Motor stator and manufacturing method thereof

Abstract

To obtain a motor stator in which a coil lead wire portion can be easily connected to a substrate via solder.SOLUTION: A motor stator includes a stator core 1, a bobbin 2 provided on the stator core 1, a coil 3 provided on the stator core 1 via the bobbin 2, and a substrate 4 attached to the bobbin 2. The coil 3 includes a winding portion 31 that is wound around the bobbin 2, and a lead-out portion 32 that is drawn out from the winding portion 31 and connected to the substrate 4 via solder. The bobbin 2 includes a flange portion 22 facing in the radial direction D2, and the flange portion 22 includes a slit 24 that extends in the circumferential direction D3. The substrate 4 includes a substrate main body 41 formed in an annular shape and a protrusion portion 42 that protrudes from the substrate main body 41 in the radial direction D2, and the protrusion portion 42 is inserted into the slit 24.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This invention relates to a motor stator and a method for manufacturing the same.

Background Art

[0002] Conventionally, a motor stator including a stator core, a bobbin, a coil, and a substrate has been known. The bobbin is provided on the stator core. The coil is provided on the stator core via the bobbin. The substrate is fixed to the stator core via a housing. The coil and the substrate are electrically connected to each other (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The coil includes a winding portion that is a portion wound around the bobbin and a lead wire portion drawn from the winding portion. The electrical connection between the coil and the substrate is made by connecting the lead wire portion of the coil to the substrate via solder.

[0005] In order to reduce the axial dimension of the motor stator, the substrate may be attached to the bobbin. When the substrate is attached to the bobbin, the distance between the substrate and the winding portion of the coil becomes small, and there is a problem that the operation of connecting the lead wire portion of the coil to the substrate via solder becomes difficult.

[0006] This invention has been made to solve the above-described problems, and an object thereof is to provide a motor stator and a method for manufacturing the same that can easily connect the lead wire portion of the coil to the substrate via solder.

Means for Solving the Problem

[0007] The motor stator according to this invention includes a stator core, a bobbin provided on the stator core, a coil provided on the stator core via the bobbin, and a substrate attached to the bobbin. The coil has a winding portion that is the portion wound around the bobbin, and a lead-out portion that is drawn out from the winding portion and connected to the substrate via solder. The bobbin has a flange portion facing in the radial direction, and a slit extending in the circumferential direction is formed in the flange portion. The substrate has an annular substrate body and a protrusion protruding radially from the substrate body. The protrusion is inserted into the slit. In the motor stator according to this invention, the slit is open on the other side in the circumferential direction, and the protrusion is inserted into the slit when the substrate rotates in one direction in the circumferential direction with respect to the bobbin. The manufacturing method of the motor stator according to this invention includes a lead-out portion connection step of connecting the lead-out portion of the coil to the substrate via solder in a state where the protrusion is disengaged from the slit, and a substrate attachment step of inserting the protrusion into the slit and attaching the substrate to the bobbin after the connection step.

Advantages of the Invention

[0008] According to the motor stator and its manufacturing method according to this invention, the lead-out portion of the coil can be easily connected to the substrate via solder.

Brief Description of the Drawings

[0009]

Figure 1

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Figure 17

Mode for Carrying Out the Invention

[0010] Embodiment 1. FIG. 1 is a perspective view showing a motor stator according to Embodiment 1. FIG. 2 is a longitudinal sectional view showing the motor stator of FIG. 1. The motor stator according to Embodiment 1 includes a stator core 1, a plurality of bobbins 2, a plurality of coils 3, and a substrate 4.

[0011] The stator core 1 includes a core back 11 and a plurality of teeth 12 provided on the core back 11. The shape of the core back 11 is annular. The stator core 1 is composed of a plurality of laminated steel plates.

[0012] The direction along the axis of the core back 11 is defined as the axial direction D1. The direction along the radius of the circle centered on the axis of the core back 11 in the plane orthogonal to the axis of the core back 11 is defined as the radial direction D2. The direction along the circumference of the circle centered on the axis of the core back 11 in the plane orthogonal to the axis of the core back 11 is defined as the circumferential direction D3.

[0013] The plurality of teeth 12 are arranged in a row in the circumferential direction D3. Specifically, nine teeth 12 are arranged in a row in the circumferential direction D3. Each tooth 12 protrudes from the inner peripheral surface of the core back 11 toward the inner side in the radial direction D2. The tip surface of each tooth 12 faces a rotor (not shown).

[0014] The plurality of bobbins 2 are provided one by one on the plurality of teeth 12. Accordingly, the plurality of bobbins 2 are arranged in a row in the circumferential direction D3. Specifically, nine bobbins 2 are arranged in a row in the circumferential direction D3. Each bobbin 2 is made of resin.

