JP2006141076A - Stator structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator structure in which the size can be reduced, assembling process is simplified, a strong coil structure enduring even against an external force is provided, and quality of the coil can be ensured. <P>SOLUTION: The stator structure 1 having a stator core section 11 for forming a slot 21 is further provided with a linear portion conductor segment 32 consisting of the conductor surface, an insulator 31 being inserted into the slop 21 and having a hole 41 for inserting the linear portion conductor segment 32, a coil end portion conductor segment 33 having opposite end faces formed in the same direction, and a conductive adhesive 34 for bonding the end face of the linear portion conductor segment 32 and the end face of the coil end portion conductor segment 33. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a stator structure that can be miniaturized in the axial direction and a manufacturing method thereof.

As prior art, there are inventions described in the following patent documents.
First, Patent Document 1 will be described as Prior Art 1 with reference to FIGS. 13 and 14. FIG. 13 is an outline view showing the stator structure 101 of the rotating electrical machine in Patent Document 1 in an exploded manner. FIG. 14 is a schematic connection diagram between the integrated multilayer coil pieces 120a and 120m.
As shown in FIG. 13, the stator structure 101 of the rotating electrical machine described in Patent Document 1 includes a stator core 110, a laminated coil piece 120, a connection ring side thin plate-like connection coil piece 130, and the other end side thin plate. The connection coil piece 140 and the connection ring 150 are configured.
The stator core 110 has 12 tooth portions 112 arranged in the circumferential direction, and 12 slots 114 formed between adjacent tooth portions 112 are arranged.

  The laminated coil piece 120 includes 12 independent integrated laminated coil pieces 120a, 120b,..., 120k, 120m (hereinafter referred to as “integrated laminated coil pieces 120a etc.”). Here, as shown in FIG. 14, the integral laminated coil piece 120 a and the like are obtained by laminating a plurality of thin plate conductors (for example, copper) at a predetermined interval and integrally molding them using an insulating resin. In the 12 slots 114 of the stator core 110, the integrated laminated coil piece 120a and the like are respectively inserted. Further, at both ends of the integrated laminated coil piece 120a and the like, connection end portions 122a1, 122a2,..., 122m2 (hereinafter referred to as “connection end portion 122a1 etc.”) and connection end portions 124a1, 124a2,. , “Connection end portion 124a1 etc.”). In FIG. 13, for convenience of expression, only three each (connection end portions 122a1, 122a2, 122m2 and connection end portions 124a1, 124a2, 124m2) are provided with reference numerals.

  The connection ring side thin plate-like connection coil piece 130 includes twelve connection coil pieces 130ab, 130bc,... 130km, 130ma (hereinafter referred to as “connection coil pieces 130ab etc.”), which are arranged in an annular shape. . In FIG. 13, only the connection coil piece 130ma is shown for convenience of expression. Here, the connection coil pieces 130ab and the like are obtained by laminating a plurality of thin plate conductors (for example, copper) at regular intervals and integrally molding them using an insulating resin. As shown in FIG. 14, for example, the connection coil piece 130ma includes a connection end portion 122a1 provided on the connection ring side thin plate-like connection coil piece 130 side of the integrated multilayer coil piece 120a, and an integrated multilayer coil piece. A connecting end 122m2 provided on the 120m connecting ring side thin plate connecting coil piece 130 side is connected.

  The other end side thin plate-like connecting coil piece 140 includes twelve connecting coil pieces 140ab, 140bc,... 140km, 140ma (hereinafter referred to as “connecting coil pieces 140ab etc.”), which are arranged in an annular shape. . In FIG. 13, only the connecting coil piece 140ma is shown for convenience of expression. Here, the connection coil pieces 140ab and the like are obtained by laminating a plurality of thin plate conductors (for example, copper) at a predetermined interval and integrally molding them using an insulating resin. As shown in FIG. 14, for example, the connection coil piece 140ma includes a connection end portion 124a1 provided on the other end side thin plate-like connection coil piece 140 side of the integrated laminated coil piece 120a, and an integrated laminated coil piece. The connection end 124m2 provided on the other end side thin plate-like connection coil piece 140 side of 120m is connected.

  The connection ring 150 connects the integrated laminated coil piece 120a and the like, and is connected to the outside from a plurality of independent connection ring pieces and neutral pieces. Each of the plurality of connecting ring pieces and the neutral piece is formed by integrally molding a plurality of thin plate-like conductors (for example, copper) in an annular shape with a gap therebetween, and then using an insulating resin.

