Molded electric motors and outdoor units

Abstract

A molded motor according to one aspect of the present disclosure comprises: a rotor that rotates about a central axis; a stator that radially faces the rotor and has a coil; a circuit board to which the coil is wired; a motor frame that is formed to cover at least a portion of the stator and the circuit board with a molding resin; a plurality of lead wires that are connected to the circuit board; a lead wire holding member for drawing the plurality of lead wires to the outside of the motor frame; and a tube for bundling and covering the plurality of lead wires to be positioned outside the motor frame. The lead wire holding member has a protruding part that protrudes from the outer surface of the motor frame and is provided with a plurality of openings of a plurality of through-holes. The tube has a facing end part that is disposed via a gap from the plurality of openings. A notched part that extends in the length direction of the tube is provided to the facing end part, and a sealing material that straddles the facing end part and a frame-shaped part and covers the plurality of lead wires is provided to the facing end part.

Description

Technical Field

[0001] The present disclosure relates to a molded motor and an outdoor unit.

Background Art

[0002] The outdoor unit of a refrigeration cycle device has a fan motor and a fan connected to the fan motor. As the fan motor inside the outdoor unit, a molded motor in which a stator is molded with a molded resin may be adopted. The molded motor is provided with a lead wire holding member (bushing) that holds a lead wire extending from a motor frame made of molded resin (for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003] S

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The lead wire holding member is provided with a through hole for holding the lead wire. Since the opening of the through hole of the lead wire holding member can be a path for moisture to enter the motor, it is preferable to seal the opening of the through hole with a sealing material. However, since a plurality of lead wires extending from the opening are arranged side by side with a gap between each other, it is difficult for the sealing material to wrap around between the lead wires, and the waterproof reliability could not be enhanced without performing complicated work.

[0005] In view of the above circumstances, one object of the present disclosure is to provide a molded motor with enhanced waterproof reliability and an outdoor unit including such a molded motor.

Means for Solving the Problems

[0006] One embodiment of a molded electric motor according to the present disclosure comprises a rotor that rotates about a central axis, a stator radially opposite to the rotor and having coils, a circuit board to which the coils are connected, a motor frame formed by covering at least a part of the stator and the circuit board with molded resin, a plurality of lead wires connected to the circuit board, a lead wire holding member that leads the plurality of lead wires to the outside of the motor frame, and a tube that bundles and covers the plurality of lead wires located outside the motor frame, wherein the lead wire holding member has a plurality of through holes for holding each of the plurality of lead wires, an embedded portion that is embedded in the motor frame, and a protruding portion that protrudes from the outer surface of the motor frame and is provided with a plurality of openings of the plurality of through holes, and the tube has opposing ends that are arranged with gaps between the plurality of openings. The plurality of lead wires are held by the lead wire holding member with gaps between them in the direction in which the plurality of openings are aligned in a straight line, and extend so as to spread out in the direction between the opposing ends and the plurality of openings. The opposing end is provided with a notch extending in the longitudinal direction of the tube, and a sealing material is provided that spans the opposing end and the frame-shaped portion, covering the plurality of lead wires.

[0007] One embodiment of a molded electric motor according to the present disclosure comprises a rotor that rotates about a central axis, a stator radially opposite the rotor and having coils, a circuit board to which the coils are connected, a motor frame formed by covering at least a part of the stator and the circuit board with molded resin, a plurality of lead wires connected to the circuit board, a lead wire holding member that leads the plurality of lead wires to the outside of the motor frame, and a tube that bundles and covers the plurality of lead wires located outside the motor frame, wherein the lead wire holding member has a plurality of through holes for holding each of the plurality of lead wires, an embedded portion that is embedded in the motor frame, and a protruding portion that protrudes from the outer surface of the motor frame and is provided with a frame-shaped portion that surrounds the plurality of openings of the plurality of through holes, and the tube has opposing ends that are positioned with gaps between them and the plurality of openings, and a sealing material that covers the plurality of lead wires is provided spanning the opposing ends and the frame-shaped portion.

[0008] One embodiment of the outdoor unit according to the present disclosure is an outdoor unit of a refrigeration cycle system, comprising a compressor, a heat exchanger, and a blower that generates an airflow passing through the heat exchanger, wherein the blower comprises the above-mentioned molded motor and a rotor that is rotated by the molded motor. [Effects of the Invention]

[0009] According to this disclosure, it is possible to provide a molded electric motor with enhanced waterproofing reliability, and an outdoor unit equipped with such a molded electric motor. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram showing the general configuration of the refrigeration cycle device in the first embodiment. [Figure 2] This is a schematic diagram of the outdoor unit of the first embodiment. [Figure 3] This is a cross-sectional view of a molded electric motor according to the first embodiment. [Figure 4] This is a perspective view of a lead wire holding member provided in a molded electric motor according to the first embodiment. [Figure 5] This is a front view of a tube provided in a molded electric motor according to the first embodiment. [Figure 6] This is a front view of a modified tube provided in the molded electric motor of the first embodiment. [Figure 7] This is a perspective view of a lead wire holding member provided in a molded electric motor according to the second embodiment. [Figure 8] This is a front view of a tube provided in a molded electric motor according to the second embodiment. [Modes for carrying out the invention]

[0011] Embodiments of this disclosure will be described below with reference to the drawings. However, the scope of this disclosure is not limited to the embodiments described below and can be modified at will within the scope of the technical concept of this disclosure. Furthermore, in the following drawings, the scale and number of components in each structure may differ from those in the actual structure in order to make the configurations easier to understand.

