature control mechanisms are used for cooling, the temperature rise of the resin composition P caused by shear heat can be more efficiently suppressed. On the contrary, if these temperature control mechanisms are used for heating the resin composition P, more uniform heating can be achieved.

[0083] The cooling of the resin composition P by the first temperature control mechanism 70 or the cooling of the resin composition P by the first temperature control mechanism 70 and the second temperature control mechanism 80 can be performed at any timing during the conveyance of the resin composition P, so that the temperature of the conveyed resin composition P is 100° C. or less, preferably 70° C. or less, and more preferably 60° C. or less. The specific control of these temperature control mechanisms 70 and 80 can be mainly implemented by the control device 60.

[0084] In addition, in the motor core manufacturing device 1 of the present embodiment, the screw 52 of the first temperature regulating mechanism 70 is manufactured by the process shown in FIG2 , but it can also be manufactured by a method other than this manufacturing method. Therefore, several examples of screw bodies manufactured by a manufacturing method different from the above method are described below.

[0085] FIG3 is an explanatory diagram showing a first modified example of the screw shown in FIG2 , Figure 3A 1 is a cross-sectional view and a side view showing the first screw body, Figure 3B is a cross-sectional view and a side view showing a first flow path forming member, Figure 3C 1 is a cross-sectional view and a side view of the screw of the first variant. Figure 3C As shown, the screw 52A of the first modification may include a first screw body 72A and a first flow path forming member 73A.

[0086] like Figure 3A As shown in FIG. 3 , the first screw body 72A may be composed of a cylindrical member having a bottomed hole 72H extending in the longitudinal direction formed inside by blocking the top end. Fins 52F are formed on the periphery of the first screw body 72A, but are omitted in FIG. 3 . In the first screw body 72A, the base end side where the bottomed hole 72H is opened is connected to the motor 59, and the top end side may be arranged in the sleeve 51 as a free end.

[0087] like Figure 3B As shown, the first flow path forming member 73A can be formed by a cylindrical body having a through hole 77 extending in the long dimension direction at its center. The first flow path forming member 73A formed by the cylindrical body can be formed with a plurality of, for example, four, grooves 78 extending in the long dimension direction at its periphery. Then, the outer diameter of the first flow path forming member 73A is adjusted so that the first flow path forming member 73A can be embedded in the bottomed hole 72H of the first screw body 72A.

[0088] In addition, it is preferable that the outer peripheral surface of the first flow path forming member 73A where the groove 78 is not formed is provided with a non-illustrated anti-rotation structure for rotating with the first screw body 72A when inserted into the first screw body 72A. As the anti-rotation structure, a known meshing shape or the like can be adopted.

[0089] like Figure 3C As shown, the screw 52A of the first modified example can be formed by embedding (or pressing) the first flow path forming member 73A into the bottomed hole 72H of the first screw body 72A. When the first flow path forming member 73A is embedded in the bottomed hole 72H, the embedding length of the first flow path forming member 73A is set to be shorter than the depth of the bottomed hole 72H. As a result, a gap can be formed between the top end of the first flow path forming member 73A and the bottom surface of the bottomed hole 72H constituting the bottom in the first screw body 72A, so that the gap functions as a communication path 76.

[0090] The inflow passage 74 formed in the screw 52A can be formed by the through hole 77 of the first flow passage forming member 73A embedded in the bottom hole 72H. Similarly, the outflow passage 75 formed in the screw 52A can be formed by four passages defined by the inner peripheral surface of the bottom hole 72H and the groove 78 of the first flow passage forming member 73A embedded in the bottom hole 72H. And, one end of the inflow passage 74 formed in the screw 52A can be connected to one end of each outflow passage 75 via the above-mentioned connecting passage 76. In this way, by assembling two components to manufacture the screw 52A, the processing of the parts can be simplified.

[0091] FIG4 is an explanatory diagram showing a second modified example of the screw shown in FIG2 , Figure 4A is a cross-sectional view and a side view showing a state before the second screw body and the second flow path forming member are assembled, Figure 4B 1 is a cross-sectional view and a side view showing a state after the second screw body and the second flow path forming member are assembled. Figure 4B As shown, the screw 52B of the second modification may include a second screw body 72B and a second flow path forming member 73B.

