Stator of motor and assembly method therefor

Abstract

A stator of a motor and a manufacturing method therefor are disclosed. In the stator of a motor and the manufacturing method therefor, according to the present invention, an insulating sheet comprises a plurality of individual insulating sheets so as to provide insulation between a stator core and stator coils, wherein, in the individual insulating sheet, a second insulating part cut from a first insulating part is bent at one of two ends of the first insulating part in the circumferential direction so as to surround the stator coils and is provided between the stator coils wound around two teeth parts that are adjacent in the circumferential direction. Therefore, the insulating sheet providing insulation between the stator core and the stator coils can be integrally formed such that manufacturing cost for the stator can be lowered while the number of components and amount of assembly labor for the insulating sheet are reduced. In addition, since the insulating sheet is inserted between both stator coils, an insulation distance between the stator coils is minimized and the space factor of the stator coils is increased such that motor efficiency can be improved.

Description

Motor stator and assembly method thereof

[0001] The present invention relates to a stator of a motor and a method of assembling the same.

[0002] Generally, the stator plays the role of magnetizing the iron core in a motor to create magnetic force and generating rotational force through interaction with the rotor. To create this magnetic force, a magnetic field is formed by winding coils around the iron core. Therefore, most stators require a structure that allows more coils to be packed into the slots of the core to increase efficiency or power density.

[0003] The core is constructed by laminating multiple electrical steel sheets to reduce iron loss, and due to these constraints, significant technical effort is required to increase the packing density, which is the ratio of the coil cross-sectional area to the slot area.

[0004] Conventionally, a core formed as a single unit for the stator core of a motor (hereinafter referred to as a "solid core") was used. While this has the advantage of excellent reliability in the manufacturing process, there was a problem in that the motor's efficiency was reduced because the area of ​​the effective slot where the stator coil is wound was reduced as space for the nozzle for the winding operation had to be secured.

[0005] In consideration of this, a core (hereinafter referred to as a "divided core") in which a stator core forming a motor is divided to wind stator coils and then assembled, and / or a core (hereinafter referred to as an "expanded core" or "expanded core") in which a stator core is extended to wind stator coils and then rolled to form a cylindrical shape.

[0006] A split core is disclosed in Patent Document 1 (Korean Published Patent No. 10-2005-0048962), and a spread core is disclosed in Patent Document 2 (Korean Registered Patent No. 10-1178331). However, Patent Document 1 does not mention an insulation structure between the stator core and the stator coil, and Patent Document 2 only discloses an individual insulation sheet between the stator core and the stator coil, and does not mention an insulation structure between the stator cores.

[0007] On the other hand, Patent Document 3 (International Publication WO2010 / 100890) discloses an example in which an insulating sheet is inserted into the tooth portion of the stator core in a split core and a unfolding core. Patent Document 3 discloses an example in which individual insulating sheets are individually inserted into and fixed to each tooth portion.

[0008] However, as in the conventional method, if individual insulating sheets are inserted into each tooth portion separately, the number of parts for the insulating sheets increases, which may lead to higher assembly labor and manufacturing costs. Furthermore, since multiple insulating sheet supports must be provided within the slots of the stator core to maintain the shape of the insulating sheets, the filling factor of the stator coils is reduced by the amount occupied by these insulating sheet supports, which may result in a decrease in motor efficiency.

[0009] In addition, conventionally, as adjacent teeth are arranged in different phases, a certain insulation distance must be secured between adjacent coils for inter-phase insulation. As a result, the winding fill factor within the slot space is further reduced, which can further lower motor efficiency.

[0010] The objective of the present invention is to provide a motor stator and a method for assembling the same, which can reduce the assembly time for an insulating sheet insulating between a stator core and a stator coil.

[0011] Another objective of the present invention is to provide a motor stator and a method for assembling the same that can improve motor efficiency by increasing the fill factor of the stator coil wound on the stator core.

[0012] Another objective of the present invention is to provide a motor stator and a method for assembling the same, which can stably maintain the stator coil in the stator core while increasing the fill factor of the stator coil.

[0013] To achieve the objective of the present invention, a stator of a motor comprising a stator core, a stator coil, and an insulating sheet may be provided. The stator core may be formed in an annular shape by rolling or combining a plurality of unit cores, each having a tooth portion extending from a yoke portion and a shoe portion extending from the inner end of each tooth portion in both circumferential directions. The stator coil may be wound on the tooth portion. The insulating sheet may consist of a plurality of unit insulating sheets provided along the inner circumferential surface of the stator core to insulate between the stator core and the stator coil.

[0014] Here, the unit insulating sheet may include a first insulating portion and a second insulating portion. The first insulating portion may be composed of a yoke sheet portion insulating the yoke portion, a tooth sheet portion extending from the yoke sheet portion to insulate the tooth portion, and a shoe sheet portion extending from the tooth sheet portion to insulate the shoe portion, and may be provided on the inner circumferential surface of a slot between adjacent tooth portions. The second insulating portion may be folded at one of the circumferential ends of the shoe sheet portion to wrap around the stator coil, and may include a second insulating portion provided between the stator coils wound on the two circumferentially adjacent tooth portions. Through this, the insulating sheet insulating the stator core and the stator coil is formed as a single unit, thereby reducing the number of parts and assembly steps for the insulating sheet and lowering the manufacturing cost of the stator. In addition, as the insulating sheet is inserted between the two stator coils, the insulation distance between the two stator coils can be minimized as much as possible. Accordingly, the fill factor of the stator coil increases, which can improve motor efficiency.

