stata

Abstract

To manufacture a stator 1 at a low cost.SOLUTION: In a split core 11 of a stator 1, two core pieces 111 adjacent to each other in an axial direction 71 are bonded to each other with adhesive films 12A, 12B formed over the entirety of slot surfaces 118A, 118B. Insulators 14A, 14B each have a protrusion 144. The protrusions 144 respectively protrude from the slot surfaces 118A, 118B toward slots 117A, 117B so that a coil 13 may be electrically insulated from the split core 11.SELECTED DRAWING: Figure 7

Description

[[Technical Field]]

[0001] The present invention relates to a stator used in a rotating electric machine such as a motor or a generator. [[Background Art]]

[0002] In a motor for an electric vehicle or the like, a core is manufactured by laminating a plurality of core pieces and joining them with an adhesive. The core forms slots for arranging coils by means of teeth and a core back (see Patent Document 1). [[Prior Art Documents]] [[Patent Documents]]

[0003] [[Patent Document 1]] Japanese Unexamined Patent Publication No. 2021-111977 [[Summary of the Invention]] [[Problems to be Solved by the Invention]]

[0004] For example, when a plurality of core pieces are joined with an adhesive interposed between the plurality of core pieces, the axial dimension of the core pieces increases, and the proportion of the core pieces, which are magnetic bodies, occupied in the volume of the core decreases. In Patent Document 1, for joining all core pieces, an adhesive is applied to a part of a slot surface that defines a slot in the core to form an adhesive film. However, in order to electrically insulate the coil from the slot surface, a resin insulating sheet is attached to the slot. Therefore, in the motor manufacturing process, a process of cutting and bending the insulating sheet according to the slot shape, a process of attaching the insulating sheet to the slot, and the like are required. As a result, manufacturing cost has increased.

[0005] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a stator that can be manufactured at low cost without reducing the proportion of core pieces, which are magnetic bodies, occupied in the volume of the core. [[Means for Solving the Problems]]

[0006] (1) The present invention relates to a stator comprising: a core having a slot surface along the axial direction that divides a slot, wherein a plurality of core pieces are stacked in the axial direction; an adhesive film covering the entire area of ​​the slot surface; a plurality of insulators each covering two end faces of the core that are perpendicular to the axial direction, and each having a protrusion that projects from the slot surface along the end faces to the slot; and a coil wound around the plurality of insulators.

[0007] According to the above configuration, the adhesive film joins multiple core pieces together, making it possible to reduce the axial dimensions of the core. Since the adhesive film electrically insulates between the slot surface and the coil, there is no need to separately provide an insulating sheet inside the slot.

[0008] (2) The above-mentioned insulator does not cover the above-mentioned adhesive film.

[0009] With the above configuration, since the insulator does not cover the adhesive film, the insulator does not affect the space factor occupied by the coil in the slot.

[0010] (3) The insulator has a groove extending along the end face at a position closer to the end face than the protrusion, and a portion of the adhesive film enters the groove.

[0011] According to the above configuration, as the adhesive hardens, the adhesive film that has entered each groove contracts in the axial direction, causing multiple core pieces to adhere tightly to each other.

[0012] (4) The core has a hole that is recessed in the axial direction from the end face, and the insulator has a rod portion that enters the hole.

[0013] According to the above configuration, the rod portion enters the hole, allowing the insulator to be positioned at the end face of the core.

[0014] (5) The core has a core back extending in the circumferential direction centered on the axial direction, and teeth extending radially from the core back centered on the axial direction, and the hole is located in the core back at a position radially away from the teeth.

[0015] With the above configuration, the holes are less likely to affect the magnetic flux formed by the coil. [Effects of the Invention]

[0016] According to the present invention, a stator can be manufactured at low cost without reducing the proportion of magnetic core pieces that occupy the core volume. [Brief explanation of the drawing]

