Abstract:
The present invention ensures reliability while reducing the size of an axial air gap rotating electric machine. An axial air gap rotating electric machine has: a stator comprising a plurality of core members arranged in a ring shape, said core members each having an iron core, a coil wound in an iron core outer periphery direction, and a bobbin disposed between the iron core and the coil; and a rotor plane-facing an end surface of the iron core via an air gap in a rotating shaft radial direction. The bobbin has: a tubular portion facing the outer peripheral side surface of the iron core and shorter than the length of the iron core; flange portions extending in the vicinity of both ends of the tubular portion from the outer periphery of the tubular portion toward the vertical direction outside by a predetermined length; and a projection portion being on the outside surface of at least one of the flange portions and near the inner edge of the tubular portion, having an inner peripheral surface facing the end outer peripheral side surface of the inserted iron core, and further projecting in an extending direction of the tubular portion.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to an axial air gap rotating electric machine and a rotating electric machine bobbin. 
       BACKGROUND ART 
       [0002]    An axial air gap rotating electric machine has a configuration in which a substantially donut-shaped stator and a disk-shaped rotator are disposed to face each other in a rotation axis direction. The stator includes multiple core members for a single slot disposed in an annular shape in a diameter direction around a rotation axis. The core member includes an iron core, a tube-shaped bobbin (insulator) into which the iron core is inserted, a coil wound around an outer periphery of the bobbin, and the like. Since a gap surface generating a torque increases substantially in proportional to a square of a diameter, the axial air gap rotating electric machine is considered to be suitable for a thin shape. In recent years, this attracts attention as a structure useful for reducing the size and increasing the efficiency in rotating electric machines required to be made into a thin shape. 
         [0003]    In general, in order to reduce the size and increase the efficiency of rotating electric machines, it is important to arrange the iron core and armature coils directly contributing to the torque output with a higher density within the stator. The iron core forms a magnetic circuit of the rotating electric machine, and when the iron core is formed to have a low magnetic resistance with respect to the main magnetic flux, a magnetic flux generated by coils and permanent magnets can be effectively used. The armature coil is the source of the magnetomotive force, and in a case where the same number of turns is assumed, the armature coil is formed to increase this volume, so that the wire diameter is expanded, and accordingly, the joule loss in the coil can be reduced, i.e., the efficiency of the rotating electric machine can be enhanced. 
         [0004]    In the axial air gap rotating electric machine, an increase in the density of iron cores and coils is an important technical problem, and in the past many inventions have been made. 
         [0005]    Patent Literature 1 discloses a method for winding a coil in an axial air gap rotating electric machine and a method for producing a coil. In this case, a coil is wound around a predetermined shaft having a predetermined width, and a method for directly winding a coil around an iron core having a flange portion and a method for winding a wire around a bobbin having a flange portion are shown. Patent Literature 2 discloses a method for directly connecting bobbins in the axial direction while the iron core is inserted into the inside of the bobbin, and the wire is continuously wound around the bobbin. 
         [0006]    At the side where the coil is applied, i.e., at the bobbin and the iron core, some tightening force is applied to deform it. For this reason, it is easier to insert a core into a bobbin when the coil is applied to the bobbin while the iron core is inserted thereto. Further, when a coil is turned and wound, the winding bulge can be suppressed by applying tension to the coil, so that the coil can be wound with a higher density. In this case, however, a large force is also applied to the winding shaft which holds the coil, and therefore, it is necessary to rigidly hold the core member. 
       CITATION LIST 
     Patent Literatures 
       [0007]    PATENT LITERATURE 1: Japanese Patent Laid-Open No. 2008-182867 
         [0008]    PATENT LITERATURE 2: Japanese Patent Laid-Open No. 2007-14146 
       SUMMARY OF INVENTION 
     Technical Problem 
       [0009]    However, in a case where a wire is wound around a bobbin into which a core is inserted, the core member cannot be held from the inside of the bobbin with a wire winding jig. Therefore, the core member has to be held by using its end surface of the core member. For example, it may be possible to hold an iron core protruding from the bobbin. In this case, the iron core is required to have an adequate level of strength, and therefore, a laminated structure of foil belt-like soft magnetic material such as amorphous metal and Finemet and a compressed structure of soft magnetic material in powder form such as dust magnetic core are difficult to be used as the iron core. 