[0015] The plurality of coils 3 are provided one by one on the plurality of teeth 12 via the corresponding bobbins 2. Accordingly, the plurality of coils 3 are arranged in a row in the circumferential direction D3. Specifically, nine coils 3 are arranged in a row in the circumferential direction D3.

[0016] Each coil 3 has a winding portion 31 wound around the corresponding bobbin 2. The plurality of coils 3 have a plurality of lead-out wire portions 32 drawn from the plurality of winding portions 31. Specifically, six lead-out wire portions 32 are drawn from the plurality of winding portions 31. Each lead-out wire portion 32 is connected to the substrate 4 via solder.

[0017] The substrate 4 is provided on the bobbin 2. The substrate 4 is disposed on one side of the bobbin 2 in the axial direction D1. In FIGS. 1 and 2, the upper side is one side in the axial direction D1.

[0018] FIG. 3 is an enlarged view showing the substrate 4 of FIG. 1. The substrate 4 includes a substrate body 41 and a plurality of protrusions 42. The number of the protrusions 42 corresponds to the number of the bobbins 2.

[0019] The shape of the substrate body 41 is annular. The substrate body 41 is arranged so as to overlap the plurality of coils 3 when viewed along the axial direction D1. Each lead wire portion 32 is connected to the substrate body 41 via solder.

[0020] A plurality of grooves 41a are formed in the outer peripheral portion of the substrate body 41. The plurality of grooves 41a extend from the outer peripheral surface of the substrate body 41 toward the inside in the radial direction D2. The plurality of grooves 41a are arranged in a row in the circumferential direction D3. Specifically, six grooves 41a are arranged in a row in the circumferential direction D3. A plurality of lead wire portions 32 are inserted into the plurality of grooves 41a, one by one.

[0021] A plurality of solder connection portions 41b are formed on one surface of the substrate body 41 in the axial direction D1. The plurality of solder connection portions 41b are arranged corresponding to the plurality of grooves 41a, one by one. Each solder connection portion 41b is arranged adjacent to the corresponding groove 41a on the inside in the radial direction D2.

[0022] The plurality of protrusions 42 are arranged in a row in the circumferential direction D3. Each protrusion 42 is provided at the outer end of the substrate body 41 in the radial direction D2. Each protrusion 42 protrudes from the outer peripheral surface of the substrate body 41 toward the outside in the radial direction D2.

[0023] FIG. 4 is a perspective view showing the bobbin 2 of FIG. 1. FIG. 5 is a front view showing the bobbin 2 of FIG. 4. The bobbin 2 includes a cylindrical portion 21 and a pair of flange portions 22.

[0024] An insertion hole 23 into which the teeth 12 are inserted is formed in the cylindrical portion 21. The bobbin 2 is attached to the teeth 12 by inserting the teeth 12 into the insertion hole 23. The cylindrical portion 21 is arranged so that the insertion hole 23 extends in the radial direction D2.

[0025] A pair of flange portions 22 are respectively provided at both ends of the cylindrical portion 21 in the radial direction D2. Among the pair of flange portions 22, the flange portion 22 provided outside the cylindrical portion 21 in the radial direction D2 is defined as the first flange portion 22a, and the flange portion 22 provided inside the cylindrical portion 21 in the radial direction D2 is defined as the second flange portion 22b.

[0026] The distance from the cylindrical portion 21 in the axial direction D1 to the tip surface of the first flange portion 22a is larger than the distance from the cylindrical portion 21 in the axial direction D1 to the tip surface of the second flange portion 22b.

[0027] A slit 24 extending in the circumferential direction D3 is formed in a portion of the first flange portion 22a on one side in the axial direction D1. The other side in the circumferential direction D3 of the slit 24 is open. In FIG. 5, the left side is one side in the circumferential direction D3, and the right side is the other side in the circumferential direction D3.

[0028] The distance from the cylindrical portion 21 in the axial direction D1 to the tip surface of the first flange portion 22a is larger than the distance from the cylindrical portion 21 in the axial direction D1 to the slit 24. The distance from the cylindrical portion 21 in the axial direction D1 to the slit 24 is the same as the distance from the cylindrical portion 21 in the axial direction D1 to the tip surface of the second flange portion 22b. Note that the distance from the cylindrical portion 21 in the axial direction D1 to the slit 24 may be equal to or greater than the distance from the cylindrical portion 21 in the axial direction D1 to the tip surface of the second flange portion 22b.

