JP2008148429A - Stator of motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a stator of a motor, in which an adhesive layer is hardly peeled in assembling the stator when the adhesive layer is provided on a bonding surface. <P>SOLUTION: The stator 50 of the motor has a stator core 30 formed by laminating a plurality of recessed slots 32 in its internal circumference; a laminate conductor 10 formed by laminating a plurality of thin plates 11; and an end connection conductor 20 formed by laminating a plurality of connection thin plates 21 each used for connecting the end of the laminate conductor 10 to the end of another laminate conductor 10. In the stator 50, a bonding portion 21a abutting on the thin plate 11 of the laminate conductor 10 is formed each of the connection thin plates 21, a thin plate end 11a connected to the bonding end portion 21a of each of the connection thin plates 21 is formed on the end of the thin plate 11, and a protrusion 21c is formed on the connection thin plate bonding surface 21b of each of the thin connection plates 21, and an adhesive layer 22 is provided on a portion having a plate thickness smaller than that of the protrusion 21c. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a structure of a stator used in a motor, and more particularly, to a stator with improved assemblability of a motor that is used as a conductor by laminating thin plates without using windings.

The main type of stator used in motors is a wound-type stator in which an enamel-coated copper wire is wound around a stator core. In recent years, a stator using a thin laminated conductor as shown in Patent Document 1 has been proposed for the purpose of downsizing and high output of the stator.
There are two advantages of a stator using a thin laminated conductor over a wound stator. As a first advantage, the thickness of the coil end portion can be reduced by adopting a method in which the thin plate laminated conductors inserted into the slots are joined to each other using the end connecting conductors obtained by laminating the thin plates. It can be suppressed and can contribute to miniaturization of the stator.
As a second advantage, the winding type stator is configured to wind the enamel-coated copper wire around the teeth portion of the stator, but it is necessary to secure a minimum bending radius in order to prevent cracking of the enamel coating. As a result, there is a limit to the thickness of the winding that can be used. Compared with a wound stator, a stator using thin laminated conductors is connected at the end, so the cross-sectional area can be increased, and the slot ratio of the conductor is increased. This makes it possible to increase the current density.

FIG. 14 shows an exploded perspective view of a stator of a motor shown in Patent Document 1 which is an example of a stator using a thin laminated conductor.
The motor of Patent Document 1 is configured by combining a stator core 110 with a laminated coil piece 120, an annular connecting coil piece 130, the other end side connecting coil piece 140, and a connecting ring 150. The laminated coil piece 120 is formed by integrally molding two laminated thin sheet conductors with insulating resin. The annular connecting coil piece 130 and the other end side connecting coil piece 140 are formed by integrally molding laminated thin plate conductors with an insulating resin. The connection ring 150 is formed by integrally molding an U-, V-, and W-phase connection line and a neutral line that are arranged in an annular shape with an insulating resin.

An end portion of the laminated coil piece 120 inserted into the slot 114 provided in the stator core 110 and machined, and an end portion of the laminated coil piece 120 inserted into the other slot 114 are annular. The ends of the machined thin plates constituting the connection coil piece 130 and the other end side connection coil piece 140 are abutted, welded, and electrically connected.
The laminated thin plate conductors are combined by resin molding and electrically connected to form a thin laminated stator, so that the end of the stator has an annular connecting coil piece 130, etc. Only the thickness of the end side connection coil piece 140 and the connection ring 150 is required, which is advantageous for making the stator compact. Further, since the stator core 110 inserted into the slot 114 is formed by stacking thin plates, the space factor of the slot 114 can be increased and the current density can be increased. This is also advantageous for higher output.

However, in the motor stator disclosed in Patent Document 1, there are 400 or more joint portions between the thin plates on both sides. Therefore, even if any welding method such as TIG welding or laser welding is used to weld the joining portions of the thin plates, the TIG welding torch or laser welding spot is accurately positioned with respect to all the contacts. Because it is necessary, welding takes time.
In addition, the enamel covering the thin plate may be burned out due to the influence of heat generated during welding. Furthermore, since the thin plate end is machined, the processing cost is high, and it is necessary to position the laminated coil piece 120, the annular connecting coil piece 130 and the other end side connecting coil piece 140 with high accuracy for welding. There is.

As means for solving the problem of Patent Document 1, the applicant has proposed a stator manufacturing method disclosed in Patent Document 2 and a technique related to a stator of a rotating electrical machine manufactured by the stator manufacturing method. In Patent Document 2, a conductive adhesive is used for joining thin plates. According to this method, after forming a thin plate with a press, a conductive adhesive is applied to the end of at least one thin plate, the thin plate is assembled to the end of the stator, and the joint is pressed after assembly. Therefore, it is possible to reduce the time required for joining.
JP 2001-178053 A JP 2005-137174 A

However, Patent Document 2 has a problem regarding the assemblability of the stator end.
As shown in Patent Document 2, when a conductive adhesive is applied to the end connection surface of one thin plate, the corner of the other thin plate is applied to one end of the stator when the stator end is assembled. There is a possibility that the conductive adhesive may be peeled off by scratching the surface.
In order to avoid this, it is required to increase the manufacturing accuracy of the parts themselves and to assemble them so that the relative positions of the parts are in appropriate positions, both of which increase the cost and reduce the assemblability. It will end up.

It is desirable that the conductive adhesive applied to the end connection surface of the thin plate is uniformly applied in order to ensure the electrical conductivity after joining. However, when the coated surface becomes non-uniform, for example, when the conductive adhesive is peeled off, the current-carrying area of the bonded surface is reduced, which may increase the resistance at the bonded surface. When the resistance at the joint surface increases as described above, the motor generates heat.
In particular, drive motors for hybrid vehicles are required to be smaller and have higher output than conventional motors. Therefore, the motor is densified and a high voltage current is passed through the stator of the motor. However, if a high-voltage current is passed through the motor stator having a high density, the heat generation of the motor increases, and the durability of the motor becomes a problem.

  Accordingly, in order to solve such problems, the present invention provides a motor stator that can maintain the uniformity of the conductive adhesive layer during assembly when a conductive adhesive layer is provided on the joint surface. The purpose is to provide.

