JP2016163393A - Stator structure, electric motor, device, manufacturing method for stator structure and manufacturing method for electric motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator structure having high reliability that is configured to have an unfilled space portion of heat radiating resin material between a heat-radiating resin material and an electrical connection portion while efficiently radiating heat generated in a winding body.SOLUTION: A stator intermediate assembly includes a stator having a stator core 1, an insulator 2 and a wound body 3, and a printed circuit board 5. The stator intermediate assembly is arranged on one side in the axial direction on the printed circuit board 5, and all of a connection wire end portion of a connecting portion of the wound body 3, a connecting wire end portion of the winding body 3 to be connected to the connector 6 and a connection wire of the wound body 3 to be connected to the printed circuit board 5 are wired on the arrangement side of the printed circuit board 5. The printed circuit board 5 is configured to be annular, fan-shaped or the like, and has a hollow portion at the center. The output shafts of the rotor and the motor are loosely inserted in the hollow portion. An open end of a stator frame 4 is set at the upper side, and a shaft hole of the stator frame 4 is set at the lower side.SELECTED DRAWING: Figure 4

Description

  The present invention relates to an electric motor, and more particularly, to a stator structure including a stator and a stator frame.

  In the home appliance field, industrial equipment field, electrical equipment field, etc., there is a constant demand for downsizing, thinning, and high output of devices including winding bodies such as electric motors and transformers.

  As an example, FIGS. 1 and 2 show a stator structure of an electric motor. In FIG. 1, a stator of an electric motor is configured by winding an insulated wire around a stator magnetic core 1 via an insulator 2 and providing a wound body 3. By inserting this stator into a stator frame 4 made of metal or the like, a stator structure is formed. The wound body 3 and the connector 6 are electrically connected via the printed wiring board 5. In FIG. 2, the end 3 a of the wound body is electrically connected to the printed wiring board 5 by solder 7.

  When the motor and the stator structure are reduced in size, thickness, and output are increased, heat generation of the wound body wound around the stator core becomes a problem. Excessive heat generation of the wound body is not preferable because it affects not only the power efficiency of the device but also the safety of the device members and the life of the device. In order to achieve both miniaturization and thinning of the device and high reliability, there is a strong demand for improvement in heat dissipation characteristics of the electric motor and the stator structure.

  In order to meet such a demand, the following conventional techniques are known.

  For example, Patent Document 1 describes that a stator structure with improved heat dissipation is obtained by filling a heat dissipation material in a vacuum state between the stator frame and the stator winding.

  In addition, for example, in Patent Document 2 and the like, the stator frame body is provided with an exhaust hole for resin filling, and the stator frame body and the stator are cast, filled, molded, etc. It is noted that an improved stator construction is obtained.

  Further, for example, Patent Document 3 describes that a stator structure with improved heat dissipation is obtained by injecting a heat dissipation material through a resin injection port provided in an end bracket of an electric motor.

Japanese Patent Laid-Open No. 60-28755 Japanese Patent Laid-Open No. 1-1448 JP 2010-104220 A

  In the conventional stator structure, an air layer exists between the stator winding and the stator frame, and thermal resistance is generated by the air layer. For this reason, the combined value of the thermal resistance of the entire stator structure is dominated by the influence of the thermal resistance of the air layer, and with this configuration, there is a limit to improving the heat dissipation of the stator structure.

  Therefore, in order to improve the heat dissipation of the stator structure, the heat resistance is reduced by filling the air layer between the stator winding and the stator frame with a heat dissipation material, thereby reducing the heat resistance of this part. Stator constructions with increased resistance have been proposed.

  However, as in the technique described in Patent Document 1 or the like, in the case where the heat dissipation resin is filled between the stator and the stator frame, the stator and the stator are prevented in order to prevent air bubbles from being included in the heat dissipation resin. Vacuum equipment that keeps the entire periphery of the frame in a vacuum state is required, and the manufacturing equipment becomes larger. In this case, the amount of capital investment soars, causing problems from a management perspective. Moreover, the man-hour of a manufacturing process will also be invited and the problem of the management viewpoint will be caused also in terms of productivity.

  In addition, as in the technique described in Patent Document 2 or the like, when an exhaust hole is installed in the lower part of the casting mold and resin is cast from the upper part of the mold, the flow of the resin is controlled. Requires advanced manufacturing technology. For this reason, all the air in the stator frame cannot be discharged out of the stator frame, and an air pocket (void) is formed inside the resin when the resin is cured. Air pockets in the resin are undesirable because they hinder insulation and heat dissipation of the stator windings. In order to remove air pockets (voids), defoaming by vacuum equipment may be performed, but this is the same as the technique described in the above-mentioned Patent Document 1 and causes a new problem from the viewpoint of management.

