motor

Abstract

The present invention is a motor, which comprises: a stator having a stator core and a coil; a rotor having a rotating shaft and a rotating body; a bearing that supports the rotor so that it can rotate freely; and a molded resin that is used to cover the stator. The coil of the present motor has a coil end extending from the stator core along the axial (X) direction, and is provided with a non-combustible layer covering the coil end. The non-combustible layer is, for example, a metal cover made of metal. In addition, the metal cover is configured to cover the periphery of a coil assembly, wherein the coil assembly is formed on the stator core through an insulator, and the metal cover is integrated together with the coil assembly using a molded resin.

Description

[0001] This application is a divisional application of PCT application PCT / JP2017 / 041969 filed by the applicant Panasonic Intellectual Property Management Co., Ltd. on November 22, 2017, which entered the national phase on May 27, 2019, with application number 201780073322.0 and invention name “Motor”. Technical Field

[0002] The present invention relates to a motor whose stator is covered with a molded resin. Background Art

[0003] Fig.41 2 is a cross-sectional view showing a structural example of a conventional motor 900. Fig.41 As shown, in a motor 900 including a rotor 920 and a stator 910 , a motor having a structure in which the stator 910 is covered with a mold resin 931 is also called a molded motor and is widely known (for example, Patent Document 1, etc.).

[0004] like Fig.41 As shown in FIG. 1 , the stator 910 includes a stator core 911 formed of a plurality of metal plates and a coil 912 having a winding wound around the stator core 911. The coil 912 provided in the stator 910 is covered with a molded resin 931. Fig.41 As shown, in particular, the portion of the coil 912 extending from the stator core 911 is also referred to as a coil end 912a. For the purpose of electrical insulation between the coil 912 and the stator core 911, an insulator 913 is installed between the coil 912 and the stator core 911.

[0005] In addition, if too much current flows through the coil 912, the coil 912 will heat up and become extremely hot, and a partial short circuit may occur. That is, the outer periphery of the conductor that forms the winding of the coil 912 is covered with an insulator. However, if the coil 912 heats up, for the winding insulated by the insulator, the insulator may melt due to heat, which may cause the conductors to short-circuit with each other. When the coil 912 is partially short-circuited in a special environment where all safety protection devices are not working, sparks may sometimes be generated. In the case of sparks caused by a partial short circuit, the sparks ignite the gas generated by the heating of the insulator 913, etc., which may cause a fire.

[0006] Meanwhile, the physical properties of the mold resin 931 may be degraded due to heat etc. applied to the contact portion between the coil 912 and the mold resin 931. If the physical properties of the mold resin 931 are degraded, cracks etc. may occur in the mold resin 931.

[0007] Therefore, if a partial short circuit occurs when cracks occur in the molded resin 931 , there is a possibility that the gas generated by the insulator 913 etc. will ignite, and the resulting fire may leak out of the motor 900 from the cracked area in the molded resin 931 etc.

[0008] Here, the portion of the coil 912 other than the coil end 912a is surrounded by the stator core 911, so the possibility of fire and smoke leaking to the outside is extremely small. However, the coil end 912a extends from the stator core 911 and is in contact with the molded resin 931. Therefore, there is a possibility that the portion of the molded resin 931 in contact with the coil end 912a will catch fire and fire and smoke will leak to the outside.

[0009] In the above-mentioned motor and equipment equipped with a motor (also called motor equipment), usually, a safety protection circuit for preventing excessive current from flowing in the stator coil is arranged inside the motor (for example, inside a control substrate inside the motor) or the motor equipment to prevent the occurrence of fire or smoke due to excessive current flowing in the coil as described above.

[0010] Prior art literature

[0011] Patent Literature

[0012] Patent Document 1: International Publication No. 2012 / 101976 Summary of the invention

[0013] The motor of the present invention comprises a stator and a rotor. The stator comprises a stator core and a coil wound on the stator core. In addition, the rotor comprises a rotating shaft extending in the axial direction and a rotating body including a magnetic component, extending in the axial direction and fixed to the rotating shaft, and the rotor is located inside the stator. Furthermore, the motor comprises a bearing for supporting the rotor to rotate freely and a molded resin for covering the stator. Furthermore, the coil comprises a coil end extending from the stator core in the axial direction, and a non-combustible layer covering the coil end is provided in the motor.

[0014] Utilizing this structure, a non-combustible layer is provided to cover the coil ends of the stator coil. Therefore, even if the safety protection circuit for preventing excessive current from flowing in the stator coil malfunctions and excessive current flows in the stator coil to cause a partial short circuit, fire caused by insulators, etc. will be blocked by the non-combustible layer, thereby preventing fire and smoke from leaking from the motor to the outside.

[0015] In addition, in the motor of the present invention, at least a portion of the non-combustible layer is formed to extend in the axial direction at a position closer to the outer peripheral side than the coil end portion.

[0016] With this structure, even if the fire is about to spread to the position closer to the outer peripheral side than the coil end, the fire is blocked by the non-combustible layer. In addition, the non-combustible layer can also be formed on the outer surface of the molded resin.

[0017] In addition, in the motor of the present invention, at least a portion of the non-combustible layer is formed to extend in the radial direction at a position on the opposite side to the stator core with respect to the coil end.

[0018] With this structure, even if fire spreads to the side opposite to the stator core from the coil end, that is, the outer side in the axial direction, the fire is blocked by the non-combustible layer. In addition, the non-combustible layer may be formed on the outer surface of the molded resin.

[0019] Furthermore, the non-combustible layer of the motor of the present invention may be formed to surround the coil end from a position on the outer circumference side of the coil end, a position on the opposite side of the stator core relative to the coil end, and a position on the inner circumference side of the coil end.

[0020] With this structure, even if fire attempts to spread in any direction including a position closer to the outer circumference than the coil end, a position on the opposite side of the stator core relative to the coil end, or a position closer to the inner circumference than the coil end, the fire is blocked by the non-combustible layer.

[0021] In addition, the non-combustible layer may be formed of air or non-combustible materials such as metal, ceramics and other inorganic substances. In addition, it is preferable to further include a metal cover covering the coil end through the mold resin.

[0022] In addition, the non-combustible layer of the motor of the present invention may also cover the overlapping wires of the coils in addition to the ends of the coils. The conductive wires of the coils that form the stator may sometimes break. In the event that the safety protection circuit for preventing excessive current from flowing through the coils of the stator does not function properly, excessive current flows through the conductive wires (e.g., overlapping wires) that form the coils of the stator and break, and sparks are generated when the wires break, there is a possibility that the sparks ignite the gas generated by the insulator, etc., and a fire may occur. However, even in this case, since the non-combustible layer also covers the overlapping wires of the coils, the fire generated from the overlapping wires when the wires break is also blocked by the non-combustible layer.

[0023] As described above, the present invention is provided with a non-combustible layer covering the coil ends extending from the stator core in the axial direction. Therefore, even if the safety protection circuit for preventing excessive current from flowing in the stator coil does not function properly, excessive current flows in the stator coil and a partial short circuit occurs, according to the present invention, the fire caused by the insulator and the like is also blocked by the non-combustible layer. Therefore, it is possible to prevent fire and smoke from leaking out of the motor. As a result, the reliability and safety of the motor can be further improved. In addition, if a metal cover is provided to cover the coil ends through a molded resin, it is possible to more reliably prevent fire and smoke from leaking out of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a half cross-sectional view of the motor according to the first embodiment of the present invention.

[0025] Figure 2 The above motor Figure 1 The plane section view along line 2-2.

[0026] Figure 3 The above motor Figure 1 The plane section view along line 3-3.

[0027] Figure 4 It is an exploded perspective view of the above motor.

[0028] Figure 5 It is an enlarged half-section view of the main parts of the above-mentioned motor.

[0029] Figure 6 It is a half cross-sectional view of a modification of the motor of the above embodiment.

[0030] Figure 7 It is a half cross-sectional view of a motor according to a second embodiment of the present invention.

[0031] Figure 8 It is a half cross-sectional view of a motor according to a third embodiment of the present invention.

[0032] Fig. 9 It is a half cross-sectional view of a motor according to a fourth embodiment of the present invention.

[0033] Fig.10 It is an enlarged half-section view of the main parts of the above-mentioned motor.

[0034] Fig.11 It is a half-sectional view of a modified example of the above-mentioned motor.

[0035] Fig.12 It is a half cross-sectional view of a motor according to a fifth embodiment of the present invention.

[0036] Fig.13 It is a half-sectional view of a modified example of the above-mentioned motor.

[0037] Fig.14 It is a half-sectional view of another modified example of the above-mentioned motor.

[0038] Fig.15 It is a half-sectional view of another modified example of the above-mentioned motor.

[0039] Fig.16 It is an exploded perspective view of a motor according to a sixth embodiment of the present invention.

[0040] Fig.17 is a cross-sectional view of the motor.

[0041] Fig.18 The above motor Fig.17 The sectional view along line 18-18.

[0042] Fig.19 It is a perspective view of the appearance of the above-mentioned motor.

[0043] Fig. 20 It is an exploded perspective view of another motor according to the sixth embodiment of the present invention.

[0044] Fig.21 It is a cross-sectional view showing a cross section of a metal inner cover of the motor and the cross section where a coil is wound around a single tooth.

[0045] Fig. 22 It is an exploded perspective view of the coil assembly and the metal inner cover of the above motor.

[0046] Fig.23 This is a structural diagram in which a metal inner cover is arranged on the outer periphery of the coil assembly of the above-mentioned motor.

[0047] Fig.24 It is a diagram for explaining the metal cover of the above-mentioned motor.

[0048] Fig.25 It is a cross-sectional view of a motor according to a seventh embodiment of the present invention.

[0049] Fig.26 It is a three-dimensional view of the metal inner cover of the above-mentioned motor.

[0050] Fig. 27 is a cross-sectional view of the metal inner cover and coil assembly of the above motor.

[0051] Fig.28 It is a cross-sectional view of a motor according to an eighth embodiment of the present invention.

[0052] Fig.29 It is an enlarged cross-sectional view of the vicinity of the notch portion of the above-mentioned motor.

[0053] Fig.30 The above motor Fig.29 The 30-30 line cross-sectional view.

[0054] Fig.31 This is an enlarged cross-sectional view of another notch portion of the motor.

[0055] Fig.32 It is a cross-sectional view of a motor according to a ninth embodiment of the present invention.

[0056] Fig.33 This is an enlarged view of the vicinity of the metal cover of the above-mentioned motor.

[0057] Fig.34 It is a partial cross-sectional view showing a modified example of the above-mentioned motor.

[0058] Fig.35 It is a plan cross-sectional view showing a state before caulking in which a coil assembly is fitted into a metal inner cover of a motor according to a tenth embodiment of the present invention.

[0059] Fig.36 The above motor Fig.35 An enlarged cross-sectional view of the AA portion.

[0060] Fig.37 It is a perspective view showing the appearance of the coil assembly of the above motor.

[0061] Fig.38 It is a cross-sectional view of a motor according to an eleventh embodiment of the present invention.

[0062] Fig.39 It is an exploded perspective view of the terminal cover, metal inner cover and coil assembly of the above motor.

[0063] Fig.40 It is a partially enlarged cross-sectional view of a motor according to a twelfth embodiment of the present invention.

[0064] Fig.41 This is a front cross-sectional view of a conventional motor. DETAILED DESCRIPTION

[0065] The motor according to the embodiment of the present invention can more reliably prevent fire and smoke from leaking to the outside from the motor by using the structure described below.

[0066] That is, as mentioned above, in the past, although a safety protection circuit for excessive current was provided, in the event that all safety protection circuits fail to function properly, excessive current may flow in the stator coil. Therefore, in order to improve the tolerance of motor equipment, the motor as its component is required to further improve safety. Specifically, there is the following problem: in the aforementioned special environment, it is required to prevent fire from leaking from the motor to the outside of the motor even if a partial short circuit occurs in the coil.

[0067] Therefore, in this embodiment, a non-combustible layer covering at least the coil end is provided in the motor molded by the mold resin. Thus, according to this embodiment, it is possible to more reliably prevent fire and smoke from leaking out of the motor.

[0068] Hereinafter, embodiments of the present invention will be described based on the drawings. In the following description, the same components are denoted by the same reference numerals, and the description is hereby incorporated by reference.

