CN112994306A

CN112994306A - Insulating sheet, stator and motor

Info

Publication number: CN112994306A
Application number: CN202011381231.3A
Authority: CN
Inventors: 桧皮隆宏; 岩永贤勇朗
Original assignee: Nidec Corp
Current assignee: Nidec Corp
Priority date: 2019-12-02
Filing date: 2020-12-01
Publication date: 2021-06-18
Also published as: JP2021090242A

Abstract

The invention provides an insulating sheet, a stator and a motor. The insulating sheet has: a pair of insulating members for electrically insulating the coil portions from each other; and a connecting member formed of a member different from the pair of insulating members, for connecting the pair of insulating members to each other. The coupling member extends in a1 st direction. The insulating member is provided with a1 st groove portion. The connecting member is provided with a2 nd groove portion to be fitted with the 1 st groove portion.

Description

Insulating sheet, stator and motor

Technical Field

The invention relates to an insulating sheet, a stator and a motor.

Background

Conventionally, in motors mounted on electric vehicles, hybrid vehicles, and the like, an insulating sheet is provided to insulate coil ends of coil portions provided in a stator. The insulating sheet often includes a pair of insulating portions for insulating the coil end portions and a connecting portion for connecting the pair of insulating portions to each other (see, for example, patent document 1).

Patent document 1: japanese Kokai publication Sho 58-83964

Here, it is a current problem to improve both the yield in obtaining an insulating sheet from a raw material and the assemblability of the insulating sheet.

Disclosure of Invention

In view of the above circumstances, an object of the present invention is to provide an insulating sheet capable of improving yield and assemblability.

An exemplary insulating sheet of the present invention includes: a pair of insulating members for electrically insulating the coil portions from each other; and a connecting member formed of a member different from the pair of insulating members, for connecting the pair of insulating members to each other. The coupling member extends in a1 st direction. The insulating member is provided with a1 st groove portion. The connecting member is provided with a2 nd groove portion to be fitted with the 1 st groove portion.

According to the exemplary insulating sheet of the present invention, yield and assemblability can be improved.

Drawings

Fig. 1 is a sectional view of an electric drive device according to an embodiment.

Fig. 2 is a perspective view of one axial end of the stator.

Fig. 3 is a perspective view of the stator core.

Fig. 4 is a flowchart for explaining an example of the stator manufacturing method.

Fig. 5 shows an example of a coil portion formed in the stator manufacturing process.

Fig. 6 is a diagram showing a state in which slot paper and an insulating sheet are assembled to a stator core.

Fig. 7 shows an example of an axial end portion of the stator before the coil end portion is pressed in the stator manufacturing process.

Fig. 8 is a plan view of the insulation sheet according to embodiment 1 in an exploded state.

Fig. 9 is a plan view of the assembled insulating sheet of embodiment 1.

Fig. 10A is a view showing an example of a sheet material as a material of an insulating sheet.

Fig. 10B is a view showing another example of a sheet material as a raw material of the insulating sheet.

Fig. 11 is an enlarged plan view of the insulating member according to embodiment 1.

Fig. 12 is a partially enlarged plan view of the coupling member according to embodiment 1.

Fig. 13 is a main part enlarged plan view showing a state where the coupling member is brought close to the insulating member in embodiment 1.

Fig. 14 is an enlarged plan view of a main portion of the front side showing a connection portion between the insulating member and the connecting member according to embodiment 1.

Fig. 15 is a main part enlarged plan view showing a back side of a connection portion between the insulating member and the connecting member according to embodiment 1.

Fig. 16 is a main part enlarged plan view showing a claw part of an insulating member according to embodiment 1.

Fig. 17 is a diagram showing a positional relationship of the coil part with respect to the insulating member in embodiment 1.

Fig. 18 is a partial plan view of the insulation sheet according to embodiment 2 in an exploded state.

Fig. 19 is a partial plan view of the insulation sheet according to embodiment 3 in an exploded state.

Fig. 20 is a partial plan view of the insulation sheet according to embodiment 4 in an exploded state.

Fig. 21 is a partial plan view of the insulation sheet according to embodiment 5 in an exploded state.

Description of the reference symbols

100: a motor; 11: a rotor; 110: a shaft; 111: a rotor core; 112: a magnet; 12: a stator; 121: a stator core; 122: a coil section; 122 u: a U-phase coil section; 122 v: a V-phase coil section; 122 w: a W-phase coil section; 1221: a coil end; 1222: a straight portion; 123(1231, 1232, 1233, 1234, 1235): an insulating sheet; 1. 1A, 1B: a connecting member; 1A1, 1B 1: a2 nd groove part; 11(11A, 11B): a leg portion; 111: a2 nd groove part; 111A, 111B: a groove edge; 111C: a bottom; 12(12A, 12B): a connecting portion; 12A 1: a recess; 2(2A, 2B): an insulating member; 2A 1: opposed edges; 20: a base; 21: a1 st claw part; 21A: an inclined edge portion; 22: a2 nd claw portion; 22A: a protrusion portion; 23. 231A, 231B: a1 st groove part; 23A, 23B: a groove edge; 23C: a bottom; 24: a recess; 25: a recess; 26: a1 st groove part; 27: an insertion portion; h: a recess; 124: a binding member; 125: grooving paper; s: a groove; 400: a housing; 401: a motor housing; 402: a reduction housing; 700: an electric drive device; dx: the 1 st direction; dx 1: the 1 st direction side; dx 2: the other side in the 1 st direction; dy: a2 nd direction; dy 1: the 2 nd direction side; dy 2: the other side of the 2 nd direction.

Detailed Description

Hereinafter, exemplary embodiments will be described with reference to the drawings.

In the present description, a direction parallel to the central axis CA of the motor 100 in the electric drive device 700 is referred to as an "axial direction". In the axial direction, a direction from a2 nd shaft 110b to a1 st shaft 110a, which will be described later, is referred to as "one axial side", and a direction from the 1 st shaft 110a to the 2 nd shaft 110b is referred to as "the other axial side". In each component, the end on the one axial side is referred to as "end on one axial side". The other end in the axial direction is referred to as "the other end in the axial direction".

