Rotating electric machine bobbin, rotating electric machine, rotating electric machine manufacturing method, rotating electric machine manufacturing device, and resin injection molding mechanism

Abstract

To provide a magnet wire short-circuit prevention technique that improves workability and reduces costs in the injection molding process in the manufacture of rotating electrical machines. [Solution] The rotating electric machine bobbin 10 is an insulating bobbin for a rotating electric machine that is resin molded by injection molding, and consists of an outer diameter portion 2 on the yoke Y side of the stator, an inner diameter portion 3 on the end side of the teeth T of the stator, and a winding portion 4 in which a coil portion is formed by winding magnet wire, and a notched portion 5 is provided at the tip of the inner diameter portion 3, which allows a gap 8 to be formed between the teeth T.

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine bobbin, a rotating electric machine, a method for manufacturing a rotating electric machine, an apparatus for manufacturing a rotating electric machine, and a resin injection molding mechanism, and more particularly to a technique for preventing short circuits in magnet wires during the manufacture of a rotating electric machine. [Background technology]

[0002] FIG. 7 is an explanatory diagram showing the problems with the injection molding method of the conventional technology from two directions. In the figure, (h) shows the injection molding method in a plan view, and (v) shows the resulting problems in a side view. Also, FIG. 8 is an explanatory diagram showing a conventional solution to the problems shown in FIG. 7. As shown in these figures, in the injection molding process used in conventional motor manufacturing, pressure inside the bobbin 910 is applied from the yoke Y side of the stator toward the teeth T side. Therefore, as shown in (v) of FIG. 7, the magnet wire Mw extruded from the bobbin 910 toward the teeth T may cause a ground fault between the teeth T, T. Therefore, as shown in FIG. 8, insulating tape Ft is attached to the bridge portions Tb of the teeth T to prevent short circuits between the magnet wire and the iron core.

[0003] Patent applications have also been filed for technologies related to injection molding during motor manufacturing. For example, Patent Document 1, listed below, discloses an insulating coating technology that prevents deformation of the bobbin during injection molding, in which the outer flange of the bobbin is made thick on the outer surface that protrudes in an arc shape to increase out-of-plane rigidity, and the inner flange has a reinforcing rib integrally formed on the outer surface of the flat body.

[0004] Furthermore, Patent Document 2 discloses a structure in which large chamfers are applied to the four corners of the outer and inner flanges of the bobbin as a reliable insulation coating technology for the surface of a motor stator. This allows the injected resin to quickly pass through the gaps between the inner and outer flanges and fill every corner of the cavity, preventing damage to the insulation coating layer without requiring high injection pressure and preventing bobbin deformation. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-143206 "Motor stator" [Patent Document 2] Japanese Patent Application Laid-Open No. 2005-143205 "Motor stator" Summary of the Invention [Problem to be solved by the invention]

[0006] However, the method of attaching insulating tape to the bridges of the teeth as a measure to prevent short circuits between the magnet wire and iron core is not easy to work with and the insulating tape is costly.There is a need for a magnet wire short circuit prevention technology that is easier to work with and can reduce costs.

[0007] Therefore, the problem that the present invention aims to solve is to eliminate the problems of the conventional technology and to provide a magnet wire short circuit prevention technology that is more efficient and allows for cost reduction in the injection molding process in manufacturing rotating electrical machines. [Means for solving the problem]

[0008] The inventors of the present application have investigated the above-mentioned problems. As a result, they have discovered that by forming a gap between the bobbin and the stator core, resin can be poured into the gap during injection molding, thereby eliminating the pressure difference between the inside and outside of the bobbin and preventing the magnet wire from being extruded. Based on this, they have completed the present invention. That is, the invention claimed in this application, or at least the invention disclosed therein, as a means for solving the above-mentioned problems is as follows.

