Stator, rotary electric machine, manufacturing method of stator, and manufacturing method of rotary electric machine

Abstract

To provide a stator having satisfactory circularity, a rotary electric machine, a manufacturing method of the stator, and a manufacturing method of the rotary electric machine without increasing machining costs, facility costs, and the number of components.SOLUTION: A stator comprises: an iron core 110 comprising an annular core back part 111, and a plurality of tooth parts 112 to be formed on an inner peripheral surface 11A of the core back part 111 by projecting in a circumferential direction Z at intervals; a coil 3 wound around the tooth parts 112 via an insulator 2; and a mold resin part 5 which covers the iron core 110 and the coil 3, wherein the core back part 111 is formed by being separated for at least one part in the circumferential direction Z, the insulator 2 comprises two or more projections 21 projecting to the outside X1 in a radial direction X from an outer peripheral surface 11B of the core back part 111 in the circumferential direction Z, and the mold resin part 5 does not cover a projection surface 21 along an axial direction Y on the outside X1 of the radial direction X of the projections 21.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present application relates to a stator, a rotating electric machine, a method for manufacturing a stator, and a method for manufacturing a rotating electric machine. [Background technology]

[0002] Conventionally, a structure in which a molding process is performed on an annular core around which a conductor is wound via an insulator has been known for use as a stator for a rotating electric machine. Dividing this core into multiple core pieces allows for higher density during winding and a smaller core press. However, to ensure the roundness of the stator after molding, the core pieces must be fixed together by welding or press-fitting, which increases processing and equipment costs. Furthermore, because the core must not be exposed from the outer shell of the stator formed from molded resin, a method of directly pressing the core with a mold cannot be used.

[0003] To solve these problems, for example, Patent Document 1 proposes a method in which core pieces are arranged in a ring shape, restrained by a jig, molded into the slots to temporarily fix them, and then the jig is removed and molding is performed on the entire core, including its outer periphery.In addition, as another method, for example, Patent Document 2 proposes a method in which, although it is an example of an outer rotor stator, it is also possible to use an inner rotor stator in the same way, in which an insulator is used in which an annular groove is formed by arranging core pieces in a ring shape, and a ring member is inserted into the formed annular groove to ensure roundness after molding. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5274091 [Patent Document 2] Japanese Patent Application Publication No. 2018-93582 Summary of the Invention [Problem to be solved by the invention]

[0005] In the conventional method disclosed in Patent Document 1, for example, the cost of equipment such as welding machines and press-fitting equipment is reduced, but the number of molding processes increases to two, which makes it difficult to control processing costs. Also, in Patent Document 2, for example, a ring member is required, which increases the number of parts.

[0006] The present application discloses technology for solving the above-mentioned problems, and aims to provide a stator, a rotating electric machine, a method for manufacturing a stator, and a method for manufacturing a rotating electric machine that have good roundness without increasing processing costs, equipment costs, or the number of parts. [Means for solving the problem]

[0007] The stator disclosed in the present application comprises: A stator comprising: an iron core having a core back portion formed in an annular shape; and a plurality of teeth formed on an inner peripheral surface of the core back portion in a radial direction, the teeth protruding radially inward at intervals in the circumferential direction; coils wound around the teeth via insulators; and a molded resin portion covering the iron core and the coils, When the molded resin portion is defined as a first molded resin portion that contacts a part of a surface of at least one of one end side or the other end side in the axial direction of the insulator, and a second molded resin portion that contacts the remainder, A boundary line is provided at the boundary between the first molded resin part and the second molded resin part. Further, the rotating electric machine disclosed in the present application is The stator described above; a rotor arranged coaxially and rotatably inside the stator in the radial direction; and a bracket for holding a bearing that holds a rotating shaft of the rotor, the bearing being installed at at least one end of the stator in the axial direction. Further, the method for manufacturing a stator disclosed in the present application includes the steps of: an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of covering the stator with a molding resin to form the stator; In the molding process, the second molded resin portion is formed with a movable pin abutting against at least one surface of one end side or the other end side of the insulator in the axial direction, and then the first molded resin portion is formed with the movable pin moved away from at least one surface of the insulator in the axial direction. Further, the method for manufacturing a rotating electric machine disclosed in the present application includes: a placement step of placing a rotatable coaxial rotor radially inside the stator formed by the stator manufacturing method; and an attachment step of attaching a bracket for holding a bearing that holds the rotating shaft of the rotor to at least one end of the stator in the axial direction. [Effects of the Invention]

[0008] According to the stator, the rotating electric machine, the method for manufacturing the stator, and the method for manufacturing the rotating electric machine disclosed in the present application, A stator having good roundness, a rotating electric machine, a method for manufacturing a stator, and a method for manufacturing a rotating electric machine are provided without increasing processing costs or the number of parts. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view showing the configuration of a split coil winding body according to the first embodiment. FIG. [Figure 2] 2 is a plan view showing the configuration of a split core piece that constitutes the split coil winding body shown in FIG. 1. FIG. [Figure 3] 3 is a plan view showing a configuration in which insulators are provided on the split core pieces shown in FIG. 2. FIG. [Figure 4] 3 is a side view showing a configuration in which an insulator is installed on the split core piece shown in FIG. 2. FIG. [Figure 5] 2 is a plan view showing a configuration in which a plurality of the split coil winding bodies shown in FIG. 1 are arranged in an annular shape. [Figure 6] FIG. 2 is a perspective view showing the configuration of a stator according to the first embodiment. [Figure 7] 7 is a perspective view showing the configuration of a rotating electric machine using the stator shown in FIG. 6. [Figure 8] 1 is a cross-sectional view showing a configuration of a molding die according to the first embodiment. FIG. [Figure 9] 9 is an enlarged schematic view showing the positional relationship between the upper side of the split coil wound body shown in FIG. 1 in the axial direction and the molding die shown in FIG. 8. FIG. [Figure 10] 9 is an enlarged schematic view showing the positional relationship between the lower side of the split coil wound body shown in FIG. 1 in the axial direction and the molding die shown in FIG. 8. FIG. [Figure 11] 9 is a plan view illustrating the relationship between the force of the split coil wound body shown in FIG. 1 and the molding resin, the split coil wound body being placed in the molding die shown in FIG. 8. FIG. [Figure 12] 3 is a flowchart showing a manufacturing process for the rotating electric machine according to the first embodiment. [Figure 13] 10 is a side view showing a configuration in which an insulator is provided on a split core segment in the second embodiment. FIG. [Figure 14] 14 is an enlarged schematic view showing the positional relationship between the upper side of the split coil wound body shown in FIG. 13 in the axial direction and the molding die shown in FIG. 8. FIG. [Figure 15] 14 is an enlarged schematic diagram showing the positional relationship between the lower side of the split coil wound body shown in FIG. 13 in the axial direction and the molding die shown in FIG. 8. FIG. [Figure 16] 14 is an enlarged schematic diagram showing the upper side of the paper in the axial direction of the positional relationship between the other split coil wound body shown in FIG. 13 and the molding die shown in FIG. 8. FIG. [Figure 17] 14 is an enlarged schematic diagram showing the upper and lower sides of the paper in the axial direction of the positional relationship between the other split coil wound body shown in FIG. 13 and the molding die shown in FIG. 8. FIG. [Figure 18] FIG. 13 is a plan view showing the configuration of a stator core in a seventh embodiment. [Figure 19] 19 is a plan view showing a state of a winding process when an insulator is installed on the iron core shown in FIG. 18. FIG. [Figure 20] FIG. 13 is a plan view showing the configuration of a stator core in the eighth embodiment. [Figure 21] 21 is a plan view showing a configuration in which insulators are disposed around the iron core shown in FIG. 20 in an annular arrangement. FIG. [Figure 22] 21 is a cross-sectional view showing the configuration of a connecting portion of the axially laminated core shown in FIG. 20. FIG. [Figure 23] 23 is a cross-sectional view showing the configuration of a first core material and a second core material of the axially laminated core shown in FIG. 22. FIG. [Figure 24] FIG. 13 is a perspective view showing the configuration of a split core piece on which an insulator according to a ninth embodiment is installed. [Figure 25] 25 is a plan view showing a configuration in which a plurality of split core pieces, on which the insulators shown in FIG. 24 are provided, are arranged in an annular shape. FIG. [Figure 26] FIG. 20 is a perspective view showing the configuration of a split core segment on which another insulator according to the ninth embodiment is installed. [Figure 27] FIG. 8 is a cross-sectional view showing the configuration of the rotating electric machine shown in FIG. [Figure 28] FIG. 11 is a perspective view showing the configuration of a stator according to a third embodiment. [Figure 29] 10 is a flowchart showing a manufacturing process for a rotating electric machine according to a third embodiment. [Figure 30] FIG. 10 is a perspective view showing the configuration of a stator according to a fourth embodiment. [Figure 31] FIG. 11 is a side view showing a configuration in which insulators are provided on split core segments in a fourth embodiment. [Figure 32] FIG. 10 is a cross-sectional view showing a configuration of a molding die according to a fourth embodiment. [Figure 33] 33 is an enlarged schematic diagram showing the positional relationship between the upper side of the split coil wound body shown in FIG. 31 in the axial direction and the molding die shown in FIG. 32. FIG. [Figure 34]33 is an enlarged schematic diagram showing the positional relationship between the upper side of the split coil wound body shown in FIG. 31 in the axial direction and the molding die shown in FIG. 32. FIG. [Figure 35] 33 is an enlarged schematic diagram showing the positional relationship between the upper side of the split coil wound body shown in FIG. 31 in the axial direction and the molding die shown in FIG. 32. FIG. [Figure 36] 13 is an enlarged schematic view showing the positional relationship between other split core pieces and a molding die according to the fourth embodiment. FIG. [Figure 37] FIG. 13 is a plan view showing a configuration in which insulators are provided on split core segments in a fifth embodiment. [Figure 38] FIG. 20 is a plan view showing a configuration in which insulators are provided on split core segments in a sixth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] In the following description, each direction in the rotating electric machine is represented as the circumferential direction Z, the axial direction Y, the radial direction X, the outer side X1 of the radial direction X, and the inner side X2 of the radial direction X. Therefore, these directions are the same in the stator and rotor that make up the rotating electric machine, and in each part that makes up the stator and rotor, and these directions will be described as the reference. Furthermore, the rotating electric machine shown in each figure is an example, and the number of poles and slots of the rotating electric machine can be increased or decreased as appropriate.

