Stator unit, electric valve, and method for manufacturing stator unit

Abstract

Provided are a stator unit, an electrically operated valve, and a method for manufacturing the stator unit, wherein electromagnetic waves emitted from a stator can be suppressed, and malfunction of an electronic component can be suppressed. The stator unit (8) has a stator (80) and a synthetic resin housing (100) integrally formed with the stator (80). The stator unit (8) has an electromagnetic wave suppression film (90) disposed between the stator (80) and the housing (100).

Description

Technical Field

[0001] The invention relates to a stator unit, an electric valve and a method for manufacturing the stator unit. Background Art

[0002] Patent document 1 discloses a conventional electric valve assembled in an air conditioning system. The electric valve of Patent document 1 has a housing provided with a housing space. A cover, a stator, and a control substrate are arranged in the housing space. A magnetic rotor is arranged inside the cover. The magnetic rotor and the stator constitute a stepping motor.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent No. 6826727

[0006] Technical problem to be solved by the invention

[0007] The current for rotating the magnetic rotor flows through the stator. Electromagnetic waves are sometimes emitted from the stator by the current flowing through the stator. There is a concern that the electromagnetic waves may affect the electronic equipment near the control substrate and the electric valve. By applying electromagnetic wave suppression paint to the stator, the electromagnetic waves emitted from the stator can be suppressed. The electromagnetic wave suppression paint sometimes peels off from the stator. The electromagnetic wave suppression paint is conductive. Therefore, there is a concern that the peeled electromagnetic wave suppression paint may cause a short circuit in the control substrate or the electronic equipment, causing malfunction of the electronic components mounted on these components. Summary of the invention

[0008] Therefore, an object of the present invention is to provide a stator unit, an electric valve, and a method for manufacturing the stator unit, which can suppress electromagnetic waves emitted from a stator and suppress malfunction of electronic components.

[0009] Technical means for solving technical problems

[0010] To achieve the above object, a stator unit according to one aspect of the present invention includes a stator and a synthetic resin housing formed integrally with the stator, and includes an electromagnetic wave suppression film disposed between the stator and the housing.

[0011] In the present invention, it is preferred that the stator has an A-phase stator and a B-phase stator, the A-phase stator has an A-phase yoke in a hollow circular ring shape, an A-phase winding frame arranged on the inner side of the A-phase yoke, and an A-phase coil wound on the A-phase winding frame, the B-phase stator has a B-phase yoke in a hollow circular ring shape, a B-phase winding frame arranged on the inner side of the B-phase yoke, and a B-phase coil wound on the B-phase winding frame, the A-phase stator and the B-phase stator are coaxially arranged, the first end face of the A-phase yoke is in contact with the first end face of the B-phase yoke, the second end face of the A-phase yoke, the outer peripheral surface of the A-phase yoke, the second end face of the B-phase yoke, and the outer peripheral surface of the B-phase yoke constitute an outer surface of the yoke, and the electromagnetic wave suppression film is arranged between the outer surface of the yoke and the housing.

[0012] In the present invention, preferably, the stator also has a resin component integrally formed with the A-phase stator and the B-phase stator, the resin component has a terminal support portion, the terminal support portion extends from the A-phase yoke and the B-phase yoke in a direction orthogonal to the axial direction, the coil terminals connected to the A-phase coil and the B-phase coil protrude from the top end surface of the terminal support portion, and the electromagnetic wave suppression film is arranged between the terminal support portion and the housing.

[0013] In the present invention, preferably, the resin component further includes a toroidal annular portion disposed on a second end surface of the A-phase yoke or a second end surface of the B-phase yoke, and the electromagnetic wave suppression film is disposed between the annular portion and the housing.

[0014] In the present invention, preferably, a portion of the terminal support portion including the top end surface is arranged in a substrate accommodating space provided in the shell, the coil terminal is connected to the substrate arranged in the substrate accommodating space, and the surface of the portion of the terminal support portion as a whole directly faces the substrate accommodating space.

[0015] In the present invention, it is preferable that the synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

[0016] In order to achieve the above object, a stator unit according to another aspect of the present invention includes a stator and a synthetic resin housing formed integrally with the stator, wherein the synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

[0017] In order to achieve the above object, another aspect of the present invention relates to an electric valve having a valve body assembly and the stator unit, wherein the valve body assembly has a cylindrical housing and a magnet rotor arranged inside the housing, and the stator is arranged outside the housing.

[0018] In order to achieve the above-mentioned purpose, one embodiment of the present invention involves a method for manufacturing a stator unit, which has a stator and a synthetic resin shell formed integrally with the stator, an electromagnetic wave suppression film is formed on the surface of the stator, and the shell is injection molded in a manner such that the shell covers the electromagnetic wave suppression film.

[0019] Effects of the Invention

[0020] The stator unit has an electromagnetic wave suppression film disposed between the stator and the housing. Thus, the electromagnetic wave suppression film is held by the stator and the housing, and the electromagnetic wave suppression film can be suppressed from falling off. Therefore, the electromagnetic waves emitted from the stator can be suppressed, and malfunction of the electronic components can be suppressed.

[0021] The synthetic resin constituting the outer shell of the stator unit contains the electromagnetic wave suppression material. Thus, the electromagnetic wave suppression material is contained in the synthetic resin constituting the outer shell, and the electromagnetic wave suppression material does not fall off. Therefore, the electromagnetic waves emitted from the stator can be suppressed, and malfunction of the electronic components can be suppressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a cross-sectional view of an electric valve according to an embodiment of the present invention.

[0023] Figure 2 yes Figure 1 A cross-sectional view of a valve body assembly of an electric valve.

