JP2010028914A - Resin molded coil, resin molded stators, and manufacturing method for the stators - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin molded coil wherein the installation position of a core or a coil will not displace and it is possible to enhance the radiative performance of the core. <P>SOLUTION: The molded coil 1 is molded with resin 4 and has a hole 9, into which a core 2 is inserted at its inner radius portion. The molded coil is provided with a resin introduction passage 15 that is extended from outside a coil end portion 7 to the hole 9 and guides resin to a gap H, formed between the outer circumferential portion of the core and the inner circumferential portion of the hole. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a resin-molded coil having at least a surface resin-molded, a resin-molded stator using the resin-molded coil, and a stator manufacturing method.

  For example, a stator of a motor or a generator is configured by winding a coil around a core. The core includes a yoke portion disposed on the outer peripheral side of the stator and a tooth portion protruding from the yoke portion toward the inner peripheral side. The coil is configured by winding a winding around the outer periphery of the tooth portion. In recent years, resin-molded coils obtained by resin-molding coil members have been proposed.

JP 2007-195333 A

  The invention described in Patent Document 1 includes a tooth portion and a yoke portion arranged in an annular shape. The annular tooth portion is configured by connecting a plurality of teeth in a ring shape, and the yoke portion is configured by connecting a plurality of yokes in a ring shape. The resin mold coil is attached to each tooth of the annular tooth portion.

  In the stator according to the invention described in Patent Document 1, the work of assembling the core and the coil is simplified, and an insulator for performing insulation is not necessary. For this reason, productivity improves and it can also reduce manufacturing cost.

  When the resin molded coil as described in Patent Document 1 is employed, a gap is generated between the core outer peripheral portion and the resin molded coil inner peripheral portion in a state where the resin molded coil is assembled to the core. For this reason, the coil rattles during use, causing the mounting position to shift, and causing vibration and noise.

  Further, when the electric motor is configured, there is a possibility of interference with the rotor if the position of the coil is shifted to the rotor side.

  Furthermore, if there is a gap, the mold resin between the core and the coil may deteriorate due to partial discharge or the like, and the insulation between the coil and the core may decrease. Further, the presence of the gap reduces the heat conduction between the coil and the core, thereby reducing the heat dissipation of the coil.

  This invention makes it a subject to solve the said problem, and to provide the resin mold coil which can raise the heat dissipation to a core, without the position of a core and a coil shifting | deviating.

  The invention described in claim 1 is a molded coil which is molded with resin and has a hole portion into which the core is inserted in the inner peripheral portion, and communicates with the hole portion from the outside of the coil end portion. A resin introduction path for introducing resin is provided in a gap formed between the outer peripheral portion and the inner peripheral portion of the hole.

  The resin mold coil is formed by covering the wound windings and the outer peripheral surface of the cylindrical coil with resin. In addition, the coil terminal part and the coil front-end | tip part facing a rotor can be comprised by exposing a winding from resin.

  By providing the resin introduction path, it is possible to fill the gap in the gap between the resin mold coil inner periphery and the core outer periphery after being assembled to the core. By filling the resin, the resin mold coil and the core are integrated, and no gap is generated between them. Further, there is no occurrence of displacement or rattle due to the gap. Moreover, since the assembly position of the resin mold coil and the core is not shifted, there is no possibility of interference with the rotor.

  Furthermore, the core outer peripheral portion and the coil inner peripheral portion can be reliably separated via the filling resin. Therefore, there is no fear that the electrical insulation property is lowered.

  The resin is not particularly limited, and the same resin as that molded from the resin mold coil can be used. In addition, by filling a resin having high thermal conductivity, heat generated in the coil can be efficiently radiated to the core.

  The resin introduction path cannot be provided in a portion where the winding is embedded. Moreover, in the state assembled in an annular shape, adjacent coils are positioned in the circumferential direction, so it is difficult to provide the resin introduction path on the coil side. Therefore, in the invention described in claim 2, the resin introduction path is configured by providing a resin injection groove that leads from the outer edge of the coil end portion to the hole at the tip of the resin molded coil.

