JP2010183791A - Method of manufacturing split permanent magnet, and electric motor using split permanent magnet - Google Patents

Method of manufacturing split permanent magnet, and electric motor using split permanent magnet Download PDF

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JP2010183791A
JP2010183791A JP2009027113A JP2009027113A JP2010183791A JP 2010183791 A JP2010183791 A JP 2010183791A JP 2009027113 A JP2009027113 A JP 2009027113A JP 2009027113 A JP2009027113 A JP 2009027113A JP 2010183791 A JP2010183791 A JP 2010183791A
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permanent magnet
split
positioning sheet
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magnet piece
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JP5298905B2 (en
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Takenari Okuyama
豪成 奥山
Toshiharu Oki
俊治 大木
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Nissan Motor Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing split permanent magnets that facilitates forming insulating layers among each permanent magnet piece, even when the number of the permanent magnet pieces is increased, and to provide an electric motor using the split permanent magnets. <P>SOLUTION: A positioning sheet 3 having an elasticity is stuck on joint surfaces 22 perpendicular to the split boundary surfaces 21 of each permanent magnet piece 2 and each permanent magnet piece 2 is connected, and the whole is curved under the state joining the permanent magnet pieces 2 with the positioning sheet 3. Openings 23 are formed among the permanent magnet pieces 2, and the openings 23 are filled with liquefied insulating materials 4. Accordingly, a series of the filling works of the liquefied insulating materials 4 are facilitated, thereby the insulating layers I can be formed easily among the permanent magnet pieces 2 and 2 even when the number of the permanent magnet pieces 2 is increased. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、複数に分割された永久磁石片を絶縁層を介在させて結合した分割永久磁石の製造方法およびその分割永久磁石を用いた電動機に関する。   The present invention relates to a method for manufacturing a split permanent magnet in which a plurality of split permanent magnet pieces are joined with an insulating layer interposed therebetween, and an electric motor using the split permanent magnet.

複数に分割した永久磁石片を絶縁層を介在させて結合した分割永久磁石は、たとえば、電動機に用いられてその永久磁石に発生する過電流を低減させることができる。従来の分割永久磁石としては、永久磁石片と永久磁石片との間に、絶縁基材と接着材を含む絶縁シートを絶縁層として挟み込んだものがある（例えば、特許文献１参照）。   A divided permanent magnet obtained by combining a plurality of divided permanent magnet pieces with an insulating layer interposed therebetween can be used, for example, in an electric motor to reduce an overcurrent generated in the permanent magnet. As a conventional divided permanent magnet, there is one in which an insulating sheet including an insulating base material and an adhesive material is sandwiched as an insulating layer between a permanent magnet piece and a permanent magnet piece (see, for example, Patent Document 1).

特開２００３−１６４０８３号公報Japanese Patent Laid-Open No. 2003-164083

しかしながら、かかる従来の分割永久磁石では、永久磁石片と永久磁石片との間に絶縁シートを個別に挟み込む必要があるため、結合する永久磁石片の数が増加すると、その挟み込み作業に手間が掛かってしまう問題があった。   However, in such a conventional divided permanent magnet, it is necessary to sandwich an insulating sheet between the permanent magnet pieces individually. Therefore, when the number of permanent magnet pieces to be joined increases, the sandwiching work takes time. There was a problem.

そこで、本発明は、永久磁石片の数が増加した場合にも、各永久磁石片間に簡単に絶縁層を設けることができる分割永久磁石の製造方法とその分割永久磁石を用いた電動機を提供するものである。   Accordingly, the present invention provides a method of manufacturing a split permanent magnet that can easily provide an insulating layer between the permanent magnet pieces even when the number of permanent magnet pieces increases, and an electric motor using the split permanent magnet. To do.

本発明にかかる分割永久磁石の製造方法にあっては、永久磁石片の分割境界面に対して直交する１つの面に、接着力と弾性とを有する位置決めシートを貼り付けてそれぞれの永久磁石片を連結した後、位置決めシートで拘束したそれぞれの永久磁石片を全体的に湾曲させてそれぞれの永久磁石片間に隙間を形成し、それら隙間に絶縁層となる液状絶縁材を充填することを特徴とする。   In the manufacturing method of the split permanent magnet according to the present invention, a positioning sheet having adhesive force and elasticity is attached to one surface orthogonal to the split boundary surface of the permanent magnet piece, and each permanent magnet piece. After connecting the two, the respective permanent magnet pieces restrained by the positioning sheet are entirely curved to form gaps between the respective permanent magnet pieces, and the gaps are filled with a liquid insulating material serving as an insulating layer. And

また、本発明にかかる電動機にあっては、前述の方法によって製造した分割永久磁石を、ロータコアに用いたことを特徴とする。   In the electric motor according to the present invention, the split permanent magnet manufactured by the above-described method is used for the rotor core.

本発明によれば、永久磁石片の１つの面に位置決めシートを貼り付けて、それぞれの永久磁石片を位置決めシートで拘束しつつ全体的に湾曲させた後、その湾曲によって形成される隙間に液状絶縁材を塗布するなどして充填させればよい。従って、永久磁石片の数が増加した場合にも、一連の液状絶縁材の充填作業が容易になるため、各永久磁石片間に簡単に絶縁層を設けることができる。   According to the present invention, a positioning sheet is attached to one surface of a permanent magnet piece, and each permanent magnet piece is curved while being constrained by the positioning sheet, and then liquid is formed in a gap formed by the bending. What is necessary is just to fill it by apply | coating an insulating material. Therefore, even when the number of permanent magnet pieces increases, a series of liquid insulating material filling operations are facilitated, so that an insulating layer can be easily provided between the permanent magnet pieces.

また、本発明にかかる電動機の発明によれば、前述した方法によって製造した分割永久磁石をロータコアに用いたので、前記分割永久磁石の効果を備えた電動機を提供できる。   In addition, according to the invention of the electric motor according to the present invention, since the divided permanent magnet manufactured by the above-described method is used for the rotor core, an electric motor having the effect of the divided permanent magnet can be provided.

本発明の第１実施形態にかかるそれぞれの永久磁石片に位置決めシートを貼り付けた状態を示す斜視図である。It is a perspective view which shows the state which affixed the positioning sheet | seat on each permanent magnet piece concerning 1st Embodiment of this invention. 本発明の第１の実施形態にかかるそれぞれの永久磁石片を全体的に湾曲させて隙間を形成した状態を示す斜視図である。It is a perspective view which shows the state which curved each whole permanent magnet piece concerning the 1st Embodiment of this invention, and formed the clearance gap. 本発明の第１の実施形態にかかるそれぞれの永久磁石片間の隙間に液状絶縁材を充填した状態を示す側面図である。It is a side view which shows the state which filled the liquid insulating material in the clearance gap between each permanent magnet piece concerning the 1st Embodiment of this invention. 本発明の第１の実施形態にかかる液状絶縁材を隙間に充填したそれぞれの永久磁石片を平面状に戻した状態を示す側面図である。It is a side view which shows the state which returned each permanent magnet piece which filled the liquid insulating material concerning the 1st Embodiment of this invention in the gap | interval to planar shape. 本発明の第１の実施形態にかかるそれぞれの永久磁石片の隙間からはみ出した液状絶縁材を除去した状態を示す側面図である。It is a side view which shows the state which removed the liquid insulating material which protruded from the clearance gap between each permanent magnet piece concerning the 1st Embodiment of this invention. 本発明の第１の実施形態にかかる湾曲したそれぞれの永久磁石片を平面状に戻す装置を概略的に示す側面図である。It is a side view which shows roughly the apparatus which returns each curved permanent magnet piece concerning the 1st Embodiment of this invention to planar shape. 本発明の第１の実施形態にかかる位置決めシートの拡大断面図である。It is an expanded sectional view of the positioning sheet concerning the 1st embodiment of the present invention. 本発明の第２の実施形態にかかるそれぞれの永久磁石片間の隙間に液状絶縁材を充填した状態を示す側面図である。It is a side view which shows the state which filled the liquid insulating material in the clearance gap between each permanent magnet piece concerning the 2nd Embodiment of this invention. 本発明の第２の実施形態にかかる液状絶縁材を充填したそれぞれの永久磁石片を平面状に戻した状態を示す側面図である。It is a side view which shows the state which returned each permanent magnet piece filled with the liquid insulating material concerning the 2nd Embodiment of this invention to planar shape. 本発明の第２の実施形態にかかるそれぞれの永久磁石片の隙間からはみ出した液状絶縁材を除去した状態を示す側面図である。It is a side view which shows the state which removed the liquid insulating material which protruded from the clearance gap between each permanent magnet piece concerning the 2nd Embodiment of this invention. 本発明の第２の実施形態にかかる湾曲したそれぞれの永久磁石片を平面状に戻す装置を概略的に示す側面図である。It is a side view which shows roughly the apparatus which returns each curved permanent magnet piece concerning 2nd Embodiment of this invention to planar shape. 本発明の第３の実施形態にかかる分割溝を形成した磁石片基材の斜視図である。It is a perspective view of the magnet piece base material in which the division | segmentation groove | channel concerning the 3rd Embodiment of this invention was formed. 本発明の第３の実施形態にかかる磁石片基材に位置決めシートを貼り付けた状態を示す斜視図である。It is a perspective view which shows the state which affixed the positioning sheet | seat on the magnet piece base material concerning the 3rd Embodiment of this invention. 本発明の第３の実施形態にかかる磁石片基材を分割溝から割った状態を示す斜視図である。It is a perspective view which shows the state which divided the magnet piece base material concerning the 3rd Embodiment of this invention from the division | segmentation groove | channel. 本発明の第３の実施形態の変形例となる磁石片基材を分割した状態を示す斜視図である。It is a perspective view which shows the state which divided | segmented the magnet piece base material used as the modification of the 3rd Embodiment of this invention. 本発明の第４の実施形態にかかるロータコアの磁石取付穴内で分割永久磁石が固化される状態を示す断面図である。It is sectional drawing which shows the state by which a split permanent magnet is solidified within the magnet attachment hole of the rotor core concerning the 4th Embodiment of this invention. 本発明の第４の実施形態にかかる磁石取付穴が形成されたロータコアを概略的に示す斜視図である。It is a perspective view which shows roughly the rotor core in which the magnet attachment hole concerning the 4th Embodiment of this invention was formed. 図１６中要部の拡大断面図である。It is an expanded sectional view of the principal part in FIG. 本発明の第５の実施形態にかかる位置決めシートの拡大断面図である。It is an expanded sectional view of the positioning sheet concerning the 5th Embodiment of this invention. 本発明の第５の実施形態にかかる液状絶縁材を固化させた状態の分割永久磁石の正面図である。It is a front view of the division | segmentation permanent magnet of the state which solidified the liquid insulating material concerning the 5th Embodiment of this invention. 本発明の第５の実施形態にかかる位置決めシートを剥離した状態を示す分割永久磁石の正面図である。It is a front view of the division | segmentation permanent magnet which shows the state which peeled the positioning sheet concerning the 5th Embodiment of this invention. 本発明の第５の実施形態にかかる湾曲したそれぞれの永久磁石片を平面状に戻す装置を概略的に示す側面図である。It is a side view which shows roughly the apparatus which returns each curved permanent magnet piece concerning the 5th Embodiment of this invention to planar shape. 本発明の第６の実施形態にかかる複数に分割された永久磁石片を示す斜視図である。It is a perspective view which shows the permanent magnet piece divided | segmented into plurality concerning the 6th Embodiment of this invention. 本発明の第６の実施形態にかかるそれぞれの永久磁石片に位置決めシートを貼り付けた状態を示す斜視図である。It is a perspective view which shows the state which affixed the positioning sheet | seat on each permanent magnet piece concerning the 6th Embodiment of this invention. 本発明の第６の実施形態にかかる貼り付けた位置決めシートを加熱して発泡材を膨張させた状態を示す斜視図である。It is a perspective view which shows the state which heated the sticking positioning sheet concerning the 6th Embodiment of this invention, and expanded the foaming material. 本発明の第６の実施形態にかかる位置決めシートの拡大断面図である。It is an expanded sectional view of the positioning sheet concerning the 6th Embodiment of this invention. 本発明の第７の実施形態にかかる分割溝を形成した磁石片基材の斜視図である。It is a perspective view of the magnet piece base material in which the division | segmentation groove | channel concerning the 7th Embodiment of this invention was formed. 本発明の第７の実施形態にかかる磁石片基材に位置決めシートを貼り付けた状態を示す斜視図である。It is a perspective view which shows the state which affixed the positioning sheet | seat on the magnet piece base material concerning the 7th Embodiment of this invention. 本発明の第７の実施形態にかかる磁石片基材を分割溝から割った状態を示す斜視図である。It is a perspective view which shows the state which divided the magnet piece base material concerning the 7th Embodiment of this invention from the division groove. 本発明の第７の実施形態の変形例となる磁石片基材を分割した状態を示す斜視図である。It is a perspective view which shows the state which divided | segmented the magnet piece base material used as the modification of the 7th Embodiment of this invention. 本発明の第８の実施形態にかかるロータコアの磁石取付穴内で分割永久磁石が固化される状態を示す断面図である。It is sectional drawing which shows the state by which a split permanent magnet is solidified within the magnet attachment hole of the rotor core concerning the 8th Embodiment of this invention. 本発明の第８の実施形態にかかるロータコアの磁石取付穴に永久磁石片を挿入した状態を概略的に示す斜視図である。It is a perspective view which shows roughly the state which inserted the permanent magnet piece in the magnet attachment hole of the rotor core concerning the 8th Embodiment of this invention. 本発明の第８の実施形態にかかるロータコアの磁石取付穴に永久磁石片を挿入して加熱した状態を概略的に示す斜視図である。It is a perspective view which shows roughly the state which inserted and heated the permanent magnet piece in the magnet attachment hole of the rotor core concerning the 8th Embodiment of this invention.

