Mold stator

Abstract

The present invention is a mold stator in which displacement of a terminal exposed after integral molding is suppressed.　A stator core (1), an insulator (2), a coil (3), a terminal (4), and a terminal holder (5) are covered by a mold resin (6) and integrally molded. The terminal holder (5) comprises: a terminal holding section (51) having a terminal insertion hole (52) into which the terminal (4) is inserted; and a step section (53) surrounding an end section in the circumferential direction and an end section on the inner side in the radial direction in the terminal holding section (51). The stator core (1), the insulator (2), the coil (3), and the terminal holder (5) are covered by the mold resin (6) so that the surface on one axial end side of the terminal holding section (51) is exposed. A mold fill section (531) with which the step section (53) is equipped is filled with the mold resin (6) and is any one of a through hole passing through in the axial direction, a recess provided in the surface on one end side in the axial direction, and a bumpy area provided on the surface on one end side in the axial direction.

Description

Molded Stator

[0001] The present disclosure relates to molded stators.

[0002] Conventionally, a so-called molded stator has been known as a stator for a rotating electric machine, in which a stator core, a coil, and an insulator are integrally molded with a molded resin. In the conventional molded stator, terminals connected to the coil wound around the stator core and an insulator that holds the terminals are exposed from the molded resin so as to be electrically connected to a circuit board (see, for example, Patent Document 1).

[0003] Patent No. 4140628

[0004] However, conventional molded stators had a problem in that due to the difference in thermal expansion coefficient between the molding resin and the insulator or terminal, there was a risk that the position of the terminal or insulator could become misaligned due to contraction caused by cooling after integral molding.

[0005] The present disclosure discloses a technique for solving the above-mentioned problems, and aims to provide a molded stator that suppresses misalignment of exposed terminals after integral molding.

[0006] The molded stator of the present disclosure includes a stator core, an insulator, a coil, terminals, a terminal holder, and molded resin, and is a molded stator in which the stator core, the insulator, the coil, the terminals, and the terminal holder are integrally molded while being covered with molded resin, the coil is wound around the stator core via the insulator, the terminal is electrically connected to the coil and extends to one end side of the molded stator in the axial direction, and the terminal holder has a terminal holding portion having a terminal insertion hole into which the terminal is inserted, and a terminal holder at the end of the terminal holding portion in the circumferential direction of the molded stator. and a step portion surrounding the radially inner end of the molded stator, and contacting one axial end side of the insulator, the molded resin covers the stator core, the insulator, the coil, and the terminal holder so that the surface of one axial end side of the terminal holding portion is exposed, the step portion has a molded filling portion, which is either a through hole passing through the step portion in the axial direction, a recess provided on the surface of one axial end side of the step portion, or an uneven portion provided on the surface of one axial end side of the step portion, and is filled with molded resin.

[0007] The molded stator of the present disclosure is formed by integrally molding a stator core, an insulator, a coil, terminals, and a terminal holder covered with molded resin, the terminal holder comprising a terminal holding portion having a terminal insertion hole into which a terminal is inserted, and a step portion surrounding the circumferential end and the radially inner end of the terminal holding portion, the molded resin covering the stator core, the insulator, the coil, and the terminal holder so that the surface of one axial end side of the terminal holding portion is exposed, the step portion comprising a molded filling portion which is either a through hole passing through the step portion in the axial direction, a recess provided on the surface of one axial end side of the step portion, or an uneven portion provided on the surface of one axial end side of the step portion, and since it is filled with molded resin, misalignment of the exposed terminals after integral molding is suppressed.

[0008] 1. A perspective view of a stator according to embodiment 1. A perspective view of a stator core according to embodiment 1. A perspective view of an insulator according to embodiment 1. A top view of a ring assembly according to embodiment 1. A perspective view of a terminal according to embodiment 1. A top view of a terminal holder according to embodiment 1. A perspective view of the terminal holder according to embodiment 1, seen from one end side. A perspective view of the terminal holder according to embodiment 1, seen from the other end side. A cross-sectional view showing another example of a terminal holder and an insulator according to embodiment 1. A cross-sectional view of the terminal holder according to embodiment 1. A top view of a molded stator according to embodiment 1. A top view of a terminal holding portion in the molded stator according to embodiment 1. A cross-sectional view of the molded stator according to embodiment 1. A cross-sectional view of the molded stator according to embodiment 1. A top view of a motor according to embodiment 1. A cross-sectional view of the motor according to embodiment 1. A perspective view of a part of another example of a terminal holder according to embodiment 1, seen from the other end side. A cross-sectional view of another example of a terminal holder according to embodiment 1. A cross-sectional view of yet another example of a terminal holder according to embodiment 1.

