Core of rotary electric machine, armature, and rotary electric machine

Abstract

A stator core (26) is configured to include a magnetic powder (42) having: a powdery iron powder (44) formed using an iron-based material; and a covering part (46) that is formed using an insulating material and covers the iron powder (44). The stator core (26) is configured to include a plurality of types of magnetic powders (42A, 42B) in which at least one of the thickness and the material of the covering part (46) is different. A stator (14) is configured to include the stator core (26). Furthermore, motors (10A, 10B, 10C) are configured to include the stator (14).

Description

Rotating electric machine core, armature and rotating electric machine CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on Japanese Application No. 2024-021462 filed on February 15, 2024, the contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a core of a rotating electric machine, an armature, and a rotating electric machine.

[0003] Patent Document 1 below discloses a stator core formed using a powder magnetic core obtained by pressure-molding a soft magnetic powder, which is an aggregate of a plurality of soft magnetic particles. In the stator core described in this document, the average particle size of the soft magnetic particles located in the second portion of the stator core is larger than the average particle size of the soft magnetic particles located in the first portion. This makes it possible to make the magnetic permeability of the first portion and the second portion of the stator core different.

[0004] JP 2008-16670 A

[0005] The configuration described in Patent Document 1 is useful from the viewpoint of being able to adjust the magnetic permeability of each part of the core of a rotating electric machine, such as a stator core, but does not take into consideration adjusting the insulation of each part of the core of the rotating electric machine.

[0006] An object of the present disclosure is to provide a rotating electric machine core, an armature, and a rotating electric machine that are capable of adjusting the insulation properties of each part.

[0007] In a first aspect of the present disclosure, a core of a rotating electric machine is configured to include magnetic powder having a powdered base material formed using an iron-based material and a coating portion formed using a material that has insulating properties and has higher insulating properties than the base material and covers the base material, and the coating portion has multiple types of magnetic powder with at least one of a thickness and a material of the coating being different. Also, an armature is configured to include a rotating electric machine core having a powdered base material formed using an iron-based material and a coating portion formed using a material that has insulating properties and has higher insulating properties than the base material and covers the base material, the magnetic powder being configured to include multiple types of magnetic powder with at least one of a thickness and a material of the coating being different, and a coil arranged along the core of the rotating electric machine and generating a magnetic field when current is applied. Furthermore, the rotating electric machine is configured to include magnetic powder having a powdered base material formed using an iron-based material and a coating portion that is formed using a material that has insulating properties and is more insulating than the base material and covers the base material, and the magnetic powder is provided with a rotating electric machine core that is configured to include multiple types of magnetic powder that differ in at least one of the thickness and material of the coating portion, one of a stator and a rotor that is configured to include an armature with a coil that is arranged along the core of the rotating electric machine and generates a magnetic field when current is passed through it, and the other of the stator and rotor that has a magnet that is arranged opposite the coil and the core of the rotating electric machine.

[0008] By configuring in this manner, it is possible to appropriately adjust the insulation properties of each part of the core of the rotating electrical machine.

