Armature and motor

Abstract

To achieve improvement in torque while suppressing increase in physique.SOLUTION: A stator 14 includes; an annularly formed stator core 26; a plurality of coils 16; and an insulator 28. The plurality of coils 16 includes: a pair of opposing parts 36, each of which is formed by winding an electrically conductive winding and which forms a central portion in an axial direction or a radial direction and is arranged at intervals in the circumferential direction; and a pair of coil end parts which connects the pair of opposing portions in a circumferential direction and is arranged along the stator core 26. An insulator 28 is provided between a stator core 26 and a plurality of coils 16 and includes a soft magnetic part 52 formed using a soft magnetic material in a base 50 formed using an insulating material.SELECTED DRAWING: Figure 8A

Description

[Technical field]

[0001] The present disclosure relates to an armature and a motor. [Background technology]

[0002] The following Patent Document 1 discloses a slotless motor having a stator and a rotor. The stator includes a cylindrical stator core and a plurality of outer coils and inner coils attached to the inner periphery of the stator core. The rotor includes a plurality of permanent magnets on the outer periphery and is arranged on the axis of the stator so as to face the stator with a gap therebetween. The stator of the slotless motor described in this document includes a cylindrical ring-shaped insulator in which slots having openings on the inner periphery and slots having openings on the outer periphery are alternately arranged in the circumferential direction. The outer coils pass through the outer periphery opening of the insulator and are wound from the outside so as to sandwich one slot therebetween. The inner coils pass through the inner periphery opening and are wound from the inside so as to sandwich one slot therebetween. This simplifies the stator manufacturing process and enables the coil span to be increased. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-176982 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the slotless motor described in Patent Document 1, the insulator is a part that does not contribute to the torque of the rotor or contributes little to the torque of the rotor. Therefore, the motor described in Patent Document 1 has room for improvement in terms of improving the torque while suppressing an increase in the motor size.

[0005] In consideration of the above, an object of the present disclosure is to provide an armature and a motor that can improve torque while suppressing an increase in size. [Means for solving the problem]

[0006] The armature (14) that solves the above problems includes an armature core (26) formed in an annular shape, a pair of opposing portions (36) each formed by winding a conductive winding, forming a central portion in the axial or radial direction and arranged at a distance in the circumferential direction, and a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction, a plurality of coils (16) arranged along the armature core, and an insulator (28) provided between the armature core and the plurality of coils, the insulator (28) including a soft magnetic portion (52) formed of a soft magnetic material in a base (50) formed of an insulating material. Also, a motor (10, 54, 60-84) is configured to include this armature.

[0007] With this configuration, it is possible to improve the torque while suppressing an increase in the size of the engine. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a partially cutaway perspective view showing a rotor and a stator of the motor according to the first embodiment. [Diagram 2] 2 is a side cross-sectional view showing a cross section of the motor taken along the axial direction. FIG. [Diagram 3] FIG. 2 is a plan view showing a stator and a rotor. [Figure 4] FIG. 2 is a cross-sectional plan view showing a stator and a rotor. [Diagram 5] FIG. [Figure 6A] FIG. [Figure 6B] FIG. [Figure 7] FIG. [Figure 8A]FIG. 2 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor. [Figure 8B] FIG. 2 is an enlarged cross-sectional view showing a schematic view of a portion of the insulator. [Figure 9] FIG. 2 is a schematic diagram for explaining connections of a U phase, a V phase, and a W phase. [Figure 10] FIG. 2 is a schematic diagram for explaining connections and arrangements of U-phase, V-phase, and W-phase. [Figure 11] 2 is a perspective view showing an insulator and a coil supported by a stator core via the insulator; FIG. [Figure 12] 2 is a perspective view showing an insulator and a U-phase coil, a V-phase coil, and a W-phase coil supported by a stator core via the insulator. FIG. [Figure 13] 4 is an enlarged cross-sectional side view showing a schematic diagram of a flow of magnetic flux from a magnet to a stator core. FIG. [Figure 14] FIG. 6 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a second embodiment. [Figure 15A] FIG. 11 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a third embodiment. [Figure 15B] 11 is a plan view of the insulator as viewed from the side where a gap is formed, showing another example of the gap. FIG. [Figure 15C] 11 is a plan view of the insulator as viewed from the side where a gap is formed, showing another example of the gap. FIG. [Figure 15D] 11 is a plan view of the insulator as viewed from the side where a gap is formed, showing another example of the gap. FIG. [Figure 16] 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a fourth embodiment. FIG. [Figure 17] FIG. 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a fifth embodiment. [Figure 18] 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor of a sixth embodiment. FIG. [Figure 19] 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a seventh embodiment. FIG. [Figure 20] 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to an eighth embodiment. FIG. [Figure 21] 13 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a ninth embodiment. FIG. [Figure 22] FIG. 23 is a perspective view showing a stator core and coils of a stator constituting a part of a motor according to a tenth embodiment. [Diagram 23] FIG. 23 is a cross-sectional plan view showing a stator and a rotor of a motor according to a tenth embodiment. [Figure 24] 24 is a side cross-sectional view showing a cross section of the motor taken along line AA shown in FIG. 23. [Diagram 25] FIG. 23 is a cross-sectional plan view showing a stator and a rotor of a motor according to an eleventh embodiment. [Figure 26] 26 is a side cross-sectional view showing a cross section of the motor taken along line BB shown in FIG. 25. [Figure 27] FIG. 23 is a perspective view showing an insulator that constitutes a part of the motor of an eleventh embodiment. [Figure 28] FIG. 23 is a side cross-sectional view showing a stator and a rotor of a motor according to a twelfth embodiment. [Figure 29] 29 is a cross-sectional view showing a cross section of the stator taken along line CC shown in FIG. 28. [Diagram 30] FIG. 23 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a thirteenth embodiment. [Diagram 31] FIG. 23 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a fourteenth embodiment. [Diagram 32] FIG. 23 is an enlarged cross-sectional side view showing a part of a stator and a part of a rotor that configure a motor according to a fifteenth embodiment. [Diagram 33] 11A to 11C are enlarged perspective views for explaining variations of the terminal portions of the windings that form the coil. [Diagram 34] 11A to 11C are enlarged perspective views for explaining variations of the terminal portions of the windings that form the coil. [Diagram 35] 11A to 11C are enlarged perspective views for explaining variations of the terminal portions of the windings that form the coil. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] (First embodiment) A motor 10 according to a first embodiment of the present disclosure will be described with reference to Figures 1 to 12. Note that the direction of arrow Z, the direction of arrow R, and the direction of arrow C, appropriately shown in the figures, respectively indicate one side in the rotational axial direction, the outer side in the rotational radial direction, and one side in the rotational circumferential direction of a rotor 12, which will be described later. In the following, when simply indicating an axial direction, a radial direction, or a circumferential direction, this refers to the rotational axial direction, the rotational radial direction, and the rotational circumferential direction of the rotor 12, unless otherwise specified.

