Stator of electric motor

Abstract

The invention provides a stator of a motor. The stator comprises an iron core; a plurality of coils wound around the iron core; a housing having at least two pillars that come into contact with the end surface of the iron core, and a bridge section that connects the at least two pillars to each other; and a resin covering the iron core, the plurality of coils, and the housing.

Description

Technical Field

[0001] The present disclosure relates to a stator of an electric motor. Background Art

[0002] Nowadays, the stator of the motor is molded with resin for the purpose of waterproofing, etc. (for example, Patent Document 1). Molding refers to a method of injecting resin into the mold after filling the mold with inserts. That is, after filling the mold with the stator, the resin is injected into the mold. As a result, the outside of the stator is covered with resin, and the resin is filled around the coil. In order to miniaturize the molded stator, it is necessary to reduce the thickness of the resin covering the outside of the stator.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2014-218063 Summary of the invention

[0006] Problems to be solved by the invention

[0007] In order to reduce the thickness of the resin covering the outside of the stator, it is necessary to narrow the gap between the mold and the outer part of the stator during molding. However, if the gap is narrowed, there is a concern that the resin will not be able to fully reach the gap during molding. In other words, there is a concern that poor molding will occur during molding. In order to avoid poor molding, the injection pressure of the resin is sometimes increased. However, if the injection pressure is increased, there is a concern that the components of the stator such as the coil will be damaged.

[0008] Therefore, a technology for improving the flow of resin during molding without increasing the injection pressure of the resin is required.

[0009] Solutions to Solve Problems

[0010] The stator of the present disclosure includes: an iron core; a plurality of coils wound around the iron core; a housing having at least two pillars abutting against an end surface of the iron core and a bridge connecting the at least two pillars to each other; and a resin covering the iron core, the plurality of coils and the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1A is a top view of the stator before molding.

[0012] Figure 1B It is an exploded top view of the stator before molding.

[0013] Figure 1C This is a right side view of the stator before molding.

[0014] Figure 1D This is a left side view of the stator before molding.

[0015] Figure 2 is a top view of the stator after molding.

[0016] Figure 3A It is an exploded perspective view of the iron core.

[0017] Figure 3B It is an exploded perspective view of the iron core.

[0018] Figure 4 This is a schematic diagram for explaining the flow of resin during molding.

[0019] Figure 5 It is a perspective view of a stator according to another embodiment. DETAILED DESCRIPTION

[0020] Hereinafter, a stator of a motor according to an embodiment of the present disclosure will be described with reference to the accompanying drawings. In the following description, the same reference numerals are used for structures having the same or similar functions, and repeated descriptions of these structures may be omitted.

[0021] <One Implementation Method>

[0022] Figure 1A is a top view of the stator before molding. Figure 1B It is an exploded top view of the stator before molding. Figure 1C This is a right side view of the stator before molding. Figure 1D This is a left side view of the stator before molding. Figure 2 is a top view of the stator after molding. Figure 3A and Figure 3B It is an exploded perspective view of the iron core.

[0023] The stator 1 is a component constituting the motor and generates a magnetic force for rotating a rotor (not shown).

[0024] The stator 1 includes an iron core 2, a plurality of coils 3, an insulating portion 4, a first case 5, a second case 6, and a resin 7. At least one of the first case 5 and the second case 6 corresponds to a case described in the claims.

[0025] The iron core 2 is a component that serves as a path for magnetic flux. The iron core 2 is manufactured by laminating a plurality of plate materials formed by press working or the like. The plate materials are, for example, electromagnetic steel plates.

[0026] The core 2 includes a core back (not shown) formed in a substantially cylindrical shape and teeth (not shown) extending from the core back in a central direction.

[0027] The core 2 has a first end face 21 and a second end face 22. The first end face 21 is a face constituting an end of the core 2 along a first direction of the central axis. The second end face 22 is a face constituting an end of the core 2 along a second direction of the central axis. The second direction is the opposite direction to the first direction. In addition, at least one of the first end face 21 and the second end face 22 corresponds to an end face described in the claims.

[0028] The plurality of coils 3 are wound around the teeth of the core 2. The plurality of coils 3 are made of, for example, copper wires.

[0029] The insulating portion 4 is a member interposed between the teeth and the coil 3 to insulate the teeth from the coil 3. The insulating portion 4 is formed of a predetermined insulating material. A printed circuit board (not shown) may be buried in the insulating portion 4.

