JP2002084698A - Stator of motor, motor, dc brushless motor, and air conditioner - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the vibration and noise of a motor by enhancing the rigidity of a divided/unfolding type of stator core or making it into a vibration-proof structure. SOLUTION: In the stator of a motor, which is constituted by being divided into every tooth and whose teeth are coupled with each other at a thin coupling part provided at the core back of a stator core, and they are stacked in a condition with their being unfolded on a straight line; and after insertion of insulator into each tooth, winding is given concentrically to them, and they are bent with the thin coupling part as a fulcrum, the insulator inserted into each tooth is constituted of insulating material having high mechanical strength, and also the slot opening of the insulator on the tip side of the slot is provided with a slot opening contact face with the other insulators of adjacent teeth abutting, when the stator core is bent at the thin coupling part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric motor having a stator structure in which a stator core is divided into teeth, and an air conditioner using the same.

[0002]

2. Description of the Related Art Generally, an integrated iron core is obtained by punching a stator core from a steel plate in a circular state as shown in FIG.
6 are laminated.

On the other hand, a split stator core divided and developed for each tooth has a slot opening enlarged to facilitate winding work, improve a space factor of the winding, and improve motor efficiency. It is used to achieve However, while high efficiency can be achieved, when the core is configured, the divided teeth are only joined at a few points of the thin portion or the welded portion of the core outer periphery, so the rigidity of the stator is low. , Vibration and noise.

FIG. 17 shows, for example, Japanese Patent Application Laid-Open No. 8-126240.
FIG. 1 is a diagram illustrating a split core disclosed in Japanese Patent Application Laid-Open Publication No. H10-209,873. Here, an elastic material is used for the insulator, and when the divided cores are combined, the insulators are joined to each other at the slot opening, thereby increasing the insulation distance between the winding and the iron core. ing. By matching insulators together,
Although the insulator can be deformed freely, it does not apply enough stress to the insulator to affect the joining and assembling work, and does not contribute to the improvement of the core rigidity.

[0005] In order to supplement the rigidity of the core, molding with resin is often performed.
Material costs are higher than in the case of using a sheet metal frame, and the resin molding time is long, which is disadvantageous in cost. In addition, in consideration of recyclability, separation is difficult because the metal is buried in the resin.

[0006]

As is apparent from the above description, the conventional split-type stator core has the following problems. (1) Although high efficiency can be achieved, when the core is formed, the divided teeth are joined only at a few points of the thin portion or the welded portion of the outer peripheral portion of the core, so that the rigidity of the stator is reduced. Low, has an effect on vibration and noise. (2) In the case of the split core disclosed in Japanese Patent Application Laid-Open No. 8-126240, although the insulator is freely deformed by abutting of the insulators, a stress that affects the joining and assembling work is reduced. And does not contribute to improving core rigidity. (3) Molding with resin to compensate for the rigidity of the core is disadvantageous in terms of cost because the material cost and the molding time of the resin are longer than in the case of using a sheet metal frame. In addition, in consideration of recyclability, separation is difficult because the metal is buried in the resin.

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and the vibration of the motor can be reduced and the noise can be reduced by improving the rigidity of the split / developed stator core or by adopting a vibration-proof structure. It is intended. In addition, this makes it possible to use a steel plate for the frame of the electric motor using the split iron core, thereby reducing the material cost and improving the recyclability of the conventional resin mold.

[0008]

A stator for an electric motor according to the present invention is a stator for an electric motor constituted by connecting a predetermined number of annular cores divided into teeth and wound on each other. The insulator to be inserted into each tooth is made of an insulating material having high mechanical strength, and the insulators of adjacent teeth are connected to the slot opening of the insulator at the end of the slot so that the laminated iron core is joined in a ring shape. In this case, a contact surface of the slot opening is provided which abuts on the occasion.

