Rotor structure

Abstract

To provide a rotor structure capable of suppressing a decrease in the flux value of a magnet and a resulting decrease in rotor performance while minimizing the amount of resin required to fix a magnet.SOLUTION: A rotor structure includes a magnet 30 fixed to a magnet accommodating portion 26 provided in a rotor core, the magnet 30 has a polyhedral shape with a plurality of constituent faces, and a resin accommodating portion 34 that accommodates a resin on the surface of at least one of the constituent faces before being accommodated in the magnet accommodating portion 26, and the magnet 30 and rotor core 20 are joined inside the magnet accommodating portion 26 via the resin accommodated in the resin accommodating portion 34.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a rotor structure.

Background Art

[0002] Conventionally, a permanent magnet embedded type rotor as disclosed in Patent Document 1 below, a method for manufacturing the rotor, and the like have been provided. In the method for manufacturing the permanent magnet embedded type rotor disclosed in this document, a nozzle is inserted through a hole portion of a sealing steel plate and brought into contact with a step portion which is an end surface on one end side of the permanent magnet and an end surface on one end side of the steel plate laminate, and while restricting the axial position of the permanent magnet, resin is filled into a gap between the magnet insertion hole and the permanent magnet.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the prior art according to Patent Document 1 above, in order to fix a magnet in a rotor core, a resin material is poured into a through hole of the rotor core through a mold and hardened. In such a configuration, since the resin material used to seal the magnet remains in the upper mold or the like, there is a problem that the manufacturing cost increases. Further, in the case of the configuration as in Patent Document 1 above, since resin is filled when fixing the magnet, heat tends to accumulate in the vicinity of the magnet during use, leading to a decrease in the flux value of the magnet, which may cause a decrease in the performance of the rotor. Therefore, in the case of the configuration of the prior art of Patent Document 1 above, in order to avoid a decrease in the performance of the rotor due to a decrease in the flux value of the magnet, an expensive magnet must be employed.

[0005] Therefore, an object of the present invention is to provide a rotor structure capable of suppressing a decrease in the flux value of a magnet and a resulting decrease in the performance as a rotor while minimizing the amount of resin required for fixing the magnet.

Means for Solving the Problems

[0006] (1) The rotor structure of the present invention includes a magnet fixed to a magnet housing portion provided in a rotor core. The magnet has a polyhedral shape with a plurality of constituent surfaces, and at least one of the constituent surfaces has a resin housing portion for housing resin before being housed in the magnet housing portion. The magnet and the rotor core are joined inside the magnet housing portion through the resin housed in the resin housing portion.

[0007] The rotor structure of the present invention can suppress the resin remaining in a mold or the like as in the prior art, so that the amount of resin required for fixing the magnet can be minimized. Further, the rotor structure of the present invention can minimize the heat accumulation in the vicinity of the magnet when the magnet is used. Thereby, the rotor structure of the present invention can suppress a decrease in the flux value of the magnet caused by heat accumulation in the vicinity of the magnet during manufacturing and a resulting decrease in the performance as a rotor as compared with the prior art.

[0008] (2) It is preferable that the rotor structure of the present invention is characterized in that a gap is formed on the side of the magnet in the magnet housing portion.

[0009] By configuring the rotor structure of the present invention as described in (2) above, a gap is formed on the side of the magnet in the magnet housing portion where resin is not filled or fixed, and the magnet is exposed to the gap. Therefore, by configuring the rotor structure of the present invention as described in (2) above, the magnet can be air-cooled by utilizing the aforementioned gap, or the magnet can be cooled by passing water or oil through the gap. Accordingly, by configuring the rotor structure of the present invention as described in (2) above, it is possible to suppress a decrease in the flux value of the magnet and a resulting decrease in the performance as a rotor, or to avoid using a high-performance magnet considering a decrease in the flux value of the magnet.

[0010] (3) The rotor structure of the present invention is preferably characterized in that the magnet housing portion has a joint surface joined to the magnet via the resin, and the resin housing portion is formed so as to be able to leach the resin toward the joint surface.

[0011] By configuring the rotor structure of the present invention as described in (3) above, directivity can be given to the leaching direction of the resin housed in the resin housing portion, and the resin can be surely leached toward the joint surface. Therefore, by configuring the rotor structure of the present invention as described in (3) above, it is possible to suppress the resin from leaching to locations other than the joint surface and to join the magnet to the joint surface with a minimum amount of resin.

