Stator, rotary electric machine, and manufacturing method for stator

Abstract

This stator (10) comprises: a stator core (24); an insulating member (30) that is installed on the stator core and insulates the stator core; a plurality of wound winding parts (18) that are wound around the stator core with the insulating member therebetween; an insulating sheet (80) that is disposed between adjacent wound winding parts among the plurality of wound winding parts and insulates the adjacent wound winding parts; and a locking structure (100, 110, 120) that locks the insulating sheet to the insulating member.

Description

Stator, rotating electrical machine, and method of manufacturing a stator Cross-reference to related applications

[0001] This application is based on Japanese Application No. 2024-182185 filed on October 17, 2024, claims the benefit of its priority, and all of the contents of the patent application are incorporated herein by reference.

[0002] The technology of the present disclosure relates to a stator, a rotating electrical machine, and a method of manufacturing a stator.

[0003] Conventionally, there is a stator including a stator core, an insulating member attached to the stator core to insulate the stator core, a plurality of winding portions wound around the stator core via the insulating member, and an insulating sheet disposed between adjacent winding portions among the plurality of winding portions to insulate the adjacent winding portions (see, for example, Japanese Patent No. 6633227).

[0004] As a result of the inventors' detailed examination, the following problems have been found. That is, in the above stator, if the position of the insulating sheet is displaced with respect to the insulating member, the insulation between adjacent winding portions may be reduced.

[0005] The technology of the present disclosure provides a stator, a rotating electrical machine, and a method of manufacturing a stator that can suppress the displacement of the insulating sheet with respect to the insulating member and ensure the insulation between adjacent winding portions.

[0006] A first aspect of the technology of the present disclosure is a stator including a stator core, an insulating member attached to the stator core to insulate the stator core, a plurality of winding portions wound around the stator core via the insulating member, an insulating sheet disposed between adjacent winding portions among the plurality of winding portions to insulate the adjacent winding portions, and a locking structure that locks the insulating sheet to the insulating member.

[0007] A second aspect of the technology of the present disclosure is a rotating electrical machine including the stator according to the first aspect and a rotor rotatably accommodated inside the stator core.

[0008] A third aspect of the technology of the present disclosure is a method for manufacturing a stator according to the first aspect, comprising: an insulating member mounting step of mounting the insulating member to the stator core; a winding step of winding the winding portion around the stator core via the insulating member; and a locking step of locking the insulating sheet to the insulating member using the locking structure.

[0009] The present invention provides a stator, a rotating electric machine, and a method for manufacturing a stator, which can suppress displacement of the insulating sheet relative to the insulating member and ensure insulation between adjacent winding sections.

[0010] This is a cross-sectional view of a stator according to the first embodiment. This is a cross-sectional view of a stator component according to the first embodiment. This is a perspective view showing the stator component according to the first embodiment before the second insulating sheet is assembled. This is a plan view of a core member according to the first embodiment. This is a cross-sectional view of adjacent stator components according to the first embodiment. This is a perspective view of a stator component according to the first embodiment. This is a diagram illustrating a method for manufacturing a stator according to the first embodiment. This is a perspective view of a stator component according to a modified example of the first embodiment. This is a perspective view showing adjacent stator components according to the second embodiment before the second insulating sheet is assembled. This is a diagram illustrating the process of assembling the second insulating sheet in adjacent stator components according to the second embodiment. This is a perspective view of a stator component according to the third embodiment. This is a perspective view of the second insulating sheet according to the third embodiment. This is a perspective view of a stator component according to the fourth embodiment. This is a perspective view of the second insulating sheet according to the fourth embodiment. This is a diagram illustrating the process of locking the second insulating sheet to the insulating member in a stator component according to the fourth embodiment.

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

[0012] As shown in Figure 1, the rotating electric machine M comprises a stator 10 and a rotor 11. The stator 10 has a stator core 24, a plurality of insulators 16 that insulate the stator core 24, and a plurality of winding portions 18 wound around the stator core 24 via each insulator 16. The stator core 24 is formed in an annular shape, and the rotor 11 is rotatably housed inside the stator core 24. The stator 10 and rotor 11 constitute an inner rotor type 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. Furthermore, in the following explanation, the circumferential direction of the stator 10 refers to the direction around the central axis of the stator 10. The tangential, radial, axial, and circumferential directions of the stator core 24 are the same as the tangential, radial, axial, and circumferential directions of the stator 10, respectively.

[0014] The stator 10 comprises a plurality of stator components 12. The stator 10 is formed by combining the plurality of stator components 12 in a ring shape. Figure 1 shows the configuration of half of the rotating electric machine M, including the stator 10 and rotor 11. The configuration of the stator 10 of the rotating electric machine M will be described in detail below.

