Core unit and drive unit

Abstract

This invention provides a technology to facilitate the positioning of insulating members relative to the motor core. [Solution] The motor core 14 is composed of a plurality of laminated plates 12A to 12D stacked in the axial direction, and a first insulating member 16 is positioned on one side of the motor core 14 in the axial direction. Each of the plurality of laminated plates 12A to 12D is fixed by press-fitting a crimping projection 20 provided on one of the adjacent laminated plates into a crimping recess 26 provided on the other of the adjacent laminated plates. A first fitting portion 30 is provided on the first end face portion on one side of the motor core 14 in the axial direction at a position that overlaps with the crimping projection 20 of some of the laminated plates in the axial direction, and a first fitted portion 32 is provided on the first insulating member 16 that fits into the first fitting portion 30.

Description

Technical Field

[0001] The present disclosure relates to a core unit using a motor core.

Background Art

[0002] Patent Document 1 discloses a core unit including a motor core composed of a plurality of laminated plates and an insulating member arranged axially with respect to the motor core.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In fixing the insulating member to the motor core, it is necessary to position the insulating member with respect to the motor core. The disclosed technique of Patent Document 1 has not made any particular contrivance from the viewpoint of facilitating the positioning of the insulating member with respect to the motor core.

[0005] Therefore, one object of the present disclosure is to provide a technique for facilitating the positioning of the insulating member with respect to the motor core.

Means for Solving the Problems

[0006] The core unit of the present disclosure comprises a motor core composed of a plurality of laminated plates stacked in the axial direction, and a first insulating member disposed on one side in the axial direction with respect to the motor core, wherein each of the plurality of laminated plates is fixed by press-fitting a crimping projection provided on one of the adjacent laminated plates into a crimping recess provided on the other of the adjacent laminated plates, a first fitting portion is provided on the first end face portion on the one side of the motor core at a position that overlaps in the axial direction with some of the crimping projections of the laminated plates, and the first insulating member is provided with a first fitted portion that fits into the first fitting portion. [Effects of the Invention]

[0007] According to this disclosure, the positioning of the first insulating member relative to the motor core can be facilitated. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view showing the core unit of the first embodiment. [Figure 2] This is an exploded perspective view showing the core unit of the first embodiment. [Figure 3] This is an exploded perspective view showing the motor core of the first embodiment. [Figure 4] This is a cross-sectional view showing a cross-section along the radial direction passing through section IV in Figure 1. [Figure 5] This is a cross-sectional view showing a cross-section along the radial direction passing through section V in Figure 1. [Figure 6] This is a view of the motor core of the first embodiment as seen from the axial direction. [Figure 7] This is a perspective view showing the core unit of the second embodiment. [Figure 8] This is a cross-sectional view showing a cross-section along the radial direction passing through section VIII in Figure 7. [Modes for carrying out the invention]

[0009] Embodiments for implementing the core unit of this disclosure are described below. Identical or equivalent elements are denoted by the same reference numerals, and redundant descriptions are omitted. For the sake of clarity, components are omitted, enlarged, or reduced in each drawing as appropriate. Drawings should be viewed in accordance with the orientation of the reference numerals. In this specification, the notation "nth" (where n is a natural number), such as "first," "second," etc., is used solely as a formal description to distinguish multiple elements and has no other substantive meaning. For example, the notation "nth" does not limit the order of each element. Furthermore, each element designated as "nth" may exist independently without continuity. For example, a "second" element may exist without a "first" element.

[0010] (First Embodiment) Refer to Figures 1 and 2. The core unit 10 is used in a drive device as part of either the stator or the rotor that generates a rotating magnetic field. The drive device includes a motor consisting of a stator and a rotor, as well as a motor shaft that rotates due to the rotating magnetic field of the motor. The specific example of the drive device is not particularly limited. For example, the drive device may be a motor device that can output rotation to the outside from the motor shaft. Alternatively, the drive device may be a gear motor equipped with a reduction gear that can reduce the rotation of the motor shaft and output rotation to the outside. The positional relationships of the various elements of the core unit 10 will be described below using the axial, radial, and circumferential directions of the motor shaft that is rotated by the motor into which the core unit 10 is incorporated.

[0011] The core unit 10 comprises a motor core 14 composed of multiple laminated plates 12A to 12D stacked in the axial direction, a first insulating member 16 positioned on one side of the motor core 14 in the axial direction (upper side of the paper in Figure 2), and a second insulating member 18 positioned on the other side of the motor core 14 in the axial direction (lower side of the paper in Figure 2). Some of the laminated plates 12A to 12D are omitted in Figure 1, etc.

[0012] The motor core 14 in this embodiment is a stator core used in an inner rotor type motor, but it may also be a rotor core. Furthermore, the motor core 14 may be used in an outer rotor type motor. The motor core 14 comprises an annular portion 14a and a plurality of tooth portions 14b protruding radially from the annular portion 14a. The motor core 14 comprises a first end face portion 14c on one side in the axial direction and a second end face portion 14d on the other side in the axial direction. In this embodiment, the plurality of tooth portions 14b protrude radially inward from the annular portion 14a, but they may also protrude radially outward from the annular portion 14a. A coil (not shown) is wound around each of the plurality of tooth portions 14b. In this embodiment, the motor core 14 is continuous in an annular shape in the circumferential direction, but it may also be constructed by combining a plurality of divided cores divided in the circumferential direction.

