How to assemble the motor and interphase insulation paper

Abstract

This inter-phase insulating paper is composed of a plurality of insulating papers arranged so as to circle a stator core 2 in the circumferential direction, such that the plurality of insulating papers 1 insulate coils of different phases provided to the stator core 2 from each other. Each insulating paper 1 includes a pair of leg sections 11 for inserting into a pair of slots 21 among a plurality of slots 21 formed in the stator core 2, and a pair of flat sections 12 that are connected to the pair of leg sections 11 and protrude from both end surfaces of the stator core 2 in the axial direction so as to insulate the coils of different phases from each other. The pair of leg sections 11 are connected to central portions of the edges of the flat sections 12.

Description

[Technical field]

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

[0002] JP2007-60819A 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. Summary of the Invention

[0003] However, in JP2007-60819A, 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.

[0004] 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 equipped with the interphase insulating paper, and an assembly method for the interphase insulating paper.

[0005] According to one aspect of the present invention, there is provided an interphase insulating paper that is made of a plurality of insulating papers arranged around a stator core in a circumferential direction, and that provides interphase insulation for each phase coil provided in the stator core using the plurality of insulating papers. The insulating paper includes a pair of legs that are inserted into a pair of slots among a plurality of slots formed in the stator core, and a pair of flat portions that are connected to the pair of legs and protrude from both axial end faces of the stator core to provide interphase insulation for each phase coil, and the pair of legs are connected to the center portions of the edges of the flat portions. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic diagram of an insulating paper constituting the interphase insulating paper of this embodiment. [Diagram 2] FIG. 2 is a diagram showing the insulating paper of this embodiment attached to a stator core, developed in the circumferential direction of the stator core. [Diagram 3] Figure 3 is a diagram explaining the insulating paper that makes up the interphase insulating paper of the comparative example, where Figure 3(a) is a plan view of the insulating paper of the comparative example, Figure 3(b) is a diagram showing the case where the insulating paper of the comparative example pops out of the slot by itself when inserting the insulating paper of the comparative example into a stator core, and Figure 3(c) is a diagram showing the case where the insulating paper inserted later pops out of the slot due to force from the insulating paper inserted earlier when inserting the insulating paper of the comparative example into a stator core. [Figure 4] FIG. 4 is a diagram (copy) showing a state in which insulating paper of a comparative example is attached. [Diagram 5] Figure 5 is a diagram showing the assembly process of the interphase insulating paper in this embodiment, where Figure 5(a) shows the state after the U-phase coil and the outer peripheral insulating paper have been attached, and Figure 5(b) is a diagram showing the flat portion of the outer peripheral insulating paper as viewed from the axial direction. [Figure 6] Figure 6 is a diagram showing the assembly process of the interphase insulating paper of this embodiment, where Figure 6(a) shows the state in which the V-phase coil is installed in the slot into which the leg of the outer insulating paper is inserted and the leg of the inner insulating paper is inserted into the slot into which the W-phase coil is installed, and Figure 6(b) is a diagram showing the flat portion of the inner insulating paper as viewed from the axial direction. [Figure 7] FIG. 7 is a diagram showing an assembly process of the interphase insulating paper of this embodiment, illustrating a state in which the W-phase coil is mounted in the slot into which the leg portion of the insulating paper on the inner periphery side has been inserted. [Figure 8] FIG. 8 is a diagram (copy) showing the process of assembling the interphase insulating paper of this embodiment, showing the state after the insulating paper on the inner periphery side has been inserted into the slot. [Figure 9] Figure 9 is a diagram (copy) showing the assembly process of the interphase insulating paper in this embodiment, in which the V-phase coil is inserted into the slot and then the outer insulating paper and the V-phase coil are folded toward the outer periphery of the stator core. Figure 9(a) shows the case where there is no arc portion on the flat surface, while Figure 9(b) shows the case where there is an arc portion on the flat surface. [Figure 10]FIG. 10 is a diagram (copy) showing the assembly process of the interphase insulating paper of this embodiment, where FIG. 10(a) shows the state before the insulating paper and each phase coil are bundled with wire, and FIG. 10(b) shows the state after bundling. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0008] [Basic composition of insulating paper 1 that makes up the interphase insulating paper] 1 is a schematic diagram of insulating paper 1 constituting the interphase insulating paper of this embodiment. The interphase insulating paper of this embodiment is composed of multiple pieces of insulating paper 1 attached to slots 21 of a stator core 2 of a motor (not shown) so as to go around the circumferential direction of the stator core 2. The interphase insulating paper provides interphase insulation between each phase coil (U-phase coil U, V-phase coil V, W-phase coil W) attached to the stator core 2.

[0009] 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.

[0010] The insulating paper 1 of this embodiment has a shape in which two rectangular flat sections 12 are connected by two leg sections 11, and has a planar shape without any irregularities before being attached to the stator core 2. The insulating paper 1 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.

[0011] The leg portion 11 is connected to the edge of the flat portion 12 and to the center of the flat portion 12 in the longitudinal direction (circumferential direction of the stator core 2). The leg portion 11 is a portion whose longitudinal dimension is approximately the same as the axial length of the stator core 2 (slots 21) and whose width dimension is, for example, equal to or smaller than the circumferential width at the position of the inner wall of the outermost periphery of the slots 21. The leg portion 11 is inserted from the groove of the slot 21.

