Patent Description:
Motors are used in home electric apparatuses and various apparatuses. For example, a motor is used as a fan motor mounted on an outdoor unit of an air conditioner. A fan motor includes a motor having a stator and a rotor, and a rotary fan attached to a rotating shaft of the motor.

A fan motor used in an outdoor unit of an air conditioner is installed in a body (installation object) of the outdoor unit. In this case, the fan motor is attached to the body of the outdoor unit with vibration-proof rubber interposed so that vibration generated by the fan motor is not transmitted to the outside (see PTLs <NUM> and <NUM>). This can suppress the vibration of the fan motor from being transmitted to the body of the outdoor unit, and therefore noise reduction can be achieved.

As a motor in a fan motor, a mold motor in which a stator is covered with mold resin is used. The mold motor includes, for example, a stator, a rotor disposed inside the stator, and a mold resin covering the stator from the outside. In the mold motor, the mold resin constitutes an outline of the mold motor (see PTL <NUM>).

When the mold motor is installed on the installation object with vibration-proof rubber interposed, the vibration-proof rubber is attached to the leg protruding outward from the side surface of the mold resin, and the vibration-proof rubber and the installation object are fixed with a screw or the like. For example, when the fan motor including the mold motor is installed in the body of the outdoor unit, the fan motor can be attached to the body of the outdoor unit by fixing the vibration-proof rubber attached to the leg of the mold motor and the body of the outdoor unit with screws (see PTLs <NUM> and <NUM>).

In this case, after the stator is covered with the mold resin to complete the stator mold, the vibration-proof rubber is attached to the leg of the mold resin. That is, the vibration-proof rubber is retrofitted to the mold resin.

However, in recent years, there is a concern about occurrence of an event in which the mold motor installed on the installation object with the vibration-proof rubber interposed falls off from the installation object due to expansion of the force of a typhoon, occurrence of an earthquake, or the like. In particular, since the frequency of occurrence of typhoons having an extremely large force that is expressed even once every several decades is high, it is strongly required to prevent the fan motor having the mold motor in which the vibration-proof rubber is retrofitted to the mold resin from falling off the body of the outdoor unit.

The present disclosure has been made in order to solve such problem. An object of the present disclosure is to provide a mold motor as disclosed in independent claim <NUM> capable of suppressing the mold motor from falling off from an installation object even when the mold motor is installed on the installation object using vibration-proof rubber for noise reduction.

In order to achieve the above object, one aspect of a mold motor according to the present disclosure includes a stator; a rotor including a rotation shaft and rotating by a magnetic force of the stator; a mold resin covering at least a part of the stator; an elastic body attached to an installation object in which the mold motor is installed; and one or more hard members disposed around the elastic body, the one or more hard members being harder than the elastic body, in which the elastic body and the one or more hard members are fixed to the mold resin by integral molding.

It is preferable that the mold resin includes a protrusion protruding outward in a radial direction that is a direction orthogonal to an axial direction of the rotation shaft, and the elastic body and the hard members are disposed in the protrusion.

It is preferable that the mold motor includes a tubular member as the hard member, and the tubular member is disposed outside the elastic body to surround the elastic body.

A part of the tubular member may be embedded in the elastic body.

The mold motor may include a first tubular member and a second tubular member as the hard members, the first tubular member may be disposed outside the elastic body to surround the elastic body, and the second tubular member may be disposed inside the elastic body.

At least one of the first tubular member and the second tubular member is partially embedded in the elastic body.

It is preferable that the hard members are made of a metal material.

The mold resin may be made of an unsaturated polyester resin.

The elastic body may be provided with an insertion hole through which a fixing member for attaching the mold motor to the installation object is inserted.

It is preferable that the elastic body is a vibration-proof rubber that suppresses transmission of vibration generated in the mold motor to the installation object.

It is preferable that the vibration-proof rubber is made of ethylene propylene rubber or nitrile rubber.

According to the present disclosure, it is possible to suppress the mold motor from falling off the installation object even when the mold motor is installed on the installation object using the elastic body.

Hereinafter, an exemplary embodiment of the present disclosure will be described with reference to the drawings. Note that the exemplary embodiment described below illustrates one specific example of the present disclosure. Thus, numerical values, configuration elements, placement positions and connection forms of the configuration elements, steps, order of the steps, and the like, which are described in the following exemplary embodiment, are illustrative and are not to limit the scope of the present disclosure. Thus, among the configuration elements in the following exemplary embodiment, configuration elements that are not described in independent claims indicating the highest concept of the present disclosure are described as optional configuration elements.

Note that each of the drawings is a schematic view, and is not necessarily strictly illustrated. In addition, in each of the drawings, substantially the same components are denoted by the same reference marks, and redundant description will be omitted or simplified. In addition, in the present description, the terms "above/up" and "below/down/low" do not necessarily indicate an upward direction (vertically above) and a downward direction (vertically below) in terms of absolute spatial recognition.

First, an overall configuration of mold motor <NUM> according to the exemplary embodiment will be described with reference to <FIG>. <FIG> is a perspective view of mold motor <NUM> according to the exemplary embodiment as viewed obliquely from above. <FIG> is a perspective view of mold motor <NUM> as viewed obliquely from below. <FIG> is a top view of mold motor <NUM>. <FIG> is a cross-sectional view of mold motor <NUM>. <FIG> is an enlarged view of region V surrounded by a broken line in <FIG>.

As illustrated in <FIG>, mold motor <NUM> includes stator <NUM>, rotor <NUM>, mold resin <NUM>, and attachment member <NUM>. Rotor <NUM> rotates by the magnetic force of stator <NUM>. Mold resin <NUM> covers at least a part of stator <NUM>. Attachment member <NUM> is a member for installing mold motor <NUM> onto an installation object. Mold motor <NUM> is attached to the installation object (attachment object) via attachment member <NUM>.

Mold motor <NUM> further includes first bearing <NUM>, second bearing <NUM>, first bracket <NUM>, and second bracket <NUM>. In mold motor <NUM>, mold resin <NUM> and second bracket <NUM> constitute an outline of mold motor <NUM>.

