Stator and method for manufacturing the same

Abstract

To improve heat dissipation of a coil.SOLUTION: A coil 20 includes a first coil part 21, at least a part of which is arranged in a slot 15, and a second coil part 22, one end of which is press-fitted into one end of the first coil part 21. An insulation resin 30 has a continuous filling part 31 to be continuously filled between an inner wall of the slot 15 and the first coil part 21, at a central part in the slot 15 in an axial direction. A positioning component (first positioning component 40) is arranged on one side of the continuous filling part 31 in the axial direction, and positions the first coil part 21 while at least a part of the positioning component is interposed between the inner wall of the slot 15 and the first coil part 21 in a circumferential direction of the stator core 10. A gap G between the first coil part 21 and the second coil part 22 which are press-fitted into each other is covered with the positioning component (first positioning component 40) in the circumferential direction.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present disclosure relates to a stator and a method for manufacturing a stator. [Background technology]

[0002] A stator is disclosed in Patent Documents 1, 2, and Fig. 3D of Patent Document 3. In this stator, a coil is fixed to a stator core via insulating paper. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-62911 [Patent Document 2] Japanese Patent Publication No. 2020-33433 [Patent Document 3] Patent Publication No. 2021-191051 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned stator, it is desirable to improve the heat dissipation performance of the coil.

[0005] Therefore, an object of the present disclosure is to provide a technique that can improve the heat dissipation properties of a coil. [Means for solving the problem]

[0006] The stator of the present disclosure comprises: The rotor includes an annular stator core, a coil, an insulating resin, and a positioning component. The stator core has a plurality of slots arranged annularly and axially penetrating the stator core, the coil has a first coil portion at least a portion of which is disposed within the slot, and a second coil portion having one end press-fitted into one end of the first coil portion; the insulating resin has a continuous filling portion that is continuously filled between an inner wall of the slot and the first coil portion at a central portion in the axial direction within the slot, the positioning component is disposed on one side of the continuous filling portion in the axial direction, and positions the first coil portion in a state where at least a portion of the positioning component is inserted between an inner wall of the slot and the first coil portion in the circumferential direction of the stator core; The gap between the first coil portion and the second coil portion that are press-fitted together is covered in the circumferential direction by the positioning component.

[0007] The method for manufacturing a stator according to the present disclosure includes: A method for manufacturing a stator comprising: an annular stator core; and a coil, the stator core having a plurality of slots arranged annularly and penetrating the stator core in an axial direction; and the coil having a first coil segment and a second coil segment, A jig is placed on one side of the slot in the axial direction. death, a positioning step of positioning the first coil segment using the jig; a press-fitting step of press-fitting one end of the second coil segment into one end of the first coil segment positioned in the positioning step; a filling step of continuously filling an insulating resin between an inner wall of the slot and the first coil segment in a central portion of the slot in the axial direction, In the press-fitting step, one end of the second coil segment is press-fitted into one end of the first coil segment, with one end of the first coil segment being positioned within a range in which the jig exists in the axial direction. [Effects of the Invention]

[0008] According to the present disclosure, the heat dissipation properties of the coil can be improved. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of a stator core. [Figure 2] FIG. 2 is a cross-sectional view of a part of a cross section of the stator taken in a direction perpendicular to the axial direction, as viewed from the other side in the axial direction. [Figure 3] FIG. 3 is a perspective view of the first positioning component as viewed from one side in the axial direction. [Figure 4] FIG. 4 is a perspective view of the first positioning component as viewed from the other axial side. [Figure 5] FIG. 5 is a side view of the first coil segment and the second coil segment. [Figure 6] FIG. 6 is a cross-sectional view illustrating a state in which the first coil segment is positioned by the first positioning component and the second positioning component. [Figure 7] FIG. 7 is a cross-sectional view showing a state in which the slot is filled with insulating resin. [Figure 8] FIG. 8 is a cross-sectional view showing a state in which the second coil segment is press-fitted into the first coil segment. [Figure 9] FIG. 9 is an explanatory diagram for explaining a first alternative embodiment of the first positioning component. [Figure 10] FIG. 10 is an explanatory view for explaining a second alternative embodiment of the first positioning component. DETAILED DESCRIPTION OF THE INVENTION

[0010] [Description of the embodiments of the present disclosure] In the following, embodiments of the present disclosure are listed and illustrated.

[0011] [1] A motor comprising an annular stator core, a coil, an insulating resin, and a positioning component; The stator core has a plurality of slots arranged annularly and axially penetrating the stator core, the coil has a first coil portion at least a portion of which is disposed within the slot, and a second coil portion having one end press-fitted into one end of the first coil portion; the insulating resin has a continuous filling portion that is continuously filled between an inner wall of the slot and the first coil portion at a central portion in the axial direction within the slot, the positioning component is disposed on one side of the continuous filling portion in the axial direction, and positions the first coil portion in a state where at least a portion of the positioning component is inserted between an inner wall of the slot and the first coil portion in the circumferential direction of the stator core; A gap between the first coil portion and the second coil portion that are press-fitted together is covered in the circumferential direction by the positioning component. Stator.

[0012] With this configuration, the insulating resin is continuously filled between the inner wall of the slot and the first coil portion without the need for insulating paper, thereby improving the heat dissipation performance of the coil compared to a configuration in which insulating paper is used. Furthermore, because the first coil portion is positioned by the positioning component while the insulating resin is filled between the inner wall of the slot and the first coil portion, the position of the first coil portion is easily stabilized, which results in stable heat dissipation performance of the first coil portion via the insulating resin. Furthermore, because the gap between the first coil portion and the second coil portion is covered in the circumferential direction by the positioning component, foreign matter is less likely to enter.

