Stator member, rotating electrical machine, and method for manufacturing a stator member

Abstract

This stator member, which is used in a dynamo-electric machine, comprises: a core back part that is a molded body formed from soft magnetic powder, the core back part having an end surface facing in a first direction following the rotation axis of the dynamo-electric machine when the stator member is incorporated into the dynamo-electric machine, and a first end and a second end that are the two ends in the circumferential direction centered on the rotation axis; and a winding part on which a coil is wound. The winding part is provided between the first end and the second end on the end surface.

Description

Technical Field

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[0001] The present invention relates to a stator member used in a rotating electrical machine, a rotating electrical machine including the stator member, and a method for manufacturing the stator member used in the rotating electrical machine.

Background Art

[0002] As an invention related to a conventional stator member, for example, a motor described in Patent Document 1 is known. The motor described in Patent Document 1 includes a drive coil, a stator around which the drive coil is wound, an insulating member that insulates the stator, a tying pin that protrudes from the insulating member and around which an end of the winding of the drive coil is tied, a substrate bonding pin that protrudes from the insulating member and is electrically connected to the tying pin, and a circuit board having a through-hole and a conductive pattern. The substrate bonding pin penetrates through the through-hole. The conductive pattern is formed at the edge of the through-hole. The substrate bonding pin is connected to the conductive pattern.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the manufacture of the motor described in Patent Document 1, a process of manufacturing a tying portion, a process of assembling the stator and the insulating member, and a process of arranging the tying pins on the insulating member are each required. There is a desire to reduce the manufacturing process in the motor described in Patent Document 1.

[0005] Therefore, an object of the present invention is to provide a stator member, a rotating electrical machine, and a method for manufacturing the stator member that can achieve simplification of the manufacturing process of the motor.

Means for Solving the Problems

[0006] A stator member according to one embodiment of the present invention is A stator component used in a rotating electric machine, A core back portion which is a molded body formed from soft magnetic powder, having an end face that faces a first direction along the rotation axis of the rotating electric machine when the stator member is incorporated into the rotating electric machine, and a first end and a second end which are both ends in the circumferential direction with respect to the rotation axis, The winding section around which the coil is wound, Equipped with, The winding portion is provided between the first end and the second end on the end face. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a stator member, a rotating electromachine, and a method for manufacturing a stator member that can simplify the manufacturing process of a motor. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is an external perspective view of the brushless motor 100. [Figure 2] Figure 2 is a schematic perspective view showing a portion of the brushless motor 100 in a cutaway section. [Figure 3] Figure 3 is a perspective view of the stator member 1. [Figure 4] Figure 4 is an enlarged cross-sectional view of the vicinity of the winding portion 4, viewed in the opposite direction to the third direction DIR3. [Figure 5] Figure 5 is a plan view of the core back portion 2 and the winding portion 4 as seen in the second direction DIR2. [Figure 6] Figure 6 is a flowchart showing an example of a method for manufacturing the stator member 1. [Figure 7] Figure 7 is a cross-sectional view at AA showing an example of the manufacturing process for the stator member 1. [Figure 8] Figure 8 is a perspective view of the stator member 1a. [Figure 9] Figure 9 is a perspective view of the stator member 1b. [Figure 10] Figure 10 is a perspective view of the stator member 1c. [Figure 11] Figure 11 is a perspective view of the stator member 1d. [Figure 12] Figure 12 is a perspective view of the stator member 1e. [Figure 13] Figure 13 is a perspective view of the stator member 1f. [Figure 14] Figure 14 is a flowchart showing an example of a manufacturing method of the stator member 1f. [Figure 15] Figure 15 is a cross-sectional view taken along A-A showing an example of a manufacturing process of the stator member 1f. [Figure 16] Figure 16 is a cross-sectional view taken along A-A showing an example of a manufacturing process of the stator member 1f. [Figure 17] Figure 17 is a flowchart showing an example of a manufacturing method of the stator member 1g. [Figure 18] Figure 18 is a cross-sectional view taken along A-A showing an example of a manufacturing process of the stator member 1g. [Figure 19] Figure 19 is a cross-sectional view taken along A-A showing an example of a manufacturing process of the stator member 1g. [Figure 20] Figure 20 is a perspective view showing an example of a manufacturing process of the stator member 1g. [Embodiments for Carrying Out the Invention]

[0009] [First Embodiment] (Configuration of the Brushless Motor 100) Hereinafter, the configuration of the stator member 1 according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is an external perspective view of the brushless motor 100. FIG. 2 is a schematic perspective view showing a part of the brushless motor 100 broken away. In FIG. 2, reference numerals are attached only to the representative stator member 1 and coil 13 among the plurality of stator members 1 and the plurality of coils 13, respectively.

