Core of rotating electrical machine, armature, and rotating electrical machine

Abstract

To provide the core of a rotating electrical machine which can adjust the insulation property of each part, an armature, and a rotating electrical machine.SOLUTION: A stator core 26 includes magnetic powder 42 containing: iron powder 44 formed using an iron-based material; and a covering part 46 covering the iron powders 44, formed using an insulating material. The stator core 26 includes plural different types of magnetic powder 42A and 42B in which at least one of thickness and material of the covering part 46 is different. The stator 14 includes the stator core 26. Motors 10A, 10B, and 10C include the stator 14.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present disclosure relates to a core of a rotating electric machine, an armature, and a rotating electric machine. [Background technology]

[0002] Patent Document 1 below discloses a stator core formed using a powder magnetic core obtained by pressure-molding soft magnetic powder, which is an aggregate of multiple soft magnetic particles. In the stator core described in this document, the average particle size of the soft magnetic particles located in the second portion of the stator core is larger than the average particle size of the soft magnetic particles located in the first portion. This makes it possible to make the magnetic permeability of the first portion and the second portion of the stator core different. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-16670 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, the configuration described in Patent Document 1 is useful from the viewpoint of being able to adjust the magnetic permeability of each part of the core of a rotating electric machine, such as a stator core, but does not take into consideration adjusting the insulation of each part of the core of the rotating electric machine.

[0005] In consideration of the above, an object of the present disclosure is to provide a rotating electric machine core, an armature, and a rotating electric machine that are capable of adjusting the insulation properties of each part. [Means for solving the problem]

[0006] The rotating electric machine core (26) that solves the above problem includes magnetic powder (42) having a powdered base material (44) made of an iron-based material and a coating portion (46) that is formed of an insulating material with higher insulating properties than the base material and covers the base material, and has a plurality of types of magnetic powder (42A, 42B) with at least one of the thickness and material of the coating portion differing. Also, the armature (14) includes a rotating electric machine core (26) that includes magnetic powder (42) having a powdered base material (44) made of an iron-based material and a coating portion (46) that is formed of an insulating material with higher insulating properties than the base material and covers the base material, and the magnetic powder includes a plurality of types of magnetic powder (42A, 42B) with at least one of the thickness and material of the coating portion differing, and a coil (16) that is arranged along the rotating electric machine core and generates a magnetic field when current is applied. Furthermore, the rotating electric machine (10A, 10B, 10C) is configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) that is insulating and is formed using a material that is more insulating than the base material and covers the base material, and the magnetic powder is configured to include multiple types of magnetic powder (42A, 42B) that differ in at least one of the thickness and material of the coating portion, a rotating electric machine core (26), one of a stator (14) and a rotor (12) configured to include an armature (14) having a coil (16) arranged along the core of the rotating electric machine and that generates a magnetic field when current is passed through it, and the other of the stator and rotor has a magnet (18) arranged opposite the coil and the core of the rotating electric machine.

