JP6914533B2 - Resin molding method, jig, and resin molding equipment - Google Patents

Description

The present invention relates to a resin molding method, a jig, and a resin molding device. Specifically, a resin molding method for resin-molding a stator assembly in which a winding is wound around an iron core, and a jig used to carry out the method. And the resin molding device.

Generally, a rotary electric machine such as a motor is composed of a stator and a rotor provided in the stator. The stator is provided in the stator by winding the winding around an annular iron core, and when a current flows through the winding, a magnetic force is generated and the stator and rotor are attracted or repelled by each other. The rotor is rotated.

In a stator (referred to as a "stator assembly") in which windings are wound around an iron core, resin molding is performed to ensure insulation, heat dissipation, strength, and the like. As an apparatus for performing resin molding, for example, the apparatus described in Patent Document 1 is provided. This device includes a vacuum chamber, a rotary table that rotates in the vacuum chamber, a double cylinder that is supported by the rotary table and into which the stator assembly before resin molding is inserted, and the stator assembly from above. It is equipped with a feeder that supplies the mold liquid. By rotating the stator assembly in a vacuum chamber and dropping the mold liquid from the feeder onto the rotating stator assembly, the mold liquid is supplied over the entire circumference of the stator assembly.

Japanese Unexamined Patent Publication No. 2005-218292

However, in the apparatus described in Patent Document 1, the stator assembly is rotated by using a turntable in order to evenly supply the molding liquid made of molten resin to the annular stator assembly over the entire circumference. The device became large and the configuration of the device was complicated.
The present invention has been made in view of the above problems, and provides a resin molding method, a jig, and a resin molding device capable of supplying molten resin to the entire circumference of an annular stator assembly with a simple configuration. The challenge is to do.

The resin molding method according to the present invention resin molds a jig assembly in which windings are wound around an iron core, and the tip is tapered to one end of a columnar main body in a space surrounded by the iron core. A step of inserting a jig having a shaped guide portion to project the guide portion from one end side of the iron core, and a step of thermally expanding the main body portion of the jig in the radial direction so that the outer peripheral surface of the main body portion becomes the iron core. The process of closing the space surrounded by the iron core by the jig in close contact with the iron core, and the molten resin is dropped on the jig with the guide portion facing upward under a vacuum state, and the molten resin is allowed to flow down along the guide portion. It includes a step of impregnating the jig assembly and a step of curing the resin impregnated in the jig assembly.

The guide part of the jig has a tapered shape at the tip of the columnar shape, and when the molten resin hangs down from the upper position of the guide part of the jig to the tip of the guide part, the molten resin is substantially even on the entire outer peripheral surface of the guide part. It flows down while spreading to. Since the inner space surrounded by the iron core of the stator assembly is closed by the thermal expansion of the main body of the jig, the molten resin reaches the upper end surface of the stator assembly and the stator assembly is formed from the upper end surface. Is impregnated with resin. As described above, the molten resin can be completely supplied over the entire circumference of the stator assembly with a simple structure in which the tip of the guide portion of the jig is tapered.

The above object of the present invention is also achieved by a jig used for resin molding a stator assembly in which a winding is wound around an iron core. The jig is made of a synthetic resin that thermally expands by heating, and has a columnar main body having a diameter that can be inserted into and removed from the space surrounded by the iron core and a length that fits into the space surrounded by the iron core. A guide portion having a tapered tip that protrudes from the space when the main body portion is inserted into the space surrounded by the iron core is integrally formed at one end of the main body portion.

According to the above configuration, the tip of the guide portion of the jig is tapered. Therefore, when the molten resin is dropped from the upper position of the guide portion of the jig to the tip of the guide portion, the entire outer peripheral surface of the guide portion is covered. The molten resin flows down while spreading substantially evenly, and is impregnated up to the upper end surface of the stator assembly. As described above, the molten resin can be completely supplied over the entire circumference of the stator assembly with a simple structure in which the tip of the guide portion of the jig is tapered.

In one embodiment, the main body is provided with a base at the other end, and the base is made of a synthetic resin that fits into the inner peripheral surface of the end of the casing of the iron core and thermally expands by heating. It is equipped with a ring-shaped ridge.

In a preferred embodiment, an annular member provided on one end side of the casing of the iron core is further provided, and the annular member is made of a synthetic resin that thermally expands by heating, and has a tubular wall portion along the inner peripheral surface of the casing. , A flange portion that covers the end face of the casing is integrally provided.