以下、本発明の実施形態を図面と共に詳述する。   Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[第１の実施形態]
図１〜図７は本発明にかかる分割永久磁石の製造方法の第１の実施形態を示す。尚、本実施形態の分割永久磁石を説明するにあたって、電動機のロータコアに組み込まれる分割永久磁石に例を取って説明するものとし、この場合の分割永久磁石１とは、図５に示すように、複数に分割された永久磁石片２を絶縁層Ｉを介在させて結合したものである。このように永久磁石を複数の永久磁石片２に分割することにより、電動機を駆動する際に永久磁石に発生する過電流を低減して、電動機の出力低下を抑制できる。 [First embodiment]
FIGS. 1-7 shows 1st Embodiment of the manufacturing method of the split permanent magnet concerning this invention. In the description of the split permanent magnet of the present embodiment, the split permanent magnet incorporated in the rotor core of the electric motor will be described as an example. In this case, the split permanent magnet 1 is as shown in FIG. The permanent magnet pieces 2 divided into a plurality are combined with an insulating layer I interposed therebetween. By dividing the permanent magnet into the plurality of permanent magnet pieces 2 in this way, the overcurrent generated in the permanent magnet when the motor is driven can be reduced, and the output reduction of the motor can be suppressed.

本実施形態の分割永久磁石１の製造方法は、まず、図１に示すように、それぞれの永久磁石片２の分割境界面２１に対して直交する接合面（本実施形態では下面）２２に、接着力と弾性とを有する位置決めシート３を貼り付けてそれぞれの永久磁石片２を連結する。次に、図２に示すように、位置決めシート３に接合させたそれぞれの永久磁石片２を全体的に湾曲させて、それぞれの永久磁石片２間に隙間２３を形成する。そして、図３に示すように、それぞれの永久磁石片２間に形成された隙間２３に液状絶縁材４を充填する。この液状絶縁材４の充填は塗布により行われ、その液状絶縁材４が固化することにより前述した絶縁層Ｉとして機能する。   As shown in FIG. 1, first, the manufacturing method of the divided permanent magnet 1 of the present embodiment is performed on a bonding surface (lower surface in the present embodiment) 22 orthogonal to the divided boundary surface 21 of each permanent magnet piece 2. A positioning sheet 3 having adhesive strength and elasticity is attached to connect the permanent magnet pieces 2 to each other. Next, as shown in FIG. 2, the respective permanent magnet pieces 2 bonded to the positioning sheet 3 are entirely curved to form gaps 23 between the respective permanent magnet pieces 2. Then, as shown in FIG. 3, the liquid insulating material 4 is filled in the gaps 23 formed between the permanent magnet pieces 2. The filling of the liquid insulating material 4 is performed by coating, and the liquid insulating material 4 functions as the insulating layer I described above by solidifying.

次に、それぞれの永久磁石片２間の隙間２３に液状絶縁材４を充填した後に、全体的に湾曲させていたそれぞれの永久磁石片２を、図４に示すように、位置決めシート３の伸展を伴いつつ平面状に戻して平坦化させる。このとき、各隙間２３に充填した液状絶縁材４は、隙間２３の間隔が狭まることにより押し出されるとともに、分割境界面２１の全体に押し延ばされて確実に絶縁層Ｉを形成することができる。そして、液状絶縁材４が隙間２３からはみ出した余剰部分４ａは液状であるため、図５に示すように、簡単に拭き取り除去できて最終的に分割永久磁石１が形成される。   Next, after filling the gaps 23 between the respective permanent magnet pieces 2 with the liquid insulating material 4, the respective permanent magnet pieces 2 which are curved as a whole are extended as shown in FIG. And flatten it back to a flat shape. At this time, the liquid insulating material 4 filled in the gaps 23 is pushed out as the gaps 23 are narrowed, and the liquid insulating material 4 is pushed over the entire dividing boundary surface 21 to reliably form the insulating layer I. . And since the surplus part 4a which the liquid insulating material 4 protruded from the clearance gap 23 is a liquid, as shown in FIG. 5, it can wipe off easily and finally the division | segmentation permanent magnet 1 is formed.

図６は、湾曲していたそれぞれの永久磁石片２を平面状に戻す装置Ｍを示し、それぞれの永久磁石片２間の隙間２３に液状絶縁材４を充填した状態で、それら永久磁石片２の湾曲方向の上下面を一対の平坦状の治具板５、５ａ間に挟み込む。そして、それら治具板５、５ａに加圧力を付与しつつ、それぞれの永久磁石片２を、平面一体形状に加圧（拘束）した状態で液状絶縁材４を硬化させることができる。このとき、フッ素フィルムなどの非接着シート６を、液状絶縁材４がはみ出す側の面と治具板５ａとの間に介在させておくことにより、はみ出した液状絶縁材４と治具板５ａとが固着されるのを防止して、脱型時に治具板５ａを容易に剥離させることができる。   FIG. 6 shows a device M for returning the curved permanent magnet pieces 2 to a flat shape, and the permanent magnet pieces 2 are filled with the liquid insulating material 4 in the gaps 23 between the permanent magnet pieces 2. Are sandwiched between a pair of flat jig plates 5 and 5a. The liquid insulating material 4 can be cured in a state where each permanent magnet piece 2 is pressed (restrained) into a planar integrated shape while applying pressure to the jig plates 5 and 5a. At this time, the non-adhesive sheet 6 such as a fluorine film is interposed between the surface on the side where the liquid insulating material 4 protrudes and the jig plate 5a, whereby the protruding liquid insulating material 4 and the jig plate 5a Is prevented from being fixed, and the jig plate 5a can be easily peeled off at the time of demolding.

前述の位置決めシート３は、図７に示すように、中間部に配置される粘着層３１と、粘着層３１の外側面に添着されるフィルム３２と、粘着層３１の内側面を覆う剥離シート３３と、からなる３層構造となっている。粘着層３１は、剥離シート３３を剥がして永久磁石１の接合面２２に貼り付けた時、それぞれの永久磁石片２を一体に保持する機能を有する。剥離シート３３は、位置決めシート３を永久磁石片２に貼り付けるまで粘着層３の品質を保護する機能を有する。フィルム３２は、柔軟に曲げることが可能で適度な伸び弾性を有して滑り性が良くなっており、たとえば、アクリル、ナイロン、ＰＰＳ、ＬＣＰ、ＰＥＴなどの素材によって、厚さ約５０μｍ程度の薄型化が可能となる高耐熱性樹脂シートとなっている。   As shown in FIG. 7, the positioning sheet 3 includes an adhesive layer 31 disposed in the middle part, a film 32 attached to the outer surface of the adhesive layer 31, and a release sheet 33 that covers the inner surface of the adhesive layer 31. And has a three-layer structure. The adhesive layer 31 has a function of integrally holding the permanent magnet pieces 2 when the release sheet 33 is peeled off and attached to the bonding surface 22 of the permanent magnet 1. The release sheet 33 has a function of protecting the quality of the adhesive layer 3 until the positioning sheet 3 is attached to the permanent magnet piece 2. The film 32 can be flexibly bent, has an appropriate stretch elasticity, and has a good sliding property. For example, the film 32 is a thin film having a thickness of about 50 μm depending on materials such as acrylic, nylon, PPS, LCP, and PET. It is a highly heat-resistant resin sheet that can be made.