[0007] By configuring in this manner, it is possible to appropriately adjust the insulation properties of each part of the core of the rotating electrical machine. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing a radial gap type teethless motor, with a portion of the motor cut away. [Figure 2] FIG. 2 is an exploded perspective view showing the motor with some components cut away. [Figure 3] FIG. 1 is a perspective view showing an axial gap type teethless motor, with a portion of the motor cut away. [Figure 4] FIG. 2 is an exploded perspective view showing the motor with some components cut away. [Figure 5] FIG. 1 is a perspective view showing an axial gap type toothed motor, with a portion of the motor cut away. [Figure 6] FIG. 2 is an exploded perspective view showing the motor with some components cut away. [Figure 7] FIG. 2 is a schematic diagram showing a powder magnetic core constituting the stator core of the first embodiment. [Figure 8] 5A to 5C are diagrams schematically showing a manufacturing process of the stator core. [Figure 9] FIG. 2 is a diagram showing a schematic view of magnetic powder after the first coating. [Figure 10] FIG. 10 is a diagram showing a schematic view of magnetic powder after the second coating. [Figure 11] FIG. 10 is a diagram showing a schematic view of magnetic powder after the third coating. [Figure 12] FIG. 2 is a diagram schematically illustrating a first type of magnetic powder. [Figure 13] FIG. 4 is a diagram schematically illustrating a second type of magnetic powder. [Figure 14] FIG. 2 is a diagram schematically showing magnetic powder produced by crushing a stator core. [Figure 15] FIG. 6 is a perspective view showing a coil body and a stator core according to a second embodiment. [Figure 16] 16 is a plan view schematically showing the stator core and other components of the second embodiment in a state where a coil body is attached, as viewed from the direction of arrow S1 shown in FIG. 15. FIG. [Figure 17] 16 is a side cross-sectional view schematically showing the stator core and the like of the second embodiment in a state in which a coil body is attached, as viewed from the direction of arrow S2 shown in FIG. 15. FIG. [Figure 18]18 is an enlarged cross-sectional side view corresponding to FIG. 17, which schematically shows the stator core and the like of the second embodiment in a state where a coil body is attached, and shows an enlarged portion surrounded by a line S3 in FIG. 17. [Figure 19] FIG. 10 is a perspective view showing a coil body, a magnet, and a stator core of a third embodiment. [Figure 20] 20 is a side cross-sectional view schematically showing a stator core and the like of a third embodiment, seen from the direction of an arrow S4 shown in FIG. 19. FIG. [Figure 21] 21 is an enlarged cross-sectional side view corresponding to FIG. 20, which schematically shows a stator core and the like of a third embodiment, and shows an enlarged view of a portion surrounded by a line S5 in FIG. 20. FIG. [Figure 22] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the second embodiment, showing a step in which a first type of magnetic powder is poured into a first die. [Figure 23] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the second embodiment, showing a step in which a first type of magnetic powder introduced into a first die is pressed. [Figure 24] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the second embodiment, showing a state in which molding of the portion formed by the first type of magnetic powder in the stator core according to the second embodiment has been completed. FIG. [Figure 25] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the second embodiment, showing the step of injecting a second type of magnetic powder into the interior of a mold. [Figure 26] 10 is a diagram schematically showing a molded product in which a portion formed from a first type of magnetic powder and a portion formed from a second type of magnetic powder are integrated in a stator core according to a second embodiment. FIG. [Figure 27] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the third embodiment, showing the step of putting the second type of magnetic powder into the first die. FIG. [Figure 28] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the third embodiment, showing a step in which the second type of magnetic powder introduced into the first die is pressed. FIG. [Figure 29] 10 is a schematic diagram for explaining the manufacturing process of the stator core according to the third embodiment, showing a step in which a first type of magnetic powder is poured into a first die. [Figure 30] 10 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of pressing the first type of magnetic powder put into the first mold together with the second type of magnetic powder. FIG. [Figure 31] 10 is a diagram schematically showing a molded product in which a portion formed from a first type of magnetic powder and a portion formed from a second type of magnetic powder are integrated in a stator core according to a third embodiment. FIG. [Figure 32] FIG. 11 is a perspective view of a stator core according to a fourth embodiment, as viewed from the other axial side. [Figure 33] FIG. 10 is a schematic diagram for explaining a method for inspecting magnetic permeability. [Figure 34] FIG. 10 is a schematic diagram for explaining a method for inspecting resistivity. [Figure 35] FIG. 10 is a schematic diagram for explaining a method for inspecting hardness. [Figure 36] FIG. 11 is a perspective view of a stator core according to a fifth embodiment, as viewed from one axial side. [Figure 37] FIG. 13 is a perspective view of a stator core according to a sixth embodiment, as viewed from the other axial side. [Figure 38] 10 is a schematic diagram for explaining the process of forming the stanchion core body and the inspection portion, showing the process of putting a first type of magnetic powder into a first mold. FIG. [Figure 39] FIG. 10 is a schematic diagram for explaining the process of forming the stanchion core body and the inspection portion, showing the process of compressing the first type of magnetic powder that has been put into the first die. [Figure 40] 10 is a schematic diagram for explaining the process of forming the stanchion core body and the inspection portion, showing the process of putting the second type of magnetic powder into a third mold. FIG. [Figure 41] 10 is a schematic diagram for explaining the process of forming the stanchion core body and the inspection portion, showing the process of compressing the second type of magnetic powder that has been put into the third mold. FIG. [Figure 42]FIG. 2 is a diagram schematically showing a stay core body and an inspection portion. DETAILED DESCRIPTION OF THE INVENTION

[0009] 1 to 6, the configurations of three types of motors 10A, 10B, and 10C to which the rotating electric machine core structure of the present disclosure is applied will be described. Note that the arrow Z direction, arrow R direction, and arrow C direction appropriately shown in the figures respectively indicate one side in the rotational axis direction, the outer side in the rotational radial direction, and one side in the rotational circumferential direction of a rotor 12 described below. Furthermore, hereinafter, when simply indicating an axial direction, a radial direction, or a circumferential direction, it will refer to the rotational axis direction, rotational radial direction, or rotational circumferential direction of the rotor 12 unless otherwise specified. Furthermore, the three types of motors 10A, 10B, and 10C are examples of rotating electric machines.

[0010] (1st type motor 10A) As shown in FIGS. 1 and 2, the first type of motor 10A is a radial gap brushless motor in which a rotor 12 as a rotor is disposed radially inside a stator 14 as an armature and a stator.

[0011] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings 20, a rotor core 24 fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the radially outer surface of the rotor core 24. The pair of bearings 20 are supported by a frame 21 and an end frame 23, respectively. The stator 14 and other components are housed between the frame 21 and the end frame 23.

[0012] The rotor core 24 includes a first cylindrical portion 24A to which the rotating shaft 22 is fixed by press-fitting or the like, and a second cylindrical portion 24B disposed radially outward of the first cylindrical portion 24A and also formed cylindrically. The outer peripheral surface, which is the radially outer surface of the second cylindrical portion 24B, is formed cylindrically along the circumferential direction. A magnet 18, which will be described later, is fixed to the outer peripheral surface of the second cylindrical portion 24B.

