阅读说明：本技术 环状层叠芯材及环状层叠芯材的制造方法 (Annular laminated core material and method for manufacturing annular laminated core material ) 是由 成濑新二 藤森龙士 田中康纪 于 2020-01-09 设计创作，主要内容包括：提供消除由从各芯材的结合部分发生的涡电流等造成的铁损、并且不需要追加的工序的环状层叠芯材及其制造方法。环状层叠芯材(1)具备：芯主体(4),将多个环状的芯材层叠而形成为圆筒形状,在半径方向内方的内周面或半径方向外方的外周面形成有沿轴向延伸的槽部；树脂成型体(2),一体成形有以将芯主体(4)的轴向两端面的至少一部分覆盖的方式形成的一对主体部(2a)以及将一对主体部(2a)连结的连结部(2b)；以及绝缘片(6),被配置在槽部的内表面上；绝缘片(6)的轴向两端部分别与树脂成型体(2)的主体部(2a)抵接。(Provided are a ring-shaped laminated core material and a method for manufacturing the same, wherein iron loss caused by eddy current generated from a joint portion of each core material is eliminated, and an additional process is not required. The annular laminated core material (1) is provided with: a core main body (4) formed in a cylindrical shape by laminating a plurality of annular core members, and having a groove portion extending in the axial direction formed on an inner circumferential surface on the inside in the radial direction or an outer circumferential surface on the outside in the radial direction; a resin molded body (2) in which a pair of main body sections (2 a) formed so as to cover at least a part of both axial end surfaces of a core main body (4) and a connecting section (2 b) connecting the pair of main body sections (2 a) are integrally formed; and an insulating sheet (6) disposed on the inner surface of the groove portion; the axial ends of the insulating sheet (6) are in contact with the main body (2 a) of the resin molded body (2).)

1. A ring-shaped laminated core material, characterized in that,

the disclosed device is provided with:

a core main body formed in a cylindrical shape by laminating a plurality of annular core members, and having a groove portion extending in an axial direction formed on an inner circumferential surface on an inner side in a radial direction or an outer circumferential surface on an outer side in the radial direction;

a resin molded body integrally formed with a pair of main bodies formed so as to cover at least a part of both axial end surfaces of the core main body, and a coupling portion coupling the pair of main bodies; and

an insulating sheet disposed on an inner surface of the groove portion;

the insulating sheet has both axial ends respectively abutting against the main body of the resin molded body.

2. The annular laminate core according to claim 1,

a through hole extending between the axial end surfaces is formed in the core body;

the connecting portion connects the pair of body portions through the through hole of the core body.

3. The annular laminate core according to claim 1,

a circumferential groove portion extending between the two axial end surfaces is formed on the inner circumferential surface or the outer circumferential surface of the core main body;

the connecting portion connects the pair of main body portions through the peripheral groove portion of the core main body.

4. The annular laminated core material according to any one of claims 1 to 3,

the annular core material has flat surfaces on both axial surfaces thereof, and the flat surfaces of each core material and the adjacent core material are in direct contact with each other.

5. The annular laminated core material according to any one of claims 1 to 4,

the insulating sheet and the resin molded body are connected without using an adhesive.

6. The annular laminated core material according to any one of claims 1 to 5,

the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5mm or more.

7. The annular laminated core material according to any one of claims 1 to 6,

the insulating sheet and the resin molded body are connected by impregnating a surface of the insulating sheet, which is in contact with the resin molded body, with a resin constituting the resin molded body.

8. The annular laminated core material according to any one of claims 1 to 7,

the resin molded body is formed by using a polymer having an amide bond;

the surface of the insulating sheet that is in contact with the resin molded body is composed of a polymer having an amide bond.

9. The annular laminated core material according to any one of claims 1 to 7,

the resin molded body is formed by using a polymer having an amide bond;

the surface of the insulating sheet that is in contact with the resin molded body is made of aramid paper formed of aramid fibrids and aramid short fibers.

10. A motor is characterized in that a motor is provided,

a stator in which a coil is wound using the annular laminated core material according to any one of claims 1 to 9.

11. A motor-generator is characterized in that,

a stator in which a coil is wound using the annular laminated core material according to any one of claims 1 to 9.

12. A generator, characterized in that it comprises a generator body,

a stator in which a coil is wound using the annular laminated core material according to any one of claims 1 to 9.

13. A method for manufacturing a ring-shaped laminated core material,

the method comprises the following steps:

a disposing step of disposing a core main body, which is formed in a cylindrical shape by stacking a plurality of annular core blocks and has a groove portion extending in an axial direction formed on an inner circumferential surface on an inner side in a radial direction or an outer circumferential surface on an outer side in the radial direction, in a mold so that an insulating sheet is disposed in the groove portion; and

and a resin molding step of injecting a resin into the mold to integrally mold a resin molded body including a pair of body portions formed so as to cover at least a part of both axial end surfaces of the core body.

Technical Field

The present invention relates to a ring-shaped laminated core material and a method for manufacturing the ring-shaped laminated core material.

Background

Conventionally, there has been known an annular laminated core material such as a motor core (motor core) in which a predetermined number of annular core materials punched out from a strip-shaped thin plate material are bonded in a laminated state. As a method for manufacturing the annular laminated core material, for example, an in-mold automatic lamination method is known. In the in-mold automatic laminating method, first, a desired die-cutting process is sequentially applied to the core sheet portions of a strip-shaped sheet material while the strip-shaped sheet material is intermittently transferred by a forward-feed mold device. Next, the core material sheet portion is punched by an outer diameter punching punch, and is separated from the band-shaped sheet material and sequentially punched out into the die. Then, the punched core materials are bonded in a laminated state by a predetermined number of sheets each time by a caulking bonding mechanism which is a kind of temporary bonding mechanism provided in advance to the core materials.

