Method for manufacturing metal component and device therefor

Abstract

This method for manufacturing a metal component (38) comprises a forming step in which a molten metal material is amorphized into a thin sheet on a predetermined surface (S), and at the same time the metal material is formed into the shape of the metal component (38) on the predetermined surface (S).

Description

Method and apparatus for manufacturing metal parts

[0001] The present disclosure relates to a method and an apparatus for manufacturing metal parts.

[0002] The electric motor described in Patent Document 1 has a stator provided with a core made of laminated amorphous metal. Since the amorphous metal is very thin compared to a general electromagnetic steel sheet, by using a laminate of amorphous metal, eddy currents in the plane of the plate thickness are less likely to flow, and an increase in iron loss is suppressed.

[0003] Japanese Patent No. 6656428

[0004] By the way, there is a method of forming a metal part using a mold shaped like the metal part. In this method, the metal part can be formed by punching a metal plate placed on the mold.

[0005] However, although the amorphous metal foil is thin, it has very hard physical properties and does not undergo plastic deformation. Therefore, the load generated on the mold when punching the amorphous metal foil is relatively high, and if the amorphous metal foil is continuously punched, the mold is likely to be damaged such as cracked or chipped. Each time the mold is damaged, repair or replacement of the mold is required, so the manufacturing cost of the metal part cannot be reduced.

[0006] An object of the present disclosure is to easily manufacture a metal part made of amorphous metal.

[0007] The first aspect is directed to a method for manufacturing a metal part (38). The manufacturing method has a forming step of simultaneously making a molten metal material amorphous in a thin plate shape on a predetermined surface (S) and forming the metal material into the shape of the metal part (38) on the predetermined surface (S).

[0008] In the first embodiment, since there is no process of punching out metal parts (38) from amorphous metal foil, a mold can be eliminated. Because the metal parts (38) are formed without using a mold, the cost of repairing or replacing molds due to damage is eliminated, and manufacturing costs can be reduced. In addition, the amorphization of the metal and the forming of the metal parts (38) can be carried out simultaneously, and the metal parts (38) can be manufactured continuously, thus simplifying and speeding up the forming of the metal parts (38).

[0009] A second embodiment is, in the first embodiment, the predetermined surface (S) is the outer circumferential surface (S) of a cylindrical roller member (51), and the molding step comprises a supply step of supplying the molten metal material in a thin sheet form onto the outer circumferential surface (S), a cooling step of cooling the metal material supplied onto the outer circumferential surface (S), and a feeding step of rotating the roller member (51) in the circumferential direction to feed the cooled metal material in the rotational direction.

[0010] In the second embodiment, the molten metal rapidly cooled on the outer surface (S) of the rotating roller member (51) can be amorphous and formed into a thin plate shape.

[0011] In a third embodiment, in the first or second embodiment, a first convex portion (61) or a first recess (71) is provided on the predetermined surface (S) so as to follow the edge of the shape of the metal part (38), and in the molding process, the metal part (38) is formed in the inner region (R) formed by the first convex portion (61) or the first recess (71) on the predetermined surface (S).

[0012] In the third embodiment, the metal part (38) can be easily formed simply by providing a first protrusion (61) or a first recess (71) on a predetermined surface (S) according to the shape of the metal part (38).

[0013] A fourth aspect is provided in the third aspect, wherein the predetermined surface (S) is provided with a first groove (81) that connects two adjacent inner regions (R), and molten metal material is supplied to the first groove (81).

[0014] In the fourth embodiment, the metals in adjacent inner regions (R) are connected to each other via the metal that has flowed into the first groove (81). That is, the metal members formed in the first groove (81) function as connecting members that connect the metal parts (38) formed in adjacent inner regions (R). Such connecting members allow multiple metal members to be recovered as a series of metal members. This prevents the multiple metal parts (38) formed in the inner regions (R) from scattering separately and facilitates the recovery of the multiple metal parts (38).

[0015] A fifth aspect is provided on the predetermined surface (S) a second convex portion (62) or a second concave portion (72) that forms a frame-shaped recessed groove (G) surrounding the inner region (R), and a second groove portion (82), the second groove portion (82) communicating the recessed groove (G) and the inner region (R), and the molten metal material is supplied to the second groove portion (82).

[0016] In the fifth embodiment, a frame-shaped metal member is formed around the inner region (R) by a second protrusion (62) or a second recess (72). The metal part (38) within the inner region (R) and the frame-shaped metal member are connected via metal that flows into the second groove (82). That is, the metal that flows into the second groove (82) functions as a connecting member that connects the frame-shaped metal member and the metal within the inner region (R). With such a connecting member, the metal part is fixed and protected inside the frame-shaped metal member. As a result, damage or deformation of the metal part that occurs when removing the metal part from a predetermined surface can be suppressed.

[0017] A sixth aspect is provided on the predetermined surface (S) such that a first convex portion (61) or a first recess (71) is formed along the edge of the shape of the metal part (38), and in the molding step, the metal part (38) is formed in an inner region (R) formed by the first convex portion (61) or the first recess (71) on the predetermined surface (S), and in the supply step, while the roller member (51) is rotating, the molten metal material is intermittently supplied to the inner region (R).

[0018] In the sixth embodiment, since molten metal material is intermittently supplied to the inner region (R), it is possible to suppress the adhesion of molten metal to the region between adjacent inner regions (R) on a predetermined surface (S). As a result, it is possible to avoid the metal material overflowing from the inner region (R), and thus metal parts (38) can be manufactured easily.

[0019] The seventh aspect is the sixth aspect, wherein the cross-section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the area of ​​the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), then in the supply process, the molten metal material is supplied to the central portion (CR) when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51).

[0020] In the seventh embodiment, the metal supplied to the central part between the first wall surface (W1) and the second wall surface (W2) by the rotation of the roller member (51) flows evenly along the outer peripheral surface (S) of the roller member (51) in the forward and backward directions of rotation. This suppresses unevenness in the thickness of the metal supplied to the inner region (R).

[0021] The eighth aspect is the sixth aspect, wherein the cross-section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the region of the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), then in the supply process, when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51), the molten metal material is supplied to the region in front of the central portion in the direction of rotation.

[0022] According to the eighth embodiment, molten metal is applied to the bottom surface from the front in the direction of rotation towards the rear. Since the supply position of the molten metal is located in front of the center in the direction of rotation, the molten metal is applied sequentially from the front to the rear of the bottom surface as the roller rotates. This makes it possible to form amorphous metal with a more uniform thickness on the bottom surface.

[0023] The ninth aspect further comprises, in the seventh or eighth aspect, an inhibitory structure (100) that suppresses adhesion or seizing of the metal material supplied to the inner region (R) in the first wall surface (W1) and the second wall surface (W2).

[0024] In the ninth embodiment, metal parts can be easily recovered from the outer surface of the roller.

[0025] A tenth aspect, in the third aspect, further includes a heating step of heating the metal material in the inner region (R) that has been cooled in the molding step.

[0026] According to the tenth embodiment, a nanocrystalline soft magnetic material can be obtained by heating an amorphous metal.

[0027] An eleventh aspect further includes, in the third aspect, a removal step of removing the metal part (38) of the inner region (R) formed by the molding step.

[0028] In the eleventh embodiment, the molded metal part (38) can be removed by the removal process.

[0029] The twelfth aspect relates to a method for manufacturing a stator core comprising a laminate (M) composed of a plurality of the metal parts (38) manufactured by any one of the manufacturing methods of the first to eleventh aspects. The thickness of each metal part (38) is 20 to 100 μm.

