Stator and method for manufacturing stator

Abstract

A stator (1) is provided with a stator core (10), a coil (20), a conductor part (60), and an insulating resin (40). The stator core (10) is annular. The coil (20) is provided with a protruding part (29), and the protruding part (29) protrudes towards one side of the axial direction compared with the end part of one side of the axial direction of the stator core (10). The conductor part (60) is connected to the protruding part (29). The insulating resin (40) forms a press-fit groove (50) between the insulating resin (40) and the protrusion (29). The conductor part (60) is press-fitted into the press-fitting groove (50) and is disposed in a state of being pressed against the protruding part (29).

Description

Technical Field

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

[0002] Patent document 1 discloses a stator portion of a molded motor. The stator portion includes a winding. Terminal pins are soldered to the winding ends of the winding. The terminal pins are connected to an actual machine (e.g., a component of a drive motor) via a connector. In patent document 1, the terminal pins are soldered, but welding can usually be used instead of soldering. Prior art literature Patent Literature

[0003] Patent Document 1: Japanese Patent Application Publication No. 2013-215025 Summary of the invention Problems to be solved by the invention

[0004] There is a demand for a technology that can easily maintain the connection state between the coil and the conductor portion (terminal pin) even without providing the above-mentioned welded portion and soldered portion.

[0005] One of the objects of the present invention is to provide a technology that can easily maintain the connection state between a coil and a conductor portion even without providing a welded portion or a soldered portion. Solutions to Solve Problems

[0006] The stator of the present invention has: a ring-shaped stator core; The coil has a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion on one side in the axial direction of the stator core; a conductor portion connected to the protruding portion; and The insulating resin forms a press-fit groove between the insulating resin and the protrusion. The conductor portion is press-fitted into the press-fit groove and is arranged in a state of being pressed against the protrusion.

[0007] The stator manufacturing method of the present invention includes a preparation step and a press-fitting step. In the preparation step, a stator body is prepared, wherein the stator body includes: an annular stator core; a coil having a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion of the stator core on one side in the axial direction; a conductor connected to the protrusion; and an insulating resin forming a press-fit groove between the coil and the protrusion. In the press-fitting step, the conductor portion is press-fitted into the press-fitting groove in the stator body to press the conductor portion against the protruding portion. Effects of the Invention

[0008] The technology of the present invention can easily maintain the connection state between the coil and the conductor part even without providing a welding part or a soldering part. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a perspective view of the stator according to the first embodiment. Figure 2 It is a top view of the stator according to the first embodiment. Figure 3 This is a perspective view of a state where a coil is mounted on a stator core. Figure 4 It is a three-dimensional diagram of the stator body. Figure 5 This is a perspective view of the stator body cut along the axial direction. Figure 6 It is an explanatory diagram showing a state before the unit components are assembled to the stator body. Figure 7 It is explained in Figure 2 An explanatory diagram of a state in which a conductor portion is pressed into a press-fit groove in a cross section along line AA of FIG. Figure 8 It is an explanatory diagram for explaining a state where a conductor portion according to the second embodiment is press-fitted into a press-fit groove. Fig. 9 It is a top view of the periphery of the press-fit groove in the second embodiment. Fig.10 It is an explanatory diagram for explaining a state where a conductor portion according to the third embodiment is press-fitted into a press-fit groove. Fig.11 It is a top view of the periphery of the press-fit groove according to the third embodiment. Fig.12 It is an explanatory diagram for explaining a state where a conductor portion according to a fourth embodiment is press-fitted into a press-fit groove. Fig.13 It is a top view of the periphery of the press-fit groove in the fourth embodiment. Fig.14 It is a top view of the stator body of the fifth embodiment. Fig.15 It is a top view of the stator of the fifth embodiment. DETAILED DESCRIPTION

[0010] Hereinafter, embodiments of the present invention will be described by way of example.

[0011] [1] A stator comprising: a ring-shaped stator core; The coil has a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion on one side in the axial direction of the stator core; a conductor portion connected to the protruding portion; and The insulating resin forms a press-fit groove between the insulating resin and the protrusion. The conductor portion is press-fitted into the press-fit groove and is arranged in a state of being pressed against the protrusion.

[0012] In the above-mentioned stator, since the conductor portion is press-fitted into the press-fit groove and arranged in a state of being pressed against the protrusion, the connection state between the coil and the conductor portion can be easily maintained even without providing a welding portion or a soldering portion.

[0013] [2] In the stator described in [1], A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. A plurality of the conductor parts are provided, further comprising a holding portion for holding a plurality of the conductor portions, The conductor portions held by the holding portion are each pressed into the press-fit groove and are arranged in a state of being pressed against the protruding portions.

[0014] In the above-mentioned stator, since the plurality of conductor portions connected to the separately separated protruding portions are held by the holding portion, the relative positional relationship of the plurality of conductor portions can be easily maintained.

[0015] [3] In the stator described in [2], The plurality of press-fit grooves arranged along the circumferential direction extend radially along the radial direction of the stator core. Each of the press-fit grooves has an opening portion that opens toward one side in the axial direction. Each of the conductor parts can be removed from the press-fit groove through the opening.

[0016] In a structure where a plurality of press-fit grooves extend radially, if the conductor parts pressed into the respective press-fit grooves are removed from the radially outer side at once, the respective conductor parts will interfere with the inner wall of the press-fit groove. However, in the above-mentioned stator, since the conductor parts can be removed from one side in the axial direction through the opening part, the conductor parts are unlikely to interfere with the inner wall of the press-fit groove, and as a result, the plurality of conductor parts integrated via the retaining part can be easily removed at once.

