WO2011101986A1 - Stator and method for producing same - Google Patents

Stator and method for producing same Download PDF

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Publication number
WO2011101986A1
WO2011101986A1 PCT/JP2010/052597 JP2010052597W WO2011101986A1 WO 2011101986 A1 WO2011101986 A1 WO 2011101986A1 JP 2010052597 W JP2010052597 W JP 2010052597W WO 2011101986 A1 WO2011101986 A1 WO 2011101986A1
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WO
WIPO (PCT)
Prior art keywords
stator core
stator
resin
electromagnetic steel
coil
Prior art date
Application number
PCT/JP2010/052597
Other languages
French (fr)
Japanese (ja)
Inventor
常治 吉村
浩二 中西
泰弘 上野
修一 中山
直希 吉田
尚文 千葉
Original Assignee
トヨタ自動車株式会社
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Publication date
Application filed by トヨタ自動車株式会社 filed Critical トヨタ自動車株式会社
Priority to PCT/JP2010/052597 priority Critical patent/WO2011101986A1/en
Publication of WO2011101986A1 publication Critical patent/WO2011101986A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/52—Fastening salient pole windings or connections thereto
    • H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
    • H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/09—Magnetic cores comprising laminations characterised by being fastened by caulking
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12—Machines characterised by the bobbins for supporting the windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/325—Windings characterised by the shape, form or construction of the insulation for windings on salient poles, such as claw-shaped poles

Definitions

  • the present invention relates to a stator used by forming a stator core by laminating electromagnetic steel sheets and a stator manufacturing method, and to a technique for suppressing distortion generated in the stator core.
  • Patent Document 1 discloses a technique regarding a stator of a motor.
  • a groove portion extending in the axial direction is formed on the inner peripheral side of the yoke portion of the stator core.
  • the resin filling part with which each groove part is filled is provided integrally. Since the covering member is firmly fixed to the stator core in the resin-filled portion, it is possible to prevent the covering member from being cracked or peeled off.
  • Patent Document 2 discloses a technique related to a stator piece and a stator of a motor.
  • the core piece of the stator core formed by laminating electromagnetic steel sheets is formed so that the teeth width of one electromagnetic steel sheet located at both ends in the stacking direction is narrower than the teeth width of the electromagnetic steel sheet located in the center in the stacking direction.
  • Patent Document 3 discloses a technique regarding a stator, a manufacturing method thereof, and an electric motor using the stator.
  • a core piece of a stator core formed by laminating electromagnetic steel sheets is composed of an electromagnetic steel sheet having a narrow tooth width and an electromagnetic steel sheet having a wide tooth width, and is alternately stacked.
  • Patent Document 4 discloses a technique related to a split stator and a split stator manufacturing method.
  • an adhesive layer is provided around the teeth portion of the stator core so that the filler mixed in the resin used for the insulator does not have directionality. . Since the direction of the filler mixed in the insulator can be arranged at random, it is possible to suppress the influence of the filler that hinders heat transfer, and to improve the thermal conductivity.
  • FIG. 13 is a schematic cross-sectional view of a connecting portion that connects the stator cores by caulking.
  • the electromagnetic steel sheet 150 includes a caulking recess 111b, and the electromagnetic steel sheet 150 is overlapped to form a split stator core 111.
  • FIG. 14 is a cross-sectional view showing a state where an insulator is insert-molded in the stator core.
  • the insulator 114 covers the teeth portion 111a as shown in FIG.
  • the thermal expansion coefficients of the insulator 114 made of resin and the split stator core 111 formed by laminating the metal electromagnetic steel plates 150 are different. For this reason, when the insulator 114 is molded and cooled, a contraction force F1 is generated on the teeth portion 111a side and an expansion force F2 is generated on the outer peripheral side of the split stator core 111.
  • an object of the present invention is to provide a stator or a stator manufacturing method in which distortion is less likely to occur due to stress generated during insulator molding.
  • a stator according to an aspect of the present invention has the following characteristics. (1) A stator core that is formed by winding a conductor, and a stator core that is formed by laminating electromagnetic steel plates and that protrudes from an outer ring portion toward an inner peripheral side, and that is inserted into the coil.
  • a resin mold part in which a coil end portion of the coil inserted into the resin is covered with a resin, and the electromagnetic steel sheet constituting the stator core is provided with a caulking recess, and the caulking recess is used to
  • the stator core is formed by connecting electromagnetic steel sheets, and a groove portion is provided in the outer ring portion of the stator core or the root portion of the teeth in parallel to the axial direction of the stator core, and the groove portion A resin column is provided.
  • the outer ring portion here refers to a portion of the stator core that is formed in an annular shape and has a teeth portion on the inner peripheral side, excluding the teeth portion. Therefore, it refers to a region surrounded by a virtual plane connecting the bottom surface of the slot formed between both end surfaces and the outer peripheral surface of the stator core and between the teeth, and the bottom surface of the adjacent slots.
  • a stator manufacturing method has the following characteristics.
  • the portion, in the stator manufacturing method laminating the electromagnetic steel sheets using the caulking recess used in the electromagnetic steel sheet, forming the stator core, and setting the stator core in a mold,
  • the insulator is formed by insert molding, and a resin column is formed by pouring resin into a groove provided in the outer ring portion of the electromagnetic steel sheet or the root portion of the teeth in parallel with the axial direction of the stator core.
  • the following actions and effects can be obtained by the stator according to one aspect of the present invention having such characteristics.
  • the aspect of the invention described in the above (1) includes a coil formed by winding a conductor and a tooth formed by laminating electromagnetic steel plates and inserting the coil so as to protrude from the outer ring portion toward the inner peripheral side.
  • the electromagnetic steel sheet constituting the stator core is provided with a crimp recess, and the crimp recess
  • the stator core is formed by connecting the electromagnetic steel sheets using the outer peripheral portion of the stator core or the root portion of the teeth, the groove portion is provided in parallel to the axial direction of the stator core, and the resin column is provided in the groove portion. It is what is provided.
  • the stator core is connected by caulking recesses to create a slight gap between the electromagnetic steel sheets.
  • the stator core includes a groove portion in the outer ring portion, and a resin column is formed in the groove portion. For this reason, even if the insulator is insert-molded in the stator core and the resin constituting the insulator is contracted, the stator core is not deformed. This is because the resin pillar provided in the outer ring portion of the stator core is integrated with the electromagnetic steel plate constituting the stator core, and when the insulator shrinks when the insulator is insert-molded, the insulator and the resin This is because, since the columns contract in the same direction, the force generated when the insulator contracts is offset by the force generated when the resin column contracts.
  • a coil is formed by winding a conductor, and the coil is inserted into a tooth formed on a stator core made of laminated electromagnetic steel sheets.
  • the stator manufacturing method of forming a resin mold part that covers a portion with resin the electromagnetic steel sheets are laminated using the caulking recesses used in the electromagnetic steel sheet to form a stator core, and the stator core is formed into a mold.
  • the insulator is formed by insert molding, and a resin column is formed by pouring resin into a groove provided parallel to the axial direction of the stator core in the outer ring portion of the electromagnetic steel sheet or the root portion of the teeth. .
  • the insulator and the resin pillar provided in the groove of the outer ring portion it is possible to suppress the distortion of the stator core due to the shrinkage of the insulator.
  • Magnetic steel sheets and insulators have different coefficients of thermal expansion due to differences in materials. For this reason, when the resin melted at the time of insulator molding is injected into the cavity, insert molded, and solidified, the resin constituting the insulator contracts and a force is generated on the teeth side to compress in the stator core axial direction. In order to generate a force that counteracts this, a resin column is formed on the outer ring portion of the stator core.
