Stator and method for manufacturing the same

Abstract

To provide a technique for easily maintaining a connection state between a coil and a conductor part without providing a weld part and a soldering part.SOLUTION: A stator 1 includes a stator core 10, a coil 20, a conductor part 60, and an insulation resin 40. The stator core 10 has an annular shape. The coil 20 has a projection part 29 projecting to a side closer to one side in an axial direction than the end on the one side in the axial direction of the stator core 10. In the conductor part 60, the insulation resin 40 connected to the projection part 29 forms a press-fitting groove 50 between the projection part 29 and the insulation resin 40. The conductor part 60 is press-fit into the press-fitting groove 50, and is arranged in a state of being pushed against the projection part 29.SELECTED DRAWING: Figure 7

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a stator portion of a molded motor. This stator portion includes a winding. Terminal pins are soldered to the ends of the windings. The terminal pins are connected to the actual device (for example, a component that drives the motor) through a connector. In Patent Document 1, the terminal pins are soldered, but welding is also commonly used instead of soldering. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-215025 Summary of the Invention [Problem to be solved by the invention]

[0004] There is a demand for a technique that makes it easy to maintain the connection between the coil and the conductor (terminal pin) without providing the above-mentioned welded or soldered portions.

[0005] An object of the present disclosure is to provide a technique that makes it easy to maintain the connection between a coil and a conductor without providing a welded or soldered portion. [Means for solving the problem]

[0006] The stator of the present disclosure comprises: an annular stator core; a coil having a protruding portion that protrudes toward one axial direction beyond an end portion of the stator core on one axial direction side; a conductor portion connected to the protrusion; an insulating resin that forms a press-fit groove between the insulating resin and the protruding portion, The conductor portion is press-fitted into the press-fit groove and is arranged in a state where it is pressed against the protrusion portion.

[0007] The method for manufacturing a stator according to the present disclosure includes: a preparation step of preparing a stator body including: an annular stator core; a coil having a protruding portion that protrudes further toward one axial end of the stator core in the axial direction than the other axial end; a conductor portion connected to the protruding portion; and insulating resin that forms a press-fit groove between the conductor portion and the protruding portion; and a press-fitting step of press-fitting the conductor portion into the press-fit groove in the stator body to press the conductor portion against the protrusion. [Effects of the Invention]

[0008] The technology according to the present disclosure makes it easy to maintain the connection between the coil and the conductor without providing a welded or soldered portion. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of a stator according to a first embodiment. [Figure 2] FIG. 2 is a plan view of the stator of the first embodiment. [Figure 3] FIG. 3 is a perspective view of the stator core with the coils attached thereto. [Figure 4] FIG. 4 is a perspective view of the stator body. [Figure 5] FIG. 5 is a perspective view of the stator body cut in the axial direction. [Figure 6] FIG. 6 is an explanatory diagram showing a state before the unit parts are attached to the stator body. [Figure 7] FIG. 7 is an explanatory diagram illustrating a state in which the conductor portion is press-fitted into the press-fit groove in a cross section taken along line AA in FIG. [Figure 8] FIG. 8 is an explanatory view illustrating how the conductor portion of the second embodiment is press-fitted into the press-fit groove. [Figure 9] FIG. 9 is a plan view of the press-fit groove and its periphery in the second embodiment. [Figure 10]FIG. 10 is an explanatory view illustrating how the conductor portion of the third embodiment is press-fitted into the press-fit groove. [Figure 11] FIG. 11 is a plan view of the press-fit groove and its periphery in the third embodiment. [Figure 12] FIG. 12 is an explanatory view illustrating how the conductor portion of the fourth embodiment is press-fitted into the press-fit groove. [Figure 13] FIG. 13 is a plan view of the press-fit groove and its periphery in the fourth embodiment. [Figure 14] FIG. 14 is a plan view of the stator body of the fifth embodiment. [Figure 15] FIG. 15 is a plan view of the stator of the fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

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

[0011] [1] An annular stator core; a coil having a protruding portion that protrudes toward one axial direction beyond an end portion of the stator core on one axial direction side; a conductor portion connected to the protrusion; an insulating resin that forms a press-fit groove between the insulating resin and the protruding portion, The conductor portion is press-fitted into the press-fit groove and is disposed in a state where it is pressed against the protrusion portion. Stator.

[0012] The stator is arranged with the conductor portion press-fitted into the press-fit groove and pressed against the protrusion, so that the connection between the coil and the conductor portion can be easily maintained without providing welding or soldering portions.

[0013] [2] The protrusion is provided in plurality, The plurality of protrusions are arranged side by side in the circumferential direction of the stator core, the insulating resin forms a plurality of press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of protruding portions arranged in the circumferential direction, The conductor portion is provided in plurality, Further, a holding portion for holding the plurality of conductor portions is provided, The conductor portions held by the holding portion are press-fitted into the press-fit grooves and are disposed in a state of being pressed against the protrusions. The stator described in [1].

[0014] In the stator, the plurality of conductors connected to the separate protrusions are held by the holding portion, and therefore the relative positional relationship between the plurality of conductors can be easily maintained.

[0015] [3] The press-fit grooves arranged in the circumferential direction extend radially along the radial direction of the stator core, Each of the press-fit grooves has an opening that opens toward one side in the axial direction, Each of the conductor portions is removable from the press-fit groove through the opening. The stator according to [2].

[0016] In a configuration in which multiple press-fit grooves extend radially, if the conductor portions press-fitted into each press-fit groove are to be removed all at once from the radially outward direction, each conductor portion will interfere with the inner wall of the press-fit groove. However, in the above-mentioned stator, the conductor portions can be removed from one axial side through the openings, so the conductor portions are less likely to interfere with the inner wall of the press-fit groove. As a result, the multiple conductor portions integrated via the holding portions can be easily removed all at once.

