Armature, rotary electric machine, and method for manufacturing armature

Abstract

Provided is an armature in which a plurality of magnetic pole teeth (31) are arranged in an annular shape, wherein: the magnetic pole teeth (31) include a coil (31b) that is wound integrally with insulating cores (31a1), (31a2), which are divided into a plurality of portions in the axial direction; the insulating cores (31a1), (31a2) are provided with divided cores (321), (322) in which a yoke portion (34) extending in the circumferential direction and a tooth portion (35) protruding in the radial direction from the yoke portion (34) are formed, and insulating members (331), (332) that are coated onto a shaft end surface (35a) and a side surface (35b) of the tooth portion (35); the plurality of insulating cores (31a1), (31a2) are in contact with each other with portions of the insulating members (331), (332) interposed therebetween; and the coil (31b) is wound around each of the tooth portions (35) with the other portions of the insulating members (331), (332) interposed therebetween.

Description

Armature, rotating electric machine, and method for manufacturing the armature

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

[0002] A conventional armature for a rotating electric machine is composed of an armature core having multiple teeth along the radially inner side, and a coil wound around each tooth of the armature core via an insulating member. The armature core is composed of multiple split cores arranged in the circumferential direction, and the teeth of the split cores are integrally molded with insulators that cover the axial end faces and side faces of the teeth in the axial direction. This configuration insulates the split cores from the coil with high productivity (see, for example, Patent Document 1).

[0003] Patent No. 5363255

[0004] In conventional technology, when constructing an armature for a rotating electric machine with a long axial length, it is necessary to integrally mold an insulating member onto the axially long split core. This requires making the insulating member thick on the side surfaces of the split core to ensure resin flowability, resulting in a problem of narrowing the coil winding area. Furthermore, integrally molding the insulating member onto the axially long split core requires large molding equipment and molding dies, resulting in high investment costs. Furthermore, thermal contraction of the resin after integral molding causes the split core to be subjected to a force in the axial tightening direction, causing warping of the split core, which could result in a deterioration in the assembly accuracy of the armature.

[0005] The present disclosure has been made to solve the above-mentioned problems, and aims to provide an armature, a rotating electric machine, and a method for manufacturing an armature that are highly productive when integrally molding split cores and insulating members, even when constructing an armature for a rotating electric machine with a long axial length.

[0006] The armature according to the present disclosure comprises a plurality of magnetic pole teeth arranged in a circular ring shape around a central axis, each of the plurality of magnetic pole teeth including an insulating core divided into a plurality of pieces in the axial direction and a coil wound around the plurality of insulating cores as a unit, each of the plurality of insulating cores including a divided core having a yoke portion extending circumferentially outward and a tooth portion protruding radially inward from the yoke portion, and an insulating member covering the axial end faces and side faces of the tooth portion in the axial direction, and the plurality of insulating cores abut against each other via a portion of the insulating member, and a coil wound around each tooth portion via another portion of the insulating member.

[0007] According to the present disclosure, even when constructing an armature for a rotating electric machine with a long axial length, the split cores are split in the axial direction, so that an armature, rotating electric machine, and a method for manufacturing an armature can be obtained that have high productivity when integrally molding the split cores and insulating members.

[0008] 1. A cross-sectional view showing the configuration of a rotating electric machine according to a first embodiment. 2. A perspective view showing the configuration of an armature according to the first embodiment. 3. A perspective view showing the configuration of a split core according to the first embodiment. 4. A perspective view showing the configuration of an insulating core according to the first embodiment. 5. A perspective view showing the configuration of a one-teeth core according to the first embodiment. 6. A perspective view showing the configuration of a magnetic pole tooth according to the first embodiment. 7. A perspective view showing the configuration of an insulating core according to a second embodiment. 8. A cross-sectional view showing the assembly of an insulating core using the A-A cross-sectional view of FIG. 8. 9. A cross-sectional view showing another example of the assembly of the insulating core shown in FIG. 10. 10. A perspective view showing the configuration of a split core according to a third embodiment. 11. A top view showing the abutment portion of an insulating core according to the third embodiment. 12. A cross-sectional view showing the assembly of an insulating core using the B-B cross-sectional view of FIG. 12. 13. A perspective view showing the configuration of a magnetic pole tooth according to a fourth embodiment. 14. A perspective view showing the configuration of the third insulating core in FIG. 14. 15. A cross-sectional view showing the assembly of an insulating core using the C-C cross-sectional view of FIG. FIG. 21 is a cross-sectional view showing another example of assembly of the insulating core shown in FIG. 16. FIG. 22 is a side view showing the configuration of an insulating core according to embodiment 5. FIG. 23 is a side view showing typically the amount of warping of a comparative insulating core. FIG. 24 is a side view showing typically the amount of warping of the insulating core shown in FIG. 18. FIG. 24 is a cross-sectional view showing the configuration of an insulating core according to embodiment 6. FIG. 25 is a cross-sectional view showing typically the amount of tilting of a comparative insulating core. FIG. 26 is a side view showing typically the amount of tilting of the insulating core shown in FIG. 21. FIG. 27 is a top view showing a contact portion of an insulating core according to embodiment 7. FIG. 28 is a perspective view showing the configuration of magnetic pole teeth according to embodiment 7.

[0009] The present embodiment will be described below with reference to the drawings. In each drawing, the same reference numerals indicate the same or corresponding parts. Furthermore, FIGS. 1 to 25 relate to one embodiment, and the present disclosure is not limited to these drawings.

[0010] Embodiment 1. In this disclosure, unless otherwise specified, the terms "axial direction," "radial direction," "circumferential direction," "inner peripheral side," and "outer peripheral side" refer to the "axial direction," "radial direction," "circumferential direction," "inner peripheral side," and "outer peripheral side" of an armature in a rotating electric machine, respectively. Note that in the drawings, X indicates the axial direction, Y indicates the radial direction, and Z indicates the circumferential direction.

