Stator and motor

Abstract

To provide a stator structure in which wave windings, each wound once per phase, are disposed between slots of a stator core in a stator, and which enables securing insulation distances between the wave windings and between the wave winding and the stator core and to provide a motor employing the stator.SOLUTION: By disposing three types of slot insulating members 5a, 5b, 5c having different axial lengths between coil sides 10 of respective phase coils 7 and slots 4 of a stator core 1, the amount of projection from at least one end surface 1A of the stator core 1 is varied. In addition, a portion 11a of at least the first coil end 11 of each phase coil 7, which extends radially outward, is disposed on one axial end of slot insulating members 5a, 5b, 5c.SELECTED DRAWING: Figure 12

Description

Technical Field

[0001] The present invention relates to a stator structure capable of ensuring insulation between wave-wound coils and between a wave-wound coil and a stator core in a stator having wave-wound coils wound in one turn per phase between slots of a stator core, and a motor employing the stator.

Background Art

[0002] Conventionally, a motor is known in which a conductor having a rectangular cross-sectional shape (hereinafter referred to as a rectangular wire) is wound in a slot of a stator core to form a coil. For example, a technique related to a stator in which each phase coil wound between slots of a stator core is one turn each, and a motor using the stator has been published (see Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0004] The coil described in Patent Document 1 above includes a coil side extending in the axial direction of the stator core in a slot of the stator, a first coil end connecting between one ends of the coil sides on one end face side of the stator core and extending radially outward and circumferentially of the stator core, and on the other end face side of the stator core, a second coil end connecting between the other ends of the coil sides and extending radially inward and circumferentially of the stator core.

[0005] Only one coil side of one-phase coil is disposed in one slot of the stator core. The coils of each phase arranged in this way are arranged in a substantially stepped manner such that a part of the first and second coil ends is located above or below a part of the first and second coil ends of other-phase coils.

Summary of the Invention

[0006] In the stator described in the above Patent Document 1, the coils of each phase are molded with insulating resin to insulate the stator core from the coils and between the coils of each phase. By filling and molding the coils, which are the main heat source of the stator, with molding resin, the cooling effect of the motor can be improved. In addition, integral molding with molding resin enables a design with low vibration, low noise, compact size, and excellent environmental resistance.

[0007] On the other hand, after molding, the stator may have thin resin burrs on its inner diameter, which may cause problems due to the thin burrs falling off. In addition, integral molding with molded resin increases the cost of the motor. Furthermore, in response to the recent demand for recycling of product materials, it is difficult to recover the internal core and coils as resources from the stator covered with hardened molded resin, which is not in line with the needs of the times.

[0008] Therefore, an object of the present invention is to provide a stator that can insulate wave winding coils, each of which is wound with one turn for each phase, between the slots of a stator core without using molding, and a motor using such a stator. [Means for solving the problem]

[0009] The invention according to claim 1 is configured such that each phase coil wound between slots of a stator core is formed by one turn, and the coil includes a coil side extending in the axial direction of the stator core within the slot, and on one end face side of the stator core, a first coil end formed by connecting one ends of the coil sides continuously, a portion extending radially outward from the one end, and a portion extending circumferentially; and on the other end face side of the stator core, a second coil end formed by connecting the other ends of the coil sides continuously, a portion extending radially inward from the other end, and a portion extending circumferentially. A step is provided between each phase coil by a part of the first and second coil ends of one phase coil being located above or below a part of the first and second coil ends of another phase coil. In the stator, by arranging slot insulating members having different axial lengths between the coil side and the slot, the protruding amounts of the slot insulating members from at least one end face of the stator core are made different. The slot insulation makes the protruding amounts of the slot insulating members protruding from one end face of the stator core different, and the protruding amounts from the other end face are the same. It is also possible to make the protruding amounts from the other end face different.

[0010] The invention according to claim 2 is characterized in that the axial end of the slot insulating member according to claim 1 is bent to form a cuff portion, and the cuff portion is hooked on the end face of the stator core.

