Apparatus for manufacturing motor core and method for manufacturing motor core

Abstract

To provide an apparatus for manufacturing a motor core and a method for manufacturing a motor core which can suppress losses and filling defects of the resin composition.SOLUTION: An apparatus for manufacturing a motor core includes: a mold for holding a motor core including a resin filling part; a chamber which is formed in the mold, and whose one end communicates with a resin composition filling path communicating with the resin filling part; a plunger for conveying a thermosetting resin composition conveyed to the chamber toward the resin composition filling path; a heater which is arranged in the mold or in the mold and the periphery of the chamber; and an extruder for conveying the resin composition to the chamber while kneading the resin composition so as to charge the resin composition to the chamber, wherein the extruder includes an extrusion conveyance path for conveying the resin composition therein, a screw which is arranged in the extrusion conveyance path and conveys the resin composition while kneading the resin composition, and a first temperature-adjusting mechanism at least a part of which is arranged inside the screw.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an apparatus for manufacturing a motor core and a method for manufacturing a motor core.

Background Art

[0002] Some rotating electrical machines have a motor core, for example, a rotor core with a permanent magnet attached thereto. When attaching a permanent magnet to a motor core in this way, a method is known in which, after inserting the permanent magnet into a slot provided in the motor core, a resin composition is filled around the magnet and cured (see, for example, Japanese Patent Application Laid-Open No. 2013-009453).

[0003] Japanese Patent Application Laid-Open No. 2013-009453 describes that when filling a thermosetting resin composition into a slot of a rotor core, a resin tablet of a predetermined size considering the required filling amount is put into a pot and heated in the pot to soften and melt it before filling.

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the apparatus described in Japanese Patent Application Laid-Open No. 2013-009453, it is normal to prepare more resin than the specified filling amount in consideration of the dimensional tolerances of the product so that the resin filled in the slot, for example, a thermosetting resin, is not insufficient. However, in this case, since the thermosetting resin cannot be reused after curing, if the resin filling portion is small due to the dimensional tolerance, waste of the resin increases. In addition, various shapes are adopted for the motor core, and accordingly, the slot shapes into which the magnets are inserted can also take various shapes, so it is almost impossible for the slot shapes to be the same in different vehicle models. Therefore, if resin tablets of the optimal size are to be prepared for each motor core, it is necessary to secure storage space and the like, resulting in high management costs. There are also problems such as the management of various resin tablets becoming complicated.

[0005] In addition, as the development of rotary electric machines for driving and power generation mounted on electrified vehicles accelerates, the amount of resin used also tends to increase due to the diversification of the size and slot shape of the rotary electric machine itself. Therefore, it is necessary to increase the size of the resin tablet. When the amount of resin to be filled increases, temperature management of the resin tends to become more difficult compared to the case where the amount of resin is small, and temperature unevenness such as local overheating or insufficient heating is likely to occur. Such temperature unevenness can be a factor in the variation of the curing timing when using a thermosetting resin composition, and as a result, it may cause poor filling of the resin composition.

[0006] In view of the above problems, an object of the present disclosure is to provide a motor core manufacturing apparatus and a motor core manufacturing method capable of suppressing poor filling of a resin composition while suppressing loss of the resin composition.

Means for Solving the Problems

[0007] To achieve the above object, a motor core manufacturing apparatus according to a first aspect of the present disclosure includes a mold that holds a motor core including a resin filling portion, a chamber that communicates with a resin composition filling path formed in the mold and having one end thereof communicating with the resin filling portion, a plunger that conveys a thermosetting resin composition conveyed to the chamber toward the resin composition filling path, a heater disposed inside the mold or around the mold and the chamber, and an extruder that conveys the resin composition to the chamber while kneading the resin composition. The extruder includes an extrusion conveyance path through which the resin composition is conveyed, a screw disposed in the extrusion conveyance path for conveying the resin composition while kneading it, and a first temperature control mechanism at least partially disposed inside the screw.

[0008] In the manufacturing apparatus for a motor core as described above, it is not necessary to use a resin composition pre-molded into a tablet form as the resin composition to be introduced into the chamber. Since the supply amount of the resin composition to the chamber can be easily changed, loss of the resin composition can be suppressed. Further, since the resin composition conveyed by the screw can be cooled or heated by the first temperature control mechanism, for example, if the first temperature control mechanism is used for cooling the resin composition, an increase in temperature due to shear heat generated during conveyance of the resin composition can be suppressed. Thereby, it is possible to suppress the progress of an unintended curing reaction during conveyance of the resin composition, and to avoid defective filling of the resin composition. Further, if the first temperature control mechanism is used for heating the resin composition, it is possible to assist rapid temperature increase when the temperature of the resin composition in the extruder increases. Further, shear heat generated during conveyance of the resin composition often occurs locally and can cause temperature unevenness. However, if the resin composition is heated by the first temperature control mechanism, an effect of suppressing this temperature unevenness can also be expected.

[0009] The manufacturing apparatus for a motor core according to the second aspect of the present disclosure is the manufacturing apparatus for a motor core according to the first aspect of the present disclosure, wherein the extruder further includes a second temperature control mechanism disposed in the extrusion conveyance path surrounding a part of the screw.

[0010] In the manufacturing apparatus for a motor core as described above, by including a second temperature control mechanism disposed in the extrusion conveyance path in addition to the first temperature control mechanism disposed inside the screw, the resin composition conveyed in the extrusion conveyance path can be cooled or heated from both the inner and outer sides. Thereby, temperature control of the resin composition during conveyance can be more reliably performed.

[0011] The manufacturing apparatus for a motor core according to the third aspect of the present disclosure is the manufacturing apparatus for a motor core according to the first or second aspect of the present disclosure, wherein the first temperature control mechanism includes an inflow path having a heat medium supply port at one end and extending along the central axis of the screw from the proximal end side of the screw, and an outflow path having one end communicating with the other end of the inflow path and extending toward the proximal end side of the screw.

[0012] In the manufacturing apparatus for a motor core as described above, by forming a passage through which a heat medium can pass inside the screw, the heat medium can be supplied inside the screw to cool or heat the screw and the resin composition around the screw.

[0013] The manufacturing apparatus for a motor core according to the fourth aspect of the present disclosure is the manufacturing apparatus for a motor core according to the third aspect of the present disclosure, wherein the heat medium used in the first temperature control mechanism is a gas.

[0014] In the manufacturing apparatus for a motor core as described above, by adopting a gas as the heat medium used in the first temperature control mechanism, its handling becomes easier compared to the case where a liquid heat medium is used.

[0015] The manufacturing apparatus for a motor core according to the fifth aspect of the present disclosure is the manufacturing apparatus for a motor core according to any one of the first to fourth aspects of the present disclosure, wherein the screw includes a cylindrical first screw body having fins for conveying the resin composition formed on its outer periphery and its tip closed, and a first flow path forming member which is a cylindrical body provided with a through hole extending along the longitudinal direction in its central portion and having a plurality of concave grooves formed along the longitudinal direction on its outer periphery. The first flow path forming member is fitted into the first screw body so that a gap is formed between its tip and the bottom inside the first screw body.

[0016] In the manufacturing apparatus for a motor core as described above, by assembling two members, an inflow path and an outflow path can be formed inside the screw, facilitating the processing of the parts used for the screw.

[0017] The manufacturing apparatus for a motor core according to the sixth aspect of the present disclosure is the manufacturing apparatus for a motor core according to any one of the first to fourth aspects of the present disclosure above, wherein the screw includes a second screw body having fins for conveying the resin composition formed on the outer periphery and a plurality of through holes extending along the longitudinal direction formed therein, and a second flow path forming member connected to the tip of the second screw body for communicating the ends of the plurality of through holes with each other.

[0018] In the manufacturing apparatus for a motor core as described above, an inflow path and an outflow path can be formed inside the screw by assembling two members, which facilitates the processing of the parts used for the screw.