[0030] In the twelfth embodiment, while a normal electrical steel sheet is approximately 400 μm thick per sheet, the amorphous metal is 20 to 100 μm thick per sheet. Therefore, when manufacturing an electric motor of the same size, 4 to 20 times the number of amorphous metal sheets are required compared to a normal electrical steel sheet, and the aforementioned problems of the punching method become more pronounced. However, in the twelfth embodiment, the amorphousization of the metal and the forming of the metal parts (38) can be performed simultaneously, eliminating the need to punch out the metal parts and allowing the stator core to be manufactured simply and quickly. Furthermore, since the stator core is composed of amorphous metal parts (38), an electric motor having the stator core of this embodiment can achieve a reduction in eddy current loss and a reduction in iron loss.

[0031] The thirteenth aspect relates to a method for manufacturing an electric motor equipped with the stator core manufactured by the manufacturing method of the twelfth aspect.

[0032] In the 13th embodiment, a stator core manufactured by the manufacturing method of the 12th embodiment can be applied to a method for manufacturing an electric motor.

[0033] The 14th aspect relates to a method for manufacturing a blower equipped with an electric motor manufactured by the manufacturing method of the 13th aspect.

[0034] In the fourteenth embodiment, an electric motor (30) manufactured by the manufacturing method of the thirteenth embodiment can be applied to a method for manufacturing a blower.

[0035] The 15th aspect relates to a method for manufacturing a compressor equipped with the electric motor manufactured by the manufacturing method of the 13th aspect.

[0036] In the 15th embodiment, an electric motor (30) manufactured by the manufacturing method of the 13th embodiment can be applied to the method for manufacturing a compressor.

[0037] The sixteenth aspect relates to a method for manufacturing a refrigeration apparatus equipped with the compressor manufactured by the manufacturing method of the fifteenth aspect.

[0038] In the sixteenth aspect, a compressor (10) manufactured by the manufacturing method of the fifteenth aspect can be applied to a method for manufacturing a refrigeration system.

[0039] Aspect 17 is directed to an apparatus for manufacturing a thin plate-shaped amorphous metal part (38). The manufacturing apparatus includes a cylindrical roller member (51) having a rotation axis and rotating in the circumferential direction, and a supply unit (52) for supplying molten metal material to the outer peripheral surface (S) of the roller member (51). On the outer peripheral surface (S) of the roller member (51), a first convex portion (61) or a first concave portion (71) is provided along the edge of the shape of the metal part (38). The molten metal material is supplied to the inner region (R) formed by the first convex portion (61) or the first concave portion (71), and the molten metal material is cooled on the outer peripheral surface (S).

[0040] In Aspect 17, a manufacturing apparatus having the same effect as in Aspect 1 can be provided.

[0041] Aspect 18 is the Aspect 17, in which a first groove portion (81) communicating two adjacent inner regions (R) is provided on the outer peripheral surface (S), and the molten metal material is supplied to the first groove portion (81).

[0042] In Aspect 18, a manufacturing apparatus having the same effect as in Aspect 4 can be provided.

[0043] Aspect 19 is the Aspect 17, in which a second convex portion (62) or a second concave portion (72) forming a frame-shaped concave groove (G) surrounding the inner region (R) and a second groove portion (82) are provided on the outer peripheral surface (S). The second groove portion (82) communicates the concave groove (G) and the inner region (R), and the molten metal material is supplied to the second groove portion (82).

[0044] In Aspect 19, a manufacturing apparatus having the same effect as in Aspect 5 can be provided.

[0045] Aspect 20 is the Aspect 17, in which the supply unit (52) intermittently supplies the molten metal material to the inner region (R) formed by the first convex portion (61) or the first concave portion (71) while the roller member (51) is rotating.

[0046] In Aspect 20, a manufacturing apparatus having the same effect as in Aspect 6 can be provided.

[0047] In the 21st aspect, in the 17th aspect, the cross-section of the inner region (R) orthogonal to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the rotational direction, a second wall surface (W2) located behind the first wall surface (W1) in the rotational direction, and a bottom surface portion (B) connecting the first wall surface (W1) and the second wall surface (W2). When, viewed from the axial direction, a region intermediate between the first wall surface (W1) and the second wall surface (W2) in the bottom surface portion (B) is defined as a central portion (CR), the supply portion (52) supplies the molten metal material to the central portion (CR) when the central portion (CR) reaches the highest height position due to the rotation of the roller member (51).

[0048] In the 21st aspect, a manufacturing apparatus having the same effects as those in the 7th aspect can be provided.

[0049] In the 22nd aspect, in the 17th aspect, the cross-section of the inner region (R) orthogonal to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the rotational direction, a second wall surface (W2) located behind the first wall surface (W1) in the rotational direction, and a bottom surface portion (B) connecting the first wall surface (W1) and the second wall surface (W2). When, viewed from the axial direction, a region intermediate between the first wall surface (W1) and the second wall surface (W2) in the bottom surface portion (B) is defined as a central portion (CR), the supply portion (52) supplies the molten metal material to a region in front of the central portion in the rotational direction when the central portion (CR) reaches the highest height position due to the rotation of the roller member (51).

[0050] In the 22nd aspect, a manufacturing apparatus having the same effects as those in the 8th aspect can be provided.

[0051] The 23rd embodiment is the 17th embodiment, wherein the cross section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the rotational direction, a second wall surface (W2) located behind the first wall surface (W1) in the rotational direction, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and further comprises an inhibitory structure (100) that suppresses adhesion or seizing of the metal material supplied to the inner region (R) on the first wall surface (W1) and the second wall surface (W2).

[0052] In the 23rd embodiment, a manufacturing apparatus having the same effects as in the 9th embodiment can be provided.

[0053] The 24th embodiment is one of the 17th to 23rd embodiments, wherein the roller member (51) has a first roller (51a) and a second roller (51b) arranged so that their outer peripheral surfaces (S) face each other, the supply unit (52) supplies the molten metal material between the first roller (51a) and the second roller (51b), and the first roller (51a) and the second roller (51b) rotate to push out the metal material sandwiched between the first roller (51a) and the second roller (51b).

[0054] In the 24th embodiment, an amorphous metal foil strip of uniform thickness can be manufactured by pouring molten metal between a first roller (51a) and a second roller (51b). Furthermore, a metal foil strip of a desired thickness can be manufactured by setting the distance between the first roller (51a) and the second roller (51b).

[0055] The 25th embodiment is one of the 17th to 23rd embodiments, wherein the height of the protrusion or the depth of the recess is the same as or greater than the thickness of the metal part (38).

[0056] In the 25th embodiment, the metal in the inner region (R) can be separated from the other metals, or the molten metal can be placed only in the inner region (R). This makes it easier to remove the metal part (38) from the roller member (51).

[0057] The 26th embodiment is one of the 17th to 23rd embodiments, wherein the first protrusion (61) or the first recess (71) is formed in an annular shape along the edge of the shape of the metal part (38).

[0058] In the 26th embodiment, the inner region (R) and the remaining region can be separated by a first protrusion (61) or a first recess (71). This allows the metal part (38) to be molded more precisely.