  • stator of this embodiment It is a perspective view of the stator of this embodiment. It is a perspective view of the split type stator core of this embodiment. It is a perspective view in the state where insert molding of an insulator was carried out to a stator core of this embodiment. It is a perspective view in the state where a coil was inserted in a stator core of this embodiment. It is a perspective view in the state where the resin mold part was formed in the stator core of this embodiment. It is a mimetic diagram at the time of insert-molding an insulator of this embodiment. It is a schematic perspective view of the stator core of this embodiment. It is a schematic sectional drawing of the stator core of this embodiment. It is a perspective view showing another embodiment of a stator core of this embodiment.
  • FIG. 1 It is a perspective view showing another embodiment of a stator core of this embodiment. It is a perspective view showing another embodiment of a stator core of this embodiment. It is a perspective view showing another embodiment of a stator core of this embodiment. It is a perspective view showing another embodiment of a stator core of this embodiment. It is a schematic cross section of the connection part which connects a stator core by caulking joining. It is the side surface cross-section schematic diagram of the stator core which showed the contractive force which generate
  • FIG. 1 the perspective view of the stator of this embodiment is shown.
  • FIG. 2 is a perspective view of a split-type stator core.
  • FIG. 3 is a perspective view of a state where an insulator is insert-molded into the stator core.
  • FIG. 4 is a perspective view of a state where a coil is inserted into the stator core.
  • FIG. 5 is a perspective view of a state where the resin mold portion 113 is formed on the stator core. It should be noted that details are different from FIG. 1 for convenience of explanation.
  • the stator 10 uses a split-type stator core 111, and is formed by arranging 18 stator core units 110 in an annular shape and fitting an outer ring 102 on the outer periphery.
  • a bus bar holder 101 is provided at the coil end of the stator 10.
  • the stator core 111 is formed by laminating a plurality of electromagnetic steel plates 150 formed in a substantially T shape by press working.
  • the state of lamination is as shown in FIG.
  • the stator core 111 includes a tooth portion 111a so as to protrude toward the inner peripheral side of the stator 10, and the electromagnetic steel plates 150 are fixed to each other by a caulking recess 111b.
  • the groove part 111e is formed in the outer ring part 111c provided along the outer peripheral side of the stator core 111 from the teeth part 111a.
  • the groove 111e is a V-shaped groove formed at the time of pressing.
  • a coil 112 is inserted into the tooth portion 111a after an insulator 114 is provided.
  • the insulator 114 is insert-molded with respect to the stator core 111 as shown in FIG.
  • the insulator 114 includes a flange portion 114a, an annular portion 114b, and a coil support wall 114c, and is formed of an insulating resin.
  • the resin forming the insulator 114 needs to transfer heat from the heated coil 112 to the stator core 111 side. For this reason, the filler is mixed in the insulator 114 for the purpose of improving heat transferability.
  • FIG. 6 is a schematic view when insert-molding the insulator.
  • the stator core 111 is disposed between the movable mold D1 and the fixed mold D2, so that an insulator forming cavity B1 and a resin column forming cavity B2 are formed between the movable mold D1 and the stator core 111. Is done.
  • the insulator 114 and the resin column 130 are insert-formed by pouring molten resin into the insulator forming cavity B1 and the resin column forming cavity B2, cooling, and releasing.
  • the insulator forming cavity B1 and the resin column forming cavity B2 are provided with a gate for supplying resin. The same resin is injected into the insulator forming cavity B1 and the resin column forming cavity B2.
  • the coil 112 is wound by edgewise bending a rectangular conductor having a rectangular cross section.
  • a flat conductor is a conductor having a high conductivity such as copper and is coated with an insulating resin such as enamel.
  • an outer terminal portion 112a and an inner terminal portion 112b are formed and connected to a bus bar (not shown).
  • the coil 112 is inserted into the insulator 114 in a tooth portion 111 a formed in the stator core 111.
  • the resin mold portion 113 is formed so as to cover the coil 112 as shown in FIG.
  • the stator 10 of this embodiment is the said structure, there exists an effect demonstrated below.
  • the stator 10 of this embodiment has a coil 112 formed by winding a conductor and a tooth portion 111a formed by laminating electromagnetic steel plates 150 and inserting the coil 112 protruding from the outer ring portion 111c toward the inner peripheral side.
  • the electromagnetic steel plate 150 constituting the stator core 111 is provided.
  • stator core 111 is formed on the outer ring portion 111c of the stator core 111 with the axial direction of the stator core 111.
  • the groove 111e is provided in parallel, and the resin pillar 130 is provided in the groove 111e.
  • FIG. 7 shows a schematic perspective view of the stator core. Note that the insulator is omitted for convenience of explanation.
  • FIG. 8 shows a schematic cross-sectional view of the stator core.
  • Stator core 111 is formed by laminating electromagnetic steel plates 150. The electromagnetic steel sheet 150 is punched with a press, and at the same time, a caulking recess 111b is formed. Then, after press working, the stator core 111 is overlapped with the crimped recess 111b and integrated as shown in FIG. In FIG. 2, only one crimping recess 111b is shown, but a plurality of crimping recesses 111b may be provided depending on the size and required strength of the stator core 111.
  • the insulator 114 is insert-molded and the resin pillar 130 is formed at the same time.
  • the resin column 130 is formed by pouring resin into a groove 111e formed in the outer ring portion 111c of the stator core 111, and is in close contact with the stator core 111 by slightly entering the resin into the gap d. It is formed integrally.
  • the shrinkage force of the resin column 130 is determined by the type of resin, the thickness of the resin column 130, and the like.
  • a method of changing the material of the resin column 130 is also conceivable, but since the merit of forming together with the insulator 114 is impaired, the position of the groove 111e formed on the outer peripheral surface 111d of the outer ring portion 111c is changed.
  • a method of changing is also conceivable.
  • FIG. 9 is a perspective view showing another embodiment of the stator core.
  • the resin pillar 130 can be increased to two places by increasing the number of grooves 111e formed on the outer peripheral surface 111d to two.
  • FIG. 10 is a perspective view showing another embodiment of the stator core.
  • FIG. 11 is a perspective view showing another embodiment of the stator core.
  • FIG. 12 is a perspective view showing another embodiment of the stator core.
  • the pattern as shown in FIG. 10 in which the resin pillar 130 is provided on the dividing surface of the split-type stator core 111, the pattern as shown in FIG. 11 in which the resin pillar 130 is provided at the root of the tooth portion 111a, or A pattern as shown in FIG. 12 in which a resin pillar 130 is provided at the bottom of the slot is conceivable.
  • the resin column 130 is provided to cancel the force generated by the contraction of the insulator 114.
  • it is possible to offset the force that effectively contracts by devising not only the size of the resin pillar 130 but also the position and number of formation. It becomes.
  • the resin column 130 that generates a force that cancels the contracting force of the insulator 114, it is possible to make it difficult for the stator core 111 of the stator core unit 110 to be distorted. Since the distortion of the stator core unit 110 is less likely to occur, it becomes easy to ensure the roundness of the inner periphery of the stator 10, and the clearance between the rotor disposed on the inner periphery side (not shown) and the stator 10 is minimized. Can be set to the limit. Since the gap between the stator 10 and the rotor affects the output and performance of the motor using the stator 10, it is desirable that the gap can be narrowed.
  • the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.