[0013] [2] The positioning component positions both the first coil portion and the second coil portion. The stator described in [1].

[0014] According to this configuration, both the first coil portion and the second coil portion are positioned by the positioning component, so that they are less likely to rattle with each other.

[0015] [3] The positioning component positions the first coil portion and the second coil portion inside and outside the slot in the axial direction. The stator according to [2].

[0016] According to this configuration, the first coil portion and the second coil portion are positioned both inside and outside the slot, so that the positions of the first coil portion and the second coil portion tend to be stable.

[0017] [4] A recess is provided at one end of the first coil portion and a protrusion is provided at the other end of the second coil portion, The protrusion is press-fitted into the recess. The stator according to any one of [1] to [3].

[0018] This configuration makes it easy to simplify the structure in which the first coil portion and the second coil portion are press-fitted.

[0019] [5] The recess is provided in the first coil portion, The protrusion is provided on the second coil portion. The stator according to [4].

[0020] The mating surface between the recess and protrusion is prone to heat generation when current flows. However, with this configuration, compared to a configuration in which the recess is provided in the second coil section and the protrusion is provided in the first coil section, the mating surface between the recess and protrusion is positioned closer to the insulating resin, making it easier for the heat generated at this mating surface to be released from the insulating resin.

[0021] [6] The positioning component positions both the first coil portion and the second coil portion, The length of the region where the positioning component positions the second coil portion in the axial direction is longer than both the protruding dimension of the convex portion and the depth of the concave portion. The stator according to [4] or [5].

[0022] According to this configuration, the second coil portion can be positioned with higher precision.

[0023] [7] A method for manufacturing a stator comprising: an annular stator core; and a coil, wherein the stator core has a plurality of slots arranged annularly and penetrating the stator core in the axial direction; and the coil has a first coil segment and a second coil segment, A jig is placed on one side of the slot in the axial direction. death, a positioning step of positioning the first coil segment using the jig; a press-fitting step of press-fitting one end of the second coil segment into one end of the first coil segment positioned in the positioning step; a filling step of continuously filling an insulating resin between an inner wall of the slot and the first coil segment in a central portion of the slot in the axial direction, In the press-fitting step, one end of the second coil segment is press-fitted into one end of the first coil segment in a state where one end of the first coil segment is positioned within a range in which the jig exists in the axial direction. A method for manufacturing a stator.

[0024] With this configuration, since no insulating paper is interposed between the inner wall of the slot and the first coil segment in the continuous filling section, heat from the first coil segment is easily dissipated. Moreover, since one end of the second coil segment is press-fitted into one end of the first coil segment while one end of the first coil segment is positioned within the range of the jig in the axial direction, the first coil segment is less likely to shift position and the second coil segment is easily press-fitted.

[0025] [8] The jig has a pair of positioning surfaces that position the first coil segment and the second coil segment, and a pair of inclined surfaces that guide the second coil segment between the pair of positioning surfaces, The aforementioned Positioning process the jig is disposed so that the pair of inclined surfaces are located on the one side in the axial direction relative to the pair of positioning surfaces. A method for manufacturing a stator according to [7].

[0026] With this configuration, when the second coil segment is inserted between the pair of positioning surfaces, even if the position of the second coil segment is slightly misaligned, the inclined surfaces guide the second coil segment between the pair of positioning surfaces, making it easy to insert the second coil segment between the pair of positioning surfaces from one axial side.

[0027] [9] A recess is provided at one end of the first coil segment and a protrusion is provided at the other end of the second coil segment, The protrusion is press-fitted into the recess, the jig has a pair of positioning surfaces that position the first coil segment and the second coil segment, In the positioning step, the first coil segment is positioned so that the length in the axial direction of the region of the pair of positioning surfaces that positions the second coil segment is longer than the protruding dimension of the convex portion. A method for manufacturing a stator according to [7] or [8].

[0028] With this configuration, the second coil segment can be press-fitted into the first coil segment while being guided between the pair of positioning surfaces, making it easier to press-fit the second coil segment into the first coil segment.

[0029]

[10] In the filling step, the insulating resin is filled into the slot while the opening on the one side in the axial direction of the slot is closed with the jig. A method for manufacturing a stator according to any one of [7] to [9].

[0030] According to this configuration, the jig can easily prevent the insulating resin from leaking out from the opening on one side of the slot in the axial direction.

[0031] First Embodiment 1. Stator 1 configuration The stator 1 of the first embodiment is used as a component of a rotating electric machine (specifically, a motor). The stator 1 has an annular shape, more specifically, a circular ring shape. As shown in FIGS. 2 and 8, the stator 1 includes a stator core 10, a coil 20, an insulating resin 30, a first positioning component 40, and a second positioning component 60.

[0032] 1, the stator core 10 is annular, more specifically, circular. Hereinafter, the radial direction of the stator core 10 will be referred to as the radial direction, the axial direction of the stator core 10 will be referred to as the axial direction, and the circumferential direction of the stator core 10 will be referred to as the circumferential direction.

[0033] As shown in FIGS. 1 and 2 , the stator core 10 has a yoke portion 11 and teeth portions 12. The yoke portion 11 is annular, more specifically, circular. A plurality of teeth portions 12 are arranged in an annular pattern along the inner circumferential surface of the yoke portion 11. The teeth portions 12 are spaced apart from one another in the circumferential direction. Each tooth portion 12 protrudes radially inward from the inner circumferential surface of the yoke portion 11. Each tooth portion 12 has a wall shape extending along the radial and axial directions. Each tooth portion 12 has a tooth main body 13 having a wall shape extending along the radial and axial directions, and a tooth protrusion portion 14 protruding on both circumferential sides from the tip end (in other words, the radially inner end) of the tooth main body 13.