[0017] [4] Each of the press-fit grooves has an outer peripheral opening that opens radially outward of the stator core, the retaining portion is disposed at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction, Each of the conductor portions held by the holding portion protrudes from the radially inner surface of the holding portion and is disposed in the press-fit groove through the outer peripheral opening. The stator according to [2] or [3].

[0018] In the above stator, the holding portion that holds the multiple conductor portions is positioned radially outward of the multiple press-fit grooves that are aligned in the circumferential direction, making it easy to reduce the axial size of the stator.

[0019] [5] A stator used in a motor, a terminal portion electrically connected to a drive portion that drives the motor; The terminal portion protrudes from the radially outer surface of the holding portion. The stator according to any one of [2] to [4].

[0020] In the above-described stator, the terminal portions protrude from the radially outer surface of the holding portion, and therefore the axial size of the stator can be easily reduced.

[0021] [6] Each of the press-fit grooves has an outer peripheral opening that opens radially outward of the stator core, the retaining portion is disposed at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction, Each of the conductor portions press-fitted into each of the press-fit grooves is connected to the radially inner surface of the holding portion via the outer peripheral opening, The opening and the outer peripheral opening are open continuously. The stator according to any one of [3] to [5].

[0022] In the above stator, the retaining portion that holds the multiple conductor portions is positioned radially outward of the multiple circumferentially arranged press-fit grooves, which facilitates reducing the axial size of the stator. In other words, the above stator allows the multiple conductor portions integrated via the retaining portion to be removed collectively from one axial side, while also facilitating reducing the axial size of the stator.

[0023] [7] The holding portion has a shape extending in an arc shape along the circumferential direction, Each of the conductor portions is disposed on the circumferential center side of the holding portion with respect to the protrusion portion to be connected. The stator according to any one of [2] to [6].

[0024] In the above-mentioned stator, even if the holding portion thermally expands and deforms so that the curvature becomes smaller, each conductor portion tends to displace toward the protrusion portion to which it is connected, so the connection state between the conductor portion and the protrusion portion is likely to be maintained.

[0025] [8] The protrusion is provided in plurality, The plurality of protrusions are arranged side by side in the circumferential direction of the stator core, the insulating resin forms a plurality of press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of protruding portions arranged in the circumferential direction, The conductor portion is provided in plurality, Each of the conductor portions is press-fitted into each of the press-fit grooves and is disposed in a state of being pressed against each of the protrusions, the entire axial length of each of the conductor portions is fitted into each of the press-fit grooves, The side of the protrusion opposite to the press-fit groove is covered with the insulating resin. The stator according to any one of [1] to [7].

[0026] In the above-mentioned stator, the entire axial direction of the conductor portion fits into the press-fit groove, and the side of the protrusion opposite the press-fit groove is covered with insulating resin, making it easy to insulate between the protrusion and the protrusion adjacent to it in the circumferential direction and the conductor portion connected to the adjacent protrusion.

[0027] [9] The stator core has a plurality of slots arranged in the circumferential direction of the stator core, the coil has an insert disposed within the slot; the insulating resin has a filling portion that is continuously filled between the inner wall of the slot and the insertion portion, and a forming portion that forms the press-fit groove, The filling portion and the forming portion are integrally formed. A stator according to any one of [1] to [8].

[0028] In the stator, heat generated in the insertion portion and the conductor portion of the coil is easily transferred to the stator core via the insulating resin, so that heat from the coil is easily released.

[0029]

[10] The coil includes two or more of the protrusions arranged side by side in the radial direction of the stator core, one press-fitting groove is formed between the two or more protrusions and the insulating resin, One of the conductor portions is press-fitted into one of the press-fit grooves and is disposed in a state of being pressed against the two or more protrusions that form the press-fit groove. A stator according to any one of [1] to [9].

[0030] In the stator, one conductor portion can be connected to two or more protrusions arranged in a radial direction.

[0031]

[11] A preparation process for preparing a stator body including an annular stator core, a coil having a protruding portion that protrudes toward one axial direction beyond one axial end of the stator core, a conductor portion connected to the protruding portion, and an insulating resin that forms a press-fit groove between the conductor portion and the protruding portion; a press-fitting step of press-fitting the conductor portion into the press-fit groove in the stator body and pressing the conductor portion against the protrusion. A method for manufacturing a stator.

[0032] According to the above-described method for manufacturing a stator, the conductor portion is pressed into the press-fit groove, thereby pressing the conductor portion against the protrusion, making it easy to maintain the connection between the conductor portion and the protrusion without providing a welding or soldering portion.

[0033]

[12] The preparing step includes preparing a unit component having a configuration in which a plurality of the conductor portions are held by a holding portion; The protrusions are provided in plurality, The plurality of protrusions are arranged side by side in the circumferential direction of the stator core, the insulating resin forms a plurality of press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of protruding portions arranged in the circumferential direction, Each of the press-fit grooves has an opening that opens toward one side in the axial direction, The press-fitting step presses the conductor portions into the press-fit grooves through the openings by displacing the unit component toward the other side in the axial direction. A method for manufacturing a stator according to

[11] .

[0034] According to the above-described method for manufacturing a stator, a plurality of conductor portions can be press-fitted into the respective press-fit grooves at once and pressed against the protrusions that form the respective press-fit grooves.