[0010] In this specification, directions are defined as follows: The first direction DIR1 is defined as the axial direction along the rotation axis of the brushless motor 100 in which the shaft 21 protrudes from the opening OP to the outside of the housing 12. The second direction DIR2 is defined as the opposite direction of the first direction DIR1. The third direction DIR3 is defined as one of the radial directions around the rotation axis of the brushless motor 100, and, with respect to the first direction DIR1, the direction from the tooth tip 32 toward the rotation axis of the brushless motor 100. The fourth direction DIR4 is defined as the circumferential direction around the rotation axis of the brushless motor 100, and, with respect to the second direction DIR2, the direction that is counterclockwise with respect to the rotation axis of the brushless motor 100. Note that the definitions of directions in this specification are examples.

[0011] As shown in Figure 2, the brushless motor 100 comprises a rotor 20 and a stator assembly 10. The stator assembly 10 is arranged around the rotor 20 when viewed in the first direction DIR1. In other words, the brushless motor 100 is an inner rotor type. The brushless motor 100 is an example of a rotating electric machine of the present invention.

[0012] The rotor 20 includes a shaft 21 and a rotor member 22. The shaft 21 is cylindrical and extends in a first direction DIR1. The rotor member 22 is cylindrical and extends in a first direction DIR1. The central axes of the shaft 21 and the rotor member 22 are the Z-axis. That is, the axis of rotation of the brushless motor 100 is the Z-axis. Therefore, the first direction DIR1 and the second direction DIR2 are both directions along the Z-axis.

[0013] The rotor member 22 has a soft magnetic material 23 and a hard magnetic material 24. The rotor member 22 is attached to the outer circumferential surface of the shaft 21 in the radial direction about the Z-axis. More specifically, the soft magnetic material 23 is attached to the outer circumferential surface of the shaft 21 in the radial direction about the Z-axis. The hard magnetic material 24 is attached to the outer circumferential surface of the soft magnetic material 23 in the radial direction about the Z-axis.

[0014] The soft magnetic material 23 is a soft magnetic material. The hard magnetic material 24 is a magnetized hard magnetic material. When a hard magnetic material is subjected to an external magnetic field, it becomes magnetized. After that, even if the application of the magnetic field is stopped, the hard magnetic material does not lose its magnetization.

[0015] The stator assembly 10 includes a bearing 11, a housing 12, a coil 13, and a stator member 1.

[0016] The bearing 11 supports the shaft 21 so that it can rotate in the circumferential direction about the Z-axis. More specifically, the bearing 11 has a first bearing 11a and a second bearing 11b. Each of the first bearing 11a and the second bearing 11b is, for example, a ball bearing. Each of the first bearing 11a and the second bearing 11b is cylindrical and extends in a first direction DIR1. The central axis of each of the first bearing 11a and the second bearing 11b is the Z-axis. That is, the central axes of each of the first bearing 11a and the second bearing 11b coincide with the central axis of the shaft 21.

[0017] The second bearing 11b is located in the second direction DIR2 relative to the first bearing 11a. The first bearing 11a is located in the first direction DIR1 relative to the rotor member 22. The second bearing 11b is located in the second direction DIR2 relative to the rotor member 22. The second bearing 11b supports the end of the shaft 21 in the second direction DIR2.

[0018] As shown in Figure 1, the housing 12 has a first housing 12a and a second housing 12b. As shown in Figures 1 and 2, the first housing 12a is cylindrical. The central axis of the first housing 12a is the Z-axis. The first housing 12a is located in a first direction DIR1 relative to the second housing 12b. The first housing 12a also has an opening OP. As a result, the shaft 21 protrudes from the opening OP in the first direction DIR1. In other words, the brushless motor 100 is a single-shaft type.

[0019] The first housing 12a supports the first bearing 11a, a plurality of stator members 1, and a plurality of coils 13. The second housing 12b supports the second bearing 11b. The materials of the first housing 12a and the second housing 12b are, for example, highly rigid materials such as SUS.

[0020] The number of coils 13 and the number of stator members 1 are both nine. Each of the nine coils 13 and nine stator members 1 is arranged in the circumferential direction centered on the Z-axis. The nine stator members 1 are positioned around the hard magnetic material 24, with some space between them.