[0012] (4) The rotor structure of the present invention preferably has at least a first resin housing portion provided on a first configuration surface which is one of the configuration surfaces, and a second resin housing portion provided on a second configuration surface facing the first configuration surface, and the magnet and the rotor core are joined inside the magnet housing portion via the resin housed in the first resin housing portion and the resin housed in the second housing portion.

[0013] By configuring the rotor structure of the present invention as described in (4) above, magnets can be joined to the magnet housing portion on a pair of first and second opposing constituent surfaces that form the magnets. As a result, the rotor structure of the present invention can join the magnets to the rotor core with high strength using a minimum amount of resin.

[0014] (5) It is preferable that the rotor structure of the present invention is characterized in that the first resin housing portion and the second resin housing portion communicate with each other.

[0015] By configuring the rotor structure of the present invention as described in (5) above, resin can be spread over both the first resin housing portion and the second resin housing portion, and the magnets can be joined to the rotor core with high strength.

[0016] (6) A method for manufacturing the rotor structure of the present invention is a method for manufacturing a rotor structure having a magnet fixed to a magnet housing portion provided in a rotor core, wherein the magnet has a polyhedral shape having a plurality of constituent surfaces, and at least one resin housing portion for housing resin before housing in the magnet housing portion is provided on the surface layer of the constituent surface. A magnet preparation step of preparing a magnet, a resin setting step of housing resin in the resin housing portion of the magnet prepared in the magnet preparation step, a magnet housing step of housing the magnet in which the resin has been housed in the resin housing portion in the magnet housing portion, and a joining step of joining the magnet and the rotor core inside the magnet housing portion via the resin housed in the resin housing portion.

[0017] The manufacturing method of the rotor structure of the present invention can securely fix the magnet to the rotor core while suppressing the resin from remaining in the mold or the like as in the prior art. Thereby, the manufacturing method of the rotor structure of the present invention can minimize the amount of resin required for fixing the magnet. Further, the manufacturing method of the rotor structure of the present invention can minimize the heat accumulation in the vicinity of the magnet during use as compared with the prior art method. Thereby, according to the manufacturing method of the rotor structure of the present invention, a rotor structure can be manufactured that suppresses a decrease in the magnetic flux value of the magnet caused by heat accumulation in the vicinity of the magnet during use and a decrease in the performance as a rotor caused thereby as compared with the prior art one.

Effect of the Invention

[0018] According to the present invention, it is possible to provide a rotor structure and a manufacturing method of the rotor structure that solve the above-described problems.

Brief Description of the Drawings

[0019]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiment for Carrying Out the Invention

[0020] Hereinafter, a rotor structure 10 according to an embodiment of the present invention and a method for manufacturing the rotor structure 10 will be described in detail with reference to the drawings. In the following description, first, the configuration of the rotor structure 10 will be described, and then the operation of the rotor structure 10 will be described. It should be noted that each figure is schematically shown for easy understanding, and there may be cases where it is different from the actual shape, size, and arrangement of components. Also, note that hatching may be omitted in the cross-section of each figure.

[0021] ≪Configuration of Rotor Structure 10≫ The rotor structure 10 of the present embodiment is for constituting an electric motor in combination with a separately provided stator (not shown) or the like. As shown in FIG. 1, FIG. 2, etc., the rotor structure 10 includes a rotor core 20 and a magnet 30.

[0022] The rotor core 20 is formed by laminating a plurality of steel plates having a substantially donut shape in a front view. The rotor core 20 can be configured by stacking a plurality of rotor core pieces each formed of a laminated body of electromagnetic steel plates, for example. The rotor core 20 has a shaft insertion hole 22 for inserting a shaft 12 at the axial center position (radial center portion). Further, the rotor core 20 is provided with a plurality of magnetic pole portions 24 in the circumferential direction at the periphery of the shaft insertion hole 22. In the present embodiment, the rotor core 20 is provided with eight magnetic pole portions 24 at the periphery of the shaft insertion hole 22. The rotor core 20 is configured such that magnets 30, 30 having different magnetization directions are arranged at the circumferentially adjacent magnetic pole portions 24, 24, so that the magnetic poles are alternately reversed in the circumferential direction.

