Stator, rotary electric machine, and insulating sheet

Abstract

A stator (10) is provided with a stator core (24), an insulating sheet (50) for insulating the stator core, and a coil wound part (18) wound on the stator core with the insulating sheet interposed therebetween. A conductor (80) is provided in at least a portion between the stator core and the coil wound part. The insulating sheet is overlapped with the conductor, and has insulators (82, 84) provided between the conductor and the coil wound part and / or between the conductor and the stator core.

Description

Stator, rotating electric machine, and insulating sheet CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2024-147891, filed on August 29, 2024, the entire contents of which are incorporated herein by reference.

[0002] The technology of the present disclosure relates to a stator, a rotating electric machine, and an insulating sheet.

[0003] Conventionally, there is a stator for a rotating electric machine that includes a stator core, an insulating sheet that insulates the stator core, and a winding wound around the stator core via the insulating sheet. In addition, some stators of this type insulate the stator core by stacking multiple insulating sheets (see, for example, the pamphlet of International Publication No. 2016 / 208555).

[0004] As a result of detailed investigations, the inventors discovered the following problem. When insulating a stator core by stacking multiple insulating sheets, the multiple insulating sheets take up space in the slots between multiple teeth. This reduces the space factor of the winding in the slot (i.e., the slot space factor) and increases the stray capacitance between the winding and the stator core. Therefore, the challenge is to reduce the thickness of the insulating sheet while maintaining its insulating properties.

[0005] The technique disclosed herein provides a stator, a rotating electric machine, and an insulating sheet that can reduce the thickness of the insulating sheet while ensuring the insulating properties of the insulating sheet.

[0006] A first aspect of the technology disclosed herein is a stator comprising a stator core, an insulating sheet that insulates the stator core, and a winding winding portion wound around the stator core via the insulating sheet, wherein a conductor is provided at least partially between the stator core and the winding winding portion, and the insulating sheet is superimposed on the conductor, with an insulator provided at least partially between the conductor and the winding winding portion and between the conductor and the stator core.

[0007] A second aspect of the technique of the present disclosure is a rotating electric machine including the stator according to the first aspect.

[0008] A third aspect of the technology of the present disclosure is an insulating sheet that insulates a stator core, the insulating sheet having a conductor provided in at least a portion between the stator core and a winding winding portion wound around the stator core via the insulating sheet, and an insulator superimposed on the conductor and provided at least one between the conductor and the winding winding portion and between the conductor and the stator core.

[0009] According to the technology of the present disclosure, a stator, a rotating electric machine, and an insulating sheet are provided that enable the insulating sheet to be thinned while ensuring the insulating properties of the insulating sheet.

[0010] 1 is a cross-sectional view of a stator according to a first embodiment; FIG. 2 is a perspective view of a stator component according to the first embodiment; FIG. 3 is a diagram illustrating an assembly process of a stator component according to the first embodiment; FIG. 4 is a longitudinal cross-sectional view of a stator component according to the first embodiment, cut at the center of a tooth in the Y direction; FIG. 5 is a cross-sectional view of a stator component according to the first embodiment, cut at the end face of a tooth in the Z direction; FIG. 6 is a cross-sectional view (schematic view) of a stator component according to the first embodiment, cut at the center of a tooth in the Z direction; FIG. 7 is a perspective view (perspective view including a cross section) of an enlarged main portion of an insulating sheet according to the first embodiment; FIG. 8 is a diagram illustrating the relationship between an insulating structure between a winding winding portion and a stator core according to the first embodiment and an equivalent circuit; FIG. 9 is a diagram illustrating an assembly process of a stator component according to a second embodiment; FIG. 10 is a cross-sectional view of a stator component according to the second embodiment, cut at the end face of a tooth in the Z direction; FIG. 11 is a cross-sectional view (schematic view) of a stator component according to the second embodiment, cut at the center of a tooth in the Z direction; FIG. 12 is an exploded perspective view of a stator component according to a third embodiment; FIG. 13 is an exploded perspective view of a stator component according to a modification of the third embodiment. 10 is a cross-sectional view (schematic diagram) of a stator component according to a fourth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 11 is a cross-sectional view (schematic diagram) of a stator component according to a modification of the fourth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 12 is a cross-sectional view (schematic diagram) of a stator component according to a fifth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 13 is a cross-sectional view (schematic diagram) of a stator component according to a modification of the fifth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 14 is a cross-sectional view (schematic diagram) of a stator component according to a sixth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 15 is a cross-sectional view (schematic diagram) of a stator component according to a modification of the sixth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 16 is a cross-sectional view (schematic diagram) of a stator component according to a modification of the sixth embodiment, cut at the center of the tooth portion in the Z direction. FIG. 17 is an enlarged perspective view (perspective view including a cross section) of a main part of an insulating sheet according to a seventh embodiment. FIG. 18 is a diagram for explaining a method for manufacturing an insulating sheet according to the seventh embodiment. FIG. 19 is an enlarged perspective view (perspective view including a cross section) of a main part of an insulating sheet according to a first modification of the seventh embodiment. 13A to 13C are diagrams illustrating a method for manufacturing an insulating sheet according to a first modified example of the seventh embodiment.13 is an enlarged perspective view (perspective view including a cross section) of a main part of an insulating sheet according to a second modified example of the seventh embodiment; FIG. 14 is a view illustrating a manufacturing method of an insulating sheet according to a second modified example of the seventh embodiment; FIG. 15 is a view illustrating a manufacturing method of an insulating sheet according to a third modified example of the seventh embodiment; FIG. 16 is a view illustrating a variation example of an insulating structure using an insulating sheet according to an eighth embodiment; FIG. 17 is a view illustrating a variation example of an insulating structure using an insulating sheet according to an eighth embodiment; FIG. 18 is a view illustrating a variation example of an insulating structure using an insulating sheet according to an eighth embodiment; FIG. 19 is a cross-sectional view of a stator according to a ninth embodiment, cut at the position of an end face in the Z direction of a tooth portion; FIG. 19 is a cross-sectional view of a stator according to a ninth embodiment, cut at the position of a central part in the Z direction of a tooth portion; FIG. 19 is a cross-sectional view of a stator according to a modified example of the ninth embodiment, cut at the position of an end face in the Z direction of a tooth portion; FIG. 19 is a cross-sectional view of a stator according to a tenth embodiment, cut at the position of an end face in the Z direction of a tooth portion;

[0011] First Embodiment First, a first embodiment of the technology of the present disclosure will be described.

[0012] 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 rotating electric machine such as a brushless motor.

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

[0014] 1 and 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 when viewed from the Z direction, and has teeth portions 20 and a core back portion 22. The core back portion 22 extends in the circumferential direction of the stator core 24, and the teeth portions 20 extend inward in the Y direction from the center of the core back portion 22. The tip portions of the teeth portions 20 are free ends, and the base ends of the teeth portions 20 are connected to the core back portion 22. The core member 14 is a laminate in which multiple core sheets are stacked in the Z direction.

[0015] A stator core 24 (see FIG. 1) is constructed by combining a plurality of core members 14 in an annular shape. That is, the stator core 24 is formed by a plurality of core members 14 divided into individual tooth portions 20. When the stator core 24 is constructed, the plurality of core back portions 22 form an annular portion 26 (see FIG. 1) that is the outer periphery of the stator core 24, and the plurality of tooth portions 20 extend radially from the center of the stator core 24. Slots 28 (see FIG. 1) are formed between the plurality of tooth portions 20.

[0016] As shown in FIG. 3 , the insulator 16 has a pair of insulating members 30 and a pair of insulating sheets 50. The insulating members 30 are three-dimensional resin parts formed by resin molding. The insulating sheets 50 are sheet-shaped resin sheets. The pair of insulating members 30 are attached to the core member 14 from both sides in the Z direction. The pair of insulating sheets 50 are disposed between the pair of insulating members 30 in the Z direction and attached to the core member 14 from both sides in the X direction. The insulating sheets 50 are folded. The pair of insulating members 30 are formed symmetrically in the Z direction, and the pair of insulating sheets 50 are formed symmetrically in the X direction. Below, one of the pair of insulating members 30 will be described. Similarly, one of the pair of insulating sheets 50 will be described.

