MOTOR-DRIVED COMPRESSOR

Abstract

A motor-driven compressor comprises a compression unit, a motor with a stator, and a casing. The stator includes a stator core, multi-phase coils, an insulator, a phase-to-phase insulating sheet, and a cover. The cover has an annular end wall and a tubular inner wall extending towards the insulator's inner wall from a radially inner section of the end wall. The end wall has a conical inclined wall, angled such that the distance between the end wall and the insulator's inner wall decreases as the end wall extends towards the inner wall. The inclined wall is continuous with the inner wall.

Description

[0001] This application is based on and claims priority from Japanese patent application JP 2023-134737, filed on August 22, 2023, the entire contents of which are incorporated herein by reference. Background of the inventionTechnical field

[0002] The following disclosure relates to a motor-driven compressor. State of the art

[0003] A motor-driven compressor comprises a rotating shaft, a compression unit, a motor, and a housing. The compression unit compresses a fluid by rotating the rotating shaft. The motor rotates the rotating shaft. The housing comprises a motor chamber. The motor chamber houses the motor. The motor comprises a stator.

[0004] For example, Japanese Patent Publication JP 2022-150980 discloses a stator comprising a stator core, multiple phase coils, and insulators. The stator core is fixed to the housing. The coils of the respective phases are formed by windings of multiple phases tightly wound on the stator core. The coils of the respective phases have coil ends. The coil ends protrude from core end faces of the stator core in the axial direction of the rotating shaft. The insulators are arranged to face the core end face of the stator core. The insulators insulate the coils and the core end face from each other. The insulators each have an insulator inner wall.

[0005] Each insulator inner wall is arranged at a position inside of and overlapping with one of the coil ends in the radial direction of the rotary shaft.

[0006] The stator has phase-to-phase insulating sheets. Each phase-to-phase insulating sheet extends in the radial direction of the rotating shaft. Each phase-to-phase insulating sheet insulates coils adjacent to each other in the circumferential direction of the rotating shaft. The phase-to-phase insulating sheets protrude from the core end faces of the stator core. Each phase-to-phase insulating sheet insulates coil ends adjacent to each other in the circumferential direction of the rotating shaft in a state where a part of the phase-to-phase insulating sheet protrudes beyond the coil ends on the side opposite the core end face. Since the phase-to-phase insulating sheets partially protrude beyond the coil ends on the side opposite the core end face, insulation between the coil ends adjacent to each other in the circumferential direction of the rotating shaft is easily ensured.

[0007] This type of stator is coupled to the housing by fitting the stator core to the inner peripheral surface of the housing, for example, by shrink fitting. During shrink fitting, the housing is thermally expanded so that the inner diameter of the housing becomes wider than the outer diameter of the stator core. The stator core is then inserted into the housing to achieve a predetermined shrink fit position. Then, as the temperature of the housing approaches normal temperature, the housing shrinks. This brings the inner peripheral surface of the housing into close contact with the outer peripheral surface of the stator core.

[0008] Thus, when the stator core is shrink-fitted to / into the housing, the stator core is positioned, for example, by inserting an alignment fixture into the stator core. The housing is arranged with respect to the stator core such that the stator core, whose position relative to the alignment fixture is determined, is inserted into the inner peripheral surface of the housing at the predetermined shrink-fit position. In this way, the stator is coupled to the housing.

[0009] When inserting the alignment fixture into the stator core, the alignment fixture may touch the coil ends or a portion of the phase-to-phase insulation sheet extending beyond the coil ends and the insulator inner walls on the side opposite the core end face. This may damage the coils or deform the phase-to-phase insulation sheets, thus preventing reliable insulation between the coil ends adjacent to each other in the circumferential direction of the rotating shaft. This reduces motor reliability.

[0010] The stator may include a cover member having insulating properties. The cover member is arranged to face the insulators. Such a cover member may, for example, include an annular cover end wall and a tubular cover inner wall. The cover end wall covers the coil ends on the side opposite the core end face with respect to the coil ends in the axial direction of the rotating shaft. Furthermore, the cover end wall covers a portion of each phase-to-phase insulating sheet that protrudes beyond the coil ends and the insulator inner wall on the side opposite the core end face. The cover inner wall extends toward the insulator inner walls from a radially inner portion of the cover end wall.

[0011] With this configuration, when an alignment jig for shrink-fitting the stator core into the housing is inserted, the cover end wall and the cover inner wall prevent the alignment jig from contacting the coil ends. The cover end wall and the cover inner wall also prevent the alignment jig from contacting a portion of the phase-to-phase insulation sheet that protrudes beyond the coil ends and the insulator inner wall on the side opposite the core end face. This prevents the coils from being damaged and prevents the phase-to-phase insulation sheets from being deformed. Accordingly, the insulation between the coil ends adjacent to each other in the circumferential direction of the rotating shaft is not impaired. Motor reliability is thus improved.

[0012] However, if the cover end wall of the cover member is arranged to cover the coil ends or parts of the phase-to-phase insulation sheets that protrude beyond the coil ends or the insulator inner wall on the side opposite the core end face, the alignment fixture interferes with the cover member when inserted into the stator core. This can hinder smooth insertion of the alignment fixture into the stator core. This reduces the efficiency of assembling the stator to the housing.

[0013] Therefore, it is desirable to facilitate the insertion of the alignment fixture into the stator core while avoiding contact between the alignment fixture and the coil ends, as well as between the alignment fixture and the portions of the phase-to-phase insulation sheets that protrude beyond the coil ends or the insulator inner wall on the side opposite the core end face. This means that it is desirable to facilitate the assembly efficiency of the stator to the housing while simultaneously improving the reliability of the motor. Summary of the invention

[0014] This summary is intended to present, in a simplified form, a selection of concepts described further below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0015] In a general aspect, a motor-driven compressor includes a rotating shaft, a compression unit configured to compress a fluid by rotating the rotating shaft, a motor configured to rotate the rotating shaft, and a housing having a motor chamber accommodating the motor. The motor includes a stator. The stator includes a stator core mounted in the housing, coils, an insulator, phase-to-phase insulating sheets, and a cover member. The coils of multiple phases are formed by tightly wound windings of multiple phases on the stator core. The coils have coil ends protruding from a core end face of the stator core in an axial direction of the rotating shaft. The insulator is arranged to face the core end face. The insulator insulates the coils and the core end face from each other.Each of the phase-to-phase insulating sheets extends in a radial direction of the rotating shaft and insulates the coils adjacent to each other in a circumferential direction of the rotating shaft. The cover member has an insulating property and is arranged to face the insulator. The insulator has an insulator inner wall arranged at a position overlapping with the coil ends on an inner side of the coil ends in the radial direction of the rotating shaft. Each phase-to-phase insulating sheet insulates the coil ends adjacent to each other in the circumferential direction in a state where the phase-to-phase insulating sheet protrudes beyond the core end face on a side opposite to the core end face and partially protrudes beyond the insulator inner wall. The cover member has an annular cover end wall and a tubular cover inner wall.The annular cover end wall covers the coil ends on a side opposite the core end face in the axial direction and covers a portion of each phase-to-phase insulating sheet that protrudes beyond the insulator inner wall on the side opposite the core end face. The tubular cover inner wall extends toward the insulator inner wall from a radially inner portion of the cover end wall. The cover end wall has a conical inclined wall inclined such that the distance between the cover end wall and the insulator inner wall decreases as the cover end wall extends toward the cover inner wall. The inclined wall is continuous with the cover inner wall.

[0016] Further features and aspects will become apparent from the following detailed description, drawings and claims. Short description of the characters Fig. 1 is a cross-sectional view showing a motor-driven compressor according to an embodiment. Fig. 2 is a cross-sectional view of an engine. Fig. 3 is an exploded perspective view of a stator core, a first insulator, and a second insulator. Fig. 4 is a perspective view of a stator showing a state before a cover member is arranged on the first insulator. Fig. 5 is a perspective view of a stator showing a state in which the cover member is arranged on the first insulator. Fig. 6 is a cross-sectional view showing a portion of the stator. Fig. 7 is a perspective view for explaining a phase-to-phase insulating sheet. Fig. Figure 8 is a cross-sectional view showing a portion of the stator. Fig. 9 is a cross-sectional view showing a portion of the stator. Fig. 10 is a cross-sectional view showing a portion of the motor-driven compressor. Fig. 11 is a cross-sectional view showing a shrink fitting process. Fig. 12 is a cross-sectional view showing the shrink fitting process.