[0009] Hereinafter, a molded stator according to an embodiment will be described in detail with reference to the drawings. Note that the same reference numerals in each drawing indicate the same or corresponding parts. In the following description, the stator before being integrally molded with mold resin will be referred to as the stator, and the stator after being integrally molded will be referred to as the molded stator.

[0010] Embodiment 1. FIG. 1 is a perspective view of a stator 100 according to embodiment 1, showing the stator before being integrally molded with molded resin. In the following description, the direction in which the rotation axis of a shaft (described later) extends is referred to as the axial direction of the stator and molded stator. FIG. 1 is a perspective view of the stator 100 as seen obliquely from above at one axial end. The stator 100 includes a stator core 1, an insulator 2, a coil 3, terminals 4, and a terminal holder 5. The terminals 4 extend toward one axial end of the stator 100. FIG. 2 is a perspective view of the stator core 1. The stator core 1 is made of a magnetic material such as an electromagnetic steel sheet and has a stator core groove 11 as shown in FIG. 2. FIG. 3 is a perspective view of the insulator 2. The insulator 2 is made of an insulating material such as resin and is used by sandwiching the stator core 1. In the stator 100, the insulators 2 contact the terminal holders 5 at their outer diameter support surfaces 21 on the outer diameter side, and support the terminal holders 5 by the outer diameter support surfaces 21. In the stator 100, some of the insulators 2 contact the terminal holders 5 at their inner diameter support surfaces 22 on the inner diameter side, and support the terminal holders 5 by the inner diameter support surfaces 22. The coils 3 are electric wires made of a conductive material such as aluminum or copper, and are wound around the stator core 1 via the insulators 2.

[0011] FIG. 4 is a top view of the annular assembly 13 as viewed from one axial end. The annular assembly 13 is formed by fixing the stator core 1, around which the coil 3 is wound, via the insulator 2, into an annular shape by, for example, welding. The annular assembly 13 in the first embodiment is formed by, for example, winding the coil 3 around the stator core 1 shown in FIG. 2 and then fixing it into an annular shape. However, the annular assembly 13 may be formed by winding the coil 3 around a stator core 1 that has been previously formed into an annular shape. FIG. 5 is a perspective view of the terminal 4. The terminal 4 is made of a conductive material such as copper. The terminal 4 includes a coil winding portion 41 for winding the terminal wire of the coil 3 and an external connection portion 42 for connecting to the outside.

[0012] FIG. 6 is a top view of the terminal holder 5 according to the first embodiment, as viewed from one axial end. FIG. 7 is a perspective view of the terminal holder 5 according to the first embodiment, as viewed from diagonally above the one axial end. FIG. 8 is a perspective view of the terminal holder 5 according to the first embodiment, as viewed from diagonally below the other axial end opposite the one axial end. The terminal holder 5 is made of a high-strength insulating material, such as PBT (Polybutylene Terephthalate) resin, and has a ring shape as shown in FIG. 6 . The terminal holder 5 includes a terminal insertion hole 52 into which the terminal 4 is inserted, in a terminal holding portion 51, which is the area surrounded by a thin two-dot chain line in FIG. 6 . Furthermore, as shown in FIG. 8 , the terminal holder 5 has a terminal insertion slit 58 at the other axial end of the position where the terminal 4 is inserted. 1, the three terminals 4 are inserted into the terminal insertion holes 52 from the other axial end side of the terminal holder 5, i.e., from the insulator 2 side of the terminal holder 5, until the external connection portions 42 of the terminals 4 contact the bottom surfaces of the terminal insertion slits 58. The terminal insertion holes 52 are sized to provide an interference fit with the external connection portions 42 of the terminals 4, and are sized so that the molded resin will not pass through the terminal insertion holes 52 with the terminals 4 inserted during integral molding with the molded resin.