  • the resin pillar 130 formed on the outer ring portion 111c and the tooth portion 111a is shown in FIGS. 7 and 9 to 12, but is not limited to this example because it is just an example. It does not prevent the resin column 130 from being formed in a position and size that can cancel the force generated in the insulator 114, and does not prevent the resin column 130 from being disposed in a place that does not hinder the magnetic circuit generated in the stator core 111. .
  • the stator core unit 110 is of a split type, but it does not prevent the resin pillar 130 from being provided on an annular stator core.
  • the materials exemplified in the present embodiment do not preclude changing in a range that does not deviate from the function and application.
  • the formation timing of the resin pillar 130 is made simultaneously with the insulator 114, it does not prevent any one from being formed first.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

Disclosed is a stator resistant to distortion from stresses arising during insulator moulding and a method for producing same. The stator is provided with a coil formed by winding around an electric conductor, a stator core equipped with projecting teeth running from the outside to the inside inserted into the coil which is formed by lamination with electromagnetic steel sheet, and a resin-moulded part where the resin-covered end part of the coil is inserted into the stator core. The electromagnetic steel sheet which comprises the stator core is provided with concave recesses, the stator core is made up of two interconnected electromagnetic steel sheets provided with concave recesses, and the outer surface of the stator core is provided with grooves parallel to the axial direction thereof, where the grooves are provided with resin columns.

Description

固定子及び固定子製造方法Stator and stator manufacturing method
　本発明は、電磁鋼板を積層して固定子コアを形成し固定子に用いる固定子及び固定子の製造方法に関するものであり、固定子コアに生じる歪みを抑制する技術に関する。 The present invention relates to a stator used by forming a stator core by laminating electromagnetic steel sheets and a stator manufacturing method, and to a technique for suppressing distortion generated in the stator core.
　近年、自動車の駆動力にモータを用いる需要が増加している。特にハイブリッド車へモータを搭載するにあたっては、小型化、高性能化に加えてコストダウンが重要であり、様々な開発がなされている。
　特許文献１にはモータの固定子についての技術が開示されている。
　固定子コアのヨーク部の内周側に軸方向に伸びる溝部を形成している。そして、各溝部に充填される樹脂充填部が一体的に設けられる。被覆部材としては樹脂充填部においてステータコアと強固に固定された状態となるため、被覆部材にクラックや剥がれが発生することを抑えることが可能である。 In recent years, there has been an increasing demand for using motors for driving power of automobiles. In particular, when mounting a motor on a hybrid vehicle, cost reduction is important in addition to downsizing and high performance, and various developments have been made.
Patent Document 1 discloses a technique regarding a stator of a motor.
A groove portion extending in the axial direction is formed on the inner peripheral side of the yoke portion of the stator core. And the resin filling part with which each groove part is filled is provided integrally. Since the covering member is firmly fixed to the stator core in the resin-filled portion, it is possible to prevent the covering member from being cracked or peeled off.
　特許文献２には固定子ピース及びモータの固定子に関する技術が開示されている。
　電磁鋼板を積層して形成される固定子コアのコアピースは、積み厚方向両端部に位置する一枚の電磁鋼板のティース幅が、積み厚方向中央部に位置する電磁鋼板のティース幅より狭く形成されている。
　固定子コア端面に配置される電磁鋼板のティース幅を狭くすることで、インシュレータの筒部の四隅に発生する集中応力を低減させることが可能となる。 Patent Document 2 discloses a technique related to a stator piece and a stator of a motor.
The core piece of the stator core formed by laminating electromagnetic steel sheets is formed so that the teeth width of one electromagnetic steel sheet located at both ends in the stacking direction is narrower than the teeth width of the electromagnetic steel sheet located in the center in the stacking direction. Has been.
By narrowing the teeth width of the electromagnetic steel sheet arranged on the end face of the stator core, it is possible to reduce the concentrated stress generated at the four corners of the tubular portion of the insulator.
　特許文献３には、固定子とその製造方法及びこの固定子を用いた電動機についての技術が開示されている。
　電磁鋼板を積層して形成される固定子コアのコアピースは、ティース幅が狭い電磁鋼板とティース幅の広い電磁鋼板とからなり、交互に積み重ねられている。
　このように固定子コアを形成することで、インサート成形されるインシュレータとの密着性を高めることが可能であり、耐久性を向上させることが可能である。 Patent Document 3 discloses a technique regarding a stator, a manufacturing method thereof, and an electric motor using the stator.
A core piece of a stator core formed by laminating electromagnetic steel sheets is composed of an electromagnetic steel sheet having a narrow tooth width and an electromagnetic steel sheet having a wide tooth width, and is alternately stacked.
By forming the stator core in this way, it is possible to improve the adhesion with the insert-molded insulator, and it is possible to improve the durability.
　特許文献４には、分割固定子及び分割固定子製造方法に関する技術が開示されている。
　分割型の固定子コアにインシュレータをインサート成形する際に、固定子コアのティース部分の周囲に接着剤層を設けることで、インシュレータに用いる樹脂に混入するフィラーに方向性を持たせないようにする。
　インシュレータに混入するフィラーの方向がランダムに配置できることで、熱伝達を阻害するフィラーによる影響を抑えることができ、熱伝導率を向上させることができる。 Patent Document 4 discloses a technique related to a split stator and a split stator manufacturing method.
When insert-molding an insulator into a split-type stator core, an adhesive layer is provided around the teeth portion of the stator core so that the filler mixed in the resin used for the insulator does not have directionality. .
Since the direction of the filler mixed in the insulator can be arranged at random, it is possible to suppress the influence of the filler that hinders heat transfer, and to improve the thermal conductivity.
特開平１１－３４１７１４号公報JP 11-341714 A 特開２００４－２４８４４０号公報JP 2004-248440 A 特開２００７－１６６７５９号公報JP 2007-166759 A 特開２００９－２１９２３５号公報JP 2009-219235 A
　しかしながら、特許文献１乃至特許文献４に記載の技術には、以下に説明する課題があると考えられる。
　モータのコストダウンを更に推し進めるため、固定子コアに用いる電磁鋼板は、溶接によって接合するのではなく、電磁鋼板にカシメ穴を設け、電磁鋼板の外形をプレス加工で打ち抜いた後に重ねることで、連結する方法が検討されている。
　図１３に、固定子コアをカシメ接合によって連結する連結部分の模式断面図を示す。
　図示されるように電磁鋼板１５０はカシメ凹部１１１ｂを備えており、電磁鋼板１５０が重ね合わされることで分割型の固定子コア１１１を形成する。このような電磁鋼板の積層方法を採用することで、電磁鋼板同士を連結するための溶接工程を省くことが可能となり、コストダウンに貢献する。 However, it is considered that the techniques described in Patent Documents 1 to 4 have problems described below.
In order to further reduce the cost of the motor, the electromagnetic steel sheet used for the stator core is not joined by welding, but a caulking hole is provided in the electromagnetic steel sheet, and the outer shape of the electromagnetic steel sheet is punched out by pressing and then connected. How to do is being studied.
FIG. 13 is a schematic cross-sectional view of a connecting portion that connects the stator cores by caulking.
As shown in the drawing, the electromagnetic steel sheet 150 includes a caulking recess 111b, and the electromagnetic steel sheet 150 is overlapped to form a split stator core 111. By adopting such a method of laminating electromagnetic steel sheets, it becomes possible to omit a welding process for connecting the electromagnetic steel sheets, which contributes to cost reduction.
