Stator, rotary electric machine, and production method for stator

Abstract

A stator (10) comprises a stator core (24), an insulating sheet (40) that is installed on the stator core, an insulating member (30) that is installed on the stator core, and a wound winding part (18) that is wound on the stator core with the insulating sheet and the insulating member therebetween. The stator core has an insulated surface (20A, 20B, 22A) that is oriented in a direction orthogonal to the axial direction of the stator core, the insulating sheet insulates the insulated surface, and the insulating member is installed on the stator core from one side in the axial direction of the stator core and insulates the insulated surface over the insulating sheet. The stator core has a protruding part (70) that protrudes in the orthogonal direction relative to the insulated surface at a position that is on the one side in the axial direction of the stator core relative to the insulated surface.

Description

Stator, Rotating Electric Machine, and Method for Manufacturing Stator Cross - reference to Related Applications

[0001] This application is based on Japanese Application No. 2024 - 195491 filed on November 7, 2024, and Japanese Application No. 2025 - 045322 filed on March 19, 2025, claims the benefit of their priorities, and all the contents of the patent applications are incorporated herein by reference.

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

[0003] Conventionally, there is a stator including a stator core, an insulating sheet attached to the stator core, an insulating member attached to the stator core, and a winding - winding portion wound around the stator core via the insulating sheet and the insulating member (see, for example, Japanese Patent No. 5762638). In this stator, the stator core has an insulated surface facing a direction orthogonal to the axial direction of the stator core (for example, the side surface of the main body portion of the tooth portion, the outer surface of the tip portion of the tooth portion, and the inner surface of the core back portion). The insulating sheet insulates the insulated surface. The insulating member is attached to the stator core from one side in the axial direction of the stator core and insulates the insulated surface via the insulating sheet.

[0004] As a result of the inventors' detailed examination, the following problems have been found. That is, in the stator having the above configuration, when the insulating member is attached to the stator core from one side in the axial direction of the stator core, there is a risk that the insulating member interferes with the end portion of the insulating sheet (that is, the end portion located on one side in the axial direction of the stator core). When the end portion of the insulating sheet is a cutting edge portion where the insulating sheet is cut, since the edge is standing, the cutting edge portion is likely to catch on the insulating member. If the insulating member catches on the end portion of the insulating sheet, the insulating sheet may be deformed, and the insulating property of the insulating sheet may be impaired. Therefore, it is desirable to be able to suppress the interference between the insulating member and the end portion of the insulating sheet when the insulating member is attached to the stator core from one side in the axial direction of the stator core.

[0005] The technology disclosed herein provides a stator, a rotating electric machine, and a method for manufacturing a stator, which can suppress interference between the insulating member and the edge of the insulating sheet when the insulating member is attached to the stator core from one axial side of the stator core.

[0006] A first aspect of the technology of the present disclosure is a stator comprising: a stator core; an insulating sheet mounted on the stator core; an insulating member mounted on the stator core; and a winding portion wound around the stator core via the insulating sheet and the insulating member, wherein the stator core has an insulated surface facing in a direction perpendicular to the axial direction of the stator core; the insulating sheet insulates the insulated surface; the insulating member is mounted on the stator core from one axial side of the stator core and insulates the insulated surface via the insulating sheet; and the stator core has a projection formed thereon that is located on one axial side of the stator core with respect to the insulated surface and projecting in a direction perpendicular to the insulated surface.

[0007] A second aspect of the technology of the present disclosure is a rotating electric machine comprising a stator according to the first aspect and a rotor rotatably housed inside the stator.

[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 sheet mounting step of mounting the insulating sheet to the stator core; an insulating member mounting step of mounting the insulating member to the stator core; and a winding winding step of winding the winding portion to the stator core via the insulating sheet and the insulating member, wherein the insulating member mounting step includes protecting the end of the insulating sheet with the protrusion when mounting the insulating member to the stator core from one axial side of the stator core.

[0009] The present invention provides a stator, a rotating electric machine, and a method for manufacturing a stator, which can suppress interference between the insulating member and the edge of the insulating sheet when the insulating member is attached to the stator core from one axial side of the stator core.

[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 an exploded perspective view of a stator component according to the first embodiment. This is an enlarged exploded perspective view of the main part of the stator according to the first embodiment. This is an enlarged plan view of the main part of the stator according to the first embodiment. This is a schematic longitudinal cross-sectional view of a stator component according to the first embodiment. This is a two-view drawing (longitudinal section and side view) of a stator component according to the first embodiment. This is a flowchart illustrating the manufacturing method of a stator according to the first embodiment. This is the first explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is the second explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is the third explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is the fourth explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is the fifth explanatory diagram illustrating the manufacturing method of a stator according to the first embodiment. This is an exploded perspective view of a stator component according to the second embodiment. This is a schematic longitudinal cross-sectional view of a stator component according to the second embodiment. This is an exploded perspective view showing a modified example of a stator component according to the second embodiment. This is a perspective view of a stator component according to the third embodiment. This is a cross-sectional view of a stator component according to the third embodiment. This is an enlarged plan view of the main part of the stator according to the third embodiment. This is a schematic longitudinal cross-sectional view of a stator component shown to illustrate the problems to be solved in the fourth embodiment. This is a schematic longitudinal cross-sectional view of a stator component according to the fourth embodiment. This is a schematic longitudinal cross-sectional view of a modified example of a stator component according to the fourth embodiment. This is a graph showing an example of the relationship between the uppermost stage area ratio and the step height ratio. This is a graph showing an example of the relationship between the ratio of uppermost stage area / internal height of the insulating part and the ratio of curved surface radius / half tooth width.

[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 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.

[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. The X, Y, and Z directions are mutually orthogonal directions. In the following description, the circumferential direction of the stator 10 refers to the direction around the central axis of the stator 10. The tangential, radial, axial, and circumferential directions of the stator core 24, described later, are the same directions as the tangential, radial, axial, and circumferential directions of the stator 10, respectively. The tangential and radial directions of the stator core 24 are examples of "directions orthogonal to the axial direction of the stator core" in the technology of this disclosure.

[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, 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 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.

[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 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.

[0017] The stator core 24 (see Figure 1) is formed by combining 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).

[0018] The core member 14 is formed symmetrically in the X direction. The configuration of one side of the core member 14 in the X direction will be mainly described below. The main body portion 21A of the teeth portion 20 has a side surface 20A facing the X direction. The side surface 20A extends in the Y direction and the Z direction. The tip portion 21B of the teeth portion 20 has an outward-facing surface 20B facing outward in the Y direction. The outward-facing surface 20B is inclined with respect to the X direction and extends in the Z direction. The core back portion 22 has an inward-facing surface 22A facing inward in the Y direction. The inward-facing surface 22A extends in the X direction and the Z direction. The side surface, outward-facing surface, and inward-facing surface are examples of "insulated surfaces" according to the technology of this disclosure.

[0019] As shown in Figures 2 and 3, each stator component 12 comprises a core member 14, an insulator 16, and a winding section 18. In Figures 3 and subsequent figures, Z1 indicates one axial side of the stator 10, and Z2 indicates the other axial side of the stator 10. 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.

