stator

Abstract

The utility model provides a stator which can alleviate stress caused by thermal expansion and contraction at the connecting part of multiple segmented coils. The stator comprises: a stator core; and a stator coil, the multiple segmented coils of the stator coil are connected via a connecting member and fixed by a resin layer, and the resin layer around the connecting part of the multiple segmented coils is thinner than the resin layer of other parts.

Description

Technical Field

[0001] This disclosure relates to the stator. Background Technology

[0002] Patent document 1 discloses a stator having stator coils formed by connecting multiple segmented coils via connecting components.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2019-126153

[0004] In the stator disclosed in Patent Document 1, segmented coils are arranged in slots within the stator core, and resin flows into (or is applied to) these slots, thereby fixing the segmented coils and the stator coils in place. At this time, the resin flows into the periphery of the connecting portion of the multiple segmented coils, and thus the resin around this connecting portion repeatedly expands / contracts due to temperature changes, potentially applying stress. Utility Model Content

[0005] This disclosure was made in view of the above circumstances, and its object is to provide a stator capable of mitigating stress caused by thermal expansion and contraction at the connection points of multiple segmented coils.

[0006] The stator disclosed herein comprises: a stator core; and a stator coil, wherein a plurality of segmented coils of the stator coil are connected by a connecting member and fixed by a resin layer, wherein the resin layer around the connecting portion of the plurality of segmented coils is thinner than the resin layer in other portions.

[0007] According to this disclosure, it is possible to mitigate stress caused by thermal expansion and contraction at the connection points of multiple segmented coils. Attached Figure Description

[0008] Figure 1 This is a cross-sectional view showing the structure of a stator coil with a number of slots in the stator according to the embodiment.

[0009] Figure 2 This indicates that in the existing stator and Figure 1 A schematic diagram of the connection structure of the segmented coil at the position corresponding to part A.

[0010] Figure 3 This indicates that in the stator of the implementation method, and Figure 1 A schematic diagram of the first connection structure of the segmented coil at the position corresponding to part A.

[0011] Figure 4 This indicates that in the stator of the implementation method, and Figure 1 A schematic diagram of the second connection structure of the coil at the position corresponding to part A.

[0012] Figure 5 This indicates that in the stator of the implementation method, and Figure 1 A schematic diagram of the third connection structure of the segmented coil corresponding to the position of part A.

[0013] Figure 6 This indicates that in the stator of the implementation method, and Figure 1 A schematic diagram of the fourth connection structure of the segmented coil at the position corresponding to part A. Detailed Implementation

[0014] The stator of the embodiments involved in this disclosure will be described with reference to the accompanying drawings. Furthermore, the constituent elements in the following embodiments include elements that can and are easily substituted by those skilled in the art, or elements that are substantially the same.

[0015] Reference Figures 1-6 The stator of the embodiment will be described. The stator and rotor involved in the embodiment are combined to form a rotary electric motor. This rotary electric motor is, for example, mounted in a vehicle and functions as an electric motor and generator. Examples of vehicles equipped with this rotary electric motor include hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs). Furthermore, the rotary electric motor can also be mounted in fuel cell electric vehicles (FCEVs) and battery electric vehicles (BEVs).

[0016] like Figure 1 As shown, the stator 1 includes a stator core 11 and a stator coil 12. The stator core 11 is composed of, for example, a laminated steel plate with multiple electromagnet plates stacked on top of each other, a powder core, etc. The stator coil 12 is housed in a slot (accommodation space) provided in the stator core 11. In addition, the stator coil 12 is composed of multiple segmented coils 121 and a connecting member 124 that connects the multiple segmented coils 121.

[0017] Here, Figure 2 Indicates that in the existing stator and Figure 1 The connection structure of the segmented coils at the position corresponding to part A. In this connection structure, multiple segmented coils 121 with their exposed conductor portions 123 mated together are connected by a connecting member 124 within the slot of the stator core 11. In addition, by allowing resin to flow into (or apply) into the slot, the segmented coils 121 are fixed to each other, as well as to the stator core 11 and the segmented coils 121.