[0069] (First embodiment)

[0070] Figure 1 It is a half cross-sectional view of the motor 101 according to the first embodiment of the present invention. Figure 2 The motor 101 Figure 1 The plane section view along line 2-2. Figure 3 The motor 101 Figure 1 The plane section view along line 3-3. Figure 4 1 is an exploded perspective view of the motor 101. Figure 5 It is an enlarged half-sectional view of a main part of the motor 101.

[0071] like Figure 1 to Figure 5 As shown, the motor 101 has a stator 10, a rotor 20 located inside the stator 10, a pair of bearings 30A, 30B, and a molded resin 31 covering the stator 10. In addition, the rotor 20 has a rotating shaft 21 arranged at its center. Moreover, the two sides of the rotating shaft 21 are respectively held by a pair of bearings 30A, 30B, so that the rotor 20 is supported to rotate freely. In addition, the illustrated motor 101 is a brushless motor. In addition, in the present embodiment, the motor 101 is also provided with a circuit substrate 34, a first bracket 32 ​​and a second bracket 33 made of metal and having a roughly circular plate shape when viewed from above, which become a part of the outer shell (housing) of the motor 101.

[0072] The stator 10 includes a stator core 11 formed by stacking a plurality of metal plates and a coil 12 wound around the stator core 11. Figure 2 , Figure 3 As shown, the stator core 11 includes a yoke 11 a formed in an annular shape so as to surround the rotor 20 disposed along the axis X of the rotating shaft 21 , and a plurality of teeth 11 b protruding from the yoke 11 a toward the axis X in a convex shape.

[0073] In the following description, the terms teeth (plural form of tooth) and single tooth (tooth) are used to distinguish. Specifically, a plurality of teeth protruding toward the center of the annular stator core are referred to as teeth (plural form of tooth). In addition, one tooth among the plurality of teeth of the stator core is referred to as a single tooth (tooth).

[0074] In addition, the axis X is sometimes referred to as the axial direction X.

[0075] like Figure 1 , Figure 4 As shown, the rotor 20 has a rotating shaft 21 extending in the axis X direction and a rotating body 22 including a magnetic component, extending in the axis X direction and fixed to the rotating shaft 21. In addition, the rotating body 22 is configured as follows: a plurality of magnets 24 as permanent magnets are assembled on the outer peripheral surface of the rotor core 23 in such a manner that the polarities of adjacent magnets 24 are alternated. The rotating shaft 21 of the rotor 20 is rotatably supported by a bearing 30A embedded in the center of the first bracket 32 ​​and a bearing 30B embedded in the center of the second bracket 33, and the rotor 20 is rotatably supported.

[0076] like Figure 5 As shown, the coil 12 is wound around the stator core 11 via an insulator 13 made of an insulating material such as resin. The insulator 13 generally includes a bottom surface portion 13a, an outer peripheral wall portion 13b, and an inner peripheral wall portion 13c.

[0077] The bottom surface 13a of the insulator 13 is mounted on the end surface of the stator core 11, etc. In the present embodiment, the bottom surface 13a of the insulator 13 is formed by a surface extending in a direction intersecting the axis X. The outer peripheral wall portion 13b of the insulator 13 is erected on the outer peripheral side of the portion where the coil 12 is wound to limit the coil position. In the present embodiment, the outer peripheral wall portion 13b of the insulator 13 is formed by a wall surface extending in the direction along the axis X. The inner peripheral wall portion 13c of the insulator 13 is erected on the inner peripheral side of the portion where the coil 12 is wound to limit the coil position. The inner peripheral wall portion 13c of the insulator 13 is formed by a wall surface extending in the direction along the axis X. The inner peripheral wall portion 13c of the insulator 13 is located closer to the axis X side than the outer peripheral wall portion 13b. In addition, the insulator 13 is not limited to this shape as long as it can insulate the coil 12 from the stator core 11.

[0078] The coil 12 has a coil end 12a extending from the stator core 11 in the axial direction X. Figure 1 , Figure 5 In the figure, the coil end 12a protrudes from the stator core 11 to the upper and lower sides of the paper. Figure 2 , Figure 3As shown, the coil 12 except for the coil end 12a is housed in the stator core 11. Furthermore, except for the inner circumference of each single tooth 11b, the coil 12, the insulator 13 and the stator core 11 of the stator 10 are covered with a molded resin 31. In addition, the outer circumferential surface side portion of the molded resin 31 is formed into a cylindrical shape to form a main body (shell main body) 31a, which is a part of the outer shell (housing) of the motor 101. The end edge of the main body 31a is embedded in and fixed to the outer circumference of the first bracket 32 ​​and the second bracket 33. In addition, as shown Figure 1 As shown, in this embodiment, a circuit board 34 is mounted on a portion of the mold resin 31 covering the coil 12 . The circuit board 34 has electronic components 34 a mounted thereon, such as a connection circuit connected to the coil 12 , various control circuits, and a safety protection circuit.

[0079] The motor 101 is provided with non-combustible layers 41A, 41B, 42A, 42B, and 43 covering the coil end 12a. Figure 1 , Figure 5 As shown, non-combustible layers 41A, 41B, 42A, 42B, and 43 formed of air in the space portion are provided to further cover the portion of the mold resin 31 covering the coil end portion 12a, that is, the coil end portion mold portion 31b from the outside.

[0080] To discuss in more detail, a groove-shaped recessed portion is formed between the coil end molded portion 31b and the main body portion 31a, and the air in the space of the groove-shaped recessed portion is used to form the non-combustible layers 41A and 41B that become the groove portion. These non-combustible layers 41A and 41B extend in the axis X direction at a position closer to the outer peripheral side than the coil end 12a of the molded resin 31 in a manner that includes at least a size range corresponding to the coil end 12a. That is, in this embodiment, the dimension h1 of the non-combustible layers 41A and 41B in the axis X direction is formed to be longer than the dimension h3 of the mounting portion where the coil end molded portion 31b and the insulator 13 are mounted on the end surface of the stator core 11 along the axis X direction.

[0081] In other words, if Figure 5 As shown, in the direction intersecting the axis X, that is, in the radial direction (in the figure, the direction indicated by the arrow Y. Hereinafter, it is referred to as "radial direction Y"), the non-combustible layers 41A and 41B forming the groove portions are located on the outer peripheral side of the coil end portion 12a. Alternatively, in the radial direction Y, the non-combustible layers 41A and 41B are located between the coil end portion 12a and the molded resin 31. In addition, in the direction of the axis X, the height h1 of the non-combustible layers 41A and 41B is higher than the height h2 of the coil end portion 12a.

[0082] In addition, on the side where the circuit substrate 34 is mounted, spaces are formed between the coil end molded portion 31b and the circuit substrate 34, and between the coil end molded portion 31b and the first bracket 32, excluding the mounting portion of the circuit substrate 34, and the air in each space forms the non-combustible layers 42A and 42B. Furthermore, a space is formed between the coil end molded portion 31b and the second bracket 33 on the side close to the second bracket 33, and the air in the space forms the non-combustible layer 43.

[0083] These non-combustible layers 42A, 42B, 43 are formed so as to extend in the radial direction Y at a position on the opposite side of the stator core 11 with respect to the coil end 12a, that is, on the outer side in the axial direction. In addition, in the present embodiment, the non-combustible layers 42A, 42B, 43 formed by spaces are provided within the dimension range in the radial direction Y where the coil end molded portion 31b is provided.

[0084] In other words, if Figure 5 As shown, in the direction along the axis X, the non-combustible layers 42A and 42B are located in the direction opposite to the direction in which the stator core 11 is located relative to the coil end 12a. In the direction intersecting the axis X, that is, in the radial direction Y, the width W1 of the space formed by the non-combustible layers 42A and 42B is larger than the width W2 of the coil end 12a.

[0085] In addition, the non-combustible layer 43 is located in the direction opposite to the direction in which the stator core 11 is located relative to the coil end 12a in the direction along the axis X. In the direction intersecting the axis X, that is, in the radial direction Y, the width W3 of the space formed by the non-combustible layer 43 is larger than the width W2 of the coil end 12a.

[0086] If the above structure is adopted, the following effects can be obtained. That is, if the safety protection circuit for preventing excessive current from flowing in the coil 12 of the stator 10 does not function properly, excessive current will flow in the coil 12 of the stator 10. Then, the coil 12 heats up and becomes extremely high temperature, causing a partial short circuit. When a partial short circuit occurs in the coil 12, sparks are generated. The generated sparks ignite the gas generated by the insulator 13, etc., which may cause a fire. In response to such an undesirable situation, in the present embodiment, non-combustible layers 41A, 41B, 42A, 42B, 43 are provided to further cover the coil end molded portion 31b covering the coil end 12a. Therefore, even in the case of a partial short circuit, the fire caused by the insulator 13, etc. is blocked by the non-combustible layers 41A, 41B, 42A, 42B, 43, and as a result, it is possible to prevent fire and smoke from leaking from the motor 101 to the outside.

[0087] That is, for example, suppose that a fire starts from the coil end 12a and the fire is about to spread to the outer peripheral side of the coil end mold 31b and the insulator 13 covering the coil end 12a in the radial direction Y. In this regard, in the present embodiment, non-combustible layers 41A and 41B formed to extend in the axis X direction are provided at the outer peripheral side of the coil end 12a. Therefore, even if the fire is about to spread as described above, the fire and smoke are blocked by the non-combustible layers 41A and 41B, making it difficult for them to leak to the outside of the motor 101.

[0088] In addition, for example, suppose that a fire starts from the coil end 12a and the fire spreads to the side of the coil end molded portion 31b and the insulator 13 that cover the coil end 12a and are opposite to the stator core 11 in the axial center X direction. In this regard, in the present embodiment, non-combustible layers 42A, 42B, and 43 formed to extend in the radial direction Y are provided at positions that are opposite to the stator core 11 than the coil end 12a. Therefore, even if the fire spreads as described above, the fire and smoke are blocked by the non-combustible layers 42A, 42B, and 43, making it difficult for them to leak to the outside of the motor 101.

[0089] In addition, in the present embodiment, the following case is illustrated: in the radial direction Y, the non-combustible layers 41A and 41B extending in the axis X direction are formed at the outer peripheral side of the coil end 12a in parallel with the axis X direction. However, this is not limited to this, and the non-combustible layers can be formed in parallel with the axis X direction even if the distance from the axis X changes. It is sufficient as long as at least a part is connected in the axis X direction. In addition, the following case is illustrated: the non-combustible layers 42A, 42B, and 43 extending in the radial direction Y are formed on the side opposite to the stator core 11 (outer side in the axis X direction) in a manner substantially along the radial direction Y. However, this is not limited to this, and the non-combustible layers can be formed in parallel with the axis X direction even if the position relative to the axis X direction changes.

[0090] In addition, in the present embodiment, a first bracket 32 ​​is further provided on the outside of the non-combustible layer 42A in the axis X direction, that is, on the side opposite to the stator core 11 with respect to the coil end 12a. Therefore, the first bracket 32 ​​also functions as a metal cover covering the coil end 12a, and can more reliably prevent fire and smoke from leaking out of the motor 101 to the outside, thereby improving reliability.

[0091] In the above-mentioned embodiment, the following is described: in the radial direction Y, the non-combustible layers 41A and 41B formed at the outer peripheral side of the coil end 12a and extending in the axis X direction are extended in a manner longer than the dimension h3 of the mounting portion where the coil end molded portion 31b and the insulator 13 are mounted on the end surface of the stator core 11 in the axis X direction. However, the present invention is not limited to this. For example, Figure 6As shown, other structures are also possible. Figure 6 is a half-section view of a modified example of this embodiment. Figure 6 As shown, the motor 101a is formed with the non-combustible layers 41C and 41D in such a manner that they are deeper than the dimension h3 of the mounting portion where the coil end molded portion 31b and the insulator 13 are mounted on the end surface of the stator core 11 along the axis X direction, and are bitten into the outer peripheral side of the stator core 11. Thus, even if the safety protection circuit does not function properly and a fire is ignited from the area near the coil end 12a to the coil end molded portion 31b and the insulator 13, it is possible to more reliably prevent the fire from leaking out of the motor 101 and the motor 101a to the outside, and the reliability can be improved.

[0092] (Second embodiment)

[0093] Figure 7 It is a half cross-sectional view of a motor 102 according to a second embodiment of the present invention.

