Magnetic core, winding with magnetic core, rotating electric machine and brushless motor

Abstract

The present invention relates to a magnetic material core used in a rotary electric machine. The magnetic material core includes a back yoke portion including a first lower surface, a tooth tip portion including a second upper surface, and a tooth portion around which a winding portion of a conductor is wound as viewed in a vertical direction. The magnetic material core has at least one of a structure (A) and a structure (B). (A) The first lower surface is provided with one or more first protruding portions shaped to protrude downward. (B) The second upper surface is provided with one or more second protruding portions shaped to protrude upward.

Description

[Technical field]

[0001] The present invention relates to a magnetic core used in a rotating electric machine, a magnetic cored winding including the magnetic core, a rotating electric machine including the magnetic core, and a brushless motor including the magnetic core. [Background technology]

[0002] As an example of an invention relating to a conventional magnetic core, a rotary-linear synchronous motor described in Patent Document 1 is known. This rotary-linear synchronous motor includes a split core. Windings are provided on the teeth of the split core. A stator is formed by arranging a plurality of split cores. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2004-343903 A Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, in the split core described in Patent Document 1, there is a demand for improving the electrical insulation between the core and the windings.

[0005] SUMMARY OF THE PRESENTLY PREFERRED EMBODIMENTS An object of the present invention is to provide a magnetic core, a winding with a magnetic core, a rotating electrical machine, and a brushless motor that can improve the electrical insulation between the iron core and the winding. [Means for solving the problem]

[0006] A magnetic core according to one embodiment of the present invention includes: A magnetic core used in a rotating electric machine in which a rotor rotates, comprising: The magnetic core is A back yoke portion having a first upper surface and a first lower surface aligned in the vertical direction; a tooth tip portion having a second upper surface and a second lower surface aligned in the vertical direction; a teeth portion having a shape extending in the vertical direction, an upper end contacting the first lower surface and a lower end contacting the second upper surface, and a conductor winding portion is wound around the teeth portion as viewed in the vertical direction; It is equipped with an outer edge of the back yoke portion when viewed in the vertical direction surrounds an outer edge of the tip portion of the teeth when viewed in the vertical direction, an outer edge of the tip portion of the teeth when viewed in the vertical direction surrounds an outer edge of the tooth portion when viewed in the vertical direction, It has at least one of the structures (A) and (B). (A) The first lower surface is provided with one or more first protrusions having a shape protruding downward. (B) The second upper surface is provided with one or more second protrusions having an upwardly protruding shape.

[0007] In this specification, the directions are defined as follows. In the magnetic core 1, the direction in which the teeth portion 4 extends is defined as the up-down direction. In addition, the direction in which the short side of the first upper surface US1 extends is defined as the left-right direction. In addition, the direction in which the long side of the first upper surface US1 extends is defined as the front-rear direction. The up-down direction, the left-right direction, and the front-rear direction are perpendicular to each other. In addition, in the brushless motor 100, the direction in which the shaft 23 extends is defined as the Z-axis direction. One side of the Z-axis direction is defined as the Z+ direction. The other side of the Z-axis direction is defined as the Z- direction. The definitions of the directions in this specification are merely examples. Therefore, the directions in the actual use of the magnetic core 1 do not need to match the directions in this specification. In addition, the up-down direction may be reversed in FIGS. 1 to 11 and 15 to 21. The left-right direction may be reversed in FIGS. 1 to 11 and 15 to 21. The front-rear direction may be reversed in Figures 1 to 11 and Figures 15 to 21. Also, the Z-axis direction may be reversed in Figures 12 to 14.

[0008] In the following, X and Y are parts or members of brushless motor 100. In this specification, unless otherwise specified, each part of X is defined as follows. The upper part of X means the upper half of X. The upper end of X means the upper end of X. The upper end part of X means the upper end of X and its vicinity. This definition also applies to directions other than the upward direction.

[0009] Moreover, "X is located above Y" means that X is located directly above Y. Therefore, when viewed in the vertical direction, X overlaps with Y. "X is located above Y" means that X is located directly above Y and that X is located diagonally above Y. Therefore, when viewed in the vertical direction, X may or may not overlap with Y. This definition also applies to directions other than the upward direction.

[0010] In this specification, "X and Y are electrically connected" means that electricity is conducted between X and Y. Therefore, X and Y may or may not be in contact with each other. When X and Y are not in contact with each other, Z having electrical conductivity is disposed between X and Y. Effect of the Invention

