Stator, rotating electric machine and method for manufacturing stator

Abstract

The problem to be solved by the present invention is to provide a stator which is provided with an insulator capable of circulating a cooling liquid between a conductor and a slot, and which can be easily and economically manufactured. In order to solve the problem, the present invention provides a stator provided with a conductor in a slot formed in a stator core, and an insulator disposed between the slot and the conductor, the stator having a cooling liquid flow path through which a cooling liquid flows between the slot and the conductor, the insulator having a foaming layer that foams by being heated in the slot, and the insulating layer having an insulating layer that foams by being heated in the slot. The foaming layer has: a foaming function section that fills the gap between the slot and the conductor by means of a heating foaming function; and a foaming function reduction part which is thinner than the foaming function part due to the fact that the heating foaming function of the foaming layer is lower than that of the foaming function part, and a gap through which the cooling liquid can flow is formed between the slot and the conductor.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a stator, a rotary electric machine, and a manufacturing method of a stator. BACKGROUND

[0002] In the past, a stator in which a conductor is arranged inserted via an insulator in a slot of a stator of a rotary electric machine has been known. On the insulator, between the conductor, a cooling liquid flow path that cools the conductor is formed. A surface of the insulator that faces the conductor has a plurality of columns of foamed resin layers that are formed by heating and foaming a plurality of columns of foamed adhesives. The cooling liquid flow path is formed by gaps between adjacent foamed resin layers (for example, refer to Patent Literature 1).

[0003] [Prior Art Documents]

[0004] (Patent Literature)

[0005] Patent Literature 1: Japanese Patent Application Publication No. 2017-127063 SUMMARY

[0006] [Problems to be Solved by the Invention]

[0007] However, in the existing technology, the foamed adhesive needs to be formed by being coated in columns on a base material of the insulator, and thus the manufacturing of the insulator is complicated. Also, depending on the type of the stator (thickness of the stator core, cross-sectional shape of the conductor, number of columns of the conductor, size of the slot with respect to the conductor), the configuration of the cooling liquid flow path differs. In the case where the type of the stator differs, the foamed adhesive needs to be formed by being coated with a changed configuration of the foamed adhesive according to the type. Thus, the cost of the insulator becomes high, and the manufacturing cost of the stator increases.

[0008] Thus, an object of the present disclosure is to provide a stator, a rotary electric machine provided with the stator, and a manufacturing method of a stator, the stator being provided with an insulator that enables a cooling liquid to flow between a conductor and a slot, and being capable of being easily and economically manufactured.

[0009] [Technical Means to Solve the Problems]

[0010] (1) A stator (for example, stator 3 described later) provided with a conductor (for example, conductors 8, 81, 82 described later) in a slot (for example, slot 7 described later) formed in a stator core (for example, stator core 6 described later), and an insulator (for example, insulator 11 described later) disposed between the slot and the conductor, having a coolant flow path (for example, second coolant flow path 21b described later) through which a coolant (for example, coolant CL described later) flows between the slot and the conductor, and the insulator has a foamed layer (for example, foamed layer 112 described later) that foams due to heating in the slot, the foamed layer has a foaming function portion (for example, foaming function portion Fa described later) that fills a gap between the slot and the conductor by a heating foaming function, and a foaming function reduction portion (for example, foaming function reduction portion Fb described later) that is thinner in thickness than the foaming function portion and forms a gap between the slot and the conductor through which the coolant can flow, because the heating foaming function of the foamed layer is reduced compared to the foaming function portion.

[0011] According to the above (1), only for the foamed layer formed in the insulator, the foaming function portion that fills the gap between the slot and the conductor, and the foaming function reduction portion that is thinner in thickness than the foaming function portion and forms the gap between the slot and the conductor through which the coolant can flow, can easily and economically produce a stator having an insulator through which a coolant can flow.

[0012] (2) The stator according to the above (1), wherein the conductor has a normal shape portion (for example, normal shape portions 8N, 81N, 82N described later) and a specific shape portion (for example, specific shape portions 8S, 81S, 82S described later) at a portion inserted into the slot, the specific shape portion is thinner in conductor width along the circumferential direction of the stator core than the conductor width of the normal shape portion, the coolant can flow in the radial direction of the stator core, and the foaming function reduction portion of the insulator is disposed at a portion corresponding to the specific shape portion of the conductor.

[0013] According to the above (2), the coolant can be made to flow smoothly along the crushed portion of the conductor in the slot, and thus the cooling performance of the conductor is improved.

[0014] (3) The stator according to the above (1) or (2), wherein the slot has a slit (for example, slit 71 described later) that opens toward a central axis hole (for example, central axis hole 61 described later) of the stator core, and the foaming function portion of the insulator is disposed in a manner to plug the slit.

[0015] According to the above (3), the coolant flowing into the slot can be effectively prevented from leaking out of the slit.

[0016] (4) A rotary electric machine (for example, the rotary electric machine 1 described later) including the stator (for example, the stator 3 described later) according to any one of (1) to (3) described above.

[0017] According to (4) described above, only for the foamed layer formed on the entire surface of the insulator, the foamed function portion that fills the gap between the slot and the conductor and the foamed function reducing portion that has a smaller thickness than the foamed function portion and forms a gap through which the coolant can flow between the slot and the conductor can be formed, and thus a stator having an insulator through which the coolant can flow can be easily and economically manufactured.

[0018] (5) A method of manufacturing a stator (for example, the stator 3 described later) including a conductor (for example, the conductors 8, 81, and 82 described later) in a slot (for example, the slot 7 described later) formed in a stator core (for example, the stator core 6 described later), and an insulator (for example, the insulator 11 described later) disposed between the slot and the conductor, having a coolant flow path (for example, the second coolant flow path 21b described later) through which a coolant (for example, the coolant CL described later) flows between the slot and the conductor, and the insulator having a foamed layer (for example, the foamed layer 112 described later) that foams due to heating in the slot, the method of manufacturing the stator including locally heating and foaming the foamed layer at least at a portion of the foamed layer where a gap through which the coolant can flow is required between the conductor and the insulator before the insulator is inserted into the slot, then reducing the foaming function of the foamed layer by applying pressure to the foamed portion, thereby forming a foamed function reducing portion (for example, the foamed function reducing portion Fb described later) in the foamed layer, forming a foamed function portion (for example, the foamed function portion Fa described later) in the foamed layer other than the foamed function reducing portion by inserting the insulator having the foamed function reducing portion formed therein into the slot and heating the entire insulator, and filling the gap between the slot and the conductor by the foamed function portion.

[0019] According to (5) described above, the foamed function reducing portion can be formed in the foamed layer by locally heating and foaming the foamed layer formed in the insulator and then applying pressure to the foamed portion, and the foamed function portion that fills the gap between the slot and the conductor can be formed by heating the entire insulator, and thus a stator including an insulator having a portion through which the coolant can flow can be easily and economically manufactured.

[0020] (6) The manufacturing method of the stator according to the above (5), wherein, at a portion where the conductor is inserted into the slot, a regular shape portion (for example, the regular shape portions 8N, 8 IN, 8 2N described later) and a specific shape portion (for example, the specific shape portions 8S, 8 IS, 8 2S described later) are formed, the specific shape portion is locally thinner than the conductor width of the regular shape portion in the conductor width in the circumferential direction of the stator core, the cooling liquid is able to flow in the radial direction of the stator core; and the foaming function reducing portion of the insulator is formed so as to be disposed at a portion corresponding to the specific shape portion of the conductor.

