JP2016116418A - Coil winding component of rotary electric machine, and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil winding component of a rotary electric machine, and a manufacturing method of the same in which displacement of a plurality of plates in a core can be suppressed while winding the coil conductive wire so that workability of the winding work of the coil conductive wire and product quality can be improved.SOLUTION: In a coil winding component, a core 9 is constituted by laminating a plurality of plates 8 having magnetism. An insulator 10 comprises: a resin molding part 40; and an insulation paper 20 which is connected with the resin molding part 40 and is arranged to cover at least one part of circumferential direction end surface of a tooth part. The insulation paper 20 is provided while at least one end of the lamination direction both end surfaces of the tooth part is opened. The resin molding part 40 comprises: a pair of wall parts which contacts with the lamination direction both end surfaces of the tooth part; and a lamination straddling part which straddles a plurality of plates 8 in a lamination direction at the circumferential direction both sides of the tooth part to connect with the wall parts. The resin molding part 40 is integrally molded with respect to the tooth part and the insulation paper.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a coil wound part of a rotating electrical machine used for vehicle driving, regenerative power generation, and the like, and a method for manufacturing the same.

In a rotating electrical machine used for vehicle driving, regenerative power generation, and the like, a stator and a rotor are provided with coil winding parts for winding a coil conductor.
For example, a stator is known in which a plurality of divided stator pieces arranged in an annular shape are constituted by a coil winding component and a coil conductor wound around the coil winding component.

  The coil winding component used here includes a core formed by laminating a plurality of magnetic plates such as electromagnetic steel plates in the axial direction, and an insulator made of an insulating resin or the like fixed to the core. The core has a teeth portion around which a coil conductor is wound via an insulator. The insulator is usually formed by a plurality of split cylinder-like divided blocks, and is attached from the outside to the outer periphery of the tooth portion of the core.

By the way, in the coil winding component, the space factor of the coil conductor is important in increasing the magnetomotive force of the rotating electrical machine. For this reason, it is effective to reduce the thickness of the insulator fixed to the core, but there is a limit to reducing the overall thickness of the insulator.
Therefore, a coil-wound component in which a part of the insulator is formed of an insulating sheet such as an insulating film or insulating paper has been devised (for example, see Patent Document 1).

  The coil-wound component described in Patent Document 1 includes a thin insulating film (insulating sheet) covering the circumferential end surface of the tooth portion, and a resin mold coating (fixed to the end surface in the axial direction (stacking direction) of the teeth portion ( The axial end of the insulating film that covers the circumferential end surface of the tooth portion is integrally molded with the resin molded portion that covers the axial end surface of the tooth portion. In this coil-wound component, since the end surface in the circumferential direction of the tooth portion is made of a thin insulating film, the space factor of the coil conductor wound around the tooth portion can be increased.

  Further, the coil-wound component described in Patent Document 2 includes a thin insulating paper (insulating sheet) that covers the circumferential end surface and the axial end surface of the tooth portion, and an insulating paper on the axial end surface of the tooth portion. And a resin molded body attached from above. Also in the case of this coil-wound component, since the circumferential end surface of the teeth portion around which the coil conductor is wound is formed of thin insulating paper, the space factor of the coil conductor can be increased.

JP 2005-86950 A JP 2013-132110 A

  However, in the coil wound parts described in Patent Documents 1 and 2, an insulating sheet (insulating film or insulating paper) having low rigidity is covered with the circumferential end surface of the tooth part and fixed to the tooth part. The coil conductor is wound on an insulator including an insulating sheet. For this reason, when a large winding force is applied to the coil conductor when the coil conductor is wound, there is a concern that the plurality of core plates laminated through the insulating sheet portion having low rigidity may be displaced and the entire core may be twisted. Is done. If the core is twisted when the coil conductor is wound, an operation for correcting the product shape is required, and a large load acts on a part of the insulating sheet.

  Accordingly, the present invention provides a coil winding for a rotating electrical machine capable of suppressing the shift of a plurality of core plates during winding of the coil conductor, thereby improving the winding workability of the coil conductor and improving the product quality. It is an object of the present invention to provide a rotating part and a manufacturing method thereof.

  In order to solve the above problems, the following configuration is adopted in the coil-wound component of the rotating electrical machine and the manufacturing method thereof according to the present invention.

  The invention according to claim 1 is configured by laminating a plurality of magnetic plates (for example, the plate 8 of the embodiment), and extends along the radial direction to form a coil conductor (for example, the coil conductor 2 of the embodiment). ) Is wound around the core (for example, the core 9 of the embodiment) having the teeth portion (for example, the teeth portion 12 of the embodiment), and is fixed to the teeth portion of the core and between the core and the coil conductor. In the coil winding component (for example, the coil winding component 7 of the embodiment) of the rotating electrical machine including the insulator (for example, the insulator 10 of the embodiment) interposed in the insulator, the insulator is a resin molded portion (for example, implementation) Resin molded portion 40) and an insulating sheet that is connected to the resin molded portion and arranged to cover at least a part of the circumferential end surface of the teeth portion. (For example, the insulating paper 20 of the embodiment), and the insulating sheet has at least one of both end surfaces in the stacking direction of the teeth portion opened, and the resin molded portion is the teeth portion. The pair of walls straddling the plurality of plates in the laminating direction on both sides in the circumferential direction of the teeth portion, such as a pair of wall portions (for example, the front walls 16b and 16c of the embodiment) facing both end surfaces in the laminating direction It is characterized by being integrally molded with respect to the teeth part and the insulating sheet so as to have a laminated straddle part (for example, the outer flange 16d and the inner flange 16e of the embodiment) connecting the parts. is there.

