Motor core manufacturing method, motor core, and motor including the motor core

Abstract

To provide a motor core and a motor equipped with the motor core which can effectively cool a coil.SOLUTION: In a preparation step, through holes are formed on first electromagnetic steel plates as at least a part of a plurality of electromagnetic steel plates 100, and coating layers 38 which cover the surfaces of the plurality of electromagnetic steel plates 100 are formed. In lamination step S4, by lamination of the plurality of electromagnetic steel plates 100, the through holes of the first electromagnetic steel plates communicate with one another and a cooling flow channel 34 on which a cooling medium can circulate is formed. In adhesion step S6, the electromagnetic steel plates 100 adjacent to each other are adhered by using the coating layers 38, and intervals between the electromagnetic steel plates 100 adjacent to each other are sealed by the coating layers 38.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a motor core manufacturing method and a motor equipped with the motor core. [Background technology]

[0002] Conventionally, techniques for manufacturing a motor core and a motor equipped with a motor core have been publicly known, as described in Patent Document 1, for example.

[0003] Patent Document 1 describes a motor that can cool a coil by injecting oil toward the coil. Specifically, the motor described in Patent Document 1 has an annular circumferential oil passage formed on the inner side surface of the housing, extending along the circumferential direction of the motor. Furthermore, a member (oil passage cover) that covers the circumferential oil passage is formed with a plurality of injection holes that inject oil flowing through the circumferential oil passage toward the coil. With this configuration, the oil flowing through the circumferential oil passage is discharged from the plurality of injection holes toward the coil, thereby cooling the coil.

[0004] However, the technology described in Patent Document 1 is configured to indirectly cool the coil from the outside, and is therefore insufficient to cool the motor core wound around the coil. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 5347380 Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a motor core that can be effectively cooled and a motor equipped with the motor core. [Means for solving the problem]

[0007] The problem to be solved by the present invention is as described above, and the means for solving this problem will now be described.

[0008] That is, claim 1 provides a method for manufacturing a motor core, comprising a preparation step of preparing a plurality of electromagnetic steel sheets, a lamination step of laminating the prepared plurality of electromagnetic steel sheets, and a bonding step of bonding the laminated plurality of electromagnetic steel sheets, wherein in the preparation step, through holes are formed in first electromagnetic steel sheets which are at least some of the plurality of electromagnetic steel sheets, and a coating layer is formed to cover the surfaces of the plurality of electromagnetic steel sheets, and in the lamination step, by laminating the plurality of electromagnetic steel sheets, the through holes of the first electromagnetic steel sheets are connected to each other, thereby forming cooling channels through which a cooling medium can flow, and in the bonding step, adjacent electromagnetic steel sheets are bonded together using the coating layer, and the adjacent electromagnetic steel sheets are sealed by the coating layer. The plurality of laminated electromagnetic steel sheets have a main body portion formed in an annular shape when viewed in the axial direction of the motor core, and a plurality of protruding pieces protruding radially inward or radially outward from the main body portion in a comb-teeth shape, and the cooling flow passages include circulation flow passages formed in the plurality of protruding pieces and circulating inside the protruding pieces, and connection flow passages formed in the main body portion and connecting the circulation flow passages adjacent to each other. It is something.

[0009] In claim 2, A method for manufacturing a motor core, comprising: a preparation step of preparing a plurality of electromagnetic steel sheets; a lamination step of stacking the prepared plurality of electromagnetic steel sheets; and a bonding step of bonding the stacked plurality of electromagnetic steel sheets, wherein in the preparation step, through holes are formed in first electromagnetic steel sheets, which are at least some of the plurality of electromagnetic steel sheets, and coating layers are formed to cover the surfaces of the plurality of electromagnetic steel sheets; in the lamination step, by stacking the plurality of electromagnetic steel sheets, the through holes of the first electromagnetic steel sheets are connected to each other, forming cooling channels through which a coolant can flow; in the bonding step, adjacent electromagnetic steel sheets are bonded together using the coating layer, and the coating layer seals the adjacent electromagnetic steel sheets; and in the bonding step, the adjacent electromagnetic steel sheets are vulcanization-bonded together by the coating layer. It is something.

[0010] In claim 3, In the lamination step, second electromagnetic steel sheets different from the first electromagnetic steel sheets among the plurality of electromagnetic steel sheets are laminated so as to sandwich the first electromagnetic steel sheets from both axial sides of the motor core. It is something.

[0011] In the fourth aspect of the present invention, in the preparation step, the coating layer is applied to the surfaces of the plurality of electromagnetic steel sheets.

[0012] In claim 5, in the preparation step, the coating layer is formed to a thickness of 25 microns or less.

[0013] In claim 6, A motor core comprising a plurality of stacked electromagnetic steel plates, the motor core comprising: a cooling flow path formed by interconnecting through holes of at least some of the plurality of electromagnetic steel plates, through which a coolant can flow, and a coating layer that seals the spaces between the adjacent electromagnetic steel plates by bonding the adjacent electromagnetic steel plates together; wherein the stacked electromagnetic steel plates have a main body portion formed in an annular shape when viewed in the axial direction of the motor core, and a plurality of protruding pieces that protrude radially inward or radially outward in a comb-teeth shape from the main body portion; and the cooling flow path includes circulation flow paths formed in the plurality of protruding pieces and that circulate inside the protruding pieces, and connection flow paths formed in the main body portion and that connect adjacent circulation flow paths. It is something.

[0014] According to claim 7, there is provided a motor core having a plurality of laminated electromagnetic steel sheets, the motor core comprising: a cooling flow path formed by connecting through holes of at least some of the plurality of electromagnetic steel sheets to each other, through which a cooling medium can flow; and a coating layer that bonds the adjacent electromagnetic steel sheets together to seal the spaces between the adjacent electromagnetic steel sheets. The adjacent magnetic steel sheets are bonded by the coating layer. It is something.

[0015] In claim 8, claim 1 or claim 2 A motor core manufactured by the motor core manufacturing method described in Or claim 6 or The motor comprises the motor core according to claim 7. [Effects of the Invention]

[0016] The present invention has the following effects.