[0013] Each insulating member 16, 18 is, for example, an insulating end plate, an insulator, etc. Each insulating member 16, 18 is made of a material such as a resin that has electrical insulating properties. Each insulating member 16, 18 covers the motor core 14 from the axial direction at a position that overlaps with each tooth portion 14b of the motor core 14. The first insulating member 16 insulates the coil from the first end face portion 14c of the motor core 14 at a position that overlaps with each tooth portion 14b of the motor core 14. The second insulating member 18 insulates the coil from the second end face portion 14d of the motor core 14 at a position that overlaps with each tooth portion 14b of the motor core 14. The space between the circumferential side surface of each tooth portion 14b of the motor core 14 and the coil is insulated by various insulating elements such as insulating paper.

[0014] The first insulating member 16 has a first opposing surface portion 16a that faces the first end face portion 14c of the motor core 14 in the axial direction. The second insulating member 18 has a second opposing surface portion 18a that faces the second end face portion 14d of the motor core 14 in the axial direction.

[0015] Refer to FIG. 3. The plurality of laminated plates 12A to 12D are composed of various soft magnetic materials used for motor cores such as electromagnetic steel plates and permalloys. The plurality of laminated plates 12A to 12D include at least one first end-side laminated plate 12A, 12B on one side in the axial direction (the upper side on the paper surface in FIG. 3), at least one second end-side laminated plate 12C on the other side in the axial direction (the lower side on the paper surface in FIG. 3), and a plurality of intermediate laminated plates 12D between the first end-side laminated plates 12A, 12B and the second end-side laminated plate 12C. The contour lines of the main parts of each of the laminated plates 12A to 12D are common when viewed from the axial direction. Here, the main part in the laminated plates 12A to 12D refers to a part including the locations where each tooth part 14b and the annular part 14a of the motor core 14 are formed. The caulking convex part 20, caulking concave part 26, first and second through holes 22, 24 described later are provided at positions separated from the contour lines of the main parts of the laminated plates 12A to 12D.

[0016] The first end-side laminated plates 12A, 12B include the first outermost laminated plate 12A which is on the most one side in the axial direction among the plurality of laminated plates 12A to 12D. Here, the symbol 12B is attached to the first end-side laminated plate except the first outermost laminated plate 12A. In this embodiment, at least one first end-side laminated plate 12A, 12B is composed of a plurality of laminated plates 12A, 12B that are continuous with the first outermost laminated plate 12A in the arrangement order of the plurality of laminated plates 1.A to 12D. In addition to this, at least one first end-side laminated plate 12A, 12B may be composed of only the first outermost laminated plate 12A.

[0017] In this embodiment, at least one second end-side laminated plate 12C is composed of a plurality of laminated plates 12C that are continuous with the laminated plate 12C which is on the most other side in the axial direction in the arrangement order of the plurality of laminated plates 12A to 12D. In addition to this, at least one second end-side laminated plate 12C may be composed of only the laminated plate 12C which is on the most other side in the axial direction.

[0018] In this embodiment, an example is shown in which there are four first end-side laminated plates 12A and 12B, three second end-side laminated plates 12C, and four or more intermediate laminated plates 12D. In FIG. 3 and the like, among the four or more intermediate laminated plates 12D, only two intermediate laminated plates 12D that are continuous with the first end-side laminated plate 12B and two intermediate laminated plates 12D that are continuous with the second end-side laminated plate 12C in the above-described order are shown, and the other intermediate laminated plates 12D are omitted. The number of each of these laminated plates is not particularly limited.

[0019] In this embodiment, there are differences in the configuration regarding the caulking protrusions 20 described below among (1) the intermediate laminated plates 12D, (2) the first end-side laminated plates 12B and the second end-side laminated plates 12C excluding the first outermost laminated plate 12A, and (3) the first outermost laminated plate 12A. Here, for the convenience of explanation, these laminated plates 12A to 12D are shown separately by the presence or absence of dots and the difference in dot patterns. A plurality of caulking protrusions 20 are provided on the intermediate laminated plates 12D in (1) at intervals (equal angular intervals in this embodiment) in the circumferential direction. Here, an example in which a total of 12 caulking protrusions 20 are provided on the intermediate laminated plates 12D is shown. In the first and second end-side laminated plates 12B and 12C in (2), first through-holes 22 are formed at positions axially overlapping with some of the caulking protrusions 20 of the intermediate laminated plates 12D, and caulking protrusions 20 are formed at positions axially overlapping with the other caulking protrusions 20 of the intermediate laminated plates 12D. Here, an example in which a total of 6 caulking protrusions 20 and a total of 6 first through-holes 22 are formed in the end-side laminated plates 12B and 12C in (2) is shown. In the first outermost laminated plate 12A in (3), first through-holes 22 are formed at positions axially overlapping with some of the caulking protrusions 20 of the intermediate laminated plates 12D, and second through-holes 24 are formed at positions axially overlapping with the other caulking protrusions 20 of the intermediate laminated plates 12D. Here, an example in which a total of 6 first through-holes 22 and a total of 6 second through-holes 24 are formed in the first outermost laminated plate 12A is shown. Details thereof will be described below.