[0034] The stator core 10 may be, for example, a laminated steel plate manufactured by stacking multiple electromagnetic steel plates (e.g., silicon steel plates) in the thickness direction, or may be a dust core formed by press-molding insulating coated magnetic particles.

[0035] As shown in FIG. 1, the stator core 10 has a plurality of slots 15. The slots 15 are arranged in a ring shape. The slots 15 penetrate the stator core 10 in the axial direction. As shown in FIGS. 1 and 8, the slots 15 have a first opening 16, a second opening 17, and a third opening 18. The first opening 16 is formed in one axial surface of the stator core 10. The second opening 17 is formed in the other axial surface of the stator core 10. The third opening 18 is formed in the radially inner surface of the stator core 10. The third opening 18 is continuous with the first opening 16 and the second opening 17. As shown in FIG. 2, the slot 15 is defined by two adjacent tooth portions 12. The slot 15 is defined on both circumferential sides by the tooth portions 12 and on the radially outer surface by the yoke portion 11.

[0036] The coil 20 may be a distributed winding or a concentrated winding. The coil 20 passes through the slot 15 and is wound around the tooth portion 12. As shown in FIG. 2, the coil 20 has a rectangular cross section cut perpendicular to the longitudinal direction. The coil 20 includes a core wire forming a conductive path and a coating portion that covers the core wire. The core wire is a conductor. The core wire is a rectangular wire, and has a rectangular cross section cut perpendicular to the longitudinal direction. The coating portion forms an insulating layer. The material of the coating portion is not particularly limited. In this embodiment, the coating portion is a low-dielectric-constant enamel having a low dielectric constant. The coating portion may be mainly composed of a thermosetting resin, such as polyvinyl formal, thermosetting polyurethane, thermosetting acrylic, epoxy, thermosetting polyester, thermosetting polyesterimide, aromatic polyamide, thermosetting polyamideimide, or thermosetting polyimide. The covering portion may be mainly composed of a thermoplastic resin such as polyetherimide, polyphenylene ether, polyethersulfone, polyphenylene sulfide, polyetheretherketone, thermoplastic polyimide, etc. Here, the term "main component" refers to the component that is contained in the greatest amount, for example, a component that is contained in an amount of 50 mass % or more.

[0037] As shown in FIG. 8 , the coil 20 has a first coil portion 21 and a second coil portion 22. The first coil portion 21 and the second coil portion 22 are each linear. The first coil portion 21 and the second coil portion 22 are connected by press-fitting one end thereof. The first coil portion 21 and the second coil portion 22 that are press-fitted together form a linear shape as a whole. One end of the first coil portion 21 (i.e., the end on one side in the axial direction) is provided with a recess 23. One end of the second coil portion 22 (i.e., the end on the other side in the axial direction) is provided with a protrusion 24. The first coil portion 21 and the second coil portion 22 are press-fitted together by press-fitting the protrusion 24 into the recess 23.

[0038] As shown in Fig. 8, at least a portion of the first coil portion 21 is disposed within the slot 15. One end side (one end on one axial side) of the first coil portion 21 is preferably disposed within the slot 15. In other words, one end of the first coil portion 21 is preferably disposed at the same position as the edge of the first opening 16 in the axial direction, or on the other axial side of the edge of the first opening 16. In the example shown in Fig. 8, one end of the first coil portion 21 is disposed at the same position as the edge of the first opening 16 in the axial direction.

[0039] The recess 23 of the first coil portion 21 is formed by recessing a portion of the end face 21A on one axial side of the first coil portion 21. The recess 23 opens to one axial side of the first coil portion 21. The recess 23 is provided in the circumferential center of the first coil portion 21 and opens to both radial sides of the first coil portion 21. The recess 23 has a pair of inner surface 23A and a rear surface 23B that are provided on both circumferential sides and face each other. The pair of inner surface 23A and the rear surface 23B are each flat surfaces. The rear surface 23B faces one axial side. The rear surface 23B is continuous with the other axial end portions of the pair of inner surface 23A and connects the other axial end portions of the pair of inner surface 23A to each other.

[0040] 8, at least a portion of the second coil portion 22 is disposed within the slot 15. One end side of the second coil portion 22 (the other end side in the axial direction) is inserted into the slot 15.

[0041] The protrusion 24 of the second coil portion 22 is formed to protrude from a reference surface 22A on the other axial side of the second coil portion 22. The protrusion 24 protrudes to the other axial side. The reference surface 22A is a flat surface, and the protrusion 24 is formed to protrude from the reference surface 22A on the other axial side. On the other hand The protrusion 24 is provided in the circumferential center of the second coil portion 22 and faces in the axial direction relative to the reference surfaces 22A arranged on both sides in the circumferential direction. On the other hand The protrusions 24 are provided over the entire radial area of ​​the second coil portion 22. The cross section of the protrusions 24 taken in a direction perpendicular to the axial direction is rectangular. The protrusions 24 have a pair of first outer surfaces 24A and a pair of second outer surfaces 24B that constitute the outer circumferential surface of the protrusions 24, and a protruding end surface 24C. The pair of first outer surfaces 24A each face in the circumferential direction. The pair of second outer surfaces 24B each face in the radial direction. The protruding end surface 24C faces in the axial direction. On the other hand The protruding end surfaces 24C are located between the pair of first outer surfaces 24A and the pair of second outer surfaces 24B. On the other hand The pair of first outer surfaces 24A and the pair of second outer surfaces 24B are connected to the end portions of the pair of first outer surfaces 24A and the pair of second outer surfaces 24B. On the other hand The side ends are connected together.

