stata

Abstract

To provide a stator that improves vibration resistance.SOLUTION: A stator includes a conductive member, an annular-shaped case, and a magnetic body. The conductive member has a band-shaped outline wound in a spiral shape. The annular-shaped case accommodates the conductive member. The magnetic body passes through the annual-shaped case. The inner surface of the case includes a plurality of fitting portions in the direction of the winding axis of the conductive member. The conductive member includes the plurality of fitting portions in the direction of the winding axis of the conductive member.SELECTED DRAWING: Figure 5

Description

Technical Field

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[0001] The present invention relates to a stator.

Background Art

[0002] With the increase in the output of motors, in order to cope with the increase in power, techniques using edgewise coils that can increase the cross-sectional area of coils and flat coils conforming to their shapes are known. The flat coil is arranged on the magnetic body of the stator by being inserted into, for example, a bobbin or the like.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] Since the flat coil has a spring shape, it is likely to resonate with the vibration of the motor. In addition, when the flat coil is arranged on the magnetic body of the stator, the flat coil may not be sufficiently fixed, so the vibration resistance may decrease.

[0005] On one side, an object is to provide a stator that can improve vibration resistance.

Means for Solving the Problems

[0006] In one embodiment, the stator comprises a conductive member, an annular case, and a magnetic material. The conductive member has a strip-like outer shape that is wound in a spiral. The annular case houses the conductive member. The magnetic material passes through the annular case. The inner surface of the case has a plurality of fitting portions in the winding axis direction of the conductive member. The conductive member has a plurality of fitted portions in the winding axis direction of the conductive member.

[0007] In one embodiment, vibration resistance can be improved. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing an example of a segmented core attached to a stator core in an embodiment. [Figure 2] Figure 2 is a perspective view showing an example of a divided core in an embodiment. [Figure 3] Figure 3 is a perspective view showing an example of a divided core in an embodiment. [Figure 4] Figure 4 is an exploded perspective view showing an example of a divided core in an embodiment. [Figure 5] Figure 5 is an exploded perspective view showing an example of a divided core in an embodiment. [Figure 6] Figure 6 is a perspective view showing an example of a segmented core in the first modified example. [Figure 7] Figure 7 is an exploded perspective view showing an example of a segmented core in the first modified example. [Figure 8] Figure 8 is an exploded perspective view showing an example of a segmented core in the first modified example. [Figure 9] Figure 9 is a perspective view showing an example of the process of attaching the coil to the housing in a second modified example. [Figure 10] Figure 10 is a perspective view showing an example of a segmented core in a second modified example. [Figure 11] Figure 11 is a cross-sectional perspective view showing an example of a segmented core in a second modified example. [Figure 12]Figure 12 is a perspective view showing an example of the process of attaching the coil to the housing in a third modified example. [Figure 13] Figure 13 is a perspective view showing an example of a coil housed in a third modification. [Figure 14] Figure 14 is an enlarged perspective view showing an example of the engagement portion of the coil housed in the housing in a third modified example. [Modes for carrying out the invention]

[0009] The embodiments of the stator disclosed in this application will be described in detail below with reference to the drawings. Note that the dimensional relationships and ratios of each element in the drawings may differ from those in reality. There may also be differences in dimensional relationships and ratios between drawings. In some drawings, for the sake of clarity, a coordinate system may be shown in which the direction in which the shaft 99 (described later) extends is defined as the axial direction, and the radially outer side of the rotor 91 (described later) is defined as the positive direction.

[0010] [Embodiment] First, the stator in the embodiment will be described using Figure 1. Figure 1 is a perspective view showing an example of a segmented core attached to the stator core in the embodiment. As shown in Figure 1, the motor 1 in this embodiment comprises a stator 80 and a rotor 91. The motor 1 is a so-called inner rotor type motor in which, for example, the rotor 91 is arranged radially inward relative to the stator 80. The motor 1 is also housed in a frame, for example, not shown.

