Axial gap type rotating electric machine and manufacturing method thereof

Abstract

To provide an axial gap type rotary electric machine comprising a lightweight rotor in which influences of an axial gap upon a magnetic flux are suppressed, and a manufacturing method thereof.SOLUTION: An axial gap type rotary electric machine comprises a rotor and a stator. The rotor includes a support plate 10 and a permanent magnet 20 disposed on the support plate 10. The support plate 10 includes an inner core 40. The inner core 40 includes a plurality of vertical walls 42. The plurality of vertical walls 42 is disposed radially. The plurality of vertical walls 42 is disposed in rotational symmetry with respect to a central axis. The plurality of vertical walls 42 is positioned at a back part of the permanent magnet 20. The plurality of vertical walls 42 functions as a member against axial force and radial force acting on the permanent magnet 20.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The disclosure in this specification relates to an axial gap type rotating electric machine and a manufacturing method thereof. [Background technology]

[0002] Patent Document 1 discloses an axial gap motor. The motor includes a rotor having a permanent magnet. The permanent magnet is supported by a rotor support. The rotor is configured such that the rotor support and the permanent magnet are sandwiched between two reinforcing members. The reinforcing members are plate-shaped members. The contents of the prior art documents are incorporated by reference as explanations of the technical elements in this specification. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-136777 Summary of the Invention [Problem to be solved by the invention]

[0004] In the configuration of the prior art document, the surface of the permanent magnet is covered with a reinforcing member that provides strength to the rotor. The reinforcing member is located in the axial gap. As a result, the performance may be limited due to the reinforcing member. For example, the reinforcing member may increase the distance in the axial gap. Also, the reinforcing member may reduce the magnetic flux in the axial gap. Furthermore, there is a lower limit to the thickness of the reinforcing member from the viewpoint of the strength required for the rotor. In the above-mentioned viewpoints and other viewpoints not mentioned, further improvements are required for the axial gap type rotating electric machine.

[0005] One disclosed object is to provide an axial gap type rotating electric machine including a lightweight rotor in which the effect of the axial gap on the magnetic flux is suppressed, and a manufacturing method thereof. [Means for solving the problem]

[0006] The axial gap type rotating electric machine disclosed herein includes a stator (7) and a rotor (6) that are magnetically coupled to each other at an axial gap in the axial direction. The rotor includes a permanent magnet (20) that is arranged facing the axial gap, and a support plate (10) that is arranged behind the permanent magnet. The support plate is located behind the permanent magnet, is arranged rotationally symmetrically with respect to a central axis (AX) of the rotor, and includes a plurality of vertical walls (42) that extend in the axial direction. The vertical walls are arranged radially so that each vertical wall extends along a radial direction (RD). The support plate includes an inner core (40) having the vertical walls and an end plate (30) joined to at least one end surface of the inner core. do.

[0007] According to the disclosed axial gap type rotating electric machine, the force acting on the permanent magnet is received by the vertical wall, thereby providing an axial gap type rotating electric machine having a lightweight rotor with reduced effect on the magnetic flux of the axial gap.

[0008] Disclosed here the above A manufacturing method for an axial gap type rotating electric machine includes a step of assembling a support plate, a step of connecting the support plate and a permanent magnet to assemble a rotor, and a step of assembling the rotor and the stator opposite each other across an axial gap to form a rotating electric machine. The step of assembling the support plate includes a lamination step of stacking a plurality of strips (D46) so as to be joined by a plurality of joining layers (D47), an expansion step of expanding the laminate stacked by the lamination step while bending the plurality of strips along a circumferential direction (CD) to form an annular inner core (40), and a step of joining the inner core to an end plate (30). The manufacturing method of an axial gap type rotating electric machine disclosed herein includes a stator (7) and a rotor (6) that are magnetically coupled at an axial gap in the axial direction, the rotor includes a permanent magnet (20) arranged facing the axial gap and a support plate (10) arranged behind the permanent magnet, the support plate being located behind the permanent magnet, arranged rotationally symmetrically with respect to a central axis (AX) of the rotor, and including a plurality of vertical walls (42) extending in the axial direction, the manufacturing method of an axial gap type rotating electric machine includes a step of assembling the support plate; The method for manufacturing an axial gap type rotating electric machine includes a step of connecting a support plate and a permanent magnet to form a rotor, and a step of assembling the rotor and stator opposite each other across an axial gap to form a rotating electric machine, and the step of assembling the support plate includes a lamination step of stacking a plurality of strip-shaped bodies (D46) so as to be joined by a plurality of joining layers (D47), an expansion step of expanding the laminated body stacked in the lamination step while bending the plurality of strip-shaped bodies in a circumferential direction (CD) to form an annular inner core (40), and a step of joining the inner core and the end plate (30).

[0009] The various embodiments disclosed in this specification employ different technical means to achieve their respective objectives. The claims and the parenthetical symbols described in this section are merely illustrative of the corresponding relationship with the embodiments described below, and are not intended to limit the technical scope. The objectives, features, and effects disclosed in this specification will become more apparent by referring to the following detailed description and the accompanying drawings. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a partial exploded perspective view of the electrically powered device according to the first embodiment. [Diagram 2] FIG. [Diagram 3] FIG. [Figure 4] FIG. 2 is a cross-sectional view showing a cross section of an inner core. [Diagram 5] FIG. [Figure 6] FIG. 11 is an exploded perspective view of a support plate according to a second embodiment. [Figure 7] FIG. [Figure 8] FIG. 11 is an exploded cross-sectional view of a support plate according to a third embodiment. [Figure 9] FIG. 13 is an exploded cross-sectional view of a support plate according to a fourth embodiment. [Figure 10] FIG. 13 is a cross-sectional view of an inner core according to a fifth embodiment. [Figure 11] FIG. 13 is a cross-sectional view of an inner core according to a sixth embodiment. [Figure 12] FIG. 13 is a cross-sectional view of an inner core according to a seventh embodiment. [Figure 13] FIG. 13 is a cross-sectional view of an inner core according to an eighth embodiment. [Figure 14] FIG. 13 is a cross-sectional view of an inner core according to a ninth embodiment. [Figure 15] FIG. 23 is a cross-sectional view of an inner core according to a tenth embodiment. [Figure 16]FIG. 23 is a cross-sectional view of an inner core according to an eleventh embodiment. [Figure 17] FIG. 23 is a cross-sectional view of an inner core according to a twelfth embodiment. [Figure 18] FIG. 23 is a partial cross-sectional view of an inner core according to a thirteenth embodiment. [Figure 19] 4A to 4C are cross-sectional views showing a manufacturing process of the inner core. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] A number of embodiments will be described with reference to the drawings. In a number of embodiments, functionally and / or structurally corresponding and / or associated parts may be given the same reference numerals or reference numerals different in the hundredth or more digits. For corresponding and / or associated parts, reference may be made to the description of other embodiments. A number of figures are somewhat exaggerated to facilitate understanding of the shape, function, and interrelationship of the device.

[0012] First embodiment In FIG. 1, the electric device 1 is illustrated in a partially exploded perspective view. The electric device 1 includes a rotating electric machine 2, a rotating device 3 (LD), and a shaft 4. The rotating electric machine 2 is an axial gap type rotating electric machine. The rotating electric machine 2 is a motor. The rotating electric machine 2 may be a generator or a motor-generator. The shaft 4 is rotatably supported in the electric device 1 or in a device to which the electric device 1 is applied. The rotating electric machine 2 is connected to the rotating device 3 via the shaft 4. In this embodiment, the rotating electric machine 2 and the rotating device 3 are directly connected by the shaft 4. The rotating electric machine 2 and the rotating device 3 may be indirectly connected via a coupling device using a gear mechanism or a fluid mechanism.

