stator of a motor

Abstract

The utility model discloses a kind of stator of motor.In the stator of the utility model of motor, stator includes stator core, stator coil and insulating sheet, the insulating sheet is provided with multiple unit insulating sheets along the inner circumferential surface of stator core, so that stator core and stator coil are insulated;Unit insulating sheet includes: first insulation part, by the yoke piece part of yoke part insulation, the tooth piece part of extending from yoke piece part and the tooth part insulation, and the shoe piece part of extending from tooth piece part and the shoe part insulation, and is set in the slot inner circumferential surface between the tooth part of each other adjacent;And second insulation part, in one side front end of circumferential two ends of shoe piece part bending to surround stator coil, and is set between stator coil of winding in circumferential adjacent two sides tooth part. Thus, the component quantity and assembly procedure of insulating sheet can be reduced by integrally forming the insulating sheet of making stator core and stator coil insulation, so as to reduce the manufacturing cost of stator.

Description

Technical Field

[0001] This utility model relates to a stator of a motor. Background Technology

[0002] Typically, the stator in a motor generates magnetic force by magnetizing an iron core, which in turn generates rotational force through interaction with the rotor. To produce this magnetic force, coils are wound around the iron core to create a magnetic field. Therefore, to improve efficiency or output density, most stators require a structure that allows for filling more coils into the slots of the iron core.

[0003] To reduce iron loss, the iron core is made up of multiple layers of electrical steel plates. Due to this constraint, a great deal of technical effort is required to increase the space factor, which is the ratio of slot area to coil cross-sectional area.

[0004] In the prior art, a core that is integrally formed into the stator core of the motor (hereinafter referred to as "integral core") is used. Although this type of core has the advantage of excellent manufacturing process reliability, the effective slot area for winding the stator coil is correspondingly reduced because space needs to be ensured for the winding nozzle used for winding operations, resulting in a decrease in motor efficiency.

[0005] In view of this, a core is proposed that consists of a stator core that is divided and wound with stator coils to form the stator of a motor, and then assembled into a stator core (hereinafter referred to as "divided core") and / or a core that is extended and wound with stator coils to form a cylindrical shape (hereinafter referred to as "expanded core" or "expanded core").

[0006] Patent Document 1 (Korean Patent Publication No. 10-2005-0048962) discloses a spaced core, and Patent Document 2 (Korean Patent No. 10-1178331) discloses an unfolded core. However, Patent Document 1 does not mention the insulation structure between the stator core and the stator coil, and Patent Document 2 only discloses an insulating sheet located between the stator core and the stator coil, without mentioning the insulation structure between the stator cores.

[0007] Conversely, Patent Document 3 (International Publication WO2010 / 100890) discloses an example in which an insulating sheet is inserted into the teeth of the stator core in both the split core and the unfolded core. Patent Document 3 also discloses an example where the insulating sheet is inserted separately and fixed to the teeth.

[0008] However, in the existing technology, when an insulating sheet is inserted individually into its respective tooth, the number of insulating sheet components increases, leading to increased assembly processes and manufacturing costs. Furthermore, to maintain the shape of the insulating sheet, multiple insulating sheet supports are required within the slots of the stator core, which correspondingly reduces the stator coil stacking factor and motor efficiency.

[0009] Furthermore, in existing technologies, since adjacent teeth are configured with different phases, a certain insulation distance must be maintained between adjacent coils to ensure phase-to-phase insulation. This further reduces the winding fill factor within the slot space, leading to a further decrease in motor efficiency. Utility Model Content

[0010] The purpose of this invention is to provide a motor stator that reduces the assembly process of the insulating sheet used to insulate the stator core and stator coil.

[0011] Another objective of this invention is to provide a motor stator and its assembly method that can improve motor efficiency by increasing the fill factor of the stator coil wound around the stator core.

[0012] Another objective of this invention is to provide a stator for a motor and a method for assembling the stator thereon, which can improve the fill factor of the stator coil and keep the stator coil stably in the stator core.

[0013] To achieve the objective of this invention, a stator for a motor comprising a stator core, a stator coil, and insulating sheets can be provided. In the stator core, a plurality of unit cores can be wound or combined into a ring. In each of the plurality of unit cores, a tooth extends radially from its respective yoke, and a shoe extends circumferentially from the inner end of its respective tooth. The stator coil can be wound around the teeth. In the insulating sheets, a plurality of unit insulating sheets can be provided along the inner circumferential surface of the stator core to insulate the stator core and the stator coil.