[0015] As shown in Figure 2, each stator component 12 comprises a core member 14, an insulator 16, and a winding section 18. The core member 14 is formed in a T-shape when viewed from the Z direction and has a teeth section 20 and a core back section 22. The core member 14 is formed symmetrically in the X direction. The core back section 22 is located on the outside in the Y direction relative to the teeth section 20. The core back section 22 extends on both sides in the X direction relative to the teeth section 20, and the teeth section 20 extends inward in the Y direction from the center of the core back section 22 in the X direction.

[0016] The teeth portion 20 has a main body portion 21A and a tip portion 21B. The main body portion 21A of the teeth portion 20 is the portion between the tip portion 21B and the base portion of the teeth portion 20. The tip portion 21B of the teeth portion 20 is a free end, and the base portion of the teeth portion 20 is connected to the core back portion 22. The tip portion 21B of the teeth portion 20 is located on the opposite side of the main body portion 21A from the core back portion 22 (i.e., on the inside in the Y direction), and its width widens in the X direction relative to the main body portion 21A of the teeth portion 20. The winding portion 18 is wound around the main body portion 21A of the teeth portion 20.

[0017] The main body portion 21A of the teeth portion 20 has a pair of side surfaces 20A facing both sides in the X direction and an end surface 20B (see Figure 4) facing in the Z direction. The side surfaces 20A extend in the Y and Z directions, and the end surface 20B extends in the X and Y directions. The tip portion 21B of the teeth portion 20 has a pair of outward-facing surfaces 20C facing outward in the Y direction. The outward-facing surfaces 20C are inclined with respect to the X direction and extend in the Z direction. The core back portion 22 has a pair of inward-facing surfaces 22A facing inward in the Y direction and an end surface 22B (see Figure 4) facing in the Z direction. The inward-facing surfaces 22A extend in the X and Z directions, and the end surface 22B extends in the X and Y directions.

[0018] The core member 14 is a laminate formed by stacking multiple core sheets in the Z direction. The stator core 24 (see Figure 1) is formed by combining the multiple core members 14 in an annular shape. That is, the stator core 24 is formed by multiple core members 14 divided into tooth portions 20. In the state in which the stator core 24 is formed, the multiple core back portions 22 form an annular portion 26 (see Figure 1), which is the outer circumference of the stator core 24, and the multiple tooth portions 20 extend radially from the center of the stator core 24. The spaces between the multiple tooth portions 20 are formed as slots 28 (see Figure 1).

[0019] The insulator 16 comprises a pair of insulating members 30 (see also Figure 3), a pair of first insulating sheets 40, and a pair of second insulating sheets 80. The second insulating sheets 80 are an example of an "insulating sheet" according to the technology of this disclosure. The insulating members 30 are three-dimensional resin parts formed by resin molding. The pair of insulating members 30 are attached to the core member 14 from both sides in the Z direction and insulate the core member 14. The pair of insulating members 30 are arranged symmetrically in the Z direction.

[0020] The first insulating sheet 40 is a sheet material made of resin and formed in a sheet shape. The first insulating sheet 40 is folded in a three-dimensional manner. A pair of first insulating sheets 40 are attached to the core member 14 from both sides in the X direction to insulate the core member 14. The pair of first insulating sheets 40 are formed symmetrically in the X direction. The second insulating sheet 80 is placed between adjacent winding sections 18 to insulate adjacent winding sections 18 (see also Figure 5). The pair of second insulating sheets 80 are formed symmetrically in the X direction.

[0021] The insulating member 30 has a main body insulating portion 31A that insulates the main body portion 21A of the teeth portion 20, a tip insulating portion 31B that insulates the tip portion 21B of the teeth portion 20, and a core back insulating portion 32 that insulates the core back portion 22. The first insulating sheet 40 has a main body insulating portion 41A that insulates the main body portion 21A of the teeth portion 20, a tip insulating portion 41B that insulates the tip portion 21B of the teeth portion 20, and a core back insulating portion 42 that insulates the core back portion 22.

[0022] The main body insulating portion 31A of the insulating member 30 has a pair of side insulating portions 30A that insulate by covering a pair of side surfaces 20A of the tooth portion 20. The tip insulating portion 31B of the insulating member 30 has a pair of outward-facing surface insulating portions 30C that extend in the X direction corresponding to the spread of the tip portion 21B of the tooth portion 20 in the X direction and insulate by covering a pair of outward-facing surfaces 20C. The outward-facing surface insulating portion 30C includes not only the portion that covers the outward-facing surfaces 20C, but also the portion that extends in the X direction from the portion that covers the outward-facing surfaces 20C. The core back insulating portion 32 of the insulating member 30 has a pair of inward-facing surface insulating portions 32A that insulate by covering a pair of inward-facing surfaces 22A of the core back portion 22.

