Motor manufacturing method and motor

Abstract

The manufacturing method of the motor comprises a mounting step of mounting an end plate provided with a first end plate through hole and a second end plate through hole in a housing accommodating a motor stator wound with a coil; a first injection step in which, after the mounting step, an uncured resin is injected from the first end plate through-hole into a motor rotor arrangement region of the housing in which the motor stator is housed; and a second injection step of injecting an uncured resin from the second end plate through hole into the motor rotor arrangement region of the housing.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a motor manufacturing method and a motor. BACKGROUND

[0002] A motor has a rotor as a rotating body, and a stator disposed around the rotor. The stator has a core, and a coil wound around the core. The stator is resin-sealed in order to achieve waterproofing and rust prevention of the coil as an electric conductor. Patent Documents 1 to 3 disclose technologies related to motors. For example, a manufacturing method of a PM motor is disclosed in Patent Document 1. In the manufacturing method disclosed in Patent Document 1, after the coil is disposed on the inner diameter side of the stator core, resin is injected from a mold injection port. Then, the injected resin is cured by heating or the like, thereby forming a molded resin layer that covers the stator core and the coil. Patent Documents 2 and 3 disclose technologies for fixing magnets with resin.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2022-184651

[0004] Patent Document 2: Japanese Patent Application Publication No. 2018-130026

[0005] Patent Document 3: International Publication No. 2021 / 200817

[0006] In recent years, technologies for increasing the output of a motor have been studied. In the case of increasing the output of a motor, more current is supplied to the coil. As a result, the amount of heat generated by the coil increases, and thus cooling of the coil becomes important. Therefore, a case in which resin for waterproofing and rust prevention of the coil is further utilized as a heat path that carries away heat from the coil has been studied.

[0007] Generally, a resin having a high thermal conductivity has a high viscosity when uncured. If such an uncured resin is injected into a structure in which the stator is disposed in a housing, a long time is required until the gap resin spreads. Also, in the case of using a resin with a short pot life, it can be possible that the resin is cured before filling is completed.

[0008] In order to utilize resin as a heat path, it is desirable that the resin is in contact with the coil, and the resin is also in contact with a frame that houses the coil. Even if the resin is in contact with the coil, if the resin is not in contact with the frame, a gap between the resin and the frame becomes a thermal resistance. As a result, the resin cannot sufficiently function as a heat path. SUMMARY

[0009] The present disclosure provides a motor manufacturing method capable of manufacturing a motor that easily releases heat to the outside in a short time, and a motor that easily releases heat to the outside.

[0010] The manufacturing method of a motor as one embodiment of the present disclosure includes a mounting step of mounting an end plate provided with a first end plate through-hole and a second end plate through-hole to a housing in which a fixing member in which a coil is wound is accommodated, a first injecting step of injecting an uncured resin to a fixing member arrangement region of the housing in which the fixing member is accommodated from the first end plate through-hole that can visually recognize a first portion of the coil from an outside of the housing after the mounting step, and a second injecting step of injecting the uncured resin to the fixing member arrangement region of the housing from the second end plate through-hole that can visually recognize a second portion of the coil different from the first portion from the outside of the housing.

[0011] In the manufacturing method of a motor as one embodiment, the uncured resin is injected after the end plate is mounted. Further, the uncured resin is injected to the fixing member arrangement region by the step of injecting from the first end plate through-hole and the step of injecting from the second end plate through-hole different from the first end plate through-hole. Thus, compared to a case where the uncured resin is injected from one place, the time until the uncured resin spreads to the fixing member arrangement region can be shortened. Therefore, even if the resin is high in viscosity and high in thermal conductivity, the time until the uncured resin spreads to the fixing member arrangement region can be shortened. As a result, a motor that easily releases heat to the outside can be manufactured in a short time.

[0012] In the manufacturing method of a motor as one embodiment, the uncured resin can be caused to protrude from at least one of the first end plate through-hole or the second end plate through-hole by repeating the first injecting step and the second injecting step. In a state where the uncured resin protrudes from at least one of the first end plate through-hole or the second end plate through-hole, the uncured resin is in contact with a back surface of the end plate. Therefore, a path through which heat moves from the coil to the end plate via the resin can be reliably formed.

[0013] The manufacturing method of a motor as another embodiment of the present disclosure includes an injecting step of injecting an uncured resin to a fixing member arrangement region of a housing in which a fixing member in which a coil is wound is accommodated from an opening of the housing, and a mounting step of mounting an end plate provided with a first end plate through-hole and a second end plate through-hole to the housing after the injecting step. In the step of mounting the end plate, the uncured resin is caused to protrude from the first end plate through-hole and / or the second end plate through-hole by pressing the end plate to a liquid surface of the uncured resin.

[0014] As another method of manufacturing the motor, the uncured resin is injected from a plurality of positions different from each other to the fixing member arrangement region. Therefore, compared with the case where the uncured resin is injected from one place, the time until the uncured resin spreads to the fixing member arrangement region can be shortened. Then, after the uncured resin is injected, the end plate is installed. At the time of installing the end plate, the uncured resin is exposed from the first end plate through hole and / or the second end plate through hole by pressing the end plate to the liquid surface of the uncured resin. By the pressing of the end plate, the uncured resin is exposed from the first end plate through hole and / or the second end plate through hole means that the back surface of the end plate is in contact with the uncured resin. Therefore, the motor which easily releases heat to the outside can be manufactured in a short time.

[0015] In the injection step of the method of manufacturing the motor as another aspect, the uncured resin can be continuously injected while the housing and a device for supplying the uncured resin are relatively rotated around the axis of the housing. By this step, the time until the uncured resin spreads to the fixing member arrangement region can be shortened.