[0059] Figure 1 is a schematic diagram of the configuration of a refrigeration apparatus according to an embodiment. Figure 2 is a longitudinal cross-sectional view corresponding to a cross-section parallel to the axial direction in the compressor according to the embodiment. Figure 3 is a transverse cross-sectional view corresponding to a cross-section perpendicular to the axial direction in the electric motor. Figure 4 is a stereoscopic perspective view showing a schematic configuration of the manufacturing apparatus according to the embodiment. Figure 5 is a schematic diagram showing a cross-section perpendicular to the axial direction of the roller member of the manufacturing apparatus, and an enlarged view of a part thereof. Figure 6 is a view of the outer circumferential surface of the roller member viewed from the front. Figure 7 is a block diagram showing the configuration of the manufacturing apparatus. Figure 8 is a flow chart showing each step of the manufacturing method according to the embodiment. Figure 9 is a diagram corresponding to Figure 5, which is an enlarged view of a part of the cross-section of the outer circumferential surface of the roller member of the manufacturing apparatus according to Modification 1. Figure 10 is a schematic diagram showing a cross-section perpendicular to the axial direction of the roller member of the manufacturing apparatus according to Modification 2, and an enlarged view of a part thereof. Figure 11 is a flow chart showing each step of the manufacturing method according to Modification 3. Figure 12 is a schematic diagram showing the outer circumferential surface of the roller member of the manufacturing apparatus according to Modification 4. Figure 13 is a schematic diagram showing a cross-section perpendicular to the axial direction of the roller member of the manufacturing apparatus according to Modification 4, and an enlarged view of a part thereof. Figure 14 is a schematic diagram showing the outer circumferential surface of the roller member of the manufacturing apparatus for Modification 5. Figure 15 is a diagram corresponding to Figure 9, illustrating the manufacturing method for Modification 6. Figure 16 is a schematic diagram showing the restraint structure provided on the wall surface in the manufacturing apparatus for Modification 7.

[0060] Embodiments of this disclosure will be described below with reference to the drawings. The following embodiments are essentially preferred examples and are not intended to limit the scope of the present invention, its applications, or its uses. Furthermore, the embodiments, modifications, and other examples described below can be combined or partially replaced to the extent that the present invention is implementable.

[0061] (1) Refrigeration device The refrigeration device (1) shown in Figure 1 has a refrigerant circuit (1a) filled with refrigerant. The refrigerant circuit (1a) is equipped with a compressor (10), a heat sink (2), an expansion valve (3), and an evaporator (4). The refrigerant circuit (1a) performs a vapor compression type refrigeration cycle.

[0062] In the refrigeration cycle, the refrigerant compressed by the compressor (10) releases heat into the air in the heat exchanger (2). The refrigerant that has released heat is depressurized by the expansion valve (3) and evaporates in the evaporator (4). The evaporated refrigerant is drawn back into the compressor (10).

[0063] The refrigeration system (1) 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.

[0064] (2) Compressor The compressor (10) shown in Figure 2 comprises a casing (11), an electric motor (30), a drive shaft (20), and a compression mechanism (22).

[0065] (2-1) Casing The casing (11) houses the electric motor (30), the drive shaft (20), and the compression mechanism (22). The casing (11) is a completely sealed container. The inside of the casing (11) is filled with high-pressure refrigerant discharged from the compression mechanism (22).

[0066] The casing (11) is made of a metal material. The casing (11) has a body (12), a bottom (13), and a top (14). The body (12) is a cylindrical metal member. Openings are formed at both axial ends of the body (12). The bottom (13) closes the lower opening of the body (12). The top (14) closes the upper opening of the body (12).

[0067] (2-2) Electric Motor As shown in Figures 2 and 3, the electric motor (30) is positioned above the compression mechanism (22). The operating frequency of the electric motor (30) is controlled by an inverter device. In other words, the compressor (10) is an inverter type with a variable operating frequency.

[0068] The electric motor (30) has a stator (31) and a rotor (40). The stator (31) is supported by the body (12) of the casing (11).

[0069] The stator (31) has a stator core (32) and a coil (33) wound around the stator core (32). The stator core (32) has an annular back yoke (34) and a plurality of teeth (6 in this example) (35) extending radially inward from the inner circumferential surface of the back yoke (34). A plurality of core cuts (6 in this example) (36) are formed on the outer circumferential surface of the back yoke (34). The core cuts (36) are grooves extending axially from the stator core (32).

[0070] The stator core (32) is a laminate (M) of a plurality of thin, plate-like metal parts (38). Each metal part (38) is formed in the shape of the stator core (32) as viewed from the lamination direction. Specifically, each metal part (38) has the shape of a back yoke (34) and the shape of teeth (35) as viewed from the lamination direction of the stator core (32).

[0071] The metal part (38) in this embodiment is a metal plate made of amorphous metal. Specifically, the metal part (38) is a metal plate made of amorphous metal containing an amorphous soft magnetic material. Hereinafter, a metal plate made of amorphous metal may be simply referred to as a metal plate.

[0072] As will be described in detail later, the metal part (38) is obtained by forming the stator core (32) shape from a thin metal sheet. The thickness of the amorphous metal sheet is formed to be 20 μm or more and 100 μm or less per sheet, preferably 20 μm or more and 50 μm or less, and more preferably 20 μm or more and 30 μm or less.

[0073] The rotor (40) is positioned inside the stator core (32). A drive shaft (20) is fixed to the axis of the rotor (40). Multiple slots (41) are formed in the rotor (40). Permanent magnets are embedded inside the slots (41).

[0074] (2-3) Drive shaft The drive shaft (20) extends vertically along the axis of the casing (11). The drive shaft (20) is rotationally driven by an electric motor (30). The drive shaft (20) is rotatably supported by a bearing (29).

[0075] (2-4) Compression mechanism The compression mechanism (22) includes a cylinder (23) and a piston (24) provided inside the cylinder (23). A cylinder chamber (25) is formed between the inner surface of the cylinder (23) and the outer surface of the piston (24). In the cylinder chamber (25), the fluid is compressed by the piston (24) driven by the drive shaft (20).

[0076] (2-5) Suction and discharge pipes The compressor (10) has a suction pipe (26) and a discharge pipe (27). The suction pipe (26) penetrates the body (12) radially and communicates with the cylinder chamber (25). Low-pressure refrigerant from the refrigerant circuit (1a) is drawn into the cylinder chamber (25) through the suction pipe (26). The discharge pipe (27) penetrates the top (14) axially and communicates with the internal space of the casing (11). The refrigerant compressed by the compression mechanism (22) flows through the core cut (36) of the electric motor (30), etc., and is then sent to the refrigerant circuit (1a) from the discharge pipe (27).

[0077] (3) Manufacturing of metal parts A manufacturing apparatus (50) and manufacturing method for metal parts (38) will be described with reference to Figures 4 to 8. The material of the metal plate in this embodiment may be any alloy that can be amorphous. For example, the material of the metal plate is mainly composed of iron.

[0078] (3-1) Manufacturing apparatus for metal parts As shown in Figures 4 and 5, the manufacturing apparatus (50) comprises a roller member (51) formed in the shape of a horizontally elongated cylinder and a supply unit (52) that supplies molten metal material to the outer circumferential surface (S) of the rotating roller member (51). The metal material supplied to the roller member (51) is cooled by contact with the outer circumferential surface (S) and amorphous formation proceeds. In the following, the molten metal material may be simply referred to as molten metal.

[0079] (3-1-1) Roller Member The roller member (51) has a rotation axis (55) that extends horizontally. The roller member (51) rotates circumferentially around the rotation axis (55). The roller member (51) is mainly made of copper. In particular, the outer circumferential surface (S) of the roller member (51) is made of copper. The outer circumferential surface (S) of the roller member (51) is an example of a predetermined surface (S).