[0011] The rotor 91 is rotatably mounted in the motor 1 around the shaft 99, which is the axis of rotation. The rotor 91 comprises the shaft 99, a rotor yoke (yoke), and a magnet (not shown).

[0012] The shaft 99 is a rotation axis and is formed in a cylindrical shape at the innermost part in the radial direction of the rotor 91. The rotor yoke is formed in a cylindrical shape from a magnetic material such as iron, for example. And the inner peripheral surface of the rotor 91 is arranged so as to contact the outer peripheral surface of the shaft 99.

[0013] The stator 80 includes a stator core 81 and a plurality of divided cores 2. The stator core 81 is an annular member formed by axially laminating a plurality of magnetic bodies such as stainless steel or magnetic steel sheets, for example. As shown in FIG. 1, a plurality of recesses 84 recessed outward in the radial direction are formed on the inner peripheral surface of the stator core 81.

[0014] The plurality of divided cores 2 are respectively fixed to the recesses 84 of the stator core 81. Although only one divided core 2 is shown in FIG. 1, the divided cores 2 are respectively accommodated in, for example, the 12 recesses 84 shown in FIG. 1.

[0015] As shown in FIGS. 2 and 3, the divided core 2 in the embodiment includes a magnetic body 10, a case 20, and a coil 50. FIGS. 2 and 3 are perspective views showing an example of the divided core in the embodiment. FIG. 2 shows the divided core 2 as viewed from the negative direction side in the radial direction, that is, from the inside, and FIG. 3 shows the divided core 2 as viewed from the positive direction side in the radial direction, that is, from the outside.

[0016] As shown in FIGS. 4 and 5, the coil 50 as a conductive member has a belt-shaped outer shape 54 wound in a spiral shape. FIGS. 4 and 5 are exploded perspective views showing an example of the divided core in the embodiment. FIG. 4 shows the components constituting the divided core 2 as viewed from the negative direction side in the radial direction, that is, from the inside, and FIG. 5 shows the components constituting the divided core 2 as viewed from the positive direction side in the radial direction, that is, from the outside. The coil 50 is a coil such as an edgewise coil that can increase the cross-sectional area, for example. The coil 50 is formed by spirally winding a flat conductive member made of a metal such as copper with the radial direction as the winding axis direction. The belt-shaped outer shape 54 is wound in a substantially rectangular shape with respect to the winding axis direction. Note that the coil 50 is an example of a conductive member.

[0017] Furthermore, as shown in Figures 4 and 5, the coil 50 has terminals 51 and 52 that protrude in the positive direction in the axial direction. Terminal 51 is located on the negative side in the radial direction, and terminal 52 is located on the positive side in the radial direction.

[0018] Furthermore, the coil 50 has through holes 53a to 53c and a hole portion 54e that extend radially, i.e., in the winding axis direction of the coil 50. The through holes 53a to 53c are formed, for example, in the parts of the four corners of the substantially rectangular outer shape 54 where terminals 51 and 52 are not formed. The hole portion 54e is the part enclosed by the outer shape 54. Note that the through holes 53a to 53c are examples of multiple mating portions.

[0019] The magnetic material 10 is formed by stacking metal plates, such as stainless steel, in the axial direction. As shown in Figure 3, the magnetic material 10 has a first portion 11 and a pair of second portions 12. The first portion 11 extends outward in the winding axis direction, i.e., radially, as shown in Figure 4. A portion of the first portion 11 protrudes radially outward in the divided core 2 and fits into a recess 84 of the stator core 81, as shown in Figure 1. The second portions 12 extend away from the first portion 11 in both directions in the circumferential direction.

[0020] The case 20 shown in Figures 2 and 3 is, for example, made of resin and has a housing 30 located radially inward and a lid 40 located radially outward. The coil 50 is housed in the housing 30 and covered radially outward by the lid 40, as shown in Figures 4 and 5.