Such a stator structure 101 of a rotating electrical machine is formed as follows.
First, the connection end portion 122a1 provided on the connection ring side thin plate-like connection coil piece 130 side of the integrated laminated coil piece 120a is abutted against the connection coil piece 130ma disposed in the connection ring side thin plate connection coil piece 130. After being welded. Then, the connecting end 122m2 provided on the connecting ring side thin plate-like connecting coil piece 130 side of the integrated laminated coil piece 120m adjacent to the integrated laminated coil piece 120a is also abutted and then welded.
Similarly, a connecting end portion 124a1 provided on the other end side thin plate-like connecting coil piece 140 side of the integrated laminated coil piece 120a is connected to the connecting coil piece 140ma arranged in the other end side thin plate connecting coil piece 140. After being abutted, they are welded together. The connection end portion 124m2 provided on the other end side thin plate-like connecting coil piece 140 side of the integrated laminated coil piece 120m adjacent to the integrated laminated coil piece 120a is also abutted and then welded.
The connection as described above is sequentially performed from the integrated laminated coil piece 120a to the integrated laminated coil piece 120m.
That is, in order to form a stator coil wound around each tooth portion 112 of the stator core 110, both ends of the integrated laminated coil piece 120 are connected to the connecting ring side thin plate-like connecting coil piece 130 and the other end side. It is assumed that the connection is made by the thin plate-like connecting coil piece 140.
Thereafter, the stator structure 101 of the rotating electrical machine is formed by connecting the connection ring 150 to a predetermined position.

Next, Patent Document 2 will be described as Prior Art 2 with reference to FIG. FIG. 15 shows a stator structure 201 of a rotating electrical machine in Patent Document 2. FIG. 15 (a) is an external view, and FIG. 15 (b) is a cross-sectional view.
As shown in FIG. 15, the stator structure 201 of the prior art 2 mainly includes a shaft 202, an armature core 203, a coil divided body 205, and a coil divided body 206. And the coil division body 205 and the coil division body 206 are inserted in the through-hole 204 formed in the armature core 203, and each end surface is joined. In addition, the coil division body 205 is comprised from coil piece 205a, 205b, and the coil division body 206 is comprised from coil piece 206a, 206b.

The stator structure 201 is assembled as follows.
First, the coil pieces 205 a and 205 b of the coil divided body 205 and the coil pieces 206 a and 206 b of the coil divided body 206 are inserted into the through holes 204 so that the end faces are joined to each other. And these end surfaces are electrically joined by the following methods.
(1) A method of welding the end faces by energizing both the coil divided body 205 and the coil divided body 206 while pressing them in the axial direction.
(2) A method in which the coil divided body 205 and the coil divided body 206 are joined by applying ultrasonic waves to the two while pressing the coil divided body 206 in the axial direction.
(3) A method of joining by brazing using a metal material having a melting point lower than that of the coil divided body 205 or the coil divided body 206.
(4) A method in which fitting means are provided between the end faces of the coil pieces 205a and 205b of the coil divided body 205 and the coil pieces 206a and 206b of the coil divided body 206 and mechanically coupled. (For example, the convex portions provided on the end faces of the coil pieces 205a and 205b of the coil divided body 205 and the concave portions provided on the end faces of the coil pieces 206a and 206b of the coil divided body 206 are respectively pressed and fitted from the axial direction. how to.)

Next, Patent Document 3 will be described as Prior Art 3 with reference to FIGS. 16 and 17. FIG. 16 is an external view of a part of a stator structure 301 of a rotating electrical machine in Patent Document 3. FIG. 17 is an external view of the conductor segment 333.
As shown in FIG. 16, the stator structure 301 of the prior art 3 has a stator core 332, a conductor segment 333, and an insulator 334. The stator core 332 is formed by overlapping thin steel plates in order to form a large number of slots 335 on the inner peripheral surface thereof. The conductor segment 333 forms a stator winding as a plurality of electric conductors. The insulator 334 electrically insulates between the stator core 332 and the conductor segment 333. The coil end 331 of the stator winding is formed by a conductor segment 333 exposed from the stator core 332.

The stator structure 301 is assembled as follows.
First, a conductor segment 333 formed in a substantially U shape as shown in FIG. 17 is inserted into each slot 335 of the stator core 332. After the insertion, the conductor segment 333 is bent, and the end portions 333a of the arbitrary conductor segments 333 are welded and connected.

Next, Patent Document 4 will be described as Prior Art 4 with reference to FIG. FIG. 18 is an external view of a part of a stator structure 401 of a rotating electrical machine in Patent Document 4.
As shown in FIG. 18, the stator structure 401 includes a stator 412, a conductor segment 416, and a strip spacer 420. A slot 414 is formed in the stator 412.
The stator structure 401 is assembled as follows.
A plurality of conductor segments 416 formed in a substantially U shape are inserted into the slot 414 in the circumferential direction and the radial direction. Then, the conductor segment 416 is bent at a portion protruding when the conductor segment 416 is inserted into the slot 414, and the end portions of the arbitrary conductor segment 416 are welded together. A plurality of phase coils formed in this way are formed with a phase angle. Then, a spacer 420 is inserted into a radially adjacent portion of the joint 418 where the conductor segments 416 are welded together. The spacer 420 is formed of a highly insulating material such as resin, and the joint portions 418 adjacent in the radial direction are insulated from each other.
JP 2001-178053 (paragraphs 0011-0019, 0032, 0037, FIG. 1) Japanese Patent Laid-Open No. 10-117455 (paragraphs 0013 and 0014, FIG. 1) JP-A-11-341730 (paragraphs 0017, 0029-0032, FIG. 6) JP 2003-219591 (paragraphs 0009 and 0010, FIG. 1)