[0017] [Figure 1] A cross-sectional view showing the internal structure of the rotating electric machine 100. [Figure 2] A cross-sectional view of the rotating electric machine 100 along line II-II in Figure 1. [Figure 3] Decomposed perspective view of the split core 11 and insulators 14A and 14B. [Figure 4] (A) is a schematic diagram showing the slots 117A and 117B formed by the divided core 11, and (B) is a perspective view showing the grooves 145A and 145B of the insulator 14A. [Figure 5] (A) is a front view of the protrusion 144 of the insulator 14A, and (B) is a side view of the protrusion 144 of the insulator 14A in figure (A). [Figure 6] A perspective view showing insulators 14A and 14B attached to the split core 11. [Figure 7] (A) is a cross-sectional view of adhesive films 12A and 12B along line II-II in Figure 1, and (B) is a side view of adhesive film 12B shown in Figure (A). [Figure 8] (A) is a cross-sectional view of coil 13 along line II-II in Figure 1, and (B) is a side view of coil 13 shown in Figure (A). [Figure 9] A schematic diagram showing the configuration of the rotating electric machine 200. [Figure 10](A) is a schematic diagram showing the stator 8 as viewed from the outside in the radial direction 73, and (B) is a cross-sectional view of the stator 8 taken along line X-X in FIG. (A). [Figure 11] A front view of the stator 8. MODE FOR CARRYING OUT THE INVENTION

[0018] Hereinafter, a rotary electric machine 100 including the stator 1 according to an embodiment of the present invention will be described. It goes without saying that the embodiment described below is merely an example of the present invention, and the embodiment can be appropriately changed without changing the gist of the present invention.

[0019] [Schematic Configuration of Rotary Electric Machine 100] As shown in FIG. 1, the rotary electric machine 100 is an inner-rotor type brushless motor. The rotary electric machine 100 includes a stator 1, a rotor 2, and a shaft 3 inside a housing 4. The rotary electric machine 100 is electrically connected to a controller 6 via a harness 5.

[0020] [Rotor 2, Shaft 3] Hereinafter, the rotor 2 and the shaft 3 will be described. As shown in FIG. 1, the rotor 2 is rotatable around an axis 21. The axis 21 extends in the axial direction 71. As shown in FIG. 2, in the rotor 2, a rotor core 22 has a substantially cylindrical outer peripheral surface 23 and an inner peripheral surface 24. Eight magnets 25 are arranged on the outer peripheral surface 23 at equal angular intervals in the circumferential direction 72 of the axis 21. That is, the rotor 2 is of a SPM type. By each of the magnets 25, N poles and S poles alternately appear on the outer peripheral surface 23 in the circumferential direction 72.

[0021] As shown in FIGS. 1 and 2, the shaft 3 is inserted through a through hole formed by the inner peripheral surface 24 and fixed to the inner peripheral surface 24. The shaft 3 protrudes from the rotor 2 in the axial direction 71 and is supported by a bearing 41 provided on the housing 4. One end of the shaft 3 protrudes to the outside of the housing 4 and serves as an output shaft of the brushless motor. Hereinafter, for convenience of description, the side where the shaft 3 protrudes in the housing 4 is defined as the "front side" in the axial direction 71.

[0022] [Stator 1, Split Core 11] As shown in Figure 2, the stator 1 has a generally cylindrical shape and is positioned to surround the outer circumferential surface 23 of the rotor 2. The stator 1 has 12 segmented cores 11. As shown in Figure 3, each segmented core 11 is manufactured by stacking multiple core pieces 111 in the axial direction 71 and joining them with adhesive films 12A, 12B (see Figure 7). Each core piece 111 is made of electrical steel sheet with a thickness of approximately 0.25 mm.

[0023] As shown in Figures 2 and 3, each segmented core 11 has a roughly T-shape when viewed from the front in the axial direction 71 (hereinafter also referred to as "front view"), and has a core back 112 and teeth 113.

[0024] As shown in Figure 2, the core back 112 is located away from the rotor 2 in the radial direction 73 of the axis 21. As shown in Figure 3, the core back 112 has a plate-like shape that is elongated in the axial direction 71 and has an outer surface 112A, side surfaces 112B, 112C, inner surfaces 112D, 112E, and end surfaces 112F, 112G. Note that each figure shows an example of the radial direction 73. With respect to the radial direction 73, the side farther from the axis 21 is referred to as the "outer side". Also, the side closer to the axis 21 in the radial direction 73 is referred to as the "inner side".

[0025] The outer surface 112A faces outward in the radial direction 73 and has a roughly circular arc shape when viewed from the front. Hereinafter, the perpendicular bisector passing through the center of the circumferential direction 72 on the outer surface 112A will be referred to as the "reference plane 114". The direction perpendicular to the reference plane 114 will be referred to as the "orthogonal direction 74". Each figure shows an example of the orthogonal direction 74. In the orthogonal direction 74, the side farther from the reference plane 114 will be referred to as the "far side". In the orthogonal direction 74, the side closer to the reference plane 114 will be referred to as the "near side".

