Stators, motors and fans

Abstract

To provide a stator having improved waterproofness.SOLUTION: A stator of an outer rotor motor includes: a stator core; a lower insulator that has a cylinder part covering at least part of the stator core and extending to one side of an axis direction; winding that is wound on the stator core via the lower insulator; a substrate which is positioned on the one side of the lower insulator in the axis direction, and on which a circuit to supply power to the winding is mounted; and a resin member that covers at least part of the substrate, the winding, and the lower insulator. An inner surface of the cylinder part includes a step part that faces the stator core in the axis direction. The resin member includes an end part that fills a space between at least the stator core and the step part and is in close contact with the stator core.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a stator, a motor, and a fan. [Background technology]

[0002] Motor parts such as axial fans used to cool office equipment, etc., are required to be waterproof depending on the environment in which they are used. As described in Patent Document 1, it is known to resin-mold the circuit board on which the windings of the stator part of the motor and the motor's drive circuit are mounted, and this configuration ensures waterproofness of the circuit board. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3401640 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the temperature of a motor's stator changes due to the ambient temperature and heat generated by current flowing through the windings and circuits. These temperature changes cause the resin mold to expand and contract. This expansion and contraction can cause the resin mold to peel off from the insulator it was in close contact with, potentially reducing its waterproofing effect.

[0005] Thus, conventionally, there is room for improvement in the waterproofing of the stator.

[0006] SUMMARY OF THE INVENTION It is an object of the present invention to provide a stator with improved waterproofing. [Means for solving the problem]

[0007] A first exemplary invention of the present application is a stator for an outer rotor motor, comprising: a stator core; a lower insulator having a cylindrical portion covering at least a portion of the stator core and extending to one side in the axial direction; a winding wound around the stator core via the lower insulator; a substrate located on one side in the axial direction of the lower insulator and mounting a circuit for energizing the winding; and a resin member covering the substrate, the winding, and at least a portion of the lower insulator. an inner surface of the cylindrical portion of the lower insulator contacting the resin member located radially inside thereof; do having a contact surface, the contact surface is connected to the substrate via an end face on one axial side of the cylindrical portion and an outer peripheral surface of the cylindrical portion, The contact surface is located on one axial side of the stator core and has a step portion facing the stator core in the axial direction, the contact surface is located on one axial side of the stator core and has a step portion facing the stator core in the axial direction, the resin member has at least an end portion that fills the gap between the stator core and the step portion and is in close contact with the stator core, and the resin member extends to one axial side radially inside the portion that fills the gap between the stator core and the step portion, and then covers the one axial side end of the cylindrical portion from one axial side. [Effects of the Invention]

[0008] According to the first exemplary aspect of the present invention, it is possible to provide a stator with improved waterproofing. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view showing a stator according to an embodiment of the present invention. [Figure 2] 2 is a perspective cross-sectional view of the stator 10 shown in FIG. 1 cut along a plane perpendicular to the Z axis. [Figure 3] 2 is a side cross-sectional view of the stator 10 shown in FIG. 1 taken along a plane perpendicular to the X-axis. [Figure 4] FIG. [Figure 5] 5 is a perspective cross-sectional view of the stator 10 shown in FIG. 1 cut along a plane parallel to the Z axis and including line AA in FIG. 4. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, a stator according to an embodiment of the present invention will be described with reference to the drawings. Note that in the drawings, the scale and number of components may differ from the actual structure in order to make each component easier to understand.

[0011] In addition, in the drawings, an XYZ coordinate system is shown as a three-dimensional Cartesian coordinate system as appropriate. In the XYZ coordinate system, the Z axis direction is parallel to the axis of the central axis J shown in Figure 1. The Y axis direction is the radial direction relative to the central axis J, which is the left-right direction in Figure 3. The X axis direction is perpendicular to both the Y axis direction and the Z axis direction. In each of the X axis direction, the side indicated by the arrow in the drawing is the positive side, and the opposite side is the negative side.

[0012] In the following description, the positive side (+Z side) in the Z-axis direction will be referred to as the "front side" or "one side," and the negative side (-Z side) in the Z-axis direction will be referred to as the "rear side" or "other side." Note that the terms "rear side" (other side) and "front side" (one side) are names used merely for the purpose of explanation and do not limit the actual positional relationship or direction. Furthermore, unless otherwise specified, the direction parallel to the central axis J (Z-axis direction) will be referred to simply as the "axial direction," the radial direction centered on the central axis J will be referred to simply as the "radial direction," and the circumferential direction centered on the central axis J, i.e., around the axis of the central axis J, will be referred to simply as the "circumferential direction." The side approaching the central axis J in the radial direction will be referred to as the "radially inner side," and the side away from the central axis J will be referred to as the "radially outer side."