[0035]

[13] The stator core has a plurality of slots arranged in the circumferential direction of the stator core, the coil has an insert disposed within the slot; The method further includes a filling step of filling a space between the inner wall of the slot and the insertion portion with a resin material, The filling step forms the press-fit groove while filling the resin material between the inner wall of the slot and the insertion portion. A method for manufacturing a stator according to

[11] or

[12] .

[0036] According to the above-described method for manufacturing a stator, when filling the space between the inner wall of the slot and the insertion portion with resin material, the press-fit groove can also be formed, which makes it easy to simplify the manufacturing process.

[0037] First Embodiment 1. Stator 1 configuration The stator 1 of the first embodiment is used as a component of a motor. The stator 1 has an annular shape, more specifically, a circular ring shape. As shown in Figures 1 and 6, the stator 1 has a configuration in which a unit component 3 is connected to a stator main body 2.

[0038] As shown in FIG. 5, the stator body 2 includes a stator core 10, a coil 20, and an insulating resin 40.

[0039] Stator core 10 has an annular shape, more specifically, a circular ring shape, as shown in Fig. 3. Hereinafter, the radial direction of stator core 10 will be referred to as the radial direction, the axial direction of stator core 10 will be referred to as the axial direction, and the circumferential direction of stator core 10 will be referred to as the circumferential direction.

[0040] The stator core 10 may be, for example, a laminated steel plate manufactured by stacking multiple electromagnetic steel plates (e.g., silicon steel plates) in the axial direction (thickness direction), or may be a dust core formed by press-molding insulatingly coated magnetic particles.

[0041] As shown in FIG. 3 , the stator core 10 has a yoke portion 11 and a plurality of teeth 12. The yoke portion 11 is annular, more specifically, circular. The plurality of teeth 12 are arranged in a ring shape along the inner circumferential surface of the yoke portion 11. The teeth 12 are spaced apart from one another in the circumferential direction. Each tooth 12 protrudes radially inward from the inner circumferential portion of the yoke portion 11. Each tooth 12 is wall-shaped along the radial and axial directions. The radially inner end of each tooth 12 protrudes on both circumferential sides.

[0042] As shown in FIG. 3, the stator core 10 has a plurality of slots 15. The plurality of slots 15 are arranged side by side in the circumferential direction to form a ring. The slots 15 penetrate the stator core 10 in the axial direction. As shown in FIG. 3, each slot 15 is formed by being partitioned between a yoke portion 11 and two adjacent tooth portions 12. The slots 15 open to both axially opposite surfaces of the stator core 10 and to a radially inner surface of the stator core 10.

[0043] As shown in FIG. 3, the coil 20 is mounted on the stator core 10. The coil 20 is wound around the stator core 10 (more specifically, the tooth portion 12). The coil 20 may be a distributed winding or a concentrated winding. If the coil 20 is a distributed winding, it may be a wave winding, a concentric winding, or a lap winding. In this embodiment, the coil 20 will be described as a wave winding. The coil 20 passes through the slots 15 and is wound around the tooth portion 12. The coil 20 may be a coated electric wire in which the outer periphery of the core wire is covered with a coating, or may be an uncoated electric wire. In this embodiment, the coil 20 is a rectangular wire. Note that the coil 20 does not have to be a rectangular wire and may be, for example, a round wire.

[0044] As shown in FIG. 5, the coil 20 has an insertion portion 21, a first coil end 22, and a second coil end 23.

[0045] As shown in FIG. 5 , the insertion portion 21 is disposed in the slot 15. The insertion portion 21 has a longitudinal shape that is long in the axial direction. A plurality of insertion portions 21 (four in this embodiment) are provided in the slot 15. The insertion portions 21 are disposed side by side in the radial direction in the slot 15. The insertion portions 21 are disposed in each slot 15.

[0046] 3 and 5, the one-side coil end 22 is positioned on one axial side of the one axial end of the stator core 10. The one-side coil end 22 is continuous with the one axial end of the insertion portion 21. As shown in FIGS. 3 and 7, the one-side coil end 22 includes a first coil end 24 that is not connected to the conductor portion 60 (see FIG. 6), and a second coil end 25 that is connected to the conductor portion 60.

[0047] As shown in FIG. 3, the first coil end 24 has a first lead portion 26 and an extending portion 27. The first lead portion 26 is continuous with one axial end of the insertion portion 21. The first lead portion 26 is inclined in the circumferential direction. The extending portion 27 extends from one axial end of the first lead portion 26 (the end of the first lead portion 26 opposite the insertion portion 21) toward one axial side. The extending portion 27 extends along the axial direction. The extending portion 27 is connected to another extending portion 27. The connection method is not particularly limited, and may be welding or soldering.

[0048] As shown in FIG. 3 , the second coil end 25 has a second lead portion 28 and a protruding portion 29. The second lead portion 28 is continuous with the end portion on one axial side of the insertion portion 21. The second lead portion 28 is inclined toward one circumferential direction. The protruding portion 29 protrudes toward one axial side from the end portion on one axial side of the second lead portion 28 (the end portion of the second lead portion 28 opposite the insertion portion 21 side). The protruding portion 29 protrudes along the axial direction. The protruding portion 29 is longer than the extending portion 27. The tip end (end portion on one axial side) of the protruding portion 29 is located on one axial side of the tip end (end portion on one axial side) of the extending portion 27. The tip end (end portion on one axial side) of the protruding portion 29 is located on one axial side of the tip end (end portion on one axial side) of the first coil end 24. A plurality of protruding portions 29 are provided. The plurality of protruding portions 29 are arranged side by side in the circumferential direction.

[0049] 3 and 5, the other coil end 23 is disposed on the other axial side of the other axial end of the stator core 10. The other coil end 23 is continuous with the other axial end of the insertion portion 21.