[0010] 1 to 3, motor 10 of this embodiment is an inner rotor type brushless motor in which rotor 12 as a rotor is disposed radially inside stator 14 as an armature and a stator. Note that the drawings shown in Figs. 1 to 5 are drawings of motor 10 etc. shown as an example, and there are some parts which do not match those described below in terms of the number of coils 16, the number of magnets 18, and the shapes of the details.

[0011] The rotor 12 includes a rotating shaft 22 rotatably supported via a pair of bearings 20, a rotor core 24 formed in a bolt-type cylindrical shape and fixed to the rotating shaft 22, and a plurality of magnets 18 fixed to the radially outer surface of the rotor core 24.

[0012] The rotor core 24 includes a first cylindrical portion 24A to which the rotating shaft 22 is fixed by press-fitting, a second cylindrical portion 24B disposed radially outside the first cylindrical portion 24A and formed cylindrical, and a disk-shaped connecting plate portion 24C that radially connects one axial end of the first cylindrical portion 24A to one axial end of the second cylindrical portion 24B. The outer peripheral surface, which is the radially outer surface of the second cylindrical portion 24B, is formed into a cylindrical surface along the circumferential direction. A magnet 18, which will be described later, is fixed to the outer peripheral surface of the second cylindrical portion 24B.

[0013] The magnets 18 are formed using a magnetic compound having an intrinsic coercivity Hc of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more. 11 TiN, Nd2Fe 14 B, SmFe 17 The rotor core 24 is formed of a magnetic compound such as N3, FeNi, etc. A plurality of magnets 18 are fixed to the outer peripheral surface of the second cylindrical portion 24B of the rotor core 24. The magnets 18 whose radially outer surfaces are N poles and the magnets 18 whose radially outer surfaces are S poles are arranged alternately in the circumferential direction. The number of magnets 18 may be appropriately set in consideration of the output required for the motor 10, etc.

[0014] 5, the stator 14 includes a stator core 26 formed in an annular shape as an armature core, an insulator 28 attached to the stator core 26 by adhesion, fitting, or the like, and a plurality of coils 16 attached to the stator core 26 via the insulators 28. The stator 14 of this embodiment has a teethless structure in which no part of the stator core 26 is disposed inside the coils 16.

[0015] 1 and 5, the stator core 26 is formed in an annular shape using a soft magnetic material such as steel. The radial thickness of the stator core 26 is set to be larger than the radial dimension of a coil end portion 38 of the coil 16, which will be described later. The stator core 26 is disposed coaxially with the rotor 12, and the axial center position of the stator core 26 and the axial center position of the multiple magnets 18 fixed to the rotor core 24 coincide with each other in the axial direction.

[0016] The stator core 26 of this embodiment is formed by stacking core constituent plates 27, each having an axial thickness direction, in the axial direction and integrating them by crimping, welding, etc. In this embodiment, all of the core constituent plates 27 constituting the stator core 26 have the same thickness. The core constituent plates 27 are formed using steel plates.

[0017] 8A and 8B, the insulator 28 is formed using a resin containing metal particles. The insulator 28 covers the radially inner surface and both axial end surfaces of the stator core 26 when the insulator 28 is attached to the stator core 26. The specific configuration of the insulator 28 will be described in detail later.

[0018] As shown in Figs. 5 to 7, the coils 16 are formed by winding a conductive wire (conductor) in a circular shape. Here, as shown in Figs. 6A and 7, the winding 30 forming the coil 16 of this embodiment has a rectangular cross section in which a dimension L1 of the winding 30 in a first direction (arrow A1 direction) is set to be larger than a dimension L2 in a second direction (arrow A2) perpendicular to the first direction, in a cross section cut along the longitudinal direction. The winding 30 may be a wire assembly formed by bundling conductive wires. The resistance between the bundled wires is larger than the resistance of the wire itself. The cross-sectional shape of the winding 30 may be an oval or elliptical shape. In general, an enameled wire is preferably used for the winding 30, and the conductive material may be copper or aluminum.

[0019] As shown in Figures 5 to 7, the stator 14 of this embodiment is configured to include two types of coils 16 with different axial dimensions. Here, the coil 16 shown in Figure 6A is referred to as a short coil 32. Also, the coil 16 shown in Figure 7 is referred to as a long coil 34. The number of coils 16 may be appropriately set in consideration of the output required of the motor 10, etc.

[0020] 6A and 6B, the short coil 32 is formed by winding the winding 30 in a rectangular shape so as to be stacked in the second direction (the direction of the arrow A2), and then bending both axial ends radially outward. As a result, the short coil 32 has a pair of opposing parts 36 in which parts of the winding 30 are arranged side by side in the circumferential direction and spaced apart from each other in the circumferential direction, one coil end part 38 that connects the ends of the pair of opposing parts 36 on one axial side in the circumferential direction, and the other coil end part 38 that connects the ends of the pair of opposing parts 36 on the other axial side in the circumferential direction. The pair of opposing parts 36 constitute the axial center part of the short coil 32, and the one coil end part 38 and the other coil end part 38 constitute both axial side parts of the short coil 32.

[0021] Moreover, the terminal portion 40 on one side of the winding 30 forming the short coil 32 is drawn out from one circumferential side of the opposing portion 36 on the other circumferential side between the pair of opposing portions 36 to one axial side. Moreover, the terminal portion 40 on the other side of the winding 30 forming the short coil 32 is drawn out from the opposite side (one circumferential side) of the opposing portion 36 on the one circumferential side to one axial side. In the following description, the terminal portion 40 on one side of the winding 30 forming the short coil 32 may be referred to as the "winding start terminal portion 40A" and the terminal portion 40 on the other side of the winding 30 forming the short coil 32 may be referred to as the "winding end terminal portion 40B". Moreover, by arranging the terminal portion 40 in this way, in the short coil 32 of this embodiment, the number of laminations of the winding 30 at the coil end portion 38 on one axial side is smaller than the number of laminations of the winding 30 at the coil end portion 38 on the other axial side. More specifically, the number of lamination layers of the winding 30 at the coil end portion 38 on one axial side is six, and the number of lamination layers of the winding 30 at the coil end portion 38 on the other axial side is seven. The number of lamination layers of the winding 30 at the pair of opposing portions 36 is seven.

[0022] Here, as shown in FIG. 6B, the pair of opposing parts 36 are parts that are in the center of the short coil 32 in the axial direction and extend linearly in the axial direction. The coil end part 38 on one axial side is a part of the short coil 32 that is located on one axial side of the ends of the pair of opposing parts 36 on one axial side. The coil end part 38 on one axial side includes a pair of curved parts 38A that are curved radially outward from the ends of the pair of opposing parts 36 on one axial side, and a coil end part 38B that extends radially outward from the ends of the pair of curved parts 38A on the opposite side to the opposing parts 36. The boundary between the pair of opposing parts 36 and the pair of curved parts 38A of the coil end part 38 on one axial side is referred to as a bending start point 38C. The boundary between the pair of curved parts 38A and the coil end part 38B is referred to as a bending end point 38D.

