Motor, blower, refrigeration device, vehicle, motor recycling method, and motor manufacturing method

Abstract

To provide a motor, a blower, a refrigeration device, a vehicle, a motor recycling method, and a motor manufacturing method that make it easy to collect recycled parts.SOLUTION: A motor includes a sealing portion 40 made of a sealing resin and a sealed portion 50 sealed by the sealing portion 40. The sealing portion 40 includes a first region 41 and a second region 42 that is more susceptible to thermal decomposition than the first region 41. The second region 42 is provided between the first region 41 and the sealed portion 50. The second region 42 includes a first filler that is thermally decomposed at a temperature equal to or higher than a first temperature. The content of the first filler in the second region 42 is greater than the content of the first filler in the first region 41.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a motor, a blower, a refrigeration device, a vehicle, a motor recycling method, and a motor manufacturing method. [Background technology]

[0002] Motors that are sealed with sealing resin are known. Patent Document 1 discloses an example of such a motor (called a molded motor in Patent Document 1). In this type of motor, a sealed portion that includes recycled parts is sealed with a sealing portion. Examples of recycled parts are parts made of metal, magnets, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-20348 Summary of the Invention [Problem to be solved by the invention]

[0004] From the viewpoint of recycling, it is preferable to be able to separate recycled parts from the rest of the motor. However, in order to protect the sealed part, the sealing part is configured to be highly stable against heat, light, etc., and to be difficult to separate from the sealed part.

[0005] One method for separating the sealing portion from the sealed portion involves heating the motor to burn the sealing portion, but burning the sealing portion can result in the adhesion of soot, ash, and other contaminants to the sealed portion. Contamination caused by combustion can also reduce the quality of the recycled parts contained in the sealed portion. In addition to burning, another method involves crushing the motor and recovering the recycled parts, but this method requires large-scale equipment, which increases the cost of recovering the recycled parts. Furthermore, with conventional motors, it is difficult to separate the sealing portion from the sealed portion in a way that allows the recycled parts to be extracted in an easily recyclable state, so they are sometimes disposed of as industrial waste. [Means for solving the problem]

[0006] A motor according to a first aspect of the present invention solves this problem and is a motor comprising a sealing portion made of a sealing resin and a sealed portion sealed by the sealing portion, wherein the sealing portion includes a first region and a second region that is more susceptible to thermal decomposition than the first region, the second region being provided between the first region and the sealed portion, the second region including a first filler that is thermally decomposed at a temperature equal to or higher than a first temperature, and the content of the first filler in the second region being greater than the content of the first filler in the first region.

[0007] With this configuration, the content of the first filler in the second region is higher than the content of the first filler in the first region, so the second region is more susceptible to thermal decomposition than the first region. Because the second region is more susceptible to thermal decomposition than the first region, the first region of the sealed portion can be separated from the sealed portion by heating the motor to a temperature equal to or higher than the first temperature. In this way, recyclable parts contained in the sealed portion can be suitably recovered from the motor.

[0008] A motor according to a second aspect is the motor according to the first aspect, wherein the base resin of the sealing resin constituting the second region is the same type of resin as the base resin of the sealing resin constituting the first region.

[0009] With this configuration, the first region and the second region are each made of a sealing resin that uses the same type of resin as the base resin, so an interface between the first region and the second region is unlikely to occur, and the first region and the second region are thus firmly connected, thereby improving the strength of the sealing portion.

[0010] A motor according to a third aspect is the motor according to the first aspect, wherein no interface is formed between the first region and the second region.

[0011] According to this configuration, the first region and the second region are more firmly connected, and the strength of the sealing portion can be further improved.

[0012] A motor according to a fourth aspect is the motor according to any one of the first to third aspects, wherein the content of the first filler in the second region is 50% by mass or more and 80% by mass or less.

[0013] If the content of the first filler is less than 50% by mass, the thermal decomposition of the sealing portion is less likely to proceed. If the content of the first filler in the second region is 50% by mass or more, the thermal decomposition of the first filler will increase the number of voids that form in the second region, and heating to the first temperature or higher will reduce the strength of the second region. This reduces the load required to separate the first region of the sealing portion from the sealed portion. If the content of the first filler 32 is greater than 80% by mass, it will be difficult to form the sealing portion. In this regard, according to the above configuration, the content of the first filler in the second region is 50% by mass or more and 80% by mass or less. This makes it easier to thermally decompose the second region of the sealing portion, while also facilitating the formation of the second region when forming the sealing portion.

[0014] A motor of a fifth aspect is the motor of any one of the first to fourth aspects, wherein the first temperature of the first filler contained in the second region is equal to or lower than the combustion temperature of the first sealing resin that constitutes the first region.

[0015] According to this configuration, by heating at a temperature equal to or higher than the first temperature and equal to or lower than the combustion temperature, combustion of the first sealing resin constituting the first region is suppressed when the first region of the sealing portion is separated from the sealed portion, thereby suppressing adhesion of contamination due to combustion to the sealed portion.

[0016] A motor according to a sixth aspect is the motor according to any one of the first to fifth aspects, wherein the first filler is made of aluminum hydroxide.

[0017] According to this configuration, the sealing resin that forms the second region can be suitably thermally decomposed by aluminum hydroxide.

[0018] A motor of a seventh aspect is a motor of any one of the first to sixth aspects, wherein the first region includes a second filler that thermally decomposes at a temperature equal to or higher than a second temperature that is higher than the first temperature, and the content of the second filler in the second region is lower than the content of the second filler in the first region.

[0019] With this configuration, the content of the second filler in the second region is lower than the content of the second filler in the first region, making the first region less susceptible to thermal decomposition than the second region, and therefore, when separating the first region and the sealed portion of the sealing portion, the second region can be thermally decomposed before the first region.

[0020] A motor according to an eighth aspect is the motor according to any one of the first to seventh aspects, wherein the portion to be sealed includes any one of a winding, a core material, and a magnet.

[0021] According to this configuration, any one of the winding, the core material, and the magnet included in the sealed portion can be suitably separated from the first region of the sealed portion.

