JP2005224035A - Integrated type stator case of rotary electric machine, and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obviate the need for the core plate of a stator for rotary electric machines enabling shortening of the manufacturing process for it and enhance its electrical characteristics. <P>SOLUTION: A rotary electric machine is constituted of coils 5 are disposed at predetermined intervals in the circumferential direction. The entire circumferences of the coils 5 are encircled with magnetic resin 2, a composite material of magnetic powder 3 formed of metal material and thermosetting resin 4. The resin is heated and molded to integrally form a stator case 1. A rotor 6 is assembled into the integral stator case 1 to obtain the rotary electric machine. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

    The present invention relates to a stator of a rotating electric machine such as an electric motor and a generator, and a method for manufacturing the same.

7 to 9 show a conventional stator and its manufacturing apparatus disclosed in, for example, Japanese Patent Publication No. 49-95103. In the figure, reference numeral 2 denotes a magnetic powder 3 made of a magnetic metal such as iron powder. And a thermosetting resin 4 are mixed with a magnetic material resin 5, a coil whose surface is electrically insulated and formed in a predetermined shape, 51 is a stator core, and a predetermined number of inner cores along the circumferential direction. A predetermined number of circular core plates 51a made of thin steel plates provided with slots 52 are laminated in the axial direction, and the outer periphery is fixed by welding or the like. 53 is an insulating sheet, and 54 is a coil stopper made of an insulating material.
Reference numerals 55 and 56 denote split molding dies, and grooves 55a and 56a are formed along the circumferential direction on the split surface to form spaces 55b and 56b. 57 is a flow path into which the filling material of the magnetic resin 2 is poured, and 58 is an extended flow path, which is provided at the tip of the flow path 57 and extends to the center of the inner peripheral surface of the stator core 51. And the front-end | tip of this extended flow path 58 is match | combined with the position of the slot 52, and is provided in several places at equal pitches.

Next, the operation will be described. After inserting the insulating sheet 53 into the slot 52 of the stator core 51 formed by laminating a predetermined number of circular core plates 51a made of thin steel plates and fixing the outer periphery by welding or the like, and then inserting the coil 5 Then, the coil stopper 54 made of an insulating material is inserted to fix the coil 5 in the slot 52. Thereby, a stator around which the coil 5 is wound is formed.
Next, one of the split molds 55 is installed with the groove 55a as the upper surface. The coil 5 wound around the stator core 51 is installed in the groove 55a of the molding die 55 in this state.
Next, the other molding die 56 provided with the flow path 57 is laminated on the lower molding die 55 so as to cover the coil 5 with the groove 56a protruding upward.
This state is shown in FIG. Next, the magnetic resin 2 in which the magnetic powder 3 as the filling material and the thermosetting resin 4 are mixed is sent from the flow path 57 of the molding die 56 under pressure.
As a result, the magnetic resin 2 is diverted from the central portion in the width direction of the stator to the end surfaces on both sides from the flow passage 57 through the flow passage 58, and the molding dies 55 and 56 are respectively separated. The spaces 55b and 56b are filled and further filled while flowing through the gap between the coil 5 and the gap between the coil 5 and the slot 52.
As described above, when the injection of the magnetic resin 2 is completed, the molding dies 55 and 56 are heated at a predetermined temperature for a predetermined time to cure the magnetic resin 2.
Next, the split molding dies 55 and 56 are opened to take out the stator.
JP 49-95103 A

Since the conventional stator of a rotating electric machine is configured as described above, a mold and a press punching operation are required to form a circular iron core plate and a slot made of a thin steel plate, and these circular iron core plates are laminated. It must be fixed by welding, etc., and the cost increases, the manufacturing process is long, the manufacturing time is long, only the coil material shape that can be easily inserted into the slot can be selected, and the coil space factor is reduced. There were problems, such as being unable to take large.

The present invention has been made to solve the above-described problems. Since a stator core is not required, the cost can be reduced, the number of manufacturing days can be shortened, and the coil material shape can be freely fed. It is an object of the present invention to provide an integrated stator container for a rotating electrical machine that can be selected, and to provide a manufacturing method suitable for this apparatus.

