Insulator, stator of dynamo-electric machine, dynamo-electric machine, and method for manufacturing stator of dynamo-electric machine

Abstract

An insulator (51) is mounted on a split core (22) having a circumferentially extending back yoke part (22B) and a tooth part (22T) protruding radially inward from the back yoke part (22B), the insulator (51) electrically insulating a wound coil (12) and the split core (22). On both circumferential-direction sides on the axial end surface of the back yoke part (22B), an engagement part (55) for connecting the circumferentially adjacent split cores (22) together is formed. Each of the engagement parts (55) of each of the insulators (51) is configured to be capable of engaging with the engagement part (55) of another circumferentially adjacent insulator (51) from only the axial-direction side.

Description

Insulator, rotating electric machine stator, rotating electric machine, and method for manufacturing rotating electric machine stator

[0001] The present disclosure relates to an insulator, a stator for a rotating electric machine, a rotating electric machine, and a method for manufacturing a stator for a rotating electric machine.

[0002] In the stator of a rotating electrical machine, a split core structure is used in which the stator core is divided circumferentially into individual teeth to improve the coil space factor. Each split core is combined with an insulator of a shape corresponding to the split core, and a coil is wound around the teeth of each split core via the insulator. Adjacent insulators are connected by connecting portions formed on each insulator. A rotating electrical machine stator having an insulator with the following configuration has been devised.

[0003] That is, in a conventional stator for a rotating electric machine, a first insulator member and a second insulator member, each having a connecting pivot portion at both circumferential ends, are combined with each split core, and the split cores combined with the first insulator member and the split cores combined with the second insulator member are arranged alternately in the circumferential direction. The connecting pivot portions at both circumferential ends of the first insulator member have connecting protrusions that protrude in the axial direction, and the connecting pivot portions at both circumferential ends of the second insulator member have connecting recesses that are recessed in the axial direction. The connecting recesses have openings that open radially outward. In a circumferentially adjacent split core, when the connecting protrusions of the first insulator member are pressed radially outward against the connecting recesses of the second insulator member, the circumferential opening width of the connecting recesses widens, causing the connecting protrusions to enter into the connecting recesses, connecting the first and second insulator members and connecting the circumferentially adjacent split cores (see, for example, Patent Document 1).

[0004] JP 2010-110048 A

[0005] However, in the insulator members combined with each split core of the stator of the conventional rotating electric machine, the connecting protrusion of the first insulator member is inserted into and engaged with the connecting recess of the second insulator member while elastically deforming to widen the opening width of the connecting recess. Because the connecting recess of the second insulator member elastically deforms to widen its opening width, the rigidity of the connecting portion against a circumferential load is low. This causes a problem in that the split cores may become misaligned in the circumferential direction, increasing the outer diameter of the stator and reducing its roundness. Furthermore, a reduction in the roundness of the stator increases noise in a rotating electric machine using the stator, resulting in poor performance. The present disclosure discloses techniques for solving the above-mentioned problems, and aims to provide an insulator that can suppress changes in the outer diameter of a stator and maintain its roundness, a stator for a rotating electric machine that suppresses changes in the outer diameter and maintains its roundness, a rotating electric machine that maintains high performance, and a method for manufacturing a stator for such a rotating electric machine.

[0006] The insulator of the present disclosure is an insulator that is attached to a split core having a back yoke portion extending circumferentially and teeth protruding radially inward from the back yoke portion, and electrically insulates the split core from a wound coil, wherein engaging portions that connect circumferentially adjacent split cores are formed on both circumferential sides of an axial end face of the back yoke portion, and each engaging portion of each insulator is configured to be engageable only axially with the engaging portion of another circumferentially adjacent insulator. The stator of a rotating electric machine of the present disclosure is a stator for a rotating electric machine in which the coil is wound around the teeth of each split core to which the insulator configured as described above is attached, and the split cores are connected in an annular shape by each engaging portion, and a frame or molded resin is disposed to cover the outer periphery of the annularly connected split cores, and a pressing force from the radially outer side to the radially inner side is applied to each split core by the frame or the molded resin. The present disclosure also provides a rotating electric machine comprising: a rotating electric machine stator configured as described above; and a rotor arranged coaxially with the stator. The present disclosure also provides a manufacturing method for a stator of a rotating electric machine, comprising a connecting step of arranging the split cores, each fitted with an insulator configured as described above, in an annular shape, and forming a core assembly in which adjacent split cores in the circumferential direction are connected by the engaging portion, wherein in the connecting step, the split cores constituting both ends of the core assembly are brought close to each other in the circumferential direction, and the split core having the convex portion at one end of the brought-close core assembly is slid axially upward to be positioned above the concave portion at the other end, and with the core side surfaces of the split cores constituting both ends of the core assembly in contact with each other, the convex portion is inserted into the concave portion from above in the axial direction to engage with the concave portion.

[0007] The insulator and the stator of the rotating electric machine according to the present disclosure can suppress changes in the outer diameter of the stator and ensure its roundness. Furthermore, the rotating electric machine and the method for manufacturing the stator of the rotating electric machine according to the present disclosure can ensure high performance of the rotating electric machine.

[0008] 1 is a cross-sectional view showing an example of a schematic configuration of a rotating electric machine according to a first embodiment; FIG. 2 is an exploded perspective view showing split cores that configure a stator core of a stator according to a first embodiment and insulating portions attached to the split cores; FIG. 3 is a perspective view showing a coil wound body according to the first embodiment; FIG. 4 is a top view showing an enlarged view of an engaging portion of an insulator according to the first embodiment; FIG. 5 is a top view showing a state in which the engaging portions of the insulator according to the first embodiment are engaged; FIG. 6 is a diagram showing the direction of a repulsive force that accompanies folding of an insulating film when engaging the insulator according to the first embodiment; FIG. 7 is a perspective view showing a state in which coil wound bodies according to the first embodiment are coupled to each other; FIG. 8 is an enlarged perspective view showing a state in which coil wound bodies according to the first embodiment are coupled to each other; FIG. 9 is a top view showing another configuration of the engaging portion of the insulator according to the first embodiment; FIG. 10 is a cross-sectional view showing another example configuration of a rotating electric machine according to the first embodiment; FIG. 11 is a perspective view showing a schematic configuration of an engaging portion of an insulator according to a second embodiment; FIG. 12 is a perspective view showing a state in which coil wound bodies according to a third embodiment are coupled to each other; FIG. 13 is an enlarged perspective view of an engaging portion in a state in which coil wound bodies according to the third embodiment are coupled to each other; FIG. 11 is a perspective view showing a state in which coil wound bodies according to embodiment 3 are connected to each other.