[0050] As shown in Figures 2 and 4, the insulating resin 40 forms a press-fit groove 50 between itself and the protrusion 29. The press-fit groove 50 extends radially. The press-fit groove 50 has a width in a direction perpendicular to the direction in which the press-fit groove 50 extends and perpendicular to the axial direction. The press-fit groove 50 has an opening 51 that opens toward one axial side. The opening 51 opens on a surface of the stator body 2 on one axial side. The press-fit groove 50 has an outer peripheral opening 52 that opens radially outward. The outer peripheral opening 52 opens on a radially outer surface of the stator body 2. The opening 51 and the outer peripheral opening 52 open continuously. The insulating resin 40 forms a plurality of press-fit grooves 50 that are aligned in the circumferential direction between itself and a plurality of protrusions 29 that are aligned in the circumferential direction.

[0051] As shown in Fig. 5, insulating resin 40 has a filling portion 41 and a forming portion 42. Filling portion 41 is continuously filled between the inner wall of slot 15 and insertion portion 21. Forming portion 42, together with protrusion 29, forms press-fit groove 50. Filling portion 41 and forming portion 42 are integrally formed. With this configuration, heat generated in insertion portion 21 and conductor portion 60 of coil 20 is easily transferred to stator core 10 via insulating resin 40, making it easy for stator 1 to dissipate heat from coil 20.

[0052] As shown in FIG. 4, insulating resin 40 includes one-side resin 43 provided on one axial side of stator core 10 and another-side resin 44 provided on the other axial side of stator core 10. Insulating resin 40 has a first side 43 and a second side 44 provided on the second axial side of stator core 10.

[0053] As shown in Figures 4 and 5, the one-side resin 43 covers the entire first coil end 24 and the second lead portion 28 of the second coil end 25. In other words, the one-side resin 43 covers the one-side coil end 22 except for the protruding portion 29. The one-side resin 43 includes a forming portion 42. The one-side resin 43 has a recess 45 that is recessed radially inward from the radially outer end of the stator core 10. The outer peripheral opening 52 described above opens to the back surface of the recess 45. The one-side resin 43 is continuous with the filling portion 41. The recess 45 opens to one axial side surface of the insulating resin 40.

[0054] 5, the other-side resin 44 covers the entire other-side coil end 23. The other-side resin 44 is continuous with the filling portion 41.

[0055] 1 and 6, the unit component 3 includes a conductor portion 60, a holding portion 70, and a terminal portion 80. The unit component 3 has a configuration in which a plurality of conductor portions 60 are held by the holding portion 70.

[0056] The conductor portion 60 is configured as, for example, a bus bar. As shown in FIG. 6, the conductor portion 60 has a plate shape. The thickness direction of the conductor portion 60 is along the circumferential direction. Before being pressed in, the thickness of the conductor portion 60 is slightly larger than the width of the press-fit groove 50 (the distance between the protruding portion 29 and the forming portion 42 of the insulating resin 40). Therefore, the conductor portion 60 is arranged in a pressed-fit state in the press-fit groove 50. The conductor portion 60 extends along the radial direction.

[0057] 7, the conductor portion 60 is press-fitted into the press-fit groove 50 and is arranged in a state where it is pressed against the protrusion 29. This connects the conductor portion 60 to the protrusion 29 that forms the press-fit groove 50. In this way, the stator 1 is arranged with the conductor portion 60 press-fitted into the press-fit groove 50 and pressed against the protrusion 29, so that the connection between the coil 20 and the conductor portion 60 can be easily maintained without providing a welding portion or a soldering portion.

[0058] 2 and 6, a plurality of conductor portions 60 are provided. The plurality of conductor portions 60 are arranged side by side in the circumferential direction. The plurality of conductor portions 60 are arranged radially.

[0059] As shown in FIGS. 2 and 6 , the retaining portion 70 has a shape that extends in an arc shape along the circumferential direction. The inner peripheral surface of the retaining portion 70 has a shape that extends in an arc shape along the circumferential direction. The outer peripheral surface of the retaining portion 70 has a shape that extends in an arc shape along the circumferential direction. The retaining portion 70 holds a plurality of conductor portions 60. Each conductor portion 60 held by the retaining portion 70 is press-fit into a respective press-fit groove 50 and is arranged in a state where it is pressed against a respective protrusion 29. In this way, since the stator 1 holds a plurality of conductor portions 60 connected to different protrusions 29 in the retaining portion 70, the relative positional relationship of the plurality of conductor portions 60 is easily maintained.

[0060] As shown in Figures 1 and 2, the retaining portion 70 is arranged in a state where it is fitted into the recess 45 of the insulating resin 40. The retaining portion 70 is arranged with a gap between it and the insulating resin 40. The retaining portion 70 protrudes radially outward beyond the insulating resin 40. The retaining portion 70 protrudes to one axial side beyond the insulating resin 40. The other axial end of the retaining portion 70 is arranged on the other axial side beyond the one axial end of the press-fit groove 50.

[0061] As shown in FIG. 1 , the terminal portions 80 are electrically connected to a drive unit 90 that drives a motor (not shown). The motor is a motor using the stator 1. The motor is, for example, a three-phase motor. Three terminal portions 80 are provided. Three-phase AC is applied to the three terminal portions 80. The terminal portions 80 are connected to the conductor portion 60 via relay portions (not shown). The relay portions are, for example, embedded in the holding portion 70. The terminal portions 80 protrude radially outward from the radially outer surface of the holding portion 70. In this way, since the terminal portions 80 protrude from the radially outer surface of the holding portion 70, the axial size of the stator 1 can be easily reduced. Furthermore, one axial end of the terminal portions 80 is positioned on the other axial side of the one axial end of the holding portion 70.

