Stator and motor

Abstract

To provide a stator and a motor designed to prevent short-circuit between teeth and coils.SOLUTION: A stator 1 includes a ring core 2, a plurality of teeth 3, a plurality of insulators 4, and a plurality of coils 12. The teeth 3 are mounted on the ring core 2 so as to protrude from the ring core 2 toward the inside in radial direction D1 of the ring core 2. The insulators 4 are fitted on outer circumferences 30 in the radial direction D1 of the teeth 3. The coils 12 are wound via the insulators 4 on the outer circumferences 30 of the teeth 3. Each of the insulators 4 includes a first resin section 41, a second resin section 42, and a fusing section 43. The first resin section 41 is located inside in the radial direction D1. The second resin section 42 is located outside in the radial direction D1. The fusing section 43 is located between the first and second resin sections 41, 42 to couple the first and second resin sections 41, 42.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a stator and a motor, and more particularly to a stator including a ring core, teeth, and an insulator, and a motor including the stator. [Background technology]

[0002] Patent Document 1 discloses a method of attaching a coil to a stator core (see

[0232] to

[0234] , Figures 19A and 19B). In this attachment method, the coil is sandwiched between a pair of cassettes, and the cassettes are attached to the stator core. Specifically, the cassette has a support portion that is inserted into the inner periphery of the spiral structure of the coil to support the coil, and a flange portion provided on one surface in the axial direction.

[0003] In this case, the support part is inserted into the inner periphery of the coil from the side of one cassette where the flange part is not formed, and the other cassette is placed on top of it, and the two are engaged at the engaging part provided on the support part. Then, this cassette-coil assembly is attached to the stator core. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2020-14299 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the mounting method described in Patent Document 1, the pair of cassettes are simply engaged with each other, leaving a gap between them, which means that the space where the coil is located and the space where the stator core is located communicate with each other through the gap, making it difficult to prevent a short circuit between the coil and the stator core.

[0006] An object of the present disclosure is to provide a stator and a motor that can easily prevent short circuits between teeth and coils. [Means for solving the problem]

[0007] A stator according to one aspect of the present disclosure includes an annular ring core, a plurality of teeth, a plurality of insulators, and a plurality of coils. The plurality of teeth are attached to the ring core so as to protrude radially inward from the ring core. The plurality of insulators are fitted onto the outer peripheral surface of each of the plurality of teeth in the radial direction. The plurality of coils are wound around the outer peripheral surface of each of the plurality of teeth via each of the plurality of insulators. Each of the plurality of insulators has a first resin portion, a second resin portion, and a weld portion. The first resin portion is located on the inner side in the radial direction. The second resin portion is located on the outer side in the radial direction. The weld portion is located between the first resin portion and the second resin portion and connects the first resin portion and the second resin portion.

[0008] A motor according to one aspect of the present disclosure includes the stator and a rotor facing the stator. [Effects of the Invention]

[0009] In the stator and motor of the present disclosure, short circuits between the teeth and the coils can be easily prevented. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of a stator according to a first embodiment. [Figure 2] FIG. 2 is a schematic cross-sectional view of a motor having the stator of the same. [Figure 3] Fig. 3A is a cross-sectional view of the stator of the same, and Fig. 3B is an enlarged view of part A in Fig. 3A. [Figure 4] FIG. 4 is an exploded perspective view illustrating a method for manufacturing the stator. [Figure 5]FIG. 5 is an exploded perspective view illustrating a method for manufacturing the stator. [Figure 6] FIG. 6 is a perspective view illustrating a method for manufacturing the stator. [Figure 7] Fig. 7A is a cross-sectional view of a stator according to a second embodiment, and Fig. 7B is an enlarged view of part B in Fig. 7A. [Figure 8] Fig. 8A is a cross-sectional view of a stator according to a third embodiment, and Fig. 8B is an enlarged view of part C in Fig. 8A. [Figure 9] Fig. 9A is a cross-sectional view of a stator according to a fourth embodiment, and Fig. 9B is an enlarged view of part D in Fig. 9A. [Figure 10] FIG. 10 is an enlarged cross-sectional view of a portion of the stator according to the fifth embodiment. [Figure 11] FIG. 11 is an enlarged cross-sectional view of a portion of the stator according to the sixth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] (1) Overview A stator and a motor according to the present disclosure will be described. The embodiments described below are merely a part of various embodiments of the present disclosure, and various modifications can be made depending on the design and the like as long as the object of the present disclosure can be achieved in the following embodiments.

