Electric motor, blower, air conditioning device, and method for manufacturing electric motor

Abstract

This electric motor comprises a rotor, a stator that surrounds the rotor, a lead wire support component that supports the lead wire, and an outer shell member that covers the stator and the lead wire support component. The lead wire support component has a holding portion that is attached to the stator and holds the lead wire, and a lead-out portion that is provided so as to protrude from the outer shell member and draws out the lead wire to the outside of the outer shell member. The holding portion and the lead-out portion are arranged at positions separated from each other. The holding portion has a first engagement portion, and the lead-out portion has a second engagement portion, the first and second engagement portions having shapes that can engage with each other.

Description

Electric motor, blower, air conditioner, and method for manufacturing an electric motor

[0001] The present disclosure relates to an electric motor, a blower, an air conditioner, and a method for manufacturing an electric motor.

[0002] There is known an electric motor that includes a stator, a lead wire support component that supports lead wires, and an outer casing member such as a molded resin part that covers these components. The lead wire support component has an outlet portion for drawing the lead wires out of the electric motor (see, for example, Patent Document 1).

[0003] International Publication No. WO2014 / 148537 (see FIG. 7)

[0004] In conventional electric motors, the lead wire support member's lead portion protrudes from the outer casing, which can allow moisture to seep into the motor from around the lead portion, causing motor failure.

[0005] The present disclosure has been made to solve the above-mentioned problems, and aims to suppress the intrusion of moisture into the interior of an electric motor.

[0006] The electric motor of the present disclosure includes a rotor, a stator surrounding the rotor, a lead wire support component supporting lead wires, and an outer casing covering the stator and lead wire support component. The lead wire support component is attached to the stator and has a holding portion that holds the lead wires, and a lead portion that protrudes from the outer casing and leads the lead wires to the outside of the outer casing. The holding portion and the lead portion are arranged at positions spaced apart from each other. The holding portion has a first engaging portion, and the lead portion has a second engaging portion, and the first engaging portion and the second engaging portion have shapes that allow them to engage with each other.

[0007] According to the present disclosure, the holding portion and the lead portion of the lead wire support component are positioned apart from each other, so even if moisture penetrates around the lead portion, it is difficult for the moisture to reach the holding portion and the stator. This makes it possible to suppress moisture penetration into the interior of the electric motor. Furthermore, when manufacturing the electric motor, the holding portion and the lead portion can be handled as a single component due to the engagement between the first engaging portion and the second engaging portion, simplifying the manufacturing process.

[0008] FIG. 1 is a cross-sectional view showing an electric motor of embodiment 1. FIG. 2 is a cross-sectional view showing a molded stator of embodiment 1. FIG. 3 is a top view showing a stator of embodiment 1. FIG. 4 is a perspective view showing a lead wire supporting component of embodiment 1. FIG. 5 is a perspective view (A) showing a lead portion of embodiment 1, and a perspective view (B) showing a state in which the lead portion has been separated into two. FIG. 6 is a perspective view (A) showing an engaging portion between a holding portion and a lead portion of embodiment 1, and a perspective view (B) showing a state in which the holding portion and the lead portion have been separated. FIG. 7 is a plan view (A) and a side view (B) showing a state in which the holding portion and the lead portion of embodiment 1 are engaged, and a side view (C) showing a state in which the holding portion and the lead portion have been separated. FIG. 8 is a flowchart showing a method for manufacturing the electric motor of embodiment 1. FIG. 9 is a cross-sectional view showing a molding die used in the manufacturing process of the electric motor of embodiment 1. FIG. 10 is a cross-sectional view showing a molded stator of an electric motor of embodiment 2. 1A is a perspective view (A) showing an engagement portion between a holding portion and a lead portion of a lead wire support component of embodiment 2, and a perspective view (B) showing a state in which the holding portion and the lead portion are separated. FIG. 1B is a plan view (A) and a side view (B) showing a state in which the holding portion and the lead portion of embodiment 2 are engaged, and a side view (C) showing a state in which the holding portion and the lead portion are separated. FIG. 1C is a plan view (A) and a side view (B) showing a state in which the holding portion and the lead portion of a lead wire support component of embodiment 3 are engaged, and a side view (C) showing a state in which the holding portion and the lead portion are separated. FIG. 1D is a cross-sectional view showing a molding die used in a manufacturing process of an electric motor of embodiment 3. FIG. 1E is a cross-sectional view showing a molded stator of an electric motor of embodiment 4. FIG. 1F is a plan view (A) and a side view (B) showing a state in which the holding portion and the lead portion of a lead wire support component of embodiment 4 are engaged, and a side view (C) showing a state in which the holding portion and the lead portion are separated. FIG. 1F is a flowchart showing a manufacturing method of an electric motor of embodiment 4. Fig. 10 is a cross-sectional view showing a molded stator of an electric motor of embodiment 5. Fig. 11 is a plan view (A) and a side view (B) showing a state in which a holding portion and a lead portion of a lead wire supporting component of embodiment 5 are engaged, and a side view (C) showing a state in which the holding portion and the lead portion are separated. Fig. 11 is a flowchart showing a method for manufacturing an electric motor of embodiment 5. Fig. 12 is a diagram showing an air conditioning device to which the electric motor of each embodiment can be applied, and a diagram showing an outdoor unit of the air conditioning device.

[0009] Each embodiment will be described in detail below with reference to the drawings, but the present disclosure is not limited to these embodiments.

[0010] Embodiment 1. <Configuration of electric motor 1> Fig. 1 is a perspective view showing an electric motor 1 in embodiment 1. The electric motor 1 shown in Fig. 1 is a brushless DC motor used in, for example, a blower of an air conditioner.

[0011] The electric motor 1 has a rotating shaft 50, a rotor 6 fixed to the rotating shaft 50, and a molded stator 4 surrounding the rotor 6. The molded stator 4 has a stator 3, a lead wire supporting component 10, and a molded resin part 40 as an outer casing member that covers these components.

[0012] In the following description, the direction of the center of rotation of the rotor 6, i.e., the central axis Ax of the rotating shaft 50, will be referred to as the "axial direction." The circumferential direction centered on the central axis Ax will be referred to as the "circumferential direction." The radial direction centered on the central axis Ax will be referred to as the "radial direction." The central axis Ax will also be referred to as the rotation axis.

[0013] The rotating shaft 50 protrudes from the molded stator 4 to one axial side (the left side in FIG. 1 ), and an impeller of a blower, for example, is attached to the protruding portion. Therefore, the protruding side of the rotating shaft 50 is referred to as the "load side," and the opposite side is referred to as the "anti-load side."

[0014] The rotor 6 has a rotor core 60 fixed to the rotating shaft 50 and a plurality of permanent magnets 62 attached to the rotor core 60. The rotating shaft 50 is fixed by press-fitting or the like into a shaft hole formed in the center of the rotor core 60. However, resin or the like may be provided between the rotating shaft 50 and the rotor core 60.

[0015] The rotor core 60 is a cylindrical member centered on the central axis Ax. The rotor core 60 has a plurality of laminated elements stacked in the axial direction. The plurality of laminated elements are integrated by caulking or the like. The laminated elements are, for example, electromagnetic steel sheets, and have a thickness of 0.1 mm to 0.7 mm.

