Connection terminal, stator assembly, electric motor, and method for manufacturing stator assembly

Abstract

A connection terminal connected to a winding disposed in a slot of a stator core of an electric motor (1), the connection terminal comprising: a first connection pin connected to one end of the winding; a second connection pin connected to the other end of the winding; and a connecting part for connecting the first connecting pin and the second connecting pin.

Description

Technical Field

[0001] The present disclosure relates to a connection terminal for a motor, a stator assembly including the connection terminal, a motor including the stator assembly, and a method for manufacturing the stator assembly. Background Art

[0002] Electric motors are used in various electric devices such as household appliances and industrial appliances. As electric motors, there are known commutator motors using brushes and brushless motors not using brushes.

[0003] The brushless motor includes, for example, a rotor, a stator, and a circuit board (see, for example, Patent Document 1). The rotor has a magnet. The stator has a stator core and a winding wound around the stator core via an insulator. A circuit component is mounted on the circuit board, and the circuit component is used to generate a current supplied to the winding of the stator.

[0004] The stator and the circuit board are combined into a stator assembly. In the stator assembly, the windings of the stator and the circuit board are electrically connected. There is a known technology in which a connecting pin is pre-fixed on an insulator of the stator, and the windings of the stator and the circuit board are electrically connected using the connecting pin. Specifically, the end of the winding is wound around the connecting pin and soldered, and the connecting pin is inserted into a through hole of the circuit board and the connecting pin and the circuit board are soldered. In this way, the connecting pin and the circuit board can be electrically and mechanically connected. In addition, the windings of the stator and the circuit board can be electrically connected with the help of the connecting pin, and the stator and the circuit board can be combined.

[0005] However, sometimes the connecting pin tilts due to stress when the connecting pin is wound around the end of the winding or thermal stress when the winding wound on the connecting pin is brazed. If the connecting pin tilts, even if the connecting pin is inserted into the through hole of the circuit board, it cannot be inserted reliably. As a result, poor wiring occurs. Therefore, it is also considered to set up a process for correcting the tilted connecting pin. However, if such a process is set up, productivity will decrease and production costs will increase.

[0006] In particular, in the case of using a stator whose stator core is divided into a plurality of core blocks, the above-mentioned poor connection is prone to occur. Specifically, in the case where the stator core is divided into a plurality of core blocks, the stator is composed of a plurality of intermediate assemblies arranged in a cylindrical shape. Each intermediate assembly has a core block, a winding wound on the core block through an insulator, and a pair of connecting pins held on the insulator. The end where the winding of the winding starts is wound around one of the pair of connecting pins. The end where the winding of the winding ends is wound around the other of the pair of connecting pins. In the stator thus constructed, a pair of connecting pins is provided in each of the plurality of intermediate assemblies. Therefore, a plurality of pairs of connecting pins are provided corresponding to the number of divided core blocks. Therefore, if only one of the plurality of pairs of connecting pins falls over, the plurality of pairs of connecting pins cannot be inserted into the through holes of the circuit board. As a result, the stator and the circuit board cannot be combined. If the stator core is divided into a plurality of core blocks in this way, the connecting pins are prone to falling over.

[0007] Furthermore, in a small motor, the components constituting the stator and the circuit board that are the objects of the work are small. Therefore, the connection work between the stator and the circuit board is difficult, and the connecting pins are prone to fall over. In addition, if the number of slots in the stator increases, the number of connecting pins also increases. Therefore, if the number of slots in the stator increases, the risk of failing to combine the stator and the circuit board due to the falling of the connecting pins increases.

[0008] Prior art literature

[0009] Patent Literature

[0010] Patent Document 1: Japanese Patent Application Publication No. 2020-88981 Summary of the invention

[0011] The present disclosure is made to solve such a problem. The purpose of the present disclosure is to provide a connection terminal capable of suppressing the connection pin from falling due to stress or thermal stress, a stator assembly having the connection terminal, an electric motor having the stator assembly, and a method for manufacturing the stator assembly.

[0012] In order to achieve the above-mentioned purpose, in one embodiment of the connecting terminal disclosed in the present invention, the connecting terminal is connected to a winding configured in a slot of a stator core of an electric motor, wherein the connecting terminal has: a first connecting pin connected to one end of the winding; a second connecting pin connected to the other end of the winding; and a connecting portion connecting the first connecting pin and the second connecting pin.

[0013] Preferably, the connection terminal is formed of a metal plate, and a cutting portion having a width smaller than a thickness of the metal plate is provided at a portion of the connection portion that is connected to the first connection pin and the second connection pin.

[0014] Preferably, the direction in which the first connection pin and the second connection pin extend is defined as a width direction, and a groove extending in the entire width direction of the connection portion is formed on a surface of the metal plate of the connection portion.

[0015] Preferably, the connection terminal further includes an extension portion, which is located between the first connection pin and the second connection pin when the connection terminal is viewed from the front and extends from the connection portion along the length direction of the first connection pin.

[0016] Preferably, when observing the connecting terminal from the side, with respect to the first connecting pin, the second connecting pin and the extending portion, a first plane including the first connecting pin and the second connecting pin and a second plane including the extending portion are present at positions offset in the front-to-back direction in a direction intersecting the direction in which the first connecting pin and the second connecting pin extend.

[0017] Preferably, the extension portion protrudes from the connection portion to a side opposite to the tip end portion side of the first connection pin, and then makes a U-turn to extend toward the tip end portion side of the first connection pin.

[0018] As a preferred solution, the first connecting pin has a first main body extending in one direction and a first connecting portion connected to one end of the winding. The second connecting pin has a second main body extending in the one direction and a second connecting portion connected to the other end of the winding. The first connecting portion protrudes from the side portion of the outer side of the first main body and is bent inwardly in a manner opposite to the first main body. The second connecting portion protrudes from the side portion of the outer side of the second main body and is bent inwardly in a manner opposite to the second main body.

[0019] Preferably, the stator core is divided into a plurality of core blocks, and the connection terminals are provided corresponding to the plurality of core blocks, respectively.

[0020] In one embodiment of the stator assembly disclosed herein, the stator assembly includes: a stator core; a winding arranged in a slot of the stator core; a connecting terminal connected to the winding; and a circuit board connected to the connecting terminal, the connecting terminal having a first connecting pin connected to one end of the winding and a second connecting pin connected to the other end of the winding, a protrusion whose top end surface is a fracture surface is formed on a portion of the end surface of the first connecting pin on the side of the second connecting pin, and a protrusion whose top end surface is a fracture surface is formed on a portion of the end surface of the second connecting pin on the side of the first connecting pin.

[0021] Preferably, the stator core is composed of a plurality of core blocks, and the connection terminals are provided corresponding to the plurality of core blocks, respectively.

[0022] Preferably, the connection terminal is held by an insulator, and the insulator is fixed to the plurality of core blocks.

[0023] In one aspect of the electric motor disclosed herein, the electric motor includes: the stator assembly described above; and a rotor facing the stator assembly.

[0024] In one embodiment of the manufacturing method of a stator assembly disclosed in the present invention, the manufacturing method of the stator assembly includes: a process of preparing a stator having a connection terminal, a stator core and a winding; and a process of connecting the stator to the circuit board by connecting the connection terminal to the circuit board, the connection terminal having a first connection pin connected to one end of the winding, a second connection pin connected to the other end of the winding, and a connection portion connecting the first connection pin and the second connection pin. In the process of connecting the stator to the circuit board, the first connection pin and the second connection pin of the connection terminal are electrically and mechanically connected to the circuit board, respectively. The manufacturing method of the stator assembly includes the process of disconnecting the connection portion of the connection terminal after connecting the connection terminal to the circuit board.

