Manufacturing method for stator of a rotating electric machine

Abstract

To provide a stator of a rotary electric machine and a method for manufacturing the stator with which it is possible to easily fix a cylindrical cover member to the inner circumferential part of a stator core without requiring complex processing.SOLUTION: A stator 10 comprises an annular stator core 14, a coil 15, and a cylindrical cover member. The stator core 14 includes a plurality of teeth arranged in the circumferential direction, and a plurality of slots 31 formed between the teeth that are adjacent in the circumferential direction. The coil 15 has a plurality of conductors 15a wound around respective teeth through the slots 31. The cover member is inserted and disposed in the inner circumferential part of the stator core 14 so that the outer circumferential surface faces an opening 40 on the radial inside of the plurality of slots 31. Each slot 31 is filled with a foamable insulating member 43 covering the outer surfaces of the plurality of conductors 15a of the coil 15 and adhered to the outer circumferential surface of the cover member through the opening 40 of the slot 31.SELECTED DRAWING: Figure 4

Description

Technical Field

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[0006]

[0001] The present invention relates to a method for manufacturing a rotor. No S

Background Art

[0002] Rotating electrical machines such as electric motors and generators include a stator and a rotor that rotates relative to the stator. The stator includes a stator core and a coil wound around the stator core. The stator core is formed integrally, for example, of a cylindrical back yoke (yoke) and a plurality of teeth protruding radially inward from the back yoke. Slots are formed between a plurality of adjacent teeth in the circumferential direction so as to open radially inward. A plurality of conductor portions of the coil are inserted into each slot.

[0003] ​​​​​​​​​​​​​​​​​​​​​​​​​​​​​The stator described in Patent Document 1 requires that multiple engagement holes be formed in the cylindrical cover member and that locking protrusions be formed on the inner surface of the stator core in order to fix the cover member to the inner surface of the stator core. For this reason, the stator described in Patent Document 1 requires complicated processing of the cover member and the stator core, and there is room for improvement in terms of production efficiency.

[0007] Therefore, the present invention provides a rotating electric machine that can easily fix a cylindrical cover member to the inner circumference of the stator core without requiring complicated processing. No S This aims to provide a method for manufacturing data. [Means for solving the problem]

[0008] The stator of a rotating electric machine and the method for manufacturing the stator according to the present invention employ the following configuration in order to solve the above problems. That is, the stator of the rotating electric machine according to the present invention comprises an annular stator core (e.g., stator core 14 in the embodiment) having a plurality of teeth arranged in the circumferential direction (e.g., teeth 28 in the embodiment) and a plurality of slots formed between adjacent teeth in the circumferential direction (e.g., slots 31 in the embodiment); a coil (e.g., coil 15 in the embodiment) in which a plurality of conductor portions (e.g., conductor portion 15a in the embodiment) are wound around each of the teeth through the slots; and a cylindrical cover member (e.g., annular partition wall 37 in the embodiment) inserted and disposed on the inner circumference of the stator core such that its outer surface faces radially inward openings (e.g., openings 40 in the embodiment) of the plurality of slots, wherein each of the slots is loaded with a foamed insulating member (e.g., foamed insulating member 43 in the embodiment) that covers the outer surfaces of the plurality of conductor portions of the coil and is adhered to the outer surface of the cover member through the opening.

[0009] With the above configuration, the foamed insulating material is bonded to the outer surface of the cylindrical cover member through the opening of each slot. As a result, the cover member is fixed to the foamed insulating material in each slot through the openings of multiple slots. In addition, the conductors of the coils housed in each slot are electrically insulated by the foamed insulating material. When this configuration is adopted, there is no need to perform complicated machining on the cover member or stator core to fix them together, and the cylindrical cover member can be easily fixed to the inner circumference of the stator core.

[0010] It is desirable that the foam adhesive be placed on the outer surface of the foam insulating member.

[0011] In this case, by covering the outer surfaces of multiple wire sections of the coil with a foamed insulating material and inserting them into the corresponding slots, and then foaming the foamed adhesive, the cover material can be easily and securely fixed to the foamed insulating material in the multiple slots using the foamed adhesive.

[0012] Multiple of the aforementioned slots may be configured to form coolant passages that allow coolant to flow from one end to the other in the axial direction of the stator core.

[0013] In this configuration, the coolant flows through the slot, efficiently cooling the wire portion of the coil inserted and positioned within the slot. At this time, the outflow of coolant radially inward from the slot is prevented by the cylindrical cover member. Furthermore, the opening of the slot is sealed by a foamed insulating member, and the portion of the outer surface of the cover member that is subjected to the pressure of the coolant is reinforced by the foamed insulating member. As a result, deformation of the cover member can be suppressed without increasing the overall thickness of the cover member. Therefore, by adopting this configuration, the thickness of the cover member can be reduced, narrowing the gap between the stator and rotor and improving the magnetic performance of the rotating electric machine.

