Rotor for motor and method of manufacturing the same

1 . A method of manufacturing a rotor for a motor, the method comprising:

preparing a rotor plate, a rotor core, and a plurality of permanent magnets;

coupling the rotor core to the rotor plate; and

forming a molding part, wherein the molding part is formed by molding a resin composition for a molding material on the plurality of permanent magnets so that the molding part is shaped to integrally connect the plurality of permanent magnets in a circumferential direction of the rotor core,

wherein the rotor is manufactured such that the rotor plate, the rotor core, the plurality of permanent magnets, and the formed molding part are coupled,

wherein the molding part covers a surface of the rotor core between adjacent permanent magnets in the plurality of permanent magnets.

2 . The method of claim 1 , wherein the rotor core is coupled and bonded to the rotor plate using a bonding agent.

3 . The method of claim 1 , wherein a permanent magnet resin molded product, in which the molding part is integrated with the plurality of permanent magnets, is manufactured by installing the plurality of permanent magnets so that the plurality of permanent magnets are arranged in the circumferential direction in a mold for forming the molding part, and injecting a molten resin composition for a molding material into the mold, and

wherein the permanent magnet resin molded product is coupled to a surface of the rotor core coupled to the rotor plate.

4 . The method of claim 3 , wherein the permanent magnet resin molded product is bonded to the surface of the rotor core coupled to the rotor plate using a bonding agent.

5 . The method of claim 3 , wherein the molding part is formed so that a first surface of each of the permanent magnets is exposed, and a second surface of each of the permanent magnets is embedded in the molding part.

6 . The method of claim 1 , wherein the molding part is formed on the plurality of permanent magnets by:

installing the rotor plate, the rotor core, and the plurality of permanent magnets in a mold for forming the molding part, wherein the rotor plate is coupled to the rotor core, and wherein the plurality of permanent magnets are arranged in the circumferential direction; and

injecting a molten resin composition for a molding material into the mold.

7 . The method of claim 6 , wherein the rotor core is coupled and bonded to the rotor plate using a bonding agent.

8 . The method of claim 6 , wherein the molding part is formed so that a first surface of each of the permanent magnets is exposed, and a second surface of each of the permanent magnets is embedded in the molding part.

9 . The method of claim 8 , wherein the molding part is formed to cover each of an outer peripheral surface of the rotor core, an outer peripheral surface of the rotor plate, and outer surfaces of the arranged permanent magnets, and

wherein a ring portion of the molding part, which covers the each of the outer peripheral surface of the rotor core, the outer peripheral surface of the rotor plate, and the outer surfaces of the arranged permanent magnets, serves as a support ring that prevents the permanent magnets from being scattered by a centrifugal force.

10 . The method of claim 9 , wherein a sleeve, comprising carbon fiber reinforced plastic, is formed along an entire periphery of an outer peripheral surface of the ring portion.

11 . The method of claim 1 , wherein the resin composition for a molding material for forming the molding part comprises:

0.1 to 15 wt. % of epoxy resin;

0.1 to 15 wt. % of a curing agent;

50 to 92 wt. % of a filler;

0.01 to 1 wt. % of silane A;

0.1 to 1 wt. % of silane B;

0.1 to 1 wt. % of wax;

0.1 to 1 wt. % of a colorant;

0.1 to 1 wt. % of a catalyst;

0.1 to 1 wt. % of a flame retardant; and

0.1 to 1 wt. % of an additive.

12 . A rotor for a motor, the rotor comprising:

a rotor core;

a plurality of permanent magnets arranged in a circumferential direction of the rotor core;

a rotor plate coupled to the rotor core; and

a molding part formed by molding a resin composition for a molding material on the plurality of permanent magnets so that the molding part is shaped to integrally connect the plurality of permanent magnets arranged in the circumferential direction,

wherein the rotor plate, the rotor core, the plurality of permanent magnets, and the formed molding part are coupled on the rotor,

wherein the molding part covers a surface of the rotor core between adjacent permanent magnets in the plurality of permanent magnets.

13 . The rotor of claim 12 , wherein the rotor plate and the rotor core are coupled and bonded using a bonding agent.

14 . The rotor of claim 12 , wherein a first surface of each of the plurality of permanent magnets is exposed, and a second surface of each of the plurality of permanent magnets is embedded in the molding part.

15 . The rotor of claim 14 , wherein the molding part formed on the plurality of permanent magnets is coupled and bonded to a surface of the rotor core using a bonding agent.

16 . The rotor of claim 12 , wherein the molding part is formed to cover an outer peripheral surface of the rotor core, an outer peripheral surface of the rotor plate, and the first surface of each of the plurality of permanent magnets arranged in the circumferential direction, and

wherein a ring portion of the molding part covers the outer peripheral surface of the rotor core, the outer peripheral surface of the rotor plate, and the outer surfaces of the arranged permanent magnets, the ring portion serving as a support ring that prevents the permanent magnets from being scattered by a centrifugal force.

17 . The rotor of claim 12 , wherein the resin composition for a molding material for forming the molding part on the plurality of permanent magnets comprises:

0.1 to 15 wt. % of epoxy resin;

0.1 to 15 wt. % of a curing agent;

50 to 92 wt. % of a filler;

0.01 to 1 wt. % of silane A;

0.1 to 1 wt. % of silane B;

0.1 to 1 wt. % of wax;

0.1 to 1 wt. % of a colorant;

0.1 to 1 wt. % of a catalyst;

0.1 to 1 wt. % of a flame retardant; and

0.1 to 1 wt. % of an additive.

18 . A method of manufacturing a rotor for a motor, the method comprising:

preparing a rotor plate, a rotor core, and a plurality of permanent magnets;

coupling the rotor core to the rotor plate; and

forming a molding part, wherein the molding part is formed by molding a resin composition for a molding material on the plurality of permanent magnets so that the molding part is shaped to integrally connect the plurality of permanent magnets in a circumferential direction of the rotor core,

wherein the rotor is manufactured such that the rotor plate, the rotor core, the plurality of permanent magnets, and the formed molding part are coupled,

wherein the molding part is formed by a molding process in which the plurality of permanent magnets is installed in a cavity of a mold to be disposed at predetermined intervals in a circumferential direction, and then the molten resin composition for a molding material is injected into the cavity of the mold in which the permanent magnets are installed.