[0013] The rotating device 3 is a device that rotates together with the rotating electric machine 2. The rotating device 3 may be a load that is rotated by the rotating electric machine 2 in an active state. The rotating device 3 may be a power source that rotates the rotating electric machine 2 in an active state.

[0014] The rotating equipment 3 is provided in a stationary equipment or a mobile equipment. The stationary equipment may be a blower, a water pump, a conveying equipment, etc. The rotating equipment 3 may be a fan, a pump, etc. The mobile equipment may be a vehicle, an aircraft, a ship, etc. The rotating equipment 3 in a mobile equipment may be a propulsion device of the mobile equipment. The propulsion device may be a wheel, a propeller, etc. The rotating equipment 3 in a mobile equipment may be a load of an equipment called an auxiliary machine in the mobile equipment. In this case, the rotating equipment 3 may be, for example, a wiper, a fan, a pump, etc. In this embodiment, the rotating equipment 3 is, for example, a propeller of an aircraft.

[0015] The electric device 1 includes a control device 5 (ECU). The control device 5 controls the state of current supply to the coil of the rotating electric machine 2. The control device 5 may also be called an electronic control unit (ECU). The control device or control system is provided by (a) an algorithm as a plurality of logics called an if-then-else format, or (b) an algorithm as a trained model tuned by machine learning, for example, a neural network.

[0016] The control device is provided by a control system including at least one computer. The control system may include multiple computers linked by data communication devices. The computer includes at least one processor (hardware processor) that is hardware. The hardware processor may be at least one processor core that executes a program stored in at least one memory. The memory is also called a storage medium. The memory is a non-transient and tangible storage medium that non-temporarily stores "programs and / or data" that can be read by the processor. The hardware processor may be a hardware logic circuit. In this case, the computer is provided by a digital circuit including a large number of programmed logic units (gate circuits). The digital circuit is also called a logic circuit array, for example, ASIC: Application-Specific Integrated Circuit, FPGA: Field Programmable Gate Array, etc. The digital circuit may include a memory that stores the program and / or data. The computer may be provided by an analog circuit. The computer may be provided by a combination of a digital circuit and an analog circuit.

[0017] The rotating electric machine 2 includes a rotor 6 and a stator 7. In the following description, a three-axis Cartesian coordinate system is defined based on the central axis AX of the shaft 4. The direction parallel to the central axis AX is called the axial direction AD. The direction perpendicular to the central axis AX is called the radial direction RD. The direction around the central axis AX is called the circumferential direction CD. The circumferential direction CD is also called the tangential direction.

[0018] The rotor 6 and the stator 7 are magnetically coupled to each other at an axial gap in the axial direction AD. The rotor 6 and the stator 7 rotate relatively to each other. The rotor 6 and the stator 7 are arranged in a laminated manner with respect to the axial direction AD. The rotor 6 and the stator 7 are separated from each other with a gap GP in the axial direction AD. The rotor 6 and the stator 7 face each other in the axial direction AD with a gap GP in between. Magnetic flux passes through the gap GP.

[0019] The rotor 6 is connected to the shaft 4. The rotor 6 includes a support plate 10 and a permanent magnet 20. The permanent magnet 20 is disposed facing the axial air gap. The support plate 10 is disposed behind the permanent magnet 20.

[0020] The support plate 10 is a disk-shaped member. The support plate 10 is connected to the shaft 4 at an inner portion in the radial direction RD. The support plate 10 supports the permanent magnet 20. The support plate 10 is a member that supports the permanent magnet 20. The support plate 10 is disposed behind the permanent magnet 20 in the rotating electric machine 2. The rear refers to the opposite side to the gap GP in the axial direction AD of the permanent magnet 20.

[0021] The support plate 10 provides the rotor 6 with the strength in the axial direction AD required. The support plate 10 provides the rotor 6 with the strength in the radial direction RD required. The support plate 10 provides the rotor 6 with the strength in the circumferential direction CD required. The support plate 10 is a main member that provides mechanical strength to the rotor 6. The support plate 10 has the strength to hold the permanent magnet 20 at a specified position against a force in the axial direction AD acting on the permanent magnet 20. The support plate 10 has the strength to hold the permanent magnet 20 at a specified position against a force in the radial direction RD acting on the permanent magnet 20. The support plate 10 has the strength to hold the permanent magnet 20 at a specified position against a force in the circumferential direction CD acting on the permanent magnet 20.

[0022] The support plate 10 may be made of a magnetic material. The support plate 10 may be made of a non-magnetic material. For example, the support plate 10 may be made of aluminum or an aluminum alloy. For example, the support plate 10 may be made of carbon fiber reinforced plastic. For example, the support plate 10 may be made of a composite material of an aluminum alloy and a carbon fiber reinforced plastic.

[0023] The permanent magnet 20 may be a single body having a plurality of permanent magnet portions, or a connected body in which a plurality of permanent magnet portions are connected. The permanent magnet 20 has a plurality of magnetic poles 20a, 20b arranged alternately along the circumferential direction CD. The plurality of magnetic poles 20a, 20b provide, for example, N poles and S poles. The plurality of magnetic poles of the permanent magnet 20 are positioned and magnetized so as to face the magnetic poles of the stator 7 in the axial direction AD. As a result, the plurality of magnetic poles of the rotor 6 appear as an annular row arranged along the circumferential direction CD on the end surface of the rotor 6. The surface of the permanent magnet 20 is covered by a protective member 20c. The protective member 20c chemically protects the permanent magnet 20. The protective member 20c is provided by a protective layer that is thinner than the support plate 10. The protective member 20c is positioned in the air gap GP. However, the protective member 20c is obviously thinner than the support plate 10, and has a very small effect on the magnetic flux.

[0024] Due to an electromagnetic force acting between the magnetic poles of the permanent magnet 20 and the magnetic poles of the stator 7, a force in the axial direction AD acts on the permanent magnet 20. Due to an electromagnetic force acting between the magnetic poles of the permanent magnet 20 and the magnetic poles of the stator 7, a force in the circumferential direction CD acts on the permanent magnet 20.

[0025] In this embodiment, the rotating electric machine 2 includes a first rotor 6a and a second rotor 6b on either side of the axial direction AD relative to the stator 7. The first rotor 6a and the second rotor 6b rotate relatively at both ends of the common stator 7. In the drawing, the second rotor 6b is shown in an exploded state.

[0026] The first rotor 6a includes a support plate 11 and a permanent magnet 21. The second rotor 6b includes a support plate 12 and a permanent magnet 22. The first rotor 6a and the second rotor 6b are disposed at both ends of the stator 7. The support plates 11, 12 of the first rotor 6a and the second rotor 6b are positioned at both ends of the axial direction AD of the rotating electric machine 2. The first rotor 6a and the second rotor 6b are positioned such that the permanent magnets 21, 22 face both end faces of the stator 7.

[0027] The stator 7 is fixedly supported in the electric device 1 or in a device to which the electric device 1 is applied. The stator 7 has a plurality of coils 8 for providing magnetic poles on an end face in an axial direction AD. The plurality of coils 8 may include a coil having a coil axis parallel to the axial direction AD. The plurality of coils 8 are arranged in an annular shape along a circumferential direction CD within the stator 7. As a result, during operation, the plurality of magnetic poles of the stator 7 appear on the end face of the stator 7 as an annular row arranged along the circumferential direction CD. The supply of current to the plurality of coils 8 is controlled by the control device 5.