[0011] The invention according to claim 3 is a motor having the stator according to any one of claims 1 or 2.

Advantages of the Invention

[0012] According to the invention described in claim 1, the slot insulating member disposed in the slot of the stator surely insulates between the stator core and the coil. Also, by the slot insulating members protruding with different lengths from one end face (the other end face) of the stator core, an insulation distance between the coil ends of each phase coil can be ensured.

[0013] According to the invention described in claim 2, the cuffs of the slot insulating member disposed in the slots of the stator are hooked on the end faces of the stator core, thereby reliably preventing the slot insulating member from moving axially within the slots.

[0014] According to the invention described in claim 3, a motor having the effects of claim 1 or claim 2 can be realized.

Brief Description of the Drawings

[0015]

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

Embodiments for Carrying Out the Invention

[0016] The content of the present invention will be described in this specification. In this specification, the description of "axial direction" refers to the extending direction of the rotation center line of the rotor in an inner-rotating type motor in which the rotor, which will be described later, constituting the motor of the present invention is rotatably arranged on the inner diameter side of the stator.

[0017] Further, the description of "circumferential direction" refers to the circumferential direction centered on the rotation center line when viewed in a cross-section perpendicular to the "axial direction" in a state where the rotor is rotatably arranged relative to the inner diameter of the stator, or in a state where the coil is attached to the stator.

[0018] Furthermore, the description of "radial direction" refers to the radial direction passing through the rotation center line when viewed in a cross-section perpendicular to the "axial direction" in a state where the rotor is rotatably arranged relative to the inner diameter of the stator.

[0019] In addition, the description of "radially inner side" refers to the side closer to the rotation center line in the radial direction, and the description of "radially outer side" refers to the side opposite to the rotation center line in the radial direction.

[0020] In addition, in this specification, the descriptions of "cylindrical", "C-shaped", "corrugated", "rectangular", and "same length" are used to include "substantially cylindrical", "substantially C-shaped", "substantially corrugated", "substantially rectangular", and "substantially the same length", respectively. Furthermore, in this specification, for convenience, the illustrated "upper side" and "lower side" are respectively described as "one axial side" and "the other axial side", and the "left side" and "right side" are respectively described as "one circumferential side" and "the other circumferential side". Also, the "inner side" and "outer side" are respectively described as "radially inner side" and "radially outer side", but "one" and "the other", "inner side" and "outer side" are not limited thereto, and appropriate directions can be selected.

[0021] Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 14. FIG. 1 is a perspective view of a stator core 1 constituting a stator A of the present invention. The stator core 1 is composed of an annular yoke portion 2 and a plurality of teeth 3 protruding radially inward from the yoke portion 2. A plurality of slots 4 are formed in the circumferential direction between the plurality of teeth 3.

[0022] The stator core 1 is formed by stacking thin iron plates to form a laminated core, and by forming a laminated core, eddy current loss can be suppressed. However, such a laminated structure is not an essential condition for the stator core 1, and the stator core 1 may be configured as a single solid. Also, it is possible to form the stator core 1 by using a core member having a laminated structure or a single solid and having a divided structure in which the core member is subdivided in the circumferential direction, and joining the core members together in an annular shape.

[0023] A hollow portion H is formed inside the stator core 1 in the radial direction, and a cylindrical rotor (not shown) is rotatably disposed in the hollow portion H. The rotor rotates circumferentially within the hollow portion H by a rotating magnetic field formed by a coil attached to the stator core 1. At this time, the rotation axis of the rotor has its extending direction coinciding with the rotation center line, and both ends of the rotation axis are pivotally supported by bearings (not shown) so as to rotate within the hollow portion H. That is, the longitudinal direction of the rotation axis of the rotor becomes the "axial direction".

[0024] FIG. 2 is a perspective view showing the slot insulating members 5a, 5b, 5c disposed in the slot 4 of the stator core 1 shown in FIG. 1. The slot insulating members 5a, 5b, 5c are formed of, for example, a film made of a resin having insulating properties and are bent so that the cross-sectional shape becomes a U-shape. As the resin film, a resin film formed of various known resins is used.