[0023] The main body insulating portion 41A of the first insulating sheet 40 has a pair of side insulating portions 40A that insulate by covering a pair of side surfaces 20A of the tooth portion 20. The tip insulating portion 41B of the first insulating sheet 40 has a pair of outward-facing surface insulating portions 40C that extend in the X direction corresponding to the spread of the tip portion 21B of the tooth portion 20 in the X direction and insulate by covering a pair of outward-facing surfaces 20C. The outward-facing surface insulating portion 40C includes not only the portion that covers the outward-facing surfaces 20C, but also the portion that extends in the X direction from the portion that covers the outward-facing surfaces 20C. The core back insulating portion 42 has a pair of inward-facing surface insulating portions 42A that insulate by covering a pair of inward-facing surfaces 22A of the core back portion 22.

[0024] The side insulating portion 40A of the first insulating sheet 40 is superimposed on the side insulating portion 30A of the insulating member 30. The side insulating portion 40A of the first insulating sheet 40 is located inside the side insulating portion 30A of the insulating member 30. In other words, the side insulating portion 40A is located between the side insulating portion 30A and the side 20A in the X direction. The inward-facing surface insulating portion 42A of the first insulating sheet 40 is superimposed on the inward-facing surface insulating portion 32A of the insulating member 30. The inward-facing surface insulating portion 42A of the first insulating sheet 40 is located inside the inward-facing surface insulating portion 32A of the insulating member 30. In other words, the inward-facing surface insulating portion 42A is located between the inward-facing surface insulating portion 32A and the inward-facing surface 22A.

[0025] As shown in Figure 5, adjacent second insulating sheets 80 are arranged in an overlapping state between adjacent winding portions 18. The adjacent second insulating sheets 80 are arranged symmetrically in the circumferential direction of the stator core 24. A first groove 34 is formed in the core back insulating portion 32 of the insulating member 30 (more specifically, the inward-facing insulating portion 32A), opening in the tangential and axial directions of the stator core 24, and a second groove 36 is formed in the tip insulating portion 31B of the insulating member 30 (more specifically, the outward-facing insulating portion 30C), opening in the tangential and axial directions of the stator core 24.

[0026] Each second insulating sheet 80 has a first insertion portion 82 inserted into the first groove 34 and a second insertion portion 84 inserted into the second groove 36. The first insertion portion 82 overlaps with the inward-facing insulating portion 32A when inserted into the first groove 34. The second insertion portion overlaps with the outward-facing insulating portion 30C when inserted into the second groove 36.

[0027] A third groove 38 is formed in the outward-facing insulating portion 30C of the insulating member 30, opening in the axial direction of the stator core 24, and the outward-facing insulating portion 40C of the first insulating sheet 40 is inserted into the third groove 38. A retaining groove 39 is formed in the outward-facing insulating portion 30C of the insulating member 30, penetrating in the axial direction of the stator core 24 and opening in the tangential direction of the stator core 24, and the winding terminal portion 19 connected to the winding winding portion 18 is held in the retaining groove 39 by being inserted into it.

[0028] By the way, when assembling each stator component 12 and then combining multiple stator components 12 in a ring shape, if the position of the second insulating sheet 80 is misaligned with respect to the insulating member 30, there is a risk that the insulation between adjacent winding sections 18 will decrease. Therefore, in the first embodiment, the following configuration is added to the insulating member 30 and the second insulating sheet 80.

[0029] Specifically, as shown in Figure 6, each stator component 12 is provided with a locking structure 100 that locks the second insulating sheet 80 to one of the insulating members 30. The locking structure 100 is provided on the core back portion 22 side of the winding portion 18. The locking structure 100 has a locking portion 102 formed on the insulating member 30 and a locked portion 104 formed on the insulating sheet. The locking portion 102 is formed in the shape of a projection, and the locked portion 104 is formed in the shape of a rectangular hole. By inserting the locking portion 102 inside the locked portion 104, the locked portion 104 is locked to the locking portion 102 in the X and Z directions. The locking portion 102 has an inclined surface 102A that is inclined with respect to the Z direction.

[0030] More specifically, the locking structure 100 is provided inside the first groove 34. The inner surface of the first groove 34 has a pair of side surfaces 34A and 34B facing each other in the Y direction, and the locking portion 102 is formed on the side surface 34A, which is located on the inside in the Y direction of the pair of side surfaces 34A and 34B. Side surface 34A is located outside the winding portion 18 in the Y direction and faces outward in the Y direction. Side surface 34A is an example of an "outward-facing surface" according to the technology of this disclosure. The locked portion 104 is formed on the first insertion portion 82 of the second insulating sheet 80, which is inserted into the first groove 34.

[0031] As shown in Figure 7, the core back portion insulating portion 32 of the insulating member 30 has a first protrusion 33 that protrudes in the Z direction from the end face 22B of the core back portion 22. The second insulating sheet 80 also has a second protrusion 83 that protrudes in the Z direction from the end face 22B of the core back portion 22. The locking portion 102 is formed on the first protrusion 33, and the locked portion 104 is formed on the second protrusion 83.

