Stator

Abstract

A stator (10) comprises: a stator core (24) having a plurality of teeth (22) that extend radially; a plurality of insulators (16) that are mounted to the plurality of teeth; and a plurality of coil winding parts (18) that are wound around the plurality of teeth with the insulators therebetween. Each insulator has a pair of first insulating parts (30) that extend in the axial direction of the stator and that are arranged on both sides of the teeth in a tangential direction of the stator core, and a second insulating part (32) that extends in the tangential direction of the stator core, that is positioned on one side of the teeth in the axial direction of the stator core, and that joins the pair of first insulating parts. The space between each pair of first insulating parts is open on the other side in the axial direction of the stator core, and ends (30A) of the first insulating parts on the opposite side from the second insulating part protrude on the other side with respect to the teeth in the axial direction of the stator core.

Description

Stator CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-017407, filed February 7, 2024, the entire contents of which are incorporated herein by reference.

[0002] The technology of the present disclosure relates to a stator of a rotating electric machine.

[0003] In the technical field of stators for rotating electrical machines, there is a stator that includes a stator core having a plurality of radially extending teeth, a plurality of insulators attached to the plurality of teeth, and a plurality of windings wound around the plurality of teeth via the insulators. Among these types of stators, there is one insulator that includes a pair of first insulating portions extending in the axial direction of the stator core and arranged on both sides of the teeth in the tangential direction of the stator core, and a second insulating portion that extends in the tangential direction of the stator core, arranged on one side of the teeth in the axial direction of the stator core, and connects the pair of first insulating portions, with the space between the pair of first insulating portions being open to the other side in the axial direction of the stator core (see, for example, JP 2018-198515 A).

[0004] As a result of detailed investigations by the inventors, the following problem was discovered: In the stator having the above configuration, if the end of each first insulating portion opposite the second insulating portion terminates at the same position as the end face of the other side of the tooth portion in the axial direction of the stator core, the winding winding portion comes into contact with the end face of the other side of the tooth portion, which may result in insufficient insulation of the tooth portion from the winding winding portion.

[0005] The technique of the present disclosure provides a stator that can ensure insulation of the teeth from the winding portion.

[0006] A stator according to one aspect of the disclosed technology comprises a stator core having a plurality of radially extending tooth portions, a plurality of insulators attached to the plurality of tooth portions, and a plurality of winding winding portions wound around the plurality of tooth portions via each of the insulators, each of the insulators having a pair of first insulating portions extending in the axial direction of the stator core and arranged on both sides of the tooth portions in the tangential direction of the stator core, and a second insulating portion extending in the tangential direction of the stator core and arranged on one side of the tooth portions in the axial direction of the stator core, connecting the pair of first insulating portions, the space between the pair of first insulating portions being open to the other side of the axial direction of the stator core, and the end of each of the first insulating portions opposite the second insulating portion protruding to the other side of the tooth portions in the axial direction of the stator core.

[0007] According to the technique of the present disclosure, a stator is provided that can ensure insulation of the teeth from the winding portion.

[0008] 1 is a plan view of a stator according to the first embodiment. FIG. 2 is a plan view of a stator component according to the first embodiment. FIG. 3 is a plan view of a core member according to the first embodiment. FIG. 4 is a perspective view showing a state after the insulator according to the first embodiment has been assembled to the core member. FIG. 5 is a perspective view showing a state before the insulator according to the first embodiment has been assembled to the core member. FIG. 6 is a longitudinal sectional view schematically showing a state after the insulator according to the first embodiment has been assembled to the core member. FIG. 7 is a perspective view showing a state after the insulator according to the second embodiment has been assembled to the core member. FIG. 8 is an explanatory view schematically illustrating a process of assembling the insulator according to the second embodiment to the core member. FIG. 9 is a perspective view showing a state after the insulator according to the third embodiment has been assembled to the core member. FIG. 10 is an explanatory view schematically illustrating a process of assembling the insulator according to the third embodiment to the core member. FIG. 11 is a perspective view showing a state after the insulator according to the fourth embodiment has been assembled to the core member. FIG. 12 is an explanatory view schematically illustrating a process of assembling the insulator according to the fourth embodiment to the core member. FIG. 13 is an explanatory view schematically illustrating a process of assembling the insulator according to the fourth embodiment to the core member. FIG. 14 is a perspective view showing a state after the insulator according to the fourth embodiment has been assembled to the core member. FIG. 15 is a perspective view showing a state after the insulator according to the fifth embodiment has been assembled to the core member. FIG. 16 is an explanatory view schematically illustrating a process of assembling the insulator according to the fifth embodiment to the core member. 10A and 10B are perspective views showing a state after the insulator according to the sixth embodiment has been assembled to a core member, plan views showing a state after the insulator according to the sixth embodiment has been assembled to a core member, and explanatory views schematically illustrating a process of assembling the insulator according to the sixth embodiment to a core member.

