Coil unit, motor member, method for manufacturing coil unit, and method for manufacturing motor member

Abstract

Provided are a motor member and a method for manufacturing the motor member, the motor member being lightweight, capable of flexibly adapting to any shape, and capable of simplifying a manufacturing process. The invention provides a coil unit, a motor member, a method for manufacturing the coil unit, and a method for manufacturing the motor member, which can improve operability when the coil unit is assembled into a final product and can reduce the number of components relative to the final product. The motor member 1 is composed of a resin molded body containing a soft magnetic material. The motor member (20) has a stator core (1) molded from a resin containing a soft magnetic material, and a coil (30) provided to the stator core (1).

Description

Technical Field

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

[0002] Previously, as a stator, it is known that a stator core is formed by assembling segmented cores made by punching and stacking electromagnetic steel sheets into a ring (for example, see Patent Document 1).

[0003] Furthermore, there are known configurations where a coil is covered by an injection-molded resin layer (see, for example, Patent Document 1). In this way, compared to a configuration where the coil, wound into a spiral shape, is covered by an insulating film, the operability of assembling products with the coil as a component (such as motors) can be improved.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2021-052574 Patent Document 2: Japanese Patent Application Publication No. 2022-76171 Summary of the Invention

[0005] Technical issues However, when the stator core is made of electromagnetic steel sheet, there are limitations in terms of weight reduction. Furthermore, for example, when the stator core is divided as described in Patent Document 1, electromagnetic steel sheets punched into the same shape are stacked to form a divided core, and then the divided cores are arranged in a ring to form the stator core, resulting in a complex and cumbersome manufacturing process. In addition, processing deviations are easily generated in each divided core, and there are also limitations in the degree of freedom in the shape (processing) of the divided cores. As a result, there is a lack of progress in miniaturizing, reducing weight, and lowering cost of the motor.

[0006] Furthermore, to achieve mass production, we hope to further improve operability. Additionally, with a large number of parts during assembly, there are issues with deviations in the final product and processing time depending on the skill level of the assembly operator. Therefore, we strongly seek to reduce the number of parts relative to the finished product.

[0007] The purpose of this invention is to provide a lightweight motor component that can flexibly adapt to any shape and simplify the manufacturing process, as well as a method for manufacturing the motor component. In addition, it provides a coil unit, a motor component, a method for manufacturing the coil unit, and a method for manufacturing the motor component that can improve operability when assembled into a final product and reduce the number of parts relative to the final product.

[0008] Technical solution This invention relates to motor components made of resin molded bodies containing soft magnetic materials.

[0009] In addition, the present invention relates to a motor component, characterized in that it has a core molded from a resin containing a soft magnetic material, and a coil disposed on the core.

[0010] In addition, the present invention relates to a method for manufacturing a motor component, characterized by comprising a step of arranging a coil in a mold, and a step of injecting resin containing a soft magnetic material into the mold to form a core.

[0011] In addition, the present invention relates to a method for manufacturing a motor component, characterized by comprising a step of arranging a coil in a mold, and a step of injecting resin containing a soft magnetic material into the mold to form a core.

[0012] In addition, the present invention relates to a method for manufacturing a motor component, characterized in that it includes a step of molding a plurality of teeth by a first resin containing a soft magnetic material, a step of molding a support portion capable of integrally supporting the plurality of teeth by a second resin containing a soft magnetic material, and a step of assembling the plurality of teeth and the support portion together.

[0013] In addition, the present invention relates to a method for manufacturing a motor component, characterized by a step of injecting a resin containing a soft magnetic material into a mold and then curing it.

[0014] In addition, the present invention relates to a coil unit, characterized in that it has a plurality of coils and an injection-molded resin integrally covering the plurality of coils.

[0015] In addition, the present invention relates to a motor component, characterized in that it has the above-described coil unit and a core for mounting the coil unit.

[0016] In addition, the present invention relates to a method for manufacturing a coil unit, characterized in that it includes a step of arranging a plurality of coils in a mold, and a step of injecting injection molding resin into the mold to integrally cover the plurality of coils.

[0017] In addition, the present invention relates to a method for manufacturing a motor component, characterized in that it includes a step of arranging a plurality of coils in a mold, a step of injecting injection molding resin into the mold and integrally covering the plurality of coils to form a coil unit, and a step of assembling the coil unit and the core.

[0018] Technical effect According to the present invention, a lightweight motor component that can flexibly adapt to any shape and simplify the manufacturing process, as well as a method for manufacturing the motor component, can be provided. In addition, a coil unit, a motor component, a method for manufacturing the coil unit, and a method for manufacturing the motor component can be provided that can improve operability when assembled into a final product while reducing the number of parts relative to the final product. Attached Figure Description

[0019] Figure 1 This is a top view schematic diagram showing an integral stator core according to the first embodiment of the present invention.

[0020] Figure 2 This is a diagram showing the combined stator core of the first embodiment. Figure 2 (A) is a top view diagram. Figure 2 (B) is a three-dimensional view of the exterior.

[0021] Figure 3 This is a diagram showing the combined stator core of the first embodiment. Figure 3 (A) is a top view diagram. Figure 3 (B) is a side view. Figure 3 (C) is a side view.

[0022] Figure 4 This is a top view schematic diagram showing the stator of the first embodiment.

[0023] Figure 5 This diagram illustrates the molded coil of the first embodiment. Figure 5 (A) is a three-dimensional view of the exterior. Figure 5 (B) is a sectional view. Figure 5 (C) is a three-dimensional view of the exterior. Figure 5 (D) is a sectional view. Figure 5 (E) is a sectional view.

[0024] Figure 6 This is a flowchart illustrating a first manufacturing method of the stator according to the first embodiment.

[0025] Figure 7 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0026] Figure 8 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0027] Figure 9 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0028] Figure 10 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0029] Figure 11 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0030] Figure 12 This is a flowchart illustrating a second manufacturing method for the stator according to the first embodiment.

[0031] Figure 13 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0032] Figure 14 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0033] Figure 15 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0034] Figure 16 This is a diagram illustrating the manufacturing method of the stator according to the first embodiment.

[0035] Figure 17 This is a diagram illustrating the stator core and stator of the first embodiment.

[0036] Figure 18 This is a diagram illustrating the characteristics of the stator according to the first embodiment.

[0037] Figure 19 This is a diagram illustrating the characteristics of the stator according to the first embodiment.

[0038] Figure 20 This is a top view schematic diagram illustrating the coil unit of the second embodiment of the present invention.

[0039] Figure 21 This diagram illustrates the coil unit of the second embodiment. Figure 21 (A) is a three-dimensional view of the coil's appearance. Figure 21 (B) is a cross-sectional view of the coil. Figure 21 (C) is a cross-sectional view of the coil unit.

[0040] Figure 22 This is a top view schematic diagram illustrating the manufacturing method of the coil unit according to the second embodiment.

[0041] Figure 23 This is a top view schematic diagram illustrating the manufacturing method of the coil unit according to the second embodiment.

[0042] Figure 24 This is a diagram illustrating the stator core of the second embodiment. Figure 24 (A) is a top view diagram. Figure 24 (B) is a three-dimensional view of the exterior.

[0043] Figure 25 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0044] Figure 26 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0045] Figure 27 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0046] Figure 28 This is a diagram illustrating the stator core of the second embodiment. Figure 28 (A) is a top view diagram. Figure 28 (B) is a side view. Figure 28 (C) is a side view.

[0047] Figure 29 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0048] Figure 30 This is a diagram illustrating the stator core of the second embodiment. Figure 30 (A) is a top view diagram. Figure 30 (B) is the unfolded side view. Figure 30 (C) is a top view diagram. Figure 30 (D) is a top view diagram.

[0049] Figure 31 (A) is a top view schematic diagram showing the manufacturing method of the stator according to the second embodiment. Figure 31 (B) is a top view schematic diagram showing the stator core of the second embodiment.

[0050] Figure 32 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0051] Figure 33 This is a flowchart illustrating a method for manufacturing the stator according to the second embodiment.

[0052] Figure 34 This is a flowchart illustrating a method for manufacturing the stator according to the second embodiment.

[0053] Figure 35 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0054] Figure 36 This is a top view schematic diagram illustrating the manufacturing method of the stator according to the second embodiment.

[0055] Figure 37This is a flowchart illustrating a method for manufacturing the stator according to the second embodiment.

[0056] Symbol Explanation 1. Stator core 1A and 1B integrated stator core 1C and 1D combined stator core 2, 4 Support sections 3, 5, 12, 18 teeth 11, 14, 19 Segment Cores 12 teeth 13. Arc-shaped part (connecting part) 15 convex part 16. Support (Connecting) Part 17 recess 18 teeth 20 (20A~20J) Stator Coil Units 21, 22, and 23 30 coils 201 Mold for molding 202 Core Molding Mold 204 Single Core Molding Mold 301-303 Molded Coils 311 Spiral Structure 312 Injection Molding Resin (Injection Molding Resin Layer) 500 coil unit (molded coil unit) 502 coil 503 Injection Molding Resin (Injection Molding Resin Layer) 505 Through Hole 523 Injection Molding Resin 600 stator core 601, 611, 621 Segment Cores Teeth 602, 612, 625, 631, 641, 651 603, 613 Arc section 622 convex part 623 Support (Connecting Part) 624 recess 632 Connecting Part 633 teeth 634 convex part 635 Support section 636 recess 642 Support section 652 Support section 800 Motor Components (Stator) 800p partial stator unit 901 Injection molding die (mold for molding) 902 Injection Molding Mold (Core Molding Mold) Detailed Implementation

[0057] <<First Implementation Method>> The following is for reference Figures 1-19 The first embodiment of the present invention will be described in detail below. The first embodiment relates to a motor component and a method for manufacturing the same. As an example, the case where the motor component is a stator core 1 or a stator 20 will be described below.

[0058] <Stator Core> Figures 1 to 3 This is an external view showing an example of the stator core 1 according to the first embodiment. The stator core 1 of the first embodiment is a resin molded body made of resin containing soft magnetic material. Specifically, the stator core 1 (resin molded body) is obtained by melting resin particles mixed with soft magnetic material using heat, injecting them into a mold of the desired shape, and then cooling and solidifying them. In terms of volume ratio (content ratio), the soft magnetic material is more abundant than the resin. The soft magnetic material is, for example, Permendur alloy.

[0059] The stator core 1 in the following description refers to the integrated stator cores 1A and 1B (see reference). Figure 1 ) and combined stator cores 1C, 1D, and 1E (refer to respectively) Figure 2 , Figure 3 , Figure 10 The term refers to the general category of stator cores 1A and 1B. The integrated stator cores 1A and 1B are single components, referring to stator cores 1 in which multiple teeth 3 and 5 arranged in a ring are integrally supported by support parts 2 and 4. The combined stator cores 1C, 1D, and 1E are stator cores 1 composed of multiple segmented cores 11, 14, and 19, respectively.

[0060] Figure 1 This is a top view schematic diagram showing an example of an integral stator core 1A, 1B.

[0061] Figure 1 (A) For example, in an internal rotor type motor, an integral stator core 1A is used, which is integrally (inseparably) composed of a cylindrical (annular) support portion 2 and a plurality of teeth 3. The plurality of teeth 3 are arranged at equal intervals in the circumference of the generally annular support portion 2 when viewed from above, and protrude radially inward toward the support portion 2. A coil (not shown here) is mounted on each tooth 3.

[0062] Figure 1(B) For example, in an external rotor type motor, an integral stator core 1B is used, which is integrally (inseparably) composed of a cylindrical (plate) support portion 4 and a plurality of teeth 5. The plurality of teeth 5 are arranged at approximately equal intervals in the circumferential direction of the generally annular support portion 4 when viewed from above, and protrude radially outward from the support portion 4. A coil (not shown here) is mounted on each tooth 5.

[0063] Figure 2 This is a diagram showing the combined stator core 1C. Figure 2 (A) is a top view of the combined stator core 1C. Figure 2 (B) is a perspective view showing the appearance of a segmented core 11. The combined stator core 1C is composed of a plurality of segmented cores 11 that are approximately T-shaped when viewed from above. The plurality of segmented cores 11 are of the same shape and each has an arc portion 13 and teeth 12 protruding radially inward toward the arc portion 13. Furthermore, by arranging and connecting the arc portions 13 of the plurality of segmented cores 11 along the arc length direction, a combined stator core 1C with the plurality of teeth 12 arranged in a ring is formed. In this case, the arc portion 13 may also be referred to as the connecting portion. For the segmented cores 11 of the resin molded body, even when multiple are formed in the same shape, compared with the case of forming the stator core by stacking electromagnetic steel sheets, mass production can be easily achieved, and shape deviations can be suppressed.

[0064] Figure 3 This is a diagram showing the combined stator core 1D. Figure 3 (A) is a top view of the combined stator core 1D. Figure 3 (B) Figure 3 (C) is a diagram showing the state in which the segmented core 14 is assembled onto the combined stator core 1D, which is from the circumferential direction. Figure 3 A side view of the roughly annular combined stator core 1D as viewed from above (A).