[0009] The above and other objects, features, and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which Fig. 1 is a perspective view of a radial gap type teethless motor, with a portion of the motor cut away, Fig. 2 is an exploded perspective view of the motor, with some components cut away, Fig. 3 is a perspective view of an axial gap type teethless motor, with a portion of the motor cut away, Fig. 4 is an exploded perspective view of the motor, with some components cut away, and Fig. 5 is a perspective view of an axial gap type teethed motor, with a portion of the motor cut away. 6 is an exploded perspective view showing the motor disassembled, with some parts cut away, FIG. 7 is a schematic diagram showing a powder magnetic core constituting the stator core of the first embodiment, FIG. 8 is a diagram showing a manufacturing process of the stator core, FIG. 9 is a diagram showing a schematic diagram of magnetic powder after the first coating, FIG. 10 is a diagram showing a schematic diagram of magnetic powder after the second coating, FIG. 11 is a diagram showing a schematic diagram of magnetic powder after the third coating, FIG. 12 is a diagram showing a first type of magnetic powder, and FIG. 13 is a diagram showing a second type of magnetic powder. 14 is a diagram showing magnetic powder produced by crushing a stator core; FIG. 15 is a perspective view showing a coil body and a stator core of the second embodiment; FIG. 16 is a plan view showing the stator core of the second embodiment with the coil body attached, as viewed from the direction of arrow S1 shown in FIG. 15; and FIG. 17 is a side cross-sectional view showing the stator core of the second embodiment with the coil body attached, as viewed from the direction of arrow S2 shown in FIG. 18 is an enlarged cross-sectional side view corresponding to FIG. 17 that schematically shows the stator core etc. of the second embodiment with the coil body attached, and shows an enlarged view of the portion surrounded by line S3 in FIG. 17; FIG. 19 is a perspective view showing the coil body, magnet, and stator core of the third embodiment; FIG. 20 is a cross-sectional side view schematically showing the stator core etc. of the third embodiment, and is a cross-sectional side view seen from the direction of arrow S4 shown in FIG. 19; and FIG. 21 is an enlarged cross-sectional side view corresponding to FIG. 20 that schematically shows the stator core etc. of the third embodiment.20 shows an enlarged view of the portion surrounded by line S5, FIG. 22 is a schematic diagram for explaining the manufacturing process of the stator core of the second embodiment, showing a step in which the first type of magnetic powder is poured into the first mold, FIG. 23 is a schematic diagram for explaining the manufacturing process of the stator core of the second embodiment, showing a step in which the first type of magnetic powder poured into the first mold is pressed, and FIG. 24 is a schematic diagram for explaining the manufacturing process of the stator core of the second embodiment, showing a step in which molding of the portion formed by the first type of magnetic powder in the stator core of the second embodiment is completed. 25 is a schematic diagram for explaining the manufacturing process of the stator core of the second embodiment, showing the step of injecting the second type of magnetic powder into the interior of a mold; FIG. 26 is a diagram for schematically showing a molded product in which a portion formed by the first type of magnetic powder and a portion formed by the second type of magnetic powder are integrated in the stator core of the second embodiment; FIG. 27 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of introducing the second type of magnetic powder into a first mold; and FIG. 28 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of introducing the second type of magnetic powder into a first mold. 29 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of putting the first type of magnetic powder into the first mold, FIG. 30 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of putting the first type of magnetic powder into the first mold together with the second type of magnetic powder, and FIG. 31 is a schematic diagram for explaining the manufacturing process of the stator core of the third embodiment, showing the step of putting the first type of magnetic powder into the first mold together with the second type of magnetic powder, and FIG. 32 is a perspective view of the stator core of the fourth embodiment as seen from the other axial side, FIG. 33 is a schematic diagram for explaining a method for inspecting magnetic permeability, FIG. 34 is a schematic diagram for explaining a method for inspecting resistivity, FIG. 35 is a schematic diagram for explaining a method for inspecting hardness, FIG. 36 is a perspective view of the stator core of the fifth embodiment as seen from one axial side, FIG. 37 is a perspective view of the stator core of the sixth embodiment as seen from the other axial side, and FIG. 38 is a perspective view of the stator core of the sixth embodiment as seen from39 is a schematic diagram for explaining the process of forming the stay core body and the inspection portion, showing the process of putting a first type of magnetic powder into a first mold, FIG. 40 is a schematic diagram for explaining the process of forming the stay core body and the inspection portion, showing the process of putting a second type of magnetic powder into a third mold, FIG. 41 is a schematic diagram for explaining the process of forming the stay core body and the inspection portion, showing the process of putting the second type of magnetic powder into the third mold, and FIG. 42 is a diagram schematically showing the stay core body and the inspection portion.

[0010] 1 to 6, the configurations of three types of motors 10A, 10B, and 10C to which the rotating electric machine core structure of the present disclosure is applied will be described. Note that the arrow Z direction, arrow R direction, and arrow C direction shown as appropriate in the figures respectively indicate one side in the rotational axis direction, the outer side in the rotational radial direction, and one side in the rotational circumferential direction of a rotor 12, which will be described later. Furthermore, hereinafter, when simply referring to the axial direction, radial direction, or circumferential direction, unless otherwise specified, this refers to the rotational axis direction, rotational radial direction, or rotational circumferential direction of the rotor 12. Furthermore, the three types of motors 10A, 10B, and 10C are examples of rotating electric machines.

[0011] (First Type of Motor 10A) As shown in Figures 1 and 2, the first type of motor 10A is a radial gap type brushless motor in which a rotor 12 as a rotor is arranged radially inside a stator 14 as an armature and a stator.

[0012] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings 20, a rotor core 24 fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the radially outer surface of the rotor core 24. The pair of bearings 20 are supported by a frame 21 and an end frame 23, respectively. The stator 14 and other components are housed between the frame 21 and the end frame 23.

[0013] The rotor core 24 includes a first cylindrical portion 24A to which the rotating shaft 22 is fixed by press-fitting or the like, and a second cylindrical portion 24B disposed radially outward of the first cylindrical portion 24A and also formed cylindrically. The outer peripheral surface, which is the radially outer surface of the second cylindrical portion 24B, is formed cylindrically along the circumferential direction. A magnet 18, which will be described later, is fixed to the outer peripheral surface of the second cylindrical portion 24B.

[0014] The magnets 18 are formed using a magnetic compound having an intrinsic coercivity Hc of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more. １１ TiN, Nd ２ Fe １４ B, Sm ２ Fe １７ N ３ The rotor core 24 is formed using a magnetic compound such as FeNi. A plurality of magnets 18 are fixed to the outer peripheral surface of the second cylindrical portion 24B of the rotor core 24. The magnets 18 whose radially outer surfaces are N poles and the magnets 18 whose radially outer surfaces are S poles are arranged alternately in the circumferential direction.

[0015] The stator 14 includes a stator core 26 formed in an annular shape as a core of a rotating electrical machine, and a coil body 32 attached to the stator core 26. The stator 14 has a teethless structure in which no part of the stator core 26 is disposed between the coils that form part of the coil body 32.