[0025] As another embodiment, the connecting terminal further includes an extension portion, which is located between the first connecting pin and the second connecting pin and extends from the connecting portion along the length direction of the first connecting pin and the second connecting pin. A notch portion is formed at the end of the circuit board. In the process of connecting the stator to the circuit board, the first connecting pin and the second connecting pin are inserted into the through hole provided in the circuit board and the extension portion is inserted into the notch portion. In the process of disconnecting the connecting portion, the connecting portion is disconnected by rotating the extension portion with the connecting portion as a fulcrum, so that the connecting portion and the extension portion are removed from the first connecting pin and the second connecting pin as a whole.

[0026] Preferably, after one end of the winding is connected to the first connection pin and the other end of the winding is connected to the second connection pin, the connection portion of the connection terminal is disconnected.

[0027] Preferably, the stator core is composed of multiple core blocks, the connecting terminals are respectively arranged corresponding to the multiple core blocks, and an intermediate assembly is composed of one core block, one connecting terminal and one winding. The stator is constructed by arranging the multiple intermediate assemblies into a cylindrical shape, and in the stator, the connecting terminals of each of the multiple intermediate assemblies protrude in one direction of the cylindrical axis direction of the stator.

[0028] According to the present disclosure, it is possible to suppress the connection pin from falling down due to stress or thermal stress. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a cross-sectional view of the electric motor according to the embodiment cut along a plane passing through the rotation axis.

[0030] Figure 2 This is a cross-sectional view of the electric motor according to the embodiment when cut along a plane perpendicular to the rotation axis.

[0031] Figure 3 This is an exploded perspective view of the electric motor according to the embodiment as seen from obliquely above.

[0032] Figure 4 This is an exploded perspective view of the electric motor according to the embodiment as seen from obliquely below.

[0033] Figure 5 It is a perspective view of the stator assembly according to the embodiment.

[0034] Figure 6 It is a cross-sectional view of the stator assembly according to the embodiment.

[0035] Figure 7 It is a perspective view of an intermediate assembly of a stator according to an embodiment.

[0036] Figure 8 It is an exploded perspective view of an intermediate assembly of a stator according to an embodiment.

[0037] Fig. 9 This is a perspective view of the connection terminal according to the embodiment as seen from the front side.

[0038] Fig.10 This is a perspective view of the connection terminal according to the embodiment as seen from the back side.

[0039] Fig.11A It is a front view of the connection terminal of the embodiment.

[0040] Fig. 11B It is a side view which enlarges the main part of the connection terminal of embodiment.

[0041] Fig.12 This is an enlarged perspective view showing a part of the connection terminal according to the embodiment.

[0042] Fig.13A It is a diagram for explaining the step of preparing an intermediate assembly in the method for manufacturing a stator assembly according to the embodiment.

[0043] Fig. 13B It is a diagram for explaining the process of preparing a stator and a circuit board in the method for manufacturing a stator assembly according to the embodiment.

[0044] Fig. 13CIt is a diagram for explaining the step of connecting the stator and the circuit board in the method for manufacturing the stator assembly according to the embodiment.

[0045] Fig.13D It is a diagram for explaining the step of disconnecting the coupling portion of the connection terminal in the method for manufacturing the stator assembly according to the embodiment.

[0046] Fig.14 This is a diagram showing a photograph of the first protrusion formed on the first connecting pin after the connecting portion of the connecting terminal is disconnected.

[0047] Fig.15A This is an enlarged front view of the connection terminal of Modification Example 1.

[0048] Fig. 15B The connection terminal of Modification Example 1 is along Fig.15A Cross-sectional view of line B-B.

[0049] Fig.16 This is an enlarged front view of the connection terminal of Modification Example 2.

[0050] Fig.17 This is an enlarged front view of the connection terminal of Modification 3. DETAILED DESCRIPTION

[0051] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. In addition, the embodiments described below all represent a specific example of the present disclosure. Therefore, the numerical values, constituent elements, configuration positions and connection forms of constituent elements, and processes and the order of processes shown in the following embodiments are examples, and the main purpose is not to limit the present disclosure. Therefore, the constituent elements of the following embodiments that are not recorded in the independent claims representing the highest concept of the present disclosure are described as arbitrary constituent elements.

[0052] Each figure is a schematic diagram and is not necessarily a strict illustration. In each figure, the same reference numerals are given to structures that are substantially the same as those in other figures, and repeated descriptions are omitted or simplified. In addition, in this specification, the terms "upper" and "lower" do not necessarily refer to the upper direction (vertically above) and the lower direction (vertically below) in absolute spatial cognition.

[0053] (Implementation Method)

[0054] First, use Figure 1 to Figure 6 The structure of the electric motor 1 according to the embodiment will be described. Figure 1 It is a cross-sectional view of the motor 1 according to the embodiment when cut along a plane passing through the rotating shaft 31 . Figure 2 It is a cross-sectional view of the electric motor 1 according to the embodiment when cut along a plane perpendicular to the rotating shaft 31 . Figure 2 Indicates along Figure 1The cross section of line II-II. Figure 3 This is an exploded perspective view of the electric motor 1 according to the embodiment as seen from obliquely above. Figure 4 This is an exploded perspective view of the electric motor 1 according to the embodiment as viewed from obliquely below. Figure 3 and Figure 4 The winding 12 is omitted. Figure 5 It is a perspective view of the stator assembly 2 according to the embodiment. Figure 6 It is a cross-sectional view of the stator assembly 2 according to the embodiment.

[0055] like Figure 1 to Figure 4 As shown, the motor 1 includes a stator 10, a circuit board 20, and a rotor 30 having a rotating shaft 31. Figure 5 As shown, the stator 10 and the circuit board 20 are combined into a stator assembly 2 .

[0056] like Figure 1 As shown, the motor 1 further includes a first bearing 41 , a second bearing 42 , a first bracket 51 and a second bracket 52 .

[0057] The motor 1 is a brushless motor. The motor 1 can be used as, for example, a blower motor or a drive motor that is small and requires high output. As an example, the size of the motor 1 is 50 mm or less in diameter.

[0058] like Figure 1 and Figure 2 As shown, the electric motor 1 is an inner rotor type motor in which the rotor 30 is arranged inside the stator 10. That is, the stator 10 is arranged so as to surround the rotor 30. Therefore, the rotor 30 rotates inside the stator 10 with the axis C of the rotating shaft 31 as the rotation center.

[0059] A stator 10 is disposed opposite to the rotor 30 with a small air gap therebetween. Specifically, the stator 10 is disposed so as to surround a rotor core 32 of the rotor 30.

[0060] The stator 10 generates magnetic force acting on the rotor 30. Specifically, the stator 10 is configured such that a plurality of N poles and a plurality of S poles alternately and repeatedly exist in the air gap surface between the stator 10 and the rotor core 32 of the rotor 30 in the rotation direction to generate magnetic flux. The stator 10 and the rotor 30 together constitute a magnetic circuit.

[0061] The stator 10 constitutes an armature. The stator 10 includes a stator core 11 (stator iron core) and a winding 12 disposed on the stator core 11. The winding 12 is a winding coil wound around the stator core 11.

[0062] like Figure 2As shown, the stator core 11 has a plurality of teeth 11a protruding toward the rotor 30. Specifically, the plurality of teeth 11a extend radially in a direction (radial direction) orthogonal to the axis C of the rotating shaft 31. The plurality of teeth 11a have slots 11b formed between two adjacent teeth 11a and are arranged at equal intervals in the circumferential direction. The stator core 11 has nine teeth 11a. That is, the number of slots in the stator 10 is nine.

[0063] The winding 12 is arranged in the slot 11b of the stator core 11. The winding 12 is a stator coil serving as an armature winding of the stator 10. As an example, the winding 12 is a concentrated winding coil wound around each tooth 11a.

[0064] The winding 12 is a three-phase winding so that the rotor 30 can be rotated as a three-phase synchronous motor. Specifically, the winding 12 is composed of unit coils of three phases, namely, the U phase, the V phase, and the W phase, which are 120 degrees different in electrical phase from each other. That is, the winding 12 wound on each tooth 11a is energized and driven by three-phase alternating current that is energized in phase units of the U phase, the V phase, and the W phase. As a result, the main magnetic flux of the stator 10 is generated in each tooth 11a. In other words, each tooth 11a is a magnetic pole tooth. Each tooth 11a is an electromagnet that generates magnetic force by the flow of current in the winding 12.

