Methods for manufacturing metal parts, methods for manufacturing stator cores, methods for manufacturing motors, methods for manufacturing compressors, methods for manufacturing blowers, and methods for manufacturing refrigeration equipment.

Abstract

This helps to prevent a decrease in the lifespan of the mold. [Solution] A method for manufacturing a metal part (2) having a predetermined shape from a metal plate (1) including an amorphous metal or nanocrystalline metal, comprising: a crystallization step of crystallizing a cut portion (13) located outside the part region (10) or on the boundary between the part region (10) and an outer region (10A) located outside the part region (10), and along the edge (11) of the part region (10), while suppressing the crystallization of the part region (10) having the predetermined shape on the metal plate (1); and a cutting step of cutting the metal plate (1) at the cut portion (13) using a mold (30).

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing metal parts, a method for manufacturing a stator core, a method for manufacturing a motor, a method for manufacturing a compressor, a method for manufacturing a blower, and a method for manufacturing a refrigeration device.

Background Art

[0002] The motor disclosed in Patent Document 1 has a stator core provided with a core composed of laminated amorphous metal.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Metals containing amorphous metal or nanocrystalline metal are extremely thin compared to general electromagnetic steel sheets, but are very hard. Therefore, when a large amount of the above metals are punched by a punching method during mass production, an excessive load continues to be applied to the die, resulting in cracks, chips, etc. in the die, and thereby the life of the die may be reduced.

[0005] An object of the present disclosure is to be able to suppress a reduction in the life of the die.

Means for Solving the Problems

[0006] The first aspect is a method for manufacturing a metal part (2) having a predetermined shape from a metal plate (1) containing an amorphous metal or a nanocrystalline metal, comprising: a crystallization step of crystallizing a cut portion (13) located outside the part region (10) or on the boundary between the part region (10) and an outer region (10A) located outside the part region (10), and along the edge (11) of the part region (10), while suppressing the crystallization of the part region (10) having the predetermined shape on the metal plate (1); and a cutting step of cutting the metal plate (1) at the cut portion (13) using a mold (30). Crystallizing the cut portion (13) includes not only crystallizing the entire area of ​​the cut portion (13) but also crystallizing at least a portion of the area of ​​the cut portion (13).

[0007] According to the first embodiment, by crystallizing the cut portion (13) of the component region (10) on the metal plate (1), the load on the mold (30) when cutting the metal plate (1) at the cut portion (13) using the mold (30) can be reduced, thereby suppressing a decrease in the lifespan of the mold (30).

[0008] In a second embodiment, the crystallization step includes the steps of forming a plurality of cuts (14) on the cut portion (13) and heating the outer portion (12) of the cut portion (13).

[0009] According to the second embodiment, when the outer portion (12) is heated to crystallize the cut portion (13) adjacent to the outer portion (12), the cut (14) formed in the cut portion (13) can suppress heat transfer to the component region (10), thereby suppressing crystallization of the component region (10).

[0010] A third aspect is the crystallization step, in the first aspect, which includes heating the cut portion (13) or the outer portion (12) of the cut portion (13) while cooling the component region (10) or the edge portion (11) of the component region (10).

[0011] According to the third embodiment, when heating the cut portion (13) or the outer portion (12) to crystallize the cut portion (13) adjacent to the outer portion (12), the crystallization of the component region (10) can be suppressed by cooling the component region (10) or the edge (11) of the component region (10) on the metal plate (1).

[0012] A fourth aspect is the first aspect, wherein the crystallization step includes heating a separated portion (12a) on the metal plate (1) that is separated by a predetermined distance (D) or more from the cut portion (13) to the outside of the component region (10).

[0013] According to the fourth embodiment, when the separated portion (12a) is heated to crystallize the cut portion (13), the component region (10) is located at a position further apart from the separated portion (12a) than the cut portion (13), so the amount of heat transferred to the component region (10) is suppressed compared to the cut portion (13). As a result, crystallization of the component region (10) can be suppressed.

[0014] The fifth aspect is that, in the fourth aspect, the predetermined distance (D) has a size of 0 mm or more and 5 mm or less.

[0015] According to the fifth embodiment, on the metal plate (1), a location can be heated at least at a distance from the edge (11) of the component area (10) by the width of the cut portion (13).

[0016] In the sixth aspect, in the first aspect, the crystallization step includes a step of resistance heating the cut portion (13).