[0080] (3-1-2) Supply section The supply section (52) supplies molten metal to the outer surface (S) of the roller member (51). The supply section (52) has a receiver (53) for temporarily storing the molten metal. The supply section (52) transports the molten metal to the receiver (53) and supplies the molten metal to the roller member (51) from a supply port (53a) formed at the lower end of the receiver (53). The supply section (52) supplies the molten metal from the supply port (53a) to the outer surface (S) of the roller member (51) at a constant flow rate.

[0081] The receiver (53) is formed in a box shape. The receiver (53) is positioned above the roller member (51). The receiver (53) has a pair of side plates (53b, 53b) that extend in the longitudinal direction of the roller member (51). The opposing surfaces of the pair of side plates (53b, 53b) are inclined downward so as to move toward each other. A gap is formed between the lower ends of the pair of side plates (53b, 53b). This gap is the supply port (53a).

[0082] The supply port (53a) is formed in the shape of a slit extending in the longitudinal direction of the roller member (51). The supply port (53a) is positioned directly above the highest point on the outer circumferential surface (S) of the roller member (51) when viewed from the direction of the rotation axis. The molten metal supplied from the supply port (53a) to the outer circumferential surface (S) of the roller member (51) is dropped to the highest point on the outer circumferential surface (S) of the roller member (51).

[0083] The supply unit (52) has the function of supplying molten metal to the receiver (53). The supply unit (52) controls the flow rate of the molten metal flowing out of the supply port (53a) by adjusting the pressure inside the receiver (53), and also controls the start and stop of the supply of molten metal to the roller member (51). The supply unit (52) may also be configured to supply the molten metal from the supply port (53a) to the roller member (51) by the weight of the molten metal itself.

[0084] (3-1-3) First protrusion The roller member (51) shown in Figures 5 and 6 is provided with a first protrusion (61). The first protrusion (61) is formed on the outer circumferential surface (S) so as to follow the edge of the metal part (38).

[0085] The first protrusion (61) is formed as a ridge. Specifically, the first protrusion (61) is formed in an annular shape along the edge of the shape of the metal part (38). In other words, the first protrusion (61) is formed to border the shape of the metal part (38). The area inside the annular first protrusion (61) is called the inner region (R). The inner region (R) is formed in the shape of the metal part (38).

[0086] The inner region (R) is composed of the inner wall surface (W) of the annular first protrusion (61) and the bottom surface (B) surrounded by it. The bottom surface (B) is part of the outer surface (S).

[0087] Here, as shown in Figure 5, the cross-section of the inner region (R) perpendicular to the rotation axis (55) of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the rotation direction, a second wall surface (W2) located behind the first wall surface (W1) in the rotation direction, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2). The first wall surface (W1) and the second wall surface (W2) constitute the inner wall surface (W) of the first convex portion (61).

[0088] The height H of the first protrusion (61) is greater than the thickness T of the metal part (38). In other words, the height H from the outer circumferential surface (S) to the top of the first protrusion (61) is greater than the thickness T of the metal part (38). The roller member (51) may have a plurality of first protrusions (61) on its outer circumferential surface (S). In other words, a plurality of inner regions (R) may be formed on the outer circumferential surface (S).

[0089] (3-1-4) Control device As shown in Figure 7, the manufacturing apparatus (50) has a control device (C). The control device (C) controls various components of the manufacturing apparatus (50). The control device (C) includes a CPU, GPU, ROM, RAM, etc., and executes the processing of the OS and applications. The control device (C) realizes various functions by executing processing according to the program.

[0090] For example, the control device (C) controls the rotational speed of the roller member (51) and the supply unit (52) to adjust the flow rate and timing of the supply of molten metal supplied from the supply port (53a) to the roller member (51).

[0091] (3-2) Manufacturing Method The manufacturing method of the metal part (38) shown in Figure 8 includes a molding step of shaping the metal material into the form of the metal part (38). In this embodiment, the molding step involves amorphousizing the molten metal material into a thin sheet on the outer surface (S) of a cylindrical roller member (51), and at the same time, shaping the metal material into the form of the metal part (38) on the outer surface (S).

[0092] Specifically, the molding process involves the following steps in order: supply, cooling, feeding, and removal. The supply process involves supplying molten metal material in a thin sheet form onto the outer surface (S). The cooling process cools the metal material supplied onto the outer surface (S). The feeding process involves rotating a roller member (51) in the circumferential direction to feed the cooled metal material in the rotational direction. The removal process involves removing the metal part (38) from the inner region (R).

[0093] In the supply process, the roller member (51) and the supply unit (52) are controlled so that the metal material supplied from the supply unit (52) onto the outer circumferential surface (S) of the roller member (51) reaches the desired thickness of the metal part (38). Since the roller member (51) is made of copper, the molten metal that comes into contact with the outer circumferential surface (S) of the roller member (51) during the cooling process is rapidly cooled and amorphous due to the temperature difference with the copper. As the roller member (51) rotates, the metal material supplied from the supply unit (52) is successively amorphous on the outer circumferential surface (S).

[0094] Here, on the outer circumferential surface (S) of the roller member (51), the first protrusion (61) divides the metal material into an inner region (R) and the metal material in the other regions. In this way, as the molten metal material is supplied from the supply unit (52) to the roller member (51) and the roller member (51) rotates, the metal material becomes amorphous on the outer circumferential surface (S) of the roller member (51) and is simultaneously formed into the shape of the metal part (38).

[0095] In the feeding process, the foil-shaped metal material is fed out by the continuous rotation of the roller member (51). At this time, metal parts (38) are formed within the inner region (R), so the metal parts (38) are also fed out simultaneously by the rotation of the roller member (51). The thickness of each fed-out metal part (38) is 20 to 100 μm.

[0096] In the extraction process, the first protrusion (61) separates the metal material in the inner region (R) from the other metal material, so the metal parts (38) are separated and recovered from the amorphous metal foil strip fed out from the roller member (51).

[0097] (6) Features (6-1) Feature 1 The manufacturing method of the metal part (38) of this embodiment comprises a molding step of amorphously molten metal material into a thin plate shape on a predetermined surface (S) and simultaneously shaping the metal material into the shape of the metal part (38) on the predetermined surface (S).

[0098] This eliminates the need for a process of punching out metal parts (38) from amorphous metal foil, thus enabling the manufacture of metal parts (38) without the use of molds. In this way, there are no issues such as mold wear or breakage, allowing for stable production of metal parts (38). In addition, since the amorphization of the metal and the molding of the metal parts (38) can be performed simultaneously, metal parts (38) can be manufactured simply.

[0099] (6-2) Feature 2 The predetermined surface (S) in this embodiment is the outer circumferential surface (S) of the cylindrical roller member (51). The molding process includes a supply step of supplying molten metal material in a thin sheet form onto the outer circumferential surface (S), a cooling step of cooling the metal material supplied onto the outer circumferential surface (S), and a feeding step of rotating the roller member (51) in the circumferential direction to feed the cooled metal material in the rotational direction.

[0100] The supply process, cooling process, and dispensing process are carried out in parallel. By performing these processes simultaneously, the metal material can become amorphous on the outer surface (S) of the roller member (51) and the metal part (38) can be formed at the same time.

[0101] (6-3) Feature 3 A first protrusion (61) is formed on the outer circumferential surface (S) of the roller member (51) in this embodiment, so as to follow the edge of the shape of the metal part (38). In the molding process, the metal part (38) is formed in the inner region (R) formed by the first protrusion (61) on the outer circumferential surface (S).

