Motor of refrigeration cycle device and refrigeration cycle device including same

Abstract

This motor comprises: a rotor; a stator intermediate assembly having a coil and an insulator that holds the coil; a wiring board (425) that allows electricity to flow through the coil; a terminal (460) that connects the coil and the wiring board (425); and a resin that fills the periphery of the wiring board (425). A through-hole (425b) is formed in the wiring board (425). The terminal (460) has a fixing part (465) that is fixed to the wiring board (425) via the through-hole (425b). A spacer (480) is provided between a terminal box (423) of the insulator and the wiring board (425) separately from the terminal (460).

Description

Refrigeration cycle device motor and refrigeration cycle device equipped with the same

[0001] The present invention relates to a motor for a refrigeration cycle device and a refrigeration cycle device including the motor.

[0002] Patent Document 1 (JP Patent Publication No. 10-174338A) discloses a motor in which a coil and a wiring board are connected by terminals, and the insulating frame that holds the coil and the wiring board are filled with resin. Terminals are inserted into holes in the wiring board and soldered.

[0003] However, when manufacturing the motor described above, depending on the method of connecting the terminals to the wiring board and the method of resin molding, problems such as poor connection between the wiring board and the terminals due to force acting on the wiring board during resin molding, or restrictions on the resin pressure during resin molding, may be anticipated.

[0004] A motor according to a first aspect is a motor for use in a refrigeration cycle device, and includes a rotor, a stator intermediate assembly, a wiring board, terminals, and resin. The stator intermediate assembly has a coil and a coil holding portion that holds the coil. The wiring board passes electricity through the coil. The terminals connect the coil and the wiring board. The resin fills at least the periphery of the wiring board. A through hole is formed in the wiring board. The terminals have fixing portions that are fixed to the wiring board via the through hole. A spacer is provided between the coil holding portion and the wiring board, separate from the terminals.

[0005] In this motor, a spacer separate from the terminals is provided between the coil holding portion and the wiring board, which prevents changes in the relative position between the wiring board and the terminal fixing portion when the resin is molded around the wiring board, or changes in the relative posture between the wiring board and the terminal fixing portion when the resin is molded around the wiring board, thereby preventing poor connections between the wiring board and the terminals of the motor and reducing restrictions on resin molding during motor manufacturing.

[0006] A motor according to a second aspect is the motor for the refrigeration cycle device according to the first aspect, in which the resin is molded around the wiring board by a molding method in which a resin that is liquid or gel-like during injection molding is poured around the wiring board and hardened. The spacer suppresses changes in the relative position or orientation between the fixing portion and the through hole during molding of the resin.

[0007] A motor according to a third aspect is the motor for the refrigeration cycle device according to the first or second aspect, wherein the resin fills at least the space between the coil holding portion and the wiring board.

[0008] In this motor, the space between the coil holding portion and the wiring board is filled with resin, so a spacer is not necessary in the finished motor. However, to prevent the above-mentioned possible problems, a spacer is provided between the coil holding portion and the wiring board.

[0009] A motor according to a fourth aspect is the motor of the refrigeration cycle device according to any one of the first to third aspects, wherein the spacer is a member separate from the stator intermediate assembly.

[0010] A motor according to a fifth aspect is the motor for the refrigeration cycle device according to any one of the first to third aspects, wherein the spacer is part of the stator intermediate assembly and extends from the coil holding portion toward the wiring board.

[0011] A motor according to a sixth aspect is the motor for the refrigeration cycle device according to any one of the first to fifth aspects, wherein the fixing portion is press-fitted into the through-hole.

[0012] In this motor, the fixed portion is fixed to the wiring board by press-fitting, so if a large force is applied to the wiring board during resin molding, there is a risk that the fixed state created by press-fitting may be lost. However, in this motor, a spacer is provided between the coil holding portion and the wiring board, which prevents the fixed state from being lost.

[0013] A motor according to a seventh aspect is a motor of a refrigeration cycle device according to any one of the first to sixth aspects, wherein the fixed portion is fixed to a wiring board without soldering and is electrically connected to the wiring board.

[0014] In this motor, the terminal fixing portion is fixed to the wiring board without soldering, so if a large force is applied to the wiring board during resin molding, the electrical connection of the terminal to the wiring board may be damaged, which could result in a connection failure.However, in this motor, a spacer is provided between the coil holding portion and the wiring board, which prevents connection failure.