[0013] The magnets 18 are formed using a magnetic compound having an intrinsic coercivity Hc of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more. 11 TiN, Nd2Fe 14 B, SmFe 17 The rotor core 24 is formed using a magnetic compound such as N3 or FeNi. A plurality of magnets 18 are fixed to the outer peripheral surface of the second cylindrical portion 24B of the rotor core 24. The magnets 18 whose radially outer surfaces are N poles and the magnets 18 whose radially outer surfaces are S poles are arranged alternately in the circumferential direction.

[0014] Stator 14 includes stator core 26 formed in an annular shape as the core of a rotating electrical machine, and coil body 32 attached to stator core 26. Stator 14 has a teethless structure in which no part of stator core 26 is disposed between the coils that form part of coil body 32.

[0015] Stator core 26 is formed into a cylindrical shape using magnetic powder 42 (see FIG. 7), which will be described later. Stator core 26 is arranged coaxially with rotor 12, and the axial center position of stator core 26 and the axial center position of multiple magnets 18 fixed to rotor core 24 coincide in the axial direction. Here, the radially inner surface of stator core 26 serves as coil-facing surface 26A, which is arranged radially opposite the coils, and as magnet-facing surface 26B, which is arranged radially opposite the magnets 18.

[0016] (Second type motor 10B) As shown in FIGS. 3 and 4, the motor 10B is an axial gap brushless motor in which a rotor 12 as a rotor and a stator 14 as an armature and a stator are arranged facing each other in the axial direction.

[0017] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings (not shown), a rotor core 24 fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the other axial surface of the rotor core 24. The pair of bearings are supported by a frame 21 and an end frame 23, respectively. The stator 14 and other components are housed between the frame 21 and the end frame 23.

[0018] The rotor core 24 includes a first cylindrical portion 24A formed in a cylindrical shape and to which the rotating shaft 22 is fixed by press-fitting or the like, and a disk portion 24B extending radially outward from one axial end of the first cylindrical portion 24A. The disk portion 24B is formed in a disk shape with its thickness direction in the axial direction. A magnet 18, which will be described later, is fixed to the surface on the other axial side of the disk portion 24B.

[0019] The plurality of magnets 18 are formed using the same magnetic compound as in the motor 10A described above. The plurality of magnets 18 are fixed to the other axial surface of the disc portion 24B of the rotor core 24. The magnets 18 whose axial surface is the north pole and the magnets 18 whose axial surface is the south pole are arranged alternately in the circumferential direction.

[0020] The stator 14 includes a stator core 26 serving as a core of a rotating electrical machine formed in a disk shape with its thickness in the axial direction, and a coil body 32 arranged along one axial surface of the stator core 26. The stator 14 of this embodiment has a teethless structure in which no part of the stator core 26 is arranged between the coils 16 that form part of the coil body 32.

[0021] The stator core 26 is formed using magnetic powder 42 (see FIG. 7 ), which will be described later. The stator core 26 is formed in a plate shape with its thickness in the axial direction and is formed in an annular shape when viewed from the axial direction. The stator core 26 is arranged coaxially with the rotor 12, and the radial center position of the stator core 26 and the radial center position of the multiple magnets 18 fixed to the rotor core 24 coincide in the radial direction. One axial surface of the stator core 26 serves as a coil-facing surface 26A that faces the coil 16 in the axial direction, and a magnet-facing surface 26B that faces the magnet 18 in the axial direction.

[0022] The coil body 32 includes an annular substrate 34 made of an insulating material and the coil 16 formed on the substrate 34 .

[0023] (Third type motor 10C) 5 and 6, the configuration of motor 10C is the same as that of motor 10B, except for the points described below. Therefore, the members and parts of motor 10C corresponding to those of motor 10B are denoted by the same reference numerals, and their description may be omitted.

[0024] 5 and 6, the stator core 26 of the motor 10C of this embodiment includes a base plate portion 26C formed in a disk shape with its thickness in the axial direction, and teeth portions 26D that protrude from the base plate portion 26C toward one axial side and are arranged at equal intervals along the circumferential direction. One axial surface of the base plate portion 26C forms a coil-facing surface 26A that faces the coil 16. One axial end surface of each of the teeth portions 26D forms a magnet-facing surface 26B that faces the magnet 18 in the axial direction. Both circumferential and radial end surfaces of each of the teeth portions 26D form the coil-facing surfaces 26A that face the coil 16.

[0025] The coil body 32 of the motor 10B described above is configured to have holes through which the teeth 26D are inserted. The plurality of teeth 26D of the stator core 26 are arranged between the plurality of coils 16 that make up the coil body 32.

[0026] (First embodiment) Next, a detailed configuration of the stator core 26 of the first embodiment will be described. The configuration of the stator core 26 of the first embodiment can be applied to the stator core 26 of each of the motors 10A, 10B, and 10C described above and the stator core 26 of other motors.

[0027] FIG. 7 schematically illustrates a powder magnetic core 40 constituting the stator core 26. The powder magnetic core 40 is formed from magnetic powder 42 molded into a predetermined shape and dimensions. The magnetic powder 42 includes iron powder 44 as a base material and a coating 46 that covers the iron powder 44. The iron powder 44 is iron powder that has been pulverized to have a particle size within a predetermined range. The coating 46 is an insulating coating formed using an inorganic material that is more insulating than the iron powder 44 as the base material. The coating 46 that covers the magnetic powder 42 is formed by applying a paint for forming this coating to the magnetic powder 42. Here, examples of materials that can be used to form the coating 46 include phosphate-based, SiO2-based (silicon dioxide-based), Al2O3-based (alumina-based), MgO-based (magnesium oxide-based), and ferrite-based materials. These materials can also be used in combination.

