Interphase insulation paper, motor, and method for manufacturing motor

Abstract

To provide interphase insulation paper that facilitates mounting of a stator core on a slot, a motor using the same, and a method of manufacturing the motor.SOLUTION: Interphase insulation paper 1 is mounted in a state of being arranged in a circumferential direction in a stator cores 3 and performs interphase insulation of each phase coil (coil 4) provided with the stator core 3. Part of mutually adjacent interphase insulation paper (interphase insulation paper 2A, interphase insulation paper 2B) overlaps with each other, and a joining section 26 is provided that joins the interphase insulation paper (interphase insulation paper 2A and interphase insulation paper 2B) to each other on the part.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an interphase insulating paper, a motor, and a method for manufacturing a motor. [Background technology]

[0002] Patent Document 1 discloses that in a three-phase motor, interphase insulating paper is provided separately to ensure insulation between the U phase and the V phase, interphase insulating paper to ensure insulation between the V phase and the W phase, and interphase insulating paper to ensure insulation between the W phase and the U phase, and each interphase insulating paper is individually attached to a slot in a stator core. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2007-60819 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in Patent Document 1, the interphase insulating paper is individually installed in the slots of the stator core in sequence, so that the earlier installed interphase insulating paper generates a force that pushes the later installed interphase insulating paper toward the inner circumference of the stator core, making it difficult to install the interphase insulating paper.

[0005] An object of the present invention is to provide an interphase insulating paper that can be easily attached to a slot of a stator core, a motor using the interphase insulating paper, and a method for manufacturing the motor. [Means for solving the problem]

[0006] One aspect of the present invention is an interphase insulating paper that is attached to a stator core in a state where a plurality of pieces are arranged in a circumferential direction and provides interphase insulation for each phase coil provided in the stator core, the interphase insulating paper includes a pair of legs that are inserted into different slots of the stator core, respectively, and a band portion that is disposed outside the slots and supported by the pair of legs; The adjacent interphase insulating papers are partially overlapped with each other, and the overlapping portions are provided with joints for joining the interphase insulating papers to each other. a pair of interphase insulating papers are formed by joining the first and second legs together, the first leg being arranged on a side where one of the pair of legs of one of the pair of interphase insulating papers overlaps with the other of the pair of interphase insulating papers, and the second leg being arranged on a side where the other of the pair of interphase insulating papers overlaps with one of the pair of interphase insulating papers, the distance between these first and second legs being set to be equal to the distance between a pair of adjacent slots, and the joint is arranged in a region where a part of the band part of one of the pair of interphase insulating papers and a part of the band part of the other of the pair of interphase insulating papers overlap with each other, at a position between the first leg and the second leg in the direction in which the one of the pair of interphase insulating papers and the other of the pair of interphase insulating papers are aligned, and is biased toward the first and second legs. . Effect of the Invention

