JP2017131088A - Manufacturing method of stator and stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator easy-to-manufacture and capable of reliably fixing a coil.SOLUTION: The manufacturing method includes the steps of: forming a coil 4 by winding a conductor wire on a stator core, which has a yoke 21, teeth 22, a teeth-tip yoke 23, a yoke 21 and a slot 24 enclosed by the teeth 22 and the teeth-tip yoke 23 via an insulation member 3 on a wall part of the slot 24; disposing a B-stage shaped thermosetting resin composition sheet 5B on the peripheral surface of the coil 4 wound on the stator core; and curing the thermosetting resin composition sheet 5B by heating the same along the outer periphery of the coil 4.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a stator manufacturing method and a stator, and more particularly to formation of a thermosetting resin composition sheet for fixing coils adjacent to the stator.

  Conventionally, in a stator of a rotating machine, a technique such as varnish impregnation or resin molding is used for fixing a coil. A stator of a rotating machine normally includes a stator core having a yoke portion, a teeth portion, and a slot surrounded by the yoke portion and the teeth portion, and a coil wound separately around the teeth portion. It is necessary to insulate the stator core from the coil.

  Therefore, in order to insulate and fix the stator core and the coil, in Patent Document 1, the coil is wound around the inner wall surface of the slot of the stator via an insulating sheet in which a base material is provided with a fusion material. A technique for ensuring insulation between the two is disclosed.

  In patent document 1, the insulating sheet is installed on the inner wall surface of the slot. That is, since the coil wound with the wire is not covered with the coil but is disposed along the inner wall surface of the slot, there is a gap between the coil and the insulating sheet, and the coil fixing may be incomplete. . In addition, since the insulating sheet contains a base material, the sheet is not stretchable, and there is a case where a gap exists between the coil and the insulating sheet, resulting in imperfect coil fixation. Therefore, varnish impregnation or molding treatment is indispensable for ensuring insulation and fixing the coil.

JP-A-9-308158

  However, according to the conventional technique described in Patent Document 1, both the varnish impregnation and the resin mold are poor in work efficiency, have a lot of material loss, and securely fix the stator coil with good workability. There was a problem that it was difficult.

  The present invention has been made in view of the above, and an object of the present invention is to obtain a stator that is easy to manufacture and that can securely fix a coil.

  In order to solve the above-described problems and achieve the object, a method for manufacturing a stator according to the present invention includes a step of winding a conductive wire around a stator core to form a coil, and a coil wound around the stator core. Including a step of disposing a B-stage-shaped thermosetting resin composition sheet on the peripheral surface, and a step of heating and curing the thermosetting resin composition sheet along the outer periphery of the coil.

  ADVANTAGE OF THE INVENTION According to this invention, manufacture is easy and the stator which can fix a coil reliably can be obtained.

Cross-sectional view showing stator for rotating machine of embodiment 1 Partial enlarged perspective view of FIG. (A) to (d) is a perspective view showing the main part of the manufacturing process of the stator of the first embodiment. The flowchart which shows the principal part of the manufacturing process of the stator of Embodiment 1. In the manufacturing process of the stator of Embodiment 1, it is a figure which shows the state which attached the thermosetting resin composition sheet | seat of B stage to the coil wound before thermosetting, (a) is thermosetting of B stage. The principal part expansion perspective sectional view which shows the coil with which the conductive resin composition sheet was mounted | worn, (b) is sectional drawing In the manufacturing process of the stator of Embodiment 1, it is a figure which shows the layer of the thermosetting resin by which thermosetting was made along the external shape of the coil wound, (a) is fixed with the thermosetting resin. The principal part expansion perspective sectional view which shows the coil which was cut, (b) is sectional drawing It is explanatory drawing which shows the relationship between the width | variety of the thermosetting resin composition sheet | seat of B stage, and the winding state of a coil in the manufacturing process of the stator of Embodiment 1, (a) is a coil in a division | segmentation iron core. The figure which shows the state wound, (b) is a figure which shows the state by which the thermosetting resin composition sheet | seat of B stage was arranged so that a coil might be covered. Explanatory drawing which shows the relationship between the coating width of the thermosetting resin composition sheet | seat of the B stage in Embodiment 2, and the winding state of a coil Explanatory drawing which shows the relationship between the coating width of the thermosetting resin composition sheet | seat of the B stage in Embodiment 3, and the winding state of a coil Explanatory drawing which shows the relationship between the width | variety of the thermosetting resin composition sheet | seat of the B stage in Embodiment 4, and the winding state of a coil. Explanatory drawing which shows the relationship between the width | variety of the thermosetting resin composition sheet | seat of the B stage in Embodiment 5, and the winding state of a coil. Explanatory drawing which shows the relationship between the width | variety of the thermosetting resin composition sheet | seat of the B stage in Embodiment 6, and the winding state of the coil 4 Explanatory drawing which shows the case where several through-holes are formed in the thermosetting resin composition sheet | seat of the B stage in Embodiment 7. Explanatory drawing which shows the case where a some slit is formed in the thermosetting resin composition sheet | seat of the B stage in Embodiment 8. The perspective view which shows the coating state of the thermosetting resin in the division | segmentation iron core unit which comprises the stator in Embodiment 9. FIG. The perspective view which shows the coating state of the thermosetting resin in the division | segmentation iron core unit which comprises the stator in Embodiment 10. FIG. The perspective view which shows the coating state of the thermosetting resin in the division | segmentation iron core unit which comprises the stator in Embodiment 11 In the manufacturing process of the stator of Embodiment 12, it is a figure which shows the state which attached the thermosetting resin composition sheet | seat of B stage to the coil wound before thermosetting, (a) is thermosetting of B stage. The principal part expansion perspective view which shows the coil with which the conductive resin composition sheet was mounted | worn, (b) is sectional drawing.

