JP2003319594A

JP2003319594A - Interphase insulating paper of electric rotating machine

Info

Publication number: JP2003319594A
Application number: JP2002116713A
Authority: JP
Inventors: Masayuki Nakamura; 雅之中村
Original assignee: Toyota Motor Corp
Current assignee: Toyota Motor Corp
Priority date: 2002-04-18
Filing date: 2002-04-18
Publication date: 2003-11-07

Abstract

<P>PROBLEM TO BE SOLVED: To reduce the cost by enhancing the yield of an insulating material without sacrificing the productivity. <P>SOLUTION: A pair of interphase parts 10 and 11 opposing trough a distance shorter than the axial length of a stator core, and parts 20 and 20 having nonlinear parts, i.e., bends 22 and 22, at least partially and coupling the interphase parts 10 and 11 integrally are formed integrally by cutting off the unnecessary parts of the elastically deformable insulating material. Area of the unnecessary parts to be cut off and wasted is reduced as the distance between the interphase parts 10 and 11 is shortened. When the interphase insulating paper is fixed to the stator, it is inserted into the slot of the stator core under such a state as the bends 22 and 22 at the coupling parts 20 and 20 are elongated linearly through elastic deformation, and the interphase parts 10 and 11 are arranged between the coils of different phase at respective coil end parts. <P>COPYRIGHT: (C)2004,JPO

Description

【発明の詳細な説明】【０００１】【発明の属する技術分野】本発明は、ステータのコイル
エンド部で異相のコイル間を絶縁するために用いられる
回転電機の相間絶縁紙に関する。【０００２】【従来の技術】車両用交流発電機等の回転電機における
ステータ（固定子）は、一般に、複数のスロットをもつ
ステータコア（固定子鉄心）と、このステータコアの軸
方向両端側にそれぞれコイルエンド部を形成しながらス
ロットに装着された多相のコイルとを備えている。そし
て、このような多相のコイルをもつものでは、コイルエ
ンド部において異相のコイル間の相間絶縁がなされてい
る。【０００３】かかる相間絶縁を行うための相間絶縁紙と
しては、図６に示されるように、それぞれのコイルエン
ド部で異相のコイル間に配設される一対の相間部８０、
８１と、両相間部８０、８１を一体に連結しスロット内
に挿入、配設される一対の接続部９０、９１とからなる
ものが知られている（特開昭５８−１２５４９号公報等
参照）。なお、この相間絶縁紙では、両相間部８０、８
１間の距離はステータコアの軸方向長さと略同等とされ
ている。【０００４】ここに、両相間部８０、８１を接続部９
０、９１により一体に連結するのは、相間絶縁紙をステ
ータに装着する際、相間絶縁紙の取扱い容易性を向上さ
せるとともに、異相のコイル間に確実に相間絶縁紙を保
持させるためである。【０００５】このように両相間部８０、８１と接続部９
０、９１とが一体となった相間絶縁紙は、一般にシート
状等の絶縁材料（例えば、ポリエステルフィルム）の不
要部を切断除去することにより、一体に形成される。例
えば、略矩形状のシート状絶縁材料の両端部を一対の相
間部８０、８１として残すとともに、この両相間部８
０、８１の間に一対の接続部９０、９１を残しつつ、両
相間部８０、８１の間を中抜き等して不要部を切断除去
することにより、一対の相間部８０、８１と両相間部８
０、８１を一体に接続する一対の接続部９０、９１とが
一体に形成される。【０００６】また、特開昭５８−１８６３４６号公報に
開示されているように、別々に形成した両相間部を糸で
連結した相間絶縁紙もある。【０００７】【発明が解決しようとする課題】ところで、回転電機の
相間絶縁紙は、２００℃程度以上の耐熱性を有する絶縁
材料を用いる必要があることから、極めて高価なものと
なる。このため、相間絶縁紙に要するコストを抑えるこ
とができれば、回転電機のコスト低減に大きく貢献する
ことが可能となる。【０００８】ところが、上述のように相間部の間を中抜
き等して不要部を切断除去することにより、相間絶縁紙
を形成すると、中抜き等した不要部の絶縁材料が無駄と
なる。このため、高価格の絶縁材料の材料歩留りが悪く
なり、相間絶縁紙の原価が上昇してしまう。【０００９】一方、別々に形成した両相間部を糸で連結
する相間絶縁紙によれば、無駄となる不要部を少なくす
ることができる。しかし、この場合、糸を相間部に固定
するための工程が別途必要となり、工程数の増加により
生産性が低下してしまう。【００１０】本発明は上記実情に鑑みてなされたもので
あり、生産性を低下させることなく、絶縁材料の材料歩
留りを向上させて原価を低減させることのできる相間絶
縁紙を提供することを解決すべき技術課題とするもので
ある。【００１１】【課題を解決するための手段】上記課題を解決する本発
明の回転電機の相間絶縁紙は、一対の相間部と両該相間