[0065] The combined stator core 1D consists of multiple segmented cores 14 that are roughly I-shaped when viewed from above, and a cylindrical (annular) support portion (connecting portion) 16. The segmented cores 14 and the support portion 16 are separately constructed. Each segmented core 14 has a wedge-shaped protrusion 15 at one end (inner radial direction) of the support portion 16, and the support portion 16 has recesses 17 at equal intervals along the circumferential direction on its outer peripheral surface, following the shape of the protrusion 15. That is, the protrusion 15 and the recesses 17 can engage, and through their engagement, the segmented core 14 becomes a tooth 18 protruding radially outward from the outer peripheral surface of the support portion 16.

[0066] The method for installing the dividing core 14 (tooth 18) onto the support portion 16 is as follows: Figure 3 (B) Figure 3As shown in (C), the protrusion 15 of the dividing core 14 and the recess 17 of the support portion 16 are aligned vertically along the central axis of the generally annular (cylindrical) support portion 16, and then inserted and fixed. In this case, the wedge-shaped protrusion 15 of the dividing core 14 and the recess 17 of the support portion 16 can be inserted and slide in the vertical direction; on the other hand, they are set to a gap that will not cause wobbling after engagement.

[0067] Thus, the stator core 1 of the first embodiment is based on an injection-molded resin body, and is therefore not limited to the shape shown in the accompanying drawings of the first embodiment. Even complex shapes can be molded into any shape according to the mold. In addition, since the resin body contains resin in a portion, it can achieve weight reduction compared to conventional stator cores that are made entirely of metal components such as electromagnetic steel plates.

[0068] <Stator> Reference Figures 4 to 17 An example of the stator 20 (20A to 20J) of the first embodiment will be described. The stator 20 of the first embodiment has a stator core 1 (as a resin molded body) molded from a resin containing a soft magnetic material, and a coil 30 provided on the teeth (e.g., teeth 3, 5, 12, 18, 191, etc.) of the stator core 1.

[0069] Figure 4 This is a diagram illustrating an example of stator 20 (20A). Figure 4 (A) is a top schematic view of stator 20A. Figure 4 (B) is a top view of a coil unit 21 that constitutes the stator 20A.

[0070] Figure 4 The stator 20A shown has Figure 2 The combined stator core 1C (multiple segmented cores 11) and coil 30 arranged around its teeth 12 are shown.

[0071] The coil 30 has, for example, a molding structure in which a spiral structure made of conductors is formed by covering an injection-molded resin layer (also called injection-molded resin, the same in the first embodiment) 312. Hereinafter, the coil having this molding structure will be referred to as the molded coil 300 (301, 302, 303). The injection-molded resin layer 312 is a different resin from the stator core 1 (e.g., polyphenylene sulfide (PPS), liquid crystal polymer (LCP), nylon, etc.).

[0072] exist Figure 4 In the example, such as Figure 4As shown in (B), a coil unit 21 is formed by inserting a roughly T-shaped tooth 12 of the segmented core 11 into the center portion of the molded coil 300 (301). Furthermore, a plurality of these coil units 21 are arranged along the arc length of the arc portion 13 of the segmented core 11 to form a stator 20A. Figure 4 (A)).

[0073] Figure 5 Yes Figure 4 The diagram shown illustrates the molded coil 301. Figure 5 (A) is a perspective view of the molded coil 301. Figure 5 (B) is Figure 5 (A) xx-line section view. Figure 5 (C) ~ Figure 5 (E) is a schematic diagram illustrating an example of a method for manufacturing the molded coil 301. Figure 5 (C) is with Figure 5 (A) corresponds to the three-dimensional view of the exterior. Figure 5 (D) Figure 5 (E) is with Figure 5 (B) is the corresponding sectional view.

[0074] The molded coil 301 includes a spiral structure 311 formed by a conductor and an injection-molded resin layer 312 that is in direct contact with and covers the spiral structure 311 (conductor).

[0075] like Figure 5 (A) Figure 5 As shown in (C), the coil 30 is a component that forms a helical structure 311 through a conductor, and is integrally covered by an injection-molded resin layer 312 except for its end TS. Here, the helical structure 311 is exemplified as a so-called concentrated wound coil in which the surrounding area CR of one turn of the helix substantially overlaps in the axial direction of the helix.

[0076] like Figure 5 As shown in (B), the molded coil 301 is also provided with an injection-molded resin layer 312 between the surrounding regions CR (gap G), and the multiple surrounding regions CR that overlap in the helical axis direction are insulated from each other by the injection-molded resin layer 312.

[0077] An example of a manufacturing method for the molded coil 301 will be explained. First, as... Figure 5 (C) Figure 5As shown in (D), the spiral structure 311 is formed by a conductor (e.g., a metallic conductor mainly composed of copper and / or aluminum). For example, multiple strip-shaped (e.g., U-shaped) flat conductors (coil sheets) are prepared, and the end faces along the long side direction are pressed together to form the spiral structure 311. However, it is not limited to this, and any method can be used to manufacture the spiral structure 311. For example, it can also be formed by pressing together the end faces of multiple strip-shaped round conductors. In addition, the spiral structure 311 can be formed by winding a long-length flat conductor wire (without splicing in the middle), or by winding a long-length round conductor wire (without splicing in the middle). Alternatively, the spiral structure 311 can be formed by winding a long-length round conductor wire into a spiral shape and then stamping it along the spiral axis to form a flat conductor wire shape. However, in any case, the spiral structure 311 is composed of the conductor itself and is not covered by an insulating film (it is a conductor without an insulating film).

[0078] And, as Figure 5 As shown in (E), the spiral structure 311 is covered by injection-molded resin layer 312 while maintaining a gap G with distance P between the surrounding regions CR.

[0079] In this case, for example, the surrounding regions CR of the spiral structure 311 are pre-formed such that they are separated by a predetermined distance P. Figure 5 In (E), all surrounding regions CR are separated by approximately equal distances P. In this case, Figure 5 (D) to Figure 5 (E) shows an example of forming the spiral structure 311 with the surrounding regions CR expanded to a distance P. However, the spiral structure 311 after formation generally has deviations at any distance between the surrounding regions CR, and is not necessarily limited to being formed to expand to a distance P. That is, the surrounding regions CR are formed in such a way that they are expanded or reduced to become approximately equal distances P. The distance P can be ensured to be approximately equal, for example, by a spacer member integrally provided with the spiral structure 311 or a separate spacer member (not shown). However, the distance P can also be ensured by elastic deformation and / or plastic deformation without using spacer members.

[0080] Next, the spiral structure 311 is placed in a predetermined injection molding mold (molding mold). Then, molten resin (e.g., PPS, LCP, nylon, etc.) is injected and allowed to solidify to form an injection-molded resin layer 312. Thus, a product is obtained. Figure 5 (A) Figure 5The molded coil 301 shown in (B). It should be noted that the spiral structure 311 may not be pre-formed, but spacers that separate the surrounding areas CR by a predetermined distance P are provided in the molding die, thereby separating the surrounding areas CR of the spiral structure 311 to form the injection-molded resin layer 312.

[0081] Thus, the entire molded coil 301 of the first embodiment is integrally covered by the injection-molded resin layer 312. Furthermore, as... Figure 6 As shown in (B), the helical structure 311 is in direct contact with the injection-molded resin layer 312 around its periphery (in the absence of an insulating coating), and the multiple overlapping surrounding regions CR in the helical axis direction are insulated from each other by the injection-molded resin layer 312. Furthermore, the surrounding regions CR are fixed together by the injection-molded resin layer 312 while ensuring a distance P. Thus, the molded coil 301 does not have an insulating coating covering the conductor; instead, the conductor is insulated by the injection-molded resin layer 312. The distance P is arbitrary, but is set to a size that allows the injection-molded resin to reliably enter between the surrounding regions CR and insulate the surrounding regions CR from each other.

[0082] Figure 7 This is a flowchart illustrating an example of the process of a first manufacturing method for the stator 20 according to the first embodiment. The manufacturing method for the stator 20 includes the steps of preparing a spiral structure 311 (step S01), forming a molded coil 300 (step S03), placing the molded coil 300 in a core forming mold 202 (step S05), and molding a resin molded body constituting the stator core 1 (step S07).

[0083] Reference Figure 7 The first manufacturing method of stator 20 is described in detail. Figure 4 It shows that it is formed by the first manufacturing method Figure 7 (B) is a schematic diagram of the process of forming a coil unit 21 and a stator 20A.

[0084] First, such as Figure 6 As shown in (A), a helical structure 311 is formed by a conductor. Figure 7 Step S01). Then, the spiral structure 311 is separated into its surrounding regions CR by a predetermined distance P, as shown in the figure. Figure 7 As shown in (B), it is arranged within the molding die 201. Alternatively, the distance P between the surrounding areas CR is maintained and ensured within the molding die 201. Then, resin particles (e.g., PPS, LCP, nylon, etc.) are melted using heat, injected into the molding die 201, and allowed to cool and solidify. Thus, as shown in (B), Figure 6As shown in (C), the molded coil 301, except for the end TS, which forms the spiral structure 311, is covered by the injection-molded resin layer 312. Figure 7 Step S03).

[0085] After that, as Figure 6 As shown in (D), the molded coil 301 is placed inside another injection molding die (core molding die 202). Figure 7 Step S05). Then, the resin particles mixed with the soft magnetic material are melted using heat, injected into the core molding mold 202, and allowed to cool and solidify. Thus, as Figure 6 As shown in (E), a roughly T-shaped segmented core 11 (constituting the resin molded body of the stator core 1) is formed. Figure 7 Step S07). That is, in the first manufacturing method, the molded coil 301 is injection molded with a resin mixed with a soft magnetic material, thereby subsequently forming a segmented core 11, which is then mounted with the molded coil 301 on its teeth 12.

[0086] In this case, the injection molding temperature (melting temperature of the resin particles) in the core molding mold 202 is set to a temperature at which the injection molding resin layer 312 of the molded coil 301 will not melt again (e.g., 350 to 450°C) (hereinafter, the melting temperature of the resin particles is the same in the first manufacturing method).

[0087] Thus, a coil unit 21 is formed by integrating the teeth 12 of the segmented core 11 and the molded coil 301. Figure 4 of (E), Figure 4 (B)). The coil unit 21 is arranged in a ring shape to form Figure 8 The stator 20A is shown in (A). It should be noted that multiple helical structures 311 (coils 30) are appropriately connected by wiring members (busbars, etc.) not shown here. Conventionally, helical structures (coils) with insulating films are mounted to the teeth via insulating members (e.g., insulating paper). However, problems exist such as: the helical structure is elastic, and when mounted to the teeth, the overlapping surrounding areas in the helical axis direction shift relative to each other, resulting in poor operability, or damage to the thin insulating film, leading to voltage degradation. According to the first embodiment, by employing a molded coil 301, the shape of the helical structure 311 can be fixed while insulating the surrounding areas CR, thus significantly improving operability when mounted to the teeth 12. Furthermore, voltage degradation due to conductor exposure can be avoided. Moreover, since the molded coil 301 can be integrated with the teeth 12, operability when assembling the stator 20A is improved, achieving operational efficiency.

[0088] Figure 8 This is a top view schematic diagram showing another example of stator 20. (See diagram below.) Figure 8As shown in (D), Figure 7 The stator 20 (20B) shown has a coil 30 (molded coil 302) and a stator core 1.

[0089] Figure 8 The coil 30 shown is a molded coil 301 in which a single spiral structure 311 is covered by an injection-molded resin layer 312, while Figure 1 The coil 30 is a molded coil 302 in which multiple helical structures 311 are arranged in a ring and integrally covered by an injection-molded resin layer 312. Additionally, as an example, the shape of the stator core 1 in this case is... Figure 8 The integral stator core 1A shown in (A) is shown.

[0090] Figure 6 The manufacturing method of the stator 20B shown is the same as the first manufacturing method described above. Figure 8 (Same.) First, as... Figure 6 As shown in (A), multiple (total number constituting stator 20B) uninsulated spiral structures 311 are arranged in a ring within a molding die 201 while ensuring that the distance P between their respective circumferential regions CR is a predetermined distance. Figure 8 Step S01).

[0091] Then, as Figure 6 As shown in (B), molten resin (e.g., PPS, LCP, nylon, etc.) is injected into the molding mold 201 and cured to form an injection-molded resin layer 312. Figure 5 (Step S03). Thus, a ring-shaped molded coil 302 is formed, in which multiple spiral structures 11 are integrally covered by an injection-molded resin layer 312. Figure 8 Similarly, in the molded coil 301 shown, the molded coil 302 has an injection-molded resin layer 312 embedded between the multiple overlapping surrounding regions CR in the helical axis direction of each helical structure 311, thereby being insulated. In addition, the surrounding regions CR are fixed by the injection-molded resin layer 312 while ensuring a distance P.

