Metal component manufacturing method, stator core manufacturing method, motor manufacturing method, compressor manufacturing method, blower manufacturing method, and refrigeration device manufacturing method

Abstract

The present invention pertains to a metal component manufacturing method for manufacturing a metal component (2), which has a prescribed shape, from a metal plate (1) containing an amorphous metal or a nanocrystalline metal, the method comprising: a crystallization step for, while suppressing crystallization of a component region (10) having the prescribed shape on the metal plate (1), crystallizing a cutting part (13) that extends along an edge portion (11) of the component region (10) and is located outside the component region (10) or at a boundary between the component region (10) and an outside region (10A) located outside the component region (10); and a cutting step for cutting the metal plate (1) at the cutting part (13) by using a mold (30).

Description

Method for manufacturing metal parts, method for manufacturing stator core, method for manufacturing motor, method for manufacturing compressor, method for manufacturing blower, and method for manufacturing 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 made of laminated amorphous metal.

[0003] Japanese Patent No. 6656428

[0004] Metals containing amorphous metal or nanocrystalline metal are extremely thin compared to general electromagnetic steel sheets, but are very hard. Therefore, when a large amount of the above metals are punched out by a punching method during mass production, an excessive load continues to be applied to the mold, resulting in cracks, chips, 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, while suppressing crystallization of a part region (10) having the predetermined shape on the metal plate (1), on the outside of the part region (10), or on the boundary between the part region (10) and an outer region (10A) located outside the part region (10), and crystallizing a cutting portion (13) along an edge portion (11) of the part region (10). The method includes a crystallization step and a cutting step of cutting the metal plate (1) with the cutting portion (13) using a mold (30). Crystallizing the cutting portion (13) includes not only crystallizing the entire area of the cutting portion (13) but also crystallizing at least a part of the area of the cutting portion (13).

[0007] According to the first embodiment, by crystallizing the cut portion (13) of the component region (10) on the metal plate (1), the load on the mold (30) when cutting the metal plate (1) at the cut portion (13) using the mold (30) can be reduced, thereby suppressing a decrease in the lifespan of the mold (30).

[0008] A second aspect is the crystallization step, in the first aspect, which includes the steps of forming a plurality of cuts (14) on the cut portion (13) and heating the outer portion (12) of the cut portion (13).

[0009] According to the second embodiment, when the outer portion (12) is heated to crystallize the cut portion (13) adjacent to the outer portion (12), the cut (14) formed in the cut portion (13) can suppress heat transfer to the component region (10), thereby suppressing crystallization of the component region (10).

[0010] A third aspect is the crystallization step, in the first aspect, which includes heating the cut portion (13) or the outer portion (12) of the cut portion (13) while cooling the component region (10) or the edge portion (11) of the component region (10).

[0011] According to the third embodiment, when heating the cut portion (13) or the outer portion (12) to crystallize the cut portion (13) adjacent to the outer portion (12), the crystallization of the component region (10) can be suppressed by cooling the component region (10) or the edge (11) of the component region (10) on the metal plate (1).

[0012] A fourth aspect is the first aspect, wherein the crystallization step includes heating a separated portion (12a) on the metal plate (1) that is separated by a predetermined distance (D) or more from the cut portion (13) to the outside of the component region (10).

[0013] According to the fourth embodiment, when the separated portion (12a) is heated to crystallize the cut portion (13), the component region (10) is located at a position further apart from the separated portion (12a) than the cut portion (13). Therefore, the amount of heat transferred to the component region (10) is suppressed compared to the cut portion (13). As a result, crystallization of the component region (10) can be suppressed.

[0014] The fifth aspect is that, in the fourth aspect, the predetermined distance (D) has a size of 0 mm or more and 5 mm or less.

[0015] According to the fifth embodiment, on the metal plate (1), a location can be heated at least at a distance from the edge (11) of the component area (10) by the width of the cut portion (13).

[0016] A sixth aspect is the first aspect, wherein the crystallization step includes a step of resistance heating the cut portion (13).