[0014] Furthermore, the present invention relates to a method for manufacturing a stator for a rotating electric machine, comprising: an annular stator core having a plurality of teeth arranged in the circumferential direction and a plurality of slots formed between adjacent teeth in the circumferential direction; a coil in which a plurality of conductor portions are wound around each of the teeth through the slots; and a cylindrical cover member inserted and disposed on the inner circumference of the stator core such that its outer surface faces the radially inward openings of the plurality of slots, characterized in that the outer surfaces of the plurality of conductor portions of the coil are covered with a foamed insulating member, the plurality of conductor portions are inserted into the slots together with the foamed insulating member, and then the foamed insulating member is foamed to adhere the foamed insulating member to the outer surface of the cover member through the openings of the slots.

[0015] In this case, by covering the outer surfaces of multiple wire sections of the coil with a foamed insulating material and inserting them into corresponding slots to allow the foamed insulating material to expand, the cylindrical cover member can be adhesively fixed to the foamed insulating material in the multiple slots through the openings of the slots.

[0016] Furthermore, a rod-shaped spacer member (for example, spacer member 45 in the embodiment) may be placed radially inward of the wire portion that is positioned most radially inward within the slot, extending substantially along the wire portion, the outer surfaces of the spacer member and the plurality of wire portions may be covered with the foamed insulating member, the spacer member and the plurality of wire portions may be inserted into the slot together with the foamed insulating member, and then the foamed insulating member may be foamed to adhere the foamed insulating member to the outer surface of the cover member through the opening of the slot.

[0017] In this case, the outer surfaces of the spacer member and multiple wire sections of the coil are covered with a foamed insulating material, and the foamed insulating material is foamed within the corresponding slots, making it possible to position the multiple wire sections in the correct radially outer positions of the slots. Furthermore, in this case, the pressure of the coolant is less likely to act on the radially outer end face of the outermost radial wire section within the slot. As a result, the multiple wire sections are less likely to be pressed radially inward by the coolant. Furthermore, when the portion of the foamed insulating member located radially inward of the slot foams, the inner side of the foamed insulating member (the side separated from the slot opening) is supported by the spacer member. Therefore, when the foamed insulating member foams, a portion of the foamed insulating member expands and displaces toward the slot opening while its inner side is supported by the spacer member. Consequently, when this configuration is adopted, a portion of the foamed insulating member passes through the slot opening, and that portion is reliably bonded to the cover member through the opening.

[0018] The foamed insulating member may be foamed, and after the foamed insulating member is bonded to the outer circumferential surface of the cover member through the opening of the slot, the spacer member may be removed from the inside of the foamed insulating member.

[0019] In this case, the weight of the stator can be reduced by removing the rod-shaped spacer member after the foamed insulating material has been foamed. Furthermore, after the rod-shaped spacer is removed, a communication hole is formed on the inside of the foamed insulating material, aligned with the axial direction of the stator. By using this communication hole as a coolant passage, the coil's conductors can be cooled efficiently. [Effects of the Invention]

[0020] The stator of the rotating electrical machine according to the present invention is loaded with a foamed insulating member that covers the outer surfaces of a plurality of conductor portions of a coil in each slot of a stator core and is adhered to the outer peripheral surface of a cover member through an opening of the slot. Therefore, a cylindrical cover member is adhered to the foamed insulating members in a plurality of slots through the openings of the slots. Accordingly, when the stator according to the present invention is adopted, the cylindrical cover member can be easily fixed to the inner peripheral portion of the stator core without requiring complicated processing.

[0021] In the method for manufacturing a stator of a rotating electrical machine according to the present invention, with the outer surfaces of a plurality of conductor portions of a coil covered with a foamed insulating member, the plurality of conductor portions are inserted into slots together with the foamed insulating member, and then the foamed insulating member is foamed to adhere the foamed insulating member to the outer peripheral surface of a cover member through the slots. Therefore, by simply covering the outer surfaces of the plurality of conductor portions with the foamed insulating member, inserting them into corresponding slots, and foaming the foamed insulating member, the cylindrical cover member can be adhered and fixed to the foamed insulating members in a plurality of slots through the openings of the slots. Accordingly, when the method for manufacturing a stator according to the present invention is adopted, the cylindrical cover member can be easily fixed to the inner peripheral portion of the stator core without requiring complicated processing.