[0017] In the present invention, the motor core can be cooled effectively. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a schematic cross-sectional side view of a motor including a motor core according to an embodiment of the present invention; [Figure 2] FIG. [Figure 3] FIG. [Figure 4] 4 is a flowchart showing a method for manufacturing a motor core. [Figure 5] 1A is a front view showing the first electromagnetic steel sheet, and FIG. 1B is a perspective view showing the first block and the seventh block in which the first electromagnetic steel sheets are stacked. [Figure 6] 1A is a front view showing the second electromagnetic steel sheet, and FIG. 1B is a perspective view showing a second block in which the second electromagnetic steel sheets are stacked. [Figure 7] 10(a) is a front view showing the third electromagnetic steel sheet, and FIG. 10(b) is a perspective view showing a third block in which the third electromagnetic steel sheets are stacked. [Figure 8] 10(a) is a front view showing a fourth electromagnetic steel sheet, and FIG. 10(b) is a perspective view showing a fourth block in which the fourth electromagnetic steel sheets are stacked. [Figure 9] 10(a) is a front view showing the fifth electromagnetic steel sheet, and FIG. 10(b) is a perspective view showing a fifth block in which the fifth electromagnetic steel sheets are stacked. [Figure 10] 10(a) is a front view showing the sixth electromagnetic steel sheet, and FIG. 10(b) is a perspective view showing a sixth block in which the sixth electromagnetic steel sheets are stacked. [Figure 11] (a) is a cross-sectional view showing a state in which a coating layer is formed on an electromagnetic steel sheet, and (b) is a cross-sectional view showing a state in which electromagnetic steel sheets are stacked. [Figure 12] FIG. 2 is a perspective view showing the overall configuration of a cooling flow path. [Figure 13] FIG. 3 is an enlarged front view of the cooling flow path and a portion thereof. [Figure 14] 13(a) is a perspective view showing how cooling water flows in an enlarged part of FIG. 13(b), and FIG. 13(b) is a view showing a cutout portion that constitutes the cooling flow path in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0019] In the following description, the directions indicated by arrows U, D, F, B, L, and R in the drawings are defined as the upward, downward, forward, backward, leftward, and rightward directions, respectively. Note that in each drawing, the size and shape of each component are exaggerated or reduced for the sake of convenience.

[0020] First, the outline of the configuration of a motor 1 equipped with a motor core 3 according to a first embodiment of the present invention will be described with reference to FIGS.

[0021] The motor 1 according to this embodiment is used in a drive device for an automobile (such as a hybrid automobile (HV) or an electric automobile (EV)). The motor 1 mainly includes a housing 2, a motor core 3, a coil 4, a rotor 5, and a rotating shaft 6.

[0022] The housing 2 accommodates other components (such as the motor core 3) that make up the motor 1. The motor core 3 is fixed inside the housing 2. As shown in FIG. 2, the motor core 3 is formed in a substantially cylindrical shape. The motor core 3 is arranged with its axis oriented in the front-to-rear direction. A coil 4 is formed around the motor core 3 by winding a conductive wire. The coil 4 is formed in a cylindrical shape concentric with the motor core 3. The front and rear ends of the coil 4 are arranged to protrude from the front and rear ends of the motor core 3, respectively.

[0023] The rotor 5 is formed in a substantially cylindrical shape. The rotor 5 is disposed inside the motor core 3. The rotor 5 is disposed with its axis oriented in the front-to-rear direction. The rotating shaft 6 is disposed with its axis oriented in the front-to-rear direction and passing through the center of the rotor 5. The rotating shaft 6 is rotatably disposed in the housing 2 via a bearing. The rotor 5 and the rotating shaft 6 are disposed coaxially (concentrically) with the motor core 3 and the coil 4.

[0024] In the motor 1 configured as described above, when the coil 4 is energized, a magnetic field is generated in the motor core 3. When a magnetic field is generated in the motor core 3, the magnetic field generates a rotational force in the rotor 5, causing the rotor 5 and the rotating shaft 6 to rotate.

[0025] Furthermore, when the coil 4 is energized, the coil 4 generates heat due to internal resistance, and the motor core 3 wound around the coil 4 also becomes hot. In this embodiment, the motor core 3 has a cooling structure, which cools the motor core 3 (and thus the coil 4) and prevents problems (such as a decrease in efficiency) from occurring.

[0026] The configuration of the motor core 3 will be described in detail below with reference to FIGS.

[0027] The motor core 3 is formed by stacking a plurality of substantially annular electromagnetic steel sheets 100 (see FIG. 5, etc.) in the axial direction. As will be described later, the plurality of electromagnetic steel sheets 100 of the motor core 3 can be conveniently divided into a plurality of blocks in the axial direction, and therefore, in FIG. 2, the boundary lines between the blocks are shown. In addition, in FIG. 3, an exploded perspective view of each block is shown. The motor core 3 includes a back yoke portion 31, teeth portions 32, slot portions 33, and cooling channels 34.

[0028] The back yoke portion 31 is formed in a generally cylindrical shape. A fixing portion 37 that protrudes radially outward is formed on the outer peripheral surface of the back yoke portion 31. The motor core 3 is fixed to the housing 2 via the fixing portion 37. A hole that passes through the fixing portion 37 in the axial direction is formed in the fixing portion 37, and a bolt (not shown) for fastening the motor core 3 is inserted through the hole.

[0029] The teeth 32 protrude radially inward from the inner circumferential surface of the back yoke portion 31. A plurality of teeth 32 are provided and are formed at equal intervals in the circumferential direction.

[0030] The slots 33 are formed between the teeth 32 adjacent to each other in the circumferential direction. The conductor wire is inserted into the slots 33. In this manner, the conductor wire inserted into the slots 33 is wound around the teeth 32, thereby forming the coil 4.

[0031] The cooling flow passage 34 is a flow passage for a coolant (water in this embodiment) for cooling the motor core 3. As shown in FIG. 3, the cooling flow passage 34 is formed inside the motor core 3 by a through-hole that penetrates each block in the axial direction. A water inlet 35 to the cooling flow passage 34 and a water outlet 36 from the cooling flow passage 34 are formed on the outer peripheral surface of the motor core 3 (in this embodiment, the outer peripheral surface facing upward on the axial front side). The configuration of the cooling flow passage 34 will be described in detail later.