In order to achieve the above object, the stator of the motor according to the present invention has the following characteristics.
(1) A stator core in which a plurality of concave slots are formed on the inner periphery, a laminated conductor in which a plurality of thin plates are laminated, and a plurality of conductors that connect ends of the laminated conductor and other laminated conductors In a stator of a motor having an end connection conductor formed by laminating connection thin plates, the connection thin plate is formed with a connection portion that comes into contact with the thin plate of the multilayer conductor, and at the end of the thin plate A contact end portion connected to a connection portion of the connection thin plate is formed, and a convex portion is formed on the connection portion of the connection thin plate, or a connection surface of the contact end portion of the thin plate; An adhesive coating layer is provided on a portion having a plate thickness thinner than that of the convex portion.

(2) In the motor stator described in (1), a fitting groove portion into which the convex portion is fitted is formed on the connection portion of the connection thin plate or the connection surface of the contact portion of the thin plate. When the thin plate and the connecting thin plate are connected, the convex portion is fitted into the fitting groove portion.

(3) In the stator of the motor described in (1), the convex portion is formed at a predetermined distance from the adhesive application layer by forming a concave portion with a load applying means, and thereby, by the bulge of the pushed material. It is formed.

With the motor according to the present invention having such characteristics, the following operations and effects can be obtained.
First, in the invention described in (1), the connection thin plate is formed with a connection portion that comes into contact with the thin plate of the laminated conductor, and the end portion of the thin plate has a contact end that connects with the connection portion of the connection thin plate. A convex portion is formed on the connecting portion of the connecting thin plate or the contact end portion of the thin plate, and a portion having a plate thickness thinner than the convex portion, that is, a connecting surface other than the convex portion. Is provided with an adhesive coating layer.
With such a configuration, when the connecting portion of the connecting thin plate is inserted into the end gap formed between the ends of the adjacent thin plates, a convex portion is formed on the connecting surface of the connecting thin plate. Thus, the convex portion is inserted into the end portion gap while contacting the thin plate. On the other hand, the conductive adhesive layer provided on the connection surface of the connection thin plate is provided in a portion where the plate thickness is thinner than the convex portion, so that the conductive adhesive layer is rubbed against the thin plate or conductive adhesive. Peeling due to the agent layer being scratched by the corners of the thin plate can be prevented.
Therefore, even when a conductive adhesive layer is provided on the bonding surface, the uniformity of the conductive adhesive layer can be maintained during assembly, and it becomes possible to reduce bonding defects and reduce the defective rate of products. .

Further, the invention described in (2) is the fitting in which the convex portion is fitted into the connection portion of the connection portion of the thin plate for connection or the contact portion of the thin plate in the stator of the motor described in (1). When the groove portion is formed and the thin plate and the connection thin plate are connected, the convex portion is fitted into the fitting groove portion, so that in the process of connecting the connection portion of the connection thin plate and the contact end portion of the thin plate, ( As described in the effect of 1), the conductive adhesive layer is protected by the convex portion, and when connected, the convex portion is fitted into the fitting groove portion, and the connection surface of the connecting portion provided with the conductive adhesive layer Is in surface contact with the surface provided at the connecting portion of the thin plate, and the bonding is performed satisfactorily.
When the convex portion of the connecting thin plate needs to have a certain height to protect the conductive adhesive layer, when the connecting thin plate and the thin plate are joined, the convex portion is formed. It is possible that the surface becomes insufficiently crimped, resulting in poor bonding, but if the insertion groove is formed on the thin plate side and the convex part is inserted into the insertion groove when connected, the connection to the surface on the thin plate side Since the connection surfaces on the thin plate side are in contact with each other, pressure is evenly applied to the bonding surfaces, and connection failure due to insufficient crimping or the like is less likely to occur, and the product failure rate can be reduced.

  Further, the invention described in (3) is the motor stator described in (1), wherein the convex portion is formed at a predetermined distance from the adhesive coating layer by a load applying means. Since it is formed by the bulge of the pushed material, it becomes possible to form convex portions by simple load application means such as press and marking, and even when a conductive adhesive layer is provided on the joint surface The effect of maintaining the uniformity of the conductive adhesive layer during assembly can be easily obtained.

(First embodiment)
Next, a first embodiment will be described with reference to the drawings. First, the outline of the stator assembly process will be described with reference to FIGS.
FIG. 1 shows a perspective view of the stator 50 in the insertion step of the first embodiment. FIG. 2 is a perspective view of the stator 50 in the joining process. FIG. 3 is a perspective view of the stator 50 in the coil connection process. FIG. 4 is a perspective view of the stator 50 in the resin molding process.
In the stator 50, first, the laminated conductor 10 is inserted into a predetermined position of the stator core 30, as shown in FIG. Then, as shown in FIG. 2 in the <joining step>, the ends of the laminated conductor 10 are joined by the end connecting conductor 20 to form a coil. Further, as shown in FIG. 3 in <Coil connection step>, the formed coils are connected by the connection lines 40 (connection lines 40W01 to 40U05). Finally, as shown in FIG. 4 in <resin molding step>, resin mold portions 45 are formed on both surfaces of the end portion of the stator core 30.

Hereinafter, description of each part which comprises the stator 50, and the procedure of an assembly are demonstrated.
<Insertion process>
The <inserting step> is a step of inserting the laminated conductor 10 into the slot 32 formed in the stator core 30.
5 to 8 are views for explaining the laminated conductor 10 inserted into the slot 32 formed in the stator core 30. FIG. FIG. 5 shows a perspective view of the laminated conductor 10. FIG. 6 is a perspective view showing a state in which the laminated conductors 10 are arranged with the plate insulator 15 interposed therebetween. FIG. 7 is a perspective view showing a state in which the laminated conductor 10 is inserted into the case-like insulator 16.
The laminated conductor 10 is obtained by laminating 9 sheets of insulating plates attached to the surface of the thin plate 11. Note that the number of thin plates 11 to be stacked is determined by the design of the coil, and varies depending on the design.
The thin plates 11 are referred to as a first thin plate 1101 to a ninth thin plate 1109 in the order in which they are arranged inside when inserted into the stator core 30. However, for the sake of convenience, the simple plate 11 refers to any or all of the first thin plate 1101 to the ninth thin plate 1109.