A direction perpendicular to the center axis CA is referred to as a "radial direction", and a rotational direction around the center axis CA is referred to as a "circumferential direction". In the radial direction, a direction approaching the center axis CA is referred to as "radially inner side", and a direction away from the center axis CA is referred to as "radially outer side". In each constituent element, the radially inner end is referred to as a "radially inner end". Further, the radially outer end is referred to as a "radially outer end". Among the side surfaces of the respective components, the side surface facing radially inward is referred to as a "radially inner side surface", and the side surface facing radially outward is referred to as a "radially outer side surface".

In the present specification, the term "annular" includes not only a shape continuously connected without a slit over the entire circumference of the circumferential direction around the central axis CA, but also an arc shape having a slit over a part of the entire circumference around the central axis CA.

The above-described matters are not strictly applied when incorporated into an actual apparatus.

< 1. Structure of electric drive device

The electric drive device 700 according to the embodiment is mounted on a vehicle having the motor 100 as a drive source, such as a Hybrid Electric Vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or an Electric Vehicle (EV), and is used as a drive source for rotationally driving wheels of the vehicle. Fig. 1 is a sectional view of an electric drive device 700 according to an embodiment. Fig. 1 shows a cross-sectional structure of the electric drive device 700 cut on a virtual plane including the central axis CA of the motor 100.

As shown in fig. 1, electric drive device 700 includes motor 100, reduction gear unit 200, a differential gear unit (not shown), and case 400. The housing 400 has: a motor case 401 that houses the motor 100; a reduction housing 402 that houses the reduction gear 200; and a differential case (not shown) that houses the differential device. The motor 100 is driven by three-phase alternating current. The reduction gear unit 200 is connected to the motor 100, and increases the torque transmitted from the motor 100 at a predetermined reduction ratio and transmits the torque to the differential gear unit. The differential device is connected to the motor 100 via the reduction gear 200, and transmits the torque transmitted from the reduction gear 200 to the wheels.

< 2. Structure of motor

As shown in fig. 1, the motor 100 has a rotor 11 and a stator 12.

The rotor 11 is provided radially inward of the stator 12 and is rotatable in the circumferential direction about the center axis CA. The rotor 11 includes a shaft 110, a rotor core 111, and a magnet 112.

The shaft 110 is a rotation shaft of the rotor 11. The shaft 110 is rotatably supported by the motor housing 401 via a bearing (reference numeral omitted). The shaft 110 has a1 st shaft 110a, a2 nd shaft 110b, and a1 st gear portion 110 c. The 1 st shaft 110a and the 2 nd shaft 110b are hollow cylinders extending in the axial direction. The other axial end of the 1 st shaft 110a is connected to one axial end of the 2 nd shaft 110 b. The 1 st gear portion 110c is a gear that meshes with the 2 nd gear portion 210 of the reduction gear transmission 200, and transmits the driving force of the motor 100 to the reduction gear transmission 200. The 1 st gear portion 110c is provided on a radially outer side surface of the 2 nd shaft 110 b. The 2 nd shaft 110b protrudes from the motor housing 401 to the other side in the axial direction. Therefore, the other axial side portion of the 2 nd shaft 110b and the 1 st gear portion 110c are housed in the reduction case 402.

The rotor core 111 is an annular magnetic body centered on the central axis CA, and in the present embodiment, is a laminated body in which a plurality of plate-shaped electromagnetic steel plates are laminated. The rotor core 111 is fixed to a radially outer surface of the 1 st shaft 110 a. The rotor core 111 has a plurality of through holes 1111 that penetrate the rotor core 111 in the axial direction. The through holes 1111 are arranged at intervals in the circumferential direction.

The magnet 112 includes a plurality of magnet pieces (not shown). Each magnet piece is shaped like a flat plate extending in a direction perpendicular to the radial direction, and is held in each through hole 1111 of the rotor core 111. In other words, the magnet pieces are arranged at intervals in the circumferential direction.

The stator 12 drives the rotor 11 to rotate. The stator 12 is annular with a center axis CA as a center. Fig. 2 is a perspective view of one axial end of the stator 12.

The stator 12 includes a stator core 121, a coil portion 122, an insulating sheet 123, a binding member 124, a slot sheet 125 (shown in fig. 6 described later), and a pressing member (not shown).

Fig. 3 is a perspective view of the stator core 121. In fig. 3, for the purpose of explaining the arrangement of the coil part 122 to the slots S of the stator core 121, a U-phase coil part 122U, a V-phase coil part 122V, and a W-phase coil part 122W are schematically illustrated. However, the coil part 122 shown in fig. 3 is a part of the coil part 122 actually provided.

The stator core 121 is an annular magnetic body centered on the central axis CA, and is a laminated body in which a plurality of plate-shaped electromagnetic steel plates are laminated in the present embodiment. As shown in fig. 3, stator core 121 has an annular core back 1211, a plurality of teeth 1212, and a plurality of slots S.

The plurality of teeth 1212 extend radially inward from the radially inner end portion of the core back 1211 and are arranged in the circumferential direction. A plurality of grooves S are provided between circumferentially adjacent teeth. The plurality of slots S are provided at the radially inner end portion of the annular stator core 121 and arranged in the circumferential direction.

Each cell S accommodates a slot sheet 125 made of an insulating material and a linear portion 1222 of the coil portion 122 (see fig. 5 described later). The linear portion 1222 is received in the slot paper 125. At the radially inner end of each of the cells S, a strip-shaped pressing member extending in the axial direction is disposed radially inward of the linear portion 1222 of the coil portion 122 in the cell S so that the lead of the coil portion 122 does not protrude from the cell S.

Each coil portion 122 is provided so as to straddle between different cells S. In the present embodiment, the plurality of coil portions 122 are wound in a single-layer overlapping manner so as to be distributed. More specifically, the coil portion 122 includes a U-phase coil portion 122U, a V-phase coil portion 122V, and a W-phase coil portion 122W. The

coil portions

122u, 122v, and 122w of the respective phases are Y-connected in the present embodiment. The coil portions 122 of the same phase are electrically connected via bonding wires or bus bars, not shown. The coil portions 122 of the same phase are stored in the separate cells S across the plurality of cells S storing the coil portions 122 of the other 2 phases by the distributed winding method. Further, the coil portions 122 of the same phase are housed in the respective cells S by single-layer lap winding. In other words, the coil portions 122 of different phases are not housed in the same cell S.

