Insulators, stators and motors

Abstract

To provide an insulator capable of improving insulation characteristics of a stator.SOLUTION: An insulator consists of a first insulator 200A and a second insulator 200B. The first insulator 200A and second insulator 200B comprise a first flange part and a second flange part, and a trunk part 230, and the second flange part of the first insulator 200A and the second flange part of the second insulator 200B are put one over the other to form a lap part. The lap part consists of: a raised part 220B35, a second curved line part 220B34, a first tip surface 220B32, a second tip surface 220B33, and a side face part 220B3 of the second flange part of the first insulator 200A; and a raised part 400B26, a first step 400B24, a second step 400B25, a side face reverse part 400B23, a fourth curved line part 400B22, and a side face part 400B2 of the second flange part of the second insulator 200B.SELECTED DRAWING: Figure 22

Description

[Technical Field]

[0001] The present invention relates to an insulator for winding a stator winding around teeth of a stator core, and a stator and an electric motor including the insulator. [Background technology]

[0002] Electric motors that have a stator and a rotor and in which the stator winding is wound around the teeth of the stator core that constitutes the stator using a concentrated winding method (called "concentrated winding motors") are used as compressor drive motors, vehicle drive motors, in-vehicle device drive motors, etc. In concentrated winding motors, the stator winding is wound around the teeth via an insulator (called a "resin bobbin").

[0003] Furthermore, in such concentrated winding motors, in order to increase the number of turns of the stator winding and thereby improve the space factor of the stator winding, motors have been proposed that use a stator core made up of split cores (called a "split-structure stator core").

[0004] Electric motors using split-core stator cores are disclosed in, for example, Patent Documents 1 to 3 listed below. As shown in FIG. 1 of Patent Document 1, the electric motor disclosed in Patent Document 1 includes a stator, a rotor arranged inside the stator, and a housing arranged outside the stator. The stator includes an annular stator core, windings, and insulators, and the stator core is formed by connecting multiple core pieces in an annular shape. The multiple core pieces have a back yoke and teeth arranged inward from the back yoke, and multiple (12) core pieces are arranged at 30-degree intervals in the circumferential direction.

[0005] The insulators are assembled to the back yoke and teeth of the stator core, and the windings are formed by winding insulating coated magnet wire around the insulators in a coil shape. As shown in Figure 5 of Patent Document 1, the insulators have pin insertion holes at both ends, and adjacent insulators are connected by inserting connecting pins into the pin insertion holes while the pin insertion holes of the adjacent insulators are overlapped.

[0006] As shown in FIG. 1 of Patent Document 2, the electric motor disclosed in Patent Document 2 has a stator core divided into radial magnetic pole teeth that are integrated on the inner diameter side and a ring-shaped outer yoke that is fixed to the outer diameter side of the magnetic pole teeth.

[0007] A coil bobbin with a coil wound around it is attached independently to each of the radial magnetic pole teeth, and then the outer diameter side end of the magnetic pole teeth is fitted and fixed to the inner diameter part of the outer yoke to form the stator core.

[0008] As shown in FIG. 2 of Patent Document 3, the electric motor disclosed in Patent Document 3 has a stator core divided into an annular stator core body and stator teeth, and the rear ends of multiple stator teeth, around which windings are wound via bobbins, are fitted into the inner diameter side of the stator core body to form a stator.

[0009] A polygonal hole is formed in the center of the stator core body, and fitting grooves are formed in the center of each side face of the hole. The rear ends of stator teeth, which have the same shape as the polygonal hole, are press-fitted into the fitting grooves using a press or the like, thereby assembling the stator core body and the multiple stator teeth around which windings are wound into one unit.

[0010] As shown in FIG. 5 of Patent Document 3, the windings wound around adjacent stator teeth are of different phases (U phase, V phase, W phase), so insulation is required between the windings at the positions between adjacent phases, and between the windings and the stator core.

[0011] To ensure this insulation, the outer end of the outer bobbin is cut diagonally to provide a gap between the cut surface and the inner surface of the stator core body, as shown in Figure 6 of Patent Document 3. A T-shaped flange of insulating paper bent into a T shape is inserted into this gap to sandwich the wire, and the T-shaped center of the insulating paper is inserted between adjacent windings. [Prior art documents] [Patent documents]

[0012] [Patent Document 1] International Publication No. 2017 / 175358 [Patent Document 2] Japanese Patent Application Publication No. 63-299734 [Patent Document 3] Japanese Patent Application Laid-Open No. 2002-171704 Summary of the Invention [Problem to be solved by the invention]

[0013] The stator core disclosed in Patent Document 1 has coils wound around the teeth of the divided core pieces via insulators, and the stator coil and core pieces are insulated from each other, but as shown in Figure 2 of Patent Document 1, both ends of the tooth portions of the teeth are positioned in contact with the inner diameter side of the insulator, so when the stator coil is wound around the insulator, the creepage distance between the coil and both ends of the tooth portions is short, and if this stator core is used in a high-voltage motor, partial discharge may occur between the stator coil and both ends of the tooth portions. Also, connecting pins are required to connect adjacent insulators, which increases the number of parts.

[0014] In the stator core disclosed in Patent Document 2, coil bobbins with wound coils are individually attached to radial magnetic pole teeth that are integrated on the inner diameter side, and a ring-shaped outer yoke is fixed to the outer diameter side of the magnetic pole teeth, so adjacent coil bobbins attached to the magnetic pole teeth are not connected to each other, and no connecting pins are required to connect the insulators (coil bobbins) as in the stator described in Patent Document 1. However, like the stator in Patent Document 1, gaps are formed between adjacent coil bobbins attached to the magnetic pole teeth on their inner diameter side, and when coils are wound around the magnetic pole teeth, partial discharges may occur between the coils and the tooth portions.

[0015] In the case of the stator core disclosed in Patent Document 3, a plurality of stator teeth, each having a winding wound thereon via bobbins, are fitted into a stator core body to form a stator, and therefore adjacent bobbins are not connected to one another, similar to the stator core of Patent Document 2, and both have the advantage of not requiring connecting pins to connect the bobbins. Meanwhile, insulating paper is inserted between the windings of different phases wound on adjacent stator teeth, ensuring insulation between the windings, but in the case of the stator core of Patent Document 3, gaps are formed on the inner diameter side of the bobbins attached to the stator teeth, and partial discharges are likely to occur between the windings wound on the bobbins and the teeth of the stator teeth through these gaps, similar to Patent Documents 1 and 2.

