Rotor and rotor manufacturing method

Abstract

To provide a rotor which can secure insulation property between a rotor core and a permanent magnet, even if the permanent magnet is not covered with an insulation coating.SOLUTION: A rotor 100 includes an adhesive member 30 which includes a first resin material 31 and a first insulation material 32 that has predetermined thickness t1 and has a sheet shape, is mounted on a first surface 21 of a permanent magnet 20 and is bonded to a first inner peripheral surface 11a of a magnet arrangement hole 11.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a rotor and a method for manufacturing a rotor. [Background technology]

[0002] Conventionally, a rotor is known that includes an adhesive member attached to one surface of a permanent magnet that is not covered with an insulating coating and bonded to one inner circumferential surface of a magnet placement hole (see, for example, Patent Document 1).

[0003] Patent Document 1 discloses an embedded magnet rotor (rotor) including a non-expanding adhesive sheet (adhesive member) containing a resin material attached to one surface of a permanent magnet that is not covered with an insulating coating and adhered to one inner circumferential surface of a slot (magnet placement hole), and an expansive adhesive sheet (expansion member) containing a resin material attached to the other surface of the permanent magnet and expanding to press against the other surface of the permanent magnet and the other inner circumferential surface of the slot. In the embedded magnet rotor described in Patent Document 1, the non-expansive adhesive sheet is configured to expand when heated. Then, by heating the non-expansive adhesive sheet and the permanent magnet to which the expansive adhesive sheet is attached, the resin material of the non-expansive adhesive sheet melts, adhering the non-expansive adhesive sheet to one inner circumferential surface of the slot, and expanding the expansive adhesive sheet to press against the other surface of the permanent magnet and the other inner circumferential surface of the slot. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-104273 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the conventional embedded magnet rotor described in Patent Document 1, the resin material of the non-expanding adhesive sheet (adhesive member) is melted, which can cause the resin material to flow and result in the thickness of the non-expanding adhesive sheet being smaller than the distance required to ensure insulation between one inner circumferential surface of the slot (magnet placement hole) and one surface of the permanent magnet. In this case, insulation between the rotor core and the permanent magnet cannot be ensured. For this reason, there is a need for a rotor and a method for manufacturing a rotor that can ensure insulation between the rotor core and the permanent magnet even when the permanent magnet is not covered with an insulating coating.

[0006] The present invention has been made to solve the above-mentioned problems, and one object of the present invention is to provide a rotor and a method for manufacturing a rotor that can ensure insulation between the rotor core and permanent magnets even when the permanent magnets are not covered with an insulating coating. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, a rotor in a first aspect of the present invention comprises a rotor core having a magnet arrangement hole formed therein, a permanent magnet arranged in the magnet arrangement hole and not covered with an insulating coating, an adhesive member comprising a first resin material and a sheet-like first insulating material having a predetermined thickness, attached to a first surface of the permanent magnet and bonded to a first inner surface of the magnet arrangement hole, and an expansion member comprising a second resin material, attached to a second surface opposite the first surface of the permanent magnet, and expanded so as to press against the second surface of the permanent magnet and the second inner surface opposite the first inner surface of the magnet arrangement hole.

[0008] As described above, a rotor according to a first aspect of the present invention includes an adhesive member including a first resin material and a sheet-like first insulating material having a predetermined thickness, attached to the first surface of the permanent magnet, and bonded to the first inner circumferential surface of the magnet placement hole. This allows the sheet-like first insulating material having a predetermined thickness to maintain the thickness of the adhesive member at or above the predetermined thickness even if the resin material flows when melted. In other words, the distance between the first inner circumferential surface of the magnet placement hole and the first surface of the permanent magnet can be maintained at or above the predetermined thickness. As a result, insulation between the rotor core and the permanent magnet can be ensured even when the permanent magnet is not covered with an insulating coating.

[0009] In the rotor according to the first aspect, the first insulating material of the adhesive member is preferably configured in the form of a woven fabric.

[0010] With this configuration, the first insulating material can be easily formed into a sheet having a predetermined thickness.

[0011] In the aforementioned rotor according to the first aspect, the adhesive member preferably includes a first resin material that is a thermoplastic resin, and the expansion member preferably includes a second resin material that is a thermoplastic resin.

[0012] With this configuration, because the first resin material and the second resin material are thermoplastic resins, the first resin material and the second resin material can be repeatedly heated to melt and cooled to solidify. As a result, after attaching the adhesive member to the first surface of the permanent magnet and the expansion member to the second surface of the permanent magnet, the permanent magnet to which the adhesive member and the expansion member are attached can be heated to melt the first resin material of the adhesive member and expand the expansion member.

[0013] In the rotor according to the first aspect, the first resin material of the adhesive member and the second resin material of the expansion member are preferably made of the same material.

[0014] With this configuration, the melting points of the first and second resin materials are the same, so the adhesive member containing the first resin material and the expansion member containing the second resin material can be heated and melted simultaneously. As a result, with the adhesive member placed on the first surface of the permanent magnet and the expansion member placed on the second surface of the permanent magnet, simply heating the permanent magnet once can melt the first resin material of the adhesive member and expand the expansion member, simplifying the rotor manufacturing process.

