stator

Abstract

A stator (10) comprises: a stator core (24) having a plurality of radially extending pole teeth (22); a resin insulator (16) mounted on the stator core; and a winding portion (18) wound around the plurality of pole teeth with respect to the insulator. The stator core has mounting surfaces (20A, 22A) for mounting the insulator, and grooves (36, 38) are formed on the mounting surfaces. These grooves are located on the opposite side of the winding portion with respect to the insulator, and a gas layer (40, 42) is formed between the stator core and the insulator through the grooves.

Description

[0001] Citation of relevant applications

[0002] This application claims priority to Japanese Patent Application No. 2023-199407, filed on November 24, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The technology disclosed herein relates to a stator. Background Technology

[0004] Conventionally, there exists a stator comprising: a stator core having a plurality of radially extending pole teeth; a resin insulator mounted on the stator core; and a winding portion wound around the plurality of pole teeth with the insulator in between. Among such stators, there is a stator in which an insulating film is provided between the pole teeth and the winding portion (for example, see Japanese Patent Application Publication No. 2018-198515). Summary of the Invention

[0005] The inventors' detailed research revealed the following technical problem: In the prior art described above, the insulating film may experience insulation failure when a high voltage is applied to the winding portion. While increasing the thickness of the resin portion located between the pole teeth and the winding portion of the insulator to withstand high voltage is an option, this could potentially increase the stator's size.

[0006] The purpose of this disclosure is to provide a stator that can suppress stator enlargement and ensure insulation relative to the winding portion.

[0007] The stator of this disclosure comprises: a stator core having a plurality of radially extending pole teeth; a resin insulator mounted on the stator core; and a winding portion wound around the plurality of pole teeth with respect to the insulator. The stator core has a mounting surface for mounting the insulator, and a groove is formed on the mounting surface. The groove is located on the opposite side of the winding portion with respect to the insulator, and a gas layer is formed between the stator core and the insulator through the groove.

[0008] The stator according to the technology of this disclosure can suppress the enlargement of the stator and can ensure insulation relative to the winding portion. Attached Figure Description

[0009] Figure 1 This is a top view of the stator in the first embodiment.

[0010] Figure 2 This is a planar sectional view of the stator components of the first embodiment.

[0011] Figure 3 This is a planar sectional view of the stator components of the second embodiment.

[0012] Figure 4 This is a planar sectional view of the stator components of the third embodiment.

[0013] Figure 5 This is a planar sectional view of the stator component of the fourth embodiment.

[0014] Figure 6 This is a planar sectional view of the stator component according to the fifth embodiment. Detailed Implementation

[0015] [First Implementation Method]

[0016] First, the first embodiment of the technology disclosed herein will be described.

[0017] like Figure 1 As shown, the stator 10 of the first embodiment includes a plurality of stator constituent members 12. The stator 10 is constructed by arranging the plurality of stator constituent members 12 in a ring. Figure 1 The structure of half of the stator 10 is shown. The stator 10 is suitable for a brushless motor. Brushless motors can also be used for any application. Examples of brushless motors include fan motors, pump drive motors, and compressor motors.

[0018] In the figures, the X direction represents the tangential direction of the stator 10, the Y direction represents the radial direction of the stator 10, and the Z direction represents the axial direction of the stator 10. Furthermore, in the following description, the circumferential direction of the stator 10 refers to the direction about the central axis of the stator 10. The tangential, radial, axial, and circumferential directions of the stator core 24, as described later, are the same as the tangential, radial, axial, and circumferential directions of the stator 10, respectively.

[0019] like Figure 2 As shown, each stator component 12 includes a core component 14, an insulator 16, and a winding portion 18. The core component 14 has a core back 20 and a pole tooth portion 22. The core back 20 extends circumferentially over the stator core 24, and the pole tooth portion 22 extends inwardly in the Y direction from the center of the core back 20. The head end of the pole tooth portion 22 is a free end, and the base end of the pole tooth portion 22 is connected to the core back 20.

[0020] The stator core 24 is formed by arranging multiple core components 14 in a ring (see reference). Figure 1 With the stator core 24 in place, multiple core backs 20 form annular portions 26 (see reference). Figure 1Multiple pole teeth 22 extend radially from the center of the stator core 24. Grooves 28 are formed between the multiple pole teeth 22.

[0021] Furthermore, when viewed from the Z direction, the structure containing the detailed parts of each stator component 12 is strictly asymmetrical in the X direction. However, for convenience, it is assumed that the main structure of each stator component 12 is symmetrical in the X direction when viewed from the Z direction, and the structure of one side of each stator component 12 will be described below.