[0017] According to the sixth embodiment, the cut portion (13) can be locally heated by resistive heating, so that the cut portion (13) crystallizes by resistive heating while suppressing the crystallization of the component region (10).

[0018] A seventh aspect is the first aspect, wherein the crystallization step includes heating the cut portion (13) by irradiating it with laser light or an electron beam.

[0019] According to the seventh embodiment, the cut portion (13) can be locally heated by laser light or an electron beam, so that the cut portion (13) can be crystallized by laser light or an electron beam while suppressing the crystallization of the component region (10).

[0020] The eighth aspect involves pulse heating of the cutting portion (13) in the sixth or seventh aspect.

[0021] According to the eighth aspect, the amount of heat transmitted from the cut portion (13) to the component area (10) can be effectively suppressed.

[0022] The ninth 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 eighth aspects.

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

[0024] The tenth aspect is a method for manufacturing a motor, comprising manufacturing a motor including a stator core according to the ninth aspect.

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

[0026] The eleventh aspect is a method for manufacturing a compressor, comprising manufacturing a compressor including a motor according to the tenth aspect.

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

[0028] A twelfth aspect is a method for manufacturing a blower, comprising manufacturing a blower including a motor according to the tenth aspect.

[0029] In the twelfth embodiment, a blower can be manufactured that includes a stator core made from a metal plate (1).

[0030] The thirteenth aspect is a method for manufacturing a refrigeration apparatus, the method for manufacturing a refrigeration apparatus including a compressor according to the eleventh aspect.

[0031] In the thirteenth embodiment, a refrigeration system can be manufactured that includes a stator core made from a metal plate (1).

[0032] Figure 1 is a plan view of an amorphous metal sheet according to an embodiment. Figure 2(a) is a cross-sectional view of an amorphous metal sheet being punched out by a die. Figure 2(b) is a perspective view of a metal part. Figure 3 is a flow chart of a method for manufacturing a metal part. Figure 4(a) is a plan view of an amorphous metal sheet with cuts formed on the cut portion. Figure 4(b) is a perspective view showing the outer part of the amorphous metal sheet being heated. Figure 5 is a perspective view showing the outer part of the amorphous metal sheet being heated while the part area is being cooled. Figure 6 is a plan view showing the separated portions of the outer part of the amorphous metal sheet, which are the heated areas. Figure 7 is a perspective view showing the amorphous metal sheet being resist-heated. Figure 8 is a perspective view showing the amorphous metal sheet being heated by laser light. Figure 9 is a schematic configuration diagram of a refrigeration device. Figure 10 is a longitudinal cross-sectional view corresponding to a cross section parallel to the axial direction in a compressor. Figure 11 is a transverse cross-sectional view corresponding to a cross section perpendicular to the axial direction in a motor.

[0033] 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.

[0034] (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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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). The thickness direction (A) of the metal plate (1) is the direction indicating the thickness of the metal plate (1), and in Figures 1, 4(a), 4(b), 6(a), and 6(b), it is the direction perpendicular to the drawing.

[0041] (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.

[0042] In FIG. 1, the component region (10) has a predetermined shape and has the same shape as the metal component (2). That is, the component region (10) is the region of the metal plate (1) that becomes the metal component (2).

[0043] In FIG. 1, a cutting portion (13) and an outer portion (12) are shown.

[0044] The cutting portion (13) is the portion of the metal plate (1) to be cut. The cutting portion (13) is located on the metal plate (1) outside the component region (10) or on the boundary between the component region (10) and the outer region (10A) located outside the component region (10), and is a region that extends along the edge (11) of the component region (10) while being adjacent to the edge (11). The cutting portion (13) is a linear region (a strip-shaped region having a minute width of about several millimeters). The cutting portion (13) is the cutting allowance of the metal plate (1) (the portion that is shaved off and disappears when the metal plate (1) is cut).

[0045] The outer portion (12) is a region that is located on the metal plate (1) around the cutting portion (13) and outside the component region (10). The outer portion (12) is a strip-shaped region that extends along the cutting portion (13) while being adjacent to the cutting portion (13). The cutting portion (13) is located between the outer portion (12) and the edge (11) of the component region (10).