[0016] In the injection step of the method of manufacturing the motor as another aspect, the uncured resin can be continuously injected while the housing and a device for supplying the uncured resin are relatively rotated around the axis of the housing. By this step, the time until the uncured resin spreads to the fixing member arrangement region can be shortened.

[0017] As a motor according to still another aspect of the present disclosure, there is provided a motor including: a fixing member in which a coil is wound; a rotating member surrounded by the fixing member and rotating together with a shaft; a housing receiving the fixing member and the rotating member from a housing opening, forming a fixing member arrangement region in which the fixing member received is accommodated; an end plate installed to the housing opening; and a resin portion filled in the fixing member arrangement region. The resin portion is in contact with the coil and in contact with the end plate. The end plate includes a plurality of end plate through holes exposing the resin portion.

[0018] The resin portion of the motor according to still another aspect is in contact with the coil and in contact with the end plate. According to this structure, a path through which heat moves from the coil to the end plate via the resin can be reliably formed. As a result, heat can be appropriately discharged to the outside.

[0019] In the motor according to still another aspect, an exposed surface of the resin portion exposed from the end plate through hole can be located at a position between an opening edge on the back surface side of the end plate and an opening edge on the main surface side of the end plate. According to this structure, a configuration in which the resin portion reliably comes into contact with the back surface of the end plate can be obtained.

[0020] The end plate as a further mode of the motor can also include: an inner peripheral side cylindrical portion of a circular ring shape including an end plate shaft insertion hole through which a shaft is inserted; an outer peripheral side cylindrical portion of a circular ring shape that surrounds the inner peripheral side cylindrical portion in the circumferential direction and has an inner diameter larger than an outer diameter of the inner peripheral side cylindrical portion; and a linking portion provided with a plurality of portions spaced apart from each other around an axis line of the shaft in a manner that links an outer peripheral surface of the inner peripheral side cylindrical portion to an inner peripheral surface of the outer peripheral side cylindrical portion. The end plate through hole can also be a region sandwiched by a pair of linking portions adjacent to each other around the axis line of the shaft. An end surface of the inner peripheral side cylindrical portion can also protrude in the axis line direction of the shaft from the linking portion. According to this configuration, it is possible to suppress the attachment of uncured resin to the end surface of the inner peripheral side cylindrical portion, and thus it is possible to use the end surface of the inner peripheral side cylindrical portion as a mounting surface of the component.

[0021] According to the manufacturing method of the motor of the present disclosure, it is possible to manufacture a motor that easily releases heat to the outside in a short time. According to the motor of the present disclosure, it is possible to appropriately release heat to the outside. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is a cross-sectional view showing the configuration of the motor of the present disclosure.

[0023] Figure 2 is a cross-sectional view showing Figure 1 is a cross-sectional perspective view showing a main part of an end plate provided in the motor shown in

[0024] Figure 3 is a front view of the motor shown in Figure 1

[0025] Figure 4 (a) of FIG. 10 is a cross-sectional view showing one example of a resin portion exposure surface. Figure 4 (b) of FIG. 10 is a cross-sectional view showing another example of a resin portion exposure surface.

[0026] Figure 5 is a flowchart of a first manufacturing method of a motor.

[0027] Figure 6 (a) of FIG. 11 is a view showing a process of housing a motor assembly in a vacuum chamber. Figure 6 (b) of FIG. 11 is a view showing a process of injecting an uncured resin from a first end plate through hole.

[0028] Figure 7 (a) of FIG. 12 is a view showing a process of injecting an uncured resin from a second end plate through hole. Figure 7 (b) of FIG. 12 is a view showing a condition in which it is determined that a resin portion exposure surface of an uncured resin material has reached a prescribed position.

[0029] Figure 8 is a flowchart of a second manufacturing method of a motor. ​

[0030] Figure 9 This is a diagram illustrating the first, second, and third parts. Detailed Implementation

[0031] Hereinafter, the embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same elements are labeled with the same reference numerals, and repeated descriptions are omitted.

[0032] Figure 1 This is a cross-sectional view showing the construction of the motor 1 of this disclosure. Motor 1 is used, for example, in a vehicle turbocharger. When the torque on shaft 2 is insufficient, such as during vehicle acceleration, motor 1 applies torque to shaft 2 to compensate for the insufficient torque. In this case, an impeller (not shown) is mounted at the end of shaft 2.

[0033] Motor 1 is, for example, a brushless AC motor. Motor 1 includes a shaft 2, a motor rotor 3, a motor stator 4, a housing 5, and an end plate 6. As the drive source for motor 1, a vehicle battery can be used. When the vehicle decelerates, motor 1 can also use the rotational energy of motor rotor 3 to generate electricity regenerated. Motor 1 can handle high-speed rotation of shaft 2 (e.g., 100,000 to 200,000 rpm).

[0034] The motor rotor 3, which is a rotating component, is positioned between a pair of bearings 21 and 22 arranged along the axis A. The main component constituting the motor rotor 3 is a cylindrical magnet. The motor rotor 3 may also have elements for transmitting the torque acting on the magnet to the shaft 2, as needed. For example, the motor rotor 3 may also have end rings disposed at both ends of the cylindrical magnet, or armor covering the outer circumference of the magnet, as needed.

[0035] The motor stator 4, acting as a so-called fixed component, is housed within the housing 5. The motor stator 4 is configured to circumferentially surround the motor rotor 3. The motor stator 4 includes an iron core 4A and a coil 4B. Current is supplied to the coil 4B, resulting in the coil 4B generating a magnetic field. Through this magnetic field, a circumferential force acts on the magnets of the motor rotor 3. As a result, a torque is applied to the shaft 2.