[0017] The insulating member 30 has a first insulating portion 32 that insulates the tooth portion 20 and a second insulating portion 34 that insulates the core back portion 22. The insulating sheet 50 has a first insulating portion 52 that insulates the tooth portion 20, a second insulating portion 54 that insulates the core back portion 22, and a third insulating portion 56 that insulates adjacent winding winding portions 18 in the circumferential direction of the stator core 24. With the third insulating portion 56 spread in the X direction, the winding is wound around the tooth portion 20 in the Y direction to form the winding winding portion 18. That is, the winding winding portion 18 is wound around the tooth portion 20 via the insulating member 30 and the insulating sheet 50. The third insulating portion 56 is bent inward in the Y direction after the winding winding portion 18 is formed.

[0018] The first insulating portion 32 of the insulating member 30 is provided between the tooth portion 20 and the winding winding portion 18 to insulate the tooth portion 20, and the second insulating portion 34 of the insulating member 30 is provided between the core back portion 22 and the winding winding portion 18 to insulate the core back portion 22. The first insulating portion 52 of the insulating sheet 50 is provided between the tooth portion 20 and the winding winding portion 18 to insulate the tooth portion 20, the second insulating portion 54 of the insulating sheet 50 is provided between the core back portion 22 and the winding winding portion 18 to insulate the core back portion 22, and the third insulating portion 56 of the insulating sheet 50 is provided between adjacent winding winding portions 18 to insulate adjacent winding winding portions 18 from each other.

[0019] 4, the tooth portion 20 has an end face 20A facing the Z direction and a side face 20B facing the X direction. The end face 20A extends in the X direction and the Y direction, and the side face 20B extends in the Y direction and the Z direction. The width of the tooth portion 20 along the X direction is constant throughout the Z direction. In other words, the tooth portion 20 is formed in a quadrangular shape when viewed from the Y direction.

[0020] The first insulating portion 32 of the insulating member 30 insulates the tooth portion 20 from the Z direction. Specifically, the first insulating portion 32 of the insulating member 30 covers the end face 20A of the tooth portion 20 from the Z direction, insulating the end face 20A from the winding portion 18. The first insulating portion 52 of the insulating sheet 50 insulates the tooth portion 20 from the X direction. Specifically, the first insulating portion 52 of the insulating sheet 50 covers the side face 20B of the tooth portion 20, insulating the side face 20B from the winding portion 18.

[0021] As shown in FIG. 5 , the core back portion 22 has an inner surface 22A facing inward in the Y direction. The inner surface 22A extends in the X and Z directions. At the Z-direction end surface 20A of the tooth portion 20 (i.e., the position of the cut surface in FIG. 5 ), the first insulating portion 32 of the insulating member 30 and the first insulating portion 52 of the insulating sheet 50 overlap in the X direction, and the second insulating portion 34 of the insulating member 30 and the second insulating portion 54 of the insulating sheet 50 overlap in the Y direction. At the Z-direction end of the tooth portion 20, the first insulating portion 52 of the insulating sheet 50 is sandwiched between the first insulating portion 32 of the insulating member 30 and the side surface 20B of the tooth portion 20, and the second insulating portion 54 of the insulating sheet 50 is sandwiched between the second insulating portion 34 of the insulating member 30 and the inner surface 22A of the core back portion 22.

[0022] The first insulating portion 32 of the insulating member 30 and the first insulating portion 52 of the insulating sheet 50 insulate the tooth portion 20 from the X direction. Specifically, the first insulating portion 32 of the insulating member 30 and the first insulating portion 52 of the insulating sheet 50 cover the side surface 20B of the tooth portion 20, insulating the side surface 20B from the winding winding portion 18. The second insulating portion 34 of the insulating member 30 and the second insulating portion 54 of the insulating sheet 50 insulate the core back portion 22 from the Y direction. Specifically, the second insulating portion 34 of the insulating member 30 and the second insulating portion 54 of the insulating sheet 50 cover the inner surface 22A of the core back portion 22, insulating the inner surface 22A from the winding winding portion 18.

[0023] The insulating member 30 has a tip insulating portion 36 that insulates the tip of the tooth portion 20. The tip insulating portion 36 has a winding holding portion 38 that holds the winding terminal portion 19 connected to the winding winding portion 18. The winding holding portion 38 is formed in a groove shape that opens in the X direction and the Z direction. The tip insulating portion 36 also has an insulating sheet holding portion 40. The insulating sheet holding portion 40 is formed in a groove shape.

[0024] The tip portions 56A of the third insulating portions 56 of the insulating sheet 50 are bent along the tips of the teeth 20 and are held by being inserted into the insulating sheet holding portion 40. The tip portions 52A of the first insulating portions 52 of the insulating sheet 50 are bent along the tips of the teeth 20 and are held by being sandwiched between the tips of the teeth 20 and the tip insulating portion 36 via the tip portions 56A of the third insulating portions 56. The tip portions 52A of the first insulating portions 52 and the tip portions 56A of the third insulating portions 56 form a lap portion 70 and overlap each other. Note that in the lap portion 70, the tip portions 52A of the first insulating portions 52 are located between the tips of the teeth 20 and the tip portions 56A of the third insulating portions 56, but the tip portions 56A of the third insulating portions 56 may also be located between the tips of the teeth 20 and the tip portions 52A of the first insulating portions 52.

[0025] Fig. 6 schematically illustrates the insulating sheet 50 and the winding winding portion 18. As shown in Figs. 6 and 7, the insulating sheet 50 has a conductor 80, a first insulator 82, and a second insulator 84. The first insulator 82 and the second insulator 84 are examples of "insulators" according to the technology of the present disclosure. Details of the material, structure, manufacturing method, etc. of the insulating sheet 50 will be described in the seventh and eighth embodiments.

[0026] The conductor 80, the first insulator 82, and the second insulator 84 are all formed in a sheet shape and are stacked on top of each other. The conductor 80 is provided between the first insulator 82 and the second insulator 84. The conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50. In other words, the conductor 80, the first insulator 82, and the second insulator 84 are provided across the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56 of the insulating sheet 50.

[0027] In the first insulating portion 52 and the second insulating portion 54, the conductor 80 is provided between the stator core 24 (more specifically, the core member 14) and the winding winding portion 18, and the first insulator 82 is provided between the conductor 80 and the winding winding portion 18. In the first insulating portion 52 and the second insulating portion 54, the second insulator 84 is provided between the conductor 80 and the stator core 24. In the third insulating portion 56, the first insulator 82 is provided between the conductor 80 and the winding winding portion 18, and the second insulator 84 is provided on the opposite side of the conductor 80 from the first insulator 82.

[0028] 8, the insulating structure between the winding portion 18 and the stator core 24 is represented by an equivalent circuit. That is, the coating 102 covering the wire 100 of the winding portion 18, the gas layer 104 between the winding portion 18 and the first insulator 82, the first insulator 82, and the second insulator 84 are each represented by a capacitor, and the conductor 80 is represented by a resistor.

[0029] Here, the voltage V of the first insulator 82 is ３ is expressed by the formula 1, and the shared voltage V of the second insulator 84 is ５ is expressed by the formula 2. By providing the conductor 80 between the first insulator 82 and the second insulator 84, the voltage V ３ and the shared voltage V of the second insulator 84 ５ can be reduced compared to when the conductor 80 is not used. The effect of reducing the thickness of the first insulator 82 and the second insulator 84 can be obtained when the dielectric constants of the first insulator 82 and the second insulator 84 are equal to or greater than a predetermined value. The impedance Z' corresponding to the combined stray capacitance of the first insulator 82 and the second insulator 84 is expressed by the formula shown in Equation 3. The impedance Z' is expressed by Z ３ =Z ５ When the impedance Z of the first insulator 82 is ３ It will be half of that.

[0030] where V is the voltage applied between the wire 100 of the winding portion 18 and the stator core 24, and V １ is the voltage applied to the coating 102 of the winding turn 18, and V ２ is the voltage applied to the gas layer 104, and V ４ is the voltage applied to the conductor 80, and Z １ is the impedance of the coating 102 of the winding turn 18, and Z ２ is the impedance of the gas layer 104, and Z ３ is the impedance of the first insulator 82, and Z ５ is the impedance of the second insulator 84.

[0031] According to the first embodiment, by providing the conductor 80 between the first insulator 82 and the second insulator 84, the voltage V ３ and the shared voltage V of the second insulator 84 ５ can be reduced compared to when the conductor 80 is not used. This allows the thickness of the first insulator 82 and the second insulator 84 to be thinner compared to when the conductor 80 is not used, so that the insulating sheet 50 can be made thinner while ensuring the insulating properties of the insulating sheet 50. As a result, the slot space factor can be improved, so that the output performance can be improved while the rotating electric machine is downsized.