[0065] The stator core 11 is divided into a plurality of core blocks 110 (divided cores). In other words, the stator core 11 of the stator 10 is composed of a plurality of core blocks 110 .

[0066] The plurality of core blocks 110 are arranged in a circular ring shape as a whole. Specifically, the nine core blocks 110 are arranged in a circular ring shape. Two adjacent core blocks 110 are connected to each other. In other words, the stator core 11 is formed by connecting the plurality of core blocks in a circular ring shape. The windings 12 are respectively wound around the plurality of core blocks 110. Since the stator 10 has nine core blocks 110, nine windings 12 are used.

[0067] like Figure 2 As shown, the intermediate assembly 100 is composed of one core block 110 and one winding 12. Therefore, the stator 10 is composed of nine intermediate assemblies 100. The intermediate assembly 100 is an intermediate member used when manufacturing the stator assembly 2. The detailed structure of the intermediate assembly 100 will be described later.

[0068] The circuit board 20 is, for example, a printed circuit board (PCB) in which wiring formed of a conductive material such as copper is formed in a predetermined pattern. As the base substrate of the circuit board 20, a resin substrate such as a glass epoxy substrate or a metal substrate such as an aluminum alloy substrate can be used. A plurality of electronic components (not shown) are mounted on the circuit board 20, and the plurality of electronic components are used to generate current supplied to the winding 12 of the stator 10. The plurality of electronic components constitute a circuit for generating three-phase alternating current of the U phase, the V phase, and the W phase.

[0069] like Figure 1 , Figure 3 and Figure 4 As shown in FIG. 2 , a through hole 21 is provided on the circuit board 20. Figure 1 As shown, the through hole 21 is connected to the connection terminal 120 of the intermediate assembly 100 corresponding to the core block 110. The connection terminal 120 is a connection terminal connected to the winding 12 of the stator 10. The connection terminal 120 connected to the winding 12 is inserted into the through hole 21. Thus, the connection terminal 120 and the circuit board 20 are connected. Specifically, as Figure 5 and Figure 6 As shown, the first connecting pin 121 and the second connecting pin 122 of the connecting terminal 120 are inserted into the through hole 21. In this way, the circuit board 20 is a wiring substrate connected to the winding 12 by means of the connecting terminal 120. A plurality of through holes 21 are provided on the circuit board 20. Specifically, at least twice the number of through holes 21 as the number of the intermediate assembly 100 (that is, the number of the core blocks 110) is provided. The inner periphery of each through hole 21 is coated with a conductive film, which is electrically connected to the wiring formed on the main surface of the circuit board 20. The conductive film is, for example, a copper plating layer. The detailed structure of the connecting terminal 120 will be described later.

[0070] The rotor 30 rotates under the action of the magnetic force generated by the stator 10. The rotor 30 is configured so that a plurality of N poles and a plurality of S poles alternately and repeatedly exist along the rotation direction. Thus, the rotor 30 generates a magnetic force acting on the stator 10. The direction of the magnetic flux generated by the rotor 30 is a direction orthogonal to the direction in which the axis C included in the rotating shaft 31 extends (axial direction). In other words, the direction of the magnetic flux generated by the rotor 30 is a radial direction (radial direction).

[0071] like Figure 1 and Figure 2 As shown, the rotor 30 includes a rotating shaft 31, a rotor core 32, and permanent magnets 33. The rotor 30 is an interior permanent magnet rotor (IPM (Interior Permanent Magnet) rotor) in which the permanent magnets 33 are embedded in the rotor core 32. Therefore, the motor 1 is an IPM motor.

[0072] The rotating shaft 31 is a longitudinally long shaft. The rotating shaft 31 is, for example, a metal rod. The rotating shaft 31 is fixed to the rotor core 32. Specifically, the rotating shaft 31 is inserted into a through hole provided in the center of the rotor core 32 so as to extend to both sides of the rotor core 32 in the direction in which the axis C extends, and is fixed to the rotor core 32.

[0073] The rotor core 32 is a laminated body formed by laminating a plurality of steel plates along the direction (axial direction) in which the axis C of the rotating shaft 31 extends. The plurality of steel plates are, for example, electromagnetic steel plates punched into a predetermined shape. The plurality of steel plates are fixed to each other by, for example, caulking.

[0074] The permanent magnet 33 is inserted into the magnet insertion hole 32a provided in the rotor core 32. Six magnet insertion holes 32a are provided in the rotor core 32 at equal intervals throughout the circumference. Therefore, the rotor 30 has six permanent magnets 33 arranged at equal intervals throughout the circumference. That is, the number of poles of the motor 1 is 6. The permanent magnet 33 is a sintered magnet. However, the permanent magnet 33 may also be a bonded magnet.

[0075] The first bearing 41 and the second bearing 42 for holding the rotating shaft 31 rotatably are provided on the rotating shaft 31 of the rotor 30. The first bearing 41 and the second bearing 42 are bearings for holding the rotating shaft 31 rotatably. The first bearing 41 supports a portion of the rotating shaft 31 protruding from one side of the rotor core 32. The second bearing 42 supports a portion of the rotating shaft 31 protruding from the other side of the rotor core 32. As an example, the first bearing 41 and the second bearing 42 are ball bearings. However, this is not limited thereto.

[0076] The first bracket 51 holds the first bearing 41. Specifically, the first bearing 41 is fixed to a recessed portion provided in the first bracket 51. The second bracket 52 holds the second bearing 42. Specifically, the second bearing 42 is fixed to a recessed portion provided in the second bracket 52. The first bracket 51 and the second bracket 52 are made of a metal material or a resin material.

[0077] The first bracket 51 and the second bracket 52 constitute the outer contour of the motor 1. Specifically, the first bracket 51 is a bottomed cylindrical frame (housing) having an opening. The second bracket 52 is a bottom plate that closes the opening of the first bracket 51. The first bracket 51 is a metal frame made of metal. The second bracket 52 is a resin plate made of resin.

[0078] The rotating shaft 31 of the rotor 30 passes through the first bracket 51. A portion of the rotating shaft 31 protrudes from the first bracket 51 to the outside. Although not shown, a load such as a rotary fan is mounted on the portion of the rotating shaft 31 protruding from the first bracket 51 to the outside. In other words, the portion of the rotating shaft 31 protruding from the first bracket 51 is the output shaft.

[0079] In the motor 1 thus constructed, when the winding 12 of the stator 10 is energized, a field current flows in the winding 12, thereby generating a magnetic flux in the stator 10 (stator core 11). As a result, a magnetic flux is generated from the stator 10 toward the rotor 30. Specifically, a magnetic flux is generated from the teeth 11a of the stator core 11 of the stator 10 toward the rotor core 32 of the rotor 30. On the other hand, in the rotor 30, a magnetic flux passing through the stator 10 is generated by the permanent magnets 33 embedded in the rotor core 32. The magnetic force generated by the interaction between the magnetic flux generated in the stator 10 and the magnetic flux generated from the permanent magnets 33 of the rotor 30 becomes a torque that rotates the rotor 30. As a result, the rotor 30 rotates.

[0080] Next, refer to Figure 1 to Figure 6 and use Figure 7 and Figure 8 The structure of the intermediate assembly 100 of the stator 10 according to the present embodiment will be described. Figure 7 It is a perspective view of an intermediate assembly 100 of the stator 10 according to the embodiment. Figure 8 FIG. 1 is an exploded perspective view of an intermediate assembly 100 of a stator 10 according to an embodiment. Figure 7 and Figure 8 The winding 12 is omitted.

[0081] like Figure 2 to Figure 5 As shown, the stator 10 is formed by arranging a plurality of intermediate assemblies 100 in a cylindrical shape. Specifically, the plurality of intermediate assemblies 100 are arranged in a cylindrical shape.

