Motor

Abstract

To provide a motor capable of improving assemble ability of a conductor with respect to a substrate.SOLUTION: In a motor according to an embodiment, an insulator 12 includes a wall portion 122 having two recesses (insulator-side first recess 126, insulator-side second recess 127) facing two lead positions of a lead wire 14 drawn from a coil 13 in a radial direction. From among the two lead positions, one is on an outer periphery of the coil 13 and the other is at inside of the outer periphery. A substrate 2 is recessed radially inward from the outer peripheral end, and has a substrate-side first recess 21 and a substrate-side second recess 22 adjacent to each other in the circumferential direction. The substrate-side first recess 21 faces the insulator-side first recess 126, and the substrate-side second recess 22 faces the insulator-side second recess 127.SELECTED DRAWING: Figure 11A

Description

[Technical Field]

[0001] The present invention relates to a motor. [Background technology]

[0002] Conventionally, motors have multiple stator cores, and both ends of a conductor wound around each stator core are physically and electrically connected to connecting members such as bus bars and substrates (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-205877 Summary of the Invention [Problem to be solved by the invention]

[0004] However, when the connecting member is a substrate, for example, when a conductor (hereinafter also referred to as a "lead wire") drawn from a coil is routed to a substrate placed on the stator core, the lead wire interferes with the wall of the insulator, making it difficult to route the conductor, and there is room for improvement in terms of the ease of assembling the conductor to the substrate.

[0005] An example of an object of the present invention is to provide a motor that can improve the ease of assembling a lead wire to a board. [Means for solving the problem]

[0006] A motor according to one aspect of the present invention includes a stator having a magnetic body, an insulator surrounding the magnetic body, and a coil formed by a conductor wound around the magnetic body via the insulator; an annular substrate provided on the stator; and a conductive land connected to the conductor. Two conductors are drawn out from the coil, one of which is at the outer periphery of the coil and the other is located inside the outer periphery. The substrate is recessed radially inward from the outer periphery end, and has first and second recesses adjacent in the circumferential direction, and a protrusion located between the first and second recesses. A first end of the conductor is disposed inside the first recess, and a second end of the conductor is disposed inside the second recess, and the land is formed on the protrusion of the substrate. The insulator has a wall portion located on the outer periphery of the substrate assembled to the stator, and the wall portion is a first end in an axial direction; The connector has a third recess facing one of the lead-out positions of the conductor wire, a fourth recess facing the other of the lead-out positions of the conductor wire, and a protrusion located between the third recess and the fourth recess. In the axial direction, the convex portion of the wall is lower than the first end portion of the wall. The first recess faces the third recess in the radial direction, and the second recess faces the fourth recess in the radial direction. The protrusion of the substrate faces the protrusion of the insulator in the axial direction. In the radial direction, the end of the first recess of the substrate faces the third recess of the insulator via the first end of the conductor, and in the radial direction, the end of the second recess of the substrate faces the fourth recess of the insulator via the second end of the conductor.

[0007] According to one aspect of the present invention, it is possible to improve the ease of assembling a conductor to a substrate. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is an external perspective view of a stator according to an embodiment. [Figure 2] FIG. 2 is a partial exploded perspective view of the stator according to the embodiment. [Figure 3] FIG. 3 is a vertical cross-sectional view of the stator according to the embodiment. [Figure 4] FIG. 4 is a perspective view of the appearance of a split core that constitutes the stator. [Figure 5] FIG. 5 is an enlarged plan view of the connection portion between the split core and the substrate. [Figure 6] FIG. 6 is a partially exploded perspective view of the split core. [Figure 7] FIG. 7 is a schematic cross-sectional view of the insulator and coil that constitute the split core. [Figure 8] FIG. 8 is a schematic cross-sectional view of adjacent split cores. [Figure 9] FIG. 9 is a vertical cross-sectional view of the insulator. [Figure 10] FIG. 10 is a schematic diagram showing the change in position of the conductor wire when the substrate is attached to the split core. [Figure 11A] FIG. 11A is an enlarged side view of a connection portion between a split core and a substrate. [Figure 11B] FIG. 11B is a schematic diagram showing an example of a state in which a conductor wire is soldered to a recessed portion of a substrate. [Figure 12A] FIG. 12A is an enlarged plan view of a wire connection portion in a first modified example of the embodiment. [Figure 12B] FIG. 12B is an enlarged side view of the wire connection portion. [Figure 13A] FIG. 13A is an enlarged perspective view of a wire connection portion in a second modified example of the embodiment. [Figure 13B] FIG. 13B is an enlarged side view of the wire connection portion. [Figure 14A] FIG. 14A is an enlarged perspective view of a substrate recess in a third modified example of the embodiment. [Figure 14B] FIG. 14B is an enlarged plan view of the front surface side of the recessed portion of the substrate. [Figure 14C] FIG. 14C is an enlarged plan view of the back surface side of the recessed portion of the substrate. [Figure 15] FIG. 15 is a schematic diagram showing an example of a state in which a conductor wire is soldered to a recessed portion of a substrate in a third modified example of the embodiment. [Figure 16] FIG. 16 is an external perspective view of a split core according to a fourth modified example of the embodiment. [Figure 17A] FIG. 17A is an enlarged side view of a connection portion between a split core and a substrate in a fourth modified example of the embodiment. [Figure 17B] FIG. 17B is an enlarged plan view of a connection portion in the fourth modified example of the embodiment. [Figure 18] FIG. 18 is a schematic diagram showing a change in the position of the conductor wire when a substrate is attached to a split core in a fourth modified example of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments shown below. Furthermore, the dimensional relationships and ratios of elements in the drawings may differ from the actual situation. Furthermore, the dimensional relationships and ratios may differ between the drawings. Furthermore, the content described in one embodiment or modification is, in principle, applicable to other embodiments or modifications in the same manner.