[0028] 2, the support plate 10 is a disk-shaped member. The support plate 10 has a connecting portion CP with the shaft 4. The connecting portion CP is provided by a flange portion that is fastened to the flange portion of the shaft 4 by a fastening member such as a bolt, and a bolt hole.

[0029] The support plate 10 includes an end plate 30 and an inner core 40. The end plate 30 is a disk-shaped member having an opening in the center. The support plate 10 has one end surface and the other end surface. The end plate 30 includes a first plate 31 that provides one end surface of the support plate 10. The end plate 30 includes a second plate 32 that provides the other end surface of the support plate 10. The inner core 40 includes a plurality of vertical walls 42 for defining a thickness TH. The vertical walls 42 extend in an axial direction AD to provide the thickness TH of the support plate 10. The vertical walls 42 are approximately perpendicular to the end plate 30. Note that the vertical here is not mathematically perpendicular. The vertical should be understood as allowing an industrial error range. The vertical walls 42 connect the first plate 31 and the second plate 32 in the direction of the thickness TH. The direction of the thickness TH is the axial direction AD. The plurality of vertical walls 42 are provided at intervals G41 in the circumferential direction CD. The multiple vertical walls 42 are provided at equal intervals in the circumferential direction CD.

[0030] The vertical walls 42 have a height that defines the thickness TH, and are arranged at intervals G41 in the circumferential direction CD. As a result, a volume chamber having a predetermined volume is defined between the vertical walls 42. This provides a lighter support plate 10 than when the entire thickness TH is provided by the material of the end plate 30.

[0031] 3, the support plate 10 includes an end plate 30 and an inner core 40. The end plate 30 and the inner core 40 are arranged in a layered manner and joined together. The joining can be achieved by bonding with an adhesive, welding, connecting with rivets, brazing with a brazing material, or the like.

[0032] The inner core 40 is formed by radially positioning a plurality of cylindrical bodies 41. The inner core 40 is positioned between the first plate 31 and the second plate 32 and joined to the first plate 31 and the second plate 32.

[0033] The cylindrical body 41 is a square tube. The cylindrical body 41 is disposed between the inner surface of the first plate 31 and the inner surface of the second plate 32 so as to extend along these inner surfaces. The cylindrical body 41 has a polygonal cross section in a plane perpendicular to the radial direction RD. The cylindrical body 41 has a quadrilateral cross section in a plane perpendicular to the radial direction RD. The cylindrical body 41 is a long tube whose cross-sectional shape is long and continuous in the radial direction RD. The cylindrical body 41 is disposed along the radial direction RD. The cylindrical bodies 41 are radially arranged on the support plate 10. The cylindrical bodies 41 are annularly arranged along the circumferential direction CD. The cylindrical bodies 41 are arranged with a gap G41 between them. The gap G41 corresponds to a predetermined angular range with respect to the central axis AX. The gap G41 is also called an angular range G41.

[0034] When the gap G41 is open to the inside and outside in the radial direction RD, it may function as a passage for air to cool the rotor 6. The air flowing through the gap G41 flows from the inside to the outside in the radial direction RD. The gap G41 may contribute to suppressing the temperature of the rotor 6.

[0035] The cylindrical body 41 includes a vertical wall 42 and a horizontal wall 43. The cylindrical body 41 includes a pair of vertical walls 42 and a pair of horizontal walls 43. The pair of vertical walls 42 are positioned so as to face each other in the circumferential direction CD. The pair of horizontal walls 43 are positioned so as to face each other in the axial direction AD. The vertical walls 42, the horizontal walls 43, the vertical walls 42, and the horizontal walls 43 are connected in this order to form a cylindrical shape.

[0036] The cavity in the cylindrical body 41 may function as a passage for air to cool the rotor 6. The air flowing through the cavity in the cylindrical body 41 flows from the inside to the outside in the radial direction RD. The cavity in the cylindrical body 41 may contribute to suppressing the temperature of the rotor 6.

[0037] The cylindrical body 41 has both ends. One end is positioned at the outer end in the radial direction RD of the support plate 10. The outer end is an open end. The other end is positioned at the inner end in the radial direction RD of the support plate 10. The inner end is closed by an end wall 44. The end wall 44 is a wall extending linearly along the axial direction AD. The end wall 44 is curved along the circumferential direction CD so as to be convex from the outside to the inside in the radial direction RD. Alternatively, the cylindrical body 41 may not have the end wall 44. In this case, the cylindrical body 41 is a cylindrical body with both ends open. Furthermore, the cylindrical body 41 may have both the outer end and the inner end closed. In this case, the cylindrical body 41 has end walls 44 at both ends. Furthermore, the outer end may be a closed end and the inner end may be an open end. In this case, the cylindrical body 41 has the end wall 44 only at the outer end.

[0038] FIG. 4 shows a cross section of the support plate 10. In this figure, the area where the permanent magnets 20 are arranged and fixed is shown by a broken line. The end plate 30 is shown by a broken line. Each vertical wall 42 extends along the radial direction RD. As a result, the multiple vertical walls 42 extend radially. The multiple vertical walls 42 are arranged radially. In the support plate 10, the vertical walls 42 are positioned behind the area where the permanent magnets 20 are installed. As a result, the force acting on the permanent magnets 20 can be received by the vertical walls 42. The multiple vertical walls 42 function as members that resist the force in the axial direction AD acting on the permanent magnets 20. The multiple vertical walls 42 function as members that resist the force in the radial direction RD acting on the permanent magnets 20.

[0039] The multiple vertical walls 42 are distributed rotationally symmetrically with respect to the central axis AX. Any one vertical wall 42 is rotationally symmetric with other vertical walls 42 located at positions shifted by a predetermined rotation angle with the central axis AX as the center of rotation. Note that the rotational symmetry here is not intended to be mathematically precise. The rotational symmetry includes an industrially acceptable error range. For example, the other vertical walls 42 that are rotationally symmetric with respect to any one vertical wall 42 may be located within a predetermined error range.

[0040] The vertical walls 42 are present in both the inner portion of the support plate 10 in the radial direction RD and the outer portion of the support plate 10 in the radial direction RD. One vertical wall 42 occupies a predetermined cross-sectional area that is equal in both the outer portion and the inner portion. In the cylindrical cross section extending in the axial direction AD in the inner portion of the radial direction RD of the support plate 10, n vertical walls 42 are present. In the cylindrical cross section extending in the axial direction AD in the outer portion of the radial direction RD of the support plate 10, n vertical walls 42 are also present. The number of vertical walls 42 is the same in both the inner portion and the outer portion. However, the area of ​​the outer cylindrical cross section is larger than the area of ​​the inner cylindrical cross section. Therefore, the proportion of the outer cylindrical cross section occupied by the vertical walls 42 is lower than the proportion of the inner cylindrical cross section occupied by the vertical walls 42. For example, an outer cylindrical cross section extending in the axial direction AD at the outer end 20d of the range in which the permanent magnet 20 exists can be assumed. Similarly, an inner cylindrical cross section can be assumed to extend in the axial direction AD at the inner end 20e of the range in which the permanent magnet 20 is present. The total occupation area of ​​the vertical walls 42 in the outer cylindrical cross section is smaller than the total occupation area of ​​the vertical walls 42 in the inner cylindrical cross section. This provides necessary strength in the inner portion where stress that bends the support plate 10 in the axial direction AD is likely to concentrate.

