JP2010242624A - Pump, heat pump type hot-water supply device, and method of manufacturing pump - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pump tightly capable of assembling a mold stator and a pump part. <P>SOLUTION: The pump 10 includes: a stator; prepared hole components 81a, 81b provided at the outer peripheral side of a stator iron core of insulation part and having a prepared hole; a stator assembly 49 in which a substrate is assembled to the stator; a mold stator 50 formed by molding the stator assembly 49 by mold resin in which the prepared holes of the prepared hole components 81a, 81b are exposed at one end face in an axial direction; a pump part 40 formed by assembling a casing 41 having a water intake port 42 and a water discharge port 43 and a bowl-shaped partition wall component 90 having a bowl-shaped partition wall 90a in which a rotor 60 is suitable for shaft 70 and a flange 90b, the pump part having a plurality of screw holes in the vicinity of its outer periphery; and a plurality of tapping screws 160. The tapping screws 160 are fastened to the exposed prepared holes of the mold stator 50 through the screw holes of the pump part 40 to assemble the pump part 40 and the mold stator 50. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a pump manufactured by combining a mold stator and a pump unit, and a method for manufacturing the pump. Furthermore, it is related with the heat pump type hot water supply apparatus using the pump.

  In order to improve the motor efficiency by reducing the gap between the stator core of the pump and the magnet, and to improve the cooling performance of the coil and the control circuit, the coil, the stator core, the control circuit and the partition plate are inserted and molded with a mold resin. As a result, the thickness of the partition plate can be reduced and the gap between the stator core and the magnet can be reduced, so that the motor efficiency can be improved. In addition, a pump has been proposed in which a coil that is a heating element and a control circuit are filled with a partition plate together with a mold resin having good thermal conductivity so that heat conduction is improved and cooling performance is improved (for example, Patent Document 1). reference).

  In addition, in order to provide a pump motor that can be manufactured at low cost and can prevent rust from being generated in the stator when liquid leakage can be prevented, a resin material having a flow path through which fluid flows is provided. And a stator that is provided integrally with the casing and disposed at a position surrounding the flow path, a stator that is disposed in the flow path, and a shaft that is connected to the stator and drives a fluid pump. The stator is attached to the core portion, the inner portion of the stator being separated from the flow path via the resin material, and the outer portion of the stator being in the housing, and the housing The coil base is positioned from the end side in the direction along the axial center line direction of the shaft, and the lid body, the casing body, and the coil base are fastened together by a bolt screw so that the lid body is enclosed. On the body It has been proposed to be constant. (For example, refer to Patent Document 2).

JP 2006-200197 A JP-A-10-243599

  However, the pump of the above-mentioned patent document 1 is connected to the casing through a screw hole provided in the casing with respect to a stator (corresponding to the stator of the present invention) formed of a thermosetting mold resin such as unsaturated polyester resin. Since the stator is assembled with the tapping screw, the assembly strength between the casing and the stator may be reduced due to deterioration of the mold resin due to vibration or the like.

  Moreover, the pump of the above-mentioned patent document 2 is screwed into the coil base on the stator end face and screwed together, so that the stator becomes larger and the cost is increased in order to secure space. There is a problem that resin molding burrs are likely to enter a hole into which a bolt screw of a coil base cannot be fixed.

  The present invention has been made in order to solve the above-described problems, and is capable of firmly assembling a mold stator and a pump unit, a method for manufacturing the pump, and a heat pump hot water supply using the pump. An object is to provide an apparatus.

The pump according to the present invention is a stator in which a coil is formed by winding around a plurality of teeth provided with an insulating portion of a stator core,
A pilot hole component formed on the outer peripheral side of the stator core of the insulating portion and having a pilot hole;
A stator assembly in which an electronic component is mounted on the stator and a board on which a lead wire lead-out component for attaching a lead wire is mounted is assembled;
The stator assembly is formed by molding resin with a mold resin, and a mold stator in which a pilot hole of a pilot hole part is exposed on one axial end surface;
A casing having a water suction port and a water discharge port, a bowl-shaped partition wall portion that is fitted so that the shaft cannot be rotated inside and that has a rotor portion and an impeller on the shaft, and a flange portion; A pump part having a plurality of screw holes in the vicinity of the outer peripheral part;
A plurality of tapping screws, and
A tapping screw is fastened to a pilot hole exposed on the mold stator through a screw hole of the pump part, and the pump part and the mold stator are assembled.

  In the pump according to the present invention, the tapping screw is fastened to the pilot hole exposed by the mold stator through the screw hole of the pump part, and the pump part and the mold stator are assembled. Can be firmly assembled.

FIG. 3 shows the first embodiment and is a configuration diagram of a heat pump hot water supply apparatus 300. FIG. FIG. 3 is an exploded perspective view of the pump 10 showing the first embodiment. FIG. 5 shows the first embodiment and is a perspective view of a mold stator 50. FIG. 5 shows the first embodiment and is a plan view of a mold stator 50. FIG. 4 is a YY sectional view. FIG. 5 shows the first embodiment, and is a perspective view of the stator assembly 49 as seen from the connection side. FIG. 5 shows the first embodiment and is a plan view of the stator assembly 49 as viewed from the connection side. FIG. 5 shows the first embodiment and is a front view of a stator assembly 49; FIG. 5 shows the first embodiment, and is a perspective view of a stator assembly 49 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of the stator 47 as seen from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of the stator 47 as viewed from the connection side. FIG. 5 shows the first embodiment and is a plan view of the stator 47 as viewed from the anti-connection side. FIG. 5 shows the first embodiment and is a plan view of the stator 47 as viewed from the connection side. FIG. 5 shows the first embodiment and is a front view of a stator 47. FIG. FIG. 5 shows the first embodiment, and is a perspective view of the pilot hole part 81a as viewed from the connection side. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of the pilot hole part 81a as viewed from the anti-connection side. FIG. 5 shows the first embodiment and is a perspective view of the pilot hole part 81b as viewed from the connection side. FIG. 5 is a diagram showing the first embodiment, and is a perspective view of the pilot hole part 81b as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of a stator 47 of Modification 1 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of the stator 47 of the first modification viewed from the connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of Modification 1 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of a first modification viewed from the connection side. FIG. 6 shows the first embodiment and is a front view of a stator 47 of a first modification. FIG. 5 shows the first embodiment, and is a perspective view of the pilot hole part 81a of the first modification as viewed from the connection side. FIG. 5 shows the first embodiment, and is a perspective view of the pilot hole part 81a of the first modification viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of the pilot hole part 81b of the first modification viewed from the connection side. FIG. 9 shows the first embodiment, and is a perspective view of the pilot hole part 81b of the first modification viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of a stator 47 of Modification 2 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of a stator 47 of Modification 2 as viewed from the connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of Modification 2 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of Modification 2 as viewed from the connection side. FIG. 5 shows the first embodiment and is a front view of a stator 47 of a second modification. FIG. 5 shows the first embodiment, and is a perspective view of a pilot hole part 81b of a second modification viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of a stator 47 of Modification 3 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a perspective view of a stator 47 of Modification 3 as viewed from the connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of Modification 3 as viewed from the anti-connection side. FIG. 5 shows the first embodiment, and is a plan view of a stator 47 of Modification 3 as viewed from the connection side. FIG. 5 shows the first embodiment and is a front view of a stator 47 of a third modification. FIG. 5 shows the first embodiment, and is an exploded perspective view of the pump unit 40; FIG. 3 shows the first embodiment, and is a cross-sectional view of the pump 10. FIG. 9 shows the second embodiment and is a perspective view of the stator 147 viewed from the anti-connection side. FIG. 9 shows the second embodiment, and is a perspective view of the stator 147 as seen from the connection side. FIG. 9 shows the second embodiment and is a plan view of the stator 147 as seen from the anti-connection side. FIG. 9 shows the second embodiment and is a plan view of the stator 147 as seen from the connection side. FIG. 9 shows the second embodiment and is a front view of a stator 147. FIG. 9 shows the second embodiment and is a perspective view of the pilot hole part 181a as viewed from the connection side. In the figure which shows Embodiment 2, the perspective view which looked at the pilot hole components 181a from the reverse connection side. FIG. 5 shows the second embodiment, and is a perspective view of the pilot hole part 181b as viewed from the connection side. In the figure which shows Embodiment 2, the perspective view which looked at the pilot hole components 81b from the anti-connection side. FIG. 9 shows the second embodiment, and is a perspective view of the stator 147 of the first modification viewed from the anti-connection side. FIG. 9 shows the second embodiment, and is a perspective view of the stator 147 as seen from the connection side. FIG. 9 shows the second embodiment, and is a plan view of the stator 147 of the first modification viewed from the anti-connection side. FIG. 9 shows the second embodiment and is a plan view of the stator 147 of the first modification as viewed from the connection side. FIG. 11 shows the second embodiment and is a front view of a stator 147 of a first modification. FIG. 9 shows the second embodiment, and is a plan view of a stator 147 of a second modification as viewed from the anti-connection side. The A section enlarged view of FIG. FIG. 6 shows the third embodiment and shows the manufacturing process of the pump 10.

