JP2007104825A - Interphase insulating paper and method of manufacturing interphase insulating paper - Google Patents

Interphase insulating paper and method of manufacturing interphase insulating paper Download PDF

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JP2007104825A
JP2007104825A JP2005292885A JP2005292885A JP2007104825A JP 2007104825 A JP2007104825 A JP 2007104825A JP 2005292885 A JP2005292885 A JP 2005292885A JP 2005292885 A JP2005292885 A JP 2005292885A JP 2007104825 A JP2007104825 A JP 2007104825A
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main body
stator core
insulating paper
interphase
interphase insulating
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Kiyotaka Koga
清隆 古賀
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Aisin AW Co Ltd
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Aisin AW Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide interphase insulating paper which exhibits good insulation performance, without being peeled off or teared when it receives a load in a molding process of trimming the form of a coil end in such a state that it is interposed between each phase coil and the next, and besides is flexurally transformed easily, and also to provide a method of manufacturing such interphase insulating paper. <P>SOLUTION: In this manufacturing method, the first interphase insulating paper 14A has one main body 16 and the other main body 17 which constitute the main body 14a of interphase insulating paper. For one side of the main body 16 and the other side of an insulating part 20, insulating parts 18 and 20 which are to be severally interposed between each phase coil and the next and one pair each of couplings 19 and 21 which are to be inserted into slots, are cut off integrally from a sheet body. Then, both couplings 19a of one main body 16 and both couplings 21 of the other main body 17 are bonded to each other, whereby the main body 14a of interphase insulating paper in the shape of a roughly rectangular annulus is made. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、回転電機のステータコアに複数相のコイルを組み付ける際に、各相コイルの相間絶縁を確保するために各相コイル間に介装される相間絶縁紙、及び、そのような相間絶縁紙の製造方法に関する。   The present invention relates to an interphase insulating paper interposed between phase coils in order to secure interphase insulation between the phase coils when a plurality of phase coils are assembled to a stator core of a rotating electrical machine, and such interphase insulating paper. It relates to the manufacturing method.

一般に、三相モータ等の回転電機を製造する過程では、予め電線（マグネットワイヤ）を巻回して形成した複数相（Ｕ相、Ｖ相、Ｗ相）の界磁コイルがステータコアのスロット内に数スロットずつ周方向へ順次位置ずれするようにして挿入組み付けされる。そして、こうした各相コイルのステータコアへの組み付けに際しては、ステータコアの各端面上へスロット内から引き出された各相コイルのコイルエンド部間の絶縁を図るべく、Ｕ相コイルとＶ相コイルの間及びＶ相コイルとＷ相コイルの間に例えば特許文献１に記載されるような相間絶縁紙がそれぞれ介装される。   In general, in the process of manufacturing a rotating electrical machine such as a three-phase motor, a plurality of (U-phase, V-phase, W-phase) field coils formed in advance by winding an electric wire (magnet wire) are several in a stator core slot. The slots are inserted and assembled so that the slots are sequentially displaced in the circumferential direction. When assembling each phase coil to the stator core, in order to insulate between the coil end portions of each phase coil drawn out from the slot onto each end face of the stator core, Between the V-phase coil and the W-phase coil, for example, interphase insulating paper as described in Patent Document 1 is interposed.

相間絶縁紙は、ステータコアの各端面上に各々位置して各相コイルのコイルエンド部間に挟み込まれる一対の絶縁部と、それら両絶縁部間を連結してステータコアにおける所定スロット分だけ周方向へ離間した各スロット内に各々挿入される一対の連結部とを有している。そして、これら一対の絶縁部と一対の連結部とによって相間絶縁紙は略矩形環状をなすように形成されている。また、絶縁部は、連結部と同一平面内に位置するフラットなシート状の平面部と、この平面部上に立体形状をなすように形成されるノーズ部とを有している。ノーズ部は、前記絶縁部が各相コイルのコイルエンド部間に挟入配置された場合に、前記スロット内からのコイルエンド部の軸方向立ち上がり部をステータコアの径方向内方側から被覆するものである。そして、三相全てのコイルがそれら各相コイル間に相間絶縁紙を介装させた状態でステータコアに組み付けられると、各相コイルのコイルエンド部の形状を整える成形工程と、その成形工程を経た各相コイルのコイルエンド部を綴じ糸にて各々束ねるレーシング工程が実施される。
特開２００５−１１０４１７号公報 The interphase insulating paper is positioned on each end face of the stator core and is sandwiched between the coil end portions of each phase coil, and the two insulating portions are connected to each other in the circumferential direction by a predetermined slot in the stator core. And a pair of connecting portions respectively inserted into the spaced slots. The interphase insulating paper is formed in a substantially rectangular ring shape by the pair of insulating portions and the pair of connecting portions. Moreover, the insulating part has a flat sheet-like plane part located in the same plane as the connecting part, and a nose part formed so as to form a three-dimensional shape on the plane part. The nose portion covers the axially rising portion of the coil end portion from within the slot from the radially inner side of the stator core when the insulating portion is interposed between the coil end portions of the respective phase coils. It is. Then, when all three-phase coils are assembled to the stator core with interphase insulating paper interposed between the respective phase coils, a molding process for adjusting the shape of the coil end portion of each phase coil and the molding process are performed. A lacing process is performed in which the coil end portions of the respective phase coils are bundled with binding yarns.
JP 2005-110417 A

ところで、相間絶縁紙における絶縁部のノーズ部は、絶縁部が各相コイルのコイルエンド部間に挟み込まれた場合にコイルエンド部の軸方向立ち上がり部を被覆するものであるため、その形状はコイルエンド部の軸方向立ち上がり部に対応した最適形状に形成されていることが望ましい。この点、平面部とノーズ部とがシート体から一体的に打ち抜かれた相間絶縁紙の場合には、折り曲げ形成できるノーズ部の形状に制約があるため、最適形状のノーズ部を得ることが困難である。そこで、従来は、特許文献１に記載の相間絶縁紙のように、平面部とは別体で最適形状のノーズ部を予め形成しておき、この別体形成されたノーズ部を後工程において平面部に接着して一体化する方法が主流であった。   By the way, the nose part of the insulating part in the interphase insulating paper covers the axially rising part of the coil end part when the insulating part is sandwiched between the coil end parts of the respective phase coils. It is desirable to form the optimum shape corresponding to the axially rising portion of the end portion. In this regard, in the case of interphase insulating paper in which the flat surface portion and the nose portion are integrally punched from the sheet body, there are restrictions on the shape of the nose portion that can be bent, so it is difficult to obtain an optimally shaped nose portion It is. Therefore, conventionally, as in the interphase insulating paper described in Patent Document 1, a nose portion having an optimal shape is formed in advance separately from the flat portion, and the nose portion formed separately is flat in a subsequent process. The method of adhering to the part and integrating them was the mainstream.

しかしながら、平面部にノーズ部が接着された絶縁部の場合には、前述したコイルエンド部の成形工程において成形のための荷重が絶縁部に加わったときに、平面部とノーズ部との接着部分が剥がれたり破れたりし易く、相間絶縁不良を招く虞があった。その一方、こうした剥がれや破れを抑制するべく平面部とノーズ部との接着部分の接着強度を強化した場合には、その接着部分において絶縁部の紙厚が二倍となるため、ステータコアの周方向に沿う円弧状に絶縁部が曲がりにくく、成形工程での荷重により絶縁部が位置ずれしてしまう虞があった。   However, in the case of an insulating part in which a nose part is bonded to a flat part, when a load for molding is applied to the insulating part in the above-described forming process of the coil end part, the bonded part between the flat part and the nose part May be easily peeled off or torn and may cause interphase insulation failure. On the other hand, when the adhesive strength of the adhesion part between the flat part and the nose part is reinforced to suppress such peeling and tearing, the paper thickness of the insulating part is doubled at the adhesion part, so the circumferential direction of the stator core The insulating part is difficult to bend in a circular arc shape along the line, and the insulating part may be displaced due to a load in the molding process.

本発明は、このような事情に鑑みなされたものであって、その目的は、各相コイル間に挟入配置された状態においてコイルエンド部の形状を整える成形工程で荷重を受けた場合に、剥がれたり破れたりすることがなく、且つ容易に曲げ変形することができ、良好な絶縁性能を発揮し得る相間絶縁紙、及び、そのような相間絶縁紙の製造方法を提供することにある。   The present invention has been made in view of such circumstances, and its purpose is to receive a load in a molding process of adjusting the shape of the coil end portion in a state of being sandwiched between the phase coils. An object of the present invention is to provide an interphase insulating paper that can be easily bent and deformed without being peeled off or torn, and exhibiting good insulating performance, and a method for producing such an interphase insulating paper.