[0032] A method for manufacturing the motor core 3 will be described below with reference to FIGS.

[0033] In this embodiment, the manufacturing method of the motor core 3 includes a steel plate punching step S1, a coating step S2, a drying step S3, a laminating step S4, a pressing step S5, a bonding step S6, and a vertical welding step S7.

[0034] As shown in FIG. 4, in the manufacturing method of the motor 1, a steel plate punching step S1 is first performed. The steel plate punching step S1 is a step of punching out an electromagnetic steel plate, which is a type of soft magnetic material. In the steel plate punching step S1, for example, a coil material is prepared, and an electromagnetic steel plate is unwound from the coil material, and then a plurality of parts (hereinafter referred to as "electromagnetic steel plates 100") having a predetermined shape are formed by blanking or pressing. The electromagnetic steel plates 100 are formed into a substantially annular shape (see FIG. 5, etc.).

[0035] In this embodiment, a plurality of (six types in this embodiment) electromagnetic steel sheets 100 with different shapes are formed. The six types of electromagnetic steel sheets 100 have the same external shape, but are formed so that the configurations (shapes and arrangements) of the through holes (cutout portions) that penetrate through them in the thickness direction are different from each other, as will be described later. Note that below, the six types of electromagnetic steel sheets 100 may be referred to as the "first electromagnetic steel sheet 110," "second electromagnetic steel sheet 120," "third electromagnetic steel sheet 130," "fourth electromagnetic steel sheet 140," "fifth electromagnetic steel sheet 150," and "sixth electromagnetic steel sheet 160," respectively.

[0036] 5(a) is formed in a plurality (eight in this embodiment). The first electromagnetic steel sheet 110 includes a first bolt fixing portion 111, a first inner peripheral cutout portion 112, a first main body portion 118, and a first protruding piece portion 119.

[0037] The first bolt fixing portions 111 are formed on the outer periphery so as to bulge outward in the radial direction. Three first bolt fixing portions 111 are provided, and are formed so as to be equally spaced from one another in the circumferential direction. Each first bolt fixing portion 111 has a through-hole (bolt fixing hole) formed therein that penetrates in the thickness direction.

[0038] The first inner peripheral cutouts 112 are formed in the inner peripheral portion so as to penetrate in the thickness direction and extend radially outward. A plurality of first inner peripheral cutouts 112 are provided and are formed so as to be equally spaced from one another in the circumferential direction.

[0039] The first main body portion 118 is a portion of the first electromagnetic steel sheet 110 that is radially outward of the first inner peripheral cutout portion 112. The first main body portion 118 is formed in an annular shape in the thickness direction.

[0040] The first protruding piece 119 is a portion of the first electromagnetic steel sheet 110 that protrudes radially inward from the first main body portion 118. A plurality of first protruding pieces 119 are provided, and thus the first protruding piece 119 is formed in a comb-like shape as a whole. The first protruding piece 119 is formed between the first inner peripheral cutout portions 112 that are adjacent to each other in the circumferential direction.

[0041] 6(a) is formed in a plurality (ten in this embodiment). The second electromagnetic steel sheet 120 includes a second bolt fixing portion 121, a second inner peripheral cutout portion 122, a second arch-shaped cutout portion 123, a second main body portion 128, and a second protruding piece portion 129.

[0042] The second bolt fixing portion 121, the second inner peripheral notch portion 122, the second main body portion 128 and the second protrusion portion 129 are configured in the same manner as the first bolt fixing portion 111, the first inner peripheral notch portion 112, the first main body portion 118 and the first protrusion portion 119 of the first electromagnetic steel sheet 110, respectively, and therefore their description will be omitted.

[0043] The second arch-shaped cutout 123 penetrates in the thickness direction and is formed in an arch shape that is open radially inward when viewed from the front. The second arch-shaped cutout 123 does not communicate with the outer periphery or inner periphery of the second electromagnetic steel sheet 120. The radially inner end of the second arch-shaped cutout 123 is formed near the inner periphery of the second electromagnetic steel sheet 120.

[0044] The second arch-shaped cutout 123 has second leg portions 123a formed in second protruding pieces 129 adjacent to each other in the circumferential direction, and second connecting portions 123b formed in the second main body portion 128 so as to connect the radially outer ends of the two second leg portions 123a. Thus, the second arch-shaped cutout 123 is formed so as to straddle one second inner peripheral cutout 122 inward in the thickness direction. A plurality of second arch-shaped cutouts 123 are provided, and are formed so as to be equally spaced from each other in the circumferential direction, except for the uppermost portion of the second electromagnetic steel sheet 120. The second arch-shaped cutout 123 is formed so as to straddle every other second inner peripheral cutout 122 among the plurality of second inner peripheral cutouts 122 arranged in the circumferential direction.

[0045] 7(a) is formed in a plurality (ten in this embodiment). The third electromagnetic steel sheet 130 includes a third bolt fixing portion 131, a third inner peripheral cutout portion 132, a third arch-shaped cutout portion 133, a third outer peripheral cutout portion 134, a third main body portion 138, and a third protruding piece portion 139.

[0046] The third bolt fixing portion 131, the third inner peripheral notch 132, the third arch-shaped notch 133 (third leg portion 133a and third connecting portion 133b), the third main body portion 138 and the third protrusion portion 139 are configured in the same manner as the first bolt fixing portion 111, the first inner peripheral notch 112 of the first electromagnetic steel sheet 110, the second arch-shaped notch 123 (second leg portion 123a and second connecting portion 123b), the first main body portion 118 and the first protrusion portion 119, respectively, and therefore their description will be omitted.

[0047] The third outer peripheral cutout 134 is formed at the upper end of the third electromagnetic steel sheet 130, penetrating through in the thickness direction and extending radially inward from the outer peripheral portion. Two third outer peripheral cutouts 134 are provided, spaced apart from each other in the circumferential direction and sandwiching one third inner peripheral cutout 132. The radially inner end of the third outer peripheral cutout 134 is formed near the inner peripheral portion of the third electromagnetic steel sheet 130.