[0009] First Embodiment First, a first embodiment of the technology of the present disclosure will be described.

[0010] As shown in FIG. 1 , a stator 10 according to the first embodiment includes a plurality of stator components 12. The stator 10 is configured by combining a plurality of stator components 12 in an annular shape. FIG. 1 shows the configuration of half of the stator 10. The stator 10 is applied to a brushless motor. Brushless motors may be used for any purpose. Examples of brushless motors include fan motors, pump drive motors, and compressor motors.

[0011] In each figure, the X direction indicates the tangential direction of the stator 10, the Y direction indicates the radial direction of the stator 10, and the Z direction indicates the axial direction of the stator 10. In the following description, the circumferential direction of the stator 10 refers to the direction around the central axis of the stator 10. The tangential direction, radial direction, axial direction, and circumferential direction of the stator core 24, which will be described later, are the same directions as the tangential direction, radial direction, axial direction, and circumferential direction of the stator 10, respectively.

[0012] 2 and 3 , each stator component 12 includes a core member 14, an insulator 16, and a winding winding portion 18. The core member 14 is formed in a T-shape in a plan view and has a core back portion 20 and teeth portions 22. The core back portion 20 extends in the circumferential direction of the stator core 24, and the teeth portions 22 extend inward in the Y direction from the center of the core back portion 20. The tip portions of the teeth portions 22 are free ends, and the base ends of the teeth portions 22 are connected to the core back portion 20.

[0013] A stator core 24 (see FIG. 1) is formed by combining a plurality of core members 14 in an annular shape. In other words, the stator core 24 is formed by having a plurality of core members 14 divided in the circumferential direction of the stator core 24. When the stator core 24 is formed, the plurality of core back portions 20 form an annular portion 26 (see FIG. 1) that is the outer periphery of the stator core 24, and the plurality of tooth portions 22 extend radially from the center of the stator core 24. Slots 28 (see FIG. 1) are formed between the plurality of tooth portions 22.

[0014] The insulator 16 is attached to the tooth portion 22. The insulator 16 is made of resin. Examples of resins that can be used to form the insulator 16 include polyimide, polyamide, polyphenylene sulfide (PPS), and polybutylene terephthalate (PBT). The resin that can be used to form the insulator 16 may be any resin.

[0015] The winding portion 18 is wound around the tooth portion 22 via the insulator 16. The winding portion 18 is formed by winding a wire around the tooth portion 22 in the Y direction.

[0016] 3, an inner surface 20A is formed in the core back portion 20, and side surfaces 22A are formed in the tooth portions 22. The inner surface 20A is the surface on the inner circumferential side of the core back portion 20, extends in the X direction and the Z direction, and faces inward in the Y direction. The side surface 22A extends in the Y direction and the Z direction, and faces the X direction.

[0017] The configuration of the insulator 16 will be described in more detail below. In each drawing, an arrow Z1 indicates one side in the Z direction, and an arrow Z2 indicates the other side in the Z direction.