上記目的を達成するために、相間絶縁紙に係る請求項１に記載の発明は、回転電機のステータコアに複数相のコイルを組み付ける際に各相コイルの相間絶縁を確保するために各相コイル間に介装される相間絶縁紙であって、前記ステータコアの一方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される一方側絶縁部と該一方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の一方側連結部とが一体的に打ち抜かれて形成された一方側本体部と、前記ステータコアの他方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される他方側絶縁部と該他方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の他方側連結部とが一体的に打ち抜かれて形成された他方側本体部とを含んでなる相間絶縁紙本体を有し、該相間絶縁紙本体は、前記一方側連結部と前記他方側連結部とを繋げることにより、前記一方側本体部と前記他方側本体部とが一体化されていることを特徴とする。   In order to achieve the above object, the invention according to claim 1 relating to the interphase insulating paper is provided between the phase coils in order to secure the interphase insulation of the respective phase coils when assembling a plurality of phase coils to the stator core of the rotating electrical machine. Interphase insulating paper interposed between the one-side insulating portion located on one end face of the stator core and sandwiched between the coil end portions of each phase coil, and extending from the one-side insulating portion A plurality of one-side connecting portions each inserted into a slot of the stator core are integrally punched, and a coil of each phase coil located on the other end face of the stator core The other-side insulating portion sandwiched between the end portions and a plurality of other-side connecting portions extending from the other-side insulating portion and inserted into the slots of the stator core are integrally punched. With the other side body part The interphase insulating paper main body includes the one side main body portion and the other side main body portion by connecting the one side connecting portion and the other side connecting portion. It is characterized by being.

請求項２に記載の発明は、請求項１に記載の相間絶縁紙において、前記一方側本体部及び前記他方側本体部は、前記一方側連結部の先端部と前記他方側連結部の先端部同士とが接着されることにより一体化されていることを特徴とする。   According to a second aspect of the present invention, in the interphase insulating paper according to the first aspect, the one-side main body portion and the other-side main body portion include a tip portion of the one-side connecting portion and a tip portion of the other-side connecting portion. It is characterized by being integrated by bonding together.

請求項３に記載の発明は、請求項１又は請求項２に記載の相間絶縁紙において、前記一方側絶縁部及び前記他方側絶縁部は、前記各相コイルのコイルエンド部間に挟入配置されるシート状の平面部と、該平面部が前記コイルエンド部間に挟入配置された場合に前記スロット内からのコイルエンド部の軸方向立ち上がり部を前記ステータコアの径方向内方側から被覆可能な立体形状をなすように前記平面部上に連続して折り曲げ形成されるノーズ部とをそれぞれ有していることを特徴とする。   According to a third aspect of the present invention, in the interphase insulating paper according to the first or second aspect, the one-side insulating portion and the other-side insulating portion are interposed between the coil end portions of the respective phase coils. A sheet-like flat surface portion, and when the flat portion is sandwiched between the coil end portions, the axially rising portion of the coil end portion from within the slot is covered from the radially inner side of the stator core. And a nose portion that is continuously bent and formed on the plane portion so as to form a possible three-dimensional shape.

請求項４に記載の発明は、請求項３に記載の相間絶縁紙において、前記ノーズ部は、前記連結部が延びる方向と平行であって且つ前記平面部との境界となる一対の谷折り曲げ線と、この両谷折り曲げ線の間で前記連結部が延びる方向へ向かうに従い次第に前記連結部から離れるように斜状をなす一対の山折り曲げ線とを介して前記立体形状をなすように折り曲げ形成されることを特徴とする。   According to a fourth aspect of the present invention, in the interphase insulating paper according to the third aspect, the nose portion is parallel to a direction in which the connecting portion extends and is a pair of valley fold lines that are boundaries with the flat portion. And a pair of mountain fold lines that form an oblique shape so as to gradually move away from the connecting portion as the connecting portion extends in a direction extending between the two valley fold lines. It is characterized by that.

一方、相間絶縁紙の製造方法に係る請求項５に記載の発明は、請求項１〜請求項４のうち何れか一項に記載の相間絶縁紙において、回転電機のステータコアに複数相のコイルを組み付ける際に各相コイルの相間絶縁を確保するために各相コイル間に介装される相間絶縁紙の製造方法であって、
前記ステータコアの一方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される一方側絶縁部と該一方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の一方側連結部とを一体的に打ち抜いて一方側本体部を形成すると共に、前記ステータコアの他方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される他方側絶縁部と該他方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の他方側連結部とを一体的に打ち抜いて他方側本体部を形成し、その後、前記一方側連結部と前記他方側連結部とを繋げることにより、前記一方側本体部と前記他方側本体部とが一体化されてなる相間絶縁紙本体を形成することを特徴とする。 On the other hand, the invention according to claim 5 according to the method for producing interphase insulating paper is the interphase insulating paper according to any one of claims 1 to 4, wherein a plurality of coils are provided on a stator core of a rotating electrical machine. A method for producing interphase insulating paper interposed between each phase coil in order to ensure interphase insulation of each phase coil when assembled,
A one-side insulating portion located on one end face of the stator core and sandwiched between the coil end portions of each phase coil, and a plurality extending from the one-side insulating portion and inserted into slots of the stator core. The other-side insulating portion that is integrally punched with the one-side coupling portion to form the one-side main body portion and is interposed between the coil end portions of the phase coils that are located on the other end face of the stator core And a plurality of other side connecting portions that extend from the other side insulating portion and are respectively inserted into slots of the stator core to form the other side main body portion, and then the one side connecting portion and the By connecting the other side connecting portion, an interphase insulating paper main body in which the one side main body portion and the other side main body portion are integrated is formed.

本発明によれば、各相コイル間に挟入配置された状態においてコイルエンド部の形状を整える成形工程で荷重を受けた場合に、剥がれたり破れたりすることがなく、且つ容易に曲げ変形することができ、良好な絶縁性能を発揮し得る。   According to the present invention, when a load is applied in a molding process for adjusting the shape of the coil end portion in a state of being sandwiched between the phase coils, the coil end portion is not peeled off or torn and is easily bent and deformed. And good insulation performance can be exhibited.

以下、本発明を、回転電機の一種である三相モータにおける相間絶縁紙、及びその製造方法に具体化した一実施形態を図１〜図９にしたがって説明する。
図１及び図２に示すように、三相モータにおけるステータ１０は略円環状をなすステータコア１１（図１及び図２では周方向の一部のみ図示）を有している。ステータコア１１の内周側には複数のスロット１２が周方向へ等間隔をおいて凹設され、各スロット１２内には予め電線（マグネットワイヤ）を巻回して形成された複数相（Ｕ相、Ｖ相、Ｗ相）のコイル１３が各相コイル１３間に相間絶縁紙１４Ａ，１４Ｂを介装した状態で組み付けられている。すなわち、各スロット１２内には、Ｕ相コイル１３Ｕを最も径方向外方に位置させて、以下、ステータコア１１の径方向外方側から径方向内方側へ、第１相間絶縁紙１４Ａ、Ｖ相コイル１３Ｖ、第２相間絶縁紙１４Ｂ、Ｗ相コイル１３Ｗの挿入順で組み付けされている。 Hereinafter, an embodiment in which the present invention is embodied in an interphase insulating paper in a three-phase motor, which is a kind of rotating electrical machine, and a manufacturing method thereof will be described with reference to FIGS.
As shown in FIGS. 1 and 2, the stator 10 in the three-phase motor has a substantially annular stator core 11 (only a part in the circumferential direction is shown in FIGS. 1 and 2). A plurality of slots 12 are recessed at equal intervals in the circumferential direction on the inner peripheral side of the stator core 11, and a plurality of phases (U-phase, The V-phase and W-phase coils 13 are assembled between the phase coils 13 with interphase insulating papers 14A and 14B interposed therebetween. That is, in each slot 12, the U-phase coil 13U is positioned most radially outward, and hereinafter, the first interphase insulating paper 14A, V from the radially outer side of the stator core 11 to the radially inner side. The phase coil 13V, the second interphase insulating paper 14B, and the W phase coil 13W are assembled in the order of insertion.

前記各相（Ｕ相、Ｖ相、Ｗ相）コイル１３のうち、Ｕ相コイル１３Ｕは、ステータコア１１の周方向へ連続する４つのスロットを跳ばした２つのスロット１２に跨るようにしてステータコア１１に組み付けられている。そして、Ｖ相コイル１３Ｖは、ステータコア１１の周方向一方側（図１及び図２では時計方向側）へ前記Ｕ相コイル１３Ｕが組み付けられた２つのスロット１２よりも２スロット分だけ各々位置ずれした２つのスロット１２に跨るようにしてステータコア１１に組み付けられている。また、Ｗ相コイル１３Ｗは、同様に、ステータコア１１の周方向一方側へ前記Ｖ相コイル１３Ｖが組み付けられた２つのスロット１２よりも２スロット分だけ各々位置ずれした２つのスロット１２に跨るようにしてステータコア１１に組み付けられている。   Among the respective phase (U-phase, V-phase, W-phase) coils 13, the U-phase coil 13 </ b> U is formed on the stator core 11 so as to straddle the two slots 12 jumping four slots continuous in the circumferential direction of the stator core 11. It is assembled. The V-phase coil 13V is displaced by two slots from the two slots 12 in which the U-phase coil 13U is assembled to one side in the circumferential direction of the stator core 11 (clockwise in FIGS. 1 and 2). The stator core 11 is assembled so as to straddle the two slots 12. Similarly, the W-phase coil 13W extends over the two slots 12 that are displaced by two slots from the two slots 12 in which the V-phase coil 13V is assembled on one side in the circumferential direction of the stator core 11. The stator core 11 is assembled.