[0028] FIG. 8 schematically shows the manufacturing process of the stator core 26. To manufacture the stator core 26, first, the paint that forms the coating portion 46 is applied to the iron powder 44. As a result, the iron powder 44 is covered with the coating portion 46, forming the magnetic powder 42. Next, a predetermined amount of the magnetic powder 42 is placed in a mold and compressed, thereby molding the magnetic powder 42 placed in the mold into a predetermined shape and dimensions. For example, the magnetic powder 42 placed in the mold is molded into a shape and dimensions corresponding to the shape and dimensions of the stator core 26 of each of the motors 10A, 10B, and 10C described above. Next, the magnetic powder 42 molded into the predetermined shape and dimensions is heated. Here, annealing is performed as a heat treatment. Through these processes, the stator core 26 is manufactured.

[0029] Here, for magnetic powder 42 having iron powder 44 and a coating 46 that covers the iron powder 44, the insulating performance of magnetic powder 42 can be adjusted by the following method. For example, as shown in FIG. 9, magnetic powder 42 having iron powder 44 and a coating 46 that covers the iron powder 44 is formed by a first painting process. Also, as shown in FIG. 10, the magnetic powder 42 that has been subjected to the first painting process is painted a second time, thereby increasing the thickness of the coating 46. Furthermore, as shown in FIG. 11, the magnetic powder 42 that has been subjected to the second painting process is painted a third time, thereby increasing the thickness of the coating 46. In this way, by increasing the thickness of the coating 46, the insulating properties of magnetic powder 42 can be improved. In other words, by adjusting the thickness of the coating 46, the insulating performance of magnetic powder 42 can be adjusted.

[0030] The insulating performance of the magnetic powder 42 can also be adjusted by changing the material forming the coating 46. For example, the insulating performance of the magnetic powder 42 can be improved by changing the coating 46 from an iron-based oxide film to a film containing a phosphate-based, borophosphate-based, or silicon-based material.

[0031] As described above, the insulating performance of the magnetic powder 42 can be adjusted by changing at least one of the thickness and material of the coating portion 46.

[0032] Here, the stator core 26 of this embodiment is formed using a first type of magnetic powder 42A shown in FIG. 12 and a second type of magnetic powder 42B shown in FIG. 13. That is, the stator core 26 is configured to include multiple types of magnetic powder. Here, the first type of magnetic powder 42A and the second type of magnetic powder 42B differ in the thickness of their covering portions 46. The thickness T2 of the covering portion 46 of the second type of magnetic powder 42B is thicker than the thickness T1 of the covering portion 46 of the first type of magnetic powder 42A. As a result, the insulating properties of the second type of magnetic powder 42B are higher than the insulating properties of the first type of magnetic powder 42A. Note that the first type of magnetic powder 42A corresponds to one type of magnetic powder, and the second type of magnetic powder 42B corresponds to the other type of magnetic powder.

[0033] 7, in a stator core 26 (powder magnetic core 40) formed using magnetic powder 42 having iron powder 44 and a coating 46 that covers the iron powder 44, the insulating coating 46 that covers the iron powder 44 can reduce eddy current I when magnetic flux B from each direction is taken into the stator core 26 (powder magnetic core 40). As a result, heat generation in the stator core 26 (powder magnetic core 40) is suppressed, and loss in a motor configured including the stator core 26 (powder magnetic core 40) can be reduced.

[0034] Furthermore, stator core 26 of the present embodiment is formed using first type of magnetic powder 42A shown in Fig. 12 and second type of magnetic powder 42B shown in Fig. 13. Therefore, the insulating properties of the portions of stator core 26 where first type of magnetic powder 42A is present can be made different from the insulating properties of the portions of stator core 26 where second type of magnetic powder 42B is present. That is, with stator core 26 of the present embodiment, the insulating properties of each portion of stator core 26 can be adjusted.

[0035] Furthermore, the stator core 26 formed using magnetic powder 42 having iron powder 44 and a coating 46 covering the iron powder 44 can be recycled by the following procedure. First, the stator core 26 removed from a disassembled motor is crushed to produce magnetic powder 42C shown in FIG. 14. The thickness T3 of the coating 46 of the magnetic powder 42C formed by crushing the stator core 26 deteriorates due to damage to the coating 46 caused by crushing. That is, the thickness T3 of the coating 46 of the magnetic powder 42C formed by crushing the stator core 26 is thinner in some places than the thickness T1 of the coating 46 of the first type of magnetic powder 42A shown in FIG. 12. Therefore, the thickness of the coating 46 is increased by painting the magnetic powder 42C formed by crushing the stator core 26. Here, the thickness T3 of the coating 46 of the magnetic powder 42C is set to the same thickness as the thickness T2 of the coating 46 of the second type of magnetic powder 42B shown in FIG. 13. That is, the second type of magnetic powder 42B is manufactured from the magnetic powder 42C. In other words, the second type of magnetic powder 42B can also be called a recycled material manufactured using the magnetic powder 42C. Then, a new stator core 26 can be manufactured using the first type of magnetic powder 42A and the second type of magnetic powder 42B, which is a recycled material.