[0094] In the first embodiment, the non-combustible layers 41A, 41B, 41C, 41D, 42A, 42B, and 43 are formed of air, but the present invention is not limited thereto and the non-combustible layers may be formed of non-combustible materials. That is, in the present embodiment, the motor 102 having the non-combustible layers 44 and 45 formed of metal is described.

[0095] like Figure 7 As shown, the non-combustible layers 44 and 45 are formed of a non-combustible material formed of metal. In addition, in the present embodiment, the coil end molded portion 31b is covered with the metal non-combustible layers 44 and 45 from the outside of the molded resin 31. In a specific example, the non-combustible layer 44 is formed to extend along the axis X direction at a position closer to the outer peripheral side than the coil end 12a close to the circuit substrate 34 on the outer peripheral surface of the main body 31a of the molded resin 31. That is, the non-combustible layer 44 is formed to include the coil end molded portion 31b in the axis X direction.

[0096] In other words, the non-combustible layer 44 is located on the outer peripheral side of the coil end 12a in the direction intersecting the axis X, that is, in the radial direction Y. In the axis X direction, the height h11 of the non-combustible layer 44 is higher than the height h2 of the coil end 12a.

[0097] In addition, the non-combustible layer 45 extends from the outer peripheral surface of the main body 31a of the molded resin 31 to the vicinity of the bearing 30B. In a more specific example, the non-combustible layer 45 extends in the axial X direction at a position on the outer peripheral side of the coil end 12a close to the second bracket 33 on the outer peripheral surface of the main body 31a of the molded resin 31, and is formed to include the coil end molded portion 31b in the axial X direction. In addition, the non-combustible layer 45 also extends in the radial direction Y at a position on the opposite side of the stator core 11 with respect to the coil end 12a, and is formed to include the coil end molded portion 31b in the radial direction Y.

[0098] In other words, the non-combustible layer 45 is formed so as to cover the coil end 12a in the entire range from the end 45a located in the direction along the axis X to the end 45b located in the radial direction Y. Specifically, in the direction along the axis X, the height h12 of the non-combustible layer 45 is higher than the height h2 of the coil end 12a. In addition, in the radial direction Y, the width W31 of the non-combustible layer 45 is wider than the width W2 of the coil end 12a.

[0099] As described above, in the event that the safety protection circuit for preventing an excessive current from flowing in the coil 12 of the stator 10 does not function properly, an excessive current flows in the coil 12 of the stator 10. As a result, the coil 12 heats up and becomes extremely hot, causing a partial short circuit. When a partial short circuit occurs in the coil 12, sparks are generated. The generated sparks ignite the gas generated by the insulator 13, etc., and there is a possibility of fire. In response to such an undesirable situation, in the present embodiment, non-combustible layers 44 and 45 formed of a non-combustible material formed of metal are provided. Therefore, even if the fire is about to spread to the outer peripheral side of the motor 102, the fire and the smoke accompanying it are blocked by the non-combustible layers 44 and 45, and the fire and smoke can be prevented from leaking to the outside of the motor 102.

[0100] In addition, for example, when a fire starts at the coil end 12a and the fire tries to spread from the coil end molded portion 31b to the side opposite to the stator core 11 in the axial X direction, the fire and smoke are blocked by the non-combustible layer 45, non-combustible layers 42A, 42B, and 44, thereby preventing the fire and smoke from leaking to the outside of the motor 102.

[0101] In addition, the non-combustible layers 44 and 45 formed of metal described above can be made of metal materials such as iron, stainless steel, brass, and aluminum.

[0102] In particular, when iron or brass is used, the rust-proof function can be improved by plating the surface thereof. Specifically, when iron is used, hot-dip galvanized steel sheet (Japanese Industrial Standard JIS standard: SGCD) or electrogalvanized steel sheet (Japanese Industrial Standard JIS standard: SECD) can be used.

[0103] In addition, in the present embodiment, the case where the non-combustible layers 44 and 45 are formed of a non-combustible material formed of metal is described, but the present invention is not limited to this, and inorganic materials such as ceramics and aluminum hydroxide molded products may be used instead.

[0104] (Third embodiment)

[0105] Figure 8 It is a half cross-sectional view of a motor 103 according to a third embodiment of the present invention.

[0106] In this embodiment, if Figure 8 As shown in the figure, similarly to the first embodiment, non-combustible layers 41A and 41B are provided in the radial direction Y, and the non-combustible layers 41A and 41B are formed of air formed as a space portion extending in the axis X direction at a position closer to the outer peripheral side than the coil end 12a. In addition, at the same time, a metal cover is provided on the outside of the molded resin 31. That is, in this embodiment, the first bracket 32 ​​and the second bracket 33 are extended along the main body 31a of the molded resin 31, and the metal cover portions 46 and 47 as the extended portions also have the function of a non-combustible layer.

[0107] With this structure, it is possible to more reliably prevent fire and smoke from leaking out of the motor 103, thereby improving reliability. In addition, in the present embodiment, the first bracket 32 ​​and the second bracket 33 are extended to form the metal cover parts 46 and 47, but the present invention is not limited thereto. Figure 7 A metal cover is independently provided like the non-combustible layer 44.

[0108] (Fourth embodiment)

[0109] Fig. 9 1 is a half-section view of a motor 104 according to a fourth embodiment of the present invention. Fig.10 It is an enlarged half-sectional view of a main part of the above-mentioned motor 104.

[0110] In this embodiment, using Fig. 9 Such non-combustible layers 50, 51 cover the coil end 12a and the insulator 13 for holding the coil end 12a. The non-combustible layers 50, 51 may be air, but more preferably non-combustible materials such as inorganic substances such as metals and ceramics. In addition, the space between the non-combustible layers 50, 51 and the coil end 12a may be air or filled with the molding resin 31.

[0111] exist Fig. 9 , Fig.10 In FIG. 1 , the non-combustible layers 50 and 51 are formed of a cover-shaped metal. The non-combustible layers 50 and 51 are formed in a manner to surround the coil end 12a and the insulator 13 holding the coil end 12a. More specifically, as Fig.10As shown, the non-combustible layer 50 includes: an outer peripheral surrounding portion 50a, which is located on the outer peripheral side of the outer peripheral wall portion 13b of the insulator 13; a side surrounding portion 50b, which is located on the opposite side of the stator core relative to the insulator 13; and an inner peripheral surrounding portion 50c, which is located on the inner peripheral side of the inner peripheral wall portion 13c of the insulator 13. Similarly, the non-combustible layer 51 includes an outer peripheral surrounding portion 51a, a side surrounding portion 51b, and an inner peripheral surrounding portion 51c.

[0112] In other words, the non-combustible layers 50 and 51 respectively have outer peripheral surrounding portions 50a and 51a and inner peripheral surrounding portions 50c and 51c in the radial direction Y. In the radial direction Y, the outer peripheral surrounding portions 50a and 51a are respectively located on the outer peripheral side of the outer peripheral wall portion 13b of the insulator 13. In the radial direction Y, the inner peripheral surrounding portions 50c and 51c are respectively located on the axis X side of the inner peripheral wall portion 13c of the insulator 13.

[0113] The non-combustible layers 50 and 51 have side surrounding portions 50b and 51b, respectively, in the direction along the axis X. In the direction along the axis X, the side surrounding portions 50b and 51b are located at positions facing the bottom surface portion 13a across the coil end portion 12a.

[0114] As described above, in the event that the safety protection circuit for preventing an excessive current from flowing in the coil 12 of the stator 10 does not function properly, an excessive current flows in the coil 12 of the stator 10. As a result, the coil 12 is heated to an extremely high temperature, causing a partial short circuit. When a partial short circuit occurs in the coil 12, sparks are generated. The generated sparks ignite the gas generated by the insulator 13, etc., and there is a possibility of fire. In response to such an undesirable situation, in the present embodiment, non-combustible layers 50 and 51 covering the coil end 12a of the coil 12 of the stator 10 and the insulator 13 are provided. Therefore, even when a partial short circuit occurs in the coil 12, the fire caused by the insulator 13, etc. is blocked by the non-combustible layers 50 and 51, which can prevent fire and smoke from leaking from the motor 104 to the outside.

[0115] That is, the non-combustible layers 50 and 51 have outer peripheral surrounding portions 50a and 51a formed to extend in the axis X direction at positions on the outer peripheral side of the coil end portion 12a and the outer peripheral wall portion 13b of the insulator 13. Thus, for example, when a fire starts from the coil end portion 12a and the fire tries to spread to the outer peripheral side of the coil end portion 12a and the insulator 13 in the radial direction Y, the fire and smoke are blocked by the outer peripheral surrounding portions 50a and 51a, and can be prevented from leaking to the outside of the motor 104.

[0116] In addition, the non-combustible layers 50 and 51 have side surrounding portions 50b and 51b formed to extend in the radial direction Y on the side opposite to the stator core 11 from the coil end portion 12a, that is, on the outer side in the axial direction. Thus, for example, when a fire starts from the coil end portion 12a and the fire tries to spread to the side opposite to the stator core 11 from the coil end portion 12a and the insulator 13 in the axial direction X, the fire and smoke are blocked by the side surrounding portions 50b and 51b, and can be prevented from leaking to the outside of the motor 104.

[0117] Furthermore, the non-combustible layers 50 and 51 have inner peripheral surrounding portions 50c and 51c formed to extend in the axis X direction at positions on the inner peripheral side of the coil end portion 12a and the inner peripheral wall portion 13c of the insulator 13. Thus, for example, when a fire starts at the coil end portion 12a and the fire tries to spread to positions on the inner peripheral side of the coil end portion 12a and the insulator 13 in the radial direction Y, the fire and smoke are blocked by the inner peripheral surrounding portions 50c and 51c, and can be prevented from leaking to the outside of the motor 104.

[0118] In the above-mentioned present embodiment, the cross-sectional shape of the non-combustible layers 50 and 51 is set to be roughly in the shape of the Japanese Katakana U, but it is not limited to this, and any shape can be used as long as it covers the outer side of the coil end 12a and the insulator 13 well. In addition, in the present embodiment, there is an advantage that even if the fire leaks from the coil end 12a to the inner peripheral side, it is possible to well prevent the fire and smoke from leaking to the outside from the non-combustible layers 50 and 51. However, it is not limited to this, and it can also be set as Fig.11 The structure disclosed in the half-section view of the modified example of the present embodiment shown in FIG. Fig.11 The motor 104a shown has outer peripheral surrounding parts 52a, 53a and side surrounding parts 52b, 53b as non-combustible layers 52, 53. Even with such a structure without an inner peripheral surrounding part, it is possible to prevent the fire from starting from the coil end 12a and leaking from the coil end 12a and the insulator 13 to the outer peripheral side and the side. Therefore, compared with the case where the non-combustible layers 52, 53 are not provided, it is possible to suppress the fire from leaking to the outside from the motor 104a to a certain extent.

[0119] In the above-mentioned embodiments, the following is described: in any embodiment, the non-combustible layer includes a portion formed at the outer peripheral side of the coil end 12a and extending in the axial direction, such as the non-combustible layers 41A, 41B, 41C, 41D, 44, 45, 50a, 51a, 52a, and 53a, and a portion formed at the opposite side of the stator core 11 with respect to the coil end 12a and extending in the radial direction Y, such as the non-combustible layers 42A, 42B, 43, 45, 50b, 51b, 52b, and 53b. And, with this structure, even if a fire starts from the coil end 12a, it is possible to well block the fire from the coil end 12a of the motor to the outside, that is, to the outside in the radial direction Y and the axial direction X, and it is possible to prevent the fire and smoke from leaking to the outside of the motor. However, the present invention is not limited thereto, and the non-combustible layer may be configured to include only a portion extending in the axial direction X at a position on the outer peripheral side of the coil end 12a, such as the non-combustible layers 41A, 41B, 41C, 41D, 44, 45, 50a, 51a, 52a, and 53a, or may be configured to include only a portion extending in the radial direction Y at a position on the opposite side of the stator core 11 with respect to the coil end 12a, such as the non-combustible layers 42A, 42B, 43, 45, 50b, 51b, 52b, and 53b. In either case, compared with a motor having no non-combustible layer, fire and smoke are less likely to leak to the outside.

[0120] (Fifth embodiment)

[0121] Fig.12 It is a half cross-sectional view of a motor 105 according to a fifth embodiment of the present invention.