[0015] For example, the unit insulating sheet may be formed such that the second insulating portions are each folded in the same circumferential direction. Through this, the second insulating portions can insulate the stator coils adjacent to each other in the circumferential direction without any gaps.

[0016] For example, the second insulating part may come into contact with the first insulating part between the two stator coils adjacent to each other in the circumferential direction. Through this, the two stator coils located on each side in the circumferential direction can be tightly insulated by the insulating sheet.

[0017] For example, a connecting protrusion may be formed on the yoke sheet portion, protruding in a direction facing away from the yoke portion between the two stator coils adjacent to each other in the circumferential direction. The second insulating portion may be provided between the two stator coils adjacent to each other in the circumferential direction, in contact with the connecting protrusion. Through this, the two stator coils can be insulated while being tightly separated by the second insulating portion and the connecting protrusion.

[0018] Specifically, the connecting protrusion can be formed by folding the yoke sheet portion. This facilitates the production of an insulating sheet including a first insulating portion, while simultaneously raising the connecting protrusion toward the second insulating portion during rolling of the stator core to stably secure the contact area with the second insulating portion.

[0019] As another example, an insulator may be provided on the axial side of the stator core to insulate between the stator core and the stator coil. An insulating sheet support portion may be formed in the insulator to support the insulating sheet in the axial direction. Through this, the second insulating portion of the insulating sheet can be stably supported in one axial direction by the insulating sheet support portion.

[0020] For example, the insulator may have a shoe insulation portion formed facing the axial side of the shoe portion. The insulation sheet support portion may be formed by extending circumferentially from at least one of the circumferential ends of the shoe insulation portion. Through this, not only can the insulation sheet support portion be easily formed, but the insulation sheet can also be stably supported while increasing the actual area of ​​the slot portion.

[0021] Specifically, the insulator may include a first insulator and a second insulator located on both axial sides of the stator core. A first insulating sheet support portion supporting the insulating sheet in one axial direction may be formed in the first insulator, and a second insulating sheet support portion supporting the insulating sheet in the other axial direction may be formed in the second insulator. Through this, not only can the winding of the stator coil be facilitated, but the circumferential length of both unit core shoe portions can also be expanded to increase the actual slot area and thereby increase the filling rate of the stator coil.

[0022] More specifically, the first insulating sheet support and the second insulating sheet support may be formed to extend in opposite directions along the circumferential direction. Through this, the insulating sheet can be stably supported while minimizing the number of insulating sheet support.

[0023] In addition, a coil winding groove may be formed on the side of the insulator facing away from the stator core along the winding direction of the stator coil. Through this, the alignment of the stator coil during winding can be improved, thereby suppressing a decrease in the filling factor of the stator coil.

[0024] To achieve the objective of the present invention, the method may include the steps of: assembling an insulating sheet, which is folded along the shape of the inner surface of a stator core having insulators assembled at both axial ends, onto the inner surface of the stator core; winding a stator coil onto the tooth portion of the stator core; and rolling or joining the stator core to form an annular stator. Before rolling or joining the stator core to form an annular stator, a step may be performed to cut a portion of the insulating sheet and wrap the stator coil wound on the tooth portion with the cut portion of the insulating sheet so that it is positioned between adjacent stator coils. Through this, the insulating sheet is formed as an integral unit, making it easy to handle and easy to assemble onto the stator core.

[0025] For example, in the step of positioning the insulating sheet between the stator coils, a second insulating part may be formed by cutting at one end in the circumferential direction of the first insulating part that surrounds the shoe of the stator core, and the second insulating part may be folded at the other end in the circumferential direction of the shoe to surround the stator coil. Through this, the stator coils adjacent in the circumferential direction can be easily and tightly insulated from each other.

[0026] For example, in the step of forming the stator into an annular shape by rolling or joining the stator core, when rolling the stator core into an annular shape, the second insulating part may be made to come into contact with the first insulating part between the two stator coils adjacent to each other in the circumferential direction. Through this, the stator coils adjacent to each other in the circumferential direction can be insulated more easily and tightly.

[0027] Specifically, in the step of forming the stator into an annular shape by rolling or joining the stator core, a connecting protrusion may be formed on the first insulating part such that the first insulating part is folded and protrudes toward the second insulating part. Through this, the stator coils adjacent in the circumferential direction can be insulated more easily and tightly.

[0028] The stator of the motor according to the present invention comprises a plurality of unit insulating sheets such that the insulating sheets insulate between the stator core and the stator coils. The unit insulating sheets are folded such that a second insulating portion wraps around a stator coil at one of the circumferential ends of the first insulating portion, and can be provided between stator coils wound on adjacent circumferential teeth portions. Through this, the insulating sheets insulating between the stator core and the stator coils are formed as a single unit, thereby reducing the number of parts and assembly steps for the insulating sheets and lowering the manufacturing cost of the stator. Additionally, as the insulating sheets are inserted between the two stator coils, the insulation distance between the stator coils is minimized, thereby increasing the packing density of the stator coils and improving motor efficiency.