  Furthermore, when the entire stator winding is covered with a thermosetting resin material as in the technique described in Patent Document 3 and the like, a live part that is an electrical connection portion that connects the stator winding and the drive power supply Is covered with a heat dissipating material (resin) and has a sealed structure. Therefore, when the equipment is used due to overloading or when the equipment is used in a high temperature environment, deterioration in the live parts, which are the electrical connections, is caused by the decomposition gas of the insulating material including the thermosetting resin material. It is also considered that the reaction proceeds at an accelerated rate, and a great amount of cost is required for confirmation and verification of reliability.

  The present invention solves the above-mentioned problems, and by integrating the stator frame and the heat dissipation material (resin), while efficiently dissipating the heat generated by the wound body, the heat dissipation material (resin) An object of the present invention is to provide a highly reliable stator structure that has a non-filling space portion of a heat dissipation material (resin) between the electrical connection portion.

  In order to solve the above-mentioned problem, a first invention is a fixed including a stator magnetic core, an insulator covering each of a plurality of teeth portions of the stator magnetic core, and a wound body wound around each of the insulators. A stator intermediate assembly including a stator, a printed wiring board electrically connected to the winding body of the stator, a connector electrically connected to the stator intermediate assembly, and the stator intermediate A stator frame housing the assembly and including the connector; a self-close valve provided in each of a part or a plurality of locations of a wall portion of the stator frame; and A resin material filled in a lower space of a gap between a bottom and a lower portion of the stator intermediate assembly, a resin material filled in a gap between an inner wall of the stator frame and the stator magnetic core, and adjacent windings A stator structure including a resin material filled in a gap between the bodies In the body, a live part of the winding connection line of the wound body, a live part of the wiring pattern of the printed wiring board, a live part which is an electrical connection part of the connector, a space including these live parts And it is a stator structure which comprises the resin non-filling space part which is not filled with the said resin material.

  Moreover, 2nd invention is a stator structure of 1st invention, The thermosetting resin is included in the resin material.

  Moreover, 3rd invention is a stator structure of 1st invention, The resin material contains either the epoxy resin of a thermosetting resin, a polyester resin, or a polyurethane resin.

  According to a fourth invention, in the stator structure according to the first invention, the resin material contains either aluminum oxide or silicon nitride.

  Moreover, 5th invention is an electric motor containing the stator structure of 1st invention to 4th invention.

  Moreover, 6th invention is an apparatus carrying the electric motor containing the stator structure of 1st invention to 4th invention.

  The seventh invention includes a stator including a stator core, an insulator that covers each of a plurality of teeth portions of the stator core, and a wound body wound around each of the insulators, and the stator. A stator intermediate assembly including a printed wiring board electrically connected to the winding body, a connector electrically connected to the stator intermediate assembly, and housing the stator intermediate assembly; A stator frame provided with the connector, a self-close valve provided in each of a part or a plurality of locations of the wall portion of the stator frame, a bottom portion of the stator frame, and the middle of the stator In the gap between adjacent winding bodies, the resin material filled in the lower space of the gap between the lower part of the assembly, the resin material filled in the gap between the inner wall of the stator frame and the stator magnetic core, and In a method of manufacturing a stator structure including a resin material to be filled A live part of the winding connecting line of the wound body, a live part of the wiring pattern of the printed wiring board, a live part which is an electrical connection part of the connector, a space including these live parts, and the A method of manufacturing a stator structure having a resin-unfilled space portion that is not filled with a resin material, the step of inserting a cylindrical center jig in close contact with the inner wall of the hollow portion of the stator core And opening the self-close valve to inject the resin material into the stator frame and controlling the injection amount of the resin material to the extent that the resin non-filling space is formed; It is a manufacturing method of a stator structure including a step of curing the resin after the injection of the resin material and a step of removing the central jig inserted into the inner wall of the hollow portion of the stator magnetic core.

  Moreover, 8th invention is a manufacturing method of the stator structure of 7th invention. WHEREIN: A thermosetting resin is included in the resin material.

  Moreover, 9th invention is a manufacturing method of the stator structure of 7th invention, The resin material contains either the epoxy resin of a thermosetting resin, a polyester resin, or a polyurethane resin.

  According to a tenth aspect, in the method for manufacturing a stator structure according to the seventh aspect, the resin material contains either aluminum oxide or silicon nitride.

