JP2021164187A - Manufacturing method and manufacturing apparatus of stator - Google Patents

Abstract

To reduce a position deviation of a work-piece (a coil conductor) caused by an injection pressure at an injection molding.SOLUTION: The present invention discloses a manufacturing method of a stator (21), includes: a step of preparing a plurality of coil conductors (22a) in which both end parts extended to an outside of a slot (2111) of a stator core (211) are bonded; a mold closing step of performing a mold closing of a first molding and a second molding in a state where an end part (400) bonded to the plurality of coil conductors is positioned in a molding space (30) formed by the first molding (70 and 140) and the second molding (80 and 150); and an injection molding step of forming a molding part (60 and 60A) of a molding material at each end part by transmitting the molding material welded in the molding space in a state where the mold closing of the first molding and the second molding is performed in the mold closing step. The mold closing step contains a step of pressing the plurality of coil conductors in a mold closing direction by the first and second moldings.SELECTED DRAWING: Figure 4C

Description

The present disclosure relates to a method for manufacturing a stator and an apparatus for manufacturing a stator.

The ends of a plurality of coil conductors in which the ends are joined are set in the mold, and the melted resin material (molding material) is fed into the mold to form the resin material into the ends. Is known as a technique for molding by injection molding.

JP-A-2019-106828

However, in the above-mentioned conventional technique, the work (coil conductor) may be displaced from the normal position set in the mold due to the injection pressure during injection molding. If the work is displaced from the normal position in the mold, the molded portion may not be formed in a desired manner.

Therefore, on one aspect, the present disclosure aims to reduce the positional deviation of the work (coil conductor) due to the injection pressure during injection molding.

On one side, the process of preparing multiple coil conductors with their ends extending outside the slots of the stator core joined together,
The first molding die and the second molding die are molded with the joined ends of the plurality of coil conductors positioned in the molding space formed by the first molding die and the second molding die. Molding process and
In a state where the first molding die and the second molding die are molded by the mold clamping step, the molten molding material is sent into the molding space, and injection molding is performed to form a molded portion of the molding material at the end portion. With process
The mold clamping step provides a method for manufacturing a stator, which comprises pressing the plurality of coil conductors in the mold clamping direction by the first molding die and the second molding die.

On one side, according to the present disclosure, it is possible to reduce the misalignment of the work (coil conductor) due to the injection pressure during injection molding.

It is sectional drawing which shows a part of a stator. It is explanatory drawing of the molded part. It is a perspective view which shows the upper mold included in the manufacturing apparatus by this Example. It is a perspective view which shows the lower mold included in the manufacturing apparatus by this Example. It is sectional drawing which shows the upper mold and the lower mold in a mold-clamped state. It is an enlarged view of the Q1 part of FIG. 4A. It is a figure which shows the state which the joint end part is set in the upper mold and the lower mold in the mold-clamped state. It is a front view which shows the upper mold and the lower mold in the mold-fastened state by the view of the arrow P2 of FIG. 4A. It is an enlarged view of the Q2 part of FIG. 5A. It is explanatory drawing of the comparative example (the 1). It is explanatory drawing of the comparative example (the 2). It is explanatory drawing of the comparative example (the 3). It is explanatory drawing of the normal cross-sectional shape of the pressed part. It is explanatory drawing of the cross-sectional shape of the pressed portion when the upper die and the lower die are in a mold-tightened state. It is a perspective view which shows the molded part formed by the upper mold and the lower mold by a comparative example. It is a figure which shows an example of the mold structure which mold-fastens in the Y direction. It is explanatory drawing of the molding method of the molding part using the mold structure of FIG. It is a perspective view which shows the molded part formed by the mold structure of FIG.

Hereinafter, each embodiment will be described in detail with reference to the accompanying drawings.

Hereinafter, an example of the stator 21 manufactured by the manufacturing method and the manufacturing apparatus according to the present embodiment will be described prior to the description of the manufacturing method and the manufacturing apparatus according to the present embodiment. In addition, in FIG. 1 and the like, for the sake of easy viewing, there are cases where a reference reference numeral is only partially attached to a plurality of parts having the same attribute.