As a general caulking mechanism in the in-mold automatic lamination method, for example, a structure is adopted in which a cut-and-raised portion is provided in advance in each core material as in patent document 1 (japanese patent application laid-open No. 58-116033), or a projection (pin) is provided as in patent document 2 (japanese patent application laid-open No. 49-37103), and the core materials adjacent to each other in the up-and-down direction are caulked and joined by the cut-and-raised portion or the projection in a laminated state.

Also, laminated core materials in which core materials are bonded together with an adhesive or a laser beam, for example, are known.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 58-116033

Patent document 2: japanese patent laid-open publication No. S49-37103.

Disclosure of Invention

Problems to be solved by the invention

However, in the above caulking joint mechanism, since the joint portion formed by the cut-and-raised portion, the knock-out projection, and the like is left as it is even when assembled into the motor, there is a problem that an eddy current or the like occurs in the caulking joint portion, and an efficiency drop of several percent due to iron loss occurs.

In the method of bonding with an adhesive or a laser beam, an additional step of fitting the resin molded body to the laminated core material is required to secure electrical insulation from the winding after the step of applying the adhesive or irradiating the laser beam.

Accordingly, an object of the present invention is to provide a ring-shaped laminated core material and a method for manufacturing the same, which can eliminate iron loss caused by eddy current or the like generated from a joint portion of each core material and does not require an additional step.

Means for solving the problems

The present invention is a ring-shaped laminated core material, comprising: a core main body formed in a cylindrical shape by laminating a plurality of annular core members, and having a groove portion extending in an axial direction formed on an inner circumferential surface on an inner side in a radial direction or an outer circumferential surface on an outer side in the radial direction; a resin molded body in which a pair of main bodies formed so as to cover at least a part of both axial end surfaces of a core main body and a connecting portion connecting the pair of main bodies are integrally molded; and an insulating sheet disposed on an inner surface of the groove portion; the insulating sheet has both axial ends respectively abutting against the main body of the resin molded body.

According to the present invention having the above-described configuration, the pair of body portions of the resin molded body are integrated by the connecting portion, and further, the insulating sheet and the resin molded body are connected by contact, so that the laminated core members can be integrated without temporary fixation such as caulking or bonding. This eliminates the need for providing a caulking joint for caulking on the core material, thereby suppressing iron loss, and eliminates the need for additional steps such as application of an adhesive and a laser beam.

In the present invention, it is preferable that a through hole extending between both end faces in the axial direction is formed in the core main body; the connecting part passes through the through hole of the core main body to connect the pair of main bodies.

According to the present invention having the above configuration, since the molten resin is filled into the space corresponding to the pair of body portions and the coupling portion through the through hole when the resin molded body is molded, the body portions and the coupling portion can be integrated.

In the present invention, it is preferable that a groove portion extending across both end surfaces in the axial direction is formed in the inner peripheral surface or the outer peripheral surface of the core main body; the connecting portion connects the pair of main body portions through the groove portion of the core main body.

According to the present invention having the above configuration, since the molten resin is filled into the space corresponding to the pair of main body portions and the coupling portion through the circumferential groove portions when the resin molded body is molded, the main body portions and the coupling portion can be integrated.

In the present invention, it is preferable that the annular core member has flat surfaces on both axial surfaces thereof, and the flat surfaces of each core member and the adjacent core member are in direct contact with each other.

According to the present invention having the above configuration, the iron loss can be further suppressed.

In the present invention, it is preferable that the insulating sheet and the resin molded body are connected without using an adhesive.

According to the present invention having the above-described configuration, the annular laminated core material can be manufactured without performing an additional step such as bonding.

In the present invention, it is preferable that the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5mm or more.

According to the present invention having the above configuration, since the axial length of the contact portion between the insulating sheet and the resin molded body is 0.5mm or more, when the linear segment conductor is arranged in the groove portion of the annular laminated core material and bent, there is no variation between the core materials, and the linear segment conductor can withstand the load applied during bending.

In the present invention, it is preferable that the insulating sheet and the resin molded body are connected by impregnating a surface of the insulating sheet, which is in contact with the resin molded body, with a resin constituting the resin molded body.

According to the present invention having the above configuration, the insulating sheet and the resin molded body can be more firmly connected.

In the present invention, it is preferable that the resin molded body is formed using a polymer having an amide bond; the surface of the insulating sheet that is in contact with the resin molded body is composed of a polymer having an amide bond.

According to the present invention having the above-described configuration, the polymer and the insulating sheet are entangled with each other on a molecular scale, and the insulating sheet and the resin molded body can be more firmly connected.

In the present invention, it is preferable that the resin molded body is formed using a polymer having an amide bond; the surface of the insulating sheet that is in contact with the resin molded body is made of aramid paper formed of aramid fibrids and aramid short fibers.

According to the present invention having the above-described configuration, the polymer and the insulating sheet are entangled with each other on a molecular scale, and the insulating sheet and the resin molded body can be more firmly connected.

The motor of the present invention uses a stator in which a coil is wound around the above-described annular laminated core material.

The motor having the above structure exhibits the above-described effects.

The motor generator of the present invention uses a stator in which a coil is wound around the annular laminated core.

The motor generator with the structure has the functions and effects.

The generator of the present invention uses a stator in which a coil is wound around a ring-shaped laminated core.

According to the generator with the structure, the above effects are achieved.