[0021] The coil 13 is made of a conductive material such as copper. The coil 13 has a structure in which the surface of the copper wire is covered with an insulating coating. Because the surface of the copper wire is covered with an insulating coating, the coil 13 and the stator member 1 are electrically insulated. However, at the two ends of the coil 13, the surface of the copper wire is not covered with an insulating coating, and the copper wire is exposed.

[0022] The coil 13 is supplied with current from a power source (not shown). The coil 13 generates a magnetic field when current flows through it. The stator member 1 is magnetized by the magnetic field generated by the hard magnetic material 24 and the magnetic field generated by the coil 13. The rotation of the rotor 20 is controlled by controlling the current supplied from the power source (not shown).

[0023] (Configuration of stator member 1) The configuration of the stator member 1 according to one embodiment of the present invention will be described below with reference to the drawings. Figure 3 is a perspective view of the stator member 1. Figure 4 is an enlarged cross-sectional view of the vicinity of the winding portion 4 viewed in the opposite direction to the third direction DIR3. Figure 5 is a plan view of the core back portion 2 and the winding portion 4 viewed in the second direction DIR2.

[0024] As shown in Figure 3, the stator member 1 has a core back portion 2, a teeth portion 3, and a winding portion 4. The core back portion 2, the teeth portion 3, and the winding portion 4 are all included in the stator member 1, which is a single component. The teeth portion 3 has a shape that extends from the core back portion 2 in a third direction DIR 3. More specifically, the teeth portion 3 has a teeth body portion 31 that extends from the core back portion 2 in a third direction DIR 3, and a teeth tip portion 32 formed at the tip of the teeth body portion 31. As shown in Figure 2, a coil 13 is wound around the teeth body portion 31. The teeth tip portion 32 faces the hard magnetic material 24. However, there is an air gap between the teeth tip portion 32 and the hard magnetic material 24.

[0025] The stator member 1 is a soft magnetic material. More specifically, in this embodiment, the stator member 1 is a molded body formed from soft magnetic powder. That is, the core back portion 2 and the teeth portion 3 are each molded bodies formed from soft magnetic powder. The soft magnetic powder material includes, for example, iron and a binder. The binder is, for example, a resin. The soft magnetic powder is, for example, a mixture of iron powder and epoxy resin powder, which is an example of a binder powder. Such a stator member 1 is manufactured, for example, by compression molding. In addition, the outer surface of the stator member 1 that comes into contact with other members is treated with an insulating coating.

[0026] As shown in Figure 3, the core back portion 2 has a first end face S1 facing the first direction DIR1, a second end face S2 facing the second direction DIR2, an inner main surface facing the third direction DIR3, an outer main surface facing the opposite direction of the third direction DIR3, a side surface facing the fourth direction DIR4, and a side surface facing the opposite direction of the fourth direction DIR4 when the stator member 1 is assembled to the brushless motor 100. The first end face S1 includes a first end E1 and a second end E2, which are both ends with respect to the fourth direction DIR4, and a third end E3 and a fourth end E4, which are both ends with respect to the third direction DIR3. The first end E1 is located further to the fourth direction DIR4 than the second end E2. The third end E3 is located further to the third direction DIR3 than the fourth end E4. In this embodiment, the first end face S1, the second end face S2, and the inner main surface are all planar. The outer main surface and each of the two sides are curved surfaces.

[0027] A recess R1 is provided in the first end face S1. In this embodiment, the recess R1 is provided in the central part of the first end face S1. The recess R1 has a shape that is recessed in the second direction DIR2. In this embodiment, the recess R1 is provided between the first end E1 and the second end E2. Furthermore, the recess R1 connects the inner main surface and the outer main surface. That is, by providing the recess R1, the length of a part of the core back portion 2 in the first direction DIR1 is shortened.

[0028] In this embodiment, one winding section 4 extends from the core back section 2 in the first direction DIR 1. As shown in Figure 4, a coil 13 is wound around the winding section 4. More specifically, in this embodiment, one of the two ends of the coil 13 wound around the teeth body section 31 of the stator member 1 is wound around the winding section 4 such that one of the two ends of the coil 13 wound around the teeth body section 31 of the stator member 1 is in contact with one of the two ends of the coil 13 wound around the teeth body section 31 of the stator member 1 located next to the stator member 1 in the fourth direction DIR 4. In the brushless motor 100 as a whole, at the winding portion 4 of each of the nine stator members 1, one of the two ends of the coil 13 wound around the tooth body portion 31 of the stator member 1 comes into contact with one of the two ends of the coil 13 wound around the tooth body portion 31 of the stator member 1 located next to the stator member 1 in the fourth direction DIR 4, thereby enabling the nine coils 13 to be connected in series in groups of three.