[0015] In order to achieve the above object, a rotor manufacturing method according to a second aspect of the present invention includes an adhesive member arranging step of arranging an adhesive member including a first resin material and a sheet-like first insulating material having a predetermined thickness on a first surface of a permanent magnet that is not covered with an insulating coating, an expansion member arranging step of arranging an expansion member including a second resin material on a second surface of the permanent magnet opposite to the first surface, and a step of arranging an expansion member including a second resin material on a first surface of a magnet arrangement hole of a rotor core after the adhesive member arranging step and the expansion member arranging step. and a heating step, after the magnet insertion step, of heating the permanent magnet on which the adhesive member and expansion member are arranged so that a first resin material of the adhesive member, which includes a sheet-like first insulating material having a predetermined thickness, melts and the expansion member expands so that the expansion member presses against the second surface of the permanent magnet and the second inner surface of the magnet arrangement hole.

[0016] A rotor manufacturing method according to a second aspect of the present invention includes, after the magnet insertion step, a heating step of heating the adhesive member and the permanent magnet with the expansion member disposed thereon, the adhesive member including a sheet-like first insulating material having a predetermined thickness, so that the first resin material of the adhesive member melts and the expansion member expands so that the expansion member presses against the second surface of the permanent magnet and the second inner circumferential surface of the magnet placement hole. As a result, similar to the rotor according to the first aspect, the sheet-like first insulating material having a predetermined thickness allows the adhesive member to maintain a thickness equal to or greater than the predetermined thickness even if the first resin material of the adhesive member flows when melted. As a result, similar to the rotor according to the first aspect, insulation between the rotor core and the permanent magnet can be ensured even if the permanent magnet is not covered with an insulating coating.

[0017] In the aforementioned method for manufacturing a rotor according to the second aspect, the adhesive member arranging step is preferably a step of arranging an adhesive member including a first insulating material configured in a woven fabric form on the first surface of the permanent magnet.

[0018] With this configuration, the first insulating material can be easily formed into a sheet having a predetermined thickness, as in the rotor according to the first aspect.

[0019] In the rotor manufacturing method according to the second aspect, the adhesive member placement step is preferably a step of placing an adhesive member containing a first resin material which is a thermoplastic resin by attaching it to a first surface of the permanent magnet by thermocompression bonding, and the expansion member placement step is a step of placing an expansion member containing a second resin material which is a thermoplastic resin by attaching it to a second surface of the permanent magnet by thermocompression bonding.

[0020] With this configuration, similar to the rotor according to the first aspect, the first and second resin materials are thermoplastic resins, allowing for repeated heating, melting, and cooling to solidify the first and second resin materials. This allows for a heating step in which the adhesive member and the permanent magnet are heated after the adhesive member is attached to the first surface of the permanent magnet by thermocompression bonding in the adhesive member arranging step and after the expansion member is attached to the second surface of the permanent magnet by thermocompression bonding, so that the first resin material of the adhesive member melts and the expansion member expands. Furthermore, because the expansion member is attached to the second surface of the permanent magnet by thermocompression bonding, the expansion member can be heated while being pressurized when being attached to the second surface of the permanent magnet. This prevents the second resin material from softening due to heating, which would otherwise cause the expansion member to expand when being attached to the second surface of the permanent magnet.

[0021] In the above-mentioned configuration in which the adhesive member placement step is a step of placing the adhesive member by attaching it to the first surface of the permanent magnet by thermocompression and the expansion member placement step is a step of placing the expansion member by attaching it to the second surface of the permanent magnet by thermocompression, preferably, the adhesive member placement step is a step of placing the adhesive member by attaching it to the first surface of the permanent magnet by thermocompression at a first temperature, the expansion member placement step is a step of placing the expansion member by attaching it to the second surface of the permanent magnet by thermocompression at the first temperature, and the heating step is a step of heating the permanent magnet on which the adhesive member and expansion member are placed at a second temperature higher than the first temperature.

[0022] With this configuration, the temperature for thermocompression bonding the adhesive member to the first surface of the permanent magnet in the adhesive member placement step and the temperature for thermocompression bonding the expansion member to the second surface of the permanent magnet in the expansion member placement step are relatively low, which reduces energy consumption in the rotor manufacturing process and shortens the cooling time after heating, thereby shortening the rotor manufacturing time. Furthermore, because thermocompression bonding exerts an adhesive force equal to the amount of pressure applied, the heating temperature can be reduced by the amount of pressure applied to achieve the same adhesive force.

[0023] In the present application, the rotor according to the first aspect may also have the following configuration.

[0024] (Additional note 1) In the rotor manufacturing method according to the second aspect, the expansion member placement process is preferably a process of placing an expansion member including a second resin material made of the same material as the first resin material of the adhesive member on the second surface of the permanent magnet.