[0092] like Figure 4A and Figure 4B As shown, the second screw body 72B can be composed of a columnar member having a plurality of through holes 74B, 75B extending in the longitudinal direction formed therein. The fin 52F is formed on the periphery of the second screw body 72B in the same manner as the first screw body 72A, but its illustration is also omitted in FIG. 4 . In the second screw body 72B, the base end side is connected to the motor 59, and the top end side can be arranged in the sleeve 51 as a free end. The through holes 74B, 75B formed in the second screw body 72B can include: a through hole 74B that can extend along the central axis of the second screw body 72B to form an inlet path 74; and a plurality of other through holes 75B that can form an outlet path 75 that is arranged around the one through hole 74B and extends substantially parallel to the one through hole 74B.

[0093] As an alternative, Figure 4AAs shown, the second screw body 72B of this modified example can also be formed by connecting a plurality of, for example, three, segmented bodies 72B1 to 72B3. The segmented bodies 72B1 to 72B3 can be composed of a columnar component having fins 52F formed on the periphery and a plurality of through holes 74B, 75B extending in the long dimension direction formed on the inside. The second screw body 72B can be formed by connecting each segmented body 72B1 to 72B3 in a manner that the plurality of through holes 74B, 75B of each segmented body 72B1 to 72B3 are connected to each other. In this way, when a structure is adopted in which a plurality of segmented bodies 72B1 to 72B3 are connected to form a second screw body 72B, the length of the screw 52B can be simply changed by appropriately changing the number of the above-mentioned connected segmented bodies.

[0094] The second flow path forming member 73B can be connected to the top end of the second screw body 72B so that the ends of the plurality of through holes 74B and 75B provided in the second screw body 72B are connected to each other. The second flow path forming member 73B can be composed of a columnar member whose outer diameter is adjusted according to the second screw body 72B. In addition, a connecting path 76B for connecting the top end of one through hole 74B with the top ends of two other through holes 75B can be formed at the base end of the second flow path forming member 73B.

[0095] The communication path 76B can be formed by, for example, a bottomed hole extending from the base end side of the second flow path forming member 73B along the central axis of the second flow path forming member 73B and two bottomed holes extending from the base end side of the second flow path forming member 73B in a direction inclined relative to the central axis of the second flow path forming member 73B so as to communicate with the bottom of the bottomed hole. In this modified example, the communication path 76B can be formed by only penetrating three bottomed holes extending linearly, so that its processing is relatively easy.

[0096] like Figure 4B As shown, the screw 52B of the second modified example can be formed by connecting the above-mentioned second screw body 72B and the second flow path forming member 73B in the axial direction. In this modified example, the screw 52B can also be manufactured by connecting a plurality of components, so the processing of the components can be simplified. In addition, the screw 52B can be divided into a plurality of components, so the processing of the holes (specifically, the bottomed holes forming the through holes 74B, 75B and the connecting path 76B) formed in each of the divided bodies 72B1 to 72B3 and the second flow path forming member 73B becomes easy.

[0097] Returning to the description of the extruder 50, a waiting space 51A of a specified size without a screw 52 can be formed between the delivery port 54 of the sleeve 51 and the top end (specifically, the free end) of the screw 52. The waiting space 51A can be a space for temporarily storing the paste resin composition P2 that has been kneaded and transported by the rotation of the screw 52 while being temperature-controlled by the first temperature control mechanism 70. In addition, a known conveying unit such as a conveyor belt or a scraper (not shown) can be provided in the waiting space 51A. The conveying unit, for example, operates in conjunction with the opening of the shutter 56, thereby enabling a specific amount of the paste resin composition P2 temporarily stored in the waiting space 51A to be immediately put into the chamber 30.