[0017] [4] In the stator described in [2] or [3], Each of the press-fit grooves has an outer peripheral opening portion that opens toward the radially outer side of the stator core. The holding portion is arranged at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction. Each of the conductor portions held by the holding portion protrudes from the radially inner surface of the holding portion and is arranged in the press-fit groove via the outer peripheral opening.

[0018] In the above-mentioned stator, since the holding portion holding the plurality of conductor portions is arranged radially outward of the plurality of press-fit grooves arranged in the circumferential direction, it is easy to reduce the size of the stator in the axial direction.

[0019] [5] In the stator described in any one of [2] to [4], The stator is used for an electric motor, The stator includes a terminal portion electrically connected to a driving portion that drives the motor. The terminal portion is formed to protrude from the radially outer surface of the holding portion.

[0020] In the above-mentioned stator, since the terminal portion is formed to protrude from the radially outer surface of the holding portion, it is easy to reduce the size of the stator in the axial direction.

[0021] [6] In the stator described in any one of [3] to [5], Each of the press-fit grooves has an outer peripheral opening portion that opens toward the radially outer side of the stator core. The holding portion is arranged at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction. Each of the conductor portions pressed into each of the press-fit grooves is connected to the radially inner surface of the holding portion via the outer peripheral opening. The opening portion and the outer peripheral opening portion are continuously opened.

[0022] Since the stator has a retaining portion for retaining a plurality of conductors disposed radially outwardly of a plurality of press-fit grooves arranged in the circumferential direction, the stator can be easily miniaturized in the axial direction. That is, the stator can remove a plurality of conductors integrated via the retaining portion from one side in the axial direction, and the stator can be easily miniaturized in the axial direction.

[0023] [7] In the stator described in any one of [2] to [6], The retaining portion is formed to extend in an arc shape along the circumferential direction, Each of the conductor portions is arranged on the circumferential center side of the holding portion with respect to the protruding portion of the connection target.

[0024] In the above-mentioned stator, even if the holding portion is thermally expanded and deformed to reduce the curvature, each conductor portion tends to be displaced toward the protruding portion side of the connection object, so that the connection state between the conductor portion and the protruding portion is easily maintained.

[0025] [8] In the stator described in any one of [1] to [7], A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. A plurality of the conductor parts are provided, Each of the conductor parts is pressed into each of the press-in grooves and is arranged in a state of being pressed against each of the protruding parts. The axial direction of each conductor part is entirely embedded in each press-fit groove. The side of the protrusion opposite to the press-fit groove side is covered with the insulating resin.

[0026] In the above-mentioned stator, since the conductor part is entirely embedded in the press-fit groove in the axial direction and the side of the protrusion opposite to the press-fit groove is covered with insulating resin, it is easy to insulate the protrusion from the protrusion adjacent to the protrusion in the circumferential direction and the conductor part connected to the adjacent protrusion.

[0027] [9] In the stator described in any one of [1] to [8], The stator core has a plurality of slots arranged along the circumferential direction of the stator core. The coil has an insertion portion arranged in the slot, The insulating resin includes a filling portion that continuously fills a space between the inner wall of the slot and the insertion portion and a forming portion that forms the press-fit groove. The filling portion and the forming portion are integrally formed.

[0028] In the above-mentioned stator, since the heat generated in the insertion portion and the conductor portion of the coil is easily transferred to the stator core via the insulating resin, the heat of the coil is easily dissipated.

[0029]

[10] In the stator described in any one of [1] to [9], The coil includes two or more protrusions arranged in a radial direction of the stator core. One of the press-fit grooves is formed between the two or more protrusions and the insulating resin, One of the conductor portions is press-fitted into one of the press-fit grooves and is arranged in a state of being pressed against the two or more protrusions forming the press-fit groove.

[0030] The above-mentioned stator can connect one conductor portion to two or more protrusions arranged in the radial direction.

[0031]

[11] A method for manufacturing a stator, comprising a preparation step and a pressing step, In the preparation step, a stator body is prepared, wherein the stator body includes: an annular stator core; a coil having a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion of the stator core on one side in the axial direction; a conductor connected to the protrusion; and an insulating resin forming a press-fit groove between the coil and the protrusion. In the press-fitting step, the conductor portion is press-fitted into the press-fitting groove in the stator body to press the conductor portion against the protruding portion.

[0032] According to the stator manufacturing method, the conductor portion is pressed against the protrusion by press-fitting the conductor portion into the press-fit groove, so that the connection between the conductor portion and the protrusion can be easily maintained even without providing a welded portion or a soldered portion.

[0033]

[12] In the method for manufacturing a stator as described in

[11] , In the preparation step, a unit component is prepared, wherein the unit component has a structure in which a plurality of the conductor parts are held by a holding part. A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. Each of the press-fit grooves has an opening portion that opens toward one side in the axial direction. In the press-fitting step, the unit member is displaced to the other side in the axial direction, so that the conductor portions are press-fitted into the press-fitting grooves through the openings.

[0034] According to the above-mentioned method for manufacturing a stator, a plurality of conductor parts can be press-fitted into each press-fit groove at a time and pressed against the protrusion forming each press-fit groove.

[0035]

[13] In the method for manufacturing a stator described in

[11] or

[12] , The stator core has a plurality of slots arranged along the circumferential direction of the stator core. The coil has an insertion portion arranged in the slot, The method further comprises a filling step of filling a resin material between an inner wall of the slot and the insertion portion, In the filling step, the press-fit groove is formed while the resin material is filled between the inner wall of the slot and the insertion portion.

