Rotary electric machine

Abstract

To provide a rotary electric machine capable of contributing to enhancement of cooling efficiency of coils.SOLUTION: A stator 21 in a rotary electric machine 3 has: a stator core 27 which has a cylindrical yoke 39 and a plurality of teeth 43, and in which slots 47 are partitioned between adjacent teeth 43 in a circumferential direction of the yoke 39; coils 31 each wound around the respective teeth 43; and resin mold parts 35 obtained by mold-forming the stator core 27 and the coils 31 with a resin. Columnar insulation members 33 that block respective slot openings 48 that open in a radial direction of the yoke 39 are disposed in the respective slots 47. The resin mold parts 35 are provided between the insulation members 33 and the coils 31 in the slots 47, thereby the insulation members 33 and the coils 31 are disposed spaced apart from each other.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] The present invention relates to a rotating electrical machine.

Background Art

[0002] Conventional rotating electrical machines are disclosed in Patent Document 1. This rotating electrical machine includes a rotating shaft, a rotor, a stator, and a housing that houses these rotating shaft, rotor, and stator.

[0003] The rotor is fixed to the rotating shaft and rotates integrally with the rotating shaft. The stator has a stator core disposed outside the rotor, a coil, and a resin mold portion.

[0004] The stator core has a cylindrical yoke and a plurality of teeth protruding from the inner peripheral surface of the yoke toward the rotor. Slots are formed between adjacent teeth in the circumferential direction.

[0005] The coil is wound around the teeth.

[0006] The resin mold portion resin-molds the stator core and the coil.

[0007] In this rotating electrical machine, the coil is sealed inside the resin mold portion, and the coil is fixed to the stator core by the resin mold portion. Further, in this rotating electrical machine, by covering the coil partially with the resin mold portion instead of covering the entire coil, the cooling efficiency of the coil is enhanced.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0009] However, in a rotating electrical machine, in order to improve the heat dissipation efficiency, it is desired to further improve the cooling efficiency of the coil.

[0010] The present invention has been made in view of the above-described conventional circumstances, and an object thereof is to provide a rotating electrical machine that can contribute to improving the cooling efficiency of a coil.

Means for Solving the Problems

[0011] The rotating electrical machine of the present invention includes a rotating shaft and, a rotor fixed to the rotating shaft and rotating integrally with the rotating shaft, a stator disposed outside the rotor, having a cylindrical yoke and a plurality of teeth protruding from the inner peripheral surface of the yoke toward the rotor, and a stator core in which slots are defined between the adjacent teeth in the circumferential direction of the yoke, a coil wound around the teeth, and a resin molded portion obtained by molding the stator core and the coil with resin, a rotating electrical machine including a housing that houses the rotating shaft, the rotor, and the stator, a columnar insulating member that closes a slot opening in which the slot opens in the radial direction of the yoke toward the rotor is disposed in the slot, In the slot, the resin molded portion is provided between the insulating member and the coil, whereby the insulating member and the coil are spaced apart from each other.

[0012] In the rotating electrical machine of the present invention, the radially inner slot opening in the slot is closed by the insulating member. And in the slot, the resin molded portion is provided between the insulating member and the coil, whereby the insulating member and the coil are spaced apart from each other.

[0013] In such a configuration, when the resin mold part is formed in the slot, a pressure from the uncured resin that is gradually filled between the insulating member and the coil acts on the coil in the slot. As a result, the coil is pushed in a direction away from the insulating member in the slot. Consequently, the contact area between the coil and the stator core increases. The pressure that attempts to push the coil in a direction away from the insulating member is maintained by the resin mold part provided between the insulating member and the coil in the slot. Therefore, during the operation of the rotating electrical machine, the heat transfer performance from the coil to the stator core is improved.

[0014] Therefore, the rotating electrical machine of the present invention can contribute to improving the cooling efficiency of the coil.

[0015] In the slot, it is preferable that the minimum thickness of the resin mold part between the insulating member and the coil in the radial direction of the yoke is thinner than the maximum thickness of the insulating member in the radial direction of the yoke.

[0016] In this case, compared with the case where the minimum thickness of the resin mold part between the insulating member and the coil in the radial direction is thicker than the maximum thickness of the insulating member in the radial direction, it is advantageous to increase the radial outward pressure acting on the coil from the resin mold part between the insulating member and the coil to increase the contact area between the coil and the stator core. For this reason, the heat transfer performance from the coil to the stator core can be further improved.

[0017] The insulating member preferably has an axially extending path that extends in the axial direction of the yoke and in which a resin mold part is provided, and a branch path that branches from the axially extending path, opens toward the coil, and in which a resin mold part is provided.

[0018] In this case, the resin of the resin mold part is molded from the opening of the branch path toward the coil. For this reason, the coil can be more effectively pushed in a direction away from the insulating member by the resin of the resin mold part. As a result, the heat transfer performance from the coil to the stator core can be further improved.

[0019] The insulating member preferably has, in the slot, a plurality of protrusions that protrude toward the coil and are arranged in the axial direction of the yoke, and a plurality of through passages that each penetrate the plurality of protrusions in the axial direction and are provided with resin molded portions inside. And it is preferable that the resin of the resin molded portion is molded toward the coil from between the respective through passages.