[0036] In this embodiment, the material of the coating 46 that covers the iron powder 44 is an inorganic material, which makes it unnecessary to separate organic matter from the coating 46 during the recycling process.

[0037] (Second embodiment) Next, a detailed configuration of the stator core 26 of the second embodiment will be described. Note that, in the stator core 26 of the second embodiment, members and parts corresponding to those of the stator core 26 of the first embodiment described above will be denoted by the same reference numerals as those corresponding to those of the stator core 26 of the first embodiment, and their description may be omitted.

[0038] 15 to 18 show a stator core 26 of a second embodiment having a configuration similar to that of the stator core 26 constituting a part of the motor 10C described above. As shown in these figures, in the stator core 26 of this embodiment, a surface layer 26E along the coil-facing surface 26A, which is the surface on one axial side of the substrate portion 26C, is formed of the second type of magnetic powder 42B. In addition, in the stator core 26 of this embodiment, the surface layer 26E along the coil-facing surface 26A, which is the circumferential and radial end faces of the plurality of teeth 26D, is formed of the second type of magnetic powder 42B. Furthermore, in the stator core 26 of this embodiment, a portion 26F other than the surface layer 26E along the coil-facing surface 26A is formed of the first type of magnetic powder 42A.

[0039] In the stator core 26 of the present embodiment described above, the surface layer 26E along the coil-facing surface 26A is formed of the second type of magnetic powder 42B, and the portion 26F other than the surface layer 26E along the coil-facing surface 26A is formed of the first type of magnetic powder 42A. With this configuration, the insulation between the coil 16 and the coil-facing surface 26A of the stator core 26 can be improved compared to a configuration in which the entire stator core 26 is formed of the first type of magnetic powder 42A.

[0040] The configuration of the stator core 26 of this embodiment can also be applied to the stator core 26 constituting a part of the motors 10A and 10B described above. In this case, as shown in Fig. 2, the surface layer 26E along the coil-facing surface 26A, which is the radially inner surface of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26E along the coil-facing surface 26A may be formed from the first type of magnetic powder 42A. Also, as shown in Fig. 4, the surface layer 26E along the coil-facing surface 26A, which is the surface on one axial side of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26E along the coil-facing surface 26A may be formed from the first type of magnetic powder 42A.

[0041] (Third embodiment) Next, a detailed configuration of the stator core 26 of the third embodiment will be described. Note that the members and parts of the stator core 26 of the third embodiment that correspond to those of the stator core 26 of each embodiment already described will be denoted by the same reference numerals as those corresponding to those of the stator core 26 of each embodiment, and the description thereof may be omitted.

[0042] 19 to 21 show a stator core 26 of a third embodiment having a configuration similar to that of the stator core 26 constituting a part of the motor 10C described above. As shown in these figures, in the stator core 26 of this embodiment, a surface layer 26G along the magnet-facing surface 26B, which is the end face on one axial side of each of the plurality of teeth 26D, is formed of the second type of magnetic powder 42B. In addition, in the stator core 26 of this embodiment, a portion 26H other than the surface layer 26G along the magnet-facing surface 26B is formed of the first type of magnetic powder 42A.

[0043] In the stator core 26 of the present embodiment described above, the surface layer 26G along the magnet-facing surface 26B is formed of the second type of magnetic powder 42B, and the portion 26H other than the surface layer 26G along the magnet-facing surface 26B is formed of the first type of magnetic powder 42A. With this configuration, compared to a configuration in which the entire stator core 26 is formed of the first type of magnetic powder 42A, it is possible to reduce loss caused by leakage magnetic flux B of the magnet 18 interlinking with the plurality of teeth 26D.

[0044] The configuration of the stator core 26 of this embodiment can also be applied to the stator core 26 constituting a part of the motors 10A and 10B described above. In this case, as shown in Fig. 2, the surface layer 26G along the magnet-facing surface 26B, which is the radially inner surface of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26G along the magnet-facing surface 26B may be formed from the first type of magnetic powder 42A. Also, as shown in Fig. 4, the surface layer 26G along the magnet-facing surface 26B, which is the surface on one axial side of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26G along the magnet-facing surface 26B may be formed from the first type of magnetic powder 42A.

[0045] (Method for manufacturing the stator core 26 of the second embodiment) Next, a method for manufacturing the stator core 26 of the second embodiment will be briefly described.

[0046] 22 to 25 schematically show a portion of equipment for manufacturing the stator core 26 of the second embodiment. As shown in these figures, the first type of magnetic powder 42A and the second type of magnetic powder 42B that form the stator core 26 of the second embodiment are molded using a first mold 48, a second mold 50, a third mold 52, a fourth mold 54, and an injection device 56.

[0047] 22, a recess 48A is formed in the first mold 48, the recess 48 having a shape and dimensions corresponding to a portion 58A (see FIG. 24) formed by the first type of magnetic powder 42A in the stator core 26 of the second embodiment. The first type of magnetic powder 42A is poured into this recess 48A.