Mold motor <NUM> is a brushless motor for which no brush is used. Mold motor <NUM> is an inner rotor type motor in which rotor <NUM> is disposed inside stator <NUM>.

Mold motor <NUM> configured as described above is used, for example, as a fan motor mounted on an outdoor unit of an air conditioner. When mold motor <NUM> is used as a fan motor, a rotary fan is attached to rotating shaft <NUM> of mold motor <NUM>. In this case, the installation object of mold motor <NUM> is the body of the outdoor unit of the air conditioner, and mold motor <NUM> is attached to the body (for example, frame) of the outdoor unit of the air conditioner via attachment member <NUM>.

Hereinafter, each component of mold motor <NUM> will be described in detail.

As illustrated in <FIG>, stator <NUM> is disposed to oppose rotor <NUM> with a minute air gap interposed between the stator and rotor <NUM>. Specifically, stator <NUM> is disposed so as to surround rotor core <NUM> of rotor <NUM>.

Stator <NUM> includes stator core <NUM>, coil <NUM>, and insulator <NUM>.

Stator core <NUM> serves as a core of stator <NUM>. Stator core <NUM> generates a magnetic force for rotating rotor <NUM>. Stator core <NUM> is, for example, a stacked body in which a plurality of electromagnetic steel sheets are stacked in a direction in which axial center C of rotating shaft <NUM> of rotor <NUM> extends. Note that stator core <NUM> is not limited to the stacked body, and may be a bulk body made of a magnetic material.

Stator core <NUM> includes a yoke formed in an annular shape so as to surround rotor <NUM> and a plurality of teeth protruding from the yoke toward rotating shaft <NUM>. The yoke is a back yoke formed outside each tooth. Each of the plurality of teeth protruding toward rotating shaft <NUM> faces rotor core <NUM> of rotor <NUM>. The plurality of teeth radially extend in a direction (radial direction) orthogonal to axial center C of rotating shaft <NUM>. The plurality of teeth are arranged at equal intervals along the rotation direction of rotating shaft <NUM> while forming a slot between two adjacent teeth.

The plurality of coils <NUM> are armature windings of stator <NUM>, and are wound around stator core <NUM>. Coil <NUM> is a winding coil wound around stator core <NUM> via insulator <NUM>. As an example, coil <NUM> is a concentrated winding coil wound around each of a plurality of teeth included in stator core <NUM>, and is housed in a slot of stator core <NUM>. Note that coil <NUM> is not limited to concentrated winding, and may be distributed winding.

Coil <NUM> has a three-phase winding so as to be able to rotate rotor <NUM> as a three-phase synchronous motor. Specifically, coil <NUM> includes unit coils of three phases of a U phase, a V phase, and a W phase electrically different from one another by <NUM> degrees. That is, coil <NUM> wound around each of the teeth of stator core <NUM> is energized and driven by three-phase alternating current energized in units of phases of the U phase, the V phase, and the W phase. Due to this, a main magnetic flux as stator <NUM> is generated in each tooth of stator core <NUM>. That is, each tooth around which coil <NUM> is wound is a magnetic pole tooth, and is an electromagnet that generates magnetic force by energizing coil <NUM>.

The end of coil <NUM> of each phase is connected by a winding connection included in circuit board <NUM>. In circuit board <NUM>, pattern wiring for electrically connecting the plurality of coils <NUM> is formed for each phase of the U phase, the V phase, and the W phase. The end of coil <NUM> of each phase is electrically connected to the pattern wiring of circuit board <NUM> by solder or the like.

Insulator <NUM> is a coil bobbin. Insulator <NUM> has a frame-shaped frame body around which coil <NUM> is wound. The frame body of insulator <NUM> is an insulating frame that covers stator core <NUM>. Specifically, the frame body of insulator <NUM> is provided so as to cover the teeth of stator core <NUM>. Insulator <NUM> is provided in each of the plurality of teeth, but is not limited to this. Insulator <NUM> is made of, for example, an insulating resin material such as polybutylene terephthalate (PBT).

Stator <NUM> configured as described above generates a magnetic force acting on rotor <NUM> by a current flowing through coil <NUM>. Specifically, stator <NUM> generates a magnetic flux on an air gap surface with rotor core <NUM> included in rotor <NUM> so that N poles and S poles are alternately present along the rotation direction (circumferential direction) of rotating shaft <NUM>. The direction of the main magnetic flux generated by stator <NUM> is a direction (radial direction) orthogonal to axial center C of rotating shaft <NUM>. Stator <NUM> constitutes a magnetic circuit together with rotor <NUM>.

Next, rotor <NUM> will be described. Rotor <NUM> rotates by a magnetic force generated in stator <NUM>. As illustrated in <FIG>, rotor <NUM> includes rotating shaft <NUM>. Rotor <NUM> rotates about axial center C of rotating shaft <NUM>.

Rotor <NUM> is disposed to oppose stator <NUM>. In the present exemplary embodiment, rotor <NUM> opposes stator <NUM> in a direction (radial direction) orthogonal to the direction in which axial center C of rotating shaft <NUM> extends.

Rotor <NUM> has a configuration in which a plurality of N poles and S poles are repeatedly present along the rotation direction of rotating shaft <NUM>. Rotor <NUM> is an interior permanent magnet (IPM) rotor. Therefore, mold motor <NUM> is an IPM motor.

Specifically, rotor <NUM> includes rotating shaft <NUM>, rotor core <NUM>, and permanent magnet <NUM> inserted into each of a plurality of magnet insertion holes 22a formed in rotor core <NUM>.

Rotor core <NUM> serves as a core of rotor <NUM>. Rotor core <NUM> is a substantially columnar stacked body in which a plurality of electromagnetic steel sheets are stacked along the direction in which axial center C of rotating shaft <NUM> extends. Note that rotor core <NUM> is not limited to a stacked body including a plurality of steel plates, and may be a bulk body including a magnetic material.

The plurality of magnet insertion holes 22a formed in rotor core <NUM> exist at equal intervals along the rotation direction of rotating shaft <NUM>. Each of the plurality of magnet insertion holes 22a penetrates rotor core <NUM> in the direction in which axial center C of rotating shaft <NUM> extends, but need not penetrate rotor core <NUM>. Permanent magnet <NUM> is embedded in each magnet insertion hole 22a. Permanent magnet <NUM> is a sintered magnet, and one permanent magnet <NUM> is inserted into each magnet insertion hole 22a. Note that permanent magnet <NUM> may be a bonded magnet.

