Stator of a rotating electric machine

Abstract

A stator for a rotary electric machine is provided that improves the reliability of the electrical connection at the connection between the conductive component and the coil. The stator (10) of the rotary electric machine (MG) includes: (a) a coil (30) wound around a stator core (20); (b) a power line (50) serving as a conductive component, having a main line (54) that electrically connects one end (54t) to a terminal (70) of an external component, and a first branch line (56) and a second branch line (58) that branch off from the other end of the main line (54), i.e., a branch line (52), and the first branch line (56) is electrically connected to the lead wire (40) of the coil (30) by a welding part (= connection part) (46); and (c) a resin part (90) that seals at least a portion of the coil end (32) and the second branch line (58) in the coil (30).

Description

Technical Field

[0001] The present invention relates to the stator of a rotating electric machine that uses a connecting part to electrically connect a coil wound on the stator core to a conductive component. Background Technology

[0002] A known stator of a rotary electric machine connects a coil wound around the stator core to a power line, which is a conductive component, via a connecting part. Furthermore, it is known to connect one end of the power line to an external component, seal and fix the other end of the power line with resin, and electrically connect the power line to the coil between the two ends. For example, the stator of the rotary electric machine described in Patent Document 1 is such a stator.

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-161716 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In the stator of the rotary electric machine described in Patent Document 1, the two ends of the power line are fixed by connecting one end of the power line to an external component and fixing the other end of the power line to a resin part. When the two ends of the power line are fixed, the vibration of the power line is suppressed. As a result, in the stator of the rotary electric machine described in Patent Document 1, the magnitude of vibration (e.g., the amplitude or rate of change of vibration) applied to the connection portion provided between one end and the other end of the power line that is electrically connected to the coil is suppressed, and the reliability of the electrical connection at the connection portion is easily ensured. However, it is desirable to further improve the reliability of the electrical connection at the connection portion.

[0008] The present invention was made against the background described above, and its object is to provide a stator of a rotating electric machine that can improve the reliability of the electrical connection at the connection between the conductive component and the coil.

[0009] Methods for solving problems

[0010] The key point of the first invention is that a stator of a rotary electric machine comprises: (a) a coil wound around a stator core; (b) a conductive member having a main section electrically connected at one end in the longitudinal direction to an external member and a first branch section and a second branch section branching out from a branch section at the other end in the longitudinal direction of the main section, and the first branch section being electrically connected to the coil by a connecting portion; and (c) a resin section for sealing at least a portion of the coil end in the coil and at least a portion of the second branch section.

[0011] The key point of the second invention is that, in the first invention, the second branch portion has a sealed area that is sealed by the resin portion and a non-sealed area that is not sealed by the resin portion.

[0012] The key point of the third invention is that, in the second invention, the distance of the non-sealed region in the length direction of the second branch is shorter than the distance from the branch to the end in the length direction of the main branch.

[0013] The key point of the fourth invention is that, in the second or third invention, (a) the second branch portion has a plate-like portion in the non-sealed area, and (b) in the plate-like portion of the second branch portion, the second branch portion is bent in a manner different from the plate thickness direction.

[0014] The key point of the fifth invention is that, in any of the second to fourth inventions, compared with the cross-sectional shape of the second branch portion in the branch portion, the cross-sectional shape of the second branch portion at the boundary between the sealed region and the unsealed region becomes rounded.

[0015] The key point of the sixth invention is that, in any one of the first to fifth inventions, (a) the first branch portion has a plate-shaped portion, (b) the coil has a plate-shaped portion, and (c) the plate surface of the plate-shaped portion in the first branch portion and the plate surface of the plate-shaped portion in the coil are electrically connected by welding.

[0016] Invention Effects

[0017] The stator of the rotary electric machine according to the first invention comprises: (a) a coil wound around a stator core; (b) a conductive member having a main section electrically connected to an external component at one end in the longitudinal direction, and a first branch section and a second branch section branching off from a branch section at the other end in the longitudinal direction of the main section, and the first branch section being electrically connected to the coil by a connecting portion; and (c) a resin section sealing at least a portion of the coil end in the coil and at least a portion of the second branch section. Thus, the first branch section branches off from a branch section located between one end of the main section connected to the external component and the second branch section sealed and fixed by the resin section, and the first branch section is electrically connected to the coil by a connecting portion. Therefore, compared to the case where the conductive member only has a main section and is electrically connected to the coil between one end of the main section connected to the external component and the other end of the main section sealed by the resin section, the force applied to the connecting portion connecting the first branch section to the coil during vibration is suppressed, and the reliability of the electrical connection at the connecting portion is easily ensured.

[0018] According to the stator of the rotary motor of the second invention, in the first invention, the second branch section has a sealed area that is sealed by the resin section and a non-sealed area that is not sealed by the resin section. When the second branch section has a non-sealed area, compared to the case where this is not the case, vibration is more easily absorbed through elastic deformation of this non-sealed area, thus reducing the force applied from the second branch section to the surface of the resin section during vibration. Consequently, cracks are less likely to occur between the resin section and the second branch section, and the effect of fixing the second branch section to the resin section is easily maintained. Therefore, the force applied to the connection section connecting the first branch section and the coil during vibration is suppressed, easily ensuring the reliability of the electrical connection at the connection section.

[0019] According to the stator of the rotary motor of the third invention, in the second invention, the distance of the non-sealed region in the longitudinal direction of the second branch section is shorter than the distance from the branch to the end in the longitudinal direction of the main line section. Compared with the external component connected to one end of the main line section, the resin part sealing the coil end and the coil can move more easily in conjunction. When the distance of the sealed region in the longitudinal direction of the second branch section is shorter than the distance from the branch to the end in the longitudinal direction of the main line section, the magnitude of the relative vibration at the branch section relative to the resin part during vibration is smaller than when this is not the case. Therefore, the force applied to the connection between the first branch section branching from the branch section and the coil during vibration is suppressed, and the reliability of the electrical connection at the connection is easily ensured.