[0019] The manufacturing apparatus for a motor core according to the seventh aspect of the present disclosure is the manufacturing apparatus for a motor core according to the sixth aspect of the present disclosure above, wherein the second screw body is formed by connecting a plurality of divided bodies each having fins formed on the outer periphery and a plurality of through holes extending along the longitudinal direction formed therein so that the plurality of through holes communicate with each other.

[0020] In the manufacturing apparatus for a motor core as described above, since the screw body can be formed by connecting a plurality of divided bodies, the length of the screw body can be easily varied.

[0021] The method for manufacturing a motor core according to the eighth aspect of the present disclosure includes a step of holding the motor core in a mold in which a resin composition filling path is formed so that the resin composition filling path communicates with a resin filling portion of the motor core; and a step of conveying the resin composition toward a chamber communicating with the resin composition filling path while adjusting the temperature using an extruder capable of conveying the resin composition, wherein the extruder includes an extrusion conveyance path through which the resin composition is conveyed, a screw disposed in the extrusion conveyance path for kneading and conveying the resin composition, and a first temperature control mechanism at least partially disposed inside the screw. The method further includes a step of operating a plunger movable within the chamber to fill the softened resin composition within the chamber into the resin filling portion; and a step of curing the softened resin composition filled within the resin filling portion.

[0022] In the method for manufacturing a motor core as described above, it is not necessary to use a resin composition pre-molded into a tablet shape as the resin composition to be introduced into the chamber, and the supply amount of the resin composition to the chamber can be easily changed, so that loss of the resin composition can be suppressed. Further, since the resin composition can be conveyed to the chamber while adjusting the temperature using, for example, the first temperature control mechanism, for example, when the first temperature control mechanism is used for cooling the resin composition, it is possible to suppress a temperature rise caused by shear heat generated during conveyance of the resin composition. Thereby, it is possible to suppress the progress of an unintended curing reaction during conveyance of the resin composition and avoid defective filling of the resin composition. Further, if the first temperature control mechanism is used for heating the resin composition, it is possible to assist rapid temperature rise when the temperature of the resin composition in the extruder is increased. Further, shear heat generated during conveyance of the resin composition often occurs locally and can cause temperature unevenness, but if the resin composition is heated by the first temperature control mechanism, an effect of suppressing this temperature unevenness can also be expected.

Advantages of the Invention

[0023] According to the motor core manufacturing apparatus and the motor core manufacturing method of the present disclosure, it is possible to suppress loss of the resin composition and suppress defective filling of the resin composition.

Brief Description of the Drawings

[0024]

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DETAILED DESCRIPTION OF THE INVENTION

[0025] This application is based on Japanese Patent Application No. 2022-092469 filed in Japan on June 7, 2022, the content of which forms a part of the content of this application. Further, the present disclosure will be more fully understood from the following detailed description. The further scope of application of this application will become apparent from the following detailed description. However, the detailed description and specific examples are desirable embodiments of the present disclosure and are described only for the purpose of explanation. This is because various changes and modifications will be apparent to those skilled in the art within the spirit and scope of the present disclosure from this detailed description. The applicant has no intention of dedicating any of the described embodiments to the public, and among the disclosed modifications and alternatives, those that may not be literally included within the scope of the claims are also considered part of the invention under the doctrine of equivalents.

[0026] Embodiments for implementing the present disclosure will be described below with reference to the drawings. In the following, the scope necessary for the description to achieve the object of the present disclosure is schematically shown, and mainly the scope necessary for the description of the corresponding part of the present disclosure will be described, and the parts omitted from the description are assumed to be based on known techniques. In addition, the same or corresponding members in the drawings are denoted by the same or similar reference numerals, and duplicate descriptions are omitted. Further, when a plurality of the same or corresponding members are included in one drawing, in order to make the drawing easy to view, some of them may be denoted by reference numerals.

[0027] <Manufacturing apparatus for motor core> FIG. 1 is a schematic explanatory diagram showing an example of a manufacturing apparatus for a motor core according to an embodiment of the present disclosure. The manufacturing apparatus 1 for a motor core according to the present embodiment may be an apparatus for attaching a permanent magnet 3 to a motor core, for example, an inner rotor type rotor core 2. And the attachment of this permanent magnet 3 may be realized by resin molding. In the present embodiment, the rotor core 2 is exemplified as the motor core, and the slot portion 4 (more precisely, the filling space 6) of the rotor core 2 is exemplified as an example of the resin filling portion of the motor core. However, the present disclosure is not limited thereto. Specifically, the manufacturing apparatus 1 for the motor core can be used, for example, for resin molding a portion around which a coil of a stator core as a motor core is wound, or for filling a resin into a through hole provided in the axial direction of a non-crimped laminated core to integrally fix the laminated core. In the following description, for ease of understanding, the X direction shown in FIG. 1 may be described as the left-right direction, the Y direction as the front-rear direction, and the Z direction as the height direction (or the up-down direction).

[0028] The resin composition P used in the manufacturing apparatus 1 for a motor core according to the present embodiment is a thermosetting resin composition. More specifically, it may mainly contain a thermosetting resin such as an epoxy resin, a phenol resin, an unsaturated polyester resin, or a cyanate resin. In addition, a curing agent, a filler, etc. may be added to this resin composition P in addition to the thermosetting resin.

[0029] As shown in FIG. 1, the manufacturing apparatus 1 for a motor core according to this embodiment includes at least a manufacturing apparatus main body 10, a mold 20 for holding a rotor core 2, a chamber 30 capable of accommodating a resin composition P, a plunger 35 for conveying the resin composition P in the chamber 30, a heater 40 as an example of a heater capable of heating the mold 20 and the chamber 30, and an extruder 50 for introducing the resin composition P into the chamber 30.

[0030] The manufacturing apparatus main body 10 may include a base 11, a plurality of (for example, four) columns 12 erected on the surface of the base 11, and a top plate 13 supported at the tip portions of the columns 12. The top plate 13 may have an upper mold 21 of the mold 20 described later fixed to its lower surface, and may be movable up and down in the vertical direction together with the columns 12 and the upper mold 21 using an actuator (not shown).

[0031] The mold 20 is a member for holding the rotor core 2. Specifically, the mold 20 may include an upper mold 21 that abuts and supports the upper part of the rotor core 2, specifically, its upper surface, and a lower mold 22 that abuts and supports the lower part of the rotor core 2, specifically, its lower surface. Among these, the lower mold 22 may include a lower mold main body 23 and a stage 24 provided on the lower mold main body 23 on which the rotor core 2 is placed. The rotor core 2 can be placed on this stage 24 or conveyed from the stage 24 by a robot arm (not shown) or the like.

[0032] In addition, inside the stage 24, a resin composition filling path 25 for supplying the resin composition P to the appropriate position of the rotor core 2 placed on the stage 24 may be provided. The path structure of the resin composition filling path 25 may be changed according to the structure of the rotor core 2 placed on the stage 24. A plurality of stages 24 having different structures of the resin composition filling path 25 may be prepared in advance, and they may be appropriately changed and used according to the dimensions of the rotor core 2 held in the mold 20, the position of the slot portion 4, etc. Further, the lower mold 22 may further include a lifter 26 for raising and lowering the stage 24 in order to clean the resin composition filling path 25, etc. Note that in this embodiment, the resin composition filling path 25 is provided in the lower mold 22, and the mode of filling the resin composition P from below is exemplified, but it is not limited thereto. For example, a resin composition filling path may be provided in the upper mold 21, and the resin composition P may be filled from above.