[0020] One of the pair of insulating members 30 is attached to the core member 14 from the Z1 side, and the other insulating member 30 is attached to the core member 14 from the Z2 side. Hereinafter, when describing the pair of insulating members 30 separately, the insulating member 30 located on the Z1 side will be referred to as "insulating member 30U," and the insulating member 30 located on the Z2 side will be referred to as "insulating member 30L." Insulating member 30U is an example of the "first insulating member" according to the technology of this disclosure. Insulating member 30L is an example of the "second insulating member" according to the technology of this disclosure.

[0021] The pair of insulating members 30 are formed symmetrically in the Z direction. Each insulating member 30 is also formed symmetrically in the X direction. The pair of insulating sheets 40 are formed symmetrically in the X direction. Each insulating sheet 40 is also formed symmetrically in the Z direction. The following will mainly describe the configuration of one side in the X direction of the insulating member 30 located on the Z1 side of the pair of insulating members 30. Similarly, the configuration of the Z1 side of the insulating sheet 40 located on one side in the X direction of the pair of insulating sheets 40 will be mainly described.

[0022] 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.

[0023] The main body insulating portion 31A has a side insulating portion 30A 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 31B has an outward-facing surface insulating portion 30B 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 30B 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 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 an inward-facing surface insulating portion 32A that insulates the core back portion 22 by covering the inward-facing surface 22A of the core back portion 22.

[0024] 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 18.

[0025] 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 accordance 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 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.

[0026] 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 surface 20A of the tooth portion 20, and the side insulating portion 30A of the insulating member 30 insulates the side surface 20A of the tooth portion 20 via the side insulating portion 40A of the insulating sheet 40. The outward-facing insulating portion 40B of the insulating sheet 40 is positioned between the outward-facing insulating portion 30B of the insulating member 30 and the outward-facing surface 20B of the tooth portion 20, and the outward-facing insulating portion 30B of the insulating member 30 insulates the outward-facing surface 20B of the tooth portion 20 via the outward-facing insulating portion 40B of the insulating sheet 40.

[0027] 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, and the inward-facing insulating portion 32A of the insulating member 30 insulates the inward-facing surface 22A of the core back portion 22 via the inward-facing insulating portion 42A of the insulating sheet 40. The winding portion insulating portion 50 is connected to the outward-facing insulating portion 40B and is bent toward the core back portion 22 with the tip portion 21B side of the teeth portion 20 as the base end.

[0028] The side insulating portion 40A of the insulating sheet 40 is an example of the "first side insulating portion" according to the technology of this disclosure. The outward-facing insulating portion 40B of the insulating sheet 40 is an example of the "first outward-facing insulating portion" according to the technology of this disclosure. The inward-facing insulating portion 42A of the insulating sheet 40 is an example of the "first inward-facing insulating portion" according to the technology of this disclosure. The side insulating portion 30A of the insulating member 30 is an example of the "second side insulating portion" according to the technology of this disclosure. The outward-facing insulating portion 30B of the insulating member 30 is an example of the "second outward-facing insulating portion" according to the technology of this disclosure. The inward-facing insulating portion 32A of the insulating member 30 is an example of the "second inward-facing insulating portion" according to the technology of this disclosure.

[0029] As shown in Figure 4, the main body portion 21A of the teeth portion 20 has an end face 20C facing the Z direction, and the core back portion 22 has an end face 22B facing the Z direction. The main body insulating portion 31A of the insulating member 30 has an end face insulating portion 30C that insulates the end face 20C, and the core back portion insulating portion 32 of the insulating member 30 has an end face insulating portion 32B that insulates the end face 22B.

[0030] The side insulating portion 30A and the inward insulating portion 32A of the insulating member 30 extend in the Z direction. Specifically, the side insulating portion 30A and the inward insulating portion 32A extend on the opposite side from the end insulating portion 30C and the end insulating portion 32B. The extended end of the side insulating portion 30A has an inclined portion 44 that is inclined with respect to the Z direction. The inclined portion 44 is formed at a position corresponding to the outward insulating portion 40B of the insulating sheet 40. The extended end of the inward insulating portion 32A has an inclined portion 46 that is inclined with respect to the Z direction. The inclined portion 46 is formed at a position corresponding to the inward insulating portion 42A of the insulating sheet 40.

[0031] As shown in Figure 5, in a state where multiple stator components 12 are assembled in a ring shape (see also Figure 1), the multiple insulating sheets 40 attached to each of the multiple core members 14 are arranged in a line in the circumferential direction of the stator 10. Similarly, the multiple winding portions 18 wound around each of the multiple core members 14 are arranged in a line in the circumferential direction of the stator 10.

[0032] The winding section insulating portion 50 of each insulating sheet 40 is positioned between adjacent winding sections 18 of the multiple winding sections 18. The winding section insulating portions 50 of adjacent insulating sheets 40 are overlapped in the circumferential direction of the stator 10. Specifically, each winding section insulating portion 50 has an insulating body portion 50A that extends in the radial direction of the stator 10, and the insulating body portions 50A of adjacent winding section insulating portions 50 are overlapped in the circumferential direction of the stator 10.

[0033] Each winding section insulation section 50 has, in addition to the insulation body section 50A, a first overlap section 52 that overlaps with the outward-facing surface insulation section 30B of the insulation member 30 in the tangential direction to the stator 10, and a second overlap section 54 that overlaps with the inward-facing surface insulation section 32A of the insulation member 30 in the tangential direction to the stator 10. The first overlap section 52 is formed at the end of the insulation body section 50A on the tip section 21B side of the teeth section 20. The second overlap section 54 is formed at the end of the insulation body section 50A on the core back section 22 side. The first overlap section 52 is inserted into a groove 36 formed in the outward-facing surface insulation section 30B of the insulation member 30.

[0034] As shown in Figure 6, the core member 14 is a laminate formed by stacking a plurality of core sheets 15 in the Z direction. The core member 14 has a projection 70 that is located on the Z1 side relative to the side surface 20A of the teeth portion 20 and protrudes in the X direction relative to the side surface 20A. The projection 70 is formed, for example, by protrusions formed on some of the core sheets 15 that are located at the ends in the Z direction among the plurality of core sheets 15. The projection 70 protrudes in the X direction more than the side insulating portion 40A of the insulating sheet 40. That is, the dimension of the projection 70 in the projection direction is set to be larger than the thickness dimension of the side insulating portion 40A.

[0035] The protruding portion 70 is formed not only along the side surface 20A, but also along the outward-facing surface 20B, the side surface 20A, and the inward-facing surface 22A (see Figure 4). That is, the protruding portion 70 has a side protruding portion 70A that protrudes in the X direction relative to the side surface 20A, an outward-facing surface protruding portion 70B that protrudes outward in the Y direction relative to the outward-facing surface 20B, and an inward-facing surface protruding portion 70C that protrudes inward in the Y direction relative to the inward-facing surface 22A (see Figure 4).

[0036] Furthermore, a protrusion 70 similar to the protrusion 70 formed on the Z1 end of the core member 14 is formed on the Z2 end of the core member 14. The protrusion 70 formed on the Z1 end of the core member 14 (hereinafter also referred to as "protrusion 70U") is an example of the "first protrusion" according to the technology of this disclosure. The protrusion 70 formed on the Z2 end of the core member 14 (hereinafter also referred to as "protrusion 70L") is an example of the "second protrusion" according to the technology of this disclosure.