[0048] Next, as shown in FIG. 23, the first type of magnetic powder 42A placed in the recess 48A of the first mold 48 is compressed between the first mold 48 and a second mold 50.

[0049] By going through the steps up to this point, the portion 58A formed by the first type of magnetic powder 42A is molded in the stator core 26 of the second embodiment. Next, the portion 58A formed by the first type of magnetic powder 42A in the stator core 26 of the second embodiment is set in the third mold 52.

[0050] 24 and 25, a portion 58A formed of the first type of magnetic powder 42A in the stator core 26 of the second embodiment is set between the third mold 52 and the fourth mold 54. Here, a gap 60 having a shape and dimensions corresponding to a portion 58B (see FIG. 26) formed of the second type of magnetic powder 42B in the stator core 26 of the second embodiment is formed between the portion 58A formed of the first type of magnetic powder 42A in the stator core 26 of the second embodiment and the fourth mold 54. Next, the second type of magnetic powder 42B is injected into the gap 60 from an injection device 56 connected to the fourth mold 54.

[0051] 25 and 26, a molded product 58 in which a portion 58A formed by the first type of magnetic powder 42A and a portion 58B formed by the second type of magnetic powder 42B in the stator core 26 of the second embodiment are integrated is removed from between the third mold 52 and the fourth mold 54, and the molded product 58 is subjected to an annealing heat treatment. Through these steps, the stator core 26 of the second embodiment is manufactured.

[0052] (Method for manufacturing the stator core 26 of the third embodiment) Next, a method for manufacturing the stator core 26 of the third embodiment will be briefly described.

[0053] 27 to 30 schematically show a portion of equipment for manufacturing the stator core 26 of the third embodiment. As shown in these figures, the first type of magnetic powder 42A and the second type of magnetic powder 42B that form the stator core 26 of the third embodiment are molded using a first mold 62, a second mold 64, and a third mold 66.

[0054] 27, a first mold 62 has formed therein a recess 62A whose shape and dimensions correspond to a molded product 68 (see FIG. 31) in which a portion 68A formed by the first type of magnetic powder 42A and a portion 68B formed by the second type of magnetic powder 42B are integrated in the stator core 26 of the third embodiment. The second type of magnetic powder 42B is poured into this recess 62A.

[0055] 28, the second type of magnetic powder 42B introduced into the recess 62A of the first mold 62 is compressed between the first mold 62 and the second mold 64. This results in the formation of a portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment.

[0056] Next, as shown in FIG. 29, the first type of magnetic powder 42A is poured into the depression 62A formed in the first mold 62.

[0057] Next, as shown in Figure 30, the first type of magnetic powder 42A introduced into the first mold 62 is compressed between the first mold 62 and the third mold 66 together with the second type of magnetic powder 42B (portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment).

[0058] 30 and 31 , a molded product 68 in which a portion 68A formed by the first type of magnetic powder 42A and a portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment are integrated is removed from between the first mold 62 and the third mold 66, and the molded product 68 is subjected to annealing heat treatment. Through these steps, the stator core 26 of the third embodiment is manufactured.

[0059] (Management of performance of parts made from recycled materials) As described above, the stator core 26 of each of the above-described embodiments can be manufactured using the first type of magnetic powder 42A and the second type of magnetic powder 42B, which is a recycled material. In this case, it is important to manage the performance of the portion formed using the second type of magnetic powder 42B, which is a recycled material. Below, a configuration and method for managing the performance of the portion formed using the second type of magnetic powder 42B, which is a recycled material, will be described.

[0060] (Stator core 26 of the fourth to sixth embodiments) The detailed configuration of the stator core 26 of the fourth embodiment will be described using Figure 32. Note that the members and parts of the stator core 26 of the fourth embodiment that correspond to those of the stator core 26 of each embodiment that have already been described are denoted by the same reference numerals as those corresponding to those of the stator core 26 of each embodiment, and the description thereof may be omitted.

[0061] As shown in Fig. 32, the configuration of the stator core 26 of the fourth embodiment is similar to that of the stator core 26 of the second embodiment (see Fig. 18) or the stator core 26 of the third embodiment (see Fig. 21), except that an inspection portion 70 is provided. In the following description, the portion of the stator core 26 of the fourth embodiment corresponding to the stator core 26 of the second embodiment or the stator core 26 of the third embodiment may be referred to as a stator core main body 72.

[0062] The inspection portion 70 is provided at a position different from the coil-facing surface 26A (see FIG. 18, etc.) and the magnet-facing surface 26B (see FIG. 18, etc.). The inspection portion 70 is formed of the same second type of magnetic powder 42B as that used to form the stator core body 72. More specifically, the stator core 26 of the fourth embodiment is provided with a plurality of inspection portions 70 (three in this embodiment) that protrude from the surface on the other axial side of the substrate portion 26C toward the other axial side. The plurality of inspection portions 70 are formed in a cylindrical shape. The plurality of inspection portions 70 are also arranged in the radial center of the substrate portion 26C and at equal intervals along the circumferential direction.

