Stator and insulator
The stator design with integrally connected insulator components addresses the challenge of accommodating axial length changes by using a common molding die for the end face covering portion and adjustable side covering portions, ensuring efficient insulation and reduced manufacturing complexity.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- DENSO CORP
- Filing Date
- 2025-11-12
- Publication Date
- 2026-06-11
AI Technical Summary
Existing stators face challenges in accommodating changes in axial length while maintaining efficient manufacturing and insulating properties, particularly when different output specifications are required.
The stator design incorporates an insulator with an end face covering portion made of insulating resin and side covering portions made of insulating material, where the side covering portions are integrally connected to the end face covering portion through resin molding, allowing for easy adjustment in axial length without requiring separate molds for each length variation.
This configuration enables the stator to easily accommodate changes in axial length while maintaining effective insulation and reducing manufacturing complexity by using a common molding die for the end face covering portion, and allowing easy adjustment of side covering portions through cutting, thus enhancing manufacturing efficiency and flexibility.
Smart Images
Figure JP2025039641_11062026_PF_FP_ABST
Abstract
Description
Stator and insulator Cross-reference to related applications
[0001] This application is based on Japanese Application No. 2024-210697 filed on December 3, 2024, the contents of which are incorporated herein by reference.
[0002] This disclosure relates to a stator and an insulator.
[0003] As a stator used in a rotating electrical machine, a stator configured by winding a conducting wire around teeth of a stator core made of a magnetic metal is known. In a stator having such a configuration, an insulator made of an insulating material is provided so as to be interposed between the stator core and the conducting wire in order to avoid direct contact of the conducting wire with the teeth or the like of the stator core (see, for example, Patent Document 1).
[0004] Japanese Patent No. 7394216
[0005] When developing and preparing rotating electrical machines with different output specifications, etc., one way of dealing with it is to keep the axial shape of the stator as it is and change the axial length of the stator. In this case, the key is how to rationally manufacture an insulator that is partially or entirely molded using a mold, taking into account the manufacturing cost and productivity of the stator.
[0006] An object of the present disclosure is to provide a stator and an insulator that can easily cope with a change in the axial length of the stator. The stator according to the first aspect of the present disclosure is a stator including a stator core having teeth, an insulator attached to the stator core, and a coil formed by winding a conducting wire around the teeth with the insulator interposed therebetween, wherein the insulator includes an end face covering portion made of an insulating resin disposed on an axial end face of the stator core including the teeth and mainly covering the axial end face, and a side face covering portion made of an insulating member disposed on a side face in the width direction of the teeth and mainly covering the side face in the width direction, the side face covering portion has a coupling portion, and the coupling portion is integrally coupled to the end face covering portion by resin molding of the end face covering portion.
[0007] An insulator according to a second aspect of the present disclosure is an insulator that is mounted on a stator core having teeth and interposed between the teeth and a coil formed by winding wires around the teeth, the insulator comprising: an end face covering portion made of an insulating resin that is arranged on the axial end face of the stator core including the teeth and mainly covers the axial end face; and a side covering portion made of an insulating member that is arranged on the widthwise side surface of the teeth and mainly covers the widthwise side surface, the side covering portion having a connecting portion, the connecting portion being integrally connected to the end face covering portion by resin molding of the end face covering portion.
[0008] According to the above configuration, the insulator is manufactured by separately forming an end-face covering portion that is positioned on the axial end face of the stator core and a side covering portion that is positioned on the widthwise side of the teeth. During resin molding of the end-face covering portion, the side covering portion is integrally joined to the end-face covering portion through a joint. Resin molding is used for the end-face covering portion because it has a complex shape, but it is possible to use the same shape even if the axial length of the stator is changed, and a common molding die can be used. As for the side covering portion, since it has a simple shape that extends along the side of the teeth, sheet-like or plate-like insulating material can be used, and the length can be easily changed by cutting, etc. In other words, it is possible to provide an insulator and a stator equipped with an insulator that can easily accommodate changes in the axial length of the stator.
[0009] The above-mentioned and other purposes, features and advantages of this disclosure will become clearer from the following detailed description with reference to the attached drawings. The drawings are as follows: Figure 1 is an axial view showing the stator of a rotating electric machine of one embodiment; Figure 2 is an exploded perspective view showing a part of the stator of one embodiment; Figure 3 is a perspective view showing the insulator of one embodiment; Figure 4 is a perspective view showing the insulator of one embodiment; Figure 5 is a plan view showing the insulator of one embodiment; Figure 6 is a perspective view showing the insulator of one embodiment; Figure 7 is a perspective view showing the insulator of one embodiment; and Figure 8 shows the insulator of the first modification. Figure 10 is a perspective view of the insulator of the first modification example, Figure 11 is a perspective view of the insulator of the second modification example, Figure 12 is a perspective view of the insulator of the third modification example, Figure 13 is a plan view of the insulator of the third modification example, Figure 14 is a perspective view of the insulator of the fourth modification example, Figure 15 is a plan view of the insulator of the fourth modification example, and Figure 16 is a perspective view of the insulator of the fifth modification example. Figure 17 is a perspective view showing the insulator of the 5th modification example, Figure 18 is a perspective view showing the insulator of the 6th modification example, Figure 19 is a perspective view showing the insulator of the 6th modification example, Figure 20 is a perspective view showing the insulator of the 7th modification example, Figure 21 is a perspective view showing the insulator of the 7th modification example, Figure 22 is a perspective view showing the insulator of the 8th modification example, Figure 23 is a perspective view showing the insulator of the 8th modification example, and Figure 24 shows the 9th to 13th modifications. Figure 25 is a perspective view showing the example insulator, Figure 26 is a plan view showing the insulator of the 9th modification example, Figure 27 is a plan view showing the insulator of the 11th modification example, Figure 28 is a plan view showing the insulator of the 12th modification example, Figure 29 is a plan view showing the insulator of the 13th modification example, Figure 30 is a perspective view showing the insulator of the 14th modification example, and Figure 31 is a perspective view showing the insulator of the 14th modification example.