[0041] In this embodiment, all of the multiple vertical walls 42 are multiple radial vertical walls 42a extending along the radial direction RD. The multiple radial vertical walls 42a form a predetermined interval G41 in the circumferential direction CD. This interval G41 is narrower at an inner portion in the radial direction RD and wider at an outer portion in the radial direction RD. In other words, the interval G41 at the inner portion in the radial direction RD is narrower than the interval G41 at the outer portion in the radial direction RD. The relationship of the intervals in the circumferential direction CD between the multiple radial vertical walls is provided in common to multiple embodiments described in this specification.

[0042] In FIG. 5, the relationship between the cylindrical body 41, the first plate 31, and the second plate 32 in the support plate 10 is modeled and illustrated. FIG. 5 shows a cylindrical cross section extending in the axial direction AD near the center of the radial direction RD in the support plate 10. The vertical wall 42 provided by the cylindrical body 41 acts as a beam between the first plate 31 and the second plate 32. The horizontal wall 43 provided by the cylindrical body 41 is positioned parallel to the first plate 31 or the second plate 32. Furthermore, the horizontal wall 43 provided by the cylindrical body 41 is joined to the first plate 31 or the second plate 32. As a result, the cylindrical body 41 is firmly joined to the first plate 31 or the second plate 32. As a result, the vertical wall 42 is also firmly joined to the first plate 31 or the second plate 32.

[0043] The manufacturing method of the electric device 1 includes a step of preparing the rotating device 3, a step of assembling the rotating electric machine 2, and a step of connecting the rotating electric machine 2 and the rotating device 3. The step of assembling the rotating electric machine 2 includes a step of assembling the rotor 6, a step of assembling the stator 7, and a step of assembling the rotating electric machine 2 with the rotor 6 and the stator 7.

[0044] The process of assembling the rotor 6 includes a step of assembling the support plate 10, a step of preparing the permanent magnets 20, and a step of connecting the support plate 10 and the permanent magnets 20 to assemble the rotor 6.

[0045] The process of assembling the support plate 10 includes a process of preparing an end plate 30, a process of preparing an inner core 40, and a process of joining the end plate 30 and the inner core 40. The process of preparing the inner core 40 includes a process of forming a plurality of cylindrical bodies 41, a process of radially arranging the plurality of cylindrical bodies 41, and a connecting process of connecting the plurality of cylindrical bodies 41 to the end plate 30. The connecting process includes a process of sandwiching the plurality of cylindrical bodies 41 between the first plate 31 and the second plate 32, and a connecting process of joining the plurality of cylindrical bodies 41 to the first plate 31 and the second plate 32. The process of assembling the rotating electric machine 2 includes a process of assembling the rotor 6 and the stator 7 so as to face each other in the axial air gap, and forming the rotating electric machine 2.

[0046] According to the embodiment described above, the support plate 10 is provided to support the permanent magnet 20 behind the permanent magnet 20. The support plate 10 includes a plurality of vertical walls 42. The vertical walls 42 are arranged radially. The vertical walls 42 are arranged rotationally symmetrically about the central axis AX. As a result, the support plate 10 is provided with light weight and high strength. The vertical walls 42 of the support plate 10 are arranged behind the area in which the permanent magnet 20 is arranged. As a result, the vertical walls 42 receive the force acting on the permanent magnet 20. The axial gap type rotating electric machine 2 includes a rotor 6 that has a required strength and is lightweight. As a result, the axial gap type rotating electric machine 2 is provided with a lightweight rotor 6 in which the effect of the axial gap on the magnetic flux is suppressed.

[0047] Second embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the cylindrical bodies 41 are arranged at a predetermined interval G41. Instead of this, in this embodiment, the cylindrical bodies 41 are densely arranged in the circumferential direction CD.

[0048] 6 and 7, the inner core 40 includes a plurality of cylindrical bodies 41. The cylindrical bodies 41 include vertical walls 242 that are in contact with adjacent cylindrical bodies 41. The vertical wall 242 of one cylindrical body 41 is disposed in contact with the vertical wall 242 of the adjacent cylindrical body 41. The vertical wall 242 of one cylindrical body 41 may be joined to the vertical wall 242 of the adjacent cylindrical body 41.

[0049] In this embodiment, more vertical walls 242 are disposed between the first plate 31 and the second plate 32 than in the first embodiment. Specifically, the total number of the vertical walls 242 in the second embodiment may reach twice the total number of the vertical walls 42 in the first embodiment. In this embodiment, all of the vertical walls 242 are radial vertical walls 242a extending along the radial direction RD. In this embodiment, the vertical walls 42 are also provided by the vertical walls 242. In this embodiment, the same effects as those of the preceding embodiment can be obtained.

[0050] Third embodiment This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, the inner core 40 is provided by a plurality of cylindrical bodies 41. Instead, in this embodiment, the inner core 40 is provided by a plate-like member 341 having a cross-sectional shape similar to a rectangular wave.

[0051] In FIG. 8, the inner core 40 includes a plate-shaped member 341. The plate-shaped member 341 is an annular member. The plate-shaped member 341 has a cross-sectional shape that can be called a rectangular wave shape or a pulse wave shape in a cylindrical cross section. The plate-shaped member 341 has a cross-sectional shape in which a horizontal wall 343, a vertical wall 342, a horizontal wall 343, and a vertical wall 342 are repeated in sequence along the circumferential direction CD. The horizontal wall 343 is disposed in parallel to and joined to the first plate 31 or the second plate 32. The plate-shaped member 341 provides a cross-sectional shape similar to the multiple vertical walls 42 illustrated in FIG. 4.

[0052] In this embodiment, the inner core 40 is provided by a smaller number of plate-like members 341 than the number of cylindrical bodies 41. In this embodiment, all of the vertical walls 342 are a plurality of radial vertical walls 342a extending along the radial direction RD. In this embodiment, the vertical walls 342 also provide a plurality of vertical walls 42. In this embodiment, the same effects as those of the preceding embodiment can be obtained.

[0053] Fourth embodiment This embodiment is a modification of the preceding embodiment as a basic form. In the preceding embodiment, the inner core 40 is provided by a plurality of cylindrical bodies 41 or plate-like members 341. Instead, in this embodiment, the inner core 40 is provided by a plurality of strip-shaped bodies 441.

[0054] In FIG. 9, the inner core 40 includes a plurality of band-shaped bodies 441. One band-shaped body 441 is a band-shaped member extending in the radial direction RD. One band-shaped body 441 includes a horizontal wall 443, a vertical wall 442, and a horizontal wall 443. The two horizontal walls 443 are arranged in a crank shape with respect to one vertical wall 442. One horizontal wall 443 is arranged to extend in one direction from one end of the axial direction AD of the vertical wall 442. The other horizontal wall 443 is arranged to extend in the other direction from the other end of the axial direction AD of the vertical wall 442. The other direction is the opposite direction to the one direction. The horizontal wall 443 is arranged in parallel to the first plate 31 or the second plate 32 and is joined thereto. The multiple vertical walls 442 provide the multiple band-shaped bodies 441 with a cross-sectional shape similar to that of the multiple vertical walls 42 illustrated in FIG. 4. The vertical wall 442 and the two horizontal walls 443 of the band-shaped body 441 may be arranged in a bracket shape instead of a crank shape. Also, the band-shaped body 441 may have only the vertical wall 442 without the horizontal wall 443. In this case, the end face of the vertical wall 442 is arranged so as to contact the end plate 30, and the end face of the vertical wall 442 is joined to the end plate 30.

[0055] The multiple strip-shaped bodies 441 can be manufactured by a process of folding both long sides of a strip-shaped material by a predetermined width. Therefore, the multiple vertical walls 442 can be mass-produced easily and at low cost. In this embodiment, all of the multiple vertical walls 442 are multiple radial vertical walls 442a extending along the radial direction RD. In this embodiment as well, the multiple vertical walls 442 provide multiple vertical walls 42. In this embodiment as well, the same effects as those of the preceding embodiment can be obtained.