[0024] Figure 3 yes Figure 1 A cross-sectional view of a stator unit included in an electric valve.

[0025] Figure 4 yes Figure 3 A cross-sectional view of a stator having an electromagnetic wave suppression film formed on the surface thereof, which is included in a stator unit.

[0026] Figure 5 It is a cross-sectional view of the stator before the electromagnetic wave suppression film is formed.

[0027] Figure 6 This is a perspective view of a stator having an electromagnetic wave suppression film formed on the surface.

[0028] Figure 7 It is a perspective view showing a stator before the electromagnetic wave suppression film is formed.

[0029] Figure 8 This is a side view of a stator having an electromagnetic wave suppression film formed on the surface.

[0030] Fig. 9 This is a side view of the stator before the electromagnetic wave suppression film is formed.

[0031] Fig.10Yes means Figure 1 A sectional view of the structure of a modified example of the electric valve.

[0032] Fig.11 yes Fig.10 A cross-sectional view of a stator unit included in an electric valve. DETAILED DESCRIPTION

[0033] Below, refer to Figures 1 to 11 An electric valve according to an embodiment of the present invention will be described. The electric valve is incorporated in, for example, an air conditioning system mounted on a vehicle or installed in a house. The electric valve according to this embodiment is used, for example, to adjust a refrigerant flow rate.

[0034] Figure 1 It is a cross-sectional view of an electric valve according to an embodiment of the present invention. Figure 2 yes Figure 1 A cross-sectional view of a valve body assembly of an electric valve. Figure 3 yes Figure 1 A cross-sectional view of a stator unit included in an electric valve. Figures 4 to 9 Yes means Figure 3 A stator unit has a diagram of a stator. Figure 4 , Figure 5 is a cross-sectional view of the stator. Figure 6 , Figure 7 It is a three-dimensional diagram of the stator.

[0035] Figure 8 , Fig. 9 is a side view of the stator. Figure 4 , Figure 6 , Figure 8 This figure shows a stator having an electromagnetic wave suppression film formed on the surface. Figure 5 , Figure 7 , Fig. 9 It shows the stator before the electromagnetic wave suppression film is formed. Fig.10 Yes means Figure 1 A sectional view of the structure of a modified example of the electric valve. Fig.11 yes Fig.10 A cross-sectional view of a stator unit of an electric valve. Figure 3 , Figure 4 , Fig.11 In FIG. 1 , the electromagnetic wave suppression film is schematically indicated by a thick line. Figure 6 , Figure 8 , the electromagnetic wave suppression film is schematically represented by a dotted area. In each figure, the X direction indicated by the arrow X is the left-right direction, the Y direction indicated by the arrow Y is the front-back direction, and the Z direction indicated by the arrow Z is the up-down direction. The side with the letter "X" in the arrow X is the right side, the side with the letter "Y" in the arrow Y is the rear side, and the side with the letter "Z" in the arrow Z is the top side.

[0036] like Figure 1 As shown, the electric valve 1 according to the present embodiment includes a valve body assembly 5 and a stator unit 8 .

[0037] like Figure 2 As shown, the valve body assembly 5 includes a valve body 10 , a retainer 20 , a valve element support member 25 , a cover 30 , a drive mechanism 40 , and a valve element 70 .

[0038] The valve body 10 has a rectangular parallelepiped shape. The valve body 10 has a valve chamber 13 and a valve port 14 connected to the valve chamber 13. The valve body 10 has a first passage 17 and a second passage 18. One end of the first passage 17 is connected to the valve chamber 13, and the other end of the first passage 17 opens at the rear surface 10a of the valve body 10. One end of the second passage 18 is connected to the valve chamber 13 via the valve port 14, and the other end of the second passage 18 opens at the front surface 10b of the valve body 10. The valve body 10 has a mounting hole 19. The mounting hole 19 is arranged on the upper surface 10c of the valve body 10. An internal thread is formed on the inner circumferential surface of the mounting hole 19. The lower end of the mounting hole 19 is connected to the valve chamber 13.

[0039] The retainer 20 has a cylindrical shape. The lower portion of the retainer 20 is disposed in the mounting hole 19. An external thread is formed on the outer peripheral surface of the retainer 20. The external thread of the retainer 20 is screwed into the internal thread of the mounting hole 19 of the valve body 10. The retainer 20 is mounted on the valve body 10 by the threaded structure. The upper portion of the retainer 20 protrudes from the upper surface 10c.

[0040] The valve core support member 25 has a cylindrical shape. The valve core support member 25 is arranged between the valve body 10 and the retainer 20 on the inner side of the mounting hole 19. The lower part of the valve core support member 25 is pressed into the valve chamber 13. An annular plane 25a is provided on the outer peripheral surface of the valve core support member 25. The annular plane 25a faces downward. The annular plane 25a abuts against the bottom surface 19a of the mounting hole 19. The valve core support member 25 supports the valve core 70 so that it can move in the up and down directions.

[0041] The cover 30 has a cylindrical shape. The upper end of the cover 30 is closed and the lower end is open. The lower end of the cover 30 is joined to the outer peripheral edge of the coupling member 35 in the shape of a circular ring plate. The upper part of the retaining frame 20 is arranged inside the coupling member 35. The inner peripheral edge of the coupling member 35 is joined to the retaining frame 20. The cover 30 is a housing mounted on the valve body 10 via the coupling member 35 and the retaining frame 20.

[0042] The drive mechanism 40 moves the valve body 70 in the up-down direction. The drive mechanism 40 includes a magnet rotor 41 , a planetary gear mechanism 50 , a guide member 60 , a drive shaft 65 , and a ball 68 .