[0033] Also, as described above, the upper mold 21 may be movable in the vertical direction together with the top plate 13. When the rotor core 2 is placed on the stage 24, the upper mold 21 descends and presses the upper surface of the rotor core 2 with a predetermined pressing force, so that the rotor core 2 can be held sandwiched between the upper mold 21 and the lower mold 22. The surfaces of the upper mold 21 and the stage 24 that come into contact with the rotor core 2 are adjusted in terms of their shape, material, etc. so that the resin composition P does not leak out of the rotor core 2 during the filling of the resin composition P described later, in other words, so that the contact surfaces are in a sealed state when the rotor core 2 is sandwiched. Further, in this embodiment, as described above, a structure in which the upper mold 21 is moved up and down together with the top plate 13 is adopted, but any other structure can be adopted as long as the vertical positions of the upper mold 21 and the lower mold 22 can be relatively changed. Specifically, for example, instead of moving the upper mold 21 in the vertical direction, a structure in which the lower mold 22 is moved in the vertical direction, or a structure in which both the upper mold 21 and the lower mold 22 are moved may be adopted.

[0034] In this embodiment, as the slot portion 4 of the rotor core 2, a rectangular parallelepiped shape having substantially no gap in the front-rear and left-right directions is exemplified. Therefore, the upper mold 21 and the lower mold 22 employ those having substantially flat contact surfaces, but the shapes of the contact surfaces of the upper mold 21 and the lower mold 22 can be appropriately changed according to the shape of the rotor core 2 to be held. For example, when the motor core manufacturing apparatus 1 according to this embodiment is used for resin molding of an inner rotor type stator core, it is preferable to adopt the upper mold 21 and the lower mold 22 including protrusions to be inserted into the space formed in the center of the stator core.

[0035] The rotor core 2 held by the mold 20 described above can be composed of, for example, a substantially cylindrical magnetic body formed by laminating a plurality of thin electromagnetic steel sheets. A through hole 5 into which a shaft constituting a rotating shaft when assembled as a motor is inserted may be provided in the axial center portion of the rotor core 2. Further, one or a plurality of slot portions 4 extending along the axial direction of the rotor core 2 may be provided so as to surround the through hole 5. The slot portion 4 can be formed in a rectangular parallelepiped shape, for example, but its specific shape is not particularly limited as long as it is a shape into which the permanent magnet 3 described later can be inserted.

[0036] The slot portion 4 of the rotor core 2 may be one into which the permanent magnet 3 is inserted and fixed. The permanent magnet 3 can be composed of, for example, a rectangular parallelepiped slightly smaller than the slot portion 4. Also, whether or not this permanent magnet 3 is magnetized does not matter. When the permanent magnet 3 is inserted into the slot portion 4, a gap is at least partially formed between the outer peripheral surface of the permanent magnet 3 and the inner peripheral surface of the slot portion 4. This gap can function as a filling space 6 as an example of a resin filling portion. When the rotor core 2 is placed on the stage 24, a part of each of these plurality of filling spaces 6 can communicate with the end of the resin composition filling path 25.

[0037] The chamber 30 may form a space into which a predetermined amount of the resin composition P to be filled in the filling space 6 is introduced. This chamber 30 may be formed to extend in the vertical direction inside a support base 31 provided on the base 11. The upper end portion of the chamber 30 may communicate with a resin composition filling path 25 of a stage 24 included in a lower mold 22 disposed on the support base 31.

[0038] The plunger 35 may be a member for conveying the resin composition P conveyed into the chamber 30 toward the resin composition filling path 25. The plunger 35 according to the present embodiment may form the lower surface of the chamber 30 and may be connected to an actuator (not shown) so as to be movable up and down in the chamber 30.

[0039] The heater 40 may be composed of a well-known heater or the like and may heat appropriate positions of the manufacturing apparatus 1. The heater 40 according to the present embodiment may include a mold heater 41 disposed in the mold 20, specifically, in the upper mold 21 and the lower mold body 23, and a chamber heater 42 disposed around the chamber 30 in the support base 31 so as to be close to the outer periphery of the chamber 30. As the mold heater 41 and the chamber heater 42, well-known heaters such as an infrared heater or a sheathed heater can be employed.

[0040] An extruder (sometimes referred to as an "extruder") 50 may be such that one end communicates with the chamber 30 and is capable of conveying the resin composition P while kneading it toward the chamber 30. This extruder 50 includes at least a barrel 51 as an example of an extrusion conveyance path through which the resin composition P is conveyed inside, and a screw 52 disposed inside the barrel 51 and configured to convey and knead the resin composition P supplied into the barrel 51, for example, the powdery resin composition P1. In the present embodiment, an extruder 50 extending in the left-right direction is illustrated, but the extending direction of the extruder 50 is not limited to this. For example, it may extend obliquely upward from the chamber 30 or may extend in the vertical direction so as to be aligned with the chamber 30. When the extruder 50 and the chamber 30 are arranged side by side, it is preferable to secure a space for conveying the resin composition P between the extruder 50 and the chamber 30. Further, in the present disclosure, although the case where the powdery resin composition P1 is supplied as the resin composition P supplied to the barrel 51 is illustrated, it is not limited to the powdery one, and other shapes, for example, at least a part thereof may be in a paste form or a pellet form. Furthermore, the powdery resin composition P1 in the present disclosure refers to a resin composition P1 formed of relatively small particles such as granular or particulate (these particles include particles such as small pieces obtained by pulverizing and crushing a relatively large resin block).

[0041] The barrel 51 may be a conveyance path for conveying the resin composition P while kneading it, extending in one direction, for example, the left-right direction. A supply port 53 for supplying the powdery resin composition P1 may be formed at one end of the barrel 51, and a discharge port 54 connected to the chamber 30 may be formed at the other end. A resin composition supply source 58 may be connected to the supply port 53 via a resin composition supply path 57. Further, a shutter 56, for example, a slide type or a rotary type, may be provided at the discharge port 54.

[0042] The screw 52 can be constituted by a long member having spiral fins 52F formed on its outer peripheral surface and rotated by a motor 59 connected to one end thereof. This screw 52 may be disposed in the barrel 51 along its extending direction so as to convey the powdery resin composition P1 supplied from the supply port 53 toward the discharge port 54 while kneading it. Also, if the powdery resin composition P1 is continuously supplied to the screw 52, the resin composition P being conveyed can also be pressurized. Therefore, the powdery resin composition P1 conveyed in the barrel 51 may gradually change into a paste-like resin composition P2 by being kneaded and pressurized by the screw 52 during the conveyance process. Here, the paste-like state refers to a state in which the resin composition P that was powdery has integrated to form a mass and has become paste-like or clay-like.

[0043] The motor 59 connected to the screw 52 can adjust the conveyance amount of the resin composition P according to its rotation speed. Therefore, the amount of the paste-like resin composition P2 input from the extruder 50 into the chamber 30 can be accurately adjusted by controlling the rotation speed of the motor 59. Here, the paste-like resin composition P2 may be a mixture of the paste-like resin composition P2 and the powdery resin composition P1. Also, in the present embodiment, an example in which the input amount of the paste-like resin composition P2 into the chamber 30 is controlled by the rotation speed of the motor 59 is shown, but the control of the input amount is not limited to such a method. For example, the input amount of the paste-like resin composition P2 into the chamber 30 can also be controlled from the volume of the paste-like resin composition P2 in the barrel 51 or from the thrust required to convey the paste-like resin composition P2.

[0044] The extruder 50 may further include a temperature sensor that detects the temperature of the powdery resin composition P1 or the paste-like resin composition P2 conveyed inside the barrel 51, or the room temperature inside the barrel 51. Then, by controlling the rotation speed of the motor 59 based on the detection result of the temperature sensor and the preset input amount of the resin composition into the chamber 30, the input amount of the paste-like resin composition P2 into the chamber 30 can be adjusted more accurately. Note that the extruder 50 according to the present embodiment exemplifies an extruder with one screw 52, but the number of screws 52 may be two or more.