Rotating shaft <NUM> is fixed to the center of rotor core <NUM>. Rotating shaft <NUM> is a shaft having axial center C. Rotating shaft <NUM> is an elongated rod-like member such as a metal rod. Axial center C of rotating shaft <NUM> serves as a rotation center when rotor <NUM> rotates. The longitudinal direction (extending direction) of rotating shaft <NUM> is a direction (axial direction) in which axial center C extends.

Rotating shaft <NUM> is fixed to rotor core <NUM> in a state of penetrating rotor core <NUM> so as to extend on both sides of rotor core <NUM> in a direction in which axial center C of rotating shaft <NUM> extends. Specifically, rotating shaft <NUM> is inserted into a through hole provided at the center of rotor core <NUM> and fixed to rotor core <NUM>. Rotating shaft <NUM> is fixed to rotor core <NUM>, for example, by being press-fitted or shrink-fitted into a through hole of rotor core <NUM>. Rotating shaft <NUM> is rotatably supported by first bearing <NUM> and second bearing <NUM>.

Rotor <NUM> configured as described above generates a magnetic force acting on stator <NUM>. Similarly to stator <NUM>, the orientation of the main magnetic flux generated by rotor <NUM> is a direction (radial direction) orthogonal to axial center C of rotating shaft <NUM>. That is, the orientations of the magnetic fluxes generated by stator <NUM> and rotor <NUM> are both radial directions.

Rotor <NUM> rotates by a magnetic flux generated by rotor <NUM> itself and a magnetic flux generated by stator <NUM>. Specifically, when electric power is supplied from circuit board <NUM> to coil <NUM> of stator <NUM>, a field current flows through coil <NUM>, and a magnetic flux is generated in stator core <NUM>. A magnetic force generated by the interaction between the magnetic flux generated in stator core <NUM> and the magnetic flux generated from permanent magnet <NUM> included in rotor <NUM> becomes a torque for rotating rotor <NUM>, and rotor <NUM> rotates.

Next, mold resin <NUM> will be described. As illustrated in <FIG>, mold resin <NUM> covers stator <NUM>. Mold resin <NUM> covers the outer portion of stator <NUM> over the entire circumference of stator <NUM>. Specifically, mold resin <NUM> covers the outer portions of stator core <NUM>, coil <NUM>, and insulator <NUM>. Mold resin <NUM> is in contact with the outer surfaces of coil <NUM> and insulator <NUM>.

Mold resin <NUM> is made of an insulating resin material having excellent thermal conductivity, such as a polyester resin or an epoxy resin. Mold resin <NUM> is made of a thermosetting resin. In the present exemplary embodiment, mold resin <NUM> is made of unsaturated polyester that is a thermosetting resin. Specifically, mold resin <NUM> is made of white bulk molding compound (BMC) unsaturated polyester resin. The color of the BMC constituting mold resin <NUM> is not particularly limited, and may be another color, for example, black.

As illustrated in <FIG>, mold resin <NUM> is a part of an outline of mold motor <NUM>, and constitutes a housing. Specifically, as illustrated in <FIG>, mold resin <NUM> covering stator <NUM> constitutes a housing enclosing rotor <NUM>.

Mold resin <NUM> includes main body <NUM> constituting a trunk of mold motor <NUM> and protrusion <NUM> provided in main body <NUM>. Protrusions <NUM> are provided in main body <NUM>. Specifically, as illustrated in <FIG>, main body <NUM> is provided with four protrusions <NUM>. Note that main body <NUM> and protrusions <NUM> are integrally formed by molding to form one mold resin <NUM>.

Main body <NUM> covers the outer portion of stator <NUM> over the entire circumference of stator <NUM>. Specifically, main body <NUM> covers stator core <NUM>, coil <NUM>, and insulator <NUM>. As illustrated in <FIG>, main body <NUM> is a tubular body having an opening at each of one end and the other end in the direction in which axial center C of rotating shaft <NUM> extends.

As illustrated in <FIG> and <FIG>, protrusion <NUM> protrudes outward in a direction (radial direction) orthogonal to a direction in which axial center C of rotating shaft <NUM> extends. Specifically, each of the plurality of protrusions <NUM> protrudes in a protruding shape from the outer surface of main body <NUM>. As illustrated in <FIG>, the plurality of protrusions <NUM> radially extend in a direction (radial direction) orthogonal to axial center C of rotating shaft <NUM> in top view. The plurality of protrusions <NUM> are provided at equal intervals along the rotation direction of rotating shaft <NUM>. Specifically, four protrusions <NUM> are provided at intervals of <NUM> degrees along the rotation direction of rotating shaft <NUM>.

Protrusion <NUM> is a leg of mold motor <NUM>, and functions as an attachment part for attaching mold motor <NUM> to an installation object. Mold motor <NUM> is attached to an installation object via attachment member <NUM> fixed to each protrusion <NUM>.

Next, attachment member <NUM> will be described. Attachment member <NUM> is a component for installing mold motor <NUM> onto an installation object. The installation object on which mold motor <NUM> is installed is a rigid body made of a metal material, a resin material, or the like. For example, when mold motor <NUM> is installed in a fan motor of an outdoor unit of an air conditioner, mold motor <NUM> of the fan motor is installed in the body of the outdoor unit that is the installation object.

As illustrated in <FIG>, attachment member <NUM> is fixed to mold resin <NUM>. Attachment member <NUM> is fixed to mold resin <NUM> by integral molding. In the present exemplary embodiment, as illustrated in <FIG>, attachment member <NUM> is fixed to protrusion <NUM> in a state where a part of attachment member <NUM> is embedded in protrusion <NUM> of mold resin <NUM>.