The present invention is a method for manufacturing a ring-shaped laminated core material, including: a disposing step of disposing a core main body, which is formed in a cylindrical shape by stacking a plurality of annular core blocks and has a groove portion extending in an axial direction formed on an inner circumferential surface on an inner side in a radial direction or an outer circumferential surface on an outer side in the radial direction, in a mold so that an insulating sheet is disposed in the groove portion; and a resin molding step of injecting a resin into the molding die, and integrally molding a resin molded body including a pair of main bodies formed so as to cover at least a part of both axial end surfaces of the core main body and a coupling portion coupling the pair of main bodies.

According to the present invention having the above-described configuration, the body portion and the coupling portion can be integrally formed, and the laminated core members can be integrated without temporary fixation such as caulking or bonding.

Effects of the invention

According to the present invention, it is possible to provide a ring-shaped laminated core material and a method for manufacturing the same, which can eliminate iron loss caused by eddy current or the like generated from a joint portion of each core material and which does not require an additional step.

Drawings

Fig. 1 is a schematic perspective view showing a structure of a ring-shaped laminated core material according to an embodiment of the present invention.

Fig. 2 is a perspective view showing a core body of the annular laminated core material shown in fig. 1.

Fig. 3 is a perspective view showing a core material constituting the core main body shown in fig. 2.

Fig. 4 is a perspective view showing an insulating sheet of the annular laminated core member shown in fig. 1.

Fig. 5 is a perspective view showing a core body of an annular laminated core material according to another embodiment.

Detailed Description

Hereinafter, a ring-shaped laminated core material and a method for manufacturing the same according to an embodiment of the present invention will be described with reference to the drawings.

(Ring-shaped laminated core Material)

Fig. 1 is a schematic perspective view showing a structure of a ring-shaped laminated core material according to an embodiment of the present invention. As shown in fig. 1, the annular laminated core member is cylindrical and has a shape in which a plurality of arm portions extending radially inward are formed on an inner peripheral surface thereof and a groove portion is formed between the arm portions. The annular laminated core material 1 preferably has an axial length of a contact portion between the insulating sheet and the resin molded body of 0.5mm or more. The annular laminated core material of the present embodiment is used as a stator of a motor, a motor generator (motor generator), or a generator by winding a wire around each arm portion, for example.

(core body)

Fig. 2 is a perspective view showing a core body of the annular laminated core material shown in fig. 1. As shown in fig. 2, the core body 4 is a cylindrical member in which a plurality of annular core members 8 are laminated, and a plurality of grooves that open on the inner peripheral surface are formed so as to extend in the axial direction. The boundaries of the laminated core members 8 forming the core main body 4 are not necessarily visible, but are illustrated for the sake of explanation in fig. 1, 2, and 5.

Fig. 3 is a perspective view showing a core material constituting the core main body shown in fig. 2. As shown in fig. 3, the core member 8 is a plate-shaped member whose both axial surfaces are formed as flat surfaces, and has a cross section in which the radially outer peripheral side of a substantially H-shaped portion is connected to a circle. The core member 8 includes an annular ring portion 8a, a plurality of arm portions 8b extending radially inward from the ring portion 8a, and protruding portions 8c extending from the tip portions of the arm portions 8b to both circumferential sides. Between the arm portions 8b, a substantially trapezoidal groove portion 8d surrounded by the adjacent arm portions 8b, the annular portion 8a, and the protruding portion 8c is formed. Further, on the outer peripheral surface of the annular portion 8a, 6 outer peripheral groove portions 8e are formed at equal angular intervals in the circumferential direction. As the material of the core member 8, a metal such as a silicon steel plate can be used.

As shown in fig. 2, the core body 4 is stacked with a plurality of core members 8 in a state where the temporary fastening means is not provided. That is, on the surface of each core member 8, a cut-and-raised portion or a projection for caulking is not formed. The flat surfaces of the core members 8 adjacent to each other in the axial direction are directly in close contact with each other, and no adhesive or weld mark by a laser beam is present between the core members 8. The core main body 4 has the same cross-sectional shape over the entire axial length, and includes a cylindrical portion 4a, a plurality of arm portions 4b extending radially inward from the cylindrical portion 4a, and protruding portions 4c extending from the distal ends of the arm portions 4b to both circumferential sides. The thickness of the core main body 4 in the axial direction is equal to the thickness obtained by removing the pair of main bodies 2a of the resin molded body 2 from the axial direction of the annular laminated core material 1. The cylindrical portion 4a of the core main body 4 is formed by laminating the annular portions 8a of the core member 8, the arm portions 4b of the core main body 4 are formed by laminating the arm portions 8b of the core member 8, and the protruding portion 4c of the core main body 4 is formed by laminating the protruding portions 8c of the core member 8.

Between the arm portions 4b, a substantially trapezoidal groove portion 4d is formed, which is surrounded by the adjacent arm portion 4b, cylindrical portion 4a, and protruding portion 4c and extends in the axial direction. The groove portion 4d of the core main body 4 is formed by the groove portions 8d of the laminated core members 8 being continuous in the axial direction. Further, on the outer peripheral surface of the cylindrical portion 4a, 6 outer peripheral groove portions 4e formed at equal angular intervals in the circumferential direction and extending in the axial direction are formed. The outer peripheral groove portion 4e of the core main body 4 is formed by stacking a plurality of outer peripheral groove portions 8e of the core members 8.