Embodiment 1 FIG.
In the present embodiment, a stator having a plurality of pilot hole parts on the outer peripheral side of the insulating portion, and a mold stator integrally formed with a mold resin so that the pilot holes for the tapping screws of the pilot hole parts are exposed. The pump part and the mold stator are firmly assembled by fastening the pump part to the pilot hole of the pilot hole part with the tapping screw and assembling the screw part through the screw hole formed in the pump part. .

  First, an outline of a heat pump type hot water supply apparatus in which a pump is used will be briefly described.

  FIG. 1 is a diagram showing the first embodiment and is a configuration diagram of a heat pump type hot water supply apparatus 300. The heat pump hot water supply apparatus 300 includes a heat pump unit 100, a tank unit 200, and an operation unit 11 on which a user performs a driving operation.

  In FIG. 1, a heat pump unit 100 includes a compressor 1 that compresses refrigerant, a refrigerant-water heat exchanger 2 that exchanges heat between the refrigerant and water, a decompression device 3 that decompresses and expands high-pressure refrigerant, and a low-pressure two-phase refrigerant. A refrigerant circuit in which the evaporator 4 for evaporating the refrigerant is annularly connected by a refrigerant pipe 15, a pressure detection device 5 that detects the discharge pressure of the compressor 1, a fan 7 that blows air to the evaporator 4, and a fan that drives the fan 7 And a motor 6.

  For the compressor 1 that compresses the refrigerant, for example, a hermetic compressor such as a rotary compressor or a scroll compressor is used.

Further, carbon dioxide (CO ₂ ) is used as the refrigerant of the heat pump hot water supply apparatus 300. The reason why carbon dioxide is used is as follows.

The coefficient of performance (COP, Coefficient of Performance) of the heat pump is expressed by COP = heat output / compressor power. Compared to 12.9 of the ideal cycle COP for hot water supply, the COP of the CO ₂ refrigerant is 11.5, which is the highest compared to other refrigerants. The COPs of the chlorofluorocarbon and hydrocarbon refrigerants excluding R410A are about 8. The COP of R410A is slightly higher, 9.1.

The COP of the CO ₂ refrigerant is high because the critical temperature of the CO ₂ refrigerant is as low as 30 ° C. and the high pressure side is in a supercritical condition, so there is no condensation process, and the TS diagram of the ideal cycle for hot water supply (or The entropy diagram is a diagram with the temperature on the vertical axis and the entropy on the horizontal axis. The area on this diagram represents the amount of heat for a reversible change, and is also called a heat diagram. It is to become.

In the refrigeration cycle using the CO ₂ refrigerant, since the pressure on the high pressure side is increased to a critical pressure or higher, the pressure (high pressure) cannot be estimated from the temperature as in R410A widely used for air conditioning.

  In addition, the heat pump type hot water supply apparatus 300 is operated even in summer when the outside air temperature is high, and thus has a feature that the pressure is likely to increase particularly when operated under a high temperature and high humidity condition.

  Further, depending on the use state of the user, the temperature at the lower part of the hot water tank 14 described later becomes high, and the hot water supply operation state in which high-temperature hot water is circulated to the refrigerant-water heat exchanger 2 is made, and the pressure is likely to rise. There are features.

  The heat pump type hot water supply apparatus 300 that uses carbon dioxide as a refrigerant cannot estimate pressure (high pressure) based on the refrigerant temperature, and further has a feature that the pressure is likely to rise depending on the external environment and the use state of the user. The pressure detection device 5 is provided in the refrigerant circuit. When the pressure (high pressure) detected by the pressure detection device 5 exceeds a predetermined pressure, the compressor 1 is stopped.

  The heat pump unit 100 includes, as temperature detection means, a boiling temperature detection means 8 of the refrigerant-water heat exchanger 2, a feed water temperature detection means 9 of the refrigerant-water heat exchanger 2, and an outside air temperature detection means 17. I have. These temperature detection means are composed of, for example, a thermistor.

  The heat pump unit 100 includes a heat pump unit control unit 13. The heat pump unit controller 13 receives signals from the pressure detector 5, the boiling temperature detector 8, the feed water temperature detector 9, and the outside air temperature detector 17, and controls the rotation speed of the compressor 1 and opens the decompressor 3. Degree control, fan motor 6 rotation speed control, and the like.

  On the other hand, the tank unit 200 includes a hot water tank 14 that stores hot water heated by exchanging heat with a high-temperature and high-pressure refrigerant in the refrigerant-water heat exchanger 2, and bath water reheating heat that replenishes bath water. Exchanger 31, bath water circulation device 32, “pump 10” which is a hot water circulation device arranged between refrigerant-water heat exchanger 2 and hot water tank 14, hot water circulation pipe 16, and refrigerant-water heat exchange A mixing valve 33 connected to the vessel 2, the hot water tank 14 and the bath water reheating heat exchanger 31, and a bath water retreating pipe 37 connecting the hot water tank 14 and the mixing valve 33.

  Further, as temperature detection means, a tank water temperature detection device 34, a water temperature detection device 35 for detecting the water temperature after passing through the bath water reheating heat exchanger, and a water temperature after passing through the mixing valve 33 are detected. A post-mixing water temperature detector 36 is provided. These temperature detection devices are composed of, for example, a thermistor.

  A tank unit controller 12 is also provided. The tank unit controller 12 receives signals from the in-tank water temperature detection device 34, the reheated water temperature detection device 35, and the mixed water temperature detection device 36, and controls the rotation speed of the “pump 10” and opens and closes the mixing valve 33. Signals are transmitted to and received from the control and operation unit 11.

  The operation unit 11 is a remote controller, an operation panel, or the like provided with a switch or the like for the user to perform hot water temperature setting, hot water instruction, and the like.

  In FIG. 1, a normal boiling operation operation in the heat pump type hot water supply apparatus 300 configured as described above will be described. When the boiling operation instruction from the operation unit 11 or the tank unit 200 is transmitted to the heat pump unit control unit 13, the heat pump unit 100 performs the boiling operation.

  The heat pump unit controller 13 provided in the heat pump unit 100 controls the rotational speed of the compressor 1 and the decompression device 3 based on the detection values of the pressure detection device 5, the boiling temperature detection means 8, the feed water temperature detection means 9, and the like. The opening degree control and the rotation speed control of the fan motor 6 are performed.

  Further, the detection value of the boiling temperature detection means 8 is transmitted and received between the heat pump unit control unit 13 and the tank unit control unit 12, and the tank unit control unit 12 sets the temperature detected by the boiling temperature detection means 8 as the target. The rotation speed of the “pump 10” is controlled so as to reach the boiling temperature.