[0013] As shown in Fig. 7 , the terminal holder 5 has a stator core positioning projection 57. When the terminal holder 5 with three terminals 4 inserted is attached to the ring assembly 13, the stator core positioning projection 57 is fitted into the stator core groove 11 shown in Fig. 2. When the terminal holder 5 is attached to the ring assembly 13, the inner diameter side insulator abutment surface 563 shown in Fig. 8 contacts the inner diameter side support surface 22 shown in Fig. 3, and the outer diameter side insulator abutment surface 59 shown in Fig. 8 contacts the outer diameter side support surface 21 shown in Fig. 3. After the terminal holder 5 with the three terminals 4 inserted is attached to the ring assembly 13, the terminal wire of the coil 3 is wound around the coil winding portion 41 of the terminal 4, and the terminal 4 is electrically connected to the coil 3. By fitting the stator core positioning protrusions 57 into the stator core grooves 11 of the stator core 1 of the annular assembly 13, the central axis of the annular assembly 13 and the central axis of the terminal holder 5 can be aligned, and the circumferential position of the terminal holder 5 can also be aligned with respect to the annular assembly 13. This allows the position of the coil winding portion 41 to be aligned with the position where the terminal wires of the coil 3 emerge, allowing the winding work to be performed at a specified length of the terminal wires. While the terminal holder 5 of the first embodiment has three stator core positioning protrusions 57, the number of stator core positioning protrusions 57 may be any number that determines the circumferential position of the terminal holder 5 with respect to the annular assembly 13. For example, the number of stator core positioning protrusions 57 may be any number equal to or greater than two. The terminal wires of the coil 3 wound around the coil winding portion 41 are fixed to the coil winding portion 41 by a method such as soldering, welding, fusing, or mechanical joining. 9 is a cross-sectional view showing another example of the terminal holder 5 and the insulator 2 according to the first embodiment. In the example shown in Fig. 9, a hooking protrusion 23 is formed on the radially outer side of the insulator 2, and an engaging portion 591 that engages with the hooking protrusion 23 is formed on the terminal holder 5. As shown in Fig. 9, the engaging portion 591 is engaged with the hooking protrusion 23 of the insulator 2 by a snap-fit ​​mechanism that limits the axial movement of the terminal holder 5 relative to the insulator 2, and can prevent the terminal holder 5 from being unintentionally detached when an external force is applied to the terminal holder 5 in a direction away from the annular assembly member 13.9, the axial position of the terminal holder 5 is stabilized. That is, it is possible to suppress axial positional deviation of the terminal holder 5 after integral molding, and it is also possible to suppress axial positional deviation of the terminals 4 inserted into the terminal holder 5. The number of engaging portions 591 may be two or more as long as it is possible to prevent the terminal holder 5 from coming off.

[0014] As shown in Fig. 6, the terminal holder 5 has a mold die positioning hole 55. When a mold die used for integral molding with a mold resin is attached to the stator 100, a pin provided on the mold die is fitted into the mold die positioning hole 55, thereby aligning the central axis of the terminal holder 5 with the central axis of the mold die and aligning the circumferential position of the terminal holder 5 with the circumferential position of the mold die. As a result, the terminals 4 inserted into the terminal holder 5 can also be positioned with respect to the mold die. Furthermore, because the stator core 1 and the terminal holder 5 are positioned by the stator core positioning protrusions 57, the central axis and circumferential position of the entire stator 100 are also aligned with respect to the mold die. The terminal holder 5 in embodiment 1 has three mold die positioning holes 55, but the number of mold die positioning holes 55 may be any number that determines the circumferential position of the terminal holder 5 relative to the mold die, and for example, the number of mold die positioning holes 55 may be any number greater than or equal to two.