[0021] According to the above (6), the cooling liquid can be smoothly circulated along the crushed portion of the conductor in the slot, the cooling performance of the conductor is improved, and the stator can be easily and economically manufactured.

[0022] (7) The manufacturing method of the stator according to the above (5) or (6), wherein the slot has a slit (for example, the slit 71 described later) that is open toward a center axis hole (for example, the center axis hole 61 described later) of the stator core, and the foaming function portion of the insulator is formed so as to be disposed at the slit.

[0023] According to the above (7), a stator in which the cooling liquid flowing into the slot can be effectively prevented from leaking out of the slit can be easily and economically manufactured.

[0024] (EFFECTS OF THE INVENTION)

[0025] According to the present disclosure, a stator, a rotary electric machine provided with the stator, and a manufacturing method of the stator can be provided, the stator being provided with an insulator that is able to circulate a cooling liquid between a conductor and a slot, and being able to be easily and economically manufactured. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 is a conceptual view of a cooling liquid circulation mechanism in a rotary electric machine that is an example of the present disclosure.

[0027] Figure 2 is a schematic view illustrating an example of a cooling liquid flow path from a stator core to a conductor in the rotary electric machine of Figure 1

[0028] Figure 3 is a schematic view illustrating another example of a cooling liquid flow path from a stator core to a conductor in the rotary electric machine of Figure 1

[0029] Figure 4A is a view illustrating one process in an example of a manufacturing method of a conductor applied in the rotary electric machine of Figure 1

[0030] ​​​Figure 4B is a drawing illustrating a next step in the example of the manufacturing method of the conductor applied in the rotating electrical machine of Figure 1

[0031] Figure 4C is a drawing illustrating a next step in the example of the manufacturing method of the conductor applied in the rotating electrical machine of Figure 1

[0032] Figure 5 is a drawing illustrating a next step in the example of the manufacturing method of the conductor applied in the rotating electrical machine of Figure 2 and Figure 3 is a schematic view of the coolant flow path within the rectangular region IS in

[0033] Figure 6 is a schematic view of the coolant flow path of Figure 5 cut by the A-A line section.

[0034] Figure 7 is a schematic view of the coolant flow path of Figure 5 cut by the B-B line section.

[0035] Figure 8 is a perspective view illustrating a stator of a rotating electrical machine as another example of the present disclosure.

[0036] Figure 9 is a schematic view illustrating an example of the coolant flow path within the slot in the stator of Figure 8

[0037] Figure 10 is a schematic view of the coolant flow path within the rectangular region IS in Figure 9

[0038] is a schematic view of the coolant flow path of Figure 11 cut by the A-A line section. Figure 10

[0039] Figure 12 is a schematic view of the coolant flow path of Figure 10 cut by the B-B line section.

[0040] Figure 13 is a drawing illustrating another example of the conductor arranged within the slot of the rotating electrical machine of Figure 1 and Figure 8

[0041] Figure 14 is a drawing illustrating yet another example of the conductor arranged within the slot of the rotating electrical machine of Figure 1 and Figure 8

[0042] Figure 15A is a drawing illustrating yet another example of the conductor arranged within the slot of the rotating electrical machine of Figure 1 and Figure 8 ​​​​​​FIG. 1 is a diagram illustrating a step in another example of a manufacturing method of a conductor applied in a rotating electric machine.

[0043] Figure 15B FIG. 2 is a diagram illustrating a next step in the example of the manufacturing method of the conductor applied in the rotating electric machine. Figure 1 Figure 8 FIG. 3 is a diagram illustrating a further next step in the example of the manufacturing method of the conductor applied in the rotating electric machine.

[0044] Figure 15C FIG. 4 is a diagram illustrating a still further next step in the example of the manufacturing method of the conductor applied in the rotating electric machine. Figure 1 Figure 8 FIG. 5 is a diagram illustrating a still further next step in the example of the manufacturing method of the conductor applied in the rotating electric machine.

[0045] Figure 16 FIG. 6 is a perspective view illustrating an example of a structure around a cooling liquid flow path shown in FIG. 1. Figures 5-7

[0046] FIG. 7 is a conceptual view extracting and illustrating a part of the cooling liquid flow path in FIG. 1. Figure 17 Figure 16 FIG. 8 is a perspective view illustrating another example of the structure around the cooling liquid flow path shown in FIG. 1.

[0047] Figure 18 Figures 5-7 FIG. 9 is a conceptual view extracting and illustrating a part of the cooling liquid flow path in FIG. 1.

[0048] Figure 19 FIG. 10 is a perspective view illustrating still another example of the structure around the cooling liquid flow path shown in FIG. 1. Figure 18

[0049] FIG. 11 is a conceptual view extracting and illustrating a part of the cooling liquid flow path in FIG. 1. Figure 20 Figures 5-7 FIG. 12 is a perspective view illustrating yet another example of the structure around the cooling liquid flow path shown in FIG. 1.

[0050] Figure 21 Figure 20 FIG. 13 is a conceptual view extracting and illustrating a part of the cooling liquid flow path in FIG. 1.

[0051] Figure 22 FIG. 14 is a sectional view of an insulator used in the rotating electric machine shown in the present embodiment.

[0052] Figure 23 FIG. 15 is a front view illustrating the insulator used in the rotating electric machine shown in the present embodiment, which is drawn by being spread out.

[0053] Figure 24 FIG. 16 is a schematic view illustrating a slot of a stator in which the insulator and the conductor shown in FIG. 15 are housed, which is drawn in a longitudinal section. Figure 23

[0054] FIG. 17 is a schematic view illustrating the slot of FIG. 16, which is drawn in a C-C line section. Figure 25 Figure 24 FIG. 18 is a schematic view illustrating the slot of FIG. 16, which is drawn in a D-D line section.​​​​​​​

[0055] Figure 26 is a schematic view illustrating a relationship of a crush portion of a conductor of a slot of Figure 24 .

[0056] Figure 27 is a view illustrating a manufacturing process of the insulator shown in Figure 23 . DETAILED DESCRIPTION

[0057] Hereinafter, a rotating electric machine of the present disclosure will be described with reference to the drawings. In each of the drawings shown below, the same reference numerals are attached to corresponding portions. In addition, with respect to the drawings with a direction display, AD indicates an axial direction of the rotating electric machine and the stator, CD indicates a circumferential direction of the rotating electric machine and the stator, and RD indicates a radial direction of the rotating electric machine and the stator.

[0058] Figure 1 is a conceptual view of a cooling liquid circulation mechanism in a rotating electric machine 1 as an example of the present disclosure. In Figure 1 , the rotating electric machine 1 is configured to include a rotor 2 and a stator 3. The rotor 2 is formed in a cylindrical shape. The stator 3 is disposed around the rotor 2 in a manner having a prescribed gap. The stator 3 has a stator core 6 formed in a ring shape. The stator core 6 has a central shaft hole 61 penetrating in the axial direction in the center.

[0059] A housing 4 constituting an outer shell of the rotating electric machine 1 is provided in contact with the outer periphery of the stator 3. A rotating shaft 5 penetrates the center of rotation of the rotor 2. The rotating shaft 5 is supported by bearings not shown at both end surface portions in the axial direction of the housing 4.

