motor

Abstract

To provide a motor which is appropriately molded.SOLUTION: A motor 1 comprises: a stator 20; a substrate 30 that is supported by the stator 20; and a resin member 50 that covers the stator 20. In a shaft direction, the substrate 30 comprises: a first surface 30F that is opposite to the stator 20; and a second surface 30S on the side opposite to the first surface 30F. The first surface 30F of the substrate 30 is contacted to the resin member 50, the second surface 30S of the substrate 30 comprises: an inner peripheral part 30i; an outer peripheral part 30o; and an intermediate part 30m existed between the inner peripheral part 30i and the outer peripheral part 30o. In the intermediate part 30m, at least one conductive pad 40 is provided, and a concave part 45 surrounding the pad 40 is formed. An end part of the concave part 45 in a radial direction is formed in an outer side d from the inner peripheral part 30i in the radial direction and an inner side c from the outer peripheral part 30o in the radial direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a motor.

Background Art

[0002] A motor in which a stator, a substrate for supplying power to the stator, etc. are molded is known (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the motor as described in Patent Document 1 above, a properly molded motor is required.

[0005] Therefore, one of the problems of the present invention is to provide a motor that is properly molded.

Means for Solving the Problems

[0006] The motor of the present invention includes a stator, a substrate supported by the stator, and a resin member covering the stator. In the axial direction, the substrate has a first surface facing the stator and a second surface on the opposite side of the first surface. The first surface of the substrate is in contact with the resin member. The second surface of the substrate includes an inner peripheral portion, an outer peripheral portion, and an intermediate portion between the inner peripheral portion and the outer peripheral portion. At least one conductive pad is provided in the intermediate portion, and a recess surrounding the pad is formed. The radial end portion of the recess is formed on the radially outer side of the inner peripheral portion and on the radially inner side of the outer peripheral portion.

[0007] Such a motor may further include at least one of the following configurations:

[0008] The recess may be formed in the shape of a polygon or a closed curve, and the pad may be provided within the polygon or closed curve shape. The recess may be formed only in the intermediate portion. Alternatively, the device may have three pads including the pad, and three recesses including the recess, with each of the three pads corresponding to one of the U phase, V phase, and W phase, and each of the three recesses surrounding one of the three pads. The substrate is formed by alternately stacking a plurality of conductor layers and a plurality of insulating layers, and the outer periphery of the substrate is provided with a connection portion that is electrically connected to the stator, and the pad is provided in the first conductor layer located at the axial end of the substrate, and the pad and the connection portion may be electrically connected in the conductor layers of the other layers except for the first conductor layer. In this case, the recess may penetrate the first conductor layer in the axial direction. The substrate is provided with annular portions on both the outer and inner periphery, and the radial ends of the recesses may be located on the intermediate side of each annular portion. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view showing a motor in an embodiment of the present invention. [Figure 2] Figure 1 is a perspective view showing the stator assembly of the motor. [Figure 3] Figure 2 is a plan view of the stator assembly as seen from one side in the axial direction. [Figure 4] Figure 3 is a cross-sectional view of the stator assembly in the axial direction. [Figure 5] Figure 2 is a perspective view of the stator assembly, excluding the resin components. [Figure 6] Figure 5 is a perspective view showing the stator and substrate separated in the stator assembly. [Figure 7]This figure schematically shows a portion of the cross-sectional view of the substrate along line VII-VII shown in Figure 6. [Figure 8] This diagram illustrates some of the steps in the manufacturing process of the assembly shown in Figure 2. [Modes for carrying out the invention]

[0010] The following examples illustrate embodiments of the motor according to the present invention, along with the accompanying drawings. The embodiments illustrated below are provided to facilitate understanding of the present invention and are not intended to limit its interpretation. The present invention can be modified and improved from the following embodiments without departing from its spirit. In addition, in the accompanying drawings, the dimensions of each component may be exaggerated or reduced, or hatching may be omitted, in order to facilitate understanding.