[0043] The magnetic rotor 41 has a cylindrical shape. The magnetic rotor 41 is arranged on the inner side of the cover 30. The outer diameter of the magnetic rotor 41 is slightly smaller than the inner diameter of the cover 30. The magnetic rotor 41 has a plurality of N poles and a plurality of S poles. The plurality of N poles and the plurality of S poles are arranged on the outer peripheral surface of the magnetic rotor 41. The plurality of N poles and the plurality of S poles extend in the up-down direction. The plurality of N poles and the plurality of S poles are arranged alternately and at equal intervals in the circumferential direction. In the present embodiment, the magnetic rotor 41 has 12 N poles and 12 S poles.

[0044] A disk-shaped connecting member 42 is joined to the upper end of the magnet rotor 41. The connecting member 42 closes the upper end of the magnet rotor 41. The rotor shaft 43 penetrates the center of the connecting member 42. The magnet rotor 41 is connected to the rotor shaft 43 via the connecting member 42.

[0045] The planetary gear mechanism 50 is arranged inside the magnet rotor 41. The planetary gear mechanism 50 includes a gear case 51, a fixed ring gear 52, a sun gear 53, a plurality of planetary gears 54, a planetary carrier 55, an output gear 56, and an output shaft 57.

[0046] The gear box 51 has a cylindrical shape. The gear box 51 is coaxially engaged with the upper portion of the retainer 20. The fixed ring gear 52 is an internal gear. The fixed ring gear 52 is fixed to the upper end of the gear box 51. The sun gear 53 is coaxially arranged with the connecting member 42. The sun gear 53 is integrated with the connecting member 42. The rotor shaft 43 passes through the sun gear 53. The sun gear 53 rotates together with the magnetic rotor 41 and the connecting member 42.

[0047] A plurality of planetary gears 54 are arranged between the fixed ring gear 52 and the sun gear 53. The planetary gear carrier 55 has a disc shape. The rotor shaft 43 passes through the center of the planetary gear carrier 55. The planetary gear carrier 55 can rotate around the rotor shaft 43. The planetary gear carrier 55 has a plurality of support shafts 55a. The plurality of support shafts 55a support the plurality of planetary gears 54 so as to be rotatable. The output gear 56 has a bottomed cylindrical shape. The output gear 56 is an internal gear. A plurality of planetary gears 54 are arranged between the output gear 56 and the sun gear 53.

[0048] The output shaft 57 has a cylindrical shape. The upper portion of the output shaft 57 is arranged in a hole provided at the bottom of the output gear 56. The output shaft 57 is fixed to the output gear 56. A slit 57a extending in the up-down direction is formed at the lower portion of the output shaft 57. The rotation of the sun gear 53 is decelerated by the fixed ring gear 52, the plurality of planetary gears 54, the planetary gear carrier 55, and the output gear 56, and is transmitted to the output shaft 57.

[0049] The guide member 60 has a cylindrical shape. The guide member 60 is arranged inside the upper part of the holder 20. The guide member 60 is fixed to the holder 20. An internal thread is formed at the lower part of the inner peripheral surface of the guide member 60. The output shaft 57 is arranged inside the guide member 60. The guide member 60 supports the output shaft 57 so as to be rotatable.

[0050] The drive shaft 65 includes a cylindrical portion 66 and a flat portion 67. The flat portion 67 is connected to the upper end of the cylindrical portion 66. The cylindrical portion 66 and the flat portion 67 are formed as one body. An external thread is formed on the outer peripheral surface of the cylindrical portion 66. The external thread of the cylindrical portion 66 is screwed with the internal thread of the guide member 60. The flat portion 67 is arranged in the slit 57a of the output shaft 57 so as to be movable in the up-down direction. The drive shaft 65 is rotated by the output shaft 57 and moves in the up-down direction by the screw feeding action.

[0051] The valve body 70 includes a rod 71 , a valve portion 72 , a spring receiving portion 73 , and a ball receiving portion 74 .

[0052] The rod 71 has a cylindrical shape. The rod 71 is arranged inside the valve body support member 25. The rod 71 is supported by the valve body support member 25 so as to be movable in the up-down direction.

[0053] The valve portion 72 is disposed at the lower end of the rod 71. The valve portion 72 has an annular shape. The valve portion 72 protrudes radially outward from the outer peripheral surface of the rod 71. The valve portion 72 and the valve port 14 face each other in the up-down direction.

[0054] The spring receiving portion 73 has a cylindrical shape. The spring receiving portion 73 is engaged with the upper end of the rod 71. The spring receiving portion 73 has a flange portion 73a protruding radially outward.

[0055] The ball receiving portion 74 integrally includes a circular flat plate portion and a convex portion connected to the lower surface of the flat plate portion. The convex portion is fitted into a hole provided on the upper end surface of the spring receiving portion 73. A ball 68 is arranged between the flat plate portion of the ball receiving portion 74 and the drive shaft 65. The ball 68 is engaged with the lower end of the drive shaft 65.

[0056] A valve opening spring 75 is arranged between the flange portion 73a of the spring receiving portion 73 and the valve core support member 25. The valve opening spring 75 is a compression coil spring. The valve opening spring 75 presses the valve core 70 (flange portion 73a) upward. The valve core 70 moves forward and backward relative to the valve port 14 through the valve portion 72, and changes the opening area of ​​the valve port 14 steplessly (including substantially steplessly). In the present embodiment, the minimum area of ​​the valve port 14 is 0 (i.e., the state in which the valve port 14 is closed). The minimum area of ​​the valve port 14 may also be larger than 0 (i.e., the state in which the valve port 14 is slightly open).