[0060] In the stator core 6 in the stator 3, a plurality of slots 7 are arranged in parallel and at equal intervals in the circumferential direction. The slots 7 each have a slit 71 opening toward the central shaft hole 61 of the stator core 6. The slit 71 is formed along the axial direction of the stator core 6. A plurality of conductors 8 are arranged in the plurality of slots 7 of the stator core 6, respectively. The conductors 8 are flat conductors (square conductors) having a rectangular cross section. The plurality of conductors 8 are electrically connected to form a coil 9 provided to the stator core 6.

[0061] In each of the plurality of slots 7, an insulator 11 is provided along an inner wall surface 10. As shown in Figure 22 , the insulator 11 has a foamed layer 112 on one side of a sheet-shaped base material 111 over the entire surface, and has an adhesive layer 113 that does not foam on the other side. Further, the adhesive layer is formed only in the corresponding portion.

[0062] The rotating electric machine 1 generates heat due to copper loss and iron loss. Therefore, the stator core 6 and the coil 9 are cooled by a coolant circulating in a coolant flow path 12 to be described later formed in the stator 3. As the coolant, for example, an automatic transmission fluid (ATF) or the like can be used. The coolant from a coolant reservoir 13 provided to the housing 4 is supplied to a suction side of a pump 15 via a filter 14. The coolant is cooled by heat exchange with a coolant flowing in an external coolant flow path 17 via a heat exchanger 16 provided to a discharge side of the pump 15. The cooled coolant is supplied to a coolant supply port 19 of the stator core 6 via a coolant supply passage 18. The coolant supplied to the stator core 6 flows while cooling the stator core 6 and the conductor 8 in the slot 7 in a path to be described later, is recovered to the coolant reservoir 13, and is repeatedly recirculated.

[0063] Figure 2 is a schematic view illustrating an example of the coolant flow path 12 from the stator core 6 to the coil 9 in the rotating electric machine 1 of Figure 1 Figure 3 is a schematic view illustrating another example of the coolant flow path 12 from the stator core 6 to the coil 9 in the rotating electric machine 1 of Figure 1 Referring to Figure 2 , the coolant flow path 12 is constituted from the stator core 6 side of the housing 4 through a stator core inner coolant flow path 20 provided in the stator core 6 to the coil 9 of the slot 7. Here, in each of the following drawings, the illustration of the insulator 11 in the slot 7 is sometimes omitted in order to easily understand the coolant flow path 12.

[0064] Figure 2 The coolant flow path 12 of Figure 2 has the stator core inner coolant flow path 20 provided in the stator core 6. The stator core inner coolant flow path 20 is constituted so as to communicate the coolant supply port 19 of the housing 4 with the outer peripheral end portion of the slot 7.

[0065] On the other hand, Figure 3 ​The stator core inner cooling liquid flow path 20 in the cooling liquid flow path 12 extends from the cooling liquid supply port 19 provided at the side end portion near the outer periphery of the stator core 6 toward the axial direction, changes the orientation toward the radially inner side at the middle position of the thickness dimension of the stator core 6, and reaches the outer periphery side end portion of the slot 7 to communicate with the first cooling liquid flow path 21a described later. The first cooling liquid flow path 21a communicates with the second cooling liquid flow path 21b along the length direction of the straight portion of the conductor 8. Further, Figure 3 The stator core inner cooling liquid flow path 20 communicates with the cooling liquid bypass communication passage 21 formed in the circumferential direction (in the direction intersecting the paper surface) at a position in the middle of the way to the radially inner side. Figure 3

[0066] Here, reference will be made to Figure 4A , Figure 4B , Figure 4C The conductor 8 constituting the coil 9 will be described. Figure 4A is a view illustrating one step in an example of a manufacturing method of the conductor 8 applied in the rotating electric machine 1. Figure 4B is a view illustrating the next step in the example of the manufacturing method of the conductor 8. Figure 4C is a view illustrating the further next step in the example of the manufacturing method of the conductor 8.

[0067] First, the conductor 8 shown in Figure 4A is prepared. The conductor 8 is rectangular in cross-sectional shape and fixed over the entire length, and the dimension of the cross section is also fixed. The conductor 8 is covered with an insulating film like a general flat conductor of this kind.

[0068] Next, for the conductor 8, the middle portion of the straight portion arranged in the slot 7 is locally pressed by a press machine. The direction in which the conductor 8 is pressed is the direction along the circumferential direction of the stator core 6 when the conductor 8 is inserted into the slot 7. By this pressing, as shown in Figure 4B , the conductor 8 of the middle portion is locally crushed and deformed to form a specific shape portion 8S in which the conductor width along the circumferential direction of the stator core 6 is locally thin. Regarding the specific shape portion 8S, the thickness dimension in the direction orthogonal to the length direction of the conductor 8 is relatively thin (in the dimension CW) in one direction and relatively thick (in the dimension EW) in the other direction. In this case, the normal shape portion 8N of the conductor 8 other than the specific shape portion 8S is not crushed by the press machine but maintains the initial form like that in Figure 4B , in which the cross-sectional shape is rectangular and fixed over the entire length, and the dimension of the cross section is also fixed as before. Therefore, the conductor width of the normal shape portion 8N along the circumferential direction of the stator core 6 is thicker than the conductor width of the specific shape portion 8S along the circumferential direction of the stator core 6. Further, the inventors have verified that even if the conductor 8 is locally pressed by the press machine at a plurality of positions in the length direction of the conductor 8, the same effect as that of the example shown in Figure 4B Figure 4A Figure 4B ​​​The conductor 8 is locally pressed by a press machine to deform it, and no damage occurs on the insulating film.

[0069] In the next process, as shown in FIG. 6, the conductor 8 shaped as shown in FIG. 5 is arranged in the slot 7 in a plurality of parallel manner with the positions of the specific shape portions 8S coinciding with each other. Figure 4C Figure 4B In the next process, as shown in FIG. 6, the conductor 8 shaped as shown in FIG. 5 is arranged in the slot 7 in a plurality of parallel manner with the positions of the specific shape portions 8S coinciding with each other. Figure 4A Figure 4B In the next process, as shown in FIG. 6, the conductor 8 shaped as shown in FIG. 5 is arranged in the slot 7 in a plurality of parallel manner with the positions of the specific shape portions 8S coinciding with each other.

[0070] As described above, by using the conductor 8 in which the specific shape portions 8S, which are the crushed portions formed by locally crushing and deforming the conductor 8, are formed between the normal shape portions 8N, the coolant flow path around the coil 9 is formed. Next, the coolant flow path around the coil 9 will be described with reference to FIGS. 8 to 11. Figure 5 Figure 6 Figure 7

[0071] Figure 5 is a schematic view illustrating the coolant flow path in the rectangular region IS in FIGS. 8 and 9. Figure 2 Figure 3 is a schematic view illustrating the coolant flow path in FIG. 10. Figure 6 is a schematic view illustrating the coolant flow path in FIG. 10 with A-A line section. Figure 5 is a schematic view illustrating the coolant flow path in FIG. 11 with B-B line section. In the portion of Figure 7 , the specific shape portions 8S of the conductor 8 are arranged in the slot 7 without gaps in the radial direction (the radial direction of the stator core 6) of the slot 7. Figure 5 Figure 6 In FIG. 10, the portion of the specific shape portion 8S in which the dimension CW is relatively thicker than the dimension EW is arranged in the slot 7 so as to overlap the portion of the specific shape portion 8S in which the dimension EW is relatively thinner than the dimension CW in the radial direction of the slot 7.