[0017] According to the sixth embodiment, the cut portion (13) can be locally heated by resistive heating, so that the cut portion (13) crystallizes by resistive heating while suppressing the crystallization of the component region (10).

[0018] A seventh aspect is the first aspect, wherein the crystallization step includes heating the cut portion (13) by irradiating it with laser light or an electron beam.

[0019] According to the seventh aspect, since the cutting portion (13) can be locally heated by a laser beam or an electron beam, it is possible to suppress crystallization of the component region (10) while crystallizing the cutting portion (13) by the laser beam or the electron beam.

[0020] The eighth aspect is that, in the sixth or seventh aspect, the cutting portion (13) is pulse-heated.

[0021] According to the eighth aspect, the amount of heat transferred from the cutting portion (13) to the component region (10) can be effectively suppressed.

[0022] The ninth aspect is a method for manufacturing a stator core, which manufactures a stator core by laminating a plurality of metal components (2) manufactured by the manufacturing method according to any one of the first to eighth aspects.

[0023] In the ninth aspect, a stator core can be manufactured from the metal plate (1).

[0024] The tenth aspect is a method for manufacturing a motor, which manufactures a motor including the stator core of the ninth aspect.

[0025] In the tenth aspect, a motor including a stator core manufactured from the metal plate (1) can be manufactured.

[0026] The eleventh aspect is a method for manufacturing a compressor, which manufactures a compressor including the motor of the tenth aspect.

[0027] In the eleventh aspect, a compressor including a stator core manufactured from the metal plate (1) can be manufactured.

[0028] The twelfth aspect is a method for manufacturing a blower, which manufactures a blower including the motor of the tenth aspect.

[0029] In the twelfth aspect, a blower including a stator core manufactured from the metal plate (1) can be manufactured.

[0030] The thirteenth aspect is a method for manufacturing a refrigeration system, comprising manufacturing a refrigeration system including a compressor according to the eleventh aspect.

[0031] In the 13th embodiment, a refrigeration system can be manufactured that includes a stator core made from a metal plate (1). [Brief explanation of the drawing]

[0032] [Figure 1] Figure 1 is a plan view of an amorphous metal plate according to an embodiment. [Figure 2] Figure 2(a) is a cross-sectional view of an amorphous metal sheet being punched out by a die. Figure 2(b) is a perspective view of a metal part. [Figure 3] Figure 3 is a flowchart of the manufacturing method for metal parts. [Figure 4] Figure 4(a) is a plan view of an amorphous metal plate with a cut formed on the cut surface. Figure 4(b) is a perspective view showing the outer part of the amorphous metal plate being heated. [Figure 5] Figure 5 is a perspective view showing the state in which the outer part of an amorphous metal plate is being heated while the component area is being cooled. [Figure 6] Figure 6 is a plan view showing the separated outer portion of the amorphous metal plate, which is the heated area. [Figure 7] Figure 7 is a perspective view showing an amorphous metal plate being heated by resistance. [Figure 8] Figure 8 is a perspective view showing an amorphous metal plate being heated by laser light. [Figure 9] Figure 9 is a schematic diagram of the refrigeration system. [Figure 10] Figure 10 is a longitudinal cross-sectional view of the compressor, corresponding to a cross-section parallel to the axial direction. [Figure 11] Figure 11 is a cross-sectional view of the motor, corresponding to a cross-section perpendicular to the axial direction. [Modes for carrying out the invention]

[0033] The embodiments of this disclosure will be described in detail below with reference to the drawings. This disclosure is not limited to the embodiments shown below, and various modifications are possible without departing from the technical idea of ​​this disclosure. Since the drawings are for conceptual explanation of this disclosure, dimensions, ratios, or numbers may be exaggerated or simplified as necessary for ease of understanding. In each embodiment, example, modification, and drawing, the same or corresponding parts are denoted by the same reference numerals, and detailed descriptions and their associated effects will not be repeated.

[0034] (1)Metal plate The metal plate (1) includes an amorphous metal or a nanocrystalline metal. The metal plate (1) is formed from a magnetic material. The magnetic material is an amorphous soft magnetic material that forms an amorphous metal, or a nanocrystalline soft magnetic material that forms a nanocrystalline metal. The amorphous soft magnetic material or nanocrystalline soft magnetic material used in the magnetic material is composed of, for example, at least one magnetic metal selected from the group consisting of iron, cobalt, and nickel, and at least one non-magnetic metal. The at least one non-magnetic metal is selected from the group consisting of, for example, boron, carbon, phosphorus, aluminum, silicon, titanium, vanadium, chromium, manganese, copper, yttrium, zirconium, niobium, molybdenum, hafnium, tantalum, and tungsten. The amorphous soft magnetic material or nanocrystalline soft magnetic material in the magnetic material is not limited to the above examples.