[0010] The following describes one embodiment of the stator and insulator. (Configuration of the stator 10) As shown in Figure 1, the stator 10 of this embodiment, used in a rotating electric machine, is annular in shape and applies a rotating magnetic field to the rotor R located inside itself to drive the rotor R to rotate. The stator 10 comprises an annular stator core 11, an insulator 12 attached to the stator core 11, and a coil 13 attached to the stator core 11 with the insulator 12 interposed therebetween.
[0011] The stator core 11 has an annular portion 11a on its radially outward side and teeth 11b extending radially inward from the annular portion 11a. Multiple teeth 11b are provided at equal intervals in the circumferential direction of the annular portion 11a and are the parts around which the conductor wire 13a that functions as a coil 13 is wound.
[0012] As shown in Figures 1 and 2, the stator core 11 of this embodiment uses a plurality of divided cores 11x, each divided for each individual tooth 11b. The division points are set at intermediate positions in the annular portion 11a connecting adjacent teeth 11b. The stator core 11 is constructed by stacking, for example, a plurality of magnetic metal plates in the axial L1 direction (hereinafter simply referred to as the axial direction) for each divided core 11x. An insulator 12 is attached to each divided core 11x.
[0013] The insulator 12 is made of an insulating material. The insulator 12 is composed of a pair of first insulator 12a and second insulator 12b for each divided core 11x. The first insulator 12a is provided to mainly cover one axial end face 11c, one widthwise side face 11d and the other widthwise side face 11e of the teeth 11b for each divided core 11x. The second insulator 12b is provided to mainly cover the other axial end face 11f of the teeth 11b.
[0014] In manufacturing the stator 10, before the segmented cores 11x are connected in an annular shape as the stator core 11, the wires 13a are wound around each tooth 11b via the insulator 12 to form coils 13. The segmented cores 11x with the coils 13 attached are then connected in an annular shape to form a circumferential connection. Then, the three-phase connection of the coils 13 to be provided as the stator 10 is performed to manufacture the segmented core type stator 10 of this embodiment.
[0015] (Configuration of Insulator 12) As shown in Figure 2, the first insulator 12a is configured to include a first end face covering portion 21, a first side covering portion 22, and a second side covering portion 23. The first end face covering portion 21 is positioned on one axial end face 11c of the divided core 11x including the teeth 11b and mainly covers that portion. The first side covering portion 22 is positioned on one widthwise side surface 11d of the teeth 11b and mainly covers that portion. The second side covering portion 23 is positioned on the other widthwise side surface 11e of the teeth 11b and mainly covers that portion.
[0016] The first end face covering portion 21 comprises a winding portion 21a, an outer diameter side restricting wall 21b, and an inner diameter side restricting wall 21c. The winding portion 21a is the part around which the conductor 13a is wound, and its corners have a curved shape. The outer diameter side restricting wall 21b is located radially outward from the winding portion 21a, and the inner diameter side restricting wall 21c is located radially inward. The outer diameter side restricting wall 21b and the inner diameter side restricting wall 21c each protrude axially from the winding portion 21a, restricting the radial movement of the conductor 13a wound around the winding portion 21a to the radially outward and radially inward directions, thereby preventing winding collapse (see Figure 1).
[0017] The first and second side covering portions 22 and 23 each comprise tooth side portions 22a and 23a, annular side portions 22b and 23b, and tip side portions 22c and 23c, respectively. The annular side portion 23b is hidden in Figure 2, but a part of it is visible in Figure 3 and other images of the first end covering portion 21 before resin molding. The tooth side portions 22a and 23a correspond to the radial straight portion 11b1 of the tooth 11b. The annular side portions 22b and 23b are provided continuously with the tooth side portions 22a and 23a and correspond to the inner surface portion 11a1 of the annular portion 11a of the stator core 11. The tip side portions 22c and 23c are provided continuously with the tooth side portions 22a and 23a and correspond to the inner surface portion 11b2 of the tip widening portion of the tooth 11b. The tooth side portions 22a, 23a, the annular side portions 22b, 23b, and the tip side portions 22c, 23c cover the entire inner surface of the slot between adjacent teeth 11b that may come into contact with the conductor 13a during and after winding.