[0015] 6, terminal holder 5 includes mold die support portion 54, which is the portion surrounded by a thick two-dot chain line around mold die positioning hole 55, terminal holding portion 51, which is the portion surrounded by a thin two-dot chain line, and step portions 53 provided to surround the circumferential end and radially inner end of terminal holding portion 51, and these portions protrude radially inward from the annular portion of terminal holder 5. When the surface on one axial end side of terminal holder 5 is the upper surface, when stator 100 is integrally molded with mold resin, axial positioning of stator 100 including terminal holder 5 with respect to the mold die can be performed by abutting the upper surface of mold die support portion 54 against the mold die. Furthermore, by pressing the upper surface of mold die support portion 54 against the mold die and at the same time pressing the mold die against the upper surface of terminal holding portion 51 so as to surround terminal 4, terminal 4 can be exposed from the mold resin, and adhesion of the mold resin to external connection portion 42 of terminal 4 can be prevented. Furthermore, by pressing the upper surface of mold die support portion 54 against the mold die and the upper surface of terminal holding portion 51 against the mold die to perform integral molding, in the molded stator after stator 100 is integrally molded with mold resin, the upper surface, which is the surface on one axial end side of mold die support portion 54 of terminal holder 5, and the upper surface, which is the surface on one axial end side of terminal holding portion 51, are exposed from the mold resin, and the molded resin covers stator core 1, insulator 2, coil 3, and terminal holder 5.

[0016] Circumferential positioning is performed by fitting pins provided on the mold die into mold die positioning holes 55, and axial positioning is performed by abutting the upper surface of mold die support portion 54 against the mold die. Furthermore, stator 100 is poured into the mold die so that the inner diameter of the stator core (described later) matches the core rod of the mold die, and the molded stator is formed as a single unit using mold resin. The mold resin is preferably an insulating material capable of being molded into a thick wall, such as BMC (bulk molding compound). Since it is used for the mating surfaces of the bracket and bearing (described later), it is desirable for the mold resin to have good dimensional stability after molding. Furthermore, the material of the mold resin in embodiment 1 is preferably different from the material of terminal holder 5. By using different materials for the mold resin and the terminal holder 5, it is possible to select materials suitable for the respective applications for terminal holder 5 and mold resin, thereby ensuring the required strength for each.

[0017] As shown in FIG. 6 , the terminal holder 5 includes a stepped portion 53 that surrounds the circumferential end and the radially inner end of the terminal holding portion 51. FIG. 10 is a cross-sectional view showing a cross section A-A at the cut portion indicated by the dashed line in FIG. 6 . As shown in FIG. 10 , the axial thickness of the stepped portion 53 is thinner than the axial thickness of the terminal holding portion 51, and the position of the upper surface of the stepped portion 53, which is surrounded by the thick dashed double-dashed line, is located closer to the other end than the position of the upper surface of the terminal holding portion 51, which is surrounded by the thin dashed double-dashed line. Furthermore, the stepped portion 53 includes a mold filling portion 531 that is filled with mold resin. In the terminal holder 5 shown in FIG. 10 , the mold filling portion 531 is a through-hole that penetrates the stepped portion 53 in the axial direction. As a result, when the stator 100 is integrally molded with mold resin, the molded resin covers the stepped portion 53, and the through-hole, which is the mold filling portion 531, is filled with molded resin. The circumferential width of the step portion 53 adjacent to the circumferential end of the terminal holding portion 51 and the radial width of the step portion 53 adjacent to the radially inner end of the terminal holding portion 51 may be such that a through hole, which is the mold filling portion 531, can be arranged.

[0018] FIG. 11 is a top view of a molded stator 110, which is a stator after being integrally molded with molded resin, as viewed from one axial end. The molded stator 110 includes a stator core 1, an insulator 2, a coil 3, terminals 4, a terminal holder 5, and molded resin 6. The stator core 1, the insulator 2, the coil 3, the terminals 4, and the terminal holder 5 are integrally molded and covered with the molded resin 6. FIG. 12 is an enlarged view of a portion of FIG. 11 and is a top view of a terminal holding portion 51 of the terminal holder 5 in the molded stator 110. In FIG. 12, the portion of the terminal holder 5 covered with the molded resin 6 is indicated by a hidden line (broken line). FIG. 13 is a cross-sectional view showing the B-B cross section at the cut portion indicated by the thick dashed line in FIG. 12. 13 , in the molded stator 110, the stepped portion 53 of the terminal holder 5 is covered with molded resin 6 on the surfaces on one and the other axial ends and on the circumferential end faces, and the through-holes, which are mold filling portions 531 of the stepped portion 53, are filled with molded resin 6. The molded resin 6 covering the stepped portion 53 and the molded resin 6 filling the through-holes, which are mold filling portions 531, function to surround and fasten the terminal holder 5. If the thermal expansion coefficient of the material of the terminal holder 5 differs from the thermal expansion coefficient of the material of the molded resin 6, filling the through-holes, which are mold filling portions 531, with molded resin 6 allows the molded resin 6 to fasten the terminal holder 5 during cooling after integral molding, thereby suppressing misalignment due to the difference in the amount of contraction between the terminal holding portion 51 of the terminal holder 5 and the molded resin 6. That is, it is possible to prevent the terminal holder 5 from being displaced after integral molding, and it is also possible to prevent the terminals 4 inserted into the terminal holder 5 from being displaced.