[0021] As shown in Figures 4 and 5, the housing 30 has a rear surface 31, an inner wall 32, and an outer wall 33. The rear surface 31 is located on the negative radial side. The inner wall 32 and the outer wall 33 extend from the rear surface 31 on the positive radial side. The portion enclosed by the inner wall 32 forms a through hole 32e that extends radially. An opening 35e is formed between the inner wall 32 and the outer wall 33, opening on the positive radial side. The outer wall 33 also has an opening 33d that opens on the positive axial side, as shown in Figures 4 and 5.

[0022] On the radially positive side surface of the back surface 31 of the housing 30, three protrusions 34a to 34c are formed that project outward in the winding axis direction of the coil 50, i.e., in the radial direction. Each of the protrusions 34a to 34c is formed at a position corresponding to the through holes 53a to 53c of the coil 50. In this case, protrusion 34a faces the through hole 53a, protrusion 34b faces the through hole 53b, and protrusion 34c faces the through hole 53c in the radial direction. Note that the radially positive side surface of the back surface 31 of the housing 30 is an example of the inner surface of the case, and the protrusions 34a to 34c are an example of multiple fitting parts.

[0023] As shown in Figures 4 and 5, when the coil 50 is housed in the housing 30, the protruding portions 34a to 34c, which are the fitting portions, fit into the through holes 53a to 53c, which are the fitted portions. That is, the inner surface 31 of the housing 30 has a plurality of fitting portions 34a to 34c in the winding axis direction of the coil 50. The coil 50 also has a plurality of fitted portions 53a to 53c in the winding axis direction of the coil 50. Furthermore, the fitting portions 34a to 34c of the inner surface 31 of the housing 30 are protruding portions that extend in the winding axis direction of the coil 50, and the fitted portions 53a to 53c of the coil 50 are holes. In this case, the protruding portion 34a is in the hole 53a, the protruding portion 34b is in the hole 53b, and the protruding portion 34c is in the hole 53c.

[0024] Furthermore, as shown in Figures 4 and 5, the magnetic material 10 is inserted through the through hole 32e on the inside of the housing 30 from the negative radial side. The coil 50 is housed in the opening 35e from the positive radial side. In this case, the inner surface of the inner wall 32 faces and contacts the first portion 11 of the magnetic material 10, while the outer surface of the inner wall 32 faces and contacts the hole 54e of the coil 50. In this case, the resin inner wall 32 insulates the first portion 11 of the magnetic material 10 from the coil 50. Also, as shown in Figures 2 and 3, the terminals 51 and 52 of the coil 50 protrude in the positive axial direction from the opening 33d formed in the outer wall 33 of the housing 30.

[0025] The lid 40 also has three through holes 43a to 43c and a hole 45e. The through holes 43a to 43c are formed at positions corresponding to the protrusions 34a to 34c of the housing 30, and the hole 45e is formed at a position corresponding to the inner wall 32 of the housing 30. In this case, the protrusion 34a fits into the through hole 43a, the protrusion 34b fits into the through hole 43b, and the protrusion 34c fits into the through hole 43c. The hole 45e fits into the inner wall 32.

[0026] As described above, the stator in this embodiment comprises a conductive member (coil 50) having a strip-shaped outer shape and wound in a spiral, an annular case 20 housing the coil 50, and a magnetic body 10 passing through the annular case 20. The inner surface 31 of the case 20 is provided with a plurality of fitting portions 34a to 34c in the winding axis direction of the coil 50, and the coil 50 is provided with a plurality of fitted portions 53a to 53c in the winding axis direction of the coil 50. With this configuration, the conductive member can be more securely fixed to the stator, thereby improving vibration resistance.

[0027] Furthermore, from the viewpoint of increasing the cross-sectional area of ​​the coil 50, it is preferable to reduce the cross-sectional area of ​​the holes 53a to 53c formed in the coil 50.

