Stator of electric motor, compressor and refrigeration cycle device

Abstract

A stator of an electric motor, a compressor, and a refrigeration cycle device are provided with: a stator core connected in a circular ring shape by a plurality of divided cores having a back yoke in a circular arc shape and teeth extending from a circumferential center in an inner surface of the back yoke toward a central axis; a coil wound around the teeth of the divided cores; and an insulating member insulating the divided cores and the coil, a slot in which the coil is disposed is formed between two teeth adjacent to each other in the stator core, the insulating member has a continuous slot insulating member disposed in the slot and covering a surface of an inner peripheral wall of the slot in the stator core, the slot insulating member includes a joint covering portion covering a joint portion connecting two back yokes in the inner peripheral wall, and a protruding portion protruding toward the central axis is formed only in a central portion in an axial direction in the joint covering portion or a protruding portion protruding toward a radial direction outer side is formed only in end portions on both sides in the axial direction.

Description

Technical Field

[0001] This disclosure relates to the stator of an electric motor, a compressor, and a refrigeration cycle device, and particularly to the construction of the stator of an electric motor. Background Technology

[0002] Generally, the stator of an electric motor used in compressors and the like comprises a stator core, coils, and insulating components that insulate the stator core and coils. The stator core has a cylindrical back yoke and multiple teeth extending from the back yoke toward the central axis. The coils are wound around each tooth via the insulating components, and the coils are arranged in slots formed between adjacent teeth. In the stator of an electric motor, it is desirable to increase the space factor (winding density) of the coils in order to improve the performance of the motor. To this end, there is a technique in which the stator core is composed of multiple arc-shaped segmented cores, thereby minimizing the dead zone of the slots, and during winding, the slots are expanded by setting the multiple segmented cores in an unfolded state arranged in a straight line, thereby facilitating winding (for example, see Patent Document 1). In Patent Document 1, in the unfolded state of the stator core, the back yokes of adjacent segmented cores are connected to each other on the outer peripheral side of their circumferential ends, and a V-shaped gap is formed on the inner peripheral side of the connection. When the multiple segmented cores are transformed into a ring shape after winding, the gap on the inner peripheral side of the connection closes. The stator of the electric motor in Patent Document 1 has a winding frame at the coil end and a slot insulation member as insulating components, both formed of insulating resin material. In the slot insulation member, a bent portion is provided in the portion opposite the connection portion to the back yoke (hereinafter referred to as the connection covering portion) to facilitate insulation between the stator core and the coil. Furthermore, a sheet-like insulating material is used as the slot insulation member to ensure a wider winding area. In the stator of Patent Document 1, when multiple segmented cores are deformed into a ring shape, the bent portion is formed in a mountain-shaped form on the inner side, i.e., the central axis side, to prevent the slot insulation member from being sandwiched between the back yokes of adjacent segmented cores. The bent portion extends from one end to the other axially in the connection covering portion that covers the connection portion of the back yoke.

[0003] Patent Document 1: Japanese Patent Application Publication No. 9-191588

[0004] As shown in Patent Document 1, during winding, the winding nozzle passes through the slots between the teeth, above the teeth, and below the teeth. Therefore, in a structure where the bending portion is formed from one end of the connecting cover to the other, as in the slot insulation member of Patent Document 1, when the winding nozzle changes direction at the end of the teeth during winding, the bending portion of the connecting cover may sometimes get caught in the winding. When the winding gets caught in the slot insulation member, the arrangement of the winding is disrupted, and the space factor (winding density) of the coil in the slot decreases.

[0005] Furthermore, to prevent the slot insulation components from getting tangled, if the connecting cover portion of the slot insulation component is made straight without any bends, the structure that maintains the shape of the connecting cover portion in the unfolded state of the stator core is lost, and the shape of the connecting cover portion becomes unstable. Therefore, even in this case, the slot insulation components can still get tangled, disrupting the winding arrangement and reducing the space factor of the coils within the slot. Summary of the Invention

[0006] This disclosure was made to solve the aforementioned problems, and its purpose is to provide a stator, compressor, and refrigeration cycle device for an electric motor that suppresses the reduction of the space factor of the coil caused by the disruption of the winding arrangement.

[0007] The stator of the electric motor disclosed herein comprises: a stator core, formed by connecting a plurality of segmented cores into a ring shape, the segmented core having an arc-shaped back yoke and teeth extending from the circumferential center of the inner surface of the back yoke toward the central axis; a coil wound around the teeth of the segmented core; and an insulating member that insulates the segmented core and the coil, wherein a slot for arranging the coil is formed between two adjacent teeth in the stator core, the insulating member having a continuous slot insulating member disposed in the slot and covering the surface of the inner peripheral wall of the slot in the stator core, the slot insulating member including a connecting covering portion that covers the connecting portion in the inner peripheral wall of the slot connecting two back yokes, wherein a protrusion protruding toward the central axis is formed only at the central portion in the axial direction, or a protrusion protruding radially outward is formed only at the ends on both sides in the axial direction.

[0008] In addition, the compressor disclosed herein includes: an electric motor having a stator and a rotor configured to rotate relative to the stator; and a compression element driven by the electric motor to compress refrigerant.

[0009] In addition, the refrigeration cycle apparatus disclosed herein includes a refrigerant circuit, which is configured by connecting the aforementioned compressor, first heat exchanger, pressure reducing device and second heat exchanger by refrigerant piping.

[0010] According to this disclosure, in the connecting cover portion of the slot insulation member, a protrusion protruding towards the central axis is formed only in the central portion along the axial direction, or a protrusion protruding radially outward is formed only at the ends on both sides along the axial direction. In either case, since either type of protrusion is formed in the connecting cover portion of the slot insulation member, the shape of the connecting cover portion is stable. Furthermore, in either case, there is no structure protruding into the slot at the ends on both sides of the connecting cover portion of the slot insulation member along the axial direction. Therefore, entanglement of the slot insulation member during winding is suppressed, thus enabling the provision of stators for electric motors, compressors, and refrigeration cycle devices that suppress the reduction in the space factor of the coil caused by winding arrangement disruption. Attached Figure Description

[0011] Figure 1 This is a perspective view showing the structure of the stator of the electric motor according to Embodiment 1.

[0012] Figure 2 It means Figure 1 A top view of the stator structure.

