Stator core, stator and electric motor

Abstract

To provide technology which can raise rigidity of an annular stator core and suppress occurrence of vibration and noise while reducing operation man hour of the stator core.SOLUTION: A connecting core is constituted of a plurality of connecting core members. The adjacent connecting core members are connected with each other by a connecting part. A first end connecting core member located on one end is provided with a fitting recess and a second end connecting core member located on the other end is provided with a fitting projection formed with a first pin insertion hole among the plurality of connecting core members. The connecting core is annularly molded to form a stator core by fitting the fitting projection into the fitting recess. The stator core is constituted by laminating the first end connecting core member and the second end connecting core member in an axial direction, and the position of the first pin insertion hole coincides. Rigidity of the stator core is raised by press-fitting and fixing a pin into the first pin insertion hole.SELECTED DRAWING: Figure 11

Description

Technical Field

[0001] The present invention relates to a stator core having a characteristic shape of laminated electromagnetic steel sheets, a stator including the stator core, and an electric motor.

Background Art

[0002] An electric motor (hereinafter referred to as a "concentrated winding motor") including a stator and a rotor, in which a stator winding is wound around a tooth portion of a stator core constituting the stator in a concentrated winding method, is used for various applications. In a concentrated winding motor, the stator winding is wound around the tooth portion via an insulator (hereinafter referred to as an "electrical insulator assembly") attached to the stator core.

[0003] When winding the stator winding around the tooth portion, in order to increase the number of turns of the stator winding and increase the fill factor of the stator winding, a motor using a stator core (hereinafter referred to as a "stator core with a connecting structure") employing a so-called connecting core has been proposed (see Patent Document 1 below).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

[0005] Patent Document 1 discloses a conventionally existing stator core with a connecting structure (hereinafter referred to as a "conventional stator core") as a premise of the invention presented in that document. The conventional stator core is a type of stator in which a continuous strip-shaped core formed by connecting a plurality of connecting cores by a connecting portion is bent into a ring shape, and is bent into a ring shape only by joining both ends of the strip-shaped core within a range of 360° for one turn.

[0006] Patent Document 1 points out the following problems: excessive force acts on a connection part of a part of the conventional stator core, resulting in deterioration of roundness and vibration caused by a radial exciting force corresponding to the number of magnetic poles of the magnet; also, since the ends are joined at one location within one circumference, the rigidity is low with respect to the second and fourth annular vibration modes, and problems of vibration and noise generation are pointed out.

[0007] In contrast, in the invention disclosed in Patent Document 1, by forming an annular shape by joining a plurality (for example, three) of connecting cores, which are segments, after each connecting core is bent into an arc shape, it is possible to improve roundness. As a result, it is possible to reduce vibration and noise caused by a radial exciting force corresponding to the number of magnetic poles of the magnet.

[0008] Also, by setting the number of the segments to an odd number (for example, three), the connection parts of the segments do not face each other through the center of the circle, so it is possible to increase the rigidity with respect to the second and fourth annular vibration modes. As a result, it is described that vibration and noise can be reduced.

[0009] Note that both the conventional stator core described in Patent Document 1 and the stator core of the connection structure disclosed as an invention are formed by stacking a plurality of steel sheets formed by punching electromagnetic steel sheets, and pieces having a substantially T-shaped planar shape are connected via connection parts in the same manner. Teeth are formed on each piece, and an end portion facing the rotor, which becomes the radial direction when bent into an annular shape, is a magnetic pole portion.

[0010] Also, the stator core of the connection structure disclosed as an invention is formed by a plurality (for example, four) of pieces to form a connecting core, which is one segment, and after bending a plurality (for example, three) of segments into arc shapes respectively, they are joined together to form an annular stator core.

Summary of the Invention

Problems to be Solved by the Invention

[0011] However, as described in Patent Document 1, in the conventional stator core, excessive force acts on some connecting portions, resulting in deterioration of roundness and vibration due to the radial exciting force corresponding to the number of magnetic poles of the magnet. Further, the stator core having the connecting structure disclosed as an invention in Patent Document 1 can reduce vibration and noise caused by the radial exciting force corresponding to the number of magnetic poles of the magnet by improving the roundness. However, after bending the connecting cores, which are a plurality of segments, into an arc shape, it is necessary to form them into a ring shape by combining the respective connecting cores. Therefore, a plurality of operations are required to form the annular stator core, and there is a problem that the number of man-hours increases compared to a stator formed by bending a conventional stator core (a continuous belt-shaped core) into a ring shape.

[0012] The present invention has been devised in view of the above problems, and an object thereof is to provide a technology capable of reducing the number of man-hours for an annular stator core, increasing the rigidity of the stator core, and suppressing the generation of vibration and noise.

Means for Solving the Problems

[0013] A first invention is a stator core formed by bending a laminate formed by laminating a plurality of connecting cores connected by connecting portions into a ring shape, including a plurality of connecting yoke portions arranged in the circumferential direction, a teeth base portion extending radially inward from the connecting yoke portion, and a teeth portion including teeth tooth portions extending in the circumferential direction at the open side tip end portion of the teeth base portion. Among the plurality of connecting yoke portions, a fitting concave portion is provided at the open end portion of the first end connecting yoke portion located at one end portion, and a fitting convex portion having a first pin insertion hole formed therein is provided at the open end portion of the second end connecting yoke portion located at the other end portion. By fitting the fitting convex portion and the fitting concave portion, the laminate is formed into a ring shape, and by laminating the first end connecting yoke portion and the second end connecting yoke portion along the axial direction, the positions of the first pin insertion holes are aligned. The stator core is characterized by this.

[0014] The second invention is characterized in that a second or fourth or sixth pin insertion hole is formed in the connecting yoke portion described in the first invention, and the connecting cores are laminated so that the positions of the second or fourth or sixth pin insertion holes coincide with each other to form a stator core.

[0015] The third invention is characterized in that a third or fifth or seventh pin insertion hole is formed in the tooth portion described in the first invention, and the connecting cores are laminated so that the positions of the third or fifth or seventh pin insertion holes coincide with each other to form a stator core.

[0016] The fourth invention is a stator comprising a stator core, an electrical insulator assembly, and a stator winding, characterized in that the stator core described in any one of the first invention to the third invention is provided as the stator.

[0017] The fifth invention is an electric motor comprising a stator and a rotor, characterized in that the stator described in the fourth invention is used as the stator.

Advantages of the Invention

[0018] According to the first invention, by bending a laminate formed by laminating a continuous strip-shaped connecting core into a ring shape, an annular stator core can be formed by a single operation of joining both ends of the laminate, so that the man-hours for manufacturing the stator core can be reduced. Further, the fitting concave portion of the first end connecting yoke portion formed at one end of the strip-shaped connecting core forming the laminate and the fitting convex portion of the second end connecting yoke portion formed at the other end of the strip-shaped connecting core are fitted, and while alternately laminating the first end connecting yoke portion and the second end connecting yoke portion in the axial direction (thickness direction), by aligning the positions of the first pin insertion holes formed in the second end connecting portion, a pin can be press-fitted and fixed into the first pin insertion holes, and the rigidity of the annularly formed stator core can be increased.