[0022] A motor according to a ninth aspect is the motor according to the eighth aspect, wherein the sealed portion includes the magnet, and the first temperature of the first filler included in the second region is higher than the Curie temperature of the magnet.

[0023] According to this configuration, the magnet can be demagnetized when the sealing portion is heated, which makes it easier to retrieve the magnet from the motor.

[0024] A blower according to a tenth aspect includes the motor according to any one of the first to ninth aspects.

[0025] According to this configuration, recyclable parts included in the sealed portion can be suitably recovered from the motor of the blower.

[0026] A refrigeration device according to an eleventh aspect includes the motor according to any one of the first to ninth aspects.

[0027] According to this configuration, recyclable parts included in the sealed portion can be suitably recovered from the motor of the refrigeration device.

[0028] A vehicle according to a twelfth aspect includes the motor according to any one of the first to ninth aspects. According to this configuration, recycled parts contained in the sealed portion can be suitably recovered from the motor of the vehicle.

[0029] A motor recycling method according to a thirteenth aspect is the motor recycling method according to any one of the first to ninth aspects, and includes a heating step of heating the motor to a temperature equal to or higher than the first temperature.

[0030] According to this configuration, the motor is heated to a temperature equal to or higher than the first temperature in the heating step, whereby the second region of the sealing portion is thermally decomposed. The thermal decomposition of the second region separates the first region of the sealing portion from the sealed portion, allowing recyclable parts contained in the sealed portion to be recovered from the motor.

[0031] A fourteenth aspect of the motor manufacturing method that solves this problem is a method for manufacturing a motor that includes a sealing portion made of a first sealing resin and a second sealing resin that is more susceptible to thermal decomposition than the first sealing resin, and a sealed portion that is sealed by the sealing portion, and includes a molding step of forming the sealing portion, in which the sealing portion is formed so that the second sealing resin is provided between the first sealing resin and the sealed portion.

[0032] This configuration makes it possible to construct a motor in which the sealing portion and the sealed portion are easily separated by heat.

[0033] A motor manufacturing method according to a fifteenth aspect is the motor manufacturing method according to the fourteenth aspect, wherein in the molding step, the sealing portion is formed by a single transfer molding using an injection cylinder that contains the first sealing resin and the second sealing resin.

[0034] This configuration allows the sealing portion to be formed by a single transfer molding process, thereby reducing the number of manufacturing steps for the motor.

[0035] A motor of a 16th aspect is a motor manufacturing method of the 14th aspect, wherein the molding step includes a step of forming a part of the sealing portion with the second sealing resin, and a step of forming another part of the sealing portion with the first sealing resin so as to cover at least a part of the forming part formed with the second sealing resin.

[0036] According to this configuration, the first region of the sealing portion made of the first sealing resin and the second region of the sealing portion made of the second sealing resin are formed separately, which allows the second sealing resin to be suitably disposed between the first sealing resin and the sealed portion. [Brief explanation of the drawings]

[0037] [Figure 1] 1 is a cross-sectional view of a blower according to a first embodiment. [Figure 2] FIG. 3 is a schematic diagram of a first region and a second region of a sealing portion. [Figure 3] FIG. 2 is a cross-sectional view taken along line D3-D3 in FIG. [Figure 4] 3A to 3C are diagrams illustrating a molding step in the manufacturing method of the motor according to the first embodiment. [Figure 5] 3A to 3C are diagrams illustrating a molding step in the manufacturing method of the motor according to the first embodiment. [Figure 6] 3A to 3C are diagrams illustrating a molding step in the manufacturing method of the motor according to the first embodiment. [Figure 7] FIG. 10 is a diagram showing a heating step in a motor recycling method. [Figure 8] FIG. 1 is a diagram showing a separation process in a motor recycling method. [Figure 9] 10A to 10C are diagrams illustrating a molding step in a manufacturing method of a motor according to a second embodiment. [Figure 10] 10A to 10C are diagrams illustrating a molding step in a manufacturing method of a motor according to a second embodiment. [Figure 11] 10A to 10C are diagrams illustrating a molding step in a manufacturing method of a motor according to a second embodiment. [Figure 12] 10A to 10C are diagrams illustrating a molding step in a manufacturing method of a motor according to a second embodiment. [Figure 13] FIG. 10 is a schematic configuration diagram of a refrigeration device according to a third embodiment. [Figure 14] FIG. 10 is a cross-sectional view of a compression device of a refrigeration device according to a third embodiment. [Figure 15] FIG. 10 is a schematic diagram of a stator core and magnets according to a third embodiment. [Figure 16] FIG. 10 is a schematic configuration diagram of a vehicle according to a fourth embodiment. [Figure 17] 10A and 10B are schematic diagrams showing modified examples of a sealing portion and a sealed portion. [Figure 18] 10A and 10B are schematic diagrams showing modified examples of a sealing portion and a sealed portion. [Figure 19] 10A and 10B are schematic diagrams showing modified examples of a sealing portion and a sealed portion. DETAILED DESCRIPTION OF THE INVENTION

[0038] First Embodiment A blower 1, a motor 10, a method for manufacturing the motor 10, and a method for recycling the motor 10 according to a first embodiment will be described with reference to FIGS.

[0039] <Blower> Referring to Figure 1, blower 1 includes motor 10. Fan 2 is attached to a rotary shaft 13 of motor 10. Motor 10 is a fan motor that rotates fan 2 of blower 1. Motor 10 is housed in casing 3.

[0040] <Motor> In one example, the motor 10 is configured as an outer rotor motor. The motor 10 includes a stator 11, a rotor 12, and a rotating shaft 13.

[0041] The stator 11 has a stator body 14, a stator core 15, and windings 16. In one example, the stator core 15 and the windings 16 are integrally formed with the stator body 14. The stator body 14 has a through hole 17 in which the rotating shaft 13 is disposed. The stator core 15 is fixed to the stator body 14. The stator core 15 is made of a core material 18. In one example, the core material 18 is made of laminated electromagnetic steel sheets. The windings 16 are wound around the teeth of the stator core 15 via insulators 19. In one example, the windings 16 are made of copper wire.