[0029] A plurality of protrusion portions 42 can be inserted into each slit 24 one by one. When the substrate 4 rotates with respect to the bobbin 2 on one side in the circumferential direction D3, the protrusion portion 42 is inserted into the corresponding slit 24. On the other hand, when the substrate 4 rotates with respect to the bobbin 2 on the other side in the circumferential direction D3, the protrusion portion 42 comes out of the corresponding slit 24.

[0030] Of the inner wall surface of the slit 24, the surface facing the other side in the circumferential direction D3 is defined as the circumferential side wall surface 25. The substrate 4 can rotate relative to the bobbin 2 to one side in the circumferential direction D3 until the protruding portion 42 reaches the circumferential side wall surface 25.

[0031] When the protruding portion 42 reaches the circumferential side wall surface 25, the position of the substrate 4 relative to the bobbin 2 is determined in the axial direction D1, the radial direction D2, and the circumferential direction D3.

[0032] Each slit 24 includes a slit main body 24a and a narrow portion 24b. The narrow portion 24b is disposed at the opening side portion of the slit 24. The slit main body 24a is the portion of the slit 24 other than the narrow portion 24b. The dimension of the narrow portion 24b in the axial direction D1 is smaller than the dimension of the slit main body 24a in the axial direction D1. Also, the dimension of the narrow portion 24b in the axial direction D1 is smaller than the dimension of the protruding portion 42 in the thickness direction. Thereby, it is suppressed that the protruding portion 42 inserted into the slit 24 easily comes off from the slit 24. When inserting the protruding portion 42 into the slit 24, the protruding portion 42 is pressed against the flange portion 22 to deform the flange portion 22 so that the dimension of the narrow portion 24b in the axial direction D1 becomes larger than the dimension of the protruding portion 42 in the thickness direction. Note that the dimension of the narrow portion 24b in the axial direction D1 may be equal to or larger than the dimension of the protruding portion 42 in the thickness direction.

[0033] Next, a method for manufacturing the motor stator according to Embodiment 1 will be described. FIG. 6 is a flowchart showing the method for manufacturing the motor stator according to Embodiment 1. FIG. 7 is a perspective view showing a state where the lead wire portion 32 in FIG. 1 is connected to the substrate 4 via solder. FIG. 8 is a plan view showing the motor stator in FIG. 7. FIG. 9 is a front view showing the motor stator in FIG. 7.

[0034] In the manufacturing process of the motor stator, first, in step S101, a lead wire connecting process is performed. In the lead wire connecting process, first, with the protruding portion 42 of the substrate 4 placed on the front end surface of the first flange portion 22a of the bobbin 2, the lead wire portion 32 is connected to the solder connection portion 41b of the substrate 4 via solder. At this time, the length of the lead wire portion 32 is longer than the distance between the winding portion 31 and the substrate 4 when the protruding portion 42 is inserted into the slit 24. Thereby, the lead wire portion 32 can be easily connected to the substrate 4 via solder.

[0035] FIG. 10 is a perspective view showing a state in which the protruding portion 42 of FIG. 7 is inserted into the corresponding slit 24 in the circumferential direction D3. FIG. 11 is a plan view showing the motor stator of FIG. 10. FIG. 12 is a front view showing the motor stator of FIG. 10.

[0036] In the manufacturing process of the motor stator, after the lead wire connecting process, in step S102, a substrate mounting process is performed. In the substrate mounting process, the substrate 4 is brought close to the winding portion 31, and while the substrate 4 is rotated in one direction of the circumferential direction D3 with respect to the bobbin 2, the protruding portion 42 is inserted into the corresponding slit 24 in one direction of the circumferential direction D3. When the substrate 4 approaches the winding portion 31, slack occurs in the lead wire portion 32. When the substrate 4 is rotated in one direction of the circumferential direction D3 with respect to the bobbin 2, the slack in the lead wire portion 32 is reduced.

[0037] FIG. 13 is a perspective view showing a state in which the protruding portion 42 of FIG. 7 has reached the circumferential side wall surface 25 of the corresponding slit 24. FIG. 14 is a plan view showing the motor stator of FIG. 13. FIG. 15 is a front view showing the motor stator of FIG. 13. The substrate 4 is rotated in one direction of the circumferential direction D3 with respect to the bobbin 2 until the protruding portion 42 reaches the circumferential side wall surface 25 of the corresponding slit 24. When the protruding portion 42 reaches the circumferential side wall surface 25 of the corresponding slit 24, the slack in the lead wire portion 32 is eliminated.