[0019] According to the second invention, a second or fourth or sixth pin insertion hole is formed in the connecting yoke portion of the connecting core, and the connecting cores are laminated in the axial direction (thickness direction) so that the positions of the second or fourth or sixth pin insertion holes coincide with each other. Thus, a pin can be press-fitted and fixed into the second or fourth or sixth pin insertion hole, and the rigidity of the stator core can be further increased.

[0020] According to the third invention, a third or fifth or seventh pin insertion hole is formed in the teeth portion of the connecting core, and the connecting cores are laminated in the axial direction (thickness direction) so that the positions of the third or fifth or seventh pin insertion holes coincide with each other. Thus, a pin can be press-fitted and fixed into the third or fifth or seventh pin insertion hole, and the rigidity of the stator core can be further increased.

[0021] According to the fourth invention, a stator capable of reducing the generation of vibration and noise can be provided by increasing the rigidity.

[0022] According to the fifth invention, a motor capable of obtaining the same effect as the third invention can be provided.

Brief Description of the Drawings

[0023]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Mode for Carrying Out the Invention

[0024] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this specification, the description of "axial direction" indicates the extending direction of the rotation center line P (see FIGS. 1, 11 to 13) of the rotor in a state where the rotor is disposed rotatably relative to the stator. The description of "circumferential direction" indicates the circumferential direction centered on the rotation center line P when viewed in a cross section perpendicular to the axial direction in a state where the rotor is disposed rotatably relative to the stator.

[0025] The description of "radial direction" indicates the direction passing through the rotation center line P when viewed in a cross section perpendicular to the axial direction in a state where the rotor is disposed rotatably relative to the stator. The description of "radial inner circumferential side" indicates the side along the radial direction toward the rotation center line P, and the description of "radial outer circumferential side" indicates the side opposite to the rotation center line P along the radial direction.

[0026] In addition, in this specification, the left side of FIG. 1 and the upper sides of FIGS. 11 and 12 are described as the "one axial direction side", and the right side of FIG. 1 and the lower sides of FIGS. 11 and 12 are described as the "other axial direction side". Also, the clockwise direction in FIGS. 11 and 13 is described as the "one circumferential direction side", and the counterclockwise direction in FIGS. 11 and 13 is described as the "other circumferential direction side".

[0027] Embodiments of the present invention will be described with reference to FIGS. 1 to 14. FIG. 1 is a longitudinal sectional view showing an example of a motor A according to the present invention. As shown in FIG. 1, the motor A according to the present invention is schematically composed of a stator 1 and a rotor 2 rotatably supported within the hollow portion of the stator 1. The stator 1 is composed of a stator core 3 formed by laminating a plurality of electromagnetic steel plates, an electrical insulator assembly 4 attached to both axial end faces of the stator core 3, and a stator winding 5 wound around the stator core 3 via the electrical insulator assembly 4. The electrical insulator assembly 4 is composed of a first electrical insulator assembly 4a installed on the end face on one axial direction side of the stator core 3 and a second electrical insulator assembly 4b installed on the end face on the other axial direction side of the stator core 3.

[0028] The electrical insulator assembly 4 is formed of a resin having insulating properties, for example, polybutylene terephthalate (PBT) resin, polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP) resin, nylon, or the like. The first electrical insulator assembly 4a is composed of an outer wall portion 4a1, an inner wall portion 4a2, and a bottom face portion 4a3. The second electrical insulator assembly 4b is composed of an outer wall portion 4b1, an inner wall portion 4b2, and a bottom face portion 4b3.

[0029] The electrical insulator assembly 4 (4a, 4b) is installed to insulate between the stator winding 5 and the stator core 3. When the electrical insulator assembly 4 (4a, 4b) is installed only on both end faces of the stator core 3 as shown in FIG. 1, in the slots of the stator core 3 described later, in order to insulate between the stator core 3 and the stator winding 5 separately, for example, a slot insulating member made of an insulating film (not shown) is arranged. By winding the stator winding 5 through the slot insulating member, insulation between the stator core 3 and the stator winding 5 can be achieved. Alternatively, by using an electrical insulator assembly having a portion extending in the slot of the stator core 3, the stator winding 5 may be wound around the stator core 3 through the extending portion to insulate between the stator core 3 and the stator winding 5. The stator winding 5 is wound in a concentrated winding manner using the slots of the stator core 3.

[0030] The rotor 2 is composed of a rotor core 6 formed by laminating a plurality of electromagnetic steel plates having a substantially disc shape, and a rotor shaft 7 extending in the axial direction and fixed in a state of passing through the center of the rotor core 6. A permanent magnet 8 that acts with the stator 1 to generate a rotational force is attached to the rotor core 6. In FIG. 1, the rotor 2 with the permanent magnet 8 attached to the surface of the rotor core 6 is shown, but the rotor 2 may be configured such that the permanent magnet is embedded inside the rotor core 6. If the magnet is embedded, the mechanical safety is higher and high-speed rotation becomes possible compared to the case of attaching it to the surface.

[0031] The rotor shaft 7 is rotatably supported by a bearing 11 fixed in a substantially hollow cylindrical first bearing fixing member 10 protruding inside the case 9 at the other axial end face of the case 9, and a bearing 14 fixed in a substantially hollow cylindrical second bearing fixing member 13 protruding inside the bracket 12 at the one axial end face of the bracket 12 screwed to the case 9.

[0032] Case 9 and bracket 12 both have a substantially bottomed hollow cylindrical shape. Case 9 is provided with a flange portion 15 that extends radially outward at its opening. A plurality of hole portions 16 through which fixing members (not shown) for fixing the electric motor A shown in FIG. 1 to a target device (such as a compressor in an indoor unit or an outdoor unit of an air conditioner) using the electric motor A are formed along the circumferential direction of the flange portion 15.

[0033] Case 9 and bracket 12 are fixed by screwing a threaded extension portion (not shown) that extends from the flange portion 15 of case 9 to the inner peripheral surface side of bracket 12 and a threaded portion (not shown) formed on the inner peripheral surface of bracket 12. The stator 1 is fixed by fixing the stator core 3 to the inner peripheral surface of case 9.

[0034] On one axial side of the rotor shaft 7, if the electric motor A is used in an air conditioner, for example, a fan (not shown) is attached. When the electric motor A is used as a drive source for the blower fan of the air conditioner, the electric motor A is fixed inside the case of the indoor unit by using the hole portion 16 formed in the flange portion 15 of the bracket 12. When the electric motor A is used for the purpose of cooling the refrigerant of the air conditioner, it is fixed inside the compressor case of the outdoor unit.

[0035] FIG. 2(a) shows a connecting core B1 that forms the stator core 3. The connecting core B1 shown in FIG. 2(a) is formed by punching an electromagnetic steel sheet such as a silicon steel sheet with a press (forging machine) or the like (not shown). The formed connecting core B1 is composed of a plurality (12 in FIG. 2(a)) of connecting core members, and includes a first end connecting core member 17 located at the left end shown in FIG. 2(a), a second end connecting core member 18 located at the right end, and a first intermediate connecting core member 19 located between the two.

[0036] The connecting core B1 shown in Fig. 2(a) forms odd-numbered layers when laminated in the axial direction to form a laminate described later. The laminate formed by laminating the connecting core B1 and the like is bent into an annular shape to form the stator core 3 shown in Fig. 1. The connecting core B1 shown in Fig. 2(a) shows a linearly open state at a stage before each connecting core member 17 to 19 is bent into an annular shape.