[0122] In the first to fourth embodiments described above, for example, the case where the coil end portion 12a is covered with the non-combustible layer such as the non-combustible layer 44, 45 is described, but in the present embodiment, Fig.12 As shown, the structure is such that the non-combustible layers 54 and 55 also cover the overlapping wires 12b of the coils 12. That is, in the motor 105, the overlapping wires 12b that connect the coils 12 to each other within the range of each single tooth (11b) are arranged on the periphery of the outer peripheral wall portion 13b of the insulator 13, etc. In this embodiment, the non-combustible layers 54 and 55 are provided so as to also cover these overlapping wires 12b.

[0123] In addition, in the present embodiment, the non-combustible layers 54 and 55 are formed of non-combustible materials such as annular metal plates. Furthermore, the non-combustible layers 54 and 55 are formed to extend along the axis X direction at positions closer to the outer periphery than the coil end 12a, the outer peripheral wall 13b of the insulator 13, and the lap wire 12b. Moreover, in addition to the coil end 12a and the outer peripheral wall 13b of the insulator 13, the non-combustible layers 54 and 55 also cover positions closer to the outer periphery than the lap wire 12b. In addition, the dimensions of the non-combustible layers 54 and 55 in the axis X direction, that is, the height h21, can ensure the following height: even if sparks are generated due to the breakage of the lap wire 12b, the sparks caused by the sparks will not fly to the main body 31a of the molded resin 31. In addition, the non-combustible layers 54 and 55 can also be composed of non-combustible materials such as inorganic substances and air. When the non-combustible layers 54 and 55 are formed of air, in addition to the dimension in the axial X direction, the non-combustible layers 54 and 55 also need to ensure a dimension in the radial direction Y that is equal to the height h21.

[0124] With this structure, the motor 105 is provided with non-combustible layers 54 and 55 that cover not only the coil end 12a of the coil 12 of the stator 10 but also the jumper wire 12b. The wire that becomes the coil 12 of the stator 10 may be disconnected. In the event that the safety protection circuit for preventing an excessive current from flowing in the coil 12 of the stator 10 does not function properly, an excessive current flows in the wire that becomes the coil 12 of the stator 10. Moreover, the jumper wire 12b that connects the coils 12 may be disconnected. When the jumper wire 12b is disconnected, a spark may be generated at the disconnected portion, thereby generating a spark. The spark generated by the spark ignites the gas generated by the insulator 13 and the like, which may cause a fire. In view of such an undesirable situation, by setting the structure of this embodiment, even if a spark caused by a spark is generated, the fire caused by the insulator 13 and the like is blocked by the non-combustible layers 54 and 55, and it is possible to prevent fire and smoke from leaking from the motor 105 to the outside.

[0125] That is, the non-combustible layers 54 and 55 are formed at positions on the outer peripheral side of the outer peripheral wall portion 13b of the insulator 13 and the overlapped line 12b so as to extend in the axis X direction. Therefore, for example, when a fire starts from the overlapped line 12b and the fire tries to spread to the outer peripheral side of the insulator 13 and the overlapped line 12b in the radial direction Y, the fire and smoke are blocked by the non-combustible layers 54 and 55, and the fire and smoke can be prevented from leaking to the outside of the motor 105.

[0126] In the above-mentioned embodiment, the case where the overlapping wire 12b of the coil 12 is also covered by the two non-combustible layers 54 and 55 is described, but the present invention is not limited to this. Fig.13 Such a structure is disclosed in the half cross-sectional view of the modification example of this embodiment shown. Fig.13The motor 105a shown may also be configured so that not only the coil end 12a and the overlap wire 12b of the coil 12 of the stator 10 but also the outer peripheral side of the stator core 11 are covered by a non-combustible layer 56. Thus, the non-combustible layer 56 also blocks fire and smoke, and can prevent fire and smoke from leaking to the outside of the motor 105a.

[0127] In addition, Fig.12 , Fig.13 In the motors 105 and 105a shown in FIG. 1 , the non-combustible layers 54, 55, and 56 are all arranged on the inner side (inner circumference side) of the molded resin 31, but the present invention is not limited to this. Fig.14 The structure disclosed in the half cross-sectional view of another modified example of the present embodiment is shown. Fig.14 The motor 105b shown may also have the non-combustible layers 57 and 58 disposed on the inner and outer circumferences of the mold resin 31. The non-combustible layers 57 and 58 are formed of non-combustible materials such as metal plates and ceramics.

[0128] In this variation, if Fig.14 As shown, the non-combustible layer 57 is formed to extend along the axis X direction on the inner peripheral side of the molded resin 31. That is, the non-combustible layer 57 is formed to include the circuit substrate 34, one coil end 12a on the side near the first bracket 32, the insulator 13, the overlap wire 12b, and the stator core 11 in the axis X direction. In this way, the non-combustible layer 57 covers these components from the outer peripheral side in the radial direction Y.

[0129] In addition, the non-combustible layer 58 is formed on the outer peripheral side of the molded resin 31 and Fig.14 The non-combustible layer 58 is formed to extend from the outer peripheral surface of the main body 31a of the molded resin 31 to the vicinity of the bearing 30B, that is, to extend in the axial X direction and the radial direction Y. That is, the non-combustible layer 58 extends in the axial X direction at a position on the outer peripheral side of the outer peripheral surface of the main body 31a of the molded resin 31 that is closer to the outer peripheral side than the coil end 12a close to the second bracket 33. In addition, the non-combustible layer 58 is formed to include the coil end molded portion 31b in the axial X direction, or to include the coil end 12a, the insulator 13, the overlap wire 12b, and the stator core 11 as in the present embodiment. In addition, the non-combustible layer 58 is formed to extend in the radial direction Y also at a position on the opposite side of the stator core 11 with respect to the coil end 12a, and includes the coil end molded portion 31b in the radial direction Y. Thus, the non-combustible layer 58 covers the coil end 12a from the end 58a located in the direction along the axis X to the end 58b located in the radial direction Y, and covers the coil end 12a, the insulator 13, and the overlapping wire 12b as in the present embodiment.

[0130] In this modification, the non-combustible layer 57 and the end 58a of the non-combustible layer 58 overlap in a height range h31 along the axis X. The end 58b of the non-combustible layer 58 and the second bracket 33 overlap in a radial direction Y in a radial range W32.

[0131] As described above, in the structure of this modified example, the non-combustible layers 57 and 58 are formed on the inner and outer circumferential sides of the molded resin 31 so as to extend in the direction of the axis X at positions closer to the outer circumferential side than the outer circumferential wall portion 13b of the insulator 13 and the overlapped line 12b. Thus, for example, when a fire starts at the overlapped line 12b and the fire tries to spread to the outer circumferential side of the insulator 13 and the overlapped line 12b in the radial direction Y, the fire and smoke caused by the insulator 13 and the like are blocked by the non-combustible layers 57 and 58, and the fire and smoke can be prevented from leaking to the outside of the motor 105b.

[0132] In addition, in this modification, the non-combustible layer 57 and the end 58a of the non-combustible layer 58 overlap in the height range h31 along the axis X direction. Therefore, in the case of a fire from the adjacent lap wire 12b or the coil end 12a, the fire and smoke blocking performance is further improved, and the fire and smoke can be prevented from leaking to the outside of the motor 105b more effectively. In addition, the end 58b of the non-combustible layer 58 and the second bracket 33 overlap in the radial range W32 along the radial direction Y. Therefore, in the case of a fire from the adjacent lap wire 12b or the coil end 12a, the fire and smoke blocking performance is further improved, and the fire and smoke can be prevented from leaking to the outside of the motor more effectively.

[0133] Alternatively, you can also set it as Fig.15 The structure disclosed in the half cross-sectional view of still another modified example of the present embodiment is shown. Fig.15 The motor 105c shown is also provided with a non-combustible layer 59 on the outer peripheral side of the molded resin 31 in a manner that overlaps with the end of the bulging portion 57a ​​of the non-combustible layer 57 in the axis X direction with a height range h33. The non-combustible layer 59 is formed of a non-combustible material such as a metal plate or ceramic. As a result, the fire and smoke blocking performance is further improved, and the fire and smoke can be prevented from leaking to the outside of the motor more effectively. In addition, the non-combustible layer 59 may be formed by extending the end of the radial outer peripheral side of the first bracket 32 ​​along the axis X direction instead of independently providing the non-combustible layer 59.

[0134] (Sixth embodiment)

[0135] Fig.16 It is an exploded perspective view of a motor 106 according to a sixth embodiment of the present invention. Fig.17 It is a cross-sectional view of the motor 106 . Fig.18 The motor 106 Fig.17 The sectional view along the line 18-18 in the figure. In addition, Fig.19is a perspective view of the appearance of the motor 106. Fig. 20 It is an exploded perspective view of another motor according to the sixth embodiment of the present invention.

[0136] In this embodiment, the motor 106 is also described as an example of a brushless motor having a permanent magnet in the rotor. Fig.16 As shown in FIG. 1 , the direction indicated by the reference numeral X in which the rotation axis 21 extends is defined as the axial direction. Fig.18 In this way, the description will be made with the direction of reference numeral Y extending from the center X of the rotation shaft 21 being referred to as the radial direction, and the direction of reference numeral Z rotating around the center X being referred to as the circumferential direction.

[0137] In addition, if Fig.17 As shown, in this embodiment, in order to prevent fire and smoke from leaking out from the main body of the motor 106 to the outside due to an unfavorable situation such as an excessive current flowing through the coil 62 due to the malfunction of the safety protection circuit, a non-combustible layer is provided. Specifically, in this embodiment, a metal cover made of metal is used as the non-combustible layer. More specifically, the metal cover includes a metal inner cover 66 and a metal outer cover 76.

[0138] First, if Fig.16 As shown, the motor 106 in this embodiment includes a stator 60, a rotor 80, a first bracket 35, a circuit board 34, two bearings 30A and 30B, and a metal outer cover 76. In order to make the structure of the motor 106 easier to understand, the metal inner cover (66) described later is not described.

[0139] like Fig.17 As shown, the stator 60 includes a coil assembly 64 including a stator core 61, a coil 62, and an insulator 63. As in the above-described embodiments, the coil 62 is wound around the stator core 61 via the insulator 63 formed of an insulating material to form the coil assembly 64.

[0140] In addition, if Fig.18As shown, the stator core 61 has an annular yoke 61a and a plurality of teeth 61b extending radially inward from the inner circumferential surface of the yoke 61a. The plurality of teeth 61b have slots 61c as openings formed between each other, and the plurality of teeth 61b are arranged at equal intervals along the circumferential direction Z. In this embodiment, an example of using a plurality of teeth 61b and setting the number of slots to 12 slots is shown. In addition, a single tooth top end portion 61bb extending along the circumferential direction Z is formed at the extended top end portion of each single tooth 61b in a manner wider than the extended single tooth middle portion 61ba. The inner circumferential surface of the single tooth top end portion 61bb becomes a magnetic pole surface opposite to the outer circumferential surface of the rotor 80. For the stator core 61 of such a structure, the winding is wound around each single tooth 61b while passing the winding through the opening space of the slot 61c, thereby forming a coil 62. In addition, the coils 62 are connected to each other by, for example, a lap wire as described in the fifth embodiment. The coil 62 of each single tooth 61 b ​​is energized and driven by, for example, three-phase alternating current of a U phase, a V phase, and a W phase whose phases are electrically different from each other by 120 degrees.

[0141] Furthermore, in this embodiment, if Fig.18 As shown, the stator 60 includes a metal inner cover 66 arranged to surround the outer periphery of the stator core 61 and a metal inner cover 66 as shown in FIG. Fig.16 The configuration shown is a second bracket 65 protruding from the stator 60. Fig.17 As shown, the coil assembly 64, the metal inner cover 66 and the second bracket 65 of the stator 60 are arranged at a predetermined position, and except for the inner circumferential surface of each single tooth (61b) and the protruding portion of the second bracket 65, these components are integrally formed by molded resin in a manner of covering these components with resin material. In this way, the stator 60 including the molded resin portion 69 formed by integrating these components with molded resin is formed. The stator 60 constructed in this way has a roughly cylindrical shape, and a mounting portion 69a, a wiring hole 69b, etc. for mounting the motor 106 on an external device, etc. are also formed on the cylindrical surface. In addition, one of the two circular surfaces of the stator 60 is open, and the first bracket 35 is installed in the opening in a manner of being set as a cover, and the other surface is closed, and the second bracket 65 is arranged protrudingly as described above. In addition, the structure of the stator 60 is further described in detail below.