[0035] Typical amorphous soft magnetic materials or nanocrystalline soft magnetic materials used in magnetic materials include, for example, iron-cobalt alloys, iron-nickel alloys, iron-aluminum alloys, iron-silicon alloys, iron-tantalum alloys, or iron-zirconium alloys. Examples of iron-cobalt alloys include Fe·Co alloys and Fe·Co·V alloys. Examples of iron-nickel alloys include Fe·Ni alloys, Fe·Ni·Mo alloys, Fe·Ni·Cr alloys, and Fe·Ni·Si alloys. Examples of iron-aluminum alloys or iron-silicon alloys include Fe·Al alloys, Fe·Al·Si alloys, Fe·Al·Si·Cr alloys, Fe·Al·Si·Ti·Ru alloys, and Fe·Al·O alloys. Examples of iron-tantalum alloys include Fe·Ta alloys, Fe·Ta·C alloys, and Fe·Ta·N alloys. An example of an iron-zirconium alloy is Fe·Zr·N alloy.

[0036] Furthermore, typical amorphous soft magnetic materials or nanocrystalline soft magnetic materials used in magnetic materials may include, for example, cobalt alloys containing cobalt and at least one element from the group consisting of zirconium, hafnium, niobium, tantalum, titanium, and yttrium. Cobalt alloys preferably contain 80 at% or more cobalt. Cobalt alloys containing 80 at% or more cobalt tend to become amorphous when formed into films. In addition, cobalt alloys containing 80 at% or more cobalt have excellent magnetic properties because they have low crystalline magnetic anisotropy, fewer crystalline defects, and fewer grain boundaries. Suitable amorphous soft magnetic materials include, for example, Co·Zr alloys, Co·Zr·Nb alloys, and Co·Zr·Ta alloys.

[0037] Amorphous soft magnetic materials have an amorphous structure as their main structure. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they do not have clear peaks in the X-ray diffraction pattern. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they have a broad halo pattern.

[0038] Nanocrystalline soft magnetic materials are formed by applying heat treatment to amorphous soft magnetic materials that have an amorphous structure. Nanocrystalline soft magnetic materials are soft magnetic materials in which nanocrystals are deposited by heat treatment of amorphous soft magnetic materials. Nanocrystalline soft magnetic materials have a nanocrystalline structure. Nanocrystals are polycrystalline materials with particle sizes ranging from several nanometers to tens of nanometers.

[0039] When observing the X-ray diffraction pattern of nanocrystalline soft magnetic materials, X-ray diffraction peaks are observed at positions corresponding to the lattice spacing of the crystal planes. The crystallite size can be calculated from the width of the X-ray diffraction peaks using Scherrer's formula. A nanocrystal is defined as a material whose crystallite size, calculated from the full width at half maximum (FWHM) of the X-ray diffraction peaks using Scherrer's formula, is less than 1 micrometer. In this disclosure, the crystallite size of the nanocrystal (the crystallite size calculated from the FWHM of the X-ray diffraction peaks using Scherrer's formula) is preferably 100 nanometers or less, and more preferably 50 nanometers or less. Furthermore, the crystallite size of the nanocrystal is preferably 5 nanometers or more.

[0040] Nanocrystalline soft magnetic materials can improve magnetic properties because the crystallite size of the nanocrystals is 100 nanometers or less, as described above. Conventional electrical steel sheets have crystallite sizes on the order of micrometers, generally 50 micrometers or more. The thickness of the metal plate (1) is formed to be, for example, 20 μm to 100 μm, preferably 20 μm to 50 μm, and more preferably 20 μm to 30 μm. The metal plate (1) is formed in a plate-like (thin film) form. The metal plate (1) is formed in a rectangular shape when viewed in the thickness direction (A). The thickness direction (A) of the metal plate (1) is the direction indicating the thickness of the metal plate (1), and in Figures 1, 4(a), 4(b), 6(a), and 6(b), it is the direction perpendicular to the drawing.

[0041] (2) Method of manufacturing metal parts A method for manufacturing a metal part (2) having a predetermined shape from a metal plate (1) will be described.