[0056] Fifth embodiment This embodiment is a modification based on the preceding embodiment. In the above embodiment, the vertical walls 42 extend long from the inner end to the outer end along the radial direction RD. Instead, in this embodiment, the vertical walls 42 include an inner short vertical wall 542b arranged only in a partial range of the radial direction RD of the support plate 10. The inner short vertical wall 542b is provided only in the inner range of the radial direction RD of the support plate 10.

[0057] In FIG. 10, the inner core 40 includes one or more wall members 541. The wall member 541 provides a plurality of vertical walls 42. The wall member 541 can be provided by a cylindrical body, a plate-like member, or a strip-like piece. The plurality of vertical walls 42 include a plurality of long vertical walls 542a and a plurality of inner short vertical walls 542b. The long vertical wall 542a extends long from the inner end to the outer end along the radial direction RD. The inner short vertical wall 542b extends short from the inner end to a middle position along the radial direction RD. The middle position can be set at the center of the radial direction RD. The middle position can be set outside the center of the radial direction RD. The middle position can be set inside the center of the radial direction RD. The middle position is selected according to the installation range, weight, strength, etc. of the permanent magnet 20.

[0058] Both a plurality of long vertical walls 542a and a plurality of inner short vertical walls 542b are arranged in the inner range in the radial direction RD of the support plate 10. Only a plurality of long vertical walls 542a are arranged in the outer range in the radial direction RD of the support plate 10. Therefore, more vertical walls 42 are arranged in a portion of the range in the radial direction RD of the support plate 10 than in the remaining range. M vertical walls 42 are arranged on the inner side in the radial direction RD of the support plate 10. L vertical walls 42, which is less than M, are arranged on the outer side in the radial direction RD of the support plate 10.

[0059] According to this embodiment, the number of vertical walls 42 can be changed along the radial direction RD of the support plate 10. Specifically, the number of vertical walls 42 can be decreased from the inside to the outside. This provides a support plate 10 having higher strength on the radially inside than on the radially outside. In this embodiment as well, the multiple vertical walls 42 are provided by the multiple long vertical walls 542a and the multiple inner short vertical walls 542b. In this embodiment as well, the same effects as those of the preceding embodiment can be obtained.

[0060] Sixth embodiment This embodiment is a modification of the preceding embodiment as a basic form. In this embodiment, the multiple vertical walls 42 include an outer short vertical wall 642b arranged only in a partial range in the radial direction RD of the support plate 10. The outer short vertical wall 642b is provided only in the outer range of the support plate 10 in the radial direction RD.

[0061] In FIG. 11, the inner core 40 includes one or more wall members 641. The wall member 641 provides a plurality of vertical walls 42. The wall member 641 can be provided by a cylindrical body, a plate-like member, or a strip-like piece. The plurality of vertical walls 42 include a plurality of long vertical walls 642a and a plurality of outer short vertical walls 642c. The long vertical wall 642a extends long from the inner end to the outer end along the radial direction RD. The outer short vertical wall 642c extends short from the outer end to a middle position along the radial direction RD. The middle position can be set at the center of the radial direction RD. The middle position can be set outside the center of the radial direction RD. The middle position can be set inside the center of the radial direction RD. The middle position is selected according to the installation range, weight, strength, etc. of the permanent magnet 20.

[0062] Both the multiple long vertical walls 642a and the multiple outer short vertical walls 642c are arranged in the outer range of the support plate 10 in the radial direction RD. Only the multiple long vertical walls 642a are arranged in the inner range of the support plate 10 in the radial direction RD. Therefore, more vertical walls 42 are arranged in a portion of the range of the support plate 10 in the radial direction RD than in the remaining range. M vertical walls 42 are arranged on the inner side of the support plate 10 in the radial direction RD. N vertical walls 42, which is more than M, are arranged on the outer side of the support plate 10 in the radial direction RD.

[0063] According to this embodiment, the number of vertical walls 42 can be changed along the radial direction RD of the support plate 10. Specifically, the number of vertical walls 42 can be increased from the inside to the outside. This provides a support plate 10 having higher strength on the radial outside than on the radial inside. In this embodiment as well, multiple vertical walls 42 are provided by multiple long vertical walls 642a and multiple outer short vertical walls 642c. In this embodiment as well, the same effects as those of the preceding embodiment can be obtained.

[0064] Seventh embodiment This embodiment is a modification of the preceding embodiment, in which the vertical walls 42 are spaced apart from each other along the radial direction RD of the support plate 10.

[0065] In Fig. 12, the inner core 40 includes one or more wall members 741. The wall member 741 provides a plurality of vertical walls 42. The wall member 741 can be provided by a cylindrical body, a plate-like member, or a strip-like piece. The multiple vertical walls 42 are disposed apart from each other in the radial direction RD of the support plate 10. The multiple vertical walls 42 are disposed in a sparsely arranged manner on the support plate 10. It can also be said that the multiple vertical walls 42 are disposed in a dispersed manner or intermittently.

[0066] The vertical walls 42 can be classified into a plurality of groups 745, 746, and 747 arranged radially. The vertical walls 42 have an inner group 745 located at the innermost position in the radial direction RD. The inner group 745 has a plurality of inner short vertical walls 742d arranged radially. The vertical walls 42 have an outer group 746 located at the outermost position in the radial direction RD. The outer group 746 has a plurality of outer short vertical walls 742e arranged radially. The vertical walls 42 have a middle group 747 located at the middle of the radial direction RD. The middle group 747 is located between the inner group 745 and the outer group 746. The middle group 747 has a plurality of middle and short vertical walls 742f arranged radially.

[0067] The multiple vertical walls 42 are arranged so that two vertical walls 42 adjacent to each other in the radial direction RD are not continuous in the radial direction RD. For example, the inner short vertical wall 742d and the middle short vertical wall 742f are arranged at positions shifted by a predetermined angle with respect to the central axis AX. For example, the middle short vertical wall 742f and the outer short vertical wall 742e are arranged at positions shifted by a predetermined angle with respect to the central axis AX. The inner short vertical wall 742d and the outer short vertical wall 742e are arranged on the same radial direction RD, but are separated from each other in the radial direction RD.

[0068] In the illustrated embodiment, the vertical walls 42 can be classified into three groups. Alternatively, the vertical walls 42 may be arranged so as to be classified into two groups, four groups, five groups, and even more groups.

[0069] According to this embodiment, a plurality of vertical walls 42 can be dispersedly disposed on the support plate 10. In this embodiment, the plurality of vertical walls 42 are also provided by the plurality of inner short vertical walls 742d, the plurality of middle short vertical walls 742f, and the plurality of outer short vertical walls 742e. In this embodiment, the same effects as those of the preceding embodiment can be obtained.

[0070] Eighth embodiment This embodiment is a modification based on the previous embodiment. In the previous embodiment, the vertical walls 42 are spaced apart from each other in the circumferential direction CD or the radial direction RD. Instead, in this embodiment, the vertical walls 42 are provided by a continuous wall that divides the cells 848.

[0071] In FIG. 13, the inner core 40 includes a wall member 841 that divides a plurality of cells 848. The wall member 841 is a porous body that divides a plurality of cells 848. The cells 848 are polygons with n or more sides. n is, for example, a natural number of 3 or more, or 4 or more. The polygon has a shape in which at least one side extends along the radial direction RD of the support plate 10. Desirably, the polygon has a shape in which two sides that are separated from each other extend along the radial direction RD of the support plate 10. The areas of the plurality of cells 848 positioned along one radial direction RD are set to be gradually larger toward the outside of the radial direction RD. The areas of the plurality of cells 848 positioned along one circumferential direction CD are approximately equal along the circumferential direction CD. Note that the term "equal" does not intend to mean "equal" in a mathematical sense. "Equal" includes an industrially acceptable error range. The polygon may be, for example, a hexagon. In this case, the wall member 841 is a so-called honeycomb body.