[0019] By suppressing misalignment due to the difference in the amount of shrinkage between the terminal holding portion 51 of the terminal holder 5 and the molded resin 6, it is possible to suppress the problem of the circuit board being unable to be connected due to misalignment of the terminals 4 when connecting the circuit board to the terminals 4 (described later). Furthermore, suppressing misalignment also improves workability. Furthermore, even if the thermal expansion coefficient of the material of the terminal holder 5 differs from that of the molded resin 6, suppressing misalignment allows materials with different thermal expansion coefficients to be used for the terminal holder 5 and the molded resin 6. This broadens the range of materials to be selected for the terminal holder 5 and the molded resin 6, allowing more suitable materials to be selected for the terminal holder 5 and the molded resin 6. Since misalignment between the terminal holder 5 and the molded resin 6 after integral molding is suppressed, the gap at the interface 61 between the upper surface of the terminal holder 5 and the molded resin 6 can be reduced. This stabilizes the visual quality of the molded stator 110 after integral molding.

[0020] In the first embodiment, the axial thickness of the step portion 53 is, for example, half the axial thickness of the terminal holding portion 51. In this case, the thickness of the molded resin 6 covering one axial end of the step portion 53 is the same as the thickness of the step portion 53. The axial thickness of the step portion 53 may be any thickness that ensures the required strength of the step portion 53 and the strength of the molded resin 6 covering one axial end of the step portion 53. A thinner molded resin 6 covering one axial end of the step portion 53 can reduce the molding pressure during integral molding and make it easier to suppress the outflow of the molded resin to the upper surface of the terminal holding portion 51. Therefore, it is desirable to make the thickness of the molded resin 6 covering one axial end of the step portion 53 as thin as possible within a range that ensures resin flow.

[0021] In the first embodiment, the step portion 53 of the terminal holder 5 has three through holes that are mold filling portions 531. Each through hole that is the mold filling portion 531 has a rectangular or a partially cut-out shape of a circle. However, as long as the fluidity of the molded resin 6 can be ensured, the through holes that are the mold filling portions 531 may have any shape, such as a circular hole. Furthermore, the number of through holes that are the mold filling portions 531 may be at least one near a circumferential end of the step portion 53 and at least one near a radially inner end of the step portion 53, and may be two or more in total. If misalignment between the terminal holder 5 and the molded resin 6 after integral molding needs to be suppressed in only one direction, for example, if misalignment in only the circumferential direction needs to be suppressed, only one through hole that is the mold filling portion 531 may be provided near a circumferential end of the step portion 53.

[0022] In the molded stator 110 according to the first embodiment, for example, the terminal holder 5 is made of PBT resin, and the molded resin 6 is made of BMC, and the terminal holder 5 and the molded resin 6 have different thermal expansion coefficients. Because the thermal expansion coefficient of BMC is smaller than that of PBT resin, the molded resin 6, which has a smaller thermal expansion coefficient, fastens the terminal holder 5 that holds the terminals 4, thereby stably suppressing misalignment of the terminals 4. Even when other materials are used for the terminal holder 5 and the molded resin 6, it is desirable that the thermal expansion coefficient of the material of the molded resin 6 be smaller than that of the material of the terminal holder 5.

[0023] As shown in Fig. 7, the terminal holder 5 has an insulator protrusion 56 extending from the radially inner end of the step portion 53 toward the other axial end. A notch 561 that opens toward the other axial end is provided in the circumferential center of the insulator protrusion 56. At the other axial end of each of the circumferential ends of the insulator protrusion 56, a core rod protrusion 562 extends radially inward. The insulator protrusion 56 comes into contact with the inner diameter side support surface 22 at one axial end of the insulator 2, thereby supporting the terminal holder 5 on the insulator 2.