         [0010]    Even in a case where soft magnetic materials having rigidity care laminated such as electrical steel, the cross-sectional shape is dependent on the precision of cut process and the precision of arrangement during lamination, and therefore, it is difficult to stably ensure a contact surface between a jig and a side surface of the iron core. This will bring about the deterioration of the workability and the increase in the processing machine. 
         [0011]    As another method, there is a method for holding the bobbin itself In this case, by using a flange side surface, a protrusion, or a recessed portion of the bobbin, the core member can be held regardless of the material of the core. There is a smaller variation in the shape of a bobbin made of resin, and therefore, the contact surface with the jig can be ensured stably. However, the bobbin made of resin is difficult to have a sufficient level of strength. When the rigidity of the bobbin is increased by simply increasing the thickness, the size of the rotating electric machine increases, and the cost increases. 
         [0012]    It is desired to achieve a configuration for ensuring reliability while achieving the reduction in the size of the axial air gap rotating electric machine. 
       Solution to Problem 
       [0013]    To achieve the above object, for example, configurations described in claims are applied. That is, the configurations include an axial air gap rotating electric machine including a stator in which a plurality of core members including an iron core made of a pillar body shape having an end surface in a substantially trapezoid shape, a coil wound in an outer periphery direction of the iron core, and a bobbin disposed between the iron core and the coil are arranged in an annular shape around a rotation axis, and a rotator facing an end surface of the iron core with a predetermined air gap interposed in a rotation axis diameter direction, wherein the bobbin includes: a tube portion facing an outer periphery side surface of the iron core and being shorter than a length of the iron core; flange portions provided around both end portions of the tube portion and extending a predetermined length to an external side of a direction perpendicular to an outer periphery of the tube portion; and a protruding portion provided on a surface of an external side of at least one of the flange portions and close to an inner edge of the tube portion and having an inner periphery surface facing an end portion outer periphery side surface of the inserted iron core and further protruding in an drawing direction of the tube portion. 
         [0014]    Further, the configurations include a rotating electric machine bobbin including: a tube portion including an internal tube having a cross section of a substantially trapezoid shape into which an iron core is inserted and an external tube around which a coil is wound; flange portions provided in proximity to end portions of both openings of the tube portion and extending a predetermined width from an entire periphery of the external tube in a direction perpendicular thereto; and a protruding portion provided on a surface of an external side of at least one of the flange portions and close to an inner edge of the tube portion and further extending in an drawing direction of the internal tube along at least a part of the inner edge. 
       Advantageous Effects of Invention 
       [0015]    According to an aspect of the present invention, a rotating electric machine for ensuring reliability while achieving the reduction in the size of the rotating electric machine and enhancing the performance thereof can be obtained. 
         [0016]    The problems, configurations, and the effects other than those explained above would be understood from the following description. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]      FIG. 1  is a perspective view illustrating a schematic configuration of an axial air gap rotating electric machine according to a first embodiment to which the present invention is applied. 
           [0018]      FIG. 2  is a perspective view illustrating a configuration of a core member for a single slot according to the first embodiment. 
           [0019]      FIG. 3  is a cross sectional view illustrating a configuration of a core member for a single slot according to the first embodiment. 
           [0020]      FIG. 4  is a schematic diagram illustrating how a coil is wound by using a wire winding jig according to the first embodiment. 
           [0021]      FIG. 5  is a schematic diagram illustrating resin mold according to a second embodiment. 
           [0022]      FIG. 6( a )  is a perspective view illustrating a configuration of a core member for a single slot according to the second embodiment.  FIG. 6( b )  is a cross sectional view illustrating a configuration of a core member for a single slot according to the second embodiment. 
           [0023]      FIG. 7( a )  is a perspective view illustrating a configuration of a core member for a single slot according to the third embodiment.  FIG. 7( b )  is a cross sectional view illustrating a configuration of a core member for a single slot according to the third embodiment. 
           [0024]      FIG. 8  is a schematic diagram illustrating how an iron core is inserted by using an insertion jig according to the third embodiment. 
           [0025]      FIG. 9( a )  is an upper surface side perspective view illustrating a configuration of a core member for a single slot according to a fourth embodiment.  FIG. 9( b )  is a bottom surface side perspective view illustrating a configuration of a core member for a single slot according to the fourth embodiment. 
           [0026]      FIG. 10( a )  is an upper surface side perspective view illustrating a configuration of a core member for a single slot according to a first modification of the fourth embodiment.  FIG. 10( b )  is a bottom surface side perspective view illustrating a configuration of a core member for a single slot according to the first modification of the fourth embodiment. 
