JPH06122133A - Method for molding resin package of rotor - Google Patents

Abstract

(57) [Summary] [Purpose] To prevent the resin from filling the slits of the flat commutator. [Structure] A jig 20 is mounted on the outer periphery of a protective member 18 constituting a segment 11 of a flat commutator 3, and each sealing piece 22 of the jig 20 is inserted into each slit 13 of the protective member 18. Then, the rotor 10 having the jig 20 mounted thereon is housed in the cavity 34, and the resin 3 is placed in the cavity 34.
Fill 9. As a result, the resin package 40 is molded around the commutator 3 and the armature core 4 of the rotor 1. As the sealing piece 22 is inserted into the slit 13 when the resin package 40 is molded, the resin 39 can be prevented from entering the slit 13. As a result, it is possible to prevent the brush from being worn by the resin in the slit 13 when the segment 11 is worn. On the other hand, the resin package 40 can protect the commutator 3 and the armature coil 5, and the resistance can be suppressed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technique for manufacturing a rotor having a resin package on the outside of an armature, and more particularly to a method for molding a resin package by filling a cavity containing an armature with resin. For example,
The present invention relates to a technique effectively used for a rotor of an in-tank fuel supply pump integrated motor.

[0002]

2. Description of the Related Art Generally, there is an in-tank type pump installed inside a fuel tank as a pump for supplying fuel to an automobile. Some are soaked in. Then, as a rotor used in this type of motor, an armature core externally mounted on the rotary shaft, an armature coil wound around the armature core, and a commutator to which the armature coil is connected are surrounded by a resin package, Some packages are configured to prevent the armature from being eroded by the fuel and suppress the resistance to the rotating fuel.

Conventionally, such a resin package for a rotor is molded by accommodating a rotor in which a commutator, an armature core and the like are assembled in a cavity, and filling the cavity with resin from a gate.

[0004]

However, in the rotor using the flat commutator, the resin package cannot be molded by the conventional molding method, or cannot be put into practical use even if molded. It was revealed by the present inventor that there is a problem.

That is, in the flat type commutator, a plurality of fan-shaped segments are circularly arranged and fixed to each other through slits on a circular end surface of a boss portion integrally molded in a flat disc shape using resin. There is. And since it is necessary to cover the connection position between the armature coil and the commutator segment with the resin package, the mold position of the resin package is set to a position higher than the slit of the flat commutator, and the resin flows into the slit and becomes the slit. The resin is filled and cured. When the resin hardens in the slit, the flat commutator comes into contact with the brush and wears the surface of the segment, so that the resin protrudes from the surface of the segment and the hardened resin causes wear of the brush.

Therefore, it is conceivable to form a large number of blades in the mold and set the blades and the slits of the commutator in alignment with each other to mold the resin package, but the mold structure becomes complicated. However, there is a problem in workability when the rotor is aligned and set in the molding die or when the rotor is taken out from the molding die on which the resin is stuck.

An object of the present invention is to provide a resin molding method for a rotor, which can prevent resin from being filled in the insulating slit formed in the flat commutator.

[0008]

A rotor resin molding method according to the present invention comprises a commutator fixed to one end of a rotary shaft and an armature core fixed to an intermediate part of the rotor shaft. , The armature coil wound around this core, and the commutator has a plurality of segments arranged at equal intervals in the circumferential direction on the axially one end face of the disk-shaped integrally molded boss portion made of resin. And a resin package molding method for a rotor that is insulated and fixed to each other through a slit, in a circular ring shape having an inner diameter larger than the commutator outer diameter, and A jig provided with a plurality of sealing pieces which are provided inward in the radial direction at intervals around the circumference and are formed so as to be inserted in the slits, and the commutator is provided. The jig is attached to the outer periphery so that the main body is concentric with the commutator, and the seal pieces are inserted into and fitted into the slits, respectively, and in this state, the rotor is the cavity of the mold. It is characterized in that it is housed inside and a resin package is molded on the outer periphery of the commutator and the outer periphery of the armature core and the armature coil.

[0009]

In the above-mentioned means, the jig is attached to the outer periphery of the commutator and the sealing pieces of the jig are inserted into the slits before the rotor is housed in the cavity of the mold. It

After that, the rotor on which the jig is mounted is housed in the cavity of the molding die, and in this state, the cavity is filled with resin. The resin filled in the cavity forms a resin package on the outer periphery of the commutator and the armature core of the rotor, and the resin package covers the commutator and the armature core. Since the sealing piece of the jig is inserted into the slit of the commutator at the time of filling the resin, the resin is prevented from being filled in the slit of the commutator.

[0011]

FIG. 1 is an exploded perspective view, partly omitted, showing the relationship between a rotor and a molding apparatus used in a resin package molding method for a rotor according to an embodiment of the present invention, and FIG. It is a side sectional view shown. 3A and 3B are a partially cut side view and a partially omitted front view showing the rotor after molding, and FIG. 4 is an enlarged partially omitted side sectional view thereof. FIG. 5 is an enlarged perspective view, partly omitted, showing the commutator before molding.