[0016] The rotor core 60 has a plurality of magnet insertion holes 61 along its outer periphery. The magnet insertion holes 61 are arranged at equal intervals in the circumferential direction. The number of magnet insertion holes 61 corresponds to the number of poles of the rotor 6. The number of poles of the rotor 6 is, for example, 6 poles, 8 poles, etc., but is not limited to these.

[0017] A permanent magnet 62 is inserted into each magnet insertion hole 61. The permanent magnet 62 is made of, for example, a rare earth magnet containing neodymium (Nd), iron (Fe), and boron (B). The permanent magnets 62 in each magnet insertion hole 61 form a magnetic pole.

[0018] The rotating shaft 50 is rotatably supported by bearings 51 and 52. The bearing 51 is disposed on the load side of the rotor 6, and the bearing 52 is disposed on the anti-load side of the rotor 6.

[0019] 2 is a cross-sectional view showing the molded stator 4. As shown in FIG. 2, the molded stator 4 has a stator 3, a lead wire supporting component 10, and a molded resin portion 40.

[0020] The molded resin portion 40 is formed of a molded resin, such as a thermosetting resin such as an unsaturated polyester resin or an epoxy resin. As an example, the molded resin portion 40 is formed of a bulk molding compound (BMC) in which glass fiber or the like is mixed with an unsaturated polyester resin.

[0021] The molded resin part 40 is an outer shell member that covers the stator 3 and the lead wire supporting component 10. The molded resin part 40 is cylindrical with a bottom, and has an opening 41 on the load side and a bottom 42 on the anti-load side. The rotor 6 is inserted into the molded stator 4 through the opening 41.

[0022] A stepped portion 44 is formed on the load side of the molded resin portion 40 so as to surround the opening 41. A metal bracket 55 (FIG. 1) is attached to the stepped portion 44. As shown in FIG. 1, the bracket 55 holds a bearing 51. A bearing 52 is held on the bottom portion 42 of the molded resin portion 40.

[0023] Here, the molded resin part 40 is provided as an example of the outer casing member, but the outer casing member is not limited to the molded resin part 40 and may be, for example, a metal shell.

[0024] <Configuration of Stator 3> Fig. 3 is a top view showing the stator 3. As shown in Fig. 3, the stator 3 has an annular stator core 30 that surrounds the rotor 6 (Fig. 1), a coil 32 wound around the stator core 30, and an insulating portion 31 provided between the stator core 30 and the coil 32.

[0025] The stator core 30 has a plurality of laminated elements stacked in the axial direction. The plurality of laminated elements are integrally fixed by caulking or the like. The laminated elements are, for example, electromagnetic steel sheets. The thickness of the laminated steel sheets is, for example, 0.1 mm to 0.7 mm.

[0026] The stator core 30 has a yoke 30a extending annularly in the circumferential direction around the central axis Ax, and a plurality of teeth 30b extending radially inward from the yoke 30a. The number of teeth 30b is nine here. However, the number of teeth 30b is not limited to nine, and may be two or more.

[0027] Resin insulating portions 31 are provided to surround the teeth 30b of the stator core 30. The insulating portions 31 are formed of insulating resin, for example, thermoplastic resin such as PBT (polybutylene terephthalate). The insulating portions 31 are formed by integrally molding the resin with the stator core 30 or by assembling a resin molded body to the stator core 30.

[0028] The insulating portion 31 has an outer peripheral wall 31 a located on the outer periphery of the tooth 30 b and an inner peripheral wall 31 b located on the inner periphery of the tooth 30 b. The outer peripheral wall 31 a and the inner peripheral wall 31 b guide the coil 32 wound around the tooth 30 b from both sides in the circumferential direction.

[0029] The outer peripheral wall 31a of the insulating portion 31 is provided with a plurality of pins 33 that support the lead wire supporting component 10 and terminal portions 34 that are electrically connected to the coil 32. In the example shown in Fig. 3, four pins 33 and three terminal portions 34 are provided, but the number is not limited to these.

[0030] The coils 32 are formed of, for example, magnet wire and are wound around the teeth 30b of the stator core 30 via the insulating portion 31. The ends of the magnet wire constituting the coils 32 are connected to terminal portions 34 provided on the insulating portion 31 by fusing, soldering, or the like (see FIG. 4 described later).

[0031] <Configuration of lead wire support part 10> Fig. 4 is a perspective view showing the lead wire support part 10. The lead wire support part 10 shown in Fig. 4 is disposed at one axial end of the stator 3, more specifically, at the end on the anti-load side (see Fig. 1). The lead wire support part 10 supports N lead wires 8 (N is an integer of 1 or more).

[0032] The number N of lead wires 8 is 3 in this example. Specifically, the lead wires 8 are lead wires 8a, 8b, and 8c that supply U-phase, V-phase, and W-phase electric power to the coil 32 of the electric motor 1. The lead wires 8a, 8b, and 8c are bundled together with a cable tie B or the like outside the electric motor 1. The lead wires 8a, 8b, and 8c will be referred to as lead wire 8 when there is no need to particularly distinguish between them.

[0033] The lead wire support component 10 has a holding portion 11 that holds the lead wires 8 inside the electric motor 1, and an output portion 12 that pulls the lead wires 8 out of the electric motor 1. The holding portion 11 is attached to the stator 3 (FIG. 1). The output portion 12 is arranged so that a portion of it protrudes from the molded resin portion 40. Both the holding portion 11 and the output portion 12 are made of a thermoplastic resin such as PBT.

[0034] The lead wires 8 are held in a routed state by the holding portion 11. The holding portion 11 has an annular base 110 that is attached to the stator 3. The annular base 110 is formed in an annular shape centered on the central axis Ax.

[0035] The annular base 110 has mounting legs 119 along its outer periphery. Here, four mounting legs 119 are arranged circumferentially, but the number of mounting legs 119 may be one or more. The mounting legs 119 abut against the axial end face of the outer peripheral wall 31 a ( FIG. 3 ) of the insulating portion 31.

[0036] The mounting legs 119 have mounting holes 119a through which the pins 33 (FIG. 3) of the stator 3 are inserted. The pins 33 (FIG. 3) are heat-welded while inserted into the mounting holes 119a, thereby fixing the holding portion 11 to the stator 3.

[0037] Between two of the four mounting legs 119 of the annular base 110, a receiving portion 111 is formed, which is a recess for mounting the lead portion 12.

[0038] A lead wire guide 112 for holding the lead wires 8 is formed radially inside the housing portion 111 of the annular base 110. The lead wire guide 112 has three grooves 112a (FIG. 6A) through which the lead wires 8a, 8b, and 8c pass in the radial direction.

[0039] The three grooves 112a of the lead wire guide 112 are formed, for example, side by side in the circumferential direction. When the lead wires 8a, 8b, and 8c pass through the grooves 112a of the lead wire guide 112, the lead wires 8a, 8b, and 8c are held on the holding portion 11.