[0045] In addition, in order to control each component such as the motor 59 described above, the manufacturing apparatus 1 according to the present embodiment can further include a control device 60. The control device 60 may be communicably connected to each component via wired or wireless communication, for example, as shown by the dotted line in FIG. 1. This control device 60 can be realized using a sequencer (Programmable Logic Controller, PLC) or a well-known computer.

[0046] The manufacturing apparatus 1 for a motor core according to the present embodiment mainly employs the extruder 50 having the above-described configuration, so that an arbitrary amount of the resin composition P can be supplied to the chamber 30 without using a pre-molded tablet-shaped resin composition. As a result, the conveyance amount of the resin composition P to the chamber 30 (that is, the input amount into the chamber 30) can be freely adjusted by controlling the rotation speed of the motor 59. Therefore, the input amount into the chamber 30 can be freely changed, and the loss of the resin composition P generated during the manufacturing process can be reduced. In addition, there is no need to select a resin tablet according to the filling amount of the resin composition into the motor core (resin composition filling amount).

[0047] In the case of using a screw 52 for kneading and conveying the resin composition P, such as the extruder 50 described above, the resin composition P is shear-deformed by the screw 52 during its conveyance. Therefore, due to the shear heat generated during the deformation, the temperature of the resin composition P may at least partially increase. When a thermosetting resin composition P is used as in the present embodiment, the curing reaction may proceed contrary to intention due to the shear heat, and a part of it may be cured inside the barrel 51.

[0048] The progress of the unintended curing reaction of the resin composition P in the barrel 51 as described above can cause variations in the supply amount of the resin composition P to the chamber 30, increase the frequency of cleaning inside the extruder 50, or stop the rotational operation of the screw 52 due to the resin composition in which the curing reaction has proceeded getting caught, etc., and can be a factor in various problems. In addition, the progress of the unintended curing reaction described above can be a factor in variations in the (melt) viscosity of the resin composition P supplied to the chamber 30. If the (melt) viscosity becomes too high, the fluidity inside the resin composition filling path 25, the slot portion 4, etc. may be impaired, and the resin composition P may not be able to fill the filling space 6 inside the rotor core 2. In the manufacturing apparatus 1 of the motor core according to the present embodiment, in view of this point, in order to suppress the unintended temperature increase of the resin composition P described above, a first temperature control mechanism 70 is employed. Hereinafter, the first temperature control mechanism 70 will be described.

[0049] FIG. 2 is a view showing a part of the first temperature control mechanism of the manufacturing apparatus of the motor core shown in FIG. 1. FIGS. 2A and 2B are a cross-sectional view and a side view showing a state in the manufacturing process of the screw, and FIG. 2C is a cross-sectional view and a side view showing the manufactured screw. In FIG. 2, the illustration of the fins 52F formed around the screw 52 is omitted. Each cross-sectional view shown in FIG. 2 is a view obtained by cutting the screw 52 along a plane extending in the longitudinal direction passing through its central axis, and the side view shows the surface on the base end side of the screw 52 connected to the motor 59.

[0050] As shown in FIG. 2C, the first temperature control mechanism 70 of the motor core manufacturing apparatus 1 according to the present embodiment suppresses the temperature rise of the resin composition P kneaded and conveyed by the screw 52 by disposing at least a part thereof inside the screw 52. The heat medium used in the first temperature control mechanism 70 may be a gas. Specifically, the first temperature control mechanism 70 of the present embodiment can be an air-cooled cooling mechanism using air as the heat medium, and can include an inflow passage 74 and an outflow passage 75 provided in the screw 52. As described above, when a gas is adopted as the heat medium of the first temperature control mechanism 70, its handling becomes easier than when a cooling mechanism using a liquid such as water is adopted as the heat medium.

[0051] In the present embodiment, the first temperature control mechanism 70 is exemplified as one for cooling the resin composition P. However, if the temperature of the heat medium is adjusted, the resin composition P can be kept warm or heated using the first temperature control mechanism 70. That is, it can be said that the first temperature control mechanism 70 adjusts the temperature of the resin composition P conveyed in the barrel 51.

[0052] When the first temperature control mechanism 70 is used for heating the resin composition P, for example, when it is desired to raise the temperature of the resin composition P in the extruder 50, rapid temperature rise can be assisted. In addition, since the shear heat generated during the conveyance of the resin composition P in the extruder 50 often occurs locally in the barrel 51, it can cause temperature unevenness. However, if the resin composition P in the barrel 51 is heated by the first temperature control mechanism 70, an effect of suppressing this temperature unevenness can also be expected.

[0053] More specifically, as shown in FIGS. 1 and 2C, the first temperature control mechanism 70 of the present embodiment can include a blower 71 as an example of a heat medium supply source, and a screw 52 provided with an inflow passage 74 and an outflow passage 75 through which the air supplied from the blower 71 passes inside thereof.

[0054] The blower 71 is an example of a heat medium supply source, and can be connected to a heat medium supply port provided at the proximal end side of the inflow path 74 formed in the screw 52, and is capable of supplying air as the heat medium into the inflow path 74. In the present embodiment, since an air-cooled cooling mechanism is adopted for the first temperature control mechanism 70, an example using air as the heat medium is illustrated, but the heat medium is not limited thereto. Specifically, for example, water or other fluids can also be adopted as the heat medium. In that case, other heat medium supply means may be adopted instead of the blower 71.

[0055] The screw 52 may be formed with an inflow path 74 at its center and a plurality of outflow paths 75 formed at positions close to its outer peripheral surface. The inflow path 74 can be configured as a passage extending along the central axis of the screw 52, with one end located at the proximal end side of the screw 52 opening at the end of the screw 52 to form a heat medium supply port, and the other end located at the distal end side of the screw 52 communicating with the outflow path 75. Further, the outflow path 75 can be formed by a plurality of (two in FIG. 2) passages extending substantially parallel to the inflow path 74 between the inflow path 74 and the outer peripheral surface of the screw 52. This outflow path 75 may be a passage where one end located at the distal end side of the screw 52 communicates with the other end of the inflow path 74, and the other end located at the proximal end side of the screw 52 communicates with the outside of the barrel 51.

[0056] As described above, forming the inflow path 74 along the central axis of the screw 52 can simplify the connection structure between the inflow path 74 formed in the rotating screw 52 and the blower 71, which is preferable. In this regard, in the first temperature control mechanism 70 of the present embodiment, since air is adopted as the heat medium, it is not necessary to recover the air that has exited the outflow path 75. Therefore, the other end of the outflow path 75 only needs to communicate with the outside of the barrel 51. In the present embodiment, an example is illustrated in which two outflow paths 75 are provided so as to sandwich the inflow path 74 from above and below, but the arrangement and number of the outflow paths 75 can be changed as appropriate. For example, four outflow paths 75 can also be provided so as to sandwich the inflow path 74 from both the vertical and horizontal directions.

[0057] The other end of the inflow path 74 and one end of the outflow path 75 communicate with each other via a communication path 76. As shown in FIG. 2C, this communication path 76 can be formed as a path extending in a direction intersecting the extending direction of the screw 52. The first temperature control mechanism 70 can mainly cool the resin composition P conveyed around the screw 52 and the screw 52 by air as a heat medium passing through the inside of the communication path 76 and the outflow path 75 described above. Therefore, the communication path 76 and the outflow path 75 may be disposed at positions close to the outer peripheral surface of the screw 52.

[0058] An example of a method for manufacturing the screw 52 including the above-described configuration will be briefly described below. First, as shown in FIG. 2A, three bottomed holes are formed along the longitudinal direction of the long screw 52 from the proximal end side of the screw 52. Each of these bottomed holes can form the inflow path 74 and the outflow path 75. Next, as shown in FIG. 2B, a through hole is formed from the outer peripheral surface of the screw 52 so as to cross the bottoms of the three bottomed holes. This through hole can form the communication path 76. And finally, by closing the two opening portions of the through hole with the sealing member 76S, it is possible to provide the screw 52 including the inflow path 74 and the outflow path 75 whose ends communicate with each other via the communication path 76.