また、液状絶縁材４は、接着性あるいは固着力を発生する材料を使用する。このときの接着材の固化手段は、嫌気性、熱硬化性、常温硬化性、脱溶剤反応性などの硬化型接着材を用いる方法でよい。   The liquid insulating material 4 is made of a material that generates adhesiveness or fixing force. The solidifying means of the adhesive at this time may be a method using a curable adhesive such as anaerobic, thermosetting, room temperature curable, and solvent removal reactivity.

以上説明したように、第１の実施形態にかかる分割永久磁石１の製造方法およびその方法により製造された分割永久磁石１によれば、それぞれの永久磁石片２の接合面２２に位置決めシート３を貼り付けて全体的に湾曲させた後、その湾曲によって形成される隙間２３に液状絶縁材４を塗布するなどして充填させればよい。従って、永久磁石片２の数が増加した場合にも、一連の液状絶縁材４の充填作業が容易になるため、それぞれの永久磁石片２間に簡単に絶縁層Ｉを設けることができる。   As described above, according to the method for manufacturing the split permanent magnet 1 according to the first embodiment and the split permanent magnet 1 manufactured by the method, the positioning sheet 3 is attached to the joint surface 22 of each permanent magnet piece 2. After being pasted and curved as a whole, the liquid insulating material 4 may be filled in the gap 23 formed by the curvature. Accordingly, even when the number of permanent magnet pieces 2 increases, a series of filling operations of the liquid insulating material 4 is facilitated, so that the insulating layer I can be easily provided between the respective permanent magnet pieces 2.

また、本実施形態では、位置決めシート３でそれぞれの永久磁石片２の相対位置を拘束した上で湾曲されるため、それぞれの永久磁石片２を一体に連結した形状や寸法を損なわずに液状絶縁材４を充填するための隙間２３を確保できる。これにより、複数の永久磁石片２を一体化させて分割永久磁石１を形成した後にも、寸法精度を得るための加工工程が不要となり、また、材料歩留まりが悪化されることも無くなる。   Further, in the present embodiment, the positioning sheet 3 is curved after constraining the relative positions of the permanent magnet pieces 2, so that the liquid insulation can be achieved without impairing the shape and dimensions of the permanent magnet pieces 2 connected together. A gap 23 for filling the material 4 can be secured. Thus, even after the plurality of permanent magnet pieces 2 are integrated to form the split permanent magnet 1, a processing step for obtaining dimensional accuracy is not required, and the material yield is not deteriorated.

更に、複数の永久磁石片２に位置決めシート３を貼り付けた時の寸法と、それぞれの永久磁石片２間に形成した隙間２３に液状絶縁材４を充填した後の寸法とは、絶縁層Ｉが数μｍ〜５０μｍ程度の僅かの寸法しか変化しないため、分割永久磁石１の寸法精度を維持することが容易であり、また、仕上げ加工が不要となるため安価に製造することができる。   Furthermore, the dimension when the positioning sheet 3 is attached to the plurality of permanent magnet pieces 2 and the dimension after the liquid insulating material 4 is filled in the gaps 23 formed between the permanent magnet pieces 2 are the insulating layer I However, since the dimensional accuracy of the split permanent magnet 1 can be easily maintained, and the finishing process is not necessary, it can be manufactured at low cost.

更にまた、液状絶縁材４を隙間２３に充填した後、湾曲させた状態から平面状に戻す際に不要な液状絶縁材４が隙間２３から押し出されるため、分割境界面２１の隅々まで液状絶縁材４が行き渡って、確実かつ安定的に絶縁層Ｉをそれぞれの永久磁石片２間に介在させることが可能となる。   Furthermore, since the liquid insulating material 4 is filled into the gap 23 and then the unnecessary liquid insulating material 4 is pushed out of the gap 23 when returning from the curved state to the flat shape, the liquid insulation is applied to every corner of the dividing boundary surface 21. The material 4 spreads, and the insulating layer I can be interposed between the permanent magnet pieces 2 reliably and stably.

従って、本実施形態の製造方法で製造された分割永久磁石１を電動機に用いた場合に、高い信頼性をもって過電流の低減を達成できるとともに、分割永久磁石１を安価に製造することができる。   Therefore, when the split permanent magnet 1 manufactured by the manufacturing method of this embodiment is used for an electric motor, reduction of overcurrent can be achieved with high reliability, and the split permanent magnet 1 can be manufactured at low cost.

[第２の実施形態]
図８〜図１１は本発明の第２の実施形態を示し、前記第１の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。 [Second Embodiment]
8 to 11 show a second embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals and redundant description is omitted.

本実施形態の分割永久磁石１Ａの製造方法は、基本的に第１の実施形態で説明した製造方法と同様であり、図８に示すように、それぞれの永久磁石片２の接合面２２に位置決めシート３を貼り付けてそれぞれの永久磁石片２を連結し、それら永久磁石片２を位置決めシート３で拘束した状態で全体的に湾曲させて隙間２３を形成し、その隙間２３に液状絶縁材４を充填するようになっている。   The manufacturing method of the split permanent magnet 1A of the present embodiment is basically the same as the manufacturing method described in the first embodiment, and is positioned on the bonding surface 22 of each permanent magnet piece 2 as shown in FIG. A sheet 3 is pasted to connect the permanent magnet pieces 2, and the permanent magnet pieces 2 are curved in a state of being constrained by the positioning sheet 3 to form a gap 23, and the liquid insulating material 4 is formed in the gap 23. It is supposed to be filled.

ここで、本実施形態の製造方法が第１の実施形態と主に異なる点は、液状絶縁材４に、粒状の固形絶縁材７を混合させたことにある。   Here, the main difference between the manufacturing method of this embodiment and the first embodiment is that the liquid insulating material 4 is mixed with a granular solid insulating material 7.

固形絶縁材７は、絶縁材料によって粒状に形成されたものであればよく、その粒径は、図９に示すように、それぞれの永久磁石片２を直線状に戻した際の隙間２３の間隔よりも小さければよい。例えば、本実施形態の固形絶縁材７としては、粒径５０μｍ程度のガラスビーズが用いられ、そのガラスビーズが液状絶縁材４に略均等に散在するように混入される。   The solid insulating material 7 may be formed in a granular shape by an insulating material, and the particle size thereof is an interval between the gaps 23 when each permanent magnet piece 2 is returned to a straight shape as shown in FIG. Smaller than that. For example, as the solid insulating material 7 of the present embodiment, glass beads having a particle diameter of about 50 μm are used, and the glass beads are mixed so as to be scattered almost evenly in the liquid insulating material 4.

そして、本実施形態にあっても、それぞれの永久磁石片２を湾曲させた状態（図８参照）から平面状に戻した状態で、隙間２３に充填した液状絶縁材４が押し出され、その押し出された液状絶縁材４の余剰部分４ａは、図１０に示すように、拭き取り除去されて分割永久磁石１Ａが形成される。このとき、位置決めシート３は、第１の実施形態と同様に接着力と弾性とを有した構造（例えば、図７参照）が用いられる。   Even in the present embodiment, the liquid insulating material 4 filled in the gap 23 is pushed out in a state where each permanent magnet piece 2 is returned to a flat shape from the curved state (see FIG. 8). As shown in FIG. 10, the surplus portion 4a of the liquid insulating material 4 is wiped off to form the divided permanent magnet 1A. At this time, the positioning sheet 3 has a structure (see, for example, FIG. 7) having an adhesive force and elasticity as in the first embodiment.

また、第１の実施形態と同様に本実施形態は、図１１に示すように、湾曲していたそれぞれの永久磁石片２を平面状に戻す際に装置Ｍを用いて、それぞれの永久磁石片２の湾曲方向の上下面を一対の平坦状の治具板５、５ａ間に挟み込むことによって簡単かつ正確に平面状に戻すことができる。勿論、この場合にあっても、フッ素フィルムなどの非接着シート６を、液状絶縁材４がはみ出す側の面と治具板５ａとの間に介在させておくことが好ましい。   Further, as in the first embodiment, as shown in FIG. 11, the present embodiment uses the apparatus M to return each curved permanent magnet piece 2 to a flat shape, and each permanent magnet piece. By sandwiching the upper and lower surfaces of the two curved directions between the pair of flat jig plates 5 and 5a, it is possible to easily and accurately return the flat surface. Of course, even in this case, it is preferable to interpose a non-adhesive sheet 6 such as a fluorine film between the surface on the side where the liquid insulating material 4 protrudes and the jig plate 5a.

以上説明したように、第２の実施形態にかかる分割永久磁石１Ａの製造方法およびその方法により製造された分割永久磁石１Ａによれば、固形絶縁材７が隣接する永久磁石片２間に介在されることで、それぞれの永久磁石片２間の隙間２３の最小間隔を制約することができる。これにより、液状絶縁材４が固化された際に形成される絶縁層Ｉの厚さを所定厚さ若しくはそれ以上に確保でき、絶縁信頼性の高い絶縁層Ｉを持った分割永久磁石１Ａを提供できる。また、固形絶縁材７の粒径を予め選択しておくことにより、それぞれの永久磁石片２間の間隔および絶縁性能を制御できるようになる。   As described above, according to the manufacturing method of the split permanent magnet 1A according to the second embodiment and the split permanent magnet 1A manufactured by the method, the solid insulating material 7 is interposed between the adjacent permanent magnet pieces 2. Thus, the minimum gap of the gap 23 between the permanent magnet pieces 2 can be restricted. Thereby, the thickness of the insulating layer I formed when the liquid insulating material 4 is solidified can be ensured to a predetermined thickness or more, and a split permanent magnet 1A having an insulating layer I with high insulation reliability is provided. it can. In addition, by selecting the particle size of the solid insulating material 7 in advance, the spacing between the permanent magnet pieces 2 and the insulating performance can be controlled.

[第３の実施形態]
図１２〜図１４は本発明の第３の実施形態を示し、前記第１の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。本実施形態の分割永久磁石１Ｂの製造方法は、基本的に第１の実施形態で説明した製造方法と同様であり、図１４に示すように、それぞれの永久磁石片２の接合面２２に位置決めシート３を貼り付けてあり、そして、その位置決めシート３で拘束した状態でそれぞれの永久磁石片２を全体的に湾曲（図２参照）させるようになっている。 [Third embodiment]
12 to 14 show a third embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals and redundant description is omitted. The manufacturing method of the split permanent magnet 1B of this embodiment is basically the same as the manufacturing method described in the first embodiment, and is positioned on the joint surface 22 of each permanent magnet piece 2 as shown in FIG. The sheet 3 is affixed, and each permanent magnet piece 2 is generally curved (see FIG. 2) while being restrained by the positioning sheet 3.