[0012] Furthermore, the drawings show the X, Y, and Z axes as appropriate. The X axis indicates the front-to-back direction of the outdoor unit in the following embodiment. The Y axis indicates the width direction of the outdoor unit, which is perpendicular to the front-to-back direction. The Z axis indicates the vertical direction. The front-to-back direction, width direction, and vertical direction are perpendicular to each other. In the front-to-back direction, the side in which the X-axis arrow points (+X side) is the front of the outdoor unit, and the side opposite to the side in which the X-axis arrow points (-X side) is the rear of the outdoor unit. The width direction is the left-to-right direction of the outdoor unit. The left-to-right direction is the left-to-right direction when viewing the outdoor unit in the following embodiment from the front (+X side). That is, in the left-to-right direction, the side in which the Y-axis arrow points (+Y side) is the right side, and the side opposite to the side in which the Y-axis arrow points (-Y side) is the left side. In the vertical direction, the side in which the Z-axis arrow points (+Z side) is upward, and the side opposite to the direction in which the Z-axis arrow points (-Z side) is downward. Furthermore, in this specification, the front-facing surface of each part may be simply called the front surface, and the rear-facing surface may be called the rear surface.

[0013] (First Embodiment) Figure 1 is a schematic diagram showing the general configuration of the refrigeration cycle device 100 in the first embodiment. In this embodiment, the refrigeration cycle device 100 is an air conditioner. As shown in Figure 1, the refrigeration cycle device 100 comprises an outdoor unit 10, an indoor unit 20, and a circulation path section 18. The outdoor unit 10 is located outdoors. The indoor unit 20 is located indoors. The outdoor unit 10 and the indoor unit 20 are connected to each other by a circulation path section 18 through which the refrigerant 19 circulates.

[0014] The refrigeration cycle device 100 can adjust the temperature of the indoor air by performing heat exchange between the refrigerant 19 flowing in the circulation path section 18 and the indoor air where the indoor unit 20 is arranged. Examples of the refrigerant 19 include fluorine-based refrigerants or hydrocarbon-based refrigerants with a low global warming potential (GWP: Global Warming Potential). Examples of the refrigerant 19 include any single refrigerant such as R1234yf, R1234ze, R32, or R290, or a mixed refrigerant of any two or more of these, or a mixed refrigerant of any of these and another refrigerant. Further, examples of the refrigerant 19 include a mixed refrigerant containing R1132(E) or a mixed refrigerant containing R1123. Further, examples of the refrigerant 19 include a mixed refrigerant such as R516A, R445A, R444A, R454C, R444B, R454A, R455A, R457A, R459B, R452B, R454B, R447B, R447A, R446A, or R459A.

[0015] The outdoor unit 10 includes a housing 11, a compressor 12, a heat exchanger 13, a flow rate adjustment valve 14, a blower 15, a four-way valve 16, and a control unit 17. Inside the housing 11, the compressor 12, the heat exchanger 13, the flow rate adjustment valve 14, the blower 15, the four-way valve 16, and the control unit 17 are accommodated.

[0016] The compressor 12, the heat exchanger 13, the flow rate adjustment valve 14, and the four-way valve 16 are provided in a portion of the circulation path section 18 located inside the housing 11. The compressor 12, the heat exchanger 13, the flow rate adjustment valve 14, and the four-way valve 16 are connected by a portion of the circulation path section 18 located inside the housing 11.

[0017] The four-way valve 16 is provided at a portion of the circulation path section 18 that is connected to the discharge side of the compressor 12. The four-way valve 16 can reverse the direction of the refrigerant 19 flowing in the circulation path section 18 by switching a part of the path in the circulation path section 18. When the path connected by the four-way valve 16 is the path indicated by the solid line in the four-way valve 16 of FIG. 1, the refrigerant 19 flows in the circulation path section 18 in the direction indicated by the solid line arrow in FIG. 1. On the other hand, when the path connected by the four-way valve 16 is the path indicated by the broken line in the four-way valve 16 of FIG. 1, the refrigerant 19 flows in the circulation path section 18 in the direction indicated by the broken line arrow in FIG. 1.

[0018] The indoor unit 20 includes a housing 21, a heat exchanger 22, a blower 23, and a control device 24. Inside the housing 21, the heat exchanger 22, the blower 23, and the control device 24 are accommodated. The indoor unit 20 can perform a cooling operation for cooling the air in the room where the indoor unit 20 is disposed and a heating operation for heating the air in the room where the indoor unit 20 is disposed.

[0019] When the indoor unit 20 is in the cooling operation, the refrigerant 19 flowing in the circulation path section 18 flows in the direction indicated by the solid line arrow in FIG. 1. That is, when the indoor unit 20 is in the cooling operation, the refrigerant 19 flowing in the circulation path section 18 circulates so as to return to the compressor 12 through the compressor 12, the heat exchanger 13 of the outdoor unit 10, the flow rate adjustment valve 14, and the heat exchanger 22 of the indoor unit 20 in this order. In the cooling operation, the heat exchanger 13 in the outdoor unit 10 functions as a condenser, and the heat exchanger 22 in the indoor unit 20 functions as an evaporator.