[0098] As an option, a sleeve heater 55 for preheating the paste resin composition P2 conveyed to the waiting space 51A by the screw 52 is preferably provided on the periphery of the waiting space 51A. The sleeve heater 55 can be composed of a known heater like the mold heater 41, for example, the sleeve heater 55 can be arranged to substantially surround the entire circumference of the waiting space 51A. The sleeve heater 55 can preheat the paste resin composition P2 in the waiting space 51A to 50°C to 100°C, more preferably to 90°C to 100°C. By adopting the sleeve heater 55, the paste resin composition P2 conveyed to the waiting space 51A can be heated before being put into the cavity 30, which can promote softening. As a result, the heating time required to soften / melt the paste resin composition P2 in the cavity 30 can be greatly shortened.

[0099] In the present embodiment, an example is given in which the carrying port 54 of the sleeve 51 is connected to the chamber and a waiting space 51A is provided adjacent to the carrying port 54, but the present disclosure is not limited thereto. For example, it may also be provided that a conveying mechanism not shown is provided between the carrying port 54 of the sleeve 51 and the chamber 30, and the paste resin composition P2 is put into the chamber 30 by operating the conveying mechanism. Similarly, a mechanism for exhausting air from the paste resin composition P2 after kneading may also be additionally provided between the carrying port 54 of the sleeve 51 and the baffle 56 or the chamber 30. The mechanism may, for example, exhaust air from the paste resin composition P2 by compressing the paste resin composition P2 or providing a decompression chamber.

[0100] It should be particularly noted that the resin composition P directly or indirectly introduced into the chamber 30 from the extruder 50 of the motor core manufacturing device 1 of the present embodiment is a paste resin composition P2 rather than a resin composition formed into a sheet in advance. In this way, the paste resin composition P2 is introduced into the chamber 30, and the amount of the resin composition P to be introduced into the chamber 30 can be easily adjusted by controlling the rotation speed of the motor 59, etc. It should be noted that the paste resin composition P2 introduced into the chamber 30 from the extruder 50 may also be a resin composition temporarily formed into a prescribed shape. As a method for the temporary forming, for example, there is a method of pressing the paste resin composition P2 against the baffle 56 by continuously conveying the paste resin composition P2 to the waiting space 51A to increase the density for temporary forming. In addition, the pressing action of the paste resin composition P2 can also be achieved by temporarily moving the screw 52 itself along the conveying direction. Alternatively, a jig (not shown) may be disposed between the extruder 50 and the cavity 30 , and the paste-state resin composition P2 may be temporarily molded into an arbitrary shape using the jig.

[0101] As described above, in the motor core manufacturing device 1 of the present embodiment, the amount of the resin composition P introduced into the cavity 30 can be easily changed without preparing resin sheets of various sizes, so that the loss of the resin composition P can be reduced. In addition, since the uniformly heated paste resin composition P2 is introduced, the resin composition P can be smoothly filled into the groove 4. Moreover, the temperature of the resin composition P conveyed by the screw 52 can be controlled by the first temperature control mechanism 70, so that the unintended progress of the curing reaction of the resin composition P can be prevented, and the occurrence of filling failure can be suppressed.

[0102] <Motor core manufacturing method>

[0103] Next, an example of a method for manufacturing a motor core according to the present embodiment will be briefly described. It should be noted that, below, a case where the method for manufacturing a motor core according to the present embodiment is implemented using the manufacturing apparatus 1 of the motor core according to the above-mentioned embodiment will be described as an example.

[0104] The method for manufacturing a motor core of the present embodiment includes: a step (S4) of holding the rotor core 2 in a mold 20 having a resin composition filling path 25 formed therein so that the resin composition filling path 25 is connected to the groove portion 4; a step (S5) of adjusting the temperature of the resin composition P having a measured filling amount of the resin composition using an extruder 50 capable of conveying the resin composition P, and conveying the resin composition P toward a chamber 30 connected to the resin composition filling path 25, wherein the extruder 50 includes: a sleeve 51 for conveying the resin composition P inside; a screw 52 disposed in the sleeve 51 for kneading and conveying the resin composition P; and a first temperature regulating mechanism 70, at least a portion of which is disposed inside the screw 52; a step (S8) of actuating a plunger 35 capable of moving inside the chamber 30 to fill the softened resin composition (equivalent to the liquid resin composition P3) in the chamber 30 into the groove portion 4; and a step (S9) of solidifying the softened resin composition filled in the groove portion 4. The following describes this in more detail.

