Armature and method for manufacturing the same

Abstract

The present invention relates to an armature and a method for manufacturing an armature. For the stator armature (100), the first leg (71) has a first surface side portion (71b) whose radial thickness is smaller than that of the first leg main body portion (71d), the second leg (81) has a second surface side portion (81b) whose radial thickness is smaller than that of the second leg main body portion (81d), and in the radial direction, the thickness of the joint portion (90) is greater than the thickness of the portion (E2) other than the joint portion (90).

Description

Technical Field

[0001] The present invention relates to an armature and a method for manufacturing the armature. Background Art

[0002] Conventionally, an armature having an armature core provided with a plurality of slots extending in the axial direction is known. For example, Japanese Patent Application Laid-Open No. 2015-23771 discloses such an armature.

[0003] A rotating electric machine stator including a plurality of slots is disclosed in Japanese Patent Gazette No. 2015-23771. The rotating electric machine stator includes a coil portion, which is composed of a first fan-shaped conductor and a second fan-shaped conductor that are inserted into each of the plurality of slots and are arranged axially opposite to each other. Specifically, a first leg portion that is arranged in a manner extending along the axial direction of the first fan-shaped conductor and a second leg portion that is arranged in a manner extending along the axial direction of the second fan-shaped conductor are engaged in the slot. In addition, the first leg portion has a convex portion that protrudes in the axial direction, and the second leg portion has a concave portion that is recessed in the axial direction. Moreover, the first fan-shaped conductor and the second fan-shaped conductor move relative to each other in a manner of approaching each other along the axial direction, thereby engaging the convex portion of the first leg portion with the concave portion of the second leg portion.

[0004] In addition, although not described in Japanese Patent Gazette No. 2015-23771, it is known that there is a rotating electric machine stator in which the front end portions of the first legs of a plurality of first fan-shaped conductors and the front end portions of the second legs of a plurality of second fan-shaped conductors are squeezed in the radial direction and thus joined. In addition, the front end portion of the first leg is formed to have a smaller radial thickness than the base portion of the first leg. Similarly, the front end portion of the second leg is formed to have a smaller radial thickness than the base portion of the second leg. Moreover, in the rotating electric machine stator, the front end portions of the first legs of a plurality of first fan-shaped conductors and the front end portions of the second legs of a plurality of second fan-shaped conductors are arranged in a radially adjacent manner. Moreover, the front end portions of the first legs of a plurality of first fan-shaped conductors and the front end portions of the second legs of a plurality of second fan-shaped conductors are squeezed in the radial direction by a clamp. As a result, the front end portions of the first legs of a plurality of first fan-shaped conductors are joined to the front end portions of the second legs of a plurality of second fan-shaped conductors.

[0005] Patent Document 1: Japanese Patent Application Publication No. 2015-23771

[0006] Here, in the past, in the rotating electric machine stator in which the front end portions of the first legs of the plurality of first fan-shaped conductors and the front end portions of the second legs of the plurality of second fan-shaped conductors are squeezed in the radial direction and thus joined, there is a case where the shape (size) and the like of the coil (first fan-shaped conductor, second fan-shaped conductor) are deviated. In this case, when the front end portions of the first legs of the plurality of first fan-shaped conductors and the front end portions of the second legs of the plurality of second fan-shaped conductors are arranged in a radially adjacent manner, the total thickness (radial thickness) of the front end portions of the first legs and the front end portions of the second legs is relatively small. Alternatively, there is a case where the total thickness (joint portion) of the front end portions of the first legs and the front end portions of the second legs is smaller than the total radial thickness outside the joint portion. In these cases, there is a case where the front end portions of the first legs and the front end portions of the second legs cannot be squeezed with sufficient force by the clamp. For example, when the clamp is configured to move a constant distance in the radial direction, there is a case where the total thickness (radial thickness) of the front end portion of the first leg and the front end portion of the second leg is small (i.e., the front end portion of the first leg and the front end portion of the second leg are separated greatly relative to the clamp), so that the clamp cannot apply sufficient force to the front end portion of the first leg and the front end portion of the second leg even if it moves a constant distance. As a result, there is a problem in that the front end portion of the first leg and the front end portion of the second leg cannot be fully joined. Summary of the invention

[0007] The present invention has been made to solve the above-mentioned problems, and one object of the present invention is to provide an armature capable of preventing the first sector-shaped conductor and the second sector-shaped conductor from being insufficiently joined.

[0008] In order to achieve the above-mentioned object, an armature of a first aspect of the present invention comprises: an armature core provided with a plurality of slots extending in the axial direction; a plurality of first sector-shaped conductors including a first leg portion arranged on one axial side of the armature core and extending to the other axial side; a plurality of second sector-shaped conductors including a second leg portion arranged on the other axial side of the armature core and extending to one axial side; and a coil portion including a joint portion, wherein at least a portion of a first surface provided on the front end side of each of the first leg portions of the plurality of first sector-shaped conductors and provided in a manner extending in the axial direction and at least a portion of a second surface provided on the front end side of each of the second leg portions of the plurality of second sector-shaped conductors and provided in a manner extending in the axial direction are joined within one slot or outside the axial direction of one slot, wherein the first leg portion comprises: a first leg portion body portion; and a first surface side portion provided with a first surface and having a radial thickness smaller than that of the first leg portion body portion, and the second leg portion comprises: a second leg portion body portion; and a second surface side portion provided with a second surface and having a radial thickness smaller than that of the second leg portion body portion, and in the radial direction, the thickness of the joint portion is greater than the thickness of the portion other than the joint portion. The joining portion has a broad meaning including not only portions joined via an adhesive but also portions merely in contact without an adhesive.

[0009] In the armature of the first embodiment of the present invention, as described above, in the radial direction, the thickness of the joint is greater than the thickness of the portion other than the joint. Thus, since the thickness of the joint is greater than the thickness of the portion other than the joint (the joint is not radially recessed compared to the portion other than the joint), the joint can be squeezed by a fixture (or a spring member, etc.) and with sufficient force. As a result, it is possible to prevent the first fan-shaped conductor and the second fan-shaped conductor from being unable to be fully joined. In addition, in the case where the radial thickness of the joint is less than the radial thickness of the portion where the first and second surfaces are not provided, if the joint is squeezed by a fixture, the coil portion (the first fan-shaped conductor, the second fan-shaped conductor) bends. Therefore, by constituting as described above, it is possible to prevent the coil portion from bending even when the joint is squeezed by a fixture. In addition, the radial thickness of the first surface side portion is less than the radial thickness of the first leg main body portion, and the radial thickness of the second surface side portion is less than the radial thickness of the second leg main body portion, so that the area of ​​the joint surface can be ensured and the radial thickness of the joint portion can be suppressed to be large.

[0010] An armature according to a second aspect of the present invention comprises: an armature core provided with a plurality of slots extending in the axial direction; a plurality of first sector-shaped conductors including a first leg portion which is arranged on one axial side of the armature core and extends to the other axial side; a plurality of second sector-shaped conductors including a second leg portion which is arranged on the other axial side of the armature core and extends to one axial side; and a coil portion including a joint portion, wherein at least a portion of a first surface which is provided on the front end side of the first leg portion of each of the plurality of first sector-shaped conductors and is provided in a manner extending in the axial direction is joined with at least a portion of a second surface which is provided on the front end side of the second leg portion of each of the plurality of second sector-shaped conductors and is provided in a manner extending in the axial direction, within one slot or on the axial outer side of one slot. The first leg has a first leg main body having a radial thickness greater than that of a first surface side portion on which the first surface is provided, and the minimum value of a range of dimensional deviation of the radial thickness of the first surface side portion of a plurality of first sector-shaped conductors arranged in one slot is more than 1 / 2 of a maximum value of a range of dimensional deviation of the thickness of the first leg main body portion of a plurality of first sector-shaped conductors arranged in one slot, and the second leg has a second leg main body having a radial thickness greater than that of a second surface side portion on which the second surface is provided, and the minimum value of a range of dimensional deviation of the radial thickness of the second surface side portion of a plurality of second sector-shaped conductors arranged in one slot is more than 1 / 2 of a maximum value of a range of dimensional deviation of the thickness of the second leg main body portion of a plurality of second sector-shaped conductors arranged in one slot.

[0011] In the armature of the second embodiment of the present invention, as described above, the minimum value of the range of the dimensional deviation of the radial thickness of the first face side portion of the plurality of first sector conductors arranged in one slot is more than 1 / 2 of the maximum value of the range of the dimensional deviation of the thickness of the first leg body portion of the plurality of first sector conductors arranged in one slot, and the minimum value of the range of the dimensional deviation of the radial thickness of the second face side portion of the plurality of second sector conductors arranged in one slot is more than 1 / 2 of the maximum value of the range of the dimensional deviation of the thickness of the second leg body portion of the plurality of second sector conductors arranged in one slot. Thus, even if the radial thickness of the first face side portion and the second face side portion (joint portion) is the minimum value, it is greater than the radial thickness of the first leg body portion and the second leg body portion (portion where the first face and the second face are not provided), so the first face side portion and the second face side portion (joint portion) can be pressed by a fixture (or a spring member, etc.) and with sufficient force. As a result, an armature that can prevent the first sector conductor and the second sector conductor from being insufficiently joined can be provided. In addition, when the radial thickness of the joint portion is less than the radial thickness of the portion where the first and second surfaces are not provided, if the joint portion is pressed by a fixture, the coil portion (the first fan-shaped conductor, the second fan-shaped conductor) bends. Therefore, by configuring as described above, an armature can be provided that can prevent the coil portion from bending even when the joint portion is pressed by a fixture.

[0012] A third embodiment of the invention is a method for manufacturing an armature core provided with a plurality of slots extending in the axial direction, and the method for manufacturing the armature core is characterized in that it comprises: a process of preparing a plurality of first sector-shaped conductors, the plurality of first sector-shaped conductors including a first leg portion which is arranged on one axial side of the armature core and extends to the other axial side; a process of preparing a plurality of second sector-shaped conductors, the plurality of second sector-shaped conductors including a second leg portion which is arranged on the other axial side of the armature core and extends to one axial side; a process of moving the plurality of first sector-shaped conductors, the plurality of first sector-shaped conductors being moved from one axial side of the armature core to the slot side; a process of moving the plurality of second sector-shaped conductors, the plurality of second sector-shaped conductors being moved from the other axial side of the armature core to the slot; and a process of forming a joint portion by joining at least a portion of a first surface which is arranged on the front end side of the first leg portion of each of the plurality of first sector-shaped conductors and is arranged in a manner extending in the axial direction to a first surface which is arranged At least a portion of a second surface that is arranged in an axially extending manner on the front end side of each second leg of a plurality of second fan-shaped conductors is joined in a slot or on the axially outer side of a slot to form a joint. The process of preparing a first fan-shaped conductor is a process of preparing a first fan-shaped conductor such that the first leg of the first fan-shaped conductor has: a first leg body; and a first surface side portion, which is provided with a first surface and has a radial thickness smaller than that of the first leg body. The process of preparing a second fan-shaped conductor is a process of preparing a second fan-shaped conductor such that the second leg of the second fan-shaped conductor has: a second leg body; and a second surface side portion, which is provided with a second surface and has a radial thickness smaller than that of the second leg body. In the process of preparing the first fan-shaped conductor and the process of preparing the second fan-shaped conductor, the first fan-shaped conductor and the second fan-shaped conductor are prepared in such a way that the thickness of the joint in the radial direction is greater than the thickness of the portion other than the joint.

[0013] In the manufacturing method of the armature of the third aspect of the present invention, as described above, in the process of preparing the first fan-shaped conductor and the process of preparing the second fan-shaped conductor, the first fan-shaped conductor and the second fan-shaped conductor are prepared in such a way that the thickness of the joint portion is greater than the thickness of the portion other than the joint portion in the radial direction. Thus, since the thickness of the joint portion is greater than the thickness of the portion other than the joint portion (the joint portion is not radially recessed compared to the portion other than the joint portion), the joint portion can be pressed by a fixture (or a spring member, etc.) and with sufficient force. As a result, a manufacturing method of an armature that can prevent the first fan-shaped conductor and the second fan-shaped conductor from being unable to be fully joined can be provided. In addition, in the case where the radial thickness of the joint portion is less than the radial thickness of the portion where the first and second surfaces are not provided, if the joint portion is pressed by the fixture, the coil portion (the first fan-shaped conductor, the second fan-shaped conductor) is bent. Therefore, by configuring as described above, a manufacturing method of an armature that can prevent the coil portion from bending even when the joint portion is pressed by the fixture can be provided. In addition, the radial thickness of the first surface side portion is smaller than the radial thickness of the first leg main body portion, and the radial thickness of the second surface side portion is smaller than the radial thickness of the second leg main body portion, thereby providing a method for manufacturing an armature that can ensure the area of ​​the joint surface and suppress the radial thickness of the joint portion.

[0014] According to the present invention, as described above, it is possible to prevent the first fan-shaped conductor and the second fan-shaped conductor from being insufficiently joined together. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a plan view showing the structure of the stator (rotating electric machine) according to the first embodiment.

[0016] Figure 2 It is a perspective view showing the structure of the stator according to the first embodiment.

[0017] Figure 3 It is a plan view showing the structure of the stator core according to the first embodiment.

[0018] Figure 4 It is a cross-sectional view showing the structure of the first insulating member and the second insulating member according to the first embodiment.

[0019] Figure 5 : is a circuit diagram showing the connection structure of the coil part of the first embodiment.

[0020] Figure 6 It is a cross-sectional view showing the structure of the fan-shaped conductor according to the first embodiment.

[0021] Fig. 7 is a perspective view showing the structure of the first fan-shaped conductor of the first embodiment. (Fig. 7(A) is a perspective view of the first fan-shaped conductor viewed from the radially outer side. Fig. 7(B) is a perspective view of the first fan-shaped conductor viewed from the radially inner side.)

[0022] Fig. 8 is a perspective view showing the structure of the second fan-shaped conductor of the first embodiment. (Fig. 8(A) is a perspective view of the second fan-shaped conductor viewed from the radially outer side. Fig. 8(B) is a perspective view of the second fan-shaped conductor viewed from the radially inner side.)

[0023] Fig. 9 It is a diagram showing the structure of the power sector conductor according to the first embodiment.

[0024] Fig.10 It is a diagram showing the structure of the radially outer neutral point conductor according to the first embodiment.

[0025] Fig.11 It is a diagram showing the structure of the inner diameter side neutral point conductor according to the first embodiment.

[0026] Fig.12 It is along Figure 1 A cross-sectional view of the 1000-1000 line.

[0027] Fig.13 yes Fig.12 A partial enlarged view of the vicinity of the joint.

[0028] Fig.14 yes Fig.13 A partial enlarged view of the vicinity of the joint.

[0029] Fig.15 It is a partial enlarged view near the joining portion (an example in which the thickness of the joining portion is greater than the thickness of a portion where the first surface and the second surface are not provided).

