Rotor, motor, blower, and refrigeration device

Abstract

Provided is a rotor (40) which is for a motor (20) and which comprises: a tubular bonded magnet (50) that includes a magnetic powder; and a support member (21) that supports the bonded magnet (50). The bonded magnet (50) has a first magnet part (51) that is constituted by a first bonded magnet material and a second magnet part (52) that is constituted by a second bonded magnet material. The second bonded magnet material has a lower elastic modulus than the first bonded magnet material. The second magnet part (52) is disposed between the first magnet part (51) and the support member (21).

Description

Rotor, motor, blower, and refrigeration device

[0001] The present disclosure relates to a rotor, a motor, a blower, and a refrigeration device.

[0002] Patent Document 1 discloses a motor in which an elastic body is provided between the rotating shaft of the motor and the rotor. The elastic body in Patent Document 1 suppresses the transmission of vibration from the rotor to the rotating shaft of the motor.

[0003] Japanese Patent Application Laid-Open No. 2006-158035

[0004] When there are restrictions on the size of the motor, in order to provide an elastic body to the motor, it is necessary to reduce the size of the rotor. However, when the size of the rotor becomes small, the performance of the motor may deteriorate. Therefore, in a motor having a mechanism for suppressing vibration, a rotor capable of suppressing a decrease in magnetic force is required.

[0005] The rotor according to the first aspect of the present disclosure is a rotor of a motor, and includes a cylindrical bonded magnet containing magnetic powder and a support member that supports the bonded magnet. The bonded magnet has a first magnet portion made of a first bonded magnet material and a second magnet portion made of a second bonded magnet material. The second bonded magnet material has a smaller elastic modulus than the first bonded magnet material, and the second magnet portion is disposed between the first magnet portion and the support member.

[0006] According to the above configuration, the rotor can suppress a decrease in the magnetic force of the rotor by the second magnet portion having a smaller elastic modulus than the first magnet portion. The rotor according to the second aspect is the rotor according to the first aspect, and the second bonded magnet material contains an elastomer.

[0007] According to the above configuration, since the second magnet portion is made of a second bonded magnet material containing an elastomer, the rotor can preferably suppress vibration. The rotor according to the third aspect is the rotor according to the first or second aspect, the first bonded magnet material contains the magnetic powder having magnetic anisotropy, and the second bonded magnet material contains the magnetic powder having magnetic anisotropy.

[0008] According to the above configuration, the first bonded magnet material and the second bonded magnet material contain magnetic powder having magnetic anisotropy, thereby increasing the overall magnetic force of the bonded magnet. In the rotor of the fourth aspect, in any one of the rotors of the first to third aspects, the support member is a rotating shaft that rotates around the central axis of the rotor, and the second magnet portion is arranged in the radial direction of the rotating shaft between the inner surface of the first magnet portion and the outer surface of the rotating shaft.

[0009] According to the above configuration, the second magnet section is positioned between the first magnet section and the rotating shaft, thereby effectively suppressing motor vibrations. In the fifth aspect, the rotor, in any one of the rotors from the first to third aspects, has a top plate positioned at one end of the bonded magnet in a direction along the central axis of the rotor, and the second magnet section is positioned between the first magnet section and the top plate.

[0010] According to the above configuration, the second magnet section can effectively suppress vibrations by being positioned between the first magnet section and the top plate. In the rotor according to the sixth viewpoint, in any one of the rotors according to the first to fifth viewpoints, the first magnet section has two or more magnetic poles adjacent to each other in the circumferential direction of the bonded magnet.

[0011] According to the above configuration, the first magnet section can generate a suitable magnetic force with two or more magnetic poles adjacent to each other in the circumferential direction of the bonded magnet. The motor of the seventh aspect comprises a rotor and a stator, which are one of the first to sixth aspects.

[0012] According to the above configuration, the motor can suppress performance degradation and vibration through the rotor. The blower in the eighth aspect comprises the motor in the seventh aspect and a fan section driven by the motor.

[0013] According to the above configuration, the blower can blow air effectively using a motor. The refrigeration system according to the ninth aspect is equipped with the motor according to the seventh aspect. According to the above configuration, the refrigeration system can improve its energy utilization efficiency using a motor.

