Stator unit, motor-operated valve, and method for manufacturing the stator unit

Abstract

To provide a stator unit, an electric valve which can suppress electromagnetic waves emitted from a stator and suppress a defect of an operation of the electronic component, and a manufacturing method of the stator unit.SOLUTION: A stator unit 8 comprises: a stator 80; and a synthetic resin housing 100 integrally molded with the stator 80. In addition, the stator unit 8 comprises an electromagnetic wave suppression membrane 90 arranged between the stator 80 and the housing 100.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a stator unit, a motor-operated valve, and a method for manufacturing a stator unit. [Background technology]

[0002] Patent Document 1 discloses a conventional motor-operated valve that is incorporated into an air conditioning system. The motor-operated valve of Patent Document 1 has a housing with an accommodation space. A can, a stator, and a control board are arranged in the accommodation space. A magnet rotor is arranged inside the can. The magnet rotor and the stator form a stepping motor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6826727 Summary of the Invention [Problem to be solved by the invention]

[0004] An electric current flows through the stator to rotate the magnet rotor. The electric current flowing through the stator can cause electromagnetic waves to be emitted from the stator. These electromagnetic waves may affect electronic devices located near the control board and the motorized valve. The electromagnetic waves emitted from the stator can be suppressed by applying an electromagnetic wave suppression paint to the stator. The electromagnetic wave suppression paint may peel off from the stator. The electromagnetic wave suppression paint is conductive. Therefore, peeled-off electromagnetic wave suppression paint may cause a short circuit in the control board or electronic device, which may cause malfunctions in the operation of the electronic components mounted thereon.

[0005] Therefore, an object of the present invention is to provide a stator unit and an electric valve that can suppress electromagnetic waves emitted from a stator and suppress malfunctions in the operation of electronic components, as well as a method for manufacturing a stator unit. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, a stator unit according to one embodiment of the present invention is a stator unit having a stator and a housing made of synthetic resin that is molded integrally with the stator, and is characterized in having an electromagnetic wave suppression film disposed between the stator and the housing.

[0007] In the present invention, it is preferable that the stator has an A-phase stator and a B-phase stator, the A-phase stator has a hollow annular A-phase yoke, an A-phase bobbin arranged inside the A-phase yoke, and an A-phase coil wound around the A-phase bobbin, the B-phase stator has a hollow annular B-phase yoke, a B-phase bobbin arranged inside the B-phase yoke, and a B-phase coil wound around the B-phase bobbin, the A-phase stator and the B-phase stator are arranged coaxially, a first end face of the A-phase yoke and a first end face of the B-phase yoke are in contact, a second end face of the A-phase yoke, an outer peripheral surface of the A-phase yoke, a second end face of the B-phase yoke, and the outer peripheral surface of the B-phase yoke constitute a yoke outer surface, and the electromagnetic wave suppression film is arranged between the yoke outer surface and the housing.

[0008] In the present invention, it is preferable that the stator further has a resin member molded integrally with the A-phase stator and the B-phase stator, the resin member has a terminal support portion, the terminal support portion extends from the A-phase yoke and the B-phase yoke in a direction perpendicular to the axial direction, coil terminals connected to the A-phase coil and the B-phase coil protrude from a tip surface of the terminal support portion, and the electromagnetic wave suppression film is disposed between the terminal support portion and the housing.

[0009] In the present invention, it is preferable that the resin member further has a circular ring-shaped annular portion, the annular portion is arranged on the second end face of the A-phase yoke or the second end face of the B-phase yoke, and the electromagnetic wave suppression film is arranged between the annular portion and the housing.

[0010] In the present invention, it is preferable that a portion of the terminal support portion including the tip surface is arranged in a board accommodating space provided in the housing, the coil terminal is connected to a board arranged in the board accommodating space, and the entire surface of the portion of the terminal support portion directly faces the board accommodating space.

[0011] In the present invention, it is preferable that the synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

[0012] In order to achieve the above object, a stator unit according to another aspect of the present invention is a stator unit having a stator and a housing made of synthetic resin that is molded integrally with the stator, and is characterized in that the synthetic resin that constitutes the housing contains an electromagnetic wave suppressing material.

[0013] In order to achieve the above-mentioned object, another aspect of the present invention is an electric valve having a valve body assembly and a stator unit, wherein the valve body assembly has a cylindrical case and a magnet rotor arranged inside the case, and the stator is arranged outside the case.

[0014] In order to achieve the above-mentioned object, a manufacturing method for a stator unit according to one embodiment of the present invention is a manufacturing method for a stator unit having a stator and a housing made of synthetic resin that is molded integrally with the stator, characterized in that an electromagnetic wave suppression film is formed on a surface of the stator, and the housing is injection molded so that the housing covers the electromagnetic wave suppression film. Effect of the Invention

[0015] The stator unit has an electromagnetic wave suppression film disposed between the stator and the housing. This allows the electromagnetic wave suppression film to be held by the stator and the housing, and prevents the electromagnetic wave suppression film from falling off. This makes it possible to suppress electromagnetic waves emitted from the stator and to prevent malfunctions in the operation of electronic components.