           [0027]      FIG. 11( a )  is an upper surface side perspective view illustrating a configuration of a core member for a single slot according to the second modification of the fourth embodiment.  FIG. 11( b )  is a bottom surface side perspective view illustrating a configuration of a core member for a single slot according to the second modification of the fourth embodiment. 
           [0028]      FIG. 12  is a bottom surface view illustrating a core member according to the second modification of the fourth embodiment. 
           [0029]      FIG. 13  is a bottom surface view illustrating a core member according to a comparative example. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
     First Embodiment 
       [0030]    Hereinafter, modes for carrying out the present invention will be explained with reference to drawings.  FIG. 1  illustrates a schematic configuration of an armature with an axial air gap motor  1  (which may be hereinafter simply referred to as “motor  1 ”) which is the first embodiment to which the present invention is applied. The motor  1  is an example of a double rotor-type axial air gap motor. 
         [0031]    The motor  1  has an armature configuration in which a single cylindrical stator and two disk-shaped rotators are facing each other with a predetermined air gap interposed therebetween in a diameter direction of a rotation axis A. A stator  19  is fixed to an inner periphery of a housing  40 , and multiple core members  20  for a single slot are disposed around a rotation axis A. The core member  20  includes a pillar-shaped iron core  21  having an end surface in a substantially trapezoid shape, a bobbin  22  in a tube shape having substantially the same internal diameter as the outer periphery external diameter of the iron core  21 , and a coil  23  wound around the outer periphery of the bobbin  22 . The stator  19  is configured so that the inner peripheral portion of the housing  40  and the core members  20  disposed in the annular shape are molded each other with resin in an integral manner. 
         [0032]    The iron core  21  is a laminated iron core obtained by laminating, from the rotation axis to the housing  40 , plate pieces (including those in a tape form) that are cut so that the width of the thin plate having magnetic material such as amorphous gradually increases. As a result, the iron core  21  has a pillar body in which a cross section has a substantially trapezoid pillar shape. It should be noted that the present invention is not limited to the laminated iron core. Alternatively, the present invention can also be applied to a dust iron core and a machined iron core. 
         [0033]    A rotator  30  includes permanent magnets  31  facing a rotation-axis-direction end surface of the iron core  21  and a yoke  32  for holding the permanent magnets  31 . Although not shown in the drawing, the yoke  32  is coupled with the shaft rotation axis, and is rotatably held on an end bracket via bearings. The end bracket is mechanically connected to the housing  40 . A terminal box (not shown) is provided on an outer periphery side surface of the housing  40 . An electrical wire at a primary side and an electrical wire at a secondary side are electrically connected via a terminal block. A connecting line extending from the core member  20  is connected to the secondary side. 
         [0034]      FIG. 2  is a configure illustrating a core member  20  for a single slot.  FIG. 3  illustrates a diameter-direction cross sectional view of the core member  20 . The bobbin  22  is made of resin. A tube portion  22   a  has its both ends open. The internal tube portion of the tube portion  22   a  has an internal diameter that substantially matches the external diameter of the iron core  21  having a substantially trapezoid shape. The coil  23  is wound around the external tube portion of the tube portion  22   a.  In the first embodiment, the tube portion  22   a  is shorter than the length of the iron core  21 . 
         [0035]    At around the openings of both end portions of the tube portion  22   a,  a flange portion  22   b  extending for a predetermined length over the entire periphery from the external tube portion in the direction perpendicular thereto. The predetermined length is preferably longer than the width of the coil  23  wound around. This is to achieve insulation of the coils  23  between each other and insulation from the inner periphery of the housing and the like. The predetermined length does not need to be uniform over the entire area of the flange portion  22   b , and can be changed as necessary in accordance with the design. For example, the length thereof at the rotation axis side and at the housing side may be increased. 
         [0036]    On the surface of the outside of the flange portion  22   b  and close to an inner edge of the internal tube portion, a protruding portion  10  is provided. The protruding portion  10  protrudes in the rotation axis direction (drawing direction of internal tube portion), and is provided to enclose the opening of the internal tube portion (provided continuously around the opening portion of the internal tube of the bobbin  22 ). 