Attachment member <NUM> includes vibration-proof rubber <NUM>, which is an elastic body, and tubular member <NUM> disposed around vibration-proof rubber <NUM>. Vibration-proof rubber <NUM> is attached to the installation object on which mold motor <NUM> is installed. <FIG> is a perspective view of attachment member <NUM> in mold motor <NUM> according to the exemplary embodiment. <FIG> is a top view of attachment member <NUM>. <FIG> is a cross-sectional view taken along line VIIB-VIIB in <FIG>. As illustrated in <FIG>, and <FIG>, attachment member <NUM> is a component in which vibration-proof rubber <NUM> and tubular member <NUM> are integrated. Before attachment member <NUM> is fixed to mold resin <NUM>, vibration-proof rubber <NUM> and tubular member <NUM> are integrally molded by resin molding.

Vibration-proof rubber <NUM>, which is an elastic body, has a function of absorbing or attenuating vibration of mold motor <NUM> so that the vibration of mold motor <NUM> is not transmitted to the installation object. That is, vibration-proof rubber <NUM> suppresses transmission of vibration generated in mold motor <NUM> to the installation object. Specifically, vibration-proof rubber <NUM>, which is an elastic body, is made of an elastomer having rubber elasticity. As an example, vibration-proof rubber <NUM> is made of a rubber material such as ethylene propylene rubber (EPM), ethylene propylene dene rubber (EPDM), and ethylene propylene (EP), or nitrile rubber (NBR). EPM is a copolymer of ethylene and propylene as the ethylene propylene rubber, and EPDM is a terpolymer containing a smaller amount of the third component in addition to ethylene and propylene.

As illustrated in <FIG>, and <FIG>, vibration-proof rubber <NUM> is provided with insertion hole 41a through which a screw, a bolt, or the like (hereinafter, referred to as "screw or the like"), which is a fixing member for attaching mold motor <NUM> to the installation object, is inserted. The shape of vibration-proof rubber <NUM> is a thick tubular member having a large thickness. Vibration-proof rubber <NUM> has a cylindrical shape. As an example, the thickness of vibration-proof rubber <NUM> in the radial direction is substantially the same as the diameter of insertion hole 41a, but is not limited to this. From the viewpoint of suppressing vibration of mold motor <NUM>, the thickness of vibration-proof rubber <NUM> in the radial direction is preferably larger than the diameter of insertion hole 41a. A screw or the like as a fixing member is selected in a state of an attachment portion of an installation object to which mold motor <NUM> is attached, for example, a frame. Specifically, if a female screw is formed in the frame, a screw can be used as the fixing member. When a through hole is formed in the frame, a bolt and a nut can be used as the fixing member.

Tubular member <NUM> is disposed outside vibration-proof rubber <NUM> so as to surround vibration-proof rubber <NUM>. Tubular member <NUM> has a shape corresponding to the outer shape of vibration-proof rubber <NUM>. In this case, the shape of tubular member <NUM> and the shape of vibration-proof rubber <NUM> are preferably similar to each other. Since vibration-proof rubber <NUM> has a cylindrical shape, tubular member <NUM> also has a cylindrical shape. Tubular member <NUM> is disposed such that the inner surface of tubular member <NUM> and the outer surface of vibration-proof rubber <NUM> are in contact with each other. Therefore, the inner diameter of tubular member <NUM> and the outer diameter of vibration-proof rubber <NUM> are the same.

Although the height of tubular member <NUM> is lower than the height of vibration-proof rubber <NUM>, the present invention is not limited to this. For example, the height of tubular member <NUM> and the height of vibration-proof rubber <NUM> may be the same. The shape of vibration-proof rubber <NUM> and the shape of tubular member <NUM> need not be a circular shape, and may be a square tubular shape including a polygon such as a quadrangle. The shape of vibration-proof rubber <NUM> and the shape of tubular member <NUM> need not be the same or may be different. Tubular member <NUM> is a ring member. Therefore, the shape of tubular member <NUM> in top view is a closed ring shape, but may be a C shape. That is, the side wall of tubular member <NUM> may be provided with a slit. There may be a step on the surface of tubular member <NUM>, or a hole may be formed in a part of the side wall of tubular member <NUM>.

Tubular member <NUM> is a hard member harder than vibration-proof rubber <NUM>. That is, the hardness of tubular member <NUM> is harder than the hardness of vibration-proof rubber <NUM>. Tubular member <NUM> is made of a metal material. As an example, tubular member <NUM> is an iron cylindrical tube formed of an iron-based material. Note that the material of tubular member <NUM> is not limited to a metal material as long as the material is harder than vibration-proof rubber <NUM>, and may be made of a ceramic material, a hard resin material, or the like. Tubular member <NUM> is only required to be made of a material that can sufficiently withstand the maximum injection pressure (for example, about <NUM> MP) of liquid resin 30a (see <FIG>) injected at the time of molding mold resin <NUM>.

The hardness of tubular member <NUM> and the hardness of vibration-proof rubber <NUM> can be evaluated on the basis of an index such as durometer hardness, Vickers hardness, or Shore hardness. The hardness of tubular member <NUM> and the hardness of vibration-proof rubber <NUM> may be evaluated by the elastic modulus (Young's modulus) of the material constituting tubular member <NUM> and vibration-proof rubber <NUM>. For example, when the elastic modulus (Young's modulus) of tubular member <NUM> is larger than the elastic modulus (Young's modulus) of vibration-proof rubber <NUM>, the hardness of tubular member <NUM> is harder than the hardness of vibration-proof rubber <NUM>.

As an example, vibration-proof rubber <NUM> is made of EPDM having durometer hardness of rubber hardness <NUM>. The material of tubular member <NUM> is iron.

As illustrated in <FIG> and <FIG>, vibration-proof rubber <NUM> and tubular member <NUM> are fixed to mold resin <NUM> by integral molding. That is, vibration-proof rubber <NUM> and tubular member <NUM> are structured not to be detached from mold resin <NUM>. Therefore, vibration-proof rubber <NUM> and tubular member <NUM> cannot be removed from mold resin <NUM>.

Vibration-proof rubber <NUM> and tubular member <NUM> are disposed on protrusion <NUM> of mold resin <NUM>. That is, vibration-proof rubber <NUM> and tubular member <NUM> are fixed to protrusion <NUM> of mold resin <NUM> by integral molding. Specifically, vibration-proof rubber <NUM> and tubular member <NUM> are fixed to mold resin <NUM> as attachment member <NUM> as described above.