[0029] In the stator of the motor according to the present invention, the second insulating portion may come into contact with a connecting protrusion provided in the first insulating portion between two stator coils adjacent to each other in the circumferential direction. Through this, the two stator coils located on each side in the circumferential direction can be tightly insulated by an insulating sheet.

[0030] The stator of the motor according to the present invention may have an insulating sheet support member in which an insulator provided on the axial side of the stator core supports the insulating sheet in the axial direction. Through this, the second insulating portion of the insulating sheet can be stably supported in one axial direction by the insulating sheet support member.

[0031] The method for manufacturing a stator of a motor according to the present invention may proceed with the step of cutting a portion of an insulating sheet and wrapping a stator coil wound on a tooth portion of the stator core with the cut portion of the insulating sheet before rolling or joining the stator core in an annular shape, so as to position it between adjacent stator coils. Through this, as the insulating sheet is formed as an integral part, not only is handling of the insulating sheet easy, but it can also be easily assembled to the stator core.

[0032] FIG. 1 is a perspective view showing a stator according to the present invention.

[0033] FIG. 2 is a plan view of the stator according to FIG. 1.

[0034] FIG. 3 is a perspective view showing the insulator and insulating sheet in a stator according to the present invention disassembled from the stator core.

[0035] FIG. 4 is an assembled perspective view of FIG. 3.

[0036] Fig. 5 is a frontal perspective view of Fig. 4.

[0037] Fig. 6 is a plan view of Fig. 4.

[0038] Fig. 7 is a bottom view of Fig. 4.

[0039] FIGS. 8a to 8c are schematic diagrams shown to explain the insulation process of an insulating sheet according to the present invention.

[0040] FIG. 9 is a block diagram shown to explain the assembly process of each member forming a stator according to the present invention.

[0041] Hereinafter, the stator of a motor and the assembly method thereof according to the present invention will be described in detail with reference to an attached embodiment. As previously described, in addition to a solid core in which a stator coil is wound while a single stator core is formed in an annular shape, a split core and a spread core are known in which a stator core consisting of a plurality of unit cores is linearly spread out, the stator coil is wound, and then rolled to form an annular shape. In this embodiment, a split core and a spread core may be applied as the stator core, respectively. The following description focuses on an example in which a spread core is applied, but the same or nearly the same may apply when a split core is applied.

[0042] In addition, the stator is equipped with insulators on each axial side of the stator core to insulate the axial sides of the stator core from the stator coils facing them axially. In this case, the insulators may be pre-assembled to the stator core by insert molding, or they may be manufactured separately and post-assembled to the stator core. Although this embodiment is described primarily with an example where the insulators are post-assembled to the stator core, the same or nearly the same conditions may apply when the insulators are pre-assembled to the stator core.

[0043] FIG. 1 is a perspective view showing a stator according to the present invention, and FIG. 2 is a plan view of the stator according to FIG. 1.

[0044] Referring to FIGS. 1 and 2, the stator (100) of the motor according to the present embodiment may include a stator core (110), a stator coil (120), an insulator (130), and an insulating sheet (140). The stator core (110) is a member that forms a magnetic path, the stator coil (120) is a member that causes a magnetic path to be formed in the stator core (110), the insulator (130) is a member that insulates the axial side of the stator core (110), and the insulating sheet (140) is a member that insulates the inner surface of the stator core (110).

[0045] The stator core (110) according to the present embodiment may be formed in an annular shape by stacking a plurality of steel plates. The stator core (110) may be a split core or a spread core, but the present embodiment will be described with a spread core as described above.

[0046] For example, the stator core (110) can be formed as a single unit by connecting multiple unit cores (110a) to each other. In other words, the stator core (110) forming the development core consists of multiple unit cores (110a) connected to each other along the longitudinal direction and arranged in a single line, while the unit cores (110a) located at both ends can be separated from each other and then reassembled. Accordingly, the development core can be manufactured in a linear shape and then formed into an annular shape.

[0047] Specifically, a plurality of unit cores (110a) may each include a yoke portion (111), a tooth portion (112), a shoe portion (113), and a slot portion (114). The yoke portion (111), the tooth portion (112), and the shoe portion (113) are each provided for each unit core (110a), and the slot portion (114) may be formed between two adjacent unit cores (110a). Accordingly, in the unfolded core, the yoke portion (111), the tooth portion (112), and the shoe portion (113) form a fixed cross-sectional area of ​​the stator core (110), and the slot portion (114) may form a variable cross-sectional area of ​​the stator core (110).

[0048] The yoke portion (111) may be formed in an arc shape. For example, the outer surface of the yoke portion (111) may be formed in an uneven arc shape, and the inner surface of the yoke portion (111) may be formed as a straight surface perpendicular to the circumferential side of the tooth portion (112) to be described later. Accordingly, when unfolded, the inner surface of the yoke portion (111) may form a straight line with the inner surface of an adjacent yoke portion (111).

[0049] The yoke portion (111) may be formed with both circumferential ends inclined. For example, connecting surfaces (1111) may be formed at both circumferential ends of the yoke portion (111), and the connecting surfaces (1111) may be formed inclined so as to narrow from the outer surface of the yoke portion (111) toward the inner surface. Accordingly, the circumferential side of the yoke portion (111) may form a rolling groove (1112) that is cut radially from the inner surface of the yoke portion (111) toward the outer surface of the yoke portion (111), together with the circumferential side of an adjacent yoke portion (111).