  The eleventh invention is a method for manufacturing an electric motor including the method for manufacturing a stator structure according to the first to fourth inventions.

  The stator structure of the present invention includes a stator structure in which a stator winding made of a magnetic core having a winding body wound inside a stator frame is provided, wherein the stator winding and the frame are connected to each other. Spatial layer, space layer of the stator winding wire and stator core, between the wires of the winding, by providing an air layer or space layer between the electrical connection and the heat dissipation material, the heat dissipation material is electrically connected A highly reliable stator structure is provided, while preventing contact with a portion and efficiently radiating heat generated during energization generated from a stator winding.

Furthermore, by having a casting port for the heat dissipation material on a part of the lower side of the stator frame, the heat dissipation material can be placed inside the heat dissipation material without requiring a special device such as a high pressure injection device or a vacuum device for the heat dissipation material. A heat dissipating material can be filled without generating air pockets (voids), and a highly reliable and productive stator structure can be provided while reducing capital investment.

  Thus, the stator structure of the present invention has high heat dissipation and reliability compared to the conventional stator structure, thereby suppressing a temperature rise, and can be used in a high temperature environment. Industrial value is high.

Cross section of conventional motor Sectional view of conventional electrical connection Sectional drawing when manufacturing the electric motor of the present invention Sectional view of the electric motor of the present invention Sectional view of the electrical connection of the present invention

  Hereinafter, the present invention will be described with reference to the drawings. In addition, this invention is not limited by the following embodiment or an Example.

  The stator intermediate assembly includes a stator including a stator magnetic core 1, an insulator 2 and a wound body 3, and a printed wiring board 5. In this stator intermediate assembly, on one side in the axial direction, the printed wiring board 5 is arranged, the connection line end of the connection portion between the winding bodies 3, and the connection line end of the winding body 3 connected to the connector 6. Both the connecting lines of the wound body 3 connected to the printed wiring board 5 and the printed wiring board 5 are wired on the arrangement side of the printed wiring board 5.

  The printed wiring board 5 has an annular shape (doughnut shape), a fan shape (arc shape), a C-shape, and the like, and has a hollow portion at the center. The hollow portion has a rotor or an electric motor. The output shaft is inserted loosely.

  And the opening end of the stator frame 4 is installed upward, while the shaft hole of the stator frame 4 is installed below. The stator intermediate assembly is placed in the stator frame 4 in this state from the opening end side of the stator frame 4. At this time, the stator intermediate assembly positions the printed wiring board 5 on the side of the opening end of the stator frame 4. In addition, a connector window portion in which the connector 6 is arranged is provided in the vicinity of the opening end of the stator frame 4. The connector 6 disposed in the connector window and the stator intermediate assembly are electrically connected.

  Then, a cylindrical center jig 8 is inserted into the inner wall of the hollow portion of the stator magnetic core 1 in a close contact state. Next, a self-closing valve 10 is provided in the resin inlet 9 provided in a part of the wall portion of the stator frame 4 or in each of a plurality of locations, and the nozzle of the dispenser is inserted into the self-closing valve 10 so as to be liquid. Resin 11 is injected.

  The resin 11 is supplied to the lower space of the stator frame 4, and the resin 11 flows into the gap between the stator magnetic core 1 and the stator frame 4 and the gap between the wound bodies 3. At this time, since the resin 11 flows while discharging the air inside the gap from the upper side of the stator intermediate assembly, bubbles are not included in the resin 11 and air is trapped in the cured resin (void). Therefore, it is possible to provide a low-cost stator structure having stable heat dissipation characteristics and high reliability after the resin 11 is cured.

  The cylindrical center jig 8 inserted into the hollow portion of the stator magnetic core 1 is removed after the resin 11 is cured.

  The injection method of the resin 11 will be further described. A needle of a resin injection dispenser is inserted into the self-close valve 10 of the stator frame 4 and a heat-dissipating resin 11 such as a liquid epoxy resin is injected via the needle. The resin 11 is supplied into the lower space where the stator is located, and the space between the outer peripheral surface of the stator magnetic core 1 and the stator frame body and the space between the adjacent wound bodies 3 mainly from the lower space portion. And the gaps are also filled.

  Since the self-closing valve 10 has an opening / closing mechanism using rubber elasticity or the like, when the needle of the dispenser is pulled out after resin injection, the self-closing valve 10 that is vacant when the needle is inserted is automatically closed, and from the inside of the stator. The resin 11 injected to the outside of the stator does not cause backflow or leakage. For this reason, the scattered resin does not adhere to the production line equipment and the product itself, and troubles such as cleaning and malfunction operation of the production equipment are suppressed, so that the production capacity of the production line becomes high. Naturally, there is no increase in production tact and no increase in the number of man-hours in the manufacturing process, and it is possible to provide a highly reliable product at a low cost, and the industrial value is great.