[0016] The present invention was devised in consideration of these points, and aims to provide technology relating to the structure of an insulator that can improve the insulating performance between the stator coil and the tooth tips of the stator core. [Means for solving the problem]

[0017] The first invention is an insulator attached to the tooth base of a stator, the insulator comprising a yoke extending circumferentially, a plurality of tooth bases extending radially inward from the yoke, tooth tips disposed radially inward from the tooth bases and extending circumferentially, and a connecting portion connecting the tooth tips. The insulator comprises a first insulator and a second insulator, each of which has a first flange portion, a second flange portion, and a body portion connecting the first flange portion and the second flange portion. The tooth base is inserted into a through hole of the body portion, and a stator winding is wound around the body. The first and second insulators have substantially the same first flange structure, and the second flange portion of the first insulator and the second flange portion of the second insulator have an overlapping portion that closes the gap between the second flange portions. The second flange portion of the second insulator comprises a side portion that extends circumferentially from a through hole formed in the inner peripheral surface of the body portion and abuts against a connecting portion that connects the teeth of the stator, a fourth curved portion that continues from the side portion and forms the tip end of the overlapping portion, a side rear portion that continues from the fourth curved portion and extends in the opposite direction to the extension direction of the side portion, a first step formed at the end of the side rear portion, a second step that continues from the first step, and a rising portion that extends from the second step toward the outer peripheral surface of the body portion. The second flange portion of the first insulator includes a first curved portion extending in the circumferential direction of the stator from a through hole formed in the inner peripheral surface of the trunk portion and abutting the connecting portion and the fourth curved portion of the stator, a side portion continuing from the first curved portion and abutting the rear portion of the side surface of the second insulator, a first tip face and a second tip face continuing from the side face and constituting the tip portion of the overlapping portion, a second curved portion continuing from the second tip face, and a rising portion extending from the second curved portion toward the outer peripheral surface of the trunk portion. The overlapping portion is not connected to the folded central portion of the winding insulating member, which is formed by folding a central portion in the width direction and extending in the axial direction, and folded end portions folded in the width direction and extending in the axial direction. The folded central portion is disposed in the space between the first step and second step of the second insulator and the second tip face and second curved portion of the first insulator. By doing so, insulation between the connecting portion and the stator winding is ensured.

[0018] The second invention is: The bent end portion of the winding insulating member according to the first invention is disposed radially outside the first flange portion of the first insulator and the first flange portion of the second insulator, and is configured to include a recess that restricts the bent end portion from moving in one circumferential direction and one axial direction. .

[0019] The third invention is The stator includes a stator core, an insulator, a stator winding, and a winding insulating member, and the insulator according to claim 1 or 2 is used as the insulator.

[0020] The fourth invention is A stator having an insulator according to either the first or second invention, comprising a first core member consisting of the tooth base, the tooth tip, and the connecting portion, and a second core member consisting of the yoke having a recess into which the radially outer end of the tooth base is fitted.

[0021] The fifth invention is An electric motor including the stator according to any one of the first to third aspects of the present invention and a rotor that can rotate relatively to the stator. . [Effects of the Invention]

[0024] According to the first invention, a common structure can be adopted for the first flange of the first insulator and the first flange of the second insulator. Also, the second flange of the first insulator and the second flange of the second insulator can close the radially inner side of the stator by the overlapping portion. Therefore, when the stator winding is wound around each of the first insulator and the second insulator, an overlapping portion is interposed between the stator winding and the tooth tips (tooth portions) of the stator core, thereby improving the insulation performance between the stator winding and the tooth portions.

[0025] No. 1According to the invention, the second flange of the second insulator abuts against the connecting portion of the stator core. The first insulator attached to the teeth of the stator core abuts against the second flange of the second insulator. The first curved portion of the second flange of the first insulator is interposed between the tooth tip and the connecting portion and between the tooth tip and the fourth curved portion of the second flange of the second insulator. The first distal end surface of the second flange of the first insulator abuts against the first step of the second flange of the second insulator. Because the second flanges of the first insulator and the second insulator are arranged in this manner, the first and second insulators can form an overlapping portion without any gaps, thereby reliably improving the insulation performance between the stator windings wound around the first and second insulators and the stator teeth.

[0026] No. 1 According to the invention, the folded central portion of the winding insulating member that is disposed between the stator windings wound around the first insulator and the second insulator can be disposed between the first step and the second step in the second insulator and the second tip surface and the second curved portion in the first insulator, thereby improving the insulation performance on the radially inner side of the stator between the stator windings of different phases that are wound around the first insulator and the second insulator.

[0027] No. 2 According to the invention, the bent end portions of the winding insulating member are arranged in the recesses of the first flange portion of the first insulator and the first flange portion of the second insulator, so that the winding insulating member can be interposed between the recesses and the stator core and securely held therein.

[0028] No. 3 According to the present invention, a stator can be configured that can achieve the same effects as the first to fourth aspects of the present invention.

[0029] No. 4 According to the invention, in addition to the effects of the first to fifth inventions, a stator core can be formed by simultaneously fixing a first core member consisting of a plurality of teeth to a second core member that forms a circular yoke portion.

[0030] No. 5 According to the invention, the first to third inventions4 It is possible to configure an electric motor that can achieve the same effects as the present invention.

[0031] By using the insulator of the present invention, the insulating properties of a stator or an electric motor can be improved. [Brief explanation of the drawings]

[0032] [Figure 1] FIG. 2 is a perspective view showing the lead side of the stator of the present invention. [Figure 2] FIG. 2 is an enlarged perspective view showing a portion of the lead side of the stator of the present invention. [Figure 3] 1 is a plan view showing a schematic configuration of a stator core of a stator according to the present invention; [Figure 4] FIG. 1 is a perspective view showing a first insulator of the present invention. [Figure 5] 4 is a front view of the first insulator of the present invention as seen from the direction of IV shown in FIG. 3. FIG. [Figure 6] 4 is a rear view of the first insulator of the present invention as seen from the direction V in FIG. 3. FIG. [Figure 7] 6 is a right side view of the first insulator of the present invention as viewed from the direction of VI in FIG. 3. FIG. [Figure 8] 7 is a cross-sectional view of the first insulator of the present invention as seen from the direction of VII in FIG. 3. FIG. [Figure 9] 2 is an enlarged cross-sectional view showing a portion of the first insulator of the present invention. FIG. [Figure 10] FIG. 10 is a perspective view illustrating the operation of attaching the first insulator of the present invention to the teeth. [Figure 11] FIG. 2 is a perspective view showing a second insulator of the present invention. [Figure 12] 12 is a front view of the second insulator of the present invention as seen from the direction of IV shown in FIG. 11. FIG. [Figure 13] 12 is a rear view of the second insulator of the present invention as seen from the direction of V in FIG. 11. FIG. [Figure 14] 12 is a left side view of the second insulator of the present invention as seen from the direction of VI in FIG. 11. FIG. [Figure 15]FIG. 12 is a cross-sectional view of the second insulator of the present invention as seen from the direction of VII in FIG. [Figure 16] FIG. 2 is an enlarged cross-sectional view showing a portion of a second insulator of the present invention. [Figure 17] FIG. 10 is a perspective view illustrating the operation of attaching the second insulator of the present invention to the teeth. [Figure 18] FIG. 4 is a plan view illustrating the operation of attaching the first insulator and the second insulator of the present invention to the first core member of the stator core. [Figure 19] FIG. 2 is a plan view showing a state in which the first insulator and the second insulator of the present invention are attached to a first core member of a stator core. [Figure 20] FIG. 10 is a perspective view illustrating the operation of arranging a second insulator adjacent to a first insulator of the present invention. [Figure 21] FIG. 2 is a perspective view showing a state in which a second insulator is disposed adjacent to a first insulator of the present invention. [Figure 22] FIG. 2 is an enlarged plan view showing an overlapping portion between a first insulator and a second insulator of the present invention. [Figure 23] 1 is a perspective view showing a state in which a second insulator is disposed adjacent to a first insulator of the present invention, viewed from the first flange side. [Figure 24] 10 is a perspective view illustrating a case where a winding insulating member is inserted from the side opposite the lead of the stator of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0033] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this specification, the term "axial direction" refers to the direction in which the rotational center line P (see FIG. 1) of the rotor extends when the rotor is rotatably arranged relative to the stator. The term "circumferential direction" refers to the circumferential direction centered on the rotational center line P when viewed in a cross section perpendicular to the axial direction when the rotor is rotatably arranged relative to the stator.