         [0037]    In this case, the entire length of the bobbin  22  in the rotation axis direction is shorter than the length of the iron core  21 . Therefore, after the insertion, the iron core  21  is configured so that a part of the end portion side protrudes from the bobbin  22 . Since the part is protruding, this can be expected to achieve a cooling effect of the iron core  21  and to be used as a connection portion for earthling and the like. In the present embodiment, each of the protruding portions  10  formed at both of the flange portions  22   b  are configured to protrude to be lower than the protruding portion of the iron core  21 . More specifically, both end portions of the iron core  21  are configured to protrude from the bobbin  22 . In the present embodiment, the inner periphery surface of the internal end side of the protruding portion  10  faces the outer periphery side surface of the iron core  21 , or the inner periphery surface of the internal end side of the protruding portion  10  and the outer periphery side surface of the iron core  21  come into contact with each other. 
         [0038]    When the coil  23  is wound around the bobbin  22  into which the iron core  21  is inserted, a wire winding jig of the winding machine is configured not to support the iron core  21  and configured to support the protruding portion  10 . 
         [0039]    The sectional side view of  FIG. 4  schematically illustrates how the coil  23  is wound in the core member  20 . Iron core jigs  51  and  52  hold, from both ends, the protruding portions  22  of the bobbin  22  into which the iron core  21  is inserted. The jig is in contact with the surface of the protruding portion  22  and the flange portion  22   b.  The jig is rotated by a winding shaft B, and at the same time, a tension F is applied to the coil  23 , so that the coil  23  is wound in such a manner that the coil  23  is in close contact with the tube portion  22   a.  The coil  23  is provided from a movable nozzle, and any given number of turns can be wound by moving the nozzle up and down. 
         [0040]    According to the motor  1  of the first embodiment, the coil  23  is wound while the iron core  21  is inserted into the bobbin, and therefore, the insertion property of the iron core does not deteriorate because of deformation of the tube portion  22   a  caused by the coil  23 . 
         [0041]    When the coil  23  is wound, a portion of the bobbin  22  is held by the jig, and more specifically, the protruding portion  10  is held by the jig, and therefore, the coil  23  can be applied regardless of the rigidity of the iron core  21 . Therefore, the coil  23  can be safely wound around a core material having a low rigidity such as amorphous metal, Finemet, dust magnetic core, and the like. 
         [0042]    The load of the wire winding jig is received by the protruding portion  10  provided at the innermost periphery of the bobbin, and therefore, the torque of the contact surface can minimized. As a result, the rigidity of the bobbin required for holding can be ensured with the minimum increase in the amount of resin, and the amount of use of material can be reduced. 
         [0043]    The protruding portion  10  is on the extension line of the tube portion  22   a,  and therefore, it can withstand a force in the direction of the tube portion  22   a.  More specifically, the support force of the wire winding jig for the bobbin  22  can be increased. Even when the tension F applied to the coil  23  is increased, this does not affect the winding of the coil. As a result, the coil  23  can be brought into contact with each other, and the tube portion  22   a  and the coil  23  can be brought into contact with each other, so that the density of the coil  23  is increased, and a larger number of winding coils can be disposed in a predetermined area, and this can increase the output of the motor  1  and can increase the efficiency. 
         [0044]    Further, the wire winding jigs  51  and  52  are configured to support not only the protruding portion  10  but also a portion of the surface of the flange portion  22   b,  and therefore, this can cope with the increasing stress caused by expansion in the direction between the flange portions  22   b  as the coil  23  is wound, and this can also be expected to prevent the damage of the bobbin. 
         [0045]    The first embodiment has been hereinabove explained, but various other configurations may be considered. For example, the wire winding jigs  51  and  52  are configured to support the protruding portion  10  and a portion of the flange portion  22   b,  but the wire winding jigs  51  and  52  may not contact the surface of the flange portion  22   b,  and may be configured to hold only the surface and the outer periphery of the protruding portion  10 . 
       Second Embodiment 
       [0046]    One of the characteristics of a bobbin  22  according to the second embodiment is that, at least at one side, the horizontal-direction-position (the positions in the rotation axis direction) of an end surface of the protruding portion  10  and an end surface of the iron core  21  are the same. Hereinafter, the second embodiment will be explained, but the same portions as those of the first embodiment will be denoted with the same reference numerals, and explanation thereabout is omitted. 
         [0047]    Like the first embodiment, the motor  1  of the second embodiment is configured so that a stator  19  is integrally formed by resin mold.  FIG. 5  schematically illustrates a resin mold step. A housing  40  is inserted into a lower die  62 , of which internal diameter substantially matches therewith, and from an opposite side opening of the housing  40 , a tube-shaped middle die  61  for forming an axial space through which a rotation axis penetrates later is disposed in the center of the lower die. Core members  20  are arranged in an annular shape around the middle die, and thereafter, an upper die, not shown, is inserted from the housing opening at the side opposite to the lower die  62 , so that the core members  20  are sandwiched and supported. Thereafter, resin is sealed from the opposing surfaces of the upper die and lower die  62 . 