[0042] The rotor 12 has a rotor body 20 and a magnet 21. The magnet 21 is formed integrally with the rotor body 20. The rotor body 20 is formed in a cup shape with the stator 11 housed inside. The magnet 21 is provided inside the cylindrical portion of the rotor body 20. The magnet 21 is located radially outside the stator core 15 of the stator 11. In one example, the magnet 21 is a neodymium magnet. The rotor body 20 is fixed to the rotating shaft 13 by a metal fitting 22.

[0043] The rotating shaft 13 is disposed in a through hole 17 of the stator body 14 via a bearing 23 so as to rotate relative to the stator 11. In one example, a fan 2 is attached to a tip end 24 of the rotating shaft 13.

[0044] <Sealing resin> 1 and 2, the stator body 14 and the rotor body 20 are made of a sealing resin 30. The sealing resin 30 is made by adding a filler to a resin containing a base resin 31. In one example, the base resin 31 is the resin that is contained in the largest amount in the sealing resin 30. The filler is contained in the resin containing the base resin 31 for purposes such as improving strength, reducing costs, and adjusting the dielectric constant.

[0045] The filler contained in the resin containing base resin 31 includes at least one of a first filler 32 and a second filler 33. The first filler 32 and the second filler 33 are thermally decomposable fillers that decompose when the temperature reaches or exceeds a predetermined temperature. The filler contained in the resin containing base resin 31 may include other fillers different from both the first filler 32 and the second filler 33. Examples of other fillers include low-profile materials such as polystyrene, polyvinyl acetate, elastomers, and polymethyl methacrylate; reactive monomers such as styrene, vinyl toluene, and methyl methacrylate; curing agents such as organic peroxides; fillers such as calcium carbonate and clay; colorants such as pigments; mold release agents such as metal soaps; thickeners such as alkaline earth metal oxides and hydroxides; and reinforcing fibers such as glass fiber, carbon fiber, and organic fiber.

[0046] In one example, the first filler 32 and the second filler 33 are particulate. In one example, the particle diameter of the first filler 32 and the second filler 33 is 1 μm or more and 200 μm or less. Preferably, the particle diameter of the first filler 32 and the second filler 33 is 5 μm or more and 100 μm or less. By setting the particle diameter of the first filler 32 and the second filler 33 to 5 μm or more and 100 μm or less, the dispersibility of the first filler 32 and the second filler 33 in the base resin 31 can be further improved.

[0047] When the first filler 32 and the second filler 33 are organic, the first filler 32 and the second filler 33 are fibrous. In one example, the cross-sectional diameter of the fibrous first filler 32 and the second filler 33 is 1 nm or more and 100 nm or less. Preferably, the cross-sectional diameter of the fibrous first filler 32 and the second filler 33 is 3 nm or more and 50 nm or less.

[0048] In one example, the fiber length of the fibrous first filler 32 and second filler 33 is 10 nm or more and 10 μm or less. Preferably, the fiber length of the fibrous first filler 32 and second filler 33 is 100 nm or more and 1 μm or less.

[0049] <Base resin> For example, the base resin 31 is composed of either a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins include unsaturated polyester resin, epoxy resin, and vinyl ester resin. Examples of thermoplastic resins include nylon and PPS (polyphenylene sulfide). In one example, the content of the base resin 31 in the sealing resin 30 is 10% by mass or more and 20% by mass or less. The content of the base resin 31 is the ratio of the mass of the base resin 31 to the mass of the sealing resin 30 per unit volume.

[0050] <First filler> The first filler 32 is thermally decomposed at a temperature equal to or higher than a first temperature. In one example, the first temperature is equal to or higher than 200° C. and equal to or lower than 400° C. The first temperature is determined by the material that constitutes the first filler 32.

[0051] For example, the first filler 32 may be composed of any one of carbonate, hydroxide, and organic fillers. Examples of carbonate first fillers 32 include zinc carbonate and sodium carbonate. Examples of hydroxide first fillers 32 include magnesium hydroxide and aluminum hydroxide. Examples of organic first fillers 32 include cellulose nanofibers.

[0052] In one example, the first filler 32 is made of aluminum hydroxide. Aluminum hydroxide is a thermally decomposable filler and also contributes to improving the flame retardancy of the sealing resin 30. In one example, the first temperature is a temperature at which aluminum hydroxide starts to thermally decompose. When aluminum hydroxide is contained in the sealing resin 30, the aluminum hydroxide decomposes at the first temperature, making the second region 42 brittle. On the other hand, aluminum hydroxide generates water vapor during thermal decomposition, which suppresses combustion of the sealing resin 30.

[0053] <Second filler> In one example, the second filler 33 is thermally decomposed at a temperature equal to or higher than a second temperature, which is higher than the first temperature. The second filler 33 is made of a material that is thermally decomposed at a temperature higher than the first temperature at which the first filler 32 is thermally decomposed.

[0054] For example, the second filler 33 is made of any one of carbonates, hydroxides, and organic fillers different from the first filler 32. For example, the second filler 33 is sodium carbonate or magnesium hydroxide.

[0055] <First sealing resin and second sealing resin> Referring to FIG. 2, the sealing resin 30 includes a first sealing resin 34 and a second sealing resin 35. The first sealing resin 34 is a resin that constitutes a first region 41, which will be described later, and the second sealing resin 35 is a resin that constitutes a second region 42, which will be described later. The first sealing resin 34 and the second sealing resin 35 have different properties due to differences in the types and contents of various fillers blended into the base resin 31. In one example, the content of the base resin 31 in the second sealing resin 35 is approximately equal to the content of the base resin 31 in the first sealing resin 34.

[0056] The second sealing resin 35 includes the first filler 32. The first sealing resin 34 may or may not include the first filler 32. The content of the first filler 32 in the second sealing resin 35 is greater than the content of the first filler 32 in the first sealing resin 34. In one example, the content of the first filler 32 is the ratio of the mass of the first filler 32 to the mass of the sealing resin 30 per unit volume. Note that when the first sealing resin 34 does not include the first filler 32, the content of the first filler 32 in the first sealing resin 34 is 0 mass%.