[0037] The side insulating portion 40A of the insulating sheet 40 and the side insulating portion 30A of the insulating member 30 have overlapping portions 60 that overlap in the Z direction. Similarly, the outward-facing insulating portion 40B of the insulating sheet 40 and the outward-facing insulating portion 30B of the insulating member 30 (see Figure 4) also overlap in the Z direction, and the inward-facing insulating portion 42A of the insulating sheet 40 and the inward-facing insulating portion 32A of the insulating member 30 (see Figure 4) also overlap in the Z direction.

[0038] As shown in Figure 7, the winding insulation portion 50 has an extension portion 56 that extends in the Z direction beyond the core member 14. More specifically, the extension portion 56 extends in the Z direction beyond the end face 20C of the teeth portion 20 and the end face 22B of the core back portion 22.

[0039] Next, with reference to Figure 8, 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 includes a sheet material winding step ST1, a sheet material processing step ST2, a sheet material rewinding step ST3, a winding habit removal step ST4, an insulating sheet cutting step ST5, an insulating sheet bending step ST6, an insulating sheet mounting step ST7, an insulating member mounting step ST8, a winding wire winding step ST9, a winding wire winding section insulating section bending step ST10, and an annular formation step ST11.

[0040] As shown in Figure 9, the sheet material winding process ST1 is a process of winding a long sheet material 80 (see Figure 9), which will be the material for the insulating sheet 40, into a roll. The sheet material 80 is a resin sheet material formed into a long shape with insulating properties. The sheet material processing process ST2 is a process of pulling out the rolled sheet material 80 and processing the sheet material 80 into a shape in which multiple insulating sheets 40 are connected. In the sheet material processing process ST2, the sheet material 80 is processed into a shape in which multiple insulating sheets 40 are connected such that the inward-facing insulating portion 42A (see Figure 2) of one of the insulating sheets 40 adjacent to each other in the longitudinal direction of the sheet material 80 is connected to the second overlap portion 54 (see Figure 2) of the other. The sheet material rewinding process ST3 is a process of winding the processed sheet material 80 again.

[0041] As shown in Figure 10, the coiling deformity removal process ST4 is a process of pulling out the rolled sheet material 80 and removing the coiling deformity from the sheet material 80. The insulating sheet cutting process ST5 is a process of cutting the insulating sheet 40 from the sheet material 80 from which the coiling deformity has been removed. The insulating sheet bending process ST6 is a process of bending the insulating sheet 40 into a shape that can be attached to the core member 14.

[0042] As shown in Figure 11, the insulating sheet mounting process ST7 is a process of mounting a pair of insulating sheets 40 to the core member 14. The multiple core members 14 (see Figure 1) are classified, for example, into U-phase, V-phase, and W-phase, and in the insulating sheet mounting process, an insulating sheet 40 is mounted to the core member 14 for each phase. In addition, a jig 82 is used in the insulating sheet mounting process. The jig 82 has a shape that corresponds to the core member 14 (see Figure 1) located next to the core member 14 to which the insulating sheet 40 is mounted. Specifically, the jig 82 is a block body having the same outer shape as the laminated core member 14. The insulating sheet 40 is inserted into a slot 84 (i.e., a pseudo-slot) between the core member 14 and the adjacent jig 82, and is held in the slot 84 by utilizing the springback force F acting on the side insulating portion 40A and the winding portion insulating portion 50. The core member 14 to which the insulating sheet 40 is mounted is an example of the "first core member" according to the technology of this disclosure. A core member 14 located next to the core member 14 on which the insulating sheet 40 is attached (see Figure 1) is an example of a "second core member" according to the technology of this disclosure.

[0043] As shown in Figure 12, the insulating member mounting step ST8 is a step of sequentially mounting a pair of insulating members 30 onto the core member 14. In the insulating member mounting step ST8, when mounting the insulating member 30U onto the core member 14 from the Z1 side, the Z1 side end 40C of the insulating sheet 40 is protected by the protrusion 70 formed on the Z1 side end of the core member 14. The Z1 side end 40C of the insulating sheet 40 is, for example, the Z1 side end of the side insulating portion 40A, the outward-facing insulating portion 40B, and the inward-facing insulating portion 42A (see Figure 4). Next, the core member 14 and the jig 82 are inverted upside down, and the insulating member 30L is mounted onto the core member 14 from the Z2 side. At this time as well, the Z2 side end 40D of the insulating sheet 40 is protected by the protrusion 70 formed on the Z2 side end of the core member 14. The Z2-side end 40D of the insulating sheet 40 is, for example, the Z2-side end of the side insulating portion 40A, the outward-facing insulating portion 40B, and the inward-facing insulating portion 42A (see Figure 4).

[0044] As shown in FIG. 13, the winding process ST9 is a process of winding the winding portion 18 around the core member 14 via a pair of insulating members 30 and a pair of insulating sheets 40. In the winding process, the insulating portion 50 of the winding portion is expanded in the X direction so that the nozzle of a winding machine (not shown) for winding the winding portion 18 does not interfere with the insulating portion 50 of the winding portion. The insulating portion bending process ST10 of the winding portion is a process of bending the insulating portion 50 of the winding portion in a closing direction. Thus, each stator component 12 is assembled individually. The annularization process ST11 is a process of forming the stator 10 by annularly combining a plurality of stator components 12. Through the above processes, the stator 10 is manufactured.

[0045] As described in detail above, in the stator 10 according to the first embodiment, the insulating sheet 40 insulates the side surface 20A, the outer surface 20B, and the inner surface 22A of the core member 14. Here, the end portion 40C on the Z1 side of the insulating sheet 40 is a cut cutting edge portion, and since the edge stands up, it is likely to get caught on the insulating member 30U. When the insulating member 30U gets caught on the end portion 40C on the Z1 side of the insulating sheet 40, the insulating sheet 40 may be deformed and the insulating property of the insulating sheet 40 may be impaired. Therefore, when mounting the insulating member 30U to the core member 14 from the Z1 side, it is desirable to be able to suppress the insulating member 30U from interfering with the end portion 40C on the Z1 side of the insulating sheet 40.

[0046] In this regard, in the stator 10 according to the first embodiment, a protruding portion 70 (that is, the protruding portion 70U) is formed at the end portion on the Z1 side of the core member 14, which is located on the Z1 side with respect to the side surface 20A, the outer surface 20B, and the inner surface 22A and protrudes with respect to the side surface 20A, the outer surface 20B, and the inner surface 22A. Therefore, when mounting the insulating member 30U to the core member 14 from the Z1 side, the end portion 40C on the Z1 side of the insulating sheet 40 (that is, the end portions on the Z1 side in each of the side surface insulating portion 40A, the outer surface insulating portion 40B, and the inner surface insulating portion 42A) can be protected by the protruding portion 70 formed at the end portion on the Z1 side of the core member 14. Thereby, it is possible to suppress the insulating member 30U from interfering with the end portion 40C on the Z1 side of the insulating sheet 40.

[0047] Further, the protruding portion 70 includes a side surface protruding portion 70A that protrudes in the X direction from the side surface 20A, an outer surface protruding portion 70B that protrudes outside in the Y direction from the outer surface 20B, and an inner surface protruding portion 70C that protrudes inside in the Y direction from the inner surface 22A. Thereby, it is possible to suppress the interference of the insulating member 30U with the Z1-side end portions of the side surface insulating portion 40A, the outer surface insulating portion 40B, and the inner surface insulating portion 42A, respectively.