[0020] On the other hand, when the indoor unit 20 is in the heating operation, the refrigerant 19 flowing in the circulation path section 18 flows in the direction indicated by the broken line in FIG. 1. That is, when the indoor unit 20 is in the heating operation, the refrigerant 19 flowing in the circulation path section 18 circulates so as to return to the compressor 12 through the compressor 12, the heat exchanger 22 of the indoor unit 20, the flow rate adjustment valve 14, and the heat exchanger 13 of the outdoor unit 10 in this order. In the heating operation, the heat exchanger 13 in the outdoor unit 10 functions as an evaporator, and the heat exchanger 22 in the indoor unit 20 functions as a condenser.

[0021] Next, we will explain the outdoor unit 10 in more detail. Figure 2 is a schematic diagram of the outdoor unit 10. As shown in Figure 2, the housing 11 of the outdoor unit 10 is roughly rectangular box-shaped. The housing 11 has a front panel 11a that covers the internal space of the housing 11 from the front. The front panel 11a is provided with a front opening 11b. The front opening 11b penetrates the front panel 11a in the front-to-back direction (X-axis direction) and opens to the front. The front opening 11b is covered by a grille, which is not shown in the figure.

[0022] The enclosure 11 contains a fan room 11A that houses the heat exchanger 13 and the blower 15, and a machine room 11B that houses the compressor 12. The fan room 11A and the machine room 11B are separated by a partition member (not shown).

[0023] The blower 15 is located in front of the heat exchanger 13 (on the +X side). The circulation path 18 is connected to the heat exchanger 13. A refrigerant flows inside the heat exchanger 13. The heat exchanger 13 is cooled by the blower 15.

[0024] The blower 15 includes a molded electric motor 60 having a rotating shaft 62c, and a rotor blade 15b fixed to the rotating shaft 62c. The rotor blade 15b is rotated around a central axis J by the molded electric motor 60. The rotor blade 15b is positioned inside the housing 11, facing the front opening 11b. The rotor blade 15b is also positioned in front of the heat exchanger 13. By rotating the rotor blade 15b, the blower 15 blows air out from the front opening 11b to the front of the housing 11 and also passes air through the heat exchanger 13.

[0025] Figure 3 is a cross-sectional view of the molded electric motor 60 of this embodiment. The molded motor 60 in this embodiment is an inner rotor type motor. However, the molded motor 60 may also be an outer rotor type motor.

[0026] The molded electric motor 60 of this embodiment includes a rotor 62, a stator 61, a circuit board 63, a motor frame 64, a pair of bearings 67 and 68, a bearing holder 66, a cover 69, a lead wire holding member 70, a plurality of lead wires 80, and a tube 90.

[0027] The rotor 62 rotates around the central axis J. In the following description of the molded motor 60, the direction parallel to the central axis J may be referred to as the "axial direction," and the radial direction relative to the central axis J may simply be referred to as the "radial direction." Furthermore, the radial direction away from the central axis J may be referred to as the "radial outward direction," and the radial direction approaching the central axis J may be referred to as the "radial inward direction." In this embodiment, the axial direction coincides with the front-to-back direction (X-axis direction).

[0028] The rotor 62 comprises a rotating shaft 62c, a rotor core 62a, and a plurality of magnets 62b. The rotating shaft 62c extends axially about a central axis J. The rotating shaft 62c is supported by a pair of bearings 67 and 68. The rotor core 62a is fixed to the outer circumferential surface of the rotating shaft 62c. The plurality of magnets 62b are assembled to the rotor core 62a.

[0029] The stator 61 faces the rotor 62 in the radial direction. The stator 61 is annular in shape with a central axis J and surrounds the rotor 62 from the radially outer side. The stator 61 has a stator core 61a and a coil 61b. The stator core 61a has an annular core back and a plurality of teeth that project radially inward from the core back. The coil 61b is constructed by winding coil wire around the teeth.

[0030] The circuit board 63 is located behind (-X) the stator 61. The circuit board 63 is positioned perpendicular to the central axis J. The ends of the coil wires that make up the coil 61b are connected to the circuit board 63. In other words, the coil 61b is connected to the circuit board 63. The circuit board 63 controls the rotation of the rotor 62 by controlling the voltage applied to the coil 61b.

[0031] The motor frame 64 constitutes the outer casing of the molded electric motor 60. The motor frame 64 is formed by covering at least a portion of the stator 61 and circuit board 63 with molded resin 64M. The motor frame 64 is provided with a concave portion 64a that extends in the front-rear direction around the central axis J. The concave portion 64a opens forward. The rotor 62 is arranged inside the concave portion 64a. A bearing holding portion 64b is formed at the bottom of the concave portion 64a. The bearing holding portion 64b has a cylindrical surface facing radially inward, and holds the bearing 68 from the radially outward direction on this cylindrical surface. A bearing holder 66 is fixed to the opening of the concave portion 64a. The bearing holder 66 holds the bearing 67. A cover 69 that covers the bearing holder 66 is arranged in front of the bearing holder 66. The outer circumferential surface of the motor frame 64 facing radially outward has a convex portion 64c. The protrusion 64c projects radially outward. A portion of the lead wire holding member 70 is embedded inside the protrusion 64c.

[0032] Multiple lead wires 80 transmit power and control signals to be supplied to the circuit board 63. Each lead wire 80 has a first end 80a and a second end 80b. The first end 80a is connected to the circuit board 63. A connector portion 89 is provided at the second end 80b. The connector portion 89 is connected to the control unit 17 of the outdoor unit 10 (see Figure 1). Therefore, the multiple lead wires 80 connect the circuit board 63 of the molded motor 60 to the control unit 17 of the outdoor unit 10.

