INSULATING COMPONENT OF AN ENGINE

Abstract

Insulating component (2) of a motor, the motor comprising: a stator (1), a stator housing (4) attached to the stator (1), several windings (14) arranged in the stator (1), and a wiring board (3) arranged in an axial direction of the stator (1) at one end of the stator (1) and used for wiring the windings (14), wherein the insulating component (2) comprises: a first insulating wall (21) which is arranged between adjacent windings (14) with different phases and electrically insulates the adjacent windings (14); and a second insulating wall (22) arranged between the windings (14) and the wiring board (3) and electrically insulates the windings (14) and the wiring board (3); and a third insulating wall (23) arranged between the wiring board (3) and the stator housing (4) and electrically insulates the wiring board (3) and the stator housing (4).

Description

BACKGROUND OF THE INVENTION Area of ​​the invention

[0001] The present invention relates to an insulating component of a motor. Related technology

[0002] DE 10 2012 001 263 A1 discloses an insulation arrangement for a stator assembly of an electrical machine, comprising a ring-shaped casing attached to a stator core and several coil isolators supported by the ring-shaped casing and extending axially from the casing along a longitudinal axis. One coil isolator is arranged between each adjacent pair of coils to prevent contact between adjacent coils with a different electrical phase. The coil isolators are slidably inserted between the adjacent pairs of coils, with the ring-shaped casing positioning and supporting the coil isolators.

[0003] JP H10-304613A discloses a holding device for printed circuit boards for driving, wherein an insulator, which forms an insulating stator core and is integrally formed with a cylindrical insulating wall coaxially to an inner circumferential surface of the slot of the stator core and the board holding sections, extends from the top of the cylindrical insulating wall in the form of a one-sided arrowhead. A printed circuit board for driving is secured by aligning the insertion holes with the tips of the board holding sections, making the holes at the tips, and then clamping the printed circuit board between a downward-facing side of the board holding sections and an upper side of the cylindrical insulating wall.Since the downward surfaces of the plate-holding sections are manufactured from a mold that forms the slot within the circumferential surface, the mold moves only vertically and requires no special sliding mechanism if the downward surfaces are formed in one piece. Furthermore, since the upper side of the cylindrical insulating wall is annular, the printed circuit board is neither tilted nor deformed during driving and is held stably.

[0004] In recent years, the windings attached to the stators of motors used in various industrial devices have been arranged more densely to achieve further miniaturization and higher performance. However, a dense arrangement of the windings carries the risk of contact between a winding and a gear unit or between adjacent windings with different phases.

[0005] Therefore, a stator had to exhibit improved insulating properties with regard to safety. In this respect, various stators with an insulating structure were proposed (see, for example, Patent 1). Patent 1 states that the insulating properties of a stator can be improved by inserting insulating paper between the phases of the windings.

[0006] Patent specification 1: Unexamined Japanese patent application, Publication No. JP 2000 - 333 399 A SUMMARY OF THE INVENTION

[0007] Traditionally, ensuring insulation between windings required the laborious process of inserting insulating paper into each intermediate phase, a process that was extremely time-consuming. Similarly, to ensure insulation between the winding and the wiring board, an additional insulating element such as insulating paper had to be inserted between the winding and the wiring board, resulting in further labor costs and a larger number of parts.

[0008] The present invention was realized in light of the circumstances described above. The present invention aims to provide an insulating component for a motor, comprised of a single component suitable for ensuring insulating properties. (1) An insulating component (for example, an insulating component 2 described later) according to the present invention forms a motor comprising: a stator (for example, a stator 1 described later), a stator housing (for example, a stator housing 4 described later) attached to the stator, several windings (for example, windings 14 described later) arranged in the stator, and a wiring board (for example, a wiring board 3 described later) arranged in an axial direction of the stator at one end of the stator and used for wiring the windings.The insulating component comprises: a first insulating wall (for example, a first insulating wall 21 described later) which is arranged between adjacent windings with different phases and electrically insulates the adjacent windings; and a second insulating wall (for example, a second insulating wall 22 described later) which is arranged between the windings and the wiring board and electrically insulates the windings and the wiring board. (2) The insulating component of the motor described in (1) further comprises a third insulating wall (for example, a third insulating wall 23 described later) which is arranged between the wiring board and the stator housing and electrically insulates the wiring board and the stator housing. (3) The insulating component of the motor described under (1) or (2) may further comprise a fastening unit (for example, a fastening unit 20 or 29 described later) for fastening the wiring board to a predetermined position of the stator. (4) In the insulating component of the motor described in (3), at least one through-hole (for example, a through-hole 31 described later) may be formed in the wiring board, and the fastening unit (for example, the fastening unit 20 described later) may comprise a first snap-in part (for example, a first snap-in part 20b described later) which passes through the through-hole and engages with the wiring board. (5) In the case of the insulating component of the motor described in (3) or (4), the fastening unit (for example, the fastening unit 29 described below) may include second locking parts provided in pairs (for example, second locking parts 29b described below) which engage with each other in the direction of the plane opposite ends (for example, the ends 32, 32 described below opposite ends in the direction of the plane) of the wiring board. (6) The insulating component of the motor described under any of points (1), (2), (3), (4) or (5) may be made of resin.