[0017] In the drawings and the detailed description, the same reference numerals refer to the same elements. The drawings may not be to scale; and the relative size, proportions, and representation of elements in the drawings may be exaggerated for clarity, illustration, and convenience. Detailed description of the embodiment

[0018] This description provides a comprehensive understanding of the described methods, devices, and / or systems. Modifications and equivalents of the described methods, devices, and / or systems will be apparent to those skilled in the art. Sequences of operations are exemplary and may be modified as apparent to those skilled in the art, except for operations that necessarily occur in a particular order. Descriptions of functions and structures well known to those skilled in the art may be omitted.

[0019] Example embodiments may take various forms and are not limited to the described examples. However, the described examples are thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0020] In this description, “at least one of A and B” should be understood to mean “only A, only B, or both A and B.”

[0021] A motor-driven compressor 10 according to an embodiment will now be described with reference to the Fig. 1 to 12. The motor-driven compressor 10 of the present embodiment is used, for example, in a vehicle air conditioner. Basic configuration of motor-driven compressor

[0022] As in Fig. As shown in Figure 1, the motor-driven compressor 10 includes a tubular housing 11. The housing 11 includes an outlet housing portion 12, a motor housing portion 13, and an inverter housing 14. The outlet housing portion 12, the motor housing portion 13, and the inverter housing 14 are made of metal. The outlet housing portion 12, the motor housing portion 13, and the inverter housing 14 are made of aluminum, for example.

[0023] The motor housing part 13 has an end wall 13a and a peripheral wall 13b. The end wall 13a is plate-shaped. The peripheral wall 13b extends tubularly from the outer periphery of the end wall 13a. The outlet housing part 12 is tubular. The outlet housing part 12 is coupled to one end of the peripheral wall 13b of the motor housing part 13 on a side opposite the end wall 13a. The inverter housing 14 is tubular. The inverter housing 14 is coupled to the end wall 13a of the motor housing part 13. The end wall 13a of the motor housing part 13 and the inverter housing 14 define / form an inverter chamber S1.

[0024] The motor housing part 13 has a hub 13c. The hub 13c is cylindrical. The hub 13c protrudes from a central portion of the end wall 13a of the motor housing part 13. The hub 13c extends from a surface of the end wall 13a that defines a motor chamber S2. The axis of the hub 13c coincides with the axis of the peripheral wall 13b of the motor housing part 13. The end wall 13a of the motor housing part 13 has a hole 13h. The hole 13h extends through the end wall 13a of the motor housing part 13 in the thickness direction. The hole 13h is located closer to the peripheral wall 13b than the hub 13c.

[0025] The motor housing part 13 has a suction port 13d. The suction port 13d is provided in a portion of the peripheral wall 13b of the motor housing part 13 that is close to the end wall 13a. The suction port 13d connects the interior and exterior of the motor housing part 13. Coolant, which is a fluid, is sucked into the suction port 13d from the exterior.

[0026] The motor-driven compressor 10 includes a rotating shaft 15, a compression unit 16, an inverter 17, and a motor 20. The rotating shaft 15, the compression unit 16, and the motor 20 are housed in the motor housing part 13. Thus, the housing 11 houses the motor 20. The rotating shaft 15 is arranged in the motor housing part 13, with the axis of the rotating shaft 15 coinciding with the axis of the peripheral wall 13b of the motor housing part 13. The inverter 17 is housed in the inverter chamber S1.

[0027] The compression unit 16 and the motor 20 are arranged side by side in an axial direction along the axis of the rotating shaft 15. The motor 20 is arranged closer to the end wall 13a of the motor housing part 13 than the compression unit 16. The compression unit 16, the motor 20, and the inverter 17 are arranged in this order in the axial direction of the rotating shaft 15.

[0028] The motor-driven compressor 10 has a shaft bearing part 18. The shaft bearing part 18 is arranged between the compression unit 16 and the motor 20. The shaft bearing part 18 thus serves as a partition between the motor 20 and the compression unit 16. The end wall 13a and the peripheral wall 13b of the motor housing part 13 and the shaft bearing part 18 define the motor chamber S2. The housing 11 thus has the motor chamber S2. The motor chamber S2 accommodates the motor 20. Coolant is drawn into the motor chamber S2 through the suction port 13d.

[0029] The shaft bearing part 18 has an insertion hole 18h. The insertion hole 18h is located in the center of the shaft bearing part 18. The axis of the insertion hole 18h coincides with the axis of the hub 13c. A first end of the rotary shaft 15 is inserted through the insertion hole 18h. A radial bearing 19a is provided between the insertion hole 18h and the first end of the rotary shaft 15. The first end of the rotary shaft 15 is rotatably supported by the shaft bearing part 18 with the radial bearing 19a. A second end of the rotary shaft 15 is inserted into the hub 13c. A radial bearing 19b is provided between the hub 13c and the second end of the rotary shaft 15. The second end of the rotary shaft 15 is rotatably supported by the hub 13c with the radial bearing 19b.

[0030] The compression unit 16 includes a fixed scroll 16a and an orbiting scroll 16b. The fixed scroll 16a is fixed to the motor housing part 13. The fixed scroll 16a is thus fixed to the housing 11. The orbiting scroll 16b is arranged to oppose the fixed scroll 16a. The orbiting scroll 16b engages the fixed scroll 16a and orbits as the rotating shaft 15 rotates. The compression unit 16 is driven by rotation of the rotating shaft 15. The compression unit 16 compresses refrigerant. Compression chambers S3, whose volume is variable, are defined between the fixed scroll 16a and the orbiting scroll 16b. A discharge chamber S4 is defined between the fixed scroll 16a and the discharge housing portion 12. Changes in the volumes of the compression chambers S3 compress the refrigerant, which is then discharged into the discharge chamber S4.The motor 20 rotates the rotating shaft 15. The compression unit 16 is driven by the rotation of the rotating shaft 15. The compression unit 16 compresses the coolant by rotating the rotating shaft 15. Schematic configuration of engine

[0031] The motor 20 includes a rotor 21 and a stator 22. The stator 22 is tubular. The rotor 21 is arranged on the inside of the stator 22. The rotor 21 includes a cylindrical rotor core 21a and permanent magnets (not shown) embedded in the rotor core 21a. The rotor core 21a is fixed to the rotating shaft 15. The rotor core 21a is configured to rotate integrally with the rotating shaft 15. Stator core

[0032] The stator 22 has a stator core 23. The stator core 23 is fixed to the inner peripheral surface of the peripheral wall 13b of the motor housing part 13. The stator core 23 is thus fixed to the housing 11. The stator 22 is coupled to the housing 11 by joining / fitting the stator core 23 to the inner peripheral surface of the peripheral wall 13b of the motor housing part 13, for example, by / by means of shrink fitting. The axis of the stator core 23 coincides with the axis of the rotating shaft 15. Thus, the axial direction of the stator core 23 coincides with the axial direction of the rotating shaft 15.

[0033] As in Fig. 2 and Fig. As shown in Figure 3, the stator core 23 includes a yoke 24 and teeth 25. The yoke 24 is cylindrical. The stator core 23 is fixed to the motor housing part 13 by fitting the outer peripheral surface of the yoke 24 into the inner peripheral surface of the peripheral wall 13b of the motor housing part 13. The axial direction of the yoke 24 is also referred to as the axial direction of the stator core 23. Therefore, the axial direction of the yoke 24 is also referred to as the axial direction of the rotating shaft 15.