[0012] As shown in FIGS. 1 to 3 , a stator 1 according to the present disclosure includes an annular ring core 2, a plurality of teeth 3, a plurality of insulators 4, and a plurality of coils 12. The plurality of teeth 3 are attached to the ring core 2 so as to protrude inward in a radial direction D1 of the ring core 2. The plurality of insulators 4 are fitted onto the outer peripheral surfaces 30 of the plurality of teeth 3 in the radial direction D1. The plurality of coils 12 are wound around the outer peripheral surfaces 30 of the plurality of teeth 3 via the plurality of insulators 4, respectively. Each of the plurality of insulators 4 has a first resin portion 41, a second resin portion 42, and a weld portion 43. The first resin portion 41 is located on the inner side in the radial direction D1. The second resin portion 42 is located on the outer side in the radial direction D1. The weld portion 43 is located between the first resin portion 41 and the second resin portion 42 to connect the first resin portion 41 and the second resin portion 42.

[0013] Moreover, the motor 9 according to the present disclosure includes a stator 1 and a rotor 91 facing the stator 1.

[0014] In the stator 1 and motor 9 described above, short circuits between the teeth 3 and the coils 12 can be easily prevented.

[0015] (2) First embodiment 1 and 2, a stator 1 constituting a motor 9 includes an annular ring core 2, a plurality of teeth 3, a plurality of insulators 4, and a plurality of coils 12. The stator 1 further includes a bus bar 13.

[0016] (2.1) Stator core 1, stator core 11 has a ring core 2 and a plurality of teeth 3. In other words, ring core 2 and a plurality of teeth 3 configure stator core 11.

[0017] (2.1.1) Ring Core 2, the ring core 2 has an annular shape surrounding a rotation shaft 92 of a rotor 91 that rotates relative to the stator 1. In this embodiment, the ring core 2 has an annular shape when viewed in a direction 200 in which an axis 20 extends (hereinafter referred to as the extension direction 200; see FIG. 1), and the center of the ring core 2 (the position of the axis 20) coincides with the axis of the rotation shaft 92 of the rotor 91. Here, the direction that passes through the axis 20 and is perpendicular to the extension direction 200 is defined as a radial direction D1.

[0018] The ring core 2 has a plurality of steel plates stacked in the extension direction 200. The steel plates are formed of a magnetic material such as silicon steel plate. Here, fitting portions 21 into which a plurality of teeth 3 are fitted are formed at the end of the ring core 2 on the axis center 20 side (hereinafter referred to as the inner side). In this embodiment, 18 fitting portions 21 are formed at equal intervals in the circumferential direction of the inner end of the ring core 2. The ring core 2 constitutes a back yoke of the stator core 11.

[0019] (2.1.2) Teeth The teeth 3 are attached to the ring core 2 so as to protrude inward in the radial direction D1 of the ring core 2. The teeth 3 protrude from the inner peripheral surface of the ring core 2 toward the axis 20. In this embodiment, 18 teeth 3 are provided on the stator core 11. The teeth 3 are molded separately from the ring core 2 and fitted into the ring core 2, integrating the ring core 2 and the teeth 3.

[0020] The teeth 3 are each formed with a fitting portion 31 at an outer end in the radial direction D1, the fitting portion 31 corresponding to the fitting portion 21 of the ring core 2. The fitting portions 31 of the teeth 3 are fitted into the fitting portions 21 of the ring core 2, and the teeth 3 are attached to the ring core 2 integrally.

[0021] 3A, a flange 32 that is larger than a middle portion in the radial direction D1 is formed at an inner end portion in the radial direction D1 of each of the teeth 3. The flange 32 prevents the coil 12 and the insulator 4 from falling off toward the inside in the radial direction D1.

[0022] (2.2) Coil As shown in FIGS. 1, 3A, and 3B, a plurality of coils 12 are wound around the outer peripheral surface 30 of each of a plurality of teeth 3, with a plurality of insulators 4 interposed therebetween. The coils 12 are formed of conductor wires 121. In this embodiment, 18 coils 12 are provided on the stator core 11. The cross-sectional shape of the conductor wires 121 is rectangular. In particular, in this embodiment, the coils 12 are formed coils. The formed coils in this disclosure do not include coils in which a conductor wire with a constant width and thickness is simply wound spirally.

[0023] The formed coil is formed, for example, by preparing a plurality of rectangular plate materials of different lengths, widths, or thicknesses and joining these plate materials by cold welding, welding, or other methods. The plate materials are made of a so-called low-resistivity material such as copper or aluminum.

[0024] Alternatively, the formed coil may be formed by so-called casting, in which copper or the like is melted and poured into a mold. Furthermore, the formed coil may be formed by bending a plate-shaped conductor wire, which has been formed in advance so that its width and thickness vary along the way, at a predetermined position. Alternatively, the formed coil may be formed by rolling a plate-shaped conductor wire with a constant width and thickness at a predetermined position, changing the width or thickness along the way, and then winding the wire into a spiral shape. In short, the formed coil is formed by adding another process to winding the conductor wire, or by a method other than simple winding.

