Method for manufacturing metal component, method for manufacturing stator core, method for manufacturing motor, method for manufacturing compressor, method for manufacturing blower, and method for manufacturing refrigeration device

Abstract

A metal component manufacturing method for manufacturing a metal component (2) having a predetermined shape from a metal plate (1) containing an amorphous metal or a nanocrystalline metal, the metal component manufacturing method comprising: a cut forming step for forming a plurality of cuts (14) in a cutting portion (13) that is located outside a component region (10) having the predetermined shape on the metal plate (1) or located on a boundary between the component region (10) and an outside region (10A) located outside the component region (10) and formed along an edge (11) of the component region (10); and a cutting step for cutting the metal plate (1) at the cutting portion (13) using a die (30).

Description

Method for manufacturing metal parts, method for manufacturing a stator core, method for manufacturing a motor, method for manufacturing a compressor, method for manufacturing a blower, and method for manufacturing a refrigeration device

[0001] The present disclosure relates to a method for manufacturing metal parts, a method for manufacturing a stator core, a method for manufacturing a motor, a method for manufacturing a compressor, a method for manufacturing a blower, and a method for manufacturing a refrigeration device.

[0002] The motor disclosed in Patent Document 1 has a stator core provided with a core composed of laminated amorphous metal.

[0003] Japanese Patent No. 6656428

[0004] Although metals containing amorphous metal or nanocrystalline metal are very thin compared to general electromagnetic steel sheets, they are very hard. Therefore, when a large amount of such metals are punched by a punching method during mass production, an excessive load continues to be applied to the mold, resulting in cracks, chips, wear, etc. in the mold, which may reduce the life of the mold.

[0005] An object of the present disclosure is to suppress a decrease in the life of the mold.

[0006] A first aspect is a method for manufacturing a metal part for manufacturing a metal part (2) having a predetermined shape from a metal plate (1) containing amorphous metal or nanocrystalline metal, on the outside of a part region (10) having the predetermined shape on the metal plate (1), or on the boundary between the part region (10) and an outer region (10A) located outside the part region (10), a notch forming step of forming a plurality of notches (14) in a cutting portion (13) along an edge (11) of the part region (10), and a cutting step of cutting the metal plate (1) at the cutting portion (13) using a mold (30).

[0007] According to the first embodiment, by forming multiple cuts (14) in the cut portion (13) of the metal plate (1), the load on the mold (30) when cutting the metal plate (1) along the cut portion (13) using the mold (30) can be reduced, thereby suppressing a decrease in the lifespan of the mold (30). Furthermore, since the cut surface of the part shape of the metal plate (1) can be guided to a desired cut surface, multiple metal parts (2) can be stacked in an orderly and accurate manner, which is particularly useful for metal plates (1) containing nanocrystalline metal.

[0008] In the second embodiment, the cut portion (13) includes a bent portion (13a), and the cut (14) is formed in the bent portion (13a).

[0009] According to the second embodiment, by forming cuts (14) in the bent portion (13a) where the shape of the cut portion (13) changes significantly, it is possible to suppress an increase in the number of cuts (14), thereby preventing the work of forming the cuts (14) from becoming complicated.

[0010] In the third embodiment, the plurality of cuts (14) are formed to be arranged at equal intervals along the cut portion (13), as in the first embodiment.

[0011] According to the third embodiment, the metal plate (1) can be easily cut along a plurality of equally spaced cuts (14).

[0012] In the fourth embodiment, in any one of the first to third embodiments, the plurality of cuts (14) have the same shape as one another.

[0013] According to the fourth embodiment, the metal plate (1) can be cut along a plurality of cuts (14) that have the same shape as each other.

[0014] The fifth embodiment is one of the first to fourth embodiments, in which the plurality of cuts (14) are formed to be arranged in a dashed line pattern at least in part of the cut portion (13).

[0015] According to the fifth embodiment, the metal plate (1) can be cut along a plurality of dashed lines (14).

