Stator and motor

Abstract

The present invention increases the winding space of a coil and improves the output of a motor.　This stator (200) comprises a magnetic body (210), an insulator (300), and a coil (400), wherein: the magnetic body (210) comprises a magnetic pole part (230), a ring (220), and a spoke (250) that connects the magnetic pole part (230) and the ring; the spoke (250) comprises a side part (253) and an end part (211a) in the X direction of a rotational axis; the insulator (300) comprises a plate (350) that covers the end part of the spoke (250); the width (w1) of the plate (350) is greater than the width (w2) of the spoke (250) in the circumferential direction; a conductive wire (401) of the coil (400) is wound around the spoke (250); the side part (253) of the spoke (250) faces the conductive wire (401); the end part (211a) of the spoke (250) is narrower than the width (w3) of another part (213a) of the spoke (250) in the circumferential direction; and the plate (350) is fitted to the end part (211a) of the spoke (250).

Description

Stator and Motor

[0001] The present invention relates to a stator and a motor.

[0002] Conventionally, in the stator that constitutes a motor, a coil is wound around teeth that are arranged intermittently at a predetermined pitch, via an insulator, but it is required that the heat of the coil be dissipated to the outside of the motor by the driving current.

[0003] For this reason, a motor has been proposed in which the upper and lower parts of the teeth are covered with upper and lower corner covers, and a resin part is interposed between the teeth and the upper and lower corner covers, thereby ensuring a heat transfer path from the coil conductor to the teeth and efficiently dissipating heat from the motor (see, for example, Patent Document 1).

[0004] JP 2013-66314 A

[0005] However, in the motor of Patent Document 1, the coil conductor is covered with a resin part and upper and lower corner covers, which narrows the winding space for the coil conductor, making it unsuitable for improving motor output. Therefore, one example of the objective of the present invention is to provide a stator that can expand the winding space for the coil conductor, and a motor using such a stator.

[0006] The stator of the present invention comprises a magnetic body, an insulator covering the magnetic body, and a coil, wherein the magnetic body comprises a magnetic pole portion, a ring, and spokes connecting the magnetic pole portion and the ring, the spokes having end and side portions in the direction of the rotation axis, and the insulator comprises a plate covering the end portions of the spokes, wherein the width of the plate is greater than the width of the spokes in the circumferential direction, a conducting wire forming the coil is wound around the spokes via the plate, the side portions of the spokes face the conducting wire, the end portions of the spokes are narrower in width than other portions of the spokes in the circumferential direction, and the plate is fitted with the end portions of the spokes.

[0007] FIG. 1 is a longitudinal sectional view showing the overall configuration of a motor including a stator according to a first embodiment of the present invention, which is an example of the present invention; FIG. 2 is a perspective view showing a state in which an insulator is attached to a stator core according to a first embodiment of the present invention (the coil wire is not wound around it); FIG. 3 is an exploded perspective view showing the configuration of a stator core and an insulator according to a first embodiment of the present invention, which is an example of the present invention; FIG. 4 is a perspective view showing the overall configuration of a stator core according to a first embodiment of the present invention, as viewed obliquely from above; FIG. 5 is a partially enlarged perspective view showing the configuration of a stator core according to a first embodiment of the present invention, which is an example of the present invention; FIG. 6 is a partially enlarged perspective view showing the configuration of spokes of a stator core according to a first embodiment of the present invention, which is an example of the present invention; FIG. 7 is a perspective view showing the overall configuration of an upper plate of an insulator according to a first embodiment of the present invention, as viewed obliquely from above; FIG. 8 is a perspective view showing the overall configuration when the upper plate of the insulator according to a first embodiment of the present invention is turned upside down; FIG. 9 is a partially enlarged perspective view showing a state in which the upper plate of the insulator according to a first embodiment of the present invention is attached to a stator core. 1 is a partially enlarged perspective view showing a state in which a gap is formed between a spoke of a stator core and a conductor wire when the conductor wire is wound around the spoke via an upper plate and a lower plate of an insulator according to a first embodiment of the present invention; FIG. 2 is a partially enlarged perspective view showing a configuration of an insulator according to a second embodiment of the present invention; FIG. 3 is a partially enlarged perspective view showing a state in which a gap is formed between a spoke of a stator core and a conductor wire when the conductor wire is wound around the spoke via an upper plate and a lower plate of an insulator according to the second embodiment of the present invention; FIG. 4 is a partially enlarged perspective view showing a configuration of an insulator according to a third embodiment of the present invention; FIG. 5 is a partially enlarged perspective view showing the shape of an insulator according to the third embodiment of the present invention and a state in which a coil conductor wire is wound around the spoke; FIG. 6 is a partially enlarged perspective view showing the shape of an insulator according to a fourth embodiment of the present invention; FIG. 7 is a partially enlarged sectional view showing the shape of an insulator according to the fourth embodiment of the present invention;

[0008] <Embodiments> Hereinafter, first to fourth embodiments, which are examples of the present invention, will be described in order with reference to the drawings.

[0009] Fig. 1 is a longitudinal cross-sectional view showing the overall configuration of a motor 100 including a stator 200 according to a first embodiment of the present invention. Fig. 2 is a perspective view showing a state in which an insulator 300 is attached to a stator core 210 according to the first embodiment of the present invention (the conductor 401 of a coil 400 is not wound). Fig. 3 is an exploded perspective view showing the configurations of the stator core 210 and the insulator 300 according to the first embodiment of the present invention.

[0010] Fig. 4 is a perspective view showing the overall configuration of stator core 210 according to a first embodiment of the present invention, as viewed obliquely from above. Fig. 5 is a partially enlarged perspective view showing the configuration of stator core 210 according to the first embodiment of the present invention. Fig. 6 is a partially enlarged perspective view showing the configuration of spokes 211a of stator core 210 according to the first embodiment of the present invention.

[0011] Fig. 7 is a perspective view showing the overall configuration of the upper plate 310 of the insulator 300 according to the first embodiment, which is an example of the present invention, when viewed from diagonally above. Fig. 8 is a perspective view showing the overall configuration of the upper plate 310 of the insulator 300 according to the first embodiment, which is an example of the present invention, when the upper plate 310 is turned upside down. Fig. 9 is a partially enlarged perspective view showing a state in which the upper plate 310 of the insulator 300 according to the first embodiment, which is an example of the present invention, is attached to the stator core 210.

[0012] Figure 10 is a partially enlarged oblique view showing a state in which a gap S is formed between the spoke 250 and the conductor 401 when the conductor 401 of the coil 400 is wound around the spoke 250 of the stator core 210 via the upper plate 310 and the lower plate 360 ​​of the insulator 300 according to the first embodiment, which is an example of the present invention.

[0013] In the description of the first to fourth embodiments of the present invention, for convenience of explanation, the direction of arrow a along the rotation axis X will be referred to as the upper side or one side. The direction of arrow b along the rotation axis X will be referred to as the lower side or the other side. Here, the direction of arrows ab will be referred to as the up-down direction or the direction of the rotation axis X. However, the upper side and the lower side do not necessarily coincide with the upper side and the lower side in the vertical direction. Furthermore, the direction of arrows c and d will be referred to as the radial direction, the direction of arrow c away from the rotation axis X will be referred to as the outer circumferential side or one radial side, and the direction of arrow d approaching the rotation axis X will be referred to as the inner circumferential side or the other radial side. Furthermore, the direction of rotation around the rotation axis X will be referred to as the circumferential direction.

[0014] 1, a motor 100 according to a first embodiment of the present invention is an outer rotor type three-phase brushless DC motor having an overall cylindrical shape. Note that motor 100 is not limited to a three-phase brushless DC motor, and may be, for example, a three-phase brushless DC motor or other motors.

[0015] The motor 100 includes a base 110 , a shaft 130 , a bearing device 150 , a rotor 170 , and a stator 200 .

[0016] <Base> The base 110 of the motor 100 includes a substantially disk-shaped plate 111, a cylindrical outer peripheral portion (hereinafter referred to as the outer peripheral wall) 112 extending a predetermined length upward (in the direction of arrow a) from the radially outer end (in the direction of arrow c) of the plate 111, and a cylindrical inner peripheral portion (hereinafter referred to as the inner peripheral wall) 113 protruding a predetermined length upward (in the direction of arrow a) from the radially inner end (in the direction of arrow d) on the other radial side of the plate 111.