[0059] In the manufacturing apparatus 1 for the motor core according to the present embodiment, when the screw 52 is operated to convey the resin composition P to the chamber 30, the first temperature control mechanism 70 including the above-described configuration is operated. Thereby, the screw 52 and the resin composition P conveyed while being kneaded around the screw 52 can be cooled. As a result, it becomes possible to suppress an unintended temperature rise due to the shear heat generated during the conveyance by the screw 52, and to effectively suppress filling defects caused by the progress of the curing reaction of the resin composition P before filling, more specifically, conveyance defects of the resin composition P in the barrel 51 and an increase in the frequency of cleaning operations in the barrel 51.

[0060] In order to more reliably suppress the temperature rise caused by shear heat generated in the resin composition P, in addition to the first temperature control mechanism 70 described above, the manufacturing apparatus 1 of the motor core according to the present embodiment can also be provided with a second temperature control mechanism 80 on the barrel 51 side. As shown in FIG. 1, the second temperature control mechanism 80 is preferably provided at least in a portion surrounding the screw 52 of the barrel 51. The second temperature control mechanism 80 can be constituted by, for example, a heat medium passage routed inside the barrel 51. The heat medium supplied to the heat medium passage is not particularly limited, and water, air, or the like can be employed.

[0061] If the above-described second temperature control mechanism 80 is employed in addition to the first temperature control mechanism 70, the resin composition P conveyed while being kneaded by the screw 52 can be cooled or heated from both the inner and outer surfaces. Therefore, if these temperature control mechanisms are used for cooling, the temperature rise of the resin composition P due to shear heat can be more effectively suppressed. Conversely, if these temperature control mechanisms are used for heating the resin composition P, more uniform heating can be achieved.

[0062] The cooling of the resin composition P by the first temperature control mechanism 70 or by the first temperature control mechanism 70 and the second temperature control mechanism 80 can be operated at an arbitrary timing during the period in which the resin composition P is being conveyed so that the temperature of the conveyed resin composition P becomes 100°C or lower, preferably 70°C or lower, more preferably 60°C or lower. The specific control of these temperature control mechanisms 70 and 80 can be mainly implemented by the control device 60.

[0063] In addition, in the manufacturing apparatus 1 of the motor core according to the present embodiment, the screw 52 of the first temperature control mechanism 70 is exemplified as being manufactured through the process shown in FIG. 2, but it can also be manufactured by a method other than such a manufacturing method. Therefore, some examples of screw bodies manufactured through a manufacturing method different from the above-described method will be described below.

[0064] FIG. 3 is an explanatory diagram showing a first modification of the screw shown in FIG. 2. FIG. 3A is a cross-sectional view and a side view showing a first screw body, FIG. 3B is a cross-sectional view and a side view showing a first flow path forming member, and FIG. 3C is a cross-sectional view and a side view of a screw according to the first modification. The screw 52A according to the first modification may include, as shown in FIG. 3C, a first screw body 72A and a first flow path forming member 73A.

[0065] As shown in FIG. 3A, the first screw body 72A can be constituted by a cylindrical member in which a bottomed hole 72H extending along the longitudinal direction is formed inside by closing the tip. Fins 52F are formed on the outer periphery of the first screw body 72A, but are not shown in FIG. 3. The base end side of the first screw body 72A where the bottomed hole 72H opens is connected to the motor 59, and the tip side can be disposed in the barrel 51 in a free end state.

[0066] As shown in FIG. 3B, the first flow path forming member 73A can be constituted by a cylindrical body provided with a through hole 77 extending along the longitudinal direction at its central portion. The first flow path forming member 73A made of this cylindrical body may have a plurality of, for example, four concave grooves 78 extending along the longitudinal direction formed on its outer periphery. And the outer diameter dimension of this first flow path forming member 73A is preferably adjusted so that it can be fitted into the bottomed hole 72H of the first screw body 72A.

[0067] Further, it is preferable that a non-illustrated anti-rotation structure for rotating together with the first screw body 72A is provided on the outer peripheral surface of the first flow path forming member 73A where the concave groove 78 is not formed when it is fitted into the first screw body 72A. As this anti-rotation structure, a well-known meshing shape or the like can be adopted.

[0068] As shown in FIG. 3C, the screw 52A according to the first modification can be configured by fitting (or press-fitting) a first flow path forming member 73A into the bottomed hole 72H of the above-described first screw body 72A. When the first flow path forming member 73A is fitted into the bottomed hole 72H, the fitting length of the first flow path forming member 73A is set shorter than the depth of the bottomed hole 72H. Thereby, a gap is formed between the tip of the first flow path forming member 73A and the bottom surface of the bottomed hole 72H that constitutes the bottom in the first screw body 72A, and this gap can function as a communication path 76.

[0069] The inflow path 74 formed in the screw 52A can be formed by a through hole 77 of the first flow path forming member 73A fitted into the bottomed hole 72H. Similarly, the outflow path 75 formed in the screw 52A can be formed by four passages defined by the inner peripheral surface of the bottomed hole 72H and the concave groove 78 of the first flow path forming member 73A fitted into the bottomed hole 72H. And one end of the inflow path 74 formed in the screw 52A and one end of each outflow path 75 can be communicated via the above-described communication path 76. In this way, by manufacturing the screw 52A by assembling two members, the processing of parts can be simplified.

[0070] FIG. 4 is an explanatory view showing a second modification of the screw shown in FIG. 2. FIG. 4A is a cross-sectional view and a side view showing a state before assembling the second screw body and the second flow path forming member, and FIG. 4B is a cross-sectional view and a side view showing a state after assembling the second screw body and the second flow path forming member. As shown in FIG. 4B, the screw 52B according to the second modification may include a second screw body 72B and a second flow path forming member 73B.

[0071] As shown in FIGS. 4A and 4B, the second screw body 72B can be constituted by a columnar member having a plurality of through holes 74B and 75B formed therein and extending along the longitudinal direction. Fins 52F are formed on the outer periphery of the second screw body 72B in the same manner as the first screw body 72A, but the illustration thereof is omitted in FIG. 4 as well. The base end side of the second screw body 72B is connected to the motor 59, and the tip end side can be disposed in the barrel 51 in a free end state. The through holes 74B and 75B formed in the second screw body 72B extend along the central axis of the second screw body 72B, and may include one through hole 74B capable of forming the inflow path 74 and a plurality of other through holes 75B disposed around the one through hole 74B and extending substantially parallel to the one through hole 74B and capable of forming the outflow path 75.

[0072] Optionally, as shown in FIG. 4A, the second screw body 72B according to this modification can also be configured by connecting a plurality of, for example, three divided bodies 72B1 to 72B3. The divided bodies 72B1 to 72B3 can be constituted by columnar members having fins 52F formed on the outer periphery and a plurality of through holes 74B and 75B formed therein and extending along the longitudinal direction. The second screw body 72B can be formed by connecting the divided bodies 72B1 to 72B3 so that the plurality of through holes 74B and 75B of each of the divided bodies 72B1 to 72B3 communicate with each other. By adopting a structure in which a plurality of divided bodies 72B1 to 72B3 are connected to form one second screw body 72B, the length of the screw 52B can be easily changed by appropriately changing the number of the divided bodies to be connected as described above.

[0073] The second flow path forming member 73B may be connected to the tip of the second screw body 72B and communicate the ends of a plurality of through holes 74B and 75B provided in the second screw body 72B. The second flow path forming member 73B can be composed of a columnar member whose outer diameter dimension is adjusted according to the second screw body 72B. And a communication path 76B for communicating the tip of one through hole 74B and the tips of two other through holes 75B may be formed at the base end of the second flow path forming member 73B.