  The resin injection groove can be formed, for example, by cutting out the coil tip side of the mold resin. The resin injection groove can be formed at the same time when the resin molded coil is formed, or can be formed by machining or the like after the resin molded coil is formed.

  The resin injection groove communicates with the gap between the outer peripheral portion of the core and the inner peripheral portion of the resin mold coil from the outside of the coil end portion by cooperating with a mold member disposed on the coil tip side. The resin introduction path to be configured is configured, and the resin can be introduced into the gap from the outside of the resin molded coil.

  In addition, as in the invention described in claim 3, the resin injection groove can be formed in the leading end side stepped portion of the winding constituting the coil. In particular, when a winding having a large cross-sectional area is employed, the step of the winding step-down portion where the winding moves to the next turn becomes large at the coil tip. In the invention described in this claim, the resin injection groove is provided by using the step. By adopting this configuration, the resin injection groove can be provided without increasing the thickness of the mold resin at the coil tip.

  According to a fourth aspect of the present invention, the resin introduction path is configured by providing a resin injection hole that leads from the outer surface on the proximal end side of the coil end portion to the hole portion.

  It is desirable to set the distance between the coil tip side and the rotor as small as possible. For this reason, the thickness of the mold resin covering the coil may not be set large, and it may be difficult to configure a sufficient resin introduction path with the resin injection groove according to claim 2 or claim 3. By providing the resin injection hole on the base end side outer surface of the coil end portion, that is, the yoke side outer surface, a resin flow path can be secured. Thereby, resin can be reliably filled in the clearance gap between a core outer peripheral part and a resin mold coil inner peripheral part.

  The method of providing the resin injection hole is not particularly limited, and can be formed simultaneously with the molding of the resin mold coil, or can be provided by machining after the molding.

  According to a fifth aspect of the present invention, a concave portion is provided on the inner peripheral portion of the resin-molded coil so as to ensure the gap between the core outer peripheral portion and the resin-molded coil.

  If the gap between the outer periphery of the core and the inner periphery of the resin mold coil is small, the flow of the resin becomes worse. For this reason, it may be difficult to fill the entire area of the gap with resin. By providing the concave portion, a gap between the outer peripheral portion of the core and the inner peripheral portion of the resin mold coil can be set large. Therefore, the flow of the filling resin is not hindered, and the resin can be filled in the entire gap. In addition, the coil and the core can be reliably separated from each other, and there is no risk of dielectric breakdown or the like.

  The structure of the said recessed part is not specifically limited. What is necessary is just a form which can form a required clearance gap between the outer peripheral part of the said core, and the said resin mold coil inner peripheral part. For example, the concave portion can be provided leaving a portion in contact with the corner of the rectangular core. Moreover, it can also form in the shape of a groove | channel which can ensure the flow path of filling resin. Furthermore, a rectangular recess can be provided on each inner peripheral surface having a rectangular cross section, and a groove-like recess that allows the plurality of recesses to communicate with each other can also be provided.

  The invention described in claim 6 is a core assembled to the resin molded coil according to any one of claims 1 to 5, wherein the core is disposed between the outer peripheral portion and the inner periphery of the resin molded coil. Are provided with a recess for ensuring the above gap.

  The said core is assembled | attached integrally with the resin mold coil described in Claims 1-5. Therefore, by providing a recess in the outer peripheral part of the core, a gap between the inner peripheral part of the resin mold coil and the outer peripheral part of the core can be secured.

  According to a seventh aspect of the present invention, the plurality of resin molded coils according to any one of the first to fifth aspects are assembled to the core and arranged in an annular shape, and at least the resin molded coil is It is an invention related to a resin molded stator in which a gap between an inner peripheral portion and the core outer peripheral portion is filled with resin.

  The resin may be filled in at least a gap between the inner peripheral portion of the resin molded coil and the outer peripheral surface portion of the core. Moreover, the resin mold stator of the form which integrated the some core and coil by filling the said resin between adjacent resin mold coils can also be comprised. Furthermore, the bus bar to which the terminal portion of each resin mold coil is connected can be integrally molded together with the resin mold coil and the core to constitute a resin molded stator.