[0014] This is a schematic diagram of the indoor unit for a refrigeration system of the first embodiment. This is a cross-sectional view showing the motor and fan of the indoor unit for the refrigeration system of Figure 1. This is a cross-sectional view of the rotor of the motor of Figure 2. This is a cross-sectional view of the mold body for manufacturing bonded magnets of Figure 3. This is a cross-sectional view showing the first movable part movement process, in which the first movable part is moved toward the mold body of Figure 4. This is a cross-sectional view showing the second movable part movement process, in which the second movable part is moved toward the mold body of Figure 4. This is a cross-sectional view showing the motor and fan of the second embodiment. This is an enlarged cross-sectional view of a part of the rotor of Figure 7.

[0015] <First Embodiment> Referring to Figures 1 to 6, the rotor 40 of the motor 20, the motor 20, the blower 10, and the refrigeration system of the first embodiment will be described.

[0016] The refrigeration system includes a motor 20. Examples of refrigeration systems include an air conditioner, a water heater, a chiller unit, and a cooling device for cooling the air inside the storage area. The air conditioner is either a dedicated refrigeration unit, a dedicated heating unit, or a heating and cooling unit that can switch between cooling and heating. The air inside the storage area is the air inside refrigerators, freezers, display cases, and containers. In this embodiment, the refrigeration system will be described as an air conditioner.

[0017] Figure 1 shows the indoor unit 1 of an air conditioner. In this embodiment, the motor 20 is provided in the indoor unit 1. The indoor unit 1 is, for example, a wall-mounted type that is attached to the wall of a room. The indoor unit 1 is connected to the outdoor unit of the air conditioner by refrigerant piping.

[0018] The indoor unit 1 includes a heat exchanger that exchanges heat with the air drawn in from the intake port, a blower 10, and a casing 2 that supports the heat exchanger and the blower 10. The heat exchanger and the blower 10 are arranged in the internal space of the casing 2.

[0019] The blower 10 comprises a motor 20 and a fan unit 11 driven by the motor 20. The fan unit 11 is located downstream of the heat exchanger in the airflow path from the intake to the outlet of the indoor unit 1. The fan unit 11 is a propeller fan, a centrifugal fan, or a cross-flow fan. Examples of centrifugal fans include turbo fans and sirocco fans. In this embodiment, the fan unit 11 is a cross-flow fan.

[0020] <Motor> As shown in Figure 2, the motor 20 is, for example, an inner rotor type motor. The motor 20 comprises a rotor 40 and a stator 30.

[0021] The stator 30 has a stator core 31 and a coil 32. These components constituting the stator 30 are integrally molded by resin molding. The stator core 31 is formed by laminating conductive steel plates. The steel plates are soft magnetic materials. The stator core 31 has a plurality of teeth. The coil 32 is formed by winding a wire around the teeth of the stator core 31. The winding is made of copper wire or aluminum wire. The winding is covered with an insulating material such as enamel resin.

[0022] An insulator is provided between the stator core 31 and the coil 32. The insulator is made of an insulating resin material. The insulator insulates the stator core 31 and the coil 32 so that the current flowing through the coil 32 is not transmitted to the stator core 31.

[0023] The rotor 40 of the motor 20 comprises a cylindrical bonded magnet 50 containing magnetic powder and a support member 21 that supports the bonded magnet 50. In this embodiment, the support member 21 is a rotating shaft 22 that rotates around the central axis C1 of the rotor 40. The bonded magnet 50 has a through hole 50X in which the rotating shaft 22 is positioned. The rotating shaft 22 is positioned in the through hole 50X so as to rotate integrally with the bonded magnet 50. Details of the bonded magnet 50 will be described later.

[0024] The motor 20 further comprises a Boscore 23. The Boscore 23 is provided to increase the contact area between the bonded magnet 50 and the rotating shaft 22. The Boscore 23 is provided between the bonded magnet 50 and the rotating shaft 22 in the radial direction of the rotor 40. The Boscore 23 is cylindrical. The Boscore 23 has a through hole 23A into which the rotating shaft 22 is inserted. The rotating shaft 22 is, for example, press-fitted into the through hole 23A of the Boscore 23. The Boscore 23 is formed of a metallic material.

