JP2018107921A - Stator of rotary electric machine - Google Patents

Stator of rotary electric machine Download PDF

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JP2018107921A
JP2018107921A JP2016252523A JP2016252523A JP2018107921A JP 2018107921 A JP2018107921 A JP 2018107921A JP 2016252523 A JP2016252523 A JP 2016252523A JP 2016252523 A JP2016252523 A JP 2016252523A JP 2018107921 A JP2018107921 A JP 2018107921A
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stator
stator core
insulating paper
teeth
varnish
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JP6680199B2 (en
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啓友 河西
Keisuke Kasai
啓友 河西
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Toyota Motor Corp
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Toyota Motor Corp
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Abstract

PROBLEM TO BE SOLVED: To suppress generation of a gap between an insulation paper after foaming and a stator core even in heat history over a long period in a stator of a rotary electric machine which uses a foaming insulation paper.SOLUTION: A stator 10 of a rotary electric machine is provided with: a stator core 12; a stator coil 20; insulation paper 30; and varnish. The stator core 12 comprises: an annular back yoke 14; a plurality of teeth 16 projecting toward an inner peripheral side from the back yoke 14; and a plurality of slots 18 which are spaces between the adjacent teeth 16. The stator coil 20 is wound around the teeth 16 of the stator core 12. The insulation paper 30 is arranged between the teeth 16 and the stator coil 20, and has foaming adhesive layers 42, 44 on both sides of a base material 40. The varnish 50 is arranged in a gap between the forming adhesive layer 44 on a side facing the stator core 12 of the insulation paper 30 and the stator core 12.SELECTED DRAWING: Figure 1

Description

本開示は、回転電機のステータに係り、特に、加熱によって膨張する発泡層を含む絶縁紙を有する回転電機のステータに関する。   The present disclosure relates to a stator for a rotating electrical machine, and more particularly, to a stator for a rotating electrical machine having an insulating paper including a foam layer that expands by heating.

回転電機のステータにおいて、ステータコアとステータコイルとの間の電気的絶縁性の確保のために、ステータコアのスロットには、ステータコアとコイルとの間に絶縁紙が配置される。   In the stator of a rotating electrical machine, in order to ensure electrical insulation between the stator core and the stator coil, insulating paper is disposed between the stator core and the coil in the slot of the stator core.

例えば、特許文献１の回転電機のステータにおいては、絶縁紙として、絶縁性フィルムからなる基材に、加熱によって膨張する発泡材と、接着層とを積層した発泡シートが開示されている。   For example, in the stator of a rotating electrical machine disclosed in Patent Document 1, a foam sheet in which a foam material that expands by heating on a base material made of an insulating film and an adhesive layer is disclosed as insulating paper.

特許文献２のステータコアのスロット構造として、ステータコイルと絶縁紙との間にはワニスが充填され、さらに、絶縁紙の外周とステータコアとの間が、部分的にワニスまたはエポキシ樹脂で固着されることが開示されている。   As the slot structure of the stator core of Patent Document 2, varnish is filled between the stator coil and the insulating paper, and the outer periphery of the insulating paper and the stator core are partially fixed with varnish or epoxy resin. Is disclosed.

特許文献３には、複数の小孔を有する絶縁紙を用い、ステータのコイルエンド側からワニスを滴下してスロット内の絶縁紙とステータコイルとの間にワニスを充填し、そのワニスを複数の小孔を介して絶縁紙とステータコアとの間に供給することが開示されている。   In Patent Document 3, insulating paper having a plurality of small holes is used, varnish is dropped from the coil end side of the stator, and the varnish is filled between the insulating paper in the slot and the stator coil. It is disclosed to supply between insulating paper and a stator core via a small hole.

特許文献４の回転電機のステータにおいては、スロットの内壁面に沿ってステータコイルとの間に一枚の絶縁紙を配置し、内周側で折返し部を重ね合わせ、スロットの内周側からウエッジ部材を挿入して折返し部を押圧する構成が開示される。絶縁紙は、基材のステータコイル側に接着層、基材のステータコア側に発泡層が配置されており、発泡層にも接着性があるので、ステータコアに固着すると述べている。また、折返し部付きの絶縁紙の変形例として、発泡層を用いずに多孔性絶縁基材または不織布を用い、これにワニスを含浸させると共に、折返し部やウエッジ部材においても隙間をなくすようにワニスを充填することが開示されている。   In the stator of the rotating electrical machine of Patent Document 4, a sheet of insulating paper is disposed between the stator coil along the inner wall surface of the slot, the folded portion is overlapped on the inner peripheral side, and the wedge is formed from the inner peripheral side of the slot. The structure which inserts a member and presses a folding | returning part is disclosed. The insulating paper has an adhesive layer on the stator coil side of the base material, and a foam layer on the stator core side of the base material. Further, as a modified example of the insulating paper with the folded portion, a porous insulating base material or nonwoven fabric is used without using the foam layer, and the varnish is impregnated with the varnish, and the varnish is also eliminated in the folded portion and the wedge member. Is disclosed.