[0142] Next, if Figure 16 to Figure 18 As shown, the rotor 80 is inserted into the inner side of the stator 60 at a predetermined interval in the radial direction Y. That is, the motor 106 is an inner rotor type motor in which the rotor 80 is arranged inside the stator 60. This embodiment also cites an example of such an inner rotor type motor 106.

[0143] The rotor 80 includes a rotating body 82 for holding a magnet 84, with the rotating shaft 21 being rotatably held by the bearings 30A and 30B as the center. Fig.17 As shown, the rotating body 82 includes a rotor core 83, a magnet 84, and a rotor resin portion 86. The rotor core 83 is formed by, for example, stacking a plurality of thin iron plates in the axial direction X, and is fixed to the rotating shaft 21 at a substantially central portion of the rotating shaft 21. The magnet 84 is a permanent magnet and is disposed inside the rotor core 83 in the present embodiment.

[0144] like Fig.18 As shown, a plurality of magnet insertion holes 83a extending in the axial direction X are formed in the rotor core 83 at equal intervals in the circumferential direction Z. A magnet 84 is inserted into each magnet insertion hole 83a. In the present embodiment, an IPM (Interior Permanent Magnet) type motor 106 is shown in which a magnet 84 is enclosed inside such a rotor core 83. In addition, in the present embodiment, an example is shown in which the number of magnetic poles is set to 10 in such a manner that the S pole and the N pole of the magnet 84 alternate in the circumferential direction Z. That is, in the present embodiment, an example of a brushless motor with 10 poles and 12 slots is cited as the motor 106.

[0145] Furthermore, in this embodiment, if Fig.17 As shown, the rotor core 83 is molded by covering the two ends of the magnet insertion hole 83a into which the magnet 84 is inserted with a resin material, thereby forming a rotating body 82 having a rotor resin portion 86 formed therein. That is, in the present embodiment, the rotor core 83 is also provided with a resin through hole 83b that penetrates in the axial direction X. Moreover, at both axial ends of the rotor resin portion 86, a disc-shaped end plate resin portion 86a is formed that is arranged in a manner that each magnet 84 is sandwiched in the axial direction X. Furthermore, in the present embodiment, the resin through hole 83b of the rotor core 83 is also filled with a resin material, thereby connecting the end plate resin portion 86a in the axial direction X with the resin. The resin material filled in the resin through hole 83b constitutes an internal resin portion 86b as a part of the rotor resin portion 86. In the present embodiment, each magnet 84 is reliably fixed to the rotor core 83 by using such a rotor resin portion 86. In addition, by using this structure, even if the motor 106 is used in a device that comes into contact with rainwater or condensed water, such as a water swirl device or an outdoor unit of an air conditioner, it is possible to prevent the magnet 84 from coming into contact with water. In addition, in this embodiment, such an inner rotor type motor 106 is described, but as Fig. 20 As shown, a surface magnet type motor (Surface Permanent Magnet Motor: SPM motor) in which magnets are held on the outer peripheral surface of the rotor 80 as in the first to fifth embodiments may be used.

[0146] As described above, the rotor 80 includes Fig.16 The cylindrical rotating body 82 and the rotating shaft 21 passing through the center of the rotating body 82 are shown.

[0147] The rotating shaft 21 to which the rotating body 82 is fastened is supported by two bearings, the bearing 30A and the bearing 30B, so as to be rotatable. The bearings 30A and 30B are bearings having a plurality of small-diameter balls. In the present embodiment, the bearings 30A and 30B are fixed by means of a first bracket 35 and a second bracket 65 made of metal, which are respectively arranged on both sides of the stator 60 in the axial direction.

[0148] like Fig.16 and Fig.17 As shown in FIG. 1 , the first bracket 35 is formed in a substantially disk shape and is configured to be mounted on the opening side of the stator 60. A cylindrically recessed holding portion 35a is formed in the center of the first bracket 35, and the bearing 30A is held in the holding portion 35a. That is, by mounting the first bracket 35 with the bearing 30A inserted in the holding portion 35a to the stator 60, one side of the rotating shaft 21 is supported to be rotatable.

[0149] In addition, the diameter of the second bracket 65 is smaller than the diameter of the first bracket 35, and is formed into a shape obtained by combining a disk and a cylinder. In addition, by using the above-mentioned molding, the second bracket 65 is fixed to the molded resin portion 69 of the stator 60. In addition, a retaining portion 65a that is recessed in a cylindrical shape is also formed in the central portion of the second bracket 65, and the bearing 30B is retained in the retaining portion 65a. That is, by inserting the bearing 30B into the retaining portion 65a, the other side of the rotating shaft 21 is supported to rotate freely relative to the stator 60. In addition, in the present embodiment, an opening 65b is formed in the center of the retaining portion 65a, and the rotating shaft 21 protrudes outward through the opening 65b. Moreover, the protruding portion of the rotating shaft 21 becomes an output shaft 21p for connecting a load, etc.

[0150] In addition, the following details are described. In the present embodiment, a metal cover 76 made of metal is attached to the second bracket 65 side of the stator 60. The metal cover 76 is formed in a hollow cup shape having an opening 76h at the center. The second bracket 65 included in the stator 60 attaches the metal cover 76 to the stator 60 in a manner that penetrates the opening 76h of the metal cover 76.

[0151] In addition, in this embodiment, a configuration example is shown in which the motor 106 has a circuit substrate 34 built into the opening side of the stator 60. The circuit substrate 34 in this embodiment is formed in a substantially disc-like shape, and an opening 34b for the rotation shaft 21 to pass through is formed in the center. Electronic components (34a) such as a drive circuit are mounted on the circuit substrate 34, and connection wires for applying power supply voltage and control signals are also connected. In addition, the connection wires for connecting to the outside are led out to the outside through the wiring holder 68 mounted on the wiring hole 69b.

[0152] As described above, the motor 106 is constructed by the following steps. That is, first, the stator 60 is formed by arranging the coil assembly 64, the metal inner cover 66 and the second bracket 65 at predetermined positions and molding them as a whole. In addition, bearings 30A and 30B are installed on both sides of the rotating shaft 21 of the rotor 80. Moreover, the rotor 80 in a state where the bearings 30A and 30B are installed is inserted into the stator 60 in such a way that the output shaft 21p protrudes from the opening 65b of the second bracket 65. Next, the bearing 30B is pressed into the retaining portion 65a of the second bracket 65. Next, the circuit substrate 34 is installed on the opening side of the stator 60. The connecting wire connected to the circuit substrate 34 is led out to the outside via the wiring retaining member 68. Moreover, the bearing 30A is pressed into the retaining portion 35a of the first bracket 35, and the first bracket 35 is installed on the opening side of the stator 60 in a manner as a cover. Finally, the metal outer cover 76 is installed on the second bracket 65 side of the stator 60. In this way, the process is completed. Fig.19 Motor 106 as shown.

[0153] The motor 106 configured as described above is driven by supplying power supply voltage, control signals, etc. through the connection line, and the coil 62 is energized by the drive circuit mounted on the circuit board 34. When the coil 62 is energized, the drive current flows in the coil 62, and a magnetic field is generated from the stator core 61. Then, the alternating magnetic field from the stator core 61 and the magnetic field from the magnet 84 of the rotor 80 are used to generate attractive force and repulsive force according to the polarity of these magnetic fields, and these forces are used to rotate the rotor 80 in the circumferential direction Z around the rotating shaft 21.

[0154] Next, regarding the motor 106 configured as described above, a detailed structure of the stator 60 including the metal inner cover 66 will be described.

[0155] Fig.21 It is a cross-sectional view showing a cross section of the metal inner cover 66 and the cross section where the coil 62 is wound around the single tooth 61 b. Fig. 22 64 and the metal inner cover 66. Fig.23 This is a structural diagram in which a metal inner cover 66 is arranged on the outer periphery of a coil assembly 64 .

[0156] like Fig.21 As shown, the insulator 63 roughly has a bottom portion 63a, an outer peripheral wall portion 63b and an inner peripheral wall portion 63c. The bottom portion 63a is formed by a surface orthogonal to the axial direction X. Moreover, the surface formed as the bottom portion 63a is mounted on the end surface of the stator core 61 in the axial direction X. In addition, the outer peripheral wall portion 63b and the inner peripheral wall portion 63c are formed by wall surfaces parallel to the axial direction X. Such an outer peripheral wall portion 63b is erected on the outer peripheral side of the portion where the coil 62 is formed, and is used to limit the position of the coil. A pin 63d is installed on the outer peripheral wall portion 63b in a manner of protruding toward the side opposite to the stator core 61. As shown Fig.17 As shown in FIG. 6 , the pin 63d electrically connects the coil 62 wound on the single tooth (61b) and the circuit board 34. The pin 63d passes through the terminal cover 36 and is connected to the circuit board 34. Fig.21 As shown, the inner peripheral wall portion 63c is located radially inward of the outer peripheral wall portion 63b, and is erected on the inner peripheral side of the portion where the coil 62 is formed, and is used to restrict the position of the coil.

[0157] The bottom surface 63a of the insulator 63 is attached to both ends of the single tooth 61b in the axial direction X. The winding is wound across the pair of insulators 63 attached. By performing such an operation, one coil 62 is formed with respect to the stator core 61. Then, the same coil 62 is formed with respect to each single tooth 61b, and the coils 62 are electrically connected to each other according to a predetermined wire connection pattern, thereby completing Fig. 22 A coil assembly 64 as shown.

[0158] like Fig.21 As shown in FIG. 1 , in the coil assembly 64 formed in this way, the coil 62 has coil ends 62a extending from both sides of the stator core 61 in the axial direction X. Fig.18 As shown, the portion of the coil 62 other than the coil end 62a is accommodated in the slot 61c of the stator core 61. In order to electrically connect the coils 62 to each other, the jumper wire 62b connecting the coils 62 to each other is arranged on the outer periphery of the outer peripheral wall portion 63b of the insulator 63, etc., in the entire range between the single teeth 61b.

[0159] Here, as described in the above-mentioned background technology, in a motor having such a coil assembly 64, if the safety protection function for preventing an excessive current from flowing through the coil 62 is malfunctioned, an excessive current will flow through the coil 62. Then, the coil 62 and the jumper wire 62b are heated to extremely high temperatures. As a result, a partial short circuit may occur, or a spark caused by the partial short circuit may be generated, and further, the generated spark may ignite the gas generated from the insulator 63 and the like, and ignite. Moreover, in particular, since the coil end 62a and the jumper wire 62b described above protrude from the stator core 61, the possibility of such an inconvenience occurring is increased.

[0160] Therefore, similarly to the fifth embodiment, in this embodiment, Fig.23 As shown, a metal inner cover 66 as a non-combustible layer is arranged outside the coil assembly 64. Fig.21 and Fig. 22 As shown, the metal inner cover 66 is a metal cylinder formed into a substantially cylindrical shape with both sides open. Moreover, in the present embodiment, such a metal inner cover 66 is arranged in a manner of being spaced apart from the outer periphery of the coil assembly 64 in the radial direction at a predetermined interval and surrounding the outer side of the outer periphery. Fig. 22 As shown, the metal inner cover 66 has a small diameter portion 66 a and a large diameter portion 66 b having a larger diameter than the small diameter portion 66 a .

[0161] The inner diameter of the small diameter portion 66a is made substantially equal to the outer diameter of the stator core 61, so that the small diameter portion 66a can be embedded in the outer periphery of the stator core 61. In addition, the dimension of the small diameter portion 66a in the axial direction X is also substantially equal to the dimension of the stator core 61 in the axial direction X. Thus, the metal inner cover 66 is embedded in the coil assembly 64 in such a manner that the outer peripheral surface of the stator core 61 and the inner peripheral surface of the small diameter portion 66a of the metal inner cover 66 are joined, so that the coil assembly 64 is formed. Fig.23 As shown, the metal inner cover 66 is simply and temporarily fixed to the coil assembly 64 .

[0162] In addition, if Fig.21 As shown, the dimension of the large diameter portion 66b in the axial direction X is larger than the dimension of the coil end portion 62a in the axial direction X. Such a large diameter portion 66b is provided on the metal inner cover 66 only on one side of the small diameter portion 66a in the axial direction X. By attaching such a metal inner cover 66 to the coil assembly 64, the large diameter portion 66b of the metal inner cover 66 is arranged to surround the coil end portion 62a and the lap wire 62b on one side in the axial direction X.