[0042] In Figure 1, the component region (10) has a predetermined shape, and is the same shape as the metal part (2). That is, the component region (10) is the region of the metal plate (1) that will become the metal part (2).

[0043] Figure 1 shows the cut portion (13) and the outer portion (12).

[0044] The cut portion (13) is the part of the metal plate (1) that is cut. The cut portion (13) is located on the metal plate (1) outside the component area (10), or on the boundary between the component area (10) and the outer area (10A) located outside the component area (10), and is adjacent to and extends along the edge (11) of the component area (10). The cut portion (13) is a linear area (a strip-shaped area with a very small width of a few millimeters). The cut portion (13) is the cutting allowance of the metal plate (1) (the part that is shaved off and disappears when the metal plate (1) is cut).

[0045] The outer portion (12) is a region on the metal plate (1) that is located around the cut portion (13) and outside the component region (10). The outer portion (12) is a strip-shaped region that is adjacent to the cut portion (13) and extends along the cut portion (13). The cut portion (13) is located between the outer portion (12) and the edge portion (11) of the component region (10).

[0046] As shown in Figures 1 and 3, a crystallization process is performed in step S1. In the crystallization process, the cut portion (13) is crystallized while suppressing the crystallization of the component region (10) on the metal plate (1). In the crystallization process, the cut portion (13) is crystallized by raising its temperature to above the crystallization start temperature. The crystallization start temperature is the temperature at which crystallization occurs in amorphous soft magnetic materials. The crystallization start temperature varies depending on the material, but for example, it is 300 to 500°C. Crystallizing the cut portion (13) includes not only crystallizing the entire area of ​​the cut portion (13), but also crystallizing at least a portion of the area of ​​the cut portion (13).

[0047] As shown in Figures 2(a) and 3, a cutting process is performed in step S2. In the cutting process, the component area (10) of the metal plate (1) is punched out by the mold (30). The mold (30) includes a punch (31) and a die (32). With the metal plate (1) placed in the die (32), the punch (31) punches out the component area (10) of the metal plate (1) into the die hole (33). As a result, the metal plate (1) is cut at the cutting section (13). Consequently, the component area (10) is separated from the metal plate (1).

[0048] As shown in Figures 2(a) and 2(b), the part region (10) punched out into the die hole (33) by the punch (31) separates from the metal plate (1) and becomes a metal part (2).

[0049] (3) Effects As described above, by crystallizing the cut portion (13) of the component region (10) on the metal plate (1), the load on the mold (30) when cutting the metal plate (1) at the cut portion (13) using the mold (30) can be reduced, thereby suppressing a decrease in the lifespan of the mold (30).

[0050] Furthermore, since the crystallization of the component region (10) can be suppressed, the deterioration and functional degradation of the metal component (2) can be prevented.

[0051] (4) First example of the crystallization process As shown in Figures 3 and 4(a), the crystallization step (step S1) may include a first step of forming a plurality of cuts (14) on the cut portion (13) (see Figure 1) of the metal plate (1), and a second step of heating the outer portion (12).

[0052] As shown in Figure 4(a), the cuts (14) are holes that penetrate the metal plate (1). The cuts (14) penetrate the metal plate (1) in the thickness direction (A). Multiple cuts (14) are arranged along the direction in which the cut portion (13) extends. On the cut portion (13) (see Figure 1), multiple cuts (14) are formed adjacent to the edge portion (11) of the component area (10). The number of multiple cuts (14) and the size of the spacing between adjacent cuts (14) are not particularly limited. The shape of the cuts (14) is not particularly limited. The cuts (14) may be, for example, round holes or elongated holes. Part of the cuts (14) may protrude from the cut portion (13) to the outer portion (12). In this embodiment, the multiple cuts (14) are arranged at equal intervals. In the first step, the cuts (14) may be formed, for example, by punching holes in the metal plate (1) using a die. Alternatively, the cuts (14) may be formed using tools such as a drill and a hole-punching roller.

[0053] As shown in Figures 4(a) and 4(b), in the first step, after multiple cuts (14) are formed on the cut portion (13), the process moves to the second step, where the outer portion (12) is heated. In the first step, for example, heating elements (41, 42) having the same shape as the outer portion (12) on the opposing surface to the outer portion (12) are brought into contact with the outer portion (12) by abutting them against the outer portion (12). The heating elements (41, 42) generate heat while not in contact with the component area (10) and the cut portion (13) (for example, the component area (10) and the cut portion (13) are in contact with the air). As a result, the outer portion (12) is directly heated without the component area (10) and the cut portion (13) being directly heated. In this embodiment, the outer portion (12) of the metal plate (1) is heated from both sides by a pair of heating elements (41, 42). The heating elements (41, 42) contain a metal such as a copper alloy and generate heat when an electric current is passed through them.