[0057] like Figure 3As shown, the stator unit 8 includes a stator 80 , an electromagnetic wave suppression film 90 , a housing 100 , a cover member 110 , and a control device 120 .

[0058] like Figures 4 to 9 As shown, the stator 80 has a cylindrical shape. The stator 80 includes an A-phase stator 81 , a B-phase stator 82 , and a resin member 83 .

[0059] The A-phase stator 81 includes an A-phase yoke 81 a , an A-phase bobbin 81 b , and an A-phase coil 81 c .

[0060] The A-phase yoke 81a has a hollow ring shape. The radial section of the A-phase yoke 81a is rectangular. The A-phase yoke 81a is made of metal. A plurality of claw-pole type pole teeth 81d and 81e are provided on the inner periphery of the A-phase yoke 81a. The top of the pole tooth 81d faces downward, and the top of the pole tooth 81e faces upward. The pole teeth 81d and the pole teeth 81e are alternately arranged at equal angles in the circumferential direction. In the present embodiment, the A-phase yoke 81a has 12 pole teeth 81d and 12 pole teeth 81e.

[0061] The A-phase winding frame 81b integrally includes a cylindrical portion and a flange portion protruding radially outward from the upper end and the lower end of the cylindrical portion. The A-phase winding frame 81b is made of synthetic resin. The A-phase winding frame 81b is coaxially arranged in the internal space of the A-phase yoke 81a. The A-phase coil 81c is wound on the A-phase winding frame 81b. When current flows through the A-phase coil 81c, the pole teeth 81d and the pole teeth 81e become different polarities from each other.

[0062] The B-phase stator 82 includes a B-phase yoke 82 a , a B-phase bobbin 82 b , and a B-phase coil 82 c .

[0063] The B-phase yoke 82a has a hollow ring shape. The radial section of the B-phase yoke 82a is rectangular. The B-phase yoke 82a is made of metal. A plurality of claw-pole type pole teeth 82d and 82e are provided on the inner periphery of the B-phase yoke 82a. The top of the pole tooth 82d faces downward, and the top of the pole tooth 82e faces upward. The pole teeth 82d and the pole teeth 82e are alternately arranged at equal angles in the circumferential direction. In the present embodiment, the B-phase yoke 82a has 12 pole teeth 82d and 12 pole teeth 82e.

[0064] The B-phase winding frame 82b integrally includes a cylindrical portion and a flange portion protruding radially outward from the upper end and the lower end of the cylindrical portion. The B-phase winding frame 82b is made of synthetic resin. The B-phase winding frame 82b is coaxially arranged in the internal space of the B-phase yoke 82a. The B-phase coil 82c is wound on the B-phase winding frame 82b. When current flows through the B-phase coil 82c, the pole teeth 82d and the pole teeth 82e become different polarities from each other. The B-phase stator 82 has the same structure as the A-phase stator 81 (including substantially the same).

[0065] The A-phase yoke 81a and the B-phase yoke 82a are coaxially arranged. The lower surface 81f of the A-phase yoke 81a and the upper surface 82g of the B-phase core 82a are in contact with each other. When viewed from the top and bottom direction (axis L direction), the angle between the pole teeth 81d of the A-phase yoke 81a and the pole teeth 82d of the B-phase yoke 82a adjacent to each other is 7.5 degrees.

[0066] An upper surface 81g of the A-phase yoke 81a, an outer peripheral surface 81h of the A-phase yoke 81a, an outer peripheral surface 82h of the B-phase yoke 82a, and a lower surface 82f of the B-phase yoke 82a constitute a yoke outer surface 80b.

[0067] The lower surface 81f is a first end surface of the A-phase yoke 81a, and the upper surface 81g is a second end surface of the A-phase yoke 81a. The upper surface 82g is a first end surface of the B-phase yoke 82a, and the lower surface 82f is a second end surface of the B-phase yoke 82a.

[0068] The resin member 83 is injection-molded (insert-molded) integrally with the A-phase stator 81 and the B-phase stator 82. The synthetic resin constituting the resin member 83 is, for example, polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT).

[0069] The resin member 83 includes a first portion 83a and a second portion 83b. The first portion 83a constitutes the stator inner peripheral surface 80a together with the pole teeth 81d, 81e, 82d, and 82e. The diameter of the stator inner peripheral surface 80a is the same as (including substantially the same as) the outer diameter of the cover 30. The second portion 83b fills the inner space of the A-phase yoke 81a and the inner space of the B-phase yoke 82a.

[0070] The resin member 83 further includes a terminal support portion 84 and an annular portion 87 .

[0071] The terminal support portion 84 extends forward (in a direction perpendicular to the axis L) from the yoke opening 80c provided across the outer peripheral surface 81h of the A-phase yoke 81a and the outer peripheral surface 82h of the B-phase yoke 82a. The terminal support portion 84 supports a plurality of coil terminals 88. The coil terminals 88 are connected to the A-phase coil 81c and the B-phase coil 82c.

[0072] The terminal support portion 84 has a base 85 and a top end 86. The base 85 is connected to the second portion 83b. The base 85 extends from the inside of the A-phase yoke 81a and the B-phase yoke 82a to the outside through the yoke opening 80c. The top end 86 is connected to the top end surface 85a of the base 85. On the top end surface 86a of the top end 86, a plurality of coil terminals 88 protrude.