[0023] As shown in FIGS. 1 to 3, in the rotor core 20, a magnet accommodating portion 26 for accommodating the magnet 30 is provided in a portion forming the magnetic pole portion 24. The magnet accommodating portions 26 may be provided one by one in each magnetic pole portion 24, but it is preferable to provide a plurality (three in this embodiment) as shown in the illustrated example. The magnet accommodating portion 26 may be any as long as it can accommodate the magnet 30. In this embodiment, it is constituted by a hole penetrating in the axial direction of the rotor core 20 (the penetrating direction of the shaft insertion hole 22).

[0024] The magnet accommodating portion 26 is such that the opening shape and the cross-sectional shape are both longer in one direction (hereinafter also referred to as the “longitudinal direction”) than in the direction intersecting therewith (hereinafter also referred to as the “lateral direction”). The length of the magnet accommodating portion 26 in the lateral direction is sufficiently larger than the length of the side (hereinafter also referred to as the “first side 30a”) intersecting the second side 30b of the magnet 30, and the length in the lateral direction is equal to or slightly larger than the length of one side of the magnet 30 (hereinafter also referred to as the “second side 30b”) which will be described in detail later. Among the inner surfaces forming the magnet accommodating portion 26, those formed to expand in the longitudinal direction are the joint surfaces 26a, 26a joined to the magnet 30. Further, among the inner surfaces forming the magnet accommodating portion 26, the surfaces formed to expand in the lateral direction at both ends in the longitudinal direction are non-joint surfaces 26c, 26d not used for joining to the magnet 30.

[0025] As shown in FIG. 2 and the like, in a state where the rotor core 20 is viewed from the front, one of the three magnet accommodating portions 26 constituting one magnetic pole portion 24 is open in a shape extending in the tangential direction of the rotor core 20 at the circumferential intermediate portion with respect to the remaining two magnet accommodating portions 26, 26. Further, among the three magnet accommodating portions 26 constituting one magnetic pole portion 24, the two magnet accommodating portions 26, 26 located on the circumferential side portions are located more radially inward of the rotor core 20 than the magnet accommodating portion 26 located at the circumferential central portion, and extend from the radially inner side to the outer side and are arranged so as to expand in a “C” shape.

[0026] The magnet 30 is assumed to have a polyhedral shape with a plurality of constituent surfaces. In the present embodiment, as shown in FIG. 4, the magnet 30 has an elongated shape extending in a rod shape. The magnet 30 is assumed to have a substantially identical rectangular cross-sectional shape at any position in the longitudinal direction. The magnet 30 is such that the length of the first side 30a extending in the longitudinal direction in the cross-sectional shape is smaller than the length in the longitudinal direction of the opening region forming the magnet housing portion 26 of the rotor core 20. Further, the magnet 30 is such that the length of the second side 30b extending in the short direction in the cross-sectional shape is equal to or slightly smaller than the length in the short direction of the opening region forming the magnet housing portion 26 of the rotor core 20.

[0027] The magnet 30 has a first constituent surface 32a and a second constituent surface 32b that extend along the first side 30a. The first constituent surface 32a and the second constituent surface 32b are in a positional relationship of facing each other. Further, the magnet 30 has a third constituent surface 32c and a fourth constituent surface 32d that extend along the second side 30b. The third constituent surface 32c and the fourth constituent surface 32d are in a positional relationship of facing each other.

[0028] As shown in FIGS. 4 and 5, the magnet 30 has resin housing portions 34 (first resin housing portion 34a, second resin housing portion 34b) on the first constituent surface 32a and the second constituent surface 32b. The resin housing portion 34 is a portion provided for previously housing the resin 50 before housing and fixing the magnet 30 in the magnet housing portion 26 of the rotor core 20. The resin housing portion 34 is formed so that the resin 50 can ooze out toward the joint surface of the magnet housing portion in a state where the magnet 30 is housed in the magnet housing portion 26 of the rotor core 20. In the present embodiment, the resin housing portions 34 (first resin housing portion 34a, second resin housing portion 34b) are provided so as to open outward on the surface layers of the first constituent surface 32a and the second constituent surface 32b.