[0011] Figure 1 is a perspective view showing a motor in an embodiment. As shown in Figure 1, the motor 1 includes a rotor 10 and a stator assembly 60 arranged concentrically with respect to the central axis X. The type of motor 1 is not particularly limited, but in this embodiment, the motor 1 is an AC motor, and more specifically, it is configured as a 2-pole 3-phase induction motor. The rotor 10 and the stator assembly 60 are each formed in a cylindrical shape with a thickness equal to the length in the direction of the central axis X (hereinafter simply referred to as the "axial direction"). Figure 1 is a perspective view of the motor 1 from side a in the axial direction. The side opposite to side a in the axial direction will be referred to as side b. If the direction perpendicular to the axial direction is defined as the radial direction, in this embodiment, each of the rotor 10 and the stator assembly 60 is formed in a thin shape with a radial length (i.e., outer diameter) that is larger than the axial thickness. Also, in this embodiment, the thickness of the rotor 10 is smaller than the thickness of the stator assembly 60. In the radial direction, the side approaching the central axis X will be referred to as the inner side c, and the side moving away from the central axis X will be referred to as the outer side d.

[0012] For example, the stator assembly 60 may be fixed inside a housing (not shown), and the rotor 10 may be rotatably supported inside the housing relative to the housing and the stator assembly 60.

[0013] The rotor 10 includes a cylindrical rotor core 11 centered on a central axis X, and a plurality of magnets 12 arranged radially within the rotor core 11 and supported by the rotor core 11. In this embodiment, each of the magnets 12 is rectangular when viewed from the axial direction and extends generally parallel to one another. The direction of extension of each of the magnets 12 may be parallel to the axial direction or inclined with respect to the axial direction. The rotor core 11 may be made of laminated silicon steel sheets, although this is not particularly limited. Furthermore, a rotating shaft (not shown) may be attached to the inner circumferential surface 11i of the rotor core 11, for example by press-fitting, and this rotating shaft may protrude to the outside of the housing.

[0014] Next, the stator assembly 60 will be described. Figure 2 is a perspective view of the stator assembly 60 viewed from side a in the axial direction, Figure 3 is a plan view of the stator assembly 60 viewed from side a in the axial direction, and Figure 4 is a cross-sectional view of the stator assembly 60 in the axial direction. As shown in Figures 2 to 4, the stator assembly 60 includes a stator 20, a substrate 30, and a resin member 50. The resin member 50 partially covers the stator 20 and the substrate 30. This point will be explained again later.

[0015] Figures 5 and 6 show the stator assembly 60 with the resin member 50 removed. Specifically, Figure 5 is a perspective view of the stator 20 and substrate 30 as seen from the axial side a, and Figure 6 shows the stator 20 and substrate 30 separated.

[0016] As shown in Figures 5 and 6, the stator 20 is formed in a thin cylindrical shape with a central axis X. In this embodiment, the stator 20 is configured as an assembly of a plurality of stator components 21 arranged in a ring shape along the circumferential direction. The number of stator components 21 is not particularly limited, but in this embodiment there are 18. Each of the stator components 21 has a similar configuration except for the winding direction of the coil. As shown in Figures 4 to 6, each of the plurality of stator components 21 includes an iron core 24, an insulator 22, and a coil 23. The iron core 24 may be made of, for example, laminated silicon steel sheets. Most of the iron core 24 is covered and insulated by the insulator 22. On the other hand, the inner circumferential surface 24i and the outer circumferential surface 24o of the iron core 24 are exposed from the insulator 22. The inner circumferential surface 24i is the radially inner surface c of the iron core 24, and the outer circumferential surface 24o is the radially outer surface d. The coil 23 is wound around the iron core 24 via the insulator 22. When viewed from the axial direction a, the inner circumferential surfaces 24i of each of the multiple stator components 21 are generally arranged on a first circle C1 centered on the central axis X, and the outer circumferential surfaces 24o of each of the multiple stator components 21 are generally arranged on a second circle C2 which has a larger diameter than the first circle C1 centered on the central axis X. Furthermore, two stator components 21 adjacent to each other in the circumferential direction are arranged with their inner circumferential portions 21i and outer circumferential portions 21o in contact with each other in the circumferential direction. As a result, a gap G is formed between the portions of stator components 21 adjacent to each other in the circumferential direction, excluding the inner circumferential portions 21i and outer circumferential portions 21o. The inner circumferential portion 21i includes the inner circumferential surface 24i, and the outer circumferential portion 21o includes the outer circumferential surface 24o.