Thereby, when the resin molding part of the insulator is molded integrally with the tooth part of the core and the insulating sheet, at least a part of the circumferential end surface of the tooth part of the plurality of plates of the core is covered with the insulating sheet of the insulator. . At this time, the pair of wall portions of the resin molded portion are in contact with both end surfaces of the teeth portion in the stacking direction, and the stack straddling portion of the resin molded portion straddles a plurality of plates in the stacking direction and connects the pair of wall portions to each other. . For this reason, the insulating sheet molded integrally with the resin molding part is held with high rigidity by the laminated straddling part of the resin molding part.
Therefore, even when a winding force (tension) is applied to the coil conductor when the coil conductor is to be wound around the core on which the insulator is mounted, the occurrence of deviations in the plurality of plates of the stacked core is suppressed. It is possible to suppress the entire core from being twisted.

Here, when the insulating sheet and the resin molded portion are formed in advance as an integrated insulator and the insulator is fitted into the tooth portion of the core, the following inconvenience occurs.
Since the insulator must be formed in a size that allows insertion into the teeth part in consideration of variations in the thickness of the core in the stacking direction, a gap is generated between the core and the insulator, and the coil-wound component There is a possibility that the size of the coil conductor increases and the space factor of the coil conductors also decreases.
Furthermore, when the insulating sheet is formed in, for example, a cylindrical shape and the cylindrical portion covers the periphery of the tooth portion, an extra length is generated in the insulating sheet due to variations in the thickness of the core in the stacking direction. There is concern about wrinkles and distortion.
On the other hand, in the invention according to claim 1, the resin molded portion connects the pair of wall portions in contact with both end surfaces in the stacking direction of the teeth portion and the pair of wall portions across the plurality of plates in the stacking direction. Since the core is integrally molded with the tooth portion and the insulating sheet so as to have the laminated straddling portion, the core is formed by laminating a plurality of plates. Even if there is variation, the resin molded part is molded so that it is in close contact with the core, so the variation in the thickness of the core in the stacking direction can be canceled by the resin molded part, increasing the size and taking up space A decrease in rate can be suppressed.
Further, according to the invention according to claim 1, since the insulating sheet is open at least one of the both end surfaces of the teeth portion in the stacking direction, the thickness of the core in the stacking direction varies. However, it is possible to form an insulator by closely attaching the insulating sheet to the surface of the tooth portion while suppressing wrinkles and distortion of the insulating sheet, and it is possible to suppress a decrease in the space factor.

According to a second aspect of the present invention, in the coil-wound component of the rotating electrical machine according to the first aspect, the insulating sheet disposed in the tooth portion includes one end in the circumferential direction at the radial end portion of the tooth portion, or A bent extension portion (for example, the first bent extension portion 20b and the second bent extension portion 20c of the embodiment) bent to the other side is provided, and the resin molded portion is joined to the bent extension portion. To be configured.
In this case, since the bending extension part of the insulating sheet is joined to the resin molded part, the insulating sheet is held by the resin molded part with high rigidity. Moreover, even if the resin molded portion is deteriorated by external force or internal stress, the shape of the insulator can be held by the bent extension portion of the insulating sheet.

According to a third aspect of the present invention, in the coil wound part of the rotating electric machine according to the second aspect, at least a part of the bent extension portion is embedded in the resin molded portion.
In this case, since at least a part of the bent extension portion is embedded in the resin molded portion, the bent extension portion is difficult to peel from the resin of the resin molded portion.

According to a fourth aspect of the present invention, in the coil wound part of the rotating electric machine according to the third aspect, the resin molded portion is provided with a portion that exposes a part of the bent extension portion to the outside.
In this case, when the core and insulating sheet are placed in the mold, and the insulator is molded by filling the mold with resin, a part of the insulating sheet is pressed against a part of the core with a pressing protrusion in the mold. be able to. For this reason, it is possible to prevent the insulating sheet from dripping when the resin is filled into the mold. Therefore, the product quality of the molded product can be improved.

According to a fifth aspect of the present invention, in the coil-wound component of the rotating electrical machine according to the third or fourth aspect, the bent extension portion is arranged in a range not protruding from the resin molded portion.
In this case, since the end of the bent extension portion of the insulating sheet does not protrude from the resin molded body, the end of the insulating sheet touches the surrounding members and hinders assembly, or is caught in other members during use. It will not be.

According to a sixth aspect of the present invention, in the coil winding part of the rotating electric machine according to the fifth aspect, the radial end of the tooth portion has a flange portion extending to one side or the other side in the circumferential direction (for example, The flanges 11a and 13a) of the embodiment are provided, and the extension length of the bent extension part arranged in the collar part is the exposed boundary position of the insulating sheet on the teeth part (for example, the The coil in which a path (for example, path R in the embodiment) from the exposed boundary position P) to the flange through the bent extension part and the resin molded part is wound around the teeth part. It was made to set to the length which maintains the insulation distance between conducting wire and the said collar part.
In this case, when the coil conductor is wound around the teeth portion from above the insulator fixed to the core, the insulator between the coil conductor and the core is insulated. However, if the path from the exposed boundary position of the insulating paper on the tooth part to the collar part via the bent extension part and the insulating resin joint is short, the path is an electrical short circuit path between the coil conductor and the core. It is possible that For this reason, the electrical extension short-circuit between the coil conductor and the core is reliably prevented by setting the extension length of the bent extension part so that the path can be maintained at an insulation distance.

The invention according to claim 7 is the coil-wound component of the rotating electrical machine according to any one of claims 1 to 6, wherein the core is a divided core piece divided into a plurality in the circumferential direction, and the divided core A plurality of pieces were arranged in a circular shape.
In this case, since the shape of the core molded integrally with the resin molding portion is simplified, the shape of the molding die can be simplified, and the insulating sheet can be easily and accurately disposed on the molding die. For this reason, an insulating sheet can be correctly positioned in a shaping | molding die, and can be made to closely_contact | adhere to a teeth part.