[0024] Figure 14 is a cross-sectional view showing the CC section at the cut portion indicated by the thin dashed line in Figure 12. When the stator 100 is integrally molded using molded resin 6, the stator core inner diameter 12 of the stator core 1 of the stator 100 is aligned with the mold die core rod to radially position the mold and the stator 100. The molded resin 6 has a bracket fitting portion 62 radially inside the insulator protrusion 56. By abutting the core rod protrusion 562 of the insulator protrusion 56 against the mold die core rod, the insulator protrusion 56 is prevented from bending radially inward due to the molding pressure of the molded resin from the radial outside, i.e., the coil 3 side. This prevents the portion of the insulator protrusion 56 other than the core rod protrusion 562 from ejecting from the bracket fitting portion 62. This stabilizes the thickness and dimensional accuracy of the molded resin at the bracket fitting portion 62. Although the terminal holder 5 in the first embodiment has two core rod projections 562, it may have three or more core rod projections 562 as long as the fluidity of the molding resin during integral molding can be ensured.

[0025] 7 , the insulator protrusion 56 of the terminal holder 5 has a notch 561 that opens toward the other axial end. By providing the insulator protrusion 56 with the notch 561, the molding resin can easily flow toward the radially inner side of the insulator protrusion 56 during integral molding, thereby stabilizing the thickness and dimensional accuracy of the molding resin in the portion molded as the bracket fitting portion 62. The terminal holder 5 in the first embodiment has one notch 561, but the insulator protrusion 56 may have two or more notches 561 as long as it can ensure the strength to withstand the stress generated when a molding die is pressed against one axial end of the terminal holding portion 51.

[0026] FIG. 15 is a top view of a motor 200 according to embodiment 1, as seen from one axial end. FIG. 16 is a cross-sectional view showing the D-D cross section in FIG. 15. The motor 200 includes a molded stator 110, a shaft 81, a rotor 82, a bearing 83, a bracket 84, and lead wires 85. In the motor 200, the molded stator 110 includes a circuit board 7. The external connection portions 42 of the terminals 4, exposed from the molded resin 6 and extending toward one axial end, are electrically connected to the circuit board 7. The rotor 82 is fixed to the shaft 81, and the shaft 81 is rotationally supported by two bearings 83. The bracket 84 holds the bearing 83 at one axial end and is fitted into the bracket fitting portion 62 of the molded resin 6. The lead wires 85 connected to the circuit board 7 are pulled out from a hole provided in the bracket 84 and connected to the outside. FIG. 17 is a perspective view of a portion of another example of the terminal holder 5 according to embodiment 1, as seen from the other end. 17 , a terminal tilt suppression portion 581 that is narrower than the other portion of the terminal insertion slit 58 and that sandwiches the terminal 4 is formed in a portion of the terminal insertion slit 58. In the example shown in Fig. 17 , it is possible to suppress tilting of the terminal 4 after the terminal 4 is inserted into the terminal insertion slit 58. In the example shown in Fig. 17 , two terminal tilt suppression portions 581 are provided for one terminal insertion slit 58, but two or more terminal tilt suppression portions 581 may be provided as long as insertability can be ensured, or only one terminal tilt suppression portion 581 may be provided as long as tilt can be suppressed.

[0027] Figure 18 shows another example of a cross-sectional view showing an A-A cross section at the cut portion indicated by the dashed dotted line in Figure 6. In the example shown in Figure 10, the step portion 53 includes a mold filling portion 531 that is a through hole that passes through the step portion 53 in the axial direction, but in the example shown in Figure 18, the step portion 53 includes a mold filling portion 531 that is a recess provided in the surface at one end side of the step portion 53 in the axial direction. Figure 19 shows yet another example of a cross-sectional view showing an A-A cross section at the cut portion indicated by the dashed dotted line in Figure 6. In the example shown in Figure 19, the step portion 53 includes a mold filling portion 531 that is an irregularity provided in the surface at one end side of the step portion 53 in the axial direction. The molded resin 6 is filled into the molded filling portion 531, which is a recess provided on the surface of one axial end of the stepped portion 53, or into the molded filling portion 531, which is an uneven portion provided on the surface of one axial end of the stepped portion 53. This allows the molded resin 6 to fasten the terminal holder 5 during cooling after integral molding, thereby preventing misalignment due to a difference in the amount of shrinkage of the terminal holding portion 51 of the terminal holder 5 and the amount of shrinkage of the molded resin 6. Furthermore, the terminal holder 5 shown in FIGS. 18 and 19 has fewer thin portions than the example shown in FIG. 10, thereby improving the strength of the terminal holder 5. Furthermore, the terminal holder 5 shown in FIGS. 18 and 19 has the molded filling portion 531 formed on the surface of the stepped portion 53 rather than a through hole, which increases the options for the direction in which the mold can be removed when molding the terminal holder 5, compared to the terminal holder 5 shown in FIG. 10.