The thin plate 11 is a rectangular copper plate having a thickness of several mm, and is formed by press molding. One surface of the thin plate end portion 11a formed at the end portion of the thin plate 11 is defined as a thin plate bonding surface 11b. Further, a fitting groove portion 11c is formed on the thin plate joining surface 11b, which is the root portion of the thin plate end portion 11a.
The thin plate end portion 11a is formed at the end portion of the thin plate 11 and is thinner than other portions. An insulating film is applied to one surface of the surface facing the thin plate bonding surface 11b. The insulating film is a resinous thin film that can ensure insulation, such as polyamide or amideimide. A thermosetting adhesive is applied to one side of the insulating film, and the thermosetting adhesive application surface is bonded to the thin plate 11 and pressed with a heated roller. The thermosetting adhesive between the insulating film heated by pressure and the thin plate 11 is cured to form an insulating layer on one surface of the thin plate 11.
The thin plate bonding surface 11b is one surface of the thin plate end portion 11a and serves as a contact surface with a connection thin plate bonding surface 21b described later. When connecting to the connecting thin plate bonding surface 21b, the thin plate bonding surface 11b has an area of several times the cross-sectional area of the thin plate 11 for the purpose of ensuring a large bonding area and preventing resistance.
The fitting groove portion 11c is a groove into which a convex portion 21c formed in the connection thin plate 21 described later enters. When the thin plate 11 is press-molded, a recess of about several hundreds μm is formed in the base portion of the thin plate end portion 11a to form the fitting groove portion 11c.

The laminated conductor 10 has a trapezoidal shape as shown in FIG. 5, and the widths of the thin plates 11 constituting the laminated conductor 10 are slightly different. The narrowest width is the first thin plate 1101 positioned on the inner diameter side when inserted into the stator core 30, and the widest width is the ninth thin plate 1109 positioned on the outer diameter side. It is.
Also, the thicknesses of the first thin plate 1101 to the ninth thin plate 1109 are slightly different from each other. The largest thickness is the first thin plate 1101 positioned on the inner diameter side when inserted into the stator core 30, and the smallest thickness is the ninth thin plate 1109 positioned on the outer diameter side. It is. When inserted into the stator core 30, the cross-sectional area of all the thin plates 11 can be made the same by increasing the width toward the outer peripheral portion and reducing the thickness. This is because the power factor can be increased and the power output can be increased.

Then, as shown in FIG. 6, a plate insulator 15 is sandwiched between the two sets of laminated conductors 10. The two sets of laminated conductors 10 are inserted into one slot 32. Therefore, the plate insulator 15 is provided in order to ensure insulation between the adjacent laminated conductors 10.
The plate insulator 15 is made of a heat-resistant insulating resin. Since the heat-resistant temperature is determined by the temperature at the time of motor operation or the like, the material of the plate insulator 15 may be appropriately selected according to the temperature.
At the front end of the laminated conductor 10, the insertion groove 11c of the thin plate end portion 11a provided in the thin plate 11 is arranged with the plate insulator 15 sandwiched between the two sets of laminated conductors 10 as shown in FIG. Will be lined up together.
As shown in FIG. 7, two sets of laminated conductors 10 are prepared and sandwiched between plate-like insulators 15 and inserted into case-like insulators 16. The case-like insulator 16 is provided with a flange 16a, and when the case-shaped insulator 16 is inserted into a stator core 30 described later, the flange 16a serves as a stopper. The material of the case-like insulator 16 is the same as that of the plate-like insulator 15 and has insulation and heat resistance.
The plate insulator 15 is structured to be fitted inside the case insulator 16, and the laminated conductor 10 and the plate insulator 15 are placed in the case insulator 16 by being fitted together with the laminated conductor 10 into the case insulator 16. Can be held.
Since the laminated conductor 10 inserted into the case-like insulator 16 is surrounded by the plate-like insulator 15 and the case-like insulator 16, insulation between the laminated conductors 10 is ensured and insulation from the stator core 30 described later. Can be secured.

FIG. 8 shows a perspective view of the stator core 30.
The stator core 30 is manufactured by laminating annular thin plates, and a plurality of teeth portions 31 and slots 32 are formed. The slot 32 has an opening on the inner peripheral side of the stator core 30, and has a structure in which a protrusion formed on the case-like insulator 16 enters and can be positioned. In addition, although the front-end | tip of the teeth part 31 comprises the wall of the stator core 30 inner peripheral side of the slot 32 formed in right and left, depending on the design concept of the stator 50, there is no such an overhanging part. Also good. In the first embodiment, 18 teeth portions 31 and the same number of slots 32 are formed in the stator core 30.
Note that the slots 32 provided at the 18 locations are referred to as first slot 3201 to 18th slot 3218 for convenience. However, the term “slot 32”, unless otherwise specified, indicates any one or all of the first slot 3201 to the eighteenth slot 3218.
Then, the laminated conductor 10 set in the case-like insulator 16 as shown in FIG. 7 is inserted into the slot 32 of the stator core 30. FIG. 1 shows a state in which the laminated conductor 10 set on the case-like insulator 16 is inserted into the stator core 30.

<Joint process>
The <joining step> is a step of assembling the end connection conductor 20 so as to be in the state shown in FIG. 2 in a state where the laminated conductor 10 is set on the stator core 30 as shown in FIG.
FIG. 9 is a schematic perspective view when the end connection conductor 20 is inserted into the laminated conductor 10 inserted into the stator core 30.
First, the end connection conductor 20 will be described.
The end connection conductor 20 shown in FIG. 9 is obtained by laminating nine connection thin plates 21. As shown in FIG. 9, the connecting thin plate 21 includes a first connecting thin plate 2101 to a ninth connecting thin plate 2109 from the inside when connected to the stator core 30. For the sake of convenience, the simple description of the connection thin plate 21 refers to any or all of the first connection thin plate 2101 to the ninth connection thin plate 2109.