[0009] The present invention is suitable for providing an insulating component of a motor, which is formed from a single component suitable for ensuring the insulating properties. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of an insulating component according to an embodiment of the present invention; Fig. 2 is a radially shown sectional view of a stator in which the insulating component is arranged according to this embodiment; Fig. 3 is an axially shown sectional view of the stator in which the insulating component is arranged according to this embodiment; Fig. Figure 4 is a sectional view showing an example of a fastening unit of the insulating component according to this embodiment; Fig. 5 is a sectional view showing another example of the fastening unit of the insulating component according to this embodiment; Fig. 6 is a radially shown sectional view of a conventional stator in which insulating paper is arranged; Fig. Figure 7 is an axially shown sectional view of a conventional stator in which a winding and an insulating element of a wiring board are arranged; Fig. Figure 8 is an axially shown sectional view of a conventional stator in which a wiring board and an insulating element of a stator housing are arranged; and Fig. Figure 9 is a top view of a conventional stator with a wiring board attached to it. DETAILED DESCRIPTION OF THE INVENTION

[0010] An embodiment of the present invention is described in detail below with reference to the drawings. An insulating component 2 according to this embodiment is arranged in a stator 1 of a motor (not shown in the drawings) and serves to impart insulating properties to the motor. The insulating component 2 according to this embodiment also serves to attach a wiring board 3 to the stator 1.

[0011] Fig. Figure 1 is a perspective view of the insulating component 2 according to this embodiment. Fig. Figure 2 is a radially shown sectional view of the stator 1 in which the insulating component 2 is arranged according to this embodiment. Fig. Figure 3 is an axially oriented sectional view of the stator 1 in which the insulating component 2 is arranged according to this embodiment. The configuration of the motor with the insulating component 2 according to this embodiment is described first.

[0012] The motor according to this embodiment comprises the stator 1, a rotor not shown in the drawings, the insulating component 2, the wiring board 3, a stator housing 4 and several windings 14.

[0013] The stator 1 is a shaped stator divided into a tooth unit 11 and an external unit 12. However, this is not the only configuration of the stator 1. The tooth unit 11 is formed by stacking several magnetic steel plates along an axis X corresponding to the central axis of the stator 1. The tooth unit 11 comprises a circular cylindrical part 111 and several projecting parts 112. The presence of the circular cylindrical part 111 and the projecting parts 112 forms several slots 113 in a circumferential direction.

[0014] The circular cylindrical part 111 has a circular cylindrical shape and is arranged at a radially inner position of the stator 1. The rotor, not shown in the drawings, is rotatably arranged in a hollow section of the circular cylindrical part 111. The projecting part 112 is designed to project radially outwards from the circular cylindrical part 111. The projecting part 112 comprises several projecting parts 112 spaced uniformly apart in the circumferential direction of the circular cylindrical part 111. All projecting parts 112 extend in the axial direction of the stator 1 from one end to the opposite end of the stator 1.

[0015] The external unit 12 is designed to cover the outer circumference of the tooth unit 11. The external unit 12 forms an outer section of the stator 1. Like the tooth unit 11, the external unit 12 is formed by stacking several magnetic steel plates in the axial direction of the stator 1. As described above, the stator 1 in this embodiment is a formed stator. Resin is poured from the axial direction of the stator 1 into the slot 113 surrounded by the external unit 12 and the tooth unit 11. As described in Fig. As shown in Figure 1, the external unit 12 according to this embodiment has a substantially square shape in a radially shown sectional view. However, this is not the only shape of the external unit 12.