Brief Description of the Drawings

[0022] [Figure 1] Vertical sectional view of the rotating electrical machine of the embodiment. [Figure 2] Cross-sectional view taken along line II-II of FIG. 1 of the rotating electrical machine of the embodiment. [Figure 3] Cross-sectional view corresponding to FIG. 2 during the manufacture of the rotating electrical machine of the embodiment. [Figure 4] Partial enlarged cross-sectional view of FIG. 2 after the manufacture of the rotating electrical machine of the embodiment.

Modes for Carrying Out the Invention

[0023] Hereinafter, embodiments of the present invention will be described based on the drawings. FIG. 1 is a vertical sectional view of a rotating electrical machine 1 of the present embodiment. The rotating electric machine 1 of this embodiment comprises a stator 10 and a rotor 11. The stator 10 and rotor 11 are housed inside a rotating electric machine case 12. The stator 10 is fixed inside the rotating electric machine case 12 by fastening with bolts 13 or the like. The stator 10 comprises a cylindrical stator core 14 and a plurality of coils 15 wound around the stator core 14. The rotor 11 is rotatably arranged radially inward of the stator core 14 (stator 10).

[0024] The rotor 11 has permanent magnets (not shown) attached near its outer surface. The rotor 11 is also supported by a sleeve 16 so as to be integrally rotatable with the rotating shaft 17. The rotating shaft 17 becomes the output shaft when the rotating electric machine 1 is used as a motor, and becomes the power input shaft when the rotating electric machine 1 is used as a generator. The rotating shaft 17 and the sleeve 16 are rotatably supported by the rotating electric machine case 12 via a bearing 18. In the following explanation, the direction parallel to the rotation axis C of the rotor 11 will be referred to as the axial direction, the direction of rotation of the rotor 11 will be referred to as the circumferential direction, and the radial direction of the rotor 11 that is perpendicular to the axial and circumferential directions will be referred to as the radial direction.

[0025] An annular first side case 19 and a second side case 20 are positioned at one axial end and the other end of the stator core 14. The main parts of the first side case 19 and the second side case 20 are formed by the rotating electric machine case 12.

[0026] The first side case 19 covers one axial end face of the stator core 14 and the exposed portion of the coil 15 protruding from that end face from the outside. Together with the axial end face of the stator core 14, the first side case 19 forms an annular first liquid chamber 21. The first side case 19 has an introduction port 24 for introducing coolant 23 into the first liquid chamber 21. The introduction port 24 is connected to a circulation circuit 25 for the coolant 23. The coolant 23 introduced into the first liquid chamber 21 cools the exposed portion of the coil 15 protruding from one end face of the stator core 14, and then flows through the inside of the stator core 14 to the other axial end of the stator core 14.

[0027] The second side case 20 covers the other axial end face of the stator core 14 and the exposed portion of the coil 15 protruding from that end face from the outside. Together with the other axial end face of the stator core 14, the second side case 20 forms an annular second liquid chamber 22. Coolant 23 introduced into the first liquid chamber 21 flows into the second liquid chamber 22 through the interior of the stator core 14. The coolant 23 introduced into the second liquid chamber 22 cools the exposed portion of the coil 15 protruding from the other end face of the stator core 14. The second side case 20 has a discharge port 26 for discharging the coolant 23 from the second liquid chamber 22 to the outside. The discharge port 26 is connected to a coolant circulation circuit 25. The coolant 23 that has cooled the coil 15 in the second liquid chamber 22 is returned to the circulation circuit 25 from the discharge port 26.

[0028] The circulation circuit 25 has a supply pump P connected to it. Upstream of the supply pump P in the circulation circuit 25, a heat exchanger OC is connected to cool the coolant 23 by heat exchange with the outside air. Downstream of the supply pump P is connected to the inlet port 24. Also, upstream of the heat exchanger OC in the circulation circuit 25 is connected to the discharge port 26.

[0029] Figure 2 is a cross-sectional view of the rotating electric machine 1 along the line II-II in Figure 1. The stator core 14 is formed, for example, by laminating multiple electromagnetic steel sheets in the axial direction. As shown in Figure 2, the stator core 14 is integrally molded with a cylindrical back yoke 27 and multiple teeth 28 that protrude radially inward from the inner circumference of the back yoke 27. The back yoke 27 is formed so that the center of the cylinder coincides with the axis of rotation C.

[0030] The teeth 28 are arranged at intervals in the circumferential direction. The teeth 28 are formed in a T-shape when viewed from the axial direction. That is, the teeth 28 are integrally molded with a tooth body 29 that protrudes radially inward from the inner circumference of the back yoke 27 and flange portions 30 that extend circumferentially from the radially inner end of the tooth body 29 on both sides.

