JP4711877B2 - Method for manufacturing sintered core connection structure and sintered core connection structure - Google Patents

Method for manufacturing sintered core connection structure and sintered core connection structure Download PDF

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JP4711877B2
JP4711877B2 JP2006110455A JP2006110455A JP4711877B2 JP 4711877 B2 JP4711877 B2 JP 4711877B2 JP 2006110455 A JP2006110455 A JP 2006110455A JP 2006110455 A JP2006110455 A JP 2006110455A JP 4711877 B2 JP4711877 B2 JP 4711877B2
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sintered core
sintered
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lower insulators
core
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JP2007288852A (en
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成敏 宮田
一徳 吹沢
勝 天野
文雄 中村
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Yamada Manufacturing Co Ltd
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Description

本発明は、理想的な絶縁手法を会得し、工程上必要な巻き線を行うことにより、同時に接着剤等を使用せずに焼結コアと上下部インシュレータとを固定して簡易且つ迅速に組立ができると共に製造費を格安にでき、さらに直列形状を円筒形状に丸めるだけでモータに取り付けることができるブラシレスＤＣモータ用の焼結コア連結構造の製造法及びその焼結コア連結構造に関する。   The present invention provides an ideal insulation method, and by performing winding necessary in the process, the sintered core and the upper and lower insulators can be fixed easily and quickly without using an adhesive or the like at the same time. The present invention relates to a method for manufacturing a sintered core connection structure for a brushless DC motor, which can be assembled, can be manufactured at a low cost, and can be attached to a motor simply by rounding a serial shape into a cylindrical shape, and the sintered core connection structure.

従来より、モータは、内周又は外周の片側に電磁石、それと対向する側に永久磁石を配置したものである。電気の流れる方向を交互に入れ替えることで、電磁石のＮ極とＳ極を交互に入れ替え、電磁石と永久磁石の反発力と吸引力で回転させ得る。本件の発明においても外周に電磁石、内周に永久磁石を配置したものである。Ｎ極とＳ極の数を極数というが、磁石は必ずＮ極とＳ極が対になるため、極数は必ず偶数となる。内周側の円筒状の永久磁石は例を挙げれば本発明では６極であるが、別に磁石が６個ある訳ではなく、１つの鉄芯の固まりを円周上に均等角度でＮ極とＳ極を着磁し、磁極を生成したものである。   Conventionally, a motor has an electromagnet on one side of the inner periphery or outer periphery and a permanent magnet on the opposite side. By alternately switching the direction in which electricity flows, the N pole and S pole of the electromagnet can be alternately switched and rotated by the repulsive force and attractive force of the electromagnet and permanent magnet. Also in the present invention, an electromagnet is disposed on the outer periphery and a permanent magnet is disposed on the inner periphery. The number of N poles and S poles is referred to as the number of poles. However, since the magnets always have a pair of N poles and S poles, the number of poles is always an even number. For example, in the present invention, the cylindrical permanent magnet on the inner peripheral side has six poles, but there are not six magnets separately, but a single iron core mass is arranged on the circumference with N poles at equal angles. The S pole is magnetized to generate a magnetic pole.

内周側の永久磁石に対向して置かれている外周側の電磁石は、電気の流れる方向により永久磁石と対向する内周側がＮ極、対向しない外周側がＳ極となることもあれば、その反対になることもある。電流を交互に入れ替えることで、Ｎ極とＮ極との反発力、Ｎ極とＳ極との吸引力を利用して順次回転させていく。Ｎ極とＳ極を交互に反転させるため、電気の流れる方向を交互に入れ替える必要があるが、機械的手段（ブラシ）によって切り替えるものをブラシモーター、電気回路の制御により切り替えるものをブラシレスモータと呼ぶ。   The outer peripheral electromagnet placed opposite to the inner peripheral permanent magnet may have an N pole on the inner peripheral side facing the permanent magnet and an S pole on the outer peripheral side that does not face the permanent magnet. It may be the opposite. By alternately switching the current, the repulsive force between the N pole and the N pole and the attractive force between the N pole and the S pole are used to sequentially rotate the current. In order to alternately invert the N and S poles, it is necessary to alternately change the direction of electricity flow. However, a motor that is switched by mechanical means (brush) is called a brush motor, and a motor that is switched by controlling an electric circuit is called a brushless motor. .