[0040] Three lead wire end holding portions 116, the same number as the number of lead wires 8 (i.e., N), are arranged on the outer periphery of the annular base 110. Core wire holding portions 117 are arranged circumferentially spaced from each lead wire end holding portion 116. The end portions of the lead wires 8 are held by the lead wire end holding portions 116, and the core wires 80 from which the coating of the lead wires 8 has been stripped are held by the core wire holding portions 117.

[0041] When the lead wire support component 10 is attached to the stator 3, the terminal portion 34 (FIG. 3) of the stator 3 is located between the lead wire end holding portion 116 and the core wire holding portion 117. The core wire 80 of the lead wire 8 held between the lead wire end holding portion 116 and the core wire holding portion 117 is joined to the terminal portion 34 by fusing or soldering.

[0042] Fig. 5(A) is a perspective view showing the lead portion 12. As shown in Fig. 5(A), the lead portion 12 has a lead portion main body 120 that can be accommodated in the accommodation portion 111 (Fig. 4) of the holding portion 11, and a protrusion 125 as a second engagement portion that protrudes radially inward from the lead portion main body 120. The protrusion 125 is provided on both circumferential ends of the lead portion main body 120. The protrusion 125 is formed, for example, as a plate-like piece having a thickness in the axial direction.

[0043] Three holes 123 are formed in the lead portion body 120 to allow the lead wires 8a, 8b, and 8c to pass through. The holes 123 are arranged in a line in the circumferential direction and all extend radially. When the lead portion 12 is attached to the housing portion 111 (FIG. 4) of the holder 11, the holes 123 in the lead portion body 120 face the lead wire guide 112 (FIG. 4).

[0044] Fig. 5(B) is a perspective view showing an example of the configuration of the lead-out portion 12. As shown in Fig. 5(B), the lead-out portion main body 120 of the lead-out portion 12 is configured to be separable in the axial direction on a plane passing through the three holes 123 into a first portion 121 and a second portion 122.

[0045] The first part 121 and the second part 122 can be fitted to each other. Specifically, the first part 121 has a protrusion 121a, and the second part 122 has a recess 122a into which the protrusion 121a fits. However, this is not limited to the protrusion 121a and the recess 122a, and it is sufficient that the first part 121 and the second part 122 have a part that can be fitted to each other (i.e., a fitting portion).

[0046] When the first portion 121 and the second portion 122 are separated from each other, the hole 123 is divided by the plane, and a groove having a semicircular cross section is formed in each of the first portion 121 and the second portion 122. The lead wires 8a, 8b, and 8c are aligned with the grooves, and the first portion 121 and the second portion 122 are combined in the axial direction, thereby assembling the lead portion 12.

[0047] The above-described protrusion 125 is formed on the first portion 121. Therefore, the first portion 121 may be attached to the annular base 110 first, the lead wires 8 a, 8 b, and 8 c may be aligned with the grooves of the first portion 121, and then the second portion 122 may be attached to the first portion 121.

[0048] 6A is a perspective view showing the engagement portion between the holding portion 11 and the outlet portion 12. As shown in FIG. 6A, in the annular base 110 of the holding portion 11, recesses 115 serving as first engagement portions are formed on both circumferential sides of the accommodating portion 111. The recesses 115 are formed between a first protruding piece 113 and a second protruding piece 114 formed on the annular base 110.

[0049] The protruding pieces 113, 114 protrude radially outward from the annular base 110 and face each other in the axial direction. The second protruding piece 114 is located axially between the first protruding piece 113 and the stator core 30. The recessed portion 115 opens radially outward and engages with the protruding portion 125 of the lead portion 12.

[0050] The projection 125 of the lead portion 12 engages with the recess 115 of the holding portion 11, thereby integrating the holding portion 11 and the lead portion 12. The projection amount of the second protruding piece 114 is greater than the projection amount of the first protruding piece 113, so that the projection 125 of the lead portion 12 can be held on the second protruding piece 114.

[0051] Fig. 6(B) is a perspective view showing a state in which the holding portion 11 and the lead portion 12 have been separated. As shown in Fig. 6(B), by pulling the lead portion 12 outward in the radial direction, the engagement between the recess 115 of the holding portion 11 and the protrusion 125 of the lead portion 12 is released, and the holding portion 11 and the lead portion 12 are separated. It is desirable that the recess 115 and the protrusion 125 are engaged in an engagement state that allows them to be separated with a relatively light force.

[0052] Fig. 7A is a plan view schematically showing a state in which the holding portion 11 and the lead outlet portion 12 of the lead wire support component 10 are engaged with each other. Fig. 7B is a side view schematically showing a state in which the holding portion 11 and the lead outlet portion 12 of the lead wire support component 10 are engaged with each other.

[0053] 7A and 7B, the recess 115 of the holding portion 11 engages with the protrusion 125 of the lead portion 12, thereby integrating the holding portion 11 and the lead portion 12 to form the lead wire support component 10. In the manufacturing process of the electric motor 1, the lead wire support component 10 is handled as a single component.

[0054] 7(C) is a side view schematically showing a state in which the holding portion 11 and the lead portion 12 of the lead wire supporting component 10 are separated. As shown in Fig. 7(C), the holding portion 11 and the lead portion 12 are separated by releasing the engagement between the recess 115 of the holding portion 11 and the protrusion 125 of the lead portion 12. When the molded stator 4 is completed, the holding portion 11 and the lead portion 12 are held in the molded resin part 40 in a state in which they are spaced apart in the axial direction.

[0055] <Manufacturing Method> Fig. 8 is a flowchart showing the manufacturing process of the electric motor 1. First, a plurality of laminated elements are stacked in the axial direction and fixed by caulking or the like to form the stator core 30 (step S101).

[0056] Next, the insulating portion 31 is attached to the stator core 30 or is integrally formed therewith (step S102). Furthermore, the coil 32 is wound around the stator core 30 with the insulating portion 31 interposed therebetween (step S103). In this way, the stator 3 is formed. Steps S101 to S103 correspond to the process of manufacturing the stator 3.

[0057] Next, the lead wires 8 are attached to the lead wire support component 10 (step S104). Specifically, the lead wires 8a, 8b, and 8c are placed in the holder 11 and held by the lead wire guide 112. The lead wires 8a, 8b, and 8c are routed as shown in FIG. 4, and the ends of the lead wires 8a, 8b, and 8c are fixed to the lead wire end holder 116.

[0058] Before attaching the lead wires 8a, 8b, and 8c to the holding portion 11, it is desirable to attach the first portion 121 of the lead portion 12 (FIGS. 5A and 5B) to the holding portion 11. In this case, the convex portion 125 of the first portion 121 of the lead wire 12 is engaged with the concave portion 115 of the holding portion 11. Thereafter, the second portion 122 is attached to the first portion 121 so that the lead wires 8a, 8b, and 8c are accommodated in the holes 123.

[0059] Next, the lead wire support part 10 is attached to the stator 3 (step S105). Specifically, the pins 33 (FIG. 3) of the stator 3 are inserted into the mounting holes 119a (FIG. 4) of the mounting legs 119 of the lead wire support part 10, and the tips of the pins 33 are welded to fix the lead wire support part 10 to the stator 3.