[0046] As shown in FIGS. 1 and 3, in step S1, a crystallization process is performed. In the crystallization process, the cutting portion (13) is crystallized while suppressing the crystallization of the component region (10) on the metal plate (1). In the crystallization process, the cutting portion (13) is crystallized by raising the temperature of the cutting portion (13) to the crystallization start temperature or higher. The crystallization start temperature is the temperature at which crystallization of the amorphous soft magnetic material occurs. The crystallization start temperature varies depending on the material, but is, for example, 300 to 500 °C. Crystallizing the cutting portion (13) includes not only crystallizing the entire region of the cutting portion (13) but also crystallizing at least a part of the region of the cutting portion (%).

[0047] As shown in FIGS. 2(a) and 3, in step S2, a cutting process is performed. In the cutting process, the component area (10) of the metal plate (1) is punched out by a mold (30). The mold (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 area (10) of the metal plate (1) into the die hole (33). As a result, the metal plate (1) is cut at the cutting part (13). Consequently, the component area (10) is separated from the metal plate (1).

[0048] As shown in FIGS. 2(a) and 2(b), the component area (10) punched into the die hole (33) by the punch (31) is separated from the metal plate (1) and becomes a metal component (2).

[0049] (3) Effect As described above, by crystallizing the cutting part (13) of the component area (10) on the metal plate (1), when cutting the metal plate (1) at the cutting part (13) using the mold (30), the load on the mold (30) can be reduced, so that the reduction of the life of the mold (30) can be suppressed.

[0050] Also, since the crystallization of the component area (10) can be suppressed, the deterioration of the metal component (2) and the reduction of its function can be suppressed.

[0051] (4) First Example of the Crystallization Process As shown in FIGS. 3 and 4(a), the crystallization process (step S1) may include a first step of forming a plurality of cuts (14) on the cutting part (13) (see FIG. 1) in the metal plate (1), and a second step of heating the outer part (12).

[0052] As shown in Figure 4(a), the cuts (14) are holes that penetrate the metal plate (1). The cuts (14) penetrate 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 portion (11) of the component area (10). The number of multiple cuts (14) and the size of the spacing between adjacent cuts (14) are not particularly limited. The shape of the cuts (14) is not particularly limited. The cuts (14) may be, for example, round holes or elongated holes. Part of the cuts (14) may protrude from the cut portion (13) to the outer portion (12). In this embodiment, multiple cuts (14) are arranged at equal intervals. In the first step, the cuts (14) may be formed, for example, by punching holes in the metal plate (1) using a die. Alternatively, the cuts (14) may be formed using tools such as a drill and a hole-punching roller.

[0053] As shown in Figures 4(a) and 4(b), in the first step, after a plurality of cuts (14) are formed on the cut portion (13), the process moves to the second step, where the outer portion (12) is heated. In the first step, for example, heating elements (41, 42) having the same shape as the outer portion (12) on the opposing surface to the outer portion (12) are brought into contact with the outer portion (12) by abutting them against the outer portion (12). The heating elements (41, 42) generate heat while not in contact with the component area (10) and the cut portion (13) (for example, the component area (10) and the cut portion (13) are in contact with the air). As a result, the outer portion (12) is directly heated without the component area (10) and the cut portion (13) being directly heated. In this embodiment, the outer portion (12) of the metal plate (1) is heated from both sides by a pair of heating elements (41, 42). The heating elements (41, 42) contain a metal such as a copper alloy and generate heat when an electric current is passed through them.

[0054] In the second step, the outer portion (12) of the metal plate (1) is heated, and the heat from the outer portion (12) is transferred to the cut portion (13), causing the temperature of the cut portion (13) to rise above the crystallization start temperature. As a result, the cut portion (13) crystallizes. At this time, since multiple cuts (14) are formed in the cut portion (13), the amount of heat transferred from the outer portion (12) to the component region (10) is suppressed by the multiple voids of the cuts (14). As a result, the temperature of the component region (10) on the metal plate (1) is prevented from rising above the crystallization start temperature, and crystallization of the component region (10) is suppressed.