[0013] In this specification, "extending in the axial direction" includes not only extending strictly in the axial direction (Z-axis direction) but also extending in a direction tilted by less than 45° with respect to the axial direction. In addition, in this specification, "extending in the radial direction" includes not only extending strictly in the radial direction, i.e., in a direction perpendicular to the axial direction (Z-axis direction), but also extending in a direction tilted by less than 45° with respect to the radial direction. Furthermore, "parallel" includes not only being strictly parallel but also being tilted by an angle of less than 45° with respect to each other.

[0014] [First embodiment] FIG. 1 is a perspective view showing a stator according to one embodiment of the present invention. The stator 10 is the stator of an outer rotor motor. A rotor of the outer rotor motor is disposed radially outside the stator 10. The shaft of the outer rotor motor is disposed along the central axis J. Known configurations can be used for the rotor and shaft, and therefore illustrations and descriptions thereof are omitted. Furthermore, an outer rotor motor including the stator 10 can be used in a fan. This fan has an outer rotor motor including the stator 10 and an impeller that rotates together with the rotor of the outer rotor motor.

[0015] The stator 10 has a stator core 11 and a resin member 14. The stator core 11 is covered with the resin member 14 from one axial side and the other axial side. The stator core 11 has an outer surface 11a on the radially outer side and an inner surface 11b on the radially inner side. The outer surface 11a and the inner surface 11b are exposed in the radial direction.

[0016] The resin member 14 has an other side portion 14a located on the other axial side of the stator core 11. The resin member 14 has an intermediate portion 14b that is at the same axial position as the stator core 11. The resin member 14 has one side portion 14c located on one axial side of the stator core 11. The resin member 14 has a substrate portion 14d located on one axial side of the one side portion 14c and covering the substrate 16 (see Figure 3). The stator 10 has a lead wire 15 that supplies power to the substrate 16. The other side portion 14a is connected to the intermediate portion 14b. The intermediate portion 14b is connected to the one side portion 14c. The one side portion 14c is connected to the substrate portion 14d.

[0017] Fig. 2 is a perspective cross-sectional view showing the stator 10 shown in Fig. 1 cut along a plane perpendicular to the axial direction. Fig. 2 is a cross-sectional view showing the stator 10 cut at the position of the stator core 11. 3 is a side cross-sectional view of the stator 10 shown in FIG. 1 cut along a plane perpendicular to the X-axis. FIG. 3 is a cross-sectional view taken at a position passing through the central axis J.

[0018] The stator 10 has an upper insulator 12 and a lower insulator 13. The stator 10 has a winding 11f. The resin member 14 covers the substrate 16, the winding 11f, and at least a portion of the upper insulator 12 and the lower insulator 13. The upper insulator 12 covers at least a portion of the other axial side of the stator core 11. The lower insulator 13 covers at least a portion of one axial side of the stator core 11. The winding 11f is wound around the stator core 11 via the upper insulator 12 and the lower insulator 13. The end face on the other axial side of the upper insulator 12 is covered by the end 14aa of the other side portion 14a.

[0019] The upper insulator 12 has a cylindrical portion 12a. The cylindrical portion 12a extends in the axial direction. The shaft of the outer rotor motor passes through a cylindrical hole in the cylindrical portion 12a. The lower insulator 13 has a cylindrical portion 13j (see FIG. 4), a cylindrical portion 13e, and a cylindrical portion 13f. The cylindrical portions 13j, 13e, and 13f extend in the axial direction.

[0020] The cylindrical portion 13j of the lower insulator 13 is located on the other axial side of the cylindrical portion 13e. The cylindrical portion 13e is located on the other axial side of the cylindrical portion 13f. The inner surface of the cylindrical portion 13e is located radially outward of the inner surface of the cylindrical portion 13f. The stepped portion 13d is a step formed by the difference between the inner surfaces of the cylindrical portions 13e and 13f, and the stepped surface faces the other axial side. The stepped portion 13d faces the stator core 11 in the axial direction. The resin member 14 fills at least the space between the stator core 11 and the stepped portion 13d. One side portion 14c of the resin member 14 has an inner surface 14e that fills the radially inner side of the lower insulator 13. The inner surface 14e is connected to the base portion 14d on one axial side. The end of the inner surface 14e on the other axial side is in close contact with the surface of the stator core 11 on one axial side. The shaft of the outer rotor motor passes through a cylindrical hole in the inner surface 14e.