[0034] The teeth 25 extend inward from an inner peripheral surface 24a of the yoke 24 in a radial direction of the yoke 24. The radial direction of the yoke 24 is also referred to as the radial direction of the rotating shaft 15. The teeth 25 are spaced apart from each other in the circumferential direction of the yoke 24. The teeth 25 are arranged at equal intervals in the circumferential direction of the yoke 24. The circumferential direction of the yoke 24 is also referred to as the circumferential direction of the stator core 23. The circumferential direction of the yoke 24 is also referred to as the circumferential direction of the rotating shaft 15. Each tooth 25 extends from the inner peripheral surface 24a of the yoke 24 toward the axis of the stator core 23. In the present embodiment, the stator core 23 has fifteen teeth 25. Although the number of teeth 25 is not particularly limited, the number of teeth 25 is a multiple of three.

[0035] As in Fig. 3, opposite end surfaces of the yoke 24 in the axial direction are flat. Opposite end surfaces of each tooth 25 in the axial direction of the yoke 24 are flat. The length of the yoke 24 in the axial direction is equal to the length of each tooth 25 in the axial direction of the yoke 24. One side in the axial direction of the yoke 24, i.e., a first end surface located on a first side, is located on / in the same plane as one side of each tooth 25 in the axial direction of the yoke 24, i.e., a first end surface on the first side of each tooth 25. The other side in the axial direction of the yoke 24, i.e., a second end surface located on a second side, is located on / in the same plane as the other side of each tooth 25 in the axial direction of the yoke 24, i.e., a second end surface on the second side of each tooth 25.

[0036] The first end face of the yoke 24 on the first side in the axial direction and the first end faces of the teeth 25 on the first side in the axial direction of the yoke 24 form a first core end face 23a located on the first side in the axial direction of the stator core 23. The second end face of the yoke 24 on the second side in the axial direction and the second end faces of the teeth 25 on the second side in the axial direction of the yoke 24 form a second core end face 23b located on the second side in the axial direction of the stator core 23. The stator core 23 thus has the first core end face 23a and the second core end face 23b. The first core end face 23a is a core end face located on the first side in the axial direction of the rotary shaft 15 in the stator core 23. The second core end face 23b is a core end face located on the second side in the axial direction of the rotary shaft 15 in the stator core 23.

[0037] As in Fig. 1, the stator core 23 is arranged in the motor housing part 13 such that the first core end face 23a faces the shaft bearing part 18 in the axial direction of the rotary shaft 15 and that the second core end face 23b faces the end wall 13a of the motor housing part 13 in the axial direction of the rotary shaft 15.

[0038] As in Fig. 2 and Fig. 3, each tooth 25 has a tooth extension 26 and a tooth flange 27. The tooth extension 26 is a thin plate extending from the inner peripheral surface 24a of the yoke 24. The tooth extension 26 extends from the first core end surface 23a to the second core end surface 23b of the stator core 23. The tooth extension 26 has tooth side surfaces 26a located on opposite sides of the tooth extension 26 in the circumferential direction of the yoke 24. The tooth side surfaces 26a are continuous with the inner peripheral surface 24a of the yoke 24. The tooth flange 27 protrudes from the ends of the tooth side surfaces 26a on the side opposite the yoke 24 in the circumferential direction of the yoke 24. The tooth flange 27 thus projects from / from the end of the tooth extension 26 on the side opposite the yoke 24 towards / towards the opposite sides in the circumferential direction of the yoke 24.

[0039] The stator core 23 has slots 30. Each slot 30 is formed between two of the teeth 25 that are adjacent to each other in the circumferential direction of the yoke 24. Each slot 30 is a space defined by an inner circumferential surface 24a of the yoke 24, tooth side surfaces 26a that are adjacent to each other in the circumferential direction of the yoke 24, and surfaces of the tooth flanges 27 that face the yoke 24. Furthermore, the stator core 23 has slot openings 31. Each slot opening 31 is a gap between two of the tooth flanges 27 that are adjacent to each other in the circumferential direction of the yoke 24. Each slot opening 31 is connected to the associated slot 30.

[0040] As in Fig. 3, Fig. 4 and Fig. 5, the yoke 24 has first insertion recesses 34. Each first insertion recess 34 is formed in the outer peripheral surface of the yoke 24. Each first insertion recess 34 opens into the first core end face 23a of the stator core 23. The first insertion recesses 34 are arranged in the outer peripheral surface of the yoke 24 at equal intervals in the circumferential direction of the yoke 24. The yoke 24 has, for example, four first insertion recesses 34. Each first insertion recess 34 has a locking projection 34f. The locking projection 34f protrudes from the first insertion recess 34 in the radial direction of the yoke 24.

[0041] The yoke 24 has second insertion recesses 35. Each second insertion recess 35 is formed in the outer peripheral surface of the yoke 24. Each second insertion recess 35 opens into the first core end face 23a of the stator core 23. The second insertion recesses 35 are arranged in the outer peripheral surface of the yoke 24 at equal intervals in the circumferential direction of the yoke 24. Insulators

[0042] As in Fig. As shown in Figure 3, the stator 22 includes a first insulator 50. The first insulator 50 is tubular. The stator 22 also includes a second insulator 60. The second insulator 60 is tubular. The first insulator 50 and the second insulator 60 are made of plastic, for example.

[0043] The first insulator 50 and the second insulator 60 each have an insulator base 51 and insulator tooth portions 52. The insulator base 51 is cylindrical. The first insulator 50 and the second insulator 60 are arranged on the stator core 23, with the axes of the insulator bases 51 coinciding with the axis of the yoke 24. The axial direction of each insulator base 51 is also referred to as the axial direction of the yoke 24. The circumferential direction of each insulator base 51 is also referred to as the circumferential direction of the yoke 24. Furthermore, the radial direction of each insulator base 51 is also referred to as the radial direction of the yoke 24.

[0044] The first insulator 50 is arranged to face the first core end face 23a of the stator core 23 while being in contact with the first core end face 23a. The second insulator 60 is arranged to face the second core end face 23b of the stator core 23 while being in contact with the second core end face 23b. The outer diameter of each insulator base 51 is smaller than the outer diameter of the yoke 24. The inner diameter of each insulator base 51 is equal to the inner diameter of the yoke 24.

[0045] The insulator tooth portions 52 extend inward in the radial direction of the insulator base 51 from an inner peripheral surface 51a of the insulator base 51. The insulator tooth portions 52 are spaced apart from each other in the circumferential direction of the insulator base 51. The insulator tooth portions 52 are arranged at equal intervals in the circumferential direction of the insulator base 51. Each insulator tooth portion 52 extends from the inner peripheral surface 51a of the insulator base 51 toward the axis of the insulator base 51. In the present embodiment, each of the first insulator 50 and the second insulator 60 has fifteen insulator tooth portions 52. The number of insulator tooth portions 52 is the same as the number of teeth 25 of the stator core 23.

[0046] Each insulator tooth portion 52 has an insulator extension 53. The first insulator 50 and the second insulator 60 thus have a plurality of insulator extensions 53. Each insulator extension 53 has the shape of a post extending inward in the radial direction of the insulator base 51 from the inner peripheral surface 51a of the insulator base 51. The width of each insulator extension 53 in the circumferential direction of the insulator base 51 is equal to the width of each tooth extension 26 in the circumferential direction of the yoke 24. Each insulator extension 53 is in contact with the associated tooth 25. Thus, each insulator extension 53 is located at a position overlapping with the associated tooth extension 26 in the axial direction of the yoke 24.

[0047] Each insulator tooth portion 52 has an insulator inner wall 54. Each of the first insulator 50 and the second insulator 60 thus has the insulator inner walls 54. Each insulator inner wall 54 protrudes along the insulator base 51 from one end of the insulator extension 53 on the side opposite the insulator base 51. Each insulator inner wall 54 protrudes from the associated insulator extension 53 toward the opposite sides in the circumferential direction of the insulator base 51 and toward the side opposite the stator core 23 in the axial direction of the insulator base 51. In this way, each insulator inner wall 54 protrudes from the associated insulator extension 53. Each insulator inner wall 54 is located at a position that overlaps with the associated tooth flange 27 in the axial direction of the yoke 24.