部を一体に連結する接続部とを有し、複数のスロットを
もつステータコアと該ステータコアの両端側にそれぞれ
コイルエンド部を形成しながら該スロットに装着された
多相のコイルとを備えた回転電機のステータに装着され
た状態で、各該相間部が各該コイルエンド部でそれぞれ
異相の該コイル間に配設されるとともに該接続部が該ス
ロット内に直状に伸びた状態で配設される相間絶縁紙で
あって、上記ステータコアの軸方向長さよりも短い距離
を隔てて対向する両上記相間部と、非直状部を少なくと
も一部にもち両該相間部を一体に連結する上記接続部と
が、弾性変形可能な絶縁材料の不要部を切断除去するこ
とにより一体に形成されてなることを特徴とするもので
ある。【００１２】【発明の実施の形態】本発明の回転電機の相間絶縁紙
は、複数のスロットをもつステータコアと、該ステータ
コアの両端側にそれぞれコイルエンド部を形成しながら
該スロットに装着された多相のコイルとを備えた回転電
機のステータに用いられるものであって、上記ステータ
に装着された状態で、各該コイルエンド部でそれぞれ異
相の該コイル間に配設される一対の相間部と、該スロッ
ト内に直状に伸びた状態で配設され両該相間部を一体に
連結する接続部とを有している。【００１３】そして、本発明の相間絶縁紙は、上記ステ
ータコアの軸方向長さよりも短い距離を隔てて対向する
両上記相間部と、非直状部を少なくとも一部にもち両該
相間部を一体に連結する上記接続部とが、弾性変形可能
な絶縁材料の不要部を切断除去することにより一体に形
成されてなることを最大の特徴とする。【００１４】このように本発明の相間絶縁紙は、弾性変
形可能な絶縁材料の不要部を切断除去することにより、
ステータコアの軸方向長さよりも短い距離を隔てて対向
する両相間部と、非直状部を少なくとも一部にもち両相
間部を一体に連結する接続部とが、一体に形成されてい
る。このため、切断除去されて無駄となる不要部の面積
が、両相間部間の距離が短くなった分だけ小さくなる。
したがって、絶縁材料の材料歩留りを向上させることが
でき、相間絶縁紙の原価の低減を図ることが可能とな
る。【００１５】また、本発明の相間絶縁紙は、シート状の
絶縁材料を所定形状に中抜き等することにより、両相間
部とこれらを一体に連結する接続部とを同時に形成する
ことができるため、例えば両相間部を連結するための糸
を後から固定したりする必要がなく、生産性も良好であ
る。【００１６】本発明の相間絶縁紙を回転電機のステータ
に装着する際には、接続部の非直状部を弾性変形により
直状に伸ばした状態でステータコアのスロット内に挿
入、配設するとともに、両相間部をそれぞれのコイルエ
ンド部で異相のコイル間に配設する。【００１７】この相間絶縁紙を構成する絶縁材料として
は、必要とされる電気絶縁性を示すとともに、接続部の
非直状部が直状に伸びる程度に弾性変形可能なものであ
れば、特に限定されない。例えば、珪素樹脂、ナイロン
（６６ナイロン等）やポリイミドを採用することができ
る。【００１８】上記接続部の形状は、湾曲部や屈曲部等の
非直状部を少なくとも一部に有するものであれば特に限
定されない。【００１９】ここに、回転電機のステータに装着する前
の状態における接続部（湾曲部又は屈曲部等の非直状部
がそのままの湾曲又は屈曲形状にある接続部。以下、装
着前の接続部という。）の両端同士を結ぶ距離（装着前
の接続部の両端距離：ｄ）を短くすれば、すなわち、ス
テータに装着すべく非直状部を直状に伸ばした後の状態
における接続部（以下、伸張後の接続部という。）の両
端同士を結ぶ距離（Ｄ、ｄ＜Ｄ）に対する装着前の接続
部の両端距離（ｄ）の比（ｄ／Ｄ）を小さくすれば、両
相間部間で中抜き等されて除去される不要部の面積を小
さくすることができ、絶縁材料の材料歩留りをより向上
させることができる。なお、伸張後の接続部の両端距離
（Ｄ）は、ステータコアの軸方向長さに略等しく、一定
である。【００２０】そこで、上記（ｄ／Ｄ）の値は、２／３以
下、１／２以下、１／３以下、……と、非直状部が弾性
変形により直状に伸びるときに亀裂等の発生を防止しう
る範囲内で、可能な限り小さくすることが好ましい。【００２１】また、接続部の非直状部として湾曲部（円
弧により構成されたものをいう。）を採用した場合は、
曲率を大きくする方が上記（ｄ／Ｄ）の値を小さくする
ことができ、好ましい。一方、接続部の非直状部として
屈曲部を採用した場合は、折り曲げ角度を小さくする方
が上記（ｄ／Ｄ）の値を小さくすることができ、好まし
い。【００２２】さらに、非直状部が弾性変形により直状に
伸びるとき、亀裂等の発生を防止する観点より、接続部
は、弾性変形する際の応力集中により亀裂等が発生し易
い角部をもたない形状とすることが好ましい。例えば、
非直状部を屈曲部とする場合は、この屈曲部の折り曲げ
点（屈曲先端）に丸みをつけたり、あるいは接続部の一
部を湾曲部又は屈曲部にするとともに他の部分を直線部
にする場合は、直線部と湾曲部又は屈曲部との境界に丸
みをつけて直線部と屈曲部又は湾曲部とを曲線でつなぐ
ようにしたりすることが好ましい。【００２３】また、接続部の非直状部は、直状に伸びる
際の亀裂等の発生を防止等しうるように必要最小限の強
度を確保しうる範囲内で、できるだけ細く（幅を狭く）
することが好ましく、特に変形量が大きくなる部分に局
所的な幅狭部を有することが特に好ましい。【００２４】上記接続部の数は特に限定されず、１本で
も２本以上でもよいが、接続部の強度を確保するととも
に相間絶縁紙をステータに装着する際の装着作業性を良
好にする等の観点より、２本（又は３本）とすることが
好ましい。【００２５】本発明の相間絶縁紙は、シート状又はフィ
ルム状等の絶縁材料の不要部を所定形状に切断除去する
ことにより、一体に形成される。例えば、略矩形状のシ
ート状絶縁材料の両端部を一対の相間部として残すとと
もに、この両相間部の間に一対の接続部を残しつつ、両
相間部の間を中抜き等して不要部を所定形状に切断除去
することにより、一対の相間部と両相間部を一体に接続
する一対の接続部とからなる相間絶縁紙を一体に形成す
ることができる。【００２６】シート状等の絶縁材料から不要部を切断除
去する方法は特に限定されないが、複雑形状でも精度高
く切断することのできるレーザ切断を利用することが好
ましい。【００２７】なお、特開昭５８−１２５４９号公報に
は、一対の相間部と両相間部を一体に接続する一対の接
続部とが一体に形成された相間絶縁紙であって、スロッ
トへの装着性及びその作業性を向上させるべく、各接続
部が互いに離間する方向（外側）に円弧状に曲がった一
