Stator, rotating electric machine, and method for manufacturing stator

Abstract

A stator (10) includes a plurality of stator constituent members (12) assembled in an annular shape. Each stator constituent member includes a core member (14) constituting a stator core (24), an insulation sheet (40) attached to the core member, and coil winding parts (18) wound around the core member with the insulation sheet therebetween. The insulation sheet has a coil winding part insulation part (50) arranged between adjacent coil winding parts. The stator includes a closing structure (70) that closes the coil winding part winding insulation part against a springback force that acts in an opening direction on the coil winding part insulation part.

Description

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

[0001] This application is based on Japanese Patent Application No. 2024-191125 filed on October 30, 2024, claims the benefit of its priority, and all 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 for manufacturing a stator.

[0003] Conventionally, there is a stator including a plurality of stator constituent members combined in a ring shape (see, for example, Japanese Patent Application Laid-Open No. 2018-198515). In this stator, each stator constituent member includes a core member constituting a stator core, an insulating sheet attached to the core member, and a winding winding portion wound around the core member via the insulating sheet. The insulating sheet has a winding winding portion insulating portion disposed between adjacent winding winding portions.

[0004] As a result of the inventors' detailed examination, the following problems have been found. That is, in the above stator, when a plurality of stator constituent members are combined in a ring shape, if the winding winding portion insulating portion is opened by a springback force, there is a problem that it is difficult to assemble adjacent stator constituent members.

[0005] The technology of the present disclosure provides a stator, a rotating electrical machine, and a method for manufacturing a stator that can easily assemble adjacent stator constituent members when combining a plurality of stator constituent members in a ring shape.

[0006] A first aspect of the technology of the present disclosure is a stator including a plurality of stator constituent members combined in a ring shape, each of the stator constituent members including a core member constituting a stator core, an insulating sheet attached to the core member, and a winding winding portion wound around the core member via the insulating sheet, the insulating sheet having a winding winding portion insulating portion disposed between adjacent winding winding portions, and the stator including a closing structure that closes the winding winding portion insulating portion against a springback force acting in a direction to open the winding winding portion insulating portion.

[0007] A second aspect of the technology of the present disclosure is a stator composed of a plurality of stator components, each of which comprises a core member constituting a stator core, an insulating sheet attached to the core member, and a winding portion wound around the core member via the insulating sheet, wherein the insulating sheet has a winding portion insulating portion disposed between adjacent winding portions, and the stator is equipped with a reduction structure that reduces the springback force acting in the winding portion insulating portion in an opening direction.

[0008] A third aspect of the technology of this disclosure is a rotating electric machine comprising a stator according to the first or second aspect, and a rotor rotatably housed inside the stator core.

[0009] A fourth aspect of the technology of the present disclosure is a method for manufacturing a stator according to the first aspect, comprising: a stator component assembly step of assembling the stator components by attaching the insulating sheet to the core member and winding the winding portion on the core member via the insulating sheet; and an annular formation step of forming the stator by combining a plurality of the stator components in an annular shape, wherein the annular formation step includes using the closing structure to close the winding portion insulating portion against a springback force acting in the direction of opening the winding portion insulating portion.

[0010] The present invention provides a stator, a rotating electric machine, and a method for manufacturing a stator, which enable easy assembly of adjacent stator components when combining multiple stator components in a ring shape.

[0011] This is a cross-sectional view of a stator according to the first embodiment. This is a perspective view of a stator component according to the first embodiment. This is a cross-sectional view of a stator component according to the first embodiment. This is an enlarged cross-sectional view of the main part of a stator according to the first embodiment. This is an explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is a diagram showing the state of the winding insulation part before and after bending in a stator component according to the second embodiment. This is an enlarged plan view of the main part of a stator component according to the second embodiment. This is a diagram showing the state of the winding insulation part before and after bending in a stator component according to the third embodiment. This is a perspective view of the fixing part and its surrounding area according to the third embodiment. This is a plan view of the fixing part and its surrounding area according to the third embodiment. This is a diagram showing the state of the winding insulation part before and after bending in a stator component according to the fourth embodiment. This is a perspective view of the fixing part and its surrounding area according to the fourth embodiment. This is a perspective view of a stator component according to the fifth embodiment. This is a graph showing the characteristics of an insulating sheet.

[0012] [First Embodiment] First, a first embodiment of the technology of this disclosure will be described.

[0013] As shown in Figure 1, the rotating electric machine M comprises a stator 10 and a rotor 11. The stator 10 is formed in an annular shape, and the rotor 11 is rotatably housed inside the stator 10. The stator 10 and rotor 11 constitute an inner rotor type brushless motor.

[0014] 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, which will be described later, are the same directions as the tangential, radial, axial, and circumferential directions of the stator 10, respectively.

[0015] 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.