[0074] The communication path 76B can be formed, for example, by a bottomed hole extending along the central axis of the second flow path forming member 73B from the base end side of the second flow path forming member 73B and two bottomed holes extending in a direction inclined with respect to the central axis of the second flow path forming member 73B from the base end side of the second flow path forming member 73B so as to communicate with the bottom of the bottomed hole. In this modified example, in this way, since the communication path 76B can be formed only by drilling three linearly extending bottomed holes, the processing thereof is easy.

[0075] The screw 52B according to the second modified example can be configured by axially connecting the second screw body 72B and the second flow path forming member 73B as shown in FIG. 4B. Also in this modified example, since the screw 52B can be manufactured by connecting a plurality of members, the processing of the parts can be simplified. Further, since the screw 52B can be divided into a plurality of components, the processing of the holes formed in each divided body 72B1 to 72B3 and the second flow path forming member 73B (specifically, the through holes 74B and 75B and the bottomed holes forming the communication path 76B) becomes easy.

[0076] Returning to the description of the extruder 50, a standby space 51A of a predetermined size without the screw 52 may be formed between the discharge port 54 of the barrel 51 and the tip (specifically, the free end) of the screw 52. This standby space 51A may be a space for temporarily storing the paste-like resin composition P2 kneaded and conveyed by the rotation of the screw 52 while being temperature-controlled by the first temperature control mechanism 70. Further, well-known conveying means (not shown) such as a belt conveyor or a scraper may be provided in this standby space 51A. By operating this conveying means in conjunction with, for example, the opening of the shutter 56, a specific amount of the paste-like resin composition P2 temporarily stored in the standby space 51A can be immediately introduced into the chamber 30.

[0077] Optionally, it is preferable that a barrel heater 55 for preheating the paste-like resin composition P2 conveyed to the standby space 51A by the screw 52 is disposed around the outer periphery of this standby space 51A. This barrel heater 55 can be composed of a well-known heater similar to the mold heater 41 or the like, and can be disposed, for example, so as to substantially surround the entire circumference of the standby space 51A. The barrel heater 55 can preheat the paste-like resin composition P2 in the standby space 51A to 50 to 100°C, more preferably 90 to 100°C. By adopting this barrel heater 55, the temperature of the paste-like resin composition P2 conveyed to the standby space 51A can be raised before being introduced into the chamber 30, and softening can be promoted. As a result, the heating time required to soften and melt the paste-like resin composition P2 in the chamber 30 can be significantly shortened.

[0078] In this embodiment, an example has been shown in which the discharge port 54 of the barrel 51 is connected to the chamber and a standby space 51A is provided adjacent to the discharge port 54, but the present disclosure is not limited to this. For example, a transport mechanism (not shown) may be provided between the discharge port 54 of the barrel 51 and the chamber 30, and the paste-like resin composition P2 may be introduced into the chamber 30 by operating the transport mechanism. Similarly, a mechanism for removing air from the kneaded paste-like resin composition P2 may be additionally provided between the discharge port 54 of the barrel 51 and the shutter 56 or the chamber 30. The mechanism may be, for example, a mechanism that removes air from the paste-like resin composition P2 by compressing the paste-like resin composition P2 or providing a decompression chamber.

[0079] It should be particularly noted that the resin composition P introduced into the chamber 30 directly or indirectly from the extruder 50 of the motor core manufacturing apparatus 1 according to this embodiment is not a pre-molded tablet shape but a paste-like resin composition P2. By introducing the paste-like resin composition P2 into the chamber 30 in this way, the amount of the resin composition P introduced into the chamber 30 can be freely adjusted by controlling the rotation speed of the motor 59 or the like. The paste-like resin composition P2 introduced into the chamber 30 from the extruder 50 may be pre-formed into a predetermined shape. As the pre-forming method, for example, there is a method in which the paste-like resin composition P2 is continuously transported to the standby space 51A, and the paste-like resin composition P2 is pressed against the shutter 56 to increase the density and pre-form it. Further, the pressing operation of the paste-like resin composition P2 described above may be realized by temporarily moving the screw 52 itself along the transport direction. Alternatively, a jig (not shown) may be arranged between the extruder 50 and the chamber 30, and the paste-like resin composition P2 may be pre-formed into an arbitrary shape using the jig.

[0080] As described above, the manufacturing apparatus 1 for the motor core according to the present embodiment can easily change the amount of the resin composition P introduced into the chamber 30 without preparing resin tablets of various sizes, so that the loss of the resin composition P can be reduced. In addition, since the paste-like resin composition P2 heated uniformly is introduced, the resin composition P can be smoothly filled into the slot portion 4. Furthermore, since the temperature of the resin composition P conveyed by the screw 52 can be controlled by the first temperature control mechanism 70, the progress of the curing reaction contrary to the intention of the resin composition P can be prevented, and thus the occurrence of filling defects can be suppressed.

[0081] <Manufacturing Method of Motor Core> Next, an example of the manufacturing method of the motor core according to the present embodiment will be briefly described. Hereinafter, the case where the manufacturing method of the motor core according to the present embodiment is carried out using the manufacturing apparatus 1 for the motor core according to the above-described embodiment will be exemplarily described.

[0082] The manufacturing method of the motor core according to the present embodiment includes a step (S4) of holding the rotor core 2 in the mold 20 in which the resin composition filling path 25 is formed so that the resin composition filling path 25 communicates with the slot portion 4, and a step of using an extruder 50 capable of conveying the resin composition P to convey the resin composition P in the measured resin composition filling amount while adjusting the temperature toward the chamber 30 communicating with the resin composition filling path 25 (S5). The extruder 50 includes a barrel 51 in which the resin composition P is conveyed, a screw 52 disposed in the barrel 51 for kneading and conveying the resin composition P, and a first temperature control mechanism 70 at least partially disposed inside the screw 52. And a step of operating a plunger 35 movable in the chamber 30 to fill the softened resin composition (corresponding to the liquid resin composition P3) in the chamber 30 into the slot portion 4 (S8), and a step of curing the softened resin composition filled in the slot portion 4 (S9). Hereinafter, it will be described in more detail.

[0083] FIG. 5 is a flowchart showing an example of a method for manufacturing a motor core according to an embodiment of the present disclosure. FIGS. 6 to 8 are operation explanatory diagrams showing an example of the operation state of the motor core manufacturing apparatus shown in FIG. 1 when the method for manufacturing the motor core shown in FIG. 5 is executed. The following description will be mainly made with reference to FIGS. 5 to 8. In FIGS. 6 to 8, for ease of viewing the drawings, reference numerals are mainly attached to those related to each operation, and the reference numerals of members less related to the operation may be omitted.

[0084] In the method for manufacturing a motor core according to the present embodiment, first, after preparing the motor core manufacturing apparatus 1 shown in FIG. 6A, the filling amount of the resin composition P into the filling space 6 of the rotor core 2 (resin composition filling amount) is measured (step S1). When measuring this filling amount, for example, the volume of the slot portion 4 of the rotor core 2 and the volume of the permanent magnet 3 inserted into the slot portion 4 are measured, and the difference therebetween can be calculated for measurement. The measured resin filling amount can be sent to the control device 60 and used for adjusting the input amount of the resin composition P into the chamber 30, specifically, controlling the rotation speed of the motor 59 and the like.

[0085] In the above-described step S1, an example is shown in which the filling amount of the resin composition P is determined by measuring the volume of the slot portion 4 and the volume of the permanent magnet 3, but the filling amount may be determined by other methods. Specifically, for example, a trial production process may be executed before the start of mass production, and the filling amount may be determined from the filling amount of the resin and the amount of surplus resin in the trial production process. Alternatively, during mass production, the actual resin filling amount, surplus resin, etc. may be confirmed at a frequency that does not hinder mass production, and the filling amount may be feedback-controlled to maintain a suitable filling amount. Further, the various filling amount determination methods described above can be executed alone or in combination.

