Stator

Abstract

To provide a stator in which stress due to thermal expansion / contraction can be relaxed at the joint of a plurality of segment coils.SOLUTION: The stator includes a stator core and a stator coil, the stator coil is formed by connecting a plurality of segment coils via a connection member and fixing the plurality of segment coils by a resin layer, and the resin layer around a connection portion of the plurality of segment coils is provided thinner than the resin layer of other portions.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a stator. [Background technology]

[0002] Patent Document 1 discloses a stator including a stator coil formed by connecting a plurality of segment coils with a connecting member. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-126153 Summary of the Invention [Problem to be solved by the invention]

[0004] In the stator disclosed in Patent Document 1, each segment coil is placed in a slot in the stator core, and resin is poured (or applied) into the slot to fix each segment coil to the stator coil. In this case, the resin flows into the vicinity of the connections between multiple segment coils, and the resin around the connections may repeatedly expand and contract due to temperature changes, causing stress.

[0005] The present disclosure has been made in consideration of the above, and aims to provide a stator that can alleviate stress caused by thermal expansion and contraction at the connection points of multiple segment coils. [Means for solving the problem]

[0006] The stator according to the present disclosure comprises a stator core and a stator coil, wherein the stator coil is made up of a plurality of segment coils connected via connecting members and fixed by a resin layer, and the resin layer around the connection portions of the plurality of segment coils is thinner than the resin layer in other portions. [Effects of the Invention]

[0007] According to the present disclosure, stress caused by thermal expansion and contraction can be alleviated at the connection points of multiple segment coils. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view showing the configuration of a stator coil for one slot in a stator according to an embodiment. [Figure 2] FIG. 2 is a schematic diagram showing a connection structure of segment coils at a position corresponding to part A in FIG. 1 in a conventional stator. [Figure 3] FIG. 3 is a schematic diagram showing a first connection structure of segment coils at a position corresponding to part A in FIG. 1 in the stator according to the embodiment. [Figure 4] FIG. 4 is a schematic diagram showing a second connection structure of the segment coils at a position corresponding to part A in FIG. 1 in the stator according to the embodiment. [Figure 5] FIG. 5 is a schematic diagram showing a third connection structure of segment coils at a position corresponding to part A in FIG. 1 in the stator according to the embodiment. [Figure 6] FIG. 6 is a schematic diagram showing a fourth connection structure of the segment coils at a position corresponding to part A in FIG. 1 in the stator according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] A stator according to an embodiment of the present disclosure will be described with reference to the drawings. Note that the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially identical.

[0010] A stator according to an embodiment will be described with reference to FIGS. 1 to 6. The stator according to an embodiment is combined with a rotor to form a rotating electric machine. This rotating electric machine is mounted on, for example, a vehicle and functions as an electric motor or a generator. Examples of vehicles on which the rotating electric machine is mounted include hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs). The rotating electric machine may also be mounted on, for example, fuel cell electric vehicles (FCEVs) and battery electric vehicles (BEVs).

[0011] As shown in Fig. 1, the stator 1 includes a stator core 11 and a stator coil 12. The stator core 11 is made of, for example, a laminated steel plate in which a plurality of electromagnetic steel plates are stacked together, or a powder magnetic core. The stator coil 12 is housed in a slot (housing space) provided in the stator core 11. The stator coil 12 is also made up of a plurality of segment coils 121 and a connecting member 124 that connects the plurality of segment coils 121.

[0012] Fig. 2 shows the connection structure of segment coils in a conventional stator at a position corresponding to part A in Fig. 1. In this connection structure, multiple segment coils 121, with their exposed conductor portions 123 butted together, are connected by connecting members 124 within the slots of the stator core 11. In addition, the segment coils 121 are fixed to each other and to the stator core 11 and the segment coils 121 by pouring (or applying) resin into the slots.