[0014] Here, the unit insulating sheet may include a first insulating portion and a second insulating portion. The first insulating portion may be composed of a yoke portion that insulates the yoke portion, a toothed portion extending from the yoke portion and insulating the teeth, and a boot portion extending from the toothed portion and insulating the boot portion, and may be disposed on the inner circumferential surface of a groove between adjacent teeth. The second insulating portion may be bent at one end of one of the circumferential ends of the boot portion to surround the stator coil, and may be disposed between stator coils wound around adjacent circumferentially adjacent teeth on both sides. Thus, an insulating sheet that insulates the stator core and stator coils can be integrally formed, thereby reducing the number of components and assembly steps of the insulating sheet, and thus reducing the manufacturing cost of the stator. In addition, by inserting an insulating sheet between the two stator coils, the insulation distance between the two stator coils can be minimized as much as possible. This can improve the fill factor of the stator coils, thereby improving motor efficiency.

[0015] As an example, in the unit insulating sheet, the second insulating portion can be formed by bending each other along the same circumferential direction. Thus, the second insulating portion enables complete insulation between circumferentially adjacent stator coils.

[0016] As an example, the second insulating portion can contact the first insulating portion between the stator coils on two adjacent sides in the circumferential direction. Thus, the two stator coils located on opposite sides in the circumferential direction can be tightly insulated by the insulating sheet.

[0017] For example, in the yoke portion, a connecting protrusion protruding in a direction away from the yoke portion can be formed between the stator coils on two adjacent sides in the circumferential direction. The second insulating portion can contact the connecting protrusion and is disposed between the stator coils on two adjacent sides in the circumferential direction. Thus, the two stator coils can be tightly separated and insulated by the second insulating portion and the connecting protrusion.

[0018] Specifically, the connecting protrusion can be formed by folding the yoke portion. This allows for easy manufacturing of an insulating sheet including a first insulating portion, while during stator core winding, the connecting protrusion rises towards the second insulating portion, thereby reliably ensuring the contact area with the second insulating portion.

[0019] As another example, an insulator can be provided on the axial side of the stator core to insulate between the stator core and the stator coil. The insulator can have an insulating sheet support portion that supports the insulating sheet axially. Thus, a second insulating portion can be provided to stably support the insulating sheet axially relative to one side via the insulating sheet support portion.

[0020] For example, the insulator may have a boot insulation portion facing the axial side of the boot portion. The insulation sheet support portion may be formed by extending circumferentially from at least one end of the circumferential ends of the boot insulation portion. Thus, not only can the insulation sheet support portion be easily formed, but the insulation sheet can also be stably supported, and the area of ​​the actual groove portion can be increased.

[0021] Specifically, the insulator may include a first insulator and a second insulator located on both axial sides of the stator core. The first insulator may have a first insulating sheet support portion that axially supports the insulating sheet on one side, and the second insulator may have a second insulating sheet support portion that axially supports the insulating sheet on the other side. This not only simplifies the winding process of the stator coil but also increases the actual area of ​​the slots and improves the fill factor of the stator coil by increasing the circumferential length of the unit core shoe portions on both sides.

[0022] More specifically, the first insulating sheet support portion and the second insulating sheet support portion can be formed by extending in opposite directions along the circumference. This minimizes the number of insulating sheet support portions and provides stable support for the insulating sheet.

[0023] Furthermore, a winding groove can be formed on the side of the insulator facing away from the stator core along the winding direction of the stator coil. This allows for improved coil alignment during winding, preventing a decrease in the stator coil fill factor.

[0024] To achieve the objective of this invention, the following steps may be included: assembling an insulating sheet bent along the inner circumferential surface of a stator core to which insulators are assembled at both axial ends; winding stator coils around the teeth of the stator core; and winding or combining the stator core to form a ring shape. Before winding or combining the stator core into a ring shape, a portion of the insulating sheet may be cut off and used to surround the stator coils wound around the teeth, positioning them between adjacent stator coils. Thus, since the insulating sheet is integrally formed, not only is the processing of the insulating sheet easier, but it also allows for easy assembly onto the stator core.

[0025] As an example, in the step of placing the insulating sheet between the stator coils, a second insulating portion can be formed by cutting off one circumferential end of the first insulating portion surrounding the stator core, and the second insulating portion can be bent at the other circumferential end of the boot to surround the stator coil. This allows for easy and tight insulation between circumferentially adjacent stator coils.

[0026] For example, in the step of winding or combining the stator core to form a stator in a ring shape, when the stator core is wound into a ring, the second insulating portion can be made to contact the first insulating portion between the stator coils on opposite sides of each other in the circumferential direction. This allows for easier and tighter insulation between circumferentially adjacent stator coils.

[0027] Specifically, in the step of winding or combining the stator core to form a stator in a ring shape, a connecting protrusion can be formed in the first insulating portion, which protrudes toward the second insulating portion by folding the first insulating portion. This makes it easier and more secure to insulate adjacent stator coils in the circumferential direction. Attached Figure Description

[0028] Figure 1 This is a perspective view showing the stator of this utility model.

[0029] Figure 2 yes Figure 1 Top view of the stator.