[0037] Fig. 2(b) shows another connecting core B2 for forming the stator core 3. The connecting core B2 shown in Fig. 2(b) is also formed by punching an electromagnetic steel sheet such as a silicon steel sheet with a press machine (forging machine) not shown. The connecting core B2 shown in Fig. 2(b) includes the same number of connecting core members as the connecting core B1 shown in Fig. 2(a), a third end connecting core member 20 at the left end, and a fourth end connecting core 21 at the right end. Further, a second intermediate connecting core member 22 is provided between the third and fourth end connecting core members 20 and 21.

[0038] The first end connecting core member 17 and the fourth end connecting core member 21 have shapes that are reversed both front and back and left and right. The second end connecting core member 18 and the third end connecting core member 20 have shapes that are reversed both front and back and left and right. The first intermediate connecting core member 19 and the second intermediate connecting core member 22 have the same shape that is symmetric about the left and right. Since they are symmetric about the left and right, it can also be said that the first intermediate connecting core member 19 and the second intermediate connecting core member 22 have shapes that are reversed both front and back and left and right.

[0039] The connecting core B2 shown in Fig. 2(b) shows a linearly open state at a stage before each connecting core member 20 to 22 is bent into an annular shape, and forms even-numbered layers when laminated in the axial direction to form a laminate described later. When the connecting core B1 shown in Fig. 2(a) forms even-numbered layers, the connecting core B2 shown in Fig. 2(b) forms odd-numbered layers. That is, the connecting core B1 shown in Fig. 2(a) and the connecting core B2 shown in Fig. 2(b) are laminated alternately in the axial direction.

[0040] Fig. 3 shows the structures of the first and second intermediate connecting core members 19 and 22. The intermediate connecting core members 19 and 22 are roughly composed of a connecting yoke portion 23 extending in the left - right direction of Fig. 3 and a teeth portion 24 extending in a direction perpendicular thereto in a state where the connecting cores B1 and B2 shown in Fig. 2 are linearly opened. The teeth portion 24 is composed of a teeth base portion 25 extending in a direction perpendicular (including a substantially perpendicular direction) to the connecting yoke portion 23 and a teeth tooth portion 26 extending in a direction substantially parallel to the connecting yoke portion 23 from the open end (the lower - side end in Fig. 3) of the teeth base portion 25.

[0041] A second pin insertion hole 27 is formed in the connecting yoke portion 23. Also, a third pin insertion hole 28 is formed in the teeth portion 24. The connecting yoke portion 23 extends in the circumferential direction in a state where the connecting cores B1 and B2 shown in Fig. 2 are bent in an annular shape, and the teeth base portion 25 extending in a direction perpendicular to the connecting yoke portion 23 extends radially inward in a state where the connecting cores B1 and B2 shown in Fig. 2 are bent in an annular shape. Also, the teeth tooth portion 26 extends in the circumferential direction in a state where the connecting cores B1 and B2 shown in Fig. 2 are bent in an annular shape.

[0042] Fig. 4 shows the connection state of adjacent intermediate connecting core members 19 and 22. As shown in Fig. 4, the adjacent intermediate connecting core members 19 and 22 are connected by a connecting portion 29 provided on each connecting yoke portion 23. The connecting portion 29 is composed of an outer peripheral portion 30 forming an outer - peripheral - side arc portion and an inner peripheral portion 31 forming an inner - peripheral - side arc portion. In order to form the connecting portion 29 in an arc shape, recessed portions 32 are formed on both the left and right sides of the connecting portion 29 shown in Fig. 4.

[0043] On the inner peripheral portion 31, a pair of substantially opposing contact surfaces 33 and 34 are continuously formed on the adjacent connecting yoke portion 23 from the inner peripheral surface 31. Each of the contact surfaces 33 and 34 is inclined from the inner peripheral portion 31 toward the teeth base portion 25 side of each intermediate connecting core member 19 and 22 and is formed at both ends of each connecting yoke portion 23. The inclination angles of the contact surfaces 34 and 35 are angles toward the radially inner side in a state where the connecting cores B1 and B2 shown in Fig. 2 are bent in an annular shape.

[0044] Due to the presence of the connecting part 29 composed of the outer peripheral part 30 and the inner peripheral part 31 and the contact surfaces 33, 34, the intermediate connecting core members 19, 22 can be bent in the direction of closing the inner peripheral part 31. When the connecting cores B1, B2 are bent annularly, the pair of substantially opposing contact surfaces 33, 34 come into contact.

[0045] FIG. 5 shows the first end connecting core member 17 located at the left end of the connecting core B1 shown in FIG. 2(a). The first end connecting core member 17 is generally composed of a first end connecting yoke part 35 extending in the left-right direction of FIG. 5 and a teeth part 36 extending in a direction perpendicular (including a substantially perpendicular direction) to this when the connecting core B1 shown in FIG. 2(a) is linearly opened.

[0046] The teeth part 36 is composed of a teeth base part 37 extending in a direction perpendicular (including a substantially perpendicular direction) from the first end connecting yoke part 35 and a teeth tooth part 38 extending in a direction substantially parallel to the first end connecting yoke part 35 from the open end (the lower end in FIG. 5) of the teeth base part 37.

[0047] The first end connecting yoke part 35 extends in the circumferential direction when the connecting core B1 shown in FIG. 2(a) is bent annularly. The teeth base part 37 extends radially inward when the connecting core B1 shown in FIG. 2(a) is bent annularly, and the teeth tooth part 38 extends in the circumferential direction when the connecting core B1 shown in FIG. 2(a) is bent annularly. A fourth pin insertion hole 39 is formed in the first end connecting yoke part 35, and a fifth pin insertion hole 40 is formed in the teeth part 36.

[0048] Between the first intermediate connection core members 19 adjacent to the right side of the first end connection core member 17 (the right side in FIG. 5) are connected by a connection portion 41. The connection portion 41 is composed of an outer peripheral portion 42 forming an arc portion on the outer peripheral side and an inner peripheral portion 43 forming an arc portion on the inner peripheral side. In order to form the connection portion 41 in an arc shape, recessed portions 32 are formed on both the left and right sides of the connection portion 41 shown in FIG. 5. On the inner peripheral portion 43, at the first end connection yoke portion 35 of the first end connection core member 17, a contact surface 44 continuous from the inner peripheral surface 43 is formed. The contact surface 44 substantially faces the contact surface 34 formed on the connection yoke portion 23 of the adjacent first intermediate connection core member 19.

[0049] The contact surface 44 is formed by being inclined from the inner peripheral portion 43 toward the tooth base portion 37 side of the first end connection core member 17. The inclination angles of the contact surfaces 43 and 34 are the angles toward the radially inner side in the state where the connection core B1 shown in FIG. 2(a) is bent in a ring shape. Due to the presence of the connection portion 41 composed of the outer peripheral portion 42 and the inner peripheral portion 43 and the contact surfaces 34 and 44, the first end connection core member 17 and the first intermediate connection core member 19 can be bent in the direction of closing the inner peripheral portion 43. When the first end connection core member 17 and the first intermediate connection core member 19 are bent in a ring shape, a pair of substantially opposing contact surfaces 34 and 44 come into contact.