[0009] First Embodiment (Configuration of Rotating Electric Machine) The configuration of a rotating electric machine 100 according to the first embodiment will be described. FIG. 1 is a cross-sectional view showing an example of the schematic configuration of the rotating electric machine 100 according to the first embodiment. In this configuration, the rotating electric machine 100 includes a rotor 10 fixed to a shaft 1 serving as a rotating shaft, and a stator 20 arranged concentrically with the rotor 10 and radially outward of the rotor 10 in the X direction. The rotor 10 and the stator 20 are housed inside a hollow frame 2. Note that the circumferential direction, radial direction, and axial direction of the annular stator 20 are respectively referred to as the circumferential direction C, the radial direction X, and the axial direction of the rotating shaft. In addition, the circumferential inner side of the yoke portion of the split core constituting the stator 20 refers to the central side of the yoke portion where the teeth are present. In addition, the circumferential outer side of the back yoke portion of the split core refers to the end side of the back yoke portion where the teeth are not present, or the direction circumferentially outward from this end. Furthermore, at one axial end of the split core, the upper axial side may be referred to as the axial outer side, and the lower axial side may be referred to as the axial inner side.

[0010] (Configuration of the rotor) First, we will explain the configuration of the rotor 10. The rotor 10 has a magnet 11 fixed inside the rotor 10. The shaft 1 to which the rotor 10 is fixed is rotatably supported by a first bearing 3A located on the output side of the shaft 1 and a second bearing 3B located on the opposite side to the output side, both of which are fixed within the frame 2.

[0011] (Configuration of Stator) Next, the configuration of the stator 20 will be described. Fig. 2 is an exploded perspective view showing the split cores 22 that constitute the stator core of the stator 20 according to the first embodiment, and the insulating section 50 attached to the split cores 22. The split cores 22 are obtained by dividing the annular stator core of the inner rotor type rotating electric machine 100 in the circumferential direction C by a set number of slots. The insulating section 50 is attached to the split cores 22 and electrically insulates the split cores 22 from the wound coils.

[0012] The split core 22 has a back yoke portion 22B extending in the circumferential direction C and teeth portions 22T protruding radially inward X1 from the inner peripheral surface of the central portion of the back yoke portion 22B in the circumferential direction C. In split cores 22 adjacent to each other in the circumferential direction C, the core side surfaces 22BS of the opposing back yoke portions 22B have a planar shape extending along the radial direction X. Therefore, each split core 22 does not have the function of joining or holding adjacent split cores 22 together. In the stator 20 of this embodiment, each split core 22 is configured in such a simple shape, so it is only necessary to prepare one type of mold for the split cores 22, facilitating manufacturing.

[0013] The insulating portion 50 is made of an insulating material with a low elastic modulus, such as resin, and is shaped to fit the teeth 22T of the split core 22 so as to be fitted into the split core 22. The insulating portion 50 includes a first insulator 51U fitted to the upper axial side Y1 of the split core 22, a second insulator 51D fitted to the lower axial side Y2 of the split core 22, and insulating films 59 covering both circumferential sides of the teeth 22T of the split core 22.

[0014] In this embodiment, the first insulator 51U and the second insulator 51D are identical components having the same shape and function. However, when it is necessary to distinguish between the insulators 51 on the axial upper side Y1 and the axial lower side Y2 of the split core 22, they are referred to as the first insulator 51U and the second insulator 51D, and when it is not necessary to distinguish between them, they are referred to as the insulator 51.

[0015] Each insulator 51 has a coil winding portion 52, a back yoke covering portion 53, and an engaging portion 55. The coil winding portion 52 is arranged to overlap the tooth portion 22T of the split core 22 when viewed from the axial direction Y, and covers most of the end surface of the tooth portion 22T in the axial direction Y. The back yoke covering portion 53 covers most of the end surface of the back yoke portion 22B in the axial direction Y. The engaging portions 55 are formed on both sides of the back yoke covering portion 53 in the circumferential direction C, and although the detailed configuration will be described later, they have a shape that allows them to engage with the engaging portion 55 of another split core 22 adjacent in the circumferential direction C.

[0016] The insulating film 59 is attached along the circumferential C side surfaces of the tooth portions 22T of the split core 22, which form the inner surfaces of the slots formed between adjacent tooth portions 22T in the circumferential direction C, the radial X inner surface of the back yoke portion 22B, and the radial X outer surface of the portion protruding circumferentially outward from the radial inner end of the tooth portion 22T.

[0017] 3 is a perspective view showing a coil winding body 21 configured by winding a coil 12 around a split core 22, to which an insulating section 50 configured as described above is attached, via the insulating section 50. The stator 20 of this embodiment is configured by connecting a plurality of such coil winding bodies 21 in an annular shape. Note that, as shown in FIG. 3, in this embodiment, the back yoke covering section 53 of the insulator 51 does not cover the radially outer side X2 of the back yoke section 22B of the split core 22.

[0018] The stator 20 thus formed is fixed to the inner peripheral surface of the frame 2. When power is supplied to the coil 12, the stator 20 is excited, causing the rotor 10 disposed inside the stator 20 to rotate. Note that the rotating electric machine 100 is not limited to an electric motor, and may also be a generator.

[0019] (Configuration of Engaging Portion) The configuration of the engaging portion 55 of the insulator 51, which is a main part of this embodiment, will be described below. Fig. 4 is an enlarged top view showing the engaging portion 55 of the insulator 51 of the coil winding bodies 21 adjacent to each other in the circumferential direction C. This shows a state in which the engaging portions 55 are not engaged with each other, i.e., the coil winding bodies 21 are not connected to each other. Fig. 5 is a top view showing a state in which the engaging portions 55 of the insulators 51 of the coil winding bodies 21 adjacent to each other in the circumferential direction C are engaged with each other, and the coil winding bodies 21 are connected to each other.

[0020] In addition, since the configuration of the engaging portions 55 provided on the first insulator 51U and the second insulator 51D has the same shape and function, the same numbers will be used in the description regardless of whether they are provided on the first insulator 51U or the second insulator 51D.

[0021] As described above, the back yoke covering portion 53 of the insulator 51 is provided with the engaging portions 55 at both ends in the circumferential direction C. As shown in Fig. 3 , the engaging portion 55 on one circumferential side of the insulator 51 is formed with a convex portion 55P as a convex portion that protrudes in a set shape toward the circumferential outward, while the engaging portion 55 on the other circumferential side is formed with a concave portion 55R as a recess that is recessed in a set shape toward the circumferential inward and penetrates in the axial direction Y. Therefore, as shown in Fig. 4 , between coil winding bodies 21 adjacent to each other in the circumferential direction C, the convex portion 55P and the concave portion 55R of the engaging portion 55 of the insulator 51 provided on each of the coil winding bodies 21 face each other.

[0022] The recessed portions 55R penetrate in the axial direction Y, and therefore open on their upper axial side (axially outer side) Y1. This shape allows the insulators 51 adjacent to each other in the circumferential direction C to be engaged with each other from the axial direction Y. Furthermore, as will be described later, this shape can achieve an engaged state that fixes at least the split cores 22 so that they do not move away from each other in the circumferential direction C. In this manner, the first insulators 51U and the second insulators 51D are connected to each other by the engagement between the recessed portions 55R and the convex portions 55P formed on each insulator. Below, the configurations of the recessed portions 55R and the convex portions 55P and the connection structure of the insulators 51 formed by the engagement between the recessed portions 55R and the convex portions 55P will be described.