[0016] As shown in Figure 2, each stator component 12 comprises a core member 14, an insulator 16, and a winding section 18. The insulator 16 has a pair of insulating members 30 and a pair of insulating sheets 40. The insulating members 30 are three-dimensional resin parts formed by resin molding. The insulating sheets 40 are sheet-shaped resin materials. The insulating sheets 40 are folded in a three-dimensional manner. The pair of insulating members 30 are formed symmetrically in the Z direction. Also, each insulating member 30 is formed symmetrically in the X direction. The pair of insulating sheets 40 are formed asymmetrically in the X direction, as will be described in detail later.

[0017] As shown in Figure 3, the core member 14 is formed in a T-shape when viewed from the Z direction and has a teeth portion 20 and a core back portion 22. The core member 14 is formed symmetrically in the X direction. The core back portion 22 is located on the outside in the Y direction relative to the teeth portion 20. The core back portion 22 extends on both sides in the X direction relative to the teeth portion 20, and the teeth portion 20 extends inward in the Y direction from the center of the core back portion 22 in the X direction.

[0018] 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 core back portion 22 from the main body portion 21A (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.

[0019] 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).

[0020] The main body portion 21A of the teeth portion 20 has a pair of side surfaces 20A facing both sides in the X direction. The side surfaces 20A extend in the Y and Z directions. The tip portion 21B of the teeth portion 20 has a pair of outward-facing surfaces 20B facing outward in the Y direction. The outward-facing surfaces 20B 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. The inward-facing surfaces 22A extend in the X and Z directions.

[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 portion insulating portion 32 that insulates the core back portion 22.

[0022] The main body insulating portion 31A has a pair of side insulating portions 30A that insulate the tooth portion 20 by covering a pair of side surfaces 20A of the tooth portion 20 from both sides in the X direction. The tip insulating portion 31B has a pair of outward-facing surface insulating portions 30B 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 20B. The outward-facing surface insulating portion 30B includes not only the portion that covers the outward-facing surfaces 20B, but also the portion that extends in the X direction from the portion that covers the outward-facing surfaces 20B. The outward-facing surface insulating portion 30B has a retaining groove 38 that holds the winding terminal portion 19 connected to the winding winding portion 18. The outward-facing surface insulating portion 30B also has a groove 36. The core back insulating portion 32 has a pair of inward-facing surface insulating portions 32A that insulate the core back portion 22 by covering a pair of inward-facing surfaces 22A of the core back portion 22.

[0023] The 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, a core back portion insulating portion 42 that insulates the core back portion 22, and a winding portion insulating portion 50 that insulates adjacent winding portions.

[0024] The main body insulating portion 41A has a side insulating portion 40A that insulates the tooth portion 20 by covering the side surface 20A of the tooth portion 20 from the X direction. The tip insulating portion 41B has an outward-facing surface insulating portion 40B that extends in the X direction in correspondence with the spread of the tip portion 21B of the tooth portion 20 in the X direction and insulates by covering the outward-facing surface 20B. The outward-facing surface insulating portion 40B includes not only the portion that covers the outward-facing surface 20B, but also the portion that extends in the X direction from the portion that covers the outward-facing surface 20B. The core back insulating portion 42 has an inward-facing surface insulating portion 42A that insulates the core back portion 22 by covering the inward-facing surface 22A of the core back portion 22.

[0025] The side insulating portion 40A of the insulating sheet 40 is positioned between the side insulating portion 30A of the insulating member 30 and the side 20A of the teeth portion 20. The outward-facing insulating portion 40B of the insulating sheet 40 is inserted into a groove 36 formed in the outward-facing insulating portion 30B of the insulating member 30. The inward-facing insulating portion 42A of the insulating sheet 40 is positioned between the inward-facing insulating portion 32A of the insulating member 30 and the inward-facing surface 22A of the core back portion 22. The winding portion insulating portion 50 is positioned between adjacent winding portions 18, as will be described later (see Figure 4).

[0026] Of the pair of insulating sheets 40 attached to each core member 14, the winding section insulating portion 50 of one insulating sheet 40 and the winding section insulating portion 50 of the other insulating sheet 40 are arranged on both sides of the winding section 18. Hereinafter, when distinguishing between the pair of winding section insulating portions 50 arranged on both sides of the winding section 18, the winding section insulating portion 50 formed on one insulating sheet 40 of the pair of winding section insulating portions 50 will be referred to as the "first winding section insulating portion 50A," and the winding section insulating portion 50 formed on the other insulating sheet 40 will be referred to as the "second winding section insulating portion 50B."

[0027] The first winding section insulation section 50A has a first insulation section 52 connected to the outward-facing insulation section 40B and a second insulation section 54 connected to the inward-facing insulation section 42A. The first insulation section 52 is bent towards the core back section 22 with the tip section 21B side of the teeth section 20 as its base end. The second insulation section 54 is bent towards the tip section 21B side of the teeth section 20 with the core back section 22 side as its base end.