[0082] As described above, the stator core 11 of the stator 10 is composed of a plurality of core blocks 110. Figure 2 As shown, the plurality of core blocks 110 are connected so as to form a ring shape as a whole.

[0083] A core block 110 is provided for each intermediate assembly 100. A winding 12 of the stator 10 is also provided for each intermediate assembly 100. A connection terminal 120 is provided corresponding to each of the core blocks 110. That is, a connection terminal 120 is provided for each intermediate assembly 100.

[0084] Therefore, if Figure 7 and Figure 8 As shown, the plurality of intermediate assemblies 100 each have a core block 110, a winding 12 (in Figure 7 and Figure 8 (not shown) and a connection terminal 120. In addition, each intermediate assembly 100 has an insulator 130. The insulator 130 is composed of a first insulator 131 and a second insulator 132 as a pair of insulators. Specifically, the insulator 130 is separated into the first insulator 131 and the second insulator 132 which are independent of each other.

[0085] In each intermediate assembly 100, the core block 110 has a tooth portion 111 and a yoke portion 112. The tooth portion 111 is Figure 2 The teeth 11 a of the stator core 11 are shown.

[0086] like Figure 2 and Figure 8 As shown, the teeth 111 are formed inside the yoke 112. The teeth 111 extend from the yoke 112 toward the center of the stator core 11. Specifically, the teeth 111 extend from the yoke 112 toward the rotating shaft 31. That is, the teeth 111 extend in a manner protruding radially inward of the stator 10.

[0087] The tooth portion 111 has an extension portion extending from the tip portion on the inner circumference side of the tooth portion 111 to both sides in the circumferential direction. The pair of extension portions are formed so as to protrude from the tip portion on the inner circumference side of the tooth portion 111 along the circumferential direction. Figure 2 As shown, in two adjacent core blocks 110 , a gap (notch) exists between an extended portion of the teeth 111 of one core block 110 and an extended portion of the teeth 111 of the other core block 110 .

[0088] In two adjacent intermediate assemblies 100 , a slot 11 b for arranging the winding 12 is formed between two adjacent teeth 111 . That is, in each intermediate assembly 100 , the slot 11 b is a space region on the side of the teeth 111 .

[0089] Although in Figure 7 and Figure 8 Although not shown in the figure, the winding 12 is wound around the tooth portion 111. Specifically, the winding 12 is wound around the tooth portion 111 via the insulator 130.

[0090] In each intermediate assembly 100, the yoke portion 112 is a back yoke formed outside the tooth portion 111. The yoke portion 112 extends along the circumferential direction of the stator core 11. Specifically, the yoke portion 112 extends along the circumferential direction (rotation direction of the rotating shaft 31) centered on the axis C of the rotating shaft 31. Figure 2 As shown in FIG. 1 , in two adjacent intermediate assemblies 100 , two adjacent yoke portions 112 are connected by abutting against each other at circumferential end surfaces. Figure 2 As shown, the nine yoke parts 112 are arranged along the circumferential direction of a circle centered on the axis C of the rotating shaft 31. The nine yoke parts 112 are connected so as to form an annular shape as a whole.

[0091] The core block 110 is formed by laminating a plurality of steel plates. Specifically, the core block 110 is a laminated body in which a plurality of punched electromagnetic steel plates are laminated along the direction in which the axis C of the rotating shaft 31 extends. The plurality of electromagnetic steel plates are fixed to each other by, for example, caulking.

[0092] The connection terminals 120 are respectively arranged corresponding to the plurality of core blocks 110. Figure 7 As shown, the connection terminal 120 is held by the insulator 130 fixed to the core block 110. The connection terminal 120 is fixed to the first insulator 131 of the first insulator 131 and the second insulator 132. Specifically, the connection terminal 120 is fixed to the first insulator 131 by embedding a part of the connection terminal 120 in the insulator 130. The connection terminal 120 is fixed to the first insulator 131 in a manner protruding in one direction of the cylindrical axis direction of the stator 10 (the axial direction of the rotating shaft 31). The connection terminal 120 and the first insulator 131 can be formed integrally, for example, by insert molding.

[0093] The connection terminal 120 is a metal terminal made of a metal material. As an example, the connection terminal 120 is made of a copper alloy. For example, the connection terminal 120 is made of brass. In other words, the connection terminal 120 is made of a metal plate.

[0094] The connection terminal 120 has a pair of connection pins, namely, a first connection pin 121 and a second connection pin 122. The first connection pin 121 and the second connection pin 122 are separated from each other without contacting each other. The first connection pin 121 and the second connection pin 122 are made of metal plates. The first connection pin 121 and the second connection pin 122 are bilaterally symmetrical.

[0095] exist Figure 7 and Figure 8 Although not shown in the figure, in each intermediate assembly 100, the connection terminal 120 is connected to the winding 12. Specifically, one end of the winding 12 is connected to the first connection pin 121. The other end of the winding 12 is connected to the second connection pin 122. As an example, the first connection pin 121 is connected to the end where the winding of the winding 12 starts, which is one end of the winding 12. The second connection pin 122 is connected to the end where the winding of the winding 12 ends, which is the other end of the winding 12.

[0096] The first connecting pin 121 has a first main body 121a extending in one direction and a first connecting portion 121b connected to one end of the winding 12. The first connecting portion 121b protrudes from the side portion of the outer side of the first main body 121a and is bent inwardly in a manner opposite to the first main body 121a. In the case of connecting the first connecting portion 121b and one end of the winding 12, for example, one end of the winding 12 is wound around the first connecting portion 121b, and the first connecting portion 121b and the winding 12 are connected by, for example, welding. The method of connecting the first connecting portion 121b and the winding 12 is not limited to welding, and can also be brazing.

[0097] The second connection pin 122 has a second main body 122a extending in one direction and a second connection portion 122b connected to the other end of the winding 12. The second connection portion 122b protrudes from the side portion of the outer side of the second main body 122a and is bent inwardly in a manner opposite to the second main body 122a. In the case of connecting the second connection portion 122b and the other end of the winding 12, for example, one end of the winding 12 is wound around the second connection portion 122b, and the second connection portion 122b and the winding 12 are connected by, for example, welding. The connection method of the second connection portion 122b and the winding 12 is not limited to welding, and can also be brazing.

[0098] like Figure 1 and Figure 6 As shown, the connection terminal 120 is connected to the circuit board 20. Specifically, the first connection pin 121 and the second connection pin 122 of the connection terminal 120 are inserted into the through hole 21 of the circuit board 20. More specifically, the first body portion 121a of the first connection pin 121 and the second body portion 122a of the second connection pin 122 are inserted into the through hole 21.

[0099] The first connecting pin 121 and the second connecting pin 122 are pressed into the through hole 21 of the circuit board 20. Specifically, the first main body 121a of the first connecting pin 121 and the second main body 122a of the second connecting pin 122 are pressed into the through hole 21 of the circuit board 20. In other words, the first main body 121a of the first connecting pin 121 and the second main body 122a of the second connecting pin 122 are inserted into the through hole 21 and embedded in the through hole 21. Thus, the first connecting pin 121 and the second connecting pin 122 are fixed to the circuit board 20.

[0100] The first connection pin 121 and the second connection pin 122 are mechanically connected to the circuit board 20 by being pressed into the through hole 21 of the circuit board 20. The first connection pin 121 and the second connection pin 122 are electrically connected to the wiring of the circuit board 20 by means of the conductive film formed on the inner peripheral surface of the through hole 21. Thus, the first connection pin 121 and the second connection pin 122 can be electrically and mechanically connected to the circuit board 20 without soldering.

[0101] like Figure 7 and Figure 8 As shown, a first protrusion 121c having a fractured tip is formed on a portion of the end surface of the first connecting pin 121 on the second connecting pin 122 side. Specifically, the first protrusion 121c is formed on the side end surface of the thickness portion of the first main body portion 121a of the first connecting pin 121.