[0038] In the manufacturing process of the motor stator, after the substrate mounting process, in step S103, a molding process is performed. In the molding process, the bobbin 2 and the substrate 4 are covered with resin. At this time, since the protrusion 42 is inserted into the slit 24, the substrate 4 is suppressed from moving in a direction floating away from the bobbin 2. Thus, the manufacturing process of the motor stator is completed.

[0039] Next, the motor stator of the comparative example will be described. FIG. 16 is a perspective view showing the motor stator of the comparative example. FIG. 17 is a longitudinal sectional view showing the motor stator of the comparative example in FIG. 16. The motor stator of the comparative example is different from the motor stator according to the first embodiment in the shapes of the bobbin 2A and the substrate 4A respectively.

[0040] The substrate 4A does not have a protrusion 42. A plurality of slits 43 are formed in a portion outside the substrate 4A in the radial direction D2. The plurality of slits 43 are arranged in a row in the circumferential direction D3. Each slit 43 is formed to extend from the outer peripheral surface of the substrate 4A to the inside in the radial direction D2. The number of slits 43 corresponds to the number of bobbins 2A.

[0041] The bobbin 2A has a cylindrical portion 21A and a pair of flange portions 22A. The configuration of the cylindrical portion 21A is the same as the configuration of the cylindrical portion 21.

[0042] Of the pair of flange portions 22A, the flange portion 22A provided outside the cylindrical portion 21A in the radial direction D2 is defined as the first flange portion 22Aa, and the flange portion 22A provided inside the cylindrical portion 21A in the radial direction D2 is defined as the second flange portion 22Ab.

[0043] The first flange portion 22Aa is not formed with a slit 24. The first flange portion 22Aa has a flange body 27 and a protrusion 28 provided on the flange body 27. When the substrate 4A moves in the axial direction D1 with respect to the bobbin 2, the protrusion 28 is inserted into the slit 43 in the axial direction D1. By inserting the protrusion 28 into the slit 43 in the axial direction D1, the position of the substrate 4A with respect to the bobbin 2A is determined in the radial direction D2 and the circumferential direction D3.

[0044] The configuration of the second flange portion 22Ab is the same as the configuration of the second flange portion 22b.

[0045] In the motor stator of the comparative example, after the protrusion 28 is inserted into the slit 43 in the axial direction D1, the lead wire portion 32 is connected to the substrate 4A via solder. By connecting the lead wire portion 32 to the substrate 4A, the position of the substrate 4 with respect to the bobbin 2 is determined in the axial direction D1.

[0046] In the motor stator of the comparative example, the length of the lead wire portion 32 matches the distance between the winding portion 31 and the substrate 4A when the protrusion 28 is inserted into the slit 43. Therefore, when the distance between the winding portion 31 and the substrate 4A is small, the length of the lead wire portion 32 becomes short. This makes it difficult to connect the lead wire portion 32 to the substrate 4A via solder.

[0047] On the other hand, in the motor stator according to the first embodiment, before the substrate 4 is attached to the bobbin 2, the lead wire portion 32 is connected to the substrate 4 via solder. Thereby, the length of the lead wire portion 32 can be increased. Therefore, the lead wire portion 32 can be easily connected to the substrate 4 via solder.

[0048] As described above, the motor stator according to Embodiment 1 includes a stator core 1, a bobbin 2 provided on the stator core 1, a coil 3 provided on the stator core 1 via the bobbin 2, and a substrate 4 attached to the bobbin 2. The coil 3 has a winding portion 31 wound around the bobbin 2 and a lead portion 32 drawn out from the winding portion 31 and connected to the substrate 4 via solder. The bobbin 2 has a flange portion 22 facing the radial direction D2, and a slit 24 extending in the circumferential direction D3 is formed in the flange portion 22. The substrate 4 has an annular substrate body 41 and a protrusion 42 protruding from the substrate body 41 in the radial direction D2, and the protrusion 42 is inserted into the slit 24. According to this configuration, before the substrate 4 is attached to the bobbin 2, the lead portion 32 of the coil 3 can be connected to the substrate 4 via solder. As a result, the length of the lead portion 32 can be increased. As a result, the lead portion 32 of the coil 3 can be easily connected to the substrate 4 via solder.

[0049] Further, in the motor stator according to Embodiment 1, the slit 24 is open on the other side in the circumferential direction D3, and when the substrate 4 rotates relative to the bobbin 2 on one side in the circumferential direction D3, the protrusion 42 is inserted into the slit 24. According to this configuration, the protrusion 42 can be easily inserted into the slit 24.