[0036] According to the above-mentioned method for manufacturing a stator, even when the resin material is filled between the inner wall of the slot and the insertion portion, the press-fit groove can be formed, and thus the manufacturing process can be easily simplified.

[0037] <First Embodiment> 1. Structure of stator 1 The stator 1 of the first embodiment is used as a component of an electric motor. The stator 1 is annular, more specifically, annular. Figure 1 and Figure 6 As shown, the stator 1 is configured by connecting the unit components 3 to the stator body 2 .

[0038] like Figure 5 As shown, the stator body 2 includes a stator core 10 , a coil 20 , and an insulating resin 40 .

[0039] like Figure 3 As shown, the stator core 10 is annular, more specifically, annular. Hereinafter, the radial direction of the stator core 10 is referred to as the radial direction, the axial direction of the stator core 10 is referred to as the axial direction, and the circumferential direction of the stator core 10 is referred to as the circumferential direction.

[0040] The stator core 10 may be, for example, a laminated steel plate produced by laminating a plurality of electromagnetic steel plates (eg, silicon steel plates) in the axial direction (thickness direction), or a powder magnetic core formed by press-molding insulating coated magnetic particles.

[0041] like Figure 3 As shown, the stator core 10 has a yoke portion 11 and a plurality of teeth 12. The yoke portion 11 is annular, more specifically, circular. The plurality of teeth 12 are arranged in annular shape along the inner circumference of the yoke portion 11. The teeth 12 are arranged at intervals in the circumferential direction. The teeth 12 protrude radially inward from the inner circumference of the yoke portion 11. The teeth 12 are in the shape of a wall along the radial and axial directions. The radial inner end of each tooth 12 protrudes to both sides of the circumference.

[0042] like Figure 3 As shown in FIG. 1 , the stator core 10 has a plurality of slots 15. The plurality of slots 15 are arranged in a circumferential direction and are annular. The slots 15 penetrate the stator core 10 in the axial direction. Figure 3 As shown, each slot 15 is formed by being partitioned by the yoke portion 11 and two adjacent teeth portions 12. The slot 15 is open on both sides of the stator core 10 in the axial direction and is open on the radially inner surface of the stator core 10.

[0043] like Figure 3As shown, the coil 20 is installed on the stator core 10. The coil 20 is wound on the stator core 10 (more specifically, the tooth portion 12). The coil 20 can be either distributed winding or concentrated winding. In the case of distributed winding, the coil 20 can be either wave winding, concentric winding, or overlapping winding. In the present embodiment, the coil 20 is illustrated as being wave winding. The coil 20 passes through the slot 15 and is wound on the tooth portion 12. The coil 20 can be either a covered electric wire in which the outer periphery of the core wire is covered with a covering portion, or an uncovered electric wire. In the present embodiment, the coil 20 is a flat wire. In addition, the coil 20 may not be a flat wire, for example, it may be a round wire.

[0044] like Figure 5 As shown, the coil 20 has an insertion portion 21 , a coil end 22 on one side, and a coil end 23 on the other side.

[0045] like Figure 5 As shown, the insertion portion 21 is arranged in the slot 15. The insertion portion 21 is in an elongated shape that is long in the axial direction. A plurality of (four in this embodiment) insertion portions 21 are provided in the slot 15. The insertion portions 21 are arranged radially in the slot 15. The insertion portions 21 are arranged in each slot 15.

[0046] like Figure 3 and Figure 5 As shown, the coil end 22 is arranged on the axial side of the stator core 10. The coil end 22 is continuous with the end of the insertion portion 21 on the axial side. Figure 3 and Figure 7 As shown, one side coil end 22 includes a conductor portion 60 (see Figure 6 ) and a first coil end 24 connected to the conductor portion 60 and a second coil end 25 connected to the conductor portion 60.

[0047] like Figure 3 As shown, the first coil end 24 has a first lead portion 26 and an extension portion 27. The first lead portion 26 is continuous with the end portion on one side of the insertion portion 21 in the axial direction. The first lead portion 26 is in a circumferentially inclined shape. The extension portion 27 extends from the end portion on one side of the axial direction of the first lead portion 26 (the end portion of the first lead portion 26 on the side opposite to the insertion portion 21) to one side of the axial direction. The extension portion 27 is formed to extend along the axial direction. The extension portion 27 is connected to another extension portion 27. The connection method is not particularly limited, and it can be either welding or soldering.

[0048] like Figure 3As shown, the second coil end 25 has a second lead portion 28 and a protrusion 29. The second lead portion 28 is continuous with the end portion of the insertion portion 21 on one side in the axial direction. The second lead portion 28 is formed in a shape inclined to one side in the circumferential direction. The protrusion 29 protrudes from the end portion of the second lead portion 28 on one side in the axial direction (the end portion of the second lead portion 28 on the side opposite to the insertion portion 21) to one side in the axial direction. The protrusion 29 is formed in a shape protruding along the axial direction. The protrusion 29 is longer than the extension portion 27. The end portion (the end portion on one side in the axial direction) of the protrusion 29 is arranged on the axial side compared to the end portion (the end portion on one side in the axial direction) of the extension portion 27. The end portion (the end portion on one side in the axial direction) of the protrusion 29 is arranged on the axial side compared to the end portion (the end portion on one side in the axial direction) of the first coil end 24. A plurality of protrusions 29 are provided. The plurality of protrusions 29 are arranged in a row in the circumferential direction.

[0049] like Figure 3 and Figure 5 As shown, the other side coil end 23 is arranged on the other side in the axial direction relative to the other side end of the stator core 10. The other side coil end 23 is continuous with the other side end of the insertion portion 21 in the axial direction.