[0017] Plate 111 is disposed between inner peripheral wall 113 and outer peripheral wall 112 of base 110 in the radial direction, and the end of inner peripheral wall 113 is formed to be longer (higher) in the direction of rotation axis X than the end of outer peripheral wall 112 in the axial direction. In addition, inner peripheral wall 113 has an end face (hereinafter referred to as the "upper end face") on the upper side (direction of arrow a), and the inner peripheral portion of substrate (hereinafter referred to as circuit board) 190 is fixed to this upper end face by adhesive or the like, and an intermediate portion between the inner peripheral portion and the outer peripheral portion of circuit board 190 is fixed to insulator 300.

[0018] The circuit board 190 is formed of a thin, annular member. The circuit board 190 is provided with one or more electronic components that constitute a control circuit (not shown) that drives the rotor 170 of the motor 100, and is formed with one or more wires that are electrically connected to the one or more electronic components. The one or more wires are formed on the circuit board 190 as a single layer or multiple wiring layers, and the circuit board 190 is a so-called printed wiring board.

[0019] <Shaft> Shaft 130 is rotatably supported by upper bearing 151 and lower bearing 153 of bearing device 150. The upper end (in the direction of arrow a) of shaft 130 is fixed to inner periphery 174 of magnetic body 171 of the rotor (hereinafter referred to as rotor yoke) by press-fitting, adhesive, or the like.

[0020] <Bearing Device> Bearing device 150 is formed by an upper bearing 151, a lower bearing 153, and a sleeve 155. Upper bearing 151 and lower bearing 153 are, for example, ball bearings. Note that bearings 151 and 153 are not limited to ball bearings and may be various other bearings, such as sleeve bearings.

[0021] Incidentally, a coil spring sp is disposed between the upper end of the bearing 151 in the bearing device 150 and the disk portion 173 that is part of the rotor yoke 171 as an elastic member that applies a preload to the bearing 151 .

[0022] The sleeve 155 of the bearing device 150 is made of metal and has a cylindrical shape. The sleeve 155 is fixed to the inner circumferential surface (the radially inner surface) of the inner circumferential wall 113 of the base 110 by press-fitting or adhesive. The sleeve 155 may be formed integrally with the base 110 in a state where it is inserted into the inner circumferential wall 113.

[0023] Upper bearing 151 is disposed above shaft 130 (in the direction of arrow a) and rotatably supports the upper portion of shaft 130 (in the direction of arrow a) relative to sleeve 155. Lower bearing 153 is disposed below shaft 130 (in the direction of arrow b) and rotatably supports the lower portion of shaft 130 (in the direction of arrow b) relative to sleeve 155. Thus, shaft 130 is rotatably supported relative to sleeve 155 via the two bearings 151 and 153.

[0024] <Rotor> Rotor 170 is fixed to the upper end (direction of arrow a) of shaft 130. Rotor 170 has rotor yoke 171 and magnet 175. Rotor yoke 171 has outer circumferential portion 172 provided on the outer circumferential side, disk portion 173 provided in the center, and inner circumferential portion 174 provided on the inner circumferential side.

[0025] Outer periphery 172 of rotor yoke 171 is a cylindrical portion formed of a soft magnetic material and disposed coaxially with shaft 130. An annular magnet 175 is fixed to the inner circumferential surface (the radially inner surface) of outer periphery 172 of rotor yoke 171, coaxially with outer periphery 172. Outer periphery 172 functions as a portion that prevents leakage of the magnetic field of magnet 175.

[0026] The disk portion 173 of the rotor yoke 171 is an approximately disk-shaped portion that extends from the upper end of the outer circumferential portion 172 radially inward (in the direction of arrow d) toward the shaft 130 and closes the upper side (in the direction of arrow a) of the outer circumferential portion 172.

[0027] The inner peripheral portion 174 of the rotor yoke 171 is a cylindrical portion that extends a predetermined length from the radially inner end (in the direction of arrow d) of the disk portion 173 toward the bearing 151. In the radial direction, the dimension (inner diameter) of the inner peripheral portion 174 of the rotor yoke 171 is formed to be slightly smaller than the dimension (outer diameter) of the shaft 130. In the rotation axis direction X, the length of the inner peripheral portion 174 of the rotor yoke 171 is smaller than the length of the outer peripheral portion 172 of the rotor yoke 171, and is disposed on the upper end side of the shaft 130 relative to the bearing 151.

[0028] The upper end (in the direction of arrow a) of shaft 130 is press-fitted into the inner peripheral surface (diametrically inner surface) of inner peripheral portion 174 of rotor yoke 171, thereby fixing rotor yoke 171 and shaft 130 together.

[0029] <Stator> The stator 200 is fixed to the outer peripheral surface (radially outer surface) of the sleeve 155 of the bearing device 150. The stator 200 has a structure having, for example, 12 slots, and includes a stator core 210, an insulator 300, and a coil 400.

[0030] 2 and 3, in the stator 200, an insulator 300 is attached to the stator core 210, but is not attached so as to cover the entire periphery of the stator core 210. Note that, for ease of viewing, the coil 400 is not shown in FIGS.

[0031] Specifically, in stator 200 , an upper plate 310 of insulator 300 is attached to the upper side of stator core 210 , and a lower plate 360 ​​of insulator 300 is attached to the lower side of stator core 210 .

[0032] <Stator Core> As shown in Fig. 4, stator core 210 as a magnetic body is formed by a laminate of multiple electromagnetic steel sheets formed of a soft magnetic material. However, stator core 210 is not limited to this, and stator core 210 may be formed by, for example, compression molding. Furthermore, stator core 210 as a magnetic body (multiple electromagnetic steel sheets) may be covered with an insulating coating made of resin such as varnish or an inorganic material.

[0033] Stator core 210 has a ring 220, magnetic pole portions 230, and spokes 250 that extend radially from ring 220 toward the outer periphery (in the direction of arrow c) and connect ring 220 and magnetic pole portions 230. The spokes 250 and magnetic pole portions 230 form so-called teeth.

[0034] The stator core 210 is integrally formed with a ring 220, a magnetic pole portion 230, and spokes 250. However, for ease of explanation, the stator core 210 will be explained separately as the ring 220, the magnetic pole portion 230, and the spokes 250.

[0035] <Ring> Ring 220 of stator core 210 is provided on the inner circumferential side (direction of arrow d) and has an annular upper end surface 220a on the upper side (direction of arrow a) and a lower end surface 220b on the lower side (direction of arrow b).

[0036] The upper end surface 220a of the ring 220 is part of the upper surface of the uppermost electromagnetic steel sheet among the multiple stacked electromagnetic steel sheets, and is a flat surface along the horizontal direction perpendicular to the direction of the rotation axis X. The lower end surface 220b of the ring 220 is part of the lower surface of the lowermost electromagnetic steel sheet among the multiple stacked electromagnetic steel sheets, and is a flat surface along the horizontal direction perpendicular to the direction of the rotation axis X. Therefore, the upper end surface 220a and the lower end surface 220b are parallel to each other.

[0037] An inner peripheral surface 220i of this ring 220 is tightly fitted and fixed to the outer peripheral surface of the sleeve 155 (FIG. 1). As shown in FIGS. 3 and 4, a plurality of spokes 250 extend radially from an outer peripheral surface 220g of the ring 220 toward the outer periphery (in the direction of arrow c).

[0038] <Magnetic pole portion> The magnetic pole portion 230 of the stator core 210 is provided radially on the outer circumferential side (direction of arrow c) which is the tip of the spoke 250, and is a portion located at the end of the outer circumferential side (direction of arrow c) opposite the ring 220 of the stator core 210.

[0039] The magnetic pole portion 230 is formed integrally with the tip of the spoke 250 and has portions that protrude clockwise and counterclockwise in the circumferential direction. The distance between two adjacent protruding portions of the magnetic pole portion 230 in the circumferential direction is narrower than the distance between adjacent spokes 250.

[0040] The magnetic pole portion 230 has an upper end surface 230a on the upper side (in the direction of arrow a) of the portion protruding in the clockwise and counterclockwise directions, a lower end surface 230b on the lower side (in the direction of arrow b), an outer peripheral surface 230g, and an inner surface 230i.

[0041] The upper end surface 230a of the magnetic pole portion 230 is part of the upper surface of the uppermost electromagnetic steel sheet among the multiple stacked electromagnetic steel sheets, and is a flat surface along the horizontal direction perpendicular to the direction of the rotation axis X. The lower end surface 230b of the magnetic pole portion 230 is part of the lower surface of the lowermost electromagnetic steel sheet among the multiple stacked electromagnetic steel sheets, and is a flat surface along the horizontal direction perpendicular to the direction of the rotation axis X. Therefore, the upper end surface 230a and the lower end surface 230b are parallel to each other.