[0011] Fig. 1 is a cross-sectional view showing the configuration of a rotating electric machine 10, and Fig. 2 is a perspective view showing the configuration of an armature 30 in Fig. 1. In Fig. 1, the rotating electric machine 10 includes a field element 20 provided with a permanent magnet, an armature 30 having a plurality of magnetic pole teeth 31 arranged in an annular shape, a frame 40, a wiring-side bracket 11, an anti-wiring-side bracket 12, and a power connector 50 provided on the wiring side, with the armature 30 being press-fitted or shrink-fitted into the frame 40. The field element 20 and the armature 30 are held by the wiring-side bracket 11 and the anti-wiring-side bracket 12, and the field element 20 is disposed coaxially with the central axis of the armature 30 via a gap on the inner periphery of the armature 30 so as to be rotatable by a bearing (not shown).

[0012] Furthermore, in Figures 1 and 2, the armature 30 has a plurality of magnetic pole teeth 31 arranged in a circular ring shape around the central axis, and each magnetic pole tooth 31 includes one teeth core 31a and a coil 31b wound integrally around the one teeth core 31a, and the one teeth core 31a is composed of a first insulating core 31a1 and a second insulating core 31a2 divided in the axial direction.

[0013] Next, the structure and manufacturing method of one teeth core 31a constituting the magnetic pole tooth 31 will be described with reference to Fig. 3 to Fig. 6, illustrating an example in which one teeth core 31a is divided into two. Fig. 3 is a perspective view showing a first divided core 321 and a second divided core 322 that form the base of one teeth core 31a, Fig. 4 is a perspective view showing first and second insulating cores 31a1 and 31a2 composed of the first and second divided cores 321 and 322, Fig. 5 is a perspective view showing one teeth core 31a composed of the first and second insulating cores 31a1 and 31a2, and Fig. 6 is a perspective view showing a magnetic pole tooth 31 composed of one teeth core 31a.

[0014] As shown in Fig. 3, the first and second split cores 321, 322 are formed from a plurality of electromagnetic steel plates 36 stacked in the axial direction. A yoke portion 34 extending in the circumferential direction is formed on the outer periphery of the first and second split cores 321, 322, and teeth portions 35 protruding radially inward from the circumferential center of the yoke portion 34 are formed on the inner periphery of the yoke portion 34. Protrusions 37 extending in both circumferential directions are formed on the inner ends of the first and second split cores 321, 322. As shown in Fig. 3, the first and second split cores 321, 322 have the same shape and structure. The first and second split cores 321, 322 have their axial end faces 35a and side faces 35b in the axial direction covered with a first insulating member 331 and a second insulating member 332 made of thermoplastic resin, as shown in Figure 4, to form integrally molded first and second insulating cores 31a1, 31a2.

[0015] The first and second insulating cores 31a1 and 31a2 have the same shape and structure, and are shown arranged with their axial orientations reversed in Fig. 4. In Fig. 4, the first and second insulating cores 31a1 and 31a2 have, at one axial end face 35aa, first and second insulating members 331 and 332, respectively, which form an outer flange 38aa that protrudes in the axial direction on the outer periphery, an inner flange 38ba that protrudes in the axial direction on the inner periphery, and a body 38ca that is provided on the same plane as the tooth portion 35. Furthermore, on the other axial end face 35ab, the first and second insulating members 331, 332 respectively form an outer flange portion 38ab on the outer periphery, an inner flange portion 38bb on the inner periphery, and a body portion 38cb provided on the same plane as the tooth portion 35, and the outer flange portion 38ab, inner flange portion 38bb, and body portion 38cb, which are provided on the same plane, form an abutment portion 39.

[0016] Furthermore, outer flanges 38aa, 38ab cover yoke portion 34 from both axial sides, inner flanges 38ba, 38bb cover protruding portions 37 of teeth 35 from both axial sides, and body portions 38ca, 38cb cover teeth 35 from both axial sides. The outer flanges 38aa, 38ab are positioned slightly inward so that their radially outer peripheries do not protrude beyond the radially outer periphery of yoke portion 34. Furthermore, the circumferential width of outer flanges 38aa, 38ab is configured to be the same as the circumferential width of yoke portion 34. As shown in Figure 5, these first and second insulating cores 31a1 and 31a2 are butted together at their contact portions 39 to form one tooth core 31a, and as shown in Figure 6, the magnetic pole teeth 31 are formed by winding and connecting the coil 31b around the body portion 38ca and side surface 35b of the first and second insulating members 331 and 332, integrating the one tooth core 31a.

[0017] Here, referring to Figure 4, a manufacturing method for integrally molding the first and second split cores 321, 322 and the first and second insulating members 331, 332 will be described. The first and second split cores 321, 322 are placed in a molding die corresponding to their respective axial lengths, and the thermoplastic resin that will form the first and second insulating members 331, 332 is injected from the radially outer periphery of the axial end face 35aa, where the outer flange 38aa is provided, while maintaining its fluidity by increasing the temperature. Next, the resin is divided into left and right circumferential halves and flows toward the axial end face 35ab through the side face 35b. The flows then merge and reach the abutment portion 39, filling the entire core. The resin then hardens as the molding die cools, and the first and second split cores 321, 322 are removed from the molding die, producing the first and second insulating cores 31a1, 31a2.

