JP2021069196A - Stator structure and electric motor - Google Patents

Abstract

To provide a stator structure and an electric motor which have such new configurations as to reduce heat resistance of the stator structure.SOLUTION: A configuration of a stator structure 100 included in an electric motor includes a stator intermediate assembly 90 including a stator 80, a heat conductor 60 and a filling resin 95, inside a stator frame body 40. A configuration of the stator intermediate assembly 90 includes a stator 80, and a printing wiring board 70. A configuration of the stator 80 includes a stator magnetic core 10, an insulator 20, and a wound body 30. A configuration of the stator frame body 40 includes a bottom 40a, a bearing storage part 40c and a frame part 50. A stator intermediate assembly 90 is accommodated and put in the stator frame body 40 from the side of an open end of the stator frame body 40. At this time, in the stator intermediate assembly 90, an arrangement side of the printing wiring board 70 is positioned on the side of the open end of the stator frame body 40.SELECTED DRAWING: Figure 1

Description

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

In the fields of household electric appliances, industrial electric devices, in-vehicle electric devices, and the like, devices having coils such as electric motors and transformers are used. In recent years, these devices are required to be further miniaturized, thinned, and have high output.

As an example showing the conventional technique, FIGS. 12 to 14 show an electric motor and a stator structure included in the electric motor.

FIG. 12 is a conceptual diagram showing an outline of a stator structure included in a conventional electric motor. FIG. 13 is a conceptual diagram showing a main part of a conventional electric motor. FIG. 14 is an enlarged view of a main part of the conventional electric motor shown in FIG.

As shown in FIG. 12, the stator structure 1001 of the electric motor has a structure in which the stator intermediate assembly 120 including the stator 117 is housed inside the stator frame 114. In addition, in order to make the drawing easy to see, the rotor is not drawn in FIG.

As shown in FIG. 13, the stator 117 includes a stator core 110, an insulator 111, and a stator winding 112. The stator intermediate assembly 120 is a structure including a stator 117 and a printed wiring board 113.

An insulating electric wire 116 is wound around the stator core 110 via an insulator 111. The wound insulated wire 116 forms a stator winding 112 that is a coil. The stator winding 112 and the printed wiring board 113 are electrically connected as described later. As shown in FIG. 12, the stator core 110 around which the stator winding 112 is wound is inserted into the stator frame 114. The stator frame 114 is made of metal or the like.

The stator winding 112 and the connector 115 are electrically connected via the printed wiring board 113.

As shown in FIG. 14, the end portion 112a of the stator winding 112 is electrically connected to the printed wiring board 113 by the solder 113a.

As shown in FIG. 12, the stator 117 is fixed to the inside of the stator frame 114 by a set of fixing pins 118. There is a gap 119 between the stator 117 and the wall surface 114a included in the stator frame 114. In other words, the stator 117 is fixed by a set of fixing pins 118 apart from the wall surface 114a without coming into contact with the stator frame 114.

As the components of the electric motor, in addition to the components shown in FIG. 12, a rotor, an output shaft which is a rotating shaft, a pair of bearings, a bracket, and the like are used.

The rotor is located in the space formed inside the stator core 110. The rotor is located facing the stator 117. The rotor is rotatably supported with the rotation axis as the center of rotation.

The pair of bearings rotatably support both ends of the rotating shaft. One bearing is fixed to an accommodating portion in which an outer ring constituting the bearing is formed in a bracket. In the other bearing, the outer ring constituting the bearing is fixed to the accommodating portion formed on the bottom surface of the stator frame.

As the rotor, the output shaft which is the rotating shaft, the pair of bearings, the bracket, and the like described above, widely known ones can be used.

By the way, in the stator component 1001 shown in FIG. 12, no filler is particularly used in the gaps formed between the components. In other words, in the stator component 1001, an air layer is formed in the gaps formed between the components.

The thermal resistance of this air layer increases when the thickness dimension of the air layer and the volume of the air layer become excessive. The air layer with increased thermal resistance becomes a factor that hinders heat dissipation.

Further, in order to reduce the size, thickness and output of the electric motor, it is necessary to consider the following points.

That is, one of them is that the stator winding wound around the stator core has a resistance component. The resistance component of the stator winding generates heat when an electric current is passed through the stator winding. The heat generated by the resistance component of the stator winding is also called copper loss.

The other is heat generation due to eddy current loss and hysteresis loss that occurs in the stator core. The heat generated by the eddy current loss and the hysteresis loss is also called iron loss.

If the heat generated in the stator windings is excessive, the electrical equipment to which the motor is attached will be less power efficient. Further, if the heat generated in the stator winding is excessive, the electrical equipment to which the electric motor is attached causes a decrease in safety and a shortened life.

That is, since the electric motor has both miniaturization and thinness and high reliability, improvement of heat dissipation characteristics is strongly required.

In order to satisfy such a requirement, for example, in the electric motors in Patent Document 1 and Patent Document 6, a filled resin exists between the stator winding and the stator frame.

Further, for example, in Patent Documents 2 to 5, a highly thermally conductive resin is arranged in the gap between the coil end of the stator winding and the bracket in the electric motor, and heat is generated from the stator winding. The technical idea of promoting heat dissipation from the bracket via a highly thermally conductive resin is described.