[0026] The sides 112B and 112C extend axially 71 and radially 73 at both ends in the circumferential direction 72 of the core back 112. The sides 112B and 112C are symmetrical with respect to the reference plane 114. The inner surfaces 112D and 112E are located at the inner ends of the core back 112, are separated in the orthogonal direction 74, and are symmetrical with respect to the reference plane 114. The end faces 112F and 112G are located at both ends in the axial direction 71 of the core back 112.

[0027] A hole 115 is formed in the core back 112. The hole 115 penetrates axially 71 between the end faces 112F and 112G. In the radial direction 73, the hole 115 is located closer to the outer surface 112A than to the inner surfaces 112D and 112E. In the circumferential direction 72, the hole 115 is located midway between the side surfaces 112B and 112C. The hole 115 has a shape symmetrical with respect to the reference surface 114 (e.g., circular).

[0028] As shown in Figure 2, the teeth 113 extend from the center of the circumferential direction 72 in the core back 112 toward the rotor 2. The extended ends of the teeth 113 face the outer circumferential surface 23 of the rotor 2 with a gap between them. As shown in Figure 3, the teeth 113 have side surfaces 113A, 113B, a tooth tip surface 113C, inclined surfaces 113D, 113E, connecting surfaces 113F, 113G, and end surfaces 113H, 113I.

[0029] The side surfaces 113A and 113B extend parallel to the reference plane 114 toward the rotor 2 from the near ends of the inner surfaces 112D and 112E. The extended ends of the side surfaces 113A and 113B are slightly separated from the outer circumferential surface 23 (see Figure 2). The side surfaces 113A and 113B are separated from each other by an equal distance in the orthogonal direction 74 from the reference plane 114.

[0030] The tooth tip surface 113C has a substantially arc shape extending in the circumferential direction 72 when viewed from the front, and is symmetrical with respect to the reference surface 114. The tooth tip surface 113C faces the outer circumferential surface 23 with a gap inward from the side surfaces 113A and 113B. On the tooth tip surface 113C, both ends in the circumferential direction 72 are located further away in the orthogonal direction 74 than the side surfaces 113A and 113B. Note that in Figure 2, only one tooth tip surface is labeled with reference numeral 113C.

[0031] The inclined surface 113D has a rectangular shape that is elongated in the axial direction 71 and is inclined with respect to the orthogonal direction 74. In detail, the inclined surface 113D extends from the inner end of the side surface 113A toward the far side in the orthogonal direction 74, while narrowing the distance from the tooth tip surface 113C. The inclined surface 113E has a shape that is symmetrical with respect to the inclined surface 113D and the reference surface 114. The extended ends of the inclined surfaces 113D and 113E are connected to one end and the other end of the tooth tip surface 113C in the circumferential direction 72, respectively, via connecting surfaces 113F and 113G.

[0032] The end faces 113H and 113I are located at both ends of the tooth 113 in the axial direction 71 and are flush with the end faces 112F and 112G of the core back 112. Flush means parallel without any steps. Hereinafter, the combination of end faces 113H and 112F will be referred to as "end face 116A," and the combination of end faces 113I and 112G will be referred to as "end face 116B."

[0033] As shown in Figure 4(A), slots 117A and 117B are formed in the divided core 11. Slots 117A and 117B are spaces in which the coil 13 (see Figure 2) is placed, and are the areas enclosed by dashed lines in Figure 4(A). Slot 117A is shown to the left of the reference plane 114 in Figure 4(A). Slots 117A and 117B are demarcated by slot surfaces 118A and 118B. Slot surface 118A consists of an inner surface 112D, a side surface 113A, and an inclined surface 113D. Slot surface 118B consists of an inner surface 112E, a side surface 113B, and an inclined surface 113E.

[0034] [Insulators 14A, 14B] As shown in Figure 3, the stator 1 has two pairs of insulators 14A and 14B (an example of an insulator) for each segmented core 11. The insulators 14A and 14B are manufactured by injection molding an electrically insulating resin (such as PPS). The insulators 14A and 14B abut against the end faces 116A and 116B of the segmented core 11 and cover the end faces 116A and 116B, respectively (see Figure 6). Note that the insulators 14A and 14B do not have to completely cover the end faces 116A and 116B of the segmented core 11; for example, they may cover only a portion of the inside of the teeth 113 and core back 112 of the end faces 116A and 116B of the segmented core 11.