[0030] Figure 3 This is a perspective view showing the insulator and insulating sheet separated from the stator core in the stator of this utility model.

[0031] Figure 4 yes Figure 3 The assembled 3D diagram.

[0032] Figure 5 yes Figure 4 A three-dimensional view of the front.

[0033] Figure 6 yes Figure 4 Top view.

[0034] Figure 7 yes Figure 4 A bottom view.

[0035] Figures 8A to 8C This is a schematic diagram illustrating the insulation process of the insulating sheet of this utility model.

[0036] Figure 9 This is a block diagram illustrating the assembly process of the components constituting the stator of this utility model. Detailed Implementation

[0037] The stator of the motor of this invention and its assembly method will be described in detail below through an embodiment. As described above, in addition to a monolithic core in which a stator coil is wound in a ring shape, a motor stator also has a partitioned core and a rolled-up core, in which a stator coil is wound and formed into a ring shape by a stator core composed of a plurality of unit cores in a linearly unfolded state. In this embodiment, the stator core can be either a partitioned core or a rolled-up core. The following description focuses on an example using a rolled-up core, but the same or nearly the same applies when a partitioned core is used.

[0038] Alternatively, the stator can be insulated from the stator coils facing it axially by providing insulators on both sides of the stator core. In this case, the insulators can be pre-assembled into the stator core using insert molding, or they can be manufactured separately and then assembled into the stator core. This embodiment focuses on the example of insulators being assembled into the stator core later, but the case of insulators being pre-assembled into the stator core is the same or almost the same.

[0039] Figure 1 This is a perspective view showing the stator of this utility model. Figure 2 yes Figure 1 Top view of the stator.

[0040] Reference Figure 1 and Figure 2 The stator 100 of the motor in this embodiment may include a stator core 110, a stator coil 120, an insulator 130, and an insulating sheet 140. The stator core 110 is a component for forming a magnetic circuit, the stator coil 120 is a component for forming a magnetic circuit in the stator core 110, the insulator 130 is a component for insulating the axial side surface of the stator core 110, and the insulating sheet 140 is a component for insulating the inner circumferential surface of the stator core 110.

[0041] The stator core 110 of this embodiment can be formed into a ring by stacking multiple steel plates. The stator core 110 can be a spaced core or an unfolded core, but as described above, this embodiment will be described with an unfolded core as the focus.

[0042] For example, the stator core 110 can be formed into a single unit by connecting a plurality of unit cores 110a to each other. In other words, in the stator core 110 constituting the unfolded core, a plurality of unit cores 110a can be connected to each other in the longitudinal direction and arranged in a row, and the unit cores 110a at both ends can be separated from each other and then reassembled. Thus, the unfolded core can be manufactured in a linear fashion and then formed into a ring.

[0043] Specifically, the plurality of unit cores 110a may each include a yoke 111, a toothed portion 112, a shoe portion 113, and a slotted portion 114. Each unit core 110a may be provided with a yoke 111, a toothed portion 112, and a shoe portion 113, and the slotted portion 114 may be formed between two adjacent unit cores 110a. Thus, in the unfolded core, the yoke 111, the toothed portion 112, and the shoe portion 113 can form the fixed cross-sectional area of ​​the stator core 110, and the slotted portion 114 can form the variable cross-sectional area of ​​the stator core 110.

[0044] The yoke 111 can be formed in an arc shape. For example, the outer peripheral surface of the yoke 111 can be formed in a concave-convex arc shape, and the inner peripheral surface of the yoke 111 can be formed in a straight line orthogonal to the circumferential side surface of the tooth 112 described later. Thus, when the inner peripheral surface of the yoke 111 is unfolded, it can form a straight line with the inner peripheral surface of the adjacent yoke 111.

[0045] The circumferential ends of the yoke 111 can be formed at an angle. For example, the circumferential ends of the yoke 111 can be formed with connecting surfaces 1111, which can be angled to narrow from the outer circumferential surface of the yoke 111 to the inner circumferential surface. As a result, the circumferential side surface of the yoke 111 can form a rolling groove 1112 together with the circumferential side surface of the adjacent yoke 111, which is radially cut from the inner circumferential surface of the yoke 111 toward the outer circumferential surface of the yoke 111.

[0046] The tooth 112 can be formed as a rectangle. The tooth 112 can extend radially inward from the center of the inner circumferential surface of the yoke 111. Thus, the circumferential width of the tooth 112 can be formed to be smaller than the length between the two ends of the yoke 111, and a groove 114 forming a coil winding space is formed between adjacent teeth 112.

[0047] The tooth portion 112 can be formed with the same width along its length. In other words, the two circumferential side surfaces of the tooth portion 112 can be formed to be orthogonal to the inner circumferential surface of the yoke portion 111, respectively. As a result, the volume of the slot portion 114 can be formed as wide as possible, thereby improving the fill factor of the stator coil 120.