  In addition, although it is the self-close valve 10, as long as it has a function which prevents resin leakage before and after resin injection | pouring, another structure may be sufficient. For example, as a simple one, a configuration in which the resin inlet is opened and closed by plugging and opening with a stopper made of an elastic body may be used.

  FIG. 4 is a cross-sectional view of the stator structure of the present invention. The main resin component of the resin 11 in FIG. 4 is a thermosetting resin material such as epoxy, polyester, or polyurethane. In order to improve the heat dissipation characteristics of the stator, the resin 11 is mixed with a filler exhibiting high thermal conductivity such as aluminum oxide (commonly called alumina) or silicon nitride. In addition, when the resin enters the gaps between the adjacent wound bodies 3 or the minute gaps between the magnetic core and the stator frame, the air layer inside the stator, which inhibits the heat dissipation characteristics of the stator, Heat dissipation is enhanced by replacing the resin layer with a low resistance.

  Moreover, when the viscosity of the resin 11 is high, the penetration of the resin 11 into the above-described gap is accompanied by difficulty. For this reason, it is preferable that the resin 11 has low viscosity and high fluidity. In addition, even if it is a high-viscosity resin material, the penetration | invasion of the resin 11 to a space | gap is easy by improving the fluidity | liquidity of the resin 11 by preheating to a stator and the resin 11. FIG.

  FIG. 5 is a cross-sectional view of the stator structure of the present invention. FIG. 4 is an enlarged view of the electrical connection portion. When manufacturing the configuration of the present invention, it is easy to manage the liquid level of the resin 11 that flows after injection due to the configuration of the present invention. For example, an electrical connection part that is a connection part between the winding body 3 and the printed wiring board 5, an electrical connection part that is a connection part between the winding body 3 and the connector 6, etc. The resin 11 does not adhere. That is, a resin non-filling space portion that is not filled with the resin 11 is provided around a connection portion between the wound bodies 3 and an electrical connection portion such as a connection portion between the wound body 3 and the connector 6.

  Thus, these live parts, which are electrical connection parts, are not in direct contact with the resin 11 but through air (atmosphere). Even if some gas is generated from the resin 11, it does not stay around the live part and diffuses and disappears, and no malfunction occurs. Thereby, the configuration of the electrical connection portion is adapted to a severe use environment, and it is possible to provide an electric motor and a stator structure with higher reliability.

Table 1 compares the stator structure using the present invention with the prior art stator structure. Comparative Example A in Table 1 is a stator structure prepared by casting resin from the upper part of the stator and defoaming bubbles in the resin using vacuum equipment to reduce bubbles in the resin. Comparative Example B in Table 1 is obtained by casting the resin from the top of the stator without using vacuum equipment, and includes bubbles inevitably included in the resin. Compared with Comparative Example A and Comparative Example B, the present invention has high heat dissipation and high productivity and reliability.

  Since the stator structure of the present invention has higher heat dissipation and reliability than the conventional stator structure, it can be used for various uses and various specifications of equipment, and has a great industrial value. Is.

DESCRIPTION OF SYMBOLS 1 Stator magnetic core 2 Insulator 3 Winding body 4 Stator frame 5 Printed wiring board 6 Connector 7 Solder 8 Center jig 9 Resin injection port 10 Self-close valve 11 Resin

  The present invention relates to an electric motor, and more particularly, to a stator structure including a stator and a stator frame.

  In the home appliance field, industrial equipment field, electrical equipment field, etc., there is a constant demand for downsizing, thinning, and high output of devices including winding bodies such as electric motors and transformers.

  As an example, FIGS. 1 and 2 show a stator structure of an electric motor. In FIG. 1, a stator of an electric motor is configured by winding an insulated wire around a stator magnetic core 1 via an insulator 2 and providing a wound body 3. By inserting this stator into a stator frame 4 made of metal or the like, a stator structure is formed. The wound body 3 and the connector 6 are electrically connected via the printed wiring board 5. In FIG. 2, the end 3 a of the wound body is electrically connected to the printed wiring board 5 by solder 7.

When the motor and the stator structure are reduced in size, thickness, and output are increased, heat generation of the wound body wound around the stator core becomes a problem. Excessive heat generation of the wound body is not preferable because it affects not only the power efficiency of the device but also the safety of the device members and the life of the device. In order to achieve both miniaturization and thinning of the device and high reliability, there is a strong demand for improvement in heat dissipation characteristics of the electric motor and the stator structure.