[0032] Furthermore, compared to when a plurality of insulating sheets 50 are stacked to insulate the stator core 24, the space required for the insulating sheets 50 can be reduced, thereby improving the slot space factor.

[0033] Furthermore, the inverter that controls the stator 10 is equipped with a noise filter to remove dielectric noise, and by thinning the insulating sheet 50, the stray capacitance between the winding winding portion 18 and the stator core 24 can be reduced, making it possible to make the noise filter smaller or reduce the number of noise filters required.

[0034] Furthermore, the insulating sheet 50 has a first insulating portion 52 provided between the tooth portion 20 and the winding winding portion 18, a second insulating portion 54 provided between the core back portion 22 and the winding winding portion 18, and a third insulating portion 56 provided between the winding winding portions 18 adjacent to each other in the circumferential direction of the stator core 24, and the conductor 80, the first insulator 82, and the second insulator 84 are provided in the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56. Therefore, the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56 can be thinned while ensuring the insulation properties of the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56.

[0035] In particular, the conductor 80, the first insulator 82, and the second insulator 84 are provided in the first insulating portion 52 and the second insulating portion 54 (i.e., the portions that contribute to stray capacitance) of the insulating sheet 50. Therefore, the stray capacitance between the winding portion 18 and the stator core 24 can be reduced.

[0036] Furthermore, the insulating sheet 50 has a third insulating portion 56 provided between adjacent winding winding portions 18 in the circumferential direction of the stator core 24. Therefore, the number of parts can be reduced compared to when the third insulating portion 56 is separate from the insulating sheet 50.

[0037] Furthermore, the insulating sheet 50 has overlapping wrap portions 70, and the wrap portions 70 are also provided with conductors 80, first insulators 82, and second insulators 84. Therefore, the wrap portions 70 increase the creepage distance, which is the distance along the insulating sheet 50 from the winding winding portion 18 to the stator core 24, thereby improving the voltage resistance and reducing the thickness of the wrap portions 70. In particular, the wrap portions 70 are formed at the tip portions 52A of the first insulating portion 52 and the tip portions 56A of the third insulating portion 56, and therefore, the voltage resistance can be improved and the thickness can be reduced at the tip portions 52A of the first insulating portion 52 and the tip portions 56A of the third insulating portion 56.

[0038] Furthermore, the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50. Therefore, the insulating sheet 50 can be manufactured more easily than when, for example, the conductor 80 is provided only partially on the insulating sheet 50.

[0039] Second Embodiment Next, a second embodiment of the technique of the present disclosure will be described.

[0040] In the second embodiment, the configurations of the insulating member 30 and the insulating sheet 50 are changed as follows compared to the first embodiment: In the first embodiment, the wrap portion 70 is formed on the tip end 52A of the first insulating portion 52 and the tip end 56A of the third insulating portion 56, but in the second embodiment, as shown in Fig. 9, the wrap portion 70 is formed on the third insulating portion 56 (see also Fig. 10).

[0041] The third insulating portion 56 has a fourth insulating portion 58 connected to the first insulating portion 52 and a fifth insulating portion 60 connected to the second insulating portion 54. The fourth insulating portion 58 extends from the tip end side of the tooth portion 20 toward the core back portion 22 side, and the fifth insulating portion 60 extends from the core back portion 22 side toward the tip end side of the tooth portion 20. The wrap portion 70 is formed by the tip end portion 58A of the fourth insulating portion 58 and the tip end portion 60A of the fifth insulating portion 60 (see FIG. 10 ) overlapping each other.

[0042] 9 , when the wrap portion 70 is formed on the third insulating portion 56, the fourth insulating portion 58 and the fifth insulating portion 60 are spread out in the X direction, and the winding is then wound around the tooth portion 20 in the Y direction to form the winding portion 18. That is, the winding portion 18 is wound around the tooth portion 20 via the insulating member 30 and the insulating sheet 50. The fourth insulating portion 58 is bent outward in the Y direction after the winding portion 18 is formed, and the fifth insulating portion 60 is bent inward in the Y direction after the winding portion 18 is formed.

[0043] 10 , in the wrap portion 70, the tip portion 58A of the fourth insulating portion 58 is provided between the tip portion 60A of the fifth insulating portion 60 and the winding winding portion 18, but the tip portion 60A of the fifth insulating portion 60 may be provided between the tip portion 58A of the fourth insulating portion 58 and the winding winding portion 18. In the second embodiment, since the wrap portion 70 is formed on the third insulating portion 56, the insulating sheet holding portion 40 of the tip insulating portion 36 is changed in shape to hold the tip portion 52A of the first insulating portion 52 of the insulating sheet 50.

[0044] 11 schematically shows the insulating sheet 50 and the winding winding portion 18. As shown in Fig. 10 and Fig. 11, the insulating sheet 50 has a conductor 80, a first insulator 82, and a second insulator 84. Similar to the first embodiment, the conductor 80 is provided between the first insulator 82 and the second insulator 84, and the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50.

[0045] According to the second embodiment, the insulating sheet 50 has overlapping wrap portions 70, which are provided with a conductor 80, a first insulator 82, and a second insulator 84. Therefore, the wrap portions 70 increase the creepage distance, which is the distance along the insulating sheet 50 from the winding winding portion 18 to the stator core 24, thereby improving the voltage resistance and reducing the thickness of the wrap portions 70. In particular, since the wrap portions 70 are formed in the third insulating portion 56, the voltage resistance of the third insulating portion 56 can be improved and reduced in thickness.

[0046] In the second embodiment, the same configuration as that of the first embodiment provides the same effects as those of the first embodiment, and therefore the description thereof will be omitted.

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

[0048] In the third embodiment, the configurations of the insulating member 30 and the insulating sheets 50 are changed as follows compared to the second embodiment. That is, in the second embodiment, the pair of insulating sheets 50 are configured independent of each other, but in the third embodiment, as shown in Fig. 12, the pair of insulating sheets 50 are connected by an insulating connecting portion 72. The insulating connecting portion 72 extends in the X direction and the Y direction, and connects one end of the pair of insulating sheets 50 (more specifically, one end of the pair of first insulating portions 52) in the Z direction.

[0049] The other ends of the pair of insulating sheets 50 in the Z direction are open in the Z direction. The pair of insulating sheets 50 are attached to the core member 14 from the side that is open in the Z direction. The insulating connecting portion 72 covers the first insulating portion 32 of the insulating member 30 from the Z direction, but the arrangement of the insulating connecting portion 72 and the first insulating portion 32 of the insulating member 30 may be reversed from that in FIG. 12 so that the insulating connecting portion 72 is covered by the first insulating portion 32 of the insulating member 30 from the Z direction. Similar to the second embodiment, the pair of insulating sheets 50 and the insulating connecting portion 72 each include a conductor 80, a first insulator 82, and a second insulator 84 (see FIG. 11, etc.).

[0050] According to the third embodiment, the pair of insulating sheets 50 are connected by the insulating connecting portion 72, so the number of parts can be reduced compared to when the pair of insulating sheets 50 are configured independent of each other.

[0051] In addition, the insulating connecting portion 72, which is arranged between the winding winding portion 18 and the tooth portion 20 in the Z direction, is also provided with a conductor 80, a first insulator 82, and a second insulator 84 (see Figure 11, etc.), so the insulating connecting portion 72 can be made thinner, and ultimately the height of the winding winding portion 18 in the Z direction can be reduced.

[0052] In the third embodiment, the same configuration as that of the second embodiment provides the same effects as those of the second embodiment, and therefore the description thereof will be omitted.

[0053] 13, the insulating member 30 (see FIG. 12) provided on one side in the Z direction of the pair of insulating members 30 may be omitted, and an insulating connecting portion 72 may insulate the teeth portion 20 from the Z direction instead of the insulating member 30. In this way, the number of parts can be reduced compared to when a pair of insulating members 30 is used.

[0054] Furthermore, the insulating connecting portion 72 connects one end of the pair of insulating sheets 50 in the Z direction, but may connect any part of the pair of insulating sheets 50 .

[0055] Furthermore, the pair of insulating members 30 may be omitted, and the insulator 16 may be formed of a pair of insulating sheets 50 .

[0056] Fourth Embodiment Next, a fourth embodiment of the technique of the present disclosure will be described.

[0057] In the fourth embodiment, the configuration of the insulating sheet 50 is changed as follows compared to the first embodiment: In the first embodiment, the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50, but in the fourth embodiment, as shown in FIG.