The connecting thin plate 21 is a rectangular copper plate having a thickness of several millimeters. Thinner joints 21a are formed at both ends. In addition, a connecting thin plate bonding surface 21b and a convex portion 21c are formed in the bonding portion 21a.
The joining portion 21a is designed to be substantially the same as the thickness of the connecting thin plate 21 when the thin plate end portion 11a and the joining portion 21a are brought into contact with each other and the thicknesses of both are combined. This is because when the current is passed through the stator 50, consideration is given to prevent resistance at the connecting portion between the thin plate 11 and the connecting thin plate 21. Further, as will be described later, when the thin plate joining surface 11b and the connecting thin plate joining surface 21b are joined, pressure is applied in the thickness direction of the joining portion of the thin plate 11 and the connecting thin plate 21 so as to prevent significant deformation. There is also an effect. The first connecting thin plate 2101 to the ninth connecting thin plate 2109 are all designed with the same dimensions.
On the surface facing the surface on which the connecting thin plate joining surface 21 b is formed, an insulating film is applied to the same surface as the thin plate 11. An adhesive layer 22 is provided on the surface of the connecting thin plate bonding surface 21b. The adhesive layer 22 is not provided on the entire surface of the connecting thin plate bonding surface 21b, but is uniformly applied leaving the outer periphery as shown in FIG. This is intended to prevent the adhesive layer 22 from protruding and short-circuiting with other parts when the thin plate bonding surface 11b and the connecting thin plate bonding surface 21b are bonded.

A silver paste is used for the adhesive layer 22 of the first embodiment, which is applied by several tens of μm using screen printing, and after application, the organic solvent is volatilized by drying. What remains after drying is an adhesive layer 22 containing silver particles, which has electrical conductivity. The adhesive layer 22 is not particularly limited to silver paste, but preferably has higher conductivity than the material used for the thin plate 11 and the connecting thin plate 21. This is because the joint portion is likely to become a resistance when the coil is formed, and it is better to lower the resistance value as much as possible. Since copper is used for the thin plate 11 and the connecting thin plate 21, a silver paste having higher conductivity than copper is used in the first embodiment.
The convex portion 21c is provided on the connecting thin plate joining surface 21b, and when the connecting thin plate joining surface 21b and the thin plate joining surface 11b are connected, it fits into the fitting groove portion 11c formed on the thin plate joining surface 11b. Formed in position. Since the convex portion 21c only needs to be thicker than the thickness of the adhesive layer 22, it may be several tens of μm or more. However, there is a limitation of processing in press molding, and in the first embodiment, the height is several hundreds of μm. It is a protrusion.

  The length of the connecting thin plate 21 is set to such a length that the inner thin plate 11 inserted into the slot 32 of the stator core 30 can be joined. Since all the connecting thin plates 21 are designed with the same dimensions, when the outer diameter thin plates 11 inserted into the slots 32 of the stator core 30 are joined together, the connecting thin plates 21 are slightly shorter and the thin plate joining surface 11b. However, if the thin plate bonding surface 11b and the connecting thin plate bonding surface 21b are set wide in view of that amount, the resistance is prevented from becoming higher than other portions. be able to.

In order to join such an end connection conductor 20 to the laminated conductor 10 inserted into the stator core 30, it is necessary to insert the connection thin plate 21 into the end gap 13.
The end gap 13 is constituted by a thin plate end 11a portion of the adjacent thin plates 11, and is formed, for example, between the insulating film pasting surface of the first thin plate 1101 and the thin plate bonding surface 11b of the second thin plate 1102. It is. The end gap 13 is substantially the same as the thickness of the joining portion 21 a included in the connection thin plate 21.
When the end connection conductor 20 is assembled to the end of the laminated conductor 10, the insertion arm 75 is used.
The insertion arm 75 includes an arm 76, a clamper 77, and a holding jig 78. The arm 76 and the clamper 77 have a structure capable of holding a holding jig 78, and the holding jig 78 can be held and released by sliding the clamper 77. The holding jig 78 is formed of, for example, resin, and includes a partition portion 78a so that the connection thin plate 21 can be held at a predetermined interval.

A predetermined number of the connecting thin plates 21 are set in the holding jig 78 in advance, and after being gripped by the insertion arm 75, they are directed toward the end gap 13 formed between the adjacent thin plate end portions 11 a of the laminated conductor 10. To move.
In this way, for example, the thin plate bonding surface 11b of the first thin plate 1101 inserted in the first slot 3201 and the thin plate bonding surface 11b of the first thin plate 1101 inserted in the second slot 3202 are connected to the first connection. The thin plate 2101 is connected at the joint portion 21a.
Similarly, the second thin plate 1102 inserted into the first slot 3201 and the second thin plate 1102 inserted into the second slot 3202 are connected by the joint portion 21a of the second connecting thin plate 2102, and the first slot 3201 is connected. The third thin plate 1103 inserted into the second slot 3202 and the third thin plate 1103 inserted into the second slot 3202 are connected by the joint portion 21a of the third connecting thin plate 2103, and so on. Connected. This is shown in FIG.

FIG. 10 schematically shows the joining of the connecting thin plate 21 and the thin plate 11.
FIG. 10A to FIG. 10D show how the connection thin plate 21 is intermittently connected to the thin plate 11.
In FIG. 10A, as shown in FIG. 10, the connecting thin plate 21 is held by the insertion arm 75 above the thin plate 11 of the laminated conductor 10 inserted and held in the stator core 30. Yes. In FIG. 10B, the convex portion 21c formed on the connecting thin plate joining surface 21b abuts on the thin plate joining surface 11b.
In (c) of FIG. 10, it inserts to the base vicinity of the thin-plate edge part 11a, with the convex part 21c contacting the thin-plate joining surface 11b. At this time, since the adhesive layer 22 is provided on the connecting thin plate bonding surface 21b and is applied to a place thinner in the thickness direction than the convex portion 21c, it does not contact the thin plate bonding surface 11b. That is, the adhesive layer 22 is protected by the convex portion 21c, and the adhesive layer 22 can be prevented from being damaged. In FIG. 10D, the convex portion 21c enters the fitting groove portion 11c, and the connecting thin plate joining surface 21b provided with the adhesive layer 22 comes into contact with the thin plate joining surface 11b. In this state, the convex portion 21c is preferably designed to be slightly smaller than the inside of the fitting groove portion 11c. By forming the gap, the surface contact between the connecting thin plate bonding surface 21b and the thin plate bonding surface 11b is not hindered, and the adhesiveness by the adhesive layer 22 can be enhanced.
In addition, by forming the convex portion 21c on the connecting thin plate joining surface 21b of the connecting thin plate 21, for example, by thinning the thin plate end portion 11a, the end gap 13 is provided slightly wider, or the thin plate end portion 11a is formed. By opening outward, the means for widening the opening of the end gap 13 may be used to make it easy to insert the joint 21a of the connecting thin plate 21 into the end gap 13.