Further, the teeth are divided for each tooth, and the respective teeth are connected at a thin connecting portion provided on the core back of the stator core, and are stacked in a state of being developed on a straight line,
After the windings are concentrated on each tooth after inserting the insulator,
In the electric motor stator, which is bent around the thin connecting portion, the insulator inserted into each tooth is made of an insulating material having high mechanical strength, and the slot opening of the insulator at the slot tip side In addition, the insulators of adjacent teeth are provided with a slot opening contact surface which abuts when the stator core is bent at the thin connecting portion.

Further, an elastic material is used in the vicinity of the slot opening contact surface of the insulator.

Further, an elastic material is used on one side near the slot opening contact surface of the insulator.

The upper and lower winding frames of the insulator come into contact with the insulators of adjacent teeth.

Further, a material having high magnetic permeability is used in the vicinity of the contact surface of the insulator with the slot opening.

[0014] Adjacent insulators are fused together near the contact surface of the slot opening.

Further, an insulator protrusion for fusion is provided near the contact surface of the slot opening.

Further, the slot opening contact surface of the insulator is formed so as to protrude toward the inner diameter side, and is not brought into contact when the stator is bent, but is pushed into the inside of the slot while being fused during heat fusion. It is.

An electric motor according to the present invention uses the stator of the electric motor according to any one of claims 1 to 9 and a steel plate frame.

A DC brushless motor according to the present invention
A motor stator according to any one of claims 1 to 9 and a steel plate frame.

The air conditioner according to the present invention is described in claim 1
No. 0 is used.

Further, the DC brushless motor according to the eleventh aspect is used.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. 1 to 3 are views showing a first embodiment, FIG. 1 is a view showing a split and developed split core, FIG. 2 is a view showing a state where a thin connecting portion is bent around a fulcrum, and FIG. 3 is a plan view of a stator core. FIG. In the case of a thin connection type core, as shown in FIG. 1 (a), each tooth 1 at a thin connection portion 3 of a core back 2 of a divided core.
Are connected, and the core is unfolded and arranged on a straight line. This shape is punched out from a steel plate and laminated as shown in FIG.
An insulator 4 is inserted into the core for each tooth 1.

The insulator 4 is composed of a winding thin portion 5 covering the teeth 1 to be wound and a winding frame 6 at both ends to prevent the winding from collapsing. At this time, the slot opening of the winding frame 6 at the slot tip side has a slot opening contact surface 7 which is a flat surface that abuts when the winding frames 6 of the adjacent teeth 1 are bent by the thin connecting portion 3. It has such a shape.

After the insulator 4 is inserted, each tooth 1 is wound. The stator core is split and unfolded, and the slot opening can be wider than the integrated core, so winding work is easy and the winding density (occupation ratio) in the slot
Can be improved. After the winding operation, the thin connecting portion 3 is bent at a fulcrum as shown in FIG. By welding the butted portions of both ends 8 of the divided core of the straight core, FIG.
A core on a circle as shown in FIG.

In the case of a split-type iron core, when the stator core is formed, the teeth 1 that have been split are often joined only by a thin connecting portion 3 at a small portion on the outer peripheral portion of the core back. For this reason, if there is a gap at the tip of the teeth 1, the teeth 1 easily move around the thin connecting portion 3 on the outer periphery as a fulcrum, and the core is easily deformed as a whole. When the motor is driven, the rotor magnet and the teeth 1 of the stator mutually attract and repel each other, and a force acts on the teeth 1. Therefore, as described above, the split type stator is easily deformed.

On the other hand, in FIG. 3, at least a part of the insulator at the slot opening at the tip of the tooth is in contact with the slot opening contact surface 7 at a portion facing each other. This contact is made at all slot openings. As a result, the core divided in units of the teeth 1 comes into contact with the thin connecting portion 3 on the outer periphery and the slot opening contact surface 7 of the insulator of the slot opening at at least two places. Thus, deformation of the stator core can be prevented, and noise can be reduced.

As a material for forming the insulator 4, a rigidity of the stator can be improved by using an insulating material having a higher mechanical strength than an insulating material consisting of only a resin, such as a resin containing glass fiber. To suppress deformation of the stator due to stress caused by electromagnetic force generated when driving the motor.
As a result, low vibration,
Low noise can be achieved.