[0036] The housing 5 forms a region that houses the motor rotor 3 and the motor stator 4. As a cylindrical component, the housing 5 has a cylindrical portion 51 and a bottom 52. One end of the housing 5, extending along the axis of the shaft 2, is open to accommodate components such as the motor rotor 3 and the motor stator 4. The housing 5 has a housing opening 51h. The housing 5 is equipped with electrode portions and other structures for supplying current to the coil 4B to enable the motor 1 to function. However, details regarding these structures will be provided in [the following text is missing from the original extract]. Figure 1 Illustrations have been omitted, and detailed descriptions of the embodiments have also been omitted.

[0037] Inside the housing 5, there are a motor stator configuration area 511 (fixed member configuration area) and a motor rotor configuration area 512. The motor stator configuration area 511 is the area surrounded by the cylindrical portion 51. The cylindrical motor stator 4 is fixed to the inner circumferential surface of the cylindrical portion.

[0038] The housing opening 51h is blocked by the end plate 6. This "blocking" refers to maintaining the position of the components housed inside the housing 5. The disc-shaped end plate 6 is fixed to the end of the housing 5. The bearing 21 is fixed to the end plate 6.

[0039] <Endplate>

[0040] The shape of end plate 6 will be described in more detail. End plate 6 is approximately circular. End plate 6 has an end plate body 6A and an end plate flange 6F. End plate body 6A is embedded in the opening recess 51ha of housing 5. End plate flange 6F abuts against the opening end face 51s of housing. Several bolt through holes (not shown) are provided on end plate flange 6F. Bolts inserted into the bolt through holes are screwed into threaded holes provided on the opening end face 51s of housing. As a result, end plate 6 is fixed to housing 5.

[0041] like Figure 2 As shown, the end plate body 6A has an outer peripheral cylindrical portion 61, spokes 62 (connecting portions), and an inner peripheral cylindrical portion 63. The outer peripheral cylindrical portion 61 is integrated with the end plate flange 6F. The outer peripheral cylindrical portion 61 has an outer peripheral annular portion 611 and an outer peripheral upright portion 612. The outer peripheral upright portion 612 rises from the outer peripheral annular portion main surface 611a of the outer peripheral annular portion 611 along the direction of axis A. The end plate flange 6F extends radially from the outer peripheral upright portion outer peripheral surface 611d. The outer peripheral annular portion main surface 611a functions as a mounting surface for mounting other devices to the motor 1. The outer peripheral annular portion main surface 611a can also be defined as a part of the end plate main surface 6a.

[0042] An outer peripheral step portion 613 is formed at the corner between the main surface 611a of the outer peripheral annular portion and the inner peripheral surface 611c of the outer peripheral annular portion. The outer peripheral step portion 613 includes the main surface 613a and the inner peripheral surface 613c of the outer peripheral step. The main surface 613a is located in a recess from the main surface 611a of the outer peripheral annular portion. The inner diameter of the inner peripheral surface 613c of the outer peripheral step is larger than the inner diameter of the inner peripheral surface 611c of the outer peripheral annular portion.

[0043] The resin part 7 contacts the back surface 611b of the outer peripheral annular part (see reference). Figure 4 (a) Therefore, the back surface 611b of the outer peripheral annulus forms part of the heat path. The back surface 611b of the outer peripheral annulus can also be defined as part of the back surface 6b of the end plate. The spoke 62 is connected to a part of the inner peripheral surface 611c of the outer peripheral annulus.

[0044] Spokes 62 connect the inner circumferential cylindrical portion 63 relative to the outer circumferential cylindrical portion 61. Figure 3 In the example shown, the end plate 6 has three spokes 62. Each of the three spokes 62 can be arranged at equal intervals around axis A.

[0045] like Figure 3 As shown, the spaces between adjacent spokes 62 are defined as end plate through holes 6P1, 6P2, and 6P3. For example, end plate through hole 6P1 could also be the first part 40a, which can be visually identified (see reference). Figure 9 Similarly, the through holes 6P2 and 6P3 of the end plate can also be openings that allow visual identification of the second part 40b and the third part 40c, respectively.

[0046] exist Figure 3 In the illustrated example, end plate 6 has three through holes 6P1, 6P2, and 6P3. The through holes 6P1, 6P2, and 6P3 can be defined as the regions surrounded by a portion of the inner circumferential surface 611c of the outer circumferential annular portion, a portion of the outer circumferential surface 63d of the inner circumferential cylindrical portion, and the spoke peripheral end face 62c. The openings of the through holes 6P1, 6P2, and 6P3 on the end plate main surface 6a side can also be defined by the edge included by the spoke peripheral end face 62c. The length of the through hole 6P along axis A can also be defined as the length from the end plate back surface 6b to the spoke main surface 62a.

[0047] like Figure 2 As shown, the spoke 62 extends from the inner circumferential surface 611c of the outer circumferential annular portion to the outer circumferential surface 63d of the inner circumferential cylindrical portion. The main surface 62a of the spoke is not flush with the main surface 611a of the outer circumferential annular portion. For example, if compared with the height based on the back surface 62b of the spoke, the height of the main surface 62a of the spoke is lower than the height of the main surface 611a of the outer circumferential annular portion. The back surface 62b of the spoke is flush with the back surface 611b of the outer circumferential annular portion. The back surface 62b of the spoke, like the back surface 611b of the outer circumferential annular portion, is part of the back surface 6b of the end plate and constitutes part of the heat path.