However, the following problems exist in the prior art.
First, with regard to the prior art 1, welding connection is performed at the connection end portion 122a1 and the like and the connection end portion 124a1 that protrude from the slot 114 formed in the stator core 110. That is, the joint portion exists outside the slot 114. Therefore, the height of the connecting end 122a1 and the like and the connecting end 124a1 protruding from the slot 114 increases in the direction of the central axis of the stator structure 101 of the rotating electrical machine. Therefore, the stator structure 101 of the rotating electrical machine may be increased in size.
In addition, since welding is accurately performed between the connecting end 122a1 and the like and the connecting end 124a1 and the like, and the connecting coil piece 130ab and the connecting coil piece 140ab and the like, a sufficient working space for the welding work is ensured. It will be necessary.
Further, with regard to the prior art 1, a coil is called so-called concentrated winding, in which a coil is composed of the connecting end 122a1 and the like such as the integrated laminated coil piece 120a and the connecting end 124a1 that are inserted into the adjacent slots 114. It is assumed that the method is configured. Therefore, in terms of configuration, a coil is formed by a so-called distributed winding, in which a coil is composed of the connecting end portion 122a1 and the like such as the integrated laminated coil piece 120a and the connecting end portion 124a1 and the like that are inserted into the separated slots 114. It is not possible.

Next, with regard to the prior art 2, a welding machine, an ultrasonic machine, a brazing machine, etc. are separately used for joining, such as a method of welding while pressing, a method of joining by applying ultrasonic waves, and a method of joining by brazing. The assembly process of the stator structure 201 becomes complicated, and the cost of the material increases.
Further, regarding the method of mechanically coupling by providing the fitting means, when a tensile force acts on the fitting portion, there is a possibility that the force cannot be sufficiently resisted.

Next, for the prior art 3, the end portions 333a of the conductor segment 333 are welded to each other, and for the prior art 4, the end portions of the conductor segment 416 are welded to each other. Generally, TIG welding is considered as the welding technique. It is done. Here, in order to perform TIG welding, it is necessary to take a welding ground, and a shape for clamping the welded portion (a clamp segment 333b in the conductor segment 333 and a joint portion 418 in the conductor segment 416) is necessary. become. Therefore, the coil end portion including the end portion 333a of the conductor segment 333 and the end portion of the conductor segment 416 becomes large, and becomes large in the central axis direction of the stator structure 301 or 401 of the rotating electrical machine. Therefore, the stator structure 301 or 401 of the rotating electrical machine may be increased in size.
Further, a coil end twisting step is separately required in order to obtain a shape that can be welded at the ends of the conductor segments (333, 416). Furthermore, when a coil with an insulating film is used as the conductor segment (333, 416), a film removing step is separately required. This complicates the assembly process of the stator structure 301 or the stator structure 401, and increases the cost of the material.
In addition, by performing welding and joining, the insulation film is damaged by heat at the time of welding at the coil end, and it is difficult to ensure quality.

  Accordingly, the present invention has been made to solve the above-described problems, and can reduce the size of the stator structure, simplify the assembly process of the stator structure, and can withstand a force from the outside. An object of the present invention is to provide a stator structure that can secure the quality of a coil.

In order to achieve the above object, the present invention has the following features.
(1) In a stator structure having a stator core portion in which a slot is formed, a linear conductor segment made of a conductor surface, an insulating insulator in which an insertion hole for inserting the linear conductor segment is formed and inserted in the slot, and in the same direction A coil end portion conductor segment having both end faces formed in the direction of the first and second ends, and a conductive adhesive that bonds the end face of the straight portion conductor segment and the end face of the coil end portion conductor segment.

(2) In the stator structure described in (1), the end face of the linear conductor segment and the end face of the coil end conductor segment are bonded at a position in the insertion hole where the conductive adhesive does not overflow from the insertion hole during bonding. It is characterized by that.

(3) In the stator structure described in (1) or (2), chamfering is formed on the end face of the straight conductor segment and the end face of the coil end conductor segment, and the end face of the straight conductor segment and the coil end portion When bonding the end surface of the conductor segment with a conductive adhesive, the conductive adhesive is allowed to flow into the gap between the straight conductor segment and the insertion hole and the gap between the coil end conductor segment and the insertion hole. The adhesive area on the surface is expanded, and the input volume of the conductive adhesive between the linear conductor segment and the coil end conductor segment is increased.

(4) In any one of the stator structures described in (1) to (3), the coil end portion conductor segment is integrated with the stator end portion assembled to the stator core portion.

(5) In a method for manufacturing a stator structure having a stator core portion in which slots are formed, a step of inserting an insulating insulator into the slot, and a step of inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator And a step of applying a conductive adhesive to the end face of the straight portion conductor segment, and a step of attaching a stator end portion integrated with the coil end portion conductor segment in which both end faces are formed in the same direction to the stator core portion. It is characterized by having.