  In the heat pump type hot water supply apparatus 300 controlled as described above, the temperature of the high-temperature and high-pressure refrigerant discharged from the compressor 1 decreases while dissipating heat to the water supply circuit side in the refrigerant-water heat exchanger 2. The high-pressure and low-temperature refrigerant that has radiated heat and passed through the refrigerant-water heat exchanger 2 is decompressed by the decompression device 3. The refrigerant that has passed through the decompression device 3 flows into the evaporator 4 where it absorbs heat from outside air. The low-pressure refrigerant exiting the evaporator 4 is sucked into the compressor 1 and circulates to form a refrigeration cycle.

  On the other hand, the water in the lower part of the hot water tank 14 is guided to the refrigerant-water heat exchanger 2 by driving the “pump 10” which is a hot water circulation device. Here, water is heated by the heat radiation from the refrigerant-water heat exchanger 2, and the heated hot water is returned to the upper part of the hot water tank 14 through the hot water circulation pipe 16 and stored.

  As described above, in the heat pump hot water supply device 300, the “pump 10” is used as a hot water circulation device that circulates hot water in the hot water circulation pipe 16 between the hot water tank 14 and the refrigerant-water heat exchanger 2.

  Next, the pump 10 used as a hot water circulation device will be described.

  FIG. 2 shows the first embodiment and is an exploded perspective view of the pump 10.

  As shown in FIG. 2, the pump 10 includes a pump unit 40 that absorbs and discharges water by rotation of a rotor (described later), a mold stator 50 that drives the rotor, a pump unit 40, and a mold stator. And tapping screws 160 (four in the example of FIG. 2) for fastening 50.

  In the present embodiment, four tapping screws 160 are prepared in the pilot holes 84 (see FIG. 5) of the pilot hole component 81 embedded in the mold stator 50 through the screw holes 44a formed in the boss 44 of the pump unit 40. ) To assemble the pump 10.

  First, the configuration of the mold stator 50 will be described.

  3 to 5 show the first embodiment. FIG. 3 is a perspective view of the mold stator 50, FIG. 4 is a plan view of the mold stator 50, and FIG. 5 is a YY cross-sectional view of FIG. .

  As shown in FIGS. 3 to 5, the mold stator 50 is obtained by molding a stator assembly 49 (described later) with a mold resin 53.

  One end face (on the pump part 40 side) in the axial direction of the mold stator 50 is a flat pump part installation surface 63 along the outer peripheral edge part.

  A plurality of second grooves 64 are formed radially on the pump portion installation surface 63 in the radial direction. The second groove 64 is a relief groove for a reinforcing rib of a flange portion 90b (see FIG. 39) of the flange-shaped partition wall component 90 described later. In the example of FIG. 3, six second grooves 64 are formed at substantially equal intervals in the circumferential direction corresponding to reinforcing ribs of the flange portion 90 b of the flange-shaped partition wall component 90 described later.

  The pump portion installation surface 63 is provided with an annular third groove 65 that connects the outer end portions of the six second grooves 64. The annular third groove 65 corresponds to an annular rib formed in the flange portion 90 b of the flange-shaped partition wall component 90.

  Furthermore, pilot hole parts 81 of substantially cylindrical resin molded products are embedded in the four corners in the pump portion installation surface 63 in the axial direction. At the time of molding with the mold resin 53, one end surface (the pump part 40 side) of the pilot hole part 81 becomes a mold pressing part 82 of the molding die. Therefore, the pilot hole part 81 is exposed in a form embedded inside the pump part installation surface 63 by a predetermined distance. Exposed are the mold pressing part 82 and the pilot hole 84 for the tapping screw 160.

  A lead wire 52 drawn from a stator assembly 49 to be described later is drawn to the outside from the vicinity of the axial end surface on the opposite side of the pump portion 40 of the mold stator 50.

  The positioning of the mold stator 50 in the axial direction during molding with the mold resin 53 (thermosetting resin) is performed by a plurality of protrusions 95a (see FIG. 6) formed on a substrate pressing component 95 (see FIG. 6) described later. The end face on the outer side in the axial direction becomes the upper die holding part. Therefore, the axially outer end surfaces (die pressing surfaces) of the plurality of protrusions 95a are exposed on the axial end surface of the mold stator 50 on the substrate 58 side (not shown).

  Further, the protrusion 56a (see FIG. 8) extending further outward (in the axial direction) than the axial end surface of the insulating portion 56 on the anti-connection side becomes a lower mold pressing portion. Therefore, a plurality of protrusions 56a are exposed on the axial end surface of the mold stator 50 opposite to the substrate 58 (not shown).

  The radial positioning of the mold stator 50 at the time of molding is performed by fitting the inner peripheral surface of the stator core 54 to the mold. Therefore, the tip end portion of the teeth 54a of the stator core 54 is exposed at the inner peripheral portion of the mold stator 50 shown in FIG.

  The internal configuration of the mold stator 50, that is, the stator assembly 49 (the stator core 54, the insulating portion 56, the coil 57, the substrate 58, etc. shown in FIG. 5) will be described later.

  Next, the stator assembly 49 will be described. 6 to 9 show the first embodiment. FIG. 6 is a perspective view of the stator assembly 49 viewed from the connection side, FIG. 7 is a plan view of the stator assembly 49 viewed from the connection side, and FIG. 9 is a front view of the stator assembly 49, and FIG. 9 is a perspective view of the stator assembly 49 viewed from the anti-connection side.

  As shown in FIG. 6, the stator assembly 49 includes a stator 47, a substrate 58, a substrate pressing component 95, and the like.

The stator assembly 49 is manufactured by the following procedure.
(1) An electromagnetic steel sheet having a thickness of about 0.1 to 0.7 mm is punched into a band shape, and a band-shaped stator core 54 laminated by caulking, welding, bonding or the like is manufactured. The strip-shaped stator core 54 includes a plurality of teeth. The tips of the teeth of the stator core 54 are exposed at the inner periphery of the mold stator 50 shown in FIG. Since the stator core 54 shown here has six teeth connected by thin-walled connecting portions, the tips of the teeth of the stator core are exposed at six locations also in FIG. However, only two places are visible in FIG.
(2) The insulating portion 56 is applied to the teeth. The insulating portion 56 is formed integrally with or separately from the stator core 54 using, for example, a thermoplastic resin such as PBT (polybutylene terephthalate). In addition, a plurality of pilot hole parts 81 including pilot holes 84 for tapping screws are formed on the outer periphery of the insulating portion 56 on the side opposite to the connection side. The pilot hole parts 81 are formed at four locations at substantially equal intervals in the circumferential direction. Details of the pilot hole part 81 will be described later.
(3) A concentrated winding coil is wound around the teeth provided with the insulating portion 56. Six concentrated winding coils 57 are connected to form a three-phase single Y-connection winding.
(4) Since it is a three-phase single Y connection, a power supply terminal 59a (see FIG. 8) to which each phase (U phase, V phase, W phase) coil 57 (see FIG. 8) is connected on the connection side of the insulating portion 56. 3) and neutral point terminals 59b (1) are assembled to form the stator 47.
(5) The board | substrate 58 is attached to the insulation part 56 (side in which the terminal 59 is assembled | attached) on the connection side. The substrate 58 is sandwiched between the insulating portion 56 by the substrate pressing component 95. On the substrate 58, an IC 58a (driving element) for driving an electric motor (brushless DC motor), a Hall element for detecting the position of the rotor 60 (position detecting element, not visible because it is mounted on the back side of the substrate 58), etc. Has been implemented. The IC 58a and the Hall element are defined as electronic components. In addition, a lead wire lead-out component 61 that leads out the lead wire 52 to a notch near the outer peripheral edge portion is attached to the substrate 58.
(6) The substrate 58 to which the lead wire lead-out component 61 is attached is fixed to the insulating portion 56 by the substrate holding component 95, and the terminal 59 and the substrate 58 are soldered to complete the stator assembly 49.

  Further, the stator 47 will be described. 10 to 14 are diagrams showing the first embodiment. FIG. 10 is a perspective view of the stator 47 viewed from the anti-connection side, FIG. 11 is a perspective view of the stator 47 viewed from the connection side, and FIG. FIG. 13 is a plan view of the stator 47 viewed from the connection side, and FIG. 14 is a front view of the stator 47.