[0060] Furthermore, the lead wires 8a, 8b, and 8c arranged in the holding portion 11 are connected to the terminal portions 34 of the stator 3 (step S106). Specifically, the core wire 80 of the lead wire 8 held between the lead wire end holding portion 116 and the core wire holding portion 117 shown in FIG. 4 is joined to the terminal portions 34 of the stator 3 (FIG. 3) by fusing or soldering.

[0061] Next, the stator 3 and the lead wire supporting part 10 are placed in the molding die 7 for molding (step S107).

[0062] 9 is a cross-sectional view showing the molding die 7 and the stator 3 and lead wire supporting component 10 placed therein. As shown in Fig. 9, the molding die 7 has a fixed die 71 which is a lower die and a movable die 72 which is an upper die. The fixed die 71 and the movable die 72 have mating surfaces 71a, 72a which face each other.

[0063] The fixed mold 71 has a cavity 73 which is a molding space, a core 74 formed in the center of the cavity 73, and a supply port 75 for supplying resin to the cavity 73. The stator 3 with the lead wire support part 10 attached is housed in the cavity 73. The core 74 of the fixed mold 71 fits into the inner periphery of the stator 3, holding the stator 3 and the lead wire support part 10.

[0064] The movable mold 72 is provided so as to be movable relative to the fixed mold 71. When the movable mold 72 is in the closed position shown in Fig. 9, the cavity 73 of the fixed mold 71 is closed by the movable mold 72. When the movable mold 72 rises from the position shown in Fig. 9, the cavity 73 of the fixed mold 71 is opened.

[0065] In addition, between the fixed mold 71 and the movable mold 72, there are formed a receiving portion 76 which is a recess that accommodates the outlet portion 12 of the lead wire support component 10, and an extraction hole 77 that extracts the lead wire 8 to the outside of the molding mold 7.

[0066] In step S107 , the movable mold 72 is raised to open the cavity 73 of the fixed mold 71 , and the stator 3 with the lead wire supporting part 10 attached thereto is placed in the cavity 73 .

[0067] 7(C), the lead wire support component 10 is separated into the holding portion 11 and the lead portion 12, the lead wire 8 is drawn out through the drawing hole 77, and the lead portion 12 is housed in the receiving portion 76. In other words, the holding portion 11 is left on the stator 3, and the lead portion 12 is held at a position separated from the holding portion 11.

[0068] Next, the stator 3, the holding portion 11, and the lead portion 12 are molded (step S108). That is, the movable mold 72 is lowered to close the cavity 73 of the fixed mold 71. Then, molten molding resin is injected from the supply port 75 of the molding mold 7. The molding resin, such as BMC, fills the cavity 73 and covers the stator 3, the holding portion 11, and the lead portion 12.

[0069] Thereafter, the molding die 7 is heated to the hardening temperature of the molding resin to harden the molding resin, thereby forming the molding resin part 40 shown in Fig. 1. The molding resin part 40 holds the holding part 11 and the lead-out part 12 at positions spaced apart from each other.

[0070] This completes the molded stator 4, in which the stator 3 and the lead wire supporting component 10 are covered with the molded resin portion 40. Steps S101 to S108 correspond to the manufacturing process of the molded stator 4.

[0071] Separately from steps S101 to S108, the rotor 6 is formed. That is, a plurality of laminated elements are stacked in the axial direction and fixed by caulking or the like to form the rotor core 60 (step S109), and permanent magnets 62 are inserted into the magnet insertion holes 61 of the rotor core 60 (step S110). In this way, the rotor 6 is formed. Steps S109 to S110 correspond to the process of manufacturing the rotor 6.

[0072] Thereafter, the rotor 6 is inserted into the molded stator 4 (step S111). Specifically, the rotating shaft 50 is attached to the rotor 6, bearings 51 and 52 are attached to the rotating shaft 50, and the rotor 6 is inserted into the molded stator 4 through the opening 41. In addition, the bracket 55 is attached to the stepped portion 44 of the molded stator 4. This completes the electric motor 1.

[0073] <Function> The function of embodiment 1 will be described. In the electric motor 1, the lead wire support component 10 has its lead portion 12 protruding outside the molded resin portion 40, so there is a possibility that moisture may enter the inside of the electric motor 1 from around the lead portion 12. If moisture reaches the holding portion 11 in which the lead wires 8 are arranged or the stator 3, it may cause a malfunction of the electric motor 1.

[0074] In the electric motor 1 of the first embodiment, the lead wire support component 10 is separated into a holding portion 11 and an outlet portion 12, which are arranged at positions spaced apart from each other. Therefore, even if water infiltrates from around the outlet portion 12, it is difficult for it to reach the holding portion 11 and the stator 3. As a result, it is possible to prevent moisture from reaching the holding portion 11 and the stator 3 where the lead wires 8 are arranged, thereby preventing breakdowns in the electric motor 1. In other words, it is possible to improve the operational reliability of the electric motor 1.

[0075] Furthermore, if the lead wire support component 10 is separated into the holding portion 11 and the outlet portion 12, the number of parts increases. However, in the manufacturing process of the electric motor 1, the holding portion 11 and the outlet portion 12 can be handled as a single part as shown in Figures 7(A) and (B), which simplifies handling of the parts in the manufacturing process.

[0076] Furthermore, because lead portion 12 is divided into multiple portions (i.e., first portion 121 and second portion 122) at a plane that passes through hole 123 through which lead wire 8 passes, lead wire 8 is accommodated in hole 123 by assembling lead portion 12. This eliminates the need for the work of inserting lead wire 8 into hole 123, further simplifying the manufacturing process of electric motor 1.

[0077] Effect of First Embodiment As described above, the electric motor 1 of the first embodiment includes the rotor 6, the stator 3 surrounding the rotor 6, the lead wire support component 10 supporting the lead wires 8, and the molded resin portion 40 as an outer casing member that covers the stator 3 and the lead wire support component 10. The lead wire support component 10 has a holding portion 11 that is attached to the stator 3 and supports the lead wires 8, and an outlet portion 12 that protrudes from the molded resin portion 40 and leads the lead wires 8 to the outside of the molded resin portion 40. The holding portion 11 and the outlet portion 12 are disposed at positions spaced apart from each other. The holding portion 11 has a recess 115 as a first engaging portion, and the lead portion 12 has a protrusion 125 as a second engaging portion. The recess 115 and the protrusion 125 have shapes that allow them to engage with each other.

[0078] Since the retaining portion 11 and the lead portion 12 are disposed at positions spaced apart from each other in this manner, even if moisture penetrates from around the lead portion 12, it is possible to prevent the moisture from reaching the retaining portion 11 and the stator 3. This makes it possible to prevent breakdowns in the electric motor 1 and improve operational reliability. Furthermore, in the manufacturing process of the electric motor, the engagement between the recessed portion 115 and the protruding portion 125 allows the retaining portion 11 and the lead portion 12 to be handled as a single component, thereby simplifying the manufacturing process.