[0018] exist Figure 2In the connection structure shown, when resin flows into the slot, the resin flows into the periphery (hereinafter referred to as "coil connection periphery") of the connecting portion (the portion where the conductor protrusions 123 are joined) of the multiple segmented coils 121 within the connecting member 124, forming a resin layer 125. Therefore, for example, if the resin layer 125 repeatedly expands / contracts due to temperature changes during the use of the rotary motor, then... Figure 2 As shown in section B, axial stress may be applied to the resin layer 125 surrounding the coil connection portion. Herein, in the stator according to the embodiment, a connection structure capable of reducing stress is provided. Hereinafter, refer to... Figures 3-6 Here is an example of the connection construction of the segmented coil 121 in stator 1.

[0019] (First connection construction)

[0020] like Figure 3 As shown, the first connection structure includes multiple segmented coils 121, connecting components 124, and resin layers 125.

[0021] The segmented coil 121 is made of, for example, plate-shaped aluminum. An insulating film 122 is provided on the surface of the segmented coil 121. In addition, a conductor exposed portion 123 with the insulating film 122 removed is provided at the front end of the segmented coil 121. Multiple segmented coils 121 are connected by a connecting member 124 with their respective conductor exposed portions 123 joined together.

[0022] The connecting member 124 is, for example, a hollow copper tube. The interior of the connecting member 124 is filled with resin, such as foamed resin, and a resin layer 125 is formed therefrom. This resin layer 125 is disposed between the outer surface of the segmented coil 121 and the inner circumferential surface of the connecting member 124. Furthermore, multiple segmented coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0023] like Figure 3 As shown in section C, a gap without the resin layer 125 is provided around the coil connection portion. That is, around the coil connection portion, there is a gap between the exposed conductor portion 123 and the resin layer 125, and the exposed conductor portion 123 and the resin layer 125 do not contact each other. On the other hand, outside the coil connection portion, there is no gap between the insulating film 122 and the resin layer 125, and the insulating film 122 contacts the resin layer 125.

[0024] There are no particular limitations on the method of setting a gap around the coil connection portion. For example, various methods can be used, such as applying a thin layer of resin only around the coil connection portion, or cutting after applying resin as usual.

[0025] (Second connection construction)

[0026] like Figure 4 As shown, the second connection structure includes multiple segmented coils 121, connecting components 124, and resin layers 125.

[0027] The segmented coil 121 is made of, for example, plate-shaped aluminum. An insulating film 122 is provided on the surface of the segmented coil 121. In addition, a conductor exposed portion 123 with the insulating film 122 removed is provided at the front end of the segmented coil 121. Multiple segmented coils 121 are connected by a connecting member 124 with their respective conductor exposed portions 123 joined together.

[0028] The connecting member 124 is, for example, a hollow copper tube. The interior of the connecting member 124 is filled with resin, such as foamed resin, and a resin layer 125 is formed therefrom. This resin layer 125 is disposed between the outer surface of the segmented coil 121 and the inner circumferential surface of the connecting member 124. Furthermore, multiple segmented coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0029] like Figure 4 As shown in section D, the resin layer 125 around the coil connection portion is thinner than the resin layer 125 in other portions. That is, around the coil connection portion, there is a gap between the exposed conductor portion 123 and the resin layer 125, and the exposed conductor portion 123 does not contact the resin layer 125. On the other hand, outside the coil connection portion, there is no gap between the insulating film 122 and the resin layer 125, and the insulating film 122 contacts the resin layer 125.

[0030] There is no particular limitation on the method of making the resin layer 125 around the coil connection portion thinner than the resin layer 125 of other portions. For example, various methods can be used, such as applying resin only thinly around the coil connection portion or cutting after applying resin as usual.

[0031] (Third connection construction)

[0032] like Figure 5 As shown, the third connection structure includes multiple segmented coils 121, connecting components 124, resin layers 125, and insulating components 126.