[0015] A motor according to an eighth aspect is the motor for the refrigeration cycle device according to any one of the first to seventh aspects, wherein the terminals include first to N-th terminals (N is an integer of 2 or more) aligned along the direction of rotation of the motor, and the spacers include first to M-th spacers (M is an integer of 2 or more) aligned along the direction of rotation of the motor.

[0016] In this motor, multiple terminals are arranged along the direction of motor rotation, and multiple spacers are arranged along the direction of motor rotation, so that changes in position or posture of each of the fixed portions of the multiple terminals relative to the wiring board during resin molding are suppressed.

[0017] A motor according to a ninth aspect is the motor for the refrigeration cycle device according to any one of the first to seventh aspects, wherein the terminals include first to N-th terminals (N is an integer of 2 or more) arranged along the direction of rotation of the motor, and the spacers include at least a first spacer, which is disposed near the first to P-th terminals (P is an integer of 2 or more and N or less).

[0018] In this motor, multiple terminals are arranged in the direction of motor rotation, and first spacers are placed near the multiple terminals, so that a single first spacer can suppress changes in the position or posture of the fixing portions of the multiple terminals relative to the wiring board during resin molding. This makes it possible to stabilize the fixing state of the fixing portions of many terminals to the wiring board with a small number of spacers.

[0019] A motor according to a tenth aspect is a motor for a refrigeration cycle device according to any one of the first to ninth aspects, wherein the resin is molded around the wiring board by a molding method in which a liquid resin or a resin that becomes gel-like during injection molding is poured around the wiring board using a mold and then solidified. When molding the resin around the wiring board, the second surface is pressed by pins provided in the mold, and pin marks remain in the resin after molding. The second surface is one of both surfaces of the wiring board opposite the first surface that contacts the spacer.

[0020] In this motor, when resin is molded around the wiring board, a spacer contacts the first surface of the wiring board and a pin of a mold contacts the second surface of the wiring board, which prevents the wiring board from deforming even when the resin pressure acts on the wiring board during resin molding.

[0021] A motor according to an eleventh aspect is the motor for the refrigeration cycle device according to any one of the first to ninth aspects, wherein the resin is molded around the wiring board by a molding method using a mold in which a resin that is liquid or gelled during injection molding is poured around the wiring board and solidified. When molding the resin around the wiring board, the liquid or gelled resin is injected into the internal space of the mold at a pressure of 1.0 MPa or more, and the pressure of the liquid or gelled resin is applied to the wiring board.

[0022] In this motor, when resin is molded, liquid or gel resin is injected into the internal space of the mold at a pressure of 1.0 MPa or more, which applies a large force to the wiring board, potentially causing a change in the relative position between the wiring board and the terminal fixing portion, or a change in the relative posture between the wiring board and the terminal fixing portion when the resin is molded around the wiring board. However, in this motor, a spacer separate from the terminals is present between the coil holding portion and the wiring board, which prevents the above-mentioned change in relative position or posture from occurring.

[0023] A refrigeration cycle apparatus according to a twelfth aspect includes the motor according to any one of the first to eleventh aspects, and a fan rotated by the motor.

[0024] 1. A diagram showing a refrigerant circuit and a fan of an air conditioner that performs a refrigeration cycle. 2. An external view of an air conditioning indoor unit. 3. A longitudinal cross-sectional view of the air conditioning indoor unit. 4. A front view of a support member and the like of the air conditioning indoor unit. 5. An external view of a motor. 6. A cross-sectional view showing a motor and a support member that supports the motor. 7. A perspective view of a stator intermediate assembly and a wiring board of a motor before resin molding. 8. A view from the perspective view of FIG. 7 with the wiring board, spacer, and harness connection portion removed. 9. A side view of the stator intermediate assembly of a motor, with the stator intermediate assembly and wiring board shown in FIG. 7 viewed from the side. 10. A perspective view of a terminal. 11. A perspective view of a terminal, as viewed from a direction different from FIG. 10. 12. A perspective view of a wiring board, spacer, and harness connection portion. 13. A perspective view of a wiring board. 14. A perspective view of a spacer. 15. A perspective view of a wiring board, spacer, and harness connection portion, as viewed from a direction different from FIG. 12. 16. A cross-sectional view showing a terminal press-fitted into a wiring board, as viewed from a direction different from FIG. 17, which is a cross-sectional view showing the terminal press-fitted into a wiring board. 18B is a cross-sectional view of the wiring board and the terminals taken along the same cross section as in FIG. 18A, showing changes in position and attitude of the wiring board relative to the terminals when it is assumed that there is no spacer. FIG. 18C is an external view of the motor as seen from a direction different from that of FIG. 5. FIG. 18D is a top view of the spacer of Modification A. FIG. 18E is a cross-sectional view showing the protrusions of the terminal box as the spacer of Modification B.