[0102] In this way, the metal part (38) can be easily formed simply by providing the first protrusion (61) according to the shape of the metal part (38). In addition, since it is only necessary to remove the amorphous metal part (38) from the inner region (R), there is no need to punch it out, and the metal part (38) can be easily recovered.

[0103] (6-4) Feature 4 The molding process of this embodiment further includes a removal step of removing the metal part (38) from the inner region (R). In this embodiment, the amorphous metal material on the outer surface (S) is divided into the inner region (R) and the other regions, so the metal part (38) can be easily removed from the metal foil strip that has been fed out.

[0104] (6-5) Feature 5 In this embodiment, a method for manufacturing a stator core is provided, comprising a laminate (M) composed of a plurality of metal parts (38) manufactured by the manufacturing method of the present disclosure. The thickness of each metal part (38) is 20 to 100 μm.

[0105] While conventional electrical steel sheets are approximately 400 μm thick per sheet, the laminate (M) of the stator core (32) in this disclosure is composed of amorphous metal sheets that are 20 to 100 μm thick per sheet. Therefore, when manufacturing a laminate (M) of the same size as a laminate (M) made of electrical steel sheets using amorphous metal sheets, 4 to 20 times the number of amorphous metal sheets are required, and the aforementioned problems caused by punching become more pronounced. However, according to this embodiment, the amorphousization of molten metal and the forming of metal parts (38) can be performed simultaneously, so there is no need to punch out the metal parts (38), and the stator core (32) can be manufactured simply and quickly.

[0106] In addition, the shape of the edges (including the outer and inner edges) of the metal parts (38) that constitute the laminate (M) of the stator core (32) is relatively complex, and the length of the edges is also relatively long. Therefore, in the punching method, it is necessary to apply a high load to the press device used for punching, which tends to shorten the life of the mold. However, in the manufacturing method of this embodiment, the metal parts (38) can be formed without being affected by the length and shape of the edges. Furthermore, when the metal parts (38) become large, the punching method requires dividing the metal parts (38) into multiple parts and forming each part individually. However, in the manufacturing method of this embodiment, it is not necessary to form such multiple parts individually, so the metal parts (38) can be formed simply.

[0107] (6-6) Feature 6 According to this embodiment, a method for manufacturing an electric motor (30) equipped with a stator core (32) manufactured by the manufacturing method of the present disclosure is provided. In this way, an electric motor (30) can be manufactured using a metal part (38) manufactured by the manufacturing method of the present disclosure.

[0108] (6-7) Feature 7 According to this embodiment, a method for manufacturing a compressor (10) equipped with an electric motor (30) manufactured by the manufacturing method of the present disclosure is provided. In this way, the compressor (10) can be manufactured using metal parts (38) manufactured by the manufacturing method of the present disclosure.

[0109] (6-8) Feature 8 According to this embodiment, a method for manufacturing a refrigeration device (1) equipped with a compressor (10) manufactured by the manufacturing method of the present disclosure is provided. In this way, the refrigeration device (1) can be manufactured using metal parts (38) manufactured by the manufacturing method of the present disclosure.

[0110] (6-9) Feature 9 The manufacturing apparatus for the thin sheet-shaped amorphous metal part (38) of this embodiment comprises a cylindrical roller member (51) having a rotation axis and rotating in the circumferential direction, and a supply unit (52) that supplies molten metal material to the outer circumferential surface (S) of the roller member (51). A first convex portion (61) is formed on the outer circumferential surface (S) of the roller member (51) so as to follow the edge of the shape of the metal part (38). The manufacturing apparatus (50) cools the molten metal material on the outer circumferential surface (S) of the roller member (51). With this manufacturing apparatus (50), amorphous metal parts (38) can be formed without using a mold.

[0111] (6-10) Feature 10 According to this embodiment, the height of the first protrusion (61) is greater than the thickness of the metal part (38).

[0112] The first protrusion (61) eliminates the need for the step of separating the metal part (38) from the metal material on the outer surface (S). In this way, the metal part (38) can be easily removed from the metal foil strip.

[0113] (6-11) Feature 11 The first protrusion (61) of this embodiment is formed in an annular shape along the edge of the shape of the metal part (38). As a result, the first protrusion (61) can completely divide the inner region (R) from the other region. This allows the metal part (38) to be molded more precisely.

[0114] (7) Modifications Modifications of the manufacturing method or manufacturing apparatus (50) of the above embodiment will be described below. In the following, only configurations that differ from the above embodiment will be described.

[0115] (7-1) Modification 1 In the manufacturing apparatus (50) of Modification 1 shown in Figure 9, a first recess (71) is formed on the outer circumferential surface (S) of the roller member (51). The first recess (71) is formed so as to follow the edge of the shape of the metal part (38) when viewed from the front on the outer circumferential surface (S). In other words, the first recess (71) is formed to be recessed in accordance with the shape of the metal part (38). The inside of the first recess (71) forms the inner region (R) of the above embodiment. The depth D of the first recess (71) is the same as or greater than the thickness of the metal part (38). In other words, the depth D of the first recess (71) is the distance from the bottom surface of the first recess (71), which is the inner region (R), to the outer circumferential surface (S) outside the inner region (R).

[0116] In the molding process of the modified example 1, a metal part (38) is formed in the inner region (R) formed by the first recess (71). Specifically, a portion of the molten metal supplied from the supply unit (52) to the outer circumferential surface (S) of the roller member (51) flows into the first recess (71) on the outer circumferential surface (S). As a result, the metal part (38) is formed in the inner region (R) that is shaped like the metal part (38).

[0117] In the removal process of the modified example 1, the metal part (38) formed in the first recess (71) of the metal foil strip that was fed out in the feeding process is removed.

[0118] (7-2) Modified Example 2 In the manufacturing apparatus (50) of Modified Example 2 shown in Figure 10, the roller member (51) has a first roller (51a) and a second roller (51b) arranged so that their outer peripheral surfaces (S) face each other. The first roller (51a) and the second roller (51b) have the same configuration. The first roller (51a) and the second roller (51b) are arranged adjacent to each other in the horizontal direction. The first roller (51a) and the second roller (51b) each have a rotation axis (55), and the first roller (51a) and the second roller (51b) are controlled by a control device (C) so that their respective rotation speeds are the same.

[0119] The first roller (51a) and the second roller (51b) rotate in such a way that they push out the metal material sandwiched between them. Of the first roller (51a) and the second roller (51b), the first roller (51a), which is located on the left side when viewed from the front of the paper in Figure 10, rotates clockwise, and the second roller (51b), which is located on the right side, rotates counterclockwise. Thus, the rotation directions of the first roller (51a) and the second roller (51b) are different. The outer circumferential surface (S) of the first roller (51a) and the outer circumferential surface (S) of the second roller (51b) are separated by a distance L in the horizontal direction. The distance L is the same as the thickness T of the metal part (38).

[0120] The supply unit (52) supplies molten metal between the first roller (51a) and the second roller (51b). Specifically, the receiver (53) is positioned above the space between the first roller (51a) and the second roller (51b). The supply port (53a) opens toward the space between the first roller (51a) and the second roller (51b).

[0121] As shown in the enlarged view enclosed by the dashed line in Figure 10, a third protrusion (63) is formed on the outer circumferential surface (S) of the first roller (51a). A third recess (73) is formed on the outer circumferential surface (S) of the second roller (51b). The third protrusion (63) and the third recess (73) are formed to conform to the shape of the metal part (38).