[0011] Embodiment 1 FIG. 1 is a perspective view showing the configuration of a split coil winding body according to the first embodiment. FIG. 2 is a plan view showing the configuration of a split core piece that constitutes the split coil winding body shown in FIG. 1. FIG. 3 is a plan view showing a configuration in which an insulator is provided on the split core piece shown in FIG. 2. FIG. 4 is a side view showing a configuration in which an insulator is provided on the split core piece shown in FIG. 2. FIG. 5 is a plan view showing a configuration in which a plurality of split coil winding bodies shown in FIG. 1 are arranged in an annular shape. FIG. 6 is a perspective view showing the configuration of a stator according to the first embodiment. FIG. 7 is a perspective view showing the configuration of a rotating electric machine using the stator shown in FIG. 6. FIG. 27 is a cross-sectional view showing the configuration of the rotating electric machine shown in FIG. 7. However, unlike FIG. 7, FIG. 27 shows a simplified outline of a molded resin portion 5, which will be described later.

[0012] Fig. 8 is a cross-sectional schematic diagram showing the configuration of a molding die in embodiment 1. Fig. 9 is an enlarged schematic diagram showing the upper side on a sheet of paper in the axial direction of the positional relationship between the split coil winding body shown in Fig. 1 and the molding die shown in Fig. 8. Fig. 10 is an enlarged schematic diagram showing the lower side on a sheet of paper in the axial direction of the positional relationship between the split coil winding body shown in Fig. 1 and the molding die shown in Fig. 8. Fig. 11 is a plan view explaining the force relationship between the split coil winding body shown in Fig. 1 arranged in the molding die shown in Fig. 8 and the molding resin. Fig. 12 is a flowchart showing a method for manufacturing a rotating electric machine according to embodiment 1.

[0013] As shown in Fig. 1, the split coil winding body 1 constitutes a stator 20 (Fig. 6) of a rotating electric machine 100 (Fig. 7) described below. The split coil winding body 1 has a split core piece 11, an insulator 2 arranged on the split core piece 11, and a coil 3 formed by winding a conductor around the split core piece 11 with the insulator 2 interposed therebetween.

[0014] 2, the split core pieces 11 of the split coil winding body 1 shown in FIG. 1 have a core back portion 111 extending in the circumferential direction Z, and tooth portions 112 formed on an inner peripheral surface 11A of the core back portion 111 on the inner side X2 in the radial direction X so as to protrude toward the inner side X2 in the radial direction X. The outer side X1 of the core back portion 111 in the radial direction X is defined as an outer peripheral surface 11B, both ends of the core back portion 111 in the circumferential direction Z are defined as end faces 11C, and the inner sides X2 of the tooth portions 112 in the radial direction X are defined as tip faces 11D. The split core pieces 11 are formed, for example, by stacking a plurality of electromagnetic steel plates in the axial direction Y and fixing them to each other by crimping, welding, or bonding.

[0015] 3 and 4 show a state in which the insulator 2 is installed on the split core piece 11. The insulator 2 has protrusions 21 and 22 on both ends in the axial direction Y, extending in the radial direction X toward the outer peripheral surface 11B of the core back portion 111. The radial outer sides X1 of the protrusions 21 and 22 in the radial direction X are formed to protrude further toward the outer peripheral surface 11B of the core back portion 111 in the radial direction X1, and the outermost sides X1 in the radial direction X have protrusion surfaces 21A and 22A along the axial direction Y. The protrusion surfaces 21A and 22A are formed with a slope with respect to the axial direction Y. Note that the slope will be described in detail in the manufacturing method of the stator 20. The end faces of the protrusions 21 and 22 on the sides facing away from the split core piece 11 in the axial direction Y are referred to as axial end faces 21B and 22B.

[0016] The insulator 2 is molded from, for example, an insulating thermoplastic resin, and covers the split core pieces 11 except for the tip surfaces 11D on the inner side X2 of the tooth portions 112 in the radial direction X, the end surfaces 11C at both ends in the circumferential direction Z of the core back portion 111, and a part of the outer peripheral surface 11B on the outer side X1 in the radial direction X, thereby insulating the split core pieces 11 from the coil 3.

[0017] When a plurality of split coil winding bodies 1 shown in Fig. 1 are arranged in a ring shape, the stator 20 is formed as shown in Fig. 5 (however, the coils 3 are omitted from Fig. 5). The stator 20 is provided with a molded resin part 5 that covers the split coil winding bodies 1 arranged as shown in Fig. 5 with molded resin as shown in Fig. 6. The molded resin part 5 is formed of a thermosetting resin such as bulk molding compound (BMC).

[0018] The stator 20 is covered with the molded resin portion 5 except for the protruding surfaces 21A, 22A of the protruding portions 21, 22 of the insulator 2 mounted on the split coil winding body 1 and the tip end surfaces 11D of the split core pieces 11. In other words, the protruding surfaces 21A, 22A are exposed from the molded resin portion 5 and are not covered by the molded resin portion 5. This configuration will be described in detail in the manufacturing method of the stator 20.

[0019] 7 and 27, the rotating electric machine 100 includes a stator 20, a rotor 40 rotatably installed on the inside X2 of the stator 20 in the radial direction X and including a rotating shaft 41 and a bearing 42, and a bracket 7 that holds the bearing 42 that holds the rotating shaft 41 of the rotor 40, which is installed in an opening 200 (see FIG. 6) at one end of the stator 20 in the axial direction Y. Note that, although the first embodiment shows an example in which the bracket 7 is installed at one end in the axial direction Y, the present invention is not limited to this, and it is also possible to provide openings 200 at both ends of the stator 20 in the axial direction Y and install the bracket 7 at both ends in the axial direction Y.

[0020] Next, a method for manufacturing the stator 20 of the first embodiment configured as described above and the rotating electric machine 100 using the stator 20 will be described with reference to Fig. 12. First, an assembly process is performed in which a pre-formed insulator 2 is attached to or integrally formed with a split core piece 11 formed by stacking electromagnetic steel sheets in the axial direction Y (step ST1 in Fig. 12). Next, a winding process is performed in which a conductor is wound around the tooth portion 112 of the split core piece 11 via the insulator 2 to form a coil 3, thereby forming the split coil winding body 1 shown in Fig. 1 (step ST2 in Fig. 12).

[0021] Next, as shown in FIG. 5, an in-mold arrangement step is performed in which the multiple split coil winding bodies 1 are arranged in a mold die 50 (see FIG. 8 described later) in a ring shape centered on the central axis of the stator 20 (step ST3 in FIG. 12). Next, a molding step is performed in which a molded resin portion 5 is formed using molded resin (step ST4 in FIG. 12), resulting in the stator 20 as shown in FIG. 6. In this stator 20, the protruding surfaces 21A and 22A of the insulator 2 are exposed from the molded resin and are not covered by the molded resin. The mold die 50 used in the in-mold arrangement step and the molding step, as well as the positional relationship between the mold die 50 and the split coil winding bodies 1 and the steps involved in forming the stator 20 as described above, will now be described in detail.

