JP2007312497A - Manufacturing method for winding body for motors, winding body for motors, and stator for motors - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a winding body for motors wherein heat produced in the winding body can be efficiently radiated and a stator for motors provided with the winding body. <P>SOLUTION: The manufacturing method is for a winding body 7 used in a motor, in which the winding body 7 is formed by winding a winding 6 on a core 3 of a stator, while applying high thermal conductive resin 8 containing thermally-conductive filler to it. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a motor winding body, a motor winding body, and a motor stator. More specifically, the present invention relates to a motor winding body and a stator that can efficiently release heat generated inside the winding body of the motor.

  In hybrid vehicles and electric vehicles, an electric motor is used to drive the vehicle. This drive motor is required to be small in size and light in weight as well as high output and high efficiency. For this reason, there is a continuous demand for weight reduction and downsizing in units of grams and millimeters without reducing the output.

  In an electric motor, a winding body (coil) is formed by winding a winding around a core of a stator. However, in order to realize further downsizing at a high output, the space of the winding body such as a stator is increased. It is required to improve the rate to the limit. Also, a large current is passed through the windings to increase the magnetic force and obtain a large output.

  However, when a large current is applied, the amount of heat generated due to the resistance of the winding increases, and the amount of heat generated per unit volume of the winding body increases as the space factor increases. Heat generated in the windings is transmitted across adjacent windings, part of which is dissipated from the outer layer of the winding body, part of which is transmitted to the core, and is dissipated from the heat dissipating part provided on the outer periphery of the stator Is done. Further, it is transmitted in the axial direction of the winding and is also radiated from the introduction portion of the winding.

  The outer layer portion of the winding body and the outer peripheral portion of the core are configured to be cooled with a cooling medium, but heat generated inside the winding body is transferred to the outer peripheral portion of the winding body and the core. If it does not escape efficiently, the temperature inside the winding body rises. When the temperature inside the winding body rises, it adversely affects the insulation coating of the windings and lowers the insulation performance, and further leads to a reduction in the output and life of the motor.

  In order to solve the above problems, an invention is disclosed in which a resin (varnish) having a high thermal conductivity is dropped when the winding body is mounted on a status lot to increase the thermal conductivity between the windings.

JP2003-244907

  In the method described in the above-mentioned patent document, the varnish is impregnated in a gap between windings by a so-called capillary phenomenon. However, since the varnish contains a filler for increasing the thermal conductivity, that is, a solid component, the fluidity is low. Therefore, in a winding body in which a plurality of windings are formed, the varnish cannot reach deep inside the winding body.

  In addition, it is clear that only the resin component penetrates between the windings and the solid component filler is unevenly distributed in the vicinity of the surface layer. Therefore, in the above method, it is not possible to form a resin-filled layer having high thermal conductivity inside the winding body. On the other hand, since heat is generated and exposed to a high temperature inside the winding body, the heat generated in the winding body cannot be efficiently dissipated.

  Generally, the greater the amount of the thermally conductive filler component, the better the thermal conductivity of the resin. On the other hand, as the blending amount of the filler component increases, the viscosity of the resin increases and the permeability decreases. Therefore, in the dropping method described above, a highly conductive resin having high permeability must be employed, and a highly thermally conductive resin having high viscosity cannot be employed.

  This invention makes it a subject to solve the said problem and to provide the manufacturing method of the winding body for motors which can thermally radiate the heat which arises inside a winding body, and the stator for motors.

  The winding body according to the present invention is manufactured by winding the winding around the core of the stator while applying the high thermal conductive resin containing the thermal conductive filler. The types and forms of the stator and core to which the present invention can be applied are not limited. The present invention can be applied not only to concentrated winding stators in which one phase winding is wound around the teeth of one stator but also to distributed winding stators in which windings of a plurality of phases are wound in a plurality of slots. Moreover, the form of the core which comprises the said stator is not limited, The core which laminated | stacked the core compacted and the steel plate can be employ | adopted. In addition, it is preferable to employ | adopt the inorganic filler which has electrical insulation in addition to heat conductivity as said filler.

  The procedure for applying the high thermal conductive resin is not particularly limited. For example, like the invention described in claim 2, the high thermal conductive resin can be applied to the winding and then wound around the core. In this procedure, it is only necessary to apply a high thermal conductive resin to the moving winding, so that the apparatus can be configured very simply.

