Interphase insulating member, stator, and motor

Abstract

To provide an interphase insulating member capable of reducing workload in a process of inserting a coil into a stator core and improving workability, and a stator and a motor using the same.SOLUTION: In an interphase insulating member 500 having a generally hollow cylindrical shape and consisting of a tooth insertion hole 510, a leg portion 520, and strip-shaped portions 530 and 540, by forming a first fold 560 and a second fold 570 in the stripe-shaped portions 530 and 540, the stripe-shaped portions 530 and 540 are formed into wave shapes when a state where the interphase insulating member 500 is mounted on a stator core 200 before mounting the stator core 200 is viewed from an axial direction.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a structure of an interphase insulating member that provides insulation between different phase stator windings that constitute an electric motor. [Background technology]

[0002] In recent years, in order to make electric motors smaller and with higher output, it has become necessary to ensure reliable insulation between different phases in an electric motor. An example of this type of motor is a motor used in the field of electric vehicles. In these motors, various insulating materials are used to ensure insulation between different phase windings and between the windings and the stator.

[0003] The following Patent Document 1 illustrates an electric motor for electric vehicles, which has a cylindrical stator core with a large number of axially extending slots arranged intermittently in the circumferential direction on its inner circumference, and a multi-phase (e.g., three-phase) stator coil wound around the stator core.

[0004] A slot insulating paper that ensures insulation between the stator coil and the stator core is arranged in the slot, and the stator coil is housed in the slot by distributed winding via the slot insulating paper.

[0005] Interphase insulating paper is placed between each phase of the distributed wound stator coil to ensure insulation between the coils of different phases. When placing the interphase insulating paper between the stator coils of different phases, annular coils formed by mechanical winding in a state where the annular coils are connected in series are inserted into the slots, and then the coil end portions protruding from the end faces of the stator core are pushed outward toward the outer diameter side by, for example, mechanical forming.

[0006] Next, interphase insulating paper is placed on the inner diameter side of the toroidal coil inserted in the slot. After the interphase insulating paper is placed, the next phase toroidal coil for all poles is inserted on the inner diameter side, and the coil end portions are then pushed outwardly. After this, the process of placing interphase insulating paper, inserting all poles of the toroidal coil, and pushing the coil end portions outwardly is repeated for each phase. In the case of a three-phase, interphase insulating paper is placed on the inner diameter side of the next phase toroidal coil (whose coil end portions have been pushed outwardly), and then the toroidal coil of the next phase is placed on the inner diameter side of that to complete the process. There is no need to push the coil end portions of the next phase toroidal coil outwardly.

[0007] The annular coils are inserted into the slots of the stator core in the above manner, but there is a risk that the inserted annular coil may come into contact with the interphase insulating paper placed just before it, causing the position of the interphase insulating paper to shift or become entangled and damaging the interphase insulating paper. As a means for solving such problems, for example, the technology described in Patent Document 1 below has been presented. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] JP 2020-150683 A

[0009] According to the technology described in Patent Document 1, four first coils are arranged at 90 degree intervals around the circumferential direction of the stator core, and four second coils are arranged at 90 degree intervals around the circumferential direction. Four interphase insulating papers are arranged between the four first coils and four second coils, and four third coils are also arranged at 90 degree intervals around the circumferential direction of the stator core. Four interphase insulating papers are also arranged between the four second coils and four third coils.

[0010] The interphase insulating paper has a pair of sheet-shaped insulating portions protruding from a pair of axial end faces of the stator core, respectively, and a plurality of legs connecting the pair of sheet-shaped insulating portions to each other, the pair of sheet-shaped insulating portions being disposed between the coil end portions of the first coil and the coil end portions of the second coil, and the multiple legs being fitted into slots in the stator core.

[0011] This structure and arrangement of the interphase insulating paper prevents the first-installed interphase insulating paper from coming into contact with the second coil that is inserted later, causing it to become misaligned or entangled and become damaged. Summary of the Invention [Problem to be solved by the invention]

[0012] The technology described in the above Patent Document 1 is believed to be able to prevent, to a certain extent, the interphase insulating paper that was previously installed from shifting or getting wrapped around by the coil that is inserted later. However, since the structure requires multiple pieces of interphase insulating paper to be installed between the first coil and the second coil that are arranged in the circumferential direction of the stator core, the labor required to install the interphase insulating paper increases. In addition, since the interphase insulating paper is made up of multiple sheets, the size of each piece of interphase insulating paper is small, making it even more susceptible to shifting when it comes into contact with the coil that is inserted later.