[0048] Each insulator tooth section 52 has a surface 52a on a side opposite the insulator base 51. The surface 52a is located on / in the same plane as a surface 25a of the associated tooth 25 on the side opposite the yoke 24. Each insulator inner wall 54 has a surface on the side opposite the insulator base 51 that forms the surface 52a of the insulator tooth section 52 on the side opposite the insulator base 51. A surface of each tooth flange 27 located on the side opposite the yoke 24 forms a surface 25a of the associated tooth 25 located on the side opposite the yoke 24. The thickness of each insulator inner wall 54 is greater than the thickness of each tooth flange 27. Thus, parts of each tooth flange 27 on the surfaces facing the yoke 24 are blocked in the associated slots 30 by the associated insulator inner walls 54 in the axial direction of the yoke 24.

[0049] Each insulator inner wall 54 has insertion grooves 54a. Each insertion groove 54a is formed in one of the surfaces of the corresponding insulator inner wall 54 on the opposite sides in the circumferential direction of the insulator base 51. The insertion grooves 54a extend through the insulator inner wall 54 in the axial direction of the insulator base 51. The space within each insertion groove 54a is a portion of the space between two of the insulator inner walls 54 that are adjacent to each other in the circumferential direction of the yoke 24.

[0050] The first insulator 50 has three guide grooves 55. The three guide grooves 55 are arranged in the axial direction of the first insulator 50. The three guide grooves 55 are formed in the outer peripheral surface of the insulator base 51. The three guide grooves 55 extend in the circumferential direction of the first insulator 50. The first insulator 50 has five through grooves 56, each corresponding to one of the guide grooves 55. Each through groove 56 extends through the insulator base 51 in the radial direction. Wash

[0051] As in Fig. 2, the stator 22 has coils 28 of multiple phases. The stator 22 has coils 28 corresponding to a U phase, a V phase, and a W phase, respectively. The coils 28 are formed by windings 29 of respective phases densely wound on the stator core 23. Therefore, the stator 22 has the coils 28 of multiple phases formed by the windings 29 of multiple phases densely wound on the stator core 23. The coil 28 of each phase has portions passing through the corresponding slots 30.

[0052] As in Fig. 1, the stator 22 has first coil ends 32 and second coil ends 33. The first coil ends 32 are each part of the coil 28 of the corresponding phase and protrude from the first core end face 23a. The second coil ends 33 are each part of the coil 28 of the corresponding phase and protrude from the second core end face 23b. Thus, the first coil ends 32 and the second coil ends 33 are parts of the coils 28 of the respective phases and protrude from the core end faces. In this way, each coil 28 has coil ends formed by windings 29 wound on the stator core 23. The coil ends protrude from the core end faces of the stator core 23, which are end faces in the axial direction of the rotary shaft 15.

[0053] The coils 28 of the respective phases are each formed in a series winding configuration. In a series winding configuration, the windings 29 of each phase, which pass through the corresponding slots 30, are first wound around the corresponding tooth extensions 26, the corresponding insulator extensions 53 of the first insulator 50, and the corresponding insulator extensions 53 of the second insulator 60. The winding 29 of each phase is sequentially wound around every third set of the tooth extension 26, the insulator extension 53 of the first insulator 50, and the insulator extension 53 of the second insulator 60 in the circumferential direction of the stator core 23 using a dense winding configuration. Thus, the coils 28 of each phase are arranged with two sets of extensions 26, 53 in between in the circumferential direction of the stator core 23. In the present embodiment, five coils 28 are provided for each phase.The coils 28 of the respective phases are arranged in the slots 30 such that coils 28 of different phases are adjacent to each other in the circumferential direction of the rotating shaft 15. In this way, the coils 28 are formed by the windings 29 passing through the slots 30 and wound around the respective sets of the tooth extensions 26, the insulator extensions 53 of the first insulator 50, and the insulator extensions 53 of the second insulator 60.

[0054] The first insulator 50 insulates the coils 28 of the respective phases from the first core end face 23a. The insulator base 51 of the first insulator 50 is arranged at a position overlapping with the first coil ends 32 on the outer side of the first coil ends 32 in the radial direction of the rotating shaft 15. Each insulator inner wall 54 of the first insulator 50 is arranged at a position overlapping with the corresponding first coil end 32 on the inner side of the first coil end 32 in the radial direction of the rotating shaft 15. Thus, each insulator inner wall 54 of the first insulator 50 is located at a position overlapping with the associated tooth flanges 27 in the axial direction of the rotary shaft 15 and also overlapping with the associated first coil end 32 in the radial direction of the rotary shaft 15.

[0055] The second insulator 60 insulates the coils 28 of the respective phases from the second core end face 23b. The insulator base 51 of the second insulator 60 is arranged at a position overlapping with the second coil ends 33 on the outer side of the second coil ends 33 in the radial direction of the rotating shaft 15. Each insulator inner wall 54 of the second insulator 60 is arranged at a position overlapping with the corresponding second coil end 33 on the inner side of the second coil end 33 in the radial direction of the rotating shaft 15. Thus, each insulator inner wall 54 of the second insulator 60 is located at a position overlapping with the associated tooth flanges 27 in the axial direction of the rotary shaft 15 and also overlapping with the associated second coil end 33 in the radial direction of the rotary shaft 15.

[0056] As in Fig. As shown in Figure 4, the windings 29 of each phase have connecting wires 57 that connect the coils 28 of the same phase in the circumferential direction of the stator core 23. The connecting wires 57 of each phase are led out from the first coil ends 32 of the coils 28 of the corresponding phase and guided from the corresponding through slots 56 to the corresponding guide slots 55. Slot insulation sections

[0057] As in Fig. As shown in Figure 2, the stator 22 includes slot insulating portions 36. One slot insulating portion 36 is disposed in each slot 30. Each slot insulating portion 36 is in the shape of a sheet / plate. Each slot insulating portion 36 is formed by bending a band-shaped insulating sheet along the inner peripheral surface 24a of the yoke 24 and the associated tooth side surfaces 26a, which are adjacent to each other in the circumferential direction of the yoke 24. The slot insulating portion 36 is inserted into the slot 30 with the longitudinal direction of the slot insulating portion 36 coinciding with the axial direction of the yoke 24. The slot insulating portion 36 extends from the first core end face 23a to the second core end face 23b of the stator core 23. The slot insulating portion 36 further protrudes in the axial direction of the rotary shaft 15 from both the first core end face 23a and the second core end face 23b.The slot insulating sections 36 insulate the stator core 23 from parts of the coils 28 that pass through the slots 30.

[0058] As in Fig. As shown in Figure 6, each slot insulating portion 36 includes an insulating main body 37. The insulating main body 37 is a portion of the slot insulating portion 36 that extends along the inner peripheral surface 24a of the yoke 24 and the tooth side surfaces 26a that are adjacent to each other in the circumferential direction of the yoke 24. Therefore, the slot insulating portion 36 extends along the inner peripheral surface 24a of the yoke 24 and the tooth side surfaces 26a that are adjacent to each other in the circumferential direction of the yoke 24.

[0059] Each slot insulating portion 36 has two projections 38. The projections 38 extend toward each other from the two ends of the insulating main body 37 located on the opposite side of the inner peripheral surface 24a of the yoke 24. Thus, the two projections 38 each project toward each other from the tooth side surfaces 26a adjacent to each other in the circumferential direction of the yoke 24. The two projections 38 insulate the associated tooth flanges 27 located on the opposite sides of the slot opening 31 and the associated coils 28 from each other. Each projection 38 is spaced apart from the associated tooth flange 27. Phase-to-phase insulation sheet

[0060] As in Fig. 2, the stator 22 has phase-to-phase insulating sheets 46. A (single) phase-to-phase insulating sheet 46 is arranged in each slot 30. Each phase-to-phase insulating sheet 46 has a sheet / plate shape. Each phase-to-phase insulating sheet 46 is formed by bending a band-shaped insulating sheet. The phase-to-phase insulating sheet 46 is inserted into the slot 30, with the longitudinal direction of the phase-to-phase insulating sheet 46 coinciding with the axial direction of the yoke 24. Thus, the longitudinal direction of the phase-to-phase insulating sheet 46 coincides with the axial direction of the rotating shaft 15.