In the above-described embodiment, the teeth 1 are connected by the thin connecting portions 3 provided on the core back of the stator core. However, the teeth 1 are completely divided without the thin connecting portions 3. It is also applicable to things.

Embodiment 2 Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. 4 to 6 show a second embodiment, and are partial perspective views of a stator core. This embodiment is different from the first embodiment in that the insulator 4 used is made of a material having elasticity at least at the tip end of the teeth and the contact surface 7 of the slot opening.

As in the first embodiment, when the stator is deformed due to the stress caused by the electromagnetic force generated when the motor is driven by contacting the insulator at the tooth tip and the slot opening when the stator is bent, The insulator 4 at the slot opening serves as a cushioning material and absorbs the vibration. As a result, vibration is attenuated, and low vibration and low noise can be achieved.

As described above, since the insulator 4 also has the role of the winding frame 6, if an elastic material is used, the winding frame 6 is deformed during the winding operation. As a result, there is a possibility of falling down on the inner diameter side of the stator. Therefore, by arranging the elastic resin component 9 only in the slot opening as shown in FIG. 4, it is possible to perform vibration isolation while maintaining the strength of the winding frame portion.

At this time, since the elastic resin component 9 to be separately attached only needs to be present in the slot opening, it is not necessary to provide it on the slot opening contact surfaces 7 at both ends of the teeth, and only on one side as shown in FIG. It is also possible to take the form of installation.

Also, as in the first embodiment, it is not always necessary to make contact with the entire surface of the slot opening, and it is also possible to make contact with only the insulator contact surface 10 as shown in FIG. This is because if the vibration cannot be sufficiently attenuated at the narrow opening between the teeth,
Here, it is also possible to obtain the elasticity required for damping.

Embodiment 3 Hereinafter, a third embodiment of the present invention will be described with reference to the drawings. FIG. 7 shows the third embodiment and is a partial sectional view of the electric motor. In the case of this embodiment, the difference between the above embodiments is that the material used for the insulator 4 is at least
Is a resin containing a magnetic substance or a magnetic material.

At the time of driving the motor, when the load and output increase, the current flowing through the winding increases and the magnetic flux density of the teeth 1 increases. Especially in the slot opening at the tip of the tooth,
Since the magnetic flux is concentrated, when a rotor having magnets arranged on the surface is used, the concentrated magnetic flux may pass through the rotor-side magnetic path 11 to partially demagnetize the rotor magnet 13.

However, since the magnetic material is contained in the insulator 4, the magnetic permeability inside the insulator 4 is higher than the gap between the rotor and the stator. As shown in FIG. 7, the magnetic flux leaking from
It passes through the internal magnetic path 12 in the insulator. Thereby, concentration of magnetic flux on the surface of the rotor magnet 13 can be avoided, and demagnetization of the rotor magnet 13 can be prevented.

Here, considering that the entire insulator 4 is made of a resin containing a magnetic material, the resin is not very elastic and has poor fluidity during molding. In addition to the difficulties, there may be disadvantages in terms of cost. in this case. The same effect can be obtained by using another part made of a resin containing a magnetic material only at the tip of the tooth 1. This method of configuring the separate parts can be realized by a method similar to that of FIGS. 4 and 5 in the second embodiment.

Embodiment 4 FIG. Hereinafter, a fourth embodiment of the present invention will be described with reference to the drawings. FIG. 8 shows the fourth embodiment and is a view partially showing a stator core. As in the first to third embodiments, the teeth contact the insulator 4 in the slot opening, but after the stator is formed, the insulator 4 in the contacted slot opening is fused and integrated.

When the thin connecting portion 3 of the stator core is bent at the fulcrum to form a circular stator core, the resins that are in contact with each other at the slot openings are melted by heating and fused together.

As a result, the insulator 4 has been enhanced in rigidity or damped vibration in the contraction direction, but the effect can be obtained in the extension direction. The effect on noise is obtained.