[0016] The multiple windings 14 are each wound with a given number of turns around the projecting part 112 of the tooth assembly 11 such that they are arranged in the slot 113. In this way, the multiple windings 14 are arranged close together in the circumferential direction of the stator 1, extending in the direction of the axis X of the stator 1. Windings 14 that lie next to each other in the circumferential direction have different phases. One end of the winding 14 is connected to a wiring board, which is connected to a power terminal (not shown in the drawings), thus forming a three-phase connection. The opposite end of this winding 14 is connected to the opposite end of another winding.

[0017] The wiring board 3 is arranged along the X-axis at one end of the stator 1. The wiring board 3 includes a power terminal (not shown in the drawings) and several connection terminals (not shown in the drawings) that are connected to the power terminal and the corresponding windings 14. More precisely, the windings 14 are connected using the wiring board 3 to form a three-phase connection.

[0018] The wiring board 3 has at least one through-hole 31. A first snap-in element 20b of a fastening unit 20, described later, is passed through the through-hole 31 and engages with the wiring board 3. Therefore, the through-hole 31 is located in a position corresponding to the fastening unit 20.

[0019] The stator housing 4 is attached to the stator 1. The stator housing 4 includes a circular cylindrical insert 41, which is provided at the aforementioned end of the stator 1 in the direction of axis X, where the wiring board 3 is located. The insert 41 is inserted into a hollow section of the stator 1 along the inner wall of the hollow section.

[0020] Next, the insulating component 2 according to this embodiment will be described in detail. As in Fig. As shown in Figure 1, the insulating component 2 comprises a first insulating wall 21, a second insulating wall 22, a third insulating wall 23, and the fastening unit 20. The first insulating wall 21, the second insulating wall 22, the third insulating wall 23, and the fastening unit 20 are formed in one piece. More precisely, the insulating component 2 is a single component. The insulating component 2 is made of resin and is formed in one piece, for example, by resin molds.

[0021] The first insulating wall 21 is formed from an elongated rectangular plate element, with one end longitudinally coupled to the second insulating wall 22. The first insulating wall 21 is arranged such that its longitudinal direction extends along the stator 1 in the direction of axis X from one end to the opposite end, and that the direction of the short side of the first insulating wall 21 extends radially along the stator 1 from a radially inner edge to a radially outer edge of the second insulating wall 22.

[0022] The first insulating wall 21 comprises several first insulating walls 21 arranged in a radial pattern. As shown in Fig. As shown in Figure 1, the first insulating walls 21 are inserted between adjacent windings 14 with different phases. In this way, the first insulating walls 21 are arranged side by side and evenly spaced in the circumferential direction of the stator 1. The first insulating walls 21 are each formed from an electrically insulating element to provide electrical insulation between the adjacent windings 14 with different phases.

[0023] The presence of the first insulating wall 21 essentially eliminates any gap between the phases of adjacent windings 14. This makes it unlikely that resin will be injected from a radially outer position to the winding 14 and its surroundings during the injection molding of the stator 1. This restricts movement of the winding 14 during injection molding, thereby reducing the probability of contact between windings 14 with different phases.

[0024] The second insulating wall 22 is formed from an annular plate element corresponding to the diameter of the hollow section of the stator 1. The multiple first insulating walls 21 are coupled by the second insulating wall 22 in such a way that they become a single, continuous wall. As shown in Fig. As shown in Figure 3, the second insulating wall 22 is arranged between the winding 14 and the wiring board 3. The second insulating wall 22 is formed from an electrically insulating element to provide electrical insulation between the winding 14 and the wiring board 3.

[0025] The third insulating wall 23 is formed from a circular cylindrical element corresponding to the diameter of the hollow section of the stator 1. The third insulating wall 23 is coupled to an inner circumferential edge of the second insulating wall 22. As shown in Fig. As shown in Figure 3, the third insulating wall 23 is arranged between the wiring board 3 and the insert 41 of the stator housing 4. The third insulating wall 23 is formed from an electrically insulating element to provide electrical insulation between the wiring board 3 and the stator housing 4.

[0026] The fastening unit 20 comprises at least one fastening unit 20, which is provided at a position adjacent to the third insulating wall 23 on the second insulating wall 22. In this embodiment, the fastening unit 20 comprises three fastening units 20, which are arranged on the annular second insulating wall 22 such that they are uniformly spaced in the circumferential direction. The fastening unit 20 has the function of fastening the wiring board 3 at a predetermined position of the stator 1. The fastening unit 20 will be described later with further reference to Fig. 4 described.