[0031] Between adjacent teeth 28 in the circumferential direction, a slot 31 is formed, which is open radially inward. The slot 31 is formed by being surrounded by the mutually opposing side walls of adjacent teeth 28 and the inner circumferential wall of the back yoke 27. The side walls of each tooth 28 are formed by the side of the tooth body 29 and the side of the flange 30. The portion of the slot 31 formed by the side of the left and right tooth bodies 29 is of approximately constant width. Furthermore, the width of the portion of the slot 31 formed by the side of the left and right flange 30 is narrower than the width of the portion formed by the side of the left and right tooth bodies 29. Furthermore, the radially inner opening 40 of each slot 31 is formed by being sandwiched between the tips of the flange portions 30 on both sides (circumferentially) of the slot 31.

[0032] The coil 15 is provided with, for example, three phases: U-phase, V-phase, and W-phase. The coil 15 is composed of, for example, multiple segment coils connected to each other. The conductor portion 15a of the coil 15 has a metal core wire 41, the outer surface of which is covered with an insulating coating 42. The conductor portion 15a of the coil 15 is made of flat rectangular wire. That is, the cross-sectional shape of each conductor portion 15a is formed to be approximately rectangular.

[0033] As shown in Figure 2, the multiple wire portions 15a of the coil 15 inserted into the same slot 31 are arranged in a line along the radial direction. In this embodiment, for example, five wire portions 15a are inserted into the same slot 31. However, the number of wire portions 15a inserted into the same slot 31 is not limited to this and can be set arbitrarily.

[0034] Multiple wire sections 15a, which are inserted and arranged within each slot 31, are bundled together in a parallel line, and their periphery is covered by a sheet of foamed insulating material 43. The foamed insulating material 43 can be, for example, one in which a foamed adhesive is placed (applied) on the surface of an electrically insulating base sheet (the surface facing outward when encasing the wire sections 15a), and a non-foaming adhesive is placed (applied) on the back surface of the base sheet. The foamed insulating material 43 is inserted and arranged within the corresponding slot 31 together with the multiple wire sections 15a, covering their periphery. The foamed insulating material 43 then foams within the corresponding slot 31 by heat treatment or the like. The behavior of the foamed insulating material 43 during foaming will be described in detail later.

[0035] As described above, even after the wire portion 15a of the coil 15 and the foamed insulating member 43 are placed in the slot 31, a gap is maintained inside the slot 31 to connect one end and the other end of the stator core 14 in the axial direction. This gap constitutes a coolant passage 44 for flowing the coolant introduced into the first liquid chamber 21 to the second liquid chamber 22. Specifically, the gaps constituting the coolant passage 44 include the gap between the inner surface of the foamed insulating member 43 and the wire portion 15a, the gap between adjacent wire portions 15a, and the gap between the outer surface of the foamed insulating member 43 and the inner wall of the slot 31. The coolant 23 flowing through the coolant passage 44 in the slot 31 absorbs heat from the wire portion 15a of the coil 15.

[0036] Furthermore, grooves 50 extending along the axial direction of the stator core 14 are formed on the radially inward and radially outward faces of each conductor portion 15a arranged within each slot 31. The grooves 50 are formed in a substantially arc shape, recessed toward the central region in the width direction of the conductor portion 15a. When multiple conductor portions 15a are arranged in the slot 31 together with the foamed insulating member 43, the grooves 50 form gaps (coolant passages 44) that extend substantially along the axial direction between the end faces of radially adjacent conductor portions 15a, and between the end faces of the conductor portions 15a and the inner surface of the foamed insulating member 43.

[0037] As shown in Figure 1, the first side case 19 on one axial end of the stator core 14 is provided with a first inner peripheral wall 32 facing the first liquid chamber 21. The first inner peripheral wall 32 protrudes cylindrically from the radially inward end of the end side wall 33 of the first side case 19, which is located at the axial outer end of the first liquid chamber 21, toward one axial end face of the rotor 11. In this embodiment, the first inner peripheral wall 32 is composed of a peripheral wall body portion 12a formed integrally with the rotating electric machine case 12 (end side wall 33), and a separate cylindrical member 34 attached to the outer circumferential surface of the extended end of the peripheral wall body portion 12a. The space between the peripheral wall body portion 12a and the cylindrical member 34 is sealed by an annular sealing member 60. However, the first inner peripheral wall 32 may be formed integrally with the rotating electric machine case 12 (end side wall 33) as a whole.

[0038] Furthermore, the second side case 20 on the other axial end of the stator core 14 is provided with a second inner peripheral wall 35 facing the second liquid chamber 22. The second inner peripheral wall 35 protrudes cylindrically from the radially inner end of the end side wall 36 of the second side case 20, which is located at the axial outer end of the second liquid chamber 22, toward the other axial end face of the rotor 11. In this embodiment, the second inner peripheral wall 35 is formed integrally with the rotating electric machine case 12 (end side wall 36). However, the second inner peripheral wall 35 may be composed of a peripheral wall body that is integrated with the rotating electric machine case 12 (end side wall 36), similar to the first inner peripheral wall 32, and a separate cylindrical member.

