Stator and production method for stator

Abstract

A stator (10) comprises: a stator core (24) that has a plurality of radially extending teeth (22); a plurality of insulators (16) that are installed on the plurality of teeth; a plurality of coil winding parts (18) that are wound around the plurality of teeth over the insulators; and a plurality of plates (36) that are provided between the plurality of coil winding parts and thereby separate adjacent coil winding parts.

Description

Stator and method for manufacturing the same CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-121429, filed on July 26, 2024, the entire contents of which are incorporated herein by reference.

[0002] The technology of the present disclosure relates to a stator and a method for manufacturing the stator.

[0003] Conventionally, there has been a stator including a stator core having a plurality of radially extending teeth, a plurality of insulators attached to the plurality of teeth, and a plurality of windings wound around the plurality of teeth via the insulators (see, for example, JP 2016-208757 A). Some stators of this type include a plurality of sheet-shaped sheets (i.e., insulating sheets) that are arranged between the plurality of windings to separate adjacent windings. The sheet materials separating adjacent windings narrow the flow path of the coolant flowing between the adjacent windings, thereby increasing the flow rate of the coolant and improving the cooling efficiency of the windings.

[0004] As a result of detailed investigations by the inventors, the following problem was discovered: In the above-described stator, the sheet material is formed into a sheet shape, which results in insufficient bending rigidity of the sheet material, and the sheet material may be deformed by the force of the coolant flowing between adjacent winding portions. If the sheet material is deformed, the flow rate of the coolant flowing between the adjacent winding portions becomes uneven, which may cause local temperature increases in the winding portions.

[0005] The technique of the present disclosure provides a stator and a method for manufacturing the stator that can suppress local temperature increases in the winding portions.

[0006] A first aspect of the technology of the present disclosure is a stator comprising a stator core having a plurality of radially extending tooth portions, a plurality of insulators attached to the plurality of tooth portions, a plurality of winding winding portions wound around the plurality of tooth portions via each of the insulators, and a plurality of plate-shaped plate members arranged between the plurality of winding winding portions to separate adjacent ones of the winding winding portions.

[0007] A second aspect of the technique of the present disclosure is a method for manufacturing a stator, the stator comprising: a stator core having a plurality of radially extending tooth portions; a plurality of insulators attached to the plurality of tooth portions; a plurality of winding winding portions wound around the plurality of tooth portions via the insulators; and a plurality of plate-shaped plates that are arranged between the plurality of winding winding portions to provide insulation between the plurality of winding winding portions, the stator core being constituted by a plurality of core members divided in the circumferential direction of the stator core, the plurality of insulators being divided in the circumferential direction of the stator core, and base ends of the plate members being connected to the insulators in a bendable manner, and the manufacturing method comprising: a winding winding process of winding the winding winding portions around the tooth portions of the core member via the insulators while the plate members are spread out; a bending process of bending the plate members; and an assembly process of assembling the plurality of core members into an annular shape.

[0008] The techniques disclosed herein provide a stator and a method for manufacturing a stator that can suppress local temperature increases in the winding portions.

[0009] 1 is a cross-sectional view of a stator according to a first embodiment; FIG. 2 is a cross-sectional view of an enlarged essential portion of the stator according to the first embodiment; FIG. 3 is a plan view of an enlarged essential portion of the stator according to the first embodiment; FIG. 4 is a plan view illustrating an assembly process of a stator component according to the first embodiment; FIG. 5 is a perspective view illustrating an assembly process of a stator component according to the first embodiment; FIG. 6 is a plan view of an enlarged essential portion of the stator according to the first embodiment; FIG. 7 is a side view and a perspective view of a plate according to the first embodiment; FIG. 8 is a flowchart illustrating a manufacturing method of the stator according to the first embodiment; FIG. 9 is a longitudinal cross-sectional view illustrating a flow of a refrigerant between adjacent winding winding portions according to the first embodiment; FIG. 10 is a plan view of an enlarged essential portion of the stator according to the second embodiment; FIG. 11 is a plan view of an enlarged essential portion of the stator according to the third embodiment; FIG. 12 is a side view and a perspective view of a plate according to a first variation of the fourth embodiment; FIG. 13 is a side view and a perspective view of a plate according to a second variation of the fourth embodiment; FIG. 14 is a side view and a perspective view of a plate according to a third variation of the fourth embodiment; FIG. 15 is a side view and a perspective view of a plate according to a fourth variation of the fourth embodiment; FIG. 16 is a front view and a longitudinal cross-sectional view of a plate according to a fifth variation of the fourth embodiment; FIG. 17 is a front view and a longitudinal cross-sectional view of a plate according to a sixth variation of the fourth embodiment. FIG. 10 is a front view and a longitudinal cross-sectional view of a plate according to a seventh variation of the fourth embodiment. FIG. 11 is a front view and a longitudinal cross-sectional view of a plate according to an eighth variation of the fourth embodiment. FIG. 12 is a front view and a longitudinal cross-sectional view of a plate according to a ninth variation of the fourth embodiment. FIG. 13 is a front view and a longitudinal cross-sectional view of a plate according to a tenth variation of the fourth embodiment. FIG. 14 is a front view and a longitudinal cross-sectional view of a plate according to an eleventh variation of the fourth embodiment. FIG. 15 is a front view and a longitudinal cross-sectional view of a plate according to a thirteenth variation of the fourth embodiment. FIG. 16 is a side view of a plate according to a fourteenth variation of the fourth embodiment. FIG. 17 is a front view and a longitudinal cross-sectional view of a plate according to a fifteenth variation of the fourth embodiment. FIG. 18 is a front view and a longitudinal cross-sectional view of a plate according to a sixteenth variation of the fourth embodiment.