[0042] The outer surface 230g of the magnetic pole portion 230 is a curved surface that follows the inner surface of the magnet 175, and a predetermined gap (magnetic gap) is formed between the outer surface 230g and the inner surface of the magnet 175 in the radial direction.

[0043] The inner surface 230i of the magnetic pole portion 230 is inclined from both side ends of the outer surface 230g toward the spoke 250 and toward the outer surface 220g of the ring 220, and extends to the side surface 253c of the side portion 253 of the spoke 250.

[0044] <Spokes> The spokes 250 extend radially from the outer peripheral surface 220 g of the ring 220 toward the magnetic pole portion 230 on the outer peripheral side (direction of arrow c), and are portions that connect the ring 220 and the magnetic pole portion 230 .

[0045] The spokes 250 extend in the direction of the rotation axis X and have a rectangular parallelepiped shape in a plan view. However, this is not limited to this, and the spokes 250 may have, for example, a tapered trapezoid shape in a plan view that gradually becomes thinner from the ring 220 toward the magnetic pole portion 230.

[0046] Each spoke 250 has a first end 251 as an end having an upper end surface 251 a, a second end 252 as an end having a lower end surface 252 b, and a side portion 253 having a side surface 253 c between the first end 251 and the second end 252. The two side surfaces 253 c of the side portion 253 of the spoke 250 face back to back.

[0047] 5 mainly shows the spokes 250 and magnetic pole portions 230 of the stator core 210, while in FIG. 6 the magnetic pole portions 230 of the stator core 210 are not shown, and only the spokes 250 are mainly shown.

[0048] The first end 251 (FIG. 4) of the spoke 250 is a spoke 211a of one of the electromagnetic steel plates 211 arranged at one end in the direction of the rotation axis X (in the direction of the arrow a) among the plurality of laminated electromagnetic steel plates that make up the stator core 210.

[0049] Therefore, the upper end surface 251a of the first end 251 (FIG. 4) of the spoke 250 means the upper end surface 211at of the spoke 211a of one of the electromagnetic steel plates 211 that constitutes part of the stator core 210, and is a flat surface along the horizontal direction that intersects (is perpendicular to) the direction of the rotation axis X. The upper end surface 211at of the spoke 211a is connected to be flush with the upper end surface 220a of the ring 220 and the upper end surface 230a of the magnetic pole portion 230.

[0050] Similarly, the second end 252 (FIG. 4) of the spoke 250 is a spoke 217a of one of the electromagnetic steel sheets 217, which is arranged at the other end in the direction of the rotation axis X (in the direction of the arrow b) among the multiple electromagnetic steel sheets stacked to form the stator core 210.

[0051] Therefore, lower end surfaces 252b of second ends 252 (FIG. 4) of spokes 250 refer to lower end surfaces 217at of spokes 217a of some of the electromagnetic steel plates 217 that make up stator core 210, and are flat surfaces along the horizontal direction that intersects (is perpendicular to) the direction of rotation axis X. Lower end surfaces 217at of spokes 217a are connected flush with lower end surfaces 220b of ring 220 and lower end surfaces 230b of magnetic pole portions 230.

[0052] The upper end surface 251a of the first end 251 of the spoke 250 (the upper end surface 211at of the spoke 211a of the electromagnetic steel plate 211) and the lower end surface 252b of the second end 252 of the spoke 250 (the lower end surface 217at of the spoke 217a of the electromagnetic steel plate 217) are parallel to each other.

[0053] In this case, the side surface 253c of the side portion 253 of the spoke 250 means the aggregate of the side surfaces 213at of the spokes 213a of the multiple electromagnetic steel plates 213 sandwiched between the uppermost electromagnetic steel plate 211 and the lowermost electromagnetic steel plate 217.

[0054] Therefore, the side surface 253c of the side portion 253 of the spoke 250 is an aggregate of the side surfaces 213at of the spokes 213a of the multiple electromagnetic steel plates 213, and each side surface 213at is flush with each other and forms a flat surface overall along the direction of the rotation axis X.

[0055] Therefore, the two side surfaces 253c of the side portions 253 of the spokes 250 (the multiple side surfaces 213at of the multiple electromagnetic steel plates 213) are parallel to each other. However, this is not limitative, and since the side surfaces 253c of the side portions 253 of the spokes 250 are exposed to the insulator 300, the side surfaces 253c do not have to be completely flush.

[0056] In this way, the side surface 253c of the side portion 253 of the spoke 250 (the multiple side surfaces 213at of the multiple electromagnetic steel plates 213) is a portion exposed by the upper plate 310 and the lower plate 360 ​​of the insulator 300 described later (Figure 2), but the conducting wire 401 of the coil 400 is curved and faces the side surface 253c of the spoke 250 with a predetermined gap between them, and is wound around the side surface 253c of the spoke 250 without contacting it.

[0057] As shown in Figure 6, among the multiple electromagnetic steel plates that make up the stator core 210, the width w3 of the spokes 211a of the electromagnetic steel plate 211 that is arranged at the top and the width w5 of the spokes 217a of the electromagnetic steel plate 217 that is arranged at the bottom are formed smaller (thinner) in the circumferential direction than the width w2 of the side surfaces 213at of the spokes 213a of the other multiple electromagnetic steel plates 213 that are located between the two electromagnetic steel plates 211 and the electromagnetic steel plate 217.

[0058] In other words, the spokes 211a of the uppermost electromagnetic steel plate 211 and the spokes 217a of the lowermost electromagnetic steel plate 217 are formed narrower in the circumferential direction than the spokes 213a of the other electromagnetic steel plates 213.

[0059] Each spoke 211a of the electromagnetic steel plate 211 has an upper end surface 211at on the upper side (in the direction of arrow a) and side surfaces 211as extending downward (in the direction of arrow b) perpendicular to the upper end surface 211at from both end portions of the upper end surface 211at. The two side surfaces 211as have the same size and shape and are parallel to and facing each other.

[0060] Similarly, each spoke 217a of the electromagnetic steel plate 217 has a lower end surface 217at on the lower side (in the direction of arrow b) and side surfaces 217as extending upward (in the direction of arrow a) from both end portions of the lower end surface 217at and perpendicular to the lower end surface 217at. The two side surfaces 217as have the same size and shape and are parallel to and back-to-back with each other.

[0061] Spokes 211a of electromagnetic steel sheet 211 and spokes 217a of electromagnetic steel sheet 217 are identical in size and shape. Therefore, the width w3 of spokes 211a of electromagnetic steel sheet 211 and the width w5 of spokes 217a of electromagnetic steel sheet 217 described above are the same.

[0062] <Coil> Coil 400 (FIGS. 1 and 10) is formed of conductive wire 401 wound around spokes 250 of stator core 210 via upper plate 310 and lower plate 360 ​​of insulator 300.

[0063] The conductor 401 of the coil 400 starts winding from a winding start position (not shown) on the inner side of the spoke 250 (in the direction of arrow d), moves toward the outer side (in the direction of arrow c), returns to the inner side (in the direction of arrow d), and then is wound around the adjacent spoke 250.

[0064] In this case, the conductor 401 of the coil 400 faces but does not contact the side surface 253c of the spoke 250 (the side surface 213at of the plurality of electromagnetic steel plates 213) via the upper plate 310 and the lower plate 360 ​​of the insulator 300.

[0065] <Insulator> Next, a description will be given of the configuration of insulator 300 in stator 200. As shown in Fig. 3 , insulator 300 has upper plate 310 as a first plate attached to the upper side (direction of arrow a) of stator core 210, and lower plate 360 ​​as a second plate attached to the lower side (direction of arrow b) of stator core 210.

[0066] Ring 220, magnetic pole portion 230, and spokes 250 of stator core 210 are arranged in the vertical direction (the direction of arrows a and b) between upper plate 310 and lower plate 360 ​​of insulator 300. Since upper plate 310 and lower plate 360 ​​have the same shape, for convenience, only upper plate 310 will be described here, and a detailed description of lower plate 360 ​​will be omitted.

[0067] <Upper Plate> As shown in Figures 7 and 8, upper plate 310 has an annular portion (hereinafter referred to as the "upper annular plate") 320 that covers upper end surfaces 220a of rings 220 in stator core 210 from above (in the direction of arrow a), a portion (hereinafter referred to as the "upper rectangular plate") 350 that covers upper end surfaces 251a of spokes 250 from above (in the direction of arrow a), and a portion (hereinafter referred to as the "upper tip plate") 330 that covers upper end surfaces 230a of magnetic pole portions 230 from above (in the direction of arrow a).