[0092] After that, as Figure 6 As shown in (C), the annular molded coil 302 is placed inside the core forming mold 202. Figure 8 (Step S05). Then, the resin particles mixed with the soft magnetic material are melted using heat, injected into the core molding mold 202, and then cooled and solidified, as shown. Figure 6 As shown in (D), the integral stator core 1A of the resin molded body is formed. Figure 8 Step S07). Thus, a stator 20B is formed by mounting the annular molded coil 302 onto the tooth 3 (the tooth 3 and the annular molded coil 302 are integrally formed).

[0093] Since the one-piece stator core 1A can be resin molded, the annular molded coil 302 can be mounted on the one-piece stator core 1A for the inner rotor. In addition, in this case, compared with the configuration of mounting a single coil 30 (molded coil 300) on the tooth 12 (for example, the configuration of mounting the coil (molded coil 300) on the split core 11 and joining the split core 11), the operation efficiency can be improved.

[0094] It should be noted that, although the illustrations are omitted, multiple spiral structures 311 (coils 30) are appropriately connected by wiring components (busbars). The connection of multiple coils 30 to each other can be achieved through... Figure 8 The process can be carried out before the formation of the injection molding resin layer 312 shown in (A), or it can be done before... Figure 9 The process can be carried out after the formation of the injection-molded resin layer 312 shown in (B) and before the formation of the stator core 1A, or after the formation of the stator 20B.

[0095] Figure 1 (A) is a top view schematic diagram showing another stator 20. This stator 20 (20C) is in... Figure 8 The integrated stator core 1B for the outer rotor shown in (B) is mounted with Figure 8 The structure of the annular molded coil 302 is shown. Except for the shape of the integral stator core 1B and the relative arrangement of the integral stator core 1B and the molded coil 302, the manufacturing method of this stator 20C is the same. Figure 9 The manufacturing method of the stator 20B is the same, so the description is omitted. Since the one-piece stator core 1B can be resin molded, even the one-piece stator core 1B for the outer rotor can be fitted with an annular molded coil 302. In addition, in this case, compared with the configuration of mounting a single coil 30 (molded coil 300) on the tooth 12, the work efficiency can be significantly improved.

[0096] in addition, Figure 1 (B) is a top view schematic diagram showing another stator 20. This stator 20 (20D) has a plurality of molded coils 301 that are successively covered by injection-molded resin layers 312 of helical structures 311, and, for example... Figure 6 The integral stator core 1A shown in (A) is manufactured using the same method as the first manufacturing method. That is, a helical structure 311 is prepared. Figure 6 Step S01): Multiple molded coils 301 are formed by sequentially covering the spiral structure 311 with injection-molded resin layers 312. Figure 6 Step S03). Then, they are arranged in a ring shape in the core forming mold 202 ( Figure 6Step S05). Then, the resin particles mixed with soft magnetic material are melted by heat, injected into the core forming mold 202, and then cooled and solidified to form an integral stator core 1A. Figure 10 (Step S07). Thus, a stator 20D is formed by integrally mounting the molded coil 301 (coil 30) onto the tooth 3.

[0097] Figure 10 This is a diagram showing another example of stator 20. In this example, stator 20 (20E) is constructed from a different coil unit 22, which consists of a molded coil 303 and a segmented core 19. The manufacturing method of stator 20E (coil unit 22) in this case is also the same as the first manufacturing method described above. First, as... Figure 6 As shown in (A), multiple (three in this case) spiral structures 311 are prepared, for example, electrically connected to each other via wiring component W. Figure 10 Step S01), the resin layer 312 is used to integrally cover it, forming Figure 6 The molded coil 303 shown in (B) Figure 10 (Step S03). In this case, for example, the three coils 30 (spiral structure 311) constituting the U-phase, V-phase, and W-phase of the three-phase motor can also be integrally molded.

[0098] In this example, the number of coils 30 (helical structures 311) contained in the molded coil 303 is more than two but less than the total number of those constituting the stator 20.

[0099] Then, as Figure 6 As shown in (C), the molded coil 303 is placed inside the core forming mold 202. Figure 10 Step S05): The resin particles mixed with the soft magnetic material are melted by heat, injected into the core molding mold 202, and then cooled and solidified to form the core. Figure 6 The segmented core 19 (resin molded body) shown in (D) Figure 10 (Step S07). In this example, the segmented core 19 is configured such that, corresponding to the number of coils 30 (spiral structures 311) integrated by the injection-molded resin layer 312, multiple (three in this case) teeth 191 are integrally supported on the arc-shaped support portion 192. Furthermore, by forming the segmented core 19, a coil unit 22 is formed by integrally combining the molded coil 303 and the segmented core 19.

[0100] Then, as Figure 10 As shown in (E), multiple sets of the coil units 22 (partially omitted from the diagram) are arranged along the arc length of the segmented core 19 to form a stator 20E. It should be noted that the stator core 1 formed by the segmented core 19 is also a combined stator core.

[0101] Figure 10 Figure (F) further illustrates another type of coil unit 23. The coil unit 23 is a component formed by arranging a plurality of molded coils 301 in a core forming mold 202 and forming a segmented core 19, wherein the plurality of molded coils 301 are formed by successively covering the spiral structure 311 with injection molding resin layers 312.

[0102] exist Figure 3 The example illustrates the case where three spiral structures 311 are electrically connected, but they can also be unconnected.

[0103] It should be noted that the shape of the stator core 1 is not limited to the examples described above; for example, even if it has... Figure 1 The stator core 1D with the roughly I-shaped segmented core 14 shown can also be implemented in the same way.

[0104] Since the stator core 1 of the first embodiment is formed of resin containing soft magnetic material, it can be significantly lighter than conventional stator cores based on metal materials such as electromagnetic steel sheets. Furthermore, since it can be formed by injection molding, even complex shapes and shapes that were previously difficult to achieve can be easily realized. For example, conventionally, stator cores formed from materials such as electromagnetic steel sheets and... Figure 8 When a stator core 1A is identical to the one-piece stator core 1A in (A), and coils are mounted (or wound) on its teeth, there is a situation where the coils interfere with each other and cannot be mounted on the teeth (which is very difficult). According to the first embodiment, the stator core 1 can be formed by injection molding. That is, since the stator core 1 can be formed after the coils 30 (molded coils 301, 302) are arranged in the mold, thus, as Figure 11 As shown, even the internal rotor type stator 20B can be constructed from a single-piece stator core 1A. Since the assembly of the segmented cores 11 and 14 is not required when the stator core is a single-piece stator core 1A (1B), the manufacturing process / operation is simplified and made more efficient.

[0105] Furthermore, in the case of the molded coils 301 to 303 of the first embodiment, the installation process of insulating components (insulating paper, insulating resin components) disposed between the coil and the teeth, which is required for the assembly of the stator in the past, is not necessary. In addition, since the winding regions CR of the coil 30 are fixed to each other, it is possible to prevent the winding regions CR from shifting or expanding relative to each other. That is, the operation of the coil 30 itself during the manufacturing process of the stator 20 becomes easier, realizing the efficiency of the manufacturing process and the reduction of component costs.

[0106] Furthermore, the surrounding areas CR of the coil 30 are insulated from each other by the injection-molded resin layer 312, eliminating the need for an insulation coating process for the coil 30. When performing an insulation coating on the coil 30 (copper wire), thorough film thickness management is required. Even with film thickness management, it is almost impossible to completely eliminate pinholes, making it difficult to simplify the manufacturing process and reducing yield. Since the molded coils 301-303 of the first embodiment do not require an insulation coating process, the manufacturing process can be simplified, and the yield can be improved.

[0107] On the other hand, a coil 30 with an insulating coating on the conductor (spiral structure 311) can be used instead of the molded coils 301 to 303 in the above embodiments.

[0108] Figure 1 This is a perspective view showing another example of the stator 20. The stator 20 (20F) in this example has… Figure 11 The integral stator core 1A and the coil 30 with insulating film shown are illustrated.

[0109] like Figure 11 As shown in (A), the coil 30 in this example is formed by, for example, preparing multiple strip-shaped (e.g., U-shaped) flat conductors (coil sheets), pressing and joining the long-side end faces together to form a spiral structure 311, and forming an insulating film around it (the conductor). Alternatively, the spiral structure 311 can be formed by winding an insulating film-coated wire (flat conductor or round conductor). Multiple such coils 30 are arranged in a ring within a core forming mold (not shown here). The "coil 30 with insulating film" in the first embodiment refers to a coil in which the conductor constituting the spiral structure 311 is covered by an insulating film, that is, a coil in which the long-dimensional member is continuously covered by an insulating film when the conductor is considered as a continuous long-dimensional member.

[0110] Then, the resin particles mixed with soft magnetic material are melted using heat, injected into a core molding mold, and allowed to cool and solidify. This forms a stator 20F with coils 30 mounted on the teeth 3 of the integral stator core 1A.

[0111] In addition, Figure 7 In this process, the number of insulating-coated coils 30 disposed within the core forming mold can be fewer than the total number constituting the stator 20 (e.g., three), or it can be a single coil. That is, it can be formed as follows: Figure 10 or Figure 12 The coils of coil units 21 and 22 shown.

[0112] Figure 13This is a flowchart illustrating an example of another manufacturing method (second manufacturing method) for the stator 20 according to the first embodiment. The second manufacturing method for the stator 20 includes the steps of preparing a spiral structure 311 (step S11), forming molded coils 301 to 303 (step S13), separately molding a resin molded body constituting the stator core 1 using a single core molding mold 204 (step S15), and assembling the resin molded body and the molded coils 301 to 303 (step S17).

[0113] Reference Figure 13 The manufacturing method (second manufacturing method) of stator 20 is described in detail. Figure 4 This illustrates the formation of the structure using a second manufacturing method. Figure 13 A schematic diagram of a coil unit 21 of the stator 20A shown.

[0114] First, such as Figure 13 (A) ~ Figure 12 As shown in (C), the spiral structure 311 is placed in the molding mold 201 and covered by the injection molding resin layer 312 to form the molded coil 301. Figure 13 (Steps S11 and S13).

[0115] In addition, such as Figure 13 (D) Figure 12 As shown in (E), separately, resin particles mixed with soft magnetic material are melted by heat, injected into a mold 204 for molding a monomer core, and then cooled and solidified to form, for example, a roughly T-shaped segmented core 11 (resin molded body). Figure 13 Step S15). In this case, since the molded coil 301 and the segmented core 11 are molded separately, the molding temperature of the segmented core 11 is not limited by the melting temperature of the injection-molded resin layer 312 of the molded coil 301 (hereinafter, the same applies in the second manufacturing method).

[0116] Then, as Figure 12 As shown in (F), the molded coil 301 is assembled onto the teeth 12 of the segmented core 11 to form a coil unit 21. Figure 4 Step S17). Multiple of them are arranged in a ring to form stator 20A (…). Figure 14 (A)).

[0117] Figure 14 This is a top view schematic diagram showing another type of stator 20. The stator 20 (20G) of this example has annular molded coil 302 and stator core 1 (combined stator core 1A). The stator 20G is formed by the second manufacturing method described above.

[0118] First, such as Figure 14 (A)Figure 12 As shown in (B), multiple spiral structures 311 are prepared to form a ring-shaped molded coil 302 that integrates them. Figure 14 (Steps S11 and S13). The method for forming the molded coil 302 is the same as in the above-described embodiment, so the description is omitted.

[0119] Alternatively, such as Figure 14 (C) Figure 12 As shown in (D), resin particles mixed with soft magnetic material are melted by heat, injected into a mold 204 for molding a monomer core, and then cooled and solidified to form a segmented core 11 (resin molded body) in a roughly T-shape, for example. Figure 14 Step S15).

[0120] After that, as Figure 12 As shown in (E), the teeth 12 of the segmented core 11 are assembled to the center of each helical structure 311 of the molded coil 303 to form the stator 20G. Figure 15 Step S17).

[0121] Figure 15 This is a top view schematic diagram showing another type of stator 20. The stator 20 (20H) of this example has multiple molded coils 301 and a stator core 1 (e.g., a combined stator core 1B). The stator 20H is formed by the second manufacturing method described above.

[0122] First, such as Figure 12 As shown in (A), multiple spiral structures 311 are prepared, and injection-molded resin layers 312 are respectively set on each to form multiple molded coils 301. Figure 15 (Steps S11, S13). Alternatively, as... Figure 15 (B) Figure 12 As shown in (C), an integral stator core 1B is formed by a single-core forming mold 204. Figure 15 (Step S15). Afterwards, as... Figure 12 As shown in (D), the molded coils 301 are assembled onto the teeth 5 of the integral stator core 1B. Figure 15 Step S17), forming stator 20H.

[0123] In particular, in the case of an external rotor type, where adjacent molded coils 301 do not interfere, a pre-formed, one-piece stator core 1B can be used. Furthermore, in... Figure 4 Alternatively, separately molded composite stator cores 1C and 1D can be used to replace the integral stator core 1B.

[0124] Alternatively, for example, it can also be formed by a second manufacturing method. Figure 16The stator 20A is shown in (A). That is, the segmented core 11 can also be separately formed by the single core forming mold 204 and assembled with the molded coil 301.