According to an eighth aspect of the present invention, in the method for manufacturing a coil-wound component of a rotating electrical machine according to any one of the third to sixth aspects, a mold for inserting the core and the insulating sheet and filling a resin (for example, The mold 25) of the embodiment is prepared, the core and the insulating sheet are installed in the mold, and the bending extension portion of the insulating paper is moved forward and backward. The holding member 32) is held in contact with the core, and in that state, the resin in the mold is filled with the resin, and the holding member is retracted from the cavity immediately before the resin flows in. .
In this case, since the bent extension portion of the insulating sheet is held in contact with the core by the holding member until immediately before the resin flows, the bent extension portion separates from the core when the resin is filled. Can be prevented. Therefore, the bending extension part can be reliably embedded in the resin molding part.

According to a ninth aspect of the present invention, in the coil wound part of the rotating electrical machine according to any one of the first to seventh aspects, the radial end portion of the tooth portion extends to one side or the other side in the circumferential direction. The flange part (for example, collar part 11a, 13a of embodiment) to take out is provided, and the resin of the said resin molding part is in the area | region which covers the part adjacent to the said collar part of the said teeth part among the said insulators. A resin bulging portion (for example, the winding guide 22 of the embodiment) that bulges so as to press down the surface of the insulating sheet is provided.
In this case, since the resin bulging portion provided in the region covering the portion adjacent to the flange portion of the insulator presses the surface of the insulating sheet, the insulating bulge and the lifting can be suppressed by the resin bulging portion. . Also, when the core and insulating sheet are placed in the mold, and the insulator is molded by filling the mold with resin, the resin wraps around the part that forms the resin bulge in the mold. The insulation sheet set in the mold can be prevented from curling.

  According to the present invention, the pair of wall portions of the resin molded portion abuts against both end surfaces of the teeth portion in the stacking direction, and in that state, the stack straddling portion of the resin molded portion straddles the plurality of plates in the stacking direction. Since the insulating sheet is molded integrally with the resin molded portion and held with high rigidity, the plurality of core plates can be prevented from shifting when the coil conductor is wound. . Therefore, according to the present invention, the winding operation of the coil conductor can be efficiently performed, and the product quality of the final product can be improved.

It is a front view of the stator of the rotary electric machine of one Embodiment of this invention. It is a perspective view of the division | segmentation stator piece of the stator of one Embodiment of this invention. It is a side view of the division | segmentation stator piece of the stator of one Embodiment of this invention. It is a perspective view of the coil winding components of one embodiment of this invention. It is a perspective view of the coil winding components of one embodiment of this invention. It is sectional drawing corresponding to the VI-VI cross section of FIG. 4 of the coil winding components of one Embodiment of this invention. It is a partial section side view of the coil winding components of one embodiment of this invention. It is a perspective view of the insulating paper of the coil winding components of one embodiment of this invention. It is an enlarged view of the IX part of FIG. 6 of the coil winding components of one Embodiment of this invention. It is an enlarged view of the X section of FIG. 6 of the coil winding components of one Embodiment of this invention. It is a graph which shows the relationship between a withstand voltage and creepage distance. It is sectional drawing of the shaping | molding die which manufactures the coil winding components of one Embodiment of this invention. It is sectional drawing of the shaping | molding die which manufactures the coil winding components of one Embodiment of this invention. It is a perspective view of the shaping | molding die which manufactures the coil winding components of one Embodiment of this invention. It is sectional drawing for demonstrating operation | movement in the shaping | molding die which manufactures the coil winding components of one Embodiment of this invention.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a view showing a stator 1 incorporated in the rotating electrical machine of this embodiment.
The rotating electrical machine of this embodiment is a three-phase AC type rotating electrical machine used for vehicle driving and regenerative power generation of an electric vehicle or a hybrid vehicle, and a rotor (not shown) is rotatably disposed inside the annular stator 1. Has been. The rotor is connected to the axle of the vehicle through a speed reduction mechanism or the like so that power can be transmitted.

  The stator 1 includes an annular stator body 3 on which a plurality of coil conductors 2 are mounted by salient pole concentrated winding, and a substantially cylindrical holder 4 into which the stator body 3 is press-fitted and fixed. Power supply terminals 5U, 5V, and 5W of corresponding phases are connected to the power supply side ends of the U-phase, V-phase, and W-phase coil conductors 2 drawn outward in the radial direction. In this embodiment, the coil conductor 2 is a rectangular wire having a horizontally long rectangular cross section.

  The stator body 3 is configured by a plurality of divided stator pieces 6 assembled in an annular shape. In each divided stator piece 6, the coil conducting wire 2 is wound around a coil winding part 7 having a substantially fan shape when viewed from the front. One end side of each coil conducting wire 2 wound around the coil winding part 7 is connected to the power supply terminals 5U, 5V, 5W of the corresponding phases collected for each phase, and the other end side of each coil conducting wire 2 is They are connected to each other at the midpoint connecting portion 15. Therefore, in the stator 1 of this embodiment, the coil conducting wires 2 of each phase are connected by Y-shaped connection.

FIG. 2 is a perspective view showing the divided stator piece 6 in which the coil conducting wire 2 is wound around the coil winding component 7, and FIG. 3 is a side view of the divided stator piece 6. 4 and 5 are perspective views of the coil winding component 7. In addition, including other figures, the arrows R and Ax in the figure indicate the radial direction and the axial direction of the stator main body 3, respectively.
The coil winding component 7 includes a core 9 formed by laminating a plurality of magnetic plates 8 such as electromagnetic steel plates, and an insulator 10 that is fixed to the outer region of the core 9 and electrically insulates the core 9. I have. The plurality of plates 8 constituting the core 9 are stacked along the axial direction Ax of the stator body 3.