[0020] For the sake of explanation, the multiple crimping protrusions 20 of the intermediate laminate 12D are divided into two types: Type 1 crimping protrusions 20-1 and Type 2 crimping protrusions 20-2, which do not overlap with each other. For the sake of explanation, only the crimping protrusions 20 of the intermediate laminate 12D on the axial side of Figure 3 (the upper side of the paper in Figure 3) are denoted by symbols ("-1" and "-2") to distinguish between Type 1 crimping protrusions 20-1 and Type 2 crimping protrusions 20-2. Here, we will describe an example in which there are six Type 1 crimping protrusions 20-1 spaced circumferentially (equally spaced in this embodiment) and six Type 2 crimping protrusions 20-2 spaced circumferentially (equally spaced in this embodiment). The example shown illustrates the first type of crimping projection 20-1 and the second type of crimping projection 20-2 being positioned alternately in the circumferential direction, but their arrangement is not particularly limited, nor is their number particularly limited.

[0021] Refer to Figures 4 and 5. Figure 4 is a cross-sectional view passing through position P1, which overlaps with the first crimping projection 20-1 in the axial direction, and Figure 5 is a cross-sectional view passing through position P2, which overlaps with the second crimping projection 20-2 in the axial direction.

[0022] Each of the multiple laminates 12A to 12D is fixed using a dowel rivet. When this is used, each of the multiple laminates 12A to 12D is fixed by press-fitting a crimping projection 20 provided on one of the adjacent laminates 12A to 12D into a crimping recess 26 provided on the other of the adjacent laminates 12A to 12D. The crimping projection 20 and the crimping recess 26 are crimped together by press-fitting the crimping projection 20 into the crimping recess 26.

[0023] At least some of the laminates 12B to 12D among the multiple laminates 12A to 12D have a crimping projection 20 and a crimping recess 26-1 formed on both sides. In this embodiment, each laminate 12B to 12D, excluding the first outermost laminate 12A, has a crimping projection 20 and a crimping recess 26-1 formed on both sides. Here, "integrated on both sides" means that in the common laminates 12A to 12D, the portion forming the crimping projection 20 integrally forms a crimping recess 26-1 corresponding to the axial opposite side of the crimping projection 20. The crimping projection 20 and crimping recess 26-1 integrated on both sides can be obtained, for example, by press working. Hereinafter, the crimping projection 20 and the crimping recess 26-1 integrated on both sides will be referred to as "integrated crimping recess 26-1," and a "-1" will be added to the end of the reference numeral to distinguish it from other crimping recesses 26.

[0024] Refer to Figure 4. At positions P1 that axially overlap with each first type crimping projection 20-1 of the intermediate laminate 12D, individual first through holes 22 are formed in the first end laminates 12A and 12B. At positions P1, there are no pairs of crimping projections 20 and crimping recesses 26 that contribute to fixing adjacent first end laminates 12A and 12B together. In this embodiment, at positions P1, adjacent first end laminates 12B and intermediate laminates 12D are fixed by a pair of crimping recesses 26 formed by the first through holes 22 of the first end laminates 12B and the crimping projections 20 of the intermediate laminates 12D. At positions P1, adjacent intermediate laminates 12D are fixed by a pair of crimping projections 20 and integral crimping recesses 26-1. The first through holes 22 penetrate the laminates axially.

[0025] Refer to Figure 5. At positions P2 that axially overlap with each of the second type crimping protrusions 20-2 of the intermediate laminate 12D, individual crimping protrusions 20 are provided on the first end laminates 12B, excluding the first outermost laminate 12A. At the same position P2, a second through hole 24 is formed in the first outermost laminate 12A. At the same position P2, adjacent first end laminates 12B, excluding the first outermost laminate 12A, and adjacent first end laminates 12B and the intermediate laminate 12D are fixed by a set of crimping protrusions 20 and integrated crimping recesses 26-1. At the same position P2, adjacent first outermost laminates 12A and first end laminates 12B are fixed by a set of crimping recesses 26 formed by the second through hole 24 of the first outermost laminate 12A and the crimping protrusions 20 of the first end laminate 12B. At the same position P2, adjacent intermediate laminates 12D are fixed by a set of crimping protrusions 20 and integral crimping recesses 26-1. The second through hole 24 refers to one that penetrates the laminate in the axial direction.