[0013] Figure 3 yes Figure 1 A three-dimensional view of the segmented iron core in the stator, viewed from the inside.

[0014] Figure 4 yes Figure 1 A three-dimensional view of the segmented iron core in the stator as seen from the outside.

[0015] Figure 5 yes Figure 1 A partial sectional view of the stator.

[0016] Figure 6 yes Figure 1 A three-dimensional view of the segmented stator as seen from the inside.

[0017] Figure 7 It means Figure 5 A diagram illustrating the unfolded state of the stator before winding.

[0018] Figure 8 yes Figure 1 A perspective view from the inside of the unfolded state of adjacent segmented iron cores in the stator before winding, with insulating components installed.

[0019] Figure 9 yes Figure 8 A three-dimensional view of one of the adjacent segmented iron cores as viewed from the outside.

[0020] Figure 10 yes Figure 1 A partial structural diagram of the stator before winding, viewed from the outside.

[0021] Figure 11 It means Figure 10 A sectional view of section AA of the stator.

[0022] Figure 12 It means Figure 10 A sectional view of the BB section of the stator.

[0023] Figure 13 yes Figure 6 A cross-sectional view of the segmented stator.

[0024] Figure 14 It means Figure 1 A three-dimensional diagram showing the positional relationship between the stator and the winding nozzle during stator winding.

[0025] Figure 15 yes Figure 14 A partial structural diagram of the stator and winding nozzle, viewed from the lower side of the segmented stator.

[0026] Figure 16 It means possessing Figure 1 A longitudinal sectional view of the compressor stator.

[0027] Figure 17 It means possessing Figure 16 The refrigerant circuit diagram of the compressor's refrigeration cycle unit.

[0028] Figure 18 This is a partial structural diagram of the stator in embodiment 2, viewed from the tooth side outwards in its unfolded state before winding.

[0029] Figure 19 It means Figure 18 A cross-sectional view of the CC section of the stator.

[0030] Figure 20 It means Figure 18 A sectional view of the DD section of the stator. Detailed Implementation

[0031] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. Furthermore, in each drawing, the same or equivalent parts are labeled with the same reference numerals, and their descriptions are appropriately omitted or simplified. Additionally, the shape, size, and arrangement of the structures depicted in each drawing can be appropriately modified.

[0032] Implementation Method 1

[0033] (stator)

[0034] Figure 1 This is a perspective view showing the structure of the stator of the electric motor according to Embodiment 1. Figure 2 It means Figure 1A top view of the stator structure. (Example) Figure 1 As shown, the stator 34 has a cylindrical shape. Additionally, as... Figure 2 As shown, the stator 34 is composed of a plurality of segmented stators 50 arranged in a ring shape when viewed from above. Although described below, the stator 34, together with the rotor configured to rotate relative to the stator 34, constitutes the electric motor 100. Figure 16 ).exist Figure 1 The central axis O of the stator 34 is shown. Hereinafter, the structure of the stator 34 will be described using the axial direction of the central axis O (arrow Z direction) as the vertical direction of the stator 34.

[0035] (Segmentation of stator 50)

[0036] exist Figure 1 In the example shown, nine segmented stators 50 are connected in a circular ring to form stator 34. For example... Figure 1 As shown, the segmented stator 50 has a segmented core 10, an insulating component 8 disposed on the segmented core 10, and a coil 5 composed of wires wound on the segmented core 10.

[0037] (Segmented iron core 10)

[0038] Figure 3 yes Figure 1 A three-dimensional view of the segmented iron core in the stator, viewed from the inside. Figure 4 yes Figure 1 A three-dimensional view of the segmented iron core in the stator, viewed from the outside. (See image below.) Figure 3 As shown, the segmented core 10 has multiple core plates 1. Each core plate 1 is composed of a magnetic plate-like component, for example, formed by punching an electromagnetic steel plate, which is a soft magnetic material, using a die. Multiple core plates 1 are stacked in the vertical direction (arrow Z direction) and integrated using riveting or the like, thereby forming a block-shaped segmented core 10 with thickness in the vertical direction (arrow Z direction). In the following description, the multiple segmented cores 10 in the stator 34 will sometimes be collectively referred to as the stator core.

[0039] The segmented core 10 has an arc-shaped back yoke 10a that forms the outer periphery of the stator 34, extending from the inner surface 10ai of the back yoke 10a towards the central axis O. Figure 1 The back yoke 10a has a tooth 10b extending laterally and boots 10c disposed on both circumferential sides of the end portion 10b1 of the tooth 10b. Figure 4 As shown, the outer circumference 10ao appears as an arc when viewed from above. Figure 3 The inner surface 10ai, which appears as a straight line when viewed from above, and the outer circumferential surface 10ao, which connects to the two ends in the circumferential direction. Figure 4The two sides 10as of the inner surface 10ai. The ends of the split core 10 on both sides of the back yoke 10a are connected to the adjacent split core 10.

[0040] Figure 5 yes Figure 1 A partial sectional view of stator 34. (See attached image.) Figure 5 As shown, in adjacent segmented stators 50, the outer peripheral surface 10ao of the side surface 10as of the back yoke 10a is connected. Hereinafter, the part in which the back yokes 10a of adjacent segmented cores 10 are connected to each other will sometimes be referred to as the connecting part.

[0041] Tooth 10b extends circumferentially from the center of the inner surface 10ai of the back yoke 10a toward the central axis O. Figure 3 In the example shown, tooth 10b is circumferentially located on the back yoke 10a side and the central axis O ( Figure 1 The back yoke 10a has a constant thickness, and its inner surface 10ai is connected to the side surface 10bs of the tooth 10b at a right angle. However, although in this embodiment the inner surface 10ai of the back yoke 10a is connected to the side surface 10bs of the tooth 10b at a right angle, it may not be at a right angle.

[0042] like Figure 3 As shown, the boot 10c has an inner surface 10ci on the side of the central axis O and an outer surface 10co on the side of the back yoke 10a. Figure 4 The inner surface 10ci of the boot 10c is smoothly connected to the inner surface 10bi of the tooth 10b to form the inner surface 10i of the segmented core 10. The inner surface 10i of the segmented core 10 has an arc shape.

[0043] like Figure 2 As shown, with multiple segmented stators 50 configured in a ring shape, Figure 4 The two sides 10as of the back yoke 10a of the shown segmented core 10 are in contact with the sides 10as of the back yoke 10a of the other two adjacent segmented cores 10. Hereinafter, the state in which multiple segmented stators 50 are arranged in a ring shape is sometimes referred to as the state of stator core closure.