[0125] Figure 16 This is a top view further illustrating another stator 20. This example stator 20 (20I) has another coil unit 23 consisting of a molded coil 301 and a segmented core 11. This stator 20I can also be formed using the second manufacturing method described above.

[0126] First, such as Figure 16 (A) Figure 12 As shown in (B), multiple (three in this case) spiral structures 311, which are to be electrically connected to each other via wiring component W, are respectively covered by injection-molded resin layer 312 to form molded coils 301. Figure 16 (Steps S11 and S13).

[0127] In addition, such as Figure 16 (C) Figure 12 As shown in (D), resin particles mixed with soft magnetic material are melted using heat, injected into a mold 204 for molding a monomer core, and then cooled and solidified. In this example, a roughly T-shaped segmented core 11 (resin molded body) is formed. Figure 16 Step S15).

[0128] After that, as Figure 12 As shown in (E), the molded coils 301 are assembled onto the teeth 12 of the segmented core 11 to form coil units 23. Figure 16 (Step S17). And, as... Figure 16 As shown in (F) (part of the illustration is omitted), multiple sets of coil units 23 are arranged in a ring to form a stator 20I.

[0129] In this case, the coil 30 of each coil unit 23 is individually covered by an injection-molded resin layer 312, and the stator core 1 is a combined stator core 1C (segmented core 11). Therefore, as Figure 3 As shown in (D), coils 30 of other groups of coil units 23B can be arranged between the coils 30 of a certain group of coil units 23A. It should be noted that the coils 30 of coil units 23 may not be electrically connected to each other. Additionally, the stator core 1 may also be... Figure 10 The combined stator core 1D shown is illustrated.

[0130] Alternatively, stator core 1 can also be made of Figure 10 The stator core shown is a composite type composed of segmented core 19, but in this case, it cannot be like this. Figure 17 As shown in (F), coils 30 from other groups are arranged between coils 30 in a certain group.

[0131] Alternatively, if the molded coils 301 do not interfere with each other, integral stator cores 1A and 1B can also be used.

[0132] Alternatively, it can be set up as a unified coverage. Figure 2 The configuration shown in (B) consists of a molded coil 303 formed by injection-molded resin layer 312 of multiple spiral structures 311 and separately formed segmented core 19, instead of the molded coil 301 that is individually covered by injection-molded resin layer 312.

[0133] Figure 3 This is a top view further showing another stator core 1 and stator 20. The stator core 1 is formed of resin containing soft magnetic material, but in a stator core 1, the volume ratio of soft magnetic material to resin (the content ratio of soft magnetic material) can be different in regions with relatively high magnetic flux density and regions with relatively low magnetic flux density.

[0134] Specifically, in stator core 1, the connecting part ( Figure 17 The arc portion 13 shown or Figure 3 The magnetic flux density of the support portion 16 shown is generally lower than that of the tooth 12. That is, for the tooth portion 12, the volume ratio (content ratio) of the soft magnetic material is increased, while for the connecting portion (arc portion 13 or support portion 16), the volume ratio (content ratio) of the soft magnetic material is decreased. As a result, the degradation of characteristics can be suppressed, and the overall stator core 1 can be made lighter.

[0135] In this case, for example, such as Figure 17 As shown in (A), in the combined stator core 1D (refer to) Figure 17 In the process, a plurality of roughly I-shaped segmented cores 14 can be formed by a first soft magnetic material resin M1 with a high volume ratio (content ratio) of soft magnetic material, and an annular support portion 16 can be formed by a second soft magnetic material resin M2 with a low volume ratio (content ratio) of soft magnetic material.

[0136] The manufacturing method of the stator core 1 includes: a step of molding a plurality of teeth 12 by a first resin containing soft magnetic material M1, a step of molding a support portion 16 capable of supporting the plurality of teeth by a second resin containing soft magnetic material M2, and a step of assembling the plurality of teeth 12 and the support portion together.

[0137] Furthermore, when using the stator core 1 to manufacture the stator 20, the process includes mounting the coils 30 onto the plurality of teeth 12 respectively. In this case, the coils 30 can be pre-mounted onto the plurality of teeth 12 and then assembled onto the support portion 16, or the coils 30 can be mounted onto the teeth 12 after the plurality of teeth 12 have been assembled onto the support portion 16.

[0138] Specifically, refer to Figure 17 (B) and Figure 7 Figure (C) illustrates the manufacturing method of stator 20 (20J) using a molded coil 301 (300) as an example.

[0139] Figure 7 (B) pertains to a method for forming the coil 30 and the teeth 12 by a first manufacturing method. In this case, a molded coil 300 is first formed. For the molded coil 300, the spiral structure 311 is disposed within a molding die 201 (see reference). Figure 17 (B) In the molding mold 201, the resin is injected and cooled to solidify, thereby forming the injection molded resin layer 312.

[0140] Next, the molded coil 301 is placed in another injection molding mold (the core molding mold 202 for tooth 12, see reference). Figure 7 Then, the first resin M1 containing soft magnetic material is injected into the core molding mold 202 and cooled and solidified. The first resin M1 containing soft magnetic material is a resin formed by melting resin particles mixed with soft magnetic material in a first content ratio using heat. Thus, as Figure 17 As shown in (B), a coil unit 21 is formed integrally with a roughly I-shaped segmented core 11 (tooth 12) and a molded coil 300.

[0141] Additionally, a core forming mold 202 (see reference) is used separately for the support portion 16. Figure 7 (D) The second resin M2 containing soft magnetic material is injection molded and then cooled and cured. The second resin M2 containing soft magnetic material is a resin formed by melting resin particles containing soft magnetic material at a second content ratio lower than that of the first resin using heat. Then, a plurality of teeth 12 (coil units 21) are assembled on the support portion 16 to form the stator 20J.

[0142] Figure 17 (C) is formed by a second manufacturing method. In this case, the stator core 1D is formed separately from the molded coil 301. That is, the core forming mold 202 for the gear 12 (see reference) Figure 7 (D)) Injection molding of a first resin containing soft magnetic material M1, followed by cooling and curing. The first resin containing soft magnetic material M1 and Figure 17 The resin described in (B) is the same.

[0143] Additionally, a core forming mold 202 (see reference) is used separately for the support portion 16. Figure 17 (D)) Injection molding of the second resin containing soft magnetic material M2, followed by cooling and curing. The second resin containing soft magnetic material M2 also... Figure 17 The resin described in (B) is the same.

[0144] Then, the tooth 12 is assembled to the support part 16 to form the stator core 1D.

[0145] Separately, with Figure 2 Similarly, in case (B), molded coils 301 are pre-formed and installed in each of the teeth 12. Thus, stator 20J is formed.

[0146] Alternatively, the tooth 12 and the support portion 16, as well as the molded coil 301, can be formed separately in different processes, and the component formed by mounting the molded coil 301 on the tooth 12 can be assembled on the support portion 16 to form the stator 20J.

[0147] It should be noted that, Figure 1 The invention is illustrated using a combined stator core 1D as an example. However, despite the increased complexity, the invention can also be applied to other applications. Figure 1 The combined stator core 1C is shown. That is, in the segmented core 11, the volume ratio of the soft magnetic material can be different in the teeth 12 and the arc portion 13. Furthermore, the volume ratio of the soft magnetic material in the teeth 3 and 5 and the support portions 2 and 4 can also be... Figure 18 The integrated stator cores 1A and 1B shown are different.

[0148] In the above embodiments, the combination of molded coils 301-303 and stator core 1 can be appropriately replaced or selected, provided that the molded coils 301-303 can be installed (without interference). For example, in the above embodiments, a combined stator core 1D can be used instead of a combined stator core 1C. Furthermore, especially for the stator 20 used in an external rotor type motor, since interference with the molded coils 301 and 302 can be disregarded in most cases, a separately formed integral stator core 1B can also be used, for example. Figure 18 It is assembled from (B) and coils 30 that are individually covered by injection-molded resin layers 312.

[0149] Alternatively, in the above embodiments, a coil 30 with an insulating film can be used instead of molded coils 301 to 303.

[0150] Alternatively, the molded coils 301 to 303 described above can also be covered by an injection-molded resin layer 312 while the insulating film is set on the spiral structure 311.

[0151] Furthermore, in the above embodiment, the case where the coil 30 is a concentrated wound coil is illustrated, but it can also be a distributed wound (wave-wound, lap-wound, etc.) coil.

[0152] Furthermore, in the above embodiment, as a motor component, a structure in which the stator core 1 (stator 20) is molded using resin containing a soft magnetic material is exemplified. However, the present invention is not limited to this; for example, part or all of the rotor (support portion of the magnet) may also be molded using resin containing a soft magnetic material.

[0153] <Resin molded bodies, soft magnetic materials> Reference Figure 18 The characteristics of the stator core 1 (resin molded body) and the soft magnetic material of the first embodiment will be described. Figure 18 This shows a motor with a conventional stator. Figure 4 (A) and a motor having a stator 20A according to the first embodiment ( Figure 18 The graph shows the magnetic flux density distribution of (B). The stator 20A of the first embodiment is composed of assembled... Figure 18 The stator 20A shown is composed of a generally T-shaped segmented core 11 of the molded coil 301. Conventional stators are composed of generally T-shaped segmented cores made by stacking steel plates. That is, the shape and size of the stator cores are generally the same. However, conventional stators use coils with insulating films instead of molded coils 300.

[0154] Figure 18 The forming conditions of stator 20A shown in (B) are as follows.

[0155] Molding temperature: 200℃~350℃ (adjusted appropriately according to the material of the injection molding resin layer 312 of the molded coil 300).

[0156] Mold temperature: room temperature to 150℃ (adjusted appropriately according to the material of the injection molding resin layer 312 of the molded coil 300).

[0157] The filling pressure during injection molding should be adjusted appropriately according to the shape and size of the finished product.

[0158] from Figure 19 It is clear that, according to the first embodiment, the stator 20 (stator core 1) can achieve a magnetic flux density at the same level as that of a stator core made of electromagnetic steel sheets, thus providing excellent characteristics for the motor. It should be noted that, although in Figure 19 The image shows a state where only a portion of the teeth have high magnetic flux density, but it indicates the state of magnetic flux density at a certain moment. The high magnetic flux density of the teeth changes over time according to the rotation of the motor.

[0159] Furthermore, in this case, compared to a stator made of electromagnetic steel sheets, the weight of the stator 20 in the first embodiment can be reduced by approximately 15%. In addition, the induced voltage can maintain the same performance as that of a stator made of electromagnetic steel sheets.

[0160] <Soft Magnetic Materials> The soft magnetic material in the first embodiment uses Permalloy. However, it is not limited to this; in addition to iron-based powders (iron powder, pure iron powder), powders of silicon steel (Fe-Si alloy), iron-silicon-aluminum alloy (Sendust) (Fe-Si-Al alloy), permalloy (Fe-Ni alloy), amorphous soft magnetic alloys, etc., can also be used as soft magnetic materials. The soft magnetic material has a predetermined particle size (for example, less than 500 μm).

[0161] As the resin in which soft magnetic materials are compounded, thermoplastic resins (such as polyamide (PA) resins like PA12, PA6, PA66, and polyphenylene sulfide (PPS) resins) are preferably used. Furthermore, when further heat resistance is required, heat-resistant nylon (PA6, PA66) or PPS resin can be used instead of PA12.

[0162] For stator core 1, in the volume percentage of the resin molded body, for example, the amount of soft magnetic material is 55% or more and 85% or less, and the amount of resin is 45% or more and 15% or less. It is desirable that the amount of soft magnetic material is 65% or more and 80% or less, and the amount of resin is 35% or more and 25% or less. It is more preferably that the amount of soft magnetic material is 70% or more and 80% or less, and the amount of resin is 30% or more and 20% or less. More preferably, the amount of soft magnetic material is about 75% or more, and the amount of resin is about 25% or more.

[0163] In the above embodiments, the soft magnetic material can also be heat-treated in its material state (before being mixed with resin). For example, particularly in the case of Permünde alloy, heat treatment is preferred, specifically heat treatment at 700°C to 1000°C for 1 to 5 hours in a hydrogen atmosphere, preferably at 800°C to 900°C for 2 to 4 hours, and more preferably at, for example, 850°C for 3 hours. Afterward, it is mixed with resin and injection molded to form the stator core 1.

[0164] Figure 10 This is a graph showing the variation of saturation magnetic flux density in the stator core 1 of the first embodiment, based on the volume ratio of the soft magnetic material. The vertical axis represents the saturation magnetic flux density (T), and the horizontal axis represents the volume ratio of the soft magnetic material to the resin molded body. The target value (T) shown by the dotted line in the graph is the saturation magnetic flux density equivalent to that of a stator core with approximately the same shape as that made of electromagnetic steel sheets.