Japanese Unexamined Patent Publication No. 60-28755 Japanese Unexamined Patent Publication No. 8-223866 Japanese Unexamined Patent Publication No. 2000-116063 JP-A-2002-369449 Japanese Unexamined Patent Publication No. 2004-274884 Japanese Unexamined Patent Publication No. 2007-60834

In order to improve the heat dissipation of the entire electric motor, a method of filling a resin between the stator winding where the air layer is located and the stator frame body has been proposed in the conventional electric motor. With this configuration, the thermal resistance generated between the stator winding and the stator frame can be reduced, so that the heat dissipation is good.

On the other hand, the technique described in Patent Document 1 and the like has the following items to be examined. That is, when the resin is filled between the stator and the stator frame, in the electric motor shown in Patent Document 1 and the like, the surrounding air is likely to be mixed as bubbles in the filled resin.

In particular, when the resin to be filled contains a filler, the higher the filler content, the higher the viscosity of the resin. If a resin having a high viscosity is used, the amount of air bubbles mixed in the resin increases. That is, when only the thermal conductivity is emphasized, it is conceivable that a resin having a high filler content and a high viscosity is used.

In order to prevent air bubbles from being mixed into the resin to be filled, equipment for performing the related manufacturing process in a vacuum state is required. That is, in order to expect the effect of the electric motor described in Patent Document 1 and the like, a large-scale equipment is required.

Therefore, in order to manufacture the electric motor described in Patent Document 1 and the like, a large amount of investment is required for the manufacturing equipment. Further, in order to manufacture the electric motor described in Patent Document 1 and the like, there is a concern that the man-hours in the manufacturing process will increase.

In other words, the electric motor described in Patent Document 1 and the like includes management problems due to cost increase due to capital investment and increase in man-hours.

Further, in the techniques described in Patent Documents 2 to 5 and the like, a specific mode for suppressing the gap caused by the inhomogeneous shape of the coil end in the stator winding of the electric motor is specified. Was not shown and was unknown.

The present invention solves the above-mentioned problems, and an object of the present invention is to provide a stator structure and an electric motor having a novel structure for reducing the thermal resistance of the stator structure.

In order to solve the above problems, the first invention includes a stator core, an insulator covering each of the teeth of the stator core, and a winding body for winding an insulated wire for each insulator. A stator intermediate assembly including a child, a winding body of the stator and a printed wiring board electrically connected to the stator, a stator frame body accommodating the stator intermediate assembly, and the stator frame body. With each of the coil end portions located between the bottom portion of the stator and the facing portion of the stator intermediate assembly facing the bottom portion and located on the bottom side of the stator frame body in the winding body. Each of the plurality of heat-dissipating coupling portions included in the stator frame includes a heat conductor that thermally couples with the bottom of the stator frame, and each of the plurality of heat-dissipating coupling portions included in the heat conductor comes into contact with each of the coil ends. It is a stator structure in which the filler resin is in contact with each of the coil ends located on the opening side of the stator frame in the wound body, and the filler resin and the heat conductor are in contact with each other.

The second invention is a stator structure in which the filler resin is contained in a part or all of the gaps in the abutting portion where the coil end portion and the heat conductor abut each other in the first invention. ..

Further, the third invention is the stator structure in which the stator frame body includes a bearing accommodating portion located at the center of the bottom portion of the stator frame body in the first invention.

Further, in the fourth invention, in the first invention, the stator frame body has a bottom portion including a bottom portion of the stator frame body and a bearing accommodating portion located at the center of the bottom portion, and the fixing portion thereof. It is a stator structure including a frame portion including a frame portion excluding the bottom portion from the child frame body.

Further, in the fifth invention, in the first invention, the stator frame includes a bearing accommodating portion located at the center of a bottom portion of the stator frame, and further, the hole in the bottom portion. The heat conductor is arranged in a portion other than the portion and the bearing accommodating portion, a position regulating portion that regulates the arrangement position of the heat conductor is arranged in a part of the bottom portion, and the position regulating portion is arranged in a part of the heat conductor. It is a stator structure including a position-restricting part corresponding to the above.

Further, in the sixth invention, in the first invention, the stator frame body has a bottom portion including a bottom portion of the stator frame body and a bearing accommodating portion located at the center of the bottom portion, and the fixing portion thereof. The heat conductor is arranged in a portion of the bottom portion of the bottom portion excluding the hole portion and the bearing accommodating portion, and includes the frame portion including the frame portion excluding the bottom portion from the child frame body. It is a stator structure including a position regulating unit that regulates the position of arrangement of the heat conductor in a part thereof and a position regulating portion corresponding to the position regulating portion in a part of the heat conductor.

Further, in the seventh invention, in the first invention, the stator frame body has a hole located at the center of the bottom portion of the stator frame and a bearing accommodating portion located at the edge of the hole. Further, the heat conductor is arranged in a portion other than the hole portion and the bearing accommodating portion in the bottom portion of the stator frame, and the bottom portion hits in contact with the heat conductor in the bottom portion. It is a stator structure including a structure in which a contact surface has a flat surface and a surface in contact with the heat conductor in contact with the bottom portion of the heat conductor has a flat surface.