[0034] The term "radial direction" refers to the direction passing through the rotation center line P when viewed in a cross section perpendicular to the axial direction in a state in which the rotor is rotatably disposed relative to the stator. The term "radial inner peripheral side" refers to the side of the rotation center line P along the radial direction, and the term "radial outer peripheral side" refers to the side opposite the rotation center line P along the radial direction.

[0035] It should be noted that with respect to the insulator, the terms "axial direction," "circumferential direction," and "radial direction" refer to the "axial direction," "circumferential direction," and "radial direction" when the insulator is attached to both axial sides of the stator core.

[0036] Furthermore, in this specification, the terms "parallel," "right-angled," and "flat" are used to include "substantially parallel," "substantially right-angled," and "substantially flat," respectively. Furthermore, in this specification, for convenience, the upper and lower sides in Figures 5 and 12 are described as "one axial side" and "other axial side," respectively, and the right and left sides in Figures 5 and 12 are described as "one circumferential side" and "other circumferential side," respectively, but "one side" and "other side" are not limited to these and any appropriate direction can be selected.

[0037] An embodiment of the insulator of the present invention will be described with reference to Figs. 1 to 24. Fig. 1 is a perspective view showing the lead side (the side on which lead wires (not shown) connected to stator windings 610 are arranged) of a stator 100 constituting an electric motor of the present invention, and Fig. 2 is an enlarged perspective view showing a portion of the stator 100 of Fig. 1. As shown in Fig. 1, the stator 100 of this embodiment is generally composed of a stator core 110, insulators 200 (200A, 200B), a stator winding 610, and a winding insulating member (insulating film) 310 shown in Fig. 2.

[0038] The stator core 110 has core end faces 110A and 110B on both axial sides. The stator core 110 is configured as a split stator core. In this embodiment, the stator core 110 is configured by a first core member 120 and a second core member 130, as shown in Fig. 3. Note that Fig. 3 shows the first core member 120 and the second core member 130 as viewed from a direction perpendicular to the axial direction.

[0039] The first core member 120 (also called the "inner core") is composed of a laminate in which multiple electromagnetic steel sheets are stacked together using crimping protrusions 126. The first core member 120 has multiple teeth 121 that extend radially and are spaced apart circumferentially. Each tooth 121 has a tooth base 122 that extends radially and a tooth tip 123 that is located radially inner of the tooth base 122 and extends circumferentially. The tooth tip 123 of circumferentially adjacent teeth 121 is connected by a connecting portion 125.

[0040] The second core member 130 (also called the "outer core") is composed of a laminate in which multiple electromagnetic steel sheets are stacked using crimping protrusions 136. The second core member 130 has a yoke 131 and a yoke inner peripheral surface 133 that extend in the circumferential direction.

[0041] Yoke 131 has yoke outer peripheral surface 132 and yoke inner peripheral surface 133. It also has recess-forming surface 134a that is recessed radially outward from yoke inner peripheral surface 133. Recess-forming surface 134a forms recesses 134 into which radially outer ends of teeth 121 (more specifically, tooth bases 122) of first core member 120 can be fitted. Note that yoke inner peripheral surface 133 has yoke inner peripheral surface portions 133a and 133b formed between two circumferentially adjacent recesses 134 (recess-forming surfaces 134a).

[0042] The yoke inner surface portions 133a and 133b are inclined so that the radial width of the yoke 131 becomes thinner from the connection between the yoke inner surface portion 133a and the recess 134 and from the connection between the yoke inner surface portion 133b and the recess 134 toward the circumferential center of both recesses 134.

[0043] Stator core 110 is formed by press-fitting, shrink-fitting, or cold-fitting the end portions of tooth bases 122 of first core member 120 opposite (on the radially outer peripheral side) to tooth tips 123 into recesses 134 of second core member 130. That is, when viewed in a cross section perpendicular to the axial direction, stator core 110 has a yoke 131 extending circumferentially and a plurality of teeth 121 extending radially inward from yoke 131, and teeth 121 have tooth bases 122 extending radially inward from yoke 131, and tooth tips 123 provided radially inner of tooth bases 122 and extending circumferentially.

[0044] Teeth tip surfaces 124 are formed on the radially inner circumferential side of tooth tip portions 123. Teeth tip surfaces 124 form rotor insertion spaces into which a rotor (not shown) is inserted.

[0045] The electric motor of the present invention is constructed by the stator 100 and a rotor rotatably inserted into the rotor insertion space.

[0046] The stator windings 610 (see FIGS. 1 and 2) are wound around the insulators (200A, 200B) attached to the teeth 121. That is, the stator windings 610 are wound around the teeth 121 using a concentrated winding method. Methods that can be used to wind the stator windings around the teeth 121 include a method in which the insulators (200A, 200B) are attached to the teeth 121 and then the stator windings 610 are wound around the insulators (200A, 200B), and a method in which the stator windings 610 are wound around the insulators (200A, 200B) and then the insulators (200A, 200B) are attached to the teeth 121.

[0047] An embodiment of the first insulator attached to the tooth 121 will be described with reference to Figs. 4 to 10. Fig. 4 is a perspective view showing a first insulator 200A according to the present invention. Fig. 5 is a view (front view) of Fig. 4 seen from the direction of arrow IV, and Fig. 6 is a view (rear view) of Fig. 4 seen from the direction of arrow V. Fig. 7 is a view (right side view) of Fig. 4 seen from the direction of arrow VI, and Fig. 8 is a view (cross-sectional view) of Fig. 4 seen from the direction of arrow VII.

[0048] The first insulator 200A (called a "resin bobbin") is formed from a resin having insulating properties, such as polybutylene terephthalate (PBT) resin, polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP) resin, nylon, etc.

[0049] The first flange portion 210 of the first insulator 200A extends in the axial direction (up and down in FIG. 5) and the circumferential direction (left and right in FIG. 5), and has an outer peripheral surface 210A on the radially outer side (front side of the paper in FIG. 5), an inner peripheral surface 210B on the radially inner side (back side of the paper in FIG. 5), an end face 211 on one axial side (top side in FIG. 5), an end face 212 on the other axial side (bottom side in FIG. 5), a side surface 213 on one circumferential side (right side in FIG. 5), and a side surface 214 on the other circumferential side (left side in FIG. 5).

[0050] The second flange portion 220 of the first insulator 200A is positioned radially inner than the first flange portion 210, extends along the axial and circumferential directions, and has an outer peripheral surface 220A on the radial outer side, an inner peripheral surface 220B on the radial inner side, an end face 227 on one axial side, an end face 222 on the other axial side, a side surface 223 on one circumferential side, and a side surface (224) on the other circumferential side.

[0051] Body 230 is provided between first flange 210 and second flange 220 and extends radially. Through-hole 240 is formed inside body 230 so as to extend radially and axially, and opens to outer peripheral surface 210A of first flange 210 and inner peripheral surface 220B of second flange 220.