また、第１相間絶縁紙１４Ａは、Ｕ相コイル１３ＵとＶ相コイル１３Ｖの間に介装されることにより、前記各スロット１２内からステータコア１１の端面１１ａ上に引き出されたＵ相コイル１３ＵとＶ相コイル１３Ｖの両コイルエンド部１５間の絶縁を図るようになっている。同様に、第２相間絶縁紙１４Ｂは、Ｖ相コイル１３ＶとＷ相コイル１３Ｗの間に介装されることにより、前記各スロット１２内からステータコア１１の端面１１ａ上に引き出されたＶ相コイル１３ＶとＷ相コイル１３Ｗの両コイルエンド部１５間の絶縁を図るようになっている。   Further, the first interphase insulating paper 14A is interposed between the U-phase coil 13U and the V-phase coil 13V, so that the U-phase coil 13U drawn from the slot 12 onto the end surface 11a of the stator core 11 Insulation between both coil end portions 15 of the V-phase coil 13V is intended. Similarly, the second interphase insulating paper 14B is interposed between the V-phase coil 13V and the W-phase coil 13W, so that the V-phase coil 13V drawn from the slot 12 onto the end surface 11a of the stator core 11 is drawn. And the coil end portions 15 of the W-phase coil 13W are insulated.

なお、第１相間絶縁紙１４Ａと第２相間絶縁紙１４Ｂとは、前記各スロット１２内からのコイルエンド部１５の軸方向立ち上がり部１５ａ（図７参照）を被覆可能な立体形状をなすノーズ部２３，２８（図３（ａ），図４（ａ）参照）の大きさ及び形成位置のみが相違しており、他の点では同一構成になっている。従って、以下では第１相間絶縁紙１４Ａについて、その具体的な構成を説明することとし、第２相間絶縁紙１４Ｂについては、図４（ａ）（ｂ）において第１相間絶縁紙１４Ａと対応する構成部分に同一符号を付すことで、第１相間絶縁紙１４Ａとの重複説明は省略するものとする。   The first interphase insulating paper 14A and the second interphase insulating paper 14B are a nose portion having a three-dimensional shape capable of covering the axially rising portion 15a (see FIG. 7) of the coil end portion 15 from the inside of each slot 12. 23 and 28 (see FIG. 3A and FIG. 4A) are different only in size and formation position, and are otherwise identical in configuration. Accordingly, the specific configuration of the first interphase insulating paper 14A will be described below, and the second interphase insulating paper 14B corresponds to the first interphase insulating paper 14A in FIGS. 4 (a) and 4 (b). By giving the same reference numerals to the constituent parts, the overlapping explanation with the first interphase insulating paper 14A will be omitted.

図３（ａ）（ｂ）に示すように、第１相間絶縁紙１４Ａは、ステータコア１１に組み付けられた場合に、ステータコア１１の一方の端面１１ａ側に位置することになる一方側本体部１６と、ステータコア１１の他方の端面（図示略）側に位置することになる他方側本体部１７を備えている。ここで、一方側本体部１６と他方側本体部１７とは、後述するように、所定の樹脂製のシート体（図５参照）３８から別々に切り抜かれる構成となっている。そして、別々に切り抜かれた一方側本体部１６と他方側本体部１７とが、その後において互いに繋げられて（例えば、接着されて）一体化されることにより、第１相間絶縁紙１４Ａにおける略矩形環状の相間絶縁紙本体１４ａ（第２相間絶縁紙１４Ｂの場合は相間絶縁紙本体１４ｂ）が形成されるようになっている。   As shown in FIGS. 3A and 3B, the first interphase insulating paper 14 </ b> A is positioned on the one end surface 11 a side of the stator core 11 when assembled to the stator core 11. The other side main body part 17 which is located on the other end face (not shown) side of the stator core 11 is provided. Here, the one-side body portion 16 and the other-side body portion 17 are configured to be cut out separately from a predetermined resin sheet body (see FIG. 5) 38, as will be described later. Then, the one side main body portion 16 and the other side main body portion 17 that are cut out separately are connected to each other (for example, bonded) and integrated to form a substantially rectangular shape in the first interphase insulating paper 14A. An annular interphase insulating paper main body 14a (in the case of the second interphase insulating paper 14B, an interphase insulating paper main body 14b) is formed.

前記一方側本体部１６は、前記ステータコア１１の一方の端面１１ａ上に位置してＵ相コイル１３ＵとＶ相コイル１３Ｖの両コイルエンド部１５間に挟入配置される一方側絶縁部１８と、この一方側絶縁部１８から細い帯状をなすように延設され、前記ステータコア１１の対応する各スロット１２内に挿入される一対の一方側連結部１９とを有している。同様に、他方側本体部１７は、前記ステータコア１１の他方の端面（図示略）上に位置してＵ相コイル１３ＵとＶ相コイル１３Ｖの両コイルエンド部１５間に挟入配置される他方側絶縁部２０と、この他方側絶縁部２０から細い帯状をなすように延設され、前記ステータコア１１の対応する各スロット１２内に挿入される一対の他方側連結部２１とを有している。   The one-side body portion 16 is located on one end surface 11a of the stator core 11 and is sandwiched and disposed between the coil end portions 15 of the U-phase coil 13U and the V-phase coil 13V. It has a pair of one-side connecting portions 19 that extend from the one-side insulating portion 18 so as to form a thin band and are inserted into the corresponding slots 12 of the stator core 11. Similarly, the other side main body portion 17 is located on the other end surface (not shown) of the stator core 11 and is sandwiched between the coil end portions 15 of the U-phase coil 13U and the V-phase coil 13V. It has an insulating portion 20 and a pair of other side connecting portions 21 that extend from the other side insulating portion 20 so as to form a thin band and are inserted into the corresponding slots 12 of the stator core 11.

前記一方側絶縁部１８は、前記Ｕ相コイル１３ＵとＶ相コイル１３Ｖの両コイルエンド部１５間に挟み込まれるシート状の平面部２２を有している。そして、この平面部２２上には、図３（ａ）（ｂ）に示すように、前記各スロット１２内からのコイルエンド部１５の軸方向立ち上がり部１５ａを前記ステータコア１１の径方向内方側から被覆可能な立体形状のノーズ部２３が前記平面部２２と交差する方向へ突出するように設けられている。このノーズ部２３は、前記平面部２２との境界となる一対の谷折り曲げ線２４と、この両谷折り曲げ線２４の間に設けられる一対の山折り曲げ線２５を介して、前記平面部２２上において立体形状をなすように折り曲げ形成されている。   The one-side insulating portion 18 has a sheet-like flat portion 22 sandwiched between both coil end portions 15 of the U-phase coil 13U and the V-phase coil 13V. On the flat surface portion 22, as shown in FIGS. 3A and 3B, the axially rising portion 15 a of the coil end portion 15 from the inside of each slot 12 is radially inward of the stator core 11. A three-dimensional nose portion 23 that can be covered is provided so as to protrude in a direction intersecting with the plane portion 22. The nose portion 23 is formed on the plane portion 22 via a pair of valley fold lines 24 that are boundaries with the plane portion 22 and a pair of mountain fold lines 25 provided between the valley fold lines 24. It is bent to form a three-dimensional shape.

ここで、前記谷折り曲げ線２４は、前記一方側連結部１９が延びる方向と平行に設けられる一方、前記山折り曲げ線２５は、前記一方側連結部１９が延びる方向（すなわち、連結部１９の先端方向）へ向かうに従い次第に前記一方側連結部１９から離れるように斜状に設けられている。従って、これら両折り曲げ線２４，２５を介して折り曲げられることで、ノーズ部２３は、所謂くちばし状をなすように形成され、その内側には前記コイルエンド部１５の軸方向立ち上がり部１５ａを収容可能な空間部２６（図６参照）が形成されることになる。   Here, the valley fold line 24 is provided in parallel with the direction in which the one side connecting portion 19 extends, while the mountain fold line 25 is in the direction in which the one side connecting portion 19 extends (that is, the tip of the connecting portion 19). It is provided in a slanted shape so as to gradually move away from the one side connecting portion 19 as it goes to (direction). Therefore, the nose portion 23 is formed to have a so-called beak shape by being bent through both the folding lines 24 and 25, and the axially rising portion 15a of the coil end portion 15 can be accommodated therein. A space 26 (see FIG. 6) is formed.

一方、前記他方側本体部１７における他方側絶縁部２０も、前記一方側絶縁部１８と同様の構成要素を有している。すなわち、前記他方側絶縁部２０は、前記一方側絶縁部１８における前記平面部２２、ノーズ部２３、谷折り曲げ線２４、山折り曲げ線２５と同一構成の、平面部２７、ノーズ部２８、谷折り曲げ線２９、山折り曲げ線３０を有している。そして、その所謂くちばし状の立体形状をなすノーズ部２８の内側には、前記コイルエンド部１５の軸方向立ち上がり部１５ａを収容可能な空間部２６（図６参照）が形成されることになる。   On the other hand, the other-side insulating portion 20 in the other-side main body portion 17 also has the same components as the one-side insulating portion 18. That is, the other-side insulating portion 20 has the same configuration as the planar portion 22, the nose portion 23, the valley fold line 24, and the mountain fold line 25 in the one-side insulating portion 18, and the plane portion 27, the nose portion 28, and the valley fold line. A line 29 and a mountain fold line 30 are provided. A space portion 26 (see FIG. 6) that can accommodate the axially rising portion 15a of the coil end portion 15 is formed inside the nose portion 28 having a so-called beak-shaped three-dimensional shape.