[0050] A fitting recess 45 is formed at the open end of the left end (the left end in FIG. 5) of the first end connection core member 17. By forming the fitting recess 45, a step portion 46 is formed at the open end portion of the first end connection core member 17.

[0051] The fitting recess 45 is formed by a first surface 46a that forms a stepped portion 46, a second surface 46b that extends in a direction substantially perpendicular to the first surface 46a, and a third surface 46c that is continuous from the second surface 46b and extends in the same direction (including substantially the same direction) as the first surface 46a. The first surface 46a and the third surface 46c extend in a direction along the radial direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape, and the first surface 46a is located on the outer side in the radial direction and on one side in the circumferential direction with respect to the third surface 46c. The second surface 46b is a surface that connects the first surface 46a and the third surface 46c, and extends in a direction along the circumferential direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape.

[0052] Fig. 6 shows a second end connecting core member 18 located at the right end of the connecting core B1 shown in Fig. 2(a). The second end connecting core member 18 is generally composed of a second end connecting yoke portion 47 that extends in the left-right direction in Fig. 6 and a teeth portion 48 that extends in a direction perpendicular (including substantially perpendicular) to the second end connecting yoke portion 47.

[0053] The second end yoke portion 47 extends in the circumferential direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape. The teeth portion 48 is composed of a teeth base portion 49 that extends in a direction perpendicular (including substantially perpendicular) to the second end connecting yoke portion 47 and a teeth tooth portion 50 that extends in a direction substantially parallel to the second end connecting yoke portion 47 from the open end (the lower end in Fig. 6) of the teeth base portion 49. The teeth base portion 49 extends in the radial direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape, and the teeth tooth portion 50 extends in the circumferential direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape. A sixth pin insertion hole 51 is formed in the second end connecting yoke portion 47, and a seventh pin insertion hole 52 is formed in the teeth base portion 49.

[0054] Between the second end connection yoke portion 47 and the first intermediate connection core member 19 adjacent to the left side (the left side in FIG. 6), they are connected by a connection portion 53. The connection portion 53 is composed of an outer peripheral portion 54 forming an arc portion on the outer peripheral side and an inner peripheral portion 55 forming an arc portion on the inner peripheral side. In order to form the connection portion 53 in an arc shape, recessed portions 32 are formed on both the left and right sides of the connection portion 53 shown in FIG. 6. On the inner peripheral portion 55, a contact surface 56 facing the contact surface 33 continuous from the inner peripheral surface 55 is formed at the second end connection yoke portion 47 of the second end connection core member 18. The contact surface 56 substantially faces the contact surface 33 formed on the connection yoke portion 23 of the adjacent first intermediate connection core member 19.

[0055] The contact surface 56 is continuously formed from the inner peripheral portion 55 and inclined toward the tooth base portion 49 side of the second end connection core member 18. The inclination angles of the contact surfaces 33 and 56 are angles directed radially inward in the state where the connection core B1 shown in FIG. 2(a) is bent in an annular shape. Due to the presence of the connection portion 53 composed of the outer peripheral portion 54 and the inner peripheral portion 55 and the contact surfaces 33 and 56, the second end connection core member 18 and the first intermediate connection core member 19 can be bent in the direction of closing the inner peripheral portion 55. When the second end connection core member 18 and the first intermediate connection core member 19 are bent in an annular shape, a pair of substantially opposing contact surfaces 33 and 56 come into contact.

[0056] A fitting convex portion 57 is formed at the open end at the right end of the second end connection core member 18 shown in FIG. 5. By forming the fitting convex portion 57, a stepped portion 58 is formed at the open end portion of the second end connection core member 18. A first pin insertion hole 59 is formed in the fitting convex portion 57.

[0057] The fitting convex portion 57 is formed by a fourth surface 58a that forms a stepped portion 58, a fifth surface 58b that extends in a direction substantially perpendicular to the fourth surface 58a, and a sixth surface 58c that extends in a direction substantially the same as the fourth surface 58a. The fourth surface 58a and the sixth surface 58c extend in a direction along the radial direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape. The fourth surface 58a is located on the outer side in the radial direction and on one side in the circumferential direction with respect to the sixth surface 58c. The fifth surface 58b is a surface that connects between the first surface 58a and the third surface 58c, and extends in a direction along the circumferential direction in a state where the connecting core B1 shown in Fig. 2(a) is bent in an annular shape.

[0058] When the connecting core B1 shown in Fig. 2(a) is bent in an annular shape, the first end connecting core member 17 shown in Fig. 5 and the second end connecting core member 18 shown in Fig. 6 are fitted with each other, with the fitting concave portion 45 of the first end connecting core member 17 and the fitting convex portion 57 of the second end connecting core member 18. That is, by engaging the stepped portion 46 of the first end connecting core member 17 and the stepped portion 58 of the second end connecting core member 18, the connecting core B1 shown in Fig. 2(a) is connected in an annular shape. At this time, the first surface 46a constituting the stepped portion 46 of the first end connecting core member 17 contacts the fourth surface 58a constituting the stepped portion 58 of the second end connecting core member 18, and the second surface 46b of the stepped portion 46 contacts the fifth surface 58b of the stepped portion 58. Further, by the third surface 46c of the stepped portion 46 contacting the sixth surface 58c of the stepped portion 58, the stepped portions 46 and 58 are engaged with each other, preventing displacement in the radial direction. As a result, it becomes possible to improve the roundness of the stator core 3.

[0059] Note that as described above, the connecting core B2 shown in Fig. 2(b) has a shape obtained by inverting both the front and back and the left and right of the connecting core B1 shown in Fig. 2(a). Therefore, the third end connecting core member 20 located at the left end of the connecting core B2 shown in Fig. 2(b) has a shape obtained by inverting both the front and back and the left and right of the second end connecting core member 18 shown in Fig. 6, and the fourth end connecting core member 21 located at the right end of the connecting core B2 shown in Fig. 2(b) has a shape obtained by inverting both the front and back and the left and right of the first end connecting core member 17 shown in Fig. 5. Therefore, a detailed description of the shapes of the third and fourth end connecting core members 20 and 21 of the connecting core B2 shown in Fig. 2(b) will be omitted.

[0060] Fig. 7 shows a laminate 60 formed by axially laminating the connecting core B1 shown in Fig. 2(a) and the connecting core B2 shown in Fig. 2(b). In Fig. 7, the laminated state of the connecting cores B1 and B2 is depicted only at the left and right ends, and the central portion of the laminate 60 is simplified in the figure by omitting the laminated state.

[0061] As shown in Fig. 7, the laminate 60 is configured by alternately laminating the connecting core B1 shown in Fig. 2(a) and the connecting core B2 shown in Fig. 2(b) along the axial direction. The laminate 60 is in an open state in a straight line, similar to the connecting cores B1 and B2 shown in Figs. 2(a) and 2(b).

[0062] Fig. 8 is a plan view of the laminate 60 shown in Fig. 7. The connecting core B1 shown in Fig. 2(a) is arranged on the uppermost surface of the laminate 60, and the connecting core B2 shown in Fig. 2(b) is arranged below the uppermost connecting core B1. In this way, the connecting core B1 and the connecting core B2 are alternately laminated along the axial direction to form the laminate 60.