[0010] First Embodiment First, a first embodiment of the technology of the present disclosure will be described.

[0011] As shown in Fig. 1, the stator 10 includes a plurality of stator components 12. The stator 10 is configured by combining the plurality of stator components 12 in an annular shape. Fig. 1 shows the configuration of half of the stator 10. The stator 10 is applied to a brushless motor.

[0012] 2 , each stator component 12 includes a core member 14, an insulator 16, and a winding winding portion 18. The core member 14 is formed in a T-shape in a plan view, and has a core back portion 20 and teeth portions 22.

[0013] The X direction, Y direction, and Z direction are three axial directions set with respect to the tooth portion 22. The X direction indicates the tangential direction of the stator 10, the Y direction indicates the radial direction of the stator 10, and the Z direction indicates the axial direction of the stator 10. In the following description, the circumferential direction of the stator 10 refers to the direction around the central axis of the stator 10. The tangential direction, radial direction, axial direction, and circumferential direction of the stator core 24, which will be described later, are the same directions as the tangential direction, radial direction, axial direction, and circumferential direction of the stator 10, respectively.

[0014] The core back portion 20 extends in the circumferential direction of the stator core 24, and the teeth portions 22 extend inward in the Y direction from the center of the core back portion 20. The tip portions of the teeth portions 22 are free ends, and the base ends of the teeth portions 22 are connected to the core back portion 20. The core member 14 is a laminate in which multiple core sheets are stacked in the Z direction.

[0015] The stator core 24 is formed by combining multiple core members 14 in an annular shape. When the stator core 24 is formed, the multiple core back portions 20 form an annular portion 26 that is the outer periphery of the stator core 24, and the multiple tooth portions 22 extend radially from the center of the stator core 24. Slots 28 are formed between the multiple tooth portions 22. The multiple core members 14 and the multiple insulators 16 are each configured to be divided in the circumferential direction of the stator core 24.

[0016] The insulator 16 is divided in the Z direction and attached to the core member 14 from both sides in the Z direction. The insulator 16 is made of insulating resin. The insulator 16 has a first insulating portion 30 that insulates the core back portion 20, a second insulating portion 32 that insulates the teeth portions 22, and a third insulating portion 34 that insulates the tips of the teeth portions 22.

[0017] The winding portion 18 is wound around the tooth portion 22 via the insulator 16 (more specifically, the second insulating portion 32). The winding portion 18 is formed by winding a wire around the tooth portion 22 in the Y direction.

[0018] 2 and 3 , the insulator 16 has a plate-shaped plate material 36 (i.e., an insulating plate). Each insulator 16 has one plate material 36. The plate material 36 is disposed between adjacent winding winding portions 18, thereby separating the adjacent winding winding portions 18.

[0019] A coolant, which is a gas or liquid, for cooling the winding portions 18 is supplied between adjacent winding portions 18 separated by the plate material 36. The coolant flows, for example, from one side to the other in the Z direction. The plate material 36 has a thickness sufficient to suppress deformation even when the coolant is supplied between adjacent winding portions 18. In other words, the plate material 36 is a member with higher bending rigidity than conventional sheet materials (i.e., insulating sheets).