[0086] When the measurement of the required filling amount of the resin composition P is completed, next, a permanent magnet 3 is inserted into the slot portion 4 of the rotor core 2 (step S2). Then, preheating of the mold 20 and the rotor core 2 is performed (step S3). Preheating of the mold 20 can be realized by operating the mold heater 41. At this time, it is preferable to also preheat the chamber 30 together with the mold 20. Preheating of the chamber 30 can be realized by operating the chamber heater 42. Further, preheating of the rotor core 2 can be performed using a well-known heating means (not shown). The preheating of the rotor core 2 may be performed separately from the mold 20 before being placed on the stage 24, or may be performed simultaneously with the preheating of the mold 20 in a state where it is placed on the stage 24. When preheating the mold 20 and the rotor core 2 simultaneously, it is preferable to perform a step S4 described later before step S3. The preheating temperature of the mold 20 and the rotor core 2 can be set to about 100 to 180°C. Note that the preheating may be performed on only one of the mold 20 and the rotor core 2.

[0087] When the preheating of the mold 20 and the rotor core 2 is completed, as shown in FIG. 6B, the rotor core 2 is placed on the stage 24, and the upper mold 21 is moved downward to hold the rotor core 2 in the mold 20 (step S4). At this time, the upper mold 21 is adjusted to press the upper surface of the rotor core 2 with a predetermined pressure, whereby the upper surface of the upper mold 21 and the rotor core 2, and the lower surface of the lower mold 22 and the rotor core 2 can be brought into close contact with each other. Note that a part of the measurement of the filling amount of the resin composition P into the filling space 6 of the rotor core 2 can be performed when holding the rotor core 2. Specifically, the vertical height of the slot portion 4 can be specified from the control signal of an actuator (not shown) used when moving the upper mold 21 in the vertical direction, and can be used for the measurement of the filling amount. In this case, the above-described step S1 is preferably executed after step S4.

[0088] Next, the powdery resin composition P1 is kneaded and conveyed using the extruder 50 (step S5). In this step, first, the powdery resin composition P1 is supplied (for example, continuously) from the resin composition supply source 58 to the supply port 53 of the barrel 51, and the motor 59 is driven to rotate the screw 52, thereby kneading the powdery resin composition P1 supplied to the supply port 53 and conveying it to the discharge port 54. At this time, in the manufacturing apparatus 1 of the motor core according to the present embodiment, before or simultaneously with the rotation of the screw 52, the first temperature control mechanism 70 and the second temperature control mechanism 80 are operated to adjust the temperature of the conveyed resin composition P, for example, to perform cooling. By this cooling operation, the temperature rise caused by the kneading and conveying of the resin composition P by the screw 52 can be controlled, and thus the progress of the curing reaction contrary to the intention of the resin composition P can be suppressed.

[0089] In step S5, the rotation speed of the motor 59 is controlled by the control device 60 so that an amount of the powdery resin composition P1 corresponding to the filling amount of the resin composition P measured in step S1 is conveyed to the standby space 51A while being changed into the paste-like resin composition P2 (see FIG. 6B). However, the amount corresponding to the filling amount of the resin composition P here refers to not only the volume of the filling space 6 but also the amount necessary to fill the filling space 6 with the resin composition P, such as the volume of the resin composition filling path 25. Note that the adjustment of the amount of the paste-like resin composition P2 input to the chamber 30 is not limited to the method performed based on the rotation speed of the motor 59 described above. For example, the amount of the paste-like resin composition P2 input to the chamber 30 may be adjusted by adjusting the amount of the powdery resin composition P1 supplied from the resin composition supply source 58 so as to match the filling amount of the resin composition measured in step S1. Further, by providing a sensor (not shown), for example, a weight sensor in the standby space 51A, the amount of the paste-like resin composition P2 stored in the standby space 51A is measured and compared with the filling amount of the resin composition measured in advance, so that the amount of the paste-like resin composition P2 input to the chamber 30 may be adjusted.

[0090] The resin composition P kneaded and transported in step S5 is transported to the waiting space 51A in the form of a paste-like resin composition P2, or in the form of a mixture of the granular resin composition P1 and the paste-like resin composition P2. At this time, the barrel heater 55 may be driven to preheat the resin composition P transported to the waiting space 51A. The preheating temperature by the barrel heater 55 can be adjusted, for example, in the range of 50 to 100°C. By the above-mentioned kneading and transport, most of the granular resin composition P1 supplied from the supply port 53 is changed into the paste-like resin composition P2 in the waiting space 51A.

[0091] When a predetermined amount of the resin composition P is transported to the waiting space 51A, as shown in FIG. 7A, the shutter 56 is opened, and the paste-like resin composition P2 temporarily stored in the waiting space 51A is introduced into the chamber 30 using a transport means (not shown) (step S6). The paste-like resin composition P2 temporarily stored in the waiting space 51A is adjusted to an amount that matches the measured filling amount of the resin composition as described above. In addition, the paste-like resin composition P2 temporarily stored in the waiting space 51A is preheated to 50 to 100°C by heating with the barrel heater 55. The paste-like resin composition P2 has been changed into a paste-like state by the above-mentioned preheating, etc., and may become a lump of the whole, but it can be introduced into the chamber 30 without any problems.

[0092] After the paste-like resin composition P2 is introduced into the chamber 30, the shutter 56 is closed and the chamber heater 42 is operated to heat and soften the paste-like resin composition P2 (step S7). The chamber heater 42 can be controlled to heat the paste-like resin composition P2 in the chamber 30 to about 100 to 180°C, for example. By this heating, the paste-like resin composition P2 is softened and melted, and changes into a liquid resin composition P3 with high fluidity. Here, in the manufacturing process of the motor core according to this embodiment, since the paste-like resin composition P2 has already been preheated to 50 to 100°C as described above, the time required for softening in the chamber 30 is shorter than in the past.

[0093] In step S7, when the paste-like resin composition P2 changes to the liquid resin composition P3, next, as shown in FIG. 6B, the plunger 35 is raised, and the liquid resin composition P3 is pushed up toward the filling space 6 of the rotor core 2 to fill the resin composition P (step S8). The liquid resin composition P3 pushed up by the plunger 35 passes through the resin composition filling path 25 from the chamber 30 and flows into the filling space 6. In order to smoothly perform the filling of the liquid resin composition P3 into the filling space 6 in step S8, for example, an air hole (not shown) for venting the air in the filling space 6 may be provided at an appropriate position of the upper mold 21.

[0094] When the filling of the liquid resin composition P3 into the filling space 6 is completed, the mold heater 41 is operated to heat and cure the liquid resin composition P3 in the filling space 6 (step S9). When curing the liquid resin composition P3, it may be heated at, for example, 100 to 180° C. for about several minutes. When the liquid resin composition P3 changes to the cured resin composition P4 by the heating, the permanent magnet 3 is fixed in the slot portion 4 of the rotor core 2 by resin molding. Note that the heating time in this step S9 can be appropriately adjusted according to the specific composition of the resin composition P and the like.

[0095] When the above-described series of resin molding steps is completed, as shown in FIG. 8A, the upper mold 21 is raised, and the resin-molded rotor core 2 is carried out using a conveying means (not shown) such as a robot arm (step S10). The carried-out rotor core 2 is transferred to another device, for example, for attaching a shaft. Then, when the carrying out of this rotor core 2 is completed, the manufacturing apparatus 1 is cleaned (step S11). The cleaning of the manufacturing apparatus 1 may be performed by a cleaning unit (not shown) including a cleaning member such as a brush.

[0096] When cleaning the resin composition filling path 25 of the stage 24 during the above-mentioned cleaning, the operation may be as follows. That is, first, operate the lifter 26 to separate the stage 24 from the lower mold body 23, thereby removing the cured resin composition P4 that blocks the resin composition filling path 25 from the resin composition filling path 25. Then, separate this cured resin composition P4 from the lower mold body 23 by further raising the plunger 35 (see Fig. 8B). Then, grasp and remove the separated cured resin composition P4 with a robot arm or the like (not shown), and clean the surfaces of the stage 24 and the lower mold body 23 and the inside of the resin composition filling path 25 with a brush or the like. When a series of cleaning is completed, return to the state shown in Fig. 6A and wait until the next rotor core 2 is carried in.