[0048] 8(a) is formed in a plurality (12 sheets in this embodiment). The fourth electromagnetic steel sheet 140 includes a fourth bolt fixing portion 141, a fourth inner peripheral cutout portion 142, a fourth arch-shaped cutout portion 143, a fourth rectangular cutout portion 145, a fourth main body portion 148, and a fourth protruding piece portion 149.

[0049] The fourth bolt fixing portion 141, the fourth inner peripheral notch 142, the fourth arch-shaped notch 143 (fourth leg portion 143a and fourth connecting portion 143b), the fourth main body portion 148 and the fourth protrusion portion 149 are configured in the same manner as the first bolt fixing portion 111, the first inner peripheral notch 112 of the first electromagnetic steel sheet 110, the second arch-shaped notch 123 (second leg portion 123a and second connecting portion 123b), the first main body portion 118 and the first protrusion portion 119 of the second electromagnetic steel sheet 120, respectively, and therefore their description will be omitted.

[0050] The fourth rectangular cutout 145 is formed in the fourth protruding piece 149. The fourth rectangular cutout 145 is formed in a generally rectangular shape that penetrates in the thickness direction and extends in the radial direction. The fourth rectangular cutout 145 does not communicate with the inner periphery and outer periphery of the fourth electromagnetic steel sheet 140. Two fourth rectangular cutouts 145 are provided, and are formed in two fourth protruding pieces 149 that are adjacent to each other in the circumferential direction at the top of the fourth electromagnetic steel sheet 140. The radially inner end of the fourth rectangular cutout 145 is formed in the vicinity of the inner periphery of the fourth electromagnetic steel sheet 140.

[0051] 9(a) is formed in a plurality (168 in this embodiment). The fifth electromagnetic steel sheet 150 includes a fifth bolt fixing portion 151, a fifth inner peripheral cutout portion 152, a fifth rectangular cutout portion 155, a fifth main body portion 158, and a fifth protruding piece portion 159.

[0052] The fifth bolt fixing portion 151, the fifth inner notch portion 152, the fifth main body portion 158 and the fifth protrusion portion 159 are configured in the same manner as the first bolt fixing portion 111, the first inner notch portion 112, the first main body portion 118 and the first protrusion portion 119 of the first electromagnetic steel sheet 110, respectively, and therefore their description will be omitted.

[0053] The fifth rectangular cutout 155 is configured in substantially the same manner as the fourth rectangular cutout 145 of the fourth electromagnetic steel sheet 140. Unlike the fourth rectangular cutout 145, the fifth rectangular cutout 155 is formed in all of the fifth projecting pieces 159.

[0054] 10(a) is formed in a plurality (32 in this embodiment). The sixth electromagnetic steel sheet 160 includes a sixth bolt fixing portion 161, a sixth inner peripheral cutout portion 162, a sixth arch-shaped cutout portion 163, a sixth main body portion 168, and a sixth protruding piece portion 169.

[0055] The sixth bolt fixing portion 161, the sixth inner peripheral notch portion 162, the sixth main body portion 168 and the sixth protrusion portion 169 are configured in the same manner as the first bolt fixing portion 111, the first inner peripheral notch portion 112, the first main body portion 118 and the first protrusion portion 119 of the first electromagnetic steel plate 110, respectively, and therefore their description will be omitted.

[0056] The sixth arch-shaped cutout 163 (sixth leg portion 163a and sixth connecting portion 163b) is configured in a manner generally similar to the second arch-shaped cutout 123 (second leg portion 123a and second connecting portion 123b) of the second electromagnetic steel sheet 120. Unlike the second arch-shaped cutout 123, the sixth arch-shaped cutout 163 is also provided at the uppermost portion of the sixth electromagnetic steel sheet 160. The sixth arch-shaped cutout 163 is formed so as to be out of phase with the second arch-shaped cutout 123 in the circumferential direction. Specifically, the sixth leg portion 163a of the sixth arch-shaped cutout 163 is formed at a position overlapping with the second leg portion 123a of the second arch-shaped cutout 123 in the circumferential direction, while the sixth connecting portion 163b of the sixth arch-shaped cutout 163 is formed at a position not overlapping with the second connecting portion 123b of the second arch-shaped cutout 123 in the circumferential direction.

[0057] As shown in Fig. 4, once the steel plate punching step S1 is completed, the coating step S2 is carried out. In the coating step S2, a rubber material is applied (coated) to the electromagnetic steel sheet 100 to form a coating layer 38 as shown in Fig. 11(a). In the coating step S2, coating is performed on both side surfaces in the thickness direction of the electromagnetic steel sheet 100. In this way, the coating layer 38 is formed so as to cover the surface of the electromagnetic steel sheet 100.

[0058] Various coating methods can be used, such as pre-coating, partial coating, and flow coating. In this embodiment, partial coating is used. This allows the coating layer 38 to be formed with as thin and uniform a thickness as possible. In this embodiment, the coating layer 38 is formed to a thickness of 25 microns or less. Preferably, the coating layer 38 is formed to a thickness of 15 microns or less. More preferably, the coating layer 38 is formed to a thickness of 5 microns or less. The rubber material used is one that is insulating and elastically deformable. This allows the rubber material to elastically deform, thereby suppressing noise caused by vibration of the motor 1. In this way, various rubber materials, such as fluorine-based and nitrile-based rubbers, can be used.

[0059] In the coating step S2, the electromagnetic steel sheet 100 is cleaned as a pretreatment for coating. After cleaning the electromagnetic steel sheet 100, for example, a chemical conversion treatment may be performed on both sides of the electromagnetic steel sheet 100 in the thickness direction, or a primer may be applied after the chemical conversion treatment, in order to increase the adhesion between the electromagnetic steel sheet 100 and the coating layer 38. In the coating step S2, the coating may be performed on only one side of the electromagnetic steel sheet 100, rather than on both sides.

[0060] After the coating step S2 is completed, the drying step S3 is carried out. The drying step S3 is a step of drying the coating layer 38 formed in the coating step S2. In the drying step S3, the coating layer 38 is dried while the electrical steel sheet 100 is left to stand.