The above object of the present invention is also achieved by a device for resin-molding a stator assembly in which a winding is wound around an iron core. The device is made of a synthetic resin that thermally expands by heating, and includes a columnar main body having a diameter that can be inserted into and removed from the space surrounded by the iron core and a length that fits into the space surrounded by the iron core. A jig having a guide portion having a tapered tip protruding from the space when the main body portion is inserted into a space surrounded by the iron core is integrally formed at one end of the main body portion. A preheating unit that has a heating means for heating the stator assembly in which the jig is inserted in a space surrounded by an iron core and thermally expands the jig, and the jig is inserted in a space surrounded by the iron core. The stator assembly is placed under a vacuum state, and the stator assembly is impregnated with a molten resin for resin-molding the stator assembly. A vacuum processing unit including a nozzle for dropping the molten resin onto the jig, and a curing unit having a heating means for heating the resin impregnated in the stator assembly and curing the resin.

According to the above configuration, the guide portion of the jig has a columnar tip having a tapered shape, and when the molten resin is hung down on the tip of the guide portion by a nozzle, the molten resin is substantially even on the entire outer peripheral surface of the guide portion. It flows down while spreading to the upper end surface of the stator assembly and is impregnated. As described above, the molten resin can be completely supplied over the entire circumference of the stator assembly with a simple structure in which the tip of the guide portion of the jig is tapered.

According to the present invention, the molten resin can be completely supplied over the entire circumference of the stator assembly with a simple structure in which the tip of the guide portion of the jig is tapered.

It is sectional drawing which shows the state which the jig which concerns on one Embodiment of this invention is inserted into a stator assembly. It is a top view which shows the state which the jig is inserted into the stator assembly. It is a front view which shows the overall schematic structure of the resin molding apparatus which concerns on one Embodiment of this invention. It is a top view of the work plate. It is explanatory drawing which shows the schematic structure of the whole vacuum unit. It is a flowchart which shows the procedure of resin molding the stator assembly.

Embodiments of the present invention will be described with reference to the drawings.
The resin molding method of the present invention is carried out by using the jig 10 shown in FIGS. 1 and 2, and is a stator set in which a winding 103 is wound around an annular iron core 102 surrounded by a casing 101. The solid 100 is resin-molded. The jig 10 has a base portion 11 mounted on the work plate 110 and a columnar main body portion attached to the base portion 11 and inserted into the inner space S1 surrounded by the iron core 102 of the stator assembly 100. 12 and an annular member 13 provided at the upper end of the casing 101 of the stator assembly 100. The stator assembly 100 is supported by the main body 12 of the jig 10 so that the shaft core faces in the vertical direction.

The base portion 11, the main body portion 12, and the annular member 13 of the jig 10 are each made of a synthetic resin that thermally expands by heating, and are also represented as high-density polyethylene (also referred to as “HDPE” or “PE-HD”), for example. ) Is used.

The base portion 11 is a plate-shaped member having a rectangular planar shape, and a recess 14 into which the main body portion 12 is fitted is formed in the central portion. Screw holes 14a for passing screws 15 for screwing the main body portion 12 to the base portion 11 and supporting the screw heads are formed at two locations on the bottom surface of the recess 14. An annular ridge 16 is integrally formed on the upper surface of the base portion 11. The ridge 16 fits into the inner peripheral surface 101a of the lower end portion of the casing 101 with the stator assembly 100 inserted in the main body portion 12. The four corners of the base portion 11 are screwed to the work plate 110 by screws 16.

The main body 12 has a diameter that can be inserted into and removed from the inner space S1 surrounded by the iron core 102 of the stator assembly 100 and a length that fits into the space S1. At the upper end of the main body 12, when the main body 12 is inserted into the inner space S1 surrounded by the iron core 102, a guide portion 17 having a tapered tip that protrudes upward from the space S1 is integrally formed. .. The guide portion 17 has a conical shape that is convex upward, but the tip may be sharp, the tip may be rounded as in the present embodiment, and the tip may be flat. .. Further, as long as the molten resin can flow down substantially uniformly in the circumferential direction of the stator assembly 100, it may have a pyramid shape.

At the bottom of the main body 12, two screw holes 12a into which screws 15 for screwing to the base 11 are screwed are formed at positions corresponding to through holes 14a of the base 11.
In the above embodiment, the main body portion 12 and the base portion 11 are formed as separate bodies, but they may be integrally formed by injection molding or the like.