特開２０１６−０９６５９７号公報Japanese Patent Laid-Open No. 2006-096597 特開２００７−１２９８７８号公報JP 2007-129878 A 特開２００７−１６６７３１号公報JP 2007-166731 A 特開２０１２−２３９３２２号公報JP 2012-239322 A

発泡層を含む絶縁紙を用いてスロット内のステータ巻線を固定する方法によれば、膨張した絶縁紙によってステータ巻線とステータコアとの間の固定力が確保されるので、固定の信頼性が高まる。実際に発泡層を含む絶縁紙をハイブリッド車両に搭載される回転電機のステータに適用し、耐熱試験や冷熱衝撃耐久試験を行うと、ステータ巻線とステータコアとの間の固定力が低下することがある。その原因を調べてみると、発泡後の絶縁紙とステータコアとの間に空隙が発生する課題があることが分かった。発生した空隙によってステータコアの表面が酸化され、結果としてステータ巻線とステータコアとの間の固定力が低下すると考えられる。そこで、発泡層を含む絶縁紙とステータコアとの間にワニスを配置すると、この課題が解決した。従来技術において発泡層を含む絶縁紙は知られているが、上記の課題は知られておらず、また、従来技術においてワニスも知られているが、上記の課題解決のためにワニスが有効であることも知られていない。これらのことから、（ステータコアの微細な凹凸）と（発泡層を含む絶縁紙）によって生じる固定力の低下という課題は、（ステータコア）と（発泡層を含む絶縁紙）と（ワニス）の組合せによって初めて解決するものである。
上記では、耐熱試験や冷熱衝撃耐久試験において見出されたが、使用環境が厳しいハイブリッド車両に搭載される回転電機では、長期間に渡る熱履歴等によって発泡後の絶縁紙とステータコアとの間に空隙が生じ得ると考えられる。そこで、長期間に渡る熱履歴において発泡後の絶縁紙とステータコアとの間の空隙発生を抑制できる回転電機のステータが要望される。 According to the method of fixing the stator winding in the slot using the insulating paper including the foam layer, the fixing force between the stator winding and the stator core is ensured by the expanded insulating paper, so that the fixing reliability is ensured. Rise. When insulation paper containing a foam layer is actually applied to a stator of a rotating electrical machine mounted on a hybrid vehicle and a heat resistance test or a thermal shock durability test is performed, the fixing force between the stator winding and the stator core may be reduced. is there. When the cause was investigated, it was found that there was a problem that a gap was generated between the insulating paper after foaming and the stator core. It is considered that the surface of the stator core is oxidized by the generated gap, and as a result, the fixing force between the stator winding and the stator core is reduced. Therefore, this problem has been solved by arranging a varnish between the insulating paper including the foam layer and the stator core. Insulating paper containing a foam layer is known in the prior art, but the above problem is not known, and varnish is also known in the prior art, but varnish is effective for solving the above problem. There is no known thing. From these facts, the problem of a reduction in fixing force caused by (fine irregularities of the stator core) and (insulating paper including the foam layer) is due to the combination of (stator core), (insulating paper including the foam layer) and (varnish). It will be solved for the first time.
In the above, it was found in the heat resistance test and the cold shock durability test. It is believed that voids can occur. Accordingly, there is a demand for a stator for a rotating electrical machine that can suppress the generation of a gap between the foamed insulating paper and the stator core in a long-term heat history.

本開示に係る回転電機のステータは、円環状のバックヨーク、前記バックヨークから内周側に突き出す複数のティース、及び、隣接する前記ティース間の空間である複数のスロットを含むステータコアと、前記ステータコアの前記ティースに巻回されるステータ巻線と、前記ティースと前記ステータ巻線との間に配置され、基材の両面に発泡接着層を有する絶縁紙と、前記絶縁紙の前記ステータコアに向い合う側の前記発泡接着層と前記ステータコアとの間の隙間に配置されたワニスと、を備える。   A stator of a rotating electrical machine according to the present disclosure includes an annular back yoke, a plurality of teeth protruding from the back yoke to the inner peripheral side, and a plurality of slots serving as spaces between adjacent teeth, and the stator core A stator winding wound around the teeth, an insulating paper disposed between the teeth and the stator winding and having a foam adhesive layer on both surfaces of the base material, and facing the stator core of the insulating paper And a varnish disposed in a gap between the foamed adhesive layer on the side and the stator core.