[0044] like Figure 2 As shown, slots 6 are formed between adjacent segmented iron cores 10 in the stator 34, and teeth 10b are arranged around the slots 6 via insulating members 8. Figure 4 The coil 5. That is, the slot 6 is the space enclosed by the side surfaces 10bs of the teeth 10b that are opposite each other in the adjacent segmented iron cores 10, the outer surface 10co of the adjacent boot 10c, and the inner surface 10ai of the adjacent back yoke 10a. Hereinafter, these surfaces that form the slot 6 in the adjacent segmented iron cores 10 will sometimes be referred to as the inner peripheral walls of the slot.

[0045] (Coil 5)

[0046] Figure 6 yes Figure 1 A three-dimensional view of the segmented stator 50 in the stator, viewed from the inside. (See image below.) Figure 6 As shown, coil 5 is a conductor consisting of a core wire as a conductor and an insulating sheath covering the core wire. The core wire is made of, for example, copper, aluminum, or an alloy with conductivity. The conductor constituting coil 5 is wound multiple times around the teeth 10b of the segmented iron core 10 via the insulating member 8, and coil 5 has a loop shape that is long in the vertical direction (arrow Z direction). Coil 5 forms magnetic poles by winding the conductor around the teeth 10b. Therefore, it is configured such that when current flows in the conductor of the coil, magnetic flux is generated in each tooth 10b. The conductor is wound multiple times between the back yoke 10a and the boot 10c around the teeth 10b ( Figure 3 The windings of the stator 50 are provided in multiple layers at the upper end of the stator 50, each layer including multiple windings arranged in a row.

[0047] (Insulating component 8)

[0048] Figure 7 It means Figure 5 A diagram illustrating the unfolded state of stator 34 before winding. (See diagram for reference.) Figure 7 As shown, during the manufacturing stage of the stator 34, the winding is performed with multiple segmented cores 10 arranged in a straight line. Hereinafter, the state in which multiple segmented cores 10 are arranged in a straight line is sometimes referred to as the unfolded state. In the unfolded state, among the adjacent segmented cores 10 connected by the connecting part 10r, a V-shaped gap 10g is formed on the inner surface 10ai side of the side surface 10as of the back yoke 10a.

[0049] Figure 8 yes Figure 1 A perspective view from the inside of the unfolded state of the adjacent segmented iron core 10 before winding, after the installation of the stator insulation component 8. Figure 9 yes Figure 8 A three-dimensional view of one of the adjacent segmented iron cores 10 as viewed from the outside. (See image below.) Figure 8 As shown, the insulating member 8 insulates the segmented iron core 10, which is made of iron or the like, from the coil 5, which is made of copper or the like. The insulating member 8 has a set of end face insulating members 4 mounted on the end faces on both sides of the segmented iron core 10 in the axial direction (arrow Z direction), and a continuous slot insulating member 7 disposed in the slot 6 of the stator iron core and covering the surface of the inner peripheral wall of the slot.

[0050] Figure 10 yes Figure 1 A partial structural diagram of the stator before winding, viewed from the tooth side outwards. Figure 11 It means Figure 10 A sectional view of section AA of the stator. Figure 12 It means Figure 10The sectional view of the stator's BB section. See below for reference. Figures 7-12 The structure of the slot insulation component 7 and a set of end face insulation components 4 will be described.

[0051] (Slot insulation component 7)

[0052] like Figure 7 As shown, slot insulation components 7 are disposed in each slot 6 of the stator 34. The slot insulation components 7 ensure an insulation distance of thickness between the coil 5 and the inner peripheral wall of the adjacent segmented iron core 10 slot, thereby insulating them from each other.

[0053] like Figure 8 As shown, the slot insulation component 7 disposed in each slot 6 is made of a thin sheet of insulating material. The slot insulation component 7 can be made of, for example, a PET (polyethylene terephthalate) sheet.

[0054] like Figure 7 As shown, the slot insulation member 7 seamlessly covers the inner peripheral wall of the adjacent segmented iron core 10 constituting the slot 6, and the connecting portion 10r of the adjacent segmented iron core 10 is also covered by the slot insulation member 7. The slot insulation member 7 includes: a back yoke covering portion 7a, covering adjacent back yokes 10a in the inner peripheral wall of the slot; two tooth covering portions 7b, covering two teeth 10b; and two boot covering portions 7c, covering two boots 10c. Hereinafter, the circumferentially central area in the back yoke covering portion 7a that covers the connecting portion 10r of adjacent back yokes 10a will be referred to as the connecting covering portion 70 (see reference). Figure 10 ).

[0055] like Figure 8 As shown, in the unfolded state where adjacent back yokes 10a are arranged in a straight line, the upper end 7a1 and lower end 7a2 of the back yoke covering portion 7a are arranged along the inner surface 10ai of the back yoke 10a via a set of end face insulating members 4. However, the set of end face insulating members 4 does not have a structure in which a connecting covering portion 70 for directly holding groove insulating members 7 is provided.

[0056] like Figure 12 As shown, in the connecting covering portion 70 of the covering connecting portion 10r in the back yoke covering portion 7a of the groove insulation member 7, a protrusion 71 extending axially (arrow Z direction) and shaped like a mountain on the central axis O side is formed. Figure 10 As shown, a protrusion 71 with a constant length in the axial direction (arrow Z direction) is formed on the connecting cover portion 70 of each slot insulation member 7. The mountain-shaped protrusion 71 on the central axis O side is formed only in the central portion 70c in the axial direction (arrow Z direction) of the connecting cover portion 70 of the back yoke cover portion 7a, and not in the upper end portion 70a and lower end portion 70b of the connecting cover portion 70. Figure 11As shown, in the unfolded state of the stator core, the upper end 70a and the lower end 70b of the connecting cover 70, that is, the ends on both sides of the connecting cover 70 in the axial direction (arrow Z direction), have a generally planar shape along the inner surface 10ai of the back yoke 10a.

[0057] In this way, the shape of the connecting cover portion 70 is stabilized by forming a protrusion 71 in the axial central portion 70c of the connecting cover portion 70. In addition, no structure protruding into the groove 6 is provided at the end of the connecting cover portion 70. As a result, the entanglement of the groove insulation member during winding is suppressed, so it is possible to prevent the winding arrangement from being disrupted.