[0016] The sixth aspect is an aspect of any one of the first to fifth aspects in which the cut (14) penetrates the metal plate (1) or is a recess (bottomed hole) formed in the metal plate (1).

[0017] According to the sixth embodiment, when cutting a metal plate (1) using a mold, the load on the mold can be suppressed at the location of the cut (14) on the metal plate (1), thereby suppressing a decrease in the lifespan of the mold (30).

[0018] The seventh aspect is a method for manufacturing a stator core, wherein a stator core is manufactured by stacking a plurality of metal parts (2) manufactured by the manufacturing method of any one of the first to sixth aspects.

[0019] In the seventh embodiment, the stator core can be manufactured from a metal plate (1).

[0020] The eighth aspect is a method for manufacturing a motor, comprising manufacturing a motor including a stator core according to the seventh aspect.

[0021] In the eighth embodiment, a motor can be manufactured that includes a stator core made from a metal plate (1).

[0022] The ninth aspect is a method for manufacturing a compressor, comprising manufacturing a compressor including a motor according to the eighth aspect.

[0023] In the ninth embodiment, a compressor can be manufactured that includes a stator core made from a metal plate (1).

[0024] The tenth aspect is a method for manufacturing a blower, comprising manufacturing a blower including a motor according to the eighth aspect.

[0025] In the tenth embodiment, a blower can be manufactured that includes a stator core made from a metal plate (1).

[0026] The eleventh aspect is a method for manufacturing a refrigeration apparatus, comprising manufacturing a refrigeration apparatus including a compressor according to the ninth aspect.

[0027] In the eleventh embodiment, a refrigeration system can be manufactured that includes a stator core made from a metal plate (1).

[0028] Figure 1 is a plan view of a metal plate according to an embodiment. Figure 2(a) is a plan view of a metal plate with a cut formed on the cut portion. Figure 2(b) is a cross-sectional view of Figure 2(a) along II(b)-II(b). Figure 3 is a cross-sectional view of a metal plate being punched out by a die. Figure 4 is a perspective view of a metal part. Figure 5 is a flow chart of a method for manufacturing a metal part. Figure 6 is a plan view showing a modified example of a cut formed on the cut portion of a metal plate. Figure 7 is a schematic configuration diagram of a refrigeration device. Figure 8 is a longitudinal cross-sectional view corresponding to a cross section parallel to the axial direction in a compressor. Figure 9 is a transverse cross-sectional view corresponding to a cross section perpendicular to the axial direction in a motor.

[0029] The embodiments of this disclosure will be described in detail below with reference to the drawings. This disclosure is not limited to the embodiments shown below, and various modifications are possible without departing from the technical idea of ​​this disclosure. Since the drawings are for conceptual explanation of this disclosure, dimensions, ratios, or numbers may be exaggerated or simplified as necessary for ease of understanding. In each embodiment, example, modification, and drawing, the same or corresponding parts are denoted by the same reference numerals, and detailed descriptions and their associated effects will not be repeated.

[0030] (1) Metal plate The metal plate (1) includes an amorphous metal or a nanocrystalline metal. The metal plate (1) is formed of a magnetic material. The magnetic material is an amorphous soft magnetic material that forms an amorphous metal, or a nanocrystalline soft magnetic material that forms a nanocrystalline metal. The amorphous soft magnetic material or nanocrystalline soft magnetic material used in the magnetic material is composed of, for example, at least one magnetic metal selected from the group consisting of iron, cobalt, and nickel, and at least one non-magnetic metal. The at least one non-magnetic metal is selected from the group consisting of, for example, boron, carbon, phosphorus, aluminum, silicon, titanium, vanadium, chromium, manganese, copper, yttrium, zirconium, niobium, molybdenum, hafnium, tantalum, and tungsten. The amorphous soft magnetic material or nanocrystalline soft magnetic material in the magnetic material is not limited to the above examples.