[0025] The air conditioner and the motor that is a component of the air conditioner will be described below with reference to the drawings.

[0026] (1) Configuration of the Air Conditioning Apparatus FIG. 1 is a schematic diagram of an air conditioning apparatus 100 (refrigeration cycle apparatus). The air conditioning apparatus 100 is an apparatus that cools and heats the interior of a building or the like using a vapor compression refrigeration cycle. The air conditioning apparatus 100 includes an indoor unit 1 and an outdoor unit 2. The indoor unit 1 and the outdoor unit 2 are connected via a liquid refrigerant connection pipe 105 and a gas refrigerant connection pipe 106. The refrigerant circuit that constitutes the vapor compression refrigeration cycle of the air conditioning apparatus 100 is formed by connecting the indoor unit 1 and the outdoor unit 2 via the refrigerant connection pipes 105, 106. The refrigerant circuit is filled with refrigerant.

[0027] The indoor unit 1 is installed indoors and forms part of the refrigerant circuit. The indoor unit 1 mainly includes an indoor heat exchanger 12 and an indoor fan 14.

[0028] The indoor heat exchanger 12 functions as a refrigerant evaporator to cool the indoor air during cooling operation, and functions as a refrigerant radiator to heat the indoor air during heating operation.

[0029] The indoor fan 14 draws indoor air into the indoor unit 1, exchanges heat with the refrigerant in the indoor heat exchanger 12, and then supplies the air to the room as supply air. The frequency (number of rotations) of the motor 40 of the indoor fan 14 can be changed by an inverter.

[0030] The outdoor unit 2 is installed outdoors and constitutes part of the refrigerant circuit. The outdoor unit 2 has a compressor 121, a four-way switching valve 122, an outdoor heat exchanger 123, an expansion valve 124, a liquid-side shut-off valve 126, a gas-side shut-off valve 127, and an accumulator 128. The outdoor unit 2 also has an outdoor fan 136. Each component of the outdoor unit 2 is a part of the outdoor unit of a commonly used room air conditioner, so detailed description will be omitted.

[0031] (2) Operation of the Air Conditioning Apparatus The air conditioning apparatus 100 performs cooling operation and heating operation.

[0032] In cooling operation, the four-way selector valve 122 is switched to the cooling cycle state (the state shown by the solid line in FIG. 1), and high-pressure gas refrigerant exchanges heat with outdoor air in the outdoor heat exchanger 123, releasing heat and becoming high-pressure liquid refrigerant. In addition, in cooling operation, the refrigerant decompressed by the expansion valve 124 exchanges heat with indoor air in the indoor heat exchanger 12 and evaporates. This cools the indoor air, which is then supplied to the room to cool it.

[0033] In heating operation, the four-way selector valve 122 is switched to the heating cycle state (the state indicated by the dashed line in FIG. 1 ), and the high-pressure gas refrigerant exchanges heat with the indoor air in the indoor heat exchanger 12, releasing heat and becoming a high-pressure liquid refrigerant. This heats the indoor air, which is then supplied to the room, heating the room. The liquid refrigerant leaving the indoor heat exchanger 12 is decompressed by the expansion valve 124, exchanges heat with the outdoor air in the outdoor heat exchanger 123, evaporates, and is drawn into the compressor 121.

[0034] (3) Detailed Configuration of the Indoor Unit The indoor unit 1 is a wall-mounted unit that is used by hanging its rear face on a wall inside a room, as shown in Figures 2 to 4. The directions when the indoor unit 1 is hung on a wall and viewed from the front side toward the wall are indicated by front, rear, up, down, right, and left arrows in Figures 2 to 4.

[0035] The indoor unit 1 includes a support body 11, a front panel 11a, a main body cover 11b, an indoor heat exchanger 12, an indoor fan 14, and a flap 15. The indoor heat exchanger 12 and the indoor fan 14 are supported by the support body 11 and covered by the front panel 11a and the main body cover 11b.

[0036] The main body cover 11b has an upper surface formed with an inlet B2 and a lower surface formed with an outlet B1. The flap 15 is disposed at the outlet B1.

[0037] A refrigerant flows inside the many heat transfer tubes of the indoor heat exchanger 12 and exchanges heat with the air flowing between the heat transfer tubes. Air is drawn in through the air inlet B2 by the rotation of the indoor fan 14. The air that flows from the air inlet B2 to the indoor heat exchanger 12 passes through the indoor fan 14 and is blown out into the indoor space from the air outlet B1.