  According to an eighth aspect of the present invention, there is provided an assembling step of assembling the plurality of resin molded coils according to any one of the first to fifth aspects to a core and arranging them in an annular shape, and at least an inner peripheral portion of each resin molded coil And a resin filling step of filling the gap between the outer periphery of the core and a resin.

  In the invention described in this claim, after the plurality of cores and the resin mold coil are assembled in an annular shape, the gap is filled between the outer periphery of the core and the inner periphery of the resin mold coil. For this reason, it becomes possible to simultaneously fill and integrate the resin between the plurality of cores and the resin mold coils assembled thereto. Therefore, the manufacturing process can be reduced.

  Moreover, the connection process of connecting the terminal part of each said resin mold coil arrange | positioned cyclically | annularly to the bus bar arrange | positioned at the yoke part side can also be included after the said assembly | attachment process. Further, the resin filling step can be performed so as to integrally mold the bus bar as well as the core and the resin mold coil.

  Moreover, before performing a resin filling process, the metal mold member which divides a resin filling area | region can be mounted | worn, and the said resin can also be filled from the resin filling port of this metal mold member. Thereby, it is possible to configure a resin molded stator in which gaps between the core, the resin molded coil, and the bus bar are filled and these are integrally assembled.

  According to a ninth aspect of the invention, the resin filling step is performed by injecting resin into the gap through a resin introduction path that leads to the gap from the outside of the coil end portion of the resin molded coil. .

  By filling the resin through the resin introduction path leading to the gap from the outside of the coil end portion of the resin mold coil, the gap can be reliably filled with resin.

  By filling the gap between the inner periphery of the resin-molded coil and the outer periphery of the core with resin, there is no risk of the core and coil being displaced and interfering with the rotor. The heat dissipation to the core can be improved.

  Embodiments of the present invention will be specifically described below with reference to the drawings.

  FIG. 1 is an overall perspective view of a resin mold coil 1 according to the present invention and a core 2 assembled thereto. FIG. 2 is a front view of the resin molded coil 1 to which the core 2 is assembled. FIG. 3 is a plan view of the resin molded coil 1. In addition, although this embodiment shows the example which applied the resin mold coil which concerns on this invention to the coil which comprises the stator of an electric motor, it applies to the coil used for other apparatuses, such as a stator of another form, and a transformation transformer. You can also

  The resin mold coil 1 is configured by coating a mold resin 4 on at least an outer peripheral surface of a coil body 3 configured by edgewise winding a rectangular wire having a rectangular cross section in a truncated pyramid shape. In the present embodiment, the coil end side (rotor side) winding is exposed from the mold resin, and the connection terminal portions 5 and 6 are extended from one coil end portion 7. Further, a pair of extending portions 12 and 12 for assembling the core 2 are integrally formed with the mold resin on the proximal end side (outer peripheral side of the stator) of the coil. The material which comprises the said coil is not specifically limited, For example, copper, aluminum, silver, and these alloy wires can be employ | adopted. Further, the form of the winding is not particularly limited, and a flat wire, a round wire, a hexagonal wire, or the like composed of a plurality of dividing lines may be employed.

  As the mold resin 4, a thermosetting resin such as an epoxy resin, a thermoplastic resin, or the like can be used. In order to improve the heat dissipation from the coil body 3, it is preferable to employ a highly thermally conductive resin containing an inorganic filler or the like.

  The core 2 includes a tooth portion 17 that is inserted into the inner peripheral hole portion 9 of the coil, and a yoke portion 16 that is integrally formed on the base end side of the tooth portion 17. The core 2 according to the present embodiment is formed by compacting magnetic metal powder. In addition, the core comprised by laminating | stacking an electromagnetic steel plate is also employable.

  The hole 9 of the resin mold coil 1 is formed in a shape corresponding to the tooth portion 17 of the core 2. In the present embodiment, the step portions 11 for positioning in contact with the corner portions of the teeth portion 17 are formed at the four corners of the hole portion 9, and the concave portions 10a and 10b are formed at the center portions of the respective inner peripheral surfaces. Is formed. Also, holding portions 13 for preventing the windings from being separated from the coil body are formed at four locations on the surface of the winding exposed at the coil body tip side so as to cover the mold resin.