[0018] Furthermore, in the first insulator 12a, the first end face covering portion 21 is made of insulating resin as an insulating material, while the first and second side covering portions 22 and 23 are each made of insulating paper as insulating materials. In other words, the first insulator 12a of this embodiment is integrally constructed from the first end face covering portion 21 made of insulating resin and the first and second side covering portions 22 and 23 made of insulating paper. In addition, this embodiment employs a configuration that further improves the bonding between the resin first end face covering portion 21 and the paper side covering portions 22 and 23.
[0019] As shown in Figures 3, 4, 5, and 6, the first and second side covering portions 22 and 23 each have protruding pieces 22d, 22e and 23d, 23e, respectively, which are inserted and joined into the first end covering portion 21 that is later formed at the upper end. Two protruding pieces 22d, 22e, 23d, and 23e are provided for each side covering portion 22 and 23, spaced apart from each other. The protruding pieces 22d, 22e, 23d, and 23e protrude in a substantially rectangular shape, extending axially from the main body of each side covering portion 22 and 23, similar to the main body.
[0020] Each of the protruding pieces 22d, 22e, 23d, and 23e has a hooking piece 22f, 22g and a hooking piece 23f, 23g, respectively. The hooking pieces 22f, 22g, 23f, and 23g are formed by cutting and raising a part of each of the protruding pieces 22d, 22e, 23d, and 23e, for example, along a fold line along the axial direction. The hooking pieces 22f, 22g, 23f, and 23g are hooked onto the upper end surface 30a of a jig 30 which has the same shape as the divided core 11x used when resin molding the first end face covering portion 21 with a molding die (not shown), and suspend and support each of the side covering portions 22 and 23 along the axial direction. The protruding pieces 22d, 22e, 23d, and 23e, including the latching pieces 22f, 22g, 23f, and 23g, are embedded inside the first end face covering portion 21 during the molding of the first end face covering portion 21, thereby improving the bonding between the first end face covering portion 21 and the respective side covering portions 22 and 23.
[0021] As shown in Figures 2 and 7, the axial lengths of the first and second side covering portions 22 and 23 are set to be the same as the axial length of the teeth 11b. Each side covering portion 22 and 23 covers the entire axial length of the inner surface of the slot that spans the adjacent teeth 11b and the annular portion 11a between them. Since each side covering portion 22 and 23 is a part of insulating paper that does not require resin molding, changes in the axial length of each side covering portion 22 and 23 can be easily accommodated by changing the cutting positions X1 and X2 of the insulating paper (see Figure 7).
[0022] The second insulator 12b is configured as a second end face covering portion 25 having the same shape as the first end face covering portion 21. The second end face covering portion 25 is positioned on the other axial end face 11f of the divided core 11x, which includes the teeth 11b, and mainly covers that portion.
[0023] The second end face covering portion 25, like the first end face covering portion 21, includes a winding portion 25a, an outer diameter regulating wall 25b, and an inner diameter regulating wall 25c. The winding portion 25a is the part around which the conductor 13a is wound, and its corners are curved. The outer diameter regulating wall 25b and the inner diameter regulating wall 25c protrude beyond the winding portion 21a to prevent the winding of the conductor 13a wound around the winding portion 21a from becoming unraveled. The second end face covering portion 25 is made of insulating resin as an insulating material. In other words, the second insulator 12b of this embodiment is made solely of insulating resin material.
[0024] (Manufacturing of the first insulator 12a) The first insulator 12a of this embodiment is integrally composed of a first end face covering portion 21 made of resin and first and second side covering portions 22 and 23 made of paper.
[0025] As shown in Figures 3 to 5, when manufacturing the first insulator 12a, first, the fastening pieces 22f, 22g, 23f, and 23g are fastened to the upper end surface 30a of the jig 30, and the first and second side covering portions 22 and 23 are supported by the jig 30. The jig 30 is positioned in the molding die (not shown) of the first end covering portion 21 so as to include at least the portion of the upper end surface 30a of the jig 30 in which each side covering portion 22 and 23 is supported.
[0026] Next, molten insulating resin for molding the first end face covering portion 21 is poured into the mold. The protruding pieces 22d, 22e, 23d, and 23e, each having a latching piece 22f, 22g, 23f, and 23g, are inserted into the resin forming the first end face covering portion 21 so that they protrude into the cavity of the mold for molding the first end face covering portion 21.
[0027] As shown in Figure 6, the molten resin solidifies, creating the first end face covering portion 21 itself, and the first and second side covering portions 22 and 23 are integrally bonded to the first end face covering portion 21 by the protruding pieces 22d, 22e, 23d, and 23e. The bonding strength of each side covering portion 22 and 23 to the first end face covering portion 21 is high.
[0028] (Operation of this embodiment) The operation of this embodiment will now be explained. Incidentally, as one way to develop and prepare rotating electric machines with different output specifications, the axial shape of the stator 10 is kept the same, while the axial length of the stator 10 is changed.