上記構成の回転電機のステータによれば、（ステータコア）と（発泡接着層を有する絶縁紙）と（ワニス）の組合せを用いるので、ワニスがない場合に比較し、長期間に渡る熱履歴において発泡後の絶縁紙とステータコアとの間の空隙発生を抑制できる。   According to the stator of the rotating electrical machine having the above configuration, since a combination of (stator core), (insulating paper having a foam adhesive layer), and (varnish) is used, foaming is performed in a heat history over a long period of time as compared with the case without varnish. Generation | occurrence | production of the space | gap between a subsequent insulating paper and a stator core can be suppressed.

上記構成の回転電機のステータによれば、長期間に渡る熱履歴において発泡後の絶縁紙とステータコアとの間の空隙発生を抑制できる。   According to the stator of the rotating electrical machine having the above-described configuration, it is possible to suppress generation of a gap between the foamed insulating paper and the stator core in a long-term heat history.

実施の形態に係る回転電機のステータの斜視図である。It is a perspective view of the stator of the rotary electric machine which concerns on embodiment. 実施の形態に係る回転電機のステータに用いられる絶縁紙の構成図である。図２（ａ）は、絶縁紙の展開図であり、（ｂ）は絶縁紙の断面図である。It is a block diagram of the insulating paper used for the stator of the rotary electric machine which concerns on embodiment. FIG. 2A is a development view of the insulating paper, and FIG. 2B is a cross-sectional view of the insulating paper. 実施の形態に係る回転電機のステータにおいて、１つのスロットについての径方向に垂直な断面図である。図３（ａ）は、全体図で、（ｂ）は、ステータコアの表面の微細な凹凸を示す拡大図である。In the stator of the rotary electric machine which concerns on embodiment, it is sectional drawing perpendicular | vertical to the radial direction about one slot. FIG. 3A is an overall view, and FIG. 3B is an enlarged view showing fine irregularities on the surface of the stator core. 実施の形態に係る回転電機のステータにおいて、１つのスロットについての軸方向に垂直な断面図である。In the stator of the rotary electric machine which concerns on embodiment, it is sectional drawing perpendicular | vertical to the axial direction about one slot.

以下に図面を用いて本発明に係る実施の形態につき、詳細に説明する。以下では、回転電機として、ハイブリッド車両に搭載される回転電機を述べるが、これは、使用環境が厳しい用途の例示であって、ハイブリッド車両以外の電動車両に搭載されてもよく、場合によっては車両搭載以外の用途であっても構わない。以下では、ステータ巻線の巻回方法を分布巻として述べるが、これは説明のための例示であって、発泡性の絶縁紙を用いてステータコアに巻回されるステータ巻線であれば、それ以外の巻回方法であってもよい。例えば、集中巻であってもよい。また、ステータ巻線はセグメントコイルを用いてティースに巻回されるものを述べるが、これは分布巻に用いられる場合の例示であって、セグメントコイルを用いずに、絶縁皮膜付き導体線を用いて連続的にティースに巻回してもよい。   Embodiments according to the present invention will be described below in detail with reference to the drawings. In the following, a rotating electrical machine mounted on a hybrid vehicle will be described as a rotating electrical machine. However, this is an example of an application where the usage environment is severe, and the rotating electrical machine may be mounted on an electric vehicle other than the hybrid vehicle. It may be used for purposes other than mounting. In the following, the winding method of the stator winding is described as distributed winding, but this is an example for explanation, and if it is a stator winding wound around the stator core using foamable insulating paper, Other winding methods may be used. For example, a concentrated winding may be used. In addition, the stator winding is described as being wound around a tooth using a segment coil, but this is an example when used for distributed winding, and a conductor wire with an insulating film is used without using a segment coil. May be wound continuously around the teeth.

以下で述べる形状、寸法、ステータ巻線の巻数、材質等は、説明のための例示であって、回転電機のステータの仕様に合わせ、適宜変更が可能である。以下では、全ての図面において同様の要素には同一の符号を付し、重複する説明を省略する。   The shape, dimensions, number of turns of the stator winding, material, and the like described below are examples for explanation, and can be appropriately changed according to the specifications of the stator of the rotating electrical machine. Below, the same code | symbol is attached | subjected to the same element in all the drawings, and the overlapping description is abbreviate | omitted.