FIG. 6 is a cross-sectional view of the coil winding component 7 corresponding to the VI-VI cross section of FIG. 4, and FIG. 7 is a partial cross-sectional side view of the coil winding component 7.
The core 9 includes a back yoke portion 11 that forms an annular region on the outer peripheral side of the stator body 3, and a teeth portion 12 that protrudes from the inner peripheral side of the back yoke portion 11 toward the inner side in the radial direction R of the stator body 3. And a magnetic inlet / outlet part 13 provided at the extending end of the tooth part 12. The back yoke portion 11 has a pair of flange portions 11a and 11a projecting on both sides along the circumferential direction of the stator body 3, and the magnetic entry / exit portion 13 is also formed on both sides along the circumferential direction of the stator body 3. It has a pair of collar parts 13a and 13a which project to. When the back yoke portion 11 is press-fitted into the holder 4, the adjacent cores 9 are connected to form an annular magnetic path.
In addition, although the tooth part 12 of this embodiment is formed in a rectangular shape whose cross section orthogonal to the extending direction is long in the axial direction Ax, in the following, for convenience of explanation, one of the teeth part 12 in the axial direction Ax. The end face is referred to as “front end face”, the other end face is referred to as “rear end face”, and the end faces on both sides intersecting with the front end face and the rear end face are referred to as “side end faces”. In this embodiment, the side end surface of the tooth portion 12, the lower surfaces of the flange portions 11 a and 11 a, and the upper surface of the flange portions 13 a and 13 a constitute a coil holding slot in the core 9.

  The insulator 10 includes an outer peripheral surface of the tooth portion 12 of the core 9, a coil winding portion 16 that covers a part of the flange portions 11 a, 11 a, 13 a, and 13 a, and a coil conductor 2 that is wound around the coil winding portion 16. And a conducting wire guide portion 17 for guiding the leading end side and the terminating end drawing portion. The conducting wire guide portion 17 includes a support wall 17a extending outward in the radial direction R from a region covering the front end face of the tooth portion 12, a guide wall 17b projecting from the support wall 17a toward the axial direction Ax, have.

The coil winding portion 16 of the insulator 10 covers the side walls 16a and 16a covering the side end surface of the tooth portion 12 of the core 9, the front wall 16b covering the front end surface of the tooth portion 12, and the rear end surface covering the teeth portion 12. It has a wall 16c, an outer flange 16d that covers the lower surface of the flange portion 11a on the back yoke portion 11 side, and an inner flange 16e that covers the upper surface side of the flange portion 13a on the magnetic input / output portion 13 side. In addition, in the part connected to the front wall 16b of the outer flange 16d, there is a recess 18 for pulling out the leading end side and the terminating end drawing portion of the coil conducting wire 2 wound around the coil winding portion 16 toward the conducting wire guide portion 17 side. Is provided.
In this embodiment, the front wall 16b and the rear wall 16c constitute a wall portion that faces both end surfaces of the teeth portion 12 in the stacking direction.

The insulator 10 is formed of insulating paper 20 and insulating resin. The insulating paper 20 is used over almost the entire side walls 16 a and 16 a on both sides of the coil winding portion 16. The insulating paper 20 used here is preferably a paper material excellent in electrical insulation and strength, such as aramid insulating paper.
As will be described in detail later, the insulator 10 is formed integrally with the core 9 by disposing the core 9 and the insulating paper 20 in a mold and filling the mold with an insulating resin in this state. In this embodiment, a portion (a portion other than the insulating paper 20) of the insulator 10 that is formed of an insulating resin at the time of mold forming constitutes the resin molded portion 40.

FIG. 8 is a view showing insulating papers 20 and 20 used in the insulator 10.
A pair of insulating papers 20, 20 having a symmetrical shape is used for the insulator 10. The insulating paper 20 includes a main part 20a disposed on the side wall 16a of the coil winding part 16, a first bent extension part 20b provided on one end side of the main part 20a, and the other end side of the main part 20a. And a second bent and extended portion 20c provided on the head. The first bent extension portion 20b and the second bent extension portion 20c are bent at substantially right angles outward (one side and the other side in the circumferential direction) with respect to the main portion 20a. The first bent extension portion 20b is set to have a longer extension length than the second bent extension portion 20c. The first bent extension portion 20b is disposed so as to overlap the lower surface of the flange portion 11a on the back yoke portion 11 side, and the second bent extension portion 20c overlaps the upper surface of the flange portion 13a on the magnetic input / output portion 13 side. Arranged.

FIG. 9 is an enlarged view of the IX portion of FIG. 6, and FIG. 10 is an enlarged view of the X portion of FIG.
As shown in FIGS. 6, 9, and 10, the side wall 16 a of the coil winding portion 16 of the insulator 10 is substantially composed of the main portion 20 a alone of the insulating paper 20, and the back yoke portion 11 side and the magnetic input / output portion 13 side. Each of the flange portions 11a and 13a is formed by bonding a first bent extension portion 20b and a second bent extension portion 20c of the insulating paper 20 to an insulating resin. Therefore, the main portion 20 a of the insulating paper 20 that forms the side wall 16 a of the coil winding portion 16 is fixed to the laminated portion of the plurality of plates 8 in the coil holding slot region of the tooth portion 12. In the case of this embodiment, the first bent extension portion 20b and the second bent extension portion 20c are embedded in the insulating resin. In addition, the front wall 16b and the rear wall 16c of the coil winding portion 16 of the insulator 10 are made of a single insulating resin, and the end of the insulating resin that goes around in the direction of the side wall 16a of the front wall 16b and the rear wall 16c. The edge is joined to the side end of the main portion 20 a of the insulating paper 20.
Moreover, the conducting wire guide part 17 of the insulator 10 is comprised with the insulating resin single-piece | unit. Upper portions of the front wall 16b and the rear wall 16c are joined to the outer flange 16d and the conductor guide portion 17, and lower portions of the front wall 16b and the rear wall 16c are joined to the inner flange 16e.