[0058] 14 schematically illustrates the insulating sheet 50 and the winding winding portion 18. More specifically, the conductor 80 and the first insulator 82 are provided in the first insulating portion 52 and the second insulating portion 54 of the insulating sheet 50 (i.e., the portions that contribute to stray capacitance). That is, the first insulating portion 52 and the second insulating portion 54 of the insulating sheet 50 include the conductor 80 and the first insulator 82. Meanwhile, the second insulator 84 is provided over the entire insulating sheet 50. More specifically, the second insulator 84 is provided in the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56. That is, the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56 of the insulating sheet 50 include the second insulator 84.

[0059] In addition to the third insulating portion 56, the conductor 80 is not provided at the bent portion 66 between the second insulating portion 54 and the third insulating portion 56, nor at the bent portion 68 at the tip end 56A of the third insulating portion 56. In other words, the conductor 80 is provided in the insulating sheet 50 except for the bent portions 66, 68 and the third insulating portion 56.

[0060] According to the fourth embodiment, the conductor 80, the first insulator 82, and the third insulator 84 are provided in the first insulating portion 52 and the second insulating portion 54 of the insulating sheet 50 (i.e., the portions that contribute to stray capacitance). This reduces the stray capacitance between the winding winding portion 18 and the stator core 24. Furthermore, since the conductor 80 and the first insulator 82 are not provided in the third insulating portion 56 of the insulating sheet 50, the material costs of the insulating sheet 50 can be reduced compared to when the conductor 80 and the first insulator 82 are provided in the third insulating portion 56.

[0061] Furthermore, the conductors 80 are provided in portions of the insulating sheet 50 excluding the bent portions 66, 68 and the third insulating portion 56, and the conductors 80 are not provided in the bent portion 66 between the second insulating portion 54 and the third insulating portion 56, and in the bent portion 68 at the tip portion 56A of the third insulating portion 56. Therefore, compared to when the conductors 80 are provided in the bent portions 66, 68, the bending rigidity of the bent portions 66, 68 can be reduced, making it easier to bend the bent portions 66, 68. Furthermore, compared to when the conductors 80 are provided in the bent portions 66, 68, the radius of curvature of the bent portions 66, 68 can be made smaller, improving the slot space factor.

[0062] In the fourth embodiment, the same configuration as that of the first embodiment provides the same effects as those of the first embodiment, and therefore the description thereof will be omitted.

[0063] In the fourth embodiment, the wrap portion 70 may be formed at a position shown in Fig. 15 , which schematically illustrates the insulating sheet 50 and the winding winding portion 18. That is, the wrap portion 70 may be formed on the third insulating portion 56 (specifically, the tip portion 58A of the fourth insulating portion 58 and the tip portion 60A of the fifth insulating portion 60). When the wrap portion 70 is formed on the third insulating portion 56 in this manner, the voltage resistance of the third insulating portion 56 can be improved.

[0064] Fifth Embodiment Next, a fifth embodiment of the technique of the present disclosure will be described.

[0065] In the fifth embodiment, the configuration of the insulating sheet 50 is changed as follows compared to the first embodiment: In the first embodiment, the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50, but in the fifth embodiment, as shown in FIG.

[0066] 16 schematically illustrates the insulating sheet 50 and the winding winding portion 18. The insulating sheet 50 has folded portions 62, 64, 66, and 68. The folded portion 62 is formed at the tip portion 52A of the first insulating portion 52, the folded portion 64 is formed between the first insulating portion 52 and the second insulating portion 54, the folded portion 66 is formed between the second insulating portion 54 and the third insulating portion 56, and the folded portion 68 is formed at the tip portion 56A of the third insulating portion 56. The conductor 80 is provided in the insulating sheet 50 except for the folded portions 62, 64, 66, and 68.

[0067] According to the fifth embodiment, the conductors 80 are provided in the insulating sheet 50 except for the bent portions 62, 64, 66, and 68. The conductors 80 are not provided in the bent portion 62 at the tip 52A of the first insulating portion 52, the bent portion 64 between the first insulating portion 52 and the second insulating portion 54, the bent portion 66 between the second insulating portion 54 and the third insulating portion 56, or the bent portion 68 at the tip 56A of the third insulating portion 56. Therefore, compared to when the conductors 80 are provided in the bent portions 62, 64, 66, and 68, the bending rigidity of the bent portions 62, 64, 66, and 68 can be reduced, making it easier to bend the bent portions 62, 64, 66, and 68. Furthermore, compared to when the conductors 80 are provided in the bent portions 62, 64, 66, and 68, the radius of curvature of the bent portions 62, 64, 66, and 68 can be reduced, improving the slot space factor.

[0068] In the fifth embodiment, the same configuration as that of the first embodiment provides the same effects as those of the first embodiment, and therefore the description thereof will be omitted.

[0069] In the fifth embodiment, the wrap portion 70 may be formed at a position shown in Fig. 17 , which schematically illustrates the insulating sheet 50 and the winding winding portion 18. That is, the wrap portion 70 may be formed on the third insulating portion 56 (specifically, the tip portion 58A of the fourth insulating portion 58 and the tip portion 60A of the fifth insulating portion 60). When the wrap portion 70 is formed on the third insulating portion 56 in this manner, it is possible to improve the voltage resistance of the third insulating portion 56 and reduce its thickness.

[0070] Sixth Embodiment Next, a sixth embodiment of the technique of the present disclosure will be described.

[0071] In the sixth embodiment, the configuration of the insulating sheet 50 is modified as follows compared to the fifth embodiment. In the fifth embodiment, the conductor 80, the first insulator 82, and the second insulator 84 are provided in the first insulating portion 52, the second insulating portion 54, and the third insulating portion 56 of the insulating sheet 50. However, in the sixth embodiment, as shown in FIG. 18 , the conductor 80 and the first insulator 82 of the conductor 80, the first insulator 82, and the second insulator 84 are provided in the first insulating portion 52 and the second insulating portion 54 of the insulating sheet 50, but not in the third insulating portion 56 of the insulating sheet 50. Furthermore, the conductor 80 is not provided in each of the folded portions 62, 64, 66, and 68. FIG. 18 schematically illustrates the insulating sheet 50 and the winding winding portion 18.

[0072] According to the sixth embodiment, the conductor 80, the first insulator 82, and the third insulator 84 are provided in the first insulating portion 52 and the second insulating portion 54 of the insulating sheet 50 (i.e., the portions that contribute to stray capacitance). This reduces the stray capacitance between the winding winding portion 18 and the stator core 24. Furthermore, since the conductor 80 and the first insulator 82 are not provided in the third insulating portion 56 of the insulating sheet 50, the material cost of the insulating sheet 50 can be reduced compared to when the conductor 80 and the first insulator 82 are provided in the third insulating portion 56.

[0073] Furthermore, the conductors 80 are provided in portions of the insulating sheet 50 excluding the bent portions 62, 64, 66, and 68 and the third insulating portion 56, and the conductors 80 are not provided in the bent portions 62, 64, 66, and 68. Therefore, compared to when the conductors 80 are provided in the bent portions 62, 64, 66, and 68, the bending rigidity of the bent portions 62, 64, 66, and 68 can be reduced, making it easier to bend the bent portions 62, 64, 66, and 68. Furthermore, compared to when the conductors 80 are provided in the bent portions 62, 64, 66, and 68, the radius of curvature of the bent portions 62, 64, 66, and 68 can be reduced, thereby improving the slot space factor.

[0074] In the sixth embodiment, the same configuration as that of the fifth embodiment provides the same effects as those of the fifth embodiment, and therefore the description thereof will be omitted.

[0075] In the sixth embodiment, the wrap portion 70 may be formed at a position shown in Fig. 19 , which schematically illustrates the insulating sheet 50 and the winding winding portion 18. That is, the wrap portion 70 may be formed on the third insulating portion 56 (specifically, the tip portion 58A of the fourth insulating portion 58 and the tip portion 60A of the fifth insulating portion 60). When the wrap portion 70 is formed on the third insulating portion 56 in this manner, the voltage resistance of the third insulating portion 56 can be improved.

[0076] Seventh Embodiment Next, a seventh embodiment of the technique of the present disclosure will be described.

[0077] In the seventh embodiment, details of the material, structure, manufacturing method, etc. of the insulating sheet 50 applied to each of the above-described embodiments will be described.