対の円弧状接続部により、両相間部が一体に接続された
相間絶縁紙が開示されている。この相間絶縁紙は、ステ
ータコアのスロット幅よりも大きな曲げ量をもって曲げ
られた円弧状接続部をスロット内壁へ圧接させることに
より、スロットからの抜けの防止を図って装着作業性を
高めたものである。したがって、この相間絶縁紙では、
ステータに装着する前の状態における接続部の両端同士
を結ぶ距離（装着前の接続部の両端距離：ｄ）は、ステ
ータコアの軸方向長さよりも短くされていない。【００２８】【実施例】以下、本発明の実施例を具体的に説明する。【００２９】（実施例１）本実施例の相間絶縁紙１は、
図１に示されるように、上、下一対の相間部１０、１１
と、上相間部１０及び下相間部１１を一体に連結する一
対の接続部２０、２０とを有している。【００３０】この相間絶縁紙１は、後述する回転電機の
ステータ３０に装着される前の状態において、ステータ
３０のステータコア３１の軸方向長さ（Ｌ）よりも短い
距離（ｄ）を隔てて対向する上相間部１０及び下相間部
１１が、非直状部として一つの屈曲部２２、２２をそれ
ぞれ一部に有する一対の接続部２０、２０により一体に
連結されている。【００３１】各接続部２０、２０の一部としてそれぞれ
設けられた屈曲部２２、２２は、いずれも折り曲げ点
（屈曲先端）２２ａ、２２ａが外側を向くように折れ曲
がっている。また、この折り曲げ点２２ａ付近は、他の
部分よりも幅の狭い局所的な幅狭部とされている。【００３２】各接続部２０は、上相間部１０と一体に形
成され、上相間部１０及び下相間部１１の対向方向に直
状に短く伸びる上端直状部２１と、この上端直状部２１
と一体に形成された屈曲部２２と、この屈曲部２２及び
下相間部１１と一体に形成され、上相間部１０及び下相
間部１１の対向方向に直状に短く伸びる下端直状部２３
とが一体に形成されている。そして、各接続部２０は、
角部やエッジをもたない形状とされている。すなわち、
上端直状部２１と上相間部１０との境界部２０ａ、上端
直状部２１と屈曲部２２との境界部２０ｂ、屈曲部２２
の折り曲げ点（屈曲先端）２２ａ、屈曲部２２と下端直
状部２３との境界部２０ｃ及び下端直状部２３と下相間
部１１との境界部２０ｄは、いずれも角部やエッジをも
たない丸みをもった形状とされており、上端直状部２１
及び下端直状部２３と屈曲部２２とが曲線でつながれて
いる。【００３３】かかる形状の相間絶縁紙１は、弾性変形可
能な絶縁材料としての６６ナイロンよりなるフィルムの
不要部を、レーザ切断を利用して所定形状に切断除去す
ることにより、一体に形成した。【００３４】この相間絶縁紙１は、図２に示されるよう
に、各接続部２０、２０の屈曲部２２、２２を直状に伸
ばした状態で、図示しない回転電機のステータ３０に装
着されて使用に供される。なお、本実施例では、伸張後
の接続部２０の両端同士を結ぶ両端距離（Ｄ）に対する
装着前の接続部２０の両端距離（ｄ）の比（ｄ／Ｄ）
は、約１／２とされている。また、この伸張後の接続部
２０の両端距離（Ｄ）は、ステータコア３１の軸方向長
さ（Ｌ）と略同等と（又は若干長く）されている。【００３５】回転電機のステータ（固定子）３０は、図
３に図示されるように、複数のスロット３１ａをもつス
テータコア３１と、このステータコア３１の軸方向両端
側にそれぞれコイルエンド部３２ａを形成しながらスロ
ット３１ａに装着された多相（本実施例では、Ｕ相、Ｖ
相及びＷ相の３相）のコイル３２とを備えている。な
お、図３には、３相のコイル３２のうちＵ相のコイル３
２のみが図示されている。また、各コイル３２は、絶縁
被膜が被覆された銅線を所定のコイル形状に巻いて巻線
形状とした後に、ステータコア３１に装着されたもので
ある。【００３６】そして、図４に図示されるように、本実施
例の相間絶縁紙１は、回転電機のステータ３０に装着さ
れた状態で、各相間部１０、１１が、各コイルエンド部
３２ａでそれぞれ異相のコイル３２間に配設されるとと
もに、各接続部２０、２０が、スロット３１ａ内に直状
に伸びた状態で配設される。すなわち、ステータコア３
１の軸方向一端側（図４の上端側）において、ある一の
相のコイル３２のコイルエンド部３２ａと他の相のコイ
ル３２のコイルエンド部３２ａとの間に上相間部１０が
配設されるとともに、ステータコア３１の軸方向他端側
（図４の下端側）において、当該一の相のコイル３２の
コイルエンド部３２ａと当該他の相のコイル３２のコイ
ルエンド部３２ａとの間に下相間部１１が配設される。【００３７】この相間絶縁紙１のステータ３０への装着
は、まず、ステータコア３１のあるスロット３１ａ及び
このスロット３１ａから所定磁極ピッチ離れたスロット
３１ａに、図示しないＵ字状のスロット絶縁体をそれぞ
れ挿入してから別途巻き回し形成した例えばＵ相のコイ
ル３２を挿入する。そして、このＵ相のコイル３２が挿
入された各スロット３１ａにそれぞれ隣接する各スロッ
ト３１ａの底部に、各接続部２０、２０の屈曲部２２、
２２を直状に伸ばした状態でステータコア３１の求心側
から相間絶縁紙１を挿入するとともに、ステータコア３
１の軸方向一端側及び他端側において、この相間絶縁紙
１の上相間部１０及び下相間部１１をＵ相のコイル３２
のコイルエンド部３２ａ上にそれぞれ配設する。その
後、この各接続部２０、２０が挿入された当該スロット
３１ａ内に別途巻き回し形成した例えばＶ相のコイル３
２をステータコア３１の軸方向一端側から挿入する。こ
のとき、ステータコア３１の軸方向一端側及び他端側に
おいて、Ｕ相のコイル３２のコイルエンド部３２ａの上
に配設された上記相間絶縁紙１の上相間部１０及び下相
間部１１の上にＶ相のコイル３２のコイルエンド部３２
ａをそれぞれ配設することにより、Ｕ相のコイル３２の
コイルエンド部３２ａとＶ相のコイル３２のコイルエン
ド部３２ａとの間に上記相間絶縁紙１の上相間部１０及
び下相間部１１をそれぞれ配設する。【００３８】以上のとおり、本実施例の相間絶縁紙１
は、弾性変形可能な絶縁材料としての６６ナイロンより
なるシートの不要部を、レーザ切断を利用して所定形状
に切断除去することにより、ステータコア３１の軸方向
長さ（Ｌ）よりも短い距離を隔てて対向する両相間部１
０、１１と、非直状部としての屈曲部２２を一部にもち
両相間部１０、１１を一体に連結する一対の接続部２
０、２０とが、一体に形成されている。そして、伸張後
の接続部２０の両端距離（Ｄ）に対する装着前の接続部
２０の両端距離（ｄ）の比（ｄ／Ｄ）が約１／２とされ
ている。このため、切断除去されて無駄となる不要部の
面積も従来と比べて約１／２程度となる。したがって、