[0035] [Insulator 14A] As shown in Figure 3, the insulator 14A has a roughly T-shape when viewed from the front and comprises a coiled body portion 141 and flange portions 142 and 143.

[0036] The winding drum portion 141 is located between the flange portions 142 and 143 in the radial direction 73 and has main surfaces 141A and 141B, and side surfaces 141C and 141D. The main surface 141A has a rectangular shape symmetrical with respect to the reference surface 114. As shown in Figure 5(B), the main surface 141A abuts against and covers the end surface 116A of the divided core 11. The main surface 141B has substantially the same external shape as the main surface 141A in a front view and is located further forward in the axial direction 71 than the main surface 141A and away from the divided core 11. As shown in Figure 5, each of the side surfaces 141C and 141D is located between the main surfaces 141A and 141B at both ends in the orthogonal direction 74 on the winding drum portion 141.

[0037] As shown in Figure 3, the flange portion 142 has an inner surface 142A, an outer surface 142B, side surfaces 142C, 142D, and end surfaces 142E, 142F. The inner surface 142A is located at the inner end of the flange portion 142. The inner surface 142A is located forward in the axial direction 71 from the main surface 141A, and extends forward in the axial direction 71 and farther in the orthogonal direction 74 from the outer end in the radial direction 73 of the coiled drum portion 141. The outer surface 142B is substantially arc-shaped in a front view and is located at the outer end of the flange portion 142. The outer surface 142B is located inside the hole 115 in the radial direction 73 (see Figures 5 and 6). The side surfaces 142C and 142D are located at both ends in the orthogonal direction 74. The end surfaces 142E and 142F are located at both ends in the axial direction 71.

[0038] The flange portion 143 extends from the inner end of the coiled body portion 141 in the same direction as the flange portion 142. The flange portion 143 has an outer surface 143A, an inner surface 143B, side surfaces 143C, 143D, and end surfaces 143E, 143F. The outer surface 143A is located at the outer end of the flange portion 143. The inner surface 143B is located at the inner end of the flange portion 143. The outer surface 143A is forward of the main surface 141A and extends forward in the axial direction 71 and farther in the orthogonal direction 74 from the inner end of the coiled body portion 141. The inner surface 143B has a substantially arc shape in front view and is located inside the outer surface 143A and outside the tooth tip surface 113C (see Figures 5 and 6). The side surfaces 143C and 143D are located at both ends in the orthogonal direction 74. The end faces 143E and 143F are located at both ends in the axial direction 71.

[0039] [Protrusion 144 of insulator 14A] As shown in Figure 5(A), the insulator 14A has a protrusion 144. The protrusion 144 projects from the slot surfaces 118A, 118B along the end surface 116A to the slots 117A, 117B, respectively. Specifically, in the winding drum portion 141, the protrusion 144 includes a portion that projects farther in the perpendicular direction 74 from the side surfaces 113A, 113B that form the slot surfaces 118A, 118B, and has side surfaces 141C, 141D as the protruding end surface. In the flange portion 142, the protrusion 144 further includes a portion that projects radially 73 inward from the inner surfaces 112D, 112E that form the slot surfaces 118A, 118B, and has an inner surface 142A as the protruding end surface. The protrusion 144 further includes a portion of the flange 143 that protrudes radially 73 outward from the inclined surfaces 113D and 113E that form the slot surfaces 118A and 118B, and has the outer surface 143A as the protruding end face.

[0040] As shown in Figure 5(A), in the convex portion 144, both end faces in the orthogonal direction 74 (i.e., side surfaces 141C, 141D), the face facing inward in the radial direction 73 (i.e., inner surface 142A), and the face facing outward in the radial direction 73 (i.e., outer surface 143A) overlap with the slots 117A, 117B in a front view.

[0041] As shown in Figure 5(B), insulator 14A does not overlap with slots 117A and 117B when viewed from the orthogonal direction 74.

[0042] [Insulator 14A grooves 145A, 145B] As shown in Figure 4(B), the insulator 14A has grooves 145A and 145B in the flange portion 142. The grooves 145A and 145B are formed further away from the winding drum portion 141 in the orthogonal direction 74. In the axial direction 71, the grooves 145A and 145B extend along the end face 112F of the core back 112 (end face 116A of the split core 11) closer to the split core 11 than the convex portion 144 of the flange portion 142. As shown in Figure 5(B), the groove 145B is in contact with the end face 112F (end face 116A) without moving away in the axial direction 71 and is recessed outward from the inner surfaces 142A and 112E. The groove 145A is symmetrical with the groove 145B with respect to the reference surface 114.