[0016] The synthetic resin that constitutes the housing of the stator unit contains an electromagnetic wave suppressing material. Since the electromagnetic wave suppressing material is contained in the synthetic resin that constitutes the housing, the electromagnetic wave suppressing material will not fall off. This makes it possible to suppress electromagnetic waves emitted from the stator and to suppress malfunctions in the operation of electronic components. [Brief description of the drawings]

[0017] [Figure 1] 1 is a cross-sectional view of a motor-operated valve according to an embodiment of the present invention. [Diagram 2] 2 is a cross-sectional view of a valve body assembly of the motor-operated valve of FIG. 1. [Diagram 3] 2 is a cross-sectional view of a stator unit of the motor-operated valve of FIG. 1. [Figure 4] 4 is a cross-sectional view of a stator included in the stator unit of FIG. 3, the stator having an electromagnetic wave suppression film formed on its surface. [Diagram 5] FIG. 4 is a cross-sectional view of a stator before an electromagnetic wave suppression film is formed. [Figure 6] FIG. 2 is a perspective view of a stator having an electromagnetic wave suppression film formed on its surface. [Figure 7] FIG. 4 is a perspective view showing a stator before an electromagnetic wave suppression film is formed. [Figure 8] 4 is a side view of a stator having an electromagnetic wave suppression film formed on its surface. FIG. [Figure 9] FIG. 4 is a side view of the stator before the electromagnetic wave suppression film is formed. [Figure 10] 1. FIG. 4 is a cross-sectional view showing a configuration of a modified example of the motor-operated valve of FIG. [Figure 11] 11 is a cross-sectional view of a stator unit of the motor-operated valve of FIG. 10. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Hereinafter, a motor-operated valve according to an embodiment of the present invention will be described with reference to Figs. 1 to 11. The motor-operated valve is incorporated, for example, in an air conditioning system installed in a vehicle or an air conditioning system installed indoors. The motor-operated valve according to this embodiment is used, for example, to adjust the flow rate of a refrigerant.

[0019] FIG. 1 is a cross-sectional view of an electrically operated valve according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of a valve body assembly included in the electrically operated valve of FIG. 1. FIG. 3 is a cross-sectional view of a stator unit included in the electrically operated valve of FIG. 1. FIGS. 4 to 9 are diagrams showing a stator included in the stator unit of FIG. 3. FIGS. 4 and 5 are cross-sectional views of the stator. FIGS. 6 and 7 are perspective views of the stator. FIGS. 8 and 9 are side views of the stator. FIGS. 4, 6 and 8 show a stator having an electromagnetic wave suppression film formed on the surface. FIGS. 5, 7 and 8 show a stator having an electromagnetic wave suppression film formed on the surface. Figure 9 shows a stator before the electromagnetic wave suppression film is formed. FIG. 10 is a cross-sectional view showing the configuration of a modified example of the motor-operated valve of FIG. 1. FIG. 11 is a cross-sectional view of a stator unit of the motor-operated valve of FIG. 10. In FIGS. 3, 4, and 11, the electromagnetic wave suppression film is shown typically by a thick line. In FIGS. 6 and 8, the electromagnetic wave suppression film is shown typically by a dotted region. In each drawing, the X direction indicated by the arrow X is the left-right direction, the Y direction indicated by the arrow Y is the front-rear direction, and the Z direction indicated by the arrow Z is the up-down direction. The side with the letter "X" on the arrow X is the right side, the side with the letter "Y" on the arrow Y is the rear, and the side with the letter "Z" on the arrow Z is the top.

[0020] As shown in FIG. 1, the motor-operated valve 1 according to this embodiment includes a valve body assembly 5 and a stator unit 8.

[0021] As shown in FIG. 2, the valve body assembly 5 includes a valve body 10, a holder 20, a valve body support member 25, a can 30, a drive mechanism 40, and a valve body 70.

[0022] The valve body 10 has a rectangular parallelepiped shape. The valve body 10 has a valve chamber 13 and a valve port 14 connected to the valve chamber 13. The valve body 10 has a first passage 17 and a second passage 18. One end of the first passage 17 is connected to the valve chamber 13, and the other end of the first passage 17 opens to the rear surface 10a of the valve body 10. One end of the second passage 18 is connected to the valve chamber 13 via the valve port 14, and the other end of the second passage 18 opens to the front surface 10b of the valve body 10. The valve body 10 has a mounting hole 19. The mounting hole 19 is disposed on the upper surface 10c of the valve body 10. An internal thread is formed on the inner peripheral surface of the mounting hole 19. The lower end of the mounting hole 19 is connected to the valve chamber 13.

[0023] The holder 20 has a cylindrical shape. The lower part of the holder 20 is disposed in the mounting hole 19. A male thread is formed on the outer peripheral surface of the holder 20. The male thread of the holder 20 is screwed into the female thread of the mounting hole 19 of the valve body 10. The holder 20 is attached to the valve body 10 by a screw structure. The upper part of the holder 20 protrudes from the top surface 10c.

[0024] The valve body support member 25 has a cylindrical shape. The valve body support member 25 is disposed inside the mounting hole 19, between the valve body 10 and the holder 20. The lower part of the valve body support member 25 is press-fitted into the valve chamber 13. An annular flat surface 25a is provided on the outer circumferential surface of the valve body support member 25. The annular flat surface 25a faces downward. The annular flat surface 25a abuts against the bottom surface 19a of the mounting hole 19. The valve body support member 25 supports the valve body 70 so that it can move up and down.

[0025] The can 30 has a cylindrical shape with a closed upper end and an open lower end. The lower end of the can 30 is joined to the outer periphery of a circular plate-shaped joining member 35. The upper part of the holder 20 is disposed inside the joining member 35. The inner periphery of the joining member 35 is joined to the holder 20. The can 30 is a case.

[0026] The drive mechanism 40 moves the valve body 70 in the vertical direction. The drive mechanism 40 has a magnet rotor 41, a planetary gear mechanism 50, a guide member 60, a drive shaft 65, and a ball 68.