[0078] First, an example of the material of the insulating sheet 50 will be described. The conductor 80 may be a magnetic material, a non-magnetic material, a paint film, or a powder-mixed resin material. The conductor 80 may also be a composite material containing at least one of a magnetic material, a non-magnetic material, a paint film, and a powder-mixed resin material. The paint film is a film formed by painting with a conductive paint, and the entire film is conductive. The paint film may be a magnetic material or a non-magnetic material. The powder-mixed resin material is a component in which conductive powder is mixed with a resin binder, and the component as a whole is conductive. The powder may be a magnetic material or a non-magnetic material.

[0079] However, if the conductor 80 is made of a magnetic material (e.g., iron), there is a risk of magnetic flux leakage from the stator core 24 to the conductor 80. On the other hand, if the conductor 80 is made of a non-magnetic material, it is possible to suppress magnetic flux leakage from the stator core 24 to the conductor 80. The non-magnetic material may be aluminum or stainless steel.

[0080] Furthermore, the conductor 80 may be, more specifically, an austenitic stainless steel (e.g., SUS305). Even when a non-magnetic conductor 80 is used, the relative permeability of the conductor 80 increases after the insulating sheet 50 is bent, resulting in increased leakage of magnetic flux from the stator core 24 to the conductor 80 and a significant impact on the performance of the rotating electric machine. Therefore, by using austenitic stainless steel for the conductor 80, the relative permeability of the conductor 80 is less likely to increase even after the bending process, thereby minimizing the impact on the performance of the rotating electric machine. Austenitic stainless steel has the following characteristics: a more stabilized austenite phase and less martensite induced after cold working, compared to SUS304.

[0081] Furthermore, the conductor 80 may have a higher electrical resistivity than the winding portion 18. If the electrical resistivity of the conductor 80 is higher than the electrical resistivity of the winding portion 18, the voltage applied to the conductor 80 can be increased, and the voltage V ３ and the shared voltage V of the second insulator 84 ５ can be further reduced.

[0082] The first insulator 82 and the second insulator 84 may be, for example, a resin material, a coating film, a gas layer, a glass material, or a ceramic material. The first insulator 82 and the second insulator 84 may also be, for example, a composite material containing at least one of a resin material, a coating film, a gas layer, a glass material, and a ceramic material. The first insulator 82 and the second insulator 84 may be formed of the same material or different materials. The first insulator 82 and the second insulator 84 may have the same thickness or different thicknesses. The conductor 80 may be thicker than at least one of the first insulator 82 and the second insulator 84, or may be thinner than at least one of the first insulator 82 and the second insulator 84.

[0083] Next, an example of the structure of the insulating sheet 50 will be described. As shown in FIG. 20 , the insulating sheet 50 specifically includes a conductor 80, a first insulator 82, and a second insulator 84, as well as a first adhesive 86 and a second adhesive 88. The first adhesive 86 and the second adhesive 88 are, for example, foamable adhesives having insulating and thermosetting properties. The first adhesive 86 and the second adhesive 88 are examples of the "adhesive" according to the technology disclosed herein. The first adhesive 86 is provided in the form of a layer between the conductor 80 and the first insulator 82, bonding the conductor 80 to the first insulator 82. The second adhesive 88 is provided in the form of a layer between the conductor 80 and the second insulator 84, bonding the conductor 80 to the second insulator 84. The first adhesive 86 may be considered part of the first insulator 82. Similarly, the second adhesive 88 may be considered part of the second insulator 84.

[0084] Next, an example of a manufacturing method of the insulating sheet 50 will be described. The manufacturing method of the insulating sheet 50 includes a laminating step of laminating a conductor 80, a first insulator 82, and a second insulator 84. As shown in FIG. 21 , in the laminating step, the conductor 80, the first insulator 82, and the second insulator 84 are first prepared. Next, a sheet-like first adhesive 86 is placed between the conductor 80 and the first insulator 82, and a sheet-like second adhesive 88 is placed between the conductor 80 and the second insulator 84. Next, the insulating sheet 50 is heated to foam the first adhesive 86 and the second adhesive 88, and the foamed first adhesive 86 is filled between the conductor 80 and the first insulator 82, and the foamed second adhesive 88 is filled between the conductor 80 and the second insulator 84. Then, the first adhesive 86 and the second adhesive 88 are heated and cured, so that the conductor 80 and the first insulator 82 are bonded together by the first adhesive 86, and the conductor 80 and the second insulator 84 are bonded together by the second adhesive 88. In this way, the insulating sheet 50 is completed.

[0085] Next, a first modified example of the insulating sheet 50 will be described. As shown in FIG. 22 , the insulating sheet 50 according to the first modified example includes a first adhesive 90 and a second adhesive 92. The first adhesive 90 and the second adhesive 92 are, for example, thermosetting adhesives. The first adhesive 90 and the second adhesive 92 are examples of the "adhesive" according to the technology of the present disclosure. The first adhesive 90 is provided in the form of a layer between the conductor 80 and the first insulator 82, bonding the conductor 80 to the first insulator 82. The second adhesive 92 is provided in the form of a layer between the conductor 80 and the second insulator 84, bonding the conductor 80 to the second insulator 84. Note that the first adhesive 90 may be considered part of the first insulator 82. Similarly, the second adhesive 92 may be considered part of the second insulator 84.

[0086] Next, an example of a manufacturing method of the insulating sheet 50 according to the first modification will be described. The manufacturing method of the insulating sheet 50 according to the first modification includes a laminating step of laminating a conductor 80, a first insulator 82, and a second insulator 84. As shown in FIG. 23 , in the laminating step, the conductor 80, the first insulator 82, and the second insulator 84 are first prepared. Next, a liquid first adhesive 90 is injected between the conductor 80 and the first insulator 82, and a liquid second adhesive 92 is injected between the conductor 80 and the second insulator 84. The first adhesive 90 and the second adhesive 92 are then heated and cured, thereby bonding the conductor 80 and the first insulator 82 together with the first adhesive 90, and bonding the conductor 80 and the second insulator 84 together with the second adhesive 88. This completes the insulating sheet 50.

[0087] Next, a second modified example of the insulating sheet 50 will be described. As shown in Fig. 24, the insulating sheet 50 according to the second modified example is composed of a conductor 80, a first insulator 82, and a second insulator 84. The first insulator 82 and the second insulator 84 are formed by a coating film that is applied to the conductor 80 by electrodeposition coating.

[0088] Next, an example of a manufacturing method of the insulating sheet 50 according to the second modification will be described. The manufacturing method of the insulating sheet 50 according to the second modification includes a laminating step of laminating a conductor 80, a first insulator 82, and a second insulator 84. As shown in FIG. 25 , in the laminating step, the conductor 80 is first immersed in an electrodeposition paint tank 110 and connected to the negative electrode 112 of a pair of electrodes 112 arranged in the electrodeposition paint tank 110. Next, when electricity is passed between the pair of electrodes 112, paint particles are deposited on the surface of the conductor 80 as a paint film. Next, the paint film is baked and cured in a baking and drying furnace 114. This completes the insulating sheet 50.

[0089] Next, a description will be given of a third modified example of the insulating sheet 50. In the third modified example, the first insulator 82 and the second insulator 84 are formed by a paint film that is spray-painted onto the conductor 80.

[0090] Next, an example of a manufacturing method of the insulating sheet 50 according to the third modification will be described. The manufacturing method of the insulating sheet 50 according to the third modification includes a laminating step in which a conductor 80, a first insulator 82, and a second insulator 84 are laminated together. As shown in FIG. 26 , in the laminating step, the conductor 80 is transported from a coating booth 122 to a baking oven 124 by a conveyor 120 connected to earth. In the coating booth 122, the conductor 80 is degreased and then spray-painted using an electrostatic gun 126, and the paint film is baked and cured in the baking oven 124. This completes the insulating sheet 50.

[0091] Next, a fourth modification of the insulating sheet 50 will be described. In the fourth modification, the conductor 80 is formed by a conductive coating film.

[0092] Next, an example of a manufacturing method for the insulating sheet 50 according to the fourth modification will be described. The manufacturing method for the insulating sheet 50 according to the fourth modification includes a laminating step in which the conductor 80, the first insulator 82, and the second insulator 84 are laminated together. In the laminating step, a zinc phosphate coating is formed on the opposing surfaces of the first insulator 82 and the second insulator 84 after degreasing. Next, the first insulator 82 and the second insulator 84 are immersed in a water-soluble paint bath, and the conductor 80 is formed between the first insulator 82 and the second insulator 84 by a conductive paint film. Next, the paint film is baked and cured in a baking and drying oven. This completes the insulating sheet 50.