Vibration-proof rubber <NUM> is embedded in protrusion <NUM> such that the upper end and the lower end in the axial direction are exposed. That is, in vibration-proof rubber <NUM>, the upper end top surface, the upper end outer peripheral side surface, the lower end bottom surface, and the lower end outer peripheral side surface are exposed. On the other hand, tubular member <NUM> is embedded in protrusion <NUM> without exposing the entire outer peripheral side surface. The upper end top surface of tubular member <NUM> is present at a position recessed from the outer surface of protrusion <NUM>, and the lower end bottom surface of tubular member <NUM> is flush with the outer surface of protrusion <NUM>.

Next, first bearing <NUM>, second bearing <NUM>, first bracket <NUM>, and second bracket <NUM> will be described.

As illustrated in <FIG>, first bearing <NUM> and second bearing <NUM> rotatably support rotating shaft <NUM>. Specifically, first portion 21a of rotating shaft <NUM> protruding to one side from rotor core <NUM> is supported by first bearing <NUM>. On the other hand, second portion 21b of rotating shaft <NUM> protruding from rotor core <NUM> to the other side is supported by second bearing <NUM>. As an example, first bearing <NUM> and second bearing <NUM> are bearings such as ball bearings.

In the present exemplary embodiment, first portion 21a of rotating shaft <NUM> is an output shaft, and protrudes from first bearing <NUM> and first bracket <NUM>. A load such as a rotary fan is attached to first portion 21a of rotating shaft <NUM>. Second portion 21b of rotating shaft <NUM> is a counter output shaft and does not protrude from second bearing <NUM> and second bracket <NUM>.

First bracket <NUM> retains first bearing <NUM>. First bearing <NUM> is fixed to a recess of first bracket <NUM>. Second bracket <NUM> retains second bearing <NUM>. Second bearing <NUM> is fixed to second bracket <NUM>.

First bracket <NUM> is provided at one end of mold resin <NUM> in the direction in which axial center C of rotating shaft <NUM> extends. Specifically, first bracket <NUM> is disposed so as to close the opening on one end side of main body <NUM> of mold resin <NUM>.

Second bracket <NUM> is provided at the other end of mold resin <NUM> in the direction in which axial center C of rotating shaft <NUM> extends. Specifically, second bracket <NUM> is disposed so as to close the opening on the other end side of main body <NUM> of mold resin <NUM>.

The entire outer diameter of first bracket <NUM> is smaller than the entire outer diameter of second bracket <NUM>. That is, the outer size of second bracket <NUM> is larger than that of first bracket <NUM>.

First bracket <NUM> and second bracket <NUM> are made of a metal material such as iron. For example, first bracket <NUM> and second bracket <NUM> are made of a metal plate having a constant thickness. First bracket <NUM> and second bracket <NUM> are fixed to mold resin <NUM>. Specifically, first bracket <NUM> is fixed to mold resin <NUM> together with stator <NUM> when stator <NUM> is molded by resin. On the other hand, second bracket <NUM> is fixed to mold resin <NUM> after molded.

As described above, mold motor <NUM> of the present exemplary embodiment includes stator <NUM>, rotor <NUM> rotating by the magnetic force of stator <NUM>, mold resin <NUM> covering at least a part of stator <NUM>, elastic body <NUM> attached to an installation object on which mold motor <NUM> is installed, and one or more hard members disposed around elastic body <NUM> and harder than elastic body <NUM>, and elastic body <NUM> and the hard members are fixed to mold resin <NUM> by integral molding.

Accordingly, even when mold motor <NUM> is installed on the installation object using elastic body <NUM>, it is possible to prevent mold motor <NUM> from falling off from the installation obj ect.

Next, the manufacturing method for mold motor <NUM> will be described with reference to <FIG>, <FIG>. In particular, a method of fixing attachment member <NUM> to mold resin <NUM> will be mainly described below. <FIG> is a flowchart of the manufacturing method for mold motor <NUM> according to the exemplary embodiment. <FIG> are views for explaining the method for fixing attachment member <NUM> to mold resin <NUM> in the manufacturing method for mold motor <NUM>. <FIG> is an enlarged view of protrusion <NUM> of mold resin <NUM> in mold motor <NUM> after completed. <FIG> is a view illustrating a state when mold resin <NUM> is molded by mold <NUM> in a cross section taken along line IXB-IXB in <FIG>.

First, attachment member <NUM> having the structure illustrated in <FIG>, and <FIG> is separately prepared. Specifically, as illustrated in <FIG>, attachment member <NUM> is prepared by integrally molding vibration-proof rubber <NUM> and tubular member <NUM> (step S11). Attachment member <NUM> can be prepared by, for example, insert molding. In this case, metal tubular member <NUM> is disposed in a mold for resin molding, and a liquid resin of a resin material constituting vibration-proof rubber <NUM> is injected into the mold and cured, whereby attachment member <NUM> in which tubular member <NUM> is fixed to vibration-proof rubber <NUM> can be prepared by integral molding.

Next, as illustrated in <FIG>, attachment member <NUM> and stator <NUM> are molded together with mold resin <NUM> (step S12). As a result, mold resin <NUM> in which attachment member <NUM> and stator <NUM> are fixed can be prepared by integral molding.

Specifically, first, stator <NUM> having stator core <NUM> around which coil <NUM> is wound via insulator <NUM> and attachment member <NUM> are disposed in mold <NUM> of the injection molding machine as illustrated in <FIG>. At this time, first bracket <NUM> is also disposed on mold <NUM>.

Mold <NUM> includes a plurality of blocks. For example, when a horizontal injection molding machine is used, as illustrated in <FIG>, mold <NUM> is configured to be opened and closed in the vertical direction by first block <NUM> as a lower mold and second block <NUM> as an upper mold. In this case, by inserting projection 101a of first block <NUM> into insertion hole 41a formed in vibration-proof rubber <NUM> of attachment member <NUM>, attachment member <NUM> is disposed in mold <NUM>. The diameter of projection 101a is the same as the inner diameter of insertion hole 41a of vibration-proof rubber <NUM>, and projection 101a inserted into insertion hole 41a of vibration-proof rubber <NUM> is in close contact with vibration-proof rubber <NUM>.