[0018] As shown in Figures 4 and 5, the insulator 16 has a pair of first insulating portions 30 and a second insulating portion 32. Each of the pair of first insulating portions 30 extends in the Z direction. The pair of first insulating portions 30 is arranged on both sides of the tooth portion 22 in the X direction, and covers each of the side surfaces 22A of the tooth portion 22 on both sides in the X direction. The second insulating portion 32 extends in the X direction. The second insulating portion 32 is arranged on one side of the tooth portion 22 in the Z direction, and connects the ends of the pair of first insulating portions 30 on one side in the Z direction. The second insulating portion 32 covers the tooth portion 22 from one side in the Z direction. The space between the pair of first insulating portions 30 is open to the other side in the Z direction.

[0019] An end 30A of each first insulating portion 30 opposite the second insulating portion 32 (i.e., an end 30A of each first insulating portion 30 on the other side in the Z direction) protrudes to the other side in the Z direction relative to the tooth portion 22. That is, the end 30A of each first insulating portion 30 is formed as a protrusion that protrudes to the other side in the Z direction beyond the tooth portion 22.

[0020] Each first insulating portion 30 has a protrusion 34 that protrudes from an end portion 30A of the first insulating portion 30 toward the tooth portion 22. Each protrusion 34 is disposed on the other side of the tooth portion 22 in the Z direction. The pair of protrusions 34 protrude to opposite sides in the X direction. The formation of the pair of protrusions 34 on the pair of first insulating portions 30 restricts movement of the insulator 16 attached to the tooth portion 22 to one side in the Z direction. In other words, the pair of protrusions 34 are formed as anti-slip portions for preventing the insulator 16 from slipping off the tooth portion 22. The pair of protrusions 34 may be in contact with the end surface 22B of the tooth portion 22 on the other side in the Z direction, or may have a gap between them.

[0021] Each first insulating portion 30 also has a third insulating portion 36 that extends in the X direction from an outer end of the first insulating portion 30 in the Y direction along the inner surface 20A of the core back portion 20. The third insulating portion 36 is formed over the entire length of the first insulating portion 30 in the Z direction. That is, the third insulating portion 36 is formed from one end of the first insulating portion 30 to the other end in the Z direction. The third insulating portion 36 covers the inner surface 20A of the core back portion 20 from the inside in the Y direction.

[0022] The insulator 16 is flexible overall, and can be attached to the teeth 22 from one side in the Z direction by deforming the pair of first insulating parts 30 in the X direction.

[0023] As described above in detail, in the first embodiment, each insulator 16 includes a pair of first insulating portions 30 arranged on either side of the tooth portion 22 in the X direction and a second insulating portion 32 connecting the ends of the pair of first insulating portions 30 on one side in the Z direction. The end 30A of each first insulating portion 30 opposite the second insulating portion 32 protrudes toward the other side in the Z direction relative to the tooth portion 22 (see FIG. 6 ). Therefore, a longer distance (i.e., creepage distance L) can be ensured between the end 30A of the first insulating portion 30 and the winding portion 18 compared to when the end 30A of each first insulating portion 30 terminates at the same position as the end face 22B of the tooth portion 22 on the other side in the Z direction. This ensures insulation of the tooth portion 22 from the winding portion 18 (i.e., insulation of the end face 22B of the tooth portion 22 on the other side in the Z direction).

[0024] Each first insulating portion 30 has a protrusion 34 that protrudes toward the tooth portion 22 from an end portion 30A of the first insulating portion 30 opposite the second insulating portion 32. Each protrusion 34 is disposed on the other side of the tooth portion 22 in the Z direction. Therefore, the pair of protrusions 34 can limit movement of the insulator 16 attached to the tooth portion 22 to one side in the Z direction.

[0025] Each first insulating portion 30 also has a third insulating portion 36 that extends in the X direction from the outer end of the first insulating portion 30 in the Y direction along the inner surface 20A of the core back portion 20. The third insulating portion 36 covers the inner surface 20A of the core back portion 20 from the inside in the Y direction. This ensures insulation of the inner surface 20A of the core back from the winding winding portion 18.

[0026] Second Embodiment Next, a second embodiment of the technique of the present disclosure will be described.