[0048] Further, the protruding portion 70 protrudes more than the insulating sheet 40. Specifically, the side surface protruding portion 70A of the protruding portion 70 protrudes in the X direction more than the side surface insulating portion 40A, the outer surface protruding portion 70B of the protruding portion 70 protrudes outside in the Y direction more than the outer surface insulating portion 40B, and the inner surface protruding portion 70C of the protruding portion 70 protrudes inside in the Y direction more than the inner surface insulating portion 42A. Thereby, it is possible to more effectively suppress the interference of the insulating member 30U with the Z1-side end portion 40C of the insulating sheet 40.

[0049] Further, the side surface insulating portion 30A of the insulating member 30U extends to the Z2 side, and the extending end portion of the side surface insulating portion 30A has an inclined portion 44 that is inclined with respect to the Z direction. The inclined portion 44 is formed at a position corresponding to the outer surface insulating portion 40B of the insulating sheet 40. Therefore, when the insulating member 30U is assembled to the core member 14, the inclined portion 44 formed at the extending end portion of the side surface insulating portion 30A gradually contacts the Z1-side end portion (that is, the cutting edge portion) of the outer surface insulating portion 40B, so that it is possible to suppress the outer surface insulating portion 40B from being rubbed or deformed during the assembly of the insulating member 30U.

[0050] Similarly, the inner surface insulating portion 32A of the insulating member 30U extends to the Z2 side, and the extending end portion of the inner surface insulating portion 32A has an inclined portion 46 that is inclined with respect to the Z direction. The inclined portion 46 is formed at a position corresponding to the inner surface insulating portion 42A of the insulating sheet 40. Therefore, when the insulating member 30U is assembled to the core member 14, the inclined portion 46 formed at the extending end portion of the inner surface insulating portion 32A gradually contacts the Z1-side end portion (that is, the cutting edge portion) of the inner surface insulating portion 42A, so that it is possible to suppress the inner surface insulating portion 42A from being rubbed or deformed during the assembly of the insulating member 30.

[0051] Furthermore, a projection 70 (i.e., projection 70L) is formed on the Z2-side end of the core member 14, projecting relative to the side surface 20A, the outward-facing surface 20B, and the inward-facing surface 22A. Therefore, when attaching the insulating member 30L to the core member 14 from the Z2 side, the projection 70 formed on the Z2-side end of the core member 14 protects the Z2-side end 40D of the insulating sheet 40 (i.e., the Z2-side end of each of the side insulating portion 40A, the outward-facing insulating portion 40B, and the inward-facing insulating portion 42A). This prevents the insulating member 30L from interfering with the Z2-side end 40D of the insulating sheet 40.

[0052] Furthermore, the insulating sheet 40 has a winding section insulating section 50 positioned between adjacent winding sections 18. Therefore, it is possible to insulate the adjacent winding sections 18, thereby improving the insulation between adjacent winding sections 18.

[0053] Furthermore, the winding insulation portion 50 has an extension portion 56 that extends in the Z direction from the core member 14. This ensures an insulation distance along the extension portion 56 (i.e., the ground insulation distance D1 in Figure 7) between the end face 22B of the core back portion 22 and the winding insulation portion 18, thereby improving the insulation performance with respect to the core member 14.

[0054] Furthermore, the side insulating portion 40A of the insulating sheet 40 and the side insulating portion 30A of the insulating member 30 have overlapping portions 60 that overlap in the Z direction. This ensures an insulating distance along the overlapping portion 60 (i.e., the ground insulating distance D2 in Figure 7) between the core member 14 and the winding portion 18, thereby improving the insulating properties with respect to the core member 14.

[0055] Furthermore, the insulating portions 50 of adjacent insulating sheets 40 are overlapped. This further improves the insulation between adjacent insulating portions 18.

[0056] Furthermore, the winding insulation portion 50 has a first overlap portion 52 that overlaps with the outward-facing insulation portion 30B of the insulating member 30 in the tangential direction of the stator 10. This ensures an insulation distance (i.e., the phase-to-phase insulation distance D3 in Figure 5) between adjacent winding terminal portions 19 along the outward-facing insulation portion 30B and the first overlap portion 52, thereby improving the insulation between adjacent winding terminal portions 19.

[0057] Furthermore, the winding section insulation portion 50 has a second overlap portion 54 that overlaps with the inward-facing surface insulation portion 32A of the insulating member 30 in the tangential direction of the stator 10. This ensures that an insulation distance (i.e., the phase-to-phase insulation distance D4 in Figure 5) is secured between adjacent winding sections 18 along the inward-facing surface insulation portion 32A and the second overlap portion 54, thereby improving the insulation between adjacent winding sections 18.

[0058] In the first embodiment, the winding insulation portion 50 has both a first overlap portion 52 and a second overlap portion 54, but either the first overlap portion 52 or the second overlap portion 54 may be omitted.

[0059] Furthermore, in the first embodiment, the stator core 24 is divided into a plurality of core members 14, and the plurality of core members 14 are configured independently of each other, but the plurality of core members 14 may be rotatably connected by a rotational connecting portion that has 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 a rotational connecting portion, the plurality of insulating members 30 attached to each of the plurality of core members 14 may be rotatably connected by a rotational connecting portion. Also, the plurality of core members 14 may be formed as a single unit, and the plurality of insulating members 30 may also be formed as a single unit.

[0060] [Second Embodiment] Next, a second embodiment of the technology of the present disclosure will be described.

[0061] As shown in Figures 14 and 15, in the second embodiment, an insulating sheet 90 is used compared to the first embodiment. The insulating sheet 90 is configured in which a pair of insulating sheets 40 are connected by a connecting portion 92. The connecting portion 92 connects the Z2-side ends of the pair of insulating sheets 40 (specifically, the Z2-side ends of the pair of side insulating portions 40A).

[0062] In this way, when the ends of the pair of insulating sheets 40 on the Z2 side are connected by the connecting portion 92, it is possible to avoid the ends of the pair of insulating sheets 40 on the Z2 side becoming cutting edges. Therefore, when attaching the insulating member 30L to the core member 14 from the Z2 side, it is possible to prevent the insulating member 30L from getting caught on the cutting edges of the insulating sheets 40.

[0063] As shown in Figure 16, the insulating member 30L and the insulating sheet 90 may be integrated by insert molding.

[0064] [Third Embodiment] Next, a third embodiment of the technology of the present disclosure will be described.

[0065] As shown in Figures 17 to 19, in the third embodiment, the configuration of the insulating sheet 40 is changed from that of the first embodiment as follows. That is, in the third embodiment, the winding section insulating section 50 has a first winding section insulating section 74 extending from the tip portion 21B side of the teeth section 20 to the core back section 22 side, and a second winding section insulating section 76 extending from the core back section 22 side to the tip portion 21B side of the teeth section 20. The first winding section insulating section 74 is connected to the outward-facing surface insulating section 40B, and the second winding section insulating section 76 is connected to the inward-facing surface insulating section 42A. The tip portion of the first winding section insulating section 74 and the tip portion of the second winding section insulating section 76 form an inter-winding overlap section 78 that overlaps radially in the stator 10.