[0063] As shown in Fig. 8, the laminate 60 is laminated in a state where the first intermediate connecting core member 19 constituting the connecting core B1 and the second intermediate connecting core member 22 (see Fig. 2(b)) constituting the connecting core B2 are completely overlapped. That is, the second intermediate connecting core member 22 having the same shape is overlapped without deviation below the first intermediate connecting core member 19.

[0064] In this state, the positions of the second pin insertion hole 27 and the third pin insertion hole 28 (see FIG. 4) formed in the first intermediate connection core member 19 and the second intermediate connection core member 22 match each other.

[0065] FIG. 9 is a side view with both ends enlarged by partially omitting the middle part in the length direction for the purpose of clarifying the laminated state of the first connection core B1 and the second connection core B2 in the laminate 60 shown in FIG. 7. The laminate 60 formed by alternately laminating the first connection core B1 and the second connection core B2 along the axial direction is laminated at both ends thereof in a state where the fitting convex portion 57 of the second end connection core member 18 protrudes outward (left and right sides in FIG. 8) from the fitting concave portion 45 of the first end connection core member 17, as shown in FIG. 9.

[0066] At this time, the first pin insertion holes 59 (see FIG. 6) formed in the fitting convex portions 57 arranged at both ends of the laminate 60 are laminated in a state where their positions match in the vertical direction every other layer in the axial direction. Since the shapes of the first end connection core member 17 and the third end connection core member 20, and the second end connection core member 18 and the fourth end connection core member 21 constituting the laminate 60 are different as shown in FIGS. 2(a) and 2(b), even when the first intermediate connection core member 19 of the first connection core B1 and the second intermediate connection core member 22 of the second connection core B2 are overlapped without misalignment, the first end connection core member 17 and the third end connection core member 20, and the second end connection core member 18 and the fourth end connection core member 21 are overlapped in a misaligned state.

[0067] Fig. 10(a) is an enlarged plan view of the right end portion of the laminate 60 in which the connecting cores B1 and B2 are alternately laminated. In the figure, the solid line indicates the second end connecting core member 18 of the connecting core B1, and the dotted line indicates the fourth end connecting core member 21 of the connecting core B2 laminated below the second end connecting core member 18. As shown in Fig. 10(a), the sixth surface 58c forming the step portion 58 of the second end connecting core member 18 and the third surface 46c forming the step portion 46 of the fourth end connecting core member 21 are overlapped in position to form the same surface along the axial direction. The first surface 58a and the second surface 58b forming the step portion 58 of the second end connecting core member 18 are located at positions symmetric with respect to the left-right direction of Fig. 10(a) with the first surface 46a and the second surface 46b forming the step portion 46 of the fourth end connecting core 17 and the first pin insertion hole 59 interposed therebetween.

[0068] In the laminated state shown in Fig. 10(a), the positions of the sixth pin insertion hole 51 of the second end connecting core member 18 and the fourth pin insertion hole 39 of the fourth end connecting core member 21 are aligned. Also, the positions of the seventh pin insertion hole 52 of the second end connecting core member 18 and the fifth pin insertion hole 40 of the fourth end connecting core member 21 are aligned.

[0069] Fig. 10(b) is an enlarged plan view of the left end portion of the laminate 60 in which the first connecting core B1 and the second connecting core B2 are alternately laminated. In the figure, the solid line indicates the first end connecting core member 17 of the connecting core B1, and the dotted line indicates the third end connecting core member 20 of the connecting core B2 laminated below the first end connecting core member 17. As shown in Fig. 10(b), the third surface 46c forming the step portion 46 of the first end connecting core member 17 and the sixth surface 58c forming the step portion 58 of the third end connecting core member 20 are overlapped in position to form the same surface along the axial direction. The first surface 46a and the second surface 46b forming the step portion 46 of the first end connecting core member 17 are located at positions symmetric with respect to the left-right direction of Fig. 10(b) with the fourth surface 58a and the fifth surface 58b forming the step portion 58 of the third end connecting core 20 and the first pin insertion hole 59 interposed therebetween.

[0070] In the stacked state shown in Fig. 10(b), the positions of the fourth pin insertion hole 39 of the first end connection core member 17 and the sixth pin insertion hole 51 of the third end connection core member 20 are aligned. Also, the positions of the fifth pin insertion hole 40 of the first end connection core member 17 and the seventh pin insertion hole 52 of the third end connection core member 20 are aligned.

[0071] The laminate 60 formed in this way is in a linearly opened state as shown in Figs. 7 to 9, and pins are press-fitted and fixed into the second to seventh pin insertion holes 27, 28, 39, 40, 51, 52 so as to firmly fix the stacked state shown in Figs. 7 to 9 without deviation. Then, the electrical insulator assemblies 4a, 4b shown in Fig. 1 are installed on both axial end faces of the laminate 60 shown in Figs. 7 and 8, and the stator winding 5 is wound around the teeth bases 25, 37, 49 through the electrical insulator assemblies 4a, 4b. That is, the stator winding 5 is wound in a concentrated winding method in the slot 61 between the teeth bases 25, 37, 49 in a state where the laminate 60 is linearly opened as shown in Figs. 7 and 8. By winding the stator winding 5 in this way, a winding nozzle (not shown) for feeding out the stator winding 5 reaches the innermost part of the slot 61, and the occupancy ratio of the stator winding 5 in the slot 61 can be increased.

[0072] The laminate 60 wound with the stator winding 5 forms the stator 1 by being bent into a ring shape from the linearly opened state shown in Figs. 7 and 8. In Fig. 11, only the stator core 3 bent into a ring shape is shown, and the electrical insulator assemblies 4a, 4b attached to the stator core 3 and the stator winding 5 wound around the teeth bases 25, 37, 49 of the stator core 3 through these are not shown.

[0073] When folding the laminate 60, the connecting portions 29 (see FIG. 4) between the adjacent intermediate connecting core members 19 (22) shown in FIG. 8, the connecting portion 41 between the intermediate connecting core member 19 (22) and the first (fourth) end connecting core member 17 (21) shown in FIG. 5, and the connecting portion 53 between the intermediate connecting core member 19 (22) and the second (third) end connecting core member 18 (20) shown in FIG. 6 are bent in a direction to close the inner peripheral portions 31, 43, 55 formed therein, respectively.

[0074] By closing the inner peripheral portions 31, 43, 55, a pair of substantially opposing contact surfaces 33, 34, 34, 44, 33, 56 come into contact, and as described with reference to FIG. 8, the laminate 60 with the electrical insulator assemblies 4a, 4b and the stator winding 5 attached is bent into an annular shape. In the annularly bent state, both ends of the laminate 60 shown in FIG. 8 are connected as shown in FIG. 11. The connection of both ends is performed by fitting the first end connecting core member 17 and the second end connecting core member 18 shown in FIG. 9, and by fitting the third end connecting core member 20 and the fourth end connecting core member 21.