[0009] [1] An insulating bobbin for a rotating electrical machine that is resin-molded by injection molding, The stator comprises an outer diameter portion on the yoke side, an inner diameter portion on the teeth end side of the stator, and a winding portion in which a coil portion is formed by winding a magnet wire. A notched portion is provided at the tip of the inner diameter portion, This allows a gap to be formed between the rotating electric machine bobbin and the teeth. [2] The rotating electric machine bobbin according to [1], wherein the notched portion is provided around at least a portion of the periphery of the inner diameter portion. [3] The rotating electric machine bobbin according to [1], wherein the notched portion is provided around the entire circumference of the tip of the inner diameter portion. [4] The rotating electric machine bobbin according to any one of [1], [2], and [3], characterized in that the gap allows excess resin to be discharged outside the coil portion during injection molding. [5] A rotating electric machine formed using the rotating electric machine bobbin according to any one of [1], [2], and [3], characterized in that a gap is formed between the teeth of the stator and the rotating electric machine bobbin.

[0010] [6] The rotating electric machine according to [5], characterized in that the coil portion is formed without leaving any protruding magnet wire. [7] A method for manufacturing a rotating electric machine using a rotating electric machine bobbin described in any one of [1], [2], and [3], characterized in that the method includes a coil portion forming process in which the magnet wire is wound around the rotating electric machine bobbin, and a resin injection process in which resin is injected into the coil portion. [8] The method for manufacturing a rotating electric machine according to [7], wherein in the resin injection process, injection is performed so as to suppress a difference in injection pressure to the coil portion. [9] The method for manufacturing a rotating electric machine according to [8], characterized in that in the resin injection process, injection is performed by applying injection pressure not only from the yoke side of the stator but also from the teeth side.

[0011]

[10] An apparatus for manufacturing a rotating electric machine using a rotating electric machine bobbin according to any one of [1], [2], and [3], characterized in that the rotating electric machine manufacturing apparatus comprises a coil portion forming section in which the magnet wire is wound around the rotating electric machine bobbin, and a resin injection section in which resin is injected into the coil portion after the coil portion is formed by the coil portion forming section.

[11] The rotating electrical machine manufacturing apparatus according to

[10] , characterized in that the resin injection section performs injection so as to suppress a difference in injection pressure with respect to the coil section.

[12] A resin injection molding mechanism used when manufacturing a rotating electric machine using a rotating electric machine bobbin described in any one of [1], [2], and [3], characterized in that injection pressure is applied not only from the yoke side of the stator but also from the teeth side to the coil portion formed by winding the magnet wire around the rotating electric machine bobbin, so as to suppress the difference in injection pressure on the coil portion. [Effects of the Invention]

[0012] Since the rotating electric machine bobbin, rotating electric machine, rotating electric machine manufacturing method, rotating electric machine manufacturing apparatus, and resin injection molding mechanism of the present invention are configured as described above, it is possible to eliminate the need for applying insulating tape during the injection molding process in rotating electric machine manufacturing, thereby improving workability and reducing costs in the work of preventing magnet wire short circuits.

[0013] That is, according to the rotating electric machine bobbin of the present invention, by providing a gap between the teeth and the bobbin, it is possible to suppress the pressure difference applied inside the bobbin during injection molding, thereby suppressing play in the magnet wire during injection molding and preventing the magnet wire from shorting to the iron core. Note that the above-mentioned Document 1 is a technology that aims to suppress bobbin deformation by adding a rib shape to the bobbin, and Document 2 is a technology that improves molding conditions by providing a gap, and the present invention is different from these. [Brief explanation of the drawings]