  Hereinafter, embodiments of a method for manufacturing a stator according to the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited by this embodiment, In the range which does not deviate from the summary of this invention, it can change suitably. In the drawings shown below, the scale of each member may be different from the actual scale for easy understanding. The same applies between the drawings.

Embodiment 1 FIG.
1 is a transverse sectional view showing a stator for a rotating machine according to Embodiment 1, and FIG. 2 is a partially enlarged perspective view of FIG.

  As shown in FIGS. 1 and 2, the stator 1 of the rotating machine according to the first embodiment connects a plurality of T-shaped split cores 20 each having a yoke part 21, a tooth part 22, and a tooth tip yoke part 23. And a stator core 2 formed in a cylindrical shape. The split iron core 20 is formed by laminating electromagnetic steel plates. In the stator 1 of the rotating machine according to the first embodiment, the coils 4 are wound around the divided cores 20 of the stator core 2 via the insulating member 3, and the outermost layer of the coil 4 is thermoset on the B stage. After being covered with the resin composition sheet 5 </ b> B, the thermosetting resin 5 is formed in a shape along the outer shape of the coil 4 by thermosetting. In the split iron core 20, a slot 24 that accommodates a coil 4 described later is formed so as to be surrounded by the yoke portion 21, the tooth portion 22, and the tooth tip yoke portion 23. Moreover, the coil 4 is wound around each teeth part 22. The B stage is an intermediate stage of the reaction, in which the material softens and expands when heated, but does not completely melt or dissolve when contacted with a certain liquid. Close fixation is realized.

  Both end portions in the axial direction A of the tooth portion 22 of the split iron core 20 and the wall portion of the slot 24 are covered with a non-expandable insulating member 3 such as an insulator, insulating paper, or insulating coating. The coil 4 is wound around the tooth portion 22 from above the insulating member 3. The insulation member 3 covers the ends of the teeth 22 in the axial direction and the walls of the slots 24, and the coils 4 are wound around the individual divided cores 20 before the stator core 2 is assembled.

  The nine divided cores 20 in which the coil 4 is wound around the slot 24 and the outer side of the wound coil 4 is covered with the thermosetting resin 5 are welded to each other between the yoke portions 21 and the tooth tip yoke portions 23. The cylindrical stator core 2 is configured by being fixed. An aluminum frame 6 is attached to the outer side of the stator core 2 in the radial direction. The thermosetting resin 5 covering the outside of the wound coil 4 is cured along the outer shape of the coil 4 to form a coating layer having a uniform thickness. Accordingly, the adjacent cores 20 and 20 are fixed and constitute the stator core 2. The yoke portions 21 positioned on the outside of the cylinder and the tooth tip yoke portions 23 positioned on the inner side are fixed in contact with each other, but between the yoke portion 21 and the teeth tip yoke portion 23, that is, the portion of the slot 24. A gap 7 is formed between the thermosetting resins 5 in the above.

  Next, a method for manufacturing the stator according to the first embodiment will be described. FIG. 3A to FIG. 3D are perspective views showing the main part of the manufacturing process of the stator of the first embodiment. FIG. 4 is a flowchart showing a main part of the manufacturing process of the stator according to the first embodiment. First, as shown in FIG. 3A, in step S <b> 101, the core members cut by press working are stacked, the divided cores 20 are assembled, and the divided cores 20 are formed. Thereafter, the assembled split iron core 20 is subjected to an initial insulation process between the ground. As the initial insulation process, there is a process of attaching the insulating member 3 to portions corresponding to the upper and lower portions of the split iron core 20 in the axial direction A. In addition to this, a process of applying insulating coating to the entire divided iron core 20 or a process of attaching an insulating paper as the insulating member 3 to the side surface of the divided iron core 20 may be mentioned as the initial insulation process. Further, two or more of the plurality of processes described above may be combined for the initial insulation process.