[0079] Furthermore, since the outlet portion 12 is located on the opposite side of the holding portion 11 from the stator 3 in the axial direction, after the stator 3 and lead wire support part 10 are placed in the molding die 7 as shown in Figure 9, it is easy to position the outlet portion 12 at a position away from the holding portion 11.

[0080] Furthermore, since the holding portion 11 has the lead wire guide 112 that holds the lead wire 8, there is no need to provide a separate member for holding the lead wire 8, and the number of parts of the electric motor 1 can be reduced.

[0081] Furthermore, since the stator 3 has a pin 33 as a support member that supports the holding portion 11, the lead wire support part 10 and the stator 3 can be handled as a single unit during the manufacturing process of the electric motor 1, further simplifying the manufacturing process of the electric motor 1.

[0082] Furthermore, since the lead portion 12 is composed of the first portion 121 and the second portion 122 and the lead wire 8 is held between the first portion 121 and the second portion 122, the lead wire 8 is accommodated in the hole 123 by assembling the lead portion 12. This eliminates the need to insert the lead wire 8 into the hole 123 of the lead portion 12, further simplifying the manufacturing process of the electric motor 1.

[0083] Furthermore, since the first engaging portion is the recess 115 and the second engaging portion is the protrusion 125, the holding portion 11 and the lead-out portion 12 can be combined and separated with a simple configuration.

[0084] Embodiment 2. Fig. 10 is a cross-sectional view showing a molded stator 4A of an electric motor according to embodiment 2. As shown in Fig. 10, the electric motor according to embodiment 2 differs from electric motor 1 according to embodiment 1 in the engagement portion between holding portion 11A and lead portion 12A of lead wire supporting component 10A.

[0085] In the molded stator 4A of the second embodiment, the holding portion 11A has a protrusion 118 as a first engagement portion, and the lead portion 12A has a recess 128 as a second engagement portion. The protrusion 118 and the recess 128 have shapes that allow them to engage with each other. As in the first embodiment, the holding portion 11A and the lead portion 12A are arranged spaced apart from each other.

[0086] Fig. 11(A) is a perspective view showing the engagement portion between the holding portion 11A and the lead portion 12A. As described in the first embodiment, the lead portion 12A has a first portion 121 and a second portion 122 (Fig. 5(A)), but the second portion 122 is omitted in Fig. 11(A).

[0087] As shown in Fig. 11A, in the annular base 110 of the holding portion 11A, convex portions 118 are formed on both sides in the circumferential direction of the accommodation portion 111. Note that one of the convex portions 118 is hidden in Fig. 11A.

[0088] The lead portion 12A has a recess 128 that engages with the protrusion 118 of the holding portion 11A. The recess 128 is formed between a first protrusion 126 and a second protrusion 127 formed on the lead portion main body 120. The protrusions 126, 127 protrude radially inward from the lead portion main body 120 and face each other in the axial direction. The second protrusion 127 is located axially between the first protrusion 126 and the stator core 30. The recess 128 opens radially inward and engages with the protrusion 118 of the holding portion 11A.

[0089] The projection 118 of the holding portion 11A engages with the recess 128 of the lead portion 12A, thereby integrating the holding portion 11A and the lead portion 12A.

[0090] 11(B) is a perspective view showing the state in which the holding portion 11A and the lead portion 12A are separated. As shown in FIG. 11(B), by pulling the lead portion 12A outward in the radial direction, the engagement between the convex portion 118 of the holding portion 11A and the concave portion 128 of the lead portion 12A is released, and the holding portion 11A and the lead portion 12A are separated. It is desirable that the convex portion 118 and the concave portion 128 are engaged in an engagement state in which they can be separated with a relatively light force.

[0091] Fig. 12A is a plan view schematically showing the state in which the holding portion 11A and the lead outlet portion 12A of the lead wire supporting part 10A are engaged with each other, and Fig. 12B is a side view schematically showing the state in which the holding portion 11A and the lead outlet portion 12A of the lead wire supporting part 10A are engaged with each other.

[0092] 12A and 12B, the convex portion 118 of the holding portion 11A engages with the concave portion 128 of the lead portion 12A, thereby integrating the holding portion 11A and the lead portion 12A to form the lead wire support part 10A. In the manufacturing process of the electric motor 1, the lead wire support part 10A is handled as a single component.

[0093] 12(C) is a side view schematically illustrating a state in which the holding portion 11A and the lead portion 12A of the lead wire supporting component 10A are separated. As shown in FIG. 12(C), the holding portion 11A and the lead portion 12A are separated by releasing the engagement between the convex portion 118 of the holding portion 11A and the concave portion 128 of the lead portion 12A. When the molded stator 4 is completed, the holding portion 11A and the lead portion 12A are held in the molded resin portion 40 in a state in which they are spaced apart in the axial direction.

[0094] Except for the points mentioned above, the electric motor of the second embodiment is configured similarly to the electric motor 1 of the first embodiment.

[0095] As described above, in the electric motor of embodiment 2, the holding portion 11A and the lead portion 12A of the lead wire supporting component 10A are arranged at positions spaced apart from each other, the holding portion 11A has the convex portion 118 as a first engaging portion, the lead portion 12A has the concave portion 128 as a second engaging portion, and the convex portion 118 and the concave portion 128 have shapes that allow them to engage with each other. Therefore, as in embodiment 1, even if moisture penetrates from around the lead portion 12A, it is possible to prevent the moisture from reaching the holding portion 11A and the stator 3. Furthermore, in the manufacturing process of the electric motor, the engagement between the convex portion 118 and the concave portion 128 allows the holding portion 11A and the lead portion 12A to be handled as a single component, thereby simplifying the manufacturing process.

[0096] Third Embodiment An electric motor according to a third embodiment differs from the electric motor 1 according to the first embodiment in the engagement state between the lead wire supporting component 10B and the lead portion 12B.

[0097] Fig. 13(A) is a plan view schematically showing a state in which the holding portion 11B and the lead portion 12B of the lead wire supporting component 10B are engaged with each other in the electric motor of embodiment 3. Fig. 13(B) is a side view schematically showing a state in which the holding portion 11B and the lead portion 12B are engaged with each other.

[0098] 13A and 13B, in the electric motor of the third embodiment, the joint surface 11e of the holding portion 11B and the joint surface 12e of the lead portion 12B are fixed by adhesive. Both joint surfaces 11e and 12e are flat. The joint surface 11e is also referred to as the first joint surface, and the joint surface 12e is also referred to as the second joint surface. In the manufacturing process of the electric motor 1, the lead wire supporting part 10B is handled as a single component.

[0099] 13(C) is a side view schematically illustrating a state in which the holding portion 11B and the lead portion 12B of the lead wire support part 10B are separated. As shown in FIG. 13(C), the adhesive between the joint surface 11e of the holding portion 11B and the joint surface 12e of the lead portion 12B is removed by heating or the like, thereby separating the lead wire support part 10B into the holding portion 11B and the lead portion 12B. When the molded stator 4 is completed, the holding portion 11B and the lead portion 12B are held in the molded resin part 40 in a state in which they are spaced apart in the axial direction.