Further, in the eighth aspect of the invention, in the first invention, the stator frame is located at a bottom portion of the stator frame body, a hole located at the center of the bottom portion, and an edge portion of the hole portion. A bottom portion including a bearing accommodating portion and a frame portion including a frame portion excluding the bottom portion from the stator frame body, and further, a portion excluding the hole portion and the bearing accommodating portion of the bottom portion of the bottom portion. The heat conductor is arranged, the bottom portion contact surface in contact with the heat conductor in the bottom portion has a flat surface, and the heat conductor contact surface in contact with the bottom portion in the heat conductor. It is a stator structure including a structure having a flat surface.

Further, the ninth invention is a stator structure including a concave shape corresponding to each convex coil end shape of the coil end in the configuration of the heat radiation coupling portion in the first invention.

Further, in the tenth invention, in the first invention, in the configuration of the heat dissipation coupling portion, an elastic contact that is easily deformed to a surface layer portion of the thermal conductor at a position where the coil end and the thermal coupling portion are in pressure contact with each other. It is a stator structure including a tangent part.

Further, the eleventh invention is a stator structure including a structure in which a plurality of groove-shaped recesses are arranged in a row in the structure of the elastic contact portion in the first invention.

Further, the twelfth invention is a stator structure including a structure in which a plurality of ridge-shaped convex portions are arranged in a row in the structure of the elastic contact portion in the first invention.

Further, the thirteenth invention is a stator structure including a structure in which a plurality of square weights are arranged in a checkered pattern in the structure of the elastic contact portion in the first invention.

Further, the fourteenth invention is a stator structure including a structure in which a plurality of trapezoidal weights are arranged in a checkered pattern in the structure of the elastic contact portion in the first invention.

Further, the fifteenth invention is an electric motor including the stator component of the first invention.

According to the present invention, with respect to the heat dissipation configuration of the wound body of the stator, the stator structure can be realized at low cost and low man-hours, and has great industrial value.

Sectional drawing which shows the outline of the stator structure in Embodiment 1 and Embodiment 2. Top view showing an outline of an example of the shape of a thermal conductor Cross-sectional view between A and A in FIG. 2A showing a thermal conductor Top view showing the outline of the concave structure part and the convex structure part of the heat conductor. Cross-sectional view between BB in FIG. 3A showing a thermal conductor The figure which shows the contact state between an example of a heat dissipation coupling part and a coil end The figure which shows the contact state with the coil end with another example of a heat dissipation coupling part. Top view showing the outline of the elastic contact part which arranges groove-shaped recesses in a row Front view showing the outline of the elastic contact portion in which the groove-shaped recesses are arranged in a row. Top view showing the outline of the elastic contact part which arranges the ridge-shaped convex part in a row Front view showing the outline of the elastic contact portion in which the ridge-shaped convex portions are arranged in a row. Top view showing an elastic contact portion where square weights are arranged in a checkered pattern. Front view showing an elastic contact portion where square weights are arranged in a checkered pattern. The figure which shows the outline of the position regulation part of the heat conductor which regulates the arrangement of the heat conductor arranged in the bottom part of a stator frame body. The figure which shows the outline of the position regulation part which regulates the arrangement of the heat conductor arranged in the bottom part of a stator frame body. A perspective assembly view showing a main part of an electric motor including a stator component according to the first embodiment. Perspective view illustrating the segment core included in the stator core Front view showing the appearance of the electric motor including the stator component in the present invention. Side view showing the appearance of the electric motor including the stator structure in the present invention. (I) Conceptual diagram showing an outline of a conventional electric motor (I) Conceptual diagram showing the main part of the electric motor of the conventional example (I) Enlarged view of the main part of the electric motor of the conventional example

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below.

(Embodiment 1)
FIG. 1 shows an outline of the stator structure 100 according to the present embodiment. The structure of the stator structure 100 included in the electric motor includes a stator intermediate assembly 90 including the stator 80, a heat conductor 60, and a filling resin 95 inside the stator frame body 40. The structure of the stator intermediate assembly 90 includes a stator 80 and a printed wiring board 70. The structure of the stator 80 includes a stator magnetic core 10, an insulator 20, and a winding body 30. The structure of the stator frame body 40 includes a bottom portion 40a, a rotating shaft insertion hole 40b, a bearing accommodating portion 40c, and a frame portion 50.

In FIG. 1, the open end of the stator frame 40 is shown upward, while the bottom 40a of the stator frame 40 is shown below. The stator intermediate assembly 90 is placed in the stator frame 40 in the illustrated state from the side of the opening end of the stator frame 40. At this time, the stator intermediate assembly 90 positions the arrangement side of the printed wiring board 70 on the side of the open end of the stator frame body 40.

Although not shown in FIG. 1, a connector window portion for arranging the connector is provided in the vicinity of the opening end of the stator frame body 40. The connector arranged in the connector window portion and the stator intermediate assembly 90 are electrically connected to each other.