  Subsequently, as shown in FIG. 3B, in step S <b> 102, a copper wire covered with an insulating material is wound around the tooth portion 22 of the split iron core 20, so that the coil 4 is attached to the tooth portion 22. The surface of the coil 4 is insulated by forming a coating of an insulating material on the core wire 4a made of a copper wire, which will be described later, in this embodiment, an enamel coating 4b. The copper wire constituting the coil is not limited to copper, but may be a conductive wire made of a conductor.

  Next, as shown in FIG. 3C, in step S103, the B stage thermosetting resin composition sheet 5B is attached to the outside of the coil 4 attached to the split core 20. The width of the thermosetting resin composition sheet 5 </ b> B is approximately the same as the winding width of the entire mounted coil, and is covered so as to cover the entire outermost layer of the coil 4.

  After the coil 4 is mounted on the tooth 22 and the B-stage thermosetting resin composition sheet 5B is mounted on the outside of the coil 4, as shown in FIG. The B stage thermosetting resin composition sheet 5B is cured. The B-stage thermosetting resin composition sheet 5 </ b> B is melted by heating and is cured following the shape of the coil 4, thereby fixing the coil 4 between the wires. A layer of the thermosetting resin 5 having a constant film thickness is formed along the outer periphery of the coil 4 by attaching the B-stage thermosetting resin composition sheet 5B to the wound coil 4 and heating and curing it. The coil 4 is securely fixed.

  FIGS. 5A and 5B are views showing a state where the B-stage thermosetting resin composition sheet 5B is mounted on the coil 4 before the thermosetting resin composition sheet 5B is thermoset. In other words, FIG. 5A is an enlarged perspective cross-sectional view of the main part showing the coil 4 on which the B-stage thermosetting resin composition sheet 5B is mounted, and FIG. 5B is a cross-sectional view. The surface of the coil 4 is insulated by forming an enamel coating 4b on a core wire 4a made of a copper wire.

  After the coil 4 is mounted, the outside of the coil 4 is covered with a B-stage thermosetting resin composition sheet 5B, and the B-stage thermosetting resin composition sheet 5B is cured by heat treatment at 60 ° C. for 30 minutes or more. A layer of the thermosetting resin 5 is formed. FIGS. 6A and 6B are diagrams showing a layer of the thermosetting resin 5 that has been thermoset so as to follow the outer shape of the coil 4 wound around the slot 24 of the split core 20. FIG. 6A is an enlarged perspective cross-sectional view of the main part showing the coil 4 fixed by the thermosetting resin 5, and FIG. 6B is a cross-sectional view.

  The B-stage thermosetting resin composition sheet 5 </ b> B is melted by heating, and is cured following the shape of the coil 4, thereby fixing the wires between the coils 4. By attaching the B-stage thermosetting resin composition sheet 5B to the coil 4 and heat-curing, the thermosetting resin 5 adheres and adheres along the outer surface of the coil 4 so that the coil 4 The coils 4 can be fixed to each other and on the divided iron core 20 while being wound around the divided iron core 20.

  The thermosetting resin composition sheet 5B does not contain a thermoplastic resin, a glass cloth, and a non-woven fabric, is mainly composed of only a thermosetting resin, and is processed into a B-stage sheet shape, so that any coil shape can be obtained. It is possible to follow unevenness. Since the thermosetting resin 5 obtained by curing the thermosetting resin composition sheet 5B of the B stage has insulation properties, after curing, insulation between the copper wires wound around the coil 4 or interphase insulation between the coils 4 That is, the insulation between the U-phase coil, the V-phase coil, and the W-phase coil is ensured. Therefore, the varnish impregnation step or the mold sealing step after mounting the coil 4 is not necessary. As a result, it becomes possible to abolish pretreatment processes such as preheating and jig mounting or reduce waste materials.

  The heating method for curing the B-stage thermosetting resin composition sheet 5B includes heating by an oven or dielectric heating, but the heating method is not limited thereto. In addition, it is possible to appropriately select a method for curing the B-stage thermosetting resin composition sheet 5B by heating. Since the entire assembly including the split iron core 20 is heated by using oven heating for heating the B-stage thermosetting resin composition sheet 5B, the state of the entire assembly is stabilized. Can be achieved.

  On the other hand, by using heating by dielectric heating, only the B-stage thermosetting resin composition sheet 5B requiring heating can be selectively heated and cured by heating in a short time. It is possible to prevent deterioration of the split iron core 20 and the like.