[0025] The slot insulating members 5a, 5b, 5c have different axial lengths respectively. The first slot insulating member 5a shown in FIG. 2(a) is the shortest, and the third slot insulating member 5c shown in FIG. 2(c) is the longest. The second slot insulating member 5b shown in FIG. 2(b) has an intermediate length.

[0026] Cuff portions 6a1, 6a2, 6b1, 6b2, 6c1, 6c2 formed by bending the resin film in the axial direction are formed at both axial ends of the first to third slot insulating members 5a, 5b, 5c. The lengths of the respective cuff portions 6a1, 6b1, 6c1 formed at one axial end (the upper side in FIG. 2) are different by changing the amount of bending of the resin film.

[0027] Note that the lengths of the fourth cuff portions 6a2 formed at the other axial end of the first slot insulating member 5a, the fifth cuff portions 6b2 formed at the other axial end of the second slot insulating member 5b, and the sixth cuff portions 6c2 formed at the other axial end of the third slot insulating member 5c are the same. However, similar to the one axial end, the lengths of the cuff portions 6a2, 6b2, and 6c2 may be made different. In that case, however, for the slot insulating member with the longest cuff portion formed at one axial end, the cuff portion at the other axial end is made the shortest, and for the slot insulating member with the shortest cuff portion formed at one axial end, the length of the cuff portion at the other axial end is made the longest.

[0028] FIG. 3 shows a state where the slot insulating members 5a, 5b, and 5c shown in FIG. 2 are attached to the stator core 1 shown in FIG. 1. The slot insulating members 5a, 5b, and 5c are arranged in the plurality of slots 4 of the stator core 1 such that the opening sides of the U-shaped slot insulating members 5a, 5b, and 5c face the opening sides of the slots 4.

[0029] The slot insulating members 5a, 5b, and 5c arranged in the slots 4 are arranged one by one in three adjacent slots 4, namely, the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c. For example, they are arranged in the order of the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c toward one side in the circumferential direction (clockwise direction in the circumferential direction), and thereafter, they are arranged in the slots 4 toward one side in the circumferential direction in this order. In this case, the first slot insulating member 5a is arranged in the slot 4 adjacent to the one side in the circumferential direction of the third slot insulating member 5c.

[0030] Alternatively, they may be arranged in the order of the first slot insulating member 5a, the second slot insulating member 5b, and the third slot insulating member 5c toward the other side in the circumferential direction (counterclockwise direction in the circumferential direction), and thereafter, they are arranged in the slots 4 toward the other side in the circumferential direction in this order. In this case, the first slot insulating member 5a is arranged in the slot 4 adjacent to the other side in the circumferential direction of the third slot insulating member 5c.

[0031] Alternatively, they may be arranged in the order of the second slot insulating member 5b, the third slot insulating member 5c, and the first slot insulating member 5a toward one side in the circumferential direction, or in the order of the second slot insulating member 5b, the first slot insulating member 5a, and the third slot insulating member 5c. Alternatively, toward the other side in the circumferential direction, they may be arranged in the order of the second slot insulating member 5b, the third slot insulating member 5c, and the first slot insulating member 5a, or in the order of the second slot insulating member 5b, the first slot insulating member 5a, and the third slot insulating member 5c.

[0032] When arranging the slot insulating members 5a, 5b, and 5c in the slot 4, each of the slot insulating members 5a, 5b, and 5c is inserted into the slot 4 of the stator core 1 from one side in the axial direction shown in FIG. 1 (the upper side in FIG. 1), and pushed into the slot 4 toward the other side in the axial direction of the stator core 1 (the lower side in FIG. 1). As shown in FIG. 3, each of the slot insulating members 5a, 5b, and 5c is pushed into the slot 4 until the bent lower ends of the respective cuff portions 6a1, 6b1, and 6c1 formed at one axial end contact the one end face (the upper end face in FIG. 3) 1A of the stator core 1.