[0032] As shown in Figure 8, the manufacturing method of the stator 10 according to the first embodiment comprises a first insulating sheet mounting step, an insulating member mounting step, a winding step, a second insulating sheet mounting step, and an annular formation step. The first insulating sheet mounting step is a step of mounting a pair of first insulating sheets 40 to the core member 14. The insulating member mounting step is a step of mounting a pair of insulating members 30 to the core member 14. The winding step is a step of winding the winding portion 18 around the core member 14 via the pair of insulating members 30 and the pair of first insulating sheets 40.

[0033] The second insulating sheet mounting step is the step of mounting each second insulating sheet 80 to a pair of insulating members 30. The second insulating sheet mounting step includes a first insertion step of inserting the first insertion portion 82 into the first groove 34, a second insertion step of inserting the second insertion portion 84 into the second groove 36, and a locking step of locking the second insulating sheet 80 to the insulating member 30 using the locking structure 100. The assembly direction when assembling the second insulating sheet 80 to the insulating member 30 may be in the Z direction or the X direction. The annular assembly step is the step of assembling a plurality of stator components 12 in an annular shape.

[0034] As described in detail above, the stator 10 according to the first embodiment includes a locking structure 100 for locking the second insulating sheet 80 to the insulating member 30. Therefore, when assembling each stator component 12 and then combining a plurality of stator components 12 in a ring shape, it is possible to suppress the displacement of the second insulating sheet 80 relative to the insulating member 30. As a result, it is possible to suppress the displacement of the second insulating sheet 80 which is positioned between adjacent winding sections 18, and thus the second insulating sheet 80 can ensure insulation between adjacent winding sections 18.

[0035] Furthermore, the locking structure 100 has a locking portion 102 formed on the insulating member 30 and a locked portion 104 formed on the second insulating sheet 80, and the locked portion 104 is locked to the locking portion 102 in the X and Z directions. Therefore, it is possible to suppress the displacement of the position of the second insulating sheet 80 relative to the insulating member 30 in the X and Z directions.

[0036] Furthermore, the locking portion 102 is formed in a protruding shape, the locked portion 104 is formed in a hole shape, and the locking portion 102 has an inclined surface 102A that is inclined with respect to the Z direction. Therefore, when locking the locked portion 104 to the locking portion 102 from the Z direction, the adjacent portion of the locked portion 104 is guided by the inclined surface 102A, so that the locked portion 104 can be easily locked to the locking portion 102 from the Z direction.

[0037] Furthermore, the locking structure 100 is located on the core back portion 22 side of the winding section 18. Therefore, interference between the nozzle of the winding machine and the locking structure 100 can be suppressed when winding the winding section 18. As a result, for example, a decrease in the space occupied by the winding section 18 can be suppressed compared to the case where the locking structure 100 is located within the trajectory of the nozzle.

[0038] In particular, the core back insulating portion 32 of the insulating member 30 is located outward in the Y direction from the winding portion 18 and has a side surface 34A facing outward in the Y direction, and the locking portion 102 is formed on the side surface 34A. Therefore, compared to, for example, the case where the locking portion 102 is formed on the inward insulating portion 32A of the core back insulating portion 32, interference between the nozzle of the winding machine and the locking structure 100 when winding the winding portion 18 can be reliably suppressed.

[0039] Furthermore, the core back portion insulating portion 32 of the insulating member 30 has a first groove 34 that opens in the tangential direction to the stator core 24, and the second insulating sheet 80 has a first insertion portion 82 that is inserted into the first groove 34. By being inserted into the first groove 34, the first insertion portion 82 overlaps with the inward-facing insulating portion 32A of the core back portion insulating portion 32. Therefore, a creepage distance (i.e., the ground insulation distance L1 in Figure 5) can be secured between the core back portion 22 and the winding portion 18 along the first insertion portion 82 and the inward-facing insulating portion 32A, thereby improving the insulation performance with respect to the core member 14. In addition, a creepage distance (i.e., the phase-to-phase insulation distance L2 in Figure 5) can be secured between adjacent winding portions 18 along the first insertion portion 82 and the inward-facing insulating portion 32A, thereby improving the insulation performance between adjacent winding portions 18.

[0040] Furthermore, the tip insulating portion 31B of the insulating member 30 has a second groove 36 that opens in the tangential direction to the stator core 24, and the second insulating sheet 80 has a second insertion portion 84 inserted into the second groove 36. The second insertion portion 84 overlaps with the outward-facing insulating portion 30C of the tip insulating portion 31B by being inserted into the second groove 36. Therefore, a creepage distance (i.e., the ground insulation distance L3 in Figure 5) can be secured between the tip portion 21B of the teeth portion 20 and the winding terminal portion 19 along the second insertion portion 84 and the outward-facing insulating portion 30C, thereby improving the insulation performance with respect to the core member 14. In addition, a creepage distance (i.e., the phase-to-phase insulation distance L4 in Figure 5) can be secured between adjacent winding terminal portions 19 along the second insertion portion 84 and the outward-facing insulating portion 30C, thereby improving the insulation performance between adjacent winding terminal portions 19.

