Stator for axial gap motor made by three-dimensionally processing wound soft magnetic ribbon

By integrating the back core and teeth in a cylindrical laminated soft magnetic thin strip and simplifying the stator fabrication process, the method addresses the inefficiencies and high costs of existing stator manufacturing methods, achieving improved magnetic properties and efficiency.

JP2025073923APending Publication Date: 2025-05-13ECDL LIMITED LIABILITY COMPANY
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Patent Information

Application Number
JP2023185114
Authority / Receiving Office
JP · JP
Patent Type
Applications
Current Assignee / Owner
Filing Date
2023-10-27
Publication Date
2025-05-13

AI Technical Summary

Technical Problem

Existing stator manufacturing methods for axial gap motors are costly and inefficient, with high material waste and complex processes, making it difficult to produce energy-efficient, low-loss motors.

Method used

The method involves applying adhesive to a ribbon-shaped soft magnetic thin strip, winding it, and then forming a cylindrical laminated soft magnetic thin strip. This strip is then ground to create a concave shape for the back core and convex teeth, which are integral and simplify the stator fabrication process.

Benefits of technology

This approach reduces material waste, simplifies the manufacturing process, and results in a stator with improved magnetic properties and efficiency, while also lowering production costs.

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Abstract

To provide a stator for an axial gap motor that can be manufactured at low cost through a process with good work efficiency, efficient use of materials, and little waste of materials without going through the processes of press punching and stacking soft magnetic ribbons one by one.SOLUTION: A ribbon-shaped soft magnetic ribbon is coated with an adhesive and wound, or the ribbon-shaped soft magnetic ribbon is wound and then impregnated with adhesive to form a cylindrical laminated soft magnetic ribbon, and a portion of the ribbon-shaped soft magnetic ribbon is ground into a concave shape, with the remaining convex portions being used as teeth, and the portions not ground remain integral with the teeth as back cores, and windings are applied to the teeth to manufacture a stator for an axial gap type motor.SELECTED DRAWING: Figure 1
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Description

[Technical field]

[0001] The present invention relates to a stator for an axial gap motor that is manufactured by three-dimensionally processing a wound soft magnetic ribbon. [Background technology]

[0002] Motor losses include copper loss, iron loss, and mechanical loss, but the main loss is iron loss, which depends on the soft magnetic material used. In general motors, soft magnetic steel sheets are used in the iron core. Soft magnetic materials include high-performance materials such as amorphous materials and nanocrystalline materials, which have higher magnetic permeability and lower hysteresis loss than magnetic steel sheets, but these materials are very thin, at only 0.025 mm thick, and have low eddy current loss. Nanocrystalline materials also have low rigidity and are brittle, which poses many manufacturing challenges, making it difficult to create an energy-efficient motor with low loss.

[0003] Moreover, the stator core of a motor, generator, etc. is constructed by connecting teeth with a back core. In order to reduce iron loss, stators made from electromagnetic steel sheets are made by press-punching thin soft magnetic ribbons with a thickness of 1 mm or less, then assembling them, stacking them, and assembling them to create stators for motors and generators. Axial gap motors use stators made by compressing insulating coated iron powder into compacted form, allowing stators of any three-dimensional shape to be formed in a single press. Compared to radial gap motors made from electromagnetic steel sheets, they are thinner, have greater torque, higher output, and are more energy efficient, but they have higher production costs. An axial gap motor has been put to practical use by cutting an amorphous ribbon into strips of different ribbon widths, stacking them to make only the teeth portion, forming a stator, and sandwiching the stator between a rotor via a gap (Non-Patent Document 1). However, because the teeth do not have a back core, it is difficult to dissipate heat when current is passed through the stator, and there remains the problem that efficiency decreases when a motor with a one-stator, one-rotor structure is made to make the motor thinner. Currently, compared to electromagnetic steel sheets, the soft magnetic properties of the materials are better in the order of pressed powder, amorphous ribbon, and nanocrystalline ribbon, and the eddy current loss is also lower, resulting in lower energy loss in the manufactured stator.