[0013] The above-mentioned Patent Document 1 also discloses a method for preventing such misalignment. By providing multiple legs in the area where the first coil and the second coil overlap, the multiple legs are arranged in a position where a strong force is likely to act on the interphase insulating paper, or the multiple legs are formed so that their cross-sectional shape is V-shaped, thereby preventing misalignment. Alternatively, by providing a notch at the upper end of the folded part of the sheet-like insulating part formed to make it easier to arrange it between the first coil and the second coil, it is possible to prevent a coil to be inserted later from getting caught on the upper end and wrapping the interphase insulating paper.

[0014] As described above, conventional methods have the drawback of being inefficient, requiring the installation of multiple pieces of interphase insulating paper, and even the technology disclosed as a method for preventing the interphase insulating paper from easily shifting requires additional processing of the interphase insulating paper, resulting in problems of increased processing man-hours.

[0015] Therefore, the present invention provides an interphase insulating paper having a structure as simple as possible, which simplifies the installation work on the stator core, improves the ease of inserting each phase coil, and reliably solves problems such as misalignment and winding of the interphase insulating paper, as well as a stator equipped with said interphase insulating paper, and an electric motor equipped with said stator. [Means for solving the problem]

[0016] The invention described in claim 1 is an interphase insulating member arranged between stator coils of different phases, the interphase insulating member comprising a pair of strip-shaped portions located between the coil end portions of the stator coils protruding from both axial end faces of the stator core, the strip-shaped portions being connected by a plurality of legs located in slots of the stator core, and the strip-shaped portions of the interphase insulating member having wavy folds formed therein before being attached between the stator coils, when viewed from the axial direction when the interphase insulating member is attached to the stator core.

[0017] The invention as set forth in claim 2 is the interphase insulating member as set forth in claim 1, characterized in that the band-shaped portion is deformed into a substantially hollow cylindrical shape by forming folds in the band-shaped portion.

[0018] The invention described in claim 3 is characterized in that the band-shaped portion of the interphase insulation member described in claim 1 has wavy folds formed in the band-shaped portion when viewed in the axial direction when attached to the stator core, and a curved portion is formed toward the radially outer periphery when viewed in the axial direction.

[0019] The invention as recited in claim 4 is characterized in that in the band-shaped portion of the interphase insulation member as recited in claim 2, folds are formed in a wave shape when viewed from the axial direction when attached to the stator core, and a curved portion is formed toward the radially outer periphery when viewed from the axial direction.

[0020] The invention described in claim 5 is a stator comprising a yoke extending circumferentially and a stator core consisting of a plurality of teeth extending radially inward from the yoke, with a stator coil inserted into a slot consisting of the plurality of teeth, characterized in that an interphase insulating member described in claims 1 to 4 is arranged between different phases between the stator coils.

[0021] The invention as set forth in claim 6 is characterized in that it is an electric motor including the stator as set forth in claim 5, and a rotor that is disposed relative to the stator and rotatably supported. Effect of the Invention

[0022] According to the invention described in claim 1, it is only necessary to attach a single interphase insulating member to the stator, improving workability. Also, since there is only a single interphase insulating member, it is less likely to become misaligned or entangled compared to when multiple small interphase insulating members are arranged.

[0023] Furthermore, since the band-shaped portion of the interphase insulation material has wavy folds formed when viewed from a radial cross section before being installed between the stator coils, shaping of the interphase insulation material (adjusting the dimensions of the waveform, etc.) is easier than in the case where the interphase insulation material is deformed into a wave shape after being installed between the stator coils.

[0024] According to the invention described in claim 2, by forming a corrugated fold in the interphase insulating material, the interphase insulating material can be deformed into a substantially hollow cylindrical shape, thereby making it possible to efficiently attach the interphase insulating material to the stator core.

[0025] According to the invention described in claims 3 and 4, the interphase insulating member is formed with a curved portion toward the radially outer periphery when viewed from the axial direction when attached to the stator core. Therefore, when inserting the stator coil into the stator core, the interphase insulating member does not get in the way, and it is possible to reliably prevent the interphase insulating member from shifting or becoming wrapped up.

[0026] According to the invention as recited in claim 5, a stator can be manufactured in which the interphase insulating member is free from misalignment or winding, and the quality of the stator can be ensured.