[0055] Once the second process is completed, the process moves on to the cutting process (step S2).

[0056] (5) Second example of the crystallization process As shown in Figures 3 and 5, the crystallization process (step S1) may include a third step of heating the outer part (12) while cooling the component region (10) or the edge (11) of the component region (10).

[0057] In the third step, for example, the heating elements (41, 42) are brought into contact with the outer part (12), and the heat-absorbing elements (51, 52), whose opposing surfaces have the same shape as the component area (10), are brought into contact with the component area (10). As a result, the heating elements (41, 42) generate heat, while the heat-absorbing elements (51, 52) are cooled. This causes the outer part (12) to be heated by the heating elements (41, 42) while the component area (10) is cooled by the heat-absorbing elements (51, 52).

[0058] According to this, the outer part (12) is heated, and the heat from the outer part (12) is transferred to the cut part (13), causing the temperature of the cut part (13) to rise above the crystallization initiation temperature. As a result, the cut part (13) crystallizes. In contrast, the component region (10) is cooled, which prevents it from reaching a temperature above the crystallization initiation temperature. As a result, crystallization of the component region (10) is suppressed.

[0059] In this embodiment, the outer portion (12) of the metal plate (1) is heated from both sides by a pair of heating elements (41, 42), while the component area (10) of the metal plate (1) is cooled from both sides by a pair of heat-absorbing elements (51, 52). The heat-absorbing elements (51, 52) contain a metal such as a copper alloy, and have channels formed inside, through which cooling water flows to cool them.

[0060] In this embodiment, the heating elements (41, 42) and the heat-absorbing elements (51, 52) are insulated from each other by forming a gap (void) between them or by arranging an insulator between them.

[0061] In this embodiment, in the third step, the cut portion (13) does not come into contact with either the heating element (41, 42) or the heat-absorbing element (51, 52), but is in contact with, for example, air. In this case, when the outer portion (12) is heated by the heating element (41, 42), the heat from the outer portion (12) is transferred to the cut portion (13), causing the cut portion (13) to crystallize. However, in the third step, the heating element (41, 42) may come into contact with the cut portion (13), and the cut portion (13) may be directly heated by the heating element (41, 42) to crystallize. In this case (when the cut portion (13) is directly heated), neither the outer portion (12) nor the cut portion (13) may be heated, and only the cut portion (13) may be heated.

[0062] In the third step, the component region (10) is cooled, so even if the outer part (12) is heated, the temperature of the component region (10) is prevented from exceeding the crystallization start temperature. As a result, crystallization of the component region (10) is suppressed. In addition, in the third step, the entire component region (10) may not be cooled, but only the edge (11) of the component region (10) may be cooled. In this case, for example, the heat-absorbing elements (51, 52) may be formed in a cylindrical shape. In this case, the inner part of the edge (11) of the component region (10) is not directly heated or cooled because it is in contact with, for example, the hollow part of the cylindrical heat-absorbing elements (51, 52).

[0063] Once the third step is completed, the process moves on to the cutting step (step S2).

[0064] (6) Third example of the crystallization process As shown in Figures 3 and 6, the crystallization process (step S1) may include a fourth step of heating a separated portion (12a) which is a part of the outer portion (12) on the metal plate (1).

[0065] The outer portion (12) includes a separated portion (12a) and a close portion (12b). The separated portion (12a) is the portion of the outer portion (12) that is separated from the cut portion (13) by a predetermined distance (D) or more. The close portion (12b) is the portion of the outer portion (12) that is located within a distance shorter than the predetermined distance (D) from the cut portion (13). The close portion (12b) is located between the separated portion (12a) and the cut portion (13). The predetermined distance (D) has a size of 0 mm or more and 5 mm or less. Preferably, the predetermined distance (D) is 0.5 mm or more and 5 mm or less.