[0020] According to the stator of the rotary motor of the fourth invention, in the second or third invention, (a) the second branch portion has a plate-like portion in the non-sealed region, and (b) in the plate-like portion of the second branch portion, the second branch portion is bent in a manner different from the thickness direction. The plate-like portion is more prone to elastic deformation in the thickness direction compared to its length and width directions. When the plate-like portion in the non-sealed region of the second branch portion is bent in a manner different from the thickness direction, there are multiple directions in which the plate-like portion is prone to elastic deformation, i.e., the thickness direction. Therefore, compared to the case where the plate-like portion is not bent, there are multiple directions in which the plate-like portion is more prone to absorbing vibration, and thus the force applied from the second branch portion to the surface of the resin portion during vibration is more easily reduced. As a result, it is difficult for cracks to occur between the resin portion and the second branch portion, and it is easier to maintain the effect of fixing the second branch portion to the resin portion. Therefore, the force applied to the connection portion connecting the first branch portion and the coil during vibration is suppressed, and the reliability of the electrical connection at the connection portion is easily ensured.

[0021] According to the stator of the rotary motor of the fifth invention, in any of the second to fourth inventions, the cross-sectional shape of the second branch portion at the boundary between the sealed region and the non-sealed region is rounded compared to the cross-sectional shape of the second branch portion in the branch. When the cross-sectional shape of the second branch portion at the boundary between the sealed region and the non-sealed region is rounded compared to the cross-sectional shape of the second branch portion in the branch, the stress concentration caused by the force applied from the second branch portion in the surface portion of the resin portion during vibration is mitigated, compared to the case where this is not the case. When the stress concentration generated in the surface portion of the resin portion is mitigated, cracking is less likely to occur between the resin portion and the second branch portion. Therefore, it is easier to maintain the effect of fixing the second branch portion to the resin portion, and the force applied to the connection portion connecting the first branch portion and the coil during vibration is suppressed, thus easily ensuring the reliability of the electrical connection at the connection portion.

[0022] According to the stator of the rotary electric machine of the sixth invention, in any of the first to fifth inventions, (a) the first branch section has a plate-shaped portion, (b) the coil has a plate-shaped portion, and (c) the plate surface of the plate-shaped portion in the first branch section and the plate surface of the plate-shaped portion in the coil are electrically connected by welding. In the plate-shaped portion, the plate surface is more likely to increase the connection area with other components compared to the side surface. When the plate surface of the plate-shaped portion in the first branch section and the plate surface of the plate-shaped portion in the coil are welded, it is easier to form a structure that increases the connection area in the connection portion connecting the first branch section and the coil compared to the case where this is not done. Therefore, it is easier to ensure the reliability of the electrical connection at the connection portion. Attached Figure Description

[0023] Figure 1 This is a perspective view illustrating the schematic structure of the stator of a rotary motor mounted on a vehicle according to Embodiment 1 of the present invention.

[0024] Figure 2 It is against the general Figure 1 A perspective view illustrating the structure of the power line connecting the coil leads to the external components.

[0025] Figure 3 yes Figure 2 The diagram showing the circumferential views of the dynamic lines.

[0026] Figure 4 This diagram illustrates the structure of the power line connecting the coil leads to the external components in the stator of the rotary electric machine according to Embodiment 2 of the present invention.

[0027] Figure 5 This diagram illustrates the structure of the power line connecting the coil leads to the external components in the stator of the rotary electric machine according to Embodiment 3 of the present invention. Detailed Implementation

[0028] Hereinafter, various embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be noted that in the embodiments described below, the drawings are appropriately simplified or modified for ease of understanding, and the dimensional ratios and shapes of the parts are not necessarily depicted accurately. Furthermore, in each embodiment, the description focuses on the parts that differ from the prior embodiments, and parts that are substantially functionally common with the prior embodiments are labeled with the same reference numerals and their descriptions are appropriately omitted. Hereinafter, in this specification, "direction parallel to axis CL," "radial direction of stator core 20," and "circumferential direction of stator core 20" will be abbreviated as "axis CL direction," "radial direction," and "circumferential direction," respectively.

[0029]

Example 1

[0030] Figure 1 This is a perspective view illustrating the schematic structure of the stator 10 of the rotary motor MG mounted on a vehicle 100 according to Embodiment 1 of the present invention.

[0031] A rotating electric motor MG is a rotating electric machine installed in a vehicle 100, such as a hybrid vehicle or an electric vehicle, that functions as both a motor and a generator; it is a so-called electric generator. The rotating electric motor MG serves as a drive source for the vehicle 100. The rotating electric motor MG has a cylindrical stator 10 centered on an axis CL and a rotor (not shown) disposed on the inner circumference of the stator 10. The rotor is capable of rotating by a rotating magnetic field generated by the stator 10. Figure 1 In the diagram, axis CL is shown vertically along the plane of the paper. However, in a case where, for example, the rotary motor MG is mounted on vehicle 100, axis CL is horizontal. It should be noted that the horizontal direction in this case does not have to be strictly horizontal; it can be inclined relative to the strictly horizontal direction. That is, axis CL only needs to extend horizontally.

[0032] Stator 10 includes stator core 20, coil 30, and power line 50 (see reference). Figure 2The stator core 20 is, for example, cylindrical about the axis CL. While cylindrical is preferred, its shape is not limited to cylindrical; any cylindrical shape is acceptable. At equal angular intervals (360 / 48 degrees in this embodiment), the inner circumference of the stator core 20 has multiple slots, or slots 22, having a depth in the radial direction towards the outer periphery and extending in a direction parallel to the axis CL. In this embodiment, there are 48 slots 22. Teeth 24 are formed between adjacent slots 22. A coil 30 is disposed within the slot 22 and wound around the teeth 24. The teeth 24 are the portion that becomes an electromagnet by allowing alternating current to flow through the coil 30. The portion of the stator core 20 other than the teeth 24, which serves as the path of the magnetic lines of force between the teeth 24 that become electromagnets, is a yoke.