[0026] Returning to Figure 3, for the sake of explanation, we will now classify the multiple crimping protrusions 20 of the intermediate laminate 12D into three types: Type 3 crimping protrusions 20-3 and Type 4 crimping protrusions 20-4, which do not overlap with each other. For the sake of explanation, we will now add symbols ("-3" and "-4") to the end of the designation for the crimping protrusions 20 of the intermediate laminate 12D located on the far axial side of Figure 3 (the bottom side of the paper in Figure 3) to distinguish between Type 3 crimping protrusions 20-3 and Type 4 crimping protrusions 20-4. The concepts of Type 3 and Type 4 crimping protrusions 20-3 and 20-4 overlap with either Type 1 crimping protrusions 20-1 or Type 2 crimping protrusions 20-2. Here, we show an example in which all Type 1 crimping protrusions 20-1 are Type 3 crimping protrusions 20-3 and all Type 2 crimping protrusions 20-2 are Type 4 crimping protrusions 20-4, but we are not limited to this. In this embodiment, the Type 3 crimping protrusions 20-3 and Type 4 crimping protrusions 20-4 are positioned alternately in the circumferential direction, but their arrangement is not particularly limited, nor is their number.

[0027] Refer to Figure 4. Figure 4 is also a cross-sectional view passing through position P3, which overlaps axially with the third type crimping projection 20-3. Individual first through holes 22 are formed in the second end laminate 12C at position P3, which overlaps axially with each third type crimping projection 20-3 of the intermediate laminate 12D. At position P3, there are no pairs of crimping projections 20 and crimping recesses 26 that contribute to fixing adjacent second end laminates 12C to each other or to fixing adjacent second end laminates 12C to the intermediate laminate 12D. At position P3, adjacent intermediate laminates 12D are fixed by a pair of crimping projections 20 and integral crimping recesses 26-1.

[0028] Refer to Figure 5. Figure 5 is also a cross-sectional view passing through position P4, which overlaps axially with the fourth type crimping projection 20-4. The second end laminate 12C is provided with individual crimping projections 20 at position P4, which overlaps axially with each of the fourth type crimping projections 20-4 of the intermediate laminate 12D. At position P4, adjacent second end laminates 12C to each other, and adjacent second end laminates 12C to the intermediate laminate 12D are fixed by a set of crimping projection 20 and integrated crimping recess 26-1. At the same position, adjacent intermediate laminates 12D are fixed by a set of crimping projection 20 and integrated crimping recess 26-1. The positional relationship of the crimping projections 20 of each laminate 12A to 12D described above is an example and is not limited thereto.

[0029] Each laminated board 12A to 12D, on which the crimping protrusions 20, crimping recesses 26, and through holes 22 and 24 are formed, is obtained, for example, by press working. The motor core 14 is obtained by stacking these individual laminated boards 12A to 12D. When stacking multiple laminated boards 12A to 12D, they are crimped together by press-fitting the crimping protrusions 20 into the crimping recesses 26 of adjacent laminated boards 12A to 12D.

[0030] Refer to Figures 2 and 4. A first fitting portion 30 is provided on the first end face portion 14c of the motor core 14 at a position P1 that axially overlaps with the first crimping projection 20-1 of the intermediate laminate 12D among the multiple laminates 12A to 12D. The first insulating member 16 is provided with a first fitted portion 32 that is fitted into the first fitting portion 30. One of the first fitting portion 30 and the first fitted portion 32 is a convex structure, and the other is a concave structure into which the convex structure is fitted. In this embodiment, the first fitting portion 30 is a concave structure and the first fitted portion 32 is a convex structure. In this case, the concave structure is concave in the axial direction on the first end face portion 14c of the motor core 14, and the convex structure is convex in the axial direction on the first opposing surface portion 16a of the first insulating member 16.

[0031] The first fitting portion 30 is provided using a protrusion or recess formed in at least one of the first end laminates 12A, 12B. Here, "provided using a protrusion or recess" means, for example, any of the following (A1) to (A4): (A1) means that the first fitting portion 30 is formed by a crimping protrusion 20 formed in the first outermost laminate 12A. (A2) means that the first fitting portion 30 is formed by an integral crimping recess 26-1 formed in the first outermost laminate 12A. (A3) means that the first fitting portion 30 is formed by a first through hole 22 as a recess formed in the first outermost laminate 12A, or in each of the multiple first end laminates 12A, 12B. (A4) means that the first fitting portion 30 is formed by a portion of the pin 60 (see Figure 8) which is press-fitted into the first through-hole 22, which is formed as a recess in each of the multiple first end laminates 12A and 12B.

[0032] The concave first fitting portion 30 is formed by either the integral crimping recess 26-1 of (A2) or the first through hole 22 of (A3). The convex first fitting portion 30 is formed by either the crimping protrusion 20 of (A1) or a part of the pin 60 of (A4). Here, an example is shown in which the concave first fitting portion 30 is formed by the first through hole 22, as in (A3). More specifically, an example is shown in which the first fitting portion 30 is formed by the first through holes 22 formed in each of the three first end laminates 12A and 12B. In this case, the number of first end laminates 12A and 12B in which the first through holes 22 are formed is not limited to this and may be one, two, or four or more.