[0122] In a cross-section perpendicular to the longitudinal direction of the roller member (51), the third protrusion (63) and the third recess (73) are provided such that they coincide at the position where the outer circumferential surface (S) of the first roller (51a) and the outer circumferential surface (S) of the second roller (51b) are closest to each other. In other words, at the position where the outer circumferential surface (S) of the first roller (51a) and the outer circumferential surface (S) of the second roller (51b) are closest to each other, the third protrusion (63) and the third recess (73) are adjacent to each other in the horizontal direction. Furthermore, when the third protrusion (63) and the third recess (73) are adjacent to each other in the horizontal direction, the top of the third protrusion (63) is located inside the third recess (73).

[0123] In the supply and cooling steps of the modified example 2, the first roller (51a) and the second roller (51b) rotate, and molten metal is supplied between the first roller (51a) and the second roller (51b) by the supply unit (52). As a result, the metal material sandwiched between the first roller (51a) and the second roller (51b) becomes amorphous and is formed to the desired thickness.

[0124] Furthermore, the third protrusion (63) of the first roller (51a) and the third recess (73) of the second roller (51b) interlock with each other at horizontally adjacent positions, so that the metal plate formed by being sandwiched between the outer peripheral surfaces (S) of the first roller (51a) and the second roller (51b) is divided by the third protrusion (63) and the third recess (73) into the metal material in the inner region (R) and the metal material in the other regions.

[0125] In the feeding and unfeeding processes of the modified example 2, the amorphous metal foil strip is fed out by the first roller (51a) and the second roller (51b), and at the same time, the amorphous metal parts (38) within the inner region (R) detach from the metal plate.

[0126] In this way, the molten metal is sandwiched between the first roller (51a) and the second roller (51b) and rapidly cooled, making it possible to manufacture an amorphous metal plate with a uniform thickness. Furthermore, the thickness of the metal part (38) can be adjusted by setting the distance between the first roller (51a) and the second roller (51b).

[0127] (7-3) Modification 3 As shown in Figure 11, the manufacturing method of the metal part of Modification 3 includes a heating step of heating the metal material in the inner region (R) that has been cooled in the molding step. By heating the metal material that has been transformed into an amorphous soft magnetic material by the cooling step, it can be transformed into a nanocrystalline metal. The nanocrystalline metal includes nanocrystalline soft magnetic materials. For example, if the amorphous soft magnetic material includes Fe-Cu-B and Fe-Cu-Si-B, the heating conditions in the heating step are 400°C to 500°C. The heating treatment time can be set arbitrarily. In this way, the metal part (38) of nanocrystalline soft magnetic material can be manufactured in Modification 3. The timing of the heating step can be after the cooling step, and it can be before or after the removal step. In addition, the manufacturing apparatus for the metal part of Modification 3 may have a heating device (not shown) for heating the metal material.

[0128] (7-4) Modification 4 As shown in Figures 12 and 13, in the manufacturing apparatus of Modification 4, the outer circumferential surface (S) of the roller member (51) is provided with a first groove (81) that connects two adjacent inner regions (R). Molten metal is supplied to the first groove (81).

[0129] At least two first recesses (71) are formed on the outer circumferential surface (S) of the roller member (51). In this modified example, two first recesses (71) are provided on the outer circumferential surface (S). As a result, two inner regions (R) are formed on the outer circumferential surface (S). One of the two inner regions (R) is designated as the first inner region (R1), and the other as the second inner region (R2).

[0130] The first groove (81) is a recessed groove connecting the first inner region (R1) and the second inner region (R2). Specifically, the depth of the recess of the first groove (81) is the same as the depth of the first recess (71). The first groove (81) is formed in a straight line. One end of the first groove (81) is connected to the first inner region (R1), and the other end is connected to the second inner region (R2). The first groove (81) is provided at a position where the first recess (71) constituting the first inner region (R1) and the first recess (71) constituting the second inner region (R2) face each other.

[0131] A manufacturing method for modified example 4 will now be described. The supply step of modified example 4 also includes a step of supplying molten metal to the first groove (81). In the supply step, the molten metal supplied to the first groove (81) merges with the molten metal in the first inner region (R1) and the second inner region (R2). In this state, when the cooling step is started, the metal parts (38) in the first inner region (R1) and the metal parts (38) in the second inner region (R2) are sent out connected by the metal in the first groove (81).

[0132] Since the two metal parts (38) are sent out connected, they can be removed as a single unit during the removal process. Removing multiple connected metal parts as a single unit makes it easier to organize the metal parts after the removal process and makes them easier to use in subsequent processes than removing the metal parts (38) one by one. For example, when stacking multiple metal parts (38) after the removal process, stacking multiple units of metal parts makes subsequent retrieval easier than stacking individual metal parts (38).

[0133] (7-5) Modified Example 5 As shown in Figure 14, in the manufacturing apparatus of Modified Example 5, a second recess (72) and a second groove (82) are provided on the outer circumferential surface (S) of the roller member (51). The second recess (72) forms a recessed groove (G) surrounding the inner region (R) formed by the first recess (71). The recessed groove (G) is formed in the shape of a rectangular frame. One inner region (R) is provided within the rectangular frame formed by the recessed groove (G). The depth of the second recess (72) (depth of the recessed groove (G)) is the same as the depth of the inner region (R).

[0134] The second groove (82) connects the recessed groove (G) and the inner region (R). The second groove (82) is formed in a straight line. The depth of the second groove (82) is the same as the depth of the recessed groove (G) and the inner region (R). Molten metal is supplied to the second groove (82). In modified example 5, four second grooves (82) are provided for each frame formed by the recessed groove (G). Since the frame is formed in a rectangular shape, the second grooves (82) are provided so as to extend from each side of the frame into the inner region (R).

[0135] A manufacturing method for modified example 5 will now be described. The supply step of modified example 5 includes a step of supplying molten metal to the recessed groove (G) and the second groove (82). In the supply step, the molten metal is supplied to the inner region (R), the recessed groove (G), and the second groove (82). The molten metal supplied to the second groove (82) merges with the molten metal in the inner region (R) and the recessed groove (G). In this state, when the cooling step is started, the metal part (38) in the inner region (R) is formed in a state where it is connected to the frame-shaped metal formed in the recessed groove (G) via the metal in the second groove (82). After that, through a feeding step and a removal step, the metal part (38) can be removed in a state where it is fixed inside the frame-shaped metal. Since the frame-shaped metal part has the function of protecting the metal part (38), damage or deformation that may occur to the metal part (38) during the removal step, for example, can be suppressed.

[0136] (7-6) Modified Example 6 In the manufacturing method of Modified Example 6, molten metal is intermittently supplied to the inner region (R) while the roller member (51) is rotating during the supply process. Specifically, as shown in Figure 15, in a cross section perpendicular to the rotation axis (55) direction of the roller member (51), when the region between the first wall surface (W1) and the second wall surface (W2) of the bottom surface (B) that forms the inner region (R) is defined as the central region (CR), in the manufacturing method of Modified Example 6, molten metal is supplied to the central region (CR) when the central region (CR) reaches its highest height position due to the rotation of the roller member (51). In Modified Example 6, the inner region (R) is formed by the first convex portion (61), but it may also be formed by the first concave portion (71). Furthermore, the position of the central region (CR) differs depending on the position in the axial direction at which the cross section of the roller member (51) is cut, as the positions of the first wall surface (W1) and the second wall surface (W2) differ. Therefore, in the modified example 6, the central portion (CR) is defined as the intermediate region of the bottom portion (B) in the cross-section where the distance between the first wall surface (W1) and the second wall surface (W2) is maximized when viewed from the rotation axis direction of the roller member (51).