ブラシ部分が回転摺動により摩耗してしまうため、長寿命化にはブラシレス化が不可欠であり、コストが高いため一部例外があるものの産業用としてはブラシレスモータが多用されている。外周の電磁石にはいろいろな呼び名があるが、広く使われているコアという呼び方を本明細書中に使用することとする。コア（電磁石）としてはコイルを巻いただけでも磁力は発生するが、鉄芯の周りにコイルを巻くと、磁力が大幅に上昇するため、鉄芯の周りにコイルを巻いたものが殆ど使用されている。
特開２００４−４０８７１ 特開平９−１６３６９０ Since the brush portion is worn due to rotational sliding, brushless is indispensable for extending the life, and although there are some exceptions due to high cost, brushless motors are frequently used for industrial purposes. Although there are various names for the electromagnets on the outer periphery, the term core that is widely used is used in this specification. As a core (electromagnet), even if a coil is wound, a magnetic force is generated. However, when a coil is wound around an iron core, the magnetic force rises significantly. Therefore, a coil wound around an iron core is mostly used. Yes.
JP2004-40871 JP-A-9-163690

従来、上記鉄芯には薄い鋼板を数多く貼り合わせたいわゆる積層鋼板が使われていたが、形状の自由度が低く、作業性も悪いため積層鋼板の代わりに焼結体を使ったものが特許文献１として開示されている。またコアは複数個連結され、円形となるが、コイルの巻き線部分が内周側に向くため、コイルが非常に巻きにくく、非能率とならざるを得ないという欠点がある。   Conventionally, so-called laminated steel sheets with many thin steel sheets bonded to each other have been used for the iron core. However, because the degree of freedom of shape is low and workability is poor, the one using a sintered body instead of laminated steel sheets is patented. It is disclosed as Document 1. In addition, a plurality of cores are connected to form a circular shape, but since the winding portion of the coil faces the inner peripheral side, there is a disadvantage that the coil is very difficult to wind and has to be inefficient.

その欠点を解消したのが、特許文献２であり、この発明による複数のコアヘのコイル連続巻きは既に述べられている。但し、コアとコアとの連結には専用の連結部材を設けねばならず、扱いも面倒で、重くなり、部品点数も増えてしまう不都合があった。鉄芯自体には絶縁性が無いため、鉄芯を絶縁しなければショート（短絡又は漏電）してしまう欠点があった。そのコアを絶縁する手段としてはコアの周りを塗装する手段や、焼結粉と樹脂粉を混入し加熱し硬化させる（焼結粉の周りが樹脂で包まれる）等の手段がある。   Patent Document 2 has solved the drawback, and the continuous winding of coils on a plurality of cores according to the present invention has already been described. However, the connection between the cores has to be provided with a dedicated connection member, which is cumbersome and cumbersome and increases the number of parts. Since the iron core itself is not insulative, there is a drawback that if the iron core is not insulated, a short circuit (short circuit or electric leakage) occurs. As means for insulating the core, there are means for painting around the core, and means for mixing sintered powder and resin powder and heating and curing (the periphery of the sintered powder is wrapped with resin).

前者の塗装の場合にはピンホールと呼ばれる微小な塗装の穴がどのようにしても出来てしまい、完壁な絶縁は難しいという欠点がある。後者は焼結粉と樹脂粉を混入するため焼結粉の密度が下がり、どうしても磁束密度の低下は免れない。また積層鋼板を数多く貼り合わせたものでは磁気抵抗が大きくかつ磁束バラツキも大きくなってしまう。さらにモータの製造には接着剤を使うことが多いが、接着剤の扱いにはある程度の熟練が必要であり、また乾燥に時間がかかり、どうしても製造のサイクルタイムが伸びてしまう。また接着強度バラツキも大きい。   In the case of the former coating, there is a drawback that a minute hole called a pinhole can be formed in any way, and complete insulation is difficult. In the latter, since the sintered powder and the resin powder are mixed, the density of the sintered powder decreases, and a decrease in the magnetic flux density is inevitable. Moreover, when many laminated steel plates are bonded together, the magnetic resistance increases and the magnetic flux variation also increases. In addition, an adhesive is often used for manufacturing a motor, but handling of the adhesive requires a certain level of skill, and it takes time to dry, which inevitably increases the manufacturing cycle time. Also, the adhesive strength variation is large.

