JP2011193636A - Method and structure for sealing winding end - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and a structure capable of unfailingly covering a connection portion between a winding end and an opposite material with a uniform insulation film even having a complicated structure. <P>SOLUTION: Ends of coils 22 are connected to terminals 23a, 23b, and then a part of stators 1 including the connection portion 27 thereof is sealed with a housing 40 and the inside is vacuumed, and a material gas is introduced into the housing 40. Thus, an insulating film containing DLC and/or fullerene and/or DLC containing fullerene is formed in a sealed space of a stator 1, and the connection portion 27 is sealed with the insulating film. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method and a structure for sealing a connection portion in which an end portion of a winding such as a motor coil is connected to a terminal or the like.

  Conventionally, a stator of a rotating electrical machine such as an electric motor constituted by salient pole concentrated winding mainly includes a split core in which a coil is wound around an insulator housed in a stator core, and the split core is connected in a ring shape to form a case. And the terminal of the power feeding unit that is energized from the outside and the end of the coil are connected via the connection terminal. The connection portion between the end portion of the coil and the connection terminal in such a stator usually requires electrical insulation in order to prevent leakage, and is insulated by resin molding, powder resin insulation, or the like ( (See Patent Documents 1 to 3).

JP-A-5-83905 JP 2008-17484 A JP 2009-296767 A

  However, in the case of a resin mold, there is a problem that unnecessary insulation other than the conductor is covered with the resin, which causes unnecessary weight increase and increases the amount of material used, resulting in an increase in cost. In addition, there are disadvantages such as a long curing time of the resin and inferior productivity. On the other hand, in the case of powder resin insulation, the amount of material used can be minimized as compared with resin molds. However, in general, the connection part between the coil and the connection terminal in the stator has a complicated and complicated structure, and many Since it exists in a location, it has been difficult to sufficiently supply the powder resin to such a connecting portion to ensure adhesion.

  The present invention has been made in view of the above circumstances, and it is possible to reliably cover the connection portion between the end portion of the winding such as the coil and the counterpart material with a uniform insulating film even in a complicated configuration. An object of the present invention is to provide a winding end sealing method and a sealing structure capable of ensuring insulation and reducing costs and improving productivity.

  In the sealing method of the winding end of the present invention, after connecting the winding end to a mating member, the connection between the winding end and the mating member is sealed with a sealing member, and then the sealing member The connection portion is sealed with an insulating film made of DLC (Diamond-Like Carbon) and / or fullerene and / or fullerene-containing DLC by introducing a raw material gas into the inside.

  According to the present invention, since the insulating film made of DLC and / or fullerene and / or fullerene-containing DLC is formed at the connection portion between the winding end and the counterpart material by supplying the raw material gas, the connection portion is complicated. Even if it exists in many places by structure, a connection part can be reliably covered with a uniform insulating film, and a connection part can be insulated reliably. Further, the insulating film is lighter than the conventional resin mold, and accordingly, the cost can be reduced. Furthermore, since the time required for curing the insulating film can be relatively short, productivity can be improved.

In addition, since DLC has a low frictional resistance and high hardness and good wear resistance, the DLC can stably obtain insulating properties over a long period of time. In particular, when the insulating film is made of fullerene-containing DLC, the durability of the film, such as the withstand voltage, is increased, and a more reliable insulating film can be obtained. The fullerene used in the present invention includes C ₆₀ , C ₇₀ , C ₇₆ , C ₇₈ , C ₈₂ , C ₈₄ , C ₉₀ , C ₉₄ , C ₉₆ , C _{100 and the} like, and / or a mixture of these simple substances. The body and / or compound can be used. In addition, a modified fullerene such as C ₆₀ -F _X (fullerene fluoride), C ₆₀ -O _X (fullerene oxide), C ₆₀ -OH _X (fullerene hydroxide), or a mixture thereof (element symbol at the lower right) X is a coefficient), and a mixture with an unmodified fullerene can also be used.

  As a specific method for forming and sealing the insulating film of the present invention in the connection portion, a generally known film forming method, that is, thermal CVD, plasma CVD, photo CVD, catalytic chemical vapor deposition (Cat-CVD) is used. , Atmospheric pressure CVD, vacuum deposition method, ion plating (direct current excitation, high frequency excitation), sputtering method (bipolar sputtering, magnetron sputtering, ECR sputtering), laser ablation method, ion beam deposition, ion implantation method, etc. . In the case where the insulating film of the present invention is fullerene-containing DLC, for example, the fullerene is mixed into the DLC by, for example, adding a fullerene to the source gas or the target. The raw material gas containing fullerene can be obtained, for example, by melting fullerene in toluene and gasifying the liquid. If the above film forming method is used with this raw material gas, the fullerene-containing DLC is formed into a base material. Can be formed on top.

The insulating film of the present invention can be formed by the above film forming method, and the following method is particularly preferable.
That is, a discharge is generated on the surface of the connection portion, and the source gas is introduced into the discharge generation region to ionize the source gas, thereby sealing the connection portion with the insulating film.