[0018] In this case, even if the thicknesses of the first and second insulating members 331, 332 covering the side surface 35b are made thin, the axial lengths of the first and second split cores 321, 322 are short, allowing the resin to be filled securely. Furthermore, the thickness of the abutting portion 39 is made thinner than the thickness of the body portion 38ca so that it does not protrude axially from the first and second split cores 321, 322. With this configuration, when combined with the magnetic pole teeth 31, the abutting portion 39 reduces the central region where the first and second split cores 321, 322 are not present, thereby shortening the axial length of the rotating electric machine 10.

[0019] The thinner the contact portion 39 and the side surface 35b, the better the performance of the rotating electrical machine 10. However, the side surface 35b must be thick enough to provide the required insulation distance. Both the contact portion 39 and the side surface 35b must be thick enough to ensure a sufficient path for the resin to flow. Depending on the viscosity of the resin material, both are approximately the same thickness, between 0.1 and 1.0 mm. Because a weld line (a line where the resin flows together) forms in the contact portion 39, the thickness of the contact portion 39 may be greater than the thickness of the side surface 35b.

[0020] According to the armature 30 of the first embodiment, the magnetic pole teeth 31 are configured with the first and second insulating cores 31a1, 31a2 that are divided in the axial direction, so that the thickness of the side surface 35b can be made thin, and as shown in Fig. 6, space for winding the coil 31b can be secured. With this configuration, for example, the number of turns of the coil 31b can be increased accordingly, thereby improving the output without increasing the size of the rotating electric machine 10. Furthermore, because the first and second divided cores 321, 322, each having a short axial length, can be integrally molded, the size of the molding die can be reduced, and the size of the molding machine for filling the resin can also be reduced, resulting in a low-cost configuration and reduced capital investment.

[0021] Furthermore, when the integrally molded resin cools and hardens, it thermally shrinks, generating stress that compresses the first and second split cores 321, 322 in the axial direction. However, because the first and second split cores 321, 322 have short axial lengths, the accuracy of the core shape due to the stress acting on the first and second split cores 321, 322 is improved, facilitating shrink-fitting or press-fitting of the frame 40, and improving the accuracy of the shape of the armature 30, thereby suppressing torque pulsation. Furthermore, because the radial outer periphery of the outer flanges 38aa, 38ab is located more inward than the radial outer periphery of the yoke portion 34, the frame 40 and the yoke portion 34 are in reliable contact with each other, improving the accuracy of the shape of the armature 30. Furthermore, the outer flanges 38aa, 38ab do not come into contact with each other when the frame 40 is shrink-fitted or press-fitted, preventing wear and cracking of the insulating members. Furthermore, since the circumferential width of the outer flange portions 38aa, 38ab is configured to be the same as the circumferential width of the yoke portion 34, the yoke portion 34 is reliably covered with an insulating material, and an insulating distance between the coil 31b and the yoke portion 34 is ensured, thereby improving insulation performance.

[0022] 4, the first and second split cores 321, 322 and the first and second insulating members 331, 332 are configured as shown in FIG. 4, but the shapes are not limited thereto. For example, the outer flanges 38aa, 38ab of the first and second insulating cores 31a1, 31a2 may be formed in different shapes. Also, although the abutting portion 39 is provided from the tooth portion 35 to a portion of the yoke portion 34 in FIG. 3, it may be configured to cover the entire axial end surfaces 35a of the first and second split cores 321, 322, i.e., the outer periphery of the yoke portion 34. By increasing the abutting area, stress acting on the abutting portion 39 after winding the coil 31b is dispersed, thereby suppressing deterioration of the resin.

[0023] Embodiment 2. Embodiment 2 will be described with reference to FIGS. 7 to 10, focusing on differences from Embodiment 1. FIG. 7 is a perspective view showing the configuration of an insulating core 51 according to Embodiment 2, and FIG. 8 is a top view showing the abutment portion 59 of the insulating core 51 in FIG. 7. FIG. 9 is a cross-sectional view showing the assembly of a first insulating core 51a and a second insulating core 51b using the A-A cross-sectional view of FIG. 8, and FIG. 10 is a cross-sectional view showing another example of the assembly of the first and second insulating cores 51a, 51b shown in FIG. 9. In FIGS. 7 and 8, the insulating core 51 includes a split core 52 and an insulating member 53, and an abutment portion 59 is formed on one axial end surface of the insulating member 53.

[0024] The abutment portions 39 of the first and second insulating cores 31a1 and 31a2 according to the first embodiment have axial end faces that are flat and free of irregularities, but the abutment portion 59 of the insulating core 51 according to the second embodiment has a mutually engaging protrusion 54 and hole 55, as shown in Fig. 7. The protrusion 54 and hole 55 are provided near the center of the abutment portion 59, at positions that are the same distance from the circumferential center, that is, at positions that are symmetrical with respect to the circumferential center, as shown in Fig. 8.

[0025] 9, the first and second insulating cores 51a, 51b are configured to satisfy the conditional expressions φt≦φa and Ht≦Ht, where the projections 54a, 54b provided on the contact portions 59a, 59b of the first split core 52a and the second split core 52b have a diameter φt and a height Ht, the holes 55a, 55b have a diameter φa and a depth Ha, and the thickness of the contact portions 59a, 59b is D. Next, during assembly, the contact portions 59a, 59b are brought into contact with each other so that the projections 54a and the holes 55a of the first insulating core 51a engage with the projections 54b and the holes 55b of the second insulating core 51b, and the coil 31b is wound and connected in the same manner as in the first embodiment, thereby forming the magnetic pole teeth 31.

[0026] According to the armature 30 of the second embodiment, the butting position of the first insulating core 51a and the second insulating core 51b is determined by the engagement of the protrusions 54a, 54b and the holes 55a, 55b, thereby improving the shape accuracy of the magnetic pole teeth 31. Furthermore, when the coil 31b is wound around one teeth core 31a under tension, the first and second insulating cores 51a, 51b do not shift, and deterioration of the shape accuracy during winding can be suppressed. With this configuration, the shape accuracy of the armature 30 is improved and torque pulsation of the rotating electric machine 10 can be suppressed.