(6) In a method of manufacturing a stator structure having a stator core portion in which slots are formed, a step of inserting an insulating insulator into the slot, and a step of inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator. A step of attaching a stator end part integrated with a coil end part conductor segment having both end faces formed in the same direction to the stator core part, and pressurizing the stator end part to press the end part of the straight part conductor segment and the coil And a step of diffusion bonding the end faces of the end conductor segments.

The present invention having such characteristics has the following operations and effects.
(1) The present invention provides a stator structure having a stator core portion in which a slot is formed, and an insulating insulator that is inserted into a slot in which a linear conductor segment made of a conductor surface and an insertion hole into which the linear conductor segment is inserted are formed. And a coil end conductor segment having both end faces formed in the same direction, and a conductive adhesive that bonds the end face of the straight conductor segment and the end face of the coil end conductor segment. By reducing the height of the stator, the stator structure can be reduced in size, and the stator structure can be completed simply by assembling the stator core part and the stator end part. Securely bonds the end face of the segment to the end face of the coil end conductor segment Te has strong coil structure can withstand the external force, the welding operation is attained that ensure quality of unnecessary and it without exposing the straight portions conductor segments and the coil end section conductor segments to high temperature coil.

(2) In the stator structure described in (1), the end face of the linear conductor segment and the end face of the coil end conductor segment are bonded at a position in the insertion hole where the conductive adhesive does not overflow from the insertion hole during bonding. Therefore, in addition to the effect described in (1), necessary insulation can be ensured.

(3) In the stator structure described in (1) or (2), chamfering is formed on the end face of the straight conductor segment and the end face of the coil end conductor segment, and the end face of the straight conductor segment and the coil end portion When bonding the end surface of the conductor segment with a conductive adhesive, the conductive adhesive is allowed to flow into the gap between the straight conductor segment and the insertion hole and the gap between the coil end conductor segment and the insertion hole. In addition to the effect described in (1) or (2), the adhesive area on the surface is enlarged and the input volume of the conductive adhesive between the linear conductor segment and the coil end conductor segment is enlarged. Adhesive strength increases due to the expansion of the bonding area of the conductive adhesive, and between the end face of the straight conductor segment and the end face of the coil end conductor segment. The tensile stress acting between the linear conductor segment and the coil end conductor segment is dispersed due to the expansion of the cross-sectional area of the adhesive part in this case, and a sufficiently durable adhesive state is realized even with a large tensile force. be able to.

(4) In the stator structure described in (1) to (3), the coil end portion conductor segment is integrated with the stator end portion assembled to the stator core portion, so that (1) to (3) In addition to the effects to be described, the stator structure can be completed simply by assembling the stator core portion and the stator end portion, so that the assembly process of the stator structure is simplified.

(5) In a method for manufacturing a stator structure having a stator core portion in which slots are formed, a step of inserting an insulating insulator into the slot, and a step of inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator And a step of applying a conductive adhesive to the end face of the straight portion conductor segment, and a step of attaching a stator end portion integrated with the coil end portion conductor segment in which both end faces are formed in the same direction to the stator core portion. Therefore, the stator structure can be miniaturized by reducing the height of the coil end portion, and the stator structure can be completed simply by assembling the stator core portion and the stator end portion. The edge of the straight conductor segment and the coil It has a strong coil structure that can withstand external forces by securely bonding the end surface of the conductor part of the conductor part, and welding work is unnecessary, and the straight part conductor segment and the coil end part conductor segment can be exposed to high temperatures As a result, coil quality can be ensured.

(6) In a method of manufacturing a stator structure having a stator core portion in which slots are formed, a step of inserting an insulating insulator into the slot, and a step of inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator. A step of attaching a stator end part integrated with a coil end part conductor segment having both end faces formed in the same direction to the stator core part, and pressurizing the stator end part to press the end part of the straight part conductor segment and the coil Because it has a step of diffusion bonding the end faces of the end conductor segments, it can withstand external force by exerting stronger bonding force due to the property of diffusion bonding that uses diffusion of atoms of the bonding material A stator structure made of a strong coil can be realized.

  Examples of the present invention will be described below.

The stator structure 1 of Example 1 will be described.
First, the structure of the stator structure 1 will be described with reference to FIGS.
Here, FIG. 1 is an external view showing the configuration of the stator structure 1, FIG. 2 is an exploded view of components constituting the stator structure 1, and FIG. 2A is an overall external view, 2 (b) shows a schematic view of the coil end portion conductor segment 33 protruding from the stator end portion 12 (portion surrounded by a dotted line in FIG. 2 (a)). 3 is an external view of the stator core portion 11, FIG. 4 is an external view of the stator end portion 12 (partially a perspective view) and an external view of the coil end portion conductor segment 33, and FIG. 5 is an external view of the coil in the stator structure 1. FIG. 5A shows a state where the coil is divided into three parts, and FIG. 5B shows the details of the divided part of the coil (the part surrounded by the dotted line in FIG. 5A). ing.

