JP2013236450A - Insulator of armature and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce a thickness of an insulator 3 of an armature, which is made of an insulation resin molding a split core 2a so as to cover a periphery of a teeth part 21 of the split core 2a and electrically insulating the teeth part 21 from a coil wound around the teeth part 21, and thereby efficiently transmit heat generated from the coil to the split core 2a to improve the cooling effect.SOLUTION: A coil wound part 31a of an insulator 3 covering a coil end side end surface of a teeth part 21 of a split core 2a includes an opening 34 formed by a teeth support part 420 provided in a mold 4 during molding and penetrating from a surface of the coil wound part 31a to the coil end side end surface of the teeth part 21.

Description

  The present invention relates to an armature insulator that electrically insulates a tooth portion of an armature and a coil wound around the tooth portion, and a method of manufacturing the same.

The armature teeth area is molded with an insulating resin with high thermal conductivity, and a thin insulator is formed integrally with the teeth area to efficiently cool the heat generated from the coil wound around the teeth area. Technology is known. However, in general, an insulating resin having a high thermal conductivity has poor fluidity, so it is difficult to make the insulator made of a resin mold thin.
A conventional insulator (insulator) includes a corner portion, and the thickness of the corner portion is larger than the thickness of other portions. An insulator having such a corner portion is formed by molding a stator core with an insulating resin in which the width of the tooth portion at both ends in the stacking direction is smaller than the width of the tooth portion at the center portion. According to this step, the fluidity of the insulating resin is improved, and the portions other than the corners of the insulator can be made relatively thin (for example, Patent Document 1).

JP 2010-268586 A

  The conventional insulator as shown in Patent Document 1 is intended to improve the fluidity of the insulating resin. However, even if the fluidity of the corner is improved, the flow resistance of the portion other than the corner over a wide range is still large, and there is a concern that the entire insulator cannot be sufficiently thinned. If the insulator cannot be sufficiently thinned, heat generated from the coil wound around the tooth portion cannot be efficiently transmitted to the stator core, resulting in a problem that the cooling performance cannot be improved. In addition, since the insulating resin has a lower thermal conductivity than the stator core, there is a problem that the cooling effect of the coil is lowered by increasing the thickness of the corners of the insulator.

  The present invention has been made in order to solve the above-described problems. An insulator having a high cooling performance that can reduce the thickness of the insulator of the armature and efficiently transmit the heat generated from the coil to the armature core. The purpose is to obtain.

  The armature insulator according to the present invention is formed by molding the armature core so as to cover the periphery of the tooth portion formed to protrude from the core back portion of the armature core, and is wound around the tooth portion and the tooth portion. Armature insulator made of an insulating resin that electrically insulates the coil. The coil winding portion that covers the coil end side end surface of the tooth portion is formed by a tooth support portion provided in a molding die at the time of molding from the surface of the coil winding portion to the coil end side end surface of the tooth portion. It has an opening that penetrates.

  The armature insulator manufacturing method according to the present invention includes: molding the armature core so as to cover the periphery of the tooth portion formed to protrude from the core back portion of the armature core; This is a method of manufacturing an insulator for an armature made of an insulating resin that electrically insulates a coil wound around a part. The step of disposing the coil end side end surface of the teeth portion on the teeth support portion provided in the molding die, and the insulating resin in the molding die while supporting the teeth portion by the teeth support portion. Filling and molding the armature core.

The armature insulator according to the present invention is formed by molding the armature core so as to cover the periphery of the tooth portion formed to protrude from the core back portion of the armature core, and is wound around the tooth portion and the tooth portion. Armature insulator made of an insulating resin that electrically insulates the coil. The coil winding portion that covers the coil end side end surface of the tooth portion is formed by a tooth support portion provided in a molding die at the time of molding from the surface of the coil winding portion to the coil end side end surface of the tooth portion. It has an opening that penetrates.
Since such an insulator can be manufactured by filling the molding die with an insulating resin while supporting the tooth portion by the tooth support portion, the filling pressure can be increased. For this reason, the thickness of the insulator can be reduced, and the heat generated from the coil can be efficiently cooled.

The armature insulator manufacturing method according to the present invention includes: molding the armature core so as to cover the periphery of the tooth portion formed to protrude from the core back portion of the armature core; This is a method of manufacturing an insulator for an armature made of an insulating resin that electrically insulates a coil wound around a part. The step of disposing the coil end side end surface of the teeth portion on the teeth support portion provided in the molding die, and the insulating resin in the molding die while supporting the teeth portion by the teeth support portion. Filling and molding the armature core.
For this reason, the insulating resin can be filled in the molding die with a high pressure, and a thin insulator can be obtained.