[0028] The second winding section insulation section 50B has a third insulation section 56 connected to the inward-facing insulation section 42A and a fourth insulation section 58 connected to the outward-facing insulation section 40B. The third insulation section 56 is bent towards the tip section 21B of the teeth section 20, with the core back section 22 side as its base end. The fourth insulation section 58 is bent towards the core back section 22, with the tip section 21B of the teeth section 20 as its base end.

[0029] The length of the second insulating section 54 is longer than the length of the first insulating section 52, and the length of the fourth insulating section 58 is longer than the length of the third insulating section 56. Also, the length of the first insulating section 52 is the same as the length of the third insulating section 56, and the length of the second insulating section 54 is the same as the length of the fourth insulating section 58. When adjacent stator components 12 are not assembled to each other, a springback force acts on the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58, respectively, causing the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 to open.

[0030] In Figure 3, the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 are shown in an open state. When the first insulating section 52 and the second insulating section 54 are open, the first winding section insulating section 50A is open, and when the third insulating section 56 and the fourth insulating section 58 are open, the second winding section insulating section 50B is open. The second insulating section 54 has a greater degree of opening due to springback force (i.e., a greater amount of springback) than the first insulating section 52. Similarly, the fourth insulating section 58 has a greater degree of opening due to springback force than the third insulating section 56.

[0031] As shown in Figure 4, when adjacent stator components 12 are assembled together, the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 are each in a closed state against the springback force. In Figure 4, the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 are each shown in a closed state. The state in which the first insulating section 52 and the second insulating section 54 are closed corresponds to the state in which the first winding section insulating section 50A is closed, and the state in which the third insulating section 56 and the fourth insulating section 58 are closed corresponds to the state in which the second winding section insulating section 50B is closed.

[0032] A closing structure 70 is applied to the first winding section insulation 50A and the second winding section insulation 50B to close them against the springback force acting on the first winding section insulation 50A and the second winding section insulation 50B in an opening direction. That is, when one of the adjacent stator components 12 (hereinafter also referred to as the "first stator component 12A") and the other adjacent stator component 12 (hereinafter also referred to as the "second stator component 12B") are assembled, the closing structure 70 includes a structure in which the first winding section insulation 50A and the second winding section insulation 50B push against each other in a closing direction due to the springback force.

[0033] Specifically, the second insulating portion 54 is positioned between the third insulating portion 56 and the fourth insulating portion 58. The second insulating portion 54 pushes the third insulating portion 56 in a closing direction due to a springback force, and the third insulating portion 56 pushes the second insulating portion 54 in a closing direction due to a springback force. Similarly, the fourth insulating portion 58 is positioned between the first insulating portion 52 and the second insulating portion 54. The fourth insulating portion 58 pushes the first insulating portion 52 in a closing direction due to a springback force, and the first insulating portion 52 pushes the fourth insulating portion 58 in a closing direction due to a springback force.

[0034] The second insulating portion 54 and the fourth insulating portion 58 have an overlapping winding portion 60 that overlaps each other. That is, the tip of the second insulating portion 54 and the tip of the fourth insulating portion 58 overlap each other to form the overlapping winding portion 60.

[0035] Next, with reference to Figure 5, a method for manufacturing the stator 10 according to the first embodiment will be described. The method for manufacturing the stator 10 according to the first embodiment comprises a stator component assembly step and an annular formation step. The stator component assembly step is a step of assembling each stator component 12 individually, and comprises an insulating sheet mounting step, an insulating member mounting step, a winding step, and an insulating sheet bending step.

[0036] The insulating sheet mounting process is the process of attaching a pair of insulating sheets 40 (see also Figure 2) to the core member 14. The insulating member mounting process is the process of attaching a pair of insulating members 30 (see also Figure 2) to the core member 14. The winding process is the process of winding the winding section 18 onto the core member 14 via the pair of insulating members 30 and the pair of insulating sheets 40. In the winding process, the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 are spread out in the X direction as shown by the dashed lines, so that the nozzle of the winding machine (not shown) that winds the winding section 18 does not interfere with the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58, respectively. The insulating sheet bending process involves bending the first insulating section 52, the second insulating section 54, the third insulating section 56, and the fourth insulating section 58 in a closing direction. Through this process, each stator component 12 is assembled individually.

[0037] The annular formation process is a process of forming a stator 10 by combining a plurality of stator components 12 in an annular shape. The annular formation process includes closing the first winding section insulating section 50A and the second winding section insulating section 50B, respectively, using a closing structure 70, in opposition to the springback force acting in the opening direction of the first winding section insulating section 50A and the second winding section insulating section 50B.