[0050] like Figure 2 and Figure 4 As shown, the insulating resin 40 forms a press-in groove 50 between the protrusion 29. The press-in groove 50 is formed to extend in the radial direction. The press-in groove 50 has a width in a direction perpendicular to the direction in which it extends and perpendicular to the axial direction. The press-in groove 50 has an opening 51 that opens toward one side in the axial direction. The opening 51 opens on the surface of the stator body 2 on one side in the axial direction. The press-in groove 50 has an outer peripheral opening 52 that opens toward the radial outside. The outer peripheral opening 52 opens on the radially outer surface of the stator body 2. The opening 51 and the outer peripheral opening 52 open continuously. The insulating resin 40 forms a plurality of press-in grooves 50 arranged in the circumferential direction between the insulating resin 40 and the plurality of protrusions 29 arranged in the circumferential direction.

[0051] like Figure 5 As shown, the insulating resin 40 has a filling portion 41 and a forming portion 42. The filling portion 41 is continuously filled between the inner wall of the slot 15 and the insertion portion 21. The forming portion 42 forms a press-fit groove 50 together with the protrusion 29. The filling portion 41 and the forming portion 42 are formed integrally. According to this structure, the stator 1 can easily release the heat of the coil 20 because the heat generated in the insertion portion 21 and the conductor portion 60 of the coil 20 is easily transferred to the stator core 10 via the insulating resin 40.

[0052] like Figure 4 As shown, the insulating resin 40 includes a one side resin 43 provided on one side of the stator core 10 in the axial direction and an other side resin 44 provided on the other side of the stator core 10 in the axial direction.

[0053] like Figure 4 and Figure 5 As shown, the one-side resin 43 covers the entire first coil end 24 and the second lead portion 28 of the second coil end 25. That is, the one-side resin 43 covers the one-side coil end 22 except the protrusion 29. The one-side resin 43 includes a forming portion 42. The one-side resin 43 has a recessed portion 45 recessed from the radially outer end of the stator core 10 to the radially inner side. The above-mentioned outer peripheral opening portion 52 opens at the bottom surface of the recessed portion 45. The one-side resin 43 is continuous with the filling portion 41. The recessed portion 45 opens at the surface on one side of the axial direction of the insulating resin 40.

[0054] like Figure 5 As shown, the other side resin 44 covers the entire other side coil end 23 . The other side resin 44 is continuous with the filling portion 41 .

[0055] like Figure 1 and Figure 6 As shown in FIG. 1 , the unit component 3 includes a conductor portion 60 , a holding portion 70 , and a terminal portion 80 . The unit component 3 has a structure in which the plurality of conductor portions 60 are held by the holding portion 70 .

[0056] The conductor part 60 is configured as a bus bar, for example. Figure 6 As shown in FIG. 1 , the conductor part 60 is in a plate shape. The plate thickness direction of the conductor part 60 is along the circumferential direction. The plate thickness of the conductor part 60 is slightly larger than the width of the press-in groove 50 (the interval between the protrusion 29 and the forming portion 42 of the insulating resin 40) before being pressed. Therefore, the conductor part 60 is arranged in a state of being pressed into the press-in groove 50. The conductor part 60 extends in the radial direction.

[0057] like Figure 7 As shown in the figure, the conductor part 60 is pressed into the press-in slot 50 and arranged in a state of being pressed against the protrusion 29. Thus, the conductor part 60 is connected to the protrusion 29 forming the press-in slot 50. In this way, since the conductor part 60 of the stator 1 is pressed into the press-in slot 50 and arranged in a state of being pressed against the protrusion 29, it is easy to maintain the connection state between the coil 20 and the conductor part 60 even if a welding part or a soldering part is not provided.

[0058] like Figure 2 and Figure 6 As shown, a plurality of conductor parts 60 are provided. The plurality of conductor parts 60 are arranged in a circumferential direction. The plurality of conductor parts 60 are arranged radially.

[0059] like Figure 2 and Figure 6As shown, the retaining portion 70 is formed to extend in an arc shape along the circumferential direction. The inner circumferential surface of the retaining portion 70 is formed to extend in an arc shape along the circumferential direction. The outer circumferential surface of the retaining portion 70 is formed to extend in an arc shape along the circumferential direction. The retaining portion 70 retains a plurality of conductor portions 60. Each conductor portion 60 retained by the retaining portion 70 is pressed into each press-fit groove 50 and is arranged in a state of being pressed against each pressing protrusion 29. In this way, since the plurality of conductor portions 60 connected to the respective separated protrusions 29 are retained by the retaining portion 70, the relative positional relationship of the plurality of conductor portions 60 can be easily maintained.

[0060] like Figure 1 and Figure 2 As shown, the holding portion 70 is arranged in a state of being embedded in the recess 45 of the insulating resin 40. The holding portion 70 is arranged at a distance from the insulating resin 40. The holding portion 70 protrudes radially outward from the insulating resin 40. The holding portion 70 protrudes axially to one side from the insulating resin 40. The end portion on the other side in the axial direction of the holding portion 70 is arranged on the other side in the axial direction than the end portion on one side in the axial direction of the press-fit groove 50.

[0061] like Figure 1 As shown, the terminal portion 80 is electrically connected to a driving portion 90 that drives an electric motor not shown. The electric motor is an electric motor using a stator 1. The electric motor is, for example, a three-phase electric motor. Three terminal portions 80 are provided. Three-phase alternating current is applied to the three terminal portions 80. The terminal portion 80 is connected to the conductor portion 60 via a relay portion not shown. The relay portion is, for example, buried in the retaining portion 70. The terminal portion 80 is formed in a shape protruding from the radially outer surface of the retaining portion 70 toward the radially outer side. In this way, the stator 1 is formed in a shape in which the terminal portion 80 protrudes from the radially outer surface of the retaining portion 70, so it is easy to miniaturize the size of the stator 1 in the axial direction. In addition, the end of the terminal portion 80 on one side in the axial direction is arranged on the other side in the axial direction than the end of the retaining portion 70 on one side in the axial direction.