[0027] In the second embodiment, the configuration of the insulator 16 is modified from that of the first embodiment as follows. That is, as shown in Figures 7 and 8, the insulator 16 has flexible second insulating portions 32, and by bending the second insulating portions 32, the pair of first insulating portions 30 can be deformed in the X direction. The insulator 16 can be attached to the tooth portion 22 from one side in the Z direction in a state in which the width between the end portions 30A of the pair of first insulating portions 30 on the other side in the Z direction is expanded in the X direction by bending the second insulating portions 32.

[0028] An example of a configuration in which the second insulating portion 32 is flexible is that the thickness dimension in the Z direction of the second insulating portion 32 is smaller than the thickness dimension in the X direction of each first insulating portion 30.

[0029] In this way, when the second insulating portion 32 is flexible, the pair of first insulating portions 30 can be deformed in the X direction by bending the second insulating portion 32. This allows the width between the end portions 30A on the other side in the Z direction of the pair of first insulating portions 30 to be expanded in the X direction by bending the second insulating portion 32, making it possible to easily attach the insulator 16 to the tooth portion 22 from one side in the Z direction.

[0030] Furthermore, when the force applied to the pair of first insulating portions 30 in the X direction is released, the restoring force of the second insulating portion 32 causes the pair of first insulating portions 30 to return to their original positions, so that the insulator 16 can be maintained in a state attached to the tooth portion 22.

[0031] Third Embodiment Next, a third embodiment of the technique of the present disclosure will be described.

[0032] In the third embodiment, the configuration of the insulator 16 is modified as follows compared to the first embodiment. That is, as shown in Figures 9 and 10, a recess 40 that opens to one side in the Z direction is formed in the center of the second insulating part 32 in the X direction. The recess 40 penetrates in the Y direction. As an example, the cross-sectional shape of the recess 40 when viewed from the Y direction is V-shaped, but it may be any shape.

[0033] In this way, when the recess 40 that opens to one side in the Z direction is formed in the center of the second insulating portion 32 in the X direction, the pair of first insulating portions 30 can be deformed in the X direction by bending the second insulating portion 32 starting from the recess 40. This allows the width between the end portions 30A on the other side in the Z direction of the pair of first insulating portions 30 to be expanded in the X direction by bending the second insulating portion 32, making it possible to easily attach the insulator 16 to the tooth portion 22 from one side in the Z direction.

[0034] Furthermore, when the force applied to the pair of first insulating portions 30 in the X direction is released, the restoring force of the second insulating portion 32 causes the pair of first insulating portions 30 to return to their original positions, so that the insulator 16 can be maintained in a state attached to the tooth portion 22.

[0035] The recess 40 is formed in the center of the second insulating portion 32 in the X direction, but may be formed at an end portion in the X direction of the second insulating portion 32. Furthermore, a plurality of recesses 40 may be formed in the second insulating portion 32.

[0036] Fourth Embodiment Next, a fourth embodiment of the technique of the present disclosure will be described.

[0037] In the fourth embodiment, the configuration of the insulator 16 is modified as follows compared to the first embodiment. That is, as shown in Figures 11 and 12, recesses 42 that open to the other side in the Z direction are formed on both end portions of the second insulating portion 32 in the X direction. Each recess 42 penetrates in the Y direction. The cross-sectional shape of each recess 42 as viewed from the Y direction is, for example, V-shaped, but may be any shape.

[0038] In this way, when the recesses 42 that open to the other side in the Z direction are formed on both end portions of the second insulating portion 32 in the X direction, the pair of first insulating portions 30 can be deformed in the X direction by bending the second insulating portion 32 starting from the recesses 42. This allows the width between the end portions 30A on the other side in the Z direction of the pair of first insulating portions 30 to be expanded in the X direction by bending the second insulating portion 32, making it possible to easily attach the insulator 16 to the tooth portion 22 from one side in the Z direction.

[0039] Furthermore, when the force applied to the pair of first insulating portions 30 in the X direction is released, the restoring force of the second insulating portion 32 causes the pair of first insulating portions 30 to return to their original positions, so that the insulator 16 can be maintained in a state attached to the tooth portion 22.