[0023] The coil end portion 38 on the other axial direction is a portion of the short coil 32 that is located on the other axial side of the ends of the pair of opposing portions 36 on the other axial direction. The coil end portion 38 on the other axial direction includes a pair of curved portions 38A that are curved radially outward from the ends of the pair of opposing portions 36 on the other axial direction, and a coil end portion 38B that extends radially outward from the ends of the pair of curved portions 38A opposite to the opposing portions 36. The boundary between the pair of opposing portions 36 and the pair of curved portions 38A of the coil end portion 38 on the other axial direction is referred to as a bending start point 38C. The boundary between the pair of curved portions 38A and the coil end portion 38B is referred to as a bending end point 38D.

[0024] In order to distinguish the coil end portions 38 of the short coils 32 from the coil end portions 38 of the long coils 34 described below, the coil end portions 38 of the short coils 32 are sometimes referred to as curved coil end portions 380. The curved coil end portions 380 refer to the coil end portions 38 of the multiple coils 16 constituting the stator 14 that are disposed closest to the axial end face of the stator core 26.

[0025] 6A and 7, the long coil 34 has the same configuration as the short coil 32, except that the axial dimension H2 of the long coil 34 is larger than the axial dimension H1 of the short coil 32. Here, the parts of the long coil 34 corresponding to the short coil 32 are given the same reference numerals as the short coil 32, and the description of these parts will be omitted. The long coil 34 is manufactured through the same process as the short coil 32. Incidentally, the length of the winding 30 forming the long coil 34 is longer than the length of the winding 30 forming the short coil 32. As a result, the electrical resistance of the long coil 34 is higher than the electrical resistance of the short coil 32.

[0026] Next, the connections of the multiple coils 16 will be described.

[0027] As shown in FIG. 9, the coils 16 are connected in a star connection, for example. In this example, the U-phase 42U, the V-phase 42V, and the W-phase 42W are each configured to include two short coils 32 and two long coils 34. In the U-phase 42U, the four coils 16 are connected in series in the order of the long coil 34, the short coil 32, the long coil 34, and the short coil 32 from the neutral point 44 side. In the V-phase 42V, the four coils 16 are connected in series in the order of the long coil 34, the short coil 32, the long coil 34, and the short coil 32 from the neutral point 44 side. In the W-phase 42W, the four coils 16 are connected in series in the order of the short coil 32, the long coil 34, the short coil 32, and the long coil 34 from the neutral point 44 side. Note that the coils 16 are connected to each other using a bus bar, for example.

[0028] Here, in the U phase 42U, the range from the short coil 32 farthest from the neutral point 44 to the neutral point 44 is referred to as the U-phase coil connection body 46U. In addition, in the V phase 42V, the range from the short coil 32 farthest from the neutral point 44 to the neutral point 44 is referred to as the V-phase coil connection body 46V. Furthermore, in the W phase 42W, the range from the long coil 34 farthest from the neutral point 44 to the neutral point 44 is referred to as the W-phase coil connection body 46W. In this embodiment, the number of long coils 34 and the number of short coils 32 are set to the same number in the coil connection bodies 46U, 46V, 46W of each phase, so that the combined resistance of the coil connection bodies 46U, 46V, 46W of each phase is the same. Here, the combined resistance of the coil connections 46U, 46V, 46W of each phase being the same means that the difference between the combined resistance of the coil connection 46U of one phase and the combined resistance of the coil connections 46V, 46W of the other phase is within plus or minus 5%.

[0029] Fig. 10 shows the relative arrangement of the coils 16 in the U phase 42U, the coils 16 in the V phase 42V, and the coils 16 in the W phase 42W. As shown in Fig. 10 (also see Fig. 8A), the short coil 32 farthest from the neutral point 44 in the U phase 42U and the short coil 32 farthest from the neutral point 44 in the V phase 42V are arranged adjacent to each other in the circumferential direction along the stator core 26. In addition, the long coil 34 farthest from the neutral point 44 in the W phase 42W is arranged so as to straddle the short coil 32 farthest from the neutral point 44 in the U phase 42U and the short coil 32 farthest from the neutral point 44 in the V phase 42V.

[0030] In addition, the short coil 32 farthest from the neutral point 44 in the V phase 42V and the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the opposite side of the neutral point 44 in the U phase 42U is arranged so as to straddle the short coil 32 farthest from the neutral point 44 in the V phase 42V and the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W.

[0031] In addition, the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W and the short coil 32 on the neutral point 44 side in the U phase 42U are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the opposite side of the neutral point 44 in the V phase 42V is arranged so as to straddle the short coil 32 on the opposite side of the neutral point 44 in the W phase 42W and the short coil 32 on the neutral point 44 side in the U phase 42U.

[0032] In addition, the short coil 32 on the neutral point 44 side in the U phase 42U and the short coil 32 on the neutral point 44 side in the V phase 42V are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the W phase 42W is arranged so as to straddle the short coil 32 on the neutral point 44 side in the U phase 42U and the short coil 32 on the neutral point 44 side in the V phase 42V.

[0033] In addition, the short coil 32 on the neutral point 44 side in the V phase 42V and the short coil 32 on the neutral point 44 side in the W phase 42W are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the U phase 42U is arranged so as to straddle the short coil 32 on the neutral point 44 side in the V phase 42V and the short coil 32 on the neutral point 44 side in the W phase 42W.

[0034] In addition, the short coil 32 on the neutral point 44 side in the W phase 42W and the short coil 32 farthest from the neutral point 44 in the U phase 42U are arranged adjacent to each other in the circumferential direction along the stator core 26. Furthermore, the long coil 34 on the neutral point 44 side in the V phase 42V is arranged so as to straddle the short coil 32 on the neutral point 44 side in the W phase 42W and the short coil 32 farthest from the neutral point 44 in the U phase 42U.

[0035] Next, the configuration of the insulator 28 will be described.

[0036] 8A, the insulator 28 to which each coil 16 is attached includes an inner surface covering portion 28A as an intervening portion between opposing portions that covers the radially inner surface of the stator core 26. The insulator 28 also includes a pair of axial end covering portions 28B as intervening coil end portions that cover both axial end surfaces of the stator core 26. The axial thickness dimension T2 of the axial end covering portions 28B is set to be larger than the radial thickness dimension T1 of the inner surface covering portion 28A. The insulator 28 also includes a pair of outer circumferential flange portions 28C that extend in the axial direction from radially outer ends of the pair of axial end covering portions 28B.

[0037] 11, the insulator 28 includes a plurality of circumferential positioning portions 28D for positioning the short coil 32 in the circumferential direction. The plurality of circumferential positioning portions 28D are formed in a convex shape extending radially inward from the outer circumferential flange portion 28C and are arranged at equal intervals along the circumferential direction. The coil end portion 38 of the short coil 32 is arranged between a pair of circumferential positioning portions 28D adjacent to each other in the circumferential direction, thereby positioning the short coil 32 in the circumferential direction. Note that the plurality of circumferential positioning portions 28D may be provided on one outer circumferential flange portion 28C, but may be provided on both outer circumferential flange portions 28C.

[0038] As shown in FIG. 8A, the insulator 28 of this embodiment has a two-part structure that is divided in the axial direction at the center of the inner surface covering portion 28A in the axial direction.