絶縁材料の材料歩留りを向上させることができ、相間絶
縁紙の原価の低減を図ることが可能となる。【００３９】また、本実施例の相間絶縁紙１は、シート
状の絶縁材料を所定形状に中抜き等することにより、両
相間部１０、１１とこれらを一体に連結する接続部２
０、２０とを同時に形成することができるため、例えば
両相間部１０、１１を連結するための糸を後から固定し
たりする必要がなく、生産性も良好である。【００４０】さらに、本実施例の相間絶縁紙１の各接続
部２０は、弾性変形する際の応力集中により亀裂等が発
生し易い角部をもたない形状である。しかも、この接続
部２０の屈曲部２２では、直状に伸びる際に特に変形量
が大きくなる部分である折り曲げ点２２ａ付近が他の部
分よりも幅の狭い局所的な幅狭部とされている。したが
って、非直状部としての屈曲部２２が弾性変形により直
状に伸びる際に亀裂等が発生することを効果的に防止す
ることができる。【００４１】なお、本実施例では、各接続部２０の屈曲
部２２は、いずれも折り曲げ点（屈曲先端）２２ａが外
側を向くように折り曲がった形状をなしているが、双方
の折り曲げ点がいずれも内側を向いたり、あるいは一方
の折り曲げ点が外側を向くとともに他方の折り曲げ点が
内側を向くように折り曲がった形状とすることも勿論可
能である。【００４２】（実施例２）図５に示す本実施例の相間絶
縁紙１は、非直状部としての屈曲部２２を各接続部２０
に２個ずつ設けたもので、その他の構成は上記実施例１
と同様である。【００４３】すなわち、この相間絶縁紙１の各接続部２
０は、非直状部として２個の屈曲部２２、２２を部分的
に有するもので、全体形状が略Ｓ字状をなしている。そ
して、この屈曲部２２、２２の折り曲げ点（屈曲先端）
２２ａ、２２ａ付近も、実施例１と同様、他の部分より
も幅の狭い局所的な幅狭部とされている。【００４４】また、本実施例においても、各接続部２０
は、角部やエッジをもたない形状とされている。すなわ
ち、接続部２０と上相間部１０との境界部２０ａ、各屈
曲部２２、２２の折り曲げ点（屈曲先端）２２ａ、２２
ａ及び接続部２０の下相間部１１との境界部２０ｄは、
いずれも角部やエッジをもたない丸みをもった形状とさ
れている。【００４５】なお、本実施例においても、伸張後の接続
部２０の両端同士を結ぶ両端距離（Ｄ）に対する装着前
の接続部２０の両端距離（ｄ）の比（ｄ／Ｄ）は、約１
／２とされている。【００４６】したがって、本実施例の相間絶縁紙１も上
記実施例１と同様の作用効果を奏する。【００４７】【発明の効果】以上詳述したように、本発明の回転電機
の相間絶縁紙は、ステータコアの軸方向長さよりも短い
距離を隔てて対向する両上記相間部と、非直状部を少な
くとも一部にもち両該相間部を一体に連結する接続部と
が、弾性変形可能な絶縁材料の不要部を切断除去するこ
とにより一体に形成されてなるものであるから、両上記
相間部の距離が短くなった分だけ、切断除去されて無駄
となる不要部の面積を小さくすることができる。したが
って、絶縁材料の材料歩留りを向上させることができ、
相間絶縁紙の原価の低減を図ることが可能となる。【００４８】また、本発明の相間絶縁紙は、シート状の
絶縁材料を所定形状に中抜き等することにより、両相間
部とこれらを一体に連結する接続部とを同時に形成する
ことができるため、例えば両相間部を連結するための糸
を後から固定したりする必要がなく、生産性も良好であ
る。【００４９】したがって、本発明によれば、生産性を低
下させることなく、絶縁材料の材料歩留りを向上させて
原価を低減させることのできる相間絶縁紙を提供するこ
とが可能となる。Description: BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to an interphase insulating paper of a rotary electric machine used to insulate coils of different phases at a coil end portion of a stator. 2. Description of the Related Art In general, a stator (stator) in a rotating electric machine such as an AC generator for a vehicle generally has a stator core (stator core) having a plurality of slots, and coils at both axial ends of the stator core. And a polyphase coil mounted in the slot while forming an end portion. In a coil having such a multi-phase coil, interphase insulation is provided between coils of different phases at a coil end portion. As an interphase insulating paper for performing such interphase insulation, as shown in FIG. 6, a pair of interphase portions 80 arranged between coils of different phases at respective coil end portions,
81 and a pair of connecting portions 90 and 91 that are integrally connected to each other and are inserted and disposed in a slot, are known (see Japanese Patent Application Laid-Open No. 58-12549, etc.). ). In this interphase insulating paper, the interphase portions 80, 8
The distance between them is substantially equal to the axial length of the stator core. Here, the inter-phase portions 80 and 81 are connected to the connection portion 9.