[0054] In the second step, the outer part (12) of the metal plate (1) is heated, and the heat from the outer part (12) is transferred to the cut part (13), causing the temperature of the cut part (13) to rise above the crystallization start temperature. As a result, the cut part (13) crystallizes. At this time, since multiple cuts (14) are formed in the cut part (13), the amount of heat transferred from the outer part (12) to the component region (10) is suppressed by the multiple voids of the cuts (14). As a result, the temperature of the component region (10) on the metal plate (1) is prevented from rising above the crystallization start temperature, and crystallization of the component region (10) is suppressed.

[0055] Once the second process is completed, the process moves on to the cutting process (step S2).

[0056] (5) Second example of the crystallization process As shown in Figures 3 and 5, the crystallization step (step S1) may include a third step of heating the outer part (12) while cooling the component region (10) or the edge (11) of the component region (10).

[0057] In the third step, for example, the heating elements (41, 42) are brought into contact with the outer part (12), and the heat-absorbing elements (51, 52), whose opposing surfaces have the same shape as the component area (10), are brought into contact with the component area (10). As a result, the heating elements (41, 42) generate heat, while the heat-absorbing elements (51, 52) are cooled. This causes the outer part (12) to be heated by the heating elements (41, 42) while the component area (10) is cooled by the heat-absorbing elements (51, 52).

[0058] According to this, the outer part (12) is heated, and the heat from the outer part (12) is transferred to the cut part (13), causing the temperature of the cut part (13) to rise above the crystallization initiation temperature. As a result, the cut part (13) crystallizes. In contrast, the component region (10) is cooled, which prevents it from reaching a temperature above the crystallization initiation temperature. As a result, crystallization of the component region (10) is suppressed.

[0059] In this embodiment, the outer portion (12) of the metal plate (1) is heated from both sides by a pair of heating elements (41, 42), while the component area (10) of the metal plate (1) is cooled from both sides by a pair of heat-absorbing elements (51, 52). The heat-absorbing elements (51, 52) contain a metal such as a copper alloy, and have channels formed inside, through which cooling water flows for cooling.

[0060] In this embodiment, the heating elements (41, 42) and the heat-absorbing elements (51, 52) are insulated from each other by forming a gap (void) or by placing an insulator between them.

[0061] In this embodiment, in the third step, the cut portion (13) does not come into contact with either the heating element (41, 42) or the heat-absorbing element (51, 52), but is instead in contact with air, for example. In this case, when the outer portion (12) is heated by the heating element (41, 42), the heat from the outer portion (12) is transferred to the cut portion (13), causing the cut portion (13) to crystallize. However, in the third step, the heating element (41, 42) may come into contact with the cut portion (13), and the cut portion (13) may be directly heated by the heating element (41, 42) to crystallize. In this case (when the cut portion (13) is directly heated), neither the outer portion (12) nor the cut portion (13) may be heated, and only the cut portion (13) may be heated.

[0062] In the third step, the component region (10) is cooled, so even if the outer part (12) is heated, the temperature of the component region (10) is prevented from exceeding the crystallization start temperature. As a result, crystallization of the component region (10) is suppressed. In addition, in the third step, the entire component region (10) may not be cooled, and only the edge (11) of the component region (10) may be cooled. In this case, for example, the heat-absorbing elements (51, 52) may be formed in a cylindrical shape. In this case, the inner part of the edge (11) of the component region (10) is not directly heated or cooled because it is in contact with, for example, the hollow part of the cylindrical heat-absorbing elements (51, 52).

[0063] Once the third step is completed, the process moves on to the cutting step (step S2).

[0064] (6) Third example of the crystallization process As shown in Figures 3 and 6, the crystallization step (step S1) may include a fourth step of heating a separated portion (12a) which is a part of the outer portion (12) on the metal plate (1).