[0025] (2.3) Insulator (2.3.1) First resin part, second resin part, and welded part As shown in FIG. 3A, the insulator 4 is interposed between the stator core 11 and the coil 12 to electrically insulate the stator core 11 from the coil 12. The insulator 4 is made of a resin material, which is an insulator. The multiple insulators 4 are fitted onto the outer peripheral surface 30 of each of the multiple teeth 3 in the radial direction D1. As shown in FIG. 3B, each of the multiple insulators 4 has a first resin portion 41, a second resin portion 42, and a welded portion 43.

[0026] The first resin portion 41 is located on the inner side in the radial direction D1. The first resin portion 41 is a member (portion) that constitutes at least the inner end portion of the insulator 4 in the radial direction D1. Suitable resin materials for the first resin portion 41 include thermoplastic resins such as PPS (Poly Phenylene Sulfide), LCP (Liquid Crystal Polymer), PA (Polyamide), PBT (Poly Butylene Terephthalate), and PET (Poly Ethylene Terephthalate), but are not limited to these. The laser transmittance of the resin material for the first resin portion 41 is preferably 10% or less, more preferably 5% or less, and even more preferably 3% or less. The smaller the transmittance, the better, but the numerical value is not particularly limited. The laser used in this case is a laser with a wavelength of 800 to 1200 nm (preferably 800 to 1100 nm) that is used in laser welding.

[0027] The second resin portion 42 is located on the outside in the radial direction D1. The second resin portion 42 is a member (portion) that constitutes at least the outer end portion of the insulator 4 in the radial direction D1. Suitable resin materials for the second resin portion 42 include thermoplastic resins such as PPS, LCP, PA, PBT, and PET, but are not limited to these. The laser transmittance of the resin material for the second resin portion 42 is preferably 30% or more, more preferably 35% or more, and even more preferably 40% or more. The higher the transmittance, the better, but the numerical value is not particularly limited.

[0028] In the first embodiment, the resin material that forms the second resin portion 42 has a higher laser transmittance than the resin material that forms the first resin portion 41.

[0029] The welded portion 43 is located between the first resin portion 41 and the second resin portion 42 and connects the first resin portion 41 and the second resin portion 42. The welded portion 43 in the first embodiment is a weld mark formed by laser welding. The welded portion 43 includes both the resin material constituting the first resin portion 41 and the resin material constituting the second resin portion 42.

[0030] Before molding the insulators 4, each of the plurality of insulators 4 has the first resin portion 41 and the second resin portion 42 prepared as separate bodies, and does not have the welding portion 43. After molding, each of the plurality of insulators 4 has the first resin portion 41, the second resin portion 42, and the welding portion 43, and is formed integrally as a whole.

[0031] (2.3.2) First flange, second flange and cylindrical portion Each of the plurality of insulators 4 has a first flange 51, a second flange 52, and a cylindrical portion 50.

[0032] The first flange 51 is located on the inner side in the radial direction D1. In the first embodiment, the first flange 51 constitutes the inner end portion of the insulator 4 in the radial direction D1. That is, the first flange 51 is included in the first resin portion 41 that constitutes the inner end portion of the insulator 4 in the radial direction D1.

[0033] The second flange 52 is located on the outer side in the radial direction D1. In the first embodiment, the second flange 52 constitutes the outer end portion of the insulator 4 in the radial direction D1. That is, the second flange 52 is included in the second resin portion 42 that constitutes the outer end portion of the insulator 4 in the radial direction D1.

[0034] The tubular portion 50 is located between the first flange 51 and the second flange 52 and faces the outer circumferential surfaces 30 of the plurality of teeth 3. In the first embodiment, the first resin portion 41 includes at least a portion of the tubular portion 50.

[0035] More specifically, the first resin portion 41 includes most of the cylindrical portion 50 except for a portion of the outer end portion in the radial direction D1. Of the cylindrical portion 50 included in the first resin portion 41, the outer end portion in the radial direction D1 is referred to as a first portion 411.

[0036] The second resin part 42 includes the remaining portion of the tubular part 50. That is, the second resin part 42 includes the outer end part of the tubular part 50 in the radial direction D1 excluding the part included in the first resin part 41. Of the tubular part 50 included in the second resin part 42, the outer end part in the radial direction D1 is defined as a second part 421. In the first embodiment, the tubular part 50 included in the second resin part 42 is only the second part 421.

[0037] The first portion 411 and the second portion 421 overlap in a direction perpendicular to the radial direction D1.

[0038] The welded portion 43 is formed between the second flange 52 and the cylindrical portion 50. That is, in the first embodiment, the welded portion 43 is formed at the outer end of the cylindrical portion 50 in the radial direction D1.