[0010] (Embodiment) FIG. 1 is an external perspective view of a stator according to an embodiment. FIG. 2 is a partially exploded perspective view of the stator. FIG. 3 is a longitudinal cross-sectional view of the stator. FIG. 4 is an external perspective view of a split core constituting the stator. FIG. 5 is an enlarged plan view of a connection portion between the split core and a substrate. FIG. 6 is a partially exploded perspective view of the split core. FIG. 7 is a schematic cross-sectional view of an insulator and a coil constituting the split core. FIG. 8 is a schematic cross-sectional view of adjacent split cores. FIG. 9 is a longitudinal cross-sectional view of an insulator. FIG. 10 is a schematic diagram showing a change in the position of a conductor when a substrate is attached to the split core. FIG. 11A is an enlarged side view of a connection portion between the split core and a substrate. FIG. 11B is a schematic diagram showing an example of a state in which a conductor is soldered to a recess in a substrate.

[0011] In the following description, for convenience, the illustrated axial direction is the direction of the rotation axis of the motor in this embodiment. One of the axial directions is referred to as the first direction, and the other is referred to as the second direction. The illustrated radial direction is the radial direction perpendicular to the rotation axis direction of the motor in this embodiment. Of the radial directions, the direction away from the illustrated rotation axis X is referred to as the radially outward direction, and the direction toward the rotation axis X is referred to as the radially inward direction. The illustrated circumferential direction is the direction that coincides with the rotation direction of the motor in this embodiment.

[0012] A stator 1 according to the embodiment is applied to, for example, an inner rotor type brushless motor. The motor according to the embodiment includes an inner rotor, which is a rotor, a shaft fixed to the inner rotor, the stator 1 having a coil and a magnetic body around which the coil is wound, and an annular substrate 2 provided on the stator 1. Note that the motor to which the stator 1 is applied is not limited to a brushless motor.

[0013] The stator 1 shown in FIG. 1 is disposed so as to surround an inner rotor (not shown). As shown in FIG. 4, the stator 1 includes a plurality of split cores 10, which are so-called split cores. The stator 1 is formed by arranging the plurality of split cores 10 in an annular shape along the circumferential direction, and joining adjacent split cores 10 together. As shown in FIG. 2, the stator 1 has a substrate 2 formed in an annular shape disposed on a first axial direction side. The plurality of split cores 10 are integrated, for example, by insert molding while being arranged in an annular shape along the circumferential direction.

[0014] As shown in FIGS. 3 and 4, the split core 10 includes a stator core 11, an insulator 12, and a coil 13 that surrounds the stator core 11 with the insulator 12 interposed therebetween.

[0015] The stator core 11 is a magnetic body having a laminated structure in which, for example, multiple electromagnetic steel sheets are stacked. The multiple stator cores 11 are arranged in a circular ring shape along the circumferential direction. The stator core 11 has teeth 11a and yokes 11b. The teeth 11a extend radially inward from the inner periphery of the yoke 11b. As shown in FIG. 8, when the multiple split cores 10 are arranged in a circular ring shape along the circumferential direction, the yokes 11b are connected to adjacent yokes 11b in the circumferential direction.

[0016] Insulator 12 is formed of, for example, an insulating material and is interposed between stator core 11 and coil 13 to provide electrical insulation. As shown in Fig. 6, insulator 12 has a housing portion 121 that houses stator core 11 therein and a wall portion 122 formed at the radially outer end of housing portion 121. Insulator 12 is formed so as to be separable into two pieces, and can house stator core 11 inside in the divided state.

[0017] The wall portion 122 is located on the outer periphery of the substrate 2 in an assembled state in which the substrate 2 is assembled to the stator 1. The wall portion 122 is formed in a substantially rectangular shape when viewed in the radial direction, and is formed to protrude from the yoke portion 11b in the axial direction. The wall portion 122 has two recesses that face each other in the radial direction at positions where the two conducting wires 14 are drawn out from the coil 13. Specifically, as shown in FIG. 9 , the wall portion 122 has a first insulator-side recess 126 and a second insulator-side recess 127.

[0018] The insulator-side first recess 126 (third recess) is formed corresponding to one of the lead-out positions of the conductor 14, and one of the conductors 14 is disposed inside in a direction intersecting the extending direction of the conductor 14. The insulator-side second recess 127 (fourth recess) is formed corresponding to the other of the lead-out positions of the conductor 14, and the other conductor 14 is disposed inside in a direction intersecting the extending direction of the other conductor 14. As shown in FIGS. 5 and 11A, the insulator-side first recess 126 and the insulator-side second recess 127 are formed in the split core 10 at positions facing the lead-out positions of the conductor 14 led out from the coil 13. Specifically, the insulator-side first recess 126 is formed in the split core 10 at a position facing the first end 141 of the conductor 14 led out from the coil 13. The insulator-side second recess 127 is formed in the split core 10 at a position facing the second end 142 of the conducting wire 14 drawn out from the coil 13. An insulator-side protrusion 128 is formed circumferentially between the insulator-side first recess 126 and the insulator-side second recess 127. The insulator-side protrusion 128 extends outward without protruding from the axial end of the wall portion 122 in the first direction. The insulator-side protrusion 128 faces the board protrusion 23 in the axial direction when the board 2 is assembled to the stator 1.

[0019] Furthermore, the insulator-side first recess 126 and the insulator-side second recess 127 face the board-side first recess 21 and the board-side second recess 22 of the board 2, respectively, in an assembled state in which the board 2 is assembled to the stator 1. Specifically, the insulator-side first recess 126 faces the board-side first recess 21 in an assembled state in which the board 2 is assembled to the stator 1. The insulator-side second recess 127 faces the board-side second recess 22 in an assembled state in which the board 2 is assembled to the stator 1. The insulator-side first recess 126 and the insulator-side second recess 127 form spaces for allowing the first end 141 and the second end 142 of the conducting wire 14 to escape radially outward when the conducting wire 14 drawn out from the coil 13 is connected to the board 2. The first substrate-side recess 21 and the second substrate-side recess 22 of the substrate 2 form a space for joining the first end 141 and the second end 142 of the conductor 14 to the substrate 2 side when connecting the conductor 14 drawn out from the coil 13 to the substrate 2.