[0066] In this way, when the tip of the first winding section insulation portion 74 and the tip of the second winding section insulation portion 76 overlap in the radial direction of the stator 10, an insulation distance (i.e., the ground insulation distance D5 in Figure 18) can be secured between the core member 14 and the winding end portion 19 along the first winding section insulation portion 74, the outward-facing surface insulation portion 30B, and the outward-facing surface insulation portion 40B, thereby improving the insulation performance with respect to the core member 14.

[0067] Furthermore, since an insulation distance (i.e., the ground insulation distance D6 in Figure 18) can be secured between the core member 14 and the winding section 18 along the inter-winding overlap section 78 and the second winding section insulation section 76, the insulation performance with respect to the core member 14 can be improved. In addition, since an insulation distance (i.e., the phase insulation distance D7 in Figure 19) can be secured between adjacent winding sections 18 along the inter-winding overlap section 78, the insulation performance between adjacent winding sections 18 can be improved.

[0068] [Fourth Embodiment] Next, a fourth embodiment of the technology of the present disclosure will be described.

[0069] First, let me explain the problems to be solved in the fourth embodiment. For example, as shown in Figure 20, the insulating member 30 has an insulating portion 100 provided between the teeth portion 20 and the winding portion 18 in the Z direction. The winding portion 18 has a tangential portion 18A extending in the X direction, an axial portion 18B extending in the Z direction, and an arc portion 18C connecting the tangential portion 18A and the axial portion 18B. The insulating portion 100 has a curved portion 102 (i.e., an R-shaped corner portion) that supports the arc portion 18C.

[0070] Here, if a protrusion 70 is formed on the side surface 20A of the teeth portion 20, it is necessary to ensure the required thickness of the portion of the insulating member 30 that is required to be thick (hereinafter referred to as the "required thickness portion 104"). Since the area near the protrusion 70 is the starting point of the curved portion 102, increasing the thickness of the required thickness portion 104 will increase the radius of the curved portion 102. Furthermore, as the radius of the curved portion 102 increases, the thickness of the insulating portion 100 in the Z direction increases accordingly, and the wasted space between the winding portion 18 and the teeth portion 20 in the Z direction increases.

[0071] In the fourth embodiment, the following configuration is added to the teeth portion 20 in order to solve the above problem. That is, as shown in Figure 21, the teeth portion 20 has a convex portion 106 that protrudes toward the Z1 side relative to the protruding portion 70. The teeth portion 20 has a first core sheet 110 which constitutes the portion of the teeth portion 20 opposite to the convex portion 106 relative to the protruding portion 70, a second core sheet 112 which constitutes the portion of the teeth portion 20 having the protruding portion 70, and a third core sheet 114 which constitutes the convex portion 106.

[0072] In the vertical cross-section of the main body portion 21A of the teeth portion 20 shown in Figure 21, the width Wb of the second core sheet 112 along the X direction is set to be wider than the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction, due to the presence of the protruding portion 70. Furthermore, the same core sheet is used for the first core sheet 110 and the third core sheet 114, and the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction are set to be the same width.

[0073] Thus, in the fourth embodiment, the teeth portion 20 has a protrusion 106 that projects toward the Z1 side relative to the projection 70. Therefore, compared to the case where the teeth portion 20 does not have a protrusion 70, the space between the winding portion 18 and the teeth portion 20 in the Z direction can be effectively utilized as a magnetic flux path. The protrusion 106 may be formed by stacking the third core sheet 114 to the limit while ensuring the thickness of the required thickness portion 104.

[0074] Furthermore, the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction are set to the same width, and the same core sheet is used for both the first core sheet 110 and the third core sheet 114. Therefore, compared to the case where the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction are set to different widths, and different core sheets are used for the first core sheet 110 and the third core sheet 114, cost increases can be suppressed.

[0075] In this example, the same core sheet is used for both the first core sheet 110 and the third core sheet 114, so the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction are set to the same width. However, if different core sheets are used for the first core sheet 110 and the third core sheet 114, the width Wa of the first core sheet 110 along the X direction and the width Wc of the third core sheet 114 along the X direction may be set to different widths.

[0076] Furthermore, as shown in Figure 22, the teeth portion 20 may have a protrusion 108 (i.e., a second protrusion) that further protrudes towards Z1 relative to the protrusion 106 (i.e., the first protrusion). The protrusion 106 is an example of the "first protrusion" according to the technology of this disclosure, and the protrusion 108 is an example of the "second protrusion" according to the technology of this disclosure. The protrusion 108 is composed of a fourth core sheet 116, and the width Wd of the fourth core sheet 116 along the X direction is set to be narrower than the width Wc of the third core sheet 114 along the X direction.

[0077] Thus, if the teeth portion 20 has a protrusion 108 that further protrudes toward the Z1 side relative to the protrusion 106, the space between the winding portion 18 and the teeth portion 20 in the Z direction can be utilized more effectively as a magnetic flux path. The protrusion 108 may be formed by stacking the fourth core sheet 116 to the limit while ensuring the thickness of the required thickness portion 104.

[0078] Furthermore, in the example shown in Figure 22, the teeth portion 20 may have a protrusion that further protrudes toward Z1 relative to the protrusion 108 (i.e., a third protrusion). The number of protrusions formed on the teeth portion 20 can be any number.

[0079] Furthermore, the number of second core sheets 112 constituting the portion of the toothed portion 20 having the protruding portion 70 may be one or multiple. If the number of second core sheets 112 constituting the portion of the toothed portion 20 having the protruding portion 70 is one, the moldability of the Z-direction end 30A of the insulating member 30 can be improved.

[0080] Next, an example of a suitable dimensional setting for the configuration described in the fourth embodiment will be explained. Figure 23 shows an example of the relationship between the uppermost step area ratio and the step height ratio. The vertical axis represents the uppermost step area ratio, and the horizontal axis represents the step height ratio.

[0081] The uppermost area ratio shown on the vertical axis refers to the ratio of the cross-sectional areas of the uppermost protrusions formed on the teeth portion 20, where the case where the cross-sectional area of ​​the uppermost protrusion on the teeth portion 20 is maximized is set to 1 in the vertical cross-section of the main body portion 21A of the teeth portion 20 shown in Figure 22. The uppermost area ratio varies according to the step ratio.

[0082] The step ratio shown on the horizontal axis refers to the ratio of the second width W2 to the first width W1, where the first width W1 is half the width along the X direction at the position of the protruding portion 70 in the teeth portion 20 (i.e., the width Wb of the second core sheet 112 along the X direction) in the vertical cross-section of the main body portion 21A of the teeth portion 20 shown in Figure 22, and the second width W2 is the width along the X direction at the step difference between the lowest protrusion and the uppermost protrusion.

[0083] In the example shown in Figure 23, five different radii are used for the curved surface 102. Graph lines G1 to G5 represent five different radii, including the minimum and maximum values ​​within the range that can be set for the curved surface 102, with the radii increasing in the order of graphs G1 to G5. Line La represents 1, which is the maximum value of the uppermost area ratio; line Lb1 is an approximation line for the increasing section of graph line G1; line Lb2 is an approximation line for the increasing section of graph line G3; line Lb3 is an approximation line for the decreasing section of graph line G3; and line Lb4 is an approximation line for the decreasing section of graph line G5.