[0041] Further, the locking structure 100 is provided inside the first groove 34 (that is, the dead space). Therefore, the insulator 16 can be miniaturized as compared with the case where the locking structure 100 is provided at a location other than the dead space.

[0042] Further, the core back portion insulator 32 of the insulating member 30 has a first protruding portion 33 that protrudes in the Z direction from the end face 22B of the core back portion 22, and the second insulating sheet 80 has a second protruding portion 83 that protrudes in the Z direction from the end face 22B of the core back portion 22. Thereby, an insulating distance (that is, the ground insulation distance L5 in FIG. 7) along the first protruding portion 33 and the second protruding portion 83 can be secured between the end face 22B of the core back portion 22 and the winding winding portion 18, so that the insulation property with respect to the core member 14 can be improved.

[0043] Further, the locking portion 102 is provided on the first protruding portion 33, and the locked portion 104 is provided on the second protruding portion 83. Therefore, since the first protruding portion 33 and the second protruding portion 83 are used as the installation location of the locking structure 100, for example, compared with the case where the locking structure 100 is provided at a dedicated location other than the first protruding portion 33 and the second protruding portion 83, the insulator 16 can be miniaturized.

[0044] In the first embodiment, the locking portion 102 is formed in a protruding shape and the locked portion 104 is formed in a hole shape. However, the locking portion 102 may be formed in a hole shape and the locked portion 104 may be formed in a protruding shape.

[0045] In the first embodiment, the locked portion 104 has a shape that is locked to the locking portion 102 in the X direction and the Z direction. However, it may have a shape that is locked to the locking portion 102 in only one of the X direction and the Z direction.

[0046] Also, in the first embodiment, although the inclined surface 102A of the locking portion 102 is inclined with respect to the Z direction, as shown in FIG. 9, it may be inclined with respect to the X direction. In this case, when the locked portion 104 is locked to the locking portion 102 from the X direction, the adjacent portion of the locked portion 104 is guided by the inclined surface 102A, so that the locked portion 104 can be easily locked to the locking portion 102 from the X direction.

[0047] Also, in the first embodiment, between the adjacent winding portions 18, a pair of second insulating sheets 80 are arranged in a superposed state, but either one of the pair of second insulating sheets 80 may be omitted.

[0048] [Second Embodiment] Next, a second embodiment of the technology of the present disclosure will be described.

[0049] In the second embodiment, the assembling procedure and configuration of the second insulating sheet 80 are changed as follows with respect to the first embodiment. That is, in the second embodiment, as shown in FIG. 10, after a plurality of stator constituent members 12 are assembled annularly, the second insulating sheet 80 is inserted between adjacent winding portions 18.

[0050] As shown in FIG. 11, the second insulating sheet 80 has a folded-back portion 86 folded back on the tip portion 21B side of the tooth portion 20, and a pair of winding portion insulating portions 88 connected via the folded-back portion 86. The pair of winding portion insulating portions 88 are arranged between adjacent winding portions 18. A first insertion portion 82 is formed on the tip side of each winding portion insulating portion 88, and a second insertion portion 84 is formed on the base end side (that is, the folded-back portion 86 side) of each winding portion insulating portion 88.

[0051] A spring-back force F acts on the pair of winding portion insulating portions 88 in a direction away from each other starting from the folded-back portion 86. The first insertion portion 82 formed on the tip side of each winding portion insulating portion 88 is held in a state of being inserted into the first groove 34 by utilizing the spring-back force F.

[0052] Thus, when the second insulating sheet 80 has a pair of winding section insulating sections 88, the number of parts and assembly man-hours can be reduced compared to when a pair of independent second insulating sheets 80 are placed between adjacent winding sections 18, thus reducing costs.

[0053] Furthermore, a springback force F acts on the pair of winding section insulating portions 88, moving them away from each other starting from the folded portion 86. The first insertion portion 82 formed on the tip side of each winding section insulating portion 88 is held in place by the springback force F, inserted into the first groove 34. This makes it possible to more effectively suppress the displacement of the second insulating sheet 80 relative to the insulating member 30.

[0054] In the second embodiment, the folded portion 86 connects a pair of winding section insulating portions 88 on the tip portion 21B side of the teeth portion 20, but the pair of winding section insulating portions 88 may be connected on the core back portion 22 side. Furthermore, the second insertion portion 84 formed on the tip portion 21B side of the teeth portion 20 in each winding section insulating portion 88 may be held in a state inserted into the second groove 36 using the springback force F. Even in this way, the displacement of the second insulating sheet 80 relative to the insulating member 30 can be suppressed even more effectively.

[0055] In the second 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 each other, but the plurality of core members 14 may be rotatably connected by a rotational connecting portion that uses the axial direction of the stator core 24 as the axis of rotation. Alternatively, instead of the plurality of core members 14 being rotatably connected by the connecting portion, the plurality of insulating members 30 attached to each of the plurality of core members 14 may be rotatably connected by the rotational connecting portion. Furthermore, the plurality of core members 14 may be formed integrally, and the plurality of insulating members 30 may also be formed integrally.