For example, in the present embodiment, one straight line portion 1222 of one coil portion 122 of the same phase is housed in each of two slots S arranged in the circumferential direction. For example, in the slots S1 to S16 aligned toward the circumferential one side in fig. 3, the straight portion 1222 of one U-phase coil portion 122U of the two U-phase coil portions 122U is housed in the slots S16 and S9 across the slots S15 to S10. Further, the straight portion 1222 of the other U-phase coil portion 122U of the two U-phase coil portions 122U is received in the grooves S15 and S10 across the grooves S14 to S11. Further, the straight portion 1222 of one V-phase coil portion 122V of the two V-phase coil portions 122V is housed in the grooves S12 and S5 across the grooves S11 to S6. Further, the straight portion 1222 of the other V-phase coil portion 122V of the two V-phase coil portions 122V is housed in the grooves S11 and S6 across the grooves S10 to S7. Further, the straight portion 1222 of one of the two W-phase coil portions 122W is housed in the grooves S8 and S1 across the grooves S7 to S2. Further, the straight portion 1222 of the other W-phase coil portion 122W of the two W-phase coil portions 122W is housed in the grooves S7 and S2 across the grooves S6 and S3. The linear portions 1222 of the coil portions 122 of the respective phases are similarly housed in the other plurality of cells S.

In the present embodiment, a round wire having a circular cross-sectional shape is used as the conductive wire of the coil portion 122. However, the present invention is not limited to this example, and a wire having a cross-sectional shape other than a circle may be used. For example, the cross-sectional shape of the wire may be a polygonal shape such as a rectangle or a hexagon.

Each coil portion 122 has a coil end 1221. The coil end 1221 is a portion of the coil portion 122 that protrudes from the slot S to the outside, and is provided on one axial side of an end of the stator core 121 on one axial side and on the other axial side of the end of the stator core 121 on the other axial side.

The insulating sheet 123 is provided to electrically insulate the different coil portions 122 from each other. The insulating sheet 123 is so-called interphase insulating paper, and is configured by, for example, attaching a nonwoven fabric to both surfaces of a plate-shaped thin resin plate. The structure of the insulating sheet 123 will be described in detail later.

The binding member 124 is in the form of an insulating rope, and binds the conductive wires of the coil end 1221.

< 3. method for manufacturing stator

Next, a method of manufacturing the stator 12 will be described. Fig. 4 is a flowchart for explaining an example of the method for manufacturing the stator 12.

First, a wire is wound around a jig having a longitudinal direction to form a coil shape, thereby molding the coil portion 122 (S101). In the present embodiment, half of the total number of the cells S of the coil portion 122 is molded. The coil portion 122 is shaped, for example, as shown in fig. 5, to have a coil end 1221 having both ends in the longitudinal direction and a pair of linear portions 1222 extending in the longitudinal direction. The pair of linear portions 1222 includes a1 st linear portion 1222a and a2 nd linear portion 1222 b. At this time, as shown in fig. 5, the coil shape of each coil portion 122 perpendicular to the extension direction dL is formed into a hexagonal shape having a longitudinal direction in the present embodiment. However, the coil shape is not limited to this example, and may be, for example, an elliptical shape having a longitudinal direction.

Next, the slot paper 125 is attached to the stator core 121 (S102). At this time, the slot sheet 125 is inserted into the slot S. Here, fig. 6 shows a state where the slot sheet 125 is inserted into the slot S. As shown in fig. 6, the slot sheet 125 extends in the axial direction, and has a shape that is bent along the inner wall of the slot S and opened toward the radially inner side. The notch sheet 125 projects from the notch S toward one axial side and the other axial side.

Next, the insulating sheet 123 is attached to the stator core 121 (S103). Here, as shown in fig. 9 described later, the insulating sheet 123 includes a pair of insulating members 2(2A, 2B) and a coupling member 1 that couples the pair of insulating members 2 to each other. The connecting member 1 has a pair of leg portions 11(11A, 11B). When the insulating sheet 123 is attached to the stator core 121, as shown in fig. 6, the leg portions 11 of the insulating sheet 123 are inserted into the slot paper 125. That is, the coupling member 1 is disposed in the groove S.

In the present embodiment, as shown in fig. 7, the leg portions 11 of the respective insulation sheets 123 are inserted in order with two slots S in the circumferential direction. One leg 11 and the other leg 11 of the two legs 11 are inserted into respective slots S which are arranged consecutively in the circumferential direction and which receive the linear portions 1222 of the coil portions 122 in the same phase, respectively. For example, among the slots S1 to S16 arranged continuously in the circumferential direction, the respective leg portions 11 of the same insulating sheet 123 are inserted into the slots S3 and S4. The respective legs 11 of the same insulating sheet 123 are also inserted in the slots S7 and S8, S11 and S12, S15 and S16, and the like.

Next, two coil portions 122 of the same phase are sequentially mounted on stator core 121. First, the linear portions 1222 of the two coil portions 122 of the same phase are arranged at the same circumferential position as the groove S at positions radially inward of the groove S in which the linear portions 1222 are accommodated (S104). At this time, the linear portions 1222 are aligned so as to be received in the corresponding grooves S as shown in fig. 3. For example, in the case of two U-phase coil units 122U, the two straight line units 1222 of one U-phase coil unit 122U of the two U-phase coil units 122U are arranged at the same circumferential positions as the slots S16 and S9 at positions radially inward of the slots S16 and S9, respectively, while focusing on the slots S1 to S16 in fig. 3. Each straight line portion 1222 of the other U-phase coil portion 122U of the two U-phase coil portions 122U is arranged at the same circumferential position as the slots S15 and S10 at a position radially inward of the slots S15 and S10, respectively.