[0011] The magnetic core according to the present invention can improve the electrical insulation between the iron core and the windings. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of a magnetic core 1 according to the first embodiment. [Diagram 2] FIG. 2 is a plan view of the back yoke portion 2 according to the first embodiment viewed from above. [Diagram 3] FIG. 3 is a plan view of the back yoke portion 2 according to the first embodiment as viewed in the front direction. [Figure 4] FIG. 4 is a plan view of tooth tip portion 3 according to the first embodiment viewed downward. [Diagram 5]FIG. 5 is a plan view of tooth tip portion 3 according to the first embodiment viewed in the forward direction. [Figure 6] FIG. 6 is a plan view of the magnetic core 1 according to the first embodiment viewed from above. [Figure 7] FIG. 7 is a perspective view of the magnetic core 1 and the conductor 5 according to the first embodiment. [Figure 8] FIG. 8 is a plan view of the back yoke portion 2 and the winding portion 6 according to the first embodiment viewed from above. [Figure 9] FIG. 9 is a plan view of tooth tip portions 3 and winding portions 6 according to the first embodiment viewed downward. [Figure 10] FIG. 10 is a plan view of the magnetic core 1 and the winding portion 6 according to the first embodiment viewed from above. [Figure 11] FIG. 11 is a plan view of the magnetic core 1 and the winding portion 6 according to the first embodiment, viewed in the front direction. [Figure 12] FIG. 12 is an external perspective view of a brushless motor 100 in which the magnetic core 1 according to the first embodiment is used. [Figure 13] FIG. 13 is an exploded perspective view of a brushless motor 100 in which the magnetic core 1 according to the first embodiment is used. [Figure 14] FIG. 14 is an exploded perspective view of the rotor 20 according to the first embodiment. [Figure 15] FIG. 15 is a cross-sectional view of the rotor 20 according to the first embodiment taken along line AA. [Figure 16] FIG. 16 is a plan view of the back yoke portion 2 according to the first modified example, viewed from above. [Figure 17] FIG. 17 is a plan view of tooth tip portion 3 according to the first modified example viewed downward. [Figure 18] FIG. 18 is a plan view of the back yoke portion 2 and the winding portion 6 according to the first modified example, viewed from above. [Figure 19] FIG. 19 is a plan view of tooth tip portions 3 and winding portions 6 according to the first modified example, viewed downward. [Figure 20]FIG. 20 is a plan view of the back yoke portion 2 according to the second modified example, viewed in the forward direction. [Figure 21] FIG. 21 is a plan view of a back yoke portion 2 according to a third modified example, viewed in the front direction. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] [First embodiment] (Configuration of magnetic core 1) The configuration of the magnetic core 1 according to the first embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of the magnetic core 1 according to the first embodiment. FIG. 2 is a plan view of the back yoke portion 2 according to the first embodiment viewed from above. FIG. 3 is a plan view of the back yoke portion 2 according to the first embodiment viewed from the front. FIG. 4 is a plan view of the teeth tip portion 3 according to the first embodiment viewed from below. FIG. 5 is a plan view of the teeth tip portion 3 according to the first embodiment viewed from the front. FIG. 6 is a plan view of the magnetic core 1 according to the first embodiment viewed from above. FIG. 7 is a perspective view of the magnetic core 1 and the conductor 5 according to the first embodiment. FIG. 8 is a plan view of the back yoke portion 2 and the winding portion 6 according to the first embodiment viewed from above. FIG. 9 is a plan view of the teeth tip portion 3 and the winding portion 6 according to the first embodiment viewed from below. FIG. 10 is a plan view of the magnetic core 1 and the winding portion 6 according to the first embodiment viewed from above. Fig. 11 is a plan view of the magnetic core 1 and the winding portion 6 according to the first embodiment, viewed in the front direction. In Figs. 1, 2, and 6 to 8, only a representative first protrusion P1 among the multiple first protrusions P1 is given a reference symbol. In Figs. 4 and 9, only a representative second protrusion P2 among the multiple second protrusions P2 is given a reference symbol. In Fig. 8, only a representative first portion PP1 among the multiple first portions PP1 is given a reference symbol. In Fig. 9, only a representative second portion PP2 among the multiple second portions PP2 is given a reference symbol.

[0014] The magnetic core 1 is used in a brushless motor 100 that rotates a rotor 20. The brushless motor 100 is an example of a rotating electric machine of the present invention.

[0015] As shown in Fig. 1, the magnetic core 1 includes a back yoke portion 2, a tooth tip portion 3, and a tooth portion 4. The material of the magnetic core 1 is, for example, a powder magnetic core. A powder magnetic core is a mixture of a metal magnetic powder such as iron powder and a resin compound. The magnetic core 1 is produced by, for example, injection molding. The outer surface of the magnetic core 1 is also subjected to an insulating treatment.

[0016] As shown in FIG. 1, the back yoke portion 2 has a first upper surface US1 and a first lower surface DS1 aligned in the up-down direction. The first upper surface US1 is located above the first lower surface DS1. Also, as shown in FIG. 2, each of the first upper surface US1 and the first lower surface DS1 has a front side, a rear side, a left side, and a right side when viewed in the up-down direction. In this embodiment, the length of each of the left side and the right side of the first upper surface US1 and the first lower surface DS1 is longer than the length of each of the front side and the rear side of the first upper surface US1 and the first lower surface DS1, as shown in FIG. 2. Also, in this embodiment, the outer edge of the first lower surface DS1 when viewed in the up-down direction coincides with the outer edge of the first upper surface US1 when viewed in the up-down direction.

[0017] As shown in FIG. 3, the first lower surface DS1 is provided with one or more first protrusions P1 having a shape protruding downward. In this embodiment, the first lower surface DS1 is provided with a plurality of first protrusions P1. In this embodiment, the plurality of first protrusions P1 are not in contact with each other. As shown in FIG. 2, the plurality of first protrusions P1 include a first left protrusion PL1 located to the left of the teeth 4 and a first right protrusion PR1 located to the right of the teeth 4 when viewed in the vertical direction. More specifically, the plurality of first protrusions P1 located to the left of the teeth 4 are aligned in the front-rear direction when viewed in the vertical direction. Also, the plurality of first protrusions P1 located to the right of the teeth 4 are aligned in the front-rear direction when viewed in the vertical direction. That is, the plurality of first protrusions P1 are aligned in the front-rear direction when viewed in the vertical direction.

[0018] As shown in FIG. 1, the tooth tip portion 3 has a second upper surface US2 and a second lower surface DS2 aligned in the up-down direction. The second upper surface US2 is located above the second lower surface DS2. Also, as shown in FIG. 4, the second lower surface DS2 has a front side, a rear side, a left side, and a right side when viewed in the up-down direction. In this embodiment, the length of each of the left side and the right side of the second upper surface US2 and the second lower surface DS2 is longer than the length of each of the front side and the rear side of the second upper surface US2 and the second lower surface DS2, as shown in FIG. 4. Also, in this embodiment, the outer edge of the second lower surface DS2 when viewed in the up-down direction coincides with the outer edge of the second upper surface US2 when viewed in the up-down direction.