[0025] With this configuration, as with the rotor according to the first aspect, the melting points of the first and second resin materials are the same, so that the adhesive member containing the first resin material and the expansion member containing the second resin material can be heated and melted simultaneously. As a result, with the adhesive member disposed on the first surface of the permanent magnet and the expansion member disposed on the second surface of the permanent magnet, the heating step can be performed once to heat the permanent magnet on which the adhesive member and the expansion member are disposed so that the first resin material of the adhesive member melts and the expansion member expands, thereby simplifying the rotor manufacturing process. [Effects of the Invention]

[0026] According to the present invention, as described above, it is possible to provide a rotor and a method for manufacturing a rotor that can ensure insulation between the rotor core and the permanent magnet even when the permanent magnet is not covered with an insulating coating. [Brief explanation of the drawings]

[0027] [Figure 1] 1 is a plan view showing a rotor according to an embodiment of the present invention; [Figure 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Figure 3] 1 is a cross-sectional view showing an adhesive member according to an embodiment of the present invention. [Figure 4] 3 is a view of a first insulating material of an adhesive member according to an embodiment of the present invention, viewed from the thickness direction of the adhesive member. FIG. [Figure 5] 1 is a view of a nonwoven fabric member that is a material for an inflatable member according to one embodiment of the present invention, viewed from the thickness direction of the inflatable member. [Figure 6] 1 is a cross-sectional view showing a process of forming a nonwoven fabric integrated member from a nonwoven fabric-like member according to one embodiment of the present invention. [Figure 7] 1 is a cross-sectional view illustrating a process of forming an expansion member from a nonwoven fabric integrated member according to one embodiment of the present invention. [Figure 8] 4 is a cross-sectional view showing a state in which permanent magnets are inserted into magnet arrangement holes of a rotor core according to an embodiment of the present invention. FIG. [Figure 9] A cross-sectional view showing the state in which a permanent magnet is inserted into a magnet placement hole of a rotor core according to one embodiment of the present invention, and the rotor core is heated, causing the expansion member to expand so as to press against the permanent magnet and the magnet insertion hole. [Figure 10] FIG. 3 is a flow diagram illustrating a method for manufacturing a rotor according to an embodiment of the present invention. [Figure 11] 5A to 5C are schematic diagrams illustrating an adhesive member forming step in the method for manufacturing a rotor according to an embodiment of the present invention. [Figure 12] 4 is a cross-sectional view illustrating an adhesive member and expansion member arranging step in a method for manufacturing a rotor according to an embodiment of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0028] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. [Rotor configuration] The configuration of a rotor 100 according to one embodiment of the present invention will be described with reference to FIGS.

[0029] In the following description, the axial, radial, and circumferential directions of the rotor 100 are referred to as the Z direction, R direction, and C direction, respectively. One side and the other side in the axial direction (Z direction) are referred to as the Z1 side and the Z2 side, respectively. The inner and outer sides in the radial direction (R direction) are referred to as the R1 side and the R2 side, respectively.

[0030] (Overall rotor configuration) 1, the rotor 100 is formed in an annular shape. The rotor 100, together with a stator (not shown) disposed on the R2 side of the rotor 100 so as to face the rotor 100, constitutes a part of an inner rotor type rotating electric machine (not shown). The rotating electric machine is, for example, a motor, a generator, or a motor / generator.

[0031] The rotor 100 includes a rotor core 10 and a permanent magnet 20 .

[0032] The rotor core 10 is formed by stacking a plurality of electromagnetic steel plates (for example, silicon steel plates) in the Z direction. Magnet arrangement holes 11 are formed in the rotor core 10. The magnet arrangement holes 11 penetrate the rotor core 10 in the Z direction. A plurality of magnet arrangement holes 11 are formed in the rotor core 10. Each of the plurality of magnet arrangement holes 11 is arranged in the R2 side portion of the rotor core 10.

[0033] A permanent magnet 20 is arranged in each of the multiple magnet arrangement holes 11. When viewed from the Z direction, the permanent magnet 20 has a rectangular shape. The permanent magnet 20 is not covered with an insulating coating. Note that, although the figure shows an example in which one permanent magnet 20 is arranged in each of the multiple magnet arrangement holes 11, the number of permanent magnets 20 arranged in each of the multiple magnet arrangement holes 11 may be two or more.

[0034] (Permanent magnet fixing structure) 2, the rotor 100 includes an adhesive member 30 and an expansion member 40. The permanent magnets 20 are fixed to the rotor core 10 in the magnet arrangement holes 11 by the adhesive member 30 and the expansion member 40.

[0035] As shown in FIG. 3, the adhesive member 30 includes a first resin material 31. The first resin material 31 is a thermoplastic resin. The first resin material 31 is, for example, polyetherimide. The adhesive member 30 includes a sheet-like first insulating material 32 having a predetermined thickness t1. The first insulating material 32 is, for example, glass fiber. The predetermined thickness t1 is equal to or less than a thickness t2 of the adhesive member 30.