Embodiment 5 Hereinafter, a fifth embodiment of the present invention will be described with reference to the drawings. FIGS. 9 and 10 show the fifth embodiment, in which the stator core is partially shown. As shown in FIG. 9, insulator protrusions 14 for fusion are provided in advance at the tips of the teeth 1 and the slot openings,
After the bending operation, the opposing insulator protrusions 14 are connected to each other as shown in FIG.
By fusing like 0, it is possible to fix adjacent teeth and obtain the same effect as in the fourth embodiment.

Since the insulator protrusions 14 are provided and the fusion is performed here, the teeth can be sufficiently fixed to each other even if the insulator 4 in the slot opening does not always contact when the core is bent.

Embodiment 6 FIG. Hereinafter, a sixth embodiment of the present invention will be described with reference to the drawings. FIG. 11 shows Embodiment 6
FIG. 7 is a view partially showing a stator core. As a shape similar to that of the fifth embodiment, as shown in FIG.
When the resin 14a protruding during heat fusion is pushed into the slot without being contacted when the stator is bent, the resin 14a which is opposed and protrudes at the slot opening is pressed.
4a can be fused together in the slot.

The dimensional accuracy of the insulator 4 cannot be sufficiently ensured.
This is an effective means in a case where contact between the insulators 4 at the time of bending the core may affect the roundness of the inner diameter and the like.

Embodiment 7 FIG. Hereinafter, a seventh embodiment of the present invention will be described with reference to the drawings. FIG. 12 shows Embodiment 7
FIG. 3 is a configuration diagram of a motor. The motor shown in FIG. 12 is a DC brushless motor using the steel plate frame 15, and uses the stator 16 using the split-type core described in the first to sixth embodiments. For the conventional split type,
The rigidity of the stator is weak, and there is a problem in terms of noise and vibration when used for the motor of the steel plate frame 15.

By using the stator cores of the first to sixth embodiments, the rigidity of the core can be improved or the vibration to be generated can be suppressed. Equivalent vibration and noise can be suppressed.

In addition, this makes it possible to reduce the cost of the motor without deteriorating vibration and noise. In addition, since it is not molded with resin, it is easy to disassemble, and the recyclability of the motor is improved.

Also, here, an example is shown in which the stators of the first to sixth embodiments are used for a DC brushless motor. However, a split type core can be used for a stator such as a reluctance motor. Motors,
Similarly, the effect of reducing vibration and noise can be obtained.

Embodiment 8 FIG. Hereinafter, an eighth embodiment of the present invention will be described with reference to the drawings. FIG. 13 shows an eighth embodiment.
FIG. 3 is a diagram showing a duct-type ventilation fan attached to a ceiling. In the present embodiment, the DC brushless motor according to the seventh embodiment is mounted on a ventilation fan which is an example of an air conditioner. Since the DC brushless motor 17 is mounted on the ventilation fan as compared with the conventional induction motor, the efficiency of the motor is improved, so that energy saving can be achieved. Further, since the motor itself can be reduced in size, the size and weight of the ventilation fan can be reduced.

The motor mounted on the ventilation fan is required to have a certain degree of durability against high temperature, oil adhesion, etc. due to the environment in which it is used. Unsuitable for environmental durability. Therefore, by using the DC brushless motor of the seventh embodiment, it is possible to cope with the above-described environment and
It is possible to further increase the efficiency while suppressing the deterioration of vibration and noise.

Embodiment 9 FIG. Hereinafter, a ninth embodiment of the present invention will be described with reference to the drawings. FIG. 14 shows Embodiment 9
FIG. 3 is a diagram illustrating a configuration of an air conditioner. This is an example in which the DC brushless motor of Embodiment 7 is mounted on an air conditioner that is an example of an air conditioner. As shown in FIG. 14, the air conditioner is divided into an outdoor unit 18 and an indoor unit 19, and the fan motor 20 for the outdoor unit and the indoor unit configured by the DC brushless motor of the seventh embodiment, respectively. Fan motor 21 is mounted. By using a DC brushless motor having a steel plate frame, as described in the seventh embodiment, the cost of the motor can be reduced, and at the same time, the recyclability can be improved. In addition, since the weight of the motor can be reduced, the weight of the unit can be reduced.