[0030] Fig.16 It is a cross-sectional view schematically showing the structure of the first insulating member according to the first embodiment.

[0031] Fig.17 It is a cross-sectional view showing the structure of the first insulating member and the second insulating member including the fixing layer before foaming according to the first embodiment.

[0032] Fig.18 It is a cross-sectional view showing the structure of the first insulating member and the second insulating member including the foamed fixing layer according to the first embodiment.

[0033] Fig.19 It is a cross-sectional view showing the structure of the second insulating member according to the first embodiment.

[0034] Fig. 20 It is a perspective view showing the structure of the second insulating member according to the first embodiment.

[0035] Fig.21 This is an exploded perspective view of the stator core, the first insulating member, and the second insulating member according to the first embodiment.

[0036] Fig. 22 It is a diagram showing the thickness of the first insulating member and the thickness of the second insulating member in the first embodiment.

[0037] Fig.23 It is a diagram showing a stator manufacturing apparatus according to the first embodiment.

[0038] Fig.24 This is a flowchart showing the method for manufacturing the stator according to the first embodiment.

[0039] Fig.25 It is a perspective view showing the structure of a stator according to the second embodiment.

[0040] Fig.26 It is an exploded perspective view of a stator according to the second embodiment.

[0041] FIG27 is a cross-sectional view showing the structure of a fan-shaped conductor according to the second embodiment. Fig.27A This is a cross-sectional view of the foot. Fig.27B This is a cross-sectional view of the coil end.)

[0042] FIG28 is a perspective view showing the structure of the first fan-shaped conductor of the second embodiment. Fig.28A This is a perspective view of the first sector-shaped conductor as viewed from the radially outer side. Fig.28B This is a three-dimensional view of the first sector-shaped conductor viewed from the radial inside.)

[0043] FIG29 is a perspective view showing the structure of a second fan-shaped conductor according to the second embodiment. Fig.29A This is a perspective view of the second sector-shaped conductor as viewed from the radially outer side. Fig.29B This is a three-dimensional view of the second sector-shaped conductor viewed from the radial inside.)

[0044] Fig.30 This is a cross-sectional view along the radial direction in the slot of the second embodiment.

[0045] Fig.31 yes Fig.30 A local enlarged view of the vicinity of the contact portion.

[0046] Fig.32 It is a cross-sectional view showing the structure of an insulating member according to the second embodiment.

[0047] Fig.33 It is a cross-sectional view showing the structure of the insulating layer and the fixing layer of the contact insulating portion according to the second embodiment.

[0048] Fig.34 It is a cross-sectional view showing the structure of the insulating layer and the fixing layer of the core pin insulating portion according to the second embodiment.

[0049] Fig.35 This is a flowchart showing a method for manufacturing a stator according to the second embodiment.

[0050] Fig.36 It is a perspective view showing the structure of a stator according to a third embodiment.

[0051] Fig.37 This is a cross-sectional view along the radial direction in the slot of the third embodiment.

[0052] Fig.38 It is a cross-sectional view showing the structure of an insulating member according to a third embodiment.

[0053] Fig.39 It is a cross-sectional view showing the structure of the insulating layer and the fixing layer of the contact insulating portion according to the third embodiment.

[0054] Fig.40 It is a cross-sectional view showing the structure of the insulating layer and the fixing layer of the core pin insulating portion according to the third embodiment.

[0055] Fig.41 It is a cross-sectional view showing the vicinity of a joining portion according to a first modification example of the first embodiment.

[0056] Fig.42 It is a cross-sectional view showing the vicinity of a joining portion according to a second modification of the first embodiment.

[0057] Fig. 43 is a perspective view of a first fan-shaped conductor and a second fan-shaped conductor of a third variation of the first embodiment. (Fig. 43(A) is a perspective view of the first fan-shaped conductor viewed from the radial outside. Fig. 43(B) is a perspective view of the second fan-shaped conductor viewed from the radial outside.)

[0058] Fig.44 It is a cross-sectional view of the vicinity of a joining portion according to a fourth modified example of the first embodiment. DETAILED DESCRIPTION

[0059] Hereinafter, this embodiment of the present invention will be described based on the drawings.

[0060] [Stator structure]

[0061] Reference Figure 1 to Figure 23 , the structure of the stator 100 of the first embodiment will be described. The stator 100 has a circular ring shape centered on the central axis C1. The stator 100 is an example of the "armature" of the technical claim.

[0062] In this application specification, Figure 1As shown, "axial direction (axial direction, axial direction)" refers to the direction (Z direction) along the central axis C1 of the stator 100 (the rotation axis of the rotor 101). In addition, "circumferential direction" refers to the circumferential direction of the stator 100 (A1 direction, A2 direction). In addition, "radial direction" refers to the radial direction (R direction) of the stator 100. In addition, "radially inner side" refers to the direction (R1 direction) along the radial direction toward the central axis C1 of the stator 100. In addition, "radially outer side" refers to the direction (R2 direction) along the radial direction toward the outside of the stator 100.

[0063] The stator 100 and the rotor 101 together constitute a part of the rotating electrical machine 102. The rotating electrical machine 102 is constituted as, for example, a motor, an engine, or a motor and an engine. Figure 1 As shown, the stator 100 is arranged radially outside a rotor 101 provided with permanent magnets (not shown). That is, in the first embodiment, the stator 100 constitutes a part of an inner rotor type rotating electrical machine 102.

[0064] like Figure 2 As shown, the stator 100 includes: a stator core 10, a first insulating member 20, and a coil unit 30. The coil unit 30 includes a first coil assembly 30a (reverse guide side coil) and a second coil assembly 30b (guide side coil). In addition, the coil unit 30 is composed of a plurality of fan-shaped conductors 40 (see Figure 4 In the first embodiment, the stator 100 includes a second insulating member 21 (see Figure 4 ). In addition, the stator core 10 is an example of the "armature core" of the technical claim. In addition, the second insulating member 21 is an example of the "joint portion insulating member" of the technical claim.

[0065] (Structure of stator core)

[0066] The stator core 10 has a central axis C1 (see Figure 1 ) is a cylindrical shape with the central axis. In addition, the stator core 10 is formed by, for example, stacking a plurality of electromagnetic steel sheets (for example, silicon steel sheets) in the axial direction. Figure 3 As shown, the stator core 10 is provided with a back yoke 11 having an annular shape when viewed in the axial direction, and a plurality of slots 12 provided radially inside the back yoke 11 and extending in the axial direction. In addition, a plurality of teeth 13 are provided on both sides of the slots 12 in the circumferential direction of the stator core 10.

[0067] The slot 12 is a portion surrounded by the wall portion 11a of the back yoke 11 disposed radially outward and the circumferential side surfaces 13a of the two teeth 13. In addition, an opening portion 12a opening radially inward is provided in the slot 12. In addition, the slot 12 is opened in both axial directions. The teeth 13 are formed so as to protrude radially inward from the back yoke 11, and a convex portion 13b constituting the opening portion 12a of the slot 12 is formed at the front end portion on the radial inner side.

[0068] The opening portion 12a has an opening width W1 along the circumferential direction. Here, the opening width W1 corresponds to the distance between the front ends of the protrusions 13b of the teeth 13. In addition, the width W2 of the portion of the slot 12 where the coil portion 30 is arranged is greater than the opening width W1. That is, the slot 12 is configured as a half-open slot. Here, the width W2 corresponds to the distance between the circumferential side surfaces 13a of the teeth 13 arranged on both sides of the slot 12 in the circumferential direction. In addition, the width W2 of the slot 12 is substantially constant throughout the radial direction.

[0069] (Structure of coil section)

[0070] like Figure 4 As shown, the coil part 30 is made of a rectangular wire. For example, the coil part 30 is made of copper or aluminum.

[0071] In addition, if Figure 2 As shown, the coil portion 30 is formed by combining and joining a first coil component 30a disposed on one axial side (the side in the direction of arrow Z2) and a second coil component 30b disposed on the other axial side (the side in the direction of arrow Z1) in the axial direction. The first coil component 30a and the second coil component 30b are respectively formed to be connected to the stator core 10 on the same central axis C1 (refer to Figure 1 ) is a ring centered. Figure 4 As shown, in the first embodiment, first leg portions 71 and second leg portions 81 described later of a plurality of sector-shaped conductors 40 are joined at a joining portion 90 to form the coil portion 30 .

[0072] The coil portion 30 is configured as a wave winding coil, for example. The coil portion 30 is configured as an 8-turn coil. That is, the coil portion 30 is configured by arranging eight sector-shaped conductors 40 in parallel in the radial direction in the slot 12 .

[0073] <Connection structure of coil section>

[0074] like Figure 5As shown, in the coil unit 30, it is configured to supply three-phase AC power from a power supply unit (not shown), thereby generating a magnetic flux. Specifically, the coil unit 30 is connected (wired) by a three-phase Y connection. That is, the coil unit 30 includes a U-phase coil unit 30U, a V-phase coil unit 30V, and a W-phase coil unit 30W. Moreover, a plurality of (for example, two) neutral points N are provided in the coil unit 30. Specifically, the coil unit 30 is wired in four parallel connections (star connection). That is, four neutral point connection ends NtU and four power line connection ends PtU are provided in the U-phase coil unit 30U. Four neutral point connection ends NtV and four power line connection ends PtV are provided in the V-phase coil unit 30V. Four neutral point connection ends NtW and four power line connection ends PtW are provided in the W-phase coil unit 30W. In the following description, the neutral point connection end and the power line connection end are simply described as “neutral point connection end Nt” and “power line connection end Pt” without distinguishing between U phase, V phase, and W phase.

[0075] 〈Structure of coil assembly〉

[0076] like Figure 2 As shown, the first coil component 30a is composed of a plurality of first sector-shaped conductors 70 (hereinafter referred to as "first conductors 70") as the sector-shaped conductors 40. It is preferable that the first coil component 30a is composed of only a combination of the plurality of first conductors 70.

[0077] In addition, the second coil component 30b includes: a plurality of (for example, three) power sector conductors 50 (hereinafter referred to as "power conductors 50") as the sector conductors 40, a plurality of (for example, two) neutral point sector conductors 60 (hereinafter referred to as "neutral point conductors 60") as the sector conductors 40, and a second sector conductor 80 (hereinafter referred to as "second conductor 80") as a conductor different from the power conductors 50 and the neutral point conductors 60 among the plurality of sector conductors 40 (common sector conductors 40) and constituting the coil portion 30. That is, the power conductors 50 and the neutral point conductors 60 provided in the stator 100 are all provided in the second coil component 30b.

[0078] (Structure of fan-shaped conductor)

[0079] like Figure 6 As shown, the fan-shaped conductor 40 is formed as a square wire having a substantially rectangular cross section. Furthermore, an insulating film 40a having a thickness t1 is provided on the conductor surface 40b of the fan-shaped conductor 40. The thickness t1 of the insulating film 40a is set, for example, to ensure the interphase insulation performance (insulation between the first coil end portions 72 and insulation between the second coil end portions 82, see Figure 2 ) level. In addition, Figure 6In the figure, for the purpose of explanation, the size relationship such as thickness is highlighted and illustrated, but the present invention is not limited to the example shown in the figure.

[0080] <Structure of the First Conductor and the Second Conductor>

[0081] As shown in Fig. 7 and Fig. 8, the plurality of fan-shaped conductors 40 include a plurality of first conductors 70 arranged on one side (Z2 direction side) of the axial direction of the stator core 10, and a plurality of second conductors 80 located on the other side (Z1 direction side) of the axial direction of the stator core 10 and arranged opposite to the first conductor 70 in the axial direction. That is, the first conductor 70 divided into two in the axial direction is joined with the second conductor 80 to form the coil portion 30. Here, the second conductor 80 refers to the fan-shaped conductor 40 other than the power conductor 50 and the neutral point conductor 60 in the fan-shaped conductor 40 constituting the second coil assembly 30b. Moreover, in the first embodiment, the first conductor 70 includes a first leg 71 having an axial length L1 and extending in the axial direction. The first leg 71 extends to the other side (Z1 direction side) of the axial direction. In addition, the second conductor 80 includes a second leg 81 arranged on the Z1 direction side of the first leg 71, having a length L2 greater than the length L1 in the axial direction and extending in the axial direction. The second leg 81 extends to one side (Z2 direction side) of the axial direction.

[0082] In the first embodiment, as shown in FIG. 7(A) and FIG. 7(B), a plurality of first conductors 70 are respectively formed as a pair of first legs 71 arranged in different slots 12 and connected to each other, thereby having a U-shape (roughly U-shape) when viewed in the radial direction. The coil pitch of the first conductor 70 is 6. That is, a pair of first legs 71 are arranged at different positions in the circumferential direction with a size of 6 slots 12. That is, five slots 12 are provided between a slot 12 in which one of the first legs 71 is arranged and a slot 12 in which the other first leg 71 is arranged. Specifically, the first conductor 70 includes a pair of first legs 71 arranged in different slots 12 and formed in a straight line along the axial direction, and a first coil end portion 72. The first leg 71 refers to the end face 10a (refer to FIG. 1 ) in the axial direction of the stator core 10. Figure 2 ) is configured in the slot 12 at an axial position, and the first coil end portion 72 refers to a portion formed continuously with the first leg portion 71 and configured at a position axially outside the end face 10a of the stator core 10. In addition, the first coil end portion 72 has a curved shape bent in the axial direction. In addition, the first coil end portion 72 has a first crank portion 73 formed in a crank shape that is bent into a stepped shape by the width of one fan-shaped conductor 40 in the radial direction when viewed from the axial direction. In other words, the radial width of the first crank portion 73 is twice the width of one fan-shaped conductor 40.

[0083] The axial lengths L1 of the pair of first leg portions 71 are substantially equal to each other. The axial length L1 refers to the length of the portion of the first conductor 70 that extends linearly in the axial direction in the slot 12. The axial length L1 is smaller than the axial length L3 of the stator core 10 (see Figure 2 ) In addition, the axial length L3 of the stator core 10 refers to the axial distance (interval) between the end surface 10a and the end surface 10b in the axial direction.

[0084] Similarly, as shown in FIG. 8(A) and FIG. 8(B), the second conductor 80 includes a pair of second legs 81 arranged in the slot 12, and a second coil end portion 82. In addition, the second coil end portion 82 has a second crank portion 83. In the first embodiment, the second conductor 80 is formed such that a pair of second legs 81 arranged in different slots 12 are connected to each other, thereby having a U-shape. In addition, the axial lengths L2 of the pair of second legs 81 of the second conductor 80 are substantially equal to each other. In addition, the axial length L2 of the pair of second legs 81 of the second conductor 80 is greater than the axial length L1 of the pair of first legs 71 of the first conductor 70 (L2>L1). In addition, the axial length L2 refers to the length of the portion of the second conductor 80 that extends linearly in the axial direction in the slot 12.