[0084] When the range of the step ratio is set at the intersection of the approximate lines for the increasing and decreasing sections of each graph line G1 to G5 and line La, the magnetic path cross-section of the uppermost convex portion under the conditions of each graph line can be suitably secured.

[0085] The intersection of line La and line Lb1 indicates the step ratio at which the uppermost area ratio is maximized to 1 when the graph line is G1, and its value is 0.16. The intersection of line La and line Lb2 indicates the step ratio at which the uppermost area ratio is maximized to 1 when the graph line is G3, and its value is 0.17. The intersection of line La and line Lb3 indicates the step ratio at which the uppermost area ratio is maximized to 1 when the graph line is G3, and its value is 0.36. The intersection of line La and line Lb4 indicates the step ratio at which the uppermost area ratio is maximized to 1 when the graph line is G5, and its value is 0.38.

[0086] Here, if the step ratio is set to a range of less than 0.16 or greater than 0.38, it includes a region where the magnetic path cross-section cannot be suitably secured under the conditions of graphs G1 to G5 of the curved surface, resulting in a situation where the magnetic path cross-section of the uppermost convex portion cannot be effectively secured. In contrast, if the step ratio is set to 0.16 to 0.38, the magnetic path cross-section of the uppermost convex portion can be suitably secured under all conditions of graphs G1 to G5 of the curved surface, thus effectively securing the magnetic flux within the stator core in all cases within the range that can be set for the curved surface 102.

[0087] Furthermore, for a step ratio of 0.175 to 0.35 to be met, it is preferable that the thickness of the laminated steel plate be set to 0.25 mm to 0.5 mm.

[0088] Figure 24 shows an example of the relationship between the ratio of the uppermost area to the internal height of the insulating section and the ratio of the curved surface radius to the half-width of the teeth. The vertical axis shows the S1 / H1 ratio, and the horizontal axis shows the R / W1 ratio. The half-width of the teeth refers to the first width W1. The internal height of the insulating section H1 is the height obtained by subtracting the thickness of the required thickness section 104 from the distance between the second core sheet 112 and the winding section 18 on the central axis line passing through the center of the teeth section 20 in the X direction.

[0089] The S1 / H1 ratio shown on the vertical axis refers to the ratio of the cross-sectional area S1 of the uppermost protrusion to the internal height H1 of the insulating part in the vertical cross-section of the main body 21A of the teeth portion 20 shown in Figure 22.

[0090] The R / W1 ratio shown on the horizontal axis refers to the ratio of the radius R of the curved surface portion 102 to the first width W1 in the vertical cross-section of the main body portion 21A of the teeth portion 20 shown in Figure 22. The first width W1 is an example of the "first width" related to the technology of this disclosure.

[0091] In the example shown in Figure 24, line Lc represents 0.935, which is the value when the S1 / H1 ratio is at its maximum. Line Ld1 is an approximation line for the increasing interval of graph line G, and line Ld2 is an approximation line for the decreasing interval of graph line G.

[0092] The intersection of line Lc and line Ld1 indicates the R / W1 ratio at which the S1 / H1 ratio reaches its maximum value of 0.935 when the radius of the curved surface is small relative to the half width of the teeth, and this value is 0.70. Similarly, the intersection of line Lc and line Ld2 indicates the R / W1 ratio at which the S1 / H1 ratio reaches its maximum value of 0.935 when the radius of the curved surface is large relative to the half width of the teeth, and this value is 0.92.

[0093] Here, if the R / W1 ratio is below 0.70, the internal height of the insulating section becomes smaller, and the uppermost area also becomes smaller, making it difficult to secure a magnetic path cross-section. On the other hand, if the R / W1 ratio is above 0.92, the internal height of the insulating section becomes larger, and the uppermost area can be set larger, but on the other hand, it becomes difficult to effectively arrange the magnetic path cross-section for miniaturization. In contrast, when the R / W1 ratio is set between 0.70 and 0.92, the uppermost area is set by effectively utilizing the internal height of the insulating section, so that the coil end height can be suppressed while securing the magnetic path cross-section, and it is possible to contribute to miniaturization of the motor section while effectively securing the magnetic flux in the stator core. Furthermore, when the R / W1 ratio is set in the range of 0.80 to 0.92, the radius of the curved section can be set larger compared to when the R / W1 ratio is less than 0.80, so winding floating in the slot can be suppressed, and further high volumetric (= miniaturization) can be achieved.

[0094] Furthermore, X1 to X5 in Figure 24 and the curved surface portion 102 in Figure 23, are setting conditions corresponding to the case where the uppermost area ratio in the graph lines G1 to G5 is 1. Here, X3 in Figure 24 is the setting condition that makes the most effective use of the internal height of the insulating part compared to the other setting conditions (X1, 2, 4, 5). For this reason, by setting the step ratio in Figure 23 to the range of 0.17 to 0.36 under the setting condition of X3, the magnetic path cross section can be suitably secured, thereby more effectively securing the magnetic flux in the stator core and suppressing the coil end height.

[0095] Furthermore, for an R / W1 ratio of 0.70 to 0.92 to be achieved, it is preferable that the laminated steel plate thickness be set to 0.25 mm to 0.5 mm and the minimum thickness of the insulating member to 0.5 to 1.0 mm.

[0096] Although the first to fourth embodiments of the technology disclosed herein have been described in order, the present invention is not limited to those described above, and it is of course possible to implement it in various modified forms without departing from the spirit of the invention.

[0097] Furthermore, the combinable configurations described in the first to fourth embodiments may be combined as appropriate.