FIGS. 7A and 7B are explanatory views showing the relationship between the width of the thermosetting resin composition sheet 5B of the B stage and the winding state of the coil 4, and FIG. The figure which shows the state by which the coil 4 was wound, (b) is a figure which shows the state by which the thermosetting resin composition sheet | seat 5B of B stage was distribute | arranged so that the coil 4 might be covered. 7A and 7B are both top views. The B-stage thermosetting resin composition sheet 5B has the same width as the winding width W ₀ of the coil 4 as shown in FIGS. According to this configuration, the coil 4 is securely fixed, and insulation is also ensured.

Embodiment 2. FIG.
As Embodiment 2, an example in which the mounting state of the layer of the thermosetting resin 5 is different will be described. FIG. 8 is an explanatory view showing the relationship between the coating width of the thermosetting resin composition sheet 5B of the B stage and the winding state of the coil 4, and the coil 4 having a width approximately equal to the winding width W ₀ of the coil 4. shows a state where the winding length of about half of the thermosetting resin composition sheet 5B in a B-stage so as to cover the length L ₁ of the L ₀ was arranged for. The state where the coil 4 is wound around the split iron core 20 is the same as in FIG. The method for manufacturing the stator according to the second embodiment is the same as that of the first embodiment, including the configuration of the split iron core 20 except for the mounting state of the thermosetting resin 5 layer. Omitted. The same parts as those in the first embodiment are denoted by the same reference numerals.

  When the thermosetting resin 5 is formed so as to cover about half of the winding width of the coil 4, the copper wires constituting the coil 4 are securely fixed to each other while the coil 4 has a degree of freedom. Therefore, even when the coil 4 expands due to a temperature change, the thermosetting resin 5 is not cracked and can be reliably fixed.

Embodiment 3 FIG.
As Embodiment 3, an example in which the mounting state of the layer of the thermosetting resin 5 is different will be described. FIG. 9 is an explanatory diagram showing the relationship between the coating width of the thermosetting resin composition sheet 5B of the B stage and the winding state of the coil 4, and covers the entire winding width W ₀ of the coil 4 in four parts. In addition, a thermosetting resin 5 is formed. The state where the coil 4 is wound around the split iron core 20 is the same as in FIG. The stator manufacturing method of the third embodiment is the same as that of the first embodiment except for the configuration of the split core 20 and the mounting state of the thermosetting resin 5 layer. Omitted.

According to this configuration, the thermosetting resin composition of the B stage having a width W ₁ that is about a quarter of the winding width W ₀ of the coil 4 so as to cover the entire winding length of the coil 4 in four divisions. The sheet 5B is mounted on the coil 4 in four turns. Therefore, the thermosetting resin composition sheet 5B of the B stage is more easily deformed according to the outer shape of the coil 4 than in the case of the first embodiment, and the thermosetting resin 5 has a shape along the outer shape of the coil 4. Therefore, the copper wire constituting the coil 4 can be reliably fixed. In addition, since the winding start of the coil 4 is on the teeth tip yoke portion 23 side and the winding end is on the yoke portion 21 side, winding is performed from the small winding diameter side to the large winding side. A winding state in close contact with the peripheral surface can be formed.

Embodiment 4 FIG.
As Embodiment 4, an example in which the mounting state of the thermosetting resin 5 layer is different will be described. FIG. 10 is an explanatory diagram showing the relationship between the width of the thermosetting resin composition sheet 5 </ b> B of the B stage and the winding state of the coil 4. In the stator manufacturing method of the fourth embodiment, the thermosetting resin composition of the B stage used in the first embodiment so as to cover the winding width W ₀ of the coil 4 in four divisions as in the third embodiment. quarter width of the thermosetting resin composition sheet 5B in a B-stage of the winding width W ₀ of the sheet 5B is formed. In the fourth embodiment, the outer diameter of the coil 4 is two and a half turns, and the B-stage thermosetting resin composition sheet 5B is mounted. The state where the coil 4 is wound around the split iron core 20 is the same as in FIG. Moreover, since it is the same as that of Embodiment 1 except the structure of the division | segmentation iron core 20 except the mounting state of the layer of the thermosetting resin 5, description is abbreviate | omitted here.

  According to this configuration, the thermosetting resin composition sheet 5B of the B-stage having a quarter width of the coil winding length is covered by two and a half turns so as to cover the entire winding length of the coil 4 in four divisions. It is installed with. Therefore, the thermosetting resin composition sheet 5B of the B stage is more easily deformed according to the outer shape of the coil 4, and the thermosetting resin 5 is likely to have a shape along the outer shape of the coil 4, so that the fixed fixation is maintained. can do. Compared to the case of the third embodiment, since the thermosetting resin composition sheet 5B of the B stage is attached only to the places that need to be fixed, manufacturing is easy and material saving is realized.