[0065] The outer portion (12) includes a separated portion (12a) and a close portion (12b). The separated portion (12a) is the portion of the outer portion (12) that is separated from the cut portion (13) by a predetermined distance (D) or more. The close portion (12b) is the portion of the outer portion (12) that is located within a distance shorter than the predetermined distance (D) from the cut portion (13). The close portion (12b) is located between the separated portion (12a) and the cut portion (13). The predetermined distance (D) has a size of 0 mm or more and 5 mm or less. Preferably, the predetermined distance (D) is 0.5 mm or more and 5 mm or less.

[0066] In the fourth step, the separated portion (12a) comes into contact with, for example, the heating element (41, 42) (see Figure 4(b)). As a result, the separated portion (12a) is directly heated. The adjacent portion (12b) does not come into contact with the heating element (41, 42). As a result, the adjacent portion (12b) is not directly heated. Furthermore, the component area (10) and the cut portion (13) do not come into contact with the heating element (41, 42). As a result, the component area (10) and the cut portion (13) are not directly heated.

[0067] As described above, the separated portion (12a) is directly heated, while the adjacent portion (12b) is not directly heated. As a result, the heat applied to the separated portion (12a) is transferred to the cut portion (13) via the adjacent portion (12b), causing the cut portion (13) to reach a temperature above the crystallization start temperature and crystallize.

[0068] In contrast, with respect to the component region (10), the heat applied to the separated portion (12a) is transferred through the adjacent portion (12b) and the cut portion (13), which is the cutting allowance. However, as the heat applied to the separated portion (12a) is transferred to the component region (10) via the adjacent portion (12b) and the cut portion (13), it gradually weakens, which prevents the temperature of the component region (10) from exceeding the crystallization initiation temperature. As a result, crystallization of the component region (10) is suppressed.

[0069] Once the fourth step is completed, the process moves on to the cutting step (step S2).

[0070] (7) Fourth example of the crystallization process As shown in Figures 3 and 7, the crystallization step (step S1) may include a fifth step in which the outer part (12) is heated by resistance heating.

[0071] In the fifth step, metal rollers (61, 62) are pressed against the cut portion (13) of the metal plate (1), and with current flowing through the rollers (61, 62), they are rolled on the outer portion (12) (seam welding). As a result, the rollers (61, 62) are heated by the resistance heating generated when current is flowing through them, and the heated rollers (61, 62) roll on the cut portion (13) of the metal plate (1), thus heating the cut portion (13). Heating an object by pressing a metal object such as rollers (61, 62) against it and applying current to the object, thereby generating resistance heating, is sometimes referred to as resistance heating. Using resistance heating, it is possible to locally heat (generate heat) a targeted area of ​​the object (the area where a metal object such as rollers (61, 62) is pressed).

[0072] In the fifth step, the cut portion (13) is locally heated by resistance heating. This causes the temperature of the cut portion (13) to rise above the crystallization initiation temperature. As a result, the cut portion (13) crystallizes.

[0073] The component area (10) is not in contact with the rollers (61, 62) and is not directly heated by resistance heating.

[0074] By locally heating the cut portion (13), the amount of heat transferred from the cut portion (13) to the component region (10) can be suppressed. This prevents the temperature of the component region (10) from rising above the crystallization temperature, thereby suppressing crystallization of the component region (10).

[0075] In this embodiment, when resistively heating the cutting portion (13) by applying current to a metal object such as rollers (61, 62), the current is applied continuously, but pulse heating may be performed by applying pulsed current. This allows the cutting portion (13) to crystallize through resistive heating while suppressing excessive heating of the cutting portion (13), thereby effectively suppressing the amount of heat transferred from the cutting portion (13) to the component region (10). As a result, crystallization of the component region (10) can be effectively suppressed.

[0076] Once the fifth step is completed, the process moves on to the cutting step (step S2).

[0077] (8) Fifth example of the crystallization process As shown in Figures 3 and 8, the crystallization step (step S1) may include a sixth step of heating the outer part (12) by irradiating it with laser light (L) or an electron beam.

[0078] In the sixth step, for example, the laser light (L) emitted from the irradiation device (LA) is focused by a focusing lens (LB) and locally irradiated onto the cutting portion (13). When heating an object by irradiating it with laser light (L) or an electron beam, it becomes possible to locally heat (generate heat) a targeted area of ​​the object (the area irradiated by the laser light (L) or electron beam).

[0079] In the sixth step, the cut portion (13) is heated locally by irradiating it with laser light (L) or an electron beam. This causes the temperature of the cut portion (13) to rise above the crystallization start temperature. As a result, the cut portion (13) crystallizes.