[0068] Lower plate 360 ​​(Figure 3) also has a shape similar to that of upper plate 310, and includes an annular portion (hereinafter referred to as the lower annular plate) 380 that covers lower end surface 220b of ring 220 in stator core 210 from below (in the direction of arrow b), a portion (hereinafter referred to as the lower rectangular plate) 370 that covers lower end surface 252b (Figure 4) of second end 252 of spoke 250 from below (in the direction of arrow b), and a portion (hereinafter referred to as the lower tip plate) 390 that covers lower end surface 230b (Figure 4) of magnetic pole portion 230 from below (in the direction of arrow b).

[0069] In the upper plate 310, the upper annular plate 320, the upper rectangular plate 350, and the upper tip plate 330 are integrally formed. However, this is not a limitation, and the upper annular plate 320, the upper rectangular plate 350, and the upper tip plate 330 may be formed as separate members and attached to the stator core 210 individually. Similarly, in the lower plate 360, the lower annular plate 380, the lower rectangular plate 370, and the lower tip plate 390 are integrally formed. However, this is not a limitation, and the lower annular plate 380, the lower rectangular plate 370, and the lower tip plate 390 may be formed as separate members and attached to the stator core 210 individually.

[0070] <Upper annular plate> Upper annular plate 320 of upper plate 310 is a ring-shaped flat plate formed from a flat, annular plate-like member, and is a part that is fixed by adhesive or the like while in contact with upper end surface 220a of ring 220 of stator core 210. It is desirable that upper annular plate 320 be as thin as possible in order to increase the number of turns of conductive wire 401 of coil 400 or to increase the space in which conductive wire 401 is wound.

[0071] The dimension (inner diameter) of the inner circumferential portion of upper annular plate 320 is larger than the dimension (inner diameter) of the inner circumferential portion of ring 220 of stator core 210. That is, in this case, the inner circumferential portion of upper end surface 220a of ring 220 of upper annular plate 320 is exposed ( FIG. 2 ). However, this is not limited thereto, and the dimension (inner diameter) of the inner circumferential portion of upper annular plate 320 may be the same as or smaller than the dimension (inner diameter) of the inner circumferential portion of ring 220 of stator core 210.

[0072] The outer circumferential dimension (outer diameter) of the upper annular plate 320 is slightly larger than the outer circumferential dimension (outer diameter) of the ring 220 of the stator core 210. For example, the outer diameter of the upper annular plate 320 is larger than the outer circumferential dimension (outer diameter) of the ring 220 of the stator core 210 by a predetermined amount (for example, approximately 0.1 mm to 0.15 mm).

[0073] That is, in this case, the upper annular plate 320 protrudes slightly outward by about 0.1 mm to 0.15 mm from the outer peripheral surface 220g (FIGS. 2 and 4) of the ring 220. This is because the conducting wire 401 of the coil 400 is arranged with a predetermined gap from the outer peripheral surface 220g of the ring 220 in the radial direction, and contact with the outer peripheral surface 220g of the ring 220 is avoided.

[0074] <Upper rectangular plate> Upper rectangular plate 350 of upper plate 310 is a portion that is attached with an adhesive or the like while being in contact with upper end surfaces 251 a of spokes 250 of stator core 210. The radial length of upper rectangular plate 350 is the same as the radial length of spokes 250.

[0075] Upper rectangular plate 350 has a predetermined bending rigidity. By providing upper rectangular plate 350 with the predetermined bending rigidity, upper rectangular plate 350 can be prevented from warping upward (in the direction of arrow a) after being attached to upper end surfaces 251 a of spokes 250 (upper end surfaces 211 at of spokes 211 a of electromagnetic steel plate 211), and upper rectangular plate 350 is in close contact with upper end surfaces 251 a of spokes 250.

[0076] 7 and 8 , upper rectangular plate 350 is provided with wall portions 351 extending in the direction of rotation axis X from both circumferential end portions. Wall portions 351 have a rectangular shape in side view, and have a height in the direction of rotation axis X that corresponds to the thickness of one of spokes 211 a of electromagnetic steel sheets 211 and spokes 217 a of electromagnetic steel sheets 217 that form stator core 210.

[0077] The radial length between the inner surfaces of the two wall portions 351 of the upper rectangular plate 350 is the same as the radial length of the spokes 211 a of the electromagnetic steel sheet 211 and the spokes 217 a of the electromagnetic steel sheet 217 .

[0078] The two wall portions 351 of the upper rectangular plate 350 have the same height and thickness and are formed parallel to each other. Inside the two wall portions 351, the spokes 211 a of the electromagnetic steel sheet 211 and the spokes 217 a of the electromagnetic steel sheet 217 fit into the inner surfaces of the two wall portions 351, forming a space (accommodation portion) K that accommodates the spokes 211 a and the spokes 217 a.

[0079] The distance d1 (FIG. 8) between the two wall portions 351 of the upper rectangular plate 350 is the same as the width w3 (FIG. 6) of the spokes 211a of the electromagnetic steel sheet 211 and the width w5 (FIG. 6) of the spokes 217a of the electromagnetic steel sheet 217.

[0080] However, this is not limited to this, and the distance d1 between the two wall portions 351 may be slightly larger or slightly smaller than the width w3 of the spoke 211a and the width w5 of the spoke 217a, as long as it is a distance large enough to accommodate the spokes 211a and the spokes 217a.

[0081] That is, as long as the two wall portions 351 of the upper rectangular plate 350 can accommodate the spokes 211a and 217a, any of an intermediate fit, an interference fit, and a loose fit may be used.

[0082] Lower plate 360 ​​(FIG. 3) has lower rectangular plate 370 (FIG. 3) having the same structure as upper rectangular plate 350 of upper plate 310. Therefore, lower rectangular plate 370 has wall portion 371 (FIG. 9) having the same structure as wall portion 351 of upper rectangular plate 350.

[0083] 9, in the circumferential direction, width w1 of upper rectangular plate 350 including wall portion 351 is greater than width w2 (the distance between two side surfaces 213at (side surfaces 253c of side portions 253)) of spokes 213a of the multiple electromagnetic steel plates 213 that make up side portions 253 of spokes 250. Note that for convenience, FIG. 9 also illustrates a state in which upper tip plate 330 is separated from upper rectangular plate 350.

[0084] More specifically, in the circumferential direction, the width w1 of the upper rectangular plate 350 is greater than the width w3 of the spokes 211a of the electromagnetic steel plate 211 (FIG. 6) and the width w5 of the spokes 217a of the electromagnetic steel plate 217 (FIG. 6).

[0085] More specifically, the width w1 of the upper rectangular plate 350 in the circumferential direction is formed to be approximately 0.2 mm larger than the width w2 of the plurality of electromagnetic steel plates 213 that make up the spokes 250 in the circumferential direction.

[0086] That is, the upper rectangular plate 350 protrudes in the circumferential direction from the side surface 213at (the side surface 253c of the side portion 253) of the spoke 250 by a predetermined distance (0.1 mm).

[0087] However, this is not limited to this, and the amount of protrusion of the upper rectangular plate 350 from the side surface 213at (side surface 253c of side portion 253) of the spoke 250 may be 0.1 mm or less, as long as the conductive wire 401 of the coil 400 can maintain a curved non-contact state with the side surface 253c of the spoke 250 by a predetermined gap.

[0088] <Upper tip plate> As shown in Figures 7 and 8, the upper tip plate 330 of the upper plate 310 has a flat portion 331 (hereinafter referred to as the flat portion) having a flat surface that extends radially in the radial direction, and a protrusion 333 that is approximately rectangular parallelepiped in shape and is provided on the flat portion 331.

[0089] The flat portion 331 of the upper tip plate 330 has the same shape as the upper end surface 230a of the magnetic pole portion 230 (Figure 4), and has a curved surface 331g on the outermost side (hereinafter referred to as the "curved surface") and two inclined surfaces 331k that are inclined obliquely from both side ends of the curved surface 331g toward the upper rectangular plate 350.

[0090] Here, the flat surface portion 331 has the same shape as the upper end surface 230a of the magnetic pole portion 230 in the stator core 210, but is formed slightly larger than the upper end surface 230a.