[0061] As shown in FIG. 4 , after the drying step S3 is completed, the laminating step S4 is performed. The laminating step is a step of stacking electromagnetic steel sheets 100. In the laminating step, a predetermined number of electromagnetic steel sheets 100 are stacked to assemble the motor core 3. Herein, in the motor core 3 according to the present embodiment, six types of electromagnetic steel sheets 100 are stacked in a predetermined order and in a predetermined number, and for convenience, the motor core 3 is roughly divided into seven blocks in the laminating direction, as shown in FIGS. 2 and 3 . Hereinafter, the multiple blocks arranged in order from the front side to the rear side in the laminating direction may be referred to as a "first block 100B," a "second block 120B," a "third block 130B," a "fourth block 140B," a "fifth block 150B," a "sixth block 160B," and a "seventh block 170B," respectively.

[0062] As shown in FIG. 5(b), the first block 100B and the seventh block 170B are formed by stacking first electromagnetic steel sheets 110. In this embodiment, the first block 100B and the seventh block 170B are each formed by stacking four first electromagnetic steel sheets 110. In this manner, the first block 100B and the seventh block 170B are each formed to a thickness of, for example, 1 mm. In the first block 100B, the first bolt fixing portion 111, the first inner peripheral cutout portion 112, the first main body portion 118, and the first protruding piece portion 119 are overlapped in the stacking direction.

[0063] As shown in FIG. 6(b), the second block 120B is formed by stacking second electromagnetic steel sheets 120. In this embodiment, the second block 120B is formed by stacking ten second electromagnetic steel sheets 120. In this way, the thickness of the second block 120B is formed to be, for example, 2.5 mm. In the second block 120B, the second bolt fixing portion 121, the second inner peripheral cutout portion 122, the second arch-shaped cutout portion 123, the second main body portion 128, and the second protruding piece portion 129 are overlapped in the stacking direction.

[0064] As shown in FIG. 7(b), the third block 130B is formed by stacking third electromagnetic steel sheets 130. In this embodiment, the third block 130B is formed by stacking ten third electromagnetic steel sheets 130. In this way, the thickness of the third block 130B is formed to be, for example, 2.5 mm. In the third block 130B, the third bolt fixing portion 131, the third inner peripheral cutout portion 132, the third arch-shaped cutout portion 133, the third outer peripheral cutout portion 134, the third main body portion 138, and the third protruding piece portion 139 are overlapped in the stacking direction.

[0065] As shown in FIG. 8(b), the fourth block 140B is formed by stacking fourth electromagnetic steel sheets 140. In this embodiment, the fourth block 140B is formed by stacking twelve fourth electromagnetic steel sheets 140. In this manner, the fourth block 140B is formed to have a thickness of, for example, 3 mm. In the fourth block 140B, the fourth bolt fixing portion 141, the fourth inner peripheral cutout portion 142, the fourth arch-shaped cutout portion 143, the fourth rectangular cutout portion 145, the fourth main body portion 148, and the fourth protruding piece portion 149 are overlapped in the stacking direction.

[0066] As shown in FIG. 9(b), the fifth block 150B is formed by stacking fifth electromagnetic steel sheets 150. In this embodiment, the fifth block 150B is formed by stacking 168 fifth electromagnetic steel sheets 150. In this manner, the fifth block 150B is formed to have a thickness of, for example, 42 mm. In the fifth block 150B, the fifth bolt fixing portion 151, the fifth inner peripheral cutout portion 152, the fifth rectangular cutout portion 155, the fifth main body portion 158, and the fifth protruding piece portion 159 are overlapped in the stacking direction.

[0067] As shown in FIG. 10(b), the sixth block 160B is formed by stacking sixth electromagnetic steel sheets 160. In this embodiment, the sixth block 160B is formed by stacking 32 sixth electromagnetic steel sheets 160. In this way, the sixth block 160B is formed to a thickness of, for example, 8 mm. In the sixth block 160B, the sixth bolt fixing portion 161, the sixth inner peripheral cutout portion 162, the sixth arch-shaped cutout portion 163, the sixth main body portion 168, and the sixth protruding piece portion 169 are overlapped in the stacking direction.

[0068] When the motor core 3 is assembled in this manner, the overlapping portions of each block in the stacking direction form the back yoke portion 31, teeth 32, slots 33, and cooling channels 34 of the motor core 3. Specifically, the overlapping portions of the main body portions 118, 128, 138, 148, 158, and 168 of each block form the back yoke portion 31. The overlapping portions of the bolt fixing portions 111, 121, 131, 141, 151, and 161 form the fixing portion 37.

[0069] The overlapping portions of the protruding pieces 119, 129, 139, 149, 159, and 169 of the blocks assemble the teeth portion 32. The overlapping portions of the inner cutouts 112, 122, 132, 142, 152, and 162 of the blocks assemble the slot portion 33.

[0070] Additionally, the overlapping portions of the arch-shaped notches 123, 133, 143, and 163, the outer peripheral notch 134, and the rectangular notches 145 and 155 of each block are connected to each other to form the cooling flow passage 34. The configuration of the cooling flow passage 34 will be described in detail later.

[0071] As shown in Fig. 4, once the stacking step S4 is completed, the pressing step S5 is carried out. The pressing step S5 is a step in which the entire stacked electromagnetic steel sheets 100 (from the first block 100B to the seventh block 170B) are pressed in the stacking direction. In the pressing step S5, for example, a predetermined clamp is used, and the entire stacked electromagnetic steel sheets 100 are pressed inward in the stacking direction. In this embodiment, as described above, the film thickness of the coating layer 38 is formed to be 25 microns or less (i.e., relatively thin). Therefore, even when the stacked electromagnetic steel sheets 100 are pressed, the coating layer 38 is configured to be less likely to protrude from between the electromagnetic steel sheets 100.

[0072] As shown in FIG. 4, after the pressurizing step S5, the bonding step S6 is performed. The bonding step S6 is a step of bonding adjacent electromagnetic steel sheets 100 in the stacking direction. The bonding step S6 is performed in a state where the entire stacked electromagnetic steel sheets 100 are pressurized. In the present embodiment, in the bonding step S6, adjacent electromagnetic steel sheets 100 are bonded by vulcanization bonding using the coating layer 38. As a result, as shown in FIG. 11(b), the adjacent pressed electromagnetic steel sheets 100 are joined in a tightly contacted state, and the entire stacked electromagnetic steel sheets 100 (from the first block 100B to the seventh block 170B) are integrally formed. In the bonding step S6, the coating layer 38 is used as an adhesive, so that the entire surface between adjacent electromagnetic steel sheets 100 can be sealed.