[0022] First, the configuration of a molding die 50 used in the molding process will be described with reference to Figure 8. The molding die 50 is configured to include a movable die 51 and a fixed die 52 that are opened and closed at a particle surface 55, with a cavity 53 formed between them. The fixed die 52 is formed with a cylindrical center shaft 54 ​​that protrudes into the cavity 53. The outer diameter of the center shaft 54 ​​matches the inner diameter of the stator 20. The mold inner peripheral surface 51A of the movable die 51 is inclined with respect to the central axis of the center shaft 54 ​​so that the opening area (opening diameter) increases toward the fixed die 52.

[0023] Before the molding process, as shown in Fig. 8, the movable die 51 is moved in the opposite direction from the fixed die 52 to open the die, and multiple split coil winding bodies 1 are arranged in a ring shape in the cavity 53, as shown in Fig. 5, with the central axis of the stator 20 as the center. Details of the state in which the split coil winding bodies 1 are arranged in the molding die 50 in this manner will be explained using Figs. 9 and 10. Fig. 9 shows the relationship of the split coil winding body 1 shown in Fig. 4 to the upper molding die 50 on the plane of the drawing in the axial direction Y. Fig. 10 shows the relationship of the split coil winding body 1 shown in Fig. 4 to the lower molding die 50 on the plane of the drawing in the axial direction Y.

[0024] As shown in FIGS. 9 and 10 , the slope of the protrusion surface 21A of the protrusion 21 at one end in the axial direction Y with respect to the axial direction Y is the same as the slope of the protrusion surface 22A of the protrusion 22 at the other end in the axial direction Y with respect to the axial direction Y (except for a slope angle of 0 degrees). Furthermore, the slope of the protrusion surfaces 21A, 22A of the protrusions 21, 22 of the insulator 2 of the split coil winding body 1 with respect to the axial direction Y is oriented in the same direction as the slope of the mold inner circumferential surface 51A of the movable mold 51 with respect to the axial direction Y. That is, the protrusion surfaces 21A, 22A and the mold inner circumferential surface 51A are parallel to each other. Note that the slope is actually less than 10° with respect to the axial direction Y, and in reality, it is difficult to distinguish it from a surface parallel to the axial direction Y, as shown in FIG. 4 . 9 and 10, the relationship between the gradient of the protrusion surfaces 21A, 22A of the protrusions 21, 22 relative to the axial direction Y and the gradient of the inner peripheral surface 51A of the molding die 50 relative to the axial direction Y is exaggerated.

[0025] Then, when the movable die 51 is moved toward the fixed die 52 for die closing and the molding die 50 is closed, there is an interference between the movable die 51 and the fixed die 52, and before the die is closed and as the movable die 51 is moving, the protruding surfaces 21A, 22A of the insulator 2 protruding outward X1 in the radial direction X come into contact with the inner circumferential surface 51A of the movable die 51.

[0026] When the movable die 51 continues to move and closes the die, because the mold inner peripheral surface 51A of the movable die 51 and the protruding surfaces 21A, 22A of the protruding portions 21, 22 of the insulator 2 are sloped, the clamping force, which is the load in the axial direction Y when the movable die 51 moves, is converted into a load in the radial direction X on the split coil winding body 1. As a result, the elastic force of the protruding portions 21, 22 presses the split coil winding body 1 from the outside X1 toward the inside X2 in the radial direction X, and the tip surfaces 11D of the teeth 112 are pressed against the center shaft 54.

[0027] Specifically, as shown in FIG. 11, due to the interference between the protrusions 21, 22 and the mold inner peripheral surface 51A, the value obtained by multiplying the load N generated in the outer X1 direction of the radial direction X of the protrusions 21, 22 by the friction coefficient μN generated between the protrusion surfaces 21A, 22A of the protrusions 21, 22 and the mold inner peripheral surface 51A is greater than the load F that the protrusions 21, 22 receive in the circumferential direction Z due to the resin pressure.

[0028] In this way, it is desirable to form the protrusion surfaces 21A, 22A of the protrusion portions 21, 22 so that they form the same angle as the gradient of the mold inner surface 51A with respect to the axial direction Y when the mold is closed, so that the protrusion surfaces 21A, 22A can press the split coil winding body 1 uniformly in the axial direction Y from the outside X1 to the inside X2 in the radial direction X.

[0029] When the split coil winding body 1 is placed in the molding die 50 and closed, the protruding surfaces 21A, 22A of the protruding portions 21, 22 come into contact with the inner surface 51A of the mold, and the elastic force of the protruding portions 21, 22 causes the insulator 2 to push the split core piece 11 from the outside X1 to the inside X2 in the radial direction X, and the tip surface 11D of the tooth portion 112 is pressed against the center shaft 54, so that the dimensions are formed such that the split coil winding body 1 does not move due to resin pressure when the molding resin is injected.

[0030] Furthermore, the protrusions 21 and 22 are not limited to this example, and when the split coil winding body 1 is placed in the molding die 50 and closed, they come into contact with the inner surface 51A of the die, and the elastic force presses the tip surface 11D of the tooth portion 112 against the center shaft 54 ​​from the outside X1 to the inside X2 in the radial direction X, so that the split coil winding body 1 does not move due to resin pressure even when the molding resin is injected, and the width in the circumferential direction Z of the protrusion surfaces 21A and 22A of the protrusions 21 and 22, and the number of protrusions formed in the circumferential direction Z of the protrusion surfaces 21A and 22A of the protrusions 21 and 22 may be more than one for one split coil winding body 1.

[0031] In this state, molten molding resin is injected into cavity 53 to cover split coil winding body 1. After the molding resin is injected into cavity 53, molding die 50 is heated. This hardens the molding resin in cavity 53, and stator 20 as shown in FIG. 6 is formed. After the molding resin is hardened and molding resin portion 5 is formed, movable die 51 is moved in the opposite direction from fixed die 52 to open the mold, and stator 20 is removed from molding die 50. In stator 20 formed in this manner, molding resin portion 5 is formed with protruding surfaces 21A and 22A of insulator 2 in close contact with mold inner circumferential surface 51A, so that protruding surfaces 21A and 22A of insulator 2 are exposed from the molding resin and are not covered by the molding resin.

[0032] Next, the rotating electric machine 100 is manufactured using the stator 20 manufactured as described above. First, an arrangement step is performed in which the rotor 40 is inserted through the opening 200 of the stator 20 and arranged so as to face the tip surface 11D of the tooth portion 112 (step ST5 in FIG. 12). Next, an attachment step is performed in which the bracket 7 that holds the bearing 42 that holds the rotating shaft 41 of the rotor 40 is attached to the opening 200 of the stator 20 (step ST6 in FIG. 12), completing the manufacture of the rotating electric machine 100.

[0033] According to the stator of the first embodiment configured as described above, A stator comprising: an iron core having a core back portion formed in an annular shape; and a plurality of teeth formed on an inner peripheral surface of the core back portion in a radial direction, the teeth protruding radially inward at intervals in the circumferential direction; coils wound around the teeth via insulators; and a molded resin portion covering the iron core and the coils, The core back portion is formed so as to be separated from the core back portion at at least one location in the circumferential direction, the insulator has two or more protrusions in a circumferential direction that protrude radially outward from an outer circumferential surface of the core back portion, The molded resin portion does not cover a protruding surface of the protruding portion along the axial direction on the radial outer side thereof, Furthermore, according to the rotating electric machine of the first embodiment configured as described above, The stator described above; a rotor arranged coaxially and rotatably inside the stator in the radial direction; a bracket for holding a bearing for holding a rotating shaft of the rotor, the bracket being installed at at least one end of the stator in the axial direction, Furthermore, according to the method for manufacturing the stator of the first embodiment performed as described above, an assembly process of installing the insulator on the iron core; a winding process for forming a coil on the teeth portion of the iron core via the insulator; a mold placement step of placing the iron core in a mold die for forming the molded resin portion; a molding step of exposing the protruding surfaces of the protruding portions and covering them with molding resin to form the stator, Furthermore, according to the method for manufacturing the rotating electric machine of the first embodiment performed as described above, a placement step of placing a rotatable coaxial rotor radially inside the stator formed by the stator manufacturing method; and an attachment step of attaching a bracket for holding a bearing that holds a rotating shaft of the rotor to at least one end of the stator in the axial direction, It is possible to provide a stator with good roundness, a rotating electric machine, a method for manufacturing a stator, and a method for manufacturing a rotating electric machine, without increasing processing costs, equipment costs, or the number of parts.

[0034] Furthermore, according to the stator of the first embodiment configured as described above, The protrusions are formed so that the value obtained by multiplying the load generated in the radially outward direction of the protrusions against the inner peripheral surface of the mold for forming the molded resin portion by the coefficient of friction generated between the protrusion surface of the protrusions and the inner peripheral surface of the mold for forming the molded resin portion is greater than the load that the protrusions receive in the circumferential direction due to the resin pressure when the molded resin is injected into the molded resin portion. A stator with better roundness can be obtained.