  By the way, in the insulator 10 according to this embodiment, the insulating resin of the outer flange 16d and the inner flange 16e of the coil winding portion 16 extends in the axial direction Ax so as to straddle the laminated portion of the plurality of plates 8 of the core 9. In addition, the insulating paper 20 is integrally joined. In this embodiment, the insulating resin of the outer flange 16d and the inner flange 16e constitutes a stacked straddling portion. The outer flange 16d and the inner flange 16e that constitute the stacked straddling portion connect the front wall 16b and the rear wall 16c that are in contact with both end surfaces of the teeth portion 12 in the stacking direction, respectively.

  As shown in FIGS. 5 and 7, the first bent and extended portion 20 b of the insulating paper 20 is exposed to the outside on the outer flange 16 d of the insulator 10 fixed to the lower surface of the flange portion 11 a. An exposure window 21 is provided.

Further, as shown in FIG. 9, the first bent and extended portion 20b of the insulating paper 20 is disposed in a range that does not protrude from the end portion of the insulating resin of the outer flange 16d.
Similarly, as shown in FIG. 10, the second bent and extended portion 20c of the insulating paper 20 is disposed in a range that does not protrude from the end portion of the insulating resin of the inner flange 16e. The extension length of the second bent extension portion 20c having a shorter extension length than that of the first bent extension portion 20b is set as follows.

That is, the extension length of the second bent extension portion 20c is from the exposed boundary position P of the insulating paper 20 fixed on the tooth portion 12 via the joint portion of the second bent extension portion 20c and the insulating resin. Thus, the path R leading to the flange portion 13a of the core 9 is set to a length that maintains an insulation distance between the coil conductor 2 wound around the insulating paper 20 and the flange portion 13a.
FIG. 11 is a graph showing the relationship between the withstand voltage and the creepage distance. As shown in the graph, the withstand voltage increases approximately in proportion to the increase of the creepage distance. For this reason, in this embodiment, the above-described path R is set to be not less than the creeping distance L ₁ that can ensure the withstand voltage P ₁ .

Further, as shown in FIGS. 2, 3, 5, etc., the coil winding portion 16 of the insulator 10 has a coil near the corner portion adjacent to the front wall 16b and the outer flange 16d of the one side wall 16a. A winding guide 22 having substantially the same width as the conductor 2 is formed. The winding guide 22 is formed to bulge with respect to the general surfaces of the front wall 16b and the side wall 16a with an insulating resin. The winding guide 22 functions as a guide for the coil conductor 2 when the coil conductor 2 starts to be wound around the coil winding portion 16 of the insulator 10 while being shifted obliquely.
A part 22a of the winding guide 22 formed of an insulating resin bulges so as to press down on a part of the surface of the main part 20a of the insulating paper 20 and the first bent extension part 20b of the side wall 16a. In this embodiment, the winding guide 22 forms a resin bulging portion.

It continues and the manufacturing method of the coil winding components 7 is demonstrated.
In the coil-wound component 7 of this embodiment, the core 9 and the insulating paper 20 are inserted, and the resin molding portion 40 of the insulator 10 is molded.

12 and 13 are cross-sectional views of a mold 25 for manufacturing the coil-wound component 7, and FIG. 14 is a perspective view showing a part of the mold 25.
The mold 25 includes left and right side molds 25A and 25B that shape the side part of the insulator 10 by pressing the core 9, a lower mold 25C and an upper mold 25D that press the core 9 from the radial direction R, and a front part of the insulator 10. A front mold 25E and a rear mold 25F for shaping the rear part are provided.

  The left and right side molds 25A and 25B are provided with convex portions 26 corresponding to the coil holding slots of the core 9, and cavity grooves 27 and 28 for modeling the outer flange 16d and the inner flange 16e of the insulator 10. The front mold 25E is provided with a cavity groove 29 for integrally forming the conductor guide portion 17 of the insulator 10, the outer flange 16d, the front wall 16b, and the inner flange 16e, and the rear mold 25F has an outer flange 16d. A cavity groove 30 for integrally shaping the rear wall 16c and the inner flange 16e is provided.

First, the insulating paper 20 is attached to the side surface of the tooth portion 12 of the core 9 and the flange portions 11a and 13a. At this time, the insulating paper 20 has the first bent extension portion 20b and the second bent extension portion 20c bent in advance with respect to the main portion 20a, and the main portion 20a is formed on the side surface of the tooth portion 12 of the core 9. At the same time, the first bent extension portion 20 b is brought into contact with the flange portion 11 a on the back yoke portion 11 side, and the second bent extension portion 20 c is brought into contact with the flange portion 13 a of the magnetic input / output portion 13. Next, in this state, the core 9 and the insulating papers 20 and 20 are set inside the mold 25 that is opened, and the mold 25 is clamped in this state. As a result, the upper and lower cavity grooves 27, 27 of the left and right side molds 25A, 25B are electrically connected to the cavity grooves 29, 30 of the front mold 25E and the rear mold 25F. As a result, the core 9 is surrounded in the mold 25. A continuous cavity is formed.
In this way, the cavity in the mold 25 that has been clamped is injected and filled with, for example, insulating resin melted from the front mold 25E and the rear mold 25F.