[0033] Then, when the bent lower ends of the cuff portions 6a1, 6b1, and 6c1 contact the one end face 1A of the stator core 1, the slot insulating members 5a, 5b, and 5c are locked at the opening of the slot 4 by the bent lower ends of the cuff portions 6a1, 6b1, and 6c1 and are not pushed in any further. In this state, the protruding amount of the cuff portion from the one end face 1A of the stator core 1 toward one side in the axial direction is the shortest for the first cuff portion 6a1 of the first slot insulating member 5a, the longest for the third cuff portion 6c1 of the third slot insulating member 5c, and the intermediate length for the second cuff portion 6b1 of the second slot insulating member 5b.

[0034] On one side, the other end face (the lower end face in Fig. 3) 1B of the stator core 1 is in a state where the bent upper ends of the fourth, fifth, and sixth cuff portions 6a2, 6b2, and 6c2 of the first, second, and third slot insulating members 5a, 5b, and 5c shown in Fig. 2 are in contact. As a result, one end face 1A and the other end face 1B of the stator core 1 are in a state of being sandwiched between the first, second, and third cuff portions 6a1, 6b1, and 6c1 and the fourth, fifth, and sixth cuff portions 6a2, 6b2, and 6c2 of the first, second, and third slot insulating members 5a, 5b, and 5c. Thereby, the first, second, and third slot insulating members 5a, 5b, and 5c are restricted from moving in the axial direction within the slot 4 of the stator core 1.

[0035] Fig. 4 shows the coil 7 attached to the stator core 1 of Fig. 1. The coil 7 is formed by attaching a conductor formed and manufactured in a waveform shape into the slot 4 of the stator core 1 to form a wave-wound coil, and is composed of a total of three coils 7u, 7v, and 7w for three phases of U-phase, V-phase, and W-phase. Since the shapes and structures of the coils 7u, 7v, and 7w of each phase are the same, in Fig. 4, the U-phase coil 7u will be described.

[0036] As shown in Fig. 4, the coil 7u is formed by forming and manufacturing a single conductor in a waveform shape. Specifically, it includes one open end 8 and the other open end 9 of the coil 7u, and the portion between both open ends 8 and 9 is formed and manufactured in a waveform shape. One open end 8 is composed of a coil side 10 in a linear thin plate shape extending toward one side in the axial direction (the upper side in Fig. 4), and includes a first coil end 11 composed of a portion 11a extending radially outward and a portion 11b extending in one circumferential direction from the end of the coil side 10 on one side in the axial direction (the upper side in Fig. 4).

[0037] On one circumferential side of the first coil end 11, a thin plate-shaped coil side 10 extending toward the other side in the axial direction (the lower side in Fig. 4) is connected, and a second coil end 12 composed of a portion 12a extending radially inward and a portion 12b extending in one circumferential direction from the end of the coil side 10 on the other side in the axial direction (the lower side in Fig. 4) is connected.

[0038] On one circumferential side of the second coil end 12, a coil side 10 extending toward one axial side is connected. At one axial side end of the coil side 10, a first coil end 11 having the same shape as described above is connected. Thereafter, similarly, the coil sides 10, the second coil end 12, and the coil sides 10 are continuous in this order toward one circumferential side. And, in front of the other open end 9, a first coil end 11 composed of a portion 11a extending radially outward from one axial side end of the coil side 10 and a portion 11b extending toward one circumferential side is connected, and a coil side 10 extending toward the other axial side is continuous on one circumferential side of the first coil end 11. The other open end 9 is formed by the final coil side 10.

[0039] The coil 7u schematically configured in this way has detailed structures such as the width dimension, plate thickness dimension of the coil side 10 and the first and second coil ends 11 and 12, and the shape and dimension of the portion where the coil side 10 is connected to the first and second coil ends 11 and 12, which are determined in consideration of the size of the motor incorporating the coil 7u, the various devices incorporating the motor, the cross-sectional area required to pass current through the coil 7u, or the space distance (insulation distance) between the phase coils 7u, 7v, and 7w.