It is a top view which shows the structure of the rotor in Embodiment 1 of this invention. It is AA sectional drawing in the top view of FIG. It is explanatory drawing explaining the detailed structure of the rotor core in Embodiment 1 of this invention. It is a perspective view which shows the structure of the division | segmentation core and insulator in Embodiment 1 of this invention. It is a top view which shows the structure of the division | segmentation core and insulator in Embodiment 1 of this invention. It is BB sectional drawing in the top view of FIG. It is CC sectional drawing in the top view of FIG. FIG. 8 is a partially enlarged view of FIG. 7. It is a schematic diagram for demonstrating the manufacturing method of the insulator of the armature in Embodiment 1 of this invention. It is a schematic diagram for demonstrating the manufacturing method of the insulator of the armature of the comparative example in Embodiment 1 of this invention. It is a perspective view which shows the structure of the insulator of the armature of another example in Embodiment 1 of this invention. It is a perspective view which shows the structure of the insulator of the armature in Embodiment 2 of this invention. It is a top view which shows the structure of the insulator of the armature in Embodiment 2 of this invention. It is DD sectional drawing in the top view of FIG. It is a perspective view which shows the structure of the insulator of the armature of another example in Embodiment 2 of this invention. It is a top view which shows the structure of the insulator of the armature of another example in Embodiment 2 of this invention. It is EE sectional drawing in the top view of FIG. It is a top view which shows the structure of the stator in Embodiment 3 of this invention. It is FF sectional drawing in the top view of FIG. It is a schematic diagram for demonstrating the manufacturing method of the insulator of the armature in Embodiment 3 of this invention. It is a schematic diagram for demonstrating the manufacturing method of the insulator of the armature of the comparative example in Embodiment 3 of this invention.

Embodiment 1 FIG.
The structure of the armature insulator in the first embodiment of the present invention will be described below. FIG. 1 is a plan view showing a configuration of a rotor 10 as an armature of a rotating electrical machine, and FIG. 2 is a cross-sectional view taken along line AA in the plan view of FIG.
The rotor 10 includes a rotor core 2 as an armature core disposed around the rotating shaft 1 and an insulator 3 formed so as to cover the periphery of the tooth portion 21 of the rotor core 2. A coil is wound around the tooth portion 21 via the insulator 3.

FIG. 3 is an explanatory diagram illustrating a detailed configuration of the rotor core 2. As shown in FIG. 3, the rotor core 2 is configured by combining two divided cores 2a and 2b. An insulator 3 is molded integrally with each of the divided cores 2a and 2b. 3, FIG. 4 is a perspective view of the split core 2 a and the insulator 3 arranged on the lower side in the axial direction, FIG. 5 is a plan view, and FIG. 6 is a BB cross-sectional view in the plan view of FIG. A CC cross-sectional view in the plan view of FIG. 5 is shown in FIG. 6 indicates the central axis (rotation center line) of the split core 2a.
The split core 2a is configured by connecting a plurality (three in this case) of tooth portions 21 that protrude in the direction of the rotation axis 1 from a core back portion 22 that extends in the circumferential direction. It is the structure connected by. The connecting portion 23 of the split core 2a is provided so as to connect the lower half of the teeth portion 21 in the axial direction. An insertion hole 24 into which the rotating shaft 1 is inserted is provided at the center of the connecting portion 23.
In addition, the split core 2b shown in FIG. 3 is obtained by arranging split cores having the same shape as the split core 2a with their axial directions reversed. The split core 2a has a connecting portion 23 located in the lower half of the axial direction, and the split core 2b has a connecting portion located in the upper half of the axial direction. The split cores 2a and 2b arranged in this way are moved in the direction of the arrow in FIG. 3, and the split cores 2a and 2b are combined so that the tooth portions of the split core 2b are positioned between the tooth portions 21 of the split core 2a. The rotor core 2 is configured.