[0137] The manufacturing apparatus (50) supplies molten metal to the central portion (CR) when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51). Specifically, the manufacturing apparatus (50) is configured with a set amount of molten metal to be supplied at one time and a set timing for supplying the molten metal. The amount of molten metal to be supplied is determined based on the volume of the inner region (R). The inner region (R) can be determined based on the area of ​​the bottom surface (B) and the height of the first wall surface (W1) or the second wall surface (W2). The timing for supplying the molten metal can be determined based on the position of the central portion on the outer circumferential surface (S) and the rotational speed of the roller member (51). The number of central portions (CR) is the same as the number of inner regions (R) formed on the outer circumferential surface (S).

[0138] The manufacturing apparatus (50) may rotate the roller member (51) at a constant rotational speed, or it may stop the rotation of the roller member (51) while supplying molten metal in the supply process.

[0139] In the manufacturing method and manufacturing apparatus (50) of the modified example 6, since molten metal material is supplied intermittently to the inner region (R), it is possible to suppress the adhesion of molten metal to the region between adjacent inner regions (R) on a predetermined surface (S). As a result, it is possible to avoid the metal material overflowing from the inner region (R), and thus metal parts (38) can be manufactured easily.

[0140] (7-7) Modified Example 7 As shown in Figure 16, the manufacturing apparatus (50) of Modified Example 7 includes an inhibitory structure (100) that suppresses adhesion or seizing of the metal material supplied to the inner region (R) on the first wall surface (W1) and the second wall surface (W2).

[0141] Specifically, the suppression structure (100) has countless fine irregularities on the inner wall surface (W) of the peripheral wall provided at the outer edge of the bottom surface (B). This surface treatment allows air to enter the fine irregularities. As a result, the presence of air between the inner wall surface (W) and the metal material suppresses adhesion or seizing of the metal material on the inner wall surface (W).

[0142] (8) Other embodiments The above embodiments and each of the above modifications may be configured as follows.

[0143] Amorphous soft magnetic materials or nanocrystalline soft magnetic materials are 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. Amorphous soft magnetic materials or nanocrystalline soft magnetic materials are not limited to the above examples.

[0144] Typical amorphous or nanocrystalline soft 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 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.

[0145] Typical amorphous soft magnetic materials or nanocrystalline soft 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. The cobalt alloy preferably contains 80 at% or more cobalt. Cobalt alloys containing 80 at% or more cobalt tend to become amorphous when formed into films. Furthermore, cobalt alloys containing 80 at% or more cobalt have excellent magnetic properties due to their low crystalline magnetic anisotropy, low crystalline defects, and low grain boundaries. Suitable amorphous soft magnetic materials include, for example, Co·Zr alloys, Co·Zr·Nb alloys, and Co·Zr·Ta alloys.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] Nanocrystalline soft magnetic materials can improve magnetic properties because the crystallite size of the nanocrystals is 100 nanometers or less, as described above. In contrast, the crystallite size of conventional electrical steel sheets is on the order of micrometers, and is generally 50 micrometers or larger.

[0150] The metal component (38) is not limited to the components that make up the laminate (M) of the stator core (32).

[0151] The predetermined surface (S) does not have to be the outer circumferential surface (S) of the roller member (51). The predetermined surface (S) just needs to be configured to cool the molten metal on the surface (S) and form it into the shape of the metal part (38).

[0152] The outer surface (S) of the roller member (51) may be made of a metal other than copper. Furthermore, the roller member (51) may be equipped with a cooling device capable of rapidly cooling the molten metal on its outer surface (S).

[0153] The first protrusion (61) in the above embodiment does not have to be formed in an annular shape to resemble the shape of the metal part (38). The first protrusion (61) only needs to be formed in a convex shape along the outer edge of the metal part (38), and may be arranged in a part of the outer edge.

[0154] The height H of the first protrusion (61) or the depth D of the first recess (71) may be less than the thickness T of the metal part (38). This prevents the metal material in the inner region (R) from being separated from the metal material in the other regions, and allows the metal part (38) to be easily detached and recovered from the metal foil strip fed out by the feeding process without the need for a mold.

[0155] In the modified example 2, the third protrusion (63) and the third recess (73) may be provided on the first roller (51a) and the second roller (51b) so as to be adjacent to each other in the horizontal direction, and may be arranged along the outer edge of the metal part (38) and on a part of the outer edge. As a result, the metal material in the inner region (R) is not separated from the metal material in the other regions, and a part of the metal part (38) is bonded to the metal plate that is fed out in the feeding process. In the removal process, the metal part (38) can be recovered by removing this bonded part, so the metal part can be recovered more easily than by the punching method.

[0156] In the manufacturing method and apparatus of the modified example 4, an inner region (R) may be formed by the first protrusion (61). There may be one inner region (R) formed on the outer circumferential surface (S), or there may be three or more. The first groove (81) may be provided to connect all of the multiple inner regions (R) formed on the roller member (51). This allows for the formation of a continuous metal part (38) as long as the roller member (51) continues to rotate. When there is one inner region (R) provided on the outer circumferential surface (S), the portion of the inner region (R) closer to the front in the direction of rotation and the portion closer to the rear in the direction of rotation are connected by the first groove (81).

[0157] In the manufacturing method and apparatus of modified example 5, the roller member (51) may have a second protrusion (62) that forms a groove (G) instead of the second recess (72). The second protrusion (62) is provided so as to form a frame-shaped groove (G) on the outer circumferential surface (S). For example, the second protrusion (62) is a pair of ridges extending parallel to each other on the outer circumferential surface (S), and a groove (G) is formed between adjacent ridges.

[0158] In the manufacturing method and apparatus of modified example 5, a plurality of inner regions (R) may be provided inside a single groove (G). In this case, a first groove (81) and a second groove (82) are formed on the outer surface (S). Specifically, a second groove (82) is formed between the groove (G) and an adjacent inner region (R), and a first groove (81) is formed between two adjacent inner regions (R).

[0159] The groove (G) in modified example 5 may be formed in a grid pattern. The frame of the groove (G) is not limited to a rectangle and may not be formed in any other shape. The inner region (R) may also be formed by the first protrusion (61).

[0160] The manufacturing method and manufacturing apparatus (50) of the modified example 6 may be configured such that, in the supply process, molten metal is intermittently supplied to the inner region (R) while the roller member (51) is rotating.

[0161] In the manufacturing method and manufacturing apparatus (50) of the modified example 6, the supply unit (52) may supply molten metal to the region in front of the central portion (CR) in the direction of rotation when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51). As a result, molten metal material is supplied intermittently to the inner region (R), so that molten metal does not adhere to the region between adjacent inner regions (R). As a result, it is possible to avoid the metal material overflowing from the inner region (R), and thus metal parts (38) can be manufactured easily.

[0162] The suppression structure (100) in modified example 7 may be a heating section that heats the inner wall surface (W). Heating the inner wall surface (W) suppresses adhesion and scorching of the metal material.

[0163] The electric motor (30) of the above embodiment may also be applied to a method for manufacturing a blower. The blower may have a fan (not shown) that is rotationally driven by, for example, a fan motor (not shown). In this case, the electric motor (30) is a fan motor. Thus, a blower can be manufactured using the metal part (38) of the above embodiment.