[0020] The plate material 36 is formed integrally with the insulator 16. Specifically, the outer end of the plate material 36 in the Y direction is the base end of the plate material 36, and the base end of the plate material 36 is bendably connected to one end of the core back portion 20 of the insulator 16 in the X direction. The inner end of the plate material 36 in the Y direction is the tip end of the plate material 36, and the tip end of the plate material 36 is a free end.

[0021] 4 and 5 , the plate material 36 is molded integrally with the insulator 16 so as to extend from one end of the core back portion 20 in the X direction to one side in the X direction. Then, with the plate material 36 extended in the X direction, the winding portion 18 is wound around the teeth portion 22 of the core member 14 via the insulator 16. After the winding portion 18 is wound, the plate material 36 is bent inward in the Y direction. When multiple core members 14 are assembled into an annular shape, the tip end of the plate material 36 is sandwiched between adjacent insulators 16. Specifically, the third insulating portion 34 has a sandwiching portion 35, and the tip end of the plate material 36 is sandwiched between adjacent third insulating portions 34 (more specifically, between the sandwiching portions 35).

[0022] 6 , the x-direction, y-direction, and z-direction are three axial directions set with respect to the plate material 36. The x-direction indicates the tangential direction of the stator 10, the y-direction indicates the radial direction of the stator 10, and the z-direction indicates the axial direction of the stator 10.

[0023] The imaginary plane 38 is a plane that passes through the center between adjacent winding portions 18 and extends in the y direction. The imaginary plane 38 is, for example, a plane obtained by extending the joining surfaces 20A of adjacent core back portions 20 inward in the y direction, or a plane obtained by extending the joining surfaces 34A of adjacent third insulating portions 34 outward in the y direction. When the imaginary plane 38 is set, the plate material 36 is arranged so that end faces 36A on both sides of the plate material 36 in the y direction intersect with the imaginary plane 38.

[0024] The plate material 36 is preferably disposed parallel to the imaginary plane 38, but may be inclined with respect to the imaginary plane 38 as long as the end faces 36A on both sides of the plate material 36 intersect with the imaginary plane 38. The plate material 36 has a shape in which the distance from the imaginary plane 38 to the surface 36B of the plate material 36 in the x direction increases and decreases along the Z direction. This will be explained in detail below.

[0025] As shown in FIG. 7 , the plate 36 has a plurality of protrusions 40. The protrusions 40 are formed on both surfaces 36B of the plate 36. On each surface 36B of the plate 36, the protrusions 40 are arranged at intervals in the z direction. Each protrusion 40 is formed as a ridge extending in the y direction. Each protrusion 40 is formed from one end of the surface 36B of the plate 36 in the y direction to the other end. Each protrusion 40 protrudes in the x direction. Each protrusion 40 is formed in a triangular cross-section whose height in the x direction decreases toward one side in the z direction (i.e., the direction of the arrow in the Z direction). By having the protrusions 40 on each surface 36B, the plate 36 has a shape in which the distance in the x direction from the imaginary plane 38 to the surface 36B of the plate 36 increases and decreases along the z direction.

[0026] Next, a manufacturing method of the stator 10 will be described. As shown in FIG. 8 , the manufacturing method of the stator 10 includes an insulator mounting process, a winding process, a bending process, and an assembling process. The insulator mounting process includes mounting the insulators 16 to the core members 14. The winding process includes winding the winding portions 18 around the teeth 22 of the core members 14 via the insulators 16 while the plate members 36 are spread in the X direction. The bending process includes bending the plate members 36 inward in the Y direction after winding the winding portions 18. The assembling process includes assembling the multiple core members 14 into an annular shape, and, when assembling the multiple core members 14 into an annular shape, clamping the leading ends of the plate members 36 between adjacent insulators 16 (specifically, between clamping portions 35 formed on adjacent third insulating portions 34).

[0027] As described above in detail, in the first embodiment, adjacent winding winding portions 18 are separated by disposing the plate material 36 between the plurality of winding winding portions 18. Therefore, the flow path of the coolant flowing between adjacent winding winding portions 18 is narrowed, which increases the flow rate of the coolant, thereby improving the cooling efficiency of the winding winding portions 18.

[0028] Furthermore, the plate material 36 is formed in a plate shape and has a thickness sufficient to suppress deformation even when a coolant is supplied between adjacent winding winding portions 18. That is, the plate material 36 is a member having higher bending rigidity than conventional sheet materials (i.e., insulating sheets). Therefore, the bending rigidity of the plate material 36 can be ensured, and deformation of the plate material 36 due to the force of the coolant flowing between adjacent winding winding portions 18 can be suppressed. This makes it possible to make the flow rate of the coolant flowing between adjacent winding winding portions 18 uniform, thereby suppressing local temperature increases in the winding winding portions 18.