[0020] In this case, between the plurality of protrusions arranged in the axial direction, the resin of the resin molded portion can push the coil in a direction away from the insulating member. For this reason, it is possible to push the coil in a direction away from the insulating member at a portion close to the central portion in the axial direction within the slot, that is, at a portion where the coil within the slot is likely to become hot. As a result, the heat transfer property from the coil to the stator core can be further improved.

Advantages of the Invention

[0021] The rotating electrical machine of the present invention can contribute to improving the cooling efficiency of the coil.

Brief Description of the Drawings

[0022]

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

Figure 17

Figure 18

DETAILED DESCRIPTION OF THE INVENTION

[0023] Hereinafter, Embodiments 1 to 3 embodying the present invention will be described with reference to the drawings. The electric compressor including the rotating electrical machines of Embodiments 1 to 3 is mounted on a vehicle (not shown) and constitutes a refrigeration circuit of the vehicle.

[0024] (Embodiment 1) As shown in FIG. 1, the electric compressor including the rotating electrical machine of Embodiment 1 includes a housing 1, an electric motor 3, a compression mechanism 5, and an inverter 7. The electric motor 3 is an example of the "rotating electrical machine" in the present invention. The housing 1 has a cylindrical housing body 11, a first cover 13, and a second cover 15.

[0025] In this embodiment, the front-rear direction of the electric compressor and the electric motor 3 is defined by the solid arrows shown in FIG. 1. This electric compressor is mounted on the vehicle in a posture such that its front is the front of the vehicle and its rear is the rear of the vehicle. Note that the electric compressor can appropriately change its posture according to the vehicle on which it is mounted.

[0026] As shown in FIG. 1, the housing body 11 has a rear wall 11a and a peripheral wall 11b. The rear wall 11a is located at the rear end of the housing body 11 and extends in the radial direction of the housing body 11. The peripheral wall 11b is connected to the rear wall 11a and extends forward from the rear wall 11a in the direction of the axis O. With these rear wall 11a and peripheral wall 11b, the housing body 11 is formed in a bottomed substantially cylindrical shape extending in the direction of the axis O. Here, the direction of the axis O is parallel to the front-rear direction of the electric motor 3. In the following description, when simply referring to the radial direction or the circumferential direction, they respectively mean the radial direction or the circumferential direction in the direction of the axis O.

[0027] These rear walls 11a and peripheral walls 11b form a motor chamber 17 inside the housing body 11. The motor chamber 17 is partitioned from the outside of the housing body 11, and thus from the outside of the electric compressor, by the rear wall 11a and the peripheral walls 11b. Although not shown, an intake port communicating with the motor chamber 17 is formed in the peripheral wall 11b. Refrigerant gas is inhaled into the motor chamber 17 through this intake port.

[0028] Also, a plurality of bolt holes 11c are formed at the front end of the peripheral wall 11b. The bolt holes 11c extend rearward in the direction of the axis O. Note that in FIG. 1, only one of the plurality of bolt holes 11c is shown.

[0029] The first cover 13 is located in front of the housing body 11. The first cover 13 is fixed to the front end of the peripheral wall 11b by a plurality of bolts 13a inserted through the respective bolt holes 11c. A discharge chamber (not shown) is formed inside the first cover 13. Note that in FIG. 1, only one of the plurality of bolts 13a is shown.

[0030] The second cover 15 is located behind the housing body 11. The second cover 15 is fixed to the rear wall 11a by a plurality of bolts (not shown). The second cover 15 is formed in a bottomed cylindrical shape and forms an inverter chamber 19 between it and the rear wall 11a.

[0031] The inverter 7 is housed in the inverter chamber 19. The inverter 7 controls the operation of the electric motor 3. Note that the inverter 7 is a commercial product, and a detailed description of its configuration will be omitted.

[0032] Specifically, the electric motor 3 is an electric motor for a compressor. The electric motor 3 is provided inside the motor chamber 17. Also, the electric motor 3 is electrically connected to the inverter 7.

[0033] The electric motor 3 includes a stator 21, a rotating shaft 23, and a rotor 25.

[0034] The stator 21 is disposed outside the rotor 25, and includes a stator core 27 shown in FIGS. 3 and 4 etc., a coil 31 shown in FIGS. 1, 4, 6 to 10, a separator 33 shown in FIGS. 5 to 10, and a resin mold portion 35 shown in FIGS. 1, 2, 9 and 10. The separator 33 is an example of the "insulating member" in the present invention.

[0035] As shown in FIG. 1, the stator core 27 is formed by laminating a number of electromagnetic steel sheets 37 in the direction of the axis O. As shown in FIGS. 3 and 4 etc., the stator core 27 has a cylindrical yoke 39 and six teeth 43. The outer peripheral edge portions 41 of the yoke 39 in each electromagnetic steel sheet 37 are welded to each other, so that the stator core 27 is integrated. Note that each electromagnetic steel sheet 37 may be fixed by caulking. The portions of each electromagnetic steel sheet 37 other than the outer peripheral edge portion 41 of the yoke 39 are only laminated with the adjacent electromagnetic steel sheets 37 in the direction of the axis O and are not fixed to each other. The stator 21 is fixed to the peripheral wall 11b of the housing body 11 by shrink fitting.

[0036] The yoke 39 has a cylindrical shape extending in the direction of the axis O, that is, the front-rear direction, with the axis O as the center. The direction of the axis O coincides with the axial direction of the yoke 39, and the radial direction and the circumferential direction in the direction of the axis O coincide with the radial direction and the circumferential direction of the yoke 39, respectively.