[0062] like Figure 6 As shown, a plurality of press-in grooves 50 arranged in the circumferential direction extend radially in the radial direction. Each press-in groove 50 has an opening portion 51 opened toward one side in the axial direction. Each conductor portion 60 can be removed from the press-in groove 50 through the opening portion 51. In a structure in which a plurality of press-in grooves 50 extend radially, if the conductor portions 60 pressed into each press-in groove 50 are to be removed from the radial outer side at once, each conductor portion 60 will interfere with the inner wall of the press-in groove 50. However, since the conductor portion 60 of the stator 1 can be removed from one side in the axial direction through the opening portion 51, the conductor portion 60 is not likely to interfere with the inner wall of the press-in groove 50, and as a result, a plurality of conductor portions 60 integrated via the retaining portion 70 can be easily removed at once.

[0063] like Figure 2 and Figure 6As shown in FIG. 1 , each of the press-fit grooves 50 has an outer peripheral opening 52 that opens toward the radially outer side. The holding portion 70 is arranged at a position radially outward of the stator core 10 relative to the plurality of press-fit grooves 50 arranged in the circumferential direction. Each of the conductor portions 60 held by the holding portion 70 protrudes from the radially inner surface of the holding portion 70 and is arranged in the press-fit groove 50 via the outer peripheral opening 52. In this way, since the holding portion 70 that holds the plurality of conductor portions 60 is arranged at a position radially outward relative to the plurality of press-fit grooves 50 arranged in the circumferential direction, the size of the stator 1 in the axial direction can be easily reduced in size.

[0064] like Figure 2 and Figure 6 As shown, each press-in slot 50 has an outer peripheral opening portion 52 that opens toward the radial outside. The retaining portion 70 is arranged at a position radially outside the stator core 10 relative to the plurality of press-in slots 50 arranged in the circumferential direction. Each conductor portion 60 pressed into each press-in slot 50 is connected to the radially inner surface of the retaining portion 70 via the outer peripheral opening portion 52. The opening portion 51 and the outer peripheral opening portion 52 are opened continuously. In this way, since the retaining portion 70 that retains the plurality of conductor portions 60 of the stator 1 is arranged at a position radially outside the plurality of press-in slots 50 arranged in the circumferential direction, it is easy to miniaturize the size of the stator 1 in the axial direction. That is, the stator 1 can remove the plurality of conductor portions 60 integrated via the retaining portion 70 from one side in the axial direction, and it is easy to miniaturize the size of the stator 1 in the axial direction.

[0065] like Figure 1 and Figure 7 As shown, a plurality of protrusions 29 are provided. The plurality of protrusions 29 are arranged in a circumferential direction of the stator core. The insulating resin 40 forms a plurality of press-in slots 50 arranged in a circumferential direction between the plurality of protrusions 29 arranged in the circumferential direction. A conductor portion 60 is provided. Each conductor portion 60 is pressed into each press-in slot 50 and arranged in a state pressed against each protrusion 29. The axial direction of each conductor portion 60 is entirely embedded in each press-in slot 50. The side of the protrusion 29 opposite to the press-in slot 50 is covered by the insulating resin 40. In this way, since the axial direction of the conductor portion 60 of the stator 1 is entirely embedded in the press-in slot 50 and the side of the protrusion 29 opposite to the press-in slot 50 is covered by the insulating resin 40, it is easy to insulate the protrusion 29 from the protrusion 29 adjacent to the protrusion 29 in the circumferential direction and the conductor portion 60 connected to the adjacent protrusion 29.

[0066] like Figure 2As shown, the coil 20 includes two or more protrusions 29 arranged in a radial direction of the stator core 10. One press-fit groove 50 is formed between the two or more protrusions 29 arranged in the radial direction and the insulating resin 40. One conductor portion 60 is pressed into one press-fit groove 50 and is arranged in a state pressed against the two or more protrusions 29 forming the press-fit groove 50. According to this structure, the stator 1 can connect one conductor portion 60 to the two or more protrusions 29 arranged in the radial direction.

[0067] 2. Method for manufacturing stator 1 The method for manufacturing the stator 1 includes a filling step, a preparation step, and a press-fitting step.

[0068] The filling process is a process of filling the slot 15 of the stator core 10 with the coil 20 installed therein with a resin material. In the filling process, the stator body 2 is insert-molded using the stator core 10 with the coil 20 installed therein as an insert component. In the filling process, the press-in groove 50 is formed while the resin material is filled between the inner wall of the slot 15 and the insertion portion 21. According to this method, the press-in groove 50 can be formed while the resin material is filled between the inner wall of the slot 15 and the insertion portion 21, so that the manufacturing process can be easily simplified.

[0069] In the preparation step, the stator body 2 and the unit components 3 are prepared.

[0070] In the press-fitting step, the conductor part 60 is press-fitted into the press-fitting groove 50 in the stator body 2, and the conductor part 60 is pressed against the protrusion 29. According to this method, the conductor part 60 is pressed against the protrusion 29 by pressing the conductor part 60 into the press-fitting groove 50, so that the connection state between the conductor part 60 and the protrusion 29 is easily maintained even without providing a welding part or a soldering part.

