WO2022209762A1 - 電動機 - Google Patents
電動機 Download PDFInfo
- Publication number
- WO2022209762A1 WO2022209762A1 PCT/JP2022/010907 JP2022010907W WO2022209762A1 WO 2022209762 A1 WO2022209762 A1 WO 2022209762A1 JP 2022010907 W JP2022010907 W JP 2022010907W WO 2022209762 A1 WO2022209762 A1 WO 2022209762A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- heat sink
- electric motor
- resin
- circuit board
- outer shell
- Prior art date
Links
- 229920005989 resin Polymers 0.000 claims abstract description 111
- 239000011347 resin Substances 0.000 claims abstract description 111
- 230000002093 peripheral effect Effects 0.000 claims abstract description 63
- 238000004512 die casting Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 description 15
- 239000002184 metal Substances 0.000 description 15
- 239000000853 adhesive Substances 0.000 description 11
- 230000001070 adhesive effect Effects 0.000 description 11
- 238000012546 transfer Methods 0.000 description 10
- 238000012545 processing Methods 0.000 description 9
- 238000005266 casting Methods 0.000 description 8
- 238000005520 cutting process Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 5
- 230000017525 heat dissipation Effects 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 239000000696 magnetic material Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000005855 radiation Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 239000004412 Bulk moulding compound Substances 0.000 description 2
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- -1 polybutylene terephthalate Polymers 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 210000000078 claw Anatomy 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 238000009751 slip forming Methods 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/30—Structural association with control circuits or drive circuits
- H02K11/33—Drive circuits, e.g. power electronics
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/08—Insulating casings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K9/00—Arrangements for cooling or ventilating
Definitions
- the present invention relates to an electric motor, and more particularly to a heat dissipation structure for a circuit board built into the electric motor.
- Electric motors having heat sinks are also known in which the circuit board includes electronic components that generate heat when energized, and the heat generated by the electronic components is dissipated to the outside of the motor.
- Patent Document 1 a resin for molding a stator core (hereinafter referred to as a resin shell) and a bearing on the non-output side of the motor are supported and attached to the end of the resin shell on the non-output side of the motor.
- a metal bracket a radiation fin (heat sink) fixed to an end of the resin shell via the metal bracket and including projections that can be inserted into holes provided on the outer surface of the metal bracket;
- a brushless motor is provided with a circuit board disposed inside, and a structure is described in which the protrusions are brought into contact with electronic components on the circuit board via thermally conductive resin.
- heat radiation fins as heat sinks are fixed to the ends of the resin shell via metal brackets.
- motors with heat sinks are subject to dimensional variations and assembly variations.
- Dimensional variations are variations in the dimensions of each part itself.
- Assembly variations are variations in the relative positions of the parts (the position of one part when the position of the other part is used as a reference) that occurs when the parts are assembled.
- the heat sink is formed by casting (die casting)
- the dimensional accuracy of the heat sink itself tends to be low, and dimensional variations tend to increase.
- an object of the present invention is to provide an electric motor that can stably dissipate heat generated in a circuit board.
- An electric motor includes: a cylindrical resin shell having an open end on one end in an axial direction; a stator core integrally formed with the resin shell; and an inner diameter side of the stator core. a rotor arranged in the inner space, a heat sink covering the open end of the resin shell, and a circuit board arranged in an internal space covered with the resin shell and the heat sink.
- the heat sink includes a disk portion, an annular protrusion projecting from the disk portion toward the circuit board in the axial direction, and an inner diameter side of the resin outer shell relative to the annular protrusion. a projecting portion projecting from the terminal toward the circuit board side and in thermal contact with the circuit board.
- the disc portion has an axial positioning portion that contacts the open end of the resin shell, and the annular protrusion has a radial positioning portion that contacts the inner or outer peripheral surface of the resin shell. .
- the axial positioning portion abuts the opening end portion of the resin outer shell, and the radial positioning portion abuts the inner peripheral surface or the outer peripheral surface of the resin outer shell, whereby the heat sink is provided. Positional accuracy in the axial direction and the radial direction between the protrusion and the circuit board is ensured. Thereby, the heat generated in the circuit board can be stably dissipated through the heat sink.
- the radial positioning portion may be formed on the outer peripheral surface of the annular projecting portion and may abut on the inner peripheral surface of the resin outer shell.
- the axial positioning portion may be located on the outer peripheral side of the annular protrusion of the disk portion.
- the protrusion height in the axial direction of the protrusion may be greater than the protrusion height of the annular protrusion.
- the circuit board may include a wiring board and an electronic component mounted on the wiring board that generates heat when energized, and the protrusion may have a facing surface facing the electronic component.
- the cylindrical resin shell may have a mounting surface to which the circuit board is fixed.
- the heat sink may further have a bearing accommodating portion that accommodates a first bearing that rotatably supports the rotating shaft.
- a method of manufacturing an electric motor according to one embodiment of the present technology forms the heat sink by die casting.
- the heat generated in the circuit board can be stably dissipated.
- FIG. 1 is a cross-sectional view of an electric motor according to a first embodiment of the present invention
- FIG. 4 is a perspective view of a resin outer shell in the electric motor
- FIG. It is a perspective view of the heat sink in the said electric motor
- FIG. 4A is a cross-sectional view showing a process for processing a heat sink in the electric motor, wherein (A) is a cross-sectional view showing a process for processing a radial positioning portion, and (B) is a process for processing an axial positioning portion and a facing surface; It is a sectional view.
- FIG. 7 is a cross-sectional view of a main part of an electric motor according to a second embodiment of the invention.