The stator core 10 is formed by laminating steel plates in the direction along the rotation axis. The stator magnetic core 10 may adopt another configuration as long as it can obtain the same action and effect as the laminated steel plate. A winding body 30 is wound around the stator core 10 via an insulator 20. The insulator 20 is installed to electrically insulate the stator core 10 and the winding body 30. Further, the material of the insulator 20 is made of polyphenylene sulfide, polyimide, polyetherketone, liquid crystal polymer, etc. to have high strength, and in order to increase the rigidity of these materials, a filler such as glass fiber or an inorganic filler is added. Use the added resin.

The stator core 10 is fixed to the frame portion 50 in a circular shape. For this fixing, various methods such as press-fitting, baking fit, and fixing by curing the adhesive can be adopted.

The stator frame body 40 includes a frame portion 50, a bottom portion 40a, a rotating shaft insertion hole 40b, and a bearing accommodating portion 40c. In the present embodiment, the structure of the bearing accommodating portion 40c is cylindrical, but a suitable structure can be appropriately selected according to the specifications of the stator frame 40 and the like.

The bottom portion 40a included in the stator frame body 40 is fixed to the frame portion 50 so as to cover the direction along the rotation axis of the stator core 10 and the winding body 30. Although the bottom 40a and the frame 50 of the stator frame 40 are shown as separate members in FIG. 1, the bottom 40a and the frame 50 of the stator frame 40 are integrally configured. Is also good. The bottom portion 40a of the stator frame 40 is generally made of a metal member such as aluminum or carbon steel. The central portion of the bottom portion 40a is provided with a rotary shaft insertion hole 40b for inserting a rotary shaft (not shown). The edge of the rotary shaft insertion hole 40b is provided with a bearing accommodating portion 40c for accommodating a bearing (not shown) and stabilizing the holding. It is one end of a rotating shaft rotatably supported by a bearing (not shown), and the one end of the rotating shaft may slightly protrude from the axial end face of the bearing. Then, a part of one end of the rotating shaft inserts the rotating shaft insertion hole 40b. When adopting a configuration in which one end of the rotating shaft does not protrude from the axial end surface of the bearing, the rotating shaft insertion hole 40b may not be particularly provided.

A distance of several mm to several cm is provided between the winding body 30 and the bottom portion 40a of the stator frame body 40 in consideration of insulating properties. The shape of the bottom portion 40a of the stator frame body 40 is designed according to the size and type of the bearing to be installed. Further, since the minimum required rigidity is maintained, a lightening structure or a rib structure may be provided in order to reduce the weight and material cost. Since it has the above shape, it is difficult for a sheet-like object to fill the gap between the winding body 30 and the bottom portion 40a of the stator frame body 40.

The heat conductor 60 is arranged between the winding body 30 and the bottom portion 40a of the stator frame body 40. Since it is pre-molded so as to fit in the space between the winding body 30 and the bottom portion 40a of the stator frame body 40, it can be arranged without impairing the design freedom of the bottom portion of the stator frame body 40. .. Further, the material is composed of a material having rubber elasticity and having a thermal conductivity of a value larger than the thermal conductivity of air (0.025 W / m · K). Since the heat conductor 60 has rubber elasticity, the heat conductor 60 can be brought into good contact with the coil end 31, which has an unstable shape, by deforming the heat conductor 60. Further, since it has a thermal conductivity higher than that of air, the heat generation (copper loss) generated in the winding body 30 can be satisfactorily conducted to the bottom 40a of the stator frame 40, and the heat dissipation effect of the winding body 30 can be obtained. Can be enhanced.

The filler resin 95, which is a cured product of the resin material, has at least a part of the stator core 10, the insulator 20, and the wound body 30 embedded therein. The resin material used for the filling resin 95 is generally an epoxy resin, BMC, PPT or the like. The filled resin 95, which is a cured product of the resin material, has a role of conducting heat generated from the stator core 10 and the wound body 30 to the outside during the operation of the electric motor. It also has the effect of preventing vibration of the winding of the winding body 30 that occurs when the electric motor operates.

The construction method adopted when providing the filling resin 95 which is a cured product of the resin material is roughly classified into two methods.

One example is a method called potting. After the liquid resin is poured into the stator constituent 100 before the filler 95 is formed, the liquid resin is cured by heating together with the stator constituent 100 to form the filler 95. It is a method.

Another example is a method called insert molding. This is a method in which the stator structure 100 before the filling resin 95 is formed is set in a mold, a liquid or semi-liquefied resin is poured into the mold, the resin is cured, and then the resin is cooled and taken out from the mold. In the stator structure 100 of the electric motor of the present invention, the filling resin 95 may be formed by using any of the above methods.

Since the heat conductor 60 is installed between the coil end 31 and the bottom 40a before the filling resin 95 is formed, at least a part of the heat conductor 60 has a structure of being buried in the filling resin 95. .. By burying the heat conductor 60 in the filling resin 95, it is possible to prevent the heat conductor 60 from falling off due to vibration of the electric motor or the like.

The thermal conductor 60 is made of a resin material such as an epoxy resin, PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PPT (polypropylene terephthalate), and BMC (unsaturated polyester resin), and is compared with the filling resin 95. It also has the characteristics of high thermal conductivity and low strength.