In this embodiment, the method for molding a resin package for a rotor according to the present invention is applied to mold a resin package for a rotor in an in-tank type fuel supply pump integrated motor. And the molding apparatus shown in FIG. 2 is used.

Here, as shown in FIGS. 2 to 5, a rotor 1 on which a resin package is molded has a rotor shaft 2 which substantially constitutes a motor shaft, and a rotor shaft 2 which is fixed to the rotor shaft 2. The commutator 3 is mounted on the rotor shaft 2, an armature core 4 is fixedly mounted on the rotor shaft 2 adjacent to the commutator 3, and an armature coil 5 wound around the armature core 4 and connected to the commutator.

The commutator 3 has a flat commutator structure, and is made of a resin having an insulating property and formed into a thick disk-like boss portion 10. Each boss portion 10 is formed into a substantially fan-like shape. A plurality of sets of segments 11 radially arranged at substantially equal intervals on the surface of 10 and riser pieces 12 integrated with each of the segments 11.
And a slit 13 for making adjacent segments 11 electrically insulated from each other. A shaft mounting port 14 is concentrically opened in the boss portion 10, and one end of the rotor shaft 2 is inserted into the shaft mounting port 14 to fix the commutator 3 to the rotor shaft 2. In this state,
The commutator 3 is adjacent to the armature core 4.

Each segment 11 has a base material 15 made of copper or its alloy and a protective member 1 made of carbon fired.
8 and a solder layer 19 that secures the protective member 18 to the base material 15. The base material 15 is disposed on an end surface (hereinafter, referred to as an upper surface) of the boss portion 10 opposite to the armature core 4 and is insert-molded on the boss portion 10. The base material 15 is securely fixed to the boss portion 10 by embedding the claws 16 projecting integrally with the base material 15 in the boss portion 10.

The riser piece 12 has a substantially U-shaped cross section, and after the end of the armature coil 5 of the armature core 4 is wound around the U-shaped folded portion, it is welded by fusing treatment. By doing so, the armature coil 5 is electrically connected to the riser piece 12.

On the upper surface of the base material 15, a protective member 18 formed by firing carbon into a substantially fan shape is fixed by a solder layer 19 made of a solder material as an electrically conductive and heat-melting adhesive. Therefore, the protection member 18
Is in a state of being mechanically and electrically connected to the base material 15. Then, the upper surface of the protective member 18 is brought into sliding contact with a brush (not shown), so that the solder layer 19 and the base material 1 are formed.
5, the armature coil 5 is energized via the riser piece 12.

Each segment 11 is electrically separated by a slit 13 cut between the adjacent segments 11, 11, but a plurality of fan-shaped segments 11 are formed in advance by slits 13. It may be placed in a circular ring shape and insert-molded in the boss portion 10.

In this embodiment, a jig 20 for forming assistance, which is mounted on the rotor 1 and accommodated in the cavity of the forming die, is prepared in advance. The jig 20 includes a main body 21, and the main body 21 is formed in a circular ring shape having an inner diameter larger than that of the protective member 18 so as to maintain a gap for a resin passage between the side surface of the protective member 18. Further, the outer diameter is formed larger than the outer diameter of the armature core 4. A seal piece 2 that can be fitted to each slit 13 is provided on the inner circumference of the main body 21.
The same number of 2 pieces are radially provided at the same pitch as each slit 13. Then, each seal piece 22 is attached to each slit 1
The jig 20 is mounted on the outer periphery of the commutator 3 by being inserted into each of the three.

Molding device 3 shown in FIGS. 1 and 2.
1 includes an upper die 32 and a lower die 33 which are configured to be mold-fittable with each other, and a pair of upper and lower cavity recesses 34a and 34b are provided on a mating surface of the upper die 32 and the lower die 33. Together, they are respectively recessed to form a cavity 34 for molding the resin package of the rotor.

On one side of the cavity recesses 34a, 34b on the mating surfaces of the upper and lower molds 32, 33, a pair of upper and lower recesses 35a, 35b cooperate with each other to hold the protruding end of the rotor shaft 2. The holders 35 are respectively submerged. Similarly, on the other end side, a pair of upper and lower recesses 36a, 36b and 37a, 37b cooperate with each other, and a holding portion 36 for holding the commutator 3,
The holders 37 for holding the jigs 20 are respectively submerged so as to constitute the holders 37.

A gate 38 is provided on the mating surface of the lower mold 33.
Are opened so as to communicate with the lower cavity recess 34b. The gate 38 is connected to a filling resin supply source (not shown) such as an injection molding machine.

Next, a method of molding the resin package of the rotor using the molding apparatus having the above-mentioned structure will be described.