[0039] As shown in Fig. 8A, Fig. 10 and Fig. 12, the facing portions 36 of the short coils 32 and the facing portions 36 of the long coils 34 are disposed along the radially inner surface of the stator core 26 via the inner covering portion 28A of the insulator 28 and disposed at the same position in the radial direction. In detail, in the state shown in Fig. 12, the facing portions 36 on one circumferential side of the U-phase short coils 32 and the facing portions 36 on the other circumferential side of the V-phase short coils 32 that are adjacent in the circumferential direction are disposed adjacent to each other in the circumferential direction, and the facing portions 36 on one circumferential side of the U-phase short coils 32 and the facing portions 36 on the other circumferential side of the V-phase short coils 32 that are adjacent in the circumferential direction are disposed between a pair of facing portions 36 of the W-phase long coils 34. As shown in Fig. 10 and Fig. 12, the facing portions 36 of the other short coils 32 and the facing portions 36 of the other long coils 34 are also disposed along the radially inner surface of the stator core 26 in a similar relationship. In addition, with the axial center position of the opposing portion 36 of the short coil 32 and the axial center position of the opposing portion 36 of the long coil 34 and the axial center position of the magnet 18 aligned in the axial direction, the opposing portions 36 of the short coil 32 and the opposing portions 36 of the long coil 34 and the magnet 18 are arranged facing each other in the radial direction. In addition, the first direction of the windings 30 constituting the opposing portions 36 of the short coil 32 and the opposing portions 36 of the long coil 34 is directed towards the magnet 18.

[0040] As shown in Fig. 8A, Fig. 10 and Fig. 12, the pair of coil end portions 38 of the short coil 32 are arranged along both axial end faces of the stator core 26 via the pair of axial end surface covering portions 28B of the insulator 28. The pair of coil end portions 38 of the long coil 34 are arranged along both axial end faces of the stator core 26 via the coil end portions 38 of the two short coils 32 adjacent in the circumferential direction and the pair of axial end surface covering portions 28B of the insulator 28. That is, the pair of coil end portions 38 of the long coil 34 are arranged to overlap in the axial direction with the pair of coil end portions 38 of the two short coils 32 adjacent in the circumferential direction. More specifically, in the state shown in Fig. 12, the pair of coil end portions 38 of the W-phase long coil 34 are arranged to overlap in the axial direction with the circumferential one side portion of the pair of coil end portions 38 of the U-phase short coil 32 adjacent in the circumferential direction and the circumferential other side portion of the pair of coil end portions 38 of the V-phase short coil 32. As shown in FIGS. 10 and 12, the coil end portions 38 of the other short coils 32 and the coil end portions 38 of the other long coils 34 are also arranged along both axial end faces of the stator core 26 in a similar relationship.

[0041] (Actions and Effects of the Present Embodiment) Next, the operation and effects of this embodiment will be described.

[0042] 3, 6A, 7, 9, and 10, in the motor 10 of this embodiment, a rotating magnetic field is generated on the inner circumference of the stator 14 by switching the energization of the U-phase coil connection body 46U, the V-phase coil connection body 46V, and the W-phase coil connection body 46W that constitute a part of the stator 14. This causes the rotor 12 to rotate.

[0043] In the motor 10 of this embodiment, the number of long coils 34 and the number of short coils 32 in the coil connections 46U, 46V, 46W of each phase are set to be the same, so that the combined resistances of the coil connections 46U, 46V, 46W of each phase are the same. This makes it difficult for electrical imbalances to occur in the coil connections 46U, 46V, 46W of each phase. As a result, it is possible to suppress deterioration of the torque ripple of the motor 10.

[0044] Furthermore, in the motor 10 of this embodiment, the coil end portions 38 of the long coils 34 and the coil end portions 38 of the short coils 32 are configured to be bent at right angles radially outward relative to the opposing portions 36, and the coil end portions 38 of the long coils 34 and the coil end portions 38 of the short coils 32 are configured to be overlapped in the axial direction. This makes it possible to prevent the stator 14 from becoming large in size in the axial direction. As a result, it is possible to prevent the motor 10 from becoming large in size in the axial direction.

[0045] Furthermore, in the motor 10 of this embodiment, the cross-sectional shape of the winding 30 forming the coil 16 is a rectangle with the first direction (arrow A1 direction) as the longitudinal direction. In addition, the first direction of the winding 30 of the portion forming the opposing portion 36 of the short coil 32 and the opposing portion 36 of the long coil 34 is directed toward the magnet 18. This makes it possible to reduce the area of ​​the portion of the winding 30 facing the magnet 18 while ensuring the cross-sectional area of ​​the winding 30. This makes it possible to suppress an increase in the electrical resistance of the winding 30 while suppressing an increase in AC copper loss due to eddy currents generated in the opposing portion 36. In addition, in the motor 10 of this embodiment, the opposing portion 36 has a single-layer structure along the radially inner surface of the stator core 26. This makes it easier to form the shape of the opposing portion 36 as viewed from the axial direction into a curved shape corresponding to the radially inner surface of the stator core 26. This makes it possible to improve the space factor.

[0046] In the motor 10 of this embodiment, the pair of terminal portions 40 are disposed on one axial side in a state in which the number of laminations of the winding 30 in the coil end portion 38 on one axial side of the coil 16 is smaller than the number of laminations of the winding 30 in the coil end portion 38 on the other axial side. With this configuration, the length of the portion of the coil 16 around which the winding 30 is wound can be shortened. This makes it possible to suppress an increase in the electrical resistance of the coil 16.

[0047] (Structure for improving torque while suppressing increase in size) Next, a configuration for improving torque while suppressing an increase in the physical size, which is applied to the motor 10 of the first embodiment, will be described.

[0048] 8A, in this embodiment, the axial dimension of the stator core 26 is set to be smaller than the axial dimension of the magnet 18 of the rotor 12. In addition, in this embodiment, the entire stator core 26 is disposed radially opposite the magnet 18 of the rotor 12. Also, the entire inner surface covering portion 28A and the axial end surface covering portion 28B of the insulator 28 are disposed radially opposite the magnet 18 of the rotor 12. Note that a portion of the magnet 18 of the rotor 12 located on one axial side of the end face on one axial side of the stator core 26 and a portion located on the other axial side of the end face on the other axial side of the stator core 26 are referred to as overhang portions 18A.

[0049] 8B, the insulator 28 of the present embodiment is configured to include a soft magnetic portion 52 formed of a soft magnetic material in a base 50 formed of an insulating material. Note that the insulator 28 of the present embodiment is configured such that the entire insulator 28 includes the soft magnetic portion 52 in the base 50. As an example, in the present embodiment, a resin material is used as the base 50. Also, in the present embodiment, atomized powder of a metal having soft magnetism, such as iron, is used as the soft magnetic portion 52.

[0050] The average particle size of the soft magnetic portion 52 (atomized metal powder) is set to be ⅕ or less of the radial thickness dimension T1 of the inner surface covering portion 28A. As an example, when the radial thickness dimension T1 of the inner surface covering portion 28A is set to 0.5 mm, the average particle size of the soft magnetic portion 52 is set to 100 μm or less.