  Moreover, like the invention described in claim 3, after each winding layer of the winding of the winding body is formed, the heat conductive resin can be applied to the surface of each winding layer. . According to this method, since the resin can be directly applied between the wound windings, the gap between the windings can be almost completely filled.

  Furthermore, both the method described in claim 2 and the method described in claim 3 can be applied simultaneously.

  The method of applying the high thermal conductivity resin is not limited. For example, as in the invention described in claim 4, it is conceivable that the winding is passed between rollers impregnated with a high thermal conductive resin. Further, as in the invention described in claim 5, the high thermal conductive resin can be sprayed and applied to the windings by a spraying device. Furthermore, before winding the winding, the winding may be passed through a resin reservoir filled with high thermal conductivity resin.

  The invention described in claim 6 of the present application is to fix the winding introduction portion (coil end portion) of the winding body to the core surface through a high thermal conductive resin. The winding body is provided with a winding introduction part for passing a current, and is arranged so as to pass through the vicinity of the core. Since the core is made of a ferromagnetic metal, it has high thermal conductivity. Therefore, if the contact can be fixed so that heat can be radiated from the winding introduction portion of the winding body to the core surface, heat transmitted in the axial direction of the winding can be efficiently radiated. The step of fixing the winding introduction part to the core can also be performed at the final stage of the winding. In addition, the method of applying the high thermal conductive resin to the introduction portion of the winding is not particularly limited, and for example, the same method as described in claim 4 or claim 5 can be adopted. Moreover, when the groove | channel which accommodates a coil | winding introduction part is formed, you may add the process of filling a high heat conductive resin in the said groove | channel.

  By adopting the above-described configuration, not only can the winding lead portion be securely fixed to the core, but also heat dissipation from the winding can be enhanced with almost no change to the conventional structure.

  The type or form of the stator or electric motor on which the winding body is formed is not limited. For example, as in the invention described in claim 7, the winding body can be formed in a core of a split stator that is assembled in an annular shape and constitutes a stator of an electric motor.

  In the present invention, as described in claim 8, the high thermal conductive resin can be directly applied to the winding being wound. For example, in order to achieve sufficient thermal conductivity, it is preferable to apply a heat conductive resin containing at least 20% by volume of a heat conductive filler.

  By each of the manufacturing methods described above, it is possible to fill between the windings with a highly thermally conductive resin having a very high filler concentration, which could not be employed in the conventional example. As a result, it is possible to form an inter-winding filling layer having high thermal conductivity. That is, a winding body is formed in which a gap formed between each winding wound around a core formed of a ferromagnetic material is filled with a high thermal conductive resin containing at least 20% by volume of a heat conductive inorganic filler or the like. It is also possible to do.

  There is no limitation on the type of electric motor or stator on which the winding body is provided. That is, the present invention can be applied to an electric motor having a conventional distributed winding stator or concentrated winding stator. Furthermore, the present invention can be applied to various winding bodies that require heat dissipation to generate a high magnetic force.

  As shown in FIG. 1, in the present embodiment, the present invention is applied to a winding body of a concentrated winding stator for an electric motor constituted by combining a plurality of divided stators in an annular shape. The present invention relates to a winding body, and can be applied to other types of stators for motors and various motor windings.

  The stator 1 is assembled by assembling a plurality of split stators 2 in an annular shape, and then enclosing and fixing them from the outside using a ring member (not shown). An electric motor is configured by disposing a rotor (not shown) provided with permanent magnets inside the stator 1. FIG. 1 shows a cross section perpendicular to the axis of the annular stator so that the structure of each split stator can be understood.

  As shown in FIG. 2, each of the divided stators 2 was attached to a ferromagnetic core 3 formed by compression molding of powder metal and then sintered, and a tooth portion 4 of the core 3. A resin insulator 5 and a winding body 7 formed by winding a winding 6 around the insulator 5 are configured.

  And in this invention, as shown in FIG. 3, the high heat conductive resin 8 is filled into the clearance gap which arises between each coil | winding 7 which comprises the said winding body 6. As shown in FIG.