[0091] Therefore, when the flat portion 331 of the upper tip plate 330 is fixed with adhesive or the like while in contact with the upper end surface 230a of the magnetic pole portion 230, the two inclined surfaces 331k will protrude slightly toward the ring 220 of the stator core 210.

[0092] Therefore, when the conducting wire 401 of the coil 400 is wound around the spokes 250 of the stator core 210, the two inclined surfaces 331k on the flat surface 331 of the upper tip plate 330 separate the conducting wire 401 of the coil 400 and the inner surface 230i (FIGS. 2 to 4) of the magnetic pole portion 230 by a predetermined gap, thereby preventing them from contacting each other. However, the curved surface 331g of the flat surface 331 and the outer circumferential surface 230g (FIG. 3) of the magnetic pole portion 230 are flush with each other.

[0093] The protruding portion 333 of the upper tip plate 330 is a portion that is integrally formed on the flat portion 331 and has a substantially rectangular parallelepiped shape. The protruding portion 333 can prevent the wire 401 of the coil 400 wound around the spokes 250 of the stator core 210 from becoming unwound.

[0094] <Procedure for Mounting Insulator to Stator Core> A procedure for mounting upper plate 310 and lower plate 360 ​​of insulator 300 to stator core 210 in motor 100 will be described.

[0095] In the radial direction, the length of spokes 211a of electromagnetic steel sheet 211 and the length of spokes 217a of electromagnetic steel sheet 217 are equal to the length of upper rectangular plate 350 of upper plate 310 and the length of lower rectangular plate 370 of lower plate 360.

[0096] Therefore, in motor 100 , spokes 211 a of electromagnetic steel plate 211 are housed in space K between two wall portions 351 , and upper plate 310 is positioned and attached to stator core 210 .

[0097] Thereafter, stator core 210 and upper plate 310 are attached and fixed together with adhesive or the like, thereby making it possible to integrate stator core 210 and upper plate 310 at an accurate position.

[0098] Similarly, in motor 100, spokes 217a of electromagnetic steel plate 217 are accommodated in space K between two wall portions 371 formed in lower rectangular plate 370 of lower plate 360, and lower plate 360 ​​is accurately positioned and attached to stator core 210.

[0099] Thereafter, stator core 210 and lower plate 360 ​​are fixed together with an adhesive or the like, thereby integrating stator core 210 and lower plate 360 ​​in an accurate position. Thus, in motor 100, upper plate 310 and lower plate 360 ​​can be fixed to stator core 210 in an accurate positioned state.

[0100] Furthermore, since the height of the two wall portions 351 in the upper rectangular plate 350 is the same as the thickness of the spokes 211a of the electromagnetic steel plate 211 located at the top of the stator core 210, the spokes 211a of the electromagnetic steel plate 211 are covered and accommodated in the space K between the two wall portions 351.

[0101] At this time, the two wall portions 351 of the upper rectangular plate 350 come into contact with the upper end surface of the electromagnetic steel sheet 213 located directly below the uppermost electromagnetic steel sheet 211. Furthermore, because the width w3 of the spokes 211a of the electromagnetic steel sheet 211 is the same as the distance d1 between the two wall portions 351 of the upper rectangular plate 350, the inner surfaces of the two wall portions 351 and the side surfaces 211as of the spokes 211a come into contact with no gaps. As a result, the motor 100 can be accommodated in the space K with the two wall portions 351 of the upper rectangular plate 350 and the spokes 211a of the electromagnetic steel sheet 211 in close contact with each other.

[0102] Therefore, upper rectangular plate 350 accommodates and covers spokes 211 a of electromagnetic steel plates 211 in stator core 210. Furthermore, upper rectangular plate 350 and spokes 211 a are integrated in close contact with each other, which can prevent the position of upper plate 310 from shifting circumferentially and radially relative to stator core 210.

[0103] Note that lower rectangular plate 370 is also accommodated in a state in which it completely covers spokes 217a of electromagnetic steel plates 217 in stator core 210. Furthermore, lower rectangular plate and spokes 217a are integrated in a tight contact state, which can prevent the position of lower plate 360 ​​from shifting circumferentially and radially relative to stator core 210.

[0104] In the above configuration, in motor 100 according to the first embodiment, as shown in FIG. 2 , side surfaces 253 c of side portions 253 of spokes 250 of stator core 210 are exposed from upper plate 310 and lower plate 360 ​​of insulator 300, and upper end surfaces 251 a ( FIG. 4 ) of spokes 250 are covered by upper rectangular plate 350 of upper plate 310, while lower end surfaces 252 b ( FIG. 4 ) of spokes 250 are covered by lower rectangular plate 370 of lower plate 360.

[0105] The width w1 (Figure 9) of the upper rectangular plate 350 of the upper plate 310 and the lower rectangular plate 370 of the lower plate 360 ​​is larger than the circumferential width w2 of the side surfaces 213at (side surfaces 253c of the side portions 253) of the multiple electromagnetic steel plates 213 that mainly constitute the spokes 250 of the stator core 210, and is formed to a size that extends approximately 0.1 mm beyond each of the two side surfaces 213at.

[0106] 10 , in motor 100, when conducting wire 401 of coil 400 is wound via upper plate 310 and lower plate 360 ​​of insulator 300, gap S is formed between conducting wire 401 and side surfaces 213at (side surfaces 253c of spokes 250) of multiple electromagnetic steel sheets 213 that form spokes 250. Thus, motor 100 can prevent conducting wire 401 of coil 400 from coming into contact with side surfaces 213at of electromagnetic steel sheets 213 that form spokes 250.

[0107] Furthermore, in motor 100, side surface 213at (side surface 253c of side portion 253 of spoke 250) of electromagnetic steel plate 213 constituting spoke 250 is exposed to insulator 300, so the number of turns of conducting wire 401 of coil 400 wound around spoke 250, or the space (area) occupied by the coil formed after winding, can be increased by the amount of the thickness of insulator 300 compared to conventional cases, thereby improving motor output.

[0108] The upper rectangular plate 350 of the upper plate 310 is a flat plate with a flat upper end surface, and the wall portion 351 and the upper end surface form a corner that is approximately right-angled, but the conductor wire 401 of the coil 400 does not bend 90 degrees along the corner, but is wound in a curved state relative to the corner.

[0109] Therefore, a gap S (Figure 10) is reliably formed between the conductor 401 of the coil 400 and the side surface 213at (side surface 253c of the side portion 253 of the spoke 250) of the electromagnetic steel plate 213 that constitutes the spoke 250, thereby preventing a short circuit from occurring between the conductor 401 and the side surface 253c of the spoke 250.

[0110] Furthermore, the flat upper rectangular plate 350 is preferably as thin as possible to increase the space occupied by the coil 400 formed later, but has sufficient bending rigidity to prevent warping of the upper end surfaces 251a of the spokes 250.

[0111] This allows the upper rectangular plate 350 in the motor 100 to remain in close contact with the upper end surfaces 251a of the spokes 250, thereby preventing the space occupied by the subsequently formed coils 400 from being reduced and improving motor output.

[0112] Furthermore, in motor 100, the circumferential width w3 of spokes 211a in electromagnetic steel plate 211 of stator core 210 and the circumferential width w5 of spokes 217a in electromagnetic steel plate 217 are formed to be smaller (narrower (thinner)) than the circumferential width w2 of the other multiple electromagnetic steel plates 213.

[0113] This makes it possible to minimize the amount by which wall portions 351 and 371 of upper rectangular plate 350 of upper plate 310 and lower rectangular plate 370 of lower plate 360 ​​protrude outward from side surfaces 213at of multiple electromagnetic steel sheets 213. Thus, motor 100 can expand the space occupied by coils 400, thereby improving motor output.

[0114] Furthermore, in the insulator 300, the wall portion 351 of the upper rectangular plate 350 and the wall portion 371 of the lower rectangular plate 370 cover the spokes 211a of the electromagnetic steel plate 211, which is the first end of the stator core 210, and the spokes 217a of the electromagnetic steel plate 217, which is the second end.

[0115] Therefore, in motor 100, when the conductor 401 of coil 400 is wound, wall portion 351 of upper rectangular plate 350 and wall portion 371 of lower rectangular plate 370 make it easier for the conductor 401 to maintain parallelism with side surfaces 213at (side surfaces 253c of side portions 253 in spokes 250) of multiple electromagnetic steel plates 213, thereby further reducing the occurrence of short circuits in the conductor 401.