[0061] As in Fig. 6, each phase-to-phase insulating sheet 46 has a first insulating portion 47, a second insulating portion 48, and a third insulating portion 49. The first insulating portion 47 is arranged between one of the two toothed flanges 27 located on the opposite sides of the slot opening 31 and the corresponding one of the two projections 38 located on the opposite sides of the slot opening 31. That is, the first insulating portion 47 is arranged between the toothed flange 27 on the left side in Fig. 6 and the overhang 38 on the left side in Fig. 6. The first insulating portion 47 and the associated projection 38 overlap in the radial direction of the yoke 24. The first insulating portion 47 insulates the associated tooth flange 27 from / against one of the two coils 28, which are adjacent to each other in the circumferential direction of the yoke 24 in the associated slot 30.

[0062] The second insulating section 48 is arranged between the other of the two toothed flanges 27 located on the opposite sides of the slot opening 31 and the corresponding one of the two projections 38 located on the opposite sides of the slot opening 31. That is, the second insulating section 48 is arranged between the toothed flange 27 on the right side in Fig. 6 and the overhang 38 on the right side in Fig. 6. The second insulating portion 48 and the associated projection 38 overlap in the radial direction of the yoke 24. Thus, the projections 38 and the phase-to-phase insulating sheet 46 overlap in the radial direction of the yoke 24. The second insulating portion 48 insulates the associated tooth flange 27 from the other of the two coils 28 that are adjacent to each other in the circumferential direction of the yoke 24 in the associated slot 30.

[0063] The third insulating portion 49 has a V-shaped cross-sectional shape that extends from the end of the first insulating portion 47 closer to the second insulating portion 48 toward the inner peripheral surface 24a of the yoke 24, then is bent and extends toward the second insulating portion 48 to be connected to the end of the second insulating portion 48 closer to the first insulating portion 47. The third insulating portion 49 thus connects the first insulating portion 47 and the second insulating portion 48 to each other. In this way, the phase-to-phase insulating sheet 46 extends in the radial direction of the rotating shaft 15. The third insulating portion 49 is arranged in each slot 30 between the coils 28 that are adjacent to each other in the circumferential direction of the rotating shaft 15. The third insulating portion 49 insulates the coils 28, which are adjacent to each other in the circumferential direction of the rotary shaft 15, in the slot 30.Thus, the third insulating portion 49 has a V-shaped cross-sectional shape that connects the first insulating portion 47 and the second insulating portion 48 to each other and insulates the coils 28 that are adjacent to each other in the slot 30 in the circumferential direction of the rotary shaft 15.

[0064] In this way, the phase-to-phase insulating sheet 46 is arranged to extend across the slot opening 31 in the circumferential direction of the rotating shaft 15. The phase-to-phase insulating sheet 46 insulates the toothed flanges 27 and the coils 28 on the opposite sides of the slot opening 31 from each other. The phase-to-phase insulating sheet 46 extends in the radial direction of the rotating shaft 15 and insulates the coils 28 located adjacent to each other in the circumferential direction of the rotating shaft 15.

[0065] As in Fig. 4, the opposite ends in the longitudinal direction of each phase-to-phase insulating sheet 46 protrude from the first core end face 23a and the second core end face 23b, respectively. As shown in Fig. As shown in Fig. 6, parts of the first insulating portion 47 and the second insulating portion 48 of each phase-to-phase insulating sheet 46, which protrude from the first core end face 23a and the second core end face 23b, are inserted into the space between two of the insulator inner walls 54 that are adjacent to each other in the circumferential direction of the rotary shaft 15. The first insulating portion 47 is inserted into one of the insertion grooves 54a that form part of the space between two of the insulator inner walls 54 that are adjacent to each other in the circumferential direction of the yoke 24. The second insulating portion 48 is inserted into the other of the insertion grooves 54a that form part of the space between the two of the insulator inner walls 54 that are adjacent to each other in the circumferential direction of the yoke 24.In this way, the phase-to-phase insulating sheet 46 protrudes from each of the first core end face 23a and the second core end face 23b into the space between two of the insulator inner walls 54 adjacent to each other in the circumferential direction of the rotary shaft 15.

[0066] As in Fig. 4, each phase-to-phase insulating sheet 46 partially protrudes beyond the insulator inner walls 54 of the first insulator 50 on the side opposite the first core end face 23a and insulates the associated first coil ends 32, which are adjacent to each other in the circumferential direction of the rotary shaft 15, from each other. Although not shown, each phase-to-phase insulating sheet 46 partially protrudes beyond the insulator inner walls 54 of the second insulator 60 on the side opposite the second core end face 23b and insulates the associated second coil ends 33, which are adjacent to each other in the circumferential direction of the rotary shaft 15, from each other.

[0067] As in Fig. As shown in FIG. 7, an edge 46e of each phase-to-phase insulating sheet 46 in the axial direction of the rotary shaft 15 has first edges 461 and second edges 462. The first edges 461 are parts of the edge 46e of the phase-to-phase insulating sheet 46 and protrude beyond the first coil ends 32 on the side opposite the first core end face 23a. The first edges 461 protrude beyond the first coil ends 32 on the side opposite the first core end face 23a. On the side opposite the first core end face 23a, the first edges 461 protrude beyond the inner wall ends 54e of the insulator inner walls 54 on the side opposite the first core end face 23a. The first edges 461 are formed by the edges of the third insulating portion 49 in the axial direction of the rotary shaft 15.

[0068] The second edges 462 are (those) parts of the edge 46e of the phase-to-phase insulating sheet 46 that do not protrude from the inner wall ends 54e of the insulator inner wall 54. In other words, the second edges 462 are parts of the edge 46e of the phase-to-phase insulating sheet 46 that have a shorter length than the inner wall ends 54e of the insulator inner walls 54. Therefore, the second edges 462 do not protrude beyond the inner wall ends 54e of the insulator inner walls 54 on the side opposite the first core end face 23a. The second edges 462 are located closer to the first core end face 23a than the insulator inner walls 54. The second edges 462 do not protrude beyond the first coil ends 32 on the side opposite the first core end face 23a.The second edges 462 are formed by parts of the edge of the third insulating portion 49 located on the inner side of the parts forming the first edges 461 in the radial direction of the rotating shaft 15 and the edges of the first insulating portion 47 and the second insulating portion 48 in the axial direction of the rotating shaft 15. The second edges 462 are provided to extend from ends E1 of the first edges 461 located on the inner side in the radial direction of the rotating shaft 15 to edges of the phase-to-phase insulating sheet 46 located on the inner side in the radial direction of the rotating shaft 15. Cover part

[0069] As in Fig. As shown in Figure 5, the stator 22 has a cover member 65. The cover member 65 is cylindrical. The cover member 65 has an insulating property. The cover member 65 is made of, for example, plastic. The cover member 65 is arranged to face the first insulator 50.

[0070] The cover part 65 has a cover end wall 66, a cover outer wall 67, and a cover inner wall 68. The cover end wall 66 is annular. The cover end wall 66 has a plurality of through holes 65h.

[0071] The cover end wall 66 has a flat wall 69 and an inclined wall 70. The flat wall 69 is annular. The flat wall 69 has the shape of a flat plate. The flat wall 69 extends in the radial direction of the rotary shaft 15. The inclined wall 70 is conical and extends from the radially inner portion of the flat wall 69 toward the radially inner side of the cover end wall 66, being inclined. A radially inner portion of the inclined wall 70 forms a radially inner portion of the cover end wall 66. The radially outer portion of the flat wall 69 forms the radially outer portion of the cover end wall 66.

[0072] As in Fig. As shown in Figure 8, the cover end wall 66 faces the first coil end 32 in the axial direction of the rotating shaft 15. The cover end wall 66 covers the first coil ends 32 on the side opposite the first core end face 23a in the axial direction of the rotating shaft 15 and covers portions of the phase-to-phase insulating sheets 46 that protrude beyond the insulator inner wall 54 on the side opposite the first core end face 23a.

[0073] The cover outer wall 67 extends cylindrically in the axial direction of the rotary shaft 15 from the radially outer portion of the flat wall 69. The cover outer wall 67 thus extends cylindrically from the radially outer portion of the cover end wall 66. The inner diameter of the cover outer wall 67 is wider than the outer diameter of the insulator base 51. The cover outer wall 67 surrounds the insulator base 51 of the first insulator 50.