[0007] According to the present invention, a pair of interphase insulating papers are formed, joined by a joint, and one interphase insulating paper holds the other. Therefore, when the interphase insulating papers are fitted into the slots of the stator core, neither of the interphase insulating papers is pushed inward of the stator core. Furthermore, when the interphase insulating papers are fitted into the slots of the stator core, the pair of interphase insulating papers bends gently as a whole, so that none of the pair of interphase insulating papers is pushed inward of the stator core. As a result, the interphase insulating paper can be easily fitted into the slots of the stator core. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram of the interphase insulating paper of the first embodiment, where FIG. 1(a) is a plan view, FIG. 1(b) is a cross-sectional view taken along line AA in FIG. 1(a), and FIG. 1(c) is a cross-sectional view taken along line BB in FIG. 1(a). [Diagram 2] FIG. 2 is a diagram showing an example of the interphase insulating paper of the first embodiment being attached to a stator core, and includes a diagram of the stator core linearly developed with respect to a circumferential path, a partially enlarged view of the diagram, and a diagram of the interphase insulating paper attached to the stator core. [Diagram 3] FIG. 3 is a diagram for explaining the function and effect of the interphase insulating paper of the first embodiment, where FIG. 3(a) is a diagram for explaining the function and effect of the joint portion, and FIG. 3(b) is a diagram for explaining the function and effect of the joint portion and non-joint portion. [Figure 4] FIG. 4 is a diagram (copy) for explaining the function and effect of the interphase insulating paper of the first embodiment, where FIG. 4(a) is a diagram (copy) for explaining the function and effect of the joint portion, and FIG. 4(b) is a diagram (copy) for explaining the function and effect of the joint portion and non-joint portion. [Diagram 5]Figure 5 is a diagram for explaining the interphase insulating paper of the first comparative example, where Figure 5(a) is a plan view of the interphase insulating paper of the first comparative example, Figure 5(b) is a diagram showing the case where the interphase insulating paper of the first comparative example pops out of the slot by itself when the interphase insulating paper of the first comparative example is inserted into the stator core, and Figure 5(c) is a diagram showing the case where the interphase insulating paper inserted later pops out of the slot due to force from the interphase insulating paper inserted earlier when the interphase insulating paper of the first comparative example is inserted into the stator core. [Figure 6] FIG. 6 is a diagram (copy) showing a mounting state of the interphase insulating paper of the first comparative example. [Figure 7] FIG. 7 is a diagram for explaining the interphase insulating paper of the second comparative example, where FIG. 7(a) is a plan view of the interphase insulating paper of the second comparative example, and FIG. 7(b) is a diagram (copy) showing the mounting state of the interphase insulating paper of the second comparative example. [Figure 8] Figure 8 is a diagram for explaining the interphase insulating paper of the second embodiment, where Figure 8(a) is a plan view (developed view) of the interphase insulating paper of the second embodiment, Figure 8(b) is a diagram showing the shape of the interphase insulating paper of the second embodiment when installed in a slot of the stator core, and Figure 8(c) is a diagram showing the relationship between the interphase insulating paper of the second embodiment and the stator core. [Figure 9] Figure 9 is a diagram for explaining a first modified joint, where Figure 9(a) is a plan view of the first modified joint (before bending), Figure 9(b) is a cross-sectional view of the first modified joint (before bending), Figure 9(c) is a plan view of the first modified joint (after bending), and Figure 9(d) is a cross-sectional view of the first modified joint (after bending). [Figure 10] FIG. 10 is a diagram for explaining a second modified example of the joint, where FIG. 10(a) is a cross-sectional view of the second modified example of the joint (before joining), and FIG. 10(b) is a cross-sectional view of the second modified example of the joint (after joining). [Figure 11] Figure 11 is a cross-sectional view for explaining a third modified example of a joint, where Figure 11(a) shows the state before the slit is inserted into the convex portion (before the bending portion is folded), Figure 11(b) shows the state before the slit is inserted into the convex portion (after the bending portion is folded), Figure 11(c) shows the state after the slit is inserted into the convex portion (before the bending portion is unfolded), Figure 11(d) shows the state after the slit is inserted into the convex portion (after the bending portion is unfolded), and Figure 11(e) shows the state after the convex portion is folded. [Figure 12] Figure 12 is a plan view for explaining a third modified example of the joint, where Figure 12(a) shows the protrusion before being inserted into the slit (corresponding to Figure 11(a) or Figure 11(b)), and Figure 12(b) shows the protrusion after being inserted into the slit and bent (corresponding to Figure 11(e)). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0010] [First embodiment] Fig. 1 is a schematic diagram of the interphase insulating paper 1 of the first embodiment, Fig. 1(a) is a plan view, Fig. 1(b) is a cross-sectional view taken along line AA in Fig. 1(a), and Fig. 1(c) is a cross-sectional view taken along line BB in Fig. 1(a). Fig. 2 is a diagram showing an example in which the interphase insulating paper 1 of the first embodiment is mounted on a stator core 3, and includes a diagram in which the stator core 3 is linearly developed with respect to a circumferential path, a partially enlarged view thereof, and a diagram in which the interphase insulating paper 1 mounted on the stator core 3 is extracted. Fig. 3 is a diagram for explaining the function and effect of the interphase insulating paper 1 of the first embodiment, Fig. 3(a) is a diagram for explaining the function and effect of the joint portion 26, and Fig. 3(b) is a diagram for explaining the function and effect of the joint portion 26 and the non-joint portion 27. FIG. 4 is a diagram (copy) for explaining the effect of the interphase insulating paper 1 of the first embodiment, where FIG. 4(a) is a diagram (copy) for explaining the effect of the joint portion 26, and FIG. 4(b) is a diagram (copy) for explaining the effect of the joint portion 26 and the non-joint portion 27.

[0011] In the drawing, the interphase insulating paper 1 (legs 25A and 25B) and the portions of each phase coil (coil 4) that are placed in slots 31 are indicated by hatching. The coil 4 is not shown in Fig. 3(a).

[0012] The interphase insulating paper 1 of the first embodiment is mounted in slots 31 of a stator core 3 of a motor (not shown) and provides interphase insulation between the coils 4 of each phase mounted in the stator core 3.

[0013] Here, the motor is used, for example, for driving a vehicle. In this case, the motor rotates by receiving power from a power source such as a battery, and functions as an electric motor that drives the wheels of the vehicle. The motor also functions as a generator that generates electricity when driven by an external force. In other words, the motor is configured as a so-called motor generator that functions as both an electric motor and a generator. Note that the motor may be used not only as a motor for driving a vehicle, but also as a drive source for a system other than the vehicle.

[0014] The interphase insulating paper 1 of this embodiment has a configuration in which interphase insulating paper 2A and interphase insulating paper 2B are stacked on top of each other. Interphase insulating paper 2A (as well as interphase insulating paper 2B) has a shape in which a rectangular insulating paper is provided with a rectangular opening 21. The insulating paper is made of a three-layer laminate material, for example, in which aramid fiber paper is laminated on both sides of a polyethylene terephthalate (PEN) film, and is formed by punching using a dedicated die.

[0015] The interphase insulating paper 2A has strips 22A disposed at both longitudinal ends thereof. The strips 22A are members whose longitudinal direction coincides with the short side direction of the interphase insulating paper 2A.