[0004] The process of manufacturing a stator by pressing electromagnetic steel sheets requires high power costs, and requires the steps of laminating the teeth and back core and assembling them in a circumferential shape to create the stator. Stators made from dust cores using fine powder of pure iron or soft magnetic alloys with high saturation magnetic flux density have the advantage of having lower energy loss than electromagnetic steel sheets. However, the production costs are high because of the processes required to prepare the fine powder, press it using a press mold, harden it, and sinter it. Amorphous block cores are commercially available, and it is possible to use wire cutting to machine them into the shape of a stator in which the teeth and back core of a motor are integrated, making a prototype; however, this method takes a long time to manufacture and there are also cost issues, so no motor prototypes have been made so far. As described above, conventional methods for manufacturing stators have both advantages and disadvantages, and various improvements have been reported.

[0005] In Patent Document 1, the amorphous alloy ribbon is thin and hard, and conventional press punching is not suitable for producing stators because the life of the die is short when using the amorphous alloy ribbon. However, the design of the punching die has been revised, making it possible to press punch the amorphous ribbon in the same way as conventional electromagnetic steel sheets. As a result, it has become possible to produce stators from the amorphous ribbon using the same method as electromagnetic steel sheets.

[0006] In general, the stator core of a motor or generator is constructed by integrating the teeth and the back core, but in Patent Document 2, the stator is made only of the teeth portion, which is the magnetic field generating portion, without the back core. In order to improve the efficiency of the stator, it is sandwiched in two places by the rotor with gaps on both sides. The stator core of the axial gap motor is formed into a sector shape by winding a ribbon-shaped amorphous alloy. The amorphous alloy ribbon is wound and then cut perpendicular to the lamination surface to create the teeth.

[0007] In Patent Document 3, a radial gap type stator is manufactured by constructing both the teeth core and the adjacent back core from a laminated body in which a foil strip of a soft magnetic material is cut one by one and then laminated together. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Patent No. 7129048 [Patent Document 2] JP 2009-284578 A [Patent Document 3] JP 2023-087409 A [Non-patent literature]

[0009] [Non-Patent Document 1] Yuji Enomoto and two others, "Development and Practical Application of Energy-Saving Industrial Motors Using Amorphous Magnetic Alloy Foils," [online], June 26, 2020, [Retrieved October 18, 2023], Internet<URL:https: / / www.sgkz.or.jp / prize / science / report / index_52_03.html> Summary of the Invention [Problem to be solved by the invention]

[0010] The object is to provide a stator that can be manufactured at low cost through a process that is efficient in the use of materials and work, without going through the processes of press punching or stacking soft magnetic ribbons one by one, and that reduces material waste. Another object is to provide an axial gap motor that uses the stator and is thin and has good magnetic properties. [Means for solving the problem]

[0011] The stator for an axial gap type motor according to the present invention is characterized in that a cylindrical laminated soft magnetic ribbon is formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, and then grinding a portion of the cylindrical laminated soft magnetic ribbon into a concave shape, the remaining convex portion being used as a tooth, and the portion not ground remains integral with the tooth as a back core, and a winding is applied to the tooth to form a stator.

[0012] The stator for an axial gap type motor according to the present invention is characterized in that a cylindrical laminated soft magnetic ribbon formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, is used as a back core, a cylindrical laminated soft magnetic ribbon formed by separately applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, is cut in the cylindrical axial direction, and a plurality of fan-shaped bodies are used as teeth, the plurality of teeth are brought into contact with the cylindrical back core to connect a magnetic circuit, and the plurality of teeth are wound to form a stator. Effect of the Invention