[0033] Multiple lead wires 80 are drawn out from inside the motor frame 64 to the outside. At the first end 80a of the multiple lead wires 80, they are embedded in the motor frame 64, and at the second end 80b, they are exposed from the motor frame 64. The multiple lead wires 80 are bundled together outside the motor frame 64 and covered by a tube 90.

[0034] The lead wire holding member 70 leads out multiple lead wires 80 to the outside of the motor frame 64. The lead wire holding member 70 holds the multiple lead wires 80. The lead wire holding member 70 is also held by the motor frame 64.

[0035] Figure 4 is a perspective view of a lead wire holding member 70 provided in the molded electric motor 60 of this embodiment. The lead wire holding member 70 has block-shaped first member 71 and second member 72. The first member 71 and the second member 72 are stacked in the front-rear direction. The first member 71 is located in front of (+X) the second member 72. The first member 71 has a first opposing surface 71f facing rear (-X). The first opposing surface 71f is provided with a plurality of first grooves 71g extending in the vertical direction (Z-axis direction). The second member 72 has a second opposing surface 72f facing forward (+X). The second opposing surface 72f is provided with a plurality of second grooves 72g extending in the vertical direction (Z-axis direction). The first opposing surface 71f and the second opposing surface 72f face each other and are in contact. The first groove 71g and the second groove 72g face each other and overlap to form a through hole 70h. That is, the lead wire holding member 70 has multiple through holes 70h. The through holes 70h penetrate the lead wire holding member 70 in the vertical direction (Z-axis direction). The through holes 70h are circular when viewed from the vertical direction. A lead wire 80 is passed through each of the through holes 70h. That is, the multiple through holes 70h hold each of the multiple lead wires 80. In addition, the first member 71 and the second member 72 sandwich the multiple lead wires 80 from the front-to-back direction (X-axis direction).

[0036] The lead wire holding member 70 is partially embedded in the protrusion 64c of the motor frame 64, and the other part protrudes from the outer surface of the motor frame 64 and is exposed from the motor frame 64. That is, the lead wire holding member 70 has an embedded portion 70b that is embedded in the motor frame 64 and a protruding portion 70a that protrudes from the outer surface of the motor frame 64. The protruding portion 70a has a protruding surface 70d that faces downward (-Z). Multiple openings 70k of through holes 70h are provided in the protruding surface 70d. The multiple openings 70k are arranged in a straight line in the left-right direction (Y-axis direction). Multiple lead wires 80 extend out from their respective openings 70k.

[0037] The first member 71 and the second member 72 of the lead wire holding member 70 are held in the mold that forms the motor frame 64 with the lead wire 80 sandwiched between them. The protruding portion 70a is sandwiched between the mold that opens and closes in the front-to-back direction (X-axis direction), and the embedded portion 70b is positioned inside the cavity of the mold. This allows the protruding portion 70a to protrude from the outer surface of the motor frame 64, and the embedded portion 70b to be embedded inside the motor frame 64.

[0038] Figure 5 is a front view of the tube 90 provided in the molded electric motor 60 of this embodiment. The tube 90 is flexible. The tube 90 bundles and covers a plurality of lead wires 80 located outside the motor frame 64. The tube 90 has an opposing end 91 that faces the protruding surface 70d of the lead wire holding member 70. That is, the opposing end 91 is positioned with a gap between a plurality of openings 70k.

[0039] In this embodiment, a sealing material 9 is provided in the region between the opposing end 91 of the tube 90 and the protrusion 64c of the motor frame 64. The sealing material 9 is applied to the target region in an uncured state and then cured. It is preferable to use acrylic modified silicone resin as the sealing material 9. Acrylic modified silicone resin has excellent heat resistance and cold resistance. Therefore, by using acrylic modified silicone resin as the sealing material 9, the sealing performance of the sealing material 9 can be maintained even when used outdoors regardless of the season. Furthermore, since acrylic modified silicone resin cures at room temperature, heating for curing is unnecessary, and the manufacturing process of the molded electric motor 60 can be simplified.

[0040] The sealing material 9 has a first sealing portion 9a, a second sealing portion 9b, a third sealing portion 9c, and a fourth sealing portion 9d. The first sealing portion 9a, the second sealing portion 9b, the third sealing portion 9c, and the fourth sealing portion 9d are connected to each other. The first sealing portion 9a covers a plurality of lead wires 80. The first sealing portion 9a seals the gap between the opening 70k and the lead wires 80. The second sealing portion 9b covers the surface of the protruding portion 70a. The second sealing portion 9b seals the gap at the boundary between the first member 71 and the second member 72. The third sealing portion 9c covers the boundary between the protruding portion 70a and the motor frame 64. The third sealing portion 9c seals the gap at the boundary between the motor frame 64 and the lead wire holding member 70. The fourth sealing portion 9d covers the tip edge of the opposing end 91 of the tube 90. The fourth sealing portion 9d, together with the first sealing portion 9a, seals the gap between the lead wire 80 and the tube 90.

[0041] According to this embodiment, the sealing material 9 blocks the water ingress path into the motor frame 64 at the first sealing portion 9a, the second sealing portion 9b, and the third sealing portion 9c, thereby protecting the circuit board 63 located inside the motor frame 64.