  Here, the guide forming recess 31 (see FIG. 14) for forming the winding guide 22 described above is continuously formed in the vicinity of the front upper end of the convex portion 26 of the one side mold 25B and the front mold 25E. Has been. The portion formed on the convex portion 26 of the side mold 25B of the guide shaping concave portion 31 is the first of the insulating paper 20 when the core 9 and the insulating paper 20 are set in the mold 25 and clamped as described above. It is located on the surface of the base part of the bending extension part 20b and the main part 20a. For this reason, when the insulating resin is introduced into the cavity and flows into the guide shaping recess 31, the insulating resin is filled so as to press down the surface of the insulating paper 20. Therefore, the rising of the first bent extension portion 20b of the insulating paper 20 on the side mold 25B side at the time of filling the insulating resin is suppressed by the insulating resin introduced into the guide shaping concave portion 31.

  Further, as shown in FIG. 14, the front die 25E is provided with a holding member 32 that can be moved forward and backward so as to face the cavity groove 27 of the other side die 25A. The holding member 32 protrudes in the direction of the cavity groove 27, so that the tip end portion of the first bent extension portion 20 b of the insulating paper 20 disposed in the cavity groove 27 is the flange portion 11 a on the back yoke portion 11 side. The first bent extension portion 20b can be held in the pressed state.

FIG. 15 is a diagram in which (A) and (B) sequentially show the behavior of the holding member 32 when the insulating resin flows into the cavity groove 27 from the teeth portion 12 side when the insulating resin is filled.
As shown in the figure, when filling the mold 25 with the insulating resin, the holding member 32 protrudes in the direction of the cavity groove 27, and the leading end of the first bent extension 20 b of the insulating paper 20 is held by the holding member 32. It is held on the flange 11a. The holding of the first bent extension portion 20 b by the holding member 32 is continued until immediately before the insulating resin flows into the front end side in the cavity groove 27. The holding member 32 is retracted from the cavity groove 27 immediately before the insulating resin flows into the distal end side in the cavity groove 27.

  In addition, pressing protrusions (not shown) are provided on the upper surfaces of the convex portions 26 of the left and right side molds 25A and 25B. The pressing protrusion is provided at a position corresponding to the exposed portion 21 of the outer flange 16d of the insulator 10, and when the insulating paper 20 is set in the mold 25 and clamped, the insulating paper 20 is fixed to the flange portion 11a. It works to press directly against.

  As described above, the coil-wound component 7 according to this embodiment is configured so that the almost entire area of the side wall 16a of the coil winding portion 16 of the insulator 10 is formed of the insulating paper 20. The space factor at the time of winding around the teeth part 12 via the winding part 16 can be improved efficiently.

  Further, in the coil-wound component 7 according to this embodiment, the front wall 16b and the rear wall 16c of the resin molded portion 40 of the insulator 10 are in contact with the end faces in the stacking direction of the teeth portion 12, and in this state The outer flange 16d and the inner flange 16e, which are parts, connect the front wall 16b and the rear wall 16c to each other, and the insulating paper 20 is molded integrally with the resin molding part 40 and held with high rigidity. Therefore, by adopting this coil winding part 7, it is possible to prevent the plurality of plates 8 of the core 9 from shifting when a strong winding force is applied to the core 9 when the coil conductor 2 is wound. Can do. Therefore, by adopting this coil winding part 7, the coil conductor 2 can be wound efficiently and the product quality of the final product can be improved.

  In particular, in the coil-wound component 7 according to this embodiment, the insulating paper 20 molded integrally with the resin molding portion 40 is not only the front wall 16b and the rear wall 16c of the resin molding portion 40 but also a laminated straddling portion. It is also held by the outer flange 16d and the inner flange 16e. For this reason, the insulating paper 20 can be stably held with higher rigidity. Therefore, the displacement of the insulating paper 20 when the coil conductor 2 is wound can be effectively suppressed.

  In general, when a core is configured by stacking a plurality of plates, it is necessary to regulate the mutual displacement by crimping the plates at a plurality of locations. On the other hand, in the case of the coil-wound component 7 in this embodiment, the peripheral area of the laminated plate 8 is the front wall 16b and the rear wall 16c of the resin molded portion 40, and the insulating paper 20 and the outer flange joined thereto. Since it is surrounded by 16d and the inner flange 16e, it is possible to prevent misalignment between the plates 8 without having to caulk the plates 8 constituting the split core piece at a plurality of locations. For this reason, generation | occurrence | production of the eddy current loss resulting from a crimping part can be prevented beforehand.

  Further, in the coil-wound component 7 according to this embodiment, the resin molded portion 40 has an outer flange 16 d that covers the front wall 16 b and the rear wall 16 c that are in contact with both end surfaces of the teeth portion 12 in the stacking direction and the stacked portion of the plate 8. In addition, the teeth portion 12 and the insulating paper 20 are integrally molded so as to have the inner flange 16e. For this reason, even when there are variations in the thickness in the stacking direction of the plates 8 constituting the core 9, the resin molded portion 40 is formed so as to be in close contact with the core 9 at the time of mold forming. Can be absorbed by the resin molding portion 40. For this reason, the fall of the space factor of the coil conducting wire 2 and the enlargement of the insulator 10 can be suppressed.

  In particular, in the case of the coil-wound component 7 according to this embodiment, the insulating paper 20 is not formed in an annular shape so as to surround the tooth portion 12 (at least one of both end surfaces in the stacking direction of the tooth portion 12 is open). Therefore, even when the thickness of the core 9 in the stacking direction varies, the insulating paper 20 is brought into close contact with the surface of the tooth portion 12 while suppressing the wrinkles and distortion of the insulating paper 20 to form the insulator 10. be able to. For this reason, it becomes more advantageous when raising the space factor of the coil conducting wire 2.