[0033] In all cases (A1) to (A4), the protrusion or recess used in the first fitting portion 30 is provided at a position P1 that axially overlaps with the first crimping protrusion 20-1 of the intermediate laminate 12D. Such first fitting portions 30 are provided at circumferential intervals (equal angular intervals in this embodiment) similar to the first through holes 22 (see Figure 2). In this embodiment, a total of six first fitting portions 30 are provided. In addition, the first fitted portions 32 provided on the first insulating member 16 are provided individually corresponding to each of the multiple first fitting portions 30 provided on the motor core 14, and are fitted into the corresponding first fitting portions 30. In this embodiment, a total of six first fitted portions 32 are provided. The number of first fitting portions 30 and first fitted portions 32 is not particularly limited and may be one or more.

[0034] The first fitting portion 30 and the first fitted portion 32 are fitted together by press-fitting. This means that the convex structure of one of the first fitting portion 30 and the first fitted portion 32 is fitted together by press-fitting. In this embodiment, there are multiple sets of the first fitting portion 30 and the first fitted portion 32. The number of sets of the first fitting portion 30 and the first fitted portion 32 that are fitted together by press-fitting is not particularly limited and may be multiple or single. As a result, the first insulating member 16 can be fixed to the motor core 14 by press-fitting the first fitting portion 30 and the first fitted portion 32. Consequently, adhesive can be eliminated when fixing the first insulating member 16 to the motor core 14. When adhesive is used, application work is required, which increases the number of work steps. Eliminating the need for such adhesive is advantageous in reducing the number of work steps.

[0035] A second fitting portion 38 is provided on the second end face portion 14d of the motor core 14 at a position P3 that axially overlaps with the third crimping projection 20-3 of the intermediate laminate 12D. The second insulating member 18 is provided with a second fitted portion 40 that fits into the second fitting portion 38. One of the second fitting portion 38 and the second fitted portion 40 is a convex structure, and the other is a concave structure into which the convex structure is fitted. In this embodiment, the second fitting portion 38 is a concave structure and the second fitted portion 40 is a convex structure. In this case, the concave structure is concave in the axial direction on the second end face portion 14d of the motor core 14, and the convex structure is convex in the axial direction on the second opposing surface portion 18a of the second insulating member 18.

[0036] The second fitting portion 38 is provided using a protrusion or recess formed on at least one of the second end laminates 12C. Here, "provided using a protrusion or recess" means one of the following (B1) to (B4), similar to (A1) to (A4) described above. (B1) means that the second fitting portion 38 is formed by a crimping protrusion 20 formed on the laminate 12C that is furthest to the other side in the axial direction. (B2) means that the second fitting portion 38 is formed by an integral crimping recess 26-1 formed on the laminate 12C that is furthest to the other side in the axial direction. (B3) means that the second fitting portion 38 is formed by a first through hole 22 as a recess formed in each of one or more second end laminates 12C. (B4) means that the second fitting portion 38 is formed by a part of a pin 60 (see Figure 8) that is press-fitted into the first through hole 22 as a recess formed in each of the multiple second end laminates 12C.

[0037] The concave second fitting portion 38 is composed of either the integral crimping recess 26-1 of (B2) or one or more first through holes 22 of (B3). The convex second fitting portion 38 is composed of either the crimping protrusion 20 of (B1) or a part of the pin 60 of (B4). Here, an example is shown in which the concave second fitting portion 38 is composed of first through holes 22 as in (B3). More specifically, an example is shown in which the first fitting portion 30 is composed of first through holes 22 formed in each of the three second end laminates 12C. In this case, the number of second end laminates 12C in which the first through holes 22 are formed is not limited to this and may be one, two, or four or more.

[0038] In all cases (B1) to (B4), the protrusion or recess used in the second fitting portion 38 is provided at a position P3 that axially overlaps with the third crimping protrusion 20-C of the intermediate laminate 12D. These second fitting portions 38 are provided at circumferential intervals (equal angular intervals in this embodiment), similar to the first through-holes 22. In this embodiment, a total of six second fitting portions 38 are provided. In addition, the second fitted portions 40 provided on the second insulating member 18 are provided individually to correspond to each of the multiple second fitting portions 38 provided on the motor core 14, and are fitted to the corresponding second fitting portion 38. In this embodiment, a total of six second fitted portions 40 are provided (see Figure 2). The number of second fitting portions 38 and second fitted portions 40 is not particularly limited and may be one or more.

[0039] The second fitting portion 38 and the second fitted portion 40 are fitted together by press-fitting. This means that the convex structure of one of the second fitting portion 38 and the second fitted portion 40 is fitted together by press-fitting. In this embodiment, there are multiple sets of the second fitting portion 38 and the second fitted portion 40. The number of sets of the second fitting portion 38 and the second fitted portion 40 that are fitted together by press-fitting is not particularly limited and may be multiple or single. As a result, the second insulating member 18 can be fixed to the motor core 14 by press-fitting the second fitting portion 38 and the second fitted portion 40. Consequently, adhesive can be eliminated when fixing the second insulating member 18 to the motor core 14.

[0040] The effects of the motor core 14 described above will now be explained.

