JP2014050185A - Method of manufacturing resin mold stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To achieve satisfactory adhesion to an end part member, of a mold resin which covers a coil end part of a stator core by mold forming using a masking jig, without requiring exact dimensional accuracy and a complicated structure of the masking jig for use when an open end of a casing is closed with the end part member.SOLUTION: A method of manufacturing a resin mold stator employs a process of forming second mold parts 15a and 15b, by mold forming, in annular spaces 25a and 25b constituted of spaces between first mold parts 13a and 13b formed on respective coil end parts 3a and 3b by mold forming using a masking jig 21, and end part members 7 closing a casing 1 and open ends 1a and 1b of the casing. Therefore, coatings (first and second mold parts 13a, 15a, 13b, and 15b) of mold resin having high adhesion to the casing 1 and the end part members 7 can be formed on the respective coil end parts 3a and 3b.

Description

  The present invention relates to a method of manufacturing a resin molded stator in which a coil end portion of a stator core is covered with a mold resin.

  In a stator of a rotating machine such as an electric motor or a generator, a stator coil wound around the stator core has a coil end portion led out from a slot formed on an end surface of the stator core to the outer side in the rotation center axis direction of the rotor. Unlike the coil portion in the core, this coil end portion does not contact the stator core, so it is important how efficiently the heat generated by energization is removed.

  For cooling the coil end part, there is a method of spraying a cooling medium such as oil on the coil end in a sealed space. However, when there is an oil-free requirement, a cooling medium is supplied to the coil end part. It is not possible to adopt when it is difficult. Therefore, a resin having a relatively high thermal conductivity is used as a mold resin for insulatingly sealing the coil end part by molding, and the heat of the coil end part is released to the casing through the mold resin covering the coil end part. It has been broken.

  When molding the coil end portion, with the stator core housed in the casing, the end surface of the stator core, the inner peripheral wall and end surface of the casing, and the inner peripheral surface of the radius corresponding to the air gap between the stator and the rotor An enclosed annular space is formed. Then, mold resin is filled into the annular space from the outside of the casing through the gate (for example, Patent Document 1).

  In order to accommodate the stator core, at least one end surface of the casing must be an open end. Therefore, on the open end face side of the casing, after accommodating the casing, the open end face is closed with a masking jig to temporarily form an annular space, and in this state, the mold resin is filled into the annular space. In the case of a casing with both ends open, both end surfaces are closed with a masking jig after the stator core is accommodated to fill the annular space with mold resin.

  Thereafter, the open end of the casing is closed with an end member instead of the masking jig. The end member that closes the open end of the casing supports a rotating shaft that rotates together with the rotor, or supports a fixed shaft that rotatably supports the rotor.

JP 2004-120923 A

  When molding is performed on the coil end portion using the masking jig described above, the tip end portion (surface) in the protruding direction of the coil end portion from the stator core has a shape corresponding to the masking jig. Therefore, the shape of the masking jig portion that faces the end surface of the stator core during molding is precisely matched with the shape of the end member portion that faces the end surface of the stator core when the open end of the casing is closed. There is a need.

  Otherwise, after molding, when the end member is attached to the open end of the casing instead of the masking jig, the mold resin is in close contact with the end member due to the difference in shape from the masking member. Without the possibility that the necessary heat transfer performance cannot be obtained.

  In order to avoid the occurrence of such a phenomenon, a strict dimensional accuracy is required for the masking jig, and a complicated structure for securing or supplementing it is required. This hinders the spread of molding of the coil end portion using the masking jig.

  The present invention has been made in view of the above circumstances, and the object of the present invention is to close the open end of the casing with an end member without requiring strict dimensional accuracy or a complicated structure for the masking jig to be used. Another object of the present invention is to provide a method for manufacturing a resin-molded stator that can satisfactorily adhere a mold resin that covers a coil end portion of a stator core by molding using a masking jig to an end member.