図１は、回転電機のステータ１０の構成を示す斜視図である。以下では、特に断らない限り、回転電機のステータ１０を、ステータ１０と呼ぶ。ステータ１０が用いられる回転電機は、ハイブリッド車両に搭載される回転電機である。回転電機は、ハイブリッド車両が力行するときは電動機として機能し、ハイブリッド車両が制動時にあるときは発電機として機能するモータ・ジェネレータで、三相同期型の回転電機である。回転電機は、図１に示すステータ１０と、ステータ１０の内周側に所定の間隔を隔てて配置されるロータ（図示せず）とで構成される。   FIG. 1 is a perspective view showing a configuration of a stator 10 of a rotating electrical machine. Hereinafter, unless otherwise specified, the stator 10 of the rotating electrical machine is referred to as a stator 10. The rotating electrical machine in which the stator 10 is used is a rotating electrical machine mounted on a hybrid vehicle. The rotating electrical machine is a three-phase synchronous rotating electrical machine that functions as an electric motor when the hybrid vehicle is powered and functions as a generator when the hybrid vehicle is braking. The rotating electrical machine includes the stator 10 shown in FIG. 1 and a rotor (not shown) arranged at a predetermined interval on the inner peripheral side of the stator 10.

ステータ１０は、ステータコア１２と、ステータ巻線２０と、絶縁紙３０と、ワニス５０（後述する図３、図４参照）とを含む。図１に、軸方向と径方向と周方向とを示す。軸方向は、中心穴の中心軸ＣＬに沿った方向であり、図示されていない動力線がステータ巻線２０から引き出されるステータ１０の軸方向端面側の方向がリード側で、その反対方向が反リード側である。径方向は、軸方向に垂直な面内で中心軸ＣＬを通る放射状の方向であり、周方向は、中心軸ＣＬを中心として円周方向に沿った方向である。   The stator 10 includes a stator core 12, a stator winding 20, an insulating paper 30, and a varnish 50 (see FIGS. 3 and 4 described later). FIG. 1 shows an axial direction, a radial direction, and a circumferential direction. The axial direction is a direction along the center axis CL of the center hole. The power line (not shown) is drawn from the stator winding 20, the axial end surface direction of the stator 10 is the lead side, and the opposite direction is opposite. It is the lead side. The radial direction is a radial direction passing through the central axis CL in a plane perpendicular to the axial direction, and the circumferential direction is a direction along the circumferential direction about the central axis CL.

ステータコア１２は、ロータが配置される中心穴を有する磁性体部品で、円環状のバックヨーク１４とバックヨーク１４から内周側に突き出す複数のティース１６とを含む。隣接するティース１６の間の空間はスロット１８である。三相同期型の回転電機の場合、ティース１６とスロット１８の数は、同じ３の倍数である。図１では、ステータ１０の一部分として、紙面の手前側の円環状部分における５つのスロット１８、向こう側の円環状部分における７つのティース１６に対応する部分を示す。   The stator core 12 is a magnetic part having a central hole in which the rotor is disposed, and includes an annular back yoke 14 and a plurality of teeth 16 protruding from the back yoke 14 toward the inner peripheral side. A space between adjacent teeth 16 is a slot 18. In the case of a three-phase synchronous rotating electric machine, the number of teeth 16 and slots 18 is the same multiple of three. In FIG. 1, as a part of the stator 10, a portion corresponding to the five slots 18 in the annular portion on the front side of the paper and the seven teeth 16 in the annular portion on the far side is shown.

かかるステータコア１２は、バックヨーク１４とティース１６とを含み、スロット１８が形成されるように所定の形状に成形された円環状の磁性体薄板１９を所定枚数で軸方向に積み重ねた積層体である。成形されたステータコア１２におけるスロット１８の内壁面には微細な凹凸１３がある（後述する図３（ｂ）参照）。磁性体薄板の両面には電気的な絶縁処理が施される。磁性体薄板の材質としては、珪素鋼板の一種である電磁鋼板を用いることができる。場合によっては、磁性体薄板の積層体に代えて、磁性粉末を一体化成形したものをステータコア１２としてもよい。   The stator core 12 includes a back yoke 14 and teeth 16, and is a laminated body in which a predetermined number of annular magnetic thin plates 19 formed in a predetermined shape so as to form slots 18 are stacked in the axial direction. . The inner wall surface of the slot 18 in the molded stator core 12 has fine irregularities 13 (see FIG. 3B described later). Both surfaces of the magnetic thin plate are electrically insulated. As a material of the magnetic thin plate, an electromagnetic steel plate which is a kind of silicon steel plate can be used. In some cases, the stator core 12 may be formed by integrally molding magnetic powder instead of the laminated body of magnetic thin plates.

ステータ巻線２０は、三相の分布巻コイルで、１つの相巻線が複数のティース１６に跨って巻回されて形成される。ステータ巻線２０は、複数のセグメントコイル２２を用いてステータコア１２のティース１６に巻回される。   The stator winding 20 is a three-phase distributed winding coil, and is formed by winding one phase winding across a plurality of teeth 16. The stator winding 20 is wound around the teeth 16 of the stator core 12 using a plurality of segment coils 22.