[0029] That is, as shown in Figure 2, the axial length of the stator core 11 is adjusted, for example, by increasing or decreasing the number of stacked magnetic metal plates. The conductors 13a constituting the coil 13 are wound in a manner in which the axial length of the winding section of the teeth 11b is lengthened or shortened. As for the insulator 12, the external shapes of the first end face covering portion 21 of the first insulator 12a and the second end face covering portion 25 of the second insulator 12b can both be maintained as they are. Since both the first end face covering portion 21 and the second end face covering portion 25 are made of resin molding, a common molding die can be used even if the axial length of the stator core 11 is changed.
[0030] On the other hand, as the axial length of the stator core 11 changes, both the first side covering portion 22 and the second side covering portion 23 of the first insulator 12a need to be adjusted in length. In this case, since both side covering portions 22 and 23 are made of insulating paper, they are adjusted in advance by cutting to match the axial length of the teeth 11b. Alternatively, it is possible to adjust the length by cutting after they have been integrally formed with the first end covering portion 21. In any case, since this is a length adjustment for paper parts that do not require resin molding, it is easier to handle compared to the method of resin molding each side covering portion 22 and 23, as it does not involve the hassle of preparing a separate mold for each different length.
[0031] (Effects of this embodiment) The effects of this embodiment will now be described. (1) The insulator 12 provided on the stator 10 comprises a first insulator 12a having a first end face covering portion 21 and first and second side covering portions 22 and 23 integrally, and a second insulator 12b having only a second end face covering portion 25. The first insulator 12a is manufactured by separately forming a first end face covering portion 21 which is arranged on one axial end face 11c of the stator core 11, and first and second side covering portions 22 and 23 which are arranged on one widthwise side surface 11d and the other widthwise side surface 11e, respectively, of the teeth 11b. When the first end face covering portion 21 is resin molded, the side covering portions 22 and 23 are integrally joined to the first end face covering portion 21 through protruding pieces 22d, 22e, 23d, and 23e which function as joining portions. The first end face covering portion 21 has a complex shape, so resin molding is used, but it is possible to use the same shape even if the axial length of the stator 10 is changed, and a common molding die can be used. The side covering portions 22 and 23 have a simple shape that extends along the sides 11d and 11e of the teeth 11b, so insulating paper can be used as in this embodiment, and the length can be easily changed by cutting, etc. Furthermore, the second insulator 12b, which consists only of the second end face covering portion 25, can also be manufactured using a common molding die even if the axial length of the stator 10 is changed. In other words, the insulator 12 of this embodiment and the stator 10 equipped with the insulator 12 can easily accommodate changes in the axial length of the stator 10.
[0032] (2) The protruding pieces 22d, 22e, 23d, and 23e of the first and second side covering portions 22 and 23 are embedded inside the first end covering portion 21, and it is expected that the bonding with the first end covering portion 21 will be improved.
[0033] (3) The protruding pieces 22d, 22e, 23d, and 23e of the first and second side covering portions 22 and 23 have hooking pieces 22f, 22g, 23f, and 23g which serve as hooking portions for hooking each side covering portion 22 and 23 onto the jig 30 used in resin molding of the first end covering portion 21. By providing the hooking pieces 22f, 22g, 23f, and 23g, each side covering portion 22 and 23 can be supported by the jig 30.
[0034] (4) The latching pieces 22f, 22g, 23f, and 23g are made by cutting and raising a part of the protruding pieces 22d, 22e, 23d, and 23e, so that the latching pieces 22f, 22g, 23f, and 23g can be easily manufactured.
[0035] (Example of modification) This embodiment can be implemented with the following modifications. This embodiment and the following examples of modifications can be combined with each other to the extent that they do not contradict each other technically.
[0036] The configuration of the insulator 12 in the above embodiment is an example, and may be modified as follows, for example. The first modification shown in Figures 8 and 9 modifies the joint between the first end face covering portion 21 made of insulating resin and the first and second side covering portions 22 and 23 made of insulating paper in the first insulator 12a. The first and second side covering portions 22 and 23 each have a bent piece 22h and a bent piece 23h at their upper ends as a joint. The bent pieces 22h and 23h are provided, for example, on the teeth side portions 22a and 23a, the annular side portions 22b and 23b, and the tip side portions 22c and 23c of each side covering portion 22 and 23.
[0037] The bent pieces 22h and 23h are bent at right angles to the main body of each side covering portion 22 and 23 along fold lines perpendicular to the axis, following the corners of the upper end surface 30a of the jig 30. The bent pieces 22h and 23h also function as fasteners, fastening to the upper end surface 30a of the jig 30 to support each side covering portion 22 and 23. By resin molding the first end covering portion 21, the bent pieces 22h and 23h are embedded in the surface of the first end covering portion 21 and joined together, thereby integrally forming the first end covering portion 21 and each side covering portion 22 and 23. The bent pieces 22h and 23h support the respective side covering portions 22 and 23 to the jig 30 before the first end covering portion 21 is formed, and function to connect the first end covering portion 21 to the respective side covering portions 22 and 23 after the first end covering portion 21 is formed. Furthermore, by setting the bending angle of the bent pieces 22h and 23h, it is expected that the attachment of the respective side covering portions 22 and 23 to the upper end surface 30a of the jig 30 will be made more stable.