[0014] [Figure 1]1 is an explanatory diagram schematically illustrating the basic configuration of a rotating machine bobbin according to the present invention in comparison with the prior art; [Figure 2] FIG. 2 is an enlarged view of a main part of FIG. [Figure 3] 1A to 1C are explanatory views showing an embodiment of a rotating machine bobbin according to the present invention from five directions. [Figure 3-2] 4 is a cross-sectional view taken along the line BB in FIG. 3. [Figure 3-3] 4 is a cross-sectional view taken along line DD, a detailed view of part E, and a detailed view of part F in FIG. 3. [Figure 4] 1 is a flowchart showing a main part of a method for manufacturing a rotating electrical machine according to the present invention; [Figure 5] 4A and 4B are explanatory diagrams showing the operation of the method for manufacturing a rotating electric machine according to the present invention, as viewed from above ((h) in the figure) and from the side ((v) in the figure). [Figure 6] 1 is a conceptual diagram showing a basic configuration of a rotating electrical machine manufacturing apparatus according to the present invention; [Figure 7] 1A and 1B are explanatory diagrams showing problems with the injection molding method in the prior art from two directions. [Figure 8] FIG. 8 is an explanatory diagram showing a conventional method for dealing with the problem shown in FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention will be described in detail below with reference to the drawings. FIG. 1 is an explanatory diagram showing a schematic diagram of the basic configuration of a rotating machine bobbin of the present invention in comparison with the prior art. In the diagram, (i) shows the present invention, and (ii) shows the prior art. FIG. 2 is an enlarged view of the main part of FIG. 1. As shown in (i) of each diagram, the rotating machine bobbin 10 is an insulating bobbin for a rotating machine that is resin-molded by injection molding. It comprises an outer diameter portion 2 on the yoke Y side of the stator, an inner diameter portion 3 on the end side of the stator teeth T, and a winding portion 4 in which a coil portion is formed by winding magnet wire. A notch 5 is provided at the tip of the inner diameter portion 3, which allows a gap 8 to be formed between the inner diameter portion 2 and the teeth T. This is a characteristic configuration.

[0016] This rotating electric machine bobbin 10 is used in the manufacture of rotating electric machines, and a magnet wire is wound around the winding portion 4 to form a coil portion, with the outer diameter portion 2 contacting the yoke Y of the stator and the inner diameter portion 3 contacting the teeth T. At this time, the notched portion 5 at the tip of the inner diameter portion 3, which is on the end side of the teeth T of the stator, forms a gap 8 between the teeth T.

[0017] When the bobbin is subjected to resin molding, i.e., injection molding, in this state, excess resin is ejected from the coil portion through the gap 8. This suppresses the generation of injection pressure differences within the bobbin 10, suppresses play and protrusion of the magnet wire, and prevents short-circuiting to the iron core.

[0018] On the other hand, in the prior art shown in (ii) in each figure, pressure inside the bobbin 810 is applied from the yoke Y side to the teeth T side during injection molding, and the magnet wire extruded from the bobbin 810 to the teeth T side tends to cause ground faults between the teeth. This problem is solved by the rotating electric machine bobbin 10 of the present invention.

[0019] The cutout portions 5, which are a feature of the present rotating electrical machine bobbin 10, may be provided on at least a portion of the periphery of the inner diameter portion 3. In other words, they may be located and shaped in such a way that a gap 8 sufficient for discharging excess resin can be formed between the teeth T. Of course, the cutout portions 5 may also be configured to be provided around the entire periphery of the tip of the inner diameter portion 3.

[0020] The scope of the present invention also includes a rotating electric machine formed using the rotating electric machine bobbin 10 described above, in which a gap 8 is formed between the stator teeth T and the rotating electric machine bobbin 10. Due to the action of this gap 8, a rotating electric machine can be obtained in which a coil portion is formed without any protruding portions of the magnet wire.

[0021] FIG. 3 is an explanatory diagram showing an embodiment of a rotating machine bobbin according to the present invention from five directions. In this figure, (i) is a front view, and (ii), (iii), (iv), and (v) are a left side view, a right side view, a top view, and a bottom view, respectively. Also, FIG. 3-2 is a cross-sectional view taken along line BB in FIG. 3, and FIG. 3-3 is a cross-sectional view taken along line DD in FIG. 3 ((d) in the figure), a detailed view of part E ((e) in the figure), and a detailed view of part F ((f) in the figure). The rotating machine bobbin 310 of this example is It consists of an outer diameter portion 32 on the yoke Y side of the stator, an inner diameter portion 33 on the end side of the teeth T of the stator, and a winding portion 34 in which a coil portion is formed by winding magnet wire, and a notched portion 35 is provided at the tip of the inner diameter portion 33.