[0057] The second sealing resin 35 is more susceptible to thermal decomposition than the first sealing resin 34. The second sealing resin 35 has a higher content of the first filler 32 than the first sealing resin 34, and therefore decomposes to a greater extent than the first sealing resin 34. In one example, the second sealing resin 35 starts to thermally decompose when heated to a first temperature or higher.

[0058] In one example, the first sealing resin 34 includes the second filler 33. The second sealing resin 35 may or may not include the second filler 33. The content of the second filler 33 in the first sealing resin 34 is greater than the content of the first filler 32 in the second sealing resin 35. In one example, the content of the second filler 33 is the ratio of the mass of the second filler 33 to the mass of the sealing resin 30 per unit volume. Note that when the second sealing resin 35 does not include the second filler 33, the content of the second filler 33 in the second sealing resin 35 is 0 mass%.

[0059] <Sealing part and sealed part> 1 and 2 , the motor 10 includes a sealing portion 40 and a sealed portion 50. The sealing portion 40 is formed of a sealing resin 30. In one example, the sealing portion 40 is formed of the sealing resin 30. In one example, the sealing portion 40 includes the stator body portion 14 of the stator 11. In one example, the sealing portion 40 includes the rotor body portion 20 of the rotor 12.

[0060] The sealed portion 50 includes a component made of a material other than a resin material. In one example, the sealed portion 50 includes recycled components such as metals and magnets that are collected when the motor 10 is recycled. The sealed portion 50 is sealed by the sealing portion 40. In one example, the sealed portion 50 includes one of the winding 16, the core material 18, and the magnet 21. The sealed portion 50 may also include one of the insulator 19, the metal fitting 22, and the bearing 23.

[0061] In one example, the sealed portion 50 includes the windings 16 and the core material 18 of the stator core 15. In this case, the sealing portion 40 is the stator body 14, and the sealed portion 50 is the windings 16 and the core material 18. In another example, the sealed portion 50 includes the magnet 21. In this case, the sealing portion 40 is the rotor body 20, and the sealed portion 50 is the magnet 21. Note that FIG. 3 illustrates an example in which the sealing portion 40 is the stator body 14, and the sealed portion 50 is the windings 16 and the core material 18.

[0062] <Placement of sealing part> Please refer to Figures 2 and 3. Figure 3 illustrates a cross-sectional view taken along line D3-D3 in Figure 1. Figure 3 illustrates two windings 16 arranged in the circumferential direction and a core material 18 as viewed from the radially outer side.

[0063] The sealing portion 40 includes a first region 41 and a second region 42. The second region 42 is provided between the first region 41 and the sealed portion 50. The second region 42 is located closer to the sealed portion 50 than the first region 41. In one example, the second region 42 is directly bonded to the sealed portion 50. The first region 41 is bonded to the sealed portion 50 via the second region 42.

[0064] In one example, the sealing portion 40 is composed of a first sealing resin 34 and a second sealing resin 35. The base resin 31 of the sealing resin 30 that constitutes the second region 42 is the same type of resin as the base resin 31 of the sealing resin 30 that constitutes the first region 41. In one example, the first region 41 is composed of the first sealing resin 34, and the second region 42 is composed of the second sealing resin 35. No interface is formed between the first region 41 and the second region 42. The first sealing resin 34 that constitutes the first region 41 and the second sealing resin 35 that constitutes the second region 42 are mixed at the boundary BA between the first region 41 and the second region 42, thereby connecting the first region 41 and the second region 42 together.

[0065] The second region 42 includes the first filler 32. The first region 41 may or may not include the first filler 32. The second region 42 is more susceptible to thermal decomposition than the first region 41. In one example, the content of the first filler 32 in the second region 42 is greater than the content of the first filler 32 in the first region 41. In one example, the content of the first filler 32 in the second region 42 is 50% by mass or more and 80% by mass or less.

[0066] The first temperature of the first filler 32 contained in the second region 42 is equal to or lower than the combustion temperature of the first sealing resin 34 constituting the first region 41. The combustion temperature of the first sealing resin 34 is the temperature at which the first sealing resin 34 starts to burn. Preferably, the first temperature of the first filler 32 contained in the second region 42 is lower than the combustion temperature of the first sealing resin 34 constituting the first region 41. It is sufficient that the second region 42 starts to thermally decompose when the first region 41 of the sealing portion 40 starts to burn. In this way, by heating the sealing portion 40 to a temperature equal to or higher than the first temperature and lower than the combustion temperature, the second region 42 thermally decomposes before the first region 41 of the sealing portion 40 burns.

[0067] The first region 41 includes the second filler 33. The second region 42 may or may not include the second filler 33. The content of the second filler 33 in the second region 42 is lower than the content of the second filler 33 in the first region 41.

[0068] The filler content of the first region 41 is approximately equal to the filler content of the second region 42. The filler content is the ratio of the combined mass of the first filler 32, the second filler 33, and other fillers to the mass of the sealing resin 30 per unit volume. Because the filler content of the first region 41 is approximately equal to the filler content of the second region 42, the content of the base resin 31 of the sealing resin 30 in the first region 41 is approximately equal to the content of the base resin 31 of the sealing resin 30 in the second region 42. This makes it easy to handle the first sealing resin 34 and the second sealing resin 35 when forming the sealing portion 40.

[0069] <Motor manufacturing method> 4 to 6, a method for manufacturing a motor 10 including a sealing portion 40 and a sealed portion 50 will be described. The method for manufacturing the motor 10 includes a molding process. The molding process is a process for forming the sealing portion 40. In the molding process, the sealing portion 40 is formed so that the second sealing resin 35 is provided between the first sealing resin 34 and the sealed portion 50.

[0070] Please refer to FIG. 4. The motor 10 of this embodiment is formed by transfer molding. In one example, an injection cylinder 60 is used in the molding process. The injection cylinder 60 has an injection hole 62 connected to a mold 61. The sealed part 50 is fixed inside the mold 61. A piston 63 pushes the resin inside the injection cylinder 60 out through the injection hole 62, thereby filling the mold 61 with the resin.