When the end connection conductor 20 is assembled to the end of the laminated conductor 10, the state shown in FIG. In this state, the laminated conductor 10 and the end connection conductor 20 are joined with high conductivity by the conductive adhesive by pressing and heating the joint from the inner peripheral side and the outer peripheral side of the stator core 30.
In this way, the end portion of the laminated conductor 10 housed in one slot 32 and the end portion of the laminated conductor 10 housed in the other slot 32 are connected to the teeth portion 31 by connecting the end connecting conductor 20. On the other hand, a coil is formed in a spiral shape. Since 18 teeth portions 31 are formed on the stator core 30, 18 pairs of coils are formed.

After the pressurizing and heating treatment of the laminated conductor 10 and the end connection conductor 20 on the stator first surface 30a, it is necessary to perform the bonding on the stator second surface 30b side, but insulation is ensured before that. Check if it is.
Then, after the insulation test is completed, the end connection conductor 20 on the stator second surface 30b side is joined. Here, in order to form a coil, it is necessary to shift one assembly by one pitch. In the first embodiment, the stator first surface 30a shown in FIG. 2 is joined without shifting, and the stator second surface 30b (not shown) is joined with a shift of 1 pitch.
Therefore, on the stator second surface 30b, the thin plate joining surface 11b of the first thin plate 1101 provided in the laminated conductor 10 inserted into the first slot 3201, and the second thin plate provided in the laminated conductor 10 inserted into the second slot 3202 are provided. The thin plate joining surface 11 b of 1102 is electrically coupled by the second connecting thin plate 2102.

Hereinafter, the second thin plate 1102 of the first slot 3201 and the third thin plate 1103 of the second slot 3202 of the stator second surface 30b are connected by the third connection thin plate 2103, and the third thin plate 1103 of the first slot 3201 is connected. And the fourth thin plate 1104 of the second slot 3202 are connected by the fourth connecting thin plate 2104 and so on, and are connected in a shifted state by the connecting thin plate 21.
Of course, the thin plates 11 inserted into the third slot 3203 through the eighteenth slot 3218 are also connected by the connecting thin plate 21 in the same manner.
As a result of this connection, the other end of the first slot 3201 joined to the thin plate joining surface 11b of the first thin plate 1101 provided in the laminated conductor 10 inserted into the second slot 3202, and the first slot 3201 are inserted. One thin plate joining surface 11b of the ninth thin plate 1109 provided in the laminated conductor 10 is left without being joined.

<Coil connection process>
In the <coil connection step>, the end of the laminated conductor 10 is joined by the end connection conductor 20 to form a coil, and then the connection line 40 is joined to form a circuit.
As shown in FIG. 3, a connection line 40 electrically connects the coil constituted by the laminated conductor 10 and the end connection conductor 20.
The connection line 40 is a copper plate and is covered with an insulation. By this connection line 40, 18 pairs of coils formed in the tooth portion 31 of the stator core 30 by the laminated conductor 10 and the end connection conductor 20 are electrically connected. That is, the other end of the first slot 3201 joined to the thin plate joining surface 11b of the first thin plate 1101 included in the laminated conductor 10 inserted into the second slot 3202 described above, and the laminated conductor 10 inserted into the first slot 3201. The connecting wires 40 are connected to the thin plate bonding surface 11b of the ninth thin plate 1109 included in the coil, whereby the coils are electrically connected.

Since the laminated conductor 10 and the end connection conductor 20 are spirally connected to the coil composed of the laminated conductor 10 and the end connection conductor 20 around the teeth portion 31, the end of the connection thin plate 21 per one coil. There are two more parts. One of the surplus ends and one end of another coil are electrically connected by a connecting line 40. Thus, the coil connected to the connection line 40 forms any one of the U phase, the V phase, and the W phase.
For example, the coil formed by the laminated conductor 10 inserted into the first slot 3201 and the second slot 3202 and the end connection conductor 20 connecting the end portions thereof is inserted into the fourth slot 3204 and the fifth slot 3205. The laminated conductor 10 is connected to the coil formed by the end connection conductor 20 connecting the end portions thereof with the connecting line 40U01, and further inserted into the seventh slot 3207 and the eighth slot 3208, and the end thereof. Connected to the coil formed by the end connection conductor 20 that connects the sections and the connecting line 40U02, and further, the end connection conductor that connects the stacked conductor 10 inserted in the tenth slot 3210 and the eleventh slot 3211 and the end thereof 20 is connected to the coil formed by the connecting line 40U03, and is further inserted into the thirteenth slot 3213 and the fourteenth slot 3214. The coil formed by the end connection conductor 20 that connects the body 10 and the end thereof, and the connection line 40U04, and the laminated conductor 10 inserted in the 16th slot 3216 and the 17th slot 3217 and the end thereof are connected. It is connected to the coil formed by the end connection conductor 20 to be connected by the connecting line 40U05.
The V phase and the W phase are similarly connected at different positions from the U phase, and are connected to the connection lines 40V01 to 40V05 and the connection lines 40W01 to 40W05 to form a concentrated winding coil.

That is, six coils connected by connection lines 40U01 to 40U05 form a U phase, a U-phase terminal 41U is connected to the end of the coil, and six coils connected by connection lines 40V01 to 40V05 are connected. The V phase is formed, the V phase terminal 41V is connected to the end of the coil, the six coils connected by the connection lines 40W01 to 40W05 form the W phase, and the W phase terminal 41W is formed at the end of the coil. Connected.
Note that the connection lines 40U01 to 40U05, the connection lines 40V01 to 40V05, and the connection lines 40W01 to 40W05 are simply named for convenience. One or all of them.
Further, when the U phase terminal 41U, the V phase terminal 41V, and the W phase terminal 41W are described as the terminal 41, any one or all of them are indicated.