[0012] Between the legs 11 there are elongated holes 13. The elongated holes 13 are rectangular openings having a width dimension equal to or greater than the circumferential width of the teeth 22 between the slots 21. The teeth 22 are inserted into the elongated holes 13 when the legs 11 are inserted into the slots 21.

[0013] The flat portions 12 are substantially rectangular members, and are formed so as to protrude from both axial ends of the stator core 2 when the leg portions 11 are inserted into the slots 21. The longitudinal direction of the flat portions 12 is perpendicular to the longitudinal direction of the leg portions 11, and the flat portions 12 are disposed along the circumferential direction of the stator core 2 when the leg portions 11 are inserted into the slots 21. The flat portions 12 are disposed so as to insulate the coil ends (portions protruding from the slots 21) of the coils of each phase from each other.

[0014] The arc portion 15 is a cutout formed on the edge of the flat portion 12 facing the stator core 2. The arc portion 15 is formed in an arc shape following the shape of the portion protruding from the slot 21 of each phase coil.

[0015] The notch 14 (cutout) is disposed in a portion of the flat portion 12 that forms the short side of the slot portion 13. The notch 14 is used to position the wire 4 and to guide the flat portion 12 in cutting, which will be described later.

[0016] Fig. 2 is a diagram showing the insulating paper 1 of this embodiment attached to the stator core 2, developed in the circumferential direction of the stator core 2. Fig. 2 shows only one side in the axial direction of the stator core 2, but the positional relationship between the coils of each phase and the insulating paper 1 is the same on the lead side (the side that exchanges current with the outside) and the anti-lead side.

[0017] A plurality of coils of the same phase are attached to the stator core 2 in a state of being lined up in the circumferential direction (see FIG. 7). Correspondingly, as shown in FIG. 2, the insulating papers 1 are attached in a state of being lined up in the circumferential direction of the stator core 2 in the same number as the number of coils of the same phase (8 pieces, see FIG. 7). The insulating papers 1 are also arranged so that the flat portions 12 of adjacent insulating papers 1 in the circumferential direction overlap each other in the circumferential direction.

[0018] Therefore, as shown in Figure 2, if the circumferential length of the flat portion 12 is A and the circumferential misalignment of adjacent insulating papers 1, i.e., the circumferential spacing between a pair of teeth 22 each inserted into the long hole portions 13 of adjacent insulating papers 1, is B, then the relationship A>B holds.

[0019] As shown in FIG. 2, the stator core 2 includes a U-phase coil U (first phase coil), a V-phase coil V (second phase coil), a W-phase coil W (third phase coil), 3 The U-phase coil U, the V-phase coil V, and the W-phase coil W have the same circumferential width, and have a width equivalent to six slots 21 (a width spanning five teeth 22), for example.

[0020] The V-phase coil V is disposed at a position displaced, for example, by two slots 21 in one circumferential direction (left side in Figure 2) from the U-phase coil U, and the W-phase coil W is disposed at a position displaced, for example, by four slots 21 in one circumferential direction (left side in Figure 2) from the U-phase coil U.

[0021] 2, the insulating paper 1 is arranged so that the teeth 22 sandwiched between a pair of V-phase coils V (or other phases) adjacent to each other in the circumferential direction are inserted into the long hole 13. The insulating paper 1 is also arranged so that the teeth 22 sandwiched between a pair of W-phase coils W (or other phases) adjacent to each other in the circumferential direction are inserted into the long hole 13, as described later.

[0022] 1 and 2, the insulating paper 1 has a bilaterally symmetrical shape with the legs 11 connected to the longitudinal center of the flat portion 12. However, the legs 11 may be connected to a position displaced to one side in the longitudinal direction from the longitudinal center of the flat portion 12, giving the insulating paper 1 an asymmetrical shape.

[0023] Furthermore, in the insulating paper 1, the pair of legs 11 are arranged to sandwich one tooth 22 therebetween, but the insulating paper 1 may be configured such that the legs 11 are connected to the flat portion 12 so as to straddle two or more teeth 22.

[0024] Furthermore, the circumferential length of the flat portion 12 of the insulating paper 1 may be set so that the flat portions 12 of a pair of adjacent insulating papers 1 overlap each other in the circumferential direction when multiple pieces are mounted around the stator core 2, regardless of the number of coils for each phase.

[0025] [Interphase insulation paper of comparative example] Fig. 3 is a diagram for explaining the insulating paper 1X that constitutes the interphase insulating paper of the comparative example, Fig. 3(a) is a plan view of the insulating paper 1X of the comparative example, Fig. 3(b) is a diagram showing a case where the insulating paper 1X of the comparative example jumps out of the slot 21 by itself when the insulating paper 1X of the comparative example is inserted into the stator core 2, and Fig. 3(c) is a diagram showing a case where the insulating paper 1X inserted later when the insulating paper 1X of the comparative example is inserted into the stator core 2 jumps out of the slot 21 due to the force from the insulating paper 1X inserted earlier. Fig. 4 is a diagram (copy) showing the installation mode of the insulating paper 1X of the comparative example.

[0026] The coils of each phase are not shown in Fig. 3(b) and Fig. 3(c). Fig. 4 shows a case where insulating paper 1X of the comparative example is attached after V-phase coil V is attached.