[0075] Specifically, the fitting convex portion 57 of the second end connecting core member 18 shown in FIG. 10(a) is fitted into the fitting concave portion 45 of the first end connecting core member 17 shown in FIG. 10(b). Also, the fitting convex portion 57 of the third end connecting core member 20 shown in FIG. 10(b) is fitted into the fitting concave portion 45 of the fourth end connecting core member 21 shown in FIG. 10(a). At this time, the step portion 46 of the first (fourth) end connecting core member 17 (21) and the step portion 58 of the second (third) end connecting core member 18 (20) are engaged. Specifically, the first surface 46a of the step portion 46 and the fourth surface 58a of the step portion 58 are in contact, the second surface 46b of the step portion 46 and the fifth surface 58b of the step portion 58 are in contact, and the third surface 46c of the step portion 46 and the sixth surface 58c of the step portion 58 are in contact. As a result, the stator core 3 constituting the stator 1 formed in an annular shape is reliably prevented from being displaced in the radial direction at the fitting portion.

[0076] The stator core 3 of the stator 1 formed in an annular shape has a connecting portion 41 between the first end connecting core member 17 and the first intermediate connecting core member 19, a connecting portion 29 between adjacent first intermediate connecting core members 19, a connecting portion 53 between the first intermediate connecting core member 19 and the second end connecting core member 18, and a connecting portion 53 between the third end connecting core member 20 and the second intermediate connecting core member 22, a connecting portion 29 between adjacent second intermediate connecting core members 22, and a connecting portion 41 between the second intermediate connecting core member 22 and the fourth end connecting core member 21. When formed into an annular shape, they are stretched in the circumferential direction, but the connected state is maintained. At this time, since the recessed portion 32 is formed around the connecting portions 29, 41, and 53, when the laminate 60 is bent into an annular shape, it is possible to prevent the connecting portions 29, 41, and 53 from protruding radially outward from the perfect circular orbit of the stator core 3. As a result, it becomes possible to securely fix the stator core 3 to the inner peripheral surface of the case 9 (see FIG. 1).

[0077] In the odd-numbered layers laminated in the axial direction, the stator core 3 constituting the stator 1 formed in this way is, as shown in the side view of FIG. 12, such that the fitting convex portion 57 of the second end connecting core member 18 is arranged toward one side in the circumferential direction, and thus is fitted into the fitting concave portion 45 of the first end connecting core member 17 arranged toward the other side in the circumferential direction. In the even-numbered layers, the fitting convex portion 57 of the third end connecting core member 20 arranged toward the other side in the circumferential direction is fitted into the fitting concave portion 45 of the fourth end connecting core member 21 arranged toward one side in the circumferential direction. Then, due to the fitting positions where the fitting convex portions 57 of the odd-numbered layers and the fitting convex portions 57 of the even-numbered layers overlap along the axial direction, the positions of the first pin insertion holes 59 formed in the fitting convex portions 57 of the odd-numbered layers and the first pin insertion holes 59 formed in the fitting convex portions 57 of the even-numbered layers match as shown in FIG. 11.

[0078] Then, by press-fitting pins into the first pin insertion holes 59 of the stator core 3 shown in FIG. 11, pins are press-fitted and fixed into all the pin insertion holes 59, 27, 28, 39, 40, 51, 52. In the state where the stator core 3 is formed in an annular shape, it becomes possible to firmly maintain the laminated state. Further, in the stator core 3 shown in FIG. 11, the fitting positions of the fitting convex portion 57 of the second end connecting core member 18 and the fitting concave portion 45 of the first end connecting core member 17 are sandwiched by the fitting convex portion 57 of the third end connecting core member 20 arranged vertically in the axial direction. Therefore, the axial rigidity of the fitting portion of the annularly formed stator core 3 can be enhanced.

[0079] FIG. 13 shows a plan view of the stator core 3 constituting the stator 1 formed in an annular shape. As shown in FIG. 13, the annularly formed stator core 3 is circular except for the recessed portions 32 of the connecting portions 29, 41, 53. When fixing the stator core 3 of the stator 1 in the case 9 of the motor A shown in FIG. 1, for example, it can be fixed by shrink fitting, and the fixing portion is the circular portion (outer diameter portion other than the recessed portion 32) of the stator core 3 and the inner peripheral surface of the case 9.

[0080] FIG. 14 is an enlarged plan view of the connecting portion 29 of the stator core 3 shown in FIG. 13. As shown in FIG. 14, in the annular stator core 3, although the connecting portion 29 is slightly extended in the circumferential direction, the connecting state is maintained. In other words, by extending the connecting portion 29 in the circumferential direction, the laminated body 60 in the linearly opened state shown in FIGS. 7 to 9 can be formed into the annular stator core 3 as shown in FIGS. 11 to 13.

[0081] In addition, in FIG. 14, the connecting portion 29 between the first and second intermediate connecting core members 19, 22 is illustrated and described. However, the connecting portion 41 between the first end connecting core member 17 and the first intermediate connecting core member 19, the connecting portion 53 between the first intermediate connecting core member 19 and the second end connecting core member 18, and the connecting portion 53 between the third end connecting core member 20 and the second intermediate connecting core member 22, and the connecting portion 41 between the second intermediate connecting core member 22 and the fourth end connecting core member 21 also maintain the connecting state by being slightly extended in the circumferential direction in the same manner.

[0082] By stretching each connecting portion 41, 53 in the circumferential direction, the connection state is maintained also between the adjacent first end connecting core member 17 and the first intermediate connecting core member 19, between the first intermediate connecting core member 19 and the second end connecting core member 18, between the third end connecting core member 20 and the second intermediate connecting core member 22, and between the second intermediate connecting core member 22 and the fourth end connecting core member 21.

[0083] In the hollow portion of the stator 1, the rotor 2 is supported by the bearings 11, 14 shown in FIG. 1, and thus is rotatably attached around the rotation center line P (see FIG. 13). A bracket 12 is fixed to the case 9, for example, by screwing, and houses the stator 1 and the rotor 2. In addition, for electrical insulation measures and vibration measures during operation, the inside of the case 9 can also be molded with resin. In this way, the electric motor of the present invention is configured.

[0084] FIG. 15 shows a laminate 60A in another embodiment of the present invention, and FIG. 16 shows a laminate 60B in yet another embodiment. FIGS. 15 and 16 are side views in which the intermediate portion is partially omitted in the length direction and both ends are enlarged for the purpose of clarifying the laminated state of the connecting core B1 and the connecting core B2 constituting the laminates 60A and 60B, similar to FIG. 9. In FIGS. 15 and 16, instead of laminating the first connecting core B1 and the second connecting core B2 alternately along the axial direction, a state where the number of laminated sheets of the first connecting core B1 and the number of laminated sheets of the second connecting core are arbitrarily changed is shown. Also in the laminate 60A shown in FIG. 15 and the laminate 60B shown in FIG. 16, at both ends thereof, the fitting convex portion 57 of the second (third) end connecting core member 18 (20) protrudes outward (the left and right sides in FIG. 8) from the fitting concave portion 45 of the first (fourth) end connecting core member 17 (21) and is laminated, which is the same as the case of FIG. 9.