[0163] In addition, Fig.21 In order to further clarify the configuration of the metal inner cover 66, the insulator 63, the coil end 62a and the lap wire 62b are also distinguished and represented as follows. Fig.21 In the axial direction X, the insulator 63B, the coil end 62aB and the jumper 62bB are arranged on one side relative to the stator core 61, and the insulator 63T, the coil end 62aT and the jumper 62bT are arranged on the other side opposite thereto.

[0164] That is, Fig.21As shown in the figure, the metal inner cover 66 is configured such that its large diameter portion 66b surrounds the insulator 63B, the coil end 62aB, and the lap wire 62bB. On the other hand, the insulator 63T, the coil end 62aT, and the lap wire 62bT are not surrounded by the metal inner cover 66. In particular, the outer periphery of the insulator 63T located at the lower part of the figure has a positioning portion 63e that is not included in the insulator 63B located at the upper part of the figure. The insulator 63T has the positioning portion 63e, so when the metal inner cover 66 is installed, the positional relationship between the small diameter portion 66a and the stator core 61 and the large diameter portion 66b and the insulator 63B is uniquely determined.

[0165] In addition, in the metal inner cover 66 of the present embodiment, the large diameter portion 66b is formed to have a larger diameter than the small diameter portion 66a. Thus, the large diameter portion 66b is mounted on the stator core 61 while maintaining a sufficient insulation distance from the pin 63d. Fig.17 As shown, the side wall of the terminal cover 36 is located between the large diameter portion (66b) and the pin 63d. If the terminal cover 36 is formed of an insulating material, the insulation distance between the large diameter portion (66b) and the pin 63d can be ensured with more margin.

[0166] As described above, the large diameter portion 66b of the metal inner cover 66 as a non-combustible layer is arranged at a position on the outer peripheral side of the coil end 62aB, the outer peripheral wall portion 63b of the insulator 63B, and the jumper wire 62bB. Therefore, even if a fire starts from the coil 62 due to a malfunction caused by the partial short circuit or the like, and the fire tries to spread to a position on the radially outer peripheral side of the insulator 63B and the jumper wire 62bB, the large diameter portion 66b of the metal inner cover 66 can block the fire and smoke, and prevent the fire and smoke from leaking to the outside of the motor 106.

[0167] In addition, as mentioned above, the Fig.23 Such a fire prevention structure is covered by the resin material of the molded resin portion 69 except for the inner peripheral surface of the single tooth 61b. That is, for example, in the fifth embodiment, in addition to the inner peripheral surface of the single tooth 11b, the insulator 13, the coil end 12a, etc. are also exposed, while in this embodiment, only the inner peripheral surface of the tooth 11b is exposed. In other words, in this embodiment, the insulator 63, the coil end 62a as a whole and the metal inner cover 66 as a whole are covered by the resin material. In this embodiment, by setting such a structure, while implementing the above-mentioned fire prevention measures, the holding strength of the coil assembly 64 of the stator 60 is also fully ensured.

[0168] And, if Fig.15As shown, both sides of the insulator 13 used in the fifth embodiment have protrusions 63f protruding in the radial direction Y. Therefore, in the case of this structure, when the non-combustible layer 57, especially the non-combustible layer 57 formed of a metal material, is mounted on the stator core 11, a manufacturing process of winding a plate-shaped metal material on the stator core 11 is required.

[0169] On the other hand, by using the insulators 63T and 63B of the present embodiment, it is possible to utilize the cylindrical metal inner cover 66. This facilitates the work of attaching the metal inner cover 66 to the stator core 61, and improves productivity.

[0170] like Fig.17 As shown, on the basis of such fire prevention measures in the stator 60, in the present embodiment, a structure is further provided with a metal cover 76 as a non-combustible layer. The metal cover 76 is attached to the outer surface of the molded resin portion 69 of the stator 60. In the present embodiment, the metal cover 76 is attached to the outer side of the stator 60 on the output shaft 21p side. In addition, by attaching in this way, the metal cover 76 is arranged at a position on the opposite side of the large diameter portion (66b) of the metal inner cover 66 relative to the stator core 61 in the axial direction X.

[0171] Fig.24 76 is a diagram for explaining the metal cover 76. Fig.24 7 shows the arrangement relationship between the coil assembly 64, the metal inner cover 66 and the second bracket 65 together with the metal outer cover 76. Fig.17 As shown, by installing the metal cover 76, as shown in Fig.24 As shown, the metal outer cover 76 is arranged at a position on the opposite side of the large diameter portion 66b of the metal inner cover 66 relative to the stator core 61 in the axial direction X. Here, as described above, the insulator 63T, the coil end 62aT, and the lap wire 62bT are arranged together with the second bracket 65 from which the output shaft (21p) protrudes on the side opposite to the large diameter portion 66b. In addition, in the following, in the axial direction X, the side opposite to the large diameter portion 66b of the metal inner cover 66 relative to such a stator core 61 is set as the output shaft side where the output shaft (21p) is arranged, and the side opposite to the output shaft side is set as the output shaft opposite side for appropriate description.

[0172] The metal cover 76 includes a top surface 76a, a curved surface 76b, and a cylindrical portion 76c, and is formed into a hollow cup shape. The top surface 76a of the metal cover 76 is in a disk shape and has an opening 76h at the center. The curved surface 76b is bent at a substantially right angle from the top surface 76a into a curved surface shape. The cylindrical portion 76c extends from the curved surface 76b in a cylindrical shape, and the end side of the cylindrical portion 76c is open. In addition, the inner diameter of the cylindrical portion 76c is made substantially equal to the outer diameter of the stator 60, so that the cylindrical portion 76c can be embedded in the outer periphery of the stator 60.

[0173] When the metal cover 76 is mounted on the stator 60, the dimension of the metal cover 76 in the axial direction X is set to a dimension such that an overlapping portion 76ca is generated where the cylindrical portion 76c and the metal inner cover 66 overlap in the axial direction X. In other words, the mounting position of the metal cover 76 is set to a position such that an overlapping portion 76ca is generated where the cylindrical portion 76c and the stator core 61 overlap in the axial direction X when the metal cover 76 is mounted on the stator 60. As a specific example, an example is shown where the overlapping portion 76ca has a dimension h61.

[0174] As described above, in the present embodiment, at least a portion of the cylindrical portion 76c overlaps the stator core 61 as an overlapping portion 76ca on the output shaft side in the axial direction X. Furthermore, the metal cover 76 is arranged relative to the coil assembly 64 in such a manner that the overlapping portion 76ca of the cylindrical portion 76c surrounds the outer side of the outer periphery of the stator core 61 at a predetermined interval in the radial direction Y from the outer periphery of the stator core 61. The metal cover 76 is attached to the stator 60 in such an arrangement relationship relative to the coil assembly 64. Thus, the metal cover 76 surrounds the insulator 63T, the coil end portion 62aT, and the overlap wire 62bT on the output shaft side and covers these components.

[0175] As described above, the coil end 62aT, the insulator 63T, and the jumper wire 62bT are covered by the metal cover 76 as a non-combustible layer. Therefore, even if a fire occurs due to a malfunction such as the partial short circuit described above, and the fire spreads to the radially outer peripheral side of the insulator 63B and the jumper wire 62bB, the metal cover 76 blocks the fire and smoke, and the fire and smoke can be prevented from leaking to the outside of the motor 106.

[0176] Furthermore, in this embodiment, the same as in the fifth embodiment Fig.14 , Fig.15 Similarly to the structure of the metal cover 76, at least a portion of the top surface 76a of the metal cover 76 overlaps with the second bracket 65 in the radial direction Y as an overlapping portion 76aa. More specifically, a portion of the top surface 76a that is closer to the outside than the outer periphery of the opening 76h forms an annular overlapping portion 76aa that overlaps with a portion of the outer periphery of the second bracket 65 in the radial direction Y. Fig.24, an example is shown in which the overlapping portion 76aa has a size w62. In this way, in the present embodiment as well, by providing the overlapping portion 76aa of the metal cover 76 overlapping the second bracket 65, the effect of blocking the fire and smoke generated inside the motor 106 from the outside is improved.

[0177] As described above, the motor 106 of the present embodiment includes the metal inner cover 66 and the metal outer cover 76 as the non-combustible layers.

[0178] By molding the metal inner cover 66 in a state in which it is attached to the side of the stator core 61 as described above, the stator 60 including the molded resin portion 69 in which these components are integrated is formed. In such a stator 60, the large diameter portion 66b of the metal inner cover 66 is arranged on the opposite side of the output shaft so as to surround the insulator 63B, the coil end portion 62aB, and the lap wire 62bB. Therefore, on the opposite side of the output shaft, the large diameter portion 66b of the metal inner cover 66 can block fire and smoke generated inside the motor 106.

[0179] In addition, in the present embodiment, the metal cover 76 is embedded in the outer periphery of the stator 60 as described above. Thus, on the output shaft side, the metal cover 76 is arranged so as to cover the insulator 63T, the coil end 62aT, and the lap wire 62bT. Therefore, on the output shaft side, the metal cover 76 can block fire and smoke generated inside the motor 106.

[0180] Furthermore, in the present embodiment, only the inner peripheral surface of the single tooth 11b is exposed, and the insulator 63 and the entire coil end 62a are covered by the molded resin portion 69 together with the entire metal inner cover 66. Therefore, while the above-mentioned fire prevention measures are implemented, the holding strength of the coil assembly 64 of the stator 60 is also sufficiently ensured.

[0181] In addition, in this embodiment, the metal inner cover 66 and the metal outer cover 76 made of metal are described as the non-combustible layer, but the metal inner cover 66 and the metal outer cover 76 can be made of non-combustible materials. The metal inner cover 66 and the metal outer cover 76 can also be made of materials other than metal such as ceramics as non-combustible materials.

[0182] (Seventh Implementation Method)

[0183] Fig.25 It is a cross-sectional view of a motor 107 according to a seventh embodiment of the present invention. Fig.26 It is a perspective view of the metal inner cover 661 of the motor 107. Fig. 27 It is a cross-sectional view of the metal inner cover 661 and the coil assembly 641 of the motor 107.

[0184] and Fig.17Compared with the sixth embodiment shown in FIG. 1 , the motor 107 in this embodiment includes a metal inner cover 661 obtained by deforming the metal inner cover 66 in the sixth embodiment and an insulator 631 obtained by deforming the insulator 63 in the sixth embodiment. Fig.25 As shown, the motor 107 includes a stator 601, a metal inner cover 661 is mounted on a coil assembly 641 including an insulator 631, and includes a molded resin portion 69 that integrates these components. In addition, other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are attached to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts.

[0185] First, if Fig.26 As shown, the metal inner cover 661 as the non-combustible layer is also a metal tube formed in a substantially cylindrical shape with both sides open. In addition, the metal inner cover 661 has a tapered portion 661c in addition to the small diameter portion 66a and the large diameter portion 66b similar to the metal inner cover 66 of the sixth embodiment.

[0186] The tapered portion 661c is provided at the end of the small diameter portion 66a on the opposite side from the large diameter portion 66b. The tapered portion 661c is formed in an inverted tapered shape, and its diameter increases as it approaches the end from the boundary with the small diameter portion 66a at the metal inner cover 661.

[0187] Furthermore, in accordance with the tapered portion 661 c , in the present embodiment, the coil assembly 641 includes an insulator 631 that is different from the insulator 63 of the sixth embodiment.

[0188] That is, Fig. 27 As shown, first, the coil assembly 641 in this embodiment is provided with the same insulator 63 as in the sixth embodiment on the opposite side of the output shaft, and in contrast, the insulator 631 is provided on the output shaft side. The insulator 631 has a tapered portion 631c in addition to the bottom portion 63a, the outer peripheral wall portion 63b and the inner peripheral wall portion 63c as in the sixth embodiment. On the output shaft side, when the insulator 631 is mounted on the stator core 61, the tapered portion 631c is arranged in a manner to be located on the outer periphery of the stator core 61. The cross section of the tapered portion 631c is triangular in shape, and the whole is formed in an inverted tapered shape, and the diameter thereof increases as it approaches the end of the stator core 61. In addition, the tapered portion 631c and the tapered portion 661c of the metal inner cover 661 are formed in a manner that the angle of the side surfaces and the length in the axial direction X are substantially equal to each other.