[0029] The first resin storage portion 34a and the second resin storage portion 34b can be constituted by recesses or holes formed in the surface layers of the first configuration surface 32a and the second configuration surface 32b. In the present embodiment, the first resin storage portion 34a and the second resin storage portion 34b are constituted by through holes penetrating across the first configuration surface 32a and the second configuration surface 32b. Therefore, the first resin storage portion 34a and the second resin storage portion 34b communicate with each other. Also, the first resin storage portion 34a and the second resin storage portion 34b can each be constituted by a single hole or recess, but it is preferable that they are constituted by a plurality of holes or recesses. In the present embodiment, the first resin storage portion 34a and the second resin storage portion 34b are constituted by a number of holes as shown in FIG. 4. Further, the first resin storage portion 34a and the second resin storage portion 34b can be provided in an appropriate arrangement on the first configuration surface 32a and the second configuration surface 32b, but in the present embodiment, they are provided substantially evenly over substantially the entire first configuration surface 32a and the second configuration surface 32b.

[0030] The magnet 30 is inserted into and fixed to the magnet accommodation portion 26 of the rotor core 20. Specifically, as shown in FIGS. 3 and 5(c), (d), etc., the magnet 30 is oriented such that the short side direction is in the short side direction of the magnet accommodation portion 26 and the long side direction is in the long side direction of the magnet accommodation portion 26, and is inserted from the open end of the magnet accommodation portion 26. Thereby, the first configuration surface 32a and the second configuration surface 32b of the magnet 30 are in a state of facing the joint surfaces 26a, 26a of the magnet accommodation portion 26 with substantially no gap. Also, the magnet 30 is inserted at the longitudinal intermediate portion of the magnet accommodation portion 26. Thereby, a gap 40 is formed between the lateral sides on one side and the other side in the longitudinal direction of the magnet 30, that is, the third configuration surface 32c and the fourth configuration surface 32d, and the inner peripheral surface of the magnet accommodation portion 26. The gap 40 penetrates in the axial direction of the rotor core 20 and is configured to allow air, cooling water, etc. to pass through.

[0031] The magnet 30 is fixed to the magnet housing portion 26 via the resin 50 housed in the first resin housing portion 34a and the second resin housing portion 34b. Specifically, the first resin housing portion 34a and the second resin housing portion 34b house a resin 50 such as, for example, an epoxy resin, a polyurethane resin, an acrylic resin, a phenolic resin, a cyanoacrylate resin, or the like. In the present embodiment, an epoxy resin is housed in the first resin housing portion 34a and the second resin housing portion 34b. The magnet 30 is inserted into the magnet housing portion 26 in a state where the resin 50 is previously housed in the first resin housing portion 34a and the second resin housing portion 34b, and then heated to leach out the resin 50, thereby being joined to the rotor core 20 in a state of being housed inside the magnet housing portion 26.

[0032] ≪Manufacturing Method of Rotor Structure 10≫ Subsequently, the manufacturing method of the rotor structure 10 described above will be explained. The manufacturing method of the rotor structure 10 is characterized by a step of fixing the magnet 30 to the magnet housing portion 26 provided in the rotor core 20. Specifically, the manufacturing method of the rotor structure 10 includes a plurality of steps including a magnet preparation step, a resin setting step, a magnet housing step, and a joining step, and fixes the magnet 30 to the magnet housing portion 26 provided in the rotor core 20.

[0033] The magnet preparation step is a step of preparing the magnet 30 described above. Specifically, the magnet preparation step prepares, as the magnet 30, a polyhedron having a plurality of configuration surfaces including a first configuration surface 32a, a second configuration surface 32b, a third configuration surface 32c, and a fourth configuration surface 32d, and having a resin housing portion 34 for housing the resin 50 provided on the surface layer of at least one configuration surface before being housed in the magnet housing portion 26 of the rotor core 20. In the present embodiment, when manufacturing the magnet 30 by sintering, the first resin housing portion 34a and the second resin housing portion 34b that function as the resin housing portion 34 are provided in advance on the surfaces that will become the first configuration surface 32a and the second configuration surface 32b. In the present embodiment, as shown in FIG. 5(a), a plurality of holes communicating across the first configuration surface 32a and the second configuration surface 32b of the magnet 30 are formed, whereby the resin housing portion 34 (the first resin housing portion 34a, the second resin housing portion 34b) is formed.

[0034] The resin setting step is a step of housing the resin 50 in the resin housing portion 34 of the magnet prepared in the magnet preparation step described above. In the present embodiment, as shown in FIG. 5(b), the resin 50 such as an epoxy resin is housed in the resin housing portion 34 (the first resin housing portion 34a, the second resin housing portion 34b) constituted by the holes communicating across the first configuration surface 32a and the second configuration surface 32b, whereby the resin setting step is completed.