[0072] In FIG. 10, the portion of the specific shape portion 8S in which the dimension CW is relatively thicker than the dimension EW is arranged in the slot 7 so as to overlap the portion of the specific shape portion 8S in which the dimension EW is relatively thinner than the dimension CW in the radial direction of the slot 7. Figure 6 Figure 4B Figure 6 Figure 6 ​​​​​​​​​​As schematically shown on the right, coolant CL flows radially from the outside to the inside in the second coolant flow path 21b. Furthermore, on the insulator 11 within the slot 7, at a position corresponding to the bottom wall surface 10a within the slot 7 opposite to the slit 71, an opening 114 is formed to allow coolant CL flowing from the coolant flow path 20 within the stator core into the slot 7 to flow between the conductor 8 and the insulator 11.

[0073] On the other hand, Figure 7 In this part, the conventionally shaped portions 8N of conductor 8 are arranged radially within slot 7, overlapping each other with open gaps. Figure 7 In the specific shape part 8S Figure 4B The relatively thicker portion of size EW between size CW and size EW is as follows: Figure 6 As shown, the overlap results in gaps between the conventionally shaped portions 8N of the conductor 8, which are not of a specific shape 8S. These gaps constitute the first coolant flow path 21a. Figure 7 The area schematically surrounded by dashed lines on the right side is the first coolant flow path 21a. Coolant CL flows axially in the stator 3 through multiple first coolant flow paths 21a.

[0074] Next, refer to Figure 8 The rotary motor 1, which is another example of this disclosure, will be described. Figure 8 This is a perspective view of the stator 3 of a rotary electric machine 1, which is another example of this disclosure. On the stator core 6 of the rotary electric machine 1, which has an annular cross-section, a plurality of slots 7 are arranged side-by-side and at equal intervals in the circumferential direction. A plurality of conductors 8 are arranged in each of the plurality of slots 7. The conductors 8 are flat conductors (square conductors) with a rectangular cross-section, and the plurality of conductors 8 are electrically connected at their ends to form a coil 9.

[0075] Conductor 8 and Reference Figure 4B , Figure 4C The conductors described are the same. At the axial front end of stator core 6 ( Figure 8 In the middle, near the anterior side) and the axial rear end side ( Figure 8 In the middle (depth side), an annular front cover component 22 and a rear cover component 23 are assembled to cover the front and rear ends of the coil 9. The front cover component 22 and the rear cover component 23 internally house the connecting conductor portions of the front and rear ends of the coil 9 and form part of the flow path of the coolant CL. That is, the coolant CL introduced into the front cover component 22 is annularly surrounded inside the front cover component 22, and reaches the rear cover component 23 through the first coolant flow path 21a (partially the second coolant flow path 21b) formed between the conductors 8 in the slot 7, and circulates through a coolant circulation channel (not shown). This constitutes the coolant flow path 12.

[0076] Figure 9 is a schematic view of an example of the cooling liquid flow path 12 in the slot 7 in the rotary electric machine 1 illustrated in Figure 8 . Figure 10 is a schematic view of the cooling liquid flow path in the rectangular region IS illustrated in Figure 9 . Figure 11 is a schematic view of the cooling liquid flow path illustrated in Figure 10 , taken along the A-A line section. Figure 12 is a schematic view of the cooling liquid flow path illustrated in Figure 10 , taken along the B-B line section. Figure 9 In the cooling liquid flow path 12, the cooling liquid CL introduced to the front cover member 22 reaches the rear cover member 23 side through the first cooling liquid flow path 21a (partially the second cooling liquid flow path 21b between the both sides of the conductor 8 and the inner wall of the slot 7) constituted by the gaps between the conductors 8 (the regular shape portions 8N of the conductors 8), and returns to the not-illustrated circulation path.

[0077] In Figure 10 , Figure 11 and Figure 12 , the formation of the first cooling liquid flow path 21a and the second cooling liquid flow path 21b, and the flow-through form of the cooling liquid CL in these first cooling liquid flow path 21a and second cooling liquid flow path 21b are substantially the same as described with reference to Figure 5 , Figure 6 and Figure 7 . Therefore, in the description of the formation of the first cooling liquid flow path 21a and the second cooling liquid flow path 21b, and the flow-through form of the cooling liquid CL in these first cooling liquid flow path 21a and second cooling liquid flow path 21b in Figure 10 , Figure 11 and Figure 12 , the same description as in Figure 5 , Figure 6 and Figure 7 is referred to.

[0078] Figure 13 is a view illustrating another example of the conductors arranged in the slot of the rotary electric machine illustrated in Figure 1 , Figure 8 . Figure 13In the example, conductor 81 is a flat conductor (square conductor) with a rectangular cross-section. In the straight section within the slot 7 of the rotary motor 1, it has two crushed portions, namely, specific-shaped portions 81S. A conventional-shaped portion 81N is connected to these two specific-shaped portions 81S, and to both ends of the straight section. The specific-shaped portions 81S themselves are the same as the specific-shaped portions 8S described above. Furthermore, the conventional-shaped portions 81N themselves are the same as the conventional-shaped portions 8N described above. Thus, by making conductor 81 have two specific-shaped portions 81S in the straight section, two second coolant flow paths 21b can be formed radially within a slot 7. Therefore, the overall flow resistance related to the coolant CL can be reduced, improving the energy efficiency of the rotary motor 1.

[0079] Figure 14 It is a drawing Figure 1 , Figure 8 A diagram of another example of conductors arranged in the slot of a rotating electric motor. Figure 14 In the example, conductor 82 is a flat conductor (square conductor) with a rectangular cross-section. In the straight section arranged within the slot 7 of the rotary motor 1, it has three crushed portions, namely, specific-shaped portions 82S. A conventional-shaped portion 82N is connected to these three specific-shaped portions 82S, and to both ends of the straight section. The specific-shaped portions 82S themselves are the same as the specific-shaped portions 8S described above. Furthermore, the conventional-shaped portions 82N themselves are the same as the conventional-shaped portions 8N described above. Thus, by making conductor 82 have three specific-shaped portions 82S in the straight section, three radial second coolant flow paths 21b can be formed in one slot 7. Therefore, the overall flow resistance related to the coolant CL can be reduced, improving the energy efficiency of the rotary motor 1.

[0080] Here, refer to Figure 15A , Figure 15B and Figure 15C Another example of a method for manufacturing a conductor will be explained. Figure 15A It is a drawing Figure 1 , Figure 8 A diagram of a step in another example of the manufacturing method of the conductor 8 used in the rotary electric motor 1. Figure 15B This is a diagram illustrating the next step in another example of the manufacturing method of the conductor 8 used in the rotary electric machine 1. Figure 15C It is a drawing Figure 1 , Figure 8 A diagram of the next step in another example of the manufacturing method of the conductor 8 used in the rotary electric motor 1.