[0037] As shown in FIGS. 3 and 4 etc., each tooth 43 has the same shape and is arranged at equal intervals in the circumferential direction of the yoke 39. Each tooth 43 is integral with the yoke 39 and extends radially inward from the inner peripheral surface 39a of the yoke 39 toward the center of the stator core 27, that is, the axis O. Each tooth 43 extends over the entire yoke 39 in the direction of the axis O from the front end to the rear end of the yoke 39, and thus the stator core 27.

[0038] Each tooth 43 gradually decreases in circumferential width from the outer side in the radial direction toward the inner side. Each tooth 43 has a flange portion 45 that protrudes in an arc shape on both sides in the circumferential direction at the tip portion 44 on the inner side in the radial direction. The tip surface 43a of the tooth 43 including both flange portions 45 is an arc surface. Each flange portion 45 has an outer surface 45a facing the outer side in the radial direction.

[0039] Six slots 47 are formed between adjacent teeth 43 in the circumferential direction. Each slot 47 is arranged at equal intervals in the circumferential direction. Each slot 47 has the same shape and extends from the front end to the rear end of the yoke 39 in the direction of the axis O. Each slot 47 has a slot opening 48 that is open toward the inner side in the radial direction. Specifically, the slot opening 48 is formed by the gap between the flange portions 45 facing each other in the circumferential direction of adjacent teeth 43.

[0040] Although illustration is omitted, both side surfaces in the circumferential direction of each tooth 43, both end surfaces in the direction of the axis O of each tooth 43, and the outer surface 45a of each flange portion 45 of each tooth 43 are covered with insulating paper.

[0041] The coil 31 is provided by winding a conducting wire having an insulating coating around each tooth 43. As shown in FIGS. 1, 4, 6 to 10, the coil 31 has a pair of coil end portions 49 and six slot accommodating portions 51. Each coil end portion 49 protrudes from the stator core 27 in the direction of the axis O. Each slot accommodating portion 51 is respectively accommodated in the slot 47.

[0042] The separator 33 is made of a resin having electrical insulation and heat resistance, specifically, made of PPS (polyphenylene sulfide). The separator 33 is columnar and extends in the direction of the axis O within the slot 47. The separator 33 has two separator portions 331.

[0043] As shown in FIGS. 5, 6, 8, etc., each separator portion 331 has an outer shape obtained by dividing a cylinder into two along the axial direction of the cylinder, and includes a rectangular plane 33a corresponding to the cut surface of the two-divided portion, a strip-shaped curved surface 33b protruding outward in the radial direction, and two semi-circular side surfaces 33c. Each separator portion 331 has a protruding portion 53 protruding in a semi-circular shape outward in the radial direction along the axial center O direction. And the apex portion of the semi-circular arc that is the protruding tip of the protruding portion 53 is the pressing portion 53a.

[0044] Also, each separator portion 331 has a through passage 54 extending parallel to the axial center O direction. The through passage 54 extends parallel to the rectangular plane 33a along the longitudinal direction of the rectangular plane 33a, and both ends of the through passage 54 are open to the strip-shaped curved surface 33b. That is, the through passage 53 penetrates the protruding portion 53 in the axial center O direction.

[0045] In each slot 47, two separators 33 are arranged side by side in the circumferential direction at positions outside the radial direction of each flange portion 45. In each separator 33, two separator portions 331 are arranged side by side in the axial center O direction. That is, a total of 12 separators 33 are provided, and a total of 24 separator portions 331 are provided. And each separator 33 protrudes toward the slot housing portion 51 of the coil 31 in the slot 47 and has two protruding portions 53 arranged in the axial center O direction. The length of each separator 33 in the axial center O direction is slightly longer than the length of the teeth 43 in the axial center O direction. One separator portion 331 in the axial center O direction protrudes in one direction of the axial center O from the teeth 43. The other separator portion 331 in the axial center O direction protrudes in the other direction of the axial center O from the teeth 43.

[0046] As shown in Fig. 7, for each separator 33, the rectangular plane 33a of each separator part 331 abuts against the outer face 45a of the flange part 45, and the pressing part 53a abuts against the slot housing part 51. Also, for the two separators 33 arranged in the circumferential direction within the slot 47, the semi-circular side faces 33c of the separator parts 331 facing each other in the circumferential direction abut against each other. As a result, the slot opening 48 of each slot 47 is blocked by the rectangular planes 33a of the separator parts 331 of the two separators 33.

[0047] The resin mold part 35 is made of a resin having electrical insulation and heat resistance, and specifically, it is made of an epoxy resin mixed with a filler of ceramic powder.

[0048] As shown in Figs. 1, 2, 9, and 10, the resin mold part 35 covers the stator core 27 and the coil 31 by molding the stator core 27 and the coil 31 with resin. The resin mold part 35 has a pair of end covering parts 55 and six slot filling parts 57.

[0049] Note that Fig. 7 is a cross-sectional view in a direction perpendicular to the axial center O direction cut at the position of the pressing part 53a which is the protruding tip of the protruding part 53 of the separator part 331. Also, Fig. 9 is a cross-sectional view in a direction perpendicular to the axial center O direction cut between two separator parts 331 arranged in the axial center O direction. Further, in Figs. 9 and 10, although resin hatching indicating the resin mold part 35 is not shown in the part indicating the coil 31, actually, the resin of the resin mold part 35 has also penetrated and filled the gaps between the conducting wires of the coil 31.