[0042] According to this embodiment, the sealing material 9 seals the gap between the lead wire 80 and the tube 90 in the first sealing portion 9a and the fourth sealing portion 9d. Since the lead wires 80 extending from the opening 70k are aligned in the left-right direction with a gap in between, the sealing material 9 may not wrap around the lead wires 80 sufficiently, and uncoated areas may remain between the lead wires 80. If these uncoated areas reach the lower (-Z side) end of the sealing material 9, they may become a pathway for water to enter the motor frame 64. According to this embodiment, the sealing material 9 covers the entirety of the multiple lead wires 80 between the opposing end 91 and the protruding portion. This prevents the uncoated areas that may form between the multiple lead wires 80 from becoming pathways for moisture to enter, and protects the circuit board 63 from moisture. According to this embodiment, a molded electric motor 60 with improved waterproof reliability can be provided.

[0043] In this embodiment, the opposing end 91 is provided with a single notch 91c extending in the longitudinal direction of the tube 90. Multiple lead wires 80 are bundled together without gaps inside the tube 90. On the other hand, the multiple lead wires 80 are held by the lead wire holding member 70 with gaps between them in the left-right direction. As a result, the multiple lead wires 80 extend so as to spread out in the left-right direction between the opposing end 91 and the opening 70k. According to this embodiment, by providing the notch 91c in the opposing end 91, the opening of the opposing end 91 can be widened. This makes it possible to bring the tip of the opposing end 91 closer to the opening 70k compared to the case where the notch 91c is not provided, and the amount of sealing material 9 (first sealing portion 9a) used between the opposing end 91 and the protruding portion 70a can be reduced.

[0044] Furthermore, according to this embodiment, by bringing the opposing end 91 closer to the protruding portion 70a, at least a portion of the gap between the lead wires 80 can be covered with the tube 90. Therefore, when applying uncured sealant 9 to multiple lead wires 80 with the paper depth direction of Figure 5 as the direction of gravity, it is possible to prevent the uncured sealant 9 from flowing down to the opposite side through the gap between the lead wires 80, thereby simplifying the sealant application process and reducing the amount of sealant 9 used.

[0045] In Figure 5, the outer circumference of the tube 90 is shown covered with the sealing material 9 over the entire circumference of a region equivalent to the depth of the notch 91c of the tube 90. However, the sealing material 9 may cover only the tip edge of the opposing end 91 and the notch 91c.

[0046] (Summary of the first embodiment) As shown in Figure 3, the molded electric motor 60 of this embodiment comprises a rotor 62, a stator 61, a circuit board 63, a motor frame 64, a plurality of lead wires 80, a lead wire holding member 70, and a tube 90. The rotor 62 rotates around a central axis J. The stator 61 faces the rotor 62 radially and has coils 61b. The circuit board 63 is to which the coils 61b are connected. The motor frame 64 is formed by covering at least a portion of the stator 61 and the circuit board 63 with molded resin 64M. The plurality of lead wires 80 are connected to the circuit board 63. The lead wire holding member 70 leads the plurality of lead wires 80 to the outside of the motor frame 64. The tube 90 bundles and covers the plurality of lead wires 80 located outside the motor frame 64. As shown in Figure 4, the lead wire holding member 70 has a plurality of through holes 70h for holding each of the plurality of lead wires 80, an embedded portion 70b that is embedded in the motor frame 64, and a protruding portion 70a that protrudes from the outer surface of the motor frame 64. The protruding portion 70a is provided with a plurality of openings 70k of the plurality of through holes 70h. The tube 90 has opposing ends 91 that are positioned with gaps between the plurality of openings 70k. The opposing ends 91 are provided with notches 91c that extend in the longitudinal direction of the tube 90. As shown in Figure 5, a sealing material 9 is provided that covers the plurality of lead wires 80, spanning the opposing ends 91 and the protruding portion 70a.

[0047] According to the above configuration, the sealing material 9 can cover the multiple lead wires 80 between the opposing end 91 and the protruding portion 70a, thereby sealing the gap between the lead wires 80 and the tube 90. This prevents uncoated portions of the sealing material 9 that may form between the multiple lead wires 80 from becoming pathways for moisture to enter the motor frame 64. Furthermore, according to the above configuration, the opposing end 91 is provided with a notch 91c that extends in the longitudinal direction of the tube 90. The multiple lead wires 80 extend between the opposing end 91 and the opening 70k, widening the gap between them as they move toward the opening 70k. By providing the notch 91c in the opposing end 91, the opening of the opposing end 91 can be widened to accommodate the multiple lead wires 80. This makes it possible to bring the tip of the opposing end 91 closer to the opening 70k compared to the case where the notch 91c is not provided, thereby reducing the amount of sealing material 9 used between the opposing end 91 and the protruding portion 70a. Furthermore, by bringing the opposing end 91 closer to the protruding portion 70a, at least a portion of the gap between the lead wires 80 can be covered with the tube 90. This prevents uncured sealant 9 from flowing out of the gap between the lead wires 80 during the coating process, and simplifies the coating process for the sealant 9.

[0048] Furthermore, as shown in Figure 5, the sealing material 9 of this embodiment covers multiple lead wires 80 and protrusions 70a across the opposing end 91 and the motor frame 64. According to this embodiment, the sealing material 9 can suppress the intrusion of moisture from the boundary between the motor frame 64 and the protrusions 70a. Moreover, when the lead wire holding member 70 is composed of multiple members (first member 71 and second member 72) and its boundary appears on the surface of the protrusions 70a, the intrusion of moisture from that boundary can be suppressed.