[0105] Figure 5 FIG. 6 is a flowchart showing an example of a method for manufacturing a motor core according to an embodiment of the present disclosure. Figure 5 In the case of the method for manufacturing the motor core shown in Figure 1 The following is an operation diagram of an example of the operation state of the motor core manufacturing device shown in FIG. Figure 5 It is to be explained with reference to Fig. 8. It should be noted that in Figs. 6 to 8, for the convenience of illustration, reference numerals are sometimes centered around components related to each action, and reference numerals of components less related to the action are omitted.

[0106] In the method for manufacturing a motor core of this embodiment, first, a Fig. 6A The manufacturing device 1 of the motor core shown in the figure then measures the filling amount of the resin composition P into the filling space 6 of the rotor core 2 (resin composition filling amount) (step S1). When measuring the filling amount, for example, the volume of the groove portion 4 of the rotor core 2 and the volume of the permanent magnet 3 to be inserted into the groove portion 4 can be measured, and the difference between the two can be calculated to perform the measurement. The measured resin filling amount can be sent to the control device 60 and used to adjust the amount of the resin composition P to be fed into the cavity 30, specifically, used to control the rotation speed of the motor 59, etc.

[0107] In the above-mentioned process S1, an example is given of determining the filling amount of the resin composition P by measuring the volume of the groove portion 4 and the volume of the permanent magnet 3, but the filling amount can also be determined by other methods. Specifically, for example, a trial production process can be performed before the start of mass production, and the filling amount can be determined based on the filling amount of the resin in the trial production process, the amount of the remaining resin, etc. Alternatively, it can also be set as follows: in mass production, the actual resin filling amount, the remaining resin, etc. are confirmed at a frequency that does not hinder mass production, and the appropriate filling amount is maintained by feedback control of the filling amount. In addition, the above-mentioned various methods for determining the filling amount can be performed individually or in combination.

[0108] When the measurement of the required filling amount of the resin composition P is completed, the permanent magnet 3 is then inserted into the groove portion 4 of the rotor core 2 (step S2). Then, the mold 20 and the rotor core 2 are preheated (step S3). The preheating of the mold 20 can be achieved by operating the mold heater 41. At this time, the cavity 30 can also be preheated while the mold 20 is preheated. The preheating of the cavity 30 can be achieved by operating the cavity heater 42. In addition, the preheating of the rotor core 2 can be performed using a known heating unit not shown. The preheating of the rotor core 2 can be performed separately from the mold 20 before being placed on the stage 24, or it can be performed simultaneously with the preheating of the mold 20 while being placed on the stage 24. When the mold 20 and the rotor core 2 are preheated at the same time, it is better to implement the step S4 described later before step S3. The preheating temperature of the mold 20 and the rotor core 2 can be set to about 100°C to 180°C. It should be noted that the preheating may be performed on only one of the mold 20 and the rotor core 2 .

[0109] When the preheating of the mold 20 and the rotor core 2 is completed, Figure 6B As shown, the rotor core 2 is placed on the stage 24, and the upper mold 21 is moved downward, thereby holding the rotor core 2 in the mold 20 (step S4). At this time, the upper mold 21 is adjusted to press the upper surface of the rotor core 2 with a specified pressure, thereby enabling the upper mold 21 and the upper surface of the rotor core 2 and the lower mold 22 and the lower surface of the rotor core 2 to be in close contact with each other. It should be noted that a part of the measurement of the filling amount of the resin composition P into the filling space 6 of the rotor core 2 can be implemented while the rotor core 2 is being held. Specifically, the height of the groove 4 in the vertical direction can be determined based on the control signal of an actuator not shown in the figure used when the upper mold 21 is moved in the vertical direction, thereby using the height for the measurement of the filling amount. In this case, it is better to perform the above-mentioned step S1 after step S4.