[0058] In addition, although Figure 11 In the example shown, the axial ends of the connecting cover portion 70 are generally planar, but additional radially outwardly mountain-shaped protrusions may also be formed at the ends of the connecting cover portion 70. For example... Figure 1 As shown, with the stator core closed, a set of end-face insulating members 4 of adjacent segmented stators 50 are separated from each other at a position closer to the outer periphery than the back yoke covering portion 7a. Therefore, even if an additional protrusion in the radially outward mountain shape is formed at the end of the connecting covering portion 70, the deformation of the stator core will not be hindered when the stator core is deformed into a ring shape after winding.

[0059] (A set of end-face insulating components 4)

[0060] like Figure 8 As shown, a set of end-face insulating components 4 are disposed on each segmented iron core 10. The set of end-face insulating components 4 consists of an upper end-face insulating component 2 mounted on the upper end face of the segmented iron core 10 and a lower end-face insulating component 3 mounted on the lower end face of the segmented iron core 10. The upper end-face insulating component 2 ensures an insulation distance of a certain thickness between the coil 5 and the upper end face of the segmented iron core 10, thus insulating them from each other. Similarly, the lower end-face insulating component 3 ensures an insulation distance of a certain thickness between the coil 5 and the lower end face of the segmented iron core 10, thus insulating them from each other. Furthermore, the set of end-face insulating components 4 mounted on the segmented iron core 10 also functions as a winding frame for the coil 5.

[0061] (Upper end face insulating component 2)

[0062] The upper end face insulating member 2 has an outer flange 2a, an inner flange 2b disposed radially inward of the outer flange 2a, and a toothed end cover portion 2c disposed between the outer flange 2a and the inner flange 2b. Additionally, the upper end face insulating member 2 has: a stepped portion 2d connecting the toothed end cover portion 2c and the outer flange 2a; and a beveled portion 2e. Figure 9The outer flange 2a and the inner flange 2b connect the tooth end covering portion 2c and the inner flange 2b. The outer flange 2a and the inner flange 2b restrict the arrangement of the upper layer windings in the multi-layer windings constituting the coil 5. In addition, the stepped portion 2d and the inclined portion 2e ( Figure 9 ()Restricts the arrangement of the lower layer windings in the multi-layer windings that constitute coil 5.

[0063] The outer flange 2a has a cubic shape, and its lower surface contacts the central axis O side of the upper surface of the back yoke 10a. This is such that the inner surface of the outer flange 2a contacts the inner surface 10ai of the back yoke 10a. Figure 3 The outer flange 2a is disposed on the back yoke 10a in a coplanar manner. Specifically, a portion of the back yoke covering portion 7a of the slot insulation member 7 is disposed at the lower part of both circumferential sides along the inner surface of the outer flange 2a. The circumferential width of the outer flange 2a is shorter than the circumferential width of the back yoke 10a, and the outer flanges 2a of adjacent segmented stators 50 are separated from each other.

[0064] The inner flange 2b has an inner surface 2bi on the side of the central axis O that is arc-shaped and approximately cuboid in shape. The inner surface 2bi of the inner flange 2b is formed into an arc shape with a curvature approximately the same as that of the inner surface 10i of the segmented core 10, and the inner flange 2b is positioned on the boot 10c in such a way that the inner surface 2bi of the inner flange 2b and the inner surface 10i of the segmented core 10 are coplanar. Slits 2b1 are formed at the lower part of the two circumferential sides of the inner flange 2b. Each slit 2b1 is formed from the inclined portion 2e to the side of the inner flange 2b in the circumferential direction, and the two circumferential sides of each slit 2b1 are open. A part of the boot cover 7c of the slot insulation member 7 is disposed in the slit 2b1. Specifically, the upper end of the boot cover 7c is inserted into the slit 2b1 from below, thereby restricting the position of the upper end of the boot cover 7c.

[0065] The tooth end cover 2c is connected to the lower part of the outer flange 2a and the lower part of the inner flange 2b. The tooth end cover 2c is, for example, constructed from a plate-like component bent into a U-shape, with the circumferential ends 2c1 of the tooth end cover 2c extending downwards. The tooth end cover 2c covers the upper surface of the tooth 10b and the two side surfaces 10bs of the tooth 10b. Figure 4 The upper part of ).

[0066] The step portion 2d is configured to rise from the tooth end covering portion 2c toward the outer flange 2a. That is, in the step portion 2d, the outer diameter is larger the closer the step is to the outer flange 2a. The step portion 2d has a generally U-shaped shape along the tooth end covering portion 2c, and the two circumferential ends 2d1 of the step portion 2d extend downward.

[0067] A gap is formed between the end 2d1 of the stepped portion 2d and the inner surface of the outer flange 2a. A portion of the toothed portion 7b of the upper end 7a1 of the back yoke covering portion 7a is disposed in this gap and pressed against the back yoke 10a side of the segmented core 10. Similarly, a gap is formed between the end 2d1 of the stepped portion 2d and the end 2c1 of the toothed end covering portion 2c. A portion of the back yoke covering portion 7a of the upper end of the toothed portion 7b is disposed in this gap and pressed against the tooth 10b side of the segmented core 10. In other words, the end 2d1 of the stepped portion 2d presses the boundary between the toothed portion 7b and the back yoke covering portion 7a in the slot insulation member 7 toward the segmented core 10. Hereinafter, the end 2d1 of the stepped portion 2d will sometimes be referred to as the pressing portion.

[0068] like Figure 9 As shown, the beveled portion 2e has a shape in which its outer diameter increases as it slopes from the tooth end covering portion 2c toward the inner flange 2b. The beveled portion 2e has a generally U-shaped form along the tooth end covering portion 2c, and the circumferentially oriented ends 2e1 of the beveled portion 2e extend downwards. However, in Figure 9 In the example shown, in order not to obstruct the insertion of the boot cover 7c into the slit 2b1 formed in the lower part of the inner flange 2b, the end 2e1 extending downward in the inclined surface 2e is not provided at the height of the slit 2b1.