- FIG. 1 is a cross-sectional view of an electric motor 1 according to the first embodiment.
- the electric motor 1 of the present embodiment is used, for example, as a rotational drive source for a blower fan mounted in an indoor unit of an air conditioner.
- the electric motor 1 includes a stator core 21 , a rotor 3 , a resin shell 10 , a first bearing 71 , a second bearing 81 , a heat sink 4 and a circuit board 5 .
- the stator core 21 is integrally formed with the resin outer shell 10 .
- the rotor 3 is fixed to the rotating shaft 6 and arranged on the inner diameter side of the stator core 21 .
- the resin shell 10 has a cylindrical shape having an open end 101 at one end in a direction parallel to the axis C of the rotating shaft 6 (hereinafter also referred to as an axial direction).
- the heat sink 4 is arranged to cover the open end 101 of the resin shell 10 .
- the circuit board 5 is arranged in an internal space covered with the resin shell 10 and the heat sink 4 .
- an inner rotor type brushless DC motor in which a cylindrical rotor 3 having a permanent magnet portion 31 is rotatably disposed radially inside a cylindrical stator 2 that generates a rotating magnetic field will be described.
- a motor 1 will be described.
- the electric motor 1 is of course not limited to this, and may be, for example, an outer rotor type brushless DC motor, an AC motor, or another electric motor.
- the axis C of the rotating shaft 6 is also the central axis of the electric motor 1, that is, the rotating shaft of the rotor 3.
- the radial direction is a direction passing through the axis C and orthogonal to the axial direction.
- the inner diameter side is the inner side in the radial direction, and the outer diameter side is the outer side in the radial direction.
- the circumferential direction is the direction of rotation about the axis C. As shown in FIG.
- the rotor 3 has an annular permanent magnet portion 31 and a rotor main body 30 .
- the rotor main body 30 has an outer peripheral surface and an inner peripheral surface.
- a permanent magnet portion 31 is fixed to the outer peripheral surface of the rotor main body 30 .
- a rotary shaft 6 is fixed to the inner peripheral surface of the rotor main body. As a result, the rotating shaft 6 rotates integrally with the rotor main body 30 .
- the rotor 3 is a surface magnet type in which a permanent magnet portion 31 is annularly fixed to the outer peripheral surface.
- the permanent magnet portion 31 is annularly formed of a plurality of (e.g., 8 or 10) permanent magnets so that N poles and S poles appear alternately at equal intervals in the circumferential direction.
- the permanent magnet portion 31 is typically made of a sintered metal such as an Nd--Fe--B alloy. A plastic magnet may also be used.
- the rotor body 30 has an outer core 32, an insulating member 33, and an inner core .
- the outer core 32 is annular and forms the outer peripheral surface of the rotor main body 30 .
- the outer core 32 is a laminate of plates made of a soft magnetic material such as a plurality of electromagnetic steel plates.
- the inner peripheral iron core 34 is formed in an annular shape and forms the inner peripheral surface of the rotor main body 30 .
- the inner peripheral core 34 is a laminate of plates made of a soft magnetic material such as a plurality of electromagnetic steel plates.
- the rotating shaft 6 is fixed to the center of the inner peripheral iron core 34 by press fitting or caulking.
- the insulating member 33 electrically insulates between the outer core 32 and the inner core 34 .
- the insulating member 33 is made of dielectric resin such as PBT (polybutylene terephthalate) or PET (polyethylene terephthalate), and is fixed between the outer core 32 and the inner core 34 .
- the insulating member 33 may be an annular molded body, or may be a resin material filled between the outer core 32 and the inner core 34 by insert molding or the like.
- the stator 2 includes a stator core 21 having a cylindrical yoke portion and a plurality of teeth extending radially from the yoke, and windings (coils) 22 wound around the teeth.
- the stator core 21 is, for example, a laminate of plates made of a soft magnetic material such as a plurality of electromagnetic steel plates.
- the outer peripheral surface of the stator 2 (stator core 21) is covered with a resin shell 10 (see FIG. 1).
- the stator 2 is arranged such that the permanent magnet portion 31 of the rotor 3 faces the stator core 21 of the stator 2 in the radial direction via an air gap (magnetic gap).
- the resin shell 10 is made of an insulating resin material.
- FIG. 2 is a perspective view of the resin shell 10 in the electric motor 1, and as shown in FIG. It is formed in a hollow cylindrical shape with
- the counter-output end portion 61 is the end portion of the rotary shaft 6 opposite to the output end portion 62 .
- the output end portion 62 is the end portion of the electric motor 1 on the load side (the side connected to the load).
- the resin shell 10 is integrally molded with the stator 2 .
- the resin material forming the resin shell 10 is not particularly limited, and is formed of, for example, BMC (Bulk Molding Compound: unsaturated polyester resin) resin.
- the resin shell 10 has a mounting surface 9 .
- the mounting surface 9 is formed on the side of the inner peripheral surface 10a of the resin outer shell 10, is an inner peripheral plane perpendicular to the axial direction, and is axially opposite to the rotor 3 with a gap therebetween. It is provided on the end portion 61 side.
- the mounting surface 9 supports the circuit board 5 which will be described later.
- the mounting surface 9 is the surface of the counter-output end portion 61 side of the step provided so as to protrude from the inner peripheral surface 10a of the resin outer shell 10 toward the inner diameter side.
- the mounting surface 9 may be formed continuously in the circumferential direction of the inner peripheral surface 10a of the resin outer shell 10, or may be formed at a plurality of locations at intervals in the circumferential direction.