  The one coil end portion 7 of the resin mold coil 1 is provided with a positioning recess 14 for positioning a bus bar (not shown).

  A resin injection groove 15 that leads from the surface edge portion of the coil end portion 7 to the hole portion 9 is formed on the front end surface of the resin mold coil 1. In the present embodiment, as shown in FIG. 3, the resin injection groove 15 is formed by cutting out the mold resin in a rectangular shape at the leading end side stepped portion of the wound winding.

  As shown in FIG. 4, when the resin molded coil 1 is assembled to the core 2, the holding portions 11 at the four corners of the hole portion 9 come into contact with the corner portions 17 a of the teeth portion 17 of the core 2, and the core 2 and the resin mold coil 1 are positioned. Further, since the recesses 10 a and 10 b are provided, a predetermined gap H is formed between the inner peripheral surface of the hole 9 and the outer peripheral surface of the tooth portion 17. Then, as shown in FIG. 5, the resin injection groove 15 is communicated with the gap H from the tip edge portion of one coil end portion 7.

  FIGS. 7 to 12 show examples in which a plurality of the resin mold coils 1 and the cores 2 are assembled to form a stator.

  The stator 100 according to the present embodiment is configured such that a plurality of the resin mold coils 1 and the core 2 are assembled in an annular shape along an inner peripheral wall of a cylindrical case 27.

  Between the back surface side of the resin mold coil 1 and the inner peripheral surface of the case 27, a bus bar 28 having wirings 25a, 26a and the like provided therein is fitted. On the upper surface of the bus bar 28, connection portions 25 and 26 to which the terminal portions 5 and 6 of the resin molded coil 1 are connected are extended from the wirings 25a and 26a.

  As shown in FIGS. 9 and 10, the terminal portions 5 and 6 are bent along the outer surface 7 of the coil end portion of the resin molded coil 1 and connected to the corresponding connecting portions 25 and 26.

  After the terminal portions 5 and 6 are connected to the connection portions 25 and 26, as shown in FIG. 11, the mold apparatus 30 is disposed on the inner peripheral side of the annular resin mold coil 1 and on the coil end side. .31 is installed. By mounting the mold apparatus 30.31, a resin filling path 29 communicating with the resin injection groove 15 is formed. In the mold device 31 according to the present embodiment, a gap L corresponding to the thickness of the connection terminal portions 25 and 26 is formed between the outer surface of the coil end portion 7 and the inner surface of the mold device 31. Are positioned as follows. Further, the inner surface of the mold device 30 disposed on the inner peripheral side of the resin mold coil 1 is disposed so as to abut on the tip surface of the tooth portion 17. Further, the inner surface of the mold apparatus 30 and the resin injection groove 15 cooperate to form a resin introduction path that communicates from the outer surface of the coil end portion 7 to the inner peripheral portion of the hole portion 9. It is configured.

  When the resin is injected from the resin filling path 29, the resin is filled into the gap L between the outer surface of the coil end portion 7 and the mold apparatus 31, and the resin is added via the resin injection groove 15. Guided to the gap H between the inner peripheral portion of the hole 9 of the mold coil 1 and the outer peripheral portion of the tooth portion 17. Since the concave portions 10 a and 10 b are formed in the inner peripheral portion of the hole portion 9, the resin injected from the resin injection groove 15 is injected into the inner peripheral surface of the hole portion 9 and the outer periphery of the tooth portion 17. The gaps formed between the surfaces are filled all over.

  By adopting the above configuration, the plurality of resin molded coils 1 and the core 2 are integrally joined. For this reason, the resin molded coil and the core do not rattle. Therefore, vibration or the like does not occur, and there is no possibility that the mounting position of the core 2 and the resin mold coil 1 is shifted and interferes with the rotor. And the heat dissipation from the resin mold coil 1 to the core 2 can be improved. In addition, the plurality of the resin mold coils 1, the core 2, and the bus bar 28 can be assembled and fixed at a time without using a screw or the like in a state where insulation is ensured without using an insulator or the like. For this reason, an assembly process becomes easy and productivity can be improved significantly.