[0031] Typical amorphous soft magnetic materials or nanocrystalline soft magnetic materials used in magnetic materials include, for example, iron-cobalt alloys, iron-nickel alloys, iron-aluminum alloys, iron-silicon alloys, iron-tantalum alloys, or iron-zirconium alloys. Examples of iron-cobalt alloys include Fe・Co alloys and Fe・Co・V alloys. Examples of iron-nickel alloys include Fe・Ni alloys, Fe・Ni・Mo alloys, Fe・Ni・Cr alloys, and Fe・Ni・Si alloys. Examples of iron-aluminum alloys or iron-silicon alloys include Fe・Al alloys, Fe・Al・Si alloys, Fe・Al・Si・Cr alloys, Fe・Al・Si・Ti・Ru alloys, and Fe・Al・O alloys. Examples of iron-tantalum alloys include Fe・Ta alloys, Fe・Ta・C alloys, and Fe・Ta・N alloys. Iron-zirconium alloys include, for example, Fe-Zr-N alloys.

[0032] Furthermore, typical amorphous soft magnetic materials or nanocrystalline soft magnetic materials used in magnetic materials may include, for example, cobalt alloys containing cobalt and at least one element from the group consisting of zirconium, hafnium, niobium, tantalum, titanium, and yttrium. Cobalt alloys preferably contain 80 at% or more cobalt. Cobalt alloys containing 80 at% or more cobalt tend to become amorphous when formed into films. In addition, cobalt alloys containing 80 at% or more cobalt have excellent magnetic properties because they have low crystalline magnetic anisotropy, fewer crystalline defects, and fewer grain boundaries. Suitable amorphous soft magnetic materials include, for example, Co·Zr alloys, Co·Zr·Nb alloys, and Co·Zr·Ta alloys.

[0033] Amorphous soft magnetic materials have an amorphous structure as their main structure. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they do not have clear peaks in the X-ray diffraction pattern. When observing the X-ray diffraction pattern of amorphous soft magnetic materials, they have a broad halo pattern.

[0034] Nanocrystalline soft magnetic materials are formed by applying heat treatment to amorphous soft magnetic materials that have an amorphous structure. Nanocrystalline soft magnetic materials are soft magnetic materials in which nanocrystals are deposited by heat treatment of amorphous soft magnetic materials. Nanocrystalline soft magnetic materials have a nanocrystalline structure. Nanocrystals are polycrystalline materials with particle sizes ranging from several nanometers to tens of nanometers.

[0035] When observing the X-ray diffraction pattern of nanocrystalline soft magnetic materials, X-ray diffraction peaks are found at positions corresponding to the lattice spacing of the crystal planes. The crystallite size can be calculated from the width of the X-ray diffraction peaks using Scherrer's equation. A nanocrystal is defined as a material whose crystallite size, calculated from the full width at half maximum of the diffraction peaks using Scherrer's equation, is less than 1 micrometer. In this disclosure, the crystallite size of the nanocrystal (the crystallite size calculated from the full width at half maximum of the diffraction peaks using Scherrer's equation) is preferably 100 nanometers or less, and more preferably 50 nanometers or less. Furthermore, the crystallite size of the nanocrystal is preferably 5 nanometers or more.

[0036] Nanocrystalline soft magnetic materials can improve magnetic properties because the crystallite size of the nanocrystals is 100 nanometers or less, as described above. Conventional electrical steel sheets have crystallite sizes on the order of micrometers, generally 50 micrometers or more. The thickness of the metal plate (1) is, for example, 20 μm to 100 μm, preferably 20 μm to 50 μm, and more preferably 20 μm to 30 μm. The metal plate (1) is formed in a plate-like (thin film) form. The metal plate (1) is formed in a rectangular shape when viewed in the thickness direction (A) of the metal plate (1). The thickness direction (A) of the metal plate (1) is the direction indicating the thickness of the metal plate (1), and in Figures 1, 2(a), and 6, it is the direction perpendicular to the drawing.

[0037] (2) Method for manufacturing metal parts A method for manufacturing metal parts (2) having a predetermined shape from a metal sheet (1) will be described.