- the resin outer shell 10 further has a second bearing accommodating portion 82 that accommodates a second bearing 81, which will be described later.
- the general shape of the second bearing accommodating portion 82 is a cylindrical shape centered on the axis C and one end side of which is closed.
- the second bearing accommodating portion 82 is provided on the bottom portion 102 of the resin outer shell 10 on the side opposite to the open end portion 101 .
- the circuit board 5 includes a wiring board 50 and an electronic component 51 mounted on the surface of the wiring board 50 (the surface on the side opposite to the output end 61 of the rotary shaft 6) and generating heat when energized.
- the circuit board 5 is generally disc-shaped, and the periphery of the circuit board 5 is supported by the mounting surface 9 and fixed by, for example, adhesion, adhesion, screw fastening, soldering, or the like.
- a positioning protrusion may be provided on the peripheral edge of the circuit board 5, and a positioning recess may be provided on the inner peripheral surface 10a of the resin shell 10 to engage with the protrusion. It can be fixed to the mounting surface 9 while being positioned in the circumferential direction.
- the electronic components 51 that generate heat when energized are mainly semiconductor package components such as power supply ICs and motor drive current control ICs, but may also include passive components such as capacitors.
- the wiring board 50 is mounted with other components such as a connector component to be connected to a power cable, but illustration of these components is omitted.
- the power cable is connected to a power source (not shown) through a cable insertion portion 105 formed in the vicinity of the open end portion 101 of the resin shell 10 over a predetermined angular range in the circumferential direction.
- the mounting surface 9 is provided with a plurality of (two in this example) positioning pins 9c penetrating the circuit board 5 .
- the inner peripheral surface 10a of the resin outer shell 10 may be partially provided with a positioning recess 104 for accommodating the circuit board 5. This also allows the circuit board 5 to be positioned on the mounting surface 9 in a state of being positioned in the circumferential direction. can be fixed to 2 is formed to be electrically connected to the circuit board 5, and the circuit board 5 is positioned on the mounting surface 9 by a plurality of positioning pins 9c. At the same time, it is fixed on the mounting surface 9 by soldering the circuit board 5 and the end portion 221 of the coil.
- the first bearing 71 is a ball bearing having an outer ring 711, an inner ring 712, a plurality of balls 713, and the like.
- the second bearing 81 is a ball bearing having an outer ring 811, an inner ring 812, balls 813, and the like.
- the outer ring 711 of the first bearing 71 is fixed to the heat sink 4 (first bearing housing portion 41), and the inner ring 712 of the first bearing 71 is fixed to the counter-output end portion 61 side of the rotary shaft 6.
- the outer ring 813 of the second bearing 81 is fixed to the resin outer shell 10 (second bearing accommodating portion 82 ), and the inner ring 812 of the second bearing 81 is fixed to the output end portion 62 of the rotary shaft 6 .
- the rotating shaft 6 is rotatably supported around the axis C with respect to the heat sink 4 and the resin shell 10 by the first bearing 71 and the second bearing 81 .
- the heat sink 4 has a first bearing accommodating portion 41 , a disk portion 42 , an annular projecting portion 43 and a projecting portion 44 .
- the heat sink 4 is attached and fixed to the open end 101 of the resin shell 10 .
- the heat sink 4 is made of a metal material having excellent thermal conductivity, such as aluminum.
- the heat sink 4 is integrally formed with a disk portion 42, an annular projecting portion 43, and a projecting portion 44, respectively.
- the heat sink 4 is molded by die casting (casting), for example.
- the heat sink 4 functions as a cover member (bracket) that closes the opening of the resin outer shell 10 by covering the opening end 101 of the resin outer shell 10, and a bearing housing part (bearing house) that supports the first bearing 71. and a function as a heat radiating member that radiates heat generated by the electronic components 51 inside the motor to the outside of the motor.
- the heat sink 4 is fixed to the open end 101 of the resin outer shell 10 using a plurality of unillustrated screw members.
- FIG. 3(A) is a perspective view of the inner side of the heat sink 4 (lower side in FIG. 1)
- FIG. 3(B) is a perspective view of the outer side of the heat sink 4 (upper side in FIG. 1).
- the disk portion 42 is an annular plate portion having a center hole 40 centered on the axis C.
- the outer diameter of the disc portion 42 is the same or substantially the same size as the outer diameter of the open end portion 101 of the resin shell 10 .
- the disk portion 42 has an upper surface 423 and a rear surface 424 on the opposite side.
- the upper surface portion 423 of the disc portion 42 is formed with the first bearing accommodating portion 41 .
- a rear surface 424 of the disk portion 42 is provided with the axial positioning portion 420 , the annular projection portion 43 and the projection portion 44 .
- the annular projecting portion 43 is formed so as to project from the rear surface 424 side of the disk portion 42 toward the circuit board 5 side. Further, the annular projecting portion 43 has a radial positioning portion 430 that contacts the inner peripheral surface 10 a of the resin outer shell 10 .
- the projecting portion 44 is arranged on the inner diameter side of the annular projecting portion 43, projects from the back surface 424 side of the disk portion 42 toward the circuit board 5 side, and thermally contacts the circuit board 5 (the electronic component 51 in this embodiment). come into contact with
- the protrusion 44 is formed in a region between the first bearing accommodating portion 41 and the annular protrusion 43 in the radial direction. It is arranged and faces the electronic component 51 . The details of each unit will be described below.
- the first bearing housing portion 41 houses the first bearing 71 .
- the first bearing accommodating portion 41 has a cylindrical shape with one end side centered on the axis C and is closed, and accommodates the first bearing 71 .