  In order to meet such a demand, the following conventional techniques are known.

  For example, Patent Document 1 describes that a stator structure with improved heat dissipation is obtained by filling a heat dissipation material in a vacuum state between the stator frame and the stator winding.

  In addition, for example, in Patent Document 2 and the like, the stator frame body is provided with an exhaust hole for resin filling, and the stator frame body and the stator are cast, filled, molded, etc. It is noted that an improved stator construction is obtained.

  Further, for example, Patent Document 3 describes that a stator structure with improved heat dissipation is obtained by injecting a heat dissipation material through a resin injection port provided in an end bracket of an electric motor.

Japanese Patent Laid-Open No. 60-28755 Japanese Patent Laid-Open No. 1-1448 JP 2010-104220 A

  In the conventional stator structure, an air layer exists between the stator winding and the stator frame, and thermal resistance is generated by the air layer. For this reason, the combined value of the thermal resistance of the entire stator structure is dominated by the influence of the thermal resistance of the air layer, and with this configuration, there is a limit to improving the heat dissipation of the stator structure.

  Therefore, in order to improve the heat dissipation of the stator structure, the heat resistance is reduced by filling the air layer between the stator winding and the stator frame with a heat dissipation material, thereby reducing the heat resistance of this part. Stator constructions with increased resistance have been proposed.

  However, as in the technique described in Patent Document 1 or the like, in the case where the heat dissipation resin is filled between the stator and the stator frame, the stator and the stator are prevented in order to prevent air bubbles from being included in the heat dissipation resin. Vacuum equipment that keeps the entire periphery of the frame in a vacuum state is required, and the manufacturing equipment becomes larger. In this case, the amount of capital investment soars, causing problems from a management perspective. Moreover, the man-hour of a manufacturing process will also be invited and the problem of the management viewpoint will be caused also in terms of productivity.

  In addition, as in the technique described in Patent Document 2 or the like, when an exhaust hole is installed in the lower part of the casting mold and resin is cast from the upper part of the mold, the flow of the resin is controlled. Requires advanced manufacturing technology. For this reason, all the air in the stator frame cannot be discharged out of the stator frame, and an air pocket (void) is formed inside the resin when the resin is cured. Air pockets in the resin are undesirable because they hinder insulation and heat dissipation of the stator windings. In order to remove air pockets (voids), defoaming by vacuum equipment may be performed, but this is the same as the technique described in the above-mentioned Patent Document 1 and causes a new problem from the viewpoint of management.

Furthermore, when the entire stator winding is covered with a thermosetting resin material as in the technique described in Patent Document 3 and the like, a live part that is an electrical connection portion that connects the stator winding and the drive power supply Is covered with a heat dissipating material (resin) and has a sealed structure. Therefore, when the equipment is used due to overloading or when the equipment is used in a high temperature environment, deterioration in the live parts, which are the electrical connections, is caused by the decomposition gas of the insulating material including the thermosetting resin material. It is also considered that the reaction proceeds at an accelerated rate, and a great amount of cost is required for confirmation and verification of reliability.

  The present invention solves the above-mentioned problems, and by integrating the stator frame and the heat dissipation material (resin), while efficiently dissipating the heat generated by the wound body, the heat dissipation material (resin) An object of the present invention is to provide a highly reliable stator structure that has a non-filling space portion of a heat dissipation material (resin) between the electrical connection portion.

In order to solve the above-mentioned problem, a first invention is a fixed including a stator magnetic core, an insulator covering each of a plurality of teeth portions of the stator magnetic core, and a wound body wound around each of the insulators. A stator intermediate assembly including a stator, a printed wiring board electrically connected to the winding body of the stator, a connector electrically connected to the stator intermediate assembly, and the stator intermediate A stator frame housing the assembly and including the connector; a self-close valve provided in each of a part or a plurality of locations of a wall portion of the stator frame; and A resin material filled in a lower space of a gap between a bottom and a lower portion of the stator intermediate assembly, a resin material filled in a gap between an inner wall of the stator frame and the stator magnetic core, and adjacent windings A stator structure including a resin material filled in a gap between the bodies In the body, live parts of the drawer connecting line of the wound body, and live parts are electrical connection points of the live parts and the connector of the wiring pattern of the printed wiring board, the space including these electroactive portion a stator structure comprising a resin unfilled space to unfilled by the resin material.

  Moreover, 2nd invention is a stator structure of 1st invention, The thermosetting resin is included in the resin material.