Next, the structure of the insulator 3 molded integrally with the split core 2a will be described with reference to FIGS. 4 to 7 and FIG. 8 which is a partially enlarged view of FIG. The insulator 3 electrically insulates the tooth part 21 and the coil wound around the tooth part 21 from an insulating resin.
The insulator 3 has a coil winding portion 31 that covers the periphery of the tooth portion 21, and a portion of the coil winding portion 31 that covers the end surface on the coil end side is the first coil winding portion 31 a and the teeth portion 21. A thin portion covering the circumferential side surface is defined as a second coil winding portion 31b. Further, the core back portion 22 of the split core 2a and the tip portion of the tooth portion 21 are provided with a winding wall portion 32 and a winding wall portion 33 for preventing the coil wound around the tooth portion 21 from collapsing. Each of them is provided as a part of the insulator 3. That is, the insulator 3 includes a first coil winding portion 31a, a second coil winding portion 3b, a winding wall portion 32, and a winding wall portion 33. Here, the coil end means a portion of the coil wound around the tooth portion 21 that is located on the end surface in the axial direction of the tooth portion 21, and the end surface on the coil end side of the tooth portion 21 is the axis of the tooth portion. Refers to the direction end face.

Of the first coil winding portion 31a that covers both end surfaces on the coil end side of the tooth portion 21, the first coil winding portion 31a on one side (here, the upper side in the axial direction) has a tooth portion extending from the surface thereof. An opening 34 having a substantially circular cross section that penetrates to the end face of the coil end 21 is provided.
Here, as shown in FIG. 8, the surface of the first coil winding portion 31 a includes a parallel surface region 310 formed of a surface parallel to the coil end side end surface of the tooth portion 21, and both sides in the circumferential direction of the parallel surface region 310. And an arc surface area 311 provided on the outer periphery of the tooth portion 21 so that the coil can be wound around the teeth portion 21 without bending the coil. The opening 34 is provided in the parallel surface region 310 of the first coil winding portion 31a, and is disposed at a substantially central portion in the circumferential direction of the first coil winding portion 31a. The thickness d of the parallel surface region 310 is set to a predetermined thickness that can secure an insulation distance between the coil passing over the opening 34 and the tooth portion 21. In the first embodiment, the electrical appliance safety law The thickness d is set so as to be equal to or greater than the prescribed insulation distance.
Although the insulator 3 covering the split core 2a has been described here, the shape of the insulator covering the split core 2b is basically the same as that covering the split core 2a. In the split core 2b of FIG. An opening is provided in the first coil winding portion on the lower side in the direction.

  Next, a method for manufacturing the insulator 3 molded integrally with the split core 2a will be described with reference to FIG. FIG. 9 is a schematic diagram for explaining a method of manufacturing the insulator 3. FIG. 9A is a cross-sectional view of the split core 2a in a state before the insulator 3 is molded integrally with the mold. The split core 2a shown in the cross-sectional view of FIG. 6 is rotated 180 degrees. 9B and 9C are sectional views of the split core 2a and the molding die 4. FIG. In addition, the dashed-dotted line in FIG. 9 shows the center axis | shaft of the split core 2a.

The insulator 3 is manufactured by arranging the split core 2 a in the molding die 4 and filling the insulating resin 5 in the cavity 40 formed between the split core 2 a and the molding die 4.
The molding die 4 includes an upper die 41 and a lower die 42, and is formed so as to correspond to the shape of the split core 2a. A gate 410 is opened in the upper die 41 to fill the cavity 40 of the molding die 4 with the insulating resin 5, and a coil end side end surface of the teeth portion 21 is supported from below on the lower die 42. For this purpose, a columnar tooth support 420 having a substantially circular cross section is provided as a part of the molding die 4.

First, as shown in FIG. 9B, the split core 2 a shown in FIG. 9A is placed in the lower mold 42. The split core 2 a is supported by the lower mold 42 in contact with the lower mold 42 on the lower surface of the connecting portion 23, the inner peripheral surface of the insertion hole 24, and the like. Furthermore, the split core 2a is arranged on the tooth support portion 420 of the lower mold 42 so that the end surface on the coil end side of the tooth portion 21 is positioned, so that the lower surface of the tooth portion 21 is also supported by the tooth support portion 420. . After the split core 2 a is arranged at a fixed position in the lower mold 42, the upper mold 41 is set on the lower mold 42.
Next, as shown in FIG. 9C, the insulating resin 5 is injected from the gate 410 of the upper mold 41 and filled into the cavity 40 of the molding mold 4. The insulating resin 5 injected from the gate 410 first enters the cavity 40 of the upper mold 41, and the thin-walled portions (second coil) located on both sides in the circumferential direction of the teeth portion 21 of the cavity 40 of the lower mold 42. It fills up to the inside of the cavity 40 on the lower surface side of the teeth portion 21 via a portion corresponding to the winding portion 31b (see FIG. 7).
Thereafter, the molding die 4 is removed, and the insulator 3 covering the divided core 2a is completed. The region of the teeth support portion 420 that supported the teeth portion 21 of the split core 2a at the time of molding becomes the opening 34 of the first coil winding portion 31a of the insulator 3.
By the method as described above, the insulator 3 integrally molded is formed around the teeth portion 21 and the core back portion 22 of the split core 2a.