[0043] [Insulator 14B] As shown in Figures 3 and 6, insulator 14B differs from insulator 14A in the following respects. The differences will be explained below, and the common features of insulators 14A and 14B will not be explained. The difference is that insulator 14B further has a rod base 146 and a rod 147. As shown in Figure 3, the rod base 146 protrudes radially 73 outward from the center of the circumferential direction 72 on the outer surface 142B along the end face 142E, and extends to a position outside the hole 115. As shown in Figure 3, the rod base 146 does not protrude forward in the axial direction 71 beyond the end face 142E. The rod 147 extends axially 71 from the rod base 146, is inserted into the hole 115 from the end face 116B side, and reaches the end face 116A.

[0044] [Adhesive film 12A, 12B] As shown in Figure 7, adhesive films 12A and 12B are formed on the entire surface of the slot surfaces 118A and 118B of the divided core 11. In Figure 7, the areas of adhesive films 12A and 12B are hatched. Adhesive films 12A and 12B are also formed in the grooves 145A and 145B that run along the slot surfaces 118A and 118B. The adhesive films 12A and 12B exhibit electrical insulation properties. The thickness of the adhesive films 12A and 12B is appropriately selected so that they do not protrude from the convex portion 144 when viewed from the axial direction 71 in a plan view.

[0045] [Coil 13] As shown in Figure 8, the coil 13 is laid out in slots 117A and 117B. Specifically, as shown in Figure 8(B), the innermost wire in the coil 13 is wound around the winding drum portions 141 of insulators 14A and 14B. As shown in Figure 8(B), the innermost wire extends axially 71 between the winding drum portions 141 of insulators 14A and 14B, at a position far from the adhesive films 12A and 12B. The number of turns of the coil 13 is adjusted as appropriate so as not to extend beyond the flange portions 142 and 143 in the direction perpendicular to the flange portions 74.

[0046] [Method for manufacturing Stator 1] Multiple core pieces 111 are formed by punching out electromagnetic steel sheets using a press machine. Each core piece 111 has the planar shape shown in Figure 4(A). A laminate is formed by stacking a predetermined number of core pieces 111. The laminate is sandwiched from both sides in the stacking direction by insulators 14A and 14B. At this time, the rod 147 of the insulator 14B is inserted through the hole 115 of each core piece 111. The insulators 14A and 14B and the laminate are fixed in the positional relationship shown in Figure 5 using a special jig, and then set in an adhesive application device. The application device applies adhesive to the entire area of ​​the laminate that will become the slot surfaces 118A and 118B after the stator 1 is completed (application process). The adhesive also enters the areas that will become the grooves 145A and 145B. As the adhesive hardens, adhesive films 12A and 12B are formed, joining two adjacent core pieces 111 together in the laminate, and insulators 14A and 14B are joined to the core pieces 111 at both ends in the lamination direction. This completes a segmented core 11 made by laminating multiple core pieces 111 and joining them with adhesive films 12A and 12B. Because the adhesive shrinks during the process from application to hardening, two adjacent core pieces 111 in the axial direction 71 adhere closely together, making it difficult for gaps to form between the core pieces 111.

[0047] Slots 117A and 117B (see Figure 4(A)) are formed in the divided core 11 for laying out the coils 13. The divided core 11 is set in a coil winding machine. The winding machine lays out the coils 13 in the slots 117A and 117B (winding process). By laying out the coils 13 in the divided core 11 during the winding process, the positions of the insulators 14A and 14B relative to the divided core 11 are securely fixed. The worker joins the side surface 112C of each of the 12 divided cores 11 to the side surface 112B of another divided core 11. As a result, all the core backs 112 form a cylindrical yoke 15 as shown in Figure 2. At this time, the end faces 116A and 116B are arranged alternately in the circumferential direction 72 in the yoke 15, and the insulators 14A and 14B are arranged alternately adjacent to each other in the circumferential direction 72.