Then, each linear portion 1222 is pressed radially outward and inserted into the corresponding groove S (S105). Thus, the coil portions 122 are provided so as to extend between the different cells S (see fig. 3). For example, when focusing on the explanation of the cells S1 to S16 of fig. 3, in the case of two U-phase coil sections 122U, the respective straight sections 1222 of one U-phase coil section 122U of the two U-phase coil sections 122U are inserted into the cells S16 and S9, and the respective straight sections 1222 of the other U-phase coil section 122U are inserted into the cells S15 and S10.

Next, when all the coil parts 122 are not mounted on the stator core 121 (no in S106), the linear parts 1222 of the two coil parts 122 of the other phase adjacent to each other in the circumferential direction are arranged at the same circumferential position as the slot S at positions radially inward of the slot S in which the linear part 1222 is housed (S107). At this time, the linear portions 1222 are also arranged so as to be received in the corresponding grooves S as shown in fig. 3. For example, when the explanation is focused on the slots S1 to S16 in fig. 3, in the case where the straight sections 1222 of the two U-phase coil sections 122U are inserted in step S105, the straight sections 1222 of one V-phase coil section 122V of the two V-phase coil sections 122V are arranged at the same circumferential positions as the slots S12 and S5 at positions radially inward of the slots S12 and S5, respectively. Each straight line portion 1222 of the other V-phase coil portion 122V of the two V-phase coil portions 122V is arranged at the same circumferential position as the slots S11 and S6 at a position radially inward of the slots S11 and S6, respectively. Alternatively, when the straight portions 1222 of the two V-phase coil portions 122V are inserted in step S105, each straight portion 1222 of one W-phase coil portion 122W of the two W-phase coil portions 122W is arranged at the same circumferential position as the slots S8 and S1 at a position radially inward of the slots S8 and S1, respectively. Each straight line portion 1222 of the other W-phase coil portion 122W of the two W-phase coil portions 122W is arranged at the same circumferential position as the slots S7 and S2 at a position radially inward of the slots S7 and S2, respectively.

Then, each linear portion 1222 is pressed radially outward and inserted into the corresponding groove S (S108). Thus, the coil portions 122 are provided so as to extend between the different cells S (see fig. 3). For example, when focusing on the explanation of the cells S1 to S16 of fig. 3, in the case of two V-phase coil sections 122V, the straight section 1222 of one V-phase coil section 122V of the two V-phase coil sections 122V is inserted into the cells S12 and S5, and the straight section 1222 of the other V-phase coil section 122V is inserted into the cells S11 and S6. Alternatively, in the case of two W-phase coil sections 122W, the straight section 1222 of one 122W-phase coil section of the two W-phase coil sections 122W is inserted into the slots S8 and S1, and the straight section 1222 of the other 122W-phase coil section is inserted into the slots S7 and S2.

Next, when all the coil portions 122 are mounted on the stator core 121 (yes in S106), a band-shaped pressing member is axially inserted into each slot S (S109). Further, the pressing member 109 is provided inside the groove S in the radial direction more inward than the linear portion 1222 and the leg portion 11. The pressing member prevents the linear portion 1222 (i.e., the wire) and the leg portion 11 from being exposed from the groove S.

Next, the insulating member 2 of the insulating sheet 123 is sandwiched between the coil end portions 1221 of the coil portions 122 of different phases adjacent in the circumferential direction (S110). That is, the insulating member 2 insulates between the coil ends 1221 of the different coil portions 122 protruding from the slots S to the outside at both ends in the axial direction of the stator 12.

For example, as shown in fig. 7, the insulating member 2 of the insulating sheet 123 with the leg portions 11 inserted into the slots S7 and S8 is sandwiched between the coil end 1221 of the W-phase coil portion 122W and the coil end 1221 of the V-phase coil portion 122V. In addition, the insulating member 2 of the insulating sheet 123 with the leg portions 11 inserted into the slots S10 and S11 is sandwiched between the coil end 1221 of the V-phase coil portion 122V and the coil end 1221 of the U-phase coil portion 122U.

Next, the coil end 1221 having the insulating member 2 provided between the different coil ends 1221 is pressed in the axial direction (S111). That is, the coil end 1221 on one axial side of the stator 12 is pressed toward the other axial side together with the one insulating member 2, and is molded so that the axial height is reduced. The coil end 1221 on the other axial side of the stator 12 is pressed toward the one axial side together with the other insulating member 2, and is molded so that the axial height is reduced.

Next, in order to prevent the wire of the coil end 1221 from being scattered, the pressed coil end 1221 is bundled together with the insulating member 2 by the bundling member 124 (S112: see fig. 2), and the coil end is impregnated with an insulating varnish (S113).

< 4. embodiment 1 of the insulating sheet

Next, the structure of the insulating sheet 123 will be described in detail. In the following, for each embodiment of the insulating sheet 123, the reference numerals of the embodiment are given to the reference numeral 123 for convenience. In addition, a structure in which the insulating sheet 123 is developed in a planar state will be described below, and in a state in which the insulating sheet 123 is developed in a planar state, a direction in which the coupling member 1 extends will be referred to as a "1 st direction dx", and a direction parallel to the plate-shaped insulating member 2 and perpendicular to the 1 st direction dx will be referred to as a "2 nd direction dy". In addition, in the 1 st direction dx, one side is illustrated as dx1, the other side is illustrated as dx2, and in the 2 nd direction dy, one side is illustrated as dy1, and the other side is illustrated as dy 2.

Fig. 8 is a plan view showing an exploded state of the insulating sheet 1231 of embodiment 1. Fig. 9 is a plan view showing an assembled state of the insulating sheet 1231 of embodiment 1.

As shown in fig. 8 and 9, the insulating sheet 1231 includes a pair of insulating members 2 and a coupling member 1. As described above, the pair of insulating members 2 are used to insulate the coil ends 1221 of the different coil portions 122 from each other. That is, the insulating sheet 1231 has a pair of insulating members 2 for electrically insulating the coil portions 122 from each other. The connecting member 1 is formed of a member different from the pair of insulating members 2, and connects the pair of insulating members 2 to each other.