ここで、本実施形態の製造方法が第１の実施形態と主に異なる点は、複数の永久磁石片２が、位置決めシート３を貼り付けた磁石片基材８を割って形成されることにある。   Here, the manufacturing method of the present embodiment is mainly different from the first embodiment in that the plurality of permanent magnet pieces 2 are formed by breaking the magnet piece base material 8 to which the positioning sheet 3 is attached. is there.

即ち、本実施形態の分割永久磁石１Ｂは、図１２に示すように、一体形状の磁石片基材８の表面における分割予定部位に分割溝８ａを形成した後、図１３に示すように、その分割溝８ａの形成面とは反対側（裏面側）の接合面２２Ａに位置決めシート３を貼り付け、この状態で、図１４に示すように、磁石片基材８を外力の付与により分割溝８ａに沿って割ることにより形成する。   That is, the split permanent magnet 1B according to the present embodiment has a split groove 8a formed in a predetermined split portion on the surface of the integral magnet piece base 8 as shown in FIG. The positioning sheet 3 is affixed to the joining surface 22A opposite to the formation surface of the divided groove 8a (back surface side), and in this state, as shown in FIG. It forms by dividing along.

永久磁石の素材は脆性に乏しく、応力集中される分割溝８ａを予め形成しておくことにより、そこに外力を加えることで、図１４に示すように、分割溝８ａを基端としてクラックＣが発生し、そのクラックＣを分割境界面２１として複数の永久磁石片２が得られることになる。分割溝８ａは、放電加工や鋭利な刃物によるケガキ、または、鋭利な回転砥石による加工等で形成できる。また、加える外力としては、衝撃力や剪断力または曲げ力等を用いることができる。   The material of the permanent magnet is poor in brittleness, and by forming the split groove 8a where stress is concentrated in advance, by applying an external force there, as shown in FIG. A plurality of permanent magnet pieces 2 are obtained using the crack C as the dividing boundary surface 21. The dividing grooves 8a can be formed by electric discharge machining, scribing with a sharp blade, or machining with a sharp rotating grindstone. Further, as an external force to be applied, an impact force, a shear force, a bending force, or the like can be used.

勿論、本実施形態にあっても、磁石片基材８を割って複数の永久磁石片２に分割した後に、それら永久磁石片２を位置決めシート３で拘束した状態で全体的に湾曲させて隙間２３を形成し、その隙間２３に液状絶縁材４を充填することは前記各実施形態と同様である。   Of course, even in this embodiment, after the magnet piece base material 8 is divided and divided into a plurality of permanent magnet pieces 2, the permanent magnet pieces 2 are entirely curved while being constrained by the positioning sheet 3. 23 is formed, and the gap 23 is filled with the liquid insulating material 4 in the same manner as in the above embodiments.

以上説明したように、第３の実施形態の分割永久磁石１Ｂの製造方法およびその方法により製造された分割永久磁石１Ｂによれば、一体形状の磁石片基材８に外力を加えて分割する場合、分割された複数の永久磁石片２を元の形状に一体化する手段が別途必要となってしまうが、本実施形態のように分割前に位置決めシート３を貼り付けておくことで、分割後も磁石片基材８の一体形状を維持することができる。つまり、分割されたそれぞれの永久磁石片２の相対位置がずれるのを防止できる。従って、本実施形態では一体化の手段を別途必要としなくなるため、分割永久磁石１Ｂを安価にかつ簡単に製造できる。   As explained above, according to the manufacturing method of the split permanent magnet 1B of the third embodiment and the split permanent magnet 1B manufactured by the method, the magnetic piece base material 8 having an integral shape is split by applying an external force. In addition, a separate means for integrating the plurality of divided permanent magnet pieces 2 into the original shape is required. However, by attaching the positioning sheet 3 before the division as in the present embodiment, Also, the integral shape of the magnet piece base material 8 can be maintained. That is, it is possible to prevent the relative positions of the divided permanent magnet pieces 2 from shifting. Therefore, in the present embodiment, no separate means for integration is required, so that the split permanent magnet 1B can be manufactured inexpensively and easily.

ところで、本実施形態ではそれぞれの永久磁石片２の分割境界面２１はクラックＣによるものであるため、平坦面では無く自由曲面となるが、このように分割境界面２１が自由曲面であっても隙間２３に液状絶縁材４を充填した際に、その絶縁材４が液状であるため分割境界面２１の隅々まで浸透させることができる。従って、安価に永久磁石片２の分割化を実現しつつ、信頼性の高い絶縁層Ｉを確保できる。また、本実施形態のクラックＣが分割境界面２１となる分割永久磁石１Ｂを電動機に用いた場合にも、ロータコア１０（図１６参照）への組み付け性を損なうことは無い。   By the way, in this embodiment, since the division | segmentation boundary surface 21 of each permanent magnet piece 2 is based on the crack C, it becomes a free-form surface instead of a flat surface, but even if the division | segmentation boundary surface 21 is a free-form surface in this way, When the liquid insulating material 4 is filled in the gap 23, the insulating material 4 is in a liquid state, so that it can penetrate to every corner of the dividing boundary surface 21. Therefore, it is possible to secure a highly reliable insulating layer I while realizing the division of the permanent magnet piece 2 at a low cost. Further, even when the split permanent magnet 1B in which the crack C of the present embodiment becomes the split boundary surface 21 is used in the electric motor, the assembling property to the rotor core 10 (see FIG. 16) is not impaired.

図１５は前記第３の実施形態の変形例を示しており、具体的には、磁石片基材を分割した状態を示す斜視図である。   FIG. 15 shows a modification of the third embodiment, and specifically, is a perspective view showing a state where the magnet piece base material is divided.

本変形例は、基本的に第３の実施形態と同様であり、複数の永久磁石片２が、位置決めシート３を貼り付けた磁石片基材８を割って形成されるが、特に、本変形例では、図１５に示すように、磁石片基材８が縦・横の２方向に分割されている。勿論、磁石片基材８の表面（位置決めシート３の貼り付け面とは反対面）には、分割予定部位に縦・横の分割溝８ａが予め形成される。   This modification is basically the same as that of the third embodiment, and a plurality of permanent magnet pieces 2 are formed by breaking the magnet piece base material 8 to which the positioning sheet 3 is attached. In the example, as shown in FIG. 15, the magnet piece base material 8 is divided into two vertical and horizontal directions. Of course, on the surface of the magnet piece base material 8 (the surface opposite to the attachment surface of the positioning sheet 3), vertical and horizontal dividing grooves 8a are formed in advance at the planned division site.

従って、本変形例のように磁石片基材８を縦・横に分割する場合にも、第３の実施形態に示した分割永久磁石１Ｂの製造方法と同様の作用効果を奏する。また、この場合に、磁石片基材８を分割する方向は２方向に限ることなく、斜め方向を含めた２方向以上に分割してもよい。   Therefore, even when the magnet piece base material 8 is divided vertically and horizontally as in the present modification, the same operational effects as the method for manufacturing the divided permanent magnet 1B shown in the third embodiment can be obtained. In this case, the direction of dividing the magnet piece base material 8 is not limited to two directions, and may be divided into two or more directions including an oblique direction.

[第４の実施形態]
図１６〜図１８は本発明の第４の実施形態を示し、前記第１の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。本実施形態の分割永久磁石１Ｃの製造方法は、基本的に第１の実施形態と同様であるが、特に前記各実施形態と異なる点は、図１６に示すように、分割永久磁石１Ｃの絶縁層Ｉを電動機のロータコア１０の磁石取付穴１１内で固化させたことにある。 [Fourth Embodiment]
16 to 18 show a fourth embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals and redundant description is omitted. The manufacturing method of the split permanent magnet 1C of the present embodiment is basically the same as that of the first embodiment. In particular, the difference from each of the above embodiments is the insulation of the split permanent magnet 1C as shown in FIG. The layer I is solidified in the magnet mounting hole 11 of the rotor core 10 of the electric motor.

即ち、本実施形態では、それぞれの永久磁石片２間に形成された隙間２３に充填する液状絶縁材４を、ロータコア１０への磁石固定用の接着材１３（図１８参照）と同一としてある。つまり、ロータコア１０への磁石固定用の接着材１３を液状絶縁材として用いてある。   That is, in this embodiment, the liquid insulating material 4 filling the gaps 23 formed between the permanent magnet pieces 2 is the same as the adhesive 13 for fixing the magnet to the rotor core 10 (see FIG. 18). That is, the adhesive 13 for fixing the magnet to the rotor core 10 is used as the liquid insulating material.

図１６に示すように、ロータコア１０は、図示省略した環状のステータ内で回転するロータ１４に設けられる。ロータコア１０は、図１７に示すように、中心部に回転軸１５の取付穴１６が形成された積層鋼板により厚肉円筒状に形成され、その厚肉部分には、断面が細長い矩形状となる複数の磁石取付穴１１が中心軸方向に貫通して設けられる。そして、図１６に示すように、ロータコア１０の両端に側板１７が配置されている。   As shown in FIG. 16, the rotor core 10 is provided on a rotor 14 that rotates in an annular stator (not shown). As shown in FIG. 17, the rotor core 10 is formed in a thick cylindrical shape by a laminated steel plate in which a mounting hole 16 of the rotary shaft 15 is formed in the center, and the thick portion has a rectangular shape with a long cross section. A plurality of magnet mounting holes 11 are provided penetrating in the central axis direction. As shown in FIG. 16, side plates 17 are arranged at both ends of the rotor core 10.

ここで、本実施形態の分割永久磁石１Ｃの製造方法は、液状絶縁材４と同一の接着材１３をロータコア１０の磁石取付穴１１に塗布し、その後、それぞれの永久磁石片２間に形成した隙間２３に液状絶縁材４を充填して、それら永久磁石片２を磁石取付穴１１に挿入する。そして、接着材１３の固化と液状絶縁材４の固化とを同時に行うようになっている。   Here, in the manufacturing method of the split permanent magnet 1 </ b> C of the present embodiment, the same adhesive material 13 as the liquid insulating material 4 is applied to the magnet mounting holes 11 of the rotor core 10 and then formed between the permanent magnet pieces 2. The gap 23 is filled with the liquid insulating material 4 and the permanent magnet pieces 2 are inserted into the magnet mounting holes 11. The adhesive 13 is solidified and the liquid insulating material 4 is simultaneously solidified.