[0073] The annular portion 87 has a circular ring shape. The inner diameter of the annular portion 87 is the same as (including substantially the same as) the diameter of the stator inner circumferential surface 80a. The annular portion 87 is coaxially arranged on the lower surface 82f of the B-phase yoke 82a. The annular portion 87 can also be coaxially arranged on the upper surface 81g of the A-phase yoke 81a. The annular portion 87 is connected to the first part 83a of the resin component 83. In the molding die for the stator 80, a gate is connected to the cavity corresponding to the annular portion 87. When the resin component 83 is injection molded, the resin material flows circumferentially in the cavity and enters between the pole teeth 81d, 81e, 82d, and 82e, thereby forming the first part 83a. In the resin component 83, the annular portion 87 can also be omitted.

[0074] The stator 80 is arranged outside the cover 30. The magnet rotor 41 is arranged inside the cover 30. The magnet rotor 41 and the stator 80 constitute a stepping motor 46.

[0075] The electromagnetic wave suppression film 90 is a film composed of a coating (electromagnetic wave suppression coating) containing a material having the property of effectively attenuating electromagnetic waves. Metals such as silver, copper, and nickel are materials having the property of effectively attenuating electromagnetic waves. As the electromagnetic wave suppression coating, for example, a coating called silver paste or copper paste can be used. The electromagnetic wave suppression film 90 is formed by applying the electromagnetic wave suppression coating to the surface of the stator 80. In addition, the electromagnetic wave suppression film 90 can also be a sheet (electromagnetic wave suppression sheet) containing a material having the property of effectively attenuating electromagnetic waves pasted on the surface of the stator 80.

[0076] The electromagnetic wave suppression film 90 is disposed on the yoke outer surface 80b (upper surface 81g, outer peripheral surface 81h, outer peripheral surface 82h, lower surface 82f). The electromagnetic wave suppression film 90 is also disposed on the peripheral surface 85b of the base 85 of the terminal support portion 84. The electromagnetic wave suppression film 90 is also disposed on the lower surface 87a and the outer peripheral surface 87b of the annular portion 87.

[0077] The housing 100 is made of synthetic resin. The synthetic resin constituting the housing 100 is, for example, polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). In addition, as the synthetic resin constituting the housing 100, a synthetic resin containing a material having the property of effectively attenuating electromagnetic waves (electromagnetic wave suppressing synthetic resin) may also be used. As the electromagnetic wave suppressing synthetic resin, for example, a substance containing 5 to 40 weight % of silver powder, silver-plated copper powder, nickel powder or carbon black in PPS is used. Silver powder, silver-plated copper powder, nickel powder and carbon black are materials having the property of effectively attenuating electromagnetic waves, namely, electromagnetic wave suppressing materials. In the stator unit 8, when the housing 100 is composed of an electromagnetic wave suppressing synthetic resin, the electromagnetic wave suppressing film 90 may also be omitted.

[0078] The housing 100 accommodates the stator 80 and the control device 120. The housing 100 is integrally injection-molded (insert-molded) with the stator 80 having the electromagnetic wave suppression film 90 formed on the surface thereof.

[0079] The housing 100 integrally includes a peripheral wall portion 101, an upper wall portion 102, a box portion 103, and a connector portion 104. A cover member 110 is joined to the box portion 103 of the housing 100. The cover member 110 has a flat plate shape.

[0080] The peripheral wall portion 101 has a cylindrical shape. The stator 80 is embedded in the peripheral wall portion 101. An electromagnetic wave suppression film 90 is arranged between the stator 80 and the peripheral wall portion 101. The diameter of the inner peripheral surface 101a of the peripheral wall portion 101 is the same as the diameter of the stator inner peripheral surface 80a. The inner peripheral surface 101a is connected to the stator inner peripheral surface 80a without a step difference. The upper wall portion 102 has a dome shape. The upper wall portion 102 is connected to the upper end of the peripheral wall portion 101. The inner peripheral surface 101a of the peripheral wall portion 101, the inner surface 102a of the upper wall portion 102 and the stator inner peripheral surface 80a form an inner space 106 of the stator unit 8. The cover 30 is arranged in the inner space 106.

[0081] The box portion 103 has a square tube shape and extends forward from the peripheral wall portion 101. The inner space of the box portion 103 is a substrate accommodating space 107. An opening 108 communicating with the substrate accommodating space 107 is provided at the top end 103a of the box portion 103. The cover member 110 is joined to the top end 103a of the box portion 103 in a manner covering the opening 108. The cover member 110 closes the opening 108. The connector portion 104 is arranged on the upper surface of the box portion 103. The connector portion 104 has a tube shape and extends in the front-rear direction. The top end of the connector portion 104 is open and faces forward.

[0082] The substrate accommodating space 107 is adjacent to the inner space 106. The stator 80 and the peripheral wall portion 101 are arranged between the inner space 106 and the substrate accommodating space 107. The stator 80 and the peripheral wall portion 101 divide the inner space 106 and the substrate accommodating space 107. The top end portion 86 of the terminal support portion 84 of the stator 80 protrudes from the peripheral wall portion 101 and is arranged in the substrate accommodating space 107. The electromagnetic wave suppression film 90 is not formed on the top end surface 86a and the peripheral surface 86b of the top end portion 86, and the top end surface 86a and the peripheral surface 86b directly face the substrate accommodating space 107. A plurality of connector terminals 109 are embedded in the housing 100. One end of the connector terminal 109 is arranged in the inner space of the connector portion 104. The other end of the connector terminal 109 is arranged in the substrate accommodating space 107.

[0083] A bracket 111 is attached to the peripheral wall portion 101. The bracket 111 is fixed to the valve body 10 by screws 112. Thus, the stator unit 8 is fixed to the valve body assembly 5.