[0116] Second Embodiment Next, a second embodiment of the present invention will be described. A motor 500 according to the second embodiment has a basic structure in common with the motor 100 according to the first embodiment, and the following description will focus on the differences.

[0117] Fig. 11 is a partially enlarged perspective view showing the configuration of an insulator 300A according to a second embodiment of the present invention. Fig. 12 is a partially enlarged perspective view showing a state in which a gap S is formed between a spoke 250 and a conductive wire 401 of a coil 400 when the conductive wire 401 is wound around the spoke 250 of a stator core 210 via an upper plate 310A and a lower plate 360A of the insulator 300A according to the second embodiment of the present invention.

[0118] As shown in FIG. 11, in which parts corresponding to those in FIG. 9 are given the same reference numerals, a motor 500 according to the second embodiment has an insulator 300A instead of the insulator 300 according to the first embodiment.

[0119] The insulator 300A includes an upper plate 310A and a lower plate 360A. In this case, the upper plate 310A and the lower plate 360A have the same shape, so only the upper plate 310A will be described and a detailed description of the lower plate 360A will be omitted.

[0120] The upper plate 310A has the same basic structure as the upper plate 310 of the insulator 300 in the first embodiment, and also has two wall portions 351 on both sides of the upper rectangular plate 350A.

[0121] The side surfaces 351c of the two wall portions 351 of the upper rectangular plate 350A are provided with a plurality of recesses (or protrusions) 351r and a plurality of flat portions 351p. The recesses 351r are aligned in the radial direction. The recesses 351r formed on the side surfaces 351c of the wall portions 351 of the upper rectangular plate 350A have a width sufficient to accommodate the conducting wires 401 of the coil 400.

[0122] The plurality of recesses 351r provided in the wall portion 351 of the upper rectangular plate 350A have a width (circumferential width) and depth (radial width) that can accommodate a portion of the conductor 401 of the coil 400. However, the recesses 351r of the wall portion 351 may have a width and depth that can accommodate the entire conductor 401.

[0123] Additionally, adjacent recesses 351r of the multiple recesses 351r are spaced apart by a predetermined distance in the radial direction. Flat portions (hereinafter referred to as flat portions) 351p serving as convex portions are formed between the recesses 351r in the radial direction, and the flat portions 350p have a predetermined width (the same width as the recesses 350r in this embodiment). That is, the recesses 351r and the flat portions 351p are alternately provided in the radial direction on the side surface 351c of the wall portion 351 of the upper rectangular plate 350A. Note that as long as the recesses 351r and the flat portions 351p are alternately provided, the area of ​​the recesses 351r and the width of the flat portions 351p may be different.

[0124] The flat portion 351p can be regarded as a protrusion with respect to the recess 351r. Therefore, the side surface of the upper rectangular plate 350A has a plurality of protrusions 351p arranged in the radial direction with respect to the recess 351r of the wall portion 351.

[0125] On the side surfaces 351c of the two wall portions 351 of the upper rectangular plate 350A, recesses 351r and recesses 351r are formed so as to face each other back to back in the circumferential direction or in the diagonal direction (a direction having a radial component and a circumferential component), and flat portions 351p and flat portions 351p are formed so as to face each other back to back in the circumferential direction.

[0126] Similarly to the upper plate 310A, the lower plate 360A also has recesses 350r and 350r arranged back to back in the circumferential direction or in an oblique direction (a direction having a radial component and a circumferential component), and flat portions 350p and 350p arranged back to back in the circumferential direction. The lower rectangular plate 370A also has two wall portions 371. The lower rectangular plate 370A has a plurality of recesses 371r and a plurality of flat portions 371p on a side surface 371c of the wall portion 371.

[0127] The plurality of recesses 371r and flat portions 371p provided on the wall portion 371 of the lower rectangular plate 370A are the same as the plurality of recesses 351r and flat portions 351p provided on the wall portion 351 of the upper rectangular plate 350A.

[0128] The plurality of recesses 371r and the plurality of flat portions 371p in the lower rectangular plate 370A are arranged to face the plurality of recesses 351r and the plurality of flat portions 351p in the upper rectangular plate 350A in the direction of the rotation axis X or in an oblique direction (a direction having a radial component and a circumferential component).

[0129] In the above configuration, the motor 500 of the second embodiment has the same advantages as the motor 100 of the first embodiment described above, and in addition, has the following advantages.

[0130] In motor 500, side surfaces 213at (side surfaces 253c of side portions 253 of spokes 250) of multiple electromagnetic steel plates 213 that make up the majority of spokes 250 are exposed to upper plate 310A and lower plate 360A of insulator 300A, and therefore conducting wire 401 of coil 400 can be wound in a housed state in recess 351r of upper rectangular plate 350A and recess 371r of lower rectangular plate 370A. This allows motor 500 to increase the number of turns of conducting wire 401 of coil 400 wound around spokes 250 or the space (area) occupied by the coil compared to conventional motors.

[0131] Thus, compared to conventional cases where insulators are attached around the entire circumference of the spokes, motor 500 can increase the number of turns of wire 401 of coil 400 or increase the space (area) occupied by the coil by using upper plate 310A and upper plate 310B of insulator 300A, thereby improving motor output.

[0132] In the motor 500, the conductor 401 of the coil 400 is wound while being accommodated in a recess 351r provided in the wall portion 351 of the upper rectangular plate 350A and a recess 371r provided in the wall portion 371 of the lower rectangular plate 370A.

[0133] At this time, the width w1 of the upper rectangular plate 350A and the lower rectangular plate 370A of the motor 500 is formed to be larger than the width w2 of the multiple electromagnetic steel plates 213, so although the conductor 401 approaches the side surfaces 213at of the multiple electromagnetic steel plates 213 (side surfaces 253c of the side portions 253 of the spokes 250), it is possible to avoid contact between the conductor 401 and the side surfaces 213at of the electromagnetic steel plates 213 and causing a short circuit.

[0134] In addition, in the motor 500, by accommodating the conductor 401 of the coil 400 in the recess 351r of the upper rectangular plate 350A and the recess 371r of the lower rectangular plate 370A, the conductor 401 can be wound efficiently while preventing the attachment position of the conductor 401 of the coil 400 relative to the spoke 250 from shifting radially.

[0135] The upper rectangular plate 350A of the upper plate 310A is a flat plate with a flat upper end surface, and the side surface 351c of the wall portion 351 on which the recess 351r and the flat portion 351p are formed forms a substantially right-angled corner with the upper end surface. However, in reality, the conductor wire 401 of the coil 400 is not bent 90 degrees along the corner, but is wound in a curved state at the corner.

[0136] Therefore, as shown in Figure 12, a gap S is reliably formed between the conductor 401 of the coil 400 and the side surfaces 213at (side surfaces 253c of the side portions 253 of the spokes 250) of the multiple electromagnetic steel plates 213 that make up the majority of the spokes 250, thereby preventing a short circuit from occurring between the conductor 401 and the side surfaces 213at of the electromagnetic steel plates 213.

[0137] Furthermore, although it is desirable for the flat upper rectangular plate 350A to be as thin as possible in order to increase the space occupied by the coil 400 formed later, it also has sufficient bending rigidity to prevent the upper rectangular plate 350A from warping upward (in the direction of arrow a) when attached to the upper end surface 211at (Figures 5 and 6) of the spoke 250.

[0138] As a result, in the motor 500, the upper rectangular plate 350A is maintained in close contact with the upper end surfaces 211at of the spokes 250, preventing a reduction in the number of turns of the conductor 401 of the coil 400 and a reduction in the space occupied by the coil, thereby contributing to improved motor output.

[0139] Third Embodiment Next, a third embodiment of the present invention will be described. A motor 600 according to the third embodiment has a basic structure in common with the motor 100 according to the first embodiment, and the following description will focus on the differences.

[0140] Fig. 13 is a partially enlarged perspective view showing the configuration of an insulator 300B according to a third embodiment, which is an example of the present invention. Fig. 14 is a perspective view showing a state in which, when a conducting wire 401 of a coil 400 is wound around an upper rectangular plate 350B of the insulator 300B according to the third embodiment, which is an example of the present invention, a gap S is formed between the conducting wire 401 and side surfaces 213at (side surfaces 253c of side portions 253 of the spokes 250) of the plurality of electromagnetic steel plates 213 constituting the spokes 250.

[0141] As shown in FIG. 13, a motor 600 according to the third embodiment has an insulator 300B instead of the insulator 300 according to the first embodiment.