In the present embodiment, the outer circumferential groove portion 4e is formed in the outer circumferential surface of the core main body 4, and the coupling portion 2b is formed in the outer circumferential groove portion 4e, but the present invention is not limited to this, and for example, as shown in fig. 5, a through hole 104b penetrating in the axial direction may be formed in the core main body 104. In this case, the outer circumferential groove portion 4e is not required. When the core main body 104 having such a structure is used, a coupling portion is formed in the through hole 104b, and the main bodies 2a can be coupled to each other through the through hole 104 b. When such a through hole is formed, it is preferably formed in the cylindrical portion 104 a. In the present embodiment, the groove portion 4d is formed on the inner circumferential surface of the core main body 4 in the radial direction, but a groove portion may be formed on the outer circumferential surface of the core main body 4 in the radial direction. In this case, instead of the outer circumferential groove portion 4e, an inner circumferential groove portion extending in the axial direction may be formed on the inner circumferential surface on the radially inner side, and the coupling portion of the resin molded body may be formed in the inner circumferential groove portion, or a through hole may be formed in the cylindrical portion, and the coupling portion of the resin molded body may be formed in the through hole.

(insulating sheet)

Fig. 4 is a perspective view showing an insulating sheet of the annular laminated core member shown in fig. 1. As shown in fig. 4, the insulating sheet 6 has the same cross-sectional shape of approximately コ in the axial direction and has the same axial length as that of the annular laminated core 1. The insulating sheet 6 is formed by bending a long strip-shaped sheet, and has a central portion 6a, a left bent portion 6b, and a right bent portion 6 c. The central portion 6a has a width equal to the width of the bottom of the groove portion 4d of the core main body 4. The left bent portion 6b and the right bent portion 6c have a width equal to a radially extending surface of the groove portion 4d of the core main body 4. The radially inner end edges of the left bent portion 6b and the right bent portion 6c are bent so as to face each other, and distal end bent portions 6d and 6e are formed.

As shown in fig. 1, the insulating sheet 6 is disposed on the inner surface of each groove portion 4d of the core body 4. The center portion 6a of the insulating sheet 6 is disposed on the bottom (radially outer surface) of the groove portion 4d, and the left bent portion 6b and the right bent portion 6c are disposed on the radially extending surface of the groove portion 4 d. The distal end bent portions 6d and 6e are arranged on the radially outer surfaces of the protruding portions 8 c. The insulating sheet 6 has both axial ends projecting outward beyond both axial ends of the core main body 4 by a length equal to the thickness of the main body 2a of the resin molded body 2. The insulating sheet 6 is provided to insulate the wire from the inner circumferential surface of the groove portion 4d of the core main body 4 when the wire of the motor is wound around the arm portion 4b of the core main body 4.

In the present embodiment, as the insulating sheet, paper, nonwoven fabric, film having insulating properties, or a composite or laminated sheet thereof can be used. Examples of the laminate include an insulating paper such as an aramid paper composed of aramid fibrids (aramid fibers) and aramid short fibers, a plastic film such as a polyphenylene sulfide film, a polyimide film, a polyether ether ketone film, a polyethylene terephthalate film, and a polyethylene naphthalate film, and a laminate sheet thereof. In particular, a laminate sheet in which at least one side face comprises aramid paper composed of aramid fibrids and aramid short fibers is preferable. As the adhesive used for laminating the aramid paper, an appropriate adhesive generally used in the art can be used, and examples thereof include, but are not limited to, epoxy adhesives, acrylic adhesives, phenol adhesives, urethane adhesives, silicon adhesives, polyester adhesives, and amide adhesives. In addition, when the film is laminated with an adhesive, the film is often stretched, and when a bobbin (bobbin) for a motor is produced by the melt injection molding method of the present invention described later, the laminated sheet is likely to be deformed by shrinkage. Therefore, a laminate sheet obtained by laminating a film formed by melt-forming a polymer film on the aramid paper and heating and pressing the laminate sheet to melt-impregnate the polymer in the aramid paper, a laminate sheet obtained by laminating a sheet (web) of the polymer on the aramid paper or laminating the sheet on the aramid paper and heating and pressing the laminate sheet to melt-impregnate the resin in the aramid paper, a laminate sheet obtained by melt-extruding the resin on the aramid paper and thermally melt-bonding the resin, and the like are preferably used.

The number of layers of the laminate sheet may be appropriately selected depending on the use and purpose of the laminate. For example, there are a 2-layer laminate sheet of a polymer and an aramid paper having a ratio of epoxy group-containing phenoxy resin of 30 to 50 mass%, and an aramid paper, and a 3-layer laminate sheet of a polymer and an aramid paper, which are composed of an aromatic polyamide resin produced by a method of melt-extruding a resin onto an aramid paper and thermally bonding the resin thereto, as described in jp 2006-a 321183 a, but the present invention is not limited thereto.

When the insulating sheet is not sufficiently adhered to the resin molded body described later and is peeled off at the time of winding of the winding wire, it is preferable to perform surface treatment on the surface of the insulating sheet contacting the resin molded body to improve the adhesiveness. Examples of the surface treatment include plasma (plasma) surface treatment, corona surface treatment, and surface treatment by liquid immersion. By performing such surface treatment, the surface energy of the surface of the insulating paper is increased and the interface energy with the resin molded body is decreased, and as a result, the adhesiveness with the resin molded body is improved. Plasma surface treatment is particularly preferred because of the ease of treatment.

The thickness of the insulating sheet may be appropriately selected depending on the use and purpose of the insulating sheet, and any thickness may be selected as long as there is no problem in workability such as bending and winding. In general, a thickness in the range of 50 to 1000 μm (particularly 70 to 200 μm) is preferable from the viewpoint of workability, but the thickness is not limited thereto.