[0035] Furthermore, according to the stator of the first embodiment configured as described above, the protrusions are formed on both axial end sides of the core back portion, a gradient of the protrusion surface at one axial end of the protrusion with respect to the axial direction; The slope of the protrusion surface on the other end side of the protrusion in the axial direction with respect to the axial direction is the same (excluding the slope angle of 0 degrees), A stator with good roundness can be easily obtained.

[0036] Furthermore, according to the stator of the first embodiment configured as described above, The protrusions are formed on both axial ends of the core back portion, A stator with better roundness can be obtained.

[0037] Embodiment 2 Fig. 13 is a side view showing a configuration in which insulators are provided on split core pieces in embodiment 2. Fig. 14 is an enlarged schematic view showing the upper side of the layout of the split coil winding body shown in Fig. 13 and the molding die shown in Fig. 8 in the axial direction, on a sheet of paper. Fig. 15 is an enlarged schematic view showing the upper side of the layout of the split coil winding body shown in Fig. 13 and the molding die shown in Fig. 8 in the axial direction, on a sheet of paper. Fig. 16 is an enlarged schematic view showing the upper side of the layout of another split coil winding body shown in Fig. 13 and the molding die shown in Fig. 8 in the axial direction, on a sheet of paper. Fig. 17 is an enlarged schematic view showing the upper side of the layout of another split coil winding body shown in Fig. 13 and the molding die shown in Fig. 8 in the axial direction, on a sheet of paper.

[0038] In each drawing, parts that are the same as those in the first embodiment are given the same reference numerals, and their description will be omitted. Furthermore, the gradients shown in Figures 14 to 16 actually have a gradient angle of less than 10° with respect to the axial direction Y, and are therefore difficult to distinguish from surfaces that are parallel to the axial direction Y, as shown in Figure 13. For this reason, in Figures 14 to 16, the relationship between the gradient of protrusion surfaces 21A, 22A and extension portions 201, 202 of protrusions 21, 22 with respect to the axial direction Y and the gradient of mold inner circumferential surface 51A of molding die 50 with respect to the axial direction Y is exaggerated.

[0039] In the second embodiment, the protrusions 21 and 22 not only protrude outward X1 from the outer peripheral surface 11B of the core back portion 111, but also have extending portions 201 and 202 that extend along the outer peripheral surface 11B of the split core piece 11 toward the center in the axial direction Y of the split core piece 11. By providing the extending portions 201 and 202, higher rigidity can be obtained compared to the insulator 2 of the first embodiment.

[0040] As in the first embodiment, when the split coil winding body 1 is placed in the molding die 50 and the die is closed, the protruding surfaces 21A, 22A of the protruding portions 21, 22 come into contact with the outer peripheral surface 11B of the core back portion 111 and the inner peripheral surface 51A of the die, and the split coil winding body 1 is pressed from the outside X1 to the inside X2 in the radial direction X by elastic force, and the tip surfaces 11D of the teeth portions 112 are pressed against the center shaft 54. This results in a dimensional relationship in which the split coil winding body 1 does not move due to resin pressure even when molding resin is injected.

[0041] For example, as shown in Figures 14 and 15, when the extension portions 201, 202 are formed along the outer peripheral surface 11B of the core back portion 111, the inclination angle of the protrusion surfaces 21A, 22A with respect to the axial direction Y is the same as the inclination angle of the mold inner peripheral surface 51A with respect to the axial direction Y.

[0042] Furthermore, as shown in Figure 16, when the extension portion 201 is formed away from the outer peripheral surface 11B of the core back portion 111 and the direction of the gradient of the opposing surface 201A of the extension portion 201 facing the core back portion 111 with respect to the axial direction Y is the same as the direction of the gradient of the mold inner peripheral surface 51A with respect to the axial direction Y, the gradient angle θ22 of the protrusion surface 21A of the protrusion portion 21 with respect to the axial direction Y is formed at an angle obtained by adding the gradient angle θ12 of the mold inner peripheral surface 51A with respect to the axial direction Y to the gradient angle θ32 formed by the opposing surface 201A of the extension portion 201 of the protrusion portion 21 and the outer peripheral surface 11B of the core back portion 111.

[0043] Furthermore, as shown in Figure 17, when the extension portion 202 is formed away from the outer peripheral surface 11B of the core back portion 111 and the direction of the gradient of the opposing surface 202A of the extension portion 202 facing the core back portion 111 with respect to the axial direction Y is different from the direction of the gradient of the inner peripheral surface 51A of the mold with respect to the axial direction Y, the gradient angle θ21 of the protrusion surface 22A of the protrusion portion 22 with respect to the axial direction Y is formed at an angle obtained by subtracting the gradient angle θ31 formed by the opposing surface 202A of the extension portion 202 of the protrusion portion 22 and the outer peripheral surface 11B of the core back portion 111 from the gradient angle θ11 of the inner peripheral surface 51A of the mold with respect to the axial direction Y.

[0044] As shown in Figures 14 and 16, in the case of the protrusion 21 on the upper side of the paper, the slope angle of a portion 21AA of the protrusion surface 21A of the protrusion 21 relative to the axial direction Y can be made larger than the slope angle of the mold inner surface 51A relative to the axial direction Y, or the corners 21AR can be rounded, thereby preventing breakage and buckling of the protrusion 21 due to mold closing.

[0045] Specifically, while movable mold 51 is moving toward fixed mold 52 to close the mold, particle surface 55 of movable mold 51, which is the dividing surface between fixed mold 52 and movable mold 51, interferes with axial end surface 21B of protrusion 21, causing a load to be applied to extension 201 in axial direction Y rather than radial direction X, resulting in shear stress and fracture. This can be prevented by reducing the area of ​​axial end surface 21B by adding partial surface 21AA and corner 21AR to protrusion surface 21A, and also by preventing buckling due to a load in radial direction X being applied to parts of protrusion 21 other than extension 201 after mold closing.

[0046] As shown in Figures 15 and 17, in the case of the protrusion 22 on the lower side of the paper, not only is the slope angle of one surface 22AA of the protrusion 22 with respect to the axial direction Y made larger than the slope of the mold inner surface 51A with respect to the axial direction Y and the corners 22AR made rounded, but also the slope of one surface 22AB of the protrusion surface 22A of the protrusion 22 with respect to the axial direction Y is made opposite to the slope of the mold inner surface 51A with respect to the axial direction Y, thereby preventing damage such as breakage and buckling of the protrusion 22 when the mold is closed.

[0047] Specifically, while movable mold 51 is moving toward fixed mold 52 to close the mold, particle surface 55 of movable mold 51, which is the dividing surface between fixed mold 52 and movable mold 51, interferes with extended tip surface 22C of protrusion 22, causing a load to be applied to extended portion 202 in axial direction Y rather than radial direction X, resulting in shear stress and breakage. This can be prevented by reducing the area of ​​extended tip surface 22C by adding partial surface 22AA and corner 22AR to protrusion surface 22A, and also by preventing buckling due to a load in radial direction X being applied to parts other than extended portion 202 of protrusion 22 after mold closing.

[0048] 16 and 17, the opposing surfaces 201A, 202A of the extending portions 201, 202 of the protruding portions 21, 22 have a slope with respect to the axial direction Y so as to move away from the outer peripheral surface 11B of the core back portion 111. This allows the split core pieces 11 and the insulator 2 to be fitted together when the pre-formed insulator 2 is assembled to the split core pieces 11 even if there is dimensional variation in the split core pieces 11.

[0049] When the split coil winding body 1 is placed in the molding die 50 and closed, the protrusions 21, 22 come into contact with both the outer peripheral surface 11B of the core back portion 111 and the inner peripheral surface 51A of the die, and the split coil winding body 1 is pushed by elastic force from the outside X1 to the inside X2 in the radial direction X, and the tip surfaces 11D of the teeth portions 112 are pressed against the center shaft 54, so that as long as the split coil winding body 1 does not move due to resin pressure even when the molding resin is injected, the width of the protrusion surfaces 21A, 22A of the protrusions 21, 22 in the circumferential direction Z and the number of the protrusion surfaces 21A, 22A of the protrusions 21, 22 formed in the circumferential direction Z may not be one but multiple for one split coil winding body 1. Hereinafter, as in the first embodiment, a rotating electric machine 100 can be configured using the stator 20.

[0050] According to the stator of the second embodiment configured as described above, In addition to providing the same effects as those of the first embodiment, The protrusion includes an extension formed to extend toward the center in the axial direction along the outer peripheral surface of the core back portion of the iron core in the radial direction. A stator with high rigidity and better roundness can be obtained.

[0051] Furthermore, according to the stator of the second embodiment configured as described above, the extension portion is formed along an outer peripheral surface of the core back portion, The direction of the gradient of the protrusion surface of the protrusion with respect to the axial direction is the same as the direction of the gradient of the inner peripheral surface of the mold for forming the molded resin portion with respect to the axial direction. A stator with better roundness can be obtained.