[0038] In Figure 1, the component region (10) has a predetermined shape, and is the same shape as the metal part (2). That is, the component region (10) is the region of the metal plate (1) that will become the metal part (2).

[0039] As shown in Figures 1, 2(a), and 2(b), in step S1, a cut formation process is performed. In the cut formation process, multiple cuts (14) are formed in the cut portion (13) on the metal plate (1).

[0040] The cut portion (13) is the part of the metal plate (1) that is cut. The cut portion (13) is located on the metal plate (1) outside the component area (10), or on the boundary between the component area (10) and the outer area (10A) located outside the component area (10), and is adjacent to and extends along the edge (11) of the component area (10). The cut portion (13) is a linear area (a strip-shaped area with a very small width of a few millimeters). The cut portion (13) is the cutting allowance of the metal plate (1) (the part that is shaved off and disappears when the metal plate (1) is cut).

[0041] The cut (14) is a hole that penetrates the metal plate (1). The cut (14) penetrates the metal plate (1) in the thickness direction (A). Multiple cuts (14) are arranged along the direction in which the cut portion (13) extends. On the cut portion (13) (see Figure 1), multiple cuts (14) are formed adjacent to the edge (11) of the component region (10). The cut (14) does not penetrate the metal plate (1) and may be a recess (bottomed hole) formed in the metal plate (1).

[0042] The cuts (14) may be formed, for example, by punching holes or pressing a metal plate (1) using a die. Alternatively, the cuts (14) may be formed using tools such as a drill, a hole-punching roller, and a punch.

[0043] As shown in FIGS. 3 and 5, in step S2, a cutting process is performed. In the cutting process, the component region (10) of the metal plate (1) is punched out by a die (30). The die (30) includes a punch (31) and a die (32). With the metal plate (1) placed on the die (32), the punch (31) punches out the component region (10) of the metal plate (1) into the die hole (33). As a result, the metal plate (1) is cut at the cutting portion (13). Consequently, the component region (10) is separated from the metal plate (1).

[0044] As shown in FIGS. 3 and 4, the component region (10) punched into the die hole (33) by the punch (31) is separated from the metal plate (1) and becomes a metal component (2).

[0045] (3) Effect As described above, by forming a plurality of cuts (14) in the cutting portion (13) of the metal plate (1), when cutting (punching) the metal plate (1) along the cutting portion (13) using the die (30), the load applied to the die (30) can be reduced, so that the deterioration of the life of the die (30) can be suppressed. Also, since the cutting surface of the component shape of the metal plate (1) can be guided to a desired cutting surface, a plurality of metal components (2) can be stacked neatly and accurately, which is particularly useful for a metal plate (1) containing nanocrystalline metal.

[0046] Further, by forming a plurality of cuts (14) in the cutting portion (13) of the metal plate (1), when cutting the metal plate (1) along the cutting portion (13) using the die (30), the desired location (cutting portion (13)) of the metal plate (1) can be easily cut along the plurality of cuts (14), so that the metal component (2) can be manufactured accurately.

[0047] (4) Configuration example of the cut lines The number of the plurality of cut lines (14) and the size of the interval between adjacent cut lines (14) are not particularly limited. The shape of the cut lines (14) is not particularly limited. The cut lines (14) may be, for example, round holes or may be long holes. A part of the cut lines (14) may protrude from the cutting portion (13) to the outer portion (12). The outer portion (12) is an area located around the cutting portion (13) on the metal plate (1) and outside the component area (10). In the present embodiment, the plurality of cut lines (14) have the same shape as each other and are arranged at equal intervals. The plurality of cut lines (14) do not have to have the same shape (length) as each other, and the shape of at least one of the plurality of cut lines (14) may be different from the shape of the other cut lines (14). The plurality of cut lines (14) do not have to be arranged at equal intervals, and the interval between one adjacent cut line (14) may be different from the interval between the other adjacent cut lines (14). The plurality of cut lines (14) may be formed so as to be arranged in a dashed line at at least a part of the cutting portion (13).