         [0048]    When the core member  20  is sandwiched by the upper die and the lower die  62 , the end surface (top portion) of the iron core  21  is in contact therewith, but the position of each core member  20  may deviate because of the pressure caused by sealing of resin, and therefore, the force during sandwiching with the dies tend to be relatively large. The support force generated during sandwiching with the dies may damage an end surface (especially, an edge portion) of the iron core  21 . 
         [0049]      FIG. 6( a )  is a perspective view expressing a configuration of a core member  20  according to the second embodiment.  FIG. 6( b )  illustrates a rotation-axis-direction cross section of the core member  20 . 
         [0050]    As shown in the drawing, the protruding portion  10  encloses the entire periphery of the end portion outer periphery of the iron core  21  protruding from the tube portion  22   a,  and further, the horizontal-direction-positions (rotation axis-direction-positions) of the top portion of the protruding portion  10  and the end surface of the iron core  21  are substantially at the same position. Therefore, when the core member  20  is arranged in the mold die, the iron core  21  and the bobbin  22  come into contact with the die, so that the iron core  21  is expected to be prevented from being damaged because of the holing of the die, and in addition, the positioning of the core member  20  with respect to the die can be achieved safely. 
         [0051]    The present embodiment showed, for example, at both of the upper and lower positions, the end surface of the protruding portion  10  and the end surface of the iron core  21  match each other. Alternatively, at only one of the upper and lower positions, the end surface of the protruding portion  10  and the end surface of the iron core  21  may match each other. When the axial length of the bobbin  22  including the protruding portion  10  is designed to be shorter than the axial length of the iron core  21 , this can prevent the bobbin axial length from being longer than the iron core due to processing error. Therefore, when the stator axial length and the iron core axial length are caused to match each other, a spatial gap between the rotator  30  and the stator  19  is reliably ensured, and, for example, a contact between the rotator  30  and the stator  19  can be prevented. 
       Third Embodiment 
       [0052]    One of the characteristics of a motor  1  according to the third embodiment is that the motor  1  has a configuration in which a groove  10   b  is provided over the entire periphery between the protruding portion  10  and the iron core  21 . 
         [0053]      FIG. 7( a )  illustrates a perspective view of core members  20  for a single slot of the motor  1  according to the third embodiment.  FIG. 7( b )  illustrates a cross sectional view of the core member  20  taken in a rotation axis A direction. It should be noted that the same portions as those of the first embodiment will be denoted with the same reference numerals, and explanation thereabout is omitted. 
         [0054]    As illustrated in  FIGS. 7( a ), 7( b ) , the protruding portion  10  has an internal diameter of which diameter is larger than an internal diameter extension line of the tube portion  22   a  and the extension of the tube portion  22   a  in a drawing direction. More specifically, the inner periphery surface of the protruding portion  10  is away a predetermined width from the extension line obtained by extending the inner periphery of the tube portion  22   a.  The predetermined width is preferably, for example, the same as the end width of the insertion jig of the iron core explained later, but in a case where a portion from the inner periphery surface of the protruding portion  10  to the inner periphery of the tube portion  22   a  is formed in a tapered shape, the configuration is not limited thereto. 
         [0055]    When the iron core  21  is inserted into the bobbin  22  according to the above configuration, the groove  10   b  is formed between the protruding portion  10  and the outer periphery of the protruding portion of the iron core  21 . The groove  10   b  mainly has a function of reliably inserting the iron core  21 . 
         [0056]      FIG. 8  illustrates an example of a step for inserting the iron core  21  into the bobbin  22 . The iron core  21  is configured such that the iron core  21  supported by an insertion jig  71  is inserted from the other end portion of the bobbin  22  placed on a base  72  of the iron core insertion jig on which one opening side of the bobbin  22  is placed. The insertion jig  71  sandwiches the iron core  21  in a laminated state from both sides in the lamination direction and other two directions. The end of the insertion jig  71  is a sharp shape, and is disposed to face the bottom surface of the groove  10   b.  In this state, the iron core  21  is pressurized in the direction perpendicular thereto, and inserted into the inside of the bobbin  22 . 