セグメントコイル２２は、断面が矩形形状の平角線を導体素線２４として、両端のリード部を除いて導体素線２４の周囲に絶縁皮膜２６（後述する図３、図４参照）を被覆し、所定の形状に成形した絶縁皮膜付き導体線である。導体素線２４としては、銅線、銅錫合金線、銀メッキ銅錫合金線等を用いることができる。絶縁皮膜２６としては、ポリアミドイミドのエナメル皮膜が用いられる。これに代えて、ポリエステルイミド、ポリイミド、ポリエステル、ホルマール等を用いることができる。   The segment coil 22 uses a rectangular wire with a rectangular cross section as a conductor wire 24, and covers an insulating film 26 (see FIGS. 3 and 4 described later) around the conductor wire 24 except for lead portions at both ends. It is a conductor wire with an insulating film formed into a predetermined shape. As the conductor wire 24, a copper wire, a copper tin alloy wire, a silver plating copper tin alloy wire, or the like can be used. As the insulating film 26, a polyamide-imide enamel film is used. Instead of this, polyesterimide, polyimide, polyester, formal and the like can be used.

セグメントコイル２２は、ステータコア１２に巻回される前は、図示しないが略Ｕ字状の形状を有する。略Ｕ字状の形状のうち、真っ直ぐに延びる２つのストレート部分は、先端がリード部となるスロット内導体線部である。２つのストレート部分はリード部の反対側で互いに接続されて山形に折り曲げ成形された接続部となる。   The segment coil 22 has a substantially U-shape (not shown) before being wound around the stator core 12. Of the substantially U-shaped shape, the two straight portions extending straight are the in-slot conductor line portions whose leading ends are the lead portions. The two straight portions are connected to each other on the opposite side of the lead portion to form a connection portion that is bent into a mountain shape.

セグメントコイル２２の先端の２つのリード部の間隔距離は、予め定めた３の倍数のスロット間隔に設定される。一例として、６スロット間隔に設定される場合、セグメントコイル２２の先端の２つのリード部は、ステータコア１２で周方向に沿って６スロット間隔だけ離れた２つのスロット１８にそれぞれ挿入される。挿入は、ステータコア１２の反リード側の端面側から行われ、リード側の端面において２つのリード部が突き出す。突き出た２つのリード部は、それぞれ別のセグメントコイル２２のリード部と溶接等によって接合される。予め定めた接合順序によって各セグメントコイル２２のリード部は順次接合されて、三相のステータ巻線２０が形成される。ステータ１０のリード側の端面から突き出したステータ巻線２０の部分は、リード側のコイルエンド２８である。図示しないが、ステータ１０の反リード側の端面には、セグメントコイル２２の山形の接続部によって、反リード側のコイルエンドが形成される。   The distance between the two lead portions at the tip of the segment coil 22 is set to a predetermined slot interval that is a multiple of three. As an example, when the interval is set to 6 slots, the two lead portions at the tip of the segment coil 22 are respectively inserted into the two slots 18 separated by the 6 slot interval along the circumferential direction in the stator core 12. The insertion is performed from the end surface side of the stator core 12 on the side opposite to the lead, and the two lead portions protrude from the end surface on the lead side. The two protruding lead portions are joined to the lead portions of different segment coils 22 by welding or the like. The lead portions of the segment coils 22 are sequentially joined according to a predetermined joining order to form a three-phase stator winding 20. The portion of the stator winding 20 protruding from the lead-side end face of the stator 10 is a lead-side coil end 28. Although not shown, a coil end on the side opposite to the lead is formed on the end surface on the side opposite to the lead of the stator 10 by a mountain-shaped connecting portion of the segment coil 22.

絶縁紙３０は、ティース１６とステータ巻線２０との間の電気的絶縁性を確保するために、ティース１６とステータ巻線２０との間に配置され、スロット１８の形状に合わせて折り曲げられたシートである。図２に、絶縁紙３０を示す。図２（ａ）は、絶縁紙３０を折り曲げられる前の状態に展開した展開図で、折り曲げ線３２，３４を破線で示す。折り曲げた後の絶縁紙３０は、一方側の発泡接着層４２がセグメントコイル２２側に向かい合い、他方側の発泡接着層４４がステータコア１２におけるスロット１８の内壁面に向かい合う。図２（ｂ）は、絶縁紙３０の厚さ方向の構成を示す断面図である。   The insulating paper 30 is disposed between the teeth 16 and the stator windings 20 and is bent in accordance with the shape of the slot 18 in order to ensure electrical insulation between the teeth 16 and the stator windings 20. It is a sheet. FIG. 2 shows the insulating paper 30. FIG. 2A is a development view in which the insulating paper 30 is developed before being folded, and the folding lines 32 and 34 are indicated by broken lines. In the insulating paper 30 after being bent, the foam adhesive layer 42 on one side faces the segment coil 22 side, and the foam adhesive layer 44 on the other side faces the inner wall surface of the slot 18 in the stator core 12. FIG. 2B is a cross-sectional view showing the configuration of the insulating paper 30 in the thickness direction.