[0027] According to the invention as recited in claim 6, it is possible to manufacture a motor having a stator without misalignment or winding of the interphase insulating member, thereby ensuring the quality of the motor. [Brief description of the drawings]

[0028] [Figure 1] FIG. 2 is a perspective view showing a stator of the present invention. [Diagram 2] FIG. 2 is a plan view showing a stator of the present invention. [Diagram 3] FIG. 2 is a development view of the interphase insulating member of the present invention. [Figure 4] FIG. 2 is a perspective view showing an interphase insulating member of the present invention. [Diagram 5] FIG. 2 is a perspective view showing a state in which one phase of a stator coil is inserted into the stator of the present invention. [Figure 6] 2 is a perspective view showing a state in which one phase of a stator coil and a middle / outer layer interphase insulating member are attached to the stator of the present invention. FIG. [Figure 7] 2 is a plan view showing a state in which one phase of a stator coil and a middle-to-outer layer interphase insulating member are attached to the stator of the present invention. FIG. [Figure 8] FIG. 2 is a perspective view showing a state in which two phases of stator coils and intermediate / outer layer interphase insulating members are attached to the stator of the present invention. [Figure 9] FIG. 2 is a perspective view showing a state in which two phases of stator coils, a middle-to-outer layer interphase insulating member, and an inner-middle layer interphase insulating member are attached to the stator of the present invention. [Figure 10] 2 is a plan view showing a state in which two phases of stator coils, middle-to-outer layer interphase insulating members, and inner-middle layer interphase insulating members are attached to the stator of the present invention. FIG. [Figure 11] FIG. 2 is a perspective view showing a state in which three phases of stator coils, middle-to-outer layer interphase insulating members, and inner-middle layer interphase insulating members are attached to the stator of the present invention. [Figure 12]2 is a plan view showing a state in which three phases of stator coils, middle-to-outer layer interphase insulating members, and inner-middle layer interphase insulating members are attached to the stator of the present invention. FIG. [Figure 13] FIG. 11 is a perspective view showing a comparative example of the present invention, illustrating a stage prior to mounting a substantially cylindrical interphase insulating member to a stator core. [Figure 14] FIG. 13 is a development view of an interphase insulating member having a substantially cylindrical shape as a comparative example of the present invention. [Figure 15] FIG. 11 is a perspective view showing a state in which a substantially cylindrical interphase insulating member is attached to a stator core as a comparative example of the present invention. [Figure 16] FIG. 11 is a perspective view showing a state in which a band-shaped portion of a substantially cylindrical interphase insulating member attached to a stator core is deformed into a corrugated shape, as a comparative example of the present invention. [Figure 17] 4 is an enlarged plan view of a main portion of the interphase insulating member, showing a state in which a strip-shaped portion of the interphase insulating member has been deformed into a corrugated shape by mechanical forming. FIG. [Figure 18] FIG. 13 is an enlarged plan view of a main portion showing a state in which a band-shaped portion has been deformed into a wavy shape by utilizing folds according to the present invention. [Figure 19] 1 is a vertical cross-sectional view showing an example of an electric motor of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In this specification, the term "axial direction" refers to the extension direction of the rotation center line P of the rotor 900 shown in Fig. 19 in a state in which the rotor 900 is arranged rotatably relative to the stator 100 shown in Figs. 1, 2, and 19. In addition, the term "circumferential direction" refers to the circumferential direction centered on the rotation center line P when viewed in a cross section perpendicular to the axial direction in a state in which the rotor 900 is arranged rotatably relative to the stator 100.

[0030] The term "radial direction" refers to the direction from the rotation center line P of the rotor 900 to the opposite side of the rotation center line P (stator outer diameter) when viewed in a cross section perpendicular to the axial direction when the rotor 900 is arranged to be rotatable relative to the stator 100, or the direction from the opposite side of the rotation center line P (stator outer diameter) of the rotor 900 to the rotation center line P. The term "radial inner side" refers to the side of the rotation center line P, and the term "radial outer side" refers to the opposite side of the rotation center line P.

[0031] Furthermore, when the terms "axial direction," "circumferential direction," "radial direction," "radial inner side," and "radial outer side" are used with respect to an interphase insulating member, these refer to the same directions as the "axial direction," "circumferential direction," "radial direction," "radial inner side," and "radial outer side" when the interphase insulating member is attached to the stator core.

[0032] Fig. 1 is a perspective view showing a stator 100 constituting an electric motor of the present invention, and Fig. 2 is a plan view of the stator 100. The stator 100 is generally composed of a stator core 200 formed by laminating electromagnetic steel sheets, a stator coil 300 wound around the stator core 200, a slot insulating member 400, and an interphase insulating member 500 shown in Fig. 2.

[0033] As shown in FIG. 2, the stator core 200 has a yoke 210 extending in the circumferential direction and a plurality of teeth 220 extending in the radial direction when viewed from one side in the axial direction.