[0038] The second modified example shown in Figures 10 and 11 is a modification of the joint portion in the same manner as described above. The first and second side covering portions 22 and 23 each have a bent piece 22i and a bent piece 23i at their upper ends. The bent pieces 22i and 23i are provided, for example, on the teeth side portions 22a and 23a and the annular side portions 22b and 23b of each side covering portion 22 and 23.
[0039] The bent pieces 22i and 23i are bent at an angle different from the corner of the upper end surface 30a of the jig 30, in this example, at an angle slightly larger than the corner, along a fold line perpendicular to the axis of the main body of each side covering portion 22 and 23. The bent pieces 22i and 23i also have multiple through holes 22j and 23j that penetrate through their front and back sides. The bent pieces 22i and 23i also function as fastening parts, and are fastened to the upper end surface 30a of the jig 30 to support each side covering portion 22 and 23. By resin molding the first end covering portion 21, the bent pieces 22i and 23i are embedded and joined inside the first end covering portion 21, thereby integrally forming the first end covering portion 21 and each side covering portion 22 and 23. The bent pieces 22i and 23i support the respective side covering portions 22 and 23 to the jig 30 before the molding of the first end covering portion 21, and function to connect the first end covering portion 21 with the respective side covering portions 22 and 23 after the molding of the first end covering portion 21. Furthermore, because the bent angles of the bent pieces 22i and 23i cause their tips to float slightly above the upper end surface 30a of the jig 30, resin can easily flow between them and the upper end surface 30a of the jig 30. As a result, the bent pieces 22i and 23i are easily embedded inside the first end covering portion 21. In addition, because resin flows through the through holes 22j and 23j provided in the bent pieces 22i and 23i to connect the front and back surfaces, it is expected that the bonding with the first end covering portion 21 will be improved.
[0040] The third modified example shown in Figures 12 and 13 is a modification of the joint in the same manner as described above. The first and second side covering portions 22 and 23 have connecting pieces 24 that connect their upper ends to each other. The connecting pieces 24 are provided, for example, to connect the tooth side portions 22a and 23a of each side covering portion 22 and 23 to each other.
[0041] The connecting pieces 24 are bent at right angles to the upper end surface 30a of the jig 30 along fold lines perpendicular to the axis of the main body of each side covering portion 22, 23. The connecting pieces 24 also function as latches, and are latched to the upper end surface 30a of the jig 30 to support each side covering portion 22, 23. When the first end covering portion 21 is resin-molded, the connecting pieces 24 are embedded in the surface of the first end covering portion 21 and joined together, so that the first end covering portion 21 and each side covering portion 22, 23 are integrally formed. The connecting pieces 24 function to support each side covering portion 22, 23 to the jig 30 before the molding of the first end covering portion 21, and to connect the first end covering portion 21 and each side covering portion 22, 23 after the molding of the first end covering portion 21. Furthermore, since the connecting piece 24 is hooked in such a way that it crosses the upper end surface 30a of the jig 30, it is possible to more reliably support each side covering portion 22, 23.
[0042] The fourth modification example shown in Figures 14 and 15 is a modification of the joint portion in the same manner as described above. The first and second side covering portions 22 and 23 each have a bent piece 22k and a bent piece 23k at their upper ends. The bent pieces 22k and 23k are provided, for example, on the tooth side portions 22a and 23a, the annular side portions 22b and 23b, and the tip side portions 22c and 23c of each side covering portion 22 and 23.
[0043] The bent pieces 22k and 23k are bent at angles different from the corners of the upper end face 30a of the jig 30 along the fold lines in the direction perpendicular to the axis with respect to the main body portions of the respective side surface covering portions 22 and 23. In this example, the angles are slightly smaller than the corners respectively. The bent pieces 22k and 23k also function as latching portions, and are latched to the upper end face 30a of the jig 30 to support the respective side surface covering portions 22 and 23. By resin molding of the first end face covering portion 21, the bent pieces 22k and 23k are embedded and joined to the surface portion of the first end face covering portion 21, whereby the first end face covering portion 21 and the respective side surface covering portions 22 and 23 are integrally formed. The bent pieces 22k and 23k support the respective side surface covering portions 22 and 23 with respect to the jig 30 before the molding of the first end face covering portion 21, and function to join the first end face covering portion 21 and the respective side surface covering portions 22 and 23 after the molding of the first end face covering portion 21. Also, since the bent shape of the bent pieces 22k and 23k is stabilized by setting their bending angles, it can be expected that the latching of the respective side surface covering portions 22 and 23 to the upper end face 30a of the jig 30 becomes more stable. Similarly, by setting the bending angles, the bent pieces 22i and 23i are easily embedded inside the first end face covering portion 21, and the resin easily wraps around their inner sides. Therefore, it can be expected to enhance the bonding property with the first end face covering portion 21.
[0044] In the fifth modification example shown in FIGS. 16 and 17, with respect to the bent pieces 22k and 23k provided at the upper end portions of the first and second side surface covering portions 22 and 23 of the fourth modification example, they have a plurality of through holes 22l and 23l penetrating through their front and back surfaces respectively. The through holes 22l and 23l are provided at the portions of the bent pieces 22k and 23k protruding from the upper end face 30a of the jig 30, for example, at the portions extending in the axial direction before the bent portions. In addition to the above functions of the bent pieces 22k and 23k, it can be expected to enhance the bonding property with the first end face covering portion 21 by the resin flowing through the through holes 22l and 23l to connect the front and back surfaces of the bent pieces 22k and 23k.