[0074] The cover inner wall 68 extends in the axial direction of the rotary shaft 15 from the radially inner portion of the inclined wall 70. The cover inner wall 68 thus extends cylindrically from the radially inner portion of the cover end wall 66. The cover inner wall 68 faces the insulator inner walls 54 of the first insulator 50 in the axial direction of the rotary shaft 15. Therefore, the cover inner wall 68 extends from the radially inner portion of the cover end wall 66 toward the insulator inner wall 54 and overlaps with the insulator inner wall 54 in the axial direction of the rotary shaft 15. The inclined wall 70 is inclined such that the distance between the inclined wall 70 and the insulator inner wall 54 decreases (as the inclined wall 70 extends toward the cover inner wall 68). The inclined wall 70 is continuous with the cover inner wall 68.

[0075] A case where each first coil end 32 is divided into three equal parts along the length in the radial direction of the rotary shaft 15 will now be described. Each first coil end 32 has a radially inner portion 32a and a radially outer portion 32b. The radially inner portion 32a is a part located at the innermost position in the radial direction of the rotary shaft 15 when the first coil end 32 is divided into three equal parts along the length in the radial direction of the rotary shaft 15. The radially outer portion 32b is a part of the first coil end 32 located at an outer side of the radially inner portion 32a in the radial direction of the rotary shaft 15.

[0076] The inclined wall 70 is inclined from a part of the cover end wall 66 that overlaps with the radially outer portion 32b of each first spool end 32 in the axial direction of the rotary shaft 15. Specifically, the radially outer portion 32b includes a first radially outer portion 321b and a second radially outer portion 322b. The first radially outer portion 321b is a part of the radially outer portion 32b located at the outermost position in the radial direction of the rotary shaft 15 when the first spool end 32 is divided into three equal parts along the length in the radial direction of the rotary shaft 15. The second radially outer portion 322b is a part of the radially outer portion 32b located inward of the first radially outer portion 321b in the radial direction of the rotary shaft 15.The inclined wall 70 is inclined from a part of the cover end wall 66 that overlaps with the second radially outer portion 322b of the first coil end 32 in the axial direction of the rotary shaft 15.

[0077] As in Fig. As shown in FIG. 9, the cover end wall 66 is provided with a restricting portion 71, i.e., a stopper. The restricting portion 71 protrudes from an inner surface of the cover end wall 66 facing the first coil ends 32. The restricting portion 71 is annular and extends in the circumferential direction of the cover end wall 66. The restricting portion 71 has the shape of a thin plate. The restricting portion 71 protrudes toward the first coil end 32 from the boundary between the flat wall 69 and the inclined wall 70 of the cover end wall 66.

[0078] The limiting portion 71 is configured such that the distal end of the limiting portion 71 contacts the edge 46e of each phase-to-phase insulating sheet 46. The distal end of the limiting portion 71 is allowed to contact the center in the radial direction of the rotating shaft 15 of the first edge 46e of each phase-to-phase insulating sheet 46. In this way, the limiting portion 71 contacts the edges 46e of the phase-to-phase insulating sheets 46 in the axial direction of the rotating shaft 15. The limiting portion 71 contacts the edges 46e of the phase-to-phase insulating sheets 46 in the axial direction of the rotating shaft 15, thereby limiting / restricting movement of the phase-to-phase insulating sheets 46 in the axial direction of the rotating shaft 15.

[0079] As in Fig. As shown in Figure 1, the outer cover wall 67 of the cover part 65 is located between the connecting wires 57 of the respective phases and the peripheral wall 13b of the motor housing part 13. The outer cover wall 67 of the cover part 65 provides insulation between the connecting wires 57 of the respective phases and the motor housing part 13.

[0080] As in Fig. 5, the cover member 65 has a plurality of pairs of locking tabs 72. Each pair of locking tabs 72 extends in the axial direction of the yoke 24 from the edge of the cover outer wall 67 of the cover member 65 on the side opposite the cover end wall 66. The pairs of locking tabs 72 are arranged at equal intervals in the circumferential direction of the cover outer wall 67 of the cover member 65. The cover member 65 has, for example, four pairs of locking tabs 72.

[0081] Each locking tab 72 has the shape of an elongated flat plate. The longitudinal direction of the locking tab 72 coincides with the axial direction of the yoke 24. The locking tabs 72 extend parallel to each other. The distal ends of the locking tabs 72 are hook-shaped and face each other.

[0082] Each first insertion recess 34 receives a pair of locking tabs 72. Each first insertion recess 34 receives a pair of locking tabs 72 such that the locking projection 34f is located between the two locking tabs 72. Accordingly, the locking tab 72 is engaged with the locking projection 34f. In this way, the cover member 65 is attached to the stator core 23. When the locking tabs 72 are engaged with the locking projections 34f, the locking tabs 72 are prevented from disengaging from the first insertion recess 34. In this way, the engagement of the locking projection 34f with the locking tabs 72 restricts movement of the cover member 65 relative to the first insulator 50 in the axial direction of the yoke 24.

[0083] The cover part 65 has a plurality of insertion tabs 73. Each insertion tab 73 extends in the axial direction of the yoke 24 from the edge of the cover outer wall 67 of the cover part 65 on the side opposite the cover end wall 66. The insertion tabs 73 are arranged at equal intervals in the circumferential direction of the cover inner wall 68. Each insertion tab 73 has the shape of an elongated plate. Each insertion tab 73 has a longitudinal direction that coincides with the longitudinal direction of the yoke 24.

[0084] Each insertion tab 73 is inserted into the associated second insertion recess 35. Each insertion tab 73 is allowed to contact the side surfaces of the associated second insertion recess 35 in a state where the insertion tab 73 is inserted into the second insertion recess 35. When the cover member 65 vibrates, each insertion tab 73 is displaceable relative to the side surfaces of the associated second insertion recess 35. The sliding movement of each insertion tab 73 on the side surfaces of the associated second insertion recess 35 suppresses friction between each pair of locking tabs 72 and the side surfaces of the associated first insertion recess 34.

[0085] As in Fig. As shown in Figure 10, the rotating shaft 15 includes a counterweight 74. The counterweight 74 is in the shape of a plate. The counterweight 74 protrudes outward in the radial direction of the rotating shaft 15 from a portion of the outer peripheral surface of the rotating shaft 15 located on an inner side of the cover inner wall 68. The counterweight 74 cancels the centrifugal force acting on the orbiting scroll 16b due to the rotation of the rotating shaft 15. The rotating shaft 15 is thus provided with the counterweight 74 configured to cancel the centrifugal force acting on the orbiting scroll 16b due to the rotation of the rotating shaft 15.

[0086] The balance weight 74 has a first extension 74a, a second extension 74b, and a third extension 74c. The first extension 74a extends in the radial direction of the rotary shaft 15 from the outer peripheral surface of the rotary shaft 15. The second extension 74b extends obliquely with respect to the extending direction of the first extension 74a from an end of the first extension 74a on the side opposite the outer peripheral surface of the rotary shaft 15. The second extension 74b extends obliquely with respect to the axial direction of the rotary shaft 15. The second extension 74b extends from the first extension 74a in a direction away from the stator core 23. The third extension 74c extends outward in the radial direction of the rotary shaft 15 from an end of the second extension 74b on a side opposite the first extension 74a. The second extension 74b of the counterweight 74 extends along the inclined wall 70.Therefore, the balance weight 74 extends along the inclined wall 70 and projects outward in the radial direction of the rotary shaft 15 from the part of the outer peripheral surface of the rotary shaft 15 that is located on the inside of the cover inner wall 68. Hermetic connection

[0087] As in Fig. As shown in Figure 1, the motor-driven compressor 10 has a hermetic connection 40. The hermetic connection 40 has three guide elements 41, each corresponding to the coils 28 of the respective phases. The motor-driven compressor 10 thus has the guide elements 41. Fig. 1 shows only one (single) conductive element 41. Each conductive element 41 is a columnar metal terminal that extends linearly. Each conductive element 41 has a first end that is electrically connected to the inverter 17 in the inverter chamber S1. Each conductive element 41 has a second end that protrudes from the inverter chamber S1 through the hole 13h into the motor housing part 13. The hermetic terminal 40 has a bearing plate / support plate 42. The bearing plate 42 supports the three conductive elements 41 and insulates the three conductive elements 41 from one another. The bearing plate 42 is attached to the outer surface of the end wall 13a of the motor housing part 13 around the hole 13h in the inverter chamber S1.