[0085] Then, the first pin insertion holes 59 (see FIG. 6) formed in the fitting convex portions 57 disposed at both ends of the laminates 60A and 60B are laminated in a state where their positions coincide in the longitudinal direction along the axial direction. Since the shapes of the first end connecting core members 17 and the third end connecting core members 20 constituting the laminates 60A and 60B, and the second end connecting core members 18 and the fourth end connecting core members 21 are different as shown in FIGS. 2(a) and 2(b), even when the first intermediate connecting core member 19 of the first connecting core B1 and the second intermediate connecting core member 22 of the second connecting core B2 are overlapped without misalignment, the first end connecting core members 17 and the third end connecting core members 20, and the second end connecting core members 18 and the fourth end connecting core members 21 are overlapped in a misaligned state.

[0086] The enlarged state of the right ends of the laminates 60A and 60B in which the connecting cores B1 and B2 are laminated in an arbitrary number in the axial direction is the same as that in FIG. 10(a). In the figure, the solid line indicates the second end connecting core member 18 of the connecting core B1, and the dotted line indicates the fourth end connecting core member 21 of the connecting core B2 laminated below the second end connecting core member 18. As shown in FIG. 10(a), the sixth surface 58c forming the step portion 58 of the second end connecting core member 18 and the third surface 46c forming the step portion 46 of the fourth end connecting core member 21 are positionally overlapped to form the same surface along the axial direction. The fourth surface 58a and the fifth surface 58b forming the step portion 58 of the second end connecting core member 18 are located at positions symmetric with respect to the left-right direction of FIG. 10(a) with respect to the positions where the first surface 46a and the second surface 46b forming the step portion 46 of the fourth end connecting core 21 are located, with the first pin insertion hole 59 interposed therebetween.

[0087] In the laminated state shown in FIG. 10(a), the positions of the sixth pin insertion hole 51 of the second end connecting core member 18 and the fourth pin insertion hole 39 of the fourth end connecting core member 21 coincide. Also, the positions of the seventh pin insertion hole 52 of the second end connecting core member 18 and the fifth pin insertion hole 40 of the fourth end connecting core member 21 coincide.

[0088] Fig. 10(b) is an enlarged plan view of the left end portions of the laminates 60A and 60B in which the connecting cores B1 and B2 are axially laminated in arbitrary numbers. In this figure, the solid line indicates the first end connecting core member 17 of the connecting core B1, and the dotted line indicates the third end connecting core member 20 of the connecting core B2 laminated below the first end connecting core member 17. As shown in Fig. 10(b), the third surface 46c forming the stepped portion 46 of the first end connecting core member 17 and the sixth surface 58c forming the stepped portion 58 of the third end connecting core member 20 are positionally overlapped to form the same surface along the axial direction. The first surface 46a and the second surface 46b forming the stepped portion 46 of the first end connecting core member 17 are located at positions symmetric in the left-right direction of Fig. 10(b) with respect to the positions where the fourth surface 58a and the fifth surface 58b forming the stepped portion 58 of the third end connecting core 20 are located, with the first pin insertion hole 59 interposed therebetween.

[0089] In the laminated state shown in Fig. 10(b), the positions of the fourth pin insertion hole 39 of the first end connecting core member 17 and the sixth pin insertion hole 51 of the third end connecting core member 20 are aligned. Also, the positions of the fifth pin insertion hole 40 of the first end connecting core member 17 and the seventh pin insertion hole 52 of the third end connecting core member 20 are aligned.

[0090] The laminates 60A and 60B formed in this way are firmly fixed in the linearly opened state so that their laminated states do not shift by press-fitting and fixing pins into the second to seventh pin insertion holes 27, 28, 39, 40, 51, 52. Then, the electrical insulator assemblies 4a and 4b shown in Fig. 1 are installed on both end faces in the axial direction of the laminates 60A and 60B, and the stator winding 5 is wound around the teeth bases 25, 37, 49 through the electrical insulator assemblies 4a and 4b. That is, the stator winding 5 is wound in a concentrated winding manner in the slot 61 between the teeth bases 25, 37, 49 in the state where the laminates 60A and 60B are linearly opened. By winding the stator winding 5 in this way, a winding nozzle (not shown) for feeding out the stator winding 5 reaches the innermost part of the slot 61, and the occupancy ratio of the stator winding 5 in the slot 61 can be increased.

[0091] The laminated bodies 60A and 60B around which the stator winding 5 is wound form the stator 1 by being bent into a ring shape from a linearly opened state. When bending the laminated bodies 60A and 60B into a ring shape, the connecting portions 29 (see FIG. 4) between the adjacent intermediate connecting core members 19 (22) shown in FIG. 8, the connecting portions 41 between the intermediate connecting core members 19 (22) and the first (fourth) end connecting core members 17 (21) shown in FIG. 5, and the connecting portions 53 between the intermediate connecting core members 19 (22) and the second (third) end connecting core members 18 (20) shown in FIG. 6 are bent in a direction to close the inner peripheral portions 31, 43, and 55 respectively formed therein.

[0092] By closing the inner peripheral portions 31, 43, and 55, a pair of substantially opposing contact surfaces 33, 34, 34, 44, 33, 56 come into contact, and as described with reference to FIG. 8, the laminated bodies 60A and 60B to which the electrical insulator assemblies 4a and 4b and the stator winding 5 are attached are bent into a ring shape. In the state of being bent into a ring shape, both ends of the laminated bodies 60A and 60B shown in FIG. 8 are connected. The connection of both ends is performed by fitting the first end connecting core member 17 and the second end connecting core member 18, and the third end connecting core member 20 and the fourth end connecting core member 21 shown in FIGS. 15 and 16.

[0093] Specifically, the fitting convex portion 57 of the second end connecting core member 18 shown in FIG. 10(a) is fitted into the fitting concave portion 45 of the first end connecting core member 17 shown in FIG. 10(b). Also, the fitting convex portion 57 of the third end connecting core member 20 shown in FIG. 10(a) is fitted into the fitting concave portion 45 of the fourth end connecting core member 21 shown in FIG. 10(b). At this time, the step portion 46 of the first (fourth) end connecting core member 17 (21) and the step portion 58 of the second (third) end connecting core member 18 (20) mesh with each other. Specifically, the first surface 46a of the step portion 46 and the fourth surface 58a of the step portion 58 come into contact, the second surface 46b of the step portion 46 and the fifth surface 58b of the step portion 58 come into contact, and the third surface 46c of the step portion 46 and the sixth surface 58c of the step portion 58 come into contact. As a result, it is ensured that the stator core 3 constituting the stator 1 formed in a ring shape does not shift in the radial direction at the connection portion.

[0094] The stator core 3 of the stator 1 formed in an annular shape has a connecting portion 41 between the first end connecting core member 17 and the first intermediate connecting core member 19, a connecting portion 29 between adjacent first intermediate connecting core members 19, a connecting portion 53 between the first intermediate connecting core member 19 and the second end connecting core member 18, and a connecting portion 53 between the third end connecting core member 20 and the second intermediate connecting core member 22, and a connecting portion 29 between adjacent second intermediate connecting core members 22, and a connecting portion 41 between the second intermediate connecting core member 22 and the fourth end connecting core member 21. When formed into an annular shape, they are stretched in the circumferential direction, but the connected state is maintained. At this time, since the recessed portion 32 is formed around the connecting portions 29, 41, 53, when the laminates 60A, 60B are bent into an annular shape, it is possible to prevent the connecting portions 29, 41, 53 from protruding radially outward from the perfect circular orbit of the stator core 3. Thereby, it becomes possible to securely fix the stator core 3 to the inner peripheral surface of the case 9 (see FIG. 1).