[0066] In the fourth step, the separated portion (12a) comes into contact with, for example, the heating elements (41, 42) (see Figure 4(b)). As a result, the separated portion (12a) is directly heated. The adjacent portion (12b) does not come into contact with the heating elements (41, 42). As a result, the adjacent portion (12b) is not directly heated. Furthermore, the component area (10) and the cut portion (13) do not come into contact with the heating elements (41, 42). As a result, the component area (10) and the cut portion (13) are not directly heated.

[0067] As described above, the separated portion (12a) is directly heated, while the adjacent portion (12b) is not directly heated. As a result, the heat applied to the separated portion (12a) is transferred to the cut portion (13) via the adjacent portion (12b), causing the cut portion (13) to reach a temperature above the crystallization start temperature and crystallize.

[0068] In contrast, with respect to the component region (10), heat applied to the separated portion (12a) is transferred through the adjacent portion (12b) and the cut portion (13), which is the cutting allowance. However, as the heat applied to the separated portion (12a) is transferred to the component region (10) via the adjacent portion (12b) and the cut portion (13), it gradually weakens, preventing the temperature of the component region (10) from exceeding the crystallization initiation temperature. As a result, crystallization of the component region (10) is suppressed.

[0069] Once the fourth step is completed, the process moves on to the cutting step (step S2).

[0070] (7) Fourth example of the crystallization process As shown in Figures 3 and 7, the crystallization process (step S1) may include a fifth step in which the outer part (12) is heated by resistance heating.

[0071] In the fifth step, metal rollers (61, 62) are pressed against the cut portion (13) of the metal plate (1), and with current flowing through the rollers (61, 62), they are rolled on the outer portion (12) (seam welding). As a result, the rollers (61, 62) are heated by the resistance heating generated when current is flowing through them, and the heated rollers (61, 62) roll on the cut portion (13) of the metal plate (1), thus heating the cut portion (13). Heating an object by pressing a metal object such as rollers (61, 62) against it and applying current to the object, thereby generating resistance heating, is sometimes referred to as resistance heating. Using resistance heating, it is possible to locally heat (generate heat) a targeted area of ​​the object (the area where a metal object such as rollers (61, 62) is pressed).

[0072] In the fifth step, the cut portion (13) is locally heated by resistance heating. This causes the temperature of the cut portion (13) to rise above the crystallization initiation temperature. As a result, the cut portion (13) crystallizes.

[0073] The component area (10) is not in contact with the rollers (61, 62) and is not directly heated by resistance heating.

[0074] By locally heating the cut portion (13), the amount of heat transferred from the cut portion (13) to the component region (10) can be suppressed. This prevents the temperature of the component region (10) from rising above the crystallization temperature, thereby suppressing crystallization of the component region (10).

[0075] In this embodiment, when resistively heating the cutting portion (13) by applying current to a metal object such as rollers (61, 62), the current is applied continuously, but pulse heating may be performed by applying pulsed current. This allows the cutting portion (13) to crystallize through resistive heating while suppressing excessive heating of the cutting portion (13), thereby effectively suppressing the amount of heat transferred from the cutting portion (13) to the component region (10). As a result, crystallization of the component region (10) can be effectively suppressed.

[0076] Once the fifth step is completed, the process moves on to the cutting step (step S2).

[0077] (8) Fifth example of the crystallization process As shown in Figures 3 and 8, the crystallization process (step S1) may include a sixth step of heating the outer part (12) by irradiating the outer part (12) with laser light (L) or an electron beam.

[0078] In the sixth step, for example, the laser light (L) emitted from the irradiation device (LA) is focused by a focusing lens (LB) and locally irradiated onto the cutting area (13). When heating an object by irradiating it with laser light (L) or an electron beam, it becomes possible to locally heat (generate heat) a targeted area of ​​the object (the area irradiated by the laser light (L) or electron beam).

[0079] In the sixth step, the cut portion (13) is heated locally by irradiating it with laser light (L) or an electron beam. This causes the temperature of the cut portion (13) to rise above the crystallization start temperature. As a result, the cut portion (13) crystallizes.