[0050] Each end covering part 55 covers each coil end part 49. Each slot filling part 57 is filled in each slot 47 and covers each slot housing part 51. Each end covering part 55 and each slot filling part 57 are integrally formed.

[0051] Each slot filling portion 57 has a gap filling portion 59. The gap filling portion 59 is interposed between the separator 33 and the slot housing portion 51 in the radial direction and is in contact with the separator 33 and the slot housing portion 51. As shown in FIG. 10, the minimum thickness T2 in the radial direction of the gap filling portion 59, that is, the minimum thickness T2 of the gap filling portion 59 between the separator 33 and the slot housing portion 51 in the radial direction within the slot 47, is thinner than the maximum thickness T1 of the separator 33 in the radial direction by a predetermined amount. Note that the minimum thickness T2 of the gap filling portion 59 between the separator 33 and the slot housing portion 51 in the radial direction can also be described as the shortest distance between the separator 33 and the inner peripheral surface of the slot housing portion 51 in the radial direction.

[0052] As shown in FIGS. 9 and 10, the resin mold portion 35 has 24 protruding portion inner filling portions 61. Each protruding portion inner filling portion 61 is filled in the through hole 54 of each separator portion 331. Each protruding portion inner filling portion 61 is integrally formed with the gap filling portions 59 provided on one side and the other side in the axial direction O of each separator portion 331, respectively.

[0053] Specifically, the protruding portion inner filling portion 61 in one separator portion 331 in the axial direction O is integrally formed with the gap filling portion 59 filled in the first gap S1 and the gap filling portion 59 filled in the third gap S3, which will be described later, respectively. Also, the protruding portion inner filling portion 61 in the other separator portion 331 in the axial direction O is integrally formed with the gap filling portion 59 filled in the third gap S3 and the gap filling portion 59 filled in the second gap S2, which will be described later, respectively.

[0054] This stator 21 can be manufactured as follows. First, after attaching insulating paper to each tooth of the stator core 27 as shown in FIG. 4, wind the coil 31 around each tooth 43, and arrange the slot housing portion 51 in each slot 47. At this time, the slot housing portion 51 is arranged outward in the radial direction within the slot 47. The radial dimension of the slot housing portion 51 at this time is C1.

[0055] Then, as shown in FIGS. 6 to 8, in each slot 47, between each flange portion 45 and the slot housing portion 51, separator portions 331 are pushed in from one side and the other side in the direction of the axis O, respectively, and each separator portion 331 is clamped between the flange portion 45 and the slot housing portion 51. Thereby, the slot housing portion 51 is pushed outward in the radial direction by the pressing portion 53a of each separator portion 331, and the slot housing portion 51 is pressed against the inner peripheral surface 39a of the yoke 39. That is, the slot housing portion 51 is clamped between the separator 33 and the yoke 39. As shown in FIG. 8, the radial dimension of the slot housing portion 51 at this time is C2 which is smaller than C1.

[0056] In this state, as shown in FIG. 8, first to third gaps S1 to S3 in the radial direction are formed between each separator portion 331 and the slot housing portion 51 on one side and the other side in the direction of the axis O with respect to the protruding portion 53 of each separator portion 331. The first gap S1 is formed on one side in the direction of the axis O with respect to the separator portion 331 on one side in the direction of the axis O. The second gap S2 is formed on the other side in the direction of the axis O with respect to the separator portion 331 on the other side in the direction of the axis O. The third gap S3 is formed on the other side in the direction of the axis O with respect to the separator portion 331 on one side in the direction of the axis O and on one side in the direction of the axis O with respect to the separator portion 331 on the other side in the direction of the axis O. That is, the third gap S3 is formed between two separator portions 331 arranged in the direction of the axis O.

[0057] Then, an integral body of the stator core 27, the coil 31, and each separator 33 is placed in the cavity of a mold, and uncured resin is injected and filled into the cavity from one side in the direction of the axis O at a predetermined injection pressure, and the resin mold portion 35 is formed by transfer molding.

[0058] At this time, the uncured resin injected into the cavity is injected into the through passage 54 and the first gap S1 of one separator portion 331 in the direction of the axis O, then injected into the third gap S3 and the through passage 54 of the other separator portion 331 in the direction of the axis O, and finally injected into the second gap S2. Then, the through passage 54 of one separator portion 331 in the direction of the axis O, the first gap S1, the third gap S3, the through passage 54 of the other separator portion 331 in the direction of the axis O, and the second gap S2 are filled with the uncured resin. As a result, in the slot 47, the resin is molded toward the slot housing portion 51 at both end portions in the direction of the axis O, and the resin is molded toward the slot housing portion 51 from the central portion in the direction of the axis O, that is, between the two through passages 54. As a result, in the slot 47, a gap filling portion 59 of the resin molding portion 35 is provided between the separator 33 and the slot housing portion 51, so that the separator 33 and the slot housing portion 51 are arranged to be radially separated.

[0059] In this way, the resin molding portion 35 in which the pair of end covering portions 55, the six slot filling portions 57, and the twenty-four protruding portion inner filling portions 61 are integrally formed is molded, and the stator 21 is completed. The radial dimension of the final slot housing portion 51 is C3 which is smaller than C2.