[0048] As shown in FIG. 6, when the cutting portion (13) includes a bent portion (13a), the cut lines (14) may be formed in the bent portion (13a). Also, on the cutting portion (13), the cut lines (14) may be formed only in the bent portion (13a). Thus, by forming the cut lines (14) in the bent portion (13a) where the shape of the cutting portion (13) changes significantly, an increase in the number of cut lines (14) can be suppressed, and the operation of forming the cut lines (14) can be simplified.

[0049] (5) Other embodiments A plurality of metal components (1038) (see FIG. 9) may be manufactured by the above method (the same method as when manufacturing the metal component (2)), and the plurality of metal components (1038) may be laminated and fixed to each other to manufacture a stator core (1032) (see FIG. 9).

[0050] Furthermore, a motor (electric motor) (1030) (see Figures 8 and 9) including a stator core (1032) manufactured by stacking and fixing together multiple metal parts (1038) may be manufactured. A blower including this motor (1030) may also be manufactured. The blower includes a motor (1030) and an impeller, and blows air by rotating the impeller with the motor (1030). A compressor (1010) including this motor (1030) may also be manufactured. Furthermore, a refrigeration device (101) (see Figure 7) including this compressor may also be manufactured.

[0051] The refrigeration system (101) will now be described. The refrigeration system (101) shown in Figure 7 has a refrigerant circuit (101a) filled with refrigerant. The refrigerant circuit (101a) includes a compressor (1010), a heat exchanger (102), an expansion valve (103), and an evaporator (104). The refrigerant circuit (101a) performs a vapor compression type refrigeration cycle.

[0052] In the refrigeration cycle, the refrigerant compressed by the compressor (1010) releases heat into the air in the heat exchanger (102). The refrigerant that has released heat is depressurized by the expansion valve (103) and evaporates in the evaporator (104). The evaporated refrigerant is drawn back into the compressor (1010).

[0053] The refrigeration equipment (101) may also be an air conditioning system, a water heater, a chiller unit, a cooling system for cooling the air inside the storage unit, etc.

[0054] The compressor (1010) shown in Figure 8 comprises a casing (1011), a motor (1030), a drive shaft (1020), and a compression mechanism (1022).

[0055] The casing (1011) houses the motor (1030), the drive shaft (1020), and the compression mechanism (1022). The casing (1011) is a fully enclosed container. The inside of the casing (1011) is filled with high-pressure coolant discharged from the compression mechanism (1022).

[0056] The casing (1011) is made of a metal material. The casing (1011) has a body (1012), a bottom (1013), and a top (1014). The body (1012) is a cylindrical metal member. Openings are formed at both axial ends of the body (1012). The bottom (1013) closes the lower opening of the body (1012). The top (1014) closes the upper opening of the body (1012).

[0057] As shown in Figures 8 and 9, the motor (1030) is positioned above the compression mechanism (1022). The motor (1030) has its operating frequency controlled by an inverter device. In other words, the compressor (1010) is an inverter type with a variable operating frequency.

[0058] The motor (1030) has a stator (1031) and a rotor (1040). The stator (1031) is supported by the body (1012) of the casing (1011).

[0059] The stator (1031) has a stator core (1032) and a coil (1033) wound around the stator core (1032). The stator core (1032) has an annular back yoke (1034) and a plurality of teeth (1035) extending radially inward from the inner circumferential surface of the back yoke (1034). A plurality of core cuts (1036) (6 in this example) are formed on the outer circumferential surface of the back yoke (1034). The core cuts (1036) are grooves extending axially from the stator core (1032).

[0060] The stator core (1032) has a laminate (M). The laminate (M) is constructed by stacking multiple metal parts (1038) (multiple thin plates that, when viewed in the thickness direction, have the shape of the stator core (1032) shown in Figure 9) manufactured from a metal plate (1) by the above method (Figures 1 to 6) in the thickness direction. The metal parts (1038) are thin plate-shaped parts that have a back yoke (1034) and teeth (1035). In other words, the multiple metal parts (1038) of this disclosure constitute the laminate (M) of the stator core (1032).