In order to achieve the above object, a method for producing a resin-molded stator of the present invention described in claim 1 comprises:
A method of manufacturing a resin-molded stator in which coil end portions respectively protruding from both end portions of an annular stator core housed in a cylindrical casing are coated with a mold resin,
The stator core is housed inside from the open end of the casing, the open end is closed with a masking jig, and the end opposite to the open end is inserted with the masking jig inserted inside the stator core. By filling the casing with the mold resin from the side, at least the coil end portion of the coil end portion positioned on the open end side is coated with the mold resin at a predetermined length from the stator core end portion. A first molding step for forming a proximal end side annular covering portion;
In a state where the open end from which the masking jig has been removed is closed with an end member, an annular seal member provided on the end member is brought into elastic contact with the inner peripheral surface of the base end side annular covering portion, An annular space surrounded by the casing, the end member, the seal member, and the proximal-side annular covering portion is formed, and the annular space is filled with a mold resin, and the coil end on the open end side is formed. A second molding step for forming a distal end side annular covering portion connected to the proximal end side annular covering portion in the part;
It is characterized by including.

  According to the method for manufacturing a resin-molded stator of the present invention described in claim 1, in the first molding step, the open end of the casing containing the stator core is closed with a masking jig, and the masking jig is inserted inside the stator core. The coil end portions at both ends of the stator core communicate with each other inside the casing through a gap between the masking jig and the inner peripheral surface of the stator core.

  Therefore, when the mold resin is filled into the casing from the end side opposite to the open end of the casing, the mold resin flows into the stator core end on the open end side of the casing through the gap between the stator core and the masking jig. . Then, the coil end portion at least a predetermined length from the end portion of the stator core on the open end side of the casing is covered with the mold resin filled between the end portion of the stator core on the open end side of the casing and the masking member. . Thereby, the base end side cyclic | annular coating | coated part is formed in the coil end part of the stator core end part located in the open end side of a casing.

  Further, in the second molding step, when the open end of the casing is closed with an end member, and the annular seal member of the end member is brought into elastic contact with the inner peripheral surface of the proximal-side annular covering portion, the casing, the end member, and the seal An annular space surrounded by the member and the base end side annular covering portion is formed, and the coil end portion on the open end side is accommodated in this space.

  Therefore, when the annular space is filled with the mold resin, a distal end side annular covering portion connected to the proximal end side annular covering portion is formed in the open end side coil end portion, and the entire coil end portion is formed by both annular covering portions. While being covered with the mold resin, the mold resin constituting the tip-side annular covering portion is in close contact with the end member.

  Therefore, even if the masking jig to be used does not require strict dimensional accuracy or a complicated structure, when the open end of the casing is closed with an end member, the coil end of the stator core is molded by using the masking jig. The mold resin covering the portion can be satisfactorily adhered to the end member.

Moreover, the manufacturing method of the resin mold stator of this invention described in Claim 2 is the manufacturing method of the resin mold stator of this invention described in Claim 1,
The casing has the open ends at both ends;
In the first molding step, in the state where one open end of the casing is closed with the masking jig, the inside of the casing is filled with mold resin from the other open end of the casing. A coil end portion having a predetermined length from at least each stator core end portion is coated with the mold resin, and the base end side annular covering portion is formed on each coil end portion. 3 mold steps are included,
In the state where the other open end from which the masking jig is removed is closed with the end member, the sealing member of the end member is covered with the inner peripheral surface of the base-side annular covering portion on the other open end side. To form an annular space surrounded by the casing, the end member, the seal member, and the proximal-side annular covering portion on the other open end side, and mold resin is placed in the annular space. A fourth mold step of filling the coil end portion on the other open end side to form a distal end side annular covering portion connected to the proximal end side annular covering portion;
It is characterized by that.

  According to the method for manufacturing a resin molded stator of the present invention described in claim 2, in the method of manufacturing the resin molded stator of the present invention described in claim 1, when both ends of the casing are open ends, the first A third molding step can be performed during the molding step. Then, when the third molding step is performed, not only the coil end portion on one open end side covered with the masking jig but also the coil end portion on the other open end side filled with the mold resin from the end portion of the stator core. A coil end portion of a portion longer than a predetermined length is covered. Thereby, the base end side cyclic | annular coating | coated part is each formed in the coil end part of the stator core edge part located in the both open end sides of a casing, respectively.

  In the fourth molding step, the other open end of the casing is closed with an end member, and the annular seal member of the end member is elastically brought into contact with the inner peripheral surface of the base end-side annular covering portion on the other open end side. An annular space surrounded by the casing, the end member, the seal member, and the proximal end side annular covering portion is formed, and the coil end portion on the other open end side is accommodated in this space.