[0060] As shown in FIG. 1, the rotor 25 is disposed inside the stator 21. The rotor 25 has a cylindrical shape extending in the direction of the axis O. Further, a permanent magnet (not shown) is provided on the rotor 25. A rotating shaft 23 is fixed to the rotor 25 by shrink fitting, and the rotor 25 and the rotating shaft 23 are integrated. The rotor 25 can rotate around the axis O integrally with the rotating shaft 23 when an electric current flows through the coil 31.

[0061] As the compression mechanism 5, a known scroll type compression mechanism is adopted. The compression mechanism 5 is housed within the housing main body 11. The compression mechanism 5 has, within the housing main body 11, a fixed scroll fixed to the inner peripheral surface of the peripheral wall 11b in front of the motor chamber 17, and a movable scroll disposed opposite to the fixed scroll and rotatable by the rotary shaft 23. The fixed scroll and the movable scroll are engaged with each other, and a compression chamber for compressing the refrigerant gas is formed therebetween. Note that the illustrations of the fixed scroll, the movable scroll, and the compression chamber are all omitted.

[0062] In the stator 21 of the electric motor 3 provided in this electric compressor, in the slots 47, each rectangular plane 33a of each separator part 331 of the two separators 33 arranged in the circumferential direction abuts against the outer facing surface 45a of the flange part 45, whereby the radially inner slot opening 48 in the slots 47 is blocked. Further, the slot accommodation part 51 of the coil 31 accommodated in the slots 47 is covered by the slot filling part 57 of the resin molding part 35 filled in the slots 47. And the gap filling part 59 of the slot filling part 57 is interposed between the separator 33 and the slot accommodation part 51 in the radial direction and abuts against both of them.

[0063] Therefore, when the gap filling part 59 is formed by the curing of the uncured resin filled in the slots 47, a pressing force from the uncured resin that is gradually filled between the separator 33 and the slot accommodation part 51 acts on the slot accommodation part 51. As a result, the slot accommodation part 51 is pushed outward in the radial direction. Consequently, the contact area between the slot accommodation part 51 and the inner peripheral surface 39a of the yoke 39 increases. Thus, during the operation of the electric motor 3, the heat transfer property from the slot accommodation part 51 to the stator core 27 is improved, so that the heat of the coil 31 can be effectively conducted from the slot accommodation part 51 to the stator core 27.

[0064] Therefore, the electric motor 3, and thus the electric compressor of Embodiment 1 provided with this electric motor 3, can contribute to the improvement of the cooling efficiency of the coil 31.

[0065] In particular, in this electric motor 3, in the slot 47, the minimum thickness T2 of the gap filling portion 59 between the separator 33 and the slot accommodation portion 51 in the radial direction is made thinner than the maximum thickness T1 of the separator 33 in the radial direction by a predetermined amount. Therefore, the gap filling portion 59 formed between the separator 33 and the slot accommodation portion 51 can effectively press the slot accommodation portion 51 outward in the radial direction.

[0066] In this electric motor 3, two separator portions 331 arranged in the direction of the axis O each have a protruding portion 53 protruding outward in the radial direction, and a through passage 54 penetrating the protruding portion 53 in the direction of the axis O is formed in each protruding portion 53. Then, first to third gaps S1 to S3 in the radial direction are formed between the separator 33 and the slot accommodation portion 51 on one side and the other side in the direction of the axis O with respect to the two protruding portions 53, and the gap filling portion 59 filled in these first to third gaps S1 to S3 and the protruding portion internal filling portion 61 filled in the two through passages 54 are integrally formed.

[0067] Therefore, the three gap filling portions 59 filled in the first to third gaps S1 to S3 and the two protruding portion internal filling portions 61 are integrated to press the slot accommodation portion 51 outward in the radial direction, so that the pressing force outward in the radial direction increases. Also, in the slot 47, since the slot accommodation portion 51 is pressed outward in the radial direction at three locations: both end portions and the central portion in the direction of the axis O, the slot accommodation portion 51 can be more evenly pushed outward in the radial direction in the direction of the axis O. Therefore, the heat transfer performance from the slot accommodation portion 51 to the stator core 27 can be further improved.

[0068] Also, when attaching the separator 33 to the teeth 43, by pushing the slot housing portion 51 radially outward by the pressing portion 53a of each separator portion 331, the slot housing portion 51 can be pressed against the inner peripheral surface 39a of the yoke 39. Therefore, the contact area between the slot housing portion 51 and the stator core 27 can be further increased, and the heat of the coil 31 can be more effectively conducted from the slot housing portion 51 to the stator core 27.

[0069] (Embodiment 2) The electric compressor of Embodiment 2 includes an electric motor 3A shown in FIG. 12 instead of the electric motor 3. The electric motor 3A is also an example of the "rotating electrical machine" in the present invention. In this electric motor 3A, the stator 21A includes a bobbin 63 instead of the separator 33.

[0070] As shown in FIG. 11, the teeth 43A of the stator core 27A in this stator 21A have a flange portion 45A that protrudes less in the circumferential direction compared to the flange portion 45 in Embodiment 1. Therefore, the slot opening 48A radially inward of the slot 47, which is formed by the gap between the flange portions 45A facing each other in the circumferential direction within the slot 47, is larger than the slot opening 48 in Embodiment 1.

[0071] The bobbin 63 is made of a resin having electrical insulation and heat resistance, specifically made of PPS (polyphenylene sulfide). The bobbin 63 has two bobbin portions 631. The two bobbin portions 631 are arranged side by side in the direction of the axis O.

