Linear motor armature and manufacturing method thereof

Abstract

The present disclosure provides a linear motor armature comprising: an iron core having a plurality of teeth and a plurality of slots; a resin molded part; and a sheet-like reinforcing member. The reinforcing member has formed therein a recess that is recessed toward the opposite side of the plurality of teeth. The recessed portion is connected to a side surface of the reinforcing member that is orthogonal to the thickness direction. The recessed portion is filled with a resin material.

Description

Technical Field

[0001] The present disclosure relates to a linear motor armature and a method for manufacturing the same. Background Art

[0002] A linear motor armature is disclosed in Japanese Patent Laid-Open No. 5-111234, in which a fiber-reinforced resin sheet is provided on a wall portion on a tooth side of a resin molded article covering an iron core. Summary of the Invention

[0003] There is a desire to provide a better linear motor armature and a method for manufacturing the same.

[0004] A first aspect of the present disclosure is a linear motor armature including: an iron core having a plurality of teeth and a plurality of slots, and coils being respectively provided in the plurality of slots; a resin molded article made of a resin material and covering the iron core; and a sheet-like reinforcing member provided on the wall portions on the plurality of tooth sides of the resin molded article to reinforce the wall portions, wherein a concave portion recessed toward a side opposite to the plurality of teeth is formed in the reinforcing member, the concave portion is connected to a side surface of the reinforcing member orthogonal to the thickness direction, and the resin material is filled in the concave portion.

[0005] A second aspect of the present disclosure is a method for manufacturing a linear motor armature, the linear motor armature including: an iron core having a plurality of teeth and a plurality of slots, and coils being respectively provided in the plurality of slots; a resin molded article made of a resin material and covering the iron core; and a sheet-like reinforcing member provided on the wall portions on the plurality of tooth sides of the resin molded article to reinforce the wall portions, wherein the method for manufacturing the linear motor armature includes: a preparation step of preparing a sheet member having a concave portion formed on a surface thereof; a configuration step of disposing the sheet member on a bottom surface of a molding die with the concave portion facing upward; a placement step of placing the iron core on the sheet member in contact with the plurality of teeth; and a molding step of molding the resin molded article by curing a liquid resin injected into the interior of the molding die, and in the molding step, the sheet member becomes the reinforcing member, and the liquid resin is filled in the concave portion. Brief Description of the Drawings

[0006] Figure 1 is a longitudinal sectional view of the linear motor armature. In addition, Figure 1 is along Figure 2 sectional view taken along line I-I.

[0007] Figure 2 is along Figure 1 sectional view taken along line II-II in the transverse direction.

[0008] Figure 3It is a flowchart showing a method for manufacturing a linear motor armature.

[0009] Figure 4A And Figure 4B It is an explanatory diagram of a preparation step.

[0010] Figure 5 It is an explanatory diagram of a placement step and a mounting step.

[0011] Figure 6 It is a first explanatory diagram of a forming step.

[0012] Figure 7 It is a second explanatory diagram of a forming step.

[0013] Figure 8A It is a transverse cross-sectional view of a linear motor armature having a reinforcing member of Modification 1. Figure 8B It is a transverse cross-sectional view of a linear motor armature having a reinforcing member of Modification 2. Detailed Description of the Invention

[0014] The above-described prior art linear motor armature is formed by injecting liquid resin into a mold for a molded article in a state where the teeth of the iron core are in contact with a fibrous sheet member disposed on the bottom surface of the mold for the molded article and curing the resin. In this case, the liquid resin penetrates the fibrous sheet member to form a fiber-reinforced resin sheet. However, it is difficult for the liquid resin to penetrate the sheet member. Therefore, for example, if the entire surface of the teeth facing the sheet member is in contact with the sheet member, it may not be possible to cover the entire iron core with the resin molded article.

[0015] Hereinafter, the linear motor armature 10 and its manufacturing method according to the present embodiment will be described with reference to the drawings. As Figure 1 shown, the linear motor armature 10 is disposed facing the stator 200 to form a mover that is pushed and moves.