[0165] Furthermore, the solid line represents the change in saturation magnetic flux density based on the volume ratio of the soft magnetic material, showing the change when heat treatment was performed before the soft magnetic material was mixed into the resin during the molding of stator core 1. The dashed line represents the change in saturation magnetic flux density based on the volume ratio of the soft magnetic material, showing the change when heat treatment was not performed before the soft magnetic material was mixed into the resin.

[0166] according to Figures 20 to 37 It is known that by performing heat treatment during the molding of the stator core 1 (before mixing with the resin), the target saturation magnetic flux density can be approached even at the same volume ratio, compared to the case without heat treatment. Furthermore, without heat treatment, it is (admittedly) possible to approach the target saturation magnetic flux density by increasing the volume ratio of the soft magnetic material.

[0167] It should be noted that, Figure 20 The diagram shows a configuration where multiple helical structures 311 within a molded coil 303 are connected by wiring members W. However, within a molded coil 303, all helical structures 311 may be connected by wiring members W, or at least one helical structure 311 may not be connected to other helical structures 311 within the same molded coil 303, but may be connected to helical structures 311 of other molded coils 303. Furthermore, the multiple helical structures 311 within a molded coil 303 may also be connected without wiring members W.

[0168] <<Second Implementation Method>> Next, refer to Figure 20 The second embodiment of the present invention will be described in detail below.

[0169] <Coil Unit> Figure 20 This is a top view (top surface) schematic diagram for explaining the coil unit 500 (500A) of the second embodiment. The coil unit 500 constitutes a motor component (stator), for example, by being assembled to a stator core. Figure 20 (A) is a diagram showing an example of the coil unit 500, which is a top view taken from a direction orthogonal to the helical axis AX1 of the coil 502 shown by the single-dotted line (for example, along the rotation axis AX2 of the motor in the case where the coil unit 500 is assembled in the stator). Figure 20 (B) Figure 20 (C) is a top view showing a portion of the coil unit 500. Both the top view and the top view in the second embodiment are planes viewed along the direction of the motor's rotation axis AX2.

[0170] Reference Figure 20In embodiment (A), the coil unit 500 (500A) of the second embodiment has a plurality of coils 502 and an injection-molded resin (also referred to as an injection-molded resin layer. The same applies hereinafter in the second embodiment) 503 that integrally covers these plurality of coils 502. The coils 502 are formed into helical structures, for example, by means of conductors. As an example, in Figure 20 The diagram shows a case where three coils 502 (conductors) are integrally covered by injection molding resin 503. Injection molding resin 503 is, for example, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), nylon, etc.

[0171] In the second embodiment, the coil 502 covered by the injection molding resin 503 is referred to as a molded coil. That is, the coil unit 500 of the second embodiment is a molded coil unit.

[0172] It should be noted that in the accompanying drawings of the second embodiment, for ease of explanation, the coil 502 inside the molded coil unit 500 (500A) is sometimes shown with dashed lines. However, in reality, viewed from the outside of the molded coil unit 500, at least the helical structure of the coil 502 is not visible except for the end TS of the coil 502. It should also be noted that all coils 502 are arranged such that, when viewed from above (e.g., ...), the coil 502 is not visible. Figure 20 (A) For example, all ends of TS are visible on the same plane side (the same in the following implementation).

[0173] Figure 20 (B) is a top view showing the coil 502 inside the coil unit (molded coil unit) 500 extracted. Although the multiple coils 502 have the same size and shape (including the number of turns), they may also be configured such that at least one of the multiple coils 502 has a different shape and / or size than the other coils 502.

[0174] Sometimes, each coil 502 of the molded coil unit 500 is appropriately connected to the outside (other molded coil units 500) or other coils 502 of the same molded coil unit 500 through wiring components W (busbars, linear conductors, etc.) according to the desired potential relationship. Figure 20The illustration is schematic and does not limit the scenario where all coils 502 within a molded coil unit 500 are connected via the wiring member W. That is, within a molded coil unit 500, all coils 502 can be connected via the wiring member W, with three coils 502 connected in the helical direction. Alternatively, at least one coil 502 can be connected to coils 502 of other molded coil units 500 without being connected to other coils 502 of the same molded coil unit 500. Furthermore, the three coils 502 may not be connected via the wiring member W.

[0175] The wiring member W is connected to the spiral end TS of the coil 502 and exposed from the injection molding resin 503, but at least a portion of the wiring member W can also be covered by the injection molding resin 503. For example, when at least one coil 502 included in a molded coil unit 500 is connected to other coils 502 included in the same molded coil unit 500 or other molded coil units via the wiring member W, at least a portion of the wiring member W and the end TS of the coil 502 connected to the wiring member W can be covered by the injection molding resin 503 or exposed. Although the wiring member W is omitted from the illustration in the following embodiments, the wiring member W (the connection relationship between the coils) in the second embodiment is similar to that described above. Figure 20 The explanation is the same as in the previous text.

[0176] In a molded coil unit 500, multiple coils 502 are Figure 20 The arrangement is partially annular when viewed from above. Here, "partially annular" refers to the shape (arc shape) of a portion of the circumference of the circular plate or ring, for example, the shape of a portion of the circumference (arc shape) when the stator's top view (shape viewed along the direction of the motor's rotation axis AX2) is a circular plate or ring. That is, the shape of the molded coil unit 500 is also partially annular. Figure 20 (A)).

[0177] Figure 21 (C) is a diagram showing only the injection molding resin (injection molding resin layer) 503 of the molded coil unit 500 extracted. Figure 21 (C) is a top view of the stator when the direction along the rotation axis AX2 is taken as the height direction of the coil 502, and the stator is cut radially using a cutting line near the center of the height direction.

[0178] In the injection molding resin 503, through holes 505 are provided along the central portion of the spiral structure of each coil 502, specifically along the inner circumference of the spiral structure. When the coil unit (molded coil unit) 500 is installed on the stator core, a portion (tooth) of the stator core is inserted through the through hole 505.

[0179] Reference Figure 21 Further explanation is needed. Figure 21 (A) is a perspective view showing the appearance of a coil 502 in a molded coil unit 500 (500A). Figure 21 (B) is Figure 21 A sectional view of line xx of (A). Figure 21 (C) is in the state covered by injection molding resin 503 (molded coil unit 500A), equivalent to Figure 24 A sectional view of the yy line section of (A).

[0180] like Figure 5 As shown in (A), the coil 502 is formed by forming a helical structure through the conductor C. Here, as an example, the coil 502 is a so-called concentrated wound coil in which a region (the surrounding region CR) around the helical axis AX1 is substantially overlapped in the direction of the helical axis AX1. Furthermore, a through hole 505 is provided in the injection molding resin 503 in such a way as along the central portion 504 of the helical structure around the helical axis AX1. Figure 21 (C)).

[0181] As an example, the multiple coils 502 included in a molded coil unit 500 all have the same shape. Specifically, the size, shape, and number of turns of the entire coil 502 are identical. Furthermore, the size and shape of the winding regions CR of the multiple coils 502 are identical on corresponding turns. That is, the size and shape of the winding regions CR of the first turn of each of the three coils 502 forming their respective helical structures are approximately the same, the size and shape of the winding regions CR of the second turn are approximately the same, and the size and shape of the winding regions CR of the nth turn are approximately the same. Moreover, except for the ends (starting and ending ends) TS of the helix, the entire coil 502 is integrally covered by injection molding resin 503. The coil 502 (conductor C) is not exposed in the through-holes 505 of the injection molding resin 503 (see reference). Figure 21 (A)).

[0182] like Figure 21 (B) Figure 21 As shown in (C), specifically, the coils 502 of the molded coil unit 500 (500A) all have a predetermined gap G between the surrounding regions CR, and injection molding resin 503 is also provided in this gap G. That is, for the coil 502, the conductor C covering the entire region except for the end TS is in direct contact with the injection molding resin 503, and the multiple surrounding regions CR that overlap in the direction of the helical axis AX1 are insulated from each other by the injection molding resin 503.

[0183] In addition, such as Figure 22As shown in (C), injection molding resin 503 is also disposed in adjacent regions 506 of the plurality of coils 502 in the molded coil unit 500A.

[0184] Traditionally, for example, in the coils of the stator that constitute a component of a motor, a conductor with a spiral structure is spread throughout the entire spiral travel direction (long side direction), and is coated with an insulating resin by impregnation, spraying, etc., and then installed on the teeth of the stator core via insulating components (such as insulating paper, insulating resin material, etc.).

[0185] However, when applying an insulating coating to coil 502 (copper wire) through methods such as spraying or impregnation, thorough film thickness management is required. Furthermore, even with film thickness management, it is almost impossible to eliminate pinholes, which makes it difficult to simplify the manufacturing process and reduces the yield.

[0186] In addition, the following problems exist: the spiral structure is elastic, and when installed on the teeth, the overlapping circumferential areas in the spiral axis direction are misaligned with each other, resulting in poor operability, or damage to the thin insulating film, resulting in deterioration of the withstand voltage.

[0187] According to the second embodiment, the coils 502 are molded coils, and the surrounding areas CR of the coils 502 are insulated from each other by injection molding resin 503. In addition, adjacent coils 502 in a molded coil unit 500A are also insulated from each other by injection molding resin 503.

[0188] Therefore, an insulating coating process (based on impregnation, spraying, or other methods of applying insulating resin) is not required for coil 502. Furthermore, since the surrounding areas CR of coil 502 are fixed to each other by injection molding resin 503, misalignment and expansion / contraction of the overlapping surrounding areas CR in the helical axis AX1 direction can be prevented. In particular, for example, when multiple coils 502 are connected, by integrally covering them with injection molding resin 503, misalignment and damage to the coils 502 can be prevented.

[0189] Furthermore, the installation process of insulating components (insulating paper, insulating resin components, etc.) placed between the coil and the teeth, which is required for the assembly of the stator in the past, can be eliminated. Therefore, for example, the operability when installing it on the teeth can be greatly improved, and the number of parts can be reduced. In addition, the degradation of withstand voltage caused by conductor C exposure can be avoided.

[0190] Furthermore, since multiple (n) coils 502 are integrated (molded) by a single injection molding resin 503, the operability in the assembly process can be further improved compared to the case where each of the n coils 502 is individually molded coil.

[0191] Furthermore, compared to individually molding each of the n coils 502, the number of parts in the finished product can be reduced to 1 / n. As a result, deviations in the assembled product and deviations in work time caused by the skill level of the assembly operator can be reduced.

[0192] Furthermore, it also enables good operability when the stator is assembled by an assembly device without relying on an operator (automating the assembly process).

[0193] That is, the operation of coil 502 itself in the stator manufacturing process becomes easier, realizing the efficiency (simplification) of the manufacturing process, the improvement of yield, and the reduction of component costs.

[0194] Furthermore, by using, for example, a thermally conductive resin as the injection molding resin 503, heat dissipation efficiency can be improved. This allows the molded coil unit 500 to be placed in close contact with the motor housing. By having the injection molding resin 503 directly contact the housing, the heat generated by the coil 502 is released to the outside through the housing, thereby improving the heat dissipation of the coil 502 and thus improving the characteristics of the motor. Additionally, since excess space can be reduced to make the housing smaller, this contributes to the miniaturization of the motor.

[0195] Reference Figure 22 and Figure 21 An example of a method for manufacturing the molded coil unit 500 (500A) of the second embodiment will be described. Figure 22 This is a top view schematic diagram showing the manufacturing method of the molded coil unit 500A.

[0196] First, such as Figure 22 (A) Figure 21 As shown in (A), a coil (spiral structure) 502 is formed by a conductor C (e.g., a metal conductor mainly composed of copper and / or aluminum). For example, multiple strip-shaped (e.g., U-shaped) conductors C (flat conductors (coil sheets)) are prepared, and the end faces in the long side direction are pressed together to form the coil 502. However, the method of manufacturing the coil 502 is not limited to this, and any method can be used. For example, multiple strip-shaped round wire conductors (conductors C with a cross-section of approximately circular in the long side direction) can be pressed together to form the coil. Alternatively, a long-length (final length of the coil 502, the same below) flat conductor (without interruption) can be wound as the coil 502, or a long-length round wire conductor (without interruption) can be wound as the coil 502. Alternatively, a long-length round wire conductor can be wound into a spiral shape and then stamped along the spiral axis AX1 to form a flat conductor wire coil 502.

[0197] Whether formed by connecting strip conductor C or by winding a long conductor C, immediately after coil 502 is completed, as follows: Figure 21 As shown in (A), the spacing between the surrounding regions CR typically deviates at arbitrary distances. Therefore, the spacing between the surrounding regions CR is expanded or reduced in the direction of the helical axis AX1, and the spacing between each surrounding region CR becomes... Figure 21 The molding process is carried out using approximately equal distances P, as shown in (B). Furthermore, the molding process is completed by adjusting the alignment of the surrounding area CR. Figure 22 The coil 502 shown in (B) has a surrounding region CR that overlaps in such a way that the center of the entire surrounding region CR is aligned with the helical axis AX1.