A first object of an integrated stator container for a rotating electrical machine according to the present invention is to arrange wound coils at a predetermined interval along the circumferential direction, and magnetic powder and a thermosetting resin around the entire circumference of these coils. And a stator core part is formed while being surrounded and fixed by a magnetic resin made of a mixed material.
The second object of the present invention is to improve the electrical safety such as electric leakage because the outer peripheral portion and inner peripheral portion of the integral stator container and the surface portions of the both side surface portions are formed only by a thermosetting resin having a predetermined thickness. To do.
The third object of the present invention is that the outer shape of the integrated stator container is not an ordinary cylindrical shape or a square shape, but is formed to be a different shape, for example, an aesthetic appearance such as an ornament, and an object to be viewed. is there.
A fourth object of the present invention is to provide a manufacturing method in which a wound and formed coil is fixed to the core of a stator container forming device, inserted into a mold and sealed, and magnetic powder, a thermosetting resin, A magnetic resin mixed with is injected from the injection port and then cured by heat treatment to be integrally formed as a stator.
According to a fifth object of the present invention, in the manufacturing method, the magnetic resin is injected by making the fitting gap of the lower fitting portion between the core and the mold of the stator container forming device smaller than the magnetic powder. At this time, only the thermosetting resin flows out from the fitting gap and the magnetic powder remains so that no electrical loss occurs.
The sixth object of the present invention is to easily form the outer shape of the stator container into a different shape by forming the material of the mold of the stator container forming apparatus with a non-metal, for example, a gypsum member, in the manufacturing method. .
A seventh object of the present invention is to provide a manufacturing method in which a coil is disposed in a stator container forming device, a magnetic resin is injected, and then a predetermined current is applied to the lead wire of the coil impregnated in the resin. Thus, an electromagnetic action is improved by applying an electrical action to the magnetic powder in the magnetic resin.
An eighth object of the present invention is to inject the thermosetting resin after applying a predetermined thickness on the inner surface of the stator container forming device on the surface facing the outer surface and inner peripheral parts of the stator container in the manufacturing method. The magnetic resin is thermoformed at the same time.

As described above, according to the first aspect of the present invention, since the entire periphery of the coil is cured and molded with the mixed material of magnetic powder and thermosetting resin to form the integral stator container, the stator core is unnecessary. This eliminates the need for expensive die manufacturing costs, punching operations, core stacking operations, and iron core welding operations. In addition, since there is no slot, the coil material shape can be freely selected. It is possible to reduce the spacing between the slots and to increase the coil space factor because there is no need to consider the strength of the iron core between the slots. In addition, a stator frame for fixing the stator is not necessary, and can be directly brought into contact with the outside air.
Thus, the cost required for production can be reduced, the production process can be shortened, and the electrical characteristics can be improved.
According to the second aspect of the present invention, since the entire outer surface of the stator container integrated with the magnetic material resin is coated with the thermosetting resin, the electrical insulation is good and the water can be cooled. Therefore, the operation efficiency is improved, and there is an effect that it can be used even in water.
According to the third aspect of the present invention, since the outer shape of the stator container is formed in a different shape, an unexpected viewing effect such as an ornament can be obtained.
Further, according to the fourth aspect of the present invention, since the manufacturing method of solidifying the entire surface of the coil formed by the winding with the magnetic resin mixed with the magnetic powder and the thermosetting resin, the stator can be manufactured easily. There is an effect that can be made.
According to the fifth aspect of the present invention, since the size of the fitting gap of the part for injecting the magnetic resin is configured to be smaller than the particle size of the magnetic powder, the electrical characteristics do not flow out. There is an effect that can prevent the decrease.
According to claim 6 of the present invention, the form of the stator container forming apparatus is configured to be provided with a non-metallic material. Therefore, even if the outer shape of the stator container is complicated, gypsum or the like is used. It has the effect of being easy and quick to produce.
Further, according to the seventh aspect of the present invention, since the magnetic material resin is injected into the stator container forming apparatus and then the predetermined current is applied to the coil, the magnetic material mixed in the thermosetting resin is configured. Since powder moves and concentrates in the flow direction of magnetic flux due to electrical correspondence, there is an effect that a field portion with good electrical efficiency can be obtained.
Further, according to the eighth aspect of the present invention, when the integrated stator container is manufactured, since the outer insulating portion and the inner peripheral portion of the stator container are configured to form an electrically insulating film with a thermosetting resin, There are effects such as improvement of operating efficiency and use in water by water injection cooling.