[0013] Compared to existing work processes, the stator for an axial gap motor is manufactured by processing the laminated surface of a cylindrical laminated soft magnetic ribbon wound with an amorphous alloy ribbon, a nanocrystalline alloy ribbon, and these composite soft magnetic ribbons to form teeth, which improves productivity by simplifying the structure and reduces production costs by reducing the amount of waste of materials used. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 is a diagram showing a process for manufacturing a stator in which a back core and a plurality of teeth are integrally formed according to the first embodiment. [Diagram 2] FIG. 2 is a diagram showing an axial gap motor including one stator and one rotor according to a second embodiment. [Diagram 3]FIG. 3 is a diagram showing a process for producing a stator including a plurality of teeth connected to a back core according to the third embodiment. [Figure 4] FIG. 4 is a diagram showing a separate manufacturing process for manufacturing a stator including a plurality of teeth connected to a back core according to the third embodiment. [Diagram 5] FIG. 5 is a cross-sectional view of a structure according to a third embodiment in which a cylindrical laminated soft magnetic ribbon for guide is provided on the outside of a cylindrical laminated soft magnetic ribbon for back core. [Figure 6] FIG. 6 is a diagram showing an axial gap motor according to a fourth embodiment, which is composed of one rotor and one stator without using magnets. [Figure 7] FIG. 7 is a diagram showing a manufacturing process of a rotor for an axial gap motor composed of two stators and one rotor according to the fifth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the mode for carrying out the present invention will be described in detail with reference to the drawings by way of examples. EXAMPLES

[0016] FIG. 1a shows a cylindrical laminated soft magnetic ribbon 1 formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive. As the soft magnetic ribbon, an amorphous alloy ribbon, a nano-alloy ribbon, or a composite soft magnetic ribbon of these can be used. A part of the cylindrical laminated soft magnetic ribbon 1 shown in FIG. 1a is ground into a concave shape, and the remaining convex part is used as the tooth 3, and the part that was not ground is used as the back core 2, and the back core 2 and multiple teeth 3 are three-dimensionally processed together to form FIG. 1b. A coil is wound around the teeth 3 to form a stator 5. This stator 5 is used for an axial gap motor 4. FIG. 1b is composed of two (two pole) teeth 3, but the number of poles can be increased appropriately depending on the motor, and a teeth configuration can be used. Stator parts with good material usage efficiency and work efficiency can be manufactured. EXAMPLES

[0017] 2 shows an axial gap motor 4 composed of a stator 5 produced by the method of Example 1 and a rotor 6 produced separately. The back core 2 and teeth 3 of the stator 5 are integrally formed by three-dimensional machining, and the teeth 3 are wound with windings 7. The height of the back core 2 is preferably about half the width of the teeth 3. The stator 5 and the rotor 6 are connected by a rotating shaft 9 and a bearing 10. A normal magnet 8 is disposed on the back core 2 of the rotor 6 in contact therewith. The axial gap motor with one stator and one rotor in Fig. 2 is an integrated type, so there is no boundary between the teeth 3 and the back core 2 (yoke), and high performance is possible because a high performance soft magnetic ribbon is used. In addition, the motor structure is simple, so there are few processes for manufacturing. As with the one stator, one rotor axial gap motor, it is also possible to make a two stator, one rotor axial gap motor by arranging a stator 5 produced by the method of Example 1 by three-dimensionally processing a cylindrical laminated soft magnetic ribbon wound around both sides of a rotor. By using two stators, it is possible to fully utilize the performance of the magnet of the rotor.

[0018] By implementing the embodiment described in Example 1, heat dissipation from the back core is achieved compared to the case of only teeth, and the heat dissipation efficiency of the windings is improved. A large current can be passed through the coil, so high power density can be achieved. A stator can be formed simply by cutting a cylindrical laminated soft magnetic ribbon and winding a coil around the teeth, resulting in a highly productive and high-performance motor. As amorphous ribbon and nanocrystalline ribbon can be used as the soft magnetic ribbon, it is possible to achieve high motor efficiency by reducing iron loss, and a compact and high power density motor by increasing motor speed. EXAMPLES

[0019] A cylindrical laminated soft magnetic ribbon 1 is produced as shown in FIG. 3a by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, and used for the back core 2. Similarly, a cylindrical laminated soft magnetic ribbon 1 is produced as shown in FIG. 3b by applying adhesive to a ribbon-shaped soft magnetic ribbon whose ribbon width is the height of the teeth 3, and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive. Next, the cylindrical laminated soft magnetic ribbon 1 is cut in multiple places along the cutting surface 11 in the cylindrical axial direction to extract multiple teeth 3. The cylindrical laminated soft magnetic ribbon 1 in FIG. 3a is used as the back core 2, and multiple teeth 3 are connected to the back core 2 by contacting them. It is important to connect the teeth 3 and the back core 2 as a magnetic circuit, and there are several methods for reliably contacting, connecting, and fixing them, such as making grooves in the back core 2, gluing, and tightening with a ring. The windings 7 are wound around the teeth 3 to form the three-dimensionally processed stator 5. The three-dimensional processing results in almost no material loss, making it possible to manufacture the stator 5 at low cost.