[0085] 〈Structure of power conductor〉

[0086] like Fig. 9 As shown, in the power conductor 50, a plurality of (for example, four) power line connection ends Pt of the same phase are electrically connected to each other, and the connected plurality of power line connection ends Pt are electrically connected to one power terminal member 51. For the power conductor 50, one of the pair of first leg portions 71 is engaged (see Fig.12 ) is connected to the power terminal member 51. In addition, the power conductor 50 has a function of introducing power from a power supply unit (not shown) to the coil unit 30.

[0087] Specifically, the power conductor 50 includes: Figure 1 ), and has an outer diameter side power conductor 52 with a power line connection end Pt, and an inner diameter side power conductor 53 with a power line connection end Pt, which is arranged at a position radially inward and axially outward of the outer diameter side power conductor 52. In other words, the power conductor 50 is formed in a forked shape.

[0088] In addition, the outer diameter side power conductor 52 is electrically connected to the power terminal component 51 through the lead wire 54. In addition, the inner diameter side power conductor 53 is electrically connected to the power terminal component 51 through the lead wire 54. The outer diameter side power conductor 52 and the inner diameter side power conductor 53 are electrically connected via the power terminal component 51 and the lead wire 54. In addition, the lead wire 54 is formed of, for example, a twisted wire (conductor), and the insulating tube 51a is arranged on the outer periphery.

[0089] The second leg portion 81 is provided on the outer diameter side power conductor 52 and the inner diameter side power conductor 53, respectively, while the first coil end portion 72 or the second coil end portion 82 is not provided. In addition, in the outer diameter side power conductor 52 and the inner diameter side power conductor 53, the lead wire 54 is joined to the second leg portion 81 via the conductor plate 55. For example, the joining can be implemented by brazing or welding (for example, any one of resistance welding, arc welding, laser welding, or high energy beam welding).

[0090] 〈Structure of Neutral Point Conductor〉

[0091] like Figure 1 As shown, the neutral point conductor 60 includes an outer diameter side neutral point conductor 61 and an inner diameter side neutral point conductor 62. Figure 5 As shown, the outer diameter side neutral point conductor 61 and the inner diameter side neutral point conductor 62 respectively include a neutral point N, and are electrically connected to the neutral point connection end NtU of the U-phase coil unit 30U, the neutral point connection end NtV of the V-phase coil unit 30V, and the neutral point connection end NtW of the W-phase coil unit 30W.

[0092] like Fig.10 As shown, the outer diameter side neutral point conductor 61 includes two U-phase and W-phase neutral point sector conductors 61a and two V-phase neutral point sector conductors 61b. The U-phase and W-phase neutral point sector conductors 61a include a second leg 81 for the U phase connected to the first leg 71 of the first conductor 70 of the U phase in the three-phase AC, a second leg 81 for the W phase connected to the first leg 71 of the W phase, and two neutral point coil end portions 61c connecting the second leg 81 for the U phase and the second leg 81 for the W phase. The neutral point coil end portion 61c is formed continuously with the second leg 81 for the U phase and is formed continuously with the second leg 81 for the W phase.

[0093] The U-phase and W-phase neutral point sector conductors 61a are formed in a substantially U-shaped (substantially C-shaped) shape when viewed from the radial inside. The V-phase neutral point sector conductors 61b are formed in a substantially linear shape when viewed from the radial inside.

[0094] like Figure 1As shown, the neutral point coil end portion 61c is formed along the circumferential direction on the radially outer side of the second coil end portion 82 of the second conductor 80. Moreover, the neutral point coil end portion 61c is formed in a substantially arc shape when viewed in the direction of arrow Z2. One of the two U-phase and W-phase neutral point sector conductors 61a is arranged on the axially outer side (arrow Z1 direction side) of the other.

[0095] like Fig.10 As shown, the V-phase neutral point sector conductor 61b includes a second leg portion 81 for the V-phase connected to the first conductor 70 of the V-phase, and a neutral point coil end portion 61d. The neutral point coil end portion 61d is formed so as to protrude axially outward (in the direction of the arrow Z1) from the second leg portion 81. Furthermore, the two neutral point coil end portions 61d are respectively joined to both of the two neutral point coil end portions 61c, thereby electrically joining.

[0096] like Fig.11 As shown, the inner diameter side neutral point conductor 62 includes two U-phase and W-phase neutral point sector conductors 62a, and two V-phase neutral point sector conductors 62b. The U-phase and W-phase neutral point sector conductors 62a include a second leg 81 for the U phase connected to the first leg 71 of the first conductor 70 of the U phase in the three-phase AC, a second leg 81 for the W phase connected to the first conductor 70 of the W phase, and a neutral point coil end portion 62c connecting the second leg 81 for the U phase and the second leg 81 for the W phase. The neutral point coil end portion 62c is formed continuously with the second leg 81 for the U phase, and is formed continuously with the second leg 81 for the W phase. Thus, when viewed from the radial inside, the U-phase and W-phase neutral point sector conductors 62a are formed in a roughly U shape. When viewed from the radial inside, the V-phase neutral point sector conductors 62b are formed in a roughly straight line.

[0097] like Fig.12 As shown, the neutral point coil end portion 62c is formed so as to protrude axially outward from the second coil end portion 82 of the second conductor 80. Furthermore, the neutral point coil end portion 62c is arranged close to the axially outer side of the second coil end portion 82 of the second conductor 80, and is formed along the circumferential direction when viewed in the axial direction. Furthermore, one of the two U-phase and W-phase neutral point sector conductors 62a is arranged radially outward of the other.

[0098] The V-phase neutral point sector conductor 62b includes a second leg 81 for the V-phase connected to the first leg 71 of the V-phase first conductor 70, and a neutral point coil end portion 62d. The neutral point coil end portion 62d is formed so as to protrude axially outward (in the direction of the arrow Z1) from the second leg 81. The two neutral point coil end portions 62d are respectively joined to both of the two neutral point coil end portions 62c, thereby being electrically joined.

[0099] (Structure of the joint)

[0100] like Fig.12 and Fig.13 As shown, a plurality of first leg portions 71 are provided in one slot 12 so as to be adjacent to each other in the radial direction of the stator core 10. In addition, a plurality of second leg portions 81 are provided in one slot 12 so as to be adjacent to each other in the radial direction of the stator core 10. A first surface 71a, which will be described later, of the first leg portion 71 is joined to a second surface 81a, which will be described later, of the second leg portion 81, thereby forming a joint portion 90.

[0101] In addition, in one slot 12, a plurality of first conductors 70 (first leg portions 71) are joined to a plurality of second conductors 80 (second leg portions 81). Specifically, in one slot 12, a plurality of first surface configuration portions 71b provided with a first surface 71a described later of the first leg portions 71 and a plurality of second surface configuration portions 81b provided with a second surface 81a described later of the second leg portions 81 are alternately arranged along the radial direction. That is, the plurality of first leg portions 71 and the plurality of second leg portions 81, described later, are arranged in a manner adjacent to each other in the radial direction in one slot 12. In addition, the first surface configuration portion 71b and the second surface configuration portion 81b are examples of the "first surface side portion" and the "second surface side portion" of the technical solution, respectively.

[0102] Specifically, in the first embodiment, the joints 90 of the first conductor 70 and the second conductor 80 arranged in one slot 12 are configured in such a manner that the radially adjacent joints 90 overlap when viewed from the radial direction. Specifically, a plurality of (all) joints 90 arranged in one slot 12 are configured in such a manner that they overlap when viewed from the radial direction. That is, all the joints 90 arranged in one slot 12 are arranged in a state of being arranged in parallel along the horizontal direction. In other words, in one slot 12, the respective positions of the plurality of joints 90 in the axial direction are substantially equal to each other. In addition, as described later, the joint 90 is a portion where the first surface 71a of the first leg portion 71 and the second surface 81a of the second leg portion 81 are joined (overlapped) when viewed from the radial direction.

[0103] In addition, if Fig.14 As shown, each of the front end portion 71c of the first leg portion 71 and the front end portion 81c of the second leg portion 81 has a tapered shape. Specifically, when viewed from the circumferential direction (direction A), the front end portion 71c of the first leg portion 71 and the front end portion 81c of the second leg portion 81 have a tapered shape.

[0104] A first surface 71a is provided on the front end portion 71c side of each of the first leg portions 71 of the plurality of first conductors 70 so as to extend in the axial direction. In addition, a second surface 81a is provided on the front end portion 81c side of each of the second leg portions 81 of the plurality of second conductors 80 so as to extend in the axial direction. Specifically, in the first embodiment, each of the first surface 71a and the second surface 81a is provided so as to extend parallel to the axial direction. In addition, the first leg portion 71 and the second leg portion 81 respectively include a first surface configuration portion 71b on which the first surface 71a is provided, and a second surface configuration portion 81b on which the second surface 81a is provided.

[0105] In addition, the first leg portion 71 includes a first leg main body portion 71d provided continuously with the first surface configuration portion 71b provided with the first surface 71a. The first leg main body portion 71d is provided on the opposite side (Z2 direction side) of the front end portion 71c with respect to the first surface configuration portion 71b. In addition, the second leg portion 81 includes a second leg main body portion 81d provided continuously with the second surface configuration portion 81b provided with the second surface 81a. The second leg main body portion 81d is provided on the opposite side (Z1 direction side) of the front end portion 81c with respect to the second surface configuration portion 81b.

[0106] Here, in the first embodiment, as Fig.14 As shown, the radial thickness t2 of the first surface configuration portion 71b is smaller than the radial thickness t3 of the first leg main body portion 71d. In addition, the radial thickness t4 of the second surface configuration portion 81b is smaller than the radial thickness t5 of the second leg main body portion 81d. Fig.15 As shown, in the radial direction, the thickness (t2+t4) of the joint 90 is greater than the thickness (t3 or t5) of the portion E2 other than the joint 90. In addition, the total thickness t21 of the joint 90 is also greater than the total thickness t22 of the portion E2 other than the joint 90.

[0107] Here, in the first embodiment, as Fig.13 As shown in FIG. 1 , the minimum value t2 of the dimensional variation range of the radial thickness t2 of the first surface arrangement portion 71 b of the plurality of first conductors 70 arranged in one slot 12 is min is the maximum value t3 of the range of dimensional variation of the thickness t3 of the first leg body 71d in the plurality of first conductors 70 arranged in one slot 12. max Specifically, the thickness t2 of the first surface configuration portion 71b of the first conductor 70 and the thickness t3 of the first leg portion main body 71d may fluctuate (dimensional deviation) due to the deviation in the shape of the first conductor 70, the manufacturing deviation when processing the first surface configuration portion 71b, etc. min(When the thickness t2 is the smallest within the range of dimensional variation) is the maximum value t3 of the range of dimensional variation of the thickness t3 of the first leg portion main body 71d. max The first conductor 70 is manufactured (processed) in a manner that is 1 / 2 or more of the thickness t3 (in the range of dimensional deviation, the thickness t3 is the largest). Similarly, the minimum value t4 of the dimensional deviation range of the radial thickness t4 of the second surface arrangement portion 81b of the plurality of second conductors 80 arranged in one slot 12 is min is the maximum value t5 of the range of dimensional variation of the thickness t5 of the second leg body 81d in the plurality of second conductors 80 arranged in one slot 12. max In addition, the thickness t2 is substantially equal to the thickness t4, and the thickness t3 is substantially equal to the thickness t5.

[0108] With the above configuration, in the first embodiment, in the plurality of first conductors 70 and the plurality of second conductors 80 arranged in one slot 12, the minimum value t21 of the range of dimensional variation of the total thickness t21 in the radial direction of the joint 90 (portion E1) is min The maximum value t22 of the range of the dimensional deviation of the total thickness t22 in the radial direction of the portion E2 where the first surface 71a and the second surface 81a are not provided is max Here, the joint portion 90 (portion E1) refers to the portion where the first surface 71a and the second surface 81a are joined to each other (the portion where the first surface 71a and the second surface 81a overlap when viewed from the radial direction). In addition, the portion E2 where the first surface 71a and the second surface 81a are not provided refers to the portion where a plurality of first leg body portions 71d are stacked in the radial direction, and the portion where a plurality of second leg body portions 81d are stacked in the radial direction. That is, at the joint portion 90 (portion E1), the first surface configuration portion 71b (t2 min ≥t3 max / 2) and the second surface arrangement portion 81b (t4 min ≥t5 max / 2) are alternately stacked in multiples (e.g., 8 by 8, 16 in total) along the radial direction. In addition, at the portion E2, the first leg body 71d (t3) or the second leg body 81d (t5) are stacked in multiples (e.g., 8 by 8) along the radial direction. Thus, t21 min (=8×t2 min +8×t4 min )≥t22 max (=8×t3 max , or, 8×t5 max ) relationship is established.

[0109] In addition, Fig.13 In the figure, t21 is shown min =t22 maxThat is, it shows t2 min =t3 max ×1 / 2, and t4 min =t5 max ×1 / 2 state. On the other hand, Fig.15 In the figure, t2 is shown min >t22 max That is, it shows t2 min >t3 max ×1 / 2, and t4 min >t5 max ×1 / 2 state.

[0110] In addition, in the first embodiment, if Fig.14 As shown, a conductive adhesive 91 is provided at the joint 90 to bond the first surface 71a and the second surface 81a and to conduct the first leg 71 and the second leg 81. Fig.13 and Fig.15 , the conductive adhesive 91 is omitted. The detailed structure of the conductive adhesive 91 will be described later. In addition, among the plurality of first conductors 70 and the plurality of second conductors 80 arranged in one slot 12, the minimum value t21 of the range of dimensional variation of the total thickness t21 in the radial direction of the joint portion 90 (portion E1) including the conductive adhesive 91 is min The maximum value t22 of the range of dimensional deviation of the total thickness t22 in the radial direction of the portion E2 where the first surface 71 a and the second surface 81 a are not provided is max Here, the conductive adhesive 91 contains a component (resin component) that volatilizes when heated as described later, and the volume of the conductive adhesive 91 decreases as the volatile component is heated. Therefore, the thickness of the conductive adhesive 91 is the thickness of the silver particles (described later) that remain after the volatile component volatilizes. Therefore, when the thickness of the conductive adhesive 91 is taken into account, t21 is maintained. min ≥t22 max relationship.

[0111] In addition, in the first embodiment, if Figure 13 to Figure 15As shown, a sheet-shaped second insulating component 21 is provided for insulating radially adjacent joints 90 in the joint 90 from each other. The detailed structure of the second insulating component 21 will be described later. In addition, the second insulating component 21 is arranged between the joints 90, between the first leg main bodies 71d, and between the second leg main bodies 81d. In other words, the second insulating component 21 is arranged in a manner extending from the first leg main body 71d to the second leg main body 81d. Moreover, among the plurality of first conductors 70 and the plurality of second conductors 80 arranged in one slot 12, the minimum value t21 of the range of dimensional deviation of the radial total thickness t21 of the joint 90 (portion E1) including the second insulating component 21 is min The maximum value t22 of the range of dimensional variation of the total thickness t22 in the radial direction of the portion E2 including the second insulating member 21 is max That is, the second insulating member 21 is arranged so as to extend from the first leg body 71d to the second leg body 81d, so the thickness t21 is min and thickness t22 max The thickness of the second insulating member 21 is included in each of them. On the other hand, when the thickness of the second insulating member 21 is taken into account, t21 is also maintained. min ≥t22 max relationship.