- the first bearing accommodating portion 41 is formed on the upper surface 423 side of the inner peripheral edge portion 401 of the center hole 40 of the disc portion 42 .
- the disk portion 42 has an axial positioning portion 420 . As shown in FIG. 3A, the axial positioning portion 420 is formed on the rear surface 424 side of the outer peripheral edge portion 422 of the disc portion 42 . In this embodiment, the outer peripheral edge portion 422 is a region of the disk portion 42 on the outer diameter side of the annular projecting portion 43 .
- the axial thickness of the disk portion 42 in the region on the inner diameter side of the outer peripheral edge portion 422 may be thinner than the axial thickness of the outer peripheral edge portion 422 .
- the thickness of the disk portion 42 in the area on the inner diameter side of the outer peripheral edge portion 422 is made thinner than the outer peripheral edge portion 422, as shown in FIG. 425 may be provided.
- a plurality of rib portions 425 are radially formed from the first bearing accommodating portion 41 toward the annular projecting portion 43 . By providing the plurality of rib portions 425, the strength of the heat sink 4 can be ensured.
- the axial positioning portion 420 is formed on the rear surface 424 side of the outer peripheral edge portion 422 and contacts the open end portion 101 of the resin outer shell 10 . As shown in FIG. 1, the axial positioning portion 420 abuts the open end portion 101 in the direction of the axis C. As shown in FIG.
- the axial positioning portion 420 may be processed into a flat surface by a lathe or the like after the heat sink 4 is formed by die casting or the like. In this embodiment, the axial positioning portion 420 is formed on a plane perpendicular to the axis C. As shown in FIG.
- the axial positioning portion 420 is formed by a plane perpendicular to the axis C over the entire rear surface 424 side of the outer peripheral edge portion 422, but this is not the only option.
- the axial positioning portion 420 of the heat sink 4 may have an annular projection projecting toward the open end 101, and the open end 101 of the resin shell 10 has an annular projection corresponding to the projection. It may have grooves.
- a cross section of the protruding portion viewed from the radial direction may be trapezoidal or curved.
- holes 421 through which screws are inserted are formed at a plurality of locations on the outer peripheral edge portion 422 of the disc portion 42 .
- three holes 421 are provided at equal angular intervals on the outer peripheral edge 422 .
- the number and positions of the holes 421 provided in the outer peripheral edge portion 422 can be changed as appropriate, and the outer peripheral edge portion 422 need not be provided with the hole portions 421 .
- the opening end 101 of the resin shell 10 is formed with the screw receiving portion 103 shown in FIG.
- the heat sink 4 is fixed to the open end 101 of the resin outer shell 10 with a plurality of screws inserted through the holes 421 . At this time, the heat sink 4 is positioned in the circumferential direction with respect to the open end portion 101 of the resin shell 10 .
- the disc part 42 further has a notch part 426 formed over a predetermined angular range in a part of the outer peripheral edge part 422 thereof.
- the notch portion 426 is provided at a position corresponding to the above-described cable insertion portion formed over the vicinity of the open end portion 101 of the resin outer shell 10 . Accordingly, the notch 426 can be used as a mark for positioning the heat sink 4 in the resin shell 10 in the circumferential direction when the heat sink 4 is assembled to the open end 101 of the resin shell 10 .
- the annular projection 43 has a radial positioning portion 430 .
- the radial positioning portion 430 is formed on the outer peripheral surface of the annular projecting portion 43 that contacts the inner peripheral surface of the open end portion 101 of the resin outer shell 10 . That is, as shown in FIGS. 1, 2, and 3A, the radial positioning portion 430 has a cylindrical surface that fits into the inner peripheral surface 10a of the resin outer shell 10. As shown in FIG.
- the annular projecting portion 43 is formed in an annular shape around the axis C on the rear surface 424 of the disc portion 42 .
- the cross section parallel to the axis C of the annular protrusion 43 is generally rectangular.
- the annular projecting portion 43 is continuously formed in the circumferential direction without any discontinuities, but this is not the only option, and a discontinuous portion may be provided.
- the projecting portion 44 is arranged on the inner diameter side of the annular projecting portion 43 and projects from the back surface 424 of the disk portion 42 toward the circuit board 5 side in the axial direction.
- the protrusion 44 is a rectangular parallelepiped block that protrudes toward the electronic component 51 mounted on the circuit board 5 . Furthermore, the protrusion 44 has a facing surface 441 that faces the electronic component 51 .
- the shape of the protrusion 44 is not limited to a rectangular parallelepiped shape, and may be, for example, a cylindrical shape.
- the projection height of the projection 44 in the axial direction be greater than the projection height of the annular projection 43 .
- the protruding height here is the height protruding in the axial direction with respect to the back surface 424 of the disc portion 42 .
- the facing surface 441 of the protrusion 44 is positioned closer to the circuit board 5 than the tip of the annular protrusion 43 in the axial direction.
- the protrusion height of the protrusion 44 is such that when the axial positioning portion 420 of the disc portion 42 abuts against the open end portion 101 of the resin shell 10 , the facing surface 441 of the protrusion 44 touches the upper surface of the electronic component 51 . It is set to form a gap with a size within a predetermined range.
- the shape of the facing surface 441 viewed from the electronic component 51 side may be formed in accordance with the shape of the electronic component 51, and is, for example, a square plane (see FIG. 3A).
- the facing surface 441 may be processed into a flat surface by a lathe or the like after the heat sink 4 is formed by die casting or the like, for example.