[0061] The rotor (1040) is positioned inside the stator core (1032). A drive shaft (1020) is fixed to the axis of the rotor (1040). Multiple slots (1041) are formed in the rotor (1040). Permanent magnets are embedded inside the slots (1041).

[0062] The drive shaft (1020) extends vertically along the axis of the casing (1011). The drive shaft (1020) is rotationally driven by a motor (1030). The drive shaft (1020) is rotatably supported by a bearing (1029).

[0063] The compression mechanism (1022) includes a cylinder (1023) and a piston (1024) located inside the cylinder (1023). A cylinder chamber (1025) is formed between the inner surface of the cylinder (1023) and the outer surface of the piston (1024). In the cylinder chamber (1025), the fluid is compressed by the piston (1024), which is driven by a drive shaft (1020).

[0064] The compressor (1010) has an intake pipe (1026) and a discharge pipe (1027). The intake pipe (1026) penetrates the body (1012) radially and communicates with the cylinder chamber (1025). Low-pressure refrigerant from the refrigerant circuit (101a) is drawn into the cylinder chamber (1025) through the intake pipe (1026). The discharge pipe (1027) penetrates the top (1014) axially and communicates with the internal space of the casing (1011). The refrigerant compressed by the compression mechanism (1022) flows through the core cut (1036) of the motor (1030), etc., and is then sent to the refrigerant circuit (101a) from the discharge pipe (1027).

[0065] While embodiments and modifications have been described above, it will be understood that a variety of changes in form and details are possible without departing from the spirit and scope of the claims. Furthermore, these embodiments and modifications may be combined or substituted as appropriate, as long as they do not impair the functions of the subject matter of this disclosure. The terms “first,” “second,” etc., described above are used to distinguish the phrases to which these terms are attached and do not limit the number or order of such phrases.

[0066] As described above, this disclosure is useful for manufacturing metal parts, manufacturing stator cores, manufacturing motors, manufacturing compressors, manufacturing blowers, and manufacturing refrigeration equipment.

[0067] 1 Metal plate 2 Metal part 10 Part area 11 Edge 12 Outer part 13 Cut part 13a Bent part 14 Cut 30 Mold

Claims

1. A method for manufacturing a metal part (2) having a predetermined shape from a metal plate (1) containing an amorphous metal or a nanocrystalline metal, comprising: a cut formation step of forming a plurality of cuts (14) in a cutting portion (13) located outside the predetermined shape of the part region (10) on the metal plate (1), or on the boundary between the part region (10) and an outer region (10A) located outside the part region (10), and along the edge (11) of the part region (10); and a cutting step of cutting the metal plate (1) at the cutting portion (13) using a mold (30).

2. The method for manufacturing a metal part according to claim 1, wherein the cut portion (13) includes a bent portion (13a), and the cut (14) is formed in the bent portion (13a).

3. The method for manufacturing a metal part according to claim 1, wherein the plurality of cuts (14) are formed to be arranged at equal intervals along the cut portion (13).

4. The method for manufacturing a metal part according to any one of claims 1 to 3, wherein the plurality of cuts (14) have the same shape as each other.

5. The method for manufacturing a metal part according to any one of claims 1 to 4, wherein the plurality of cuts (14) are formed to be arranged in a dashed line pattern at least in part of the cut portion (13).

6. The method for manufacturing a metal part according to any one of claims 1 to 5, wherein the cut (14) penetrates the metal plate (1) or is a recess formed in the metal plate (1).

7. A method for manufacturing a stator core, comprising stacking a plurality of metal parts (2) manufactured by the manufacturing method described in any one of claims 1 to 6.

8. A method for manufacturing a motor, comprising manufacturing a motor including the stator core described in claim 7.

9. A method for manufacturing a compressor, comprising manufacturing a compressor including the motor described in claim 8.

10. A method for manufacturing a blower, comprising manufacturing a blower including the motor described in claim 8.

11. A method for manufacturing a refrigeration apparatus, comprising a compressor as described in claim 9.

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