Rotor for rotating electrical machine, rotating electric machine, and method for producing rotor for rotating electrical machine with magnet having surfaces tilted with respect to magnet insertion hole

Patent metadata

Field	Value
Publication number	US-9608485-B2
Application number	US-201114114791-A
Country	US
Kind code	B2
Filing date	Jun 9, 2011
Priority date	Jun 9, 2011
Publication date	Mar 28, 2017
Grant date	Mar 28, 2017

Abstract

Provided is a rotor for a rotating electrical machine which is capable of minimizing increases in eddy current losses via a magnet, while making insulating film processing of the surface of the magnet unnecessary. The rotor for the rotating electrical machine includes: a rotor core having a magnet insertion hole extending inside; a magnet inserted in the magnet insertion hole; and an insulating filler which is filled between the inner wall of the magnet insertion hole and the magnet so as to secure the magnet. The magnet is secured by the filler in such a manner that the surface of the magnet inside the magnet insertion hole is in an inclined position with respect to the extending direction of the inner wall of the magnet insertion hole.

First claim

The invention claimed is:

1. A rotary electric machine rotor with a built-in magnet, the rotary electric machine rotor comprising:
a rotor core with a magnet insertion hole extending inside;
a magnet inserted in the magnet insertion hole; and
an insulating filler filled between an inner wall of the magnet insertion hole and the magnet to fix the magnet,
wherein the magnet is fixed with the filler such that a radial inner surface and a radial outer surface of the magnet inside the magnet insertion hole are tilted with respect to an extending direction of the inner wall of the magnet insertion hole.

2. The rotary electric machine rotor according to claim 1 , wherein
the magnet insertion hole is formed along an axial direction of the rotor core;
the magnet has an axial cross section of an elongated quadrilateral shape; and
the magnet contacts the inner wall of the magnet insertion hole at a corner on one axial end side and at another corner on the other axial end side which is diagonally opposite to the corner on the one axial end side.

3. The rotary electric machine rotor according to claim 2 , wherein
the magnet has an axial cross section of a parallelogram shape and axial end surfaces which are flush with axial end surfaces of the rotor core.

4. The rotary electric machine rotor according to claim 2 , wherein
the magnet has an axial cross section of a rectangular shape.

5. The rotary electric machine rotor according to claim 1 , wherein
the magnet is segmented into a plurality of magnetic pieces; and
the filler is integrally filled between each other of the magnet pieces in addition to between the inner wall of the magnet insertion hole and the magnet.

6. A rotary electric machine comprising:
the rotor according to claim 1 ; and
a stator disposed around the rotor.

7. A method for manufacturing a rotary electric machine rotor with a built-in magnet, the method comprising:
preparing a magnet and a rotor core with a magnet insertion hole extending inside;
inserting the magnet into the magnet insertion hole; positioning, in a mold die, the rotor core with the magnet inserted inside;
holding the magnet with a portion of the mold die such that a radial inner surface and a radial outer surface of the magnet inside the magnet insertion hole are tilted with respect to an extending direction of an inner wall of the magnet insertion hole;
filling an insulating filler between the inner wall of the magnet insertion hole and the magnet through an inlet provided with the mold die to fix the magnet to the rotor core; and
assembling, to the shaft, the rotor core in which the magnet is fixed with the filler.

8. The method for manufacturing the rotary electric machine rotor according to claim 7 , wherein the magnet has an axial cross section of a parallelogram shape and axial end surfaces which are flush with axial end surfaces of the rotor core; and in the holding, flat inner side surfaces of the mold die abut axial end surfaces of the rotor core and axial end surfaces of the magnet such that the magnet is held in a tilted position inside the magnet insertion hole.

9. The method for manufacturing the rotary electric machine rotor according to claim 7 , wherein the magnet has an axial cross section of a rectangular shape; and in the holding, inclined surfaces of protruding portions which protrude on inner side surfaces of the mold die abut axial end surfaces of the magnet and press the magnet in an axial direction such that the magnet is held in a tilted position inside the magnet insertion hole.

10. The method for manufacturing the rotary electric machine rotor according to claim 7 , wherein the magnet has an axial cross section of a rectangular shape; and in the holding, inclined surfaces of protruding portions which are elastically provided with the mold die and capable of moving forward and backward abut corner portions of axial end portions of the magnet and press the axial end portions of the magnet in a direction substantially perpendicular to the axial direction such that the magnet is held in a tilted position inside the magnet insertion hole.

Assignees

• Yamagishi Yoshitada
• Watanabe Yuta
• Toyota Motor Co Ltd

Inventors

• Yamagishi Yoshitada
• Watanabe Yuta

Classifications

• H02K1/2766 Primary

  having a flux concentration effect · CPC title

• H02K1/27

  Rotor cores with permanent magnets · CPC title

• H02K1/28 Primary

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

• H02K15/03

  having permanent magnets · CPC title