[0112] In addition, in the first embodiment, if Fig.13 As shown, in the plurality of first conductors 70 and the plurality of second conductors 80 arranged in one slot 12, the maximum value t21 of the range of dimensional variation of the total thickness t21 of the joint portion 90 (portion E1) in the radial direction is max It is equal to or less than the radial width W3 of the slot 12. That is, the first conductor 70 and the second conductor 80 do not protrude toward the inner diameter side (R1 direction side) of the slot 12.

[0113] In addition, the coil portion 30 (see Figure 2 ) includes a joint portion 90 where the first surface 71a and the second surface 81a are joined in one slot 12. That is, the joint portion 90 is located at the end surface 10a (refer to Figure 2 ) and end surface 10b (refer to Figure 2 )between.

[0114] In addition, if Fig.14 As shown, the first surface 71a and the second surface 81a are joined to each other in the radial direction (R direction) at the joint portion 90. Specifically, a surface portion 71e of a part of the front end portion 71c side of the first surface 71a and a surface portion 81e of a part of the front end portion 81c side of the second surface 81a are joined in the radial direction. In other words, the first surface 71a and the second surface 81a are joined in a state of being offset in the axial direction.

[0115] In addition, the first surface 71a (surface portion 71e) and the second surface 81a (surface portion 81e) extend in parallel with respect to the axial direction and are arranged in a manner opposite to each other in the radial direction. That is, each of the first surface 71a (surface portion 71e) and the second surface 81a (surface portion 81e) extends in a manner orthogonal to the radial direction. In addition, the first surface 71a (surface portion 71e) faces radially inward (R1 direction side), and the second surface 81a (surface portion 81e) faces radially outward.

[0116] In addition, a first gap portion 74 extending in the axial direction is provided between the first conductor 70 and the second conductor 80 which are mutually opposed in the axial direction, and between the front end portion 71c of the first leg portion 71 and the second leg portion 81. In addition, a second gap portion 84 extending in the axial direction is provided between the first conductor 70 and the second conductor 80 which are mutually opposed in the axial direction, and between the front end portion 81c of the second leg portion 81 and the first leg portion 71. Specifically, when viewed from the circumferential direction (direction A), the first gap portion 74 is surrounded by the first leg portion 71 and the second leg portion 81 which are mutually joined, and the second insulating member 21 which is adjacent to the radial inner side (R1 direction side). In addition, when viewed from the circumferential direction (direction A), the second gap portion 84 is surrounded by the first leg portion 71 and the second leg portion 81 which are mutually joined, and the second insulating member 21 which is adjacent to the radial outer side (R2 direction side). In addition, the details of the configuration of the second insulating member 21 will be described later.

[0117] In addition, each of the first gap portion 74 and the second gap portion 84 is provided for each set of the first leg portion 71 and the second leg portion 81 that are joined to each other. That is, a plurality of the first gap portions 74 and the second gap portions 84 are provided in parallel in the radial direction (eight in the first embodiment, see Fig.13 ). Specifically, when viewed from the radial direction, the plurality of first gap portions 74 overlap with each other, and the plurality of second gap portions 84 overlap with each other.

[0118] In addition, the axial length L4 of the first gap 74 is substantially equal to the axial length L5 of the second gap 84. In addition, the length L4 of the first gap 74 refers to the axial distance between the front end 71c of the first leg 71 and the second leg 81. In addition, the length L5 of the second gap 84 refers to the axial distance between the front end 81c of the second leg 81 and the first leg 71.

[0119] In addition, both the axial length L4 of the first gap portion 74 and the axial length L5 of the second gap portion 84 are greater than the radial thickness t2 of the first surface arrangement portion 71b provided with the first surface 71a of the first leg portion 71 and the radial thickness t4 of the second surface arrangement portion 81b provided with the second surface 81a of the second leg portion 81. In addition, the length L4 of the first gap portion 74 and the length L5 of the second gap portion 84 are each set to a length that can absorb the dimensional deviation generated in the manufacture of the first conductor 70 and the second conductor 80 and the assembly deviation generated when the first conductor 70 and the second conductor 80 are assembled.

[0120] In addition, a first step portion 71g is provided between the first surface configuration portion 71b provided with the first surface 71a of the first leg portion 71 and the first leg portion main body portion 71d, and the first step portion 71g includes a corner inner surface 71f having a circular shape facing the second gap portion 84. In addition, a second step portion 81g is provided between the second surface configuration portion 81b provided with the second surface 81a of the second leg portion 81 and the second leg portion main body portion 81d, and the second step portion 81g includes a corner inner surface 81f having a circular shape facing the first gap portion 74. Specifically, the corner inner surface 71f and the corner inner surface 81f have an arc shape with a curvature radius smaller than the radial thickness t2 of the first surface configuration portion 71b and the radial thickness t4 of the second surface configuration portion 81b, respectively. In this case, the first leg portion 71 and the second leg portion 81 are provided with a flat surface 71h and a flat surface 81h provided continuously with the corner inner surface 71f and the corner inner surface 81f, respectively. The flat surface 71h and the flat surface 81h are each provided so as to extend orthogonally to the axial direction.

[0121] In addition, if Fig.13 As shown, each of the first gap portion 74 and the second gap portion 84 is disposed in the slot 12. Specifically, each of the first gap portion 74 and the second gap portion 84 is disposed in the slot 12 as a whole.

[0122] In addition, the length L1 of the pair of first leg portions 71 (see FIG. 7 ) and the length L2 of the pair of second leg portions 81 (see FIG. 8 ) are different from each other, so the first surface 71a of the first leg portion 71 and the second surface 81a of the second leg portion 81 are joined, and thus each of the first gap portion 74 and the second gap portion 84 (joining portion 90) is provided at a position axially smaller than the axial center C2 (see FIG. 9 ). Fig.12) is located on the side of the end face 10a. Thus, each of the first gap portion 74 and the second gap portion 84 is disposed at a position closer to the end face 10a of the stator core 10 than the axial center C2 of the stator core 10. Specifically, the edge of the axial side (Z2 direction side) of the second gap portion 84 is disposed at approximately the same position as the end face 10a of the stator core 10 in the axial direction. In addition, the edge of the axial side (Z2 direction side) of the second gap portion 84 may also be disposed within a range of approximately the insulating creepage distance moved from the end face 10a in the Z1 direction or the Z2 direction.

[0123] In addition, the stator 100 has a conductive adhesive 91 at the joint 90 for bonding the first surface 71a and the second surface 81a and for conducting the first leg 71 and the second leg 81. The conductive adhesive 91 is, for example, a paste-like bonding material (silver nanopaste) containing metal particles obtained by micronizing silver to a nanometer level as conductive particles in a solvent. In addition, the conductive adhesive 91 is configured to melt by heat.

[0124] In addition, the conductive adhesive 91 contains a component (resin component) that evaporates when heated, and has the function of reducing the volume of the conductive adhesive 91 by heating the evaporated component, thereby bringing the first surface 71a and the second surface 81a closer together. In addition, in order to join the first surface 71a and the second surface 81a, the first conductor 70 and the second conductor 80 are assembled in a state where the conductive adhesive 91 is applied in advance to a portion corresponding to the joining portion 90 of at least one of the first surface 71a and the second surface 81a (at least one of the surface portion 71e and the surface portion 81e). In addition, in Fig.14 In the figure, the thickness of the conductive adhesive 91 is highlighted for the sake of explanation, but the present invention is not limited to the example shown in the figure.

[0125] In addition, the conductive adhesive 91 is applied to at least one of the surface portion 71e and the surface portion 81e, and is also applied to the surface portion 71i of the first surface 71a facing the second gap portion 84 and the surface portion 81i of the second surface 81a facing the first gap portion 74 when viewed from the radial direction. Specifically, the conductive adhesive 91 is applied to the entire surface portion 71i and the entire surface portion 81i. That is, when viewed from the radial direction, the entire surface of the first surface 71a and the second surface 81a are covered with the conductive adhesive 91. In addition, the conductive adhesive 91 is not applied to each of the corner inner surface 71f and the corner inner surface 81f.

[0126] (Structure of the First Insulating Member)

[0127] like Figure 4 As shown, the first insulating member 20 is disposed between the wall portion 11a and the teeth 13 and the first leg portion 71 and the second leg portion 81 (sector-shaped conductor 40). Fig.16As shown in FIG. 1 , the first insulating component 20 has a three-layer structure. Specifically, Fig.12 As shown, the first insulating member 20 includes: a wall portion 11a of the back yoke 11 and a circumferential side surface 13a of the tooth 13 (see Figure 4 ) between the first leg 71 and the second leg 81, and an insulating layer 20a that insulates the wall portion 11a and the circumferential side surface 13a from the first leg 71 and the second leg 81, and a portion 20b of the insulating layer 20a that is at a position (region) (P2) different from the axial position P1 corresponding to the joint 90, and a fixing layer 20c that fixes the stator core 10 to the second leg 81. The fixing layer 20c is preferably configured as an adhesive layer containing an adhesive. In addition, the position P2, for example, includes the entire area in the slot 12 excluding the axial position P1 in the axial direction, and the vicinity of the end face 10b of the stator core 10 (including the portion axially outside the slot 12).

[0128] Furthermore, when viewed in the direction of arrow Z2, the first insulating member 20 is arranged so as to integrally cover the periphery of the plurality of second leg portions 81 arranged in parallel in the radial direction. In other words, both circumferential sides and both radial sides of the plurality of second leg portions 81 arranged in parallel in the radial direction are covered by the first insulating member 20. Thus, the insulation between the joint 90 and the stator core 10 can be ensured by the first insulating member 20.

[0129] The insulating layer 20a is made of, for example, polyphenylene sulfide resin (PPS). Alternatively, the insulating layer 20a may be formed into a non-woven fabric such as aramid paper. Fig.12 As shown in FIG. 1 , the insulating layer 20a is provided in a manner extending from the end face 10a on one side of the stator core 10 in the axial direction to the end face 10b on the other side. That is, the insulating layer 20a is arranged in each slot in a manner covering the wall portion 11a and the circumferential side surface 13a. In addition, “covering” does not only mean covering the entire portion of the wall portion 11a and the circumferential side surface 13a. Figure 4 The above-mentioned description refers to a broad concept including the case where the radially inner portion (front end gap portion) of the circumferential side surface 13 a is exposed.

[0130] like Fig.16 As shown, the fixing layer 20c includes a foaming agent 20d (expansion agent) that foams due to heat. Specifically, the fixing layer 20c is formed by, for example, mixing a plurality of capsules as the foaming agent 20d with a thermosetting resin 20e. The foaming agent 20d is configured so that the volume of the capsules expands by being heated to a foaming temperature T1 or higher. The fixing layer 20c is heated, for example, during the manufacturing process of the stator 100, thereby increasing the thickness t6 (see Fig.17 ) increases to a thickness of t7 (refer to Fig.18). Thus, when the fixing layer 20c is heated, the foaming agent 20d foams (expands) and fills the space between the second leg portion 81 and the wall portion 11a and the circumferential side surface 13a.

[0131] The thermosetting resin 20e is configured to be cured by being heated to a temperature higher than the foaming temperature T1, that is, to a curing temperature T2 or higher. The thermosetting resin 20e constituting the fixing layer 20c is, for example, an epoxy resin. The fixing layer 20c is configured to be cured by the thermosetting resin 20e when heated, thereby bonding and fixing the second leg portion 81 to the wall portion 11a and the circumferential side surface 13a.

[0132] like Fig.12 As shown, at least a portion of the second leg portion 81 is filled between the wall portion 11a and the circumferential side surface 13a constituting the slot 12 at a position P2 different from the axial position P1 corresponding to the joint 90 by a fixing layer 20c including a foaming agent 20d in a foamed state. Specifically, the fixing layer 20c is overlapped with a portion 20b of the insulating layer 20a that is closer to the other axial side (Z1 direction side) than the axial position P1 corresponding to the joint 90. In other words, the fixing layer 20c is overlapped with a portion 20b of the insulating layer 20a that is closer to the other axial side (Z2 direction side) than the end face 10a on one axial side (Z2 direction side). In addition, the fixing layer 20c is overlapped with a portion 20b of the insulating layer 20a that is arranged between the second leg portion 81 and the stator core 10 in the slot 12. For example, as Fig.15 As shown, the fixing layer 20 c is overlapped and provided at a portion 20 b of the insulating layer 20 a at a position different from the position in the axial direction corresponding to the joint portion 90 , so as to sandwich the insulating layer 20 a .

[0133] In addition, if Fig.13 As shown in FIG. 1 , a first insulating member 20 is provided between the slot 12 and the coil portion 30, and a second insulating member 21 is provided separately from the first insulating member 20. Fig.19 As shown, in a joint portion 90 obtained by joining the first surface 71a of the first leg portion 71 of the first conductor 70 and the second surface 81a of the second leg portion 81 of the second conductor 80 between radially adjacent coils in one slot 12, the radially adjacent joint portions 90 are insulated from each other by a sheet-like second insulating component 21 provided separately from the first insulating component 20. In addition, the "coil" refers to a linear portion of the coil portion 30 arranged in the slot 12 after the first conductor 70 and the second conductor 80 are joined. Therefore, a plurality of coils are arranged in one slot 12. In addition, the second insulating component 21 is an example of the "joint portion insulating component" of the technical solution.

[0134] In addition, if Fig.19As shown, the second insulating component 21 is formed by folding a sheet of insulating components such as Nomex material. Moreover, the second insulating component 21 includes: an opposing surface insulating portion 21a that covers the opposing surface 90a of the radially adjacent joints 90, and a circumferential surface insulating portion 21b that is continuous from both circumferential ends of the opposing surface insulating portion 21a and covers at least the insulation distance amount on either side of the circumferential surface 90b of the radially adjacent joints 90. In addition, the opposing surface 90a of the joint 90 indicates the radially outer surface and the radially inner surface of the radially adjacent joints 90 that are opposite to each other. In addition, the insulation distance is the length along the radial direction of the circumferential surface insulating portion 21b, and refers to a sufficient distance (surface distance) for insulating the radially adjacent joints 90 from each other.

[0135] In addition, if Fig. 20 As shown, the second insulating member 21 includes a portion 21 c that covers the radially outer side of the joining portion 90 disposed on the outermost diameter side, and a portion 21 d that covers the radially inner side of the joining portion 90 disposed on the innermost diameter side.