(aromatic polyamide)

In the present embodiment, the aramid refers to a linear polymer compound (aramid) in which 60% or more of amide bonds are directly bonded to an aromatic ring. Examples of such aromatic polyamides include polyisophthaloyl metaphenylene diamine and copolymers thereof, polyparaphenylene terephthalamide and copolymers thereof, and poly (p-phenylene) -co-poly (3, 4' -diphenyl ether) terephthalamide. These aromatic polyamides can be produced industrially by, for example, a conventionally known interfacial polymerization method or a solution polymerization method using isophthalamide chloride (isophthalate chloride), and are commercially available as products, but are not limited thereto. Among these aromatic polyamides, polyisophthaloyl metaphenylene diamine is preferably used in view of its excellent molding processability, heat adhesiveness, flame retardancy, heat resistance and other properties.

(aramid fibrids)

In the present embodiment, the aramid fibrids are film-like aramid particles having a papermaking property, and are also called aramid pulp (see Japanese patent publication (Kokoku) Nos. 35-11851 and 37-5732).

As is well known in the art, aramid fibrids are widely used as a paper stock by subjecting the fibrids to a disintegration and beating process, and are subjected to a so-called beating process for the purpose of maintaining the quality suitable for paper making. The beating process may be performed by a disc refiner (disc refiner), a beater, or other paper stock processing equipment that brings about a mechanical cutting action. In this operation, the morphological change of the fibrids can be monitored by the drainage test method (freeness) specified by japanese industrial standard P8121. In the present embodiment, the freeness of the aramid fibrids after the beating treatment is preferably at 10cm³～300cm³(Canadian freeness (JISP 8121)). In fibrids having a drainage capacity greater than this range, the aramid paper that is then formed has a strength that is acceptableCan be lowered. On the other hand, if more than 10cm is to be obtained³When the drainage degree is small, the utilization efficiency of the mechanical power to be input becomes small, the treatment amount per unit time becomes small, and further, the fibrids are excessively miniaturized, which tends to cause a so-called deterioration of the binder function. Thus, even then, a ratio of 10cm is obtained³The small drainage level, no significant advantage can be seen.

(aramid staple fiber)

The aramid staple fiber is obtained by cutting a fiber made of aramid, and examples of such a fiber include fibers available under the trade names of "teijin conex (registered trademark)" of imperial corporation and "Nomex (registered trademark)" of dupont corporation, but are not limited thereto.

The length of the aramid staple fiber may be generally selected from the range of 1mm or more and less than 50mm, preferably 2 to 10 mm. If the length of the short fibers is less than 1mm, the mechanical properties of the sheet material are deteriorated, while if the length is 50mm or more, "entanglement", "bunching", etc. are likely to occur in the production of wet-process aramid paper, and are likely to cause defects.

(aramid paper)

In the present embodiment, the aramid paper is a sheet mainly composed of the aramid fibrids and the aramid short fibers described above, and generally has a thickness in the range of 20 to 1000 μm, preferably 25 to 200 μm. Further, aramid paper typically has a weight of 10g/m²～1000g/m²Preferably 15 to 200g/m²Basis weight (weight per square meter) in the range of (1). Here, the mixing ratio of the aramid fibrids to the aramid short fibers may be any, but the ratio (mass ratio) of the aramid fibrids/the aramid short fibers is preferably 1/9 to 9/1, more preferably 2/8 to 8/2, particularly 3/7 to 7/3, but is not limited to this range.

The aramid paper is generally produced by a method of mixing the aramid fibrids with the aramid short fibers and then sheeting the mixture. Specifically, for example, a method of forming a sheet by dry mixing the aramid fibrids and the aramid short fibers and then using an air stream, a method of dispersing and mixing the aramid fibrids and the aramid short fibers in a liquid medium, spraying the mixture onto a liquid-permeable support such as a net or a belt to form a sheet, removing the liquid, and drying the sheet, or the like can be employed.

In the wet papermaking method, generally, an aqueous slurry containing at least one or a mixture of aramid fibrids and aramid short fibers is fed to a papermaking machine, dispersed, dewatered, rolled and dried to be wound into a sheet. As paper machines, a fourdrinier wire machine, a cylinder machine, an inclined paper machine, a combination (combination) paper machine combining these machines, and the like are used. In the case of production by a combination paper machine, a composite sheet composed of a plurality of paper layers can be obtained by sheet-forming and uniting pulps having different blending ratios. In the paper making, additives such as a dispersibility improving agent, a defoaming agent, and a paper strength enhancing agent may be used as necessary.

The aramid paper obtained as described above can be hot-pressed at high temperature and high pressure between a pair of rolls to improve the density and mechanical strength. The hot pressing conditions may be, for example, in the case of using a metal roll, a temperature of 100 to 400 ℃ and a linear pressure of 50 to 400kg/cm, but are not limited thereto. Multiple sheets of aramid paper may also be laminated during hot pressing. The hot press processing may be performed a plurality of times in any order.