[0019] As shown in FIG. 5, the second upper surface US2 is provided with one or more second protrusions P2 having a shape protruding upward. In this embodiment, the second upper surface US2 is provided with a plurality of second protrusions P2. In this embodiment, the plurality of second protrusions P2 are not in contact with each other. As shown in FIG. 4, the plurality of second protrusions P2 includes a second left protrusion PL2 located to the left of the teeth 4 and a second right protrusion PR2 located to the right of the teeth 4 when viewed in the vertical direction. More specifically, the plurality of second protrusions P2 located to the left of the teeth 4 are aligned in the front-rear direction when viewed in the vertical direction. Also, the plurality of second protrusions P2 located to the right of the teeth 4 are aligned in the front-rear direction when viewed in the vertical direction. That is, the plurality of second protrusions P2 are aligned in the front-rear direction when viewed in the vertical direction.

[0020] 1, the teeth portion 4 has a shape that extends in the up-down direction. The upper ends of the teeth portion 4 contact the first lower surface DS1 of the back yoke portion 2. The lower ends of the teeth portion 4 contact the second upper surface US2 of the teeth tip portions 3. That is, the teeth portion 4 has an upper end that contacts the first lower surface DS1 of the back yoke portion 2 and a lower end that contacts the second upper surface US2 of the teeth tip portions 3.

[0021] 2 and 4, the teeth 4 have a left side extending in the front-rear direction and a right side extending in the front-rear direction when viewed in the up-down direction. The left side of the teeth 4 includes the left end of the teeth 4. The right side of the teeth 4 includes the right end of the teeth 4. In other words, the left side of the teeth 4 is located to the left of the right side of the teeth 4.

[0022] In this embodiment, as shown in Fig. 2, the first protrusion P1 contacts the left side of the tooth portion 4 when viewed in the up-down direction. More specifically, the first left protrusion PL1 located to the left of the tooth portion 4 contacts the left side of the tooth portion 4 when viewed in the up-down direction. Also, the first protrusion P1 contacts the right side of the tooth portion 4 when viewed in the up-down direction. More specifically, the first right protrusion PR1 located to the right of the tooth portion 4 contacts the right side of the tooth portion 4 when viewed in the up-down direction.

[0023] In this embodiment, as shown in Fig. 4, the second protrusion P2 contacts the left side of the tooth portion 4 when viewed in the up-down direction. More specifically, the second left protrusion PL2 located to the left of the tooth portion 4 contacts the left side of the tooth portion 4 when viewed in the up-down direction. Also, the second protrusion P2 contacts the right side of the tooth portion 4 when viewed in the up-down direction. More specifically, the second right protrusion PR2 located to the right of the tooth portion 4 contacts the right side of the tooth portion 4 when viewed in the up-down direction.

[0024] As shown in Fig. 6, the outer edge OE2 of the back yoke portion 2 when viewed in the vertical direction surrounds the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction. In other words, the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction does not protrude from the area surrounded by the outer edge OE2 of the back yoke portion 2 when viewed in the vertical direction, and the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction does not have a portion overlapping with the outer edge OE2 of the back yoke portion 2 when viewed in the vertical direction. In addition, the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction surrounds the outer edge OE4 of the teeth portion 4 when viewed in the vertical direction. In other words, the outer edge OE4 of the teeth portion 4 when viewed in the vertical direction does not protrude from the area surrounded by the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction, and the outer edge OE4 of the teeth portion 4 when viewed in the vertical direction does not have a portion overlapping with the outer edge OE3 of the teeth tip portion 3 when viewed in the vertical direction.

[0025] A winding portion 6 of a conductor 5 is wound around the teeth portion 4 when viewed in the up-down direction. More specifically, the conductor 5 includes the winding portion 6 as shown in FIG. 7. The conductor 5 is made of a conductive material such as copper. The conductor 5 has a structure in which the surface of a copper wire is covered with an insulating film. The conductor 5 has a first end and a second end.

[0026] 7, the winding portion 6 is wound around the tooth portion 4 so as to be located around the tooth portion 4 when viewed in the vertical direction. That is, the winding portion 6 goes around the tooth portion 4 in a clockwise or counterclockwise direction when viewed in the vertical direction. In this embodiment, the winding portion 6 is wound doubly around the tooth portion 4 so as to be located around the tooth portion 4 when viewed in the vertical direction.

[0027] 8, when the winding portion 6 is wound around the tooth portion 4, the first lower surface DS1 of the back yoke portion 2 has a first region A1 that overlaps with the winding portion 6 when viewed in the vertical direction. The first region A1 has a ring shape that goes around the tooth portion 4 once when viewed in the vertical direction. The first protrusion P1 includes a first portion PP1 located in the first region A1. In addition, the total area of ​​the lower ends of the first portions PP1 when viewed in the vertical direction is smaller than the area of ​​the first region A1 when viewed in the vertical direction.

[0028] 9, the second upper surface US2 of the tooth tip portion 3 has a second region A2 that overlaps with the winding portion 6 when viewed in the vertical direction with the winding portion 6 wound around the tooth portion 4. When viewed in the vertical direction, the second region A2 has a ring shape that goes around the tooth portion 4 once. The second protrusion P2 includes a second portion PP2 located in the second region A2. In addition, the total area of ​​the upper ends of the second portions PP2 when viewed in the vertical direction is smaller than the area of ​​the second region A2 when viewed in the vertical direction.

[0029] The first lower surface DS1 contacts the winding portion 6 at the lower end of the first portion PP1. That is, the first protrusion P1 includes a portion located above the winding portion 6, as shown in Figures 10 and 11. The contact area between the back yoke portion 2 and the winding portion 6 is the sum of the areas of the lower ends of the first portion PP1 when viewed in the up-down direction.