[0023] 4, in the engagement portions 55 adjacent to each other in the circumferential direction C, the recessed portions 55R are formed so that the radial width D2 at the circumferentially inner side is larger than the radial width D1 at the opening. The protruding portions 55P are formed so that the radial side surfaces at their tip portions are shaped to fit along the inner walls on both sides in the radial direction X of the recessed portions 55R. Therefore, the radial width D4 at the tip portion side is larger than the radial width D3 at the circumferentially inner side.

[0024] In this way, the recessed portion 55R is formed in a shape having a narrower opening than the rear side, with its minimum width D1 in the radial direction X located at the opening side and its maximum width D2 in the radial direction located at the rear side. The protruding portion 55P is formed in a shape having a narrower opening than the rear side, with its maximum width D4 located at the tip side and its minimum width D3 in the radial direction X located at the circumferentially inner root side. The radial width X of the recessed portion 55R is designed to be the same as or slightly smaller by a dimensional tolerance than the radial width X of the protruding portion 55P.

[0025] Furthermore, in this embodiment, the recessed portion 55R is formed in a shape called a "dovetail groove shape" in which the width in the radial direction X gradually increases from the opening toward the circumferentially inner side, starting from a narrow opening and widening toward the inner side. The protruding portion 55P is formed in a shape called a "dovetail shape" in which the width in the radial direction X gradually increases toward the circumferentially outer side.

[0026] 5, when the insulator 51 is assembled to the split core 22, the convex portion 55P having the above-described shape protrudes circumferentially outward beyond the core side surface 22BS on the circumferential direction C side of the split core 22. Therefore, the convex portion 55P of the insulator 51 assembled to each split core 22 overlaps in the axial direction Y with at least a portion of the other split core 22 adjacent to that split core 22.

[0027] When connecting circumferentially adjacent coil winding bodies 21, the coil winding body 21 on the convex portion 55P side is slid toward the axially upper side Y1 to bring the core side surfaces 22BS of adjacent split cores 22 into contact with each other, and then the convex portion 55P is inserted from above the concave portion 55R to engage them. As described above, the width of the concave portion 55R in the radial direction X is the same as or slightly smaller than the width of the convex portion 55P in the radial direction X. Therefore, the convex portion 55P is lightly press-fitted into the concave portion 55R while slightly expanding the concave portion 55R in the radial direction X. This state in which the convex portion 55P is fitted into the concave portion 55R is the state in which the concave portion 55R and the convex portion 55P are engaged (hereinafter, sometimes simply referred to as the "engaged state").

[0028] The load applied to the convex portion 55P and the concave portion 55R in the engaged state will be described below. When the core side surfaces 22BS of adjacent coil windings 21 are in contact with each other, the concave portion 55R is formed in a position that substantially overlaps the opposing convex portion 55P in the axial direction Y. However, although the concave portion 55R and the convex portion 55P are in a position that substantially overlaps with each other in the axial direction Y, more specifically, when the core side surfaces 22BS are in contact with each other, the concave portion 55R is formed to be shifted in the circumferential direction C with respect to the convex portion 55P in a direction away from the boundary surface BO where the core side surfaces 22BS are in contact with each other.

[0029] That is, when the core side surfaces 22BS of adjacent coil windings 21 are in contact with each other, the length D5 in the circumferential direction C from the boundary surface BO to the bottom surface of the concave portion 55R is longer than the length D6 in the circumferential direction C from the boundary surface BO to the circumferentially outermost tip of the convex portion 55P. Therefore, in order to insert the tip portion of the convex portion 55P, which is formed in the same shape as the inner wall of the concave portion 55R, into the concave portion 55R, the convex portion 55P is pulled in the direction of arrow A1 in Figure 5 beyond the boundary surface BO and then inserted into the concave portion 55R.

[0030] Furthermore, each insulator 51 is formed so that a gap G1 having a set width D7 in the circumferential direction C is secured between the side surfaces of adjacent insulators 51. Therefore, when the concave portion 55R and the convex portion 55P are engaged with each other, a tensile load F1 (+F1, -F1) in the circumferential direction C is generated in the engaging portion 55 such that the concave portion 55R is pulled toward the convex portion 55P (load -F1) and the convex portion 55P is pulled toward the concave portion 55R (load +F1).

[0031] In other words, a preload is generated in a direction that maintains close contact between the core side surfaces 22BS, which are the mating surfaces of the split cores 22. This prevents gaps from forming between the core side surfaces 22BS of the split cores 22, achieving a strong connection between circumferentially adjacent split cores 22. This suppresses changes in the outer diameter of the formed stator 20, ensuring its roundness.

[0032] 4, the outer sloped portion PX2 of the convex portion 55P closer to the radially outer side X2 and the inner sloped portion PX1 closer to the radially inner side X1 are in surface-to-surface contact with the outer sloped portion RX2 of the concave portion 55R closer to the radially outer side X2 and the inner sloped portion RX1 of the concave portion 55R closer to the radially inner side X1. In other words, the sloped portions of the convex portion 55P and the concave portion 55R are in constant contact with each other, thereby enabling fixation not only in the circumferential direction C but also in the radial direction X.

[0033] 5, the bottom surface RS of the concave portion 55R and the tip surface PS of the convex portion 55P are not in contact with each other when engaged. In other words, as described above, the concave portion 55R is formed so as to be displaced away from the convex portion 55P in the circumferential direction C when engaged, and a tensile load is applied to pull them together, so a gap G2 is generated between the bottom surface RS of the concave portion 55R and the tip surface PS of the convex portion 55P.

[0034] Here, the tensile loads (+F1, -F1) in the circumferential direction C applied to the convex portion 55P and the concave portion 55R will be further described. FIG. 6 is a diagram showing the direction of the repulsive force that accompanies folding of the insulating film 59 when engaging the insulators 51 of this embodiment. The insulating film 59 is configured to include an outer film 59O and an inner film 59I. As shown in FIG. 6, the outer film 59O is folded so as to overlap the inner film 59I. When such an insulating film 59 is folded in the engaged state of adjacent insulators 51, a repulsive load F2 (+F2, -F2) that repels in the circumferential direction C is generated as the insulating film 59 is folded.

[0035] A gap G2 is formed between the bottom surface RS of the concave portion 55R and the tip surface PS of the convex portion 55P so that the tensile load F1 is greater than the load F2, which is a repulsive force that pushes the insulating films 59 attached to adjacent split cores 22 back in the circumferential direction when they come into contact with each other. That is, when the core side surfaces 22BS of adjacent coil winding bodies 21 are in contact with each other, the length D5 in the circumferential direction C from the boundary surface BO to the bottom surface of the concave portion 55R and the length D6 in the circumferential direction C from the boundary surface BO to the tip surface of the convex portion 55P at the outermost position in the circumferential direction are adjusted so that the tensile load F1 is greater than the repulsive force F2.