[0029] Furthermore, when an imaginary plane 38 is defined, the plate 36 has a shape (for example, a shape including convex portions 40) in which the distance in the x direction from the imaginary plane 38 to the surface 36B of the plate 36 increases and decreases along the z direction. Therefore, as shown in Fig. 9 , when the refrigerant 60 flows from one side to the other in the z direction, vortices 60A can be generated in the refrigerant 60 around the convex portions 40, thereby stirring and mixing a high-temperature refrigerant layer close to the surface 36B of the winding winding portion 18 and a low-temperature refrigerant layer distant from the surface of the winding winding portion 18. This further improves the cooling efficiency of the winding winding portion 18 compared to when the surface 36B of the plate 36 is flat.

[0030] Each of the protrusions 40 has a triangular cross section whose height in the x direction decreases toward one side in the z direction. This reduces the flow resistance of the refrigerant 60 flowing from one side in the z direction, while generating vortices 60A around the apex of each of the protrusions 40, thereby ensuring the flow velocity and agitation of the refrigerant 60.

[0031] Furthermore, the plate material 36 is formed integrally with the insulator 16. Therefore, compared to when the plate material 36 is formed separately from the insulator 16, an increase in the number of parts can be suppressed.

[0032] Furthermore, the base end of the plate material 36 is bendably connected to the insulator 16. Therefore, in the winding process, the plate material 36 is spread in the X direction, and the winding portion 18 can be wound around the teeth 22 of the core member 14 via the insulator 16.

[0033] Furthermore, because the base end of the plate material 36 is fixed by being connected to the insulator 16, it is possible to prevent the position of the plate material 36 from changing due to the force of the refrigerant flowing between adjacent winding portions 18. This makes it possible to maintain a uniform flow rate of the refrigerant flowing between adjacent winding portions 18.

[0034] Furthermore, the tip end of the plate material 36 is sandwiched between adjacent insulators 16 (specifically, between sandwiching portions 35 formed on adjacent third insulating portions 34). Therefore, because the tip end of the plate material 36 is fixed to the insulators 16, it is possible to prevent the position of the plate material 36 from changing due to the force of the refrigerant flowing between adjacent winding winding portions 18. This makes it possible to maintain a uniform flow rate of the refrigerant flowing between adjacent winding winding portions 18.

[0035] Furthermore, plate material 36 is arranged so that end faces 36A on both sides of plate material 36 in the y direction intersect with imaginary plane 38. Therefore, the flow path for the coolant between adjacent winding portions 18 can be evenly divided by plate material 36, and the flow rate of the coolant flowing between adjacent winding portions 18 can be made uniform.

[0036] In the first embodiment, the stator core 24 is divided into a plurality of core members 14, and the plurality of core members 14 are configured independently of one another, but the plurality of core members 14 may be rotatably connected by connecting portions with the Z direction as the rotation axis. Also, instead of the plurality of core members 14 being rotatably connected by connecting portions, the plurality of insulators 16 attached to the plurality of core members 14, respectively, may be rotatably connected by connecting portions. Even with this configuration, the same effects as when the plurality of core members 14 are configured independently of one another can be achieved.

[0037] Second Embodiment Next, a second embodiment of the technique of the present disclosure will be described.

[0038] In the second embodiment, the configuration of the stator 10 is changed as follows compared to the first embodiment. That is, while in the first embodiment, each insulator 16 has one plate member 36, in the second embodiment, as shown in FIG. 10 , each insulator 16 has a pair of plate members 36. The pair of plate members 36 are connected to both ends of the core back portion 20 of the insulator 16 in the X direction so as to be able to be bent. In the second embodiment, the other configurations are the same as in the first embodiment.

[0039] In this way, even if each insulator 16 has a pair of plate members 36, the same effects as those of the first embodiment can be achieved.

[0040] In the second embodiment, multiple core members 14 may be rotatably connected by connecting portions, and multiple insulators 16 respectively attached to multiple core members 14 may be rotatably connected by connecting portions.

[0041] Third Embodiment Next, a third embodiment of the technique of the present disclosure will be described.