[0034] The teeth 220 have teeth bases 221 extending radially inward from the yoke 210, and teeth tips 222 provided on the radially inner side of the teeth bases 221 and extending circumferentially. A rotor insertion hole 200a into which a rotor (not shown) is inserted is formed by teeth tip surfaces 222a on the radially inner side of the teeth tip parts 222. The electric motor of the present invention is configured, for example, with a rotor 900 inserted into the rotor insertion hole 200a of the stator 100 shown in Figures 1 and 2 as shown in Figure 19, and rotatably supported by bearings 920 attached to a bracket 910 around a rotation center line P.

[0035] A slot 231 is formed by circumferentially adjacent teeth 220, and a stator coil 300 is inserted into the slot 231 via a slot insulating member 400. The stator coil 300 has a multi-phase (for example, three-phase) coil inserted into the slot 231 in a distributed winding manner.

[0036] Interphase insulating members 500 are two insulating papers arranged between different phase coils of multi-phase (three-phase) stator coils 301, 302, 303, and in Fig. 2, middle-outer layer interphase insulating member 500A is arranged on the radially outer peripheral side, and inner-middle layer interphase insulating member 500B is arranged on the radially inner peripheral side. Note that in Fig. 2, to simplify the explanation of the structure of stator 100, both interphase insulating members 500A, 500B are shown as perfect circles, but in reality, they are arranged in an intertwined state between each of coils 301, 302, 303 shown in Fig. 1.

[0037] 3 shows a development view of interphase insulating member 500 (500A, 500B). Interphase insulating member 500 of the present invention is made of a material with excellent electrical insulation properties (for example, an insulating sheet made of an engineering plastic film such as PET, PEN, PPS, Nomex, or a composite material thereof), and a single insulating sheet is subjected to, for example, a punching process to form multiple tooth insertion holes 510 spaced apart in the longitudinal direction of the insulating sheet.

[0038] A leg portion 520 is formed between each of the adjacent tooth insertion holes 510, and a pair of strip-shaped portions 530, 540 remain at both ends of the insulating sheet in the short direction. At least one of the pair of strip-shaped portions 530, 540 is formed with a recess 550 consisting of a pair of inclined portions 550a, 550b and a bottom portion 550c connecting the pair of inclined portions 550a, 550b. The strip-shaped portion 530 can have portions with and without the recess 550 alternately arranged. However, the recesses 550 can be arranged not only alternately, but also continuously, or the portions with continuous and alternating arrangement can be freely set. In FIG. 3, the recess 550 is formed in the strip-shaped portion 530, but the recess 550 may be formed in the strip-shaped portion 540 or in both the strip-shaped portions 530 and 540.

[0039] In FIG. 3, first fold 560 is folded from leg portion 520 toward strip portions 530 and 540 in a valley fold with a width equal to (or almost equal to) the width dimension of leg portion 520, and the narrow portion sandwiched between first fold 560 is called first portion 580.

[0040] Further, second folds 570 are provided in two mountain folds on the sides of band-shaped portions 530 and 540 facing each other across tooth insertion hole 510, forming a pair of folds. The portion sandwiched between the pair of second folds 570 is called second portion 590, and the portion sandwiched between first portion 580 and second portion 590 is called third portion 600.

[0041] The first fold 560 and the second fold 570 are folded so that the first portion 580 of the strip portion 530 is positioned at the innermost side of the paper and the second portion 590 is positioned at the frontmost side of the paper, and a third portion 600 connects the first portion 580 and the second portion 590.

[0042] 3 can be deformed into the generally hollow cylindrical shape shown in Fig. 4 without the application of force by an operator by forming first fold 560 and second fold 570 in band-shaped portion 530. Note that Fig. 4 shows a case in which recesses 550 are not formed in either of band-shaped portions 530, 540 of interphase insulating member 500.

[0043] By deforming interphase insulating member 500 into a generally hollow cylindrical shape, band-like portions 530, 540 are curved in a wave shape when viewed from the axial direction, with first portion 580 forming the outermost edge of the wave and second portion 590 forming the innermost edge of the wave. In the state where it is deformed into a generally hollow cylindrical shape, both longitudinal ends of interphase insulating member (insulating sheet) 500 made of a single sheet as shown in Fig. 3 can maintain the generally hollow cylindrical shape as shown in Fig. 4 without being joined. In this way, the step of joining both longitudinal ends of interphase insulating member 500 of the present invention can be omitted, but joining them is also acceptable.