[0050] Further, the manufacturing method of the motor stator according to Embodiment 1 includes a lead portion connection step and a substrate attachment step. In the lead portion connection step, the lead portion 32 is connected to the substrate 4 via solder with the protrusion 42 detached from the slit 24. In the substrate attachment step, after the lead portion connection step, the protrusion 42 is inserted into the slit 24 and the substrate 4 is attached to the bobbin 2. According to this configuration, before the substrate 4 is attached to the bobbin 2, the lead portion 32 of the coil 3 can be connected to the substrate 4 via solder. As a result, the length of the lead portion 32 can be increased. As a result, the lead portion 32 of the coil 3 can be easily connected to the substrate 4 via solder.

[0051] In addition, in the motor stator according to Embodiment 1, the configuration in which the number of protrusions 42 on the substrate 4 matches the number of bobbins 2 has been described. However, the present invention is not limited to this configuration. The number of protrusions 42 may be smaller than the number of bobbins 2.

[0052] Also, in the motor stator according to Embodiment 1, the configuration of the slit 24 having an opening on the other side in the circumferential direction D3 has been described. However, the present invention is not limited to this configuration. The slit 24 may have an opening on one side in the axial direction D1. In this case, when the substrate 4 moves in the axial direction D1 with respect to the bobbin 2, the protrusion 42 is inserted into and removed from the slit 24. After the protrusion 42 enters the slit 24, when the substrate 4 rotates in one direction in the circumferential direction D3 with respect to the bobbin 2, the protrusion 42 moves in one direction in the circumferential direction D3 inside the slit 24.

[0053] Furthermore, in the motor stator according to Embodiment 1, the configuration in which the protrusion 42 protrudes from the outer peripheral surface of the substrate body 41 toward the outside in the radial direction D2 and the slit 24 extending in the circumferential direction D3 is formed in the first flange portion 22a has been described. However, the present invention is not limited to this configuration. The protrusion 42 may protrude from the inner peripheral surface of the substrate body 41 toward the inside in the radial direction D2, and the slit 24 extending in the circumferential direction D3 may be formed in the second flange portion 22b.

[0054] Moreover, in the motor stator according to Embodiment 1, the configuration in which the slit 24 includes the narrow portion 24b has been described. However, the present invention is not limited to this configuration. The slit 24 may not include the narrow portion 24b.

[0055] Also, in the motor stator according to Embodiment 1, the configuration of the motor stator including a plurality of bobbins 2 provided one by one on a plurality of teeth 12 has been described. However, the present invention is not limited to this configuration. The motor stator may include a bobbin 2 provided across a plurality of teeth 12.

[0056] Although the motor stator and its manufacturing method according to the preferred Embodiment 1 have been described above, they are not limited to the motor stator and its manufacturing method according to the above-described Embodiment 1. Various modifications and conversions can be made to the motor stator and its manufacturing method according to the above-described Embodiment 1 without departing from the scope described in the claims.

Explanation of Signs

[0057] 1 Stator core, 2 Bobbin, 3 Coil, 4 Substrate, 11 Core back, 12 Teeth, 21 Cylindrical portion, 22 Flange portion, 22a First flange portion, 22b Second flange portion, 23 Insertion hole, 24 Slit, 24a Slit main body, 24b Narrow portion, 25 Circumferential side wall surface, 31 Winding portion, 32 Lead wire portion, 41 Substrate main body, 41a Groove, 41b Solder connection portion, 42 Projection portion.

Claims

1. A stator core (1), a bobbin (2) provided on the stator core (1), a coil (3) provided on the stator core (1) via the bobbin (2), a substrate (4) attached to the bobbin (2), comprising: The coil (3) has a winding portion (31) which is a portion wound around the bobbin (2), and a lead-out portion (32) which is drawn out from the winding portion (31) and connected to the substrate (4) via solder. The bobbin (2) has a flange portion (22) facing in the radial direction, and a slit (24) extending in the circumferential direction is formed in the flange portion (22). The substrate (4) has an annular substrate body (41) and a protrusion (42) protruding from the substrate body (41) in the radial direction. The protrusion (42) is inserted into the slit (24). A motor stator.

2. The other side in the circumferential direction of the slit (24) is open, and the protrusion (42) is inserted into the slit (24) when the substrate (4) rotates relative to the bobbin (2) on one side in the circumferential direction. The motor stator according to Claim 1.

3. A method for manufacturing the motor stator according to Claim 1 or Claim 2, a lead-out portion connection step of connecting the lead-out portion (32) to the substrate (4) via solder with the protrusion (42) disengaged from the slit (24); a substrate attachment step of inserting the protrusion (42) into the slit (24) and attaching the substrate (4) to the bobbin (2) after the lead-out portion connection step. A method for manufacturing a motor stator comprising the above steps.

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