[0048] The boot portion 113 can be formed in an arc shape. For example, the boot portion 113 can extend circumferentially to both sides from the inner end of the tooth portion 112, and the circumferential length of the boot portion 113 can be formed to be smaller than the circumferential length of the yoke portion 111. In other words, it can be spaced apart from adjacent boot portions 113 by a predetermined interval. As a result, the winding nozzle can enter and exit on the inner circumferential side of the stator core 110, and the stator coil 120 can be wound around the stator core 110.

[0049] The boot portion 113 can be formed with a uniform width along the circumference, or it can be formed to become thinner from the center towards the circumferential ends. In the former case, the magnetic reluctance at both ends of the boot portion 113 can be reduced; in the latter case, the volume of the slot portion 114 can be increased, thereby improving the fill factor of the stator coil 120. This embodiment shows an example of the latter case, i.e., the boot portion 113 becoming thinner from the circumferential center towards the circumferential ends.

[0050] The slot 114, serving as the space for winding the stator coil 120, can be formed between adjacent two-sided unit cores 110a, 110a. In other words, the slot 114 can be formed by the respective yokes 111, teeth 112, and boots 113 facing each other between adjacent unit cores 110a in the circumferential direction. Thus, the outer circumferential surface and the two circumferential side surfaces of the slot 114 can be blocked, while the inner circumferential side can have an opening (not marked) separated by the two boots 113, allowing the winding nozzle to enter and exit.

[0051] Reference Figure 1 and Figure 2 In this embodiment, the stator coil 120 can be surrounded by the teeth 112 of the stator core 110 and housed in the slots 114. For example, the stator coil 120 is inserted into the U, V, and W phase positions of the power supply terminal section (not shown) by winding nozzles of a winding machine (not shown) arranged at predetermined intervals in the stacking direction (hereinafter, axial direction) of the stator core 110. Then, while each winding nozzle moves repeatedly in both the horizontal and vertical directions, the stator coil 120 is wound around the teeth 112. After the stator coil 120 is wound around the three teeth 112, the stator core 110 is rotated 180 degrees. Then, after the winding nozzles move horizontally by the interval of the three slots 114, the stator core 110 is rotated 180 degrees again in the opposite direction. Then, after the winding nozzles are moved toward the opening side of the slots 114, the above winding operation is repeated. Then, the stator coil 120 can be cut while inserted at the U, V, and W phase positions respectively at the neutral point. This allows the stator coil 120 to be wound into the space occupied by the winding nozzle, thereby increasing the fill factor of the stator coil 120. This not only improves motor efficiency but also allows the use of aluminum coils while maintaining the same level of motor efficiency as existing motors. Furthermore, since the stator coil 120 has a structure of continuous winding without winding components, multiple winding nozzles can be used, thereby reducing manufacturing costs and increasing production efficiency.

[0052] Figure 3 This is a perspective view showing the insulator and insulating sheet separated from the stator core in the stator of this utility model. Figure 4 yes Figure 3 Assembly 3D diagram, Figure 5 yes Figure 4 Frontal 3D view, Figure 6 yes Figure 4 Top view, Figure 7 yes Figure 4 A bottom view.

[0053] Reference Figures 3 to 7 In this embodiment, the insulator 130 may include a first insulator 131 and a second insulator 132. The first insulator 131 is an insulator disposed on one side of the axial direction, and the second insulator 132 is an insulator disposed on the other side of the axial direction. Since the first insulator 131 and the second insulator 132 are formed almost identically, the following description will focus on the first insulator 131.

[0054] The first insulator 131 may include a first yoke insulating portion 1311, a first tooth insulating portion 1312, and a first shoe insulating portion 1313. The first yoke insulating portion 1311 is the portion that insulates between the yoke portion 111 of the stator core 110 and the stator coil 120; the first tooth insulating portion 1312 is the portion that insulates between the tooth portion 112 of the stator core 110 and the stator coil 120; and the first shoe insulating portion 1313 is the portion that insulates between the shoe portion 113 of the stator core 110 and the stator coil 120. Thus, in axial projection, the first yoke insulating portion 1311 may be formed in the same or similar manner as one axial side of the yoke portion 111, the first tooth insulating portion 1312 may be formed in the same or similar manner as one axial side of the tooth portion 112, and the first shoe insulating portion 1313 may be formed in the same or similar manner as one axial side of the shoe portion 113.

[0055] The first yoke insulation portion 1311 can protrude axially to a predetermined height. Thus, the first yoke insulation portion 1311 can insulate the stator core 110 and the stator coil 120 while also insulating the stator coil 120 and the components surrounding it, such as the compressor housing (not shown) including the motor housing (not shown) and / or the motor.