[0013] In the connection structure shown in FIG. 2, when resin is poured into the slots, the resin flows into the connecting member 124 up to the periphery (hereinafter referred to as the "periphery of the coil connection portion") of the connection portion of the multiple segment coils 121 (the portion where the exposed conductor portions 123 are butted), forming a resin layer 125. Therefore, if the resin layer 125 repeatedly expands and contracts due to temperature changes during use of the rotating electric machine, for example, axial stress may be applied to the resin layer 125 around the coil connection portion, as shown in part B of FIG. 2. Therefore, the stator according to the embodiment provides a connection structure that can reduce such stress. An example of a connection structure for the segment coils 121 in the stator 1 will be described below with reference to FIGS. 3 to 6.

[0014] (First connection structure) As shown in FIG. 3, the first connection structure includes a plurality of segment coils 121, a connecting member 124, and a resin layer 125.

[0015] The segment coil 121 is made of, for example, plate-shaped aluminum. An insulating coating 122 is provided on the surface of the segment coil 121. Furthermore, an exposed conductor portion 123 where the insulating coating 122 has been peeled off is provided at the tip of the segment coil 121. The multiple segment coils 121 are connected by a connecting member 124 with their exposed conductor portions 123 butted against each other.

[0016] The connecting member 124 is, for example, a hollow copper pipe. The inside of the connecting member 124 is filled with a resin such as a foamed resin, and a resin layer 125 made of the resin is provided. This resin layer 125 is provided between the outer surface of the segment coil 121 and the inner surface of the connecting member 124. Furthermore, the multiple segment coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0017] 3, a gap where the resin layer 125 is not present is provided around the coil connection portion. That is, around the coil connection portion, a gap exists between the conductor exposed portion 123 and the resin layer 125, and the conductor exposed portion 123 and the resin layer 125 are not in contact with each other. On the other hand, outside the coil connection portion, there is no gap between the insulating coating 122 and the resin layer 125, and the insulating coating 122 and the resin layer 125 are in contact with each other.

[0018] There are no particular limitations on the method for creating a gap around the coil connection portion, and various methods can be used, such as applying a thin layer of resin only around the coil connection portion, or applying resin as usual and then scraping it off.

[0019] (Second connection structure) As shown in FIG. 4, the second connection structure includes a plurality of segment coils 121, a connecting member 124, and a resin layer 125.

[0020] The segment coil 121 is made of, for example, plate-shaped aluminum. An insulating coating 122 is provided on the surface of the segment coil 121. Furthermore, an exposed conductor portion 123 where the insulating coating 122 has been peeled off is provided at the tip of the segment coil 121. The multiple segment coils 121 are connected by a connecting member 124 with their exposed conductor portions 123 butted against each other.

[0021] The connecting member 124 is, for example, a hollow copper pipe. The inside of the connecting member 124 is filled with a resin such as a foamed resin, and a resin layer 125 made of the resin is provided. This resin layer 125 is provided between the outer surface of the segment coil 121 and the inner surface of the connecting member 124. Furthermore, the multiple segment coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0022] 4, the resin layer 125 around the coil connection portion is thinner than the resin layer 125 in other portions. That is, around the coil connection portion, there is a gap between the conductor exposed portion 123 and the resin layer 125, and the conductor exposed portion 123 and the resin layer 125 are not in contact with each other. On the other hand, outside the coil connection portion, there is no gap between the insulating coating 122 and the resin layer 125, and the insulating coating 122 and the resin layer 125 are in contact with each other.

[0023] There are no particular limitations on the method for making the resin layer 125 around the coil connection portion thinner than the resin layer 125 in other portions, and various methods can be used, such as applying a thin layer of resin only around the coil connection portion, or applying the resin as usual and then scraping it off.

[0024] (Third connection structure) As shown in FIG. 5, the third connection structure includes a plurality of segment coils 121, a connecting member 124, a resin layer 125, and an insulating member 126.