[0081] In Figure 15A , Figure 15B and Figure 15C In the relevant manufacturing methods, firstly, preparation Figure 15AThe conductor 8 is a fixed rectangular cross-section along its entire length, with fixed dimensions. In this case, for conductor 8, the ratio of the longer side to the shorter side in the rectangular cross-section is chosen to be... Figure 4B The conductor in the specific shape part 8S with the ratio of EW to CW.

[0082] Secondly, for conductor 8, pressure is applied to both ends of the straight section disposed in slot 7, excluding the middle portion (middle position). The direction of pressure applied to conductor 8 is radial along the stator core 6 as conductor 8 is inserted into slot 7. Figure 15B In the image, the elliptical region PP (shown as a dashed line) represents the portion of the object being pressurized. Through this pressurization, such as... Figure 15B As shown, the portions at both ends are crushed and deformed, and conductor 8 has a corresponding Figure 4A The rectangular cross-section of the conventional shape part 8N.

[0083] The non-conventional shape of conductor 8, specifically the shape 8S of its portion 8N, will not be crushed by the press, but will instead maintain its shape. Figure 15A The initial form, that is, the cross-sectional shape is rectangular and fixed along the entire length, and the ratio of the shorter side to the longer side of the rectangle is also maintained. Figure 4B The ratio of CW to EW is defined by the specific shape portion 8S. As a result, the conductor width of the specific shape portion 8S along the circumference of the stator core 6 is thinner than the conductor width of the conventional shape portion 8N along the circumference of the stator core 6.

[0084] In the next process, such as Figure 15C As shown, it will be like Figure 15B Multiple conductors 8, formed in this manner, are arranged side-by-side in the slot 7 with their specific shape portions 8S aligned with each other. Then, the ends of the side-by-side conductors 8 (conventional shape portions 8N) are connected by welding or the like in a manner with a predetermined electrical connection, forming a state in which they function as a coil 9. As described above, by using conductors 8 with specific shape portions 8S formed between the conventional shape portions 8N, a coolant flow path is formed around the coil 9. Since the conductors 8 are not components with special grooves along their length, they are easy to manufacture.

[0085] Next, refer to Figure 16 and Figure 17 The flow path of coolant CL in a slot 7 of the rotary electric motor 1 of this disclosure is generally summarized. Figure 16 It is a drawing Figures 5-7 A perspective view of an example of the structure surrounding the coolant flow path, shown in the figure. Figure 17 It is to extract and draw Figure 16 A conceptual diagram of a portion of the coolant flow path. (See reference...)Figure 1 As described in outline, the cooling liquid CL is supplied to the axial middle position in the stator core 6 of the rotating electric machine 1 from the outside.

[0086] The supplied cooling liquid CL flows in the second cooling liquid flow path 21b toward the radially inner side, which is formed at three places in the middle position in the slot 7 by the gap between the specific shape portion 8S of each conductor 8 and the inner wall of the slot 7 stacked and arranged in the radial direction in the slot 7. Figure 16 In the example of Figure 17 , the second cooling liquid flow path 21b is provided at three places, which are the central position in the axial direction of the slot 7 and the two positions apart from the central position by a distance in the axial direction. Further, in detail, the second cooling liquid flow path 21b is formed as the gap between the insulator 11, that is, the insulating paper, and the outer surface of the conductor 8, which is in close contact with the inner wall of the slot 7.

[0087] The cooling liquid CL flowing in the second cooling liquid flow path 21b flows in the first cooling liquid flow path 21a communicating with the second cooling liquid flow path 21b. The first cooling liquid flow path 21a is formed as the gap between the regular shape portions 8N of the conductors 8 along the length direction of the conductors 8. The cooling liquid CL flowing from the second cooling liquid flow path 21b into the first cooling liquid flow path 21a flows in the axial direction of the rotating electric machine 1 in the first cooling liquid flow path 21a.

[0088] The cooling liquid CL is branched from the second cooling liquid flow path 21b at the axial central position to the axial one end side and the other end side of the first cooling liquid flow path 21a. The cooling liquid CL flowing in the second cooling liquid flow path 21b and the first cooling liquid flow path 21a exchanges heat with the conductors 8 while cooling the heat generated by copper loss, flows in the axial one end side and the other end side in the slot 7, and is ejected from the both end portions in the axial direction of the slot 7 to drip, flows into the cooling liquid reservoir 13 (refer to Figure 1 ), and is recovered as described above.

[0089] Next, another aspect of the flow path of the cooling liquid CL in one slot 7 of the rotating electric machine 1 of the present disclosure is outlined in its entirety with reference to Figure 18 and Figure 19 . Figure 18 is a perspective view illustrating another example of the configuration around the cooling liquid flow path shown in Figures 5-7 Figure 19 is a conceptual view extracting and illustrating a part of the cooling liquid flow path in Figure 18 . As outlined with reference to Figure 1 , the cooling liquid CL is supplied to the axial middle position in the stator core 6 of the rotating electric machine 1 from the outside.

[0090] ​The supplied coolant CL flows in the second coolant flow path 21b toward the radially inner side, which is formed at three positions in the middle of the slot 7 as gaps between the specific shape portions 8S of the respective conductors 8 stacked and arranged in the radial direction within the slot 7 and the inner wall of the slot 7. Further, in detail, the second coolant flow path 21b is formed as a gap between the insulator 11, that is, the insulating paper, and the outer surface of the conductor 8 in close contact with the inner wall of the slot 7.

[0091] In Figure 18 and Figure 19 , the following configuration is adopted, that is, the phase positions in the axial direction of the specific shape portions 8S of the respective conductors 8 are sequentially shifted in the axial direction as they go toward the radially inner side from the outermost conductor 8 to the innermost conductor 8. Therefore, the second coolant flow path 21b formed in the slot 7 from the outer peripheral side toward the inner peripheral side is inclined in the radial direction in accordance with the shift in the phase of the axial direction of the specific shape portions 8S described above. This second coolant flow path 21b is provided so as to be inclined as it goes toward the inner peripheral side from the central position in the axial direction of the outermost periphery of the slot 7 and the two positions apart from this central position toward the one end side and the other end side in the axial direction.

[0092] The coolant CL flowing in the second coolant flow path 21b flows in the first coolant flow path 21a communicating with the second coolant flow path 21b. The first coolant flow path 21a is formed as gaps between the regular shape portions 8N of the conductors 8 along the length direction of the conductors 8. The coolant CL flowing from the second coolant flow path 21b into the first coolant flow path 21a flows in the first coolant flow path 21a in the axial direction of the rotating electric machine 1.

[0093] The coolant CL branches from the second coolant flow path 21b at the central position in the axial direction to the one end side and the other end side in the axial direction of the first coolant flow path 21a. The coolant CL flowing in the second coolant flow path 21b and the first coolant flow path 21a exchanges heat with the conductors 8 while cooling the heat generated due to copper loss, flows toward the one end side and the other end side in the slot 7, and is ejected from the both end portions in the axial direction of the slot 7 to drip, flows into the coolant reservoir 13 (refer to Figure 1 ), and is recovered as described above.