[0039] An annular partition wall 37, which is a cylindrical cover member, is installed on the outer circumferential surface of the first inner circumferential wall 32 of the first side case 19 and on the outer circumferential surface of the second inner circumferential wall 35 of the second side case 20. The annular partition wall 37 is formed of, for example, a resin material. However, the annular partition wall 37 can also be formed of other materials such as metal. The annular partition wall 37 has a first end portion 37f facing into the first liquid chamber 21, a second end portion 37s facing into the second liquid chamber 22, and a partition wall body portion 37b located between the first end portion 37f and the second end portion 37s and facing the inner circumferential surface of the stator core 14. The first end portion 37f is formed to have the same inner diameter as the partition wall body portion 37b. The second end portion 37s has a stepped diameter reduction in the middle of its extension direction relative to the partition wall body portion 37b.

[0040] The inner circumferential surface of the first end portion 37f is slidably fitted to the outer circumferential surface of the cylindrical member 34 of the first inner circumferential wall 32. An annular groove 38f is formed on the outer circumferential surface of the cylindrical member 34, and an annular sealing member 39f, such as an O-ring, is fitted into the annular groove 38f. The space between the cylindrical member 34 (first inner circumferential wall 32) and the first end portion 37f (annular partition wall 37) is sealed liquid-tight by the sealing member 39f. In this embodiment, the first end portion 37f constitutes a guide member that guides the coolant in the first liquid chamber 21 to the opening of the slot 31 on one end of the stator core 14 in the axial direction.

[0041] The inner circumferential surface of the reduced diameter portion of the second end portion 37s is slidably fitted to the outer circumferential surface of the second inner circumferential wall 35. An annular groove 38s is formed on the outer circumferential surface of the second inner circumferential wall 35, and an annular sealing member 39s, such as an O-ring, is fitted into the annular groove 38s. The space between the second inner circumferential wall 35 and the second end portion 37s (annular partition wall 37) is liquid-tightly sealed by the sealing member 39s.

[0042] As described above, the annular partition wall 37 has its first end 37f liquid-tightly fitted to the first inner peripheral wall 32 of the first side case 19, and its second end 37s liquid-tightly fitted to the second inner peripheral wall 35 of the second side case 20. The annular partition wall 37 separates the radially inner region of the stator core 14, which is mounted inside the rotating electric machine case 12, from the outer peripheral surface of the rotor 11. Therefore, even if coolant 23 leaks from the slot 31 of the stator core 14 into the radially inner region, it can be prevented from flowing into the outer peripheral surface of the rotor 11.

[0043] Furthermore, the outer circumferential surface of the first end portion 37f of the annular partition wall 37 bulges radially outward compared to the outer circumferential surface of the partition wall body portion 37b. The end of this bulging portion on the stator core 14 side rises radially outward in a stepped manner relative to the outer circumferential surface of the partition wall body portion 37b. This upright end surface abuts against the end surface on one axial end of the stator core 14.

[0044] As shown in Figure 2, the outer circumferential surface of the main body portion 37b of the annular partition wall 37 is maintained in contact with the inner circumferential surface of the stator core 14. Furthermore, the inner circumferential surface of the main body portion 37b of the annular partition wall 37 faces the outer circumferential surface of the rotor 11 with a minute gap between them, so as not to contact the outer circumferential surface of the rotor 11.

[0045] Here, the foamed insulating member 43, which is housed in each slot 31 of the stator core 14 along with the multiple conductor portions 15a of the coil 15, is bonded to a part of the inner wall of the slot 31 by the foaming adhesive on its outer surface foaming due to heating or the like. At this time, the portion of the foamed adhesive of the foamed insulating member 43 located at the radially inner end of the slot 31 penetrates into the radially inner opening 40 of the slot 31 by foaming and is bonded to the outer surface of the annular partition wall 37 through the opening 40. As a result, the peripheral wall body portion 12a of the annular partition wall 37 is bonded and fixed to the foamed insulating member 43 inside the multiple slots 31 through the opening 40 of the slot 31.