The pair of insulating members 2 includes an insulating member 2A disposed on one side in the 1 st direction and an insulating member 2B disposed on the other side in the 1 st direction. Since the coupling member 1 is formed of a member different from the pair of insulating members 2, three sets of the pair of insulating

members

2A and 2B and three coupling members 1 can be taken out from one sheet SH1 as a raw material, as shown in fig. 10A, for example. In this case, three insulating sheets 1231 can be produced. Alternatively, for example, as shown in fig. 10B, three sets of a pair of insulating

members

2A and 2B may be obtained from a sheet SH11 as a raw material, and three connecting members 1 may be obtained from a sheet SH12 different from the sheet SH 11. As described above, in the present embodiment, the number of insulating sheets 1231 that can be produced from the same sheet as the raw material can be increased as compared with a configuration in which the pair of insulating members and the coupling member are formed of one member, and therefore, the yield can be improved.

The connecting member 1 includes a leg portion 11A and a leg portion 11B as a pair of leg portions 11, the leg portion 11A being disposed on one side in the 2 nd direction and extending in the 1 st direction, and the leg portion 11B being disposed on the other side in the 2 nd direction and extending in the 1 st direction. The coupling member 1 includes a coupling portion 12A and a coupling portion 12B as a pair of coupling portions 12, the coupling portion 12A being disposed on one side in the 1 st direction, and the coupling portion 12B being disposed on the other side in the 1 st direction. The connecting portion 12A connects the 1 st direction one end portions of the

leg portions

11A, 11B to each other, and the connecting portion 12B connects the 1 st direction other end portions of the

leg portions

11A, 11B to each other. That is, the coupling member 1 includes two leg portions 11 extending in the 1 st direction and a coupling portion 12 coupling the 1 st direction end portions of the leg portions 11 to each other.

The other end in the 1 st direction of the insulating member 2A is connected to the one end in the 1 st direction of the connecting member 1, and the one end in the 1 st direction of the insulating member 2B is connected to the other end in the 1 st direction of the connecting member 1. That is, the 1 st direction end of the insulating member 2 is connected to the 1 st direction end of the connecting member 1.

Here, as shown in fig. 9, the insulating sheet 1231 has a shape line-symmetrical in the 1 st direction with respect to the center line C1, wherein the center line C1 extends in the 2 nd direction and passes through the 1 st direction center position of the insulating sheet 1231. Therefore, for convenience of explanation, the following typically describes the structure on the 1 st direction side (insulating member 2A side) with respect to the center line C1.

Fig. 11 is an enlarged plan view of the insulating member 2A. The insulating member 2A is extended in a plane shape in the 1 st direction and the 2 nd direction. The insulating member 2A has a base portion 20, a pair of 1 st claw portions 21, and a pair of 2 nd claw portions. The pair of 1 st claw portions 21 and the pair of 2 nd claw portions 22 are formed to protrude from the other end portion in the 1 st direction of the base portion 20 to the other side in the 1 st direction. That is, the insulating member 2 has a

base portion

20 and 1 st and 2

nd claw portions

21 and 22 protruding from the base portion 20 toward the coupling member 1 side in the 1 st direction.

As shown in fig. 11, the base portion 20 has inclined

edge portions

201, 202, 203, 204. The inclined edge portion 201 extends from the 1 st direction one end portion of the base portion 20, and is inclined toward the 2 nd direction other side toward the 1 st direction other side. By forming the inclined edge portion 201 in a shape in which the corner portion of the base portion 20 is cut off, when the insulating member 2A is sandwiched between the coil portions 122, the portion of the insulating member 2A exposed from the coil end 1221 can be reduced.

The inclined edge portion 202 extends from the other end portion in the 1 st direction of the inclined edge portion 201, and is inclined toward the other side in the 1 st direction toward the one side in the 2 nd direction. By forming the inclined edge portion 202 in a shape in which the corner portion of the base portion 20 is cut off, interference between the insulating member 2A and the paper 125 can be suppressed when the insulating member 2A is sandwiched between the coil portions 122.

The inclined edge portion 203 extends from the 1 st direction side end portion of the base portion 20 and is inclined toward the 2 nd direction side as it goes toward the 1 st direction side. By forming the inclined edge portion 203 in a shape in which the corner portion of the base portion 20 is cut off, the insulating member 2A can be reduced in the portion exposed from the coil end 1221 in a state (fig. 2) in which the coil end 1221 is pressed after the insulating member 2A is sandwiched between the coil portions 122.

The inclined edge portion 204 extends from the 2 nd direction one end portion of the base portion 20, and is inclined toward the 2 nd direction other side as it goes toward the 1 st direction other side. By forming the inclined edge portion 204 in a shape in which the corner portion of the base portion 20 is cut off, interference between the insulating member 2A and the paper 125 can be suppressed when the insulating member 2A is sandwiched between the coil portions 122.

As shown in fig. 11, a pair of 1 st groove portions 23 are formed between the 1 st claw portion 21 and the base portion 20 and between the 2 nd claw portion 22 and the base portion 20. The 1 st groove 23 is also regarded as a recess, and the same applies to other grooves described below. That is, the 1 st groove portion 23 is formed by being sandwiched between the 1 st claw portion 21 and the 2 nd claw portion 22 and the base portion 20. Each of the grooves constituting the pair of 1 st grooves 23 is recessed in a direction away from each other in the 2 nd direction. Two of the pair of 1 st groove portions 23 are arranged in the 2 nd direction. Here, as shown in fig. 13 described later, the 1 st groove portion 23 includes: a groove edge 23A disposed on the other side in the 1 st direction among edges facing in the 1 st direction; a groove edge 23B disposed on the 1 st direction side among edges facing in the 1 st direction; and a bottom portion 23C connecting the groove edges 23A, 23B. That is, the 1 st groove 23 has a groove edge 23A, and the groove edge 23A is disposed on the connecting member 1 side among edges facing in the 1 st direction.

As described above, in the present embodiment, the 1 st groove portion 23 is provided at the end portion of the insulating member 2 on the connecting member 1 side in the 1 st direction.