[0020] The accommodating portion 121 is formed in a rectangular cylindrical shape when viewed from the radial direction, and in an assembled state in which the insulator 12 is assembled to the stator core 11, the teeth portion 11a is accommodated inside (FIG. 6). The accommodating portion 121 has four outer surfaces 125 on its outer circumferential surface. The conductor wire 14 is wound around the outer surfaces 125. The outer surfaces 125 are surrounded by multiple layers of coils 13. In this embodiment, the outer surfaces 125 are surrounded by two layers of coils 13, as shown in FIGS. 7 and 8. Of the four outer surfaces 125, two surfaces on both circumferential sides are composed of only flat surfaces, and two surfaces on both axial sides are composed of multiple recesses 130 and flat surfaces 131. In this embodiment, multiple recesses and flat surfaces 131 are formed on two surfaces, but it is sufficient to form them on at least one surface.

[0021] The plurality of recesses 130 are formed radially outward on two of the four outer surfaces 125 of the accommodating portion 121, one on each side in the axial direction. The recesses 130 are arranged continuously along the radial direction. For example, each recess 130 protrudes toward a first axial direction and is surrounded by two radially adjacent protrusions 132. Each recess 130 stores the conductor 14 wound around the insulator 12. As shown in FIG. 7 , the position of the conductor 14 wound around the plurality of recesses 130 is restricted by each recess 130, and the conductor 14 is arranged evenly and in a grid pattern along the teeth 11 a of the stator core 11.

[0022] The flat surfaces 131 are formed on the radially inner side of two of the four outer surfaces 125 of the accommodating portion 121, one on each side in the axial direction (FIG. 7). The flat surfaces 131 are formed on the radially inner side of the outer surface 125, on which the plurality of recesses 130 are formed on the radially outer side, and are flat surfaces on which no recesses 130 are formed. The radial length of the flat surfaces 131 is set to be longer than the outer diameter of the conducting wire 14.

[0023] The portions of the conductor 14 wound around the flat surface 131 are spaced apart in the radial direction between adjacent conductors 14 in the first layer of the coil 13. Specifically, the conductors 14a and 14b in the first layer of adjacent coils 13 are not in contact with each other but are spaced apart in the radial direction (FIG. 7). On the other hand, the portions of the conductor 14 fitted into the multiple recesses 130 are not in contact with each other but are in contact with each other in the radial direction between adjacent conductors 14 in the first layer of the coil 13.

[0024] Parts of the conductors 14 that face the two flat surfaces 131 of two circumferentially adjacent insulators 12 face each other. Specifically, of the two adjacent insulators 12, the conductors 14a to 14c that face the flat surface 131 of one insulator 12 face the conductors 14a to 14c that face the flat surface 131 of the other insulator 12 in the circumferential direction, as shown in Fig. 8 .

[0025] The portion of the conductor 14 stacked on the portion of the conductor 14 facing the flat surface 131 is positioned circumferentially inward relative to the portion of the conductor 14 stacked on the portion of the conductor 14 fitted in the multiple recesses 130. Specifically, as shown in FIG. 7 , the ninth turn of the conductor 14b in the first layer of the coil 13 is shifted radially inward, and the tenth turn of the conductor 14c, which is the first winding of the second layer, is wound so that it is positioned circumferentially more inward (e.g., toward the second axial direction) than usual. In other words, the maximum axial height of the second-layer conductor 14c stacked on the flat surface 131 is lower than the maximum axial height of the second-layer conductor 14 stacked on the recess 130 side. Furthermore, the axial distance between the central axis of the second-layer conductor 14c and the flat surface 131 is shorter than the distance between the central axis of the second-layer conductor 14 stacked on the recess 130 side and the outer surface 125.

[0026] The part of the conductor 14 facing the flat surface 131 is exposed to the outside, compared to the part of the conductor 14 stacked on the part of the conductor 14 fitted into the multiple recesses 130. Specifically, of the conductors 14a to 14c facing the flat surface 131, the conductor 14a is not shielded from the outside by the conductor 14c constituting the second layer of the coil 13, etc., as shown in Fig. 7, and can be seen from the outside.

[0027] The part of the conductor 14 facing the flat surface 131 is positioned farther from the outer surface 125 than the part of the conductor 14 fitted into the recesses 130. Specifically, the part of the conductor 14 facing the flat surface 131, conductor 14c, is stacked between conductor 14a and conductor 14b, and is therefore positioned farther from the outer surface 125 on the first axial direction side, and the separation distance at this time is smaller than the distance from the part of the conductor 14 stacked on the part of the conductor 14 fitted into the recesses 130 to the outer surface 125.

[0028] 9, the circumferential position of one of the insulator-side first recess 126 and the insulator-side second recess 127 is such that it overlaps one (the circumferentially inner side) of a pair of circumferentially opposing outer surfaces 125 of the outer surfaces of the accommodating portion 121 when viewed from the radial direction. The circumferential position of the other recess is such that it is shifted outward in the circumferential direction when viewed from the radial direction with respect to the other (the circumferentially outer side) of the pair of circumferentially opposing outer surfaces 125.

[0029] The coil 13 is formed of a conductor 14 wound around the stator core 11 via the insulator 12. The coil 13 is arranged to surround the outer surface 125 of the insulator 12. The coil 13 is formed by being wound clockwise or counterclockwise around the teeth 11a of the stator core 11 via the housing portion 121 of the insulator 12. The coil 13 is formed of a conductor 14 wound in two layers, but is not limited to this. The coil 13 may be wound in, for example, two or more even layers, or one or more odd layers. The coil 13 has a first end 141 and a second end 142 of the conductor 14 extending in the same direction as lead wires. Both the first end 141 and the second end 142 extend from the coil 13 in a first axial direction. The first end 141 is drawn out from the outer periphery of the coil 13, and the drawing position is on the outer periphery of the coil 13. The second end 142 is drawn out from the inner periphery of the coil 13, and the drawing position is inside the outer periphery of the coil 13.