[0016] The stator core 26 is formed into a cylindrical shape using magnetic powder 42 (see FIG. 7 ), which will be described later. The stator core 26 is disposed coaxially with the rotor 12, and the axial center position of the stator core 26 coincides with the axial center position of the multiple magnets 18 fixed to the rotor core 24. Here, the radially inner surface of the stator core 26 forms a coil-facing surface 26A that is disposed radially opposite the coils, and a magnet-facing surface 26B that is disposed radially opposite the magnets 18.

[0017] (Second Type of Motor 10B) As shown in Figures 3 and 4, the motor 10B is an axial gap type brushless motor in which a rotor 12 as a rotor and a stator 14 as an armature and a stator are arranged axially opposite each other.

[0018] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings (not shown), a rotor core 24 fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the other axial surface of the rotor core 24. The pair of bearings are supported by a frame 21 and an end frame 23, respectively. The stator 14 and other components are housed between the frame 21 and the end frame 23.

[0019] The rotor core 24 includes a first cylindrical portion 24A to which the rotating shaft 22 is fixed by press-fitting or the like, and a disk portion 24B extending radially outward from one axial end of the first cylindrical portion 24A. The disk portion 24B is formed in a disk shape with its thickness oriented in the axial direction. A magnet 18, which will be described later, is fixed to the surface on the other axial side of the disk portion 24B.

[0020] The plurality of magnets 18 are formed using the same magnetic compound as in the motor 10A described above, and are fixed to the other axial surface of the disc portion 24B of the rotor core 24. The magnets 18 whose axial surface is the north pole and the magnets 18 whose axial surface is the south pole are arranged alternately in the circumferential direction.

[0021] The stator 14 includes a stator core 26 serving as a core of a rotating electrical machine formed in a disk shape with its thickness in the axial direction, and a coil body 32 arranged along one axial surface of the stator core 26. The stator 14 of this embodiment has a teethless structure in which no part of the stator core 26 is arranged between the coils 16 that form part of the coil body 32.

[0022] The stator core 26 is formed using magnetic powder 42 (see FIG. 7 ), which will be described later. The stator core 26 is formed in a plate shape with its thickness in the axial direction and is formed in an annular shape when viewed from the axial direction. The stator core 26 is arranged coaxially with the rotor 12, and the radial center position of the stator core 26 coincides with the radial center position of the multiple magnets 18 fixed to the rotor core 24. One axial surface of the stator core 26 forms a coil-facing surface 26A that faces the coil 16 in the axial direction, and a magnet-facing surface 26B that faces the magnet 18 in the axial direction.

[0023] The coil body 32 includes an annular substrate 34 formed using an insulating material, and the coil 16 formed on the substrate 34 .

[0024] 5 and 6, the configuration of the motor 10C is the same as that of the motor 10B, except for the points described below. Therefore, the same reference numerals are used to designate the components and parts of the motor 10C that correspond to those of the motor 10B, and descriptions thereof may be omitted.

[0025] 5 and 6 , the stator core 26 of the motor 10C of this embodiment includes a substrate portion 26C formed in a disk shape with its thickness in the axial direction, and teeth 26D that protrude from the substrate portion 26C toward one axial side and are equally spaced along the circumferential direction. The surface on one axial side of the substrate portion 26C forms a coil-facing surface 26A that faces the coil 16. Furthermore, the end surfaces on one axial side of each of the plurality of teeth 26D form magnet-facing surfaces 26B that face the magnets 18 in the axial direction. Furthermore, both circumferential and radial end surfaces of each of the plurality of teeth 26D form the coil-facing surfaces 26A that face the coil 16.

[0026] The coil body 32 is configured to have holes through which the teeth 26D are inserted into the coil body 32 of the motor 10B described above. The plurality of teeth 26D of the stator core 26 are arranged between the plurality of coils 16 that make up the coil body 32.

[0027] First Embodiment Next, a detailed configuration of the stator core 26 of the first embodiment will be described. The configuration of the stator core 26 of the first embodiment can be applied to the stator core 26 of each of the motors 10A, 10B, and 10C described above and the stator core 26 of other motors.

[0028] FIG. 7 schematically illustrates a powder magnetic core 40 constituting the stator core 26. The powder magnetic core 40 is formed from magnetic powder 42 molded into a predetermined shape and dimensions. The magnetic powder 42 includes iron powder 44 as a base material and a coating 46 covering the iron powder 44. The iron powder 44 is iron powder pulverized to have a particle size within a predetermined range. The coating 46 is an insulating coating formed using an inorganic material that has higher insulating properties than the iron powder 44 as the base material. The coating 46 is formed by applying a paint for forming this coating to the magnetic powder 42. Examples of materials that can be used to form the coating 46 include phosphate-based, SiO2-based (silicon dioxide-based), Al2O3-based (alumina-based), MgO-based (magnesium oxide-based), and ferrite-based materials. These materials can also be used in combination.