[0198] exist Figure 22 In the completed coil 502 shown in (B), all the surrounding regions CR are separated by a substantially equal distance P. The distance P between the surrounding regions CR is a necessary and sufficient length for the completed coil 502. The distance P can be ensured to be substantially equal, for example, by a spacer member integrally provided with the coil 502 or a separate spacer member (not shown). However, the distance P can also be ensured by elastic deformation and / or plastic deformation without using a spacer member.

[0199] like Figure 22 As shown in (B), multiple (three in this example) coils 502 are prepared in this manner. It should be noted that at least one of the multiple coils 502 can be formed using a different manufacturing method than the other coils 502. However, in any case, the coils 502 (spiral structures) are constructed entirely of conductor C without an insulating coating (coil 502 without an insulating coating). The multiple coils 502 are connected as needed via wiring members W (in... Figure 21 (Illustration omitted) Connection.

[0200] After that, as Figure 22 As shown in (C), while maintaining the distance P between the winding regions CR of each coil 502, multiple coils 502 are arranged in a partially ring shape within a predetermined injection molding mold (molding mold) 901. For example, as Figure 20 As shown in (A), the shape of each coil 502 is preferably formed as a generally frustum-shaped pyramid. Furthermore, in Figure 21 In the example shown, multiple coils 502 are arranged in a partially loop (arc shape) with one side of the trapezoid facing the inner periphery when viewed from above.

[0201] It should be noted that although a detailed illustration of the injection molding mold 901 is omitted, it is shown that through holes 505 are formed at positions corresponding to the center portions 504 of each coil 502. Figure 22 (C) Figure 22The mold (C) is then filled with molten resin (e.g., PPS, LCP, nylon, etc.) and allowed to solidify. Thus, as... Figure 21 Partial perspective view of (D), Figure 20 As shown in the external diagram (E), multiple coils 502, except for the ends TS, are covered by injection-molded resin 503 to form an integrated molded coil unit 500A. The inner circumference of each coil 502 is also covered by injection-molded resin 503, and the coil 502 (conductor C) is not exposed from the through hole 505.

[0202] It should be noted that it is also possible to avoid pre-forming the distance P between the winding regions CR of the coil 502, and instead provide spacers in the molding die 901 to separate the winding regions CR by a predetermined distance P. In this case, it is possible to simultaneously form the coil 502 that separates the winding regions CR by a predetermined distance P, and to cover and integrate the coil 502 with the injection molding resin 503.

[0203] In the molded coil unit 500 (500A) of the second embodiment, the entirety of a plurality of coils 502, except for their ends TS, is integrally covered by injection-molded resin 503. Additionally, as... Figure 23 As shown in (C), for coil 502, conductor C (without an insulating coating) is in direct contact with injection molding resin 503, and the multiple overlapping surrounding regions CR in the helical axis direction are insulated between each other by injection molding resin 503. Furthermore, the surrounding regions CR are fixed between each other by injection molding resin 503 while ensuring a distance P. Thus, in the molded coil unit 500, conductor C is not provided with an insulating coating, and conductor C is insulated by injection molding resin 503. The size of distance P is arbitrary, but is set to a size that allows the injection molding resin to reliably enter between the surrounding regions CR and insulate the surrounding regions CR from each other.

[0204] Furthermore, the molded coil unit 500A has a partially ring-shaped shape. That is, by combining multiple molded coil units 500A, they collectively form a ring-shaped stator component. In this case, the molded coil unit 500A can also be referred to as a component constituting a motor (motor component).

[0205] In the case of a three-phase motor, the three coils 502 constituting the U-phase, V-phase, and W-phase of the three-phase motor can be molded integrally (as a single molded coil unit 500A). In this case, the three coils 502 constituting one molded coil unit 500A can be connected via a wiring member W. Alternatively, the three coils constituting one molded coil unit 500A can be connected without the wiring member W. That is, the U-phase coil 502 constituting one molded coil unit 500A can be connected to the U-phase coil 502 constituting another molded coil unit 500A via the wiring member W. Similarly, it can be configured such that the V-phase coil 502 constituting one molded coil unit 500A is connected to the V-phase coil 502 constituting another molded coil unit 500A via another wiring member W, and the W-phase coil 502 constituting one molded coil unit 500A is connected to the W-phase coil 502 constituting another molded coil unit 500A via another wiring member W.

[0206] For example, by making the phases of the current or voltage of the three coils 502 that constitute a set of molded coil units 500A different, for example, U phase, V phase, and W phase, a stator of a three-phase motor can be obtained.

[0207] Furthermore, for each U-phase, V-phase, and W-phase, multiple coils 502 constituting them can be integrally molded (as a single molded coil unit 500A). In this case, for each molded coil unit 500A, the multiple coils 502 within it are connected by wiring members W. Thus, the wiring members W of the coils 502 are connected to each other (see reference). Figure 23 The connection state can be adjusted according to the usage conditions. Furthermore, the wiring component W can be connected either before or after being covered by the injection-molded resin 503.

[0208] For example, by making the phases of the current or voltage of the three sets of coil units 500A different, such as U phase, V phase, and W phase, a stator of a three-phase motor can be obtained.

[0209] Reference Figure 21 Another type of molded coil unit 500 (500B) will be described. Figure 23 This is a diagram showing an example of a molded coil unit 500B, which is a top view schematic diagram viewed from the direction of the motor's rotation axis AX2.

[0210] The molded coil unit 500B integrally covers a plurality of coils 502 arranged in a ring shape with injection molding resin 503. In this case, it is desirable that each coil 502 be formed, for example, as follows: Figure 23 As shown in (A), its shape is roughly a frustum. Furthermore, in Figure 23In the example shown, multiple coils 502 are arranged in a ring shape with one side of the trapezoid (the side closer to the rotation axis AX2) facing the inner periphery when viewed from above.

[0211] Figure 23 The injection molding resin 503 shown in (A) is configured as a continuous ring. Or as... Figure 23 As shown in (B), the injection-molded resin 503 can also be generally ring-shaped, but is configured as a discontinuous, generally C-shaped structure by providing cutouts SP in a portion (between a group of adjacent coils 502). It should be noted that even in this case, the coils 502 do not protrude from the injection-molded resin 503 at the cutouts SP.

[0212] In addition, Figure 1 (A) Figure 21 The diagram of the through hole 505 is omitted in (B), but as shown in Figure (B), Figure 23 As shown in (C), a through hole 505 is provided at a position corresponding to the center portion 504 of each coil 502. In this case, the coil 502 (conductor C) is not exposed from the through hole 505.

[0213] The state of each coil 502 of the molded coil unit 500B and the injection molding resin 503 covering them, as well as the reference. Figure 23 The state of the coil 502 and the injection molding resin 503 in the molded coil unit 500A described is the same. Furthermore, although not shown in the figures, the plurality of coils 502 arranged in a ring are suitably connected to other coils 502 by one or more desired wiring members W. The wiring members W connected to the ends TS of the coils 502 are disposed outside the injection molding resin 503, but at least a portion of them may also be covered by the injection molding resin 503 (the same applies in the following embodiments).

[0214] For example, as a motor component, when the molded coil unit 500B is mounted on the stator, such as Figure 22 As shown, by integrally covering the multiple coils 502 arranged in a ring with injection molding resin 503, they become a single component, thus improving operability. In this case, for example, a stator core composed of segmented cores as described later, or a stator core that can be molded into any shape by resin molding, as in the first embodiment, can be used.

[0215] Figure 23 The manufacturing method of the molded coil unit 500B shown is similar to Figure 23 The manufacturing method of the molded coil unit 500A shown is the same.

[0216] That is, after forming a spiral structure through conductor C, it is shaped in such a way that a gap G of distance P is created between the surrounding regions CR. In addition, the surrounding regions CR are aligned and adjusted to form the coil 502 in the final shape. In this case, the coil 502 is also made of conductor C itself, without being covered with an insulating film (it is a coil 502 without an insulating film).

[0217] After that, as Figure 23 (C) Figure 23 As shown in (D), multiple coils 502 are arranged in a ring in a predetermined injection molding die (molding mold) 901 while maintaining the distance P between their respective winding regions CR. In this case, although the injection molding die 901 is not shown in the figure, it is a die in which a through hole 505 is formed near the center of each coil 502. Then, molten resin (e.g., PPS, LCP, nylon, etc.) is injected and allowed to solidify. Thus, as shown in (D), Figure 20 As shown in (A), multiple coils 502 are covered by annular injection-molded resin 503 to form an integrated molded coil unit 500B.

[0218] Alternatively, a molding die 901 with through holes 505 formed near the center of each coil 502 and slits SP formed in a portion of the annulus is used to inject molten resin (e.g., PPS, LCP, nylon, etc.) and allow it to solidify. Thus, as... Figures 24 to 37 As shown in (B), multiple coils 502 are covered by a generally C-shaped (generally ring-shaped) injection-molded resin 503 to form an integral molded coil unit 500B.

[0219] In this case, it is not necessary to pre-form the coil 502 to ensure the distance P between the winding regions CR, but instead, spacers that separate the winding regions CR by a predetermined distance P can be provided in the molding die 901. In this case, the formation of the coil 502 that separates the winding regions CR by a predetermined distance P, and the covering and integration of the coil 502 with the injection molding resin 503 can be performed simultaneously.

[0220] Based on the annular molded coil unit 500B, it is possible to obtain... Figure 24 The molded coil unit 500A shown has the same effect. In addition, compared with the partially annular molded coil unit 500A, the number of parts can be further reduced, operability can be further improved, and the manufacturing process can be made more efficient.

[0221] <Motor Components> Reference Figure 24The motor component 800 of the second embodiment will now be described. The motor component 800 includes the molded coil units 500 (500A, 500B) described above, and a core (stator core 600) for mounting the molded coil units 500. That is, the motor component 800 of the second embodiment is a stator or a component constituting a stator (partial stator unit).

[0222] Figure 24 This is a diagram showing an example of the stator core 600 (600A) of the molded coil unit 500 (500A, 500B) of the second embodiment. Figure 24 (A) is a top view diagram taken from the direction of the motor's rotation axis AX2. Figure 24 (B) is a perspective view showing a portion of the stator core 600A.

[0223] Stator core 600A is, for example, a combined stator core 600A in which multiple segmented cores 601 are combined to form a ring. Figure 25 The combined stator core 600A shown is composed of, for example, multiple segmented cores 601 that appear roughly T-shaped when viewed from above. Figure 20 (B) is a perspective view of a segmented core 601. Multiple segmented cores 601 are of the same shape and each has an arcuate portion 603 and teeth 602 protruding inward in the radial direction of the arcuate portion 603. Furthermore, by arranging and connecting the arcuate portions 603 of the multiple segmented cores 601 along the arc length direction, a combined stator core 600A with multiple teeth 602 arranged in a ring is formed. In this case, the arcuate portion 603 can also be referred to as a connecting portion.

[0224] This combined stator core 600A is a stator core used in an inner rotor type motor where the rotor is positioned on the inner circumference of the stator. The arc portion 603 is arranged in a ring shape centered on the motor's rotation axis AX2, and the teeth 602 protrude radially inward toward the arc portion 603. Multiple teeth 602 are inserted into the through holes 505 of the coil 502. The combined stator core 600A (the segmented core 601 constituting it) is, for example, made of laminated steel plates.

[0225] By assembling the stator core 600 (600A) and the molded coil unit 500, a motor component (stator 800 or part of stator unit 800p) can be formed. This will be explained in detail below.

[0226] Figure 25 This illustrates the mounting of the combined stator core 600A (its segmented core 601) onto... Figure 25 The diagram shows a top view of the state of the molded coil unit 500A. (See attached image.) Figure 25As shown in (A), the teeth 602 of the segmented core 601 are inserted through the through hole 505 of the molded coil unit 500A, so that the arcuate portions 603 of the segmented core 601 are connected to each other. Thus, it is possible to obtain... Figure 26 The unit shown in (B) that can constitute the stator (partial stator unit 800p (800pa)). Furthermore, by combining the partial stator unit 800pa in a predetermined number (four sets in this example) in an overall annular shape, the stator 800 (800A) can be obtained. Both the partial stator unit 800p (800pa) and the stator 800 (800A) are motor components in the second embodiment.

[0227] It should be noted that, as Figure 26 The manufacturing method of stator 800A shown in (B) can also be that after forming partial stator units 800pa, instead of combining them in a predetermined number, a predetermined number (4 sets in this example) of molded coil units 500A are arranged in a ring, and the teeth 602 of the dividing core 601 are inserted into their respective through holes 505, and the arc portions 603 are connected to each other.

[0228] Figure 27 This is a top view showing the state in which the roughly T-shaped segmented core 601 is mounted on the annular molded coil unit 500B.

[0229] like Figure 27 As shown in (A), the teeth 602 of the segmented core 601 are inserted into the through holes 505 of the molded coil unit 500B, so that the arcuate portions 603 of the segmented core 601 are connected to each other. Thus, a stator (motor component) 800 (800B) can be obtained by assembling the annular molded coil unit 500B onto the combined stator core 600A.