[0029] In this embodiment, the winding portion 4 is rod-shaped. Furthermore, the length of the winding portion 4 in the first direction DIR1 is smaller than the amount of recess R1 in the second direction DIR2. As shown in Figure 5, in this embodiment, the outer edge of the core back portion 2 viewed in the second direction DIR2 surrounds the outer edge of the winding portion 4.

[0030] In this embodiment, the winding portion 4 is made of a soft magnetic material. More specifically, the winding portion 4 is a molded body formed from soft magnetic powder. The soft magnetic powder material includes, for example, iron and a binder. The binder is, for example, a resin. The soft magnetic powder is, for example, a mixture of iron powder and epoxy resin powder, which is an example of a binder powder. Such a winding portion 4 is manufactured, for example, by compression molding. In this embodiment, the core back portion 2 and the winding portion 4 are integrally formed by molding soft magnetic powder. Furthermore, the outer surface of the winding portion 4 that comes into contact with the coil 13 is insulated. That is, the winding portion 4 has insulating properties.

[0031] The winding portion 4 is provided in the recess R1. As a result, a portion of the core back portion 2 is located in the first direction DIR1 from the contact surface between the first end face S1 and the winding portion 4. The winding portion 4 is also provided between the first end E1 and the second end E2 on the first end face S1. In this embodiment, the winding portion 4 is also provided between the third end E3 and the fourth end E4 on the first end face S1.

[0032] (Method for manufacturing the stator member 1) A method for manufacturing a stator member 1 according to one embodiment of the present invention will be described below with reference to the drawings. Figure 6 is a flowchart of an example of a method for manufacturing a stator member 1. Figure 7 is a cross-sectional view at AA showing an example of the manufacturing process for a stator member 1.

[0033] This manufacturing method is initiated by filling a mold DI with a soft magnetic powder mixture containing iron powder and epoxy resin powder (Figure 6: Step S11).

[0034] Next, as shown in Figure 7, the soft magnetic powder filled in the mold DI is compressed by pressurizing it with a punch P, thereby compressing the soft magnetic powder (Figure 6: Step S12). By compressing the soft magnetic powder, the core back portion 2, the teeth portion 3, and the winding portion 4 are integrally formed, creating the stator member 1 (first forming step).

[0035] [effect] The stator member 1 makes it possible to simplify the motor manufacturing process. More specifically, the winding portion 4 is provided on the first end face S1 of the core back portion 2. Therefore, the process of assembling the stator and the insulating member becomes unnecessary. As a result, the stator member 1 makes it possible to simplify the motor manufacturing process.

[0036] Furthermore, the stator member 1 allows multiple coils 13 and multiple stator members 1 to be arranged in a circumferential direction centered on the Z-axis. More specifically, the winding portion 4 is provided between the first end E1 and the second end E2 at the first end face S1 of the core back portion 2. This prevents the coils 13 wound around the winding portion 4 from protruding from the first end E1 in the fourth direction DIR4 or from the second end E2 in the opposite direction of the fourth direction DIR4 when viewed in the second direction DIR2. As a result, the stator member 1 allows multiple coils 13 and multiple stator members 1 to be arranged in a circumferential direction centered on the Z-axis.

[0037] The manufacturing method for the stator member 1 enables further simplification of the motor manufacturing process. More specifically, the stator member 1 is formed by integrally forming the core back portion 2 and the winding portion 4 by compression molding a soft magnetic powder mixture of iron powder and epoxy resin powder. This eliminates the need for the steps of creating the winding portion and arranging the winding pins on the insulating member when manufacturing the stator member 1.

[0038] The stator member 1 makes it possible to suppress the core back portion from becoming magnetically saturated. More specifically, the tooth tip portion 32 faces the hard magnetic material 24. As a result, the magnetic flux emitted by the hard magnetic material 24 flows in from the tooth tip portion 32 and flows in the order of tooth tip portion 32, tooth body portion 31, and core back portion 2. The magnetic flux that flows into the core back portion 2 spreads radially when viewed in the opposite direction of the third direction DIR3. Therefore, the magnetic flux value that reaches the first end face S1 is small. Accordingly, by providing a recess R1 on the first end face S1 that has a shape recessed in the second direction DIR2, the core back portion 2 is less likely to become magnetically saturated. In other words, because a part of the core back portion 2 is located in the first direction DIR1 from the contact surface between the first end face S1 and the winding portion 4, the core back portion 2 is less likely to become magnetically saturated. In addition, the magnetic flux value that reaches the central part of the first end face S1 is particularly small. Therefore, because the recess R1 is provided in the center of the first end face S1, the core back portion 2 is less likely to become magnetically saturated. As a result, the stator member 1 can suppress the core back portion from becoming magnetically saturated.