The annular member 13 is fixed at an upper position of the base end portion 11 by three screw members 20 having a hexagonal spacer 20a in the middle and three nuts 21. As shown in FIG. 2, the annular member 13 is a rectangular plate-shaped member having substantially the same outer shape as the base portion 11, and has a chamfered corner portion 13a. The annular member 13 integrally includes a tubular wall portion 18 along the inner peripheral surface 101b of the upper end portion of the casing 101 and a flange portion 19 that covers the end surface of the casing 101. The hollow portion 13b surrounded by the tubular wall portion 18 has a circular planar shape. The annular member 13 has a screw member 20 at a height position where the lower end of the tubular wall portion 18 is above the winding 103, and the guide portion 17 of the main body portion 12 protrudes upward through the hollow portion 13b. It is supported by the spacer 20a. The flange portion 19 is formed with three through holes 19a through which the upper end portion of the screw member 20 penetrates. The lower surface of the portion 19 is pressed against the upper end surface of the spacer 20a and fixed.

The molten resin is guided to the upper end surface of the stator assembly 100 and impregnated in a state where the main body 12 is tightly fitted in the inner space S1 surrounded by the iron core 102 of the stator assembly 100. The resin layer R is formed in the annular lower space S2 surrounded by the base portion 11, the iron core 102, the main body portion 12, the casing 101, and the ridges 16. Further, although not shown, a resin layer is formed between the winding 103 and the winding 103, between the winding 103 and the iron core 102, and between the iron core 102 and the iron core 102. Further, the resin layer R is formed in the annular upper space S3 above the upper end of the iron core 102 and below the tubular wall portion 18 of the annular member 13.

FIG. 3 shows the resin molding apparatus 30 of the present invention, which includes the jig 10 of the above embodiment mounted on the work plate 110, the preheating unit 31, the vacuum processing unit 32, and the curing unit 33. ing.

As shown in FIG. 4, a plurality of jigs 10 are attached to the work plate 110. In the present embodiment, the jigs 10 are mounted on the work plate 110 in 3 rows and 3 columns, but the number of jigs 10 is not limited.

The work plate 110 is assembled by the following procedure. First, the main body portion 12 is attached to the base portion 11 of the jig 10. Next, the base portion 11 of the jig 10 is screwed to the work plate 110. Then, the stator assembly 100 is inserted into the jig 10. At this time, the main body 12 of the jig 10 is inserted into the inner space S1 surrounded by the iron core 102 so that the ridge 16 fits into the inner peripheral surface 101a of the end portion of the casing 101 of the Teishi assembly 100. Next, the annular member 13 is attached at an upper position of the base portion 11 so that the tubular wall portion 18 is along the inner peripheral surface 101b of the casing 101.

The preheating unit 31 heats the jig 10 into which the stator assembly 100 is inserted to thermally expand the jig 10, and internally conveys a preheater such as a heater or a warmer and a work plate 110. It includes a transport mechanism (not shown) composed of a chain belt or the like for the purpose. The stator assembly 100 and the jig 10 are heated to an appropriate temperature (for example, 80 degrees) by the preheater while being conveyed in the preheating unit 31 in the direction of arrow A by the transfer mechanism.

The vacuum processing unit 32 is arranged on the downstream side of the preheating unit 31, and the work plate 110 that has passed through the preheating unit 31 is carried in. As shown in FIG. 5, in the vacuum processing unit 32, the stator assembly 100 in which the jig 10 is inserted is placed under a vacuum state, and the molten resin for resin-molding the stator assembly 100 is set as a stator. It is provided with a vacuum processing chamber 34 for performing a process of impregnating the solid 100. The vacuum processing chamber 34 is depressurized by a decompression device such as a vacuum pump (not shown). In the present specification, "vacuum" does not mean an absolute vacuum state, but means a state in a space filled with a gas having a pressure lower than atmospheric pressure.

Inside the vacuum processing chamber 34, for example, an endless belt or the like is formed, and a transport mechanism 35 for transporting the work plate 110 in the transport direction (in the X direction) indicated by the arrow B and a molten resin for hanging on the jig 10. The nozzle 36 and the nozzle moving mechanism 37 for moving the nozzle 36 in the Y direction and the Z direction orthogonal to the transport direction X are provided. The nozzle moving mechanism 37 may be composed of, for example, a linear motor, a ball screw, a nut member, a drive motor, or the like.
By the nozzle moving mechanism 37 and the conveying mechanism 35, the nozzle 36 sequentially moves to the upper position of the jig 10 on the work plate 110 to which the plurality of stator assemblies 100 are attached and stops, and the molten resin is transferred to the jig 10. It hangs down on the guide portion 17 of the main body portion 12.