[0094] Next, another example of the flow path of the coolant CL in one slot 7 of the rotating electric machine 1 according to the present disclosure will be generally described with reference to Figure 20 and Figure 21 . Figures 5-7 is a perspective view illustrating another example of the configuration around the coolant flow path shown in Figure 21 . Figure 20 is an extracted view and a perspective view illustrating another example of the configuration around the coolant flow path shown in Figure 1FIG. 2 is a conceptual view of a portion of the cooling liquid flow path in the stator core 6. As Figure 20 The outline will be described, and the cooling liquid CL is supplied to the axial middle position in the stator core 6 of the rotating electric machine 1 from the outside.

[0095] The supplied cooling liquid CL flows in the second cooling liquid flow path 21b toward the radially inner side, which is formed at three places in the middle position in the slot 7 as the gap between the specific shape portion 8S of each conductor 8 and the inner wall of the slot 7 stacked and arranged in the radial direction within the slot 7. Further, in detail, the second cooling liquid flow path 21b is formed as the gap between the insulator 11, that is, the insulating paper, and the outer surface of the conductor 8, which is in close contact with the inner wall of the slot 7.

[0096] In the example of FIG. 2, the following configuration is adopted, in which the axial phase position of the specific shape portion 8S of each conductor 8 is shifted in one direction and then returned and shifted in one direction again in a zigzag manner as it goes toward the radially inner side from the outermost conductor 8 to the innermost conductor 8. Therefore, the second cooling liquid flow path 21b formed in the slot 7 from the outer circumferential side toward the inner circumferential side becomes zigzag according to the shift of the axial phase of the specific shape portion 8S described above. This second cooling liquid flow path 21b is provided in a zigzag manner as it goes toward the inner circumferential side from the central position in the axial direction of the outermost circumferential portion of the slot 7 and the two positions that are apart from the central position by a distance in the axial direction of one end side and the other end side. Figure 21 Figure 1 In the example of FIG. 2, the following configuration is adopted, in which the axial phase position of the specific shape portion 8S of each conductor 8 is shifted in one direction and then returned and shifted in one direction again in a zigzag manner as it goes toward the radially inner side from the outermost conductor 8 to the innermost conductor 8. Therefore, the second cooling liquid flow path 21b formed in the slot 7 from the outer circumferential side toward the inner circumferential side becomes zigzag according to the shift of the axial phase of the specific shape portion 8S described above. This second cooling liquid flow path 21b is provided in a zigzag manner as it goes toward the inner circumferential side from the central position in the axial direction of the outermost circumferential portion of the slot 7 and the two positions that are apart from the central position by a distance in the axial direction of one end side and the other end side.

[0097] The cooling liquid CL flowing in the second cooling liquid flow path 21b flows in the first cooling liquid flow path 21a that communicates with the second cooling liquid flow path 21b. The first cooling liquid flow path 21a is formed as the gap between the regular shape portions 8N of the conductors 8 along the length direction of the conductors 8. The cooling liquid CL flowing from the second cooling liquid flow path 21b into the first cooling liquid flow path 21a flows in the first cooling liquid flow path 21a in the axial direction of the rotating electric machine 1.

[0098] The cooling liquid CL branches from the second cooling liquid flow path 21b at the central position in the axial direction to the axial one end side and the other end side of the first cooling liquid flow path 21a and flows. The cooling liquid CL flowing in the second cooling liquid flow path 21b and the first cooling liquid flow path 21a exchanges heat with the conductors 8 while cooling the heat generated due to copper loss, flows in the slot 7 toward the axial one end side and the other end side, and is discharged from the both end portions in the axial direction of the slot 7 and drips, flows into the cooling liquid reservoir 13 (refer to FIG. 1) and is recovered as described above. Figures 22-26

[0099] Next, the configuration of the rotating electric machine 1 will be described with reference to FIG. 3. Figure 22 ​​The insulator 11 used in the stator 3 in which the above-described conductors 8, 81, 82 are inserted into the slots 7 will be described. As shown in FIG. 10, the insulator 11 has a foamed layer 112 on one side of a sheet-like base material 111 over the entire surface, and a non-foamed adhesive layer 113 on the other side. The insulator 11 is inserted into each slot 7 together with the conductors 8, 81, 82, and is disposed between the inner wall surface 10 of the slot 7 and the conductors 8, 81, 82. Figure 23

[0100] Figure 23 A state in which one insulator 11 is flatly spread is shown. The insulator 11 is configured to have a slit shielding portion 11a, radial housing portions 11b, 11b, and turn-back portions 11c, 11d.

[0101] The slit shielding portion 11a is disposed at the central portion in the width direction of the spread insulator 11, and is formed over the entire length in the height direction of the insulator 11. The width direction of the spread insulator 11 is the direction along the circumferential direction of the stator core 6 in the slot 7. The height direction of the insulator 11 is the axial direction of the stator core 6 in the slot 7. The slit shielding portion 11a is disposed in such a manner that the entire slit 71 is plugged from inside the slot 7 when the insulator 11 is housed in the slot 7.

[0102] The radial housing portions 11b, 11b are respectively continuously formed on both sides of the slit shielding portion 11a. The radial housing portions 11b, 11b are disposed in such a manner that they cover the inner wall surface 10 in the slot 7 over the entire radial direction when the insulator 11 is housed in the slot 7.

[0103] The turn-back portions 11c, 11d are respectively continuously formed on both sides of the radial housing portions 11b, 11b. The turn-back portions 11c, 11d are disposed along the bottom wall surface 10a in the slot 7 when the insulator 11 is housed in the slot 7. In one of the turn-back portions 11c, a rectangular opening hole 11c1 is formed at substantially the central portion in the height direction of the insulator 11. In the other of the turn-back portions 11d, a cutout portion 11d1 is formed by cutting the end edge of the turn-back portion 11d in a rectangular shape at substantially the central portion in the height direction of the insulator 11.

[0104] On the insulator 11, as in FIG. 10, the conductors 8, 81, 82 are inserted into the slots 7. Figure 23 ​In the figure, a double-dot chain line is shown, and between the slit shielding portion 11a and the radial housing portions 11b, 11b, and between the radial housing portions 11b, 11b and the return portions 11c, 11d, there are mountain fold lines 11e along the height direction of the insulator 11. The mountain fold line 11e is a virtual line set to the insulator 11. The insulator 11 is formed along the inner face shape of the slot 7 by being folded along these mountain fold lines 11e, and can be arranged on the inside along the radial direction of the stator core 6 in a substantially rectangular shape with a plurality of conductors 8, 81, 82. The return portions 11c, 11d of the insulator 11 after being folded are overlapped with each other, and since the opening hole 11c1 and the cutout portion 11d1 are overlapped, an opening portion 114 is formed through which the cooling liquid CL can flow into the inside of the insulator 11.

[0105] After the insulator 11 is arranged in the slot 7 together with the conductors 8, 81, 82, the stator core 6 is heated. Due to this, the foaming layer 112 of the insulator 11 foams due to the heating foaming function, and fills in the gap between the conductors 8, 81, 82 and the inner wall face 10 of the slot 7. In the case where the insulator 11 is arranged with the adhesive layer 113 facing the conductors 8, 81, 82, it will adhere to the conductors 8, 81, 82 due to the heating, and in the case where the insulator 11 is arranged with the adhesive layer 113 facing the inner wall face 10 of the slot 7, it will adhere to the inner wall face 10 due to the heating, in either case, the insulator 11 fixes the conductors 8, 81, 82 inside the slot 7, and thereby fixes the coil 9 to the stator core 6.