　ただし、図１３に示すようにカシメ凹部１１１ｂが重ねられることで、隙間ｄが生じる結果となる。この隙間ｄは電磁鋼板の厚みに左右され、カシメ結合をする限り、ゼロにすることは困難である。
　図１４に、固定子コアにインシュレータをインサート成形した状態の断面図を示す。
　インシュレータ１１４をインサート成形すると、図１４に示すようにティース部１１１ａをインシュレータ１１４が覆うことになる。しかし、樹脂で形成されるインシュレータ１１４と、金属製の電磁鋼板１５０を積層して形成される分割型の固定子コア１１１の熱膨張率は異なる。このため、インシュレータ１１４を成型し冷却するにあたって、ティース部１１１ａ側に収縮力Ｆ１が、分割型の固定子コア１１１の外周側に拡張力Ｆ２が発生する。 However, as shown in FIG. 13, the caulking concave portion 111b is overlapped, resulting in a gap d. This gap d depends on the thickness of the electrical steel sheet, and it is difficult to make it zero as long as caulking is performed.
FIG. 14 is a cross-sectional view showing a state where an insulator is insert-molded in the stator core.
When the insulator 114 is insert-molded, the insulator 114 covers the teeth portion 111a as shown in FIG. However, the thermal expansion coefficients of the insulator 114 made of resin and the split stator core 111 formed by laminating the metal electromagnetic steel plates 150 are different. For this reason, when the insulator 114 is molded and cooled, a contraction force F1 is generated on the teeth portion 111a side and an expansion force F2 is generated on the outer peripheral side of the split stator core 111.
　これは、図１３に示すように積層された電磁鋼板１５０同士の間に、隙間ｄが形成されてしまうためである。電磁鋼板１５０に形成されるカシメ凹部１１１ｂを重ねて結合することで、隙間ｄが形成されてしまう点は避けられない。そのため、熱膨張率の差によってインシュレータ１１４にティース部１１１ａが締め付けられることで、分割型の固定子コア１１１が変形する虞がある。
　分割型の固定子コア１１１の内周側は、図示しない回転子とのクリアランスが保たれる必要があり、分割型の固定子コア１１１の変形は回転子との干渉を引き起こす虞もある。また、固定子コア１１１に歪があると、モータ駆動時の振動や音などの発生を招き、寿命が短くなるなどの問題もある。
　特許文献１乃至特許文献４には、このような事態を想定した技術ではないと考えられ、カシメ凹部１１１ｂを備えた分割型の固定子コア１１１を用いた場合には、上述した問題が発生する虞がある。 This is because a gap d is formed between the electromagnetic steel sheets 150 laminated as shown in FIG. It is inevitable that the gap d is formed by overlapping and joining the caulking concave portions 111b formed in the electromagnetic steel sheet 150. For this reason, the split-type stator core 111 may be deformed by the teeth 111a being fastened to the insulator 114 due to the difference in thermal expansion coefficient.
The inner peripheral side of the split-type stator core 111 needs to maintain a clearance with a rotor (not shown), and deformation of the split-type stator core 111 may cause interference with the rotor. In addition, when the stator core 111 is distorted, there is a problem that vibrations and sounds are generated when the motor is driven, and the life is shortened.
In Patent Documents 1 to 4, it is considered that the technology does not assume such a situation, and the above-described problem occurs when the split-type stator core 111 provided with the caulking recess 111b is used. There is a fear.
　そこで、本発明はこのような課題を解決するために、インシュレータ成形時に発生する応力に対し歪みが発生しにくい固定子又は固定子製造方法を提供することを目的とする。 Therefore, in order to solve such a problem, an object of the present invention is to provide a stator or a stator manufacturing method in which distortion is less likely to occur due to stress generated during insulator molding.
　前記目的を達成するために、本発明の一態様による固定子は、以下のような特徴を有する。
（１）導体を巻回して形成したコイルと、電磁鋼板を積層して形成され前記コイルを挿入するティースを外環部から内周側に向けて突出して備える固定子コアと、前記固定子コアに挿入した前記コイルのコイルエンド部分を樹脂で覆った樹脂モールド部と、を備える固定子において、前記固定子コアを構成する前記電磁鋼板にはカシメ凹部が設けられ、前記カシメ凹部を用いて前記電磁鋼板同士を連結することで前記固定子コアが形成され、前記固定子コアの前記外環部又は前記ティースの根本部に、前記固定子コアの軸方向と平行に溝部を備え、前記溝部に樹脂柱が備えられていることを特徴とする。 In order to achieve the above object, a stator according to an aspect of the present invention has the following characteristics.
(1) A stator core that is formed by winding a conductor, and a stator core that is formed by laminating electromagnetic steel plates and that protrudes from an outer ring portion toward an inner peripheral side, and that is inserted into the coil. And a resin mold part in which a coil end portion of the coil inserted into the resin is covered with a resin, and the electromagnetic steel sheet constituting the stator core is provided with a caulking recess, and the caulking recess is used to The stator core is formed by connecting electromagnetic steel sheets, and a groove portion is provided in the outer ring portion of the stator core or the root portion of the teeth in parallel to the axial direction of the stator core, and the groove portion A resin column is provided.
　ここで言う外環部とは、環状に形成され内周側にティース部を備える固定子コアの、ティース部を除いた部分のことを指している。したがって、固定子コアの両端面と外周面、そしてティース同士の間に形成されるスロットの底面と、その隣り合うスロットの底面を繋いだ仮想の面に囲まれる領域を指す。 The outer ring portion here refers to a portion of the stator core that is formed in an annular shape and has a teeth portion on the inner peripheral side, excluding the teeth portion. Therefore, it refers to a region surrounded by a virtual plane connecting the bottom surface of the slot formed between both end surfaces and the outer peripheral surface of the stator core and between the teeth, and the bottom surface of the adjacent slots.
　また、前記目的を達成するために、本発明の一態様による固定子製造方法は、以下のような特徴を有する。
（２）導体を巻回してコイルを形成し、前記コイルを積層された電磁鋼板からなる固定子コアに形成されたティースに挿入し、前記固定子コアの前記コイルエンド部分を樹脂で覆う樹脂モールド部を形成する、固定子製造方法において、前記電磁鋼板に用いられたカシメ凹部を用いて前記電磁鋼板を積層して、前記固定子コアを形成し、前記固定子コアを金型にセットし、インシュレータをインサート成形により形成すると共に、前記電磁鋼板の外環部又は前記ティースの根本部に前記固定子コアの軸方向と平行に備えられる溝部に、樹脂を流し込んで樹脂柱を形成することを特徴とする。 In order to achieve the above object, a stator manufacturing method according to an aspect of the present invention has the following characteristics.
(2) A resin mold in which a conductor is wound to form a coil, the coil is inserted into a tooth formed on a stator core made of laminated electromagnetic steel sheets, and the coil end portion of the stator core is covered with resin. Forming the portion, in the stator manufacturing method, laminating the electromagnetic steel sheets using the caulking recess used in the electromagnetic steel sheet, forming the stator core, and setting the stator core in a mold, The insulator is formed by insert molding, and a resin column is formed by pouring resin into a groove provided in the outer ring portion of the electromagnetic steel sheet or the root portion of the teeth in parallel with the axial direction of the stator core. And
　このような特徴を有する本発明の一態様による固定子により、以下のような作用、効果が得られる。
　上記（１）に記載される発明の態様は、導体を巻回して形成したコイルと、電磁鋼板を積層して形成されコイルを挿入するティースを外環部から内周側に向けて突出して備える固定子コアと、固定子コアに挿入したコイルのコイルエンド部分を樹脂で覆った樹脂モールド部と、を備える固定子において、固定子コアを構成する電磁鋼板にはカシメ凹部が設けられ、カシメ凹部を用いて電磁鋼板同士を連結することで固定子コアが形成され、固定子コアの外環部又はティースの根本部に、固定子コアの軸方向と平行に溝部を備え、溝部に樹脂柱が備えられているものである。 The following actions and effects can be obtained by the stator according to one aspect of the present invention having such characteristics.