[0048] [Effects of Stator 1] In the divided core 11 of the stator 1, two adjacent core pieces 111 in the axial direction 71 (hereinafter also referred to as "adjacent core pieces") are joined to each other by adhesive films 12A and 12B formed on the slot surfaces 118A and 118B. In the divided core 11, adjacent core pieces 111 are not joined by an adhesive film formed between them. Therefore, the proportion of the magnetic core pieces 111 to the volume of the divided core 11 does not decrease. By employing such a stator 1 in the rotating electric machine 100, a compact and high-output rotating electric machine 100 can be provided.

[0049] Adhesive films 12A and 12B are formed over the entire area of ​​the slot surfaces 118A and 118B. In addition, each of the insulators 14A and 14B is equipped with a protrusion 144, which protrudes from the slot surfaces 118A and 118B to the slots 117A and 117B. As a result, the adhesive films 12A and 12B and an air layer are interposed between the coil 13 and the slot surfaces 118A and 118B of the divided core 11. Furthermore, insulators 14A and 14B are interposed between the coil 13 and the end faces 116A and 116B. This allows the coil 13 to be electrically insulated from the divided core 11. Therefore, there is no need to provide a separate insulating sheet in the slots 117A and 117B. This allows the stator 1 to be manufactured at a low cost.

[0050] The insulators 14A and 14B do not overlap with the adhesive films 12A and 12B on the slot surfaces 118A and 118B. Therefore, the space available for laying out the coil 13 in slots 117A and 117B is not narrowed by the insulators 14A and 14B. In other words, the insulators 14A and 14B do not affect the space occupied by the coil 13 in slots 117A and 117B.

[0051] Since the rod 147 is inserted through the hole 115 from the end face 116B side, the insulator 14B can be positioned relative to the split core 11.

[0052] Because the holes 115 are formed by a press, the crystal structure of the electrical steel sheet changes around the holes 115, and the magnetic properties deteriorate. However, the holes 115 are formed in the core back 112 at a position radially 73 away from the teeth 113 and close to the outer surface 112A. At this position, the magnetic flux formed by the magnet 25 is sparse, so the change in crystal structure around the holes 115 does not easily affect the magnetic flux. Therefore, eddy current losses are less likely to occur around the holes 115.

[0053] [Differentiation] The following describes a modified rotating electric machine 200 equipped with a stator 8, with reference to Figures 9 to 11. The rotating electric machine 200 differs from the rotating electric machine 100 in that it has a stator 8 instead of a stator 1. The differences will be explained below, and the common features of the rotating electric machines 100 and 200 will not be explained.

[0054] As shown in Figure 9, the stator 8 comprises four segmented cores 81 and four coils 84. As shown in Figures 10 and 11, the stator 8 further comprises adhesive films 83A, 83B and a pair of insulators 82A, 82B for each segmented core 81.

[0055] As shown in Figure 9, the four segmented cores 81 are arranged around the outer circumferential surface 23 of the rotor 2 at 90° intervals in the circumferential direction 72 when viewed from the front. Since the four segmented cores 81 have similar shapes to each other, the following description will focus on the single segmented core 81 shown on the right side of Figure 9. The segmented core 81 is manufactured by stacking multiple core pieces in the axial direction 71 and joining them with adhesive films 83A, 83B (see Figures 10 and 11). Each core piece is made of an electrical steel sheet with a thickness of approximately 0.25 mm.

[0056] As shown in Figures 9 to 11, the segmented core 81 has a "U" shape in front view and is symmetrical with respect to a reference plane 114 parallel to the radial direction 73 of the axis 21. The segmented core 81 has a stator yoke 812 and two teeth 813 and 814.

[0057] The stator yoke 812 is located radially 73 away from the axis 21 (see Figure 9). The stator yoke 812 has a roughly rectangular parallelepiped shape that is elongated in the orthogonal direction 74. The teeth 813 and 814 extend parallel to the reference plane 114 (see Figure 9) toward the rotor 2 from both ends of the stator yoke 812 in the orthogonal direction 74. The extended ends of the teeth 813 and 814 are the tooth tip surfaces 813A and 814A (see Figure 9). The tooth tip surfaces 813A and 814A face the outer circumferential surface 23 with a gap between them.

[0058] A slot 815 is formed in the divided core 81. The slot 815 is the space in which the coil 84 is placed. The slot 815 is demarcated by a slot surface 816. The slot surface 816 consists of an inner surface 812A facing inward in the stator yoke 812 and end faces 813B, 814B facing near inward in the teeth 813, 814. In a modified example, the slot surface 816 does not necessarily have to cover the entire area of ​​the end faces 813B, 814B. More specifically, as shown in Figure 10(B), the slot surface 816 extends inward from the outer end of the end faces 813B, 814B. However, the inner end of the slot surface 816 does not need to reach the inner end of the end faces 813B, 814B. The position of the inner end of the slot surface 816 is appropriately determined to align with the inner end of the coil 13.