[0017] Terminal pins 25 are provided at each of the radially outer ends d of the coil 23 in the circumferential direction. The terminal pins 25 extend from the coil 23 toward side a, generally parallel to the axial direction. The starting end (winding start) of the coil 23 is wound around one of the two terminal pins 25, 25, and the ending end (winding end) of the coil 23 is wound around the other. Current is supplied to the coil 23 through these terminal pins 25, 25.

[0018] As shown in FIGS. 4 to 6, the substrate 30 is a ring-shaped plate member centered on the central axis X. The substrate 30 is disposed on the a side in the axial direction with respect to the stator 20. The inner diameter of the substrate 30 (that is, the diameter of the inner peripheral portion 30ie of the substrate 30) is substantially the same as the diameter of the first circle C1 of the stator 20. The outer diameter of the substrate 30 (that is, the diameter of the outer peripheral portion 30oe of the substrate 30) is smaller than the diameter of the second circle C2 of the stator 20, and in the radial direction, the position of the outer peripheral portion 30oe of the substrate 30 substantially coincides with the position of the outer peripheral edge 22oe of the insulator 22. In the outer peripheral portion 30oe of the substrate 30, semicircular cutouts 39 having substantially the same diameter are formed at substantially equal intervals over the entire circumferential direction. Each of these cutouts 39 is formed corresponding to each of the plurality of terminal pins 25 described above, and is formed so that each of the terminal pins 25 can be fitted therein. Therefore, when each of the terminal pins 25 is fitted into each of the cutouts 39, the substrate 30 is supported by the stator 20, and the plurality of stator components 21 are positioned and fixed to each other via the substrate 30. Thus, in the motor 1, a plurality of terminal pins 25 are provided on the outer peripheral portion 30oe of the substrate 30. When viewed from the a side in the axial direction, the substrate 30 covers most of the stator 20.

[0019] FIG. 7 is a cross-sectional view showing a part of the substrate 30 taken along the line VII-VII shown in FIG. 6, that is, a cross-sectional view in the axial direction showing a part of the substrate 30. As shown in FIG. 7, the substrate 30 includes a first surface 30F on the b side in the axial direction and a second surface 30S on the a side. As shown in FIG. 4, in the axial direction, the first surface 30F faces the stator 20, and a minute gap L is formed between the first surface 30F and the stator 20. In the present embodiment, this gap L is filled with the resin member 50.

[0020] As shown in FIGS. 6 and 7, the second surface 30S includes an inner peripheral portion 30i located on the inner side c in the radial direction, an outer peripheral portion 30o located on the outer side d in the radial direction, and an intermediate portion 30m between the inner peripheral portion 30i and the outer peripheral portion 30o. The inner peripheral portion 30i includes the end portion on the a side of the inner peripheral portion 30ie. The outer peripheral portion 30o includes the end portion on the a side of the outer peripheral portion 30oe. The outer peripheral portion 30o has a first region 30o1 located on the outer side d including the end portion on the a side of the outer peripheral portion 30oe, and a second region 30o2 located on the inner side c relative to the first region 30o1. The second surface 30S is coated with a first material 41 having insulation properties, except for a part thereof. Further, on the inner peripheral portion 30i of the second surface 30S, a second material 42 is annularly coated on the first material 41, and this second material 42 forms an annular portion. Further, on the second region 30o2 of the outer peripheral portion 30o, a third material 43 is annularly coated on the first material 41, and this third material 43 forms an annular portion. Regarding the first material 41, the second material 42, and the third material 43, all of them may be formed from the same material (for example, insulating ink), two of them may be formed from the same material, or all of them may be formed from different materials. Further, when the first material 41, the second material 42, and the third material 43 are ink, they may be coated on the second surface 30S by screen printing.