[0027] The magnet rotor 41 has a cylindrical shape. The magnet rotor 41 is disposed inside the can 30. The outer diameter of the magnet rotor 41 is slightly smaller than the inner diameter of the can 30. The outer peripheral surface of the magnet rotor 41 is provided with a plurality of N poles and a plurality of S poles. The plurality of N poles and the plurality of S poles extend in the vertical direction. The plurality of N poles and the plurality of S poles are disposed at equal intervals and alternately in the circumferential direction. In this embodiment, the magnet rotor 41 has 12 N poles and 12 S poles.

[0028] A disk-shaped connecting member 42 is joined to the upper end of the magnet rotor 41. The connecting member 42 closes the upper end of the magnet rotor 41. A rotor shaft 43 passes through the center of the connecting member 42. The magnet rotor 41 is connected to the rotor shaft 43 via the connecting member 42.

[0029] The planetary gear mechanism 50 is disposed inside the magnet rotor 41. The planetary gear mechanism 50 has a gear case 51, a fixed ring gear 52, a sun gear 53, a plurality of planetary gears 54, a carrier 55, an output gear 56, and an output shaft 57.

[0030] The gear case 51 has a cylindrical shape. The gear case 51 is coaxially joined to the upper part of the holder 20. The fixed ring gear 52 is an internal gear. The fixed ring gear 52 is fixed to the upper end of the gear case 51. The sun gear 53 is disposed coaxially with the connecting member 42. The sun gear 53 is integrated with the connecting member 42. The rotor shaft 43 passes through the sun gear 53. The sun gear 53 rotates together with the magnet rotor 41 and the connecting member 42.

[0031] The multiple planetary gears 54 are disposed between the fixed ring gear 52 and the sun gear 53. The carrier 55 has a disk shape. The rotor shaft 43 passes through the center of the carrier 55. The carrier 55 is rotatable around the rotor shaft 43. The carrier 55 has multiple support shafts 55a. The multiple support shafts 55a rotatably support the multiple planetary gears 54. The output gear 56 has a cylindrical shape with a bottom. The output gear 56 is an internal gear. The multiple planetary gears 54 are disposed between the output gear 56 and the sun gear 53.

[0032] The output shaft 57 has a cylindrical shape. An upper portion of the output shaft 57 is disposed in a hole provided in the bottom portion of the output gear 56. The output shaft 57 is fixed to the output gear 56. A slit 57a extending in the vertical direction is provided in the lower portion of the output shaft 57. The rotation of the sun gear 53 is decelerated by the fixed ring gear 52, the multiple planetary gears 54, the carrier 55, and the output gear 56, and is transmitted to the output shaft 57.

[0033] The guide member 60 has a cylindrical shape. The guide member 60 is disposed inside the upper part of the holder 20. The guide member 60 is fixed to the holder 20. A female screw is formed on the lower part of the inner circumferential surface of the guide member 60. The output shaft 57 is disposed inside the guide member 60. The guide member 60 supports the output shaft 57 rotatably.

[0034] The drive shaft 65 has a cylindrical portion 66 and a flat plate portion 67. The flat plate portion 67 is connected to the upper end of the cylindrical portion 66. The cylindrical portion 66 and the flat plate portion 67 are integrally formed. A male thread is formed on the outer circumferential surface of the cylindrical portion 66. The male thread of the cylindrical portion 66 is screwed into the female thread of the guide member 60. The flat plate portion 67 is disposed in the slit 57a of the output shaft 57 so as to be movable in the vertical direction. The drive shaft 65 is rotated by the output shaft 57 and moves in the vertical direction by the screw feed action.

[0035] The valve body 70 has a stem 71 , a valve portion 72 , a spring receiving portion 73 , and a ball receiving portion 74 .

[0036] The stem 71 has a cylindrical shape. The stem 71 is disposed inside the valve body support member 25. The stem 71 is supported by the valve body support member 25 so as to be movable up and down.

[0037] The valve portion 72 is disposed at the lower end of the stem 71. The valve portion 72 has an annular shape. The valve portion 72 protrudes radially outward from the outer circumferential surface of the stem 71. The valve portion 72 faces the valve port 14 in the up-down direction.

[0038] The spring receiving portion 73 has a cylindrical shape. The spring receiving portion 73 is joined to the upper end of the stem 71. The spring receiving portion 73 has a flange portion 73a that protrudes radially outward.

[0039] The ball receiving portion 74 integrally has a circular flat plate portion and a protrusion portion connected to the lower surface of the flat plate portion. The protrusion portion fits into a hole provided in the upper end surface of the spring receiving portion 73. A ball 68 is disposed between the flat plate portion of the ball receiving portion 74 and the drive shaft 65. The ball 68 is joined to the lower end of the drive shaft 65.

[0040] A valve-opening spring 75 is disposed between the flange portion 73a of the spring receiving portion 73 and the valve body support member 25. The valve-opening spring 75 is a compression coil spring. The valve-opening spring 75 presses the valve body 70 (flange portion 73a) upward. The valve body 70 changes the opening area of ​​the valve orifice 14 steplessly (including substantially steplessly) as the valve portion 72 advances and retreats relative to the valve orifice 14. In this embodiment, the minimum area of ​​the valve orifice 14 is 0 (i.e., the valve orifice 14 is closed). The minimum area of ​​the valve orifice 14 may be greater than 0 (i.e., the valve orifice 14 is slightly open).

[0041] As shown in FIG. 3, the stator unit 8 includes a stator 80 , an electromagnetic wave suppression film 90 , a housing 100 , a cover member 110 , and a control device 120 .