[0136] In addition, in the second insulating component 21, the radially adjacent opposing surface insulating portions 21a are connected by the circumferential surface insulating portion 21b on one side or the other side in the circumferential direction. Specifically, the radially outer opposing surface insulating portion 21a of a pair of opposing surface insulating portions 21a arranged in a radially adjacent manner and the circumferential surface insulating portion 21b provided on one side in the circumferential direction and the radially inner opposing surface insulating portion 21a of a pair of opposing surface insulating portions 21a and the circumferential surface insulating portion 21b provided on the other side in the circumferential direction are formed in a continuous manner. In other words, the circumferential surface 90b on the A1 direction side of the joint 90 and the circumferential surface 90b on the A2 direction side of the joint 90 are alternately covered by the circumferential surface insulating portion 21b. In other words, the second insulating component 21 is configured to discontinuously cover the circumferential surfaces 90b of a plurality of joints 90 arranged in a radially adjacent manner.

[0137] Thus, the second insulating member 21 has a zigzag shape (wrinkled shape) when viewed from the axial direction. In addition, since radially adjacent joints 90 disposed in one slot 12 are insulated from each other by one second insulating member 21, all joints in the slot 12 are insulated from each other. Thus, the number of steps for disposing the second insulating member 21 can be reduced compared to the case where a plurality of joints 90 disposed in one slot 12 are individually covered by an insulating member.

[0138] In addition, if Fig. 20As shown, the second insulating member 21 is configured to be able to expand and contract in the radial direction. This is because the second insulating member 21 is composed of a flexible sheet-shaped insulating member and is configured to discontinuously cover the circumferential surfaces 90b of the plurality of joints 90 arranged in a radially adjacent manner. Thus, when the first leg 71 and the second leg 81 are joined, even if the first leg 71 and the second leg 81 are squeezed in the radial direction or the axial direction, the second insulating member 21 can be deformed together with the movement of the first leg 71 and the second leg 81.

[0139] In addition, if Fig.13 As shown, the second insulating member 21 is provided to extend in the axial direction in a manner covering both the first gap portion 74 and the second gap portion 84 when viewed from the radial direction. Specifically, the second insulating member 21 is configured in a manner such that an edge portion on one axial side (Z2 direction side) protrudes outward (Z2 direction side) from the axial end surface 10a of the stator core 10. In addition, an edge portion on the other axial side (Z1 direction side) of the second insulating member 21 is provided in the slot 12 at a position closer to the other axial side (Z1 direction side) than an edge portion on the other axial side (Z1 direction side) of the first gap portion 74.

[0140] In addition, if Fig.13 As shown, the first insulating component 20 is also configured together with the second insulating component 21 to protrude outward (Z2 direction side) from the axial end face 10a of the stator core 10. Moreover, the height position h1 of the portion of the second insulating component 21 protruding outward from the end face 10a of the stator core 10 is substantially equal to the height position h2 of the portion of the first insulating component 20 protruding outward from the end face 10a of the stator core 10. In addition, the protrusion amount of the first insulating component 20 and the second insulating component 21 from the end face 10a of the stator core 10 is adjusted to an extent that the first insulating component 20 and the second insulating component 21 do not contact the first coil end portion 72 of the first sector conductor 70 and are bent.

[0141] In addition, if Fig.21 As shown, in the axial direction, the length L12 of the second insulating component 21 is smaller than the length L11 of the first insulating component 20. Specifically, the length L11 of the first insulating component 20 is larger than the axial length L3 of the stator core 10. In addition, the length L12 of the second insulating component 21 is smaller than the length L3 of the stator core 10. In addition, the second insulating component 21 is provided in a manner covering the joint 90 and extending from the joint 90 to the Z1 direction side and the Z2 direction side. The length L12 of the second insulating component 21 is adjusted based on the magnitude of the voltage applied to the coil portion 30, etc. (the required creeping distance). In addition, Fig.21 In the figure, the first conductor 70 and the second conductor 80 are omitted for simplicity.

[0142] In addition, the length L12 of the second insulating member 21 is less than the length L11 of the first insulating member 20. Fig. 22 As shown in FIG. 1 , the first insulating member 20 includes a portion 20f that overlaps with the second insulating member 21 and a portion 20b that does not overlap with the second insulating member 21 when viewed from the radial direction. Specifically, the first insulating member 20 overlaps with the second insulating member 21 near the axial end (end surface 10a) in the slot 12. Moreover, the thickness t11 of the portion 20f of the first insulating member 20 that overlaps with the second insulating member 21 is smaller than the thickness t12 of the portion 20b of the first insulating member 20 that does not overlap with the second insulating member 21.

[0143] The thickness t13 of the second insulating member 21 is smaller than the thickness t11. The thickness t12 is the thickness obtained by adding the thickness t7 of the two fixing layers 20c to the thickness t11 (t7×2).

[0144] In addition, the second insulating member 21 is arranged at a position closer to the axial side (Z2 direction side) than the fixing layer 20c of the first insulating member 20 and is arranged between the joints 90 in the radial direction, so as to insulate the joints 90 from each other. Specifically, the fixing layer 20c is arranged to overlap with a portion 20b of the insulating layer 20a that does not overlap with the second insulating member 21 when viewed in the radial direction. In addition, the insulating layer 20a is arranged at a portion 20f that overlaps with the second insulating member 21 when viewed in the radial direction.

[0145] (Stator manufacturing device)

[0146] Next, refer to Fig.23 , a manufacturing device 200a of the stator 100 is described. The manufacturing device 200a of the stator 100 includes a pressing jig 201. The pressing jig 201 is configured to independently press the first leg portion 71 of the first conductor 70 and the second leg portion 81 of the second conductor 80 arranged in the plurality of slots 12 in the radial direction for each of the plurality of slots 12. Specifically, the pressing jig 201 is configured for each of the plurality of slots 12 and is movable in the radial direction. In addition, a plurality of pressing jigs 201 are provided in a manner corresponding to the plurality of slots 12 (the same number as the number of slots 12), and each of the plurality of pressing jigs 201 is independently movable in the radial direction.

[0147] In addition, the manufacturing device 200a of the stator 100 includes a moving mechanism 202 that independently moves the pressing jig 201 for each of the plurality of slots 12. The moving mechanism 202 is provided for each of the plurality of pressing jigs 201, and is configured to be able to adjust the radial movement amount for each of the plurality of pressing jigs 201. The moving mechanism 202 is configured, for example, by an actuator.

[0148] The pressing jig 201 presses the joint 90 between the first leg portion 71 of the first conductor 70 and the second leg portion 81 of the second conductor 80 disposed in the plurality of slots 12. min ≥t22 max The relationship holds, so the joint 90 is not arranged in a state recessed radially outward (in the R2 direction) from the first leg body 71d and the second leg body 81d. Thus, the pressing force of the pressing jig 201 is sufficiently transmitted to the joint 90.

[0149] In addition, if Fig.12 As shown, the manufacturing device 200a of the stator 100 includes an adhesive layer heating unit 203. The adhesive layer heating unit 203 is arranged at a position closer to at least one of the radial inner side or the radial outer side (preferably both sides) than the stator core 10, and is configured to be able to perform induction heating (IH: induction heating). Moreover, the adhesive layer heating unit 203 is configured in a manner to heat the fixing layer 20c of the first insulating component 20 to a temperature higher than the foaming temperature T1 and higher than the curing temperature T2 (starting from room temperature). In addition, the adhesive layer heating unit 203 uses induction heating, thereby being able to heat the fixing layer 20c at a desired temperature rise rate (relatively high temperature rise rate) compared to a conventional heating furnace. In addition, the joint 90 is arranged in a heating furnace in a state of being squeezed by the squeezing jig 201, thereby being heated.

[0150] (Manufacturing method of stator)

[0151] Next, a method for manufacturing the stator 100 will be described.

[0152] like Fig.24 As shown, in step S11, a plurality of first conductors 70 including first leg portions 71 extending to the other axial side and arranged on one axial side of the stator core 10 are prepared. In addition, the first conductor 70 is prepared, wherein the first leg portion 71 of the first conductor 70 has a first leg portion body portion 71d and a first surface arrangement portion 71b provided with a first surface 71a and having a radial thickness t2 smaller than that of the first leg portion body portion 71d.

[0153] In step S12, a plurality of second conductors 80 are prepared, which are arranged on the other side of the stator core 10 in the axial direction and include a second leg portion 81 extending to one side in the axial direction. In addition, the second conductor 80 is prepared, and the second leg portion 81 of the second conductor 80 includes a second leg body portion 81d and a second surface arrangement portion 81b provided with a second surface 81a and having a radial thickness t4 smaller than that of the second leg body portion 81d. In addition, in the step of preparing the first conductor 70 in step S11 and the step of preparing the second conductor 80 in step S12, the first conductor 70 and the second conductor 80 are prepared so that the thickness of the joint portion 90 in the radial direction is greater than or equal to the thickness of the portion E2 other than the joint portion 90.

[0154] In step S13, the plurality of first conductors 70 are moved from one side of the stator core 10 to the slot 12 side (inserted into the slot 12). In addition, the first insulating member 20 is pre-arranged in the slot 12 before the first conductor 70 is inserted into the slot 12. In addition, the second insulating member 21 is pre-arranged in the slot 12, or inserted into the slot 12 together with the first conductor 70.

[0155] In step S14 , the plurality of second conductors 80 are moved from the other axial side of the stator core 10 toward the slots 12 (inserted into the slots 12 ).

[0156] In step S15, at least a portion of the first surface 71a of each of the first legs 71 of the plurality of first conductors 70 and at least a portion of the second surface 81a of each of the second legs 81 of the plurality of second conductors 80 are joined within one slot 12, thereby forming a joint 90. Specifically, the pressing jig 201 independently presses the first legs 71 of the first conductors 70 and the second legs 81 of the second conductors 80 arranged in the plurality of slots 12 in the radial direction for each of the plurality of slots 12. Thus, the joint 90 is formed. Here, in the first embodiment, in the step of forming the joint 90, the thickness of the joint 90 in the radial direction (total thickness t21) is greater than the thickness of the portion E2 other than the joint 90 (total thickness t22) (see Fig.14 and Fig.15 ) to form the joint 90. In addition, the first leg 71 and the second leg 81 are pressed by the pressing jig 201, and the conductive adhesive 91 is heated by a heating device (not shown), thereby joining at least a portion of the first surface 71a and at least a portion of the second surface 81a to form the joint 90.

[0157] [Second embodiment]

[0158] Next, refer to Figure 4 ,and Figure 25 to Figure 34 The stator 200 of the second embodiment is described. In the stator 200 of the second embodiment, unlike the stator 100 of the first embodiment which includes the first insulating member 20 and the second insulating member 21 which are provided separately from each other, an integrally formed insulating member 121, 122 is provided. In addition, for the same structure as the first embodiment, the same reference numerals as the first embodiment are attached to illustrate and the description is omitted.

[0159] [Stator structure]

[0160] Reference Figure 4 ,and Figure 25 to Figure 34 , the structure of the stator 200 of the second embodiment will be described. In addition, the stator 200 is an example of the "armature" of the technical claim.

[0161] like Fig.25 As shown in FIG. 1 , the stator 200 includes a sheet-shaped insulating member 121 and a coil unit 130. The coil unit 130 includes a first coil assembly 130a (reverse guide side coil) and a second coil assembly 130b (guide side coil). The coil unit 130 is composed of a plurality of fan-shaped conductors 140 ( Fig.27A And B reference) composition.

[0162] In addition, if Fig.26 As shown, in the axial direction, the insulating member 121 (the contact portion insulating portion 121c described later) and the core leg portion insulating portion 122 described later each have an equal length L22. The length L22 is greater than the axial length L3 of the stator core 10. In addition, Fig.26 In the figure, the first conductor 70 and the second conductor 80 are omitted for simplicity. Fig.26 , the shapes of the insulating member 121 and the core leg insulating portion 122 are schematically illustrated.

[0163] (Structure of fan-shaped conductor)

[0164] like Fig.27A and Fig.27B As shown, the fan-shaped conductor 140 is formed as a square wire having a substantially rectangular cross section. In addition, the first leg portion 171 (second leg portion 181) described later in the fan-shaped conductor 140 is exposed on the conductor surface 140b (see Fig.27A On the other hand, an insulating film 140a having a thickness t21a is provided on a conductor surface 140b of a first coil end portion 172 (second coil end portion 182) described later in the fan-shaped conductor 140 (see Fig.27B The thickness t21a of the insulating film 140a is set, for example, to ensure the interphase insulation performance (insulation between the first coil end portions 172 and insulation between the second coil end portions 182 {see Fig.28A and Fig.28B , Fig.29A and Fig.29B}). In addition, Fig.27A and Fig.27B In the figure, for the purpose of explanation, the size relationship such as thickness is highlighted and illustrated, but the present invention is not limited to the example illustrated. Fig.27A and Fig.27B In the figure, only the first conductor 170 described later is shown, but the second conductor 180 is the same and therefore is omitted from the figure.

[0165] <Structure of the First Conductor and the Second Conductor>

[0166] like Fig.28A , Fig.28Band Fig.29A , Fig.29B As shown, the plurality of fan-shaped conductors 140 include a plurality of first conductors 170 arranged on one axial side (Z2 direction side) of the stator core 10, and a plurality of second conductors 180 arranged on the other axial side (Z1 direction side) of the stator core 10. The first conductor 170 and the second conductor 180 are arranged opposite to each other in the axial direction. In addition, the first conductor 170 includes a first leg 171 having an axial length L31. The first leg 171 extends to the other axial side (Z1 direction side). In addition, the second conductor 180 includes a second leg 181 having an axial length L32. The second leg 181 extends to one axial side (Z2 direction side). In addition, the length L31 of the first leg 171 is substantially equal to the length L32 of the second leg 181. In addition, the first leg 171 and the second leg 181 are each inserted into the slot 12. In addition, the first conductor 170 and the second conductor 180 are examples of the "first fan-shaped conductor" and the "second fan-shaped conductor" of the technical solution, respectively.

[0167] like Fig.28A and Fig.28B As shown, a plurality of first conductors 170 are respectively formed as a pair of first legs 171 arranged in different slots 12 and connected to each other, thereby having a U-shape (roughly a U-shape) when viewed in the radial direction. The coil spacing of the first conductor 170 is 6. That is, for a pair of first legs 171, they are arranged at different positions in the circumferential direction with a size of 6 slots 12. That is, five slots 12 are provided between a slot 12 in which one of the first legs 171 of the pair of first legs 171 is arranged and a slot 12 in which the other first leg 171 is arranged. Specifically, the first conductor 170 includes a pair of first legs 171 arranged in different slots 12 and formed in a straight line shape in the axial direction, and a first coil end portion 172. The first leg 171 refers to the end face 10a (refer to the axial end face 10a of the stator core 10) in the axial direction. Figure 2 ) is configured in the slot 12 at an axial position, and the first coil end portion 172 refers to a portion formed continuously with the first leg portion 171 and configured at a position axially outside the end face 10a of the stator core 10. In addition, the first coil end portion 172 has a curved shape bent in the axial direction. In addition, the first coil end portion 172 has a first crank portion 173 formed in a crank shape that bends the width of one fan-shaped conductor 140 in the radial direction into a stepped shape when viewed from the axial direction. In other words, the radial width of the first crank portion 173 is twice the width of one fan-shaped conductor 140.