[0051] In addition, in a predetermined process when the insulator 28 is injection molded, the base 50 is molten. In the state where the base 50 is molten, the soft magnetic parts 52 are dispersed in a floating state in the molten base 50, so that the soft magnetic parts 52 do not adhere to each other. In addition, even after the base 50 is cooled and solidified, the soft magnetic parts 52 are maintained in a state where they do not adhere to each other. As a result, the insulation between the soft magnetic parts 52 is ensured by the base 50. In addition, the insulation between the soft magnetic parts 52 may be improved by subjecting the surface of the soft magnetic parts 52 to a chemical conversion treatment such as oxidation. In addition, the soft magnetic parts 52 may be covered with an insulating material different from that of the base 50 to improve the insulation between the soft magnetic parts 52.

[0052] As shown in Fig. 8A, in the insulator 28 of this embodiment, the inner diameter of the radially inner surface of the shaft end surface covering portion 28B on one axial side gradually increases toward the other axial side. Also, the inner diameter of the radially inner surface of the shaft end surface covering portion 28B on the other axial side gradually increases toward the one axial side. As a result, the radially inner surfaces of both shaft end surface covering portions 28B become curved surfaces 28E that are curved with respect to the surface on the stator core 26 side. As a result, it is possible to make the shape of the radially inner surfaces (curved surfaces 28E) of both shaft end surface covering portions 28B conform to the inner shape of the pair of curved portions 38A of the short coil 16 after the winding of the winding 30.

[0053] In the motor 10 of this embodiment to which the above-described configuration is applied, the insulator 28 is configured to include a soft magnetic portion 52 formed of a soft magnetic material in a base 50 formed of an insulating material. As a result, as shown in Fig. 13, the magnetic flux of the magnet 18 can be introduced into the stator core 26 via the soft magnetic portion 52 (see Fig. 8B) in the insulator 28, and the magnetic resistance between the magnet 18 and the stator core 26 can be reduced. As a result, the magnetic flux of the magnet 18 can be effectively utilized, and the torque of the motor 10 can be increased and the motor 10 can be made smaller. In Fig. 13, the magnetic flux of the magnet 18 is indicated by an arrow B.

[0054] Furthermore, in the motor 10 of this embodiment to which the configuration described above is applied, the magnetic flux of the overhang portion 18A of the magnet 18 can be introduced into the soft magnetic portion 52 in the axial end surface covering portion 28B of the insulator 28, thereby reducing the magnetic resistance between the overhang portion 18A of the magnet 18 and the stator core 26. As a result, the magnetic flux of the magnet 18 can be utilized more effectively, and the torque of the motor 10 can be further increased and the motor 10 can be made more compact.

[0055] Furthermore, in the motor 10 of this embodiment to which the above-described configuration is applied, heat from the coil 16 (windings 30) can be quickly transferred to the stator core 26 via the soft magnetic portion 52 in the insulator 28. This improves the heat dissipation performance of the coil 16 compared to a configuration in which the insulator 28 is made only of a resin material. As a result, the motor 10 can achieve even higher output.

[0056] In addition, in the motor 10 of this embodiment to which the above-described configuration is applied, the average particle size of the soft magnetic portion 52 (metal atomized powder) is set to be ⅕ or less of the radial thickness dimension T1 of the inner surface covering portion 28A. As a result, even in a configuration in which the radial thickness dimension T1 of the inner surface covering portion 28A is set to a dimension smaller than the axial thickness dimension T2 of the shaft end surface covering portion 28B as in this embodiment, the soft magnetic portion 52 can be uniformly dispersed in the inner surface covering portion 28A when the insulator 28 is molded.

[0057] (Motor 54 of the second embodiment) Next, a motor 54 according to a second embodiment of the present disclosure will be described with reference to Fig. 14. Note that members and parts of the motor 54 according to the second embodiment that correspond to those of the motor 10 according to the first embodiment will be denoted by the same reference characters used in the description of the motor 10 according to the first embodiment, and descriptions thereof may be omitted.

[0058] As shown in Fig. 14, the motor 54 of this embodiment is configured similarly to the motor 10 described above, except that it includes a first coil 56 with both axial ends bent, a second coil 58 with both axial coil end portions 38 not bent relative to a pair of opposing portions 36, and the insulator 28 is not divided into two parts in the axial direction. As a method for integrating the insulator that is not divided into two parts and the cylindrical core, a method of insert molding the insulator into the core placed in a mold, or a method of fitting a circumferentially divided core to the injection-molded insulator from the outer diameter side can be considered. In the motor 54 of this embodiment, the entire insulator 28 is configured to include the soft magnetic portion 52 in the base 50.

[0059] The coil end portion 38 of the first coil 56 includes a curved portion 38A in which a radially inner portion is bent radially outward and a radially outer portion is bent in a direction along the axial direction, and a coil end portion 38B extending in the axial direction from the curved portion 38A. The coil end portion 38B of the first coil 56 and the coil end portion 38 of the second coil 58 are disposed to overlap each other in the radial direction.

[0060] In the motor 54 of the present embodiment described above, the torque of the motor 54 can also be increased and the motor 54 can be made smaller.

[0061] (Motor 60 of the third embodiment) Next, a motor 60 according to a third embodiment of the present disclosure will be described with reference to Fig. 15A. Note that, in the motor 60 according to the third embodiment, members and parts corresponding to those of the motor 10 and the like already described will be denoted by the same reference numerals used in the description of the motor 10 and the like already described, and the description thereof may be omitted.

[0062] 15A, motor 60 of the present embodiment is configured similarly to motor 10 described above, except for the difference in the configuration of shaft end surface covering portion 28B of insulator 28. In motor 60 of the present embodiment as well, insulator 28 as a whole is configured to include soft magnetic portion 52 within base 50.

[0063] A gap 28F recessed toward the one axial side (opposite side to the stator core 26) is formed along the circumferential direction on the other axial side (stator core 26 side) of the shaft end surface covering portion 28B on the one axial side. Also, a gap 28F recessed toward the other axial side (opposite side to the stator core 26) is formed along the circumferential direction on the one axial side (stator core 26 side) of the shaft end surface covering portion 28B on the other axial side. As a result, both shaft end surface covering portions 28B are separated from the stator core 26 at the locations where the gaps 28F are formed. Also, both shaft end surface covering portions 28B contact the axial end faces of the stator core 26 at the radial inner edge portion 28G and the radial outer edge portion 28H, which are portions adjacent to the gaps 28F. The radially inner edge 28G and the radially outer edge 28H, which are adjacent to the gap 28F, function to determine the axial position of the insulator 28 relative to the stator core 26.

[0064] In the motor 60 of the present embodiment described above, both axial end surface covering portions 28B of the insulator 28 contact the axial end surface of the stator core 26 at the radially inner edge portion 28G and the radially outer edge portion 28H, which are adjacent to the gap portion 28F. This allows the magnetic flux introduced into the soft magnetic portion 52 in the axial end surface covering portion 28B of the insulator 28 to be introduced to the stator core 26 side mainly from the radially inner edge portion 28G, which is adjacent to the gap portion 28F. As a result, the area of ​​the magnetic flux inflow (outflow) portion from the axial end surface covering portion 28B of the insulator 28 to the stator core 26 is smaller than that of the configuration using the insulator 28 in which the gap portion 28F is not formed, as in the motor 10 described above. Therefore, the iron loss (mainly eddy current loss) generated in the stator core 26 can be suppressed.