以上説明したように、第４の実施形態の分割永久磁石１Ｃの製造方法およびその方法により製造された分割永久磁石１Ｃによれば、永久磁石片２を磁石取付穴１１に挿入した状態で、液状絶縁材４の硬化と接着材１３の硬化とを同時に行うことができる。従って、それぞれの永久磁石片２間の絶縁層Ｉの固化と、分割永久磁石１Ｃのロータコア１０への固定と、を同時に行うことができる。これにより、別途完成した分割永久磁石１Ｃをロータコア１０の磁石取付穴１１に挿入する工程やその分割永久磁石１Ｃを固定する工程等が不要となり、ロータコア１０への分割永久磁石１Ｃの組付作業を容易にすることができる。   As explained above, according to the manufacturing method of the split permanent magnet 1C of the fourth embodiment and the split permanent magnet 1C manufactured by the method, the permanent magnet piece 2 is inserted in the magnet mounting hole 11 in a liquid state. The insulating material 4 and the adhesive 13 can be cured at the same time. Therefore, the insulating layer I between the permanent magnet pieces 2 can be solidified and the divided permanent magnet 1C can be fixed to the rotor core 10 at the same time. As a result, the step of inserting the separately completed divided permanent magnet 1C into the magnet mounting hole 11 of the rotor core 10 and the step of fixing the divided permanent magnet 1C become unnecessary, and the assembly work of the divided permanent magnet 1C to the rotor core 10 is eliminated. Can be easily.

また、液状絶縁材４と接着材１３に同一の接着材を混合させても接着品質に悪影響はなく、接着材の固化条件を１つにできるため安価に製造できる。   Further, even if the same adhesive is mixed with the liquid insulating material 4 and the adhesive 13, there is no adverse effect on the adhesive quality, and the adhesive can be manufactured at a low cost since the adhesive can be consolidated into one condition.

更に、ロータコア１０の磁石取付穴１１の閉空間内での固化なので、その磁石取付穴１１の内部で永久磁石片２間に絶縁材兼接着材を硬化させることができる。   Furthermore, since the magnet mounting hole 11 of the rotor core 10 is solidified in the closed space, the insulating material / adhesive can be cured between the permanent magnet pieces 2 inside the magnet mounting hole 11.

[第５の実施形態]
図１９〜図２２は本発明の第５の実施形態を示し、第１の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。本実施形態の分割永久磁石１Ｄに用いられる位置決めシート３Ａは、基本的には第１の実施形態に示した位置決めシート３（図７参照）と略同様の構成となり、中間部に配置される粘着層３１と、粘着層３１の外側面に添着されるフィルム３２と、粘着層３１の内側面を覆う剥離シート３３と、からなる３層構造となっており、剥離シート３３を剥がして粘着層３１を永久磁石片２に貼り付けるようになっている。 [Fifth Embodiment]
19 to 22 show a fifth embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals, and redundant description is omitted. The positioning sheet 3A used for the split permanent magnet 1D of the present embodiment has basically the same configuration as the positioning sheet 3 (see FIG. 7) shown in the first embodiment, and is an adhesive disposed in the middle part. The adhesive layer 31 has a three-layer structure including a layer 31, a film 32 attached to the outer surface of the adhesive layer 31, and a release sheet 33 that covers the inner surface of the adhesive layer 31. Is attached to the permanent magnet piece 2.

ここで、本実施形態の位置決めシート３Ａが、第１の実施形態と主に異なる点は、図１９に示すように、粘着層を、加熱されることにより接着力を失う熱剥離粘着層３１Ａとしたことにある。熱剥離粘着層とは、加熱により粘着層が粘着力を失う性質を有している。また、液状絶縁材４には、特に熱硬化性の接着材を用いてある。   Here, the positioning sheet 3A of the present embodiment is mainly different from the first embodiment in that, as shown in FIG. It is to have done. The heat-peeling adhesive layer has the property that the adhesive layer loses its adhesive strength upon heating. The liquid insulating material 4 is particularly made of a thermosetting adhesive.

従って、図２０に示すように、位置決めシート３Ａを貼り付けた状態で、それぞれの永久磁石片２間の隙間２３に液状絶縁材４を充填した後に加熱することにより、液状絶縁材４は硬化して絶縁層Ｉを形成できると同時に、位置決めシート３Ａは永久磁石片２から剥離可能となり、図２１に示すように、位置決めシート３Ａを剥がし取ることができる。尚、位置決めシート３Ａを剥離した場合にも、それぞれ分割された永久磁石片２は、絶縁層Ｉによる接着力で相互に結合した状態が維持される。   Therefore, as shown in FIG. 20, the liquid insulating material 4 is cured by heating the liquid insulating material 4 after filling the gaps 23 between the permanent magnet pieces 2 with the positioning sheet 3 </ b> A attached. At the same time that the insulating layer I can be formed, the positioning sheet 3A can be peeled from the permanent magnet piece 2, and the positioning sheet 3A can be peeled off as shown in FIG. Even when the positioning sheet 3 </ b> A is peeled off, the divided permanent magnet pieces 2 are maintained in a state of being bonded to each other by the adhesive force of the insulating layer I.

また、本実施形態にあっても、図２２に示すように、第１の実施形態（図６参照）と同様に装置Ｍを用いて、湾曲していたそれぞれの永久磁石片２を平面状に戻すことができる。この場合、図２２に示すように、それぞれの永久磁石片２の湾曲方向の上下面を一対の平坦状の治具板５、５ａ間に挟み込み、両治具板５、５ａ間に加圧力を付与すると同時に加熱する。勿論、この場合にあっても、フッ素フィルムなどの非接着シート６を、液状絶縁材４がはみ出す側の面と治具板５ａとの間に介在させておくことが好ましい。   Also in the present embodiment, as shown in FIG. 22, each of the bent permanent magnet pieces 2 is planarized using the apparatus M as in the first embodiment (see FIG. 6). Can be returned. In this case, as shown in FIG. 22, the upper and lower surfaces of each permanent magnet piece 2 in the bending direction are sandwiched between a pair of flat jig plates 5 and 5a, and a pressing force is applied between the two jig plates 5 and 5a. Heat simultaneously with application. Of course, even in this case, it is preferable to interpose a non-adhesive sheet 6 such as a fluorine film between the surface on the side where the liquid insulating material 4 protrudes and the jig plate 5a.

本実施形態の製造方法は、前記第１の実施形態のみならず、液状絶縁材４に粒状の固形絶縁材７を混合させた第２の実施形態、および磁石片基材８を割って分割永久磁石１Ｂを形成する第３の実施形態（変形例を含む）にあっても適用することができる。   The manufacturing method of the present embodiment is not limited to the first embodiment, but the second embodiment in which the liquid insulating material 4 is mixed with the granular solid insulating material 7 and the magnet piece base material 8 are divided into permanent parts. The present invention can also be applied to the third embodiment (including the modification) in which the magnet 1B is formed.

以上説明したように、第５の実施形態の分割永久磁石１Ｄの製造方法およびその方法により製造された分割永久磁石１Ｄによれば、第１〜第３の実施形態と同様の作用効果を奏するのは勿論のこと、位置決めシート３Ａの粘着層３１を、加熱されることにより接着力を失う熱剥離粘着層３１Ａとしたので、液状絶縁材４の加熱硬化時の熱によって位置決めシート３Ａの熱剥離粘着層３１Ａが接着力を失うため、加熱完了後は位置決めシート３Ａを容易に剥がし取ることができる。   As explained above, according to the manufacturing method of the split permanent magnet 1D of the fifth embodiment and the split permanent magnet 1D manufactured by the method, the same effects as those of the first to third embodiments can be obtained. Of course, since the adhesive layer 31 of the positioning sheet 3A is a heat-peeling adhesive layer 31A that loses its adhesive strength when heated, the heat-peeling adhesive of the positioning sheet 3A by the heat during the heat curing of the liquid insulating material 4 Since the layer 31A loses the adhesive force, the positioning sheet 3A can be easily peeled off after the heating is completed.

従って、このように位置決めシート３Ａを剥がし取ることにより、分割永久磁石１Ｄの高さ寸法を小さくできる。これにより、ロータコアの磁石取付穴１１（図１７参照）と分割永久磁石１Ｄとの間の挿入隙間が極僅かで、位置決めシート３Ａの厚さが挿入性を妨げる場合には、本実施形態が特に有効となる。   Therefore, the height dimension of the split permanent magnet 1D can be reduced by peeling off the positioning sheet 3A in this way. Thus, the present embodiment is particularly effective when the insertion gap between the magnet mounting hole 11 (see FIG. 17) of the rotor core and the split permanent magnet 1D is very small, and the thickness of the positioning sheet 3A hinders the insertability. It becomes effective.

[第６の実施形態]
図２３〜図２６は本発明の第６の実施形態を示し、前記各実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。図２５に示すように、本実施形態の分割永久磁石１Ｅの製造方法は、基本的に前記各実施形態と同様に、複数に分割された永久磁石片２間に絶縁層Ｉを設けて、それぞれの永久磁石片２を結合するようになっている。 [Sixth Embodiment]
23 to 26 show a sixth embodiment of the present invention, and the same components as those of the above-described embodiments are denoted by the same reference numerals and redundant description is omitted. As shown in FIG. 25, the manufacturing method of the split permanent magnet 1E of the present embodiment is basically provided with an insulating layer I between the plurality of split permanent magnet pieces 2 in the same manner as each of the above embodiments. The permanent magnet pieces 2 are coupled.

ここで、本実施形態が前記各実施形態と主に異なる点は、複数の永久磁石片２を連結するのに、接着力と弾性とを有して加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを用いたことにある。   Here, this embodiment is mainly different from each of the above embodiments in that it is made of a foam material that has adhesive strength and elasticity and expands irreversibly by heating to connect a plurality of permanent magnet pieces 2. This is because the positioning sheet 3B is used.