(resin molded article)

The resin molded body 2 includes a pair of body portions 2a formed along both end surfaces in the axial direction of the core main body 4, and 6 coupling portions 2b coupling edges of outer peripheral portions of the pair of body portions 2a to each other. The body portion 2a has a thickness corresponding to the distance between the axial end face of the core body 4 and the end portion of the insulating sheet 6, and has the same cross-sectional shape as the core body 4 (core material 8). That is, the main body portion 2a includes an annular ring portion 2a1, a plurality of arm portions 2a2 extending radially inward from the ring portion 2a1, and protruding portions 2a3 extending from the distal end portions of the arm portions 2a2 to both circumferential sides. Between the arm portions 2a2, a substantially trapezoidal groove portion 2a4 surrounded by the adjacent arm portion 2a2, annular portion 2a1, and protrusion portion 2a3 is formed. The radially outer peripheral surface of the central portion 6a of the insulating sheet 6 abuts against the bottom of the groove portion 2a4, the left bent portion 6b and the right bent portion 6c of the insulating sheet 6 abut against the side surfaces of the arm portions 2a2, and the distal end bent portions 6d, 6e of the insulating sheet 6 abut against the radially outer peripheral surface of the protrusion portion 2a 3. The main body 2a of the resin molded body 2 is provided to insulate the winding wire of the motor from the upper surface of the arm portion 4b of the core main body 4 when the winding wire is wound around the arm portion 4b of the core main body 4. In the present embodiment, the body 2a is formed so as to cover the entire axial end surface of the core body 4, but may be formed so as to cover the arm portion 4b of the core body 4 on which the winding of the motor is disposed while coming into contact with at least the axial end portion of the insulating sheet 6. The surface of the insulating sheet 6 that is in contact with the resin molded body 2 is impregnated with the resin constituting the resin molded body 2, whereby the resin molded body 2 and the insulating sheet 6 are connected. In the present embodiment, the outer peripheral surfaces of the portions of the two end portions of the insulating sheet 6 protruding from the core main body 4 are in contact with the resin molded body 2.

The coupling portion 2b is formed in the outer peripheral groove portion 4e of the core main body 4, and couples the pair of main bodies 2a through the outer peripheral groove portion 4 e. The coupling portions 2b are provided at equal angular intervals on the outer peripheral surface of the core main body 4.

In the present embodiment, as a material constituting the resin molded body 2, for example, a PPS resin (polyphenylene sulfide resin), an acrylic nitrile-butadiene-styrene copolymer resin, a polyimide resin, a polyethylene terephthalate resin, a polyacetal resin, amide bond-containing polyamide 6, polyamide 66, polyamide 612, polyamide 11, polyamide 12, copolymerized polyamide, polyamide MXD6, polyamide 46, methoxymethylated polyamide, a polymer such as semi-aromatic polyamide, a polymer containing a polyamide resin composition as shown in japanese patent application laid-open No. 2006-321, a mixture thereof, or a mixture of the polymer and an inorganic substance such as glass fiber can be used. The resin molded body 2 is produced by a melt injection molding method in which the above-described material is injected (injected) into a desired mold in a molten state, and is removed from the mold after cooling. In particular, a molded article of a mixture of a semi-aromatic polyamide and glass fibers is preferable because it has high heat resistance and good adhesion to a laminate sheet comprising aramid paper. Examples of such a mixture include Zytel (registered trademark) HTN51G, 52G from dupont, but are not limited thereto.

By forming the groove for positioning the winding in the portion of the resin molded body 2 in contact with the winding, the position of the winding is stabilized, and the winding can be neatly wound with high accuracy, which is preferable because the efficiency of the motor generator and the like can be improved.

(method of manufacturing Ring-shaped laminated core Material)

The annular laminated core material 1 of the present embodiment can be manufactured as follows.

That is, first, a desired die-cutting process is applied to a strip-shaped thin sheet material, and further, a core material is cut by punching with an outer diameter punch. Then, the punched core material 8 is laminated into a cylindrical cavity of an injection molding die to form the core body 4. Further, the core material 8 is not formed with a cut-and-raised portion or a projection for caulking, the core material 8 is not bonded by an adhesive, a laser beam, or the like, and each core material 8 has no mark of a temporary fixing means. Next, the insulating sheet 6 is disposed in the groove portion 4d of the core body 4. At this time, the insulating sheet 6 is disposed such that both end portions of the insulating sheet 6 protrude from both end surfaces of the core main body 4 by a length corresponding to the thickness of the main body portion 2a of the resin molded body 2 (disposing step). At this time, the distance between both end surfaces in the axial direction of the core main body 4 and the inner surface of the cavity is equal to the protruding length of the insulating sheet 6, and the inner circumferential surface and the outer circumferential surface of the core main body 4 are disposed so as to be in contact with the inner surface of the cavity. Thus, a space corresponding to the body portion 2a of the resin molded body 2 is formed between both end surfaces of the core main body 4 and the inner surface of the cavity, and a space corresponding to the coupling portion 2b extending in the axial direction is formed between the outer peripheral groove portion 4e of the core main body 4 and the inner peripheral surface of the cavity. In the present embodiment, the core material 8 is laminated in the cavity to form the core main body 4, and then the insulating sheet 6 is attached, but the present invention is not limited to this, and the core main body 4 with the insulating sheet 6 attached thereto may be disposed in the cavity.

Next, the resin constituting the resin molded body 2 is injected into the cavity, and thereby the space between the core main body 4 and the inner surface of the cavity is filled with the resin. Then, the resin is cured, whereby the resin molded body 2 in which the body portion 2a and the coupling portion 2b are integrated can be molded (resin molding step). Through the above steps, the core material 8 constituting the laminated core main body 4 is fixed by the resin molded body 2 and the insulating sheet 6, and the integrated annular laminated core material 1 can be manufactured.