[0027] The shapes of the protrusions 54a, 54b and the holes 55a, 55b are not limited to the cylindrical shape shown in Fig. 9, but may also be rectangular parallelepiped or conical as shown in Fig. 10. In this case, by making the size of the holes 55a, 55b equal to or larger than the size of the protrusions 54a, 54b, the protrusions 54a, 54b can be engaged with the holes 55a, 55b without interfering with each other. In the case of a conical shape, even if the protrusions 54a, 54b are misaligned during insertion, the protrusions 54a, 54b are guided into the holes 55a, 55b to correct the misalignment, which facilitates assembly.

[0028] Although the contact portion 59a may be provided with holes 55a, 55b, which are one of the concave and convex portions, and the contact portion 59b may be provided with protrusions 54a, 54b, which are the other of the concave and convex portions, and these may be engaged with each other, a configuration in which the protrusions 54a and the hole 55a are provided on the contact portion 59a, and the protrusions 54b and the hole 55b are provided on the contact portion 59b as shown in Figure 10, and two pairs of the opposing holes 55a, 55b and the protrusions 54a, 54b are engaged, has the advantage that the same mold can be used for forming the contact portions 59a, 59b. Note that even when there is only one pair of opposing holes and protrusions, it is possible to position the insulating cores 51a, 51b relative to each other, but in this case, forming the holes and protrusions into polygonal shapes makes it easier to determine the phase of the first and second insulating cores 51a, 51b relative to each other.

[0029] Embodiment 3. Embodiment 3 will be described with reference to FIGS. 11 to 13, focusing on differences from Embodiment 1. FIG. 11 is a perspective view showing the configuration of a split core 62 according to Embodiment 3, and FIG. 12 is a top view showing the abutment portion 69 of the split core 62 in FIG. 11. FIG. 13 is a cross-sectional view showing the assembly of the first insulating core 61a and the second insulating core 61b using the B-B cross-sectional view of FIG. 12. In FIGS. 11 and 12, the split core 62 has a yoke portion 64 and teeth portion 65, and the insulating core 61 includes the split core 62 and an insulating member 63, with the abutment portion 69 formed on one axial end surface of the insulating member 63.

[0030] While the first and second split cores 321, 322 according to the first embodiment have protrusions 37 formed on the inner ends of the teeth 35 that extend circumferentially, the split core 62 according to the third embodiment has protrusions 67 formed on the inner ends of the teeth 65 that protrude from one of the two circumferential sides. Furthermore, as shown in Fig. 12 , an insulating member 63 is also formed to cover the protrusions 67 that protrude from only one circumferential side at the ends of the teeth 65, thereby forming the insulating core 61. Next, during assembly, the first insulating core 61a and the second insulating core 61b, each having protrusions 67a, 67b on one circumferential side, are arranged with their axial orientations changed as shown in Fig. 13 , and the abutting portions 69a, 69b are brought into abutment with each other. The coil 31b is wound and connected in the same manner as in the first embodiment, thereby forming the magnetic pole teeth 31.

[0031] 13 , the protrusion 67a of the first insulating core 61a is positioned on one side in the circumferential direction, i.e., only on the upper side as viewed from Fig. 13 , and the protrusion 67b of the second insulating core 61b is positioned on the other side in the circumferential direction, i.e., only on the lower side as viewed from Fig. 13 , so that the positions at which the two divided protrusions 67a, 67b are formed are misaligned in the axial direction of the magnetic pole teeth 31, thereby forming a two-stage skew. According to the armature 30 of the third embodiment, in addition to enjoying the effects based on the first embodiment, it is possible to provide a two-stage skew in the armature 30 simply by combining two first and second insulating cores 61a, 61b having the same configuration, and it is possible to add the effect of inexpensively reducing torque pulsation of the rotating electric machine 10.

[0032] Embodiment 4. Embodiment 4 will be described with reference to Figures 14 to 17, focusing on differences from embodiment 1. Figure 14 is a perspective view showing the configuration of a magnetic pole tooth 70 according to embodiment 4, and Figure 15 is a perspective view showing the configuration of a third insulating core 71c in Figure 14. Figure 16 is a cross-sectional view showing the assembly of first to third insulating cores 71a, 71b, and 71c using the CC cross-sectional view of Figure 15, and Figure 17 is a cross-sectional view showing another example of the assembly of the first to third insulating cores 71a, 71b, and 71c shown in Figure 16. In Figures 14 and 15, the magnetic pole tooth 70 includes first to third insulating cores 71a, 71b, and 71c divided in the axial direction and a coil 78, and the third insulating core 71c has a divided core 72 and an insulating member 73, and abutment portions 79c1 and 79c2 are respectively formed on axial end faces 751 and 752 on both sides in the axial direction of the insulating member 73.

[0033] The magnetic pole teeth 31 according to the first to third embodiments are configured using first and second insulating cores 31a1, 31a2, each divided into two in the axial direction, but the number of divisions is not limited to this and may be three or more. The magnetic pole teeth 70 according to the fourth embodiment are configured using first to third insulating cores 71a, 71b, 71c, each divided into three in the axial direction. The first and second insulating cores 71a, 71b are configured in the same manner as the insulating cores according to the first to third embodiments and have the same shape and structure, but the third insulating core 71c, located between them, has an insulating member 73 with a shape that is partially different from that of the first and second insulating cores 71a, 71b. In other words, the third insulating core 71c also has the same split core 72 as the first and second insulating cores 71a and 71b, but an insulating member 73 is integrally molded on its axial end faces 751 and 752, and instead of the outer flange portions 38aa and 38ab, identical abutment portions 79c1 and 79c2 configured in the same way as the abutment portions of embodiments 1 to 3 are provided, respectively.