- a heat transfer member 52 and an adhesive member 53 are arranged in order from the electronic component 51 side between the electronic component 51 and the protrusion 44 . is in thermal contact with the electronic component 51 via the .
- the distance between facing surface 441 and electronic component 51 is set to be equal to or less than the total thickness of heat transfer member 52 and adhesive member 53 . Accordingly, the opposing surface 441 can be stably brought into contact with the upper surface of the electronic component 51 via the heat transfer member 52 and the adhesive member 53 .
- only the heat transfer member 52 or the adhesive member 53 may be arranged between the electronic component 51 and the protrusion 44 .
- the heat transfer member 52 preferably has good thermal conductivity and high insulation, and for example, a heat dissipation sheet made of silicone resin is used.
- the adhesive member 53 preferably has good thermal conductivity and high insulating properties, and for example, a silicon resin adhesive is used.
- the adhesive member 53 not only bonds the heat transfer member 52 and the protrusion 44 together, but also absorbs variations in axial position between the protrusion 44 and the electronic component 51 due to deformation of the adhesive member 53 . Further, the adhesive member 53 relieves the pressing force from the protrusion 44 to the electronic component 51 by deformation of the adhesive member 53 when the heat sink 4 is fitted to the resin shell 10 . As a result, stable thermal connection between the protrusion 44 and the electronic component 51 can be ensured, and the electronic component 51 and the circuit board 5 can be prevented from being damaged by the force applied from the protrusion 44 in the axial direction.
- FIG. 4 is a schematic diagram showing a part of the processing steps of the heat sink 4 in this embodiment.
- the axial positioning portion 420 and the opposing surface 441 of the heat sink 4 are made flat. It is machined on a lathe.
- the heat sink 4 is first formed as a casting in a casting (die casting) process by solidifying a metal (alloy) poured into a mold (not shown). After that, the heat sink 4 is machined by lathe processing for the radial positioning portion 430 , the axial positioning portion 420 , and the facing surface 441 .
- a case is exemplified in which the heat sink 4 is machined in the order of the radial positioning portion 430, the axial positioning portion 420, and the facing surface 441 by a normal lathe (general-purpose lathe).
- the cast heat sink 4 is fixed to a headstock (not shown) (mechanism for rotating attached members) using a chuck (claw) not shown. As a result, the heat sink 4 rotates around the axis C. As shown in FIG. Next, by bringing a cutting tool B (cutting tool) fixed to the tool post into contact with the rotating heat sink 4 , the end surface of the heat sink 4 is shaved. At this time, by moving the cutting tool B in the radial direction of the axis C, a plane perpendicular to the axis C is formed. Further, by moving the cutting tool B parallel to the axis C, a cylindrical surface is formed.
- FIG. 4(A) is a cross-sectional view showing the machining process of the radial positioning portion 430.
- FIG. 4A by moving the cutting tool B in parallel with the axis C, the radial positioning portion 430, which is the outer peripheral surface of the annular projecting portion 43, can be adjusted with high accuracy in its radial dimension. It is formed.
- the radial positioning portion 430 is formed on the outer peripheral surface of the annular protrusion 43, when the tool B is brought closer to the lathe from the outer diameter side of the axis C, the annular protrusion 43 is machined. out of the way.
- the heat sink 4 is formed by die casting (casting)
- the outer peripheral surface (radial direction positioning portion 430) of the annular projecting portion 43 and the resin outer shell 10 can be brought into contact with the inner peripheral surface 10a (not shown) of 10 with high dimensional accuracy.
- FIG. 4B is a cross-sectional view showing the process of machining the axial positioning portion 420 and the facing surface 441.
- the axial positioning portion 420 formed on the outer diameter side of the annular projecting portion 43 moves along the axis.
- Directional dimensions are formed with high accuracy.
- the axial positioning portion 420 is formed on the outer peripheral side of the annular protrusion 43 described above, when the tool B is brought closer to the lathe from the outer diameter side of the axis C, the annular protrusion 43 does not interfere with processing.
- the heat sink 4 is formed by die casting (casting), when combining the resin outer shell 10 (not shown) and the heat sink 4, the axial positioning portion 420 of the heat sink 4 and the open end portion 101 of the resin outer shell 10 are separated. (not shown) can be brought into contact with high dimensional accuracy.
- the facing surface 441 of the protrusion 44 formed on the inner diameter side of the annular protrusion 43 is Axial dimensions are formed with high accuracy.
- the facing surface 441 is formed on the inner peripheral side of the annular projecting portion 43
- the projecting height of the projecting portion 44 is formed to be higher than the projecting height of the annular projecting portion 43 .
- the annular projecting portion 43 does not interfere with the machining.
- the circuit board 5 fixed to the resin shell 10 and the protrusions 44 of the heat sink 4 are not in contact with each other. can be positioned with high dimensional accuracy.
- the heat sink 4 of this embodiment includes the axial positioning portion 420 that contacts the open end portion 101 of the resin outer shell 10 and the radial positioning portion that contacts the inner peripheral surface of the open end portion 101 of the resin outer shell 10 . 430. Therefore, at the same time as the heat sink 4 is assembled to the resin outer shell 10 , the heat sink 4 is positioned in both the axial direction and the radial direction with respect to the resin outer shell 10 .
- the heat sink 4 which is an integrated component, is provided with an axial positioning portion 420 for positioning the relative position of the heat sink 4 in the axial direction with respect to the resin outer shell 10, and the heat sink 4 with respect to the electronic component 51 of the circuit board 5.