[0062] As shown in FIG. 6 , the multiple press-fit grooves 50 arranged in the circumferential direction extend radially along the radial direction. Each press-fit groove 50 has an opening 51 that opens toward one axial side. Each conductor portion 60 can be removed from the press-fit groove 50 through the opening 51. In a configuration in which the multiple press-fit grooves 50 extend radially, if an attempt is made to remove all of the conductor portions 60 press-fitted into the press-fit grooves 50 from the radially outer side at once, each conductor portion 60 will interfere with the inner wall of the press-fit groove 50. However, in the stator 1, the conductor portions 60 can be removed from one axial side through the openings 51, so the conductor portions 60 are less likely to interfere with the inner wall of the press-fit groove 50. As a result, it is easy to remove all of the multiple conductor portions 60 integrated via the retaining portion 70 at once.

[0063] 2 and 6 , each press-fit groove 50 has an outer peripheral opening 52 that opens radially outward. The retaining portion 70 is disposed at a position radially outward of the stator core 10 relative to the plurality of press-fit grooves 50 aligned in the circumferential direction. Each conductor portion 60 held by the retaining portion 70 protrudes from the radially inner surface of the retaining portion 70 and is disposed within the press-fit groove 50 via the outer peripheral opening 52. In this way, the retaining portion 70 that holds the plurality of conductor portions 60 of the stator 1 is disposed at a position radially outward of the plurality of press-fit grooves 50 aligned in the circumferential direction, making it easy to reduce the axial size of the stator 1.

[0064] As shown in FIGS. 2 and 6 , each press-fit groove 50 has an outer peripheral opening 52 that opens radially outward. The retaining portion 70 is disposed radially outward of the stator core 10 relative to the plurality of press-fit grooves 50 aligned in the circumferential direction. Each conductor portion 60 press-fitted into each press-fit groove 50 is connected to a radially inner surface of the retaining portion 70 via the outer peripheral opening 52. The opening 51 and the outer peripheral opening 52 are continuous. In this manner, the retaining portion 70 that holds the plurality of conductor portions 60 is disposed radially outward relative to the plurality of press-fit grooves 50 aligned in the circumferential direction, making it easy to reduce the axial size of the stator 1. In other words, the axial size of the stator 1 can be easily reduced while allowing the plurality of conductor portions 60 integrated via the retaining portion 70 to be removed collectively from one axial side.

[0065] As shown in FIGS. 1 and 7 , a plurality of protrusions 29 are provided. The plurality of protrusions 29 are arranged in a line in the circumferential direction of the stator core. The insulating resin 40 forms a plurality of press-fit grooves 50 arranged in a line in the circumferential direction between the plurality of protrusions 29 arranged in the circumferential direction. A plurality of conductor portions 60 are provided. Each conductor portion 60 is press-fit into its corresponding press-fit groove 50 and is arranged while being pressed against its corresponding protrusion 29. The entire axial length of each conductor portion 60 fits within its corresponding press-fit groove 50. The side of each protrusion 29 opposite to the press-fit groove 50 is covered with the insulating resin 40. In this way, in the stator 1, the entire axial length of each conductor portion 60 fits within the press-fit groove 50 and the side of each protrusion 29 opposite to the press-fit groove 50 is covered with the insulating resin 40. This facilitates insulation between a protrusion 29 and a protrusion 29 circumferentially adjacent to the protrusion 29 and between the conductor portion 60 connected to the adjacent protrusion 29.

[0066] As shown in Fig. 2, the coil 20 includes two or more protruding portions 29 arranged side by side in the radial direction of the stator core 10. One press-fit groove 50 is formed between the two or more protruding portions 29 arranged side by side in the radial direction and the insulating resin 40. One conductor portion 60 is press-fit into one press-fit groove 50 and is arranged in a state where it is pressed against the two or more protruding portions 29 that form the press-fit groove 50. With this configuration, the stator 1 can connect one conductor portion 60 to two or more protruding portions 29 arranged side by side in the radial direction.

[0067] 2. Manufacturing method of stator 1 The manufacturing method of the stator 1 includes a filling step, a preparation step, and a press-fitting step.

[0068] The filling process is a process of filling a resin material into the slots 15 of the stator core 10 in which the coils 20 are mounted. In the filling process, the stator body 2 is insert-molded using the stator core 10 in which the coils 20 are mounted as an insert part. In the filling process, the press-fit grooves 50 are formed while filling the gap between the inner wall of the slot 15 and the insertion portion 21 with the resin material. According to this method, the press-fit grooves 50 can also be formed when filling the gap between the inner wall of the slot 15 and the insertion portion 21 with the resin material, which makes it easy to simplify the manufacturing process.

[0069] In the preparation step, the stator body 2 and the unit components 3 are prepared.

[0070] In the press-fitting step, the conductor portion 60 is press-fitted into the press-fit groove 50 in the stator body 2, and the conductor portion 60 is pressed against the protrusion 29. According to this method, the conductor portion 60 is pressed against the protrusion 29 by being press-fitted into the press-fit groove 50, and therefore the connection between the conductor portion 60 and the protrusion 29 can be easily maintained without providing a welding portion or a soldering portion.

[0071] In the press-fitting step, the unit component 3 is displaced to the other axial side, thereby press-fitting each conductor 60 into each press-fit groove 50 through the opening 51. According to this method, the plurality of conductors 60 can be press-fitted into each press-fit groove 50 collectively, and pressed against the protrusions 29 that form each press-fit groove 50.