[0036] 4, the first insulating material 32 is configured in the form of a woven fabric. Specifically, when viewed in the thickness direction of the adhesive member 30, a plurality of fibrous first insulating materials 32 extending in a first direction and a plurality of fibrous first insulating materials 32 extending in a direction perpendicular to the first direction are woven so as to intersect with each other.

[0037] As shown in Fig. 2, the adhesive member 30 is attached to the first surface 21 on the R2 side of the permanent magnet 20 by thermocompression bonding. The adhesive member 30 is also bonded to the first inner circumferential surface 11a on the R2 side of the magnet arrangement hole 11 by fusion bonding caused by melting a first resin material 31 (see Fig. 3). Note that although the figure shows the adhesive member 30 attached to the entire first surface 21 of the permanent magnet 20 in the Z direction, it does not have to be attached to the entire first surface 21 of the permanent magnet 20 in the Z direction.

[0038] As shown in FIG. 5, the expansion member 40 includes a second resin material 41 and a second insulating material 42. The second resin material 41 is a thermoplastic resin. The second resin material 41 is made of the same material as the first resin material 31. The second resin material 41 is, for example, polyetherimide. The second insulating material 42 is made of the same material as the first insulating material 32. The second insulating material 42 is, for example, glass fiber. Note that FIG. 5 shows a sheet-shaped nonwoven fabric material 40A as the material of the expansion member 40.

[0039] The expansion member 40 is configured to expand when heated. Specifically, a plurality of sheet-like nonwoven fabric members 40A each including a fibrous second resin material 41 and a fibrous second insulating material 42 are prepared as the material for the expansion member 40. Then, as shown in FIG. 6 , the plurality of nonwoven fabric members 40A are heated and pressurized in a stacked state, whereby the plurality of nonwoven fabric members 40A are compressed and integrated to form an integrated nonwoven fabric member 40B. Stress is imparted to the integrated nonwoven fabric member 40B due to the compression. Then, as shown in FIG. 7 , when the integrated nonwoven fabric member 40B is heated without pressure being applied from both sides, the second resin material 41 melts (softens), and the stress imparted to the integrated nonwoven fabric member 40B is released, causing the integrated nonwoven fabric member 40B to expand and form the expansion member 40. As a result, as shown in Figure 8, the permanent magnet 20 with the adhesive member 30 and expansion member 40 arranged thereon is inserted into the magnet arrangement hole 11 of the rotor core 10 so that the first surface 21 and the second surface 22 of the permanent magnet 20 face the first inner surface 11a on the R2 side of the magnet arrangement hole 11 of the rotor core 10 and the second inner surface 11b on the opposite side (R1 side) of the first inner surface 11a, respectively, with the expansion member 40 having a thickness t3.Then, as shown in Figure 9, the permanent magnet 20 with the adhesive member 30 and expansion member 40 arranged thereon is heated, causing the expansion member 40 to expand (to a state where it has a thickness t4 greater than thickness t3) so that it presses against the second surface 22 of the permanent magnet 20 and the second inner surface 11b of the magnet arrangement hole 11.

[0040] 2, the expansion member 40 is attached by thermocompression to the second surface 22 of the permanent magnet 20 on the opposite side (R1 side) from the first surface 21. The expansion member 40 also expands so as to press against the second surface 22 of the permanent magnet 20 and the second inner circumferential surface 11b of the magnet arrangement hole 11 on the opposite side (R1 side) from the first inner circumferential surface 11a. Note that although the figure shows the expansion member 40 attached to the entire second surface 22 of the permanent magnet 20 in the Z direction, it does not have to be attached to the entire second surface 22 of the permanent magnet 20 in the Z direction.

[0041] [Rotor manufacturing method] A method for manufacturing the rotor 100 according to one embodiment of the present invention will be described with reference to FIGS.

[0042] (Rotor core forming process) As shown in Fig. 10, a rotor core forming step is performed in step S1. The rotor core forming step (S1) is a step of forming a rotor core 10 in which magnet arrangement holes 11 are formed.

[0043] (Adhesive member forming process) In step S2, an adhesive member forming step is performed. As shown in Fig. 3, the adhesive member forming step (S2) is a step of forming an adhesive member 30 including a first resin material 31, which is a thermoplastic resin that melts when heated, and a sheet-like first insulating material 32 that is configured like a woven fabric having a predetermined thickness t1 (see Fig. 4). Specifically, as shown in Fig. 11, the sheet-like first resin material 31, the sheet-like first insulating material 32, and the sheet-like first resin material 31 are stacked in this order and then pressurized and heated to be integrated, thereby forming the sheet-like adhesive member 30 including the first resin material 31 and the sheet-like first insulating material 32.