[0045] The sixth modification example shown in FIGS. 18 and 19 has a plurality of through-holes 22m, 23m penetrating the front and back of itself with respect to the protruding pieces 22d, 22e, 23d, 23e provided at the upper ends of the first and second side covering portions 22, 23 of the above embodiment. In the sixth modification example, a plurality of through-holes 22m, 23m are also provided for the latching pieces 22f, 22g, 23f, 23g. In addition to the above functions of the protruding pieces 22d, 22e, 23d, 23e, it is expected that the resin wraps around through the through-holes 22m, 23m to connect the front and back surfaces of the protruding pieces 22d, 22e, 23d, 23e, thereby making the bonding property with the first end surface covering portion 21 higher.
[0046] The seventh modification example shown in FIGS. 20 and 21 is such that the portions where the plurality of through-holes 22m, 23m of the sixth modification example are provided are only the latching pieces 22f, 22g, 23f, 23g. Similarly in the seventh modification, it is expected that the bonding property with the first end surface covering portion 21 can be made higher.
[0047] The eighth modification example shown in FIGS. 22 and 23 omits the description in the above embodiment, but replaces the through-holes 22m, 23m provided in the latching pieces 22f, 22g, 23f, 23g in the sixth modification example with cutouts 22n, 23n. It is expected that the resin wraps around through the cutouts 22n, 23n to connect the front and back surfaces of the protruding pieces 22d, 22e, 23d, 23e, thereby making the bonding property with the first end surface covering portion 21 higher.
[0048] The modification example shown in FIG. 24 shows the outlines of the ninth, tenth, eleventh, twelfth, and thirteenth modification examples to be described later, and is an example of making it in an insulating state for each adjacent divided core 11x. The first and second side covering portions 22, 23 of the first insulator 12a have phase insulation portions 22o, 22p and phase insulation portions 23o, 23p for any or all of the annular portion side side surfaces 22b, 23b and the tip portion side side surfaces 22c, 23c of itself.
[0049] The ninth modification example shown in Figure 25 provides an interphase insulating portion 22o only on the annular side surface portion 22b of the first side covering portion 22. The interphase insulating portion 22o is provided continuously from the end of the annular side surface portion 22b and has the same axial length as the annular side surface portion 22b. The interphase insulating portion 22o is bent radially so as to be located between the coils 13 of adjacent divided cores 11x. The interphase insulating portion 22o functions to provide insulation between adjacent coils 13 when adjacent divided cores 11x are connected to each other.
[0050] The tenth modification example shown in Figure 26 provides interphase insulating portions 22o and 22p on the annular side surface portion 22b and the tip side surface portion 22c of the first side covering portion 22, respectively. The interphase insulating portions 22o and 22p are provided continuously from the respective ends of the annular side surface portion 22b and the tip side surface portion 22c, and have the same axial length as the annular side surface portion 22b and the tip side surface portion 22c. The interphase insulating portions 22o and 22p are bent radially so that they are positioned between the coils 13 of adjacent divided cores 11x. In the tenth modification example, the length of the interphase insulating portions 22o and 22p is set so that the tips of the interphase insulating portions 22o and 22p abut against each other, and adjacent coils 13 are insulated from each other by a single layer of interphase insulating portions 22o and 22p. Furthermore, by setting the length of the interphase insulating sections 22o and 22p to overlap, it is also possible to configure the coils 13 to be insulated from each other by the double interphase insulating sections 22o and 22p (not shown).
[0051] The 11th modification shown in Figure 27 provides interphase insulating portions 22o and 23o on the annular side surfaces 22b and 23b of the first and second side covering portions 22 and 23, respectively. The interphase insulating portions 22o and 23o are provided continuously from the respective ends of the annular side surfaces 22b and 23b and have the same axial length as the annular side surfaces 22b and 23b. The interphase insulating portions 22o and 23o are bent radially so as to be located between the coils 13 of adjacent divided cores 11x. In the 11th modification, adjacent coils 13 are insulated from each other by the double interphase insulating portions 22o and 23o.
[0052] The twelfth modification shown in Figure 28 provides interphase insulating portions 22o, 23o and interphase insulating portions 22p, 23p on the annular side portions 22b, 23b and the tip side portions 22c, 23c, respectively, of the first and second side covering portions 22, 23. The interphase insulating portions 22o, 23o, 22p, 23p are provided continuously from the ends of the annular side portions 22b, 23b and the tip side portions 22c, 23c, respectively, and have the same axial length as the annular side portions 22b, 23b and the tip side portions 22c, 23c. The interphase insulating portions 22o, 23o are bent radially so that they are located between the coils 13 of adjacent divided cores 11x. In the 12th modification example, adjacent coils 13 are insulated from each other by single interphase insulating sections 22o, 23o, 22p, 23p, but they can also be insulated from each other by double interphase insulating sections 22o, 23o, 22p, 23p (not shown).