[0084] The control device 120 is disposed in the substrate housing space 107 of the housing 100 . The control device 120 includes a substrate 130 and a microcomputer 150 .

[0085] The substrate 130 is a printed circuit board on which electronic components are mounted. The substrate 130 is arranged in the substrate storage space 107. The substrate 130 is arranged along the up-down direction and the left-right direction (parallel to the XZ plane). A microcomputer 150 is mounted on the substrate 130. The coil terminal 88 of the stator 80 is connected to the substrate 130. The other end of the connector terminal 109 is connected to the substrate 130.

[0086] The microcomputer 150 is, for example, a microcomputer for built-in equipment that integrates a central processing unit, a nonvolatile memory, a working memory, a communication module, a motor driver, etc. in one package. The microcomputer 150 controls the electric valve 1. In addition, the nonvolatile memory, the working memory, the communication module, and the motor driver may also be separate electronic components connected to the outside of the microcomputer 150.

[0087] The control device 120 is communicatively connected to a control unit of an air conditioning system (not shown) in which the electric valve 1 is assembled. The control device 120 is connected to the control unit via a cable. The cable has a connector (plug) that engages with the connector portion 104 (socket). The control unit is an external device. The control device 120 controls the stepping motor 46 (i.e., the rotation of the magnetic rotor 41) according to a command sent from the control unit. In addition, the electric valve 1 can also omit the control device 120 and be directly controlled by the control unit of the air conditioning system.

[0088] In the electric valve 1, the center axes of the valve port 14, the retainer 20, the valve core support member 25, the cover 30, the magnetic rotor 41, the connecting member 42, the rotor shaft 43, the sun gear 53, the output shaft 57, the guide member 60, the drive shaft 65, the ball 68, the valve core 70 (rod 71, valve portion 72, spring receiving portion 73, ball receiving portion 74), and the stator 80 (A-phase stator 81, B-phase stator 82) are consistent with the axis L. The axis L is parallel to the up-down direction.

[0089] Next, the operation of the electric valve 1 will be described.

[0090] In the electric valve 1, current flows through the A-phase coil 81c and the B-phase coil 82c, causing the magnet rotor 41 to rotate in one direction. The rotation of the magnet rotor 41 is transmitted to the drive shaft 65 via the planetary gear mechanism 50. The drive shaft 65 moves downward due to the screw feed action of the drive shaft 65 and the guide member 60. The valve core 70 is pressed downward by the drive shaft 65, and the opening area of ​​the valve port 14 becomes smaller.

[0091] In the electric valve 1, current flows through the A-phase coil 81c and the B-phase coil 82c, causing the magnet rotor 41 to rotate in the other direction. The rotation of the magnet rotor 41 is transmitted to the drive shaft 65 via the planetary gear mechanism 50. The drive shaft 65 moves upward by the screw feed action of the drive shaft 65 and the guide member 60. The valve core 70 is pressed upward by the valve opening spring 75, and the opening area of ​​the valve port 14 becomes larger.

[0092] Next, a method for manufacturing the stator unit 8 of the electric valve 1 will be described.

[0093] The A-phase stator 81 and the B-phase stator 82 are set in a molding die for the stator 80 , and the resin member 83 is injection-molded integrally with the A-phase stator 81 and the B-phase stator 82 , thereby manufacturing the stator 80 .

[0094] Next, an electromagnetic wave suppression film 90 is formed on the surface of the stator 80. Specifically, an electromagnetic wave suppression paint is applied to the outer surface 80b of the yoke, the peripheral surface 85b of the base 85, the lower surface 87a of the annular portion 87, and the outer peripheral surface 87b of the annular portion 87. The electromagnetic wave suppression paint is not applied to the parts other than these in the stator 80. That is, the electromagnetic wave suppression paint is not applied to the inner peripheral surface 80a of the stator, the top end surface 85a of the base 85, the top end surface 86a of the top end portion 86, and the peripheral surface 86b of the top end portion 86. When the electromagnetic wave suppression paint is dried, the electromagnetic wave suppression film 90 is formed.

[0095] Next, the housing 100 is injection molded in such a manner that the housing 100 covers the electromagnetic wave suppression film 90. Specifically, the stator 80 and the connector terminal 109 having the electromagnetic wave suppression film 90 formed on the surface are set in a molding die for the housing 100. Then, the housing 100 is integrally injection molded with the stator 80 (including the electromagnetic wave suppression film 90) and the connector terminal 109. Thus, the electromagnetic wave suppression film 90 is arranged between the stator 80 and the peripheral wall portion 101 of the housing 100. In the present embodiment, the electromagnetic wave suppression film 90 is only arranged between the stator 80 and the peripheral wall portion 101, and the electromagnetic wave suppression film 90 is not exposed in the inner space 106 and the substrate accommodating space 107. The cover member 110 is injection molded in a process different from that of the housing 100.

[0096] The control device 120 is arranged in the substrate accommodating space 107 of the box portion 103 of the housing 100. The coil terminal 88 and the other end of the connector terminal 109 are soldered to the substrate 130 of the control device 120. The cover member 110 is joined to the top end 103a of the box portion 103. The joining method is, for example, infrared welding, ultrasonic welding, or joining using an adhesive. The bracket 111 is mounted on the peripheral wall portion 101 of the housing 100. In this way, the stator unit 8 is completed. The electromagnetic wave suppression film 90 is not exposed on the outer surface of the stator unit 8.

[0097] The electric valve 1 of the present embodiment includes a valve body assembly 5 and a stator unit 8. The valve body assembly 5 includes a cylindrical cover 30 and a magnet rotor 41 disposed inside the cover 30.