[0021] As shown in Figures 6 and 7, the intermediate portion 30m of the second surface 30S has at least one (three in this embodiment) area 31mn where the first material 41 is not applied. In this embodiment, a conductive pad 40 is placed over each of the three areas 31mn where the first material 41 is not applied. When viewed from the axial direction a, each of the three pads 40 substantially covers each of the areas 31mn where the first material 41 is not applied. Three recesses 45 are formed in the intermediate portion 30m in a one-to-one correspondence, corresponding to each of the three pads. That is, one recess 45 surrounds one corresponding pad 40. Each of the three recesses 45 is formed only in the intermediate portion 30m, and the radial end of each recess 45 is formed radially outward d from the inner circumference 30i and radially inward c from the outer circumference 30o. Furthermore, each of the three recesses 45 is located on the intermediate 30m side of the annular portion formed by the second material 42 and the annular portion formed by the third material 43, respectively. In this embodiment, each of the three recesses 45 is generally rectangular when viewed from side a. The shape of the recesses 45 is not particularly limited, but it is preferable that they be polygonal or closed curved when viewed from side a.

[0022] As shown in Figure 7, in this embodiment, the substrate 30 is formed by alternately stacking a plurality of conductive layers and a plurality of insulating layers. The conductive layers may be made of a conductor such as copper, and the insulating layers may be made of an insulating resin, for example. Specifically, the substrate 30 is formed by stacking the first conductive layer 31, the first insulating layer 35, the second conductive layer 32, the second insulating layer 36, the third conductive layer 33, the third insulating layer 37, and the fourth conductive layer 34 in the order of a-side, b-side, in the axial direction. That is, the first conductive layer 31 is the first conductive layer located at one end (a-side) in the axial direction, and the second surface 30S of the substrate 30 is the a-side surface of the first conductive layer 31. The fourth conductive layer 34 is the fourth conductive layer located at the other end (b-side) in the axial direction, and the first surface 30F is the b-side surface of the fourth conductive layer 34.

[0023] In this embodiment, in the region shown in Figure 7, a plurality of through-holes 46 are provided in the portion 31mn where the first material 41 is not applied (hereinafter referred to as the "conductor exposed portion 31mn"), and the first conductor layer 31 and the second conductor layer 32 are electrically connected through these through-holes 46. Therefore, the current from the pad 40 provided in the region shown in Figure 7 flows through the conductor exposed portion 31mn, through the through-holes 46, and to the second conductor layer 32. In this embodiment, a predetermined terminal pin 25 among the plurality of terminal pins 25 is electrically connected to the second conductor layer 32 in the region shown in Figure 7. That is, in this embodiment, the predetermined terminal pin 25 and the pad 40 are electrically connected in the second conductor layer 32. Thus, the current from the pad 40 flows through the coil 23 connected to the predetermined terminal pin 25 via the second conductor layer 32, excluding the first conductor layer 31. Furthermore, in a region different from the region shown in Figure 7, for example, one terminal pin 25 of one of any two coils 23 and one terminal pin 25 of the other coil may be electrically connected by the third conductor layer 33, and the other terminal pin 25 of the one coil 23 may be electrically connected to a region of the second conductor layer 32 that is electrically connected to the pad 40. In this case, the pad 40, one terminal pin 25 of one coil 23, and one terminal pin 25 of the other coil 23 are electrically connected via the second conductor layer 32 and the third conductor layer 33. Therefore, current from the pad 40 flows through the two coils 23 via the second conductor layer 32 and the third conductor layer 33. In yet another region, the two coils 23 may be connected to each other by the fourth conductor layer 34. Thus, in this embodiment, multiple coils 23 are electrically connected via multilayer conductor layers. In other words, in this embodiment, terminal pins 25 (connection parts) that are electrically connected to the stator 20 are provided on the outer peripheral portion 30o of the substrate 30, and the pads 40 are provided on the first conductor layer 31 of the first layer located at the axial end of the substrate 30, and the pads 40 and the terminal pins 25 (connection parts) are electrically connected by the conductor layers of the other layers (second conductor layer 32, third conductor layer 33, and fourth conductor layer 34) excluding the first conductor layer 31 of the first layer.