[0071] In the press-fitting step, the unit element 3 is displaced to the other side in the axial direction, so that each conductor portion 60 is press-fitted into each press-fitting groove 50 through the opening 51. According to this method, a plurality of conductor portions 60 can be press-fitted into each press-fitting groove 50 at once and pressed against the protrusion 29 forming each press-fitting groove 50.

[0072] <Second Embodiment> The conductor portion is not limited to the configuration of the first embodiment. In the second embodiment, another example of the conductor portion is described. In the description of the second embodiment, reference numerals are given to the same configurations as those of the first embodiment, and detailed descriptions thereof are omitted.

[0073] like Figure 8 and Fig. 9 As shown, the stator 201 of the second embodiment includes a stator body 2 and a unit component 203. The unit component 203 includes a conductor portion 260, a holding portion 70, and a terminal portion 80 (see Figure 1 ).

[0074] The conductor part 260 includes a spring part 261 and a support part 262. The spring part 261 is deformed in a manner of contraction in the circumferential direction. The spring part 261 is in the shape of a leaf spring, and is formed in a form of bending a metal plate. The spring part 261 includes a pair of plate parts 263, 264 and a bending part 265 connecting one end of the pair of plate parts 263, 264. The pair of plate parts 263, 264 extend from the bending part 265 to one side in the axial direction. When the pair of plate parts 263, 264 are not deformed in a state of bending, the spacing between each other becomes wider as they move away from the bending part 265. The spring part 261 is deformed in a manner of bending with the bending part 265 as a fulcrum, so that the other ends of the pair of plate parts 263, 264 approach each other. The spring part 261 is arranged in the press-fit groove 50 in a deformed state. The axial direction of the spring part 261 is arranged in the press-fit groove 50 as a whole. The spring portion 261 that is bent and deformed exerts elastic force in a manner that expands in the width direction of the press-fit groove 50. That is, the spring portion 261 is pressed into the press-fit groove 50. Therefore, the spring portion 261 is arranged in a state of pressing against the protrusion 29. The spring portion 261 is arranged in a state of pressing against two or more (two in this embodiment) protrusions 29 arranged in the radial direction.

[0075] The pair of plate portions 263 and 264 are circumferentially opposed to each other. The plate portion 264 is arranged on the protrusion 29 side relative to the plate portion 263. That is, the plate portion 264 is arranged in a state of pressing against the protrusion 29. The plate portion 264 is arranged in a state of pressing against two or more (two in the present embodiment) protrusions 29 arranged in the radial direction. According to this structure, the stator 201 is more easily stabilized in the connection state between the conductor portion 260 and the protrusion 29 because the spring portion 261 is pressed against the protrusion 29 by the elastic force of the spring portion 261.

[0076] The support portion 262 supports the spring portion 261. Figure 8 and Fig. 9 In the example shown, the support portion 262 supports the plate portion 263 of the spring portion 261. In addition, the support portion 262 can support both the plate portion 264 and the bent portion 265. The support portion 262 is fixed to the retaining portion 70. The support portion 262 forms a structure protruding from the retaining portion 70. The support portion 262 has a base 266 fixed to the retaining portion 70 and a connecting portion 267 connecting the base 266 and the spring portion 261. The base 266 is in a plate shape. The plate thickness (width) of the base 266 is smaller than the width of the press-in groove 50 and is more than half of the width of the press-in groove 50. The width of the connecting portion 267 is smaller than the width of the base 266 and smaller than half of the press-in groove 50. The plate thickness of the above-mentioned plate portions 263 and 264 is smaller than the width of the base 266 and smaller than half of the press-in groove 50.

[0077] In the press-fitting process, the unit member 203 is displaced to the other side in the axial direction so that the bent portion 265 of the spring portion 261 enters the press-fitting groove 50, thereby press-fitting the conductor portion 260 into the press-fitting groove 50 through the opening 51. Thus, the conductor portion 260 is press-fitted into the press-fitting groove 50 and pressed against the protrusion 29.

[0078] <Third Embodiment> In the third embodiment, another second example of the conductor portion will be described. In the description of the third embodiment, the same reference numerals are given to the same configurations as those in the first embodiment, and detailed descriptions thereof will be omitted.

[0079] like Fig.10 and Fig.11 As shown, the stator 301 of the third embodiment includes a stator body 2 and a unit component 303. The unit component 303 includes a conductor portion 360, a holding portion 70, and a terminal portion 80 (see Figure 1 ).

[0080] The conductor portion 360 is configured as, for example, a bus bar. The conductor portion 360 includes a conductor body 361 and an extension portion 362 extending from the conductor body 361 .

[0081] The conductor body 361 is plate-shaped. The plate thickness direction of the conductor part 60 is along the circumferential direction. The plate thickness of the conductor body 361 is slightly smaller than the width (length in the direction orthogonal to the axial direction and the radial direction) of the press-fit groove 50. The conductor body 361 extends in the radial direction. The conductor body 361 is arranged in the press-fit groove 50.

[0082] The extension 362 is a portion that is compressed when the conductor part 360 is pressed into the press-fit groove 50. The extension 362 is formed in a state where the conductor body 361 extends toward the protrusion 29. The extension 362 extends in the radial direction. The extension 362 is curved so as to be convex toward the protrusion 29.

[0083] A concave surface 363 is formed on the surface of the conductor body 361 on the side opposite to the protruding portion 362. The concave surface 363 is provided at a position corresponding to the protruding portion 362. The conductor portion 360 is formed by, for example, bending a metal plate. The protruding portion 362 and the concave surface 363 are formed simultaneously by bending.