  Therefore, when the annular space is filled with the mold resin, the distal end side annular covering portion connected to the proximal end side annular covering portion is formed in the coil end portion on the other open end side, and the coil end portion is formed by both annular covering portions. Is entirely covered with the mold resin, and the mold resin constituting the tip-side annular cover portion is in close contact with the end member closing the other open end.

  As a result, even if the masking jig to be used does not require strict dimensional accuracy or a complicated structure, the coil ends at both ends of the stator core accommodated in the casing whose both ends are open ends are closed end portions. It can be coated with a mold resin so that the adhesion to the member is good.

Furthermore, the manufacturing method of the resin molded stator of the present invention described in claim 3 is the method of manufacturing the resin molded stator of the present invention described in claim 1 or 2,
The end member has an annular protrusion that projects annularly into the casing in a state of closing the open end, and a bearing portion provided on an inner peripheral surface of the annular protrusion;
The seal member is provided on an outer peripheral surface of the annular protrusion;
In the second molding step or the second molding step and the fourth molding step, the rotating shaft of the rotor disposed inside the stator core in the casing is supported by the bearing portion of the end member. Then, the sealing member is elastically contacted with the inner peripheral surface of the proximal end side annular covering portion,
It is characterized by that.

  According to the method for manufacturing the resin-molded stator of the present invention described in claim 3, in the method for manufacturing the resin-molded stator of the present invention described in claim 1 or 2, the rotating shaft of the rotor disposed inside the stator is provided. When bearing is performed by the bearing portion of the end member, if the bearing portion is provided on the inner peripheral surface of the annular protrusion of the end member, the rotating shaft is stably supported at a location closer to the rotor.

  Therefore, when a seal member is provided on the outer peripheral surface of the annular protrusion of the end member, the seal member elastically contacts the inner peripheral surface of the proximal-side annular covering portion formed in the coil end portion at a location closer to the end portion of the stator core. For this reason, even if the predetermined length of the base end side annular covering portion formed on the coil end portion in the first molding step is short, the sealing member comes into elastic contact with the inner peripheral surface of the base end side annular covering portion. . Accordingly, the sealing of the annular space surrounded by the casing, the end member, the seal member, and the base end side annular covering portion is ensured, so that the second molding step, or the second molding step and the fourth molding step are performed. Can be appropriately executed.

  According to the present invention, even if the masking jig to be used does not require strict dimensional accuracy or a complicated structure, when the open end of the casing is closed with the end member, the stator core is molded by using the masking jig. The mold resin covering the coil end portion can be satisfactorily adhered to the end member.

It is sectional drawing which shows the 1st step of the process of manufacturing a resin mold stator by the manufacturing method which concerns on one Embodiment of this invention. It is sectional drawing which shows the state which filled with mold resin in the 1st step of FIG. 1, and removed the masking jig from the open end of the casing. FIG. 3 is a cross-sectional view showing a state where both open ends of the casing of FIG. 2 in which a rotor and a rotating shaft are accommodated inside a stator core are respectively closed with end members. FIG. 4 is a cross-sectional view showing a state in which a mold resin is filled in an annular space around a coil end portion with a mold resin filled from the gate of each end member in FIG. 3 into a casing. It is a flowchart which shows the process of the manufacturing method of the resin mold stator which concerns on one Embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an explanatory view showing a first stage of a process of manufacturing a resin molded stator by a manufacturing method according to an embodiment of the present invention. This embodiment demonstrates the case where the resin mold stator of the rotary machine used as an electric motor or a generator is manufactured.

  First, as shown in FIG. 1, in a state in which a cylindrical stator core 3 is accommodated in a cylindrical casing 1 having both ends opened to 1a and 1b, one of the casings 1 positioned below in FIG. The open end 1 a is closed with a masking jig 21.

  The masking jig 21 includes a base portion 21a having a disk shape with an outer diameter equal to or larger than the outer diameter of the casing 1, and a step portion 21b having a disk shape with an outer diameter equal to the inner diameter of the casing 1 and formed concentrically with the base portion 21a. And a columnar insertion portion 21c projecting from the center of the step portion 21b.