[0024] In this embodiment, each of the three pads 40 corresponds to one of the U-phase, V-phase, and W-phase. For convenience, the pad 40 corresponding to the U-phase will be referred to as pad 40U, the pad 40 corresponding to the V-phase as pad 40V, and the pad 40 corresponding to the W-phase as pad 40W. As shown in Figure 6, in this embodiment, pads 40U, 40W, and 40V are arranged in this order clockwise and are grouped together in an area of ​​approximately 1 / 4 circle of the substrate 30. However, it is not essential to group pads 40U, 40W, and 40V together as described above. For example, pads 40U, 40W, and 40V may be arranged at equal intervals (120° intervals) in the circumferential direction.

[0025] Thus, the motor 1 is equipped with three pads 40 and three recesses 45, where each of the three pads 40 corresponds to one of the U-phase, V-phase, and W-phase, and each of the three recesses 45 surrounds one of the three pads 40.

[0026] In this embodiment, the region shown in Figure 7 corresponds to the region of pad 40U. Through pad 40U, U-phase alternating current is supplied to a first U-layer coil group consisting of three circumferentially continuous coils 23U and a second U-layer coil group consisting of three circumferentially continuous coils 23U located on the opposite side of the central axis X from the first U-layer coil group. Additionally, W-phase alternating current is supplied through pad 40W to a first W-layer coil group consisting of three circumferentially continuous coils 23W and a second W-layer coil group consisting of three circumferentially continuous coils 23W located on the opposite side of the central axis X from the first W-layer coil group. Furthermore, V-phase alternating current is supplied through pad 40V to a first V-layer coil group consisting of three circumferentially continuous coils 23V and a second V-layer coil group consisting of three circumferentially continuous coils 23V located on the opposite side of the central axis X from the first V-layer coil group.

[0027] As shown in Figure 7, in this embodiment, the recess 45 penetrates the first conductor layer 31 (i.e., the first conductor layer) in the axial direction. Therefore, in this embodiment, in the first conductor layer 31, the exposed conductor portion 31mn that is conductive to the U-phase pad 40U, the exposed conductor portion 31mn that is conductive to the W-phase pad 40W, and the exposed conductor portion 31mn that is conductive to the V-phase pad 40V are insulated from each other.

[0028] Next, the resin member 50 will be described. The resin used to form the resin member 50 may be a thermosetting resin or a thermoplastic resin. The resin used to form the resin member 50 may also contain, for example, aluminum or silicon. The rigidity of the resin used to form the resin member 50 is not particularly limited, but it may be less rigid than that of the resin used to form the insulator 22. Furthermore, the resin member 50 may have excellent thermal conductivity and insulating properties. This resin member 50 is provided by molding, as will be described later.

[0029] As shown in Figures 2 to 4, the resin member 50 has a generally cylindrical shape with a central axis X as its central axis, and covers the stator 20 except for the inner circumferential surface 24i and outer circumferential portion 21o of each stator component 21. That is, the resin member 50 covers both the a-side and b-side in the axial direction of the stator 20. In this embodiment, in the inner part c of the stator 20, the inner circumferential surface 24i of each stator component 21 is exposed from the resin member 50, and the inner circumferential surface 50i of the resin member 50 and the inner circumferential surface 24i of each stator component 21 are generally flush. Each of these exposed inner circumferential surfaces 24i faces the outer circumferential surface of the rotor 10 (see Figure 1). On the other hand, in the outer part d of the stator 20, the outer circumferential portion 21o of each stator component 21 protrudes outward d from the outer circumferential surface 50o of the resin member 50.