絶縁紙３０は、基材４０の両側に発泡接着層４２，４４を有する発泡性の絶縁紙である。基材４０としては、耐熱性と絶縁性を有する樹脂材料をシート状に成形したものを用いる。樹脂材料としては、ポリフェニレンスルファイド（ＰＰＳ）、ポリエチレンナフタレート（ＰＥＮ）、エポキシ樹脂等が用いられる。発泡接着層４２，４４は、加熱によって膨張しその後硬化する樹脂材料の層で、それ自体が接着性を有する。発泡接着層４２，４４は、所定の加熱によって膨張し、例えば、厚さが初期状態の数倍に厚くなる。樹脂材料としては、エポキシ系の発泡樹脂材料を用いることができる。   The insulating paper 30 is a foaming insulating paper having foaming adhesive layers 42 and 44 on both sides of the base material 40. As the base material 40, a resin material having heat resistance and insulation formed into a sheet shape is used. As the resin material, polyphenylene sulfide (PPS), polyethylene naphthalate (PEN), epoxy resin or the like is used. The foamed adhesive layers 42 and 44 are layers of a resin material that expands when heated and then hardens, and have adhesiveness per se. The foamed adhesive layers 42 and 44 expand by predetermined heating, and the thickness becomes, for example, several times that of the initial state. As the resin material, an epoxy-based foamed resin material can be used.

ワニス５０は、絶縁紙３０においてステータコア１２に向かい合う側の発泡接着層４４とステータコア１２との隙間に配置される電気的絶縁性の樹脂で、液体状態では低粘度で浸透性がよく、狭い隙間に毛細管現象で浸透し、加熱によって硬化する熱硬化性樹脂である。   The varnish 50 is an electrically insulating resin disposed in the gap between the foamed adhesive layer 44 on the side facing the stator core 12 and the stator core 12 in the insulating paper 30. In the liquid state, the varnish 50 has low viscosity and good permeability, and has a narrow gap. It is a thermosetting resin that penetrates by capillary action and cures by heating.

絶縁紙３０を用いたステータ１０の製造方法の手順について、図３、図４を用いて説明する。最初に、ステータコア１２を準備する（ステータコア準備工程）。   The procedure of the method for manufacturing the stator 10 using the insulating paper 30 will be described with reference to FIGS. First, the stator core 12 is prepared (stator core preparation process).

次に、絶縁紙３０をスロット１８の内壁面に沿うように折り曲げて、各スロット１８に配置する。折り曲げは、図２の折り曲げ線３２，３４に沿って行う。必要に応じ、絶縁紙３０とスロット１８の内壁面との間に仮接着を行ってもよい（絶縁紙配置工程）。次に、セグメントコイル２２のリード部を、ステータコア１２の反リード側の端面側から、所定のスロット１８に挿入する。（セグメントコイル配置工程）。全てのセグメントコイル２２の配置が終了したら、ステータコア１２のリード側の端面から突き出した各リード部を所定の接合方法で順次接合し、ステータ巻線２０の巻回形成を行う。所定の接合方法は、三相巻線の巻回方法に従い、溶接装置等の所定の接合装置を用いて行う（接合工程）。これによって、リード側のコイルエンド２８が形成される。   Next, the insulating paper 30 is bent along the inner wall surface of the slot 18 and disposed in each slot 18. The folding is performed along the folding lines 32 and 34 in FIG. If necessary, temporary bonding may be performed between the insulating paper 30 and the inner wall surface of the slot 18 (insulating paper arrangement step). Next, the lead portion of the segment coil 22 is inserted into a predetermined slot 18 from the end surface side of the stator core 12 on the opposite lead side. (Segment coil placement step). When the arrangement of all the segment coils 22 is completed, the lead portions protruding from the end face on the lead side of the stator core 12 are sequentially joined by a predetermined joining method, and the winding of the stator winding 20 is formed. The predetermined joining method is performed using a predetermined joining device such as a welding device in accordance with the winding method of the three-phase winding (joining step). As a result, the coil end 28 on the lead side is formed.

次に、リード側のコイルエンド２８側から、各スロット１８における絶縁紙３０とステータコア１２の内壁面との間における隙間を狙って、ワニス５０を滴下する（ワニス滴下工程）。滴下されたワニス５０は、絶縁紙３０とステータコア１２の内壁面との間における隙間に毛細管現象によって浸み込み広がり、隙間に含浸されるので、適当な時間の経過後には、隙間全体がワニス５０で埋められる。   Next, the varnish 50 is dropped from the coil end 28 side on the lead side, aiming at a gap between the insulating paper 30 in each slot 18 and the inner wall surface of the stator core 12 (varnish dropping step). The dropped varnish 50 penetrates into the gap between the insulating paper 30 and the inner wall surface of the stator core 12 by capillarity and is impregnated into the gap. Filled with.