[0033] The coil 30 is made of, for example, a rectangular conductor with a rectangular cross-section perpendicular to its length direction, and multiple coils are arranged from the inner circumference to the outer circumference within the slot 22. The portion of the coil 30 protruding from the slot 22 towards the axis CL is the coil end 32 (see reference). Figure 3 In the axial direction CL, the coil end 32 is located on one end 20a side and the other end 20b side of the stator core 20. The coil 30 is, for example, a three-phase winding of U phase, V phase, and W phase. After protruding in the axial direction CL, the end of each phase of the coil 30 is bent in an L-shape in the direction toward the radial outer periphery to become a lead wire 40. The front end of the lead wire 40 has a plate-like portion 40p, the thickness direction of which is axial direction CL. It should be noted that in this specification, the cross-section of the "plate-like portion" perpendicular to its length direction is rectangular, the direction perpendicular to the side of the shorter of the two sets of opposite sides is the thickness direction, and the direction perpendicular to the side of the longer of the two sets of opposite sides is the width direction. The plate-like portion 40p of the lead wire 40 in the coil 30 is equivalent to the "plate-like portion in the coil" in this invention.

[0034] Figure 2 It is against the general Figure 1 This is a perspective view illustrating the structure of the lead wire 40 of the coil 30 connected to the power line 50 of the external component. Figure 3 yes Figure 2 The diagram shows the circumferential view of the dynamic line 50. Figure 2 In the image, the resin portion 90 and the portion sealed by the resin portion 90 are shown in dashed lines. Figure 3 In the diagram, the portion sealed by the resin section 90 is shown in dashed lines. Three power lines 50 are provided corresponding to each of the U, V, and W phases of a three-phase AC circuit, but each has the same structure; therefore, one of them will be described below as an example. It should be noted that the power line 50 corresponds to the "conductive component" in this invention.

[0035] The conductor, terminal 70, fixed to a terminal block (not shown), is connected to a power control unit (e.g., an inverter) that converts DC power from an external power source (not shown, such as a battery) into AC power and supplies it to the rotating motor MG for driving, or converts AC power generated by the rotating motor MG into DC power and stores it in the battery. That is, terminal 70 is connected to the external power source that drives the rotating motor MG. Terminal 70 is, for example, a long, strip-shaped plate-like metal body, with its length direction being radial and its thickness direction being the axial direction CL. It should be noted that terminal 70 corresponds to the "external component" in this invention. The "external component" refers to a component located outside the stator 10, connected to other vibration sources caused by the vibration of the rotating motor MG. These other vibration sources are, for example, the vehicle body that vibrates due to changes in road surface unevenness during vehicle operation.

[0036] The power line 50 includes a trunk section 54, a first branch section 56, and a second branch section 58. These trunk sections 54, first branch sections 56, and second branch sections 58 are all conductive materials such as aluminum or copper, and are preferably not separate components, but rather integrated components.

[0037] The trunk section 54 is manufactured by bending, for example, a long strip of plate-shaped metal. A connecting terminal 62 is fitted to one end 54t of the trunk section 54 on the terminal 70 side. In the longitudinal direction of the trunk section 54, the length direction is radial, and the thickness direction is along the axis CL. The connecting terminal 62 fitted to the end 54t is electrically connected to the terminal 70 via a fastening member 80. The fastening member 80 includes, for example, a bolt 82 and a nut 84 that engages with the bolt 82. Engagement means that the external threads are twisted and rotated relative to the internal threads to achieve the connection. The connecting terminal 62 and the terminal 70 are electrically connected with the bolt 82 inserted relative to the connecting terminal 62 along the axis CL.

[0038] After extending radially inward from one end 54t, i.e., the connecting terminal 62, the main line 54 extends outward toward the outside of the stator core 20 in the direction of the axis CL. Figure 2 The stator core 54 is bent in an L-shape from the upper side of the paper surface, and then bent again in an L-shape towards the radial inner circumference. "Outer side" refers to the outer side viewed from the inner side of the stator core 20. At the other end of the main line section 54, i.e., the branch section 52, its length direction is radial, and its thickness direction is the axis CL direction. Thus, by bending the main line section 54, the length direction of the main line section 54 from one end 54t to the other end changes from radial to the axis CL direction, and then back to radial.

[0039] The first branch section 56 and the second branch section 58 branch off from the other end of the main line section 54 along its length, namely the branch section 52. In other words, the main line section 54, the first branch section 56, and the second branch section 58 are electrically and mechanically connected at the branch section 52. Specifically, in the portion of the main line section 54 extending along its length from the branch section 52, a cut 60 cut along the thickness direction extends along the length direction, with one side of the cut serving as the first branch section 56 and the other side serving as the second branch section 58. Thus, the power line 50, which is a single component, is physically separated by the first branch section 56 and the second branch section 58 through the simple structure of the cut 60. The cut 60 is formed by, for example, a blanking process in stamping or by a cutting process.

[0040] The first branch section 56 has, for example, a long strip-shaped plate-like metal body, namely a plate-like section 56p. The first branch section 56 extends radially inward from the branch section 52, and its plate thickness direction is along the axis CL direction. The front end portion 56t of the first branch section 56 located on the coil 30 side is fastened to and electrically connected to the lead wire 40 by a welding part 46, which welds the plate surface of the plate-like section 56p in the front end portion 56t to the plate surface of the plate-like section 40p in the lead wire 40. It should be noted that the welding part 46 is equivalent to the "connecting part" in this invention. The plate-like section 56p is equivalent to the "plate-like section in the first branch section" in this invention.

[0041] The second branch section 58 is, for example, a long strip-shaped metal body. The front end 58t of the second branch section 58 on the side opposite to the branch section 52 in the length direction is sealed and fixed to the resin section 90.

[0042] The resin section 90 is a resin that seals the outer side of the stator core 20 along the axial direction CL of the front end portion 58t of the second branch section 58 and the coil end portion 32. For example, the sealing based on the resin section 90 is performed as follows: First, the front end portion 56t of the first branch section 56 is welded to the stator 10 of the lead wire 40 in a state where the welding portion 46 is positioned on the lower side in the vertical direction. Next, a mold with a cavity is prepared, and resin is injected into the cavity with the resin-sealed portion of the front end portion 58t of the second branch section 58 and the outer side of the coil end portion 32 inserted into the cavity, and then the injected resin is cured.