For example, when the filled resin 95 is formed by curing the fluid resin in a relatively large volume gap space that tends to occur between the coil end 31 and the bottom 40a, the volume of the resin itself shrinks due to the curing of the resin. Therefore, defects such as cracks are likely to occur in the filling resin 95. Therefore, by arranging the heat conductor 60 having a strength lower than that of the filling resin 95, the space between the coil end 31 and the bottom portion 40a is filled, and the stress generated by the curing shrinkage of the filling resin 95 is relieved by the heat conductor having a low strength. It can be alleviated by absorbing the external deformation of 60, and cracks in the filling resin 95 can be suppressed.

Further, for example, it is preferable that the heat conductor 60 is in contact with the outer peripheral portion of the bearing accommodating portion 40c for accommodating the bearing formed in the bottom portion 40a. By adopting this configuration, the stress generated by the curing shrinkage of the filling resin 95 is alleviated by absorbing it by the external deformation of the heat conductor 60 having low strength, and the deformation of the bearing accommodating portion 40c due to the curing shrinkage of the filling resin 95. Can be suppressed.

Further, the fluid resin used for forming the filling resin 95 preferably has a low viscosity. The reason is that it is desired to fill the gap between the windings of the wound body 30 with the filling resin 95. The dimension of the gap portion between the windings of the winding body 30 is a small gap of about the diameter of the conducting wire constituting the winding body 30. Therefore, in order to fill the gap with the resin in the fluid state, it is preferable that the resin in the fluid state has a low viscosity. On the other hand, in order to increase the thermal conductivity of the filling resin 95, it is possible to include an inorganic filler in the filling resin 95. However, when the content of the inorganic filler is increased, the viscosity of the resin in the fluid state also increases, which contradicts the preference that the resin in the fluid state has a low viscosity.

When forming the thermal conductor 60, a general molding method applicable to a highly viscous resin such as injection molding, transfer molding, compression molding and the like can be adopted. Therefore, it is possible to increase the thermal conductivity of the heat conductor 60 as compared with the filled resin 95. In this case, by arranging the heat conductor 60, the heat conductivity between the coil end 31 and the bottom 40a is enhanced as compared with the case where the heat conductor 60 is not arranged, and the heat dissipation of the wound body 30 is improved. It is possible to do.

The heat conductor 60 is preferably made of a material having adhesiveness with the filling resin 95. By having this configuration, the heat conductor 60 is adhered to the filling resin 95, and the possibility of the heat conductor 60 falling off can be reduced. Further, the adhesion between the heat conductor 60 and the filling resin 95 is also enhanced, and the thermal conductivity between the coil end 31 and the bottom portion 40a can be enhanced.

A resin flow groove (not shown) for flowing the filling resin 95 at the time of filling the filling resin 95, which is in a flowing state before the resin is cured, may be arranged on the surface of the heat conductor 60. By arranging the resin flow groove (not shown), it is possible to suppress phenomena such as inhibition of flow of the filled resin 95 by the heat conductor 60 and generation of an unburied region when the filled resin 95 is filled.

A resin flow hole (not shown) into which the filling resin 95 flows when the filling resin 95 is formed may be arranged inside the heat conductor 60. By arranging the resin flow holes (not shown), it is possible to suppress phenomena such as inhibition of flow of the filled resin 95 by the heat conductor 60 and generation of unburied regions when the filled resin 95 is formed. Since the structure is such that the cured filling resin 95 enters the resin flow holes (not shown), the heat conductor 60 is fixed by the filling resin 95, and the effect of suppressing the heat conductor 60 from falling off is expected.

The printed wiring board 70 and the winding body 30 are electrically connected, and the stator windings included in the winding body 30 wound around each insulator 20 by this connection are Y-connected or Δ-connected in a three-phase circuit. To configure.

2A and 2B are a cross-sectional view and a plan view showing an outline of an example of the shape of the heat conductor 60. The coil end 31 has a concave structure with respect to a peripheral structure such as an insulator 20. Therefore, since the heat conductor 60 avoids the insulator 20 and the like and approaches the coil end 31, it is preferable to have the heat dissipation coupling portion 61 having a convex structure. By having the heat radiating coupling portion 61, the coil end 31 and the heat conductor 60 can be brought closer to each other, and the heat radiating effect of the wound body can be enhanced. On the other hand, in the case of an electric motor in which the coil end 31 has a convex structure with respect to the surrounding structure, the heat dissipation coupling portion 61 has a concave structure.

Further, it is preferable that the heat conductor 60 has a connecting portion 62 in which the heat radiating coupling portions 61 are arranged in an annular shape and the heat radiating coupling portions 61 are connected to each other. By having the connecting portion 62, the heat conductor 60 has an annular integrated structure, so that the man-hours for arranging the heat conductor 60 can be reduced.

A donut-shaped metal ring (not shown) made of a metal plate having a higher thermal conductivity than that of the thermal conductor 60 may be embedded inside the thermal conductor 60. By having this configuration, it is possible to improve the heat conduction performance of the heat conductor 60 and to improve the heat conductivity between the winding body 30 and the bottom portion 40a of the stator frame 40.