[0038] Specifically, the second insulating section 54 is positioned between the third insulating section 56 and the fourth insulating section 58. The springback force of the second insulating section 54 pushes the third insulating section 56 in a closing direction, and the springback force of the third insulating section 56 pushes the second insulating section 54 in a closing direction, thereby closing the second insulating section 54 and the third insulating section 56. Similarly, the fourth insulating section 58 is positioned between the first insulating section 52 and the second insulating section 54. The springback force of the fourth insulating section 58 pushes the first insulating section 52 in a closing direction, and the springback force of the first insulating section 52 pushes the fourth insulating section 58 in a closing direction, thereby closing the first insulating section 52 and the fourth insulating section 58. The stator 10 is manufactured through the above process.

[0039] As described in detail above, the stator 10 is equipped with a closing structure 70 that closes the first winding section insulating section 50A and the second winding section insulating section 50B against the springback force acting in the direction of opening the first winding section insulating section 50A and the second winding section insulating section 50B. Therefore, when combining a plurality of stator components 12 in an annular shape, the opening of the first winding section insulating section 50A and the second winding section insulating section 50B due to the springback force is suppressed, so adjacent stator components 12 can be easily assembled.

[0040] Furthermore, the closing structure 70 includes a structure in which the first winding section insulating section 50A and the second winding section insulating section 50B push against each other in a closing direction due to springback force. Therefore, since it is not necessary to add any special structures other than the first winding section insulating section 50A and the second winding section insulating section 50B, it is possible to suppress the complexity of the insulating sheet 40 structure.

[0041] Further, the first winding portion insulation 50A has a first insulation portion 52 and a second insulation portion 54, the second winding portion insulation 50B has a third insulation portion 56 and a fourth insulation portion 58, the length of the second insulation portion 54 is longer than the length of the first insulation portion 52, and the length of the fourth insulation portion 58 is longer than the length of the third insulation portion 56. Therefore, when assembling the adjacent stator components 12, it is easy to alternately arrange the first insulation portion 52 and the second insulation portion 54 with different opening degrees due to the springback force, and the third insulation portion 56 and the fourth insulation portion 58 with also different opening degrees due to the springback force. Specifically, it is easy to arrange the second insulation portion 54 between the third insulation portion 56 and the fourth insulation portion 58, and it is easy to arrange the fourth insulation portion 58 between the first insulation portion 52 and the second insulation portion 54. Thereby, the adjacent stator components 12 can be assembled more easily.

[0042] Further, the second insulation portion 54 and the fourth insulation portion 58 have an inter-turn overlap portion 60 that overlaps each other. Therefore, an along-surface distance (that is, the phase-to-phase insulation distance D1 shown in FIG. 4) along the second insulation portion 54 and the fourth insulation portion 58 can be ensured between the adjacent winding portions 18, so that the insulation between the adjacent winding portions 18 can be improved.

[0043] Also, an along-surface distance (that is, the ground insulation distance D2 shown in FIG. 4) from the first insulation portion 52 along the outer surface insulation portion 40B can be ensured between the winding portion 18 and the tip portion 21B of the tooth portion 20, so that the insulation of the core member 14 can be improved.

[0044] [Second Embodiment] Next, a second embodiment of the technology of the present disclosure will be described.

[0045] In the second embodiment, the configuration of the insulating sheet 40 is changed as follows with respect to the first embodiment. That is, in the second embodiment, as shown in FIGS. 6 and 7, the first insulating portion 52 and the second insulating portion 54 have an inter-turn overlap portion 80 that overlaps each other. That is, the tip of the first insulating portion 52 and the tip of the second insulating portion 54 overlap each other to form the inter-turn overlap portion 80. In the inter-turn overlap portion 80, the second insulating portion 54 is located between the first insulating portion 52 and the winding winding portion 18. In the second embodiment, the pair of insulating sheets 40 are formed symmetrically with respect to the X direction.

[0046] A protruding portion 82 that protrudes in the Z direction more than the second insulating portion 54 is formed on the first insulating portion 52. The protruding portion 82 protrudes in the Z direction more than the core member 14 (more specifically, the core back portion 22). Further, the protruding portion 82 extends toward the core back insulating portion 32 side of the insulating member 30.

[0047] A concave holding portion 84 that opens inward in the Y direction is formed in the core back insulating portion 32 of the insulating member 30. The tip of the protruding portion 82 on the core back insulating portion 32 side is formed as a held portion 86. By locking the held portion 86 to the holding portion 84 in the X direction, the first insulating portion 52 is held in a closed state against the spring-back force. In the second embodiment, the closing structure 70 includes a holding portion 84 that holds the first insulating portion 52 in a closed state. Further, the closing structure 70 includes a structure that holds the second insulating portion 54 in a closed state by the second insulating portion 54 being located between the first insulating portion 52 and the winding winding portion 18 in the inter-turn overlap portion 80.

[0048] The winding winding portion 18 is wound by a complete alignment winding in which the windings are aligned, and is in contact with the second insulating portion 54 at two step portions 18A. The gap between the first insulating portion 52 held in the closed state and the winding winding portion 18 is formed as a refrigerant flow path 88 through which the refrigerant flows. The flow of the refrigerant is formed, for example, as the fan rotates when the rotating electric machine M (see FIG. 1) is used as a fan motor.