[0052] Furthermore, according to the stator of the second embodiment configured as described above, the extension portion is formed away from the outer circumferential surface of the core back portion, When the direction of the gradient of the opposing surface of the extension portion facing the core back portion with respect to the axial direction is the same as the direction of the gradient of the inner peripheral surface of the mold for forming the molded resin portion with respect to the axial direction, a gradient angle of the protrusion surface is an angle obtained by adding an angle formed by the extension portion and the outer peripheral surface of the core back portion to a gradient angle of an inner peripheral surface of a mold for forming the molded resin portion, When the direction of the gradient of the opposing surface of the extension portion facing the core back portion with respect to the axial direction is different from the direction of the gradient of the inner peripheral surface of the mold for forming the molded resin portion with respect to the axial direction, The slope angle of the protrusion surface is the slope angle of the inner surface of the mold used to form the molded resin portion minus the angle between the extension portion and the outer surface of the core back portion.Therefore, when a pre-molded insulator is assembled to an iron core, the iron core and insulator can be fitted together even if there is dimensional variation in the iron core.

[0053] Embodiment 3 Fig. 28 is a perspective view showing the configuration of a stator according to embodiment 3. Fig. 29 is a flowchart showing a method for manufacturing a rotating electric machine according to embodiment 3. In the figure, parts that are the same as those in the above embodiments are given the same reference numerals and description thereof will be omitted.

[0054] 28, in the present third embodiment, protrusion surfaces 21A, 22A along the axial direction Y on the outer side X1 in the radial direction X of the protrusions 21, 22 of the insulator 2, which are not covered by the molded resin portion 5 of FIG. 6 described in the first embodiment, are covered with a first member 6. The first member 6 is made of a material different from that of the molded resin portion 5, and examples of the material include an adhesive and a tape.

[0055] A method for manufacturing the stator of the third embodiment configured as described above and a rotating electric machine using the stator will be described with reference to Figure 29. First, similarly to the first embodiment, the assembly process through the molding process (steps ST1 to ST4 in Figure 29) are performed. Next, a covering process (step ST41 in Figure 29) is performed in which protrusion surfaces 21A, 22A along the axial direction Y on the outer side X1 in the radial direction X of protrusions 21, 22 of insulator 2 that are not covered by molded resin portion 5 are covered with first member 6. Thereafter, the same processes as those in the first embodiment are performed to complete the manufacturing of rotating electric machine 100.

[0056] The stator of the third embodiment configured as described above has the same effects as those of the above embodiments, and also has the following advantages: The protruding surface that is not covered by the molded resin portion is covered with a first member made of a material different from that of the molded resin portion. Since the insulator can be prevented from being exposed, water can be prevented from entering through the interface between the insulator and the molded resin portion.

[0057] Furthermore, according to the method for manufacturing the stator of the third embodiment carried out as described above, an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of exposing the protruding surfaces of the protruding portions and covering them with molding resin to form the stator; a covering step of covering the protruding surface of the protruding portion that is not covered with the mold resin portion with the first member; Since the insulator can be prevented from being exposed, water can be prevented from entering through the interface between the insulator and the molded resin portion.

[0058] Embodiment 4 Fig. 30 is an example of a perspective view showing the configuration of a stator according to embodiment 4. Fig. 31 is a side view showing a configuration in which insulators are provided on split core pieces used in the stator shown in Fig. 30. Fig. 32 is a cross-sectional schematic diagram showing the configuration of a molding die in embodiment 4. Figs. 33 to 35 are enlarged schematic diagrams showing the upper side of the paper in the axial direction of the positional relationship between the split coil winding body and the molding die shown in Fig. 32.

[0059] In each drawing, parts that are the same as those in the above-described embodiments are given the same reference numerals, and the description thereof will be omitted. Also, the rotating electric machine using the stator 20 configured as shown in the fourth embodiment and the manufacturing method of the rotating electric machine are the same as those in the above-described embodiments, and therefore the description thereof will be omitted as appropriate.

[0060] 32 to 36, the gradient angle with respect to the axial direction Y is actually less than 10°, and in reality, it is difficult to distinguish them from surfaces parallel to the axial direction Y, as shown in Fig. 31. For this reason, in Fig. 32 to 36, the relationship between the gradient of the protrusion and extension with respect to the axial direction Y and the gradient of the inner peripheral surface of the molding die and the movable pin with respect to the axial direction Y is exaggerated.

[0061] As shown in Fig. 31, protrusion 21 is formed only on one end side in the axial direction Y of split core piece 11 (upper side on the paper surface of Fig. 31). Protrusion 21 includes extension portion 201 formed extending toward the center side in the axial direction Y along the outer peripheral surface 11B on the outside X1 in the radial direction X of core back portion 111 of split core piece 11. As shown in Fig. 33, thickness W1 in the radial direction X of extension portion 201 of protrusion 21 formed on one end side in the axial direction Y is formed to become smaller from the center side end face of extension portion 201 in the axial direction Y (lower side end on the paper surface of Fig. 33) toward one end side in the axial direction Y (upper side on the paper surface of Fig. 33).

[0062] 30, molded resin part 5 covering split core pieces 11 and coil 3 of stator 20 is composed of first molded resin part 551 covering radially outer surface 333 (see FIG. 31) of extending part 201 of protruding part 21 of insulator 2, and second molded resin part 552 covering the rest. Then, boundary part (weld line) 555 is formed at the boundary between first molded resin part 551 and second molded resin part 552.

[0063] The molding process for the stator 20 of the fourth embodiment configured as described above will be described below. First, the molding die 50 used in the molding process will be described. As shown in FIG. 32, the molding die 50 used in the molding process includes a movable pin 33 that is movable in the axial direction Y, in addition to the structure shown in FIG. 8 described in the first embodiment above. The movable pin 33 has a sloped surface 330 that tapers toward the tip, on the side where the split coil winding body 1 is disposed. The sloped surface 330 has an inclination angle with respect to the axial direction Y that is the same as the inclination angle with respect to the axial direction Y of the surface 333 of the extension portion 201.

[0064] In the molding process of the fourth embodiment, similarly to the above-described embodiments, the split coil winding body 1 is placed in a mold die 50 and then closed. Then, the surface 333 of the extending portion 201 of the protruding portion 21 and the inclined surface 330 of the movable pin 33 come into close contact with each other. Therefore, unlike the above-described embodiments, the extending portion 201 is sandwiched between the inclined surface 330 of the movable pin 33 and the outer peripheral surface 11B of the core back portion 111, rather than the inner peripheral surface 51A of the mold. The elastic force of the extending portion 201 presses the split coil winding body 1 from the outer side X1 to the inner side X2 in the radial direction X, and the tip surface 11D of the tooth portion 112 is pressed against the center shaft 54. This prevents the split coil winding body 1 from moving due to the resin pressure when the molding resin is injected.

[0065] In this state, molten molding resin is injected into cavity 53 to cover split coil winding body 1. The state at this point is shown in Figure 33. As is clear from Figure 33, the molding resin filled in the areas excluding split coil winding body 1 and movable pin 33 becomes second molding resin portion 552. Therefore, the molding resin does not flow onto surface 333 of extension portion 201 that is in contact with inclined surface 330 of movable pin 33.

[0066] Next, before the molten molding resin is completely injected into cavity 53, movable pin 33 is retracted away from surface 333 of extension portion 201. The state at that time is shown in FIG.

[0067] Thereafter, by continuing to inject molten molding resin into cavity 53, the molding resin flows into the area where movable pin 33 was located, and first molding resin portion 551 is formed. The state at this point is shown in FIG. 35. As is clear from FIG. 35, first molding resin portion 551 is formed so as to cover surface 333 of extension portion 201, and boundary portion 555 is formed at the boundary between first molding resin portion 551 and second molding resin portion 552. In this way, molding resin portion 5 made up of first molding resin portion 551 and second molding resin portion 552 can be created in a single process of injecting molding resin. Furthermore, this process alone can prevent insulator 2 from being exposed.

[0068] In the fourth embodiment, an example has been shown in which the protrusion 21 is formed only on one end side of the core back portion 111 in the axial direction Y. However, as another example, as shown in Fig. 36, the protrusion 22 may be additionally formed on the other end side of the core back portion 111 in the axial direction Y (the lower side on the paper surface of Fig. 31). In this case, the thickness W2 in the radial direction X of the extending portion 202 of the protrusion 22 formed on the other end side in the axial direction Y is increased from the center side end face of the extending portion 202 in the axial direction Y (the upper side on the paper surface of Fig. 36) toward the other end side in the axial direction Y (the lower side on the paper surface of Fig. 36). Even in this case, the surface 336 on the outer side X1 in the radial direction X of the extension portion 202 of the protrusion portion 22 and the inclined surface 330 of the movable pin 33 are brought into close contact with each other to form the second molded resin portion 552, and then, as in Figure 34, the movable pin 33 is retracted from one end side in the axial direction Y to form the first molded resin portion 551 at the location where the movable pin 33 was located, and the boundary portion 555 is formed.