[0038] The indoor fan 14 is a cylindrical crossflow fan that extends elongatedly in the left-right direction. A motor 40 that rotates the indoor fan 14 is disposed on the right side of the indoor fan 14. The indoor fan 14 is disposed in a fan accommodating space 20A of the support body 11 shown in Fig. 4. The motor 40 is disposed in a motor accommodating space 20B of the support body 11 shown in Fig. 4. The support body 11 is a group of resin members that includes a rear surface portion 21 that also serves as a drain pan, a scroll portion 22 located below the indoor fan 14, a first motor support portion 23 and a second motor support member 24 that support the motor 40, etc.

[0039] (4) Motor Configuration (4-1) Overall Motor Configuration As shown in FIGS. 5 and 6 , the motor 40 includes a stator 45 and a rotor 46. The stator 45 includes a stator intermediate assembly 42, a power supply harness, a harness lead-out member 429, a wiring board 425, terminals 460, and resin 430. The components of the stator 45 are integrated together by the resin 430. The stator intermediate assembly 42 includes a coil 421. The rotor 46 includes a magnet 46b positioned radially outward from the coil 421. The magnet 46b is disposed on the cylindrical outer periphery of the rotor 46, and a motor rotating shaft 49 is fixed to the inner periphery of the rotor 46. The coil 421 of the stator 45 is positioned inside the cylindrical outer periphery of the rotor 46. When a current flows through the coil 421 of the stator 45, a magnetic field is generated, causing the rotor 46, including the magnet 46b, to rotate. This causes the motor rotary shaft 49 to rotate, which in turn rotates the indoor fan 14 fixed to the motor rotary shaft 49. Bearings 48 are disposed between the inner periphery of the stator 45 and the motor rotary shaft 49. The motor rotary shaft 49 and the rotor 46 are supported by the stator 45 via these bearings 48.

[0040] An outer periphery 430a of the resin 430, which is integrated with the stator intermediate assembly 42, is fixed to the first motor support portion 23 and the second motor support member 24 of the support body 11 via a sealing member 50. The motor 40 and the sealing member 50 are pressed against the indoor fan 14 by a pressing member 60. The pressing member 60 is fixed to the support body 11 with screws while pressing the motor 40 and the sealing member 50 in the direction of the rotation axis. In this way, the motor 40 is fixed to the support body 11.

[0041] (4-2) Motor Stator Intermediate Assembly and Peripheral Configuration As shown in FIGS. 5 to 9 , the stator intermediate assembly 42 includes the coil 421 and an insulator 422 that functions as a coil holder for holding the coil 421. A wiring board 425 that supplies electricity to the coil 421 is disposed near the insulator 422. The coil 421 and the wiring board 425 are electrically connected by terminals 460. A harness lead-out member 429, to which a harness that supplies three-phase power is connected, is fixed to the wiring board 425. The harness lead-out member 429 is a member for leading the harness outside the resin 430 of the resin-molded stator 45. Resin 430 is provided around the coil 421, insulator 422, wiring board 425, and terminals 460. The resin 430 fills the periphery of the wiring board 425. The resin 430 also fills the space between the insulator 422 and the wiring board 425. The insulator 422 and the wiring board 425 are embedded in the resin 430 and integrated together, and the integrated insulator 422 , coil 421 , wiring board 425 , resin 430 , etc. form the stator 45 of the motor 40 .

[0042] As shown in FIG. 13, the harness lead-out member 429 has a first portion 429a connected to the wiring board 425, a second portion 429b to which the harness is connected, and the like.

[0043] As shown in FIG. 14, the wiring board 425 has a central circular hole 425a and a plurality of (here, 12) through holes 425b formed around the central circular hole 425a.

[0044] The insulator 422 is an insulating member that holds the twelve coils 421. As shown in FIGS. 8, 17, and 18A, a terminal box 423 is provided on the inner periphery of the insulator 422. The terminal box 423 extends from the main body 422a of the insulator 422 in the direction of the rotation axis. The coils 421 are wound around the main body 422a (coil holding portion) of the insulator 422. The terminal box 423 has first to twelfth terminal boxes that are provided for each of the twelve coils 421. Here, the terminal box 423 is an assembly of the first to twelfth terminal boxes, but each individual slot may also be referred to as a terminal box 423.

[0045] One terminal 460 is provided for each of the 12 coils 421. Specifically, as shown in Figures 7 and 8, 12 terminals, numbered 1st to 12th, are provided as terminals 460 along the direction of rotation of the motor. In other words, the terminals 460 include 1st to 12th terminals that are aligned along the direction of rotation of the motor. However, in this embodiment, each individual terminal may also be referred to as a terminal 460.