[0230] Figure 27 This is another example of a stator 800 (800C) and a portion of the stator unit 800p (800pc). Figure 27 (A) Figure 27 (B) is a top view schematic diagram showing another example of stator core 600 (600B). Figure 27 (C) is a top view schematic diagram showing part of the stator unit 800p. Figure 27 (D) is a top view showing a portion of the stator 800. It should be noted that... Figure 27 These are all illustrative images, and Figure 27 (A) and Figure 27 (B) ~ Figure 27 The scale of (D) is different.

[0231] like Figure 27 (A) Figure 27As shown in (B), the stator core 600 in this example is a combined stator core 600B, composed of approximately T-shaped segmented cores 611. However, for each segmented core 611, the same number of teeth 612 as the coils 502 of the molded coil unit 500A are integrally formed with an arcuate portion 613. Specifically, in this example, three teeth 612 are integrally formed with an arcuate portion 613. If multiple (in Figure 27 In example (A), there are four groups of these segmented cores 61, which together form, for example, an inner rotor type combined stator core 600B.

[0232] In this case, such as Figure 27 As shown in (C), a partial stator unit 800pc is constructed by assembling a molded coil unit 500A onto a segmented core 611. Furthermore, although by... Figure 28 In (D), a portion of the stator unit 800pc is shown with a large dashed line and is omitted from the description, but it can be formed by combining a predetermined number of units in a ring-like manner to form the stator 800C.

[0233] In this case, the curvature of the arc portion 613, the length of the tooth 612, and the distance between adjacent teeth 612 are set to values ​​that prevent the assembled multiple molded coil units 500A from interfering with each other.

[0234] Figure 29 and Figure 28 This is a diagram showing another example of stator 800 (800D). Figure 28 The figure shows another example of a stator core 600 (600C), which is also a combined stator core 600C. Figure 28 (A) is a top view schematic diagram showing the combined stator core 600C. Figure 28 (B) Figure 28 (C) is a diagram showing the state of the segmented core 621 assembled on the combined stator core 600C, which is a top view from the circumferential direction. Figure 29 A side view of the annular combined stator core 600C observed at (A). Figure 28 This is a top view schematic diagram showing the stator 800 (800D).

[0235] Reference Figure 28(A) The combined stator core 600C consists of a plurality of segmented cores 621 that are roughly I-shaped when viewed from above, and a cylindrical (annular) support portion (connecting portion) 623. The segmented cores 621 and the support portion 623 are separately constructed. One end of the segmented core 621 in the radial direction (inner radial direction) of the support portion 623 has a wedge-shaped protrusion 622, and the support portion 623 has recesses 624 at equal intervals along the circumferential direction on its outer peripheral surface, which follow the shape of the protrusion 622. That is, the protrusion 622 and the recesses 624 can engage, and through their engagement, the segmented core 621 becomes a tooth 625 protruding radially outward from the outer peripheral surface of the support portion 623. This combined stator core 600C is a stator core used in an external rotor type motor in which the rotor is arranged on the outer periphery of the stator.

[0236] The method of mounting the dividing core 621 (tooth 625) to the support portion 623 is as follows: Figure 28 (B) Figure 29 As shown in (C), the protrusion 622 of the dividing core 621 and the recess 624 of the support portion 623 are aligned vertically along the central axis (rotation axis AX2 of the motor) of the generally annular (cylindrical) support portion 623, and then inserted and fixed along the rotation axis AX2. In this case, the wedge-shaped protrusion 622 of the dividing core 621 and the recess 624 of the support portion 623 can be inserted and slide in the vertical direction; on the other hand, they are set to a gap that will not produce wobbling after engagement.

[0237] In the manufacturing method of stator 800 (800D) based on this combined stator core 600C, firstly, as Figure 29 As shown in (A), roughly I-shaped segmented cores 621 (teeth 625) are inserted through the through holes 505 of the molded coil unit 500A. This state can also be referred to as a partial stator unit. Then, as... Figure 23 As shown in (B), the protrusion 622 of the dividing core 621 is aligned with the recess 624 of the support portion 623, and the two are inserted and fixed. Then, by combining multiple (in this case, four sets) molded coil units 500A in a generally annular manner, the stator 800D can be obtained.

[0238] It should be noted that, although the illustration is omitted, it is also possible to insert the roughly I-shaped dividing core 621 (tooth 625) through it. Figure 30 After the through holes 505 of the annular molded coil unit 500B shown, the protrusion 622 of the dividing core 621 and the recess 624 of the support portion 623 are aligned, and the two are inserted and fixed in the direction of the rotation axis AX2. Thus, a stator 800D formed by assembling the annular molded coil unit 500B onto the combined stator core 600C can be obtained.

[0239] Reference Figure 31and Figure 30 Another example of stator 800 (800E) will be explained. Figure 30 This is a diagram showing another example of stator core 600 (600D). The stator core 600 in this example is also a combined stator core 600D. Figure 30 (A) is a top view schematic diagram showing the combined stator core 600 (600D). Figure 30 (B) ~ Figure 30 (D) is a diagram showing a portion of the combined stator core 600D. Figure 30 (B) is in the view from above ( Figure 30 The (A) view shows the unfolded side view of the teeth 633 arranged in a ring shape, unfolded with the circumferential direction as the horizontal direction (left and right direction in the figure). Figure 30 (C) is a top view of tooth 633. Figure 30 (D) is a top view of the support 635. Figure 31 This is a top view schematic diagram showing another example of a stator 800E using a combined stator core 600D, and a stator core 600D (tooth 633).

[0240] like Figure 30 As shown, the combined stator core 600D can be configured such that multiple teeth 631, which appear roughly I-shaped when viewed from above, are integrally connected by annular connecting portions 632. In this example, as... Figure 30 As shown in (B), the connecting portion 632 is configured such that the upper connecting portion 632u on the upper side and the lower connecting portion 632d on the lower side are opposite each other in the direction of the rotation axis AX2 of the motor. Furthermore, all the teeth 631 are arranged in a ring at approximately equal intervals, with the upper end in the direction of the rotation axis AX2 engaging with the upper connecting portion 632u on the inner circumferential side (radially inner side of the combined stator core 600D), and the lower end in the direction of the rotation axis AX2 engaging with the lower connecting portion 632d. Thus, multiple teeth 631 are integrally supported by the connecting portion 632, forming a tooth portion 633. Alternatively, the upper connecting portion 632u and the lower connecting portion 632d can also be said to be in a state of being bridged by the teeth 631. The upper connecting portion 632u and the lower connecting portion 632d are continuous without interruption in the circumferential direction, creating a space between adjacent teeth 631. Figure 30 (B) Additionally, at least one of the multiple teeth 631, 631A (in this example, four teeth 631A positioned at 90 degrees to each other), is longer than the other teeth 631 in the radial direction of the coupled stator core 600D, and thus has a protrusion 634 at its front end (the end in the direction radially away from the rotation axis AX2). It should be noted that the connecting portion 632 preferably has strength sufficient to maintain (support) the multiple teeth 631 in predetermined positions (spaced), for example, it is made of a thin metal (steel plate).

[0241] like Figure 30 As shown in (D), the support portion 635 is cylindrical, and a recess 636 is provided on its inner circumference for engaging with the protrusion 634 of the tooth 631A. A tooth 633 is arranged inside the support portion 635, and the protrusion 634 engages with the recess 636, for example, by inserting it along the rotation axis AX2, thereby forming a combined stator core 600D. In this case, the teeth 631 other than the tooth 631A do not abut against the support portion 635, and the protrusion 634 of a specific tooth 631A (4 in this example), which is less than the total number of teeth 631 and 631A (12 in this example), engages with the recess 636 to fix the tooth 633 and the support portion 635. Therefore, compared to fixing the total number of teeth 631 and 631A to the support portion 635, work efficiency can be improved.

[0242] However, it is also possible that all teeth 631 abut against the inner circumference of the support portion 635. Alternatively, a protrusion 634 may also be provided on the teeth 631, and a recess 636 corresponding to the protrusion 634 may be provided on the support portion 635, so that all teeth 631, 631A engage with the support portion 635.

[0243] like Figure 31 As shown in (A), a stator 800E can be formed by assembling multiple molded coil units 500A onto the tooth 631 in a generally annular manner.

[0244] It should be explained that, for example Figure 31 As shown in (B), the tooth 633 may not be a continuous ring, but rather configured as a roughly C-shaped section cut off in the circumferential direction by means of connecting portions 632 having connecting portions ends T1 and T2. In this case, the connecting portion 632 is made of a material that has strength sufficient to hold (support) the plurality of teeth 631 in predetermined positions (intervals) and is deformable (flexible). For example, the connecting portions ends T1 and T2 may be separated, and after assembling the molded coil unit 500A with the connecting portion 632 unfolded, as shown in (B). Figure 31 As shown in (B), the stator 800E is formed by deforming (flexing) the connecting ends T1 and T2 close together into a ring shape and fixing it to the support 635. Even if the tooth 633 is approximately C-shaped, the multiple teeth 631 can be maintained in a ring-shaped arrangement by engaging with the ring-shaped support 635, thereby arranging the multiple molded coil units 500A in a approximately ring-shaped configuration.

[0245] In addition, in such Figure 31When the tooth 633 is configured in a roughly C-shape as shown in (B), it can be combined with the annular molded coil unit 500B, although the illustration is omitted. In particular, when the connecting part 632 is made of a material with strength that allows for bending deformation (such as a thin steel plate), the teeth 631 of the tooth 633 are inserted along the plurality of through holes 505 of the annular molded coil unit 500B, and then fixed to the support part 635, thereby forming the stator 800.

[0246] Figure 30 and Figure 31 The combined stator core 600D shown is a stator core used in an external rotor type motor, but it can also be used in an internal rotor type motor where the tooth 631 protrudes radially inward from the connecting portion 632. Specifically, Figure 30 The connecting portion 632 shown is configured such that, with the rotating shaft AX2 of the motor as the center, the tooth 631 protrudes radially outward from the center when viewed from above, that is, towards the outer periphery of the annular connecting portion 632. In contrast, although not shown in the figure, it can also be configured such that, with the shaft AX2 of the stator as the center, the tooth 631 protrudes radially inward from the center when viewed from above, that is, towards the inner periphery of the annular connecting portion 632. In this case, the support portion 635 is configured such that a recess 636 disposed on the inner periphery of the tooth portion 633 and provided on its outer periphery engages with the protrusion 634 of the tooth 631.

[0247] It should be noted that in the combined stator core 600D, the protrusion 634 of the tooth 631A can also be a recess, and the recess 636 of the support portion 635 can also be a protrusion.

[0248] Reference Figure 32 Another example of stator 800 (800F) will be explained. Figure 32 (A) is a top view schematic diagram showing another stator core 600 (600E). Figure 32 (B) is a top view diagram illustrating the stator 800F.

[0249] Reference Figure 32 In (A), the stator core 600E is an integral stator core consisting of a plurality of teeth 641 arranged in a ring shape when viewed from above, which are integrally (inseparably) supported by a cylindrical (circular plate) support portion 642 as a single component. Furthermore, this example of the integral stator core 600E is a stator core used in an external rotor type motor. The plurality of teeth 641 are arranged at approximately equal intervals in the circumferential direction of the generally circular plate support portion 642 when viewed from above, and protrude radially outward from the support portion 642.

[0250] In this case, such as Figure 32As shown in (B), a stator 800F can be formed by assembling molded coil units 500A onto teeth 641 and combining them in a predetermined number in a generally annular manner. In this case, the length of the teeth 641 and the distance between adjacent teeth 641 are set to values ​​that prevent the assembled multiple molded coil units 500A from interfering with each other.

[0251] It should be noted that although the illustration is omitted, the integrated stator core 600E can also be used in an internal rotor type motor, provided that the multiple molded coil units 500A arranged in a ring do not interfere with each other (see [reference]). Figure 35 (C)). In this case, multiple teeth 641 are arranged at equal intervals in the circumferential direction of the generally circular plate-shaped support portion 642 when viewed from above, and protrude radially inward toward the support portion 642.

[0252] Figure 33 This is a flowchart illustrating an example (first method) of a manufacturing method for a motor component (stator) 800 using the above-described molded coil unit 500. That is, the manufacturing method for the motor component 800 includes a step of preparing a plurality of coils 502 (step S101), a step of forming the molded coil unit 500 (step S103), and a step of assembling the molded coil unit 500 and the stator core 600 (step S105).

[0253] In step S101, a spiral structure is formed by conductor C to ensure the distance P between the surrounding regions CR. The alignment of the multiple surrounding regions CR is adjusted during molding to form multiple coils 502. In step S103, molded coil units 500 (500A, 500B) are formed by integrally covering the multiple coils 502 with injection molding resin 503. Furthermore, in step S105, teeth (teeth 602, 612, 625, 631, 641) of the stator core 600 are inserted into the through holes 505 of one or more molded coil units 500, forming a stator (motor component) 800 with coils 502 arranged in a ring shape and covered by injection molding resin 503. The stator core 600 described above is made of, for example, metal (electromagnetic steel sheet).