[0035] The magnet housing step is a step of housing the magnet 30 in which the resin 50 is housed in the resin housing portion 34 (the first resin housing portion 34a, the second resin housing portion 34b) in the resin setting step described above in the magnet housing portion 26. As shown in FIG. 5(c), in the magnet housing step, the first configuration surface 32a and the second configuration surface 32b of the magnet 30 face one side and the other side in the short side direction of the magnet housing portion 26, and the third configuration surface 32c and the fourth configuration surface 32d of the magnet 30 face one side and the other side in the long side direction of the magnet housing portion 26, and the magnet 30 is housed in the magnet housing portion 26. Further, the magnet 30 is housed so that gaps 40, 40 are formed between the third configuration surface 32c and the fourth configuration surface 32d and the inner peripheral surface of the magnet housing portion 26.

[0036] The joining step is a step of joining the magnet 30 housed in the magnet housing portion 26 in the magnet housing step to the rotor core 20 inside the magnet housing portion 26 using the resin 50 housed in the resin housing portion 34 of the magnet 30 in the resin setting step. In the present embodiment, the rotor core 20 in a state where the magnet 30 is housed in the magnet housing portion 26 in the magnet housing step is heated or the like to soften the resin 50 made of a thermosetting resin that is solid at normal temperature, and the resin 50 is leached from the resin housing portion 34 as shown in FIG. 5(d). Then, when further heated to cure the resin, the magnet 30 is joined to the rotor core 20. For example, when an epoxy resin is used as the resin 50, the resin 50 that is in a solid state at normal temperature is housed in the resin housing portion 34, and then heated to around 100° C. to soften the resin 50, which can be leached from the resin housing portion 34. Further, when heated to around 180° C., the resin 50 cures, and the magnet 30 is joined to the rotor core 20. Thereby, the manufacturing process of the rotor structure 10 that fixes the magnet 30 to the magnet housing portion 26 provided in the rotor core 20 is completed.

[0037] ≪Function and Effect≫ The rotor structure 10 according to the above-described embodiment and the manufacturing method of the rotor structure 10 have characteristic configurations as shown in the following (a) to (f). Thereby, the rotor structure 10 and the manufacturing method of the rotor structure 10 can exhibit effects peculiar to the present invention.

[0038] (a) The rotor structure 10 of the above embodiment includes a magnet 30 fixed to the magnet housing portion 26 provided in the rotor core 20. The magnet 30 has a polyhedral shape with a plurality of constituent surfaces, and includes a resin housing portion 34 for housing the resin 50 on the surface layer of at least one constituent surface before being housed in the magnet housing portion 26. The magnet 30 and the rotor core 20 are joined inside the magnet housing portion 26 via the resin 50 housed in the resin housing portion 34.

[0039] By configuring the rotor structure 10 as described in (a) above, the amount of resin 50 required for fixing the magnet 30 can be minimized. Further, the rotor structure 10 can minimize the heat accumulation in the vicinity of the magnet 30 when the magnet 30 is used. Thereby, compared with the prior art, the rotor structure 10 can suppress the decrease in the flux value of the magnet 30 caused by heat accumulation in the vicinity of the magnet 30 during manufacturing and the resulting decrease in the performance as a rotor.

[0040] (b) In the above-described rotor structure 10, in the magnet housing portion 26, a gap 40 is formed on the side of the magnet 30.

[0041] By configuring the rotor structure 10 as described in (b) above, a gap 40 in which the resin 50 is not filled or fixed is formed on the side of the magnet 30 in the magnet housing portion 26, and the magnet 30 is exposed to the gap 40. Therefore, by configuring the rotor structure 10 as described in (b) above, the magnet 30 can be air-cooled by utilizing the gap 40, or the magnet 30 can be cooled by passing water or oil through the gap 40. Accordingly, by configuring the rotor structure 10 as described in (b) above, it is possible to suppress the decrease in the flux value of the magnet 30 and the resulting decrease in the performance as a rotor, or to avoid using a high-performance magnet considering the decrease in the flux value of the magnet 30.

[0042] (c) The rotor structure 10 has joint surfaces 26a and 26b where the magnet housing portion 26 is joined to the magnet 30 via the resin 50, and the resin housing portion 34 is formed so as to be able to leach the resin 50 toward the joint surfaces 26a and 26b.