[0102] A second protrusion 122c whose top end surface is a fracture surface is formed on a portion of the end surface on the first connecting pin 121 side of the second connecting pin 122. Specifically, the second protrusion 122c is formed on the side end surface of the thickness portion of the second main body portion 122a of the second connecting pin 122. The first protrusion 121c and the second protrusion 122c are formed at positions opposite to each other.

[0103] As described later, the first protrusion 121c of the first connecting pin 121 and the second protrusion 122c of the second connecting pin 122 are formed when the connecting portion connecting the first connecting pin 121 and the second connecting pin 122 is disconnected and removed. In other words, the first protrusion 121c and the second protrusion 122c are disconnection marks. The fracture surface of the first protrusion 121c and the fracture surface of the second protrusion 122c become the fracture surface formed when the connecting portion is disconnected. Therefore, the surface roughness of the fracture surface of the first protrusion 121c and the surface roughness of the fracture surface of the second protrusion 122c are greater than the surface roughness of the metal plate constituting the connecting terminal 120.

[0104] like Figure 7 and Figure 8 As shown, the first connecting pin 121 is formed with a first slit 121d extending in a direction when the first connecting pin 121 is pressed into the through hole 21 of the circuit board 20 (the pressing direction of the first connecting pin 121). The first slit 121d is formed in the first main body 121a of the first connecting pin 121. The first slit 121d is formed in the center of the width direction of the first connecting pin 121. The first slit 121d is formed in a straight line with a substantially constant width.

[0105] The second connecting pin 122 is provided with a second slit 122d extending in a direction (a direction in which the second connecting pin 122 is pressed into the through hole 21 of the circuit board 20). The second slit 122d is formed in the second main body 122a of the second connecting pin 122. The second slit 122d is formed in the center of the width direction of the second connecting pin 122. The second slit 122d is formed in a straight line with a substantially constant width.

[0106] When the first connecting pin 121 and the second connecting pin 122 are pressed into the through hole 21, the first slit 121d and the second slit 122d are located in the through hole 21. Therefore, the portion of the first connecting pin 121 where the first slit 121d is formed is a contact portion that contacts the inner surface of the through hole 21. The portion of the second connecting pin 122 where the second slit 122d is formed is a contact portion that contacts the inner surface of the through hole 21.

[0107] In each intermediate assembly 100, the insulator 130 has a frame-shaped frame portion around which the winding 12 is wound. Specifically, the frame portion of the insulator 130 is formed to surround at least the main body portion of the tooth portion 111 (tooth 11a). The insulator 130 is a resin molded product made of, for example, an insulating resin material.

[0108] The insulator 130 is fixed to the core block 110. Specifically, the first insulator 131 is fixed to one end of the core block 110. The second insulator 132 is fixed to the other end of the core block 110. The first insulator 131 and the second insulator 132 are arranged so as to sandwich the teeth 111 of the core block 110 from the cylindrical axis direction of the stator 10.

[0109] By combining a plurality of intermediate assemblies 100 configured in this way, Figure 5 The stator 10 is formed as shown. The stator 10 composed of a plurality of intermediate assemblies 100 is connected to the circuit board 20. Figure 5 As shown, the stator assembly 2 is formed by combining a stator 10 composed of a plurality of intermediate assemblies 100 and a circuit board 20 .

[0110] At this time, when the stator 10 and the circuit board 20 are assembled, the connection terminals 120 of the plurality of intermediate assemblies 100 constituting the stator 10 and the circuit board 20 are connected. However, instead of using the connection terminal 120 in which the first connection pin 121 and the second connection pin 122 are separated, a connection terminal 120A in which the first connection pin 121 and the second connection pin 122 are connected together is used as described below.

[0111] Here, use Figures 9 to 12 The structure of the connection terminal 120A used when manufacturing the stator assembly 2 will be described. Fig. 9 This is a perspective view of a connection terminal 120A according to the embodiment as seen from the front side. Fig.10 This is a perspective view of a connection terminal 120A according to the embodiment as viewed from the back side. Fig.11A It is a front view of the connection terminal 120A according to the embodiment. Fig. 11B It is a side view which magnifies the main part of the connection terminal 120A of this embodiment. Fig.12 It is an enlarged perspective view showing a part of the connection terminal 120A according to the embodiment.

[0112] like Figures 9 to 12As shown, the connection terminal 120A has a first connection pin 121 connected to one end of the winding 12 and a second connection pin 122 connected to the other end of the winding 12, similarly to the connection terminal 120 described above. The connection terminal 120A further has an extension portion 124 and a connection portion 123 connecting the first connection pin 121 and the second connection pin 122. In other words, the connection terminal 120A has a structure in which the connection portion 123 and the extension portion 124 are added to the connection terminal 120 described above.

[0113] The connection terminal 120A is formed by disconnecting the connection portion 123 of the connection terminal 120A when manufacturing the stator assembly 2, and the connection terminal 120A is formed by separating the first connection pin 121 and the second connection pin 122. The details will be described later. That is, the connection terminal 120A is an intermediate component used in the manufacturing process.

[0114] The connection terminal 120A configured in this way can be made of a metal plate. Fig. 9 and Fig.10 The connecting terminal 120A shown can be made by stamping a metal plate having a constant thickness and a predetermined shape. The thickness of the metal plate constituting the connecting terminal 120A is, for example, 0.5 mm. However, this is not limited to this. It is preferable to perform a conductive surface treatment on the surface of the connecting terminal 120A. For example, a plating treatment such as gold plating or tin plating can be performed on the surface of the metal plate constituting the connecting terminal 120A as a surface treatment.

[0115] like Fig.11A As shown in FIG. 1 , when the connection terminal 120A is viewed from the front, the extension portion 124 is located between the first connection pin 121 and the second connection pin 122. The extension portion 124 extends linearly from the connection portion 123 along the length direction of the first connection pin 121 (also the length direction of the second connection pin 122). The top end of the extension portion 124 protrudes relative to the top end of the first connection pin 121 and the top end of the second connection pin 122.

[0116] like Fig. 11B As shown, when the connection terminal 120A is viewed from the side, the first plane including the first connection pin 121 and the second connection pin 122 and the second plane including the extension portion 124 are present at positions offset in the front-back direction in a direction intersecting the direction in which the first connection pin and the second connection pin extend, and the first connection pin 121 and the second connection pin 122 and the extension portion 124 are present at positions offset in the front-back direction. In other words, the extension portion 124 does not exist in the plane including the arrangement direction of the first connection pin 121 and the second connection pin 122. The extension portion 124 is formed with a step difference from the first connection pin 121 and the second connection pin 122.

[0117] The extension portion 124 protrudes from the connection portion 123 to the side opposite to the tip end side of the first connection pin 121, and then makes a U-turn and extends toward the tip end side of the first connection pin 121. Fig. 9 and Fig.10 In the illustrated posture of the connection terminal 120A, the extension portion 124 protrudes downward from the lower end of the connection portion 123 , bends 180° in a U-shape, and extends upward.

[0118] A breaking portion 123a is provided at the connection portion of the connecting portion 123 with the first connecting pin 121 and the second connecting pin 122, and the breaking portion 123a has a width smaller than the thickness of the metal plate constituting the connecting terminal 120A. That is, the width of the connection portion of the connecting portion 123 with the first connecting pin 121 and the second connecting pin 122 in the extending direction of the extending portion 124 is narrow. Specifically, when the thickness of the metal plate constituting the connecting terminal 120A is t and the width of the breaking portion 123a is W, W<t. In this embodiment, the entire connecting portion 123 is the breaking portion 123a.

[0119] As described above, the connection terminal 120A of this embodiment is connected to the winding 12 arranged in the slot 11b of the stator core 11 of the electric motor 1, and the connection terminal 120A has a first connecting pin 121 connected to one end of the winding 12, a second connecting pin 122 connected to the other end of the winding 12, and a connecting portion 123 connecting the first connecting pin 121 and the second connecting pin 122.