[0016] Legs 25A extend from both longitudinal ends of band portion 22A, on the edge facing opening 21. Legs 25A are members that extend along the longitudinal direction of interphase insulating paper 2A and connect band portions 22A. The width of legs 25A is designed to be slightly wider than the width of the groove on the inner diameter of slot 31 of stator core 3 into which interphase insulating paper 2A arrives. The length of legs 25A is set to be the same as or slightly longer than the axial length of slot 31.

[0017] The leg portions 25A are disposed between the coils 4 arranged inside the slots 31, and provide interphase insulation between adjacent coils 4 in the same slot 31. The band portions 22A are disposed so as to protrude in the axial direction from the stator core 3 while being supported by the leg portions 25A, and are disposed adjacent to the coil ends (lead side and anti-lead side) which are part of the coils 4 and are disposed so as to protrude in the axial direction from the stator core 3. The band portions 22A provide interphase insulation between adjacent coil ends.

[0018] A notch 24 (which may be omitted) is formed on the edge of the belt portion 22A on the side of the opening 21. The notch 24 can be used to position a bonding portion 26 (adhesive), and the bonding portion 26 can be set to be located at the tip of the notch 24.

[0019] A concave arc portion 23 is formed on the edge of the band portion 22A on the opening 21 side. The arc portion 23 prevents the band portion 22A from interfering with the stator core 3 and being torn when the interphase insulating paper 2A is attached to the stator core 3 and then molded together with the coil 4.

[0020] The interphase insulating paper 2B has the same shape as the interphase insulating paper 2A, and includes an opening 21, a band portion 22B, an arc portion 23, a notch 24, and legs 25B.

[0021] The interphase insulating papers 2A and 2B are joined together with portions of them overlapping each other by a joint 26. As shown in Fig. 1(a) , the interphase insulating papers 2A and 2B are arranged so that their notches 24 overlap each other in a plan view, and are joined together by a joint 26 (adhesive) at a position adjacent to the tip of the notch 24.

[0022] The adhesive 26 is made of resin, for example. The adhesive 26 is sandwiched between the belt portion 22A and the belt portion 22B, and is welded to the belt portion 22A and the belt portion 22B by applying ultrasonic waves to the overlapping portion of the belt portion 22A, the adhesive 26, and the belt portion 22B.

[0023] Here, leg 25A of interphase insulating paper 2A and leg 25B of interphase insulating paper 2B adjacent to joint 26 are respectively attached to adjacent slots 31 (see Figure 2), and the distance between leg 25A and leg 25B is set to approximately the width of tooth 32 between two adjacent slots 31.

[0024] Here, as shown in the enlarged view of FIG. 1(a), if the diameter of the joint 26 is D1, the distance from the center of the joint 26 to the edge of the opening 21 is D2, the distance between the center of the joint 26 and the leg 25A (leg 25B) in the long side direction of the band portion 22A is D3, and the distance between the leg 25A and the leg 25B is D4, it is preferable to set D1=D2=D3=D4 / 2, for example, D1=D2=D3=4mm, D4=8mm. The width of the leg 25A and the leg 25B is also set to 4mm. Meanwhile, the width (slit groove width) of the inner diameter side of the slot 31 of the stator core 3 is set to 2.5mm, and the width of the outer diameter side is set to 8mm.

[0025] As shown in Fig. 1(a), the joint portion 26 is located biasedly toward the leg portion 25A side and the leg portion 25B side in the overlapping region of the strap portion 22A and the strap portion 22B. Therefore, in the overlapping region of the strap portion 22A and the strap portion 22B, a non-joined portion 27 is formed at a position farther from the leg portion 25A and the leg portion 25B than the joint portion 26. The portions of the strap portion 22A and the strap portion 22B that become the non-joined portion 27 can be deformed independently, and the relative positions of the two can be changed arbitrarily (see Fig. 3(b) and Fig. 4(b)).

[0026] 2, the interphase insulating paper 1 of this embodiment is applied to a motor equipped with a stator core 3 equipped with a distributed winding coil 4. In the stator core 3, multiple coils 4 of the same phase are arranged concentrically (in a ring shape) in the circumferential direction, and these are arranged in triplicate in the radial direction.

[0027] The stator core 3 has, for example, 48 slots 31 and teeth 32 (see FIG. 6). The coils 4 have a width of six slots 31, and eight coils 4 are mounted concentrically around the stator core 3 per phase, for a total of 24 coils 4. For example, eight coils 4 that surround the outermost portion in the radial direction are set as the U-phase coil 4U, and the coils 4 that surround the innermost portion in the radial direction are set as the W-phase coil 4W, and eight coils 4 that surround between the U-phase coil 4U and the W-phase coil 4W are set as the V-phase coil 4V. The V-phase coil 4V is circumferentially shifted from the U-phase coil 4U by an interval of one slot 31. The W-phase coil 4W is circumferentially shifted from the V-phase coil 4V by an interval of one slot 31 and from the U-phase coil 4U by an interval of two slots 31.