[0043] The area of ​​the coil end 32 that is sealed by the resin portion 90 is called the sealed area 32a, and the area that is not sealed by the resin portion 90 is called the unsealed area 32b. The solder portion 46 is not sealed by the resin portion 90. It should be noted that the sealed area 32a corresponds to "at least a portion of the coil end" in this invention.

[0044] The second branch portion 58 has a sealed region 58a that is sealed by the resin portion 90 and a non-sealed region 58b that is not sealed by the resin portion 90. It should be noted that the sealed region 58a corresponds to "at least a portion of the second branch portion" and "sealed region" in the present invention, and the non-sealed region 58b corresponds to "non-sealed region" in the present invention.

[0045] The branch portion 52 side of the non-sealed region 58b in the second branch portion 58 is a plate-shaped metal body with a rectangular cross-section perpendicular to its length direction, namely plate portion 58p. The front end portion 58t side of the non-sealed region 58b in the second branch portion 58 is a cylindrical metal body with a circular cross-section perpendicular to its length direction, namely cylindrical portion 58s. The sealed region 58a in the second branch portion 58 is a cylindrical metal body integral with the front end portion 58t side of the non-sealed region 58b in the second branch portion 58. The cylindrical portion 58s and the cylindrical metal body of the sealed region 58a are formed, for example, by stamping the front end portion 58t side of the second branch portion 58 and causing plastic deformation. Although they have the same cross-sectional area, compared with the rectangular cross-sectional shape of the second branch portion 58 in the branch portion 52, the cross-sectional shape of the second branch portion 58 at the boundary between the sealed region 58a and the non-sealed region 58b becomes circular. The bending stiffness of the cylindrical portion 58s is higher than that of the plate portion 58p in the thickness direction, where elastic deformation is most likely to occur.

[0046] The plate-shaped portion 58p in the non-sealed region 58b of the second branch section 58 extends radially inward from the branch section 52 and then bends in an L-shape toward the outside of the stator core 20 in the direction of the axis CL. Thus, in the plate-shaped portion 58p of the non-sealed region 58b of the second branch section 58, the length direction bends radially toward the axis CL, bending in both the axis CL and radial directions in a manner different from the plate thickness direction. The distance of the non-sealed region 58b in the length direction of the second branch section 58 (equal to the distance in the length direction from the branch section 52 to the sealed region 58a) is shorter than the distance in the length direction of the main line section 54 from the branch section 52 to one end 54t. It should be noted that the plate-shaped portion 58p corresponds to the "plate-shaped portion in the second branch section" in this invention.

[0047] According to this embodiment, the device includes: (a) a coil 30 wound around a stator core 20; (b) a power line 50 having a main line portion 54 electrically connected to a terminal 70 at one end 54t in the longitudinal direction, and a first branch portion 56 and a second branch portion 58 branching off from a branch portion 52 at the other end of the main line portion 54 in the longitudinal direction, respectively, and the first branch portion 56 being electrically connected to the lead wire 40 of the coil 30 by a welding portion 46; and (c) a resin portion 90 sealing the outer side of the stator core 20 in the axial direction CL of the coil end 32 and the front end portion 58t of the second branch portion 58. Thus, the first branch portion 56 branches off from the branch portion 52 located between the end 54t of the main line portion 54 connected to the terminal 70 and the second branch portion 58 sealed and fixed by the resin portion 90, and the branched first branch portion 56 is electrically connected to the lead wire 40 of the coil 30 by the welding portion 46. Therefore, compared to the case where the power line 50 only has a trunk section 54 and is electrically connected to the lead wire 40 of the coil 30 between one end 54t of the trunk section 54 connected to the terminal 70 and the other end of the trunk section 54 sealed by the resin section 90, the force applied to the welded section 46 during vibration (especially during unstable vibration that is not a stable change) is suppressed, and the reliability of the electrical connection at the welded section 46 is easily ensured.

[0048] According to this embodiment, the second branch portion 58 has a sealed region 58a that is sealed by the resin portion 90 and a non-sealed region 58b that is not sealed by the resin portion 90. When the second branch portion 58 has the non-sealed region 58b, compared to the case where the non-sealed region 58b is not provided, vibration is easily absorbed by the elastic deformation of the non-sealed region 58b. Therefore, the force applied from the second branch portion 58 to the surface of the resin portion 90 during vibration is easily reduced. Consequently, cracks are less likely to occur between the resin portion 90 and the second branch portion 58, and the effect of fixing the second branch portion 58 to the resin portion 90 (i.e., the so-called anchoring effect) is easily maintained. Therefore, the force applied to the weld portion 46 during vibration is suppressed, and the reliability of the electrical connection at the weld portion 46 is easily ensured.

[0049] According to this embodiment, the distance of the non-sealed region 58b in the longitudinal direction of the second branch section 58 is shorter than the distance from the branch section 52 to one end 54t in the longitudinal direction of the main line section 54. Compared with the terminal 70 connected to one end 54t of the main line section 54, the resin part 90 sealing the coil end 32 and the lead wire 40 of the coil 30 can move more easily in conjunction. When the distance of the sealed region 58a in the longitudinal direction of the second branch section 58 is shorter than the distance from the branch section 52 to one end 54t in the longitudinal direction of the main line section 54, the magnitude of the relative vibration of the branch section 52 relative to the resin part 90 during vibration is smaller than that when it is not the case. Therefore, the force applied to the welded part 46 connecting the first branch section 56 branching from the branch section 52 to the lead wire 40 during vibration is suppressed, and the reliability of the electrical connection at the welded part 46 is easily ensured.