[0044] Next, a case where the interphase insulating member 500 of the present invention is attached to the stator core 200 will be described. First, the slot insulating member 400 is placed in the slot 231 of the stator core 200 as shown in Fig. 2. At this time, the slot insulating member 400 has folded parts 400a at both ends in the axial direction as shown in Fig. 5, which protrude outward from the axial end faces 200A, 200B of the stator core 200.

[0045] Next, the first phase coil 301 is inserted into the slot 231 via the slot insulating member 400. The first phase coil 301 is wound with annular coils connected in series, and is inserted so as to straddle a plurality of teeth 220 (three in FIG. 5). The coil 301 is inserted into the slot 231 by a winding insertion machine (not shown), and five coils are wound in a distributed manner at 72 degree intervals in the circumferential direction of the stator core 200. When the coil 301 is inserted, the folded portion 400a of the slot insulating member 400 abuts against the end face 200A of the stator core 200, preventing the slot insulating member 400 from shifting position. In other words, the folded portion 400a of the slot insulating member 400 functions as a stopper.

[0046] When first-phase coil 301 is inserted, the coil sides of first-phase coil 301 are housed in slots 231, and the coil end portions protrude outward from axial end faces 200A, 200B of stator core 200. The protruding coil end portions are pressed outwardly in the radial direction by mechanical forming. Pressing outwardly in the radial direction is performed commonly on both coil end portions protruding from both end faces 200A, 200B of stator core 200 shown in FIG.

[0047] Next, the middle / outer layer interphase insulating member 500A in the state shown in Fig. 4 is attached to the stator core 200. To attach the middle / outer layer interphase insulating member 500A to the stator core 200, the middle / outer layer interphase insulating member 500A formed in a substantially hollow cylindrical shape shown in Fig. 4 is inserted into the rotor insertion hole 200a along the axial direction of the stator core 200 with its diameter reduced toward the radially inner periphery.

[0048] Next, by releasing the diameter-reduced state of middle / outer layer interphase insulating member 500A in rotor insertion hole 200a, leg 520 of middle / outer layer interphase insulating member 500A is fitted from the radially inner side into slots 231 in which no coil side of first phase coil 301 is accommodated. In the case of Fig. 6, leg 520 is fitted into slot 231 that is adjacent in the circumferential clockwise direction to slot 231 into which the coil side of first phase coil 301 is inserted. That is, leg 520 of middle / outer layer interphase insulating member 500A is also inserted so as to straddle multiple teeth 220 (three in Fig. 5).

[0049] When inner-outer layer interphase insulating member 500A is attached to stator core 200, strip-shaped portions 530, 540 of inner-outer layer interphase insulating member 500A protrude from both end faces 200A, 200B of stator core 200. First portions 580 of strip-shaped portions 530, 540 are arranged at alternate circumferential positions so as to be spread out radially toward the outer periphery of first phase coil 301, and second portions 590 are arranged at positions so as not to be spread out.

[0050] Fig. 7 is a plan view showing this arrangement. As shown in Fig. 7, the strip portion 530 (540) of the inner / outer layer interphase insulating member 500A is arranged at a position where the first portion 580 is spread out toward the radial outer periphery of the first phase coil 301 and on the end surface 200A of the stator core 200 where no first phase coil 301 is present between adjacent first phase coils 301. The second portion 590 of the strip portion 530 (540) is always arranged at a position where it is not spread out toward the radial outer periphery of the first phase coil 301, and the third portion 600 connects the first portion 580 and the second portion 590.

[0051] After the first phase coil 301 and the middle-to-outer layer interphase insulating member 500A are attached to the stator core 200, the second phase coil 302 is then inserted into the slot 231 of the stator core 200. Like the first phase coil 301, the second phase coil 302 is also wound with annular coils connected in series, and is inserted so as to straddle multiple (three in FIG. 8 ) teeth 220.

[0052] At this time, the second phase coil 302 is inserted in a distributed winding manner into the slots 231 of the stator core 200 in which the first portions 580 of the middle-to-outer layer interphase insulation members 500A are disposed. Even when the second phase coil 302 is inserted, the folded portion 400a of the slot insulation member 400 abuts against the end face 200A of the stator core 200, thereby preventing the slot insulation member 400 from shifting position.

[0053] As shown in Fig. 8, the second phase coil 302 inserted into the stator core 200 has its coil sides housed in the slots 231 and its coil end portions protruding outward from the axial end faces 200A, 200B of the stator core 200. The protruding coil end portions are spread radially outward by mechanical forming, similar to the first phase coil 301. At this time, if the middle-outer layer interphase insulating member 500A interposed between the first phase coil 301 and the second phase coil 302 has the recesses 550 shown in Fig. 3 formed therein, even if the middle-outer layer interphase insulating member 500A is spread radially outward by the coil end portions of the second phase coil 302 spread radially outward, the middle-outer layer interphase insulating member 500A can be prevented from protruding radially outward and in the axial direction from the coil end portions.