As shown in FIG. 1 and FIG. 2, the stator structure 1 is configured so that the stator end portions 12 are arranged on both surfaces of the stator core portion 11. As shown in FIG. 3, the stator core portion 11 includes a plurality of grooves called “slots (21)” formed radially over the circumference. In the first embodiment, for example, 48 slots 21 are provided. Then, as will be described later, an insulating insulator 31 is inserted into each slot 21.
Moreover, as shown to Fig.5 (a), the coil in the stator structure 1 is divided into 3 parts. One is a linear portion conductor segment 32 having a linear shape, and the other two are coil end portion conductor segments 33 having both ends facing in the same direction, such as a substantially U shape or a substantially V shape. As shown in FIG. 5B, the linear conductor segment 32 and the coil end conductor segment 33 are bonded with a conductive adhesive 34.
As shown in FIGS. 4A and 4B, the coil end conductor segment 33 is molded and resin-molded with the stator end portion 12 by press molding or the like in a state where the coil end conductor segments 33 are circumferentially wired. It is integrated.

Next, a method for assembling the stator structure 1 will be described with reference to FIGS.
Here, FIG. 6 is a view showing a state where the insulating insulator 31 is inserted into the slot 21 in a part of the stator core portion 12 shown in FIG. 3, FIG. 7 is an external view of the insulating insulator 31, and FIG. 8 is an insertion of the insulating insulator 31. FIG. 9 is a diagram showing how the linear conductor segment 32 is inserted into the hole 41. FIG. 9 shows a position where the end face of the linear conductor segment 32 and the end face of the coil end conductor segment 33 are bonded in the insertion hole 41 of the insulating insulator 31. FIG. 10 is a graph showing experimental values showing the relationship between the thickness of the bonded portion and the bonding resistance, and FIG. 11 is a graph showing the relationship between the thickness of the bonded portion and the tensile strength. The graph figure of the experimental value shown is shown.

  First, as shown in FIG. 6, an insulating insulator 31 is inserted into a slot 21 formed in the stator core portion 11. As shown in FIG. 7, the insulating insulator 31 has a flange 31 a, and the flange 31 a is hooked on both sides of the slot 21, so that the insulating insulator 31 is held in the slot 21.

Next, as shown in FIG. 8, the linear conductor segment 32 is inserted into the insertion hole 41 formed in the insulating insulator 31. A plurality of insertion holes 41 are formed for each insulating insulator 31, and twelve are formed in this embodiment. The linear conductor segment 32 is positioned in the radial direction by the insertion hole 41. On the other hand, the axial direction in the insertion hole 41 is positioned by being pressed by the coil end conductor segment 33 as will be described later. The inner diameter of the insertion hole 41 is set such that the straight conductor segment 32 is press-fitted, and the straight conductor segment 32 is held in the insertion hole 41.
In addition, the cross-sectional shape of the straight conductor segment 32 can be various shapes such as a quadrangle and a circle, but in the present embodiment, it is formed in a quadrangle so that the maximum cross-sectional area can be secured in the limited slot 21. ing.
Further, the end face of the straight portion conductor segment 32 is chamfered, and is devised to be easily inserted into the insertion hole 41.
Furthermore, since insulation between the linear part conductor segments 32 can be achieved by the insulating insulator 31, it is possible to use the linear part conductor segment 32 made of a conductor surface having no insulating film.

Next, a conductive adhesive 34 is applied to both end surfaces of the linear conductor segment 32. As the conductive adhesive 34, for example, a silver paste having a silver weight content of 80% is used.
Next, the stator end portions 12 are assembled on both surfaces of the stator core portion 11. Here, as shown in FIG. 4A, the coil end portion conductor segments 33 are molded and integrated with the stator end portion 12 in a state of being circumferentially wired. Then, both end surfaces of the coil end portion conductor segment 33 protrude from the stator end portion 12 by a predetermined amount. Thus, by assembling the stator end portions 12 on both surfaces of the stator core portion 11, both end surfaces of the coil end portion conductor segment 33 are inserted into the insertion holes 41 formed in the insulating insulator 31, and the end surfaces of the straight portion conductor segments 32 are formed. The conductive adhesive 34 applied to the substrate is pressed. Furthermore, in this state, the conductive adhesive 34 is cured by heating at a predetermined temperature for a predetermined time, and the end face of the coil end conductor segment 33 and the end face of the linear conductor segment 32 are bonded. As specific bonding conditions, when the cross-sectional area of the linear conductor segment 32 and the coil end conductor segment 33 is 6 mm ² , the application amount of the conductive adhesive 34 is about 16 mg, and the applied pressure is 8.5 g / mm. ² and heated at 150 ° C. for 30 minutes. Here, since the insulating insulator 31 is made of PPS resin and has a melting point of about 280 ° C., no problem occurs even under the above-mentioned bonding conditions.
From the above, the stator structure 1 is assembled.
As shown in FIG. 9, the end surface of the straight conductor segment 32 and the end surface of the coil end conductor segment 33 are bonded to a position where the conductive adhesive 34 does not overflow from the insertion hole 41 (the insertion hole in FIG. 9). 41 at a position of depth d from the inlet 41). Therefore, necessary insulation can be ensured between the linear conductor segments 32 and between the coil end conductor segments 33.