[0028] In this embodiment, the interphase insulating paper 1 is installed between the U-phase coil 4U and the V-phase coil 4V, and between the V-phase coil 4V and the W-phase coil 4W. The interphase insulating papers 2A and 2B have a width equivalent to eight slots 31, and are joined together in an overlapping state over the length of one slot 31. As a result, one sheet of interphase insulating paper 1 has a width equivalent to 14 slots 31. Four sheets of interphase insulating paper 1 are used between the U-phase coil 4U and the V-phase coil 4V, and between the V-phase coil 4V and the W-phase coil 4W.

[0029] The interphase insulating paper 1 is attached to the stator core 3 in such a manner that the leg portions 25A and 25B adjacent to the joint portion 26 are inserted into the slots 31 in which the coils 4 are attached. The interphase insulating paper 1 and the interphase insulating paper 1 attached adjacent to it in the circumferential direction are attached so as to overlap each other over the length of one slot 31. In this way, the leg portion 25A or the leg portion 25B is inserted into all of the slots 31 in which the coils 4 are attached. The strip portion 22A (strip portion 22B) of the interphase insulating paper 1 and the strip portion 22B (strip portion 22A) of the interphase insulating paper 1 attached adjacent to it are disposed adjacent to the portion of the coil 4 protruding from the stator core 3 (coil end) in a state where they overlap each other over the length of one slot 31.

[0030] Therefore, belt portions 22A and 22B of interphase insulating paper 1 are arranged in a ring shape with no gaps in the circumferential direction and face the entire side surface of the coil end, thereby providing insulation between the coil ends of two coils 4 of different phases. Also, leg portion 25A or leg portion 25B is inserted into all slots 31 in which coils 4 are installed, and leg portion 25A or leg portion 25B is arranged between two coils 4 of different phases in slot 31, so insulation between multiple coils 4 arranged in slot 31 can be provided.

[0031] As a mounting procedure, for example, first, eight U-phase coils 4U which are the outermost in the radial direction are mounted on stator core 3, and the coil ends of U-phase coils 4U are shaped into an arc to match the shape of stator core 3.

[0032] Next, four sheets of interphase insulating paper 1 are attached inside the molded U-phase coil 4U, and eight V-phase coils 4V are attached inside them. The coil ends of the V-phase coils 4V and the band portions 22A and 22B of the interphase insulating paper 1 are molded to match the shape of the stator core 3.

[0033] Next, four sheets of interphase insulating paper 1 are attached inside the molded V-phase coil 4V and eight W-phase coils 4W are attached inside them. The coil ends of the W-phase coil 4W and the strip portions 22A and 22B of the interphase insulating paper 1 arranged between the V-phase coil 4V and the W-phase coil 4W are molded to match the shape of the stator core 3.

[0034] Note that interphase insulating paper 1 may be arranged so that interphase insulating paper 2A is on the inner diameter side of stator core 3 and interphase insulating paper 2B is on the outer diameter side of stator core 3, or vice versa. Furthermore, the front and back sides of multiple different interphase insulating papers 1 attached to stator core 3 may all face the same direction, or each may face any direction.

[0035] [First Comparative Example] Fig. 5 is a diagram for explaining interphase insulating paper 1X of the first comparative example, with Fig. 5(a) being a plan view of interphase insulating paper 1X of the first comparative example, Fig. 5(b) being a diagram showing a case where interphase insulating paper 1 by itself pops out of slot 31 when interphase insulating paper 1X of the first comparative example is inserted into stator core 3, and Fig. 5(c) being a diagram showing a case where interphase insulating paper 1X inserted later pops out of slot 31 due to a force from interphase insulating paper 1X inserted earlier when interphase insulating paper 1X of the first comparative example is inserted into stator core 3. Fig. 6 is a diagram (copy) showing the installation mode of interphase insulating paper 1X of the first comparative example.

[0036] 5(b) and 5(c) do not show the coil 4. Also, Fig. 6 shows a case where the interphase insulating paper 1X of the first comparative example is attached after the V-phase coil 4V is attached.

[0037] As shown in Fig. 5(a), the interphase insulating paper 1X of the first comparative example is the same as the interphase insulating paper 2A or the interphase insulating paper 2B. As shown in Fig. 6, the interphase insulating paper 1X is attached to the stator core 3 in the same arrangement as in Fig. 2, but eight sheets of interphase insulating paper 1X cover the entire circumference in the circumferential direction.

[0038] The interphase insulating paper 1X of the first comparative example is flat in the initial state, but since the coil ends after molding have a complex indented shape, the entire interphase insulating paper 1X that interferes with the coil ends cannot remain in the circumferential direction of the stator core 3 and can move toward the inner diameter side of the stator core 3 (see Fig. 5(b) and Fig. 6). As a result, the legs 25 of the interphase insulating paper 1X protrude from the grooves of the slots 31 of the stator core 3, causing a problem that the coil 4 of the next phase cannot be inserted (see the enlarged view at the top of Fig. 6(b)).