[0034] Next, during assembly, the third insulating core 71c is placed between the first insulating core 71a and the second insulating core 71b, as shown in Figure 16, and the abutment portion 79a of the first insulating core 71a is abutted against the abutment portion 79c1 of the third insulating core 71c, and the abutment portion 79b of the second insulating core 71b is abutted against the abutment portion 79c2 of the third insulating core 71c.With these combined, as shown in Figure 14, a coil 78 is wound around them to connect the first to third insulating cores 71a, 71b, and 71c, thereby forming the magnetic pole teeth 70.

[0035] According to the armature 30 of the fourth embodiment, the axial length of the first to third insulating cores 71a, 71b, and 71c can be reduced to two-thirds of that of the first to third embodiments. This allows for easier resin filling even when the insulating member 73 on each side is thin, allowing for smaller molding equipment and molds, thereby reducing investment costs. Furthermore, the effect of preventing deterioration in the accuracy of the split core 72 due to thermal shrinkage of the resin after molding is further enhanced. Furthermore, if the thicknesses of the side surfaces and abutment portions 79a, 79b, 79c1, and 79c2 of the first to third insulating cores 71a, 71b, and 71c are all the same, there is the advantage that the same mold can be used to mold the side surfaces and abutment portions. For example, the mold used to mold the right end surface of the first insulating core 71a shown in FIG. 16 can be replaced with the mold used to mold the abutment portion 79a on the left end surface to mold the third insulating core 71c, thereby reducing investment costs for molding molds.

[0036] While Fig. 16 shows an example in which the insulating core is divided into three, as shown in Fig. 17, it may be divided into four or more, allowing for a shorter insulating core even when manufacturing a rotating electric machine 10 with a longer axial length. Furthermore, when manufacturing rotating electric machines 10 with different axial lengths, a third insulating core 71c serving as a reference unit can be arranged in multiple stages in the axial direction, thereby enabling an expansion of the product lineup by simply producing a reference insulating core. Furthermore, as shown in the second embodiment, protrusions 771a, 771b, 771c1, and 771c2 and holes 772a, 772b, 772c1, and 772c2 may be provided. Since the greater the number of stages of the insulating core, the more misalignment contributes to a deterioration in the accuracy of the pole teeth 70, suppressing the misalignment more effectively improves the dimensional accuracy of the rotating electric machine 10.

[0037] Embodiment 5. Embodiment 5 will be described with reference to FIGS. 18 to 20 , focusing on differences from Embodiment 1. FIG. 18 is a side view showing the configuration of a first insulating core 81a and a second insulating core 81b according to Embodiment 5. FIG. 19 is a side view showing the amount of warpage of a comparative insulating core, and FIG. 20 is a side view showing the amount of warpage of the first and second insulating cores 81a and 81b shown in FIG. 18 . In FIG. 18 , the first and second insulating cores 81a and 81b have a contact portion 89a, 89b tapered at their axial end faces, with the thickness being thicker on the inner periphery than on the outer periphery. That is, the axial end faces of the contact portions 89a and 89b are not flat surfaces perpendicular to the axial direction, but are tapered planes oblique to the axial direction, as shown in FIG. 18 . When the thickness on the inner periphery is defined as Di and the thickness on the outer periphery is defined as Do, the condition Di > Do is satisfied.

[0038] Generally, due to the stress caused by thermal contraction of the resin after molding and the tightening force when the coil is wound, the inner circumferential side of the insulating core is deformed in the axial direction more than the outer circumferential side, resulting in a deterioration in shape accuracy, as if the insulating core is warped. To solve this problem, in the configurations according to the first to fourth embodiments, the insulating core is divided into multiple parts in the axial direction, which reduces the overall warpage of the insulating core compared to an insulating core with a long axial length. However, if the axial end faces of the abutting portions 892 of the two insulating cores 82 are configured as flat surfaces perpendicular to the axial direction, as shown in Figure 19, the warpage of the two insulating cores 82 may combine, increasing the radial warpage Wi1.

[0039] Therefore, as shown in FIG. 18, if the axial end surfaces of the abutment portions 89a, 89b are tapered so that the radially inner side is thicker than the radially outer side, even if the first and second insulating cores 81a, 81b are subjected to stress due to thermal contraction after molding of the resin and the tightening force when winding the coil, and the inner side is deformed in the axially contracting direction to a greater extent than the outer side, as shown in FIG. 20, the overall radial warp amount Wi2 can be suppressed to be less than the warp amount Wi1 shown in FIG. 19.

[0040] According to the armature 30 of embodiment 5, the axial end faces of the first and second insulating cores 81a, 81b are tapered so that the radially inner side is thicker than the radially outer side, thereby suppressing the overall amount of warping in the radial direction. This improves the shape accuracy of the magnetic pole teeth, makes it easier to press or shrink fit the frame, increases productivity, and also improves the shape accuracy of the rotating electric machine 10, thereby reducing torque pulsation. In addition, if the thickness of the abutment portions 89a, 89b is thickness Di on the radial inner side and thickness Do on the outer side, the axial difference between thickness Di and thickness Do is thickness Dd, the radial distance between thickness Di and thickness Do is length L1, and thickness Di = thickness Do, then the amount of warping from the axial plane perpendicular to the axial end faces of the abutment portions 89a, 89b is length L2, and the axial length of the first and second insulating cores 81a, 81b is length L3, then if Dd is configured to satisfy the condition Dd / L1 ≧ L2 / L3 / 2, the amount of warping can be actively suppressed, and the effect of improving shape accuracy will be greater.