[0049] Furthermore, as shown in Figure 2, the outdoor unit 10 of this embodiment is an outdoor unit 10 of a refrigeration cycle device 100, and comprises a compressor 12, a heat exchanger 13, and a blower 15 that generates an airflow passing through the heat exchanger 13. The blower 15 has the molded motor 60 described above and a rotor blade 15b that is rotated by the molded motor 60. With this configuration, by providing the outdoor unit 10 with a molded motor 60 that has enhanced waterproof performance, the reliability of the outdoor unit 10 can be ensured even when the outdoor unit 10 is placed outdoors.

[0050] (modified version) Figure 6 is a front view of a modified tube 190 that can be used in the molded electric motor 60 of the first embodiment. This modified tube 190 differs from the first embodiment mainly in that it has multiple notches 191c. Note that components similar to those in the above-described embodiment are denoted by the same reference numerals in the figure and their descriptions are omitted.

[0051] In this modified example, the opposing end 191 of the tube 190 is provided with a plurality of notches 191c extending in the longitudinal direction of the tube 190. The plurality of notches 191c are arranged at approximately equal intervals at the opposing end 191.

[0052] According to this modified example, by providing multiple notches 191c at the opposing end 191, the depth of each notch 191c can be reduced compared to the case where only one notch is provided. This reduces the amount of sealing material 109 that is placed on the outer circumference of the tube 190 to cover the notches 191c.

[0053] (Second Embodiment) Figure 7 is a perspective view of the lead wire holding member 270 provided in the molded electric motor 260 of the second embodiment. Note that components similar to those in the above-described embodiment and its modified form are denoted by the same reference numerals in the figure and their descriptions are omitted.

[0054] Similar to the embodiment described above, the lead wire holding member 270 has a block-shaped first member 271 and a second member 272. The first member 271 is provided with a plurality of first grooves 271g, and the second member 272 is provided with a plurality of second grooves 272g. The first member 271 and the second member 272 face each other and are in contact. As a result, the first grooves 271g and the second grooves 272g face each other and overlap to form a through hole 270h. That is, the lead wire holding member 270 has a plurality of through holes 270h. The plurality of through holes 270h hold each of the plurality of lead wires 80. In addition, the first member 271 and the second member 272 sandwich the plurality of lead wires 80 from the front-to-back direction (X-axis direction).

[0055] The lead wire holding member 270 has an embedded portion 270b that is embedded in the motor frame 64 and a protruding portion 270a that protrudes from the outer surface of the motor frame 64. The protruding portion 270a is provided with a sprouting surface 270d that faces downward (-Z) and a frame-shaped portion 270f that surrounds the sprouting surface 270d. The sprouting surface 270d is rectangular when viewed from below. The frame-shaped portion 270f protrudes downward relative to the sprouting surface 270d. The frame-shaped portion 270f is provided along the outer edge. Therefore, the frame-shaped portion 270f is rectangular when viewed from below. The sprouting surface 270d is provided with multiple openings 270k of through holes 270h. The multiple openings 270k are arranged in a straight line in the left-right direction (Y-axis direction). Multiple lead wires 80 extend out from each of the openings 270k.

[0056] Figure 8 is a front view of the tube 290 provided in the molded electric motor 260 of this embodiment. Similar to the embodiment described above, the tube 290 bundles and covers a plurality of lead wires 80 located outside the motor frame 64. The tube 290 has an opposing end 291 that faces the growing surface 270d of the lead wire holding member 270. That is, the opposing end 291 is positioned with a gap between a plurality of openings 270k.

[0057] In this embodiment, a sealing material 209 is provided in the region between the opposing end 291 of the tube 290 and the protrusion 64c of the motor frame 64. The sealing material 209 is applied to the target region in an uncured state.

[0058] The sealing material 209 has a first sealing portion 209a, a second sealing portion 209b, a third sealing portion 209c, and a fourth sealing portion 209d. The first sealing portion 209a, the second sealing portion 209b, the third sealing portion 209c, and the fourth sealing portion 209d are connected to each other. The first sealing portion 209a covers a plurality of lead wires 80. The first sealing portion 209a closes the gap between the opening 270k and the lead wires 80. The second sealing portion 209b covers at least a portion of the surface of the protruding portion 270a. The second sealing portion 209b closes the gap at the boundary between the first member 271 and the second member 272. The third sealing portion 209c covers the boundary between the protruding portion 270a and the motor frame 64. The third sealing portion 209c closes the gap at the boundary between the motor frame 64 and the lead wire holding member 270. The fourth sealing portion 209d covers the leading edge of the opposing end 291 of the tube 290. Together with the first sealing portion 209a, the fourth sealing portion 209d seals the gap between the lead wire 80 and the tube 290.

[0059] According to this embodiment, the sealing material 209 blocks the water intrusion path into the motor frame 64 at the first sealing portion 209a, the second sealing portion 209b, and the third sealing portion 209c, thereby protecting the circuit board 63 located inside the motor frame 64. According to this embodiment, a molded electric motor 260 with enhanced waterproof reliability can be provided. Furthermore, according to this embodiment, the sealing material 209 blocks the gap between the lead wire 80 and the tube 290 at the first sealing portion 209a and the fourth sealing portion 209d. This prevents uncoated portions of the sealing material 209 that may form between multiple lead wires 80 from becoming pathways for moisture to enter.