[0039] When the interphase insulating paper 1X of the first comparative example is inserted into the stator core 3, it deforms into an arc shape or an S-shape, causing the legs 25 of the interphase insulating paper 1X to twist and face in a direction that makes it easy for the legs 25 to jump out of the grooves of the slots 31. At this time, the interphase insulating paper 1X inserted later is pushed by the interphase insulating paper 1X inserted earlier, causing the legs 25 to jump out of the grooves of the slots 31 (see FIG. 5(c) and the enlarged view at the bottom of FIG. 6).

[0040] In addition, for the reasons mentioned above, once the interphase insulating paper 1X has been installed, it may protrude toward the inner diameter side of the stator core 3 before the coil 4 is inserted in the next process, causing the interphase insulating paper 1X to come out from between the coils 4 or causing the interphase insulating paper 1X to become misaligned.

[0041] As described above, in order to prevent the interphase insulating paper 1X from protruding toward the inner diameter side, it is necessary to hold the interphase insulating paper 1X with a jig or tape, which poses the problem of requiring extra tooling costs and labor.

[0042] 3(a) and 4(a), the interphase insulating papers 2A and 2B of the first embodiment have a structure in which they support each other, and the interphase insulating papers 2A and 2B deform to form the same curved surface as a whole when inserted into the stator core 3. For this reason, the interphase insulating papers 2A (2B) and 2B (2A) do not apply a force to the other toward the inner diameter side of the stator core 3.

[0043] Furthermore, when the interphase insulating paper 1 is inserted into the stator core 3, both widthwise ends and joints 26 of the interphase insulating paper 1 tend to protrude toward the outer diameter side of the stator core 3, and the areas between both widthwise ends and joints 26 tend to protrude toward the inner diameter side of the stator core 3. As a result, at least one of the legs 25A and 25B adjacent to joints 26 is not twisted, and the apparent width (e.g., 4 mm) of leg 25A or leg 25B as seen from the groove of slot 31 (e.g., 2.5 mm) is maintained to be wider than the groove of slot 31, so that leg 25A or leg 25B is engaged with the groove of slot 31.

[0044] Furthermore, legs 25A and 25B are fixed to each other via joint 26. This prevents legs 25A and 25B from protruding from the grooves of slot 31. For the reasons described above, legs 25A and 25B at both ends of interphase insulating paper 1 in the width direction are disposed on the outer diameter side of slot 31, so legs 25A and 25B at both ends of interphase insulating paper 1 in the width direction also do not protrude from the grooves of slot 31. Also, since two sheets of interphase insulating paper 1 (interphase insulating paper 2A, interphase insulating paper 2B) are assembled simultaneously (two or more sheets if two or more sheets are joined), the assembly time can be shortened.

[0045] [Second Comparative Example] 7A and 7B are diagrams for explaining the phase insulating paper 1Y of the second comparative example, with Fig. 7A being a plan view of the phase insulating paper 1Y of the second comparative example, and Fig. 7B being a diagram (copy) showing the mounting state of the phase insulating paper 1Y of the second comparative example. As shown in Fig. 7A, the outer diameter of the phase insulating paper 1Y of the second comparative example in plan view is the same as that of the first embodiment, but it is formed from a single sheet. Therefore, there are no overlapping parts in the phase insulating paper 1Y, and there are no joint parts 26 and non-joint parts 27 of the first embodiment.

[0046] The phase insulating paper 1Y of the second comparative example has the same external shape as the phase insulating paper 1Y of the first embodiment, so the leg portion 25 located at the center in the width direction does not protrude from the groove of the slot 31. However, even if the phase insulating paper 1Y is inserted into the stator core 3 and then molded together with the coil ends, the phase insulating paper 1Y does not expand in the circumferential direction following the shape of the coil ends. For this reason, as shown in Fig. 7(b), when the coil ends are deformed toward the outer diameter side of the stator core 3, circumferential tension is concentrated in the center in the width direction of the band portion 22 of the phase insulating paper 1Y, causing a crack 221, which may result in failure of interphase insulation.

[0047] On the other hand, in the interphase insulating paper 1 of the first embodiment, as shown in Figures 3(b) and 4(b), joint portion 26 joining interphase insulating paper 2A and interphase insulating paper 2B is unevenly located in a position close to leg portion 25A and leg portion 25B. Also, in the region of belt portion 22A and belt portion 22B on the opposite side of joint portion 26 of leg portion 25A and leg portion 25B, belt portion 22A and belt portion 22B form non-joined portion 27 where belt portion 22A and belt portion 22B overlap each other but are not joined to each other.

[0048] As a result, the non-jointed portion 27 expands circumferentially when the coil 4 is inserted and when the coil 4 (coil end) is molded, without compromising the flexibility of the interphase insulating paper 1. Therefore, by absorbing the circumferential tension in the non-jointed portion 27, the occurrence of cracks 221, etc. in the interphase insulating paper 1 can be prevented and interphase insulation can be maintained.