[0053] The 13th modification example shown in Figure 29 provides interphase insulating portions 22o and 23p on the annular side surface portion 22b of the first side covering portion 22 and the tip side surface portion 23c of the second side covering portion 23, respectively. The interphase insulating portions 22o and 23p are provided continuously from the respective ends of the annular side surface portion 22b and the tip side surface portion 23c, and have the same axial length as the annular side surface portion 22b and the tip side surface portion 23c. The interphase insulating portions 22o and 23p are bent radially so as to be located between the coils 13 of adjacent divided cores 11x. In the 13th modification example, adjacent coils 13 are insulated from each other by double interphase insulating portions 22o and 23p, but it is also possible to have them insulated by double interphase insulating portions 22o and 23p (not shown).
[0054] The 14th modification example shown in Figures 30 and 31 further includes covering insulation sections 22q, 22r and covering insulation sections 23q, 23r for each of the interphase insulation sections 22o, 23o in the modification example shown in Figure 24 described above. The covering insulation sections 22q, 22r, 23q, 23r are provided continuously from the respective ends of the interphase insulation sections 22o, 23o and have an axial length that protrudes beyond the axial ends of the coil 13 mounted on the divided core 11x. The covering insulation sections 22q, 22r, 23q, 23r are bent circumferentially to cover the coil 13 located at both axial ends of the divided core 11x and function to insulate the coil 13. By adjusting the overlapping state of the covering insulation sections 22q, 22r and covering insulation sections 23q, 23r, it is possible to achieve single or double insulation configurations for the covering insulation sections 22q, 22r, 23q, 23r.
[0055] - The insulator 12 is composed of a first insulator 12a having an end face covering portion 21 and side covering portions 22, 23, and a second insulator 12b having only an end face covering portion 25, but the combination of the end face covering portion and the side covering portion may be changed as appropriate.
[0056] - Although insulating paper was used as an insulating material for the first and second side covering portions 22 and 23, sheet-shaped or plate-shaped insulating resin material may also be used. - This disclosure was applied to a split-type stator 10 using a split core 11x, but it may also be applied to stators other than the split type. In addition, the configuration of the stator 10 may be changed as appropriate.
[0057] This disclosure is described in accordance with the embodiments, but it is understood that this disclosure is not limited to such embodiments or structures. This disclosure also includes various modifications and variations within the equivalence. In addition, various combinations and forms, as well as other combinations and forms that include only one, more, or fewer of those elements, fall within the scope and concept of this disclosure.
[0058] (Note) The technical ideas that can be understood from the above embodiments and modified examples are described below. [1] A stator (10) comprising: a stator core (11) having teeth (11b); an insulator (12) attached to the stator core; and a coil (13) formed by winding a conductor (13a) around the teeth with the insulator interposed, wherein the insulator comprises: an end face covering portion (21) made of insulating resin that is arranged on the axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; and side covering portions (22, 23) made of insulating material that are arranged on the widthwise side surfaces (11d, 11e) of the teeth and mainly cover the widthwise side surfaces, The stator is configured such that the side covering portion has connecting portions (22d, 22e, 22h, 22i, 22k, 23d, 23e, 23h, 23i, 23k, 24), and the connecting portions are integrally bonded to the end covering portion by resin molding of the end covering portion.
[0059] [2] The stator as described in [1] above, wherein the connecting portion (22d, 22e, 22i, 22k, 23d, 23e, 23i, 23k) is embedded inside the end face covering portion.
[0060] [3] The stator according to [2] above, wherein the connecting portion has through holes (22j, 22l, 22m, 23j, 23l, 23m) or notches (22n, 23n) that penetrate the front and back surfaces of the connecting portion itself, and the resin of the end face covering portion is configured to flow around the through holes or notches.
[0061] [4] The stator according to any one of [1] to [3] above, wherein the connecting portion has hooking portions (22f, 22g, 22h, 22i, 22k, 23f, 23g, 23h, 23i, 23k, 24) for hooking and supporting the side covering portion with respect to a jig (30) during resin molding of the end covering portion.
[0062] [5] The stator as described in [4] above, wherein the latching portion is formed by bending or cutting a part of the connecting portion.
[0063] [6] The stator according to [5] above, wherein the latching portion is bent at a different angle from the corner of the end face of the jig that latches the latching portion itself, and is configured such that the resin of the end face covering portion wraps around its front and back surfaces.
[0064] [7] The stator according to any one of the above [1] to [6], wherein the side covering portion has interphase insulating portions (22o, 22p, 23o, 23p) located between adjacent coils in the circumferential direction in the stator to provide insulation between them.
[0065] [8] The stator according to any one of the above [1] to [7], wherein the side covering portion has covering insulating portions (22q, 22r, 23q, 23r) for covering and insulating the coil located at the axial end of the stator core.