[0050] According to this embodiment, (a) the second branch portion 58 has a plate-shaped portion 58p in the non-sealed region 58b, and (b) in the plate-shaped portion 58p of the second branch portion 58, the second branch portion 58 is bent in the radial and axial CL directions in a manner different from the thickness direction. The plate-shaped portion 58p is more prone to elastic deformation in the thickness direction compared to its length and width directions. When the plate-shaped portion 58p of the second branch portion 58 in the non-sealed region 58b is bent in the radial and axial CL directions in a manner different from the thickness direction, the direction in which the plate-shaped portion 58p is prone to elastic deformation, i.e., the thickness direction, becomes both the radial and axial CL directions. Therefore, compared to the case where the plate-shaped portion 58p is not bent, the direction in which the plate-shaped portion 58p elastically deforms and easily absorbs vibration becomes both the radial and axial CL directions, thus the force applied from the second branch portion 58 to the surface of the resin portion 90 during vibration is easily reduced. Therefore, it is difficult for cracks to occur between the resin part 90 and the second branch part 58, and it is easy to maintain the effect of fixing the second branch part 58 to the resin part 90. As a result, the force applied to the weld part 46 during vibration is suppressed, and the reliability of the electrical connection at the weld part 46 is easily ensured.

[0051] According to this embodiment, compared to the cross-sectional shape of the second branch portion 58 in the branch portion 52, the cross-sectional shape of the second branch portion 58 at the boundary between the sealed region 58a and the unsealed region 58b is rounded. When the cross-sectional shape of the second branch portion 58 at the boundary between the sealed region 58a and the unsealed region 58b is rounded compared to the cross-sectional shape of the second branch portion 58 in the branch portion 52, the stress concentration caused by the force applied from the second branch portion 58 in the surface portion of the resin portion 90 during vibration is mitigated, compared to the case where this is not the case. When the stress concentration generated in the surface portion of the resin portion 90 is mitigated, cracking is less likely to occur between the resin portion 90 and the second branch portion 58. Therefore, it is easier to maintain the effect of fixing the second branch portion 58 to the resin portion 90, and the force applied to the weld portion 46 during vibration is suppressed, thus easily ensuring the reliability of the electrical connection at the weld portion 46.

[0052] According to this embodiment, (a) the first branch portion 56 has a plate-shaped portion 56p, (b) the lead wire 40 of the coil 30 has a plate-shaped portion 40p, and (c) the plate surface of the plate-shaped portion 56p of the first branch portion 56 and the plate surface of the plate-shaped portion 40p of the lead wire 40 of the coil 30 are electrically connected by welding. In the plate-shaped portion 56p, the plate surface is more likely to increase the connection area with other components compared to the side surface. When the plate surface of the plate-shaped portion 56p of the first branch portion 56 and the plate surface of the plate-shaped portion 40p of the lead wire 40 are welded, it is easier to form a structure that increases the connection area in the welded portion 46 between the first branch portion 56 and the lead wire 40 compared to a non-welded configuration. This makes it easier to ensure the reliability of the electrical connection at the welded portion 46.

[0053]

Example 2

[0054] Figure 4 This is a diagram illustrating the structure of the power line 150 in the stator 10 of the rotary electric machine MG according to Embodiment 2 of the present invention, which connects the lead wire 140 of the coil 30 to the external component. Figure 4 It is the same as in the aforementioned embodiment 1. Figure 3 The corresponding figure. The power line 150 in this embodiment has a structure that is largely the same as the power line 50 in Embodiment 1, except that the trunk section 54, the first branch section 56, and the second branch section 58 are replaced by the trunk section 154, the first branch section 156, and the second branch section 158. It should be noted that the power line 150 is equivalent to the "conductive component" in this invention.

[0055] After the ends of each phase of coil 30 protrude in the direction of axis CL, they are bent in an L-shape in the direction of radial outer periphery, and then along the inner side of stator core 20 in the direction of axis CL. Figure 4The lead wire 140 is formed by bending the lead wire 140 in an L-shape (on the underside of the paper). The front end of the lead wire 140 has a plate-like portion 140p, the thickness of which is radial. It should be noted that the plate-like portion 140p of the lead wire 140 in the coil 30 is equivalent to the "plate-like portion in the coil" in this invention.

[0056] The power line 150 includes a main line section 154, a first branch line section 156, and a second branch line section 158.

[0057] The trunk section 154 is manufactured by bending, for example, a long strip-shaped plate-like metal body. A connecting terminal 62 is fitted to one end 154t of the trunk section 154 on the terminal 70 side. In the longitudinal direction of the end 154t of the trunk section 154, the longitudinal direction is radial, and the plate thickness direction is the axial direction CL. The connecting terminal 62 fitted to the end 154t is electrically connected to the terminal 70 via a fastening member 80.

[0058] After extending radially inward from one end 154t, i.e., the connecting terminal 62, the main line section 154 is bent in an L-shape toward the inside of the stator core 20 in the direction of the axis CL. At the other end side of the main line section 154, i.e., the branch section 152 side, its length direction is the axis CL direction, and its thickness direction is radial. Thus, by bending the main line section 154, the length direction of the main line section 154 from one end 154t toward the branch section 152 changes from radial to the axis CL direction.

[0059] The first branch section 156 and the second branch section 158 branch off from the other end of the trunk section 154 along its length, namely the branch section 152. In other words, the trunk section 154, the first branch section 156, and the second branch section 158 are electrically and mechanically connected at the branch section 152. Specifically, in the portion of the trunk section 154 extending along its length from the branch section 152, a cut is made along the length direction, similar to the cut 60 in the aforementioned embodiment 1. One side of the cut is designated as the first branch section 156, and the other side is designated as the second branch section 158. Thus, the power line 150, which is a single component, is physically separated by the first branch section 156 and the second branch section 158 through this simple structure of cuts.

[0060] The first branch section 156 has, for example, a long strip-shaped plate-like metal body, namely a plate-like section 156p. The first branch section 156 extends, for example, from the branch section 152 toward the inside of the stator core 20 in the axial direction CL, and its plate thickness direction is radial. The front end portion 156t of the first branch section 156 located on the coil 30 side is fastened to and electrically connected to the lead wire 140 by a welding portion 46, which welds the plate surface of the plate-like section 156p in the front end portion 156t to the plate surface of the plate-like section 140p in the lead wire 140. The plate-like section 156p corresponds to the "plate-like section in the first branch section" in this invention.

[0061] The second branch portion 158 is, for example, a long strip of metal. The front end portion 158t of the second branch portion 158, on the side opposite to the branch portion 152 in the length direction, is sealed and fixed to the resin portion 90.