[0030] The substrate 2 is disposed on a first axial direction side of the stator 1. The substrate 2 is formed of an insulating resin material, such as epoxy. Electronic components (not shown) are disposed on the substrate 2. The electronic components include, for example, an inverter and a control IC. As shown in FIGS. 2, 5, 11A, and 11B, the substrate 2 is recessed radially inward from its outer peripheral end and has a plurality of substrate-side first recesses 21 and substrate-side second recesses 22 adjacent to each other in the circumferential direction.

[0031] 11A, in an assembled state in which the substrate 2 is assembled to the stator 1, a first end 141, which is one end of the conducting wire 14 drawn out from the coil 13, is inserted into the substrate-side first recess 21. In an assembled state in which the substrate 2 is assembled to the stator 1, a second end 142, which is the other end of the conducting wire 14 drawn out from the coil 13, is inserted into the substrate-side second recess 22. A substrate protrusion 23 is formed in the circumferential direction between the substrate-side first recess 21 and the substrate-side second recess 22. The substrate protrusion 23 is formed to protrude radially outward from the outer periphery of the substrate main body 20.

[0032] In an assembled state in which the substrate 2 is assembled to the stator 1, the first end 141 of the conducting wire 14 is located inside the substrate-side first recess 21, and the other end, the second end 142, is located inside the substrate-side second recess 22. The first end 141 and the second end 142 are arranged facing each other in the circumferential direction. The first end 141 is arranged inside the substrate-side first recess 21 in a state inclined toward the substrate-side second recess 22 in the circumferential direction. The second end 142 is arranged inside the substrate-side second recess 22 in a state inclined toward the substrate-side first recess 21 in the circumferential direction. The first end 141 and the second end 142 circumferentially sandwich the substrate protrusion 23 between the substrate-side first recess 21 and the substrate-side second recess 22. As shown in Figure 11B, the first end 141 and the second end 142 are joined to the land 30 of the substrate 2, for example by solder H, with the substrate protrusion 23 between the substrate side first recess 21 and the substrate side second recess 22 sandwiched circumferentially.

[0033] The land 30 is conductive and is connected to the conductor 14. As shown in Fig. 11B, the land 30 is physically and electrically connected by soldering to a first end 141 and a second end 142 of the conductor 14 drawn out from the coil 13. The land 30 is provided on the substrate surface 20a side.

[0034] Next, the process of winding the conductor 14 around the insulator 12 to form the coil 13 in this embodiment will be described. When the conductor 14 is wound around the insulator 12, the first through eighth turns of the first layer of the coil 13 are wound along the recesses 130, and the ninth turn is wound on the flat surface 131. From this state, when the conductor 14c of the second layer of the coil 13 is wound so that it is positioned between the conductors 14a and 14b of the first layer, the ninth turn of the first layer of the coil 13 moves radially inward, and the tenth turn, which is the first winding of the second layer, is wound so that it is positioned closer to the second axial direction than usual. In other words, because the radial position of the conductor 14 located on the flat surface 131 is not restricted, it moves due to the force generated when the conductor 14c of the second layer is wound, guiding the conductor 14c of the second layer toward the second axial direction. At this time, the ninth turn of the first layer of the conductor 14b facing the flat surface 131 of the insulator 12 is spaced apart from the first to eighth turns of the conductor 14 facing the recesses 130. Therefore, the part of the conductor 14 facing the flat surface 131 in the radial direction is spaced apart from the part of the conductor 14 fitted in the recesses 130. This makes it possible to increase the space between the conductors 14 wound around adjacent stator cores 11, as shown in FIG. 8, and to prevent electrical short circuits due to contact between the conductors 14c of adjacent coils 13.

[0035] Next, a description will be given of the work of routing the first end 141 and the second end 142 of the conductor 14, which is a lead wire drawn from the coil 13 in this embodiment, and assembling it into the first board-side recess 21 and the second board-side recess 22. When connecting the conductor 14 drawn from the coil 13 to the board 2, the first end 141 and the second end 142 of the conductor 14 are tilted radially outward and routed inside the first insulator-side recess 126 and the second insulator-side recess 127 of the insulator 12. Next, after assembling the board 2 to the stator 1, the ends of the conductor 14 that have routed inside the first insulator-side recess 126 and the second insulator-side recess 127 are placed inside the first board-side recess 21 and the second board-side recess 22. This allows the stator 1 and the board 2 to be assembled without the conductor 14 interfering with the insulator 12.

[0036] As described above, a motor according to one aspect of the present invention includes a coil 13 formed of a conductor 14 and an insulator 12 having an outer surface 125 surrounded by the coil 13. The outer surface 125 of the insulator 12 includes a plurality of recesses 130 and a flat surface 131. A portion of the conductor 14 facing the flat surface 131 is spaced apart from a portion of the conductor 14 fitted in the plurality of recesses 130. For example, when winding the conductor 14 around the insulator 12 to form the coil 13, the first to eighth turns of the conductor 14 are wound along the plurality of recesses 130, and the ninth turn is wound around the flat surface 131. As a result, the ninth turn of the conductor 14 in the first layer is shifted radially inward, and the tenth turn of the conductor 14, which is the first winding of the second layer, is wound so as to be positioned circumferentially inward (e.g., toward the second axial direction) relative to a conventional winding. That is, because the radially inward movement of the conductor 14 wound on the flat surface 131 is not restricted, the 10th turn of the conductor 14 moves due to the force generated when the conductor 14 is wound, and the 10th turn of the conductor 14 is guided circumferentially inward, thereby reducing the circumferential size (height) of the radially inner side of the coil 13. This makes it possible to prevent contact between the coils 13 formed on adjacent insulators 12.