[0041] A first fitting portion 30 is provided on the first end face portion 14c of the motor core 14, and a first fitted portion 32 is provided on the first insulating member 16 that fits into the first fitting portion 30. Therefore, by fitting the first fitted portion 32 into the first fitting portion 30, the positioning of the first insulating member 16 in the circumferential and radial directions relative to the motor core 14 can be facilitated. This is advantageous in improving the accuracy of the position of the first insulating member 16 relative to the motor core 14 compared to the case where the two are bonded together without using the first fitting portion 30 and the first fitted portion 32. In addition, there is the advantage that when positioning the first insulating member 16 relative to the motor core 14, it is not necessary to provide positioning portions at the contour lines of the main parts of each laminate (for example, the outer circumferential surface of the annular portion 14a or the side surface of the tooth portion 14b).

[0042] The first fitting portion 30 is provided using a protrusion or recess formed on at least one of the first end-side laminates 12A, 12B. These protrusions or recesses are provided at a position P1 that axially overlaps with the crimping protrusions 20-1 of the intermediate laminate 12D, similar to the first fitting portion 30. This suppresses fluctuations in the magnetic flux flow in the first end-side laminates 12A, 12B relative to the magnetic flux flow in the intermediate laminate 12D, compared to the case where the protrusions or recesses are provided on the first end-side laminates 12A, 12B at positions that do not axially overlap with each crimping protrusion 20 of the intermediate laminate 12D, thereby suppressing the influence on the magnetic characteristics of the motor core 14. Consequently, it is possible to facilitate the positioning of the first insulating member 16 relative to the motor core 14 while minimizing the influence on motor characteristics such as motor efficiency.

[0043] (X) The first fitting portion 30 is composed of either a protrusion or a recess formed on at least one of the first end laminates 12A, 12B. This means that the first fitting portion 30 is composed of any of the above-mentioned (A1) to (A3). Therefore, when providing the first fitting portion 30, it is not necessary to use a separate component from the laminate (for example, the pin 60 described later), and the required man-hours can be reduced.

[0044] The first fitting portion 30 is provided using a first through hole 22 formed in at least one of the first end laminated plates 12A, 12B. Here, "provided using a first through hole 22" means that the first fitting portion 30 is constructed by either (A3) or (A4) described above. Therefore, when the first fitting portion 30 is constructed using a first through hole 22 as in (A3), the insertion depth of the first fitted portion 32 into the first fitting portion 30 can be increased compared to when the first fitting portion 30 is constructed using an integrated crimping recess 26-1 that is integral to both sides of the crimping projection 20. This makes it more difficult for the first fitted portion 32 to come loose from the first fitting portion 30. In particular, when the first fitted portion 32 is press-fitted into the first fitting portion 30, this is advantageous in increasing the fixing strength of the first fitted portion 32 to the first fitting portion 30. Furthermore, as in (A4), when the first fitting portion 30 is formed by a pin 60 press-fitted into the first through hole 22, the insertion depth of the pin 60 into the first through hole 22 can be increased compared to when the pin 60 is press-fitted into the crimping recess 26, which is advantageous in increasing the fixing strength of the pin 60. To enhance the effects described here, the first fitting portion 30 is preferably provided using the first through holes 22 formed in each of the multiple first end laminates 12A and 12B.

[0045] A second fitting portion 38 is provided on the second end face portion 14d of the motor core 14, and a second fitted portion 40 is provided on the second insulating member 18 that fits into the second fitting portion 38. As a result, by fitting the second fitted portion 40 into the second fitting portion 38, the positioning of the second insulating member 18 in the circumferential and radial directions relative to the motor core 14 can be facilitated.

[0046] The second fitting portion 38 is provided using a protrusion or recess formed on at least one of the second end-side laminates 12C. These protrusions or recesses are provided at a position P3 that axially overlaps with the crimping protrusions 20-3 of the intermediate laminate 12D, similar to the second fitting portion 38. This suppresses the variation in the flow of magnetic flux in the second end-side laminate 12C relative to the flow of magnetic flux in the intermediate laminate 12D, compared to the case where the protrusions or recesses are provided on the second end-side laminate 12C at a position that does not axially overlap with each crimping protrusion 20 of the intermediate laminate 12D, thereby reducing the impact on the magnetic characteristics of the motor core 14. Consequently, it is possible to facilitate the positioning of the second insulating member 18 relative to the motor core 14 while minimizing the impact on motor characteristics such as motor efficiency.

[0047] Other features of the motor core 14 will be described. Refer to Figure 5. The first outermost laminate 12A has the aforementioned crimping recess 26 into which the crimping projection 20 of the laminate adjacent to the first outermost laminate 12A (in this case, the first end-side laminate 12B) is press-fitted. The crimping recess 26 of the first outermost laminate 12A is formed by the aforementioned second through hole 24. An integral crimping recess 26-1 is not formed in the first outermost laminate 12A, and a crimping projection 20 that is integral with the integral crimping recess 26-1 is not formed on the first end face portion 14c of the motor core 14. If such a crimping projection 20 is formed on the first end face portion 14c of the motor core 14, the first insulating member 16 and the crimping projection 20 will interfere with each other. In this respect, there is an advantage in that such interference can be avoided by forming the crimping recess 26 of the first outermost laminate 12A with the second through hole 24.