[0020] As shown in FIG. 4a, a cylindrical laminated soft magnetic ribbon 1 is formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, and then completely cutting it at multiple points along the cutting surface 11 in the cylindrical axis direction to be used for the back core 2. Similarly, as shown in FIG. 4b, a cylindrical laminated soft magnetic ribbon 1 is formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, and then cutting it at multiple points along the cutting surface 11 in the cylindrical axis direction to take out multiple teeth 3. The multiple teeth 3 may be connected to the back core 2 as shown in FIG. 4c by fitting the multiple teeth 3 into the cut parts of the cylindrical laminated soft magnetic ribbon 1 in FIG. 4a. In this case, the remainder obtained by subtracting the height of the cylindrical laminated soft magnetic ribbon 1 in FIG. 4a from the height of the cylindrical laminated soft magnetic ribbon 1 in FIG. 4b acts as the actual teeth 3 protruding from the back core 2.

[0021] Furthermore, after producing a cylindrical laminated soft magnetic ribbon 1 as a back core 2 by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, a ribbon-shaped soft magnetic ribbon wider than the width of the cylindrical laminated soft magnetic ribbon 1 is applied with adhesive and wound around the outside of the cylindrical laminated soft magnetic ribbon 1, or the ribbon-shaped soft magnetic ribbon is wound and then impregnated with adhesive to form a guide cylindrical laminated soft magnetic ribbon 12, as shown in Figure 5.When bringing the teeth 3 into contact with the back core 2, the guide cylindrical laminated soft magnetic ribbon 12 can be used as an outer guide, making the work easier.

[0022] Using the stator 5 manufactured by the above method and a rotor 6 manufactured separately, a one-stator, one-rotor axial gap motor 4 can be constructed. The configuration is the same as that shown in FIG. Also, it is possible to obtain a two-stator, one-rotor type axial gap motor 4 in which the stators 5 manufactured by the above method are disposed on both sides of the magnet 8 of the rotor 6 without the back core 2. The two-stator, one-rotor axial gap motor 4 has the characteristic that by passing current through the teeth 3 on both sides, it is possible to apply to the rotor 6 a magnetic field that is approximately twice as strong as that in the case of teeth 3 on one side.

[0023] By implementing the embodiment of Example 3, the cylindrical laminated soft magnetic ribbon 1 can be used as the back core 2, and the teeth 3 can be made by cutting the cylindrical laminated soft magnetic ribbon 1, so that the stator 5 can be made simply by assembling and contacting them, and the motor can be manufactured at low cost. In addition, the production equipment can be made inexpensively, and productivity can be improved. Since an amorphous ribbon or a nanocrystalline ribbon can be used as the soft magnetic ribbon, it is possible to realize high efficiency motors by reducing iron loss, and small size and high output density by increasing the motor speed. EXAMPLES

[0024] The method for producing the stator 5 used in the first embodiment is also applied to the rotor 6, and a rotor 6 without magnets 8 is produced. That is, an adhesive is applied to a ribbon-shaped soft magnetic ribbon having a ribbon width equal to the sum of the height of the teeth 3 and the height of the back core 2, and the ribbon-shaped soft magnetic ribbon is wound, or the ribbon-shaped soft magnetic ribbon is wound and then impregnated with an adhesive to form a cylindrical laminated soft magnetic ribbon 1 as shown in FIG. 1a. A part of the lamination surface of the cylindrical laminated soft magnetic ribbon 1 is ground into a concave shape, and the remaining convex parts become the teeth 3, and the parts that are not ground become the back core 2, resulting in a state shown in FIG. 1b in which the back core 2 and the multiple teeth 3 are three-dimensionally processed as one body. The rotor 6 is produced without windings on the teeth 3.