[0027] Fig. Figure 4 is a sectional view showing the fastening unit 20 as an example of a fastening unit for the insulating component 2 according to this embodiment. As shown in the Fig. 3 and Fig. As shown in Figure 4, the fastening unit 20 comprises a circular cylindrical part 20a having a circular cylindrical shape and the first snap-in part 20b provided at the top of the circular cylindrical part 20a.

[0028] The first locking element 20b is designed such that it extends from an entire outer circumferential edge at the tip of the circular cylindrical part 20a in a direction perpendicular to the axial direction of the circular cylindrical part 20a. The first locking element 20b has a tapered shape with a diameter that decreases at a position closer to the tip. As shown in Fig. As shown in Figure 4, the first locking element 20b is formed in the wiring board 3 through the through-hole 31 and engages with the wiring board 3. The presence of the fastening unit 20, including the first locking element 20b with such a bent-back structure, secures the wiring board 3 to the predetermined position of the stator 1.

[0029] Fig. Figure 5 is a sectional view showing a fastening unit 29 as another example of the fastening unit of the insulating component 2 according to this embodiment. As in Fig. As shown in Figure 5, the fastening unit 29 is used to fasten the wiring board 3 by engaging with each of the ends 32, 32 of the wiring board 3 that are opposite each other in the direction of the plane. The fastening unit 29 comprises at least pairs of fastening units 29, which are provided at corresponding ends 32, opposite each other in the direction of the plane of the second insulating wall 22.

[0030] The fastening unit 29 comprises a circular, column-like part 29a with a circular, column-like shape and a second locking element 29b provided at the apex of the circular, column-like part 29a. The second locking element 29b is configured such that it extends from an inner region in the direction of the plane, which is part of an outer circumferential edge at the apex of the circular, column-like part 29a, to a direction perpendicular to the axial direction of the circular, column-like part 29a. The second locking element 29b has a tapered shape with a reduced diameter at a position closer to the apex. More precisely, the fastening units 29, provided in pairs, comprise the second locking elements 29b, which are formed facing each other on respective sides of the fastening units 29.Due to the presence of the fastening units 29, including the second snap-in parts 29b with such a recurved structure, the paired second snap-in parts 29b engage with the ends 32, 32 of the wiring board 3 that are opposite each other in the direction of the plane. In this way, the position of the wiring board 3 is fixed, and the wiring board 3 is fastened in the fixed position, being latched between the fastening units 29 of the second insulating wall 22.

[0031] The following section describes various conventional insulating elements with reference to the drawings. Fig. Figure 6 is a radially shown sectional view of a conventional stator 9 in which insulating paper 91 is arranged. As in Fig. As shown in Figure 6, in this conventional example, the insulating paper 91 is inserted into a gap formed between adjacent windings 14 with different phases. In this conventional example, insulating paper 91, which has low strength and requires laborious work to insert, is inserted individually into each intermediate phase.

[0032] Fig. Figure 7 is an axially shown sectional view of a conventional stator 9 in which a winding 14 and an insulating element 92 of a wiring board 3A are arranged. Fig. Figure 8 is an axially shown sectional view of a conventional stator 9 in which a wiring board 3A and an insulating element 93 of a stator housing 4 are arranged. As can be seen from these conventional examples, the insulating element 92 or 93 is to be inserted individually between the winding 14 and the wiring board 3A or between the wiring board 3A and the stator housing 4, respectively, since good insulating properties are required between the winding 14 and the wiring board 3A and between the wiring board 3A and the stator housing 4.

[0033] As described above, conventionally an insulating element such as insulating paper had to be inserted individually at the point where insulation was required. In this respect, the insulating component 2 according to this embodiment is a one-piece component formed from the first insulating wall 21, the second insulating wall 22, and the third insulating wall 23. Therefore, the insulating component 2 can be installed in a single operation.

[0034] Fig. Figure 9 is a top view of a conventional stator 9 to which a wiring board 3A is attached. As in Fig.As shown in Figure 9, the conventional wiring board 3A comprises a board body 30A, paired, facing extension parts 32A, 32A, and paired screw hole parts 31A, 31A. More precisely, the wiring board 3A is fastened by means of screws 90, 90 to the screw hole parts 31A, 31A formed on the corresponding paired extension parts 32A, 32A. In contrast, in this embodiment, the wiring board 3 can be fastened using the insulating component 2 without the need for fastening by means of a screw.