[0022] An inner surface 20A is formed on the back side 20 of the core, and a side surface 22A is formed on the pole tooth portion 22. The inner surface 20A extends in the X and Z directions and faces inward in the Y direction. The side surface 22A extends in the Y and Z directions and faces in the X direction. The inner surface 20A and the side surface 22A are in contact with the groove 28.

[0023] An insulator 16 is mounted on the core component 14. The insulator 16 is made of resin. Examples of resins forming the insulator 16 include polyimide, polyamide, polyphenylene sulfide (PPS), and polybutylene terephthalate (PBT). Any resin can also be used to form the insulator 16. The insulator 16 has an inner wall portion 30 and a side wall portion 32. The inner wall portion 30 is mounted on the inner surface 20A and covers the inner surface 20A. The side wall portion 32 is mounted on the side surface 22A and covers the side surface 22A. The inner wall portion 30 and the side wall portion 32 are disposed in a groove 28.

[0024] The inner surface 20A and the side surface 22A are examples of the "mounting surfaces" of the present disclosure. In addition, the inner surface 20A is an example of the "first mounting surface" of the present disclosure, and the side surface 22A is an example of the "second mounting surface" of the present disclosure.

[0025] The winding portion 18 is wound around the pole tooth portion 22 with the insulator 16 in between. The winding portion 18 is formed by winding the winding relative to the pole tooth portion 22 in the Y direction. The winding forming the winding portion 18 may have only one winding portion 18 or may have several winding portions 18.

[0026] The winding portion 18 has an axial portion 34 extending in the Z direction. The axial portion 34 is inserted into a slot 28. The axial portion 34 has a side surface 34A and an end surface 34B. The side surface 34A is the surface formed on the side of the pole tooth portion 22 (i.e., the inner side surface) in the axial portion 34, and the end surface 34B is the surface formed on the side of the core back 20 in the axial portion 34. A sidewall portion 32 is located between the side surface 34A of the axial portion 34 and the side surface 22A of the pole tooth portion 22, and an inner wall portion 30 is located between the end surface 34B of the axial portion 34 and the inner surface 20A of the core back 20.

[0027] A first groove 36 is formed on the inner surface 20A, and a second groove 38 is formed on the side surface 22A. The first groove 36 is located in the Y direction, on the opposite side of the winding portion 18, separated by the inner wall portion 30. The second groove 38 is located in the X direction, on the opposite side of the winding portion 18, separated by the side wall portion 32. The position and width of the first groove 36 in the X direction are set such that the width range of the winding portion 18 in the X direction is within the width range of the first groove 36 in the X direction. Similarly, the position and width of the second groove 38 in the Y direction are set such that the width range of the winding portion 18 in the Y direction is within the width range of the second groove 38 in the Y direction.

[0028] A first gas layer 40 is formed between the core back 20 and the inner wall portion 30 through a first groove 36, and a second gas layer 42 is formed between the pole tooth portion 22 and the side wall portion 32 through a second groove 38. The first groove 36 and the second groove 38 are formed through the entire core in the Z direction.

[0029] The first slot 36 and the second slot 38 are examples of the "slots" of the present disclosure. The first gas layer 40 and the second gas layer 42 are examples of the "gas layers" of the present disclosure.

[0030] Next, the function and effects of the first embodiment of the technology disclosed herein will be explained.

[0031] As detailed above, in the first embodiment, a first gas layer 40 is formed between the core back 20 and the inner wall portion 30 via a first groove 36, and a second gas layer 42 is formed between the pole tooth portion 22 and the side wall portion 32 via a second groove 38. Therefore, an insulating layer consisting of the inner wall portion 30 and the first gas layer 40 is formed between the core back 20 and the winding portion 18, thus ensuring insulation relative to the winding portion 18. Furthermore, an insulating layer consisting of the side wall portion 32 and the second gas layer 42 is formed between the pole tooth portion 22 and the winding portion 18, thus ensuring insulation relative to the winding portion 18.