[0056] [Third Embodiment] Next, a third embodiment of the technology of the present disclosure will be described.

[0057] In the third embodiment, the configuration of the insulating member 30 and the second insulating sheet 80 is modified from that of the first embodiment as follows. That is, in the third embodiment, as shown in Figures 12 and 13, the core back insulating portion 32 of the insulating member 30 is located outside the winding portion 18 in the Y direction and has an outward-facing surface 32C that faces outward in the Y direction, and a locking portion 112 is formed on the outward-facing surface 32C. The locking portion 112 is formed by a recess that opens in the Z direction.

[0058] The second insulating sheet 80 has a locking portion 114 (see also Figure 13). The locking portion 114 is formed in the shape of a tongue extending in the Z direction toward the locking portion 112. The locking portion 112 and the locking portion 114 form a locking structure 110 according to the third embodiment. By inserting the locking portion 1114 inside the locking portion 112, the locking portion 114 is locked to the locking portion 112 in the X and Y directions.

[0059] Furthermore, the inside of the locking portion 112 is filled with adhesive 116 (i.e., varnish). The adhesive 116 can be any adhesive material, such as a two-part adhesive, a thermoplastic adhesive, or an ultraviolet-curing adhesive. The part to be locked 114 is fixed to the locking portion 112 by the adhesive.

[0060] In this way, when the locking portion 114 is fixed to the locking portion 112 by adhesive 116, the displacement of the second insulating sheet 80 relative to the insulating member 30 can be suppressed even more effectively.

[0061] [Fourth Embodiment] Next, a fourth embodiment of the technology of the present disclosure will be described.

[0062] In the fourth embodiment, the configuration of the insulating member 30 and the second insulating sheet 80 is modified from that of the first embodiment as follows. Specifically, as shown in Figures 14 and 15, the core back insulating portion 32 of the insulating member 30 is located outside the winding portion 18 in the Y direction and has an outward-facing surface 32D that faces outward in the Y direction, and a locking portion 122 is formed on the outward-facing surface 32D. The locking portion 122 is formed as a projection that protrudes outward in the Y direction relative to the outward-facing surface 32D and extends in the Z direction. A gap is formed between the Z-direction end of the locking portion 122 and the outward-facing surface 32D. In addition, an inclined surface 122A that is inclined with respect to the Z direction is formed on the locking portion 122.

[0063] The second insulating sheet 80 has a pair of winding section insulating sections 88 that insulate adjacent winding sections 18, and a connecting section 90 that connects the pair of winding section insulating sections 88. The connecting section 90 extends in the X direction and is provided along the outward-facing surface 32D. The central part of the connecting section 90 in the X direction is formed as a locked section 124. The locked section 122 and the locked section 124 form a locking structure 120 according to the fourth embodiment.

[0064] The locking structure 120 has a snap-fit ​​structure. That is, as shown in Figure 16, when the connecting portion 90 is brought closer to the locking portion 122 from the outside in the Y direction, the locking portion 124 formed on the connecting portion 90 is guided along the inclined surface 122A, and when the locking portion 124 goes over the Z-direction end of the locking portion 122, the locking portion 124 is inserted into the gap formed between the Z-direction end of the locking portion 122 and the outward-facing surface 32D, and the locking portion 124 is locked to the locking portion 122 in the Y direction.

[0065] Thus, if the locking structure 120 has a snap-fit ​​structure, the part to be locked 124 can be easily locked to the locking part 122.

[0066] Furthermore, the second insulating sheet 80 has a pair of winding section insulating portions 88 and a connecting portion 90 that connects the pair of winding section insulating portions 88. Therefore, compared to the case where the pair of winding section insulating portions 88 are not connected, the number of parts and assembly man-hours can be reduced, thus reducing costs.

[0067] Furthermore, the combinable configurations described in the first to fourth embodiments may be combined as appropriate.

[0068] Although one embodiment of the technology of this disclosure has been described above, the present invention is not limited to the above, and it is of course possible to implement it in various modified forms without departing from the spirit of the invention.