[0042] 4 to 9, the stator 80 has a cylindrical shape. The stator 80 has an A-phase stator 81, a B-phase stator 82, and a resin member 83.

[0043] The A-phase stator 81 includes an A-phase yoke 81a, an A-phase bobbin 81b, and an A-phase coil 81c.

[0044] The A-phase yoke 81a has a hollow annular shape with a rectangular radial cross section. The A-phase yoke 81a is made of metal. A plurality of claw-pole type pole teeth 81d, 81e are provided on the inner circumference of the A-phase yoke 81a. The tip of the pole tooth 81d faces downward, and the tip of the pole tooth 81e faces upward. The pole teeth 81d and the pole teeth 81e are alternately arranged at equal angular intervals in the circumferential direction. In this embodiment, the A-phase yoke 81a has 12 pole teeth 81d and 12 pole teeth 81e.

[0045] The A-phase bobbin 81b has a cylindrical portion and flange portions that protrude radially outward from the upper and lower ends of the cylindrical portion. The A-phase bobbin 81b is made of synthetic resin. The A-phase bobbin 81b is coaxially arranged in the internal space of the A-phase yoke 81a. The A-phase coil 81c is wound around the A-phase bobbin 81b. When a current flows through the A-phase coil 81c, the pole teeth 81d and the pole teeth 81e have polarities opposite to each other.

[0046] The B-phase stator 82 includes a B-phase yoke 82a, a B-phase bobbin 82b, and a B-phase coil 82c.

[0047] The B-phase yoke 82a has a hollow annular shape with a rectangular radial cross section. The B-phase yoke 82a is made of metal. A plurality of claw-pole type pole teeth 82d, 82e are provided on the inner circumference of the B-phase yoke 82a. The tip of the pole tooth 82d faces downward, and the tip of the pole tooth 82e faces upward. The pole teeth 82d and the pole teeth 82e are alternately arranged at equal angular intervals in the circumferential direction. In this embodiment, the B-phase yoke 82a has 12 pole teeth 82d and 12 pole teeth 82e.

[0048] The B-phase bobbin 82b integrally has a cylindrical portion and flange portions protruding radially outward from the upper and lower ends of the cylindrical portion. The B-phase bobbin 82b is made of synthetic resin. The B-phase bobbin 82b is coaxially arranged in the internal space of the B-phase yoke 82a. The B-phase coil 82c is wound around the B-phase bobbin 82b. When a current flows through the B-phase coil 82c, the pole teeth 82d and the pole teeth 82e have polarities opposite to each other. The B-phase stator 82 has the same configuration as (including substantially the same as) the A-phase stator 81.

[0049] The A-phase yoke 81a and the B-phase yoke 82a are arranged coaxially. A bottom surface 81f of the A-phase yoke 81a and a top surface 82g of the B-phase yoke 82a are in contact with each other. When viewed from the top-bottom direction (axis L direction), the angle between the pole tooth 81d of the A-phase yoke 81a and the pole tooth 82d of the B-phase yoke 82a that are adjacent to each other is 7.5 degrees.

[0050] An upper surface 81g of the A-phase yoke 81a, an outer peripheral surface 81h of the A-phase yoke 81a, an outer peripheral surface 82h of the B-phase yoke 82a, and a lower surface 82f of the B-phase yoke 82a form a yoke outer surface 80b.

[0051] The lower surface 81f is a first end surface of the A-phase yoke 81a, and the upper surface 81g is a second end surface of the A-phase yoke 81a. The upper surface 82g is a first end surface of the B-phase yoke 82a, and the lower surface 82f is a second end surface of the B-phase yoke 82a.

[0052] The resin member 83 is injection molded (insert molded) integrally with the A-phase stator 81 and the B-phase stator 82. The synthetic resin constituting the resin member 83 is, for example, polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT).

[0053] The resin member 83 has a first portion 83a and a second portion 83b. The first portion 83a constitutes a stator inner peripheral surface 80a together with the pole teeth 81d, 81e, 82d, and 82e. The diameter of the stator inner peripheral surface 80a is the same as (or substantially the same as) the outer diameter of the can 30. The second portion 83b fills the inner space of the A-phase yoke 81a and the inner space of the B-phase yoke 82a.

[0054] The resin member 83 further includes a terminal support portion 84 and an annular portion 87 .

[0055] The terminal support portion 84 extends forward (in a direction perpendicular to the axis L) from a yoke opening 80c that is provided across an outer circumferential surface 81h of the A-phase yoke 81a and an outer circumferential surface 82h of the B-phase yoke 82a. The terminal support portion 84 supports a plurality of coil terminals 88. The coil terminals 88 are connected to the A-phase coil 81c and the B-phase coil 82c.

[0056] The terminal support portion 84 has a base portion 85 and a tip portion 86. The base portion 85 is connected to the second portion 83b. The base portion 85 extends from the inside to the outside of the A-phase yoke 81a and the B-phase yoke 82a through the yoke opening 80c. The tip portion 86 is connected to a tip surface 85a of the base portion 85. A plurality of coil terminals 88 protrude from the tip surface 86a of the tip portion 86.

[0057] The annular portion 87 has a circular ring shape. The inner diameter of the annular portion 87 is the same (including substantially the same) as the diameter of the stator inner peripheral surface 80a. The annular portion 87 is disposed coaxially on the lower surface 82f of the B-phase yoke 82a. The annular portion 87 may be disposed coaxially on the upper surface 81g of the A-phase yoke 81a. The annular portion 87 is connected to the first portion 83a of the resin member 83. In the molding die for the stator 80, a gate is connected to a cavity corresponding to the annular portion 87. When the resin member 83 is injection molded, the resin material flows in the circumferential direction in the cavity and enters between the pole teeth 81d, 81e, 82d, and 82e to mold the first portion 83a. In the resin member 83, the annular portion 87 may be omitted.