[0072] Each bobbin portion 631 has a tooth covering portion 65 that covers the teeth 43A and two first lid members 67 that close the slot opening 48A of the slot 47. The first lid member 67 is an example of the "insulating member" in the present invention.

[0073] In each bobbin part 631, the two first lid members 67 are provided on both circumferential side surfaces of the radially inner end part in the tooth covering part 65. The tooth covering part 65 and the two first lid members 67 are integrally formed. The first lid member 67 of one bobbin part 631 and the first lid member 67 of the other bobbin part 631 integrally form a column shape and extend in the axial center O direction within the slot 47.

[0074] Each tooth covering part 65 covers the end surface in the axial center O direction of the teeth 43A, both circumferential side surfaces of the teeth 43A, and both flange parts 45A of the teeth 43A. Each tooth covering part 65 has a fitting concave part 65a fitted to the teeth 43A.

[0075] Each first lid member 67 has basically the same shape as the separator part 331 in the first embodiment. That is, the first lid member 67 has an outer shape obtained by dividing a cylinder along the axial direction of the cylinder, and has a rectangular plane 67a corresponding to the cut surface of the divided part, a belt-shaped curved surface 67b protruding outward in the radial direction, and two semi-circular side surfaces 67c.

[0076] Also, each first lid member 67 has a protruding part 69 and a through passage 71 penetrating the protruding part 69 in the axial center O direction. The protruding part 69 protrudes in a semi-circular shape outward in the radial direction in the axial center O direction. Note that the protruding tip of the protruding part 69 does not function as a pressing part that presses the slot housing part 51 outward in the radial direction, unlike the protruding tip of the protruding part 53 in the first embodiment. The through passage 71 extends parallel to the rectangular plane 67a along the longitudinal direction of the rectangular plane 67a, and both ends of the through passage 71 open to the belt-shaped curved surface 67b. That is, the through passage 71 penetrates the protruding part 69 in the axial center O direction.

[0077] As shown in FIGS. 11 and 12, the two bobbin portions 631 are arranged side by side in the direction of the axis O with respect to each tooth 43A. One of the bobbin portions 631 in the direction of the axis O is inserted into the tooth 43A from one side in the direction of the axis O. As a result, the fitting recess 65a of the bobbin portion 631 on one side in the direction of the axis O is fitted to one portion of the tooth 43A in the direction of the axis O. The other bobbin portion 631 in the direction of the axis O is inserted into the tooth 43A from the other side in the direction of the axis O. As a result, the fitting recess 65a of the bobbin portion 631 on the other side in the direction of the axis O is fitted to the other portion of the tooth 43A in the direction of the axis O. In this way, one bobbin portion 631 in the direction of the axis O and the other bobbin portion 631 in the direction of the axis O are attached to the tooth 43A in a butted state.

[0078] Also, in each slot 47, two first lid members 67 are arranged side by side in the circumferential direction between the flange portions 45A facing each other in the circumferential direction. The two first lid members 67 arranged side by side in the circumferential direction have the semicircular side surfaces 67c facing each other in the circumferential direction in contact with each other. As a result, the slot opening 48A of the slot 47 is blocked by the two first lid members 67 arranged side by side in the circumferential direction within the slot 47.

[0079] This stator 21A can be manufactured as follows. First, two bobbin portions 631 are attached to each tooth 43A of the stator core 27A. Then, the coil 31 is wound around the tooth covering portion 65 of each bobbin portion 631. At this time, the coil 31 is wound around the radially outer portion of the tooth covering portion 65. In this way, within the slot 47, the slot accommodating portion 51 is arranged radially outside the first lid member 67.

[0080] Then, the integrated product of the obtained stator core 27A, the coil 31, and each bobbin 63 is placed in the cavity of the mold in the same manner as in the first embodiment, and the resin molded portion is molded by transfer molding to complete the stator 21A.

[0081] In this electric motor 3A, a first lid member 67 that closes the slot opening 48A of the slot 47 is integrally formed with the bobbin 63. Therefore, by attaching the bobbin 63 to the tooth 43A, the attachment of the first lid member 67 to the tooth 43A is also completed. As a result, the assembly process of the first lid member 67 can be omitted.

[0082] Other configurations and effects are the same as those in the first embodiment.

[0083] (Embodiment 3) The electric compressor of Embodiment 3 includes an electric motor 3B shown in FIG. 17 in place of the electric motor 3. The electric motor 3B is also an example of the "rotating electric machine" in the present invention. In this electric motor 3B, the stator 21B includes a second lid member 73 in place of the separator 33. The second lid member 73 is an example of the "insulating member" in the present invention.

[0084] The tooth 43B of the stator core 27B in this stator 21B is different from the tooth 43 in the first embodiment. Except for the tip portion 44 on the inner side in the radial direction, it extends with a substantially constant circumferential width from the outer side to the inner side in the radial direction.

[0085] The second lid member 73 is made of a resin having electrical insulation and heat resistance, and specifically, it is made of PPS (polyphenylene sulfide).

[0086] As shown in FIGS. 13 and 14, the second lid member 73 has a columnar shape and extends in the axial center O direction within the slot 47. The second lid member 73 has a lid main body portion 75 and a lid head portion 77. The lid main body portion 75 has an inner surface 75a facing the inner side in the radial direction and a pair of side surfaces 75b facing the circumferential direction. An inlet 79a of an axially extending path 79, which will be described later, is opened in the lid head portion 77. The inlets 79a are respectively arranged near both ends in the circumferential direction of the lid head portion 77.