[0168] The axial lengths L31 of the pair of first leg portions 171 are substantially equal to each other. The axial length L31 refers to the length of the portion of the first conductor 170 that extends linearly in the axial direction in the slot 12. The axial length L31 is smaller than the axial length L3 of the stator core 10 (slot 12) (see Fig.26 ).

[0169] Similarly, if Fig.29A and Fig.29B As shown, the second conductor 180 includes a pair of second legs 181 arranged in the slot 12, and a second coil end portion 182. In addition, the second coil end portion 182 has a second crank portion 183. In addition, the second conductor 180 is formed so that a pair of second legs 181 arranged in different slots 12 are connected to each other, thereby having a U-shape. In addition, the axial lengths L32 of the pair of second legs 181 of the second conductor 180 are substantially equal to each other. In addition, the axial length L32 refers to the length of the portion of the second conductor 180 that extends linearly in the axial direction in the slot 12.

[0170] like Fig.30 As shown, a plurality of first leg portions 171 are provided in each of the plurality of slots 12 so as to be adjacent to each other in the radial direction of the stator core 10 . Also, a plurality of second leg portions 181 are provided in each of the plurality of slots 12 so as to be adjacent to each other in the radial direction of the stator core 10 .

[0171] In addition, in one slot 12, a plurality of first surfaces 171a provided in the first leg portion 171 and second surfaces 181a provided in the second leg portion 181 are alternately arranged in the radial direction. The first surface 171a is provided on the front end portion 171b side of the first leg portion 171. In addition, the second surface 181a is provided on the front end portion 181b side of the second leg portion 181. In addition, the first surface 171a and the second surface 181a are provided in contact with each other as described later, and the first surface 171a and the second surface 181a in contact with each other are arranged in a manner opposite to each other in the radial direction.

[0172] In addition, the stator 200 includes a spring member 210 disposed between the coil portion 130 and the opening 12a (protrusion 13b) of the slot 12 in each of the plurality of slots 12. That is, the spring member 210 is disposed in the radially inner front end gap 12b disposed in the slot 12.

[0173] The spring member 210 presses the coil portion 130 from the radial inner side so that the first surface 171a of the first leg portion 171 of the first conductor 170 contacts the second surface 181a of the second leg portion 181 of the second conductor 180. The first surface 171a of the first leg portion 171 contacts the second surface 181a of the second leg portion 181, thereby forming a contact portion 190. The contact portion 190 is an example of a "joint portion" of the technical solution.

[0174] The first surface 171a and the second surface 181a are pressed by the spring member 210 so as to contact each other without an adhesive therebetween. That is, the first surface 171a and the second surface 181a are not bonded, and the contact state between the first surface 171a and the second surface 181a is maintained by the pressing force of the spring member 210.

[0175] In addition, a plurality of (eight in the second embodiment) sets of first surfaces 171a and second surfaces 181a in contact with each other are provided in one slot 12. That is, a plurality of contact portions 190 are provided in one slot 12. The plurality of contact portions 190 are arranged in one slot 12 adjacent to each other in the radial direction.

[0176] Specifically, the plurality of contact portions 190 are arranged so as to overlap each other when viewed from the radial direction. That is, all the contact portions 190 arranged in one slot 12 are arranged in parallel in the horizontal direction. In other words, in one slot 12, the axial positions of the plurality of contact portions 190 are substantially equal to each other.

[0177] Each of the plurality of contact portions 190 is disposed in the axial center of the stator core 10 in the slot 12. The spring member 210 is also disposed in the axial center of the stator core 10. Specifically, the spring member 210 is provided so as to overlap each of the plurality of contact portions 190 when viewed from the radial direction.

[0178] In addition, each of the first surface 171a and the second surface 181a is plated. That is, the surfaces subjected to the plated treatment (the first surface 171a and the second surface 181a) are in contact with each other.

[0179] In the electroplating process, for example, metals such as Ni, Ag, Au, and Su are used. In addition, the electroplating process may be performed using a plurality of metals (for example, Ni and Ag) among the above metals.

[0180] like Fig.31As shown, the first leg portion 171 includes a first surface forming portion 171c having a first surface 171a. The first surface forming portion 171c (first surface 171a) is provided in a manner extending along the axial direction. In addition, the first leg portion 171 includes a first leg main body portion 171d which is continuous from the first surface forming portion 171c and is provided on one side (Z2 direction side) of the axial direction of the first surface forming portion 171c. The first surface forming portion 171c has a radial thickness t31. In addition, the first leg main body portion 171d has a radial thickness t32. The radial thickness t32 of the first leg main body portion 171d is greater than the radial thickness t31 of the first surface forming portion 171c.

[0181] The first leg portion 171 includes a first step portion 171e provided between the first surface forming portion 171c and the first leg portion main body 171d. A gap portion 171f is provided between the first step portion 171e and the front end portion 181b of the second leg portion 181.

[0182] The second leg portion 181 includes a second surface forming portion 181c formed with a second surface 181a. The second surface forming portion 181c (second surface 181a) is provided in a manner extending along the axial direction. In addition, the second leg portion 181 includes a second leg main body portion 181d which is continuous from the second surface forming portion 181c and is provided on the other side (Z1 direction side) of the axial direction of the second surface forming portion 181c. The second surface forming portion 181c has a radial thickness t33. In addition, the second leg main body portion 181d has a radial thickness t34. The radial thickness t34 of the second leg main body portion 181d is greater than the radial thickness t33 of the second surface forming portion 181c.

[0183] The second leg portion 181 includes a second step portion 181e provided between the second surface forming portion 181c and the second leg portion main body 181d. A gap portion 181f is provided between the second step portion 181e and the front end portion 171b of the first leg portion 171.

[0184] In addition, the radial thickness t31 of the first surface forming portion 171c is substantially equal to the radial thickness t33 of the second surface forming portion 181c. In addition, the radial thickness t32 of the first leg body 171d is substantially equal to the radial thickness t34 of the second leg body 181d. Fig.31 In order to make the insulating member 121 protrude, the insulating member 121 is shown as having a larger thickness than the actual thickness. In addition, the radial thickness (t31+t33) of the contact portion 190 is greater than the thickness (t32 or t34) of the portion other than the contact portion 190.

[0185] In addition, if Fig.32As shown, the sheet-like insulating member 121 is provided to separate the first leg portion 171 with the conductor surface 140b exposed between the coils adjacent in the radial direction in one slot 12 and the first leg portion 171 with the conductor surface 140b exposed (see Fig.27A and Fig.27B ) are insulated from each other by contacting the second leg portions 181 without using a bonding agent. Specifically, the insulating member 121 is provided between a plurality of coils (eight in the second embodiment) radially arranged in the slot 12 (a group of first leg portions 171 and second leg portions 181 in contact with each other).

[0186] Specifically, the insulating member 121 is formed by folding a sheet of insulating member such as Nomex material. Moreover, the insulating member 121 includes: an opposing surface insulating portion 121a that covers the opposing surface 190a of the radially adjacent contact portion 190, and a circumferential surface insulating portion 121b that is continuous from both ends of the opposing surface insulating portion 121a in the circumferential direction and covers at least the insulation distance amount of one of the circumferential surfaces 190b of the radially adjacent contact portion 190. In addition, the opposing surface 190a of the contact portion 190 refers to the radially outer surface and the radially inner surface of the radially adjacent contact portion 190 that are opposite to each other. In addition, the insulation distance refers to the length along the radial direction of the circumferential surface insulating portion 121b, and refers to a sufficient distance (creeping distance) for insulating the radially adjacent contact portions 190 from each other. In addition, the circumferential surface 190b refers to the surface of the contact portion 190 that intersects the circumferential direction. In other words, the circumferential surface 190 b refers to a surface extending in the radial direction and the axial direction.

[0187] In addition, the insulating component 121 includes a contact portion insulating portion 121c formed in a manner that a radially outer opposing surface insulating portion 121a of a pair of radially adjacent opposing surface insulating portions 121a and a circumferential surface insulating portion 121b arranged on one side of the circumferential direction and a radially inner opposing surface insulating portion 121a of a pair of opposing surface insulating portions 121a and a circumferential surface insulating portion 121b arranged on the other side of the circumferential direction are continuous.

[0188] In addition, the stator 200 includes a core foot insulating portion 122 that is disposed between the slot 12 and the coil portion 130 and is formed integrally with the contact portion insulating portion 121c. That is, the core foot insulating portion 122 is sheet-shaped like the contact portion insulating portion 121c, and is formed of the same material as the contact portion insulating portion 121c. In addition, the contact portion insulating portion 121c and the core foot insulating portion 122 have the same thickness (not shown). In addition, the contact portion insulating portion 121c and the core foot insulating portion 122 have the same length L22 in the axial direction (see Fig.30 ).

[0189] Specifically, the core leg insulating portion 122 is continuous with the outermost diameter opposing surface insulating portion 121a and is located on one side of the circumferential direction of the slot 12 (at Fig.32 The core leg insulating portion 122 has an insulating portion 122a on one side (left side in the figure) provided between the slot 12 (circumferential side surface 13a) and the coil portion 130 (circumferential surface 190b). In addition, the core leg insulating portion 122 has an insulating portion 121a on the opposite side of the innermost diameter and is continuous with the opposite side of the slot 12 (on the other side of the slot 12). Fig.32 The other side insulating portion 122b (right side in the center) is provided between the slot 12 (circumferential side surface 13a) and the coil portion 130 (circumferential surface 190b).

[0190] Specifically, for the insulating portion 122a on one side (the insulating portion 122b on the other side), the portion clamped by the circumferential side surface 13a of the slot 12 and the circumferential surface 190b of the coil portion 130 and the portion clamped by the circumferential side surface 13a of the slot 12 and the circumferential surface insulating portion 121b covering the circumferential surface 190b of the coil portion 130 exist alternately along the radial direction.

[0191] In the second embodiment, the one-side insulating portion 122a extends from the radially outer end 230a of the coil portion 130 in the slot 12 to the radially inner end 230b (all over the end 230b). In addition, the other-side insulating portion 122b extends from the radially inner end 230b of the coil portion 130 in the slot 12 to the radially outer end 230a (all over the end 230a). That is, the coil portion 130 in the slot 12 is provided in a manner surrounded by the outermost diameter opposing surface insulating portion 121a, the innermost diameter opposing surface insulating portion 121a, the one-side insulating portion 122a, and the other-side insulating portion 122b.

[0192] The core leg insulating portion 122 includes a radially inner insulating portion 122c which is continuous with the one side insulating portion 122a and covers the innermost diameter opposing surface insulating portion 121a from the radial inner side. The core leg insulating portion 122 includes a radially outer insulating portion 122d which is continuous with the other side insulating portion 122b and covers the outermost diameter opposing surface insulating portion 121a from the radial outer side.

[0193] Specifically, the radially inner insulating portion 122c is provided in a manner sandwiched between the innermost diameter opposing surface insulating portion 121a and the spring member 210. That is, the coil portion 130 is insulated from the spring member 210 by the innermost diameter opposing surface insulating portion 121a and the radially inner insulating portion 122c. In addition, the radially outer insulating portion 122d is provided in a manner sandwiched between the outermost diameter opposing surface insulating portion 121a and the wall portion 11a of the slot 12. That is, the coil portion 130 is insulated from the wall portion 11a of the slot 12 (the stator core 10) by the outermost diameter opposing surface insulating portion 121a and the radially outer insulating portion 122d.

[0194] In addition, the radially inner insulating portion 122c has a length L41 in the circumferential direction. In addition, the radially outer insulating portion 122d has a length L42 in the circumferential direction. The length L41 of the radially inner insulating portion 122c and the length L42 of the radially outer insulating portion 122d are each greater than, for example, the width W2 of the slot 12 (see Figure 4 )’s 1 / 2.

[0195] In addition, if Fig.30 As shown, the contact portion insulating portion 121c (refer to Fig.32 ) and the core leg insulation part (refer to Fig.32 ) The axial length L22 of each of the slots 12 is greater than the axial length L62 of the slots 12. In addition, the axial length L62 of the slots 12 is equal to the axial length L3 of the stator core 10 (see Fig.25 ) are equal. In addition, each of the contact portion insulating portion 121c and the core leg portion insulating portion 122 is configured in such a manner that the edges on both sides in the axial direction protrude outward from the axial end faces (10a, 10b) of the stator core 10. Thus, each of the contact portion insulating portion 121c and the core leg portion insulating portion 122 is provided over the entire slot 12 in the axial direction.

[0196] In addition, if Fig.33 As shown, the contact portion insulating portion 121c includes: an insulating layer 123a, and a fixing layer 123b including a foaming agent 123c that foams due to heat, and the foaming agent 123c is expanded by foaming, thereby fixing the coil (a group of first leg 171 and second leg 181 that are in contact with each other) at least axially relative to the radially adjacent coil. The fixing layer 123b is provided on both sides of the insulating layer 123a. When the fixing layer 123b is heated, the thermosetting resin 123d is cured. Thus, the fixing layer 123b of the contact portion insulating portion 121c adheres and fixes the adjacent coils to each other. In addition, in Fig.33 In the figure, the stator core 10 and the like are omitted for simplicity.

[0197] In addition, if Fig.34As shown, the core leg insulating portion 122 includes: an insulating layer 124a, and a fixing layer 124b including a foaming agent 124c that foams due to heat, and by causing the foaming agent 124c to foam and expand, thereby fixing each of the first leg 171 and the second leg 181 relative to the stator core 10 in at least the axial direction. The fixing layer 124b of the core leg insulating portion 122 is constructed in a manner that each of the first leg 171 and the second leg 181 is bonded and fixed to the stator core 10. Therefore, it is unnecessary to use a paint or the like to fix each of the first leg 171 and the second leg 181. In addition, in Fig.33 and Fig.34 In order to make the insulating component 121 and the core leg insulating portion 122 stand out, they are illustrated in a manner that makes them have a greater thickness than the actual thickness. In addition, the insulating layer 123a (124a) and the fixing layer 123b (124b) are respectively the same in structure (material) as the insulating layer 20a and the fixing layer 20c of the first embodiment, and therefore detailed descriptions are omitted.

[0198] In addition, the fixing layer 124b (fixing layer 123b) is arranged to overlap the entire surface of the insulating layer 124a (insulating layer 123a). Specifically, the fixing layer 124b (fixing layer 123b) is arranged to overlap the insulating layer 124a (insulating layer 123a) at the axial position corresponding to the contact portion 190 and the axial position corresponding to the portion of the leg (171, 181) other than the contact portion 190.

[0199] Stator manufacturing process

[0200] Next, refer to Fig.35 , the manufacturing process of the stator 200 is described.