[0040] Note that the number of waveforms between one open end 8 and the other open end 9 of the coil 7u is not limited to the number shown in FIG. 4, and has a waveform having the number of coil sides 10 that is one-third of the number of slots of the stator core 1. Since the coils 7v and 7w both have the same structure as the coil 7u shown in FIG. 4, the description of the structures of the V-phase coil 7v and the W-phase coil 7w is omitted.

[0041] As a manufacturing method of the coils 7u, 7v, and 7w, in addition to the method of forming and manufacturing the above-described single conductor into a waveform, it is also possible to manufacture, for example, from a strip material or a plate-like material. Further, the coils 7u, 7v, and 7w shown in FIG. 4 may be manufactured by joining a large number of members by welding or the like.

[0042] Next, the case of attaching the coil 7 shown in FIG. 4 to the stator core 1 to which the slot insulating members 5a, 5b, and 5c shown in FIG. 3 are attached will be described. When manufacturing the stator A according to the present invention, a total of three coils 7u, 7v, and 7w shown in FIG. 4 are prepared, one for each phase. To the stator core 1, the coils 7u, 7v, and 7w of each phase are attached in order. In this embodiment, the order of attachment to the stator core 1 will be described for the case of attaching the U-phase coil 7u, the V-phase coil 7v, and the W-phase coil 7w in this order, but it is not limited to this order. Any of the six ways of mutually swapping the order may be selected.

[0043] First, the U-phase coil 7u is attached to the stator core 1. First, as shown in FIG. 5, the coil side 10 of the coil 7u is inserted into the slot 4 to which the first slot insulating member 5a of the stator core 1 is attached, from one axial side of the stator core 1 toward the other axial side.

[0044] As shown in FIG. 5, when the coil side 10 is inserted into the slot 4 of the stator core 1, since the second coil end 12 (see FIG. 4) of the coil 7u is composed of a portion 12a extending radially inward from the second coil end 12 located radially inward of the coil side 10 and a portion 12b extending in the circumferential direction, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0045] And when the coil 7u is deeply inserted into the slot 4 of the stator core 1, as shown in FIG. 6, the first coil end 11 of the coil 7u is composed of a portion 11a extending radially outward of the coil end 10 and a portion 11b extending circumferentially on the yoke portion 2 of one end face 1A of the stator core 1. Therefore, the portion 11b of the first coil end 11 of the coil 7u extending in the circumferential direction is inserted up to the height of the cuff portion 6a1 of the first slot insulating member 5a protruding from the yoke portion 2 of the one end face 1A, and is not inserted deeper. Further, in this state, the portion 11a of the first coil end 11 of the coil 7u extending radially outward is disposed at the height position of the axially one end portion (the upper side in FIG. 6) of the first slot insulating member 5a.

[0046] On the other hand, the second coil end 12 of the coil 7u passing through the hollow portion H of the stator core 1 is such that, on the other end face 1B side of the stator core 1, the position of the portion 12b of the second coil end 12 of the coil 7u extending in the circumferential direction is determined by the protruding height of the cuff portion 6a1 of the first slot insulating member 5a protruding from the yoke portion 2 of the one end face 1A.

[0047] FIG. 7 shows the state on the other axial side of the coil 7u attached to the stator core 1. As shown in FIG. 7, one open end 8 and the other open end 9 of the coil 7u having the coil side 10 disposed in the slot 4 protrude downward from the other end face 1B. Further, on the radially inner side of the other end face 1B side of the stator core 1, a portion 12a extending radially inward and a portion 12b extending circumferentially of the second coil end 12 are disposed. FIG. 8 is a perspective view showing that state from the other end face 1B side of the stator core 1.

[0048] After completing the attachment of the coil 7u to the stator core 1, next, the V-phase coil 7v is attached to the stator core 1. The coil 7v is attached in the same manner as in the case of the coil 7u, by inserting the coil side 10 shown in FIG. 4 into the slot 4 to which the second slot insulating member 5b is attached from the one axial side to the other axial side of the stator core 1 shown in FIG. 9.