[0030] The second upper surface US2 contacts the winding portion 6 at the upper end of the second portion PP2. That is, the second protrusion P2 includes a portion located below the winding portion 6, as shown in Fig. 10 and Fig. 11. The contact area between the tooth tip portions 3 and the winding portion 6 is the sum of the areas of the upper ends of the second portions PP2 when viewed in the up-down direction.

[0031] (Configuration of brushless motor 100) The configuration of a brushless motor 100 according to a first embodiment of the present invention will be described below with reference to the drawings. FIG. 12 is an external perspective view of the brushless motor 100 using the magnetic core 1 according to the first embodiment. FIG. 13 is an exploded perspective view of the brushless motor 100 using the magnetic core 1 according to the first embodiment. Note that multiple conductors 5 are omitted in FIG. 13. FIG. 14 is an exploded perspective view of the rotor 20 according to the first embodiment. FIG. 15 is a cross-sectional view of the rotor 20 according to the first embodiment taken along line AA.

[0032] 12, the brushless motor 100 includes a stator assembly 10 and a rotor 20. The magnetic core 1 and the conductor 5 are components of the stator assembly 10. That is, the brushless motor 100 includes the magnetic core 1 and the conductor 5.

[0033] As shown in FIGS. 12 and 13, the stator assembly 10 includes a housing 11, an insulating member 12, a shaft cover member 13, a bearing 14, a plurality of magnetic cores 1, and a plurality of conductors 5.

[0034] The housing 11 has a cylindrical shape as shown in Fig. 12. The axial direction of the cylindrical shape is the Z-axis direction. The material of the housing 11 is a highly rigid material such as SUS.

[0035] 13, the insulating member 12 is disposed between the housing 11 and the multiple magnetic cores 1 when viewed in the Z-axis direction. The housing 11 and the multiple magnetic cores 1 are electrically insulated by the insulating member 12. The insulating member 12 is, for example, insulating paper.

[0036] 13, the shaft lid member 13 has a circular and plate-like shape. The center of the circle coincides with the central axis of the shaft 23, which will be described later, when viewed in the Z-axis direction. The shaft lid member 13 overlaps with the shaft 23, which will be described later, when viewed in the Z-axis direction. In addition, the shaft lid member 13 is disposed in the Z-direction from a fourth end E4 of the shaft 23, which will be described later.

[0037] 13, the bearing 14 has a cylindrical shape. The axial direction of the cylindrical shape (the central axis of the bearing 14) is the Z-axis direction. The center of the cylindrical shape coincides with the central axis of a shaft 23 described later when viewed in the Z-axis direction. The bearing 14 supports the shaft 23 described later so that it can rotate around the Z-axis direction.

[0038] The multiple magnetic cores 1 are arranged around the rotor 20 at intervals along the direction around the Z axis. The winding portions 6 of the multiple conductors 5 are wound around the teeth 4 so as to be positioned around the teeth 4 when viewed in the up-down direction, as shown in Fig. 7. The multiple magnetic cores 1 and the multiple conductors 5 form a stator.

[0039] As shown in FIGS. 12 and 13, the rotor 20 includes a rotor yoke 21, a magnet 22, and a shaft 23.

[0040] 14, the rotor yoke 21 has a main body portion 211, a shaft holding portion 212, and a connecting portion 213. The material of the rotor yoke 21 is a magnetizable metal such as SUS (Stainless Used Steel).

[0041] 14, the main body part 211 has a cylindrical shape. The axial direction of the cylindrical shape (the central axis of the main body part 211) is the Z-axis direction. The central axis of the main body part 211 coincides with the central axis of the shaft 23 described later.

[0042] 14, the shaft holding part 212 has a cylindrical shape. The axial direction of the cylindrical shape (the central axis of the shaft holding part 212) is the Z-axis direction. The central axis of the shaft holding part 212 coincides with the central axis of the shaft 23 described below. In addition, the shaft holding part 212 is disposed in the Z+ direction from the Z+ direction end of the main body part 211. The shaft holding part 212 is disposed such that the outer edge of the shaft holding part 212 as viewed in the Z-axis direction is surrounded by the inner edge of the main body part 211 as viewed in the Z-axis direction. The shaft holding part 212 holds the shaft 23.

[0043] 14, the connecting portion 213 has an annular shape and a plate shape. When viewed in the Z-axis direction, the center of the annular shape coincides with the central axis of the shaft 23 described below. The connecting portion 213 has a main surface whose normal direction is the Z-axis direction. The connecting portion 213 connects the main body portion 211 and the shaft holding portion 212.

[0044] 14, the magnet 22 has a cylindrical shape. The axial direction of the cylindrical shape (the central axis of the magnet 22) is the Z-axis direction. The central axis of the magnet 22 coincides with the central axis of the shaft 23 described below. In addition, the inner edge of the magnet 22 as viewed in the Z-axis direction coincides with the outer edge of the main body part 211 as viewed in the Z-axis direction.

[0045] As shown in FIG. 14, the shaft 23 has a cylindrical shape. The axial direction of the cylindrical shape (the central axis of the shaft 23) is the Z-axis direction. The outer edge of the shaft 23 viewed in the Z-axis direction coincides with the inner edge of the shaft holding part 212 viewed in the Z-axis direction. The shaft 23 has a third end E3 and a fourth end E4 in the Z-axis direction. The third end E3 is located in the Z+ direction from the fourth end E4. As shown in FIG. 13, the third end E3 is located in the Z+ direction from the end of the main body part 211 in the Z+ direction. The fourth end E4 is located in the Z- direction from the end of the main body part 211 in the Z- direction.