[0084] The conductor part 360 is pressed into the press-fit groove 50 and arranged in a state where the extension part 362 is pressed against the protrusion 29. The conductor part 360 is arranged in a state where the extension part 362 is pressed against two or more (two in the present embodiment) protrusions 29 arranged in the radial direction. With this structure, the stator 301 is easy to cause stress concentration during connection because the connection portion of the conductor part 360 with the protrusion 29 is easily limited to the extension part 362.

[0085] In the press-fitting step, the conductor part 360 is press-fitted into the press-fitting groove 50 and pressed against the protrusion 29. In the press-fitting step, each conductor part 360 is press-fitted into each press-fitting groove 50 through the opening 51 by displacing the unit member 303 to the other side in the axial direction.

[0086] <Fourth Implementation Method> In the fourth embodiment, another third example of the conductor portion will be described. In the description of the fourth embodiment, the same reference numerals are given to the same configurations as those in the first embodiment, and detailed descriptions thereof will be omitted.

[0087] like Fig.12 and Fig.13 As shown, the stator 401 of the fourth embodiment includes a stator body 2 and a unit component 403. The unit component 403 includes a conductor portion 460, a holding portion 70, and a terminal portion 80 (see Figure 1 ).

[0088] The conductor part 460 is configured as a bus bar, for example. The conductor part 460 has a conductor body 461. The conductor body 461 is arranged in the press-in groove 50. A concave-convex surface 462 is formed on the surface of the conductor body 461 on the side of the protrusion 29. When the conductor part 460 is pressed into the press-in groove 50, the concave-convex surface 462 is pressed by the protrusion 29 and flattened. Thus, the conductor part 460 is pressed into the press-in groove 50 and arranged in a state of being pressed against the protrusion 29. According to this structure, the connection state of the conductor part 460 and the protrusion 29 is easily stabilized in a wide range.

[0089] In the press-in process, the conductor part 460 is pressed into the press-in groove 50, and the conductor part 460 is pressed against the protrusion 29. In addition, in the press-in process, by shifting the unit component 403 to the other side in the axial direction, each conductor part 460 is pressed into each press-in groove 50 through the opening 51. In the case where the coil 20 (more specifically, the protrusion 29) is a coated wire, the coating can be peeled off by the concave-convex surface 462, and the connection state of the internal core wire and the conductor part 460 can be expected to be more reliable.

[0090] <Fifth Implementation Method> In the fifth embodiment, another example of the positional relationship between the conductor portion and the protruding portion will be described. In the description of the fifth embodiment, the same reference numerals are given to the same configurations as those in the first embodiment, and detailed descriptions thereof will be omitted.

[0091] like Fig.14 and Fig.15 As shown, the stator 501 of the fifth embodiment includes a stator body 502 and a unit component 3. The unit component 3 includes a plurality of conductor portions 60, a holding portion 70, and a terminal portion 80.

[0092] The positional relationship between the press-fit grooves and the protrusions of the stator body 502 is different from that of the stator body 2 of the first embodiment, but is the same in other respects. The stator body 502 has a plurality of protrusions 529. The plurality of protrusions 529 are arranged in a circumferential direction. The stator body 502 includes an insulating resin 540. The insulating resin 540 forms a plurality of press-fit grooves 550 arranged in the circumferential direction between the plurality of protrusions 529 arranged in the circumferential direction. Each protrusion 529 is arranged on the side opposite to the circumferential center CH side of the retaining portion 70 with respect to the press-fit grooves 550 formed by itself.

[0093] Each conductor part 60 is pressed into each press-fit groove 550. Each conductor part 60 is arranged on the circumferential center CH side of the holding part 70 relative to the protrusion 529 of the connection object. According to this structure, even if the stator 501 is thermally expanded and deformed in a manner that the curvature becomes smaller, each conductor part 60 tends to shift to the protrusion 529 side of the connection object, so it is easy to maintain the connection state between the conductor part 60 and the protrusion 529.

[0094] <Other Implementation Methods> The present invention is not limited to the embodiments described above and illustrated in the drawings. For example, the features of the embodiments described above or below can be combined in any way within the scope of non-contradiction. In addition, any feature of the embodiments described above or below can be omitted as long as it is not clearly indicated as a necessary feature. Furthermore, the embodiments described above can also be modified as follows.

[0095] The first coil end may not have the first lead portion. That is, the extension portion and the insertion portion may be continuous. The extension portion may extend from the end portion on one side in the axial direction of the stator core to one side in the axial direction.

[0096] The second coil end may not have the second lead portion. That is, the protruding portion and the insertion portion may be continuous. The protruding portion may protrude from the end portion on one side of the axial direction of the stator core toward one side in the axial direction.

[0097] In the above-described embodiments, the plurality of protrusions connected to one conductor portion are arranged on the same side in the circumferential direction with respect to the conductor portion. However, the plurality of protrusions may be arranged on both sides in the circumferential direction of the conductor portion.

[0098] In the above-mentioned embodiments, two or more protrusions are arranged in the radial direction, but the present invention is not limited to this structure. For example, the protrusions may not be arranged in the radial direction.

[0099] In the above-mentioned embodiments, the entire axial direction of the conductor portion is fitted into the press-fit groove. However, only a part of the axial direction may be fitted into the press-fit groove.

[0100] In each of the above-mentioned embodiments, the conductor portion is press-fitted into the press-fit groove from one side in the axial direction, but may be press-fitted from the radially outer side.