[0054] 4 is attached to the stator core 200. When attaching the intermediate-inner interlayer interphase insulating member 500B to the stator core 200, the intermediate-inner interlayer interphase insulating member 500B is once reduced in diameter toward the radially inner side, and then inserted into the rotor insertion hole 200a along the axial direction of the stator core 200.

[0055] When intermediate inner layer interphase insulating member 500B, which is in a diameter-reduced state inserted into rotor insertion hole 200a, is released from the diameter-reduced state, leg portions 520 of intermediate inner layer interphase insulating member 500B are fitted from the radially inner side into slots 231 which do not house the coil sides of first phase coil 301 and second phase coil 302. In the case of Fig. 9, leg portions 520 are fitted into slots 231 which are adjacent in the circumferential clockwise direction to the slot 231 into which the coil side of second phase coil 302 is inserted.

[0056] When the intermediate inner layer interphase insulating member 500B is attached to the stator core 200 together with the first phase coil 301 and the second phase coil 302, the strip-shaped portions 530, 540 of the intermediate inner layer interphase insulating member 500B protrude from both end faces 200A, 200B of the stator core 200. As shown in Fig. 10, the strip-shaped portions 530, 540 are alternately arranged at a position where the first portion 580 is spread out toward the radial outer periphery of the first phase coil 301 and a position where the first portion 580 is spread out toward the radial outer periphery of the second phase coil 302, and the second portion 590 is arranged at a position where the first portion 580 is not spread out toward the radial outer periphery of the first phase coil 301 and the second phase coil 302. The third portion 600 connects the first portion 580 and the second portion 590.

[0057] 7, after first phase coil 301, second phase coil 302 and middle inner inter-layer interphase insulation member 500B are attached to stator core 200, third phase coil 303 is then inserted into slot 231 of stator core 200. Similar to first phase coil 301 and second phase coil 302, third phase coil 303 is also wound with annular coils connected in series, and is inserted by a winding insertion machine (not shown) so as to straddle multiple (three in FIG. 8) teeth 220.

[0058] The third phase coil 303 is inserted in a distributed winding manner into the slots 231 of the stator core 200 in which the first portions 580 of the middle inner layer interphase insulation members 500B are disposed. Even when the third phase coil 302 is inserted, the folded portion 400a of the slot insulation member 400 abuts against the end face 200A of the stator core 200, preventing the slot insulation member 400 from shifting position.

[0059] As shown in Fig. 11, the third-phase coil 303 inserted into the stator core 200 has its coil sides housed in the slots 231 and its coil end portions protruding outward from the axial end faces 200A and 200B of the stator core 200. However, when only the first to third phase coils are inserted, it is not necessary to consider the insertability of the next phase coil, and therefore, unlike the first-phase coil 301 and the second-phase coil 302, it is not necessary to push the protruding coil end portions outward in the radial direction. In other words, the coil end portions of the third-phase coil 303 protrude in an upright state from both end faces 200A and 200B of the stator core 200. Since it is not necessary to push the coil end portions of the third-phase coil 303 outward in the radial direction, it is not necessary to form the recess 550 shown in Fig. 3 in the middle-inner interlayer interphase insulating member 500B. This is because recesses 550 are formed in order to prevent the interphase insulating material from protruding outward in the radial direction and in the axial direction when the coil end portions are expanded radially outward.

[0060] Fig. 12 is a plan view showing a state in which first to third phase coils 301, 302, and 303 are attached to stator core 200. As shown in Fig. 12, central inner layer interphase insulating member 500B is interposed between first phase coil 301, second phase coil 302, and third phase coil 303 to insulate them from each other. A first portion 580 of central inner layer interphase insulating member 500B is located in slot 231 into which third phase coil 303 is inserted, and a second portion 590 is located between first phase coil 301 and second phase coil 302 and at a position not pushed out toward the radially outer periphery of first phase coil 301 and second phase coil 302.

[0061] In this manner, interphase insulating members 500A, 500B of the present invention are attached to stator core 200 together with stator coils 300 (301-303), thereby forming stator 100 as shown in Fig. 12. At this time, since interphase insulating members 500A, 500B have band-shaped portions 530, 540 formed in a wave shape when viewed in the axial direction, interphase insulating members 500A, 500B do not get in the way and impede insertion when stator coil 300 is inserted into slots 231 of stator core 200, improving workability.