[0052] 10 , when the end of tooth base 122 is inserted into through hole 240 from the second flange portion 220 side, outer wall surfaces 122a, 122b, 122c, and 122d of tooth base 122 are inserted so as to face inner wall surfaces 241, 242, 243, and 244 of through hole 240, respectively.

[0053] 6 on the inner wall surfaces 241, 242, 243, and 244 of the through hole 240, facing the inner circumferential surface 220B of the second flange portion 220. This prevents the first insulator 200A from shifting axially and circumferentially relative to the tooth bases 122 (teeth 121), and allows the tooth bases 122 (teeth 121) to be easily inserted into the through hole 240 of the first insulator 200A.

[0054] 4 and 5 is provided with protrusions 250, 260, and 270 that protrude radially outward from an outer circumferential surface 210A. In this embodiment, the outer circumferential surface 210A is formed into a flat surface that extends in the circumferential and axial directions.

[0055] The protrusions 250 are provided on the end face 212 side of the through holes 240. The protrusions 250 have outer wall surfaces 251 on the end face 212 side (the other axial side) and outer wall surfaces 252 on the through hole 240 side (one axial side). The outer wall surfaces 251 are formed as an inclined surface such that the distance from the outer peripheral surface 210A increases from the end face 212 side toward the through hole 240 side. Because the outer wall surfaces 251 of the protrusions 250 are inclined, when the ends of the tooth bases 122 are inserted into the through holes 240 of the first insulator 200A and protrude from the through holes 240 (from the outer peripheral surface 210A of the first flange portions 210), the ends of the tooth bases 122 can be easily guided into the recesses 134 when they are press-fitted into the recesses 134 of the second core member 130.

[0056] The protrusion 260 is provided in an area on the side surface 213 side (one circumferential side) of the through hole 240, closer to the end face 211 (one axial side). The protrusion 260 has an outer wall surface 261 formed on the radially outer peripheral side and extending along the circumferential and axial directions, an outer wall surface 262 formed on the other axial side and extending along the circumferential direction, outer wall surfaces 264 (264a to 264e) formed on one circumferential side (opposite the protrusion 270) and extending along the axial direction, and an outer wall surface 263 formed on the other circumferential side (the side facing the protrusion 270) and extending along the axial direction. The outer wall surface of the protrusion 260 on one axial side is formed by the end face 211 of the first flange 210 (flush with the end face 211).

[0057] The outer wall surface 264 has, from one axial side to the other axial side, a first outer wall surface portion 264a, a second outer wall surface portion 264b, a third outer wall surface portion 264c, a fourth outer wall surface portion 264d, and a fifth outer wall surface portion 264e, as shown in Fig. 5. In this embodiment, the first outer wall surface portion 264a and the fourth outer wall surface portion 264d extend parallel to the axial direction and substantially on the same line, and the second outer wall surface portion 264b extends perpendicular to the axial direction from the lower end of the first outer wall surface portion 264a toward one circumferential side. Furthermore, the third outer wall surface portion 264c extends at an angle relative to the other axial side and the other circumferential side above the fourth outer wall surface portion 264d, and the fifth outer wall surface portion 264e extends at an angle relative to the one axial side and the one circumferential side below the fourth outer wall surface portion 264d.

[0058] The protrusion 270 is provided in an area closer to the end face 211 (one axial side) than the through hole 240 and closer to the side face 214 (the other circumferential side). The protrusion 270 has an outer wall surface 271 formed on the radially outer peripheral side and extending along the circumferential and axial directions, an outer wall surface 272 formed on the other axial side and extending along the circumferential direction, an outer wall surface 273 formed on one circumferential side (the side facing the protrusion 260) and extending along the axial direction, and an outer wall surface 274 (274a, 274b) formed on the other circumferential side (the side opposite the protrusion 260) and extending along the axial direction. The outer wall surface of the protrusion 270 on one axial side is formed flush with the end face 211 of the first flange 210, and the outer wall surface on the other axial side is formed flush with the outer wall surface 272.

[0059] The outer wall surface 274 has, from one axial side to the other axial side, a first outer wall surface portion 274a and a second outer wall surface portion 274b. The first outer wall surface portion 274a extends parallel to the axial direction, and the second outer wall surface portion 274b extends obliquely below the first outer wall surface portion 274a toward the other circumferential side and one axial side, and its lower end is connected to the outer wall surface 272.

[0060] Furthermore, a locking projection 277 that projects toward the other circumferential side is provided on the first outer wall surface portion 274a of the projection 270. The locking projection 277 has a projection 278 that projects toward the other axial side at its end on the other circumferential side. The locking projection 277 fixes the end of the stator winding 610. Furthermore, a working space is secured when fixing the end of the stator winding by the space 265 above the second outer wall surface portion 264b of the outer wall surface 264 and the space 275 above the second outer wall surface portion 264b of the outer wall surface 274.

[0061] The first flange 210 is provided with a recess 280 and a recess 290 recessed radially inward from the outer circumferential surface 210A. The recess 280 is provided on the side surface 213 (one circumferential side) of the through-hole 240, and is open on one circumferential side (side surface 213 side) and the radially outer circumferential side. The recess 280 is formed by a bottom surface 281a, an outer wall surface 262 provided on one axial side of the bottom surface 281a, and a side surface 281b provided on the other circumferential side of the bottom surface 281a. The bottom surface 281a of the recess 280 extends as a flat surface in the axial and circumferential directions. The recess 280 regulates the circumferential and axial positions of the other circumferential side of the insulating film 310.

[0062] The recess 290 is provided on the side surface 214 side (the other circumferential side) of the through-hole 240, and is open on the other circumferential side (side surface 214 side) and the radially outer peripheral side. The recess 290 is formed by a bottom surface 291a, an outer wall surface 272 provided on one axial side of the bottom surface 291a, and a side surface 291b provided on one circumferential side of the bottom surface 291a. The bottom surface 291a of the recess 290 extends as a flat surface in the axial and circumferential directions. The recess 290 regulates the circumferential and axial positions of the portion of the insulating film 310 on one circumferential side.

[0063] 6 and 7, the second flange 220 includes a lower surface 220B1 and side surface portions 220B2 and 220B3 that constitute the inner circumferential surface 220B, and is provided with a protruding portion 221 on one axial side, interposed between the side surface portions 220B2 and 220B3, protruding radially inward from the inner circumferential surface 220B (to the right in FIG. 7). A stepped surface 225 is formed on the lower surface of the protruding portion 221. The protruding portion 221 includes an end surface 221A located on the radially inner circumferential side (the front side of the paper in FIG. 6), and ears 221B and 221C protruding circumferentially on both sides at an upper portion of the end surface 221A.

[0064] In addition, a protruding piece 226A that protrudes radially inward is provided on the upper part of the protruding portion 221, and a protruding portion 226C that protrudes to one side in the axial direction is erected on the upper surface (end surface 211) of the protruding piece 226A, and a protruding portion 226B that protrudes radially inward (toward the front of the paper in Figure 6) is provided on the protruding portion 226C.

[0065] Fig. 8 is a cross-sectional view of first insulator 200A. As shown in Fig. 8, first insulator 200A has second flange 220 made up of outer peripheral surface 220A and inner peripheral surface 220B extending from body 230 to both circumferential sides (left and right sides in Fig. 8). Second flange 220 has a symmetrical structure on both circumferential sides (left and right sides in Fig. 8).