[0051]

According to the motor stator according to the present invention, the insulator inserted into each tooth is made of an insulating material having high mechanical strength, and the insulator is adjacent to the slot opening of the insulator at the tip end of the slot. Provided with a slot opening contact surface where insulators of different teeth abut each other when the laminated cores are joined in a ring, increasing the rigidity of the stator, suppressing deformation of the core, and reducing vibration and noise. become.

The insulator inserted into each tooth is made of an insulating material having high mechanical strength, and the insulators of adjacent teeth are connected to the stator core in the slot opening of the insulator at the end of the slot. Is provided with a slot opening contact surface that abuts when bent at the thin connecting portion, thereby increasing the rigidity of the stator, suppressing deformation of the core, and reducing vibration and noise.

Further, by using an elastic material near the slot opening contact surface of the insulator, the vibration of the stator core can be absorbed and the vibration and noise can be reduced.

Further, even if an elastic material is used on one side of the insulator near the contact surface of the slot opening, the vibration of the stator core can be absorbed and the vibration and noise can be reduced.

In the case where the insulators of adjacent teeth come into contact with each other at the upper and lower winding frames of the insulator, vibrations cannot be sufficiently attenuated at the narrow opening between the teeth. It is also possible to make contact with the upper and lower winding frames, and to obtain the elasticity required for damping here.

Further, by using a material having a high magnetic permeability in the vicinity of the slot opening contact surface of the insulator, the demagnetization of the rotor can be prevented, the reliability of the motor can be improved, and the output can be increased. To

Further, since the adjacent insulators are fused together near the contact surface of the slot opening, the rigidity of the stator can be improved or the effect of absorbing vibration can be further improved. Noise can be reduced.

In addition, the provision of the insulator projection for fusion in the vicinity of the contact surface of the slot opening allows the teeth to be sufficiently fixed even if the insulator at the slot opening does not always contact when the core is bent. Becomes possible.

Further, the contact surface of the insulator at the opening of the slot is formed so as to protrude toward the inner diameter side and is not brought into contact when the stator is bent. This is an effective means in a case where the dimensional accuracy of the insulator cannot be sufficiently ensured, and when the insulators are brought into contact with each other when the core is bent, the roundness of the inner diameter may be affected.

The electric motor according to the present invention uses the stator of the electric motor according to any one of the first to ninth aspects, so that even when used in a motor of a steel plate frame, the same vibration as when molded with resin is obtained. , Can be reduced to noise.

The DC brushless motor according to the present invention
By using the stator of the electric motor according to any one of claims 1 to 9, even when used for a motor of a steel plate frame,
Vibration and noise can be suppressed to the same level as when molding with resin.

The air conditioner according to the present invention uses the electric motor according to claim 10 as an electric motor for a blower, so that it is durable to the environment, and further increases efficiency while suppressing deterioration of vibration and noise. It becomes possible. Further, the cost of the motor can be kept low, and the recyclability can be improved at the same time.

Further, by using the DC brushless motor according to the eleventh aspect as the blower electric motor, it is durable to the environment, and it is possible to further increase the efficiency while suppressing the deterioration of vibration and noise. Further, the cost of the motor can be kept low, and the recyclability can be improved at the same time.

[Brief description of the drawings]

FIG. 1 shows the first embodiment, and is a view showing a split core that has been split and expanded.

FIG. 2 is a view showing the first embodiment, and shows a state where a thin connecting portion is bent around a fulcrum.

FIG. 3 shows the first embodiment, and is a plan view of a stator core.

FIG. 4 shows the second embodiment and is a partial perspective view of the stator core.

FIG. 5 shows the second embodiment and is a partial perspective view of the stator core.

FIG. 6 shows the second embodiment and is a partial perspective view of the stator core.

FIG. 7 shows the third embodiment and is a partial cross-sectional view of the electric motor.

FIG. 8 shows the fourth embodiment and is a diagram partially showing a stator core.

FIG. 9 shows the fifth embodiment, and is a diagram partially showing a stator core.

FIG. 10 is a view showing the fifth embodiment, and is a view partially showing a stator core.