[0088] The stator 22 has lead wires 43. The lead wires 43 extend from the motor 20. The lead wires 43 extend from the second coil ends 33 of the coils 28 of the respective phases. Thus, three lead wires 43 extend from the motor 20. Fig. 1 shows only one of the lead wires 43.

[0089] The stator 22 has a cluster block 44. The cluster block 44 accommodates three connecting terminals 45 corresponding to the coils 28 of the respective phases. The cluster block 44 has an insulating property. The cluster block 44 is made of, for example, plastic. Each connecting terminal 45 electrically connects the corresponding conducting element 41 to the corresponding conducting wire 43.

[0090] The current from the inverter 17 is supplied to the motor 20 via the conductor elements 41, the connecting terminals 45, and the lead wires 43. This drives the motor 20. The inverter 17 thus drives the motor 20. Operation of the embodiment

[0091] The operation of the present embodiment will now be described.

[0092] As in Fig. As shown in FIG. 11, the stator 22 is coupled to the housing 11 by fitting the stator core 23 to the inner peripheral surface of the peripheral wall 13b of the motor housing part 13, for example, by shrink fitting. During shrink fitting, the motor housing part 13 is thermally expanded so that the inner diameter of the peripheral wall 13b of the motor housing part 13 is wider than the outer diameter of the stator core 23. Subsequently, the stator core 23 is inserted into the motor housing part 13 to achieve a predetermined shrink fitting position. Then, as the temperature of the motor housing part 13 approaches normal temperature, the motor housing part 13 shrinks. This brings the inner peripheral surface of the peripheral wall 13b of the motor housing part 13 into close contact with the outer peripheral surface of the stator core 23.

[0093] Thus, when the stator core 23 is shrink-fitted to the motor housing part 13, the stator core 23 is positioned by, for example, inserting an alignment jig 75 into the stator core 23. The motor housing part 13 is arranged with respect to the stator core 23 such that the stator core 23, whose position relative to the alignment jig 75 is determined, is inserted into the inner peripheral surface of the peripheral wall 13b of the motor housing part 13 at the predetermined shrink-fit position. In this way, the stator 22 is coupled to the housing 11.

[0094] As in Fig.As shown in Fig. 12, when inserting the alignment jig 75, which is used for shrink-fitting the stator core 23 to the motor housing member 13, into the stator core 23, the alignment jig 75 is inserted into the stator core 23 while being guided by the inclined wall 70. Therefore, when the alignment jig 75 is inserted into the stator core 23, interference between the alignment jig 75 and the cover member 65 is avoided, thereby avoiding difficulty in inserting the alignment jig 75 into the interior of the stator core 23.

[0095] When the alignment fixture 75 is inserted into the stator core 23, the cover end wall 66 and the cover inner wall 68 prevent the alignment fixture 75 from contacting (or touching) the first coil ends 32. The cover end wall 66 and the cover inner wall 68 also prevent the alignment fixture 75 from contacting portions of the phase-to-phase insulation sheets 46 that protrude beyond the insulator inner wall 54 on the side opposite the first core end face 23a. Advantages of embodiment

[0096] The embodiment described above has the following advantages.

[0097] (1) The cover end wall 66 has the inclined wall 70, which is inclined such that the distance between the inclined wall 70 and the insulator inner wall 54 decreases as the inclined wall 70 extends toward the cover inner wall 68. The inclined wall 70 is continuous with the cover inner wall 68. Thus, when inserting the jig 75, which is used for shrink-fitting the stator core 23 to the motor housing part 13, into the stator core 23, the jig 75 is inserted into the stator core 23 while being guided by the inclined wall 70. Therefore, when the alignment jig 75 is inserted into the stator core 23, interference between the alignment jig 75 and the cover member 65 is avoided, thus preventing difficulties in inserting the alignment jig 75 into the interior of the stator core 23. This improves the assembly efficiency of the stator 22 to the housing 11.

[0098] When the alignment jig 75 is inserted into the stator core 23, the cover end wall 66 and the cover inner wall 68 prevent the alignment jig 75 from coming into contact with the first coil ends 32. The cover end wall 66 and the cover inner wall 68 also prevent the alignment jig 75 from contacting portions of the phase-to-phase insulating sheets 46 that protrude beyond the insulator inner wall 54 on the side opposite the first core end face 23a. This prevents the coils 28 from being damaged, and the phase-to-phase insulating sheets 46 are not deformed. Accordingly, the insulation between adjacent ones of the first coil ends 32 in the circumferential direction of the rotating shaft 15 is not impaired. This improves the reliability of the engine 20.Accordingly, the assembly of the stator 22 to the housing 11 is facilitated and at the same time the reliability of the motor 20 is improved.

[0099] (2) The phase-to-phase insulating sheets 46 are configured such that the edge 46e in the axial direction of the rotating shaft 15 of each phase-to-phase insulating sheet 46 has the first edge 461 protruding beyond the first coil end 32 on the side opposite the first core end face 23a. This easily ensures insulation between the first coil ends 32 adjacent to each other in the circumferential direction of the rotating shaft 15. Each phase-to-phase insulating sheet 46 is configured such that the edge 46e in the axial direction of the rotating shaft 15 of the phase-to-phase insulating sheet 46 has the second edges 462 not protruding beyond the inner wall end 54e of the insulator inner wall 54 on the side opposite the first core end face 23a.The second edges 462 are formed by cutting out portions of the first edges 461 that extend from the ends E1 located on the inner side in the radial direction of the rotating shaft 15 to the edge 46e of the phase-to-phase insulating sheet 46 located on the inner side in the radial direction of the rotating shaft 15. Thus, for example, compared to a case where the entire edge 46e of each phase-to-phase insulating sheet 46 protrudes beyond the first coil ends 32 and the insulator inner walls 54 on the side opposite the first core end face 23a, the alignment jig 75 is easily prevented from contacting the phase-to-phase insulating sheets 46.

[0100] (3) The cover end wall 66 is provided with the limiting portion 71 that contacts the edge 46e of each phase-to-phase insulating sheet 46 in the axial direction of the rotating shaft 15, thereby limiting / restricting movement of the phase-to-phase insulating sheet 46 in the axial direction of the rotating shaft 15. With this configuration, when the edge 46e of the phase-to-phase insulating sheet 46 in the axial direction of the rotating shaft 15 contacts the limiting portion 71, the movement of the phase-to-phase insulating sheet 46 in the axial direction of the rotating shaft 15 is limited / restricted. Since the position of each phase-to-phase insulating sheet 46 is determined, stable insulation between the coils 28 adjacent to each other in the circumferential direction of the rotary shaft 15 is achieved by the phase-to-phase insulating sheet 46.

[0101] (4) The inclined wall 70 is inclined from a part of the cover end wall 66 that overlaps with the radially outer portion 32b of each first coil end 32 in the axial direction of the rotating shaft 15. This configuration maximizes the inclined length of the inclined wall 70 compared to a case where the inclined wall 70 is inclined, for example, from a part of the cover end wall 66 that overlaps with the radially inner portion 32a of the first coil end 32 in the axial direction of the rotating shaft 15. Therefore, when inserting the (alignment) jig 75, which is used for shrink-fitting the stator core 23 to the motor housing part 13, into the stator core 23, the (alignment) jig 75 is easily guided through the inclined wall 70 into the stator core 23.