         [0057]    According to the third embodiment, the positioning of the bobbin  22  and the insertion jig  71  can be achieved easily. Since the positioning is done at a position closest to the insertion surface  21   a  of the iron core  21 , a high level of positioning precision is provided. As a result, the workability of the iron core insertion is greatly improved, and the yield during insertion can be improved. 
         [0058]    In the present embodiment, for example, the groove  10   b  is provided along the entire periphery. Alternatively, the groove  10   b  may be provided only in a portion thereof. 
         [0059]    The groove  10   b  may be provided on the protruding portions  10  at both sides. 
       Fourth Embodiment 
       [0060]    One of the characteristics of a motor  1  according to the fourth embodiment is that the motor  1  has a configuration in which a protruding portion  10  is provided on a portion of a protruding portion of an iron core  21 . In other words, the protruding portion  10  is formed discontinuously along the inner edge of the tube portion  22   a.    
         [0061]    When the iron core  21  has a lamination iron core configuration of a thin plate and a foil strip, it would be preferable to be able to hold each plate piece. When a portion of the iron core protruding portion is exposed through the heat discharge surface of the iron core  21 , this can be said to be advantageous because of this. 
         [0062]      FIG. 9( a )  illustrates a perspective view of a core member  20  for a single slot of the motor  1  according to the fourth embodiment.  FIG. 9( b )  illustrates a perspective view showing the core member  20  when it is seen from the bottom surface side. It should be noted that the same portions as those of the first embodiment will be denoted with the same reference numerals, and explanation thereabout is omitted. 
         [0063]    The protruding portion  10  is provided to be vertical-line asymmetrical with respect to the axial rotation direction. More specifically, a gap portion  10   c  is provided in an axial rotation direction of the protruding portion  10 . Likewise, the protruding portion  10  is provided so that it is asymmetrical also with respect to the axial diameter direction. The outer periphery portion of the iron core  21  at the position of the gap portion  10   c  is configured to be directly in contact with the mold resin. The horizontal-direction positions of the top portion of the protruding portion  10  and the end surface of the iron core  21  are like those of the second and third embodiments. 
         [0064]    According to the fourth embodiment, the plate piece constituting the iron core  21  directly come into contact with the resin at any one of the right and the left, so that the holding strength of the plate piece and the holding strength of the iron core  21  are improved. Further, due to the gap portion  10   c,  the heat of the iron core  21  is more likely to be transmitted to the resin side, and the heat radiation effect can be expected. It is to be understood that, like the other embodiments explained above, the effect of the insertion surface of the coil  23  and the effect of the positioning are also provided. 
       First Modification of Fourth Embodiment 
       [0065]    As shown in  FIGS. 10( a ) and 10( b ) , a gap portion  10   c  may be configured to be provided symmetrically in the rotation direction with respect to a central cross section S 1  in the axial direction, and may be configured to be provided vertical-line asymmetrically with respect to a cross section S 2  in the diameter direction. In particular, in the example of  FIGS. 10( a ) and 10( b ) , protruding portions  10  are configured to be arranged to enclose the four corners of the iron core  21  having a substantially trapezoid shape. The side provided with the protruding portions  10  at the four corners advantageously function as a guide for an insertion jig of an iron core  21 , and the effect of facilitating the positioning of the insertion jig and the bobbin can be expected. Further, the protruding portion  10  is asymmetrical with respect to the S 2  cross section, so that the effect of distributing the portion where the heat radiation effect can be expected at the upper and lower portions can be expected. 
       Second Modification of Fourth Embodiment 
       [0066]    A motor  1  according to the second modification of the fourth embodiment has the functions of the above embodiment, and further, one of the characteristics of the motor  1  according to the second modification of the fourth embodiment is that it has a maintenance function of resin molded in a stator  19 . 
         [0067]      FIG. 11( a )  illustrates a perspective view of a core member  20  for a single slot of the motor  1  according to the second modification.  FIG. 11( b )  illustrates a perspective view of the core member  20  when it is seen from the bottom surface side. It should be noted that the same portions as those of the first embodiment will be denoted with the same reference numerals, and explanation thereabout is omitted. 
         [0068]    The bobbin  22  according to the second modification includes not only the configuration of the protruding portion  10  according to the first modification but also a configuration for providing protruding portions  10  at the housing side corners of the iron core  21  at any opening portion side of the bobbin  22 . More specifically, as shown in  FIG. 11( b ) , protruding portions  10  are provided at side corners of the housing  40  even on the bottom surface side of the bobbin  22  (hereinafter these two protruding portions will be particularly referred to as “protruding portions  11 ”). As illustrated in the bottom surface view of the core member  20  of  FIG. 12 , the protruding portions  11  are provided with a gap from the housing side corners of the iron core  21 , so that resin is allowed to enter thereinto. 