[0056] The inner circumferential surface of the first yoke insulation portion 1311 can be formed as a straight surface to correspond to the inner circumferential surface of the yoke portion 111. As a result, the volume of the slot portion 114 of the stator core 110 can be ensured as wide as possible, thereby improving the fill factor of the stator coil 120.

[0057] The first tooth insulation portion 1312 can be formed elongatedly from the inner circumferential surface of the first yoke insulation portion 1311, and a first coil winding groove 1312a can be formed on the axial side facing away from the stator core 110. The first coil winding groove 1312a can be formed obliquely along the direction of winding the stator coil 120. Therefore, when winding the stator coil 120, the fill factor of the stator coil 120 can be prevented from decreasing by improving the uniformity of the stator coil 120.

[0058] Although not shown in the accompanying drawings, a second coil winding groove 1322a can be formed in the second toothed insulating portion 1322 of the second insulator 132. When projected axially, the second coil winding groove 1322a can be formed in a direction intersecting the first coil winding groove 1312a, for example, in a direction orthogonal to the circumferential side surface of the first toothed insulating portion 1312. This improves the uniformity of the stator coil 120 during winding.

[0059] The first boot insulation portion 1313 may extend circumferentially on both sides from the inner end of the first tooth insulation portion 1312. The first boot insulation portion 1313 may extend to the same length on both sides, or it may extend to different lengths on both sides. For example, the circumferential length of the first boot insulation portion 1313 may be the same as the circumferential length of the boot portion 113, or it may be longer than the circumferential length of the boot portion 113. In the former case, the spacing between adjacent first boot insulation portions 1313, 1313 can be ensured to the maximum extent, making the winding operation easier. In the latter case, the two ends of the first boot insulation portion 1313 may protrude more circumferentially than the two ends of the boot portion 113 and axially support the second insulation portion 142 of the insulating sheet 140 described later. This embodiment illustrates the latter case, that is, it shows an example where the circumferential length of the first boot insulation portion 1313 is longer to one side than the circumferential length of the boot portion 113.

[0060] For example, the first boot insulation portion 1313 can extend from the circumferential center of the first tooth insulation portion 1312 to both circumferential sides, and the circumferential length L11 of one side of the first boot insulation portion 1313 can be formed to be longer than the circumferential length L12 of the other side of the first boot insulation portion 1313. In other words, in the first boot insulation portion 1313, the first direction length L11 of the first boot insulation portion 1313 extending along one side of the circumferential direction with reference to the first tooth insulation portion 1312 can be formed to be longer in the circumferential direction than the second direction length L12 of the first boot insulation portion 1313 extending along the other side of the circumferential direction. Thus, one circumferential end of the first boot insulation portion 1313 can be formed to be the same as one circumferential end of the boot portion 113 of the stator core 110, and conversely, compared to the other circumferential end of the boot portion 113 of the stator core 110, the other circumferential end of the first boot insulation portion 1313 can protrude longer in the circumferential direction and form the first insulating sheet support portion 1314. Thus, the second insulating portion 142 of the insulating sheet 140 (described later) can be stably supported axially relative to one side by the first insulating sheet support portion 1314.

[0061] In this case, as described above, since the first insulating sheet support portion 1314 is formed only on one side of the two opposing shoe insulating portions 1313, 1313 in the circumferential direction, the spacing between the two shoe insulating portions 1313, 1313 can be widened accordingly. This not only makes the winding operation of the stator coil 120 easier, but also increases the actual area of ​​the slot portion 114 and improves the fill factor of the stator coil 120 by increasing the circumferential length of the shoe portions 113 of the two unit cores 110a.

[0062] In this case, the first insulating sheet support portion 1314 can be formed as a cantilever shape that protrudes only circumferentially, or it can be bent axially and protrude from the end of the first insulating sheet support portion 1314 toward the insulating sheet 140. In the former case, the manufacturing of the insulator 130 and the assembly of the insulating sheet 140 can be made easier by simplifying the shape of the first insulating sheet support portion 1314. In the latter case, since the insulating sheet 140 is inserted into and supported by the first insulating sheet support portion 1314, the insulating sheet 140 can be supported more stably. This embodiment shows the latter case, that is, the first insulating sheet support portion 1314 is shown as... An example of a bent shape.

[0063] Furthermore, the insulating sheet support portion can be formed not only on the first insulator 131 described above, but also on the second insulator 132. For example, one circumferential end of the second shoe insulating portion 1323 can be formed to be the same as one circumferential end of the shoe portion 113 of the stator core 110, while the other circumferential end of the second shoe insulating portion 1323 can protrude longer in the circumferential direction than the other circumferential end of the shoe portion 113 of the stator core 110. Thus, a second insulating sheet support portion 1324 can be formed at the other circumferential end of the second shoe insulating portion 1313, thereby enabling axial support of the other axial side of the second insulating portion 142 of the insulating sheet 140 described later.