The aspect of the invention described in the above (1) includes a coil formed by winding a conductor and a tooth formed by laminating electromagnetic steel plates and inserting the coil so as to protrude from the outer ring portion toward the inner peripheral side. In a stator comprising a stator core and a resin mold portion in which a coil end portion of a coil inserted into the stator core is covered with resin, the electromagnetic steel sheet constituting the stator core is provided with a crimp recess, and the crimp recess The stator core is formed by connecting the electromagnetic steel sheets using the outer peripheral portion of the stator core or the root portion of the teeth, the groove portion is provided in parallel to the axial direction of the stator core, and the resin column is provided in the groove portion. It is what is provided.
　固定子コアは、カシメ凹部によって連結されることで電磁鋼板同士の間にわずかな隙間を生じるが、固定子コアの外環部に溝部を備え、その溝部には樹脂柱が形成されている。このため、この固定子コアにインシュレータをインサート成形し、インシュレータを構成する樹脂の収縮が発生しても、固定子コアが変形するようなことが無くなる。
　これは、固定子コアの外環部に備える樹脂柱が、固定子コアを構成する電磁鋼板と一体化して構成されており、インシュレータをインサート成形した際に樹脂が収縮する際にはインシュレータ及び樹脂柱がそれぞれ同じ方向に収縮するため、インシュレータが収縮する際に発生する力が、樹脂柱が収縮する際に発生する力で相殺されるためである。 The stator core is connected by caulking recesses to create a slight gap between the electromagnetic steel sheets. However, the stator core includes a groove portion in the outer ring portion, and a resin column is formed in the groove portion. For this reason, even if the insulator is insert-molded in the stator core and the resin constituting the insulator is contracted, the stator core is not deformed.
This is because the resin pillar provided in the outer ring portion of the stator core is integrated with the electromagnetic steel plate constituting the stator core, and when the insulator shrinks when the insulator is insert-molded, the insulator and the resin This is because, since the columns contract in the same direction, the force generated when the insulator contracts is offset by the force generated when the resin column contracts.
　その結果、インシュレータと樹脂柱が収縮しても、固定子コアに偏荷重が発生しにくくなくなるので、固定子コアに発生する樹脂の収縮による歪みを抑制することが可能となる。
　そして、固定子コアの歪みが抑えられることで、固定子と回転子とのクリアランスを最小限に設定することが可能となる。 As a result, even if the insulator and the resin column are contracted, an uneven load is not easily generated in the stator core, so that it is possible to suppress distortion due to the contraction of the resin generated in the stator core.
And since the distortion of the stator core is suppressed, the clearance between the stator and the rotor can be set to a minimum.
　また、このような特徴を有する本発明の一態様による固定子製造方法により、以下のような作用、効果が得られる。
　上記（２）に記載される発明の態様は、導体を巻回してコイルを形成し、コイルを積層された電磁鋼板からなる固定子コアに形成されたティースに挿入し、固定子コアのコイルエンド部分を樹脂で覆う樹脂モールド部を形成する、固定子製造方法において、電磁鋼板に用いられたカシメ凹部を用いて電磁鋼板を積層して、固定子コアを形成し、固定子コアを金型にセットし、インシュレータをインサート成形により形成すると共に、電磁鋼板の外環部又はティースの根本部に固定子コアの軸方向と平行に備えられる溝部に、樹脂を流し込んで樹脂柱を形成するものである。 Moreover, the following operation | movement and an effect are acquired by the stator manufacturing method by one aspect | mode of this invention which has such a characteristic.
In the aspect of the invention described in (2) above, a coil is formed by winding a conductor, and the coil is inserted into a tooth formed on a stator core made of laminated electromagnetic steel sheets. In the stator manufacturing method of forming a resin mold part that covers a portion with resin, the electromagnetic steel sheets are laminated using the caulking recesses used in the electromagnetic steel sheet to form a stator core, and the stator core is formed into a mold. The insulator is formed by insert molding, and a resin column is formed by pouring resin into a groove provided parallel to the axial direction of the stator core in the outer ring portion of the electromagnetic steel sheet or the root portion of the teeth. .
　インシュレータと、外環部の溝に備える樹脂柱を形成することで、インシュレータの収縮による固定子コアの歪みを抑制することが可能となる。
　電磁鋼板とインシュレータでは、材質の違いから熱膨張率が異なる。このため、インシュレータ成形時に溶融した樹脂をキャビティに注入してインサート成形し、凝固させると、インシュレータを構成する樹脂が収縮してティース側に、固定子コア軸方向に圧縮する力が生じる。これと相殺させる力を発生させるために、固定子コアの外環部に樹脂柱を形成する。 By forming the insulator and the resin pillar provided in the groove of the outer ring portion, it is possible to suppress the distortion of the stator core due to the shrinkage of the insulator.
Magnetic steel sheets and insulators have different coefficients of thermal expansion due to differences in materials. For this reason, when the resin melted at the time of insulator molding is injected into the cavity, insert molded, and solidified, the resin constituting the insulator contracts and a force is generated on the teeth side to compress in the stator core axial direction. In order to generate a force that counteracts this, a resin column is formed on the outer ring portion of the stator core.
　結果、樹脂柱側にも冷却時に収縮力が発生し、固定子コアの歪みの発生を抑制することが可能となる。
　また、インシュレータをインサート成形する際に、樹脂柱も成形することで、作業工程を増やすこともなく、コストの増加を防ぐことが可能である。 As a result, a shrinkage force is also generated on the resin column side during cooling, and the occurrence of distortion of the stator core can be suppressed.
Further, when the insulator is insert-molded, the resin pillar is also molded, so that it is possible to prevent an increase in cost without increasing the work process.
本実施形態の、固定子の斜視図である。It is a perspective view of the stator of this embodiment. 本実施形態の、分割型の固定子コアの斜視図である。It is a perspective view of the split type stator core of this embodiment. 本実施形態の、固定子コアにインシュレータをインサート成形した状態の斜視図である。It is a perspective view in the state where insert molding of an insulator was carried out to a stator core of this embodiment. 本実施形態の、固定子コアにコイルを挿入した状態の斜視図である。It is a perspective view in the state where a coil was inserted in a stator core of this embodiment. 本実施形態の、固定子コアに樹脂モールド部を形成した状態の斜視図である。It is a perspective view in the state where the resin mold part was formed in the stator core of this embodiment. 本実施形態の、インシュレータをインサート成形する際の模式図である。It is a mimetic diagram at the time of insert-molding an insulator of this embodiment. 本実施形態の、固定子コアの概略斜視図である。It is a schematic perspective view of the stator core of this embodiment. 本実施形態の、固定子コアの概略断面図である。It is a schematic sectional drawing of the stator core of this embodiment. 本実施形態の、固定子コアの別の実施形態を表した斜視図である。It is a perspective view showing another embodiment of a stator core of this embodiment. 本実施形態の、固定子コアの別の実施形態を表した斜視図である。It is a perspective view showing another embodiment of a stator core of this embodiment. 本実施形態の、固定子コアの別の実施形態を表した斜視図である。It is a perspective view showing another embodiment of a stator core of this embodiment. 本実施形態の、固定子コアの別の実施形態を表した斜視図である。It is a perspective view showing another embodiment of a stator core of this embodiment. 固定子コアをカシメ接合によって連結する連結部分の模式断面図である。It is a schematic cross section of the connection part which connects a stator core by caulking joining. インシュレータを冷却する時に発生する収縮力を示した固定子コアの側面断面模式図である。It is the side surface cross-section schematic diagram of the stator core which showed the contractive force which generate | occur | produces when cooling an insulator.