  The step portion 21 b has a height equal to or less than the positional difference between one open end 1 a and the coil end portion 3 a of the stator core 3 in the central axis direction of the casing 1. The insertion portion 21 c has a height that protrudes from the other open end 1 b of the casing 1 in a state where the base 21 a is in contact with one open end 1 a of the casing 1 to close the open end 1 a.

  Therefore, on one open end 1a side of the casing 1, the end surface of the stator core 3 on the open end 1a side, the inner peripheral surface of the casing 1, and the step portion 21b and the insertion portion 21c of the masking jig 21 are open ends. An annular space 23a surrounding the coil end portion 3a on the 1a side is formed. Further, on the other open end 1 b side of the casing 1, a coil on the open end 1 b side is formed by the end surface of the stator core 3 on the open end 1 b side, the inner peripheral surface of the casing 1, and the insertion portion 21 c of the masking jig 21. An annular open space 23b surrounding the end portion 3b is formed.

  The insertion portion 21c has an outer diameter that is slightly smaller than the inner diameter of the stator core 3 and slightly larger than the outer diameter of a rotor 5 (see FIG. 3) described later that is housed inside the stator core 3. . Therefore, when the insertion portion 21 c is inserted into the stator core 3, a slight gap S is formed between the outer peripheral surface of the insertion portion 21 c and the inner peripheral surface of the stator core 3. The annular space 23a and the annular open space 23b communicate with each other through the gap S. In this state, as the first molding step, the molding resin is filled into the casing 1 from the open end 1b.

  In the present embodiment, both ends of the casing 1 are open ends 1a and 1b, and the open ends 1a and 1b are closed by end members 7 and 7 (see FIG. 3) described later. For this reason, it is necessary to coat the coil end portions 3a, 3b on both open ends 1a, 1b side with mold resin in a shape having good adhesion to the end members 7, 7. Therefore, in the first-stage manufacturing process using the masking jig 21, both the coil end portions 3a and 3b are partially coated with mold resin near the end of the stator core 3.

  Therefore, first, for the coil end portion 3a on the open end 1a side, the mold resin is filled in the annular space 23a on the open end 1a side to cover the portion near the end of the stator core 3 with the mold resin, so that the liquid level is Filling is performed until the end surface of the stator core 3 on the open end 1a side is reached.

  Following this, a step corresponding to the third molding step in the claims is performed. In this step, in the coil end portion 3b on the open end 1b side, the mold resin is filled in the gap S between the insertion portion 21c and the stator core 3 in order to cover the end portion of the stator core 3 with the mold resin. Further, the mold resin is filled into the annular open space 23b on the open end 1a side until the liquid level reaches above the end face on the open end 1b side of the stator core 3.

  The entire process described with reference to FIG. 1 corresponds to the first molding process in the claims. Then, by performing this step, when the masking jig 21 is removed after the mold resin is cooled and cured, the coil end portions 3a and 3b on the both open ends 1a and 1b side of the casing 1 are covered as shown in FIG. First mold portions 13a and 13b (corresponding to the base end side annular covering portion in claims) are formed. Further, the inner peripheral surface of the stator core 3 is also covered with a mold resin with a thickness corresponding to the gap S.

  The first mold portion 13a of the coil end portion 3a is formed with a dimension that covers almost the entire length of the coil end portion 3a from the end surface of the stator core 3 to the tip end of the coil end portion 3a in the central axis direction of the casing 1. On the other hand, the first mold portion 13b of the coil end portion 3b is formed so as to cover a part of the base end side of the coil end portion 3b from the end surface of the stator core 3 over a predetermined length.

  Next, the process corresponding to the 2nd mold process and the 4th mold process in a claim is performed. The second molding step is a step performed on the coil end portion 3a on the open end 1a side of the casing 1, and the fourth molding step is a step performed on the coil end portion 3b on the open end 1b side of the casing 1. The second molding step and the fourth molding step may be performed simultaneously, or one of them may be performed in advance.

  In this step, as shown in FIG. 3, first, the rotor 5 is accommodated inside the stator core 3, and the both ends are opened with the rotating shaft 5 a of the rotor 5 protruding from both the open ends 1 a and 1 b of the casing 1. Ends 1a and 1b are closed with end members 7 and 7, respectively.