[0042] When the protrusion 24 is press-fitted into the recess 23, the protruding end surface 24C of the protrusion 24 faces the inner surface 23B of the recess 23. Each of the pair of first outer surfaces 24A of the protrusion 24 faces each of the pair of inner surfaces 23A of the recess 23. An end surface 21A on one axial side of the first coil portion 21 faces the reference surface 22A of the second coil portion 22. A gap G is formed between one end of the first coil portion 21 and one end of the second coil portion 22 (i.e., between the end surface 21A and the reference surface 22A).

[0043] The coil 20 has a first extension portion 26 extending from the other end of the first coil portion 21 via a first bend portion 25, and a second extension portion 28 extending from the other end of the second coil portion 22 via a second bend portion 27.

[0044] The slots 15 are filled with insulating resin 30. In FIG. 2, slots 15A and 15B are shown as slots 15. The insulating resin 30 is omitted from slot 15A. Slot 15B is shown filled with insulating resin 30. The insulating resin 30 has a continuous filling portion 31 that is continuously filled between the inner wall of slot 15B (slot 15) and the first coil portion 21 at the axial center of the stator core 10. The continuous filling portion 31 is continuously filled in the axial direction except for both ends of slot 15B (slot 15). With this configuration, no insulating paper is interposed between the inner wall of slot 15 and the first coil portion 21 in the continuous filling portion 31, making it easier to dissipate heat from the coil 20.

[0045] As described above, the first coil portion 21 is provided with a recess 23. The second coil portion 22 is provided with a protrusion 24 that is press-fit into the recess 23. The mating surface between the recess 23 and the protrusion 24 is likely to generate heat when a current flows. However, with this configuration, compared to a configuration in which the recess 23 is provided in the second coil portion 22 and the protrusion 24 is provided in the first coil portion 21, the mating surfaces between the recess 23 and the protrusion 24 (more specifically, the pair of inner side surfaces 23A of the recess 23, the rear surface 23B of the recess 23, the pair of first outer side surfaces 24A of the protrusion 24, and the protruding end surfaces 24C of the protrusions) are positioned closer to the insulating resin 30, and therefore heat generated at the mating surfaces is more likely to be released from the insulating resin 30.

[0046] The first positioning component 40 is an example of a "positioning component" and an example of a "jig." The first positioning component 40 has insulating properties and is made of, for example, resin or ceramic. As shown in FIGS. 3 and 4, the first positioning component 40 has an annular shape. The first positioning component 40 has a base 41 and a protrusion 42.

[0047] The base 41 has an annular base 43 and a protruding portion 44. The annular base 43 has an annular shape. The annular base 43 has a pair of long portions 45 and a pair of short portions 46. The pair of long portions 45 extend linearly and parallel to each other. The pair of long portions 45 extend along the radial direction. The short portions 46 are shorter than the long portions 45. The pair of short portions 46 extend linearly and parallel to each other. The pair of short portions 46 extend along a direction perpendicular to the long portions 45. The pair of short portions 46 extend along the circumferential direction. The pair of long portions 45 and the pair of short portions 46 form an annular shape as a whole.

[0048] The protruding portions 44 protrude from the base portion 41 toward one side in the axial direction. The protruding portions 44 protrude from each of the pair of longitudinal portions 45 toward one side in the axial direction. That is, the protruding portions 44 form a pair. Each of the pair of protruding portions 44 has an opposing surface 47 and an inclined surface 48 that face each other. The pair of opposing surfaces 47 face each other in the circumferential direction. The opposing surface 47 is a surface that extends in the axial and radial directions. At least a portion of the opposing surface 47 is flush with the inner circumferential surface of the annular base portion 43 (more specifically, the surface where the pair of longitudinal portions 45 face each other). The pair of inclined surfaces 48 are inclined so that the distance between them increases toward the protruding side (one side in the axial direction) of the protruding portion 44. The radially inner ends of the pair of protruding portions 44 are positioned radially inward of the inner circumferential surface of the annular base portion 43 and are positioned radially inward of the inner circumferential surface of the protrusion 42. The radially outer ends of the pair of overhanging portions 44 are disposed radially outward from the inner circumferential surface of the annular base portion 43, and are disposed radially outward from the inner circumferential surface of the protruding portion 42. The radially inner ends of the pair of opposing surfaces 47 and the pair of inclined surfaces 48 are disposed radially inward from the inner circumferential surface of the annular base portion 43, and are disposed radially inward from the inner circumferential surface of the protruding portion 42. The radially outer ends of the pair of opposing surfaces 47 and the pair of inclined surfaces 48 are disposed radially outward from the inner circumferential surface of the annular base portion 43, and are disposed radially outward from the inner circumferential surface of the protruding portion 42.

[0049] The protruding portion 42 protrudes in a cylindrical shape from the base portion 41 toward the side opposite to the overhanging portion 44 (the other side in the axial direction). The protruding portion 42 protrudes in a cylindrical shape from the inner peripheral portion of the cylindrical base portion 41. The protruding portion 42 has a rectangular cylindrical shape. The protruding portion 42 has a pair of long plate portions 50 and a pair of short plate portions 51. The pair of long plate portions 50 extend linearly and parallel to each other. The pair of long plate portions 50 extend along the radial direction. The short plate portions 51 are shorter than the long plate portions 50. The pair of short plate portions 51 extend linearly and parallel to each other. The pair of short plate portions 51 extend along a direction perpendicular to the long plate portions 50. The pair of short plate portions 51 extend along the circumferential direction. The pair of long plate portions 50 and the pair of short plate portions 51 form a cylindrical shape (more specifically, a rectangular cylindrical shape) as a whole.