  Further, the connecting portion is disposed in the plasma, a negative pulse voltage is applied to the connecting portion, and the source gas ionized by the plasma is accelerated by a sheath electric field formed at the interface between the connecting portion and the plasma. Thereby, the connection part is sealed with the insulating film.

  Further, the source gas contains carbon, and a carbon ion generated by ionizing the source gas is applied with a negative current or a pulse voltage to the connection portion, thereby connecting the connection portion to the insulating film. Seal with.

  In addition to these methods, a method is adopted in which a highly reactive monomer gas is introduced into the sealing member, and the insulating film is formed by polymerization when the monomer gas contacts the surface of the connection portion. Also good. Examples of the immobilizing material in this method include fluorinated alkylsilane-based and paraxylene-based polymers.

  When the insulating film is made of DLC and / or fullerene-containing DLC, hydrogen may be contained in the DLC carbon alone in order to enhance the insulation property, and the hydrogen content in that case is preferably 20 to 50 at.%. It is. This is because if the hydrogen content is less than 20 at.%, It is difficult to obtain insulation, and if it exceeds 50 at.%, The DLC film quality becomes non-uniform.

  In the present invention, the content of fullerene in the DLC film is not particularly limited, but it is preferably 0.01 to 4.0%. If it is less than 0.01%, the content of fullerene is small, so that the contribution to the insulation to the extent that the effect is obtained cannot be obtained. Further, if it exceeds 4.0%, since it is necessary to contain fullerene in the raw material solvent in excess of the amount of the fullerene-containing raw material solvent, the fullerene is not precipitated in the solvent and becomes a uniform raw material solvent. Therefore, the electric field concentrates at a location where insulation is fragile due to non-uniformity of the film, and insulation cannot be obtained. Therefore, the content of fullerene in the DLC film is preferably 0.01 to 4.0%.

  The thickness of the DLC film is not particularly limited, but is preferably 1 nm to 100 μm. If the thickness is less than 1 nm, it is difficult to obtain insulation, and if it exceeds 100 μm, the insulation at the connection portion becomes high, electrons generated during CVD film formation stay, the potential around the terminal portion becomes unstable, and the film quality is uneven. It is because of becoming.

  Next, the winding end portion sealing structure of the present invention is a sealing structure suitably obtained by the above-described method of the present invention, and the connection portion in which the winding end portion is connected to the counterpart material is DLC and / or Or it is sealed with the insulating film which consists of fullerene and / or fullerene containing DLC.

  According to the present invention, the connecting portion between the winding end and the mating member can be reliably covered with a uniform insulating film even with a complicated configuration, ensuring insulation, and reducing cost. And the productivity can be improved.

It is a top view of the stator by which the connection part of a coil and a terminal is sealed with an insulating film by the method of one embodiment of the present invention. FIG. 2 is a partially enlarged plan view of the stator of FIG. 1. It is a top view which shows the method of introduce | transducing source gas into the predetermined location of a stator and forming an insulating film. It is the IV-IV line arrow directional view of FIG.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 shows a stator of a motor to which an embodiment is applied. The stator 1 is a three-phase Y-type stator, and includes a hollow cylindrical casing 10, three-phase input terminals U, V, and W provided in the casing 10, and a plurality of casings 10 accommodated inside the casing 10. Divided core 20. A coil (winding) 22 is wound around the split core 20 via an insulator 21 made of a resin material. These divided cores 20 are assembled in a cylindrical shape along the inner peripheral surface of the casing 10. As shown in FIG. 2, the divided cores 20 are connected to each other via a coil 22 and a first terminal (a mating member) 23 a to constitute a stator core 20 </ b> A.

  An end portion of the coil 22 on the inner peripheral side of the stator 1 is connected to the coil 22 of the adjacent divided core 20 via a first terminal 23 a provided on the divided core 20. On the other hand, the end of the coil 22 on the outer peripheral side is connected to an annular input line bus bar 24 connected to any one of the input terminals U, V, and W via a second terminal (mating member) 23b. The first and second terminals 23a and 23b are respectively provided in connecting annular grooves 25a and 25b provided on the inner peripheral side and the outer peripheral side of the split core 20, respectively.

  The conductor is exposed at the end of the coil 22, and the conductor is caulked and fixed to a cylindrical fixing portion 26 formed on the terminals 23a and 23b. In the present embodiment, the connection portion 27 between the end portion of the coil 22 and the fixing portion 26 of the terminals 23a and 23b is sealed with an insulating film made of DLC and / or fullerene and / or fullerene-containing DLC. . A method for forming the insulating film will be described below.

  As shown in FIGS. 3 and 4, the stator 1 is placed on the base 30 with the upper surface on which the connecting portion 27 is disposed upward and the axial direction parallel to the vertical direction. To do. Then, an annular housing (sealing member) 40 is set, and the upper surface and inner peripheral surface of the stator 1 are sealed by the housing 40. The housing 40 has a shape in which a cylindrical inner peripheral wall portion 42 and an outer peripheral wall portion 43 are respectively suspended from the inner peripheral side and outer peripheral side edge portions of the annular top plate portion 41. The inner peripheral wall portion 42 is inserted on the inner peripheral side of the stator 1 with a gap, and the annular lower end edge is brought into contact with the upper surface of the base 30. Further, the lower end portion of the outer peripheral wall portion 43 is bent toward the inner peripheral side, and the annular lower end edge thereof is in contact with the outer peripheral surface of the insulator 21.