  When the insulating resin 5 is filled, a filling pressure is applied from the upper side to the lower side of the tooth portion 21 and the core back portion 22. As described above, the coil end side end surface of the tooth portion 21 is supported from below by the tooth support portion 420. Yes. Accordingly, the teeth 21 and the core back 22 are prevented from being bent or plastically deformed by the filling pressure.

As a comparative example of the first embodiment, a case where there is no teeth support portion for supporting the coil end side end surface of the teeth portion in the molding die will be described with reference to FIG. FIG. 10 is a schematic diagram for explaining the manufacturing method of the comparative example, and shows a cross-sectional view of the split core 2x and the molding die 4x. 10 (a) corresponds to FIG. 9 (b) and FIG. 10 (b) corresponds to FIG. 9 (c). The shape of the split core 2x in the comparative example is the same as that of the first embodiment, and the molding die 4x is composed of the upper die 41x and the lower die 42x as in the first embodiment. 42x differs from the first embodiment in that it does not have a teeth support portion.
As shown in FIG. 10A, first, the split core 2x is placed in the lower mold 42x. At this time, the split core 2x is in contact with the lower mold 42x and supported by the lower mold 42x on the lower surface of the connecting portion 23x, the inner peripheral surface of the insertion hole 24x, etc., but nothing supports the lower surface of the teeth portion 21x. The support structure of the teeth portion 21x is an unstable structure.
Therefore, as shown in FIG. 10B, when the insulating resin 5 is filled in the molding die 4x, the teeth 21x and the like may be bent or plastically deformed by the filling pressure.

  As described above, the insulator 3 of the armature according to the first embodiment has the first coil winding portion 31a covered with the first coil winding portion 31a covering the coil end side end surface on one side of the tooth portion 21. An opening 34 penetrating from the surface to the end surface on the coil end side of the tooth portion 21 is provided. As described above, such an insulator 3 is manufactured by filling an insulating resin while supporting the teeth portion 21 from below by the teeth support portion 420 provided on the lower die 42 of the molding die 4. By manufacturing the insulator 3 by such a manufacturing method, it is possible to suppress the teeth portion 21 from being bent or plastically deformed by the filling pressure of the insulating resin, and to increase the filling pressure of the insulating resin.

  In the thin wall portions located on both sides in the circumferential direction of the teeth portion 21 in the cavity of the lower mold 42, the flow resistance of the insulating resin increases as the thickness decreases, but the filling pressure of the insulating resin can be increased. Even if the thickness of the thin portion is reduced, molding defects such as poor filling do not occur. For this reason, the insulator 3 can be thinned, and the heat generated from the coil can be efficiently transmitted to the split core 2a to be cooled. In general, insulating resin with high thermal conductivity is known to have poor fluidity. However, since the filling pressure of the insulating resin can be increased, a highly thermal conductive resin is used as the insulating resin. However, molding defects such as poor filling do not occur. For this reason, a thing with high heat conductivity can be used as insulating resin of the insulator 3, and it can reduce in thickness, and can improve the cooling effect of a coil more.

  Furthermore, if the insulator 3 can be thinned, the coil winding space can be expanded, and the coil wire diameter can be increased by the expanded winding space. Thereby, it becomes possible to reduce the electrical resistance of the coil and suppress the heat generation itself from the coil.

  Further, since the teeth portion 21 and the core back portion 22 are suppressed from being bent or plastically deformed by the filling pressure of the insulating resin, it is possible to prevent the position of the teeth portion 21 and the like from being changed during the manufacturing process of the insulator 3. The shape accuracy of the insulator 3 can be improved.