[0043] By configuring the rotor structure 10 as described in (c) above, it is possible to impart directivity to the leaching direction of the resin 50 accommodated in the resin accommodation portion 34 and reliably leach the resin 50 toward the joint surfaces 26a and 26b. Therefore, by configuring the rotor structure 10 as described in (c) above, while suppressing the resin 50 from leaching to locations other than the joint surfaces, the magnet 30 can be joined to the joint surfaces 26a and 26b with a minimum amount of resin 50.

[0044] (d) In the rotor structure 10, the resin accommodation portion 34 has at least a first resin accommodation portion 34a provided on a first configuration surface 32a which is one of the configuration surfaces, and a second resin accommodation portion 34b provided on a second configuration surface 32b facing the first configuration surface 32a. The magnet 30 and the rotor core 20 are joined inside the magnet accommodation portion 26 via the resin 50 accommodated in the first resin accommodation portion 34a and the resin 50 accommodated in the second resin accommodation portion 34b.

[0045] By configuring the rotor structure 10 as described in (d) above, the magnet 30 can be joined to the magnet accommodation portion 26 on a pair of first configuration surface 32a and second configuration surface 32b which face each other and constitute the magnet 30. As a result, the rotor structure 10 can join the magnet 30 to the rotor core 20 with high strength using a minimum amount of resin 50.

[0046] (e) The rotor structure 10 is configured such that the first resin accommodation portion 34a and the second resin accommodation portion 34b communicate with each other.

[0047] By configuring the rotor structure 10 as described in (e) above, the resin 50 can be spread over both the first resin accommodation portion 34a and the second resin accommodation portion 34b, and the magnet 30 can be joined to the rotor core 20 with high strength.

[0048] (f) The manufacturing method of the rotor structure 10 according to the above embodiment is a method for manufacturing a rotor structure 10 including a magnet 30 fixed to a magnet housing portion 26 provided in a rotor core 20. As the magnet 30, a magnet having a polyhedral shape with a plurality of constituent surfaces and provided with a resin housing portion 34 for housing a resin 50 on the surface layer of at least one of the constituent surfaces before being housed in the magnet housing portion 26 is prepared in a magnet preparation step; a resin setting step of housing the resin 50 in the resin housing portion 34 of the magnet 30 prepared in the magnet preparation step; a magnet housing step of housing the magnet 30, in which the resin 50 is housed in the resin housing portion 34 in the resin setting step, in the magnet housing portion 26; and a joining step of joining the magnet 30 and the rotor core 20 inside the magnet housing portion 26 through the resin 50 housed in the resin housing portion 34.

[0049] The manufacturing method of the rotor structure 10 exemplified in the above embodiment can surely fix the magnet 30 to the rotor core 20 while minimizing the amount of the resin 50 used. Further, according to the manufacturing method of the rotor structure 10 described above, it is possible to minimize the heat accumulation in the vicinity of the magnet 30 when using the magnet 30. Thereby, it is possible to manufacture a rotor structure 10 that suppresses a decrease in the flux value of the magnet 30 and a decrease in the performance as a rotor caused thereby.

[0050] ≪Modification Example≫ The above-described rotor structure 10 and the manufacturing method of the rotor structure 10 merely show one embodiment of the present invention, and changes, omissions, additions, etc. in the configuration can be appropriately made without departing from the gist of the present invention. That is, the rotor structure 10 may be any one provided with a resin housing portion 34 on at least one of the plurality of constituent surfaces constituting the magnet 30 as in (a) above, and either one of the first resin housing portion 34a and the second resin housing portion 34b may be omitted, or instead of either one or both of the first resin housing portion 34a and the second resin housing portion 34b, a housing portion for housing the resin 50 may be provided on another constituent surface constituting the magnet 30.

[0051] In addition, the magnet 30 used in the rotor structure 10 described above is provided with a first resin accommodating portion 34a and a second resin accommodating portion 34b each having a number of through holes. However, the present invention is not limited to this, and it is also possible to adopt a configuration in which either one or both of the first resin accommodating portion 34a and the second resin accommodating portion 34b are provided by other means. For example, as shown in FIG. 6, the magnet 30 may be configured such that concave grooves are formed as the first resin accommodating portion 34a and the second resin accommodating portion 34b, and the first resin accommodating portion 34a and the second resin accommodating portion 34b are made non-communicating.

[0052] As described above, in the rotor structure 10, as in (b) above, in the magnet accommodating portion 26, gaps 40, 40 are formed on the sides of the magnet 30. However, the present invention is not limited to this. The rotor structure 10 may be configured such that it does not include either one of the gaps 40, 40 or does not include both of the gaps 40, 40.