[0025] <Bonded Magnet> The bonded magnet 50 will be described with reference to Figures 2 and 3. The bonded magnet 50 has two or more adjacent magnetic poles in the circumferential direction of the bonded magnet 50. The bonded magnet 50 is an anisotropic magnet. The bonded magnet 50 includes an outer circumferential surface 50A and an inner circumferential surface 50B in the radial direction of the bonded magnet 50. The magnetic poles of the bonded magnet 50 are provided on either the outer circumferential surface 50A or the inner circumferential surface 50B in the radial direction of the bonded magnet 50. In this embodiment, the magnetic poles of the bonded magnet 50 are provided on the outer circumferential surface 50A of the bonded magnet 50.

[0026] The bonded magnet 50 has a first magnetic portion 51 and a second magnetic portion 52. The first magnetic portion 51 has two or more adjacent magnetic poles in the circumferential direction of the bonded magnet 50. The first magnetic portion 51 includes the central part of the magnetic poles of the bonded magnet 50. The first magnetic portion 51 is arranged on the outer circumferential surface 50A or the inner circumferential surface 50B of the bonded magnet 50. In this embodiment, the first magnetic portion 51 is arranged on the outer circumferential surface 50A of the bonded magnet 50. The second magnetic portion 52 is arranged on the outer circumferential surface 50A or the inner circumferential surface 50B of the bonded magnet 50. In this embodiment, the second magnetic portion 52 is arranged on the inner circumferential surface 50B of the bonded magnet 50.

[0027] The second magnet portion 52 is adjacent to the first magnet portion 51. The second magnet portion 52 is positioned between the first magnet portion 51 and the support member 21. In this embodiment, the second magnet portion 52 is positioned between the first magnet portion 51 and the rotating shaft 22. The second magnet portion 52 is positioned in the radial direction of the rotating shaft 22 between the inner surface 51A of the first magnet portion 51 and the outer surface 22A of the rotating shaft 22. In this embodiment, the second magnet portion 52 is positioned in the radial direction of the rotating shaft 22 between the inner surface 51A of the first magnet portion 51 and the outer surface 23B of the Boscore 23.

[0028] The first magnet section 51 is made of a first bonded magnet material. The second magnet section 52 is made of a second bonded magnet material. Each of the first bonded magnet material and the second bonded magnet material contains magnetic powder having magnetic anisotropy. The magnetic powder has an easy magnetization axis. The length of the magnetic powder in the second direction perpendicular to the easy magnetization axis is longer than the length in the first direction along the easy magnetization axis. The magnetic powder has a flattened shape. The magnetic powder is in the form of fine powder or granules. The magnetic powder is ferrite magnetic powder or rare earth-based magnetic powder. The rare earth-based magnetic powder includes NdFeB-based magnetic powder or SmCo-based magnetic powder.

[0029] The first bonded magnet material includes a first binder. The first binder includes nylon resin and PPS (Polyphenylene Sulfide) resin, etc. Examples of nylon resins include nylon 12, nylon 6, nylon 6,6, nylon 11, nylon 6,12, nylon 6,10, nylon 6,66, nylon MXD6, etc. Various nylon resins may be used individually as the first binder, or multiple types may be used in mixtures.

[0030] The second bonded magnet material includes a second binder. The second binder includes a material with a low modulus of elasticity. The second binder includes an elastomer. The elastomer includes rubber, thermosetting elastomers, and thermoplastic elastomers.

[0031] The second bonded magnet material has a lower elastic modulus than the first bonded magnet material. That is, the second bonded magnet material is more easily deformed than the first bonded magnet material. The magnetic particle density of the first bonded magnet material is higher than that of the second bonded magnet material, or the fluidity of the first binder is higher than that of the second binder. Therefore, the first magnet part 51 has a greater magnetic force than the second magnet part 52. The magnetic particle density can be confirmed, for example, by observing the surface of the bonded magnet 50 using a scanning electron microscope (SEM).