  Moreover, 3rd invention is a stator structure of 1st invention, The resin material contains either the epoxy resin of a thermosetting resin, a polyester resin, or a polyurethane resin.

  According to a fourth invention, in the stator structure according to the first invention, the resin material contains either aluminum oxide or silicon nitride.

  Moreover, 5th invention is an electric motor containing the stator structure of 1st invention to 4th invention.

  Moreover, 6th invention is an apparatus carrying the electric motor containing the stator structure of 1st invention to 4th invention.

The seventh invention includes a stator including a stator core, an insulator that covers each of a plurality of teeth portions of the stator core, and a wound body wound around each of the insulators, and the stator. A stator intermediate assembly including a printed wiring board electrically connected to the winding body, a connector electrically connected to the stator intermediate assembly, and housing the stator intermediate assembly; A stator frame provided with the connector, a self-close valve provided in each of a part or a plurality of locations of the wall portion of the stator frame, a bottom portion of the stator frame, and the middle of the stator In the gap between adjacent winding bodies, the resin material filled in the lower space of the gap between the lower part of the assembly, the resin material filled in the gap between the inner wall of the stator frame and the stator magnetic core, and In a method of manufacturing a stator structure including a resin material to be filled The live parts of the drawer connection line wound body, and live parts are electrical connection points of the live parts and the connector of the wiring pattern of the printed wiring board, the resin space containing these electroactive portion a method for manufacturing a stator structure comprising a resin unfilled space to unfilled by the material, the step of inserting in close contact center jig circle columnar the inner wall of the hollow portion of the stator core Opening the self-close valve and injecting the resin material into the stator frame and controlling the injection amount of the resin material to the extent that the resin non-filling space is formed; and curing the resin after finishing the injection of material, a step of removing the center jig inserted to the inner wall of the hollow portion of the stator core, a manufacturing method of the stator structure comprising a.

  Moreover, 8th invention is a manufacturing method of the stator structure of 7th invention. WHEREIN: A thermosetting resin is included in the resin material.

  Moreover, 9th invention is a manufacturing method of the stator structure of 7th invention, The resin material contains either the epoxy resin of a thermosetting resin, a polyester resin, or a polyurethane resin.

  According to a tenth aspect, in the method for manufacturing a stator structure according to the seventh aspect, the resin material contains either aluminum oxide or silicon nitride.

  The eleventh invention is a method for manufacturing an electric motor including the method for manufacturing a stator structure according to the first to fourth inventions.

The stator structure according to the present invention includes a stator structure in which a stator winding composed of a magnetic core having a winding body wound inside a stator frame is inscribed, and the stator winding and the stator Heat is dissipated by providing an air layer or a space layer between the space layer with the frame, the space layer between the wires of the stator winding and the stator core, and the electrical connection between the wires of the winding and the heat dissipation material. Provided is a highly reliable stator structure while preventing the material from coming into contact with the electrical connection portion and efficiently radiating heat generated during energization generated from the stator winding.

  Furthermore, by having a casting port for the heat dissipation material on a part of the lower side of the stator frame, the heat dissipation material can be placed inside the heat dissipation material without requiring a special device such as a high pressure injection device or a vacuum device for the heat dissipation material. A heat dissipating material can be filled without generating air pockets (voids), and a highly reliable and productive stator structure can be provided while reducing capital investment.

  Thus, the stator structure of the present invention has high heat dissipation and reliability compared to the conventional stator structure, thereby suppressing a temperature rise, and can be used in a high temperature environment. Industrial value is high.

Cross section of conventional motor Sectional view of conventional electrical connection Sectional drawing when manufacturing the electric motor of the present invention Sectional view of the electric motor of the present invention Sectional view of the electrical connection of the present invention

  Hereinafter, the present invention will be described with reference to the drawings. In addition, this invention is not limited by the following embodiment or an Example.

  The stator intermediate assembly includes a stator including a stator magnetic core 1, an insulator 2 and a wound body 3, and a printed wiring board 5. In this stator intermediate assembly, on one side in the axial direction, the printed wiring board 5 is arranged, the connection line end of the connection portion between the winding bodies 3, and the connection line end of the winding body 3 connected to the connector 6. Both the connecting lines of the wound body 3 connected to the printed wiring board 5 and the printed wiring board 5 are wired on the arrangement side of the printed wiring board 5.

  The printed wiring board 5 has an annular shape (doughnut shape), a fan shape (arc shape), a C-shape, and the like, and has a hollow portion at the center. The hollow portion has a rotor or an electric motor. The output shaft is inserted loosely.