[0071] In one example, in the molding process, the sealing portion 40 is formed by a single transfer molding using an injection cylinder 60. The injection cylinder 60 contains a first sealing resin 34 and a second sealing resin 35. In the injection cylinder 60, the second sealing resin 35 is contained closer to the injection hole 62 than the first sealing resin 34. As a result, when the piston 63 pushes the first sealing resin 34 and the second sealing resin 35, the first sealing resin 34 is pushed out after the second sealing resin 35 is pushed out.

[0072] See FIG. 5. The molding process includes a first stage and a second stage. In the first stage, the second sealing resin 35 is extruded into the mold 61 from the injection hole 62 by the piston 63. The second sealing resin 35 extruded into the mold 61 covers the sealed portion 50. In one example, the injection hole 62 is positioned above the sealed portion 50 fixed to the mold 61. This positioning allows the second sealing resin 35 to flow smoothly over the surface of the sealed portion 50, and therefore the second sealing resin 35 can cover the sealed portion 50 smoothly.

[0073] 6, in the second stage, the piston 63 further extrudes the resin in the injection cylinder 60, thereby extruding the first sealing resin 34 from the injection hole 62 into the mold 61. The first sealing resin 34 fills the space between the second sealing resin 35 and the mold 61.

[0074] The first sealing resin 34 and the second sealing resin 35 are cured to form a sealing portion 40 that is bonded to the sealed portion 50. In the sealing portion 40, the first region 41 is formed by the first sealing resin 34, and the second region 42 is formed by the second sealing resin 35. When the first sealing resin 34 is filled in the second stage, the second sealing resin 35 has not yet cured, so the first sealing resin 34 and the second sealing resin 35 are mixed at the boundary between the first region 41 and the second region 42. Therefore, no interface is formed between the first region 41 and the second region 42.

[0075] <How to recycle a motor> 3, 7 and 8, a description will be given of a recycling method for recycling the motor 10. The recycling method for the motor 10 is a method for recovering recycled parts included in the sealed portion 50.

[0076] Referring to FIG. 7, the method for recycling the motor 10 includes a heating step. The heating step is a step of heating the motor 10 to a temperature equal to or higher than a first temperature. In one example, the heating step is performed at a temperature equal to or lower than the combustion temperature of the sealing resin 30. The heating step is performed in a furnace using infrared and far-infrared heaters, etc. Heating the motor 10 in the heating step causes the first filler 32 contained in the sealing resin 30 that constitutes the sealing portion 40 to thermally decompose. As a result of the thermal decomposition of the first filler 32, the second region 42, which contains a large amount of the first filler 32, thermally decomposes before the first region 41. As a result of the thermal decomposition of the first filler 32, the second region 42 becomes brittle.

[0077] The recycling method for the motor 10 includes a separation process. The separation process is a process for separating the sealing portion 40 from the sealed portion 50. In the heating process, the second region 42 bonded to the sealed portion 50 is thermally decomposed, so that the sealing portion 40 can be separated from the sealed portion 50.

[0078] <effect> The operation of this embodiment will be described. When resin molding motor components using methods such as insert molding and transfer molding, the sealing resin may flow into small gaps, such as the gaps between windings. In this case, it is difficult to remove the sealing resin from the gaps when recycling the windings. In the motor 10, a second sealing resin 35 is bonded to the sealed portion 50. By heating the motor 10 to a first temperature or higher, the second region 42 of the sealing portion 40 that is bonded to the sealed portion 50 is thermally decomposed. The thermal decomposition of the second region 42 allows the first region 41 of the sealing portion 40 to be easily separated from the sealed portion 50.

[0079] <Effects> The effects of this embodiment will be described. (1-1) The motor 10 includes a sealing portion 40 and a sealed portion 50. The sealing portion 40 includes a first region 41 and a second region 42 that is more susceptible to thermal decomposition than the first region 41. The second region 42 is provided between the first region 41 and the sealed portion 50. The content of the first filler 32 in the second region 42 is greater than the content of the first filler 32 in the first region 41.

[0080] With this configuration, the content of the first filler 32 in the second region 42 is greater than the content of the first filler 32 in the first region 41, so the second region 42 is more susceptible to thermal decomposition than the first region 41. Because the second region 42 is more susceptible to thermal decomposition than the first region 41, the first region 41 of the sealing portion 40 can be separated from the sealed portion 50 by heating the motor 10 to a temperature equal to or higher than the first temperature. In this way, recyclable parts contained in the sealed portion 50 can be suitably recovered from the motor 10.

[0081] (1-2) The base resin 31 of the sealing resin 30 that constitutes the second region 42 is the same type of resin as the base resin 31 of the sealing resin 30 that constitutes the first region 41.

[0082] According to this configuration, the first region 41 and the second region 42 are each made of the sealing resin 30 having the same type of resin as the base resin 31, so that an interface is unlikely to occur between the first region 41 and the second region 42. In this way, the first region 41 and the second region 42 are firmly connected, which can improve the strength of the sealing portion 40.

[0083] (1-3) No interface is formed between the first region 41 and the second region 42.

[0084] According to this configuration, the first region 41 and the second region 42 are more firmly connected, and therefore the strength of the sealing portion 40 can be further improved.

[0085] (1-4) The content of the first filler 32 in the second region 42 is 50% by mass or more and 80% by mass or less.

[0086] If the content of the first filler 32 is less than 50% by mass, the thermal decomposition of the sealing portion 40 is less likely to proceed. If the content of the first filler 32 in the second region 42 is 50% by mass or more, the thermal decomposition of the first filler 32 causes an increase in voids in the second region 42, and heating to the first temperature or higher reduces the strength of the second region 42. This reduces the load required to separate the first region 41 of the sealing portion 40 from the sealed portion 50. If the content of the first filler 32 is greater than 80% by mass, it is more difficult to form the sealing portion 40. In this regard, according to the above configuration, the content of the first filler 32 in the second region 42 is 50% by mass or more and 80% by mass or less. This makes it easier to thermally decompose the second region 42 of the sealing portion 40, while also facilitating the formation of the second region 42 when forming the sealing portion 40.