The reason why they are integrally connected by 0 and 91 is that when the interphase insulating paper is mounted on the stator, the ease of handling of the interphase insulating paper is improved and the interphase insulating paper is reliably held between the coils of different phases. As described above, the inter-phase portions 80 and 81 and the connecting portion 9
The interphase insulating paper in which 0 and 91 are integrated is generally formed integrally by cutting and removing unnecessary portions of an insulating material (eg, a polyester film) in a sheet shape or the like. For example, both ends of the substantially rectangular sheet-shaped insulating material are left as a pair of interphase portions 80 and 81, and the two interphase portions 8 are formed.
The pair of inter-phase portions 80, 81 and the pair of inter-phase portions 80, 81 are cut and removed by cutting out unnecessary portions while leaving a pair of connection portions 90, 91 between the two inter-phase portions 80, 81. Part 8
A pair of connecting portions 90 and 91 for integrally connecting 0 and 81 are integrally formed. Further, as disclosed in Japanese Patent Application Laid-Open No. 58-186346, there is an interphase insulating paper in which both interphase portions formed separately are connected by a thread. [0007] The interphase insulating paper of the rotating electric machine is extremely expensive because it is necessary to use an insulating material having a heat resistance of about 200 ° C or more. For this reason, if the cost required for the interphase insulating paper can be suppressed, it will be possible to greatly contribute to the cost reduction of the rotating electric machine. However, when the interphase insulating paper is formed by cutting and removing the unnecessary portion by hollowing out the space between the phases as described above, the insulating material of the hollowed portion is wasted. For this reason, the material yield of the high-priced insulating material is deteriorated, and the cost of the interphase insulating paper is increased. On the other hand, according to the interphase insulating paper in which the interphase portions formed separately are connected by a thread, unnecessary portions that are wasted can be reduced. However, in this case, a step for fixing the yarn to the interphase part is separately required, and the productivity is reduced due to an increase in the number of steps. SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has an object to provide an interphase insulating paper capable of improving the material yield of the insulating material and reducing the cost without lowering the productivity. It should be a technical task to be done. An interphase insulating paper of a rotating electric machine according to the present invention for solving the above-mentioned problems has a pair of interphase portions and a connecting portion for integrally connecting the interphase portions. Each of the inter-phase portions is mounted on a stator of a rotating electrical machine having a stator core having slots and polyphase coils mounted in the slots while forming coil end portions on both ends of the stator core. An interphase insulating paper disposed between the coils of different phases at the respective coil end portions and the connecting portion disposed in a state of extending straight in the slot, wherein the axial length of the stator core is The inter-phase portions facing each other at a distance shorter than the above, and the connecting portion that has at least a portion of the non-straight portion and integrally connects the inter-phase portions are unnecessary portions of an elastically deformable insulating material. Cutting and removing It is characterized by being formed more integrally. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The interphase insulating paper of a rotating electric machine according to the present invention comprises a stator core having a plurality of slots, and a plurality of slots mounted on the slots while forming coil end portions on both ends of the stator core. And a pair of inter-phase portions disposed between the coils of different phases at each of the coil end portions while being mounted on the stator. And a connecting portion which is disposed in the slot so as to extend straight and connects the two interphase portions integrally. The interphase insulating paper according to the present invention is characterized in that the interphase portions opposing each other at a distance shorter than the axial length of the stator core and the non-straight portion at least partially have the two interphase portions integrated. The greatest feature is that the above-mentioned connecting portion to be connected to is integrally formed by cutting and removing an unnecessary portion of an elastically deformable insulating material. As described above, the interphase insulating paper of the present invention is obtained by cutting and removing unnecessary portions of an elastically deformable insulating material.
The inter-phase portions facing each other at a distance shorter than the axial length of the stator core and a connecting portion having at least a part of the non-linear portion and integrally connecting the two phase portions are integrally formed. For this reason, the area of the unnecessary portion which is cut and removed and wasted becomes smaller as the distance between the two phases becomes shorter.