[0066] 9 is an enlarged cross-sectional view of a main part of the first insulator 200A, showing an enlarged portion of the second flange 220. As shown in FIG. 9, the second flange 220 includes a first curved portion 220B31 continuing from the opening of the through-hole 240 located on the radially inner circumferential side (the lower side in FIG. 9), a side surface portion 220B3 continuing from the curved portion 220B31 and inclining toward one circumferential side (the right side in FIG. 9) and the radially inner circumferential side (the lower side in FIG. 9), and a side surface portion 220B3 extending from the side surface portion 220B3 to the radially outer circumferential side (the upper side in FIG. 9) and toward one circumferential side (the lower side in FIG. 9). 9) from the trunk portion 230. The trunk portion 230 is configured by a first tip surface 220B32 that is inclined toward the other circumferential side (the right side in FIG. 9), a second tip surface 220B33 that is located on the radially outer periphery side (the upper side in FIG. 9) from the first tip surface 220B32 and inclined toward the other circumferential side (the left side in FIG. 9), and a second curved portion 220B34 that is located between the second tip surface 220B33 and a rising portion 220B35 that extends at a right angle from the trunk portion 230 toward one circumferential side (the right side in FIG. 9). Note that the structure around the side surface portion 220B3 located on the other circumferential side (the left side in FIG. 8) shown in FIG. 8 is obtained by flipping the structure shown in FIG. 9 laterally, and therefore description thereof will be omitted.

[0067] 10 , when attaching the first insulator 200A to the teeth 121 (tooth bases 122) of the first core member 120, the ends of the tooth bases 122 of the teeth 121 are inserted into the through holes 240 of the first insulator 200A from the second flange 220 side. At this time, the ends of the tooth bases 122 are guided into the through holes 240 by the radially inner inclined surfaces 241a to 244a of the inner wall surfaces 241 to 244 that form the through holes 240. The tooth bases 122 are inserted so that the ends of the tooth bases 122 protrude from the outer peripheral surface 210A of the first flange 210.

[0068] Next, an embodiment of the second insulator attached to the teeth 121 will be described with reference to FIGS. 11 to 17. In FIGS. 11 to 17, the same components as those in FIGS. 4 to 10 will be described with the same reference numerals. FIG. 11 is a perspective view showing a second insulator 200B according to the present invention. FIG. 12 is a view (front view) of FIG. 11 as seen from the direction of arrow IV, and FIG. 13 is a view (rear view) of FIG. 11 as seen from the direction of arrow V. FIG. 14 is a view (right side view) of FIG. 11 as seen from the direction of arrow VI, and FIG. 8 is a view (cross-sectional view) of FIG. 11 as seen from the direction of arrow VII.

[0069] The second insulator 200B ("resin bobbin"), like the first insulator 200A, is formed from a resin having insulating properties, such as polybutylene terephthalate (PBT) resin, polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP) resin, nylon, etc.

[0070] The first flange portion 210 extends in the axial direction (up and down in FIG. 12) and the circumferential direction (left and right in FIG. 12), and has an outer peripheral surface 210A on the radially outer side (front side of the paper in FIG. 12), an inner peripheral surface 210B on the radially inner side (back side of the paper in FIG. 12), an end face 211 on one axial side (top side in FIG. 12), an end face 212 on the other axial side (bottom side in FIG. 12), a side surface 213 on one circumferential side (right side in FIG. 12), and a side surface 214 on the other circumferential side (left side in FIG. 12).

[0071] The second flange portion 400 of the second insulator 200B is positioned radially inner than the first flange portion 210, extends along the axial and circumferential directions, and has an outer peripheral surface 400A on the radial outer side, an inner peripheral surface 400B on the radial inner side, an end face 401 on one axial side, an end face 402 on the other axial side, a side surface 403 on one circumferential side, and a side surface (404) on the other circumferential side.

[0072] Body 230 of second insulator 200B is provided between first flange 210 and second flange 400 and extends radially. Through-hole 240 is formed inside body 230 to extend radially and axially, and opens to outer peripheral surface 210A of first flange 210 and inner peripheral surface 400B of second flange 400.

[0073] 17, when the end of the tooth base 122 is inserted into the through hole 240 from the second flange portion 400 side, the outer wall surfaces 122a, 122b, 122c, and 122d of the tooth base 122 are inserted so as to face the inner wall surfaces 241, 242, 243, and 244 of the through hole 240, respectively.

[0074] 13 on the inner wall surfaces 241, 242, 243, and 244 of through hole 240 facing inner circumferential surface 400B of second flange portion 400. This prevents axial and circumferential displacement of second insulator 200B relative to tooth bases 122 (teeth 121), and allows tooth bases 122 (teeth 121) to be easily inserted into through hole 240 of second insulator 200B.

[0075] 11 and 12, a first flange 210 of a second insulator 200B is provided with protrusions 250, 260, and 270 that protrude radially outward from an outer circumferential surface 210A. In this embodiment, the outer circumferential surface 210A is formed into a flat surface that extends in the circumferential and axial directions.

[0076] The protrusions 250 are provided on the end face 212 side of the through holes 240. The protrusions 250 have outer wall surfaces 251 on the end face 212 side (the other axial side) and outer wall surfaces 252 on the through hole 240 side (one axial side). The outer wall surfaces 251 are formed as an inclined surface such that the distance from the outer peripheral surface 210A increases from the end face 212 side toward the through hole 240 side. Because the outer wall surfaces 251 of the protrusions 250 are inclined, when the ends of the tooth bases 122 are inserted into the through holes 240 of the second insulator 200B and protrude from the through holes 240 (from the outer peripheral surface 210A of the first flange portions 210), the ends of the tooth bases 122 can be easily guided into the recesses 134 when the ends are press-fitted into the recesses 134 of the second core member 130.

[0077] The protrusion 260 is provided in an area on the side surface 213 side (one circumferential side) of the through hole 240, closer to the end face 211 (one axial side). The protrusion 260 has an outer wall surface 261 formed on the radially outer peripheral side and extending along the circumferential and axial directions, an outer wall surface 262 formed on the other axial side and extending along the circumferential direction, outer wall surfaces 264 (264a to 264e) formed on one circumferential side (opposite the protrusion 270) and extending along the axial direction, and an outer wall surface 263 formed on the other circumferential side (the side facing the protrusion 270) and extending along the axial direction. The outer wall surface of the protrusion 260 on one axial side is formed by the end face 211 of the first flange 210 (flush with the end face 211).

[0078] The outer wall surface 264 has, from one axial side to the other axial side, a first outer wall surface portion 264a, a second outer wall surface portion 264b, a third outer wall surface portion 264c, a fourth outer wall surface portion 264d, and a fifth outer wall surface portion 264e, as shown in FIG. 12 . In this embodiment, the first outer wall surface portion 264a and the fourth outer wall surface portion 264d extend parallel to the axial direction and substantially on the same line, and the second outer wall surface portion 264b extends perpendicular to the axial direction from the lower end of the first outer wall surface portion 264a toward one circumferential side. Furthermore, the third outer wall surface portion 264c extends at an angle relative to the other axial side and the other circumferential side above the fourth outer wall surface portion 264d, and the fifth outer wall surface portion 264e extends at an angle relative to the one axial side and the one circumferential side below the fourth outer wall surface portion 264d.