[0087] (1-5) The first temperature of the first filler 32 contained in the second region 42 is equal to or lower than the combustion temperature of the first sealing resin 34 that constitutes the first region 41.

[0088] According to this configuration, by heating the motor 10 to a temperature equal to or higher than the first temperature and equal to or lower than the combustion temperature, when the first region 41 of the sealing portion 40 is separated from the sealed portion 50, combustion of the first sealing resin 34 constituting the first region 41 is suppressed. This makes it possible to suppress adhesion of dirt caused by combustion to the sealed portion 50.

[0089] (1-6) The first filler 32 is made of aluminum hydroxide.

[0090] According to this configuration, the sealing resin 30 that forms the second region 42 can be suitably thermally decomposed by aluminum hydroxide.

[0091] (1-7) The content of the second filler 33 in the second region 42 is lower than the content of the second filler 33 in the first region 41.

[0092] According to this configuration, the content of second filler 33 in second region 42 is lower than the content of second filler 33 in first region 41, making first region 41 even less susceptible to thermal decomposition than second region 42. Therefore, when first region 41 and sealed portion 50 of sealing portion 40 are separated, second region 42 can be thermally decomposed before first region 41.

[0093] (1-8) The sealed portion 50 includes any one of the winding 16, the core material 18, and the magnet 21.

[0094] According to this configuration, any one of the winding 16, the core material 18, and the magnet 21 included in the sealed portion 50 can be suitably separated from the first region 41 of the sealed portion 40.

[0095] (1-9) The blower 1 includes a motor 10.

[0096] According to this configuration, recycled parts included in sealed portion 50 from motor 10 of blower 1 can be suitably recovered.

[0097] (1-10) The method for recycling the motor 10 includes a heating step. The heating step is a step of heating the motor 10 to a temperature equal to or higher than a first temperature.

[0098] According to this configuration, the motor 10 is heated to a temperature equal to or higher than the first temperature in the heating step, whereby the second region 42 of the sealing portion 40 is thermally decomposed. The thermal decomposition of the second region 42 separates the first region 41 of the sealing portion 40 from the sealed portion 50, allowing the recycled parts included in the sealed portion 50 to be recovered from the motor 10.

[0099] (1-11) The manufacturing method of the motor 10 includes a molding process. The molding process is a process of forming the sealing portion 40. In the molding process, the sealing portion 40 is formed so that the second sealing resin 35 is provided between the first sealing resin 34 and the sealed portion 50.

[0100] This configuration makes it possible to configure the motor 10 in which the sealing portion 40 and the sealed portion 50 are easily separated by heat.

[0101] In the molding step (1-12), the sealing portion 40 is formed by a single transfer molding using an injection cylinder 60 that contains the first sealing resin 34 and the second sealing resin 35.

[0102] According to this configuration, the sealing portion 40 can be formed by a single transfer molding process, thereby reducing the number of manufacturing steps for the motor 10.

[0103] Second Embodiment 2 and 9 to 12, a blower 1, a motor 10, a method for manufacturing the motor 10, and a method for recycling the motor 10 according to a second embodiment will be described. Components in this embodiment that are common to the first embodiment will be assigned the same reference numerals as in the first embodiment, and duplicated descriptions will be omitted.

[0104] In this embodiment, the molding step in the manufacturing method of the motor 10 is different from that of the first embodiment. The motor 10 of this embodiment is formed by two-shot molding. The molding step of this embodiment includes a first step and a second step.

[0105] 2 and 9. The first step is a step of forming a part of the sealing portion 40 with the second sealing resin 35. In the first step, a first injection cylinder 70 is used. The first injection cylinder 70 contains the second sealing resin 35. The first injection cylinder 70 has a first injection hole 72 connected to a first mold 71. The first mold 71 has a shape corresponding to the second region 42 of the sealing portion 40. A first piston 73 extrudes the resin in the first injection cylinder 70 from the first injection hole 72, thereby filling the first mold 71 with the resin.

[0106] 2 and 10 , in a first step, the second sealing resin 35 is extruded from the first injection cylinder 70 to form a forming portion 74 of the sealing portion 40 that covers the sealed portion 50. The forming portion 74 corresponds to the second region 42 of the sealing portion 40.

[0107] 2 and 11 . The second step is a step of forming the other portion of the sealing portion 40 with the first sealing resin 34 so as to cover at least a portion of the forming portion 74 formed with the second sealing resin 35. In the second step, a second injection cylinder 80 is used. The second injection cylinder 80 contains the first sealing resin 34. The second injection cylinder 80 has a second injection hole 82 connected to a second mold 81. The second mold 81 has a shape corresponding to the first region 41 of the sealing portion 40. A second piston 83 extrudes the resin in the second injection cylinder 80 from the second injection hole 82, thereby filling the second mold 81 with the resin.

[0108] 2 and 12 . In the second step, the first sealing resin 34 is extruded from the second injection cylinder 80 to form the portion of the sealing portion 40 other than the forming portion 74. The portion other than the forming portion 74 corresponds to the first region 41 of the sealing portion 40.

[0109] The effects of this embodiment will be described. According to this configuration, the first region 41 of the sealing portion 40, which is constituted by the first sealing resin 34, and the second region 42 of the sealing portion 40, which is constituted by the second sealing resin 35, are formed separately. Therefore, the second sealing resin 35 can be suitably disposed between the first sealing resin 34 and the sealed portion 50.

[0110] <Third embodiment> A refrigeration device 100 according to a third embodiment will be described with reference to Figures 2, 3, and 13 to 15. In this embodiment, the same components as those in the first embodiment are denoted by the same reference numerals as those in the first embodiment, and redundant description will be omitted.

[0111] The refrigeration device 100 includes a motor 200. The motor 200 includes a sealing portion 40 and a sealed portion 50 similar to those of the motor 10 of the first embodiment. In one example, the motor 200 is included in the compressor 110 of the refrigeration device 100.