[0048] The inner circumferential cylindrical portion 63 has an inner circumferential cylindrical portion main surface 63a, an inner circumferential cylindrical portion back surface 63b, an inner circumferential cylindrical portion inner circumferential surface 63c, and an inner circumferential cylindrical portion outer circumferential surface 63d. A bearing 21 is disposed on the inner circumferential cylindrical portion main surface 63a. The inner circumferential cylindrical portion main surface 63a is the bearing mounting surface. The inner circumferential cylindrical portion main surface 63a can also be defined as a part of the end plate main surface 6a.

[0049] The back surface 63b of the inner circumferential cylindrical portion is flush with the back surface 611b of the outer circumferential annular portion and the back surface 62b of the spokes. The back surface 63b of the inner circumferential cylindrical portion, like the back surface 611b of the outer circumferential annular portion and the back surface 62b of the spokes, is part of the back surface 6b of the end plate and forms part of the heat path. As described above, the spokes 62 are connected to a portion of the outer circumferential surface 63d of the inner circumferential cylindrical portion. Another portion of the outer circumferential surface 63d of the inner circumferential cylindrical portion defines the end plate through holes 6P1, 6P2, and 6P3. The inner circumferential surface 63c of the inner circumferential cylindrical portion defines the end plate shaft insertion hole 6H for the shaft 2 to pass through.

[0050] An inner circumferential step portion 633 is also formed at the corner between the main surface 63a and the inner circumferential surface 63c of the inner circumferential cylindrical portion. The inner circumferential step portion 633 includes an inner circumferential step main surface 633a and an inner circumferential step outer circumferential surface 633d. The inner circumferential step main surface 633a is located in a recessed position from the main surface 63a of the inner circumferential cylindrical portion. The outer diameter of the inner circumferential step outer circumferential surface 633d is larger than the outer diameter of the inner circumferential cylindrical portion outer circumferential surface 63d. The inner circumferential step portion 633 can also cooperate with the outer circumferential step portion 613 and be used as a part for abutting the blocking clamp in the motor manufacturing method.

[0051] <Resin Section>

[0052] like Figure 1 As shown, the motor 1 also includes a resin section 7. The resin section 7 fills the motor stator mounting area 511 where the motor stator 4 is mounted. The resin section 7 covers the coil 4B. More specifically, the resin section 7 covers the coil end 41 that protrudes from the end face of the iron core 4A. With this resin section 7, the coil 4B is not in direct contact with air. That is, the resin section 7 provides a waterproof function to protect the coil 4B from moisture and a rust-proof function to inhibit rusting of the coil 4B.

[0053] The resin portion 7 fills the motor stator mounting region 511. The resin portion 7 does not fill the rotor mounting region 311 where the motor rotor 3 is mounted. Therefore, the resin portion 7 may also form an inner peripheral surface 7c of the resin portion opposite to the motor rotor 3.

[0054] The resin portion 7 functions as a heat path for dissipating heat generated by the coil 4B to the housing 5 and the end plate 6. The resin portion 7 includes a portion 71 that fills the space between the outer peripheral surface 41b of the coil end and the inner peripheral surface 5c of the housing. More specifically, this portion 71 contacts both the outer peripheral surface 41b of the coil end and the inner peripheral surface 5c of the housing. As a result, the thermal resistance from the coil end 41 to the housing 5 is dominated by the resin portion 7. By using a material with high thermal conductivity in the resin portion 7, heat can be effectively dissipated from the coil end 41 to the housing 5.

[0055] Examples of such resins include two-component curing epoxy resins.

[0056] The resin portion 7 includes a portion 72 that fills the space between the coil end face 41a and the end plate back surface 6b. More specifically, this portion 72 contacts the coil end face 41a and also contacts the end plate back surface 6b. As a result, as described above, the thermal resistance from the coil end 41 to the end plate 6 is dominated by the resin portion 7.

[0057] like Figure 4 As shown in (a), the resin portion 7 also includes a portion 73 that fills the end plate through hole 6P. The surface of the resin portion 7 that protrudes from the end plate through hole 6P is called the resin portion exposed surface 73s. Figure 4 As shown in (a), the exposed resin portion 73s does not protrude from the end plate through hole 6P. It is assumed that the upper end of the end plate through hole 6P is defined by the opening edge 62as of the spoke main surface 62a (the opening edge on the end plate main surface side). Furthermore, it is assumed that the lower end of the end plate through hole 6P is defined by the opening edge 6bs of the end plate back surface 6b (the opening edge on the end plate back surface side). Based on this assumption, the exposed resin portion 73s is located between the spoke main surface 62a and the end plate back surface 6b. Due to the position of the exposed resin portion 73s, the inner circumferential cylindrical main surface 63a protrudes from the exposed resin portion 73s. Therefore, the resin portion 7 is not attached to the inner circumferential cylindrical main surface 63a. As a result, the bearing 21 can be properly mounted on the inner circumferential cylindrical main surface 63a.

[0058] The exposed resin surface 73s should be positioned at least 4 sides of the motor stator, closer than the main surface 63a of the inner circumferential cylindrical portion. For example, ... Figure 4 As shown in (b), the exposed resin surface 73s can also be higher than and cover the main spoke surface 62a. Even in this case, the position of the exposed resin surface 73s is lower than the position of the outer peripheral annular main surface 611a and / or the inner peripheral cylindrical main surface 63a. Therefore, the resin 7 will not adhere to the outer peripheral annular main surface 611a and / or the inner peripheral cylindrical main surface 63a. As a result, components such as the bearing 21 can be properly mounted on the outer peripheral annular main surface 611a and / or the inner peripheral cylindrical main surface 63a.

[0059] Next, the method for manufacturing motor 1 will be described. Motor 1 can be manufactured by either of the two methods described below.