[0041] Embodiment 6. Embodiment 6 will be described with reference to FIGS. 21 to 23, focusing on differences from Embodiment 1. FIG. 21 is a cross-sectional view showing the configuration of a first insulating core 91a and a second insulating core 91b according to Embodiment 6. FIG. 22 is a cross-sectional view showing the amount of tilt of a comparative insulating core, and FIG. 23 is a side view showing the amount of tilt of the first and second insulating cores 91a and 91b shown in FIG. 21. Note that the amount of tilt is exaggerated to make the explanation easier to understand. In FIG. 21, the thickness of the abutment portions 99a and 99b of the first and second insulating cores 91a and 91b is tapered, with one end of the abutment portion 99a being thicker than the other end in the circumferential direction.

[0042] That is, the axial end surfaces of the abutment portions 99a, 99b are not flat surfaces perpendicular to the axial direction, but are tapered and inclined to the axial direction, as shown in FIG. 21 . If the thickness of one side in the circumferential direction is defined as thickness Hi and the thickness of the other side is defined as thickness Ho, the condition of thickness Hi > thickness Ho is satisfied. Here, the thickness of the electromagnetic steel sheet varies depending on the position, although to a greater or lesser extent. In particular, as shown in FIG. 22 , the thickness of the two insulating cores 92 may vary in a tapered manner, with one side being thinner and the other side being thicker in the circumferential direction. That is, if the thickness of one side of the two insulating cores 92 in the circumferential direction is defined as thickness H1 and the thickness of the other side is defined as thickness H2, a deviation such that thickness H2 > thickness H1 may occur.

[0043] When an insulating core 92 is manufactured using core pieces with such thickness deviations, the thickness deviations accumulate, causing the core to tilt in the circumferential direction, as shown in Figure 22. Furthermore, in this state, stress from resin molding and the tightening force from winding the coil are applied to the insulating core 92, accelerating deformation and deteriorating the shape accuracy of the insulating core 92, as if it were tilted in the circumferential direction. To resolve this problem, the configurations of embodiments 1 to 5 divide the insulating core into multiple pieces in the axial direction, which reduces the overall tilt of the insulating core compared to an insulating core with a long axial length. However, if the axial end faces of the abutting portions 992 of the two insulating cores 92 are configured as planes perpendicular to the circumferential direction, as shown in Figure 22, the tilts of the two insulating cores 92 may combine, increasing the amount of circumferential tilt Wo1.

[0044] Therefore, if the axial end surfaces of the abutting portions 99 a, 99 b are tapered so that one circumferential side is thicker than the other circumferential side as shown in Fig. 21 , even if the first and second insulating cores 91 a, 91 b are subjected to molding stress and the tightening force when the coils are wound and are deformed more significantly in the axial contraction direction, the overall circumferential tilt Wo2 can be reduced compared to the tilt Wo1 shown in Fig. 22 as shown in Fig. 23. According to the armature 30 of the sixth embodiment, the axial end surfaces of the first and second insulating cores 91 a, 91 b are tapered so that one circumferential side is thicker than the other circumferential side to reduce the overall circumferential tilt, thereby improving the shape accuracy of the magnetic pole teeth, facilitating press-fitting or shrink-fitting of the frame, increasing productivity, and improving the shape accuracy of the rotating electric machine 10 and reducing torque pulsation.

[0045] Seventh Embodiment. The seventh embodiment will be described with reference to FIGS. 24 and 25, focusing on differences from the first embodiment. FIG. 24 is a top view showing a contact portion 939 of an insulating core 921 according to the seventh embodiment. FIG. 25 is a perspective view showing the configuration of magnetic pole teeth according to the seventh embodiment. In FIG. 24, a notch 941 is provided on the yoke portion 94 of the insulating core 921 at the radially outer periphery and at the circumferential center. This notch 941 extends in the axial direction of the yoke portion 94 and has a concave or V-shape. Furthermore, the outer periphery of an outer flange 938 coated on the contact portion 939 is formed inward relative to the bottom of the notch 941. With this configuration, as shown in Figure 25, a winding jig 900 is provided with a protrusion 901 that fits into a notch 941 to position it, and the protrusion 901 is fitted into the notch 941 of each of the first insulating core 921a and the second insulating core 921b, and by rotating the handle 902, the two insulating cores can be positioned with high precision while winding.

[0046] Furthermore, even when integrally molded, by providing a protrusion on the mold that fits into the notch 941 for positioning and molding with high precision, the multiple insulating cores are abutted against each other with their respective notches 941 aligned in the axial direction. In other words, the multiple insulating cores can be configured with minimal variation using the notch 941 as a reference. By assembling the windings and insulating cores based on the reference notch 941, high-quality assembly with minimal manufacturing variation can be performed efficiently. Furthermore, the insulating cores are not displaced during winding due to coil tension, allowing for high-density winding at high speeds, improving performance and productivity. Furthermore, the outer flange 938, whose abutment portion 939 is coated with an insulating material, has its radial outer periphery positioned more inward than the bottom of the notch 941. Therefore, the insulating material does not interfere with the protrusion 901 of the winding jig 900, preventing cracking and chipping.

[0047] 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 variations not illustrated are contemplated within the scope of the technology disclosed in this specification. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment. Various aspects of the present disclosure are described below as appendices.