[0042] In the third embodiment, the configuration of the stator 10 is modified as follows from the first embodiment. That is, in the first embodiment, the plate material 36 is formed integrally with the insulator 16, but in the third embodiment, as shown in Fig. 11 , the plate material 36 is formed separately from the insulator 16. One end of the plate material 36 is sandwiched between adjacent insulators 16 (specifically, between the sandwiching portions 31 formed on adjacent first insulating portions 30), and the other end of the plate material 36 is sandwiched between adjacent insulators 16 (specifically, between the sandwiching portions 35 formed on adjacent third insulating portions 34).

[0043] For example, in the assembly process, the plate material 36 may be sandwiched between adjacent insulators 16 when assembling the plurality of core members 14 into an annular shape, or may be sandwiched by being inserted between adjacent insulators 16 after assembling the plurality of core members 14 into an annular shape. In the third embodiment, other configurations are similar to those of the first embodiment.

[0044] In this way, even if the plate material 36 is configured as a separate member from the insulator 16, the same configuration as in the first embodiment can achieve the same effects as in the first embodiment.

[0045] In the second embodiment, multiple core members 14 may be rotatably connected by connecting portions, and multiple insulators 16 respectively attached to multiple core members 14 may be rotatably connected by connecting portions.

[0046] Furthermore, the stator core 24 may be integrally formed. By forming the plate material 36 as a separate member from the insulator 16, the plate material 36 can be applied to the stator core 24 that is integrally formed.

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

[0048] In the fourth embodiment, variations of the shape of the plate material 36 will be described. In each variation described below, the shape of the plate material 36 is changed as follows compared to the first embodiment described above. Differences between each variation and the first embodiment described above will be described below.

[0049] 12, in the first variation, each of the protrusions 40 has a triangular cross section whose height in the x direction increases toward one side in the z direction. With this configuration, vortices can be generated around the apex of each of the protrusions 40, ensuring good agitation of the refrigerant.

[0050] 13 , in the second variation, each of the protrusions 40 is formed in a cylindrical shape. The protrusions 40 are arranged in a staggered pattern. Even with this configuration, vortices can be generated around the apex of each of the protrusions 40, ensuring good agitation of the refrigerant.

[0051] 14 , in the third variation, each of the protrusions 40 is formed in a rectangular column shape. The protrusions 40 are arranged in a staggered pattern. Even with this configuration, vortices can be generated around the apex of each of the protrusions 40, ensuring good agitation of the refrigerant.

[0052] As shown in FIG. 15 , in the fourth variation, each protrusion 40 is formed in a triangular cross-section whose height in the x-direction increases toward one side in the z-direction (i.e., the direction of the arrow in the Z-direction). Furthermore, each protrusion 40 is formed in a wedge shape whose width in the y-direction decreases toward one side in the Z-direction. When each protrusion 40 is formed in a triangular cross-section whose height in the x-direction increases toward one side in the z-direction, vortices can be generated around the apex of each protrusion 40, thereby ensuring refrigerant agitation. Furthermore, when each protrusion 40 is formed in a wedge shape whose width in the y-direction decreases toward one side in the z-direction, flow resistance to the refrigerant flowing from one side in the z-direction can be reduced, thereby ensuring the refrigerant flow velocity.

[0053] In the second to fourth variation examples, the plurality of protrusions 40 are arranged in a staggered pattern, but they may also be arranged in a single row or in multiple rows.

[0054] As shown in FIG. 16 , in the fifth variation, the plate 36 has a plurality of recesses 42 instead of a plurality of protrusions 40. Each recess 42 opens in the thickness direction of the plate 36 (i.e., the x-direction). Each recess 42 is circular. Furthermore, each recess 42 has a square cross section. The recesses 42 formed on one surface 36B of the plate 36 and the recesses 42 formed on the other surface 36B of the plate 36 are located at the same position. By having the plurality of recesses 42 on each surface 36B, the plate 36 has a shape in which the distance in the x-direction from the imaginary plane 38 to the surface 36B of the plate 36 increases and decreases along the z-direction. Even with this configuration, vortices can be generated around the openings of each recess 42, ensuring the agitation of the refrigerant.

[0055] 17 , in the sixth variation, the cross-sectional shape of each recess 42 is changed to a semicircular cross-section, compared to the fifth variation. Even with this configuration, vortices can be generated around the opening of each recess 42, ensuring the stirring of the refrigerant.

[0056] 18 , in the seventh variation, the shape of each recess 42 is changed to a square shape compared to the fifth variation. Even with this configuration, vortices can be generated around the opening of each recess 42, ensuring the stirring of the refrigerant.

