JP2006191703A - Stator core of motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator core of a motor having an insulator capable of securing a creeping distance easily. <P>SOLUTION: In the stator core 10 formed by winding a straight core 12 in a ring-shape and applied with an insulator 20, a creeping distance can be secured because a first protrusion 42 projecting from one side of the insulator 20 overlaps the first recess in an adjacent insulator. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a stator core of a motor such as a brushless DC motor, and more particularly to an insulator thereof.

  The applicant firstly folds the straight core in which the plurality of divided back yokes are connected in a band shape through the connecting portions, and the teeth protrude from the respective back yokes in a ring shape at the connecting portions. Proposed a stator core formed by (see, for example, Patent Document 1).

In such a stator core, when winding a coil, a method of forming an insulating layer by pre-molding the stator core and an insulator made of synthetic resin (also called a spool) on each divided back yoke and teeth. And a coil is wound around the insulator.
Japanese Patent Laid-Open No. 10-136589

  When the above insulator is put on each divided back yoke and each tooth, the insulator is divided into two parts in advance, and the divided insulator is integrated on the upper and lower surfaces of the stator core. It is. And in order to ensure the creeping distance between a stator iron core and a coil, the processus | protrusion and thickness are provided in the division | segmentation part of the divided | segmented insulator. Therefore, the synthetic resin material for forming the insulator is used excessively, and there is a problem that the size of the motor is increased. The “creeping distance” means the shortest distance along the surface of the insulator between the two conductive portions.

  In view of the above problems, the present invention provides a stator core for a motor having an insulator that can easily ensure a creepage distance.

  In addition, when the crossover wires are routed between the teeth of each phase, tension is applied to the crossover wires because the distance between the slots becomes wide, such as when the combination of slot combinations and the outer shape of the stator core are large. There is a problem that the crossover does not fit in the insulator and hangs outside.

  In view of the above problems, the present invention provides an insulator for a motor that can easily support the crossover.

  According to the first aspect of the present invention, a straight core in which a plurality of divided back yokes are connected in a band shape via connecting portions and teeth protrude from the respective divided back yokes is bent into a ring shape at the connecting portions. In the stator core of the motor, wherein each of the divided back yokes and the teeth is covered with a synthetic resin insulator, the insulator includes upper and lower surfaces of the divided back yoke. And the inner peripheral surface, the upper and lower surfaces of the teeth and both side surfaces are covered, and at least only the inner peripheral surface of the teeth is exposed, and the upper side from the one side of the portion covering the upper surface of the divided back yoke in the insulator The first protrusion protrudes, and the lower first protrusion protrudes from one side of the portion covering the lower surface of the divided back yoke, A second protrusion protrudes from one side portion of the portion covering the inner peripheral surface of the divided back yoke, and an upper first recess is formed on the other side portion of the insulator covering the upper surface of the divided back yoke, A lower first concave portion is formed on the other side portion of the portion covering the lower surface of the divided back yoke, and a second concave portion is formed on the other side portion of the portion covering the inner peripheral surface of the divided back yoke. When the upper first protrusion is engaged with the upper first recess of the adjacent insulator, the lower first protrusion is engaged with the lower first recess of the adjacent insulator, A stator iron core for a motor, wherein the second protrusion engages with a second recess of an adjacent insulator.

  According to a second aspect of the present invention, a plurality of divided back yokes are connected in a band shape via connecting portions, and straight cores with teeth protruding from the respective divided back yokes are bent into ring shapes at the connecting portions. In the stator core of the motor, wherein each of the divided back yokes and the teeth is covered with a synthetic resin insulator, the insulator includes upper and lower surfaces of the divided back yoke. Covering the upper and lower surfaces and both side surfaces of the teeth, and exposing only the inner peripheral surface of at least the teeth, and the support wall protrudes from the portion covering the upper surface of the divided back yoke in the insulator, A connecting wire between windings wound around each of the teeth along the support wall is disposed, and the upper part of the support wall A stator core of the motor, wherein a supporting piece for supporting the Ri lines are provided.

  In the invention according to claim 3, the support walls are respectively provided on the inner peripheral side and the outer peripheral side of the upper surface of the divided back yoke, the support pieces are provided on the support wall on the inner peripheral side, and the connecting wire is The stator iron core for a motor according to claim 2, wherein the stator iron core is supported along a support wall on the inner peripheral side.