Subsequently, liquid resin 30a that is a resin material constituting mold resin <NUM> is injected into mold <NUM> through a gate provided in mold <NUM>. At this time, since tubular member <NUM> surrounds vibration-proof rubber <NUM>, when liquid resin 30a is injected from the outside of attachment member <NUM>, liquid resin 30a flows into mold <NUM> without directly contact with the outer peripheral surface of vibration-proof rubber <NUM>. Specifically, liquid resin 30a injected into mold <NUM> is filled in mold <NUM> while being in contact with the outer surface of tubular member <NUM> surrounding vibration-proof rubber <NUM>. As described above, since tubular member <NUM> is disposed outside vibration-proof rubber <NUM>, the injection pressure of liquid resin 30a can be received by tubular member <NUM>, and the injection pressure of liquid resin 30a can be prevented from being applied to vibration-proof rubber <NUM>. This makes it possible to suppress deformation of vibration-proof rubber <NUM> due to the injection pressure of liquid resin 30a.

When liquid resin 30a is injected into mold <NUM>, projection 101a of first block <NUM> is inserted into insertion hole 41a formed in vibration-proof rubber <NUM> as described above. Due to this, since vibration-proof rubber <NUM> is supported by projection 101a, it is possible to further suppress deformation of vibration-proof rubber <NUM> in mold <NUM> at the time of molding mold resin <NUM>.

After filling mold <NUM> with liquid resin 30a, liquid resin 30a is cured. Due to this, stator <NUM>, attachment member <NUM>, and first bracket <NUM> are fixed to mold resin <NUM> by integral molding.

Noted that, after that, mold motor <NUM> is completed by assembling other components such as rotor <NUM> to stator <NUM> covered with mold resin <NUM>.

Next, characteristics of mold motor <NUM> according to the present exemplary embodiment will be described, including the background leading to the technique of the present disclosure.

<FIG> is a perspective view illustrating the configuration of a conventional mold motor. Conventionally, when a fan motor having a mold motor is installed on an installation object, the fan motor is installed on the installation object with a vibration-proof rubber interposed so that vibration generated by the fan motor is not transmitted to the installation object.

In this case, as illustrated in <FIG>, in conventional mold motor 1X, after the stator is covered with mold resin 30X to complete the stator mold, vibration-proof rubber 41X is attached to protrusion 32X (leg) of mold resin 30X. <FIG> is a flowchart of a manufacturing method for a conventional mold motor. Specifically, as illustrated in <FIG>, vibration-proof rubber 41X is prepared by resin molding (step S21). The stator is molded with mold resin 30X to prepare a stator mold (step S22). Vibration-proof rubber 41X is attached to the stator mold (step S23). In this case, as illustrated in <FIG>, vibration-proof rubber 41X is laterally inserted into protrusion 32X of mold resin 30X to attach vibration-proof rubber 41X to mold resin 30X. That is, vibration-proof rubber 41X is retrofitted to mold resin 30X.

As described above, when a fan motor including mold motor 1X in which vibration-proof rubber 41X is retrofitted to mold resin 30X is installed in the installation object, there is a concern about occurrence of an event in which the fan motor falls off the installation object due to a typhoon, an earthquake, or the like.

Therefore, it is conceivable to fix vibration-proof rubber 41X to mold resin 30X by integral molding. That is, when the stator is molded with mold resin 30X, it is conceivable that vibration-proof rubber 41X is also molded with mold resin 30X together with the stator.

However, when vibration-proof rubber 41X was actually integrally molded with mold resin 30X, it has been found that vibration-proof rubber 41X is deformed. Specifically, it has been found that vibration-proof rubber 41X is deformed by the injection pressure when the liquid resin of the resin material constituting mold resin 30X is injected into the mold.

As a result of intensive studies on this problem, the inventors of the present application have obtained an idea of arranging one or more hard members harder than the vibration-proof rubber around the vibration-proof rubber and fixing the vibration-proof rubber and the hard members to the mold resin by integral molding when integrally molding the vibration-proof rubber with the mold resin.

Mold motor <NUM> according to the present disclosure has been made based on this idea. Specifically, mold motor <NUM> includes vibration-proof rubber <NUM> attached to an installation object on which mold motor <NUM> is installed, and a hard member harder than vibration-proof rubber <NUM>. One or more hard members are disposed around vibration-proof rubber <NUM>. Vibration-proof rubber <NUM> and the hard members are fixed to mold resin <NUM> by integral molding. Mold motor <NUM> includes tubular member <NUM> as a hard member disposed around vibration-proof rubber <NUM>.

In this manner, tubular member <NUM> is disposed as a hard member harder than vibration-proof rubber <NUM> around vibration-proof rubber <NUM>. As a result, even when vibration-proof rubber <NUM> is integrally molded with mold resin <NUM>, it is possible to suppress deformation of vibration-proof rubber <NUM> due to the injection pressure of liquid resin 30a for molding mold resin <NUM>.

In particular, in the present exemplary embodiment, tubular member <NUM> is disposed outside vibration-proof rubber <NUM> so as to surround vibration-proof rubber <NUM>.

With this configuration, as illustrated in <FIG>, when liquid resin 30a is injected from the outside of vibration-proof rubber <NUM>, the injection pressure of liquid resin 30a can be received by tubular member <NUM> surrounding the outside of vibration-proof rubber <NUM>. It is possible to prevent the injection pressure of liquid resin 30a from being applied to vibration-proof rubber <NUM>. This makes it possible to effectively suppress deformation of vibration-proof rubber <NUM> due to the injection pressure of liquid resin 30a.

Mold resin <NUM> has protrusion <NUM> protruding outward in a radial direction that is a direction orthogonal to the direction (axial direction) in which axial center C of rotating shaft <NUM> extends. Vibration-proof rubber <NUM> and tubular member <NUM>, which is a hard member, are disposed in protrusion <NUM>. That is, vibration-proof rubber <NUM> and tubular member <NUM> are fixed to protrusion <NUM> of mold resin <NUM> by integral molding.