[0037] In addition, in the motor according to one aspect of the present invention, the portions of the conductors 14 that face the two flat surfaces 131 of two adjacent insulators 12 in the circumferential direction face each other. This prevents the coils 13 formed on the two adjacent insulators 12 from contacting each other.

[0038] Furthermore, in a motor according to one aspect of the present invention, the portion of the conductor 14 stacked on the portion of the conductor 14 facing the flat surface 131 is arranged circumferentially inward relative to the portion of the conductor 14 stacked on the portion of the conductor 14 fitted into the recesses 130. As a result, the ninth turn of the conductor 14b in the first layer of the coil 13 moves radially inward, and the tenth turn of the conductor 14c, which is the first winding of the second layer, is wound so as to be arranged circumferentially inward (for example, toward the second axial direction) relative to normal.

[0039] Furthermore, in a motor according to one aspect of the present invention, a portion of the conductor 14 that faces the flat surface 131 is exposed to the outside, compared to a portion of the conductor 14 that is stacked on top of a portion of the conductor 14 that fits into the multiple recesses 130. This causes the ninth turn of the conductor 14 in the first layer to move radially, making it easier for the tenth turn of the conductor 14, which is the first turn of the second row, to be positioned more inward in the circumferential direction than usual.

[0040] Furthermore, in the motor according to one aspect of the present invention, the part of the conductor 14 facing the flat surface 131 is located farther from the outer surface 125 of the insulator 12 than the part of the conductor 14 fitted in the recesses 130. This makes it easier for the 9th turn of the conductor 14b in the first layer of the coil 13 to move radially.

[0041] As described above, a motor according to one aspect of the present invention includes an annular substrate 2 provided on a stator 1. The substrate 2 is recessed radially inward from its outer circumferential edge and includes a first substrate-side recess 21 and a second substrate-side recess 22 that are adjacent to each other in the circumferential direction. Of the two ends of the conductor 14, the first end 141 is located inside the first substrate-side recess 21, and the second end 142 is located inside the second substrate-side recess 22. The first end 141 and the second end 142 of the conductor 14 are arranged facing each other in the circumferential direction. This allows the first end 141 and the second end 142 of the conductor 14 to sandwich the substrate protrusion 23 between the first substrate-side recess 21 and the second substrate-side recess 22 in the circumferential direction. This restricts circumferential movement of the substrate 2 relative to the stator 1 due to, for example, vibration, and reduces the load on the conductor 14 routed between the stator 1 and the substrate 2.

[0042] Furthermore, in a motor according to one aspect of the present invention, the first end 141 is disposed inside the board-side first recess 21 in a state inclined in the circumferential direction toward the board-side second recess 22, and the second end 142 is disposed inside the board-side second recess 22 in a state inclined in the circumferential direction toward the board-side first recess 21. The first end 141 and the second end 142 sandwich the board protrusion 23 between the board-side first recess 21 and the board-side second recess 22 in the circumferential direction.

[0043] As described above, in a motor according to one aspect of the present invention, the insulator 12 includes a wall portion 122 having two recesses (a first insulator-side recess 126 and a second insulator-side recess 127) that face, in the radial direction, two lead-out positions of the conducting wire 14 drawn from the coil 13. One of the two lead-out positions is located on the outer periphery of the coil 13, and the other is located inside the outer periphery. The substrate 2 is recessed radially inward from its outer periphery and has a first substrate-side recess 21 and a second substrate-side recess 22 that are adjacent to each other in the circumferential direction. The first substrate-side recess 21 faces the first insulator-side recess 126, and the second substrate-side recess 22 faces the second insulator-side recess 127.

[0044] With the above configuration, when connecting the conductor 14 drawn out from the coil 13 to the substrate 2, the ends (first end 141, second end 142) of the conductor 14 can be routed to the recesses (insulator-side first recess 126, insulator-side second recess 127) of the insulator 12 located radially outward. Then, after the substrate 2 is assembled to the stator 1, the ends of the conductor 14 that have been routed to the recesses of the insulator 12 can be inserted into the recesses (substrate-side first recess 21, substrate-side second recess 22) on the substrate 2 side. As a result, the stator 1 and substrate 2 can be assembled without the conductor 14 interfering with the insulator 12, improving motor productivity.

[0045] 9, in a motor according to one aspect of the present invention, the circumferential position of one of the insulator-side first recess 126 and the insulator-side second recess 127 is such that it overlaps one (the circumferentially inner side) of a pair of circumferentially opposing outer surfaces 125 of the outer surfaces of the accommodating portion 121 as viewed from the radial direction. The circumferential position of the other recess is such that it is shifted outward in the circumferential direction as viewed from the radial direction with respect to the other (the circumferentially outer side) of the pair of circumferentially opposing outer surfaces 125.

[0046] The insulator-side second recess 127 is formed at a position aligned with one side (inner side in the circumferential direction) of the outer surface 125 at both circumferential ends of the accommodating portion 121 of the insulator 12 so that the conductor 14 at the start of winding of the coil 13 can enter and exit. On the other hand, the insulator-side first recess 126 is formed circumferentially outward from a position aligned with the other side (outer side in the circumferential direction) of the outer surface 125 at both circumferential ends of the accommodating portion 121 of the insulator 12 so that the conductor 14 at the end of winding of the coil 13 (the conductor 14 of the second layer in this embodiment) can enter and exit. With this configuration, when the conductor 14 drawn out from the coil 13 is connected to the substrate 2, the ends (first end 141, second end 142) of the conductor 14 can escape to the recesses (first insulator-side recess 126, second insulator-side recess 127) of the insulator 12 located radially outward. Therefore, the stator 1 and the substrate 2 can be assembled without the conductor 14 interfering with the insulator 12, and the productivity of the motor can be improved.