[0201] like Fig.35 As shown, first, in step S1 , the insulating member 121 (contact portion insulating part 121 c ) and the pin portion insulating part 122 are integrally inserted (arranged) into the socket 12 .

[0202] Next, in step S2, the second leg portion 181 (see Fig.30 ) is inserted into slot 12.

[0203] Next, in step S3, the first leg portion 171 (see FIG. 1 ) of the first conductor 170 is moved from one axial side (Z2 direction side) to the Fig.30 ) is inserted into the slot 12. At this time, the first leg portion 171 is arranged so that the first surface 171a of the first leg portion 171 and the second surface 181a of the second leg portion 181 face each other.

[0204] Next, in step S4, the spring member 210 (see Fig.30) is inserted into the slot 12 from the radial inner side through the opening 12a of the slot 12.

[0205] Then, in step S5 , the stator core 10 is heated and the fixing layer 123 b is heated, so that the foaming agent 123 c is foamed and the fixing layer 123 b is expanded. Thus, the coil portion 130 is fixed to the slot 12 at least in the axial direction.

[0206] In addition, the other structures of the second embodiment are the same as those of the above-mentioned first embodiment.

[0207] [Third Embodiment]

[0208] Next, refer to Figure 36 to Figure 40 , a stator 300 of a third embodiment is described. In the stator 300 of the third embodiment, unlike the above-mentioned second embodiment in which the fixing layer 123b is provided on the entire surface of the insulating layer 123a, the fixing layer 223b is partially provided on the insulating layer 223a. In addition, the same reference numerals as those of the second embodiment are used to illustrate the same structures as those of the second embodiment, and the description thereof is omitted.

[0209] [Stator structure]

[0210] Reference Figure 36 to Figure 40 , the structure of the stator 300 of the third embodiment will be described. In addition, the stator 300 is an example of the "armature" of the technical claim.

[0211] like Fig.36 and Fig.37 As shown, the stator 300 includes a sheet-shaped insulating member 221 and a coil portion 130 .

[0212] like Fig.38 As shown, the insulating component 221 includes a contact portion insulating portion 221c formed in a manner that a radially outer opposing surface insulating portion 221a of a pair of radially adjacent opposing surface insulating portions 221a and a circumferential surface insulating portion 221b arranged on one side of the circumference and a radially inner opposing surface insulating portion 221a of a pair of opposing surface insulating portions 221a and a circumferential surface insulating portion 221b arranged on the other side of the circumference are continuous.

[0213] In addition, the stator 300 includes a core leg insulating portion 222 which is provided between the slot 12 and the coil portion 130 and is formed integrally with the contact portion insulating portion 221 c.

[0214] Specifically, the core leg insulating portion 222 is continuous with the outermost diameter opposing surface insulating portion 221a and is located on one side of the circumferential direction of the slot 12 (at Fig.38The core leg insulating portion 222 has an insulating portion 222a on one side (left side in the figure) provided between the slot 12 (circumferential side surface 13a) and the coil portion 130 (circumferential surface 190b). In addition, the core leg insulating portion 222 has an insulating portion 221a on the opposite side of the innermost diameter and is continuous with the opposite side of the slot 12 (on the other side of the slot 12). Fig.38 The other side insulating portion 222b (right side in the center) is provided between the slot 12 (circumferential side surface 13a) and the coil portion 130 (circumferential surface 190b).

[0215] In addition, the core leg insulating portion 222 includes a radially inner insulating portion 222c provided in a manner continuous with the one side insulating portion 222a and covering the innermost diameter opposing surface insulating portion 221a from the radial inner side. In addition, the core leg insulating portion 222 includes a radially outer insulating portion 222d provided in a manner continuous with the other side insulating portion 222b and covering the outermost diameter opposing surface insulating portion 221a from the radial outer side.

[0216] In addition, if Fig.39 As shown, the contact insulating portion 221c includes: an insulating layer 223a, and a fixing layer 223b including a foaming agent 223c that foams due to heat, and the foaming agent 223c is expanded by foaming, thereby fixing the coil to the coil adjacent to the radial direction. The fixing layer 223b is provided on both sides of the insulating layer 223a. When the fixing layer 223b is heated, the thermosetting resin 223d is cured. Thus, the fixing layer 223b of the contact insulating portion 221c adheres and fixes the adjacent coils to each other. In addition, in Fig.39 In the figure, the stator core 10 and the like are omitted for simplicity.

[0217] In addition, if Fig.40 As shown, the core leg insulating portion 222 includes: an insulating layer 224a, and a fixing layer 224b including a foaming agent 224c that foams due to heat, and by causing the foaming agent 224c to foam and expand, thereby fixing each of the first leg 171 and the second leg 181 relative to the stator core 10 in at least the axial direction. The fixing layer 224b of the core leg insulating portion 222 is configured in a manner that each of the first leg 171 and the second leg 181 is bonded and fixed to the stator core 10. In addition, in Fig.39 and Fig.40 In order to make the insulating member 221 and the core leg insulating portion 222 protrude, they are illustrated in a manner that makes them have a greater thickness than the actual thickness.

[0218] Here, in the third embodiment, the fixing layer 224b (fixing layer 223b) is provided to overlap with the insulating layer 224a (insulating layer 223a) at a position different from the axial position corresponding to the contact portion 190. In other words, in the core foot insulating portion 222 (contact portion insulating portion 221c), only the insulating layer 224a (insulating layer 223a) is provided at the axial position corresponding to the contact portion 190. Specifically, the fixing layer 224b (fixing layer 223b) is provided to be separated from the first step portion 171e (refer to Fig.39 ) is closer to the axial side (Z2 direction side) than the second step portion 181e (refer to Fig.39 ) two parts on the other side of the axial direction (Z1 direction side).

[0219] In addition, the other structures of the third embodiment are the same as those of the above-mentioned second embodiment.

[0220] [Effects of the first to third embodiments]

[0221] In the first to third embodiments, the following effects can be obtained.

[0222] In the first to third embodiments, as described above, in the radial direction, the thickness of the joint (90, 190) is greater than the thickness of the portion (E2) outside the joint (90, 190). Thus, since the thickness of the joint (90, 190) is greater than the thickness of the portion (E2) outside the joint (90, 190) (the joint (90, 190) is not radially recessed compared to the portion (E2) outside the joint (90, 190)), the joint can be squeezed by a clamp (201) or a spring member (210) or the like with sufficient force. As a result, it is possible to prevent the first fan-shaped conductor (70) and the second fan-shaped conductor (80) from being unable to be fully joined. In addition, when the radial thickness of the joint (90, 190) is smaller than the radial thickness of the portion (E2), if the joint (90, 190) is pressed by a fixture (201) or a spring member (210), the coil portion (30, 130) (first fan-shaped conductor (70, 170), second fan-shaped conductor (80, 180)) bends. Therefore, by configuring as described above, even when the joint (90, 190) is pressed by a fixture (201) or a spring member (210), the coil portion (30, 130) can be prevented from bending. In addition, the radial thickness of the first surface side portion (71b, 171c) is smaller than the radial thickness of the first leg main body portion (71d, 171d), and the radial thickness of the second surface side portion (81b, 181c) is smaller than the radial thickness of the second leg main body portion (81d, 181d), thereby ensuring the area of ​​the joining surface and preventing the radial thickness of the joining portion (90, 190) from increasing.

[0223] In the first embodiment, as described above, in the plurality of first sector-shaped conductors (70) and the plurality of second sector-shaped conductors (80) arranged in one slot (12), the minimum value (t21) of the range of dimensional variation of the total thickness (t21) in the radial direction of the joint (90) (E1) is min ) is the maximum value (t22) of the range of dimensional deviation of the radial total thickness (t22) of the portion (E2) max ) or more. If so configured, even if the total radial thickness (t21) of the joint (90) is the minimum value (t21 min ), and is also greater than the total radial thickness (t22) of portion (E2), so that the joint (90) can be squeezed by the clamp (201) with sufficient force.

[0224] In the first embodiment, as described above, in the plurality of first fan-shaped conductors (70) and the plurality of second fan-shaped conductors (80) arranged in one slot (12), the minimum value (t21min) of the range of dimensional deviation of the radial total thickness (t21) of the joint (90) (E1) is the maximum value (t22min) of the range of dimensional deviation of the radial total thickness (t22) of the portion (E2). max ) or more. If so configured, even if the total radial thickness (t21) of the joint (90) is the minimum value (t21 min ), and is also greater than the total radial thickness (t22) of the portion (E2), so that the joining portion (90) can be pressed by the jig (201) with sufficient force. As a result, it is possible to prevent the first fan-shaped conductor (70) and the second fan-shaped conductor (80) from being insufficiently joined due to the deviation in the size of the fan-shaped conductor (40).

[0225] In the first embodiment, as described above, the minimum value (t2) of the range of dimensional variation of the radial thickness (t2) of the first surface side portions (71b, 171c) of the plurality of first sector-shaped conductors (70) arranged in one slot (12) is min ) is the maximum value (t3) of the range of dimensional deviation of the thickness (t3) of the first leg body (71d, 171d) of a plurality of first fan-shaped conductors (70) arranged in one slot (12). max ), the minimum value (t4) of the range of dimensional deviation of the radial thickness (t4) of the second surface side portion (81b, 181c) of a plurality of second fan-shaped conductors (80) arranged in one slot (12) is greater than 1 / 2 of the second fan-shaped conductors (80) arranged in one slot (12). min ) is the maximum value (t5) of the range of dimensional deviation of the thickness (t5) of the second leg body parts (81d, 181d) in a plurality of second fan-shaped conductors (80) arranged in one slot (12). max). If so configured, even if the radial thickness (t2, t4) of the first surface side portion (71b, 171c) and the second surface side portion (81d, 181d) (joining portion (90)) is the minimum value (t2 min 、t4 min ) and is also larger than the radial thickness (t3, t5) of the first leg main body (71d, 171d) and the second leg main body (81d, 181d) (part (E2)), so that the first surface side portion (71b, 171c) and the second surface side portion (81d, 181d) (joining portion (90)) can be squeezed by the clamp (201) and with sufficient force.

[0226] In the first embodiment, as described above, in the plurality of first sector-shaped conductors (70) and the plurality of second sector-shaped conductors (80) arranged in one slot (12), the minimum value (t21) of the range of dimensional variation of the total thickness (t21) in the radial direction of the joint (90) including the conductive adhesive (91) is min ) is the maximum value (t22) of the range of dimensional deviation of the radial total thickness (t22) of the portion (E2) max ) or more. If so constituted, even when a conductive adhesive (91) is provided between the first surface (71a) and the second surface (81a), the joining portion (90) can be joined with sufficient force by the clamp (201).

[0227] In the first embodiment, as described above, among the plurality of first sector-shaped conductors (70) and the plurality of second sector-shaped conductors (80) arranged in one slot (12), the minimum value (t21) of the range of dimensional variation of the radial total thickness (t21) of the joint portion (90) including the joint portion insulating member (21) is min ) is the maximum value (t22) of the range of dimensional deviation of the radial total thickness (t22) of the portion (E2) including the joint insulating component (21) max If so constituted, even when a joint insulating member (21) is provided between the joint (90) and on both sides of the portion (E2), the joint (90) can be squeezed with sufficient force by the clamp (201).

[0228] In the first embodiment, as described above, in the plurality of first sector-shaped conductors (70) and the plurality of second sector-shaped conductors (80) arranged in one slot (12), the minimum value (t21) of the range of dimensional variation of the total thickness (t21) in the radial direction of the joint (90) is min ) is less than the radial width (W3) of the slot (12). If so constituted, it is possible to prevent the engaging portion (90) from protruding from the slot (12).

[0229] In the first to third embodiments, as described above, the joints (90, 190) of the plurality of first fan-shaped conductors (70, 170) and the plurality of second fan-shaped conductors (80, 180) arranged in one slot (12) are arranged so as to overlap each other when viewed from the radial direction. With such a configuration, unlike the case where the plurality of joints (90, 190) are arranged so as not to overlap each other when viewed from the radial direction (arranged staggered in the axial direction), the plurality of joints (90, 190) cannot be pressed together by a jig (201) or a spring member (210) having a relatively small axial length.

[0230] In the first to third embodiments, as described above, each of the first fan-shaped conductor (70, 170) and the second fan-shaped conductor (80, 180) has a U-shape including a pair of first legs (71, 171) and a pair of second legs (81, 181). With such a configuration, the lengths (L1, L31) of the pair of first legs (71, 171) of the first fan-shaped conductor (70, 170) are substantially the same, and the lengths (L2, L32) of the pair of second legs (81, 181) of the second fan-shaped conductor (80, 180) are substantially the same. As a result, the axial positions of the plurality of joints (90, 190) can be made substantially the same, so that all of the plurality of joints (90, 190) arranged in one slot (12) can be arranged so as to overlap each other when viewed from the radial direction.

[0231] In the first to third embodiments, as described above, each of the first surface (71a, 171a) and the second surface (81a, 181a) is provided so as to extend parallel to the axial direction, and the first surface (71a, 171a) and the second surface (81a, 181a) are joined to each other in the radial direction. Here, when the first surface (71a, 171a) and the second surface (81a, 181a) intersect with the axial direction (when the first surface (71a, 171a) and the second surface (81a, 181a) are inclined surfaces), if the first surface (71a, 171a) and the second surface (81a, 181a) are pressed from the radial direction by the jig (201) or the spring member (210), the first surface (71a, 171a) and the second surface (81a, 181a) (inclined surfaces) are used as sliding surfaces, and the first leg portion (71, 171) and the second leg portion (81, 181) are moved in the axial direction so as to separate from each other. Therefore, by configuring as described above, when the first surface (71a, 171a) and the second surface (81a, 181a) are radially pressed by the clamp (201), the first leg (71, 171) and the second leg (81, 181) can be prevented from moving in the axial direction.

[0232] [Modifications]

[0233] In addition, the embodiments disclosed this time should be considered to be illustrative in all points and not limiting the present invention. The scope of the present invention is not indicated by the description of the above embodiments but by the claims, and also includes all changes (modifications) within the meaning and scope equivalent to the claims.

[0234] For example, in the first embodiment, an example is shown in which each of the first surface 71a and the second surface 81a extends parallel to the axial direction, but the present invention is not limited thereto. For example, each of the first surface 71a and the second surface 81a may be inclined at a predetermined angle (e.g., less than 5 degrees) relative to the axial direction.

[0235] In addition, in the first embodiment, an example is shown in which the second insulating member 21 is arranged from the first leg body 71d to the second leg body 81d, but the present invention is not limited thereto. For example, the second insulating member 21 may be arranged between the joints 90 (between the first surface arrangement portion 71b and the second surface arrangement portion 81b) instead of between the first leg body 71d and the second leg body 81d.