  According to a fourth aspect of the present invention, the insulator includes an upper insulator that covers an upper surface and an inner peripheral surface upper portion of the divided back yoke, an upper surface and both upper surfaces of the teeth, a lower surface of the divided back yoke, and an inner peripheral surface lower portion. 3. The stator iron core for a motor according to claim 1, wherein the stator iron core includes at least a lower surface of the teeth and a lower insulator that covers lower portions of both side surfaces.

  The invention according to claim 5 is the stator core of the motor according to claim 1 or 2, wherein the motor is a brushless DC motor.

  In the stator core of the motor according to the first aspect of the present invention, when the straight core is bent in a ring shape, the upper first protrusion engages with the upper first recess of the adjacent insulator, and the lower core The side first protrusion engages with the lower first recess of the adjacent insulator, and the second protrusion engages with the second recess of the adjacent insulator. Therefore, the creeping distance between the stator core and the coil can be ensured by the overlapping portion by the engaging portion.

  In the stator core of the motor according to the second aspect of the present invention, the crossover can be fixed along the support wall by supporting the crossover on the support piece of the support wall.

(First embodiment)
Hereinafter, the stator core 10 of the 1st Embodiment of this invention is demonstrated based on FIGS. 1-4.

  The stator core 10 of this embodiment is used for an inner rotor type three-phase brushless DC motor.

(1) Structure of straight core 12 First, the straight core 12 which comprises the stator core 10 is demonstrated based on FIG.

  In the straight core 12, T-shaped teeth 16 protrude from the inner peripheral side of the arc-shaped divided back yoke 14, and each divided back yoke 14 is connected in a band shape via a connecting portion 18. The T-shaped tooth 16 includes a base portion 30 that protrudes from the inner peripheral side of the divided back yoke 14 and an excitation portion 32 that protrudes on both sides from the inner front end portion of the base portion 30.

  The straight core 12 is manufactured by stacking one punched plate while punching it into the shape of the straight core 12.

(2) Configuration of Insulator 20 Next, the insulator 20 attached to the straight core 12 will be described.

  The insulator 20 is a component made of synthetic resin that is separate from the straight core 12 in order to insulate the stator core 10 and the coil 22, and is attached to each divided back yoke 14 and each tooth 16. It is also called “spool”. The insulator 20 is divided so that it can be attached to the divided back yoke 14 and the teeth 16, and includes an upper insulator 24 and a lower insulator 26.

  In FIG. 2, only the upper insulator 24 of the insulator 20 covered on the stator core 10 is shown by a solid line, and the lower insulator 26 is shown by a two-dot chain line.

  The upper insulator 24 covers the upper inner peripheral side and the upper part of the inner peripheral surface of the divided back yoke 14, the upper surface and upper side surfaces of the base portion 30 of the teeth 16, and the upper portion, outer peripheral surface upper portion, and both upper side portions of the excitation portion 32. is there.

  The lower insulator 26 covers the lower inner peripheral side of the divided back yoke 14 and the lower portion of the inner peripheral surface, the lower surface of the base 30 and the lower portions of both sides, the lower portion of the exciting portion 32, the lower outer peripheral surface, and the lower portions of both sides. is there.

  The upper insulator 24 will be described in more detail.

  First, in the description of the portion in the upper insulator 24, a portion covering the upper surface of the divided back yoke 14 is referred to as an upper cover 34, and a portion covering the inner peripheral surface of the divided back yoke 14 is referred to as an inner cover 46. A base cover 48 that covers the upper portion of the base 30 of the tooth 16 protrudes from the inner cover 46.

  The upper insulator 24 is exposed without being covered by the upper insulator 24 because the inner peripheral surface of the excitation portion 32 of the tooth 16 is a surface facing the rotor.

  An inner support wall 36 protrudes from the inner periphery of the upper surface of the upper cover 34. Further, an outer support wall 38 protrudes from the outer peripheral portion of the upper surface of the upper cover 34, and a groove portion 40 is formed between the inner support wall 36 and the outer support wall 38 to accommodate the crossover 54.

  A plate-like first protrusion 42 projects from one side of the upper surface of the upper cover 34 (the right side in FIG. 3) so that the upper cover 34 extends.

  A first recess 44 that is one step lower than the upper surface of the upper cover 34 is formed on the other side of the upper surface of the upper cover 34 (the left side in FIG. 3). The first recess 44 slightly protrudes from the stator core 10 when the stator core 10 is covered.