Therefore, the material yield of the insulating material can be improved, and the cost of the interphase insulating paper can be reduced. Further, the interphase insulating paper of the present invention can simultaneously form both interphase portions and a connecting portion for integrally connecting them by hollowing out a sheet-like insulating material into a predetermined shape. For example, it is not necessary to fix a yarn for connecting the inter-phase portions later, and the productivity is good. When the interphase insulating paper of the present invention is mounted on the stator of the rotating electric machine, the non-linear portion of the connecting portion is inserted and disposed in the slot of the stator core in a state where the non-linear portion is stretched straight by elastic deformation. The inter-phase portions are disposed between coils of different phases at the respective coil end portions. As the insulating material constituting the interphase insulating paper, any material can be used as long as it exhibits the required electric insulation and can be elastically deformed to such an extent that the non-straight portion of the connecting portion extends straight. Not limited. For example, silicon resin, nylon (66 nylon or the like) or polyimide can be used. The shape of the connecting portion is not particularly limited as long as it has a non-straight portion such as a curved portion or a bent portion in at least a part thereof. Here, the connecting portion before connecting to the stator of the rotating electric machine (the connecting portion in which the non-straight portion such as the curved portion or the bent portion has the same curved or bent shape. Hereinafter, the connecting portion before mounting. ) (The distance between both ends of the connecting portion before mounting: d), that is, the connecting portion (in a state after the non-straight portion is straightened to be mounted on the stator). In the following, the ratio (d / D) of the distance (d) between both ends of the connecting portion before mounting to the distance (D, d <D) connecting the both ends of the connecting portion after extension is reduced. The area of the unnecessary portion that is removed by being hollowed out between the portions can be reduced, and the material yield of the insulating material can be further improved. The distance (D) between both ends of the connecting portion after extension is substantially equal to the axial length of the stator core and is constant. Therefore, the value of (d / D) is 以下 or less, 以下 or less, １／ or less,..., When the non-straight portion is stretched straight by elastic deformation. It is preferable to make the size as small as possible within a range that can prevent the occurrence of. In the case where a curved portion (which is constituted by an arc) is adopted as the non-straight portion of the connecting portion,
It is preferable to increase the curvature because the value of (d / D) can be reduced. On the other hand, when a bent portion is employed as the non-straight portion of the connection portion, it is preferable to reduce the bending angle because the value of (d / D) can be reduced. Further, when the non-straight portion is stretched straight due to elastic deformation, from the viewpoint of preventing the occurrence of cracks and the like, the connecting portion has corners where cracks and the like are likely to occur due to stress concentration at the time of elastic deformation. It is preferable to have a shape that does not have. For example,
When the non-straight portion is a bent portion, the bending point (bending tip) of the bent portion is rounded, or a part of the connecting portion is formed as a curved portion or a bent portion, and the other portion is formed as a straight portion. In this case, it is preferable that the boundary between the straight portion and the curved portion or the bent portion is rounded so that the straight portion and the bent portion or the curved portion are connected by a curved line. The non-straight portion of the connecting portion is as thin as possible (has a narrow width) within a range in which a necessary minimum strength can be secured so as to prevent the occurrence of cracks or the like when extending straight. )
It is particularly preferable to have a local narrow portion in a portion where the amount of deformation is large. The number of the connecting portions is not particularly limited, and may be one or two or more. The strength of the connecting portions is ensured, and the mounting workability when mounting the interphase insulating paper to the stator is improved. From the viewpoint of, it is preferable to use two (or three). The interphase insulating paper of the present invention is formed integrally by cutting and removing unnecessary portions of a sheet-like or film-like insulating material into a predetermined shape. For example, while leaving both ends of the substantially rectangular sheet-shaped insulating material as a pair of interphase portions, leaving a pair of connection portions between the two interphase portions, removing unnecessary portions such as hollowing out between the two interphase portions. Is cut and removed into a predetermined shape, whereby an interphase insulating paper including a pair of interphase portions and a pair of connecting portions that integrally connect both interphase portions can be integrally formed. Although there is no particular limitation on the method of cutting and removing unnecessary portions from an insulating material such as a sheet, it is preferable to use laser cutting that can cut with high accuracy even in a complicated shape. Japanese Patent Application Laid-Open No. 58-12549 discloses an interphase insulating paper in which a pair of interphase portions and a pair of connecting portions for integrally connecting the two interphase portions are integrally formed. Disclosed is an interphase insulating paper in which both interphase portions are integrally connected by a pair of arcuate connection portions which are bent in an arc shape in a direction in which the connection portions are separated from each other (outside) in order to improve the mounting property and the workability thereof. Have been. This interphase insulating paper is designed to improve the mounting workability by pressing the arc-shaped connecting portion bent with an amount of bending larger than the slot width of the stator core against the inner wall of the slot to prevent the slot from coming off from the slot. . Therefore, in this interphase insulating paper,
The distance connecting both ends of the connection portion before mounting on the stator (distance between both ends of the connection portion before mounting: d) is not shorter than the axial length of the stator core. Examples of the present invention will be specifically described below. (Embodiment 1) The interphase insulating paper 1 of this embodiment is
As shown in FIG. 1, a pair of upper and lower interphase portions 10 and 11 are provided.
And a pair of connecting portions 20, 20 for integrally connecting the upper interphase portion 10 and the lower interphase portion 11. The interphase insulating paper 1 faces the stator 30 of the rotating electric machine at a distance (d) shorter than the axial length (L) of the stator core 31 of the stator 30 before being attached to the stator 30 of the rotating electric machine described later. The upper interphase portion 10 and the lower interphase portion 11 are integrally connected by a pair of connecting portions 20, 20 each having one bent portion 22, 22 as a non-straight portion. Each of the bent portions 22, 22 provided as a part of each of the connecting portions 20, 20 is bent such that the bending points (bending tips) 22a, 22a face outward. In addition, the vicinity of the bending point 22a is a local narrow portion that is narrower than other portions. Each of the connecting portions 20 is formed integrally with the upper interphase portion 10, and has an upper straight portion 21 which extends shortly in a straight line in a direction opposite to the upper interphase portion 10 and the lower interphase portion 11.
And a lower end straight portion 23 formed integrally with the bent portion 22 and the lower interphase portion 11 and extending short in a straight line in a direction opposite to the upper interphase portion 10 and the lower interphase portion 11.