[0058] The stator 80 is disposed outside the can 30. The stator 80 constitutes a stepping motor 46 together with the magnet rotor 41 disposed inside the can 30.

[0059] The electromagnetic wave suppression film 90 is a film made of paint (electromagnetic wave suppression paint) containing a material that has the property of effectively attenuating electromagnetic waves. Metals such as silver, copper, and nickel are materials that have the property of effectively attenuating electromagnetic waves. For example, paints called silver paste or copper paste can be used as the electromagnetic wave suppression paint. The electromagnetic wave suppression film 90 is formed by applying the electromagnetic wave suppression paint to the surface of the stator 80. Note that the electromagnetic wave suppression film 90 may be a sheet (electromagnetic wave suppression sheet) containing a material that has the property of effectively attenuating electromagnetic waves attached to the surface of the stator 80.

[0060] The electromagnetic wave suppression film 90 is disposed on the yoke outer surface 80b (upper surface 81g, outer peripheral surface 81h, outer peripheral surface 82h, and lower surface 82f). The electromagnetic wave suppression film 90 is also disposed on the peripheral surface 85b of the base portion 85 of the terminal support portion 84. The electromagnetic wave suppression film 90 is also disposed on the lower surface 87a and outer peripheral surface 87b of the annular portion 87.

[0061] The housing 100 is made of synthetic resin. The synthetic resin constituting the housing 100 is, for example, polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). The synthetic resin constituting the housing 100 may be a synthetic resin containing a material having a property of effectively attenuating electromagnetic waves (electromagnetic wave suppressing synthetic resin). The electromagnetic wave suppressing synthetic resin may be, for example, PPS containing 5 to 40 weight percent silver powder, silver-plated copper powder, nickel powder, or carbon black. Silver powder, silver-plated copper powder, nickel powder, and carbon black are electromagnetic wave suppressing materials that have a property of effectively attenuating electromagnetic waves. In the stator unit 8, when the housing 100 is made of an electromagnetic wave suppressing synthetic resin, the electromagnetic wave suppressing film 90 may be omitted.

[0062] The housing 100 accommodates the stator 80 and the control device 120. The housing 100 is integrally injection molded (insert molded) with the stator 80, which has an electromagnetic wave suppression film 90 formed on its surface.

[0063] The housing 100 integrally includes a peripheral wall portion 101, an upper wall portion 102, a case portion 103, and a connector portion 104. A lid member 110 is joined to the case portion 103 of the housing 100. The lid member 110 has a flat plate shape.

[0064] The peripheral wall portion 101 has a cylindrical shape. The stator 80 is embedded in the peripheral wall portion 101. The electromagnetic wave suppression film 90 is disposed between the stator 80 and the peripheral wall portion 101. The diameter of the inner peripheral surface 101a of the peripheral wall portion 101 is the same as the diameter of the stator inner peripheral surface 80a. The inner peripheral surface 101a is connected to the stator inner peripheral surface 80a without any step. The upper wall portion 102 has a dome shape. The upper wall portion 102 is connected to the upper end of the peripheral wall portion 101. The inner peripheral surface 101a of the peripheral wall portion 101, the inner surface 102a of the upper wall portion 102, and the stator inner peripheral surface 80a form an inner space 106 of the stator unit 8. The can 30 is disposed in the inner space 106.

[0065] The case portion 103 has a rectangular cylindrical shape and extends forward from the peripheral wall portion 101. The inner space of the case portion 103 is a board accommodating space 107. An opening 108 that communicates with the board accommodating space 107 is provided at the tip 103a of the case portion 103. The lid member 110 is joined to the tip 103a of the case portion 103 so as to cover the opening 108. The lid member 110 closes the opening 108. The connector portion 104 is disposed on the upper surface of the case portion 103. The connector portion 104 has a cylindrical shape and extends in the front-rear direction. The tip of the connector portion 104 is open and faces forward.

[0066] The board accommodating space 107 is adjacent to the inner space 106. The stator 80 and the peripheral wall portion 101 are disposed between the inner space 106 and the board accommodating space 107. The stator 80 and the peripheral wall portion 101 divide the inner space 106 and the board accommodating space 107. The tip portion 86 of the terminal support portion 84 of the stator 80 protrudes from the peripheral wall portion 101 and is disposed in the board accommodating space 107. The electromagnetic wave suppression film 90 is not formed on the tip surface 86a and the peripheral surface 86b of the tip portion 86, and the tip surface 86a and the peripheral surface 86b directly face the board accommodating space 107. A plurality of connector terminals 109 are embedded in the housing 100. One end of the connector terminal 109 is disposed in the inner space of the connector portion 104. The other end of the connector terminal 109 is disposed in the board accommodating space 107.

[0067] A bracket 111 is attached to the peripheral wall portion 101. The bracket 111 is fixed to the valve body 10 with screws 112. In this way, the stator unit 8 is fixed to the valve body assembly 5.

[0068] The control device 120 is disposed in the board accommodating space 107 of the housing 100. The control device 120 includes a board 130 and a microcomputer 150.

[0069] The board 130 is a printed circuit board on which electronic components are mounted. The board 130 is disposed in the board accommodation space 107. The board 130 is disposed parallel to the up-down and left-right directions (parallel to the XZ plane). A microcomputer 150 is mounted on the board 130. The coil terminal 88 of the stator 80 is connected to the board 130. The other end of the connector terminal 109 is connected to the board 130.