[0069] According to the stator of the fourth embodiment configured as above, A stator comprising: an iron core having a core back portion formed in an annular shape; and a plurality of teeth formed on an inner peripheral surface of the core back portion in a radial direction, the teeth protruding radially inward at intervals in the circumferential direction; coils wound around the teeth via insulators; and a molded resin portion covering the iron core and the coils, The core back portion is formed so as to be separated from the core back portion at at least one location in the circumferential direction, the insulator has two or more protrusions in a circumferential direction that protrude radially outward from an outer circumferential surface of the core back portion, the protrusion is formed on one axial end side of the core back portion, the protrusion includes an extension portion formed to extend toward the center in the axial direction along the outer peripheral surface of the core back portion of the iron core in the radial direction, The radial thickness of the extension portion of the protrusion formed on one end side of the axial direction is formed to become smaller from the end face of the extension portion on the center side of the axial direction toward the one end side of the axial direction, When the iron core and the insulator are pressed by the mold die to form the molded resin portion, the radially outer surface of the extension of the protrusion on one end in the axial direction can be used. A stator having good roundness can be provided without increasing processing costs, equipment costs, or the number of parts.

[0070] Furthermore, according to the stator of the fourth embodiment configured as described above, the protrusion is also formed on the other axial end side of the core back portion, The radial thickness of the extension portion of the protrusion formed on the other end side in the axial direction is formed so as to increase from the end face of the extension portion on the center side in the axial direction toward the other end side in the axial direction, When the iron core and the insulator are pressed by the mold die to form the molded resin portion, the radially outer surface of the extension of the protrusion on the other end in the axial direction can be additionally used. A stator having good roundness can be provided without increasing processing costs, equipment costs, or the number of parts.

[0071] Furthermore, according to the stator of the fourth embodiment configured as described above, When the molded resin portion is a first molded resin portion that covers the radially outer surface of the extension portion of the protrusion, and the remaining portion is a second molded resin portion, Since there is a boundary line at the boundary between the first molded resin part and the second molded resin part, The first molded resin portion can cover the radially outer surface of the extension of the protrusion, preventing the insulator from being exposed, thereby preventing water from entering through the interface between the insulator and the molded resin portion.

[0072] Furthermore, according to the method for manufacturing the stator of the fourth embodiment carried out as described above, an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of covering the radially outer surfaces of the extension portions of the protrusions with a molding resin without exposing them, thereby forming the stator; In the molding step, the second molded resin part is formed with a movable pin in contact with the radially outer surface of the extension part of the protrusion, and then the first molded resin part is formed with the movable pin separated from the radially outer surface of the extension part of the protrusion. The first molded resin portion can cover the radially outer surface of the extension of the protrusion, preventing the insulator from being exposed, thereby preventing water from entering through the interface between the insulator and the molded resin portion.

[0073] Embodiment 5 Fig. 37 is a plan view showing a configuration in which insulators are installed on a split core piece used in a stator in embodiment 5. In the figure, parts that are the same as those in the above embodiments are given the same reference numerals and descriptions thereof will be omitted. In embodiment 5, a case will be described in which one split core piece, i.e., one tooth portion, is provided with multiple protrusions in the circumferential direction, two in this case.

[0074] As shown in FIG. 37 , one core segment 11 is provided with two protrusions 21 in the circumferential direction Z. A dovetail groove 30 is formed on the outer peripheral surface 11B of the core back portion 111 of the core segment 11 between the two protrusions 21 in the circumferential direction Z. The dovetail groove 30 is formed extending from one end to the other end in the axial direction Y of the core back portion 111 of the core segment 11. The dovetail groove 30 is used to hold the core segment 11 in the winding process. Each extension portion 201 of the two protrusions 21 includes a line segment that bisects in the circumferential direction Z a surface 333 along the axial direction Y on the outer side X1 of the extension portion 201 in the radial direction X, and a surface 334 perpendicular to the surface 333 on the outer side X1 in the radial direction X of the extension portion 201 is formed to include the central axis O of the annular core back portion 111.

[0075] Because the extension portions 201 of the multiple protrusions 21 are formed in this manner, during the molding process, the multiple extension portions 201 can press the core back portion 111 toward the central axis O from multiple points in the circumferential direction Z, thereby allowing the split core pieces 11 to be stably pressed against the center shaft 54 ​​(see Figure 8) while suppressing the inclination of the split core pieces 11 in the circumferential direction Z, and improving the inner diameter accuracy of the split core pieces 11.

[0076] Furthermore, since the plurality of protrusions 21 can be formed while the dovetail grooves 30 are provided, the coil 3 can be stably formed while the split core pieces 11 are held using the dovetail grooves 30 in the winding process.

[0077] According to the stator of the fifth embodiment configured as described above, a plurality of the protrusions are provided for each of the teeth in the circumferential direction, The extension portions of the plurality of protrusions include a line segment that bisects the radially outer surface of the extension portion in the circumferential direction, and a plane perpendicular to the radially outer surface of the extension portion is formed to include the central axis of the annular core back portion. The same effects as those of the above embodiments can be achieved, and When forming the molded resin portion, one tooth portion can be held in place by the extending portions at multiple locations in the circumferential direction relative to the molding die, which makes it possible to improve the accuracy of the inner diameter of the core.

[0078] Embodiment 6 FIG. 38 is a plan view showing a configuration in which insulators are provided on split core pieces used in a stator according to the sixth embodiment. In the figure, parts similar to those in the above-described embodiments are denoted by the same reference numerals, and description thereof will be omitted. In the sixth embodiment, as shown in FIG. 38, a surface 335 on the outer side X1 in the radial direction X of the extension portion 201 has a curved surface that protrudes toward the central axis O (see FIG. 37) of the annular core back portion 111. As a result, the tip of the movable pin 33 (see FIG. 32) shown in the fourth embodiment is formed, for example, in a conical shape. Then, the conical movable pin 33 can be brought into contact with the surface 335 formed by the curved surface of the extension portion 202, eliminating the need to determine the phase of the movable pin 33 and simplifying installation of the molding die 50.

[0079] According to the stator of the sixth embodiment configured as above, The same effects as those of the above embodiments can be achieved, and The surface of the extension portion along the axial direction on the radial outer side has a curved surface that protrudes toward the central axis of the annular core back portion, This makes it easier to set up the mold, and simplifies the structure of the mold.

[0080] Embodiment 7 Fig. 18 is a plan view showing the configuration of a stator core in embodiment 7. Fig. 19 is a plan view showing the state of the winding process when an insulator is installed on the core shown in Fig. 18. In the figure, parts that are the same as those in the above embodiments are given the same reference numerals and their explanation will be omitted.

[0081] In the seventh embodiment, as shown in Fig. 18, the core 110 is formed integrally with the core back portions 111 connected in the circumferential direction Z by the thin-walled portions 111A, and is formed to be separated at least at one location in the circumferential direction Z. An insulator 2 is attached to the core 110 formed in this manner, and is arranged in a reverse-warped state as shown in Fig. 19. This is because the core 110 can be bent at the thin-walled portions 111A, and the teeth 112 can be arranged with the intervals between them widened.

[0082] 19, the winding process can be performed, thereby achieving high density during winding and reducing the number of parts. After the winding process, similar to FIG. 5 shown in the first embodiment, the thin-walled portion 111A is bent so that the teeth portion 112 faces inward X2 in the radial direction X and the iron core 110 is formed into an annular shape, and the core is placed in the molding die 50 as in the above-described embodiments. The subsequent processes are performed similarly to the above-described embodiments, and the stator 20 and further the rotating electric machine 100 can be manufactured.

[0083] The stator of the seventh embodiment configured as described above has the same effects as those of the above-described embodiments, and also has the following advantages: The core is formed by connecting the core back portions between the circumferentially adjacent teeth portions with thin-walled portions. This allows for high density winding, and also makes it easier to transport to the molding process and place in the molding die.

[0084] Embodiment 8 Fig. 20 is a plan view showing the configuration of a stator core in embodiment 8. Fig. 21 is a plan view showing a configuration in which insulators are installed in the core shown in Fig. 20 and are installed in a ring shape. Fig. 22 is a cross-sectional view showing the configuration of the connecting portion of the axially laminated core shown in Fig. 20. Fig. 23 is a cross-sectional view showing the configuration of the first core material and second core material of the axially laminated core shown in Fig. 22. In the figures, parts that are the same as those in the above embodiments are given the same reference numerals and descriptions thereof will be omitted.