<Resin molding process>
In the <resin molding step>, the resin mold portion 45 is formed on the stator first surface 30a side and the stator second surface 30b side of the stator core 30.
In the state where the coils formed around the teeth portion 31 provided in the stator core 30 are electrically connected by the connecting wire 40, there is a portion that is not insulated, so it is necessary to finally cover with an insulating material. is there. For this reason, the joint portion of the laminated conductor 10 and the end connection conductor 20 and the connection portion of the connecting line 40 are insulated by resin molding.
The resin constituting the resin mold part 45 is made of a highly insulating material. The resin mold portion 45 prevents the joint portion between the laminated conductor 10 and the end connection conductor 20, the joint portion between the thin plate 11 or the connection thin plate 21 and the connection line 40, or the like from being peeled off due to factors such as external force. At the same time, it is possible to prevent other parts from being deformed and in contact with each other and short-circuiting.
Thus, the stator 50 of the motor is configured.

Since the first embodiment is configured as described above, it has the following effects.
First, in the step of inserting the stator 50, the connecting thin plate 21 is held by the insertion arm 75 and inserted into the end gap 13. At this time, for example, when the first connecting thin plate 2101 is inserted into the end gap 13 formed between the first thin plate 1101 and the second thin plate 1102, the first connecting thin plate 2101 is shown in FIG. Since the convex portion 21c is formed on the connecting thin plate joining surface 21b, it is the convex portion 21c that may come into direct contact with the thin plate joining surface 11b. Therefore, the connecting thin plate joining surface 21 b does not contact the thin plate end portion 11 a of the first thin plate 1101 while the joining portion 21 a is being inserted into the end gap 13.
As a result, the adhesive layer 22 provided on the surface of the connecting thin plate joining surface 21b does not come into contact with the thin plate end portion 11a, and as a result, peeling of the adhesive layer 22 can be prevented.
In the first embodiment, a silver paste is used for the adhesive layer 22. The silver paste is easily peeled off due to scratching contact, and the adhesive layer 22 is peeled off, which may cause a bonding failure between the thin plate bonding surface 21b for connection and the thin plate bonding surface 11b. If the resistance of the joint portion is increased due to the joint failure of the joint portion between the connecting thin plate joining surface 21b and the thin plate joining surface 11b, heat is easily generated in this portion. Since the problem of heat generation in the stator of the motor is directly related to shortening of the life, if peeling of the adhesive layer 22 can be prevented by forming the convex portion 21c on the connecting thin plate joining surface 21b, the life of the motor can be shortened. It is not connected, and the reliability of the motor can be improved.

Further, in a state where the joining portion 21a has been inserted into the end gap 13, the convex portion 21c enters the fitting groove portion 11c as shown in FIG. Therefore, by forming the convex portion 21c on the connecting thin plate joining surface 21b, the surface contact between the connecting thin plate joining surface 21b and the thin plate joining surface 11b is not hindered.
The convex portion 21 c formed on the connecting thin plate bonding surface 21 b is formed thicker than the adhesive layer 22 for the purpose of protecting the adhesive layer 22. Therefore, if the fitting groove 11c is not provided, the pressure applied when the connecting thin plate joining surface 21b and the thin plate joining surface 11b are joined requires a force sufficient to crush the convex portion 21c. Since the connecting thin plate 21 is a copper plate, it is relatively easily deformed. However, deformation to an unnecessary portion may cause a short circuit. Therefore, if the fitting groove portion 11c is provided and the convex portion 21c is fitted, and the connection thin plate bonding surface 21b and the thin plate bonding surface 11b are easily brought into surface contact, the possibility of poor bonding is reduced.

Further, the convex portion 21c and the fitting groove portion 11c can be formed relatively easily if the thin plate 11 and the connecting thin plate 21 are formed by press molding.
In addition, you may deform | transform the shape of the convex part 21c and the fitting groove part 11c as needed. For example, in order to ensure the strength of the base of the thin plate end portion 11a, as shown in FIG. 11, the fitting groove portion 11c is divided into two and provided on the left and right of the thin plate end portion 11a, and the central portion does not form the fitting groove portion 11c. Corresponding to this, the convex portion 21c may be formed with a convex portion 21c divided into two left and right portions without forming a projection at the center portion. By doing so, it is possible to cope with the purpose of protecting the adhesive layer 22 when the joining portion 21 a is inserted into the end gap 13.

As described above, in the first embodiment of the present invention, the following configurations, functions, and effects can be obtained.
(1) Stator core 30 in which a plurality of concave slots 32 are formed on the inner periphery, a laminated conductor 10 in which a plurality of thin plates 11 are laminated, and end portions of the laminated conductor 10 and other laminated conductors 10 In a stator 50 of a motor having an end connection conductor 20 formed by laminating a plurality of connection thin plates 21 that connect each other, the connection thin plate 21 is joined to a thin plate 11 of the multilayer conductor 10. The thin plate 11 is formed with a thin plate end portion 11a connected to the connecting portion 21a of the connecting thin plate 21 at the end portion thereof, and a convex portion 21c is formed on the connecting thin plate joining surface 21b of the connecting thin plate 21. In addition, the adhesive layer 22 is provided on a portion having a plate thickness thinner than the convex portion 21c, that is, on the connecting thin plate joining surface 21b other than the convex portion 21c.

With such a configuration, when the joining portion 21a of the connection thin plate 21 is inserted into the end gap 13 formed between the thin plate end portions 11a of the adjacent thin plates 11, the connection thin plate of the connection thin plate 21 is inserted. By forming the convex portion 21 c on the joining surface 21 b, the convex portion 21 c is inserted into the end gap 13 while abutting against the thin plate joining surface 11 b of the thin plate 11. On the other hand, since the adhesive layer 22 provided on the connecting thin plate joining surface 21b of the connecting thin plate 21 is provided in a portion having a plate thickness thinner than the convex portion 21c, the adhesive layer 22 rubs against the thin plate 11. In addition, peeling due to the adhesive layer 22 being scratched by the corners of the thin plate 11 can be prevented.
Therefore, even when the adhesive layer 22 is provided on the connecting thin plate bonding surface 21b, the uniformity of the adhesive layer 22 can be maintained during assembly, and the bonding failure can be reduced and the defective rate of the product can be reduced. It becomes.