[0098] The following are additional notes regarding the technology of the present disclosure. (Note 1) A stator (10) comprising: a stator core (24); an insulating sheet (40) mounted on the stator core; an insulating member (30) mounted on the stator core; and a winding portion (18) wound around the stator core via the insulating sheet and the insulating member, wherein the stator core has insulated surfaces (20A, 20B, 22A) facing in a direction perpendicular to the axial direction of the stator core; the insulating sheet insulates the insulated surfaces; the insulating member is mounted on the stator core from one side in the axial direction of the stator core and insulates the insulated surfaces via the insulating sheet; and the stator core has a projection (70) formed thereon that is located on one side in the axial direction of the stator core with respect to the insulated surfaces and projecting in a direction perpendicular to the insulated surfaces. (Note 2) The stator according to Note 1, wherein the projection protrudes further in the direction perpendicular to the insulating sheet. (Note 3) The stator according to Note 1 or Note 2, comprising: a first insulating member (30U) mounted on the stator core from one axial side of the stator core and insulating the insulated surface via the insulating sheet; and a second insulating member (30L) mounted on the stator core from the other axial side of the stator core and insulating the insulated surface via the insulating sheet, wherein the stator core has a first protrusion (70U) positioned on one axial side of the stator core with respect to the insulated surface and protruding in a direction perpendicular to the insulated surface, and a second protrusion (70L) positioned on the other axial side of the stator core with respect to the insulated surface and protruding in a direction perpendicular to the insulated surface.(Note 4) The stator core 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 main body portion (21A) of the tooth portion has a side surface (20A) facing tangentially to the stator core, the tip portion (21B) of the tooth portion has an outward-facing surface (20B) facing radially outward from the stator core, the core back portion has an inward-facing surface (22A) facing radially inward from the stator core, the insulated surface includes the side surface, the outward-facing surface, and the inward-facing surface, the insulating sheet has a first side insulating portion (40A) insulating the side surface, a first outward-facing surface insulating portion (40B) insulating the outward-facing surface, and a first inward-facing surface insulating portion (42A) insulating the inward-facing surface. The insulating member has a second side insulating portion (30A) that insulates the side surface via the first side insulating portion, a second outward-facing surface insulating portion (30B) that insulates the outward-facing surface via the first outward-facing surface insulating portion, and a second inward-facing surface insulating portion (32A) that insulates the inward-facing surface via the first inward-facing surface insulating portion, and the protrusion has a side protrusion (70A) that protrudes tangentially to the stator core relative to the side surface, an outward-facing surface protrusion (70B) that protrudes radially outward from the stator core relative to the outward-facing surface, and an inward-facing surface protrusion (70C) that protrudes radially inward from the stator core relative to the inward-facing surface, the stator as described in any one of Appendix 1 to Appendix 3. (Note 5) The stator according to Note 4, comprising a plurality of insulating sheets arranged in the circumferential direction of the stator core, and a plurality of winding portions arranged in the circumferential direction of the stator core, wherein each insulating sheet has a winding portion insulating portion (50) disposed between adjacent winding portions among the plurality of winding portions. (Note 6) The stator according to Note 5, wherein each winding portion insulating portion has an extension portion (56) that extends beyond the stator core to one axial side of the stator core. (Note 7) The stator according to Note 5 or Note 6, wherein the winding portion insulating portions of adjacent insulating sheets among the plurality of insulating sheets are overlapped.(Note 8) The stator according to any one of Notes 5 to 7, wherein each winding insulation portion has at least one of a first overlap portion (52) that overlaps with the second outward-facing insulation portion in the tangential direction of the stator core, and a second overlap portion (54) that overlaps with the second inward-facing insulation portion in the tangential direction of the stator core. (Note 9) The stator according to any one of Notes 5 to 8, wherein each winding insulation portion has a first winding insulation portion (74) that extends from the tip of the teeth portion to the core back portion, and a second winding insulation portion (76) that extends from the core back portion to the tip of the teeth portion, and the tip of the first winding insulation portion and the tip of the second winding insulation portion overlap in the radial direction of the stator core. (Note 10) The stator according to any one of Notes 4 to 9, wherein the first side insulating portion and the second side insulating portion have overlapping portions (60) that overlap in the axial direction of the stator core. (Note 11) The stator according to any one of Notes 1 to 10, wherein the stator core has teeth portions (20) that extend radially of the stator core, the protrusions protrude in a direction perpendicular to the insulated surface formed on the teeth portion, and the teeth portion has a convex portion (106) that protrudes on one side in the axial direction of the stator core relative to the protrusions. (Note 12) The stator according to Note 11, wherein in the longitudinal cross-section of the main body portion between the tip and base of the teeth portion, the width (Wa) of the convex portion along the tangential direction of the stator core is set to be the same width (Wc) of the portion of the teeth portion opposite to the convex portion along the tangential direction of the stator core. (Note 13) The stator according to Note 11 or Note 12, wherein the teeth portion has a first protrusion (106) as the protrusion and a second protrusion (108) that protrudes from the first protrusion toward one axial side of the stator core.(Note 14) The stator as described in Note 13, wherein in the longitudinal cross-section of the main body between the tip and base of the teeth portion, the width of the stator core along the tangential direction at the position of the protrusion in the teeth portion is defined as the first width (W1), and the width of the stator core along the tangential direction at the step between the first protrusion and the second protrusion is defined as the second width (W2), and the ratio of the second width to the first width is set to 0.175 to 0.35. (Note 15) The stator according to any one of Notes 11 to 14, wherein the insulating member has an insulating portion (100) provided between the teeth portion and the winding portion in the axial direction of the stator core, the winding portion has a tangential portion (18A) extending in the tangential direction of the stator core, an axial portion (18B) extending in the axial direction of the stator core, and an arc portion (18C) connecting the tangential portion and the axial portion, the insulating portion has a curved surface portion (102) supporting the arc portion, and in the longitudinal cross section of the main body portion between the tip portion and the base portion of the teeth portion, when the width of the first width (W1) is half the width along the tangential direction of the stator core at the position of the protruding portion of the teeth portion, the ratio of the radius of the curved surface portion to the first width is set to 0.70 to 0.92. (Note 16) The stator as described in Note 11, wherein the teeth portion has a first protrusion (106) as the protrusion and a second protrusion (108) that protrudes from the first protrusion to one axial side of the stator core, and in the longitudinal cross section of the main body portion between the tip and base of the teeth portion, the width is set to be half the width along the tangential direction of the stator core at the position of the protrusion in the teeth portion as the first width (W1), and the width along the tangential direction of the stator core at the step between the first protrusion and the second protrusion as the second width (W2), the cross-sectional area of ​​the second protrusion varies according to the ratio of the second width to the first width, and is set based on the ratio of the cross-sectional area of ​​the second protrusion, where the case in which the cross-sectional area of ​​the second protrusion is maximum is set to 1, the ratio of the second width to the first width is set to 0.17 to 0.36, and the ratio of the radius (R) of the curved portion to the first width is set to 0.70 to 0.92.(Note 17) A rotating electric machine (M) comprising: a stator as described in any one of Notes 1 to 16; and a rotor (11) rotatably housed inside the stator. (Note 18) A method for manufacturing a stator as described in any one of Notes 1 to 16, comprising: an insulating sheet mounting step of mounting the insulating sheet onto the stator core; an insulating member mounting step of mounting the insulating member onto the stator core; and a winding winding step of winding the winding portion onto the stator core via the insulating sheet and the insulating member, wherein the insulating member mounting step includes protecting the end of the insulating sheet with the protrusion when mounting the insulating member onto the stator core from one axial side of the stator core. (Note 19) The method for manufacturing a stator according to Note 18, wherein the stator core is composed of a plurality of core members, and the insulating sheet mounting step includes arranging a jig (82) having a shape corresponding to a second core member located next to the first core member among the plurality of core members next to the first core member among the plurality of core members, and inserting the insulating sheet into a slot (84) between the first core member and the jig, and the insulating member mounting step includes mounting the insulating member to the first core member while holding the insulating sheet in the slot. (Note 20) The method for manufacturing a stator according to Note 18 or Note 19, comprising a sheet material processing step of processing a long, insulating sheet material (80) into a shape in which a plurality of insulating sheets are connected, and a sheet material cutting step of cutting the insulating sheet from the sheet material processed by the sheet material processing step.

Claims

1. A stator comprising: a stator core (24); an insulating sheet (40) mounted on the stator core; an insulating member (30) mounted on the stator core; and a winding portion (18) wound around the stator core via the insulating sheet and the insulating member, wherein the stator core has insulated surfaces (20A, 20B, 22A) facing in a direction perpendicular to the axial direction of the stator core; the insulating sheet insulates the insulated surfaces; the insulating member is mounted on the stator core from one axial side of the stator core and insulates the insulated surfaces via the insulating sheet; and the stator core has a projection (70) formed thereon, which is located on one axial side of the stator core with respect to the insulated surfaces and protrudes in a direction perpendicular to the insulated surfaces.

2. The stator according to claim 1, wherein the protruding portion protrudes in a direction perpendicular to the insulating sheet.