[0032] Furthermore, by forming a first gas layer 40 between the core back 20 and the inner wall portion 30 using a first groove 36, the thickness of the inner wall portion 30 can be reduced compared to the case where only the inner wall portion 30 is used to insulate between the core back 20 and the winding portion 18. Similarly, by forming a second gas layer 42 between the pole tooth portion 22 and the side wall portion 32 using a second groove 38, the thickness of the side wall portion 32 can be reduced compared to the case where only the side wall portion 32 is used to insulate between the pole tooth portion 22 and the winding portion 18. As a result, the cross-sectional area of ​​the slot 28 can be increased, thereby increasing the number of turns in the winding portion 18, and thus, the enlargement of the stator 10 can be suppressed. That is, the case where the stator 10 is enlarged in order to increase the cross-sectional area of ​​the slot 28 can be suppressed.

[0033] [Second Implementation]

[0034] Next, a second embodiment of the technology disclosed herein will be described.

[0035] In the second embodiment, the structure of the stator 10 is modified as follows, compared to the first embodiment. That is, as follows: Figure 3 As shown, the bottom surface of the second groove 38 has a protrusion 44 protruding toward the sidewall portion 32. The protrusion 44 contacts the sidewall portion 32 and supports it. On the other hand, a recess 46 is formed on the side of the sidewall portion 32 opposite to the contact surface with the protrusion 44. A gas layer 48 is formed between the winding portion 18 and the sidewall portion 32 through the recess 46. The recess 46 is formed in the Y direction at the same position as the protrusion 44. The recess 46 is formed through the Z direction.

[0036] With this configuration, the sidewall portion 32 is supported by the protrusion 44, thus improving the rigidity of the sidewall portion 32. Furthermore, even though the bottom surface of the second groove 38 has a protrusion 44, insulation is ensured because an air layer 48 is formed through the recess 46.

[0037] In addition, Figure 3 In the example shown, a protrusion 44 is formed on the bottom surface of the second groove 38, but multiple protrusions 44 may also be formed. In addition, corresponding to multiple protrusions 44, multiple recesses 46 may be formed on the side of the sidewall portion 32 opposite to the contact surface between the protrusions 44 and the protrusions 44.

[0038] In addition, Figure 3 In the example shown, the protrusion 44 may also be formed on the bottom surface of the first groove 36 and protrude into the inner wall portion 30 to support the inner wall portion 30. In addition, the recess 46 may also be formed on the side opposite to the contact surface between the inner wall portion 30 and the protrusion 44, forming a gas layer 48 between the winding portion 18 and the inner wall portion 30.

[0039] With this configuration, the inner wall portion 30 is supported by the protrusion 44, thus improving the rigidity of the inner wall portion 30. Furthermore, even though the bottom surface of the first groove 36 has the protrusion 44, insulation is ensured because an air layer 48 is formed through the recess 46.

[0040] [Third Implementation Method]

[0041] Next, a third embodiment of the technology disclosed herein will be described.

[0042] In the third embodiment, the structure of the stator 10 is modified as follows, compared to the first embodiment. That is, as follows: Figure 4As shown, the core member 14 has a continuous groove 50 extending from the inner surface 20A to the side surface 22A. The insulator 16 has a dividing portion 54 provided on the R-shaped portion 52, which is the connection portion between the inner surface 20A and the side surface 22A. By providing the dividing portion 54 on the R-shaped portion 52, the groove 50 is divided into a first groove 36 and a second groove 38.

[0043] If configured in this way, the groove 50 can be continuously formed from the inner surface 20A to the side surface 22A, thus making it easy to perform the machining for forming the groove 50.

[0044] Furthermore, since the insulator 16 has a dividing portion 54 provided in the R-shaped portion 52 that serves as the connection between the inner surface 20A and the side surface 22A, the inner wall portion 30 and the side wall portion 32 can be supported by the dividing portion 54. Thus, even if the groove 50 is continuously formed from the inner surface 20A to the side surface 22A, the rigidity of the inner wall portion 30 and the side wall portion 32 can be ensured.

[0045] [Fourth Implementation Method]

[0046] Next, a fourth embodiment of the technology disclosed herein will be described.

[0047] In the fourth embodiment, the structure of the stator 10 is modified as follows, compared to the first embodiment. Specifically, in the first embodiment, the inner surface 20A extends along the X direction when viewed from the Z direction, but in the fourth embodiment, as shown... Figure 5 As shown, the inner surface 20A extends in a direction inclined inward toward the Y direction relative to the X direction when viewed from the Z direction. A first gas layer 40 is formed between the core back 20 and the inner wall portion 30 through a first groove 36, and a second gas layer 42 is formed between the pole tooth portion 22 and the side wall portion 32 through a second groove 38, which is the same as in the first embodiment.

[0048] Even with this configuration, it can achieve the same effect as the first embodiment.