  The surface of the first coil winding portion 31 a of the insulator 3 includes a parallel surface region 310 parallel to the coil end side end surface of the tooth portion 21, and the opening 34 is provided in the parallel surface region 310. Therefore, the opening 34 is surrounded by parallel surfaces, and the coil that crosses over the opening 34 is not bent at the edge of the opening 34 when the coil is wound around the insulator 3. For this reason, the coil is not deformed or scratched by providing the opening 34, and the quality of the coil and the alignment of the coil can be maintained high.

  Further, the parallel surface region 310 of the first coil winding portion 31a has a thickness equal to or greater than the insulation distance specified by the Electrical Appliance and Material Safety Law so as to ensure an insulation distance between the coil passing over the opening 34 and the tooth portion 21. Therefore, electrical insulation between the coil and the tooth portion 21 can be reliably performed.

By the way, the insulator 3 formed by the above manufacturing method has few contact portions between the molding die 4 and the lower surface of the split core 2a at the time of mold integral molding, and the molding die 4 does not have the teeth support portion 420. This is particularly effective when the split core 2a cannot be supported in a balanced manner from below, for example, when the armature size is small.
Since the rotor of a rotating electrical machine rotates in the space inside the stator, it is often smaller than the size of the stator and is often small. As in the first embodiment, it can be said that the above-described effect can be easily achieved by using the insulator 3 as a rotor insulator whose size is likely to be small.

  In the first embodiment, the shape of the teeth support portion 420 of the lower mold 42 is a column shape having a substantially circular cross section, and the shape of the opening portion 34 is a substantially circular shape. Moreover, the arrangement position of the opening part 34 was made into the substantially central part of the circumferential direction of the 1st coil winding part 31a. However, the shape and position of the teeth support portion and the opening 34 are not limited to this. It is only necessary to support the coil end side end surface of the tooth portion from below with a good balance by the tooth support portion, and the tooth support portion and the opening portion are provided at a position where the coil does not bend at the edge of the opening portion of the insulator. Then, the same effect as the first embodiment can be obtained. For example, as shown in FIG. 11 as another example of the first embodiment, the cross-sectional shape of the opening 34a may be an oval shape that is long in the radial direction of the split core 2a. In this case, the shape of the tooth support portion is It has a columnar shape with an oval cross section.

Embodiment 2. FIG.
The structure of the armature insulator in the second embodiment of the present invention will be described below. The armature insulator 6 according to the second embodiment is different from the armature insulator 3 according to the first embodiment in the shape of the opening. The shape of the insulator 6 according to the second embodiment will be described with reference to FIGS. FIG. 12 corresponds to FIG. 4 of the first embodiment, and is a perspective view showing a state where the insulator 6 of the second embodiment is integrally molded with the split core 2a described in the first embodiment. 13 is a plan view of the split core 2a and the insulator 6 shown in FIG. 12, and FIG. 14 is a DD cross-sectional view in the plan view of FIG. In addition, the dashed-dotted line shown in FIG. 14 shows the central axis of the split core 2a.

  12 to 14, the shape of the split core 2 a is the same as that of the first embodiment, and the same reference numerals are given and description thereof is omitted. The shape of the insulator 6 is the same as that of the insulator 3 of the first embodiment except for the shape of the opening, and the first coil winding portion 61a covering the end surface of the tooth portion 21 on the coil end side and the periphery of the tooth portion 21 are the same. A thin-walled second coil winding portion 61 b that covers the side surface in the direction, a winding wall portion 62 provided in the core back portion 22, and a winding wall portion 63 provided at the tip portion of the teeth portion 21. . The first coil winding portion 31 a on the upper side in the axial direction in FIG. 12 is provided with an opening 64 that penetrates from the surface to the coil end side end surface of the tooth portion 21. And the opening part 64 is extended in the radial direction outer side of the 1st coil winding part 31a, penetrates the winding wall part 62 by the side of the core back part 22, and is connected with the exterior by the side of the core back part of the insulator 6. A portion extending outward in the radial direction of the opening 64, that is, a portion connecting the opening 64 and the outside on the core back portion side of the insulator 6 is defined as a passage 640.

  In the insulator 6 of the second embodiment shown in FIGS. 12 to 14, the passage 640 punches out the entire height direction of the winding wall portion 62 from the coil end side end surface of the winding wall portion 62 to the upper end surface in the axial direction. 15 to 17, for example, as in another example insulator 6a shown in FIGS. 15 to 17, a passage 640a extending radially outward from the opening 64a penetrates a part of the lower side of the winding wall portion 62a to the core. It may be configured to communicate with the outside on the back portion side.