[0046] As shown in FIGS. 10 and 11 , each terminal 460 has a central portion 461, a folded portion 462, a fixed portion 465 electrically connected to the wiring board 425, and a tip portion 466. A notch 461a is formed in the lower portion of the central portion 461, and a notch 462a is formed in the lower portion of the folded portion 462. These notches 461a and 462a are connected to form a U-shaped slot. As shown in FIGS. 8 , 17 , and 18A , the central portion 461 and the folded portion 462 of each terminal 460 are pressed into the corresponding terminal box 423. At this time, the electric wire at the end of the coil 421 is passed through the slot formed by the notches 461a and 462a, electrically connecting the end of the coil 421 to the terminal 460. In the state shown in FIG. 8, the terminal 460 is pushed into the terminal box 423 and the coil 421 and the terminal 460 are connected.

[0047] 7, 9, 17, and 18A show a state in which the twelve terminals 460 shown in FIG. 8 are covered with the wiring board 425, the tip portions 466 of the terminals 460 pass through the through holes 425b of the wiring board 425, and the fixing portions 465 of the terminals 460 are press-fitted into the through holes 425b. In this state, the fixing portions 465 of the terminals 460 are fixed to the wiring board 425 via the through holes 425b, and a spacer 480 is positioned between the terminal box 423 of the insulator 422 and the wiring board 425 in the rotational axis direction. In other words, the spacer 480 is provided between the insulator 422 and the wiring board 425, separately from the terminals 460. The fixing portions 465 of the terminals 460 preferably have spring properties, and although not shown in FIGS. 10 and 11, a fixing portion 465 with a multi-spring structure is employed here.

[0048] As shown in FIG. 15 , the spacer 480 has an annular portion 481 and three claw portions 482. As shown in FIGS. 12 and 16 , the claw portions 482 of the spacer 480 hook onto the inner periphery of the wiring board 425, thereby supporting the spacer 480 on the wiring board 425. The annular portion 481 of the spacer 480 contacts the wiring board 425. As shown in FIGS. 7 , 9 , 17 , and 18A , when the fixing portion 465 of the terminal 460 is press-fit into the through-hole 425 b of the wiring board 425, a lower surface 481 a of the annular portion 481 of the spacer 480 (the surface opposite to the surface contacting the wiring board 425) contacts the upper surface 423 a of the terminal box 423 of the insulator 422. As shown in FIG. 18A , the spacer 480 is disposed near the fixing portion 465 of the terminal 460. Specifically, the spacer 480 is located inside the fixed portion 465 in the motor radial direction, and one end of the spacer 480 contacts the upper surface 423a of the terminal box 423 that houses part of the terminal 460. As a result, the spacer 480 maintains the space between the wiring board 425 and the upper surface 423a of the terminal box 423. As a result, the spacer 480 also maintains the space between the wiring board 425 and the main body 422a of the insulator 422 around which the coil 421 is wound.

[0049] The fixed portion 465 of the terminal 460 is fixed to the wiring board 425 without soldering and is electrically connected to the wiring board 425 .

[0050] (4-3) Resin Molding Around the Stator Intermediate Assembly, Wiring Board, and Terminals of the Motor The stator assembly (as shown in FIGS. 7 and 9 ) in which the fixing portions 465 of the twelve terminals 460 are press-fitted and connected to the through holes 425b of the wiring board 425 is surrounded by resin 430. In other words, during the manufacturing process of the motor 40, the peripheries of the stator intermediate assembly 42, the wiring board 425, and the terminals 460 are resin-molded.

[0051] In motor 40, electrical connection is achieved by press-fitting fixing portions 465 of terminals 460 into through holes 425b of wiring board 425, but the dimensions of the electrical connection range in the press-fit / insertion direction (see FIGS. 10 and 11) are limited. For this reason, positioning of wiring board 425 is important when assembling motor 40, but there are as many as 12 connection points, and the press-fit force is likely to vary from one point to another due to component dimensional tolerances and the assembly work involved.