[0189] That is, when the coil assembly 641 having such a tapered portion 631c is embedded in the metal inner cover 661 having such a tapered portion 661c, the tapered portion 661c functions as a stopper when it contacts the tapered portion 631c, and cannot be further embedded. In this way, in the present embodiment, the position of the metal inner cover 661 relative to the coil assembly 641 in the axial direction X is limited by the tapered portion 661c and the tapered portion 631c.

[0190] As described above, in the present embodiment, the coil assembly 641 includes an insulator 631 having a tapered portion 631c, and the metal inner cover 661 includes a tapered portion 661c that matches the shape of the tapered portion 631c. Therefore, in the present embodiment, the metal inner cover 661 can be easily embedded in the coil assembly 641. In particular, the stopper function is realized by utilizing such a tapered shape, so it can be embedded more simply. Moreover, by such an easy operation of embedding until the tapered portion 661c and the tapered portion 631c contact, the positional relationship does not shift, and the positions of the coil assembly 641 and the metal inner cover 661 in the axial direction X can be accurately aligned. Therefore, for the insulator 63, the coil end 62aB and the lap wire 62bB located on the opposite side of the output shaft, the large diameter portion 66b of the metal inner cover 661 can be accurately arranged around these components. Therefore, according to the present embodiment, the large diameter portion 66 b of the metal inner cover 661 as the non-combustible layer can be arranged with greater accuracy, and leakage of fire and smoke to the outside of the motor 107 can be more reliably prevented.

[0191] (Eighth Implementation Method)

[0192] Fig.28 It is a cross-sectional view of a motor 108 according to an eighth embodiment of the present invention. Fig.29 It is an enlarged perspective view of the vicinity of the notch portion 692a of the motor 108. Fig.30 The motor 108 Fig.29 The 30-30 line plane section view. In addition, Fig.31 This is an enlarged stereoscopic view of another notch portion of the motor.

[0193] and Fig.17 Compared with the sixth embodiment shown in FIG. 1 , the motor 108 in this embodiment includes a molded resin portion 692 obtained by deforming the molded resin portion 69 in the sixth embodiment. Specifically, Fig.28As shown in FIG. 1 , the molded resin portion 692 of the motor 108 further includes a notch portion 692a as a notch, compared to the molded resin portion 69 of the sixth embodiment. In addition, the other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are given to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts. In addition, the details are described below. In this embodiment, the notch portion 692a is used to release moisture caused by condensation or the like generated on the metal cover 76 from the main body of the motor 108.

[0194] The notch portion 692a formed in the molded resin portion 692 is as follows. Fig.30 As shown in FIG. 1 , the cross section of the molded resin portion 692 is substantially circular, and a portion near the periphery thereof is concave toward the center. Fig.29 As shown in FIG. 6 , the cross-sectional shape of the notch portion 692 a extends in the axial direction X. That is, the notch portion 692 a is a groove or a recessed portion formed by partially cutting away the mold resin portion 692 .

[0195] In this embodiment, the notch portion 692a is formed on the side of the molded resin portion 692 on which the metal cover 76 is mounted. Fig.29 As shown in FIG. 1 , the notch portion 692a is formed so that the notch portion 692a and the cylindrical portion 76c of the metal cover 76 partially overlap. In other words, when the metal cover 76 is mounted on the molded resin portion 692, the notch portion 692a extends to the opposite side of the output shaft compared to the end of the metal cover 76 in the axial direction X. As described above, in the present embodiment, the notch portion 692a is also provided with a notch opening portion 692a1 which is an opening where the notch portion 692a and the cylindrical portion 76c of the metal cover 76 do not face each other in the radial direction Y.

[0196] Furthermore, in the present embodiment, the notch 692a is formed so that the notch 692a and the wiring hole 69b for mounting the wiring holder 68 are at substantially the same position in the circumferential direction Z. That is, the wiring hole 69b and the wiring holder 68 are arranged on an extension line of the axial direction X from the end of the notch 692a on the opposite side of the output shaft.

[0197] The metal cover 76 is attached to the molded resin portion 692 in an exposed state. Since the metal cover 76 is made of metal, condensation is more likely to occur, and moisture is likely to accumulate between the molded resin portion 692 and the metal cover 76. Therefore, in the present embodiment, by providing the groove-shaped notch portion 692a, moisture generated around the metal cover 76 is guided away from the metal cover 76.

[0198] exist Fig.29In FIG. 1 , an example of the path of the water flow is shown by arrows. That is, the motor 108 is fixed inside the device in such a manner that the notch portion 692a and the wiring retainer 68 are on the vertically downward side. As a result, the water generated between the molded resin portion 692 and the metal cover 76 is first guided to the notch portion 692a. And, the water flows out from the notch opening portion 692a1 of the notch portion 692a to the outer surface of the molded resin portion 692. And, the outflowing water flows along the ground side of the molded resin portion 692 and reaches the wiring retainer 68. Moreover, by appropriately routing the lead wire coming out of the wiring retainer 68 for water countermeasures, the water reaching the wiring retainer 68 can be guided by the lead wire in a manner that further leaves the motor 108.

[0199] As described above, in this embodiment, the molded resin portion 692 has the notch portion 692a as described above. Therefore, according to this embodiment, even if moisture adheres to the metal cover 76 for preventing fire and smoke from leaking to the outside of the motor 108 due to condensation or the like, the moisture can be guided away from the motor 108.

[0200] In addition, Fig.31 A modified example of this embodiment is shown in FIG. Fig.31 This is an enlarged stereoscopic view of another notch portion of the motor.

[0201] With the above Figure 28 to Figure 30 The difference between the embodiments shown in the figure is that a tapered portion 76d, 692a2 is formed near the notch opening 692a1. Figure 28 to Figure 30 The same reference numerals are used for the descriptions shown in the same manner.

[0202] That is, Fig.31 As shown, the end of the metal cover 76 on the opposite side of the output shaft near the notch opening 692a1 has a tapered portion 76d opened in the radial direction Y. Similarly, the molded resin portion 692 has a tapered portion 692a2 at a position opposite to the tapered portion 76d. The tapered portion 76d and the tapered portion 692a2 form an inclined surface in a direction opened toward the vertical downward direction so that the water passing through the notch 692a can be discharged smoothly. As a result, the water passing through the notch 692a is further discharged from the notch 692a to the outside.

[0203] (Ninth Implementation Method)

[0204] Fig.32 It is a cross-sectional view of a motor 109 according to a ninth embodiment of the present invention. Fig.33 It is an enlarged view of the vicinity of the metal cover 763 of the motor 109 described above.

[0205] and Fig.17Compared with the sixth embodiment shown in FIG. 1 , the motor 109 in this embodiment includes a metal cover 763 obtained by deforming the metal cover 76 in the sixth embodiment. Specifically, Fig.32 and Fig.33 As shown, the metal cover 763 of the motor 109 further includes a top end portion 763d having a chamfered portion 763d1, compared to the metal cover 76 of the sixth embodiment. In addition, the other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are given to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts.

[0206] like Fig.33 As shown in FIG. 1 , the metal cover 763 further has a chamfered portion 763d1, which is a curved surface as a so-called chamfer, at the top end portion 763d on the opening side. In this embodiment, by rounding the top end portion 763d by the chamfered portion 763d1, the metal cover 763 is easily attached to the molded resin portion 69. In addition, by setting such a top end portion 763d, scratches and damages caused by sharp corners can also be prevented. In addition, instead of setting the chamfered portion 763d1 as a curved surface, it can also be set as a flat surface chamfer.

[0207] in addition, Fig.34 2 is a partial cross-sectional view showing a modified example of the present embodiment. Fig.34 As shown, in this modification, the top end 763d of the opening side of the metal cover 763 is set as a tapered portion 763d2 in an inverted tapered shape. The diameter of the tapered portion 763d2 increases as it goes toward the opposite side of the output shaft. Thus, the metal cover 763 can also be easily mounted on the molded resin portion 69.

[0208] (10th embodiment)

[0209] Fig.35 It is a plan cross-sectional view showing a state before caulking process in which the metal inner cover 66 of the motor 110 according to the tenth embodiment of the present invention is fitted into the coil assembly 644 . Fig.36 yes Fig.35 The enlarged cross-sectional view of the AA portion of FIG. 6 shows the state where the metal inner cover 66 is mounted on the coil assembly 644 and then subjected to the caulking process. Fig.37 It is a perspective view showing the appearance of the coil assembly 644 of the motor 110 .

[0210] and Fig.17 and Fig.18Compared with the sixth embodiment shown in FIG. 1 , the motor 110 in this embodiment includes a stator core 614 of a coil assembly 644 obtained by deforming the stator core 61 of the coil assembly 64 in the sixth embodiment and a metal inner cover 664 obtained by deforming the metal inner cover 66 in the sixth embodiment by caulking. Fig.35 As shown, the motor 110 includes a stator including a metal inner cover 664 which is formed by inserting the metal inner cover 66 into the coil assembly 644 and then performing a caulking process on the metal inner cover 66. In addition, the other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are given to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts.

[0211] By performing such a caulking process, in this embodiment, Fig.36 , Fig.37 As shown in FIG. 1 , a protrusion 61d is formed on the outer periphery of the stator core 614. The number of the protrusion 61d may be one or more, and in this embodiment, an example is shown in which 12 protrusions are formed, which is the same number as the teeth 61b. In this embodiment, such protrusions 61d are formed on the outer periphery of the stator core 614 at equal intervals in the circumferential direction Z. Each protrusion 61d extends in the axial direction X, and in the radial direction Y, as shown in FIG. Fig.36 As shown, it is formed into a triangular shape that protrudes outward.

[0212] In addition, in assembling the stator of the present embodiment, first, the metal inner cover 66 similar to the sixth embodiment and the like is embedded in the stator core 614 having the protrusions 61d. At this time, the metal inner cover 66 is embedded in a state where the top ends of the protrusions 61d protruding in a triangular shape are in contact with the inner peripheral surface of the metal inner cover 66. That is, in the present embodiment, the protrusions 61d can be used to embed the metal inner cover 66 in a state where the contact area is small, thereby improving the workability.

[0213] After the metal inner cover 66 is embedded in the coil assembly 644, in this embodiment, the metal inner cover 66 is swaged from the outside of the metal inner cover 66 at the location where the protrusion 61d is located using a swaging jig. Fig.36 As shown in FIG. 1 , a triangularly concave caulking jig is pressed from the outside to the portion where the protrusion 61d of the metal inner cover 66 exists. As a result, the portion pressed by the metal inner cover 66 is as shown in FIG. Fig.36 In other words, by using such a caulking process, a protrusion with a triangular shape is formed. Fig.36 The protrusions shown in the figure, namely the metal inner cover 664 of the caulking portion 664c. In addition, of course, after the caulking process, the outer peripheral side of the protrusion 61d of the stator core 614 and the inner peripheral side of the caulking portion 664c of the metal inner cover 664 are as shown in the figure. Fig.36 The contact is shown in a triangular occlusal manner.

[0214] As described above, in the present embodiment, at least one protrusion 61d is formed in the stator core 614, and a caulking portion 664c is formed in the metal inner cover 664 in a manner corresponding to the protrusion 61d. Furthermore, the metal inner cover 664 is held on the coil assembly 64 by the protrusion 61d and the caulking portion 664c. Therefore, even during molding, for example, positional deviation between the two can be prevented. Thus, according to the present embodiment, during assembly, molding, etc., the large diameter portion (66b) of the metal inner cover 664, which is a non-combustible layer, can be prevented from being deviated from a predetermined position, etc., and therefore, it is possible to more reliably prevent fire and smoke from leaking to the outside of the motor 110.

[0215] In addition, in this embodiment, an example of holding the metal inner cover 664 on the coil assembly 64 by caulking is cited for explanation, but it can also be held by spot welding. That is, as described above, the metal inner cover 66 is embedded in the stator core 614 having the protrusion 61d, and the contact portion between the protrusion 61d and the metal inner cover 66 is spot welded, so that the metal inner cover 66 can also be fixed to the stator core 614.

[0216] (11th embodiment)

[0217] Fig.38 It is a cross-sectional view of a motor 111 according to an eleventh embodiment of the present invention. Fig.39 It is an exploded perspective view of the terminal cover 365 , the metal inner cover 66 , and the coil assembly 64 of the motor 111 .

[0218] and Fig.17 Compared with the sixth embodiment shown in FIG. 1 , the motor 111 in this embodiment includes a terminal cover 365 obtained by deforming the terminal cover 36 in the sixth embodiment. Specifically, Fig.38 and Fig.39 As shown, the terminal cover 365 of the motor 111 further includes a wall portion 365b compared to the terminal cover 36 of the sixth embodiment. In addition, the other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are given to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts.