In the manufacturing method of the present embodiment, the plurality of core materials 8 are laminated in the injection molding cavity in a state where there is no mark of the temporary bonding means between the core materials 8, and the insulating sheet 6 is disposed in advance so that at least a part thereof is in contact with a part corresponding to the resin molded body 2, whereby at least a part of the surface of the insulating sheet 6 can be impregnated with the molten polymer forming the resin molded body 2. By thus producing the annular laminated core material 1 in which the portion of the resin molded body 2 and the insulating sheet 6 are connected and fixed, it is possible to simultaneously connect and fix the portions at the time of producing the resin molded body without using an adhesive. The impregnation here means that the molten polymer penetrates into the surface of the insulating sheet. In particular, when the insulating sheet contains a polymer having an amide bond and/or aramid paper, the molten polymer penetrates into the surface of the polymer having an amide bond and/or aramid fibrids and/or aramid short fibers constituting the aramid paper. By the impregnation, the polymer and the insulating sheet 6 are entangled with each other at a molecular level (level), and the adhesion between the resin molded body 2 and the insulating sheet 6 becomes stronger. Further, since the adhesion between the insulating sheet 6 and the core material 8 is improved by the expansion of the resin and the core material 8 due to the temperature change during molding, the heat generated by the winding is efficiently transmitted to the core material 8, and excessive temperature rise is prevented, so that the copper loss of the winding is reduced, and the output as a motor is improved.

In particular, when the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that is in contact with the resin molded body 2 is formed of a polymer having an amide bond, or when the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that is in contact with the resin molded body 2 is formed of aramid paper formed of aramid fibrids and aramid short fibers, the polymer having an amide bond that constitutes the resin molded body 2 and the insulating sheet 6 are entangled with each other on a molecular scale, and the adhesion between the resin molded body 2 and the insulating sheet 6 is further strengthened.

(Effect)

According to the present embodiment, the following operational effects are exhibited.

According to the present embodiment, since the pair of main body portions 2a of the resin molded body 2 are integrated by the connecting portion 2b, and further, the insulating sheet 6 and the resin molded body 2 are connected by contact, the laminated core members 8 can be integrated without being temporarily fixed by caulking, bonding, or the like. This eliminates the need to provide a caulking joint for caulking on the core member 8, thereby suppressing iron loss and eliminating the need for additional steps such as application of an adhesive and a laser beam.

Further, according to the present embodiment, since the molten resin is filled into the space corresponding to the pair of body portions 2a and the coupling portions 2b through the outer circumferential groove portion 4e, the inner circumferential groove portion, or the through hole when the resin molded body 2 is molded, the body portions 2a and the coupling portions 2b can be integrated.

Further, according to the present embodiment, since both axial surfaces of the annular core member 8 are flat surfaces and the flat surfaces of each core member 8 and the adjacent core members 8 are in direct contact with each other, the iron loss can be further suppressed.

In the present embodiment, since the insulating sheet 6 and the resin molded body 2 are connected without using an adhesive, the annular laminated core material 1 can be manufactured without performing an additional step such as bonding.

In the present embodiment, since the axial length of the contact portion between the insulating sheet 6 and the resin molded body 2 is 0.5mm or more, the linear segment conductors (segment conductors) are arranged in the groove portions of the annular laminated core material 1, and thus, the core material can withstand the load applied during bending without variation between the core materials during bending.

In the present embodiment, the insulating sheet 6 and the resin molded body 2 are connected to each other by impregnating the resin constituting the resin molded body 2 into the surface of the insulating sheet 6 which is in contact with the resin molded body 2, and therefore the insulating sheet 6 and the resin molded body 2 can be more firmly connected to each other.

In the present embodiment, the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that is in contact with the resin molded body 2 is formed using a polymer having an amide bond, so that the polymer and the insulating sheet 6 are entangled with each other on a molecular scale, and the insulating sheet 6 and the resin molded body 2 can be more firmly coupled.

In the present embodiment, the resin molded body 2 is formed using a polymer having an amide bond, and the surface of the insulating sheet 6 that is in contact with the resin molded body 2 is formed using an aramid paper made of aramid fibrids and aramid short fibers, so that the polymer and the insulating sheet 6 are entangled with each other at a molecular level, and the insulating sheet 6 and the resin molded body 2 can be more firmly coupled.

Examples

The present invention will be described below with reference to examples. In addition, these examples are provided to illustrate the contents of the present invention, and do not limit the contents of the present invention in any way.

(preparation of raw Material)

A fibrid of polyisophthaloyl metaphenylene diamine was produced using an apparatus for producing pulp particles composed of a combination of a stator and a rotor (wet precipitator) as described in Japanese patent application laid-open No. 52-15621. This was treated with a disintegrator, a beater, and the length weighted average fiber length was adjusted to 0.9 mm. The obtained aramid fibrids had a drainage of 90cm³。

On the other hand, meta-aramid fibers (Nomex (registered trademark) having a fineness of 2 denier per filament) manufactured by dupont were cut into a length of 6mm (hereinafter referred to as "aramid short fibers").

(production of aramid paper)

Prepared aramid fibrids and aramid short fibers are dispersed in water respectivelyMaking into slurry. These pulps were mixed so that the ratio of fibrids to aramid short fibers was 1/1 (weight ratio), and the mixture was handsheet with a TAPPI type handsheet machine (cross-sectional area of 625 cm)²) To produce a sheet-like article. Then, the sheet was hot-pressed with a metal calender roll at 330 ℃ and a line pressure of 300kg/cm to obtain aramid papers shown in examples 1 and 2 of Table 1.