[0073] As shown in Figure 4, once the bonding step S6 is complete, the vertical welding step S7 is carried out. In the vertical welding step S7, welds (not shown) extending in the lamination direction are formed on the outer periphery of the electromagnetic steel sheets 100 integrated in the bonding step S6. The welds are provided in multiple locations spaced apart from one another in the circumferential direction. This improves the strength of the motor core 3 and maintains the entire electromagnetic steel sheets 100 in a crimped state. In this way, once the bonding step S6 is complete, the motor core 3 is completed.

[0074] The configuration of the cooling flow path 34 will be described in detail below with reference to FIGS. 3 and 12 to 14. FIG.

[0075] 3, the cooling passage 34 is formed inside the block between the first block 110B and the seventh block 170B in the motor core 3. That is, the cooling passage 34 is formed such that the first block 110B and the seventh block 170B sandwich from the front and rear a through-hole (notch) that axially penetrates the interior of the block between the first block 110B and the seventh block 170B. The cooling passage 34 is formed in a substantially cylindrical shape with its axial direction facing the front-to-rear direction. The cooling passage 34 includes a front arch-shaped passage 310, a rear arch-shaped passage 320, a main passage 330, an inlet passage 340, and an outlet passage 350.

[0076] The front arched passage 310 is a passage located at the front end of the cooling passage 34. The front arched passage 310 is formed in an arch shape that opens radially inward in a front view. The front side of the front arched passage 310 is closed by the first block 110B (see FIG. 3). As shown in FIG. 14, the front arched passage 310 is formed by the overlapping portions of the arch-shaped cutout portions 123, 133, and 143 of the second, third, and fourth blocks 120B, 130B, and 140B.

[0077] Of arch-shaped cutouts 123, 133, and 143, leg portions 123a, 133a, and 143a become flow passages formed in teeth portion 32 (hereinafter referred to as "front-side arch-shaped first flow passages 311"). Of arch-shaped cutouts 123, 133, and 143, connection portions 123b, 133b, and 143b become flow passages formed in back yoke portion 31 (hereinafter referred to as "front-side arch-shaped second flow passages 312").

[0078] The rear arched flow passage 320 is a flow passage located at the rear end of the cooling flow passage 34. The rear arched flow passage 320 is formed in an arch shape that opens radially inward in a front view. The rear side of the rear arched flow passage 320 is closed by the seventh block 170B (see FIG. 3). The rear arched flow passage 320 is formed by the overlapping portion of the sixth arched cutout portion 163 of the sixth block 160B.

[0079] Of the sixth arch-shaped cutout 163, the sixth leg 163a becomes a flow path (hereinafter referred to as the "rear-side first arch-shaped flow path 321") formed in the tooth portion 32. Of the sixth arch-shaped cutout 163, the sixth connection portion 163b becomes a flow path (hereinafter referred to as the "rear-side second arch-shaped flow path 322") formed in the back yoke portion 31.

[0080] The main flow passage 330 is a flow passage located between the front arched flow passage 310 and the rear arched flow passage 320 of the cooling flow passage 34. The main flow passage 330 is formed to connect the front arched flow passage 310 and the rear arched flow passage 320 to each other. The main flow passage 330 is formed to extend linearly in the axial direction. The main flow passage 330 is formed by the overlapping portion of the rectangular cutout portions 145 and 155 of the fourth and fifth blocks 140B and 150B (not shown).

[0081] In this way, the main flow passage 330 is formed in the vicinity of the inner circumferential surface of the motor core 3 inside all of the teeth 32. The main flow passage 330 is also formed so as to extend generally in the axial direction between the front end and the rear end of the teeth 32. Specifically, the main flow passage 330 is formed so as to extend in the axial direction among the teeth 32 formed in the blocks other than the first and seventh blocks 110B and 170B.

[0082] The front end of the main channel 330 is connected to the front arch-shaped first channel 311. The rear end of the main channel 330 is connected to the rear arch-shaped first channel 321. The front ends of the two main channels 330 located at the top of the multiple main channels 330 are connected to the inlet channel 340 and the outlet channel 350, respectively (not shown).

[0083] The introduction flow path 340 is a flow path for introducing cooling water into the cooling flow path 34. The introduction flow path 340 is formed to connect the water inlet 35 formed on the outer peripheral surface of the motor core 3 to one (left side in the figure) of the two uppermost main flow paths 330. The introduction flow path 340 is formed by the overlapping portion of one (left side in the figure) of the two outer peripheral cutout portions 134 provided in the third block 130B.

[0084] The outlet flow passage 350 is a flow passage for discharging the cooling water from the cooling flow passage 34. The outlet flow passage 350 is formed to connect the water outlet 36 formed on the outer peripheral surface of the motor core 3 to the other (right side in the figure) of the two uppermost main flow passages 330. The inlet flow passage 340 is formed by the overlapping portion of the other (right side in the figure) of the two outer peripheral cutout portions 134 provided in the third block 130B.

[0085] In this way, the cooling flow passage 34 is formed in a shape that moves back and forth (back and forth) in the circumferential direction, mainly by the front arched flow passage 310, the rear arched flow passage 320, and the main flow passage 330, and is arranged to cover all of the tooth portions 32.

[0086] Hereinafter, the manner in which the cooling water flows in the cooling flow passage 34 configured as described above will be described with reference to FIG. 14(a).

[0087] The cooling water introduced from the introduction flow path 340 is first guided rearward through the main flow path 330. Then, at the rear end of the main flow path 330, the cooling water is guided to one rear arched first flow path 321 of the rear arched flow path 320, then to the rear arched second flow path 322 and to the other rear arched first flow path 321 of the rear arched flow path 320 in that order, and then guided to the main flow path 330 shifted by one path to one circumferential side (counterclockwise). Then, the cooling water is guided forward through the main flow path 330.