[0065] The configuration of the gap 28F is not limited to the above example. For example, in the configuration shown in Fig. 15A, only one of the radially inner edge 28G and the radially outer edge 28H, which are adjacent to the gap 28F of the two shaft end surface covering parts 28B, may be in contact with the axial end surface of the stator core 26.

[0066] 15B, a protruding portion 28S is provided that protrudes from a radial center of the two shaft end face covering portions 28B toward the axial end faces of the stator core 26 and is formed in an annular shape when viewed in the axial direction. Both radial sides of the protruding portion 28S form gaps 28F. The protruding portion 28S, which is a portion adjacent to the gaps 28F, is adapted to come into contact with the axial end faces of the stator core 26.

[0067] 15C, multiple protrusions 28S formed in a circular shape when viewed from the axial direction are arranged at intervals along the circumferential direction. Also, gaps 28F are formed around the multiple protrusions 28S. The multiple protrusions 28S adjacent to gaps 28F are in contact with the end face of the stator core 26 in the axial direction.

[0068] 15D, a plurality of protrusions 28S extending radially as viewed from the axial direction are arranged at intervals along the circumferential direction. The plurality of protrusions 28S are surrounded by gaps 28F. The plurality of protrusions 28S, which are adjacent to gaps 28F, are in contact with the end face of the stator core 26 in the axial direction.

[0069] (Motor 62 of the fourth embodiment) Next, a motor 62 according to a fourth embodiment of the present disclosure will be described with reference to Fig. 16. Note that members and parts of the motor 62 according to the fourth embodiment that correspond to those of the motor 10 and the like already described will be denoted by the same reference numerals used in the description of the motor 10 and the like already described, and the description thereof may be omitted.

[0070] As shown in FIG. 16, the stator core 26 of the motor 62 of this embodiment is composed of a smaller number of core constituent plates 27 than the stator core 26 of the motor 10 described above. In the motor 62 of this embodiment as well, the entire insulator 28 is configured to include the soft magnetic portion 52 in the base 50. In addition, in the insulator 28 of the motor 62 of this embodiment, the axial thickness dimension T2 of the both shaft end surface covering portions 28B is set to a dimension larger than the axial thickness dimension T2 of the both shaft end surface covering portions 28B of the insulator 28 of the motor 10 described above. Note that the axial dimension H3 from the surface on one axial side of the shaft end surface covering portion 28B on one axial side to the surface on the other axial side of the shaft end surface covering portion 28B on the other axial side is set to the same dimension as that of the motor 10 described above.

[0071] In the motor 62 of the present embodiment described above, it is possible to reduce the number of core constituent plates 27 formed using steel plates in the stator core 26 of the motor 10 described above. This makes it possible to reduce the weight of the motor 62 compared to the motor 10 described above.

[0072] (Motor 64 of the fifth embodiment) Next, a motor 64 according to a fifth embodiment of the present disclosure will be described with reference to Fig. 17. Note that, in the motor 64 according to the fifth embodiment, members and parts corresponding to those of the motor 10 etc. already described will be denoted by the same reference numerals as those used in the description of the motor 10 etc. already described, and the description thereof may be omitted.

[0073] As shown in FIG. 17, the motor 64 of this embodiment is configured in the same manner as the motor 10 described above, except that the stator core 26 is formed by an insulator 28 including a soft magnetic portion 52 in a base body 50.

[0074] In the motor 64 of the present embodiment described above, the insulator 28 including the soft magnetic portion 52 in the base 50 constitutes the stator core 26, which makes it possible to reduce the number of parts constituting the motor 64. In addition, since the stator core 26 is constituted by a member including the soft magnetic portion 52 in the base 50, the weight of the motor 64 can be reduced as compared to the motor 10 described above.

[0075] (Motor 66 of the sixth embodiment) Next, a motor 66 according to a sixth embodiment of the present disclosure will be described with reference to Fig. 18. Note that, in the motor 66 according to the sixth embodiment, members and parts corresponding to those of the motor 10 etc. already described will be denoted by the same reference numerals as those used in the description of the motor 10 etc. already described, and the description thereof may be omitted.

[0076] As shown in FIG. 18, the motor 66 of this embodiment includes an insulator 28 that does not include an inner surface covering portion 28A (see FIG. 8A), and a film insulator 29 is used in a portion corresponding to the inner surface covering portion 28A. In the motor 66 of this embodiment, the entire insulator 28 also includes a soft magnetic portion 52 in a base 50. The film insulator 29 is formed in a strip shape with a thickness dimension set to a dimension thinner than the radial thickness dimension T1 of the inner surface covering portion 28A described above. The film insulator 28 is disposed along the radial inner surface of the stator core 26. As the film insulator 29, a thin sheet-like insulator such as insulating paper or polyimide film is preferably used.

[0077] In the motor 66 of the present embodiment described above, the radially inner surface of the stator core 26 and the magnet 18 of the rotor 12 can be disposed closer to each other by the difference between the thickness of the film insulator 29 and the thickness of the inner covering portion 28A, compared to the above-described motor 10. This makes it possible to reduce the magnetic gap between the stator core 26 and the magnet 18, thereby enabling the motor 66 to have a higher torque and be more compact.

[0078] (Motor 68 of the seventh embodiment) Next, a motor 68 according to a seventh embodiment of the present disclosure will be described with reference to Fig. 19. Note that, in the motor 68 according to the seventh embodiment, members and parts corresponding to those of the motor 10 etc. already described will be denoted by the same reference numerals used in the description of the motor 10 etc. already described, and the description thereof may be omitted.

[0079] 19, the motor 68 of this embodiment is configured similarly to the motor 10, except that it includes a stator core 26 formed by compressing magnetic particles 98, the axial thickness dimension T2 of the axial end surface covering portion 28B of the insulator 28 is set to a smaller dimension than that of the motor 10, and the insulator 28 is not divided into two in the axial direction. In the motor 68 of this embodiment, the entire insulator 28 is also configured to include a soft magnetic portion 52 within the base 50. The stator core 26 is a dust core formed by compressing magnetic particles 98 having an insulating coating 98A on the surface.

[0080] In the motor 68 of the present embodiment described above, the torque of the motor 68 can also be increased and the motor can be made smaller.

[0081] (Motor 70 of eighth embodiment) Next, a motor 70 according to an eighth embodiment of the present disclosure will be described with reference to Fig. 20. Note that members and parts of the motor 70 according to the eighth embodiment that correspond to those of the motor 10 and the like already described will be denoted by the same reference numerals used in the description of the motor 10 and the like already described, and the description thereof may be omitted.