[0046] The stator assembly 10 has an opening OP as shown in Fig. 12. The rotor 20 is inserted from the opening OP into a region surrounded by the inner edge of the stator as viewed in the Z-axis direction. As a result, the rotor 20 is disposed so as to be surrounded by the stator as viewed in the Z-axis direction. In other words, the stator is disposed around the rotor 20 as viewed in the Z-axis direction. That is, in this embodiment, the brushless motor 100 is an inner rotor type.

[0047] A third end E3 of the shaft 23 protrudes from the opening OP in the Z+ direction as shown in Fig. 12. A fourth end E4 is supported by the stator assembly 10 so that the shaft 23 can rotate about the Z-axis direction as shown in Fig. 13. That is, in this embodiment, the brushless motor 100 is a single-shaft type.

[0048] An electric signal is supplied to the stator from a power source (not shown). More specifically, an electric signal is supplied from the power source to first ends and second ends of the plurality of conductors 5. By controlling this electric signal, the rotation of the rotor 20 is controlled.

[0049] [effect] The magnetic core 1 can improve the electrical insulation between the iron core and the winding. More specifically, the first lower surface DS1 of the back yoke part 2 is provided with one or more first protrusions P1 having a shape protruding downward. As a result, the first lower surface DS1 comes into contact with the winding part 6 via the first protrusions P1. Therefore, the magnetic core 1 can make the contact area between the back yoke part 2 and the winding part 6 smaller than the contact area between the back yoke part 2 and the winding part 6 when the back yoke part 2 contacts with the winding part 6 via the entire first region A1 where the back yoke part 2 overlaps with the winding part 6. As a result, the magnetic core 1 can improve the electrical insulation between the iron core and the winding.

[0050] The magnetic core 1 can improve the electrical insulation between the iron core and the winding. More specifically, the second upper surface US2 of the tooth tip 3 is provided with one or more second protrusions P2 having a shape protruding upward. As a result, the second upper surface US2 comes into contact with the winding portion 6 via the second protrusions P2. Therefore, the magnetic core 1 can make the contact area between the tooth tip 3 and the winding portion 6 smaller than the contact area between the tooth tip 3 and the winding portion 6 when the tooth tip 3 contacts with the winding portion 6 via the entire second region A2 where the tooth tip 3 overlaps with the winding portion 6. As a result, the magnetic core 1 can improve the electrical insulation between the iron core and the winding.

[0051] The magnetic core 1 can improve the electrical insulation between the iron core and the winding. More specifically, the first protrusion P1 includes the first portion PP1 located in the first region A1. As a result, the first lower surface DS1 comes into contact with the winding 6 through the first portion PP1. The total area of ​​the lower end of the first portion PP1 viewed in the vertical direction is smaller than the area of ​​the first region A1 viewed in the vertical direction. Therefore, the contact area between the back yoke portion 2 and the winding 6 is smaller than the contact area between the back yoke portion 2 and the winding 6 when the back yoke portion 2 comes into contact with the winding 6 through the entire first region A1 that overlaps with the winding 6. As a result, the magnetic core 1 can improve the electrical insulation between the iron core and the winding.

[0052] The magnetic core 1 can improve the electrical insulation between the iron core and the winding. More specifically, the second protrusion P2 includes the second portion PP2 located in the second region A2. As a result, the second upper surface US2 comes into contact with the winding portion 6 through the second portion PP2. The total area of ​​the lower end of the second portion PP2 viewed in the vertical direction is smaller than the area of ​​the second region A2 viewed in the vertical direction. Therefore, the contact area between the tooth tip portion 3 and the winding portion 6 is smaller than the contact area between the tooth tip portion 3 and the winding portion 6 when the tooth tip portion 3 comes into contact with the winding portion 6 through the entire second region A2 overlapping with the winding portion 6. As a result, the magnetic core 1 can improve the electrical insulation between the iron core and the winding.

[0053] [First Modification] The magnetic core 1a according to the first modified example of the present invention will be described below with reference to the drawings. FIG. 16 is a plan view of the back yoke portion 2 according to the first modified example viewed from above. FIG. 17 is a plan view of the teeth tip portion 3 according to the first modified example viewed from below. FIG. 18 is a plan view of the back yoke portion 2 and the winding portion 6 according to the first modified example viewed from above. FIG. 19 is a plan view of the teeth tip portion 3 and the winding portion 6 according to the first modified example viewed from below. In FIG. 16 and FIG. 18, only the representative first protrusion portion P1 among the multiple first protrusion portions P1 is given a reference symbol. In FIG. 17 and FIG. 19, only the representative second protrusion portion P2 among the multiple second protrusion portions P2 is given a reference symbol. In FIG. 18, only the representative first portion PP1 among the multiple first portions PP1 is given a reference symbol. In FIG. 19, only the representative second portion PP2 among the multiple second portions PP2 is given a reference symbol. As for the magnetic core 1a according to the first modified example, only the differences from the magnetic core 1 according to the first embodiment will be described, and the rest will be omitted.

[0054] Magnetic core 1a differs from magnetic core 1 in that, as shown in FIG. 16, multiple first protrusion portions P1 are arranged in the left-right direction when viewed in the up-down direction, and in that, as shown in FIG. 17, multiple second protrusion portions P2 are arranged in the left-right direction when viewed in the up-down direction.

[0055] 16, the multiple first protrusions P1 include a first front protrusion PF1 located in front of the teeth 4 and a first rear protrusion PB1 located behind the teeth 4 in the vertical direction. More specifically, the multiple first protrusions P1 located in front of the teeth 4 are lined up in the left-right direction in the vertical direction. Also, the multiple first protrusions P1 located behind the teeth 4 are lined up in the left-right direction in the vertical direction.