[0044] (Expansion member forming process) As shown in FIG. 10, an expansion member forming step (S3) is performed. As shown in FIGS. 5 to 7, the expansion member forming step (S3) is a step of forming an expansion member 40 that includes a second resin material 41, which is a thermoplastic resin made of the same material as the first resin material 31, which is the thermoplastic resin of the adhesive member 30, and that is configured to expand when heated. Specifically, as shown in FIG. 5, a plurality of sheet-like nonwoven fabric members 40A, each including a fibrous second resin material 41 and a fibrous second insulating material 42, are prepared as the material for the expansion member 40. Then, as shown in FIG. 6, the plurality of nonwoven fabric members 40A are heated and pressurized in a stacked state, thereby compressing and integrating the plurality of nonwoven fabric members 40A to form an integrated nonwoven fabric member 40B. During this process, stress is applied to the integrated nonwoven fabric member 40B due to the compression. As a result, as shown in Figure 7, when the nonwoven fabric integrated member 40B is heated without pressure being applied from both sides, and the second resin material 41 softens, the stress applied to the nonwoven fabric integrated member 40B is released, and the nonwoven fabric integrated member 40B expands to form the expansion member 40.

[0045] (Adhesive and expansion member placement process) As shown in FIG. 10, in step S4, an adhesive member / expansion member arranging step is performed. As shown in FIG. 12, the adhesive member / expansion member arranging step (S4) is a step of arranging an adhesive member 30 on the first surface 21 of the permanent magnet 20. The adhesive member / expansion member arranging step (S4) is also a step of arranging an expansion member 40 on the second surface 22 of the permanent magnet 20 opposite the first surface 21. Specifically, the adhesive member / expansion member arranging step (S4) is a step of arranging an adhesive member 30 containing a first resin material 31, which is a thermoplastic resin, by thermocompression bonding to the first surface 21 of the permanent magnet 20 at a first temperature. The adhesive member / expansion member arranging step (S4) is also a step of arranging an expansion member 40 containing a second resin material 41, which is a thermoplastic resin, by thermocompression bonding to the second surface 22 of the permanent magnet 20 at a first temperature. The first temperature is, for example, approximately 270°C. The pressure of the thermocompression bonding for attaching the adhesive member 30 to the first surface 21 of the permanent magnet 20 and the pressure of the thermocompression bonding for attaching the expansion member 40 to the second surface 22 of the permanent magnet 20 are, for example, 5 MPa. The adhesive member / expansion member arranging step is an example of the "adhesive member arranging step" in the claims, and is also an example of the "expansion member arranging step" in the claims.

[0046] (Magnet insertion process) As shown in Fig. 10, a magnet insertion process is performed in step S5. As shown in Fig. 11, the magnet insertion process (S5) is a process of inserting the permanent magnet 20, on which the adhesive member 30 and the expansion member 40 are arranged, into the magnet arrangement hole 11 of the rotor core 10 so that the first surface 21 and the second surface 22 of the permanent magnet 20 face the first inner circumferential surface 11a on the R2 side of the magnet arrangement hole 11 of the rotor core 10 and the second inner circumferential surface 11b on the opposite side (R1 side) of the first inner circumferential surface 11a. Note that, when the magnet insertion process (S5) is completed, gaps are formed between the adhesive member 30 arranged on the first surface 21 of the permanent magnet 20 and the first inner circumferential surface 11a of the magnet arrangement hole 11, and between the expansion member 40 arranged on the second surface 22 of the permanent magnet 20 and the second inner circumferential surface 11b of the magnet arrangement hole 11.

[0047] (Heating process) As shown in Fig. 10, a heating step is performed in step S6. As shown in Fig. 12, the heating step (S6) is a step of heating the permanent magnet 20, on which the adhesive member 30 and the expansion member 40 are arranged, at a second temperature higher than the first temperature so that the first resin material 31 of the adhesive member 30, which includes the sheet-like first insulating material 32 having a predetermined thickness t1 (see Fig. 3), melts and the expansion member 40 expands so as to press against the second surface 22 of the permanent magnet 20 and the second inner circumferential surface 11b of the magnet arrangement hole 11. The second temperature is, for example, approximately 320°C. After the heating step (S6), the permanent magnet 20 with the adhesive member 30 and expansion member 40 arranged thereon is cooled, causing the first insulating material 32 of the adhesive member 30 to solidify, and the first surface 21 of the permanent magnet 20 to be adhered to the first inner surface 11a of the magnet arrangement hole 11 via the adhesive member 30, while the second insulating material 42 of the expansion member 40 solidifies, leaving the expansion member 40 in an expanded state so as to press against the second surface 22 of the permanent magnet 20 and the second inner surface 11b of the magnet arrangement hole 11.

[0048] Through the above steps, the permanent magnets 20 are fixed to the rotor core 10 in the magnet arrangement holes 11 by the adhesive members 30 and the expansion members 40.

[0049] [Effects of this embodiment] In this embodiment, the following effects can be obtained.