図３、図４は、ワニス滴下工程後のスロット１８を示す図である。図３は、１つのスロット１８の径方向に垂直な断面図であり、図４は、１つのスロット１８についての軸方向に垂直な断面図である。図４に示すように、ステータ巻線２０は、１つのスロット１８に巻数＝４で巻回される。図３は、その内の１本についての断面図である。ここでは、ステータ巻線２０として、スロット内のセグメントコイル２２を示す。ステータコア１２のスロット１８の内壁面には微細な凹凸１３がある。図３（ａ）の全体図では、微細な凹凸１３を誇張して示した。（ｂ）は拡大図である。微細な凹凸１３は、磁性体薄板１９の厚さ寸法に比べて微細な凹凸寸法である。   3 and 4 are views showing the slot 18 after the varnish dropping step. FIG. 3 is a cross-sectional view perpendicular to the radial direction of one slot 18, and FIG. 4 is a cross-sectional view perpendicular to the axial direction of one slot 18. As shown in FIG. 4, the stator winding 20 is wound in one slot 18 with the number of turns = 4. FIG. 3 is a cross-sectional view of one of them. Here, a segment coil 22 in the slot is shown as the stator winding 20. There are fine irregularities 13 on the inner wall surface of the slot 18 of the stator core 12. In the overall view of FIG. 3A, the fine irregularities 13 are exaggerated. (B) is an enlarged view. The fine irregularities 13 are fine irregularities compared to the thickness dimension of the magnetic thin plate 19.

ワニス５０は、コイルエンド２８側から滴下される。滴下されたワニス５０は、ステータコア１２のスロット１８の内壁面と他方側の発泡接着層４４との間の隙間に浸み込み、ステータコア１２のスロット１８の内壁面における微細な凹凸１３を覆いながら、毛細管現象によって隙間全体を埋める。全部のスロット１８についてのワニス５０の滴下が終了すると、ステータ１０の全体が加熱装置によって所定の温度条件の下で加熱される。これによって、発泡接着層４２，４４は膨張し、ワニス５０は硬化する。発泡接着層４２，４４も熱硬化性であるので、発泡後、硬化する（発泡硬化工程）。その後、適当な時間をおいて冷却され、ステータ１０が得られる。発泡接着層４２，４４は、冷却後において再加熱しても膨張しない。   The varnish 50 is dropped from the coil end 28 side. The dropped varnish 50 soaks into the gap between the inner wall surface of the slot 18 of the stator core 12 and the foamed adhesive layer 44 on the other side, covering the fine irregularities 13 on the inner wall surface of the slot 18 of the stator core 12, The entire gap is filled by capillary action. When the dropping of the varnish 50 for all the slots 18 is completed, the entire stator 10 is heated by a heating device under a predetermined temperature condition. As a result, the foamed adhesive layers 42 and 44 expand, and the varnish 50 is cured. Since the foamed adhesive layers 42 and 44 are also thermosetting, they are cured after foaming (foam curing process). Thereafter, the stator 10 is obtained by cooling after an appropriate time. The foamed adhesive layers 42 and 44 do not expand even when reheated after cooling.

上記工程によって、ステータコア１２のスロット１８の内壁面とセグメントコイル２２との間は、発泡接着層４２，４４の膨張によってほとんどの隙間がなくなり、所定の固定力が得られる。ワニス５０は発泡接着層４２，４４の膨張によってもともとの隙間から押し出されるが、ステータコア１２のスロット１８の内壁面と発泡接着層４４との間が微細な凹凸１３を含めて完全に埋められ、ワニス５０の固化によって固定される。これによって、（ステータコア１２の微細な凹凸１３）と（発泡層を含む絶縁紙３０）によって生じる固定力の低下という課題は、（ステータコア１２）と（発泡層を含む絶縁紙３０）と（ワニス５０）の組合せによって解決できる。   By the above process, almost no gap is eliminated between the inner wall surface of the slot 18 of the stator core 12 and the segment coil 22 due to the expansion of the foamed adhesive layers 42 and 44, and a predetermined fixing force is obtained. The varnish 50 is pushed out of the original gap by the expansion of the foam adhesive layers 42 and 44, but the space between the inner wall surface of the slot 18 of the stator core 12 and the foam adhesive layer 44 is completely filled including the fine irregularities 13, and the varnish Fixed by 50 solidification. As a result, the problem of a reduction in fixing force caused by (fine irregularities 13 of the stator core 12) and (insulating paper 30 including the foam layer) is that (stator core 12), (insulating paper 30 including the foam layer) and (varnish 50). ).