[0110] Next, the powdered resin composition P1 is kneaded and conveyed using the extruder 50 (step S5). In this step, first, the powdered resin composition P1 is supplied from the resin composition supply source 58 to the supply port 53 of the sleeve 51 (for example, continuously), and the motor 59 is driven to rotate the screw 52, ​​thereby kneading the powdered resin composition P1 supplied to the supply port 53 and conveying it to the delivery port 54. At this time, in the manufacturing device 1 of the motor core of the present embodiment, the first temperature control mechanism 70 and the second temperature control mechanism 80 are operated before or simultaneously with the rotation of the screw 52, ​​and the temperature of the conveyed resin composition P is adjusted, such as cooling. Through this cooling action, the temperature rise in the resin composition P caused by the kneading / conveying by the screw 52 can be controlled, so that the progress of the unintended curing reaction of the resin composition P can be suppressed.

[0111] In step S5, the control may be performed such that the powdery resin composition P1 in an amount matching the filling amount of the resin composition P measured in step S1 is changed into the paste-like resin composition P2 by controlling the rotation speed of the motor 59 by the control device 60, and the paste-like resin composition P2 is transported to the waiting space 51A (see Figure 6B ). However, the amount that matches the filling amount of the resin composition P mentioned here refers not only to the volume of the filling space 6, but also to the volume of the resin composition filling path 25, etc., in order to make the resin composition P fill the filling space 6. It should be noted that the adjustment of the amount of the paste resin composition P2 to be put into the cavity 30 is not limited to the method based on the rotation speed of the motor 59 mentioned above. For example, the amount of the paste resin composition P2 to be put into the cavity 30 can also be adjusted by adjusting the amount of the powdered resin composition P1 supplied from the resin composition supply source 58 to be consistent with the filling amount of the resin composition measured in step S1. In addition, the amount of the paste resin composition P2 stored in the waiting space 51A can be measured by setting a sensor (not shown) such as a weight sensor in the waiting space 51A, and the amount of the paste resin composition P2 to be put into the cavity 30 can be adjusted by comparing it with the filling amount of the resin composition measured in advance.

[0112] In addition, the resin composition P kneaded and conveyed in step S5 is conveyed to the waiting space 51A in the form of a paste resin composition P2 or in the form of a mixture of a powdered resin composition P1 and a paste resin composition P2. At this time, the sleeve heater 55 can be driven to preheat the resin composition P conveyed to the waiting space 51A. The preheating temperature achieved by the sleeve heater 55 can be adjusted within the range of 50°C to 100°C, for example. Through the above-mentioned kneading and conveying, most of the powdered resin composition P1 supplied from the supply port 53 is converted into a paste resin composition P2 in the waiting space 51A.

[0113] When a predetermined amount of the resin composition P is delivered to the waiting space 51A, Fig. 7A As shown, the shutter 56 is opened, and the paste resin composition P2 temporarily stored in the waiting space 51A is put into the chamber 30 using a conveying unit not shown (process S6). As described above, the paste resin composition P2 temporarily stored in the waiting space 51A is adjusted to an amount that matches the measured filling amount of the resin composition. In addition, the paste resin composition P2 temporarily stored in the waiting space 51A is preheated to 50°C to 100°C by heating achieved by the sleeve heater 55. The paste resin composition P2 has been changed into a paste by the above-mentioned preheating, and although the whole may form an integrated block, it can be put into the chamber 30 without any obstacles.

[0114] When the paste resin composition P2 is put into the chamber 30, the shutter 56 is then closed, and the chamber heater 42 is operated to heat the paste resin composition P2 to soften it (step S7). The chamber heater 42 can be controlled, for example, to heat the paste resin composition P2 in the chamber 30 to about 100°C to 180°C. Through this heating, the paste resin composition P2 softens and melts, and changes into a liquid resin composition P3 with high fluidity. Here, in the manufacturing process of the motor core of the present embodiment, the paste resin composition P2 has been preheated to 50°C to 100°C as described above, so the time required for softening in the chamber 30 is shorter than before.

[0115] When the paste resin composition P2 is transformed into the liquid resin composition P3 through step S7, then, Figure 6B As shown, the plunger 35 is raised to push the liquid resin composition P3 toward the filling space 6 of the rotor core 2, thereby filling the resin composition P (step S8). The liquid resin composition P3 pushed up by the plunger 35 flows from the cavity 30 through the resin composition filling path 25 and flows into the filling space 6. It should be noted that in order to smoothly perform the filling of the liquid resin composition P3 into the filling space 6 in step S8, for example, an air hole (not shown) for extracting the air in the filling space 6 can be provided at an appropriate position of the upper mold 21.