[0039] (2.4) Busbar As shown in FIG. 1 , busbar 13 is connected to conductor 121. Busbar 13 makes it easier to pass a large current. Busbar 13 is electrically connected to conductor 121 of each of coils 12 to form connections for U-phase, V-phase, and W-phase. Busbar 13 is arranged on the opposite side of coil 12 from axis 20 (i.e., the outside). Busbar 13 is adjacent to the outside of coil 12 in radial direction D1. This makes it easier to prevent the size of stator 1 from increasing in the extension direction 200.

[0040] Moreover, the busbars 13 are disposed adjacent to the ring core 2 in the extension direction 200. The stator core 11, the coils 12, the insulators 4, and the busbars 13 form the stator 1.

[0041] (2.5) Motors and rotors As shown in Fig. 2, the motor 9 includes a stator 1 and a rotor 91. The rotor 91 has a rotary shaft 92 and rotates around the axis of the rotary shaft 92. The rotor 91 faces the stator 1 in the radial direction D1. In the motor 9, magnetic flux generated from a plurality of coils 12 in the stator 1 (18 coils in Fig. 1) generates an electromagnetic force that rotates the rotor 91.

[0042] The rotor 91 has a cylindrical rotor core 93, a plurality of magnets 94, and a rotating shaft 92. The rotating shaft 92 is held inside the rotor core 93. The magnets 94 are arranged in a polygonal shape.

[0043] (2.6) Stator manufacturing method The method for manufacturing the stator 1 will be described with reference to Figures 4 to 6. The method for manufacturing the stator 1 includes first to sixth steps in this order.

[0044] (2.6.1) First step The first step is a forming step of the coil 12 shown in Fig. 4. In the first step, one coil 12 that constitutes the plurality of coils 12 is formed by bending and winding the conductive wire 121. The coil 12 formed in the first step is an air-core coil that does not have a core, and a space is formed inside in which the teeth 3 and the insulators 4 can be arranged.

[0045] (2.6.2) Second step The second step is a step of attaching the first resin part 41 to the coil 12. The first resin part 41 is inserted into the space inside the coil 12 from the inside in the radial direction D1. The first flange 51 comes into contact with the inner end surface of the coil 12 in the radial direction D1.

[0046] (2.6.3) Third step The third step is a step of attaching the second resin part 42 to the coil 12. The second resin part 42 is inserted into the internal space of the coil 12 from the outside in the radial direction D1. The second flange 52 contacts the outer end surface of the coil 12 in the radial direction D1. The second part 421 is fitted onto the outer peripheral surface of the first part 411 of the first resin part 41. This positions the second resin part 42 relative to the first resin part 41. In the third step, the first resin part 41 and the second resin part 42 are assembled to the coil 12 to form a unit.

[0047] (2.6.4) 4th step The fourth step is a step of welding the first resin part 41 and the second resin part 42. In the fourth step, the first resin part 41 and the second resin part 42 of the unit constructed in the third step are welded together. In the first embodiment, laser welding is performed in the fourth step. A laser is irradiated from the outside in the radial direction D1, i.e., from the second resin part 42 side, and passes through the second resin part 42 to the part of the first resin part 41 that faces the second resin part 42.

[0048] The resin material constituting the second resin portion 42 has high laser transmittance, while the resin material constituting the first resin portion 41 has low laser transmittance. Therefore, the laser is not easily absorbed by the second resin portion 42, but is easily absorbed by the first resin portion 41. Therefore, most of the laser irradiated from the second resin portion 42 side passes through the second resin portion 42 to reach the first resin portion 41, where it is absorbed by the first resin portion 41. The surface portion of the first resin portion 41 (the portion in contact with the second resin portion 42) that absorbs the laser increases in temperature and melts. The heat is also transferred to the second resin portion 42, melting the second resin portion 42 as well. When the melted resin cools and solidifies, a welded portion 43 is formed. In the fourth step, a coil unit 14 (see FIG. 5 ) consisting of the coil 12 and the insulator 4 is formed. That is, the fourth step also serves as a step of forming the insulator 4.

[0049] (2.6.5) Fifth step As shown in FIG. 5, the fifth step is a step of attaching the teeth 3 to the coil unit 14 formed in the fourth step. The teeth 3 are inserted into the space inside the insulator 4 (and the coil 12) from the inside in the radial direction D1. The flange 32 contacts the inner surface of the first flange 51 in the radial direction D1. In the fifth step, as shown in FIG. 6, a teeth unit 15 is formed in which the coil 12, the first resin part 41, the second resin part 42, and the teeth 3 are attached.

[0050] (2.6.6) 6th step The sixth step is a step of attaching the tooth unit 15 constructed in the fifth step to the ring core 2. The fitting portions 31 of the teeth 3 are fitted into the fitting portions 21 (see FIG. 2) formed on the ring core 2 by an appropriate method such as press fitting.