The curing unit 33 is arranged on the downstream side of the vacuum processing unit 32, and the work plate 110 that has passed through the vacuum processing unit 32 is carried in. The curing unit 33 is for heating and curing the molten resin hung on the stator assembly 100 on the work plate 110, and inside, a preheater such as a heater or a warmer and the work plate 110. Includes a transport mechanism (not shown) composed of a chain belt or the like for transporting the plastic. The work plate 110 carried in from the carry-in port is heated to an appropriate temperature (for example, 120 degrees) by a preheater while being carried in the curing unit 33 in the direction of arrow C by the carrying mechanism, whereby the resin is cured. ..

The operations of the preheating unit 31, the vacuum processing unit 32, and the curing unit 33 of the resin molding device 30 are performed by a control device (not shown).

FIG. 6 shows the resin molding method of the present invention, in which the following steps ST10 to ST13 are sequentially executed.
Step ST10 is a step of attaching the stator assembly 100 to the jig 10 of the work plate 110. Specifically, the main body 12 of the jig 10 attached to the work plate 110 is inserted into the inner space S1 surrounded by the iron core 102 of the stator assembly 100, and the stator assembly 100 is cured of the work plate 110. It is attached to the tool 10, and further, the annular member 13 of the jig 10 is attached to the base portion 11. As a result, the guide portion 17 of the main body portion 12 of the jig 10 protrudes from the annular member 13, and the ridge 16 of the base portion 11 of the jig 10 fits into the inner peripheral surface 101a of the lower end portion of the casing 101, and the annular member 13 The tubular wall portion 18 is in a state along the inner peripheral surface 101b of the casing 101.

Step ST11 is a preheating step of heating the work plate 110 including the jig 10 to which the stator assembly 100 is attached in the preheating unit 31. By the preheating step, the main body 12 of the jig 10 thermally expands in the radial direction, and the outer peripheral surface of the main body 12 comes into close contact with the iron core 102 to close the inner space S1 surrounded by the iron core 102. Further, the ridge 16 of the base portion 11 of the jig 10 thermally expands in the radial direction and comes into close contact with the inner peripheral surface 101a of the lower end portion of the casing 101, and the tubular wall portion 18 of the annular member 13 thermally expands in the radial direction. It is in close contact with the inner peripheral surface 101b of the upper end portion of the casing 101.

In the ST12, in the vacuum processing unit 32, the molten resin is dripped from the nozzle 36 toward the apex of the guide portion 17 of the jig 10 under a vacuum state, and the molten resin is allowed to flow down along the guide portion 17 to form a stator assembly. This is an impregnation step of impregnating 100. Specifically, the transfer mechanism 35 and the nozzle moving mechanism 37 position the nozzle 36 above the tapered tip portion of the guide portion 17 of the jig 10 mounted on the work plate 110. Then, when the molten resin is dripped from the nozzle 36, the molten resin flows down while spreading substantially evenly along the outer peripheral surface of the guide portion 17, reaches the upper end surface of the stator assembly 100, and gradually lowers than the upper end surface. By moving to, the stator assembly 100 is impregnated with resin. At this time, since the main body 12 of the jig 10 blocks the inner space S1 surrounded by the iron core 102, the molten resin does not enter the inner space S1 surrounded by the iron core 102, and the resin is formed on the inner peripheral wall of the iron core 102. Is prevented from adhering.

The molten resin gradually permeates the space between the winding 103 and the winding 103 of the stator assembly 100, between the winding 103 and the iron core 102, and between the iron core 102 and the iron core 102 under a vacuum state. It falls while filling the lower space S2 of the stator assembly 100. Next, molten resin is filled between the winding 103 and the winding 103, between the winding 103 and the iron core 102, and between the iron core 102 and the iron core 102, and fills the upper space S3 of the stator assembly 100. Will be done. At this time, the molten resin flows down while extruding the air retained in the stator assembly 100 upward. Further, the ridge 16 of the base portion 11 of the jig 10 is in close contact with the inner peripheral surface 101a of the lower end portion of the casing 101, and the tubular wall portion 18 of the annular member 13 is in close contact with the inner peripheral surface 101b of the upper end portion of the casing 101. Therefore, it is possible to prevent the resin from adhering to the inner peripheral surface of the casing 101. When the molten resin fills the upper space S3 of the stator assembly 100 with the molten resin, the supply of the molten resin from the nozzle 36 is stopped.