[0050] The inner peripheral surface of the protrusion 42 is continuous without any steps with the inner peripheral surface of the base 41 (annular base 43). The outer peripheral surface of the protrusion 42 has an outer peripheral tapered surface 52 that is formed so as to taper toward the protruding end.

[0051] The first positioning component 40 has an inner protruding portion 53 that protrudes radially inward from the outer peripheral surface of the protruding portion 42. As shown in FIG. 2, the inner protruding portion 53 is disposed in a gap between the tooth protruding portions 14 in the circumferential direction.

[0052] 3 and 4, the first positioning component 40 has a pair of positioning surfaces 54. The pair of positioning surfaces 54 circumferentially position the first coil portion 21 and the second coil portion 22. The pair of positioning surfaces 54 is made up of the pair of opposing surfaces 47, the inner peripheral surface of the annular base portion 43 (more specifically, the opposing surfaces of the pair of long portions 45), and the inner peripheral surface of the protruding portion 42 (more specifically, the opposing surfaces of the pair of long plate portions 50).

[0053] In this embodiment, the second positioning component 60 has the same configuration as the first positioning component 40, and therefore a detailed description thereof will be omitted.

[0054] 8, the first positioning component 40 positions the first coil portion 21 on one axial side of the continuous filling portion 31 with the protruding portion 42 inserted between the inner wall of the slot 15 and the first coil portion 21. In the circumferential direction, the protruding portions 42 position the first coil portion 21 with the protruding portions 42 inserted between the inner wall of the slot 15 and the first coil portion 21 on both sides of one first coil portion 21. In the radial direction, the protruding portions 42 position the first coil portion 21 with the protruding portions 42 inserted between the inner wall of the slot 15 and the inner wall of the slot 15 among the multiple first coil portions 21 arranged side by side in the radial direction. According to this configuration, the protrusion 42 of the first positioning part 40 positions the first coil part 21 while inserted between the inner wall of the slot 15 and the first coil part 21, which makes it easier to stabilize the position of the first coil part 21 within the slot 15, and as a result, makes it easier to stabilize the heat dissipation performance of the first coil part 21 via the insulating resin 30.

[0055] The first positioning component 40 positions both the first coil portion 21 and the second coil portion 22. According to this configuration, since both the first coil portion 21 and the second coil portion 22 are positioned by the first positioning component 40, they are less likely to rattle with each other.

[0056] The first positioning component 40 is disposed axially both inside and outside the slot 15, and positions the first coil portion 21 and the second coil portion 22 both inside and outside the slot 15. More specifically, the inner circumferential surface of the protruding portion 42 of the first positioning component 40 positions the first coil portion 21 inside the slot 15, and the inner circumferential surface of the annular base portion 43 and a pair of opposing surfaces 47 of the pair of protruding portions 44 position the second coil portion 22 outside the slot 15. With this configuration, the first coil portion 21 and the second coil portion 22 are positioned both inside and outside the slot 15, which makes the positions of the first coil portion 21 and the second coil portion 22 more stable.

[0057] 8, the gap G between the first coil portion 21 and the second coil portion 2, which are press-fitted together, is covered in the circumferential direction by the first positioning component 40. For this reason, foreign matter is less likely to enter the gap G between the first coil portion 21 and the second coil portion 2.

[0058] As shown in FIG. 7, the axial length L1 of the region where the first positioning component 40 positions the second coil portion 22 is longer than both the protruding dimension L2 of the protruding portion 24 and the depth L3 of the recessed portion 23. This configuration allows the second coil portion 22 to be positioned with higher accuracy. The axial length L1 of the region where the first positioning component 40 positions the second coil portion 22 is the length from the other axial end of the base portion 41 to one axial end of the opposing surface 47. The protruding dimension L2 of the protruding portion 24 is the length from the reference surface 22A to the protruding end surface 24C. The depth L3 of the recessed portion 23 is the length from the end surface 21A on one axial side of the first coil portion 21 to the back surface 23B of the recessed portion 23. The depth L3 of the recessed portion 23 is shorter than the protruding dimension L4 of the protruding portion 42.

[0059] As shown in Figure 8, the second positioning part 60 positions the first coil part 21 on the other axial side of the continuous filling part 31, with the protrusion 42 inserted between the inner wall of the slot 15 and the first coil part 21, similar to the first positioning part 40.

[0060] 8, the first coil portion 21 is positioned by a first positioning component 40 and a second positioning component 60. With this configuration, the first coil portion 21 is positioned on both sides in the axial direction, which makes it easier to stabilize the position of the first coil portion 21.

[0061] 8, the inclined surface 48 of the first positioning component 40 is disposed along the first extension portion 26 of the coil 20. The inclined surface 48 of the second positioning component 60 is disposed along the second extension portion 28 of the coil 20. With this configuration, the displacement of the first extension portion 26 is restricted by the inclined surface 48 of the first positioning component 40, and the displacement of the second extension portion 28 is restricted by the inclined surface 48 of the second positioning component 60, making it easier to stabilize the posture of the coil 20.

[0062] 2, a plurality of (four in this embodiment) first coil portions 21 are arranged in one slot 15. The plurality of first coil portions 21 are arranged in a row along the radial direction in one slot 15.

[0063] 2. Manufacturing method of stator 1 The stator 1 has, as components of the coil 20, a first coil segment 71 and a second coil segment 72 shown in FIG.

[0064] The first coil segment 71 has a pair of first coil portions 21 and a pair of first extension portions 26. The first coil portions 21 are provided on both ends of the first coil segment 71. One end of the first extension portion 26 is connected to the other end of each of the pair of first coil portions 21 via a first bent portion 25. The other ends of the first extension portions 26 are connected to each other. In other words, the other ends of the pair of first coil portions 21 are connected to each other via the first extension portion 26.