[0063] In a stator core 26 having an inspection portion 70, as shown in FIG. 33, the magnetic permeability of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by inserting the inspection portion 70 into the inner periphery of a search coil 74. Also, as shown in FIG. 34, the resistivity of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by pressing a resistivity measurement terminal 76 against the inspection portion 70. Furthermore, as shown in FIG. 35, the hardness of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by pressing a hardness measurement terminal 78 against the inspection portion 70. The inspection portion 70 shown in FIGS. 34 and 35 has a rectangular block shape.

[0064] The position of the inspection portion 70 is not limited to the above. For example, as in the stator core 26 of the fifth embodiment shown in Fig. 36, the inspection portion 70 may be provided so as to protrude radially outward from the radially outer end of the substrate portion 26C. Furthermore, as in the stator core 26 of the sixth embodiment shown in Fig. 37, the inspection portion 70 may be the entire surface of the other axial side surface of the substrate portion 26C.

[0065] Method for forming test portion 70 A method for forming test portion 70 will now be briefly described.

[0066] 38 to 41 schematically show a portion of the equipment for forming the stator core body 72 and the inspection portion 70. As shown in these figures, the first type of magnetic powder 42 that forms the stator core body 72 and the second type of magnetic powder 42B that forms the inspection portion 70 are molded using a first mold 80, a second mold 82, a third mold 84, and a fourth mold 86.

[0067] 38, a recess 80A is formed in the first mold 80, the recess 80A having a shape and dimensions corresponding to a portion 88A (see FIG. 42) formed by the first type of magnetic powder 42A in the stator core body 72. The first type of magnetic powder 42A is poured into this recess 80A.

[0068] 39, the first type of magnetic powder 42A introduced into the recess 80A of the first mold 80 is compressed between the first mold 80 and the second mold 82. This forms a portion 88A of the stator core body 72 that is formed from the first type of magnetic powder 42A. Here, a hole 80B is formed in the bottom of the first mold 80. As a result, a protrusion 88B is formed in the portion of the portion 88A where the test portion 70 is to be joined.

[0069] 40, the molded part 88A is set in a third mold. An exposure hole 84A is formed in the third mold 84, exposing the portion of the part 88A to which the test part 70 is to be joined. Then, the second type of magnetic powder 42B is poured into the exposure hole 84A.

[0070] Next, as shown in FIG. 41, the second type of magnetic powder 42B placed in the exposure holes 84A is compressed between the third die 84 and the fourth die 86 together with the portions 88A and the protrusions 88B.

[0071] Next, as shown in Figures 41 and 42, a molded product 88, in which a portion 88A formed by the first type of magnetic powder 42A in the stator core body 72 and a portion 88C forming the inspection portion 70 are integrated, is removed from between the third mold 84 and the fourth mold 86. Note that a portion formed by the second type of magnetic powder 42B in the stator core body 72 is molded in a separate process. Then, an annealing heat treatment is performed on the molded product in which the portion formed by the second type of magnetic powder 42B in the stator core body 72 and the molded product 88 are integrated. Through these processes, a stator core 26 having the inspection portion 70 is manufactured.

[0072] In the stator core 26 of each of the above-described embodiments, the material of the coating 46 that covers the iron powder 44 is an inorganic material. However, the present disclosure is not limited to this. For example, the material of the coating 46 that covers the iron powder 44 may include an organic material. The stator core 26 may also include a third type of magnetic powder. In this case, the third type of magnetic powder does not correspond to the other types of magnetic powder. The third type of magnetic powder may or may not have higher insulating properties than the first type of magnetic powder 42A and the second type of magnetic powder 42B. The thickness of the coating 46 of the third type of magnetic powder may be thicker than the thickness of the coating 46 of the first type of magnetic powder 42A and the thickness of the coating 46 of the second type of magnetic powder 42B.

[0073] Furthermore, in the stator core 26 of each of the above-described embodiments, the base material of the magnetic powder 42 is iron powder 44, but the present disclosure is not limited to this. For example, the base material of the magnetic powder 42 may be a mixture of an iron-based material and another material.

[0074] Furthermore, the configuration of the stator core 26 (powder magnetic core 40) in each of the above-described embodiments can also be applied to the core of a field element.

[0075] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above and can be implemented in various other modifications without departing from the spirit of the present disclosure. Furthermore, all or part of the configurations of the embodiments described above can be combined with each other. Furthermore, the configuration of the motor 10, etc., may be applied to a generator. Furthermore, the configuration of the present disclosure can also be applied to a rotor configured to include a coil body 32.

[0076] The above describes one embodiment of the present disclosure, but the present disclosure is not limited to the above, and it goes without saying that it can be implemented in various other modified forms within the scope that does not deviate from the gist of the present disclosure.