[0035] This embodiment with the configuration described above achieves the following results. In this embodiment, the insulating component 2 comprises the first insulating wall 21 and the second insulating wall 22. The first insulating wall 21 is arranged between adjacent windings 14 with different phases and electrically insulates the adjacent windings 14. The second insulating wall 22 is arranged between the windings 14 and the wiring board 3 and electrically insulates the windings 14 and the wiring board 3. According to this embodiment, adjacent windings 14 with different phases can be electrically insulated by the first insulating wall 21. The windings 14 and the wiring board 3 can be electrically insulated by the second insulating wall 22.Therefore, according to this embodiment, the insulating component 2 can be used as the only component to achieve insulation between the phases of adjacent windings 14 and to ensure the insulating properties of the windings 14 and the wiring board 3.

[0036] According to this embodiment, the insulating component 2 further comprises the third insulating wall 23, which is arranged between the wiring board 3 and the stator housing 4 and electrically insulates the wiring board 3 and the stator housing 4. Therefore, according to this embodiment, the wiring board 3 and the stator housing 4 can be electrically isolated from the third insulating wall 23. This allows the insulating component 2 to provide even better insulating properties as a single component.

[0037] According to this embodiment, the insulating component 2 for attaching the wiring board 3 to a predetermined position on the stator 1 further comprises the mounting unit 20 or 29. Therefore, according to this embodiment, the wiring board 3 can be attached to the predetermined position on the stator 1 by the mounting unit 20 or 29. This allows the insulating component 2 to be used as a single component both for determining the position of the wiring board 3 and for attaching the wiring board 3 to the predetermined position, as well as for achieving excellent insulating properties.

[0038] According to this embodiment, at least one through-hole 31 is formed in the wiring board 3, and the fastening unit 20, as an example of the fastening unit of the insulating component 2, comprises the first snap-in part 20b, which is passed through the through-hole 31 and engages with the wiring board 3. Therefore, the position of the wiring board 3 relative to the stator 1 can be determined, and the wiring board 3 can be more reliably fastened in the specified position.

[0039] According to this embodiment, the fastening unit 29, as another example of the fastening unit of the insulating component 2, comprises the paired second snap-in parts 29b, 29b, which engage with the ends of the wiring board 3 opposite each other in the plane. This serves to further determine the position of the wiring board 3 with respect to the stator 1 and to more reliably fasten the wiring board 3 in the specified position.

[0040] According to this embodiment, the insulating component 2 is made of resin. This makes the insulating effect described above more reliable. It also facilitates the production of the insulating component 2 as a single piece, for example, by resin molding.

[0041] The present invention is not limited to the embodiment described above, but modifications, improvements, etc., may be covered by the present invention, provided that such modifications, improvements, etc., remain within a scope that fulfills the purpose of the present invention. According to the embodiment described above, the insulating component comprises the third insulating wall and the fastening unit, as well as the first insulating wall and the second insulating wall. However, this is not the only configuration of the insulating component. The insulating component need only comprise the first insulating wall and the second insulating wall. EXPLANATION OF REFERENCE SYMBOLS 1 Stator 2 Insulating component 3 Wiring board 4 Stator housings 14 windings 20, 29 Fastening unit 20b First locking part 29b Second locking part 21 First insulating wall 22 Second insulating wall 23 Third insulating wall 31 Through hole 32 Ends opposite each other in the direction of the plane

Claims

Insulating component (2) of a motor, the motor comprising: a stator (1), a stator housing (4) attached to the stator (1), several windings (14) arranged in the stator (1), and a wiring board (3) arranged axially to the stator (1) at one end of the stator (1) and used for wiring the windings (14), the insulating component (2) comprising: a first insulating wall (21) arranged between adjacent windings (14) of different phases, which electrically insulates the adjacent windings (14); and a second insulating wall (22) arranged between the windings (14) and the wiring board (3), which electrically insulates the windings (14) and the wiring board (3);and a third insulating wall (23) arranged between the wiring board (3) and the stator housing (4) and electrically insulating the wiring board (3) and the stator housing (4). Insulating component (2) of the motor according to claim 1, which further comprises a fastening unit (20, 29) for fastening the wiring board (3) to a predetermined position of the stator (1). Insulating component (2) of the motor according to claim 2, wherein at least one through-hole (31) is formed in the wiring board (3), and the fastening unit (20) comprises a first snap-in part (20b) which is passed through the through-hole (31) and engages with the wiring board (3). Insulating component (2) of the motor according to claim 2 or 3, wherein the fastening unit (29) comprises second snap-in parts (29b) provided in pairs, which engage with each other opposite ends (32, 32) of the wiring board (3) in the direction of the plane. Insulating component (2) of the motor according to one of claims 1 to 4, wherein the insulating component (2) is made of resin.

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