[0047] (First Modification of the Embodiment) In the above embodiment, the first end 141 of the conductor 14 is disposed inside the first board recess 21 at an inclination in the circumferential direction toward the second board recess 22, and the second end 142 of the conductor 14 is disposed inside the second board recess 22 at an inclination in the circumferential direction toward the first board recess 21, but this is not limited to this. FIG. 12A is an enlarged plan view of a connection portion in a first modified embodiment. FIG. 12B is an enlarged side view of the connection portion. A motor according to a second modified embodiment differs from the above embodiment in that the first end 141 and the second end 142 of the conductor 14 each have a bent portion.

[0048] As shown in FIGS. 12A and 12B , the first end 141 of the conducting wire 14 has a first bent portion 143 in an assembled state in which the substrate 2 is assembled to the stator 1. The second end 142 of the conducting wire 14 has a second bent portion 144 in an assembled state in which the substrate 2 is assembled to the stator 1. The first bent portion 143 and the second bent portion 144 are bent in directions facing each other. The first bent portion 143 is formed in a portion of the first end 141 of the conducting wire 14, which is drawn straight from the coil 13 in the first axial direction, protruding from the inside of the substrate-side first recess 21 to the outside in the first axial direction. The first bent portion 143 is bent in the circumferential direction of the substrate 2 from the substrate-side first recess 21 toward the substrate-side second recess 22, sandwiching the substrate protrusion 23 therebetween. The second bent portion 144 is formed at a portion of the second end 142 of the conducting wire 14, which is drawn straight in the first axial direction from the coil 13, that protrudes from the inside of the board-side second recess 22 to the outside in the first axial direction. The second bent portion 144 is bent in the circumferential direction of the board 2 from the board-side second recess 22 toward the board-side first recess 21, sandwiching the board protrusion 23 therebetween.

[0049] In a motor according to one aspect of the present invention, a first end 141 of a conductor 14 drawn from a coil 13 has a first bent portion 143 bent in the circumferential direction of the substrate 2 at a portion protruding from the inside of the first substrate recess 21 to the outside. A second end 142 of the conductor 14 has a second bent portion 144 bent in the circumferential direction of the substrate 2 at a portion protruding from the inside of the second substrate recess 22 to the outside. The first bent portion 143 and the second bent portion 144 are bent in a direction facing each other. In this way, the first end 141 and the second end 142 of the conductor 14 have the first bent portion 143 and the second bent portion 144 bent inward in the circumferential direction so as to face each other, thereby holding the substrate protrusion 23 in the circumferential direction. This eliminates the need to tilt the first end 141 and the second end 142 when drawing the conductor 14 from the coil 13, making it easier to connect the conductor 14 to the substrate 2.

[0050] (Second Modification of the Embodiment) In the first modified example of the embodiment, the first end 141 and the second end 142 of the conductor 14 each have a bent portion, but this is not limited to this. Fig. 13A is an enlarged perspective view of a connection portion in the second modified example of the embodiment. Fig. 13B is an enlarged side view of the connection portion. The motor according to the second modified example of the embodiment differs from the first modified example in that the first end 141 and the second end 142 of the conductor 14 each have a bent portion and a deformed portion.

[0051] As shown in FIGS. 13A and 13B , first end 141 of conducting wire 14 has first deformed portion 145, which has a cross-sectional shape different from that of conducting wire 14, in an assembled state in which substrate 2 is assembled to stator 1. First deformed portion 145 is formed in a rectangular shape when viewed in the axial direction and is located closer to second bent portion 144 than first bent portion 143. First deformed portion 145 is, for example, a portion that is crushed in the circumferential direction before first end 141 is bent at first bent portion 143. Second end 142 of conducting wire 14 has second deformed portion 146, which has a cross-sectional shape different from that of conducting wire 14, in an assembled state in which substrate 2 is assembled to stator 1. Second deformed portion 146 is formed in a rectangular shape when viewed in the axial direction and is located closer to first bent portion 143 than second bent portion 144. The second deformed portion 146 is, for example, a portion that is crushed in the circumferential direction before the second end portion 142 is bent at the second bent portion 144 .

[0052] In a motor according to one aspect of the present invention, first end 141 of conductor 14 is located closer to second bend 144 than first bend 143 and has first deforming portion 145 with a cross-sectional shape different from that of conductor 14. Second end 142 of conductor 14 is located closer to first bend 143 than second bend 144 and has second deforming portion 146 with a cross-sectional shape different from that of conductor 14. As a result, by deforming first end 141 and second end 142 of conductor 14 in the axial direction, the axial height of the connection portion can be made lower than the outer diameter of conductor 14. As a result, the axial height of stator 1 including substrate 2 can be reduced, allowing for a more compact motor.

[0053] (Third Modification of the Embodiment) In the above embodiment, the substrate 2 has lands 30 that electrically connect the ends of the conductor wires 14 drawn from the coil 13, and the lands 30 are provided on the substrate front surface 20a side, but this is not limited to this. FIG. 14A is an enlarged perspective view of a substrate recess in a third modified embodiment. FIG. 14B is an enlarged plan view of the front surface side of the substrate recess. FIG. 14C is an enlarged plan view of the back surface side of the substrate recess. FIG. 15 is a schematic diagram showing an example of a state in which conductor wires are soldered to the substrate recess in the third modified embodiment. The motor according to the third modified embodiment differs from the above embodiment in that the lands 30 are formed not only on the front and back surfaces of the substrate main body 20 but also on the inner circumferential surface of each recess.

[0054] The land 30 includes a first land portion 31, a second land portion 32, and a third land portion 33. The first land portion 31 is disposed on one end surface of the substrate 2 in the thickness direction. Specifically, as shown in FIGS. 14A and 14B, the first land portion 31 is disposed on the front surface of the substrate main body 20 along the first substrate recesses 21 and the second substrate recesses 22. The second land portion 32 is disposed on the other end surface of the substrate 2 in the thickness direction. Specifically, as shown in FIG. 14C, the second land portion 32 is disposed on the rear surface of the substrate main body 20 along the first substrate recesses 21 and the second substrate recesses 22. As shown in FIGS. 14A to 14C, the third land portion 33 is disposed on the inner circumferential surfaces of the first substrate recesses 21 and the second substrate recesses 22. The first land portion 31, the second land portion 32, and the third land portion 33 are connected to each other. Specifically, in each of the first substrate recess 21 and the second substrate recess 22, a first land portion 31, a second land portion 32, and a third land portion 33 are continuously formed and electrically conductive. In the third modification of this embodiment, the first land portion 31 has a larger area than the third land portion 33. In addition, the second land portion 32 has a smaller area than the first land portion 31.