そして、前記第１相間絶縁紙１４Ａにおいては、前記一方側本体部１６と他方側本体部１７の両者が、互いに対応する連結部１９，２１の先端部１９ａ，２１ａ同士を重ね合わせて接着されることにより、前述した略矩形環状をなす相間絶縁紙本体１４ａが形成されるようになっている。したがって、この第１相間絶縁紙１４Ａにおいては、前記一方側本体部１６の連結部１９，２１の先端部１９ａと他方側本体部１７の連結部２１の先端部２１ａとを重ね合わせた接着部３１でのみ紙厚が二倍となる。すなわち、Ｕ相コイル１３ＵとＶ相コイル１３Ｖとの両コイルエンド部１５間に挟入配置される前記各絶縁部１８，２０には紙厚が二倍となる部分は存在しない構成となっている。   In the first interphase insulating paper 14A, both the one-side main body portion 16 and the other-side main body portion 17 are bonded by overlapping the corresponding end portions 19a, 21a of the connecting portions 19, 21. As a result, the interphase insulating paper main body 14a having a substantially rectangular ring shape as described above is formed. Therefore, in the first interphase insulating paper 14A, the adhesive portion 31 is formed by superimposing the distal end portion 19a of the connecting portions 19 and 21 of the one-side main body portion 16 and the distal end portion 21a of the connecting portion 21 of the other-side main body portion 17. The paper thickness is doubled only with. That is, the insulating portions 18 and 20 sandwiched between the coil end portions 15 of the U-phase coil 13U and the V-phase coil 13V do not have a portion where the paper thickness is doubled. .

また、前記第１相間絶縁紙１４Ａにおける一方側及び他方側の各絶縁部１８，２０の各端部（具体的には、各絶縁部１８，２０がコイルエンド部１５間に挟入配置された場合に、ステータコア１１の端面１１ａから遠い側となる各端部）１８ａ，２０ａには、それぞれ曲げ片３２，３３が一体形成されている。各曲げ片３２，３３は、それぞれ折り曲げ線３４，３５を介して絶縁部１８，２０のノーズ部２３，２８と対応する各端部１８ａ，２０ａから斜状をなすように連続形成されている。そして、このように斜状に形成されたことにより、各曲げ片３２，３３は、前記各絶縁部１８，２０がコイルエンド部１５間に挟入配置された場合に、その先端３２ａ，３３ａが基端側よりもステータコア１１の径方向内方寄りに位置するようになっている。   In addition, each end portion of each of the insulating portions 18 and 20 on the one side and the other side of the first interphase insulating paper 14A (specifically, the insulating portions 18 and 20 are sandwiched and arranged between the coil end portions 15). In this case, bending pieces 32 and 33 are integrally formed on the end portions 18a and 20a on the side far from the end face 11a of the stator core 11, respectively. The bent pieces 32 and 33 are continuously formed so as to form an oblique shape from the end portions 18a and 20a corresponding to the nose portions 23 and 28 of the insulating portions 18 and 20 via bending lines 34 and 35, respectively. By forming the slanted shape in this manner, the bent pieces 32 and 33 have their tips 32a and 33a formed when the insulating portions 18 and 20 are sandwiched between the coil end portions 15, respectively. It is located closer to the radially inner side of the stator core 11 than the base end side.

そこで次に、前記各相間絶縁紙１４Ａ，１４Ｂの製造方法について以下説明する。
さて、前述したように、第１相間絶縁紙１４Ａは、その相間絶縁紙本体１４ａを構成する一方側本体部１６と他方側本体部１７が、別々に切り抜き形成されるものとされている。すなわち、図５に示すように、前記第１相間絶縁紙１４Ａは、一方側本体部１６（又は他方側本体部１７）を展開した形状の切り抜き片３６（又は切り抜き片３７）が一枚の樹脂製シート体３８から切り抜かれるようになっている。 Next, a method for manufacturing the interphase insulating papers 14A and 14B will be described below.
As described above, in the first interphase insulating paper 14A, the one side main body portion 16 and the other side main body portion 17 constituting the interphase insulating paper main body 14a are cut out and formed separately. That is, as shown in FIG. 5, the first interphase insulating paper 14 </ b> A has a single piece of cutout piece 36 (or cutout piece 37) in a shape in which one side main body portion 16 (or the other side main body portion 17) is developed. The sheet body 38 is cut out.

前記切り抜き片３６（３７）は、前記一方側又は他方側の本体部１６（１７）が有する絶縁部１８（２０）と、その絶縁部１８（２０）の両端から延設される一対の連結部１９（２１）を同様に有している。但し、その一対の連結部１９（２１）は、前記一方側又は他方側の本体部１６（１７）が展開された状態の切り抜き片３６（３７）にあっては、両連結部１９（２１）が絶縁部１８（２０）の両端から末広がり状をなすように延設されている。また、絶縁部１８（２０）におけるノーズ部２３（２８）も、展開された状態の切り抜き片３６（３７）にあっては、平面部２２（２７）と同一平面内に位置するように平面形状をなしており、未だ立体形状はなしていない。そして、こうした切り抜き片３６（３７）が前記シート体３８から次のようにして複数切り抜かれる。   The cutout piece 36 (37) includes an insulating portion 18 (20) included in the main body portion 16 (17) on the one side or the other side, and a pair of connecting portions extending from both ends of the insulating portion 18 (20). 19 (21) as well. However, the pair of connecting portions 19 (21) is provided on the cutout piece 36 (37) in a state where the main body portion 16 (17) on the one side or the other side is unfolded. Is extended from both ends of the insulating portion 18 (20) so as to form a divergent shape. Further, the nose portion 23 (28) in the insulating portion 18 (20) also has a planar shape so that the cutout piece 36 (37) in the unfolded state is located in the same plane as the flat portion 22 (27). Has not yet been made into a three-dimensional shape. A plurality of such cutout pieces 36 (37) are cut out from the sheet body 38 as follows.

すなわち、各切り抜き片３６（３７）は、シート体３８の長手方向に沿って所定間隔をおいた複数箇所から順次に（又は複数片が同時に）切り抜かれる。この場合、図５に示すように、前記シート体３８からは、各切り抜き片３６（３７）における一対の連結部１９（２１）間に隣接する他の切り抜き片３６（３７）が近接して位置し、且つ前記各切り抜き片３６（３７）の連結部１９（２１）同士が平行となる各切り抜き位置で、複数切り抜かれる。   In other words, each cut piece 36 (37) is cut out sequentially (or simultaneously) from a plurality of locations at a predetermined interval along the longitudinal direction of the sheet body 38. In this case, as shown in FIG. 5, the other cutout pieces 36 (37) adjacent to each other between the pair of connecting portions 19 (21) of each cutout piece 36 (37) are located close to the sheet body 38. A plurality of cutout pieces 36 (37) are cut out at each cutout position where the connecting portions 19 (21) are parallel to each other.

そして、切り抜かれた切り抜き片３６（３７）を、一枚ずつ、その切り抜き片３６（３７）毎における一対の連結部１９（２１）が末広がり状から平行となるように、各切り抜き片３６）３７）における絶縁部１８（２０）の各谷折り曲げ線２４（２９）及び各山折り曲げ線２５（３０）で折り曲げる。すると、ノーズ部２３（２８）が所謂くちばし状の立体形状をなす一方側又は他方側の本体部１６（１７）が形成される。なお、他方側本体部１７を形成する場合には、図５に示すシート体３８から切り抜かれた切り抜き片３６（３７）を一旦裏返した上で前記各谷折り曲げ線２４（２９）及び各山折り曲げ線２５（３０）で折り曲げることになる。   The cut pieces 36 (37) that are cut out one by one so that the pair of connecting portions 19 (21) in each cut piece 36 (37) is parallel to the divergent shape so that they are parallel to each other. ) At each valley fold line 24 (29) and each mountain fold line 25 (30) of the insulating portion 18 (20). As a result, the main body portion 16 (17) on one side or the other side in which the nose portion 23 (28) forms a so-called beak-shaped three-dimensional shape is formed. In the case of forming the other side main body portion 17, the cut pieces 36 (37) cut out from the sheet body 38 shown in FIG. 5 are once turned over, and then the valley fold lines 24 (29) and the mountain folds are folded. It will be bent at line 25 (30).