[0072] Second Embodiment The conductor portion is not limited to the configuration of the first embodiment. In the second embodiment, another example of the conductor portion will be described. In the description of the second embodiment, the same components as those in the first embodiment will be denoted by the same reference numerals, and detailed description thereof will be omitted.

[0073] 8 and 9, a stator 201 of the second embodiment includes a stator body 2 and a unit component 203. The unit component 203 includes a conductor portion 260, a holding portion 70, and a terminal portion 80 (see FIG. 1).

[0074] The conductor portion 260 includes a spring portion 261 and a support portion 262. The spring portion 261 flexes and deforms so as to contract in the circumferential direction. The spring portion 261 has a leaf spring shape and is formed by bending a metal plate. The spring portion 261 includes a pair of plate portions 263, 264 and a bent portion 265 connecting one end of the pair of plate portions 263, 264. The pair of plate portions 263, 264 extend from the bent portion 265 to one side in the axial direction. When the spring portion 261 is not flexibly deformed, the distance between the pair of plate portions 263, 264 increases with increasing distance from the bent portion 265. The spring portion 261 flexes and deforms, with the bent portion 265 as a fulcrum, so that the other ends of the pair of plate portions 263, 264 approach each other. The spring portion 261 is disposed in the press-fit groove 50 in a flexibly deformed state. The entire axial direction of the spring portion 261 is disposed within the press-fit groove 50. The flexed and deformed spring portion 261 exerts an elastic force so as to expand in the width direction of the press-fit groove 50. In other words, the spring portion 261 is press-fitted into the press-fit groove 50. Therefore, the spring portion 261 is disposed in a state where it is pressed against the protrusion 29. The spring portion 261 is disposed in a state where it is pressed against two or more (two in this embodiment) protrusions 29 that are aligned in the radial direction.

[0075] The pair of plate portions 263, 264 face each other in the circumferential direction. Plate portion 264 is arranged closer to protruding portion 29 than plate portion 263. That is, plate portion 264 is arranged in a state where it is pressed against protruding portion 29. Plate portion 264 is arranged in a state where it is pressed against two or more (two in this embodiment) protruding portions 29 that are aligned in the radial direction. With this configuration, in stator 201, spring portion 261 is pressed against protruding portion 29 by the elastic force of spring portion 261, and therefore the connection state between conductor portion 260 and protruding portion 29 is more likely to be stable.

[0076] The support portion 262 supports the spring portion 261. In the example shown in FIGS. 8 and 9, the support portion 262 supports the plate portion 263 of the spring portion 261. The support portion 262 may support the plate portion 264 or the bent portion 265. The support portion 262 is fixed to the holding portion 70. The support portion 262 is configured to protrude from the holding portion 70. The support portion 262 has a base portion 266 fixed to the holding portion 70 and a connecting portion 267 connecting the base portion 266 and the spring portion 261. The base portion 266 is plate-shaped. The plate thickness (width) of the base portion 266 is smaller than the width of the press-fit groove 50 and is equal to or greater than half the width of the press-fit groove 50. The width of the connecting portion 267 is smaller than the width of the base portion 266 and is less than half the width of the press-fit groove 50. The thickness of the plate portions 263 and 264 is smaller than the width of the base portion 266 and is less than half the width of the press-fit groove 50 .

[0077] In the press-fitting step, the unit component 3 is displaced toward the other axial side so that the bent portion 265 of the spring portion 261 enters the press-fit groove 50, thereby press-fitting the conductor portion 260 into the press-fit groove 50 through the opening 51. As a result, the conductor portion 260 is press-fitted into the press-fit groove 50 and pressed against the protruding portion 29.

[0078] Third Embodiment In the third embodiment, a second alternative example of the conductor portion will be described. In the description of the third embodiment, the same components as those in the first embodiment will be denoted by the same reference numerals, and detailed description thereof will be omitted.

[0079] 10 and 11, a stator 301 of the third embodiment includes a stator body 2 and a unit component 303. The unit component 303 includes a conductor portion 360, a holding portion 70, and a terminal portion 80 (see FIG. 1).

[0080] The conductor portion 360 is configured as, for example, a bus bar and includes a conductor body 361 and a protruding portion 362 that protrudes from the conductor body 361.

[0081] The conductor body 361 is plate-shaped. The thickness direction of the conductor portion 60 is along the circumferential direction. The thickness of the conductor body 361 is slightly smaller than the width of the press-fit groove 50 (the length in the axial direction and in the direction perpendicular to the radial direction). The conductor body 361 extends along the radial direction. The conductor body 361 is disposed within the press-fit groove 50.

[0082] The protruding portion 362 is a portion that is crushed when the conductor portion 360 is press-fitted into the press-fit groove 50. The protruding portion 362 is a portion of the conductor main body 361 that protrudes toward the protruding portion 29. The protruding portion 362 extends in the radial direction. The protruding portion 362 is curved so as to be convex toward the protruding portion 29.

[0083] A concave surface 363 is formed on the surface of the conductor body 361 opposite to the protruding portion 362. The concave surface 363 is provided at a position corresponding to the protruding portion 362. The conductor portion 360 is formed, for example, by bending a metal plate. The protruding portion 362 and the concave surface 363 are formed simultaneously by the bending process.

[0084] The conductor portion 360 is press-fitted into the press-fit groove 50, and is arranged with the protruding portion 362 pressed against the protruding portion 29. The conductor portion 360 is arranged with the protruding portion 362 pressed against two or more (two in this embodiment) protruding portions 29 that are arranged radially. With this configuration, the connection portion of the conductor portion 360 with the protruding portion 29 in the stator 301 is likely to be limited to the protruding portion 362, and therefore stress is likely to be concentrated due to the connection.