[0116] When the filling of the liquid resin composition P3 into the filling space 6 is completed, the mold heater 41 is operated to heat / solidify the liquid resin composition P3 in the filling space 6 (step S9). When the liquid resin composition P3 is solidified, it is preferably heated at 100°C to 180°C for a few minutes. The liquid resin composition P3 is transformed into a solidified resin composition P4 by the heating, thereby fixing the permanent magnet 3 in the groove 4 of the rotor core 2 by resin molding. It should be noted that the heating time in step S9 can be appropriately adjusted to match the specific composition of the resin composition P, etc.

[0117] When the above series of resin molding processes are completed, Fig. 8A As shown, the upper mold 21 is raised, and the rotor core 2 after resin molding is transported out using a conveying unit (not shown) such as a robot arm (step S10). The transported rotor core 2 can be transferred to other devices for, for example, shaft assembly. Then, when the transport of the rotor core 2 is completed, the manufacturing device 1 is cleaned (step S11). The cleaning of the manufacturing device 1 can be implemented by a cleaning unit (not shown) including a cleaning member such as a brush.

[0118] When cleaning the resin composition filling passage 25 of the stage 24 during the above cleaning, the following operation may be performed. That is, first, the lift 26 is operated to separate the stage 24 from the lower mold body 23, thereby removing the solidified resin composition P4 blocking the resin composition filling passage 25 from the resin composition filling passage 25. Then, the plunger 35 is further raised, thereby separating the solidified resin composition P4 from the lower mold body 23 (see Figure 8B ). Then, the separated solidified resin composition P4 is grasped and removed by a robot arm (not shown), and the surface of the carrier 24 and the lower mold body 23 and the resin composition filling path 25 are cleaned with a brush. When a series of cleaning is completed, return to Fig. 6A The state shown is in a standby state until the rotor core 2 is transported in next time.

[0119] It should be noted that the order of the above series of steps can be changed within the range that can maintain the functions. For example, the conveyance of the powdered resin composition P1 or the paste resin composition P2 by the extruder 50 can be started at any timing as long as the filling amount of the resin composition P is measured. In addition, the preheating of the mold 20, the rotor core 2, and the resin composition P can also be omitted.

[0120] As described above, according to the method for manufacturing the motor core of the present embodiment, as the resin composition P to be introduced into the cavity 30, a previously formed sheet-shaped resin composition is not used, and a required amount of the resin composition P can be stably introduced into the cavity 30 using the extruder 50, so that the loss of the resin composition P can be suppressed. Therefore, it is not necessary to select the resin sheet in accordance with the amount of resin to be filled into the motor core.

[0121] The present disclosure is not limited to the above-mentioned embodiments, and various changes can be made and implemented within the scope of the main purpose of the present disclosure. Moreover, these changes are all included in the technical ideas of the present disclosure. In addition, in the present disclosure, as long as no contradiction occurs, each component can exist only one, or there can be more than two.

[0122] All documents cited in this specification, including publications, patent applications, and patents, are specifically indicated, referenced, and introduced one by one, and the entire contents of each document are referenced and introduced here to the same extent as the contents described herein.

[0123] Regarding the use of nouns and the same indicators used in association with the description of the present disclosure (especially in association with the following claims), as long as there is no special indication in this specification or there is no obvious contradiction with the context, it is interpreted as covering both single and multiple parties. Regarding the terms "have", "have", "include" and "include", as long as there is no special indication, it is interpreted as an open term (i.e., "including but not limited to..."). Regarding the specific description of the numerical range in this specification, as long as there is no special indication in this specification, it is only intended to serve as a shorthand method for referring to each value falling within the range one by one, and each value is introduced into the specification as if it is listed one by one in this specification. Regarding all methods described in this specification, as long as there is no special indication in this specification or there is no obvious contradiction with the context, it can be carried out in all appropriate orders. Regarding all examples or exemplary wordings used in this specification (such as "etc."), as long as there is no special claim, it is only intended to better illustrate the present disclosure, not to set a limitation on the scope of the present disclosure. Any wording in the specification is not interpreted as representing an element not recorded in the claims as an indispensable element in the implementation of the present disclosure.