[0040] Although a pair of recesses 42 are formed in the second insulating portion 32, a single recess 42 may be formed.

[0041] Furthermore, the recesses 42 are formed at the ends of the second insulating portion 32 in the X direction, but may be formed in the center in the X direction of the second insulating portion 32. Furthermore, the number of recesses 42 formed in the second insulating portion 32 may be any number.

[0042] Fifth Embodiment Next, a fifth embodiment of the technique of the present disclosure will be described.

[0043] In the fifth embodiment, the configuration of the insulator 16 is modified as follows compared to the first embodiment: That is, as shown in Figures 13 and 14, a notch 44 is formed in the inner corner of the connection portion between each first insulating portion 30 and each protrusion 34.

[0044] When the notches 44 are formed in the inner corners of the connection between each first insulating portion 30 and each protrusion 34 in this manner, the pair of protrusions 34 can be rotated from a state in which they protrude in the other direction in the Z direction, starting from the notches 44, to a state in which they face each other in the X direction. Therefore, the insulator 16 can be attached to the tooth portion 22 from one side in the Z direction with the pair of protrusions 34 protruding in the other direction in the Z direction, starting from the notches 44, and then the pair of protrusions 34 can be rotated from the notches 44 as a start point to a state in which they face each other in the X direction. This makes it possible to prevent the pair of protrusions 34 from interfering with the tooth portion 22 when attaching the insulator 16 to the tooth portion 22, and also eliminates the need to deform the pair of first insulating portions 30 in the X direction, making it possible to easily attach the insulator 16 to the tooth portion 22 from one side in the Z direction.

[0045] In addition, after rotating the pair of protrusions 34 so that they face each other in the X direction starting from the notch 44, adhesive may be applied to the notch 44 to fix the pair of protrusions 34 so that they face each other in the X direction.

[0046] Furthermore, the teeth 22 may be press-fitted into the inside of the pair of first insulating parts 30 .

[0047] Sixth Embodiment Next, a sixth embodiment of the technique of the present disclosure will be described.

[0048] In the sixth embodiment, the configuration of the insulator 16 is changed as follows compared to the first embodiment. That is, as shown in Figures 15 to 17 , in the sixth embodiment, the protrusion 34 (see Figures 4 to 6 ) is omitted from each first insulating portion 30, and each first insulating portion 30 is formed linearly from the end on the second insulating portion 32 side to the end on the opposite side from the second insulating portion 32.

[0049] As an example, the second insulating portion 32 is located outside the pair of first insulating portions 30 in the Y direction, and connects the ends of the pair of first insulating portions 30 on one side in the Z direction and on the outside in the Y direction.

[0050] In this way, since each first insulating portion 30 is formed in a straight line from the end on the second insulating portion 32 side to the end on the opposite side from the second insulating portion 32, when attaching the insulator 16 to the tooth portion 22, there is no need to deform the pair of first insulating portions 30 in the X direction, and the insulator 16 can be easily attached to the tooth portion 22 from one side in the Z direction.

[0051] The teeth 22 may be press-fitted into the inside of the pair of first insulating parts 30 .

[0052] Furthermore, among the configurations described in the above embodiments, configurations that can be combined may be combined as appropriate.

[0053] The above describes one embodiment of the technology of the present disclosure, but the present invention is not limited to the above, and it goes without saying that the present invention can be implemented in various modifications within the scope of the gist of the present disclosure.