[0120] This can prevent the connection pin from falling down due to stress or thermal stress.

[0121] The stator assembly 2 of the present embodiment includes a stator core 11, a winding 12 disposed in a slot 11b of the stator core 11, a connection terminal 120 connected to the winding 12, and a circuit board 20 connected to the connection terminal 120. The connection terminal 120 includes a first connection pin 121 connected to one end of the winding 12 and a second connection pin 122 connected to the other end of the winding 12. A first protrusion 121c having a top end surface being a fracture surface is formed on a portion of an end surface of the first connection pin 121 on the side of the second connection pin 122. A second protrusion 122c having a top end surface being a fracture surface is formed on a portion of an end surface of the second connection pin 122 on the side of the first connection pin 121.

[0122] The electric motor 1 of the present embodiment includes a stator assembly 2 and a rotor 30 facing the stator assembly 2 .

[0123] Next, use FIG. 13A to FIG. 13D A method for manufacturing the stator assembly 2 in which the stator 10 and the circuit board 20 are combined using the connection terminal 120A configured in this manner will be described. FIG. 13A to FIG. 13DIt is a figure for demonstrating the manufacturing method of the stator assembly 2 which concerns on embodiment. Fig.13A 1 shows a step of preparing the intermediate assembly 100A. Fig. 13B The steps of preparing the stator 10 and the circuit board 20 are shown. Fig. 13C The process of connecting the stator 10 and the circuit board 20 is shown. Fig.13D 1 shows a process of disconnecting the connection portion 123 of the connection terminal 120A. FIG. 13A to FIG. 13D The winding 12 is omitted.

[0124] like Fig.13A As shown in FIG. 1 , an intermediate assembly 100A is prepared. Specifically, an intermediate assembly 100A including a core block 110 , a connection terminal 120A, and an insulator 130 is prepared.

[0125] Although not shown, the intermediate assembly 100A is provided with the winding 12. At this time, one end of the winding 12 is connected to the first connection pin 121 of the connection terminal 120A. The other end of the winding 12 is connected to the second connection pin 122 of the connection terminal 120A.

[0126] For example, one end of the winding 12 is wound around the first connecting portion 121b of the first connecting pin 121 to connect the first connecting portion 121b and the winding 12. The other end of the winding 12 is wound around the second connecting portion 122b of the second connecting pin 122 to connect the second connecting portion 122b and the winding 12.

[0127] At this time, the first connecting pin 121 and the second connecting pin 122 are connected by the connecting portion 123. Therefore, the first connecting pin 121 and the second connecting pin 122 can be effectively prevented from tilting due to stress or thermal stress when connecting the first connecting pin 121 and the winding 12 and the second connecting pin 122 to the winding 12.

[0128] The first connection pin 121 and the winding 12, and the second connection pin 122 and the winding 12 are connected by welding. Thus, stress or thermal stress can be relieved compared to the case where the first connection pin 121 and the winding 12, and the second connection pin 122 and the winding 12 are connected by brazing. Therefore, the first connection pin 121 and the second connection pin 122 can be further prevented from tilting.

[0129] The first connection pin 121 and the winding 12, and the second connection pin 122 and the winding 12 may be connected by brazing instead of welding. Even when the first connection pin 121 and the winding 12, and the second connection pin 122 and the winding 12 are connected by brazing, the first connection pin 121 and the second connection pin 122 are connected by the connection portion 123. Thus, it is possible to suppress the first connection pin 121 and the second connection pin 122 from tilting due to stress or thermal stress when the first connection pin 121 and the winding 12, and the second connection pin 122 and the winding 12 are brazed.

[0130] Then, if Fig. 13B As shown, the stator 10 and the circuit board 20 are prepared. Specifically, the circuit board 20 and the stator 10 having the connection terminals 120A, the stator core 11 and the winding 12 (not shown) are prepared.

[0131] The stator core 11 is composed of a plurality of core blocks 110. The connection terminals 120A are provided corresponding to the core blocks 110, respectively. Therefore, the stator 10 is prepared using an intermediate assembly 100A composed of one core block 110, one connection terminal 120A, and one winding 12.

[0132] In this case, the plurality of intermediate assemblies 100A are configured in a cylindrical shape. Specifically, the plurality of intermediate assemblies 100A are arranged in a circular ring shape in a posture where the length direction of each intermediate assembly 100A is parallel to the cylindrical axis direction of the stator 10. At this time, the plurality of intermediate assemblies 100A are configured in a manner such that the connection terminals 120A of each intermediate assembly 100A are aligned in one direction. That is, the connection terminals 120A of each of the plurality of intermediate assemblies 100A protrude toward one direction in the cylindrical axis direction of the stator 10. Thus, the stator 10 composed of the plurality of intermediate assemblies 100A configured in a cylindrical shape can be prepared.

[0133] Then, if Fig. 13C As shown, the circuit board 20 and the stator 10 composed of a plurality of intermediate assemblies 100A are connected. Specifically, the stator 10 is connected to the circuit board 20 by connecting the connection terminals 120A to the circuit board 20. At this time, the connection terminals 120A of all the intermediate assemblies 100A of the stator 10 are connected to the circuit board 20 at the same time.

[0134] Specifically, in all intermediate assemblies 100A, the first connection pin 121 and the second connection pin 122 of the connection terminal 120A are simultaneously inserted into the through hole 21 of the circuit board 20. More specifically, Fig. 13BAs shown by the solid arrow, in each intermediate assembly 100A, the first main body 121a of the first connecting pin 121 is inserted into one of the two adjacent through holes 21. The second main body 122a of the second connecting pin 122 is inserted into the other of the two adjacent through holes 21.

[0135] When the first connecting pin 121 and the second connecting pin 122 are inserted into the through hole 21, the first connecting pin 121 and the second connecting pin 122 are pressed into the through hole 21. Specifically, the first main body 121a of the first connecting pin 121 and the second main body 122a of the second connecting pin 122 are lightly pressed into the through hole 21. In other words, the first main body 121a of the first connecting pin 121 and the second main body 122a of the second connecting pin 122 are inserted into the through hole 21 and tightly embedded in the through hole 21.

[0136] At this time, if Fig.11A As shown in FIG. 1 , a first slit 121d is formed in the first connecting pin 121. Fig. 13B and Fig. 13C As shown, the stress received by the first connecting pin 121 from the inner surface of the through hole 21 due to the first connecting pin 121 being pressed into the through hole 21 can be absorbed by the first slit 121d. The second connecting pin 122 is formed with the second slit 122d. Thus, the stress received by the second connecting pin 122 from the inner surface of the through hole 21 due to the second connecting pin 122 being pressed into the through hole 21 can be absorbed by the second slit 122d. In this way, the first slit 121d and the second slit 122d function as stress absorbing slits.

[0137] By pressing the first connection pin 121 and the second connection pin 122 into the through hole 21, the first connection pin 121 and the second connection pin 122 can be fixed to the circuit board 20. In other words, the connection terminal 120A is fixed to the circuit board 20. Thus, all the connection terminals 120A are fixed to the circuit board 20 at the same time. Thus, the intermediate assembly 100A is fixed to the circuit board 20.

[0138] At this time, the inner circumference of the through hole 21 of the circuit board 20 is coated with a conductive film electrically connected to the wiring formed on the main surface of the circuit board 20. Thus, the first connecting pin 121 and the second connecting pin 122 are pressed into the through hole 21 so as to contact the inner circumference of the through hole 21, thereby being able to electrically connect the first connecting pin 121 and the second connecting pin 122 to the wiring of the circuit board 20.

[0139] In this way, by pressing the first connection pin 121 and the second connection pin 122 of the connection terminal 120A into the through hole 21 of the circuit board 20, the first connection pin 121 and the second connection pin 122 can be electrically and mechanically connected to the circuit board 20, respectively. In other words, the first connection pin 121 and the second connection pin 122 can be electrically and mechanically connected to the circuit board 20, respectively, without soldering. Alternatively, the first connection pin 121 and the circuit board 20 and the second connection pin 122 and the circuit board 20 can be soldered after the first connection pin 121 and the second connection pin 122 are pressed into the through hole 21 of the circuit board 20.