  A plate-like second protrusion 50 projects from one side of the inner cover 46 (the right side in FIG. 3). A second recess 52 that is one step lower than the inner cover 46 is formed on the other side (the left side in FIG. 3) of the inner cover 46. The second protrusion 50 protrudes slightly from the first protrusion 42. Further, the second recess 52 is located slightly inside the position of the first recess 44.

  The shape of the lower insulator 26 is formed vertically symmetrical with the upper insulator 24 described above.

(3) Manufacturing method of stator core 10 As a 1st process, the straight core 12 is manufactured as mentioned above.

  As a 2nd process, the insulator 20 is covered on each division | segmentation back yoke 14 and the teeth 16, respectively. Since this insulator 20 is comprised from the upper insulator 24, the lower insulator 26, and the outer periphery insulator 28, each insulator is each engage | inserted (refer FIG. 2).

  As the third step, the coil 22 is wound around each tooth 16 of the straight core 12.

  As a 4th process, as shown in FIG. 3, the straight core 12 is bent in the connection part 18, and is formed in a ring shape. In this case, the first recess 44 of the upper insulator 24 digs under the first projection 42 of the adjacent upper insulator 24, and the second recess 52 also digs under the second projection 50 of the adjacent upper insulator 24. . As a result, the adjacent upper insulators 24 are completely engaged with each other. Similarly, in the lower insulator 26, the protrusions and the recesses engage with each other.

(4) Effects of this Embodiment In the insulator 20 of this embodiment, the creeping distance T between the stator core 10 and the coil wound around the base 30 of the tooth 16 is the second as shown in FIG. The total distance of the thickness t1 of the concave portion 52, the length t2 of the second concave portion 52, and the height t3 of the lower portion of the second concave portion 52 is obtained, and the creeping distance T can be made larger than before.

  Further, the creepage distance M between the connecting wire 54 connecting the coils 22 wound around the teeth 16 and the stator core 10 is the thickness m1 of the first recess 44 and the protruding length m2 of the first recess 44. And the sum of the height m3 of the first recess 44 that is one step lower. Therefore, the creepage distance M can be made larger than before.

  The same applies to the lower insulator 26.

  As described above, by providing the first recess 44 and the second recess 52, the material of the upper insulator 24 and the lower insulator 26 can be reduced, and the size can be further reduced by reducing the thickness of the resin.

(Second Embodiment)
The stator core 10 of 2nd Embodiment is demonstrated based on FIGS.

  The difference between this embodiment and the first embodiment is that the present embodiment does not have a structure in which the first protrusion 42, the first recess 44, the second protrusion 50, and the second recess 52 are provided, but the inner support wall 36. A support piece 56 for supporting the crossover 54 is provided on the upper part.

  The inner support wall 36 does not continuously stand on the inner peripheral side of the divided back yoke 14, and has a notch 58 in the right side portion of the divided back yoke 14 in FIG. 7.

  A support piece 56 is provided at the upper end of the left side portion of the inner support wall 36.

  The support piece 56 includes a first protrusion 60, a second protrusion 62, a third protrusion 64, a fourth protrusion 68, and a claw 66. First, the first protrusion 60 protrudes toward the left side of the inner support wall 36 from the upper end of the left side portion of the inner support wall 36, and the second protrusion extends from the lower end on the outer peripheral side of the first protrusion 60 toward the outer periphery. The part 62 protrudes. A third protrusion 64 is provided downward from the outer peripheral end of the second protrusion 62, and a fourth protrusion 68 protrudes upward from the outer peripheral end of the second protrusion 62. A claw 66 protrudes from the left side of the lower end of the third protrusion 64. The claw 66 has an inclined surface from the lower surface to the upper surface on the inner peripheral side, and protrudes to the inner peripheral side as the upper surface.

  When the crossover 54 is supported by the support piece 56, when the fourth protrusion 68 is pressed to the inner peripheral side by hand, the third protrusion 64 and the claw 66 bend to the outer peripheral side, and the third protrusion A crossover 54 is sandwiched between 64 and the inner support wall 36. Since the connecting wire 54 is supported by the claw 66, it does not fall downward from the sandwiched position. When the straight core 12 is bent after the crossover 54 is supported, the position where the support piece 56 is located moves to the position of the notch 58 of the adjacent inner support wall 36 (see FIG. 6).

  With the insulator 20 having the above-described configuration, the crossover wire 54 is prevented from drooping due to the looseness, and the crossover wire 54 does not drop outside the motor. Further, the claw 66 covers the upper cover 34 of the adjacent insulator 20 so that the crossover 54 does not fall from the inner support wall 36 until the stator core 10 is completed.