[0079] The protrusion 270 is provided in an area closer to the end face 211 (one axial side) than the through hole 240 and closer to the side face 214 (the other circumferential side). The protrusion 270 has an outer wall surface 271 formed on the radially outer peripheral side and extending along the circumferential and axial directions, an outer wall surface 272 formed on the other axial side and extending along the circumferential direction, an outer wall surface 273 formed on one circumferential side (the side facing the protrusion 260) and extending along the axial direction, and an outer wall surface 274 (274a, 274b) formed on the other circumferential side (the side opposite the protrusion 260) and extending along the axial direction. The outer wall surface of the protrusion 270 on one axial side is formed flush with the end face 211 of the first flange 210, and the outer wall surface on the other axial side is formed flush with the outer wall surface 272.

[0080] The outer wall surface 274 has, from one axial side to the other axial side, a first outer wall surface portion 274a and a second outer wall surface portion 274b. The first outer wall surface portion 274a extends parallel to the axial direction, and the second outer wall surface portion 274b extends obliquely below the first outer wall surface portion 274a toward the other circumferential side and one axial side, and its lower end is connected to the outer wall surface 272.

[0081] Furthermore, a locking protrusion 277 that protrudes toward the other circumferential side is provided on the first outer wall surface portion 274a of the protrusion 270. The locking protrusion 277 has a protrusion 278 that protrudes toward the other axial side at its end on the other circumferential side. The locking protrusion 277 fixes the end of the stator winding 610. Furthermore, a working space is secured when fixing the end of the stator winding 610 by the space 265 above the second outer wall surface portion 264b of the outer wall surface 264 and the space 275 above the second outer wall surface portion 264b of the outer wall surface 274.

[0082] The first flange 210 is provided with a recess 280 and a recess 290 recessed radially inward from the outer circumferential surface 210A. The recess 280 is provided on the side surface 213 (one circumferential side) of the through-hole 240, and is open on one circumferential side (side surface 213 side) and the radially outer circumferential side. The recess 280 is formed by a bottom surface 281a, an outer wall surface 262 provided on one axial side of the bottom surface 281a, and a side surface 281b provided on the other circumferential side of the bottom surface 281a. The bottom surface 281a of the recess 280 extends as a flat surface in the axial and circumferential directions. The recess 280 regulates the circumferential and axial positions of the other circumferential side of the insulating film 310.

[0083] The recess 290 is provided on the side surface 214 side (the other circumferential side) of the through-hole 240, and is open on the other circumferential side (side surface 214 side) and the radially outer peripheral side. The recess 290 is formed by a bottom surface 291a, an outer wall surface 272 provided on one axial side of the bottom surface 291a, and a side surface 291b provided on one circumferential side of the bottom surface 291a. The bottom surface 291a of the recess 290 extends as a flat surface in the axial and circumferential directions. The recess 290 regulates the circumferential and axial positions of the portion of the insulating film 310 on one circumferential side.

[0084] 13 and 14, the second flange 400 includes a lower surface 400B1 and side surface portions 400B2 and 400B3 that constitute the inner peripheral surface 400B, and a protruding portion 405 is provided on one axial side between the side surface portions 400B2 and 400B3, protruding radially inward from the inner peripheral surface 400B (to the right in FIG. 14). A stepped surface 406 is formed on the lower surface of the protruding portion 405. The protruding portion 405 has an end surface 405A located on the radially inner peripheral side (the front side of the paper in FIG. 13), and arc portions 405B and 405C are provided on both sides of the upper portion of the end surface 405A.

[0085] In addition, a protruding piece 407A is provided on the upper part of the protruding portion 405, protruding radially inward, and a protruding portion 407C is provided on the upper surface (end surface 401) of the protruding piece 407A, protruding to one side in the axial direction, and a protruding portion 407B is provided on the protruding portion 407C, protruding radially inward (toward the front of the paper in Figure 13).

[0086] Fig. 15 is a cross-sectional view of second insulator 200B. As shown in Fig. 15, second insulator 200B has second flange 400 made up of outer peripheral surface 400A and inner peripheral surface 400B extending from body 230 to both circumferential sides (left and right sides in Fig. 15). Second flange 400 has a structure that is reversed left and right on both circumferential sides (left and right sides in Fig. 15).

[0087] Fig. 16 is an enlarged cross-sectional view of a main portion of the second insulator 220B, showing an enlarged portion of the second flange 400. As shown in Fig. 16, the second flange 400 includes a third curved portion 400B21 continuing from the opening of the through-hole 240 located on the radially inner circumferential side (the lower side in Fig. 16), a side surface portion 400B2 continuing from the third curved portion 400B21 and inclining toward one circumferential side (the left side in Fig. 16) and the radially inner circumferential side (the lower side in Fig. 16), a fourth curved portion 400B22 curving from the side surface portion 400B2 to the radially outer circumferential side (the upper side in Fig. 16) and toward one circumferential side (the left side in Fig. 16), and the fourth curved portion 400B22 curving toward the radially outer circumferential side (the upper side in Fig. 16) and the radially inner circumferential side (the left side in Fig. 16). 16), a first step 400B24 provided from the side surface rear portion 400B23 toward the axially outer periphery (upper side in FIG. 16), a second step 400B25 provided from the first step 400B24 toward the axially outer periphery (upper side in FIG. 16), and a rising portion 400B26 extending from the second step 400B25 toward one circumferential side (right side in FIG. 16). Note that the structure around the side surface portion 400B21 located on one circumferential side (right side in FIG. 16) shown in FIG. 15 is a left-right inversion of the structure shown in FIG. 16, and therefore description thereof will be omitted.

[0088] 17, when attaching the second insulator 200B to the teeth 121 (tooth bases 122) of the first core member 120, the ends of the tooth bases 122 of the teeth 121 are inserted into the through holes 240 of the second insulator 200B from the second flange 400 side. At this time, the ends of the tooth bases 122 are guided into the through holes 240 by the radially inner inclined surfaces 241a to 244a of the inner wall surfaces 241 to 244 that form the through holes 240. The tooth bases 122 are inserted so that the ends of the tooth bases 122 protrude from the outer peripheral surface 210A of the first flange 210.

[0089] 10 and 17, the first insulators 200A and the second insulators 200B are attached to the teeth 121 (tooth bases 122) of the first core member 120 by first attaching the second insulators 200B to the teeth 121 of the first core member 120, and then attaching the first insulators 200A, as shown in Fig. 18. Fig. 19 shows the state in which the first insulators 200A and the second insulators 200B are attached to the first core member 120.

[0090] 20 is a perspective view showing the state in which first insulator 200A and second insulator 200B are attached in this order to teeth 121 of first core member 120. By attaching second insulator 200B to teeth 121 of first core 120 first, side surface portion 220B2 of first insulator 200A overlaps side surface portion 400B3 of second insulator 200B from behind. More specifically, by abutting the upper end surface 450 constituting the side portion 400B3 of the second insulator 200B against the lower surface 221B1 (see Figure 6) of the ear portion 221B of the first insulator 200A and abutting the upper end surface 451 constituting the side portion 400B3 of the second insulator 200B against the vertical surface 221A1 (see Figure 6) of the protrusion portion 221 of the first insulator 200A, the first insulator 200A overlaps its side portion 220B2 with the side portion 400B3 of the second insulator 200B, as shown in Figure 21.