[0028] As described above, the molded stator 110 according to the first embodiment includes the stator core 1, the insulator 2, the coil 3, the terminal 4, the terminal holder 5, and the molded resin 6. The stator core 1, the insulator 2, the coil 3, the terminal 4, and the terminal holder 5 are integrally molded with the molded resin 6. The coil 3 is wound around the stator core 1 via the insulator 2. The terminal 4 is electrically connected to the coil 3 and extends to one end side of the axial direction of the molded stator 110. The terminal holder 5 has a terminal holding portion 51 having a terminal insertion hole 52 into which the terminal 4 is inserted, and a terminal holder 51 at the circumferential end of the molded stator 110. and a step portion (53) surrounding the radially inner end of the molded stator (110), and contacting one axial end side of the insulator (2). Molded resin (6) covers the stator core (1), the insulator (2), the coil (3), and the terminal holder (5) so that the surface of one axial end side of the terminal holding portion (51) is exposed. The step portion (53) has a mold filling portion (531), and the mold filling portion (531) is either a through hole passing through the step portion (53) in the axial direction, a recess provided in the surface of one axial end side of the step portion (53), or an uneven portion provided in the surface of one axial end side of the step portion (53). Since the molded resin (6) is filled, displacement of the exposed terminals after integral molding is suppressed.

[0029] Although exemplary embodiments are described in the present disclosure, the various features, aspects, and functions described in the embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are anticipated within the scope of the technology disclosed in this specification. For example, variations in, addition to, or omission of at least one component are included.

[0030] The above describes in detail preferred embodiments, but the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims.

[0031] Various aspects of the present disclosure are summarized below as appendices.

[0032] (Note 1) A molded stator includes a stator core, an insulator, a coil, a terminal, a terminal holder, and a molded resin, and is integrally molded by covering the stator core, the insulator, the coil, the terminal, and the terminal holder with the molded resin, wherein the coil is wound around the stator core via the insulator, the terminal is electrically connected to the coil and extends toward one axial end of the molded stator, the terminal holder includes a terminal holding portion having a terminal insertion hole into which the terminal is inserted, and a stepped portion surrounding an end of the terminal holding portion in the circumferential direction of the molded stator and an inner end of the terminal holding portion in the radial direction of the molded stator, and is in contact with the one axial end of the insulator, and the molded resin covers the stator core, the insulator, the coil, and the terminal holder so that a surface on the one axial end side of the terminal holding portion is exposed, A molded stator, wherein the axial thickness of the step portion is thinner than the axial thickness of the terminal holding portion, the step portion includes a mold filling portion, and the mold filling portion is any one of a through hole penetrating the step portion in the axial direction, a recess provided in a surface of the step portion at one end side of the axial direction, and an unevenness provided in the surface of the step portion at one end side of the axial direction, and is filled with the molded resin. (Appendix 2) The molded stator according to Appendix 1, wherein the molded resin and the terminal holder are made of different materials. (Appendix 3) The molded stator according to Appendix 2, wherein the molded resin has a smaller thermal expansion coefficient than the terminal holder. (Appendix 4) The molded stator according to any one of Appendixes 1 to 3, wherein the terminal holder includes a mold die positioning hole into which a pin provided in a mold die used for integral molding with the molded resin is fitted. (Appendix 5) The molded stator according to any one of appendices 1 to 4, wherein the terminal holder includes a stator core positioning protrusion fitted into a stator core groove of the stator core.(Supplementary Note 6) The molded stator according to any one of Supplementary Notes 1 to 5, wherein the step portion includes an insulator protrusion extending from an inner end portion in the radial direction toward the other end side in the axial direction, and the insulator protrusion is in contact with one end side of the insulator in the axial direction. (Supplementary Note 7) The molded stator according to Supplementary Note 6, wherein the insulator protrusion includes a core rod protrusion extending inward in the radial direction at an end portion on the other end side in the axial direction. (Supplementary Note 8) The molded stator according to Supplementary Note 6 or 7, wherein the insulator protrusion has a notch that is open toward the other end side in the axial direction.