Incidentally, in the coil-wound component 7 according to this embodiment, the resin molded portion 40 is integrally molded with the tooth portion 12 and the insulating paper 20 to constitute the insulator 10. When the insulator is first integrated with the insulating paper to form the insulator, and the insulator is fitted into the tooth portion later, the collar portion cannot be formed at the radial end of the tooth portion. In this case, torque pulsation is likely to occur during operation of the rotating electrical machine, and noise and power are likely to decrease.
On the other hand, in the coil winding component 7 according to this embodiment, such a problem does not occur.

  The coil winding component 7 according to this embodiment is a divided core piece in which the core 9 is divided into a plurality of parts in the circumferential direction, and the divided core pieces are arranged in a plurality of rings and used as a part of the stator body 3. It has been. For this reason, since the shape of the core 9 molded integrally with the resin molding part 40 can be simplified, the shape of the molding die can be simplified, and the insulating paper 20 can be easily and accurately arranged in the molding die. . Therefore, by adopting this structure, the insulating paper 20 can be accurately positioned in the mold and brought into close contact with the tooth portion 12.

In addition, the coil-wound component 7 according to this embodiment is formed so that the outer flange 16d is formed with a substantially constant thickness so as to be along the entire inner peripheral surface of the flat flange portion 11a. Since the inner flange 16e is formed along the entire outer peripheral surface of the formed flange 13a, the thickness of the outer flange 16d or the inner flange 16e is increased, and the space factor of the coil conductor 2 is reduced. The rigidity of the resin molded portion 40 can be effectively increased while suppressing the occurrence of
Further, in order to provide a laminated straddling portion composed of the outer flange 16d or the inner flange 16e, the inner peripheral surface of the flange portion 11a or a part of the outer peripheral surface of the flange portion 13a is not recessed, and therefore, the core 9 is used. Can be prevented from affecting the magnetic path.

  In the coil-wound component 7 according to this embodiment, it is preferable to form both the outer flange 16d and the inner flange 16e from the viewpoint of increasing the rigidity of the resin molded portion 40, but the rigidity of the resin molded portion 40 is not limited. If only is secured, only the outer flange 16d or only the inner flange 16e may be formed. In this case, since one of the outer flange 16d and the inner flange 16e is not formed, the space factor of the coil conductor 2 can be further increased.

  Further, in the case of the coil winding component 7 according to this embodiment, the first bent and extended portions 20b and the second bent portions that are bent on the respective insulating papers 20 and cover each of the flange portions 11a and 13a of the core 9 are provided. A bent extension portion 20c is provided, and an insulating resin is joined to the first bent extension portion 20b and the second bent extension portion 20c to form an outer flange 16d and an inner flange 16e. For this reason, the coil winding component 7 can support the edge of the insulating paper 20 with high rigidity on the resin molding portion 40 via the first bent extension portion 20b and the second bent extension portion 20c. it can. Further, in the case of the coil-wound component 7 of this embodiment, since the resin molded portion 40 is joined to the first bent extended portion 20b and the second bent extended portion 20c of the insulating paper 20, the collar portion Even if the resin molding part 40 fixed to 11a, 13a may be deteriorated by external force or internal stress, the insulator 10 is insulated by the first bent extension part 20b and the second bent extension part 20c of the insulating paper 20. The shape can be maintained.

  Moreover, in the coil winding component 7 according to this embodiment, the first bent extension portion 20b and the second bent extension portion 20c of the insulating paper 20 are formed on the outer flange 16d and the resin molding portion 40 of the inner flange 16e. Since it is embedded inside, the first bent extension portion 20b and the second bent extension portion 20c are peeled off from the insulating resin during the winding operation of the coil lead wire 2 or due to deterioration with use over time. Can be suppressed.

  Further, in the coil winding component 7 according to this embodiment, a part of the first bent and extended portion 20b of the insulating paper 20 is exposed to the outside (an outer flange 16d) in the region fixed to the flange portion 11a of the insulator 10. An exposed portion 21 that is exposed is provided. For this reason, at the time of insert molding of the coil-wound component 7, when the insulating resin is filled in the mold 25, the first bent extension is performed by the pressing protrusions of the side molds 25 </ b> A and 25 </ b> B at a position corresponding to the exposed portion 21. The portion 20b can be pressed against the flange portion 11a of the core 9. Therefore, in the case of this coil-wound component 7, it is possible to prevent the insulating paper 20 from dripping when the molding die 25 is filled with the insulating resin, and as a result, the product quality of the molded product can be improved.

  Further, in the coil winding component 7 according to this embodiment, the first bent extended portion 20b and the second bent extended portion 20c of the insulating paper 20 are end portions of the insulating resins of the outer flange 16d and the inner flange 16e. Therefore, when the stator 1 is assembled, the end of the insulating paper 20 touches the surrounding members to prevent the assembly, or when the rotating electric machine is used, the end of the insulating paper 20 It can prevent being caught in the rotor.

  Furthermore, in the coil winding component 7 according to this embodiment, the extension length of the second bent extension portion 20c of the insulating paper 20 is such that the second bent extension portion 20c extends from the exposed boundary position P of the insulating paper 20. And a length that maintains an insulation distance between the coil conductor 2 wound around the path R leading to the flange portion 13a of the core 9 via the joint portion of the insulating resin and the flange portion 13a. For this reason, the electrical short circuit between the coil conducting wire 2 and the core 9 can be prevented reliably. In the case of this embodiment, the extension length of the first bent extension portion 20b of the insulating paper 20 is set longer than that of the second bent extension portion 20c. An electrical short circuit between the core 9 and the core 9 can be reliably prevented.