[0050] (Effects of the rotor of this embodiment) The rotor 100 of this embodiment includes an adhesive member 30 that includes a first resin material 31 and a sheet-like first insulating material 32 having a predetermined thickness t1. The adhesive member 30 is attached to the first surface 21 of the permanent magnet 20 and is bonded to the first inner circumferential surface 11a of the magnet arrangement hole 11. The sheet-like first insulating material 32 having the predetermined thickness t1 allows the thickness t2 of the adhesive member 30 to be maintained at or above the predetermined thickness t1, even if the first resin material 31 of the adhesive member 30 flows when melted. In other words, the distance between the first inner circumferential surface 11a of the magnet arrangement hole 11 and the first surface 21 of the permanent magnet 20 can be maintained at or above the predetermined thickness t1. As a result, insulation between the rotor core 10 and the permanent magnet 20 can be ensured even if the permanent magnet 20 is not covered with an insulating coating.

[0051] In addition, in the rotor 100 of this embodiment, the first insulating material 32 of the adhesive member 30 is configured in a woven fabric form, which makes it possible to easily form the first insulating material 32 into a sheet shape having a predetermined thickness t1.

[0052] Furthermore, in the rotor 100 of this embodiment, the adhesive member 30 includes a first resin material 31 that is a thermoplastic resin. The expansion member 40 includes a second resin material 41 that is a thermoplastic resin. As a result, since the first resin material 31 and the second resin material 41 are thermoplastic resins, the first resin material 31 and the second resin material 41 can be repeatedly heated to melt and cooled to solidify. As a result, after attaching the adhesive member 30 to the first surface 21 of the permanent magnet 20 and after attaching the expansion member 40 to the second surface 22 of the permanent magnet 20, the permanent magnet 20 to which the adhesive member 30 and the expansion member 40 are attached can be heated to melt the first resin material 31 of the adhesive member 30 and expand the expansion member 40.

[0053] Furthermore, in the rotor 100 of this embodiment, the second resin material 41 of the expansion member 40 is made of the same material as the first resin material 31 of the adhesive member 30. As a result, the melting points of the first resin material 31 and the second resin material 41 are the same, so the adhesive member 30 including the first resin material 31 and the expansion member 40 including the second resin material 41 can be heated and melted simultaneously. As a result, with the adhesive member 30 arranged on the first surface 21 of the permanent magnet 20 and the expansion member 40 arranged on the second surface 22 of the permanent magnet 20, the first resin material 31 of the adhesive member 30 can be melted and the expansion member 40 can be expanded by simply heating the permanent magnet 20 once. This simplifies the manufacturing process of the rotor 100.

[0054] (Effects of the rotor manufacturing method of this embodiment) Furthermore, the manufacturing method of the rotor 100 of this embodiment includes, after the magnet insertion step (S5), a heating step (S6) of heating the adhesive member 30 and the permanent magnet 20 on which the expansion member 40 is disposed so that the first resin material 31 of the adhesive member 30, which includes a sheet-like first insulating material 32 having a predetermined thickness t1, melts and the expansion member 40 expands so that the expansion member 40 presses against the second surface 22 of the permanent magnet 20 and the second inner circumferential surface 11b opposite the first inner circumferential surface 11a of the magnet arrangement hole 11. As a result, similar to the rotor 100 described above, the sheet-like first insulating material 32 having the predetermined thickness t1 allows the thickness t2 of the adhesive member 30 to be maintained at or above the predetermined thickness t1 even if the first resin material 31 of the adhesive member 30 flows when melted. As a result, similar to the rotor 100 described above, insulation between the rotor core 10 and the permanent magnet 20 can be ensured even if the permanent magnet 20 is not covered with an insulating coating.

[0055] Furthermore, in the manufacturing method of the rotor 100 of this embodiment, the adhesive member / expansion member arranging step (S4) is a step of arranging the adhesive member 30 including the first insulating material 32 configured in a woven fabric form on the first surface 21 of the permanent magnet 20. As a result, similar to the rotor 100 described above, the first insulating material 32 can be easily formed into a sheet shape having a predetermined thickness t1.

[0056] Furthermore, in the manufacturing method of the rotor 100 of this embodiment, the adhesive member / expansion member arranging step (S4) is a step of arranging an adhesive member 30 including a first resin material 31, which is a thermoplastic resin, by attaching it to the first surface 21 of the permanent magnet 20 by thermocompression bonding. Also, the adhesive member / expansion member arranging step (S4) is a step of arranging an expansion member 40 including a second resin material 41, which is a thermoplastic resin, by attaching it to the second surface 22 of the permanent magnet 20 by thermocompression bonding. As a result, similar to the rotor 100 described above, since the first resin material 31 and the second resin material 41 are thermoplastic resins, heating, melting, and cooling, and solidifying of the first resin material 31 and the second resin material 41 can be repeatedly performed. As a result, in the adhesive member / expansion member arranging step (S4), the adhesive member 30 is attached to the first surface 21 of the permanent magnet 20 by thermocompression bonding, and the expansion member 40 is attached to the second surface 22 of the permanent magnet 20 by thermocompression bonding. After this, a heating step (S6) can be performed in which the permanent magnet 20 on which the adhesive member 30 and the expansion member 40 are attached is heated so that the first resin material 31 of the adhesive member 30 melts and the expansion member 40 expands. Furthermore, because the expansion member 40 is attached to the second surface 22 of the permanent magnet 20 by thermocompression bonding, the expansion member 40 can be heated while being pressurized when attaching it to the second surface 22 of the permanent magnet 20. This prevents the second resin material 41 from softening due to heating, causing the expansion member 40 to expand, when attaching it to the second surface 22 of the permanent magnet 20.