[0056] 17, the second protrusions P2 include a second front protrusion PF2 located in front of the teeth 4 and a second rear protrusion PB2 located behind the teeth 4 in the vertical direction. More specifically, the second protrusions P2 located in front of the teeth 4 are aligned in the left-right direction in the vertical direction. Also, the second protrusions P2 located behind the teeth 4 are aligned in the left-right direction in the vertical direction.

[0057] 16 and 17, the teeth 4 have a front side extending in the left-right direction and a rear side extending in the left-right direction when viewed in the up-down direction. The front side of the teeth 4 includes the front end of the teeth 4. The rear side of the teeth 4 includes the rear end of the teeth 4. In other words, the front side of the teeth 4 is located in front of the rear side of the teeth 4.

[0058] In this modification, as shown in Fig. 16, the first protrusion P1 contacts the front edge of the tooth portion 4 when viewed in the up-down direction. More specifically, the first front protrusion PF1 located in front of the tooth portion 4 contacts the front edge of the tooth portion 4 when viewed in the up-down direction. Also, the first protrusion P1 contacts the rear edge of the tooth portion 4 when viewed in the up-down direction. More specifically, the first rear protrusion PB1 located behind the tooth portion 4 contacts the rear edge of the tooth portion 4 when viewed in the up-down direction.

[0059] In this modification, as shown in Fig. 4, the second protrusion P2 contacts the front edge of the tooth portion 4 when viewed in the up-down direction. More specifically, the second front protrusion PF2 located in front of the tooth portion 4 contacts the front edge of the tooth portion 4 when viewed in the up-down direction. Moreover, the second protrusion P2 contacts the rear edge of the tooth portion 4 when viewed in the up-down direction. More specifically, the second rear protrusion PB2 located behind the tooth portion 4 contacts the rear edge of the tooth portion 4 when viewed in the up-down direction.

[0060] The sum of the areas of the bottom ends of the first portion PP1 when viewed in the vertical direction is smaller than the area of ​​the first region A1 when viewed in the vertical direction, as shown in Fig. 18. Also, the sum of the areas of the bottom ends of the second portion PP2 when viewed in the vertical direction is smaller than the area of ​​the second region A2 when viewed in the vertical direction, as shown in Fig. 19.

[0061] The magnetic core 1a as described above has the same effects as the magnetic core 1.

[0062] [Second modified example] A magnetic core 1b according to a second modified example of the present invention will be described below with reference to the drawings. Fig. 20 is a plan view of the back yoke portion 2 according to the second modified example as viewed in the front direction. Regarding the magnetic core 1b according to the second modified example, only the parts different from the magnetic core 1 according to the first embodiment will be described, and the rest will be omitted.

[0063] As shown in FIG. 20, the magnetic core 1b differs from the magnetic core 1 in that the length in the left-right direction of the first upper surface US1 is longer than the length in the left-right direction of the first lower surface DS1.

[0064] The magnetic core 1b as described above has the same effects as the magnetic core 1. Furthermore, the magnetic core 1b makes it easier to arrange the magnetic core 1b inside the brushless motor 100.

[0065] [Third modified example] A magnetic core 1c according to a third modified example of the present invention will be described below with reference to the drawings. Fig. 21 is a plan view of the back yoke portion 2 according to the third modified example, viewed in the forward direction. Regarding the magnetic core 1c according to the third modified example, only the parts different from the magnetic core 1 according to the first embodiment will be described, and the rest will be omitted.

[0066] As shown in FIG. 21, the magnetic core 1c differs from the magnetic core 1 in that the length in the left-right direction of the second upper surface US2 is longer than the length in the left-right direction of the second lower surface DS2.

[0067] The magnetic core 1c as described above has the same effects as the magnetic core 1. Furthermore, the magnetic core 1c makes it easier to arrange the magnetic core 1c inside the brushless motor 100.

[0068] [Other embodiments] The magnetic core according to the present invention is not limited to the magnetic cores 1, 1a to 1c, and may be modified within the scope of the invention. Furthermore, the structures of the magnetic cores 1, 1a to 1c may be combined in any manner.

[0069] Any one of the magnetic cores 1, 1a to 1c and the conductor 5 may be modularized to form the magnetic core-equipped windings 50, 50a to 50c.

[0070] It is sufficient that brushless motor 100 includes any one of magnetic cores 1, 1a to 1c.

[0071] It should be noted that the brushless motor 100 does not have to include, for example, a plurality of magnetic cores 1. The brushless motor 100 may have, for example, a single magnetic core 1. Furthermore, the brushless motor 100 does not have to include a plurality of conductors 5. The brushless motor 100 may have a single conductor 5.

[0072] It should be noted that the brushless motor 100 is not limited to an inner rotor type, but may be, for example, an outer rotor type.

[0073] It should be noted that the brushless motor 100 is not limited to a single-shaft type, but may be, for example, a double-shaft type.

[0074] The material of the housing 11 may be a material other than SUS. The material of the housing 11 may be any material having high rigidity.

[0075] The insulating member 12 may be, for example, an insulating resin. In this case, the magnetic core 1 is fixed to the housing 11 by the insulating member 12.

[0076] The rotating electric machine is not limited to the brushless motor 100. The rotating electric machine may have a structure in which the rotor 20 rotates. In this case, the rotating electric machine may include any one of the magnetic cores 1, 1a to 1c.

[0077] The material of the magnetic core 1 is not limited to a powder magnetic core. The material of the magnetic core 1 may be, for example, a laminated magnetic core. A laminated magnetic core is made by laminating electromagnetic steel sheets or the like. The material of the magnetic core 1 may be any material as long as it is a magnetic material.

[0078] When the first protrusion P1 is provided on the first lower surface DS1, the second protrusion P2 does not have to be provided on the second upper surface US2. When the second protrusion P2 is provided on the second upper surface US2, the first protrusion P1 does not have to be provided on the first lower surface DS1.