Fig. 12 is an enlarged plan view of the coupling member 1 on the 1 st direction side. As shown in fig. 12, a pair of 2 nd groove portions 111 are formed at one end in the 1 st direction of a portion of leg 11A of the pair of legs 11, which is a portion connected to connecting portion 12A. The 2 nd groove portion 111 is relatively recessed in the 2 nd direction.

As shown in fig. 12, the coupling member 1 has a shape that is line-symmetrical in the 2 nd direction with respect to a center line C2 of the coupling member 1 extending in the 1 st direction. Thus, the pair of 2 nd groove portions 111 are also formed at the 1 st direction one end portions of the leg portion 11B of the pair of leg portions 11.

Here, as shown in fig. 13 described later, the 2 nd groove portion 111 includes: a groove edge 111A disposed on the 1 st direction side among edges facing in the 1 st direction; a groove edge 111B disposed on the other side in the 1 st direction among edges facing in the 1 st direction; and a bottom 111C connecting the groove edges 111A, 111B.

The pair of 2 nd groove portions 111 of the leg portion 11A are fitted to the pair of 1 st groove portions 23 on one side in the 2 nd direction of the insulating member 2A, the pair of 2 nd groove portions 111 of the leg portion 11B are fitted to the pair of 1 st groove portions 23 on the other side in the 2 nd direction of the insulating member 2A, and the coupling member 1 is coupled to the insulating member 2A.

That is, the connecting member 1 is provided with the 2 nd groove portion 111 to be fitted with the 1 st groove portion 23. Since the groove has an opening with a part of its edge opened, unlike the through hole, the connecting member 1 is assembled to the insulating member 2A so that the openings of the grooves are fitted to each other when the 1 st groove 23 and the 2 nd groove 111 are fitted to each other. Thus, when the insulating sheet is assembled, the 1 st groove portion 23 and the 2 nd groove portion 111 are easily fitted to each other even when the groove portions are displaced from each other, as compared with a structure in which the connecting member is assembled to the insulating member by inserting the projection formed on the connecting member into the insertion hole formed on the insulating member. That is, the assembly property of the insulating sheet 123 can be improved.

A method of connecting the insulating member 2A and the connecting member 1 will be described more specifically with reference to fig. 13 to 15. Fig. 13 is an enlarged view of a main portion showing a state where the coupling member 1 is brought close to the insulating member 2A for coupling with the insulating member 2A.

As shown in fig. 13, the pair of 1 st claw portions 21 and the pair of 2 nd claw portions 22 are line-symmetric in the 2 nd direction with respect to an axis C3 extending in the 1 st direction. The pair of 1 st claw portions 21 are disposed inside the pair of 2 nd claw portions 22.

The 1 st claw portion 21 has an inclined edge portion 21A. The inclined edge 21A is inclined toward the 1 st direction side as it goes toward the 2 nd claw 22 side. That is, the 1 st claw portion 21 has an inclined edge portion 21A, and the inclined edge portion 21A is inclined toward the 2 nd claw portion 22 side toward the opposite side of the coupling member 1 side in the 1 st direction.

The 2 nd claw portion 22 has a projection 22A, and the projection 22A projects toward the 1 st claw portion 21 side in the 2 nd direction.

In the assembling step of coupling the coupling member 1 and the insulating member 2A, the insulating member 2A is bent such that both end portions of the insulating member 2A in the 2 nd direction are positioned on the front side of the sheet of fig. 13, and the central portion of the insulating member 2A in the 2 nd direction is positioned on the back side of the sheet of fig. 13. In the state where insulating member 2A is thus bent, groove edge 111B of outer 2 nd groove 111 of the pair of 2 nd grooves 111 is hooked on protrusion 22A located on the front side. Since the pair of 2 nd claw portions 22 are disposed outside the pair of 1 st claw portions 21, the 2 nd groove portion 111 is easily hooked to the 2 nd claw portions 22 in a state where the insulating member 2A is bent as described above.

Then, the groove edge 111B of the inner 2 nd groove 111 of the pair of 2 nd grooves 111 is brought into contact with the inclined edge 21A of the 1 st claw 21, and the connecting member 1 is press-fitted to the insulating member 2A side. At this time, the coupling member 1 is easily press-fitted due to the inclination of the inclined edge portion 21A.

As described above, the coupling member 1 is assembled to the insulating member 2A by press-fitting the coupling member 1, and fitting the pair of 2 nd groove portions 111 and the pair of 1 st groove portions 23. Fig. 14 is an enlarged view of a front main portion of the coupling member 1 assembled to the insulating member 2A, and fig. 15 is an enlarged view of a rear main portion of the coupling member. In this way, in a state where the

leg portions

11A and 11B are arranged at the back side of the insulating member 2A and the coupling portion 12A is arranged at the front side of the insulating member 2A, the 1 st groove portion 23 is fitted (engaged) with the 2 nd groove portion 111. In a state where the 1 st groove portion 23 and the 2 nd groove portion 111 are fitted, the groove edge 111A can come into contact with the groove edge 23A, and the coupling member 1 is prevented from being separated from the insulating member 2A.

As shown in fig. 16, the insulating member 2A has an opposing edge 2A1 that faces the groove edge 23A in the 1 st direction. The minimum distance D1 between the end 23A1 on the bottom 23C side of the 1 st groove 23 in the groove edge 23A and the opposite edge 2a1 is longer than the length D2 of the groove edge 23A. This can prevent the portion near the groove edge 23A from being damaged by the tensile force of the connecting member 1.

Further, since the insulating member 2A has the 1 st claw portion 21 and the 2 nd claw portion 22, the coupling member 1 assembled to the insulating member 2A is not easily detached.

In the coupling member 1, since the 2 nd groove 111 is provided in each of the

leg portions

11A and 11B and the coupling portion 12A couples the

leg portions

11A and 11B to each other, the man-hours for assembling the coupling member 1 to the insulating member 2A can be reduced as compared with a case where each of the leg portions is separated from each other.