[0087] As shown in FIG. 14, the lid head portion 77 of the second lid member 73 is installed on the teeth 43B adjacent to each other in the circumferential direction. As shown in FIG. 15, in the slot 47, the inner surface 75a of the lid main body portion 75 of the second lid member 73 abuts against the outer surfaces 45a of the flange portions 45 adjacent to each other in the circumferential direction, and the pair of side surfaces 75b abut against the side surfaces of the teeth 43B adjacent to each other in the circumferential direction. As a result, the slot opening 48 of each slot 47 is blocked by the lid main body portion 75.

[0088] As shown in FIG. 16, the length of the second lid member 73 in the axial direction of the axis O is slightly longer than the length of the teeth 43B in the axial direction of the axis O. The second lid member 73 has two axially extending paths 79 and branching paths 81 that branch off from each of the axially extending paths 79 in four directions at right angles.

[0089] The axially extending paths 79 are respectively arranged near both ends in the circumferential direction of the second lid member 73. The axially extending paths 79 extend parallel to the axial direction of the axis O. The axially extending paths 79 are formed in a cul-de-sac shape having an inlet 79a on one side in the axial direction of the axis O. The other end of the axially extending path 79 in the axial direction of the axis O extends to the vicinity of the other end of the second lid member 73 in the axial direction of the axis O.

[0090] The four branching paths 81 branching from the axially extending path 79 are arranged at substantially equal intervals in the axial direction of the axis O. One of the four branching paths 81 is arranged near the inlet 79a, and the other one is arranged at the other end of the axially extending path 79 in the axial direction of the axis O. Each branching path 81 branches from the axially extending path 79 and extends parallel to the radial direction toward the outer side in the radial direction. Each branching path 81 has an outlet 81a that opens toward the outer side in the radial direction.

[0091] As shown in FIGS. 17 and 18, the resin mold portion 35B of the stator 21B has a pair of end covering portions 55B and six slot filling portions 57B.

[0092] Note that FIGS. 15 and 17 are cross-sectional views in a direction perpendicular to the axial center O direction cut so that the cut surface passes through the branch path 81. Further, in FIGS. 17 and 18, although resin hatching indicating the resin mold part 35B is not shown in the part indicating the coil 31, actually, the resin of the resin mold part 35B also enters and fills the gaps between the lead wires of the coil 31. Further, in FIG. 14, the illustration of the coil 31 is omitted.

[0093] Each end covering part 55B covers each coil end part 49. Each slot filling part 57B is filled in each slot 47 and covers each slot housing part 51. Each end covering part 55B and each slot filling part 57B are integrally formed.

[0094] Each slot filling part 57B has a gap filling part 59B. The gap filling part 59B is interposed between the lid main body part 75 of the second lid member 73 and the slot housing part 51 in the radial direction and abuts on the lid main body part 75 and the slot housing part 51. As shown in FIG. 18, in the slot 47, the minimum thickness T2 of the gap filling part 59B between the lid main body part 75 of the second lid member 73 and the slot housing part 51 in the radial direction is thinner than the maximum thickness T1 of the lid main body part 75 of the second lid member 73 by a predetermined amount in the radial direction.

[0095] Further, the resin mold part 35B has 12 lid inner filling parts 83B. Each lid inner filling part 83B is filled in the axial direction extending path 79 of each second lid member 73 and each branch path 81. Each lid inner filling part 83B is integrally formed with the gap filling part 59B.

[0096] This stator 21B can be manufactured as follows. First, after attaching insulating paper to each tooth 43B of the stator core 27B, the coil 31 is wound around each tooth 43B, and the slot housing part 51 is arranged in each slot 47. At this time, the slot housing part 51 is arranged outward in the radial direction within the slot 47. As shown in FIG. 16, the radial dimension of the slot housing part 51 at this time is C2.

[0097] Then, at the radially inner end of each slot 47, the lid main body 75 of the second lid member 73 is inserted from one direction along the axis O, and the lid head 77 of the second lid member 73 is bridged over the teeth 43B adjacent in the circumferential direction.

[0098] Then, the integrated body of the obtained stator core 27B, coil 31, and each second lid member 73 is arranged in the cavity of the mold in the same manner as in the first embodiment, and the resin molded portion 35B is molded by transfer molding to complete the stator 21B. As shown in FIG. 18, the radial dimension of the final slot housing portion 51 becomes C3, which is smaller than C2.

[0099] In this electric motor 3B, when the resin molded portion 35B is molded, an uncured resin flows out radially outward from the outlet 81a of each branch passage 81, thereby forming the gap filling portion 59B. For this reason, when the gap filling portion 59B is formed, the injection pressure of the uncured resin acts radially outward. As a result, the slot housing portion 51 can be more effectively pushed radially outward. Further, since the four branch passages 81 are provided at substantially equal intervals in the axis O direction, the slot housing portion 51 can be pushed radially outward more evenly in the axis O direction.

[0100] Other configurations and operational effects are the same as those in the first embodiment.

[0101] As described above, the present invention has been described with reference to the first to third embodiments. However, the present invention is not limited to the above-described first to third embodiments, and it goes without saying that the present invention can be appropriately modified and applied without departing from the spirit thereof.