[0021] The starter core 11 has an inner diameter portion 11c having an inner surface 11b and multiple teeth 11d extending radially outward from the inner diameter portion 11c. The teeth 11d have an outer diameter portion 11e extending circumferentially on the radially outer side. The outer surface 11a is the radially outer side surface of the outer diameter portion 11e. At least a portion of the multiple teeth 11d is covered by the upper insulator 12 and the lower insulator 13. A slot portion 13a is formed between a tooth 11d and an adjacent tooth 11d. The winding 11f is wound around the multiple teeth 11d covered by the upper insulator 12 and the lower insulator 13, and is arranged in the slot portion 13a.

[0022] The stator 10 has a substrate 16. The substrate 16 has a circular ring shape with the component mounting surface extending in a direction perpendicular to the axial direction. The substrate 16 is located on one axial side of the stator core 11. The substrate 16 mounts a circuit that energizes the winding 11f. The radially inner end of the substrate 16 fits into the radially outer side of the cylindrical portion 13f of the lower insulator 13. The stator 10 has a pin 17. The lower insulator 13 has a hole 13g into which the pin 17 fits. The substrate 16 has a hole into which the pin 17 fits.

[0023] FIG. 4 is a perspective view of the lower insulator 13. FIG. The lower insulator 13 has a winding portion 13j on the other axial side of the cylindrical portion 13e. The axial position of the winding portion 13j at least partially coincides with the axial position of the stator 11.

[0024] The lower insulator 13 has protrusions 13c that protrude radially outward from the outer surface of the winding portion 13j and extend in the axial direction. The protrusions 13c are located in the slots 13a in the circumferential direction. A plurality of protrusions 13c are arranged in the circumferential direction. In this embodiment, four protrusions 13c are arranged in each of the four slots 13a.

[0025] A through hole 13h is formed on the radially inner side of the protrusion 13c. The through hole 13h is recessed radially outward from the inner surface of the cylindrical portion 13j, extends in the axial direction, and penetrates the cylindrical portion 13e on one axial side. The through hole 13h is located in the slot portion 13a in the circumferential direction. The through hole 13h connects the radially inner side and the radially outer side of the winding portion 13j and the cylindrical portion 13e.

[0026] Although the stepped portion 13d is not continuous over the entire circumference in the circumferential direction, the present invention is not limited to this, and the stepped portion 13d may be continuous over the entire circumference in the circumferential direction.

[0027] In this embodiment, the axial length from stator core 11 to step portion 13d is two to three times the thickness from the inner surface of inner portion 14e between stator core 11 and step portion 13d to cylindrical portion 13e.

[0028] In this embodiment, the radial length of the step portion 13d is 10 to 30% of the radial thickness of the inner portion 14e at the axial position of the step portion 13d.

[0029] Fig. 5 is a perspective cross-sectional view of the stator 10 shown in Fig. 1 taken along the plane AA in Fig. 4. The plane AA in Fig. 4 is parallel to the axial direction and passes through the protrusion 13c. As can be seen from FIG. 5, the through-hole 13h on the radially inner side of the protruding portion 13c is filled with the resin member .

[0030] <Actions and effects of the stator 10, motor, and fan> Next, the functions and effects of the stator 10, the motor, and the fan will be described.

[0031] In the invention according to the above-described embodiment, a stator for an outer rotor motor includes a stator core, a lower insulator having a cylindrical portion covering at least a portion of the stator core and extending axially to one side, a winding wound around the stator core via the lower insulator, a substrate located on one axial side of the lower insulator and mounting a circuit for supplying current to the winding, and a resin member covering the substrate, the winding, and at least a portion of the lower insulator, wherein the inner surface of the cylindrical portion has a stepped portion facing the stator core in the axial direction, and the resin member has an end portion that fills at least the gap between the stator core and the stepped portion and is in close contact with the stator core. Therefore, even if the resin member is thermally deformed, the step portion ensures adhesion between the lower insulator and the resin member, and between the resin member and the stator core, and prevents water and dust from entering from the ends, thereby improving the waterproofness of the board.