[0064] Even in this case, the second insulating sheet support 1324 can be formed with the same shape as the first insulating sheet support 1314 described above. For example, the second insulating sheet support 1324 can extend circumferentially or be bent towards the insulating sheet 140. This embodiment shows the second insulating sheet support 1324 in a shape symmetrical to the first insulating sheet support 1314, that is, An example of a bent shape.

[0065] In this case, the first insulating sheet support portion 1314 and the second insulating sheet support portion 1324 can be formed by extending from the first boot insulating portion 1313 of the first insulator 131 and the second boot insulating portion 1323 of the second insulator 132 which faces it axially, respectively. Alternatively, the first boot insulating portion 1313 of the first insulator 131 and the second boot insulating portion 1323 of the second insulator 132 which faces it diagonally can be formed by extending circumferentially in opposite directions. In the former case, since one end of the unit insulating sheet 140a described later is inserted and fixed between the two insulating sheet support portions 1314 and 1324, the unit insulating sheet 140a can be assembled relatively easily. In the latter case, since each end of the two ends of the unit insulating sheet 140a described later can be supported axially, the number of insulating sheet support portions 1314 and 1324 can be minimized and the unit insulating sheet 140a can be stably supported. This embodiment illustrates the latter case, that is, it shows an example in which the insulating sheet support portions 1314 and 1324 extend from the ends of the diagonal lines of the shoe insulating portions 1313 and 1323 of the two side insulators 131 and 132, respectively.

[0066] Although not shown in the accompanying drawings, insulating sheet support portions 1314 and 1324 may also be formed at the circumferential ends of boot insulating portions 1313 and 1323, respectively. In this case, the circumferential ends of the unit insulating sheet 140a (described later) can be supported on both sides of the axial direction, thereby enabling more stable support for the unit insulating sheet 140a.

[0067] Furthermore, although not shown in the accompanying drawings, the insulating sheet support portions 1314 and 1324 may also be formed at both axial ends of the yoke insulating portions 1311 and 1321 and / or at both axial ends of the toothed insulating portions 1312 and 1322, respectively. Even in this case, the insulating sheet support portions 1314 and 1324 may be formed to face each other in the axial direction or to face each other in the diagonal direction.

[0068] Reference Figures 3 to 7In this embodiment, the insulating sheet 140 can be formed in a shape corresponding to the inner circumferential surface of the stator core 110. In other words, when the stator core 110 is unfolded, the insulating sheet 140 can be bent and irregularly formed along its length to correspond to the inner circumferential surface of the yoke portion 111, the circumferential side surface of the tooth portion 112, and the inner circumferential surface of the shoe portion 113 constituting the inner circumferential surface of the stator core 110. However, when winding the stator core 110, a portion of the insulating sheet 140 can be cut off and inserted into the corresponding slot 114 between the stator coils (e.g., coil bundles) 120a and 120b on adjacent sides. Therefore, taking the stator core 110 as an example when it is unfolded, the insulating sheet 140 can be composed of a single insulating sheet 140, just like the stator core 110. However, taking the stator core 110 as an example when it is wound, the insulating sheet 140 can be composed of a plurality of unit insulating sheets 140a, which are the same number as the unit cores 110a constituting the stator core 110. Hereinafter, the explanation will focus on an example in which a plurality of unit insulating sheets 140a are provided, based on the winding state of the stator core 110. Since the plurality of unit insulating sheets 140a are formed identically to each other, the insulating sheet 140 mentioned below can be understood to refer to any one of the plurality of unit insulating sheets 140a.

[0069] The insulating sheet 140 may include a first insulating portion 141, a second insulating portion 142, and a connecting protrusion 143. The first insulating portion 141 is the portion that insulates between the stator core 110 and the stator coil 120, the second insulating portion 142 is the portion that insulates between adjacent stator coils 120, and the connecting protrusion 143 is the portion that contacts the second insulating portion 142 and separates the stator coils 120 when the stator core 110 is wound.

[0070] Since the first insulating portion 141 is formed to have the same or nearly the same axial length (e.g., stacking height) as the stator core 110, it can be formed in a generally "U" shape to surround the slot 114 between the two adjacent side unit cores 110a, 110a in the circumferential direction. In other words, the first insulating portion 141 can be formed to traverse between the two side unit cores 110a, 110a and to connect with the inner surface of the two side yokes 111, one side of the two side teeth 112, and the outer surface of the two side boots 113. Thus, when the stator core 110 is wound, the first insulating portion 141 can be tightly attached to the inner circumferential surface of the two side unit cores 110a, 110a that constitute the circumferential surface of one side slot 114, thereby enabling insulation between the stator core 110 and the stator coil 120.