[0030] like Figure 3B As shown in the figures, when the insulating portion 4 covers the side of the coil 3, a resin hole (not shown) may be formed in the insulating portion 4 in parallel with the central axis of the core 2. The resin hole formed in the insulating portion 4 is a hole through which the resin 7 passes when the stator 1 is molded. Furthermore, the resin hole formed in the insulating portion 4 is a hole that is finally filled with the resin 7 when the stator 1 is molded.

[0031] The first case 5 is a member that covers at least a portion of the coil 3 wound around the core 2. The first case 5 is attached to the first end surface 21 of the core 2 using, for example, screws or bolts and nuts.

[0032] A center hole 51 is formed in the first housing 5 . The center hole 51 is a circular through hole centered on the central axis of the core 2 .

[0033] The first housing 5 includes at least an end face member 52 and an outer peripheral member 53. The end face member 52 is a member perpendicular to the central axis of the core 2. The outer peripheral member 53 is, for example, a member perpendicular to the end face member 52 and extending toward the first end face 21 of the core 2. The first housing 5 is integrally formed, for example, by casting.

[0034] One or more resin holes 521 are formed in the end face member 52 in parallel with the central axis of the core 2. The resin hole 521 is a through hole. The resin hole 521 is a hole through which the resin 7 passes when the stator 1 is molded. Furthermore, the resin hole 521 is a hole that is finally filled with the resin 7 when the stator 1 is molded.

[0035] The resin hole 521 is formed at a position corresponding to between the plurality of coils 3. Between the coils 3 is between two coils wound around one tooth and another tooth that are adjacent to each other. That is, the resin hole 521 is formed so that the resin hole 521 and the coil 3 are arranged on a straight line.

[0036] The second case 6 is a member that covers at least a portion of the coil 3 wound around the core 2. The second case 6 is attached to the second end surface 22 of the core 2 using, for example, screws or bolts and nuts.

[0037] The second housing 6 has at least two pillars 61, a bridge portion 62, and an end surface member 63. The at least two pillars 61, the bridge portion 62, and the end surface member 63 are integrally formed by, for example, casting.

[0038] At least two pillars 61 are members that abut against the second end surface 22 of the core 2. Each pillar 61 extends parallel to the central axis of the core 2. The cross section of each pillar 61 may have any shape. Here, the cross section refers to a cross section perpendicular to the central axis of the core 2.

[0039] The bridge 62 is a member that connects at least two pillars 61. The bridge 62 connects one end of each pillar 61. Here, one end of each pillar 61 refers to an end located on the opposite side to the end that contacts the second end surface 22 of the core 2.

[0040] A gap is formed between the second end face 22 of the core 2 and the bridge portion 62. In other words, when the second housing 6 is attached to the core 2, a hole is formed at a position surrounded by the second end face 22, the two pillars 61, and the bridge portion 62. As described below, the gap or hole allows the resin 7 to pass during molding. And, the gap is finally filled with the resin 7 by molding.

[0041] The end surface member 63 is a member perpendicular to the central axis of the core 2. The end surface member 63 covers the coil 3 and the insulating portion 4. A center hole 631 is formed in the end surface member 63. The center hole 631 is a circular through hole centered on the central axis of the core 2.

[0042] The end surface member 63 has a component mounting hole 632 formed around the center hole 631. The component mounting hole 632 is, for example, a threaded hole. After the stator 1 is molded, various components are mounted on the stator 1 using bolts or the like.

[0043] One or more resin holes 633 are formed in the end face member 63 in parallel with the central axis of the core 2. The resin hole 633 is a through hole. The resin hole 633 is a hole through which the resin 7 passes when the stator 1 is molded. Furthermore, the resin hole 633 is a hole that is finally filled with the resin 7 when the stator 1 is molded.

[0044] The resin 7 covers at least the iron core 2, the coil 3, and the case. That is, the resin 7 covers the stator 1 by molding.

[0045] Figure 4This is a schematic diagram for explaining the flow of the resin 7 during molding. The stator 1 is molded by an injection molding machine in a state of being loaded in a mold. Specifically, the resin 7 flowing from the injection port (not shown) of the resin 7 collides with the end surface component 52 of the first housing 5, or does not collide with the end surface component 52 and flows along the outer side surface of the peripheral component 53.

[0046] The resin 7 flowing along the outer surface of the outer peripheral member 53 flows in the direction where the second housing 6 is arranged. Thus, the outer surface of the stator 1 is covered with the resin 7 .