[0079] The length of the first upper surface US1 in the front-rear direction may be equal to the length of the first upper surface US1 in the left-right direction. Also, the length of the first upper surface US1 in the front-rear direction may be shorter than the length of the first upper surface US1 in the left-right direction.

[0080] The length of the first lower surface DS1 in the front-rear direction may be equal to the length of the first lower surface DS1 in the left-right direction. Also, the length of the first lower surface DS1 in the front-rear direction may be shorter than the length of the first lower surface DS1 in the left-right direction.

[0081] The length of the second upper surface US2 in the front-rear direction may be equal to the length of the second upper surface US2 in the left-right direction. Also, the length of the second upper surface US2 in the front-rear direction may be shorter than the length of the second upper surface US2 in the left-right direction.

[0082] The length of the second lower surface DS2 in the front-rear direction may be equal to the length of the second lower surface DS2 in the left-right direction. Also, the length of the second lower surface DS2 in the front-rear direction may be shorter than the length of the second lower surface DS2 in the left-right direction.

[0083] Each of the first upper surface US1, the first lower surface DS1, the second upper surface US2, and the second lower surface DS2 may have a curved surface. The first upper surface US1 may have, for example, an arc shape.

[0084] The conductor 5 is not limited to being made of copper or the like. The conductor 5 may be made of aluminum, for example. The conductor 5 may be made of any conductive material.

[0085] The magnetic core 1 is not limited to being produced by injection molding, but may be produced by transfer molding.

[0086] The winding portion 6 is not limited to being wound twice around the tooth portion 4 so as to be located around the tooth portion 4 when viewed in the vertical direction. For example, the winding portion 6 may be wound once around the tooth portion 4 so as to be located around the tooth portion 4 when viewed in the vertical direction. Also, for example, the winding portion 6 may be wound three or more times around the tooth portion 4 so as to be located around the tooth portion 4 when viewed in the vertical direction.

[0087] The number of the first protrusions P1 is not limited to a plurality of protrusions, and may be one.

[0088] The number of the second protrusions P2 is not limited to 1. The number of the second protrusions P2 may be one.

[0089] The first protrusions P1 may be in contact with each other.

[0090] The second protrusions P2 may be in contact with each other.

[0091] The first protrusions P1 do not have to be aligned in the front-rear direction when viewed in the up-down direction.Furthermore, the first protrusions P1 do not have to be aligned in the left-right direction when viewed in the up-down direction.

[0092] The second protrusions P2 do not have to be aligned in the front-rear direction when viewed in the up-down direction.Furthermore, the second protrusions P2 do not have to be aligned in the left-right direction when viewed in the up-down direction.

[0093] The first protrusion P1 does not have to be in contact with the left side of the tooth portion 4 when viewed in the vertical direction. The first protrusion P1 does not have to be in contact with the right side of the tooth portion 4 when viewed in the vertical direction. The first protrusion P1 does not have to be in contact with the front side of the tooth portion 4 when viewed in the vertical direction. The first protrusion P1 does not have to be in contact with the rear side of the tooth portion 4 when viewed in the vertical direction.

[0094] The second protrusion P2 does not have to be in contact with the left side of the tooth portion 4 when viewed in the vertical direction. The second protrusion P2 does not have to be in contact with the right side of the tooth portion 4 when viewed in the vertical direction. The second protrusion P2 does not have to be in contact with the front side of the tooth portion 4 when viewed in the vertical direction. The second protrusion P2 does not have to be in contact with the rear side of the tooth portion 4 when viewed in the vertical direction.

[0095] The first protrusion P1 may have, for example, an elliptical cone shape, an elliptical cylinder shape, a cone shape, a cylinder shape, a pyramid shape, or a prism shape. The lower end of the first protrusion P1 may be a point, a line, or a surface when viewed in the vertical direction. The lower end of the first portion PP1 may be a point, a line, or a surface when viewed in the vertical direction.

[0096] The second protrusion P2 may have, for example, an elliptical cone shape, an elliptical cylinder shape, a cone shape, a cylinder shape, a pyramid shape, or a prism shape. The upper end of the second protrusion P2 may be a point, a line, or a surface when viewed in the vertical direction. The upper end of the second portion PP2 may be a point, a line, or a surface when viewed in the vertical direction. [Explanation of symbols]

[0097] 1, 1a, 1b, 1c: Magnetic core 2: Back yoke 3: Tip of teeth 4: Teeth 5: Conductor 6: Winding section 10: Stator assembly 11: Housing 12: Insulating material 13: Shaft cover member 14: Bearings 20:Rota 21: Rotor yoke 22: Magnet 23: Shaft 50, 50a, 50b, 50c: Winding with magnetic core 100: Brushless motor 211: Main part 212: Shaft holder 213:Connection part A1:First area A2:Second area DS1: 1st bottom surface DS2: 2nd bottom surface E3: 3rd end E4: 4th end OE2: Outer edge OE3: Outer edge OE4: Outer edge OP: Opening P1: 1st protrusion P2: 2nd protrusion PB1: 1st posterior protrusion PB2: 2nd posterior protrusion PF1: 1st anterior protrusion PF2: 2nd front protrusion PL1: 1st left protrusion PL2: 2nd left protrusion PP1: 1st part PP2: 2nd part PR1: 1st right protrusion PR2: 2nd right protrusion US1: 1st top surface US2: 2nd top surface

Claims

1. A magnetic core used in a rotating electric machine in which a rotor rotates, comprising: The magnetic core is A back yoke portion having a first upper surface and a first lower surface aligned in the vertical direction; a tooth tip portion having a second upper surface and a second lower surface aligned in the vertical direction; a teeth portion having a shape extending in the vertical direction, an upper end contacting the first lower surface and a lower end contacting the second upper surface, and a conductor winding portion is wound around the teeth portion as viewed in the vertical direction; It is equipped with an outer edge of the back yoke portion when viewed in the vertical direction surrounds an outer edge of the tip portion of the teeth when viewed in the vertical direction, an outer edge of the tip portion of the teeth when viewed in the vertical direction surrounds an outer edge of the tooth portion when viewed in the vertical direction, The first lower surface is provided with a plurality of first protrusions each having a shape protruding downward, The first protrusions are arranged in the front-rear direction or the left-right direction when viewed in the up-down direction. Magnetic core.