3A and 3B are a front view and a cross-sectional view showing an outline of the concave structure portion 63 and the convex structure portion 64 included in the heat conductor 60. As shown in FIGS. 3A and 3B, the heat conductor 60 is molded so as to fit into a lightening structure (not shown) or a rib structure (not shown) provided on the bottom 40a of the stator frame 40. It is preferable to have a concave structure portion 63 and a convex structure portion 64. By having the concave structure portion 63 and the convex structure portion 64, the contact state between the heat conductor 60 and the bottom portion 40a included in the stator frame 40 becomes good, and the winding body 30 and the stator frame 40 have a good contact state. It is possible to increase the thermal conductivity with the including bottom 40a.

FIG. 4 shows an outline of the contact state between the heat radiation coupling portion 61 and the coil end 31 having a shape conforming to the R shape of the coil end 31 according to the first embodiment of the present invention. As shown in FIG. 4, an abutting portion 32 in which the coil end 31 and the heat conductor 60 abut each other is configured. It is preferable that the surface shape of the heat radiation coupling portion 61 has a concave shape 61d which is an R shape of the coil end 31 and a shape along the convex coil end shape 31a. By having this surface shape, the contact area between the coil end 31 and the heat conductor 60 is increased, and it is possible to increase the heat conductivity between the winding body 30 and the bottom portion 40a of the stator frame 40. is there. Further, it is preferable that the gap 33 and the filling resin 95 that fills a part or all of the gap 33 flow into the abutting portion 32 where the coil end 31 and the heat radiating coupling portion 61 abut and are cured. By having this configuration, heat conduction between the coil end 31 and the coil end fitting portion 72 is promoted, the heat of the coil end 31 can be efficiently conducted to the bottom portion 40a, and heat dissipation is improved. ..

FIG. 5 shows a contact state between the heat radiating coupling portion 61 and the coil end 31 in the case where the surface of the heat radiating coupling portion 61 has an elastic contact portion 61a formed of a regularly uneven molded body. As shown in FIG. 5, it is preferable that an elastic contact portion 61a made of a regularly uneven molded body is formed on the surface of the heat dissipation coupling portion 61. By forming the elastic contact portion 61a made of such a regularly uneven molded body, a structure that fits each other even with respect to the uneven outer shape of the coil end 31 is formed, and the coil is formed. The contact area between the end 31 and the heat radiation coupling portion 61 is increased, and it is possible to increase the thermal conductivity between the winding body 30 and the bottom portion 40a of the stator frame body 40.

FIG. 9A shows an outline of the position-regulating portion 65 of the heat conductor 60 according to the present embodiment. FIG. 9B shows an outline of the position regulating unit 40d that regulates the arrangement of the heat conductor 60 arranged at the bottom portion of the stator frame 40. As shown in FIGS. 9A and 9B, the heat conductor 60 includes a position-restricted portion 65 that regulates the direction of arrangement of the heat conductor 60 so that the heat-dissipating coupling portion 61 and the coil end 31 come into contact with each other. .. The position-restricted portion 65 may have a structure that fits each other with the position-regulating portion 40d, which is a specific shape portion to be arranged in a part of the bottom portion 40a of the stator frame 40, and regulates the position and the arrangement direction. Is not particularly limited. In the example of FIG. 9B, the position regulating portion 40d, which is a specific shape portion to be arranged in a part of the bottom portion 40a of the stator frame body 40, is arranged, and the heat conductor 601 is fitted so as to be fitted with the position regulating portion 40d. A position control unit 65 is formed in the unit. By having the position-restricted portion 65, when installing the heat conductor 60, it is possible to simplify complicated processes such as fine adjustment of the position and arrangement direction of the heat conductor 60, and the man-hours in the manufacturing process can be reduced. It is possible to reduce and prevent misplacement.

The virtual envelope surface that wraps the outer shape of the insulated conductor at the end of the coil end 31 is preferably substantially flat. With this configuration, there is no gap at the contact portion between the thermal conductor 60 and the coil end 31, and the thermal conductivity between the winding body 30 and the bottom portion 40a of the stator frame 40 is enhanced. It is possible.

Further, it is preferable that the copper wire constituting the wound body 30 is a self-bonding wire. With this configuration, the flatness of the surface of the coil end 31 is improved, so that the contact area between the heat conductor 60 and the coil end 31 is increased, and the winding body 30 and the bottom portion 40a of the stator frame 40 are connected to each other. It is possible to increase the thermal conductivity between them.

Further, it is preferable that the heat radiation coupling portion 61 and the coil end 31 are filled with a resin different from that of the heat conductor 60. With this configuration, even when the coil end 31 has a fine uneven shape that cannot be followed by rubber elasticity, the filling resin 95 is filled between the heat radiating coupling portion 61 and the coil end 31, so that the coil end It is possible to increase the thermal conductivity between 31 and the thermal conductor 60.

Further, it is preferable that a paint for improving emissivity is applied to the surface of the heat dissipation coupling portion 61 and at least one surface of the coil end 31. With this configuration, even if the coil end 31 has a fine uneven shape that cannot be followed by rubber elasticity, it is possible to increase the thermal conductivity between the coil end 31 and the heat conductor 60 by heat radiation. ..