[0057] Furthermore, in the manufacturing method of the rotor 100 of this embodiment, the adhesive member / expansion member arranging step (S4) is a step of arranging the adhesive member 30 by thermocompression bonding to the first surface 21 of the permanent magnet 20 at a first temperature. Also, the adhesive member / expansion member arranging step (S4) is a step of arranging the expansion member 40 by thermocompression bonding to the second surface 22 of the permanent magnet 20 at a first temperature. Also, the heating step (S6) is a step of heating the permanent magnet 20 on which the adhesive member 30 and expansion member 40 are arranged at a second temperature higher than the first temperature. As a result, the temperature for thermocompression bonding the adhesive member 30 to the first surface 21 of the permanent magnet 20 in the adhesive member / expansion member arranging step (S4), and the temperature for thermocompression bonding the expansion member 40 to the second surface 22 of the permanent magnet 20 in the adhesive member / expansion member arranging step (S4), are relatively low, which reduces energy consumption in the manufacturing process of the rotor 100 and shortens the cooling time after heating, thereby shortening the manufacturing time of the rotor 100. Note that thermocompression bonding exerts an adhesive force equal to the amount of pressure applied, so the heating temperature can be reduced by the amount of pressure applied to achieve the same adhesive force.

[0058] Furthermore, in the manufacturing method of the rotor 100 of this embodiment, the adhesive member / expansion member arrangement step (S4) is a step of arranging an expansion member 40 including a second resin material 41 made of the same material as the first resin material 31 of the adhesive member 30 on the second surface 22 of the permanent magnet 20. As a result, similar to the rotor 100 described above, since the melting points of the first resin material 31 and the second resin material 41 are the same, the adhesive member 30 including the first resin material 31 and the expansion member 40 including the second resin material 41 can be heated and melted simultaneously. As a result, with the adhesive member 30 placed on the first surface 21 of the permanent magnet 20 and the expansion member 40 placed on the second surface 22 of the permanent magnet 20, the heating step (S6) can be performed to heat the permanent magnet 20 on which the adhesive member 30 and the expansion member 40 are placed, so that the first resin material 31 of the adhesive member 30 melts and the expansion member 40 expands, by simply heating the permanent magnet 20 once, thereby simplifying the manufacturing process of the rotor 100.

[0059] [Variations] The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims rather than the above description of the embodiments, and further includes all modifications (variations) within the meaning and scope of the claims.

[0060] For example, in the above embodiment, the second resin material 41 of the expansion member 40 is made of the same material as the first resin material 31 of the adhesive member 30, but the present invention is not limited to this. In the present invention, the second resin material of the expansion member may be made of a material different from the first resin material of the adhesive member.

[0061] In addition, in the above embodiment, an example was shown in which the adhesive member / expansion member placement process (S4) is a process in which the adhesive member 30 is placed by attaching it to the first surface 21 of the permanent magnet 20 by thermocompression at a first temperature, the adhesive member / expansion member placement process (S4) is a process in which the expansion member 40 is placed by attaching it to the second surface 22 of the permanent magnet 20 by thermocompression at a first temperature, and the heating process (S6) is a process in which the permanent magnet 20 on which the adhesive member 30 and expansion member 40 are placed is heated at a second temperature higher than the first temperature, but the present invention is not limited to this. In the present invention, the adhesive member / expansion member placement process may be a process of placing the adhesive member by attaching it to a first surface of the permanent magnet by thermocompression at a first temperature, the adhesive member / expansion member placement process may be a process of placing the expansion member by attaching it to a second surface of the permanent magnet by thermocompression at a first temperature, and the heating process may be a process of heating the permanent magnet on which the adhesive member and expansion member are placed at the first temperature or a temperature lower than the first temperature.

[0062] In addition, in the above embodiment, an example is shown in which the adhesive member 30 is attached to the first surface 21 on the R2 side (radially outside the rotor 100) of the permanent magnet 20 by thermocompression bonding and is bonded to the first inner surface 11a on the R2 side of the magnet arrangement hole 11, and the expansion member 40 is attached to the second surface 22 on the R1 side (radially inside the rotor 100) of the permanent magnet 20 by thermocompression bonding and presses against the second surface 22 of the permanent magnet 20 and the second inner surface 11b on the R1 side of the magnet arrangement hole 11, but the present invention is not limited to this. In the present invention, the adhesive member may be attached to a first radially inner surface of the permanent magnet rotor by thermocompression bonding and bonded to a first radially inner inner surface of the rotor of the magnet arrangement hole, and the expansion member may be attached to a second radially outer surface of the permanent magnet rotor by thermocompression bonding and press against the second surface of the permanent magnet and the second radially outer inner surface of the rotor of the magnet arrangement hole.