[0027] 3(a), similar to the insulating paper 1 of this embodiment, the insulating paper 1X of the comparative example is attached in multiple slots 21 around the circumferential direction of the stator core 2 to form an interphase insulating paper. The insulating paper 1X also has a flat portion 12 and leg portions 16, and the leg portions 16 are disposed at both ends of the flat portion 12 in the longitudinal direction (circumferential direction).

[0028] The insulating paper 1X of the comparative example is similar to the insulating paper disclosed in the above-mentioned JP2007-60819A. Similar to the insulating paper 1 of the present embodiment, the insulating paper 1X of the comparative example is attached to the stator core 2 in a state where a plurality of sheets (eight sheets) are arranged in the circumferential direction of the stator core 2 (see FIG. 4). X are mounted in such a manner that they overlap each other in the circumferential direction by one slot 21 (see FIG. 3(c)).

[0029] The procedure for mounting each phase coil and insulating paper 1X to the stator core 2 is, for example, to mount a plurality of U-phase coils U (coils of other phases may be started) around the stator core 2 in the circumferential direction, and mount a plurality of insulating papers 1X around the stator core 2 in the circumferential direction. Next, the U-phase coils U (coil end) and the flat portion 12 of the insulating paper 1X are folded toward the outer periphery of the stator core 2, and then a plurality of V-phase coils V are mounted around the stator core 2 in the circumferential direction, and a plurality of insulating papers 1X are mounted around the stator core 2 in the circumferential direction. Then, the V-phase coils V (coil end) and the flat portion 12 of the insulating paper 1X attached later are folded toward the outer periphery of the stator core 2, and then a plurality of W-phase coils W are mounted around the stator core 2 in the circumferential direction (see FIGS. 5 to 7).

[0030] The insulating paper 1X of the comparative example is flat in the initial state, but the coil ends after molding have a complex indented shape, so that when the insulating paper 1X is fitted into the slots 21, the entire insulating paper 1X interferes with the coil ends and cannot stay in the circumferential direction of the stator core 2, but can move toward the inner diameter of the stator core 2 (see Fig. 3(b) and Fig. 4). As a result, the legs 16 of the insulating paper 1X protrude from the grooves of the slots 21 of the stator core 2, causing a problem that the next phase coil cannot be inserted (see the enlarged view at the top of Fig. 4).

[0031] The insulating paper 1X of the comparative example is deformed into an arc or S-shape when inserted into the stator core 2, so that the legs 16 of the insulating paper 1X are twisted and may face in a direction that makes it easy for the legs 16 to jump out of the grooves of the slots 21. At this time, the insulating paper 1X inserted later is pushed by the insulating paper 1X inserted earlier, so that the legs 16 may jump out of the grooves of the slots 21 (see FIG. 3(c) and FIG. 4 (See enlarged image below)

[0032] In addition, for the reasons mentioned above, once the insulating paper 1X has been attached, it may protrude toward the inner diameter side of the stator core 2 before the coils are inserted in the next process, causing the insulating paper 1X to come out from between the coils or to become misaligned.

[0033] As described above, in order to prevent the insulating paper 1X from protruding toward the inner diameter side, it is necessary to hold the insulating paper 1X with a jig or tape, which poses the problem of requiring extra tooling costs and labor.

[0034] When the insulating paper 1X is assembled to the stator core 2, the insulating paper 1X is inserted between the first phase coil (U-phase coil U) and the second phase coil (V-phase coil V), and between the second phase coil (V-phase coil V) and the third phase coil (W-phase coil W), and is deformed into a three-dimensional shape at each insertion position.

[0035] Therefore, in order to reduce the protrusion of the insulating paper 1X toward the inner diameter side, it is possible to form a three-dimensional shape by previously providing folds in the insulating paper 1X corresponding to the insertion position of the stator core 2. However, since the three-dimensional shape of the insulating paper 1X between the first phase coil (U-phase coil U) and the second phase coil (V-phase coil V) and the three-dimensional shape of the insulating paper 1X between the second phase coil (V-phase coil V) and the third phase coil (W-phase coil W) are different from each other, it is necessary to form at least two types of three-dimensional shapes in advance. This makes the assembly process complicated and requires tools for forming the three-dimensional shapes, which increases costs.

[0036] However, in this embodiment, as described below, no jigs or the like are required, and it is possible to prevent the legs 11 from protruding and the insulating paper 1 from shifting in position, and it is possible to attach the insulating paper 1 to the slots 21 of the stator core 2 without previously forming a three-dimensional shape.

[0037] [Insulating paper 1 installation process] FIG. 5 is a diagram showing an assembly process of the interphase insulating paper of this embodiment, in which FIG. 5(a) shows a state in which the U-phase coil U and the outer insulating paper 1 are mounted, and FIG. 5(b) is a diagram showing the flat portion 12 of the outer insulating paper 1 as viewed from the axial direction. FIG. 6 is a diagram showing an assembly process of the interphase insulating paper of this embodiment, in which FIG. 6(a) shows a state in which the V-phase coil V is mounted in the slot 21 into which the leg portion 11 of the outer insulating paper 1 is inserted, and the leg portion 11 of the inner insulating paper 1 is inserted into the slot 21 into which the W-phase coil W is mounted, and FIG. 6(b) is a diagram showing the flat portion 12 of the inner insulating paper 1 as viewed from the axial direction. FIG. 7 is a diagram showing an assembly process of the interphase insulating paper of this embodiment, and is a diagram showing a state in which the W-phase coil W is mounted in the slot 21 into which the leg portion 11 of the inner insulating paper 1 is inserted. Note that in FIGS. 5 to 7, the coil ends of each phase coil are not shown.