[0060] According to this embodiment, the lead wire holding member 270 has a frame-shaped portion 270f that surrounds a plurality of lead wires 80 and protrudes toward the opposing end 291 side of the tube 290. By providing the frame-shaped portion 270f, the distance between the opposing end 291 and the lead wire holding member 270 is reduced. This reduces the amount of sealing material 209 (first sealing portion 209a) used, which is placed between the tip of the opposing end 291 and the lead wire holding member 270. Furthermore, by providing the frame-shaped portion 270f on the lead wire holding member 270, at least a portion of the gap between the lead wires 80 can be covered by the frame-shaped portion 270f. Therefore, when applying uncured sealing material 209 to a plurality of lead wires 80 with the depth direction of the paper in Figure 7 as the direction of gravity, it is possible to prevent the uncured sealing material 209 from flowing down to the opposite side through the gap between the lead wires 80, and the sealing material 209 application process can be simplified.

[0061] A window portion 209w is provided in the second seal portion 209b. The window portion 209w is formed by leaving a portion of the front (+X) facing surface of the lead wire holding member 270 uncoated. The lead wire holding member 270 is exposed from the seal material 209 in the portion where the window portion 209w is provided. That is, the protruding portion 270a is provided with an exposed portion 270e that is exposed from the seal material 209. According to this embodiment, since the seal material 209 does not cover the lead wire holding member 270 in the exposed portion 270e, the amount of seal material 209 used can be reduced. This makes it possible to reduce the weight and cost of the molded motor 260.

[0062] In this embodiment, the exposed portion 270e is provided on the surface of the first member 271 facing forward (+X). That is, the exposed portion 270e is located in a different area from the boundary between the first member 271 and the second member 272. Therefore, it is possible to suppress moisture from penetrating the boundary between the first member 271 and the second member 272 via the exposed portion 270e. In Figure 8, the exposed portion 270e is shown as being provided in front (+X) of the lead wire holding member 270, but the exposed portion 270e may also be provided behind (-X) the lead wire holding member 270.

[0063] (Summary of the second embodiment) The molded electric motor 260 of this embodiment, similar to the embodiment described above (Figure 3), comprises a rotor 62, a stator 61, a circuit board 63, a motor frame 64, a plurality of lead wires 80, a lead wire holding member 270, and a tube 290. The rotor 62 rotates around a central axis J. The stator 61 faces the rotor 62 radially and has coils 61b. The circuit board 63 is to which the coils 61b are connected. The motor frame 64 is formed by covering at least a portion of the stator 61 and the circuit board 63 with molded resin 64M. The plurality of lead wires 80 are connected to the circuit board 63. The lead wire holding member 270 leads the plurality of lead wires 80 to the outside of the motor frame 64. The tube 290 bundles and covers the plurality of lead wires 80 located outside the motor frame 64. As shown in Figure 7, the lead wire holding member 270 has a plurality of through holes 270h for holding each of the plurality of lead wires 80, an embedded portion 270b that is embedded in the motor frame 64, and a protruding portion 270a that protrudes from the outer surface of the motor frame 64. The protruding portion 270a is provided with a plurality of openings 270k of the plurality of through holes 270h, and a frame-shaped portion 270f that surrounds the plurality of openings 270k. The tube 290 has opposing ends 291 that are positioned with gaps between the plurality of openings 270k. As shown in Figure 8, a sealing material 209 is provided that covers the plurality of lead wires 80, spanning the opposing ends 291 and the frame-shaped portion 270f.

[0064] According to the above configuration, the sealing material 209 can cover the multiple lead wires 80 between the opposing end 291 and the protruding portion 270a, thereby sealing the gap between the lead wires 80 and the tube 290. This prevents uncoated portions of the sealing material 209 that may form between the multiple lead wires 80 from becoming pathways for moisture to enter the motor frame 64. Furthermore, according to the above configuration, the protruding portion 270a is provided with a frame-shaped portion 270f that surrounds the multiple openings 270k. This reduces the distance between the protruding portion 270a and the opposing end 291, thereby reducing the amount of sealing material 209 (first sealing portion 209a) used between the opposing end 291 and the protruding portion 270a. In addition, since the frame-shaped portion 270f surrounds the multiple lead wires 80, at least a portion of the gap between the lead wires 80 can be covered by the frame-shaped portion 270f. This prevents uncured sealant 209 from flowing out through the gaps between the lead wires 80 during the coating process, thereby simplifying the coating process for the sealant 209.

[0065] In the molded electric motor 260 of this embodiment, the lead wire holding member 270 has a first member 271 and a second member 272 that sandwich a plurality of lead wires 80, as shown in Figure 7. As shown in Figure 8, the sealing material 209 has a first sealing portion 209a that covers the plurality of lead wires 80, a second sealing portion 209b that covers at least a part of the surface of the protruding portion 270a, a third sealing portion 209c that covers the boundary between the protruding portion 270a and the motor frame 64, and a fourth sealing portion 209d that covers the tip edge of the opposing end 291. The protruding portion 270a is provided with an exposed portion 270e that is exposed from the second sealing portion 209b. The exposed portion 270e is located in a different part from the boundary between the first member 271 and the second member 272.