[0025] In addition, the method of producing the stator 5 used in the third embodiment is also applied to the rotor 6, and the rotor 6 without the magnet 8 is produced. A cylindrical laminated soft magnetic ribbon 1 is produced as shown in FIG. 3a by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive. Similarly, a cylindrical laminated soft magnetic ribbon 1 is produced as shown in FIG. 3b by applying adhesive to a soft magnetic ribbon whose ribbon width is the height of the teeth 3 and winding it, or by winding the soft magnetic ribbon and then impregnating it with adhesive. Next, the cylindrical laminated soft magnetic ribbon 1 is cut in the cylindrical axial direction along the cut surface 11 in FIG. 3b at multiple locations to extract multiple teeth 3. The cylindrical laminated soft magnetic ribbon 1 in FIG. 3a is used as the back core 2, and multiple teeth 3 are brought into contact with the back core 2 to connect the magnetic circuit. The rotor 6 is produced without winding the teeth 3.

[0026] Combining the stator 5 of the first or third embodiment with the rotor 6 of paragraph 0024 or 0025 results in a one-stator, one-rotor type axial gap motor 4 as shown in FIG. 6, which is a switched reluctance motor. There are four possible combinations of the stator 5 produced by the method of embodiment 1 or 3 and the rotor 6 of paragraph 0024 or 0025, and any of them may be used. EXAMPLES

[0027] To construct a two-stator, one-rotor axial gap type switched reluctance motor, the rotor 6 is fabricated using the method shown in FIG. That is, a cylindrical laminated soft magnetic ribbon 1 is formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, as shown in FIG. 7a. Both sides of the cylindrical laminated soft magnetic ribbon 1 are ground into a concave shape, and the remaining convex parts are made into teeth 3, and the parts that are not ground are made into back core 2, and the back core 2 and multiple teeth 3 are three-dimensionally processed as one unit, as shown in FIG. 7b. The teeth 3 are not wound, and become the rotor 6 as it is. This integrated rotor is preferable because the rotor 6 constituting the two-stator, one-rotor axial gap type switched reluctance motor is subjected to external forces such as centrifugal force. FIG. 7b shows a three-dimensionally processed rotor 6 composed of two sets of teeth with two poles on each side of the back core 2, but the number of poles may be increased as appropriate depending on the motor.

[0028] However, a rotor 6 for a small motor may be manufactured by using a cylindrical laminated soft magnetic ribbon 1 formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, as the back core 2, and cutting a cylindrical laminated soft magnetic ribbon 1, which is separately formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding a ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, in the cylindrical axial direction to obtain a plurality of fan-shaped bodies as teeth 3, and bringing the plurality of teeth 3 into contact with both sides of the cylindrical back core 2 to connect the magnetic circuits. [Industrial Applicability]

[0029] According to the present invention, the stators and rotors of motors and generators can be manufactured by cutting the cylindrical laminated soft magnetic ribbon formed by winding, either directly or by partially processing the cut parts, which reduces the number of steps required for lamination and significantly reduces material waste, compared to the current punching method and the method of cutting one by one. This has great industrial applicability, as it makes it possible to use motors and generators that are smaller, more productive, lower cost, and more energy efficient than before. [Explanation of symbols]

[0030] 1 Cylindrical laminated soft magnetic ribbon 2. Backcore 3 Teeth 4 Axial Gap Motor 5 Stator 6 Rotor 7 Windings 8. Magnets 9 Rotation Axis 10 Bearings 11 Cut surface 12 Cylindrical laminated soft magnetic ribbon for guides

Claims

1. A stator for an axial gap type motor, characterized in that a ribbon-shaped soft magnetic ribbon is coated with adhesive and wound, or the ribbon-shaped soft magnetic ribbon is wound and then impregnated with adhesive to form a cylindrical laminated soft magnetic ribbon, a portion of which is ground into a concave shape, the remaining convex portions being used as teeth, and the portions not ground remain integral with the teeth as back cores, and windings are applied to the teeth to form a stator.

2. 2. An axial gap motor comprising one stator for an axial gap motor according to claim 1 and one rotor that is separately manufactured.

3. The rotor is formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, and then grinding a portion of the cylindrical laminated soft magnetic ribbon into a concave shape, with the remaining convex portion being the teeth, and the portion not ground being a back core that is manufactured integrally with the teeth.