  Embodiment 1 of the present invention will be described below with reference to the drawings. 1 and 2, 1 is an integrated stator container of a rotating electric machine, 3 is a magnetic metal, for example, magnetic powder made of fine 100 micron iron powder, 6 is a rotor, and 7 is one of the rotors. A bearing for bearing, 8 is a bearing for supporting the other one of the rotors, 9 is a pressing plate for fixing one bearing 7, and 10 is a pressing plate for fixing the other bearing 8. Other symbols are the same as the conventional symbols, and the description is omitted.

Next, the operation will be described. An integrated stator container 1 of a rotating electrical machine is provided between coils of a predetermined number of coils 5 arranged at predetermined intervals along the circumferential direction, and the outer and inner peripheral portions of the coils 5 and both side portions of the coil end. Since the magnetic resin 2 is filled, the member is formed of only the coil 5 and the magnetic resin. This magnetic resin 2 is obtained by mixing fine magnetic powder 3 and thermosetting resin 4 and solidifying it by heat treatment.
Next, the bearing 7 is inserted and fixed to one step portion of the rotor 6, and the bearing 8 is inserted and fixed to the other step portion. The rotor 6 in this state is inserted into the stator container 1, and the holding plates 9 and 10 are attached to the stator container 1 with bolts (not shown), whereby the bearings 7 and 8 are fixed, and the bearings 7 and 8 rotate. The child 6 is supported to form a rotating electrical machine.
Thus, since the stator container 1 does not have the stator core 51, no punching die is required, no lamination work or welding work is required, and no coil stopper 54 is required, so that the distance between the coil 5 and the inner diameter portion is reduced. can do.

Moreover, in Embodiment 1 of the said invention, the coil 5 was entirely enclosed with the magnetic body resin 2 which mixed the magnetic powder 3 and the thermosetting resin 4, and the integrated stator container 1 was formed. However, as shown in FIG. 3, the thermosetting resin 4 having a predetermined thickness is provided on the outer surface portion and the inner periphery portion formed by the outer peripheral portion and both side portions of the integral stator container 1 formed of the magnetic resin 2, respectively. The coating portion 17 is provided.
In addition, the thickness of the coating | coated part 17 is provided so that an inner peripheral part may be thinner than an outer surface part, and it may not reduce electromagnetic efficiency.
As described above, since the electrical insulating portion is formed on the entire outer surface of the integrated fixed container 1, leakage can be prevented.

In the first embodiment of the present invention, the outer shape of the integral stator container 1 formed entirely surrounded by the magnetic resin 2 is shown to have a normal square cross section. When applied to a different shape, for example, an ornament to be viewed, the aesthetic value can be increased.
An example is shown in FIG. In the figure, 18 is a vertical rotary electric machine, 19 is a vase-shaped stator container whose outer shape of the stator is formed of a magnetic resin 2 in a vase shape, 20 is a rotor, and 21 is fixed to the shaft end of the rotor 20. The vase 22 is a flower.
Next, the operation will be described. The vertical rotary electric machine 18 is provided for multiple poles, that is, for a low speed, and when the rotor 20 is rotated by operation and the vase 21 into which the flower 22 is inserted rotates, the flower 22 can be viewed from various angles. it can. In this way, by utilizing the thermosetting resin 4 that is easy to shape, the outer shape of the stator container 1 is made into the shape of an ornamental ornament, thereby providing an unexpected viewing effect. Moreover, it is good to rotate the stator container 1 by fixing the rotor 6, and the unexpectedness and the ornamental effect increase more.