  The passage 640 of the insulator 6 of the second embodiment shown in FIGS. 12 to 14 is, for example, a teeth support portion in the molding die 4 described in FIGS. 9B and 9C of the first embodiment. It can be formed by extending the shape of 420 outward in the radial direction. Moreover, the channel | path 640a of the insulator 6a of another example of this Embodiment 2 shown to FIGS. 15-17 can be formed, for example using a slide molding die.

  As described above, the armature insulator 6 according to the second embodiment and the armature insulator 6a according to another example of the second embodiment have the openings 64 and 64a and the core back portion side (diameter of the insulators 6 and 6a). Since the passages 640 and 640a communicating with the outside (in the direction outside) are provided, the following effects can be obtained in addition to the effects of the first embodiment.

  1stly, the difference between the pressure in the opening parts 64 and 64a at the time of a coil being wound by the teeth part 21 and the pressure with the exterior can be eliminated. Here, the outside refers to the periphery of the rotor 10. That is, when the coil is wound around the tooth portion 21, the openings 64 and 64 a are covered with the coil, but since the passages 640 and 640 a communicate with the outside, the opening 64 and 64 a are wound even when the coil is wound. 64a is not sealed. Therefore, the difference between the pressure in the openings 64 and 64a and the pressure around the rotor 10 can be eliminated, and the stress on the coil caused by the pressure difference can be suppressed. In addition, the rotating electrical machine is not necessarily used at room temperature and atmospheric pressure. In such a case, particularly in the openings 64 and 64a around which the coil is wound at room temperature and atmospheric pressure and around the rotor 10 The difference between the pressure and the temperature is likely to occur, and the effects of having the passages 640 and 640a are remarkably obtained.

  Secondly, after the coil is wound around the tooth portion 21, the coil such as mold resin or varnish is fixed in the openings 64 and 64a from the outside on the core back side of the insulators 6 and 6a through the passages 640 and 640a. Resin for use can be injected. Thereby, the fixing member for fixing the coil which crosses over the opening part 64, 64a is provided in the opening part 64, 64a, and the coil can be fixed, and the coil is worn by vibration or the like during the operation of the rotating electrical machine. -It is possible to suppress wear.

  The shape of the passage that communicates the opening and the outside on the core back side (radially outer side) of the insulator is not limited to the above two examples, and the shape of the opening and the core back side of the insulator is not limited. Any shape may be used as long as it communicates with the outside. Further, the formation of the passage is not necessarily performed when the insulating resin is filled in the molding die. For example, after an insulator having an opening having a substantially circular cross section as described in the first embodiment is integrally molded with a split core by filling an insulating resin in a molding die, the opening and the core back of the insulator are formed. You may form a channel | path by providing a through-hole etc. so that the exterior of a part side may be connected.

Embodiment 3 FIG.
The structure of the armature insulator according to Embodiment 3 of the present invention will be described below. In the first embodiment, the rotor insulator as the armature has been described. In the third embodiment, the stator insulator as the armature will be described. 18 is a plan view showing a configuration of a stator 100 that is an armature of a rotating electrical machine, and FIG. 19 is a cross-sectional view taken along line FF in the plan view of FIG. Note that the alternate long and short dash line in FIG. 19 indicates the central axis of the stator core 7.
The stator 100 includes a stator core 7 as an armature core and an insulator 8 formed so as to cover the periphery of the tooth portion 71 of the stator core 7, and a coil is wound around the tooth portion 71 via the insulator 8. Configured by turning. The stator core 7 is formed by annularly arranging a plurality of (here, twelve) divided cores 7a each having a core back portion 72 extending in the circumferential direction and a teeth portion 71 formed protruding from the core back portion 72. Is formed.

  The insulator 8 is different from the first embodiment in that it is integrally molded with the teeth 71 of the split core 7a constituting the stator core 7 instead of the rotor core, but the basic shape is the first embodiment. This is the same as the insulator 3 in FIG. That is, the insulator 8 includes a first coil winding portion 81 a that covers the end surface of the tooth portion 71 on the coil end side, a thin second coil winding portion that covers the circumferential side surface of the tooth portion 71, and a core back portion 72. And a winding wall portion 82 and a winding wall portion 83 for preventing the coil wound around the tooth portion 71 from being collapsed. An opening 84 that penetrates from the surface of the first coil winding portion 81a to the coil end side end surface of the teeth portion 71 is provided on one axial side of the first coil winding portion 81a (here, the upper side in the axial direction). Is provided.