[0046] Next, we will explain the specific manufacturing method of the stator 10 (the method of fixing the annular partition wall 37 to the stator core 14). Figure 3 is a cross-sectional view similar to Figure 2 at one stage of the manufacturing process. Figure 4 is an enlarged cross-sectional view of a portion of Figure 2 after manufacturing. First, bundles of multiple wire sections 15a of the coil 15, which are covered on the outside with a foamed insulating material 43, are inserted into the corresponding slots 31 of the stator core 14, and the peripheral wall main portion 12a of the annular partition wall 37 is inserted and positioned on the inner circumference of the stator core 14. When covering the outside of the multiple conductor sections 15a with the foamed insulating material 43, as shown in Figure 3, a rod-shaped spacer member 45 is placed radially inward of the conductor section 15a that is located radially inward when housed in the slot 31. The spacer member 45 can be a rod-shaped one that extends linearly along the conductor section 15a arranged in the slot 31 (along the axial direction of the stator core 14). The spacer member 45, together with the multiple conductor sections 15a, has its outer surface covered by the sheet-like foamed insulating material 43. In this embodiment, a spacer member 45 with a circular cross-section that extends linearly along the axial direction is used.

[0047] Next, in this state, the foamed insulating material 43 (foaming adhesive) in each slot 31 is foamed by heating or the like. When the foamed insulating material 43 (foaming adhesive) foams in the slot 31, the outer surface of the foamed insulating material 43 adheres to a part of the inner wall of the slot 31, and a part of the foamed insulating material 43 penetrates into the opening 40 of the slot 31, and that part adheres to the outer surface of the annular partition wall 37 through the opening 40.

[0048] After this, the rod-shaped spacer member 45 is pulled out axially from the foamed insulating member 43 (foaming adhesive) after waiting for the foaming to be completed within the slot 31. As a result, a gap of at least the cross-sectional area of ​​the spacer member 45 is created between the foamed insulating member 43 and the radially innermost conductor portion 15a, ensuring a coolant passage 44 with sufficient cross-sectional area.

[0049] In the rotating electric machine 1 with the above configuration, when current flows continuously through the coil 15 during operation, the coil 15 generates heat and becomes hot. At this time, coolant 23 is introduced into the first liquid chamber 21 of the rotating electric machine 1 from the circulation circuit 25 through the introduction port 24. The coolant 23 introduced into the first liquid chamber 21 flows within the first liquid chamber 21, cooling the region of one end of the coil 15 that is exposed to the outside from one axial end of the stator core 14. The coolant 23 also flows through the multiple slots 31 (coolant passages 44 within the slots 31) of the stator core 14 from one axial end to the other end, and flows into the second liquid chamber 22. The coolant flowing through the slots 31 cools the wire portion 15a of the coil 15 that is inserted into the slots 31. The coolant 23 that has flowed into the second liquid chamber 22 cools the region of the other end of the coil 15 that is exposed to the outside from the other axial end of the stator core 14, and is then returned to the circulation circuit 25 through the discharge port 26.

[0050] As described above, in the rotating electric machine 1, the stator 10 is always submerged in the coolant 23 within the rotating electric machine case 12, and in this state, the coolant 23 within the rotating electric machine case 12 is replaced through the circulation circuit 25. Therefore, the coils 15 of the stator 10 are efficiently cooled by the coolant 23.

[0051] As described above, in the stator 10 of the rotating electric machine 1 of this embodiment, foamed insulating material 43 is loaded into each slot 31 of the stator core 14. This material covers the outer surface of multiple conductor portions 15a of the coil 15 and is adhered to the outer surface of the annular partition wall 37 (cover member) through the opening 40 of the slot 31. Therefore, the annular partition wall 37 (cover member) is adhered to the foamed insulating material 43 in each of the multiple slots 31 through the opening 40 of each slot 31. Therefore, when the stator 10 of the rotating electric machine 1 of this embodiment is adopted, the annular partition wall 37 (cover member) can be easily and firmly fixed to the inner circumference of the stator core 14 without requiring complicated machining to fix the annular partition wall 37 (cover member) to the stator core 14.

[0052] Furthermore, in this embodiment, the stator 10 not only fixes the annular partition wall 37 (cover member) with the foamed insulating member 43 in each slot 31, but the foamed insulating member 43 can also reliably insulate the peripheral area of ​​the conductor portion 15a of the coil 15. When the stator 10 of this embodiment is used, unlike when the annular partition wall 37 (cover member) is fixed to the inner surface of the stator core 14 with a special adhesive, the annular partition wall 37 (cover member) can be fixed to the inner surface of the stator core 14 at the same time as the installation process of the foamed insulating member 43 for insulating the peripheral area of ​​the conductor portion 15a of the coil 15. Therefore, if the stator 10 of the rotating electric machine 1 of this embodiment is adopted, the manufacturing of the stator 10 can be simplified.

[0053] Furthermore, the stator 10 of the rotating electric machine 1 in this embodiment employs a foamed insulating member 43 with foamed adhesive on its outer surface. Therefore, by covering the outer surfaces of multiple conductor portions 15a of the coil 15 with the foamed insulating member 43 and inserting them into the corresponding slots 31 to foam the foamed adhesive, the annular partition wall 37 (cover member) can be easily and reliably fixed to the foamed insulating member 43 in the multiple slots 31 by the foamed adhesive.