[0039] The stator member 1 can suppress electrical connection between the coil and the core back portion. More specifically, the end portion of the coil 13 is wound around the winding portion 4. At the end portion of the coil 13, the copper wire is exposed. Therefore, the end portion of the coil 13 and the core back portion 2 are prone to electrical connection. For this reason, the winding portion 4 has insulating properties. As a result, the stator member 1 can suppress electrical connection between the coil and the core back portion.

[0040] The stator member 1 enables further simplification of the motor manufacturing process. More specifically, the core back portion 2 and the winding portion 4 are integrally formed by molding soft magnetic powder. This eliminates the need for the steps of creating the winding portion and arranging the winding pins on the insulating member when manufacturing the stator member 1.

[0041] [First variation] The stator member 1a according to the first modified example of the present invention will be described below with reference to the figures. Figure 8 is a perspective view of the stator member 1a. Note that for the stator member 1a according to the first modified example, only the parts that differ from the stator member 1 according to the first embodiment will be described, and the rest will be omitted.

[0042] The stator member 1a differs from the stator member 1 in that the first end face S1 does not have a recess R1 and the winding portion 4 is not provided in the recess R1.

[0043] The stator member 1a described above also produces the same effect as the stator member 1.

[0044] [Second variation] The stator member 1b according to the second modified example of the present invention will be described below with reference to the figures. Figure 9 is a perspective view of the stator member 1b. Note that for the stator member 1b according to the second modified example, only the parts that differ from the stator member 1a according to the first modified example will be described, and the rest will be omitted.

[0045] The stator member 1b differs from the stator member 1a in that the winding portion 4 connects the inner main surface and the outer main surface.

[0046] The stator member 1b described above also produces the same effect as the stator member 1a.

[0047] [Third variation] The stator member 1c according to the third modification of the present invention will be described below with reference to the figures. Figure 10 is a perspective view of the stator member 1c. Note that for the stator member 1c according to the third modification, only the parts that differ from the stator member 1a according to the first modification will be described, and the rest will be omitted.

[0048] The stator member 1c differs from the stator member 1a in that it has two winding portions 4a and 4b.

[0049] The winding section 4a is located in a fourth direction DIR4 from the winding section 4b. The coil 13 is wound around the winding sections 4a and 4b. More specifically, one of the two ends of the coil 13 wound around the teeth body 31 of the stator member 1c is wound around the winding section 4a such that it comes into contact with one of the two ends of the coil 13 wound around the teeth body 31 of the stator member 1c located next to the stator member 1c in the fourth direction DIR4. Furthermore, the other of the two ends of the coil 13 wound around the teeth body portion 31 of the stator member 1c, and the other of the two ends of the coil 13 wound around the teeth body portion 31 of the stator member 1c located next to the stator member 1c in the fourth direction DIR 4, are wound around the winding portion 4b so that they come into contact with each other. This allows the coil 13 wound around the teeth body portion 31 of the stator member 1c and the coil 13 wound around the teeth body portion 31 of the stator member 1c located next to the stator member 1c in the fourth direction DIR 4 to be connected in parallel.

[0050] [Fourth variation] The stator member 1d according to the fourth modification of the present invention will be described below with reference to the figures. Figure 11 is a perspective view of the stator member 1d. Note that for the stator member 1d according to the fourth modification, only the parts that differ from the stator member 1c according to the third modification will be described, and the rest will be omitted.

[0051] The stator member 1d differs from the stator member 1c in that the winding portions 4a and 4b each connect the inner main surface and the outer main surface, respectively.

[0052] The stator member 1d described above also produces the same effect as the stator member 1c.

[0053] [Fifth variation] The stator member 1e according to the fifth modification of the present invention will be described below with reference to the figures. Figure 12 is a perspective view of the stator member 1e. Note that for the stator member 1e according to the fifth modification, only the parts that differ from the stator member 1c according to the third modification will be described, and the rest will be omitted.

[0054] The stator member 1e differs from the stator member 1c in that its first end face S1 is provided with two recesses R1a and R1b.