[0048] (Supplementary Note 1) An armature having a plurality of magnetic pole teeth arranged in an annular shape about a central axis, wherein each of the plurality of magnetic pole teeth includes an insulating core divided into a plurality of pieces in the axial direction and a coil wound integrally around the plurality of insulating cores, wherein each of the plurality of insulating cores includes a split core formed with a yoke portion extending outward in the circumferential direction and a tooth portion protruding inward in the radial direction from the yoke portion, and an insulating member covering axial end faces and side faces of the tooth portion in the axial direction, wherein the plurality of insulating cores abut against each other via parts of the insulating member, and the coil is wound around each of the tooth portions via other parts of the insulating member. (Supplementary Note 2) The armature according to Supplementary Note 1, wherein the plurality of split cores are formed in the same shape using electromagnetic steel sheets laminated in the axial direction. (Supplementary Note 3) The armature according to Supplementary Note 1 or Supplementary Note 2, characterized in that the thickness of the insulating material coating the axial end surfaces of the teeth is equal to or greater than the thickness of the insulating material coating the side surfaces of the teeth. (Supplementary Note 4) The armature according to any one of Supplementary Note 1 to Supplementary Note 3, characterized in that the abutting portion of the insulating core is formed using the insulating material coating the axial end surfaces of the teeth and the insulating material of the same plane coating at least a portion of the axial end surface of the yoke portion in addition to the insulating material coating the axial end surfaces of the teeth. (Supplementary Note 5) The armature according to any one of Supplementary Note 1 to Supplementary Note 4, characterized in that the abutting portions of the multiple insulating cores are provided with protrusions and holes that engage with each other at their respective abutting portions. (Supplementary Note 6) The armature according to Supplementary Note 5, characterized in that the protrusions and the holes are provided at positions that are symmetrical about the circumferential center of the insulating core. (Supplementary Note 7) The armature according to Supplementary Note 6, characterized in that, where the size of the protrusion is a diameter φt and a height Ht, the size of the hole is a diameter φa and a depth Ha, and the thickness of the abutment portion is a thickness D, the armature is configured to satisfy the conditional expressions φt≦φa and Ht≦Ha≦D. (Supplementary Note 8) The armature according to any one of Supplementary Notes 1 to 7, characterized in that each of the plurality of split cores has a protrusion formed on an inner peripheral end of the tooth portion, protruding from one of both circumferential sides.(Supplementary Note 9) The armature according to Supplementary Note 8, characterized in that two stages of skew are formed by winding the coil around the split core arranged so that the protruding portion is located on one side of the circumferential direction and the split core arranged so that the protruding portion is located on the other side of the circumferential direction and abutting them against each other. (Supplementary Note 10) The armature according to any one of Supplementary Notes 1 to 9, characterized in that each of the plurality of magnetic pole teeth includes first and second insulating cores and one or more reference third insulating cores between the first and second insulating cores, and the first to third insulating cores include split cores of the same length in the axial direction. (Supplementary Note 11) The armature according to any one of Supplementary Notes 1 to 10, characterized in that the thickness of the abutting portions of each of the plurality of insulating cores is tapered at an axial end face in the axial direction, with the inner circumferential side being thicker in the radial direction than the outer circumferential side. (Supplementary Note 12) The armature according to Supplementary Note 11, characterized in that the thickness of the abutting portion is configured to satisfy a conditional expression of Dd / L1≧L2 / L3 / 2, where the thickness of the abutting portion is a thickness Di on an inner circumferential side and a thickness Do on an outer circumferential side, the axial difference between thickness Di and thickness Do is a thickness Dd, the radial distance between thickness Di and thickness Do is a length L1, the amount of bending from an axial plane perpendicular to an axial end face of the abutting portion when thickness Di = thickness Do is a length L2, and the axial length of the plurality of insulating cores is a length L3. (Supplementary Note 13) A rotating electric machine comprising: the armature according to any one of Supplementary Note 1 to Supplementary Note 12; and a field element rotatably and coaxially disposed on the inner circumferential side of the armature via an air gap. (Appendix 14) A method for manufacturing an armature according to any one of Appendices 1 to 12, in which the split cores and the insulating member are integrally molded, comprising: arranging the split cores divided into a plurality of pieces in a molding die corresponding to the axial length; injecting thermoplastic resin that will become the insulating member into the molding die from one of the axial end faces of the split cores in the axial direction by raising the temperature to maintain fluidity; next, dividing the resin into left and right circumferential sides of the split cores and causing it to flow through the side faces of the split cores to the other axial end face, filling the split cores so that the resin reaches the abutting portions of the split cores and joins together; thereafter, hardening the resin as the molding die cools; and removing the split cores from the molding die to integrally mold the split cores and the insulating member.

[0049] 10: Rotating electric machine, 20: Field element, 30: Armature, 31: Magnetic pole teeth, 31a: First teeth core, 31b, 78: Coil, 31a1, 51a, 61a, 71a, 81a, 91a, 921a: First insulating core, 31a2, 51b, 61b, 71b, 81b, 91b, 921b: Second insulating core, 321, 52a: First divided core, 322, 52b: Second divided core, 331: First insulating member, 332: Second insulating member, 34, 64, 94: Yoke portion, 35, 65: Teeth portion, 35a, 35aa, 35ab: Shaft end surface, 35b: Side surface, 37, 67, 67a, 67b: Protruding portion, 39, 59, 59a, 59b, 69, 69a, 69b, 79a, 79b, 79c1, 79c2, 89a, 89b, 99a, 99b, 939: abutment portion; 54, 54a, 54b, 771a, 771b, 771c1, 771c2: protrusion portion; 55, 55a, 55b, 772a, 772b, 772c1, 772c2: hole portion; 71c: third insulating core; 941: notch portion.

Claims

1. An armature in which a plurality of magnetic pole teeth are arranged in an annular shape around a central axis, Each of the plurality of magnetic pole teeth includes an insulating core divided into a plurality of pieces in the axial direction, and a coil wound integrally around the insulating cores, Each of the insulating cores includes a divided core having a yoke portion extending outward in a circumferential direction and a tooth portion protruding from the yoke portion toward an inner circumferential direction, and an insulating member covering axial end surfaces of the yoke portion and the tooth portion and side surfaces of the tooth portion in the axial direction, the insulating cores are in contact with each other via a portion of the insulating member, and the coils are wound around the respective teeth via another portion of the insulating member, a portion of the insulating material is coated on the axial end surfaces of the teeth and on a radial portion of the axial end surfaces of the yoke, thereby forming a contact portion of the insulating core, and the thickness of the insulating material coated on the side surfaces of the teeth is less than or equal to the thickness of the contact portion of the insulating core.