  The high thermal conductive resin 8 is constituted by blending a filler having high thermal conductivity with a varnish produced by dissolving a resin material in a solvent. The resin material constituting the varnish is not particularly limited, but it is necessary to adopt a material that can withstand at least the temperature generated in the winding. For example, a polyamide resin dissolved in a solvent can be used. Specifically, a high melt series 7375 of a jet-melt adhesive manufactured by Sumitomo 3M Co., Ltd. can be adopted, and a filler such as alumina or silica can be blended therein to constitute the heat conductive resin. Metal fillers can be employed as the filler, but inorganic fillers are preferably employed in order to improve insulation performance. If the blending amount of the filler is increased, the heat conduction performance is improved. On the other hand, the viscosity at the time of application becomes high and it becomes difficult to handle. In the present embodiment, as described below, since the resin is directly applied to the winding 6, the blending amount of the filler can be increased to the limit that can be applied. In order to obtain high thermal conductivity, the blending amount of the filler is preferably set to at least 20% by volume or more. Thereby, a resin filling layer having high thermal conductivity can be formed between the windings. Moreover, in order to improve thermal conductivity, a filler with two or more particle sizes can be blended to increase the blending ratio of the filler.

  As shown in FIG. 3, the heat generated in each winding is conducted across the windings 6 through the high thermal conductive resin 8, and part of the heat is generated from the outer periphery of the winding body 7. A part of the heat is radiated to the core 3 through the insulator 5.

  FIG. 4 shows a first embodiment in which a heat conductive resin is applied to the winding body. FIG. 4 shows a state where the winding is wound around the IV-IV cross section of FIG.

  The core 3 constituting the split stator 2 is held on the rotating shaft of the winding device with the insulator 5 attached thereto. On the other hand, on the outer side in the radial direction of the rotating shaft, a nozzle 9 for feeding the winding 6 is held so as to be movable in a direction perpendicular to the paper surface. While the core 3 is rotated and the nozzle 9 is moved in a direction perpendicular to the paper surface, the winding 6 is fed out from the nozzle 9, whereby the winding is wound around the tooth portion 4 of the core 3. In front of the nozzle 9 through which the winding 6 is fed, a pair of application rollers 10 and 10 are provided which sandwich the winding 6 and move in a direction perpendicular to the paper surface in synchronization with the nozzle. The coating rollers 10 and 10 are impregnated with the high thermal conductive resin 8, and are configured so that the high thermal conductive resin can be supplied by an appropriate means.

  The application rollers 10 and 10 are configured to rotate in accordance with the feeding speed of the winding 6, and the high thermal conductive resin 8 is applied to the winding 6 immediately before being wound around the core 3. Can be applied efficiently. The winding 6 coated with the high thermal conductive resin 8 is wound around the core 3 before the resin is cured. Thereby, as shown in FIG. 3, the high thermal conductive resin can be filled between the windings of the winding body 6 without any gap. In this embodiment, the roller is moved in a direction perpendicular to the paper surface in synchronization with the nozzle, but a long roller corresponding to the moving distance of the nozzle 9 is fixedly provided. You can also.

  FIG. 5 shows a second embodiment in which the heat conductive resin 8 is applied to the winding body.

  In the embodiment shown in FIG. 5, instead of the roller, a spraying device 11 that can spray and apply the high thermal conductive resin 8 to the winding 7 is provided. The spraying device 11 is also configured to move in a direction orthogonal to the paper surface of FIG. 5 in synchronism with the nozzle 9 in the same manner as the roller 10, and the highly heat conductive resin is wound around the winding 6 immediately before being wound. 8 can be applied.

  FIG. 6 shows a third example in which the heat conductive resin 8 is applied to the winding body 7.

  In this embodiment, after each winding layer of the winding 6 of the winding body 7 is formed, the heat conductive resin 8 is formed on the surface 12 of each winding layer of the winding 6 arranged and wound. Is provided with a roller 13. The roller 13 has a length corresponding to the height of the tooth portion 4 of the core 3 and is impregnated with the high thermal conductive resin 8 as in the first embodiment. The roller 13 is held so as to be able to move around the split stator 2 while rolling on the surface of the tooth portion 4 of the core 3.

  After each winding layer 12 of the winding 6 is rolled up, the rotation of the winding device is temporarily stopped, and the roller 13 is rolled on the surface of each winding layer 12 of the winding 6 so that high heat conduction is achieved. A conductive resin 8 is applied to the winding body 6. By repeating the above steps, a resin-filled layer having high thermal conductivity can be formed inside the winding body 7.