[0219] like Fig.39 As shown, the terminal cover 365 has a terminal surface 365a having a terminal for electrical connection and a wall portion 365b. The terminal cover 365 is formed of an insulating resin as an insulating material. In this embodiment, such a terminal cover 365 is arranged inside the motor 111 on the opposite side of the output shaft. Fig.39As shown in the figure, the terminal cover 365 is arranged in a manner that the terminal surface 365a faces the coil assembly 64. Moreover, the wall portion 365b extends from the outer peripheral side of the terminal surface 365a in the axial direction X. That is, the wall portion 365b is parallel to the large diameter portion 66b of the metal inner cover 66. In the radial direction Y, the wall portion 365b is arranged between the large diameter portion 66b and the outer peripheral wall portion 63b included in the insulator 63. The outer peripheral wall portion 63b is located between the wall portion 365b and the coil end 62a.

[0220] As described above, the present embodiment has a structure in which the terminal cover 365 includes the wall portion 365b. Therefore, according to the present embodiment, it is possible to prevent the terminal disposed on the terminal surface 365a from contacting the metal inner cover 66, thereby improving safety.

[0221] (12th embodiment)

[0222] Fig.40 It is a partially enlarged cross-sectional view of a motor 112 according to a twelfth embodiment of the present invention.

[0223] and Fig.17 Compared with the sixth embodiment shown in FIG. 1 , the motor 112 in this embodiment includes a molded resin portion 696 obtained by deforming the molded resin portion 69 in the sixth embodiment and a metal cover 766 obtained by deforming the metal cover 76 in the sixth embodiment. Fig.40 As shown, the motor 112 has a recess 696a formed in the molded resin portion 696, and a bent portion 766d1 formed in the top end portion 766d of the metal cover 766. In addition, the other structures and operations are the same as those of the sixth embodiment, and the same reference numerals are attached to the same components as those of the sixth embodiment, and the description of the sixth embodiment is cited for the same parts.

[0224] At least one such recess 696a is formed at a position close to the output shaft on the outer circumference of the molded resin part 696. In addition, a bent portion 766d1 is formed at the top end 766d on the opening side of the metal cover 766 so as to cooperate with the recess 696a. In such a structure, by attaching the metal cover 766 to the molded resin part 696, the bent portion 766d1 engages with the recess 696a. Therefore, according to this embodiment, the metal cover 766 can be easily attached and fixed to the molded resin part 696.

[0225] As is clear from the above description, the present disclosure can improve the safety of the motor as a single unit even when the safety protection device does not function properly when the motor is driven. In other words, the purpose of the present disclosure is to prevent fire and smoke from leaking out of the motor even in special environments.

[0226] Specifically, as described above, when the safety device does not function properly, if excessive current is continuously supplied to the motor, excessive current continuously flows through the coil. Here, if a defect occurs in the winding forming the coil, a partial short circuit occurs in the coil, and the coil may become a heat source.

[0227] The present disclosure prevents the above-mentioned outflow of fire and smoke by surrounding the coil that may become a heat source with a non-combustible layer. The non-combustible layer can be made of non-combustible materials such as air, metal materials, and ceramics.

[0228] Generally, the rotor of the motor rotates around the rotating shaft. Therefore, the outer shape of the motor is roughly columnar and extends along the rotating axis. Therefore, the non-combustible layer of the present disclosure needs to surround the side surface, bottom surface and upper surface of the columnar shape relative to the coil.

[0229] In the case of an inner rotor type motor, it is ideal to directly surround the coil or coil assembly that may become a heat source with a non-combustible layer. However, the coil is wound around the stator. Or the rotor fixed to the rotating shaft is located inside the coil assembly. Therefore, it is difficult to directly surround the above components with a non-combustible layer.

[0230] Therefore, the applicant of the present application conducted intensive research and derived the above-mentioned embodiment: for the parts that can be surrounded, the coil or the coil assembly is surrounded at least in the vicinity, and for the parts that are difficult to surround, the coil or the coil assembly is surrounded within the range that can be surrounded.

[0231] For example, the sixth embodiment, which is considered to be particularly useful in terms of manufacturing and EMC, has the following structure.

[0232] That is, the metal inner cover is directly attached to the stator core around which the coil is wound, so as to include the side surface of the coil end located on the opposite side to the output shaft.

[0233] The other parts, namely, the side surface side of the coil end located on the output shaft side, and the bottom surface side and the top surface side of the coil end located on both sides are surrounded by the first and second brackets and the metal cover.

[0234] By setting this structure, the coil assembly can be directly or indirectly surrounded all around. Thus, by using this method, as a main purpose, fire and smoke can be prevented from leaking out of the motor even in special environments. In addition, as a feature of the motor obtained by molding, a variety of shapes formed by suppressing sound and vibration or having or not having a mounting portion can be easily manufactured.

[0235] In other words, if the outer surface of the molded motor is surrounded by a metal cover, the main purpose is to prevent fire and smoke from leaking out of the motor even in special environments, but there are concerns about the following aspects.

[0236] That is, in order to surround the entire outer surface of the motor with the metal cover, it is necessary to prepare many metal covers that match various shapes such as the presence or absence of the mounting portion. Therefore, in terms of manufacturing, since various stocks are required, there is an improvement in productivity.

[0237] In addition, a slight gap is generated between the outer surface of the motor and the metal cover. This gap functions as an air layer. That is, when the motor is normally used, the air layer acts to hinder the heat dissipation of the motor. Thus, there is an improvement in the cooling of the motor.

[0238] Furthermore, when the outer surface of the motor is surrounded by a metal cover, the metal cover functions as an antenna when the motor is mounted on an electric device for use. Therefore, further improvement in EMC properties is required.

[0239] Therefore, in contrast to the spirit of the present disclosure, the method of covering the outer surface of the motor with a metal cover is not excluded, but the above method of surrounding the coil or the coil assembly at a closer position is more preferred.

[0240] Industrial Applicability

[0241] The present invention can be widely applied to a so-called molded motor in which a stator is covered with a mold resin.

[0242] Description of Reference Numerals

[0243] 101, 101a, 102, 103, 104, 104a, 105, 105a, 105b, 105c, 106, 107, 108, 109, 110, 111, 112, 900: Motor

[0244] 10, 60, 601, 910: stator

[0245] 11, 61, 614, 911: stator core

[0246] 11a, 61a: Yoke

[0247] 11b, 61b: Tooth (single tooth)

[0248] 12, 62, 912: Coil

[0249] 12a, 62a, 62aB, 62aT, 912a: Coil ends

[0250] 12b, 62b, 62bB, 62bT: Lap wire

[0251] 13, 63, 63B, 63T, 631, 913: Insulator

[0252] 13a, 63a: Bottom

[0253] 13b, 63b: Outer wall

[0254] 13c, 63c: Inner wall

[0255] 20, 80, 920: Rotor

[0256] 21: Rotation axis

[0257] 21p: Output shaft

[0258] 22, 82: Rotating body

[0259] 23, 83: Rotor core

[0260] 24, 84: Magnet

[0261] 30A, 30B: Bearings

[0262] 31, 131, 931: Molded resin

[0263] 31a: Main body

[0264] 31b: Coil end molding part

[0265] 32, 35: Bracket 1

[0266] 33, 65: 2nd bracket

[0267] 34: Circuit board

[0268] 34a: Electronic components

[0269] 34b, 65b: Open

[0270] 35a, 65a: holding part

[0271] 36, 365: Terminal cover

[0272] 41A, 41B, 41C, 41D, 42A, 42B, 43, 44, 45, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59: non-combustible layer

[0273] 45a, 45b, 58a, 58b: End

[0274] 46, 47: Metal cover

[0275] 50a, 51a, 52a, 53a: outer peripheral surrounding part

[0276] 50b, 51b, 52b, 53b: Side surrounding parts

[0277] 50c, 51c: Inner peripheral surrounding part

[0278] 57a: bulge

[0279] 61c: Slot

[0280] 61d, 63f: protrusion

[0281] 61ba: Single tooth middle

[0282] 61bb: Single tooth top

[0283] 63d: Pin

[0284] 63e: Positioning department

[0285] 64, 641, 644: Coil assembly

[0286] 66, 661, 664: Metal inner cover

[0287] 66a: Trail section

[0288] 66b: Large diameter part

[0289] 68: Wiring retainer

[0290] 69, 692, 696: Molded resin part

[0291] 69a: Installation

[0292] 69b: Wiring hole

[0293] 76, 763, 766: Metal cover

[0294] 76a: Top face

[0295] 76b: curved surface

[0296] 76c: Cylinder

[0297] 76d, 631c, 661c, 692a2, 763d2: Conical part

[0298] 76h: Opening

[0299] 76aa, 76ca: Overlapping part

[0300] 83a: Magnet insertion hole

[0301] 83b: Resin through hole

[0302] 86: Rotor resin part

[0303] 86a: End plate resin part

[0304] 86b: Internal resin part

[0305] 365a: Terminal surface

[0306] 365b: Wall

[0307] 664c: Chisel tightening part

[0308] 692a: Notch

[0309] 692a1: Notch opening

[0310] 696a: concave part

[0311] 763d, 766d: Top end

[0312] 763d1: Chamfer

[0313] 766d1: Bending part

Claims

1. A motor comprising: a stator having a stator core and a coil wound around the stator core; A rotor having a rotating shaft extending in an axial direction and a rotating body including a magnetic component, extending in the axial direction and fixed to the rotating shaft, the rotor being located inside the stator; a bearing that rotatably supports the rotor; and A molded resin for covering the stator, wherein The coil has a coil end extending from the stator core along the axial direction, and the motor is provided with a non-combustible layer for covering the coil end. The non-combustible layer is a metal cover, The metal cover covers the entire coil end portion in the axial direction and on the outer peripheral side in the radial direction via the mold resin. The metal cover constitutes a part of the outer surface of the motor, The motor further includes a bracket, wherein the bracket overlaps a portion of the metal cover when viewed from the axial direction, and the metal cover is located outside in the axial direction in the overlapping portion between the bracket and the metal cover.

2. The motor according to claim 1, wherein: The mold resin exists between the bracket and the metal cover.

3. A motor comprising: a stator having a stator core and a coil wound around the stator core; A rotor having a rotating shaft extending in an axial direction and a rotating body including a magnetic component, extending in the axial direction and fixed to the rotating shaft, the rotor being located inside the stator; a bearing that rotatably supports the rotor; and A molded resin for covering the stator, wherein The coil has coil ends extending from the stator core in each direction of the axial direction, and the motor is provided with a non-combustible layer for covering the coil ends. The non-combustible layer is a metal cover, For each coil end extending in each of the directions, the metal cover covers the entire coil end on the outer peripheral side in the axial direction and radial direction via the molded resin. The metal cover constitutes a part of the outer surface of the motor, The motor further includes a bracket, wherein the bracket overlaps a portion of the metal cover when viewed from the axial direction, and the metal cover is located outside in the axial direction in the overlapping portion between the bracket and the metal cover.

4. The motor according to claim 3, wherein: The mold resin exists between the bracket and the metal cover.

5. A motor comprising: a stator having a stator core and a coil wound around the stator core; A rotor having a rotating shaft extending in an axial direction and a rotating body including a magnetic component, extending in the axial direction and fixed to the rotating shaft, the rotor being located inside the stator; a bearing that rotatably supports the rotor; and A molded resin for covering the stator, wherein The coil has coil ends extending from the stator core in each direction of the axial direction, and the motor is provided with a non-combustible layer for covering the coil ends. The non-combustible layer is the first metal cover and the second metal cover, With respect to the coil end portion extending in one direction in the axial direction, the first metal cover covers the entire coil end portion on the outer peripheral side in the axial direction and in the radial direction via the mold resin. With respect to the coil end portion extending in the other direction of the axial direction, the second metal cover covers the entire coil end portion on the outer peripheral side in the axial direction and the radial direction via the mold resin. The first metal cover constitutes a part of the outer surface of the motor. The motor further includes a bracket, wherein the bracket overlaps a portion of the first metal cover when viewed from the axial direction, and the first metal cover is located outside in the axial direction in the overlapping portion between the bracket and the first metal cover.

6. The motor according to claim 5, wherein: The mold resin exists between the bracket and the first metal cover.

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