- a facing surface 441 of the protrusion 44 is provided for positioning the relative axial position of the . Therefore, the accuracy of the relative position of the heat sink 4 in the axial direction with respect to the resin shell 10 is ensured.
- variations in the axial relative positions (dimensional variations and assembly variations) between the facing surfaces 441 of the projections 44 and the electronic components 51 are suppressed, and heat is stably transferred from the electronic components 51 to the heat sink 4 . can sufficiently dissipate heat to the outside of the
- the heat sink 4 is formed with the radial positioning portion 430 , it is possible to reduce radial assembly variations between the heat sink 4 and the resin outer shell 10 . It is possible to accurately face the electronic component 51 on the circuit board 5 fixed to the shaft in the axial direction. Further, the first bearing 71 can be arranged coaxially with the axis C with high accuracy.
- the heat sink 4 is directly attached to the open end portion 101 of the resin shell 10 without interposing the metal bracket.
- the protrusion 44 of the heat sink 4 can be positioned with high precision with respect to the circuit board 5 (electronic component 51).
- variations in the distance between the facing surface 441 of the protrusion 44 of the heat sink 4 and the electronic component 51 of the circuit board 5 can be suppressed. Therefore, the distance between the projecting portion 44 (opposing surface 441) and the circuit board 5 (electronic component 51) becomes larger than necessary (for example, the distance between the opposing surface 441 and the electronic component 51 is greater than the thickness of the heat transfer member 52).
- the heat sink 4 includes the bearing housing portion 41, so that the first bearing 71 can be supported without the need for the metal bracket. As a result, the number of parts can be reduced and the assembling workability of the electric motor 1 can be improved.
- the axial positioning portion 420 and the opposing surface 441 are end-faced in a post-process using a lathe, so that the heat sink 4 dimensional variation in the axial direction can be reduced. Therefore, variation in the axial relative position (assembly variation) between the facing surface 441 of the protrusion 44 and the electronic component 51 is further suppressed, and heat is stably transferred from the electronic component 51 to the heat sink 4, thereby can sufficiently dissipate heat to
- FIG. 5 is a schematic cross-sectional view of essential parts of an electric motor 1A according to a second embodiment of the invention.
- configurations different from those of the first embodiment will be mainly described, and configurations similar to those of the first embodiment will be denoted by the same reference numerals, and description thereof will be omitted or simplified.
- the electric motor 1A of this embodiment includes a heat sink 4A having a disk portion 42A, an annular projecting portion 43A, and a projecting portion 44.
- the heat sink 4A of this embodiment differs from that of the first embodiment in that the annular projecting portion 43A is located outside the open end portion 101 of the resin outer shell 10 .
- the disk portion 42A has an outer diameter larger than the outer diameter of the open end portion 101 of the resin outer shell 10.
- the disk portion 42A has an axial positioning portion 420A on its rear surface 424 side, which contacts the open end portion 101 of the resin outer shell 10 .
- the axial positioning portion 420A is formed of a plane perpendicular to the axis C, as in the first embodiment.
- the annular projecting portion 43A is formed on the rear surface 424 side of the disk portion 42A so as to protrude in the axial direction from the outer peripheral edge portion 427 of the disk portion 42A.
- the outer peripheral edge portion 427 is a region of the disk portion 42A on the outer peripheral side of the axial positioning portion 420A.
- the radial positioning portion 430A is formed on the inner peripheral surface of the annular projecting portion 43A and contacts the outer peripheral surface of the resin outer shell 10 .
- the heat sink 4A of this embodiment configured as described above includes an axial positioning portion 420A that contacts the open end portion 101 of the resin outer shell 10, and a radial positioning portion 420A that contacts the outer peripheral surface of the open end portion 101 of the resin outer shell 10. It has a part 430 . Therefore, as in the first embodiment, the heat sink 4A is positioned both in the axial direction and the radial direction with respect to the resin outer shell 10 at the same time as the heat sink 4A is attached to the resin outer shell 10. FIG. As a result, the projections 44 of the heat sink 4A can be positioned with high accuracy with respect to the circuit board 5 (electronic components 51), so that good heat transfer can be achieved between the heat sink 4A and the circuit board 5 (electronic components 51). characteristics can be secured.
- a load is provided at one end of the shaft 6 of the electric motor 1, and a single-shaft motor that produces an output in response to the load has been described as an example.
- a dual-shaft motor may be used in which a load (torque) is provided to the motor and the output is generated in response to the load.
- the circuit board 5 has a disk shape along the inner peripheral surface 10a of the resin outer shell 10, but it is of course not limited to this. It may have any shape as long as it can be supported on the mounting surface 9, and may be rectangular, for example.
- the rotor main body 30 has a three-part structure consisting of the outer core 32, the insulating member 33, and the inner core 34.
- the outer core 32 the insulating member 33, and the inner core 34.
- it is not limited to this, and may be composed of a single core member. good too.
- the rotor 3 is not limited to the surface magnet type as in the embodiment, but may be an embedded magnet type in which a plurality of magnet embedding holes for embedding permanent magnets are formed in the rotor main body 30 (rotor core). good too.