  10 to 14, the power supply terminal 59a (three pieces) and the neutral point terminal 59b (one piece) assembled to the insulating portion 56 are shown, but the terminal of the magnet wire of the coil 57 is not shown. (FIGS. 11 and 13).

  With reference to the stator 47 shown in FIGS. 10 to 14, the structure of the pilot hole parts 81a and 81b, which is a characteristic part of the present embodiment, will be mainly described.

  The pilot hole parts 81 a and 81 b are formed on the outer periphery of the insulating part 56 on the side opposite to the connection side when the insulating part 56 is formed by integrally molding a thermoplastic resin on the stator core 54.

  The insulating portion 56 is applied to each tooth 54 a of the stator core 54. There are six teeth 54a in total, and an insulating portion 56 is formed independently on each of the teeth 54a.

  The six teeth 54a are arranged at substantially equal intervals in the circumferential direction.

  The pilot hole parts 81a and 81b need to be formed so as to correspond to the four screw holes 44a (FIG. 2) formed in the pump unit 40. Four screw holes 44a formed in the pump unit 40 are provided at four corners of a substantially square shape.

  Since there are six teeth 54a on which the insulating portions 56 are formed and four pilot hole parts 81a and 81b (arranged in a substantially square shape), the pilot hole parts 81a and 81b are connected to the side opposite to the insulating parts 56. When it forms in the outer periphery of this, it becomes inevitable that it will become two types of prepared hole parts 81a and 81b.

  As can be seen mainly from FIGS. 12 and 13, the pilot hole part 81 a is formed within the circumferential length of the insulating portion 56.

  On the other hand, the pilot hole part 81 b is located between the insulating portions 56. Therefore, the pilot hole part 81b is formed to be connected to any one of the adjacent insulating portions 56. When viewed from the anti-connection side (FIG. 12), the pilot hole part 81b is formed in the insulating portion 56 on the clockwise side. However, this is only an example, and the insulating portion 56 may be formed.

  The configuration of the pilot hole parts 81a and 81b will be described with reference to FIGS. 15 to 18 are diagrams showing the first embodiment, in which FIG. 15 is a perspective view of the pilot hole part 81a as viewed from the connection side, FIG. 16 is a perspective view of the pilot hole part 81a as viewed from the anti-connection side, and FIG. FIG. 18 is a perspective view of the pilot hole component 81b as viewed from the connection side, and FIG. 18 is a perspective view of the pilot hole component 81b as viewed from the opposite connection side.

  As shown in FIG. 16, the pilot hole part 81 a is formed to extend from the side opposite to the insulation part 56 to the outer peripheral part of the stator core 54. The core back 54b of the stator core 54 is sandwiched between the outer peripheral side of the insulating portion 56 and the prepared hole part 81a.

  The pilot hole component 81 a is formed within the range of the length in the circumferential direction of the insulating portion 56.

  The pilot hole component 81 a includes a pilot hole part 89 and a connecting part 87 that connects the pilot hole part 89 to the insulating part 56.

  As shown in FIG. 15, the pilot hole 89 is closed at one end (connection side) in the axial direction, and a projection 83 protruding outward in the axial direction is formed on the end surface. The protrusion 83 serves as a mold pressing portion when the mold stator 50 is molded with the mold resin 53.

  The pilot hole portion 89 includes a protrusion 85 for preventing rotation of the pilot hole component 81a on the outer peripheral portion. The protrusion 85 is formed over substantially the entire length in the axial direction.

  As shown in FIG. 16, the other end portion (anti-connection side) of the pilot hole 89 in the axial direction is open. This opening becomes a pilot hole 84 for the tapping screw 160.

  The connecting portion 87 includes a first connecting portion 87a formed along one end surface (anti-connection side) of the stator core 54, and a plurality of (two in FIGS. 15 and 16) rib-shaped second portions. It consists of the connection part 87b.

  A portion surrounded by the first connecting portion 87a, the second connecting portion 87b, and the pilot hole 89 is a cavity 86, and the pilot hole 84 and the cavity 86 are formed by the movable part of the mold together with the connection side of the insulating part 56. It is formed.

  On the other hand, the pilot hole component 81b is formed approximately in the middle of two adjacent insulating portions 56. And it connects with either of the two adjacent insulation parts 56 (for example, FIG. 12).

  The pilot hole part 81 b also includes a pilot hole part 89 and a connecting part 87 that connects the pilot hole part 89 to the insulating part 56.

  As shown in FIG. 17, the pilot hole 89 is closed at one end (connection side) in the axial direction, and a projection 83 protruding outward in the axial direction is formed on the end surface. The protrusion 83 serves as a mold pressing portion when the mold stator 50 is molded with the mold resin 53.

  The pilot hole 89 includes a protrusion 85 for preventing rotation of the pilot hole component 81b on the outer peripheral portion. The protrusion 85 is formed over substantially the entire length in the axial direction.

  As shown in FIG. 18, the other end portion (anti-connection side) of the pilot hole 89 in the axial direction is open. This opening becomes a pilot hole 84 for the tapping screw 160.

  The connecting portion 87 includes a first connecting portion 87a formed along one end surface (anti-connection side) of the stator core 54, and a plurality of ribs (two different types in FIGS. 17 and 18). 2 connecting portions 87c.

  A portion surrounded by the first connecting portion 87a, the second connecting portion 87c, and the pilot hole 89 is a cavity 86, and the pilot hole 84 and the cavity 86 are formed by the movable part of the mold together with the connection side of the insulating part 56. It is formed.

  Since the pilot hole parts 81a and 81b are each connected to one insulating portion 56, the wound band-shaped stator core 54 can be bent into a cylindrical shape.

  19 to 23 show the first embodiment. FIG. 19 is a perspective view of the stator 47 of the first modification viewed from the anti-connection side, and FIG. 20 is the stator 47 of the first modification viewed from the connection side. 21 is a plan view of the stator 47 of the first modification viewed from the anti-connection side, FIG. 22 is a plan view of the stator 47 of the first modification viewed from the connection side, and FIG. 4 is a front view of a stator 47. FIG.

  The stator 47 of the first modification will be described with reference to FIGS. In the stator 47 shown in FIGS. 10 to 14, the pilot hole parts 81 a and 81 b are connected to the outer periphery of the insulating part 56 on the side opposite to the connection side by the connecting part 87, but as shown in FIGS. 19 to 23. Moreover, you may connect with the insulation part 56 in the outer periphery of both a connection side and an anti-connection side.

  FIGS. 24 to 27 are diagrams showing the first embodiment. FIG. 24 is a perspective view of the pilot hole part 81a of the first modification as viewed from the connection side. FIG. 25 is a perspective view of the pilot hole part 81a of the first modification. 26 is a perspective view of the pilot hole part 81b of the first modification viewed from the connection side, and FIG. 27 is a perspective view of the pilot hole part 81b of the first modification viewed from the anti-connection side.

  For example, as can be seen by comparing FIG. 15 and FIG. 24, the pilot hole part 81a shown in FIG. 15 is not connected to the connection side of the insulating portion 56, whereas the pilot hole part 81a of the first modification example. Are also connected to the connection side of the insulating portion 56.

  17 and 26, the pilot hole part 81b shown in FIG. 17 is not connected to the connection side of the insulating portion 56, whereas the pilot hole part 81b of the first modification example. Are also connected to the connection side of the insulating portion 56.

  When the pilot hole parts 81a and 81b are connected to the insulating portion 56 only on the side opposite to the connection side, the connection side of the pilot hole parts 81a and 81b may be lifted from the stator 47. Thus, the pilot hole parts 81a and 81b can be prevented from being lifted, and the positions of the pilot hole parts 81a and 81b are easily determined.