FIG. 1 is a cross-sectional view showing a part of the stator 21. FIG. 1 is a cross-sectional view showing only one side of the central axis I of the stator 21 when cut in a plane including the central axis I of the stator 21.

In the following description, the axial direction refers to the direction in which the central axis I extends, and the radial direction refers to the radial direction centered on the central axis I. Therefore, the radial outer side refers to the side away from the central axis I, and the radial inner side refers to the side toward the central axis I. Further, the circumferential direction corresponds to the rotation direction around the central axis I.

The stator 21 includes, for example, a stator core 211 made of an annular magnetic laminated steel plate, and a plurality of slots 2111 around which the coil 22 is wound are formed inside the stator core 211 in the radial direction. A plurality of slots 2111 are formed at equal intervals in the circumferential direction. The number and shape of slots 2111 are arbitrary.

The coil 22 is in the form of a so-called concentric winding coil, and is a cassette coil formed by bending a flat wire wound by a predetermined number of turns. The coil 22 includes a flat wire (conductor portion) having a rectangular cross section (specifically, a rectangular shape). The flat wire may be made of a metal having high conductivity such as copper or aluminum. The coil 22 may have a flat wire covered with an insulating coating. In the following, it is assumed that the coil 22 has a configuration in which a flat wire is covered with an insulating coating, and the term "one coil conductor 22a" refers to a plurality of concentric winding coils forming the coil 22 unless otherwise specified. Refers to any one of the concentric winding coils.

As shown in FIG. 1, the plurality of coil conductors 22a are housed in the slot 2111 of the stator core 211, and the ends extending axially outward from the slot 2111 are joined to each other. The ends of the coil conductors 22a may be joined to each other by welding or the like. In this case, the ends of the coil conductors 22a may be overlapped with at least a part of the coating removed, and the parts from which the coating has been removed may be joined by welding. In this case, the welding may be realized by any method such as laser welding or TIG welding. Hereinafter, the two ends of the coil conductor 22a in which the ends are overlapped and joined in this way are also referred to as "joined ends". It should be noted that the joint end portions need not be entirely joined to each other, and only a part (for example, the tip portion) thereof may be joined to each other.

The plurality of coil conductors 22a have a molding portion 60 of a molding material at a joint end portion. The molded portion 60 has a function of ensuring electrical insulation of the joint ends of the plurality of coil conductors 22a. That is, since the coating is removed from the joint ends of the plurality of coil conductors 22a at the time of joining as described above, the molded portion 60 covers the entire portion from which the coating has been removed, and is similar to the coating. Fulfill function. In order to realize this function, the molding material is a non-conductive material. In this embodiment, the molding material is a resin material (a resin material containing PPS (polyphenylene sulfide resin)), and the molding portion 60 is a molding portion of the resin material. In this embodiment, the molding portion 60 is formed by injection molding of a resin material.

The molding portion 60 covers the entire joint end portion of the plurality of coil conductors 22a. In other words, the joint end portion of the plurality of coil conductors 22a refers to the entire portion of the two coil conductors 22a in which the ends are joined to each other, where the molding portion 60 is provided.

FIG. 2 is an explanatory view of the molding portion 60, and is a plan view seen in the direction of the arrow P in FIG.

The molding portions 60 are provided one by one for two sets of joint end portions adjacent to each other in the circumferential direction. The joint end portion of each set is formed by overlapping the end portions of the two coil conductors 22a in the axial direction. In this case, the two sets of joint ends adjacent to each other in the circumferential direction are preferably formed by the ends of the in-phase coil conductors 22a. As a result, even if a part of the molded portion 60 is damaged, the influence caused by the short circuit can be reduced.

Specifically, one molded portion 60 includes a first covering portion 61 that covers the joint end portion of the set on one side in the circumferential direction and a second coating portion that covers the joint end portion of the set on the other side in the circumferential direction. Including part 62. Further, the molding portion 60 includes a connecting portion 63 provided between the first covering portion 61 and the second covering portion 62 in the circumferential direction. The connecting portion 63 connects the first covering portion 61 and the second covering portion 62. The first covering portion 61, the second covering portion 62, and the connecting portion 63 may be integrally formed by resin molding.