[0025] The segment coil 121 is made of, for example, plate-shaped aluminum. An insulating coating 122 is provided on the surface of the segment coil 121. Furthermore, an exposed conductor portion 123 where the insulating coating 122 has been peeled off is provided at the tip of the segment coil 121. The multiple segment coils 121 are connected by a connecting member 124 with their exposed conductor portions 123 butted against each other.

[0026] The connecting member 124 is, for example, a hollow copper pipe. The inside of the connecting member 124 is filled with a resin such as a foamed resin, and a resin layer 125 made of the resin is provided. This resin layer 125 is provided between the outer surface of the segment coil 121 and the inner surface of the connecting member 124. Furthermore, the multiple segment coils 121 are fixed within the connecting member 124 by this resin layer 125.

[0027] The insulating member 126 is made of, for example, insulating paper and is arranged around the coil connection portion. By arranging the insulating member 126 around the coil connection portion in this way, resin does not get into the area around the coil connection portion, and the resin layer 125 is not provided around the coil connection portion. In other words, around the coil connection portion, the insulating member 126 prevents contact between the exposed conductor portion 123 and the resin layer 125. On the other hand, outside the area around the coil connection portion, there is no gap between the insulating coating 122 and the resin layer 125, and the insulating coating 122 and the resin layer 125 are in contact with each other.

[0028] (Fourth connection structure) The fourth connection structure includes a plurality of segment coils 121A, a connecting member 124, and a resin layer 125, as shown in FIG.

[0029] The segment coil 121A is made of, for example, plate-shaped aluminum. An insulating coating 122 is provided on the surface of the segment coil 121A. Furthermore, an exposed conductor portion 123 where the insulating coating 122 has been peeled off is provided at the tip of the segment coil 121A. The multiple segment coils 121A are connected by a connecting member 124 with their exposed conductor portions 123 butted against each other.

[0030] The width of the tip of the segment coil 121A is formed smaller than the width of the other parts. Note that, in the example of Fig. 6, the width of the tip of the segment coil 121A is shown to be gradually reduced, but for example, the tip of the segment coil 121A may be tapered.

[0031] The connecting member 124 is, for example, a hollow copper pipe. The inside of the connecting member 124 is filled with a resin such as a foamed resin, and a resin layer 125 made of the resin is provided. This resin layer 125 is provided between the outer surface of the segment coil 121A and the inner circumferential surface of the connecting member 124. Furthermore, the multiple segment coils 121A are fixed within the connecting member 124 by this resin layer 125.

[0032] As shown in part E of Figure 6, the width of the tip of segment coil 121A is smaller than the width of the other parts, so resin does not penetrate around the coil connection parts, and a gap is left without resin layer 125. In other words, around the coil connection parts, there is a gap between conductor exposed part 123 and resin layer 125, and conductor exposed part 123 and resin layer 125 are not in contact. On the other hand, outside the coil connection parts, there is no gap between insulating coating 122 and resin layer 125, and insulating coating 122 and resin layer 125 are in contact.

[0033] According to the stator of the embodiment described above, the resin layer 125 around the connection portion of the plurality of segment coils 121, 121A is made thinner than the other portions of the resin layer 125. This makes it possible to alleviate stress due to thermal expansion and contraction at the connection portion of the plurality of segment coils 121, 121A, and reduce the effects of the stress.

[0034] Further advantages and modifications will readily occur to those skilled in the art. Thus, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described above. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. [Explanation of symbols]

[0035] 1 stator 11 Stator core 12 stator coil 121,121A segment coil 122 Insulating coating 123 Exposed conductor 124 Connecting member 125 Resin layer 126 Insulating materials

Claims

[Claim 1] A stator core; A stator coil is provided. The stator coil is formed by connecting a plurality of segment coils via connecting members and fixing them by a resin layer, The resin layer around the connection portion of the plurality of segment coils is thinner than the resin layer in other portions. Stator.

Images