[0028] Although the configuration of this embodiment has been described above, the embodiment is not limited thereto. For example, the protrusions 34a to 34c may be formed on the lid 40, or the lid may be located on the negative side in the radial direction. Furthermore, although the configuration in which the case 20 comprises a housing 30 and a lid 40 has been described, the housing and the lid may be formed integrally.

[0029] Furthermore, the holes 53a to 53c of the coil 50 may not be holes that penetrate in the winding axis direction, but rather recesses that do not penetrate in the winding axis direction. In this case, the lid 40 may also have protrusions that project toward the positive direction in the winding axis direction, and the coil may have recesses that are recessed toward the negative direction in the winding axis direction and engage with the protrusions 34a to 34c of the case 20, and recesses that are recessed toward the positive direction in the winding axis direction and engage with the protrusions of the lid 40.

[0030] Furthermore, although a configuration in which both terminals 51 and 52 protrude in the positive direction in the axial direction has been described, the embodiments are not limited to this. For example, the terminals may protrude in other directions, such as the negative direction in the axial direction or the radially outward direction, and the two terminals may each face in different directions.

[0031] [First variation] Furthermore, as shown in Figure 6, the conductive member may be configured such that the second portion of the magnetic material and the outer surface of the case facing the second portion of the magnetic material are fitted together in the winding axis direction. Figure 6 is a perspective view showing an example of a divided core in the first modified example. In the following embodiments and modified examples, the same reference numerals are used for the same parts as those shown in the drawings described earlier, and redundant explanations are omitted.

[0032] As shown in Figure 6, the divided core 3 in the first modified example comprises a magnetic material 100, a coil 50, and a case 200. The case 200 comprises a housing 300 and a lid 40. The shape of the divided core 3 in the first modified example, as viewed from the positive radial direction, is substantially the same as the shape of the divided core 2 shown in Figure 3.

[0033] As shown in Figures 7 and 8, in the first modified example, the second portion 120 of the magnetic material 100 has two recesses 12a and 12b that are recessed radially outward. Figures 7 and 8 are exploded perspective views showing an example of a divided core in the first modified example. As shown in Figure 7, the two recesses 12a and 12b are formed on one side and the other side in the circumferential direction of the first portion 11 of the magnetic material 100, respectively. The recesses 12a and 12b are examples of the mating portions of the second portion of the magnetic material.

[0034] Furthermore, as shown in Figure 7, the radially negative side surface of the back surface 310 of the housing 300 is provided with protrusions 31a and 31b. Protrusion 31a is formed in the radial direction opposite to recess 12a, and protrusion 31b is formed in the radial direction opposite to recess 12b. Note that the radially negative side surface of the back surface 310 of the housing 300 is an example of the outer surface of the case, and protrusions 31a and 31b are examples of fitting portions of the outer surface of the case.

[0035] In the first modified example, the protrusion 31a fits into the recess 12a of the second portion 120 of the magnetic material 100, as shown in Figure 6. Similarly, the protrusion 31b fits into the recess 12b. That is, the fitting portions 31a and 31b of the outer surface 310 of the case 200 facing the second portion 120 of the magnetic material 100 are protrusions extending in the winding axis direction of the coil 50, and the fitted portions 12a and 12b of the second portion 120 of the magnetic material 100 are recesses, with the protrusion 31a located within the recess 12a. Also, the protrusion 31b is located within the recess 12b.

[0036] Alternatively, instead of forming a recess in the magnetic material 100 and a protrusion in the case 200, a protrusion may be formed on the magnetic material and a recess or notch may be formed on the case. Furthermore, a configuration may be used in which a recess is formed on one side of the magnetic material 100 in the circumferential direction and a protrusion is formed on the other side. In such a configuration, the magnetic material 100 and the housing 300 are fitted together by forming a protrusion on one side of the housing 300 in the circumferential direction and a recess on the other side.