FIG. 11 shows the sixth embodiment and is a diagram partially showing the stator core.

FIG. 12 shows a seventh embodiment, and is a configuration diagram of a motor.

FIG. 13 shows the eighth embodiment and is a diagram showing a duct-type ventilation fan attached to the ceiling.

FIG. 14 is a diagram showing the ninth embodiment, and is a diagram showing the configuration of the air conditioner.

FIG. 15 is a view showing a conventional integrated stator core.

FIG. 16 is a perspective view of a conventional stator in which integrated cores are stacked.

FIG. 17 is a view showing a conventional motor stator.

[Explanation of symbols]

1 teeth, 2 core backs, 3 thin joints, 4
Insulator, 5 winding thin section, 6 winding frame, 7 slot opening contact surface, 8 split core both ends, 9 resin parts, 10 insulator contact surface, 11 rotor side magnetic path, 12 magnetic path in insulator, 13 rotor magnet , 14 insulator protrusion, 14a protruding resin, 15 steel plate frame, 16 stator, 17
Motor, 18 outdoor unit, 19 indoor unit, 20 outdoor unit fan motor, 21 indoor unit fan motor.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H02K 15/10 H02K 15/10 29/00 29/00 Z F-term (Reference) 5H002 AA04 AA07 AA08 AA09 AB06 AC02 AE08 5H019 AA06 AA07 AA10 CC03 CC07 EE01 EE14 5H604 AA05 AA08 BB01 BB07 BB14 BB17 CC01 CC05 CC15 DA06 DB01 DB16 DB18 PB03 5H615 AA01 BB01 BB04 BB14 PP01 PP07 PP10 PP13 PP28 QQ02TTQ13 TT01 SS0404

Claims (13)

[Claims] 1. A stator for an electric motor which is formed by connecting a predetermined number of laminated cores, each of which is divided for each tooth and provided with a winding, in a stator, wherein the insulator inserted into each tooth has a mechanical strength. In addition to being formed of a high insulating material, a slot opening contact surface is provided in the slot opening of the insulator on the slot tip side where the insulators of adjacent teeth abut when the laminated cores are annularly coupled. A stator for an electric motor. 2. The teeth are divided for each tooth, each tooth is connected at a thin connecting portion provided on a core back of the stator core, and stacked in a state of being linearly expanded, and after inserting an insulator into each tooth. After the winding is applied intensively, in the stator of the electric motor configured to be bent with the thin connecting portion as a fulcrum, the insulator inserted into each tooth is formed of an insulating material having high mechanical strength. In addition, a slot opening contact surface is provided in the slot opening of the insulator on the tip end side of the slot where the insulators of adjacent teeth abut when the stator core is bent at the thin connecting portion. An electric motor stator. 3. The stator for an electric motor according to claim 1, wherein a material having elasticity is used near the contact surface of the insulator with the slot opening. 4. The motor stator according to claim 3, wherein an elastic material is used on one side of the insulator near the contact surface of the slot opening. 5. The stator for an electric motor according to claim 3, wherein said insulators of adjacent teeth contact at upper and lower winding frame portions of said insulator. 6. The stator for an electric motor according to claim 1, wherein a material having a high magnetic permeability is used near a contact surface of the insulator with the slot opening. 7. The stator for an electric motor according to claim 1, wherein adjacent insulators are fused together near a contact surface of a slot opening. 8. The stator for an electric motor according to claim 7, wherein an insulator protrusion for fusion is provided near the contact surface of the slot opening. 9. A structure in which a contact surface of a slot opening of an insulator is formed to protrude toward an inner diameter side, is not brought into contact when a stator is bent, and is pushed into the slot while being fused during heat fusion. The stator for an electric motor according to claim 7, wherein: 10. An electric motor using the stator of the electric motor according to claim 1 and a steel plate frame. 11. A DC brushless motor using the stator of the electric motor according to claim 1 and a steel plate frame. 12. An air conditioner using the electric motor according to claim 10. 13. An air conditioner using the DC brushless motor according to claim 11.