このため、本発明は、ブラシレスＤＣモータ用コアとコアとの連結方法を改善し、扱いやすく、軽く、部品点数も少なく、絶縁性の良い連結構造としたものであり、本発明が解決しようとする課題（技術的課題又は目的等）は、塗料塗布タイプや、樹脂に鉄粉を混入させるタイプとは異なり、理想的な絶縁手法の取得であり、ブラシレスＤＣモータ用の焼結コアにすることにより積層鋼板より磁気抵抗は小さくかつ磁束バラツキも小さくすると共に、工程上必要な巻き線を行うことにより、同時に焼結コアと上下部インシュレータとを固定してサイクルタイムを大幅に短縮させ、且つ接着剤等を不要とし、直列形状を円筒形状に丸めるだけで取付可能とし、さらには、全ての焼結コアに同時に巻き線を巻くことも可能とすることを実現することである。   For this reason, the present invention improves the connection method between the cores for brushless DC motors, is easy to handle, is light, has a small number of parts, and has a good insulating connection structure. The problem (technical problem or purpose, etc.) to be obtained is the acquisition of an ideal insulation method, unlike the paint application type or the type in which iron powder is mixed into the resin, and it should be a sintered core for a brushless DC motor As a result, the magnetic resistance is smaller and the magnetic flux variation is smaller than that of laminated steel sheets, and the winding necessary for the process is performed, so that the sintered core and the upper and lower insulators are fixed at the same time, and the cycle time is greatly shortened. This eliminates the need for an agent, enables installation by simply rolling the serial shape into a cylindrical shape, and enables winding all the sintered cores simultaneously. It is.

そこで、発明者は上記課題を解決すべく鋭意，研究を重ねた結果、請求項１の発明を、焼結コアと、該焼結コアを被覆可能で上下に分割した合成樹脂製の上部インシュレータ相互及び下部インシュレータ相互が可撓性を有するヒンジ部を介して一体形成されると共に製造後において該ヒンジ部を介して円形状に形成されるインシュレータユニットと、コイルとして形成する巻き線とからなり、前記焼結コアを互いに独立させて直列状に形成すると共に、前記インシュレータユニットの上下部インシュレータにて前記焼結コアを被覆し、その後に前記上下部インシュレータ間に前記巻き線を所定回数巻き込み形成して前記焼結コアと前記上下部インシュレータとを固定してなることを特徴とする焼結コア連結構造の製造法としたことにより、前記課題を解決した。   In view of this, the inventor has intensively studied to solve the above-mentioned problems. As a result, the invention of claim 1 is obtained by combining the sintered core and the upper insulator made of a synthetic resin which can be covered with the sintered core and divided into upper and lower parts. And the lower insulator are integrally formed through a hinge part having flexibility, and are formed into a circular shape through the hinge part after manufacturing, and a winding formed as a coil, The sintered cores are formed in series independently of each other, and the sintered core is covered with upper and lower insulators of the insulator unit, and then the winding is wound between the upper and lower insulators a predetermined number of times. By adopting a manufacturing method of a sintered core coupling structure, wherein the sintered core and the upper and lower insulators are fixed. Issues were resolved.

請求項２の発明を、前述の構成において、上下部インシュレータは、少なくとも３個以上の複数個としてなることを特徴とする焼結コア連結構造の製造法としたことにより、前記課題を解決した。請求項３の発明を、前述の構成において、前記焼結コアは、外周側片部と内周側片部と連結片部とが平面的に見て略エの字状に一体形成されてなり、前記焼結コアの前記連結片部の軸方向相互を互いに略平行状態に形成してなることを特徴とする焼結コア連結構造の製造法としたことにより、前記課題を解決した。     According to a second aspect of the present invention, the above-described problem is solved by employing a method for manufacturing a sintered core coupling structure, wherein the upper and lower insulators are a plurality of at least three or more. According to a third aspect of the present invention, in the above-described configuration, the sintered core is formed by integrally forming an outer peripheral side piece, an inner peripheral side piece, and a connecting piece in a substantially square shape when seen in a plan view. The above problems have been solved by providing a method for producing a sintered core coupling structure, wherein the coupling pieces of the sintered core are formed so that the axial directions of the coupling pieces are substantially parallel to each other.