  As described above, the lower end edge of the inner peripheral wall portion 42 is brought into contact with the upper surface of the base 30 and the lower end edge of the outer peripheral wall portion 43 is brought into contact with the outer peripheral surface of the insulator 21. And the outer peripheral surface of the insulator 21 and the sealed space surrounded by the base 30, and the upper surface and the inner peripheral surface of the stator 1 including the connecting portion 27 face the sealed space.

  A gas introduction pipe 44 is provided on the top plate portion 41 of the housing 40. When the housing 40 is set on the stator 1 and the upper surface and inner peripheral surface of the stator 1 are sealed as described above, air in the housing 40 is sucked through the gas introduction pipe 44 and then the housing 40 is introduced from the gas introduction pipe 44. A source gas is introduced into the chamber, and a predetermined process according to a film forming method (for example, plasma is generated between high-frequency electrodes in the case of plasma CVD). As a result, the insulating film is formed in the region of the stator 1 where the source gas contacts, that is, the upper surface and the inner peripheral surface including the connecting portion 27, and the connecting portion 27 is sealed by the insulating film.

  According to the above insulating film forming method, as compared with the case where batch processing is performed in which the stator is housed in the vacuum chamber and the insulating film is formed, the film formation region is hermetically sealed by the housing 40 and vacuuming and film forming processing are performed. As a result, line processing is possible. Further, since the volume in the housing 40 to be evacuated is much smaller than that of the vacuum chamber, the time required for evacuation can be shortened. From these, productivity can be improved.

  According to the stator 1 of the present embodiment, an insulating film made of DLC and / or fullerene and / or fullerene-containing DLC is formed at the connection portion 27 between the coil 22 and the terminals 23a and 23b. The connection portions 27 present at a large number of locations can be reliably covered with a uniform insulating film, and thus the connection portions 27 can be reliably insulated. Further, the insulating film is lighter than the conventional resin mold, and accordingly, the cost can be reduced. Further, since the time required for curing the insulating film can be relatively short, productivity can be improved.

  In addition, since DLC has a low frictional resistance and high hardness and good wear resistance, the DLC can stably obtain insulating properties over a long period of time. In particular, when the insulating film is made of fullerene-containing DLC, the durability of the film, such as the withstand voltage, is increased, and a more reliable insulating film can be obtained.

Next, examples of the present invention will be described.
[Example 1]
By applying a negative high voltage pulse to the connection part of the stator immersed in plasma, a sheath electric field is formed at the interface between the connection part and the plasma, and the source gas ionized by the plasma is accelerated in the sheath electric field. Thus, a method of forming an insulating film was adopted. Hydrogen was contained in the source gas of DLC, and thereby the connection part could be sealed with a DLC film containing 35 to 45% of hydrogen. In this case, the insulating film formation time was approximately 7200 seconds.

[Example 2]
As shown in FIGS. 3 and 4, the upper surface and inner peripheral surface including the stator connection portion are sealed with the housing 40, and a high-resistance hydrogen-containing amorphous material containing 35 to 45% hydrogen according to the same principle as in the first embodiment. A DLC film was formed, and the connection portion was sealed with the DLC film. In this case, the insulating film formation time was about 450 seconds.

  In both Examples 1 and 2, a good DLC film could be formed, and the connection portion was sufficiently sealed with the DLC film.

DESCRIPTION OF SYMBOLS 1 ... Stator 10 ... Casing 20 ... Split core 20A ... Stator core 21 ... Insulator 22 ... Coil (winding)
23a, 23b ... terminals (mating material)
27 ... Connection 40 ... Housing (sealing member)

Claims (5)

  After connecting the winding end with the mating member, the connection between the winding end and the mating member is sealed with a sealing member, and then the material gas is introduced into the sealing member, thereby connecting the connection A method of sealing a winding end, wherein the portion is sealed with an insulating film made of DLC and / or fullerene and / or fullerene-containing DLC.   The discharge portion is generated on the surface of the connection portion, the source gas is introduced into the discharge generation region, and the source gas is ionized to seal the connection portion with the insulating film. 1. A method for sealing a winding end according to 1.   By locating the connection in the plasma, applying a negative pulse voltage to the connection, and accelerating the source gas ionized by the plasma in a sheath electric field formed at the interface between the connection and the plasma 2. The winding end portion sealing method according to claim 1, wherein the connection portion is sealed with the insulating film.   The source gas contains carbon, and the connection portion is sealed by the insulating film by applying a negative current or a pulse voltage to the connection portion with carbon ions generated by ionizing the source gas. The winding end portion sealing method according to claim 1, wherein the winding end portion is stopped.   A winding end sealing structure, wherein a connecting portion in which a winding end is connected to a mating member is sealed with an insulating film made of DLC and / or fullerene and / or fullerene-containing DLC.

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