　まず、本発明の実施形態について説明をする。
　図１に、本実施形態の固定子の斜視図を示す。なお、説明の都合上、固定子コアの細部は省略している。
　図２に、分割型の固定子コアの斜視図を示す。図３は、固定子コアにインシュレータをインサート成形した状態の斜視図である。図４は、固定子コアにコイルを挿入した状態の斜視図である。図５は、固定子コアに樹脂モールド部１１３を形成した状態の斜視図である。なお、図１とは説明の都合上細部が異なる。
　固定子１０は、分割型の固定子コア１１１を用いており、固定子コアユニット１１０を円環状に１８個配置し、外周にアウターリング１０２を嵌めることで形成されている。固定子１０のコイルエンドにはバスバホルダ１０１が備えられている。 First, an embodiment of the present invention will be described.
In FIG. 1, the perspective view of the stator of this embodiment is shown. For convenience of explanation, details of the stator core are omitted.
FIG. 2 is a perspective view of a split-type stator core. FIG. 3 is a perspective view of a state where an insulator is insert-molded into the stator core. FIG. 4 is a perspective view of a state where a coil is inserted into the stator core. FIG. 5 is a perspective view of a state where the resin mold portion 113 is formed on the stator core. It should be noted that details are different from FIG. 1 for convenience of explanation.
The stator 10 uses a split-type stator core 111, and is formed by arranging 18 stator core units 110 in an annular shape and fitting an outer ring 102 on the outer periphery. A bus bar holder 101 is provided at the coil end of the stator 10.
　固定子コア１１１は、図２に示すようにプレス加工により略Ｔ字状に形成された電磁鋼板１５０を複数枚積層して形成されている。積層の状況は図１３に示した通りである。
　固定子コア１１１は固定子１０の内周側に突出するようにティース部１１１ａを備えており、カシメ凹部１１１ｂで電磁鋼板１５０同士が固定されている。そして、ティース部１１１ａから固定子コア１１１の外周側に向けて沿設される外環部１１１ｃには、溝部１１１ｅが形成されている。溝部１１１ｅはプレス加工時に形成されたＶ字状の溝である。ティース部１１１ａにはインシュレータ１１４を備えた上でコイル１１２が挿入される。 As shown in FIG. 2, the stator core 111 is formed by laminating a plurality of electromagnetic steel plates 150 formed in a substantially T shape by press working. The state of lamination is as shown in FIG.
The stator core 111 includes a tooth portion 111a so as to protrude toward the inner peripheral side of the stator 10, and the electromagnetic steel plates 150 are fixed to each other by a caulking recess 111b. And the groove part 111e is formed in the outer ring part 111c provided along the outer peripheral side of the stator core 111 from the teeth part 111a. The groove 111e is a V-shaped groove formed at the time of pressing. A coil 112 is inserted into the tooth portion 111a after an insulator 114 is provided.
　インシュレータ１１４は、固定子コア１１１に対して図３に示されるようにインサート成形される。インシュレータ１１４は、鍔部１１４ａ、環状部１１４ｂ、コイル支持壁１１４ｃを備えており、絶縁性を有する樹脂で形成されている。
　インシュレータ１１４を形成する樹脂には、インシュレータ１１４とコイル１１２との絶縁性を確保する機能の他に、発熱したコイル１１２からの熱を固定子コア１１１側に熱伝達する必要がある。このためインシュレータ１１４には熱伝達性を高める目的でフィラーが混入されている。 The insulator 114 is insert-molded with respect to the stator core 111 as shown in FIG. The insulator 114 includes a flange portion 114a, an annular portion 114b, and a coil support wall 114c, and is formed of an insulating resin.
In addition to the function of ensuring insulation between the insulator 114 and the coil 112, the resin forming the insulator 114 needs to transfer heat from the heated coil 112 to the stator core 111 side. For this reason, the filler is mixed in the insulator 114 for the purpose of improving heat transferability.
　図６は、インシュレータをインサート成形する際の模式図である。
　固定子コア１１１は、可動型Ｄ１と固定型Ｄ２との間に配設されることで、可動型Ｄ１と固定子コア１１１との間にインシュレータ形成用キャビティＢ１及び樹脂柱形成用キャビティＢ２が形成される。このインシュレータ形成用キャビティＢ１及び樹脂柱形成用キャビティＢ２に溶融した樹脂を流し込み、冷却、離型することで、インシュレータ１１４及び樹脂柱１３０をインサート形成する。
　なお、図では省略しているが、インシュレータ形成用キャビティＢ１及び樹脂柱形成用キャビティＢ２には樹脂を供給するための湯口などが設けられている。また、インシュレータ形成用キャビティＢ１及び樹脂柱形成用キャビティＢ２には同じ樹脂が注入されるものとする。 FIG. 6 is a schematic view when insert-molding the insulator.
The stator core 111 is disposed between the movable mold D1 and the fixed mold D2, so that an insulator forming cavity B1 and a resin column forming cavity B2 are formed between the movable mold D1 and the stator core 111. Is done. The insulator 114 and the resin column 130 are insert-formed by pouring molten resin into the insulator forming cavity B1 and the resin column forming cavity B2, cooling, and releasing.
Although not shown in the figure, the insulator forming cavity B1 and the resin column forming cavity B2 are provided with a gate for supplying resin. The same resin is injected into the insulator forming cavity B1 and the resin column forming cavity B2.
　コイル１１２は矩形断面を有する平角導体をエッジワイズ曲げ加工して巻回されている。平角導体は、銅などの導電性の高い導体の周囲にエナメルなどの絶縁性の高い樹脂にて絶縁被覆したものである。コイル１１２のコイルエンドの片側には、外側端子部１１２ａと内側端子部１１２ｂが形成されており、図示しないバスバと接続される。コイル１１２は、図４に示すように固定子コア１１１に形成されるティース部１１１ａにインシュレータ１１４に挿入される。
　固定子コア１１１にコイル１１２が挿入された後、図５に示されるようにコイル１１２を覆うように樹脂モールド部１１３が形成される。 The coil 112 is wound by edgewise bending a rectangular conductor having a rectangular cross section. A flat conductor is a conductor having a high conductivity such as copper and is coated with an insulating resin such as enamel. On one side of the coil end of the coil 112, an outer terminal portion 112a and an inner terminal portion 112b are formed and connected to a bus bar (not shown). As shown in FIG. 4, the coil 112 is inserted into the insulator 114 in a tooth portion 111 a formed in the stator core 111.
After the coil 112 is inserted into the stator core 111, the resin mold portion 113 is formed so as to cover the coil 112 as shown in FIG.