[0029] FIG. 8 schematically illustrates the manufacturing process of the stator core 26. To manufacture the stator core 26, first, the iron powder 44 is coated with a paint that will form the coating 46. As a result, the iron powder 44 is covered with the coating 46, forming the magnetic powder 42. Next, a predetermined amount of the magnetic powder 42 is placed in a mold and compressed, thereby molding the magnetic powder 42 into a predetermined shape and dimensions. For example, the magnetic powder 42 placed in the mold is molded into a shape and dimensions corresponding to the shape and dimensions of the stator core 26 of each of the motors 10A, 10B, and 10C described above. Next, the magnetic powder 42 molded into the predetermined shape and dimensions is heated. Here, annealing is performed as a heat treatment. Through these processes, the stator core 26 is manufactured.

[0030] Here, for magnetic powder 42 having iron powder 44 and a coating 46 covering the iron powder 44, the insulating performance of the magnetic powder 42 can be adjusted by the following method. For example, as shown in FIG. 9, magnetic powder 42 having iron powder 44 and a coating 46 covering the iron powder 44 is formed by a first painting process. Also, as shown in FIG. 10, the magnetic powder 42 that has been painted the first time is painted a second time, thereby increasing the thickness of the coating 46. Furthermore, as shown in FIG. 11, the magnetic powder 42 that has been painted the second time is painted a third time, thereby increasing the thickness of the coating 46. In this way, by increasing the thickness of the coating 46, the insulating properties of the magnetic powder 42 can be improved. In other words, by adjusting the thickness of the coating 46, the insulating performance of the magnetic powder 42 can be adjusted.

[0031] The insulating performance of the magnetic powder 42 can also be adjusted by changing the material forming the coating 46. For example, the insulating performance of the magnetic powder 42 can be improved by changing the coating 46 from an iron-based oxide film to a film containing a phosphate-based, borophosphate-based, or silicon-based material.

[0032] As described above, the insulating performance of the magnetic powder 42 can be adjusted by changing at least one of the thickness and material of the coating portion 46 .

[0033] The stator core 26 of this embodiment is formed using a first type of magnetic powder 42A shown in FIG. 12 and a second type of magnetic powder 42B shown in FIG. 13 . That is, the stator core 26 is configured to include multiple types of magnetic powder. The first type of magnetic powder 42A and the second type of magnetic powder 42B differ in the thickness of their coating portions 46. The thickness T2 of the coating portion 46 of the second type of magnetic powder 42B is thicker than the thickness T1 of the coating portion 46 of the first type of magnetic powder 42A. This results in higher insulation properties for the second type of magnetic powder 42B than for the first type of magnetic powder 42A. The first type of magnetic powder 42A corresponds to one type of magnetic powder, and the second type of magnetic powder 42B corresponds to the other type of magnetic powder.

[0034] 7 , in a stator core 26 (powder core 40) formed using magnetic powder 42 having iron powder 44 and a coating 46 that covers the iron powder 44, the insulating coating 46 that covers the iron powder 44 can reduce eddy current I when magnetic flux B from each direction is taken into the stator core 26 (powder core 40). As a result, heat generation in the stator core 26 (powder core 40) is suppressed, and loss in a motor configured including the stator core 26 (powder core 40) can be reduced.

[0035] Furthermore, the stator core 26 of this embodiment is formed using the first type of magnetic powder 42A shown in Fig. 12 and the second type of magnetic powder 42B shown in Fig. 13. Therefore, the insulating properties of the portions of the stator core 26 where the first type of magnetic powder 42A is present can be made different from the insulating properties of the portions of the stator core 26 where the second type of magnetic powder 42B is present. In other words, with the stator core 26 of this embodiment, the insulating properties of each portion of the stator core 26 can be adjusted.

[0036] Furthermore, a stator core 26 formed using magnetic powder 42 having iron powder 44 and a coating 46 covering the iron powder 44 can be recycled by the following procedure. First, the stator core 26 removed from a disassembled motor is crushed to produce magnetic powder 42C shown in FIG. 14. The thickness T3 of the coating 46 of the magnetic powder 42C formed by crushing the stator core 26 deteriorates due to damage to the coating 46 caused by crushing. That is, the thickness T3 of the coating 46 of the magnetic powder 42C formed by crushing the stator core 26 is thinner in some places than the thickness T1 of the coating 46 of the first type of magnetic powder 42A shown in FIG. 12. Therefore, the thickness of the coating 46 is increased by painting the magnetic powder 42C formed by crushing the stator core 26. Here, the thickness T3 of the coating 46 of the magnetic powder 42C is set to the same thickness as the thickness T2 of the coating 46 of the second type of magnetic powder 42B shown in FIG. 13. That is, the second type of magnetic powder 42B is manufactured from the magnetic powder 42C. In other words, the second type of magnetic powder 42B can also be called a recycled material manufactured using the magnetic powder 42C. Then, a new stator core 26 can be manufactured using the first type of magnetic powder 42A and the second type of magnetic powder 42B, which is a recycled material.

[0037] In this embodiment, the material of the coating 46 that covers the iron powder 44 is an inorganic material, which makes it unnecessary to separate organic matter from the coating 46 during the recycling process.