3. A stator according to claim 1 or claim 2, comprising: a first insulating member (30U) mounted on the stator core from one axial side of the stator core and insulating the insulated surface via the insulating sheet; and a second insulating member (30L) mounted on the stator core from the other axial side of the stator core and insulating the insulated surface via the insulating sheet, wherein the stator core has a first protrusion (70U) positioned on one axial side of the stator core with respect to the insulated surface and protruding in a direction perpendicular to the insulated surface, and a second protrusion (70L) positioned on the other axial side of the stator core with respect to the insulated surface and protruding in a direction perpendicular to the insulated surface.

4. The stator core has teeth (20) extending radially from the stator core, and a core back portion (22) located radially outward from the stator core relative to the teeth and connected to the base end of the teeth, the main body portion (21A) of the teeth has a side surface (20A) facing tangentially to the stator core, the tip portion (21B) of the teeth has an outward-facing surface (20B) facing radially outward from the stator core, the core back portion has an inward-facing surface (22A) facing radially inward from the stator core, the insulated surface includes the side surface, the outward-facing surface, and the inward-facing surface, the insulating sheet has a first side insulating portion (40A) insulating the side surface, a first outward-facing surface insulating portion (40B) insulating the outward-facing surface, and a first inward-facing surface insulating portion (42A) insulating the inward-facing surface. The insulating member has a second side insulating portion (30A) that insulates the side surface via the first side insulating portion, a second outward-facing surface insulating portion (30B) that insulates the outward-facing surface via the first outward-facing surface insulating portion, and a second inward-facing surface insulating portion (32A) that insulates the inward-facing surface via the first inward-facing surface insulating portion, and the protrusion has a side protrusion (70A) that protrudes tangentially to the stator core relative to the side surface, an outward-facing surface protrusion (70B) that protrudes radially outward from the stator core relative to the outward-facing surface, and an inward-facing surface protrusion (70C) that protrudes radially inward from the stator core relative to the inward-facing surface, the stator according to any one of claims 1 to 3.

5. The stator according to claim 4, comprising: a plurality of insulating sheets arranged in the circumferential direction of the stator core; and a plurality of winding portions arranged in the circumferential direction of the stator core, wherein each insulating sheet has a winding portion insulating portion (50) disposed between adjacent winding portions among the plurality of winding portions.

6. The stator according to claim 5, wherein each winding insulation portion has an extension portion (56) that extends further than the stator core to one axial side of the stator core.

7. The stator according to claim 5 or claim 6, wherein the winding portion insulating portions of adjacent insulating sheets among the plurality of insulating sheets are overlapped.

8. The stator according to any one of claims 5 to 7, wherein each winding insulation portion has at least one of a first overlap portion (52) that overlaps with the second outward-facing insulation portion in the tangential direction of the stator core, and a second overlap portion (54) that overlaps with the second inward-facing insulation portion in the tangential direction of the stator core.

9. The stator according to any one of claims 5 to 8, wherein each winding insulation portion has a first winding insulation portion (74) extending from the tip of the teeth portion to the core back portion and a second winding insulation portion (76) extending from the core back portion to the tip of the teeth portion, and the tip of the first winding insulation portion and the tip of the second winding insulation portion overlap in the radial direction of the stator core.

10. The stator according to any one of claims 4 to 9, wherein the first side insulating portion and the second side insulating portion have overlapping portions (60) that overlap in the axial direction of the stator core.

11. The stator according to any one of claims 1 to 10, wherein the stator core has teeth (20) extending radially from the stator core, the protrusions project in a direction perpendicular to the insulated surface formed on the teeth, and the teeth have convex portions (106) projecting toward one axial side of the stator core relative to the protrusions.

12. The stator according to claim 11, wherein in the longitudinal cross-section of the main body between the tip and base of the teeth portion, the width (Wa) of the protrusion along the tangential direction of the stator core is set to be the same width (Wc) of the portion of the teeth portion opposite to the protrusion along the tangential direction of the stator core.

13. The stator according to claim 11 or claim 12, wherein the teeth portion has a first protrusion (106) as the protrusion and a second protrusion (108) that protrudes from the first protrusion toward one axial side of the stator core.

14. In the longitudinal cross-section of the main body between the tip and base of the teeth portion, the width of the stator core along the tangential direction at the position of the protrusion in the teeth portion is defined as the first width (W1), and the width of the stator core along the tangential direction at the step between the first protrusion and the second protrusion is defined as the second width (W2), wherein the ratio of the second width to the first width is set to 0.16 to 0.38, as described in claim 13.

15. The stator according to any one of claims 11 to 14, wherein the insulating member has an insulating portion (100) provided between the teeth portion and the winding portion in the axial direction of the stator core, the winding portion has a tangential portion (18A) extending in the tangential direction of the stator core, an axial portion (18B) extending in the axial direction of the stator core, and an arc portion (18C) connecting the tangential portion and the axial portion, the insulating portion has a curved surface portion (102) supporting the arc portion, and in the longitudinal cross-section of the main body portion between the tip portion and the base portion of the teeth portion, when the width of the first width (W1) is half the width along the tangential direction of the stator core at the position of the protruding portion of the teeth portion, the ratio of the radius (R) of the curved surface portion to the first width is set to 0.70 to 0.

92.

16. The stator according to claim 11, wherein the teeth portion has a first protrusion (106) as the protrusion and a second protrusion (108) that protrudes from the first protrusion to one axial side of the stator core, and in the longitudinal cross section of the main body portion between the tip and base of the teeth portion, the width is set to be half the width along the tangential direction of the stator core at the position of the protrusion in the teeth portion as the first width (W1), and the width along the tangential direction of the stator core at the step between the first protrusion and the second protrusion as the second width (W2), and the cross-sectional area of ​​the second protrusion varies according to the ratio of the second width to the first width, set based on the ratio of the cross-sectional areas of the second protrusion where the cross-sectional area of ​​the second protrusion is maximum, with 1 being the case where the cross-sectional area of ​​the second protrusion is maximum, the ratio of the second width to the first width is set to 0.17 to 0.36, and the ratio of the radius (R) of the curved portion to the first width is set to 0.70 to 0.

92.

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

18. A method for manufacturing a stator according to any one of claims 1 to 16, comprising: an insulating sheet mounting step of mounting the insulating sheet to the stator core; an insulating member mounting step of mounting the insulating member to the stator core; and a winding winding step of winding the winding portion to the stator core via the insulating sheet and the insulating member, wherein the insulating member mounting step includes protecting the end of the insulating sheet with the protruding portion when mounting the insulating member to the stator core from one axial side of the stator core.

19. The method for manufacturing a stator according to claim 18, wherein the stator core is composed of a plurality of core members, the insulating sheet mounting step includes arranging a jig (82) having a shape corresponding to a second core member located next to the first core member among the plurality of core members, next to a first core member among the plurality of core members, and inserting the insulating sheet into a slot (84) between the first core member and the jig, and the insulating member mounting step includes mounting the insulating member to the first core member while holding the insulating sheet in the slot.

20. A method for manufacturing a stator according to claim 18 or claim 19, comprising: a sheet material processing step of processing a long, insulating sheet material (80) into a shape in which a plurality of the insulating sheets are connected; and a sheet material cutting step of cutting the insulating sheets from the sheet material processed by the sheet material processing step.

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