Rotor and method of manufacturing rotor

Patent metadata

Field	Value
Publication number	US-9431860-B2
Application number	US-200913389737-A
Country	US
Kind code	B2
Filing date	Dec 22, 2009
Priority date	Dec 22, 2009
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

A rotor that can reduce the used amount of resin for securing a permanent magnet is provided. The rotor includes a rotor core provided fixedly to a rotation shaft and having a magnet insertion hole extending in an axial direction formed therein, a permanent magnet embedded in the magnet insertion hole and extending in the axial direction and extending in a direction inclined relative to a radial direction of the rotor core, and a resin layer that secures the permanent magnet to the rotor core. The resin layer covers a surface of the permanent magnet and is in contact with an inner surface of the magnet insertion hole. A hollow space extending in the axial direction is left in the magnet insertion hole at an inner side in the radial direction relative to the permanent magnet. Part of the inner surface of the magnet insertion hole is exposed to the hollow space.

First claim

The invention claimed is:

1. A rotor comprising:
a rotor core provided fixedly to a rotation shaft and having a hole extending in an axial direction formed therein; and
a magnet embedded in said hole and extending in said axial direction and extending in a direction inclined relative to a radial direction of said rotor core, wherein
said magnet partitions said hole in said radial direction to contact a pair of opposite inner surfaces of said hole to define, in said hole, an outer region at an outer side in the radial direction and an inner region being separated from said outer region at an inner side in the radial direction relative to said magnet,
in said inner region, a resin layer filled with resin and a hollow space unfilled with resin are formed,
said resin layer covers a radially inner surface of said magnet, secures said magnet to said rotor core from the radially inner side, and is in contact with an inner surface of said hole,
part of said inner surface is exposed to said hollow space,
said inner region has a capacity larger than a capacity of said outer region, and
the outer region is located at a more radially outward position than a radially outer surface of the magnet, and the inner region is located at more radially inward position than a radially inner surface of the magnet;
the resin layer has a shape of a substantially thin plate and has a first plane which covers the radially inner surface of the magnet and makes a contact with the inner surface of the hole; and
the resin layer has a first surface and a second surface opposing the first surface, the first surface covers the radially inner surface of the magnet and makes contact with the inner surface of the hole, and the second surface faces the hollow space and does not contact the inner surface of the hole.

2. The rotor according to claim 1 , comprising a partition member disposed in said hole to separate said resin layer and said hollow space.

3. The rotor according to claim 2 , wherein
said rotor core has formed therein another hole extending in said axial direction and adjacent to said hole in a circumferential direction of said rotor core,
said rotor core includes a wall that separates said hole and said other hole in said circumferential direction,
said wall has a most proximate portion at an innermost side in said radial direction where said hole and said other hole are most proximate to each other, and

a side surface of said most proximate portion is exposed to said hollow space.

4. The rotor according to claim 1 , wherein
said rotor core has formed therein another hole extending in said axial direction and adjacent to said hole in a circumferential direction of said rotor core,
said rotor core includes a wall that separates said hole and said other hole in said circumferential direction,
said wall has a most proximate portion at an innermost side in said radial direction where said hole and said other hole are most proximate to each other, and
a side surface of said most proximate portion is exposed to said hollow space.

Assignees

• Endo Yasuhiro
• Toyota Motor Co Ltd

Inventors

• Endo Yasuhiro

Classifications

• H02K1/2766 Primary

  having a flux concentration effect · CPC title

• H02K1/28

  Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures · CPC title

• H02K15/03

  having permanent magnets · CPC title

• Y10T29/49012

  Rotor · CPC title