[0052] Furthermore, when the stator assembly shown in FIGS. 7 and 9 is molded with electrically insulating resin 430, there is a risk of misalignment of the electrical connection between the wiring board 425 and the fixing portion 465 of the terminal 460. If the fixing portion 465 of the terminal 460 is displaced from its proper connection position in the through-hole 425b of the wiring board 425, poor electrical connection will occur. The motor 40 uses a thermosetting unsaturated polyester resin BMC (Bulk Molding Compound) as the resin 430, and the BMC molding pressure (injection pressure in the molding machine) is 1 MPa to 10 MPa. The motor 40 is manufactured using a molding method in which liquid or gel-like resin 430 is injected around the stator assembly shown in FIGS. 7 and 9 using a mold and then hardened by thermosetting. Therefore, during the manufacture of the motor 40, a large pressure is applied to the wiring board 425 by the liquid or gel-like resin 430. If the spacer 480 were not present, there would be a high possibility that the electrical connection position between the wiring substrate 425 and the fixing portion 465 of the terminal 460 would be misaligned. Figure 18B shows an example of the change in position and posture of the wiring substrate 425 relative to the terminal 460 during BMC molding, assuming that the spacer 480 is not present. If the spacer 480 were not present, the position and posture of the wiring substrate 425 would be misaligned relative to the terminal 460, and the position and posture of the wiring substrate 425 would change to, for example, the state shown by the dashed line in Figure 18B. If the position and posture of the wiring substrate 425 were to be as shown by the dashed line in Figure 18B, poor electrical connection would occur between the wiring substrate 425 and the terminal 460.

[0053] To prevent poor electrical connection between the wiring board 425 and the terminals 460 during resin molding, the motor 40 according to this embodiment is provided with a spacer 480, which is unnecessary for the manufactured motor 40. The spacer 480 is disposed between the wiring board 425 and the terminal box 423 of the insulator 422, and supports the wiring board 425 from the stator intermediate assembly 42 when pressure is applied from the liquid or gel-like resin 430 during resin molding to push the wiring board 425 toward the stator intermediate assembly 42. This prevents changes in the relative position and orientation between the fixing portions 465 of the terminals 460 and the through holes 425b of the wiring board 425 during resin molding (see FIG. 18A ).

[0054] The mold used for resin molding has pins P (see FIG. 17 ) that contact the second surface 425 d of the wiring board 425 during resin molding. The second surface 425 d is the surface of the wiring board 425 opposite the surface facing the stator intermediate assembly 42 (see FIGS. 9 , 17 , and 18A ). The surface of the wiring board 425 opposite the second surface 425 d is the first surface 425 c. During resin molding, the second surface 425 d of the wiring board 425 is pressed by pins P provided on the mold, and pin marks 430 b remain in the resin 430 after molding of the resin 430 (see FIG. 19 ). The other first surface 425 c of the wiring board 425 is supported by the spacer 480 as described above during resin molding (see FIG. 18A and other figures).

[0055] After resin molding, the outer periphery 430a of the resin 430 is fixed to the first motor support portion 23 and the second motor support portion 24 of the support body 11 via the sealing member 50. As a result, the stator intermediate assembly 42 of the stator 45 and the wiring board 425 are supported by the support body 11, as shown in FIG.

[0056] (5) Features (5-1) In the stator 45 of the motor 40, a spacer 480 separate from the terminals 460 is present between the terminal box 423 of the insulator 422 and the wiring board 425. This suppresses a change in the relative position between the wiring board 425 and the fixing portions 465 of the terminals 460 when the resin 430 is molded around the wiring board 425, and a change in the relative posture between the wiring board 425 and the fixing portions 465 of the terminals 460 when the resin 460 is molded around the wiring board 425. This suppresses poor connection between the wiring board 425 and the terminals 460.

[0057] Furthermore, without the spacer 480, the injection pressure in the molding machine during resin molding would have to be set low to prevent poor connection between the wiring board 425 and the terminals 460; however, by providing the spacer 480, it is now possible to perform resin molding at a high injection pressure of over 1 MPa.

[0058] In the stator 45 of the motor 40, the space between the insulator 422 and the wiring board 425 is filled with the resin 430, so the spacer 480 is not necessary in the completed motor 40. However, in order to prevent problems such as poor connection between the wiring board 425 and the terminals 460, the stator 45 of the motor 40 of this embodiment has the spacer 480 provided between the insulator 422 and the wiring board 425.

[0059] (5-2) In the manufacturing process of the stator 45 of the motor 40, a stator assembly is created in which the fixing portions 465 of the terminals 460 are press-fitted and connected to the through holes 425b of the wiring board 425, and the resin 460 is molded around the stator assembly. Because the fixing portions 465 of the terminals 460 are fixed to the wiring board 425 by press-fitting, there is a risk that the fixed state created by the press-fitting will be lost if a large force is applied to the wiring board 425 during molding. However, because the stator 45 of the motor 40 is provided with the spacer 480, the fixed state between the terminals 460 and the wiring board 425 is prevented from being lost.