[0055] In an assembled state in which the substrate 2 is assembled to the stator 1, the first end 141 of the conducting wire 14 is inserted through the inside of the substrate-side first recess 21 at an incline toward the substrate-side second recess 22 in the circumferential direction. In an assembled state in which the substrate 2 is assembled to the stator 1, the second end 142 of the conducting wire 14 is inserted through the inside of the substrate-side second recess 22 at an incline toward the substrate-side first recess 21 in the circumferential direction. As shown in FIG. 15 , the outer circumferential surfaces of the first end 141 and the second end 142 of the conducting wire 14 are supported by contacting the peripheral ends of the recesses (the substrate-side first recess 21 and the substrate-side second recess 22) on the substrate front surface 20a side and the peripheral ends of the recesses on the substrate back surface 20b side. This prevents the end of the conducting wire 14, which is a lead wire, from moving relative to the substrate 2.

[0056] As described above, in a motor according to one aspect of the present invention, the first board-side recess 21 and the second board-side recess 22 are recessed radially inward from their outer circumferential ends and open radially outward. This allows the ends of the conductor 14 to be routed radially into the first board-side recess 21 and the second board-side recess 22, rather than axially (perpendicular to the board surface), unlike through holes provided in the board 2. This facilitates assembly of the conductor 14 to the board 2 and improves productivity. Furthermore, the third land portions 33 are disposed on the inner circumferential surfaces of the first board-side recess 21 and the second board-side recess 22, and the first land portions 31, the second land portions 32, and the third land portions 33 are connected to each other. This allows soldering the land 30 and the conductor 14 to not only be joined to the first land portion 31 but also to the second land portions 32 and the third land portions 33. This improves the strength of the joint between the land 30 and the conductor 14, and since the conductor 14, which is the lead wire from the coil 13, is connected widely in the thickness direction of the substrate 2, it is possible to suppress relative movement between the substrate 2 and the conductor 14 due to, for example, motor vibration, etc., and prevent breakage of the conductor 14, etc.

[0057] In the third modified example of the above embodiment, the first end 141 is disposed inside the first substrate recess 21 in a state inclined circumferentially toward the second substrate recess 22, and the second end 142 is disposed inside the second substrate recess 22 in a state inclined circumferentially toward the first substrate recess 21, but the present invention is not limited to this. The third modified example of the embodiment may be applied to the first and second modified examples of the embodiment.

[0058] Furthermore, in the third modified example of the above embodiment, the end of the conductor 14 is soldered to the substrate 2 at three locations by soldering the first land portion 31 from the substrate front surface 20a side, and the solder flowing into the third land portion 33 and the second land portion 32 in that order, but this is not limited to this. For example, the end of the conductor 14 may be soldered to the substrate 2 at two locations by soldering the first land portion 31 from the substrate front surface 20a side, and the solder flowing into the third land portion 33 may be used. Alternatively, the end of the conductor 14 may be soldered to the substrate 2 at three locations by soldering the first land portion 31 from the substrate front surface 20a side and then soldering the second land portion 32 from the substrate back surface 20b side, and the solder flowing into the third land portion 33 may be used.

[0059] (Fourth Modification of the Embodiment) In the above embodiment, the wall portion 122 of the insulator 12 has two recesses (insulator-side first recess 126 and insulator-side second recess 127) that radially face two lead-out positions of the conductor 14 led out from the coil 13, but the present invention is not limited to this. FIG. 16 is an external perspective view of a split core according to a fourth modified embodiment. FIG. 17A is an enlarged side view of a connection portion between the split core and a substrate according to the fourth modified embodiment. FIG. 17B is an enlarged plan view of the connection portion according to the fourth modified embodiment. FIG. 18 is a schematic diagram showing a change in the position of the conductor when a substrate is attached to the split core according to the fourth modified embodiment. The motor according to the fourth modified embodiment differs from the above embodiment in that the wall portion 122A of the insulator 12A has an inclined surface 152.

[0060] As shown in FIG. 16 , the insulator 12 has an accommodation portion 121 and a wall portion 122A formed at a radially outer end of the accommodation portion 121. The wall portion 122A is located on the outer periphery of the substrate 2 when the substrate 2 is assembled to the stator 1. The wall portion 122A is formed in a substantially rectangular shape when viewed radially and protrudes from the yoke portion 11b in the axial direction. As shown in FIG. 16 , the wall portion 122A has a recess 151 and an inclined surface 152. The recess 151 is formed so as to be recessed from the end of the wall portion 122A on the first axial direction side toward the second axial direction side. The recess 151 is a portion into which the substrate protrusion 23 is fitted when the substrate 2 is assembled to the stator 1. When viewed circumferentially, the inclined surface 152 is inclined so that its radial thickness becomes thinner from the middle of the axial direction of the wall portion 122A toward the end on the first axial direction side, as shown in FIG. 18 . In addition, in an assembled state in which the substrate 2 is assembled to the stator 1, the inclined surface 152 is inclined from the inside to the outside in the radial direction in the direction in which the conductor wires 14 are drawn out.