[0072] In the plane illustrated in FIG. 13, the wall member 841 provides a plurality of vertical walls 42 extending linearly. The plurality of vertical walls 42 are arranged in a net-like manner. The plurality of vertical walls 42 can also be called a plurality of short vertical walls. The plurality of vertical walls 42 have a plurality of radial vertical walls 842g and a plurality of cross vertical walls 842h. The plurality of radial vertical walls 842g extend along the radial direction RD. In the illustrated example, one radial vertical wall 842g is positioned on the first radial line RDL1. Two radial vertical walls 842g are positioned on the second radial line RDL2. The plurality of cross vertical walls 842h cross the radial direction RD at a predetermined angle. The plurality of cross vertical walls 842h extend along a direction between the radial direction RD and the circumferential direction CD. The plurality of cross vertical walls 842h extend more or less along the circumferential direction CD. The multiple cross vertical walls 842h extend to connect two adjacent radial vertical walls 842g in the circumferential direction CD. The cross vertical walls 842h are also called peripheral vertical walls. The multiple radial vertical walls 842g in this embodiment provide the multiple vertical walls 42 (742d, 742f, 742e) in the embodiment shown in FIG.

[0073] According to this embodiment, a plurality of vertical walls 42 can be disposed in a dispersed manner on the support plate 10. In this embodiment as well, a plurality of vertical walls 42 are provided. In this embodiment as well, the same effects as those of the preceding embodiment can be obtained.

[0074] Ninth embodiment This embodiment is a variation of the previous embodiment, in which the cells 848 are hexagonal. Instead, in this embodiment, the vertical walls 42 define rectangular cells 948.

[0075] In FIG. 14, the inner core 40 includes a wall member 941 that divides a plurality of cells 948. The cells 948 are rectangular. The wall member 941 includes a plurality of radial vertical walls 942g and a plurality of peripheral vertical walls 942i. The radial vertical walls 942g extend along the radial direction RD. One radial vertical wall 942g extends continuously from the inner end to the outer end along the radial direction RD. The peripheral vertical walls 942i extend along the circumferential direction CD. The peripheral vertical walls 942i are a special solution included in the concept of intersecting vertical walls.

[0076] This embodiment also provides a plurality of vertical walls 42. This embodiment also provides the same effects as the preceding embodiment.

[0077] Tenth embodiment This embodiment is a modification based on the preceding embodiment. In the preceding embodiment, one radial vertical wall 942g extends continuously from the inner end to the outer end along the radial direction RD. Instead, in this embodiment, the multiple vertical walls 42 are separated from each other.

[0078] In FIG. 15, the inner core 40 includes a wall member A41 that divides a plurality of cells A48. The cells A48 are rectangular. The wall member A41 includes a plurality of radial vertical walls A42g and a plurality of peripheral vertical walls A42i. The peripheral vertical walls A42i are a special solution included in the concept of intersecting vertical walls. The radial vertical walls A42g of this embodiment provide the plurality of vertical walls 42 (742d, 742f, 742e) in the embodiment shown in FIG. 12.

[0079] This embodiment also provides a plurality of vertical walls 42. This embodiment also provides the same effects as the preceding embodiment.

[0080] Eleventh embodiment This embodiment is a variation of the previous embodiment. In the previous embodiment, the cells are rectangular or hexagonal. Instead, in this embodiment, the vertical walls 42 define pentagonal cells B48.

[0081] In FIG. 16, the inner core 40 includes a wall member B41 that divides a plurality of cells B48. The cells B48 are pentagonal. The wall member B41 includes a plurality of radial vertical walls B42g, a plurality of intersecting vertical walls B42h, and a plurality of peripheral vertical walls B42i. The intersecting vertical walls B42h and the peripheral vertical walls B42i are included in the concept of intersecting vertical walls. The radial vertical walls B42g extend along the radial direction RD.

[0082] This embodiment also provides a plurality of vertical walls 42. This embodiment also provides the same effects as the preceding embodiment.

[0083] Twelfth embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the wall member defines a plurality of cells arranged in a stacked manner in several stages along the radial direction RD. Instead, in this embodiment, the wall member C41 defines a plurality of stages of cells C48, which is much more than a few stages.

[0084] In FIG. 17, the inner core 40 includes a wall member C41 that divides a plurality of cells C48. The plurality of cells C48 can be classified into a plurality of layers in the radial direction RD. The plurality of layers are arranged in a stacked manner along the radial direction RD. In the illustrated example, the number of layers is 18 layers. Note that the number of layers of the plurality of cells is not limited to the number of layers illustrated. The inner core 40 can include a variety of layers ranging from a few layers to 30-40 layers.

[0085] The areas of the cells C48 are gradually enlarged from the inside to the outside along the radial direction RD. The wall member C41 defines the cells C48 whose areas are gradually enlarged from the inside to the outside along the radial direction RD. The cells C48 are arranged along a spiral line SP. The areas of the cells C48 are gradually enlarged from the inside to the outside along the spiral line SP. The wall member C41 defines the cells C48 whose areas are gradually enlarged from the inside to the outside along the spiral line SP. The wall member C41 is arranged to provide a plurality of radial vertical walls C42g and a plurality of intersecting vertical walls C42h.

[0086] This embodiment also provides a plurality of vertical walls 42. This embodiment also provides the same effects as the preceding embodiment.

[0087] Thirteenth embodiment This embodiment is a modification based on the preceding embodiment, and discloses a detailed structure of the wall member and a manufacturing method thereof.

[0088] Fig. 18 shows an enlarged cross-sectional view of a portion of the embodiment shown in Fig. 13. In the figure, the wall member 841 includes a radial vertical wall 842g and a cross vertical wall 842h. The radial vertical walls 842g and the cross vertical walls 842h are alternately arranged from the inside to the outside along the radial direction RD. The wall member 841 is formed by joining a plurality of strip-shaped bodies D46. In other words, the wall member 841 is an assembly of a plurality of strip-shaped bodies D46.

[0089] The band D46 is provided by a continuous material. The band D46 is folded along the radial direction RD to provide radial vertical walls 842g and cross vertical walls 842h alternately. In the illustrated example, one band D46 alternates between a radial vertical wall 842g, a cross vertical wall 842h, a radial vertical wall 842g, a cross vertical wall 842h, and a radial vertical wall 842g alternately from the inside to the outside along the radial direction RD. The multiple bands D46 include two types of bands D46a and D46b. The bands D46a and D46b have different folding directions. The bands D46a and D46b have opposite folding directions. The bands D46a and D46b are arranged to define a cell 848 therebetween. The strip D46a and the strip D46b are arranged on either side of one radial direction RD so as to be line-symmetrical.

[0090] A plurality of bonding layers D47 are disposed between the plurality of band-shaped bodies D46. The plurality of bonding layers D47 bond two radial vertical walls 842g positioned adjacent to each other in the circumferential direction CD. The bonding layers D47 can be provided by various bonding materials such as an adhesive, a brazing material, and a solder.

[0091] 19 shows a material at an intermediate stage in the manufacturing method of the inner core 40. The wavy line slightly left of the center in the figure indicates an omission. The left side of the wavy line shows the material in the bonding process. The right side of the wavy line shows the material in the unfolding process.