[0038] 5, the stator core 2 to which the insulating paper 1 of this embodiment is applied has 48 slots 21 and teeth 22. Eight each of the U-phase coils U (U1 to U8), V-phase coils V (V1 to V8), and W-phase coils W (W1 to W8) are prepared and fitted into the slots 21.

[0039] As shown in FIG. 5(a), the U-phase coil U (U1 to U8) is mounted in the slot 21, and the legs 11 of the insulating paper 1 ((1) to (8)) (first interphase insulating paper) are inserted into the slot 21 in which the V-phase coil V is mounted.

[0040] At this time, the legs 11 of the insulating paper 1(1) are inserted into the slots 21(V1) and 21(V2). For ease of illustration, the legs 11 are shown in a position away from the slots 21(V1) and 21(V2), and the same applies below.

[0041] Similarly, the legs 11 of insulating paper 1 (2) are inserted into slots 21 (V2) and 21 (V3), the legs 11 of insulating paper 1 (3) are inserted into slots 21 (V3) and 21 (V4), and the legs 11 of insulating paper 1 (4) are inserted into slots 21 (V4) and 21 (V5).

[0042] Similarly, the legs 11 of insulating paper 1 (5) are inserted into slots 21 (V5) and 21 (V6), the legs 11 of insulating paper 1 (6) are inserted into slots 21 (V6) and 21 (V7), the legs 11 of insulating paper 1 (7) are inserted into slots 21 (V7) and 21 (V8), and the legs 11 of insulating paper 1 (8) are inserted into slots 21 (V8) and 21 (V1).

[0043] At this time, the legs 11 of the insulating paper 1 (1) to (8)) are placed on the inner wall side of the outermost circumference of the slot 21, and the portion of the flat portion 12 that overlaps with the U-phase coil U in the circumferential direction is folded toward the inner side of the stator core 2, and further folded so as to cover the inner side of the coil end of the U-phase coil U on one circumferential side of the flat portion 12 (the right side of the flat portion 12 in Figure 5(b)), thereby deforming the insulating paper 1 into the three-dimensional shape shown in Figure 5(b).

[0044] Then, in order to mount the next V-phase coil V, the coil ends of the U-phase coil U and flat portions 12 of insulating paper 1 ((1) to (8)) are folded toward the outer periphery of stator core 2 (see FIG. 9).

[0045] As shown in FIG. 6(a), the V-phase coil V (V1 to V8) is installed in the slot 21, and the leg portion 11 of the insulating paper 1 ((9) to (16)) (second interphase insulating paper) is inserted into the slot 21 in which the W-phase coil W is installed.

[0046] At this time, the legs 11 of the insulating paper 1 (9) are inserted into the slots 21 (W1) and 21 (W2), the legs 11 of the insulating paper 1 (10) are inserted into the slots 21 (W2) and 21 (W3), the legs 11 of the insulating paper 1 (11) are inserted into the slots 21 (W3) and 21 (W4), and the legs 11 of the insulating paper 1 (12) are inserted into the slots 21 (W4) and 21 (W5).

[0047] Similarly, the legs 11 of insulating paper 1 (13) are inserted into slots 21 (W5) and 21 (W6), the legs 11 of insulating paper 1 (14) are inserted into slots 21 (W6) and 21 (W7), the legs 11 of insulating paper 1 (15) are inserted into slots 21 (W7) and 21 (W8), and the legs 11 of insulating paper 1 (16) are inserted into slots 21 (W8) and 21 (W1).

[0048] At this time, the legs 11 of the insulating paper 1 (9) to (16)) are positioned on the inner wall side of the outermost circumference of the slot 21, and the parts of the flat portions 12 that overlap with the U-phase coil U and the V-phase coil V in the circumferential direction are folded toward the inner circumference of the stator core 2, and further folded so as to cover the inner circumference side of the coil end of the U-phase coil U and the inner circumference side of the coil end of the V-phase coil V, thereby deforming the insulating paper 1 into the three-dimensional shape shown in Figure 6(b).

[0049] Then, in order to install the next W-phase coil W, the coil ends of the V-phase coil V and the flat portions 12 of the insulating paper 1 ((9)-(16)) are folded toward the outer periphery of the stator core 2 (see FIG. 9). Then, as shown in FIG. 7, the W-phase coil W (W1-W8) is installed in the slots 21, completing the process of assembling the coils of each phase and the insulating paper 1 to the stator core 2.

[0050] Thereafter, the coil ends of the U-phase coil U are bundled with an insulating wire 4 (see FIG. 10), the coil ends of the V-phase coil V and the outer circumferential insulating paper 1 ((1)-(8)) are bundled with wire 4, and the coil ends of the W-phase coil W and the inner circumferential insulating paper 1 ((9)-(16)) are bundled with wire 4, and then varnish (not shown) is applied to each phase coil.