[0085] 20, the core 110 has a plurality of split core pieces 11 connected by rotatable connecting portions 111B at both ends in the circumferential direction Z of the core back portion 111. When the insulators 2 are installed on the split core pieces 11 connected in the circumferential direction Z by the connecting portions shown in FIG. 20 and arranged in a ring shape, the configuration is as shown in FIG.

[0086] The connecting portion 111B of the split core piece 11 in the eighth embodiment will be described with reference to Figs. 22 and 23. First, as shown in Fig. 22, for example, the split core piece 11 is formed of two types of core material, a first core material 101 and a second core material 102. Then, the first core materials 101 and the second core materials 102 are stacked alternately in the axial direction Y. At this time, the core back portions 111 of the first core material 101 are arranged so that the position in the circumferential direction Z of the core back portion 111 of the second core material 102 is misaligned with the position in the circumferential direction Z of the first core material 101. As a result, the first core material 101 and the second core material 102 are stacked so that the end portion in the circumferential direction Z of the first core material 101 and the end portion in the circumferential direction Z of the second core material 102 overlap in the stacking direction.

[0087] In the overlapping portions in the stacking direction, as shown in FIG. 23, the first iron core material 101 has an uneven portion 101A, and the second iron core material 102 has an uneven portion 102A, and these uneven portions 101A and 102A are fitted together in the axial direction Y to form a freely rotatable connecting portion 111B.

[0088] In the case of the iron core 110 formed in this manner, in the winding process after the insulator 2 is arranged, winding can be performed with the spacing between the tooth portions 112 of the split core pieces 11 widened, as in Figure 19 in the seventh embodiment. After the winding process, the iron core 110 is arranged in an annular shape, as in the seventh embodiment, and similarly placed in the molding die 50. The subsequent processes are performed in the same manner as in each of the above embodiments, and the stator 20 and further the rotating electric machine 100 can be manufactured.

[0089] The stator and rotating electric machine of the eighth embodiment configured as described above have the same effects as those of the above-described embodiments, and also have the following advantages: The iron core is formed by dividing the core back portion between the circumferentially adjacent tooth portions in the circumferential direction, and the divided core back portions are connected by connecting portions that are rotatable in the circumferential direction. Since the multiple split core pieces can be freely rotated at the connecting parts, they can be bent multiple times without reducing mechanical strength, and rotation is easier, resulting in improved workability and higher density during the winding process.

[0090] Embodiment 9 Fig. 24 is a perspective view showing the configuration of a split core piece on which an insulator according to embodiment 9 is installed. Fig. 25 is a plan view showing a configuration in which a plurality of split core pieces on which the insulators shown in Fig. 24 are installed are arranged in an annular shape. Fig. 26 is a perspective view showing the configuration of a split core piece on which another insulator according to embodiment 9 is installed. In the figures, parts similar to those in the above embodiments are given the same reference numerals and descriptions thereof will be omitted.

[0091] 24, an open-ring portion 211 is formed in the insulator 2 at one end in the axial direction Y, where the split core pieces are rotatably connected by snap-fit ​​connection, and at one end in the circumferential direction Z. A columnar portion 212 is formed at one end in the axial direction Y, and at the other end in the circumferential direction Z. A columnar portion 222 is formed at the other end in the axial direction Y, and at one end in the circumferential direction Z. An open-ring portion 221 is formed at the other end in the axial direction Y, and at the other end in the circumferential direction Z. Adjacent open-ring portions 211 and columnar portions 212 and open-ring portions 221 and columnar portions 222 in the circumferential direction Z of the split core pieces 11 on which the insulator 2 is installed are connected by snap-fit ​​connection, and the split core pieces 11 are arranged in an annular shape as shown in FIG.

[0092] In the ninth embodiment, adjacent core segments 11 are snap-fitted and rotatably connected by the open ring portions 211, 221 and columnar portions 212, 222 of the insulator 2, and therefore in the winding process after the insulator 2 is arranged, winding can be performed with the spacing between the teeth portions 112 of the core segments 11 widened, as in the seventh embodiment shown in FIG. 19. After the winding process, the core 110 is arranged in an annular shape, as in the seventh embodiment, and is similarly placed in the molding die 50. The subsequent processes are performed in the same manner as in the above-described embodiments, and the stator 20 and further the rotating electric machine 100 can be manufactured.

[0093] As another ninth embodiment, instead of the protrusions 21, 22 of the insulator 2 described above, protrusions 210 for contacting the mold inner peripheral surface 51A of the molding die 50 are formed in the open ring portions 211, 221 as shown in Fig. 26. Then, a protrusion surface 210A is formed along the axial direction Y on the outer side X1 in the radial direction X of the protrusion 210, which is not covered with the molding resin. Note that other configurations are the same as those of the ninth embodiment shown in Fig. 24, and the stator 20 and the rotating electric machine 100 can be manufactured in the same manner, so description thereof will be omitted as appropriate.

[0094] The stator and rotating electric machine of the ninth embodiment configured as described above have the same effects as those of the above-described embodiments, and also have the following advantages: the core and the insulator are formed by being divided in the circumferential direction of the core back portion between the circumferentially adjacent tooth portions, The divided insulators are snap-fitted in the circumferential direction and have rotatable joints, Since the multiple split core pieces can be freely rotated at the joints of the insulator, they can be bent multiple times without reducing mechanical strength, and rotation is easier, improving workability and achieving higher density during the winding process.Furthermore, transportation to the molding process and placement in the molding die can be made easier.

[0095] In the seventh to ninth embodiments, the protrusions 21, 22 of the insulator 2 are formed at all of the locations corresponding to the outer side X1 in the radial direction X of each tooth portion 112. However, the present invention is not limited to this. In the case of a core 110 in which the core pieces 11 are connected in the circumferential direction Z, in the case of a core 110 in which the core pieces 11 are connected in the circumferential direction Z, or in the case of a core 110 in which the core pieces 11 are connected in the circumferential direction Z by an insulator 2, the protrusions 21 of the insulator 2 do not need to be formed at the outer side X1 in the radial direction X of all of the tooth portions 112. For example, the protrusions 21 may be formed at only two locations T surrounded by dotted lines 180° apart in the circumferential direction Z in Fig. 24, or at only three locations H surrounded by dotted lines 120° apart. Forming the protrusions in this manner reduces rigidity and roundness compared to when the protrusions are formed at locations corresponding to all of the tooth portions 112, but allows for reduction in material and low-cost manufacturing.

[0096] Furthermore, in each of the above-described embodiments, the protrusions 21 and 22 of the insulator 2 are formed at both ends in the axial direction Y, but this is not limited to this. For example, it is also possible to form only one end in the axial direction Y, such as only the protrusion 21 or only the protrusion 22 in FIG. 4, on the insulator 2. Although this reduces rigidity and roundness compared to when the protrusions are formed at both ends in the axial direction Y, it is possible to reduce material and achieve low-cost manufacturing.

[0097] Furthermore, in each of the above-described embodiments, an example has been shown in which the protrusions 21, 22 of the insulator 2 are formed at both ends in the axial direction Y, but this is not limited thereto. For example, it is also conceivable that the protrusions 21 on one end side in the axial direction Y and the protrusions 22 on the other end side are formed alternately in the circumferential direction Z. In this case, the protrusions 21 or 22 are formed on either one end side or the other end side in the axial direction Y at locations corresponding to all of the teeth 112. Although the rigidity and roundness are lower than when the protrusions 21 and 22 are formed at both ends in the axial direction Y at locations corresponding to all of the teeth 112, this allows for less material and allows for lower manufacturing costs.

[0098] Although the present application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are conceivable within the scope of the technology disclosed in this application, including, for example, cases where at least one component is modified, added, or omitted, and cases where at least one component is extracted and combined with a component of another embodiment.

[0099] Various aspects of the present disclosure are summarized below as appendices.