そして次に、以上のように折り曲げ形成された一方側本体部１６と他方側本体部１７とを接着して一体化する。すなわち、一方側本体部１６の連結部１９と他方側本体部１７の連結部２１とを互いに接着する。具体的には、一方側連結部１９の先端部１９ａと他方側連結部２１の先端部２１ａを紙厚方向に接着剤（図示略）を介在させて重ね合わせて接着する。すると、その接着部３１において一方側本体部１６と他方側本体部１７が一体化され、略矩形環状をなす相間絶縁紙本体１４ａが形成される。   Next, the one side main body portion 16 and the other side main body portion 17 formed by bending as described above are bonded and integrated. That is, the connecting portion 19 of the one-side main body portion 16 and the connecting portion 21 of the other-side main body portion 17 are bonded to each other. Specifically, the front end portion 19a of the one side connection portion 19 and the front end portion 21a of the other side connection portion 21 are overlapped and bonded in the paper thickness direction with an adhesive (not shown) interposed therebetween. As a result, the one-side main body portion 16 and the other-side main body portion 17 are integrated in the bonding portion 31 to form the interphase insulating paper main body 14a having a substantially rectangular ring shape.

そして更に、相間絶縁紙本体１４ａにおける各絶縁部１８，２０の端部１８ａ，２０ａにおいて各曲げ片３２，３３を各々の折り曲げ線３４，３５を介して斜状に折り曲げる。具体的には、ノーズ部２３，２８が突出している方向に向けて斜状をなすように折り曲げる。すると、図６に示すように、第１相間絶縁紙１４Ａが形成される。なお、第２相間絶縁紙１４Ｂも、前述した第１相間絶縁紙１４Ａの場合と同様に、前記シート体３８から複数の切り抜き片３６（３７）が切り抜かれた後、前述したような各折り曲げ工程及び接着工程（繋ぎ工程）を経ることにより、略矩形環状の相間絶縁紙本体１４ｂを有する第２相間絶縁紙１４Ｂが形成される。   Further, the bent pieces 32 and 33 are bent obliquely through the bending lines 34 and 35 at the end portions 18a and 20a of the insulating portions 18 and 20 in the interphase insulating paper main body 14a. Specifically, it is bent so as to form an oblique shape in the direction in which the nose portions 23 and 28 protrude. Then, as shown in FIG. 6, the first interphase insulating paper 14A is formed. Note that the second interphase insulating paper 14B is also subjected to each folding step as described above after the plurality of cutout pieces 36 (37) are cut out from the sheet body 38, as in the case of the first interphase insulating paper 14A. And the 2nd phase insulation paper 14B which has the substantially rectangular annular phase insulation paper main body 14b is formed by passing through an adhesion process (joining process).

そこで次に、以上のようにして形成された第１相間絶縁紙１４Ａ（第２相間絶縁紙１４Ｂ）をステータコア１１に組み付ける場合について以下説明する。
さて、ステータコア１１には、図７に示すように、先ず、Ｕ相コイル１３Ｕがステータコア１１における所定のスロット１２内に挿入組み付けされる。そして、そのコイルエンド部１５がステータコア１１の端面１１ａ上へ引き出された後、後続のＶ相コイル１３Ｖの挿入組み付けを容易ならしめるためにステータコア１１の径方向外方側へ拡張成形されて、Ｕ相コイル１３Ｕの挿入組み付けが完了すると、次には、第１相間絶縁紙１４Ａがステータコア１１に組み付けられる。 Then, next, the case where the 1st phase insulation paper 14A (2nd phase insulation paper 14B) formed as mentioned above is assembled | attached to the stator core 11 is demonstrated below.
Now, as shown in FIG. 7, first, a U-phase coil 13 </ b> U is inserted and assembled into a predetermined slot 12 in the stator core 11. Then, after the coil end portion 15 is drawn onto the end surface 11a of the stator core 11, it is expanded and formed outwardly in the radial direction of the stator core 11 in order to facilitate insertion and assembly of the subsequent V-phase coil 13V. When the insertion assembly of the phase coil 13U is completed, the first interphase insulating paper 14A is then assembled to the stator core 11.

その際、第１相間絶縁紙１４Ａは、その絶縁部１８（２０）がステータコア１１の端面１１ａ上に位置し、且つノーズ部２３（２８）がスロット１２内からのＵ相コイル１３Ｕのコイルエンド部１５の軸方向立ち上がり部１５ａをステータコア１１の径方向内方側から被覆するようにして、ステータコア１１に組み付けられる。また、その際に、第１相間絶縁紙１４Ａの絶縁部１８（２０）は、ステータコア１１の軸線Ｐ（図８，図９参照）に沿う方向の両端部のうち、ステータコア１１の端面１１ａに近い側の端部（一方端）が端面１１ａから離間し、且つ遠い側の端部（他方端）１８ａ（２０ａ）がコイルエンド部１５よりも突出した位置状態となるように配置される。   At that time, the first interphase insulating paper 14A has the insulating portion 18 (20) positioned on the end surface 11a of the stator core 11 and the nose portion 23 (28) of the coil end portion of the U-phase coil 13U from the inside of the slot 12. The 15 axially rising portions 15 a are assembled to the stator core 11 so as to cover from the radially inner side of the stator core 11. At that time, the insulating portion 18 (20) of the first interphase insulating paper 14A is close to the end surface 11a of the stator core 11 among both end portions in the direction along the axis P (see FIGS. 8 and 9) of the stator core 11. The end (one end) on the side is spaced from the end surface 11 a, and the end (other end) 18 a (20 a) on the far side is disposed so as to protrude from the coil end portion 15.

そして、この第１相間絶縁紙１４Ａの組み付けが完了すると、以下、Ｖ相コイル１３Ｖ、第２相間絶縁紙１４Ｂ、Ｗ相コイル１３Ｗの順で、ステータコア１１に対する各々の組み付けがなされる。そして、図８に示すように、最後のＷ相コイル１３Ｗの組み付けが完了すると、次には図９に示す成形工程が開始される。なお、図８及び図９において符号３９で示す部材は、スロット１２の内壁面と各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）との絶縁を図るために各スロット１２内に配設されるスロット絶縁紙である。   When the assembly of the first interphase insulating paper 14A is completed, the assembly to the stator core 11 is performed in the order of the V phase coil 13V, the second interphase insulating paper 14B, and the W phase coil 13W. Then, as shown in FIG. 8, when the assembly of the final W-phase coil 13W is completed, the molding process shown in FIG. 9 is started next. 8 and 9, the member denoted by reference numeral 39 is a slot insulator disposed in each slot 12 in order to insulate the inner wall surface of the slot 12 from each phase coil 13 (13U, 13V, 13W). Paper.

さて、成形工程は、第１，第２の各相間絶縁紙１４Ａ，１４Ｂを介装してステータコア１１に組み付けられた各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）の形状をまとまりよく整える工程である。そして、その際には、図９に示すように、ステータコア１１の径方向内方側から外方側へ移動する第１押圧部材４０と、ステータコア１１の径方向外方側から内方側へ移動する第２押圧部材４１と、ステータコア１１の軸方向外方側（端面１１ａから遠い側）から内方側（端面１１ａに近い側）へ移動する第３押圧部材４２とが使用される。   The forming step is a step of arranging the shapes of the phase coils 13 (13U, 13V, 13W) assembled to the stator core 11 with the first and second interphase insulating papers 14A and 14B interposed therebetween. . In this case, as shown in FIG. 9, the first pressing member 40 that moves from the radially inner side of the stator core 11 to the outer side, and the stator core 11 moves from the radially outer side to the inner side. And a third pressing member 42 that moves from the axially outer side (the side far from the end surface 11a) to the inner side (the side close to the end surface 11a) of the stator core 11.

すなわち、第１〜第３の各押圧部材４０，４１，４２が、図示しない待機位置から移動して、図８に示すように、各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）の大きくばらけた形状となっている各コイルエンド部１５の集合体に対して荷重を加える。すると、各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）のコイルエンド部１５は、第１押圧部材４０と第２押圧部材４１とによりステータコア１１の径方向において挟圧され、径方向における寸法形状が小さくまとまる。また、その際において、第１相間絶縁紙１４Ａ及び第２相間絶縁紙１４Ｂの各絶縁部１８，２０は、各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）のコイルエンド部１５間に挟み込まれる。   That is, each of the first to third pressing members 40, 41, 42 is moved from a standby position (not shown), and each phase coil 13 (13U, 13V, 13W) has a greatly dispersed shape as shown in FIG. A load is applied to the assembly of the coil end portions 15. Then, the coil end part 15 of each phase coil 13 (13U, 13V, 13W) is clamped in the radial direction of the stator core 11 by the first pressing member 40 and the second pressing member 41, and the dimensional shape in the radial direction is small. It is settled. At that time, the insulating portions 18 and 20 of the first interphase insulating paper 14A and the second interphase insulating paper 14B are sandwiched between the coil end portions 15 of the respective phase coils 13 (13U, 13V, and 13W).