[0062] The second branch portion 158 has a sealed region 158a that is sealed by the resin portion 90 and a non-sealed region 158b that is not sealed by the resin portion 90. It should be noted that the sealed region 158a corresponds to "at least a portion of the second branch portion" and "sealed region" in the present invention, and the non-sealed region 158b corresponds to "non-sealed region" in the present invention.

[0063] The branch portion 152 side of the non-sealed region 158b in the second branch portion 158 is a plate-shaped metal body, namely plate portion 158p, and the front end portion 158t side of the non-sealed region 158b in the second branch portion 158 is a cylindrical metal body, namely cylindrical portion 158s. The sealed region 158a in the second branch portion 158 is a cylindrical metal body integral with the front end portion 158t side of the non-sealed region 158b in the second branch portion 158. The cylindrical portion 158s and the cylindrical metal body of the sealed region 158a are formed, for example, by stamping and plastic deformation of the front end portion 158t side of the second branch portion 158. Although they have the same cross-sectional area, compared with the rectangular cross-sectional shape of the second branch portion 158 in the branch portion 152, the cross-sectional shape of the second branch portion 158 at the boundary between the sealed region 158a and the non-sealed region 158b becomes circular. The bending stiffness of the cylindrical part 158s is higher than that of the plate part 158p in the thickness direction, where elastic deformation is most likely to occur.

[0064] The plate-shaped portion 158p in the non-sealed region 158b of the second branch portion 158 extends from the branch portion 152 toward the inner side of the stator core 20 in the direction of the axis CL, then bends in an L-shape toward the radial inner circumference, and then extends toward the outer side of the stator core 20 in the direction of the axis CL. Figure 4The plate-shaped portion 158p in the non-sealed region 158b of the second branch section 158 is bent in an L-shape along the direction of the axis CL in the length direction, with different bending directions in the thickness direction. The distance of the non-sealed region 158b in the length direction of the second branch section 158 (= the distance from the branch section 152 to the sealed region 158a in the length direction) is shorter than the distance from the branch section 152 to one end 154t in the length direction of the main branch section 154. It should be noted that the plate-shaped portion 158p corresponds to the "plate-shaped portion in the second branch section" in this invention.

[0065] According to this embodiment, by having the same structure as the aforementioned Embodiment 1, it achieves the same effect as Embodiment 1.

[0066]

Example 3

[0067] Figure 5 This is a diagram illustrating the structure of the power line 250 that connects the lead wire 240 of the coil 30 to the external component in the stator 10 of the rotary electric machine MG according to Embodiment 3 of the present invention. Figure 5 It is the same as in the aforementioned embodiment 1. Figure 2 The corresponding figure. The power line 250 in this embodiment has a structure that is largely the same as the power line 50 in Embodiment 1, except that the trunk section 54, the first branch section 56, and the second branch section 58 are replaced by the trunk section 254, the first branch section 256, and the second branch section 258. It should be noted that the power line 250 is equivalent to the "conductive component" in this invention.

[0068] After the ends of each phase of coil 30 protrude in the direction of axis CL, they are bent in an L-shape in the direction of radial outer periphery, and then along the inner side of stator core 20 in the direction of axis CL. Figure 5 The lead wire 240 is formed by an L-shaped bend in the direction of the lower side of the paper in the coil 30. The front end of the lead wire 240 has a plate-like portion 240p, the thickness of which is radial. It should be noted that the plate-like portion 240p of the lead wire 240 in the coil 30 is equivalent to the "plate-like portion in the coil" in this invention.

[0069] The power line 250 includes a main line section 254, a first branch line section 256, and a second branch line section 258.

[0070] The trunk section 254 is, for example, a long, strip-shaped plate-like metal body. A connecting terminal 62 is fitted to one end 254t of the trunk section 254 on the terminal 70 side. The length direction of the trunk section 254 is along the axis CL, and its thickness direction is radial. The connecting terminal 62 fitted to one end 254t is electrically connected to the terminal 70 via a fastening member 80. In the aforementioned embodiment 1, the bolt 82 is inserted along the axis CL; however, in this embodiment, the connecting terminal 62 and the terminal 70 are electrically connected with the bolt 82 of the fastening member 80 inserted radially relative to the connecting terminal 62.

[0071] The main line section 254 extends from one end 254t, i.e., the connecting terminal 62, toward the outside of the stator core 20 in the direction of the axis CL. Figure 5 Extending in the direction of the upper side of the paper surface.

[0072] The first branch section 256 and the second branch section 258 branch off from the other end of the main line section 254 along its length, namely the branch section 252. In other words, the main line section 254, the first branch section 256, and the second branch section 258 are electrically and mechanically connected at the branch section 252. Specifically, in the portion of the main line section 254 extending along its length from the branch section 252, a cut 60 cut along the thickness direction extends along the length direction, with one side of the cut serving as the first branch section 256 and the other side serving as the second branch section 258. Thus, the power line 250, which is a single component, is physically separated by the simple structure of the cut 60.

[0073] The first branch section 256 has, for example, a long strip-shaped plate-like metal body, namely a plate-like section 256p. The first branch section 256 extends from the branch section 252 toward the outside of the stator core 20 in the direction of the axis CL, and its plate thickness direction is radial. The front end portion 256t of the first branch section 256 located on the coil 30 side is fastened to and electrically connected to the lead wire 240 by a welding part 46, which welds the plate surface of the plate-like section 256p in the front end portion 256t to the plate surface of the plate-like section 240p in the lead wire 240. The plate-like section 256p corresponds to the "plate-like section in the first branch section" in this invention.

[0074] The second branch section 258 is, for example, a long, strip-shaped plate-like metal body. The second branch section 258 extends from the branch section 252 toward the outside of the stator core 20 in the direction of the axis CL, and its thickness direction is radial. The front end portion 258t of the second branch section 258 is sealed and fixed to the resin section 90.