[0037] As described above, in the stator of the first modified example, the magnetic body 100 comprises a first portion 11 extending in the winding axis direction of the coil 50 and a second portion 120 extending in a direction away from the first portion 11. Furthermore, in the winding axis direction of the coil 50, the second portion 120 of the magnetic body 100 is fitted to the outer surface 310 of the housing 300 that faces the second portion 120 of the magnetic body 100. With this configuration, the vibration resistance of the divided core 3 can be further improved by fitting the case 200 to which the coil 50 is fixed with the magnetic body 100.

[0038] [Second variation] Furthermore, as shown in Figure 5, the external shape of the coil 50 in this embodiment is substantially the same as the internal shape of the outer wall 33 of the case 20, but the embodiment is not limited to this. For example, if the external shape of the conductive member is smaller than the internal diameter of the outer wall 33 of the case, the gap between the outer wall 33 of the case and the conductive member housed in the case may be covered with a resin such as varnish.

[0039] Figure 9 is a perspective view showing an example of the process of attaching the coil to the housing in the second modified example. As shown in Figure 9, in the split core 4 of the second modified example, the width W2 of the outer shape 64 of the coil 60 is slightly smaller than the width W1 of the opening 35e. In this case, the outer shape 64 of the coil 60 and the outer wall 33 of the case 20 face each other with a gap G1 in between. Note that the coil 60 is another example of a conductive member.

[0040] Figure 10 is a perspective view showing an example of a split core in the second modified example. As shown in Figure 10, the width W3 of terminals 61 and 62 of coil 60 is smaller than the width of terminals 51 and 52 of coil 50 in the split core 3 in the first modified example. In this case, a gap G2 is formed between one end of coil 60 and terminals 61 and 62 in the circumferential direction of the opening 33d. The appearance of the split core 4 is substantially the same as that of the split core 2 shown in Figures 2 and 3, except for the width of terminals 61 and 62 described above.

[0041] In the second modified example, after the coil 60 is housed in the case 200, the gaps G1 and G2 between the coil 60 and the outer wall 33 of the housing 30 of the case 20 are filled with a liquid resin, such as varnish. The resin is filled, for example, from the opening 33d of the housing 30 toward the negative direction in the axial direction. Then, as the filled resin hardens, a resin member 69 is formed.

[0042] Figure 11 is a cross-sectional perspective view showing an example of a segmented core in a second modified example. Figure 11 shows a cross-section obtained by cutting Figure 10 along plane S1. As shown in Figure 11, the outer shape 64 of the coil 60 faces the outer wall 33 of the housing 30 via a resin member 69, which is another component. In this case, the coil 60 is fixed to the case 20 via the resin member 69. The portion of the opening 33d may also be covered with the resin member 69.

[0043] In this configuration, a resin member 69 is located inside the case 20, and the resin member 69 covers a portion of the coil 60. This ensures that the coil 60 is more securely fixed to the divided core 4, and vibrations are absorbed by the resin member 69, thus further suppressing the transmission of vibrations from the motor 1 to the coil 60. Furthermore, heat dissipation from the coil 60 is promoted through the resin member 69 and the case 20, which have good thermal conductivity.

[0044] [Third variation] Furthermore, the conductive member may be configured to have recesses radially opposite to the protrusions 34a to 34c, instead of through holes 53a to 53c that engage with the protrusions 34a to 34c, as shown in Figure 12. Figure 12 is a perspective view showing an example of the process of attaching the coil to the housing in the third modified example. The coil 600 shown in Figure 12 has a recess 65a in which a part of the outer shape 640 is cut out at a position radially opposite to the protrusion 34a of the housing 30. Similarly, the coil 600 has a recess 65b at a position radially opposite to the protrusion 34b, and a recess 65c at a position radially opposite to the protrusion 34c.

[0045] In this configuration, when the coil 600 is housed in the housing 30, the recesses 65a to 65c of the coil 600 contact the protrusions 34a to 34c of the housing 30 in the axial and circumferential directions, respectively, as shown in Figure 13. Figure 13 is a perspective view showing an example of a coil housed in the housing in the third modified example. Figure 13 shows the state in which the lid 40 and magnetic material 10 have been removed from the divided core 5 in the third modified example. The shape of the divided core 5 in the third modified example is substantially the same as the shape of the divided core 4 in the second modified example shown in Figure 10.