[0100] 14 is a cross-sectional view showing a molding die 7B used in the manufacturing process of the electric motor of embodiment 3, and a stator 3 and a lead wire supporting component 10B placed therein. The molding die 7B has the same configuration as the molding die 7 (FIG. 9) described in embodiment 1, but has a guide surface 78 adjacent to the receiving portion 76 of the fixed die 71, which guides the lead portion 12B into the receiving portion 76. The guide surface 78 is, for example, an inclined surface formed on the inner peripheral surface of the fixed die 71.

[0101] In the molding process of the third embodiment, the stator 3 and the lead wire support part 10B are placed in a cavity 73 of a molding die 7B. The lead wires 8 of the lead wire support part 10B are drawn out through drawing holes 77 to the outside.

[0102] Movable mold 72 is lowered to bring mating surfaces 71 a, 72 a of molds 71, 72 into contact with each other, and molten molding resin is supplied into cavity 73 from supply port 75. Molding resin such as BMC fills cavity 73 and covers stator 3, holding portion 11B, and lead-out portion 12B. The molding mold is then heated to the hardening temperature of the molding resin.

[0103] The melting temperature of the adhesive that secures the holding portion 11B and the lead portion 12B of the lead wire support component 10B is lower than the hardening temperature of the molding resin, which is a thermosetting resin. Therefore, the adhesive melts at the temperature of the molding resin, separating the holding portion 11B and the lead portion 12B. Furthermore, the pressure of the molding resin in the cavity 73 causes the lead portion 12B to flow as shown by arrow F and is guided along the guide surface 78 into the receiving portion 76.

[0104] Thereafter, the mold resin is completely cured to form the mold resin portion 40 (FIG. 1). The mold resin portion 40 holds the holding portion 11B and the lead portion 12B in positions spaced apart from each other.

[0105] In the electric motor of the third embodiment, the lead portion 12B is located on the opposite side of the holding portion 11B from the stator 3 in the axial direction. Therefore, in the molding die 7B, the receiving portion 76 can be provided above the holding portion 11B. This allows the lead portion 12B to be moved to the receiving portion 76 by utilizing the pressure of the molding resin inside the molding die 7B.

[0106] Except for the points mentioned above, the electric motor of the third embodiment is configured similarly to the electric motor 1 of the first embodiment.

[0107] As described above, in the electric motor of embodiment 3, the holding portion 11B and the lead portion 12B of the lead wire supporting component 10B are fixed by adhesive. Therefore, the holding portion 11B and the lead portion 12B can be separated by heat during molding, and the lead portion 12B can be moved to the receiving portion 76 by using molding pressure. This further simplifies the manufacturing process.

[0108] Embodiment 4. Figure 15 is a cross-sectional view showing a molded resin part 4C of an electric motor according to embodiment 4. As shown in Figure 15, the electric motor according to embodiment 4 differs from electric motor 1 according to embodiment 1 in that a sensor board 20 is attached to a holding part 11C of a lead wire supporting part 10C, and two types of lead wires 8 and 9 are drawn out from an outlet part 12C.

[0109] The sensor board 20 is, for example, a board on which a magnetic sensor for detecting the rotational position of the rotor 6 is mounted. Lead wires 9, which are sensor lead wires for transmitting detection signals of the magnetic sensor to a control circuit external to the electric motor 1, are drawn out from the sensor board 20. The number of lead wires 9 is, for example, five, but is not limited to five.

[0110] The other lead wire 8 is a power supply lead wire electrically connected to the coil 32 of the stator 3 as described in the first embodiment.

[0111] Fig. 16(A) is a plan view schematically showing a state in which the holding portion 11C and the lead portion 12C of the lead wire supporting component 10C are engaged in the electric motor of embodiment 4. Fig. 16(B) is a side view schematically showing a state in which the holding portion 11C and the lead portion 12C are engaged.

[0112] 16A and 16B, in the electric motor of the fourth embodiment, the sensor board 20 is attached to a board attachment portion 131 provided on the holding portion 11C. The board attachment portion 131 is, for example, a recess formed on the surface of the lead wire supporting component 10C, but may be any portion to which the sensor board 20 can be attached.

[0113] Connection terminals 21 to which the lead wires 9 are connected are provided on the surface of the sensor substrate 20. Here, five connection terminals 21, the same number as the number of lead wires 9, are arranged in a row in the circumferential direction. The lead wires 9 connected to the connection terminals 21 are drawn out to the outside through holes 129 formed in the outlet portion 12C.

[0114] As in the first embodiment, the lead wire 8 is held by the lead wire guide 112 provided in the holding portion 11C and is pulled out to the outside through a hole 123 (FIG. 16B) formed in the outlet portion 12C.

[0115] The lead portion 12C has a hole 123 ( FIG. 16(B) ) through which the lead wire 8 passes, and a hole 129 through which the lead wire 9 passes. The holes 123 and 129 are formed at different positions in the axial direction. However, the holes 123 and 129 may be formed at the same axial position. Furthermore, as described with reference to FIG. 5(B) , the lead portion 12C may be formed of multiple components, and the lead wires 8 and 9 may be arranged between the multiple components.

[0116] As described in the first embodiment, the holding portion 11C and the lead portion 12C are integrated by the engagement between the recess 115 of the holding portion 11C and the protrusion 125 of the lead portion 12C. Note that, as described in the second embodiment, the protrusion of the holding portion 11C may be engaged with the recess of the lead portion 12C.

[0117] 16(C) is a side view schematically illustrating a state in which the holding portion 11C and the lead portion 12C of the lead wire supporting component 10C are separated. As shown in FIG. 16(C), the holding portion 11C and the lead portion 12C are separated by releasing the engagement between the recess 115 of the holding portion 11C and the protrusion 125 of the lead portion 12C. When the molded stator 4 is completed, the holding portion 11C and the lead portion 12C are held in the molded resin part 40 in a state in which they are spaced apart in the axial direction.

[0118] 17 is a flowchart showing the manufacturing process of the electric motor according to embodiment 4. The manufacturing process of the stator 3 (steps S101 to S103) is the same as that described in embodiment 1.

[0119] Next, the lead wires 8 and 9 are attached to the lead wire support component 10C (step S104). The arrangement of the lead wire 8 in the holding portion 11C is as described in the first embodiment. In the fourth embodiment, the lead wires 8 and 9 are attached to the lead portion 12C.

[0120] That is, the lead wire 8 is inserted through the hole 123 of the lead portion 12C, and the lead wire 9 is inserted through the hole 129. As described in the first embodiment with reference to Figures 5(A) and (B) , the lead wires 8 and 9 may be accommodated in the holes 123 and 129 by combining multiple portions of the lead portion 12C.

[0121] Next, the lead wire supporting part 10C is attached to the stator 3 (step S105). The method for fixing the lead wire supporting part 10C to the stator 3 is the same as that described in the first embodiment.

[0122] Next, the sensor board 20 is attached to the lead wire supporting part 10C (step S201). Specifically, the sensor board 20 is attached to the board attachment part 131 of the holding part 11C of the lead wire supporting part 10C. The sensor board 20 may be fixed by adhesive or by other methods.