[0049] As shown in Fig. 9, when inserting the coil side 10 into the slot 4, since the second coil end 12 (see Fig. 4) of the coil 7v is located radially inside the coil side 10, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0050] And when the coil 7v is deeply inserted into the slot 4 of the stator core 1, as shown in Fig. 10, the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7v is located above the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7u, and is inserted up to the height of the cuff portion 6b1 of the second slot insulating member 5b protruding from the yoke portion 2 of one end face 1A, and is not inserted deeper than that.

[0051] In this state, the portion 11a extending radially outside the first coil end 11 of the coil 7v is arranged at the height position of the axially one end portion (the upper side in Fig. 10) of the second slot insulating member 5b. Also, since the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7v extends in the circumferential direction of the yoke portion 2 of the stator core 1, when the coil side 10 is inserted into the slot 4 of the stator core 1 and reaches a certain depth position, a part of the first coil end 11 of the coil 7v will be located above a part of the first coil end 11 of the coil 7u.

[0052] On the other hand, the second coil end 12 of the coil 7v that has passed through the hollow portion H of the stator core 1 is on the other end face 1B side of the stator core 1, and the portion 12b extending in the circumferential direction of the second coil end 12 of the coil 7v is located above the portion 12b extending in the circumferential direction of the second coil end 12 of the coil 7u, and its position is determined by the protruding height of the cuff portion 6b1 of the second slot insulating member 5b protruding from the yoke portion 2 of one end face 1A.

[0053] On the other side in the axial direction of the stator core 1, similar to the case where the coil 7u is attached, one open end 8 and the other open end 9 of the coil 7v project downward from the other end face 1B of the stator core 1. Also, the second coil end 12 is located radially inward on the side of the other end face 1B of the stator core 1.

[0054] After the attachment of the coil 7v to the stator core 1 is completed, next, the W-phase coil 7w is attached to the stator core 1. The attachment method of the coil 7w is the same as that of the coil 7u. From one side in the axial direction to the other side in the axial direction of the stator core 1 shown in FIG. 11, the coil side 10 shown in FIG. 4 is inserted into the slot 4 to which the slot insulating member 5c is attached.

[0055] As shown in FIG. 11, when the coil side 10 is inserted into the slot 4, since the second coil end 12 (see FIG. 4) of the coil 7w is located radially inside the coil side 10, in the process of inserting the coil side 10 into the slot 4 of the stator core 1, the second coil end 12 does not interfere (contact) with the stator core 1 and passes through the hollow portion H.

[0056] When the coil 7w is deeply inserted into the slot 4 of the stator core 1, as shown in FIG. 12, the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7w extends in the circumferential direction on the yoke portion 2 of the one end face 1A of the stator core 1. Therefore, the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7w is located above the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7v and is inserted up to the height of the cuff portion 6c1 of the third slot insulating member 5c protruding from the yoke portion 2 of the one end face 1A, and is not inserted deeper. Also, the portion 11a extending radially outside the first coil end 11 of the coil 7w is arranged at the height position on one side in the axial direction (the upper side in FIG. 12) of the third slot insulating member 5c.

[0057] In this state, on the other axial side of the stator core 1, similar to the case where the coils 7u and 7v are attached, one open end 8 and the other open end 9 of the coil 7w protrude downward from the other end face 1B. Also, the second coil end 12 is located radially inside the stator core 1 on the side of the other end face 1B of the stator core 1.

[0058] And since the portion 11b extending in the circumferential direction of the first coil end 11 of the coil 7w extends in the circumferential direction at a position on the yoke portion 2 of the stator core 1, when the coil side 10 is inserted into the slot 4 of the stator core 1 and reaches a certain depth position, a part of the first coil end 11 of the coil 7w will be located above a part of the first coil end 11 of the coil 7v.

[0059] On the other hand, the second coil end 12 of the coil 7w passing through the hollow portion H of the stator core 1 is such that the portion 12b extending in the circumferential direction of the second coil end 12 of the coil 7w is located above the portion 12b extending in the circumferential direction of the second coil end 12 of the coil 7v on the side of the other end face 1B of the stator core 1, and its position is determined by the protruding height of the cuff portion 6c1 of the third slot insulating member 5c protruding from the yoke portion 2 of the one end face 1A.