  A method for manufacturing the insulator 8 molded integrally with the split core 7a will be described with reference to FIG. FIG. 20 is a schematic diagram for explaining a manufacturing method of the insulator 8. FIG. 20A is a cross-sectional view of the split core 7a in a state before the insulator 8 is molded integrally with the mold, and the split core 7a shown in the cross-sectional view of FIG. 19 is rotated 180 degrees. 20B and 20C are cross-sectional views of the split core 7a and the molding die 9. FIG. In addition, in Fig.20 (a), the external shape of the insulator 8 to manufacture is shown with the dotted line.

The manufacturing method of the insulator 8 according to the third embodiment is basically the same as that in the first embodiment, and the insulator 8 includes the split core 7a and the split core 7a. The cavity 90 formed between the molding die 9 is filled with the insulating resin 5 and manufactured.
The molding die 9 includes an upper die 91 and a lower die 92, and is formed so as to correspond to the shape of the split core 7a. A gate 910 for filling the insulating resin 5 into the cavity 90 of the molding die 9 is opened in the upper die 91, and a coil end side end surface of the teeth portion 71 is supported from below on the lower die 92. For this purpose, a columnar tooth support portion 920 having a substantially circular cross section is provided as a part of the molding die 9.

First, as shown in FIG. 20 (b), the split core 7 a shown in FIG. 20 (a) is placed in the lower mold 92. The split core 7a is in contact with the lower mold 92 at the radially outer portion (the portion indicated by 720 in FIG. 20B) of the lower surface of the core back portion 72, and is supported from below by the lower mold 92. . Furthermore, the tooth support portion 920 of the lower mold 92 and the end surface on the coil end side of the tooth portion 71 abut, and the lower surface of the tooth portion 71 is also supported by the tooth support portion 920. After the divided core 7 a is disposed at a fixed position in the lower mold 92, the upper mold 91 is set on the lower mold 92.
Then, as shown in FIG. 20C, the insulating resin 5 is injected from the gate 910 of the upper mold 91 and filled in the cavity 90 of the molding mold 9. The insulating resin 5 injected from the gate 910 first enters the cavity 90 of the upper mold 91, and the thin portions (second coil) located on both sides in the circumferential direction of the teeth portion 71 in the cavity 90 of the lower mold 92. A portion corresponding to the winding portion) is filled up to the inside of the cavity 90 on the lower surface side of the teeth portion 71.
Thereafter, the molding die 9 is removed, and the insulator 8 covering the divided core 7a is completed. The region of the teeth support portion 920 that supported the teeth portion 71 of the split core 7a at the time of molding becomes the opening 84 of the first coil winding portion 81a of the insulator 8.
By the method as described above, the insulator 8 molded integrally with the teeth 71 and the core back 72 of the split core 7a is formed.

  When the insulating resin 5 is filled, a filling pressure is applied from the upper side to the lower side of the teeth portion 71 and the core back portion 72. Yes. Accordingly, the teeth 71 and the core back 72 are prevented from being bent or plastically deformed by the filling pressure.

As a comparative example of the third embodiment, a case where there is no tooth support portion for supporting the coil end side end surface of the tooth portion in the molding die will be described with reference to FIG. FIG. 21 is a schematic diagram for explaining the manufacturing method of the comparative example, and shows a sectional view of the split core 7x and the molding die 9x. 21A corresponds to FIG. 20B, and FIG. 21B corresponds to FIG. 20C. The shape of the split core 7x in the comparative example is the same as that of the third embodiment, and the molding die 9x is composed of the upper die 91x and the lower die 92x as in the third embodiment. It differs from the said Embodiment 3 by the point which does not have a teeth support part in 92x.
As shown in FIG. 21A, first, the split core 7x is arranged in the lower mold 92x. At this time, the split core 7x is supported from below by the lower mold 92x only in the radially outer portion (the portion indicated by 720x in FIG. 21A) of the lower surface of the core back portion 72x. There is nothing that supports the lower surface of the teeth portion 71x. Most of the split cores 7x are located on the cavities 90x of the lower mold 92x, and the support structure for the teeth 71x is an unstable structure.
Therefore, as shown in FIG. 21B, when the insulating resin 5 is filled in the molding die 9x, it is considered that the teeth 71x and the core back 72x are bent or plastically deformed by the filling pressure.
In particular, in the case of this comparative example, the portion where the divided core 7x is supported from below by the lower mold 92x is only the lower surface on the radially outer side of the core back portion 72x, and the position of the divided core 7x when filled with the insulating resin Is very unstable. Therefore, a remarkable effect can be obtained by manufacturing the insulator 8 by providing the teeth support portion 920 in the lower mold 92 as in the third embodiment.