[0051] The first to sixth steps result in a completed stator 1.

[0052] (2.7) Summary of the first embodiment The insulator 4 has a welded portion 43 formed between a first resin portion 41 located on the inside in the radial direction D1 and a second resin portion 42 located on the outside in the radial direction D1. Therefore, the insulator 4 (cylindrical portion 50) separates a space where the teeth 3 are located inside the cylindrical portion 50 of the insulator 4 from a space where the coil 12 is located outside the cylindrical portion 50 of the insulator 4. This prevents the coil 12 and the tooth 3 from shorting out.

[0053] Furthermore, the weld portion 43 is formed between the second flange 52 and the tubular portion 50. That is, the weld portion 43 is formed at the outer end portion in the radial direction D1 of the tubular portion 50. As a result, the boundary between the first resin portion 41 and the second resin portion 42 is not located in the middle portion in the radial direction D1 of the insulator 4, which makes it possible to prevent a gap from being formed in the middle portion in the radial direction D1, which is prone to short circuits. Furthermore, when a laser for laser welding is irradiated from the outside in the radial direction D1, the distance that the laser must pass through the second resin portion 42 is short, allowing for efficient laser welding.

[0054] Furthermore, since the first portion 411 and the second portion 421 overlap in a direction perpendicular to the radial direction D1, the first resin portion 41 and the second resin portion 42 can be easily positioned relative to each other.

[0055] Furthermore, since the welded portion 43 is a weld mark formed by laser welding, there is no need to heat a large area of ​​the first resin portion 41 or the second resin portion 42 to a high temperature, and the effects of heat on the first resin portion 41 and the second resin portion 42 can be suppressed.

[0056] Furthermore, the laser transmittance of the resin material constituting the second resin part 42 is higher than the laser transmittance of the resin material constituting the first resin part 41. This allows the laser to easily pass through the second resin part 42, enabling efficient laser welding.

[0057] (3) Second embodiment The stator 1 according to the second embodiment will be described below with reference to Figures 7A and 7B. Note that the stator 1 according to the second embodiment is mostly the same as the stator 1 according to the first embodiment, and therefore the same reference numerals are used for the overlapping components, and the detailed description thereof will be incorporated herein.

[0058] In the first embodiment, a first portion 411 at an outer end portion in the radial direction D1 of the tubular portion 50 included in the first resin portion 41 and a second portion 421 at an outer end portion in the radial direction D1 of the tubular portion 50 included in the second resin portion 42 overlap in a direction perpendicular to the radial direction D1. In contrast, in the second embodiment, the first resin portion 41 includes the entire tubular portion 50, and the second resin portion 42 does not include any of the tubular portion 50. This eliminates the possibility of a gap being formed in the middle portion (tubular portion 50) of the insulator 4 that could cause a short circuit between the coil 12 and the tooth 3, thereby further suppressing a short circuit between the coil 12 and the tooth 3.

[0059] The first resin part 41 has a cylindrical part 412 that protrudes outward in the radial direction D1 from the tooth 3 side of the cylindrical part 50, and this cylindrical part 412 is inserted into an inner edge 422 of a hole formed inside the second resin part 42. This makes it easy to position the first resin part 41 and the second resin part 42 relative to each other.

[0060] (4) Third embodiment The stator 1 according to the third embodiment will be described below with reference to Figures 8A and 8B. Note that the stator 1 according to the third embodiment is mostly the same as the stator 1 according to the second embodiment, and therefore the same reference numerals are used for the overlapping components, and the detailed description thereof will be incorporated herein.

[0061] In the second embodiment, the first resin portion 41 has a cylindrical portion 412 that protrudes outward in the radial direction D1 from the tooth 3 side portion of the cylindrical portion 50. In contrast, in the third embodiment, the first resin portion 41 does not have a cylindrical portion 412 that protrudes outward in the radial direction D1 from the tooth 3 side portion of the cylindrical portion 50. The outer end surface of the cylindrical portion 50 of the first resin portion 41 in the radial direction D1 and the inner surface of the second flange 52 of the second resin portion 42 in the radial direction D1 are butted together to form the welded portion 43.

[0062] Therefore, there is no need to protrude the cylindrical portion 412 (see FIG. 7B) from a part of the first resin portion 41 in the direction perpendicular to the radial direction D1, and it is possible to reduce the thickness T1 of the first resin portion 41 in the direction perpendicular to the radial direction D1. This makes it possible to increase the space factor of the coil 12 and improve the output of the motor 9.

[0063] (5) Fourth embodiment The stator 1 according to the fourth embodiment will be described below with reference to Figures 9A and 9B. Note that the stator 1 according to the fourth embodiment is mostly the same as the stator 1 according to the first embodiment, and therefore the same reference numerals are used for the overlapping components, and detailed descriptions thereof will be incorporated herein.