[0085] In the press-fitting process, the conductor portions 360 are press-fitted into the press-fit grooves 50, and the conductor portions 360 are pressed against the protrusions 29. Also, in the press-fitting process, the unit component 303 is displaced to the other axial side, so that each conductor portion 360 is press-fitted into each press-fit groove 50 via the openings 51.

[0086] <Fourth embodiment> In the fourth embodiment, a third alternative example of the conductor portion will be described. In the description of the fourth embodiment, the same components as those in the first embodiment will be denoted by the same reference numerals, and detailed description thereof will be omitted.

[0087] 12 and 13, a stator 401 of the fourth embodiment includes a stator body 2 and a unit component 403. The unit component 403 includes a conductor portion 460, a holding portion 70, and a terminal portion 80 (see FIG. 1).

[0088] The conductor portion 460 is configured as, for example, a bus bar. The conductor portion 460 has a conductor body 461. The conductor body 461 is disposed within the press-fit groove 50. An uneven surface 462 is formed on the surface of the conductor body 461 facing the protruding portion 29. The uneven surface 462 is pressed and crushed by the protruding portion 29 when the conductor portion 460 is press-fitted into the press-fit groove 50. As a result, the conductor portion 460 is press-fitted into the press-fit groove 50 and disposed in a state where it is pressed against the protruding portion 29. With this configuration, the connection state between the conductor portion 460 and the protruding portion 29 is likely to be stable over a wide range.

[0089] In the press-fitting process, the conductor portions 460 are press-fitted into the press-fit grooves 50, and the conductor portions 460 are pressed against the protruding portions 29. Also, in the press-fitting process, the unit component 403 is displaced to the other axial side, so that each conductor portion 460 is press-fitted into each press-fit groove 50 via the openings 51. If the coil 20 (more specifically, the protruding portions 29) is an insulated wire, the uneven surface 462 can be expected to strip the insulated wire, thereby providing a more reliable connection between the internal core wire and the conductor portions 460.

[0090] Fifth Embodiment In the fifth embodiment, another example of the positional relationship between the conductor portion and the protrusion will be described. In the description of the fifth embodiment, the same components as those in the first embodiment will be denoted by the same reference numerals, and detailed description thereof will be omitted.

[0091] 14 and 15, a stator 501 of the fifth embodiment includes a stator body 502 and a unit component 3. The unit component 3 includes a plurality of conductor portions 60, a holding portion 70, and a terminal portion 80.

[0092] The stator body 502 differs from the stator body 2 of the first embodiment in the positional relationship between the press-fit grooves and the protrusions, but is otherwise common. The stator body 502 has a plurality of protrusions 529. The plurality of protrusions 529 are arranged in a line in the circumferential direction. The stator body 502 includes insulating resin 540. The insulating resin 540 forms a plurality of press-fit grooves 550 arranged in the circumferential direction between the plurality of protrusions 529 arranged in the circumferential direction. Each protrusion 529 is arranged on the opposite side of the press-fit groove 550 formed by the protrusion 529 itself from the circumferential center CH side of the retaining portion 70.

[0093] Each conductor portion 60 is press-fit into each press-fit groove 550. Each conductor portion 60 is disposed on the circumferential center CH side of the holding portion 70 with respect to the protruding portion 529 to be connected. With this configuration, even if the holding portion 70 thermally expands and deforms so that the curvature becomes smaller, each conductor portion 60 tends to displace toward the protruding portion 529 to be connected, and therefore the connection state between the conductor portion 60 and the protruding portion 529 is likely to be maintained.

[0094] <Other embodiments> The present disclosure is not limited to the embodiments described above and in the drawings. For example, any combination of features of the above-described or following embodiments is possible within a range that does not contradict. Furthermore, any feature of the above-described or following embodiments may be omitted unless explicitly stated as essential. Furthermore, the above-described embodiment may be modified as follows.

[0095] The first coil end may not have a first lead portion. That is, the extending portion may be continuous with the insertion portion. The extending portion may extend from one axial end of the stator core to one axial side.

[0096] The second coil end may not have a second lead portion. That is, the protruding portion may be continuous with the insertion portion. The protruding portion may protrude from one axial end of the stator core to one axial side.

[0097] In each of the above embodiments, the multiple protrusions connected to one conductor portion are configured to be arranged on the same circumferential side of the conductor portion, but they may also be configured to be arranged on both circumferential sides of the conductor portion.

[0098] In each of the above embodiments, two or more protruding portions are arranged in the radial direction, but this is not limiting. For example, the protruding portions may not be arranged in the radial direction.

[0099] In each of the above embodiments, the entire conductor portion in the axial direction is fitted into the press-fit groove, but it may be configured so that only a portion of the conductor portion in the axial direction is fitted into the press-fit groove.

[0100] In each of the above embodiments, the conductor portion is press-fitted into the press-fit groove from one axial side, but it may be press-fitted from the radially outer side.