即ち、本実施形態では、図２３に示すように、まず、複数に分割された永久磁石片２を、図２４に示すように密接させて集結させる。そして、それら永久磁石片２の各分割境界面２１に対して垂直な接合面２２に、接着力と弾性とを有して加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを貼り付けて、それぞれの永久磁石片２を連結する。次に、図２５に示すように、位置決めシート３Ｂを加熱して前記発泡材を膨張させ、その位置決めシート３Ｂで連結されたそれぞれの永久磁石片２間に所定の隙間２３Ａを形成する。   That is, in this embodiment, as shown in FIG. 23, the permanent magnet pieces 2 divided into a plurality are first brought into close contact as shown in FIG. Then, a positioning sheet 3B made of a foam material that has adhesive force and elasticity and expands irreversibly by heating is attached to a joining surface 22 perpendicular to each divided boundary surface 21 of the permanent magnet pieces 2. Each permanent magnet piece 2 is connected. Next, as shown in FIG. 25, the positioning sheet 3B is heated to expand the foam material, and a predetermined gap 23A is formed between the permanent magnet pieces 2 connected by the positioning sheet 3B.

つまり、本実施形態の位置決めシート３Ｂは、図２６に示すように、中間部に配置される粘着層３１と、粘着層３１の外側面に添着されるフィルム３２と、粘着層３１の内側面を覆う剥離シート３３と、を備えるのは第１の実施形態（図７参照）と同様であるが、特に、本実施形態では粘着層３１とフィルム３２との間に前述した発泡材としての発泡樹脂層３４が介在され、全体として４層構造となっている。   That is, as shown in FIG. 26, the positioning sheet 3B of the present embodiment has an adhesive layer 31 disposed in the middle portion, a film 32 attached to the outer surface of the adhesive layer 31, and an inner surface of the adhesive layer 31. The release sheet 33 to be covered is the same as that in the first embodiment (see FIG. 7). In particular, in this embodiment, the foamed resin as the foaming material described above between the adhesive layer 31 and the film 32. The layer 34 is interposed, and has a four-layer structure as a whole.

粘着層３１は、剥離シート３３を剥がして永久磁石１の接合面２２に貼り付けた時、それぞれの永久磁石片２を一体に保持する機能を有する。剥離シート３３は、位置決めシート３Ｂを永久磁石片２に貼り付けるまで粘着層３の品質を保護する機能を有する。フィルム３２は、ロータコア１０の磁石取付穴１１（図１７参照）に挿入する際の滑り性を確保し、また、発泡樹脂層３４を破壊から保護する機能を有し、高耐熱性を有する。   The adhesive layer 31 has a function of integrally holding the permanent magnet pieces 2 when the release sheet 33 is peeled off and attached to the bonding surface 22 of the permanent magnet 1. The release sheet 33 has a function of protecting the quality of the adhesive layer 3 until the positioning sheet 3B is attached to the permanent magnet piece 2. The film 32 has a function of securing slipperiness when inserted into the magnet mounting hole 11 (see FIG. 17) of the rotor core 10 and protecting the foamed resin layer 34 from destruction, and has high heat resistance.

発泡樹脂層３４は、アクリル、ナイロン、ＰＰＳ、ＬＣＰなどの高耐熱性樹脂に発泡カプセルを混合させて形成でき、加熱による発泡によって不可逆膨張性を有する。また、発泡樹脂層３４の膨張倍率は、発泡カプセルの混合比率によって制御できる。尚、発泡樹脂層３４は、発泡カプセルを用いることなく、混合された発泡素材が加熱による気化現象によって周囲の樹脂層を圧迫して体積膨張する機能を有する素材であってもよい。   The foamed resin layer 34 can be formed by mixing a foamed capsule with a high heat resistant resin such as acrylic, nylon, PPS, or LCP, and has irreversible expansion by foaming by heating. The expansion ratio of the foamed resin layer 34 can be controlled by the mixing ratio of the foamed capsules. The foamed resin layer 34 may be a material having a function of expanding the volume of the mixed foam material by pressing the surrounding resin layer by a vaporization phenomenon due to heating without using a foam capsule.

従って、位置決めシート３Ｂは、前述した４層構造とすることにより、加熱によって厚さ方向および平面方向に膨張する性質を有するとともに、発砲後の体積は不可逆的変化となる性質を有し、体積が収縮することは無い。   Therefore, the positioning sheet 3B has the property of expanding in the thickness direction and the planar direction by heating by having the above-described four-layer structure, and the volume after firing has the property of irreversibly changing. There is no contraction.

ところで、本実施形態では、それぞれの永久磁石片２間に形成された前記隙間２３Ａが絶縁層Ｉとして機能することになり、また、それぞれの永久磁石片２は、位置決めシート３Ｂの発泡樹脂層３４が不可逆的に膨張した状態で固化されることにより相互に連結された状態が維持される。   By the way, in this embodiment, the said clearance gap 23A formed between each permanent magnet piece 2 will function as the insulating layer I, and each permanent magnet piece 2 is the foamed resin layer 34 of the positioning sheet 3B. Are solidified in an irreversibly expanded state, thereby maintaining a mutually connected state.

以上説明したように、第６の実施形態にかかる分割永久磁石１Ｅの製造方法およびその方法により製造された分割永久磁石１Ｅによれば、それぞれの永久磁石片２の接合面２２に、接着力と弾性とを有して加熱により不可逆的に膨張する発泡樹脂層３４を有する位置決めシート３Ｂを貼り付けた後、加熱して発泡樹脂層３４を膨張させる。これにより、それぞれの永久磁石片２間に隙間２３Ａが形成され、その隙間２３Ａを絶縁層Ｉとすることができる。従って、永久磁石片２の数が増加した場合にも、位置決めシート３Ｂを単に加熱して発泡樹脂層３４を膨張させるのみで、それぞれの永久磁石片２間に隙間２３Ａを形成して簡単に絶縁層Ｉを設けることができる。   As explained above, according to the manufacturing method of the split permanent magnet 1E according to the sixth embodiment and the split permanent magnet 1E manufactured by the method, the bonding surface 22 of each permanent magnet piece 2 After affixing the positioning sheet 3B having the foamed resin layer 34 that has elasticity and expands irreversibly by heating, the foamed resin layer 34 is expanded by heating. Thereby, a gap 23 </ b> A is formed between the permanent magnet pieces 2, and the gap 23 </ b> A can be used as the insulating layer I. Therefore, even when the number of permanent magnet pieces 2 increases, the positioning sheet 3B is simply heated to expand the foamed resin layer 34, so that a gap 23A is formed between the permanent magnet pieces 2 for easy insulation. Layer I can be provided.

また、発泡樹脂層３４が加熱により不可逆的に膨張するため、膨張させて永久磁石片２間に形成された隙間２３Ａは一定の間隔を維持でき、それぞれの永久磁石片２を一体に連結した形状や寸法を損なわずに絶縁層Ｉを確保できる。これにより、複数の永久磁石片２を一体化させて分割永久磁石１を形成した後にも、寸法精度を得るための加工工程が不要となり、また、材料歩留まりが悪化されることも無くなる。   Further, since the foamed resin layer 34 is irreversibly expanded by heating, the gap 23A formed between the permanent magnet pieces 2 by being expanded can maintain a constant interval, and the shape in which the permanent magnet pieces 2 are integrally connected. Insulating layer I can be secured without damaging the dimensions. Thus, even after the plurality of permanent magnet pieces 2 are integrated to form the split permanent magnet 1, a processing step for obtaining dimensional accuracy is not required, and the material yield is not deteriorated.

更に、本実施形態では、発泡樹脂層３４の不可逆的な発泡により、それぞれの永久磁石片２間に隙間２３Ａを形成した状態でそれら永久磁石片２を固定できるため、永久磁石片２間に接着材や絶縁シートの貼り付けが不要になるため、安価に製造することができる。従って、本実施形態の製造方法で製造された分割永久磁石１を電動機に用いた場合に、製品コストを低下しつつ高い信頼性をもって過電流の低減を達成できる。   Furthermore, in this embodiment, since the permanent magnet pieces 2 can be fixed in a state where the gaps 23 </ b> A are formed between the permanent magnet pieces 2 by irreversible foaming of the foamed resin layer 34, the permanent magnet pieces 2 are bonded. Since it is not necessary to attach a material or an insulating sheet, it can be manufactured at low cost. Therefore, when the split permanent magnet 1 manufactured by the manufacturing method of the present embodiment is used in an electric motor, it is possible to achieve a reduction in overcurrent with high reliability while reducing the product cost.

更にまた、本実施形態では、加熱して発泡樹脂層３４を膨張させると、それぞれの永久磁石片２間に形成される隙間２３Ａに膨張した発泡樹脂層３４の一部が入り込み、それぞれの隙間２３Ａが狭くなるのをより確実に防止することができる。   Furthermore, in this embodiment, when the foamed resin layer 34 is expanded by heating, a part of the expanded foamed resin layer 34 enters the gaps 23A formed between the respective permanent magnet pieces 2 and the gaps 23A. Can be prevented more reliably.

[第７の実施形態]
図２７〜図２８は本発明の第７の実施形態を示し、前記第６の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。本実施形態の分割永久磁石１Ｂの製造方法は、基本的に第６の実施形態で説明した製造方法と同様であり、図２９に示すように、それぞれの永久磁石片２の接合面２２に、弾性を有して加熱により不可逆的に膨張する発泡材を有する位置決めシート３Ｂを貼り付けてある。尚、本実施形態にあっても、発泡材は、図２６に示す発泡樹脂層３４に相当する。 [Seventh Embodiment]
27 to 28 show a seventh embodiment of the present invention, in which the same components as those in the sixth embodiment are denoted by the same reference numerals and redundant description is omitted. The manufacturing method of the split permanent magnet 1B of the present embodiment is basically the same as the manufacturing method described in the sixth embodiment. As shown in FIG. 29, on the joining surface 22 of each permanent magnet piece 2, A positioning sheet 3B having a foaming material that has elasticity and expands irreversibly by heating is attached. In this embodiment, the foam material corresponds to the foamed resin layer 34 shown in FIG.

ここで、本実施形態の製造方法が第６の実施形態と主に異なる点は、複数の永久磁石片２が、位置決めシート３を貼り付けた磁石片基材８を割って形成されることにある。これは、第３の実施形態（図１２〜図１４）と同様の技術思想に基づくものである。   Here, the manufacturing method of the present embodiment is mainly different from the sixth embodiment in that a plurality of permanent magnet pieces 2 are formed by breaking the magnet piece base material 8 to which the positioning sheet 3 is attached. is there. This is based on the same technical idea as the third embodiment (FIGS. 12 to 14).