[0051] [Condition of insulating paper 1 during the assembly process] 8 is a diagram (copy) showing the assembly process of the interphase insulating paper of this embodiment, and shows the state after the inner insulating paper 1 has been inserted into the slot 21. In FIG. 8, the flat portion 12 of the outer insulating paper 1 ((1)-(8)) is bent toward the outer periphery together with the V-phase coil V.

[0052] As shown in Fig. 1, the flat portion 12 of the insulating paper 1 is connected to the leg portions 11 at the circumferential center, so that the movement of the circumferential center of the flat portion 12 is restricted by the leg portions 11, but other portions can deform freely. Therefore, as shown in Fig. 8, the flat portion 12 of the insulating paper 1 can deform without being damaged. As described above, if the circumferential length of the flat portion 12 is A and the circumferential distance between a pair of teeth 22 each inserted into the long hole portions 13 of adjacent insulating paper 1 is B, then the relationship A>B holds.

[0053] Therefore, as shown in FIG. 8, even if the flat portion 12 of the insulating paper 1 ((1)-(8)) (see FIG. 7) arranged on the outer periphery is folded toward the outer periphery of the stator core 2 together with the U-phase coil U, the flat portions 12 of the insulating paper 1 adjacent to each other in the circumferential direction can maintain a state in which they overlap each other in the circumferential direction, and insulation between the U-phase coil U and the V-phase coil V can be maintained.

[0054] Similarly, even if the flat portions 12 of the insulating paper 1 (9) to (16)) (see FIG. 7) arranged on the inner periphery are folded toward the outer periphery of the stator core 2 together with the V-phase coil V, the flat portions 12 of the insulating paper 1 adjacent to each other in the circumferential direction can maintain a state in which they overlap each other in the circumferential direction, and insulation between the V-phase coil V and the W-phase coil W can be maintained.

[0055] Furthermore, as shown in Figure 8, it can be seen that the legs 11 of the insulating papers 1 ((9)-(16)) (Figure 7) arranged on the inner periphery do not protrude from the grooves of the slots 21. The same is true for the insulating papers 1 ((1)-(8)) (Figure 7) arranged on the outer periphery.

[0056] In the insulating paper 1 of this embodiment, the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the legs 11) is hardly deformed before and after installation in the slots 21, and the pair of legs 11 can be securely inserted into each of the pair of adjacent slots 21. This reduces the restoring force that may be generated due to deformation of the flat portion 12 and the legs 11. Therefore, the insulating paper 1 does not rotate when installed in the stator core 2, and is semi-fixed to the stator core 2 simply by installing the legs 11 in the slots 21.

[0057] 5(b) and 6(b), the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the leg portion 11) is hardly deformed or displaced. Specifically, the width direction of the leg portion 11 does not deform so as to face the groove of the slot 21, and the circumferential center of the flat portion 12 is hardly deformed toward the inner periphery of the stator core 2, so that the leg portion 11 is hardly displaced toward the groove of the slot 21. Therefore, protrusion of the leg portion 11 from the groove of the slot 21 can be reduced.

[0058] Figure 9 is a diagram (copy) showing the assembly process of the interphase insulating paper in this embodiment, in which the V-phase coil V is inserted into the slot 21 and then the outer peripheral insulating paper 1 and the V-phase coil V are folded toward the outer peripheral side of the stator core 2. Figure 9(a) shows the case where there is no arc portion 15 on the flat portion 12, while Figure 9(b) shows the case where there is an arc portion 15 on the flat portion 12.

[0059] As described above, after the process of assembling each phase coil and insulating paper 1 to the stator core 2, the coil ends of each phase coil are bundled with wire 4 (see Figure 10) and then varnish is applied to each phase coil, although the wire 4 is omitted in Figure 9.

[0060] In the case of the insulating paper 1 of this embodiment, in which the arc portion 15 shown in Figure 1 is absent and the flat portion 12 is rectangular, as shown in Figure 9(a), both circumferential ends of the insulating paper 1 cover the coil ends of the U-phase coil U more than necessary, which may make it difficult to apply varnish to the U-phase coil U.

[0061] However, when insulating paper 1 having arc portion 15 (insulating paper 1(1)-(8) (Figure 8)) is attached to stator core 2, the area that flat portion 12 covers over the coil end of U-phase coil U can be reduced, as shown in Figure 9(b), thereby reducing the hindrance caused by flat portion 12 when applying varnish and allowing the varnish to be applied efficiently.

[0062] Similarly, insulating paper 1 ((9) to (16)) (FIG. 7) having an arcuate portion 15 was attached. In case, Since the area that flat portion 12 covers over the coil end of V-phase coil V can be reduced, the interference caused by flat portion 12 when applying varnish is reduced, and the application of varnish can be performed efficiently.

[0063] 10A shows the state before the insulating paper 1 and each phase coil are bound with wire 4, and FIG. 10B shows the state after they have been bound. FIG. 10 shows the case where U-phase coil U and insulating paper 1 are bound together.

[0064] As shown in Figure 10(a), a notch 14 (cutout) is arranged on the flat portion 12 of the insulating paper 1 (insulating paper 1(1) and insulating paper 1(9) in Figure 10) at a position corresponding to the short side of the long hole portion 13 (Figure 1). When bundling each phase coil and insulating paper 1 with wire 4, wire 4 is anchored in notch 14.