[0059] [Insulators 82A, 82B] As shown in Figure 10, the stator 8 has a pair of insulators 82A and 82B (an example of an insulator) for each segmented core 81. The insulators 82A and 82B are manufactured by injection molding of an electrically insulating resin. The insulators 82A and 82B abut against the end faces 81A and 81B of the segmented core 81 in the axial direction 71, and cover most of the end faces 81A and 81B, respectively. The insulators 82A and 82B are symmetrical in the axial direction 71 with respect to the segmented core 81 (see Figure 10(A)). Therefore, the following description will focus on insulator 82A.

[0060] [Insulator 82A] As shown in Figures 9 to 11, the insulator 82A comprises a coiled drum portion 821 and flange portions 822 and 823.

[0061] As shown in Figure 11, the coiled drum portion 821 extends radially 73 and orthogonally 74 between the flange portions 822 and 823, and has main surfaces 821A, 821B, an outer surface 821C, and an inner surface 821D. As shown in Figure 10(A), the main surface 821A abuts against and covers one end surface 81A of the divided core 81 in the axial direction 71. The main surface 821A only needs to cover the area radially 73 outside the teeth 813 and 814 on the end surface 81A. The main surface 821A has a rectangular shape symmetrical with respect to the reference surface 114. The main surface 821B has substantially the same shape as the main surface 821A in a front view and is located forward from the main surface 821A. The outer surface 821C and inner surface 821D are located at the outer and inner ends in the radial direction 73, respectively, as shown in Figure 11. The outer surface 821C is located outside the outer surface 812B of the stator yoke 812.

[0062] As shown in Figures 9 to 11, in the insulator 82A, the flange 822 is continuous with one end of the winding drum 821 in the orthogonal direction 74 and extends parallel to the reference plane 114. The flange 822 has an outer surface 822A, an inner surface 822B, side surfaces 822C, 822D, and end surfaces 822E, 822F, as shown in Figures 10(A) and 11. The outer surface 822A and inner surface 822B are located outside and inside the stator yoke 812 in the radial direction 73, respectively. The side surfaces 822C, 822D are located at both ends of the flange 822 in the orthogonal direction 74 and extend parallel to the reference plane 114. The end surfaces 822E, 822F are located at both ends of the flange 822 in the axial direction 71 and are perpendicular to the reference plane 114. Note that the coil 84 is not shown in Figure 11.

[0063] The flange portion 823 has a shape symmetrical with respect to the flange portion 822 and the reference surface 114, and has an outer surface 823A, an inner surface 823B, side surfaces 823C, 823D, and end surfaces 823E, 823F. The outer surface 823A, inner surface 823B, side surfaces 823C, side surfaces 823D, end surfaces 823E and 823F correspond to the outer surface 822A, inner surface 822B, side surfaces 822C, side surfaces 822D, end surfaces 822E and 822F, respectively.

[0064] [Protrusion 824 of insulator 82A] As shown in Figure 11, the insulator 82A has a protrusion 824. The protrusion 824 projects from the slot surface 816 along the end surface 81A to the slot 815. Specifically, in the winding drum portion 821, the protrusion 824 includes a portion that protrudes radially 73 inward from the inner surface 812A forming the slot surface 816 and has the inner surface 821D as a protruding end surface. In the flange portions 822 and 823, the protrusion 824 further includes portions that protrude near the end surfaces 813B and 814B forming the slot surface 816 in the direction perpendicular 74 and has the side surfaces 822C and 823C as protruding end surfaces. When viewed from the radial direction 73, the protrusion 824 does not overlap with the stator yoke 812.

[0065] [Insulator 82B] As shown in Figures 9 and 10, insulator 82B has a shape that is symmetrical to insulator 82A in the axial direction 71, with the divided core 81 in between. Therefore, in insulator 82B, components corresponding to those of insulator 82A are given the same reference numerals, and their respective descriptions are omitted.