即ち、本実施形態の分割永久磁石１Ｆは、図２７に示すように、一体形状の磁石片基材８の表面の分割予定部位に分割溝８ａを形成した後、図２８に示すように、その分割溝８ａの形成面とは反対側の接合面２２Ａに、接着力と弾性とを有して加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを貼り付け、この状態で、図２９に示すように、磁石片基材８を外力の付加により分割溝８ａに沿って割ることにより形成してある。   That is, the split permanent magnet 1F of the present embodiment has a split groove 8a formed at a predetermined split portion on the surface of the integral magnet piece base 8 as shown in FIG. A positioning sheet 3B made of a foam material that has adhesive force and elasticity and expands irreversibly by heating is attached to the joining surface 22A opposite to the surface on which the divided grooves 8a are formed. In this state, FIG. As shown, the magnet piece base material 8 is formed by splitting along the dividing groove 8a by applying an external force.

永久磁石の素材は脆性に乏しく、応力集中される分割溝８ａを予め形成しておくことにより、そこに外力を加えることで、図２９に示すように、分割溝８ａを基端としてクラックＣが発生し、そのクラックＣを分割境界面２１として複数の永久磁石片２が得られることになる。分割溝８ａは、第３の実施形態にも示したように、放電加工や鋭利な刃物によるケガキ、または、鋭利な回転砥石による加工等で形成できる。また、加える外力としては、衝撃力や剪断力または曲げ力等を用いることができる。   The material of the permanent magnet is poor in brittleness, and by forming the split groove 8a where stress is concentrated in advance, by applying an external force there, as shown in FIG. 29, the crack C is generated with the split groove 8a as the base end. A plurality of permanent magnet pieces 2 are obtained using the crack C as the dividing boundary surface 21. As shown in the third embodiment, the dividing groove 8a can be formed by electric discharge machining, marking with a sharp blade, machining with a sharp rotating grindstone, or the like. Further, as an external force to be applied, an impact force, a shear force, a bending force, or the like can be used.

勿論、本実施形態にあっても、位置決めシート３Ｂを永久磁石片２に貼り付けた後、その位置決めシート３Ｂを加熱して発泡樹脂層３４（図２６参照）を膨張させ、その位置決めシート３Ｂで連結されたそれぞれの永久磁石片２間に所定の隙間２３Ａを形成し、その隙間２３Ａを絶縁層Ｉとすることは第６の実施形態と同様である。   Of course, even in this embodiment, after the positioning sheet 3B is attached to the permanent magnet piece 2, the positioning sheet 3B is heated to expand the foamed resin layer 34 (see FIG. 26), and the positioning sheet 3B As in the sixth embodiment, a predetermined gap 23A is formed between the connected permanent magnet pieces 2 and the gap 23A is used as the insulating layer I.

以上説明したように、第７の実施形態の分割永久磁石１Ｆの製造方法およびその方法により製造された分割永久磁石１Ｆによれば、一体形状の磁石片基材８に外力を加えて分割する場合、分割された複数の永久磁石片２を元の形状に一体化する手段が別途必要となってしまうが、本実施形態のように分割前に位置決めシート３Ｂを貼り付けておくことで、分割後も磁石片基材８の一体形状を維持して、分割されたそれぞれの永久磁石片２の相対位置がずれるのを防止できる。   As described above, according to the manufacturing method of the split permanent magnet 1F of the seventh embodiment and the split permanent magnet 1F manufactured by the method, the magnetic piece base material 8 having an integral shape is split by applying an external force. In addition, a separate means for integrating the plurality of divided permanent magnet pieces 2 into the original shape is required. However, by attaching the positioning sheet 3B before the division as in the present embodiment, Also, the integral shape of the magnet piece base material 8 can be maintained, and the relative positions of the divided permanent magnet pieces 2 can be prevented from shifting.

従って、本実施形態では、加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを用いた場合にも、分割された複数の永久磁石片２を一体化する手段を別途必要としなくなるため、分割永久磁石１Ｆを安価にかつ簡単に製造できる。   Therefore, in the present embodiment, even when the positioning sheet 3B made of a foam material that expands irreversibly by heating is used, a separate means for integrating the plurality of divided permanent magnet pieces 2 is not required. The permanent magnet 1F can be manufactured inexpensively and easily.

ところで、本実施形態ではそれぞれの永久磁石片２の分割境界面２１はクラックＣによるものであるため、平坦面では無く自由曲面となるが、このように分割境界面２１が自由曲面であっても、位置決めシート３Ｂが全体的に均一に膨張されることにより、それぞれの永久磁石片２間に均一な隙間２３Ａを形成することができる。従って、安価に永久磁石片２の分割化を実現しつつ、信頼性の高い絶縁層Ｉを確保できる。また、本実施形態のクラックＣが分割境界面２１となる分割永久磁石１Ｆを電動機に用いた場合にも、ロータコアへの組み付け性を損なうことは無い。   By the way, in this embodiment, since the division | segmentation boundary surface 21 of each permanent magnet piece 2 is based on the crack C, it becomes a free-form surface instead of a flat surface, but even if the division | segmentation boundary surface 21 is a free-form surface in this way, The positioning sheet 3B is uniformly expanded as a whole, so that a uniform gap 23A can be formed between the permanent magnet pieces 2. Therefore, it is possible to secure a highly reliable insulating layer I while realizing the division of the permanent magnet piece 2 at a low cost. Further, even when the split permanent magnet 1F in which the crack C of the present embodiment becomes the split boundary surface 21 is used in the electric motor, the assembling property to the rotor core is not impaired.

図３０は前記第７の実施形態の変形例を示し、具体的には、磁石片基材を分割した状態を示す斜視図である。   FIG. 30 is a perspective view showing a modified example of the seventh embodiment, specifically, a state in which the magnet piece base material is divided.

本変形例は、基本的に第７の実施形態と同様であり、複数の永久磁石片２が、接着力と弾性とを有して加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを貼り付けた磁石片基材８を割って形成される。このとき、本変形例では、図３０に示すように、磁石片基材８が縦・横の２方向に分割されている。勿論、磁石片基材８の表面（位置決めシート３Ｂの貼り付け面とは反対面）には、分割予定位置に縦・横の分割溝８ａが予め形成される。尚、本変形例にあっても、発泡材は、図２６に示す発泡樹脂層３４に相当する。   This modification is basically the same as in the seventh embodiment, and a positioning sheet 3B made of a foam material in which a plurality of permanent magnet pieces 2 have adhesive force and elasticity and expands irreversibly by heating. It is formed by breaking the pasted magnet piece base material 8. At this time, in this modification, as shown in FIG. 30, the magnet piece base material 8 is divided into two vertical and horizontal directions. Of course, on the surface of the magnet piece base material 8 (the surface opposite to the attachment surface of the positioning sheet 3B), vertical and horizontal division grooves 8a are formed in advance at the division positions. Even in this modification, the foam material corresponds to the foamed resin layer 34 shown in FIG.

従って、本変形例のように磁石片基材８を縦・横に分割する場合にも、第７の実施形態に示した分割永久磁石１Ｆの製造方法と同様の作用効果を奏する。また、この場合に、磁石片基材８を分割する方向は２方向に限ることなく、斜め方向を含めた２方向以上に分割してもよい。   Therefore, even when the magnet piece base material 8 is divided vertically and horizontally as in the present modification, the same operational effects as the method of manufacturing the divided permanent magnet 1F shown in the seventh embodiment can be obtained. In this case, the direction of dividing the magnet piece base material 8 is not limited to two directions, and may be divided into two or more directions including an oblique direction.

[第８の実施形態]
図３１〜図３３は、本発明の第８の実施形態を示し、前記第６の実施形態と同一構成部分に同一符号を付して重複する説明を省略して述べるものとする。本実施形態の分割永久磁石１Ｇの製造方法は、基本的に前記第６の実施形態の製造方法と同様であり、接着力と弾性とを有して加熱により不可逆的に膨張する発泡材からなる位置決めシート３Ｂを用いて複数の永久磁石片２を連結し、その後、位置決めシート３Ｂを加熱して発泡材を膨張させ、その位置決めシート３Ｂで連結されたそれぞれの永久磁石片２間に所定の隙間２３Ａを形成するようになっている。尚、本実施形態にあっても、発泡材は、図２６に示す発泡樹脂層３４に相当する。 [Eighth embodiment]
FIGS. 31 to 33 show an eighth embodiment of the present invention, in which the same components as in the sixth embodiment are denoted by the same reference numerals and redundant description is omitted. The manufacturing method of the split permanent magnet 1G of the present embodiment is basically the same as the manufacturing method of the sixth embodiment, and is made of a foam material that has adhesive force and elasticity and expands irreversibly by heating. A plurality of permanent magnet pieces 2 are connected using the positioning sheet 3B, and then the positioning sheet 3B is heated to expand the foam material, and a predetermined gap is provided between the permanent magnet pieces 2 connected by the positioning sheet 3B. 23A is formed. In this embodiment, the foam material corresponds to the foamed resin layer 34 shown in FIG.

ここで、本実施形態が第６の実施形態と主に異なる点は、図３１に示すように、位置決めシート３Ｂを貼り付けて複数の永久磁石片２を連結した状態で、ロータコア１０の磁石取付穴１１に挿入した後に発泡樹脂層３４を発泡させることにある。   Here, the present embodiment is mainly different from the sixth embodiment in that, as shown in FIG. 31, the magnet mounting of the rotor core 10 is performed in a state where a plurality of permanent magnet pieces 2 are connected by attaching a positioning sheet 3B. The foamed resin layer 34 is foamed after being inserted into the hole 11.

即ち、本実施形態の分割永久磁石１Ｇの製造方法では、それぞれの永久磁石片２間に所定の隙間２３Ａを形成する工程は、それぞれの永久磁石片２に位置決めシート３Ｂを貼り付けた後、図３２に示すように、それら永久磁石片２をロータコア１０の磁石取付穴１１に挿入する。その後、図３３に示すように、ロータコア１０を加熱して前述した発泡樹脂層３４を膨張させる。   That is, in the method for manufacturing the split permanent magnet 1G of the present embodiment, the step of forming the predetermined gap 23A between the permanent magnet pieces 2 is performed after the positioning sheet 3B is attached to each permanent magnet piece 2 as shown in FIG. As shown at 32, these permanent magnet pieces 2 are inserted into the magnet mounting holes 11 of the rotor core 10. Thereafter, as shown in FIG. 33, the rotor core 10 is heated to expand the above-described foamed resin layer 34.