[0098] The stator unit 8 includes a stator 80 disposed outside the cover 30 and a synthetic resin housing 100 integrally formed with the stator 80. The stator unit 8 includes an electromagnetic wave suppression film 90 disposed between the stator 80 and the housing 100. Thus, the electromagnetic wave suppression film 90 is held by the stator 80 and the housing 100, and the electromagnetic wave suppression film 90 can be suppressed from falling off. Therefore, the electromagnetic waves emitted from the stator 80 can be suppressed, and malfunction of the electronic components can be suppressed.

[0099] In addition, the stator 80 has an A-phase stator 81 and a B-phase stator 82. The A-phase stator 81 has an A-phase yoke 81a in a hollow circular ring shape, an A-phase winding frame 81b arranged on the inner side of the A-phase yoke 81a, and an A-phase coil 81c wound on the A-phase winding frame 81b. The B-phase stator 82 has a B-phase yoke 82a in a hollow circular ring shape, a B-phase winding frame 82b arranged on the inner side of the B-phase yoke 82a, and a B-phase coil 82c wound on the B-phase winding frame 82b. The A-phase stator 81 and the B-phase stator 82 are coaxially arranged. The lower surface 81f of the A-phase yoke 81a is in contact with the upper surface 82g of the B-phase yoke 82a. The upper surface 81g of the A-phase yoke 81a, the outer peripheral surface 81h of the A-phase yoke 81a, the lower surface 82f of the B-phase yoke 82a, and the outer peripheral surface 82h of the B-phase yoke 82a constitute the yoke outer surface 80b. The electromagnetic wave suppression film 90 is arranged between the yoke outer surface 80b and the housing 100. Thus, the electromagnetic waves emitted by the A-phase yoke 81a and the B-phase yoke 82a can be effectively suppressed.

[0100] In addition, the stator 80 also has a resin component 83 integrally formed with the A-phase stator 81 and the B-phase stator 82. The resin component 83 has a terminal support portion 84. The terminal support portion 84 extends forward from the A-phase yoke 81a and the B-phase yoke 82a. The coil terminal 88 connected to the A-phase coil 81c and the B-phase coil 82c protrudes from the top end surface 86a of the top end portion 86 of the terminal support portion 84. The electromagnetic wave suppression film 90 is arranged between the terminal support portion 84 (the peripheral surface 85b of the base 85) and the housing 100. As a result, the electromagnetic waves emitted through the terminal support portion 84 can be effectively suppressed.

[0101] The resin member 83 also has a toroidal ring portion 87. The ring portion 87 is disposed on the lower surface 82f of the B-phase yoke 82a. The electromagnetic wave suppression film 90 is disposed between the ring portion 87 (lower surface 87a, outer peripheral surface 87b) and the housing 100. Thus, the electromagnetic waves emitted through the ring portion 87 can be effectively suppressed.

[0102] In addition, the top end portion 86 of the terminal support portion 84 is arranged in the substrate accommodating space 107 provided in the housing 100. The coil terminal 88 is connected to the substrate 130 arranged in the substrate accommodating space 107. The entire surface of the top end portion 86 (top end surface 86a, peripheral surface 86b) directly faces the substrate accommodating space 107. As a result, the electromagnetic wave suppression film 90 is not formed on the surface of the top end portion 86 arranged in the substrate accommodating space 107. Therefore, the electromagnetic wave suppression film 90 will not fall off in the substrate accommodating space 107, and the malfunction of the electronic components mounted on the substrate 130 can be more effectively suppressed. The top end portion 86 is a part of the terminal support portion 84 that includes the top end surface 86a. In addition, the electromagnetic wave suppression film 90 can also be arranged on the peripheral surface 86b of the top end portion 86.

[0103] Furthermore, the synthetic resin constituting the housing 100 may contain an electromagnetic wave suppressing material. This can more effectively suppress the electromagnetic waves emitted from the stator 80 .

[0104] Fig.10 An electric valve 1A having a structure of a modified example of the electric valve 1 is shown. In the electric valve 1A, the same reference numerals are given to the same structures as those of the electric valve 1 (including substantially the same structures), and detailed description thereof will be omitted.

[0105] The electric valve 1A includes a valve body assembly 5 and a stator unit 8A. Fig.11 As shown, the stator unit 8A has a stator 80, an electromagnetic wave suppression film 90, and a housing 100A.

[0106] The housing 100A accommodates the stator 80. The housing 100A and the stator 80 having an electromagnetic wave suppression film 90 formed on the surface are integrally injection molded (insert molded). The electromagnetic wave suppression film 90 is arranged between the stator 80 and the housing 100A. In addition, in the stator 80 of the electric valve 1A, the annular portion 87 is arranged on the upper surface of the A-phase stator 81.

[0107] The housing 100A integrally includes a peripheral wall portion 101, an upper wall portion 102, and a connector portion 104A. The connector portion 104A has a cylindrical shape and extends forward from the peripheral wall portion 101. The top end of the terminal support portion 84 is arranged in the internal space of the connector portion 104A. The coil terminal 88 extends forward from the top end of the terminal support portion 84. The coil terminal 88 functions as a connector terminal.

[0108] The electric valve 1A also achieves the same (including substantially the same) effects as the electric valve 1 .

[0109] The electric valve 1 of this embodiment is configured to reduce the speed of rotation of the magnet rotor 41 and transmit it to the drive shaft 65. The electric valve 1 may be a direct-acting electric valve that transmits the rotation of the magnet rotor 41 directly to the drive shaft 65.