[0036] Furthermore, the dimensions are designed so that the maximum strain generated in the engaging portion 55 does not exceed the breaking strain when subjected to the load caused by light pressing when inserting the convex portion 55P into the concave portion 55R, and to a circumferential tensile load that pulls the convex portion 55P toward the concave portion 55R.

[0037] Meanwhile, as described above, the outer gradient portion PX2 and the inner gradient portion PX1 of the convex portion 55P are in contact with the surfaces of the outer gradient portion RX2 and the inner gradient portion RX1 of the concave portion 55R. In other words, the convex portion 55P is sandwiched between the outer gradient portion RX2 and the inner gradient portion RX1 of the concave portion 55R. This results in the convex portion 55P being held in a state where it is enveloped within the concave portion 55R, which has a narrow opening. Furthermore, at least the outer gradient portion PX2 and the inner gradient portion RX1 of the convex portion 55P are caught on the outer gradient portion RX2 and the inner gradient portion RX1 of the concave portion 55R when the convex portion 55P is moved in the circumferential direction C in a direction away from the boundary surface BO, and therefore the convex portion 55P does not easily come off the concave portion 55R.

[0038] In this embodiment, the axial upper side Y1 of the stator 20 is formed by connecting the first insulators 51U together, and the axial lower side Y2 of the stator 20 is formed by connecting the second insulators 51D together. As described above, the first insulators 51U and the second insulators 51D have exactly the same shape. Therefore, as shown in FIG. 3 , when the first insulator 51U assembled to the upper side of the split core 22 and the second insulator 51D assembled to the lower side of the split core 22 are viewed from the radially outer side X2 of the split core 22, the concave portions 55R of the first insulator 51U and the concave portions 55R of the second insulator 51D are located at diagonal corners of the split core 22, and the convex portions 55P of the first insulator 51U and the convex portions 55P of the second insulator 51D are also located at diagonal corners of the split core 22.

[0039] In this way, the concave portions 55R and the convex portions 55P are located at diagonal corners of the split core 22 when the split core 22 is viewed from the radially outer side X2. That is, the connection structure in the axial direction Y between the split core 22 and its adjacent split core 22 is different between one circumferential side and the other circumferential side of the back yoke portion 22B. Note that, although the first insulator 51U and the second insulator 51D have been described as having the same shape in this embodiment, even if the first insulator 51U and the second insulator 51D have different shapes, the concave portions 55R and the convex portions 55P can be located at diagonal corners of the split core 22.

[0040] (Method of manufacturing stator 20) Next, a method of manufacturing the stator 20 using the above-described connecting structure of the insulator 51 will be described. Fig. 7 is a perspective view showing a state in which the coil winding bodies 21 of the present embodiment 1 are connected to each other. Fig. 8 is an enlarged perspective view showing a state in which the coil winding bodies 21 of the present embodiment 1 are connected to each other. As shown in Fig. 7, the stator 20 of the present embodiment is composed of nine coil winding bodies 21 (split cores 22), but is not limited to this number.

[0041] In the following description, the nine coil winding bodies 21 may be individually referred to as the first coil winding body 21 to the ninth coil winding body 21. In the drawings, the positions corresponding to the first coil winding body 21 to the ninth coil winding body 21 are numbered No. 1 to No. 9, respectively.

[0042] When manufacturing the stator 20, first, a winding body forming process is performed in which the insulating parts 50 are attached to the split cores 22 and the coils 12 are wound around them to form nine coil winding bodies 21. Next, a connecting process is performed in which the nine formed coil winding bodies 21 are arranged in an annular shape and adjacent split cores 22 in the circumferential direction C are connected by the engaging parts 55 to form the core connected body 30. In the core connected body 30 shown in Figure 7, all of the engaging parts 55 are engaged except for one engagement between the first coil winding body 21 (No. 1) and the ninth coil winding body 21 (No. 9).

[0043] Then, to prevent interference between the engaging portion 55 of the first coil winding body 21 (No. 1) and the engaging portion 55 of the ninth coil winding body 21 (No. 9), the state in which the core side surfaces 22BS of the split cores 22 of the already engaged coil winding bodies 21 are in contact is changed to an engaging position in which the coils 12 of these coil winding bodies 21 are slightly spaced apart. Then, as shown in Figure 7, the space between the first coil winding body 21 (No. 1) and the ninth coil winding body 21 (No. 9) is opened in the circumferential direction C.

[0044] Thus, in the connecting step, the split core 22 of the first coil winding body 21 (No. 1) constituting one end of the core connected body 30 and the split core 22 of the first coil winding body 21 (No. 9) constituting the other end are brought into close proximity in the circumferential direction C. Then, as shown in Fig. 8 , the split core 22 of the first coil winding body 21 (No. 1), which has a convex portion 55P on one end side of the core connected body 30, is slid axially upward Y1 while maintaining the engagement between the split core 22 of the first coil winding body 21 (No. 1) and the second coil winding body 21 (No. 2) so that the end face on the axial lower side (axial inner side) Y2 of the convex portion 55P is positioned above the end face on the axial upper side Y1 of the concave portion 55R of the ninth coil winding body 21 (No. 9) on the other end side.

[0045] Then, the core side surfaces 22BS of the split cores 22 of the first coil winding body 21 and the ninth coil winding body 21 are brought into contact with each other. Then, with the core side surfaces 22BS in contact with each other, the first coil winding body 21 (No. 1) is slid downward in the axial direction Y2, and the convex portion 55P of the first coil winding body 21 is inserted axially into the concave portion 55R of the ninth coil winding body 21 (No. 9).

[0046] At this time, the tip side of the convex portion 55P of the first coil winding body 21 (No. 1) is pulled in the circumferential direction C from the boundary surface BO toward the concave portion 55R, while the convex portion 55P is inserted into the concave portion 55R from the axial direction Y. In this way, the convex portion 55P of the first coil winding body 21 (No. 1) and the concave portion 55R of the ninth coil winding body 21 (No. 9) are engaged, and the stator 20 is completed.

[0047] In this method, a torsional load is generated in each of the convex portions 55P and each of the concave portions 55R in the stator 20, but the dimensions are designed so that the maximum strain generated in the engaging portion 55 does not exceed the breaking strain. Note that a dedicated jig that can reproduce the above-mentioned manufacturing method may be used as the engaging means. Using a jig increases material and design costs, but improves workability.

[0048] Next, the completed stator 20 is press-fitted or shrink-fitted into a cylindrical frame 2 as shown in Figure 1. The frame 2 may be a steel plate frame or may be integrally molded from resin, and the stator 20 is compatible with frames of all configurations.

[0049] Next, the first bearing 3A and the second bearing 3B are press-fitted or shrink-fitted onto the shaft 1. Next, the rotor 10 is inserted into the frame 2 on which the stator 20 is mounted. Finally, a bracket is inserted and the first bearing 3A and the second bearing 3B are fixed, thereby completing the rotating electric machine 100.