Are integrally formed. And each connection part 20
It has no corners or edges. That is,
Boundary portion 20a between upper end straight portion 21 and upper interphase portion 10, boundary portion 20b between upper end straight portion 21 and bent portion 22, bent portion 22
The bending point (bending tip) 22a, the boundary portion 20c between the bent portion 22 and the lower straight portion 23, and the boundary portion 20d between the lower straight portion 23 and the lower interphase portion 11 each have a corner or an edge. It has a rounded shape and the upper straight portion 21
The lower end straight portion 23 and the bent portion 22 are connected by a curve. The interphase insulating paper 1 having such a shape was formed integrally by cutting and removing unnecessary portions of a 66-nylon film as an elastically deformable insulating material into a predetermined shape using laser cutting. As shown in FIG. 2, the interphase insulating paper 1 is mounted on a stator 30 of a rotating electric machine (not shown) with the bent portions 22, 22 of the connecting portions 20, 20 being straightened. Served for use. In the present embodiment, the ratio (d / D) of the distance (d) between both ends of the connecting portion 20 before mounting to the distance (D) connecting both ends of the connecting portion 20 after extension.
Is about 1/2. The distance (D) between both ends of the connecting portion 20 after the extension is substantially equal to (or slightly longer than) the axial length (L) of the stator core 31. As shown in FIG. 3, the stator (stator) 30 of the rotating electric machine includes a stator core 31 having a plurality of slots 31a, and coil end portions 32a formed on both ends of the stator core 31 in the axial direction. While the multi-phase (U-phase, V-phase in this embodiment)
And a W-phase coil 32). FIG. 3 shows the U-phase coil 3 out of the three-phase coils 32.
Only two are shown. Each coil 32 is formed by winding a copper wire covered with an insulating coating into a predetermined coil shape to form a winding shape, and then mounted on the stator core 31. As shown in FIG. 4, the interphase insulating paper 1 of the present embodiment is attached to the stator 30 of the rotating electric machine, and the interphase portions 10 and 11 are separated by the respective coil end portions 32a. The connecting portions 20, 20 are disposed between the coils 32 of different phases, and the connecting portions 20, 20 are disposed so as to extend straight in the slots 31a. That is, the stator core 3
At one axial end (upper end in FIG. 4), the upper interphase portion 10 is disposed between the coil end portion 32a of the coil 32 of one phase and the coil end portion 32a of the coil 32 of another phase. At the same time, the other end of the stator core 31 in the axial direction (the lower end in FIG. 4) is located between the coil end 32a of the one phase coil 32 and the coil end 32a of the other phase coil 32. A lower interphase part 11 is provided. To mount the interphase insulating paper 1 on the stator 30, first, a U-shaped slot insulator (not shown) is inserted into a slot 31a of the stator core 31 and a slot 31a separated from the slot 31a by a predetermined magnetic pole pitch. After that, the U-phase coil 32, which is separately wound and formed, is inserted. And, at the bottom of each slot 31a adjacent to each slot 31a into which the U-phase coil 32 is inserted, the bent portions 22 of the connection portions 20, 20,
22 is inserted straight from the centripetal side of the stator core 31 with the stator core 22 extended straight.
1 at the one end and the other end in the axial direction of the U-phase coil 32
Are respectively disposed on the coil end portions 32a. After that, for example, a V-phase coil 3 which is separately wound and formed in the slot 31a into which the connection portions 20 and 20 are inserted.
2 is inserted from one axial end of the stator core 31. At this time, on one end side and the other end side in the axial direction of the stator core 31, the upper and lower interphase portions 10 and 11 of the interphase insulating paper 1 disposed on the coil end portions 32 a of the U-phase coils 32. The coil end portion 32 of the V-phase coil 32
a, the upper and lower interphase portions 10 and 11 of the interphase insulating paper 1 are interposed between the coil end portion 32a of the U-phase coil 32 and the coil end portion 32a of the V-phase coil 32. Arrange each. As described above, the interphase insulating paper 1 of the present embodiment
By cutting and removing unnecessary portions of a sheet made of nylon 66 as an elastically deformable insulating material into a predetermined shape using laser cutting, a distance shorter than the axial length (L) of the stator core 31 can be reduced. Interphase part 1 facing away
0, 11 and a pair of connecting portions 2 having a bent portion 22 as a non-straight portion and connecting the inter-phase portions 10, 11 integrally.
0 and 20 are integrally formed. The ratio (d / D) of the distance (d) between both ends of the connecting portion 20 before attachment to the distance (D) between both ends of the connecting portion 20 after extension is about 1/2. For this reason, the area of the unnecessary portion which is cut and removed and wasted becomes about 1/2 as compared with the related art. Therefore,
The material yield of the insulating material can be improved, and the cost of the interphase insulating paper can be reduced. Further, the interphase insulating paper 1 of the present embodiment is formed by hollowing out a sheet-shaped insulating material into a predetermined shape or the like so that the interphase portions 10 and 11 and the connecting portion 2 for integrally connecting them are formed.
Since 0 and 20 can be formed at the same time, it is not necessary to fix a yarn for connecting the inter-phase portions 10 and 11 later, for example, and the productivity is good. Further, each connecting portion 20 of the interphase insulating paper 1 of the present embodiment has a shape having no corners where cracks or the like are liable to occur due to stress concentration during elastic deformation. In addition, in the bent portion 22 of the connecting portion 20, the vicinity of the bending point 22a, which is a portion where the amount of deformation is particularly large when extending straight, is a local narrow portion having a smaller width than other portions. . Therefore, it is possible to effectively prevent a crack or the like from being generated when the bent portion 22 as a non-straight portion extends straight by elastic deformation. In this embodiment, the bent portion 22 of each connecting portion 20 is bent so that the bending point (bending tip) 22a faces outward. Of course, it is also possible to adopt a shape in which both of them face inward, or one of the bending points faces outward and the other bending point faces inward. (Embodiment 2) The interphase insulating paper 1 of this embodiment shown in FIG.