[0102] For example, in Embodiment 1, two separator portions 331 are arranged side by side in the direction of the axis O, and in Embodiment 2, two bobbin portions 631 are arranged side by side in the direction of the axis O. However, the present invention is not limited thereto. For example, two separator portions 331 may be integrally formed, or two bobbin portions 631 may be integrally formed. Further, only one separator portion 331 having an axial length equal to or greater than the axial length of the yoke 39 may be arranged, or only one bobbin portion 631 having an axial length equal to or greater than the axial length of the yoke 39 may be arranged.

[0103] In Embodiments 1 to 3, the separator portion 331 in Embodiment 1 has a through passage 54, the first lid member 67 in Embodiment 2 has a through passage 71, and the second lid member 73 in Embodiment 3 has an axially extending path 79 and a branch path 81. However, the present invention is not limited thereto. For example, the insulating member in the present invention may not have a through passage, an axially extending path, and a branch path.

[0104] Furthermore, as the compression mechanism 5, in addition to a vane type compression mechanism or a swash plate type compression mechanism, a centrifugal type compression mechanism or the like may be employed.

[0105] In addition, the compression mechanism 5 may compress a fluid other than the refrigerant gas, such as air or hydrogen for pumping to the fuel cell. That is, the compression mechanism 5 may be used for a fuel cell vehicle application.

[0106] From the disclosure of the specification, drawings, etc., the following technical ideas can be extracted.

[0107] (Appendix 1) A rotating shaft, A rotor fixed to the rotating shaft and rotating integrally with the rotating shaft, A stator having a cylindrical yoke disposed outside the rotor, and a plurality of teeth protruding from the inner peripheral surface of the yoke toward the rotor, with slots defined between the adjacent teeth in the circumferential direction of the yoke, a coil wound around the teeth, and a resin molded portion obtained by molding the stator core and the coil with resin. A rotating electrical machine comprising: a housing that houses the rotating shaft, the rotor, and the stator. In the slot, a columnar insulating member that closes a slot opening where the slot opens in the radial direction of the yoke toward the rotor is disposed. A rotating electrical machine, characterized in that a resin molding portion is provided between the insulating member and the coil in the slot, so that the insulating member and the coil are spaced apart.

[0108] (Appendix 2) The rotating electrical machine according to Appendix 1, wherein in the slot, a minimum thickness of the resin molding portion between the insulating member and the coil in the radial direction is thinner than a maximum thickness of the insulating member in the radial direction.

[0109] (Appendix 3) The rotating electrical machine according to Appendix 1 or 2, wherein the insulating member has an axially extending path that extends in the axial direction of the yoke and in which the resin molding portion is provided inside, and a branch path that branches from the axially extending path, opens toward the coil, and in which the resin molding portion is provided inside.

[0110] (Appendix 4) In the slot, the insulating member has a plurality of protruding portions that protrude toward the coil and are arranged in the axial direction of the yoke, and a plurality of through paths that each penetrate the protruding portion in the axial direction and in which the resin molding portion is provided inside. The rotating electrical machine according to any one of Appendices 1 to 3, wherein the resin is molded toward the coil from between the respective through paths.

Industrial Applicability

[0111] The present invention can be used for electric devices such as an electric compressor for a vehicle.

Explanation of Reference Numerals

[0112] 1... Housing 3, 3A, 3B... Electric motor (rotating electrical machine) 21, 21A, 21B... Stator 23... Rotation axis 25... Rotor 27, 27A, 27B... Stator core 31... Coil 33... Separator (insulating member) 35, 35B... Resin mold part 39... Yoke 43, 43A, 43B... Teeth 47... Slot 48, 48A... Slot opening 53, 69... Protrusion 54, 71... Through passage 67... First cover member (insulating member) 73... Second cover member (insulating member) 79... Axial extension path 81... Branch path

Claims

1. A rotating shaft, A rotor that is fixed to the rotating shaft and rotates integrally with the rotating shaft, A stator having a cylindrical yoke disposed outside the rotor, and a plurality of teeth protruding from the inner peripheral surface of the yoke toward the rotor, with slots defined between adjacent teeth in the circumferential direction of the yoke, a coil wound around the teeth, and a resin-molded portion obtained by molding the stator core and the coil with resin, A rotating electrical machine comprising the rotating shaft, the rotor, and a housing that houses the stator, In the slot, a columnar insulating member that closes a slot opening where the slot opens in the radial direction of the yoke toward the rotor is disposed, A rotating electrical machine, wherein in the slot, a resin-molded portion is provided between the insulating member and the coil, whereby the insulating member and the coil are spaced apart from each other.

2. The rotating electrical machine according to Claim 1, wherein in the slot, a minimum thickness of the resin-molded portion between the insulating member and the coil in the radial direction is thinner than a maximum thickness of the insulating member in the radial direction.

3. The insulating member has an axially extending path that extends in the axial direction of the yoke and is provided with the resin-molded portion inside, and a branch path that branches from the axially extending path, opens toward the coil, and is provided with the resin-molded portion inside. The rotating electrical machine according to Claim 1 or 2.

4. The insulating member has, in the slot, a plurality of protruding portions that protrude toward the coil and are arranged in the axial direction of the yoke, and a plurality of through paths that each penetrate through the protruding portion in the axial direction and are provided with the resin-molded portion inside, The rotating electrical machine according to Claim 1 or 2, wherein the resin is molded toward the coil from between each of the through paths.

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