[0050] The tooth portion (112) can be formed in a rectangular shape. The tooth portion (112) can be extended radially inward from the center of the inner circumference of the corresponding yoke portion (111). Accordingly, the circumferential width of the tooth portion (112) is formed to be shorter than the length between the two ends of the corresponding yoke portion (111), and a slot portion (114) forming a coil winding space can be formed between adjacent tooth portions (112).

[0051] The tooth portion (112) can be formed with a uniform width along the longitudinal direction. In other words, the circumferential sides of the tooth portion (112) can be formed to be orthogonal to the inner surface of the yoke portion (111), respectively. Accordingly, the volume of the slot portion (114) can be formed as wide as possible, and the filling rate of the stator coil (120) can be improved.

[0052] The shoe (113) can be formed in an arc shape. For example, the shoe (113) may extend in both circumferential directions from the inner end of the tooth portion (112), but the circumferential length of the shoe (113) may be formed to be shorter than the circumferential length of the corresponding yoke portion (111). In other words, it may be spaced apart from adjacent shoe portions (113) by a predetermined distance. Accordingly, a winding nozzle may be inserted and removed from the inner circumferential side of the stator core (110), and a stator coil (120) may be wound on the stator core (110).

[0053] The shoe (113) may be formed with a uniform width along the circumferential direction, or it may be formed to become thinner from the center toward both ends of the circumferential direction. In the former case, the magnetic resistance at both ends of the shoe (113) can be lowered, and in the latter case, the volume of the slot portion (114) can be expanded to increase the packing efficiency of the stator coil (120). This embodiment illustrates the latter case, that is, an example in which the shoe (113) becomes thinner from the circumferential center toward both ends of the circumferential direction.

[0054] The slot portion (114) is a space where the stator coil (120) is wound, and can be formed between adjacent unit cores (110a) (110a). In other words, the slot portion (114) can be formed by each yoke portion (111), tooth portion (112), and shoe portion (113) facing each other between adjacent unit cores (110a) in the circumferential direction. Accordingly, the outer surface and both circumferential sides of the slot portion (114) are closed, while the inner side has an opening (not indicated) formed by the two shoe portions (113) being spaced apart, allowing the winding nozzle to enter and exit.

[0055] Referring to FIGS. 1 and 2, the stator coil (120) according to the present embodiment can be wound onto the tooth portion (112) of the stator core (110) and received in the slot portion (114). For example, the stator coil (120) is inserted into the U, V, and W three-phase positions of the power terminal portion (not labeled) through winding nozzles of a winding machine (not shown) arranged at regular intervals in the stacking direction (hereinafter, axial direction) of the stator core (110). Subsequently, the stator coil (120) is wound onto the tooth portion (112) while each winding nozzle moves repeatedly in the horizontal and vertical directions simultaneously. After winding the stator coil (120) onto the three tooth portions (112), the stator core (110) is rotated 180 degrees. Afterward, the winding nozzle moves horizontally by the spacing of the three slot sections (114), and then the stator core (110) is rotated 180 degrees in the opposite direction. Afterward, the winding nozzle is moved toward the opening of the slot section (114), and the previous winding operation is repeated. Afterward, the stator coil (120) is cut while inserted into the U, V, and W three-phase positions of the neutral point. Accordingly, the stator coil (120) is wound up to the space occupied by the winding nozzle, and the filling rate of the stator coil (120) can be improved. Through this, not only is motor efficiency improved, but aluminum coils can be applied while maintaining motor efficiency at an equivalent level compared to conventional motors. In addition, since the stator coil (120) has a structure in which it is wound continuously without connecting parts, multiple winding nozzles can be used, thereby reducing manufacturing costs and improving productivity.

[0056] FIG. 3 is a perspective view showing an insulator and an insulating sheet disassembled from a stator core according to the present invention, FIG. 4 is an assembled perspective view of FIG. 3, FIG. 5 is a front perspective view of FIG. 4, FIG. 6 is a top view of FIG. 4, FIG. 7 is a bottom view of FIG. 4, and FIG. 8a to 8c are schematic diagrams shown to explain the insulation process of the insulating sheet according to the present invention.

[0057] Referring to FIGS. 3 to 7, the insulator (130) according to the present embodiment may include a first insulator (131) and a second insulator (132). The first insulator (131) is an insulator disposed on one side in the axial direction, and the second insulator (132) is an insulator disposed on the other side in the axial direction. Since the first insulator (131) and the second insulator (132) are formed almost identically, the following description will focus on the first insulator (131).

[0058] The first insulator (131) may include a first yoke insulation part (1311), a first tooth insulation part (1312), and a first shoe insulation part (1313). The first yoke insulation part (1311) is a part that insulates between the yoke part (111) of the stator core (110) and the stator coil (120), the first tooth insulation part (1312) is a part that insulates between the tooth part (112) of the stator core (110) and the stator coil (120), and the first shoe insulation part (1313) is a part that insulates between the shoe part (113) of the stator core (110) and the stator coil (120). Accordingly, when projected in the axial direction, the first yoke insulation part (1311) may be formed to be identical or similar to one axial side of the yoke part (111), the first tooth insulation part (1312) may be formed to be identical to one axial side of the tooth part (112), and the first shoe insulation part (1313) may be formed to be identical to or similar to one axial side of the shoe part (113).