一方、第３押圧部材４２による軸方向外方側から内方側への荷重を受けて、各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）のコイルエンド部１５は軸方向における寸法形状が小さくまとまる。そして、その際において、第１相間絶縁紙１４Ａ及び第２相間絶縁紙１４Ｂの各絶縁部１８，２０は、それぞれの端部１８ａ，２０ａに形成された曲げ片３２，３３が第３押圧部材４２からの荷重を受けて、ステータコア１１の径方向内方側へと倒れ込む。これは、各曲げ片３２，３３が、その基端側よりも先端３２ａ，３３ａの方がステータコア１１の径方向内方寄りに位置するようにして各絶縁部１８，２０の端部１８ａ，２０ａから斜状をなすように連続形成されていることによる。したがって、この際に、各絶縁部１８，２０全体がステータコア１１の端面１１ａに向けて移動することはない。   On the other hand, the coil end portions 15 of the respective phase coils 13 (13U, 13V, 13W) receive a load from the axially outward side to the inward side by the third pressing member 42, and the dimensional shape in the axial direction is reduced. At that time, the insulating portions 18 and 20 of the first interphase insulating paper 14A and the second interphase insulating paper 14B are formed by bending pieces 32 and 33 formed at the end portions 18a and 20a, respectively, in the third pressing member 42. In response to the load from the stator core 11, the stator core 11 falls into the radially inward side. This is because the end portions 18a and 20a of the insulating portions 18 and 20 are arranged so that the bent pieces 32 and 33 are positioned so that the distal ends 32a and 33a are closer to the radially inner side of the stator core 11 than the base end side. This is because it is continuously formed so as to form an oblique shape. Accordingly, at this time, the entire insulating portions 18 and 20 do not move toward the end surface 11 a of the stator core 11.

本実施形態によれば、以下のような効果を得ることができる。
（１）各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）のコイルエンド部１５の形状を整える成形工程で各コイルエンド部１５間に挟入配置されている各相間絶縁紙１４Ａ，１４Ｂにステータコア１１の軸方向に沿う荷重がかかった場合にも、各相間絶縁紙１４Ａ，１４Ｂは、曲げ片３２，３３が径方向内方側へ倒れ込むだけである。そのため、絶縁部１８，２０がステータコア１１の軸方向に移動して位置ずれすることがなく、絶縁部１８，２０がコイルエンド部１５の軸方向立ち上がり部１５ａの根元を塞ぐこともないので、成形工程の次に実施されるレーシング工程を良好に実施することができる。 According to this embodiment, the following effects can be obtained.
(1) The stator core 11 is placed on the interphase insulating papers 14A and 14B that are sandwiched and arranged between the coil end portions 15 in the molding process of adjusting the shape of the coil end portions 15 of the phase coils 13 (13U, 13V, and 13W). Even when a load along the axial direction is applied, each of the interphase insulating papers 14A and 14B only has the bent pieces 32 and 33 fall down radially inward. Therefore, the insulating portions 18 and 20 are not moved and displaced in the axial direction of the stator core 11, and the insulating portions 18 and 20 do not block the root of the axially rising portion 15 a of the coil end portion 15. The lacing process performed next to the process can be favorably performed.

（２）また、第３押圧部材４２からの軸方向の荷重を受けて各相間絶縁紙１４Ａ，１４Ｂの各絶縁部１８，２０がステータコア１１の軸方向に不均一に位置ずれすることもなくなる。したがって、それら各相間絶縁紙１４Ａ，１４Ｂの各絶縁部１８，２０によって、各相コイル１３（１３Ｕ，１３Ｖ，１３Ｗ）のコイルエンド部１５間の絶縁を確実に図り良好な絶縁性能を発揮することができる。   (2) In addition, the insulating portions 18 and 20 of the interphase insulating papers 14 </ b> A and 14 </ b> B are not unevenly displaced in the axial direction of the stator core 11 due to the axial load from the third pressing member 42. Therefore, insulation between the coil end portions 15 of the respective phase coils 13 (13U, 13V, 13W) is reliably achieved by the insulating portions 18 and 20 of the interphase insulating papers 14A and 14B, and good insulation performance is exhibited. Can do.

（３）絶縁部１８，２０において特に立体形状をなすノーズ部２３，２８の部分は平面部２２，２７の部分よりも剛性が高いため、このノーズ部２３，２８の部分で第３押圧部材４２によるステータコア１１の軸方向に沿う荷重を受けた場合には、絶縁部１８，２０全体が軸方向に移動して位置ずれする虞がある。しかし、本実施形態では、絶縁部１８，２０のノーズ部２３，２８と対応する各端部１８ａ，２０ａから各曲げ片３２，３３が斜状をなすように形成されているため、成形工程で絶縁部１８，２０全体がステータコア１１の軸方向に沿って位置ずれすることもない。   (3) Since the portions of the nose portions 23 and 28 having a particularly three-dimensional shape in the insulating portions 18 and 20 have higher rigidity than the portions of the plane portions 22 and 27, the third pressing member 42 is formed at the nose portions 23 and 28. When the load along the axial direction of the stator core 11 is received, there is a possibility that the entire insulating portions 18 and 20 move in the axial direction and are displaced. However, in the present embodiment, since the bent pieces 32 and 33 are formed so as to form an oblique shape from the end portions 18a and 20a corresponding to the nose portions 23 and 28 of the insulating portions 18 and 20, in the molding process. The entire insulating portions 18 and 20 are not displaced along the axial direction of the stator core 11.

（４）また、各曲げ片３２，３３は絶縁部１８，２０の端部１８ａ，２０ａから折り曲げ線３４，３５を介して曲げ形成される構成であるため、絶縁部１８，２０が各コイルエンド部１５間に挟入配置された場合に各曲げ片３２，３３の先端３２ａ，３３ａが基端側よりもステータコア１１の径方向内方寄りとなるように簡単に形成できる。   (4) Since the bent pieces 32 and 33 are bent from the end portions 18a and 20a of the insulating portions 18 and 20 through the folding lines 34 and 35, the insulating portions 18 and 20 are connected to the coil ends. When sandwiched between the portions 15, the distal ends 32 a and 33 a of the bent pieces 32 and 33 can be easily formed so as to be closer to the inside in the radial direction of the stator core 11 than the base end side.

（５）また、各相間絶縁紙１４Ａ，１４Ｂにおいては、各コイルエンド部１５間に挟入配置されて成形工程では挟み込まれることになる絶縁部１８，２０の部分に接着部３１が存在せず、接着部３１はスロット１２内に挿入配置される連結部１９，２１の部分に存在する構成となっている。そのため、成形工程において、絶縁部１８，２０に接着部３１が存在する場合には、その接着部３１が剥がれたり破れたりする虞があるのに対し、本実施形態の場合には、接着部３１が存在しない絶縁部１８，２０であることから、成形工程で絶縁部１８，２０が剥がれたり破れたりすることがなく、良好な絶縁性能を発揮することができる。   (5) Further, in the interphase insulating papers 14A and 14B, the adhesive portion 31 does not exist in the portions of the insulating portions 18 and 20 that are interposed between the coil end portions 15 and are sandwiched in the molding process. The adhering portion 31 is configured to exist at the portions of the connecting portions 19 and 21 inserted and arranged in the slot 12. Therefore, in the molding process, when the bonding portion 31 is present in the insulating portions 18 and 20, the bonding portion 31 may be peeled off or torn, whereas in the present embodiment, the bonding portion 31. Therefore, the insulating portions 18 and 20 are not peeled off or broken in the molding process, and good insulating performance can be exhibited.

（６）また、接着部３１の存在する部分では紙厚が二倍となって曲げ変形しにくいという問題があるが、そのような接着部３１はスロット１２内に挟入配置される連結部１９，２１に存在して絶縁部１８，２０には存在しないことから、成形工程では、絶縁部１８，２０をステータコア１１の内周に沿った円弧状に容易に曲げ変形させることができる。従って、絶縁部１８，２０の平面部２２，２７及びノーズ部２３，２８がコイルエンド部１５に隙間なく良好に接触するようになり、この点でも、絶縁部１８，２０により各コイルエンド部１５間の絶縁を良好に図ることができる。   (6) In addition, there is a problem that the paper thickness is doubled at the portion where the adhesive portion 31 exists, and it is difficult to bend and deform. However, such an adhesive portion 31 is inserted into the slot 12 and connected. , 21 but not in the insulating portions 18, 20, the insulating portions 18, 20 can be easily bent and deformed in an arc shape along the inner periphery of the stator core 11 in the molding process. Accordingly, the flat surface portions 22 and 27 and the nose portions 23 and 28 of the insulating portions 18 and 20 come into good contact with the coil end portion 15 without any gap, and also in this respect, the coil end portions 15 are separated by the insulating portions 18 and 20. It is possible to achieve good insulation between them.

（７）その一方、スロット１２内に挿入配置するために細い帯状をなすように形成された各連結部１９，２１に紙厚が二倍となる接着部３１を設けたことにより、連結部１９，２１の剛性を高めることができ、矩形環状をなす相間絶縁紙本体１４ａ，１４ｂの形状を安定保持した状態でステータコア１１に相間絶縁紙１４Ａ，１４Ｂを組み付けできる。   (7) On the other hand, the connecting portions 19, 21 formed so as to form a thin band for insertion and placement in the slot 12 are provided with the adhesive portions 31 having a double paper thickness. , 21 can be increased, and the interphase insulating paper 14A, 14B can be assembled to the stator core 11 in a state where the shape of the interphase insulating paper main bodies 14a, 14b having a rectangular ring shape is stably maintained.