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Abstract
Description
図1は、第1の実施形態に係る電動機1の断面図である。本実施形態の電動機1は、例えば、空気調和機の室内機に搭載される送風ファンの回転駆動源に用いられる。
電動機1は、固定子鉄心21と、回転子3と、樹脂外郭10と、第1の軸受71と、第2の軸受81と、ヒートシンク4と、回路基板5とを備えている。
回転子3は、回転シャフト6に固定され、固定子鉄心21の内径側に配置される。
樹脂外郭10は、回転シャフト6の軸心Cに平行な方向(以下、軸方向ともいう)の一端に開口端部101を有する円筒形状である。
ヒートシンク4は、樹脂外郭10の開口端部101を覆うように配置される。
回路基板5は、樹脂外郭10とヒートシンク4とで覆われた内部空間に配置される。
回転子3は、環状の永久磁石部31と、回転子本体30とを有する。回転子本体30は、外周面と、内周面とを有する。回転子本体30の外周面には、永久磁石部31が固定される。回転子本体の内周面には、回転シャフト6が固定される。これにより、回転子本体30と一体となって回転シャフト6が回転駆動する。
内周側鉄心34は、複数枚の電磁鋼板等の軟磁性材料からなる板の積層体である。内周側鉄心34の中心には、回転シャフト6が圧入やカシメなどによって固着されている。
固定子2は、円筒形状のヨーク部と同ヨーク部から内径側に延びる複数のティース部を有した固定子鉄心21と、ティース部に巻回された巻線(コイル)22と、を備えている。固定子鉄心21は、例えば複数枚の電磁鋼板等の軟磁性材料からなる板の積層体である。この固定子2(固定子鉄心21)の外周面は、樹脂外郭10で覆われている(図1参照)。固定子2は、回転子3の永久磁石部31が固定子2の固定子鉄心21に径方向に空隙(磁気ギャップ)を介して対向するように配置されている。
樹脂外郭10は、絶縁性の樹脂材料で形成される。図2は、電動機1における樹脂外郭10の斜視図であり、図2に示すように、軸方向の一端側(本実施形態では回転シャフト6の反出力端部61側)に開口端部101を有する中空円筒状に形成される。ここで、反出力端部61とは、回転シャフト6の出力端部62とは反対側の端部である。出力端部62とは、電動機1の負荷側(負荷に接続される側)の端部である。
上述のように、樹脂外郭10は、固定子2と一体成形される。樹脂外郭10を形成する樹脂材料は特に限定されず、例えばBMC(Bulk Molding Compound:不飽和ポリエステル樹脂)樹脂で形成される。
回路基板5は、配線基板50と、配線基板50の表面(回転シャフト6の反出力端部61側の面)に搭載された通電により発熱する電子部品51とを含む。回路基板5は、概ね円板形状であり、回路基板5の周縁部は、載置面9に支持され、例えば、接着、粘着、ネジ締結、はんだ付け等によって固定される。なお、回路基板5の周縁部に位置決め用の凸部を、そして樹脂外郭10の内周面10aに上記凸部と係合する位置決め用の凹部をそれぞれ設けてもよく、これにより回路基板5を周方向に位置決めした状態で載置面9に固定することができる。
また、樹脂外郭10の内周面10aに、回路基板5を収容する位置決め用の凹部104を部分的に設けてもよく、これによっても回路基板5を周方向に位置決めした状態で載置面9に固定することができる。
また、図2に示されるコイル22の端部221は、回路基板5に電気的に接続されるように形成され、回路基板5は、複数の位置決めピン9cにより載置面9上に位置決めされるとともに、回路基板5とコイルの端部221とのはんだ付けにより、載置面9上に固定される。
図1に示すように、第1の軸受71は、外輪711、内輪712、複数のボール713等を有するボールベアリングである。第2の軸受81は、外輪811、内輪812、ボール813等を有するボールベアリングである。
ヒートシンク4は、第1の軸受収容部41と、円板部42と、環状突出部43と、突起部44とを有する。ヒートシンク4は、樹脂外郭10の開口端部101に取り付けられ、固定される。ヒートシンク4は、アルミニウム等の熱伝導性に優れた金属材料で形成される。ヒートシンク4は、円板部42と、環状突出部43と、突起部44とがそれぞれ一体に成形される。ヒートシンク4は例えば、ダイカスト(鋳造)によって成型される。
以下、各部の詳細について説明する。
第1の軸受収容部41は、第1の軸受71を収容する。第1の軸受収容部41は、軸心Cを中心とする一端側が塞がれた円筒形状を有し、第1の軸受71を収容する。第1の軸受収容部41は、円板部42の中心孔40の内周縁部401の上面423側に形成されている。
円板部42は、軸方向位置決め部420を有する。図3(A)に示すように、軸方向位置決め部420は、円板部42の外周縁部422の背面424側に形成される。本実施形態において、外周縁部422とは、円板部42の、環状突出部43よりも外径側の領域である。
上述したように、環状突出部43は、径方向位置決め部430を有する。本実施形態では径方向位置決め部430は、樹脂外郭10の開口端部101の内周面に当接する環状突出部43の外周面に形成されている。すなわち、図1、図2、図3(A)に示すように、径方向位置決め部430は、樹脂外郭10の内周面10aに嵌合する円筒面を有する。
上述したように、突起部44は、環状突出部43よりも内径側に配置され、円板部42の背面424から軸方向における回路基板5側に向かって突出する。
図4は、本実施形態における、ヒートシンク4の加工工程の一部を示す模式図である。本実施形態では、ダイカスト(鋳造)により形成されるヒートシンク4の軸心C方向の寸法精度を高めるため、後加工として、ヒートシンク4の軸方向位置決め部420と対向面441とが平面となるように旋盤で加工している。ヒートシンク4は、まず、鋳造(ダイカスト)工程において、図示しない金型に流し込まれた金属(合金)が固まることによって、その概形が鋳物として形成される。その後、ヒートシンク4は、旋盤加工により、径方向位置決め部430、軸方向位置決め部420、および対向面441のそれぞれが加工される。本実施形態では、ヒートシンク4を、普通旋盤(汎用旋盤)によって、径方向位置決め部430、軸方向位置決め部420、対向面441の順番で加工する場合を例示する。