  When the upper insulator 24 is integrally formed of synthetic resin, the support piece 56 has a shape protruding from the left side portion of the inner support wall 36. Therefore, the method of removing the upper insulator 24 when molding it can be performed easily.

(Example of change)
In the above-described embodiment, the insulator provided with the support piece 56 and the insulator provided with the first protrusion are described separately. However, the present invention is not limited to this, and the first protrusion 42 is provided in the insulator 20 and the inner support thereof is provided. A support piece 56 may be provided on the wall 36.

  The motor is not limited to a brushless DC motor, and may be another motor.

It is a top view of the straight core in the stator which shows the 1st Embodiment of this invention. It is a perspective view of the state where the upper insulator was put on the straight core. It is a perspective view of the state which bent the straight core in the state which covered the upper insulator. It is a partially expanded perspective view of the state which covered the upper insulator. It is a perspective view of the state where the straight insulator of the second embodiment is covered with an upper insulator. It is a perspective view of the state where the straight core which covered the upper insulator was bent. It is a partially expanded perspective view of the state which covered the stator insulator with the upper insulator.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Stator core 12 Straight core 14 Back yoke 16 Teeth 18 Connection part 20 Insulator 22 Coil 24 Upper insulator 26 Lower insulator 30 Base part 32 Excitation part 34 Upper cover 36 Inner support wall 42 1st protrusion part 44 1st recessed part 46 Inner cover 50 Second projection 52 Second recess 54 Crossover 56 Support piece

Claims (5)

A stator formed by bending a straight core, in which a plurality of divided back yokes are connected in a band shape via a connecting portion, and teeth are protruded from each divided back yoke, into a ring shape at the connecting portion. In the stator core of the motor, wherein each of the divided back yokes and the teeth is covered with a synthetic resin insulator,
The insulator covers the upper surface, the lower surface, and the inner peripheral surface of the divided back yoke, the upper surface, the lower surface, and both side surfaces of the tooth, and exposes at least the inner peripheral surface of the tooth,
The upper first protrusion protrudes from one side of the portion covering the upper surface of the split back yoke in the insulator,
The lower first protrusion protrudes from one side of the portion covering the lower surface of the divided back yoke,
The second protrusion protrudes from one side of the portion covering the inner peripheral surface of the divided back yoke,
An upper first concave portion is formed on the other side portion of the insulator covering the upper surface of the divided back yoke,
A lower first concave portion is formed on the other side portion of the portion covering the lower surface of the divided back yoke,
A second recess is formed on the other side of the portion covering the inner peripheral surface of the divided back yoke,
When the straight core is bent, the upper first protrusion engages with the upper first recess of the adjacent insulator, and the lower first protrusion engages with the lower first recess of the adjacent insulator. The stator core of the motor, wherein the second protrusion engages with a second recess of an adjacent insulator. A stator formed by bending a straight core, in which a plurality of divided back yokes are connected in a band shape via a connecting portion, and teeth are protruded from each divided back yoke, into a ring shape at the connecting portion. In the stator core of the motor, wherein each of the divided back yokes and the teeth is covered with a synthetic resin insulator,
The insulator covers the upper surface, the lower surface, and the inner peripheral surface of the divided back yoke, the upper surface, the lower surface, and both side surfaces of the tooth, and exposes at least the inner peripheral surface of the tooth,
A support wall protrudes from a portion covering the upper surface of the divided back yoke in the insulator, and a connecting wire between windings wound around the teeth is arranged along the support wall,
A stator core for a motor, wherein a support piece for supporting the crossover is provided on an upper portion of the support wall. The support walls are respectively provided on the inner peripheral side and the outer peripheral side of the upper surface of the divided back yoke, the support pieces are provided on the inner peripheral support wall, and the connecting wires are provided on the inner peripheral support wall. The stator core of the motor according to claim 2, wherein the stator core is supported along the stator core. The insulator includes an upper insulator that covers an upper surface and an inner peripheral surface of the divided back yoke, an upper surface and upper portions of both sides of the teeth, a lower surface and an inner peripheral surface of the divided back yoke, and a lower surface and both sides of the teeth. The stator core of the motor according to claim 1 or 2, wherein the stator core is composed of at least a lower insulator covering a lower portion. The stator core of the motor according to claim 1, wherein the motor is a brushless DC motor.

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