[0048] Refer to Figure 6. Figure 6 is a plan view showing the motor core 14. The protrusions or recesses 50 used in the first fitting portion 30 may be provided on the center line L14 of the radially extending teeth portion 14b in the laminated plates 12A and 12B on which the protrusions or recesses 50 are formed, when viewed from the axial direction. The center line L14 of the teeth portion 14b exists individually corresponding to each teeth portion 14b and extends radially so as to pass through the circumferential center of the teeth portion 14b when viewed from the axial direction. In order to satisfy this condition, the protrusions or recesses 50 used in the first fitting portion 30 may be provided on the teeth portion 14b or on the annular portion 14a. This condition may be satisfied in the protrusions or recesses 50 used in each of the multiple first fitting portions 30, or it may be satisfied in only the protrusions or recesses 50 used in one first fitting portion 30.

[0049] When a protrusion or recess 50 is provided on the center line L14 of the teeth portion 14b of such laminated plates 12A and 12B, the circumferential bias of the magnetic flux flowing around the center line L14 can be reduced as much as possible, which is advantageous in suppressing the influence on the magnetic characteristics of the motor core 14.

[0050] The features listed here may also be satisfied by the protrusions or recesses used in the second fitting portion 38. In other words, the protrusions or recesses used in the second fitting portion 38 may also be provided on the center line L14 of the radially extending teeth portion 14b in the second end laminate 12C where the protrusions or recesses are formed, when viewed from the axial direction. In this embodiment, although not shown, all crimping protrusions 20 and the first and second through holes 22 and 24 are provided on the center line L14 of the teeth portion 14b when viewed from the axial direction.

[0051] (Second Embodiment) Refer to Figures 7 and 8. The core unit 10 of the second embodiment will be described. In the following embodiments, the same content as in the first embodiment may apply to components that were described in the first embodiment but are not described below. The core unit 10 of this embodiment differs from the first embodiment in the features relating to the first and second fitting portions 30, 38 and the first and second fitted portions 32, 40.

[0052] In this embodiment, the first fitting portion 30 has a convex structure, and the first fitted portion 32 has a concave structure. In this case, the convex first fitting portion 30 is convex in the axial direction on the first end face portion 14c of the motor core 14, and the concave first fitted portion 32 is concave in the axial direction on the first opposing face portion 16a of the first insulating member 16. The concave first fitted portion 32 in this embodiment is composed of a through hole that penetrates the first insulating member 16 in the axial direction, but it may also be composed of a bottomed recess that does not penetrate in the axial direction.

[0053] In this embodiment, the first fitting portion 30 is configured according to the configuration described in (A4) above. Specifically, the first fitting portion 30 has a convex structure, formed by a portion of a pin 60 that is press-fitted into the first through-holes 22 formed in each of the multiple first end-side laminates 12A and 12B. The pin 60 is press-fitted into the first through-holes 22 of each of the multiple first end-side laminates 12A and 12B in the step prior to fitting the first fitted portion 32 of the first insulating member 16 into the first fitting portion 30. The first fitting portion 30 has a convex structure, formed by a portion of a pin 60 that protrudes axially from the first end face portion 14c of the motor core 14. In this embodiment as well, the first fitting portion 30 and the first fitted portion 32 are fitted together by press-fitting. In this embodiment, the first fitting portion 30 has a convex structure that penetrates the first insulating member 16.

[0054] In this embodiment, the second fitting portion 38 has a convex structure, and the second fitted portion 40 has a concave structure. In this case, the convex second fitting portion 38 is convex in the axial direction on the second end face portion 14d of the motor core 14, and the concave second fitted portion 40 is concave in the axial direction on the second opposing surface portion 18a of the second insulating member 18. The concave second fitted portion 40 in this embodiment is composed of a through hole that penetrates the second insulating member 18 in the axial direction, but it may also be composed of a bottomed recess that does not penetrate in the axial direction.

[0055] In this embodiment, the second fitting portion 38 is configured according to the configuration of (B4) described above. Specifically, the second fitting portion 38 has a convex structure, which is formed by pins 60 that are press-fitted into the first through holes 22 formed in each of the multiple second end-side laminated plates 12C. The pins 60 are press-fitted into the second through holes 24 of each of the multiple second end-side laminated plates 12C in the step prior to fitting the second fitted portion 40 of the second insulating member 18 into the second fitting portion 38. The second fitting portion 38 has a convex structure, which is formed by a part of the pins 60 that protrudes axially from the second end face portion 14d of the motor core 14. In this embodiment as well, the second fitting portion 38 and the second fitted portion 40 are fitted together by press-fitting. In this embodiment, the second fitting portion 38 has a convex structure which penetrates the second insulating member 18.

[0056] According to this embodiment, in addition to the effects described in (X) above, the same effects as the first embodiment can be obtained.

[0057] Next, we will describe the transformation forms of each component described so far.

[0058] The first outermost laminate 12A may have a crimping projection 20 that is axially convex on the first end face portion 14c of the motor core 14. In this case, the first outermost laminate 12A is fixed to the adjacent laminate by the crimping projection 20 of the adjacent laminate being press-fitted into an integrated crimping recess 26-1 which is a single unit on both sides with the crimping projection 20 of the first outermost laminate 12A.