[0091] The first insulator 200A and the second insulator 200B are attached to adjacent teeth 121 in the same manner along the circumferential direction shown in Fig. 19. That is, the side surface portion 220B3 of the first insulator 200A shown in Fig. 21 is overlapped from behind with the side surface portion 400B2 of the second insulator 200B (not shown) adjacent to the right side of Fig. 21. In this case, too, the side portion 400B2 of the second insulator 200B (not shown) adjacent to the right side of Figure 21 abuts its upper end surface 452 against the lower surface 221C1 (see Figure 6) of the ear portion 221C that constitutes the protrusion 221 of the first insulator 200A, and abuts the side surface 453 that constitutes the side portion 400B2 of the second insulator 200B against the vertical surface 221A2 (see Figure 6) of the protrusion 221 of the first insulator 200A, thereby overlapping the side portion 220B3 of the first insulator 200A with the side portion 400B2 of the second insulator 200B.

[0092] Fig. 22 is an enlarged cross-sectional view of a main portion showing the state in which side surface portions 220B2 and 220B3 of first insulator 200A and side surface portions 400B2 and 400B3 of second insulator 200B are overlapped as in Fig. 21. As shown in Fig. 22, side surface portion 400B2 of second flange portion 400 constituting second insulator 200B that is first attached to teeth 121 of first core member 120 abuts connecting portion 125 of first core member 120. First insulator 200A that is later attached to teeth 121 of first core member 120 abuts side surface portion 220B3 of second flange portion 220 against side surface rear portion 400B23 of second flange portion 400 of second insulator 200B. In this state, first curved portion 220B31 of second flange 220 of first insulator 200A is interposed between tooth tip 123 and connecting portion 125 and fourth curved portion 400B22 of second flange 400 of second insulator 200B. In addition, first tip surface 220B32 of second flange 220 of first insulator 200A abuts against first step 400B24 of second flange 400 of second insulator 220B. By arranging the second flange portion 220 of the first insulator 200A and the second flange portion 400 of the second insulator 200B in this manner, a predetermined space is formed between the first step 400B24 of the second flange portion 220 of the first insulator 200A and the second tip surface 220B33 and the second curved portion 220B34 of the second flange portion 400 of the second insulator 200B, and the insulating film 310 is arranged using this space and the gap between the stator winding 610 wound around the body portion 230 of the first insulator 200A and the body portion 230 of the second insulator 200B. That is, the folded central portion 310A of the insulating film 310 is disposed in the space between the first step 400B24 of the second flange 220 of the first insulator 200A and the second tip surface 220B33 and the second curved portion 220B34 of the second flange 400 of the second insulator 200B. This ensures that the insulating film 310 provides reliable insulation between the stator winding 610 wound around the first insulator 200A and the stator winding 610 wound around the second insulator 200B.Furthermore, by overlapping the second flange portion 220 of the first insulator 200A and the second flange portion 400 of the second insulator 200B as shown in Figure 22, a wall is formed between the connecting portion 125 of the teeth 121 and the stator winding 610 by the second flange portion 220 of the first insulator 200A and the second flange portion 400 of the second insulator 200B, thereby ensuring insulation between the connecting portion 125 of the teeth 121 and the stator winding 610.

[0093] 23 is a perspective view showing the first flange 200 side (radially outer peripheral side) when the first insulator 200A and the second insulator 200B are attached as shown in FIG. 21. In the state shown in FIG. 23, the recess 280 of the first flange 200A and the recess 290 of the second insulator 200B are bent radially inward by a predetermined angle and disposed adjacent to each other. In this state, a locking protrusion 277 protruding from the outer wall surface 274a of the protrusion 270 of the first flange 210 of the second insulator 200B toward the other circumferential side is disposed in a space 265 on one circumferential side (right side in FIG. 5) of the first outer wall surface portion 264a of the protrusion 260 of the first flange 210 of the first insulator 200A and on one axial side (upper side in FIG. 5) of the second outer wall surface portion 264b. This allows the first flange portion 210 of the first insulator 200A and the first flange portion 210 of the second insulator 200B to be arranged adjacently in the circumferential direction. Note that the first insulator 200A (not shown) is arranged on one circumferential side (right side in FIG. 23) of the second insulator 200B shown in FIG. 23. In this way, the first insulator 200A and the second insulator 200B are arranged alternately, so that both insulators 200A, 200B are arranged in an annular shape as shown in FIG. 19. In other words, the second insulator 200B (not shown) is arranged on the other circumferential side (left side in FIG. 23) of the first insulator 200A shown in FIG. 23. 23) of the first outer wall surface portion 264a of the protrusion 260 of the first flange portion 210 of the second insulator 200B, and on one axial side (upper side in FIG. 12) of the second outer wall surface portion 264b, a locking protrusion 277 is disposed in the space 265, protruding from the outer wall surface 274a of the protrusion 270 of the first insulator 200A (not shown) on one radial side (right side in FIG. 23) of the second insulator 200B. The locking protrusion 277 protruding from the first outer wall surface portion 274a of the protrusion 270 of the first flange portion 210 of the insulator 200A to the other circumferential side (left side in Figure 5) is on one circumferential side (right side in Figure 12) of the first outer wall surface portion 264a of the protrusion 260 of the second insulator 200B (not shown) which is arranged on the other circumferential side (left side in Figure 23) of the first insulator 200A shown in Figure 23, and is arranged in the space 265 on one axial side (upper side in Figure 12) of the second outer wall surface portion 264b.

[0094] 10 and 17, the stator winding 610 is wound around the insulators 200A and 200B after the first insulator 200A and the second insulator 200B are attached to the teeth 121 of the first core member 120. The stator winding 610 is wound in a space formed by the first flange portion 210, the second flange portions 220 and 400, and the body portion 230 of the insulators 200A and 200B. Regarding the attachment of the insulators 200A and 200B and the winding of the stator winding 610, it is also possible to use a method in which the insulators 200A and 200B are attached to the teeth 121 of the first core member 120 after the stator winding 610 is wound around the insulators 200A and 200B.

[0095] 2 are assembled together with the insulators 200A, 200B attached to the teeth 121 and the stator windings 610 wound around the insulators 200A, 200B. In this embodiment, the teeth 121 are inserted into the through holes 240 of the insulators 200A, 200B, and the ends of the tooth bases 122 protruding from the outer peripheral surface 210A of the first flange 210 are press-fitted into the recesses 134 formed in the yoke 131 of the second core member 130, thereby assembling the first core member 120 and the second core member 130 together.

[0096] In this embodiment, when the ends of tooth bases 122 inserted into through holes 240 of insulators 200A and 200B are pressed into recesses 134 of second core member 130 while being moved axially, the ends of tooth bases 122 are guided into recesses 134 by outer wall surfaces 251 of protrusions 250 formed on the end face 212 side of first flange 210 (the other axial side) from through holes 240. This makes it possible to prevent strong contact between first core member 120 or insulators 200A and 200B and second core member 130, and to prevent deformation of first core member 120 or second core member 130 or cracks from occurring in insulators 200A and 200B.