[0110] In this specification, each term indicating a shape such as "cylindrical" or "column" is also used for a component or a part of a component that substantially has the shape of the term. For example, a "cylindrical component" includes a cylindrical component and a substantially cylindrical component.

[0111] The above describes the embodiments of the present invention, but the present invention is not limited to the structures of the embodiments. For the above embodiments, those skilled in the art may appropriately add, delete, design and change the structures of the constituent elements and appropriately combine the features of the embodiments, which are also included in the scope of the present invention as long as they do not violate the gist of the present invention.

[0112] Explanation of symbols

[0113] 1. 1A…Electric valve

[0114] 5...valve body assembly, 10...valve body, 10a...rear surface, 10b...front surface, 10c...upper surface, 13...valve chamber, 14...valve port, 17...first passage, 18...second passage, 19...mounting hole, 19a...bottom surface, 20...retainer, 25...valve core support member, 25a...annular plane, 30...cover, 35...joining member, 40...driving mechanism, 41...magnetic rotor, 42...connecting member, 43...rotor shaft, 46...stepping motor, 50 …planetary gear mechanism, 51…gear box, 52…fixed ring gear, 53…sun gear, 54…planetary gear, 55…planetary gear carrier, 55a…support shaft, 56…output gear, 57…output shaft, 57a…slit, 60…guide member, 65…drive shaft, 66…cylindrical portion, 67…flat portion, 68…ball, 70…valve core, 71…rod, 72…valve portion, 73…spring receiving portion, 73a…flange portion, 74…ball receiving portion, 75…valve opening spring

[0115] 8, 8A... stator unit, 80... stator, 80a... stator inner peripheral surface, 80b... yoke outer surface, 80c... yoke opening, 81... A-phase stator, 81a... A-phase yoke, 81b... A-phase bobbin, 81c... A-phase coil, 81d... pole tooth, 81e... pole tooth, 81f... lower surface, 81g... upper surface, 81h... outer peripheral surface, 82... B-phase stator, 82a... B-phase yoke, 82b... B-phase bobbin, 82c... B-phase coil, 82d... pole tooth, 82e... pole tooth, 82f... lower surface, 82g... upper surface, 82h... outer peripheral surface, 83... resin component, 83a... first portion, 83b... second portion, 84... terminal support portion, 85... base portion, 8 5a…top surface, 85b…peripheral surface, 86…top portion, 86a…top surface, 86b…peripheral surface, 87…annular portion, 87a…lower surface, 87b…outer peripheral surface, 90…electromagnetic wave suppression film, 100, 100A…housing, 101…peripheral wall portion, 101a…inner peripheral surface, 102…upper wall portion, 102a…inner surface, 103…box portion, 103a…top, 104, 104A…connector portion, 106…inner space, 107…substrate accommodating space, 108…opening, 109…connector terminal, 110…cover member, 111…bracket, 112…screw, 120…control device, 130…substrate, 150…microcomputer, L…axis line.

Claims

1. A stator unit comprising a stator and a housing made of synthetic resin formed integrally with the stator, characterized in that: An electromagnetic wave suppression film is provided between the stator and the housing.

2. The stator unit according to claim 1, characterized in that The stator has an A-phase stator and a B-phase stator, The A-phase stator includes an A-phase yoke in a hollow annular shape, an A-phase bobbin disposed inside the A-phase yoke, and an A-phase coil wound around the A-phase bobbin. The B-phase stator includes a B-phase yoke in a hollow annular shape, a B-phase bobbin disposed inside the B-phase yoke, and a B-phase coil wound around the B-phase bobbin. The A-phase stator and the B-phase stator are coaxially arranged. The first end surface of the A-phase yoke contacts the first end surface of the B-phase yoke, The second end surface of the A-phase yoke, the outer peripheral surface of the A-phase yoke, the second end surface of the B-phase yoke, and the outer peripheral surface of the B-phase yoke constitute the outer surface of the yoke. The electromagnetic wave suppression film is disposed between the outer surface of the yoke and the housing.

3. The stator unit according to claim 2, characterized in that: The stator further includes a resin component integrally formed with the A-phase stator and the B-phase stator. The resin component has a terminal supporting portion, The terminal support portion extends from the A-phase yoke and the B-phase yoke in a direction perpendicular to the axial direction. The coil terminals connected to the A-phase coil and the B-phase coil protrude from the top end surface of the terminal support portion. The electromagnetic wave suppression film is arranged between the terminal support portion and the housing.

4. The stator unit according to claim 3, characterized in that: The resin component further has a ring-shaped annular portion, The annular portion is arranged on the second end surface of the A-phase yoke or the second end surface of the B-phase yoke, The electromagnetic wave suppression film is arranged between the annular portion and the housing.

5. The stator unit according to claim 3, characterized in that: A portion of the terminal support portion including the top end surface is arranged in a substrate accommodation space provided in the housing. The coil terminal is connected to a substrate disposed in the substrate receiving space. The entire surface of the portion of the terminal support portion directly faces the substrate accommodating space.

6. The stator unit according to claim 1, characterized in that: The synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

7. A stator unit comprising a stator and a housing made of synthetic resin formed integrally with the stator, characterized in that: The synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

8. An electric valve comprising a valve body assembly and the stator unit according to claim 1 or 7, characterized in that: The valve body assembly includes a cylindrical housing and a magnetic rotor disposed inside the housing. The stator is disposed outside the housing.

9. A method for manufacturing a stator unit, the stator unit comprising a stator and a housing made of synthetic resin formed integrally with the stator, characterized in that: An electromagnetic wave suppression film is formed on the surface of the stator, The housing is injection-molded in such a manner that the housing covers the electromagnetic wave suppressing film.

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