[0059] The configuration of the crimping projections 20 on the second end laminate 12C may be the same as that of the intermediate laminate 12D. For example, crimping projections 20 may be formed on the second end laminate 12C at positions that overlap axially with each crimping projection 20 of the intermediate laminate 12D.

[0060] The first fitting portion 30 and the first fitted portion 32, which are fitted together, do not necessarily have to be fitted together by press-fitting. In this case, when fixing the first insulating member 16 to the motor core 14, other fixing means such as an adhesive to bond the two may be used.

[0061] The second end face portion 14d of the motor core 14 does not need to have a second fitting portion 38, nor does the second insulating member 18 need to have a second fitted portion 40. In this case, the second insulating member 18 may be fixed to the motor core 14 while being positioned by other fixing means such as adhesive.

[0062] The protrusions or recesses used in the first and second fitting portions 30 and 38 may be provided at positions unrelated to the center line L14 of the teeth portion 14b when viewed from the axial direction. For example, they may be provided between adjacent teeth portions 14b in the annular portion 14a, or they may be provided in positions on the teeth portion 14b that do not coincide with the center line L14.

[0063] The direction in which each crimping projection 20 of each laminated plate that overlaps when viewed from the axial direction is the same (hereinafter referred to as the projection direction). In the first embodiment, the projection direction of each crimping projection 20 of each laminated plate 12A to 12D was on one side of the axial direction, but this projection direction is not particularly limited. For example, this projection direction may be on the other side of the axial direction. In addition, the projection directions of some crimping projections 20 of the same laminated plate 12A to 12D may be opposite to those of other crimping projections 20.

[0064] The contents of each component described in the embodiments above are illustrative. The abstract technical ideas derived from these should not be interpreted restrictively to the contents of this specification. Many design changes, such as modifications, additions, and deletions, are possible for the contents of each component described in the embodiments. Such design changes are emphasized by the notations "this form" and "embodiment." However, design changes are also permitted for contents without such notations. Any combination of the above components is also valid. For example, any explanatory items from other embodiments may be combined with an embodiment, or any explanatory items from an embodiment and other variants may be combined with a variant. [Explanation of symbols]

[0065] 10...Core unit, 12A...First outermost laminate, 12B...First end laminate, 12C...Second end laminate, 14...Motor core, 14a...Annular section, 14b...Teeth section, 14c...First end face section, 14d...Second end face section, 16...First insulating member, 18...Second insulating member, 20...Crimping projection, 22...First through hole, 24...Second through hole, 26...Crimping recess, 30...First fitting section, 32...First fitted section, 38...Second fitting section, 40...Second fitted section.

Claims

1. A motor core composed of multiple laminated plates stacked in the axial direction, The motor core comprises a first insulating member positioned on one side in the axial direction, Each of the aforementioned plurality of laminates is fixed by press-fitting a crimping projection provided on one of the adjacent laminates into a crimping recess provided on the other of the adjacent laminates. A first fitting portion is provided on the first end face portion on one side of the motor core, at a position that overlaps in the axial direction with a portion of the crimping protrusion of the laminated plate. The first insulating member is provided with a core unit having a first fitted portion that is fitted into the first fitting portion.

2. The plurality of laminates includes at least one first end laminate located on one side of the plurality of laminates, The core unit according to claim 1, wherein the first fitting portion is provided using a protrusion or recess formed on at least one of the first end laminates.

3. The core unit according to claim 2, wherein the first fitting portion is comprised of either a protrusion or a recess formed on the at least one first end laminate.

4. The core unit according to claim 2, wherein the first fitting portion is provided using a first through hole formed in the at least one first end laminate.

5. The core unit according to claim 2, wherein the first fitting portion is provided using first through holes formed in a plurality of first end-side laminated plates.

6. The plurality of laminates includes the first end laminate that is located on the one side of the plurality of laminates, The first outermost laminate is provided with a crimping recess into which the crimping projection of the laminate adjacent to the first outermost laminate is press-fitted. The core unit according to claim 1, wherein the crimping recess of the first outermost laminate is formed by a second through hole that penetrates the first outermost laminate in the axial direction.

7. The core unit according to claim 1, wherein the first fitting portion and the first fitted portion are fitted together by press-fitting.

8. The motor core is provided with a second insulating member positioned on the other side in the axial direction, A second fitting portion is provided on the second end face portion on the other side of the motor core, at a position that overlaps in the axial direction with a portion of the crimping protrusion of the laminated plate. The core unit according to claim 1, wherein the second insulating member is provided with a second fitted portion that is fitted into the second fitting portion.

9. The plurality of laminates includes at least one second end laminate located on the other side of the plurality of laminates, The core unit according to claim 8, wherein the second fitting portion is provided using a protrusion or recess formed on at least one of the second end laminates.

10. The motor core comprises an annular portion and a teeth portion that protrudes radially from the annular portion. The core unit according to claim 2, wherein the convex portion or recess used in the first fitting portion is provided on the center line of the radially extending teeth portion in the laminate in which the convex portion or recess is formed, when viewed from the axial direction.

11. A drive device comprising the core unit according to any one of claims 1 to 10.

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