Embodiment 5. FIG.
As Embodiment 5, an example in which a layer of the thermosetting resin 5 is mounted partially overlapped will be described. FIG. 11 is an explanatory diagram showing the relationship between the width of the thermosetting resin composition sheet 5 </ b> B of the B stage and the winding state of the coil 4. As in the third embodiment, the stator core 20 according to the fifth embodiment is formed so that the entire winding length of the coil 4 is covered with the four-stage B-stage thermosetting resin composition sheet 5B. In this respect, the configuration is the same as that of the third embodiment. The split core 20 for the stator of the fifth embodiment has a B-stage heat wider than the quarter-width B-stage thermosetting resin composition sheet 5B used in the third and fourth embodiments. This is a configuration in which the curable resin composition sheet 5B is used and wound while forming an overlapping region 8 in part. In the fifth embodiment, the B stage thermosetting resin composition sheet 5B is mounted with the number of turns of the outer diameter of the coil 4 being four. The state where the coil 4 is wound around the split iron core 20 is the same as in FIG. Moreover, since it is the same as that of Embodiment 3 except for the point which is the mounting state in which the layer of the thermosetting resin 5 has an overlap including the structure of the division | segmentation iron core 20, description is abbreviate | omitted here.

  According to this configuration, the thermosetting resin composition sheet 5B of the B stage is attached so as to cover the coil 4 with a part number of turns and 4 turns. Therefore, the thermosetting resin composition sheet 5B of the B stage is easily deformed in accordance with the outer shape of the coil 4, and a region where the thermosetting resin composition sheets 5B of the B stage are separated from each other at the time of deformation is formed. The formation of a portion where the conductive resin 5 does not exist is prevented, and the shape is likely to conform to the outer shape of the coil 4, so that reliable fixing can be maintained.

Embodiment 6 FIG.
As Embodiment 6, an example in which a layer of the thermosetting resin 5 is partially overlapped will be described. FIG. 12 is an explanatory diagram showing the relationship between the width of the thermosetting resin composition sheet 5 </ b> B of the B stage and the winding state of the coil 4. Also in the stator manufacturing method of the sixth embodiment, the entire winding length of the coil 4 is formed so as to be covered with the four-stage B-stage thermosetting resin composition sheet 5B, as in the third and fourth embodiments. ing. However, in the stator manufacturing method of the sixth embodiment, the B-stage thermosetting resin wider than the quarter-width B-stage thermosetting resin composition sheet 5B used in the third and fourth embodiments. An example in which the composition sheet 5B is used and wound while forming an overlapping region 8 in part is shown. In the fifth embodiment, the thermosetting resin composition sheet 5B of the B stage that covers the winding width W ₀ of the coil 4 by winding the outer diameter of the coil 4 four times is mounted. Then, the outer diameter of the coil 4 is two and a half turns, and the B-stage thermosetting resin composition sheet 5B is mounted. The state where the coil 4 is wound around the split iron core 20 is the same as in FIG. Moreover, since it is the same as that of Embodiment 4 except the point which is the mounting state with which the layer of the thermosetting resin 5 has an overlap including the structure of the division | segmentation iron core 20, description is abbreviate | omitted here.

  According to this configuration, the thermosetting resin composition sheet 5B of the B stage having a width wider than a quarter width of the coil winding length is divided into four parts, and the entire winding length of the coil 4 is obtained while having an overlapping portion. It is mounted in two and a half turns so as to cover it. Therefore, the thermosetting resin composition sheet 5B of the B stage is easily deformed according to the outer shape of the coil 4, and the thermosetting resin 5 is likely to have a shape along the outer shape of the coil 4, so that reliable fixing is maintained. be able to.

  As described above in the first, third, and fifth embodiments, the width of the thermosetting resin composition sheet 5B of the B stage is equal to the winding width of the coil 4 or the winding width of the coil 4 depending on the shape of the coil 4. Is also processed to be small, and the entire outermost layer of the coil 4 is coated. The winding of the B-stage thermosetting resin composition sheet 5B covering the coil 4 may be a single layer or two or more layers, and may be adjusted in accordance with the required fixing force and interphase insulation. Further, the number of times of coating winding of the thermosetting resin composition sheet 5B of the B stage, that is, the number of superpositions may be different in one coil 4. Further, the number of times of covering winding of the thermosetting resin composition sheet 5B of the B stage may be different for each slot 24 of each divided iron core 20 in the stator 1.

  Further, when it is desired to cover only the portion that needs to be fixed, the thermosetting resin composition sheet 5B of the B stage partially covers the outermost layer of the coil 4 as in the second, fourth, and sixth embodiments. Also good.

Embodiment 7 FIG.
As Embodiment 7, an example will be described in which a through hole h constituting an air hole is formed in a part of the thermosetting resin composition sheet 5B of the B stage. FIG. 13 is an explanatory diagram showing a case where a plurality of through holes h are formed in the thermosetting resin composition sheet 5B of the B stage. Since other configurations are the same as those of the first embodiment, description thereof is omitted here.