[0080] The component area (10) is located outside the irradiation area of ​​the laser light (L) or electron beam and is not directly heated by the laser light (L) or electron beam.

[0081] By locally heating the cut portion (13), the amount of heat transferred from the cut portion (13) to the component region (10) can be suppressed. This prevents the temperature of the component region (10) from rising above the crystallization temperature, thereby suppressing crystallization of the component region (10).

[0082] In this embodiment, the outer portion (12) is continuously irradiated with laser light (L) or an electron beam. However, the cut portion (13) may be pulsed-heated by pulsed irradiation with laser light (L) or an electron beam. This allows the cut portion (13) to crystallize with the laser light (L) or electron beam while suppressing excessive heating of the cut portion (13), thereby effectively suppressing the amount of heat transferred from the cut portion (13) to the component region (10). As a result, crystallization of the component region (10) can be effectively suppressed.

[0083] Once the sixth step is completed, the process moves on to the cutting step (step S2).

[0084] (9) Other Embodiments A plurality of metal parts (1038) (see Figure 11) may be manufactured by the above method (the same method as when the metal part (2) was manufactured), and the plurality of metal parts (1038) may be stacked and fixed to each other to manufacture a stator core (1032) (see Figure 11).

[0085] Furthermore, a motor (electric motor) (1030) (see Figures 10 and 11) 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 the motor (1030) rotates the impeller to produce air. A compressor (1010) including this motor (1030) may also be manufactured. Furthermore, a refrigeration device (101) (see Figure 9) including this compressor may also be manufactured.

[0086] The refrigeration system (101) will now be described. The refrigeration system (101) shown in Figure 9 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.

[0087] 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).

[0088] 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.

[0089] The compressor (1010) shown in Figure 10 comprises a casing (1011), a motor (1030), a drive shaft (1020), and a compression mechanism (1022).

[0090] 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).

[0091] 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).

[0092] As shown in Figures 10 and 11, 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.

[0093] The motor (1030) has a stator (1031) and a rotor (1040). The stator (1031) is supported by the body (1012) of the casing (1011).

[0094] 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).

[0095] 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 11) in the thickness direction, which are manufactured from a metal plate (1) by the above method (Figures 1 to 8). 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).

[0096] 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).

[0097] 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).

[0098] 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).

[0099] 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).

[0100] 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.

[0101] As described above, this disclosure is useful for manufacturing metal parts, manufacturing stator cores, manufacturing motors, manufacturing compressors, manufacturing blowers, and manufacturing refrigeration equipment.

[0102] 1 Amorphous metal sheet 2 Metal part 10 Part area 11 Edge 12 Outer part 12a Separation 13 Cutting section 14 Cut 30 Mold D Determined distance

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 crystallization step of crystallizing a cut portion (13) located outside the part region (10) 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), while suppressing the crystallization of the part region (10) having the predetermined shape on the metal plate (1); and a cutting step of cutting the metal plate (1) at the cut portion (13) using a mold (30).

2. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes the steps of forming a plurality of cuts (14) on the cut portion (13) and heating the outer portion (12) of the cut portion (13).

3. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of heating the cut portion (13) or the outer portion (12) of the cut portion (13) while cooling the part region (10) or the edge portion (11) of the part region (10).

4. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes heating a separated portion (12a) on the metal plate (1) that is separated from the cut portion (13) by a predetermined distance (D) or more from the outside of the part region (10).

5. The method for manufacturing a metal part according to claim 4, wherein the predetermined distance (D) has a size of 0 mm or more and 5 mm or less.

6. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of resistance heating the cut portion (13).

7. The method for manufacturing a metal part according to claim 1, wherein the crystallization step includes a step of heating the cut portion (13) by irradiating the cut portion (13) with laser light or an electron beam.

8. The method for manufacturing a metal part according to claim 6 or claim 7, wherein the cut portion (13) is pulse-heated.

9. 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 8.

10. A method for manufacturing a motor, comprising a stator core as described in claim 9.

11. A method for manufacturing a compressor, comprising manufacturing a compressor including the motor described in claim 10.

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

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

Images