[0080] The component area (10) is located outside the irradiation area of ​​the laser light (L) or electron beam and is not directly heated by the laser light (L) or electron beam.

[0081] By locally heating the cut portion (13), the amount of heat transferred from the cut portion (13) to the component region (10) can be suppressed. This prevents the temperature of the component region (10) from rising above the crystallization temperature, thereby suppressing crystallization of the component region (10).

[0082] In this embodiment, the outer portion (12) is continuously irradiated with laser light (L) or an electron beam. However, the cut portion (13) may be pulsed-heated by pulsed irradiation with laser light (L) or an electron beam. This allows the cut portion (13) to crystallize with the laser light (L) or electron beam while suppressing excessive heating of the cut portion (13), thereby effectively suppressing the amount of heat transferred from the cut portion (13) to the component region (10). As a result, crystallization of the component region (10) can be effectively suppressed.

[0083] Once the sixth step is completed, the process moves on to the cutting step (step S2).

[0084] (9) Other embodiments Multiple metal parts (1038) (see Figure 11) may be manufactured using the method described above (the same method as when manufacturing metal part (2)), and the multiple metal parts (1038) may be stacked and fixed together to manufacture the stator core (1032) (see Figure 11).

[0085] Furthermore, a motor (electric motor) (1030) (see Figures 10 and 11) including a stator core (1032) manufactured by stacking and fixing multiple metal parts (1038) together may be manufactured. A blower including this motor (1030) may also be manufactured. The blower includes a motor (1030) and an impeller, and the motor (1030) rotates the impeller to produce air. A compressor (1010) including this motor (1030) may also be manufactured. Furthermore, a refrigeration device (101) (see Figure 9) including this compressor may also be manufactured.

[0086] The refrigeration system (101) will now be described. The refrigeration system (101) shown in Figure 9 has a refrigerant circuit (101a) filled with refrigerant. The refrigerant circuit (101a) includes a compressor (1010), a heat exchanger (102), an expansion valve (103), and an evaporator (104). The refrigerant circuit (101a) performs a vapor compression type refrigeration cycle.

[0087] In the refrigeration cycle, the refrigerant compressed by the compressor (1010) releases heat into the air in the heat exchanger (102). The refrigerant that has released heat is depressurized by the expansion valve (103) and evaporates in the evaporator (104). The evaporated refrigerant is drawn back into the compressor (1010).

[0088] The refrigeration equipment (101) may also be an air conditioning system, a water heater, a chiller unit, or a cooling system for cooling the air inside the storage unit.

[0089] The compressor (1010) shown in Figure 10 comprises a casing (1011), a motor (1030), a drive shaft (1020), and a compression mechanism (1022).

[0090] The casing (1011) houses the motor (1030), the drive shaft (1020), and the compression mechanism (1022). The casing (1011) is a fully enclosed container. The inside of the casing (1011) is filled with high-pressure coolant discharged from the compression mechanism (1022).

[0091] The casing (1011) is made of a metal material. The casing (1011) has a body (1012), a bottom (1013), and a top (1014). The body (1012) is a cylindrical metal member. Openings are formed at both axial ends of the body (1012). The bottom (1013) closes the lower opening of the body (1012). The top (1014) closes the upper opening of the body (1012).

[0092] As shown in Figures 10 and 11, the motor (1030) is positioned above the compression mechanism (1022). The motor (1030) has its operating frequency controlled by an inverter device. In other words, the compressor (1010) is an inverter type with a variable operating frequency.

[0093] The motor (1030) has a stator (1031) and a rotor (1040). The stator (1031) is supported by the body (1012) of the casing (1011).

[0094] The stator (1031) has a stator core (1032) and a coil (1033) wound around the stator core (1032). The stator core (1032) has an annular back yoke (1034) and a plurality (six in this example) of teeth (1035) extending radially inward from the inner circumferential surface of the back yoke (1034). A plurality (six in this example) of core cuts (1036) are formed on the outer circumferential surface of the back yoke (1034). The core cuts (1036) are grooves extending axially from the stator core (1032).

[0095] The stator core (1032) has a laminate (M). The laminate (M) is constructed by stacking multiple metal parts (1038) (multiple thin plates that, when viewed in the thickness direction, have the shape of the stator core (1032) shown in Figure 11) in the thickness direction, which are manufactured from a metal plate (1) by the above method (Figures 1 to 8). The metal parts (1038) are thin plate-shaped parts that have a back yoke (1034) and teeth (1035). In other words, the multiple metal parts (1038) of this disclosure constitute the laminate (M) of the stator core (1032).