  By forming a through hole h in a portion corresponding to the inter-coil region 4s of the coil 4, when the thermosetting resin composition sheet 5B of the B stage is heated and cured, the through hole h becomes an air hole and a void is generated at the time of curing. Is suppressed. Further, the through hole h becomes an air hole, so that the followability of the thermosetting resin 5 to the irregularities on the outer peripheral surface of the coil 4 formed by winding the conducting wire is improved. The number of through holes h may be one, or one or many may be provided along the inter-coil region. Also, the shape of the through hole h is not particularly limited, and a part of the through hole h may exist at the end of the B stage thermosetting resin composition sheet 5B. The through hole h is filled at the time of heat curing, and a layer of the thermosetting resin 5 having a uniform thickness is formed.

Embodiment 8 FIG.
As an eighth embodiment, an example in which slits s are provided in a part of the thermosetting resin composition sheet 5B of the B stage instead of the through hole h will be described. FIG. 14 is an explanatory diagram showing a case where a plurality of slits s are formed in the B-stage thermosetting resin composition sheet 5B. Since other configurations are the same as those in the seventh embodiment, description thereof is omitted here.

  By forming the slit s in the portion corresponding to the inter-coil region 4 s of the coil 4, when the thermosetting resin composition sheet 5 B of the B stage is heated and cured, the slit s becomes an air hole and suppresses voids generated at the time of curing. In addition, the shape of the slit s improves the followability of the thermosetting resin 5 to the irregularities on the outer peripheral surface formed by winding the coil 4.

  The number of slits s may be one, or one or many may be formed along the inter-coil region 4s. Moreover, there is no limitation in particular also about the shape and arrangement | positioning position of the slit s, and the partial slit s opened to the edge part of the thermosetting resin composition sheet 5B of B stage may exist. The slits s are filled at the time of heat curing, and a layer of the thermosetting resin 5 having a uniform thickness is formed.

Embodiment 9 FIG.
As Embodiment 9, an example in which only a portion that needs to be fixed is covered will be described. FIG. 15 shows a perspective view of the state in which the thermosetting resin 5 is coated in the divided core unit constituting the stator of the ninth embodiment, and the outermost layer of the coil 4 is composed of the yoke portion 21 and the tooth tip yoke portion 23. The thermosetting resin composition sheet 5B of the B stage partially covers the outermost layer of the coil 4 so as to cover only the side and not cover the region corresponding to the slot 24. Since other configurations are the same as those of the first embodiment, description thereof is omitted here.

  In the ninth embodiment, the coil 4 is fixed by forming a layer of the thermosetting resin 5 only on the coil 4 partially located on the yoke portion 21 and the tooth tip yoke portion 23 side. The generated void is suppressed, and the followability to the unevenness of the outer peripheral surface formed by winding the coil 4 is improved.

Embodiment 10 FIG.
As the tenth embodiment, another example in which only the portion that needs to be fixed is covered will be described. In FIG. 16, the perspective view of the coating state of the thermosetting resin 5 in the division | segmentation iron core unit which comprises a stator is shown. As shown in FIG. 16, contrary to the ninth embodiment, the outermost layer of the coil 4 is left of the yoke portion 21 and the teeth tip yoke portion 23 side, and covers the region corresponding to the slot 24 so as to cover the region of the B stage. The thermosetting resin composition sheet 5 </ b> B is partially covered on the outermost layer of the coil 4. Since other configurations are the same as those of the ninth embodiment, description thereof is omitted here.

  In the tenth embodiment, since the layer of the thermosetting resin 5 is partially formed and the coil 4 is fixed, the outer peripheral surface formed by suppressing voids generated during curing and winding the coil 4 Improves the ability to follow unevenness.

Embodiment 11 FIG.
As an eleventh embodiment, another example in which only a portion that needs to be fixed is covered will be described. FIG. 17 shows a perspective view of a state in which the thermosetting resin 5 is coated in the divided core units constituting the stator, and the B stage is thermally cured so that the outermost layer of the coil 4 is covered only at the four corners. The resin composition sheet 5 </ b> B is partially covered on the outermost layer of the coil 4. Since other configurations are the same as those of the ninth and tenth embodiments, description thereof is omitted here.

  In the eleventh embodiment, since the coil 4 is fixed by partially forming a layer of the thermosetting resin 5, the outer peripheral surface formed by suppressing voids generated during curing and winding the coil 4. Improves the ability to follow unevenness. In particular, since the windings of the coils 4 are selectively fixed at the four corners where the coil 4 needs to be fixed, the coils 4 can be efficiently fixed to the split core 20 and can be reliably secured with a small amount of thermosetting resin. Fixing is realized.