　本実施形態の固定子１０は上記構成であるので、以下に説明する作用効果を奏する。
　まず、固定子コア１１１にインシュレータ１１４をインサート成形する際に、固定子コア１１１に発生する歪みを抑制することが可能である点が挙げられる。
　本実施形態の固定子１０は、導体を巻回して形成したコイル１１２と、電磁鋼板１５０を積層して形成されコイル１１２を挿入するティース部１１１ａを外環部１１１ｃから内周側に向けて突出して備える固定子コア１１１と、固定子コア１１１に挿入したコイル１１２のコイルエンド部分を樹脂で覆った樹脂モールド部１１３と、を備える固定子１０において、固定子コア１１１を構成する電磁鋼板１５０にはカシメ凹部１１１ｂが設けられ、カシメ凹部１１１ｂを用いて電磁鋼板１５０同士を連結することで固定子コア１１１が形成され、固定子コア１１１の外環部１１１ｃに、固定子コア１１１の軸方向と平行に溝部１１１ｅを備え、溝部１１１ｅに樹脂柱１３０が備えられているものである。 Since the stator 10 of this embodiment is the said structure, there exists an effect demonstrated below.
First, the point which can suppress the distortion which generate | occur | produces in the stator core 111 when insert-molding the insulator 114 to the stator core 111 is mentioned.
The stator 10 of this embodiment has a coil 112 formed by winding a conductor and a tooth portion 111a formed by laminating electromagnetic steel plates 150 and inserting the coil 112 protruding from the outer ring portion 111c toward the inner peripheral side. In the stator 10 including the stator core 111 provided and the resin mold portion 113 in which the coil end portion of the coil 112 inserted into the stator core 111 is covered with resin, the electromagnetic steel plate 150 constituting the stator core 111 is provided. Is formed with a caulking recess 111b, and the electromagnetic steel plates 150 are connected to each other using the caulking recess 111b, and the stator core 111 is formed on the outer ring portion 111c of the stator core 111 with the axial direction of the stator core 111. The groove 111e is provided in parallel, and the resin pillar 130 is provided in the groove 111e.
　図７に、固定子コアの概略斜視図を示す。なお、説明の都合上、インシュレータは省略してある。
　図８に、固定子コアの概略断面図を示す。
　固定子コア１１１は、電磁鋼板１５０が積層されて形成される。電磁鋼板１５０は、プレスで打ち抜かれると同時に、カシメ凹部１１１ｂが形成される。そして、プレス加工後、加圧しながら加工済みの電磁鋼板１５０と重ねられ、固定子コア１１１は図１３に示されるようにカシメ凹部１１１ｂで結合され、一体化される。なお、図２にはカシメ凹部１１１ｂは１カ所しか示されていないが、固定子コア１１１の大きさや必要強度によってはカシメ凹部１１１ｂを複数設けても良い。
　このように固定子コア１１１をカシメ加工によって結合すると、図１３に示すように電磁鋼板１５０同士の間に僅かな隙間ｄが発生してしまう。これは、課題にも示した通りカシメ凹部１１１ｂを用いて電磁鋼板１５０同士を結合している為であり、電磁鋼板１５０の板厚の関係でどうしても隙間ｄの発生は避けられない。 FIG. 7 shows a schematic perspective view of the stator core. Note that the insulator is omitted for convenience of explanation.
FIG. 8 shows a schematic cross-sectional view of the stator core.
Stator core 111 is formed by laminating electromagnetic steel plates 150. The electromagnetic steel sheet 150 is punched with a press, and at the same time, a caulking recess 111b is formed. Then, after press working, the stator core 111 is overlapped with the crimped recess 111b and integrated as shown in FIG. In FIG. 2, only one crimping recess 111b is shown, but a plurality of crimping recesses 111b may be provided depending on the size and required strength of the stator core 111.
When the stator core 111 is coupled by caulking as described above, a slight gap d is generated between the electromagnetic steel plates 150 as shown in FIG. This is because the electromagnetic steel plates 150 are coupled to each other using the caulking recess 111b as shown in the problem, and the generation of the gap d is unavoidable due to the thickness of the electromagnetic steel plates 150.
　そこで固定子コア１１１は、カシメ凹部１１１ｂにてカシメ加工された後、インシュレータ１１４をインサート成形すると同時に樹脂柱１３０を形成する。樹脂柱１３０は固定子コア１１１の外環部１１１ｃに形成される溝部１１１ｅに樹脂が流し込まれて形成されるものであり、隙間ｄにも若干樹脂が入り込むことで固定子コア１１１と密着し、一体化されて形成される。
　このように樹脂柱１３０が形成されることで、インシュレータ１１４の収縮によって発生する力に樹脂柱１３０が収縮する力で相殺される。結果、固定子コア１１１に生じる歪みの発生を抑制する事が可能となる。 Therefore, after the stator core 111 is crimped by the crimping recess 111b, the insulator 114 is insert-molded and the resin pillar 130 is formed at the same time. The resin column 130 is formed by pouring resin into a groove 111e formed in the outer ring portion 111c of the stator core 111, and is in close contact with the stator core 111 by slightly entering the resin into the gap d. It is formed integrally.
By forming the resin column 130 in this way, the force generated by the contraction of the insulator 114 is offset by the force by which the resin column 130 contracts. As a result, it is possible to suppress the occurrence of distortion that occurs in the stator core 111.
　この樹脂柱１３０の収縮力は、樹脂の種類や樹脂柱１３０の太さなどで決定される。収縮力変更には、樹脂柱１３０の材質を変更する方法も考えられるが、インシュレータ１１４と一緒に形成するメリットが損なわれるので、外環部１１１ｃの外周面１１１ｄに形成される溝部１１１ｅの位置を変更するという方法も考えられる。
　図９に、固定子コアの別の実施形態を表した斜視図を示す。
　例えば、図９に示すように外周面１１１ｄに形成される溝部１１１ｅを２カ所に増やすことで、樹脂柱１３０を２カ所に増やすことが可能となる。 The shrinkage force of the resin column 130 is determined by the type of resin, the thickness of the resin column 130, and the like. In order to change the contraction force, a method of changing the material of the resin column 130 is also conceivable, but since the merit of forming together with the insulator 114 is impaired, the position of the groove 111e formed on the outer peripheral surface 111d of the outer ring portion 111c is changed. A method of changing is also conceivable.
FIG. 9 is a perspective view showing another embodiment of the stator core.
For example, as shown in FIG. 9, the resin pillar 130 can be increased to two places by increasing the number of grooves 111e formed on the outer peripheral surface 111d to two.
　図１０に、固定子コアの別の実施形態を表した斜視図を示す。
　図１１に、固定子コアの別の実施形態を表した斜視図を示す。
　図１２に、固定子コアの別の実施形態を表した斜視図を示す。
　その他にも、分割型の固定子コア１１１の分割面に樹脂柱１３０を設けた図１０のようなパターンや、ティース部１１１ａの根本に樹脂柱１３０を設けた図１１の様なパターン、あるいは、スロット底部に樹脂柱１３０を設けた図１２の様なパターンが考えられる。
　いずれの場合にも、インシュレータ１１４の収縮により発生する力を相殺するために樹脂柱１３０が設けられる点では同じである。しかし、インシュレータ１１４の形状や厚みによって発生する収縮力に差異があるため、樹脂柱１３０の大きさだけでなく位置や形成数を工夫することで、効果的に収縮する力を相殺することが可能となる。 FIG. 10 is a perspective view showing another embodiment of the stator core.
FIG. 11 is a perspective view showing another embodiment of the stator core.
FIG. 12 is a perspective view showing another embodiment of the stator core.
In addition, the pattern as shown in FIG. 10 in which the resin pillar 130 is provided on the dividing surface of the split-type stator core 111, the pattern as shown in FIG. 11 in which the resin pillar 130 is provided at the root of the tooth portion 111a, or A pattern as shown in FIG. 12 in which a resin pillar 130 is provided at the bottom of the slot is conceivable.