As shown in FIGS. 10A and 10B, the stator core 110 is formed by connecting a plurality of segment cores 22a in an annular shape. In FIG. 10A, after the insulator 20 is attached to the segment core 22a, an insulating conductor is wound around the winding portion of the insulator 20, and a plurality of segment cores 22a provided with the winding body 30 are connected in an annular shape. Then, it is accommodated in the internal space of the stator frame body 40.

As shown in FIG. 10B, the segment core 22a includes a yoke 22, a teeth 23, and a collar 23a. The segment core 22a is formed by laminating a magnetic material such as an electromagnetic steel plate.

As shown in FIG. 10A, the stator winding 112 is wound around the teeth 23 via the insulator 20. An insulating coating is applied to the insulated wire forming the stator winding 112. Therefore, the segment core 22a and the conductor portion of the insulated wire have high insulating properties due to the insulating coating and the insulator 20.

In addition to the configurations shown in FIGS. 10A and 10B, each segment core can also be realized in other connected configurations.

FIG. 11A is a front view showing the appearance of the electric motor including the stator configuration of the present invention. FIG. 11B is a side view showing the appearance of the electric motor including the stator configuration of the present invention. As shown in FIGS. 11A and 11B, the electric motor 101 including the stator component of the present invention has each component in addition to the bearing inside the stator frame body 40. Outside the stator frame 40, a rotating shaft 24 included in the rotor and a connector 115 are shown.

(Embodiment 2)
FIG. 1 shows an outline of the stator structure 100 according to the present embodiment. The stator structure 100 in the present embodiment has the same structure as the stator structure 100 in the above-described first embodiment. The same reference numerals are given to the same configurations as those of the stator configuration 100 in the first embodiment, and the description thereof will be incorporated.

The configuration of the stator configuration 100 included in the electric motor in the present embodiment is the same as that of the stator configuration 100 in the first embodiment. Inside the stator frame 40, a stator intermediate assembly 90 including the stator 80, a heat conductor 60, and a filling resin 95 are included. The structure of the stator intermediate assembly 90 includes a stator 80 and a printed wiring board 70. The structure of the stator 80 includes a stator magnetic core 10, an insulator 20, and a winding body 30. The structure of the stator frame body 40 includes a bottom portion 40a, a rotating shaft insertion hole 40b, a bearing accommodating portion 40c, and a frame portion 50.

In the first embodiment, the thermal conductor 60 is made of a resin material such as an epoxy resin, PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PPT (polypropylene terephthalate), and BMC (unsaturated polyester resin). ..

In the second embodiment, the heat conductor 60 employs a rubber material such as nitrile rubber, silicone rubber, urethane rubber, acrylic rubber, and fluororubber. This rubber material has the characteristics of high thermal conductivity and low strength as compared with the configuration of the thermal conductor 60 in the first embodiment. Further, since it has rubber elasticity, the action of relaxing the stress generated by the curing shrinkage of the filling resin 95 by the heat conductor 60 is improved as compared with the configuration in the first embodiment, and the cracking of the filling resin 95 is further suppressed. It is possible.

In the second embodiment as well, as in the case of the first embodiment, as shown in FIG. 4, the abutting portion 32 in which the coil end 31 and the heat conductor 60 abut each other is configured. The surface shape of the heat dissipation coupling portion 61 preferably has a shape that follows the R shape of the coil end 31. By having this surface shape, the contact area between the coil end 31 and the heat conductor 60 is increased, and it is possible to increase the heat conductivity between the winding body 30 and the bottom portion 40a of the stator frame 40. is there. Since the resin used for the heat conductor 60 has rubber elasticity, it is possible to prevent damage to the coating layer of the winding even if it comes into contact with the coil end 31. It is preferable that the gap 33 and the filling resin 95 that fills a part or all of the gap 33 flow into the abutting portion 32 where the coil end 31 and the heat radiating coupling portion 61 abut and are cured. By having this configuration, heat conduction between the coil end 31 and the coil end fitting portion 72 is promoted, the heat of the coil end 31 can be efficiently conducted to the bottom portion 40a, and heat dissipation is improved. ..

6A, 6B, 7A, 7B, 8A and 8B show an outline of the configuration of the elastic contact portion arranged on the surface of the heat dissipation coupling portion 61 in the first embodiment. 6A and 6B show a configuration in which a plurality of recesses are arranged in a row as the elastic contact portion 61a. 7A and 7B show a configuration in which a plurality of square weights or a plurality of trapezoidal weights are arranged in a checkered pattern as the elastic contact portion 61b. 8A and 8B show a configuration in which a plurality of ridge-shaped convex portions are arranged in a row as the elastic contact portion 61c. With the configuration of the elastic contact portion, it is possible to increase the thermal conductivity between the winding body 30 and the bottom portion 40a of the stator frame body 40.

The present invention can be applied to an electric motor mounted on a household device, an industrial device, or the like.