（８）また、各相間絶縁紙１４Ａ，１４Ｂにおける矩形環状の相間絶縁紙本体１４ａ，１４ｂをシート体３８から一体的に切り抜きする場合には、その内側の廃棄される部分が大きな廃棄ロスとなり歩留まりが悪くなるという問題がある。この点、本実施形態では、相間絶縁紙本体１４ａ，１４ｂを２分割した形状の一方側本体部１６と他方側本体部１７がシート体３８から別々に切り抜かれて曲げ形成されるため、そのような廃棄ロスが大きくなることもなく、製造コストを低減させることができる。   (8) When the rectangular annular interphase insulating paper main bodies 14a and 14b in the interphase insulating papers 14A and 14B are cut out integrally from the sheet body 38, the discarded portions inside the main body 14a and 14b become a large waste loss and yield. There is a problem of getting worse. In this regard, in the present embodiment, the one-side main body portion 16 and the other-side main body portion 17 having a shape obtained by dividing the interphase insulating paper main bodies 14a and 14b into two parts are separately cut out from the sheet body 38 and bent, so that Therefore, the manufacturing cost can be reduced without increasing the waste loss.

（９）しかも、シート体３８からは、一方側本体部１６（又は他方側本体部１７）を展開した形状の複数の切り抜き片３６（又は切り抜き片３７）が切り抜かれるものであり、各切り抜き片３６（３７）は一対の連結部１９（２１）が絶縁部１８（２０）の両端部から末広がり状をなすように延設された形状をなしている。そして、そり切り抜き時には、各切り抜き片３６（３７）における一対の連結部１９（２１）間に隣接する他の切り抜き片３６（３７）が近接して位置し、且つ前記各切り抜き片３６（３７）の連結部１９（２１）同士が平行となる各切り抜き位置で、複数切り抜かれるようになっている。したがって、一枚のシート体３８から、多数の切り抜き片３６（３７）を非常に少ない廃棄ロスで切り抜き形成することができる。   (9) Moreover, from the sheet body 38, a plurality of cutout pieces 36 (or cutout pieces 37) having a shape in which the one side main body portion 16 (or the other side main body portion 17) is developed are cut out. 36 (37) has a shape in which a pair of connecting portions 19 (21) are extended from both ends of the insulating portion 18 (20) so as to form a divergent shape. At the time of cutting the sled, the other cut pieces 36 (37) adjacent to each other between the pair of connecting portions 19 (21) in each cut piece 36 (37) are located close to each other, and each cut piece 36 (37) is provided. A plurality of connecting portions 19 (21) are cut out at respective cutting positions where the connecting portions 19 (21) are parallel to each other. Therefore, a large number of cut pieces 36 (37) can be cut out from one sheet body 38 with very little disposal loss.

（１０）また、切り抜かれた切り抜き片３６（３７）の絶縁部１８（２０）から連結部１９（２１）と平行な谷折り曲げ線２４（２９）及び連結部１９（２１）に対して斜状をなす山折り曲げ線２５（３０）を介してノーズ部２３（２８）は曲げ形成した場合には、所謂くちばし状をなすノーズ部が形成される。したがって、ノーズ部２３（２８）を予め平面部２２（２７）とは別体で形成しておいて後に平面部２２（２７）に接着して一体化しなくても、平面部２２（２７）及びノーズ部２３（２８）が一体的に打ち抜かれた絶縁部１８（２０）から最適形状のノーズ部２３（２８）を簡単に折り曲げ形成することができる。   (10) Further, the cut-out piece 36 (37) has an oblique shape with respect to the valley fold line 24 (29) parallel to the connecting portion 19 (21) and the connecting portion 19 (21) from the insulating portion 18 (20). When the nose portion 23 (28) is bent through the mountain fold line 25 (30) forming a so-called beak-shaped nose portion. Therefore, even if the nose portion 23 (28) is formed separately from the planar portion 22 (27) in advance and is not bonded and integrated to the planar portion 22 (27) later, the planar portion 22 (27) and The optimally shaped nose portion 23 (28) can be easily bent and formed from the insulating portion 18 (20) in which the nose portion 23 (28) is integrally punched.

なお、上記実施形態は以下のような別の実施形態（別例）に変更してもよい。
・図１０（ａ）（ｂ）（ｃ）（ｄ）に示すように、各相間絶縁紙１４Ａ，１４Ｂにおける絶縁部１８，２０には、ノーズ部２３，２８と対応する端部以外に平面部２２，２７と対応する端部の部分に曲げ片３２，３３を更に追加形成してもよい。 The above embodiment may be changed to another embodiment (another example) as follows.
As shown in FIGS. 10 (a), (b), (c), and (d), the insulating portions 18 and 20 in the interphase insulating papers 14A and 14B are flat portions other than the end portions corresponding to the nose portions 23 and 28. Bending pieces 32 and 33 may be additionally formed at the end portions corresponding to 22 and 27.

・また、曲げ片３２，３３は絶縁部１８，２０の端部１８ａ，２０ａから湾曲するように連続形成されたものであってもよい。すなわち、曲げ片３２，３３は、絶縁部１８，２０が各コイルエンド部１５間に今日に優配置された場合に、その曲げ片３２，３３の先端３２ａ，３３ａが基端側よりもステータコア１１の径方向内方寄りに位置するように形成されるものであるならば、直線的な斜状にかぎらず、円弧状に湾曲したものでも、ジクザグ状のものであつてもよい。   The bent pieces 32 and 33 may be formed continuously so as to be bent from the end portions 18a and 20a of the insulating portions 18 and 20. That is, when the insulating portions 18 and 20 are preferentially disposed between the coil end portions 15 today, the bent pieces 32 and 33 have the distal ends 32a and 33a of the bent pieces 32 and 33 more than the base end side of the stator core 11. As long as it is formed so as to be located inwardly in the radial direction, it is not limited to a linear oblique shape, and may be curved in an arc or zigzag.

・曲げ片３２，３３の形状は、絶縁部１８，２０が各コイルエンド部１５間に今日に優配置された場合に、その曲げ片３２，３３の先端３２ａ，３３ａが基端側よりもステータコア１１の径方向内方寄りに位置するように形成されるものであるならば、三角形状以外に四角形状、半円形状など任意の形状を採用可能である。   The shape of the bent pieces 32 and 33 is such that, when the insulating portions 18 and 20 are preferentially arranged between the coil end portions 15 today, the distal ends 32a and 33a of the bent pieces 32 and 33 are stator cores than the base end side. Any shape other than the triangular shape, such as a quadrangular shape or a semicircular shape, can be adopted as long as it is formed so as to be positioned radially inward of 11.

・一方側本体部１６に対応する切り抜き片３６と他方側本体部１７に対応する切り抜き片３７は、別々のシート体３８から各々切り抜かれる構成であってもよい。このようにすれば、一方側本体部１６に対応する切り抜き片３６をいちいち裏返して他方側本体部１７に対応する切り抜き片３７とする必要もなくなる。   The cut-out piece 36 corresponding to the one-side main body 16 and the cut-out piece 37 corresponding to the other-side main-body portion 17 may be cut out from separate sheet bodies 38, respectively. In this way, it is not necessary to turn over the cutout piece 36 corresponding to the one-side main body portion 16 one by one to make the cutout piece 37 corresponding to the other-side main body portion 17.

・一方側本体部１６の連結部１９と他方側本体部１７の連結部２１とは先端部１９ａ，２１ａ同士ではなく、その連結部１９，２１の全体同士を重ね合わせて接着してもよい。このようにすれば、更に一層、矩形環状をなす絶縁紙本体１４ａ，１４ｂにおいて細い帯状をなす連結部１９，２１の剛性を強化できる。   The connecting portion 19 of the one-side main body portion 16 and the connecting portion 21 of the other-side main body portion 17 may be bonded to each other by overlapping the connecting portions 19 and 21 instead of the tip portions 19a and 21a. In this way, the rigidity of the connecting portions 19 and 21 having a thin strip shape in the insulating paper main bodies 14a and 14b having a rectangular ring shape can be further enhanced.

・また、一方側本体部１６の連結部１９の先端部１９ａと他方側本体部１７の連結部２１の先端部２１ａとの間を更に別の細い帯状をなす連結部材で連結してもよい。
・一方側本体部１６の連結部１９と他方側本体部１７の連結部２１とは、互いに接着によらずに、例えば、かしめ連結や超音波溶着によって互いに繋ぐようにしてもよい。 Further, the distal end portion 19a of the coupling portion 19 of the one-side main body portion 16 and the distal end portion 21a of the coupling portion 21 of the other-side main body portion 17 may be coupled by a further thin strip-shaped coupling member.
-You may make it connect the connection part 19 of the one side main-body part 16 and the connection part 21 of the other side main-body part 17 mutually by crimping connection or ultrasonic welding, for example, without adhere | attaching.

・絶縁部１８，２０においてノーズ部２３，２８を立体的に曲げ形成する各谷折り曲げ線２４，２９及び各山折り曲げ線２５，３０の本数及び形成方向（線の延びる方向）は、形成したいノーズ部２３，２８の形状に従い任意に設定可能である。   The number and direction of formation (the direction in which the lines extend) of the valley fold lines 24 and 29 and the mountain fold lines 25 and 30 that three-dimensionally bend the nose parts 23 and 28 in the insulating parts 18 and 20 are the nose to be formed. It can be arbitrarily set according to the shape of the portions 23 and 28.