[0236] In addition, in the first embodiment described above, an example is shown in which all the engagement portions 90 arranged in one slot 12 are arranged in a manner of overlapping each other when viewed from the radial direction, but the present invention is not limited to this. For example, adjacent engagement portions 90 may partially overlap each other in one slot 12, while non-adjacent engagement portions 90 may not overlap each other. In other words, a plurality of engagement portions 90 arranged in one slot 12 may be arranged in a manner of gradually staggering in the axial direction from the radial inner side toward the radial outer side.

[0237] In addition, in the first embodiment, an example is shown in which each of the first gap portion 74 and the second gap portion 84 is arranged inside the slot 12, but the present invention is not limited thereto. For example, a portion of the first gap portion 74 and the second gap portion 84 (for example, only the second gap portion 84) may be arranged outside the slot 12 (see Fig.41 ), the first gap portion 74 and the second gap portion 84 may be integrally arranged outside the slot 12 (see Fig.42 ).

[0238] In addition, in the above-mentioned first embodiment, an example is shown in which each of the first gap portion 74 and the second gap portion 84 is arranged near the end face 10a (one side end face), but the present invention is not limited to this. For example, each of the first gap portion 74 and the second gap portion 84 may be arranged near the end face 10a (one side end face) and the end face 10b (the other side end face). In this case, as shown in FIG. 43, a pair of first legs 271 of the first fan-shaped conductor 270 is configured in a manner that the lengths are different from each other (refer to FIG. 43 (A)), and a pair of second legs 281 of the second fan-shaped conductor 280 is configured in a manner that the lengths are different from each other (refer to FIG. 43 (B)). That is, the first fan-shaped conductor 270 and the second fan-shaped conductor 280 each have a J-shape (approximately a J-shape).

[0239] In the first embodiment, the second leg portion 81 is longer than the first leg portion 71 , but the present invention is not limited thereto. For example, the second leg portion 81 may be shorter than the first leg portion 71 .

[0240] In addition, in the first embodiment described above, an example is shown in which the second conductor 80 with a longer leg is a conductor on the leading side, and the first conductor 70 with a shorter leg is a conductor on the anti-leading side, but the present invention is not limited to this. For example, the second conductor 80 with a longer leg may be a conductor on the anti-leading side, and the first conductor 70 with a shorter leg may be a conductor on the leading side.

[0241] In the first embodiment, the first insulating member 20 and the second insulating member 21 (joint insulating member) are sheet-shaped, but the present invention is not limited thereto. The present invention can also be applied to a stator having the first insulating member 20 and the second insulating member 21 which are not sheet-shaped.

[0242] In the first embodiment, the first gap 74 is provided between the front end 71c of the first leg 71 and the second leg 81, and the second gap 84 is provided between the front end 81c of the second leg 81 and the first leg 71, but the present invention is not limited thereto. Fig.44 As in the fourth modified example shown in the figure, the present invention can also be applied when no gap is provided between the front end of the first leg portion 371 and the second leg portion 381 and between the front end of the second leg portion 381 and the first leg portion 371 .

[0243] In the first embodiment, the minimum value t2 of the dimensional variation range of the radial thickness t2 of the first surface arrangement portion 71b is shown. min is the maximum value t3 of the range of dimensional variation of the thickness t3 of the first leg portion main body 71d. maxand the minimum value t4 of the range of the dimensional deviation of the radial thickness t4 of the second surface arrangement portion 81b is min The maximum value t5 of the range of the dimensional variation of the thickness t5 of the second leg body 81d is max 1 / 2 of t2, but the present invention is not limited to this. In the present invention, the minimum value t2 may also be min is the maximum value t3 max The value is greater than 1 / 2 of the value above, and the minimum value t4 min is the maximum value t5 max For example, the minimum value t2 min is the maximum value t3 max 1 / 3 or more (or 2 / 3 or more), and the minimum value t4 min is the maximum value t5 max More than 2 / 3 (or more than 1 / 3).

[0244] Description of Reference Numerals

[0245] 10… stator core (armature core); 12… slot; 21… second insulating member (joint insulating member); 30… coil portion; 70, 170, 270… first conductor (first sector conductor); 71, 171, 271, 371… first leg; 71a, 171a… first surface; 71b… first surface configuration portion (first surface side portion); 71c… front end portion (front end portion of first leg); 71d, 171d… first leg body; 80, 180, 280… second conductor (second sector conductor); 81, 181, 281, 381… second leg; 81a, 181a… second surface; 81b… second surface configuration portion (second surface side portion); 81c… front end portion (front end portion of second leg) end); 81d, 181d…second leg main body; 90…joining portion; 91…conductive adhesive; 100, 200, 300…stator (armature); 171c…first surface forming portion (first surface side portion); 181c…second surface forming portion (second surface side portion); 190…contact portion; E2…portion where the first surface and the second surface are not provided; t2…thickness (thickness of the first surface side portion); t3…thickness (thickness of the first leg main body); t4…thickness (thickness of the second surface side portion); t5…thickness (thickness of the second leg main body); t21…thickness (thickness of the joining portion); t22…thickness (thickness of the portion where the first surface and the second surface are not provided); W3…width (width of the slot).

Claims

1. An armature, characterized in that: have: an armature core provided with a plurality of slots extending in the axial direction; A first sector-shaped conductor including a first leg portion disposed on one side of the axial direction of the armature core and extending toward the other side of the axial direction; a plurality of second sector-shaped conductors including a second leg portion disposed on the other side of the armature core in the axial direction and extending toward one side in the axial direction; and The coil portion includes a joint portion, wherein at least a portion of a first surface provided at the front end side of each of the plurality of first leg portions of the first sector-shaped conductors and provided in a manner extending along the axial direction is joined with at least a portion of a second surface provided at the front end side of each of the plurality of second leg portions of the second sector-shaped conductors and provided in a manner extending along the axial direction in one of the slots or outside the axial direction of one of the slots, The first leg portion comprises: a first leg portion main body portion; and a first surface side portion, which is provided with the first surface and has a radial thickness smaller than that of the first leg portion main body portion. The second leg portion comprises: a second leg portion main body portion; and a second surface side portion, which is provided with the second surface and has a radial thickness smaller than that of the second leg portion main body portion. In the radial direction, the thickness of the joint portion is greater than the thickness of the portion other than the joint portion. In the plurality of first sector-shaped conductors and the plurality of second sector-shaped conductors radially arranged in parallel in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion is greater than or equal to the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided, and the dimensional deviation refers to the dimensional deviation generated in the manufacture of each of the first leg and the second leg, It is characterized in that The armature further includes a conductive adhesive for bonding the first surface and the second surface, and the first leg portion and the second leg portion are electrically connected. Among the plurality of first fan-shaped conductors and the plurality of second fan-shaped conductors arranged in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joining portion including the conductive adhesive is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided.

2. The armature according to claim 1, characterized in that The minimum value of the range of dimensional deviation of the radial thickness of the first surface side portion of the plurality of the first sector-shaped conductors arranged in one of the slots is at least 1 / 2 of the maximum value of the range of dimensional deviation of the thickness of the first leg body portion of the plurality of the first sector-shaped conductors arranged in one of the slots, The minimum value of the range of dimensional variation in the radial thickness of the second surface side portion of the plurality of second sector-shaped conductors arranged in one slot is greater than 1 / 2 of the maximum value of the range of dimensional variation in the thickness of the second leg body portion of the plurality of second sector-shaped conductors arranged in one slot.

3. The armature according to claim 1, characterized in that further comprising a sheet-shaped joint portion insulating member for insulating the joint portions adjacent to each other in the radial direction in the joint portion, Among the plurality of the first fan-shaped conductors and the plurality of the second fan-shaped conductors arranged in one of the slots, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion including the joint insulating component is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided.

4. The armature according to claim 2, characterized in that further comprising a sheet-shaped joint portion insulating member for insulating the joint portions adjacent to each other in the radial direction in the joint portion, Among the plurality of the first fan-shaped conductors and the plurality of the second fan-shaped conductors arranged in one of the slots, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion including the joint insulating component is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided.

5. The armature according to claim 3, characterized in that The joint insulating member is also arranged between the first leg body and the second leg body. Among the plurality of the first fan-shaped conductors and the plurality of the second fan-shaped conductors arranged in one of the slots, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion including the joint insulating component is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion including the joint insulating component and where the first surface and the second surface are not provided.

6. The armature according to claim 4, characterized in that The joint insulating member is also arranged between the first leg body and the second leg body. Among the plurality of the first fan-shaped conductors and the plurality of the second fan-shaped conductors arranged in one of the slots, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion including the joint insulating component is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion including the joint insulating component and where the first surface and the second surface are not provided.

7. The armature according to any one of claims 1 to 6, characterized in that: In the plurality of the first sector-shaped conductors and the plurality of the second sector-shaped conductors arranged in one slot, a maximum value of a range of dimensional variation of a total thickness in the radial direction of the joining portion is equal to or less than a width of the slot in the radial direction.

8. The armature according to any one of claims 1 to 6, characterized in that: The joint portions of the plurality of first sector-shaped conductors and the plurality of second sector-shaped conductors arranged in one slot are arranged so as to overlap with each other when viewed in the radial direction.

9. The armature according to claim 7, characterized in that The joint portions of the plurality of first sector-shaped conductors and the plurality of second sector-shaped conductors arranged in one slot are arranged so as to overlap with each other when viewed in the radial direction.

10. The armature according to claim 8, characterized in that Each of the first sector-shaped conductor and the second sector-shaped conductor has a U-shape including a pair of the first leg portions and a pair of the second leg portions. The junctions of the plurality of first sector-shaped conductors in a U shape and the plurality of second sector-shaped conductors in a U shape arranged in one slot are arranged to overlap each other when viewed in the radial direction.

11. The armature according to claim 9, characterized in that Each of the first sector-shaped conductor and the second sector-shaped conductor has a U-shape including a pair of the first leg portions and a pair of the second leg portions. The junctions of the plurality of first sector-shaped conductors in a U shape and the plurality of second sector-shaped conductors in a U shape arranged in one slot are arranged to overlap each other when viewed in the radial direction.

12. The armature according to any one of claims 1 to 6 and 9 to 11, characterized in that: Each of the first surface and the second surface is arranged to extend parallel to the axial direction, The first surface and the second surface are joined to each other in the radial direction.

13. The armature according to claim 7, characterized in that Each of the first surface and the second surface is arranged to extend parallel to the axial direction, The first surface and the second surface are joined to each other in the radial direction.

14. The armature according to claim 8, characterized in that Each of the first surface and the second surface is arranged to extend parallel to the axial direction, The first surface and the second surface are joined to each other in the radial direction.

15. An armature, characterized in that: It comprises: an armature core provided with a plurality of slots extending in the axial direction; a plurality of first sector-shaped conductors including a first leg portion disposed on one side of the axial direction of the armature core and extending toward the other side of the axial direction; a plurality of second sector-shaped conductors including a second leg portion disposed on the other side of the armature core in the axial direction and extending toward one side in the axial direction; and The coil portion includes a joint portion, wherein at least a portion of a first surface provided at the front end side of each of the plurality of first leg portions of the first sector-shaped conductors and provided in a manner extending along the axial direction is joined with at least a portion of a second surface provided at the front end side of each of the plurality of second leg portions of the second sector-shaped conductors and provided in a manner extending along the axial direction in one of the slots or outside the axial direction of one of the slots, The first leg portion has a first leg portion main body portion having a radial thickness greater than a first surface side portion provided with the first surface, The minimum value of the range of the dimensional deviation of the radial thickness of the first surface side portion of the plurality of the first sector-shaped conductors arranged in one of the slots is more than 1 / 2 of the maximum value of the range of the dimensional deviation of the thickness of the first leg body portion of the plurality of the first sector-shaped conductors arranged in one of the slots, and the dimensional deviation refers to the dimensional deviation generated in the manufacture of each of the first leg and the second leg, The second leg portion has a second leg portion main body portion having a thickness in the radial direction greater than a second surface side portion provided with the second surface, The minimum value of the range of dimensional deviation of the radial thickness of the second surface side portion of the plurality of second fan-shaped conductors arranged in one slot is more than 1 / 2 of the maximum value of the range of dimensional deviation of the thickness of the second leg body portion of the plurality of second fan-shaped conductors arranged in one slot, In the plurality of the first sector-shaped conductors and the plurality of the second sector-shaped conductors radially arranged in parallel in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion is greater than or equal to the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided. The armature is characterized in that the armature further comprises a conductive adhesive for bonding the first surface and the second surface, and the first leg portion and the second leg portion are electrically connected. Among the plurality of first fan-shaped conductors and the plurality of second fan-shaped conductors arranged in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joining portion including the conductive adhesive is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided.

16. A method for manufacturing an armature, which is a method for manufacturing an armature core provided with a plurality of slots extending in the axial direction, the method for manufacturing the armature comprising: a step of preparing a plurality of first sector-shaped conductors including a first leg portion disposed on one side of the armature core in the axial direction and extending toward the other side of the axial direction; a step of preparing a plurality of second sector-shaped conductors, the plurality of second sector-shaped conductors including a second leg portion disposed on the other side of the armature core in the axial direction and extending toward one side in the axial direction; a step of moving the plurality of first sector-shaped conductors from one side of the armature core to a side of the slot; A step of moving the plurality of second sector-shaped conductors from the other side in the axial direction of the armature core to the slot side; and a step of forming a joint portion by joining at least a portion of a first surface provided on the front end side of each of the plurality of first fan-shaped conductors and extending along the axial direction with at least a portion of a second surface provided on the front end side of each of the plurality of second fan-shaped conductors and extending along the axial direction in one of the slots or outside the axial direction of one of the slots, The step of preparing the first fan-shaped conductor is a step of preparing the first fan-shaped conductor, wherein the first leg of the first fan-shaped conductor has: a first leg body; and a first surface side portion provided with the first surface and having a radial thickness smaller than that of the first leg body. The step of preparing the second fan-shaped conductor is a step of preparing the second fan-shaped conductor, wherein the second leg of the second fan-shaped conductor has: a second leg body; and a second surface side portion, which is provided with the second surface and has a radial thickness smaller than that of the second leg body. In the step of preparing the first fan-shaped conductor and the step of preparing the second fan-shaped conductor, the first fan-shaped conductor and the second fan-shaped conductor are prepared in such a manner that the thickness of the joint portion is greater than the thickness of the portion other than the joint portion in the radial direction. In the plurality of first sector-shaped conductors and the plurality of second sector-shaped conductors radially arranged in parallel in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joint portion is greater than or equal to the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided, and the dimensional deviation refers to the dimensional deviation generated in the manufacture of each of the first leg and the second leg, It is characterized in that The armature further includes a conductive adhesive for bonding the first surface and the second surface, and the first leg portion and the second leg portion are electrically connected. Among the plurality of first fan-shaped conductors and the plurality of second fan-shaped conductors arranged in one slot, the minimum value of the range of dimensional deviation of the radial total thickness of the joining portion including the conductive adhesive is greater than the maximum value of the range of dimensional deviation of the radial total thickness of the portion where the first surface and the second surface are not provided.

Images