  As described above, the armature insulator 8 of the third embodiment also has the first coil winding portion 81a covering the coil end side end surface of the tooth portion 71 in the first coil winding portion 81a as in the first embodiment. An opening 84 that penetrates from the surface of the coil winding portion 81 a to the coil end side end surface of the teeth portion 71 is provided. Such an insulator 8 is manufactured by filling an insulating resin while supporting the teeth portion 71 from below by a teeth support portion 920 provided on the lower die 92 of the molding die 9. As a result, the teeth 71 and the core back 72 are prevented from being bent or plastically deformed, so that the same effect as in the first embodiment can be obtained.

In the third embodiment, the case where the stator core is composed of a plurality of divided cores has been described as an example. However, the structure of the stator core may be an integrated structure that is not divided into divided cores. May be. In this case, the insulator is integrally formed with the integral stator core.
Moreover, although Embodiment 1-3 demonstrated the insulator integrally molded with the split core which comprises the rotor core or stator core of a rotary electric machine, the application range of the insulator of this invention is restricted to a rotary electric machine. Instead, it can be integrally formed with an armature core such as a linear motor.

  Further, within the scope of the present invention, the present invention can be freely combined with each other, and each embodiment can be appropriately modified or omitted.

1 rotating shaft, 2 rotor core as armature core, 2a, 2b split core,
3 Insulator, 4 Mold, 5 Insulating resin, 6, 6a Insulator,
7 Stator core as armature core, 7a split core, 8 insulator,
9 Mold, 10 Rotor as armature, 21 teeth, 22 core back,
23 connecting portion, 24 insertion hole, 31 coil winding portion, 31a first coil winding portion,
31b 2nd coil winding part, 32, 33 winding wall part, 34, 34a opening part,
40 cavity, 41 upper mold, 42 lower mold, 61a first coil winding part,
61b 2nd coil winding part, 62, 62a, 63 winding wall part, 64, 64a opening part,
71 teeth portion, 72 core back portion, 81a first coil winding portion,
82, 83 winding wall, 84 opening, 90 cavity, 91 upper mold,
92 Lower mold, 100 Stator as armature, 310 Parallel plane region,
311 arcuate surface area, 410 gate, 420 teeth support,
640, 640a passage, 910 gate, 920 teeth support.

Claims (7)

Insulation that electrically insulates the tooth part and the coil wound around the tooth part by molding the armature core so as to cover the periphery of the tooth part formed protruding from the core back part of the armature core Armature insulator made of a functional resin,
The coil winding portion that covers the coil end side end surface of the tooth portion is formed by a tooth support portion provided in a molding die at the time of molding from the surface of the coil winding portion to the coil end side end surface of the tooth portion. An armature insulator comprising an opening that penetrates the armature. 2. The electric machine according to claim 1, wherein a surface of the coil winding portion includes a parallel surface region parallel to a coil end side end surface of the tooth portion, and the opening is provided in the parallel surface region. Child insulator. 3. The armature according to claim 2, wherein the parallel surface region of the coil winding portion is formed to have a predetermined thickness that secures an insulation distance between the coil passing through the opening and the tooth portion. Insulator. The armature insulator according to any one of claims 1 to 3, further comprising a passage that allows communication between the opening and the outside on the core back side of the insulator. 5. The armature insulator according to claim 4, further comprising: a fixing member that fixes the coil made of the resin injected from the passage in the opening. The armature insulator according to any one of claims 1 to 5, wherein the armature core is a rotor core of a rotating electric machine. Insulation that electrically insulates the tooth part and the coil wound around the tooth part by molding the armature core so as to cover the periphery of the tooth part formed protruding from the core back part of the armature core A method for manufacturing an insulator for an armature made of a functional resin,
Placing the coil end side end face of the tooth part on the tooth support part provided in the molding die; and
Filling the insulating mold into the molding die and molding the armature core while supporting the teeth portion by the teeth support portion;
A method of manufacturing an armature insulator, comprising:

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