[0060] <First Method of Manufacturing Motors>

[0061] Figure 5 This diagram illustrates the main steps in the first manufacturing method of the motor. First, the motor stator 4 is mounted on the housing 5. Next, the cylindrical component 101 (see reference 512) is mounted in the area corresponding to the motor rotor mounting area 512. Figure 6(a)). This is to prevent uncured resin from being filled into the motor rotor configuration area 512 during the process of filling uncured resin. The end plate 6 is fixed to the housing 5 (S11: see reference). Figure 6 (a)). In the following description, for ease of explanation, the part in the assembly process in each manufacturing step of motor 1 will be referred to as "motor assembly".

[0062] Next, the motor assembly is housed in vacuum chamber 102 (S12: reference). Figure 6 (a)). The motor manufacturing method of this embodiment utilizes so-called vacuum filling to fill uncured resin.

[0063] Next, uncured resin 7s (S13: refer to) is injected through the through hole 6P1 of the first end plate. Figure 6 (b)). At this time, in order to maintain the flowability of the uncured resin 7s, the motor assembly can also be heated to a specified temperature. After injecting a predetermined amount of uncured resin 7s, the injection of uncured resin 7s is stopped.

[0064] At this point, the uncured resin 7s reaches the coil end 41 from the through hole 6P1 of the first end plate, and then flows to the coil end 41 on the opposite side. On the other hand, since the viscosity of the uncured resin 7s is high, it takes a considerable amount of time until the injected uncured resin 7s reaches a stationary state. The term "stationary state" here refers to the liquid level of the tilted uncured resin 7s reaching a horizontal level.

[0065] Next, before the uncured resin 7s injected through the first end plate through hole 6P1 reaches a settled state, the injection of uncured resin 7s through the second end plate through hole 6P2 begins (S14: refer to...). Figure 7 (a)). According to process S14, it becomes Figure 7 The state is shown in (a). Uncured resin 7s injected through the second end plate through hole 6P2 flows to the area not yet reached by uncured resin 7s injected through the first end plate through hole 6P1. Then, after injecting a predetermined amount of uncured resin 7s, the injection of uncured resin 7s is stopped.

[0066] Similarly, before the uncured resin 7s injected from the second end plate through hole 6P2 reaches a static state, the injection of uncured resin 7s from the third end plate through hole 6P3 begins (S15).

[0067] After step S15, it is confirmed that the level of the uncured resin 7s injected through the through holes 6P1, 6P2, and 6P3 of each end plate has reached the specified position (S16). This confirmation can be made by visually observing the position of the uncured resin 7s level 73k through the through holes 6P1, 6P2, and 6P3 of the end plate. For example, as... Figure 7 As shown in (b), the liquid level 73k of the uncured resin 7s can be determined to be at the specified position if the liquid level 73k reaches the through holes 6P1, 6P2, and 6P3 of each end plate.

[0068] When the liquid level 73k of the uncured resin 7s reaches the specified position, the injection of the uncured resin 7s is stopped. Then, the motor assembly is heated at a specified temperature. As a result, the uncured resin 7s becomes the cured resin part 7. Then, the motor 1 is obtained by performing the process of installing the motor rotor 3 and the bearing 21.

[0069] If the liquid level 73k of the uncured resin 7s is not at the specified position, the uncured resin 7s is injected again through the through hole 6P1 of the first end plate (S13).

[0070] Confirmation of whether the liquid level 73k of the uncured resin 7s has reached the specified position can be performed throughout each step S13 to S15 of injecting the uncured resin 7s. Then, if it is determined that the liquid level 73k of the uncured resin 7s has reached the specified position, the repetition of steps S13 to S15 of injecting the uncured resin 7s can be stopped, and the process can move to the next manufacturing step.

[0071] According to the first manufacturing method of the motor, uncured resin 7s is injected until it is confirmed that the liquid level of the uncured resin 7s reaches the through holes 6P1, 6P2, and 6P3 of each end plate. The term "uncured resin 7s reaching the through holes 6P1, 6P2, and 6P3" means that the uncured resin 7s is filled to contact the back surface 6b of the end plate. Therefore, a resin portion 7 can be reliably formed between the coil end 41 and the back surface 6b of the end plate.

[0072] <Second Manufacturing Method of Motor>

[0073] In the first method of manufacturing the motor, after the end plate 6 is installed onto the housing 5 (S11), uncured resin 7s is injected (S13, S14, S15). In the second method of manufacturing the motor, after the uncured resin 7s is injected, the end plate 6 is installed.

[0074] Figure 8This diagram illustrates the main steps involved in the second method of manufacturing the motor. First, the motor stator 4 is mounted on the housing 5. Next, the cylindrical component 101 is mounted in the area corresponding to the rotor mounting region 311. Then, the motor assembly is housed in the vacuum chamber 102 (S21). At this point, the end plate 6 is not mounted on the motor assembly.

[0075] Next, proceed to the first part 40a (refer to...) Figure 9 ) Inject uncured resin 7s (S22). The first part 40a is any part included in the motor stator configuration area 511 exposed from the housing opening 51h (refer to Figure 9 Then, after injecting a predetermined amount of uncured resin for 7 seconds, the injection of uncured resin for 7 seconds is stopped.

[0076] Next, proceed to the second part 40b (refer to...) Figure 9 (S23) Inject uncured resin 7s. The second part 40b is any part of the motor stator configuration area 511 exposed from the housing opening 51h, and is different from the first part 40a. Then, after injecting a predetermined amount of uncured resin 7s, the injection of uncured resin 7s is stopped.

[0077] Then, towards the third part 40c (refer to...) Figure 9 (S24) Inject uncured resin 7s. The third part 40c is any part of the motor stator arrangement area 511 exposed from the housing opening 51h, and is different from the first part 40a and the second part 40b. Then, after injecting a predetermined amount of uncured resin 7s, the injection of uncured resin 7s is stopped.