[0050] Because the engaging portion of the insulator 51 is located radially inward (X1) from the outer periphery of the split core 22, it can be press-fitted or shrink-fitted into the simple cylindrical frame 2, allowing for a simple assembly method. Because the frame 2 holds the stator 20 core, the connecting force of the insulator 51 is sufficient to withstand transportation up to the shrink-fitting process. Furthermore, the preload created by the interference of the press-fitting or shrink-fitting allows the core side surfaces 22BS, which are the mating surfaces of the split core 22, to abut evenly against each other, ensuring the roundness of the inner circumferential surface of the radially inner portion of the stator 20. This improves the workability of the annular assembly by using the same shaped insulators 51 on the top and bottom to engage in the axial direction Y. Furthermore, because the engaging portions 55 are engaged without being inserted or removed in the circumferential direction C, expansion of the outer diameter of the stator 20 due to loads generated in the circumferential direction C can be restricted, improving the workability of the frame shrink-fitting process.

[0051] The following describes an insulator 51EX having a structure different from the convex portion 55P and the concave portion 55R of the engagement portion 55 described above. Fig. 9 is a top view showing the configuration of the engagement portion 55 of the insulator 51EX according to the first embodiment. The convex portion 55P-2 and the concave portion 55R-2 of the engagement portion 55 of the insulator 51EX according to the first embodiment do not have the outer slope portions PX2, RX2 and the inner slope portions PX1, RX1 shown in Fig. 4 on both sides in the radial direction X.

[0052] The convex portion 55P-2 and the concave portion 55R-2 have surfaces parallel to the boundary surface BO, which is the contact surface between the core side surfaces 22BS parallel to the radial direction X, and the surfaces of the convex portion 55P-2 and the concave portion 55R-2 that face each other in the circumferential direction C are in contact with each other. In other words, the surface of the convex portion 55P-2 that is parallel to the core side surface 22BS and the surface of the concave portion 55R that is parallel to the core side surface 22BS are in contact with each other. Therefore, the core side surfaces 22BS are not fixed in a direction parallel to the contact surface between the core side surfaces 22BS that are parallel to the radial direction X, but are fixed only in the circumferential direction C.

[0053] In this configuration, adjacent coil winding bodies 21 are not fixed in a direction parallel to the contact surface between the core side surfaces 22BS, i.e., in the radial direction X, but are fixed so as not to shift in position in the circumferential direction C, thereby preventing large expansion of the outer diameter of the stator 20. Furthermore, by configuring the positional relationship between the convex portion 55P-2 and the concave portion 55R-2 so that a set tensile load F1 is applied to the engagement portion 55, the core side surfaces 22BS of the split core 22 are firmly attached to each other, thereby preventing shifting in the radial direction X. This configuration simplifies the dimensional design of the convex portion 55P-2 and the concave portion 55R-2, improving productivity.

[0054] The shapes of the convex and concave portions are not limited to those described above. The concave portions may be formed so that the radial width at the circumferentially inner side is larger than the radial width at the opening, and the radial side of the circumferentially outer tip portion of the convex portion may be shaped so that it fits along the inner walls of the concave portion on both radial sides. Therefore, the concave portion may have a circular inner peripheral surface, and the convex portion may have a circular tip that fits into the recess. It is sufficient that the convex portion cannot be inserted from the direction of a first surface (not shown) perpendicular to the axial direction Y, and that at least adjacent split cores are fixed in the circumferential direction C.

[0055] Next, a rotating electric machine 100A having a different configuration from the rotating electric machine 100 shown in FIG. 1 will be described. FIG. 10 is a cross-sectional view showing a schematic configuration of the rotating electric machine 100A according to the first embodiment. The rotating electric machine 100 shown in FIG. 1 has a configuration in which the outer periphery of the stator 20 is covered with a frame 2 and fastened from the outer periphery side, further adhering the core side surfaces 22BS of each split core 22 to each other. However, this configuration is not limited thereto. As shown in FIG. 10 , the outer periphery of the stator 20 assembled into a ring may be molded with resin 4. Because the stator 20 core is held in place by the molding resin, the connecting force between the insulators 51 is sufficient to withstand transportation to the molding process. This ensures the inner diameter precision of the stator 20 by aligning the stator 20 core with the mold using the molding pressure of the resin.

[0056] According to the insulator configured as described above, the insulator is attached to a split core having a back yoke portion extending circumferentially and teeth portions protruding radially inward from the back yoke portion, and electrically insulates the split core from the wound coil, wherein engaging portions that connect adjacent split cores in the circumferential direction are formed on both circumferential sides of the axial end face of the back yoke portion, and each engaging portion of each insulator is configured to be engageable with the engaging portion of another adjacent insulator in the circumferential direction only from the axial side.

[0057] As described above, the engaging portions are not circumferentially insertable and detachable, but are engageable only axially. Therefore, the load direction when engaging the engaging portions and the load direction generated at the engaging portions during engagement are different, i.e., axial and circumferential. This prevents the engaging portions from being disengaged during the manufacturing process, preventing the connected insulators from separating. Furthermore, it also prevents changes in the outer diameter and loss of roundness of the stator, which would otherwise occur if the split cores were to move apart circumferentially. Furthermore, because changes in the outer diameter and loss of roundness of the stator are prevented, it also prevents deterioration in workability when shrink-fitting the stator into a cylindrical frame. Furthermore, it also reduces noise generation in a rotating electric machine using the stator, thereby achieving a rotating electric machine with high performance.

[0058] Furthermore, in the insulator configured as described above, one of the engaging portions of each insulator has a convex portion that protrudes circumferentially outward more than the core side surface of the circumferentially adjacent split core, and the other engaging portion is provided circumferentially inward more than the core side surface and has a concave portion that is recessed circumferentially inward at the engaging portion and opens axially upward, in the circumferentially adjacent engaging portions, the concave portion is formed so that the radial width at the circumferentially inner side is larger than the radial width at the opening, the radial side surface of the circumferentially outer tip portion of the convex portion is formed in a shape that follows the inner walls on both radial sides of the concave portion, and the circumferential length from the boundary surface where the core side surfaces of the circumferentially adjacent split cores contact each other to the bottom surface of the concave portion is configured longer than the circumferential length from the boundary surface to the tip of the convex portion.

[0059] Thus, one of the engaging portions of each insulator has a convex portion that protrudes circumferentially outward, while the other has a concave portion that is recessed circumferentially inward and opens axially upward (axially outward). Therefore, when these insulators are lined up circumferentially, the convex portion and concave portion of each insulator face each other. This allows split cores to be connected using a single type of insulator with the same shape. This reduces costs and simplifies the process.