[0049] Thus, in the second embodiment, the closing structure 70 includes a holding portion 84 provided on the insulating member 30 that holds the first insulating portion 52 of the winding winding portion insulating portion 50 in a closed state. Therefore, when combining a plurality of stator components 12 in an annular shape, it is possible to suppress the opening of the first insulating portion 52 due to springback force.

[0050] Furthermore, the closing structure 70 includes a structure that holds the second insulating portion 54 in a closed state by positioning the second insulating portion 54 between the first insulating portion 52 and the winding winding portion 18 in the inter-winding overlap portion 80. Therefore, when combining multiple stator components 12 in an annular shape, it is possible to suppress the opening of the second insulating portion 54 due to springback force.

[0051] Furthermore, the first insulating portion 52 and the second insulating portion 54 have overlapping winding portions 80 that overlap each other. Therefore, creepage distances along the first insulating portion 52 and the second insulating portion 54 can be secured between adjacent winding portions 18, thereby improving the insulation between adjacent winding portions 18.

[0052] Furthermore, the protruding portion 82 protrudes in the Z direction more than the core back portion 22. This ensures an insulating distance in the Z direction along the protruding portion 82 between the core back portion 22 and the winding portion 18, thereby improving the insulation to the core member 14.

[0053] Furthermore, the protruding portion 82 has a retained portion 86 that is held by the holding portion 84. Therefore, compared to the case where a separate portion having the retained portion 86 is formed on the insulating sheet 40, the complexity of the insulating sheet 40's structure can be suppressed.

[0054] Furthermore, a refrigerant flow path 88 is formed between the second insulating portion 54, which is held in a closed state, and the winding portion 18, through which the refrigerant flows. This improves the cooling performance of the winding portion 18.

[0055] [Third Embodiment] Next, a third embodiment of the technology of the present disclosure will be described.

[0056] In the third embodiment, the configuration of the insulating sheet 40 is modified from that of the first embodiment as follows. That is, in the third embodiment, as shown in Figure 8, the first insulating portion 52 and the second insulating portion 54 have an inter-winding overlap portion 80 that overlap each other. In other words, the tip of the first insulating portion 52 and the tip of the second insulating portion 54 overlap each other to form the inter-winding overlap portion 80. In the inter-winding overlap portion 80, the second insulating portion 54 is located between the first insulating portion 52 and the winding winding portion 18. In the third embodiment, the pair of insulating sheets 40 are formed symmetrically in the X direction.

[0057] The closing structure 70 includes a fixing portion 92 that fixes the first insulating portion 52 and the second insulating portion 54 in the winding overlap portion 80. As shown in Figures 9 and 10, the fixing portion 92 has a locking portion 94 formed at the tip of the first insulating portion 52 and a locked portion 96 formed at the tip of the second insulating portion 54. A rectangular opening 98 is formed at the tip of the first insulating portion 52, and the locked portion 96 is formed by the edge of the opening 98. The locking portion 94 has a first locking portion 94A and a second locking portion 94B.

[0058] The first locking portion 94A is formed in the shape of a rectangular frame. The second locking portion 94B is formed in the shape of a tongue on the inside of the first locking portion 94A. The first locking portion 94A is inserted from the outside of the second insulating portion 54 into the inside of the opening 98. The first locking portion 94A and the second locking portion 94B are locked to the locking portion 94, which is the edge of the opening 98, from the inside and outside of the second insulating portion 54, respectively, thereby holding the first insulating portion 52 and the second insulating portion 54 in a closed state against springback force.

[0059] Thus, in the third embodiment, the first insulating portion 52 and the second insulating portion 54 have an inter-winding overlap portion 80 that overlaps each other, and the inter-winding overlap portion 80 is provided with a fixing portion 92 that fixes the first insulating portion 52 and the second insulating portion 54. Therefore, when combining a plurality of stator components 12 in a ring shape, the opening of the first insulating portion 52 and the second insulating portion 54 due to springback force is suppressed, so adjacent stator components 12 can be easily assembled.

[0060] Furthermore, the fixing portion 92 has a locking portion 94 formed on the first insulating portion 52 and a locked portion 96 formed on the second insulating portion 54. Therefore, by locking the locked portion 96 to the locking portion 94, the first insulating portion 52 and the second insulating portion 54 can be fixed in the winding overlap portion 80. This makes it easy to perform the fixing work of fixing the first insulating portion 52 and the second insulating portion 54.

[0061] Furthermore, the first insulating portion 52 and the second insulating portion 54 have overlapping winding portions 80 that overlap each other. Therefore, creepage distances along the first insulating portion 52 and the second insulating portion 54 can be secured between adjacent winding portions 18, thereby improving the insulation between adjacent winding portions 18.