[0065] As a result, as shown in Figure 10(b), when each phase coil (U-phase coil U in Figure 10) and insulating paper 1 are bundled with wire 4, the portion of wire 4 anchored to notch 14 moves linearly (upward in Figure 10(b)) toward the coil end of each phase coil, but a cut is preferentially generated in the flat portion 12 starting from notch 14 along the direction in which wire 4 moves, and the cut is formed so as to extend toward the coil end side by following the trajectory of movement of wire 4.

[0066] Even in this state, the flat portion 12 is not divided in the circumferential direction, so that the insulation between the coils of each phase provided by the flat portion 12 is maintained.

[0067] Therefore, when each phase coil and insulating paper 1 are bound with wire 4, for example, it is possible to prevent leg portion 11 from being cut and to form a cut in insulating paper 1 in the intended direction.

[0068] [Effects of this embodiment] According to this embodiment, the interphase insulating paper is composed of a plurality of insulating papers 1 arranged in a circumferential direction around the stator core 2, and the plurality of insulating papers 1 provide interphase insulation for each phase coil provided in the stator core 2. The insulating paper 1 includes a pair of legs 11 that are inserted into a pair of slots 21 out of a plurality of slots 21 formed in the stator core 2, and a pair of flat portions 12 that are connected to the pair of legs 11 and protrude from both axial end faces of the stator core 2 to provide interphase insulation for each phase coil, and the pair of legs 11 are connected to the center of the edge of the flat portions 12.

[0069] With the above configuration, the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the legs 11) is hardly deformed before and after the insulating paper 1 is fitted into the slots 21, and the pair of legs 11 can be securely inserted into the pair of adjacent slots 21, respectively. This makes it possible to reduce the restoring force that may be generated due to deformation of the flat portion 12 and the legs 11.

[0070] Furthermore, even when the flat portion 12 is deformed to follow the shape of the coil ends of each phase coil, the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the leg portion 11) is hardly deformed or displaced. Specifically, the width direction of the leg portion 11 is not deformed so as to face the groove of the slot 21, and the circumferential center of the flat portion 12 is hardly deformed toward the inner periphery of the stator core 2, so that the leg portion 11 is hardly displaced toward the groove of the slot 21. This reduces the protrusion of the leg portion 11 from the groove of the slot 21, resulting in an insulating paper 1 that can be easily attached to the slot 21 of the stator core 2.

[0071] In this embodiment, if the circumferential length of the flat portion 12 is A and the amount of circumferential misalignment of a pair of adjacent insulating papers 1 when the insulating papers 1 are attached to the stator core 2 is B, the flat portions 12 of the pair of adjacent insulating papers 1 overlap each other by satisfying the relationship A>B. This ensures interphase insulation of the coils (coil ends) of each phase.

[0072] In this embodiment, the insulating paper 1 has a flat shape before being attached to the stator core 2. This makes it easy to manage the insulating paper 1.

[0073] In this embodiment, a long hole (long hole portion 13) that matches the outer shape of the tooth 22 between the pair of slots 21 is formed between the pair of legs 11, and the tooth 22 is inserted into the long hole (long hole portion 13). This allows the leg 11 to be stably inserted into the slot 21.

[0074] In this embodiment, a cutout (notch 14) is provided in the flat portion 12 at a position corresponding to the short side of the long hole (long hole portion 13). This makes it possible to form a cut in the flat portion 12 in the intended direction when bundling the insulating paper 1 and each phase coil (coil end) with the wire 4.

[0075] In this embodiment, the edge of the flat portion 12 that faces the stator core 2 when the leg 11 is inserted into the slot 21 has an arc shape (arc portion 15) that extends from a position that is the root of the leg 11 of the edge in a direction perpendicular to the longitudinal direction of the leg 11, and moves away from the stator core 2 from a midway position toward the end of the flat portion 12, and is convex in the direction moving away from the stator core 2. This reduces the area of ​​each phase coil that is excessively covered by the flat portion 12 when applying varnish to each phase coil after the insulating paper 1 and each phase coil are assembled to the stator core 2, thereby reducing the interference of the flat portion 12 when applying the varnish, and allowing the varnish to be applied efficiently.

[0076] The motor of this embodiment is formed by assembling the insulating paper 1 together with each phase coil to the stator core 2. This results in a motor in which inter-phase insulation of each phase coil is easily and reliably achieved.

[0077] In this embodiment, the number of sheets of insulating paper 1 attached in a circumferential direction around the stator core 2 is set to be the same as the number of coils of the same phase attached in a circumferential direction around the stator core 2.

[0078] This ensures interphase insulation of each phase coil (coil end). Furthermore, the amount of insulating paper 1 can be reduced, and when assembling the insulating paper 1 and each phase coil to the stator core 2, the coils of each phase can be attached to the slots 21 and the grooves of the slots 21 can be closed in the process following the process of inserting the legs 11 into the slots 21. This shortens the time from when the legs 11 are inserted into the slots 21 to when the grooves of the slots 21 are closed, thereby reducing the protrusion of the legs 11 from the grooves of the slots 21.