First, the jig 20 is set on the rotor 1 having the armature core 4 having the commutator 3 and the coil 5 wound on the rotor shaft 2 as an exterior.

After that, the rotor 1 on which the jig 20 is mounted
However, in the lower mold 33, the rotor shaft 2 at both ends thereof has the concave portion 35b,
The jig 20 is held in the recesses 37b, and the jig 20 is held in the recesses 37b, and the commutator 3, the armature core 4 and the like at the center thereof are set in the cavity recesses 34b.

Subsequently, when the upper die 32 is aligned with the lower die 33 and clamped, the commutator 3 and the armature 4 are accommodated in the cavity 34 in a properly positioned state.

Next, as shown in FIG. 2, when a desired resin 39 such as an epoxy resin is fluidized from a resin supply source and is pumped to the gate 38, the resin 39 is caved from the gate 38. The tea 34 is sequentially filled.

After the completion of filling, when the resin 39 coins, a resin package 40 is formed around the commutator 3 and the armature core 4 so as to surround them. Next, the upper mold 32 and the lower mold 33 are opened, and the packaged rotor 1 as a molded product is released from the cavity 34.

After that, the molding portion side of the gate 38 is cut off, and the jig 20 has its armature core 4 side end surface placed on an annular base, and then the rotor shaft 2 is pushed to rotate the rotor 1.
And separated. Then, the molded resin package 40
When the surface of the above is ground, a rotor for a motor having a smooth surface, extremely low resistance, and gasoline resistance can be obtained.

As described above, in this embodiment, the jig 20 is attached to the protective member 18 of the commutator 3 before the resin package is molded on the rotor, and the jig 20 is sealed. Since the cavity 39 is filled with the resin 39 with the piece 22 mounted in each slit 13, the resin 39 is filled with
It is possible to prevent the resin 39 from being filled in the slit 13. In addition, the mold structure can be simplified,
Workability can be improved and cost can be reduced.

As a result, it is possible to prevent the brush from being abraded by the resin filled and cured in the slit 13 after long-term use. On the other hand, since the commutator 3 and the armature coil 5 are covered with the resin package 40, the resin package 40 can prevent erosion of the commutator 3 and the armature coil 5, and can suppress the resistance to the rotating fuel. it can.

[0032]

As described above, according to the present invention,
Prior to molding the resin package on the rotor, mount a jig on the outer circumference of the commutator, and with the sealing pieces of this jig sealing each slit, mold the resin package on the outer circumference of the commutator and armature core. With this configuration, it is possible to prevent the resin from filling the slits of the commutator and improve workability without complicating the mold.

[Brief description of drawings]

FIG. 1 is a partially omitted exploded perspective view showing a relationship between a rotor and a molding device used in a resin package molding method for a rotor according to an embodiment of the present invention.

FIG. 2 is a side sectional view showing the molding state.

3A and 3B are views showing the rotor after molding, in which FIG. 3A is a partially cut side view and FIG. 3B is a partially omitted front view.

FIG. 4 is a side cross-sectional view showing an enlarged part of which is omitted.

FIG. 5 is an enlarged partially omitted perspective view showing a commutator before molding.

[Explanation of symbols]

1 ... Rotor, 2 ... Rotor shaft, 3 ... Commutator, 4 ... Armature core, 5 ... Armature coil, 10 ... Boss part, 11 ... Segment, 12 ... Riser piece, 13 ... Slit, 14 ... Rotor shaft mounting port , 15 ... Base material, 16 ... Nail, 1
7 ... Solder layer, 18 ... Protective member, 19 ... Solder layer, 20
... Molding auxiliary jig, 21 ... Main body, 22 ... Sealing piece, 31
... Molding device, 32 ... Upper mold, 33 ... Lower mold, 34 ... Cavities, 34a, 34b ... Recesses, 35a, 35b, 36
a, 36b, 37a, 37b ... Recessed portion, 38 ... Gate, 3
9 ... Resin, 40 ... Resin package.

Claims (1)

[Claims] 1. A commutator fixed to one end of a rotary shaft, an armature core fixed to an intermediate part of a rotor shaft, and an armature coil wound around the core. , The commutator has a plurality of segments arranged at equal intervals in the circumferential direction on one axial end surface of a boss portion integrally molded in a disc shape using resin, and is insulated and fixed to each other through slits. In a resin package molding method for a rotor, a main body formed into a circular ring shape having an inner diameter larger than the outer diameter of the commutator, and a radially inward projection with a circumferential interval at the inner circumference of the main body. A jig provided with a plurality of sealing pieces formed so as to be inserted into the slit is prepared, the jig is provided on the outer periphery of the commutator, and the main body is concentric with the commutator. In so that, and each seal segment is fitted are respectively inserted into said slits, in this state, the rotor is accommodated in the cavity of the mold, the outer and the armature core of the commutator,
A resin package molding method for a rotor, characterized in that a resin package is molded on the outer periphery of the armature coil.