[0049] On the other hand, the portions of band portions 22A and 22B joined by joints 26 are not separated from stator core 3, and are hardly subjected to circumferential tension even when coil 4 is inserted and when coil 4 (coil end) is formed. Therefore, no circumferential gap is formed between interphase insulating paper 2A and interphase insulating paper 2B, and interphase insulation can be maintained.

[0050] [Effects of the first embodiment] According to the first embodiment, the interphase insulating paper 1 is attached in a circumferentially arranged state in multiple pieces in the stator core 3 and provides interphase insulation for each phase coil (coil 4) provided in the stator core 3, and portions of adjacent interphase insulating papers (interphase insulating paper 2A, interphase insulating paper 2B) overlap each other, and the overlapping portions are provided with joints 26 that join the interphase insulating papers (interphase insulating paper 2A, interphase insulating paper 2B) to each other.

[0051] Furthermore, according to the motor manufacturing method of the first embodiment, a motor is manufactured in which multiple interphase insulating papers 1 that provide interphase insulation for each phase coil (coil 4) provided in the stator core 3 are attached in a circumferentially aligned manner in the stator core 3, and portions of a pair of interphase insulating papers (interphase insulating paper 2A, interphase insulating paper 2B) that are assembled adjacent to each other in the stator core 3 are overlapped and joined to each other, and the pair of interphase insulating papers (interphase insulating paper 2A, interphase insulating paper 2B) are attached to the stator core 3 simultaneously.

[0052] The above-mentioned configuration and method form a pair of interphase insulating papers (interphase insulating papers 2A and 2B) joined by the joints 26, and one of the interphase insulating papers 2A (interphase insulating papers 2B) holds the other interphase insulating paper 2B (interphase insulating paper 2A). Therefore, when the interphase insulating paper 1 is fitted into the slots 31 of the stator core 3, the interphase insulating papers 1A and 1B are not pushed out toward the inner diameter side of the stator core 3. Furthermore, when the interphase insulating paper 1 is fitted into the slots 31 of the stator core 3, the interphase insulating paper 1 is gently bent as a whole pair of interphase insulating papers (interphase insulating papers 2A and 2B), so that none of the pair of interphase insulating papers (interphase insulating papers 2A and 2B) is pushed out toward the inner diameter side of the stator core 3. As a result, the interphase insulating paper 1 can be easily fitted into the slots 31 of the stator core 3.

[0053] In the first embodiment, the interphase insulating paper 1 has legs (legs 25A, 25B) that are inserted into slots 31 of the stator core 3, and bands (legs 25A, 25B) that are arranged outside the slots 31 and supported by the legs.

[0054] With the above configuration, when the interphase insulating paper 1 is inserted into the stator core 3, both widthwise ends and joints 26 of the interphase insulating paper 1 tend to protrude toward the outer diameter side of the stator core 3, and the areas between both widthwise ends and joints 26 tend to protrude toward the inner diameter side of the stator core 3. As a result, at least one of the legs 25A and 25B adjacent to joints 26 is not twisted, and the apparent width (e.g., 4 mm) of leg 25A or leg 25B as seen from the groove of slot 31 (e.g., 2.5 mm) is maintained to be wider than the groove of slot 31, so that leg 25A or leg 25B is engaged with the groove of slot 31.

[0055] Furthermore, legs 25A and 25B are fixed to each other via joint 26. This prevents legs 25A and 25B from protruding from the grooves of slot 31. For the reasons described above, legs 25A and 25B at both ends of interphase insulating paper 1 in the width direction are disposed on the outer diameter side of slot 31, so legs 25A and 25B at both ends of interphase insulating paper 1 in the width direction also do not protrude from the grooves of slot 31. Also, since two sheets of interphase insulating paper 1 (interphase insulating paper 2A, interphase insulating paper 2B) are assembled simultaneously (two or more sheets if two or more sheets are joined), the assembly time can be shortened.

[0056] In the first embodiment, the joint portion 26 is disposed at a position where the belt portions (belt portions 22A, 22B) overlap each other and is offset toward the leg portions (leg portions 25A, 25B).

[0057] As a result, in the region of the belt portions (belt portions 22A, 22B) opposite to joint portion 26 of the leg portions (leg portions 25A, 25B), non-jointed portions 27 are formed where the belt portions (belt portions 22A, 22B) overlap but are not joined to each other. Therefore, non-jointed portions 27 expand in the circumferential direction when inserting coil 4 and when molding coil 4 without impairing the flexibility of interphase insulating paper 1, and by absorbing circumferential tension in non-jointed portions 27, the occurrence of cracks 221, etc. in interphase insulating paper 1 can be prevented and interphase insulation can be maintained.

[0058] On the other hand, the portions of the band portions (band portions 22A, 22B) joined by joints 26 are not separated from the stator core 3, and are hardly subjected to circumferential tension even when inserting the coil 4 and when forming the coil 4. Therefore, no circumferential gaps are formed between the interphase insulating papers (interphase insulating papers 2A, 2B), and interphase insulation can be maintained.