[0016] The stator 200 has a base plate 202 extending in one direction (arrow X direction) and a plurality of magnets 204 provided on the base plate 202. The plurality of magnets 204 are arranged at equal intervals in the arrow X direction. The magnets 204 are permanent magnets.

[0017] As Figure 1 And Figure 2 shown, the linear motor armature 10 has a rectangular parallelepiped shape. The linear motor armature 10 extends in the arrow X direction. The linear motor armature 10 includes an iron core 12, a resin molded article 14, and a reinforcing member 16.

[0018] As Figure 1As shown, the iron core 12 has an iron core body 18 and a plurality of coils 20. The iron core body 18 is formed, for example, by laminating a plurality of electromagnetic steel sheets. The iron core body 18 has a yoke 22, a plurality of teeth 24, and a plurality of slots 26.

[0019] The yoke 22 extends in the direction of arrow X. The teeth 24 project from the yoke 22 in the thickness direction of the yoke 22 (the direction of arrow Z). The plurality of teeth 24 are arranged at intervals in the direction of arrow X. The dimension of the teeth 24 in the width direction (the dimension along arrow Y) is the same as the dimension of the yoke 22 in the width direction (the dimension along arrow Y) (see Figure 2 ). The slot 26 is a gap formed between adjacent teeth 24. The positions, sizes, shapes, etc. of the yoke 22, the teeth 24, and the slots 26 can be appropriately set.

[0020] Coils 20 are respectively provided in the plurality of slots 26. The coil 20 includes a wire (not shown) wound around the teeth 24. Insulating paper 28 for preventing electrical connection between the coil 20 and the iron core body 18 is provided in the slot 26.

[0021] As Figure 1 and Figure 2 shown, the resin molded part 14 is made of a resin material and covers the entire iron core 12. The resin material constituting the resin molded part 14 has electrical insulation properties. As the resin material constituting the resin molded part 14, for example, thermosetting resins such as epoxy resin, phenolic resin, and polyamide resin can be used. In addition, a thermoplastic resin such as methyl methacrylate can also be used as the resin material constituting the resin molded part 14. The resin molded part 14 is also provided inside the slot 26 (see Figure 1 ).

[0022] The reinforcing member 16 is formed in a sheet shape. The reinforcing member 16 has electrical insulation properties. The reinforcing member 16 is provided on the wall portion 30 on the tooth 24 side of the resin molded part 14. The wall portion 30 of the resin molded part 14 is a portion adjacent to the protruding end face 32 of the tooth 24.

[0023] The reinforcing member 16 includes a fiber-reinforced resin (FRP: Fiber Reinforced Plastics). The fiber-reinforced resin includes, for example, glass fibers. In addition, the fiber-reinforced resin may also include other fibers that are not glass fibers. Additionally, the fiber-reinforced resin may include multiple types of fibers. Also, the fibers of the fiber-reinforced resin preferably have electrical insulation properties.

[0024] As Figure 2As shown, the reinforcing member 16 is formed by folding both ends of the fiber-reinforced resin sheet 34. Specifically, both ends of the fiber-reinforced resin sheet 34 in the direction orthogonal to the arrangement direction of the plurality of teeth 24 (arrow Y direction) are folded toward the teeth 24 side. That is, the sheets at both ends of the fiber-reinforced resin sheet 34 in the arrow Y direction become double layers.

[0025] The thickness D1 of the end portion 35a of the reinforcing member 16 in the arrow Y direction is thicker than the thickness D2 of the central portion 35b of the reinforcing member 16 in the arrow Y direction. In addition, the end portion 35a is the folded part, and the central portion 35b is the non-folded part. The thickness of the wall portion 30 of the resin molded part 14 is determined by the thickness D1 of the end portion 35a of the reinforcing member 16. That is, the thickness D1 of the end portion 35a of the reinforcing member 16 is the same as the thickness of the wall portion 30 of the resin molded part 14. The thickness D1 of the end portion 35a of the reinforcing member 16 (the thickness of the wall portion 30 of the resin molded part 14) is preferably 0.1 mm or more and 0.3 mm or less, and more preferably about 0.2 mm. In this case, the magnetic gap between the iron core 12 and the stator 200 (refer to Figure 1 ) can be narrowed.