[0088] Then, at the front end of main channel 330, the cooling water is guided to one front arched first channel 311 of front arched channel 310, then to front arched second channel 312 and to the other front arched first channel 311 of front arched channel 310 in that order, and then guided to main channel 330 shifted by one channel to one circumferential side (counterclockwise).The cooling water is then guided rearward through main channel 330.

[0089] In this way, the cooling water introduced from the inlet flow passage 340 is guided forward or backward through all of the teeth 32, and after being guided so as to make a substantial circuit around the motor core 3 in the axial direction, reaches the outlet flow passage 350. This allows the teeth 32 of the motor core 3, which are particularly prone to high temperatures, to be effectively cooled.

[0090] As described above, in the manufacturing method of the motor core 3 according to this embodiment, a preparation process for preparing a plurality of electromagnetic steel sheets 100 (steel sheet punching process S1, coating process S2, drying process S3); a lamination step S4 of laminating the prepared plurality of electromagnetic steel sheets 100; a bonding step S6 of bonding the stacked electromagnetic steel sheets 100 together; A manufacturing method of a motor core 3 comprising: In the preparation step, through holes (arch-shaped notches 123, 133, 143, 163, outer peripheral notch 134, rectangular notch 145, 155) are formed in first electromagnetic steel sheets (second electromagnetic steel sheet 120, third electromagnetic steel sheet 130, fourth electromagnetic steel sheet 140, fifth electromagnetic steel sheet 150, sixth electromagnetic steel sheet 160) which are at least some of the plurality of electromagnetic steel sheets 100, and a coating layer 38 is formed to cover the surfaces of the plurality of electromagnetic steel sheets 100; In the lamination step S4, By stacking the plurality of electromagnetic steel sheets 100, the through holes of the first electromagnetic steel sheet are connected to each other to form a cooling flow path 34 through which a cooling medium can flow, In the bonding step S6, The adjacent magnetic steel sheets 100 are bonded together using the coating layer 38, and the coating layer 38 seals the gap between the adjacent magnetic steel sheets 100.

[0091] The motor core 3 manufactured with this configuration can be effectively cooled from the inside by using the cooling flow passages 34 formed by laminating a plurality of electromagnetic steel plates 100. Furthermore, in this embodiment, adjacent electromagnetic steel sheets 100 are bonded together using coating layer 38, and coating layer 38 seals the gap between adjacent electromagnetic steel sheets 100, thereby preventing the cooling medium flowing through cooling flow passage 34 from leaking to the outside of motor core 3. In this way, the cooling medium does not splash from motor core 3 into the interior of motor 1, thereby avoiding, for example, friction loss due to splashed cooling medium.

[0092] In addition, in the manufacturing method of the motor core 3, In the lamination step S4, Of the plurality of electromagnetic steel sheets 100, second electromagnetic steel sheets (first electromagnetic steel sheets 110) different from the first electromagnetic steel sheets are stacked on both axial sides of the motor core 3 so as to sandwich the first electromagnetic steel sheets.

[0093] With this configuration, one axial side and the other axial side of the cooling flow passage 34 can be defined by the first electromagnetic steel sheets 110 that form the motor core 3. That is, since there is no need to provide a dedicated member for partitioning the cooling flow path 34, costs can be reduced and the configuration can be simplified.

[0094] In addition, in the manufacturing method of the motor core 3, The laminated plurality of electromagnetic steel sheets 100 are a main body portion (main body portions 118 to 168) formed in an annular shape when viewed in the axial direction of the motor core 3; A plurality of protrusions (protrusions 119 to 169) protruding in a comb-teeth shape from the main body in the inner or outer diameter direction; and The cooling channel 34 is circulation channels (main channel 330, front arch-shaped first channel 311, rear arch-shaped first channel 321) formed in the plurality of protrusions and circulating inside the protrusions; a connecting flow path (front arch-shaped second flow path 312 and rear arch-shaped second flow path 322) formed in the main body portion and connecting the adjacent circulation flow paths; It includes:

[0095] With this configuration, the teeth 32 of the motor core 3, which are particularly prone to becoming hot, can be effectively cooled.

[0096] In addition, in the manufacturing method of the motor core 3, In the preparation step (coating step S2), The coating layer 38 is applied to the surfaces of the plurality of electromagnetic steel sheets 100.

[0097] With this configuration, the sealing performance of the coating layer 38 can be improved.

[0098] In addition, in the manufacturing method of the motor core 3, In the preparation step (coating step S2), The thickness of the coating layer 38 is 25 microns or less.

[0099] With this configuration, the coating layer 38 is formed to have a relatively thin thickness, so that even when the stacked magnetic steel sheets 100 are pressed, the coating layer 38 is less likely to protrude from between the magnetic steel sheets 100.

[0100] In addition, in the manufacturing method of the motor core 3, In the bonding step S6, The adjacent magnetic steel sheets 100 are bonded together by the coating layer 38 through vulcanization.

[0101] With this configuration, it is possible to effectively seal the entire surface between the adjacent magnetic steel sheets 100 .

[0102] In addition, in the motor core 3 according to this embodiment, A motor core 3 having a plurality of laminated electromagnetic steel sheets 100, a cooling flow path 34 through which a cooling medium can flow, formed by connecting through holes of at least some of the electromagnetic steel sheets 100 to each other; a coating layer 38 that seals the spaces between the adjacent magnetic steel sheets 100 by bonding the adjacent magnetic steel sheets 100 together; It is equipped with the following.

[0103] With this configuration, the motor core 3 can be effectively cooled from the inside using the cooling flow passages 34 formed by laminating a plurality of electromagnetic steel plates 100.

[0104] In addition, in the motor 1 according to this embodiment, The motor core 3 includes a motor core 3 manufactured by the method for manufacturing a motor core 3 according to any one of claims 1 to 6, or a motor core 3 according to claim 7.

[0105] With this configuration, the motor core 3 can be effectively cooled from the inside using the cooling flow passages 34 formed by laminating a plurality of electromagnetic steel plates 100.

[0106] Although the embodiment of the present invention has been described above, the present invention is not limited to the above configuration, and various modifications are possible within the scope of the invention described in the claims.