Here, since the end face of the coil end part conductor segment 33 and the end face of the straight part conductor segment 32 are chamfered, a part of the applied conductive adhesive 34 is transmitted along this chamfered part to the straight part. It flows into the gap between the conductor segment 32 and the insertion hole 41 and the gap between the coil end conductor segment 33 and the insertion hole 41. Therefore, not only the end surfaces of the linear conductor segment 32 and the end surfaces of the coil end conductor segment 33 are bonded to each other, but also the side surfaces of the linear conductor segment 32 and the inner peripheral surface of the insertion hole 41 as shown in FIG. And the side surface of the coil end portion conductor segment 33 and the inner peripheral surface portion of the insertion hole 41 are also bonded. Therefore, the area of the bonding portion can be widened and the adhesive force is increased among the straight portion conductor segment 32, the coil end portion conductor segment 33, and the insertion hole 41. Further, the cross-sectional area of the portion of the conductive adhesive 34 can be increased, the tensile force generated between the linear conductor segment 32 and the coil end conductor segment 33 is dispersed, and the tensile stress is reduced. Therefore, it is possible to realize the stator structure 1 having a strong coil that can withstand a force from the outside while maintaining the adhesion state between the linear conductor segment 32 and the coil end conductor segment 33.
As described above, the inner diameter of the insertion hole 41 is actually set to a size that allows the linear conductor segment 32 to be press-fitted, but FIG. 9 shows the linear conductor segment 32 and the insertion hole for convenience of explanation. 41 and the gap between the coil end portion conductor segment 33 and the insertion hole 41 are shown to be extremely large.

Moreover, according to such a stator structure 1, both end surfaces of the coil end portion conductor segment 33 are formed at an arbitrary interval, and are integrated with the stator end portion 12 by molding / resin molding, so that an arbitrary linear portion is obtained. By distributing the conductor segments 32 to each other, a distributed winding coil in which an arbitrary inductance is generated can be realized.
Furthermore, unlike the prior art, the segment twisting and winding process and the segment film removing process are unnecessary, and the stator structure 1 can be easily assembled, and the assembly process can be simplified.

Note that the thickness of the conductive adhesive 34 between the end face of the linear conductor segment 32 and the end face of the coil end conductor segment 33 after bonding (hereinafter referred to as an adhesive section thickness) is a value of the junction resistance generated at the bonded portion. And affects the tensile strength of the bonded part.
That is, since the resistance value of the conductor is generally proportional to the length and inversely proportional to the cross-sectional area, it is considered that the value of the bonding resistance generated at the bonded portion becomes smaller as the bonded portion thickness decreases.
On the other hand, in the present invention, the tensile strength of the bonded portion is determined by the tensile strength between the end face of the linear conductor segment 32 or the coil end conductor segment 33 and the conductive adhesive 34, that is, the adhesive force therebetween. This is because the linear conductor segment 32 and the coil end conductor segment 33 itself and the cured conductive adhesive 34 themselves are made of copper, and the tensile strength thereof is determined by the linear conductor segment 32 and the coil end. This is because the tensile strength (adhesive force) between the end face of the partial conductor segment 33 and the conductive adhesive 34 is considered to be sufficiently large. Therefore, it is considered that the tensile strength of the adhesive portion is influenced by the characteristics of the conductive adhesive 34 itself, and the closer to the value of the thickness of the adhesive portion where the adhesive strength is most exhibited as the characteristic of the conductive adhesive 34 itself. I think it will grow.

  Therefore, the inventors of the present application verified these effects through experiments, and obtained the results shown in FIGS. 10 and 11. FIG. 10 shows a first-order approximation line of experimental value data indicating the relationship between the thickness of the bonded portion and the bonding resistance, and FIG. 11 shows a first-order approximation of experimental value data indicating the relationship between the thickness of the bonded portion and the tensile strength. A line is shown. As is apparent from the experimental results, it can be seen that the smaller the adhesion portion thickness, the smaller the value of the joint resistance and the higher the tensile strength. Therefore, in the present invention, it is recommended that the thickness of the bonded portion be 0.01 mm or less. However, each component such as the coil end portion 12, the straight portion conductor segment 32, and the coil end portion conductor segment 33 that defines the thickness of the bonded portion. In view of the dimensional accuracy in manufacturing, it is considered difficult to make the thickness of the bonded portion 0.01 mm or less in manufacturing. Therefore, in the present invention, a recommended value is 0.1 mm or less as the value of the thickness of the bonded portion at which the tensile strength is maximized within a possible range in production.

The coil end portion 12 is manufactured by fixing the end surface of the coil end portion conductor segment 33 at a predetermined position with a molding die and pouring resin into the molding die in this state. Therefore, it is possible to manage the amount of protrusion of the coil end portion conductor segment 33 from the end face of the coil end portion 12 with the molding die. Therefore, it is possible to manage the adhesive portion thickness to 0.1 mm or less by managing the protruding amount.
In FIG. 11, the case where the adhesive portion thickness is 0 mm is a state in which there is no conductive adhesive between the end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33. However, since the tensile strength is 0 kg / mm ² , it is not shown as an experimental value when the thickness of the bonded portion is 0 mm.