[0030] Furthermore, the resin member 50 completely covers the first surface 30F on the b side of the substrate 30, the inner peripheral portion 30ie on the radially inner side c, and the outer peripheral portion 30oe on the radially outer side d. That is, the first surface 30F is in contact with the resin member 50. In addition, the resin member 50 partially covers the portion of the substrate 30 on the axial side a. Specifically, the resin member 50 covers the first material 41 applied to the first region 30o1 of the outer peripheral portion 30o on the second surface 30S of the substrate 30. However, the resin member 50 does not cover the second region 30o2 (i.e., the third material 43), the intermediate portion 30m (i.e., the first material 41), and the inner peripheral portion 30i (i.e., the second material 42) of the outer peripheral portion 30o on the second surface 30S of the substrate 30. In other words, in this motor 1, the resin member 50 is prevented from protruding inward c from the annular portion made of the third material 43 and outward d from the annular portion made of the second material 42. Furthermore, the resin member 50 is prevented from protruding into the intermediate portion 30m of the substrate 30 on which the pads 40 and wiring connected to the pads 40 are provided. In addition, because the protrusion is prevented in this way, the motor is aesthetically pleasing. Thus, in the motor 1, the resin member 50 is properly molded.

[0031] As described above, the motor 1 of this embodiment comprises a stator 20, a substrate 30 supported by the stator 20, and a resin member 50 covering the stator 20. In the axial direction, the substrate 30 has a first surface 30F facing the stator 20 and a second surface 30S opposite to the first surface 30F, and the first surface 30F of the substrate 30 is in contact with the resin member 50. The second surface 30S of the substrate 30 has an inner circumference 30i, an outer circumference 30o, and an intermediate portion 30m located between the inner circumference 30i and the outer circumference 30o. At least one conductive pad 40 is provided in the intermediate portion 30m, and a recess 45 surrounding the pad 40 is formed therein. The radial end of the recess 45 is formed radially outward d from the inner circumference 30i and radially inward c from the outer circumference 30o.

[0032] Next, we will explain how to manufacture the motor 1.

[0033] First, as the first step, a recess 45 is formed in the middle portion 30m of the second surface 30S of the substrate 30. Specifically, as shown in Figure 6, a recess 45 is formed surrounding each of the three pads 40, corresponding to each of the three pads 40. That is, three recesses 45 are formed in the substrate 30. In this case, each of the recesses 45 is formed only in the middle portion 30m. That is, the recess 45 is formed such that its radial end is radially outward d from the inner circumference 30i and radially inward c from the outer circumference 30o. Furthermore, each of the three recesses 45 is located on the middle portion 30m side of the annular portion formed by the second material 42 and the annular portion formed by the third material 43, respectively.

[0034] Next, as the second step, as shown in Figure 5, each of the terminal pins 25 of the stator 20 is fitted into a notch 39 formed in the outer periphery 30oe of the substrate 30, thereby fixing the stator 20 and the substrate 30 together. In this way, a stator 70 with a substrate is obtained. Alternatively, the substrate 30 may be fixed to the stator 20 by providing a screw groove at the end of the terminal pin 25 that protrudes from the notch 39 toward side a, and screwing a nut N onto that end of the terminal pin 25.

[0035] Next, the third step is performed. This step involves fitting the stator 70 with the substrate into the mold. As shown in Figure 8, the mold 90 used in this step includes a first mold 91 and a second mold 92.

[0036] The first mold 91 includes a base portion 91B, a cylindrical projection 91P projecting from the base portion 91B toward side a, and a stepped portion 91S projecting from the base portion 91B toward side a at a predetermined distance radially outward d from the projection 91P. A flange surface 91f projecting inward c is formed on the inner surface c of the stepped portion 91S. The diameter of the projection 91P is substantially the same as the diameter of the first circle C1 (see Figure 5) described above. The outer peripheral surface 91Po of the projection 91P, the upper surface 91Bu on side a of the base portion 91B, and the inner surface of the inner c of the stepped portion 91S form an annular recess 91C when viewed from side a.