With this configuration, mold motor <NUM> can be installed on the installation object using protrusion <NUM> of mold resin <NUM>. That is, mold motor <NUM> can be attached to the installation object via vibration-proof rubber <NUM> fixed to protrusion <NUM>. Therefore, mold motor <NUM> can be easily attached to the installation object.

Specifically, vibration-proof rubber <NUM> is provided with insertion hole 41a through which a screw or the like for attaching mold motor <NUM> to the installation object is inserted. Thus, a screw or the like is inserted into insertion hole 41a formed in vibration-proof rubber <NUM>, and mold motor <NUM> can be easily attached to the installation object by screwing.

In the present exemplary embodiment, vibration-proof rubber <NUM> is made of ethylene propylene rubber or nitrile rubber.

Thus, vibration of mold motor <NUM> can be effectively absorbed by vibration-proof rubber <NUM>. Therefore, it is possible to effectively suppress transmission of vibration of mold motor <NUM> to the installation object. For example, although mold motor <NUM> has a vibration displacement of <NUM> to <NUM>, vibration of such a vibration displacement can be effectively absorbed by vibration-proof rubber <NUM>.

Moreover, the heatproof temperature of the ethylene propylene rubber or the nitrile rubber is <NUM> or less. Specifically, the heatproof temperature (maximum specification temperature) of the ethylene propylene rubber is <NUM>. The heatproof temperature (maximum specification temperature) of the nitrile rubber is <NUM>. Therefore, since vibration-proof rubber <NUM> is made of ethylene propylene rubber or nitrile rubber, the molding temperature of liquid resin 30a when mold resin <NUM> is molded can be allowed up to <NUM>.

For example, the molding temperature at the time of resin molding using an unsaturated polyester resin is <NUM>. Therefore, since mold resin <NUM> is made of an unsaturated polyester resin, vibration-proof rubber <NUM> can be made of ethylene propylene rubber or nitrile rubber.

As described above, according to mold motor <NUM> according to the present exemplary embodiment, since vibration-proof rubber <NUM> and tubular member <NUM> are fixed to mold resin <NUM> by integral molding, vibration-proof rubber <NUM> is not detached from mold resin <NUM>. Due to this, even when mold motor <NUM> is installed on the installation object using vibration-proof rubber <NUM> for reducing noise, mold motor <NUM> can be suppressed from falling off from the installation object.

For example, when a fan motor including mold motor <NUM> is installed in the body of an outdoor unit of an air conditioner with vibration-proof rubber <NUM> interposed, the fan motor can be suppressed from falling off from the body of the outdoor unit even when a strong wind such as a typhoon or an earthquake occurs. That is, it is possible to achieve a fan motor that can achieve both noise reduction by vibration-proof rubber <NUM> and prevention of falling off from the installation object.

Mold motor <NUM> according to the present disclosure has been described above on the basis of the exemplary embodiment. However, the present disclosure is not limited to the above exemplary embodiments.

For example, in attachment member <NUM> in the above exemplary embodiments, the inner diameter of tubular member <NUM> and the outer diameter of vibration-proof rubber <NUM> are substantially the same. However, the present disclosure is not limited to this. <FIG> is a top view of attachment member 40A according to the first modification. <FIG> is a cross-sectional view taken along line XIIB-XIIB in <FIG>. For example, as in attachment member 40A illustrated in <FIG>, the inner diameter of tubular member 42A may be smaller than the outer diameter of vibration-proof rubber <NUM> in a portion where tubular member 42A and vibration-proof rubber <NUM> are in contact with each other. That is, a part of tubular member 42A in the thickness direction may be embedded in vibration-proof rubber <NUM>.

As in attachment member 40A according to the present modification, since a part of tubular member 42A is embedded in vibration-proof rubber <NUM>, tubular member 42A is less likely to be displaced in the axial direction (vertical direction) of tubular member 42A. Since a part of tubular member 42A is embedded in vibration-proof rubber <NUM>, a contact area between tubular member 42A and vibration-proof rubber <NUM> can be increased as compared with a case where a part of tubular member 42A is not embedded in vibration-proof rubber <NUM>. Due to this, when the mold motor in which attachment member 40A is fixed to the mold resin is screwed to the installation object by inserting a screw or the like into insertion hole 41a formed in attachment member 40A, idling of tubular member 42A can be suppressed.

Not only a part of tubular member 42A in the thickness direction but also entire tubular member 42A in the thickness direction may be embedded in vibration-proof rubber <NUM>. That is, the outer surface of tubular member 42A may be exposed, and the outer diameter of tubular member 42A and the outer diameter of vibration-proof rubber <NUM> may be the same. Tubular member 42A is embedded in vibration-proof rubber <NUM> on the entire circumference in the circumferential direction. However, the present disclosure is not limited to this. A part in the circumferential direction may be embedded in vibration-proof rubber <NUM>. For example, a plurality of projections may be provided on the inner surface of tubular member 42A along the circumferential direction, and only the plurality of projections may be embedded in vibration-proof rubber <NUM>.

In the above-mentioned exemplary embodiments, attachment member <NUM> has one tubular member. However, the present disclosure is not limited to this. For example, attachment member <NUM> may have a plurality of tubular members. Specifically, as in attachment member 40B illustrated in <FIG>, first tubular member 42a and second tubular member 42b may be provided as hard members harder than vibration-proof rubber <NUM>. <FIG> is a top view of attachment member 40B according to the second modification. <FIG> is a cross-sectional view taken along line XIIIB-XIIIB in <FIG>.

In attachment member 40B, first tubular member 42a is disposed outside vibration-proof rubber <NUM> so as to surround vibration-proof rubber <NUM>. Second tubular member 42b is disposed inside vibration-proof rubber <NUM>. That is, first tubular member 42a is an outer tube. Second tubular member 42b is an inner tube.

Specifically, first tubular member 42a is the same as tubular member <NUM> of attachment member <NUM> in the above exemplary embodiments. First tubular member 42a is fixed to vibration-proof rubber <NUM> in the same manner as attachment member <NUM> in the above exemplary embodiments. Therefore, first tubular member 42a is an iron cylindrical tube, and is disposed such that the inner surface of first tubular member 42a is in contact with the outer surface of vibration-proof rubber <NUM>.