[0060] (5-3) In the stator 45 of the motor 40, the fixed portions 465 of the terminals 460 are press-fitted into the through holes 425b of the wiring board 425, and are not electrically connected via solder as in the conventional case. Because the fixed portions 465 of the terminals 460 are fixed to the wiring board 425 without soldering in this manner, if a large force is applied to the wiring board 425 during resin molding, the electrical connection of the terminals 460 to the wiring board 425 may be impaired, resulting in a connection failure.

[0061] However, since the motor 40 of this embodiment is provided with the spacer 480, the occurrence of poor connection is suppressed as described above.

[0062] (5-4) In the stator 45 of the motor 40, twelve terminals 460 are arranged in the direction of motor rotation, but one annular spacer 480 is provided that extends in the direction of motor rotation. This means that only one spacer 480 is required, and manufacturing is also easy.

[0063] Furthermore, since each portion of the annular portion 481 of one spacer 480 is located near the fixing portion 465 of each of the twelve terminals 460, the connection state of each of the twelve fixing portions 465 to the wiring board 425 is maintained during and after the resin molding.

[0064] (5-5) In the manufacturing process of motor 40, during the resin molding process, spacer 480 contacts first surface 425c of wiring board 425, and pins of a mold contact second surface 425d of wiring board 425. This prevents wiring board 425 from being deformed, regardless of the direction from which pressure of liquid or gel resin 430 acts on wiring board 425 during resin molding.

[0065] In the stator 45 of the motor 40, as shown in FIG. 19, traces 430b of the pins P remain in the resin 430 after the resin 430 is molded.

[0066] (5-6) In the manufacturing process of the stator 45 of the motor 40, the liquid or gel resin 430 is injected into the internal space of the mold at a pressure of 1.0 MPa or more during the resin molding process. This applies a large force to the wiring board 425, which could cause a change in the relative position between the wiring board 425 and the fixing portion 465 of the terminal 460, or a change in the relative posture between the wiring board 425 and the fixing portion 465 of the terminal 460 when the resin 460 is molded around the wiring board 425. However, in the stator 45 of the motor 40, a spacer 480 separate from the terminal 460 is present between the terminal box 423 of the insulator 422 and the wiring board 425, thereby suppressing the occurrence of the above-mentioned change in relative position or posture. This significantly reduces the probability of manufacturing a motor 40 with poor connections.

[0067] (6) Modifications (6-1) Modification A In the above embodiment, the spacer 480 shown in FIG. 15 is used. However, instead of this, a spacer 490 shown in FIG. 20 may be used. FIG. 20 is a plan view of the spacer 490, and the dimension in the depth direction is the same as the dimension in the height direction of the spacer 480 (the vertical direction in FIG. 15; the rotation axis direction in FIG. 18A). The spacer 490 has 12 slots 490a, the same number as the number of terminals 460. The tip portion 466 and the fixing portion 465 of each terminal 460 pass through the slot 490a of the spacer 490.

[0068] With this spacer 490, the periphery of the through-hole 425b of the wiring board 425 into which the fixing portion 465 of the terminal 460 is press-fitted is entirely supported by the spacer 490.

[0069] (6-2) Modification B While the above embodiment employs the spacer 480 shown in FIG. 15 , a spacer portion 424b (see FIG. 21 ) integrally molded with the insulator may be employed instead. The terminal box 424 shown in FIG. 21 is a slot formed in the insulator, a slot that accommodates a portion of the terminal 460, and has a spacer portion 424b that protrudes toward the wiring board 425 along the rotation axis direction. The spacer portion 424b is a cylindrical protrusion formed to surround the periphery of each terminal 460. As shown in FIG. 21 , a tip surface 424b1 of the spacer portion 424b contacts a first surface 425c of the wiring board 425.

[0070] (6-3) Modification C The spacer 480 in the above embodiment and the spacer 490 in Modification A are single annular members, but instead, a spacer divided into two, three, or even more may be used. For example, when a three-part spacer is used, each spacer is provided for four of the twelve terminals 460 and includes a portion located near each of the four terminals 460.

[0071] (6-4) Modification D In the above embodiment, terminal 460 employs fixing portion 465 with a multi-spring structure, and fixing portion 465 of terminal 460 is fixed to wiring board 425 without soldering. However, instead, the terminal may be electrically connected to the wiring board by soldering. In this case, too, changes in the relative position between the wiring board and the terminal when resin is molded around the wiring board, and changes in the relative posture between the wiring board and the terminal when resin is molded around the wiring board, are suppressed. This prevents the solder connecting the wiring board and the terminal from peeling or cracking, and suppresses connection failures in the motor.