[0033] The segmented coil 121 is made of, for example, plate-shaped aluminum. An insulating film 122 is provided on the surface of the segmented coil 121. In addition, a conductor exposed portion 123 with the insulating film 122 removed is provided at the front end of the segmented coil 121. Multiple segmented coils 121 are connected by a connecting member 124 with their respective conductor exposed portions 123 joined together.

[0034] The connecting member 124 is, for example, a hollow copper tube. The interior of the connecting member 124 is filled with resin, such as foamed resin, and a resin layer 125 is formed therefrom. This resin layer 125 is disposed between the outer surface of the segmented coil 121 and the inner circumferential surface of the connecting member 124. Furthermore, multiple segmented coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0035] The insulating component 126, for example made of insulating paper, is disposed around the coil connection portion. By disposing of the insulating component 126 around the coil connection portion, resin does not enter the area around the coil connection portion, thus eliminating the need for a resin layer 125 around the coil connection portion. In other words, with the insulating component 126 disposed around the coil connection portion, the exposed conductor portion 123 does not contact the resin layer 125. On the other hand, outside the area around the coil connection portion, there is no gap between the insulating film 122 and the resin layer 125, and the insulating film 122 is in contact with the resin layer 125.

[0036] (Fourth connection construction)

[0037] like Figure 6 As shown, the fourth connection structure includes multiple segmented coils 121A, connecting components 124, and resin layers 125.

[0038] The segmented coil 121A is made of, for example, plate-shaped aluminum. An insulating film 122 is provided on the surface of the segmented coil 121A. In addition, a conductor exposed portion 123 with the insulating film 122 removed is provided at the front end of the segmented coil 121A. Multiple segmented coils 121A are connected by a connecting member 124 with their respective conductor exposed portions 123 joined together.

[0039] The width of the front end of the segmented coil 121A is smaller than the width of the rest. Furthermore, in Figure 6 In the example shown, the width of the front end of the segmented coil 121A is gradually reduced, but the front end of the segmented coil 121A can also be a shape that narrows in a conical shape.

[0040] The connecting member 124 is, for example, a hollow copper tube. The interior of the connecting member 124 is filled with resin, such as foamed resin, and a resin layer 125 is formed therefrom. This resin layer 125 is disposed between the outer surface of the segmented coil 121A and the inner circumferential surface of the connecting member 124. Furthermore, multiple segmented coils 121A are fixed within the connecting member 124 by this resin layer 125.

[0041] like Figure 6As shown in section E, the width of the front end of the segmented coil 121A is smaller than the width of the rest of the coil. Therefore, resin does not enter around the coil connection portion, and a gap without resin layer 125 is provided. That is, around the coil connection portion, there is a gap between the exposed conductor portion 123 and the resin layer 125, and the exposed conductor portion 123 does not contact the resin layer 125. On the other hand, outside the coil connection portion, there is no gap between the insulating film 122 and the resin layer 125, and the insulating film 122 contacts the resin layer 125.

[0042] According to the stator described above, the resin layer 125 around the connection portion of the plurality of segmented coils 121, 121A is thinner than the resin layer 125 of other portions. As a result, stress caused by thermal expansion and contraction can be mitigated at the connection portion of the plurality of segmented coils 121, 121A, and the effects caused by such stress can be reduced.

[0043] Further effects and variations can be readily derived by those skilled in the art. Therefore, the broader scope of this invention is not limited to the specific details and representative embodiments shown and described above. Thus, various modifications can be made without departing from the spirit or scope of the general concept of the invention as defined by the appended technical solutions and their equivalents.

[0044] Explanation of reference numerals in the attached figures:

[0045] 1…Stator; 11…Stator core; 12…Stator coil; 121, 121A…Segmented coil; 122…Insulating film; 123…Exposed conductor; 124…Connecting component; 125…Resin layer; 126…Insulating component.

Claims

1. A stator, wherein, have: Stator core; and stator coils, The stator coil segments are connected by connecting components and fixed by a resin layer. The resin layer around the connection portion of the plurality of segmented coils is thinner than the resin layer in other portions.

Images