[0066] [9] The stator according to any one of [1] to [8] above, wherein the insulator comprises: a first insulator (12a) having a first end face covering portion (21) made of an insulating resin that is arranged on one axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; first and second side covering portions (22, 23) made of an insulating member that is arranged on one widthwise side (11d) and the other widthwise side (11e) of the teeth and mainly covers the widthwise side and the other widthwise side; and a second insulator (12b) having only a second end face covering portion (25) made of an insulating resin that is arranged on the other axial end face (11f) of the stator core including the teeth and mainly covers the other axial end face.
[0067]
[10] The stator according to any one of the above items [1] to [9], wherein the side covering portion is made of insulating paper as the insulating member, and the insulator is constructed by integrally joining the end covering portion made of insulating resin and the side covering portion made of insulating paper.
[0068]
[11] The stator according to any one of the above [1] to
[10] , wherein the stator core is constructed by connecting a plurality of divided cores (11x) divided for each tooth in a ring shape, and the insulator is provided for each divided core.
[0069]
[12] An insulator (12) that is mounted on a stator core (11) having teeth (11b) and interposed between the teeth and a coil (13) formed by winding a conductor (13a) around the teeth, wherein the insulator comprises: an end face covering portion (21) made of an insulating resin that is arranged on the axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; and side covering portions (22, 23) made of an insulating material that is arranged on the widthwise side surfaces (11d, 11e) of the teeth and mainly covers the widthwise side surfaces, wherein the side covering portion has connecting portions (22d, 22e, 22h, 22i, 22k, 23d, 23e, 23h, 23i, 23k, 24), and the connecting portions are integrally bonded to the end face covering portion by resin molding of the end face covering portion.
Claims
1. A stator (10) comprising: a stator core (11) having teeth (11b); an insulator (12) mounted on the stator core; and a coil (13) formed by winding a conductor (13a) around the teeth with the insulator interposed, wherein the insulator comprises: an end face covering portion (21) made of insulating resin that is arranged on the axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; and side covering portions (22, 23) made of insulating material that are arranged on the widthwise side surfaces (11d, 11e) of the teeth and mainly cover the widthwise side surfaces, The stator is configured such that the side covering portion has connecting portions (22d, 22e, 22h, 22i, 22k, 23d, 23e, 23h, 23i, 23k, 24), and the connecting portions are integrally bonded to the end covering portion by resin molding of the end covering portion.
2. The stator according to claim 1, wherein the connecting portion (22d, 22e, 22i, 22k, 23d, 23e, 23i, 23k) is embedded inside the end face covering portion.
3. The stator according to claim 2, wherein the connecting portion has through holes (22j, 22l, 22m, 23j, 23l, 23m) or notches (22n, 23n) that penetrate the front and back surfaces of the connecting portion itself, and is configured such that the resin of the end face covering portion flows around the through holes or notches.
4. The stator according to claim 1, wherein the connecting portion has hooking portions (22f, 22g, 22h, 22i, 22k, 23f, 23g, 23h, 23i, 23k, 24) for hooking and supporting the side covering portion with respect to a jig (30) during resin molding of the end covering portion.
5. The stator according to claim 4, wherein the latching portion is formed by bending or cutting a part of the connecting portion.
6. The stator according to claim 5, wherein the latching portion is bent at a different angle from the corner of the end face of the jig that latches the latching portion itself, and is configured such that the resin of the end face covering portion wraps around its front and back surfaces.
7. The stator according to claim 1, wherein the side covering portion has interphase insulating portions (22o, 22p, 23o, 23p) located between adjacent coils in the circumferential direction in the stator to provide insulation between them.
8. The stator according to claim 1, wherein the side covering portion has covering insulating portions (22q, 22r, 23q, 23r) for covering and insulating the coil located at the axial end of the stator core.
9. The stator according to claim 1, wherein the insulator comprises: a first insulator (12a) having a first end face covering portion (21) made of an insulating resin that is arranged on one axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; and first and second side covering portions (22, 23) made of an insulating member that is arranged on one widthwise side (11d) and the other widthwise side (11e) of the teeth and mainly covers the widthwise side and the other widthwise side; and a second insulator (12b) having only a second end face covering portion (25) made of an insulating resin that is arranged on the other axial end face (11f) of the stator core including the teeth and mainly covers the other axial end face.
10. The stator according to claim 1, wherein the side covering portion is made of insulating paper as the insulating member, and the insulator is constructed by integrally joining the end covering portion made of insulating resin and the side covering portion made of insulating paper.
11. The stator according to claim 1, wherein the stator core is constructed by connecting a plurality of divided cores (11x) divided for each tooth in a ring shape, and the insulator is provided for each divided core.
12. An insulator (12) that is mounted on a stator core (11) having teeth (11b) and interposed between the teeth and a coil (13) formed by winding a conductor (13a) around the teeth, wherein the insulator comprises: an end face covering portion (21) made of insulating resin that is arranged on the axial end face (11c) of the stator core including the teeth and mainly covers the axial end face; and side covering portions (22, 23) made of insulating material that are arranged on the widthwise side surfaces (11d, 11e) of the teeth and mainly cover the widthwise side surfaces, wherein the side covering portions have connecting portions (22d, 22e, 22h, 22i, 22k, 23d, 23e, 23h, 23i, 23k, 24), and the connecting portions are integrally bonded to the end face covering portion by resin molding of the end face covering portion.