[0093] Eighth Embodiment Next, an eighth embodiment of the technique of the present disclosure will be described.

[0094] In the eighth embodiment, a variation example of an insulating structure using the insulating sheet 50 applied to each of the above-described embodiments will be described.

[0095] First, referring to Figure 27, a variation of the structure in which the winding winding portion 18 has a coating 102 and a first insulator 82 and a second insulator 84 are provided on both sides of the conductor 80 will be described. As shown in Figure 27(A), the insulation structure of the first variation is similar to the insulation structure using the insulating sheet 50 according to the first embodiment (see Figure 8), in which a portion of the first insulator 82 contacts the coating 102 of the winding winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the coating 102 of the winding winding portion 18, the conductor 80 is provided between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24.

[0096] 27(B) , the insulation structure according to the second variation has a structure in which a portion of the first insulator 82 contacts the coating 102 of the winding winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the coating 102 of the winding winding portion 18, a first conductor 80A and a second conductor 80B are provided in a stacked manner between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24. The first conductor 80A and the second conductor 80B may be formed of the same material or different materials. Furthermore, any number of conductors may be provided between the first insulator 82 and the second insulator 84. The first conductor 80A and the second conductor 80B are examples of the "conductor" and "multiple conductors" according to the technology of the present disclosure.

[0097] 27(C), the insulation structure according to the third variation has a structure in which a portion of the first insulator 82 contacts the coating 102 of the winding winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the coating 102 of the winding winding portion 18, a powder-mixed resin material as a conductor 80 is provided between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24. The powder-mixed resin material is a material in which conductive powder is mixed with a resin binder, and the material as a whole is conductive. The powder may be a magnetic material or a non-magnetic material. The powder-mixed resin material is an example of a "conductor" according to the technology of the present disclosure.

[0098] Next, with reference to Figure 28, variations of the structure in which the winding portion 18 has a coating 102 and an insulator 94 is provided on one side of the conductor 80 will be described. As shown in Figure 28(A), the insulation structure according to the first variation is such that the conductor 80 is exposed on the winding portion 18 side of the insulating sheet 50, a portion of the conductor 80 contacts the coating 102 of the winding portion 18, a gas layer 104 is provided between another portion of the conductor 80 and the coating 102 of the winding portion 18, and an insulator 94 is provided on the stator core 24 side of the conductor 80 (i.e., the side opposite the coating 102 with respect to the conductor 80), and the insulator 94 contacts the stator core 24. The insulator 94 is a member similar to the second insulator 84 described above.

[0099] 28(B), the insulation structure according to the second variation has a first conductor 80A and a second conductor 80B stacked on top of each other. The first conductor 80A is exposed on the winding portion 18 side of the insulating sheet 50. A portion of the first conductor 80A contacts the coating 102 of the winding portion 18. A gas layer 104 is provided between another portion of the first conductor 80A and the coating 102 of the winding portion 18. An insulator 94 is provided on the stator core 24 side of the second conductor 80B (i.e., the side opposite the first conductor 80A relative to the second conductor 80B), and the insulator 94 contacts the stator core 24. The first conductor 80A and the second conductor 80B may be made of the same material or different materials. Furthermore, any number of conductors may be provided between the winding portion 18 and the insulator 94. The first conductor 80A and the second conductor 80B are examples of the "conductor" and "plurality of conductors" according to the technology of the present disclosure.

[0100] 28(C), the insulation structure according to the third variation has a structure in which a powder-mixed resin material serving as a conductor 80 is exposed on the winding winding portion 18 side of the insulating sheet 50, a portion of the powder-mixed resin material contacts the coating 102 of the winding winding portion 18, a gas layer 104 is provided between another portion of the powder-mixed resin material and the coating 102 of the winding winding portion 18, and an insulator 94 is provided on the stator core 24 side of the powder-mixed resin material (i.e., the side opposite the coating 102 with respect to the conductor 80) and contacts the stator core 24. The powder-mixed resin material is a material in which conductive powder is mixed with a resin binder, and the material as a whole is conductive. The powder may be magnetic or non-magnetic. The powder-mixed resin material is an example of a "conductor" according to the technology of the present disclosure.

[0101] 29 , a variation of the structure will be described in which the winding portion 18 does not have the coating 102, so that the wire 100 is exposed, and a first insulator 82 and a second insulator 84 are provided on both sides of the conductor 80. As shown in FIG. 29 (A) , the insulation structure according to the first variation is a structure in which a portion of the first insulator 82 contacts the wire 100 of the winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the wire 100 of the winding portion 18, the conductor 80 is provided between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24.

[0102] 29(B) , the insulation structure according to the second variation has a structure in which a portion of the first insulator 82 contacts the wire 100 of the winding winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the wire 100 of the winding winding portion 18, a first conductor 80A and a second conductor 80B are provided in a stacked manner between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24. The first conductor 80A and the second conductor 80B may be formed of the same material or different materials. The first conductor 80A and the second conductor 80B are examples of the "conductor" and "multiple conductors" according to the technology of the present disclosure.

[0103] 29(C), the insulation structure according to the third variation has a structure in which a portion of the first insulator 82 contacts the wire 100 of the winding winding portion 18, a gas layer 104 is provided between another portion of the first insulator 82 and the wire 100 of the winding winding portion 18, a powder-mixed resin material as a conductor 80 is provided between the first insulator 82 and the second insulator 84, and the second insulator 84 contacts the stator core 24. The powder-mixed resin material is a material in which conductive powder is mixed with a resin binder, and the material as a whole is conductive. The powder may be a magnetic material or a non-magnetic material. The powder-mixed resin material is an example of a "conductor" according to the technology of the present disclosure.

[0104] The above variations also provide the same effects as the above embodiments.

[0105] Other variations of the insulation structure using the insulating sheet 50 are described below. That is, in each of the variations described above, the gas layer 104 is provided between the first insulator 82 and the winding winding portion 18, but a liquid layer may be provided instead of the gas layer 104. Also, the gas layer 104 may be omitted.

[0106] 28 , the first insulator 82 is omitted from the insulating sheet 50, but the second insulator 84 may also be omitted from the insulating sheet 50. Furthermore, when the second insulator 84 is omitted from the insulating sheet 50, an insulator replacing the second insulator 84 may be provided on the stator core 24. The insulator provided on the stator core 24 may include a paint film formed on the surface of the stator core 24, an insulating material attached to the stator core 24, a gas layer provided between the stator core 24 and the conductor 80, or a liquid layer provided between the stator core 24 and the conductor 80.

[0107] Ninth Embodiment Next, a ninth embodiment of the technique of the present disclosure will be described.

[0108] In the ninth embodiment, the configuration of the stator 10 is modified as follows from the first embodiment. That is, in the first embodiment, the stator core 24 is formed by a plurality of core members 14 divided for each tooth portion 20, but in the ninth embodiment, the stator core 24 is formed as a single unit, as shown in Fig. 30. That is, in the ninth embodiment, a plurality of core back portions 22 connected to the base end portions of the respective teeth portions 20 are configured to be continuous in the circumferential direction of the stator core 24.

[0109] Moreover, in the ninth embodiment, the insulating sheet 50 has a first insulating sheet 50A and a second insulating sheet 50B. The first insulating sheet 50A and the second insulating sheet 50B are inserted into the slots 28 between the circumferentially adjacent teeth 20 of the stator core 24. The first insulating sheet 50A has a pair of first insulating portions 52 covering the respective side surfaces 20B of the adjacent teeth 20, and a pair of second insulating portions 54 covering the respective inner surfaces 22A of the adjacent core back portions 22. The pair of first insulating portions 52 are connected by the pair of second insulating portions 54.

[0110] The second insulating sheet 50B has a pair of third insulating portions 56 that insulate the winding winding portions 18 adjacent to each other in the circumferential direction of the stator core 24. The pair of third insulating portions 56 are folded back by folding back portions 74 on the core back portion 22 side.

[0111] The insulating members 30 are formed in an annular shape in the circumferential direction of the stator core 24. Each insulating member 30 has a tip insulating portion 36 that insulates the tip end of the tooth portion 20. The tip insulating portion 36 has an insulating sheet holding portion 40. The insulating sheet holding portion 40 is formed in a groove shape. Similar to the first embodiment, each insulating member 30 has a first insulating portion 32 and a second insulating portion 34.