[0057] 19 , in the eighth variation, unlike the seventh variation, the recesses 42 formed on one surface 36B of the plate 36 and the recesses 42 formed on the other surface 36B of the plate 36 are staggered in the Z direction. Even with this configuration, vortices can be generated around the openings of each recess 42, ensuring the agitation of the refrigerant. Furthermore, by staggering the recesses 42 formed on one surface 36B of the plate 36 and the recesses 42 formed on the other surface 36B of the plate 36 in the Z direction, it is possible to suppress a decrease in bending rigidity due to localized thinning of the plate 36.

[0058] In the fifth to eighth variations, the recesses 42 are arranged in a staggered pattern, but they may also be arranged in a single row or in multiple rows.

[0059] As shown in FIG. 20 , in the ninth variation, the plate 36 has a plurality of grooves 44 instead of a plurality of protrusions 40. On each surface 36B of the plate 36, the plurality of grooves 44 are spaced apart in the z direction. Each protrusion 40 extends in the y direction. Each groove 44 is formed from one end of the surface 36B of the plate 36 to the other end in the y direction. Each groove 44 has a rectangular cross section. The groove 44 formed on one surface 36B of the plate 36 and the groove 44 formed on the other surface 36B of the plate 36 are located at the same position in the z direction. By having the plurality of grooves 44 on each surface 36B of the plate 36, the plate 36 has a shape in which the distance in the x direction from the imaginary plane 38 to the surface 36B of the plate 36 increases and decreases along the z direction. Even with this configuration, vortices can be generated around the openings of each groove 44, ensuring the agitation of the refrigerant.

[0060] 21 , in the tenth variation, the cross-sectional shape of each groove 44 is changed to a semicircular cross-section compared to the ninth variation. Even with this configuration, vortices can be generated around the opening of each groove 44, ensuring the stirring of the refrigerant.

[0061] 22 , in the eleventh variation, compared to the ninth variation, each groove 44 is changed to an inclined groove inclined in the y direction, and the cross-sectional shape of each groove is changed to a triangular cross-section. Even with this configuration, vortices can be generated around the opening of each groove 44, thereby ensuring the stirring of the refrigerant.

[0062] 23 , in the twelfth variation, unlike the eleventh variation, the grooves 44 formed on one surface 36B of the plate 36 and the grooves 44 formed on the other surface 36B of the plate 36 are staggered in the Z direction. Even with this configuration, vortices can be generated around the openings of each groove 44, ensuring the agitation of the refrigerant. Furthermore, by staggering the grooves 44 formed on one surface 36B of the plate 36 and the grooves 44 formed on the other surface 36B of the plate 36 in the Z direction, it is possible to suppress a decrease in bending rigidity due to localized thinning of the plate 36.

[0063] As shown in FIG. 24 , in the thirteenth variation, the plate 36 has multiple transverse ribs 48 instead of multiple protrusions 40. The transverse ribs 48 are an example of the "protrusions 40" according to the technology of the present disclosure. The transverse ribs 48 protrude in the x direction. On each surface 36B of the plate 36, multiple transverse ribs 48 are arranged at intervals in the z direction. Each transverse rib 48 extends in the y direction. Each transverse rib 48 is formed from one end to the other end of the surface 36B of the plate 36 in the y direction. Each transverse rib 48 has a rectangular cross section. The transverse rib 48 formed on one surface 36B of the plate 36 and the transverse rib 48 formed on the other surface 36B of the plate 36 are formed at the same position in the z direction. By having multiple transverse ribs 48 on each surface 36B, the plate 36 has a shape in which the distance in the x direction from the imaginary plane 38 to the surface 36B of the plate 36 increases and decreases along the z direction. Even with this configuration, vortices can be generated around the apex of each horizontal rib 48, ensuring good agitation of the refrigerant. The cross-sectional shape of the horizontal ribs 48 may be any shape.

[0064] 25 , in the fourteenth variation, the plate 36 is formed in a corrugated shape in the z direction. The plate 36 may be formed in a corrugated shape in the y direction as well as in the z direction. By forming the plate 36 in a corrugated shape in the z direction, the plate 36 has a shape in which the distance in the x direction from an imaginary plane 38 to a surface 36B of the plate 36 increases and decreases along the z direction. Even with this configuration, vortices can be generated around the peaks of the corrugations, ensuring the stirring of the refrigerant.

[0065] As shown in Fig. 26, in the fifteenth variation, the plate 36 has a plurality of holes 46 instead of the plurality of protrusions 40. Each hole 46 penetrates the plate 36 in the thickness direction. Each hole 46 is formed in a circular shape. The plurality of holes 46 are also arranged in a staggered pattern. Even with this configuration, vortices can be generated around the openings of each hole 46, ensuring the stirring of the refrigerant.