実施形態のステータコアへの各相コイルの配設位置を示す説明図。Explanatory drawing which shows the arrangement | positioning position of each phase coil to the stator core of embodiment. 各相コイル及び各相間絶縁紙が組み付けられたステータコアの一部平面図。The partial top view of the stator core in which each phase coil and each phase insulation paper were assembled | attached. （ａ）は第１相間絶縁紙の正面図、（ｂ）は第１相間絶縁紙の側面図。(A) is a front view of the first interphase insulating paper, (b) is a side view of the first interphase insulating paper. （ａ）は第２相間絶縁紙の正面図、（ｂ）は第２相間絶縁紙の側面図。(A) is a front view of the second interphase insulating paper, (b) is a side view of the second interphase insulating paper. シート体からの各切り抜き片の切り抜き態様を示す説明図。Explanatory drawing which shows the cut-out aspect of each cut-out piece from a sheet | seat body. 第１相間絶縁紙の斜視図。The perspective view of the 1st phase insulation paper. ステータコアへの第１相間絶縁紙の組み付け方法を示す説明図。Explanatory drawing which shows the assembly | attachment method of the 1st phase insulation paper to a stator core. 成形工程前のコイルエンド部を断面で示す説明図。Explanatory drawing which shows the coil end part before a formation process in a cross section. 成形工程におけるコイルエンド部を断面で示す説明図。Explanatory drawing which shows the coil end part in a formation process in a cross section. （ａ）は別例の第１相間絶縁紙の正面図、（ｂ）は別例の第１相間絶縁紙の側面図、（ｃ）は別例の第２相間絶縁紙の正面図、（ｄ）は別例の第２相間絶縁紙の側面図。(A) is a front view of another example first interphase insulating paper, (b) is a side view of another example first interphase insulating paper, (c) is a front view of another example second interphase insulating paper, (d) ) Is a side view of another example of the second interphase insulating paper.

符号の説明Explanation of symbols

１１…ステータコア、１１ａ…端面、１２…スロット、１３…コイル、１３Ｕ…Ｕ相コイル、１３Ｖ…Ｖ相コイル、１３Ｗ…Ｗ相コイル、１４Ａ，１４Ｂ…相間絶縁紙、１４ａ，１４ｂ…相間絶縁紙本体、１５…コイルエンド部、１５ａ…軸方向立ち上がり部、１６…一方側本体部、１７…他方側本体部、１８…一方側絶縁部、１９…一方側連結部、１９ａ，２１ａ…先端部、２０…他方側絶縁部、２１…他方側連結部、２２…平面部、２３，２８…ノーズ部、２４，２９…谷折り曲げ線、２５，３０…山折り曲げ線、３２，３３…曲げ片、３２ａ，３３ａ…先端、３４，３５…折り曲げ線、３６，３７…切り抜き片、３８…シート体、Ｐ…軸線。   DESCRIPTION OF SYMBOLS 11 ... Stator core, 11a ... End surface, 12 ... Slot, 13 ... Coil, 13U ... U phase coil, 13V ... V phase coil, 13W ... W phase coil, 14A, 14B ... Interphase insulation paper, 14a, 14b ... Interphase insulation paper main body 15 ... Coil end part, 15a ... Axial rising part, 16 ... One side body part, 17 ... Other side body part, 18 ... One side insulation part, 19 ... One side connection part, 19a, 21a ... Tip part, 20 ... other side insulating part, 21 ... other side connecting part, 22 ... plane part, 23, 28 ... nose part, 24, 29 ... valley fold line, 25, 30 ... mountain fold line, 32, 33 ... bent piece, 32a, 33a ... tip, 34, 35 ... fold line, 36, 37 ... cutout piece, 38 ... sheet body, P ... axis.

Claims (5)

回転電機のステータコアに複数相のコイルを組み付ける際に各相コイルの相間絶縁を確保するために各相コイル間に介装される相間絶縁紙であって、
前記ステータコアの一方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される一方側絶縁部と該一方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の一方側連結部とが一体的に打ち抜かれて形成された一方側本体部と、前記ステータコアの他方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される他方側絶縁部と該他方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の他方側連結部とが一体的に打ち抜かれて形成された他方側本体部とを含んでなる相間絶縁紙本体を有し、該相間絶縁紙本体は、前記一方側連結部と前記他方側連結部とを繋げることにより、前記一方側本体部と前記他方側本体部とが一体化されている相間絶縁紙。 Interphase insulating paper interposed between the phase coils in order to secure the interphase insulation of the phase coils when assembling a plurality of phase coils to the stator core of the rotating electrical machine,
A one-side insulating portion located on one end face of the stator core and sandwiched between the coil end portions of each phase coil, and a plurality extending from the one-side insulating portion and inserted into slots of the stator core. One side body portion formed by integrally punching the one side connection portion and the other side insulation positioned on the other end face of the stator core and sandwiched between the coil end portions of the respective phase coils Interphase insulating paper including a plurality of other side connecting portions extending from the other side insulating portion and inserted into slots of the stator core and integrally formed with the other side main body portion. The interphase insulating paper main body has a main body, and the interphase insulating paper main body is integrated with the one side main body portion and the other side main body portion by connecting the one side connecting portion and the other side connecting portion. . 前記一方側本体部及び前記他方側本体部は、前記一方側連結部の先端部と前記他方側連結部の先端部同士とが接着されることにより一体化されている請求項１に記載の相間絶縁紙。 2. The interphase according to claim 1, wherein the one-side main body portion and the other-side main body portion are integrated by bonding a tip portion of the one-side connecting portion and a tip portion of the other-side connecting portion. Insulating paper. 前記一方側絶縁部及び前記他方側絶縁部は、前記各相コイルのコイルエンド部間に挟入配置されるシート状の平面部と、該平面部が前記コイルエンド部間に挟入配置された場合に前記スロット内からのコイルエンド部の軸方向立ち上がり部を前記ステータコアの径方向内方側から被覆可能な立体形状をなすように前記平面部上に連続して折り曲げ形成されるノーズ部とをそれぞれ有している請求項１又は請求項２に記載の相間絶縁紙。 The one-side insulating portion and the other-side insulating portion include a sheet-like flat portion interposed between the coil end portions of each phase coil, and the flat portion interposed between the coil end portions. A nose portion that is continuously bent on the planar portion so as to form a three-dimensional shape capable of covering the axially rising portion of the coil end portion from the inside of the slot from the radially inner side of the stator core. The interphase insulating paper according to claim 1 or 2, which is respectively provided. 前記ノーズ部は、前記連結部が延びる方向と平行であって且つ前記平面部との境界となる一対の谷折り曲げ線と、この両谷折り曲げ線の間で前記連結部が延びる方向へ向かうに従い次第に前記連結部から離れるように斜状をなす一対の山折り曲げ線とを介して前記立体形状をなすように折り曲げ形成される請求項３に記載の相間絶縁紙。 The nose portion is a pair of valley fold lines parallel to the direction in which the connecting portion extends and serves as a boundary with the plane portion, and gradually toward the direction in which the connecting portion extends between the two valley fold lines. The interphase insulating paper according to claim 3, wherein the interphase insulating paper is formed so as to be bent so as to form the three-dimensional shape via a pair of oblique fold lines that are inclined so as to be separated from the connecting portion. 回転電機のステータコアに複数相のコイルを組み付ける際に各相コイルの相間絶縁を確保するために各相コイル間に介装される相間絶縁紙の製造方法であって、
前記ステータコアの一方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される一方側絶縁部と該一方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の一方側連結部とを一体的に打ち抜いて一方側本体部を形成すると共に、前記ステータコアの他方の端面上に位置して各相コイルのコイルエンド部間に挟入配置される他方側絶縁部と該他方側絶縁部から延設されてステータコアのスロット内に各々挿入される複数の他方側連結部とを一体的に打ち抜いて他方側本体部を形成し、その後、前記一方側連結部と前記他方側連結部とを繋げることにより、前記一方側本体部と前記他方側本体部とが一体化されてなる相間絶縁紙本体を形成する相間絶縁紙の製造方法。 A method for producing interphase insulating paper interposed between each phase coil in order to ensure interphase insulation of each phase coil when a plurality of phase coils are assembled to a stator core of a rotating electrical machine,
A one-side insulating portion located on one end face of the stator core and sandwiched between the coil end portions of each phase coil, and a plurality extending from the one-side insulating portion and inserted into slots of the stator core. The other-side insulating portion that is integrally punched with the one-side coupling portion to form the one-side main body portion and is interposed between the coil end portions of the phase coils that are located on the other end face of the stator core And a plurality of other side connecting portions that extend from the other side insulating portion and are respectively inserted into slots of the stator core to form the other side main body portion, and then the one side connecting portion and the A method for producing an interphase insulating paper, which forms an interphase insulating paper main body in which the one side main body portion and the other side main body portion are integrated by connecting the other side connecting portion.
JP2005292885A 2005-10-05 2005-10-05 Interphase insulating paper and method of manufacturing interphase insulating paper Pending JP2007104825A (en)

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