[0112] The tip portions 56A of the third insulating portions 56 of the second insulating sheet 50B are bent along the tips of the teeth 20 and are held by being inserted into the insulating sheet holding portion 40. The tip portions 52A of the first insulating portions 52 of the first insulating sheet 50A are bent along the tips of the teeth 20 and are held by being sandwiched between the tips of the teeth 20 and the tip insulating portion 36 via the tip portions 56A of the third insulating portions 56. The tip portions 52A of the first insulating portions 52 and the tip portions 56A of the third insulating portions 56 form a lap portion 70 and overlap each other. Note that the tip portions 52A of the first insulating portions 52 are located between the tips of the teeth 20 and the tip portions 56A of the third insulating portions 56, but the tip portions 56A of the third insulating portions 56 may also be located between the tips of the teeth 20 and the tip portions 52A of the first insulating portions 52.

[0113] 31 schematically shows the insulating sheet 50 and the winding winding portion 18. The first insulating sheet 50A and the second insulating sheet 50B have a conductor 80, a first insulator 82, and a second insulator 84. Similar to the first embodiment, the conductor 80 is provided between the first insulator 82 and the second insulator 84, and the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire first insulating sheet 50A and the second insulating sheet 50B.

[0114] In the ninth embodiment, the same configuration as that of the first embodiment also provides the same effects as those of the first embodiment, and therefore the description thereof will be omitted.

[0115] Alternatively, a composite sheet 500 may be used as shown in FIG. 32 . The composite sheet 500 is an example of an “insulating sheet” according to the technology of the present disclosure. The composite sheet 500 includes a first insulating sheet 150A, a second insulating sheet 150B, and a conductor 180. The conductor 180 is separate from the first insulating sheet 150A and the second insulating sheet 150B. The conductor 180 is provided only in a lap portion 170 where the first insulating sheet 150A and the second insulating sheet 150B overlap. The lap portion 170 is the same as the lap portion 70 in FIGS. 30 and 31 . The conductor 180 is provided between a tip end 152A of the first insulating portion 152 and a tip end 156A of the third insulating portion 156, which form the lap portion 170. In the wrap portion 170, the conductor 180 is provided between the stator core 24 (more specifically, the tip end of the tooth portion 20) and the winding winding portion 18. Furthermore, in the wrap portion 170, the tip end 152A of the first insulating portion 152 is provided between the conductor 180 and the stator core 24, and the tip end 156A of the third insulating portion 156 is provided between the conductor 180 and the winding winding portion 18. The tip end 152A of the first insulating portion 152 and the tip end 156A of the third insulating portion 156 are examples of "insulators" according to the technology of the present disclosure. Furthermore, the tip end 152A of the first insulating portion 152 is an example of a "first insulator" according to the technology of the present disclosure, and the tip end 156A of the third insulating portion 156 is an example of a "second insulator" according to the technology of the present disclosure.

[0116] In this manner, when the conductor 180 is provided on the wrap portion 170, the wrap portion 170 increases the creepage distance, which is the distance along the composite sheet 500 from the winding winding portion 18 to the stator core 24, thereby improving the voltage resistance and reducing the thickness of the wrap portion 170. In particular, since the wrap portion 170 is formed on the tip portion 152A of the first insulating portion 152 and the tip portion 156A of the third insulating portion 156, it is possible to improve the voltage resistance and reduce the thickness of the tip portion 152A of the first insulating portion 152 and the tip portion 156A of the third insulating portion 156. Note that although the conductor 180 is separate from the first insulating sheet 150A and the second insulating sheet 150B, it may be formed integrally with either the first insulating sheet 150A or the second insulating sheet 150B.

[0117] Tenth Embodiment Next, a tenth embodiment of the technique of the present disclosure will be described.

[0118] In the tenth embodiment, the configuration of the stator 10 is modified as follows from the second embodiment. That is, in the second embodiment, the stator core 24 is formed of a plurality of core members 14 divided for each tooth portion 20, and the plurality of core members 14 are configured independently of one another. However, in the tenth embodiment, as shown in FIG. 33 , adjacent core members 14 in the circumferential direction of the stator core 24 are rotatably connected by a rotary connecting portion 130. The rotary connecting portion 130 is provided on the outer peripheral side of adjacent core back portions 22 in the circumferential direction of the stator core 24. By rotatably connecting adjacent core members 14 by the rotary connecting portion 130, the plurality of core members 14 can be deployed linearly. By deploying the plurality of core members 14 linearly, a winding can be wound around each tooth portion 20 to form the winding winding portion 18.

[0119] In the tenth embodiment, an insulating sheet 50 is inserted into the slots 28 between the tooth portions 20 adjacent in the circumferential direction of the stator core 24. The insulating sheet 50 has a pair of first insulating portions 52 covering the side surfaces 20B of the adjacent tooth portions 20, a pair of second insulating portions 54 covering the inner surfaces 22A of the adjacent core back portions 22, and a pair of third insulating portions 56 that insulate the winding winding portions 18 adjacent in the circumferential direction of the stator core 24.

[0120] A wrap portion 70 is formed on each third insulating portion 56. The third insulating portion 56 has a fourth insulating portion 58 connected to the first insulating portion 52 and a fifth insulating portion 60 connected to the second insulating portion 54. The fourth insulating portion 58 extends from the tip end of the tooth portion 20 toward the core back portion 22, and the fifth insulating portion 60 extends from the core back portion 22 toward the tip end of the tooth portion 20. The wrap portion 70 is formed by the tip end portion 58A of the fourth insulating portion 58 and the tip end portion 60A of the fifth insulating portion 60 overlapping each other. The pair of fifth insulating portions 60 formed on each third insulating portion 56 are folded back by a fold-back portion 76 formed on the tip end of each fifth insulating portion 60. Similar to the first embodiment, each insulating member 30 has a first insulating portion 32 and a second insulating portion 34.

[0121] 34 schematically shows the insulating sheet 50 and the winding winding portion 18. The insulating sheet 50 has a conductor 80, a first insulator 82, and a second insulator 84. Similar to the second embodiment, the conductor 80 is provided between the first insulator 82 and the second insulator 84, and the conductor 80, the first insulator 82, and the second insulator 84 are provided over the entire insulating sheet 50.

[0122] In the tenth embodiment, the same configuration as that of the second embodiment provides the same effects as those of the second embodiment, and therefore the description thereof will be omitted.

[0123] In the tenth embodiment, adjacent core members 14 in the circumferential direction of the stator core 24 are rotatably connected by the rotary connecting portion 130, but adjacent insulating members 30 in the circumferential direction of the stator core 24 may also be rotatably connected by the rotary connecting portion 130. In this manner, the multiple core members 14 can also be deployed linearly.

[0124] Furthermore, among the configurations described in the first to tenth embodiments, configurations that can be combined may be combined as appropriate.

[0125] 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.