[0066] 27 , in the 16th variation, the shape of each hole 46 is changed to a square shape compared to the 15th variation. Even with this configuration, vortices can be generated around the opening of each hole 46, ensuring the stirring of the refrigerant.

[0067] In the fifteenth and sixteenth variations, the holes 46 are arranged in a staggered pattern, but they may also be arranged in a single row or in multiple rows.

[0068] As shown in FIG. 28 , in the seventeenth variation, the plate 36 has multiple vertical ribs 50 instead of multiple protrusions 40. The vertical ribs 50 protrude in the x direction. On each surface 36B of the plate 36, the multiple vertical ribs 50 are spaced apart in the y direction. Each vertical rib 50 extends in the z direction. Each vertical rib 50 is formed from one end of the surface 36B of the plate 36 to the other end in the z direction. The cross-sectional shape of the vertical ribs 50 may be any shape. This configuration ensures the bending rigidity of the plate 36, thereby preventing deformation of the plate 36 due to the force of the refrigerant flowing between adjacent winding portions 18. Furthermore, each vertical rib 50 guides the refrigerant flowing between adjacent winding portions 18, thereby improving the cooling efficiency of the winding portions 18.

[0069] Among the configurations described in the above embodiments, configurations that can be combined may be combined as appropriate.

[0070] The above describes one embodiment of the technology of the present disclosure, but the present invention is not limited to the above, and it goes without saying that the present invention can be implemented in various modifications within the scope of the gist of the present disclosure.

[0071] The following are supplementary notes regarding the technology of the present disclosure. (Supplementary Note 1) A stator (10) comprising: a stator core (24) having a plurality of radially extending tooth portions (22); a plurality of insulators (16) attached to the plurality of tooth portions; a plurality of winding winding portions (18) wound around the plurality of tooth portions with the insulators interposed therebetween; and a plurality of plate-shaped members (36) arranged between the plurality of winding winding portions to separate adjacent ones of the winding winding portions. (Supplementary Note 2) The stator according to Supplementary Note 1, wherein when an imaginary plane (38) is set that passes through a center between adjacent ones of the winding winding portions and extends in the radial direction of the stator core, the plate members have a shape such that the distance from the imaginary plane to a surface (36B) of the plate members increases and decreases along the axial direction of the stator core. (Supplementary Note 3) The stator according to Supplementary Note 2, wherein the shape includes a protrusion (40, 48) formed on the surface of the plate material. (Supplementary Note 4) The stator according to Supplementary Note 3, wherein the protrusion is formed in a triangular cross section whose height decreases or increases toward one axial side of the stator core. (Supplementary Note 5) The stator according to Supplementary Note 3, wherein the protrusion is formed in a cylindrical or prismatic shape. (Supplementary Note 6) The stator according to Supplementary Note 3 or Supplementary Note 4, wherein the protrusion is formed in a wedge shape whose width along the radial direction of the stator core decreases toward one axial side of the stator core. (Supplementary Note 7) The stator according to any one of Supplementary Notes 2 to 6, wherein the shape includes a recess (42) or groove (44) opening in a thickness direction of the plate material. (Supplementary Note 8) The stator according to any one of Supplementary Notes 2 to 7, wherein the shape includes a wave shape formed on the plate material. (Supplementary Note 9) The stator according to any one of Supplementary Notes 1 to 8, wherein the plate material has a hole (46) penetrating through the plate material in a plate thickness direction. (Supplementary Note 10) The stator according to any one of Supplementary Notes 1 to 9, wherein the plate material is formed integrally with the insulator.(Supplementary Note 11) The stator according to any one of Supplementary Notes 1 to 10, wherein the stator core is constituted by a plurality of core members (14) divided in the circumferential direction of the stator core, the plurality of insulators are divided in the circumferential direction of the stator core, and base ends of the plate materials are connected to the insulators in a manner that allows them to be bent. (Supplementary Note 12) The stator according to Supplementary Note 11, wherein tip ends of the plate materials are sandwiched between adjacent insulators. (Supplementary Note 13) The stator according to any one of Supplementary Notes 1 to 9, wherein the plate materials are formed separately from the insulators and are sandwiched between adjacent insulators. (Supplementary Note 14) The stator according to any one of Supplementary Notes 1 to 13, wherein, when an imaginary plane is set that passes through a center between adjacent ones of the winding portions and extends in a radial direction of the stator core, end faces (36A) on both sides of the plate material in the radial direction of the stator core intersect with the imaginary plane. (Supplementary Note 15) A method for manufacturing a stator, the stator comprising: a stator core having a plurality of radially extending tooth portions; a plurality of insulators attached to the plurality of tooth portions; a plurality of winding winding portions wound around the plurality of tooth portions with the insulators interposed therebetween; and a plurality of plate-shaped plates disposed between the plurality of winding winding portions to separate the plurality of winding winding portions, the stator core being constituted by a plurality of core members divided in a circumferential direction of the stator core, the plurality of insulators being divided in the circumferential direction of the stator core, and base ends of the plate members being connected to the insulators in a bendable manner, the manufacturing method comprising: a winding winding step of winding the winding portions around the tooth portions of the core member with the insulators interposed therebetween with the plate members in an expanded state; a bending step of bending the plate members; and an assembly step of assembling the plurality of core members into an annular shape. (Supplementary Note 16) The method for manufacturing a stator according to Supplementary Note 15, wherein the assembling step includes sandwiching a tip end portion of the plate material between adjacent ones of the insulators.