[0032] The first magnet portion 51 has a first width W1 in the radial direction of the rotation axis 22. The second magnet portion 52 has a second width W2 in the radial direction of the rotation axis 22. The first width W1 is larger than the second width W2. Because the first width W1 is larger than the second width W2, the volume of the first magnet portion 51 per unit volume of the bonded magnet 50 is larger than the volume of the second magnet portion 52 per unit volume of the bonded magnet 50. Therefore, the proportion of the bonded magnet 50 occupied by the first magnet portion 51 is larger, and the overall magnetic force of the bonded magnet 50 can be improved.

[0033] <Method for Manufacturing Bonded Magnets> The method for manufacturing bonded magnets 50 will be described with reference to Figures 4 to 6. Bonded magnets 50 are formed by a mold 60. The mold 60 comprises a mold body 61. The mold body 61 is made of a non-magnetic material. The non-magnetic material is, for example, non-magnetic stainless steel. The mold body 61 has a cylindrical cavity 62. In plan view, the cavity 62 is annular. Bonded magnet material is injected into the cavity 62 from an injection port. The injection port is provided on the end face of the cavity 62 in the direction CD in the cylindrical axis direction. The end face of the cavity 62 in the direction CD in the cylindrical axis direction is annular. The injection port is provided on the mold body 61 so as to correspond to the center of the magnetic pole of the magnetic field generating unit 65, which will be described later.

[0034] As shown in Figure 4, the cavity 62 has a first region 63 and a second region 64 in a cross section perpendicular to the cylindrical axis CD of the cavity 62. The dashed line in Figure 4 is a virtual line to distinguish the first region 63 and the second region 64. The second region 64 is a region different from the first region 63 in the radial direction of the cavity 62. In the radial direction of the cavity 62, the length of the first region 63 is longer than the length of the second region 64. The first region 63 is adjacent to the second region 64 in the radial direction.

[0035] The mold 60 includes a magnetic field generating unit 65 that generates a magnetic field within the cavity 62. The magnetic field generating unit 65 has magnetic poles arranged in a circumferential direction. On the outer circumference of the magnetic field generating unit 65, the south poles and north poles are arranged alternately in the circumferential direction. The number of magnetic poles of the bonded magnet 50 corresponds to the number of magnetic poles of the magnetic field generating unit 65. In this embodiment, the number of magnetic poles of the magnetic field generating unit 65 is 10. The number of magnetic poles of the magnetic field generating unit 65 is not limited to 10. The magnetic field generating unit 65 may have as many as 2 or more even natural number magnetic poles.

[0036] The cavity 62 has an outer surface 62A and an inner surface 62B in the radial direction of the cavity 62. The magnetic field generating unit 65 is positioned on either the outer surface 62A side or the inner surface 62B side of the cavity 62 in the radial direction. In this embodiment, the magnetic field generating unit 65 is positioned on the outer surface 62A side of the cavity 62.

[0037] The first region 63 faces the center of the magnetic pole of the magnetic field generating unit 65 in the radial direction of the cavity 62. The distance from the magnetic field generating unit 65 to the second region 64 is longer than the distance from the magnetic field generating unit 65 to the first region 63. The distance from the center of the magnetic pole of the magnetic field generating unit 65 to the second region 64 is longer than the distance from the center of the magnetic pole of the magnetic field generating unit 65 to the first region 63. In this embodiment, the distance from the center of the magnetic pole of the magnetic field generating unit 65 to the inner surface of the second region 64 is longer than or equal to the distance from the center of the magnetic pole of the magnetic field generating unit 65 to the outer surface of the first region 63. The magnetic field generating unit 65 is adjacent to the first region 63 in the radial direction of the cavity 62.

[0038] The magnetic powder contained in the first bonded magnet material and the second bonded magnet material is oriented by the orientation magnetic field of the magnetic field generating unit 65. In this embodiment, orientation means that the easy magnetization axis of the magnetic powder contained in the bonded magnet material is aligned in a predetermined direction.