請求項４の発明を、前述の構成において、前記上下部インシュレータ間のそれぞれに略同時に前記巻き線を所定回数巻き込み形成してなることを特徴とする焼結コア連結構造の製造法としたことにより、前記課題を解決した。また、請求項５の発明を、前述の製造法から製造されてなることを特徴とする焼結コア連結構造としたことにより、前記課題を解決したものである。     According to a fourth aspect of the present invention, there is provided a method for producing a sintered core coupling structure, wherein the winding is wound a predetermined number of times substantially simultaneously between the upper and lower insulators in the configuration described above. The problem has been solved. Moreover, the said subject is solved by making invention of Claim 5 into the sintered core connection structure characterized by being manufactured from the above-mentioned manufacturing method.

請求項１の発明においては、ブラシレスＤＣモータ用の焼結コアを合成樹脂製のインシュレータユニットにて覆うという製造方法は絶縁上の問題は発生せず、理想的な絶縁手法であり、塗料塗布タイプや、樹脂に鉄粉を混入させるタイプのコアよりも絶縁性を確保できる。特に、本発明の製造法の発明は、工程上必要な巻き線を行うことにより、同時に接着剤等を使用せずに焼結コアと上下部インシュレータとを固定できるため、サイクルタイムが大幅に短縮できると共に製造費を格安にできる。さらに直列形状を円筒形状に丸めるだけでモータに取り付けられるため、誰でも作業が可能になる。   In the first aspect of the invention, the manufacturing method of covering the sintered core for the brushless DC motor with the insulator unit made of synthetic resin does not cause an insulation problem and is an ideal insulation method. Insulation can be ensured more than the type of core in which iron powder is mixed into the resin. In particular, the invention of the manufacturing method of the present invention can significantly reduce the cycle time by performing winding necessary in the process, and at the same time, the sintered core and the upper and lower insulators can be fixed without using an adhesive or the like. In addition, the manufacturing cost can be reduced. Furthermore, since it can be attached to the motor simply by rounding the serial shape into a cylindrical shape, anyone can work.

また、請求項２及び３においては、請求項１と同様の効果を奏する。請求項４の発明では、全ての焼結コアに同時に巻き線を巻くことが可能なため、巻き線時間が大幅に短縮できる利点がある。請求項５の発明では、絶縁性を確保しつつ、製造を簡易且つ迅速にできるため製造費を格安にできる。取り扱いも簡易且つ迅速にできる利点がある。   In claims 2 and 3, the same effect as in claim 1 is obtained. In the invention of claim 4, since it is possible to wind all the sintered cores simultaneously, there is an advantage that the winding time can be greatly shortened. In the invention of claim 5, since the insulation can be ensured and the production can be performed easily and quickly, the production cost can be reduced. There is an advantage that it can be handled easily and quickly.

以下、本発明の実施形態について図面に基づいて説明すると、図１は、本発明の完成状態を示すものである。焼結コア１と、合成樹脂製の上下部インシュレータ２，３を複数備えてヒンジ部４を介して連結したインシュレータユニットＡと、巻き線５とから構成されている。前記焼結コア１は、外周側片部１１と内周側片部１２と連結片部１３とが一体形成されて平面的に見て、略エの字状を成している。側面から見て上下方向を肉厚とし、前記外周側片部１１と内周側片部１２とが同一又は略同一に形成され、前記連結片部１３は前記巻き線５を巻く個所でもあり、首状に細く形成されている。この明細書において、前記上下部インシュレータ２，３とは、上部インシュレータ２と下部インシュレータ３の総称的名称ではあるが、あくまでも、上部インシュレータ２と下部インシュレータ３とが個別的な名称として存在しており、繰り返しを避けるために使用している。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 shows a completed state of the present invention. It comprises a sintered core 1, an insulator unit A provided with a plurality of synthetic resin upper and lower insulators 2, 3 and connected via a hinge part 4, and a winding 5. In the sintered core 1, the outer peripheral side piece portion 11, the inner peripheral side piece portion 12, and the connecting piece portion 13 are integrally formed and have a substantially square shape when viewed in plan. When viewed from the side, the vertical direction is thick, the outer peripheral piece 11 and the inner peripheral piece 12 are the same or substantially the same, and the connecting piece 13 is also a place where the winding 5 is wound, The neck is thin. In this specification, the upper and lower insulators 2 and 3 are generic names of the upper insulator 2 and the lower insulator 3, but the upper insulator 2 and the lower insulator 3 exist only as individual names. Use it to avoid repetition.