[0101] It should be noted that the embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is not limited to the embodiments disclosed herein, but is intended to include all modifications within the scope indicated by the claims or the scope equivalent to the claims. [Explanation of symbols]

[0102] 1...Stator 2...Stator body 3...Unit parts 10... Stator core 11...Yoke section 12...Teeth part 15...Slot 20...Coil 21...insertion section 22...One side coil end 23...Other coil end 24...First coil end 25...Second coil end 26...First lead section 27...Extending part 28...Second lead section 29...Protruding part 40...Insulating resin 41...Filling section 42...Formation part 43...Resin on one side 44...Other side resin 45...recess 50...Press-fit groove 51...Opening 52...Peripheral opening 60...Conductor 70...Holding part 80...Terminal section 90...Drive unit 201...Stator 203...Unit parts 260...Conductor 261...Spring part 262...Support part 263...Plate part 264...Plate part 265...Bend 266...Base 267...Connecting part 301...Stator 303...Unit parts 360...Conductor 361...conductor body 362...Protrusion 363…Concave 401...Stator 403...Unit parts 460...Conductor 461...conductor body 462…Uneven surface 501...Stator 502... Stator body 529...Protrusion 540...insulating resin 550...Press-fit groove CH: Circumferential center of the retaining part

Claims

1. an annular stator core; a coil having a protruding portion that protrudes toward one axial direction beyond an end portion of the stator core on one axial direction side; a conductor portion connected to the protrusion; an insulating resin that forms a press-fit groove between the insulating resin and the protruding portion, The conductor portion is press-fitted into the press-fit groove and is disposed in a state where it is pressed against the protrusion portion. Stator.

2. The protrusions are provided in plurality, The plurality of protrusions are arranged side by side in the circumferential direction of the stator core, the insulating resin forms a plurality of the press-fit grooves arranged in the circumferential direction between the insulating resin and the plurality of the protruding portions arranged in the circumferential direction, The conductor portion is provided in plurality, Further, a holding portion for holding the plurality of conductor portions is provided, The conductor portions held by the holding portion are press-fitted into the press-fit grooves and are disposed in a state of being pressed against the protrusions. The stator according to claim 1 .

3. the press-fit grooves arranged in the circumferential direction extend radially along the radial direction of the stator core, Each of the press-fit grooves has an opening that opens toward one side in the axial direction, Each of the conductor portions is removable from the press-fit groove through the opening. The stator according to claim 2 .

4. Each of the press-fit grooves has an outer peripheral opening that opens radially outward of the stator core, the retaining portion is disposed at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction, Each of the conductor portions held by the holding portion protrudes from the radially inner surface of the holding portion and is disposed in the press-fit groove through the outer peripheral opening. The stator according to claim 2 or 3.

5. A stator for use in a motor, a terminal portion electrically connected to a drive portion that drives the motor; The terminal portion protrudes from the radially outer surface of the holding portion.

5. The stator according to claim 4.

6. Each of the press-fit grooves has an outer peripheral opening that opens radially outward of the stator core, the retaining portion is disposed at a position radially outward of the plurality of press-fit grooves arranged in the circumferential direction, Each of the conductor portions press-fitted into each of the press-fit grooves is connected to the radially inner surface of the holding portion via the outer peripheral opening, The opening and the outer peripheral opening are open continuously. The stator according to claim 3 .

7. The holding portion extends in an arc shape along the circumferential direction, Each of the conductor portions is arranged on the circumferential center side in the holding portion with respect to the protruding portion to be connected. The stator according to claim 2 or claim 3.

8. A plurality of the protruding portions are provided. The plurality of protruding portions are arranged side by side in the circumferential direction of the stator core. The insulating resin forms a plurality of press-fitting grooves arranged in the circumferential direction between the plurality of protruding portions arranged in the circumferential direction. A plurality of the conductor portions are provided. Each of the conductor portions is arranged in a state of being press-fitted into each of the press-fitting grooves and pressed against each of the protruding portions. The entire axial direction of each of the conductor portions fits into each of the press-fitting grooves. The side of the protruding portion opposite to the press-fitting groove side is covered with the insulating resin. The stator according to any one of claims 1 to 3.

9. The stator core has a plurality of slots arranged side by side in the circumferential direction of the stator core. The coil has an insertion portion arranged in the slot. The insulating resin has a filling portion continuously filled between the inner wall of the slot and the insertion portion, and a forming portion that forms the press-fitting groove. The filling portion and the forming portion are integrally formed. The stator according to any one of claims 1 to 3.

10. The coil includes two or more of the protruding portions arranged side by side in the radial direction of the stator core. One of the press-fitting grooves is formed between the two or more protruding portions and the insulating resin. One of the conductor portions is arranged in a state of being press-fitted into one of the press-fitting grooves and pressed against the two or more protruding portions that form the press-fitting groove. The stator according to any one of claims 1 to 3.

11. A preparation step of preparing a stator body including an annular stator core, a coil having a protruding portion protruding to one axial side of the stator core more than one axial side end of the stator core, a conductor portion connected to the protruding portion, and an insulating resin forming a press-fitting groove between the protruding portion; A press-fitting step of press-fitting the conductor portion into the press-fitting groove in the stator body and pressing the conductor portion against the protruding portion. A method of manufacturing a stator.

12. The preparation step prepares a unit component having a configuration in which a plurality of the conductor portions are held by a holding portion. A plurality of the protruding portions are provided. The plurality of protruding portions are arranged side by side in the circumferential direction of the stator core. The insulating resin forms a plurality of press-fitting grooves arranged in the circumferential direction between the plurality of protruding portions arranged in the circumferential direction. Each of the press-fit grooves has an opening that opens toward one side in the axial direction, The press-fitting step includes displacing the unit component toward the other axial direction, thereby press-fitting each of the conductor portions into each of the press-fit grooves through the openings. The method for manufacturing a stator according to claim 11.

13. the stator core has a plurality of slots aligned in a circumferential direction of the stator core, the coil has an insert disposed within the slot; The method further includes a filling step of filling a space between the inner wall of the slot and the insertion portion with a resin material, The filling step forms the press-fit groove while filling the resin material between the inner wall of the slot and the insertion portion. The method for manufacturing a stator according to claim 11 or 12.

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