Spirally wound laminated core for a rotary electric machine, method for manufacturing spirally wound laminated core of a rotary electric machine, and rotary electric machine

Patent metadata

Field	Value
Publication number	US-11303167-B2
Application number	US-201816482532-A
Country	US
Kind code	B2
Filing date	Feb 22, 2018
Priority date	Mar 6, 2017
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

A laminated core of a rotary electric machine having: a first spiral core constituent body layer configured by linking a plurality of metal first core constituent pieces that have a magnet mounting part, the first spiral core constituent body layer being wound in a spiral shape as an integral body; and a second spiral core constituent body layer configured by linking the plurality of first core constituent pieces and a metal second core constituent piece that has a magnet mounting part, the second core constituent piece having a different longitudinal-direction length than do the first core constituent pieces, and the second spiral core constituent body layer being wound in a spiral shape as an integral body. The second spiral core constituent body layer is laminated on the first spiral core constituent body layer in continuation with the first spiral core constituent body layer.

First claim

The invention claimed is:

1. A laminated core for a rotary electric machine, comprising:
a first spiral core forming body layer including a plurality of first core forming pieces, each being made of a metal and having a magnet mounting portion, the plurality of first core forming pieces being continuously formed and to be spirally rolled up as a single continuous body; and
a second spiral core forming body layer including a plurality of the first core forming pieces and at least one second core forming piece, which has a length different from a length of each of the plurality of first core forming pieces in a longitudinal direction of each of the first core forming pieces and the second core forming piece, has the magnet mounting portion, and is made of the metal, the plurality of first core forming pieces and the at least one second core forming piece being continuously formed and to be spirally rolled up as a single continuous body,
wherein the second spiral core forming body layer is formed on the first spiral core forming body layer so as to be continuous with the first spiral core forming body layer,
wherein the at least one second core forming piece is located at a head of the second spiral core forming body layer, and
wherein positions of the magnet mounting portions of the plurality of first core forming pieces and the at least one second core forming piece in the second spiral core forming body layer are shifted from positions of the magnet mounting portions of the plurality of first core forming pieces in the first spiral core forming body layer in a circumferential direction of the laminated core under a state in which the second spiral core forming body layer is formed on the first spiral core forming body layer.

2. The laminated core for a rotary electric machine according to claim 1 , wherein the at least one second core forming piece has the length longer than the length of each of the plurality of first core forming pieces in the longitudinal direction.

3. The laminated core for a rotary electric machine according to claim 1 , wherein the at least one second core forming piece has the length shorter than the length of each of the plurality of first core forming pieces in the longitudinal direction.

4. The laminated core for a rotary electric machine according to claim 1 , wherein a relief hole is formed between adjacent ones of the plurality of first core forming pieces and the at least one second core forming piece.

5. The laminated core for a rotary electric machine according to claim 4 ,
wherein a slit defined by two inclined sides is formed between adjacent ones of the plurality of first core forming pieces and the at least one second core forming pieces,
wherein a shape of the relief hole comprises an approximately circular shape, and
wherein a center of the relief hole is located at an intersection between the two inclined sides or on an inner side of the intersection in a radial direction of each of the plurality of first core forming pieces and the at least one second forming piece.

6. The laminated core for a rotary electric machine according to claim 1 , wherein at least one spiral core forming body layer including a plurality of the first core forming pieces and the at least one second core forming piece, which are continuously formed and are to be rolled up as a single continuous body, is formed on the second spiral core forming body layer so as to be continuous with the second spiral core forming body layer.

7. A method of manufacturing a laminated core for a rotary electric machine, comprising the steps of:
forming, through press working, first core forming pieces, each having a magnet mounting portion, and at least one second core forming piece, which has a length different from a length of each of the plurality of first core forming pieces in a longitudinal direction of each of the plurality of first core forming pieces and the at least one second core forming piece, and has a magnet mounting portion, on a band-shaped hoop member made of a metal to be fed along a longitudinal direction of the band-shaped hoop member;
forming a first band-shaped core forming body including a plurality of the first forming pieces continuously formed;
forming a second band-shaped core forming body including a plurality of the first core forming pieces and the at least one second core forming piece, which are continuously formed so that the second band-shaped core forming body is continuous with the first band-shaped core forming body; and
spirally rolling up the first band-shaped core forming body and the second band-shaped core forming body as a single continuous body, including a first spiral core forming body layer and a second spiral core forming body layer wherein positions of the magnet mounting portions of the plurality of first core forming pieces and the at least one second core forming piece in the second spiral core forming body layer are shifted from positions of the magnet mounting portions of the plurality of first core forming pieces in the first spiral core forming body layer in a circumferential direction of the laminated core under a state in which the second spiral core forming body layer is formed on the first spiral core forming body layer.

8. The method of manufacturing a laminated core for a rotary electric machine according to claim 7 , further comprising the steps of:
forming a slit defined by two inclined sides between adjacent ones of the plurality of first core forming pieces and the at least one second core forming piece and a relief hole at a periphery of an intersection between the two inclined sides; and
curving the first band-shaped core forming body and the second band-shaped core forming body so that the two inclined sides are brought into contact with each other and spirally rolling up the first band-shaped core forming body and the second band-shaped core forming body.

9. The method of manufacturing a laminated core for a rotary electric machine according to claim 8 , further comprising the step of forming the relief hole into an approximately circular shape having the intersection between the two inclined sides or a point on an inner side of the intersection in a radial direction of the first core forming piece as a center.

10. A rotary electric machine, comprising:
a laminated core including:
a first spiral core forming body layer including a plurality of first core forming pieces, each being made of a metal and having a magnet mounting portion, the plurality of first core forming pieces being continuously formed and to be spirally rolled up as a single continuous body; and
a second spiral core forming body layer including a plurality of the first core forming pieces and at least one second core forming piece, which has a length different from a length of each of the plurality of first core forming pieces in a longitudinal direction of each of the first core forming pieces and the second core forming piece, has the magnet mounting portion, and is made of the metal, the plurality of first core forming pieces and the at least one second core forming piece being continuously formed and to be spirally rolled up as a single continuous body,
wherein the second spiral core forming body layer is formed on the first spiral core forming body layer so as to be continuous with the first spiral core forming body layer,
wherein the at least one second core forming piece is located at a head of the second spiral core forming body layer, and
wherein positions of the magnet mounting portions of the plurality of first core forming pieces and the at least one second core forming piece in the second spiral core forming body layer are shifted from positions of the magnet mounting

Assignees

• Mitsubishi Electric Corp

Inventors

• Ichikawa Asami
• Umeda Takashi

Classifications

• H01F27/24

  Magnetic cores · CPC title

• H02K1/276

  Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] · CPC title

• H01F3/02

  made from sheets · CPC title

• H01F41/0233

  Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16) · CPC title

• H02K15/03 Primary

  having permanent magnets · CPC title