[0037] The second mold 92 includes a base portion 92B, a first annular projection 92P1 projecting from the base portion 92B toward side b and viewed from side b, and a second annular projection 92P2 projecting radially outward d from the first projection 92P1 toward side b at a predetermined distance and viewed from side b. The projection length of the second projection 92P2 toward side b is longer than the projection length of the first projection 92P1 toward side b. The lower surface 92Bd on side b of the base portion 92B and the inner surface of the inner side c of the first projection 92P1 form a circular first recess 92C1 in the second mold 92 when viewed from side b. The diameter of the first recess 92C1 (i.e., the inner diameter of the first projection 91P1) is substantially the same as the diameter of the projection 91P of the first mold 91. Furthermore, outside the first recess 92C1 of the second mold 92, a second annular recess 92C2 is formed when viewed from side b by the lower surface 92Bd of the base portion 92B, the outer surface of the outer d of the first projection 92P1, and the inner surface of the inner c of the second projection 92P2. A gate hole 92Ga for injecting resin to form the resin member 50 is provided in a portion of the area of ​​the lower surface 92Bd of the base portion 92B that forms the second recess 92C2, and this gate hole 92Ga is in communication with the second recess 92C2.

[0038] In this process, first, the stator 70 with substrate is placed in the recess 91C of the first mold 91. As a result, the inner circumferential surfaces 24i of each of the multiple stator components 21 come into almost complete contact with the outer circumferential surface 91Po of the protrusion 91P of the first mold 91. In addition, the outer d portion of the outer circumferential portion 21o of each of the multiple stator components 21 fits into the flange surface 91f of the stepped portion 91S and the portion of the c-side surface of the stepped portion 91S that is a-side to the flange surface 91f. As a result, the a-side upper surface 21ou of the outer circumferential portion 21o of each of the multiple stator components 21 and the a-side upper surface 91Su of the stepped portion 91S of the first mold 91 are in substantially flush contact without any gaps, and a first gap Cr1 is formed between the first mold 91 and the stator 70 with substrate on the b-side of the flange surface 91f. Specifically, this first gap Cr1 includes the gap on the b side of the inner circumferential surface 24i on the c side relative to the substrate-mounted stator 70, the gap on the b side of the substrate-mounted stator 70 relative to the substrate-mounted stator 70, and the gap on the b side of the flange surface 91f on the d side relative to the substrate-mounted stator 70.

[0039] Next, the second mold 92 is placed on the first mold 91 with its b-side surface facing the a-side surface of the first mold 91 and the a-side surface of the substrate-mounted stator 70 located within the recess 91C of the first mold 91. This state is shown in Figure 8. As a result, the a-side end 91Pu of the projection 91P of the first mold 91 fits into the first recess 92C1 of the second mold 92. In addition, the b-side surface of the first projection 92P1 of the second mold 92 substantially contacts the area of ​​the a-side surface of the substrate 30 excluding the first region 30o1. With the second mold 92 positioned in this manner, a second gap Cr2 and a third gap Cr3 are formed between the substrate-mounted stator 70 and the second mold 92. Specifically, the second gap Cr2 includes a gap located on the d-side with respect to the substrate-mounted stator 70 and a gap located on the a-side with respect to the substrate-mounted stator 70. Furthermore, the third gap Cr3 includes the gap between the stator 20 and the substrate 30, and the gap located on the c side with respect to the substrate-attached stator 70. Also, in the state shown in Figure 8 with the second mold 92 in place, the first gap Cr1, the second gap Cr2, and the third gap Cr3 are in communication via the gap G shown in Figure 6 and the gap K between the inner circumferential surfaces 24i of adjacent stator components 21.

[0040] Next, the fourth step is performed. This step involves injecting a resin (hereinafter referred to as "molding resin") into the mold 90 into which the substrate-equipped stator 70 is fitted, thereby molding the resin member 50. Specifically, liquid molding resin is injected through the gate hole 92Ga formed in the second mold 92. The liquid molding resin first flows into the second gap Cr2, and then flows into the first gap Cr1 and the third gap Cr3 through gaps G and K. Eventually, the first gap Cr1, the second gap Cr2, the third gap Cr3, gap G, and gap K are filled with the liquid molding resin, and then the liquid molding resin hardens. As a result, the resin member 50 is formed. In other words, this step completes the stator assembly 60 shown in Figures 2 to 4.