[0054] Below, supplementary notes are provided regarding the technology of the present disclosure. (Supplementary Note 1) A stator (10) comprising: a stator core (24) having a plurality of radially extending tooth portions (22); a plurality of insulators (16) attached to the plurality of tooth portions; and a plurality of winding winding portions (18) wound around the plurality of tooth portions via the insulators, wherein each of the insulators has: a pair of first insulating portions (30) extending in the axial direction of the stator core and arranged on both sides of the tooth portions in a tangential direction of the stator core; and a second insulating portion (32) extending in the tangential direction of the stator core and arranged on one side of the tooth portions in the axial direction of the stator core, connecting the pair of first insulating portions, wherein the space between the pair of first insulating portions is open to the other side in the axial direction of the stator core, and an end (30A) of each first insulating portion opposite to the second insulating portion protrudes to the other side of the tooth portions in the axial direction of the stator core. (Supplementary Note 2) The stator according to Supplementary Note 1, wherein each of the first insulating portions has a protruding portion (34) that protrudes toward the tooth portion from an end of the first insulating portion opposite the second insulating portion and is arranged on the other side of the tooth portion in the axial direction of the stator core. (Supplementary Note 3) The stator according to Supplementary Note 1 or Supplementary Note 2, wherein the second insulating portion is flexible. (Supplementary Note 4) The stator according to Supplementary Note 1 or Supplementary Note 2, wherein the second insulating portion is formed with a recess (40) that opens to one side of the axial direction of the stator core. (Supplementary Note 5) The stator according to Supplementary Note 1 or Supplementary Note 2, wherein the second insulating portion is formed with a recess (42) that opens to the other side of the axial direction of the stator core. (Supplementary Note 6) The stator according to Supplementary Note 2, wherein a notch (44) is formed in an inner corner of a connection portion between each of the first insulating portions and each of the protruding portions. (Supplementary Note 7) The stator according to Supplementary Note 1, wherein each of the first insulating portions is formed linearly from an end portion on the second insulating portion side to an end portion on the opposite side from the second insulating portion.(Appendix 8) The stator according to any one of Appendices 1 to 7, wherein the stator core has a plurality of core members (14) divided in the circumferential direction of the stator core, each of the core members has a core back portion (20) that constitutes an outer circumferential portion (26) of the stator core, the teeth portions extend from the core back portion toward the radially inner side of the stator core, and each of the first insulating portions has a third insulating portion (36) that covers an inner circumferential surface (20A) of the core back portion.

Claims

1. A stator (10) comprising: a stator core (24) having a plurality of radially extending tooth portions (22); a plurality of insulators (16) attached to the plurality of tooth portions; and a plurality of winding winding portions (18) wound around the plurality of tooth portions via the insulators, wherein each of the insulators has: a pair of first insulating portions (30) extending in the axial direction of the stator core and arranged on both sides of the tooth portion in the tangential direction of the stator core; and a second insulating portion (32) extending in the tangential direction of the stator core and arranged on one side of the tooth portion in the axial direction of the stator core, connecting the pair of first insulating portions, wherein the space between the pair of first insulating portions is open to the other side of the axial direction of the stator core, and an end (30A) of each first insulating portion opposite to the second insulating portion protrudes to the other side of the tooth portion in the axial direction of the stator core.

2. A stator as set forth in claim 1, wherein each of the first insulating portions has a protrusion (34) that protrudes toward the tooth portion from an end of the first insulating portion opposite the second insulating portion and is positioned on the other side of the tooth portion in the axial direction of the stator core.

3. The stator according to claim 1 or 2, wherein the second insulating portion is flexible.

4. A stator according to claim 1 or claim 2, wherein the second insulating portion is formed with a recess (40) that opens to one side in the axial direction of the stator core.

5. A stator according to claim 1 or claim 2, wherein the second insulating portion is formed with a recess (42) that opens to the other side in the axial direction of the stator core.

6. A stator according to claim 2, wherein a notch (44) is formed in an inner corner of a connection between each of said first insulating portions and each of said protrusions.

7. The stator according to claim 1, wherein each of the first insulating portions is formed linearly from an end on the second insulating portion side to an end on the opposite side from the second insulating portion.

8. A stator as claimed in any one of claims 1 to 7, wherein the stator core has a plurality of core members (14) divided in the circumferential direction of the stator core, each of the core members having a core back portion (20) constituting the outer periphery (26) of the stator core, the teeth portions extending from the core back portion towards the radially inward side of the stator core, and each of the first insulating portions having a third insulating portion (36) covering the inner circumferential surface (20A) of the core back portion.

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