[0077] <Additional Notes> (Appendix 1) The magnetic powder (42) includes a powdered base material (44) formed using an iron-based material, and a coating (46) that is made of an insulating material with higher insulating properties than the base material and covers the base material, A core (26) for a rotating electric machine, which has a plurality of types of magnetic powder (42A, 42B) by varying at least one of the thickness of the coating portion and the material of the coating portion. (Appendix 2) 2. The core for a rotating electric machine according to claim 1, wherein the covering portion is formed using an inorganic material. (Appendix 3) One type of magnetic powder (42A), Another type of magnetic powder (42B) has a coating portion with higher insulating properties than the one type of magnetic powder; 3. A core for a rotating electric machine according to claim 1 or 2, comprising: (Appendix 4) A core of a rotating electric machine on which a coil (16) is wound and which is provided for a stator, a coil-facing surface (26A) disposed opposite the coil (16), 4. The core of a rotating electric machine according to claim 3, wherein the magnetic powder of another type is arranged along the coil-facing surface. (Appendix 5) A core for a rotating electric machine according to claim 3 or 4, wherein the thickness of the coating portion constituting the magnetic powder of the other type is thicker than the thickness of the coating portion constituting the magnetic powder of the one type. (Appendix 6) A core for a rotating electric machine provided for a stator, a magnet-facing surface (26B) disposed opposite the magnet (18); 6. The core of a rotating electric machine according to claim 5, wherein the magnetic powder of another type is arranged along the magnet opposing surface. (Appendix 7) a coil-facing surface (26A) disposed opposite the coil (16) and a magnet-facing surface (26B) disposed opposite the magnet (18), 6. The rotating electric machine core according to claim 5, wherein an inspection portion (70) formed by another type of magnetic powder is provided. (Appendix 8) a core (26) for a rotating electric machine including magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) formed using an insulating material and covering the base material, the core (26) including a plurality of types of magnetic powder (42A, 42B) having different thicknesses and / or materials for the coating portion; a coil (16) disposed along a core of the rotating electric machine and configured to generate a magnetic field when energized; an armature (14) having (Appendix 9) one of a stator (14) and a rotor (12) configured to include an armature (14) equipped with a core (26) of a rotating electric machine configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) formed using an insulating material and covering the base material, the core (26) being configured to include a plurality of types of magnetic powder (42A, 42B) having different thicknesses and / or materials for the coating portion; and a coil (16) arranged along the core of the rotating electric machine and generating a magnetic field when current is applied; the other of the stator and the rotor, which includes a magnet (18) arranged opposite the coil and the core of the rotating electric machine; A rotating electric machine (10A, 10B, 10C) equipped with the above. [Explanation of symbols]

[0078] 10A motor (rotating electric machine), 10B motor (rotating electric machine), 10C motor (rotating electric machine), 12 rotor, 14 stator (armature, stator), 16 coil, 18 magnet, 26 stator core (core of rotating electric machine), 26A coil opposing surface, 42 magnetic powder, 42A first type of magnetic powder (one type of magnetic powder), 42B second type of magnetic powder (another type of magnetic powder), 44 iron powder (base material), 46 coating portion, 26B magnet opposing surface, 70 inspection portion

Claims

1. The magnetic powder (42) includes a powdered base material (44) formed using an iron-based material, and a covering portion (46) that is formed using a material having insulating properties and higher insulating properties than the base material and covers the base material, A core (26) for a rotating electric machine having a plurality of types of magnetic powder (42A, 42B) by varying at least one of the thickness of the coating portion and the material of the coating portion.

2. 2. The core for a rotating electrical machine according to claim 1, wherein the covering portion is formed using an inorganic material.

3. One type of magnetic powder (42A), Another type of magnetic powder (42B) having a coating portion with higher insulating properties than the one type of magnetic powder; 2. The core of claim 1, comprising:

4. A core for a rotating electric machine, on which a coil (16) is wound and which is provided for a stator, a coil-facing surface (26A) disposed opposite the coil (16); 4. The core for a rotating electric machine according to claim 3, wherein the magnetic powder of the other type is arranged along the coil-facing surface.

5. 4. The core for a rotating electric machine according to claim 3, wherein the thickness of the coating portion of the magnetic powder of the other type is greater than the thickness of the coating portion of the magnetic powder of the one type.

6. A core for a rotating electric machine provided for a stator, a magnet-facing surface (26B) disposed opposite the magnet (18); 6. The core of claim 5, wherein the magnetic particles of the other type are arranged along the magnet-facing surface.

7. The coil-facing surface (26A) is disposed opposite the coil (16), and the magnet-facing surface (26B) is disposed opposite the magnet (18), 6. The core of a rotating electric machine according to claim 5, further comprising an inspection portion (70) formed by the other type of magnetic powder.

8. a core (26) for a rotating electric machine comprising magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) that has insulating properties and is formed using a material with higher insulating properties than the base material and covers the base material, the magnetic powder being comprised of multiple types of magnetic powder (42A, 42B) that differ in at least one of the thickness and material of the coating portion; a coil (16) arranged along a core of the rotating electric machine and configured to generate a magnetic field when energized; an armature (14) comprising:

9. one of a stator (14) and a rotor (12) configured to include an armature (14) equipped with a core (26) of a rotating electric machine, the core (26) being configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) that has insulating properties and is formed using a material with higher insulating properties than the base material and covers the base material, the magnetic powder being configured to include multiple types of magnetic powder (42A, 42B) that differ in at least one of the thickness and material of the coating portion, and a coil (16) that is arranged along the core of the rotating electric machine and generates a magnetic field when current is applied; the other of the stator and the rotor, which includes a magnet (18) arranged opposite the coil and the core of the rotating electric machine; A rotating electric machine (10A, 10B, 10C) equipped with the above.

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