  FIG. 28 to FIG. 33 are diagrams showing the first embodiment. FIG. 28 is a perspective view of the stator 47 of the second modification viewed from the anti-connection side, and FIG. 29 is the stator 47 of the second modification viewed from the connection side. 30 is a plan view of the stator 47 of the second modification as viewed from the anti-connection side, FIG. 31 is a plan view of the stator 47 of the second modification as viewed from the connection side, and FIG. 33 is a front view of the child 47, and FIG. 33 is a perspective view of the pilot hole part 81b of the second modification viewed from the anti-connection side.

  In the stator 47 shown in FIGS. 10 to 14 and the stator 47 of the first modification shown in FIGS. 19 to 23, the insulating portion 56 including the pilot hole parts 81a and 81b is integrally formed with the belt-like stator core 54. As shown in FIGS. 28 to 33, the pilot hole parts 81b are arranged on both sides as shown in FIGS. The two insulating portions 56 may be connected on the side opposite to the connection.

  As shown in FIGS. 28, 30, and 33, the pilot hole part 81 b is connected to the two insulating portions 56 on both sides on the opposite side.

  34 to 38 are diagrams showing the first embodiment. FIG. 34 is a perspective view of the stator 47 of the third modification viewed from the anti-connection side, and FIG. 35 is the stator 47 of the third modification viewed from the connection side. 36 is a plan view of the stator 47 of the third modification viewed from the anti-connection side, FIG. 37 is a plan view of the stator 47 of the third modification viewed from the connection side, and FIG. 4 is a front view of a stator 47. FIG.

  As shown in FIGS. 34 to 38, an insulating portion 56 that is formed in each tooth 54a of the stator core 54 and includes the pilot hole component 81 may be connected in a ring shape. A portion where the insulating portion 56 is connected in an annular shape is referred to as an annular connecting portion 56b.

  The substantially cylindrical pilot hole parts 81a and 81b are formed on the exposed end surface (die presser) of the pilot hole parts 81a and 81b in order to prevent the pilot hole parts 81a and 81b from coming off after the stator assembly 49 is molded. It is preferable that the taper is thicker in the middle with respect to the ends of the portion 82 and the protrusion 83.

  The pilot hole parts 81a and 81b are provided with a plurality of protrusions 85 on the outer periphery of the pilot hole parts 81a and 81b for preventing rotation of the pilot hole parts 81a and 81b. The pilot hole parts 81a and 81b are connected to the insulating part 56 by the connecting part 87 and integrated with each other, so that the processing cost can be reduced by being set in the mold at once.

  When the stator assembly 49 having a plurality of pilot hole parts 81a and 81b on the outer peripheral side of the stator insulating portion 56 is molded by the mold resin 53, the opening side of the pilot hole 84 for the tapping screw 160 of the pilot hole parts 81a and 81b. The end hole parts 81a and 81b are positioned in the axial direction by sandwiching the end face (die holding part 82) of the metal plate and the projection 83 provided on the other end face of the prepared hole parts 81a and 81b with a molding die. (See FIG. 5).

  At the time of molding, the mold does not press the entire mold pressing portion 82 on the end face on the opening side of the pilot hole 84 for the tapping screw 160 of the pilot hole parts 81a and 81b but presses a part on the center side. Thereby, the pilot hole parts 81a and 81b are covered with the mold resin 53 except for a portion pressed by the mold. Therefore, since both end surfaces of the pilot hole parts 81a and 81b are covered with the mold resin 53, the exposure of the pilot hole parts 81a and 81b can be suppressed, and the quality of the pump 10 can be improved. Moreover, it can suppress that the pilot hole 84 is filled up with the mold resin 53, or a burr | flash generate | occur | produces.

  In the mold stator 50, a stator assembly 49 having a plurality of pilot hole parts 81a and 81b on the outer peripheral side of the insulating portion 56 of the stator 47 is integrally formed with the mold resin 53. At this time, the pilot hole parts 81a and 81b A pilot hole 84 for the tapping screw 160 appears. The pump unit 40 and the mold stator are assembled by fastening the pump unit 40 and the mold stator 50 to the pilot hole 84 with the tapping screw 160 via the screw holes 44a (FIG. 2) formed in the pump unit 40. 50 can be firmly assembled.

  Further, although not shown, in order to firmly attach the pump unit 40 and the mold stator 50, the pilot holes 84 of the pilot hole parts 81a and 81b are provided with protrusions for preventing slipping and rotation prevention on the outer periphery. It is also possible to use an insert nut having a metal screw hole.

Next, the configuration of the pump unit 40 will be described.
39 and 40 show the first embodiment. FIG. 39 is an exploded perspective view of the pump unit 40 and FIG. 40 is a sectional view of the pump 10.

As shown in FIGS. 39 and 40, the pump unit is configured by the following elements.
(1) A casing 41 that has a water suction port 42 and a discharge port 43 and houses the impeller 60b of the rotor 60 therein. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide). The casing 41 is provided with four boss portions 44 having screw holes 44a used at the time of assembling the pump portion 40 and the mold stator 50 at the end on the water inlet 42 side. Moreover, the casing 41 is provided with the attachment leg 45 which has the hole 45a for fixing the pump 10 to the tank unit 200 of the heat pump type hot-water supply apparatus 300, for example in three places.
(2) A first thrust bearing 71a. The material of the first thrust bearing 71a is, for example, ceramic such as alumina. Since the rotor 60 is pressed against the casing 41 via the first thrust bearing 71a by the pressure difference of water acting on the front and back of the impeller 60b of the rotor 60 during the operation of the pump 10, the first thrust bearing 71a The one made of ceramic is used to ensure wear resistance and slidability.
(3) The rotor 60. The rotor 60 includes a rotor portion 60a and an impeller 60b. The rotor portion 60a includes a ring-shaped (cylindrical) resin magnet 68 formed by pelletizing a magnetic powder such as ferrite and a resin, and a cylindrical sleeve bearing 66 (for example, carbon) provided inside the resin magnet 68. For example, PPE (polyphenylene ether). The impeller 60b is a resin molded product such as PPE (polyphenylene ether). The rotor part 60a and the impeller 60b are joined by ultrasonic welding or the like.
(4) Shaft 70. One end of the shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, and the other end of the shaft 70 is inserted into the shaft support portion 46 of the casing 41. One end of the shaft 70 inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90 is inserted so as not to rotate with respect to the shaft support portion 94. Therefore, one end of the shaft 70 is cut out of a part of a circle having a predetermined length (axial direction). The hole of the shaft support portion 94 is also shaped accordingly. The other end of the shaft 70 inserted into the shaft support portion 46 of the casing 41 is also cut out of a circular portion having a predetermined length (axial direction). That is, the axis 70 is symmetrical in the length direction. However, the other end of the shaft 70 is rotatably inserted into the shaft support portion 46 of the casing 41. The reason why the shaft 70 is symmetrical in the length direction is that when the shaft 70 is inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90, assembly is possible without being aware of the vertical direction.
(5) Second thrust bearing 71b. The material of the second thrust bearing 71b is SUS. The rotor 60 is pressed against the casing 41 via the first thrust bearing 71a by the pressure difference of water acting on the front and back of the impeller 60b of the rotor 60 during the operation of the pump 10, but depending on the operation state, the rotor 60 may rotate. Since the case where the child 60 contacts the shaft support portion 94 of the bowl-shaped partition wall component 90 via the second thrust bearing 71b is also conceivable, the second thrust bearing 71b is used.
(6) O-ring 80. The O-ring 80 performs sealing between the casing 41 of the pump unit 40 and the bowl-shaped partition wall component 90.
(7) A bowl-shaped partition wall component 90. The bowl-shaped partition wall component 90 is molded using a thermoplastic resin such as PPE (polyphenylene ether). The bowl-shaped partition wall component 90 includes a bowl-shaped partition wall portion 90 a that is a fitting portion with the mold stator 50 and a flange portion 90 b. The bowl-shaped partition wall 90a is composed of a circular bottom and a cylindrical partition. A shaft support portion 94 into which one end of the shaft 70 is inserted is erected at a substantially central portion of the inner surface of the circular bottom portion. Ribs 91 extending in the axial direction are formed on the outer peripheral surface of the bowl-shaped partition wall 90a. The rib 91 is formed to have a predetermined length in the axial direction from the base of the flange-shaped partition wall portion 90a (the connecting portion with the flange portion 90b). And the dimension of the radial direction of the rib 91 is a taper shape in which the base side of the bowl-shaped partition part 90a is large, and becomes small as it goes ahead. In the flange portion 90b, six reinforcing ribs (not shown) that reinforce the flange portion 90b are formed radially in the radial direction. The rib 91 of the bowl-shaped partition wall 90a is connected to any one of the reinforcing ribs. Thereby, manufacture of the shaping die of the bowl-shaped partition part 90 becomes easy. Further, the flange portion 90b includes an annular rib (not shown) that fits in an annular third groove 65 (FIG. 2) formed on the pump portion installation surface 63 of the pump portion 40 of the mold stator 50. Moreover, the hole 90b is formed with four holes through which the tapping screw 160 passes. Further, an annular O-ring storage groove for storing the O-ring 80 is formed on the surface of the flange portion 90b on the casing 41 side.