[0097] Note that the order of the above-described series of steps can be changed within a range where its function can be maintained. For example, the conveyance of the powdery resin composition P1 or the paste-like resin composition P2 by the extruder 50 can be started at an arbitrary timing as long as the filling amount of the resin composition P can be measured. Further, the preheating of the mold 20, the rotor core 2, the resin composition P, etc. can also be omitted.

[0098] As described above, according to the method for manufacturing a motor core according to the present embodiment, a pre-molded tablet-shaped resin composition P is not adopted as the resin composition P to be introduced into the chamber 30, and the required amount of the resin composition P can be stably introduced into the chamber 30 by using the extruder 50. Therefore, the loss of the resin composition P can be suppressed. Accordingly, there is no need to select a resin tablet according to the filling amount of the resin into the motor core.

[0099] The present disclosure is not limited to the above-described embodiments, and various modifications can be made and implemented without departing from the gist of the present disclosure. And all of them are included in the technical idea of the present disclosure. Further, in the present disclosure, each component may exist alone or in two or more as long as there is no contradiction.

[0100] All documents, including publications, patent applications, and patents, cited in this specification are hereby incorporated by reference to the same extent as if each individual document was specifically and individually indicated and incorporated by reference, and to the same extent as if all of the content thereof was set forth herein.

[0101] The use of the nouns and similar indicia used in connection with the description of the present disclosure (particularly in connection with the following claims) shall be construed to cover both the singular and the plural forms, unless otherwise indicated herein or clearly inconsistent with the context. The terms "comprising," "having," "including," and "containing" shall be construed as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise noted. The recitation of numerical ranges herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated herein as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or clearly inconsistent with the context. Any examples or exemplary language (e.g., "such as") used herein are intended merely to better illustrate the disclosure and are not intended to limit the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0102] In this specification, preferred embodiments of the present disclosure are described, including the best mode known to the inventors for carrying out the present disclosure. For those skilled in the art, upon reading the above description, variations of these preferred embodiments will become apparent. The inventors expect skilled persons to apply such variations as appropriate, and contemplate that the present disclosure will be implemented in ways other than those specifically described in this specification. Accordingly, the present disclosure includes all modifications and equivalents of the content recited in the claims appended hereto, as permitted by the applicable law. Further, any combination of the above elements in all variations is included in the present disclosure, unless otherwise specifically indicated herein or clearly inconsistent with the context.

Claims

1. a mold for holding a motor core including a resin filled portion; a chamber formed in the mold and communicating with a resin composition filling passage, one end of which communicates with the resin filling portion; a plunger that transports the thermosetting resin composition transported to the chamber toward the resin composition filling path; a heater disposed within the mold or within the mold and around the chamber; an extruder that conveys the resin composition to the chamber while kneading the resin composition so as to introduce the resin composition into the chamber as a paste-like resin composition; The extruder comprises: an extrusion conveying path through which the resin composition is conveyed; a screw disposed in the extrusion conveying path for conveying the resin composition while kneading the resin composition; A first temperature control mechanism at least a part of which is disposed inside the screw, the first temperature adjustment mechanism includes an inlet passage having a heat medium supply port at one end and extending from a base end side of the screw along a central axis of the screw, and an outlet passage having one end communicating with the other end of the inlet passage and extending toward the base end side of the screw; Motor core manufacturing equipment.

2. The heat medium used in the first temperature adjustment mechanism is a gas.

2. An apparatus for manufacturing a motor core according to claim 1.

3. a mold for holding a motor core including a resin filled portion; a chamber formed in the mold and communicating with a resin composition filling passage, one end of which communicates with the resin filling portion; a plunger that transports the thermosetting resin composition transported to the chamber toward the resin composition filling path; a heater disposed within the mold or within the mold and around the chamber; an extruder that conveys the resin composition to the chamber while kneading the resin composition so as to introduce the resin composition into the chamber as a paste-like resin composition; The extruder comprises: an extrusion conveying path through which the resin composition is conveyed; a screw disposed in the extrusion conveying path for conveying the resin composition while kneading the resin composition; A first temperature control mechanism at least a part of which is disposed inside the screw, The screw includes a cylindrical first screw body having fins formed around its outer periphery for transporting the resin composition and a closed tip, and a first flow path forming member configured as a cylindrical body having a through hole extending along the longitudinal direction at its center and having a plurality of grooves extending along the longitudinal direction formed around its outer periphery, the first flow path forming member being fitted into the first screw body such that a gap is formed between the tip of the first flow path forming member and a bottom portion inside the first screw body. Motor core manufacturing equipment.

4. a mold for holding a motor core including a resin filled portion; a chamber formed in the mold and communicating with a resin composition filling passage, one end of which communicates with the resin filling portion; a plunger that transports the thermosetting resin composition transported to the chamber toward the resin composition filling path; a heater disposed within the mold or within the mold and around the chamber; an extruder that conveys the resin composition to the chamber while kneading the resin composition so as to introduce the resin composition into the chamber as a paste-like resin composition; The extruder comprises: an extrusion conveying path through which the resin composition is conveyed; a screw disposed in the extrusion conveying path for conveying the resin composition while kneading the resin composition; A first temperature control mechanism at least a part of which is disposed inside the screw, The screw includes a second screw body having fins formed around its outer periphery for transporting the resin composition and a plurality of through holes formed inside the second screw body and extending along the longitudinal direction, and a second flow path forming member connected to a tip end of the second screw body to communicate ends of the plurality of through holes with each other. Motor core manufacturing equipment.

5. the second screw body is formed by connecting a plurality of divided bodies each having the fins formed on an outer periphery and a plurality of through holes formed inside the divided bodies extending along a longitudinal direction such that the plurality of through holes communicate with each other.

5. An apparatus for manufacturing a motor core according to claim 4.

6. a mold for holding a motor core including a resin filled portion; a chamber formed in the mold and communicating with a resin composition filling passage, one end of which communicates with the resin filling portion; a plunger that transports the thermosetting resin composition transported to the chamber toward the resin composition filling path; a heater disposed within the mold or within the mold and around the chamber; An extruder that conveys the resin composition to the chamber while kneading the resin composition in order to introduce the resin composition into the chamber; The extruder comprises: an extrusion conveying path through which the resin composition is conveyed; a screw disposed in the extrusion conveying path for conveying the resin composition while kneading the resin composition; A first temperature control mechanism at least a part of which is disposed inside the screw, the first temperature adjustment mechanism includes an inlet passage having a heat medium supply port at one end and extending from a base end side of the screw along a central axis of the screw, and an outlet passage having one end communicating with the other end of the inlet passage and extending toward the base end side of the screw; Motor core manufacturing equipment.

7. a step of holding the motor core in a mold in which a resin composition filling passage is formed, such that the resin composition filling passage communicates with a resin filling portion of the motor core; a step of using an extruder capable of conveying a resin composition to convey the resin composition toward a chamber communicating with the resin composition filling path while controlling the temperature, the extruder comprising: an extrusion conveying path through which the resin composition is conveyed; a screw disposed within the extrusion conveying path and conveying the resin composition while kneading it; and a first temperature control mechanism at least a part of which is disposed within the screw, the first temperature control mechanism comprising: an inlet passage having a heat medium supply port at one end and extending along a central axis of the screw from a base end side of the screw; and an outlet passage having one end communicating with the other end of the inlet passage and extending toward the base end side of the screw; a step of operating a plunger movable within the chamber to fill the softened resin composition in the chamber into the resin filling section; and curing the softened resin composition filled in the resin filling portion. A manufacturing method for a motor core.

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