[0123] Furthermore, of the lead wires 8 and 9 arranged on the lead wire support part 10C, the lead wire 8 is connected to the terminal portion 34 of the stator 3, and the lead wire 9 is connected to the connection terminal 21 of the sensor board 20 (step S202). As a result, the lead wire 8 is electrically connected to the coil 32 of the stator 3, and the lead wire 9 is electrically connected to the sensor board 20.

[0124] Next, the stator 3 and the lead wire support part 10C are placed in the molding die 7 (FIG. 1) (step S107), and molding is performed (step S108). This completes the molded stator 4 in which the lead wire support part 10C with the sensor substrate 20 attached and the stator 3 are covered with the molded resin part 40.

[0125] The manufacturing process of rotor 6 (steps S109 to S110) and the process of inserting rotor 6 into molded stator 4 (step S111) are the same as those described in embodiment 1. In this way, the electric motor of embodiment 4 is completed.

[0126] Except for the points mentioned above, the electric motor of the fourth embodiment is configured similarly to the electric motor 1 of the first embodiment.

[0127] As described above, in the electric motor of embodiment 4, the holding portion 11C and the lead portion 12C of the lead wire supporting component 10C are arranged at positions spaced apart from each other, and the sensor board 20 is attached to the holding portion 11C. Therefore, even if moisture penetrates from around the lead portion 12C, it is possible to prevent the moisture from reaching the sensor board 20, thereby improving the operational reliability of the electric motor.

[0128] Embodiment 5. Fig. 18 is a cross-sectional view showing a molded stator 4D of an electric motor according to embodiment 5. As shown in Fig. 18, the electric motor according to embodiment 5 differs from electric motor 1 according to embodiment 1 in that a drive circuit board 25 is attached to a holding portion 11D of a lead wire supporting component 10D.

[0129] The drive circuit board 25 is a board on which, for example, at least a part of an inverter circuit or the like for driving the electric motor 1 is mounted. Lead wires 13 for receiving control signals from an external control circuit are drawn out from the drive circuit board 25. The number of lead wires 13 is, for example, three, but is not limited to three.

[0130] The drive circuit board 25 is also electrically connected to the coil 32 of the stator 3 via the lead wires 8 (FIG. 19B) arranged on the lead wire supporting part 10D.

[0131] Fig. 19(A) is a plan view schematically showing a state in which a holding portion 11D and a lead portion 12D of a lead wire supporting component 10D are engaged with each other in the electric motor of embodiment 5. Fig. 19(B) is a side view schematically showing a state in which the holding portion 11D and the lead portion 12D are engaged with each other.

[0132] 19A and 19B, in the electric motor of the fifth embodiment, the drive circuit board 25 is attached to a board attachment portion 131 provided on the holding portion 11D. The board attachment portion 131 is, for example, a recess formed on the surface of the lead wire supporting part 10D, but it may be any portion to which the drive circuit board 25 can be attached.

[0133] Connection terminals 26 to which the lead wires 13 are connected are provided on the surface of the drive circuit board 25. Here, three connection terminals 26, the same number as the number of lead wires 13, are arranged in a row in the circumferential direction. The lead wires 13 connected to the connection terminals 26 pass through three holes 123 in the outlet portion 12D and are drawn out to the outside.

[0134] As described in the first embodiment, the holding portion 11D and the lead portion 12D are integrated by the engagement between the recess 115 of the holding portion 11D and the protrusion 125 of the lead portion 12D. Note that, as described in the second embodiment, the protrusion of the holding portion 11D may be engaged with the recess of the lead portion 12D.

[0135] 19(C) is a side view schematically illustrating a state in which the holding portion 11D and the lead portion 12D of the lead wire supporting component 10D are separated. As shown in FIG. 19(C), the holding portion 11D and the lead portion 12D are separated by releasing the engagement between the recess 115 of the holding portion 11D and the protrusion 125 of the lead portion 12D. When the molded stator 4 is completed, the holding portion 11D and the lead portion 12D are held in the molded resin part 40 in a state in which they are spaced apart in the axial direction.

[0136] 20 is a flowchart showing the manufacturing process of the electric motor according to embodiment 5. The manufacturing process of the stator 3 (steps S101 to S103) is the same as that described in embodiment 1.

[0137] Next, the lead wire 13 is attached to the lead wire support part 10D (step S104). Specifically, the lead wire 13 is attached to the lead portion 12D. At this time, the lead wire 13 may be inserted through the hole 123 of the lead portion 12D, or, as described in the first embodiment with reference to FIGS. 5A and 5B, the lead wire 13 may be accommodated in the hole 123 by combining multiple portions of the lead portion 12D.

[0138] Furthermore, the lead wire 8 (FIG. 19A) connecting the coil 32 and the drive circuit board 25 is placed on the holding portion 11D of the lead wire support part 10D and held by the lead wire guide 112.

[0139] Next, the drive circuit board 25 is attached to the lead wire support part 10D (step S301). Specifically, the drive circuit board 25 is attached to the board attachment part 131 of the holding part 11D of the lead wire support part 10D. The drive circuit board 25 may be fixed by adhesive or by other methods. Furthermore, the lead wire 13 is connected to the connection terminal 26 of the drive circuit board 25, and the lead wire 8 is connected to another connection terminal of the drive circuit board 25.

[0140] Next, the lead wire supporting part 10D is attached to the stator 3 (step S105). The method for fixing the lead wire supporting part 10D to the stator 3 is the same as that described in the first embodiment.

[0141] Next, the lead wires 8 are connected to the terminal portions 34 of the stator 3 (step S106). As a result, the drive circuit board 25 is electrically connected to the coils 32 of the stator 3 via the lead wires 8.

[0142] Next, the stator 3 and the lead wire support part 10D are placed in the molding die 7 (FIG. 1) (step S107), and molding is performed (step S108). This completes the molded stator 4 in which the lead wire support part 10D with the drive circuit board 25 attached and the stator 3 are covered with the molded resin part 40.

[0143] The manufacturing process of rotor 6 (steps S109 to S110) and the process of inserting rotor 6 into molded stator 4 (step S111) are the same as those described in embodiment 1. In this way, electric motor 1 of embodiment 5 is completed.

[0144] Except for the points mentioned above, the electric motor of the fifth embodiment is configured similarly to the electric motor 1 of the first embodiment.

[0145] As described above, in the electric motor of embodiment 5, holding portion 11D and lead portion 12D of lead wire supporting component 10D are arranged at positions spaced apart, and drive circuit board 25 is attached to holding portion 11D. Therefore, even if moisture penetrates from around lead portion 12D, it is possible to prevent the moisture from reaching drive circuit board 25, thereby improving the operational reliability of the electric motor.

[0146] It is possible to combine any of the first to fifth embodiments as appropriate. For example, the sensor board 20 of the fourth embodiment or the drive circuit board 25 of the fifth embodiment may be attached to the lead wire supporting component of the first to third embodiments.

[0147] <Air Conditioning Apparatus> Next, an air conditioning apparatus to which the electric motor of each embodiment can be applied will be described. Fig. 21 is a diagram showing an example of the configuration of an air conditioning apparatus 200 to which the electric motor 1 of embodiment 1 is applied. The air conditioning apparatus 200 includes an outdoor unit 201 and an indoor unit 202. The outdoor unit 201 and the indoor unit 202 are connected by a refrigerant pipe 203.