In the above-described method for manufacturing a coil-wound component, the core 9 and the insulating paper 20 are installed in the mold 25, and the first bent and extended portion 20b having a long extension length of the insulating paper 20 is provided. The holding member 32 that can be moved forward and backward is pressed and held on the flange portion 11a of the core 9, and in that state, the cavity in the mold 25 is filled with insulating resin, and the holding member 32 is released from the cavity just before the insulating resin flows. I try to retreat. For this reason, it is possible to prevent the first bent extension portion 20b from separating from the flange portion 11a on the core 9 side when the molding die 25 is filled with the insulating resin. Therefore, by adopting this manufacturing method, the first bent extension portion 20b can be reliably embedded in the insulating resin.
In the example described above, only the first bent and extended portion 20b of one insulating paper 20 is held by the holding member 32 in the mold 25, but the first of the other insulating paper 20 is the first. Similarly, the bending extension 20b can be held by the holding member 32 until just before the insulating resin flows. Further, when the extension length of the second bent extension portion 20c of the insulating paper 20 is long, the second bent extension portion 20c is similarly held by the holding member 32 until immediately before the insulating resin flows. You may do it.

  Further, in the coil winding component 7 according to this embodiment, the side wall 16a of the coil winding portion 16 of the insulator 10 is provided near the corner portion adjacent to the front wall 16b and the outer flange 16d of the one side wall 16a. A winding guide 22 that bulges so as to hold down the upper end side surface of the first bent extension portion 20b and the main portion 20a of the insulating paper 20 is formed of insulating resin. For this reason, at the time of manufacturing the coil-wound component 7, when the insulating resin is filled in the mold 25, the insulating resin wraps around the guide forming recess 31 in the mold 25 and presses the surface side of the insulating paper 20. become. Therefore, by adopting this structure, it is possible to prevent the insulating paper 20 set in the molding die 25 from being rolled during the manufacture of the coil-wound component 7.

  In addition, this invention is not limited to said embodiment, A various design change is possible in the range which does not deviate from the summary. For example, in the above embodiment, the insulating paper 20 is used as the insulator insulating sheet. However, the insulating sheet is not limited to the insulating paper 20 and may be an insulating film made of an insulating resin or the like.

DESCRIPTION OF SYMBOLS 2 ... Coil lead wire 7 ... Coil winding components 8 ... Plate 9 ... Core 10 ... Insulator 11a ... Gutter 12 ... Teeth 13a ... Gutter 16b ... Front wall (wall part)
16c ... Rear wall (wall part)
16d ... Outer flange (lamination straddle)
16e ... Inner flange (lamination straddle)
20 ... Insulating paper 20b ... 1st bending extension part (bending extension part)
20c ... 2nd bending extension part (bending extension part)
22 ... Winding guide (resin bulge)
25 ... Mold 32 ... Holding member 40 ... Resin molded part P ... Exposed boundary position R ... Path

Claims (9)

A core having a teeth portion that is configured by laminating a plurality of magnetic plates and that extends along the radial direction and around which the coil conductor is wound,
In the coil winding component of the rotating electrical machine, including the insulator fixed between the teeth of the core and interposed between the core and the coil conductor,
The insulator is
A resin molded part;
An insulating sheet that is connected to the resin molded part and disposed so as to cover at least a part of a circumferential end face of the teeth part;
The insulating sheet has an opening at least one of both end surfaces of the teeth portion in the stacking direction,
The resin molded part is
A pair of wall portions opposed to both end surfaces of the teeth portion in the stacking direction;
Molded integrally with the teeth portion and the insulating sheet so as to have a lamination straddling portion connecting the plurality of plates across the lamination direction and connecting the pair of wall portions on both sides in the circumferential direction of the teeth portion. A coil-wound component of a rotating electrical machine characterized by being made. The insulating sheet disposed in the tooth portion is provided with a bent extension portion that is bent to one side or the other side in the circumferential direction at a radial end portion of the tooth portion,
The coil wound part of the rotating electric machine according to claim 1, wherein the resin molded portion is joined to the bent extension portion.   The coil winding part of the rotating electrical machine according to claim 2, wherein at least a part of the bent extension portion is embedded in the resin molded portion.   The coil-wound component of the rotating electric machine according to claim 3, wherein the resin molded portion is provided with a portion that exposes a part of the bent extension portion to the outside.   5. The coil-wound component of the rotating electrical machine according to claim 3, wherein the bent extension portion is arranged in a range not protruding from the resin molding portion. The end of the teeth part in the radial direction is provided with a collar part extending to one side or the other side in the circumferential direction,
The extension length of the bent extension portion disposed in the flange portion is the junction length between the bent extension portion and the resin molding portion from the exposed boundary position of the insulating sheet on the tooth portion. 6. The rotating electrical machine according to claim 5, wherein the path leading to the flange portion is set to a length that maintains an insulation distance between the coil conductor wound around the tooth portion and the flange portion. Coil winding parts.   The rotation according to any one of claims 1 to 6, wherein the core is a divided core piece divided into a plurality in the circumferential direction, and the divided core pieces are arranged in a plurality of rings. Electric coil winding parts. In the manufacturing method of the coil winding components of the rotary electric machine according to any one of claims 3 to 6,
Preparing a mold for filling the resin by inserting the core and the insulating sheet,
The core and the insulating sheet are installed in the mold, and the bent and extended portion of the insulating paper is held in contact with the core by a movable holding member,
In this state, the resin in the mold is filled with the resin, and the holding member is retracted from the cavity immediately before the resin flows in. The end of the teeth part in the radial direction is provided with a collar part extending to one side or the other side in the circumferential direction,
A resin bulging portion that bulges so that the resin of the resin molded portion presses the surface of the insulating sheet is provided in a region of the insulator that covers a portion of the teeth portion adjacent to the flange portion. The coil winding component of the rotating electrical machine according to claim 1, wherein the coil winding component is a rotating electrical machine.

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