Next, a method for manufacturing the integral stator container 1 shown in the first embodiment of the present invention will be described. In FIG. 8, 11 is a stator container forming device, 12 is a cylindrical core that forms the inner diameter part of the integral stator container 1, and 13 is an outer shape part and one side surface part of the integral stator container 1. In this embodiment, a square inner surface 13a is provided on the inner surface. Reference numeral 14 denotes a square plate-like lower mold, which is in contact with the bottom of the mold 13 and is fixed by a bolt or the like (not shown). Reference numeral 15 denotes an upper mold that forms the other side surface portion of the integrated stator container 1. A rectangular inner surface 15 a is provided on the lower surface, an injection portion 16 is provided penetrating in the thickness direction, and the lower surface is the mold 13. It can be easily removed by coming into contact with the upper surface, for example, with bolts. These component materials are provided by, for example, steel materials.
Next, the operation will be described. The coils 5 formed in a predetermined shape are arranged and fixed at predetermined intervals along the circumferential direction around the core 12. At this time, an insulating material having a predetermined thickness is interposed between the coil 5 and the core 12 so as to be in a predetermined position in the axial direction, and is fixed with an insulating string or the like.
Next, the core 12 fitted with the coil 5 is inserted into the mold 13 fixed to the lower mold 14, and the lead wire 5 a of the coil 5 is taken out upward from a through hole provided in the upper mold 15. The upper die 15 is attached on the mold 13 by pulling outward.
Next, a mixture of magnetic powder 3 made of a metal material having a particle size of about 100 microns and thermosetting resin 4 made of epoxy resin is poured from the injection part 16 of the upper mold 15 into the mold 13 to fill the interior space. Continue until When the injection is completed, the stator container forming device 11 is heated to about 100 ° C., the injected thermosetting resin 4 is cured to fix the magnetic powder 3, and the coil 5 is entirely made of the magnetic resin 2. Thus, an integrated stator container 1 is formed.
Next, the upper mold 15 and the mold 13 are sequentially removed, and the finished product of the integrated stator container 1 incorporating the coil 5 is taken out from the mold 13.
As described above, since there are not a few constituent members of the stator, the number of manufacturing steps and the manufacturing time can be greatly reduced, and the manufacturing is simplified.

Moreover, in Embodiment 4 of the said invention, although the core 12 and the formwork 13 of the stator container forming apparatus 11 were fitted and positioned at the lower part, the fitting gap 12a was set to 100 microns or less. For example, 50 microns.
Since the particle size of the magnetic powder 3 is about 100 microns, even if it is poured into the stator container forming apparatus 11 together with the thermosetting resin 4, it is outward from the fitting gap 12a between the core 12 and the mold 13. There is no leakage and no magnetic loss occurs. (Fig. 6)

Moreover, in Embodiment 4 of the said invention, what showed the material of the mold 13 and the upper mold | type 15 of the stator container formation apparatus 11 provided with the steel material was shown, However, It is a nonmetallic material, for example, a gypsum material or a resin material. This can be provided, and even if the outer shape of the stator container 1 is different from the appearance of a conventional rotating electric machine, it can be easily manufactured and can be dealt with immediately. This is optimal for the production of the vase-shaped stator container shown in the third embodiment.
Thus, if the formwork 13 is provided with gypsum or the like, it can be easily manufactured even if it has a complicated outer shape, and is particularly effective in the case of single-piece manufacture.
Moreover, it can contribute to provision of an electrically insulating formwork in the case of Embodiment 7 described later.

Moreover, in Embodiment 4 of the said invention, although what was hardened | cured by heat processing after inject | pouring the magnetic powder 3 and the thermosetting resin 4 in the stator container formation apparatus 11, the stator container formation apparatus 11 was shown. After injecting the magnetic powder 3 and the thermosetting resin 4 into the inside, a current is applied to the lead wire 5a of the coil 5 from a predetermined device. As a result, a magnetic field is generated around the coil 5, and the magnetic powder 3 mixed in the thermosetting resin 4 is induced by the magnetic flux, and moves and concentrates along the flow of the magnetic flux. Is configured. (Fig. 7)
As a result, a highly efficient electric characteristic can be obtained.