[0060] The recess is open axially upward (axially outward), and is formed so that the radial width at the circumferentially inner side is greater than the radial width at the opening. The side surfaces of the tip portions of the protrusions are shaped to fit along the inner walls on both radial sides of the recess, i.e., the protrusions are shaped to have substantially the same shape as the recesses. In this way, the protrusions and recesses of the engaging portion can engage only from the axially upward side (axially outward), thereby reliably preventing separation of the insulators from each other.

[0061] The convex portion protrudes circumferentially outward from the core side surface, while the concave portion is circumferentially inward from the core side surface. The circumferential length from the boundary surface BO, where the core side surfaces of circumferentially adjacent split cores contact, to the bottom surface of the concave portion is longer than the circumferential length from the boundary surface BO to the tip of the convex portion. That is, to insert the tip portion of the convex portion, which is formed to have the same shape as the concave portion and fit along the inner wall of the concave portion, into the concave portion from the axial direction Y, the convex portion is pulled toward the concave portion from the boundary surface BO and inserted into the concave portion while applying a circumferential tensile load. This circumferential attractive load applied to the convex portion and the concave portion generates a preload in a direction that maintains the core side surfaces of the split cores in close contact with each other. This achieves a strong connection between adjacent split cores. This further suppresses changes in the outer diameter of the stator and deterioration of its roundness. Furthermore, even if the shape of the tip surface of the protrusion does not perfectly match the shape of the bottom surface of the recess, as long as at least the radial side surface of the protrusion is shaped to fit along the inner walls of the recess on both radial sides, it can engage with the recess when a circumferential load is applied. This makes it possible to absorb dimensional variations due to molding errors in the engaging portion when forming the insulator.

[0062] Furthermore, in the insulator configured as described above, a gap is secured between the circumferentially opposing side surfaces of the insulator, and the recessed portion and the protruding portion are configured to attract each other in the circumferential direction when engaged, and a tensile load of a set value or more is applied to the engaging portion.

[0063] In this way, a gap is secured between the side surfaces of the insulators that are pulled together in the circumferential direction, so that when the recessed and protruding portions are engaged, a tensile load greater than the desired load can be reliably applied to the engaging portion.

[0064] Embodiment 2. Hereinafter, a second embodiment of the present disclosure will be described with reference to the drawings, focusing on differences from the first embodiment. Portions similar to those in the first embodiment will be assigned the same reference numerals and will not be described again. Figure 11 is a perspective view showing a schematic configuration of an engaging portion 255 of an insulator 51 according to the second embodiment. This figure shows a state in which one of two coil winding bodies 21 adjacent to each other in the circumferential direction C is slid axially upward Y1.

[0065] In this embodiment, the insulator 51 of the coil winding body 21 has a shape in which the corners of the end face on the axially upper side (axially outer side) Y1 of the concave-shaped portion 55R and the end face on the axially lower side (axially inner side) Y2 of the convex-shaped portion 55P are chamfered to form a tapered surface TA. Furthermore, the convex-shaped portion 55P has a slit SL that is recessed circumferentially inward from the tip face on the circumferential outer side of the convex-shaped portion 55P and penetrates in the axial direction. The structure other than the tapered surface TA and the slit SL is the same as that of the engaging portion 55 of the first embodiment.

[0066] With this shape, the tapered surface TA of the concave portion 55R and the tapered surface TA of the convex portion 55P act as an inducement during engagement, reducing the resistance force when the convex portion 55P is fitted into the concave portion 55R and facilitating positioning during engagement of the engaging portion 255. Furthermore, because the dimensional tolerance of the convex portion 55P is slightly larger than that of the concave portion 55R during engagement, the convex portion 55P bites into the concave portion 55R, causing the opening of the concave portion 55R to deform in the direction of opening, but by providing a slit in the convex portion 55P, the magnitude of the distortion generated in the concave portion 55R can be reduced, thereby reducing the fitting load during engagement.

[0067] This improves workability and simplifies the jig positioning mechanism when manufacturing the stator 20. Furthermore, the shape of the slit penetrating from the axial direction simplifies the split structure of the mold for the insulator 51, thereby reducing mold costs.

[0068] The following describes, with reference to the drawings, an engaging portion 355 having a different configuration from the above-described engaging portion 255. Fig. 12 is a perspective view showing a schematic configuration of the engaging portion 355 of the insulator 51 according to the second embodiment. The figure shows a state in which one of two coil winding bodies 21 adjacent to each other in the circumferential direction C is slid upward in the axial direction Y1.

[0069] 12, in the present embodiment, an engaging portion 355 is formed by providing an inner turned portion 355PI and an outer turned portion 355PO as protrusions that protrude parallel to a first surface (not shown) perpendicular to the axial direction on the axially lower surface side of a convex portion 55P in an insulator 51 of a coil winding body 21. Other than that, the structure is the same as that of the first embodiment.

[0070] With this shape, when the stator 20 is engaged, the opening of the recessed portion 55R is deformed to open in the radial direction X by an amount corresponding to the width of the inner returned portion 355PI and the outer returned portion 355PO in the radial direction X, and the engagement is achieved. After the engagement is complete, the deformed recessed portion 55R returns to its original shape, causing the axial upper surfaces of the inner returned portion 355PI and the outer returned portion 355PO protruding toward the first surface to come into contact with the axial lower surface of the recessed portion 55R. In other words, the inner returned portion 355PI and the outer returned portion 355PO hook the recessed portion 55R and the protruding portion 55P in the axial direction Y, so the protruding portion 55P does not easily come off the recessed portion 55R. This makes it less likely for the stator 20 to come off due to an axial load when the completed workpiece is transported after manufacture, improving workability.

[0071] Note that the present invention is not limited to the configuration in which the inner turned portion 355PI and the outer turned portion 355PO open the opening of the recessed portion 55R in the radial direction X. For example, the inner turned portion 355PI and the outer turned portion 355PO may be made of an elastic material that is elastically deformed by pressure to reduce the protruding length, thereby preventing the opening of the recessed portion 55R from opening in the radial direction X.

[0072] Embodiment 3. Hereinafter, embodiment 3 of the present disclosure will be described with reference to the drawings, focusing on differences from embodiment 1 above. Portions similar to embodiment 1 above will be assigned the same reference numerals and description thereof will be omitted. Fig. 13 is a perspective view showing a state in which coil winding bodies 21 according to embodiment 3 are being connected to each other. This shows a state in which one of two coil winding bodies 21 adjacent to each other in the circumferential direction C is being slid to the axially upper side Y1. Fig. 14 is an enlarged perspective view of an engaging portion 455 in a state in which the coil winding bodies 21 according to embodiment 3 are being connected to each other. Fig. 15 is a perspective view showing a state in which the coil winding bodies 21 according to embodiment 3 are being connected to each other.

[0073] 14, the engaging portion 455 of the insulator 51 of this embodiment is formed so that an end face 55PS on the axially lower side (axially inner side) Y2 of the convex portion 55P is at the same position in the axial direction Y as an end face on the axially upper side (axially outer side) Y1 of the split core 22. Furthermore, the length H2 in the axial direction Y of the concave portion 55R of the engaging portion 455 is shorter than the length H1 in the axial direction Y of the convex portion 55P. Other than that, the structure is the same as that of the engaging portion 55 shown in the first embodiment.