[0092] The manufacturing method of the inner core 40 includes a preparation step, an application step, a joining step, an unfolding step, and an assembly step. In the preparation step, a plurality of strips D46 and a joining material are prepared. In the application step, the joining material is applied to the plurality of strips D46. In the joining step, the plurality of strips D46 are stacked while being joined by the joining material. In the unfolding step, the stacked plurality of strips D46 are unfolded and shaped into the shape of the inner core 40. In the assembly step, the inner core 40 is joined to the first plate 31 and the second plate 32.

[0093] In the application step, the bonding material can be applied by various methods such as coating, spraying, etc. The bonding material is applied to a position corresponding to the radial vertical wall 842g.

[0094] In the lamination process, the strips D46 to which the bonding material is applied are laminated. The bonding material forms a bonding layer D47. In the lamination process, the bonding material forming the bonding layer D47 is hardened. The bonding layer D47 is disposed adjacent to the radial vertical wall 842g. The bonding layer D47 is disposed between two adjacent strips D46 and bonds these two strips D46. The bonding layer D47 bonds the two radial vertical walls 842g between the two strips D46. As a result, the two radial vertical walls 842g are integrated.

[0095] In the figure, the cells 848 are a single layer. Alternatively, the cells 848 may be arranged in multiple layers as in the embodiment of FIG. 17. In this case, a plurality of bonding layers D47 are arranged between adjacent strips D46. In this case, the width WD of each of the bonding layers D47 corresponds to the width of the radial vertical walls 842g. As a result, the width WD of each of the bonding layers D47 increases stepwise from the inside to the outside along the radial direction RD. The interval LG between the bonding layers D47 increases stepwise from the inside to the outside along the radial direction RD.

[0096] Furthermore, between two adjacent strip-shaped bodies D46, the multiple bonding layers D47 are arranged in a regular arrangement pattern. There are two types of arrangement patterns between two adjacent strip-shaped bodies D46. The two types of arrangement patterns are alternately repeated along the stacking direction of the multiple strip-shaped bodies D46.

[0097] The right half of FIG. 19 shows the shape of the intermediate product in the unfolding process. In the unfolding process, the strips D46 that have been stacked and joined in the stacking process are unfolded in the stacking direction. In the unfolding process, the strips D46 are unfolded from the stack while bending the strips D46 to provide a plurality of radial vertical walls. In the unfolding process, the strips D46 are unfolded in the circumferential direction CD so as to be pulled out from the stack to partition a plurality of cells 848. In the unfolding process, the strips D46 are unfolded in the stacking direction so that the unfolded strips D46 are annular. Here, the joining layers D47 are arranged with the above-mentioned width WD and interval LG in the above-mentioned two types of arrangement patterns, and therefore extend in an annular shape. In the unfolding process, the wall member 841 is shaped so that the radial vertical walls 842g are aligned along the radial direction RD.

[0098] As a result, the process of assembling the support plate 30 includes a lamination process of laminating a plurality of strip-shaped bodies D46 so as to be joined by a plurality of joining layers D47. The process of assembling the support plate 30 includes an expansion process of expanding the plurality of strip-shaped bodies D46 from the laminated body stacked in the lamination process while bending them along the circumferential direction CD to form the annular inner core 40. The process of assembling the support plate 30 includes a process of joining the inner core 40 and the end plate 30.

[0099] The radial vertical walls 842g are spaced apart from each other in the circumferential direction CD. The spaces are narrower at inner portions in the radial direction RD and wider at outer portions in the radial direction RD. In the unfolding process, the bands D46 are bent to provide a gap between the radial vertical walls 842g in the circumferential direction CD.

[0100] In this embodiment, the inner core 40 is efficiently manufactured by a manufacturing method in which a plurality of strips D46 are stacked, joined, and expanded. In this embodiment, a plurality of vertical walls 42 are also provided. In this embodiment, the same effects as those of the preceding embodiment can be obtained.

[0101] Other embodiments The disclosure in this specification and drawings, etc. is not limited to the exemplified embodiments. The disclosure includes the exemplified embodiments and modifications by those skilled in the art based thereon. For example, the disclosure is not limited to the combination of parts and / or elements shown in the embodiments. The disclosure can be implemented by various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes the omission of parts and / or elements of the embodiments. The disclosure includes the substitution or combination of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.

[0102] The disclosure in the specification and drawings is not limited by the claims. The disclosure in the specification and drawings includes the technical ideas described in the claims, and extends to more diverse and broader technical ideas than the technical ideas described in the claims. Therefore, various technical ideas can be extracted from the disclosure in the specification and drawings without being bound by the claims.

[0103] In the preceding embodiment, the two rotors 6 are arranged in a distributed manner so as to face both end faces of one stator 7. Alternatively, the two stators may be arranged in a distributed manner so as to face both end faces of one rotor. This configuration can be seen in JP 2021-136777 A as Patent Document 1. The contents of JP 2021-136777 A are incorporated by reference as a description of the technical elements in this specification.

[0104] In the preceding embodiment, the support plate 10 has the end plates 30 joined to both end faces of the inner core 40. Alternatively, the end plates 30 may be joined to only one end face of the inner core 40. For example, in the embodiment of FIG. 6, only the first plate 31 or the second plate 32 can be joined to the inner core 40. In this case, a wall that is continuous in the circumferential direction CD is provided by the multiple lateral walls 43 also on the other end face. Therefore, a configuration in which the end plate 30 is provided on at least one end face of the inner core 40 can be adopted.

[0105] The preceding embodiment includes a plurality of square, pentagonal, and hexagonal cells. Alternatively, the plurality of N-gonal cells may be included, where N is a natural number equal to or greater than 3. For example, the plurality of cells may include a plurality of triangular cells. For example, a wall member may be employed that divides a plurality of cells that combines a plurality of hexagonal cells and a plurality of triangular cells. The plurality of cells may also include a plurality of cells that are heptagonal or higher polygonal. For example, the wall member may include a plurality of cells that are various polygonal, such as seven, eight, nine, and ten.

[0106] (Disclosure of technical ideas) This specification discloses multiple technical ideas described in the following multiple dependent claims. Some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. Furthermore, some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. The claims described in these multiple dependent forms define multiple technical ideas.

[0107] (Technical thought 1) The rotor (6) is magnetically coupled to a stator (7) through an axial gap in the axial direction. The rotor is A permanent magnet (20) disposed facing the axial gap; and a support plate (10) arranged behind the permanent magnet. The support plate is located behind the permanent magnets, arranged rotationally symmetrically about the central axis (AX) of the rotor, and has a plurality of vertical walls (42) extending in the axial direction.

[0108] (Technical thought 2) The axial gap type rotating electric machine according to Technical Idea 1, wherein the vertical walls are radially arranged so that each of the vertical walls extends along a radial direction.

[0109] (Technical Thought 3) The support plate is an inner core (40) having a plurality of the vertical walls; The axial gap type rotating electric machine according to Technical Idea 1 or 2 further comprises an end plate (30) joined to at least one end surface of the inner core.

[0110] (Technical Thought 4) An axial gap type rotating electric machine according to any one of technical ideas 1-3, wherein the plurality of vertical walls include a plurality of radial vertical walls (42a, 242a, 342a, 442a, 542a, 542b, 642a, 642c, 742d, 742e, 742f, 842g, 942g, A42g, B42g, C42g) extending along the radial direction RD.

[0111] (Technical Thought 5) The axial gap type rotating electric machine according to Technical Idea 4, wherein the plurality of vertical walls include only the plurality of radial vertical walls (42a, 242a, 342a, 442a, 542a, 542b, 642a, 642c, 742d, 742e, 742f).