[0065] The second coil segment 72 has a pair of second coil portions 22 and a pair of second extension portions 28. The second coil portions 22 are provided on both ends of the second coil segment 72. One end of the second extension portion 28 is connected to the other end of each of the pair of second coil portions 22 via a second bent portion 27. The other ends of the second extension portions 28 are connected to each other. In other words, the other ends of the pair of second coil portions 22 are connected to each other via the second extension portion 28.

[0066] The manufacturing method of the stator 1 includes an attachment step, a first positioning step, a second positioning step, a filling step, and a press-fitting step.

[0067] In the attachment process, the second positioning component 60 is attached to the first coil portion 21 of the first coil segment 71 (see FIG. 6). The first coil portion 21 is inserted between the pair of inclined surfaces 48 of the second positioning component 60 from the one end side where the recess 23 is provided, and is then inserted between the pair of positioning surfaces 54. When the first coil portion 21 is inserted between the pair of positioning surfaces 54, even if it is slightly misaligned in the circumferential direction, it is guided between the pair of positioning surfaces 54 by the pair of inclined surfaces 48. Therefore, with this configuration, the first coil portion 21 can be easily passed between the pair of positioning surfaces 54.

[0068] In the first positioning step, the second positioning component 60 attached to the first coil portion 21 is disposed on the other axial side of the slot 15, and the first coil portion 21 is positioned by the second positioning component 60 (see FIG. 6 ). The second positioning component 60 is disposed so as to cover at least a portion of the opening edge on the other axial side of the slot 15. The second positioning component 60 is inserted into the slot 15 from the protruding end side of the protruding portion 42. An outer peripheral tapered surface 52 is formed on the protruding end side of the protruding portion 42. Therefore, even if the protruding portion 42 is slightly misaligned when inserted into the slot 15, the protruding portion 42 is guided into the slot 15. Therefore, with this configuration, the protruding portion 42 of the second positioning component 60 can be easily inserted into the slot 15. The base 41 of the second positioning component 60 is disposed at the end on the other axial side of the stator core 10. The second positioning component 60 is disposed so as to block the opening (second opening 17) on the other axial side of the slot 15.

[0069] The second positioning step corresponds to an example of a "positioning step." In the second positioning step, the first positioning component 40 is disposed on one axial side of the slot 15, and the first coil portion 21 is positioned by the first positioning component 40 and the second positioning component 60 (see FIG. 6). The first positioning component 40 is disposed so as to cover at least a portion of the opening edge on one axial side of the slot 15. The first positioning component 40 is inserted into the slot 15 from the protruding end side of the protruding portion 42. An outer peripheral tapered surface 52 is formed on the protruding end side of the protruding portion 42. Therefore, even if the protruding portion 42 is slightly misaligned when inserted into the slot 15, the protruding portion 42 is guided into the slot 15. Therefore, with this configuration, the protruding portion 42 of the first positioning component 40 can be easily inserted into the slot 15. The protruding portion 42 is inserted into the gap between the inner wall of the slot 15 and the first coil portion 21, and is disposed in a state where it is sandwiched between the inner wall of the slot 15 and the first coil portion 21. The base 41 of the first positioning component 40 is disposed at one axial end of the stator core 10. The first positioning component 40 is disposed so as to close the opening (first opening 16) of the slot 15 on one axial side.

[0070] In the filling process, the insulating resin 30 is continuously filled between the inner wall of the slot 15 and the first coil portion 21 of the first coil segment 71 in the axial center of the slot 15 (see FIG. 7 ). Because the insulating resin 30 is continuously filled between the inner wall of the slot 15 and the first coil portion 21 of the first coil segment 71, heat from the first coil portion 21 is easily dissipated through the insulating resin 30, thereby improving the heat dissipation performance of the coil 20. When the insulating resin 30 is filled, the opening on one axial side of the slot 15 (first opening 16) is blocked by the first positioning component 40. The opening on the other axial side of the slot 15 (second opening 17) is blocked by the second positioning component 60. The opening on the radially inner side of the slot 15 (third opening 18) is blocked by a separate member, except for the resin injection portion. The insulating resin 30 is then filled into the slot 15 through the third opening 18. With this configuration, the first positioning component 40 and the second positioning component 60 can easily prevent the insulating resin 30 from leaking from both axial sides of the slot 15. The filling process is performed with the first coil portion 21 of the first coil segment 71 positioned by the first positioning component 40 and the second positioning component 60. With this configuration, when the insulating resin 30 hardens, the first coil segment 71 is easily positioned in an appropriate position. Furthermore, when the insulating resin 30 hardens, the first coil portion 21 is fixed within the slot 15.

[0071] In the press-fitting process, the second coil segment 72 is press-fitted into the first coil segment 71 (see FIG. 8 ). The recessed portion 23 of the first coil portion 21 and the protruding portion 24 of the second coil portion 22 are press-fitted into each other within the range in which the first positioning component 40 is present in the axial direction. This configuration makes it difficult for the recessed portion 23 and the protruding portion 24 to become misaligned with each other, thereby making it easier to avoid a situation in which the protruding portion 24 does not fit into the recessed portion 23 and is not properly press-fitted. Furthermore, the pair of inclined surfaces 48 of the first positioning component 40 are positioned on one axial side of the pair of positioning surfaces 54. With this configuration, when the second coil segment 72 is inserted between the pair of positioning surfaces 54, even if the position of the second coil segment 72 is slightly misaligned, the inclined surfaces 48 guide the second coil segment 72 between the pair of positioning surfaces 54. Therefore, with this configuration, the second coil portion 22 of the second coil segment 72 can be easily inserted between the pair of positioning surfaces 54 from one axial side. Furthermore, in the second positioning step described above, the first coil segment 71 is positioned so that the axial length L1 of the region of the pair of positioning surfaces 54 of the first positioning component 40 that positions the second coil segment 72 is longer than the protruding dimension L2 of the convex portion 24. With this configuration, the second coil segment 72 can be press-fitted into the first coil segment 71 while being guided between the pair of positioning surfaces 54. Therefore, with this configuration, the second coil segment 72 can be easily press-fitted into the first coil segment 71. Through these steps, the stator 1 is manufactured.