[0112] Please refer to Fig. 13. Fig. 13 is a schematic configuration diagram of a refrigeration device 100. The refrigeration device 100 includes a refrigerant circuit R. The refrigerant circuit R is filled with a refrigerant. The refrigerant circuit R performs a vapor compression refrigeration cycle. A compressor 110 is provided in the refrigerant circuit R of the refrigeration device 100.

[0113] 3 and 14, the compressor 110 further includes a drive shaft 111 and a compression mechanism 112. The drive shaft 111 is provided in a casing 113 so as to extend along the rotation axis. The drive shaft 111 is driven to rotate by a motor 200.

[0114] The compression mechanism 112 is housed in a casing 113. The compression mechanism 112 has a cylinder 114 and a piston 115. The piston 115 is connected to the drive shaft 111 and is provided inside the cylinder 114. A cylinder chamber 116 is formed between the inner peripheral surface of the cylinder 114 and the outer peripheral surface of the piston 115. The compression mechanism 112 has a suction pipe 117 and a discharge pipe 118. The suction pipe 117 communicates with the cylinder chamber 116 of the compression mechanism 112. The discharge pipe 118 communicates with the internal space of the casing 113.

[0115] Referring to Fig. 13, in one example, the refrigerant circuit R is provided with, in addition to the compressor 110, a radiator 120, a pressure reduction mechanism 130 constituted by an expansion valve, and an evaporator 140. In the refrigeration cycle, the refrigerant is compressed by the compressor 110 and then dissipates heat to the air in the radiator 120. The refrigerant that has dissipated heat is reduced in pressure by the pressure reduction mechanism 130 and then evaporated in the evaporator 140. The evaporated refrigerant is drawn into the compressor 110.

[0116] Low-pressure refrigerant from the refrigerant circuit R is drawn into a cylinder chamber 116 of the compression mechanism 112 via a suction pipe 117. The compression mechanism 112 compresses the refrigerant in the cylinder chamber 116 with a piston 115 driven by a drive shaft 111. The inside of the casing 113 is filled with high-pressure refrigerant discharged from the compression mechanism 112. This high-pressure refrigerant flows through the motor 200 and is then discharged into the refrigerant circuit R via a discharge pipe 118.

[0117] In this embodiment, the motor 200 is an interior magnet rotating electric machine. The motor 200 is an inner rotor motor. The motor 200 includes a rotor 210 and a stator 220.

[0118] The rotor 210 rotates around the rotation axis by the magnetic field generated by the stator 220. The rotor 210 includes a rotor core 230 and a magnet 240.

[0119] Please refer to Fig. 15. Fig. 15 is a plan view of the vicinity of the slots 231 of the rotor core 230. The magnets 240 are arranged in the slots 231 provided in the rotor core 230. In one example, the magnets 240 are fixed to the slots 231 by adhesive resin 241. The adhesive resin 241 is filled into the slots 231 as an adhesive. In one example, the adhesive resin 241 is made of the sealing resin 30 according to the first embodiment.

[0120] See Figure 14. Stator 220 is provided radially outward of rotor 210 at a distance so as to face rotor 210 in the radial direction. Stator 220 has a stator core 250 and windings 260. Stator core 250 is made of core material 251. In one example, core material 251 is made of laminated electromagnetic steel sheets. Windings 260 are wound around the teeth of stator core 250. In one example, windings 260 are made of copper wire.

[0121] The stator 220 has a molded portion 270. The molded portion 270 covers the surface of the stator core 250 and end portions 280 of the windings 260. The molded portion 270 is made of the sealing resin 30 according to the first embodiment.

[0122] 2, 3, and 14. In this embodiment, the sealing portion 40 is a molded portion 270, and the sealed portion 50 is a stator core 250 and a winding 260. In the sealing resin 30 constituting the molded portion 270, the surface of the stator core 250 and the portion in contact with an end portion 280 of the winding 260 are configured as a second region 42 of the sealing portion 40.

[0123] 2, 3, and 15. The sealing portion 40 may be adhesive resin 241, and the sealed portion 50 may be magnet 240. In the sealing resin 30 that constitutes the adhesive resin 241, the portion that contacts the magnet 240 is configured as a second region 42 of the sealing portion 40.

[0124] The effects of this embodiment will be described. According to this configuration, recycled parts included in the sealed portion 50 can be suitably recovered from the motor 200 of the refrigeration device 100.

[0125] <Fourth embodiment> A vehicle 300 according to the fourth embodiment will be described with reference to Figures 3, 14, and 16. Configurations in this embodiment that are common to the first embodiment are assigned the same reference numerals as in the first embodiment, and duplicated descriptions will be omitted.

[0126] FIG. 16 is a schematic diagram of a vehicle 300. The vehicle 300 includes a motor 310. In one example, the motor 310 is an inner rotor motor similar to the motor 200 of the third embodiment. The motor 310 includes a sealing portion 40 and a sealed portion 50 similar to the motor 200 of the third embodiment. In one example, the vehicle 300 is an electric vehicle. When the vehicle 300 is an electric vehicle, the motor 310 is configured as a drive motor for the vehicle 300.

[0127] Vehicle 300 includes front wheels 320 and rear wheels 330. In the example of Fig. 16, front wheels 320 are drive wheels of vehicle 300. Motor 310 is connected to front wheels 320. Front wheels 320 are driven by motor 310. Motor 310 may be connected to rear wheels 330, or may be connected to both front wheels 320 and rear wheels 330.

[0128] The vehicle 300 includes a battery 340. The battery 340 supplies power to the motor 310. The battery 340 may also supply power to an electrical system other than the motor 310.

[0129] The effects of this embodiment will be described. According to this configuration, recycled parts included in the sealed portion 50 can be suitably collected from the motor 310 of the vehicle 300.

[0130] <Modification> In addition to the above-described embodiments, the blower 1, motor 10, manufacturing method for motor 10, recycling method for motor 10, refrigeration device 100, and vehicle 300 of the present disclosure may also be configured in the following modified examples, or in a form that combines at least two modified examples that are not mutually contradictory.