[0062] 12, the coil end portions of the stator coils 300 (301, 302, 303) are formed by mechanical forming so that the axial and radial dimensions are minimized. After mechanical forming, the outer periphery of the stator coils 300 (301, 302, 303) is bound with binding strings.

[0063] Fig. 13 is a perspective view of interphase insulating member 700 (700A, 700B) shown as a comparative example of interphase insulating member 500 (500A, 500B) of the present invention. Interphase insulating member 700 shown in Fig. 13 has a plurality of teeth insertion holes 710 spaced apart in the circumferential direction formed in the side of an insulating sheet formed into a substantially hollow cylindrical shape. Interphase insulating member 700 is formed by joining both longitudinal ends of a single insulating sheet in which a plurality of teeth insertion holes 710 are formed by punching or the like, as shown in Fig. 14.

[0064] By forming a plurality of tooth insertion holes 710 in the insulating sheet, leg portions 720 are formed between the tooth insertion holes 710, and a pair of band-shaped portions 730, 740 are formed at both ends of the insulating sheet in the short direction. A recess 750 consisting of a pair of inclined portions 750a, 750b and a bottom portion 750c connecting the inclined portions 750a, 750b can be formed in the band-shaped portions 730, 740. When the recess 750 is formed, portions of the band-shaped portions 730, 740 where the recess 750 is formed and portions where the recess 750 is not formed can be arranged alternately in the longitudinal direction.

[0065] When the insulating sheet shown in Fig. 14 is formed into interphase insulating member 700 having a hollow cylindrical shape as shown in Fig. 13, unlike interphase insulating member 500 shown in Fig. 3, first fold 560 and second fold 570 are not formed, so that interphase insulating member 700 shown in Fig. 14 does not deform into a hollow cylindrical shape, and it is necessary for an operator to apply force to form a hollow cylindrical shape and join both longitudinal ends to maintain the hollow cylindrical shape shown in Fig. 13. Note that Fig. 13 shows interphase insulating member 700 in which recesses 750 are not formed in band-shaped portions 730, 740 of the insulating sheet shown in Fig. 14.

[0066] Middle-outer layer interphase insulating member 700A formed in a generally hollow cylindrical shape is attached to stator core 200 shown in Fig. 13. Prior to attachment of middle-outer layer interphase insulating member 700A, first phase coil 301 of stator coil 300 is inserted into slot 231 in stator core 200. The method of insertion and the radial expansion of first phase coil 301 outwardly are the same as those described with reference to Fig. 5, and therefore will not be described here.

[0067] 13 is attached to stator core 200, middle-outer layer interphase insulating member 700A having a substantially hollow cylindrical shape is reduced in diameter in the radial direction, and in this state is inserted into rotor insertion hole 200a of stator core 200, and then the reduced diameter state is released. As a result, leg 720 of middle-outer layer interphase insulating member 700A is fitted into slot 231 of stator core 200 from the radially inner periphery side.

[0068] Fig. 15 shows the state in which medium-outer layer interphase insulating member 700A is attached to stator core 200. Medium-outer layer interphase insulating member 700A is attached to stator core 200 with strip-shaped portions 730, 740 protruding in the axial direction from both axial end faces 200A, 200B of stator core 200. Next, second-phase coil 302 is to be inserted into stator core 200, but in the state shown in Fig. 15, when second-phase coil 302 is to be inserted into slot 231 of stator core 200, it interferes with medium-outer layer interphase insulating member 700A and cannot be inserted.

[0069] Therefore, it is necessary to curve a portion of strip-shaped portion 730 of middle-outer layer interphase insulation member 700A attached to stator core 200 toward the outer periphery in the radial direction so as to enable insertion of second phase coil 302, as shown in Fig. 16. One example of how such a curved shape can be achieved is to mechanically form the interphase insulation at the same time as the coil, but with mechanical forming alone, it is difficult to adjust the degree of forming, and there is a possibility that strip-shaped portion 730 of middle-outer layer interphase insulation member 700A will protrude toward the inner diameter side of stator core 200 (the rotor insertion hole 200a side), as shown in Fig. 17.

[0070] If the middle-outer layer interphase insulation material 700A protrudes toward the rotor insertion hole 200a, when inserting the second phase coil 302 into the stator core 200 in the state shown in Figure 16, it will interfere with the component jig (not shown) of the winding insertion machine used for the insertion work, causing an interruption to the insertion work.