[0055] The recess R1a is located in the fourth direction DIR4 from the recess R1b. The winding portion 4a is provided in the recess R1a. The winding portion 4b is provided in the recess R1b.

[0056] The stator member 1e described above also produces the same effect as the stator member 1c.

[0057] [Second Embodiment] The stator member 1f according to the second embodiment of the present invention will be described below with reference to the figures. Figure 13 is a perspective view of the stator member 1f. Note that only the parts of the stator member 1f according to the second embodiment that differ from the stator member 1 according to the first embodiment will be described, and the rest will be omitted.

[0058] The stator member 1f differs from the stator member 1 in that the core back portion 2 and the winding portion 4c are not integrally formed by molding soft magnetic powder.

[0059] More specifically, as shown in Figure 13, the winding portion 4c is a rod-shaped pin. The material of the winding portion 4c is, for example, a copper-based material such as phosphor bronze. The outer surface of the winding portion 4c that is in contact with the core back portion 2 is insulated. On the other hand, the outer surface of the winding portion 4c that is in contact with the coil 13 is not insulated. Therefore, the winding portion 4c is conductive. Also, the core back portion 2 and the winding portion 4c are separate components.

[0060] A method for manufacturing a stator member 1f according to one embodiment of the present invention will be described below with reference to the drawings. Figure 14 is a flowchart of an example of a method for manufacturing a stator member 1f. Figure 15 is a cross-sectional view at AA showing an example of the manufacturing process of a stator member 1f. Figure 16 is a cross-sectional view at AA showing an example of the manufacturing process of a stator member 1f.

[0061] This manufacturing method is initiated by placing a rod-shaped pin (winding portion 4c) into the punch P, as shown in Figure 15 (Figure 14: Step S21). More specifically, the punch P is provided with an insertion opening for placing the rod-shaped pin (winding portion 4c). The rod-shaped pin (winding portion 4c) is inserted into the insertion opening of the punch P.

[0062] Next, the soft magnetic powder mixture, which consists of iron powder and epoxy resin powder, is filled into the mold DI (Figure 14: Step S22).

[0063] Next, as shown in Figure 16, the soft magnetic powder filled in the mold DI and the winding portion 4c are compressed by the punch P, thereby compressing the soft magnetic powder and the winding portion 4c (Figure 14: Step S23). By compressing the soft magnetic powder and the winding portion 4c, the core back portion 2 is formed and the winding portion 4c is fixed to the first end face S1 (second forming step).

[0064] The stator member 1f, as described above, provides the same effects as the stator member 1. Furthermore, the stator member 1f allows for easy electrical connection between the end of the coil and the electrodes and busbars (not shown) of the substrate (not shown). More specifically, the winding portion 4c is conductive. Therefore, the end of the coil 13 can be electrically connected to the electrodes and busbars of the substrate via the winding portion 4c. The winding portion 4c is also fixed to the first end face S1. Therefore, by using the winding portion 4c as a positioning tool when joining the substrate and busbars to the stator member 1f, the end of the coil and the electrodes and busbars of the substrate can be easily electrically connected.

[0065] [Third Embodiment] The stator member 1g according to the third embodiment of the present invention will be described below with reference to the figures. Figure 17 is a flowchart of an example of a method for manufacturing the stator member 1g. Figure 18 is a cross-sectional view at AA showing an example of the manufacturing process for the stator member 1g. Figure 19 is a cross-sectional view at AA showing an example of the manufacturing process for the stator member 1g. Figure 20 is a perspective view showing an example of the manufacturing process for the stator member 1g. Note that for the stator member 1g according to the third embodiment, only the parts that differ from the stator member 1f according to the first embodiment will be described, and the rest will be omitted.

[0066] The stator component 1g differs from the stator component 1f in its manufacturing method.

[0067] This manufacturing method is initiated by filling a mold DI with a soft magnetic powder mixture of iron powder and epoxy resin powder (Figure 17: Step S31). More specifically, as shown in Figure 18, the punch P is provided with a projection T that protrudes in the second direction DIR2.

[0068] Next, as shown in Figure 19, the soft magnetic powder filled in the mold DI is compressed and molded by applying pressure with a punch P (Figure 17: Step S32). By compressing and molding the soft magnetic powder, a core back portion 2 with an insertion opening at the first end face S1 and a teeth portion 3 are formed (core back portion formation step).

[0069] Next, as shown in Figure 20, the winding portion 4c is fixed to the first end face S1 by inserting a portion of it into an insertion opening provided on the first end face S1 (Figure 17: Step S33, winding portion fixing step). This forms the stator member 1g.