Embodiment 12 FIG.
As Embodiment 12, an example in which a B-stage thermosetting resin composition sheet 5B is coated with two layers will be described. FIGS. 18A and 18B are views showing a state in which a B-stage thermosetting resin composition sheet 5B is attached to the wound coil 4 before thermosetting. FIG. 18A is an enlarged perspective view of the main part showing the coil 4 on which the B-stage thermosetting resin composition sheet 5B is mounted, and FIG. 18B is a cross-sectional view.

  The difference from the first embodiment is that a two-layer B-stage thermosetting resin composition sheet 5B is used instead of the single-layer B-stage thermosetting resin composition sheet 5B. In the method of the twelfth embodiment, two sheets having a film thickness half that of the thermosetting resin composition sheet 5B of the B stage used in the first embodiment are stacked and used.

  The thermosetting resin composition sheet 5B is melted by heating, and adheres between the wires of the coil 4 by following the shape of the coil 4. However, since it has a two-layer structure, the following property is better and the thermosetting resin. When 5 is closely attached and fixed along the outer surface of the coil 4, the coil 4 can be fixed more reliably.

  As described above, the thermosetting resin composition sheet 5B of the B stage is composed of only a thermosetting resin having no thermoplastic resin, glass cloth, and non-woven fabric. The shape irregularities can also be followed. And since the thermosetting resin composition sheet 5B of B stage is comprised with resin which has insulation, the interphase insulation of the coil 4 is ensured after hardening. It goes without saying that the B-stage thermosetting resin composition sheet 5B may have a multilayer structure of two or more layers instead of the two-layer structure.

  The B-stage thermosetting resin composition sheet 5B used in Embodiments 1 to 12 has the following configuration. The B-stage thermosetting resin composition sheet 5B is made of a resin containing a liquid epoxy resin, a solid epoxy resin, a curing agent, and a polyether resin.

  When the weight average molecular weight of the polyether resin is 2,000 or more and 300,000 or less, a product having high insulation and mechanical strength can be obtained. When it is less than 2000, the stretch effect of the thermosetting resin composition sheet 5 of the B stage is lost, and when wound around the coil surface, it does not follow the irregularities present on the coil surface, and after curing, there are voids in the concave portions of the coil. Exists, and the insulation and mechanical strength are reduced. If it exceeds 300,000, the amount melted in the resin composition will be reduced, it will be difficult to exhibit the stretch effect, and the viscosity of the resin composition will be high, making it difficult to form into a sheet.

  The content of the polyether resin is 0.1 to 30 parts by weight with respect to 100 parts by weight of the total of the liquid epoxy resin, the solid epoxy resin, and the curing agent. A thing with high intensity | strength can be obtained. If it is less than 0.1 parts by weight, the stretchable effect of the thermosetting resin composition sheet 5 of the B stage is lost, and when wound around the coil surface, the coil 4 does not follow the irregularities present on the coil surface and is cured after curing. There are voids in the recesses, and the insulation and mechanical strength are reduced. If it exceeds 30 parts by weight, the flexibility of the thermosetting resin composition sheet 5B of the B stage is lowered, and it becomes difficult to wind it around the coil 4.

  The B-stage thermosetting resin composition sheet 5B can contain an inorganic filler. The content of the inorganic filler is 1 volume percent or more and 150 volume percent or less with respect to 100 volume percent of the total of the liquid epoxy resin, solid epoxy resin, curing agent, and polyether resin. By setting it as the said range, insulation and mechanical strength can be improved. When the inorganic filler content is less than 1 volume percent, the effect of improving the mechanical strength of the thermosetting resin composition sheet 5B of the B stage cannot be exhibited, and the effect of improving the insulation cannot be exhibited. When the content of the inorganic filler is more than 150 volume percent, the flexibility of the B-stage thermosetting resin composition sheet 5B is lowered, and it is difficult to wind it around the coil 4.

  By setting the average particle size of the inorganic filler to 0.01 μm or more and 50 μm or less, the thermosetting resin composition can be mixed with good workability. When the average particle diameter of the inorganic filler is smaller than 0.01 μm, the inorganic filler is scattered and the workability at the time of mixing with the thermosetting resin composition is deteriorated. When the average particle size of the inorganic filler is larger than 50 μm, a part of the filler may come out on the surface of the B-stage thermosetting resin composition sheet 5B, and the B-stage thermosetting resin composition sheet. When 5B is wound, the electric wire membrane | film | coat of the coil 4 surface is damaged, and insulation falls.

  By setting the film thickness of the thermosetting resin composition sheet 5B of the B stage to 10 μm or more and 1000 μm or less, both mechanical strength and flexibility can be maintained. When the film thickness of the thermosetting resin composition sheet 5B is less than 10 μm, the mechanical strength of the B stage thermosetting resin composition sheet 5B is low, and the B stage thermosetting resin composition sheet 5B is used as the coil 4. When winding, it breaks. When the film thickness of the thermosetting resin composition sheet 5B is thicker than 1000 μm, the flexibility of the thermosetting resin composition sheet 5B of the B stage is lost and it is difficult to wind it around the coil 4.