[0066] [Adhesive film 83A, 83B] As shown in Figure 10, an adhesive film 83A is formed over the entire slot surface 816. An adhesive film 83B is formed over the entire outer surface 812B of the stator yoke 812. In Figure 10, the adhesive films 83A and 83B are hatched. The adhesive films 83A and 83B also exhibit electrical insulation properties. The thickness of the adhesive film 83A is appropriately selected so that it does not protrude beyond the protrusion 824 towards the slot 815 on the slot surface 816. The thickness of the adhesive film 83B is appropriately selected so that it does not protrude radially 73 outward from the outer surface 821C.

[0067] [Coil 84] As shown in Figure 10, the coil 84 is laid out in the slot 815. Specifically, the innermost conductor in the coil 84 is wound around the winding drum portion 821 of the insulators 82A and 82B. As a result, as shown in Figure 10(B), the adhesive film 83A and an air layer are interposed between the portion of the coil 84 inside the inner surface 812A and the inner surface 812A. The adhesive film 83B and an air layer are interposed between the portion of the coil 84 outside the outer surface 812B and the outer surface 812B. This electrically insulates the coil 84 from the divided core 81.

[0068] [Other variations] In this embodiment, grooves 145A and 145B were formed in the flange portion 142. The grooves 145A and 145B extended along the end face 112F in the axial direction 71, at a position closer to the divided core 11 than the convex portion 144 of the flange portion 142. However, the embodiment is not limited to this, and grooves similar to those of grooves 145A and 145B may also be formed in the flange portion 143 at a position opposite to those grooves 145A and 145B in the radial direction 73.

[0069] In this embodiment, the hole 115 was a through hole. However, it is not limited to this, and the hole 115 may be recessed from the end face 112G and have a bottom. In this case, the rod 147 has a length corresponding to the depth of the hole 115.

[0070] In the embodiments described, an example was given in which the stator of the present invention is applied to an inner rotor type brushless motor. However, the present invention is not limited to this, and the stator may also be applied to an outer rotor type brushless motor.

[0071] The rotating electric machine 100 may be a generator. The rotor 2 may be of the IPM type.

[0072] In this embodiment, the number of teeth 113 was 12. However, the number of teeth 113 can be 3 or more. That is, the divided core 11 can be 3 or more.

[0073] In this embodiment, the stator 1 had 12 sets of slots 117A, 117B, and the rotor core 22 had 8 poles. However, the number of slot sets and the number of magnetic poles are not limited to these.

[0074] In this embodiment, the yoke 15 was formed by joining the divided core 11 in the circumferential direction 72. However, the yoke 15 is not limited to this, and may also be formed by laminating a plurality of annular core pieces made of electromagnetic steel sheets and joining them with an adhesive. [Explanation of Symbols]

[0075] 100,200... Rotating Electric Machines 1.8...Stator 11,81... Split core 111... Core piece 112... Core Back 113,813,814... Teeth 115...hole 117A, 117B, 815... slots 118A, 118B, 816... Slot side 81A,81B...End face 15. York 812...Stater York 12A,12B,83A,83B...Adhesive film 13,84...coil 14A, 14B, 82A, 82B... Insulators 144···Convex part 145A,145B...concave groove 147... Rod 71... Axial axis 72...Circumferential direction 73...Radial 74...Orthogonal direction

Claims

1. Multiple core pieces are stacked in the axial direction, and the core has a slot surface along the axial direction that divides the slots, An electrically insulating adhesive film covering the entire surface of the slot, The above core comprises a plurality of insulators, each covering two end faces perpendicular to the axial direction, and having protrusions that project from the slot surface along the end faces into the slot, The system comprises a coil wound around the above-mentioned plurality of insulators, The above core is A core back extending in the circumferential direction centered on the axial direction, The core back has teeth extending radially with respect to the axial direction, The teeth described above are a pair of sides that form part of the slot surface, and each of these sides extends in the radial direction and is spaced apart from each other in the circumferential direction. When viewed from a direction perpendicular to the axial direction, the insulator does not overlap with the adhesive film on the slot surface. A stator in which no other components are interposed between the above-mentioned coil and the above-mentioned adhesive film.

2. The above insulator has a groove extending along the end face at a position closer to the end face than the protrusion, The stator according to claim 1, wherein a portion of the adhesive film described above enters the groove described above.

3. The above core has a hole that is recessed in the axial direction from the end face, The stator according to claim 1 or 2, wherein the insulator has a rod portion that enters the hole.

4. The stator according to claim 3, wherein the hole is located in the core back at a position radially away from the teeth.

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