[0072] Second Embodiment In the second embodiment, a first alternative embodiment of the first positioning component will be described. In the following, the same components as those in the first embodiment will be given the same reference numerals, and detailed description thereof will be omitted.

[0073] The first positioning component 240 of the second embodiment corresponds to an example of a "jig." The first positioning component 240 has insulating properties and is formed of, for example, resin or ceramic. The first positioning component 240 has an annular shape. As shown in FIG. 9, the first positioning component 240 has a base 241 disposed at one end of the stator core 10 and a protruding portion 242 that protrudes in a cylindrical shape from the base 241. The base 241 has the same shape as the base 41 of the first embodiment.

[0074] The protruding portion 242 protrudes in a cylindrical shape from the base portion 241 on the side opposite to the overhanging portion 44 (the other axial side). The protruding portion 242 protrudes in a cylindrical shape from the inner periphery of the cylindrical base portion 241. The protruding portion 242 has a square cylindrical shape.

[0075] The inner peripheral surface of the protruding portion 242 is continuous without any steps with the inner peripheral surface of the base portion 241 (annular base portion 43). The inner peripheral surface of the protruding portion 242 has an inner peripheral tapered surface 242A formed so that the hole in the protruding portion 242 widens toward the protruding end.

[0076] The first positioning component 240 differs from the first positioning component 40 of the first embodiment in that it has an inner peripheral tapered surface 242A and does not have an outer peripheral tapered surface 52, but has the same other points.

[0077] The method for manufacturing the stator of the second embodiment includes an attachment step, a first positioning step, a second positioning step, a filling step, and a press-fitting step, similar to the method for manufacturing the stator 1 of the first embodiment.

[0078] In other words, in the second positioning step, the protrusion 242 of the first positioning part 240 is inserted into the gap between the inner wall of the slot 15 and the first coil part 21, and is positioned in a state where it is inserted between the inner wall of the slot 15 and the first coil part 21.

[0079] According to this configuration, the inner circumferential surface of the protruding portion 242 has an inner circumferential tapered surface 242A, so that even if the first positioning component 240 is slightly misaligned when passing the first coil portion 21 of the first coil segment 71 through the inside of the protruding portion 242, the inner circumferential tapered surface 242A guides the first coil portion 21 into the inside of the protruding portion 242. Therefore, according to this configuration, it is easy to pass the first coil portion 21 through the inside of the protruding portion 242.

[0080] <Third embodiment> In the third embodiment, a second alternative embodiment of the first positioning component will be described. The first positioning component of the third embodiment differs from the first positioning component of the second embodiment in that it has not only an inner peripheral tapered surface but also an outer peripheral tapered surface, but is otherwise common to both. In the following, the same components as those of the first embodiment will be assigned the same reference numerals, and detailed description will be omitted.

[0081] The first positioning component 340 of the third embodiment corresponds to an example of a "jig." The first positioning component 340 has insulating properties and is formed of, for example, resin or ceramic. The first positioning component 340 has an annular shape. As shown in FIG. 10 , the first positioning component 340 has a base 341 disposed at the other end of the stator core 10 and a protruding portion 342 that protrudes in a cylindrical shape from the base 341. The base 341 has the same shape as the base 41 of the first embodiment.

[0082] The protruding portion 342 protrudes in a cylindrical shape from the base portion 341 on the side opposite to the overhanging portion 44 (the other axial side). The protruding portion 342 protrudes in a cylindrical shape from the inner periphery of the cylindrical base portion 341. The protruding portion 342 has a square cylindrical shape.

[0083] The inner peripheral surface of the protruding portion 342 is continuous without any steps with the inner peripheral surface of the base portion 341 (annular base portion 43). The inner peripheral surface of the protruding portion 342 has an inner peripheral tapered surface 342A formed so that the hole in the protruding portion 342 widens toward the protruding end.

[0084] The outer peripheral surface of the protruding portion 342 has an outer peripheral tapered surface 342B that is tapered toward the protruding end.

[0085] The first positioning component 340 has an inner peripheral tapered surface 342A and an outer peripheral tapered surface 342B, and differs from the first positioning component 40 of the first embodiment in that it does not have the outer peripheral tapered surface 52, but has the other points in common.

[0086] The method for manufacturing the stator of the third embodiment includes the same steps as the method for manufacturing the stator 1 of the first embodiment: an attachment step, a first positioning step, a second positioning step, a filling step, and a press-fitting step.

[0087] In other words, in the second positioning process, the protrusion 242 of the first positioning part 240 is inserted into the gap between the inner wall of the slot 15 and the first coil part 21, and is positioned in a state where it is inserted between the inner wall of the slot 15 and the first coil part 21.

[0088] According to this configuration, Projection 342 Since the inner peripheral tapered surface 342A and the outer peripheral tapered surface 342B are formed on the protruding end side of the protruding portion 342, even if the protruding portion 342 is slightly misaligned, the protruding portion 3 42 is guided between the inner wall of the slot 15 and the first coil portion 21. Therefore, with this configuration, the protrusion 342 of the first positioning component 40 can be easily inserted into the gap between the inner wall of the slot 15 and the first coil portion 21.