[0041] In this process, as described above, the b-side surface of the first protrusion 92P1 of the second mold 92 is in substantially complete contact with the a-side surface of the substrate 30, excluding the first region 30o1. Therefore, it is considered that the mold resin flowing into the second gap Cr2 is unlikely to penetrate into the region c inside the second region 30o2 of the substrate 30. However, as described above, in this embodiment, recesses are formed in the first conductor layer 31 of the substrate 30 to insulate the exposed conductor portion 31mn that is conductive to the pad 40U, the exposed conductor portion 31mn that is conductive to the pad 40W, and the exposed conductor portion 31mn that is conductive to the pad 40V from each other. For example, if the radially outer end d of this recess is connected to the first region 30o1, there is a risk that the mold resin in the second gap Cr2 may penetrate into the region c inside the first region 30o1 of the a-side surface of the substrate 30 through this recess (see Figures 4 and 8). Furthermore, if, for example, the radially inner end c of the recess is connected to the inner circumference 30ie of the substrate 30 (see Figures 4 and 8), there is a risk that the mold resin in the third gap Cr3 may penetrate the inner circumference 30i and the area d outside the inner circumference 30i on the a-side surface of the substrate 30. However, according to this embodiment, as described above, each of the three recesses 45 is formed only in the intermediate portion 30m, and the radial end of each recess 45 is formed radially outside d of the inner circumference 30i and radially inward c of the outer circumference 30o. Moreover, each of the three recesses 45 is located on the intermediate portion 30m side of the annular portion formed by the second material 42 and the annular portion formed by the third material 43, respectively. Therefore, it is prevented that the mold resin will penetrate the inner portion c of the substrate 30 (intermediate portion 30m, etc.) through the recesses 45. Therefore, in the motor 1 completed through this process, as described above, the molded resin is prevented from overflowing onto the inner part c of the substrate 30, and the motor is equipped with a properly molded resin member 50.

[0042] Although the present invention has been described above with reference to the above embodiments, the present invention is not limited thereto.

[0043] For example, although the above embodiment described a 2-pole 3-phase induction motor as an example, the present invention can be applied to any type of motor, such as a 4-pole 3-phase induction motor, a single-phase AC motor, or an inner-rotor type DC motor.

[0044] Furthermore, each of the recesses 45 can have a different shape. They can be changed as needed depending on the size and position of each pad. [Explanation of symbols]

[0045] 1…Motor, 20…Stator, 21i…Inner circumference, 21o…Outer circumference, 30…Substrate, 30F…First surface, 30i…Inner circumference, 30m…Intermediate section, 30o…Outer circumference, 30S…Second surface, 40…Pad, 45…Recess, 50…Resin component

Claims

1. The system comprises a stator, a substrate supported by the stator, and a resin member covering the stator. In the axial direction, the substrate has a first surface facing the stator and a second surface opposite to the first surface. The first surface of the substrate is in contact with the resin member. The second surface of the substrate comprises an inner circumferential portion, an outer circumferential portion, and an intermediate portion located between the inner circumferential portion and the outer circumferential portion. The intermediate portion is provided with at least one conductive pad, and a recess is formed surrounding the pad. The radial end of the recess is formed radially outward from the inner circumference and radially inward from the outer circumference. The substrate is formed by alternately stacking a plurality of conductive layers and a plurality of insulating layers. The outer periphery of the substrate is provided with a connection portion that is electrically connected to the stator. The pad is provided on the first conductive layer located at the axial end of the substrate, A motor in which the pad and the connection portion are electrically connected by the conductor layers of the other layers, excluding the first conductor layer.

2. The recess is formed in the shape of a polygon or a closed curve, The motor according to claim 1, wherein the pad is provided within the polygonal or closed curve shape.

3. The motor according to claim 1 or 2, wherein the recess is formed only in the intermediate portion.

4. It comprises three pads, including the aforementioned pad, It comprises three recesses, including the aforementioned recess, Each of the three pads corresponds to one of the U-phase, V-phase, and W-phase. The motor according to claim 1, wherein each of the three recesses surrounds one of the three pads.

5. The motor according to claim 1, wherein in the axial direction, the recess penetrates the first conductor layer.

6. The substrate has annular portions provided on both the outer periphery and the inner periphery, The motor according to claim 1, wherein the radial ends of the recesses are provided on the intermediate side of each of the annular portions.

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