[0062] [Fourth Embodiment] Next, a fourth embodiment of the technology of the present disclosure will be described.

[0063] In the fourth embodiment, the configuration of the fixing portion 92 in the insulating sheet 40 is changed from that of the third embodiment as follows. That is, in the fourth embodiment, as shown in Figures 11 and 12, the fixing portion 92 has a plurality of crimped portions 102 formed by crimping the first insulating portion 52 and the second insulating portion 54 together. The plurality of crimped portions 102 are formed, for example, by pressing the tip of the first insulating portion 52 and the tip of the second insulating portion 54 with a crimping device while the tip of the first insulating portion 52 and the tip of the second insulating portion 54 are overlapping.

[0064] Thus, in the fourth embodiment as well, the first insulating portion 52 and the second insulating portion 54 have an inter-winding overlap portion 80 that overlaps each other, and the inter-winding overlap portion 80 is provided with a fixing portion 92 that fixes the first insulating portion 52 and the second insulating portion 54. Therefore, when combining a plurality of stator components 12 in an annular shape, the opening of the first insulating portion 52 and the second insulating portion 54 due to springback force is suppressed, so adjacent stator components 12 can be easily assembled.

[0065] Furthermore, the fixing portion 92 has a plurality of crimped portions 102 formed by crimping the tip of the first insulating portion 52 and the tip of the second insulating portion 54 together. Therefore, when the tip of the first insulating portion 52 and the tip of the second insulating portion 54 are overlapped, the first insulating portion 52 and the second insulating portion 54 can be fixed in the winding overlap portion 80 by pressing the tip of the first insulating portion 52 and the tip of the second insulating portion 54 with a crimping device to form a plurality of crimped portions 102. This makes it easy to perform the fixing work of fixing the first insulating portion 52 and the second insulating portion 54.

[0066] Furthermore, the first insulating portion 52 and the second insulating portion 54 have overlapping winding portions 80 that overlap each other. Therefore, creepage distances along the first insulating portion 52 and the second insulating portion 54 can be secured between adjacent winding portions 18, thereby improving the insulation between adjacent winding portions 18.

[0067] [Fifth Embodiment] Next, a fifth embodiment of the technology of the present disclosure will be described.

[0068] In the fifth embodiment, the configuration of the insulating sheet 40 is modified from that of the first embodiment as follows. That is, in the fifth embodiment, as shown in Figure 13, the insulating sheet 40 includes a reduction structure 110 that reduces the springback force acting in the direction of opening to the winding portion insulating portion 50 (for example, the first insulating portion 52 and the second insulating portion 54). More specifically, the reduction structure 110 includes the insulating sheet 40 being made of fiber-reinforced plastic. The fiber-reinforced plastic may be glass fiber reinforced plastic or carbon fiber reinforced plastic.

[0069] Figure 14 shows a graph comparing the relationship between the position of the winding section insulation portion 50 in the opening / closing direction and the load, for cases where the insulating sheet 40 is made of fiber-reinforced plastic and cases where the insulating sheet 40 is made of ordinary plastic that is not fiber-reinforced plastic.

[0070] If the insulating sheet 40 is made of ordinary plastic rather than fiber-reinforced plastic, when a load F1 is applied to the winding section insulating part 50 in a closing direction, the winding section insulating part 50 deforms to position A1. Then, when the load F1 is removed, the winding section insulating part 50 opens along the slope of the elastic deformation region and returns to position A2. The difference between this position A1 and position A2 is the amount of springback of the winding section insulating part 50 when the insulating sheet 40 is made of ordinary plastic.

[0071] On the other hand, if the insulating sheet 40 is made of fiber-reinforced plastic, when a load F1 is applied to the winding section insulating part 50 in a closing direction, the winding section insulating part 50 deforms to position B1. Then, when the load F1 is removed, the winding section insulating part 50 opens along the slope of the elastic deformation region and returns to position B2. The difference between this position B1 and position B2 is the amount of springback of the winding section insulating part 50 when the insulating sheet 40 is made of fiber-reinforced plastic.

[0072] Thus, when the insulating sheet 40 is made of fiber-reinforced plastic, the amount of springback of the winding section insulating portion 50 is less than when the insulating sheet 40 is made of ordinary plastic that is not fiber-reinforced plastic. Therefore, when the insulating sheet 40 is made of fiber-reinforced plastic, the springback force acting in the direction of opening on the winding section insulating portion 50 can be reduced compared to when the insulating sheet 40 is made of ordinary plastic that is not fiber-reinforced plastic. As a result, when multiple stator components 12 are assembled in a ring shape, the opening of the winding section insulating portion 50 (for example, the first insulating portion 52 and the second insulating portion 54) due to springback force is suppressed, so adjacent stator components 12 can be easily assembled.

[0073] Furthermore, the combinable configurations described in the first to fifth embodiments may be combined as appropriate.