[0038] Second Embodiment Next, a detailed configuration of the stator core 26 of a second embodiment will be described. Note that, in the stator core 26 of the second embodiment, members and portions corresponding to those of the stator core 26 of the first embodiment described above will be denoted by the same reference numerals as those corresponding to those of the stator core 26 of the first embodiment, and descriptions thereof may be omitted.

[0039] 15 to 18 show a stator core 26 of a second embodiment having a configuration similar to that of the stator core 26 constituting a part of the motor 10C described above. As shown in these figures, in the stator core 26 of this embodiment, a surface layer 26E along the coil-facing surface 26A, which is the surface on one axial side of the substrate portion 26C, is formed of the second type of magnetic powder 42B. In addition, in the stator core 26 of this embodiment, the surface layer 26E along the coil-facing surface 26A, which is the circumferential and radial end faces of the multiple teeth 26D, is formed of the second type of magnetic powder 42B. Furthermore, in the stator core 26 of this embodiment, a portion 26F other than the surface layer 26E along the coil-facing surface 26A is formed of the first type of magnetic powder 42A.

[0040] In the stator core 26 of the present embodiment described above, the surface layer 26E along the coil-facing surface 26A is formed of the second type of magnetic powder 42B, and the portion 26F other than the surface layer 26E along the coil-facing surface 26A is formed of the first type of magnetic powder 42A. With this configuration, it is possible to improve the insulation between the coil 16 and the coil-facing surface 26A of the stator core 26 compared to a configuration in which the entire stator core 26 is formed of the first type of magnetic powder 42A.

[0041] The configuration of the stator core 26 of this embodiment can also be applied to the stator core 26 constituting a part of the motors 10A and 10B described above. In this case, as shown in Fig. 2, the surface layer 26E along the coil-facing surface 26A, which is the radially inner surface of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26E along the coil-facing surface 26A may be formed from the first type of magnetic powder 42A. Also, as shown in Fig. 4, the surface layer 26E along the coil-facing surface 26A, which is the surface on one axial side of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26E along the coil-facing surface 26A may be formed from the first type of magnetic powder 42A.

[0042] Third Embodiment Next, a detailed configuration of the stator core 26 of a third embodiment will be described. Note that, in the stator core 26 of the third embodiment, members and parts corresponding to those of the stator core 26 of each embodiment already described will be assigned the same reference numerals as those corresponding to those of the stator core 26 of each embodiment, and descriptions thereof may be omitted.

[0043] 19 to 21 show a stator core 26 of a third embodiment having a configuration similar to that of the stator core 26 constituting a part of the motor 10C described above. As shown in these figures, in the stator core 26 of this embodiment, a surface layer 26G along the magnet-facing surface 26B, which is the end face on one axial side of each of the plurality of teeth 26D, is formed from the second type of magnetic powder 42B. In addition, in the stator core 26 of this embodiment, a portion 26H other than the surface layer 26G along the magnet-facing surface 26B is formed from the first type of magnetic powder 42A.

[0044] In the stator core 26 of the present embodiment described above, the surface layer 26G along the magnet-facing surface 26B is formed of the second type of magnetic powder 42B, and the portion 26H other than the surface layer 26G along the magnet-facing surface 26B is formed of the first type of magnetic powder 42A. With this configuration, compared to a configuration in which the entire stator core 26 is formed of the first type of magnetic powder 42A, it is possible to reduce loss caused by leakage magnetic flux B of the magnet 18 interlinking with the multiple teeth 26D.

[0045] The configuration of the stator core 26 of this embodiment can also be applied to the stator core 26 that constitutes a part of the motors 10A and 10B described above. In this case, as shown in Fig. 2, the surface layer 26G that faces the magnet 26B, which is the radially inner surface of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26G that faces the magnet 26B may be formed from the first type of magnetic powder 42A. Also, as shown in Fig. 4, the surface layer 26G that faces the magnet 26B, which is the surface on one axial side of the stator core 26, may be formed from the second type of magnetic powder 42B, and the portion other than the surface layer 26G that faces the magnet 26B may be formed from the first type of magnetic powder 42A.

[0046] (Method of Manufacturing the Stator Core 26 of the Second Embodiment) Next, a method of manufacturing the stator core 26 of the second embodiment will be briefly described.

[0047] 22 to 25 schematically show a portion of equipment for manufacturing the stator core 26 of the second embodiment. As shown in these figures, the first type of magnetic powder 42A and the second type of magnetic powder 42B that form the stator core 26 of the second embodiment are molded using a first mold 48, a second mold 50, a third mold 52, a fourth mold 54, and an injection device 56.

[0048] 22, a recess 48A is formed in the first mold 48, the recess 48A having a shape and dimensions corresponding to a portion 58A (see FIG. 24) formed by the first type of magnetic powder 42A in the stator core 26 of the second embodiment. The first type of magnetic powder 42A is poured into this recess 48A.

[0049] Next, as shown in FIG. 23, the first type of magnetic powder 42A placed in the recess 48A of the first die 48 is compressed between the first die 48 and a second die 50.