[0069] (Lower end face insulating component 3)

[0070] like Figure 8 As shown, the lower end face insulating member 3 is configured with a structure almost identical to that of the upper end face insulating member 2, and similarly has an outer flange 3a, an inner flange 3b, a toothed end covering portion 3c, a stepped portion (not shown), and a beveled portion 3e. Figure 9 Additionally, a slit 3b1 is formed on the inner flange 3b of the lower end face insulating member 3. However, unlike the case of the outer flange 2a of the upper end face insulating member 2, a wiring groove 3f is formed on the outer flange 3a of the lower end face insulating member 3. The terminal portion of the wire constituting the coil 5 is disposed in the wiring groove 3f.

[0071] Figure 13 yes Figure 6 A transverse sectional view of the divided stator 50. Figure 13 The winding order of the multiple windings that make up coil 5 is marked in the text. Figure 14 It means Figure 1 A three-dimensional view showing the positional relationship between the stator 34 and the winding nozzle 20 during the winding process. Figure 15 yes Figure 14 A partial structural diagram of the stator 34 and winding nozzle 20, viewed from below the segmented stator 50. (Refer to...) Figures 13-15 The winding process during the manufacturing of stator 34 is explained.

[0072] like Figure 14 As shown, the winding process is performed with slot insulation components 7 installed on the inner circumferential walls of each slot and a set of end-face insulation components 4 installed on the end faces of both sides of each segmented iron core 10 along its axial direction. During the winding process, the coil 5 is wound while the multiple segmented iron cores 10 are unfolded in a straight line. Specifically, during the winding process, the multiple segmented iron cores 10 with insulation components 8 installed are held by components such as clamps 21 in a straight-line arrangement of their back yokes 10a. Multiple winding nozzles 20 are provided at constant intervals, and while the multiple segmented iron cores 10 are held by clamps 21, the coil 5 is wound onto multiple teeth 10b respectively. By moving the multiple winding nozzles 20 relative to clamps 21 at constant intervals, the wire 5a from each winding nozzle 20 is wound onto the teeth 10b corresponding to the winding nozzle 20. At this time, the winding nozzles 20 pass through the slots 6 on both sides, above, and below the corresponding segmented iron core 10.

[0073] exist Figure 13 In the example shown, on the upper end face of the segmented core 10, the winding begins from the step portion 2d side of the upper end face insulating member 2. The first winding is performed at a position contacting the inner surface of the first step in the step portion 2d of the upper end face insulating member 2. A first layer of wire is sequentially wound from the step portion 2d side toward the inner flange 2b in the direction of arrow D1 within the toothed end covering portion 2c. After winding the first layer a predetermined number of times, a second layer of wire is sequentially wound toward the outer flange 2a in the direction of arrow D2. The second layer of wire is wound in an alternating stacked position, contacting the adjacent wires in the first layer. Subsequently, from the third layer onwards, the winding is also performed in an alternating stacked position with the wires of the layer directly below. Once the predetermined number of windings is completed, the terminal portion of the wire 5a is positioned in the wiring groove 3f formed on the outer flange 3a of the lower end face insulating member 3.

[0074] In coil 5, the lower layer windings, such as the first and second layers, are positioned in the upper end face insulation member 2 between the stepped portion 2d and the inclined portion 2e, with the stepped portion 2d and the inclined portion 2e limiting their radial position. Specifically, in each lower layer, the winding closest to the outermost flange 2a contacts the inner surface of the stepped portion 2d, while the winding closest to the innermost flange 2b contacts the inclined portion 2e. The winding closest to the outermost flange 2a in the first layer contacts the inner surface of the first step of the stepped portion 2d, and the winding closest to the outermost flange 2a in the second layer contacts the inner surface of the second segment formed on the outer flange 2a side of the stepped portion 2d, which is higher than the first step. With this structure, radial separation of the lower layer windings of coil 5 can be suppressed, and the lower layer windings and the upper layer windings (e.g., the third and above layers) of coil 5 can be arranged in a specific configuration.

[0075] like Figure 15 As shown, since the stator 34 is composed of multiple segmented stators 50 divided by each tooth 10b, the width between the teeth 10b is increased in the unfolded state during winding compared to when the stator core is closed. Therefore, the width of the winding nozzle 20 can be increased to wind thicker conductors.

[0076] Furthermore, as described above, the connecting cover portion 70 of the slot insulation member 7 does not have a structure that protrudes into the slot 6 at its ends on both axial sides, and is formed into a shape-stable structure by means of the protrusion portion 71. Therefore, the entanglement of the slot insulation member 7 during winding is suppressed, ensuring the arrangement of the winding.

[0077] In addition, such as Figure 15 As shown, during winding, the back yoke covering portion 7a of the slot insulation member 7 is formed in a shape along the inner surface 10ai of the back yoke 10a. Therefore, the connecting covering portion 70 is located radially outward from the track of the wire 5a during winding, thus further suppressing the entanglement of the slot insulation member 7 during winding.

[0078] As described above, the stator 34 of the electric motor in Embodiment 1 includes a stator core composed of a plurality of segmented iron cores 10 connected in a circular ring, a coil 5, and an insulating member 8 that insulates the segmented iron cores 10 and the coil 5. Each segmented iron core 10 has an arc-shaped back yoke 10a and a tooth 10b extending circumferentially from the center of the inner surface 10ai of the back yoke 10a toward the central axis O. The coil 5 is wound around the tooth 10b of each segmented iron core 10. A slot 6 for arranging the coil 5 is formed in the stator core between two adjacent teeth 10b. The insulating member 8 has a continuous slot insulating member 7 that covers the surface of the inner peripheral wall of the slot in the stator core. The slot insulating member 7 includes a connecting cover portion 70 that covers the connecting portion 10r in the inner peripheral wall of the slot that connects two back yokes 10a. In the connecting cover portion 70, a protrusion 71 protruding toward the central axis O is formed only in the central portion 70c in the axial direction (arrow Z direction).

[0079] Therefore, in the connecting cover portion 70 of the slot insulation member 7, the shape of the connecting cover portion 70 is stabilized by the protrusion 71 provided in the central portion 70c in the axial direction (arrow Z direction), and the structure is configured such that there is no protruding structure at the ends on both sides in the axial direction. Therefore, the winding of the connecting cover portion 70 of the slot insulation member 7 is suppressed when the winding nozzle 20 changes direction at the end of the tooth 10b during winding, and the winding alignment can be ensured. Thus, a stator 34 of a motor can be provided that suppresses the reduction of the space factor of the coil 5 caused by the disruption of the winding alignment.