[0054] Furthermore, in the stator 10 of the rotating electric machine 1 of this embodiment, the interiors of the multiple slots 31 constitute a coolant passage 44 through which coolant 23 flows from one end to the other in the axial direction of the stator core 14. As a result, the wire portion 15a of the coil 15 inserted and arranged in the slots 31 can be efficiently cooled by the coolant 23. In addition, in this configuration, the outflow of coolant 23 from the slots 31 to the outer surface of the rotor 11 can be prevented by the annular partition wall 37 (cover member), thus eliminating the inconvenience of the rotor 11's rotation being hindered by a large amount of coolant 23 flowing into its outer surface. Furthermore, in this configuration, the openings 40 of each slot 31 are sealed by the foamed insulating member 43, and the portion of the outer surface of the partition body portion 37b of the annular partition wall 37 that is subjected to the pressure of the coolant 23 is reinforced by the adhesive portion of the foamed insulating member 43. As a result, deformation of the partition body portion 37b due to the pressure of the coolant 23 can be suppressed without increasing the thickness of the partition body portion 37b of the annular partition wall 37. Therefore, when the stator 10 of this embodiment is adopted, the thickness of the annular partition wall 37 can be reduced to narrow the gap between the stator 10 and the rotor 11, thereby improving the magnetic performance of the rotating electric machine 1.

[0055] Furthermore, in the manufacturing method of the stator 10 of this embodiment described above, the outer surfaces of the multiple conductor portions 15a of the coil 15 are covered with a foamed insulating member 43, the multiple conductor portions 15a are inserted into the slot 31 together with the foamed insulating member 43, and then the foamed insulating member 43 is foamed to adhere the foamed insulating member 43 to the outer surface of the annular partition wall 37 (cover member) through the opening 40 of the slot 31. Therefore, by simply covering the outer surfaces of the multiple conductor portions 15a with a foamed insulating member 43 and inserting them into the corresponding slots 31 to foam the foamed insulating member 43, the annular partition wall 37 (cover member) can be adhered and fixed to the foamed insulating member 43 in the multiple slots 31 through the opening 40 of the slot 31. Therefore, when the manufacturing method of the stator 10 of this embodiment is adopted, the annular partition wall 37 (cover member) can be easily and firmly fixed to the inner circumference of the stator core 14 without requiring complicated machining to fix the annular partition wall 37 (cover member) to the stator core 14.

[0056] Furthermore, in the manufacturing method of the stator 10 of this embodiment, a rod-shaped spacer member 45 is placed radially inward of the wire portion 15a that is located most radially inward within the slot 31, extending substantially along the wire portion 15a, and the outer surfaces of the spacer member 45 and the multiple wire portions 15a are covered with a foamed insulating member 43. Then, the spacer member 45 and the multiple wire portions 15a are inserted into the slot 31 together with the foamed insulating member 43, and after that, the foamed insulating member 43 is foamed to adhere the foamed insulating member 43 to the outer surface of the annular partition wall 37 through the opening 40 of the slot 31. In this way, the outer surfaces of the spacer member 45 and the multiple wire portions 15a of the coil 15 are covered with the foamed insulating member 43, and in that state the foamed insulating member 43 is foamed within the corresponding slot 31, thereby allowing the multiple wire portions 15a to be positioned at the appropriate radially outward position of the slot 31. In other words, the spacer members 45 positioned radially inside the multiple wire sections 15a allow the wire sections 15a to be positioned radially outward within the slot 31. Furthermore, when the conductor portion 15a is positioned in this manner, biased towards the radially outward side within the slot 31, the pressure of the coolant 23 is less likely to act on the radially outward end face of the radially outward conductor portion 15a within the slot 31. As a result, multiple conductor portions 15a are less likely to move radially inward due to the pressure of the coolant 23, and it becomes possible to prevent the main body portion 37b of the annular partition wall 37 from deforming radially inward due to the pressing by the conductor portions 15a.

[0057] Furthermore, when the portion of the foamed insulating member 43 located radially inward of the slot 31 foams, the inner surface of the foamed insulating member 43 (the side separated from the opening 40 of the slot 31) is supported by the spacer member 45. Therefore, when the foamed insulating member 43 foams, the inside of the foamed insulating member 43 is displaced smoothly toward the opening 40 of the slot 31 while its inner surface is supported by the spacer member 45. Consequently, when the manufacturing method of the stator 10 of this embodiment is adopted, a portion of the foamed insulating member 43 reliably passes through the opening 40 of the slot 31 during foaming, and that portion is reliably bonded to the main body portion 37b of the annular partition wall 37 through the opening 40. Thus, a portion of the foamed insulating member 43 can be reliably bonded to the outer surface of the annular partition wall 37 (cover member) through the opening 40.