[0063] In addition, in the above embodiment, an example was shown in which the adhesive member 30 includes the first resin material 31, which is a thermoplastic resin, and is attached to the first surface 21 of the permanent magnet 20 by thermocompression bonding, but the present invention is not limited to this. In the present invention, the adhesive member may include the first resin material, which is a thermosetting resin, and may be attached to the first surface of the permanent magnet by a method other than thermocompression bonding.

[0064] In addition, in the above embodiment, an example was shown in which the expansion member 40 includes the second resin material 41, which is a thermoplastic resin, and is attached to the second surface 22 of the permanent magnet 20 by thermocompression bonding, but the present invention is not limited to this. In the present invention, the expansion member may include the second resin material, which is a thermosetting resin, and may be attached to the second surface of the permanent magnet by a method other than thermocompression bonding.

[0065] In the above embodiment, the first insulating material 32 of the adhesive member 30 is configured as a woven fabric, but the present invention is not limited to this. In the present invention, the first insulating material of the adhesive member does not have to be configured as a woven fabric as long as it is formed as a sheet having a predetermined thickness.

[0066] In addition, in the above embodiment, an example was shown in which the adhesive member / expansion member arranging step (S4) is both the "adhesive member arranging step" and the "expansion member arranging step" in the claims, but the present invention is not limited to this. In the present invention, the "adhesive member arranging step" and the "expansion member arranging step" in the claims may be steps independent of each other. [Explanation of symbols]

[0067] 10...rotor core, 11...magnet arrangement hole, 11a...first inner circumferential surface (of magnet arrangement hole), 11b...second inner circumferential surface (of magnet arrangement hole), 20...permanent magnet, 21...first surface (of permanent magnet), 22...second surface (of permanent magnet), 30...adhesive member, 31...first resin material, 31...first insulating material, 40...expansion member, 41...second resin material, 100...rotor, t1...predetermined thickness

Claims

1. a rotor core having magnet arrangement holes formed therein; a permanent magnet that is disposed in the magnet placement hole and is not covered with an insulating coating; an adhesive member including a first resin material and a sheet-like first insulating material having a predetermined thickness, the adhesive member being attached to a first surface of the permanent magnet and bonded to a first inner circumferential surface of the magnet arrangement hole; a rotor including an expansion member that includes a second resin material, is attached to a second surface of the permanent magnet opposite the first surface, and expands so as to press against the second surface of the permanent magnet and the second inner surface of the magnet arrangement hole opposite the first inner surface.

2. The rotor according to claim 1 , wherein the first insulating material of the adhesive member is configured as a woven fabric.

3. the adhesive member includes the first resin material which is a thermoplastic resin, The rotor of claim 1 , wherein the expansion member includes the second resin material being a thermoplastic resin.

4. 2. The rotor according to claim 1, wherein the second resin material of the expansion member is made of the same material as the first resin material of the adhesive member.

5. an adhesive member placement step of placing an adhesive member including a first resin material and a sheet-like first insulating material having a predetermined thickness on a first surface of the permanent magnet that is not covered with an insulating coating; an expansion member disposing step of disposing an expansion member including a second resin material on a second surface of the permanent magnet opposite to the first surface; a magnet insertion step, after the adhesive member arrangement step and the expansion member arrangement step, of inserting the permanent magnet with the adhesive member and the expansion member arranged thereon into the magnet arrangement hole of the rotor core so that the first surface and the second surface of the permanent magnet face a first inner circumferential surface and a second inner circumferential surface opposite the first inner circumferential surface, respectively, of the magnet arrangement hole of the rotor core; A method for manufacturing a rotor, comprising: after the magnet insertion process, a heating process of heating the adhesive member and the permanent magnet on which the expansion member is arranged so that the first resin material of the adhesive member, which includes a sheet-like first insulating material having the predetermined thickness, melts and the expansion member expands so that the expansion member presses against the second surface of the permanent magnet and the second inner surface of the magnet arrangement hole.

6. 6. The rotor manufacturing method according to claim 5, wherein the adhesive member arranging step is a step of arranging the adhesive member including the first insulating material configured in a woven fabric form on the first surface of the permanent magnet.

7. the adhesive member arranging step is a step of arranging the adhesive member including the first resin material, which is a thermoplastic resin, by attaching it to the first surface of the permanent magnet by thermocompression bonding; 6. The rotor manufacturing method of claim 5, wherein the expansion member placement process is a process of placing the expansion member, which includes the second resin material, which is a thermoplastic resin, by attaching it to the second surface of the permanent magnet by thermocompression bonding.

8. the adhesive member arranging step is a step of arranging the adhesive member by attaching it to the first surface of the permanent magnet by thermocompression bonding at a first temperature; the expansion member disposing step is a step of disposing the expansion member by attaching it to the second surface of the permanent magnet by thermocompression bonding at the first temperature; The method for manufacturing a rotor according to claim 7 , wherein the heating step is a step of heating the permanent magnet on which the adhesive member and the expansion member are disposed at a second temperature higher than the first temperature.

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