In the fourth embodiment, the magnetic powder 3 and the thermosetting resin 4 are injected into the stator container forming apparatus 11 and then cured by heat treatment. As shown in FIG. Only the thermosetting resin 4 having a predetermined thickness is previously applied to the inner surface of the stator container forming apparatus 11, that is, the predetermined outer peripheral surface of the core 12, the inner surface 13a of the mold 13, and the inner surface 15a of the upper mold 15. Are applied and fixed, and these parts are assembled as prescribed.
Next, when the mixed material of the magnetic powder 3 and the thermosetting resin 4 is injected into the stator container forming apparatus 11 provided in this state and then cured by heat treatment, the outer surface and the inner periphery are electrically insulated. The integrated stator container 1 covered with the film is obtained.

The integrated stator container is excellent in water resistance, and can be used as a power generator for wind power generation or hydroelectric power generation using natural energy.
It can also be used as a wheel-integrated motor for electric vehicles and electric motorcycles.

It is front sectional drawing which shows the integrated stator container of the rotary electric machine by Embodiment 1 of this invention. It is a side view of FIG. 1 of this invention. It is front sectional drawing which shows the integrated stator container by Embodiment 2 of this invention. It is front sectional drawing which shows the integrated stator container by Embodiment 3 of this invention. It is front sectional drawing which shows the manufacturing method of the integrated stator container by Embodiment 4 of this invention. It is a fragmentary front sectional view which shows the fitting part of the stator container formation apparatus components by Embodiment 5 of this invention. It is a partial side view which shows the manufacturing method of the integrated stator container by Embodiment 7 of this invention. It is front sectional drawing which shows the manufacturing method of the outer periphery film | membrane of the integral type stator container by Embodiment 8 of this invention. It is a partial front view which shows the stator of the conventional rotary electric machine. It is a side view which shows the stator of the conventional rotary electric machine. It is front sectional drawing which shows the manufacturing method of the stator of the conventional rotary electric machine.

Explanation of symbols

1. Integrated stator container 2. Magnetic resin Magnetic powder 4. 4. Thermosetting resin Coil 6. Rotor 11. Stator container forming device 12. Core 12a. Fitting gap 13. Formwork 13b. Inner surface 14. Lower mold 15. Upper mold 15a. Inner surface
16. Injection part 17. Coating part

Claims (8)

Rotation characterized in that wound coils are arranged at predetermined intervals along the circumferential direction, and the entire circumference of these coils is surrounded and fixed by a magnetic resin made of a mixture of magnetic powder and thermosetting resin. Electric integrated stator container. 1. The integrated stator for a rotating electrical machine according to the first item, wherein the outer surface and the inner periphery of the integral stator container formed of magnetic resin are formed only of a thermosetting resin having a predetermined thickness. container. The integrated stator container for a rotating electric machine according to the first item, wherein the outer shape of the stator container is formed in a different shape. After the coil formed by winding is installed at a predetermined interval along the circumferential direction between the mold and the core of the stator container forming device, and after injecting a magnetic resin mixed with magnetic powder and thermosetting resin, A method of manufacturing an integrated stator container for a rotating electrical machine, wherein the stator is integrally formed by heat treatment. The manufacturing method of an integrated stator container for a rotating electrical machine according to the fourth aspect, wherein the fitting gap in the lower fitting portion between the core and the mold is smaller than that of the magnetic powder. 5. A method for manufacturing an integrated stator container for a rotating electrical machine according to claim 4, wherein the mold is formed of a non-metallic material. In the fourth item, after injecting the magnetic resin into the stator container forming device, a predetermined current is applied from the lead wire of the impregnated coil to easily orient the magnetic powder in the field. A method of manufacturing an integrated stator container for a rotating electrical machine. In the item of item 4, after applying a predetermined thickness of thermosetting resin on the inner surface of the stator container forming device and forming the outer surface portion and inner peripheral portion of the integrated stator container, the magnetic resin is injected. At the same time, it is thermoformed.

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