As shown in fig. 12, the 2 nd groove 111 is provided at the edges 11A1, 11A2 of the leg 11A facing in the 2 nd direction. That is, the 2 nd groove 111 recessed in the direction approaching each other in the 2 nd direction is provided in the edges 11a1 and 11a2 of the coupling member 1 facing in the 2 nd direction. Since the 1 st groove portion 23 is fitted to the 2 nd groove portion 111, the coupling member 1 is sandwiched by the insulating members 2A from both sides in the 2 nd direction, and separation of the insulating members 2A from the coupling member 1 can be suppressed.

Further, as shown in fig. 13, the groove edge 23A is inclined with respect to the groove edge 111B. That is, a groove edge 23A disposed on the connecting member 1 side out of edges facing in the 1 st direction of the 1 st groove 23 is inclined with respect to a groove edge 111B disposed on the opposite side to the insulating member 2A side out of edges facing in the 1 st direction of the 2 nd groove 111. This facilitates assembly of the coupling member 1 to the insulating member 2A. Further, after assembly, the portion near the groove edge 23A is not easily broken.

As shown in fig. 13, the insulating member 2A has a recess 24 recessed toward the 1 st direction side at a position sandwiched by the two sets of the pair of groove portions 23 in the 2 nd direction. The coupling portion 12A has a recess 12A1 recessed toward the 1 st direction side from the 1 st direction other side end of the coupling portion 12A at a position sandwiched between the

leg portions

11A and 11B in the 2 nd direction. As shown in fig. 14 and 15, in a state where the coupling member 1 is assembled to the insulating member 2A, a recess H is formed so as to be recessed from the recess 24 and the recess 12A1 toward the 1 st direction side. That is, the insulating member 2A has a recess H recessed toward the opposite side of the coupling member 1 in the 1 st direction. Thereby, the binding member 124 can be inserted into the recess H.

The coupling portion 12A may be bonded to the insulating member 2A with an adhesive. That is, the connecting member 1 may be connected to the insulating member 2A via an adhesive. Accordingly, since the coupling member 1 is connected to the insulating member 2A by the adhesive in addition to the fitting of the 1 st groove portion 23 and the 2 nd groove portion 111, the separation of the insulating member 2A from the coupling member 1 can be suppressed.

However, the coupling member 1 may be connected to the insulating member 2A only by fitting the 1 st groove 23 and the 2 nd groove 111. This eliminates the need for bonding, and thus can reduce the cost and man-hours.

Fig. 17 is a diagram showing a positional relationship of the

coil portions

122A and 122B with respect to the insulating member 2A in a state where the insulating member 2A is sandwiched between the

different coil portions

122A and 122B. The coil portion 122A (broken line) is located on the back side of the sheet of fig. 17 with respect to the insulating member 2A, and the coil portion 122B (alternate long and short dash line) is located on the front side of the sheet of fig. 17 with respect to the insulating member 2A. The front side of the paper is the radially inner side.

As shown in fig. 17, the insulating region RB, which is a region where the

coil portions

122A and 122B overlap, does not overlap the region RA where the 1 st groove portion 23 and the 2 nd groove portion 111 are fitted. This can suppress a decrease in the insulation performance in the insulation region RB.

< 5. embodiment 2 of insulating sheet

Various modifications of the insulating sheet 123 will be described below. In the following modification, as in embodiment 1, the insulating sheet 123 has a shape that is line-symmetrical in the 1 st direction with respect to a center line C1 (see fig. 9) extending in the 2 nd direction.

Fig. 18 is a partial plan view of the insulation sheet 1232 of embodiment 2 in an exploded state. In the insulating sheet 1232, the insulating member 2A has a concave portion 25 that is concave toward the 1 st direction side at the 1 st direction other end portion. A pair of 1 st groove portions 26 recessed in a direction away from each other in the 2 nd direction are formed at the edge of the recessed portion 25.

In addition, in the insulating sheet 1232, the coupling member 1 includes the pair of

leg portions

11A and 11B and the coupling portion 12A that couples the

leg portions

11A and 11B, as in embodiment 1. A2 nd groove 111 is formed at one end in the 1 st direction of each of the

leg portions

11A and 11B. The pair of 2 nd groove portions 111 are recessed in a direction approaching each other in the 2 nd direction. The coupling member 1 is assembled to the insulating member 2A by fitting the 2 nd groove portion 111 to the 1 st groove portion 26.

In the present embodiment, the insulating member 2A has the insertion portion 27, and the insertion portion 27 extends from each of the two 1 st direction other side end portions of the recess 25 toward the 1 st direction other side. When the insulating sheet 1232 is assembled into the slot S, the insertion portion 27 is inserted into the slot S. Thus, even when the insulating member 2A is broken in the vicinity of the insertion portion 27, the insertion portion 27 remaining after the breakage is likely to remain in the groove S.

< 6. embodiment 3 of the insulating sheet

Fig. 19 is a partial plan view of the insulation sheet 1233 of embodiment 3 in an exploded state. Fig. 19 to 21 described below are schematic views of the insulating sheet 123.

In the insulating sheet 1233, the insulating member 2A has the 1 st claw portion 21, the 2 nd claw portion 22, and the pair of 1 st groove portions 23, and the 2 nd groove portion 111 and the 1 st groove portion 23 of the coupling member 1 are fitted, as in embodiment 1. In the present embodiment, the 1 st groove portion 23 and the 2 nd groove portion 111 are formed in a slit shape extending in the 2 nd direction and having a narrow width in the 1 st direction.

< 7. embodiment 4 of the insulating sheet

Fig. 20 is a partial plan view of the insulation sheet 1234 of embodiment 4 in an exploded state. In the insulating sheet 1234, the insulating member 2A has a pair of 1 st groove portions 23 recessed in a direction approaching each other in the 2 nd direction at the other end in the 1 st direction. In the insulating sheet 1234, the coupling member 1 includes a pair of

legs

11A and 11B and a coupling portion 12A that couples the

legs

11A and 11B, as in embodiment 1. Further, a2 nd groove 111 is formed at one end in the 1 st direction of each of the

leg portions

11A and 11B. The pair of 2 nd groove portions 111 are recessed in a direction away from each other in the 2 nd direction.