[0082] As shown in FIG. 20, the motor 70 of this embodiment is configured similarly to the motor 10, except that a part of the stator core 26 is an integrally molded part 71 formed by integral molding using a soft magnetic material or a material containing a soft magnetic material, the axial thickness dimension T2 of the axial end surface covering part 28B of the insulator 28 is set to a smaller dimension than that of the motor 10, and the insulator 28 is not divided into two parts in the axial direction. In the motor 70 of this embodiment, the entire insulator 28 is configured to include a soft magnetic part 52 in the base 50. In this embodiment, the end part on one axial side and the end part on the other axial side of the stator core 26 are the integrally molded part 71. Here, the integrally molded part 71 can be formed by casting, forging, or cutting an iron-based steel material, or by compression molding and sintering an iron-based powder. The integrally molded part 71 can also be formed by injection molding or compression molding a resin containing an iron-based powder. Moreover, it can also be formed by molding using the powder magnetic core shown in the motor 68 of the seventh embodiment. Moreover, instead of integral molding, it may be formed by stacking steel plates having an inner diameter different from that of the stator core 26 in the motor 10 described above.

[0083] In the motor 70 of the present embodiment described above, the torque of the motor 70 can also be increased and the motor 70 can be made smaller.

[0084] (Motor 72 of 9th embodiment) Next, a motor 72 according to a ninth embodiment of the present disclosure will be described with reference to Fig. 21. Note that, in the motor 72 according to the ninth embodiment, members and parts corresponding to those of the motor 10 etc. already described will be denoted by the same reference numerals as those used in the description of the motor 10 etc. already described, and the description thereof may be omitted.

[0085] As shown in FIG. 21, a motor 72 of the present embodiment is configured similarly to the motor 10 described above, except that the motor 72 includes an insulator 28 having a plurality of protruding intervening portions 28J.

[0086] The multiple protruding intermediate portions 28J protrude from the inner surface covering portion 28A radially inward (toward the multiple coils 16) and are arranged at equal intervals along the circumferential direction. The multiple protruding intermediate portions 28J are respectively arranged between the opposing portions 36 of one coil 16 and the opposing portions 36 of the other coil 16 that are adjacent to each other in the circumferential direction. The multiple protruding intermediate portions 28J are configured such that a soft magnetic portion 52 is included in the base 50, similar to the inner surface covering portion 28A, etc.

[0087] In the motor 72 of the present embodiment described above, compared to the above-described motor 10, the multiple protruding intermediate portions 28J that are part of the insulator 28 can be brought closer to the magnet 18. This makes it possible to reduce the magnetic gap between the insulator 28 and the magnet 18, thereby enabling the motor 72 to have a higher torque and be made more compact.

[0088] (Motor 74 of the 10th embodiment) Next, a motor 74 according to a tenth embodiment of the present disclosure will be described with reference to Figures 22, 23, and 24. Note that the members and parts of the motor 74 according to the tenth embodiment that correspond to the motor 10 and the like already described will be given the same reference numerals used in the description of the motor 10 and the like already described, and the description thereof may be omitted. Note that in Figure 23, hatching of the cross section is omitted.

[0089] As shown in Figs. 22 and 23, in a motor 74 of this embodiment, a plurality of coils 16, each of which has both axial coil end portions 38 not bent relative to a pair of opposing portions 36, are arranged along the radially inner surface of a stator core 26. Note that insulators 28 are not shown in Fig. 22. The plurality of coils 16 are arranged adjacent to each other in the circumferential direction. Note that, unlike the motor 10 described above, the motor 74 of this embodiment is configured such that the opposing portion 36 of one coil 16 is not arranged between a pair of opposing portions 36 of another coil 16. In other words, the opposing portion 36 on one circumferential side of one coil 16 and the opposing portion 36 on the other circumferential side of the other coil 16 are arranged adjacent to each other in the circumferential direction.

[0090] As shown in FIG. 23 and FIG. 24, the insulator 28 includes a plurality of bobbin portions 28K that protrude radially inward from the axial center of the inner covering portion 28A. The plurality of bobbin portions 28K are arranged at equal intervals along the circumferential direction. The number of the plurality of bobbin portions 28K is equal to the number of the plurality of coils 16. The winding 30 is wound around the plurality of bobbin portions 28K, so that the plurality of coils 16 are formed around the plurality of bobbin portions 28K. This results in a configuration in which the plurality of bobbin portions 28K are inserted into the space inside the plurality of coils 16. The plurality of bobbin portions 28K are configured to include a soft magnetic portion 52 in the base body 50, similar to the inner covering portion 28A and the like.

[0091] In the motor 74 of the present embodiment described above, the multiple bobbin portions 28K that are part of the insulator 28 can be brought closer to the magnet 18, compared to the previously described motor 10. This makes it possible to reduce the magnetic gap between the insulator 28 and the magnet 18, thereby enabling the motor 74 to have a higher torque and be made smaller.

[0092] (Motor 76 of eleventh embodiment) Next, a motor 76 according to an eleventh embodiment of the present disclosure will be described with reference to Figs. 25, 26, and 27. Note that the members and parts of the motor 76 according to the eleventh embodiment that correspond to the motor 10 and the like already described will be given the same reference numerals used in the description of the motor 10 and the like already described, and the description thereof may be omitted. Note that in Fig. 25, hatching of the cross section is omitted.

[0093] As shown in Figs. 25, 26 and 27, the motor 76 of this embodiment is configured similarly to the motor 74 of the above-mentioned tenth embodiment, except that the motor 76 of this embodiment includes a plurality of insulators 28 corresponding to the number of the coils 16. As shown in Figs. 26 and 27, the insulator 28 includes an inner surface covering portion 28A whose axial dimension is set to be larger than the axial dimension of the stator core 26, and an inner extension portion 28L disposed radially inside the inner surface covering portion 28A and extending parallel to the inner surface covering portion 28A. The insulator 28 also includes a bobbin portion 28K that radially connects the axial and circumferential central portion of the inner surface covering portion 28A to the axial and circumferential central portion of the inner extension portion 28L. The winding 30 is wound around each of the bobbin portions 28K of the insulators 28, so that the coils 16 are formed around each of the bobbin portions 28K of the insulators 28. Further, the multiple insulators 28 are configured so that the soft magnetic portion 52 is included within the base 50 as a whole.

[0094] In the motor 76 of the present embodiment described above, the multiple inner extensions 28L, which are part of the insulator 28, can be brought closer to the magnet 18 than in the motor 10 described above. This allows the magnetic gap between the insulator 28 and the magnet 18 to be reduced, and the motor 76 can be made even more compact and have a higher torque. The axial positions of the coil 16 and the insulator 28 relative to the stator core can be determined by providing the convex portion 28T or step indicated by the two-dot chain line on the outer diameter side of the inner covering portion 28A. Here, the convex portion 28T may be formed over the entire circumferential direction of the outer diameter side of the inner covering portion 28A, or may be formed on a part of the circumferential direction. Although an example has been shown in which the inner covering portion 28A and the inner extensions 28L are integrally formed via the bobbin portion 28K, each of them or a part of them may be divided and integrated after the coil 16 is arranged.

[0095] (Motor 78 of 12th embodiment) Next, a motor 78 according to a twelfth embodiment of the present disclosure will be described with reference to Figures 28 and 29. Note that members and parts of the motor 78 according to the twelfth embodiment that correspond to those of the motor 10, etc., already described, are given the same reference numerals as those used in the description of the motor 10, etc., already described, and the description thereof may be omitted.