[0095] The fitting convex portion 57 of the second (third) end connecting core member 18 (20) arranged toward one side or the other side in the circumferential direction of the stator core 3 constituting the stator 1 formed in this way is fitted into the fitting concave portion 45 of the first (fourth) end connecting core member 17 (21) arranged toward the other side or one side in the circumferential direction. At this time, the positions of the first pin insertion holes 59 of the fitting convex portions 57 overlapping along the axial direction match.

[0096] Then, by press-fitting and fixing a pin into the first pin insertion hole 59 of the stator core 3, pins are press-fitted and fixed into all the pin insertion holes 59, 27, 28, 39, 40, 51, 52, and the stator core 3 can firmly maintain the laminated state formed in an annular shape. Further, the stator core 3 configured in this way has the fitting position of the fitting convex portion 57 of the second end connecting core member 18 and the fitting concave portion 45 of the first end connecting core member 17 sandwiched by the fitting convex portion 57 of the third end connecting core member 20 arranged vertically in the axial direction, so that the axial rigidity of the fitting portion of the annularly formed stator core 3 can be increased.

[0097] FIG. 13 shows a plan view of a stator core 3 that forms a stator 1 formed in an annular shape. As shown in FIG. 13, the annularly formed stator core 3 is circular except for the recessed portions 32 of the connecting portions 29, 41, 53. When fixing the stator core 3 of the stator 1 in the case 9 of the motor A shown in FIG. 1, for example, it can be fixed by shrink fitting, and the fixing location is the circular portion of the stator core 3 (the outer diameter portion other than the recessed portion 32) and the inner peripheral surface of the case 9.

[0098] FIG. 14 is an enlarged plan view of the connecting portion 29 of the stator core 3 shown in FIG. 13. As shown in FIG. 14, the annular stator core 3 maintains its connected state although the connecting portion 29 is slightly stretched in the circumferential direction. In other words, by stretching the connecting portion 29 in the circumferential direction, the laminated bodies 60A and 60B in a linearly open state can be formed into the annular stator core 3.

[0099] In FIG. 14, the connecting portion 29 between the first and second intermediate connecting core members 19 and 22 is illustrated and described. However, the connecting portion 41 between the first end connecting core member 17 and the first intermediate connecting core member 19, the connecting portion 53 between the first intermediate connecting core member 19 and the second end connecting core member 18, and the connecting portion 53 between the third end connecting core member 20 and the second intermediate connecting core member 22, and the connecting portion 41 between the second intermediate connecting core member 22 and the fourth end connecting core member 21 are also similarly stretched slightly in the circumferential direction to maintain the connected state.

[0100] By stretching each of the connecting portions 41 and 53 in the circumferential direction, the connected state is also maintained between the adjacent first end connecting core member 17 and the first intermediate connecting core member 19, between the first intermediate connecting core member 19 and the second end connecting core member 18, between the third end connecting core member 20 and the second intermediate connecting core member 22, and between the second intermediate connecting core member 22 and the fourth end connecting core member 21.

[0101] In the hollow portion of the stator 1, the rotor 2 is supported by the bearings 11 and 14 shown in FIG. 1, and is rotatably attached around the rotation center line P (see FIG. 13). A bracket 12 is fixed to the case 9, for example, by screwing, and houses the stator 1 and the rotor 2. In addition, for electrical insulation measures and vibration measures during operation, the inside of the case 9 can also be molded with resin. In this way, the electric motor of the present invention may be configured.

[0102] As described above, according to the stator core of the present invention, the stator core can be manufactured with only one connection by bending the laminate formed by laminating a continuous strip-shaped connection core into a ring shape. Therefore, the number of working steps required for manufacturing the stator is small, and the working man-hours and working burden of the worker can be reduced. In addition, by providing pin insertion holes in a plurality of connection core members and press-fitting and fixing pins into the pin insertion holes, excessive force does not act only on a part of the connection portions of the stator core formed in a ring shape, and the roundness can always be maintained. It is possible to solve the problem that vibration is generated by the radial exciting force according to the number of magnetic poles of the magnet.

[0103] Note that the present invention is not limited to the configuration described in the above embodiment. For example, in the above embodiment, the case where the number of connection core members constituting the connection core is 12 is illustrated and described, but the number of connection core members is not limited to this (however, it is a multiple of 3). Further, the structure of the electrical insulator assembly is not limited to the structure shown in FIG. 1, and the same applies to the structure of the electric motor. That is, various changes, additions, and deletions are possible as long as the effects of the present invention can be obtained, and it is natural that the scope of the present invention extends to any configuration.

Explanation of Signs

[0104] 1 Stator 2 Rotor 3 Stator core 4 Electrical insulator assembly 4a First electrical insulator assembly 4b Second electrical insulator assembly 4a1, 4b1 Outer wall portion Inner wall portions of 4a2 and 4b2 Bottom wall portions of 4a2 and 4b2 Stator winding Rotor shaft Permanent magnet Case First bearing fixing member Bearings of 11 and 14 Bracket Second bearing fixing member Flange portion Hole portion First end connecting core member Second end connecting core member First intermediate connecting core member Third end connecting core member Fourth end connecting core member Second intermediate connecting core member Connecting yoke portion Tooth portions of 24, 36, and 48 Tooth bases of 25, 37, and 49 Tooth tips of 26, 38, and 50 Second pin insertion hole Third pin insertion hole Connecting portions of 29, 41, and 53 Outer peripheral portions of 30, 42, and 54 Inner peripheral portions of 31, 43, and 55 Depressed portion Contact surfaces of 33, 34, 44, and 56 First end connecting yoke portion Fourth pin insertion hole Fifth pin insertion hole Fitting concave portion Step portions of 46 and 58 First surface of 46a Second surface of 46b Third surface of 46c Second end connecting yoke portion Sixth pin insertion hole Seventh pin insertion hole Fitting convex portion Fourth surface of 58a Fifth surface of 58b 58c, Side 6 59, First Pin Insertion Hole 60, 60A, 60B, Laminate 61, Slot A, Electric Motor B1, First Connecting Core B2, Second Connecting Core

Claims

1. a first end connecting yoke portion disposed at one end of said first end connecting yoke portion and a second end connecting yoke portion disposed at the other end of said first end connecting yoke portion, the first end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the second end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the second end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the first end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the second end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the first end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the second end connecting yoke portion being provided at the open end of said first end connecting yoke portion and the

2. 2. The stator core according to claim 1, characterized in that a second, fourth or sixth pin insertion hole is formed in the connecting yoke portion, and the positions of the second, fourth or sixth pin insertion holes of the connecting cores stacked along the axial direction are aligned.

3. 2. A stator core as described in claim 1, characterized in that a third, fifth or seventh pin insertion hole is formed in the tooth portion, and the positions of the third, fifth or seventh pin insertion holes of the connected cores stacked along the axial direction are aligned.

4. A stator comprising a stator core, an electrical insulator assembly and a stator winding, the stator comprising the stator core according to any one of claims 1 to 3.

5. 5. An electric motor comprising a stator and a rotor, the stator being the stator according to claim 4.

Images