The coupling member 1 is assembled to the insulating member 2A by fitting the 2 nd groove portion 111 to the 1 st groove portion 23. In embodiments 1 to 3, the insulating member 2A sandwiches the connecting member 1 from the outside of the connecting member 1 in a state where the 1 st groove portion and the 2 nd groove portion are fitted, but in the present embodiment, the connecting member 1 sandwiches the insulating member 2A from the outside of the insulating member 2A.

< 8. embodiment 5 of the insulating sheet

Fig. 21 is a partial plan view of the insulation sheet 1235 of embodiment 5 in an exploded state. In the insulating sheet 1235, the insulating member 2A has a pair of 1 st groove portions 231A and a pair of 1 st groove portions 231B at the other end in the 1 st direction. The pair of 1 st groove parts 231A and the pair of 1 st groove parts 231B are arranged in the 2 nd direction. The pair of 1 st groove portions 231A and the pair of 1 st groove portions 231B are recessed in a direction away from each other in the 2 nd direction.

The insulating sheet 1235 has the

coupling members

1A and 1B as separate members. That is, in the present embodiment, the

coupling members

1A and 1B corresponding to the leg portions are not coupled by the coupling portions and are separated. The coupling member 1A has a pair of 2 nd groove portions 1A1 recessed in a direction approaching each other in the 2 nd direction at one end in the 1 st direction. The coupling member 1B has a pair of 2 nd groove portions 1B1 recessed in the direction closer to each other in the 2 nd direction at one end in the 1 st direction.

The coupling member 1A is assembled to the insulating member 2A by fitting the 2 nd groove portion 1A1 to the 1 st groove portion 231A. The coupling member 1B is assembled to the insulating member 2A by fitting the 2 nd groove portion 1B1 to the 1 st groove portion 231B.

< 9. other >)

The embodiments of the present invention have been described above. The scope of the present invention is not limited to the above-described embodiments. The present invention can be implemented by variously changing the above-described embodiments without departing from the gist of the present invention. The matters described in the above embodiments can be arbitrarily combined as appropriate within a range not inconsistent with each other.

For example, the 1 st groove portion may be provided at an end portion of the insulating member opposite to the connecting member side in the 1 st direction. For example, the 1 st groove portion may be provided near the center of the insulating member in the 1 st direction. That is, the 1 st groove portion may not be provided at the end portion of the insulating member on the connecting member side in the 1 st direction. The 2 nd groove portion may not necessarily be provided at the 1 st direction end portion of the coupling member.

As described above, for example, since the 1 st groove portion can be provided near the center of the insulating member in the 1 st direction, the present invention is not limited to the structure in which the 1 st direction end of the insulating member is connected to the 1 st direction end of the connecting member.

Industrial applicability

As an example, the present invention can be applied to a vehicle-mounted motor and the like.

Claims

1. An insulating sheet, comprising:

a pair of insulating members for electrically insulating the coil portions from each other; and

a connecting member formed of a member different from the pair of insulating members and connecting the pair of insulating members to each other,

the coupling member extends in a1 st direction,

the insulating component is provided with a1 st groove part,

the connecting member is provided with a2 nd groove portion to be fitted with the 1 st groove portion.

2. The insulating sheet of claim 1, wherein,

the 1 st groove has a groove edge arranged on the connecting member side among edges opposed to each other in the 1 st direction,

the insulating member has an opposing edge opposing the groove edge in the 1 st direction,

the minimum distance between the end of the 1 st groove on the bottom side of the groove edge and the opposing edge is longer than the length of the groove edge.

3. The insulating sheet according to claim 1 or 2,

the connecting member is connected to the insulating member via an adhesive.

4. The insulating sheet according to claim 1 or 2,

the connecting member is connected to the insulating member only by fitting the 1 st groove portion and the 2 nd groove portion.

5. The insulating sheet according to any one of claims 1 to 4,

the connecting member includes:

two legs extending in a1 st direction; and

a connecting portion connecting the 1 st direction end portions of the leg portions to each other,

the 2 nd groove portion is provided in each of the leg portions.

6. The insulating sheet according to any one of claims 1 to 5,

the 2 nd groove portions recessed in a direction approaching each other in the 2 nd direction are provided on edges of the coupling member facing in the 2 nd direction perpendicular to the 1 st direction, respectively.

7. The insulating sheet of claim 6, wherein,

the insulating member has:

a base; and

a1 st claw portion and a2 nd claw portion protruding from the base portion toward the coupling member side in a1 st direction,

the 1 st groove portion is formed by the 1 st and 2 nd claw portions being sandwiched between the base portion and the base portion, respectively.

8. The insulating sheet of claim 7, wherein,

the 1 st claw portion has an inclined edge portion inclined toward the 2 nd claw portion side toward a side opposite to the coupling member side in the 1 st direction.

9. The insulating sheet of claim 8, wherein,

the pair of the 1 st claw portions and the pair of the 2 nd claw portions are line-symmetrical in a2 nd direction perpendicular to the 1 st direction with respect to an axis extending in the 1 st direction,

the pair of 1 st claw portions is disposed inside the pair of 2 nd claw portions.

10. The insulating sheet according to any one of claims 1 to 9,

the insulating member has a recess recessed toward a side opposite to the connecting member side in the 1 st direction.

11. The insulating sheet according to any one of claims 1 to 10,

a groove edge arranged on the connecting member side among edges of the 1 st groove facing in the 1 st direction is inclined with respect to a groove edge arranged on a side opposite to the insulating member side among edges of the 2 nd groove facing in the 1 st direction.

12. A stator, having:

an annular stator core provided with a plurality of slots arranged in a circumferential direction at a radially inner end portion thereof;

a plurality of coil portions provided across different ones of the cells; and

an insulating sheet which is the structure according to any one of claims 1 to 11 in a state of being spread out in a plane shape,

the insulating member insulates coil ends of the different coil portions protruding from the slots to the outside at both ends in the axial direction of the stator,

the coupling member is disposed in the groove.

13. A motor, comprising:

a rotor rotatable about a central axis; and

the stator of claim 12, driving the rotor.