[0254] Figure 34 This is a flowchart illustrating another example (second method) of a manufacturing method for a motor component (stator) using a molded coil unit 500.

[0255] The stator core 600 is not limited to metal (electromagnetic steel plate), but can also be molded from an injection molding resin different from that of the molded coil unit 500.

[0256] In this case, the stator core 600 (600F) is a resin molded body made from resin containing soft magnetic material. Specifically, the stator core (resin molded body) 600F is obtained by melting resin particles mixed with soft magnetic material using heat, injecting the mixture into a mold of the desired shape, and then allowing it to cool and solidify. In terms of volume ratio (content ratio), the soft magnetic material is more abundant than the resin. For example, the soft magnetic material is a permingle alloy.

[0257] Reference Figure 34 The manufacturing method of the motor component (stator) based on the second method includes a step of preparing a coil 502 (step S201), a step of forming molded coil units 500 (500A, 500B) (step S203), a step of placing the molded coil units 500 in a core forming mold 902 (step S205), and a step of molding the stator core 600F with resin (step S207). That is, the stator core 600F is subsequently formed from the molded coil units 500 arranged in a generally annular shape to constitute the stator 800.

[0258] Reference Figure 35 The method for manufacturing stator 800G based on the second method will be explained in detail. Figure 35 This is a top view diagram illustrating the method of manufacturing stator 800G using molded coil unit 500B.

[0259] First, prepare multiple coils of 502 ( Figure 34 In step S201, the coils 502 are arranged in a ring within the molding die 901 while the surrounding regions CR are separated by a predetermined distance P. Alternatively, multiple coils 502 are arranged in a ring within the molding die 901 while maintaining and ensuring the distance P between the various surrounding regions CR within the molding die 901. Then, resin particles (e.g., PPS, LCP, nylon, etc.) are melted using heat and injected into the molding die 901, where they are cooled and solidified. Thus, as... Figure 35 As shown in (A), a ring-shaped molded coil unit 500B is formed by integrally covering multiple coils 502 with injection-molded resin 503, except for the end TS. Figure 34 Step S203).

[0260] After that, as Figure 35 As shown in (B), the molded coil unit 500B is placed inside another injection molding die (core molding die 902). Figure 34 Step S205). The core forming mold 902 is, for example, capable of forming... Figure 35The mold for the integral stator core 600F of the inner rotor type shown in (C) is as follows. For this integral stator core 600F, a plurality of teeth 651 arranged in a ring are integrally (inseparably) supported by a cylindrical (circular plate) support portion 652, forming a single component. When viewed from above, the plurality of teeth 651 are arranged at approximately equal intervals in the circumferential direction of the generally circular plate support portion 652, and protrude radially inward toward the support portion 652.

[0261] Resin particles mixed with soft magnetic material are melted using heat and injected into a core-forming mold 902, where they are then cooled and solidified. Thus, as... Figure 35 (C) Figure 35 As shown in (D), a stator core 600F based on injection molding resin 523 is molded. Figure 34 (Step S207). In this case, stator core 600F is formed, and stator 800G is formed by integrating stator core 600F and molded coil unit 500B.

[0262] In this case, the injection molding temperature (melting temperature of the resin particles) in the core molding mold 902 is set to a temperature at which the injection molding resin 503 of the molded coil unit 500B will not melt again (e.g., 350 to 450°C).

[0263] Thus, even complex shapes can be molded into any shape by means of the mold for the stator core 600F made of injection molding resin 523.

[0264] In particular, the molded coil unit 500 of the second embodiment, by covering it with injection molding resin 503, eliminates deviations in the shape of the coil unit (restricting flexibility and freedom of deformation), thereby improving operability when mounted on the stator core 600. Conversely, sometimes deformation of the coil 502 is not allowed, making it difficult to assemble with the stator core 600, which is already in a predetermined shape. However, by aligning the stator core 600 with the molded coil unit 500 (500B) and injection molding it, it is possible to mold the stator core 600 into the desired shape. In this case, for example, compared to a configuration where the molded coil unit 500A is mounted on a segmented core 601 made of an electromagnetic steel plate or the like and the segmented core 601 is joined together, work efficiency can be improved.

[0265] In addition, since part of the resin molded body contains resin, it can be made lighter than conventional stator cores that are made entirely of metal components such as electromagnetic steel sheets.

[0266] Furthermore, the molded coil unit 500 and the stator core 600F can be integrated simultaneously during the molding process. That is, the operation of assembling the molded coil unit 500 to each tooth 651 is eliminated, thus improving the efficiency of the manufacturing process of the stator 800G.

[0267] Furthermore, even when multiple resin-molded stator cores 600F are formed in the same shape, they can be easily mass-produced compared to stator cores formed by stacking electromagnetic steel sheets, and shape deviations can be suppressed.

[0268] Figure 36 This is an example of assembling a ring-shaped molded coil unit 500B onto a stator core 600G of an outer rotor-type resin molded body. Although the shape of the stator core 600G is similar to... Figure 32 The stator core 600E shown is the same as that made of electromagnetic steel sheet, but it is aligned with the molded coil unit 500B and subsequently formed by injection molding. Although it is not possible to mount the annular molded coil unit 500B onto... Figure 36 The stator core 600G shown is in its completed state. However, since it is subsequently formed by injecting injection molding resin 523 into a core forming mold 902 on which the molded coil unit 500B is disposed, even an external rotor type stator core 600G can be assembled onto the annular molded coil unit 500B. Furthermore, the molded coil unit 500B and the stator core 600G can be integrally fixed by resin injection molding.

[0269] This greatly simplifies the manufacturing process of motor components (stator 800) and reduces product deviation.

[0270] It should be noted that the stator core 600 formed by injection molding resin 523 can also be, for example, the type in the second embodiment. Figure 24 , Figure 27 , Figure 28 , Figure 30 Combined stator cores with shapes as shown.

[0271] In addition, multiple can be used Figure 20 The partially annular molded coil unit 500A shown becomes approximately annular, forming a stator core 600 based on injection molding resin 523.

[0272] Alternatively, it can be molded using other injection molding resins 523 and core molding molds 902. Figure 33 The stator core 600 in the first method shown. That is, as... Figure 37 As shown, coil 502 is prepared (step S301), and molded coil unit 500 is formed (step S303). Separately, other injection molding resin 523 is injected into core forming mold 902 and cured to form resin stator core 600 (step S305). After the stator core 600 is formed, it is assembled with molded coil unit 500 (step S307).

[0273] Furthermore, the stator core 600 formed from injection molding resin 523 is not limited to the shape described in the second embodiment, but can be molded into any shape.

[0274] In the second embodiment described above, a configuration was illustrated in which the conductor C constituting the spiral structure of the coil 502 is in direct contact with the injection molding resin 503. However, it is not limited to this configuration and may also be configured as follows: In all the embodiments described above, the conductor C constituting the spiral structure of the coil 502 is coated with an insulating resin different from the injection molding resin 503 along the entire spiral travel direction (long side direction), and in this state, the insulating resin (coating) is covered by the injection molding resin 503 in a manner that is in contact with the injection molding resin 503. When coating is performed by immersing the coil 502 in insulating resin or spraying insulating resin, there is a risk of pinholes appearing in the coating, which limits the improvement of yield. However, by further covering the coated state with the injection molding resin 503, even if pinholes appear, it will not cause a problem, and it can also prevent the coating from being damaged subsequently.

[0275] In addition, the example shown is of three coils 502 constituting a molded coil unit 500A, but it is not limited to this and may also consist of two or more coils.

[0276] Additionally, the end TS of coil 502 may not be configured in a top-down view (e.g., Figure 20 (A) All of them are visible on the same plane side.

[0277] This invention is not limited to the above-described embodiments, and various modifications can be made without departing from its purpose and technical concept.

Claims

1. A motor component, characterized in that, It is composed of a resin molded body containing soft magnetic material.

2. A motor component, characterized in that, have: The core, which is molded from a resin containing soft magnetic material; and A coil, which is disposed on the core.

3. The motor component according to claim 2, characterized in that, The coil has an injection-molded resin layer based on other resins.

4. The motor component according to claim 3, characterized in that, The conductor-based helical structure of the coil is directly covered by the injection-molded resin layer.

5. A method for manufacturing a motor component, characterized in that, include: The process of placing the coil in the mold; as well as The process of injecting resin containing soft magnetic material into the mold to form the core.

6. The method for manufacturing a motor component according to claim 5, characterized in that, The manufacturing method includes a step of covering the coil with an injection-molded resin layer based on another resin before it is configured in the mold.

7. A method for manufacturing a motor component, characterized in that, include: The process involves molding the core from resin containing soft magnetic materials. as well as The process of assembling the teeth and coil of the core.

8. The method for manufacturing a motor component according to claim 7, characterized in that, The manufacturing method includes the step of covering the coil with an injection-molded resin layer based on another resin.

9. The method for manufacturing a motor component according to claim 6 or 8, characterized in that, The resin containing the soft magnetic material is molded at a temperature at which the other resins do not melt.

10. The method for manufacturing a motor component according to claim 6 or 8, characterized in that, The conductor of the coil is directly covered by an injection-molded resin layer based on the other resins.

11. The motor component according to claim 1, characterized in that, The soft magnetic material is more abundant in terms of the volume ratio of the soft magnetic material to the resin constituting the resin molded body.

12. The motor component according to claim 2, characterized in that, The soft magnetic material is more abundant in terms of the volume ratio of the soft magnetic material to the resin.

13. The method for manufacturing a motor component according to claim 5 or 7, characterized in that, The soft magnetic material is more abundant in terms of the volume ratio of the soft magnetic material to the resin.

14. The motor component according to claim 1, characterized in that, In regions with relatively high magnetic flux density and regions with relatively low magnetic flux density, the volume ratio of the soft magnetic material to the resin constituting the resin molded body is different.

15. The motor component according to claim 2, characterized in that, The core includes teeth for mounting the coil and a support portion for the teeth. The volume ratio of the soft magnetic material to the resin differs for the tooth and the support portion.

16. The motor component according to claim 15, characterized in that, The volume ratio of the soft magnetic material in the tooth is greater than the volume ratio of the soft magnetic material in the support portion.

17. A method for manufacturing a motor component, characterized in that, include: The process involves molding multiple teeth from a resin containing soft magnetic material. The process of molding a support portion containing a second soft magnetic material resin to integrally support the plurality of teeth; and The process of assembling the plurality of teeth and the support portion.

18. The method for manufacturing a motor component according to claim 17, characterized in that, The manufacturing method includes the step of mounting coils onto the plurality of teeth respectively.

19. The method for manufacturing a motor component according to claim 18, characterized in that, The manufacturing method includes: The process of placing the coil in the mold; and The process of injecting the first resin containing soft magnetic material into the mold and integrally molding the teeth and the coil.

20. The method for manufacturing a motor component according to claim 17, characterized in that, The first type of resin containing soft magnetic material has a higher content of soft magnetic material than the second type of resin containing soft magnetic material.

21. A method for manufacturing a motor component, characterized in that, This includes the process of injecting resin containing soft magnetic material into a mold and then curing it.

22. A coil unit, characterized in that, have: Multiple coils; and Injection-molded resin integrally covers the plurality of coils.

23. The coil unit according to claim 22, characterized in that, The plurality of coils are spiral structures made of conductors, which are directly covered by the injection molding resin.

24. The coil unit according to claim 22, characterized in that, The injection molding resin is disposed between adjacent coils of the plurality of coils.

25. The coil unit according to claim 22, characterized in that, The injection-molded resin has a partially cyclic shape.

26. The coil unit according to claim 22, characterized in that, The injection molding resin has a ring-shaped shape.

27. A motor component, characterized in that, have: The coil unit according to any one of claims 22 to 26; and The core is used for mounting the coil unit.

28. The motor component according to claim 27, characterized in that, The core is made of other injection-molded resins.

29. A method for manufacturing a coil unit, characterized in that, include: The process of arranging multiple coils in a mold; as well as The process of injecting injection molding resin into the mold to integrally cover the plurality of coils.

30. The method for manufacturing a coil unit according to claim 29, characterized in that, The plurality of coils are configured in a partially ring shape, and the entire plurality of coils are covered by the injection molding resin.

31. The method for manufacturing a coil unit according to claim 29, characterized in that, The plurality of coils are arranged in a ring shape, and the entire plurality of coils are covered by the injection molding resin.

32. A method for manufacturing a motor component, characterized in that, include: The process of arranging multiple coils in a mold; The process of injecting injection molding resin into the mold and integrally covering the plurality of coils to form a coil unit; as well as The process of assembling the coil unit and the core.

33. The method for manufacturing a motor component according to claim 32, characterized in that, The manufacturing method includes the step of molding the core using other injection molding resins.

34. The method for manufacturing a motor component according to claim 33, characterized in that, After the core is formed, it is assembled into the coil unit.

35. The method for manufacturing a motor component according to claim 33, characterized in that, The coil unit is placed in another mold, and the other injection molding resin is injected into the other mold to form the core.

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