[0050] By going through the steps up to this point, the portion 58A formed by the first type of magnetic powder 42A is molded in the stator core 26 of the second embodiment. Next, the portion 58A formed by the first type of magnetic powder 42A in the stator core 26 of the second embodiment is set in the third mold 52.

[0051] 24 and 25 , a portion 58A formed of the first type of magnetic powder 42A in the stator core 26 of the second embodiment is set between the third mold 52 and the fourth mold 54. Here, a gap 60 having a shape and dimensions corresponding to a portion 58B (see FIG. 26 ) formed of the second type of magnetic powder 42B in the stator core 26 of the second embodiment is formed between the portion 58A formed of the first type of magnetic powder 42A in the stator core 26 of the second embodiment and the fourth mold 54. Next, the second type of magnetic powder 42B is injected into the gap 60 from an injection device 56 connected to the fourth mold 54.

[0052] 25 and 26 , a molded product 58 in which a portion 58A formed by the first type of magnetic powder 42A and a portion 58B formed by the second type of magnetic powder 42B in the stator core 26 of the second embodiment are integrated is removed from between the third mold 52 and the fourth mold 54, and the molded product 58 is subjected to annealing heat treatment. Through these steps, the stator core 26 of the second embodiment is manufactured.

[0053] (Method of Manufacturing the Stator Core 26 of the Third Embodiment) Next, a method of manufacturing the stator core 26 of the third embodiment will be briefly described.

[0054] 27 to 30 schematically show a portion of equipment for manufacturing the stator core 26 of the third embodiment. As shown in these figures, the first type of magnetic powder 42A and the second type of magnetic powder 42B that form the stator core 26 of the third embodiment are molded using a first mold 62, a second mold 64, and a third mold 66.

[0055] 27, a first mold 62 has formed therein a recess 62A whose shape and dimensions correspond to a molded product 68 (see FIG. 31) in which a portion 68A formed by the first type of magnetic powder 42A and a portion 68B formed by the second type of magnetic powder 42B are integrated in the stator core 26 of the third embodiment. The second type of magnetic powder 42B is poured into this recess 62A.

[0056] 28 , the second type of magnetic powder 42B poured into the recess 62A of the first die 62 is compressed between the first die 62 and the second die 64. This results in the formation of a portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment.

[0057] Next, as shown in FIG. 29, the first type of magnetic powder 42A is poured into a recess 62A formed in a first mold 62.

[0058] Next, as shown in Figure 30, the first type of magnetic powder 42A introduced into the first mold 62 is compressed between the first mold 62 and a third mold 66 together with the second type of magnetic powder 42B (portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment).

[0059] 30 and 31 , a molded product 68 in which a portion 68A formed by the first type of magnetic powder 42A and a portion 68B formed by the second type of magnetic powder 42B in the stator core 26 of the third embodiment are integrated is removed from between the first mold 62 and the third mold 66, and the molded product 68 is subjected to annealing heat treatment. Through these steps, the stator core 26 of the third embodiment is manufactured.

[0060] (Performance Management of Portions Formed from Recycled Materials) As described above, the stator core 26 in each of the above-described embodiments can be manufactured using the first type of magnetic powder 42A and the second type of magnetic powder 42B, which is a recycled material. In this case, it is important to manage the performance of the portions formed from the second type of magnetic powder 42B, which is a recycled material. Below, a configuration and method for managing the performance of the portions formed from the second type of magnetic powder 42B, which is a recycled material, will be described.

[0061] (Stator core 26 of fourth to sixth embodiments) The detailed configuration of the stator core 26 of the fourth embodiment will be described using Figure 32. Note that members and parts of the stator core 26 of the fourth embodiment that correspond to those of the stator core 26 of each embodiment already described will be assigned the same reference numerals as those corresponding to those of the stator core 26 of each embodiment, and their description may be omitted.

[0062] 32, the configuration of the stator core 26 of the fourth embodiment is similar to that of the stator core 26 of the second embodiment (see FIG. 18) or the stator core 26 of the third embodiment (see FIG. 21), except for the provision of an inspection portion 70. In the following description, the portion of the stator core 26 of the fourth embodiment corresponding to the stator core 26 of the second embodiment or the stator core 26 of the third embodiment may be referred to as a stator core main body 72.

[0063] The inspection portion 70 is provided at a position different from the coil-facing surface 26A (see FIG. 18, etc.) and the magnet-facing surface 26B (see FIG. 18, etc.). The inspection portion 70 is formed of the same second type of magnetic powder 42B as that used to form the stator core body 72. More specifically, the stator core 26 of the fourth embodiment has a plurality of inspection portions 70 (three in this embodiment) that protrude from the surface of the substrate portion 26C on the other axial side toward the other axial side. The plurality of inspection portions 70 are formed in a cylindrical shape. The plurality of inspection portions 70 are also arranged in the radial center of the substrate portion 26C and at equal intervals along the circumferential direction.