  In the pump 10, the O-ring 80 is installed in the bowl-shaped partition wall part 90, the casing 41 is assembled to the bowl-shaped partition wall part 90, the pump unit 40 is assembled, the pump unit 40 is assembled to the mold stator 50, and the tapping screw 160 or the like. Fixed and assembled.

  When the mold stator 50 and the pump unit 40 are assembled, the first groove 51 formed in the axial direction on the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall 90 a of the bowl-shaped partition wall component 90 Positioning in the rotational direction (circumferential direction) is achieved by fitting the ribs 91 extending in the axial direction on the surface (FIG. 40).

  The mold stator 50 and the pump unit 40 are fitted as follows. Since the rib 91 is not provided on the part of the outer peripheral surface of the bowl-shaped partition wall part 90a opposite to the collar part 90b, the rib-shaped partition wall part 90a of the pump part 40 is provided on the inner periphery of the mold stator 50. The tip (portion without the rib 91) can be inserted at an arbitrary position.

  When the insertion progresses and the rib 91 of the bowl-shaped partition wall 90a of the pump unit 40 reaches the end on the opening side of the inner periphery of the mold stator 50, an axial direction is formed on the inner periphery of the mold stator 50. If the first groove 51 and the rib 91 extending in the axial direction are not aligned with the outer peripheral surface of the hook-shaped partition wall portion 90a of the hook-shaped partition wall component 90, further insertion is not possible. Since the bowl-shaped partition wall 90a of the pump unit 40 is inserted, the first groove 51 and the rib 91 can be easily aligned by rotating.

  If the positions of the first groove 51 and the rib 91 are aligned, the bowl-shaped partition wall portion 90 a of the pump unit 40 can be completely inserted into the inner periphery of the mold stator 50.

  On the inner periphery of the bowl-shaped partition wall portion 90 a of the bowl-shaped partition wall component 90, the rotor 60 is fitted and accommodated on the shaft 70 inserted into the shaft support portion 94 of the bowl-shaped partition wall component 90. Therefore, in order to ensure the coaxiality of the mold stator 50 and the rotor 60, the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 should be as small as possible. For example, the gap is selected to be about 0.02 to 0.06 mm.

  When the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is reduced, the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is inserted into the inner periphery of the mold stator 50. In some cases, insertion is difficult if there is no way for air to escape.

  Therefore, the first groove 51 formed in the axial direction is provided in the inner peripheral portion of the mold stator 50, and the first groove 51 is used as an air escape path.

  Further, circumferential positioning of the bowl-shaped partition wall component 90 and the mold stator 50 is necessary.

  In order to position the bowl-shaped partition wall component 90 and the mold stator 50 in the circumferential direction, the ribs of the bowl-shaped partition wall section 90a are formed in the first groove 51 formed in the axial direction on the inner circumference of the mold stator 50. 91 is fitted.

  If the ribs 91 of the bowl-shaped partition wall portion 90a block the first groove 51 of the mold stator 50, which is an air escape path, it becomes difficult to insert the bowl-shaped partition wall component 90 into the mold stator 50. Therefore, in a state where the bowl-shaped partition wall component 90 is completely inserted into the mold stator 50, a gap is formed between the first groove 51 of the mold stator 50 and the rib 91 of the bowl-shaped partition wall portion 90a. Yes. The gap is about 1 mm at the narrowest place (where the radial dimension of the rib 91 is the largest).

  As described above, the gap between the inner periphery of the mold stator 50 and the outer periphery of the bowl-shaped partition wall portion 90a of the bowl-shaped partition wall component 90 is made as small as possible (for example, about 0.02 to 0.06 mm), and the mold stator 50 rotates. A first groove 51 serving as an air escape path formed in the axial direction is provided in the inner peripheral portion of the mold stator 50 while ensuring the coaxiality with the child 60, so that the inner periphery of the mold stator 50 is provided. It is easy to insert the bowl-shaped partition wall component 90. Further, a rib 91 having a predetermined length is formed in the bowl-shaped partition wall portion 90a in the axial direction from the root of the bowl-shaped partition wall portion 90a (the connecting portion with the flange portion 90b). The base portion 90a is large and has a tapered shape that decreases as it goes forward, and the rib 91 is fitted in the first groove 51 of the mold stator 50 with a predetermined radial gap (about 1 mm). Therefore, the mold stator 50 and the bowl-shaped partition wall component 90 can be positioned, and the mold stator 50 and the bowl-shaped partition wall component 90 can be easily assembled.

Embodiment 2. FIG.
41 to 56 are diagrams showing the second embodiment. FIG. 41 is a perspective view of the stator 147 viewed from the anti-connection side, FIG. 42 is a perspective view of the stator 147 viewed from the connection side, and FIG. 44 is a plan view of the stator 147 as viewed from the connection side, FIG. 44 is a plan view of the stator 147 as viewed from the connection side, FIG. 45 is a front view of the stator 147, and FIG. 46 is a view of the pilot hole part 181a from the connection side. 47 is a perspective view of the pilot hole part 181a as viewed from the connection side, FIG. 48 is a perspective view of the pilot hole part 181b as viewed from the connection side, and FIG. 49 is a perspective view of the pilot hole part 81b as viewed from the reverse connection side. 50 is a perspective view of the stator 147 of the first modification viewed from the anti-connection side, FIG. 51 is a perspective view of the stator 147 viewed from the connection side, and FIG. 52 is the first modification viewed from the anti-connection side. 53 is a plan view of the stator 147, FIG. 53 is a plan view of the stator 147 of the first modification viewed from the connection side, and FIG. Front view of a stator 147 of Example 1, FIG. 55 is a plan view of a stator 147 of the second modification as viewed from the counter-wire-connection-side, FIG. 56 is an enlarged view of a portion A of FIG. 55.

  As shown in FIGS. 41 to 50, the stator 147 differs from the stator hole parts 81a and 81b in the configuration of the pilot hole parts 181a and 181b with respect to the stator 47 of the first embodiment. Other configurations are the same.

  As shown in FIGS. 41 to 50, the pilot hole parts 181a and 181b having a substantially U-shaped cross section are formed by integrally molding a thermoplastic resin such as PBT (polybutylene terephthalate) on the belt-shaped stator core 54. When forming 56, it is formed on the outer periphery of the insulating portion 56 on the anti-connection side.

  As in the first embodiment, there are six teeth 54a in which the insulating portion 56 is formed and four pilot hole parts 181a and 181b (arranged in a substantially square shape). When forming on the outer periphery of the insulating part 56 on the side opposite to the connection side, it is inevitable that the two types of pilot hole parts 81a and 81b are formed.

  As can be seen mainly from FIGS. 43 and 44, the pilot hole part 181a is formed within the range of the circumferential length of the insulating portion 56.