And two other parts are provided in the first embodiment.
Is the same as That is, each connecting portion 2 of the interphase insulating paper 1
Numeral 0 partially has two bent portions 22 as non-straight portions, and has an overall S-shape. Then, the bending points (bending tips) of the bending portions 22, 22
Also in the vicinity of 22a, 22a, similar to the first embodiment, a local narrow portion having a smaller width than other portions is used. Also in this embodiment, each connecting part 20
Have no corners or edges. That is, the boundary portion 20a between the connecting portion 20 and the upper interphase portion 10, and the bending points (bending tips) 22a, 22 of the respective bent portions 22, 22.
a and the boundary portion 20 d between the lower portion 11 and the connecting portion 20 are:
Each has a rounded shape without corners or edges. In this embodiment, the ratio (d / D) of the distance (d) between both ends of the connecting portion 20 before mounting to the distance (D) connecting both ends of the connecting portion 20 after extension is approximately equal. 1
/ 2. Therefore, the interphase insulating paper 1 of the present embodiment also has the same operation and effect as those of the first embodiment. As described in detail above, the interphase insulating paper of the rotating electric machine according to the present invention comprises the above-mentioned interphase portions facing each other at a distance shorter than the axial length of the stator core, and the non-linear portions. At least in part, and a connecting portion for integrally connecting the two interphase portions is formed integrally by cutting and removing an unnecessary portion of an elastically deformable insulating material. The area of the unnecessary portion that is cut and removed and wasted can be reduced by the amount corresponding to the reduced distance. Therefore, the material yield of the insulating material can be improved,
The cost of the interphase insulating paper can be reduced. Further, the interphase insulating paper of the present invention can simultaneously form both interphase portions and a connecting portion for integrally connecting them by hollowing out a sheet-like insulating material into a predetermined shape. For example, it is not necessary to fix a yarn for connecting the inter-phase portions later, and the productivity is good. Therefore, according to the present invention, it is possible to provide an interphase insulating paper capable of improving the material yield of the insulating material and reducing the cost without lowering the productivity.

【図面の簡単な説明】【図１】実施例１に係る相間絶縁紙であって、ステー
タに装着する前の状態を示す平面図である。【図２】実施例１に係る相間絶縁紙であって、ステー
タに装着すべく接続部の非直状部を弾性変形により直状
に伸ばした状態を示す平面図である。【図３】実施例１に係り、接続部の非直状部を弾性変
形により直状に伸ばした相間絶縁紙をステータに装着す
る様子を説明する斜視図である。【図４】実施例１に係る相間絶縁紙をステータに装着
した状態を示す断面図である。【図５】実施例２に係る相間絶縁紙であって、ステー
タに装着する前の状態を示す平面図である。【図６】従来の相間絶縁紙を示す平面図である。【符号の説明】１…相間絶縁紙１０…上相間部１１…下相間部２０…接続部２２…屈曲部（非直状部）３１…ステータコ
ア３１ａ…スロット３２…コイル３２ａ…コイルエンド部 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of an interphase insulating paper according to a first embodiment, showing a state before being attached to a stator. FIG. 2 is a plan view showing the interphase insulating paper according to the first embodiment, in which a non-straight portion of a connecting portion is straightened by elastic deformation to be mounted on a stator. FIG. 3 is a perspective view illustrating a state in which a non-straight portion of a connecting portion is stretched straight by elastic deformation to attach a phase-to-phase insulating paper to a stator according to the first embodiment. FIG. 4 is a cross-sectional view illustrating a state where the interphase insulating paper according to the first embodiment is mounted on a stator. FIG. 5 is a plan view of the interphase insulating paper according to the second embodiment, showing a state before being attached to a stator. FIG. 6 is a plan view showing a conventional interphase insulating paper. DESCRIPTION OF SYMBOLS 1: Interphase insulating paper 10: Upper interphase part 11: Lower interphase part 20 ... Connection part 22 ... Bent part (non-straight part) 31 ... Stator core 31a ... Slot 32 ... Coil 32a ... Coil end part

フロントページの続きＦターム(参考） 5H603 AA04 AA09 AA15 BB02 BB09 BB12 CA01 CA05 CB03 CB05 CB11 CB23 CB24 CB26 CC03 CC17 CD02 CD22 CE05 EE01 FA02 FA04 5H604 AA05 AA08 BB03 BB10 BB14 CC01 CC05 CC13 DA13 DB26 PB02 PB03 PC03 QB14 Continuation of front page F term (reference) 5H603 AA04 AA09 AA15 BB02 BB09 BB12 CA01 CA05 CB03 CB05 CB11 CB23 CB24 CB26 CC03 CC17 CD02 CD22 CE05 EE01 FA02 FA04 5H604 AA05 AA08 BB03 BB10 BB14 CC01 CC05 CC13 DA13 DB26 PB02 PB03 PC03 QB14

Claims

Claims: 1. A stator core having a pair of interphase portions and a connecting portion integrally connecting the interphase portions, a stator core having a plurality of slots, and coil end portions on both ends of the stator core, respectively. The inter-phase portions are disposed between the coils of different phases at the respective coil end portions in a state where the inter-phase portions are mounted on the stator of the rotating electric machine including the multi-phase coils mounted in the slots while forming. Interphase insulating paper provided with the connection portion extending straight in the slot, the interphase portions facing each other at a distance shorter than the axial length of the stator core; Wherein the connecting portion which has at least a portion and which integrally connects the interphase portions is integrally formed by cutting and removing an unnecessary portion of an elastically deformable insulating material. Electric phase insulation .