[0046] Similar to the second modified example, as shown in Figure 13, a resin member 691, which is part of the resin member 690, is present in the gap between the outer shape 640 of the coil 600 housed in the housing 30 and the outer wall 33 of the housing 30.

[0047] Furthermore, in the third modified example, a portion 69b of the resin member 690 exists between the recess 65b and the outer wall 33, as shown in Figures 13 and 14. Figure 14 is an enlarged perspective view showing an example of the engagement portion of the coil housed in the housing in the third modified example. Figure 14 is an enlarged view of the portion shown in frame F1 of Figure 13. Similarly, a portion 69a of the resin member 690 exists between the recess 65a and the outer wall 33, and a portion 69c of the resin member 690 exists between the recess 65c and the outer wall 33. With this configuration, the volume of the resin member 690 that fixes the coil 600 can be increased, thereby further improving vibration resistance.

[0048] Furthermore, as in the second and third modified examples, if the conductive member can be fixed to the case by a resin member 69 or the like, the case may be configured such that it does not have a lid 40.

[0049] Furthermore, the stator in the embodiment and each modification may be used in a so-called outer rotor type motor in which the stator is located radially inward relative to the rotor.

[0050] Furthermore, the embodiments and their respective modifications may be combined as appropriate. For example, in the second and third modifications, the magnetic material 100 and case 200 shown in the first modification may be used instead of the magnetic material 10 and case 20 shown in the embodiment.

[0051] Although the present invention has been described above based on embodiments and various modifications, it goes without saying that the present invention is not limited to embodiments and various modifications, and that various modifications are possible without departing from the spirit of the invention. Various modifications that do not depart from the spirit are also included in the technical scope of the present invention, and this will be clear to those skilled in the art from the description of the claims. [Explanation of Symbols]

[0052] 1 Motor, 2,3,4,5 Split core, 10,100 Magnetic material, 11 First part, 12,120 Second part, 20,200 Case, 30,300 Housing, 31,310 Back, 31a~31b Protrusion, 32 Inner wall, 32e Through hole, 33 Outer wall, 33d Opening, 34a~34c Protrusion, 35e Opening, 40 Cover, 43a~43c Through hole, 45e Hole, 50,60,600 Coil, 51,52,61,62 Terminal, 53a~53c Through hole, 54,64,640 Outer shape, 54e Hole, 65a~65c Recess, 69,690 Resin component, 80 Stator, 81 Stator core, 84 Recess, 91 Rotor, 99 shaft

Claims

1. A conductive member having a spiral winding and a strip-like outer shape, An annular case for housing the conductive member, The device comprises a magnetic material passing through the aforementioned annular case, The inner surface of the case is provided with a plurality of fitting portions in the winding axis direction of the conductive member, The conductive member has a plurality of fitting portions in the winding axis direction of the conductive member. stata.

2. The aforementioned case contains a resin component, The resin member covers a part of the conductive member. The stator according to claim 1.

3. The fitting portion on the inner surface of the case is a protrusion extending in the winding axis direction of the conductive member, The fitting portion of the conductive member is a hole, The protruding portion is located inside the hole. The stator according to claim 1.

4. The magnetic material comprises a first portion extending in the winding axis direction of the conductive member and a second portion extending in a direction away from the first portion. In the winding axis direction of the conductive member, the second portion of the magnetic material and the outer surface of the case facing the second portion of the magnetic material are fitted together. A stator according to any one of claims 1 to 3.

5. The fitting portion on the outer surface of the case facing the second portion of the magnetic material is a protrusion extending in the winding axis direction of the conductive member, The fitting portion of the second part of the magnetic material is a recess, The protruding portion is located within the recess. The stator according to claim 4.

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