[0106] Here, the insulator 11 has, in addition to the foaming function portion Fa which normally exhibits the heating foaming function when heated in the slot 7, a foaming function reduction portion Fb which, in order not to hinder the flow of the cooling liquid CL in the second cooling liquid flow path 21b formed between the insulator 11 and the specific shape portions 8S, 81S, 82S of the conductors 8, 81, 82, has a reduced heating foaming function compared to the foaming function portion Fa, does not exhibit the heating foaming function, or is less likely to exhibit the heating foaming function compared to the foaming function portion Fa when the insulator 11 is heated in the slot 7.

[0107] Regarding Figure 23 The insulator 11 shown in the figure is applied in the case where the conductor 82 having three specific shape portions 82S in the slot 7 is inserted into the slot 7. In Figure 23 Here, the region of the foaming function reduction portion Fb is indicated by hatching. The portions of the insulator 11 which are not hatched are all regions of the foaming function portion Fa. In the case of the other conductors 8, 81, the positions and number of the foaming function reduction portions Fb will differ depending on the positions and number of the specific shape portions 81S, 82S of the conductors 8, 81, but the configuration of the insulator 11 shown in the figure is applied as is. Figure 24 ​

[0108] The foaming function portions Fa in the insulator 11 are each formed at four locations on the entire slit shielding portion 11a, the radial housing portions 11b, 11b, and the turn-back portions 11c, 11d. The four foaming function portions Fa of each of the radial housing portions 11b, 11b and the turn-back portions 11c, 11d are each composed of the foaming function portions Fa, Fa at both ends in the height direction of the insulator 11 and two foaming function portions Fa disposed therebetween. The foaming function portions Fa formed on each of the radial housing portions 11b, 11b and the turn-back portions 11c, 11d are continuous in the width direction of the unfolded insulator 11 via the foaming function portions Fa of the slit shielding portion 11a.

[0109] The foaming function reducing portions Fb in the insulator 11 are each formed at three locations on the radial housing portions 11b, 11b and the turn-back portions 11c, 11d. The three foaming function reducing portions Fb of each of the radial housing portions 11b, 11b and the turn-back portions 11c, 11d are disposed between the foaming function portions Fa, Fa adjacent in the height direction of the insulator 11. The foaming function reducing portions Fb are not formed on the slit shielding portion 11a, and thus are not continuous in the width direction of the unfolded insulator 11. Therefore, six foaming function reducing portions Fb are independently disposed on the insulator 11. The opening holes 11c1 and the cutout portions 11d1 of the turn-back portions 11c, 11d are disposed within the regions of the two foaming function reducing portions Fb, Fb disposed at the center in the height direction of the insulator 11.

[0110] The foaming function portions Fa in the insulator 11 are portions in which the foamed layer 112 foams by heating the stator core 6 after the conductors 82 are inserted into the slots 7 and the insulator 11, and exhibits the heating foaming function as usual. On the other hand, the foaming function reducing portions Fb in the insulator 11 are portions in which the heating foaming function of the foamed layer 112 is reduced from the foaming function portions Fa. The foaming function reducing portions Fb are portions in which the heating foaming function of the foamed layer 112 is not exhibited at all when the stator core 6 is heated, or the heating foaming function is not easily exhibited compared with the foaming function portions Fa. Therefore, the thickness of the foaming function reducing portions Fb in the insulator 11 after the stator core 6 is heated is formed thinner than the foaming function portions Fa.

[0111] Figure 25 and Figure 24 The case in which four conductors 82 and the insulator 11 are inserted into the slots 7 is shown. In the insulator 11, the foaming function reducing portions Fb are formed at three locations on each of the radial housing portions 11b, 11b and the turn-back portions 11c, 11d. The three foaming function reducing portions Fb of each of the radial housing portions 11b, 11b and the turn-back portions 11c, 11d are disposed between the foaming function portions Fa, Fa adjacent in the height direction of the insulator 11. The foaming function reducing portions Fb are not formed on the slit shielding portion 11a, and thus are not continuous in the width direction of the unfolded insulator 11. Therefore, six foaming function reducing portions Fb are independently disposed on the insulator 11. The opening holes 11c1 and the cutout portions 11d1 of the turn-back portions 11c, 11d are disposed within the regions of the two foaming function reducing portions Fb, Fb disposed at the center in the height direction of the insulator 11. Figure 24 In the insulator 11, only the regions of the foaming function reducing portions Fb are shown by the rectangular regions formed by the broken lines. The opening portions 114 formed on the insulator 11 are disposed so as to communicate with the stator core inner coolant flow paths 20 formed on the stator core 6.

[0112] AsFigure 26 and Figure 25 As shown, the foaming function portion Fa of the insulator 11 is configured corresponding to the position of the conventional shape portion 82N of the arranged conductor 82, and the foaming function reduction portion Fb of the insulator 11 is configured corresponding to the position of the specific shape portion 82S of the arranged conductor 82. When the stator core 6 is heated, the foaming function portion Fa of the insulator 11 foams as usual, filling the gap between the conventional shape portion 82N of the conductor 82 and the inner wall surface 10 of the slot 7.

[0113] In contrast, such as Figure 26 and Figure 26 As shown, the foaming function reduction portion Fb of the insulator 11 does not exhibit heating foaming function when the stator core 6 is heated, or is less likely to exhibit heating foaming function compared to the foaming function portion Fa. Therefore, it does not fill the gap between the specific shape portion 82S of the conductor 82 and the inner wall surface 10 of the slot 7 as the foaming function portion Fa does. Consequently, the second coolant flow path 21b formed between the specific shape portion 82S of the conductor 82 and the inner wall surface 10 of the slot 7 is not blocked by the foaming layer 112, ensuring the flow of coolant CL in the second coolant flow path 21b.

[0114] In addition, such as Figure 25 As shown, the insulator 11 is disposed within the slot 7 such that the foam layer 112 faces the inner wall surface 10 of the slot 7, and the adhesive layer 113 faces the conductor 82. However, since a foaming function reduction portion Fb is formed at the location of the foam layer 112 corresponding to the specific shape portion 82S of the conductor 82, the foaming function reduction portion Fb does not press the base material 111 of the insulator 11 and the adhesive layer 113 toward the conductor 82. Therefore, the second coolant flow path 21b is properly ensured on the specific shape portion 82S of the conductor 82. Alternatively, the insulator 11 can be disposed within the slot 7 such that the foam layer 112 faces the conductor 82, and the adhesive layer 113 faces the inner wall surface 10 of the slot 7.

[0115] like Figure 23 As shown, the slit shielding portion 11a of the insulator 11 is disposed within the slot 7 on the side of the slit 71, thereby shielding the slit 71 from the inside of the slot 7. Figure 27 As shown, the entire slit shielding portion 11a, due to the foaming function portion Fa, effectively blocks the slit 71 by heating the insulator 11 within the slot 7. Therefore, the coolant CL flowing within the second coolant flow path 21b cannot leak out from the slit 71.

[0116] Next, refer to Figure 27 The method for manufacturing a stator 3 having an insulator 11 in a slot 7 of a stator core 6 will be described. ​A molding process of the insulator 11 before being arranged in the slot 7 of the stator core 6, and a molding process (ASSY) of the insulator 11 after being arranged in the slot 7 of the stator core 6 are shown.