(2) In the motor described in (1), a fitting groove portion 11c into which the convex portion 21c is fitted is formed on the thin plate joining surface 11b of the thin plate end portion 11a of the thin plate 11, and the thin plate 11 and the connecting thin plate 21 are connected. Since the convex portion 21c is fitted into the fitting groove portion 11c, the connecting portion 21a of the connecting thin plate 21 and the thin plate end portion 11a of the thin plate 11 are connected to each other as described in the function and effect (1). As the adhesive layer 22 is protected by the convex portion 21c and is connected, the convex portion 21c is fitted into the fitting groove portion 11c, so that the connecting thin plate joining of the joint portion 21a provided with the adhesive layer 22 is performed. The surface 21b comes into surface contact with the thin plate joining surface 11b provided at the thin plate end portion 11a of the thin plate 11, and the joining is performed satisfactorily.
When the convex portion 21c of the connecting thin plate 21 needs a certain height to protect the adhesive layer 22, when the connecting thin plate 21 and the thin plate 11 are joined, the convex portion 21c is formed. It is conceivable that the surface will become insufficiently crimped due to the contact between the surface and the surface, resulting in poor bonding. However, if the fitting groove 11c is formed on the thin plate 11 side and the projection 21c is fitted into the fitting groove 11c at the connected stage. Since the thin plate joining surface 11b on the thin plate 11 side and the connecting thin plate joining surface 21b on the connecting thin plate 21 side are in contact with each other, pressure is evenly applied to the joining surface, and connection failure due to insufficient crimping is less likely to occur. It is possible to reduce the defective rate of the product.

Next, the second embodiment will be described.
(Second embodiment)
The configuration of the second embodiment is substantially the same as the configuration of the first embodiment, but the configuration of the joint 21a formed on the connection thin plate 21 is slightly different. This will be described in detail below. In addition, about the structure which is not demonstrated, it shall be the same structure as 1st Example.
FIG. 12 is a perspective view showing the connecting thin plate joining surface 21b of the joining portion 21a formed at the end of the connecting thin plate 21 of the second embodiment. FIG. 13 is a cross-sectional view taken along the line AA in FIG.
As shown in FIG. 12, the connecting thin plate 21 of the second embodiment has a joint 21a at the end. An adhesive layer 22 is provided on the connecting thin plate bonding surface 21b of the bonding portion 21a, and a convex portion 21c is formed around the adhesive layer 22b. A groove portion 21d is formed around the convex portion 21c.
The joining portion 21a is formed by cutting out from a rectangular wire used for the connecting thin plate 21 with a predetermined length and press-molding. And an insulating film is affixed on the surface which opposes the thin-plate joint surface 21b for a connection of the junction part 21a.

The convex portion 21c is formed in a square frame shape with a width of several millimeters left on the outer peripheral portion on the surface of the connecting thin plate joining surface 21b. As shown in FIG. 13, the convex portion 21c is formed on the side of the groove portion 21d. However, the groove portion 21d is formed by a load applying means such as an inscription or pressing, and the bulge of the material pushed away at that time is the convex portion. Since it is 21c, it has such a configuration.
If the height of the convex portion 21c is slightly thicker than the thickness of the adhesive layer 22, the function is achieved. Therefore, it is only necessary that the swell is as thick as several tens of μm from the thickness of the adhesive layer 22. The unevenness of about several tens of μm is a thickness that can be formed by scribing or the like. If the height of the unevenness is insufficient, the convex portion 21c and the groove portion 21d may be provided by press working when the connecting thin plate 21 is formed by press working.

The adhesive layer 22 provided on the connecting thin plate bonding surface 21b uses silver paste, which is applied by several tens of μm using screen printing, and is dried after application to volatilize the organic solvent. What remains after drying is an adhesive layer 22 containing silver particles, which has electrical conductivity. The adhesive layer 22 is not particularly limited to silver paste, but preferably has higher conductivity than the material used for the thin plate 11 and the connecting thin plate 21. This is because the joint portion is likely to become a resistance when the coil is formed, and it is better to lower the resistance value as much as possible. Since copper is used for the thin plate 11 and the connecting thin plate 21, a silver paste having higher conductivity than copper is used in the first embodiment.
If the adhesive layer 22 is applied after the convex portion 21c is formed on the connection thin plate joining surface 21b, the adhesive layer 22 can be applied so as not to protrude.
Using the end connection conductor 20 constituted by such a connecting thin plate 21, the end portions of the laminated conductors 10 are connected by the end connection conductor 20 in the <joining step>.

Since the second embodiment is configured as described above, it has the following operational effects.
First, the protrusion of the adhesive layer 22 can be prevented by the convex portion 21c formed on the connecting thin plate bonding surface 21b. Then, when the joining portion 21a is inserted into the end gap 13, the height of the convex portion 21c is higher than the thickness of the adhesive layer 22, so that the corner portion of the thin plate end portion 11a and the surface of the thin plate joining surface 11b are formed. By rubbing, the possibility that the adhesive layer 22 is peeled off can be reduced.
Further, the convex portion 21c has a height of several tens of μm, and when the laminated conductor 10 and the end connection conductor 20 are joined by pressure and heating, a groove portion 21d is formed beside the convex portion 21c. The escape location of the material that escapes when pressurized is secured, and it is considered that if the force at the time of pressurization is increased somewhat, the bonding by the adhesive layer 22 will not be hindered.

  Moreover, since the convex part 21c formed in the thin plate joining surface 21b for connection is provided so that the circumference | surroundings of the adhesive bond layer 22 may be enclosed, the thin plate end part 11a of the thin plate 11 and the junction part 21a of the thin plate 21 for connection are provided. It is possible to prevent the adhesive layer 22 from sticking out when bonding. The application area of the adhesive layer 22 to the connection thin plate bonding surface 21b is narrowed so that a gap is formed around the connection, but the adhesive layer 22 may protrude if the gap is not sufficient. . On the other hand, if the protrusion area is spread and the application area of the adhesive layer 22 is narrowed more than necessary, the bonding area between the thin plate bonding surface 11b and the connecting thin plate bonding surface 21b cannot be secured sufficiently, which may cause resistance. However, providing the convex portion 21 c around the adhesive layer 22 has an effect of preventing the adhesive layer 22 from protruding. For example, even if the application area of the adhesive layer 22 is expanded or the application thickness of the adhesive layer 22 is set to be thick, it is possible to prevent the protrusion from occurring when the thin plate end portion 11a and the joint portion 21a are joined. It becomes.