[0070] The microcomputer 150 is, for example, a microcomputer for embedded devices that integrates a central processing unit, a non-volatile memory, a working memory, a communication module, a motor driver, and the like in one package. The microcomputer 150 controls the motor-operated valve 1. The non-volatile memory, the working memory, the communication module, and the motor driver may be individual electronic components that are externally connected to the microcomputer 150.

[0071] The control device 120 is communicatively connected to a control unit of an air conditioning system (not shown) in which the motor-operated valve 1 is incorporated. The control device 120 is connected to the control unit by a cable. The cable has a connector (plug) that fits into the connector portion 104 (receptacle). The control unit is an external device. The control device 120 controls the stepping motor 46 (i.e., the rotation of the magnet rotor 41) in response to commands transmitted from the control unit. Note that the motor-operated valve 1 may be directly controlled by the control unit of the air conditioning system, omitting the control device 120.

[0072] In the motor-operated valve 1, the valve port 14, holder 20, valve body support member 25, can 30, magnet rotor 41, connecting member 42, rotor shaft 43, sun gear 53, output shaft 57, guide member 60, drive shaft 65, ball 68, valve body 70 (stem 71, valve portion 72, spring receiving portion 73, ball receiving portion 74), and stator 80 (A-phase stator 81, B-phase stator 82) each have a central axis that coincides with the axis L. The axis L is parallel to the vertical direction.

[0073] Next, the operation of the motor-operated valve 1 will be described.

[0074] In the motor-operated valve 1, current is applied to the A-phase coil 81c and the B-phase coil 82c to rotate the magnet rotor 41 in one direction. The rotation of the magnet rotor 41 is transmitted to the drive shaft 65 via the planetary gear mechanism 50. The drive shaft 65 moves downward due to the screw feed action of the drive shaft 65 and the guide member 60. The drive shaft 65 pushes the valve body 70 downward, and the opening area of ​​the valve port 14 becomes smaller.

[0075] In the motor-operated valve 1, current is passed through the A-phase coil 81c and the B-phase coil 82c to rotate the magnet rotor 41 in the other direction. The rotation of the magnet rotor 41 is transmitted to the drive shaft 65 via the planetary gear mechanism 50. The drive shaft 65 moves upward due to the screw feed action between the drive shaft 65 and the guide member 60. The valve body 70 is pushed upward by the valve-opening spring 75, and the opening area of ​​the valve port 14 increases.

[0076] Next, a manufacturing method of the stator unit 8 of the motor-operated valve 1 will be described.

[0077] A-phase stator 81 and B-phase stator 82 are placed in a molding die for stator 80, and resin member 83 is injection molded integrally with A-phase stator 81 and B-phase stator 82 to produce stator 80.

[0078] Next, an electromagnetic wave suppression film 90 is formed on the surface of the stator 80. Specifically, an electromagnetic wave suppression paint is applied to the yoke outer surface 80b, the circumferential surface 85b of the base 85, the underside 87a of the annular portion 87, and the outer circumferential surface 87b of the annular portion 87. The electromagnetic wave suppression paint is not applied to any other parts of the stator 80. In other words, the electromagnetic wave suppression paint is not applied to the stator inner circumferential surface 80a, the tip surface 85a of the base 85, the tip surface 86a of the tip portion 86, and the circumferential surface 86b of the tip portion 86. The electromagnetic wave suppression film 90 is formed when the electromagnetic wave suppression paint dries.

[0079] Next, the housing 100 is injection molded so that it covers the electromagnetic wave suppression film 90. Specifically, the stator 80 with the electromagnetic wave suppression film 90 formed on its surface and the connector terminals 109 are placed in a molding die for the housing 100. The housing 100 is then injection molded integrally with the stator 80 (including the electromagnetic wave suppression film 90) and the connector terminals 109. As a result, the electromagnetic wave suppression film 90 is disposed between the stator 80 and the peripheral wall portion 101 of the housing 100. In this embodiment, the electromagnetic wave suppression film 90 is disposed only between the stator 80 and the peripheral wall portion 101, and the electromagnetic wave suppression film 90 is not exposed to the inner space 106 and the board accommodating space 107. The cover member 110 is injection molded in a separate process from the housing 100.

[0080] The control device 120 is placed in the board accommodating space 107 of the case portion 103 of the housing 100. The other ends of the coil terminal 88 and the connector terminal 109 are soldered to the board 130 of the control device 120. The cover member 110 is joined to the tip 103a of the case portion 103. The joining method is, for example, infrared welding, ultrasonic welding, or joining with an adhesive. A bracket 111 is attached to the peripheral wall portion 101 of the housing 100. In this manner, the stator unit 8 is completed.

[0081] The motor-operated valve 1 of this embodiment includes a valve body assembly 5 and a stator unit 8. The valve body assembly 5 includes a cylindrical can 30 and a magnet rotor 41 disposed inside the can 30.

[0082] The stator unit 8 has a stator 80 disposed on the outside of the can 30, and a housing 100 made of synthetic resin and molded integrally with the stator 80. The stator unit 8 has an electromagnetic wave suppression film 90 disposed between the stator 80 and the housing 100. As a result, the electromagnetic wave suppression film 90 is held by the stator 80 and the housing 100, and falling off of the electromagnetic wave suppression film 90 can be prevented. This makes it possible to suppress electromagnetic waves emitted from the stator 80 and to prevent malfunctions in the operation of electronic components.