2. A magnetic core for use in a rotating electric machine in which a rotor rotates, comprising: The magnetic core is A back yoke portion having a first upper surface and a first lower surface aligned in the vertical direction; a tooth tip portion having a second upper surface and a second lower surface aligned in the vertical direction; a teeth portion having a shape extending in the vertical direction, an upper end contacting the first lower surface and a lower end contacting the second upper surface, and a conductor winding portion is wound around the teeth portion as viewed in the vertical direction; It is equipped with an outer edge of the back yoke portion when viewed in the vertical direction surrounds an outer edge of the tip portion of the teeth when viewed in the vertical direction, an outer edge of the tip portion of the teeth when viewed in the vertical direction surrounds an outer edge of the tooth portion when viewed in the vertical direction, The first lower surface is provided with one or more first protrusions having a shape protruding downward, When viewed in the up-down direction, the teeth portion has a front side that includes a front end of the teeth portion and extends in the left-right direction, and a rear side that includes a rear end of the teeth portion and extends in the left-right direction, The first protrusion portion contacts the front edge or the rear edge when viewed in the up-down direction. Magnetic core.

3. the first lower surface has a first region overlapping with the winding portion when viewed in the up-down direction, the first protrusion includes a first portion located in the first region, A sum of areas of the lower ends of the first portions when viewed in the vertical direction is smaller than an area of ​​the first regions when viewed in the vertical direction. The magnetic core according to claim 1 or 2.

4. When viewed in the up-down direction, the teeth portion has a left side that includes a left end of the teeth portion and extends in a front-rear direction, and a right side that includes a right end of the teeth portion and extends in the front-rear direction, The first protrusion portion contacts the left side or the right side when viewed in the up-down direction. The magnetic core according to claim 1 or 2.

5. the first protrusion includes a portion located in a region above the winding portion, The magnetic core according to claim 1 or 2.

6. A magnetic core for use in a rotating electric machine in which a rotor rotates, comprising: The magnetic core is A back yoke portion having a first upper surface and a first lower surface aligned in the vertical direction; a tooth tip portion having a second upper surface and a second lower surface aligned in the vertical direction; a teeth portion having a shape extending in the vertical direction, an upper end contacting the first lower surface and a lower end contacting the second upper surface, and a conductor winding portion is wound around the teeth portion as viewed in the vertical direction; It is equipped with an outer edge of the back yoke portion when viewed in the vertical direction surrounds an outer edge of the tip portion of the teeth when viewed in the vertical direction, an outer edge of the tip portion of the teeth when viewed in the vertical direction surrounds an outer edge of the tooth portion when viewed in the vertical direction, The second upper surface is provided with a plurality of second protrusions each having an upwardly protruding shape, The second protrusions are arranged in the front-rear direction or the left-right direction when viewed in the up-down direction. Magnetic core.

7. A magnetic core for use in a rotating electric machine in which a rotor rotates, comprising: The magnetic core is A back yoke portion having a first upper surface and a first lower surface aligned in the vertical direction; a tooth tip portion having a second upper surface and a second lower surface aligned in the vertical direction; a teeth portion having a shape extending in the vertical direction, an upper end contacting the first lower surface and a lower end contacting the second upper surface, and a conductor winding portion is wound around the teeth portion as viewed in the vertical direction; It is equipped with an outer edge of the back yoke portion when viewed in the vertical direction surrounds an outer edge of the tip portion of the teeth when viewed in the vertical direction, an outer edge of the tip portion of the teeth when viewed in the vertical direction surrounds an outer edge of the tooth portion when viewed in the vertical direction, The second upper surface is provided with one or more second protrusions having an upwardly protruding shape, When viewed in the up-down direction, the teeth portion has a front side that includes a front end of the teeth portion and extends in the left-right direction, and a rear side that includes a rear end of the teeth portion and extends in the left-right direction, The second protrusion portion contacts the front edge or the rear edge when viewed in the up-down direction. Magnetic core.

8. the second upper surface has a second region overlapping with the winding portion when viewed in the up-down direction, the second protrusion includes a second portion located in the second region, A sum of areas of the upper ends of the second portions when viewed in the vertical direction is smaller than an area of ​​the second regions when viewed in the vertical direction. The magnetic core according to claim 6 or 7.

9. When viewed in the up-down direction, the teeth portion has a left side that includes a left end of the teeth portion and extends in a front-rear direction, and a right side that includes a right end of the teeth portion and extends in the front-rear direction, The second protrusion portion contacts the left side or the right side when viewed in the up-down direction. The magnetic core according to claim 6 or 7.

10. the second protrusion portion includes a portion located in a region below the winding portion, The magnetic core according to claim 6 or 7.

11. The length of the first upper surface in the left-right direction is longer than the length of the first lower surface in the left-right direction. The magnetic core according to claim 1, claim 2, claim 6, or claim 7.

12. The length of the second upper surface in the left-right direction is longer than the length of the second lower surface in the left-right direction. The magnetic core according to claim 1, claim 2, claim 6, or claim 7.

13. A magnetic core according to any one of claims 1 to 7, The conductor. Winding with magnetic core.

14. A magnetic core according to any one of claims 1 to 7, Rotating electrical machines.

15. A magnetic core according to any one of claims 1 to 7, Brushless motor.

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