[0064] In the first embodiment, the weld portion 43 was formed between the second flange 52 and the tubular portion 50. In contrast, in the fourth embodiment, the second resin portion 42 includes at least a portion of the second flange 52 and the tubular portion 50. In particular, the second resin portion 42 includes the entire tubular portion 50. Furthermore, the first resin portion 41 does not include the tubular portion 50 at all. The weld portion 43 is formed between the first flange 51 and the tubular portion 50. That is, the weld portion 43 is formed at the inner end of the tubular portion 50 in the radial direction D1. This prevents a boundary between the first resin portion 41 and the second resin portion 42 from being located in the middle of the insulator 4 in the radial direction D1, thereby preventing a gap from being formed in the middle of the insulator 4 in the radial direction D1, which is prone to short-circuiting. Furthermore, when a laser for laser welding is irradiated from the inside in the radial direction D1, the laser only needs to travel a short distance through the second resin portion 42, allowing for efficient laser welding.

[0065] Furthermore, the laser transmittance of the resin material constituting the first resin part 41 is higher than the laser transmittance of the resin material constituting the second resin part 42. This allows the laser to easily pass through the first resin part 41, enabling efficient laser welding.

[0066] Furthermore, there is no need to protrude the cylindrical portion 412 (see FIG. 7B) from a part of the first resin portion 41 in a direction perpendicular to the radial direction D1, and it is possible to reduce the thickness T1 of the first resin portion 41 in the direction perpendicular to the radial direction D1. This allows the space factor of the coil 12 to be increased, and the output of the motor 9 to be improved.

[0067] (6) Fifth embodiment The stator 1 according to the fifth embodiment will be described below with reference to Fig. 10. Note that the stator 1 according to the fifth embodiment is mostly the same as the stator 1 according to the fourth embodiment, and therefore the same reference numerals are used for the overlapping components, and detailed descriptions thereof will be incorporated herein.

[0068] In the fourth embodiment (see FIGS. 9A and 9B), the second resin portion 42 includes the entire tubular portion 50, and the first resin portion 41 does not include any of the tubular portion 50.

[0069] In contrast, in the fifth embodiment, the second resin portion 42 includes most of the cylindrical portion 50 except for a portion (first portion 411) of the inner end portion in the radial direction D1. The second portion 421 of the second resin portion 42 is formed on the tooth 3 side of the inner end portion of the cylindrical portion 50 in the radial direction D1. The first portion 411 of the first resin portion 41 is formed on the opposite side of the tooth 3 of the inner end portion of the cylindrical portion 50 in the radial direction D1.

[0070] The first portion 411 and the second portion 421 overlap in a direction perpendicular to the radial direction D1.

[0071] Furthermore, the welded portion 43 is formed between the first flange 51 and the tubular portion 50. That is, in the fifth embodiment, the welded portion 43 is formed between an inner end portion of the second portion 421 in the radial direction D1 and a portion of the first resin portion 41 that constitutes the first flange 51 and is located outside (tooth 3 side) the first portion 411.

[0072] The first portion 411 and the second portion 421 overlap in a direction perpendicular to the radial direction D1, which facilitates the positioning of the first resin portion 41 and the second resin portion 42. Furthermore, gaps connecting the coil 12 and the teeth 3 are formed, which prevents the coil 12 and the teeth 3 from shorting out.

[0073] (7) Sixth embodiment The stator 1 according to the sixth embodiment will be described below with reference to Fig. 11. Note that the stator 1 according to the sixth embodiment is mostly the same as the stator 1 according to the fifth embodiment, and therefore the same reference numerals are used for the overlapping components, and detailed descriptions thereof will be incorporated herein.

[0074] In the fifth embodiment (see FIG. 10 ), the first portion 411 at the outer end of the first resin portion 41 in the radial direction D1 and the second portion 421 at the inner end of the second resin portion 42 in the radial direction D1 overlap in a direction perpendicular to the radial direction D1. In contrast, in the second embodiment, the second resin portion 42 includes the entire tubular portion 50, and the first resin portion 41 does not include any of the tubular portion 50. This eliminates the possibility of a gap being formed in the middle portion (tubular portion 50) of the insulator 4 that could cause a short circuit between the coil 12 and the tooth 3, thereby further suppressing a short circuit between the coil 12 and the tooth 3.

[0075] The second resin part 42 has a cylindrical part 423 that protrudes inward in the radial direction D1 from the tooth 3 side of the cylindrical part 50, and this cylindrical part 423 is fitted into an inner edge 413 of a hole formed inside the first resin part 41. This makes it easy to position the first resin part 41 and the second resin part 42 relative to each other.

[0076] (8) Variations Next, modified examples of the first to fourth embodiments will be listed below. The following modified examples may be realized in appropriate combination.