Claims

1. A stator (10) comprising: a stator core (24) having a plurality of radially extending tooth portions (22); a plurality of insulators (16) attached to the plurality of tooth portions; a plurality of winding winding portions (18) wound around the plurality of tooth portions via each of the insulators; and a plurality of plate-shaped plate members (36) disposed between the plurality of winding winding portions to separate adjacent ones of the winding winding portions.

2. A stator as described in claim 1, wherein, when an imaginary plane (38) is defined that passes through the center between adjacent winding portions and extends radially of the stator core, the plate material has a shape in which the distance from the imaginary plane to the surface (36B) of the plate material increases and decreases along the axial direction of the stator core.

3. A stator according to claim 2, wherein the shape includes a protrusion (40, 48) formed on the surface of the plate material.

4. The stator according to claim 3, wherein the protrusions are formed in a triangular cross section with a height that decreases or increases toward one side in the axial direction of the stator core.

5. The stator according to claim 3, wherein the protrusions are formed in a cylindrical or prismatic shape.

6. A stator according to claim 3 or claim 4, wherein the protrusion is formed in a wedge shape whose width along the radial direction of the stator core decreases toward one side in the axial direction of the stator core.

7. A stator according to any one of claims 2 to 6, wherein the shape includes a recess (42) or a groove (44) that opens in the thickness direction of the plate material.

8. A stator according to any one of claims 2 to 7, wherein the shape includes a wave shape formed on the plate material.

9. A stator according to any one of claims 1 to 8, wherein the plate material has a hole (46) penetrating through the plate material in the thickness direction.

10. A stator according to any one of claims 1 to 9, wherein the plate material is formed integrally with the insulator.

11. A stator as claimed in any one of claims 1 to 10, wherein the stator core is constituted by a plurality of core members (14) divided in the circumferential direction of the stator core, the plurality of insulators are divided in the circumferential direction of the stator core, and the base ends of the plate materials are connected to the insulators in a manner that allows them to be bent.

12. A stator according to claim 11, wherein the tip end of the plate material is sandwiched between adjacent insulators.

13. A stator according to any one of claims 1 to 9, wherein the plate material is formed separately from the insulators and is sandwiched between adjacent insulators.

14. A stator as set forth in any one of claims 1 to 13, wherein when an imaginary plane is set that passes through the center between adjacent winding portions and extends in the radial direction of the stator core, the end faces (36A) on both sides of the plate material in the radial direction of the stator core intersect with the imaginary plane.

15. A method for manufacturing a stator, the stator comprising: a stator core having a plurality of radially extending teeth; a plurality of insulators attached to the plurality of teeth; a plurality of winding winding portions wound around the plurality of teeth via the insulators; and a plurality of plate-shaped plates arranged between the plurality of winding winding portions to separate the plurality of winding winding portions, the stator core being constituted by a plurality of core members divided in the circumferential direction of the stator core, the plurality of insulators being divided in the circumferential direction of the stator core, and base ends of the plate members being connected to the insulators in a bendable manner, the manufacturing method comprising: a winding winding process of winding the winding portions around the teeth of the core member via the insulators while the plate members are spread out; a bending process of bending the plate members; and an assembly process of assembling the plurality of core members into an annular shape.

16. A method for manufacturing a stator according to claim 15, wherein the assembling step includes clamping the leading end of the plate material between adjacent insulators.

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