[0097] Furthermore, as a method for press-fitting the ends of the tooth bases 122 into the recesses 134 of the second core member 130, a press-fitting jig can be used to apply a force to the wall surface 122a on one axial side of the tooth bases 122 protruding from the outer peripheral surface 210A of the first flange 210, moving the ends of the tooth bases 122 in a direction to insert them into the recesses 134. If the force applied by the press-fitting jig causes the ends of the tooth bases 122 to expand circumferentially and radially, the press-fitting operation becomes difficult. For this reason, it is necessary to use a press-fitting jig of an appropriate size to apply the force to appropriate locations on the ends of the tooth bases 122. In this embodiment, a movement path for the press-fitting jig is formed on the first flange 210, on the end face 211 side from the through hole 240, by the outer wall surface portion 263 of the protrusion 260 and the outer wall surface portion 273 of the protrusion 270. This allows the ends of tooth bases 122 to be press-fitted into recesses 134 of second core member 130 while preventing deformation of the ends of tooth bases 122.

[0098] FIG. 24 shows a case where insulating film 310 is attached to stator 100. FIG. 24 is a perspective view showing the anti-lead side of stator 100 (the side on which lead wires (not shown) connected to stator windings 610 are not arranged). Insulating film 310 has a shape in which, for example, the center portion in the width direction (left-right direction in FIG. 23) is folded to form folded center portion 310A extending in the axial direction (up-down direction in FIG. 23), and both end portions are folded in the width direction (left-right direction in FIG. 23) to form folded end portions 310B, but is not limited to this shape. When insulating film 310 is attached to stator 100, insulating film 310 is inserted into stator 100 from the anti-lead side of stator 100. Specifically, the insulating film 310 is inserted between the first insulator 200A and the second insulator 200B so that the folded central portion 310A of the insulating film 310 is positioned in the space between the first step 400B24 of the second flange 220 of the first insulator 200A and the second tip surface 220B33 and the second curved portion 220B34 of the second flange 400 of the second insulator 200B shown in Fig. 22, thereby disposing the insulating film 310 between the stator windings 610 between the phases. At this time, the folded end 310B of the insulating film 310 is disposed between the bottom surface 281a of the recess 280 of the first insulator 200A and the bottom surface 291a of the recess 290 of the second insulator 200B shown in Fig. 23 and the yoke inner peripheral surface portions 133a and 133b (see Fig. 3) of the stator core 110 shown in Fig. 24.

[0099] The present invention is not limited to the configurations described in the above embodiments, and various modifications, additions, and deletions are possible. For example, while the above embodiments describe a stator, the present invention can also be configured as "an electric motor including a stator and a rotor rotatably supported relative to the stator." Furthermore, the shape of the winding insulating member is not limited to the shape shown in FIG. 24, and it goes without saying that the scope of the present invention also applies to resin bobbin configurations in which the shapes of each component are modified in various ways, as long as the effects of the present invention can be achieved. [Explanation of symbols]

[0100] 100 stator 110 Stator Core 110A, 110B Core end face 120 First core member 121 Teeth 122 Teeth base 123 Teeth tip 124 Teeth tip surface 125 Connection section 126,136 Crimping protrusions 130 Second core member 131 York 132 Yoke outer surface 133 Inner surface of yoke 133a, 133b Yoke inner surface portion 134a Recessed surface 200 (200A, 200B) Insulator (first insulator, second insulator) 210 First flange 210A,220A,400A outer surface 210B,220B,400B Inner surface 211,212,222,227,221A,401,402,405A End face 213,214,223,224,281b,291b,403,404,453,454 Side 220,400 Second flange 220B1,221B1,221C1,400B1 Bottom surface 220B2,220B3,400B2,400B3 Side part 220B31 1st curve section 220B32 1st tip surface 220B33 2nd tip surface 220B34 2nd curve section 220B35,400B26 Standing part 221,405 Overhang 221A1,221A2 Vertical surface 221B,221C Ears 225,406 Step surface 226A,407A Overhang piece 226B,250,260,270,278,407B Projection 226C,407C protrusion 230 Torso 240 through hole 241~244 Inner wall 241a~244a Slope 122a~122d,251,252,261~264,271~274 External wall surface 264a,274a 1st outer wall part 264b,274b 2nd outer wall part 264c 3rd outer wall section 264d 4th outer wall section 264e 5th outer wall section 265,275 space 277 Locking protrusion 280,290 recess 281a, 291a bottom 310 Insulating film 310A Bend center part 310B bent end 400B21 3rd curve section 400B22 4th curve section 400B23 Side back part 400B24 1st step 400B25 2nd step 405B, 405C Arc section 451,452 Top surface 610 Stator Winding P rotation center line

Claims

1. A stator includes a yoke extending in a circumferential direction, a plurality of tooth bases extending radially inward from the yoke in a radial direction, tooth tips provided on the radially inner peripheral side of the tooth bases and extending in the circumferential direction, and a connecting portion connecting the tooth tip tips. The stator includes an insulator attached to the tooth bases, the insulator comprising a first insulator and a second insulator, the first insulator and the second insulator each having a first flange portion and a second flange portion and a body portion connecting the first flange portion and the second flange portion, the tooth bases are inserted into through holes in the body portion, and the body portion a stator winding wound around an outer periphery of the first insulator and a second insulator, the first flange of which has substantially the same structure, and the second flange of the first insulator and the second flange of the second insulator have overlapping portions that close the gap between the second flanges, and the second flange of the second insulator has a side portion that extends from a through hole formed in the inner peripheral surface of the body portion in the circumferential direction of the stator and abuts on a connecting portion that connects the teeth of the stator, a fourth curved portion that continues from the side portion and constitutes a tip end of the overlapping portion, and a fourth curved portion that continues from the fourth curved portion and extends in the opposite direction to the extending direction of the side portion. a first step formed at an end of the side surface back portion, a second step continuing from the first step, and a rising portion extending from the second step toward the outer circumferential surface of the trunk portion; and a second flange portion of the first insulator extends in the circumferential direction of the stator from a through hole formed in the inner circumferential surface of the trunk portion, and includes a first curved portion that abuts on the connecting portion and the fourth curved portion of the stator, a side portion that is continuous from the first curved portion and abuts on the side surface back portion of the second insulator, and a first tip surface and a second tip surface that are continuous from the side surface portion and form tip portions of the overlapping portion; and a second curved portion continuing from the second tip end surface and a rising portion extending from the second curved portion toward the outer peripheral surface of the trunk portion, wherein the overlapping portion is not connected to a folded central portion of a winding insulating member which is formed by folding a central portion in the width direction and extending in the axial direction, and which is formed by folding both end portions in the width direction and extending in the axial direction, and the folded central portion is disposed in a first step and a second step of the second insulator and in a space between the second tip end surface and the second curved portion of the first insulator, thereby ensuring insulation between the connecting portion and the stator winding.

2. 2. The insulator according to claim 1, wherein a bent end portion of the winding insulating member is disposed radially outside a first flange portion of the first insulator and a first flange portion of the second insulator, and the insulator is provided with a recess that restricts movement of the bent end portion toward one circumferential side and one axial side.

3. A stator comprising a stator core, an insulator, a stator winding, and a winding insulating member, characterized in that the insulator is an insulator described in any one of claims 1 or 2.

4. A stator comprising an insulator as described in any one of claims 1 to 3, characterized in that it is composed of a first core member consisting of the tooth base, the tooth tip and the connecting portion, and a second core member consisting of the yoke having a recess that fits into the radially outer end of the tooth base.

5. An electric motor characterized by comprising a stator described in any one of claims 1 to 4 and a rotor that can rotate relative to the stator.

Images