[0061] As described above, in a motor according to one aspect of the present invention, insulator 12A has wall portion 122A located on the outer periphery of substrate 2 in an assembled state in which substrate 2 is assembled to stator 1. Wall portion 122A has inclined surface 152 that inclines from the inside to the outside in the radial direction in the direction in which conductor 14 is drawn out in the assembled state in which substrate 2 is assembled to stator 1. This allows ends (first end 141, second end 142) of conductor 14 to escape toward inclined surface 152 of insulator 12A, which is located on the outside in the radial direction, when conductor 14 drawn out from coil 13 is connected to substrate 2. Then, after substrate 2 is assembled to stator 1, the ends of conductor 14 that escape toward inclined surface 152 of insulator 12A can be placed in recesses (first substrate-side recess 21, second substrate-side recess 22) on substrate 2. As a result, the stator 1 and the substrate 2 can be assembled without the conductor 14 interfering with the insulator 12A, and the productivity of the motor can be improved.

[0062] Furthermore, in the above embodiment and modified examples, the plurality of recesses 130 are formed so as to be recessed from the outer surface 125 toward the second axial direction, but this is not limited thereto, and the recesses 130 may be formed so as to protrude from the outer surface 125 toward the first axial direction. Furthermore, one of the four outer surfaces 125 is configured with the plurality of recesses 130 and the flat surface 131, but this is not limited thereto. For example, all of the four outer surfaces 125 may include the plurality of recesses 130 and the flat surface 131.

[0063] In the above embodiment and modified examples, it has been described that three of the four outer surfaces 125 of the insulator 12 are composed of only flat surfaces, and one is composed of a plurality of recesses 130 and a flat surface 131, but this is not limited to this. For example, the outer surface 125 composed of a plurality of recesses 130 and a flat surface 131 may be applied to all or some of the four outer surfaces 125 that constitute the outer peripheral surface of the accommodating portion 121.

[0064] Although the embodiments and modifications of the present invention have been described above, the present invention is not limited to the above embodiments and modifications, and various modifications are possible without departing from the spirit of the present invention. Furthermore, the present invention is not limited to the above embodiments and modifications. The present invention also includes configurations in which the above-described components are appropriately combined. Furthermore, further effects and modifications can be easily derived by those skilled in the art. Therefore, the broader aspects of the present invention are not limited to the above embodiments, and various modifications are possible. [Explanation of symbols]

[0065] REFERENCE SIGNS LIST 1 stator, 2 substrate, 10 split core, 11 stator core, 11a teeth portion, 11b yoke portion, 12 insulator, 13 coil, 14 conducting wire, 20 substrate body, 21 substrate side first recess, 22 substrate side second recess, 30 land, 31 first land portion, 32 second land portion, 33 third land portion, 121 accommodating portion, 122 wall portion, 125 outer surface, 126 insulator side first recess (third recess), 127 insulator side second recess (fourth recess), 128 insulator side convex portion, 130 recess, 131 flat surface, 132 convex portion, 141 first end portion, 142 second end portion, 143 first bent portion, 144 second bent portion, 145 first deformation portion, 146 second deformation portion

Claims

1. a stator including a magnetic body, an insulator surrounding the magnetic body, and a coil formed by a conductive wire wound around the magnetic body via the insulator; an annular substrate provided on the stator; a land having electrical conductivity and connected to the conductive wire; Equipped with One of the lead-out positions of the two conductors drawn out from the coil is located on the outer periphery of the coil, and the other is located inside the outer periphery, The substrate is a first recess and a second recess that are recessed radially inward from an outer circumferential end and adjacent to each other in the circumferential direction, and a protrusion that is located between the first recess and the second recess, a first end of the conducting wire is disposed inside the first recess; a second end of the conductive wire is disposed inside the second recess; the land is formed on a convex portion of the substrate, The insulator is a wall portion located on an outer periphery of the substrate assembled to the stator; The wall portion is a first axial end; a third recess facing one of the lead-out positions of the conductor; a fourth recessed portion facing the other of the lead-out positions of the conductor; a protrusion between the third recess and the fourth recess; and In the axial direction, the convex portion of the wall portion is lower than the first end portion of the wall portion; the first recess faces the third recess in the radial direction, the second recess faces the fourth recess in the radial direction, the protrusion of the substrate faces the protrusion of the insulator in the axial direction; an end of the first recess of the substrate faces the third recess of the insulator in a radial direction, with the first end of the conducting wire interposed therebetween; In a radial direction, an end of the second recess of the substrate faces the fourth recess of the insulator, with the second end of the conducting wire interposed therebetween. Motor.

2. a stator including a magnetic body, an insulator surrounding the magnetic body, and a coil formed by a conductive wire wound around the magnetic body via the insulator; an annular substrate provided on the stator; a land having electrical conductivity and connected to the conductive wire; Equipped with The substrate is a first recess and a second recess that are recessed radially inward from an outer circumferential end and adjacent to each other in the circumferential direction, and a protrusion that is located between the first recess and the second recess, a first end of the conducting wire is disposed inside the first recess; a second end of the conductive wire is disposed inside the second recess; the land is formed on a convex portion of the substrate, The insulator is a wall portion located on an outer circumferential side of the substrate in an assembled state in which the substrate is assembled to the stator; The wall portion is The groove has an inclined surface inclined from the inside to the outside in the radial direction and a recess, the protrusion of the substrate faces the recess of the insulator in the axial direction, an end of the first recess of the substrate faces the inclined surface of the wall portion of the insulator in a radial direction, with the first end of the conducting wire interposed therebetween; In the radial direction, an end of the second recess of the substrate faces the inclined surface of the wall portion of the insulator, with the second end of the conducting wire interposed therebetween. Motor.

3. The insulator is the conductive wire is wound around the magnetic body, and a housing portion is provided to house the magnetic body; In the circumferential direction, the distance from the accommodation portion to the third recessed portion is greater than the distance from the accommodation portion to the fourth recessed portion. The motor according to claim 1 .

4. a plurality of magnetic bodies including the magnetic body; a plurality of coils formed by a plurality of conductor wires, including the coil formed by the conductor wire; Equipped with The plurality of coils are wound around each of the plurality of magnetic bodies, 4. The motor according to claim 1.

5. 5. The motor according to claim 1, wherein the stator is integrated by insert molding.

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