2. 2. The armature according to claim 1, wherein the plurality of split cores are formed in the same shape using electromagnetic steel sheets laminated in the axial direction.

3. An armature as described in Claim 1, characterized in that the thickness of each of the abutment portions of the multiple insulating cores is thinner than the thickness of the insulating material coated on the axial end surfaces of the insulating cores located at both ends of the magnetic pole teeth, on which the coils are wound.

4. An armature as described in Claim 1, characterized in that at the abutment portion of the insulating core, the insulating material coated on the axial end surface of the yoke portion is arranged so that the radial outer side of the insulating material is more inward than the radial outer side of the yoke portion, and is connected to the insulating material coated on the axial end surface of the teeth portion.

5. An armature as described in Claim 4, characterized in that at the abutment portion of the insulating core, the insulating material coated on the axial end surface of the yoke portion is coated from one end to the other along the circumferential direction of the yoke portion, and its circumferential width is formed to be the same as the circumferential width of the yoke portion.

6. An armature as described in Claim 1, characterized in that at least one of the insulating cores located at both ends of the magnetic pole teeth has an injection port mark for resin that becomes the insulating member in the radial direction of the axial end face different from the abutment portion of the insulating core.

7. 2. The armature according to claim 1, wherein the insulating cores are provided with projections and holes at their respective contact portions, which are engaged with each other.

8. 8. The armature according to claim 7, wherein the protrusion and the hole are provided at positions symmetrical with respect to the center of the insulating core in the circumferential direction.

9. 9. The armature according to claim 8, wherein the armature is configured to satisfy the conditional expressions φt≦φa and Ht≦Ha≦D, where the projection has a diameter φt and a height Ht, the hole has a diameter φa and a depth Ha, and the abutment portion has a thickness D.

10. 2. The armature according to claim 1, wherein each of the plurality of split cores has a protrusion formed at an inner end of the tooth portion, the protrusion protruding from one of both circumferential sides.

11. 11. The armature according to claim 10, wherein the split core arranged so that the protrusion is located on one side in the circumferential direction and the split core arranged so that the protrusion is located on the other side in the circumferential direction are brought into contact with each other and the coil is wound around them, thereby forming a two-stage skew.

12. 2. The armature according to claim 1, wherein each of the plurality of magnetic pole teeth includes a first and a second insulating core and one or more reference third insulating cores between the first and second insulating cores, and the first to third insulating cores are provided with split cores of the same axial length.

13. An armature in which a plurality of magnetic pole teeth are arranged in an annular shape around a central axis, Each of the plurality of magnetic pole teeth includes an insulating core divided into a plurality of pieces in the axial direction, and a coil wound integrally around the insulating cores, Each of the insulating cores includes a divided core having a yoke portion extending outward in a circumferential direction and a tooth portion protruding inward in a radial direction from the yoke portion, and an insulating member covering an axial end surface and a side surface of the tooth portion in an axial direction, the insulating cores are in contact with each other via a portion of the insulating member, and the coils are wound around the respective teeth via another portion of the insulating member, The armature is characterized in that the thickness of each of the insulating cores at the abutment portion is tapered so that the thickness is thicker on the radial inner side than on the radial outer side at the axial end face.

14. 14. The armature according to claim 13, wherein the thickness of the abutting portion is defined as thickness Di on the inner peripheral side and thickness Do on the outer peripheral side, the axial difference between thickness Di and thickness Do is thickness Dd, the radial distance between thickness Di and thickness Do is length L1, the amount of bending of the abutting portion from a plane perpendicular to the axial end face in the case where thickness Di = thickness Do is length L2, and the axial length of the plurality of insulating cores is length L3, the thickness Dd satisfies a conditional expression Dd / L1≧L2 / L3 / 2.

15. 15. The armature according to claim 1, wherein the insulating cores are formed such that the thickness of the abutting portion of each of the insulating cores is tapered so that one side in the circumferential direction is thicker than the other side on an axial end surface in the axial direction.

16. 15. The armature according to claim 1, wherein each of the insulating cores has a notch formed at a circumferential center position on a radially outer periphery of the yoke portion.

17. 17. The armature according to claim 16, wherein the insulating member covering the axial end surface of the yoke portion is arranged such that a radially outer circumferential side of the insulating member is positioned radially inner than a bottom of the notch portion.

18. 17. The armature according to claim 16, wherein the insulating cores are in contact with each other with the notches aligned in the axial direction.

19. 15. A rotating electric machine comprising: the armature according to claim 1; and a field element rotatably and coaxially arranged on an inner circumferential side of the armature with a gap therebetween.

20. 15. The armature according to claim 1, wherein the split cores and the insulating member are integrally molded by a method of manufacturing the armature, The split cores divided into a plurality of pieces are placed in a molding die corresponding to the axial length, and a thermoplastic resin serving as the insulating member is injected into the molding die from one of the axial end faces of the split cores in the axial direction while the resin is heated and kept fluid; Next, the resin is divided into left and right circumferential portions of the split core, and is made to flow through the side surface of the split core to the other of the axial end surface, and the resin is filled so that it reaches the abutting portion of the split core and joins with the abutting portion, Thereafter, the resin is hardened as the molding die cools, and the split cores are removed from the molding die, thereby integrally molding the split cores and the insulating member.