4. 3. The axial gap motor according to claim 2, characterized in that the rotor is manufactured by using a cylindrical laminated soft magnetic ribbon formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, as a back core, and cutting a cylindrical laminated soft magnetic ribbon formed by separately applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, in the cylindrical axial direction, to obtain a plurality of fan-shaped bodies, as teeth, and by bringing the plurality of teeth into contact with the cylindrical back core to connect a magnetic circuit.

5. 2. An axial gap motor comprising: two stators for an axial gap motor according to claim 1 arranged on either side of a rotor fabricated separately.

6. The rotor is formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, and then grinding both sides of the cylindrical laminated soft magnetic ribbon into a concave shape, the remaining convex portions being used as teeth, and the central portion that is not ground is manufactured integrally with the teeth as a back core.

7. 6. The axial gap motor according to claim 5, wherein the rotor is manufactured by using a cylindrical laminated soft magnetic ribbon formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, as a back core, and cutting a cylindrical laminated soft magnetic ribbon formed by separately applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, in the axial direction of the cylinder, into a plurality of fan-shaped bodies, as teeth, and by bringing the plurality of teeth into contact with both sides of the cylindrical back core to connect magnetic circuits.

8. A stator for an axial gap type motor, characterized in that a cylindrical laminated soft magnetic ribbon formed by applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, is used as a back core, a cylindrical laminated soft magnetic ribbon formed by separately applying adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with adhesive, is cut in the cylindrical axial direction to obtain a plurality of fan-shaped bodies, which are used as teeth, the plurality of teeth are brought into contact with the cylindrical back core to connect a magnetic circuit, and the plurality of teeth are wound to form a stator.

9. The stator for an axial gap type motor according to claim 8, characterized in that after the cylindrical laminated soft magnetic ribbon is used as the back core, a ribbon-shaped soft magnetic ribbon wider than the width of the back core is coated with adhesive and wound around the outside of the back core, or the ribbon-shaped soft magnetic ribbon is wound and then impregnated with adhesive to form a guide cylindrical laminated soft magnetic ribbon, which serves as a guide when the multiple teeth come into contact with the cylindrical back core.

10. 9. The stator for an axial gap type motor according to claim 8, characterized in that the method of contacting the plurality of teeth with the cylindrical back core comprises cutting the back core in a cylindrical axial direction at a plurality of locations and fitting the plurality of teeth into the cut core to contact the back core.

11. 11. An axial gap motor comprising one stator for an axial gap motor according to claim 8 and one rotor that is separately manufactured.

12. The rotor is formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, and then grinding a portion of the cylindrical laminated soft magnetic ribbon into a concave shape, with the remaining convex portion being the teeth, and the portion not ground being made into a back core integral with the teeth.

13. 12. The axial gap motor according to claim 11, wherein the rotor is manufactured by using a cylindrical laminated soft magnetic ribbon formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, as a back core, and cutting a cylindrical laminated soft magnetic ribbon formed by separately applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, in the cylindrical axial direction, to obtain a plurality of fan-shaped bodies, as teeth, and by bringing the plurality of teeth into contact with the cylindrical back core to connect a magnetic circuit.

14. 11. An axial gap motor, comprising: two stators for an axial gap motor according to claim 8, arranged on either side of a rotor fabricated separately.

15. The axial gap motor according to claim 14, characterized in that the rotor is manufactured by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, grinding both sides of the cylindrical laminated soft magnetic ribbon into a concave shape, making the remaining convex portions into teeth, and the central portion that is not ground into a back core, which is manufactured integrally with the teeth.

16. 15. The axial gap motor according to claim 14, wherein the rotor is manufactured by using a cylindrical laminated soft magnetic ribbon formed by applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, as a back core, and cutting a cylindrical laminated soft magnetic ribbon formed by separately applying an adhesive to a ribbon-shaped soft magnetic ribbon and winding it, or by winding the ribbon-shaped soft magnetic ribbon and then impregnating it with an adhesive, in the cylindrical axial direction, into a plurality of fan-shaped bodies, as teeth, and by bringing the plurality of teeth into contact with both sides of the cylindrical back core to connect magnetic circuits.

Citation Information

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