[0064] In the stator core 26 having the inspection portion 70, as shown in Fig. 33, the magnetic permeability of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by inserting the inspection portion 70 into the inner periphery of a search coil 74. Also, as shown in Fig. 34, the resistivity of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by pressing a resistivity measuring terminal 76 against the inspection portion 70. Furthermore, as shown in Fig. 35, the hardness of the portion of the stator core 26 formed by the second type of magnetic powder 42B can be inspected by pressing a hardness measuring terminal 78 against the inspection portion 70. Note that the inspection portion 70 shown in Figs. 34 and 35 is in the shape of a rectangular block.

[0065] The position of the inspection portion 70 is not limited to the above. For example, as in the stator core 26 of the fifth embodiment shown in Fig. 36 , the inspection portion 70 may be provided so as to protrude radially outward from the radially outer end of the substrate portion 26C. Furthermore, as in the stator core 26 of the sixth embodiment shown in Fig. 37 , the inspection portion 70 may be the entire surface of the other axial side surface of the substrate portion 26C.

[0066] (Method for forming test portion 70) A method for forming test portion 70 will now be briefly described.

[0067] 38 to 41 schematically show a portion of equipment for forming the stator core body 72 and the inspection portion 70. As shown in these figures, the first type of magnetic powder 42 that forms the stator core body 72 and the second type of magnetic powder 42B that forms the inspection portion 70 are molded using a first mold 80, a second mold 82, a third mold 84, and a fourth mold 86.

[0068] 38, a recess 80A is formed in the first mold 80, the recess 80A having a shape and dimensions corresponding to a portion 88A (see FIG. 42) formed by the first type of magnetic powder 42A in the stator core body 72. The first type of magnetic powder 42A is poured into this recess 80A.

[0069] 39 , the first type of magnetic powder 42A poured into the recess 80A of the first mold 80 is compressed between the first mold 80 and the second mold 82. This forms a portion 88A of the stator core body 72 that is formed from the first type of magnetic powder 42A. Here, a hole 80B is formed in the bottom of the first mold 80. As a result, a protrusion 88B is formed in the portion of the portion 88A where the inspection portion 70 will be joined.

[0070] 40, the molded part 88A is set in a third mold 84. An exposure hole 84A is formed in the third mold 84, exposing the portion of the part 88A to which the inspection part 70 is to be joined. Then, the second type of magnetic powder 42B is poured into the exposure hole 84A.

[0071] Next, as shown in FIG. 41, the second type of magnetic powder 42B placed in the exposure holes 84A is compressed between the third die 84 and the fourth die 86 together with the portions 88A and the protrusions 88B.

[0072] 41 and 42 , a molded product 88, in which a portion 88A formed by the first type of magnetic powder 42A in the stator core body 72 and a portion 88C forming the inspection portion 70 are integrated, is removed from between the third mold 84 and the fourth mold 86. Note that the portion formed by the second type of magnetic powder 42B in the stator core body 72 is molded in a separate process. Then, an annealing heat treatment is performed on the molded product, in which the portion formed by the second type of magnetic powder 42B in the stator core body 72 and the molded product 88 are integrated. Through these processes, a stator core 26 having the inspection portion 70 is manufactured.

[0073] In the stator core 26 of each of the above-described embodiments, the material of the coating 46 that covers the iron powder 44 is an inorganic material. However, the present disclosure is not limited to this. For example, the material of the coating 46 that covers the iron powder 44 may include an organic material. The stator core 26 may also include a third type of magnetic powder. In this case, the third type of magnetic powder does not correspond to the other types of magnetic powder. The third type of magnetic powder may or may not have higher insulating properties than the first type of magnetic powder 42A and the second type of magnetic powder 42B. The thickness of the coating 46 of the third type of magnetic powder may be thicker than the thickness of the coating 46 of the first type of magnetic powder 42A and the thickness of the coating 46 of the second type of magnetic powder 42B.

[0074] In addition, in the stator core 26 of each of the above-described embodiments, the base material of the magnetic powder 42 is the iron powder 44, but the present disclosure is not limited to this. For example, the base material of the magnetic powder 42 may be a mixture of an iron-based material and another material.

[0075] Furthermore, the configuration of the stator core 26 (powder magnetic core 40) in each of the above-described embodiments can also be applied to the core of a field element.

[0076] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above and can be implemented in various other modifications without departing from the spirit of the present disclosure. Furthermore, all or part of the configurations of the above-described embodiments can be combined with each other. Furthermore, the configuration of the motor 10 and the like may be applied to a generator. Furthermore, the configuration of the present disclosure can also be applied to a rotor configured to include a coil body 32.

[0077] The above describes one embodiment of the present disclosure, but the present disclosure is not limited to the above, and it goes without saying that it can be implemented in various other modified forms within the scope that does not deviate from the gist of the present disclosure.

[0078] Although the present disclosure has been described with reference to the embodiments, it is understood that the present disclosure is not limited to the embodiments or structures. The present disclosure also encompasses various modifications and modifications within the scope of equivalents. In addition, various combinations and forms, as well as other combinations and forms including only one element, more than one element, or less than one element, are also within the scope and spirit of the present disclosure.