[0107] For example, in this embodiment, vulcanization bonding is used in the bonding step S6, but this is not limiting. In the bonding step S6, adjacent magnetic steel sheets 100 can be bonded together by any method.

[0108] In addition, in this embodiment, one water inlet 35 to the cooling flow passage 34 and one water outlet 36 from the cooling flow passage 34 are provided, but multiple water inlets 35 and multiple water outlets 36 may be provided (for one cooling flow passage 34). The water inlet 35 and the water outlet 36 can be formed at any location on the motor core 3. In this embodiment, only one cooling flow passage 34 is provided, but multiple water inlets 35 and multiple water outlets 36 may be provided. In this embodiment, the multiple protrusions (first protrusion portion 119, etc.) protrude radially inward, but they may protrude radially outward.

[0109] In this embodiment, the main flow passage 330 of the cooling flow passage 34 is formed so as to extend generally in the axial direction between the front end and rear end of the teeth 32 (i.e., so as to enable cooling of the entire layer), but this is not limited to this. That is, the main flow passage 330 may be formed partially in the axial direction between the front end and rear end of the teeth 32 (i.e., so as to enable cooling of a partial layer). Specifically, the main flow passage 330 may be formed only in the front or rear portion of the teeth 32. Furthermore, the main flow passage 330 may be formed only in the midpoint between the front and rear of the teeth 32.

[0110] In other words, since the cooling flow path 34 is formed by cutting out the inside of the tooth portion 32, there is a possibility that it may hinder the generation of a magnetic field. Therefore, depending on the specifications of the motor 1, a shape that allows for effective cooling without excessively hindering the generation of a magnetic field can be adopted.

[0111] The motor core according to the present invention is not limited to that of this embodiment, but may be any core used in either the rotor or stator of a motor (that is, a rotor core or a stator core). [Explanation of symbols]

[0112] 34 Cooling Channel 38 Covering layer 100 Electrical steel sheet S1 Steel plate punching process S2 coating process S3 Drying process S4 Lamination process S6 Adhesion process

Claims

1. a preparation step of preparing a plurality of electromagnetic steel sheets; a lamination step of laminating the prepared plurality of electromagnetic steel sheets; a bonding step of bonding the plurality of stacked electromagnetic steel sheets together; A method for manufacturing a motor core comprising: In the preparation step, a through hole is formed in a first electromagnetic steel sheet that is at least a part of the plurality of electromagnetic steel sheets, and a coating layer is formed to cover the surfaces of the plurality of electromagnetic steel sheets; In the lamination step, By stacking the plurality of electromagnetic steel sheets, the through holes of the first electromagnetic steel sheet are connected to each other to form a cooling flow path through which a cooling medium can flow, In the bonding step, the adjacent magnetic steel sheets are bonded together using the coating layer, and the adjacent magnetic steel sheets are sealed by the coating layer; The plurality of laminated electromagnetic steel sheets are a main body portion formed in an annular shape when viewed in the axial direction of the motor core; A plurality of protruding pieces protruding in a comb-teeth shape from the main body in an inner or outer radial direction; and The cooling channel comprises: a circulation flow path formed in the plurality of protrusions and circulating inside the protrusions; a connecting flow path formed in the main body portion and connecting adjacent circulation flow paths; Including, A manufacturing method for a motor core.

2. A preparation step of preparing a plurality of electromagnetic steel sheets; a lamination step of laminating the prepared plurality of electromagnetic steel sheets; a bonding step of bonding the plurality of stacked electromagnetic steel sheets together; A method for manufacturing a motor core comprising: In the preparation step, a through hole is formed in a first electromagnetic steel sheet that is at least a part of the plurality of electromagnetic steel sheets, and a coating layer is formed to cover the surfaces of the plurality of electromagnetic steel sheets; In the lamination step, By stacking the plurality of electromagnetic steel sheets, the through holes of the first electromagnetic steel sheet are connected to each other to form a cooling flow path through which a cooling medium can flow, In the bonding step, the adjacent magnetic steel sheets are bonded together using the coating layer, and the adjacent magnetic steel sheets are sealed by the coating layer; In the bonding step, The adjacent magnetic steel sheets are vulcanization bonded by the coating layer. A manufacturing method for a motor core.

3. In the lamination step, second electromagnetic steel sheets, which are different from the first electromagnetic steel sheets, among the plurality of electromagnetic steel sheets are stacked on both axial sides of the motor core so as to sandwich the first electromagnetic steel sheets therebetween; The method for manufacturing a motor core according to claim 1 or 2.

4. In the preparation step, The coating layer is applied to the surfaces of the plurality of electromagnetic steel sheets. The method for manufacturing a motor core according to claim 1 or 2.

5. In the preparation step, The thickness of the coating layer is formed to be 25 microns or less. The method for manufacturing a motor core according to claim 1 or 2.

6. A motor core comprising a plurality of laminated electromagnetic steel sheets, a cooling flow path through which a cooling medium can flow, the cooling flow path being formed by connecting through holes of at least some of the plurality of electromagnetic steel sheets to each other; a coating layer that bonds the adjacent magnetic steel sheets together to seal the gap between the adjacent magnetic steel sheets; Equipped with The plurality of laminated electromagnetic steel sheets are a main body portion formed in an annular shape when viewed in the axial direction of the motor core; A plurality of protruding pieces protruding in a comb-teeth shape from the main body in an inner or outer radial direction; and The cooling channel comprises: a circulation flow path formed in the plurality of protrusions and circulating inside the protrusions; a connecting flow path formed in the main body portion and connecting adjacent circulation flow paths; Including, Motor core.

7. A motor core having a plurality of laminated electromagnetic steel sheets, a cooling flow path through which a cooling medium can flow, the cooling flow path being formed by connecting through holes of at least some of the plurality of electromagnetic steel sheets to each other; a coating layer that bonds the adjacent magnetic steel sheets together to seal the gap between the adjacent magnetic steel sheets; Equipped with The adjacent magnetic steel sheets are vulcanization bonded by the coating layer. Motor core.

8. A motor core manufactured by the method for manufacturing a motor core according to claim 1 or 2, or a motor equipped with the motor core according to claim 6 or 7.

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