[0096] As shown in Figs. 28 and 29, in the motor 78 of this embodiment, the coil 16 is formed around the teeth 26A which are part of the stator core 26. The insulator 28 includes an axial end surface covering portion 28B arranged along both axial end surfaces of the teeth 26A, and a peripheral end surface covering portion 28M arranged along both circumferential end surfaces of the teeth 26A. The winding 30 forming the coil 16 is wound around the axial end surface covering portion 28B and the peripheral end surface covering portion 28M. Here, in this embodiment, the surfaces of the axial end surface covering portion 28B and the peripheral end surface covering portion 28M on the coil 16 side are curved surfaces 28N and 28P which are curved with respect to the surfaces on the stator core 26 side. The curved surfaces 28N and 28P are convex toward the opposite side to the stator core 26. This makes it possible to make the shapes of the outer circumferential surfaces (curved surfaces 28N, 28P) of axial end surface covering portion 28B and circumferential end surface covering portion 28M conform to the inner shape of coil 16 after winding of windings 30. Insulator 28 includes inner positioning portion 28Q and outer positioning portion 28R that position coil 16 in the radial direction. Insulator 28 is configured so that the soft magnetic portion 52 is included within base 50 as a whole.

[0097] In the motor 78 of the present embodiment described above, the torque of the motor 78 can be further increased and the motor can be made smaller.

[0098] In the above-described example, the insulator 28 is entirely configured to include the soft magnetic portion 52 in the base 50, but the present invention is not limited thereto. For example, as shown in Figs. 30 and 31, a part of the insulator 28 may be configured to include the soft magnetic portion 52 in the base 50. In a motor 80 according to a thirteenth embodiment shown in Fig. 30, only the inner surface covering portion 28A is configured to include the soft magnetic portion 52 in the base 50. In a motor 82 according to a fourteenth embodiment shown in Fig. 31, only the shaft end surface covering portion 28B is configured to include the soft magnetic portion 52 in the base 50. In the motor 80 according to the thirteenth embodiment shown in Fig. 30 and the motor 82 according to the fourteenth embodiment shown in Fig. 31, the same reference numerals as those of the motor 10 and the like are used to designate the members and parts corresponding to those of the motor 10 and the like.

[0099] In the above-described example, the stator 14 and the rotor 12 are disposed facing each other in the radial direction, but the present invention is not limited to this. For example, the stator 14 and the rotor 12 may be disposed facing each other in the axial direction as in a motor 84 of a fifteenth embodiment shown in Fig. 32. In the motor 84 of the fifteenth embodiment shown in Fig. 32, the same reference numerals are used for the members and parts corresponding to the above-described motor 10, etc.

[0100] In addition, in each of the above-described embodiments, the configuration has been described in which the side on which the magnet 18 is provided is the rotor 12 (rotor) and the side on which the coil 16 is provided is the stator 14 (stator), but the configuration of the present disclosure can also be applied to a configuration in which the side on which the coil 16 is provided is the rotor 12 (rotor and armature) and the side on which the magnet 18 is provided is the stator 14 (stator). Needless to say, the configuration of the present disclosure can also be applied to a generator in which the rotor is rotated by an external force.

[0101] Also, the coil 16 may be configured using the winding 30 configured as shown in Figs. 33 to 35. In the example shown in Fig. 33, the winding 30 forming the coil 16 is configured by two winding configurations 88 overlapped in the second direction (arrow A2 direction). In the example shown in Fig. 34, the winding 30 forming the coil 16 is configured by two winding configurations 88 overlapped in the first direction (arrow A1 direction). Furthermore, in the example shown in Fig. 35, the winding 30 forming the coil 16 is configured by four winding configurations 88 overlapped in the first and second directions.

[0102] Although one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above, and it goes without saying that the present disclosure can be implemented in various other modified forms without departing from the spirit and scope of the present disclosure. In addition, the configurations of the present disclosure described above can be combined with each other. [Explanation of symbols]

[0103] 10 motor, 12 rotor (rotor), 14 stator (stator, armature), 16 coil, 18 magnet, 26 stator core (armature core), 36 opposing portion, 28 insulator, 28A inner surface coating portion (portion between opposing portions), 28J protruding portion, 28B shaft end surface coating portion (portion between coil end portions), 28F recess, 28G periphery of recess, 28H periphery of recess, 28E curved surface, 28N curved surface, 28P curved surface, 28K bobbin portion, 38 coil end portion, 50 base, 52 soft magnetic portion, 54 motor, 60 motor 62 motor, 64 motor, 66 motor, 68 motor, 70 motor, 72 motor, 74 motor, 76 motor, 78 motor, 80 motor, 84 motor, 80 motor

Claims

1. an armature core (26) formed in an annular shape; a plurality of coils (16) each formed by winding a conductive winding, each having a pair of opposing portions (36) forming an axial or radial central portion and arranged at a distance from each other in the circumferential direction, and a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction, the coils being arranged along the armature core; an insulator (28) provided between the armature core and the plurality of coils, the insulator including a soft magnetic portion (52) formed of a soft magnetic material in a base (50) formed of an insulating material; Equipped with the insulator is configured to include a facing portion interposed portion (28A) disposed between the facing portion and the armature core, the insulator includes the soft magnetic portion at least in the interposed portion between the opposing portions, the insulator is configured to include a protruding intervening portion (28J) that protrudes from the intervening portion toward the coils and is disposed between the opposing portion of one of the coils and the opposing portion of the other of the coils that are adjacent to each other in the circumferential direction, The armature (14) includes the soft magnetic portion in the protruding interposition portion.

2. An armature core (26) formed in an annular shape; a plurality of coils (16) each formed by winding a conductive winding, each having a pair of opposing portions (36) forming an axial or radial central portion and arranged at a distance from each other in the circumferential direction, and a pair of coil end portions (38) connecting the pair of opposing portions in the circumferential direction, the coils being arranged along the armature core; an insulator (28) provided between the armature core and the plurality of coils, the insulator including a soft magnetic portion (52) formed of a soft magnetic material in a base (50) formed of an insulating material; Equipped with the insulator is configured to include a coil end portion interposition portion (28B) disposed between the coil end portion and the armature core, the soft magnetic portion is included in at least the coil end portion interposed portion of the insulator, a gap (28F) is formed on the armature core side of the coil end portion interposed portion and spaced apart from the armature core, An armature in which at least a portion (28G, 28H) adjacent to the gap in the coil end portion interposed portion is in contact with the armature core.

3. a curved surface (28E, 28N, 28P) curved relative to the surface of the armature core side of the insulator is formed on the surface of the insulator facing the coil, 3. The armature according to claim 1, wherein the coil is disposed along the curved surface.

4. The insulator includes a bobbin portion (28K) around which the coil is formed, The armature according to any one of claims 1 to 3, wherein the bobbin portion includes the soft magnetic portion.

5. One of a stator (14) and a rotor (12) configured to include the armature according to any one of claims 1 to 4; the other of the stator and the rotor having a magnet (18) arranged to face the opposing portions of the plurality of coils in the radial or axial direction; A motor (10, 54, 60 to 84) equipped with the motor.

Images