[0071] Specifically, the first insulating portion 141 may include a yoke insulating portion (hereinafter, yoke portion) 1411, a toothed insulating portion (hereinafter, toothed portion) 1412, and a boot insulating portion (hereinafter, booted portion) 1413. The yoke portion 1411 is the portion that insulates between the yoke portion 111 of the stator core 110 and the stator coil 120; the toothed portion 1412 is the portion that insulates between the toothed portion 112 of the stator core 110 and the stator coil 120; and the booted portion 1413 is the portion that insulates between the booted portion 113 of the stator core 110 and the stator coil 120. Thus, the yoke portion 1411 can be formed to correspond to the inner circumferential surface shape of the yoke portion 111, the toothed portion 1412 can extend from the yoke portion 1411 and be formed to correspond to the side surface shape of the toothed portion 112, and the booted portion 1413 can extend from the toothed portion 1412 and be formed to correspond to the outer circumferential surface of the booted portion 113.

[0072] Since the second insulating portion 142 is formed to have the same axial length as the first insulating portion 141, it can be bent from one end of the first insulating portion 141 toward the slot 114 between adjacent teeth 111 and disposed between two adjacent stator coils (e.g., coil bundles) 120 in the circumferential direction. For example, the second insulating portion 142 can be formed such that, after one end of the shoe portion 1413 surrounding the shoe portion 113 of the first insulating portion 141 is cut off when the stator core 110 is first unfolded, the other end of the shoe portion 1413 is bent so that it surrounds one stator coil (e.g., coil bundle) 120 and the cut end 1421 is located between the two stator coils 120. Thus, insulation between the two stator coils 120 can be easily and effectively achieved. In addition, since the second insulating part 142 is inserted between the two stator coils 120, 120, the insulation distance between the two stator coils 120, 120 can be minimized as much as possible, thereby improving the fill factor of the stator coil 120.

[0073] In this case, the second insulating portion 142 of each unit insulating sheet 140 can be formed by bending the cut-off end 1421 in the same direction. For example, each of the circumferentially arranged second insulating portions 142 can be formed by cutting off the same side ends of the boot portion 1413 of each circumferentially arranged first insulating portion 141, and then bending the respective cut-off end 1421 to surround the circumferentially adjacent stator coils 120 and insert them into the respective slots 114 located on the opposite side of the cut-off end 1421. Thus, the second insulating portion 142 can completely insulate between the circumferentially adjacent stator coils 120.

[0074] The connecting protrusion 143 can be formed to protrude radially inward from the first insulating portion 141. For example, the connecting protrusion 143 can be formed at the same height axially along the circumferential midpoint of the yoke portion 1411 of the first insulating portion 141. Thus, the circumferential side of the cut-off end 1421 of the second insulating portion 142 can contact one circumferential side of the connecting protrusion 143, thereby enabling the circumferential separation of the slot portion 114. Consequently, the two stator coils (e.g., coil bundles) 120 located on the circumferential sides of the slot portion 114 can be tightly cut by the second insulating portion 142 and the connecting protrusion 143, thereby achieving insulation.

[0075] In this case, the connecting protrusion 143 can be extended to protrude a predetermined height from the inner circumferential surface of the first insulating portion 141, or it can be folded in the middle of the first insulating portion 141 and protrude a predetermined height. In the former case, the contact area with the second insulating portion 142 can be stably ensured by freely adjusting the height of the connecting protrusion 143. In the latter case, while the insulating sheet 140 including the first insulating portion 141 can be easily manufactured, the gap between the two side unit cores 110a, 110a that form the rolling groove 1112 when winding the stator core 110 can be narrowed, and the connecting protrusion 143 can be raised towards the second insulating portion 142, thereby stably ensuring the contact area with the second insulating portion 142. This embodiment illustrates the latter case, that is, an example in which the connecting protrusion 143 is formed in a manner that folds in the middle of the first insulating portion 141.

[0076] In the unspecified accompanying drawings, reference numeral 1321 indicates the second yoke insulation portion.

[0077] The stator of this embodiment, as described above, can be assembled in the following manner. Figure 9 This is a block diagram illustrating the assembly process of the various components of the stator of this utility model.

[0078] That is, with the plurality of unit cores 110a constituting the stator core 110 extended in a linear configuration, the step of inserting and attaching the first insulator 131 and the second insulator 132 to both axial sides of the stator core 110 is performed. In this case, as described above, the first insulator 131 and the second insulator 132 may also be pre-assembled to both axial sides of the stator core 110 using an insert molding method. (T1)

[0079] Next, the insulating sheet 140 is inserted and attached to the inner circumferential surface of the stator core 110. In this case, the insulating sheet 140 is located between the first insulator 131 and the second insulator 132. At this time, insulating sheet support portions 1314 and 1324 are formed in the first insulator 131 and the second insulator 132, respectively, thereby supporting the two ends of the insulating sheet 140 in the axial direction. (T2)