[0083] The stator 80 has an A-phase stator 81 and a B-phase stator 82. The A-phase stator 81 has a hollow annular A-phase yoke 81a, an A-phase bobbin 81b arranged inside the A-phase yoke 81a, and an A-phase coil 81c wound around the A-phase bobbin 81b. The B-phase stator 82 has a hollow annular B-phase yoke 82a, a B-phase bobbin 82b arranged inside the B-phase yoke 82a, and a B-phase coil 82c wound around the B-phase bobbin 82b. The A-phase stator 81 and the B-phase stator 82 are arranged coaxially. A lower surface 81f of the A-phase yoke 81a is in contact with an upper surface 82g of the B-phase yoke 82a. An upper surface 81g of the A-phase yoke 81a, an outer peripheral surface 81h of the A-phase yoke 81a, a lower surface 82f of the B-phase yoke 82a, and an outer peripheral surface 82h of the B-phase yoke 82a form a yoke outer surface 80b. An electromagnetic wave suppression film 90 is disposed between the yoke outer surface 80b and the housing 100. This makes it possible to effectively suppress electromagnetic waves that pass through the A-phase yoke 81a and the B-phase yoke 82a and are emitted.

[0084] The stator 80 further includes a resin member 83 molded integrally with the A-phase stator 81 and the B-phase stator 82. The resin member 83 includes a terminal support portion 84. The terminal support portion 84 extends forward from the A-phase yoke 81a and the B-phase yoke 82a. Coil terminals 88 connected to the A-phase coil 81c and the B-phase coil 82c protrude from a tip surface 86a of a tip portion 86 of the terminal support portion 84. An electromagnetic wave suppression film 90 is disposed between the terminal support portion 84 (the peripheral surface 85b of the base portion 85) and the housing 100. This makes it possible to effectively suppress electromagnetic waves emitted through the terminal support portion 84.

[0085] The resin member 83 further has a circular ring-shaped annular portion 87. The annular portion 87 is disposed on a lower surface 82f of the B-phase yoke 82a. An electromagnetic wave suppression film 90 is disposed between the annular portion 87 (lower surface 87a, outer peripheral surface 87b) and the housing 100. As a result, electromagnetic waves emitted through the annular portion 87 can be effectively suppressed.

[0086] Further, the tip 86 of the terminal support 84 is disposed in a board accommodation space 107 provided in the housing 100. The coil terminal 88 is connected to the board 130 disposed in the board accommodation space 107. The entire surface of the tip 86 (tip face 86a, circumferential face 86b) directly faces the board accommodation space 107. As a result, the electromagnetic wave suppression film 90 is not formed on the surface of the tip 86 disposed in the board accommodation space 107. Therefore, the electromagnetic wave suppression film 90 does not fall off in the board accommodation space 107, and malfunctions of the electronic components mounted on the board 130 can be more effectively suppressed. The tip 86 is a part including the tip face 86a of the terminal support 84. The electromagnetic wave suppression film 90 may also be disposed on the circumferential face 86b of the tip 86.

[0087] Furthermore, the synthetic resin that constitutes the housing 100 may contain an electromagnetic wave suppressing material. In this way, the electromagnetic waves emitted from the stator 80 can be suppressed more effectively.

[0088] 10 shows a motor-operated valve 1A having a configuration that is a modified example of the motor-operated valve 1. In the motor-operated valve 1A, the same components as those in the motor-operated valve 1 (including those that are substantially the same) are given the same reference numerals and detailed description thereof will be omitted.

[0089] The motor-operated valve 1A includes a valve body assembly 5 and a stator unit 8A. As shown in Fig. 11, the stator unit 8A includes a stator 80, an electromagnetic wave suppression film 90, and a housing 100A.

[0090] The housing 100A accommodates the stator 80. The housing 100A is integrally injection molded (insert molded) with the stator 80, which has an electromagnetic wave suppression film 90 formed on its surface. The electromagnetic wave suppression film 90 is disposed between the stator 80 and the housing 100A. In the stator 80 of the motor-operated valve 1A, the annular portion 87 is disposed on the upper surface of the A-phase stator 81.

[0091] The housing 100A integrally includes a peripheral wall portion 101, an upper wall portion 102, and a connector portion 104A. The connector portion 104A has a cylindrical shape and extends forward from the peripheral wall portion 101. The tip of the terminal support portion 84 is disposed in the internal space of the connector portion 104A. The coil terminal 88 extends forward from the tip surface of the terminal support portion 84. The coil terminal 88 functions as a connector terminal.

[0092] The motor-operated valve 1A also exhibits the same effects as the motor-operated valve 1 (including substantially the same effects).

[0093] The motor-operated valve 1 of this embodiment is configured to reduce the speed of the rotation of the magnet rotor 41 and transmit it to the drive shaft 65. The motor-operated valve 1 may be a direct-acting type motor-operated valve in which the rotation of the magnet rotor 41 is directly transmitted to the drive shaft 65.

[0094] In this specification, terms indicating a shape, such as "cylinder" or "column", are also used to refer to members or portions of members that have substantially the shape of the term. For example, a "cylindrical member" includes both cylindrical members and substantially cylindrical members.