[0072] (6-5) Variation E In the above-described variation B, the spacer portion 424b protrudes from the terminal box 424 of the insulator toward the wiring board 425, but instead, the spacer portion may protrude from the main body of the insulator toward the wiring board.

[0073] (6-6) Modification F Although the embodiments of the present disclosure have been described above, it will be understood that various changes in form and details can be made without departing from the spirit and scope of the present disclosure as defined in the claims.

[0074] 14 Indoor fan 40 Motor 42 Stator intermediate assembly 45 Stator 46 Rotor 100 Air conditioner (refrigeration cycle device) 421 Coil 422 Insulator (coil holding portion) 422a Insulator body (coil holding portion) 423 Terminal box 424 Terminal box of modified example B 424b Protrusion portion (spacer portion) of terminal box of modified example B 425 Wiring board 425b Through hole 430 Resin 460 Terminal 465 Terminal fixing portion 480 Spacer 490 Spacer of modified example A P Pin of mold

[0075] Japanese Patent Application Publication No. 10-174338

Claims

1. A motor (40) for use in a refrigeration cycle apparatus (100), comprising: a rotor (46); a stator intermediate assembly (42) having a coil (421) and a coil holding portion (422) for holding the coil; a wiring board (425) for passing electricity through the coil; a terminal (460) for connecting the coil and the wiring board; and a resin (430) for filling at least the periphery of the wiring board, wherein a through hole (425b) is formed in the wiring board, and the terminal has a fixing portion (465) fixed to the wiring board via the through hole, and a spacer (480) is provided between the coil holding portion and the wiring board in addition to the terminal.

2. A motor for a refrigeration cycle device as described in claim 1, wherein the resin is molded around the wiring board by a molding method in which a resin that is in a liquid state or a gel state during injection molding is poured around the wiring board and hardened, and the spacer suppresses changes in the relative position or relative attitude between the fixing portion and the through hole during molding of the resin.

3. The motor for a refrigeration cycle device according to claim 1 or 2, wherein the resin fills at least a space between the coil holding portion and the wiring board.

4. The motor for a refrigeration cycle apparatus according to any one of claims 1 to 3, wherein the spacer is a member separate from the stator intermediate assembly.

5. The motor for a refrigeration cycle apparatus according to any one of claims 1 to 3, wherein the spacer (424b) is a part of the stator intermediate assembly and extends from the coil holding portion toward the wiring board.

6. The motor for a refrigeration cycle apparatus according to any one of claims 1 to 5, wherein the fixing portion is press-fitted into the through hole.

7. The motor for a refrigeration cycle apparatus according to any one of claims 1 to 6, wherein the fixing portion is fixed to the wiring board without using solder and is electrically connected to the wiring board.

8. A motor for a refrigeration cycle device as described in any one of claims 1 to 7, wherein the terminals include first terminal to Nth terminal (N is an integer of 2 or more) aligned along the motor rotation direction, and the spacers include first spacer to Mth spacer (M is an integer of 2 or more) aligned along the motor rotation direction.

9. A motor for a refrigeration cycle device as described in any one of claims 1 to 7, wherein the terminals have a first terminal to an Nth terminal (N is an integer of 2 or more) arranged along the motor rotation direction, the spacer has at least a first spacer, and the first spacer is arranged in the vicinity of the first terminal to the Pth terminal (P is an integer of 2 or more and N or less).

10. A motor for a refrigeration cycle device as described in any one of claims 1 to 9, wherein the resin is molded around the wiring board by a molding method in which a mold is used to pour and harden a resin that is in a liquid state or that becomes a gel during injection molding around the wiring board, and when the resin is molded around the wiring board, a second surface (425d) of the wiring board opposite a first surface (425c) with which the spacer contacts is pressed by a pin (P) provided on the mold, and marks of the pin remain in the resin after the resin is molded.

11. A motor for a refrigeration cycle device as described in any one of claims 1 to 9, wherein the resin is molded around the wiring board by a molding method in which a mold is used to pour a liquid resin or a resin that becomes a gel during injection molding around the wiring board and allow it to harden, and when molding the resin around the wiring board, the liquid or gel resin is injected into the internal space of the mold at a pressure of 1.0 MPa or more, and the pressure of the liquid or gel resin is applied to the wiring board.

12. A refrigeration cycle device (100) comprising: a motor (40) according to any one of claims 1 to 11; and a fan (14) rotated by the motor.

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