[0089] <Other embodiments> The present disclosure is not limited to the embodiments described above and in the drawings. For example, the features of the above-described or following embodiments can be combined in any combination without contradiction. Furthermore, any feature of the above-described embodiments can be omitted unless it is explicitly stated as essential.

[0090] In the above embodiments, the first positioning component, which is a part of the stator, is used as the first jig, and the second positioning component is used as the second jig. However, the stator may be manufactured using a jig that is not a part of the stator.

[0091] In the second embodiment, the second positioning component may have the same form as the first positioning component.

[0092] In the third embodiment, the second positioning component may have the same form as the first positioning component.

[0093] It should be noted that the embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is not limited to the embodiments disclosed herein, but is intended to include all modifications within the scope indicated by the claims or the scope equivalent to the claims. [Explanation of symbols]

[0094] 1: Stator 10: Stator core 11: Yoke 12: Teeth 13: Teeth body 14: Teeth protrusion 15: Slot 15A: Slot 15B: Slot 16: First opening 17: Second opening 18: Third opening 20: Coil 21: First coil section 21A: One axial end face of the first coil portion 22: Second coil section 22A: Reference surface 23: Recess 23A: Inner surface 23B: Back side 24: Convex part 24A: 1st outer surface 24B: 2nd outer surface 24C:Protruding end surface 25: 1st bending part 26: 1st extension section 27:Second bending part 28:Second extension section 30: Insulating resin 31: Continuous filling section 40: First positioning part (positioning part, jig) 41: Base 42:Protrusion 43: Annular base 44: Overhang 45:Longitudinal part 46:Short side 47: Opposite surface 48: Inclined surface 50: Long board section 51:Short plate part 52: Tapered outer surface 53: Inner protrusion 54: Positioning surface 60: Second positioning part 71: First coil segment 72: Second coil segment 240: First positioning part (positioning part, jig) 241: Base 242:Protrusion 242A: Inner tapered surface 340: First positioning part (positioning part, jig) 341: Base 342:Protrusion 342A: Inner tapered surface 342B: Tapered outer surface 362:Second protrusion G: Gap between the first coil part and the second coil part L1: Axial length of the area where the first positioning component positions the second coil part L2: Projection dimension of the convex part L3: Depth of recess L4: Projection dimension of the protrusion

Claims

1. The rotor includes an annular stator core, a coil, an insulating resin, and a positioning component. The stator core has a plurality of slots arranged annularly and axially penetrating the stator core, the coil has a first coil portion at least a portion of which is disposed within the slot, and a second coil portion one end of which is press-fitted into one end of the first coil portion, the insulating resin has a continuous filling portion that is continuously filled between an inner wall of the slot and the first coil portion at a central portion in the axial direction within the slot, the positioning component is disposed on one side of the continuous filling portion in the axial direction, and positions the first coil portion in a state where at least a portion of the positioning component is inserted between an inner wall of the slot and the first coil portion in the circumferential direction of the stator core; A gap between the first coil portion and the second coil portion that are press-fitted together is covered in the circumferential direction by the positioning component. Stator.

2. The positioning component positions both the first coil portion and the second coil portion. The stator according to claim 1 .

3. The positioning component positions the first coil portion and the second coil portion inside and outside the slot in the axial direction. The stator according to claim 2 .

4. a recess is provided at one end of the first coil portion and a protrusion is provided at the other end of the second coil portion, The protrusion is press-fitted into the recess. The stator according to any one of claims 1 to 3.

5. the recess is provided in the first coil portion, The protrusion is provided on the second coil portion.

5. The stator according to claim 4.

6. the positioning component positions both the first coil portion and the second coil portion; The axial length of the region where the positioning component positions the second coil portion is longer than both the protruding dimension of the convex portion and the depth of the concave portion.

6. The stator according to claim 5.

7. A method for manufacturing a stator comprising: an annular stator core; and a coil, the stator core having a plurality of slots arranged annularly and penetrating the stator core in an axial direction; and the coil having a first coil segment and a second coil segment, a positioning step of placing a jig on one side of the slot in the axial direction and positioning the first coil segment using the jig; a press-fitting step of press-fitting one end of the second coil segment into one end of the first coil segment positioned in the positioning step; a filling step of continuously filling an insulating resin between an inner wall of the slot and the first coil segment at a central portion of the slot in the axial direction, In the press-fitting step, one end of the second coil segment is press-fitted into one end of the first coil segment in a state where one end of the first coil segment is positioned within a range in which the jig exists in the axial direction. A method for manufacturing a stator.

8. the jig has a pair of positioning surfaces that position the first coil segment and the second coil segment, and a pair of inclined surfaces that guide the second coil segment between the pair of positioning surfaces, In the positioning step, the jig is positioned so that the pair of inclined surfaces are positioned on the one side in the axial direction relative to the pair of positioning surfaces. The method for manufacturing a stator according to claim 7 .

9. a recess is provided at one end of the first coil segment and a protrusion is provided at the other end of the second coil segment, The protrusion is press-fitted into the recess, the jig has a pair of positioning surfaces that position the first coil segment and the second coil segment, In the positioning step, the first coil segment is positioned so that the length of the region of the pair of positioning surfaces that positions the second coil segment in the axial direction is longer than the protruding dimension of the convex portion. The method for manufacturing a stator according to claim 7 or 8.

10. In the filling step, the insulating resin is filled into the slot while the opening on the one side in the axial direction of the slot is closed with the jig. The method for manufacturing a stator according to claim 9 .

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