  And the opening end of the stator frame 4 is installed upward, while the shaft hole of the stator frame 4 is installed below. The stator intermediate assembly is placed in the stator frame 4 in this state from the opening end side of the stator frame 4. At this time, the stator intermediate assembly positions the printed wiring board 5 on the side of the opening end of the stator frame 4. In addition, a connector window portion in which the connector 6 is arranged is provided in the vicinity of the opening end of the stator frame 4. The connector 6 disposed in the connector window and the stator intermediate assembly are electrically connected.

  Then, a cylindrical center jig 8 is inserted into the inner wall of the hollow portion of the stator magnetic core 1 in a close contact state. Next, a self-closing valve 10 is provided in the resin inlet 9 provided in a part of the wall portion of the stator frame 4 or in each of a plurality of locations, and the nozzle of the dispenser is inserted into the self-closing valve 10 so as to be liquid. Resin 11 is injected.

  The resin 11 is supplied to the lower space of the stator frame 4, and the resin 11 flows into the gap between the stator magnetic core 1 and the stator frame 4 and the gap between the wound bodies 3. At this time, since the resin 11 flows while discharging the air inside the gap from the upper side of the stator intermediate assembly, bubbles are not included in the resin 11 and air is trapped in the cured resin (void). Therefore, it is possible to provide a low-cost stator structure having stable heat dissipation characteristics and high reliability after the resin 11 is cured.

Incidentally, the cylindrical center jig 8 is inserted into the hollow portion of the stator core 1 is removed after curing of the resin 11.

  The injection method of the resin 11 will be further described. A needle of a resin injection dispenser is inserted into the self-close valve 10 of the stator frame 4 and a heat-dissipating resin 11 such as a liquid epoxy resin is injected via the needle. The resin 11 is supplied into the lower space where the stator is located, and the space between the outer peripheral surface of the stator magnetic core 1 and the stator frame body and the space between the adjacent wound bodies 3 mainly from the lower space portion. And the gaps are also filled.

  Since the self-closing valve 10 has an opening / closing mechanism using rubber elasticity or the like, when the needle of the dispenser is pulled out after resin injection, the self-closing valve 10 that is vacant when the needle is inserted is automatically closed, and from the inside of the stator. The resin 11 injected to the outside of the stator does not cause backflow or leakage. For this reason, the scattered resin does not adhere to the production line equipment and the product itself, and troubles such as cleaning and malfunction operation of the production equipment are suppressed, so that the production capacity of the production line becomes high. Naturally, there is no increase in production tact and no increase in the number of man-hours in the manufacturing process, and it is possible to provide a highly reliable product at a low cost, and the industrial value is great.

  In addition, although it is the self-close valve 10, as long as it has a function which prevents resin leakage before and after resin injection | pouring, another structure may be sufficient. For example, as a simple one, a configuration in which the resin inlet is opened and closed by plugging and opening with a stopper made of an elastic body may be used.

FIG. 4 is a cross-sectional view of the stator structure of the present invention. The main resin component of the resin 11 in FIG. 4 is a thermosetting resin material such as epoxy, polyester, or polyurethane. In order to improve the heat dissipation characteristics of the stator, the resin 11 is mixed with a filler exhibiting high thermal conductivity such as aluminum oxide (commonly called alumina) or silicon nitride. In addition, when the resin enters the gaps between the adjacent wound bodies 3 or the minute gaps between the magnetic core and the stator frame, the air layer inside the stator, which inhibits the heat dissipation characteristics of the stator, Heat dissipation is enhanced by replacing the resin layer with a low resistance.

  Moreover, when the viscosity of the resin 11 is high, the penetration of the resin 11 into the above-described gap is accompanied by difficulty. For this reason, it is preferable that the resin 11 has low viscosity and high fluidity. In addition, even if it is a high-viscosity resin material, the penetration | invasion of the resin 11 to a space | gap is easy by improving the fluidity | liquidity of the resin 11 by preheating to a stator and the resin 11. FIG.

  FIG. 5 is a cross-sectional view of the stator structure of the present invention. FIG. 4 is an enlarged view of the electrical connection portion. When manufacturing the configuration of the present invention, it is easy to manage the liquid level of the resin 11 that flows after injection due to the configuration of the present invention. For example, an electrical connection part that is a connection part between the winding body 3 and the printed wiring board 5, an electrical connection part that is a connection part between the winding body 3 and the connector 6, etc. The resin 11 does not adhere. That is, a resin non-filling space portion that is not filled with the resin 11 is provided around a connection portion between the wound bodies 3 and an electrical connection portion such as a connection portion between the wound body 3 and the connector 6.