本発明の実施形態では、前記焼結コア１が６個で、その外周及び内周が円形となるように形成されており、その外周側片部１１の外周面１１ａも、内周側片部１２の内周面１２ａも円形の一部での弧状をなしている。また、その６個の前記焼結コア１は、それぞれが独立し、且つ離間しているが、また、焼結コア１が６個で、その外周及び内周が円形となるように構成されたときには、外周側片部１１それぞれの一方側側面１１ｂと他方側側面１１ｃとがある圧力を有しつつ接触するように構成されている。このときでも、内周側片部１２相互間は離間している。   In the embodiment of the present invention, the number of the sintered cores 1 is six, and the outer periphery and the inner periphery thereof are formed in a circular shape. The outer peripheral surface 11a of the outer peripheral piece 11 is also the inner peripheral piece. The inner peripheral surface 12a of 12 also has an arc shape with a part of a circle. The six sintered cores 1 are independent and spaced apart from each other, and the number of the sintered cores 1 is six and the outer periphery and inner periphery thereof are circular. In some cases, the one side surface 11b and the other side surface 11c of each of the outer peripheral side pieces 11 are configured to contact each other while having a certain pressure. Even at this time, the inner circumferential side pieces 12 are separated from each other.

また、前記焼結コア１は、外周に電磁石、内周に永久磁石を配置したものであり、全体が焼結金属にて構成されている。また、前記焼結コア１は、６個で円形となるようにセットとして構成されているが、複数個として、３個、９個、１２個とすることもある。この場合には、当然に前記上下部インシュレータ２，３も対応して同一個数となる。   The sintered core 1 has an electromagnet disposed on the outer periphery and a permanent magnet disposed on the inner periphery, and is entirely composed of a sintered metal. Moreover, although the said sintered core 1 is comprised as a set so that it may become a circle with six pieces, it may be made into three pieces, nine pieces, and twelve pieces as a plurality. In this case, of course, the upper and lower insulators 2 and 3 also correspond to the same number.

前記インシュレータユニットＡは、上部インシュレータ２と，下部インシュレータ３とが複数備えられると共に、それぞれがヒンジ部４で連結されて構成されている。本発明の実施形態では、上部インシュレータ２と，下部インシュレータ３とで前記焼結コア１の厚肉を上下に分割する部位がそれぞれ装填可能に構成されている。つまり、上部インシュレータ２と，下部インシュレータ３とで前記焼結コア１全体を完全に被覆し且つ該焼結コア１を絶縁している。   The insulator unit A includes a plurality of upper insulators 2 and lower insulators 3, and each is connected by a hinge portion 4. In the embodiment of the present invention, the upper insulator 2 and the lower insulator 3 are configured so as to be able to load portions that divide the thick wall of the sintered core 1 vertically. That is, the upper insulator 2 and the lower insulator 3 completely cover the entire sintered core 1 and insulate the sintered core 1.

また、隣接する上部インシュレータ２相互も、隣接する下部インシュレータ３相互も、可撓性に富んだ合成樹脂製のヒンジ部４を介して結合されている。６個の上部インシュレータ２がそれぞれ５個のヒンジ部４とで、また、６個の下部インシュレータ３がそれぞれ５個のヒンジ部４とでそれぞれ構成されている。このような前記インシュレータユニットＡは、上部インシュレータ２と，下部インシュレータ３と、ヒンジ部４とが合成樹脂製で一体形成されている。前記ヒンジ部４は、可撓性が良好となるように、薄肉状４１［図６（Ａ）及び（Ｂ）参照］，Ｕ字状４２［図６（Ｃ）参照］又はくびれ状４３［図６（Ｄ）参照］に適宜形成されている。また、図中６、７は、前記巻き線５の両端に接続する端子であって、前記上部インシュレータ２にそれぞれ設けられている。   Further, the adjacent upper insulators 2 and the adjacent lower insulators 3 are connected to each other via a hinge portion 4 made of a synthetic resin having high flexibility. Each of the six upper insulators 2 is composed of five hinge portions 4, and each of the six lower insulators 3 is composed of five hinge portions 4. In such an insulator unit A, an upper insulator 2, a lower insulator 3, and a hinge portion 4 are integrally formed of a synthetic resin. The hinge portion 4 has a thin shape 41 [see FIGS. 6A and 6B], a U-shape 42 [see FIG. 6C], or a constricted shape 43 [see FIG. 6 (D)]]. In the figure, reference numerals 6 and 7 denote terminals connected to both ends of the winding 5, which are provided on the upper insulator 2, respectively.