[0079] <Appendix> (Appendix 1) A rotating electric machine core (26) configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material, and a coating portion (46) formed using a material having insulating properties and having a higher insulating property than the base material and covering the base material, wherein at least one of the thickness of the coating portion and the material of the coating portion are different, thereby including a plurality of types of magnetic powder (42A, 42B). (Appendix 2) A rotating electric machine core according to Appendix 1, wherein the coating portion is formed using an inorganic material. (Appendix 3) A rotating electric machine core according to Appendix 1 or Appendix 2, configured to include one type of magnetic powder (42A), and another type of magnetic powder (42B) having the coating portion with a higher insulating property than the one type of magnetic powder. (Supplementary Note 4) The rotating electric machine core according to Supplementary Note 3, wherein a coil (16) is wound around the rotating electric machine core and the rotating electric machine core is provided for a stator, the rotating electric machine core having a coil-facing surface (26A) arranged opposite the coil (16), and the other type of magnetic powder is arranged along the coil-facing surface. (Supplementary Note 5) The rotating electric machine core according to Supplementary Note 3 or Supplementary Note 4, wherein a thickness of the coating portion constituting the other type of magnetic powder is greater than a thickness of the coating portion constituting the one type of magnetic powder. (Supplementary Note 6) The rotating electric machine core according to Supplementary Note 5, wherein a rotating electric machine core is provided for a stator, the rotating electric machine core having a magnet-facing surface (26B) arranged opposite a magnet (18), and the other type of magnetic powder is arranged along the magnet-facing surface. (Supplementary Note 7) The rotating electric machine core according to Supplementary Note 5, wherein a coil-facing surface (26A) arranged opposite the coil (16) and a magnet-facing surface (26B) arranged opposite the magnet (18), and an inspection portion (70) formed by the other type of magnetic powder is provided.(Appendix 8) An armature (14) comprising: a core (26) for a rotating electric machine configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) formed using an insulating material and covering the base material, the core (26) being configured to include a plurality of types of magnetic powder (42A, 42B) that differ in at least one of the thickness and material of the coating portion; and a coil (16) arranged along the core of the rotating electric machine and that generates a magnetic field when current is passed through it. (Appendix 9) A rotating electric machine (10A, 10B, 10C) comprising: a rotating electric machine core (26) configured to include a plurality of types of magnetic powder (42A, 42B) that are different in at least one of the thickness and material of the coating; one of a stator (14) and a rotor (12) configured to include an armature (14) that includes a coil (16) that is arranged along the core of the rotating electric machine and generates a magnetic field when current is applied; and the other of the stator and rotor that includes a magnet (18) that is arranged opposite the coil and the core of the rotating electric machine.

Claims

1. A rotating electric machine core (26) comprising magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a coating portion (46) that is formed using a material that has insulating properties and has higher insulating properties than the base material and covers the base material, and at least one of the thickness of the coating portion and the material of the coating portion is different, thereby having multiple types of magnetic powder (42A, 42B).

2. The core of a rotating electrical machine according to claim 1, wherein the coating is formed using an inorganic material.

3. A core for a rotating electric machine as described in claim 1, which is composed of one type of magnetic powder (42A) and another type of magnetic powder (42B) having a coating portion with higher insulating properties than the one type of magnetic powder.

4. A core for a rotating electric machine as described in claim 3, which is wound with a coil (16) and is provided for a stator, has a coil facing surface (26A) arranged opposite the coil (16), and the other type of magnetic powder is arranged along the coil facing surface.

5. A core for a rotating electric machine according to claim 3, wherein the thickness of the coating portion of the magnetic powder of the other type is greater than the thickness of the coating portion of the magnetic powder of the one type.

6. A core for a rotating electric machine provided for a stator, comprising a magnet facing surface (26B) arranged opposite a magnet (18), and the other type of magnetic powder is arranged along the magnet facing surface.

7. A core for a rotating electric machine as described in claim 5, which has a coil facing surface (26A) arranged opposite the coil (16) and a magnet facing surface (26B) arranged opposite the magnet (18), and is provided with an inspection portion (70) formed by the other type of magnetic powder.

8. A rotating electric machine core (26) comprising magnetic powder (42) having a powdered base material (44) formed using an iron-based material and a covering portion (46) formed using a material having insulating properties and having higher insulating properties than the base material and covering the base material, the magnetic powder being comprised of multiple types of magnetic powder (42A, 42B) whose covering portion differs in at least one of thickness and material; and a coil (16) arranged along the core of the rotating electric machine and generating a magnetic field when current is passed through it.

9. A rotating electric machine (10A, 10B, 10C) comprising: a rotating electric machine core (26) configured to include magnetic powder (42) having a powdered base material (44) formed using an iron-based material; and a coating portion (46) formed using a material having insulating properties and having higher insulating properties than the base material and covering the base material, the magnetic powder being configured to include multiple types of magnetic powder (42A, 42B) whose coating portion differs in at least one of thickness and material; one of a stator (14) and a rotor (12) configured to include an armature (14) having a coil (16) arranged along the core of the rotating electric machine and generating a magnetic field when current is applied; and the other of the stator and rotor having a magnet (18) arranged opposite the coil and the core of the rotating electric machine.

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