[0074] When connecting the coil winding bodies 21 in this embodiment, a jig 60 such as that shown in Figure 15 is used to apply pressure to the end faces of the axially upper side Y1 of two adjacent engaging portions 455, thereby engaging the adjacent engaging portions 455 with each other.

[0075] At this time, as shown in FIG. 14 , the end face 55PS on the axial lower side (axial inner side) Y2 of the convex portion 55P of the insulator 51 of one coil winding body 21 contacts the end face on the axial upper side Y1 (axial outer side) of the other split core 22. As described above, because a gap G1 is secured between the side surfaces of adjacent insulators 51, the convex portion 55P provided on one coil winding body 21 straddles the axial end faces of the two adjacent split cores 22 and engages with the concave portion 55R of the other insulator 51. In other words, the axial end faces of the split cores 22 of the two adjacent coil winding bodies 21 both abut against the end face 55PS on the axial lower side Y2 of the convex portion 55P of one coil winding body 21. This allows the axial end faces of the split cores 22 of adjacent coil winding bodies 21 to be aligned flush with each other. Furthermore, since the end face 55PS of the axially lower side (axially inner side) Y2 of the convex portion 55P is at the same position in the axial direction Y as the end face of the axially upper side (axially outer side) Y1 of the split core 22, if the end face 55PS of the axially lower side Y2 of the convex portion 55P of at least one split core 22 is abutted against the axial end face of another adjacent split core 22, the axial end faces of the split cores 22 will be aligned.

[0076] Furthermore, since the length H2 in the axial direction Y of the concave-shaped portion 55R is formed shorter than the length H1 in the axial direction Y of the convex-shaped portion 55P, it is possible to suppress the misalignment in the axial direction Y of the axial end faces of the connected split cores 22 caused by the misalignment between the length in the axial direction Y of the concave-shaped portion 55R and the length in the axial direction Y of the convex-shaped portion 55P.

[0077] In the stator of the rotating electric machine of this embodiment configured as described above, the axially inner end faces of the convex portions protruding circumferentially outward from the core side surfaces and the axial end faces of the split cores are positioned at the same axial position, and in each of the split cores connected adjacent to each other in the circumferential direction, the axially inner end face of the convex portion of one split core abuts against the axial end face of the other split core adjacent to it in the circumferential direction, so that the axial end faces of each split core are flush with each other in the axial direction. This reduces misalignment of the axial end faces of the two circumferentially connected split cores after engagement of the engaging portions is complete. This suppresses change in the outer diameter of the stator and ensures its roundness, resulting in a rotating electric machine with high performance.

[0078] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are contemplated within the scope of the technology of this disclosure. For example, this includes cases where at least one component is modified, added, or omitted, and even cases where at least one component is extracted and combined with components of another embodiment.

[0079] Various aspects of the present disclosure are described below as appendices. (Appendix 1) An insulator that is attached to a split core having a back yoke portion extending circumferentially and teeth protruding radially inward from the back yoke portion, and electrically insulates the split core from a wound coil, wherein engaging portions that connect circumferentially adjacent split cores are formed on both circumferential sides of an axial end face of the back yoke portion, and each engaging portion of each insulator is configured to be engageable with the engaging portion of another circumferentially adjacent insulator only from the axial side. (Appendix 2) An insulator as described in Appendix 1, wherein one of the engaging portions of each insulator has a convex portion that protrudes circumferentially outward more than the core side surface of the circumferentially adjacent split core, and the other engaging portion is provided circumferentially inward more than the core side surface and has a concave portion that is recessed circumferentially inward at the engaging portion and opens axially upward, and in the circumferentially adjacent engaging portions, the concave portion is formed so that the radial width at the circumferentially inner side is larger than the radial width at the opening, and the circumferentially outer tip portion of the convex portion has its radial side surface formed in a shape that follows the inner walls on both radial sides of the concave portion, and the circumferential length from the boundary surface where the core side surfaces of the circumferentially adjacent split cores contact each other to the bottom surface of the concave portion is longer than the circumferential length from the boundary surface to the tip of the convex portion. (Supplementary Note 3) The insulator according to Supplementary Note 2, wherein a gap is secured between circumferentially opposing side surfaces of the insulator, and the recessed portion and the protruding portion are configured to attract each other in the circumferential direction when engaged, and a tensile load of a set value or more is applied to the engaging portion. (Supplementary Note 4) The insulator according to Supplementary Note 2 or Supplementary Note 3, wherein the tip surface of the protruding portion is recessed circumferentially inward and has a slit penetrating in the axial direction. (Supplementary Note 5) The insulator according to any one of Supplementary Note 2 to Supplementary Note 4, wherein at least one of the recessed portion or the protruding portion has a tapered surface formed by chamfering corners of an end surface in the axial direction.(Supplementary Note 6) The insulator according to any one of Supplementary Notes 2 to 5, wherein the convex portion includes a protruding portion on an axially lower side that protrudes parallel to a first surface perpendicular to the axial direction, the protruding portion being configured to reduce a protruding length when pressed, and protruding parallel to the first surface from an axially lower end face of the engaging portion having the engaged concave portion when the convex portion and the concave portion are engaged, thereby restricting axial removal of the convex portion from the concave portion. (Supplementary Note 7) The insulator according to any one of Supplementary Notes 2 to 6, wherein the concave portion is formed in a dovetail shape whose radial width gradually increases circumferentially inward from an opening thereof, and the convex portion is formed in a dovetail shape whose radial width gradually increases circumferentially outward, and circumferentially adjacent split cores are fixed in the radial direction by engagement between the concave portion and the convex portion of the engaging portion of the insulators adjacent in the circumferential direction. (Supplementary Note 8) The insulator according to any one of Supplementary Note 2 to Supplementary Note 7, wherein the insulator is provided at each axial end of each of the split cores. (Supplementary Note 9) A stator for a rotating electric machine configured by attaching the insulator according to any one of Supplementary Note 1 to Supplementary Note 8 to the split cores, the coils being wound around the teeth portions of each of the split cores, and the split cores being connected in an annular shape by each of the engaging portions, wherein a frame or molded resin is disposed to cover the outer peripheries of the split cores connected in an annular shape, and a pressing force from the radial outside to the radial inside is applied to each of the split cores by the frame or the molded resin. (Supplementary Note 10) A rotating electric machine comprising: the stator for a rotating electric machine according to Supplementary Note 9; and a rotor arranged coaxially with the stator.(Appendix 11) A method for manufacturing a stator for a rotating electric machine, comprising a connecting step of arranging the split cores, each fitted with an insulator according to any one of Appendices 2 to 8, in an annular shape to form a core assembly in which adjacent split cores in the circumferential direction are connected by the engaging portion, wherein in the connecting step, the split cores constituting both ends of the core assembly are brought close to each other in the circumferential direction, the split core having the convex portion at one end of the brought-close core assembly is slid axially upward so as to be positioned above the concave portion at the other end, and with the core side surfaces of the split cores constituting both ends of the core assembly in contact with each other, the convex portion is inserted into the concave portion from above in the axial direction to engage the concave portion with the convex portion. (Appendix 12) A method for manufacturing a stator for a rotating electric machine according to Appendix 11, wherein the circumferential length from a boundary surface where the core side surfaces of circumferentially adjacent split cores contact each other to the bottom surface of the recess and the circumferential length from the boundary surface to the tip of the protrusion are adjusted so that a tensile load of a set value or more is applied to the engagement portion, causing the recess and the protrusion to attract each other in the circumferential direction when engaged.