         [0069]    In the motor  1 , multiple core members  20  are integrally formed with each other with resin mold, and the stator  19  including the core members  20  and the inner periphery of the housing  40  are integrally formed with each other with resin mold, which as described above. The resin applied on the flange portion  22   b  has a thickness corresponding to the thickness of protrusion of the iron core  21  from the bobbin  22 , and therefore, it has a relatively thin thickness. 
         [0070]    When the motor is driven, a loss caused mainly by the coil  23  occurs, so that the temperature of the core member  20  and the resin rises. Normally, the linear expansion coefficients of the iron core  21  and the resin do not match each other, and therefore, due to the difference, a stress occurs in the resin. In particular, the resin at the position facing the corner portion of the iron core  21  has a thin thickness, and in addition, a stress concentration is likely to occur. For this reason, for example, as illustrated in  FIG. 13 , a crack and the like may occur in the resin portion. When such crack is very small, the effect on the strength and the heat radiation performance of the stator  19  can be said to be small. 
         [0071]    However, when the crack is of a size that cannot be tolerated, the effect on the motor  1  cannot be disregarded. Such cracks are considered to be largely caused by a change over time, and it is important to take a countermeasure in terms of durability. 
         [0072]    As illustrated in  FIGS. 11( a ), 11( b ) , and  FIG. 12 , in the second modification, a conductive member  13  made of conductive metal and the like is provided on the surface of the flange portion  22   b  at the side of the housing  40 . A conductive member  80  has a thinner thickness than the portion where the iron core  21  protrudes from the bobbin  22 , and the entire conductive member  80  is covered with mold resin. The conductive member  80  is electrically connected to the inner periphery of the housing  40 , and has a function of reducing the electrostatic capacity between the coil  23  and the rotator  30 . Further, the conductive member  13  has a function as a heat radiation plate of the core member  20 . 
         [0073]    As illustrated in  FIG. 13 , when a conductive member  80  is provided, the resin on the flange portion  22   b  has a thinner thickness, and the stress state of the resin therearound becomes complicated, which makes it easier to generate a crack  90 . 
         [0074]    In the second modification, the protruding portions  11  are provided on the outer periphery side (housing inner periphery side) of the core corner portions, and therefore, even when there occurs a crack caused by a corner portion and a portion therearound of the iron core  21 , the progression of the crack can be stopped. The reduction in the strength and the heat radiation property can be suppressed. A gap is provided between the protruding portion  11  and the core, and therefore, the resin coming into the gap can be prevented from flowing in the axial direction of the iron core  21 . 
         [0075]    In the upper surface side flange portion  22   b,  the protruding portion  10  facing the housing side corner of the iron core  21  achieves the function of the same purpose as the protruding portion  11 . A gap may be provided between the protruding portion  10  and the iron core  21 , but as shown in this example, when the protruding portion  10  is configured to be in contact with the iron core  21 , this is effective as a guide for the insertion jig during iron core insertion. More specifically, the protruding portion  10  of one of the flange portions  22   b  has a function of bobbin insertion guide and the protruding portion  11  of the other of the flange portions  22   b  has a function of preventing detachment of the iron core and a function of improving resin durability so as to be configured to achieve both of the convenience and the functionality. 
       Method for Producing Bobbin 
       [0076]    Finally, a method for producing the bobbin  22  according to the above embodiments will be described. The bobbin  22  according to each of the above embodiments is formed from resin having insulation property, and is produced by resin molding. However, each embodiment is not limited thereto, and can be produced by a three-dimensional molding machine shown below. More specifically, the bobbin  22  can be obtained by not only producing the bobbin  22  itself with a three-dimensional molding machine but also performing lamination molding of a resin molding die with a three-dimensional molding machine and performing cutting process with a cutting RP apparatus. 
         [0077]    Examples of applicable lamination molding methods include an optical molding method, powder sintering lamination molding method, inkjet method, resin dissolution lamination method, gypsum powder method, sheet molding method, film transfer image lamination method, metal optical molding complex process method, and the like. 
         [0078]    Data for the lamination molding and cutting process is generated by processing 3D data generated by CAD, CG software, or 3D scanner into NC data with CAM. Three dimensional molding is performed by inputting the data into a three-dimensional molding machine or a cutting RP apparatus. NC data may be directly generated from 3D data with CAD/CAM software. 