次に、本発明の製造法について説明する。まず、合成樹脂製の上下部インシュレータ２，３を複数備えて、それぞれがヒンジ部４で連結されたインシュレータユニットＡとして形成されている。特に、上部インシュレータ２と下部インシュレータ３は、それぞれ複数（実施態様では６個）備えられ、その相互間はヒンジ部４による構造であるため、上部インシュレータ２相互又は下部インシュレータ３相互間の連結部材は不要にでき、連結のための工程も不要にできるものである。   Next, the manufacturing method of this invention is demonstrated. First, a plurality of upper and lower insulators 2 and 3 made of synthetic resin are provided, and each is formed as an insulator unit A connected by a hinge portion 4. In particular, a plurality of upper insulators 2 and lower insulators 3 (six in the embodiment) are provided, and the structure between them is constituted by a hinge portion 4. Therefore, the connecting member between the upper insulators 2 or the lower insulators 3 is It can be made unnecessary, and the process for connection can be made unnecessary.

前記インシュレータユニットＡの上下部インシュレータ２，３のそれぞれによってサンドイッチ状にしつつ［図４（Ａ），（Ｂ），（Ｃ）及び図５（Ａ）等参照］前記焼結コア１の周囲を覆うようにする［図５（Ｂ）参照］。このようにして前記焼結コア１を前記インシュレータユニットＡの上下部インシュレータ２，３にて被覆して絶縁状態を確保する。このとき前記インシュレータユニットＡに装着された前記連結片部１３，１３の軸方向ｍ，ｍ相互は互いに略平行状態に形成されている。   While sandwiching each of the upper and lower insulators 2 and 3 of the insulator unit A [see FIGS. 4 (A), (B), (C) and FIG. 5 (A), etc.], the periphery of the sintered core 1 is covered. [Refer to FIG. 5B]. In this way, the sintered core 1 is covered with the upper and lower insulators 2 and 3 of the insulator unit A to ensure insulation. At this time, the axial directions m and m of the connecting pieces 13 and 13 attached to the insulator unit A are formed in a substantially parallel state.

次に、上下部インシュレータ２，３にて焼結コア１とをサンドイッチ状に被覆した後に、今度は、上下部インシュレータ２，３間に巻き線５をコイル状に巻くことで、上部インシュレータ２と下部インシュレータ３との接合面に接着剤が無くとも十分な強度を有する固着構造を提供することができる。つまり、上下部インシュレータ２，３相互と焼結コア１との一体化を接着剤不要にて製造できる。すなわち、接着剤等による接着工程を廃止できるものである。   Next, after covering the sintered core 1 in a sandwich shape with the upper and lower insulators 2 and 3, this time, by winding the winding wire 5 between the upper and lower insulators 2 and 3 in a coil shape, Even if there is no adhesive on the joint surface with the lower insulator 3, a fixing structure having sufficient strength can be provided. That is, the integration of the upper and lower insulators 2 and 3 and the sintered core 1 can be manufactured without using an adhesive. That is, the bonding process using an adhesive or the like can be abolished.

また、上下部インシュレータ２，３間に巻き線５をコイル状に巻くときにも、前記インシュレータユニットＡに装着された前記連結片部１３，１３の軸方向ｍ，ｍ相互は互いに略平行状態に形成されているため、実施形態では、焼結コア１を全６個とし、該全６個の焼結コア１に対して同時に巻き線５を巻くことができ、巻き線時間が１つずつ巻くのと比較して略１／６となる利点もある。   Further, when the winding 5 is wound in a coil shape between the upper and lower insulators 2 and 3, the axial directions m and m of the connecting piece portions 13 and 13 attached to the insulator unit A are substantially parallel to each other. Thus, in the embodiment, the number of the sintered cores 1 is six, and the winding 5 can be wound around the six sintered cores 1 at the same time, and the winding time is wound one by one. There is also an advantage of approximately 1/6 compared to