[0079] In this embodiment, when a first phase coil (U-phase coil U), a second phase coil (V-phase coil V), and a third phase coil (W-phase coil W) of different phases are mounted on stator core 2 in a state where a plurality of coils are arranged in the circumferential direction, insulating paper 1 is arranged such that legs 11 are inserted into a pair of slots 21 in which a pair of second phase coils (V-phase coil V) adjacent to each other in the circumferential direction are mounted, and one circumferential side of flat portion 12 is sandwiched between the first phase coil (U-phase coil U) and the second phase coil (V-phase coil V) and the other circumferential side of flat portion 12 is sandwiched between the third phase coil (W-phase coil W) and the first phase coil (U-phase coil U), and a first insulating paper (insulating paper 1 ((1) to (8))) is disposed on the inner circumferential side of stator core 2 than the first insulating paper (insulating paper 1 ((1) to (8))) and is sandwiched between the third phase coil (W-phase coil W) and the first phase coil (U-phase coil U). The legs 11 are respectively inserted into a pair of slots 21 into which the second phase coil (V-phase coil V) and the third phase coil (W-phase coil W) are respectively fitted, and one circumferential side of the flat portion 12 is sandwiched between the second phase coil (V-phase coil V) and the third phase coil (W-phase coil W), and the other circumferential side of the flat portion 12 is sandwiched between the third phase coil (W-phase coil W) and the first phase coil (U-phase coil U). A second insulating paper (insulating paper 1 ((9)-(16))) is sandwiched between the third phase coil (W-phase coil W) and the first phase coil (U-phase coil U). The first insulating papers (insulating papers 1 ((1)-(8))) are arranged in a row around the circumferential direction, with adjacent first insulating papers (insulating papers 1 ((1)-(8))) being arranged so as to overlap each other in the circumferential direction, and the second insulating papers (insulating papers 1 ((9)-(16))) are arranged in a row around the circumferential direction, with adjacent second insulating papers (insulating papers 1 ((9)-(16))) being ... so as to overlap each other in the circumferential direction.

[0080] The first insulating paper (insulating paper 1 ((1)-(8))) and the second insulating paper (insulating paper 1 ((9)-(16))) are deformed into different shapes when attached to the stator core 2, but can be formed from the same insulating paper 1. Therefore, the first insulating paper (insulating paper 1 ((1)-(8))) and the second insulating paper (insulating paper 1 ((9)-(16))) can be formed from one type of insulating paper 1, thereby reducing costs.

[0081] According to the method for assembling the interphase insulating paper of the present embodiment, when a first phase coil (U-phase coil U), a second phase coil (V-phase coil V), and a third phase coil (W-phase coil W) of different phases are mounted on the stator core 2 in a state in which multiple coils are lined up in the circumferential direction, and multiple insulating papers 1 are mounted around the stator core 2 in the circumferential direction to insulate the first phase coil (U-phase coil U), the second phase coil (V-phase coil V), and the third phase coil (W-phase coil W), the insulating papers 1 are formed on the stator core 2. and a pair of flat portions 12 connected to the pair of legs 11 and protruding from both axial end faces of the stator core 2 to provide interphase insulation for the coils of each phase. The pair of legs 11 are connected to the center of the edge of the flat portion 12, and the circumferential length of the flat portion 12 is set so that the flat portions 12 of the pair of adjacent insulating papers 1 overlap each other in the circumferential direction when the insulating paper 1 is attached to the stator core 2. The method of assembling interphase insulating paper is set so that the number of sheets of interphase insulating paper to be mounted around the stator core 2 in a circumferential direction is the same as the number of coils of the same phase mounted in a state where they are arranged around the stator core 2 in a circumferential direction, and after mounting a first-phase coil (U-phase coil U) on the stator core 2, the leg portions 11 are inserted into a pair of adjacent slots 21 in which a pair of second-phase coils (V-phase coil V) adjacent to each other in the circumferential direction are respectively mounted, and the leg portions 11 are overlapped with the first-phase coil (U-phase coil U) in the circumferential direction at the flat portions 12. After the second phase coil (V-phase coil V) is attached to the stator core 2 but before the third phase coil (W-phase coil W) is attached to the stator core 2, the legs 11 are inserted into a pair of adjacent slots 21 in which a pair of circumferentially adjacent third phase coils (W-phase coil W) are respectively attached, and the portions of the planar portion 12 that overlap with the first phase coil (U-phase coil U) and the second phase coil (V-phase coil V) in the circumferential direction are bent toward the inner circumference of the stator core 2.

[0082] With the above method, the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the legs 11) is hardly deformed before and after the insulating paper 1 is fitted into the slots 21, and the pair of legs 11 can be securely inserted into the pair of adjacent slots 21, respectively. This makes it possible to reduce the restoring force that may be generated due to deformation of the flat portion 12 and the legs 11.

[0083] Furthermore, even when the flat portion 12 is deformed to follow the shape of the coil ends of each phase coil, the circumferential center of the insulating paper 1 (the circumferential center of the flat portion 12 and the leg portion 11) is hardly deformed or displaced. Specifically, the width direction of the leg portion 11 is not deformed so as to face the groove of the slot 21, and the circumferential center of the flat portion 12 is hardly deformed toward the inner periphery of the stator core 2, so that the leg portion 11 is hardly displaced toward the groove of the slot 21. This reduces the protrusion of the leg portion 11 from the groove of the slot 21, making it easier to fit the insulating paper 1 into the slot 21 of the stator core 2.