[0070] The stator member 1g described above also produces the same effect as the stator member 1f.

[0071] [Other embodiments] The stator according to the present invention is not limited to stator members 1, 1a to 1g, but can be modified within the scope of its essence. Furthermore, the structures of stator members 1, 1a to 1g may be combined arbitrarily.

[0072] Furthermore, a rotating electric machine only needs to have a structure in which the rotor rotates electrically, or a structure in which electricity is generated by the rotation of the rotor. Rotating electric machines include brushless motors, permanent magnet synchronous motors, permanent magnet synchronous generators, etc. In this case, the rotating electric machine only needs to have at least one of the stator members 1, 1a to 1g, and may also have brushes.

[0073] The brushless motor 100 may also be of the outer rotor type.

[0074] Furthermore, the brushless motor 100 is not limited to a single-shaft type. For example, the brushless motor 100 may be a double-shaft type.

[0075] Note that the first bearing 11a and the second bearing 11b are not limited to ball bearings.

[0076] Furthermore, the materials used for the first housing 12a and the second housing 12b can be any material with high rigidity.

[0077] Furthermore, the number of coils 13 and the number of stator members 1 are not limited to nine.

[0078] Furthermore, in the core back portion formation process, the core back portion 2 with an insertion opening at the first end face S1 and the teeth portion 3 may be formed by compression molding of soft magnetic powder, or by laminating electrical steel sheets.

[0079] The first end face S1, the second end face S2, and the inner main surface of the core back portion 2 may each be curved. Furthermore, the outer main surface and the two side surfaces of the core back portion 2 may each be flat.

[0080] Furthermore, the tooth body portion 31 does not necessarily have to extend from the core back portion 2 in the third direction DIR3.

[0081] Furthermore, the tooth tip portion 32 does not necessarily have to be formed at the tip of the tooth body portion 31 with respect to the third direction DIR3.

[0082] The length of the winding portion 4 in the first direction DIR1 may be equal to the amount of recess in the recess R1 in the second direction DIR2. If the length of the winding portion 4 in the first direction DIR1 is less than or equal to the amount of recess in the recess R1 in the second direction DIR2, the length of the brushless motor 100 in the first direction DIR1 can be reduced. Alternatively, the length of the winding portion 4 in the first direction DIR1 may be greater than the amount of recess in the recess R1 in the second direction DIR2. In this case, the winding portion 4 can be used as a positioning tool when joining a substrate with holes (not shown) to the stator member 1, making it easier to join the substrate with holes to the stator member 1.

[0083] Furthermore, the outer surface of the stator member 1 that comes into contact with other components does not necessarily need to be insulated.

[0084] Furthermore, the outer surface of the winding portion 4 that comes into contact with the coil 13 does not necessarily need to be insulated.

[0085] Furthermore, in the stator members 1f and 1g, the material of the winding portion 4c does not have to be a copper-based material such as phosphor bronze. The material of the winding portion 4c may be, for example, resin. In this case, the winding portion 4c has insulating properties.

[0086] The first end face S1 may have three or more recesses R1.

[0087] The stator member 1 may have three or more winding sections 4.

[0088] In addition, in the stator member 1g, the winding portion 4c does not need to be fixed to the first end face S1 by inserting a portion of it into an insertion opening provided on the first end face S1. The winding portion 4c may also be fixed to the first end face S1 with adhesive.

[0089] The present invention has the following configuration.

[0090] (1) A stator component used in a rotating electric machine, A core back portion which is a molded body formed from soft magnetic powder, having an end face that faces a first direction along the rotation axis of the rotating electric machine when the stator member is incorporated into the rotating electric machine, and a first end and a second end which are both ends in the circumferential direction with respect to the rotation axis, The winding section around which the coil is wound, Equipped with, The winding portion is provided between the first end and the second end at the end face, Stator component.

[0091] (2) The end face is provided with a recess having a shape that is recessed in the opposite direction to the first direction, The winding portion is provided in the recess, (1) The stator member described above.

[0092] (3) The core back portion further has a third end and a fourth end, which are the ends in the radial direction with respect to the rotation axis, The winding portion is provided between the third end and the fourth end at the end face, (1) or (2) the stator member.

[0093] (4) A portion of the core back portion is located in the first direction from the contact surface between the end face and the winding portion, (1) to (3) the stator member described in any of these three terms.

[0094] (5) The number of the winding sections is 1. (1) to (4) the stator member described in any of these four terms.