このような工程を経て製造された後は、前記ヒンジ部４を介して上下部インシュレータ２，３相互の外周面が円周状に形成されつつ前記連結片部１３，１３の軸方向相互は互いに略放射状に形成され且つ前記焼結コア１の外周側片部１１，１１相互は接続される。具体的には、図１（Ｂ）の実線状態から図１（Ｂ）の鎖線の状態（円形状）に形成する。   After being manufactured through such a process, the outer peripheral surfaces of the upper and lower insulators 2 and 3 are formed in a circumferential shape through the hinge portion 4, and the connecting piece portions 13 and 13 are axially connected to each other. The outer peripheral side pieces 11 and 11 of the sintered core 1 are connected to each other. Specifically, it is formed from the solid line state in FIG. 1B to the chain line state (circular shape) in FIG.

このように円形状に丸めた状態では、図２（Ｂ）及び図３（Ｂ）鎖線に示すように、隣接する焼結コア１，１の外周側片部１１，１１の一方側側面１１ｂと他方側側面１１ｃとがある圧力を有しつつ接触するように構成される。この作用によっても、焼結コア１相互の連結を簡易にできる。このように手等を使って丸める荷重を加えることにより簡単に巻き線時の直列形状からモータケース６０にセットする状態の円筒形状に変化させることができ［図１（Ｂ）及び図７（Ａ）及び（Ｂ）参照］、モータケース６０に簡単に収納できる利点がある［図７Ｂ）参照］。   In such a rounded state, as shown by chain lines in FIGS. 2 (B) and 3 (B), one side surface 11b of the outer peripheral side pieces 11, 11 of the adjacent sintered cores 1, 1 and It is comprised so that it may have a certain pressure and the other side surface 11c. Also by this action, the mutual connection of the sintered cores 1 can be simplified. In this way, by applying a rounding load using a hand or the like, it is possible to easily change from a serial shape at the time of winding to a cylindrical shape set in the motor case 60 [FIG. 1 (B) and FIG. 7 (A). ) And (B)], there is an advantage that the motor case 60 can be easily stored [see FIG. 7B].

（Ａ）は本発明の製造法によって製造した製品の斜視図、（Ｂ）は（Ａ）の横断平面図である。(A) is a perspective view of the product manufactured by the manufacturing method of this invention, (B) is a cross-sectional plan view of (A). （Ａ）は本発明の製造法によって製造した製品の一部平面図、（Ｂ）は使用時に丸めた状態の一部平面図である。(A) is a partial top view of the product manufactured by the manufacturing method of this invention, (B) is a partial top view of the state rounded at the time of use. （Ａ）は本発明の製造法によって製造した製品の一部斜視図、（Ｂ）は（Ａ）の要部拡大断面図である。(A) is a partial perspective view of the product manufactured by the manufacturing method of this invention, (B) is a principal part expanded sectional view of (A). （Ａ）は本発明の製造法に用いるヒンジ部にて連続した上部インシュレータの一部斜視図、（Ｂ）はそれぞれが独立した焼結コアの斜視図、（Ｃ）は本発明の製造法に用いるヒンジ部にて連続した下部インシュレータの一部斜視図である。(A) is a partial perspective view of an upper insulator continuous in a hinge portion used in the manufacturing method of the present invention, (B) is a perspective view of an independent sintered core, and (C) is a manufacturing method of the present invention. It is a partial perspective view of the lower insulator which continued in the hinge part to be used. （Ａ）は本発明の製造法において上下部インシュレータにて焼結コアを被覆せんとする初期段階の状態図、（Ｂ）は上下部インシュレータにて焼結コアを被覆完了した中期段階の状態図、（Ｃ）は上下部インシュレータ間に巻き線を巻いた終期段階の状態図である。(A) is the initial stage state diagram in which the sintered core is coated with the upper and lower insulators in the manufacturing method of the present invention, and (B) is the intermediate stage state diagram in which the sintered core is completely coated with the upper and lower insulators. (C) is a state diagram at the final stage in which a winding is wound between the upper and lower insulators. （Ａ）は上部インシュレータ又は下部インシュレータのヒンジ部個所の要部横断拡大平面図、（Ｂ）は（Ａ）個所を使用時に丸めた状態の一部横断平面図、（Ｃ）はヒンジ部個所の別の実施形態の要部横断拡大平面図、（Ｄ）はヒンジ部個所のさらに別の実施形態の要部横断拡大平面図である。(A) is an enlarged cross-sectional plan view of the main part of the hinge part of the upper insulator or the lower insulator, (B) is a partial cross-sectional plan view of the state where the (A) part is rounded when used, and (C) is the hinge part. The principal part crossing enlarged plan view of another embodiment, (D) is a principal part crossing enlarged plan view of further another embodiment of a hinge part location. （Ａ）は本発明の製造法によって製造した製品を使用時に丸めた状態の平面図、（Ｂ）は（Ａ）のように丸めた製品をモータリングに挿入せんとする斜視図である。(A) is a top view of the state which rounded the product manufactured by the manufacturing method of this invention at the time of use, (B) is a perspective view which uses the rounded product like (A) as an insertion into a motor ring.

