Magneto-generator, method of manufacturing the same and resin molding die assembly for manufacturing the same

Abstract

A magneto-generator, a method of manufacturing the same and a resin molding die for manufacturing the same. In the magneto-generator, a guard ring is omitted with the performance of the magneto-generator being enhanced. The magneto-generator is manufactured by making use of a resin molding die ( 21 ) having an outer peripheral surface ( 21 d ) to be positioned in opposition to an inner peripheral surface of a flywheel ( 11 ) and projections ( 21 a ) provided in the outer peripheral surface ( 21 d ) for holding a plurality of magnets ( 12 ) at predetermined positions, respectively. The magnets ( 12 ) are positioned and held stationarily at predetermined positions by the aforementioned projections, respectively, and spaces defined between the resin molding die ( 21 ) and the inner peripheral surface of the flywheel ( 11 ) are filled with a resin. After hardening of the resin, the resin molding die ( 21 ) is detached from the flywheel ( 11 ).

What is claimed is:  
     
         1 . A magneto-generator, comprising: 
 a bowl-shaped flywheel;    a plurality of magnets mounted on an inner peripheral surface of said flywheel;    a resin filled around each of said individual magnets for fixedly securing said magnets to said flywheel as integral parts thereof; and    a generator coil disposed within said bowl-shaped flywheel in opposition to said magnets for generating electric power under the action of electromagnetic induction brought about through cooperation with said magnets;    wherein said magneto-generator is manufactured by making use of a resin molding die having an outer peripheral surface to be positioned in opposition to an inner peripheral surface of said flywheel and projections provided in said outer peripheral surface for holding said plurality of magnets at predetermined positions, respectively, positioning said magnets at said predetermined positions, respectively, filling said resin in spaces defined between said resin molding die and said flywheel, and detaching said resin molding die from said flywheel.    
     
     
         2 . A method of manufacturing a magneto-generator which includes a bowl-shaped flywheel, a plurality of magnets mounted on an inner peripheral surface of said flywheel, a resin filled around each of said individual magnets for fixedly securing said magnets to said flywheel as integral parts thereof, and a generator coil disposed within said bowl-shaped flywheel in opposition to said magnets for generating electric power under the action of electromagnetic induction brought about through cooperation with said magnets, 
 said manufacturing method comprising: 
 a resin filling step in which a resin molding die having an outer peripheral surface to be positioned in opposition to an inner peripheral surface of said flywheel and projections provided in said outer peripheral surface for holding said plurality of magnets at predetermined positions, respectively, is employed for filling said resin in spaces defined between said resin molding die and said flywheel while holding said magnets at said predetermined positions, respectively; and  
 a die detaching step of detaching said resin molding die from said flywheel.  
   
     
     
         3 . A method of manufacturing a magneto-generator according to  claim 2 , 
 wherein each of said projections of said resin molding die extends continuously and axially from a given position at a side of said magnet substantially up to an open end of said flywheel.    
     
     
         4 . A method of manufacturing a magneto-generator according to  claim 2 , 
 wherein said resin molding die includes a magnet sucking/holding mechanism disposed interiorly of said die for securing fixedly said magnets on said outer peripheral surface of said resin molding die upon filling of said resin.    
     
     
         5 . A resin molding die for manufacturing a magneto-generator which is comprised of a bowl-shaped flywheel, a plurality of magnets mounted on an inner peripheral surface of said flywheel, a resin filled around each of said individual magnets for fixedly securing said magnets to said flywheel as integral parts thereof, and a generator coil disposed within said bowl-shaped flywheel in opposition to said magnets for generating electric power under the action of electromagnetic induction brought about through cooperation with said magnets, 
 said resin molding die comprising: 
 an outer peripheral surface to be positioned in opposition to an inner peripheral surface of said flywheel; and  
 projections provided in said outer peripheral surface for holding said plurality of magnets at predetermined positions, respectively.  
   
     
     
         6 . A resin molding die for manufacturing a magneto-generator according to  claim 5 , 
 wherein each of said projections extends continuously and axially from a given position at a side of said magnet substantially up to an open end of said flywheel.    
     
     
         7 . A resin molding die for manufacturing a magneto-generator according to  claim 5 , 
 wherein said resin molding die includes a magnet sucking/holding mechanism disposed interiorly of said die for securing fixedly said magnets on said outer peripheral surface of said resin molding die upon filling of said resin.    
     
     
         8 . A resin molding die for manufacturing a magneto-generator according to  claim 5 , 
 further comprising: 
 a ring-like projection formed around said outer peripheral surface of said die for supporting said magnets at one end thereof.  
   
     
     
         9 . A resin molding die for manufacturing a magneto-generator according to  claim 5 , 
 further comprising: 
 a plurality of discrete projections disposed around said outer peripheral surface of said die for supporting said plurality of magnets at one ends thereof, respectively.  
   
     
     
         10 . A resin molding die for manufacturing a magneto-generator according to  claim 5 , 
 wherein said resin molding die is designed to cooperate with an outside molding die disposed around said resin molding die for supporting an open end of said flywheel.