[0026] A recess 36 is formed in the reinforcing member 16 and recesses toward the side opposite to the teeth 24. The recess 36 is located between the both end portions 35a of the reinforcing member 16. As Figure 1 shown, the recess 36 extends over the entire length of the reinforcing member 16 in the arrow X direction. In other words, the recess 36 is connected to the side surface (outer surface) of the reinforcing member 16 in the arrow X direction. As Figure 2 shown, the dimension W1 in the width direction (arrow Y direction) of the recess 36 is larger than the dimension W2 in the arrow Y direction of each of the both end portions 35a of the reinforcing member 16. A resin material is filled in the recess 36. The resin material filled in the recess 36 forms the wall portion 30.

[0027] Both end portions 35a of the reinforcing member 16 are in contact with the protruding end surface 32 of the teeth 24. The central portion 35b of the reinforcing member 16 is separated from the protruding end surface 32 of the teeth 24. The dimension of the reinforcing member 16 in the arrow X direction is the same as the dimension of the iron core 12 in the arrow X direction (refer to Figure 1 ). The dimension of the reinforcing member 16 in the arrow Y direction is the same as the dimension of the iron core main body 18 in the arrow Y direction. The size, shape, etc. of the reinforcing member 16 can be appropriately changed.

[0028] Next, a manufacturing method of the linear motor armature 10 described above will be described.

[0029] As Figure 3 shown, the manufacturing method of the linear motor armature 10 of the present embodiment includes a preparation step, an arrangement step, a placement step, and a forming step.

[0030] In a preparation step (step S1), as Figure 4A and Figure 4B shown, a sheet member 40 of a predetermined shape is prepared. Specifically, both ends of a rectangular fiber sheet 42 are folded, thereby forming the sheet member 40. The size and shape of the sheet member 40 are the same as the size and shape of the above-described fiber reinforced resin sheet 34. A recess 36 is formed in the sheet member 40. After the preparation step is completed, the placement step is entered.

[0031] In the placement step ( Figure 3 step S2), as Figure 5 shown, the sheet member 40 is placed at the center of the bottom surface 46 of the molded part mold 44. The recess 36 of the sheet member 40 faces upward. After the placement step is completed, the loading step is entered.

[0032] In the loading step ( Figure 3 step S3), the iron core 12 is loaded on the sheet member 40. The protruding end surface 32 of the tooth 24 contacts the end of the sheet member 40. After the loading step is completed, the forming step is entered.

[0033] In the forming step ( Figure 3 step S4), as Figure 6 and Figure 7 shown, a liquid resin (resin material) 48 is injected into the inside of the molded part mold 44. The liquid resin 48 injected into the inside of the molded part mold 44 is stored so as to surround the sheet member 40. Further, as Figure 6 shown, the liquid resin 48 flows into the recess 36 from both ends of the sheet member 40 in the arrow X direction, and flows toward the center of the sheet member 40 in the arrow X direction within the recess 36. Further, at this time, the liquid resin 48 also flows into each of the plurality of grooves 26. The liquid resin 48 around the sheet member 40 penetrates into the inside of the sheet member 40 (fiber sheet 42) (refer to Figure 7 ).

[0034] As Figure 6 and Figure 7 shown, when the liquid resin 48 covers the upper surface of the iron core 12, the injection of the liquid resin 48 into the inside of the molded part mold 44 is stopped. Thereafter, the liquid resin 48 is cured to form the resin molded part 14. Further, the fiber reinforced resin sheet 34 (reinforcing member 16) is formed by curing the liquid resin 48 that has penetrated (impregnated) into the sheet member 40. That is, by completing the forming step, the linear motor armature 10 is manufactured.

[0035] The present embodiment has the following effects.