[0142] The insulator 300B includes an upper plate 310B and a lower plate 360B. In this case, the upper plate 310B and the lower plate 360B have the same shape, so only the upper plate 310B will be described and a detailed description of the lower plate 360B will be omitted.

[0143] The upper plate 310B has a basic structure in common with the upper plate 310 of the insulator 300 in the first embodiment and the upper plate 310A of the insulator 300A in the second embodiment.

[0144] Therefore, the upper plate 310B is provided with a plurality of recesses 351r and a plurality of flat portions 351p formed along the direction of the rotation axis X on the side surfaces 351c of the wall portions 351 on both sides of the upper rectangular plate 350B. These recesses 351r and flat portions 351p are the same as those in the second embodiment.

[0145] An upper end surface 350Bt on one side (the direction of arrow a) of an upper rectangular plate 350B of the upper plate 310B is provided with a plurality of recesses 352r extending in the circumferential direction and a plurality of flat portions 352p. The plurality of recesses 352r and the plurality of flat portions 352p are alternately provided in the radial direction of the upper end surface 350Bt.

[0146] The recess 352r and the flat portion 352p provided on the upper end surface 350Bt of the upper rectangular plate 350B are formed in a shape that extends linearly in the circumferential direction, but are not limited to this and may be formed in a curved shape in the circumferential direction.

[0147] The recesses 352r have the same width and depth as the recesses 351r formed on the side surface 351c of the wall portion 351 of the upper rectangular plate 350B. The flat portions 352p have the same width as the flat portions 351p formed on the side surface 351c of the wall portion 351 of the upper rectangular plate 350B.

[0148] The widths of the recessed portions 351r, 352r, and the widths of the flat portions 351p, 352p are larger than the dimensions (diameter) of the conducting wire 401 of the coil 400. However, this is not limitative, and the widths of the recessed portions 351r, 352r, and the widths of the flat portions 351p, 352p may be the same as the dimensions (diameter) of the conducting wire 401 of the coil 400.

[0149] Furthermore, the flat portion 352p refers to the upper end surface 350Bt of the upper rectangular plate 350B, and can also be considered as the protrusion 352p when the recess 352r is used as a reference. Therefore, it can also be said that the upper rectangular plate 350B has a plurality of protrusions 352p formed along the circumferential direction of the upper end surface 350Bt.

[0150] Furthermore, the multiple recesses 352r and multiple flat portions 352p formed on the upper end surface 350Bt of the upper rectangular plate 350B are arranged so as to connect with the multiple flat portions 351p and recesses 351r formed on the side surface 351c of the wall portion 351.

[0151] Specifically, recess 352r formed on top end surface 350Bt of upper rectangular plate 350B is connected to flat portion 351p formed on side surface 351c of wall portion 351. Furthermore, flat portion 352p formed on top end surface 350Bt of upper rectangular plate 350B is connected to recess 351r formed on side surface 351c of wall portion 351.

[0152] Next, a description will be given of a case where the conductor 401 of the coil 400 is wound around the spokes 250 of the stator core 210 in the motor 600 according to the third embodiment. As shown in Fig. 14, in this motor 600, approximately half the diameter of the conductor 401 is accommodated in a plurality of recesses 352r formed in the upper end surface 350Bt of the upper rectangular plate 350B, and the conductor 401 is wound so as to overlap with the flat portion 351p of the side surface 351c of the wall portion 351.

[0153] This allows the conductor 401 of the coil 400 and the side surfaces 213at (side surfaces 253c of the side portions 253 of the spokes 250) of the multiple electromagnetic steel plates 213 that make up the majority of the spokes 250 to be separated by a predetermined gap, preventing them from coming into contact with each other and causing a short circuit.

[0154] In the motor 600, the conductive wire 401 can be accommodated in the recess 352r in the upper end surface 350Bt of the upper rectangular plate 350B.

[0155] It should be noted that the motor 600 of the third embodiment can naturally achieve the same advantages as the motor 100 of the first embodiment and the motor 500 of the second embodiment.

[0156] Fourth Embodiment Next, a fourth embodiment of the present invention will be described. A motor 700 according to the fourth embodiment has a basic structure in common with motor 100 according to the first embodiment and motor 500 according to the second embodiment, and the following description will focus on the differences.

[0157] Fig. 15 is a partially enlarged perspective view showing the configuration of an insulator 300C according to a fourth embodiment of the present invention, and Fig. 16 is a partially enlarged cross-sectional view showing the shape of the insulator 300C according to the fourth embodiment of the present invention.

[0158] As shown in FIGS. 15 and 16, in which parts corresponding to those in FIG. 9 are designated by the same reference numerals, a motor 700 according to the fourth embodiment has an insulator 300C instead of the insulator 300 according to the first embodiment.

[0159] The insulator 300C includes an upper plate 310C and a lower plate 360C. In this case, the upper plate 310C and the lower plate 360C have the same shape, so only the upper plate 310C will be described and a detailed description of the lower plate 360C will be omitted.

[0160] The upper plate 310C has a basic structure in common with the upper plate 310 of the insulator 300 in the first embodiment and the upper plate 310A of the insulator 300A in the second embodiment.

[0161] The upper rectangular plate 350C of the upper plate 310C extends radially from the upper annular plate 320 toward the outer periphery (in the direction of arrow c). The upper end surface of the upper rectangular plate 350C includes a flat side end surface 353v extending from the upper end 353p (in the direction of arrow a) of each of the two wall portions 351 to the upper end 353g (in the direction of arrow a) in the direction of the rotation axis X, two curved surfaces 353Cs extending in an arc from the end 353g of the side end surface 353v to form an upwardly convex shape, and a flat surface 353Cf connecting the two curved surfaces 353Cs in the circumferential direction. In this case, the side surface 351c of the wall portion 351 and the side end surface 353v form the same plane.

[0162] The curved surface 353Cs of the upper rectangular plate 350C is curved at an angle such that the conducting wire 401 of the coil 400 can be easily aligned along the curved surface 353Cs when winding the conducting wire 401. The flat surface 353Cf of the upper rectangular plate 350C is a flat surface that extends in a horizontal direction (circumferential direction) that intersects (is perpendicular to) the direction of the rotation axis X.

[0163] The upper rectangular plate 350C has two curved surfaces 353Cs smoothly and integrally connected to a flat surface 353Cf, forming an outwardly curved surface as a whole. Here, the ratio of the left curved surface 353Cs to the left half of the flat surface 353Cf is 4:1, and the ratio of the right curved surface 353Cs to the right half of the flat surface 353Cf is 4:1.

[0164] That is, overall, the ratio of the two curved surfaces 353Cs to the one flat surface 353Cf is 4:1, and the circumferential length of the two curved surfaces 353Cs is longer than the circumferential length of the flat surface 353Cf.

[0165] As a result, the conductor 401 of the coil 400 wound around the upper rectangular plate 350C can be wound smoothly at a gentle angle due to the presence of the curved surface 353Cs formed by the curved surfaces on the left and right sides which occupy a larger portion than the flat surface 353Cf, thereby preventing the conductor 401 from becoming unwound.

[0166] The upper rectangular plate 350C has a semicircular cross section formed by a bottom surface 353Cb, a side end surface 353v, a flat surface 353Cf, and a curved surface 353Cs. The flat surface 353Cf of the upper rectangular plate 350C and the upper end surface of the upper annular plate 320 form the same plane (FIG. 15).

[0167] As shown in Figure 16, the height (thickness) h1 between the flat surface 353Cf and the end 353g of the side end surface 353v of the upper rectangular plate 350C is greater than the height (thickness) h2 between the end 353g of the side end surface 353v of the upper rectangular plate 350C and the end 353p (bottom surface 353Cb) of the wall portion 351.

[0168] Therefore, the conductor 401 of the coil 400 is bent at a gentle angle by the curved surface 353Cs, which is higher than the side end surface 353v, and then extends in the direction of the rotation axis X along the flat side end surface 353v that is aligned with the direction of the rotation axis X.

[0169] This creates a predetermined gap between the side surface 213at (side surface 253c at side portion 253) of the electromagnetic steel plate 213, which constitutes the majority of the stator core 210, and the conductor wire 401 of the coil 400, thereby preventing the conductor wire 401 from coming into contact (short-circuiting) with the side surface 213at (side surface 253c).

[0170] In this way, in the motor 700, the conductor 401 of the coil 400 can be arranged along the curved surface 353Cs of the upper rectangular plate 350C, so that the conductor 401 of the coil 400 is not subjected to a load that would cause it to bend at a steep angle.