A plurality of stator assemblies 100 attached to the jig 10 are placed on the work plate 110, and the nozzle 36 is sequentially moved to an upper position of the jig 10 by the transport mechanism 35 and the nozzle moving mechanism 37. The stator assembly 100 is impregnated with the molten resin.

ST13 is a curing step of curing the resin impregnated in the stator assembly 100 in the curing unit 33. A resin layer R is formed in the annular lower space S2 and the annular upper space S3, and the winding 103 is formed. A resin layer is also formed between the winding 103 and the winding 103, between the winding 103 and the iron core 102, and between the iron core 102 and the iron core 102.
ST10 to ST13 are executed for each work plate 110, and the stator assembly 100 is resin-molded.

A cooling step for cooling the jig 10 may be provided after the curing step. By cooling the jig 10, the jig 10 contracts, and the jig 10 can be easily pulled out from the inner space S1 surrounded by the iron core 102.

In this way, with a simple structure in which the tip of the guide portion 17 of the jig 10 is tapered, the molten resin flows down while spreading evenly along the outer peripheral surface of the guide portion 17, so that the molten resin is a stator. It can be supplied without exception over the entire circumference of the assembly 100.

Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

100 Stator assembly 101 Casing 102 Iron core 103 Winding 10 Jig 11 Base part 12 Main body part 13 Circular member 16 Protrusion 17 Guide part 18 Cylinder wall part 19 Flange part 30 Resin molding device 31 Preheating unit 32 Vacuum processing unit 33 Curing unit 34 Vacuum processing chamber 36 Nozzle S1 Space surrounded by iron core

Claims (5)

This is a method of resin-molding a stator assembly in which windings are wound around an iron core.
A step of inserting a jig having a guide portion having a tapered tip at one end of a columnar main body into a space surrounded by the iron core to project the guide portion from one end side of the iron core.
A step of closing the space surrounded by the iron core by the jig by thermally expanding the main body portion of the jig in the radial direction and bringing the outer peripheral surface of the main body portion into close contact with the iron core.
A step of dropping a molten resin on the tip of the guide portion of the jig with the guide portion facing upward under a vacuum state and allowing the molten resin to flow down along the guide portion to impregnate the stator assembly.
A resin molding method including a step of curing a resin impregnated in the stator assembly. A jig used to resin mold a stator assembly in which windings are wound around an iron core.
The main body is made of a synthetic resin that expands thermally by heating, and has a columnar main body having a diameter that can be inserted into and removed from the space surrounded by the iron core and a length that fits into the space surrounded by the iron core. At one end of the portion, when the main body portion is inserted into the space surrounded by the iron core, a guide portion is integrally formed in which the tip protruding from the space has a tapered shape and the molten resin is hung on the tip. Jig. The main body has a base at the other end, and the base has an annular ridge made of a synthetic resin that fits into the inner peripheral surface of the end of the casing of the iron core and thermally expands by heating. The jig according to claim 2, further comprising. An annular member provided on one end side of the casing of the iron core is further provided.
2. The described jig. A device for resin-molding a stator assembly in which windings are wound around an iron core.
The main body is made of a synthetic resin that thermally expands by heating, and has a columnar main body having a diameter that can be inserted into and removed from the space surrounded by the iron core and a length that fits into the space surrounded by the iron core. At one end of the portion, a jig is integrally formed with a guide portion having a tapered tip that protrudes from the space when the main body portion is inserted into the space surrounded by the iron core.
A preheating unit having a heating means for heating the stator assembly in which the jig is inserted in a space surrounded by the iron core and thermally expanding the jig, and a preheating unit.
A process of placing the stator assembly in which the jig is inserted in a space surrounded by the iron core under a vacuum state and impregnating the stator assembly with molten resin for resin-molding the stator assembly. A vacuum processing unit for performing the vacuum processing chamber, a vacuum processing unit installed in the vacuum processing chamber, and a nozzle for dropping the molten resin onto the tip of the guide portion of the jig.
A resin molding apparatus including a heating means for heating the resin impregnated in the stator assembly, and a curing unit for curing the resin.

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