[0039] As shown in Figures 5 and 6, the mold 60 includes a movable part 66 configured to move relative to the mold body 61. The movable part 66 has an injection port 66A and a runner 66B. Bonded magnet material is injected into the injection port 66A. The runner 66B is arranged in the movable part 66, for example, so as to spread out radially. The movable part 66 is configured to move relative to the mold body 61 so that the runner 66B is positioned to correspond to the injection port of the cavity 62. The bonded magnet material injected from the injection port 66A is injected into the cavity 62 through the runner 66B and the injection port.

[0040] The movable part 66 includes a first movable part 67 for injecting a first bond magnet material into a first region 63 of the cavity 62, and a second movable part 68 for injecting a second bond magnet material into a second region 64 of the cavity 62. By swapping the first movable part 67 and the second movable part 68 and injecting each bond magnet material into the cavity 62, a bond magnet 50 is formed.

[0041] The first movable part 67 has a first movable part body 67A and a region partition 67B. The region partition 67B is provided on the lower end surface 67C of the first movable part body 67A. The region partition 67B may be detachably attached to the first movable part body 67A. In plan view, the region partition 67B is annular. The region partition 67B is formed of, for example, a soft magnetic material.

[0042] The region partition 67B is provided on the first movable part body 67A so as to correspond to the first region 63 or the second region 64 of the cavity 62. In this embodiment, the region partition 67B is provided on the first movable part body 67A so as to correspond to the second region 64 of the cavity 62. The runner 66B of the first movable part 67 is provided on the first movable part 67 so as to correspond to the first region 63. The runner 66B of the second movable part 68 is provided on the second movable part 68 so as to correspond to the second region 64.

[0043] The steps for manufacturing the bonded magnet 50 will now be described. The manufacturing method for the bonded magnet 50 includes a first movable part movement step. In the first movable part movement step, the first movable part 67 is moved toward the mold body 61, thereby closing the molding die 60.

[0044] The manufacturing method of the bonded magnet 50 includes a first injection step of injecting a first bonded magnet material into the first region 63 of the cavity 62. The first injection step is a step for injection molding the first magnet portion 51 of the bonded magnet 50. In the first injection step, when the first bonded magnet material is injected from the injection port 66A of the first movable part 67, the first bonded magnet material is injected into the first region 63 of the cavity 62 from the injection port through the runner 66B. In the first injection step, the first bonded magnet material flows in a direction from the injection port downward and in a direction spreading in the circumferential direction, whereby the first bonded material fills the first region 63 of the cavity 62.

[0045] The manufacturing method of the bonded magnet 50 includes a first separation step of moving the first movable part 67 in a direction away from the mold body 61. The first separation step is performed after the first bonded magnet material has hardened after the completion of the first injection step. By the first separation step, the first bonded magnet material injected into the first region 63 of the cavity 62 is separated from the first bonded magnet material in the runner 66B.

[0046] The manufacturing method of the bonded magnet 50 includes a second movable part moving step. In the second movable part moving step, the second movable part 68 is moved toward the mold body 61, whereby the mold 60 is closed.

[0047] The manufacturing method of the bonded magnet 50 includes a second injection step of injecting a second bonded magnet material into the second region 64 of the cavity 62. The second injection step is a step for injection molding the second magnet portion 52 of the bonded magnet 50. In the second injection step, when the second bonded magnet material is injected from the injection port 66A of the second movable part 68, the second bonded magnet material is injected into the second region 64 of the cavity 62 from the injection port through the runner 66B. In the second injection step, the second bonded magnet material flows in a direction from the injection port downward and in a direction spreading in the circumferential direction, whereby the second bonded magnet material fills the second region 64 of the cavity 62.

[0048] The method for manufacturing the bonded magnet 50 includes a second separation step of moving the second movable part 68 in a direction away from the mold body 61. The second separation step is performed after the second injection step and after the second bonded magnet material has hardened. By the second separation step, the second bonded magnet material injected into the second region 64 of the cavity 62 is separated from the second bonded magnet material in the runner 66B.

[0049] The method for manufacturing the bonded magnet 50 further includes a removal step of removing the bonded magnet 50 from the cavity 62. The removal step is performed after the second injection step and after the second bonded magnet material has hardened. The method for manufacturing the bonded magnet 50 further includes a magnetization step of magnetizing the bonded magnet 50. The magnetization step is performed after the second injection step. Preferably, the magnetization step is performed after the removal step.