[0171] Furthermore, in motor 700, conductor 401 is wound as close as possible to spoke 250 without coming into contact with side surface 213at (side surface 253c of side portion 253 of spoke 250) of multiple electromagnetic steel plates 213 that make up the majority of spoke 250, thereby increasing the number of turns of conductor 401 and improving motor output.

[0172] Furthermore, in the motor 700, similarly to the second embodiment, the side surface 351c of the wall portion 351 of the upper rectangular plate 350C has a recess 351r and a flat portion 351p. This allows the motor 700 to gently curve the conducting wire 401 of the coil 400 along the curved surface 353Cs of the upper rectangular plate 350C and to accommodate the conducting wire 401 in the recess 351r.

[0173] Thus, although the conductor 401 of the coil 400 comes close to the side surfaces 213at (side surfaces 253c of the side portions 253 of the spokes 250) of the multiple electromagnetic steel plates 213 that make up the majority of the spokes 250, the motor 700 is able to avoid contact between the conductor 401 and the side surfaces 213at of the electromagnetic steel plates 213.

[0174] Furthermore, in the motor 700, the conductor 401 of the coil 400 is accommodated in the recess 351r provided in the wall portion 351 of the upper rectangular plate 350C and the recess 371r provided in the wall portion 371 of the lower rectangular plate 370C, thereby enabling the conductor 401 to be wound efficiently while preventing the attachment position of the conductor 401 of the coil 400 relative to the spoke 250 from shifting radially.

[0175] Furthermore, it is desirable that the flat upper rectangular plate 350C be as thin as possible to increase the space occupied by the coil 400 formed later, but it also has enough rigidity to prevent the upper rectangular plate 350C from warping upward (in the direction of arrow a) when attached to the spokes 211a of the electromagnetic steel plate 211 of the spokes 250.

[0176] As a result, in the motor 700, the upper rectangular plate 350C is maintained in close contact with the upper end surfaces 251a of the spokes 250, preventing a reduction in the number of turns of the conductor 401 of the coil 400 and a reduction in the space occupied by the coil, thereby improving motor output.

[0177] In the motor 700, the recess 351r and the flat portion 351p are formed in the wall portion 351 of the upper rectangular plate 350C, but this is not limited to this, and the wall portion 351 may have a flat surface without forming the recess 351r and the flat portion 351p.

[0178] <Other Embodiments> In the above, the motors 100, 500, 600, and 700, which are the preferred first to fourth embodiments of the motor of the present invention, have been described as outer rotor type motors, but the motor of the present invention is not limited to the configurations of the first to fourth embodiments, and may also be applied to inner rotor type motors.

[0179] Furthermore, in the second to fourth embodiments of the present invention, the recesses 351r and flat portions 351p of the same width are alternately arranged on the side surface 351c of the wall portion 351 of the upper rectangular plates 350A, 350B, and 350C. However, the present invention is not limited to this, and the width of the flat portions 351p may be made smaller than the width of the recesses 351r, or the width of the flat portions 351p may be made larger than the width of the recesses 351r and alternately arranged.

[0180] Furthermore, in the third embodiment of the present invention, a case has been described in which the recess 352r formed on the upper end surface 350Bt of the upper rectangular plate 350B is connected to the flat portion 351p formed on the side surface 351c of the wall portion 351, and the flat portion 352p formed on the upper end surface 350Bt is connected to the recess 351r formed on the side surface 351c of the wall portion 351.

[0181] However, the present invention is not limited to this, and the upper rectangular plate 350B may be arranged so that the recess 352r formed on the upper end surface 350Bt is connected to the recess 351r formed on the side surface 351c of the wall portion 351, and the flat portion 352p formed on the upper end surface 350Bt is connected to the flat portion 351p formed on the side surface 351c of the wall portion 351.

[0182] Furthermore, in the fourth embodiment of the present invention, the upper rectangular plate 350C has been described as having a curved surface with a semicircular cross section formed as a whole by the curved surfaces 353Cs and the flat surface 353Cf connecting the curved surfaces 353Cs. However, the present invention is not limited to this. The curved surface may be formed by connecting only the two curved surfaces 353Cs, or the end portions 353g of the side end surfaces 353v of the two wall portions 351 in a semicircular shape to form a curved surface as a whole.

[0183] In addition, those skilled in the art can appropriately modify the motor of the present invention and change the combination of various components in accordance with conventional knowledge. As long as such modifications still include the components of the present invention, they are of course included in the scope of the present invention.

[0184] 100, 500, 600, 700...motor, 110...base, 111...plate, 112...outer peripheral wall, 113...inner peripheral wall, 130...shaft, 150...bearing device, 151, 153...bearing, 155...sleeve, 170...rotor, 171...rotor yoke, 172...outer peripheral portion, 173...disk portion, 174...inner peripheral portion, 175...magnet, 190...circuit board, 200...stator, 210...stator Core, 220... ring, 220a... upper end surface, 220b... lower end surface, 220g... outer circumferential surface, 230... magnetic pole portion, 230a... upper end surface, 230b... lower end surface, 250... spokes, 251... first end portion, 251a... upper end surface, 252... second end portion, 252b... lower end surface, 253... side portion, 253c... side surface, 300, 300A, 300B, 300C... insulator, 310, 310A, 310B, 310C... upper plate, 360, 360A, 360B, 360C... lower plate, 400... coil, 401... conducting wire, 320... upper annular plate, 330... upper tip plate, 331... flat portion, 333... protrusion, 331g... curved surface, 331k... inclined surface, 350, 350A, 350B, 350C... upper rectangular plate, 351... wall portion, 351c... side surface, 350r, 351r, 352r...recess, 350p, 351p, 352p...flat portion (convex portion), 350Bt...upper end surface, 370, 370A, 370B, 370C...lower rectangular plate, 370r...recess, 370p...flat portion (convex portion), 353Cs...curved surface, 353Cf...flat surface, 353Cb...bottom surface, 353v...side end surface, 353g...end portion, sp...coil spring, h1, h2...height (thickness), w1, w2...width.

Claims

1. A stator comprising: a magnetic body; an insulator covering the magnetic body; and a coil; wherein the magnetic body comprises a magnetic pole portion, a ring, and spokes connecting the magnetic pole portion and the ring; wherein the spokes have end portions and side portions in the direction of the rotation axis; and wherein the insulator comprises a plate covering the end portions of the spokes; wherein the width of the plate is greater than the width of the spokes in the circumferential direction; a conducting wire forming the coil is wound around the spokes via the plate; the side portions of the spokes face the conducting wire; wherein the end portions of the spokes are smaller in width than other portions of the spokes in the circumferential direction; and wherein the plate is fitted with the end portions of the spokes.

2. A stator as claimed in claim 1, wherein said plates house the ends of said spokes.

3. A stator as described in claim 1 or 2, wherein the plate is a first plate and the ends of the spokes are first ends, the spokes have the ends as first ends and second ends in the rotational axis direction, the insulator has the plate as the first plate and a second plate covering the second ends of the spokes, and the second plate is fitted with the second ends.

4. A stator according to claim 3, wherein said second plate houses said second end.

5. A stator according to claim 1 or 2, wherein the plates are in contact with the side surfaces of the ends of the spokes.

6. A stator according to any one of claims 3 to 5, wherein a plurality of recesses or protrusions extending in the direction of the rotation axis are formed on the side surface of the first plate.

7. A stator according to any one of claims 3 to 6, wherein a plurality of recesses or protrusions extending in the circumferential direction are formed on the end face of the first plate.

8. A stator according to any one of claims 3 to 7, wherein the end face of the first plate in the radial direction is a curved surface.

9. A stator according to any one of claims 3 to 8, wherein the first plate has a flat plate shape.

10. A stator according to any one of claims 3 to 9, wherein the first plate has bending rigidity.

11. A motor comprising: a stator; and a rotor facing the stator, wherein the stator comprises a magnetic body, an insulator covering the magnetic body, and a coil, wherein the magnetic body comprises a magnetic pole portion, a ring, and spokes connecting the magnetic pole portion and the ring, wherein the spokes have end and side portions in the direction of the rotation axis, and the insulator comprises a plate covering the end of the spoke, wherein the width of the plate is greater than the width of the spokes in the circumferential direction, a conducting wire forming the coil is wound around the spokes, the side portions of the spokes face the conducting wire, and wherein the width of the end of the spoke is smaller than the width of other parts of the spokes in the circumferential direction, and the plate is fitted into the end of the spoke.

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