(production of laminate sheet)

Aramid paper (basis weight 37 g/m) produced in the same manner as described above by containing 50 wt% of aramid paper produced by the method described in paragraph [ 0024 ] of Japanese patent laid-open No. 2006-321183²51 μm in thickness, 0.73g/cm3 in density) and an epoxy-containing phenoxy resin (formulation example 6 of jp 2006-321183 a), to obtain laminate sheets shown in examples 3 and 4 of table 1 including aramid paper having a 3-layer structure of aramid paper/resin composition/aramid paper (weight ratio 37/54/37) with the aramid paper disposed on the outer side.

Furthermore, aramid paper (basis weight 37 g/m)²Thickness of 51 μm and density of 0.73g/cm³) The laminate sheets shown in examples 5 and 6 in table 1, which included aramid papers having a 3-layer structure of aramid paper/polyethylene terephthalate film/aramid paper (weight ratio 37/54/37) with the aramid papers disposed on the outer side, were obtained by laminating a polyethylene terephthalate film (S28 ♯ 16, thickness 16 μm) manufactured by dongli corporation with an adhesive.

(production of core Material)

A non-oriented electrical steel sheet (thickness 0.5mm, thickness tolerance 0.04 mm) defined in JIS C2552 was punched out into a ring shape as shown in fig. 2, to manufacture a core member 8. Further, the core member 8 has no traces of a temporary fastening means for caulking, bonding, or the like.

(production of Ring-shaped laminated core Material)

The aramid paper or the laminate sheet produced as described above was used as an insulating sheet, the core material 8 produced as described above was used, and semi-aromatic polyamide (Zytel (registered trademark) HTN51G35 EF) manufactured by dupont was used as a polymer, and insert molding was performed under the conditions shown in table 1 to obtain a ring-shaped laminated core material 1 shown in fig. 1. That is, (1) the core material 8 is laminated and inserted into the cavity for injection molding in advance, (2) the insulating sheet 6 is fitted into the groove portion of the laminated core material 8, and (3) a semi-aromatic polyamide manufactured by dupont is introduced and injection molded by a melt injection molding method, and the resin molded body 2, the insulating sheet 6, and the laminated core material 8 are integrally molded. At this time, the molten polymer impregnates at least a part of the surface of the insulating sheet 6, and the insulating sheet 6 is directly bonded to the surface of the resin molded body 2, so that the annular laminated core material 1 shown in fig. 1 without a mark of the temporary bonding means can be obtained. The measurement method for each condition is as follows.

(measurement method)

(1) Basis weight, thickness measurement

It was carried out according to JIS C2300-2.

(2) Calculation of Density

Calculated as basis weight ÷ thickness.

(3) Tensile Strength and tensile elongation

It was carried out according to JIS C2300-2.

(4) Adhesion Property

By visually observing the bonded portion between the insulating paper and the resin molded body, a case without wrinkles (swelling of the insulating paper) in the bonded portion was judged as "good", and a case with wrinkles was judged as "poor".

(5) Appearance of the insulating sheet 6

The degree of warpage of the insulating sheet portion due to the hot tape during molding was visually determined.

(6) Adhesion of insulating sheet 6 to core material 8

Regarding the degree of adhesion between the insulating sheet portion and the core material 8, the motor bobbin including the core material 8 was impregnated with an epoxy resin, and after curing, the core material was cut perpendicularly to the axial direction at the middle point in the axial direction of the annularly laminated core material 1 by a water jet (model 626 manufactured by OMAX corporation) containing garnet fine particles, and the average value of the distance between the insulating sheet 6 and the core material 8 was measured at the cut surface.

(7) Bending resistance

Linear segment conductors were arranged in the grooves of the annular laminated core 1, and variations between the core materials when bent were visually observed, whereby the one without variations was judged as "good" and the one with variations was judged as "bad".

[ Table 1]

From the results in table 1, the annular laminated core material of the example was supported by the resin molded body through the outer peripheral surface, and was able to withstand the load acting when the segment conductor was bent in the case where the segment conductor was used for the winding. Further, since there is no trace of the temporary fastening means, no iron loss is generated by the generation of eddy current due to the residue of the caulking joint portion or the like, and the groove portion of the core material is covered with the insulating sheet having a small thickness, high efficiency due to high concentration of the winding wire can be expected. Further, since the adhesion between the insulating paper and the resin is sufficient, the dielectric breakdown voltage is also sufficiently high, and further, since the aramid paper and the polymer used have high heat resistance, it is thought that the winding can sufficiently withstand the heat generation of the winding, and therefore, the bobbin for a motor, which can withstand high efficiency and high output, such as a motor generator, is useful. In particular, in examples 3 and 4, since the resin composition of the intermediate layer of the laminate sheet has a structure similar to that of the resin molded article, it is considered that the resin composition softens at the time of molding and the adhesion between the insulating sheet and the core member is best.

Further, as compared with the case where the entire unnecessary removed thin plate portion is half-punched to be a caulking portion for temporary fastening and then the removed thin plate portion is removed by press punching as in japanese patent application laid-open No. 55-13665, a high punching force is not required and the removal is easy, and no post-processing is required such as generation of a residual portion or burr, so that a high-quality laminated core product can be manufactured with good workability.

Further, since the resin molded body and the insulating sheet are attached at the same time when they are molded, the steps of caulking and joining the resin molded body can be omitted.

Description of the reference numerals

1 annular laminated core Material

2 resin molded article

2a main body part

2a1 circular ring part

2a2 arm

2a3 projection

2a4 groove part

2b connecting part

4 core body

4a cylindrical part

4b arm part

4c projection

4d groove part

4e outer peripheral groove part

6 insulating sheet

6a central part

6b left bent part

6c right bent part

6d front end bend

6e front end bend

8 core material

8a ring part

8b arm part

8c projection

8d groove part

8e peripheral groove portion.