[0059] According to the motor of the first embodiment, the above-mentioned interphase insulating paper 1 is incorporated into the stator core 3, and interphase insulation is achieved for each phase coil (coil 4) provided in the stator core 3. This results in a motor that ensures interphase insulation and can reduce assembly time.

[0060] [Second embodiment] Figure 8 is a diagram for explaining the interphase insulating paper 1A of the second embodiment, where Figure 8(a) is a plan view (expanded view) of the interphase insulating paper 1A of the second embodiment, Figure 8(b) is a diagram showing the shape of the interphase insulating paper 1A of the second embodiment when installed in the slot 31 of the stator core 3, and Figure 8(c) is a diagram showing the relationship between the interphase insulating paper 1A of the second embodiment and the stator core 3.

[0061] Interphase insulating paper 1A of the second embodiment is formed by preparing eight sheets of interphase insulating paper 2A (or interphase insulating paper 2B) and joining them to form a cylindrical shape with joints 26. Interphase insulating paper 1Y shown in FIG. 8(b) is formed by joining the interphase insulating papers 2 at both ends shown in FIG. 8(a) to each other with joints 26. In the stator core 3, cylindrical interphase insulating paper 1Y that provides interphase insulation between U-phase coil 4U and V-phase coil 4V and cylindrical interphase insulating paper 1Y that provides interphase insulation between V-phase coil 4V and W-phase coil 4W are used.

[0062] Here, the perimeter of the phase insulation paper 1Y is set to be longer than the perimeter of the inner diameter of the stator core 3 (the diameter of the phase insulation paper 1Y is larger than the inner diameter of the stator core 3). Specifically, as shown in FIG. 8(c), when the radius of the phase insulation paper 1Y is D5, the radius of the inner diameter of the stator core 3 is D6, and the radius of the outer peripheral portion of the slot 31 of the stator core 3 is D7, the diameter D (perimeter) of the phase insulation paper 1Y is set to satisfy the relationship of D6 < D5 ≤ D7.

[0063] According to the phase insulation paper 1Y of the second embodiment, since the perimeter of the phase insulation paper 1Y joined in one turn is larger than the perimeter of the inner diameter of the stator core 3, it becomes difficult for the phase insulation paper 1Y to protrude to the inner diameter side of the stator core 3, and in particular, it is possible to prevent the leg portion 25 from protruding from the groove of the slot 31. In addition, since the phase insulation papers 2 (eight pieces) for one phase are assembled together, the assembly time can be shortened.

[0064] [First Modified Example of Joint Portion 26] FIG. 9 is a diagram for explaining the first modified example of the joint portion 26. FIG. 9(a) is a plan view (before bending) of the first modified example of the joint portion 26, FIG. 9(b) is a cross-sectional view (before bending) of the first modified example of the joint portion 26, FIG. 9(c) is a plan view (after bending) of the first modified example of the joint portion 26, and FIG. 9(d) is a cross-sectional view (after bending) of the first modified example of the joint portion 26.

[0065] In the first modified example of the joint portion 26, at the position where the joint portion 26 is arranged in the arrangement of the phase insulation paper 2A and the phase insulation paper 2B of the first embodiment (or the second embodiment), for example, as shown in FIGS. 9(a) and 9(b), a cut is made in a peninsula shape to form a section 261. The section 261 is a part where a part of the phase insulation paper 2A (band portion 22A) and a part of the phase insulation paper 2B (band portion 22B) overlap. Then, as shown in FIGS. 9(c) and 9(d), the section 261 is bent to join the phase insulation paper 2A and the phase insulation paper 2B.

[0066] [Second Modified Example of Joint Portion 26] FIG. 10 is a diagram for explaining a second modified example of the joint 26, where FIG. 10(a) is a cross-sectional view of the second modified example of the joint 26 (before joining), and FIG. 10(b) is a cross-sectional view of the second modified example of the joint 26 (after joining).

[0067] In a second modified example of the joint 26, as shown in Figures 10(a) and 10(b), an insulating staple 262 is prepared. As shown in Figure 10(a), an insertion hole 263 for inserting an insertion portion 2621 of the staple 262 is formed at a position where the joint 26 is to be arranged in the arrangement of the interphase insulating papers 2A and 2B in the first embodiment (or the second embodiment). Then, as shown in Figure 10(b), the insertion portion 2621 is inserted into the insertion hole 263 and then folded, thereby joining the interphase insulating papers 2A and 2B.

[0068] [Third modified example of joint 26] FIG. 11 is a cross-sectional view for explaining a third modified example of joint 26, in which FIG. 11(a) shows the state before convex portion 264 is inserted into slit 265 (before bending portion 2641 is bent), FIG. 11(b) shows the state before convex portion 264 is inserted into slit 265 (after bending portion 2641 is bent), FIG. 11(c) shows the state after convex portion 264 is inserted into slit 265 (before bending portion 2641 is unfolded), FIG. 11(d) shows the state after convex portion 264 is inserted into slit 265 (after bending portion 2641 is unfolded), and FIG. 11(e) shows the state after convex portion 264 is folded. Figure 12 is a plan view for explaining a third modified example of joint 26, where Figure 12(a) shows convex portion 264 before being inserted into slit 265 (corresponding to Figure 11(a) or Figure 11(b)), and Figure 12(b) shows convex portion 264 after being inserted into slit 265 and bent (corresponding to Figure 11(e)).