[0036] In the present embodiment, in the linear motor armature 10, a sheet-like reinforcing member 16 is provided on the wall portion 30 on the side of the plurality of teeth 24 of the resin molded part 14, so that the wall portion 30 can be strengthened. In addition, a recess 36 that is recessed toward the side opposite to the plurality of teeth 24 is formed in the reinforcing member 16. The recess 36 is connected to the side surface of the reinforcing member 16 that is orthogonal to the thickness direction. A resin material is filled in the recess 36. Therefore, compared with the case where the recess 36 is not formed in the reinforcing member 16, the resin material (liquid resin 48) can be easily supplied between the plurality of teeth 24 and the reinforcing member 16, so that the entire iron core 12 can be covered with the resin molded part 14. Thereby, a better linear motor armature 10 can be obtained.

[0037] The reinforcing member 16 includes a fiber-reinforced resin. According to such a structure, the wall portion 30 of the resin molded part 14 can be strengthened simply and efficiently.

[0038] The reinforcing member 16 is formed by folding both ends of the fiber-reinforced resin sheet 34. According to such a structure, the recess 36 can be simply formed in the reinforcing member 16. In addition, the thickness of the wall portion 30 of the resin molded part 14 can be defined by the thickness D1 (dimension in the arrow Z direction) of both end portions 35a of the fiber-reinforced resin sheet 34.

[0039] The plurality of teeth 24 are arranged in one direction (arrow X direction). Both ends of the fiber-reinforced resin sheet 34 in the direction (arrow Y direction) orthogonal to the arrangement direction of the plurality of teeth 24 are folded. According to such a structure, the deviation of the thickness of the wall portion 30 of the resin molded part 14 in the arrangement direction (arrow X direction) of the plurality of teeth 24 can be suppressed.

[0040] In the manufacturing method of the linear motor armature 10, in the preparation step, a sheet member 40 having a recess 36 formed on the surface is prepared. In the arrangement step, the sheet member 40 is arranged on the bottom surface 46 of the molding die 44 with the recess 36 facing upward. In the placement step, the iron core 12 is placed on the sheet member 40 in contact with the plurality of teeth 24. In the molding step, the liquid resin 48 injected into the inside of the molding die 44 is cured to mold the resin molded part 14. In addition, in the molding step, the sheet member 40 becomes the reinforcing member 16 and the liquid resin 48 is filled in the recess �6. According to such a method, the above-mentioned linear motor armature 10 can be simply manufactured.

[0041] The sheet member 40 is a fiber sheet 42. In the molding step, a fiber-reinforced resin is formed by impregnating the fiber sheet 42 with a resin material. According to such a method, the fiber-reinforced resin sheet 34 (reinforcing member 16) can be simply formed.

[0042] In the preparation step, the sheet member 40 is formed by folding both ends of the fiber sheet 42. According to such a method, the sheet member 40 can be prepared simply.

[0043] The above-described embodiment can be modified as follows. In the following modification examples, the description overlapping with the embodiment is omitted. In addition, in the drawings used in the following modification examples, the same reference numerals are given to the structures identical to those described in the embodiment.

[0044] (Modification Example 1)

[0045] As Figure 8A shown, the reinforcing member 16a of the modification example 1 of the linear motor armature 10 is formed in a sheet shape. The reinforcing member 16a is integrally formed such that both end portions 50a in the arrow Y direction of the reinforcing member 16a protrude toward the plurality of teeth 24 more than the central portion 50b in the arrow Y direction of the reinforcing member 16a.

[0046] A recess 36 is formed in the reinforcing member 16a. The recess 36 is formed by machining, for example. Both ends of the reinforcing member 16a in the arrow Y direction are not folded. The reinforcing member 16a is a fiber-reinforced resin sheet 34. According to such a structure, it is not necessary to fold both ends of the reinforcing member 16a.