[0126] The following are supplementary notes regarding the technology of the present disclosure. (Supplementary Note 1) A stator (10) comprising: a stator core (24), an insulating sheet (50, 150) that insulates the stator core, and a winding winding portion (18) wound around the stator core via the insulating sheet, wherein a conductor (80, 180) is provided at least partially between the stator core and the winding winding portion, and the insulating sheet has an insulator (82, 84, 94, 152A, 156A) superimposed on the conductor and provided at least one between the conductor and the winding winding portion and between the conductor and the stator core. (Supplementary Note 2) The stator according to Supplementary Note 1, wherein the insulating sheet (150) has a first insulating sheet (150A) and a second insulating sheet (150B), the insulator has a first insulator (152A) of the first insulating sheet and a second insulator (156A) of the second insulating sheet, and the conductor (180) is provided between the first insulator and the second insulator. (Supplementary Note 3) The stator according to Supplementary Note 1, wherein the insulating sheet (50) is a single sheet member. (Supplementary Note 4) The stator according to any one of Supplementary Notes 1 to 3, wherein the insulating sheet (50) has the conductor. (Supplementary Note 5) The stator according to any one of Supplementary Notes 1 to 4, wherein the stator core has teeth (20) around which the winding winding portion is wound, the insulating sheet has a first insulating portion (52) provided between the teeth and the winding winding portion, and the conductor and the insulator are provided in the first insulating portion. (Supplementary Note 6) The stator according to any one of Supplementary Notes 1 to 5, wherein the stator core has teeth (20) around which the winding winding portion is wound and a core back portion (22) connected to a base end of the teeth (20), the insulating sheet has a second insulating portion (54) provided between the core back portion and the winding winding portion, and the conductor and the insulator are provided in the second insulating portion. (Supplementary Note 7) The stator according to any one of Supplementary Notes 1 to 6, wherein the insulating sheet has a third insulating portion (56) provided between the winding winding portions adjacent to each other in the circumferential direction of the stator core, and the conductor and the insulator are provided in the third insulating portion.(Supplementary Note 8) The stator according to any one of Supplementary Notes 1 to 7, wherein the insulating sheets have overlapping lap portions (70), and the conductors and the insulators are provided on the lap portions. (Supplementary Note 9) The stator according to any one of Supplementary Notes 1 to 8, wherein the conductors and the insulators are provided entirely on the insulating sheets. (Supplementary Note 10) The stator according to any one of Supplementary Notes 1 to 9, comprising a pair of the insulating sheets, the pair of insulating sheets being connected by an insulating connecting portion, and the conductors and the insulators being provided on the insulating connecting portion. (Supplementary Note 11) The stator according to any one of Supplementary Notes 1 to 4, wherein the stator core has teeth portions around which the winding winding portions are wound and core back portions connected to base ends of the teeth portions, the insulating sheet has a first insulating portion provided between the teeth portions and the winding winding portions and a second insulating portion provided between the core back portion and the winding winding portions, and the conductor and the insulator are provided in the first insulating portion and the second insulating portion. (Supplementary Note 12) The stator according to any one of Supplementary Notes 1 to 11, wherein the insulating sheet has folded portions (62, 64, 66, 68), and the conductor is provided in at least a part of a portion of the insulating sheet excluding the folded portions. (Supplementary Note 13) The stator according to any one of Supplementary Notes 1 to 4, wherein the stator core has teeth around which the winding winding portion is wound and core back portions connected to base ends of the teeth, the insulating sheet has a first insulating portion provided between the teeth and the winding winding portion, a second insulating portion provided between the core back portion and the winding winding portion, and a folded portion, the conductor and the insulator are provided in the first insulating portion and the second insulating portion, and the conductor is provided on at least a part of the insulating sheet excluding the folded portion. (Supplementary Note 14) The stator according to any one of Supplementary Notes 1 to 13, wherein the conductor includes at least one of a magnetic material, a non-magnetic material, a paint film, and a powder-mixed resin material. (Supplementary Note 15) The stator according to any one of Supplementary Notes 1 to 14, wherein the conductor is a non-magnetic material.(Supplementary Note 16) The stator according to any one of Supplementary Notes 1 to 15, wherein the conductor has a higher electrical resistivity than the winding winding portion. (Supplementary Note 17) The stator according to any one of Supplementary Notes 1 to 16, wherein the insulator includes at least one of a resin material, a paint film, a gas layer, a glass material, and a ceramic material. (Supplementary Note 18) The stator according to any one of Supplementary Notes 1 to 17, wherein the conductor and the insulator are bonded by an adhesive (86, 88, 90, 92). (Supplementary Note 19) The stator according to Supplementary Note 18, wherein the adhesive includes a foam adhesive (86, 88). (Supplementary Note 20) The stator according to any one of Supplementary Notes 1 to 19, wherein the insulator has a first insulator (82) and a second insulator (84), the conductor is provided between the first insulator and the second insulator, and the first insulator and the second insulator are formed of the same material or different materials. (Supplementary Note 21) The stator according to any one of Supplementary Notes 1 to 19, wherein the insulator has a first insulator and a second insulator, and the conductor is provided between the first insulator and the second insulator. (Supplementary Note 22) The stator according to any one of Supplementary Notes 1 to 19, wherein the conductor is in contact with a coating (102) of the winding winding portion, and the insulator is provided on the opposite side of the conductor from the coating. (Supplementary note 23) The stator according to any one of Supplementary notes 1 to 22, wherein the conductor has a plurality of overlapping conductors (80A, 80B). (Supplementary note 24) The stator according to any one of Supplementary notes 1 to 23, wherein the stator core is formed by a plurality of core members (14) divided into each tooth portion around which the winding winding portion is wound. (Supplementary note 25) The stator according to any one of Supplementary notes 1 to 23, wherein the stator core is formed integrally.(Supplementary Note 26) The stator according to any one of Supplementary Notes 1 to 23, wherein the stator core has a plurality of core members divided into teeth around which the winding winding portion is wound, an insulating member (30) is attached to each of the core members, and adjacent core members or adjacent insulating members in the circumferential direction of the stator core are rotatably connected by a rotary connecting portion (130). (Supplementary Note 27) A rotating electric machine including the stator according to any one of Supplementary Notes 1 to 26. (Supplementary Note 28) An insulating sheet that insulates the stator core, comprising: a conductor provided in at least a portion between the stator core and a winding winding portion wound around the stator core via the insulating sheet; and an insulator superimposed on the conductor and provided at least one between the conductor and the winding winding portion and between the conductor and the stator core. (Supplementary Note 29) A method for manufacturing an insulating sheet according to Supplementary Note 28, comprising a laminating step of laminating the conductor and the insulator. (Supplementary Note 30) A method for manufacturing an insulating sheet according to Supplementary Note 29, wherein the laminating step includes bonding the conductor and the insulator with an adhesive. (Supplementary Note 31) A method for manufacturing an insulating sheet according to Supplementary Note 29, wherein the laminating step includes painting one of the conductor and the insulator onto the other.

Claims

1. A stator (10) comprising: a stator core (24); an insulating sheet (50, 150) that insulates the stator core; and a winding winding portion (18) wound around the stator core via the insulating sheet, wherein a conductor (80, 180) is provided at least partially between the stator core and the winding winding portion, and the insulating sheet has an insulator (82, 84, 94, 152A, 156A) superimposed on the conductor and provided at least one between the conductor and the winding winding portion and between the conductor and the stator core.

2. The stator according to claim 1, wherein the insulating sheet (150) comprises a first insulating sheet (150A) and a second insulating sheet (150B), the insulator comprises a first insulator (152A) of the first insulating sheet and a second insulator (156A) of the second insulating sheet, and the conductor (180) is provided between the first insulator and the second insulator.

3. The stator according to claim 1, wherein the insulating sheet (50) is a single sheet member.

4. A stator according to any one of claims 1 to 3, wherein the insulating sheet (50) includes the conductor.

5. A stator as claimed in any one of claims 1 to 4, wherein the stator core has teeth (20) around which the winding winding portion is wound, the insulating sheet has a first insulating portion (52) provided between the teeth and the winding winding portion, and the conductor and the insulator are provided in the first insulating portion.

6. A stator as claimed in any one of claims 1 to 5, wherein the stator core has teeth around which the windings are wound and core back portions (22) connected to the base ends of the teeth, the insulating sheet has second insulating portions (54) provided between the core back portions and the windings, and the conductors and insulators are provided in the second insulating portions.

7. A stator as set forth in any one of claims 1 to 6, wherein the insulating sheet has a third insulating portion (56) provided between adjacent winding portions in the circumferential direction of the stator core, and the conductor and the insulator are provided in the third insulating portion.

8. A stator according to any one of claims 1 to 7, wherein the insulating sheets have overlapping lap portions (70) that overlap each other, and the conductors and the insulators are provided in the lap portions.

9. A stator according to any one of claims 1 to 8, wherein the conductors and the insulators are entirely provided on the insulating sheet.

10. A stator as set forth in any one of claims 1 to 9, wherein the insulating sheet has folded portions (62, 64, 66, 68), and the conductor is provided on at least a portion of the insulating sheet excluding the folded portions.

11. A stator according to any one of claims 1 to 10, wherein the conductor is made of a non-magnetic material.

12. A stator according to any one of claims 1 to 11, wherein the conductor has a higher electrical resistivity than the winding portion.

13. A stator according to any one of claims 1 to 12, wherein the conductor is in contact with a coating (102) of the winding portion, and the insulator is provided on the opposite side of the conductor from the coating.

14. A stator according to any one of claims 1 to 13, wherein the conductor comprises a plurality of overlapping conductors (80A, 80B).

15. A stator as claimed in any one of claims 1 to 14, wherein the stator core has a plurality of core members divided into tooth portions around which the winding winding portions are wound, each of the core members is fitted with an insulating member (30), and adjacent core members in the circumferential direction of the stator core or adjacent insulating members in the circumferential direction of the stator core are rotatably connected by a rotary connecting portion (130).

16. A rotating electric machine comprising a stator according to any one of claims 1 to 15.

17. An insulating sheet for insulating a stator core, comprising: a conductor provided at least partially between the stator core and a winding winding portion wound around the stator core via the insulating sheet; and an insulator superimposed on the conductor and provided at least either between the conductor and the winding winding portion or between the conductor and the stator core.

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