[0075] The second branch portion 258 has a sealed region 258a that is sealed by the resin portion 90 and a non-sealed region 258b that is not sealed by the resin portion 90. It should be noted that the sealed region 258a corresponds to "at least a portion of the second branch portion" and "sealed region" in the present invention, and the non-sealed region 258b corresponds to "non-sealed region" in the present invention.

[0076] The branch portion 252 side of the non-sealed region 258b in the second branch portion 258 is a plate-shaped metal body, i.e., plate-shaped portion 258p, and the front end portion 258t side of the non-sealed region 258b in the second branch portion 258 is a cylindrical metal body, i.e., cylindrical portion 258s. It should be noted that plate-shaped portion 258p corresponds to the "plate-shaped portion in the second branch portion" in this invention. The sealed region 258a in the second branch portion 258 is a cylindrical metal body integral with the front end portion 258t side of the non-sealed region 258b in the second branch portion 258. The cylindrical portion 258s and the cylindrical metal body of the sealed region 258a are formed, for example, by stamping and plastic deformation of the front end portion 258t side of the second branch portion 258. Although they have the same cross-sectional area, the cross-sectional shape of the second branch portion 258 at the boundary between the sealed region 258a and the unsealed region 258b becomes circular, compared to the rectangular cross-sectional shape of the second branch portion 258 in the branch portion 252. The bending stiffness of the cylindrical portion 258s is higher than the bending stiffness in the thickness direction of the plate portion 258p, where elastic deformation is most likely to occur.

[0077] The distance of the non-sealed region 258b in the length direction of the second branch section 258 (= the distance from the branch section 252 to the sealed region 258a in the length direction) is shorter than the distance from the branch section 252 to one end 254t in the length direction of the main line section 254.

[0078] According to this embodiment, unlike the aforementioned embodiments 1 and 2, the power line 250, including the trunk section 254 and the second branch section 258, is not bent. Although the power line 250 is not bent, the first branch section 256 branches off from the branch section 252 located between one end 254t of the trunk section 254 connected to the terminal 70 in the longitudinal direction and the second branch section 258 which is sealed and fixed by the resin section 90. The branched first branch section 256 is electrically connected to the lead wire 140 of the coil 30 by the welding section 46. As a result, compared to the case where the power line 250 only has a trunk section and is electrically connected to the lead wire of the coil 30 between one end of the trunk section connected to the terminal 70 and the other end of the trunk section sealed by the resin section 90, the force applied to the welding section 46 that connects the first branch section 256 to the lead wire 240 during vibration is suppressed, and the reliability of the electrical connection at the welding section 46 is easily ensured.

[0079] According to this embodiment, by having the same structure as the aforementioned Embodiment 1, it achieves the same effect as Embodiment 1.

[0080] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings; however, the present invention is also applicable to other solutions.

[0081] In the aforementioned embodiments 1 to 3, the second branch portions 58, 158, and 258 each have sealed regions 58a, 158a, and 258a, and non-sealed regions 58b, 158b, and 258b, respectively. However, the present invention is not limited to this embodiment. For example, the second branch portions 58, 158, and 258 may have sealed regions 58a, 158a, and 258a but not non-sealed regions 58b, 158b, and 258b. That is, the second branch portions 58, 158, and 258 may be completely sealed by the resin portion 90.

[0082] In the aforementioned embodiments 1 to 3, the distances of the non-sealed regions 58b, 158b, and 258b in the length direction of the second branch sections 58, 158, and 258 are shorter than the distances from the branch sections 52, 152, and 252 to one end 54t, 154t, and 254t in the length direction of the main sections 54, 154, and 254, respectively. However, alternative solutions are also possible.

[0083] In the aforementioned embodiments 1 and 2, (a) the second branch portions 58 and 158 in the non-sealed regions 58b and 158b respectively have plate-shaped portions 58p and 158p, and (b) the second branch portions 58 and 158 in the plate-shaped portions 58p and 158p of the second branch portions 58 and 158 are bent in different directions in the thickness direction towards the axis CL and radially. However, the present invention may also be a different embodiment. For example, the thickness direction of the second branch portions 58 and 158 may be at least one of the axis CL and radial directions that are bent in a different direction. Even in such an embodiment, compared with the case where the plate-shaped portions 58p and 158p are not bent, the plate-shaped portions 58p and 158p are more likely to absorb vibration in multiple directions, so the force applied from the second branch portions 58 and 158 to the surface of the resin portion 90 during vibration is smaller.

[0084] In the aforementioned embodiments 1 to 3, the cross-sectional shapes of the second branch portions 58, 158, and 258 in the branch portions 52, 152, and 252 are rectangular, and the cross-sectional shapes of the second branch portions 58, 158, and 258 at the boundaries of the sealed regions 58a, 158a, and 258a and the unsealed regions 58b, 158b, and 258b are circular. However, the present invention is not limited to this solution. For example, the cross-sectional shapes of the second branch portions 58, 158, and 258 at the boundaries of the sealed regions 58a, 158a, and 258a and the unsealed regions 58b, 158b, and 258b can also be elliptical or rectangular with chamfered vertices. In summary, by making the cross-sectional shape of the second branch portions 58, 158, 258 at the boundary between the sealed regions 58a, 158a, 258a and the unsealed regions 58b, 158b, 258b more rounded compared to the cross-sectional shape of the second branch portions 58, 158, 258 in the branch portions 52, 152, 252, the stress concentration caused by the force applied from the second branch portions 58, 158, 258 in the surface portion of the resin portion 90 during vibration can be mitigated. "Rounding" means that the angular shape approaches a curled shape in a way that mitigates the stress concentration caused by the force applied from the second branch portions 58, 158, 258 in the surface portion of the resin portion 90. Furthermore, the present invention may also be a scheme in which the cross-sectional shape of the second branch portion 58, 158, 258 at the boundary between the sealed region 58a, 158a, 258a and the unsealed region 58b, 158b, 258b is not rounded compared to the cross-sectional shape of the second branch portion 58, 158, 258 in the branch portions 52, 152, 252.

[0085] In the aforementioned embodiments 1 to 3, the second branch portions 58, 158, and 258 respectively have plate-shaped portions 58p, 158p, and 258p, but it is also possible to have a solution without these portions. For example, the second branch portions 58, 158, and 258 may also have a cylindrical metal body between the branch portions 52, 152, and 252 and the front portions 58t, 158t, and 258t.