[0102] (5) The balance weight 74 extends along the inclined wall 70 and protrudes outward in the radial direction of the rotary shaft 15 from the portion of the outer peripheral surface of the rotary shaft 15 located on the inner side of the cover inner wall 68. With this arrangement, even if the balance weight 74 protrudes outward in the radial direction of the rotary shaft 15 from the portion of the outer peripheral surface of the rotary shaft 15 located on the inner side of the cover inner wall 68, the balance weight 74 does not interfere with the cover member 65 because the balance weight 74 extends along the inclined wall 70. This allows the balance weight 74 to protrude outward in the radial direction of the rotary shaft 15 from the portion of the outer peripheral surface of the rotary shaft 15 located on the inner side of the cover inner wall 68.Since the balance weight 74 is arranged as close to the stator core 23 as possible, the size of the motor-driven compressor 10 in the axial direction of the rotary shaft 15 is reduced. Variations

[0103] The above-described embodiment may be modified as follows. The above-described embodiment and the following modifications may be combined with each other, as long as the combined modifications remain technically compatible with each other.

[0104] For example, in the embodiment described above, the entire edge 46e of each phase-to-phase insulating sheet 46 may protrude beyond the first coil ends 32 and the insulator inner wall 54 on the side opposite the first core end face 23a.

[0105] In the embodiment described above, the cover part 65 may be configured such that the cover end wall 66 is not provided with the limiting portion 71.

[0106] In the embodiment described above, the inclined wall 70 may be inclined, for example, from a part of the cover end wall 66 that overlaps with the radially inner portion 32a of the first coil end 32 in the axial direction of the rotary shaft 15.

[0107] In the embodiment described above, the inclined wall 70 may be inclined, for example, from a part of the cover end wall 66 that overlaps with the first radially outer portion 321b of the first spool end 32 in the axial direction of the rotary shaft 15.

[0108] In the embodiment described above, the cover inner wall 68 does not necessarily have to overlap with the insulator inner wall 54 in the axial direction of the rotary shaft 15.

[0109] In the above-described embodiment, the balance weight 74 may protrude outward in the radial direction of the rotating shaft 15 from a portion of the outer peripheral surface of the rotating shaft 15 that is farther from the stator core 23 than a portion of the outer peripheral surface of the rotating shaft 15 that is located inward from the cover inner wall 68. The balance weight 74 does not necessarily have to extend along the inclined wall 70.

[0110] In the above-described embodiment, the motor-driven compressor 10 may be installed without the balance weight 74 on the rotating shaft 15. In this case, a balance weight is arranged, for example, on the sleeve of the scroll-type compression unit 16 having a conventional structure.

[0111] In the above-described embodiment, the cover member 65 may be arranged to face the second insulator 60. In this case, the stator core 23 is arranged in the motor housing member 13 such that the first core end face 23a faces the end wall 13a of the motor housing member 13 in the axial direction of the rotating shaft 15, and the second core end face 23b faces the shaft support member 18 in the axial direction of the rotating shaft 15. For example, the inverter 17 is arranged on the outer side of the peripheral wall 13b of the motor housing member 13 in the radial direction of the rotating shaft 15, and the cluster block 44 is arranged, for example, between the second insulator 60 and the shaft support member 18.

[0112] In the embodiment described above, the compression unit 16 is not limited to a scroll type, but may be, for example, a piston type or an impeller type.

[0113] In the embodiment described above, the motor-driven compressor 10 is used in the vehicle air conditioning system. However, the present disclosure is not limited to this. For example, the motor-driven compressor 10 may be mounted on a fuel cell electric vehicle and use the compression unit 16 to compress air supplied to the fuel cell as fluid.

[0114] Various changes in form and details may be made to the above examples without departing from the spirit and scope of the claims and their equivalents. The examples are for the purpose of description only and not for purposes of limitation. Descriptions of features in each example are to be considered applicable to similar features or aspects in other examples. Suitable results may be obtained by performing operations in a different order; and / or by combining components differently in a described system, architecture, device, or circuit; and / or by substituting or supplementing other components or their equivalents. The scope of the disclosure is defined by the claims and their equivalents, not the detailed description. All variations within the scope of the claims and their equivalents are intended to be included within the disclosure. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] JP 2023-134737

[0001] JP 2022-150980

[0004]

Claims

[1] Motor-driven compressor (10) with: a rotating shaft (15); a compression unit (16) configured to compress a fluid by rotating the rotary shaft (15); a motor (20) arranged to rotate the rotary shaft (15); and a housing (11) having a motor chamber (S2) accommodating the motor (20); wherein: the motor (20) has a stator (22); the stator (22) has: - a stator core (23) fixed in the housing (11); - coils (28) of a plurality of phases formed by windings (29) of a plurality of phases densely wound on the stator core (23), the coils (28) having coil ends (32, 33) projecting from a core end face (23a, 23b) of the stator core (23) in an axial direction of the rotary shaft (15); - an insulator (50, 60) arranged to face the core end face (23a, 23b), the insulator (50, 60) isolating the coils (28) and the core end face (23a, 23b) from each other; - phase-to-phase insulating sheets (46) each extending in a radial direction of the rotary shaft (15) and insulating the coils (28) adjacent to each other in a circumferential direction of the rotary shaft (15) from each other; and - a cover member (65) having an insulating property and arranged to face the insulator (50); the insulator (50) has an insulator inner wall (54) arranged at a position overlapping with the coil ends (32) on an inner side of the coil ends (32) in the radial direction of the rotary shaft (15); each phase-to-phase insulating sheet (46) insulates the coil ends (32) adjacent to each other in the circumferential direction in a state in which the phase-to-phase insulating sheet (46) projects beyond the core end face (23a) on a side opposite to the core end face (23a) and partially projects beyond the insulator inner wall (54); the cover part (65) has: - an annular cover end wall (66) covering the coil ends (32) on a side opposite the core end face (23a) in the axial direction and covering a part of each phase-to-phase insulating sheet (46) projecting beyond the insulator inner wall (54) on the side opposite the core end face (23a); and - a tubular cover inner wall (68) extending toward the insulator inner wall (54) from a radially inner portion of the cover end wall (66); the cover end wall (66) has a conical inclined wall (70) which is inclined such that the distance between the cover end wall (66) and the insulator inner wall (54) decreases as the cover end wall (66) extends towards the cover inner wall (68); and the inclined wall (70) is continuous with the inner cover wall (68). [2] The motor-driven compressor (10) according to claim 1, wherein an edge in the axial direction of each phase-to-phase insulating sheet (46) comprises: a first edge (461) projecting beyond the coil ends (32) on the side opposite the core end face (23a); and a second edge (462) extending from an end of the first edge (461) located on the inside in the radial direction of the rotary shaft (15) to an edge of the phase-to-phase insulating sheet (46) located on the inside in the radial direction, the second edge (462) not protruding beyond an inner wall end of the insulator inner wall (54) that is on the side opposite to the core end face (23a). [3] The motor-driven compressor (10) according to claim 1 or 2, wherein the cover end wall (66) is provided with a restricting portion (71), and the restricting portion (71) is configured to contact an edge in the axial direction of each phase-to-phase insulating sheet (46) to restrict movement of the phase-to-phase insulating sheet (46) in the axial direction. [4] Motor-driven compressor (10) according to claim 1, wherein: each of the coil ends (32) has: - a radially inner portion (32a) which is a part located at a radially innermost position when the coil end (32) is divided into three equal parts along a length in the radial direction; and - a radially outer portion (32b) which is a part of the coil end (32) located on an outer side of the radially inner portion (32a) in the radial direction of the rotary shaft (15); and the inclined wall (70) is inclined from a part of the cover end wall (66) which overlaps with the radially outer portion (32b) in the axial direction. [5] Motor-driven compressor (10) according to claim 1, wherein: the compression unit (16) comprises: - a fixed spiral (16a) fixed to the housing (11); and - an orbiting scroll (16b) arranged to rotate when the rotating shaft (15) rotates and to engage with the fixed scroll (16a); the rotary shaft (15) is provided with a counterweight (74) designed to cancel a centrifugal force acting on the orbiting scroll (16b) due to the rotation of the rotary shaft (15); and the balance weight (74) extends along the inclined wall (70), projecting outward in the radial direction of the rotary shaft (15) from a part of an outer peripheral surface of the rotary shaft (15) located on an inner side of the cover inner wall (68).

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