[0050] In the present embodiment, the first movable part moving step, the first injection step, and the first separation step are performed prior to the second movable part moving step, the second injection step, and the second separation step. Therefore, the magnetic powder of the first bonded magnet material injected into the first region 63 by the magnetic field generating part 65 can be preferably oriented.

[0051] <Function of the First Embodiment> The function of the first embodiment will be described. In the first embodiment, a second magnet part 52 having a smaller elastic modulus than the first magnet part 51 is disposed between the first magnet part 51 and the rotation axis 22 in the radial direction of the bonded magnet 50. Therefore, it is possible to suppress the transmission of the vibration of the bonded magnet 50 caused by the electromagnetic force applied to the bonded magnet 50 to the rotation axis 22.

[0052] <Effect of the First Embodiment> The effect of the first embodiment will be described. (1-1) The rotor 40 of the motor 20 includes a cylindrical bonded magnet 50 containing magnetic powder and a support member 21 that supports the bonded magnet 50. The bonded magnet 50 has a first magnet part 51 made of a first bonded magnet material and a second magnet part 52 made of a second bonded magnet material. The second bonded magnet material has a smaller elastic modulus than the first bonded magnet material. The second magnet part 52 is disposed between the first magnet part 51 and the support member 21.

[0053] With the above configuration, the rotor 40 can suppress the decrease in magnetic force of the rotor 40 by the second magnet portion 52, which has a lower elastic modulus than the first magnet portion 51. Furthermore, with the above configuration, the rotor 40 can suppress the decrease in magnetic force of the rotor 40 and also suitably suppress vibration of the motor 20.

[0054] (1-2) The second bonded magnet material includes an elastomer. With the above configuration, since the second magnet portion 52 is made of a second bonded magnet material including an elastomer, the rotor 40 can effectively suppress vibrations.

[0055] (1-3) The first bonded magnet material contains magnetic powder having magnetic anisotropy. The second bonded magnet material contains magnetic powder having magnetic anisotropy. With the above configuration, since the first bonded magnet material and the second bonded magnet material contain magnetic powder having magnetic anisotropy, the overall magnetic force of the bonded magnet 50 can be increased.

[0056] (1-4) The support member 21 is a rotating shaft 22 that rotates around the central axis C1 of the rotor 40. The second magnet portion 52 is positioned in the radial direction of the rotating shaft 22 between the inner surface 51A of the first magnet portion 51 and the outer surface 22A of the rotating shaft 22.

[0057] According to the above configuration, the second magnet section 52 is positioned between the first magnet section 51 and the rotating shaft 22, thereby effectively suppressing vibrations of the motor 20. (1-5) The first magnet section 51 has two or more magnetic poles adjacent to each other in the circumferential direction of the bonded magnet 50.

[0058] According to the above configuration, the first magnet section 51 can generate a suitable magnetic force with two or more magnetic poles adjacent to each other in the circumferential direction of the bonded magnet 50. (1-6) The motor 20 comprises a rotor 40 and a stator 30.

[0059] According to the above configuration, the motor 20 can suppress performance degradation and vibration with respect to the rotor 40. (1-7) The blower 10 comprises a motor 20 and a fan section 11 driven by the motor 20.

[0060] According to the above configuration, the blower 10 can blow air effectively using the motor 20. (1-8) The refrigeration system is equipped with the motor 20. According to the above configuration, the refrigeration system can improve its energy utilization efficiency with the motor 20.

[0061] <Second Embodiment> Referring to Figures 1, 7, and 8, the rotor 80 of the motor 70, the motor 70, the blower 10, and the refrigeration system of the second embodiment will be described. Components in this embodiment that are common to the first embodiment are denoted by the same reference numerals as in the first embodiment, and redundant explanations are omitted.

[0062] The refrigeration system includes a motor 70. The blower 10 includes a motor 70 and a fan section 11 driven by the motor 70. <Motor> The motor 70 is, for example, an outer rotor type motor. The motor 70 includes a rotor 80 and a stator 90.