[0086] In the aforementioned embodiments 1 to 3, (a) the first branch sections 56, 156, and 256 each have plate-shaped sections 56p, 156p, and 256p, respectively; (b) the lead wires 40, 140, and 240 in the coil 30 each have plate-shaped sections 40p, 140p, and 240p, respectively; and (c) the plate surfaces of the plate-shaped sections 56p, 156p, and 256p in the first branch sections 56, 156, and 256 and the plate surfaces of the plate-shaped sections 40p, 140p, and 240p in the lead wires 40, 140, and 240 are electrically connected by welding, but the present invention is not limited to this solution. For example, it is also possible to electrically connect the plate surfaces of the plate-shaped portions 56p, 156p, and 256p in the first branch portions 56, 156, and 256 to the side surfaces of the plate-shaped portions 40p, 140p, and 240p in the lead-out lines 40, 140, and 240, respectively.

[0087] In the aforementioned embodiments 1 to 3, the first branch portions 56, 156, and 256 respectively have plate-shaped portions 56p, 156p, and 256p, but it is also possible to have a solution without these portions. For example, the first branch portions 56, 156, and 256 may also have a cylindrical metal body between the branch portions 52, 152, and 252 and the front portions 56t, 156t, and 256t.

[0088] In the aforementioned embodiments 1 to 3, the branching portions 52, 152, and 252 branch into two parts: the first branching portions 56, 156, and 256, and the second branching portions 58, 158, and 258. However, it is also possible to branch into, for example, three parts. In this case, for example, one of the three branches can be electrically connected to the coil 30 and the remaining two can be sealed with the resin portion 90, or two of the three branches can be electrically connected to the coil 30 and the remaining one can be sealed with the resin portion 90.

[0089] In the aforementioned embodiments 1 to 3, the rotary motor MG is an electric generator that serves as a driving source for the vehicle 100; however, the present invention is not limited to this approach. For example, the rotary motor MG may also be a rotary motor for vehicle driving that has only an electric motor function and does not have a generator function, or it may be a regenerative generator that has only a generator function and does not have an electric motor function.

[0090] It should be noted that the above content is only an embodiment of the present invention. The present invention can be implemented with various changes and improvements based on the knowledge of those skilled in the art without departing from its spirit.

[0091] Explanation of reference numerals in the attached figures

[0092] 10: Stator

[0093] 20: Stator core

[0094] 30: Coil

[0095] 32: Coil end

[0096] 32a: Sealed area (at least a portion of the coil end)

[0097] 40p, 140p, 240p: Plate-shaped portion (plate-shaped portion in the coil)

[0098] 46: Welded section (connection section)

[0099] 50, 150, 250: Power lines (conductive components)

[0100] 52, 152, 252: Branch offices

[0101] 54, 154, 254: Main Line Section

[0102] 56p, 156p, 256p: Plate-like portion (plate-like portion in the first branch section)

[0103] 54t, 154t, 254t: one end

[0104] 56, 156, 256: First branch line

[0105] 58, 158, 258: Second branch section

[0106] 58a, 158a, 258a: Sealed area (at least a portion of the second branch section, sealed area)

[0107] 58b, 158b, 258b: Unsealed areas (non-sealed areas)

[0108] 58p, 158p, 258p: Plate-like portion (plate-like portion in the second branch portion)

[0109] 70: Terminal (external component)

[0110] 90: Resin section

[0111] MG: Rotary motor.

Claims

1. A stator (10) of a rotary electric machine (MG), characterized by, have: The coil (30) is wound around the stator core (20); The conductive component (50; 150; 250) has a main branch (54; 154; 254) that electrically connects one end (54t; 154t; 254t) in the longitudinal direction to an outer component (70), and a first branch (56; 156; 256) and a second branch (58; 158; 258) that branch off from the other end of the main branch (54; 154; 254) in the longitudinal direction, respectively. The first branch (56; 156; 256) is electrically connected to the coil (30) by a connecting portion (46). The resin part (90) seals at least a portion (32a) of the coil end (32) of the coil (30) and at least a portion of the second branch part (58; 158; 258).

2. The stator (10) of the rotary electric motor (MG) according to claim 1, characterized in that, The second branch portion (58; 158; 258) has a sealed area (58a; 158a; 258a) sealed by the resin portion (90) and a non-sealed area (58b; 158b; 258b) not sealed by the resin portion (90).

3. The stator (10) of the rotary electric motor (MG) according to claim 2, characterized in that, The distance of the non-sealed area (58b; 158b; 258b) in the length direction of the second branch section (58; 158; 258) is shorter than the distance in the length direction of the main line section (54; 154; 254) from the branch section (52; 152; 252) to the end point (54t; 154t; 254t).

4. The stator (10) of the rotary electric motor (MG) according to claim 2 or 3, characterized in that, The second branch portion (58; 158) has a plate-like portion (58p; 158p) in the non-sealed area (58b; 158b). In the plate-shaped portion (58p; 158p) of the second branch portion (58; 158), the second branch portion (58; 158) is bent in a manner different in the plate thickness direction.

5. The stator (10) of the rotary electric motor (MG) according to any one of claims 2 to 4, characterized in that, Compared to the cross-sectional shape of the second branch portion (58; 158; 258) in the branch portions (52; 152; 252), the cross-sectional shape of the second branch portion (58; 158; 258) at the boundary between the sealed region (58a; 158a; 258a) and the unsealed region (58b; 158b; 258b) becomes rounded.

6. The stator (10) of the rotary electric machine (MG) according to any one of claims 1 to 5, characterized in that, The first branch portion (56; 156; 256) has a plate-like portion (56p; 156p; 256p). The coil (30) has a plate-like portion (40p; 140p; 240p). The plate surfaces of the plate-shaped portions (56p; 156p; 256p) in the first branch portion (56; 156; 256) and the plate surfaces of the plate-shaped portions (40p; 140p; 240p) in the coil (30) are electrically connected by welding.

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