符号の説明Explanation of symbols

１…焼結コア、１１…外周側片部、１２…内周側片部、１３…連結片部、
Ａ…インシュレータユニット、２，３…上下部インシュレータ、４…ヒンジ部、
５…巻き線。 DESCRIPTION OF SYMBOLS 1 ... Sintered core, 11 ... Outer peripheral side piece part, 12 ... Inner peripheral side piece part, 13 ... Connection piece part,
A ... Insulator unit, 2, 3 ... Top and bottom insulators, 4 ... Hinge part,
5 ... Winding.

Claims (5)

焼結コアと、該焼結コアを被覆可能で上下に分割した合成樹脂製の上部インシュレータ相互及び下部インシュレータ相互が可撓性を有するヒンジ部を介して一体形成されると共に製造後において該ヒンジ部を介して円形状に形成されるインシュレータユニットと、コイルとして形成する巻き線とからなり、前記焼結コアを互いに独立させて直列状に形成すると共に、前記インシュレータユニットの上下部インシュレータにて前記焼結コアを被覆し、その後に前記上下部インシュレータ間に前記巻き線を所定回数巻き込み形成して前記焼結コアと前記上下部インシュレータとを固定してなることを特徴とする焼結コア連結構造の製造法。 The sintered core and the upper and lower insulators made of synthetic resin, which can be coated and divided into upper and lower parts, are integrally formed through a flexible hinge portion and the hinge portion is manufactured after manufacturing. Insulator units formed in a circular shape via a winding and windings formed as coils, the sintered cores are formed in series independently of each other, and the upper and lower insulators of the insulator units A sintered core connection structure characterized by covering the sintered core, and then forming the winding wire between the upper and lower insulators a predetermined number of times to fix the sintered core and the upper and lower insulators. Manufacturing method. 請求項１において、上下部インシュレータは、少なくとも３個以上の複数個としてなることを特徴とする焼結コア連結構造の製造法。   The method for manufacturing a sintered core coupling structure according to claim 1, wherein the upper and lower insulators are a plurality of at least three or more. 請求項１又は２において、前記焼結コアは、外周側片部と内周側片部と連結片部とが平面的に見て略エの字状に一体形成されてなり、前記焼結コアの前記連結片部の軸方向相互を互いに略平行状態に形成してなることを特徴とする焼結コア連結構造の製造法。   3. The sintered core according to claim 1, wherein the sintered core is formed by integrally forming an outer peripheral side piece, an inner peripheral side piece, and a connecting piece in a substantially square shape when seen in a plan view. A method for manufacturing a sintered core coupling structure, wherein the coupling pieces are formed so that their axial directions are substantially parallel to each other. 請求項１，２又は３において、前記上下部インシュレータ間のそれぞれに略同時に前記巻き線を所定回数巻き込み形成してなることを特徴とする焼結コア連結構造の製造法。   4. A method for manufacturing a sintered core coupling structure according to claim 1, wherein said winding is wound a predetermined number of times substantially simultaneously between each of said upper and lower insulators. 請求項１，２，３又は４における製造法から製造されてなることを特徴とする焼結コア連結構造。   A sintered core connection structure manufactured by the manufacturing method according to claim 1, 2, 3, or 4.
JP2006110455A 2006-04-13 2006-04-13 Method for manufacturing sintered core connection structure and sintered core connection structure Expired - Fee Related JP4711877B2 (en)

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