[0095] (6) The number of winding sections is 2. (1) to (4) the stator member described in any of these four terms.

[0096] (7) The winding portion has conductivity, (1) Stator member as described in any of (6).

[0097] (8) The aforementioned winding portion has insulating properties. (1) Stator member as described in any of (6).

[0098] (9) The central part of the end face is provided with a recess having a shape that is recessed in the opposite direction to the first direction, The winding portion is provided in the recess, A portion of the core back portion is located in the first direction from the contact surface between the end face and the winding portion, (1) to (8) the stator member described in any of these.

[0099] (10) The core back portion and the winding portion are integrally formed by molding soft magnetic powder. (1) Stator member as described in any of (9).

[0100] (11) (1) The stator member is provided as described in any of (10) Rotating electrical machinery.

[0101] (12) A method for manufacturing a stator member as described in any of (1) to (9), The invention comprises a first forming step of integrally forming the core back portion and the winding portion by compression molding a soft magnetic powder mixture containing iron powder and binder powder. A method for manufacturing a stator component.

[0102] (13) A method for manufacturing a stator member as described in any of (1) to (9), The invention comprises a second forming step of forming the core back portion by compression molding the soft magnetic powder, which is a mixture of iron powder and binder powder, with the winding portion, and fixing the winding portion to the end face. A method for manufacturing a stator component.

[0103] (14) A method for manufacturing a stator member as described in any of (1) to (9), A core back portion forming step is performed by compression molding a soft magnetic powder mixture of iron powder and binder powder to form the core back portion having an insertion opening on its end face, A winding portion fixing step, in which a portion of the winding portion is inserted into the insertion opening to fix the winding portion to the end face, Equipped with, A method for manufacturing a stator component. [Explanation of symbols]

[0104] 1,1a~1g: Stator components 2: Core back section 3: Teeth Department 4,4a~4c: Wrapping section 10: Stator Assembly 11: Bearings 11a: First bearing 11b: Second bearing 12: Cabinet 12a: First enclosure 12b: Second cabinet 13: Coil 20: Rotor 21: Shaft 22: Rotor component 23: Soft magnetic material 24:Hard magnetic material 31: Teeth main body 32: Tooth tip 100: Brushless motor DI: Type DIR1: 1st direction DIR2:Second direction DIR3: Third direction DIR4: Fourth direction E1: 1st end E2: 2nd end E3: 3rd end E4: End of the fourth OP: Opening P: Punch R1, R1a, R1b: recessed S1: 1st end surface S2: 2nd end face T: Protrusion

Claims

1. A stator component used in a rotating electric machine, It consists of a teeth section and a core back section. The core back portion is When the stator member is incorporated into the rotating electric machine, the end face facing a first direction along the rotation axis of the rotating electric machine, The first end and the second end are the two ends in the circumferential direction with respect to the rotation axis, The part where the coil is wound, Equipped with, The aforementioned interlocking portion is provided between the first end and the second end on the end face, The core back portion is integrally formed by molding soft magnetic powder. Stator component.

2. The end face is provided with a recess having a shape that is recessed in the opposite direction to the first direction, The aforementioned interlocking portion is provided in the recess, The stator member according to claim 1.

3. The core back portion further has a third end and a fourth end, which are the ends in the radial direction with respect to the rotation axis, The aforementioned interlocking portion is provided between the third end and the fourth end on the end face. The stator member according to claim 1 or claim 2.

4. A portion of the core back portion is located in the first direction from the contact surface between the end face and the entanglement portion, The stator member according to claim 1 or claim 2.

5. The number of the aforementioned interlocking parts is 1. The stator member according to claim 1 or claim 2.

6. The number of the aforementioned interlocking parts is 2. The stator member according to claim 1 or claim 2.

7. The aforementioned entangled portion has conductivity, The stator member according to claim 1 or claim 2.

8. The aforementioned entangled portion has insulating properties. The stator member according to claim 1 or claim 2.

9. The central part of the end face is provided with a recess having a shape that is recessed in the opposite direction to the first direction. The aforementioned interlocking portion is provided in the recess, A portion of the core back portion is located in the first direction from the contact surface between the end face and the entanglement portion, The stator member according to claim 1 or claim 2.

10. A stator member comprising the stator member described in claim 1 or claim 2, Rotating electrical machinery.

11. A method for manufacturing a stator member according to claim 1 or claim 2, The invention comprises a first forming step of integrally forming the core back portion by compression molding a soft magnetic powder mixture of iron powder and binder powder. A method for manufacturing a stator component.

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