[0096] The rotor (1040) is positioned inside the stator core (1032). A drive shaft (1020) is fixed to the axis of the rotor (1040). Multiple slots (1041) are formed in the rotor (1040). Permanent magnets are embedded inside the slots (1041).

[0097] The drive shaft (1020) extends vertically along the axis of the casing (1011). The drive shaft (1020) is rotationally driven by the motor (1030). The drive shaft (1020) is rotatably supported by the bearing (1029).

[0098] The compression mechanism (1022) includes a cylinder (1023) and a piston (1024) located inside the cylinder (1023). A cylinder chamber (1025) is formed between the inner surface of the cylinder (1023) and the outer surface of the piston (1024). In the cylinder chamber (1025), the fluid is compressed by the piston (1024), which is driven by the drive shaft (1020).

[0099] The compressor (1010) has an intake pipe (1026) and a discharge pipe (1027). The intake pipe (1026) penetrates the body (1012) radially and communicates with the cylinder chamber (1025). Low-pressure refrigerant from the refrigerant circuit (101a) is drawn into the cylinder chamber (1025) via the intake pipe (1026). The discharge pipe (1027) penetrates the top (1014) axially and communicates with the internal space of the casing (1011). The refrigerant compressed by the compression mechanism (1022) flows through the core cut (1036) of the motor (1030), etc., and is then sent to the refrigerant circuit (101a) via the discharge pipe (1027).

[0100] While embodiments and modifications have been described above, it will be understood that a variety of changes in form and details are possible without departing from the spirit and scope of the claims. Furthermore, these embodiments and modifications may be combined or substituted as appropriate, as long as they do not impair the functions of the subject matter of this disclosure. The terms “First,” “Second,” etc., used above are used to distinguish the phrases to which these terms are attached, and do not limit the number or order of such phrases. [Industrial applicability]

[0101] As described above, this disclosure is useful for manufacturing metal parts, manufacturing stator cores, manufacturing motors, manufacturing compressors, manufacturing blowers, and manufacturing refrigeration equipment. [Explanation of Symbols]

[0102] 1. Amorphous metal plate 2 Metal parts 10 component areas 11 Edge 12 Outer part 12a Separation part 13 Cut section 14 cuts 30 molds D predetermined distance

Claims

1. A method for manufacturing metal parts, comprising producing a metal part (2) having a predetermined shape from a metal plate (1) containing amorphous metal or nanocrystalline metal, A crystallization step in which crystallization occurs in the metal plate (1) while suppressing the crystallization of the component region (10) having the predetermined shape, and in the cut portion (13) located outside the component region (10), or on the boundary between the component region (10) and an outer region (10A) located outside the component region (10), and along the edge portion (11) of the component region (10), A cutting step in which the metal plate (1) is cut at the cutting section (13) using a mold (30) A method for manufacturing metal parts, including

2. The crystallization step is as follows: The process of forming a plurality of cuts (14) on the cut portion (13), A step of heating the outer part (12) of the cut portion (13) and A method for manufacturing a metal part according to claim 1, including the method described in claim 1.

3. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of heating the cut portion (13) or the outer portion (12) of the cut portion (13) while cooling the part region (10) or the edge portion (11) of the part region (10).

4. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes heating a separated portion (12a) on the metal plate (1) that is separated from the cut portion (13) by a predetermined distance (D) or more from the outside of the part region (10).

5. The method for manufacturing a metal part according to claim 4, wherein the predetermined distance (D) has a size of 0 mm or more and 5 mm or less.

6. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of resistance heating of the cut portion (13).

7. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of heating the cut portion (13) by irradiating the cut portion (13) with laser light or an electron beam.

8. A method for manufacturing a metal part according to claim 6 or claim 7, wherein the cut portion (13) is pulse-heated.

9. A method for manufacturing a stator core, comprising stacking a plurality of metal parts (2) manufactured by the manufacturing method described in any one of claims 1 to 7.

10. A method for manufacturing a motor, comprising manufacturing a motor including the stator core described in claim 9.

11. A method for manufacturing a compressor, comprising manufacturing a compressor including the motor described in claim 10.

12. A method for manufacturing a blower, comprising manufacturing a blower including the motor described in claim 10.

13. A method for manufacturing a refrigeration apparatus, comprising manufacturing a refrigeration apparatus including the compressor described in claim 11.

Images