[0080] Additionally, the insulating member 8 has a set of end face insulating members 4 mounted on both sides of the axial (arrow Z direction) end faces in the segmented core 10. This allows the upper and lower end faces of the segmented core 10 to be insulated from the coil 5 while simultaneously restricting the vertical position of the slot insulating member 7.

[0081] Additionally, the stator core has boots 10c protruding circumferentially from both ends of the end portion 10b1 of the tooth 10b. The slot insulation member 7 includes a boot cover portion 7c that covers the boot 10c in the inner peripheral wall of the slot. Slits (slits 2b1 and slits 3b1) are formed in a set of end face insulation members 4, which fix the axial ends of the boot cover portion 7c.

[0082] Therefore, the shoe-covered portion 7c of the slot insulation member 7 can be prevented from loosening along the shoe 10c of the segmented iron core 10, thereby preventing the shoe-covered portion 7c from getting tangled during winding. As a result, the disruption of the winding arrangement can be more reliably suppressed.

[0083] Additionally, the slot insulation member 7 includes: a back yoke covering portion 7a, covering the back yoke 10a in the inner peripheral wall of the slot; and a tooth covering portion 7b, covering the teeth 10b in the inner peripheral wall of the slot. One of the end face insulation members 4 (the upper end face insulation member 2) has a pressing portion (the end 2d1 of the step portion 2d) formed therein, which presses the boundary between the tooth covering portion 7b and the back yoke covering portion 7a in the slot insulation member 7 toward the side of the split core 10.

[0084] Therefore, the tooth-covering portion 7b and the back yoke-covering portion 7a can maintain the shape of the slot insulation member 7 along the segmented core 10, thereby suppressing the entanglement of the tooth-covering portion 7b and the back yoke-covering portion 7a during winding. Thus, the disruption of the winding arrangement can be suppressed more reliably.

[0085] <Rotary Compressor>

[0086] Figure 16 It means possessing Figure 1 A longitudinal sectional view of the compressor stator. The following is based on... Figure 16 The rotary compressor 300, which utilizes the stator 34 described above, will now be described. The rotary compressor 300, for example, is used in an air conditioning unit and includes a sealed container 307, a compression element 301 disposed within the sealed container 307, and an electric motor 100 that drives the compression element 301. The electric motor 100 is composed of the stator 34 described above and a rotor 33 configured to rotate relative to the stator 34.

[0087] Compression element 301 compresses the refrigerant. Compression element 301 includes: a cylinder 302 having a cylinder chamber 303; a shaft 37 rotated by an electric motor 100; and a rotary piston 304 engaged with the shaft 37. Compression element 301 also includes: vanes (not shown) dividing the cylinder chamber 303 into a refrigerant suction side and a refrigerant compression side; and an upper frame 305 and a lower frame 306 for the shaft 37 to be inserted into and to close the axial end face of the cylinder chamber 303. An upper discharge muffler 308 is installed on the upper frame 305, and a lower discharge muffler 309 is installed on the lower frame 306. The refrigerant is released into the internal space of the sealed container 307 via the upper discharge muffler 308 and the lower discharge muffler 309.

[0088] The sealed container 307 is a cylindrical container with a lid and a bottom. A glass terminal 311 is fixed to the lid of the sealed container 307. Refrigeration oil (not shown) that lubricates the sliding parts of the compression element 301 is stored at the bottom of the sealed container 307. The shaft 37 is held rotatably by an upper frame 305 and a lower frame 306, which serve as bearing portions. The rotary piston 304 rotates eccentrically within the cylinder chamber 303 inside the cylinder body 302. The shaft 37 has an eccentric shaft portion into which the rotary piston 304 is fitted.

[0089] The stator 34 of the electric motor 100 is assembled into the sealed container 307 by means of thermoforming, pressing, or welding, and is fixed to the inner circumferential surface of the sealed container 307. Power is supplied to the coils 5 of the stator 34 via glass terminals 311. The rotor 33 of the electric motor 100 has a permanent magnet 35 and a rotor core 36, with a shaft hole formed in the center of the rotor core 36. A shaft 37 is fixed to the shaft hole of the rotor 33. In the electric motor 100, the rotor is arranged inside the stator 34, and the shaft 37 is arranged along the central axis O of the stator 34 by being inserted into the shaft hole of the rotor 33. Figure 1 ).

[0090] Additionally, a receiver 310 for storing refrigerant gas is installed outside the sealed container 307. A suction pipe 313 connected to the receiver 310 is fixed to the sealed container 307, and refrigerant gas is supplied from the receiver 310 to the cylinder 302 inside the sealed container 307 via the suction pipe 313. Furthermore, a discharge pipe 312 for discharging refrigerant to the outside is provided on the cover of the sealed container 307.

[0091] Next, the operation of the rotary compressor 300 will be explained. Refrigerant gas supplied from the receiver 310 is fed into the cylinder chamber 303 of the cylinder block 302 through the suction pipe 313. When the rotor 33 is rotated by the motor 100 driven by the inverter (not shown), the shaft 37 rotates together with the rotor 33. Then, the rotary piston 304, which engages with the shaft 37, rotates eccentrically within the cylinder chamber 303, compressing the refrigerant within the cylinder chamber 303. The refrigerant compressed in the cylinder chamber 303 rises within the sealed container 307 through the upper discharge muffler 308 or the lower discharge muffler 309, and further through the air vents (not shown) of the rotor core 36. The refrigerant that has risen within the sealed container 307 is discharged through the discharge pipe 312.

[0092] In the electric motor 100 having the stator 34 described above, the multiple segmented iron cores 10 are in an extended state arranged in a straight line during winding. Therefore, since the width of the slots 6 formed between the teeth 10b is larger than the width of the slots 6 when the multiple segmented iron cores 10 are in a closed annular state during winding, the width of the winding nozzle 20 can be increased, allowing for the winding of thicker wire. This improves the motor efficiency of the electric motor 100 and increases its output. Therefore, by applying the electric motor 100 to the rotary compressor 300, the operating efficiency of the rotary compressor 300 can be improved, and its output increased.

[0093] Furthermore, the electric motor 100 with stator 34 is not limited to the rotary compressor 300 described above, and can be applied to other types of compressors.