10 Stator magnetic core 20 Insulator 22 Yoke 22a Segment core 23 Teeth 24 Rotating shaft 30 Winding body 31 Coil end 31a Convex coil end shape 32 Stator 33 Gap 40 Stator frame 40a Bottom 40b Rotating shaft insertion hole 40c Bearing accommodation Part 40d Position regulation part 50 Frame part 60 Thermal conductor 61 Heat dissipation coupling part 61a Elastic contact part 61b Elastic contact part 61c Elastic contact part 61d Concave shape 62 Connection part 63 Concave structure part 64 Convex structure part 65 Position regulation part 70 Stator 90 Stator 90 Stator intermediate assembly 95 Filling resin 100 Stator component 101 Electric machine 110 Stator Iron core 111 Insulator 112 Stator winding 112a End 113 Printed wiring board 113a Solder 114 Stator frame 114a Wall surface 115 Connector 116 Insulated wire 117 Stator 118 Stator pin 119 Gap 120 Stator intermediate assembly 1001 Stator component

Claims (15)

A stator including a stator core, an insulator covering each of the teeth of the stator core, and a winding body for winding an insulated wire for each insulator, and electrically with the winding body of the stator. A stator intermediate assembly including a printed wiring board to be connected, a stator frame body accommodating the stator intermediate assembly, and a bottom portion of the stator frame body and the stator intermediate facing the bottom portion. Heat conduction that thermally couples each of the coil end portions located between the facing portions of the assembly and located on the bottom side of the stator frame body in the winding body and the bottom portion of the stator frame body. Each of the plurality of heat radiation coupling portions including the body and the thermal conductor abuts on each of the coil ends facing each other, and is placed on the opening side of the stator frame in the winding body. A stator structure in which a filler resin is in contact with each of the positioned coil ends, and the filler resin and the heat conductor are in contact with each other. The stator component according to claim 1, wherein the filler is contained in a part or all of the gap in the abutting portion where the coil end portion and the heat conductor abut each other. The stator component according to claim 1, wherein the stator frame includes a bearing accommodating portion located at the center of a bottom portion of the stator frame. The stator frame body includes a bottom portion including a bottom portion of the stator frame body and a bearing accommodating portion located at the center of the bottom portion, and a frame portion including a frame portion excluding the bottom portion from the stator frame body. And the stator component according to claim 1. The stator frame includes a bearing accommodating portion located at the center of a bottom portion of the stator frame, and further, the heat conductor is provided in a portion of the bottom portion excluding the hole portion and the bearing accommodating portion. 1. A position-regulating portion that regulates the arrangement position of the heat conductor in a part of the bottom portion and a position-regulating portion corresponding to the position-regulating portion in a part of the heat conductor. Stator constructs described in. The stator frame body includes a bottom portion including a bottom portion of the stator frame body and a bearing accommodating portion located at the center of the bottom portion, and a frame portion including a frame portion excluding the bottom portion from the stator frame body. Further, the heat conductor is arranged in a portion other than the hole portion and the bearing accommodating portion in the bottom portion of the bottom portion, and a position for restricting the arrangement position of the heat conductor in a part of the bottom portion portion. The stator component according to claim 1, wherein a regulating unit and a positioned controlling unit corresponding to the position regulating unit are included in a part of the heat conductor. The stator frame includes a hole located at the center of the bottom portion of the stator frame and a bearing accommodating portion located at the edge of the hole, and further includes a bottom portion of the stator frame. The heat conductor is arranged in a portion other than the hole portion and the bearing accommodating portion, and the bottom portion abutted surface in contact with the heat conductor at the bottom portion has a flat surface, and the heat conductor has a flat surface. The stator component according to claim 1, which has a flat surface on the surface to be contacted by the heat conductor that comes into contact with the bottom portion. The stator frame has a bottom including a bottom portion of the stator frame, a hole located at the center of the bottom portion, and a bearing accommodating portion located at the edge of the hole, and the stator frame. The heat conductor is arranged in a portion excluding the hole portion and the bearing accommodating portion of the bottom portion of the bottom portion, including a frame portion including a frame portion excluding the bottom portion from the body, and the heat in the bottom portion. The stator according to claim 1, wherein the bottom portion contacted surface in contact with the conductor has a flat surface, and the heat conductor contacted surface in contact with the bottom portion of the heat conductor has a flat surface. Composition. The stator configuration according to claim 1, wherein the heat-dissipating coupling portion includes a concave shape corresponding to each convex coil end shape of the coil end. The stator configuration according to claim 1, wherein the heat-dissipating coupling portion includes an elastic contact portion that is easily deformed to a surface layer portion of the thermal conductor at a portion where the coil end and the thermal coupling portion are in pressure contact with each other. The stator configuration according to claim 1, wherein a plurality of groove-shaped recesses are arranged in a row in the elastic contact portion. The stator component according to claim 1, wherein a plurality of ridge-shaped convex portions are arranged in a row on the elastic contact portion. The stator component according to claim 1, wherein a plurality of square weights are arranged in a checkered pattern on the elastic contact portion. The stator component according to claim 1, wherein a plurality of trapezoidal weights are arranged in a checkered pattern on the elastic contact portion. An electric motor including the stator component according to claim 1.

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