[0164] 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.

[0165] As described above, this disclosure is useful for a method of manufacturing metal parts and an apparatus therefor.

[0166] 10 Compressor 30 Electric motor 32 Stator core 38 Metal parts 50 Manufacturing equipment 51 Roller member 51a First roller 51b Second roller 52 Supply unit 55 Rotating shaft 61 First convex part 62 Second convex part 71 First concave part 72 Second concave part 81 First groove part 82 Second groove part 100 Suppression structure B Bottom part CR Center part D Depth G Groove H Height M Laminate R Inner region S Outer surface T Thickness W1 First wall surface W2 Second wall surface

Claims

1. A method for manufacturing a metal part (38), comprising a molding step of amorphously molten metal material in the form of a thin plate on a predetermined surface (S) and simultaneously shaping the metal material on the predetermined surface (S) into the shape of the metal part (38).

2. The manufacturing method according to claim 1, wherein the predetermined surface (S) is the outer circumferential surface (S) of a cylindrical roller member (51), and the molding step comprises a supply step of supplying the molten metal material in a thin plate form onto the outer circumferential surface (S), a cooling step of cooling the metal material supplied onto the outer circumferential surface (S), and a feeding step of rotating the roller member (51) in the circumferential direction to feed the cooled metal material in the rotational direction.

3. The manufacturing method according to claim 1 or 2, wherein a first convex portion (61) or a first recess (71) is provided on the predetermined surface (S) so as to follow the edge of the shape of the metal part (38), and in the molding step, the metal part (38) is formed in the inner region (R) formed by the first convex portion (61) or the first recess (71) on the predetermined surface (S).

4. The manufacturing method according to claim 3, wherein the predetermined surface (S) is provided with a first groove (81) that connects two adjacent inner regions (R), and the molten metal material is supplied to the first groove (81).

5. The manufacturing method according to claim 3, wherein the predetermined surface (S) is provided with a second convex portion (62) or a second concave portion (72) that forms a frame-shaped recessed groove (G) surrounding the inner region (R), the second groove portion (82) connects the recessed groove (G) and the inner region (R), and the molten metal material is supplied to the second groove portion (82).

6. A first convex portion (61) or a first recess (71) is provided on the predetermined surface (S) so as to follow the edge of the shape of the metal part (38), in the molding step the metal part (38) is formed in an inner region (R) formed by the first convex portion (61) or the first recess (71) on the predetermined surface (S), and in the supply step the molten metal material is intermittently supplied to the inner region (R) while the roller member (51) is rotating, according to claim 2.

7. The manufacturing method according to claim 6, wherein the cross section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the region of the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), and in the supply step, the molten metal material is supplied to the central portion (CR) when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51).

8. The manufacturing method according to claim 6, wherein the cross-section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the region of the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), and in the supply step, when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51), the molten metal material is supplied to the region in front of the central portion in the direction of rotation.

9. The manufacturing method according to claim 7 or 8, further comprising an inhibitory structure (100) that suppresses adhesion or seizing of the metal material supplied to the inner region (R) in the first wall surface (W1) and the second wall surface (W2).

10. The manufacturing method according to claim 3, further comprising a heating step of heating the metal material in the inner region (R) that has been cooled in the molding step.

11. The manufacturing method according to claim 3, further comprising a removal step of removing the metal part (38) of the inner region (R) formed by the molding step.

12. A method for manufacturing a stator core comprising a laminate (M) composed of a plurality of metal parts (38) manufactured by the manufacturing method described in any one of claims 1 to 11, wherein the thickness of each metal part (38) is 20 to 100 μm.

13. A method for manufacturing an electric motor comprising the stator core (32) manufactured by the manufacturing method described in claim 12.

14. A method for manufacturing a blower equipped with the electric motor manufactured by the manufacturing method described in claim 13.

15. A method for manufacturing a compressor equipped with the electric motor manufactured by the manufacturing method described in claim 13.

16. A method for manufacturing a refrigeration apparatus equipped with a compressor manufactured by the manufacturing method described in claim 15.

17. A manufacturing apparatus for a thin, amorphous metal part (38), comprising: a cylindrical roller member (51) having a rotation axis and rotating in the circumferential direction; and a supply unit (52) for supplying molten metal material to the outer circumferential surface (S) of the roller member (51), wherein the outer circumferential surface (S) of the roller member (51) is provided with a first convex portion (61) or a first concave portion (71) formed along the edge of the shape of the metal part (38), and the manufacturing apparatus supplies molten metal material to an inner region (R) formed by the first convex portion (61) or the first concave portion (71), and cools the molten metal material on the outer circumferential surface (S).

18. The manufacturing apparatus according to claim 17, wherein the outer circumferential surface (S) is provided with a first groove (81) that connects two adjacent inner regions (R), and molten metal material is supplied to the first groove (81).

19. The manufacturing apparatus according to claim 17, wherein the outer peripheral surface (S) is provided with a second convex portion (62) or a second concave portion (72) that forms a frame-shaped recessed groove (G) surrounding the inner region (R), the second groove portion (82) connects the recessed groove (G) and the inner region (R), and the molten metal material is supplied to the second groove portion (82).

20. The manufacturing apparatus according to claim 17, wherein the supply unit (52) intermittently supplies the molten metal material to the inner region (R) formed by the first convex portion (61) or the first concave portion (71) while the roller member (51) is rotating.

21. The manufacturing apparatus according to claim 17, wherein the cross section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the region of the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), the supply unit (52) supplies the molten metal material to the central portion (CR) when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51).

22. The manufacturing apparatus according to claim 17, wherein the cross-section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the direction of rotation, a second wall surface (W2) located behind the first wall surface (W1) in the direction of rotation, and a bottom surface (B) connecting the first wall surface (W1) and the second wall surface (W2), and when viewed from the axial direction, the region of the bottom surface (B) between the first wall surface (W1) and the second wall surface (W2) is defined as the central portion (CR), the supply unit (52) supplies the molten metal material to the region in front of the central portion in the direction of rotation when the central portion (CR) reaches its highest height position due to the rotation of the roller member (51).

23. The manufacturing apparatus according to claim 17, wherein the cross section of the inner region (R) perpendicular to the axial direction of the roller member (51) is formed in a concave shape having a first wall surface (W1) located in front of the roller member (51) in the rotational direction, a second wall surface (W2) located behind the first wall surface (W1) in the rotational direction, and a bottom surface portion (B) connecting the first wall surface (W1) and the second wall surface (W2), and further comprising an inhibitory structure (100) that suppresses adhesion or seizing of the metal material supplied to the inner region (R) on the first wall surface (W1) and the second wall surface (W2).

24. The manufacturing apparatus according to any one of claims 17 to 23, wherein the roller member (51) has a first roller (51a) and a second roller (51b) arranged so that their outer peripheral surfaces (S) face each other, the supply unit (52) supplies the molten metal material between the first roller (51a) and the second roller (51b), and the first roller (51a) and the second roller (51b) rotate to push out the metal material sandwiched between the first roller (51a) and the second roller (51b).

25. The manufacturing apparatus according to any one of claims 17 to 23, wherein the height of the first protrusion (61) or the depth of the first recess (71) is the same as the thickness of the metal part (38), or greater than the thickness of the metal part (38).

26. The manufacturing apparatus according to any one of claims 17 to 23, wherein the first protrusion (61) or the first recess (71) is formed in an annular shape along the edge of the shape of the metal part (38).

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