[0047] The resin 7 flowing from the injection port hits the end surface member 52 of the first housing 5, or flows from the center hole 51 of the first housing 5 toward the inside of the first housing 5 without hitting the end surface member 52. The resin 7 flowing from the injection port flows from the resin hole 521 formed in the end surface member 52 of the first housing 5 toward the inside of the first housing 5.

[0048] The resin 7 flowing inside the first case 5 passes between the coils 3 wound on the core 2. Here, the coil 3 refers to the coil 3 wound on one tooth portion. Therefore, between the coils 3 refers to the gap between the coils 3 wound on two adjacent teeth portions.

[0049] A portion of the resin 7 that has passed between the coils 3 flows out from the gap formed between the second end surface 22 of the core 2 and the bridge portion 62 of the second housing 6. The remaining portion of the resin 7 that has passed between the coils 3 flows toward the inside of the second housing 6. The resin 7 that has flowed toward the inside of the second housing 6 flows out from the resin holes 633 formed in the end surface member 63 of the second housing 6. In addition, a mold is arranged at the center portion of the stator 1 in which the rotor is incorporated, so the resin 7 does not flow in the center portion.

[0050] <Other Implementation Methods>

[0051] Figure 5 The bridge portion 62 of the second housing 6 has an inclined surface 622 extending from an outer side surface 621 of the bridge portion 62 toward the coil 3. The outer side surface 621 of the bridge portion 62 is a surface of the bridge portion 62 parallel to the central axis of the core 2.

[0052] The inclined surface 622 along the direction toward the coil 3 is a surface formed by bending the outer side surface 621 of the bridge portion 62 toward the central axis of the core 2 at a predetermined angle. In this case, one end of the inclined surface 622 is arranged at the same height as the outer peripheral surface of the core 2. That is, the outer side surface 621 of the bridge portion 62 and the outer peripheral surface of the core 2 are formed on the same plane. In addition, the same plane may not be strictly the same plane. And, the other end of the inclined surface 622 opposite to one end is arranged at a position closer to the inner side of the core 2 than the outer peripheral surface of the core 2.

[0053] The inclination angle of the inclined surface 622 is, for example, in the range of 10° or more and 45° or less from the outer side surface 621 of the bridge portion 62. The angle of the inclined surface 622 may be, for example, 30°. In addition, the inclined surface 622 formed on the bridge portion 62 may be a curved surface instead of a flat surface. That is, the inclined surface 622 may have any shape as long as the resin flows smoothly from the gap between the bridge portion 62 and the core 2 during molding.

[0054] Furthermore, the support 61 may have an inclined surface 612 extending from the outer side surface 611 of the support 61 in the direction toward the central axis of the core 2. The outer side surface 611 of the support 61 refers to a surface of the support 61 formed on the same plane as the outer side surface 621 of the bridge portion 62. The inclined surface 612 extending in the direction toward the central axis of the core 2 refers to a surface formed by bending the outer side surface 611 of the support 61 toward the central axis of the core 2 at a predetermined angle.

[0055] The inclination angle of the inclined surface 612 is, for example, in the range of 10° to 45° from the outer side surface 611 of the support 61. The angle of the inclined surface 612 may be, for example, 30°. In addition, the inclined surface 612 formed on the support 61 may be a curved surface instead of a flat surface.

[0056] The stator 1 of each of the above-mentioned embodiments comprises: an iron core 2; a plurality of coils 3 wound around the iron core 2; a shell having at least two pillars 61 abutting against the end surface of the iron core 2 and a bridge portion 62 connecting the at least two pillars 61 to each other; and a resin 7 covering the iron core 2, the plurality of coils 3 and the shell.

[0057] Therefore, when the stator 1 is molded, the resin 7 flows out from the gap formed between the end surface of the core 2 and the bridge portion 62. As a result, the flow of the resin 7 is improved when the stator 1 is molded. This can prevent the occurrence of molding defects.

[0058] If the gap is not formed, in other words, if the gap is covered by the second housing 6, the flow of the resin 7 in the portion covering the gap becomes poor. For example, if the interval between the second housing 6 and the mold is narrow at this portion, there is a concern that the resin 7 may not sufficiently reach this portion. The stator 1 in this embodiment solves such a problem.

[0059] Furthermore, a resin hole 633 is formed in the end surface member 63 of the housing, and the resin hole 633 is filled with the resin 7. That is, when the stator 1 is molded, the resin 7 passes through the resin hole 633. Thus, the flow of the resin 7 during molding is further improved. When the molding is completed, the resin hole 633 is filled with the resin 7.