[0047] (Modification Example 2)

[0048] As Figure 8B shown, the reinforcing member 16b of the modification example 2 of the linear motor armature 10 has a sheet main body 52 and a pair of spacers 54. The thickness of both end portions in the arrow Y direction of the sheet main body 52 is the same as the thickness of the central portion in the arrow Y direction of the sheet main body 52.

[0049] The spacers 54 are placed on both end portions in the arrow Y direction of the sheet main body 52. The spacers 54 are formed in a sheet shape. The spacers 54 are in contact with the protruding end faces 32 of the teeth 24. The dimension W3 in the width direction (arrow Y direction) of the spacers 54 is less than 1 / 2 of the dimension W4 in the width direction of the sheet main body 52. A recess 36 is formed between the pair of spacers 54. The sheet main body 52 and the spacers 54 are fiber-reinforced resin sheets 34. According to such a structure, it is not necessary to fold both ends of the reinforcing member 16b.

[0050] In the above-described embodiment, modification example 1, and modification example 2, the size, shape, position, etc. of the recess 36 can be appropriately set as long as the recess 36 is connected to the side faces of the reinforcing members 16, 16a, 16b orthogonal to the thickness direction. The reinforcing members 16, 16a, 16b may not be fiber-reinforced resin sheets 34. The reinforcing members 16, 16a, 16b may be porous sheets impregnated with a resin material. In addition, the reinforcing members 16, 16a, 16b may be sheets or plates (metal plates, resin plates) into which the resin material does not penetrate.

[0051] Regarding the above-described embodiments, the following supplementary notes are further disclosed.

[0052] (Supplementary Note 1)

[0053] The present disclosure is a linear motor armature (10), which includes: a core (12) having a plurality of teeth (24) and a plurality of slots (26), and coils (20) are respectively provided in the plurality of slots; a resin molded part (14) made of a resin material and covering the core; and sheet-like reinforcing members (16, 16a, 16b) provided on the wall parts (30) on the side of the plurality of teeth of the resin molded part to reinforce the wall parts. In this linear motor armature (10), a concave part (36) recessed toward the side opposite to the plurality of teeth is formed in the reinforcing member, the concave part is connected to the side surface of the reinforcing member orthogonal to the thickness direction, and the resin material is filled in the concave part.

[0054] (Supplementary Note 2)

[0055] In the linear motor armature described in Supplementary Note 1 above, the reinforcing member may include a fiber-reinforced resin.

[0056] (Supplementary Note 3)

[0057] In the linear motor armature described in Supplementary Note 2 above, the reinforcing member may be formed by folding both ends of a fiber-reinforced resin sheet (34).

[0058] (Supplementary Note 4)

[0059] In the linear motor armature described in Supplementary Note 3 above, it may also be that the plurality of teeth are arranged in one direction, and both ends of the fiber-reinforced resin sheet in the direction orthogonal to the arrangement direction of the plurality of teeth are folded.

[0060] (Supplementary Note 5)

[0061] In the linear motor armature described in Supplementary Note 1 or 2 above, it may also be that the reinforcing member is integrally formed in such a manner that both end portions (50a) of the reinforcing member protrude toward the side of the plurality of teeth more than the central portion (50b) of the reinforcing member.

[0062] (Supplementary Note 6)

[0063] The present disclosure relates to a method for manufacturing a linear motor armature, the linear motor armature comprising: an iron core having a plurality of teeth and a plurality of slots, and coils being respectively disposed in the plurality of slots; a resin molded part made of a resin material and covering the iron core; and a sheet-like reinforcing member provided on the wall portions on the plurality of tooth sides of the resin molded part to reinforce the wall portions. The method for manufacturing the linear motor armature comprises: a preparation step (step S1) of preparing a sheet member (40) having recesses formed on its surface; a configuration step (step S2) of disposing the sheet member on the bottom surface (46) of a molding die (44) with the recesses facing upward; a placement step (step S3) of placing the iron core on the sheet member in contact with the plurality of teeth; and a molding step (step S4) of molding the resin molded part by curing a liquid resin (48) injected into the interior of the molding die. In the molding step, the sheet member becomes the reinforcing member, and the liquid resin fills the recesses.