[0058] In particular, in this embodiment, since a spacer member 45 with a circular cross-section that is continuous in the axial direction is used, when a part of the foamed insulating member 43 foams and enters the opening 40, the top of the circular cross-section of the spacer member 45 can efficiently support the foaming reaction force of the foamed insulating member 43. Therefore, by adopting this configuration, a part of the foamed insulating member 43 can be more reliably bonded to the outer surface of the annular partition wall 37 (cover member) through the opening 40.

[0059] Furthermore, in the manufacturing method of the stator 10 of this embodiment, the foamed insulating member 43 is foamed, and the foamed insulating member 43 is bonded to the outer circumferential surface of the partition body portion 37b of the annular partition wall 37 through the opening 40 of the slot 31, after which the spacer member 45 is removed from the inside of the foamed insulating member 43. In the manufacturing method of this embodiment, the weight of the stator 10 can be reduced because the rod-shaped spacer member 45 is removed after the foamed insulating member 43 has been foamed.

[0060] Furthermore, in the manufacturing method of this embodiment, since the rod-shaped spacer member 45 is removed after the foamed insulating member 43 has been foamed, a communication hole is formed in the area where the spacer member 45 was located inside the foamed insulating member 43, along the axial direction of the stator 10. Therefore, when the stator 10 is manufactured in this manner, the communication hole formed inside the foamed insulating member 43 can be used as a coolant passage 44, making it possible to efficiently cool the conductor portion 15a of the coil 15.

[0061] It should be noted that the present invention is not limited to the embodiments described above, and various design modifications are possible without departing from the spirit of the invention. For example, in the above embodiment, an annular partition wall 37 is arranged as a cover member on the inner circumference of the stator core 14, separating the inner surface of the stator core 14 from the outer surface of the rotor 11. However, the cover member is not limited to an annular partition wall 37 separating the inner surface of the stator core 14 from the outer surface of the rotor 11, and may be a cylindrical member that does not provide a liquid-tight partition between the stator core 14 and the rotor 11.

[0062] Furthermore, in the above embodiment, a foaming adhesive is placed on the outer surface of the foaming insulating member 43, but the foaming insulating member 43 is not necessarily limited to this structure. Alternatively, without placing a foaming adhesive on the outer surface of the foaming insulating member 43, a portion of the foaming insulating member 43 may enter the opening 40 of the slot 31 through the foaming process, and then the portion of the foaming insulating member 43 exposed to the outside through the opening 40 may be bonded separately to the outer surface of the annular partition wall 37 (cover member) with an adhesive.

[0063] Furthermore, in the above embodiment, the slot 31 of the stator core 14 constitutes a coolant passage 44 that flows the coolant 23 in the first liquid chamber 21 to the second liquid chamber 22. However, the stator may have a structure in which the coolant 23 does not flow through the slot 31. [Explanation of Symbols]

[0064] 10…Status 14… Stator core 15… Coil 15a...Conductor part 28... Teeth 31... Slot 37…Annular partition (cover member) 40…Aperture 43… Foamed insulating material 44…Cooling fluid passage 45...Spacer member

Claims

1. An annular stator core having a plurality of teeth arranged in the circumferential direction, and a plurality of slots formed between adjacent teeth in the circumferential direction, A coil in which multiple conductors are wound around each of the teeth through the slots, A method for manufacturing a stator of a rotating electric machine, comprising: a cylindrical cover member inserted and disposed on the inner circumference of the stator core such that its outer surface faces the radially inward openings of a plurality of the slots; With the outer surfaces of the multiple wire portions of the coil covered by a sheet of foamed insulating material, the multiple wire portions are inserted into the slot together with the foamed insulating material. A method for manufacturing a stator for a rotating electric machine, characterized by subsequently foaming the foamed insulating member and bonding the foamed insulating member to the outer circumferential surface of the cover member through the opening of the slot.

2. A rod-shaped spacer member is placed radially inward of the conductor portion that is located most radially inward within the slot, and extends substantially along the conductor portion. The outer surfaces of the spacer member and the plurality of conductor portions are covered with the foamed insulating member. The spacer member and the plurality of wire portions are inserted into the slot together with the foamed insulating member. The method for manufacturing a stator of a rotating electric machine according to claim 1, characterized in that the foamed insulating member is then foamed and the foamed insulating member is bonded to the outer peripheral surface of the cover member through the opening of the slot.

3. A method for manufacturing a stator of a rotating electric machine according to claim 2, characterized in that the foamed insulating member is foamed, the foamed insulating member is bonded to the outer peripheral surface of the cover member through the opening of the slot, and then the spacer member is removed from the inside of the foamed insulating member.

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