[0022] As shown in Fig. 3-2 among these figures, the present rotating electrical machine bobbin 310 has a notched portion 35 provided in the inner diameter portion 33. This forms a gap as explained in Fig. 1 above, allowing excess resin to be discharged during injection molding, thereby achieving the desired effect of the present invention.

[0023] 4 is a flow chart showing the main parts of the method for manufacturing a rotating electric machine according to the present invention. As shown in the figure, the method for manufacturing a rotating electric machine is performed using a rotating electric machine bobbin 10 or the like (shown only as "10" in the figure) having any of the configurations already described, and is characterized by including a coil portion forming process P30 in which a magnet wire 20 is wound around the rotating electric machine bobbin 10, and a resin injection process P70 in which a resin 40 is injected into the formed coil portion 30.

[0024] In the method for manufacturing a rotating electric machine of the present invention configured as described above, in the coil portion forming process P30, the magnet wire 20 is wound around the rotating electric machine bobbin 10 to form the coil portion 30, and then in the resin injection process P70, the resin 40 is injected into the coil portion 30, and at that time, the injection is performed so that the difference in injection pressure on the coil portion 30 is suppressed by the action of the notched portion 5 provided in the rotating electric machine bobbin 10 or the like, thereby obtaining the injection molded body 70. Note that the suppression of the injection pressure difference on the coil portion 30 can be strengthened not only by the structural features provided in the rotating electric machine bobbin 10 or the like, but also by the resin injection method.

[0025] FIG. 5 is an explanatory diagram showing the operation of the method for manufacturing a rotating electric machine of the present invention from a plan view ((h) in the figure) and a side view ((v) in the figure). As shown in the figure, in the resin injection process P70 of the method for manufacturing a rotating electric machine of the present invention, resin can be injected by applying injection pressure Pm not only from the yoke Y side of the stator but also from the teeth T side. This makes it possible to more effectively suppress the occurrence of injection pressure differences within the bobbin 10, etc., and further enhances the effect of preventing short circuits in the magnet wire Mw that constitutes the coil portion 30. In this way, the resin injection method can strengthen the effect of suppressing the occurrence of injection pressure differences.

[0026] 6 is a conceptual diagram showing the basic configuration of a rotating electric machine manufacturing apparatus of the present invention. As shown in the figure, this rotating electric machine manufacturing apparatus 1000 is an apparatus for manufacturing a rotating electric machine using a rotating electric machine bobbin having any of the configurations described above, and is characterized by including a coil portion forming unit 300 in which the magnet wire is wound around the rotating electric machine bobbin, and a resin injecting unit 700 in which resin is injected into the coil portion after the coil portion is formed by the coil portion forming unit 300.

[0027] According to the rotating electric machine manufacturing apparatus 1000 having such a configuration, a magnet wire is wound around the rotating electric machine bobbin of the present invention in the coil portion forming unit 300 to form a coil portion, and then resin is injected into the coil portion in the resin injection unit 700, finally manufacturing a rotating electric machine. When resin is injected in the resin injection unit 700, the injection is performed so that the difference in injection pressure on the coil portion is suppressed by the action of the notched portion provided in the rotating electric machine bobbin of the present invention, and an injection molded body is obtained.

[0028] The effect of suppressing the injection pressure difference on the coil portion can be enhanced not only by the structural features of the rotating electric machine bobbin, but also by the resin injection method used by the resin injection unit 700. For example, the injection method used by the resin injection unit 700 can be such that injection pressure is applied not only from the yoke side of the stator but also from the teeth side.