  In each of the embodiments described above, the high thermal conductive resin 8 can be directly applied to the winding 6 immediately before being wound. For this reason, a filling layer having high thermal conductivity can be formed between the windings of the winding body 7. Further, by forming the filling layer, the heat generated inside the winding body 7 is moved so as to cross between the windings, and is moved to the core side via the surface side of the winding body 7 or the insulator. It can dissipate heat. As a result, it is possible to prevent the temperature inside the wound body 7 from being lowered, the coating of the winding from being damaged, the insulation from being lowered, and the life of the motor from being lowered.

  7 and 8 show a fourth embodiment of the present application.

  In this embodiment, the high thermal conductive resin 8 is interposed between the winding lead portion 14 extending from the winding body 7 and the core 3.

  As shown in FIG. 2, the winding 6 is wound around the core 3 via a resin insulator 5. Since the insulator 5 has low thermal conductivity, it is difficult to dissipate heat to the core 3 through the insulator 5. In this embodiment, the introduction part 14 of the winding is fixed to the surface of the core 3 via the high thermal conductive resin 8 described above.

  In the embodiment, a groove 15 is formed on the upper side surface of the insulator 5 for extending the winding introduction portion 14. The groove 15 is formed by cutting the insulator 5 until the surface of the core 3 is exposed, and the winding introduction part 14 can be fixed to the surface of the core 3 through the high heat dissipation resin 8. Since the core 3 is made of metal, the thermal conductivity is very high. Therefore, according to the present embodiment, the heat conducted in the axial direction of the winding 6 can be efficiently released.

  The embodiment shown in the above embodiment is one form of the present invention, and the scope of the present invention is not limited to this. In the embodiment, the present invention is applied to an electric motor provided with concentrated winding split fixing, but may be applied to other types of electric motors provided with a winding body.

It is a figure showing the whole motor stator composition to which the present invention is applied. It is an expanded sectional view of the split stator which comprises the stator shown in FIG. FIG. 3 is an enlarged cross-sectional view schematically showing an internal structure of a winding body of the split stator shown in FIG. 2 and explaining a heat transfer state. It is a figure which shows the 1st Example of the manufacturing method of a coil | winding body, and is sectional drawing which shows the state which has wound the coil | winding to the cross section corresponding to the IV-IV line of FIG. It is a figure which shows the 2nd Example of the manufacturing method of a coil | winding body, and is sectional drawing which shows the state which has wound the coil | winding to the cross section corresponding to the IV-IV line of FIG. It is a figure which shows the 3rd Example of the manufacturing method of a coil | winding body, and is sectional drawing which shows the state which has wound the coil | winding to the cross section corresponding to the IV-IV line of FIG. FIG. 3 is an external view of the split stator shown in FIG. It is a principal part top view of the split stator shown in FIG.

Explanation of symbols

1 Stator 3 Core 6 Winding 7 Winding Body 8 High Thermal Conductive Resin

Claims (8)

A method of manufacturing a winding body used in an electric motor,
A method of manufacturing a winding body for an electric motor, wherein the winding body is formed by winding the winding around a core of a stator while applying a high thermal conductive resin containing a thermal conductive filler.   The method of manufacturing a winding body for an electric motor according to claim 1, wherein the winding body is formed by winding the core with the high thermal conductive resin and then winding the winding around the core.   The winding body is formed by coating the thermal conductive resin on the surface of each winding layer after each winding layer of the winding is formed. The manufacturing method of the coil | winding body for motors as described in any one of.   The method for manufacturing a winding body for an electric motor according to claim 2, wherein the heat conductive resin is applied to a surface of the winding or a winding layer of the winding by a roller.   The manufacturing method of the winding body for motors in any one of Claims 1-3 with which the said heat conductive resin is applied to the winding layer surface of the said coil | winding or the said coil | winding with a spraying apparatus.   The manufacturing method of the winding body for electric motors in any one of Claims 1-5 which fixes the coil | winding introduction part of the said winding body to the said core surface via highly heat conductive resin. The method for manufacturing a winding body for an electric motor according to any one of claims 1 to 6, wherein the winding body is formed in a core of a split stator that is assembled in an annular shape and constitutes a stator of the electric motor.   The manufacturing method of the winding body in any one of Claims 1-7 which coats the heat conductive resin which contains 20 volume% or more of heat conductive fillers at least.

Images