また、図4(B)に示すように、バイトBを軸心Cと垂直な径方向に移動させることで、環状突出部43の外径側に形成された軸方向位置決め部420は、その軸方向寸法が高い精度で形成される。このとき、軸方向位置決め部420が、上述の環状突出部43よりも外周側に形成されていることで、旋盤に対して軸心Cの外径側からバイトBを近づける場合に、環状突出部43が加工の邪魔にならない。そのため、ヒートシンク4がダイカスト(鋳造)により成型された場合であっても、樹脂外郭10(不図示)とヒートシンク4を組み合わせる際、ヒートシンク4の軸方向位置決め部420と樹脂外郭10の開口端部101(不図示)とを、高い寸法精度で当接させることができる。
上述のように、本実施形態のヒートシンク4は、樹脂外郭10の開口端部101と当接する軸方向位置決め部420と、樹脂外郭10の開口端部101の内周面に当接する径方向位置決め部430とを有する。このため、樹脂外郭10へのヒートシンク4の組み付けと同時に、樹脂外郭10に対してヒートシンク4が軸方向および径方向の双方向に位置決めされる。
図5は、本発明の第2の実施形態に係る電動機1Aの要部の概略断面図である。以下、第1の実施形態と異なる構成について主に説明し、第1の実施形態と同様の構成については同様の符号を付しその説明を省略または簡略化する。
以上の各本実施形態では、ヒートシンク4,4Aの突起部44が一つの場合を記載したが勿論これに限られず、電子部品等に合わせて複数設けられてもよい。例えば、異なる高さの電子部品が2つ以上ある場合、それぞれの高さに合わせた突起部を複数設けてもよいし、2つの同じ高さの電子部品が近くにある場合、一つの突起部で2つの電子部品に突出するように形成されてもよい。
4,4A…ヒートシンク
10…樹脂外郭
101…開口端部
2…固定子
21…固定子鉄心
3…回転子
31…永久磁石部
32…外周側鉄心
33…絶縁部材
34…内周側鉄心
4…ヒートシンク
41…第1の軸受収容部
42,42A…円板部
43,43A…環状突出部
44…突起部
420,420A…軸方向位置決め部
430,430A…環状突出部
5…回路基板
51…電子部品
6…回転シャフト
C…軸心
Claims (8)
- 軸方向の一端側に開口端部を有する円筒状の樹脂外郭と、前記樹脂外郭と一体的に形成された固定子鉄心と、前記固定子鉄心の内径側に配置された回転子と、前記樹脂外郭の前記開口端部を覆うヒートシンクと、前記樹脂外郭と前記ヒートシンクとで覆われた内部空間に配置される回路基板と、を備え、
前記ヒートシンクは、
円板部と、
前記円板部から前記軸方向の前記回路基板側に突出する環状突出部と、
前記環状突出部よりも前記樹脂外郭の内径側に配置され、前記円板部から前記回路基板側に向かって突出し前記回路基板と熱的に接触する突起部と、
を有し、
前記円板部は、前記樹脂外郭の前記開口端部と当接する軸方向位置決め部を有し、
前記環状突出部は、前記樹脂外郭の内周面または外周面に当接する径方向位置決め部を有する
電動機。 - 請求項1に記載の電動機であって、
前記径方向位置決め部は、前記環状突出部の外周面に形成されるとともに、前記樹脂外郭の内周面に当接する
電動機。 - 請求項1又は2に記載の電動機であって、
前記軸方向位置決め部は、前記円板部の前記環状突出部より外周側に位置する
電動機。 - 請求項1~3のいずれか1つに記載の電動機であって、
前記突起部の前記軸方向への突出高さは、前記環状突出部の突出高さよりも大きい
電動機。 - 請求項1~4のいずれか1つに記載の電動機であって、
前記回路基板は、通電により発熱する電子部品を含み、
前記突起部は、前記電子部品に対向する対向面を有する
電動機。 - 請求項1~5のいずれか1つに記載の電動機であって、
前記樹脂外郭は、前記回路基板が固定される載置面を有する
電動機。 - 請求項1~6のいずれか1つに記載の電動機であって、
前記電動機は、前記回転子が固定される回転シャフトと、前記回転シャフトを回転自在に支持する第1の軸受とを有し、
前記ヒートシンクは、前記第1の軸受を収容する軸受収容部をさらに有する
電動機。 - 請求項2~4のいずれか1つに記載の電動機の製造方法であって、
前記ヒートシンクは、ダイカスト成型によって形成される
電動機の製造方法。
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JP2007037262A (ja) * | 2005-07-26 | 2007-02-08 | Mitsubishi Electric Corp | インバータ一体型回転電機 |
JP2009131127A (ja) * | 2007-11-28 | 2009-06-11 | Panasonic Corp | ブラシレスモータ |
WO2020217790A1 (ja) * | 2019-04-24 | 2020-10-29 | 株式会社富士通ゼネラル | ステータ及び電動機 |
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JP2007037262A (ja) * | 2005-07-26 | 2007-02-08 | Mitsubishi Electric Corp | インバータ一体型回転電機 |
JP2009131127A (ja) * | 2007-11-28 | 2009-06-11 | Panasonic Corp | ブラシレスモータ |
WO2020217790A1 (ja) * | 2019-04-24 | 2020-10-29 | 株式会社富士通ゼネラル | ステータ及び電動機 |
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