[0080] Next, with the stator core 110, the two side insulators 131, 132, and the insulating sheet 140 assembled, the winding nozzles described above are inserted between the teeth 112 of the two side unit cores 110a, 110a facing each other, and the stator coil 120 is wound around the respective teeth 112. (T3)

[0081] Next, the insulating sheet 140 surrounding the unit core 110a can be positioned between adjacent stator coils 120 wound around the unit core 110a. This step is achieved by cutting off one end of the circumferential ends of the shoe portion 1413 of the first insulating portion 141 that constitutes part of the insulating sheet 140, and then bending the cut second insulating portion 142 of the insulating sheet 140 at the other circumferential end of the shoe portion 1413 and surrounding the stator coil 120 wound around the corresponding unit core 110a. At this time, the cut end 1421 of the second insulating portion 142 constituting one end of the insulating sheet 140 can be kept separate from the connecting protrusion 143 protruding between the two unit cores 110a, 110a.

[0082] (T4)

[0083] Next, in the stator core 110 unfolded in a linear shape, with the rolling groove 1112 as the center, the adjacent two side unit cores 110a, 110a are folded and wound to form the stator core 110 into a ring. At this time, the connecting protrusion 143 of the insulating sheet 140 is folded and its radial height is increased, so that the circumferential side of the cut end 1421 of the second insulating part 142 is pressed tightly against the two side stator coils 120 while in contact with one side circumferential side of the connecting protrusion 143. In this way, the two side stator coils 120 can be tightly cut off by the second insulating part 142 and the connecting protrusion 143. (T5)

[0084] Therefore, an insulating sheet that insulates the stator core and stator coil can be integrally formed, thereby reducing the number of components and assembly steps of the insulating sheet and thus reducing manufacturing costs.

[0085] In addition, by reducing the number of insulating sheet supports used to maintain the shape of the insulating sheet and correspondingly increasing the area of ​​the slot, the fill factor of the stator coil wound on the stator core can be increased, thereby improving motor efficiency.

[0086] In addition, the position of the insulating sheet support portion can be optimized, thereby increasing the fill factor of the stator coil wound in the stator core and enabling the stator coil to be stably held in the stator core, thus improving reliability.

Claims

1. A stator for a motor, characterized in that, The stator includes: The stator core is formed by winding or combining a plurality of unit cores into a ring. In the plurality of unit cores, the teeth of each unit core extend radially from its respective yoke, and the boots of each unit core extend circumferentially from the inner ends of its respective teeth. Stator coils, wound around the teeth; and An insulating sheet is provided with a plurality of unit insulating sheets along the inner circumferential surface of the stator core to insulate the stator core from the stator coil; The unit insulating sheet includes: The first insulating portion comprises a yoke portion that insulates the yoke portion, a toothed portion extending from the yoke portion and insulating the teeth, and a booted portion extending from the toothed portion and insulating the boot portion, and is disposed on the inner circumferential surface of a groove between adjacent teeth; and The second insulating portion is bent at one front end of one of the two circumferential ends of the shoe portion to surround the stator coil, and is disposed between the stator coils wound on adjacent circumferential teeth.

2. The stator of the motor according to claim 1, characterized in that, In the unit insulating sheet, the second insulating portion is formed by bending along the same circumferential direction.

3. The stator of the motor according to claim 1, characterized in that, The second insulating portion contacts the first insulating portion between the stator coils on two adjacent sides in the circumferential direction.

4. The stator of the motor according to claim 3, characterized in that, In the yoke portion, a connecting protrusion is formed between the stator coils on two adjacent sides in the circumferential direction, protruding in a direction away from the yoke portion; The second insulating portion contacts the connecting protrusion and is disposed between the stator coils on two adjacent sides in the circumferential direction.

5. The stator of the motor according to claim 4, characterized in that, The connecting protrusion is formed by folding the yoke portion.

6. The stator of the motor according to claim 1, characterized in that, An insulator is provided on the axial side of the stator core to insulate between the stator core and the stator coil; The insulator has an insulating sheet support portion that supports the insulating sheet in the axial direction.

7. The stator of the motor according to claim 6, characterized in that, The insulator has a boot insulation portion facing the axial side of the boot portion; The insulating sheet support portion is formed by extending circumferentially from at least one end of the circumferential ends of the boot insulation portion.

8. The stator of the motor according to claim 7, characterized in that, The insulator includes a first insulator and a second insulator located on both sides of the axial direction of the stator core; The first insulator has a first insulating sheet support portion that supports the insulating sheet axially on one side, and the second insulator has a second insulating sheet support portion that supports the insulating sheet axially on the other side.

9. The stator of the motor according to claim 8, characterized in that, The first insulating sheet support portion and the second insulating sheet support portion are formed by extending in opposite directions along the circumferential direction.

10. The stator of the motor according to claim 6, characterized in that, A coil winding groove is formed on the side of the insulator opposite to the stator core along the winding direction of the stator coil.

Images