  On the other hand, the pilot hole component 181b is located between the insulating portions 56. Therefore, the pilot hole component 181b is formed by being connected to any of the adjacent insulating portions 56. When viewed from the anti-connection side (FIG. 44), the pilot hole component 181b is formed in the insulating portion 56 on the clockwise side. However, this is only an example, and the insulating portion 56 may be formed.

  As shown in FIG. 47, the pilot hole component 181 a is formed to extend from the opposite side of the insulating portion 56 to the outer peripheral portion of the stator core 54. The core back 54b of the stator core 54 is sandwiched between the outer peripheral side of the insulating portion 56 and the prepared hole part 181a.

  The pilot hole part 181a is formed within the range of the circumferential length of the insulating portion 56.

  The pilot hole component 181 a includes a pilot hole part 189 and a connecting part 187 that connects the pilot hole part 189 to the insulating part 56.

  The lower hole portion 189 has a substantially U-shaped cross section, and the U-shaped opening portion faces outward.

  In addition, the prepared hole 189 has an opening on the side opposite to the connection side, and a bottom 188 on the connection side end. In order to prevent the pilot hole 189 from rotating, the side surface (a U-shaped straight portion) protrudes longer than the bottom 188 to form a projection 185.

  In addition, in order to position the pilot hole 189 in the axial direction during molding with the mold resin 53 of the stator assembly, the end face on the opening side of the pilot hole 184 for the tapping screw 160 of the pilot hole 189 (die holding part 182) And a projection-side 183 is provided on the end surface on the connection side which is held by the molding die.

  The pilot hole 184 for the tapping screw 160 in the pilot hole 189 has a substantially U-shaped straight portion longer than the screw diameter of the tapping screw.

  After the stator assembly is molded, in order to prevent the lower hole portion 189 from coming off, a taper shape that is thicker with reference to the exposed end surface (mold pressing portion 182 and protrusion 183 end portion) of the lower hole portion 189 is preferable. .

  The connecting portion 187 includes a first connecting portion 187a on the end surface of the stator core 54 and a second connecting portion 187b having a width substantially the same as the pilot hole 189 having a substantially U-shaped cross section.

  A pilot hole 184 and a bottom part 188 (including side surfaces) of the pilot hole part 189 having a substantially U-shaped cross section are formed by a fixing part of a mold.

  On the other hand, the pilot hole component 181b is formed approximately in the middle of the two adjacent insulating portions 56. And it connects with either of the two adjacent insulation parts 56 (for example, FIG. 43).

  The pilot hole component 181 b also includes a pilot hole part 189 and a connecting part 187 that connects the pilot hole part 189 to the insulating part 56.

  The structure of the pilot hole part 189 of the pilot hole part 181b is the same as that of the pilot hole part 189 of the pilot hole part 181a.

  The connecting portion 187 of the pilot hole component 181b is substantially the same width as the first connecting portion 187a formed along one end surface (the anti-connection side) of the stator core 54 and the prepared hole portion 189 having a substantially U-shaped cross section. The second connecting portion 187c.

  Since the pilot hole parts 181a and 181b are respectively connected to one insulating portion 56, the wound band-shaped stator core 54 can be bent into a cylindrical shape.

  The substantially cylindrical pilot hole parts 181a and 181b of the second embodiment have a substantially U-shaped cross section, but the pilot hole parts formed by the movable part of the mold in this way. Since 81a and 81b (Embodiment 1) can be formed by a mold fixing portion, the structure of the mold can be simplified. In addition to the same effects as those of Embodiment 1, the cost of the mold is reduced and the mold maintenance is performed. The effect of reducing processing costs by simplification can be obtained.

  Although not shown, when assembling the insulating portion 56 including the prepared lower hole parts 181a and 181b on the cylindrical stator core 54 as in the first embodiment, one of the lower hole parts 181b is attached. You may connect with the some insulating part 56, and may connect the insulating part 56 provided with the pilot hole components 181a and 181b cyclically | annularly.

  Here, the pilot hole parts 181a and 181b are connected to the outer periphery of the insulating portion 56 on the anti-connection side by the connecting portion 187. However, as shown in FIGS. 50 to 54, both the connection side and the anti-connection side are provided. You may connect with the insulation part 56 in outer periphery. When the pilot hole parts 181a and 181b are connected to the insulating part 56 only on the anti-connection side, the connection side of the pilot hole parts 181a and 181b may be lifted from the stator 147. Thus, the pilot hole parts 181a and 181b can be prevented from being lifted, and the positions of the pilot hole parts 181a and 181b can be easily determined.

  At the time of molding, the mold does not press the entire mold pressing portion 182 on the end face on the opening side of the pilot hole 184 for the tapping screw 160 of the pilot hole parts 181a and 181b, but presses a part on the center side. Thereby, the pilot hole parts 181a and 181b are covered with the mold resin 53 except for a portion pressed by the mold. Therefore, since both end surfaces of the pilot hole components 181a and 181b are covered with the mold resin 53, the exposure of the pilot hole components 181a and 181b can be suppressed and the quality of the pump 10 can be improved.

  Further, as shown in FIGS. 55 and 56, a mold holding surface 186 is provided in which a pilot hole side surface 190 having a substantially U-shaped cross section is stepped at the same position as the side surface 188a of the bottom portion 188. The mold resin 53 is intruded from the U-shaped opening surface by pressing the same surface of the mold against the side surface 188a of 188 and the mold pressing surface 186 of the pilot hole portion 189 of the substantially U-shaped section 189. , Burrs can be suppressed and prevented.

  In the mold stator, a stator assembly having a plurality of pilot hole parts 181 a and 181 b having a substantially U-shaped cross section on the outer peripheral side of the insulating portion 56 of the stator 147 is integrally formed with the mold resin 53. At this time, the pilot hole 184 for the tapping screw 160 of the pilot hole parts 181a and 181b having a substantially U-shaped cross section is exposed. The pump unit 40 and the mold stator are firmly assembled to each other by fastening the pump unit 40 and the mold stator to the pilot hole 184 with the tapping screw 160 through the screw holes 44a formed in the pump unit 40. It becomes possible.

Embodiment 3 FIG.
FIG. 57 is a diagram showing the third embodiment, and is a diagram showing a manufacturing process of the pump 10. The pump 10 of Embodiment 1 is demonstrated. The manufacturing process of the pump 10 of the second embodiment is the same.
(1) Step 1: The stator 47 is manufactured. First, an electromagnetic steel plate having a thickness of about 0.1 to 0.7 mm is punched into a strip shape, laminated by caulking, welding, adhesion, or the like, and a strip-shaped stator core 54 connected by a thin connection portion is manufactured. A thermoplastic resin such as PBT (polybutylene terephthalate) is used for the teeth, and an insulating portion 56 having a plurality of pilot hole parts 81a and 81b having pilot holes 84 on the outer periphery is applied. A concentrated winding coil 57 is wound around the teeth provided with the insulating portion 56. For example, six concentrated winding coils 57 are connected to form a three-phase single Y-connection winding. Since it is a three-phase single Y connection, a terminal 59 (a power supply terminal to which power is supplied and a medium) Sex point terminal) is assembled. In addition, the substrate 58 is manufactured. The board | substrate 58 is clamped between the insulation parts 56 by the board | substrate holding | suppressing component. On the substrate 58, an IC 58a for driving an electric motor (brushless DC motor), a hall element for detecting the position of the rotor 60, and the like are mounted. In addition, a lead wire lead-out component 61 that leads out the lead wire 52 to a notch near the outer peripheral edge portion is attached to the substrate 58. In addition, the rotor part 60a is manufactured. The rotor portion 60a includes a ring-shaped (cylindrical) resin magnet 68 formed by pelletizing a magnetic powder such as ferrite and a resin, and a cylindrical sleeve bearing 66 (for example, carbon) provided inside the resin magnet 68. For example, PPE (polyphenylene ether). At the same time, the impeller 60b is formed. The impeller 60b is molded using a thermoplastic resin such as PPE (polyphenylene ether).
(2) Step 2: Assemble the substrate 58 to the stator 47. The substrate 58 to which the lead wire lead-out component 61 is attached is fixed to the insulating portion 56 by the substrate holding component. At the same time, the impeller 60b is assembled to the rotor portion 60a by ultrasonic welding or the like. In addition, the bowl-shaped partition wall component 90 is formed. In addition, the shaft 70, the first thrust bearing 71a, and the second thrust bearing 71b are manufactured. The shaft 70 is manufactured from SUS. The first thrust bearing 71a is made of ceramic. The second thrust bearing 71b is manufactured from SUS.
(3) Step 3: The stator assembly 49 is completed by soldering the terminals 59 (power supply terminals to which power is supplied and neutral point terminals) and the substrate 58. The rotor 60 and the like are assembled to the bowl-shaped partition wall component 90. In addition, the casing 41 is molded together. The casing 41 is molded using a thermoplastic resin such as PPS (polyphenylene sulfide).
(4) Step 4: The stator assembly 49 is molded to manufacture the mold stator 50. In addition, the pump 41 is assembled by fixing the casing 41 to the bowl-shaped partition wall component 90. In addition, a tapping screw 160 is also manufactured.
(5) Step 5: The pump 10 is assembled. The pump unit 40 is assembled to the mold stator 50 and fixed with a tapping screw 160. When assembling the mold stator 50 and the pump portion 40, ribs provided on the bowl-shaped partition wall portion 90a between the first groove 51 provided on the inner diameter of the mold stator 50 and the inner diameter of the mold stator 50 of the bowl-shaped partition wall component 90 When 91 is fitted, positioning with respect to the rotation direction is performed.