[0101] The embodiments disclosed herein are to be considered in all respects as illustrative rather than restrictive. The scope of the present invention is not limited to the embodiments disclosed herein, but is intended to include all modifications within the scope of the claims or within the scope equivalent to the claims. Description of Reference Numerals

[0102] 1: Stator 2: Stator body 3: Unit components 10: Stator core 11: Yoke 12: Tooth 15: Slot 20: Coil 21: Insertion 22: One side coil end 23: The other side of the coil 24: 1st coil end 25: 2nd coil end 26: 1st lead part 27: Extension 28:: Second lead part 29: Protrusion 40: Insulating resin 41: Filling 42: Formation 43: One side resin 44: Resin on the other side 45: concave part 50: Press-in groove 51: Opening 52: Peripheral opening 60: Conductor 70: Maintaining Department 80: Terminal 90: Drive unit 201: Stator 203: Unit components 260: Conductor 261: Spring 262: Supporting part 263: Board 264: Board 265: Bending part 266: Base 267: Connection 301: Stator 303: Unit components 360: Conductor 361: Conductor body 362: Extension 363: Concave 401: Stator 403: Unit component 460: Conductor 461: Conductor body 462: Concave and convex surface 501: Stator 502: stator body 529: Protrusion 540: Insulating resin 550: Press-in groove CH: Circumferential center of the holding part

Claims

1. A stator, comprising: annular stator core; The coil has a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion on one side in the axial direction of the stator core; A conductor portion connected to the protruding portion; as well as The insulating resin forms a press-fit groove between the insulating resin and the protrusion. The conductor portion is press-fitted into the press-fit groove and is arranged in a state of being pressed against the protrusion.

2. The stator according to claim 1, wherein: A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. A plurality of the conductor parts are provided, further comprising a holding portion for holding a plurality of the conductor portions, The conductor portions held by the holding portion are each pressed into the press-fit groove and are arranged in a state of being pressed against the protruding portions.

3. The stator according to claim 2, wherein: The plurality of press-fit grooves arranged along the circumferential direction extend radially along the radial direction of the stator core. Each of the press-fit grooves has an opening portion that opens toward one side in the axial direction. Each of the conductor parts can be removed from the press-fit groove through the opening.

4. The stator according to claim 2 or claim 3, wherein: Each of the press-fit grooves has an outer peripheral opening portion that opens toward the radially outer side of the stator core. The holding portion is arranged at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction. Each of the conductor portions held by the holding portion protrudes from the radially inner surface of the holding portion and is arranged in the press-fit groove via the outer peripheral opening.

5. The stator according to claim 4, wherein: The stator is used for an electric motor, The stator includes a terminal portion electrically connected to a driving portion that drives the motor. The terminal portion is formed to protrude from the radially outer surface of the holding portion.

6. The stator according to claim 3, wherein: Each of the press-fit grooves has an outer peripheral opening portion that opens toward the radially outer side of the stator core. The holding portion is arranged at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction. Each of the conductor portions pressed into each of the press-fit grooves is connected to the radially inner surface of the holding portion via the outer peripheral opening. The opening portion and the outer peripheral opening portion are continuously opened.

7. The stator according to claim 2 or claim 3, wherein: The retaining portion is formed to extend in an arc shape along the circumferential direction, Each of the conductor portions is arranged on the circumferential center side of the holding portion with respect to the protruding portion of the connection target.

8. The stator according to any one of claims 1 to 3, wherein: A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. A plurality of the conductor parts are provided, Each of the conductor parts is pressed into each of the press-in grooves and is arranged in a state of being pressed against each of the protruding parts. The axial direction of each conductor part is entirely embedded in each press-fit groove. The side of the protrusion opposite to the press-fit groove side is covered with the insulating resin.

9. The stator according to any one of claims 1 to 3, wherein: The stator core has a plurality of slots arranged along the circumferential direction of the stator core. The coil has an insertion portion arranged in the slot, The insulating resin includes a filling portion that continuously fills a space between the inner wall of the slot and the insertion portion and a forming portion that forms the press-fit groove. The filling portion and the forming portion are integrally formed.

10. The stator according to any one of claims 1 to 3, wherein: The coil includes two or more protrusions arranged in a radial direction of the stator core. One of the press-fit grooves is formed between the two or more protrusions and the insulating resin, One of the conductor portions is press-fitted into one of the press-fit grooves and is arranged in a state of being pressed against the two or more protrusions forming the press-fit groove.

11. A method for manufacturing a stator, comprising a preparation step and a pressing step, In the preparation step, a stator body is prepared, wherein the stator body includes: an annular stator core; The coil has a protrusion, the protrusion protruding toward one side in the axial direction relative to an end portion on one side in the axial direction of the stator core; A conductor portion connected to the protruding portion; and an insulating resin, forming a press-fit groove between the insulating resin and the protruding portion, In the press-fitting step, the conductor portion is press-fitted into the press-fitting groove in the stator body to press the conductor portion against the protruding portion.

12. The method for manufacturing a stator according to claim 11, wherein: In the preparation step, a unit component is prepared, wherein the unit component has a structure in which a plurality of the conductor parts are held by a holding part. A plurality of said protrusions are provided, The plurality of protrusions are arranged along the circumferential direction of the stator core. The insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protrusions arranged in the circumferential direction. Each of the press-fit grooves has an opening portion that opens toward one side in the axial direction. In the press-fitting step, the unit member is displaced to the other side in the axial direction, so that the conductor portions are press-fitted into the press-fitting grooves through the openings.

13. The method for manufacturing a stator according to claim 11 or claim 12, wherein: The stator core has a plurality of slots arranged along the circumferential direction of the stator core. The coil has an insertion portion arranged in the slot, The method further comprises a filling step of filling a resin material between an inner wall of the slot and the insertion portion, In the filling step, the press-fit groove is formed while the resin material is filled between the inner wall of the slot and the insertion portion.

Images