[0069] The following are additional notes regarding the technology of the present disclosure. (Note 1) A stator (10) comprising: a stator core (24); an insulating member (30) mounted on the stator core and insulating the stator core; a plurality of winding portions (18) wound around the stator core via the insulating member; an insulating sheet (80) disposed between adjacent winding portions among the plurality of winding portions and insulating adjacent winding portions; and locking structures (100, 110, 120) for locking the insulating sheet to the insulating member. (Note 2) The stator according to Note 1, wherein the stator core has teeth portions (20) extending radially of the stator core and core back portions (22) extending circumferentially of the stator core and connected to the base ends of the teeth portions, and the locking structures are provided on the core back portion side of the winding portions. (Note 3) The stator according to Note 1 or Note 2, wherein the locking structure has locking portions (102, 112, 122) formed on the insulating member and locked portions (104, 114, 124) formed on the insulating sheet, and the locked portions are locked to the locking portions in at least one of the tangential, axial, and radial directions of the stator core. (Note 4) The stator according to Note 3, wherein the locking portions are formed in the shape of protrusions, the locked portions are formed in the shape of holes, and the locking portions have an inclined surface (102A) that is inclined with respect to the tangential or axial direction of the stator core. (Note 5) The stator according to Note 3 or Note 4, wherein the stator core has teeth portions extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth portions and connected to the base end of the teeth portions, the insulating member has a core back portion insulating portion (32) that insulates the core back portion, the winding portion is wound around the teeth portion, the core back portion insulating portion is located radially outward from the stator core than the winding portion and has outward-facing surfaces (34A, 32C, 32D) facing radially outward from the stator core, and the locking portion is formed on the outward-facing surface.(Note 6) The stator according to any one of Notes 1 to 5, wherein the stator core has teeth extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth and connected to the base end of the teeth, the insulating member has a core back portion insulating portion that insulates the core back portion, the core back portion insulating portion has a first groove (34) that opens tangentially to the stator core, and the locking structure is provided inside the first groove. (Note 7) The stator according to Note 6, wherein the insulating sheet has a first insertion portion (82) inserted into the first groove, and the first insertion portion overlaps with the core back portion insulating portion. (Note 8) The stator according to any one of Notes 1 to 7, wherein the stator core has teeth extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth and connected to the base end of the teeth; the insulating member has a tip insulating portion (31B) that insulates the tip portion (21B) of the teeth; the tip insulating portion has a second groove (36) that opens tangentially to the stator core; the insulating sheet has a second insertion portion (84) inserted into the second groove; the second insertion portion overlaps with the tip insulating portion. (Note 9) The stator according to any one of Notes 1 to 8, wherein the stator core has teeth portions extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth portions and connected to the base end of the teeth portions, the core back portion has an end face facing axially from the stator core, the insulating member has a core back portion insulating portion that insulates the core back portion, the core back portion insulating portion has a first protrusion (33) that protrudes axially from the stator core beyond the end face, the insulating sheet has a second protrusion (83) that protrudes axially from the stator core beyond the end face, and the locking structure is provided on the first protrusion and the second protrusion.(Note 10) The stator according to any one of Notes 1 to 9, wherein the stator core has teeth portions extending radially inward from the stator core and core back portions located radially outward from the stator core relative to the teeth portions and connected to the base ends of the teeth portions, and the insulating sheet has folded portions (86) folded back on the tip side of the teeth portions or on the core back portion side and a pair of winding portion insulating portions (88) connected via the folded portions and arranged between adjacent winding portions. (Note 11) The stator according to Note 10, wherein the insulating member has a core back insulating portion that insulates the core back portion and a tip insulating portion that insulates the tip portion of the teeth portion, the core back insulating portion has a first groove that opens in the tangential direction of the stator core, the tip insulating portion has a second groove that opens in the tangential direction of the stator core, and the pair of winding insulating portions have a pair of first insertion portions that are respectively inserted into the first grooves of adjacent core back insulating portions and a pair of second insertion portions that are respectively inserted into the second grooves of adjacent tip insulating portions. (Note 12) A springback force (F) acts on the pair of winding insulation portions, moving away from each other starting from the folded portion, and the insertion portion of the first insertion portion and the second insertion portion located on the opposite side of the folded portion is held in a state where it is inserted using the springback force into the groove of the first groove and the second groove located on the opposite side of the folded portion, as described in Note 11. (Note 13) The locked portion is fixed to the locking portion by adhesive (116), as described in Note 3 and any one of Notes 4 to 12 which are subordinate to Note 3. (Note 14) The locking structure has a snap-fit ​​structure, as described in any one of Notes 1 to 13. (Note 15) The stator according to Note 3 and any one of Notes 4 to 14 which are subordinate to Note 3, wherein the insulating sheet has a pair of winding section insulating sections that insulate adjacent winding sections and a connecting section (90) that connects the pair of winding section insulating sections, and the connecting section has the locking section.(Note 16) A rotating electric machine (M) comprising: a stator as described in any one of Notes 1 to 15; and a rotor (11) rotatably housed inside the stator core. (Note 17) A method for manufacturing a stator as described in any one of Notes 1 to 15, comprising: an insulating member mounting step of mounting the insulating member to the stator core; a winding step of winding the winding portion around the stator core via the insulating member; and a locking step of locking the insulating sheet to the insulating member using the locking structure.

Claims

1. A stator (10) comprising: a stator core (24); an insulating member (30) attached to the stator core and insulating the stator core; a plurality of winding portions (18) wound around the stator core via the insulating member; an insulating sheet (80) positioned between adjacent winding portions and insulating adjacent winding portions; and locking structures (100, 110, 120) for locking the insulating sheet to the insulating member.