  1 compressor, 2 refrigerant-water heat exchanger, 3 decompression device, 4 evaporator, 5 pressure detection device, 6 fan motor, 7 fan, 8 boiling temperature detection means, 9 feed water temperature detection means, 10 pump, 11 operation Part, 12 tank unit control part, 13 heat pump unit control part, 14 hot water tank, 15 refrigerant pipe, 16 hot water circulation pipe, 17 outside air temperature detection means, 31 bath water reheating heat exchanger, 32 bath water circulation apparatus, 33 mixing valve , 34 Water temperature detection device in tank, 35 Water temperature detection device after reheating, 36 Water temperature detection device after mixing, 37 Bath water reheating piping, 40 Pump part, 41 Casing, 42 Water inlet, 43 Discharge port, 44 Boss part, 44a Screw hole, 45 Mounting leg, 45a hole, 46 Shaft support, 47 Stator, 49 Stator assembly, 50 Mold stator, 51 1st groove, 52 lead wire, 53 mold resin, 54 stator core, 56 insulation part, 57 coil, 58 substrate, 58a IC, 59 terminal, 60 rotor, 60a rotor part, 60b impeller, 61 lead wire Leading parts, 62 projections, 63 pump portion installation surface, 64 second groove, 65 third groove, 66 sleeve bearing, 67 resin, 68 resin magnet, 70 shaft, 71a first thrust bearing, 71b second thrust Bearing, 80 O-ring, 81a pilot hole part, 81b pilot hole part, 82 mold holding part, 83 protrusion, 84 pilot hole, 85 protrusion, 86 cavity, 87 connecting part, 87a first connecting part, 87b second Connection part, 87c 2nd connection part, 90 bowl-shaped partition part, 90a bowl-shaped partition part, 90b collar part, 90c O-ring storage groove, 90d hole, 91 rib, 2 Reinforcing ribs, 93 annular ribs, 94 shaft support parts, 95 substrate holding parts, 100 heat pump units, 160 tapping screws, 181a pilot hole parts, 181b pilot hole parts, 182 mold pressing parts, 183 protrusions, 184 pilot holes, 185 Protrusion, 186 Mold holding surface, 187 connecting portion, 187a first connecting portion, 187b second connecting portion, 188 bottom portion, 188a side surface, 189 pilot hole portion, 190 pilot hole side surface, 200 tank unit, 300 heat pump hot water supply apparatus.

Claims (14)

A stator in which a coil is formed by winding around a plurality of teeth provided with an insulating portion of the stator core;
A pilot hole component formed on the outer peripheral side of the stator core of the insulating portion and having a pilot hole;
A stator assembly in which an electronic component is mounted on the stator and a board on which a lead wire lead-out component that leads out a lead wire is mounted is assembled, and
The stator assembly is formed by molding resin, and a mold stator in which the pilot hole of the pilot hole part is exposed on one end surface in the axial direction;
A casing having a water suction port and a water discharge port; a bowl-shaped partition wall portion fitted in such a manner that the shaft cannot be rotated inside and fitted with a rotor having a rotor portion and an impeller on the shaft; A pump part having a plurality of screw holes in the vicinity of the outer peripheral part;
A plurality of tapping screws, and
The pump, wherein the tapping screw is fastened to the pilot hole exposed by the mold stator through the screw hole of the pump part, and the pump part and the mold stator are assembled.   The pump according to claim 1, wherein the pilot hole component is connected to the insulating portion on one stator end face side.   The pump according to claim 1, wherein the pilot hole component is connected to the insulating portion on both stator end face sides.   2. The pump according to claim 1, wherein the pilot hole part is connected to the insulating part, and the pilot hole part is further connected and integrated in an annular shape.   The pump according to any one of claims 1 to 4, wherein the pilot hole component has a substantially cylindrical shape.   The pump according to any one of claims 1 to 3, wherein the pilot hole part has a substantially U-shaped cross section.   The pump according to any one of claims 1 to 6, wherein the pilot hole component includes a protrusion for preventing rotation of the pilot hole part on an outer peripheral part.   The pump according to any one of claims 1 to 7, wherein the pilot hole part has a tapered shape that thickens inward with reference to the exposed surface of the pilot hole part.   The pilot hole component having a substantially U-shaped cross-section has a substantially U-shaped straight portion that is longer than the screw diameter of the tapping screw, and a straight portion that protrudes radially outward from the bottom. The pump according to claim 6.   10. The pilot hole component having a substantially U-shaped cross section, wherein a substantially U-shaped straight part has a stepped mold holding surface at the same position as the side surface of the bottom. pump.   When the mold stator is molded by the mold resin, the end surface of the prepared hole part on the opening side of the prepared hole part and the protrusion provided on the other end surface of the prepared hole part are sandwiched by a mold. The pump according to any one of claims 1 to 10, wherein the pilot hole part is positioned in the axial direction.   12. The outer diameter of the die pressing portion on the opening side end face of the pilot hole part is made smaller than the outer diameter of the opening side end face of the pilot hole part. The pump according to crab. In a heat pump type hot water supply apparatus including a heat pump unit, a tank unit, and an operation unit for a user to perform an operation,
A heat pump type hot water supply apparatus, wherein the pump according to any one of claims 1 to 12 is mounted. An insulating part is formed of a thermoplastic resin on the teeth of the stator core, and a pilot hole part having a pilot hole is formed on the outer peripheral side of the stator core of the insulating part, and a coil is provided on the teeth on which the insulating part has been applied. A stator is manufactured by winding, and a substrate is mounted on which a lead wire lead-out component for mounting electronic components and lead wires is attached, and a resin magnet and a sleeve bearing provided inside the resin magnet are made of resin. A first step of producing a rotor part integrally, and further producing an impeller;
The substrate is assembled to the stator, the impeller is assembled to the rotor portion by ultrasonic welding or the like to manufacture a rotor, a bowl-shaped partition wall part is formed, and a shaft and a thrust bearing are manufactured. Two steps;
Soldering the terminal of the stator and the substrate, assembling the rotor to the bowl-shaped partition wall part, and further forming a casing;
A fourth step of manufacturing the stator by molding the stator, fixing the casing to the bowl-shaped partition wall part, assembling the pump unit, and further manufacturing a tapping screw;
And a fifth step of assembling the pump by assembling the pump portion to the mold stator and fixing with the tapping screw.

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