本実施の形態に係る回転電機のステータ１０は、ステータコア１２と、ステータ巻線２０と、絶縁紙３０と、ワニス５０とを備える。ステータコア１２は、円環状のバックヨーク１４、バックヨーク１４から内周側に突き出す複数のティース１６、及び、隣接するティース１６間の空間である複数のスロット１８を含む。ステータ巻線２０は、ステータコア１２のティース１６に巻回される。絶縁紙３０は、ティース１６とステータ巻線２０との間に配置され、基材４０の両面に発泡接着層４２，４４を有する。ワニス５０は、絶縁紙３０のステータコア１２に向い合う側の発泡接着層４４とステータコア１２との間の隙間に配置される。   A stator 10 of a rotating electrical machine according to the present embodiment includes a stator core 12, a stator winding 20, insulating paper 30, and a varnish 50. The stator core 12 includes an annular back yoke 14, a plurality of teeth 16 protruding from the back yoke 14 to the inner peripheral side, and a plurality of slots 18 that are spaces between adjacent teeth 16. The stator winding 20 is wound around the teeth 16 of the stator core 12. The insulating paper 30 is disposed between the teeth 16 and the stator winding 20 and has foamed adhesive layers 42 and 44 on both surfaces of the base material 40. The varnish 50 is disposed in a gap between the foamed adhesive layer 44 on the side facing the stator core 12 of the insulating paper 30 and the stator core 12.

上記構成により、ステータコア１２のスロット１８の内壁面とセグメントコイル２２との間は、発泡接着層４２，４４の膨張によってほとんどの隙間がなくなり、ワニス５０によって微細な凹凸１３も完全に埋められ、ワニス５０の固化によって固定される。これによって、ワニス５０がない場合に比較し、長期間に渡る熱履歴において、発泡後の絶縁紙３０とステータコア１２との間の空隙発生を抑制できる。一例を挙げると、長期間に渡る熱履歴を模擬した耐熱試験や冷熱衝撃耐久試験の後でも、発泡後の絶縁紙３０とステータコア１２との間の空隙発生が抑制され、これらの試験を行っても、発泡後の絶縁紙３０とステータコア１２との間の固定力が低下しない。   With the above configuration, almost no gap is eliminated between the inner wall surface of the slot 18 of the stator core 12 and the segment coil 22 due to the expansion of the foamed adhesive layers 42 and 44, and the fine irregularities 13 are completely filled with the varnish 50. Fixed by 50 solidification. Thereby, compared with the case where there is no varnish 50, it is possible to suppress the generation of a gap between the foamed insulating paper 30 and the stator core 12 in a heat history over a long period of time. For example, even after a heat resistance test or a thermal shock durability test simulating a heat history over a long period of time, the generation of voids between the foamed insulating paper 30 and the stator core 12 is suppressed, and these tests were performed. However, the fixing force between the insulating paper 30 after foaming and the stator core 12 does not decrease.

１０ （回転電機の）ステータ、１２ ステータコア、１３ 微細な凹凸、１４ バックヨーク、１６ ティース、１８ スロット、１９ 磁性体薄板、２０ ステータ巻線、２２ セグメントコイル、２４ 導体素線、２６ 絶縁皮膜、２８ コイルエンド、３０ 絶縁紙、３２，３４ 折り曲げ線、４０ 基材、４２，４４ 発泡接着層、５０ ワニス。   10 (rotary electric machine) stator, 12 stator core, 13 fine irregularities, 14 back yoke, 16 teeth, 18 slots, 19 magnetic thin plate, 20 stator winding, 22 segment coil, 24 conductor wire, 26 insulation coating, 28 Coil end, 30 Insulating paper, 32, 34 Fold line, 40 Base material, 42, 44 Foam adhesive layer, 50 Varnish.

Claims (1)

円環状のバックヨーク、前記バックヨークから内周側に突き出す複数のティース、及び、隣接する前記ティース間の空間である複数のスロットを含むステータコアと、
前記ステータコアの前記ティースに巻回されるステータ巻線と、
前記ティースと前記ステータ巻線との間に配置され、基材の両面に発泡接着層を有する絶縁紙と、
前記絶縁紙の前記ステータコアに向い合う側の前記発泡接着層と前記ステータコアとの間の隙間に配置されたワニスと、
を備える、回転電機のステータ。 A stator core including an annular back yoke, a plurality of teeth protruding from the back yoke to the inner peripheral side, and a plurality of slots which are spaces between the adjacent teeth;
A stator winding wound around the teeth of the stator core;
An insulating paper disposed between the teeth and the stator winding and having a foam adhesive layer on both sides of the substrate;
A varnish disposed in a gap between the foam adhesive layer on the side of the insulating paper facing the stator core and the stator core;
A stator for a rotating electrical machine.
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