[0059] The first yoke insulation portion (1311) may protrude axially by a predetermined height. Accordingly, the first yoke insulation portion (1311) can insulate the stator core (110) and the stator coil (120) at the same time insulate the stator coil (120) from a member surrounding it, such as a motor case (not shown) and / or a compressor case (not shown) including a motor.

[0060] The inner surface of the first yoke insulation portion (1311) can be formed as a straight surface corresponding to the inner surface of the yoke portion (111). Accordingly, the volume of the slot portion (114) of the stator core (110) can be secured as wide as possible, thereby increasing the packing efficiency of the stator coil (120).

[0061] The first tooth insulation portion (1312) is formed extending inward from the inner circumference of the first yoke insulation portion (1311), and a first coil winding groove (1312a) may be formed on the axial side facing away from the stator core (110). The first coil winding groove (1312a) may be formed at an angle along the direction in which the stator coil (120) is wound. Accordingly, when winding the stator coil (120), the alignment of the stator coil (120) is increased, thereby suppressing the decrease in the filling rate of the stator coil (120).

[0062] Although not illustrated in the drawing, a second coil winding groove (1322a) may be formed in the second tooth insulation portion (1322) of the second insulator (132). The second coil winding groove (1322a) may be formed in a direction that intersects the first coil winding groove (1312a) when projected in the axial direction, for example, in a direction orthogonal to the circumferential side of the first tooth insulation portion (1312). Accordingly, the alignment of the stator coil (120) can be improved when winding the stator coil (120).

[0063] The first shoe insulation portion (1313) extends in both circumferential directions from the inner end of the first tooth insulation portion (1312), and the first shoe insulation portion (1313) may extend to the same length in both directions or to different lengths. For example, the circumferential length of the first shoe insulation portion (1313) may be formed to be the same as the circumferential length of the shoe portion (113), or the circumferential length of the first shoe insulation portion (1313) may be formed to be longer than the circumferential length of the shoe portion (113). In the former case, the gap between the two adjacent first shoe insulation sections (1313) (1313) is secured to be as wide as possible, making winding work easier, and in the latter case, both ends of the first shoe insulation section (1313) protrude in the circumferential direction more than both ends of the shoe section (113), thereby supporting the second insulation section (142) of the insulation sheet (140) to be described later in the axial direction. This embodiment illustrates the latter case, that is, an example in which the circumferential length of the first shoe insulation section (1313) is formed longer on one side than the circumferential length of the shoe section (113).

[0064] For example, the first shoe insulation part (1313) may be formed to extend in both directions in the circumferential direction from the circumferential center of the first tooth insulation part (1312), such that the circumferential length (L11) of one side of the first shoe insulation part (1313) is longer than the circumferential length (L12) of the other side of the first shoe insulation part (1313). In other words, the first shoe insulation part (1313) may be formed such that the first direction length (L11) of the first shoe insulation part (1313) extending in one circumferential direction relative to the first tooth insulation part (1312) is longer in the circumferential direction than the second direction length (L12) of the first shoe insulation part (1313) extending in the other circumferential direction. Accordingly, one circumferential end of the first shoe insulation part (1313) is formed to be identical to the circumferential end of the shoe part (113) of the stator core (110), while the other circumferential end of the first shoe insulation part (1313) protrudes more circumferentially than the other circumferential end of the shoe part (113) of the stator core (110) to form the first insulation sheet support part (1314). Through this, the second insulation part (142) of the insulation sheet (140), which will be described later, can be stably supported in one axial direction by the first insulation sheet support part (1314).

[0065] In this case, as previously described, the first insulating sheet support (1314) is formed only on one of the two shoe insulating sections (1313) (1313) facing each other in the circumferential direction, thereby widening the gap between the two shoe insulating sections (1313) (1313). Accordingly, not only can the winding of the stator coil (120) be facilitated, but the circumferential length of the shoe sections (113) of both unit cores (110a) can also be expanded to increase the actual slot section (114) area and increase the filling rate of the stator coil (120).

[0066] In addition, in this case, the first insulating sheet support (1314) may be formed in a cantilever shape that protrudes only in the circumferential direction, or it may be bent axially at the end of the first insulating sheet support (1314) toward the insulating sheet (140) and protrude. In the former case, the shape of the first insulating sheet support (1314) can be simplified to facilitate the manufacturing of the insulator (130) and the assembly of the insulating sheet (140), and in the latter case, the insulating sheet (140) can be supported more stably by inserting and supporting the insulating sheet (140) into the first insulating sheet support (1314). This embodiment illustrates the latter case, that is, an example in which the first insulating sheet support (1314) is bent into an "L" shape.

[0067] Additionally, the insulating sheet support can be formed on the first insulator (131) described above as well as on the second insulator (132). For example, one circumferential end of the second shoe insulation part (1323) is formed to be identical to the circumferential end of the shoe part (113) of the stator core (110), while the other circumferential end of the second shoe insulation part (1323) may protrude more circumferentially than the other circumferential end of the shoe part (113) of the stator core (110). Accordingly, the second insulating sheet support part (1324) is formed on the other circumferential end of the second shoe insulation part (1313) to support the other axial side of the second insulating part (142) of the insulating sheet (140) described later.