[0063] The stator 90 has a stator core 91 and a coil 92. These components constituting the stator 90 are integrally molded by resin molding. The stator core 91 is formed by laminating conductive copper plates. The copper plates are soft magnetic materials. The stator core 91 has a plurality of teeth. The coil 92 is formed by winding copper wire around the teeth of the stator core 91. The copper wire is covered with an insulating material such as enamel resin.

[0064] An insulator is provided between the stator core 91 and the coil 92. The insulator is made of an insulating resin material. The insulator insulates the stator core 91 and the coil 92 so that the current flowing through the coil 92 is not transmitted to the stator core 91. Connection plates are connected to the lead wires at the beginning and end of the copper winding of the coil 92. The connection plates are connected to an external power supply, etc., via lead wires.

[0065] The motor 70 further comprises a shaft member 71. The shaft member 71 rotates integrally with the rotor 80. The stator 90 has a through hole 93 in which the shaft member 71 is positioned. At least one bearing 72 is positioned in the through hole 93. The bearing 72 supports the shaft member 71 so that it rotates relative to the stator 90. The rotor 80 is attached to one end of the shaft member 71. In this embodiment, the shaft member 71 is supported by two bearings 72 so as to be rotatable relative to the stator 90. A fan section 11 is attached to one end of the shaft member 71.

[0066] The rotor 80 comprises a cylindrical bonded magnet 50 containing magnetic powder and a support member 21 that supports the bonded magnet 50. In this embodiment, the support member 21 has a top plate 81. The bonded magnet 50 includes a first magnetic portion 51 and a second magnetic portion 52. The magnetic poles of the bonded magnet 50 are provided on the inner circumferential surface 50B of the bonded magnet 50. The first magnetic portion 51 includes the central part of the magnetic pole of the bonded magnet 50.

[0067] The top plate 81 is positioned on one end 50C of the bonded magnet 50 in a direction along the central axis C2 of the rotor 80. The top plate 81 is annular when viewed from the axial direction of the motor 70. The top plate 81 extends in a direction perpendicular to the axial direction of the motor 70. The top plate 81 has a through hole 81A. A shaft member 71 is positioned in the through hole 81A. The shaft member 71 is attached to the through hole 81A so as to rotate integrally with the top plate 81.

[0068] The rotor 80 has bonded magnet support portions 82. The bonded magnet support portions 82 extend from each end of the top plate 81 in a direction perpendicular to the axial direction of the motor 70, toward the axial direction of the motor 70.

[0069] In the bonded magnet support portion 82, a bonded magnet 50 is provided on the portion opposite to the top plate 81. The inner circumferential surface 50B of the bonded magnet 50 is smoothly connected to the inner circumferential surface 82A of the bonded magnet support portion 82.

[0070] The second magnetic portion 52 of the bonded magnet 50 is positioned between the first magnetic portion 51 and the top plate 81. In this embodiment, the second magnetic portion 52 is positioned between the first magnetic portion 51 and the top plate 81 so that the first magnetic portion 51 and the top plate 81 do not come into contact. The constituent material and elastic properties of the first magnetic portion 51 are the same as in the first embodiment. Similarly, the constituent material and elastic properties of the second magnetic portion 52 are the same as in the first embodiment. Specifically, the second bonded magnet material of the second magnetic portion 52 has a lower elastic modulus than the first bonded magnet material of the first magnetic portion 51.

[0071] <Effects of the Second Embodiment> The effects of the second embodiment will be described. (2-1) The support member 21 has a top plate 81 that is positioned on one end 50C of the bonded magnet 50 in a direction along the central axis C2 of the rotor 80. The second magnet portion 52 is positioned between the first magnet portion 51 and the top plate 81.

[0072] According to the above configuration, the second magnet section 52 can effectively suppress vibrations by being positioned between the first magnet section 51 and the top plate 81. <Modification Examples> In addition to the above embodiments, the rotor, motor, blower, and refrigeration device of the motor disclosed herein may also be, for example, modified as shown below and a combination of at least two mutually non-contradictory modifications.