[0094] <Refrigeration Cycle Unit>

[0095] Figure 17 It means possessing Figure 16 The refrigerant circuit diagram of the compressor's refrigeration cycle unit 400 is shown below. Based on... Figure 17 The refrigeration cycle device 400 equipped with the rotary compressor 300 described above will be explained. Hereinafter, the refrigeration cycle device 400 will be described as an air conditioning device.

[0096] like Figure 17 As shown, the refrigeration cycle device 400 includes: a refrigerant circuit, including the rotary compressor 300 described above; and a control unit 406 that controls the operation of the refrigeration cycle device 400. The refrigerant circuit is formed by connecting the rotary compressor 300, a four-way valve 401, a first heat exchanger 402, a pressure reducing device 403, and a second heat exchanger 404 via refrigerant piping 405. The second heat exchanger 404 is installed, for example, indoors in the space to be conditioned, and the first heat exchanger 402 is installed, for example, outdoors. The control unit 406 is configured, for example, a microcomputer, and controls the operation of the four-way valve 401 and the rotary compressor 300. The four-way valve 401 switches the flow direction of the refrigerant.

[0097] Next, the operation of the refrigeration cycle unit 400 will be explained. The rotary compressor 300 compresses the drawn-in refrigerant, turning it into a high-temperature, high-pressure gaseous refrigerant, which is then discharged. The four-way valve 401... Figure 17In the first connection state, as shown by the solid line, the refrigerant supplied from the rotary compressor 300 flows to the first heat exchanger 402. With the four-way valve 401 in the first connection state, the first heat exchanger 402 functions as a condenser. The first heat exchanger 402 performs heat exchange between the refrigerant supplied from the rotary compressor 300 and air (e.g., outdoor air) and then discharges it. In the first heat exchanger 402, the refrigerant condenses and liquefies by dissipating heat to the air. The pressure reducing device 403 expands the liquid refrigerant supplied from the first heat exchanger 402, discharging it as a low-temperature, low-pressure liquid refrigerant. With the four-way valve 401 in the first connection state, the second heat exchanger 404 functions as an evaporator. The second heat exchanger 404 performs heat exchange between the low-temperature, low-pressure liquid refrigerant supplied from the pressure reducing device 403 and air (e.g., air in the air-conditioned space) and then discharges it. In the second heat exchanger 404, the refrigerant evaporates and vaporizes by absorbing heat from the air. At this time, the air that has exchanged heat with the refrigerant in the second heat exchanger 404 is cooled. The cooled air is supplied to the air-conditioned space (e.g., a room) via a fan (not shown) to cool the air-conditioned space. The gaseous refrigerant from the second heat exchanger 404 is sent to the rotary compressor 300 via a four-way valve 401, where it is compressed again. The same cycle is then repeated.

[0098] When the four-way valve 401 is in Figure 17 In the second connection state, as indicated by the dashed line, the refrigerant delivered from the rotary compressor 300 is sent to the second heat exchanger 404, which functions as a condenser, while the first heat exchanger 402 functions as an evaporator. Thus, when the four-way valve 401 is in the second connection state, heating is performed on the air-conditioned space.

[0099] As described above, the compressor (rotary compressor 300) disclosed herein includes: an electric motor 100 having a stator 34 and a rotor 33 configured to rotate relative to the stator 34; and a compression element 301 driven by the electric motor 100 to compress the refrigerant. Thus, in the compressor (rotary compressor 300), operating efficiency can be improved and output increased.

[0100] Furthermore, the refrigeration cycle apparatus 400 disclosed herein includes a refrigerant circuit, which is configured by connecting a compressor (rotary compressor 300), a first heat exchanger 402, a pressure reducing device 403, and a second heat exchanger 404 via refrigerant piping 405. Thus, the refrigeration cycle apparatus 400 includes a rotary compressor 300 with increased output, thereby improving operating efficiency and achieving energy efficiency improvement.

[0101] Furthermore, the refrigeration cycle unit 400 equipped with the rotary compressor 300 is not limited to the air conditioning unit described above. Additionally, the refrigerant circuit of the refrigeration cycle unit 400 is not limited to the refrigerant circuit described above and can be appropriately modified. For example, the four-way valve 401 can be omitted from the refrigeration cycle unit 400.

[0102] Implementation Method 2

[0103] Figure 18 This is a partial structural diagram of the stator in its unfolded state before winding, as described in Embodiment 2, viewed from the tooth side outwards. Figure 19 It means Figure 18 A cross-sectional view of the CC section of the stator. Figure 20 It means Figure 18 A cross-sectional view of the DD section of the stator. In the stator 34 of Embodiment 2, the structure of the connecting covering portion 70 in the back yoke covering portion 7a of the slot insulation member 7 differs from that of the stator 34 of Embodiment 1. Hereinafter, refer to Figures 18-20 The differences between the stator 34 in Embodiment 2 and that in Embodiment 1 will be explained.

[0104] In the above-described implementation method 1, as follows: Figures 10-12 As shown, a protrusion 71 protruding toward the central axis O is formed in the central portion 70c of the connecting cover portion 70 of the groove insulation member 7, while no protrusion 71 is formed at the ends on both sides of the connecting cover portion 70 in the axial direction. Figure 18 As shown, in the stator 34 of Embodiment 2, similarly to the case of Embodiment 1, a protrusion 72 is formed in the connecting covering portion 70 of the back yoke covering portion 7a of the slot insulation member 7. However, in the stator of Embodiment 2, the direction in which the protrusion 72 protrudes from the central portion 70c in the axial direction and the position where the protrusion 72 is provided are different from those in Embodiment 1.

[0105] like Figure 19 As shown, in the back yoke covering portion 7a of the slot insulation member 7, the connecting covering portion 70 of the covering connecting portion 10r has a protrusion 72 extending axially (in the direction of arrow Z) and radially outward in a mountain-like shape. Figure 18 As shown, two protrusions 72 with a constant length in the axial direction (arrow Z direction) are formed in the connecting cover portion 70 of each slot insulation member 7. The radially outward, mountain-shaped protrusions 72 are formed only at the upper end 70a and lower end 70b of the connecting cover portion 70 of the back yoke cover portion 7a, and not at the central portion 70c in the axial direction (arrow Z direction) of the connecting cover portion 70. Figure 20 As shown, in the unfolded state, the central portion 70c of the connecting cover portion 70 in the axial direction (arrow Z direction) has a generally planar shape like the inner surface 10ai of the back yoke 10a.