According to the first embodiment as described above, the following effects can be obtained.
(1) According to the present invention, in the stator structure having the stator core portion 11 in which the slot 21 is formed, the straight portion conductor segment 32 formed of the conductor surface and the insertion hole 41 into which the straight portion conductor segment 32 is inserted are formed. An insulating insulator 31 inserted into the coil end, a coil end conductor segment 33 having both end faces formed in the same direction, and a conductive property for bonding the end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33 to each other. Since the adhesive 34 is provided, the stator structure can be miniaturized by reducing the height of the coil end portion, and the stator structure can be completed simply by assembling the stator core portion 11 and the stator end portion 12. Is simplified, and the linear conductor segment is formed by the conductive adhesive 34. 2 and the end face of the coil end conductor segment 33 are securely bonded to each other to have a strong coil structure that can withstand external force, and no welding work is required, and the straight conductor segment 32 and the coil end conductor The quality of the coil can be ensured without exposing the segment 33 to a high temperature.

(2) In the stator structure described in (1), the end surface of the linear conductor segment 32 and the end surface of the coil end conductor segment 33 are formed in the insertion hole 41 so that the conductive adhesive 34 does not overflow from the insertion hole 41 during bonding. Therefore, in addition to the effect described in (1), necessary insulation can be ensured.

(3) In the stator structure described in (1) or (2), chamfering is formed on the end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33, and the end face of the straight conductor segment 32 When the end surface of the coil end portion conductor segment 33 is bonded to the end surface of the coil end portion conductor segment 33 with the conductive adhesive 34, the conductive adhesive is put into the gap between the straight portion conductor segment 32 and the insertion hole 41 and between the coil end portion conductor segment 33 and the insertion hole 41. 34 is caused to flow in and the bonding area on the inner peripheral surface of the insertion hole 41 is expanded, and the input volume of the conductive adhesive 34 between the linear conductor segment 32 and the coil end conductor segment 33 is increased. In addition to the effects described in 1) or (2), the adhesive force increases due to the expansion of the bonding area of the conductive adhesive 34, and the linear portion is guided. The tensile stress acting between the linear conductor segment 32 and the coil end conductor segment 33 is dispersed due to the increase in the cross-sectional area of the adhesive portion between the end face of the segment 32 and the end face of the coil end conductor segment 33, It is possible to realize an adhesive state having sufficient durability even with a large tensile force.

(4) In the stator structure described in (1) to (3), the coil end conductor segment 33 is integrated with the stator end part 12 assembled to the stator core part 11, so In addition to the effect described in 3), since the stator structure can be completed simply by assembling the stator core portion 11 and the stator end portion 12, the assembly process of the stator structure is simplified.

(5) In the manufacturing method of the stator structure having the stator core portion 11 in which the slot 21 is formed, the step of inserting the insulating insulator 31 into the slot 21 and the straight portion made of the conductor surface in the insertion hole 41 formed in the insulating insulator 31 The step of inserting the conductor segment 32, the step of applying the conductive adhesive 34 to the end face of the straight portion conductor segment 32, and the coil end portion conductor segment 33 in which both end faces are formed in the same direction are integrated. The stator end portion 12 is attached to the stator core portion 11. Therefore, the stator structure can be reduced in size by reducing the height of the coil end portion, and the stator structure can be obtained simply by assembling the stator core portion 11 and the stator end portion 12. Since it can be completed, the assembly process of the stator structure is simplified. The end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33 are securely bonded by the conductive adhesive 34 to have a strong coil structure that can withstand external force, and no welding work is required. The quality of the coil can be ensured without exposing the straight portion conductor segment 32 and the coil end portion conductor segment 33 to a high temperature.

Next, the stator structure 2 of Example 2 will be described with reference to FIG. FIG. 12 shows a schematic diagram of diffusion bonding at the end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33.
The second embodiment is different from the first embodiment only in that the end face of the linear conductor segment 32 and the end face of the coil end conductor segment 33 are joined by diffusion bonding. Therefore, other description is omitted.
Here, the diffusion bonding is a technique in which a bonding material is heated and pressurized and bonded using diffusion of atoms.
In the present invention, as shown in FIG. 12, the end face of the straight conductor segment 32 and the end face of the coil end conductor segment 33 are preliminarily plated with gold, and both end faces are attached to each other, and then applied with a predetermined pressure for a predetermined time. By applying pressure, a phenomenon of diffusion is generated and bonded.

  According to the second embodiment as described above, the following effects can be obtained.

(1) In the present invention, since the coil end portion conductor segment 33 is integrated with the stator end portion 12 assembled to the stator core portion 11, in addition to the effects in the first embodiment, the stator core portion and the stator end portion. Since the stator structure can be completed simply by assembling, the assembly process of the stator structure is simplified.