[0053] As described above, in the rotor structure 10, as in (c) above, in the magnet accommodating portion 26, the first resin accommodating portion 34a and the second resin accommodating portion 34b are provided so that the resin 50 can ooze out toward the joint surfaces 26a, 26b. However, the present invention is not limited to this. In addition, as described above, in the rotor structure 10, as in (d) above, the first resin accommodating portion 34a and the second resin accommodating portion 34b are provided on the opposing first configuration surface 32a and second configuration surface 32b of the magnet 30, and the magnet 30 is joined to the joint surfaces 26a, 26b of the magnet accommodating portion 26 on the two surfaces of the first configuration surface 32a and the second configuration surface 32b. However, the present invention is not limited to this. For example, the rotor structure 10 described above may be configured such that one of the first resin accommodating portion 34a and the second resin accommodating portion 34b is omitted, and the magnet 30 and the inner peripheral surface of the magnet accommodating portion 26 are joined by the resin 50 on one of the joint surfaces 26a, 26b.

[0054] The above-described rotor structure 10 is manufactured by a manufacturing method having a magnet preparation step, a resin setting step, a magnet accommodation step, and a joining step as described in (f) above. However, the present invention is not limited to this, and it is also possible to be manufactured by a manufacturing method with additional steps or a manufacturing method with some steps omitted.

[0055] The present invention is not limited to the configurations described in the above-described embodiments and the like, and design changes and the like can be appropriately made without departing from the scope of the technical idea of the present invention. The constituent elements of the above-described embodiments and modification examples may be arbitrarily selected and combined. Also, any constituent element of each embodiment and modification example, any constituent element described in the means for solving the problem, the form for implementing the invention, etc., or any constituent element described in the means for solving the problem, the form for implementing the invention, etc., and the constituent elements embodying the arbitrary constituent elements may be arbitrarily combined. Regarding these, there is also an intention to acquire rights in the present application or a divisional application, a change application, etc. based on the present application.

Industrial Applicability

[0056] The present invention can be suitably used in general rotor structures including magnets fixed to magnet accommodation portions provided in a rotor core.

Explanation of Reference Numerals

[0057] 10: Rotor structure 20: Rotor core 26: Magnet accommodation portion 26a: Joining surface 26b: Joining surface 30: Magnet 32a: First configuration surface 32b: Second configuration surface 34: Resin accommodation portion 34a: First resin accommodation portion 34b: Second resin accommodation portion 40: Gap 50: Resin

Claims

1. A rotor structure comprising a magnet fixed to a magnet housing provided in a rotor core, wherein the magnet has a polyhedral shape with a plurality of constituent surfaces, and has a resin housing portion for housing resin on the surface layer of at least one of the constituent surfaces before being housed in the magnet housing portion, and the magnet and the rotor core are joined inside the magnet housing portion through the resin housed in the resin housing portion. A rotor structure characterized by that.

2. The rotor structure according to claim 1, wherein a gap is formed on the side of the magnet in the magnet housing portion.

3. The magnet housing portion has a joining surface joined to the magnet through the resin, The rotor structure according to claim 1 or 2, wherein the resin housing portion is formed so as to be able to leach the resin toward the joining surface.

4. The resin housing portion has at least a first resin housing portion provided on a first constituent surface which is one of the constituent surfaces, and a second resin housing portion provided on a second constituent surface facing the first constituent surface, The rotor structure according to claim 1 or 2, wherein the magnet and the rotor core are joined inside the magnet housing portion through the resin housed in the first resin housing portion and the resin housed in the second housing portion.

5. A method for manufacturing a rotor structure comprising a magnet fixed to a magnet housing provided in a rotor core, a magnet preparation step of preparing, as the magnet, one having a polyhedral shape with a plurality of constituent surfaces and having a resin housing portion for housing resin on the surface layer of at least one of the constituent surfaces before being housed in the magnet housing portion, a resin setting step of housing resin in the resin housing portion of the magnet prepared in the magnet preparation step, A magnet housing step of housing the magnet, which has been housed in the resin housing part in the resin set step, in the magnet housing part; A joining step of joining the magnet and the rotor core inside the magnet housing part through the resin housed in the resin housing part; A method for manufacturing a rotor structure, characterized by comprising the above steps.

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