         [0079]    In a method for obtaining the bobbin  22  and resin injection molding dies therefor, a data provider and a servicer who generated 3D data or NC data allows distribution in a predetermined file format via a communication line such as the Internet, and a user downloads the data to a 3D molding machine or a computer and the like controlling the 3D molding machine, or accesses it with a cloud type service, and the user performs molding and outputting with the three-dimensional molding machine, so that the bobbin  7  can be produced. A method in which a data provider records 3D data and NC data to a nonvolatile recording medium to be provided to the user may also be possible. 
         [0080]    When an aspect of the bobbin  22  according to the present embodiment based on such production method is shown, it is a method for producing the bobbin  22  with a three-dimensional molding machine based on three-dimensional data of a rotating electric machine bobbin including a tube portion including an internal tube having a cross section of a substantially trapezoid shape into which an iron core is inserted and an external tube around which a coil is wound, flange portions provided in proximity to end portions of both openings of the tube portion and extending a predetermined width from an entire periphery of the external tube in a direction perpendicular thereto, and a protruding portion provided on a surface of an external side of at least one of the flange portions and close to an inner edge of the tube portion and further extending in an drawing direction of the internal tube along at least a part of the inner edge. 
         [0081]    Further, when another aspect of the bobbin  22  based on such production method is shown, it is a method for transmitting and distributing, via a communication line, three-dimensional molding machine data of a rotating electric machine bobbin including a tube portion including an internal tube having a cross section of a substantially trapezoid shape into which an iron core is inserted and an external tube around which a coil is wound, flange portions provided in proximity to end portions of both openings of the tube portion and extending a predetermined width from an entire periphery of the external tube in a direction perpendicular thereto, and a protruding portion provided on a surface of an external side of at least one of the flange portions and close to an inner edge of the tube portion and further extending in an drawing direction of the internal tube along at least a part of the inner edge. 
         [0082]    Examples of the embodiments for carrying out the present invention have been hereinabove explained, but the present invention is not limited to various configurations explained above, and various configurations can be applied without deviating from the gist thereof. 
         [0083]    For example, in the above example, an example of a double rotor type and permanent magnet synchronous motor has been explained, but the embodiments can also be applied even if it is a single rotor type. In this case, the protruding portion  10  may be provided only at one of the opening portion sides of the flange portion  22   b  of the bobbin. 
         [0084]    The embodiment may be applied to a synchronous reluctance motor, a switched reluctance motor, an induction motor, and the like that does not have any permanent magnet  31  for the rotator  30 . Further, instead of a motor, the embodiment may be applied to a generator. 
         [0085]    In the rotator  30 , a back yoke may be provided between the permanent magnet  31  and the yoke  32 . The substantially trapezoid shape of the end surface shape of the iron core  21  may be a cross section having a sector or a streamline in an axial rotation direction. The flat surfaces of the stator  19  and the rotator  30  facing each other are not necessarily limited to having the air gap in the direction perpendicular to the axial center, and may be configured such that the rotation axis direction of each of them may be inclined to a certain level without deviating from the gist of the axial gap motor. 
         [0086]    It should be noted that a draft taper and an angle R, which are required for molding the bobbin with the die may be separately provided. The shapes of the protruding portions  10  and  11  may protrude in the rotation axis direction at the outer periphery side of the portion where the iron core  21  protrudes from the bobbin  22 . 
       REFERENCE SIGNS LIST 
       [0000]    
       
         
           
               1  . . . double rotor type axial air gap permanent magnet synchronous motor (motor), 
               10  . . . protruding portion, 
               10   a  . . . bottom surface, 
               10   b  . . . groove, 
               10   c  . . . gap portion, 
               11  . . . protruding portion, 
               19  . . . stator, 
               20  . . . core member, 
               21  . . . iron core, 
               22  . . . bobbin, 
               22   a  . . . tube portion, 
               22   b  . . . flange portion, 
               23  . . . coil, 
               30  . . . rotator, 
               31  . . . permanent magnet, 
               32  . . . yoke, 
               40  . . . housing, 
               51 ,  52  . . . coil winding jig, 
               61  . . . middle die, 
               62  . . . lower die, 
               71  . . . insertion jig, 
               72  . . . base, 
               80  . . . conductive member, 
               90  . . . crack, 
             A . . . rotation axis, 
             B . . . winding shaft, 
             F . . . tension, 
             S 1  . . . diameter direction cross section, 
             S 2  . . . rotation axis direction cross section