[0117] First, the insulator 11 before being heated for molding has a foaming layer 112 on one side of a sheet-like base material 111 over the entire surface, and an adhesive layer 113 on the other side (insulator molding process). As such an insulator 11, a general insulator having the foaming layer 112 formed on the entire surface on one side can be used.

[0118] Next, in the foaming layer 112 of the insulator 11, at least to the gaps between the specific shape portions 8S, 81S, 82S of the conductors 8, 81, 82, through which the coolant CL needs to flow, that is, to the regions where the foaming function reducing portions Fb should be formed, local heating is performed (local heating process). By this local heating, the foaming layer 112 locally exhibits a heating foaming function, and a local foaming portion 112a is formed at the heated portion.

[0119] The specific method for performing the local heating is not particularly limited. For example, a method in which the insulator 11 is heated while the gaps between the normal shape portions 8N, 81N, 82N of the conductors 8, 81, 82 and the inner wall surface 10 of the slot 7, that is, the regions where the foaming function portions Fa should be formed, are filled with mask members having heat insulation properties, and a method in which a heating body capable of selective heating is brought into contact with the regions of the foaming layer 112 of the insulator 11 where the foaming function reducing portions Fb should be formed, and only the contacted portion is selectively heated, and the like can be listed. The heating temperature at this time is a temperature at which the heated portion of the foaming layer 112 exhibits a heating foaming function and starts foaming, but the adhesive layer 113 has not yet exhibited an adhesive force.

[0120] Next, the foaming portion 112a of the foaming layer 112, which has been locally heated and foamed, is forcibly flattened by being subjected to pressurization (local pressurization process). If the foaming portion 112a is forcibly flattened, even if the foaming portion 112a is heated again, it does not foam or is less likely to foam. Thus, the foaming function reducing portions Fb are formed on the foaming layer 112, and the foaming function portions Fa are formed on the foaming layer 112 by the unfoamed portions 112b other than the foaming function reducing portions Fb.

[0121] Next, the insulator 11, which has formed a reduced foaming function Fb by forcibly flattening the foaming portion 112a, is inserted together with the conductors 8, 81, and 82 into the slot 7 of the stator core 6. Then, the insulator 11 is heated by heating the stator core 6, causing the foaming layer 112 to foam (heat foaming process). The heating temperature at this time is the temperature at which the foaming layer 112 begins to foam as usual, and the adhesive layer 113 exhibits adhesive strength.

[0122] At this time, the foaming function section Fa, which is the part of the foaming layer 112 that was not heated in the local heating process, except for the foaming function reduction section Fb, exhibits the heating and foaming function as usual and foams, filling the gap between the conductors 8, 81, 82 and the inner wall surface 10 of the slot 7, and fixing the conductors 8, 81, 82 in the slot 7. On the other hand, the foaming function reduction section Fb formed in the local pressurization process does not foam at all or is not easy to foam, so it is thinner than the foaming function reduction section Fb, and a proper gap is formed in the second coolant flow path 21b between the specific shape sections 8S, 81S, 82S of the conductors 8, 81, 82, allowing the coolant CL to flow.

[0123] Based on the stator 3 obtained therefrom, a high-performance rotary motor 1 can be constructed that allows for smooth flow of coolant CL between conductors 8, 81, 82 and slot 7, resulting in excellent cooling performance. The insulator 11 can be a common insulator with a foamed layer 112 formed on the entire surface of one side, thus enabling easy and economical manufacturing. Therefore, the stator 3 and the rotary motor 1 can be manufactured at low cost, resulting in excellent economic efficiency.

[0124] Figure Labels

[0125] 1 Rotary electric motor

[0126] 21b Second Coolant Flow Path

[0127] 3. Stator

[0128] 6. Stator core

[0129] 61 Central shaft hole

[0130] 7 slots

[0131] 71 Slit

[0132] 8,81,82 Conductors

[0133] 8N, 81N, 82N Standard Shape Section

[0134] 8S, 81S, 82S Specific shape parts

[0135] 11 Insulators

[0136] 112 Foaming layer

[0137] CL coolant

[0138] Fa foaming function part

[0139] Fb foaming function reduction part

Claims

1. A stator, comprising a conductor and an insulator disposed between the slot and the conductor within a slot formed on a stator core, and having a coolant flow path for coolant to flow between the slot and the conductor, and, The aforementioned insulator has a foamed layer that expands when heated within the aforementioned slot. The aforementioned foam layer has: The foaming function fills the gap between the aforementioned slot and the aforementioned conductor by means of a heated foaming function; and, The reduced foaming function section, since the heating foaming function of the aforementioned foaming layer is reduced compared to the aforementioned foaming function section, and the thickness is thinner than the aforementioned foaming function section, forms a gap between the aforementioned slot and the aforementioned conductor that allows the aforementioned coolant to flow.

2. The stator according to claim 1, wherein, The conductor has a conventional shape portion and a specific shape portion at the insertion point into the slot. The conductor width of the specific shape portion along the circumference of the stator core is locally thinner than that of the conventional shape portion, allowing the coolant to flow radially through the stator core. The aforementioned foaming function reduction portion of the aforementioned insulator is disposed at a position corresponding to the aforementioned specific shape portion of the aforementioned conductor.

3. The stator according to claim 1 or 2, wherein, The aforementioned slot has a slit that opens toward the central shaft hole of the aforementioned stator core. The aforementioned foaming functional part of the aforementioned insulator is configured to block the aforementioned slit.

4. A rotary electric motor comprising the stator as described in claim 1 or 2.

5. A method for manufacturing a stator, wherein the stator has a conductor and an insulator disposed between the slot and the conductor within a slot formed on a stator core, and has a coolant flow path for coolant to flow between the slot and the conductor; and, The aforementioned insulator has a foamed layer that expands when heated within the aforementioned slot. The method for manufacturing the stator is as follows: Before inserting the aforementioned insulator into the aforementioned slot, at least in the gap between the insulator and the aforementioned conductor where the aforementioned coolant needs to flow, the aforementioned foam layer is locally heated to cause the foam layer to foam. Then, pressure is applied to the foamed area to reduce the heating and foaming function, thereby forming a foaming function-reduced section on the aforementioned foam layer. By inserting the aforementioned insulator with the aforementioned foaming function reduction portion into the aforementioned slot and heating the entire aforementioned insulator, the aforementioned foaming layer other than the aforementioned foaming function reduction portion is heated and foamed to form the foaming function portion, and the aforementioned foaming function portion fills the gap between the aforementioned slot and the aforementioned conductor.

6. The method for manufacturing a stator according to claim 5, wherein, At the location where the aforementioned conductor is inserted into the aforementioned slot, a conventional shape portion and a specific shape portion are formed. The conductor width of the specific shape portion along the circumference of the aforementioned stator core is locally thinner than the conductor width of the aforementioned conventional shape portion, allowing the aforementioned coolant to flow radially in the aforementioned stator core. The aforementioned foaming function reduction portion of the aforementioned insulator is formed and disposed at a position corresponding to the aforementioned specific shape portion of the aforementioned conductor.

7. The method for manufacturing a stator according to claim 5 or 6, wherein, The aforementioned slot has a slit that opens toward the central shaft hole of the aforementioned stator core. The aforementioned foaming functional part of the aforementioned insulator is formed and disposed in the aforementioned slit.

Images