[0140] The first connection pin 121 and the second connection pin 122 are connected to the winding 12 . Therefore, by press-fitting the first connection pin 121 and the second connection pin 122 into the through hole 21 , the wiring of the circuit board 20 and the winding 12 can be electrically connected via the first connection pin 121 and the second connection pin 122 .

[0141] At this time, as described above, the first connecting pin 121 and the second connecting pin 122 are connected by the connecting portion 123, and the first connecting pin 121 and the second connecting pin 122 can be prevented from falling. Therefore, when the first connecting pin 121 and the second connecting pin 122 are inserted into the circuit board 20, the first connecting pin 121 and the second connecting pin 122 can be smoothly inserted into the through hole 21 without interfering with the through hole 21 of the circuit board 20. Thus, the quality of the stator assembly 2 can be ensured. In addition, cost reduction can be achieved by improving productivity.

[0142] A notch 22 is formed at the end of the circuit board 20. The notch 22 is formed corresponding to the extension 124 of the connection terminal 120A. When the stator 10 (intermediate assembly 100) is connected to the circuit board 20, Fig. 13B As shown by the dotted arrow, the extension portion 124 of the connection terminal 120A is inserted into the notch portion 22. That is, when the connection terminal 120A is connected to the circuit board 20, the first connection pin 121 and the second connection pin 122 are inserted into the through hole 21 of the circuit board 20. In addition, the extension portion 124 is inserted into the notch portion 22.

[0143] Thus, the extension portion 124 and the notch portion 22 function as a guide portion. Therefore, the connection terminal 120A can be easily connected to the circuit board 20 .

[0144] Then, if Fig.13D As shown in FIG. 1 , the connecting portion 123 of the connecting terminal 120A is disconnected. Thus, the first connecting pin 121 and the second connecting pin 122 are separated. Here, the connecting portion 123 is disconnected by the extending portion 124 .

[0145] Specifically, like Fig. 13CAs shown by the arrow in FIG. 1 , the extension portion 124 is rotated in such a way that the top end of the extension portion 124 is pulled forward to tilt. Thus, the extension portion 124 rotates with the connecting portion 123 as a fulcrum. Thus, according to this principle, the connecting portion 123 can be twisted and disconnected. At this time, the connecting portion 123 and the extension portion 124 are removed from the connecting terminal 120A as a whole. That is, the connecting portion 123 and the extension portion 124 are removed from the first connecting pin 121 and the second connecting pin 122.

[0146] Thus, by providing the extension portion 124 in the connection terminal 120A, the connection portion 123 can be easily disconnected. Moreover, the top end of the extension portion 124 protrudes relative to the top end of the first connection pin 121 and the top end of the second connection pin 122. Thus, the top end of the extension portion 124 can be easily grasped. Therefore, the workability when disconnecting the connection portion 123 can be improved.

[0147] like Fig. 9 and Fig.10 As shown in FIG. 1 , both the first connection pin 121 and the second connection pin 122 and the extending portion 124 are present at positions offset in the front-rear direction.

[0148] According to this structure, when removing the connection part 123, the extension part 124 can be pulled forward and easily rotated. Thereby, the workability when disconnecting the connection part 123 is further improved.

[0149] like Fig. 9 and Fig.10 As shown, the extension portion 124 protrudes from the connection portion 123 to the side opposite to the tip end side of the first connection pin 121 , and then makes a U-turn to extend toward the tip end side of the first connection pin 121 .

[0150] According to this structure, when the extension part 124 is rotated, the torsional stress applied to the connection part 123 can be increased. Therefore, the connection part 123 can be easily disconnected.

[0151] like Fig.11A As shown, a breaking portion 123 a having a width smaller than the thickness of the metal plate constituting the connection terminal 120A is provided at a portion of the connection portion 123 that is connected to the first connection pin 121 and the second connection pin 122 .

[0152] This can reduce the strength of the breaking portion 123a. Therefore, the connecting portion 123 can be broken more easily at the breaking portion 123a.

[0153] At this time, if Fig.13DAs shown, by disconnecting the connecting portion 123 from the first connecting pin 121 and the second connecting pin 122, a first protrusion 121c is formed on the end surface of the first connecting pin 121 on the second connecting pin 122 side. In addition, a second protrusion 122c is formed on the end surface of the second connecting pin 122 on the first connecting pin 121 side. Fig.14 An example of the first protrusion 121 c formed on the first connecting pin 121 is shown in the photograph of FIG. Fig.14 This is a diagram showing a photograph of the first protrusion 121 c formed on the first connection pin 121 after the coupling portion 123 of the connection terminal 120A is disconnected.

[0154] Like above, Fig.13D As shown, the stator assembly 2 can be manufactured by combining the circuit board 20 and the stator 10 composed of a plurality of intermediate assemblies 100A.

[0155] As described above, the manufacturing method of the stator assembly 2 of the present embodiment includes: a step of preparing the stator 10 having the connection terminal 120A, the stator core 11, and the winding 12; and a step of connecting the stator 10 to the circuit board 20 by connecting the connection terminal 120A to the circuit board 20. The connection terminal 120A includes the first connection pin 121 connected to one end of the winding 12, the second connection pin 122 connected to the other end of the winding 12, and the connection portion 123 connecting the first connection pin 121 and the second connection pin 122. In the step of connecting the stator 10 to the circuit board 20, the first connection pin 121 and the second connection pin 122 of the connection terminal 120A are electrically and mechanically connected to the circuit board 20, respectively. The manufacturing method of the stator assembly 2 includes a step of disconnecting the connection portion 123 of the connection terminal 120A after connecting the connection terminal 120A to the circuit board 20.

[0156] In this way, it is possible to manufacture the stator assembly 2 in which the circuit board 20 and the stator 10 formed of the plurality of intermediate assemblies 100A are combined.

[0157] (Variation Example)

[0158] As mentioned above, the present disclosure has been described based on the embodiments, but the present disclosure is not limited to the above-mentioned embodiments.

[0159] Fig.15A This is an enlarged front view of the connection terminal 120B according to the first modification. Fig. 15B The connection terminal 120B of the modification example 1 is along Fig.15A The cross-sectional view of the B-B line. Fig.15A and Fig. 15B Like the connecting terminal 120B shown in the figure, a groove 125 extending in the entire width direction of the connecting portion 123 is formed on the surface of the metal plate of the connecting portion 123 .

[0160] like Fig. 15B As shown, the groove 125 is, for example, a V-shaped groove having a V-shaped cross section. By forming the groove 125 in the connecting portion 123 in this way, the connecting portion 123 can be disconnected more easily. Fig.15A and Fig. 15B As shown in FIG. 1 , it is preferable that the groove 125 is formed in the breaking portion 123a of the connecting portion 123. Thus, the connecting portion 123 can be broken more easily. Fig. 15B As shown, it is preferable that the grooves 125 are formed on both sides of the metal plate of the connection portion 123 so as to face each other. Thereby, the connection portion 123 can be disconnected more easily.

[0161] In the connection terminal 120A of the above embodiment, both the first connection pin 121 and the second connection pin 122 are offset from the extension portion 124 in the front-rear direction. However, the present invention is not limited thereto. Fig.16 1 is an enlarged front view of the connection terminal 120C of the modification example 2. Fig.16 As shown in the connecting terminal 120C, the first connecting pin 121 and the second connecting pin 122 are not offset from the extending portion 124C in the front-rear direction, but are configured so that the first connecting pin 121, the second connecting pin 122 and the extending portion 124C form the same plane. In other words, the first connecting pin 121, the second connecting pin 122 and the extending portion 124C may be flush with each other on both sides.