[0078] Furthermore, in the above description, when performing steps S22, S23, and S24, the injection of uncured resin 7s is stopped after injecting a predetermined amount of uncured resin 7s into each part. For example, the injection of uncured resin 7s may not be stopped in step S22, and the process may proceed to step S23. For example, while maintaining the state of injecting uncured resin 7s from the supply device, the motor assembly may be rotated by a predetermined angle, thereby changing the injection position from the first part 40a to the second part 40b. Alternatively, while the motor assembly is fixed, the supply device for uncured resin 7s may be moved, thereby changing the injection position from the first part 40a to the second part 40b.

[0079] After step S24, confirm whether the liquid level of the uncured resin 7s has reached the specified position (S25). This confirmation can be made by visually observing the position of the liquid level of the resin through the shell opening 51h.

[0080] When the level of the uncured resin 7s reaches a predetermined position, the injection of the uncured resin 7s is stopped. Then, the motor assembly is removed from the vacuum chamber 102. Next, the end plate 6 is fixed to the housing 5 (S26). At this time, the uncured resin 7s reaches the opening recess 51ha of the housing 5. Moreover, when the end plate 6 is installed in the housing opening 51h, the uncured resin 7s reaching the opening recess 51ha flows into the end plate through holes 6P1, 6P2, and 6P3 according to the pressure received from the end plate 6. The pressure received by the uncured resin 7s is generated due to the contact between the back surface 6b of the end plate and the uncured resin 7s. That is, when the end plate 6 is installed, the uncured resin 7s flows into the end plate through holes 6P1, 6P2, and 6P3, meaning there is no gap between the back surface 6b of the end plate and the uncured resin 7s. In other words, the back surface 6b of the end plate is in contact with the uncured resin 7s. Then, the motor assembly is heated at a predetermined temperature. Then, motor 1 is obtained by performing the process of installing motor rotor 3 and bearing 21.

[0081] If the liquid level of the uncured resin 7s does not reach the specified position, the resin is injected again from the first part 40a (S22).

[0082] Similar to the first manufacturing method for motors, this method can be consistently implemented during each step S22, S23, and S24 of injecting uncured resin.

[0083] <Effects>

[0084] The background and problems of existing manufacturing methods are pointed out. Then, the manufacturing method of the motor disclosed in this paper and the effect of the motor are explained.

[0085] The motor stator, designed to ensure the coils are waterproof and rustproof, features a resin section that seals the entire structure, including the iron core and the wound coils. Additionally, motors targeting high output density sometimes employ a structure where a highly thermally conductive resin is used to fill the gap between the stator and the water-cooled motor housing, thereby efficiently transferring heat from the coils to the iron core and housing. After assembling the housing and stator, resin flows in through an opening in the housing. The housing is then heated to cure the resin. Two-component curing epoxy resins are frequently used.

[0086] One method for creating an opening is to inject resin before assembling the end plate on one side, and then assemble the end plate after the injected resin has cured. Another method for creating an opening is to make a hole in the end plate.

[0087] Because the end plates are assembled after the molded resin has cured, a gap is created between the cured resin surface and the end plates. Highly thermally conductive resins are required in electric boosters. However, these resins are very viscous, making it highly susceptible to air bubbles during injection. Therefore, to minimize defects after curing, molding is performed in a vacuum chamber. As a result, foaming occurs on the resin surface during injection. Therefore, it is difficult to strictly control the injection height. Thus, a specified gap (at least 2-3 mm) must be maintained between the end plates and the cured resin. Furthermore, the molding process requires an extremely long time to ensure sufficient settling time for the resin surface to become uniform (surface leveling time). For this reason, high-viscosity resins cannot be used. If a gap exists between the cured resin and the end plates, condensation accumulates in the gap. This seepage can cause adverse effects such as decreased insulation. The inability to dissipate heat from the coil from one end face can also negatively impact performance.

[0088] In view of the above background and problems, the motor manufacturing method and motor disclosed herein solve the problems through the following processes and structure.

[0089] The first manufacturing method of the motor 1 includes: an installation step (S11), in which an end plate 6 having a first end plate through hole 6P1 and a second end plate through hole 6P2 is installed in a housing 5 that houses a motor stator 4 wound with a coil 4B; a first injection step (S13), in which, after the installation step (S11), uncured resin 7s is injected into the motor rotor configuration area 512 of the housing 5 that houses the motor stator 4 through the first end plate through hole 6P1, which allows the first portion 40a of the coil 4B to be viewed from the outside of the housing 5; and a second injection step (S14), in which uncured resin 7s is injected into the motor rotor configuration area 512 of the housing 5 through the second end plate through hole 6P2, which allows the second portion 40b of the coil 4B, which is different from the first portion 40a, to be viewed from the outside of the housing 5.

[0090] In the first manufacturing method of motor 1, after the end plate 6 is installed, uncured resin 7s is injected. Furthermore, the uncured resin 7s is injected into the motor rotor mounting region 512 through a step (S13) from the first end plate through hole 6P1 and a step (S14) from a second end plate through hole 6P2 (different from the first end plate through hole 6P1). This shortens the time required for the uncured resin 7s to spread throughout the motor rotor mounting region 512 compared to injecting the uncured resin 7s from a single point. Therefore, even with a high-viscosity resin portion 7 exhibiting high thermal conductivity, the time required to spread throughout the motor rotor mounting region 512 can be shortened. As a result, a motor 1 that easily releases heat to the outside can be manufactured in a shorter time.