[0069] In a third modified example of the joint 26, a cut is made at the position of the joint 26 of one of the interphase insulating papers 2A (interphase insulating paper 2B), and a convex portion 264 is formed to encompass the notch 24, for example, and a slit 265 is formed at the position of the joint 26 of the other interphase insulating paper 2B (interphase insulating paper 2A).

[0070] 11(a) and 12(a), the convex portion 264 is formed, for example, by cutting the edge of the band portion 22A (band portion 22B) on the opening 21 side into a trapezoid shape, leaving a portion facing the upper and lower ends at the lower base, and bending the lower base at a right angle. The slit 265 is formed by cutting the convex portion 264 to a length approximately equal to the length of the upper base.

[0071] As shown in FIG. 11(b), the bent portion 2641 of the protrusion 264 is bent in the width direction to fold the protrusion 264 to the width of the upper base, and the folded protrusion 264 is inserted into the slit 265 as shown in FIG. 11(c).

[0072] As shown in FIG. 11(d), the folded portion 2641 is unfolded to its original position.

[0073] Finally, as shown in FIGS. 11(e) and 12(b), the entire convex portion 264 is folded back to the state shown in FIG. 12(a), thereby joining the interphase insulating paper 2A and the interphase insulating paper 2B.

[0074] Although the embodiments of the present invention have been described above, the above-mentioned embodiments merely show some of the application examples of the present invention, and it is not intended that the technical scope of the present invention be limited to the specific configurations of the above-mentioned embodiments. [Explanation of symbols]

[0075] 1 Interphase insulation paper 2A,2B Insulating paper between phases 22A,22B obi part 25A,25B Legs 3 Stator core

Claims

1. A plurality of interphase insulating papers are attached to a stator core in a circumferential direction and provide interphase insulation between coils of each phase provided in the stator core, The interphase insulating paper is A pair of legs each inserted into a different slot of the stator core; a strap portion disposed outside the slot and supported by the pair of legs; a pair of the interphase insulating papers are formed by a portion of the interphase insulating papers adjacent to each other overlapping with each other and a joint portion for joining the interphase insulating papers to each other at the overlapping portion; a first leg portion of one of the pair of legs of the pair of interphase insulating papers, the first leg portion being arranged on a side where one of the pair of interphase insulating papers overlaps with the other of the pair of interphase insulating papers, and a second leg portion of the other of the pair of legs of the pair of interphase insulating papers, the second leg portion being arranged on a side where the other of the pair of interphase insulating papers overlaps with one of the pair of interphase insulating papers, the distance between these first and second legs being set to be equal to the distance between a pair of adjacent slots; The joint is an interphase insulating paper that is arranged in a region where a portion of the band portion of one of the pair of interphase insulating papers and a portion of the band portion of the other of the pair of interphase insulating papers overlap with each other, at a position between the first leg and the second leg in the direction in which one of the pair of interphase insulating papers and the other of the pair of interphase insulating papers are aligned, and is biased toward the first leg and the second leg.

2. 2. The interphase insulating paper according to claim 1, wherein the interphase insulating paper is joined to the stator core in a cylindrical shape so as to surround the stator core, and the circumferential length of the interphase insulating paper is longer than the circumferential length of the inner diameter of the stator core.

3. 3. A motor in which the interphase insulating paper according to claim 1 or 2 is incorporated into the stator core, thereby providing interphase insulation for each phase coil provided in the stator core.

4. A method for manufacturing a motor, in which a plurality of interphase insulating papers for providing interphase insulation for each phase coil provided in a stator core are attached to the stator core so as to be aligned in the circumferential direction, the interphase insulating papers include a pair of legs that are inserted into different slots of the stator core, and a band portion that is disposed outside the slots and supported by the pair of legs, a joint portion is disposed to overlap and join a pair of the interphase insulating papers that are adjacent to each other in the stator core, thereby forming a pair of the interphase insulating papers; When forming the pair of interphase insulating papers, a first leg portion of one of the pair of legs of the pair of interphase insulating papers, the first leg portion being arranged on a side where one of the pair of interphase insulating papers overlaps with the other of the pair of interphase insulating papers, and a second leg portion of the other of the pair of legs of the pair of interphase insulating papers, the second leg portion being arranged on a side where the other of the pair of interphase insulating papers overlaps with one of the pair of interphase insulating papers, is set so as to be the interval between a pair of adjacent slots; the joint is disposed in a region where a portion of the belt portion of one of the pair of interphase insulating papers and a portion of the belt portion of the other of the pair of interphase insulating papers overlap with each other, at a position between the first leg and the second leg in a direction in which the one of the pair of interphase insulating papers and the other of the pair of interphase insulating papers are aligned, and at a position offset toward the first leg and the second leg, A method for manufacturing a motor, comprising simultaneously mounting a pair of the interphase insulating papers to the stator core.

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