As described above, in the second embodiment of the present invention, the following configurations, functions, and effects can be obtained.
(1) Stator core 30 in which a plurality of concave slots 32 are formed on the inner periphery, a laminated conductor 10 in which a plurality of thin plates 11 are laminated, and end portions of the laminated conductor 10 and other laminated conductors 10 In a stator 50 of a motor having an end connection conductor 20 formed by laminating a plurality of connection thin plates 21 that connect each other, the connection thin plate 21 is joined to a thin plate 11 of the multilayer conductor 10. The thin plate 11 is formed with a thin plate end portion 11a connected to the connecting portion 21a of the connecting thin plate 21 at the end portion thereof, and a convex portion 21c is formed on the connecting thin plate joining surface 21b of the connecting thin plate 21. In addition, the adhesive layer 22 is provided on a portion having a plate thickness thinner than the convex portion 21c, that is, on the connecting thin plate joining surface 21b other than the convex portion 21c.

With such a configuration, when the joining portion 21a of the connection thin plate 21 is inserted into the end gap 13 formed between the thin plate end portions 11a of the adjacent thin plates 11, the connection thin plate of the connection thin plate 21 is inserted. By forming the convex portion 21 c on the joining surface 21 b, the convex portion 21 c is inserted into the end gap 13 while abutting against the thin plate joining surface 11 b of the thin plate 11. On the other hand, since the adhesive layer 22 provided on the connecting thin plate joining surface 21b of the connecting thin plate 21 is provided in a portion having a plate thickness thinner than the convex portion 21c, the adhesive layer 22 rubs against the thin plate 11. In addition, peeling due to the adhesive layer 22 being scratched by the corners of the thin plate 11 can be prevented.
Therefore, even when the adhesive layer 22 is provided on the connecting thin plate bonding surface 21b, the uniformity of the adhesive layer 22 can be maintained during assembly, and the bonding failure can be reduced and the defective rate of the product can be reduced. It becomes.

(2) In the stator of the motor described in (1), the convex portion 21c is formed at a predetermined distance from the adhesive layer 22 by forming a groove portion 21d by a load applying means, thereby causing the bulge of the pushed material. Since it is formed, it becomes possible to form the convex portion 21c by a simple load applying means such as a press or an inscription, and when the adhesive layer 22 is provided on the connecting thin plate joining surface 21b, the thin plate joining surface It is possible to easily obtain the effect that the uniformity of the adhesive layer 22 can be maintained when the connecting portion 11b and the connecting thin plate joining surface 21b are joined.

Although the present invention has been described with reference to the first embodiment and the second embodiment, the present invention is not limited to the first embodiment and the second embodiment, and does not depart from the spirit of the present invention. Needless to say, the present invention can be applied with appropriate changes.
For example, a U-shaped laminated conductor may be used instead of the laminated conductor 10, and it is not disturbed that the shape of the joint portion between the thin plate 11 and the connecting thin plate 21 is changed due to design convenience.

The perspective view of the stator 50 in the insertion process of 1st Example is shown, and it is the state which inserted the case-shaped insulator 16, the plate-shaped insulator 15, and the laminated conductor 10 in the stator core 30. FIG. The perspective view of the stator 50 in the joining process of 1st Example is shown, and the state which assembled | attached the edge part connection conductor 20 to the laminated conductor 10 is shown. The perspective view of the stator 50 in the coil connection process of 1st Example is shown, After attaching the edge part connection conductor 20 to the laminated conductor 10, the state which joined the connection line 40 is shown. The perspective view of the stator 50 in the resin molding process of 1st Example is shown, and after joining the edge part connection conductor 20 and the connection line 40 to the laminated conductor 10, the state molded by resin is shown. The perspective view of the laminated conductor 10 of 1st Example is shown. The perspective view of the state which put in order and put the plate-shaped insulator 15 between the two laminated conductors 10 of 1st Example is shown. The perspective view of the state by which the laminated conductor 10 and the plate-shaped insulator 15 were inserted in the case-shaped insulator 16 of 1st Example is shown. The perspective view of the stator core 30 of 1st Example is shown. The perspective view at the time of inserting the edge part connection conductor 20 in the laminated conductor 10 inserted in the stator core 30 of 1st Example is shown. The state of connecting the thin plate 11 and the connecting thin plate 21 of the first embodiment is schematically shown in (a) to (d). The expanded perspective view showing the modification of the front-end | tip part of the laminated conductor 10 of 1st Example is shown. The perspective view which expanded the junction part 21a of the thin plate 21 for a connection of 2nd Example is shown. The AA sectional view of Drawing 2 of the 2nd example is shown. The exploded perspective view of the stator of patent documents 1 is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Laminated conductor 11 Thin plate 11a Thin plate end part 11b Thin plate joint surface 11c Insertion groove part 13 End part clearance 15 Plate-like insulator 16 Case-like insulator 16a 鍔 20 End connection conductor 21 Connection thin plate 21a Joint part 21b Connection thin plate joint surface 21c Convex part 21d Groove part 22 Adhesive layer 30 Stator core 31 Teeth part 32 Slot 40 Connection line 41 Terminal 45 Resin mold part 50 Stator 75 Insert arm 76 Arm 77 Clamper 78 Holding jig 78a Partition part

Claims (3)

A stator core having a plurality of concave slots formed on the inner periphery, a laminated conductor in which a plurality of thin plates are laminated, and a plurality of connecting thin plates that connect the ends of the laminated conductor and other laminated conductors In the stator of the motor having the end connection conductor formed by laminating,
The connection thin plate is formed with a connection portion that comes into contact with the thin plate of the laminated conductor,
The end of the thin plate is formed with an abutting end connected to the connecting portion of the connecting thin plate,
A convex portion is formed on the connecting portion of the connecting thin plate or the connecting surface of the abutting end portion of the thin plate, and an adhesive coating layer is provided on a portion having a thinner thickness than the convex portion. The stator of the motor. In the stator of the motor according to claim 1,
A fitting groove portion into which the convex portion is fitted is formed on the connection portion of the connection thin plate or the connection surface of the contact portion of the thin plate,
The stator of the motor, wherein the convex portion is fitted into the fitting groove when the thin plate and the connecting thin plate are connected. In the stator of the motor according to claim 1,
The stator of the motor, wherein the convex portion is formed by a bulge of the pushed material by forming a concave portion by a load applying means at a predetermined distance from the adhesive application layer.

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