[0068] In this case as well, the second insulating sheet support (1324) may be formed in the same shape as the first insulating sheet support (1314) described above. For example, the second insulating sheet support (1324) may be formed by extending in the circumferential direction or by extending in the circumferential direction and then bending toward the insulating sheet (140). This embodiment illustrates an example in which the second insulating sheet support (1324) is bent into a shape symmetrical to the first insulating sheet support (1314), that is, a "L" shape.

[0069] In addition, in these cases, the first insulating sheet support (1314) and the second insulating sheet support (1324) may be formed by extending from the first shoe insulating part (1313) of the first insulator (131) and the second shoe insulating part (1323) of the second insulator (132) facing it in the axial direction, respectively, or they may be formed by extending from the first shoe insulating part (1313) of the first insulator (131) and the second shoe insulating part (1323) of the second insulator (132) facing it diagonally in the circumferential direction in opposite directions to each other. In the former case, the unit insulation sheet (140a) can be assembled relatively easily by inserting and fixing one end of the unit insulation sheet (140a), which will be described later, between the two insulation sheet support parts (1314) (1324). In the latter case, the unit insulation sheet (140a) can be stably supported while minimizing the number of insulation sheet support parts (1314) (1324) by supporting both ends of the unit insulation sheet (140a), which will be described later, one end at a time in the axial direction. This embodiment illustrates the latter case, that is, an example in which the insulation sheet support parts (1314) (1324) are each extended from the diagonal ends of the shoe insulation parts (1313) (1323) of the two insulators (131) (132).

[0070] Although not illustrated in the drawing, the insulating sheet support portions (1314) (1324) may be formed at each of the circumferential ends of the shoe insulating portions (1313) (1323). In this case, the circumferential ends of the unit insulating sheet (140a), which will be described later, are supported from both sides in the axial direction, thereby allowing the unit insulating sheet (140a) to be supported more stably.

[0071] Additionally, although not illustrated in the drawings, the insulating sheet support portions (1314) (1324) may be formed at both axial ends of the yoke insulating portions (1311) (1321) and / or at both axial ends of the tooth insulating portions (1312) (1322). In these cases as well, the insulating sheet support portions (1314) (1324) may be formed to face each other in the axial direction or to face each other in the diagonal direction.

[0072] Referring to FIGS. 3 to 8c, the insulating sheet (140) according to the present embodiment may be formed in a shape corresponding to the inner surface of the stator core (110). In other words, when the stator core (110) is unfolded, the insulating sheet (140) may be formed in an uneven shape by being folded along the longitudinal direction of the insulating sheet (140) so as to correspond to the inner surface of the yoke portion (111) forming the inner surface of the stator core (110), the circumferential side of the tooth portion (112), and the inner surface of the shoe portion (113). However, when the stator core (110) is rolled, a part of the insulating sheet (140) may be cut off and inserted between the adjacent stator coils (e.g., coil bundles) (120a) (120b) in the corresponding slot portion (114). Accordingly, the insulating sheet (140) is composed of a single insulating sheet (140) similar to the stator core (110) when viewed based on the unfolded state of the stator core (110), whereas it may be composed of multiple unit insulating sheets (140a) equal to the number of unit cores (110a) forming the stator core (110) when viewed based on the rolling state of the stator core (110). Below, the description will focus on an example in which multiple unit insulating sheets (140a) are provided based on the state in which the stator core (110) is rolled. Since the multiple unit insulating sheets (140a) are formed identically to each other, the insulating sheet (140) below may be understood to refer to any one of the multiple unit insulating sheets (140a).

[0073] Referring to FIGS. 7 to 8c, the insulating sheet (140) may include a first insulating portion (141), a second insulating portion (142), and a connecting protrusion (143). The first insulating portion (141) is a portion that insulates between the stator core (110) and the stator coil (120), the second insulating portion (142) is a portion that insulates between two adjacent stator coils (120), and the connecting protrusion (143) is a portion that comes into contact with the second insulating portion (142) when the stator core (110) is rolled to separate the two stator coils (120).

[0074] The first insulating portion (141) is formed to be equal to or nearly equal to the axial length (e.g., stacking height) of the stator core (110), and can be formed in a roughly "C" shape to surround the slot portion (114) between adjacent unit cores (110a) (110a) in the circumferential direction. In other words, the first insulating portion (141) can be formed to cross between the unit cores (110a) (110a) and to contact the inner surface of both yoke portions (111), one side of both tooth portions (112), and the outer surface of both shoe portions (113). Accordingly, the first insulating part (141) is closely attached to the inner surface of both unit cores (110a) (110a) that form the main surface of one slot part (114) during winding of the stator core (110), thereby insulating the stator core (110) and the stator coil (120).

[0075] Specifically, the first insulating part (141) may include a yoke insulating sheet part (hereinafter, yoke sheet part) (1411), a tooth insulating sheet part (hereinafter, tooth sheet part) (1412), and a shoe insulating sheet part (hereinafter, shoe sheet part) (1413). The yoke sheet part (1411) is a part that insulates between the yoke part (111) of the stator core (110) and the stator coil (120), the tooth sheet part (1412) is a part that insulates between the tooth part (112) of the stator core (110) and the stator coil (120), and the shoe sheet part (1413) is a part that insulates between the shoe part (113) of the stator core (110) and the stator coil (120). Accordingly, the yoke sheet portion (1411) is formed to correspond to the inner surface shape of the yoke portion (111), the tooth sheet portion (1412) is formed to extend from the yoke sheet portion (1412) to correspond to the side shape of the tooth portion (112), and the yoke sheet portion (1413) can be formed to extend from the tooth sheet portion (1412) to correspond to the outer surface of the shoe portion (113).