[0060] As shown in FIG. 12, in the state where each phase coil 7u, 7v, 7w is attached to the stator core 1, one open end 8 of each phase coil 7u, 7v, 7w protrudes from inside the slot 4 to the side of the other end face 1B of the stator core 1. Also, the other open end 9 of each phase coil 7u, 7v, 7w protrudes from inside the slot 4 to the side of the other end face 1B of the stator core 1.

[0061] One open end 8 of each phase coil 7u, 7v, 7w is electrically connected to an external power source (not shown), and by applying three-phase power to each phase coil 7u, 7v, 7w from the external power source, a rotating magnetic field is generated by each phase coil 7u, 7v, 7w to rotate a rotor (described later) disposed in the hollow portion H of the stator core 1.

[0062] In addition, if the shape of the one open end 8 is made to be a shape that can be fitted to a power supply connection connector (not shown) of an external power supply, by simply attaching the one open end 8 to the connector, complicated terminal processing can be avoided.

[0063] FIG. 13 shows the other end face 1B of the stator core 1 shown in FIG. 12. On the other end face 1B side, when the other open ends 9 star-connect the phase coils 7u, 7v, 7w, they function as a neutral point. For example, as shown in FIG. 12, the three other open ends 9 protruding on the other end face 1B side of the stator core 1 are bent in the circumferential direction as shown in FIG. 13, and the coil bars 9a formed thereby are overlapped with the coils 7u and 7v, and the coils 7v and 7w, respectively, and are crimped by the crimp terminals 17 to connect the neutral points. In addition to forming the neutral points at two locations in this way, the phase coils 7u, 7v, 7w can also be crimped with a crimp terminal as a single neutral point. Alternatively, the neutral points can also be connected by welding the three other open ends 9 protruding on the other end face 1B side of the stator core 1 to a coil bar of a separate member. Or, the neutral points may be formed by connecting the three other open ends 9 to terminals by huging or soldering.

[0064] Also, when the phase coils 7u, 7v, 7w are delta-connected, the one open end 8 and the other open end 9 of each phase are connected and wired according to various motor specifications. That is, the motor according to the present invention is applicable regardless of star connection or delta connection.

[0065] The stator A of the present invention is configured as described above. Further, as shown in FIG. 14, the rotor 18 is rotatably assembled to the stator A of the present invention, and thus the motor B of the present invention is configured. That is, the stator A and the motor B of the present invention can insulate between the stator core 1 and each phase coil 7u, 7v, 7w, and between each phase coil 7u, 7v, 7w without molding. Thereby, the demerit of cost increase due to molding can be eliminated, and it can contribute to the demand for recycling of product materials. If cost increase and recycling are not considered, it is also possible to improve the insulation characteristics by molding the periphery of the stator core 1 and each phase coil 7u, 7v, 7w with an insulating resin.

[0066] In the above embodiment, the first coil ends 11 and the second coil ends 12 of each phase coil 7u, 7v, 7w are arranged with steps in the order of U phase, V phase, and W phase in this order from the other side in the axial direction (the lower side in FIG. 1). However, the stator of the present invention is not limited to this configuration, and the first coil ends 11 and the second coil ends 12 of each phase coil 7u, 7v, 7w may be arranged in a state where the order is appropriately switched.

[0067] Also, in FIG. 1, the case where 30 slots 4 are formed in the stator core 1 is described, but the number of slots 4 is not limited to this. Since the coil 7 shown in FIG. 4 is three-phase, it is only necessary to form a number of slots that is a multiple of 3. Naturally, the number of coil sides 10 of the coil 7u shown in FIG. 4 also changes accordingly depending on the number of slots to be selected.