[0100] (Appendix 1) A stator comprising: an iron core having a core back portion formed in an annular shape; and a plurality of teeth formed on an inner peripheral surface of the core back portion in a radial direction, the teeth protruding radially inward at intervals in the circumferential direction; coils wound around the teeth via insulators; and a molded resin portion covering the iron core and the coils, The core back portion is formed so as to be separated from the core back portion at at least one location in the circumferential direction, the insulator has two or more protrusions in a circumferential direction that protrude radially outward from an outer circumferential surface of the core back portion, The molded resin portion does not cover a protruding surface of the protruding portion along the axial direction on the radial outer side. (Appendix 2) The stator described in Appendix 1, wherein the protrusion is formed so that the value obtained by multiplying the load generated in the radially outward direction of the protrusion against the inner peripheral surface of the mold used to form the molded resin portion by the coefficient of friction generated between the protrusion surface of the protrusion and the inner peripheral surface of the mold used to form the molded resin portion is greater than the load that the protrusion receives in the circumferential direction due to resin pressure when molded resin is injected into the molded resin portion. (Appendix 3) the protrusions are formed on both axial end sides of the core back portion, a gradient of the protrusion surface at one axial end of the protrusion with respect to the axial direction; The stator according to claim 1 or 2, wherein the slope of the protrusion surface on the other axial end of the protrusion with respect to the axial direction is the same (excluding a slope angle of 0 degrees). (Appendix 4) 3. The stator according to claim 1, wherein the protrusion has an extension formed along the radially outer outer peripheral surface of the core back portion of the iron core, extending toward the center in the axial direction. (Appendix 5) the extension portion is formed along an outer peripheral surface of the core back portion, 5. A stator as described in Appendix 4, wherein the direction of the gradient of the protrusion surface of the protrusion portion relative to the axial direction is the same as the direction of the gradient of the inner surface of a mold used to form the molded resin portion relative to the axial direction. (Appendix 6) the extension portion is formed away from the outer circumferential surface of the core back portion, When the direction of the gradient of the opposing surface of the extension portion facing the core back portion with respect to the axial direction is the same as the direction of the gradient of the inner peripheral surface of the mold for forming the molded resin portion with respect to the axial direction, a gradient angle of the protrusion surface is an angle obtained by adding an angle formed by the extension portion and the outer peripheral surface of the core back portion to a gradient angle of an inner peripheral surface of a mold for forming the molded resin portion, When the direction of the gradient of the opposing surface of the extension portion facing the core back portion with respect to the axial direction is different from the direction of the gradient of the inner peripheral surface of the mold for forming the molded resin portion with respect to the axial direction, 5. The stator according to claim 4, wherein the inclination angle of the protrusion surface is an angle obtained by subtracting the angle formed between the extension portion and the outer peripheral surface of the core back portion from the inclination angle of the inner peripheral surface of a mold used to form the molded resin portion. (Appendix 7) 7. The stator according to claim 1, wherein the protrusions are formed on both axial ends of the core back portion. (Appendix 8) 8. The stator according to claim 1, wherein the core is formed by connecting the core back portions between the circumferentially adjacent tooth portions with thin-walled portions. (Appendix 9) 8. The stator according to any one of appendices 1 to 7, wherein the core is formed by dividing the core back portion between the circumferentially adjacent tooth portions in the circumferential direction, and the divided core back portions are connected by connecting portions that are rotatable in the circumferential direction. (Appendix 10) the core and the insulator are formed by being divided in the circumferential direction of the core back portion between the circumferentially adjacent tooth portions, 8. The stator according to claim 1, wherein the divided insulators are snap-fit ​​connected in the circumferential direction and have rotatable connecting portions. (Appendix 11) A stator according to any one of Supplementary Note 1 to Supplementary Note 10; a rotor arranged coaxially and rotatably inside the stator in the radial direction; a bracket for holding a bearing that holds a rotating shaft of the rotor, the bearing being installed at at least one end of the stator in the axial direction. (Appendix 12) an assembly process of installing the insulator on the iron core; a winding process for forming a coil on the teeth portion of the iron core via the insulator; a mold placement step of placing the iron core in a mold die for forming the molded resin portion; a molding step of exposing the protruding surfaces of the protruding portions and covering them with molding resin to form the stator. (Appendix 13) a disposing step of disposing a rotatable coaxial rotor radially inside the stator formed by the stator manufacturing method of appendix 12; and an attachment step of attaching a bracket for holding a bearing that holds the rotating shaft of the rotor to at least one end of the stator in the axial direction. [Explanation of symbols]

[0101] 1 split coil winding body, 100 rotating electric machine, 101 first core material, 101A uneven portion, 102 second core material, 102A uneven portion, 11 split core piece, 11A inner peripheral surface, 11B outer peripheral surface, 11C end surface, 11D tip surface, 110 iron core, 111 core back portion, 111A thin portion, 111B connecting portion, 112 teeth portion, 2 insulator, 20 stator, 200 opening, 201 extension, 201A opposing surface, 202 extension, 202A opposing surface, 21 protrusion, 21A protruding surface, 21AA one surface, 21AR corner, 21B shaft end surface, 211 open ring part, 212 columnar part, 22 protrusion, 22A protruding surface, 22AA one surface, 22AB one side, 22AR square, 22B shaft end, 22C extended tip, 221 open ring portion, 222 columnar portion, 3 coil, 30 dovetail groove, 33 movable pin, 330 gradient surface, 333 surface, 334 surface, 335 surface, 336 surface, 40 rotor, 41 rotating shaft, 42 bearing, 5 molded resin part, 50 mold die, 51 Movable mold, 51A Mold inner surface, 52 Fixed mold, 53 Cavity, 54 center shaft, 55 particle surface, 551 first mold resin portion, 552 second molded resin portion, 555 boundary portion, 6 first member, 7 bracket, O center axis, X radial direction, X1 outside, X2 inside, Y axis direction, Z circumferential direction, θ11 gradient angle, θ12 gradient angle, θ21 gradient angle, θ22 gradient angle, θ31 slope angle, θ32 slope angle, μN friction coefficient.

Claims

1. A stator comprising: an iron core having a core back portion formed in an annular shape; and a plurality of teeth formed on an inner peripheral surface of the core back portion in a radial direction, the teeth protruding radially inward at intervals in the circumferential direction; coils wound around the teeth via insulators; and a molded resin portion covering the iron core and the coils, When the molded resin portion is defined as a first molded resin portion that contacts a part of a surface of at least one of one end side or the other end side in the axial direction of the insulator, and a second molded resin portion that contacts the remainder, The stator has a boundary line at the boundary between the first molded resin part and the second molded resin part.

2. The stator according to claim 1 , wherein the insulator has a protrusion that protrudes radially outward from an outer circumferential surface of the core back portion.

3. The stator according to claim 2 , wherein the protrusion has an extension formed along the outer peripheral surface of the core back portion of the core in the radial direction and extending toward the center in the axial direction.

4. the protrusion is formed on one axial end side of the core back portion, 4. A stator as described in claim 3, wherein the radial thickness of the extension portion of the protrusion formed on one end side in the axial direction is formed so as to become smaller from the axial center side end face of the extension portion toward the one end side in the axial direction.

5. the protrusion is also formed on the other axial end side of the core back portion, 5. A stator as described in claim 4, wherein the radial thickness of the extension portion of the protrusion formed on the other end side in the axial direction is formed so as to increase from the axial center side end face of the extension portion toward the other end side in the axial direction.

6. 4. The stator according to claim 3, wherein the protrusions are provided in a plurality in the circumferential direction for each tooth portion, and the extension portions of the plurality of protrusions include a line segment that bisects the radially outer surface of the extension portion in the circumferential direction, and a plane perpendicular to the radially outer surface of the extension portion is formed to include the central axis of the annular core back portion.

7. The stator according to claim 3 , wherein a surface of the extending portion extending radially outward along the axial direction has a curved surface that protrudes toward the central axis of the annular core back portion.

8. The stator according to any one of claims 1 to 7; a rotor arranged coaxially and rotatably inside the stator in a radial direction; a bracket for holding a bearing that holds a rotating shaft of the rotor, the bearing being installed at at least one end of the stator in the axial direction.

9. an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of covering the stator with a molding resin to form the stator; 2. A method for manufacturing a stator as described in claim 1, wherein in the molding process, the second molded resin portion is formed with a movable pin abutting against at least one surface of one end side or the other end side of the insulator in the axial direction, and then the first molded resin portion is formed with the movable pin separated from at least one surface of the one end side or the other end side of the insulator in the axial direction.

10. an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of covering the stator with a molding resin to form the stator; 3. A method for manufacturing a stator as described in claim 2, wherein in the molding process, the second molded resin portion is formed with a movable pin abutting against at least one surface of one end side or the other end side of the axial direction of the protrusion portion, and then the first molded resin portion is formed with the movable pin separated from at least one surface of the one end side or the other end side of the axial direction of the protrusion portion.

11. an assembly process of installing the insulator on the iron core; a winding step of forming a coil around the teeth portion of the iron core via the insulator; and a mold placement step of placing the iron core in a mold for forming the molded resin portion. a molding step of covering the radially outer surfaces of the extension portions of the protrusions with a molding resin without exposing them, thereby forming the stator; 4. The method for manufacturing a stator according to claim 3, wherein in the molding process, the second molded resin part is formed with a movable pin abutting against the radially outer surface of the extension part of the protrusion, and then the first molded resin part is formed with the movable pin separated from the radially outer surface of the extension part of the protrusion.

12. a disposing step of disposing a rotatable coaxial rotor radially inside the stator formed by the stator manufacturing method according to any one of claims 9 to 11; and an attachment step of attaching a bracket for holding a bearing that holds the rotating shaft of the rotor to at least one end of the stator in the axial direction.

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