[0080] 10 rotor, 12 coil, 20 stator, 21 coil winding body, 22 split core, 22B back yoke portion, 22T teeth portion, 22BS core side surface, 30 core connecting body, 50 insulating portion, 51 insulator, 52 coil winding portion, 53 back yoke covering portion, 55, 255 engaging portion, 55P, 55P-2 convex portion (convex portion), 55R, 55R-2 concave portion (concave portion), 59 insulating film, 355PI inner turned portion (protruding portion), 355PO outer turned portion (protruding portion), 100, 100A rotating electric machine.

Claims

1. An insulator that is mounted on a split core having a back yoke portion extending in the circumferential direction and a tooth portion protruding radially inward from the back yoke portion, and electrically insulates the wound coil and the split core, Engagement portions for connecting the split cores adjacent to each other in the circumferential direction are respectively formed on both sides in the circumferential direction on the axial end faces of the back yoke portion, The engagement portion of the insulator is configured to be engageable only from the axial side with the engagement portion of another adjacent insulator in the circumferential direction, Insulator.

2. The core side surfaces of the split cores adjacent to each other in the circumferential direction are in contact with each other, and a gap is formed between the side surfaces of the insulators facing each other in the circumferential direction, The insulator according to claim 1.

3. One of the engagement portions of each insulator has a convex portion protruding outward in the circumferential direction from the core side surface of the split core adjacent to it in the circumferential direction, and the other of the engagement portions is provided inward in the circumferential direction from the core side surface, and has a recess that is recessed inward in the circumferential direction and opens axially in the engagement portion, In the engagement portions adjacent to each other in the circumferential direction, The recess is formed such that the radial width on the inner side in the circumferential direction is larger than the radial width at the opening, and the tip portion on the outer side in the circumferential direction of the convex portion has a shape in which the side surface on the radial side thereof is along the inner walls on both radial sides of the recess, The circumferential length from the boundary surface where the core side surfaces of the split cores adjacent to each other in the circumferential direction contact each other to the bottom surface of the recess is configured to be longer than the circumferential length from the boundary surface to the tip of the convex portion, The insulator according to claim 2.

4. A tensile load equal to or greater than a set value that pulls in the circumferential direction in a state where the recess and the convex portion are engaged is configured to be applied to the engagement portion, The insulator according to claim 3.

5. The tip surface of the convex portion is recessed inward in the circumferential direction, and a slit penetrating axially is formed, The insulator according to claim 3.

6. In at least one of the recess or the convex portion, A tapered surface with chamfered corners on the axial end face is formed, The insulator according to claim 3.

7. The convex portion includes a protruding portion protruding parallel to a first surface perpendicular to the axial direction on the inner side in the axial direction, The protruding portion is configured such that its protruding length becomes smaller by pressing. In a state where the convex portion and the concave portion are engaged, the protruding portion protrudes parallel to the first surface from the end surface on the inner side in the axial direction of the engaging portion having the engaged concave portion, and restricts the axial escape of the convex portion from the concave portion. The insulator according to any one of claims 3 to 6.

8. The concave portion is formed in a dovetail groove shape in which the radial width gradually increases from the opening toward the inner side in the circumferential direction, and the convex portion is formed in a dovetail shape in which the radial width gradually increases toward the outer side in the circumferential direction. The adjacent split cores in the circumferential direction are fixed in the radial direction by the engagement of the concave portion and the convex portion of the engaging portions of the adjacent insulators in the circumferential direction. The insulator according to any one of claims 3 to 6.

9. The insulator is provided at both axial ends of each of the split cores. The insulator according to claim 3.

10. In a stator of a rotating electrical machine configured by winding the coil around the teeth portions of each of the split cores on which the insulator according to any one of claims 1 to 6 is mounted, and annularly connecting each of the split cores by each of the engaging portions, A frame or a molded resin covering the outer circumference of the annularly connected split cores is provided. The frame or the molded resin applies a pressing force from the outer side in the radial direction to the inner side in the radial direction to each of the split cores. Stator of a rotating electrical machine.

11. One of the engaging portions of each of the insulators has a convex portion protruding toward the outer side in the circumferential direction more than the core side surface of the adjacent split cores in the circumferential direction, and the other of the engaging portions is provided on the inner side in the circumferential direction more than the core side surface, and has a concave portion that is recessed inward in the circumferential direction and opens in the axial direction at the engaging portion. The end surface on the inner side in the axial direction of the convex portion protruding toward the outer side in the circumferential direction more than the core side surface and the axial end surface of the split core are configured to be in the same position in the axial direction. In each of the split cores that are connected adjacent to each other in the circumferential direction, the end surface on the inner side in the axial direction of the convex portion in one of the split cores abuts against the axial end surface of the other split core adjacent in the circumferential direction, and the axial end surfaces of each of the split cores are configured to be flush with each other in the axial direction. The stator of the rotating electrical machine according to claim 10.

12. The stator of the rotating electrical machine according to claim 10, And a rotor arranged coaxially with the stator. Rotating electrical machine.

13. A method for manufacturing a stator of a rotating electrical machine, comprising a connecting step of arranging the segmented cores equipped with the insulator according to any one of Claims 3 to 6 in a circular array to form a core connecting body in which the segmented cores adjacent in the circumferential direction are connected by the engaging portion, in the connecting step, bringing the segmented cores respectively constituting both end sides of the core connecting body closer to each other in the circumferential direction, sliding the segmented core having the convex portion upward in the axial direction so as to be positioned above the concave portion on the other end side, and inserting the convex portion into the concave portion from above in the axial direction with the core side surfaces of the segmented cores respectively constituting both ends of the core connecting body in contact with each other to engage the concave portion and the convex portion; A method for manufacturing a stator of a rotating electrical machine.

14. such that a tensile load equal to or greater than a set value that draws in the circumferential direction is applied to the engaging portion in a state where the concave portion and the convex portion are engaged, the circumferential length from the boundary surface where the core side surfaces of the segmented cores adjacent in the circumferential direction contact each other to the bottom surface of the concave portion and the circumferential length from the boundary surface to the tip of the convex portion are adjusted; A method for manufacturing a stator of a rotating electrical machine according to Claim 13.