2. The stator according to claim 1, wherein the stator core has teeth portions (20) extending radially from the stator core and core back portions (22) extending circumferentially from the stator core and connected to the base ends of the teeth portions, and the locking structure is provided on the core back portion side of the winding portion.

3. The stator according to claim 1 or claim 2, wherein the locking structure comprises locking portions (102, 112, 122) formed on the insulating member and locked portions (104, 114, 124) formed on the insulating sheet, and the locked portions are locked to the locking portions in at least one of the tangential, axial, and radial directions of the stator core.

4. The stator according to claim 3, wherein the locking portion is formed in the shape of a projection, the locked portion is formed in the shape of a hole, and the locking portion has an inclined surface (102A) that is inclined with respect to the tangential or axial direction of the stator core.

5. The stator core has teeth portions extending radially inward from the stator core, and core back portions located radially outward from the stator core relative to the teeth portions and connected to the base ends of the teeth portions; the insulating member has a core back portion insulating portion (32) that insulates the core back portion; the winding portion is wound around the teeth portion; the core back portion insulating portion is located radially outward from the stator core than the winding portion and has outward-facing surfaces (34A, 32C, 32D) facing radially outward from the stator core; and the locking portion is formed on the outward-facing surface, as described in claim 3 or claim 4.

6. The stator core has teeth extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth and connected to the base end of the teeth; the insulating member has a core back portion insulating portion that insulates the core back portion; the core back portion insulating portion has a first groove (34) that opens tangentially to the stator core; and the locking structure is provided inside the first groove, according to any one of claims 1 to 5.

7. The stator according to claim 6, wherein the insulating sheet has a first insertion portion (82) inserted into the first groove, and the first insertion portion overlaps with the core back insulating portion.

8. The stator according to any one of claims 1 to 7, wherein the stator core has teeth portions extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth portions and connected to the base end of the teeth portions, the insulating member has a tip insulating portion (31B) that insulates the tip portion (21B) of the teeth portions, the tip insulating portion has a second groove (36) that opens tangentially to the stator core, the insulating sheet has a second insertion portion (84) inserted into the second groove, and the second insertion portion overlaps with the tip insulating portion.

9. The stator according to any one of claims 1 to 8, wherein the stator core has teeth portions extending radially inward from the stator core and a core back portion located radially outward from the stator core relative to the teeth portions and connected to the base end of the teeth portions, the core back portion has an end face facing axially from the stator core, the insulating member has a core back portion insulating portion that insulates the core back portion, the core back portion insulating portion has a first protrusion (33) that protrudes axially from the stator core beyond the end face, the insulating sheet has a second protrusion (83) that protrudes axially from the stator core beyond the end face, and the locking structure is provided on the first protrusion and the second protrusion.

10. The stator according to any one of claims 1 to 9, wherein the stator core has teeth portions extending radially inward from the stator core and core back portions located radially outward from the stator core relative to the teeth portions and connected to the base ends of the teeth portions, and the insulating sheet has folded portions (86) folded back on the tip side of the teeth portions or on the core back portion side and a pair of winding portion insulating portions (88) connected via the folded portions and arranged between adjacent winding portions.

11. The stator according to claim 10, wherein the insulating member has a core back insulating portion for insulating the core back portion and a tip insulating portion for insulating the tip portion of the teeth portion, the core back insulating portion has a first groove opening in the tangential direction of the stator core, the tip insulating portion has a second groove opening in the tangential direction of the stator core, and the pair of winding insulating portions have a pair of first insertion portions inserted into the first grooves of adjacent core back insulating portions and a pair of second insertion portions inserted into the second grooves of adjacent tip insulating portions.

12. A springback force (F) acts on the pair of winding insulation portions, moving away from each other with respect to the folded portion, and the insertion portion of the first insertion portion and the second insertion portion located on the side opposite to the folded portion is held in a state where it is inserted into the groove of the first groove and the second groove located on the side opposite to the folded portion, utilizing the springback force, as described in claim 11.

13. The stator according to claim 3, and any one of claims 4 to 12 dependent on claim 3, wherein the locked portion is fixed to the locking portion by an adhesive (116).

14. The stator according to any one of claims 1 to 13, wherein the locking structure has a snap-fit ​​structure.

15. The stator according to claim 3 and any one of claims 4 to 14 dependent on claim 3, wherein the insulating sheet has a pair of winding section insulating sections that insulate adjacent winding sections and a connecting section (90) that connects the pair of winding section insulating sections, and the connecting section has the locking section.

16. A rotating electric machine (M) comprising: a stator according to any one of claims 1 to 15; and a rotor (11) rotatably housed inside the stator core.

17. A method for manufacturing a stator according to any one of claims 1 to 15, comprising: an insulating member mounting step of mounting the insulating member to the stator core; a winding step of winding the winding portion to the stator core via the insulating member; and a locking step of locking the insulating sheet to the insulating member using the locking structure.

Images