[0029] Also within the scope of the present invention is a resin injection molding mechanism used when manufacturing a rotating electric machine using a rotating electric machine bobbin having any of the above-mentioned configurations, in which injection pressure is applied not only from the yoke side of the stator but also from the teeth side to inject the coil portion formed by winding magnet wire around the rotating electric machine bobbin, so as to suppress the difference in injection pressure on the coil portion. [Industrial Applicability]

[0030] The rotating electric machine bobbin etc. of the present invention can improve the workability of the magnet wire short circuit prevention work in the injection molding process in the manufacturing of rotating electric machines, and can also achieve cost reduction effects. Therefore, this invention has high industrial applicability in the manufacturing of rotating electric machines, fields of use, and all related fields. [Explanation of symbols]

[0031] 2, 32...outer diameter part 3, 33...inner diameter 4, 34...winding section 5, 35...Notch part 8...Gap 10, 310...Rotating electric machine bobbin 20...Magnet wire 30...Coil section 40...Resin 70...Injection molded body 300... Coil forming section 700...Resin injection part 1000...Rotating electrical machine manufacturing equipment 82, 92...outer diameter part 83, 93...inner diameter 84...Winding section 810, 910...Bobbin Ft...insulating tape Mw: Magnet wire P30...Coil formation process P70…Resin injection process Pm...injection pressure T... stator teeth Tb: Bridge of teeth Y: Stator yoke

Claims

1. An insulating bobbin for a rotating electric machine that is resin-molded by injection molding, The stator comprises an outer diameter portion on the yoke side, an inner diameter portion on the teeth end side of the stator, and a winding portion in which a coil portion is formed by winding a magnet wire, A notched portion is provided at the tip of the inner diameter portion, This allows a gap to be formed between the rotating electric machine bobbin and the teeth.

2. 2. The rotating electrical machine bobbin according to claim 1, wherein the notch is provided around at least a part of the periphery of the tip of the inner diameter portion.

3. 2. The rotating electrical machine bobbin according to claim 1, wherein the notch is provided around the entire periphery of the tip of the inner diameter portion.

4. 4. The rotating electric machine bobbin according to claim 1, wherein the gap allows excess resin to be discharged outside the coil portion during injection molding.

5. 4. A rotating electric machine formed using the rotating electric machine bobbin according to claim 1, wherein a gap is formed between the teeth of the stator and the rotating machine bobbin.

6. 6. The rotating electric machine according to claim 5, wherein the coil portion is formed without leaving any protruding magnet wire.

7. A method for manufacturing a rotating electric machine using the rotating electric machine bobbin according to any one of claims 1 to 3, comprising the steps of: a coil portion forming step in which the magnet wire is wound around the rotating electric machine bobbin; and A resin injection process is provided in which resin is injected into the coil portion. A method for manufacturing a rotating electrical machine, comprising:

8. In the resin injection process, Injection is performed so that the difference in injection pressure to the coil portion is suppressed.

8. The method for manufacturing a rotating electrical machine according to claim 7, wherein:

9. 9. The method for manufacturing a rotating electrical machine according to claim 8, wherein in the resin injection step, injection pressure is applied not only from the yoke side of the stator but also from the teeth side.

10. An apparatus for manufacturing a rotating electric machine using the rotating electric machine bobbin according to any one of claims 1 to 3, comprising: A rotating electric machine manufacturing apparatus comprising: a coil portion forming section in which the magnet wire is wound around the rotating electric machine bobbin; and a resin injection section in which resin is injected into the coil portion after the coil portion is formed by the coil portion forming section.

11. 11. The rotating electrical machine manufacturing apparatus according to claim 10, wherein the resin injection section performs injection so as to suppress a difference in injection pressure with respect to the coil section.

12. A resin injection molding mechanism used when manufacturing a rotating electric machine using the rotating electric machine bobbin according to any one of claims 1 to 3, A resin injection molding mechanism characterized in that injection pressure is applied not only from the yoke side of the stator but also from the teeth side to the coil portion formed by winding the magnet wire around the rotating electric machine bobbin, so that the difference in injection pressure on the coil portion is suppressed.

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