[0131] The first temperature may be higher than the Curie temperature of the magnet 21. In this modification, the first temperature of the first filler 32 contained in the second region 42 is higher than the Curie temperature of the magnet 21. The first filler 32 in this modification is composed of at least one of sodium carbonate and magnesium hydroxide. With this configuration, the magnet 21 can be demagnetized when the sealing portion 40 is heated. Demagnetizing the magnet 21 makes it easier to retrieve the magnet 21 from the motor 10.

[0132] 17 to 19. The first region 41 may be directly joined to the sealed portion 50. In the example of FIG. 17, the second region 42 is arranged between the winding 16 of the sealed portion 50 and the first region 41. In the example of FIG. 18, the second region 42 is arranged between the stator 11 of the sealed portion 50 and the first region 41. In the example of FIG. 19, the second region 42 is arranged between the first region 41 and some of the windings 16 and stator 11 of the sealed portion 50.

[0133] The magnet 21 may be a samarium-cobalt magnet, a ferrite magnet, or an alnico magnet instead of a neodymium magnet.

[0134] The first filler 32 may be composed of a filler other than aluminum hydroxide. When the first filler 32 is composed of zinc carbonate, the second filler 33 is composed of sodium carbonate, magnesium hydroxide, aluminum hydroxide, or cellulose nanofiber. When the first filler 32 is composed of cellulose nanofiber, the second filler 33 is composed of sodium carbonate, magnesium hydroxide, or aluminum hydroxide. When the first filler 32 is composed of magnesium hydroxide, the second filler 33 is composed of sodium carbonate. When the first filler 32 is composed of sodium carbonate, the sealing resin 30 does not need to include the second filler 33.

[0135] The base resin 31 of the sealing resin 30 that constitutes the second region 42 may be a different type of resin from the base resin 31 of the sealing resin 30 that constitutes the first region 41 .

[0136] The content of the first filler 32 in the second region 42 may be less than 50% by mass as long as the second region 42 can be thermally decomposed at the first temperature. Furthermore, the content of the first filler 32 in the second region 42 may be greater than 80% by mass as long as the sealing portion 40 can be formed in the manufacturing method of the motor 10.

[0137] The content of the second filler 33 in the second region 42 may be greater than the content of the second filler 33 in the first region 41, as long as the second region 42 can be thermally decomposed at the first temperature.

[0138] The above describes embodiments of the blower 1, the motor 10, the manufacturing method of the motor 10, the recycling method of the motor 10, the refrigeration device 100, and the vehicle 300. However, it will be understood that various changes in form and details are possible without departing from the spirit and scope of the blower 1, the motor 10, the manufacturing method of the motor 10, the recycling method of the motor 10, the refrigeration device 100, and the vehicle 300 as set forth in the claims. [Explanation of symbols]

[0139] 1...blower, 10,200,310...motor, 16,260...winding, 18,251...core material, 21,240...magnet, 30...sealing resin, 31...base resin, 32...first filler, 33...second filler, 34...first sealing resin, 35...second sealing resin, 40...sealing portion, 41...first region, 42...second region, 50...sealed portion, 60...injection cylinder, 74...forming portion, 100...refrigeration device, 300...vehicle.

Claims

1. A motor (10) comprising a sealing portion (40) made of a sealing resin (30) and a sealed portion (50) sealed by the sealing portion (40), The sealing portion (40) includes a first region (41) and a second region (42) that is more susceptible to thermal decomposition than the first region (41), The second region (42) is provided between the first region (41) and the sealed portion (50), the second region (42) includes a first filler (32) that thermally decomposes at a temperature equal to or higher than a first temperature; The content of the first filler (32) in the second region (42) is greater than the content of the first filler (32) in the first region (41). Motor.

2. The base resin (31) of the sealing resin (30) constituting the second region (42) is the same type of resin as the base resin (31) of the sealing resin (30) constituting the first region (41). The motor according to claim 1 .

3. No interface is formed between the first region (41) and the second region (42). The motor according to claim 2 .

4. The content of the first filler (32) in the second region (42) is 50% by mass or more and 80% by mass or less. The motor according to claim 1 .

5. The first temperature of the first filler (32) contained in the second region (42) is equal to or lower than the combustion temperature of the first sealing resin (34) constituting the first region (41). The motor according to claim 1 .

6. The first filler (32) is composed of aluminum hydroxide. The motor according to claim 1 .

7. the first region (41) includes a second filler (33) that thermally decomposes at a temperature equal to or higher than a second temperature that is higher than the first temperature; The content of the second filler (33) in the second region (42) is lower than the content of the second filler (33) in the first region (41). The motor according to claim 1 .

8. The sealed portion (50) includes any one of a winding (16), a core material (18), and a magnet (21). The motor according to claim 1 .

9. The sealed portion (50) includes the magnet (21), The first temperature of the first filler (32) contained in the second region (42) is higher than the Curie temperature of the magnet (21). The motor according to claim 8.

10. The motor (10) according to any one of claims 1 to 9, Blower.

11. The motor (10) according to any one of claims 1 to 9, Refrigeration equipment.

12. The motor (10) according to any one of claims 1 to 9, vehicle.

13. A method for recycling the motor (10) according to any one of claims 1 to 9, comprising the steps of: a heating step of heating the motor (10) to a temperature equal to or higher than the first temperature; How to recycle a motor.

14. A method for manufacturing a motor (10) including a sealing portion (40) made of a first sealing resin (34) and a second sealing resin (35) that is more easily thermally decomposed than the first sealing resin (34), and a sealed portion (50) sealed by the sealing portion (40), A molding step for forming the sealing portion (40) is included. In the molding step, the sealing portion (40) is formed so that the second sealing resin (35) is provided between the first sealing resin (34) and the sealed portion (50). Motor manufacturing method.

15. In the molding step, the sealing portion (40) is formed by a single transfer molding using an injection cylinder (60) that contains the first sealing resin (34) and the second sealing resin (35). The method for manufacturing the motor according to claim 14.

16. The molding step includes: forming a part of the sealing portion (40) with the second sealing resin (35); and forming another portion of the sealing portion (40) using the first sealing resin (34) so ​​as to cover at least a portion of the forming portion (74) formed by the second sealing resin (35). The method for manufacturing the motor according to claim 14.

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