[0071] On the other hand, according to interphase insulating member 500 (500A, 500B) of the present invention, as shown in FIG. 3, the degree of curvature of interphase insulating member 500 having the shape shown in FIG. 4 can be easily adjusted by adjusting the positions of first fold 560 and second fold 570 in the insulating sheet and the strength of the folds, so that when attached to stator core 200, it is possible to reliably prevent strip portion 530 of interphase insulating member 500 from protruding toward the inner diameter side of stator core 200 (rotor insertion hole 200a side) as shown in FIG. 18.

[0072] As a result, even when second phase coil 302 is inserted into stator core 200, there is no interference between interphase insulating member 500 and a jig constituting a winding insertion machine, and the insertion operation can be carried out reliably.

[0073] As described above, according to the interphase insulating member of the present invention, a single interphase insulating member made of one insulating sheet only needs to be attached to the stator, which improves the ease of installation compared to the conventional example in which multiple interphase insulating members are attached. In addition, a single interphase insulating member has the advantage that it is less likely to become misaligned or wrapped around when the stator coil is inserted into the stator core.

[0074] Furthermore, since the interphase insulating material is shaped into a wave shape when viewed from the axial direction before being installed between the stator coils, the interphase insulating material can be easily adjusted and shaped to the desired dimensions and shape compared to a case in which the interphase insulating material is deformed into a wave shape after being installed between the stator coils, the band-shaped portion is prevented from protruding toward the rotor insertion hole, and there is no hindrance to the stator coil insertion work.

[0075] Furthermore, by forming the interphase insulating member by folding the band-shaped portion of a single insulating sheet, the interphase insulating member can be deformed into an approximately hollow cylindrical shape without the worker having to apply force, eliminating the need to join both longitudinal ends of the single insulating sheet and reducing the burden of the molding work.

[0076] Furthermore, when viewed from the axial direction, the interphase insulating member has a curved portion formed toward the radially outer periphery. This reliably prevents the stator coil from coming into contact with the interphase insulating member when inserting the stator coil into the stator core, thereby reliably preventing the interphase insulating member from shifting or becoming wrapped up.

[0077] Furthermore, a stator and an electric motor equipped with the above-mentioned interphase insulating member are free from misalignment and winding of the interphase insulating member, and the product quality can be maintained at a good level. [Industrial Applicability]

[0078] It can be used with stators having coils of different phases. [Explanation of symbols]

[0079] 100 stator 200 stator core 200A, 200B Stator core end face 200a Rotor insertion hole 210 York 220 Teeth 221 Teeth base 222 Teeth tip 222a Teeth tip surface 231 Slots 300 Stator Coil 301 1st phase coil 302 Second phase coil 303 3rd phase coil 400 In-slot insulation material 400a Folded part 500,700 Interphase insulation material 500A Interphase insulation material between inner and outer layers 500B Inner layer interphase insulation material 510,710 Teeth insertion hole 520,720 Legs 530,540,730,740 Strip 550,750 Recess 550a,550b, 750a,750b Slope 550c,750c bottom 560 First Fold 570 Second Fold 580 Part 1 590 Part 2 600 3rd part 800 Wedge 900 Rotor 910 Bracket 920 Bearing

Claims

1. An interphase insulating member disposed between stator coils of different phases, the interphase insulating member including a pair of strip-shaped portions located between coil ends of the stator coils protruding from both axial end faces of a stator core, and a plurality of legs connecting the strip-shaped portions with each other and located within slots of the stator core, An interphase insulating member, characterized in that, before being attached between stator coils, the band-shaped portion of the interphase insulating member has wavy folds formed therein when viewed in the axial direction with the interphase insulating member attached to a stator core.

2. 2. The interphase insulating member according to claim 1, wherein the band-shaped portion of the interphase insulating member is deformed into a substantially hollow cylindrical shape by forming the folds.

3. 2. The interphase insulating member according to claim 1, wherein the band-shaped portion has wavy folds when viewed from the axial direction when attached to the stator core, and a curved portion is formed toward the radially outer periphery when viewed from the axial direction.

4. 3. The interphase insulating member according to claim 2, characterized in that the band-shaped portion has wavy folds when viewed from the axial direction when attached to the stator core, and a curved portion is formed toward the radially outer periphery when viewed from the axial direction.

5. A stator comprising a yoke extending in a circumferential direction and a stator core consisting of a plurality of teeth extending radially inward from the yoke, a stator coil being mounted in a slot consisting of the plurality of teeth, and an interphase insulating member according to any one of claims 1 to 4 being disposed between different phases between the stator coils.

6. 6. An electric motor comprising: a stator according to claim 5; and a rotor disposed relatively to the stator and rotatably supported thereon.

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