  When producing the B-stage thermosetting resin composition sheet 5B, first, a liquid epoxy resin, a solid epoxy resin, a curing agent, and a polyether resin are mixed. When the viscosity is high when mixing a liquid epoxy resin, a solid epoxy resin, a curing agent, and a polyether resin, the thermosetting resin composition can be diluted with a solvent to improve workability for sheeting. As a solvent to be used, a solvent such as an ether solvent, a ketone solvent, an aromatic solvent, and an acetate solvent can be used. Specific examples include tetrahydrofuran, acetone, toluene, xylene, and propylene glycol monomethyl ether acetate. May be used alone or in combination of two or more.

  When preparing the thermosetting resin composition sheet 5B, a curing catalyst may be added. Curing catalysts include organometallic salts, imidazoles, and amines. Specifically, zinc naphthenate, cobalt naphthenate, cobalt octylate, zinc octylate, 2-ethyl-4-methylimidazole, 2-phenylimidazole, 1- (2-cyanoethyl) -2-ethyl-4-methyl Imidazole, diaminodiphenylmethane, 3-phenyl-1,1-dimethylurea, DBU (1,8-diazabicyclo (5,4,0) -undecene-7), 1,5-diazabicyclo (4,3,0) -nonene -5, and may be used alone or in combination of two or more.

  The liquid epoxy resin includes bisphenol A type epoxy resin and bisphenol F type epoxy resin in consideration of heat resistance and workability, and may be used alone or in combination of two or more.

  The polyether resin has an effect of imparting stretchability to the thermosetting resin composition sheet 5B. Specifically, there is a polyhydroxy polyether, which may be used alone or in combination of two or more.

  Normally, the stator iron core is formed by assembling the divided iron cores, but one piece may take a cylindrical shape. In the case of taking a cylindrical form, the thermosetting resin composition sheet 5B is coiled on the outer periphery of the coil, and the thermosetting resin composition sheet 5B is coiled as in Embodiments 2, 4, 6, 9-11. It can be easily mounted by taking a configuration that is partially fixed to the outer periphery.

  The configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.

  DESCRIPTION OF SYMBOLS 1 Stator, 2 Stator iron core, 3 Insulating member, 4a Core wire, 4b Enamel coating, 4 Coil, 5B B stage thermosetting resin composition sheet, 5 Thermosetting resin, 6 Frame body, 7 Gap, 8 Overlapping area, 20 divided iron core, 21 yoke part, 22 teeth part, 23 tooth tip yoke part, 24 slots, h through hole, s slit.

Claims (9)

Winding a conductive wire around a stator core to form a coil; and arranging a B-stage thermosetting resin composition sheet on a peripheral surface of the coil wound around the stator core;
Heating the thermosetting resin composition sheet, and curing the sheet along the outer periphery of the coil. The stator core includes a yoke portion, a teeth portion, a teeth tip yoke portion, and a slot surrounded by the yoke portion, the teeth portion and the teeth tip yoke portion,
The step of arranging the thermosetting resin composition sheet is a step of arranging the thermosetting resin composition sheet on a part of the outer peripheral surface of the coil wound around the slot. Item 2. A method for manufacturing a stator according to Item 1. The step of arranging the thermosetting resin composition sheet includes:
It is the process of processing the said thermosetting resin composition sheet | seat to the same width as the winding width | variety of the said coil wound, and covering the said thermosetting resin composition sheet | seat. Method of manufacturing the stator. The step of arranging the thermosetting resin composition sheet includes:
2. The method for manufacturing a stator according to claim 1, wherein the thermosetting resin composition sheet is processed to a width smaller than a winding width of a coil, and the thermosetting resin composition sheet is coated. . The step of arranging the thermosetting resin composition sheet includes:
The method for manufacturing a stator according to any one of claims 1 to 4, wherein the coil is a step of coating the B-stage-shaped thermosetting resin composition sheet on the coil as a single layer. The step of arranging the thermosetting resin composition sheet includes:
5. The method for manufacturing a stator according to claim 1, wherein the coil is a step of coating the coil with two or more layers of the B-stage-shaped thermosetting resin composition sheet.   The method for manufacturing a stator according to any one of claims 1 to 6, wherein the B-stage thermosetting resin composition sheet has holes.   The method for producing a stator according to any one of claims 1 to 6, wherein the B-stage thermosetting resin composition sheet has a slit. A stator core having a yoke portion, a teeth portion, a teeth tip yoke portion, and a slot surrounded by the yoke portion, the teeth portion and the teeth tip yoke portion;
A coil wound around the wall of the slot via an insulating member;
A stator comprising a thermosetting resin composition sheet formed along the outer shape of the wound coil and covering the outer shape of the coil with a uniform thickness.

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