[0084] 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 the technical scope of the present invention is not limited to the specific configurations of the above-mentioned embodiments. In addition, the above-mentioned embodiments can be appropriately combined.

Claims

1. a stator core has a first phase coil, a second phase coil, and a third phase coil arranged in a circumferential direction, the first phase coil, the second phase coil, and the third phase coil being of different phases from one another, and a plurality of insulating papers are attached to provide interphase insulation for the coils of each phase, the insulating papers including a pair of legs inserted into a pair of slots among a plurality of slots formed in the stator core, and a pair of flat portions connected to the pair of legs and protruding from both end faces of the stator core in the axial direction to provide interphase insulation for the coils of each phase, the pair of legs being connected to central portions of edges of the flat portions and being disposed so as to sandwich one tooth disposed between the slots adjacent to one another, The insulating paper is a first insulating paper in which the legs are inserted into a pair of the slots in which a pair of the second phase coils adjacent to each other in the circumferential direction are respectively fitted, one circumferential side of the flat portion is sandwiched between the first phase coil and the second phase coil, and the other circumferential side of the flat portion is sandwiched between the third phase coil and the first phase coil; a second insulating paper that is disposed on an inner circumferential side of the stator core than the first insulating paper, the leg portions being inserted into a pair of the slots in which a pair of the third phase coils adjacent to each other in the circumferential direction are respectively mounted, one circumferential side of the flat portion being sandwiched between the second phase coil and the third phase coil, and the other circumferential side of the flat portion being sandwiched between the third phase coil and the first phase coil; the first insulating paper is arranged in a plurality of rows around the circumferential direction, and adjacent first insulating paper sheets are arranged so as to overlap each other in the circumferential direction; A motor in which a plurality of the second insulating papers are arranged side by side around the circumferential direction, and adjacent second insulating papers are arranged so as to overlap each other in the circumferential direction.

2. The motor described in claim 1, wherein the circumferential length of the flat portion is A and the circumferential shift of a pair of adjacent insulating papers when the insulating papers are attached to the stator core is B, the flat portions of the pair of adjacent insulating papers overlap each other by satisfying the relationship A > B.

3. 3. The motor according to claim 1, wherein the insulating paper has a flat shape before being attached to the stator core.

4. The motor according to claim 1 , wherein a long hole is formed between the pair of legs, the long hole conforming to an outer shape of the tooth between the pair of slots, and the tooth is inserted into the long hole.

5. The motor according to claim 4 , further comprising a notch in the flat portion at a position corresponding to a short side of the slot.

6. 6. The motor according to claim 1, wherein the edge of the flat portion that faces the stator core when the leg is inserted into the slot extends from a position that is the base of the leg of the edge in a direction perpendicular to the longitudinal direction of the leg, and moves away from the stator core from a midway position toward the end of the flat portion, and has an arc shape that is convex in the direction away from the stator core.

7. 7. The motor according to claim 1, wherein the number of sheets of insulating paper attached to wrap around the stator core in a circumferential direction is set to be the same as the number of coils of the same phase attached in a state where they are arranged around the stator core in a circumferential direction.

8. In a case where a first phase coil, a second phase coil, and a third phase coil, each of which is of different phase, are mounted on a stator core in a state in which a plurality of coils are arranged in a circumferential direction, and a plurality of insulating papers are mounted around the stator core in a circumferential direction to provide inter-phase insulation for the first phase coil, the second phase coil, and the third phase coil, the insulating papers include a pair of leg portions that are inserted into a pair of slots out of a plurality of slots formed in the stator core, and a pair of flat portions that are connected to the pair of leg portions and protrude from both axial end faces of the stator core to provide inter-phase insulation for the coils of each phase, a pair of legs are connected to the center of the edge of the flat portion and are arranged to sandwich one tooth that is arranged between a pair of adjacent slots, the circumferential length of the flat portion is set so that the flat portions of the pair of adjacent insulating papers overlap each other in the circumferential direction when the insulating paper is attached to the stator core, and the number of sheets of insulating paper attached to go around the stator core in the circumferential direction is set to the same number as the number of coils of the same phase that are attached in a line around the stator core in the circumferential direction, the first phase coil is attached to the stator core and the coil ends of the first phase are bent toward the outer periphery of the stator core, and then the legs are inserted into a pair of adjacent slots in which a pair of second phase coils adjacent to each other in the circumferential direction are attached, and a portion of the flat portion that overlaps with the first phase coil in the circumferential direction is bent toward the inner periphery of the stator core; When the second phase coil is attached to the stator core, a coil end of the second phase coil and a portion of the flat portion facing the coil end are bent toward an outer periphery of the stator core, a pair of third phase coils adjacent to each other in the circumferential direction are respectively mounted in the third phase coils, and the legs are inserted into the pair of adjacent slots in which the pair of third phase coils adjacent to each other in the circumferential direction are respectively mounted, and the portions of the planar portion that overlap with the first phase coil and the second phase coil in the circumferential direction are folded toward the inner circumference of the stator core after the second phase coil is mounted in the stator core and before the third phase coil is mounted in the stator core.

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