[0068] Furthermore, in the above-described embodiment, the case where the cross-sectional shape of the coil sides 10 of each phase coil 7u, 7v, 7w is formed by a rectangular conductor has been described. However, the coils 7u, 7v, 7w according to the present invention may have a cross-sectional shape that is circular, elliptical, square, or other polygons other than quadrilaterals. In that case, the shape of the slots 4 of the stator core 1 shown in FIG. 1 and the slot insulating members 5a, 5b, 5c disposed in the slots 4 is also made to be a shape that can accommodate the cross-sectional shape of the coils 7u, 7v, 7w. Also, by designing the gaps between the slots 4 and the slot insulating members 5a, 5b, 5c and the coils 7u, 7v, 7w to be as narrow as possible, the occupancy ratio of the coils 7u, 7v, 7w in the slots 4 can be increased.

[0069] As described above, in the stator of the present invention, the protruding amounts of the slot insulating members attached to the stator core from the end face (at least one end face) of the stator core 1 are made different, and the first coil end is disposed on one axial side and the second coil end is disposed on the other axial side. Therefore, the insulation distance between the first and second coil ends of each phase coil can be reliably ensured by the slot insulating members.

[0070] In the present embodiment, the protruding amounts of the slot insulating members protruding from one end face of the stator core are made different, and the protruding amounts from the other end face are the same. However, the protruding amounts from the other end face can also be made different. By protruding the slot insulating members from the other end face, insulation can be ensured between the outer peripheral side of each phase coil at the other end face and the case in which the motor is incorporated.

[0071] Also, since the slot insulating member forms a cuff portion by bending the axial end portion, the cuff portion can be hooked on the end face of the stator core, and it is possible to reliably prevent the slot insulating member from moving axially within the slot.

[0072] It should be noted that the technical scope of the present invention naturally extends to various modified configurations without departing from the gist of the invention described above. For example, after forming and manufacturing each phase coil, it is also possible to cover it with an insulating resin such as enamel, polyurethane, PC (polycarbonate), POM (polyacetal), PET (polyethylene terephthalate), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), LCP (liquid crystal polymer), SPS (syndiotactic polystyrene), PA66 (66 nylon), PEEK resin, etc.

Industrial Applicability

[0073] It can be used for the stator constituting various motors.

Explanation of Signs

[0074] 1 Stator core 1A One end face 1B The other end face 2 Yoke part 7u U-phase coil 7v V-phase coil 7w W-phase coil 3 Teeth 4 Slots 4a Radial bottom of the slot 5 Slot insulating member 5a First slot insulating member 5b Second slot insulating member 5c Third slot insulating member 6a1 First cuff part 6a2 Second cuff part 6b1 Third cuff part 6b2 Fourth cuff part 6c1 Fifth cuff part 6c2 Sixth cuff part 7 Coil 7u U-phase coil 7v V-phase coil 7w W-phase coil 8 One open end 9 The other open end 9a Coil bar 10 coil sides 11 first coil end 11a portion extending radially outward from the first coil end 11b portion extending circumferentially from the first coil end 12 second coil end 12a portion extending radially inward from the second coil end 12b portion extending circumferentially from the second coil end 17 crimp terminal 18 rotor A stator B motor H hollow portion

Claims

1. Each phase coil wound between slots of the stator core is configured with one turn, and the coil includes a coil side extending in the axial direction of the stator core within the slot, and on one end face side of the stator core, a first coil end formed by connecting one ends of the coil sides continuously, a portion extending radially outward from the one end, and a portion extending circumferentially; and on the other end face side of the stator core, a second coil end formed by connecting the other ends of the coil sides continuously, a portion extending radially inward from the other end, and a portion extending circumferentially. A step is provided between the phase coils by a part of the first and second coil ends being located above or below a part of the first and second coil ends of the other phase coils. In the stator, by disposing slot insulation members having different axial lengths between the coil side and the slot, the protruding amounts of the slot insulation members from at least one end face of the stator core are made different. A stator characterized by this.

2. The slot insulation member forms a cuff portion by bending an axial end portion, and the stator according to claim 1, characterized in that the cuff portion is hooked on the end face of the stator core.

3. A motor characterized by having the stator according to claim 1 or claim 2.

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