Second tubular member 42b is made of a metal material, a ceramic material, a hard resin material, or the like. As an example, second tubular member 42b is an iron cylindrical tube similarly to first tubular member 42a. Second tubular member 42b and first tubular member 42a have the same shape (both are cylindrical). However, the shapes may be different from each other. Second tubular member 42b and first tubular member 42a are made of the same material (both made of iron). However, different materials may be used.

Entire second tubular member 42b in the thickness direction of second tubular member 42b is embedded in vibration-proof rubber <NUM>. That is, the inner diameter of second tubular member 42b and the inner diameter of vibration-proof rubber <NUM> are the same, the inner surface of second tubular member 42b is exposed, and the inner surface of second tubular member 42b and the inner surface of vibration-proof rubber <NUM> are flush with each other. Therefore, in attachment member 40B, the through hole of second tubular member 42b serves as an attachment hole (screw insertion hole) when the mold motor is attached to the installation object.

As described above, attachment member 40B in the present modification has a configuration in which vibration-proof rubber <NUM> is held between first tubular member 42a and second tubular member 42b. Specifically, attachment member 40B has a configuration in which second tubular member 42b is added to attachment member <NUM> in the above exemplary embodiments.

This configuration can suppress deformation of vibration-proof rubber <NUM> due to the injection pressure of liquid resin 30a at the time of molding of mold resin <NUM> by first tubular member 42a. Since the through hole of second tubular member 42b serves as an attachment hole, the dimensional accuracy of the attachment hole of attachment member 40B can be increased. Therefore, rattling when attachment member 40B and the installation object are screwed can be eliminated, and therefore the mold motor can be stably fixed to the installation object. This further suppresses the mold motor from falling off the installation object.

Entire second tubular member 42b in the thickness direction needs not be embedded in vibration-proof rubber <NUM>. For example, a part of second tubular member 42b in the thickness direction may be embedded in vibration-proof rubber <NUM>. Alternatively, entire second tubular member 42b in the thickness direction needs not be embedded. A part or the entirety of first tubular member 42a in the thickness direction may be embedded in vibration-proof rubber <NUM>. Thus, at least one of first tubular member 42a and second tubular member 42b may be partially embedded in vibration-proof rubber <NUM>.

In attachment member <NUM> in the above exemplary embodiments, tubular member <NUM> has a tubular shape having no step on the surface, but the present disclosure is not limited to this. <FIG> is a top view of attachment member 40C according to the third modification. <FIG> is a cross-sectional view taken along line XIVB-XIVB in <FIG>. For example, as in attachment member 40C illustrated in <FIG>, tubular member 42C may have a stepped tubular shape. In this case, a stepped portion may be formed so that a part of tubular member 42C protrudes toward vibration-proof rubber <NUM>, and this stepped portion is preferably embedded in vibration-proof rubber <NUM>.

As in attachment member 40C according to the present modification, since the stepped portion of tubular member 42C is embedded in vibration-proof rubber <NUM>, tubular member 42C is less likely to be displaced in the axial direction (vertical direction) of tubular member 42C. The stepped portion is configured to be caught by vibration-proof rubber <NUM>. Therefore, tubular member 42C can also be suppressed from idling when a screw or the like is inserted into insertion hole 41a formed in attachment member 40C to screw the mold motor to the installation object.

<FIG> is a top view of attachment member 40D according to the fourth modification. <FIG> is a cross-sectional view taken along line XVB-XVB of <FIG>. As in attachment member 40D illustrated in <FIG>, tubular member 42D may be fixed to vibration-proof rubber <NUM> without embedding the stepped portion of stepped tubular member 42D into vibration-proof rubber <NUM>. With this configuration, tubular member 42D can be reliably held by mold <NUM> at the time of molding mold resin <NUM>, and the positioning accuracy of tubular member 42D can be improved.

In attachment member <NUM> in the above exemplary embodiments, the hard member disposed around vibration-proof rubber <NUM> is tubular member <NUM>. However, the present disclosure is not limited to this. That is, the shape of the hard member disposed around vibration-proof rubber <NUM> needs not be a tubular shape. That is, the hard member disposed around vibration-proof rubber <NUM> may be made of a material harder than vibration-proof rubber <NUM>, and is only required to be any material as long as the injection pressure of liquid resin 30a can be suppressed from being applied to vibration-proof rubber <NUM> when vibration-proof rubber <NUM> is fixed to mold resin <NUM> by molding.

In the above-described exemplary embodiments, tubular member <NUM> has a cylindrical shape or a square cylindrical shape, and the outer shape of tubular member <NUM> in top view is a circle or a polygon. However, the present disclosure is not limited to this. For example, tubular member <NUM> may have a tubular shape in which the outer diameter shape in top view is a star shape or the like.

In the exemplary embodiments described above, rotor <NUM> is an IPM rotor. However, the present disclosure is not limited to this. For example, when a permanent magnet type rotor is used as rotor <NUM>, rotor <NUM> may be a surface magnet type rotor (SPM rotor) in which a plurality of permanent magnets are provided on the outer surface of the rotor core.

In the exemplary embodiments described above, mold motor <NUM> is used as a fan motor, but the present disclosure is not limited to this. Mold motor <NUM> can also be applied to apparatuses other than the fan motor. That is, the load attached to rotating shaft <NUM> of mold motor <NUM> is not limited to a rotary fan.

Claim 1:
A mold motor (<NUM>) comprising: a stator (<NUM>); a rotor (<NUM>) including a rotation shaft (<NUM>) and rotating by a magnetic force of the stator (<NUM>); a mold resin (<NUM>) covering at least a part of the stator (<NUM>); an elastic body (<NUM>) attachable to an installation object in which the mold (<NUM>) is installed; and one or more hard members (<NUM>) disposed around the elastic body (<NUM>), the one or more hard members (<NUM>) being harder than the elastic body (<NUM>), wherein the elastic body (<NUM>) and the one or more hard members (<NUM>) are fixed to the mold resin (<NUM>) by integral molding