[0091] The first manufacturing method of motor 1 involves repeatedly performing a first injection step (S13) and a second injection step (S14) to expose uncured resin 7s from the through holes 6P1 and 6P2 of the first end plate. When the uncured resin 7s is exposed from the through holes 6P1 and 6P2, it is in contact with the back surface 6b of the end plate. Therefore, a reliable path can be formed for heat to move from the coil 4B to the end plate 6 via the resin portion 7.

[0092] In other words, in the motor manufacturing method, multiple openings are provided in the end plate 6. As mentioned above, the number of openings also depends on the size of the motor 1, but can be around three. After injecting uncured resin 7s through the first end plate through hole 6P1, uncured resin 7s is injected through the next second end plate through hole 6P2 during the liquid leveling time, thereby reducing the leveling time. Therefore, the efficiency of motor manufacturing is improved.

[0093] In the motor manufacturing method, it is possible to maintain a realistic production cycle and fill high-viscosity resin without gaps. The size of the end plate through-hole 6P, which serves as the opening, can be reduced. Therefore, it is possible to maintain the mounting rigidity of the bearing housing provided on the end plate 6 and the ability to dissipate heat from the end plate 6 side.

[0094] When uncured resin 7s is injected through the first end plate through hole 6P1, the liquid level 73k of the uncured resin 7s is uniformly oriented towards the second end plate through holes 6P2 and 6P3. When the liquid level 73k becomes unbalanced, uncured resin 7s is continued to be injected through the second end plate through hole 6P2. By repeating this action, the liquid can be molded while maintaining a uniform liquid level 73k. By minimizing the time that the uncured resin 7s drips onto the spokes 62 connecting the end plate through holes 6P, the risk of uncured resin 7s overflowing can be reduced.

[0095] The second manufacturing method of the motor 1 includes: an injection step (S22, S23, S24), in which uncured resin 7s is injected from the opening of the housing 5 into different first portions 40a, second portions 40b, and third portions 40c in the motor rotor configuration area 512 of the housing 5, which houses the motor stator 4 wound with coils 4B; and an installation step (S26), in which an end plate 6 having a first end plate through hole 6P1 and a second end plate through hole 6P2 is installed after the injection step (S22, S23, S24). In the step of installing the end plate 6 (S28), the uncured resin 7s is exposed from the first end plate through hole 6P1 and / or the second end plate through hole 6P2 by pressing the end plate 6 against the liquid surface of the uncured resin 7s.

[0096] The second manufacturing method of motor 1 involves injecting uncured resin 7s from multiple different locations into the motor rotor configuration area 512 (S22, S23, S24). Therefore, compared to injecting the uncured resin 7s from a single location, the time required for the uncured resin 7s to spread throughout the motor rotor configuration area 512 can be shortened. After injecting the uncured resin 7s, the end plate 6 is installed (S26). During installation of the end plate 6, the uncured resin 7s are exposed from the first end plate through-hole 6P1 and the second end plate through-hole 6P2 by pressing the end plate 6. The phrase "the uncured resin 7s are exposed from the first end plate through-hole 6P1 and the second end plate through-hole 6P2 by pressing the end plate 6" means that the back surface 6b of the end plate comes into contact with the uncured resin 7s. Therefore, a motor 1 that easily releases heat to the outside can be manufactured in a short time.

[0097] In the injection process (S22, S23, S24) of the second manufacturing method of motor 1, the housing 5 and the device for supplying uncured resin 7s are rotated relative to each other about the axis A of the housing 5 while the uncured resin 7s is continuously injected. This process can also shorten the time until the uncured resin 7s is distributed throughout the motor rotor configuration area 512.

[0098] The injection process (S22, S23, S24) of the second manufacturing method of motor 1 includes: a process of injecting a predetermined amount of uncured resin 7s into a first portion 40a of coil 4B (S22); and a process of injecting a predetermined amount of uncured resin 7s into a second portion 40b of coil 4B, which is different from the first portion 40a (S23). This process also shortens the time required for the uncured resin 7s to spread throughout the motor rotor configuration area 512.

[0099] The motor 1 includes: a motor stator 4 on which a coil 4B is wound; a motor rotor 3 surrounded by the motor stator 4 and rotating together with a shaft; a housing 5 that receives the motor stator 4 and the motor rotor 3 through an opening in the housing 5, forming a motor rotor configuration area 512 for housing the received motor stator 4; an end plate 6 mounted at the housing opening 5h; and a resin portion 7 that fills the motor rotor configuration area 512. The resin portion 7 contacts the coil 4B and the end plate 6, and the end plate 6 includes a plurality of end plate through holes 6P for exposing the resin portion 7.

[0100] The resin portion 7 of the motor 1 contacts the coil 4B and also contacts the end plate 6. This structure reliably forms a path through which heat moves from the coil 4B to the end plate 6 via the resin portion 7. As a result, heat can be properly dissipated to the outside.

[0101] In motor 1, the exposed resin portion 73s, which emerges from the multiple end plate through holes 6P, is located between the opening edge 6bs on the back surface 6b side of the end plate and the opening edge 62as on the main surface 6a side of the end plate. With this structure, a configuration in which the resin portion 7 reliably contacts the back surface 6b of the end plate can be obtained.

[0102] The end plate 6 of the motor 1 includes: an annular inner circumferential cylindrical portion 63, which includes an end plate shaft insertion hole 6H for the shaft 2 to pass through; an annular outer circumferential cylindrical portion 61, which surrounds the inner circumferential cylindrical portion 63 in the circumferential direction and has an inner diameter larger than the outer diameter of the inner circumferential cylindrical portion 63; and spokes 62, which are arranged at intervals around the axis A of the shaft 2 such that the outer circumferential surface 63d of the inner circumferential cylindrical portion 63 is connected to the inner circumferential surface 611c of the outer circumferential annular portion of the outer circumferential cylindrical portion 61. Each of the plurality of end plate through holes 6P is a region sandwiched between a pair of spokes 62 adjacent to each other around the axis A of the shaft 2. The end face of the inner circumferential cylindrical portion 63 protrudes from the spokes 62 along the axial direction of the shaft 2. According to this structure, it is possible to suppress the adhesion of uncured resin 7s to the end face of the inner circumferential cylindrical portion 63, so that the end face of the inner circumferential cylindrical portion 63 can be used as the mounting surface of the component.