[0106] As described above, the stator 34 of the motor in Embodiment 2 includes a stator core composed of a plurality of segmented iron cores 10 connected in a circular ring, a coil 5, and an insulating member 8 that insulates the segmented iron cores 10 and the coil 5. Each segmented iron core 10 has an arc-shaped back yoke 10a and a tooth 10b extending circumferentially from the center of the inner surface 10ai of the back yoke 10a toward the central axis O. The coil 5 is wound around the tooth 10b of each segmented iron core 10. A slot 6 for arranging the coil 5 is formed between two adjacent teeth 10b in the stator core. The insulating member 8 has a continuous slot insulating member 7 that covers the surface of the inner peripheral wall of the slot in the stator core. The slot insulating member 7 includes a connecting cover portion 70 that covers the connecting portion 10r in the inner peripheral wall of the slot that connects two back yokes 10a. In the connecting cover portion 70, a protrusion 72 that protrudes radially outward is formed only at the ends on both sides in the axial direction (arrow Z direction).

[0107] Therefore, in the connecting cover portion 70 of the slot insulation member 7, the shape of the connecting cover portion 70 is stabilized by the radially outward protrusions 72 provided at the ends on both sides of the axial direction (arrow Z direction). Furthermore, there is no structure protruding into the slot 6 at the ends on both sides of the axial direction or at the central portion 70c. Therefore, in Embodiment 2, similarly to Embodiment 1, the winding of the connecting cover portion 70 of the slot insulation member 7 is suppressed when the winding nozzle 20 changes direction at the end of the tooth 10b during winding, ensuring the alignment of the winding. Thus, a stator 34 of the motor can be provided that suppresses the reduction in the space factor of the coil 5 caused by the disruption of the winding alignment.

[0108] Similar to that in Embodiment 1, the stator 34 of Embodiment 2 can be applied to the rotary compressor 300, thereby improving operating efficiency and increasing output in the rotary compressor 300. Furthermore, as in Embodiment 1, the compressor (rotary compressor 300) using the stator 34 of Embodiment 2 can also be applied to the refrigeration cycle device 400. In this case, improved energy efficiency in the refrigeration cycle device 400 can be achieved.

[0109] Furthermore, the embodiments can be appropriately modified or omitted. For example, in embodiments 1 and 2, the case where the stator 34 is composed of nine segmented stators is described, but the number of segmented stators constituting the stator 34 is not limited to this.

[0110] Explanation of reference numerals in the attached figures

[0111] 1...core lamination; 2...upper end face insulation component; 2a...outer flange; 2b...inner flange; 2b1...slit; 2bi...inner surface; 2c...tooth end cover; 2c1...end; 2d...step; 2d1...end; 2e...beveled part; 2e1...end; 3...lower end face insulation component; 3a...outer flange; 3b...inner flange; 3b1...slit; 3c...tooth end cover; 3e...beveled part; 3f...wiring groove; 4...end face insulation component; 5...coil; 5a...conductor; 6...groove; 7...groove insulation component; 7a...back yoke cover; 7b...tooth cover; 7c...boot cover; 8...insulation component; 10...segmented core; 10a...back yoke; 10b...tooth; 10c...boot; 10g...gap; 10i...inner surface; 10r...connection; 20...winding nozzle; 21. 33...Clamp; 34...Rotor; 35...Stator; 36...Permanent magnet; 37...Rotor core; 50...Shaft; 50...Divided stator; 70...Connecting cover; 71...Protrusion; 72...Protrusion; 100...Motor; 300...Rotary compressor; 301...Compression element; 302...Cylinder block; 303...Cylinder chamber; 304...Rotary piston; 305...Upper frame; 306...Lower frame; 307...Sealed container; 308...Upper discharge silencer; 309...Lower discharge silencer; 310...Liquid receiver; 311...Glass terminal; 312...Discharge pipe; 313...Suction pipe; 400...Refrigeration cycle unit; 401...Four-way valve; 402...First heat exchanger; 403...Pressure reducing device; 404...Second heat exchanger; 405...Refrigerant piping; 406...Control unit; O...Central shaft.

Claims

1. A stator for an electric motor, wherein, The stator of the electric motor includes: The stator core is formed by connecting multiple segmented cores into a ring shape. The segmented core has an arc-shaped back yoke and teeth extending from the circumferential center of the inner surface of the back yoke toward the central axis. A coil, wound around the teeth of the segmented iron core; and Insulating components that insulate the segmented iron core from the coil. A slot for arranging the coil is formed between two adjacent teeth in the stator core. The insulating component has a continuous, thin-sheet slot insulating component disposed in the slot and covering the surface of the inner peripheral wall of the slot in the stator core. The slot insulation component includes a connecting cover portion that covers the connecting portion connecting the two back yokes in the inner peripheral wall of the slot. In the connecting covering portion, only the central portion in the axial direction forms a protrusion that protrudes toward the central axis and the ends on both sides of the axial direction are planar, or only the ends on both sides of the axial direction form a protrusion that protrudes radially outward and the central portion in the axial direction is planar.

2. The stator of the electric motor according to claim 1, wherein, The insulating component has a set of end-face insulating components mounted on both sides of the axial direction in the segmented iron core.

3. The stator of the electric motor according to claim 2, wherein, The stator core has boots that project circumferentially from both ends of the tooth tip. The slot insulation component includes a boot cover portion that covers the boot within the inner peripheral wall of the slot. A slit is formed in the set of end face insulating components, which secures the ends of the boot cover on both sides of the axial direction.

4. The stator of the electric motor according to claim 2 or 3, wherein, The slot insulation component includes: a back yoke covering portion covering the back yoke in the inner peripheral wall of the slot; and a tooth covering portion covering the teeth in the inner peripheral wall of the slot. At least one of the end face insulating members in the set has a pressing portion formed thereon, which presses the boundary between the tooth covering portion and the back yoke covering portion of the slot insulating member toward the segmented core side.

5. A compressor, wherein, The compressor includes: An electric motor having a stator as described in any one of claims 1 to 4, and a rotor configured to rotate relative to the stator of the electric motor; and The compression element, driven by the electric motor, compresses the refrigerant.

6. A refrigeration cycle device, wherein, It includes a refrigerant circuit, which is configured by connecting the compressor, the first heat exchanger, the pressure reducing device and the second heat exchanger as described in claim 5 by refrigerant piping.

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