[0074] 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.

[0075] The following are additional notes regarding the technology of the present disclosure. (Addendum 1) A stator (10) comprising a plurality of stator components (12) arranged in an annular shape, wherein each stator component comprises: a core member (14) constituting a stator core (24); an insulating sheet (40) attached to the core member; and a winding portion (18) wound around the core member via the insulating sheet, wherein the insulating sheet has a winding portion insulating portion (50) disposed between adjacent winding portions, and the stator comprises a closing structure (70) that closes the winding portion insulating portion against a springback force acting in the direction of opening the winding portion insulating portion. (Note 2) The stator according to Note 1, wherein one of the adjacent stator components (12A) has a first winding section insulating section (50A) as the winding section insulating section, and the other of the adjacent stator components (12B) has a second winding section insulating section (50B) as the winding section insulating section, and the closing structure includes a structure in which the first winding section insulating section and the second winding section insulating section push against each other in a closing direction due to the springback force. (Note 3) The stator as described in Note 2, wherein the core member has a tooth portion (20) extending radially from the stator core and a core back portion (22) located radially outward from the stator core relative to the tooth portion and connected to the base end of the tooth portion, the first winding section insulation portion has a first insulation portion (52) bent toward the core back portion with the tip end of the tooth portion as its base end and a second insulation portion (54) bent toward the tip end of the tooth portion with the core back portion as its base end, the second winding section insulation portion has a third insulation portion (56) bent toward the tip end of the tooth portion with the core back portion as its base end and a fourth insulation portion (58) bent toward the core back portion with the tip end of the tooth portion as its base end, the length of the second insulation portion is longer than the length of the first insulation portion and the length of the fourth insulation portion is longer than the length of the third insulation portion.(Note 4) The stator according to Note 3, wherein the second insulating portion and the fourth insulating portion have an overlapping portion (60) between windings that overlap each other. (Note 5) The stator according to Note 1, wherein each of the stator components comprises an insulating member (30) mounted on the core member, and the closing structure includes a holding portion (84) provided on the insulating member that holds the winding portion insulating portion in a closed state. (Note 6) The stator according to Note 5, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the teeth portion of the stator core and connected to the base end of the teeth portion, the winding portion insulating portion has a protruding portion (82) that protrudes axially from the core back portion of the stator core, and the protruding portion has a held portion (86) that is held by the holding portion. (Note 7) The stator according to Note 5 or Note 6, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the stator core relative to the teeth portion and connected to the base end of the teeth portion, the winding winding insulating portion has a first insulating portion (52) bent toward the core back portion with the tip end of the teeth portion as the base end and a second insulating portion (54) bent toward the tip end of the teeth portion with the core back portion as the base end, the first insulating portion and the second insulating portion have an inter-winding overlap portion (80) that overlap each other, and the closing structure includes a structure that holds the second insulating portion in a closed state by positioning the second insulating portion between the first insulating portion and the winding winding portion in the inter-winding overlap portion.(Note 8) The stator according to Note 1, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the stator core relative to the teeth portion and connected to the base end of the teeth portion, the winding winding insulating portion has a first insulating portion bent toward the core back portion with the tip end of the teeth portion as its base end and a second insulating portion bent toward the tip end of the teeth portion with the core back portion as its base end, the first insulating portion and the second insulating portion have an inter-winding overlap portion that overlaps each other, and the closing structure includes a fixing portion (92) that fixes the first insulating portion and the second insulating portion in the inter-winding overlap portion. (Note 9) The stator according to Note 8, wherein the fixing portion has a locking portion (94) formed in the first insulating portion and a locked portion (96) formed in the second insulating portion and locked to the locking portion. (Note 10) The stator according to Note 8 or Note 9, wherein the fixing portion has a crimped portion (102) that crimps the first insulating portion and the second insulating portion together. (Note 11) A stator composed of a plurality of stator components, each of which comprises: a core member constituting a stator core; an insulating sheet attached to the core member; and a winding portion wound around the core member via the insulating sheet, wherein the insulating sheet has a winding portion insulating portion disposed between adjacent winding portions, and the stator is provided with a reduction structure (110) that reduces the springback force acting in the direction of opening the winding portion insulating portion. (Note 12) The stator according to claim 11, wherein the reduction structure includes the insulating sheet being made of fiber-reinforced plastic. (Note 13) A rotating electric machine (M) comprising a stator as described in any one of Notes 1 to 12, and a rotor (11) rotatably housed inside the stator.(Note 14) A method for manufacturing a stator as described in any one of Notes 1 to 10, comprising: a stator component assembly step of assembling the stator components by attaching the insulating sheet to the core member and winding the winding portion on the core member via the insulating sheet; and an annular formation step of forming the stator by combining a plurality of the stator components in an annular shape, wherein the annular formation step includes closing the winding portion insulating portion against a springback force acting in the direction of opening the winding portion insulating portion using the closing structure.