[0073] - The Boscore 23 may be omitted. - The Boscore 23 may be formed by a first bonded magnet member or a second bonded magnet member. In this modified example, three layers of bonded magnets are arranged around the axis of the rotating shaft 22.

[0074] - The second magnet portion 52 may have multiple protrusions between the rotating shaft 22 and the second magnet portion 52. In this modified example, the multiple protrusions reduce the contact area between the Boscore 23 and the second magnet portion 52, thereby further suppressing the transmission of vibrations of the bonded magnet 50, caused by electromagnetic force acting on the bonded magnet 50, to the rotating shaft 22.

[0075] - The second binder may be made of nylon resin, PPS resin, or the like, similar to the first binder. When the second binder is made of the same material as the first binder, the magnetic particle density of the second bonded magnet material is smaller than that of the first bonded magnet material.

[0076] - The first width W1 may be smaller than the second width W2. In this modified example, the volume of the first magnet part 51 per unit volume of the bonded magnet 50 is smaller than the volume of the second magnet part 52 per unit volume of the bonded magnet 50. Therefore, the transmission of vibrations of the bonded magnet 50 caused by electromagnetic force acting on the bonded magnet 50 to the rotating shaft 22 can be further suppressed.

[0077] - In the rotor 80 of the second embodiment, the shaft member 71 may be configured not to rotate. - The second movable part movement step, the second injection step, and the second detachment step may be performed before the first movable part movement step, the first injection step, and the first detachment step.

[0078] - The magnetization process may be omitted. In this case, for example, the bonded magnet 50 is magnetized by the magnetic field generating unit 65. - The motor 20 may be used in an outdoor unit for a refrigeration system or a compressor for a refrigeration system.

[0079] While embodiments of the motor rotor, motor, blower, and refrigeration system have been described above, it should be understood that various modifications to the form and details are possible without departing from the spirit and scope of the motor rotor, motor, blower, and refrigeration system described in the claims.

[0080] 10... Blower, 11... Fan section, 20... Motor, 21... Support member, 22... Rotating shaft, 22A... Outer surface, 30... Stator, 40... Rotor, 50... Bonded magnet, 50C... End, 51... First magnet section, 51A... Inner surface, 52... Second magnet section, 70... Motor, 80... Rotor, 81... Top plate, 90... Stator.

Claims

1. A rotor (40) of a motor (20), comprising: a cylindrical bonded magnet (50) containing magnetic powder; and a support member (21) supporting the bonded magnet (50), wherein the bonded magnet (50) has a first magnet portion (51) made of a first bonded magnet material and a second magnet portion (52) made of a second bonded magnet material, the second bonded magnet material having a lower modulus of elasticity than the first bonded magnet material, and the second magnet portion (52) being positioned between the first magnet portion (51) and the support member (21), the rotor.

2. The rotor according to claim 1, wherein the second bonded magnetic material comprises an elastomer.

3. The rotor according to claim 1 or 2, wherein the first bonded magnet material includes the magnetic powder having magnetic anisotropy, and the second bonded magnet material includes the magnetic powder having magnetic anisotropy.

4. The rotor according to any one of claims 1 to 3, wherein the support member (21) is a rotating shaft (22) that rotates around the central axis (C1) of the rotor (40), and the second magnet portion (52) is disposed in the radial direction of the rotating shaft (22) between the inner surface (51A) of the first magnet portion (51) and the outer surface (22A) of the rotating shaft (22).

5. The rotor according to any one of claims 1 to 3, wherein the support member (21) has a top plate (81) positioned at one end (50C) of the bonded magnet (50) in a direction along the central axis (C2) of the rotor (80), and the second magnet portion (52) is positioned between the first magnet portion (51) and the top plate (81).

6. The rotor according to any one of claims 1 to 5, wherein the first magnetic portion (51) has two or more magnetic poles adjacent to each other in the circumferential direction of the bonded magnet (50).

7. A motor (20) comprising a rotor (40) according to any one of claims 1 to 6 and a stator (30).

8. A blower (10) comprising a motor (20) as described in claim 7, and a fan section (11) driven by the motor (20).

9. A refrigeration apparatus comprising the motor (20) described in claim 7.

Images