[0064] (Supplementary Note 7)

[0065] In the method for manufacturing a linear motor armature described in Supplementary Note 6 above, it may also be that the sheet member is a fiber sheet (42), and in the molding step, a fiber-reinforced resin sheet is formed by impregnating the fiber sheet with the resin material.

[0066] (Supplementary Note 8)

[0067] In the method for manufacturing a linear motor armature described in Supplementary Note 7 above, it may also be that in the preparation step, the sheet member is formed by folding both ends of the fiber sheet.

[0068] The present disclosure has been described in detail, but the present disclosure is not limited to the above-described respective embodiments. These embodiments can be variously added, replaced, changed, partially deleted, etc. within the scope not departing from the gist of the present disclosure, or within the scope not departing from the gist of the present disclosure derived from the content described in the claims and its equivalents. In addition, these embodiments can also be implemented in combination. For example, in the above-described embodiments, the order of each action and the order of each process are shown as an example and are not limited thereto. In addition, the same applies to the cases where numerical values or mathematical formulas are used in the description of the above-described embodiments.

[0069] Symbol Description

[0070] 10 - Linear motor armature, 12 - Iron core, 14 - Resin molded part, 16, 16a, 16b - Reinforcing member, 20 - Coil, 24 - Tooth, 26 - Slot, 30 - Wall portion, 34 - Fiber-reinforced resin sheet, 36 - Recess, 40 - Sheet member, 42 - Fiber sheet, 44 - Molding die, 46 - Bottom surface, 48 - Liquid resin.

Claims

1. A linear motor armature, comprising: A core having a plurality of teeth and a plurality of slots, and coils are respectively disposed in the plurality of slots; A resin molded part made of a resin material and covering the core; and A sheet-like reinforcing member provided on the wall portions on the plurality of tooth sides of the resin molded part to reinforce the wall portions; The linear motor armature is characterized in that: A recess recessed toward a side opposite to the plurality of teeth is formed in the reinforcing member; The recess is connected to a side surface of the reinforcing member orthogonal to the thickness direction; The resin material is filled in the recess.

2. The linear motor armature according to claim 1, characterized in that: The reinforcing member contains a fiber-reinforced resin.

3. The linear motor armature according to claim 2, characterized in that: The reinforcing member is formed by folding both ends of a fiber-reinforced resin sheet.

4. The linear motor armature according to claim 3, characterized in that: The plurality of teeth are arranged in one direction; Both ends of the fiber-reinforced resin sheet in a direction orthogonal to the arrangement direction of the plurality of teeth are folded.

5. The linear motor armature according to claim 1 or 2, characterized in that: The reinforcing member is integrally formed in such a manner that both ends of the reinforcing member protrude toward the plurality of tooth sides more than the central portion of the reinforcing member.

6. A manufacturing method of a linear motor armature, the linear motor armature comprising: A core having a plurality of teeth and a plurality of slots, and coils are respectively disposed in the plurality of slots; A resin molded part made of a resin material and covering the core; and A sheet-like reinforcing member provided on the wall portions on the plurality of tooth sides of the resin molded part to reinforce the wall portions; The manufacturing method of the linear motor armature is characterized by comprising: A preparation step of preparing a sheet member having a recess formed on its surface; An arrangement step of arranging the sheet member on the bottom surface of a molding die with the recess facing upward; A placement step of placing the core on the sheet member in contact with the plurality of teeth; and A molding step of molding the resin molded part by curing a liquid resin injected into the interior of the molding die, In the molding step, the sheet member becomes the reinforcing member, and the liquid resin is filled in the recess.

7. The manufacturing method of the linear motor armature according to claim 6, characterized in that: The sheet member is a fiber sheet; In the molding step, a fiber-reinforced resin sheet is formed by impregnating the fiber sheet with the resin material.

8. The manufacturing method of the linear motor armature according to claim 7, characterized in that: In the preparation step, the sheet member is formed by folding both ends of the fiber sheet.

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