[0148] The outdoor unit 201 includes an outdoor blower 210 as a blower, a compressor 204, a heat exchanger 205, a pressure reducing device (not shown), and a housing 206 that houses these components. The outdoor blower 210 is, for example, a propeller fan, and includes the electric motor 1 and an impeller 211 fixed to the rotating shaft 50 of the electric motor 1.

[0149] The indoor unit 202 has an indoor fan 220 as a blower, a heat exchanger 222, and a housing 223 that houses these components. The indoor fan 220 is, for example, a crossflow fan, and has an impeller 221 and an electric motor 1M that drives the impeller 221.

[0150] The compressor 204, heat exchanger 205 and pressure reducing device of the outdoor unit 201, and the heat exchanger 222 of the indoor unit 202 are connected by refrigerant piping 203 to form a refrigerant circuit.

[0151] In the outdoor unit 201, the rotation of the motor 1 of the outdoor blower 210 rotates the impeller 211, causing outdoor air to pass through the heat exchanger 205. During heating operation, when the refrigerant compressed by the compressor 204 evaporates in the heat exchanger 205, the air passing through the heat exchanger 205 is cooled by the heat of evaporation being absorbed from it. The cooled air is discharged outside by the rotation of the impeller 211.

[0152] In the indoor unit 202, an impeller 221 rotates due to rotation of the motor 1M of the indoor blower 220. During heating operation, air heated when the refrigerant condenses in the heat exchanger 222 is blown into the room by the rotation of the impeller 221.

[0153] Because the outdoor unit 201 is placed outdoors, it is exposed to rainwater. However, the motor 1 of the outdoor blower 210 has a configuration that prevents moisture from reaching the holding portion 11 of the lead wire supporting component 10 and the stator 3, thereby preventing breakdowns in the motor 1. This improves the operational reliability of the outdoor blower 210, and therefore the operational reliability of the air conditioning apparatus 200.

[0154] The electric motor of any one of the second, third, fourth, or fifth embodiments may be used in place of the electric motor 1 of the first embodiment. Although the electric motor 1 is used as the drive source for the outdoor blower 210 here, it is sufficient that the electric motor 1 is used as the drive source for at least one of the outdoor blower 210 and the indoor blower 220.

[0155] Furthermore, the electric motor 1 described in each embodiment can also be mounted on electrical equipment other than the fan of an air conditioner.

[0156] Although the preferred embodiments have been specifically described above, the present disclosure is not limited to the above-described embodiments, and various improvements and modifications can be made.

[0157] 1, 1M Electric motor, 3 Stator, 4, 4A, 4C, 4D Molded stator, 6 Rotor, 7, 7B Molding die, 8, 8a, 8b, 8c Lead wire, 9 Lead wire, 10, 10A, 10B, 10C, 10D Lead wire support part, 11A, 11B, 11C, 11D Holding part, 12A, 12B, 12C, 12D Lead out part, 13 Lead wire, 20 Sensor board (board), 25 Drive circuit board (board), 30 Stator core, 31 Insulating part, 31a Outer peripheral wall, 31b Inner peripheral wall, 32 Coil, 33 Pin, 34 Terminal, 40 Molded resin part (outer shell member), 50 Rotating shaft, 55 Bracket, 60 Rotor core, 61 Magnet insertion hole, 62 Permanent magnet, 71 Fixed mold, 72 Movable mold, 73 Cavity, 76 Receiving portion, 77 Pull-out hole, 78 Guide surface, 110 Annular base, 111 Storage portion, 112 Lead wire guide, 115 Recessed portion (first engaging portion), 118 Protruding portion (first engaging portion), 120 Lead-out portion main body, 121 First portion, 122 Second portion, 123 Hole, 125 Protruding portion (second engaging portion), 128 Recessed portion (second engaging portion), 131 Board mounting portion, 200 Air conditioning apparatus, 201 Outdoor unit, 202 Indoor unit, 210 Outdoor blower (blower), 211 Impeller, 220 Indoor blower (blower), 221 Impeller.

Claims

1. An electric motor comprising a rotor, a stator surrounding the rotor, a lead wire support component for supporting a lead wire, and an outer member covering the stator and the lead wire support component, wherein the lead wire support component is attached to the stator and has a holding portion for holding the lead wire and an outlet portion provided so as to protrude from the outer member for drawing the lead wire to the outside of the outer member, the holding portion and the outlet portion are arranged at positions spaced apart from each other, the holding portion has a first engaging portion, the outlet portion has a second engaging portion, and the first engaging portion and the second engaging portion have shapes capable of engaging with each other.

2. The electric motor according to claim 1, wherein the holding portion and the outlet portion are arranged at positions spaced apart from each other in the direction of the rotation axis of the rotor.

3. The electric motor according to claim 1 or 2, wherein the outlet portion is located on the side opposite to the stator with the holding portion interposed therebetween in the direction of the rotation axis of the rotor.

4. The electric motor according to any one of claims 1 to 3, wherein the holding portion has a lead wire guide for holding the lead wire.

5. The electric motor according to any one of claims 1 to 4, wherein the stator has a support member for supporting the holding portion.

6. The electric motor according to any one of claims 1 to 5, wherein the outlet portion is configured by combining a first portion and a second portion, and holds the lead wire between the first portion and the second portion.

7. The electric motor according to any one of claims 1 to 6, wherein the first engaging portion is a concave portion and the second engaging portion is a convex portion.

8. The electric motor according to any one of claims 1 to 6, wherein the first engaging portion is a convex portion and the second engaging portion is a concave portion.

9. The electric motor according to any one of claims 1 to 8, wherein a substrate is attached to the holding portion, and the lead wire is connected to the substrate.

10. The electric motor according to claim 9, wherein the substrate is a sensor substrate on which a sensor is mounted.

11. The electric motor according to claim 9, wherein the substrate is a drive circuit board on which a drive circuit is mounted.

12. A blower comprising the electric motor according to any one of claims 1 to 11 and an impeller rotated by the electric motor.

13. An air conditioner comprising an outdoor unit and an indoor unit connected to the outdoor unit, wherein at least one of the outdoor unit and the indoor unit has the blower according to claim 12.

14. A method for manufacturing an electric motor, the method including: a step of forming a rotor; a step of forming a stator surrounding the rotor; a step of attaching a lead wire to a lead wire support component; a step of separating the lead wire support component into a holding portion that holds the lead wire and an outlet portion that draws the lead wire to the outside; and a molding step of molding the stator, the holding portion, and the outlet portion with a molding resin.

15. The method for manufacturing an electric motor according to claim 14, wherein the holding portion has a first engaging portion, and the outlet portion has a second engaging portion having a shape that can engage with the first engaging portion.

16. The method for manufacturing an electric motor according to claim 14, wherein in the lead wire support component, the holding portion and the outlet portion are integrated by an adhesive, and the holding portion and the outlet portion are separated by melting the adhesive.

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