[0032] The axial length from the stator core to the stepped portion is two to three times the radial thickness of the end portion. This ensures close contact between the resin member and the stator core, and prevents water and dust from entering through the ends, thereby improving the waterproofing of the board.

[0033] The radial length of the step portion is 10 to 30% of the radial thickness of the end portion. This ensures close contact between the resin member and the stator core, and prevents water and dust from entering through the ends, thereby improving the waterproofing of the board.

[0034] The step portion is disposed along the circumferential direction of the inner surface of the cylindrical portion. Therefore, the resin member is fixed in the axial direction by the step portion, and waterproofing can be improved.

[0035] The step portions are arranged in a plurality along the circumferential direction of the inner surface of the cylindrical portion. Therefore, the resin member is fixed in the axial direction by the plurality of step portions, and waterproofing can be improved.

[0036] The lower insulator also has a protrusion on the outer surface of the cylindrical portion that protrudes radially outward and extends axially. Therefore, the protrusions can increase the strength of the slots. Also, there is a risk that the lower insulator may be deformed when filling the slots with a large amount of resin material, but this can be prevented.

[0037] The lower insulator has a through hole that radially communicates with the cylindrical portion, and the resin member fills the through hole. This allows the resin member to be connected to the inside and outside of the cylindrical portion. By connecting the resin member to the inside and outside of the cylindrical portion, the resin member is less likely to peel off from the lower insulator and the stator core, further improving waterproofing. In addition, the protrusions 13c and the through holes 13h act as ribs, preventing deformation of the winding portion 13j.

[0038] The motor also includes the stator and a rotor that faces the stator in the radial direction. This improves the waterproofing of the substrate in the motor.

[0039] The fan also includes the motor and an impeller that rotates together with the rotor. This improves the waterproofing of the substrate in the fan.

[0040] Although the preferred embodiments of the present invention have been described above, the present invention is not limited to these embodiments and various modifications and variations are possible within the spirit and scope of the invention. These embodiments and modifications are included in the scope and spirit of the invention, as well as in the invention described in the claims and their equivalents. [Explanation of symbols]

[0041] 10 Stator 11 Stator core 11f winding 12 Upper insulator 13 Lower insulator 13d Step 14 Resin parts 16 boards

Claims

1. A stator for an outer rotor motor, A stator core; a lower insulator having a cylindrical portion covering at least a portion of the stator core and extending axially to one side; a winding wound around the stator core via the lower insulator; a substrate located on one axial side of the lower insulator and on which a circuit for energizing the winding is mounted; a resin member that covers the substrate, the winding, and at least a portion of the lower insulator; and an inner surface of the cylindrical portion of the lower insulator has a contact surface that comes into contact with the resin member located radially inward; the contact surface is connected to the substrate via an end face on one axial side of the cylindrical portion and an outer peripheral surface of the cylindrical portion, the contact surface is located on one axial side of the stator core and has a stepped portion facing the stator core in the axial direction, the resin member has at least an end portion that fills the gap between the stator core and the step portion and is in close contact with the stator core, the resin member extends to one axial side radially inside a portion filling the gap between the stator core and the stepped portion, and then covers the one axial end of the cylindrical portion from the one axial side; Stator.

2. The axial length from the stator core to the step portion is 2 to 3 times the radial thickness of the end portion. The stator according to claim 1 .

3. The radial length of the step portion is 10 to 30% of the radial thickness of the end portion.

3. A stator according to claim 1 or 2.

4. The step portion is arranged along the circumferential direction of the inner surface of the cylindrical portion. A stator according to any one of claims 1 to 3.

5. The step portion is arranged in a plurality of steps along the circumferential direction of the inner surface of the cylindrical portion.

5. The stator according to claim 4.

6. the lower insulator has a protrusion on an outer surface of the cylindrical portion, the protrusion protruding radially outward and extending in the axial direction; A stator according to any one of claims 1 to 5.

7. the lower insulator has a through hole that radially communicates with the cylindrical portion, The resin member fills the through hole. A stator according to any one of claims 1 to 6.

8. A stator according to any one of claims 1 to 7; a rotor that faces the stator in a radial direction; having Motor.

9. a motor according to claim 8; an impeller that rotates together with the rotor; having fan.

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