[0077] In the first to fourth embodiments, the ring core 2 is ultimately formed as a single unit. In this case, it may be formed by joining multiple divided bodies together, or may be formed as a single unit from the beginning. The ring core 2 may also be formed by combining multiple divided bodies without joining them. In this case, the multiple divided bodies are housed in a housing and arranged in an annular shape to form the ring core 2. The multiple divided bodies are multiple split cores divided into portions corresponding to one tooth 3, and are divided into multiple parts in the circumferential direction of the ring core 2.

[0078] In the first to fourth embodiments, the number of fitting portions 21, teeth 3, and coils 12 provided on one stator 1 is 18, but the number is not limited to 18.

[0079] The welded portion 43 may be a weld mark formed by ultrasonic welding, which eliminates the need to heat a wide area of ​​the first resin portion 41 or the second resin portion 42 to a high temperature, thereby suppressing the influence of heat on the first resin portion 41 and the second resin portion 42.

[0080] Furthermore, the resin material constituting the first resin portion 41 and the resin material constituting the second resin portion 42 may be the same. This improves the strength of the welded portion 43 connecting the first resin portion 41 and the second resin portion 42.

[0081] (9) Summary As is clear from the above-described embodiment and its modified examples, the stator (1) of the first aspect includes an annular ring core (2), a plurality of teeth (3), a plurality of insulators (4), and a plurality of coils (12). The plurality of teeth (3) are attached to the ring core (2) so as to protrude inward in the radial direction (D1) of the ring core (2). The plurality of insulators (4) are fitted onto the outer peripheral surfaces (30) of each of the plurality of teeth (3) in the radial direction (D1). The plurality of coils (12) are wound around the outer peripheral surfaces (30) of each of the plurality of teeth (3) via the plurality of insulators (4). Each of the plurality of insulators (4) has a first resin portion (41), a second resin portion (42), and a welded portion (43). The first resin portion (41) is located on the inner side in the radial direction (D1). The second resin portion (42) is located on the outer side in the radial direction (D1). The weld portion (43) is located between the first resin portion (41) and the second resin portion (42) and connects the first resin portion (41) and the second resin portion (42).

[0082] According to the first aspect, it is easy to prevent short circuits between the plurality of teeth (3) and the plurality of coils (12).

[0083] The second aspect can be realized by combining with the first aspect. In the second aspect, each of the plurality of insulators (4) has a first flange (51), a second flange (52), and a tubular portion (50). The first flange (51) is located on the inner side in the radial direction (D1). The second flange (52) is located on the outer side in the radial direction (D1). The tubular portion (50) is located between the first flange (51) and the second flange (52) and faces the outer peripheral surfaces (30) of the plurality of teeth (3). The first resin portion (41) includes at least a portion of the first flange (51) and the tubular portion (50). The second resin portion (42) includes the second flange (52). The weld portion (43) is formed between the second flange (52) and the tubular portion (50).

[0084] According to the second aspect, it is possible to prevent a gap from being formed in the radially intermediate portion (D1) of the insulator (4), which is prone to short circuits. Furthermore, when a laser for laser welding is applied from the outside in the radial direction (D1), the laser needs to pass through the second resin portion (42) over a short distance, thereby enabling efficient laser welding.

[0085] The third aspect can be realized by combining with the first aspect. In the third aspect, each of the plurality of insulators (4) has a first flange (51), a second flange (52), and a tubular portion (50). The first flange (51) is located on the inner side in the radial direction (D1). The second flange (52) is located on the outer side in the radial direction (D1). The tubular portion (50) is located between the first flange (51) and the second flange (52) and faces the outer peripheral surfaces (30) of the plurality of teeth (3). The first resin portion (41) includes the first flange (51). The second resin portion (42) includes the second flange (52) and at least a portion of the tubular portion (50). The weld portion (43) is formed between the first flange (51) and the tubular portion (50).

[0086] According to the third aspect, it is possible to prevent a gap from being formed in the radially intermediate portion (D1) of the insulator (4), which is prone to short circuits. Furthermore, when a laser for laser welding is applied from the inside in the radial direction (D1), the distance that the laser must pass through the first resin portion (41) is short, and laser welding can be performed efficiently.

[0087] The fourth aspect can be realized by combining any one of the first to third aspects. In the fourth aspect, each of the plurality of insulators (4) has a first flange (51), a second flange (52), and a tubular portion (50). The first flange (51) is located on the inner side in the radial direction (D1). The second flange (52) is located on the outer side in the radial direction (D1). The tubular portion (50) is located between the first flange (51) and the second flange (52) and faces the outer peripheral surfaces (30) of the plurality of teeth (3). The first resin portion (41) includes the first flange (51) and a portion of the tubular portion (50). The second resin portion (42) includes the second flange (52) and other portions of the tubular portion (50). A first portion (411) of the tubular portion (50) included in the first resin portion (41) and a second portion (421) of the tubular portion (50) included in the second resin portion (42) overlap in a direction perpendicular to the radial direction (D1).