  FIG. 13 shows a second embodiment of the present invention. This figure is a cross-sectional view corresponding to FIG. 11 according to the first embodiment.

  In the present embodiment, a resin injection hole 15 a that leads from the outer surface on the proximal end side of the coil end portion 7 to the hole portion 9 is provided, and a second resin is provided in a portion corresponding to the resin injection hole 15 a of the mold member 31. A filling path 29a is provided.

  The resin is filled in the gaps H and L not only through the resin filling path 29 and the resin injection groove 15 but also through the second resin filling path 29a and the resin injection hole 15a. Therefore, even when the cross-sectional area of the resin injection groove 15 cannot be increased, the gaps H and L can be reliably filled with resin.

  The present invention is not limited to the embodiment described above. It should be thought that embodiment disclosed this time is an illustration and restrictive at no points. The scope of the present invention is defined not by the above-described meaning but by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims.

  By employing the resin mold coil according to the present invention, the assembly work can be easily performed, and the production efficiency can be increased.

It is a whole perspective view of the resin mold coil concerning this invention, and the core assembled | attached to this. It is a front view of the division | segmentation stator which assembled | attached the resin mold coil and core which were shown in FIG. It is a top view of the division | segmentation stator shown in FIG. It is sectional drawing which follows the IV-IV line in FIG. It is sectional drawing which follows the VV line in FIG. It is sectional drawing which follows the VI-VI line in FIG. FIG. 2 is an overall perspective view of a stator in which a resin molded coil and a core shown in FIG. 1 are assembled in an annular shape. It is sectional drawing which follows the VIII-VIII line in FIG. FIG. 8 is an overall perspective view of the stator shown in FIG. 7 in a state where the resin molded coil and the bus bar are connected. It is sectional drawing which follows the XX line in FIG. It is sectional drawing which shows the process of filling resin between the resin mold coil and core of the stator shown in FIG. FIG. 10 is an overall perspective view showing a state after the stator shown in FIG. 9 is filled with resin. It is a figure which shows other embodiment of this invention, and is sectional drawing equivalent to FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Resin mold coil 4 Mold resin 2 Core 9 Hole 15 Resin injection groove (resin introduction path)

Claims (9)

A molded coil that is molded with resin and has a hole into which the core is inserted in the inner periphery,
A resin mold coil provided with a resin introduction path that leads from the outside of the coil end portion to the hole portion and introduces resin into a gap formed between the core outer peripheral portion and the hole inner peripheral portion.   2. The resin molded coil according to claim 1, wherein the resin introduction path is configured by providing a resin injection groove extending from an outer edge portion of a coil end portion to the hole portion at a distal end portion of the resin molded coil.   The resin-molded coil according to claim 2, wherein the resin injection groove is formed in a leading end side stepped portion of a winding constituting the coil.   The resin molded coil according to claim 1, wherein the resin introduction path is configured by providing a resin injection hole that communicates from the outer surface on the proximal end side of the coil end portion to the hole portion.   The resin mold coil according to any one of claims 1 to 4, wherein a concave portion that secures the gap between the core outer peripheral portion and the inner peripheral portion of the resin molded coil is provided. A core to be assembled to the resin molded coil according to any one of claims 1 to 5,
The core which provided the recessed part which ensures the said clearance gap between the said resin mold coil inner peripheral parts in the outer peripheral part. The plurality of resin molded coils according to any one of claims 1 to 5, wherein the plurality of resin molded coils are assembled in a core and arranged in an annular shape,
A resin-molded stator in which a resin is filled in a gap between at least the inner peripheral part of the resin-molded coil and the outer peripheral part of the core. An assembly step of assembling the plurality of resin mold coils according to any one of claims 1 to 5 in an annular manner by assembling the core with the core;
A method of manufacturing a stator, comprising: a resin filling step of filling a resin in at least a gap between each resin mold coil inner periphery and the core outer periphery.   The method for manufacturing a stator according to claim 8, wherein the resin filling step is performed by injecting resin into the gap from outside the coil end portion of the resin mold coil through a resin introduction path that leads to the gap. .

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