[0060] Furthermore, the bridge portion 62 has an inclined surface 622 extending from an outer side surface 621 of the bridge portion 62 in a direction toward the coil 3. Furthermore, the support 61 has an inclined surface 612 extending from an outer side surface 611 of the support 61 in a direction toward the central axis of the core 2. Thus, during molding, the resin 7 passing through the coils 3 flows smoothly from the gap between the second end surface 22 and the bridge portion 62. That is, the flow of the resin 7 during molding is further improved.

[0061] Furthermore, one end of the inclined surface 622 and the inclined surface 612 is arranged at the same height as the outer peripheral surface of the core 2, and the other end opposite to the one end is arranged at a position inside the outer peripheral surface of the core 2. Therefore, the resin 7 flowing out from the gap between the second end surface 22 of the core 2 and the bridge portion 62 smoothly merges with the resin 7 flowing along the outer peripheral surface of the core 2. In other words, the flow of the resin 7 during molding is improved.

[0062] The present disclosure has been described in detail, but the present disclosure is not limited to the above-mentioned embodiments. The above-mentioned embodiments can be variously added, replaced, changed, partially deleted, etc. without departing from the scope of the main purpose of the present disclosure, or without departing from the scope of the main purpose of the present disclosure derived from the contents recorded in the claims and their equivalents. In addition, the above-mentioned embodiments can also be implemented in combination.

[0063] Hereinafter, additional notes on the embodiments of the present disclosure are shown.

[0064] Notes[1]

[0065] A stator comprises: an iron core; a plurality of coils wound around the iron core; a housing having at least two pillars abutting against an end surface of the iron core and a bridge connecting the at least two pillars to each other; and a resin covering the iron core, the plurality of coils and the housing.

[0066] Notes[2]

[0067] The stator according to Supplementary Note [1], wherein a resin hole is formed on an end surface of the housing, and the resin hole is filled with the resin.

[0068] Notes[3]

[0069] The stator according to Supplementary Note [1] or [2], wherein the resin holes are formed at positions corresponding to between coils of the plurality of coils.

[0070] Notes[4]

[0071] The stator according to any one of appendixes [1] to [3], wherein the support has an inclined surface extending from an outer side surface of the support in a direction toward a central axis of the core.

[0072] Notes[5]

[0073] The stator according to any one of appendixes [1] to [4], wherein the bridge portion has an inclined surface extending from an outer side surface of the bridge portion in a direction toward the plurality of coils.

[0074] Notes[6]

[0075] The stator according to Appendix [4] or [5], wherein one end of the inclined surface is arranged at the same height as the outer peripheral surface of the core, and the other end opposite to the one end is arranged at a position closer to the inside than the outer peripheral surface of the core.

[0076] Explanation of symbols

[0077] 1—stator, 2—iron core, 21—first end face, 22—second end face, 3—coil, 4—insulating portion, 5—first shell, 51—center hole, 52—end face component, 521—resin hole, 53—peripheral component, 6—second shell, 61—pillar, 611—outer side surface, 612—inclined surface, 62—bridge portion, 621—outer side surface, 622—inclined surface, 63—end face component, 631—center hole, 632—component mounting hole, 633—resin hole, 7—resin.

Claims

1. A stator, characterized in that: have: Iron core; A plurality of coils wound around the iron core; a housing having at least two pillars abutting against an end surface of the core and a bridge connecting the at least two pillars to each other; and A resin covers the iron core, the plurality of coils, and the housing.

2. The stator according to claim 1, characterized in that: A resin hole is formed on the end surface of the housing. The resin hole is filled with the resin.

3. The stator according to claim 2, characterized in that: The resin holes are formed at positions corresponding to between the coils of the plurality of coils.

4. The stator according to any one of claims 1 to 3, characterized in that: The support column has an inclined surface extending from an outer side surface of the support column in a direction toward a central axis of the core.

5. The stator according to any one of claims 1 to 4, characterized in that: The bridge portion has an inclined surface extending from an outer side surface of the bridge portion in a direction toward the plurality of coils.

6. The stator according to claim 4 or 5, characterized in that: One end of the inclined surface is arranged at the same height as the outer peripheral surface of the iron core, and the other end facing the one end is arranged on the inner side of the outer peripheral surface of the iron core.

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