[0066] With the above configuration, the sealing material 209 can block the water intrusion path into the motor frame 64 at the first sealing portion 209a, the second sealing portion 209b, and the third sealing portion 209c, thereby protecting the circuit board 63 located inside the motor frame 64. Furthermore, since the second sealing portion 209b does not cover the exposed portion 270e of the lead wire holding member 270, the amount of sealing material 209 used can be reduced. In addition, since the exposed portion 270e is located in a different area from the boundary between the first member 271 and the second member 272, water intrusion into the boundary between the first member 271 and the second member 272 via the exposed portion 270e can be suppressed.

[0067] While embodiments of this disclosure have been described above, this disclosure is not limited to the configurations of the embodiments described above, and the following configurations and methods may also be adopted. Furthermore, the configurations and methods described herein can be combined as appropriate, within the bounds of non-inconsistency.

[0068] For example, in the first embodiment described above, the sealing material 9 covers the entire protruding portion 70a of the lead wire holding member 70, and in the second embodiment described above, a window portion 209w is provided in the sealing material 109 that exposes the exposed portion 270e of the protruding portion 270a. However, the sealing material may form an exposed portion on the protruding portion 70a in the first embodiment, or it may cover the entire protruding portion 270a in the second embodiment.

[0069] Furthermore, the refrigeration cycle device to which the outdoor unit of this disclosure is installed may be any device that utilizes a refrigeration cycle in which a refrigerant is circulated, and is not limited to an air conditioner. The refrigeration cycle device may also be a heat pump water heater or the like. [Explanation of Symbols]

[0070] 9, 109, 209…Sealing material, 9a, 209a…First seal section, 9b, 209b…Second seal section, 9c, 209c…Third seal section, 9d, 209d…Fourth seal section, 10…Outdoor unit, 12…Compressor, 13, 22…Heat exchanger, 15, 23…Blower, 15b…Rotor blade, 60, 260…Molded motor, 61…Stator, 61b…Coil, 62…Rotor, 63…Circuit board, 64…Motor frame, 64M…Molded resin 70,270…Lead wire holding member, 70a,270a…Protruding part, 70b,270b…Buried part, 70h,270h…Through hole, 70k,270k…Opening, 71,271…First member, 72,272…Second member, 80…Lead wire, 90,190,290…Tube, 91,191,291…Opposite end, 91c,191c…Notched part, 100…Refrigeration cycle device, 270e…Exposed part, 270f…Frame-shaped part, J…Central axis

Claims

1. A rotor that rotates around a central axis, A stator having a coil and facing radially from the rotor, A circuit board to which the aforementioned coil is connected, A motor frame formed by covering at least a portion of the stator and the circuit board with molded resin, Multiple lead wires connected to the circuit board, A lead wire holding member for bringing the plurality of lead wires out to the outside of the motor frame, The motor frame comprises a tube that bundles and covers the plurality of lead wires located outside the motor frame, The lead wire holding member is Multiple through holes for holding each of the multiple lead wires, The embedded portion is embedded in the motor frame, The motor frame has a protruding portion that extends from the outer surface and is provided with multiple openings of the multiple through holes, The tube has the plurality of openings and opposing ends that are arranged with gaps between them, The plurality of lead wires are held by the lead wire holding member with gaps between them in the direction in which the plurality of openings are aligned in a straight line, and extend so as to spread out in the direction between the opposing ends and the plurality of openings. The opposing end is provided with a notch that extends in the longitudinal direction of the tube, A sealing material is provided that covers the plurality of lead wires, spanning the opposing end and the protruding portion. Molded electric motor.

2. Multiple notches are provided at the opposing end. A molded electric motor according to claim 1.

3. A rotor that rotates around a central axis, A stator having a coil and facing radially from the rotor, A circuit board to which the aforementioned coil is connected, A motor frame formed by covering at least a portion of the stator and the circuit board with molded resin, Multiple lead wires connected to the circuit board, A lead wire holding member for bringing the plurality of lead wires out to the outside of the motor frame, The motor frame comprises a tube that bundles and covers the plurality of lead wires located outside the motor frame, The lead wire holding member is Multiple through holes for holding each of the multiple lead wires, The embedded portion is embedded in the motor frame, The motor frame has a protruding portion that extends from the outer surface and has multiple openings of the multiple through holes, and a frame-shaped portion that surrounds the multiple openings, The tube has the plurality of openings and opposing ends that are arranged with gaps between them, A sealing material is provided that covers the plurality of lead wires, spanning the opposing ends and the frame-shaped portion. Molded electric motor.

4. The sealing material spans the opposing end and the motor frame, covering the plurality of lead wires and the protruding portion. A molded electric motor according to claim 1.

5. The lead wire holding member has a first member and a second member that sandwich the plurality of lead wires, A first sealing portion covering the plurality of lead wires, A second sealing portion that covers at least a part of the surface of the protruding portion, A third sealing portion covers the boundary between the protruding portion and the motor frame, It has a fourth sealing portion that covers the tip edge of the opposing end, The protruding portion is provided with an exposed portion that is exposed from the second sealing portion. The exposed portion is located in a part different from the boundary between the first member and the second member. A molded electric motor according to claim 1.

6. The sealing material is an acrylic-modified silicone resin. A molded electric motor according to claim 1.

7. An outdoor unit of a refrigeration cycle system, It comprises a compressor, a heat exchanger, and a blower that generates an airflow that passes through the heat exchanger, The aforementioned blower is, A molded electric motor according to any one of claims 1 to 6, A rotor having a rotor that is rotated by the aforementioned molded motor, outdoor unit.

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