Claims

1. A stator (10) comprising a plurality of stator components (12) arranged in an annular shape, wherein each stator component comprises: a core member (14) constituting a stator core (24); an insulating sheet (40) attached to the core member; and a winding portion (18) wound around the core member via the insulating sheet, wherein the insulating sheet has a winding portion insulating portion (50) positioned between adjacent winding portions, and the stator comprises a closing structure (70) that closes the winding portion insulating portion against a springback force acting in the direction of opening the winding portion insulating portion.

2. The stator according to claim 1, wherein one of the adjacent stator components (12A) has a first winding section insulating section (50A) as the winding section insulating section, and the other of the adjacent stator components (12B) has a second winding section insulating section (50B) as the winding section insulating section, and the closing structure includes a structure in which the first winding section insulating section and the second winding section insulating section push against each other in a closing direction due to the springback force.

3. The stator according to claim 2, wherein the core member has a tooth portion (20) extending radially from the stator core and a core back portion (22) located radially outward from the stator core relative to the tooth portion and connected to the base end of the tooth portion; the first winding section insulation portion has a first insulation portion (52) bent toward the core back portion with the tip end of the tooth portion as its base end and a second insulation portion (54) bent toward the tip end of the tooth portion with the core back portion as its base end; the second winding section insulation portion has a third insulation portion (56) bent toward the tip end of the tooth portion with the core back portion as its base end and a fourth insulation portion (58) bent toward the core back portion with the tip end of the tooth portion as its base end, the length of the second insulation portion is longer than the length of the first insulation portion and the length of the fourth insulation portion is longer than the length of the third insulation portion.

4. The stator according to claim 3, wherein the second insulating portion and the fourth insulating portion have an overlapping winding portion (60) that overlaps each other.

5. The stator according to claim 1, wherein each stator component comprises an insulating member (30) mounted on the core member, and the closing structure includes a holding portion (84) provided on the insulating member for holding the winding portion insulating portion in a closed state.

6. The stator according to claim 5, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the stator core relative to the teeth portion and connected to the base end of the teeth portion, the winding winding insulating portion has a protruding portion (82) that protrudes axially from the stator core beyond the core back portion, and the protruding portion has a held portion (86) that is held by the holding portion.

7. The stator according to claim 5 or claim 6, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the stator core relative to the teeth portion and connected to the base end of the teeth portion, the winding winding insulating portion has a first insulating portion (52) bent toward the core back portion with the tip end of the teeth portion as its base end and a second insulating portion (54) bent toward the tip end of the teeth portion with the core back portion as its base end, the first insulating portion and the second insulating portion have an inter-winding overlap portion (80) that overlap each other, and the closing structure includes a structure that holds the second insulating portion in a closed state by positioning the second insulating portion between the first insulating portion and the winding winding portion in the inter-winding overlap portion.

8. The stator according to claim 1, wherein the core member has a teeth portion extending radially from the stator core and a core back portion located radially outward from the stator core relative to the teeth portion and connected to the base end of the teeth portion, the winding winding insulating portion has a first insulating portion bent toward the core back portion with the tip end of the teeth portion as its base end and a second insulating portion bent toward the tip end of the teeth portion with the core back portion as its base end, the first insulating portion and the second insulating portion have an inter-winding overlap portion that overlaps each other, and the closing structure includes a fixing portion (92) that fixes the first insulating portion and the second insulating portion in the inter-winding overlap portion.

9. The stator according to claim 8, wherein the fixed portion has a locking portion (94) formed on the first insulating portion and a locked portion (96) formed on the second insulating portion and locked to the locking portion.

10. The stator according to claim 8 or claim 9, wherein the fixing portion has a crimped portion (102) formed by crimping the first insulating portion and the second insulating portion together.

11. A stator composed of a plurality of stator components, each of which comprises: a core member constituting a stator core; an insulating sheet attached to the core member; and a winding portion wound around the core member via the insulating sheet, wherein the insulating sheet has a winding portion insulating portion disposed between adjacent winding portions, and the stator is equipped with a reduction structure (110) that reduces the springback force acting in the direction of opening the winding portion insulating portion.

12. The stator according to claim 11, wherein the reduction structure comprises the insulating sheet being made of fiber-reinforced plastic.

13. A rotating electric machine (M) comprising: a stator according to any one of claims 1 to 12; and a rotor (11) rotatably housed inside the stator.

14. A method for manufacturing a stator according to any one of claims 1 to 10, comprising: a stator component assembly step of assembling the stator components by attaching the insulating sheet to the core member and winding the winding portion on the core member via the insulating sheet; and an annular formation step of forming the stator by combining a plurality of the stator components in an annular shape, wherein the annular formation step includes closing the winding portion insulating portion with the closing structure against a springback force acting in the direction of opening the winding portion insulating portion.

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