In any case, it is the same in that the resin column 130 is provided to cancel the force generated by the contraction of the insulator 114. However, since there is a difference in the contraction force generated depending on the shape and thickness of the insulator 114, it is possible to offset the force that effectively contracts by devising not only the size of the resin pillar 130 but also the position and number of formation. It becomes.
　このように、インシュレータ１１４が収縮する力を相殺する力を生じる樹脂柱１３０を設けることで、固定子コアユニット１１０の固定子コア１１１の歪みを生じにくくすることが可能となる。
　固定子コアユニット１１０の歪みが生じにくくなることで、固定子１０の内周の真円度を確保しやすくなり、図示しない内周側に配置される回転子と固定子１０とのクリアランスを最小限に設定することができる。
　固定子１０と回転子のギャップは、固定子１０を用いるモータの出力や性能に影響するため、このギャップを狭くできることは望ましい。 Thus, by providing the resin column 130 that generates a force that cancels the contracting force of the insulator 114, it is possible to make it difficult for the stator core 111 of the stator core unit 110 to be distorted.
Since the distortion of the stator core unit 110 is less likely to occur, it becomes easy to ensure the roundness of the inner periphery of the stator 10, and the clearance between the rotor disposed on the inner periphery side (not shown) and the stator 10 is minimized. Can be set to the limit.
Since the gap between the stator 10 and the rotor affects the output and performance of the motor using the stator 10, it is desirable that the gap can be narrowed.
　以上、本実施形態に則して発明を説明したが、この発明は前記実施形態に限定されるものではなく、発明の趣旨を逸脱することのない範囲で構成の一部を適宜変更することにより実施することもできる。
　例えば、本実施形態では外環部１１１ｃやティース部１１１ａに形成する樹脂柱１３０を、図７及び図９乃至図１２に示しているが、あくまで例示であるのでこれに限定されるものではない。インシュレータ１１４に発生する力を相殺可能な位置、大きさに樹脂柱１３０を形成することを妨げないし、より固定子コア１１１に生じる磁力回路を阻害しない場所に樹脂柱１３０を配置することを妨げない。 Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.
For example, in this embodiment, the resin pillar 130 formed on the outer ring portion 111c and the tooth portion 111a is shown in FIGS. 7 and 9 to 12, but is not limited to this example because it is just an example. It does not prevent the resin column 130 from being formed in a position and size that can cancel the force generated in the insulator 114, and does not prevent the resin column 130 from being disposed in a place that does not hinder the magnetic circuit generated in the stator core 111. .
　また、本実施形態では、固定子コアユニット１１０は分割式のものとしているが、円環状の分割式でない固定子コアに樹脂柱１３０を設けることを妨げない。
　また、本実施形態で例示した材質は、その機能や用途を逸脱しない範囲で変更することを妨げない。
　また、樹脂柱１３０の形成のタイミングはインシュレータ１１４と同時にとしているが、先に何れか一つを形成することを妨げない。 Further, in this embodiment, the stator core unit 110 is of a split type, but it does not prevent the resin pillar 130 from being provided on an annular stator core.
In addition, the materials exemplified in the present embodiment do not preclude changing in a range that does not deviate from the function and application.
Moreover, although the formation timing of the resin pillar 130 is made simultaneously with the insulator 114, it does not prevent any one from being formed first.
１０　　　固定子
１０１　　　バスバホルダ
１０２　　　アウターリング
１１０　　　固定子コアユニット
１１１　　　固定子コア
１１１ａ　　　ティース部
１１１ｂ　　　カシメ凹部
１１１ｃ　　　外環部
１１１ｄ　　　外周面
１１１ｅ　　　溝部
１１２　　　コイル
１１２ａ　　　外側端子部
１１２ｂ　　　内側端子部
１１３　　　樹脂モールド部
１１４　　　インシュレータ
１１４ａ　　　鍔部
１１４ｂ　　　環状部
１１４ｃ　　　コイル支持壁
１３０　　　樹脂柱
１５０　　　電磁鋼板
Ｂ１　　　インシュレータ形成用キャビティ
Ｂ２　　　樹脂柱形成用キャビティ
Ｄ１　　　可動型
Ｄ２　　　固定型
Ｆ１　　　収縮力
Ｆ２　　　拡張力
ｄ　　　隙間 DESCRIPTION OF SYMBOLS 10 Stator 101 Bus bar holder 102 Outer ring 110 Stator core unit 111 Stator core 111a Teeth part 111b Caulking recessed part 111c Outer ring part 111d Outer surface 111e Groove part 112 Coil 112a Outer terminal part 112b Inner terminal part 113 Resin mold part 114 Insulator 114a 鍔Part 114b annular part 114c coil support wall 130 resin pillar 150 electromagnetic steel plate B1 insulator forming cavity B2 resin pillar forming cavity D1 movable mold D2 fixed mold F1 contraction force F2 expansion force d gap

Claims (2)

  1. 　導体を巻回して形成したコイルと、電磁鋼板を積層して形成され前記コイルを挿入するティースを外環部から内周側に向けて突出して備える固定子コアと、前記固定子コアに挿入した前記コイルのコイルエンド部分を樹脂で覆った樹脂モールド部と、を備える固定子において、
    　前記固定子コアを構成する前記電磁鋼板にはカシメ凹部が設けられ、
    　前記カシメ凹部を用いて前記電磁鋼板同士を連結することで前記固定子コアが形成され、
    　前記固定子コアの前記外環部又は前記ティースの根本部に、前記固定子コアの軸方向と平行に溝部を備え、
    　前記溝部に樹脂柱が備えられていることを特徴とする固定子。     A coil formed by winding a conductor, and a stator core formed by laminating electromagnetic steel plates and protruding from the outer ring portion toward the inner peripheral side, and inserted into the stator core. In a stator comprising a resin mold portion in which a coil end portion of the coil is covered with a resin,
    The magnetic steel sheet constituting the stator core is provided with a caulking recess,
    The stator core is formed by connecting the magnetic steel sheets using the caulking recesses,
    The outer ring portion of the stator core or the root portion of the teeth includes a groove portion in parallel with the axial direction of the stator core,
    A stator having a resin column in the groove.
  2. 　導体を巻回してコイルを形成し、前記コイルを積層された電磁鋼板からなる固定子コアに形成されたティースに挿入し、前記固定子コアの前記コイルエンド部分を樹脂で覆う樹脂モールド部を形成する、固定子製造方法において、
    　前記電磁鋼板に用いられたカシメ凹部を用いて前記電磁鋼板を積層して、前記固定子コアを形成し、
    　前記固定子コアを金型にセットし、
    　　インシュレータをインサート成形により前記ティースを覆うように形成すると共に、
    　　前記電磁鋼板の外環部又は前記ティースの根本部に前記固定子コアの軸方向と平行に備えられる溝部に、樹脂を流し込んで樹脂柱を形成することを特徴とする固定子製造方法。     A coil is formed by winding a conductor, and the coil is inserted into a tooth formed on a stator core made of laminated electromagnetic steel sheets to form a resin mold portion that covers the coil end portion of the stator core with resin. In the stator manufacturing method,
    Laminating the electromagnetic steel sheet using the caulking recess used in the electromagnetic steel sheet, forming the stator core,
    Set the stator core in a mold,
    While forming the insulator so as to cover the teeth by insert molding,
    A stator manufacturing method, wherein a resin column is formed by pouring resin into a groove provided in parallel to an axial direction of the stator core in an outer ring portion of the electromagnetic steel sheet or a root portion of the teeth.
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