[0103] In other words, each of the multiple end plate through holes 6P is formed by a spoke 62. Each of the multiple end plate through holes 6P can also be connected by a groove one level lower than the mounting surface of other components, in a manner in which the resin portion 7 can adhere. Examples of the mounting surfaces of other components are the outer peripheral annular main surface 611a and the inner peripheral cylindrical main surface 63a. In addition, a dedicated surface may be provided for the blocking clamp to abut against, so that the liquid surface 73k of the foamed uncured resin 7s does not adhere to the mounting surfaces of other components. Examples of the dedicated surface for the blocking clamp to abut against are the outer peripheral step portion 613 and the inner peripheral step portion 633.

[0104] The number of openings provided in the end plate 6 can also be multiple. The resin section 7 can also be made of different types of resin materials. For example, a resin with high thermal conductivity can be molded until the coil 4B is hidden. Then, a resin with low viscosity and moderate thermal conductivity can be molded near the end plate 6. With such a structure, both control of the liquid level 73k and thermal conductivity can be achieved. Alternatively, the end plate can be molded without assembling the end plate and then assembled before the resin cures.

[0105] <Variation Example>

[0106] The above has described the manufacturing method of a motor and provided examples of motors. The manufacturing method of a motor and the motor itself are not limited to the examples described above, and can be implemented in various ways.

[0107] Explanation of reference numerals in the attached figures

[0108] 1…Motor; 2…Shaft; 3…Motor rotor (rotating component); 4…Motor stator (fixed component); 4A…Core; 4B…Coil; 5…Housing; 6…End plate; 6a…Main surface of end plate; 6b…Back side of end plate; 6P1…Through hole of first end plate; 6P2…Through hole of second end plate; 6P3…Through hole of third end plate; 62as…Opening edge on the main surface side of end plate; 6bs…Opening edge on the back side of end plate; 7…Resin part; 51h…Housing opening; 61…Outer circumferential cylindrical part; 62…Spoke (connecting part); 63…Inner circumferential cylindrical part; 73s…Exposed surface of resin part; A…Axis.

Claims

1. A method for manufacturing a motor, characterized in that, have: In the installation process, an end plate with a first end plate through hole and a second end plate through hole is installed in the housing containing the fixing component with the coil wound on it. In the first injection step, after the installation step, uncured resin is injected into the fixing member configuration area of ​​the housing containing the fixing member through the first end plate through hole, which allows the first part of the coil to be viewed from the outside of the housing. as well as In the second injection process, the uncured resin is injected into the fixing component configuration area of ​​the housing through a second end plate through hole, which is a second portion of the housing that is visually visible from the outside of the housing and is different from the first portion.

2. The method for manufacturing a motor according to claim 1, characterized in that, By repeatedly performing the first injection process and the second injection process, the uncured resin is exposed from the through hole of the first end plate and / or the through hole of the second end plate.

3. A method for manufacturing a motor, characterized in that, have: In the injection process, uncured resin is injected from the opening of the housing into multiple different locations in the fastener configuration area of ​​the housing, which houses the fastener with the coil wound on it. and In the installation process, after the injection process, an end plate with a first end plate through hole and a second end plate through hole is installed. During the process of installing the end plate, the end plate is pressed against the surface of the uncured resin, thereby exposing the uncured resin through the through hole of the first end plate and / or the through hole of the second end plate.

4. The method for manufacturing a motor according to claim 3, characterized in that, The injection process involves continuously injecting the uncured resin while rotating the housing and the device for supplying the uncured resin relative to each other about the axis of the housing.

5. The method for manufacturing a motor according to claim 3, characterized in that, The injection process includes: The process of injecting a predetermined amount of the uncured resin into the first part of the coil; and The process of injecting a predetermined amount of the uncured resin into a second portion of the coil that is different from the first portion.

6. A motor, characterized in that, have: A fastener, on which a coil is wound; A rotating component, which is surrounded by the fixed component and rotates together with the shaft; A housing that receives the fixing member and the rotating member from a housing opening, forming a fixing member configuration area for the fixing member received by the housing; End plate, which is installed at the opening of the housing; as well as The resin portion fills the area where the fastener is disposed. The resin portion is in contact with the coil and with the end plate. The end plate includes a plurality of end plate through holes that expose the resin portion.

7. The motor according to claim 6, characterized in that, The exposed surface of the resin portion, which is exposed through the through hole in the end plate, is located between the opening edge on the back side of the end plate and the opening edge on the main side of the end plate.

8. The motor according to claim 6, characterized in that, The end plate includes: The inner circumferential cylindrical portion is in the shape of an annulus, which includes an end plate shaft insertion hole for inserting the shaft. An annular outer cylindrical portion, which circumferentially surrounds the inner cylindrical portion and has an inner diameter larger than the outer diameter of the inner cylindrical portion; and The connecting portions are arranged at intervals around the axis of the shaft, such that they connect the outer peripheral surface of the inner peripheral cylindrical portion to the inner peripheral surface of the outer peripheral cylindrical portion. The end plate through hole is the area sandwiched between a pair of adjacent connecting portions about the axis of the shaft. The end face of the inner circumferential cylindrical portion protrudes from the connecting portion along the axial direction of the shaft.

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