  Thereby, the bearing part 9 provided in the inner peripheral surface near the front-end | tip of the cyclic | annular protrusion 7a which protrudes into the inside of the casing 1 from each edge part member 7 bearings the rotating shaft 5a of the rotor 5 rotatably. In addition, the annular seal member 11 provided on the outer peripheral surface near the tip of the annular protrusion 7a is in elastic contact with the inner peripheral surfaces of the first mold portions 13a and 13b of the coil end portions 3a and 3b, respectively.

  When the seal member 11 provided on each end member 7 is brought into elastic contact with the inner peripheral surfaces of the first mold portions 13a and 13b, annular spaces 25a and 25b are formed around the coil end portions 3a and 3b, respectively. . Each annular space 25a, 25b includes an inner peripheral surface of the casing 1, front end surfaces of the first mold portions 13a, 13b of the coil end portions 3a, 3b, end members 7, 7, and seal members 11, 11. By this, it becomes a space surrounded by a sealed state.

  The annular spaces 25a and 25b described above are also gaps existing between the first mold portions 13a and 13b of the coil end portions 3a and 3b and the casing 1 and the end member 7. Therefore, in order to transmit the heat of the coil end portions 3a and 3b to the casing 1 and the end member 7 through the mold resin, it is necessary to fill the annular spaces 25a and 25b with the mold resin.

  Therefore, the mold resin is filled and filled in the annular spaces 25a and 25b from the gate 7b provided in each end member 7. At this time, the seal member 11 is elastically contacted with the first mold portions 13 a and 13 b to seal, so that the mold resin is prevented from flowing into the air gap between the stator core 3 and the rotor 5.

  When the mold resin filled and filled in the annular spaces 25a and 25b is cooled and cured, as shown in FIG. 4, the second mold portion 15a is connected to the first mold portions 13a and 13b of the coil end portions 3a and 3b. , 15b are formed. And the first and second mold parts 13a, 15a, 13b, 15b of the coil end parts 3a, 3b completely fill the gaps between the coil end parts 3a, 3b and the casing 1 or the end member 7, Heat generated in the coil end portions 3 a and 3 b is transmitted to the casing 1 and the end member 7.

  In addition, when the process of the manufacturing method of the resin mold stator demonstrated above is shown with a flowchart, it will become like FIG.

  According to the manufacturing method of the resin mold stator of the present embodiment described above, the first mold portions 13a and 13b formed on the coil end portions 3a and 3b by the molding using the masking jig 21, the casing 1 and The step of forming the second mold portions 15a and 15b by molding in the annular spaces 25a and 25b constituted by the gaps with the end members 7 that close the open ends 1a and 1b was adopted. For this reason, it is possible to form coatings (first and second mold portions 13a, 15a, 13b, 15b) with good adhesion to the casing 1 and the end member 7 on the respective coil end portions 3a, 3b. it can.

  In the embodiment described above, the mold resin is filled from the open end 1b of the casing 1 when the first mold portions 13a and 13b are formed with respect to the coil end portions 3a and 3b of the open ends 1a and 1b of the casing 1. However, for example, a gate communicating with the annular space 23a of FIG. 1 may be provided in the masking jig 21 or the casing 1, and the mold resin may be filled there from there.

  Moreover, in embodiment mentioned above, the case where formation of 1st mold part 13a, 13b with respect to coil end part 3a, 3b of both the open ends 1a, 1b of the casing 1 was performed simultaneously was demonstrated. However, the formation of the first mold portion 13a with respect to the coil end portion 3a of the open end 1a and the formation of the first mold portion 13b with respect to the coil end portion 3b of the open end 1b may be performed separately.

  In that case, the formation of the first mold portion 13b for the coil end portion 3b of the open end 1b may be performed in the same process as the formation of the first mold portion 13a for the coil end portion 3a of the open end 1a. Therefore, the steps after the step corresponding to the third mold step in the claims are omitted from the steps corresponding to the first mold step in the claims.

  Furthermore, in the above-described embodiment, the case where the casing 1 has the open ends 1a and 1b at both ends has been described as an example. For example, one end portion (open end 1b side) of the casing 1 is the end. The manufacturing method of the present invention can also be applied when the closed member is integrated with the member 7. In that case, in the first molding step, the mold resin that fills the gap S between the stator core 3 and the insertion portion 21 c of the masking jig 21 and reaches the coil end portion 3 b side enters the internal space of the closed end of the casing 1. Mold resin may be injected from the gate at the closed end until it is full.