[0049] [Fifth Implementation]

[0050] Next, a fifth embodiment of the technology disclosed herein will be described.

[0051] In the fifth embodiment, the structure of the stator 10 is modified compared to the third embodiment as follows. Specifically, in the third embodiment, the inner surface 20A extends along the X direction when viewed from the Z direction, but in the fifth embodiment, as shown... Figure 6As shown, the inner surface 20A extends in a direction inclined inward toward the Y direction relative to the X direction when viewed from the Z direction. The core member 14 is formed with a groove 50 that is continuous from the inner surface 20A to the side surface 22A, and the insulator 16 has a dividing portion 54 provided in the R-shaped portion 52 that serves as the connection between the inner surface 20A and the side surface 22A, which is the same as in the third embodiment.

[0052] Even with this configuration, it can achieve the same effect as the third embodiment.

[0053] In addition, in the above embodiment, the stator core 24 is divided into multiple core components 14, but it can also be a structure in which multiple core components 14 are integrated. Furthermore, the insulators 16 installed on each core component 14 can also be integrated.

[0054] Furthermore, the combinable structures described in the above embodiments can also be appropriately combined.

[0055] The above describes one embodiment of the technology disclosed herein. However, the present invention is not limited to the above description. In addition to the above description, various modifications and implementations can be made without departing from the spirit of the present disclosure.

[0056] The following are notes on the technology disclosed herein.

[0057] (Note 1)

[0058] A stator having: The stator core (24) has a plurality of radially extending pole teeth (22). A resin insulator (16) is mounted on the stator core; and The winding portion (18) is wound around the plurality of pole teeth through the insulator. The stator core has mounting surfaces (20A, 22A) for mounting the insulator. The mounting surface is formed with grooves (36, 38, 50), which are located on the opposite side of the winding portion, separated from the insulator. A gas layer (40, 42) is formed between the stator core and the insulator through the slot.

[0059] (Note 2)

[0060] In the stator described in Appendix 1, The stator core has a core back side (20) that extends circumferentially in the stator core and connects to the base end of the pole tooth. The mounting surface has: a first mounting surface (20A) formed on the back of the core; and a second mounting surface (22A) formed on the pole teeth. The grooves (36, 38) have: a first groove (36) formed on the first mounting surface; and a second groove (38) formed on the second mounting surface.

[0061] (Note 3)

[0062] In the stator described in Appendix 2, The groove (50) is continuous from the first mounting surface to the second mounting surface. The insulator has a dividing portion (54) which is disposed at the connection portion (52) between the first mounting surface and the second mounting surface, and divides the groove into the first groove and the second groove.

[0063] (Note 4)

[0064] In any of the stators described in notes 1 to 3, A protrusion (44) is formed on the bottom surface of the groove, the protrusion protruding toward the insulator and supporting the insulator. A recess (46) is formed on the side opposite to the contact surface between the insulator and the protrusion, and the recess forms a gas layer (48) between the winding portion and the insulator.

Claims

1. A stator, said stator (10) comprising: The stator core (24) has a plurality of radially extending pole teeth (22). A resin insulator (16) is mounted on the stator core; and The winding portion (18) is wound around the plurality of pole teeth through the insulator. The stator core has mounting surfaces (20A, 22A) for mounting the insulator. A groove (36, 38, 50) is formed on the mounting surface, the groove being located on the side opposite to the winding portion of the winding, separated by the insulator. A gas layer (40, 42) is formed between the stator core and the insulator through the slot.

2. The stator according to claim 1, wherein, The stator core has a core back side (20) that extends circumferentially in the stator core and connects to the base end of the pole tooth. The mounting surface has: a first mounting surface (20A) formed on the back of the core; and a second mounting surface (22A) formed on the pole teeth. The grooves (36, 38) have: a first groove (36) formed on the first mounting surface; and a second groove (38) formed on the second mounting surface.

3. The stator according to claim 2, wherein, The groove (50) is continuous from the first mounting surface to the second mounting surface. The insulator has a dividing portion (54) which is disposed at the connection portion (52) between the first mounting surface and the second mounting surface, and divides the groove into the first groove and the second groove.

4. The stator according to any one of claims 1 to 3, wherein, A protrusion (44) is formed on the bottom surface of the groove, the protrusion protruding toward the insulator and supporting the insulator. A recess (46) is formed on the side opposite to the contact surface between the insulator and the protrusion, and the recess forms a gas layer (48) between the winding portion and the insulator.

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