[0076] The second insulating part (142) is formed to have the same axial length as the first insulating part (141), and can be provided between two adjacent stator coils (e.g., coil bundles) (120) in the circumferential direction by being bent toward the slot part (114) between adjacent tooth parts (111) at one end of the first insulating part (141). For example, the second insulating part (142) can be formed by cutting off one end of the shoe sheet part (1413) of the first insulating part (141) that was covering the shoe part (113) when the stator core (110) was first unfolded, and then bending the other end of the shoe sheet part (1413) so that the cut end (1421) is positioned between the two stator coils (120) to cover one stator coil (e.g., coil bundle) (120). Accordingly, the two stator coils (120) can be insulated easily and effectively. In addition, as the second insulating part (142) is inserted between the two stator coils (120) (120), the insulation distance between the two stator coils (120) (120) can be minimized as much as possible, thereby increasing the packing efficiency of the stator coils (120).

[0077] In this case, the second insulating portion (142) of each unit insulating sheet (140) can be formed by folding the cut end (1421) in the same direction. For example, each second insulating portion (142) arranged along the circumferential direction can be formed by cutting the same end of the shoe sheet portion (1413) of each first insulating portion (141) arranged along the circumferential direction, and then folding the cut end (1421) so that it wraps around the stator coil (120) adjacent in the circumferential direction and is inserted into the slot portion (114) located on the opposite side of the cut end (1421). Accordingly, the second insulating portion (142) can insulate the space between the stator coils (120) adjacent in the circumferential direction without any gaps.

[0078] Referring to FIGS. 8a through 8c, the connecting protrusion (143) may be formed to protrude radially inward from the first insulating part (141). For example, the connecting protrusion (143) may be formed at the same height along the axial direction at the middle of the circumferential direction of the yoke sheet part (1411) of the first insulating part (141). Accordingly, the circumferential side of the second insulating part (142) toward the cut end (1421) may come into contact with one circumferential side of the connecting protrusion (143), thereby separating the slot part (114) in the circumferential direction. Through this, the two stator coils (e.g., coil bundles) (120) located on each circumferential side of the slot part (114) may be tightly blocked and insulated by the second insulating part (142) and the connecting protrusion (143).

[0079] In this case, the connecting protrusion (143) may be formed by extending it to protrude by a predetermined height from the inner surface of the first insulating part (141), or it may be formed by folding the middle of the first insulating part (141) to protrude by a predetermined height. In the former case, the height of the connecting protrusion (143) can be freely adjusted to stably secure the contact area with the second insulating part (142). In the latter case, while facilitating the production of the insulating sheet (140) including the first insulating part (141), the gap between the two unit cores (110a) (110a) forming the rolling groove (1112) narrows when the stator core (110) is rolled, and the connecting protrusion (143) rises toward the second insulating part (142) to stably secure the contact area with the second insulating part (142). This embodiment illustrates the latter case, that is, an example in which the connecting protrusion (143) is formed to be folded in the middle of the first insulating part (141).

[0080] In the drawing, the unexplained symbol 1321 is the second yoke insulation part.

[0081] The stator according to the present embodiment as described above can be assembled as follows. FIG. 9 is a block diagram shown to explain the assembly process of each member forming the stator according to the present invention.

[0082] That is, the step of inserting and combining the first insulator (131) and the second insulator (132) respectively on both axial sides of the stator core (110) while the plurality of unit cores (110a) forming the stator core (110) are linearly unfolded is carried out. In this case, as previously explained, the first insulator (131) and the second insulator (132) may be pre-assembled on both axial sides of the stator core (110) by insert molding. (T1)

[0083] Next, an insulating sheet (140) is inserted and coupled to the inner surface of the stator core (110). In this case, the insulating sheet (140) is positioned between the first insulator (131) and the second insulator (132). At this time, an insulating sheet support portion (1314) (1324) is formed on the first insulator (131) and the second insulator (132), respectively, to support both ends of the insulating sheet (140) in the axial direction. (T2)

[0084] Next, with the stator core (110), both insulators (131)(132), and the insulating sheet (140) assembled, the winding nozzle described above is inserted between the teeth (112) of the two unit cores (110a)(110a) facing each other, and the step of winding the stator coil (120) on each tooth (112) is carried out. (T3)

[0085] Next, the insulating sheet (140) surrounding the unit core (110a) is cut at one of the circumferential ends of the shoe sheet portion (1413) of the first insulating portion (141) that forms part of the insulating sheet (140). Then, the second insulating portion (142) of the cut insulating sheet (140) is folded at the other circumferential end of the shoe sheet portion (1413) to surround the stator coil (120) wound on the corresponding unit core (110a) and position it between the stator coil (120) wound on the adjacent unit core (110a). At this time, the cut end (1421) of the second insulating portion (142) forming one end of the insulating sheet (140) can be maintained separated from the connecting protrusion (143) protruding between the two unit cores (110a) (110a). (T4)

[0086] Next, the step of forming the stator core (110) into an annular shape is performed by folding and rolling adjacent unit cores (110a) (110a) on each side of the linearly unfolded stator core (110) around the rolling groove (1112). At this time, as the connecting protrusion (143) of the insulating sheet (140) is folded, the radial height increases, so that the circumferential side of the second insulating part (142) at the cut end (1421) comes into contact with one circumferential side of the connecting protrusion (143) and is pressed against both stator coils (120). Then, the space between the two stator coils (120) can be tightly sealed by the second insulating part (142) and the connecting protrusion (143). (T5)

[0087] In this way, the insulating sheet insulating the stator core and the stator coil is formed as a single unit, thereby reducing the number of parts and assembly steps for the insulating sheet and lowering manufacturing costs.