[0124] In this specification, preferred embodiments of the present disclosure are described, including the best mode known to the inventors for implementing the present disclosure. For those skilled in the art, variations of these preferred embodiments should be obvious upon reading the above description. The inventors expect that the skilled person will appropriately apply such variations, and it is expected that the present disclosure will be implemented in a manner other than that specifically described in this specification. Therefore, as permitted by law, the present disclosure includes all modifications and equivalents of the contents described in the claims attached to this specification. Moreover, any combination of the above elements in all variations is included in the present disclosure, unless otherwise specified in this specification or clearly contradictory to the context.

Claims

1. A motor core manufacturing device, comprising: The mold holds the motor core including the resin-filled portion. A cavity is formed in the mold, one end of the cavity is connected to the resin composition filling path, wherein The resin composition filling path is in communication with the resin filling portion; a plunger for conveying the thermosetting resin composition conveyed to the chamber toward the resin composition filling path; a heater disposed in the mold, or disposed in the mold and around the cavity; and An extruder kneads the resin composition and conveys it to the cavity to inject the resin composition into the cavity, The extruder has: an extrusion conveying path for conveying the resin composition inside; a screw disposed in the extrusion conveying path to mix and convey the resin composition; and The first temperature adjustment mechanism is at least partially disposed inside the screw.

2. The motor core manufacturing device according to claim 1, wherein: The extruder further includes a second temperature regulating mechanism provided in the extrusion conveying path surrounding a portion of the screw.

3. The motor core manufacturing device according to claim 1, wherein: The first temperature control mechanism comprises: an inlet passage having a heat medium supply port at one end thereof, the inlet passage extending from the base end side of the screw along the central axis of the screw; and an outflow passage having one end connected to the other end of the inlet passage, the outflow passage extending toward the base end side of the screw.

4. The motor core manufacturing device according to claim 3, wherein: The heat medium used in the first temperature adjustment mechanism is gas.

5. The motor core manufacturing device according to any one of claims 1 to 4, wherein: The screw comprises: a first cylindrical screw body, on the periphery of which fins for conveying the resin composition are formed, and the top end of the first screw body is blocked; and a first flow path forming member, which is composed of a cylindrical body having a through hole extending in the long dimension direction at its center, and a plurality of grooves extending in the long dimension direction are formed on the periphery of the first flow path forming member, and the first flow path forming member is embedded in the first screw body in a manner that a gap is formed between the top end thereof and the bottom inside the first screw body.

6. The motor core manufacturing device according to any one of claims 1 to 4, wherein: The screw comprises: a second screw body, on the periphery of which is formed a fin for conveying the resin composition, and inside of which is formed a plurality of through holes extending in the long dimension direction; and a second flow path forming member connected to the top end of the second screw body so that the ends of the plurality of through holes are connected to each other.

7. The motor core manufacturing device according to claim 6, wherein: The second screw body is formed by connecting a plurality of split bodies each having the fin formed on the outer periphery and a plurality of through holes formed inside thereof extending in the longitudinal direction so that the plurality of through holes communicate with each other.

8. A method for manufacturing a motor core, comprising the following steps: The motor core is held in a mold having a resin composition filling path formed therein so that the resin composition filling path communicates with a resin filling portion of the motor core; An extruder capable of conveying a resin composition is used to adjust the temperature of the resin composition and convey the resin composition toward a chamber connected to the resin composition filling path, wherein the extruder comprises: an extrusion conveying path in which the resin composition is conveyed; a screw disposed in the extrusion conveying path to mix and convey the resin composition; and a first temperature regulating mechanism, at least a portion of which is disposed inside the screw; actuating a plunger movable in the cavity to fill the softened resin composition in the cavity into the resin filling portion; and The softened resin composition filled in the resin filling portion is cured.

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