  Thus, these live parts, which are electrical connection parts, are not in direct contact with the resin 11 but through air (atmosphere). Even if some gas is generated from the resin 11, it does not stay around the live part and diffuses and disappears, and no malfunction occurs. Thereby, the configuration of the electrical connection portion is adapted to a severe use environment, and it is possible to provide an electric motor and a stator structure with higher reliability.

  Table 1 compares the stator structure using the present invention with the prior art stator structure. Comparative Example A in Table 1 is a stator structure prepared by casting resin from the upper part of the stator and defoaming bubbles in the resin using vacuum equipment to reduce bubbles in the resin. Comparative Example B in Table 1 is obtained by casting the resin from the top of the stator without using vacuum equipment, and includes bubbles inevitably included in the resin. Compared with Comparative Example A and Comparative Example B, the present invention has high heat dissipation and high productivity and reliability.

  Since the stator structure of the present invention has higher heat dissipation and reliability than the conventional stator structure, it can be used for various uses and various specifications of equipment, and has a great industrial value. Is.

DESCRIPTION OF SYMBOLS 1 Stator magnetic core 2 Insulator 3 Winding body 4 Stator frame 5 Printed wiring board 6 Connector 7 Solder 8 Center jig 9 Resin injection port 10 Self-close valve 11 Resin

Claims (11)

A stator including a stator core, an insulator covering each of the plurality of teeth of the stator core, and a wound body wound around each of the insulators; and the wound body of the stator electrically A stator intermediate assembly including a printed wiring board to be connected, a connector electrically connected to the stator intermediate assembly, and a stator frame that accommodates the stator intermediate assembly and includes the connector A gap between a body, a self-close valve provided in each of a part or a plurality of locations of the wall of the stator frame, and a bottom of the stator frame and a lower portion of the stator intermediate assembly A resin material filled in a lower space, a resin material filled in a gap between the inner wall of the stator frame and the stator magnetic core, and a resin material filled in a gap between adjacent wound bodies. In the stator structure, the connecting wire of the winding body A live part, a live part of a wiring pattern of the printed wiring board, a live part that is an electrical connection portion of the connector, a space that includes these live parts, and is not filled with the resin material. The stator structure which comprises a space part. The stator structure according to claim 1, wherein the resin material includes a thermosetting resin. The stator structure according to claim 1, wherein the resin material includes one of a thermosetting epoxy resin, a polyester resin, and a polyurethane resin. The stator structure according to claim 1, wherein the resin material contains either aluminum oxide or silicon nitride. An electric motor including the stator structure according to claim 1. The apparatus which mounts the electric motor containing the stator structure of Claims 1-4. A stator including a stator core, an insulator covering each of the plurality of teeth of the stator core, and a wound body wound around each of the insulators; and the wound body of the stator electrically A stator intermediate assembly including a printed wiring board to be connected, a connector electrically connected to the stator intermediate assembly, and a stator frame that accommodates the stator intermediate assembly and includes the connector A gap between a body, a self-close valve provided in each of a part or a plurality of locations of the wall of the stator frame, and a bottom of the stator frame and a lower portion of the stator intermediate assembly A resin material filled in a lower space, a resin material filled in a gap between the inner wall of the stator frame and the stator magnetic core, and a resin material filled in a gap between adjacent wound bodies. In the method of manufacturing a stator structure, the winding body is pulled. A live part of the connection line, a live part of the wiring pattern of the printed wiring board, a live part which is an electrical connection part of the connector, a space including these live parts and the resin material not filled A method of manufacturing a stator structure having a resin-unfilled space portion, the step of inserting a cylindrical center jig in close contact with the inner wall of the hollow portion of the stator magnetic core, and the self-closing valve Opening the valve and injecting the resin material into the stator frame and controlling the injection amount of the resin material so as to form the resin non-filling space, and finishing the injection of the resin material A method for manufacturing a stator structure, comprising: a step of curing the resin after the step; and a step of removing the central jig inserted into the inner wall of the hollow portion of the stator magnetic core. The method for manufacturing a stator structure according to claim 7, wherein the resin material includes a thermosetting resin. 8. The method for manufacturing a stator structure according to claim 7, wherein the resin material includes any one of a thermosetting epoxy resin, a polyester resin, and a polyurethane resin. 8. The method for manufacturing a stator structure according to claim 7, wherein the resin material contains either aluminum oxide or silicon nitride. The manufacturing method of the electric motor containing the manufacturing method of the stator structure of Claim 7-4.

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