[0088] In addition, by reducing the number of insulation sheet support members for maintaining the shape of the insulation sheet and thereby increasing the area of ​​the slot section, the filling rate of the stator coil wound on the stator core is increased, which can improve motor efficiency.

[0089] In addition, by optimizing the position of the insulation sheet support member that supports the insulation sheet, the filling rate of the stator coil wound on the stator core can be increased, while the stator coil is stably maintained on the stator core, thereby improving reliability.

Claims

1. A stator core formed by rolling or combining a plurality of unit cores, each having a tooth portion extending radially from each yoke portion and a shoe portion extending circumferentially from both inner ends of each tooth portion to form an annular shape; A stator coil wound on the above tooth portion; and The insulating sheet includes a plurality of unit insulating sheets provided along the inner surface of the stator core to insulate between the stator core and the stator coil, and The above unit insulation sheet is, A first insulating portion provided on the inner circumference of a slot between adjacent tooth portions, comprising a yoke sheet portion insulating the yoke portion, a tooth sheet portion extending from the yoke sheet portion and insulating the tooth portion, and a shoe sheet portion extending from the tooth sheet portion and insulating the shoe portion; and A stator of a motor comprising a second insulating portion that is folded at one end of the circumferential end of the shoe sheet portion to wrap around the stator coil and is provided between the stator coils wound on the two adjacent tooth portions in the circumferential direction.

2. In Paragraph 1, The above unit insulation sheet is, A stator of a motor formed by each of the above-mentioned second insulating portions being bent in the same circumferential direction.

3. In Paragraph 1, The above second insulating part is, A stator of a motor that contacts the first insulating part between the two stator coils adjacent to each other in the circumferential direction.

4. In Paragraph 3, In the above yoke seat portion, a connecting protrusion is formed that protrudes in a direction facing away from the yoke portion between the two stator coils adjacent to each other in the circumferential direction. The above second insulating part is, A stator of a motor provided between two stator coils adjacent to each other in the circumferential direction, in contact with the above-mentioned connecting protrusion.

5. In Paragraph 4, The above connecting protrusion is, A stator of a motor formed by folding the above yoke seat portion.

6. In Paragraph 1, An insulator is provided on the axial side of the stator core to insulate between the stator core and the stator coil, and The above insulator includes, A stator of a motor having an insulating sheet support portion formed to support the insulating sheet in the axial direction.

7. In Paragraph 6, The above insulator has a shoe insulating portion formed facing the axial side of the shoe portion, and The above insulating sheet support is, A stator of a motor formed by extending circumferentially from at least one of the circumferential ends of the above-mentioned shoe insulation section.

8. In Paragraph 7, The above insulator includes a first insulator and a second insulator located on both axial sides of the stator core, and A stator of a motor having a first insulating sheet support formed in the first insulator to support the insulating sheet in one axial direction, and a second insulating sheet support formed in the second insulator to support the insulating sheet in the other axial direction.

9. In Paragraph 8, The first insulating sheet support and the second insulating sheet support are A motor stator formed by extending in opposite directions along the circumferential direction.

10. In Paragraph 6, A stator of a motor having a coil winding groove formed along the winding direction of the stator coil on the side of the insulator facing away from the stator core.

11. A step of assembling an insulating sheet, which is bent along the shape of the inner circumferential surface of a stator core having insulators assembled at both axial ends, onto the inner circumferential surface of the stator core; A step of winding a stator coil on the tooth portion of the stator core; and The method includes the step of forming a stator into an annular shape by rolling or combining the stator cores. A method for assembling a stator of a motor, wherein, before rolling or joining the stator core in an annular shape, a portion of the insulating sheet is cut and the stator coil wound on the tooth portion is wrapped with the cut portion of the insulating sheet and positioned between adjacent stator coils.

12. In Paragraph 11, In the step of positioning the insulating sheet between the stator coils, A method for assembling a stator of a motor, wherein a first insulating part surrounding the shoe portion of the stator core is cut at one end in the circumferential direction to form a second insulating part, and the second insulating part is bent at the other end in the circumferential direction of the shoe portion to surround the stator coil.

13. In Paragraph 12, In the step of forming the stator into an annular shape by rolling or combining the above stator cores, A method for assembling a stator of a motor such that when the stator core is rolled in an annular shape, the second insulating part contacts the first insulating part between the two stator coils adjacent to each other in the circumferential direction.

14. In Paragraph 13, In the step of forming the stator into an annular shape by rolling or combining the above stator cores, A method for assembling a stator of a motor such that a connecting protrusion is formed in the first insulating part, which is folded and protrudes toward the second insulating part.

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