[0112] (Technical Thought 6) The axial gap type rotating electric machine according to Technical Idea 5, wherein the inner core includes a plurality of cylindrical bodies (41) arranged radially along the circumferential direction.

[0113] (Technical Thought 7) The vertical walls include A plurality of the radial vertical walls (42a, 242a, 342a, 442a, 542a, 542b, 642a, 642c, 742d, 742e, 742f); The axial gap type rotating electric machine according to Technical Idea 4 is provided with a plurality of intersecting vertical walls (842h, 942i, A42i, B42h, B42i, C42h) extending in a direction intersecting the radial vertical wall.

[0114] (Technical Thought 8) The inner core is In a cross section perpendicular to a central axis (AX), a plurality of N-sided cells (848, 948, A48, B48, C48), where N is a natural number of 3 or more, are partitioned by the plurality of vertical walls, and The axial gap type rotating electric machine according to Technical Idea 4 or Technical Idea 7, wherein at least one of the vertical walls that divide the cells is the radial vertical wall (842g, 942g, A42g, B42g, C42g).

[0115] (Technical Thought 9) The axial gap type rotating electric machine according to technical idea 8, wherein the plurality of cells include hexagonal cells (848, C48).

[0116] (Technical Thought 10) In the method for manufacturing an axial gap type rotating electric machine according to any one of Technical Ideas 1 to 9, assembling the support plate; connecting the support plate and the permanent magnet to assemble the rotor; and assembling the rotor and the stator to face each other across the axial gap as a rotating electric machine. The step of assembling the support plate includes: a lamination step of laminating a plurality of strips (D46) so as to be bonded by a plurality of bonding layers (D47); an unfolding step of unfolding the plurality of strips from the laminated body obtained in the lamination step in a circumferential direction (CD) while bending the strips to form an annular inner core (40); and joining the inner core and an end plate (30). [Explanation of symbols]

[0117] 1 electric device, 2 rotating electric machine, 3 rotating equipment, 4 shaft, 5 control device, 6 rotor, 6a first rotor, 6b second rotor, 7 stator, 8 coil, 10, 11, 12 support plate, 20,21,22 permanent magnet, 20a, 20b magnetic pole, 20c protective member; 20d outer end; 20e inner end; 30 end plate, 31 first plate, 32 second plate, 40 inner core, 41 cylindrical body, 42 vertical wall, 43 horizontal wall, 44 end wall, AD axial direction, RD radial direction, CD circumferential direction, AX central axis, G41 spacing, TH thickness, 242 Vertical wall, 341 plate-like member, 342 vertical wall, 343 horizontal wall, 441 Band, 442 Vertical wall, 443 Horizontal wall, 541 wall member, 542a long vertical wall, 542b inner short vertical wall, 641 wall member, 642a long vertical wall, 642b outer short vertical wall, 741 Wall member, 742d Inner short vertical wall, 742e Outer short vertical wall, 742f medium and short vertical wall, 745 inner group, 746 outer group, 747 middle group, 841 wall member, 842g diameter vertical wall, 842h cross vertical wall, 848 cell, 941 wall member, 942g diameter vertical wall, 942i peripheral vertical wall, 948 cell, A41 wall member, A42g diameter vertical wall, A42i peripheral vertical wall, A48 cell, B41 wall member, B42g diameter vertical wall, B42h peripheral vertical wall, B48 cell, C41 wall member, C42g diameter vertical wall, C48 cell, SP spiral wire, D46 strip, D47 bonding layer, WD width, LG spacing.

Claims

1. The rotor (6) is magnetically coupled to a stator (7) through an axial gap in the axial direction. The rotor is A permanent magnet (20) disposed facing the axial gap; A support plate (10) arranged behind the permanent magnet; The support plate is located behind the permanent magnet, is rotationally symmetric with respect to the central axis (AX) of the rotor, and has a plurality of vertical walls (42) extending in the axial direction; The vertical walls are arranged radially such that each of the vertical walls extends along a radial direction (RD), The support plate is an inner core (40) having a plurality of the vertical walls; and an end plate (30) joined to at least one end face of the inner core.

2. The axial gap type rotating electric machine according to claim 1, wherein the plurality of vertical walls include a plurality of radial vertical walls (42a, 242a, 342a, 442a, 542a, 542b, 642a, 642c, 742d, 742e, 742f, 842g, 942g, A42g, B42g, C42g) extending along the radial direction.

3. The axial gap type rotating electric machine according to claim 2 , wherein the plurality of vertical walls include only the plurality of radial vertical walls (42 a, 242 a, 342 a, 442 a, 542 a, 542 b, 642 a, 642 c, 742 d, 742 e, 742 f).

4. 4. The axial gap type rotating electric machine according to claim 3, wherein the inner core comprises a plurality of cylindrical bodies (41) arranged radially along a circumferential direction.

5. The vertical walls include A plurality of the radial vertical walls (42a, 242a, 342a, 442a, 542a, 542b, 642a, 642c, 742d, 742e, 742f); The axial gap type rotating electric machine according to claim 2, further comprising a plurality of intersecting vertical walls (842h, 942i, A42i, B42h, B42i, C42h) extending in a direction intersecting the radial vertical wall.

6. The inner core is In a cross section perpendicular to the central axis (AX), a plurality of N-sided cells (848, 948, A48, B48, C48), where N is a natural number of 3 or more, are partitioned by a plurality of vertical walls, 3. The axial gap type rotating electric machine according to claim 2, wherein at least one of the vertical walls that divide the cells is the radial vertical wall (842g, 942g, A42g, B42g, C42g).

7. The axial gap type rotating electric machine according to claim 6 , wherein the plurality of cells include hexagonal cells (848, C48).

8. The inner core comprises a plate-like member (341), The plate-like member is an annular member, The plate-like member has a shape in which a horizontal wall (343), the vertical wall (342), another horizontal wall (343), and another vertical wall (342) are repeated in sequence along a circumferential direction (CD), The axial gap type rotating electric machine according to claim 1 , wherein the lateral wall is disposed parallel to and joined to the end plate.

9. The method for manufacturing an axial gap type rotating electric machine according to any one of claims 1 to 7, assembling the support plate; connecting the support plate and the permanent magnet to assemble the rotor; and assembling the rotor and the stator to face each other across the axial gap as a rotating electric machine. The step of assembling the support plate includes: a lamination step of laminating a plurality of strips (D46) so as to be bonded by a plurality of bonding layers (D47); an unfolding step of unfolding the plurality of strips from the laminated body obtained in the lamination step in a circumferential direction (CD) while bending the strips to form the annular inner core (40); and joining the inner core and the end plate (30).

10. A rotor (6) and a stator (7) that are magnetically coupled to each other at an axial gap in the axial direction, The rotor is A permanent magnet (20) disposed facing the axial gap; A support plate (10) arranged behind the permanent magnet; In a manufacturing method of an axial gap type rotating electric machine, the support plate is located behind the permanent magnet, is arranged rotationally symmetrically with respect to a central axis (AX) of the rotor, and includes a plurality of vertical walls (42) extending in the axial direction, assembling the support plate; connecting the support plate and the permanent magnet to assemble the rotor; and assembling the rotor and the stator to face each other across the axial gap as a rotating electric machine. The step of assembling the support plate includes: a lamination step of laminating a plurality of strips (D46) so as to be bonded by a plurality of bonding layers (D47); an unfolding step of unfolding the plurality of strips from the laminated body obtained by the lamination step in a circumferential direction (CD) while bending the strips to form an annular inner core (40); and joining the inner core and an end plate (30).

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