[0088] According to the fourth aspect, the first resin portion (41) and the second resin portion (42) can be easily positioned relative to each other.

[0089] The fifth aspect can be realized by combining with any one of the first to fourth aspects. In the fifth aspect, the welded portion (43) is a weld mark formed by laser welding or ultrasonic welding.

[0090] According to the fifth aspect, there is no need to heat a wide area of ​​the first resin portion (41) or the second resin portion (42) to a high temperature, and the influence of heat on the first resin portion (41) and the second resin portion (42) can be suppressed.

[0091] The sixth aspect can be realized by combining any one of the first to fifth aspects. In the sixth aspect, the resin material constituting the first resin portion (41) and the resin material constituting the second resin portion (42) are the same.

[0092] According to the sixth aspect, the strength of the welded portion (43) connecting the first resin portion (41) and the second resin portion (42) is improved.

[0093] The seventh aspect can be realized by combining with the second aspect. In the seventh aspect, the laser transmittance of the resin material constituting the first resin portion (41) is higher than the laser transmittance of the resin material constituting the second resin portion (42).

[0094] According to the seventh aspect, the laser can easily pass through the first resin portion (41), and the laser welding can be performed efficiently.

[0095] The eighth aspect can be realized by combining with the third aspect. In the eighth aspect, the laser transmittance of the resin material constituting the second resin portion (42) is higher than the laser transmittance of the resin material constituting the first resin portion (41).

[0096] According to the eighth aspect, the laser can easily pass through the second resin portion (42), and the laser welding can be performed efficiently.

[0097] The ninth aspect can be realized by combining with any one of the first to eighth aspects. The motor (9) of the ninth aspect includes the stator (1) of any one of the first to eighth aspects and a rotor (91) facing the stator (1).

[0098] According to the ninth aspect, it is easy to prevent short circuits between the plurality of teeth (3) and the plurality of coils (12). [Explanation of symbols]

[0099] 1 stator 12 coils 2 ring core 3 Teeth 4 insulators 41 First resin part 411 Part 1 42 Second resin part 421 Part 2 43 Welded area 50 Cylinder part 51 First flange 52 Second flange 9 Motor 91 Rotor D1 Radial direction

Claims

1. an annular ring core; a plurality of teeth attached to the ring core so as to protrude radially inward from the ring core; a plurality of insulators fitted onto outer peripheral surfaces of the plurality of teeth in the radial direction; a plurality of coils wound around the outer circumferential surface of each of the plurality of teeth via each of the plurality of insulators, Each of the plurality of insulators comprises: a first resin portion located on the inner side in the radial direction; a second resin portion located on the outer side in the radial direction; a welded portion located between the first resin portion and the second resin portion and connecting the first resin portion and the second resin portion, Stator.

2. Each of the plurality of insulators comprises: a first flange located radially inward; a second flange located radially outward; a cylindrical portion located between the first flange and the second flange and facing the outer circumferential surfaces of the plurality of teeth, the first resin portion includes the first flange and at least a portion of the cylindrical portion, the second resin portion includes the second flange, The welded portion is formed between the second flange and the cylindrical portion. The stator according to claim 1 .

3. Each of the plurality of insulators comprises: a first flange located radially inward; a second flange located radially outward; a cylindrical portion located between the first flange and the second flange and facing the outer circumferential surfaces of the plurality of teeth, the first resin portion includes the first flange, the second resin portion includes the second flange and at least a portion of the cylindrical portion, The welded portion is formed between the first flange and the cylindrical portion. The stator according to claim 1 .

4. Each of the plurality of insulators comprises: a first flange located radially inward; a second flange located radially outward; a cylindrical portion located between the first flange and the second flange and facing the outer circumferential surfaces of the plurality of teeth, the first resin portion includes the first flange and a portion of the cylindrical portion, the second resin portion includes the second flange and another portion of the cylindrical portion, a first portion of the tubular portion included in the first resin portion and a second portion of the tubular portion included in the second resin portion overlap each other in a direction perpendicular to the radial direction; The stator according to claim 1 .

5. The welded portion is a weld mark formed by laser welding or ultrasonic welding. The stator according to claim 1 .

6. The resin material constituting the first resin portion and the resin material constituting the second resin portion are the same. The stator according to claim 1 .

7. a resin material constituting the first resin portion has a higher laser transmittance than a resin material constituting the second resin portion; The stator according to claim 2 .

8. a resin material constituting the second resin portion has a higher laser transmittance than a resin material constituting the first resin portion; The stator according to claim 3 .

9. A stator according to any one of claims 1 to 8; a rotor facing the stator, Motor.

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