[0162] In the connection terminal 120A of the above embodiment, the extension portion 124 is provided, but the present invention is not limited thereto. Fig.17 This is an enlarged front view of the connection terminal 120D of the modification example 3. Fig.17 As in the illustrated connection terminal 120D, the first connection pin 121 and the second connection pin 122 are connected only by the connection portion 123 .

[0163] In the above embodiment, the connection terminal 120A is applied to the circuit board 20 of the stator assembly 2. However, the present invention is not limited thereto. The connection terminal 120A can be widely applied to circuit boards used in the motor 1. For example, the connection terminal 120A can also be applied to a circuit board of an encoder included in the motor.

[0164] In the above embodiment, the rotor 30 is an IPM rotor. However, the present invention is not limited thereto. For example, the rotor 30 may be a surface magnet rotor (SPM (Surface Permanent Magnetic) rotor) in which a plurality of permanent magnets are provided on the outer surface of the rotor core.

[0165] In the above embodiment, the rotor 30 is a laminated body formed by laminating a plurality of steel plates. However, the present invention is not limited thereto. For example, the rotor 30 may be formed of a block material.

[0166] In the above embodiment, the motor 1 has 6 poles and 12 slots. However, this is not limited to this. That is, the number of slots of the stator 10 is not limited to 12. The number of magnetic poles of the rotor 30 is not limited to 6 (that is, the number of permanent magnets 33 is 6). The number of slots of the stator 10 and the number of magnetic poles of the rotor 30 can be any number.

[0167] In addition, various modifications that can be conceived by those skilled in the art to the above-mentioned embodiments or arbitrarily combining the components and functions of the above-mentioned embodiments within the scope not departing from the gist of the present disclosure are also included in the present disclosure.

[0168] Industrial Applicability

[0169] The technology disclosed herein can be widely used in electric motors, electric devices including electric motors, and the like.

[0170] Description of Reference Numerals

[0171] 1. Motor; 2. Stator assembly; 10. Stator; 11. Stator core; 11a. Teeth; 11b. Slots; 12. Winding; 20. Circuit board; 21. Through hole; 22. Notch; 30. Rotor; 31. Rotating shaft; 32. Rotor core; 32a. Magnet insertion hole; 33. Permanent magnet; 41. First bearing; 42. Second bearing; 51. First bracket; 52. Second bracket; 100, 100A, intermediate assembly; 110, core block; 111. Teeth; 112. Yoke; 120, 120A, 120 B, 120C, 120D, connecting terminal; 121, first connecting pin; 121a, first main body; 121b, first wiring part; 121c, first protrusion; 121d, first slit; 122, second connecting pin; 122a, second main body; 122b, second wiring part; 122c, second protrusion; 122d, second slit; 123, connecting part; 123a, cutting part; 124, 124C, extension part; 125, groove; 130, insulator; 131, first insulator; 132, second insulator.

Claims

1. A connection terminal connected to a winding arranged in a slot of a stator core of an electric motor, wherein: The connection terminal has: a first connecting pin connected to one end of the winding; a second connecting pin connected to the other end of the winding; and A connecting portion connects the first connecting pin and the second connecting pin.

2. The connecting terminal according to claim 1, wherein: The connecting terminal is composed of a metal plate. A cutting portion having a width smaller than a plate thickness of the metal plate is provided at a connection portion of the coupling portion connected to the first connecting pin and the second connecting pin.

3. The connection terminal according to claim 2, wherein: The direction in which the first connection pin and the second connection pin extend is defined as a width direction, and a groove extending in the entire width direction of the connection portion is formed on the surface of the metal plate of the connection portion.

4. The connecting terminal according to any one of claims 1 to 3, wherein: The connection terminal further includes an extension portion, which is located between the first connection pin and the second connection pin when the connection terminal is viewed from the front and extends from the connection portion along the length direction of the first connection pin.

5. The connecting terminal according to claim 4, wherein: When observing the connecting terminal from the side, with respect to the first connecting pin, the second connecting pin and the extending portion, a first plane including the first connecting pin and the second connecting pin and a second plane including the extending portion are present at positions offset in the front-to-back direction in a direction intersecting the direction in which the first connecting pin and the second connecting pin extend.

6. The connecting terminal according to claim 5, wherein: The extension portion protrudes from the connection portion to the side opposite to the tip end portion side of the first connection pin, and then makes a U-shape turn to extend toward the tip end portion side of the first connection pin.

7. The connecting terminal according to any one of claims 1 to 3, wherein: The first connecting pin has a first main body portion extending in one direction and a first connecting portion connected to one end of the winding. The second connecting pin has a second main body portion extending in the one direction and a second connecting portion connected to the other end of the winding. The first connecting portion protrudes from the side portion of the outer side of the first main body portion and is bent inwardly so as to face the first main body portion. The second connecting portion protrudes from a side portion of an outer side of the second main body portion and is bent inwardly so as to face the second main body portion.

8. The connecting terminal according to any one of claims 1 to 3, wherein: The stator core is divided into a plurality of core blocks. The connection terminals are respectively arranged corresponding to the plurality of core blocks.

9. A stator assembly, wherein: The stator assembly comprises: stator core; Windings arranged in slots of the stator core; A connecting terminal connected to the winding; and a circuit board connected to the connecting terminal, The connection terminal includes a first connection pin connected to one end of the winding and a second connection pin connected to the other end of the winding. A protrusion whose top end surface is a fractured surface is formed on a portion of the end surface of the first connecting pin on the side close to the second connecting pin. A protrusion whose tip end surface is a fractured surface is formed on a portion of the end surface of the second connecting pin on the first connecting pin side.

10. The stator assembly according to claim 9, wherein: The stator core is composed of a plurality of core blocks. The connection terminals are respectively arranged corresponding to the plurality of core blocks.

11. The stator assembly according to claim 10, wherein: The connection terminal is held by an insulator, and the insulator is fixed to the plurality of core blocks.

12. An electric motor, wherein: The motor includes: The stator assembly according to any one of claims 9 to 11; and The rotor faces the stator assembly.

13. A method for manufacturing a stator assembly, wherein: The manufacturing method of the stator assembly comprises: The process of preparing a stator having connection terminals, a stator core and windings; as well as a step of connecting the stator to the circuit board by connecting the connection terminal to the circuit board, The connection terminal includes a first connection pin connected to one end of the winding, a second connection pin connected to the other end of the winding, and a connection portion connecting the first connection pin and the second connection pin. In the step of connecting the stator to the circuit board, the first connection pin and the second connection pin of the connection terminal are electrically and mechanically connected to the circuit board respectively. The method for manufacturing the stator assembly includes a step of disconnecting the connection portion of the connection terminal after the connection terminal is connected to the circuit board.

14. The method for manufacturing a stator assembly according to claim 13, wherein: The connecting terminal further includes an extension portion, which is located between the first connecting pin and the second connecting pin and extends from the connecting portion along the length direction of the first connecting pin and the second connecting pin. A notch is formed at an end of the circuit board. In the step of connecting the stator to the circuit board, the first connecting pin and the second connecting pin are inserted into the through hole provided in the circuit board and the extending portion is inserted into the notch portion. In the step of disconnecting the connection portion, the connection portion is disconnected by rotating the extension portion with the connection portion as a fulcrum, so that the connection portion and the extension portion are removed from the first connection pin and the second connection pin as a whole.

15. The method for manufacturing a stator assembly according to claim 13 or 14, wherein: After one end of the winding is connected to the first connection pin and the other end of the winding is connected to the second connection pin, the connection portion of the connection terminal is disconnected.

16. The method for manufacturing a stator assembly according to claim 13 or 14, wherein: The stator core is composed of a plurality of core blocks. The connection terminals are respectively arranged corresponding to the plurality of core blocks. An intermediate assembly is formed by one of the core blocks, one of the connection terminals and one of the windings. The stator is formed by arranging a plurality of the intermediate assemblies in a cylindrical shape. In the stator, the connection terminal of each of the plurality of intermediate assemblies protrudes in one direction of the cylindrical axis direction of the stator.

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