(2) In the manufacturing method of the stator structure having the stator core portion 11 in which the slot 21 is formed, the step of inserting the insulating insulator 31 into the slot 21 and the straight portion made of the conductor surface in the insertion hole 41 formed in the insulating insulator 31 A step of inserting the conductor segment 32, a step of attaching the stator end portion 12 integrated with the coil end portion conductor segment 33 having both end faces in the same direction to the stator core portion 11, and adding the stator end portion 12 Since it has a step of diffusion bonding the end face of the linear conductor segment 32 and the end face of the coil end conductor segment 33 by pressing, it is stronger from the property of diffusion bonding that uses the diffusion of atoms of the bonding material. Stator made of strong coils that can withstand external forces by exerting bonding strength It is possible to realize an elephant.

In addition, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the meaning.

It is an external view which shows the structure of the stator structure concerning Example 1 and Example 2 of this invention. It is an exploded view about the components which comprise the stator structure concerning Example 1 and Example 2 of this invention. It is an external view of the stator core part concerning Example 1 and Example 2 of this invention. It is the external view (a part is perspective view) of the stator end part concerning Example 1 and Example 2 of this invention, and the external view of a coil end part conductor segment. The external view of the coil in the stator structure of this invention is shown, (a) shows a mode that a coil is divided into three, (b) is a divided part (part enclosed by the dotted line shown to (a)) of a coil. Details are shown. It is a figure which shows a mode that an insulation insulator is inserted in a slot in a part of stator core part shown in FIG. It is an external view of an insulation insulator. It is a figure which shows a mode that a linear part conductor segment is inserted in the insertion hole of an insulation insulator. It is a figure which shows the adhesion state by the conductive adhesive and the position which the end surface of a linear part conductor segment and the end surface of a coil end part conductor segment join in the insertion hole of an insulation insulator. It is a graph of the experimental value which shows the relationship between the adhesive part thickness and the value of joining resistance. It is a graph of the experimental value which shows the relationship between the value of an adhesion part thickness, and tensile strength. It is a schematic diagram of diffusion bonding at the end face of the straight part conductor segment and the end face of the coil end part conductor segment. FIG. 6 is an exploded view of a stator structure of a rotating electrical machine disclosed in Patent Document 1. FIG. 6 is a schematic connection diagram between integrated multilayer coil pieces of Patent Document 1. The stator structure of the rotary electric machine of patent document 2 is shown, (a) is a front view, (b) is sectional drawing. FIG. 10 is an external view of a part of a stator structure of a rotating electrical machine disclosed in Patent Document 3. It is an external view of the conductor segment of patent document 3. 10 is an external view of a part of a stator structure of a rotating electrical machine disclosed in Patent Document 4. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator structure 11 Stator core part 12 Stator end part 21 Slot 31 Insulator 31a Head 32 Straight line conductor segment 33 Coil end part conductor segment 34 Conductive adhesive 35 Gold plating 41 Insertion hole

Claims (6)

In a stator structure having a stator core portion in which slots are formed,
A linear conductor segment comprising a conductor surface;
An insulating insulator in which an insertion hole into which the linear conductor segment is inserted is formed and inserted into the slot;
A coil end portion conductor segment having both end faces formed in the same direction;
A conductive adhesive that bonds the end face of the straight part conductor segment and the end face of the coil end part conductor segment;
A stator structure characterized by comprising: The stator structure according to claim 1,
The end face of the straight part conductor segment and the end face of the coil end part conductor segment are bonded at a position in the insertion hole where the conductive adhesive does not overflow from the insertion hole during bonding. . In the stator structure according to claim 1 or 2,
A chamfer is formed on the end face of the straight conductor segment and the end face of the coil end conductor segment, and the end face of the straight conductor segment and the end face of the coil end conductor segment are bonded by the conductive adhesive. The conductive adhesive is poured into the gap between the straight portion conductor segment and the insertion hole and the gap between the coil end portion conductor segment and the insertion hole to increase the bonding area on the inner peripheral surface of the insertion hole. And a volume of the conductive adhesive charged between the linear conductor segment and the coil end conductor segment is increased. The stator structure according to any one of claims 1 to 3,
The coil end portion conductor segment is integrated with a stator end portion assembled to the stator core portion. In a method for manufacturing a stator structure having a stator core portion in which slots are formed,
Inserting an insulating insulator into the slot;
Inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator; and
Applying a conductive adhesive to the end face of the linear conductor segment;
Attaching the stator end part integrated with the coil end part conductor segment in which both end faces are formed in the same direction to the stator core part;
A method for manufacturing a stator structure, comprising: In a method for manufacturing a stator structure having a stator core portion in which slots are formed,
Inserting an insulating insulator into the slot;
Inserting a linear portion conductor segment made of a conductor surface into an insertion hole formed in the insulating insulator; and
Attaching the stator end part integrated with the coil end part conductor segment in which both end faces are formed in the same direction to the stator core part;
Diffusion bonding of the end face of the linear conductor segment and the end face of the coil end conductor segment by pressurizing the stator end portion;
A method for manufacturing a stator structure, comprising:

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