  In the present embodiment, the seal member 11 is provided on the outer peripheral surface of the annular protrusion 7a having the bearing portion 9 provided on the inner peripheral surface. However, the portion can be elastically contacted with the inner peripheral surfaces of the first mold portions 13a and 13b. As long as the seal member 11 can be disposed in any manner, the configuration in which the seal member 11 is disposed is arbitrary.

  In addition, the annular protrusion 7a of the end member 7 is provided in order to arrange the bearing portion 9 at a location near the rotor 5 where the rotating shaft 5a can be stably supported. Therefore, if the sealing member 11 is provided on the outer peripheral surface of the annular protrusion 7a, the sealing member 11 naturally comes into elastic contact with the outer peripheral surface portion of the first mold portions 13a and 13b that is closer to the end surface of the stator core 3.

  For this reason, even if the formation length of the first mold portions 13a and 13b from the end face of the stator core 3 is short, the seal member 11 is surely brought into elastic contact with the outer peripheral surfaces of the first mold portions 13a and 13b, and each annular space 25a. 25b can be improved. Thereby, when forming 2nd mold part 15a, 15b, it can prevent that mold resin flows in into the air gap of the stator core 3 and the rotor 5. FIG.

DESCRIPTION OF SYMBOLS 1 Casing 1a, 1b Open end 3 Stator core 3a, 3b Coil end part 5 Rotor 5a Rotating shaft 7 End part member 7a Annular projection 7b Gate 9 Bearing part 11 Seal member 13a, 13b 1st mold part 15a, 15b 2nd mold part 21 Masking jig 21a Base part 21b Step part 21c Insertion part 23a Annular space 23b Annular open space 25a, 25b Annular space S Gap

Claims (3)

A method of manufacturing a resin-molded stator in which coil end portions respectively protruding from both end portions of an annular stator core housed in a cylindrical casing are coated with a mold resin,
The stator core is housed inside from the open end of the casing, the open end is closed with a masking jig, and the end opposite to the open end is inserted with the masking jig inserted inside the stator core. By filling the casing with the mold resin from the side, at least the coil end portion of the coil end portion positioned on the open end side is coated with the mold resin at a predetermined length from the stator core end portion. A first molding step for forming a proximal end side annular covering portion;
In a state where the open end from which the masking jig has been removed is closed with an end member, an annular seal member provided on the end member is brought into elastic contact with the inner peripheral surface of the base end side annular covering portion, An annular space surrounded by the casing, the end member, the seal member, and the proximal-side annular covering portion is formed, and the annular space is filled with a mold resin, and the coil end on the open end side is formed. A second molding step for forming a distal end side annular covering portion connected to the proximal end side annular covering portion in the part;
The manufacturing method of the resin mold stator characterized by including. The casing has the open ends at both ends,
In the first molding step, the open ends of the casing are filled with mold resin from the other open end of the casing in a state where one open end of the casing is closed with the masking jig. A coil end portion having a predetermined length from at least each stator core end portion is coated with the mold resin, and the base end side annular covering portion is formed on each coil end portion. 3 mold steps are included,
In the state where the other open end from which the masking jig is removed is closed with the end member, the sealing member of the end member is covered with the inner peripheral surface of the base-side annular covering portion on the other open end side. To form an annular space surrounded by the casing, the end member, the seal member, and the proximal-side annular covering portion on the other open end side, and mold resin is placed in the annular space. A fourth mold step of filling the coil end portion on the other open end side to form a distal end side annular covering portion connected to the proximal end side annular covering portion;
The method for producing a resin molded stator according to claim 1. The end member has an annular protrusion that protrudes in an annular shape inside the casing in a state in which the open end is closed, and a bearing portion provided on an inner peripheral surface of the annular protrusion,
The seal member is provided on the outer peripheral surface of the annular protrusion,
In the second molding step, or in the second molding step and the fourth molding step, the rotation shaft of the rotor disposed inside the stator core in the casing is supported by the bearing portion of the end member. Then, the sealing member is elastically contacted with the inner peripheral surface of the proximal end side annular covering portion,
The method for producing a resin molded stator according to claim 1 or 2.

Images