[0033] REFERENCE SIGNS LIST 1 stator core, 2 insulator, 3 coil, 4 terminal, 5 terminal holder, 6 molded resin, 7 circuit board, 11 stator core groove, 12 stator core inner diameter, 13 ring assembly material, 21 outer diameter side support surface, 22 inner diameter side support surface, 23 hook protrusion, 41 coil winding portion, 42 external connection portion, 51 terminal holding portion, 52 terminal insertion hole, 53 step portion, 54 mold die support portion, 55 mold die positioning hole, 56 insulator protrusion, 57 stator core positioning protrusion, 58 terminal insertion slit, 59 outer diameter side insulator contact surface, 61 boundary surface, 62 bracket fitting portion, 81 shaft, 82 rotor, 83 bearing, 84 bracket, 85 lead wire, 100 stator, 110 molded stator, 200 Motor, 531 mold filling portion, 561 notch, 562 core rod protrusion, 563 inner diameter side insulator contact surface, 581 terminal tilt suppression portion, 591 engagement portion.

Claims

1. A molded stator comprising a stator core, an insulator, a coil, terminals, a terminal holder, and molded resin, wherein the stator core, the insulator, the coil, the terminals, and the terminal holder are integrally molded by being covered with the molded resin, wherein the coil is wound around the stator core via the insulator, the terminal is electrically connected to the coil and extends toward one axial end of the molded stator, the terminal holder comprises: a terminal holding portion having a terminal insertion hole into which the terminal is inserted, and a stepped portion surrounding the circumferential end of the molded stator in the terminal holding portion and the radially inner end of the molded stator, and is in contact with the one axial end of the insulator, the molded resin covers the stator core, the insulator, the coil, and the terminal holder so that the surface at the one axial end of the terminal holding portion is exposed, and the stepped portion comprises a mold filling portion, The molded filling portion is any one of a through hole penetrating the step portion in the axial direction, a recess provided on the surface of the step portion at one end in the axial direction, and an uneven surface provided on the surface of the step portion at one end in the axial direction, and is filled with the molded resin.

2. The molded stator according to claim 1, wherein the material of the molding resin is different from the material of the terminal holder.

3. The molded stator according to claim 2, wherein the thermal expansion coefficient of said molding resin is smaller than that of said terminal holder.

4. A molded stator as described in any one of claims 1 to 3, characterized in that the terminal holder is provided with a mold positioning hole into which a pin provided in the mold used for integral molding using the mold resin is fitted.

5. A molded stator according to any one of claims 1 to 4, characterized in that the terminal holder is provided with a stator core positioning projection fitted into a stator core groove of the stator core.

6. A molded stator according to any one of claims 1 to 5, characterized in that the step portion has a protrusion for an insulator extending from the inner end in the radial direction to the other end side in the axial direction, and the protrusion for an insulator contacts one end side of the insulator in the axial direction.

7. A molded stator according to claim 6, characterized in that the insulator protrusion has a core rod projection extending radially inward at the other axial end.

8. A molded stator according to claim 6 or 7, characterized in that the insulator protrusion has a notch that opens to the other end side in the axial direction.

9. The molded stator according to claim 1, wherein the axial thickness of the step portion is thinner than the axial thickness of the terminal holding portion.

10. A molded stator as described in any one of claims 1 to 3, characterized in that the terminal holder has an engaging portion that engages with a hooking protrusion of the insulator by a snap-fit ​​mechanism that limits the axial movement of the terminal holder relative to the insulator.

11. A molded stator as described in any one of claims 1 to 3, characterized in that the terminal holder has a terminal insertion slit into which the terminal is inserted at the other axial end side of the terminal holding portion, and the terminal insertion slit has a terminal tilt suppression portion that clamps the terminal.

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