[0095] Although the embodiments of the present invention have been described above, the present invention is not limited to the configurations of the embodiments. Any addition, deletion, or design change of components by a person skilled in the art to the above-mentioned embodiments, or any combination of features of the embodiments as appropriate, is also included in the scope of the present invention as long as it does not go against the spirit of the present invention. [Explanation of symbols]

[0096] 1, 1A...Motor valve 5...valve body assembly, 10...valve body, 10a...rear surface, 10b...front surface, 10c...upper surface, 13...valve chamber, 14...valve port, 17...first passage, 18...second passage, 19...mounting hole, 19a...bottom surface, 20...holder, 25...valve body support member, 25a...annular flat surface, 30...can, 35...joint member, 40...drive mechanism, 41...magnet rotor, 42...connecting member, 43...rotor shaft, 46...stepping motor, 5 Reference Signs List 0...planetary gear mechanism, 51...gear case, 52...fixed ring gear, 53...sun gear, 54...planetary gear, 55...carrier, 55a...support shaft, 56...output gear, 57...output shaft, 57a...slit, 60...guide member, 65...drive shaft, 66...cylindrical portion, 67...flat plate portion, 68...ball, 70...valve body, 71...stem, 72...valve portion, 73...spring receiving portion, 73a...flange portion, 74...ball receiving portion, 75...valve opening spring 8, 8A... stator unit, 80... stator, 80a... stator inner peripheral surface, 80b... yoke outer peripheral surface, 80c... yoke opening, 81... A-phase stator, 81a... A-phase yoke, 81b... A-phase bobbin, 81c... A-phase coil, 81d... pole teeth, 81e... pole teeth, 81f... lower surface, 81g... upper surface, 81h... outer peripheral surface, 82... B-phase stator, 82a... B-phase yoke, 82b... B-phase bobbin, 82c... B-phase coil, 82d... pole teeth, 82e... pole teeth, 82f... lower surface, 82g... upper surface, 82h... outer peripheral surface, 83... resin member, 83a... first portion, 83b... second portion, 84... terminal support portion, 85... base portion, 85a...tip surface, 85b...circumferential surface, 86...tip portion, 86a...tip surface, 86b...circumferential surface, 87...annular portion, 87a...lower surface, 87b...outer peripheral surface, 90...electromagnetic wave suppression film, 100, 100A...housing, 101...peripheral wall portion, 101a...inner peripheral surface, 102...upper wall portion, 102a...inner surface, 103...case portion, 103a...tip, 104, 104A...connector portion, 106...inner space, 107...board accommodating space, 108...opening, 109...connector terminal, 110...cover member, 111...bracket, 112...screw, 120...control device, 130...board, 150...microcomputer, L...axis

Claims

1. A stator unit having a stator and a synthetic resin housing integrally molded with the stator, an electromagnetic wave suppression film disposed between the stator and the housing; The stator has an A-phase stator and a B-phase stator, the A-phase stator includes a hollow annular A-phase yoke, an A-phase bobbin disposed inside the A-phase yoke, and an A-phase coil wound around the A-phase bobbin, the B-phase stator includes a hollow annular B-phase yoke, a B-phase bobbin disposed inside the B-phase yoke, and a B-phase coil wound around the B-phase bobbin, The A-phase stator and the B-phase stator are arranged coaxially, a first end surface of the A-phase yoke and a first end surface of the B-phase yoke are in contact with each other, a second end surface of the A-phase yoke, an outer peripheral surface of the A-phase yoke, a second end surface of the B-phase yoke, and an outer peripheral surface of the B-phase yoke constitute a yoke outer surface, The electromagnetic wave suppression film is disposed between an outer surface of the yoke and the housing.

2. the stator further includes a resin member integrally molded with the A-phase stator and the B-phase stator, The resin member has a terminal support portion, the terminal support portion extends from the A-phase yoke and the B-phase yoke in a direction perpendicular to an axial direction, coil terminals connected to the A-phase coil and the B-phase coil protrude from a tip end surface of the terminal support portion; The stator unit according to claim 1 , wherein the electromagnetic wave suppression film is disposed between the terminal support portion and the housing.

3. The resin member further has an annular portion having a circular ring shape, the annular portion is disposed on a second end surface of the A-phase yoke or a second end surface of the B-phase yoke, The stator unit according to claim 2 , wherein the electromagnetic wave suppression film is disposed between the annular portion and the housing.

4. a portion of the terminal support portion including the tip surface is disposed in a board accommodating space provided in the housing, The coil terminal is connected to a substrate disposed in the substrate accommodating space, The stator unit according to claim 2 , wherein an entire surface of the part of the terminal support portion directly faces the board accommodating space.

5. The stator unit according to claim 1 , wherein the synthetic resin constituting the housing contains an electromagnetic wave suppressing material.

6. A motor-operated valve having a valve body assembly and a stator unit according to claim 1, The valve body assembly has a cylindrical case and a magnet rotor disposed inside the case, An electrically operated valve, wherein the stator is disposed outside the case.

7. A method for manufacturing a stator unit having a stator and a synthetic resin housing integrally molded with the stator, comprising the steps of: The stator has an A-phase stator and a B-phase stator, the A-phase stator includes a hollow annular A-phase yoke, an A-phase bobbin disposed inside the A-phase yoke, and an A-phase coil wound around the A-phase bobbin, the B-phase stator includes a hollow annular B-phase yoke, a B-phase bobbin disposed inside the B-phase yoke, and a B-phase coil wound around the B-phase bobbin, The A-phase stator and the B-phase stator are arranged coaxially, a first end surface of the A-phase yoke and a first end surface of the B-phase yoke are in contact with each other, a second end surface of the A-phase yoke, an outer peripheral surface of the A-phase yoke, a second end surface of the B-phase yoke, and an outer peripheral surface of the B-phase yoke constitute a yoke outer surface, An electromagnetic wave suppression film is formed on the outer surface of the yoke, A method for manufacturing a stator unit, comprising injection molding the housing so that the housing covers the electromagnetic wave suppression film.

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