従って、磁石取付穴１１に複数の永久磁石片２を挿入してロータコア１０を加熱することにより、位置決めシート３Ｂの発泡樹脂層３４は磁石取付穴１１内で発泡する。このとき、発泡樹脂層３４は位置決めシート３Ｂの長さ方向のみならず厚さ方向にも体積膨張し、図３３に示すように、発泡樹脂層３４が永久磁石片２と磁石取付穴１１内壁との間の隙間を埋めるとともに、永久磁石片２を磁石取付穴１１内壁に押しつけることになる。   Therefore, by inserting the plurality of permanent magnet pieces 2 into the magnet mounting hole 11 and heating the rotor core 10, the foamed resin layer 34 of the positioning sheet 3 </ b> B is foamed in the magnet mounting hole 11. At this time, the foamed resin layer 34 expands in volume not only in the length direction of the positioning sheet 3B but also in the thickness direction, and as shown in FIG. 33, the foamed resin layer 34 is formed between the permanent magnet piece 2 and the inner wall of the magnet mounting hole 11. The permanent magnet piece 2 is pressed against the inner wall of the magnet attachment hole 11.

以上説明したように第８の実施形態の分割永久磁石１Ｇの製造方法およびその方法により製造された分割永久磁石１Ｇによれば、接着力と弾性とを有して加熱により不可逆的に膨張する発泡樹脂層３４からなる位置決めシート３Ｂを用いたことにより、第６の実施形態と同様の作用効果を奏する。特に、本実施形態では、第６の実施形態の効果に加えて、位置決めシート３Ｂで連結した複数の永久磁石片２をロータコア１０の磁石取付穴１１に挿入した後に、ロータコア１０を加熱して発泡樹脂層３４を膨張させたので、それぞれの永久磁石片２間に隙間２３Ａ（絶縁層Ｉ）を形成して分割永久磁石１Ｇを製造できると同時に、その分割永久磁石１Ｇを磁石取付穴１１に固定できる。従って、分割永久磁石１Ｇを磁石取付穴１１に固定するための作業、例えば、接着材による固定や樹脂モールドによる固定などの作業が不要となり、分割永久磁石１Ｇの組付作業性を向上するとともに、製品のコストダウンを図ることができる。   As described above, according to the manufacturing method of the split permanent magnet 1G of the eighth embodiment and the split permanent magnet 1G manufactured by the method, foaming that has adhesive strength and elasticity and expands irreversibly by heating. By using the positioning sheet 3 </ b> B made of the resin layer 34, the same effects as those of the sixth embodiment are achieved. In particular, in this embodiment, in addition to the effects of the sixth embodiment, after inserting the plurality of permanent magnet pieces 2 connected by the positioning sheet 3B into the magnet mounting holes 11 of the rotor core 10, the rotor core 10 is heated and foamed. Since the resin layer 34 is expanded, a gap 23A (insulating layer I) can be formed between the permanent magnet pieces 2 to manufacture the split permanent magnet 1G, and at the same time, the split permanent magnet 1G is fixed to the magnet mounting hole 11. it can. Therefore, work for fixing the split permanent magnet 1G to the magnet mounting hole 11, for example, work such as fixing with an adhesive or resin mold is unnecessary, improving the workability of mounting the split permanent magnet 1G, Product costs can be reduced.

１、１Ａ、１Ｂ、１Ｃ、１Ｄ、１Ｅ、１Ｆ、１Ｇ 分割永久磁石
２ 永久磁石片
２１ 分割境界面
２２ 接合面
２２Ａ 反対側の面
２３、２３Ａ 隙間
３、３Ａ、３Ｂ 位置決めシート
３１ 粘着層
３１Ａ 熱剥離粘着層
３４ 発泡樹脂層（発泡材）
４ 液状絶縁材
７ 固形絶縁材
８ 磁石片基材
８ａ 分割溝
１０ ロータコア
１１ 磁石取付穴
１３ 接着材
Ｉ 絶縁層 1, 1A, 1B, 1C, 1D, 1E, 1F, 1G Split permanent magnet 2 Permanent magnet piece 21 Split boundary surface 22 Joint surface 22A Opposite surface 23, 23A Clearance 3, 3A, 3B Positioning sheet 31 Adhesive layer 31A Heat Peeling adhesive layer 34 Foamed resin layer (foaming material)
4 Liquid Insulating Material 7 Solid Insulating Material 8 Magnet Piece Base Material 8a Dividing Groove 10 Rotor Core 11 Magnet Mounting Hole 13 Adhesive Material I Insulating Layer

Claims (9)

複数に分割された永久磁石片を絶縁層を介在させて結合する分割永久磁石の製造方法において、
それぞれの永久磁石片の分割境界面に直交する接合面に、弾性を有する位置決めシートを貼り付けてそれぞれの永久磁石片を連結する工程と、
前記位置決めシートに貼着したそれぞれの永久磁石片を全体的に湾曲させてそれぞれの永久磁石片間に隙間を形成する工程と、
湾曲した状態で前記永久磁石片間の隙間に液状絶縁材を充填する工程と、
この湾曲した複数の永久磁石片を平面状に戻す工程と、を備えたことを特徴とする分割永久磁石の製造方法。 In the method for manufacturing a split permanent magnet, in which a plurality of split permanent magnet pieces are joined via an insulating layer,
A step of bonding each permanent magnet piece by attaching an elastic positioning sheet to the joining surface orthogonal to the dividing boundary surface of each permanent magnet piece;
Forming a gap between the permanent magnet pieces by curving each permanent magnet piece attached to the positioning sheet as a whole; and
Filling the liquid insulating material into the gap between the permanent magnet pieces in a curved state; and
And a step of returning the plurality of curved permanent magnet pieces to a planar shape. 前記液状絶縁材は、ロータコアへの磁石固定用の接着材と同一とし、ロータコアの磁石取付穴に前記接着材を塗布する工程と、
前記それぞれの永久磁石片間に形成した隙間に前記液状絶縁材を充填して、永久磁石片を前記磁石取付穴に挿入する工程と、を備え、
前記接着材の固化と前記液状絶縁材の固化とを同時に行うことを特徴とする請求項１に記載の分割永久磁石の製造方法。 The liquid insulating material is the same as the adhesive for fixing the magnet to the rotor core, and the step of applying the adhesive to the magnet mounting hole of the rotor core;
Filling the liquid insulating material into the gap formed between the respective permanent magnet pieces, and inserting the permanent magnet pieces into the magnet mounting holes,
The method for manufacturing a split permanent magnet according to claim 1, wherein the adhesive material is solidified and the liquid insulating material is solidified simultaneously. 一体形状の磁石片基材の表面に分割溝を形成した後、この分割溝の形成面とは反対側の接合面に前記位置決めシートを貼り付け、この状態で前記磁石片基材を外力の付加により前記分割溝に沿って割ることにより、前記複数の永久磁石片を形成することを特徴とする請求項１または２に記載の分割永久磁石の製造方法。   After forming the dividing groove on the surface of the integrally formed magnet piece base material, the positioning sheet is attached to the joint surface opposite to the surface on which the dividing groove is formed, and in this state, the magnet piece base material is applied with an external force. The method of manufacturing a split permanent magnet according to claim 1, wherein the plurality of permanent magnet pieces are formed by splitting along the split groove. 前記液状絶縁材は、粒状の固形絶縁材が混合されたことを特徴とする請求項１〜３のいずれか１つに記載の分割永久磁石の製造方法。   The method for manufacturing a split permanent magnet according to any one of claims 1 to 3, wherein the liquid insulating material is mixed with a granular solid insulating material. 前記位置決めシートは、それぞれの永久磁石片を貼着する粘着層を有し、該粘着層は、加熱されることにより接着力を失う熱剥離粘着層であることを特徴とする請求項１、３および４のいずれか１項に記載の分割永久磁石の製造方法。   The said positioning sheet has an adhesion layer which sticks each permanent magnet piece, and this adhesion layer is a heat-peeling adhesion layer which loses adhesive force by being heated. 5. A method for producing a split permanent magnet according to any one of items 4 and 4. 複数に分割された永久磁石片を絶縁層を介在させて結合する分割永久磁石の製造方法において、
それぞれの永久磁石片の分割境界面に直交する接合面に、弾性を有して加熱により不可逆的に膨張する発泡材を有する位置決めシートを貼り付けてそれぞれの永久磁石片を連結する工程と、
前記位置決めシートを加熱して前記発泡材を膨張させ、この位置決めシートで連結されたそれぞれの永久磁石片間に所定の隙間を形成する工程と、を備えたことを特徴とする分割永久磁石の製造方法。 In the method for manufacturing a split permanent magnet, in which a plurality of split permanent magnet pieces are joined via an insulating layer,
A step of attaching a positioning sheet having a foaming material that has elasticity and expands irreversibly by heating to a joining surface orthogonal to a dividing boundary surface of each permanent magnet piece, and connecting each permanent magnet piece;
Heating the positioning sheet to expand the foamed material, and forming a predetermined gap between the permanent magnet pieces connected by the positioning sheet. Method. 前記永久磁石片間に所定の隙間を形成する工程は、それぞれの永久磁石片に位置決めシートを貼り付けた後、前記永久磁石片をロータコアの磁石取付穴に挿入し、ロータコアを加熱して前記発泡材を膨張させることを特徴とする請求項６に記載の分割永久磁石の製造方法。   The step of forming a predetermined gap between the permanent magnet pieces is performed by attaching a positioning sheet to each permanent magnet piece, inserting the permanent magnet piece into a magnet mounting hole of the rotor core, and heating the rotor core to form the foam. The method of manufacturing a split permanent magnet according to claim 6, wherein the material is expanded. 前記永久磁石片を連結する工程は、一体形状の磁石片基材の表面に分割溝を形成した後、分割溝の形成面とは反対側の接合面に、前記発泡材を有する位置決めシートを貼り付け、この状態で前記磁石片基材を外力の付加により前記分割溝に沿って割ることにより、前記複数の永久磁石片を形成することを特徴とする請求項６または７に記載の分割永久磁石の製造方法。   In the step of connecting the permanent magnet pieces, after forming the dividing grooves on the surface of the integrally formed magnet piece base material, the positioning sheet having the foam material is pasted on the joint surface opposite to the forming surface of the dividing grooves. The split permanent magnet according to claim 6 or 7, wherein the plurality of permanent magnet pieces are formed by splitting the base of the magnet piece along the split groove by applying an external force in this state. Manufacturing method. 前記請求項１〜８のいずれか１項によって製造した分割永久磁石を、ロータコアに用いたことを特徴とする電動機。   An electric motor using the divided permanent magnet manufactured according to any one of claims 1 to 8 for a rotor core.
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