The connecting portion 63 is provided with a resin injection portion 63a, which functions as a resin path portion (runner) when the molding portion 60 is resin-molded. Then, when the molding portion 60 is resin-molded, the resin forms the connecting portion 63 via the resin injection portion 63a, and the resin forms the first coating portion 61 and the second coating portion 62 via the connecting portion 63. And form. That is, the connecting portion 63, the first covering portion 61, and the second covering portion 62 may be continuously formed.

In FIG. 2, one molding portion 60 is provided for each of two sets of joint end portions adjacent to each other in the circumferential direction, but one may be provided for each pair of joint end portions. One may be provided for each of three or more sets of joint ends adjacent to each other in the direction.

Next, the manufacturing method and the manufacturing apparatus according to the present embodiment will be described in detail with reference to FIGS. 3A and after.

3A and 3B are perspective views showing an upper mold 70 and a lower mold 80 included in the manufacturing apparatus 1 according to the present embodiment, respectively. FIG. 4A is a cross-sectional view showing an upper mold 70 and a lower mold 80 in a mold-tightened state. FIG. 4B is an enlarged view of the Q1 portion of FIG. 4A. FIG. 4C is a diagram showing a state in which the joint end portion 400 is set in the upper mold 70 and the lower mold 80 in the mold-tightened state. FIG. 5A is a front view showing the upper mold 70 and the lower mold 80 in the mold-tightened state with the view of arrow P2 of FIG. 4A. FIG. 5B is an enlarged view of the Q2 portion of FIG. 5A. In FIG. 4C, a state P40 before the two coil conductors 22a are set in the upper mold 70 and the lower mold 80, and a set state P41 are shown. The joint end portion 400 of the two coil conductors 22a is shown very schematically together with the welded portion (joint portion) 402 in the joint end portion 400. Here, the joint end portion 400 corresponds to the entire portion of the two coil conductors 22a in which the ends are joined to each other, which are located in the upper mold 70 and the lower mold 80 in the mold-tightened state. do. Further, in FIG. 4C, the molding space 30 is schematically shown in the hatched region.

In FIG. 3A and the like, the X direction, the Y direction, and the Z direction, which are three directions orthogonal to each other, are defined. In the following, the Z direction is the vertical direction, the Z1 side is the upper side, and the Z2 side is the lower side. Further, the X1 side and the X2 side along the X direction are defined, and the Y1 side and the Y2 side along the Y direction are defined. The Z direction corresponds to the axial direction, the Y direction corresponds to the radial direction, and the X direction corresponds to the tangential direction of the circle related to the circumferential direction.

The upper mold 70 and the lower mold 80 are molded in the vertical direction. The upper mold 70 and the lower mold 80 form a molding space 30 in which the joint end portion 400 is located in the molded state. A melted resin material is sent into the molding space 30 from a nozzle of an injection molding machine (not shown) (for example, a nozzle connected to the resin injection recess 71 shown in FIG. 3A), and the molding portion 60 described above is used. It is formed. As described above, the upper mold 70 and the lower mold 80 are adapted so that the above-mentioned molding portion 60 is molded by injection molding.

Since the upper mold 70 and the lower mold 80 are molded in the vertical direction, the joint end portions (target portions where the molding portion 60 is formed) of the two coil lead wires 22a intersect in the vertical direction. It is suitable when it extends in a direction (for example, in the radial direction) (see FIG. 2). In this case, for example, the upper mold 70 is moved from the upper side and the lower mold 80 is moved from the lower side in the vertical direction with respect to the joint end portion of the two coil conductors 22a. The joint end can be accommodated in the molding space 30.

In the molded state, the upper mold 70 and the lower mold 80 press the two coil conductors 22a (in this embodiment, as an example, two sets of two coil conductors 22a) in the mold clamping direction. In this case, the pressing position is arbitrary, but preferably a position on the Y2 side in the Y direction (a position away from the molding space 30) with respect to the joint end portion 400. Further, the pressing position may be a point, but preferably, it forms a line in the X direction or forms an XY surface. For example, the pressing position may form a line in the X direction over the entire width of the two coil conductors 22a in the X direction.

In this embodiment, the upper mold 70 and the lower mold 80 are the portions of the two coil conductors 22a, and the portion 220 on the Y2 side in the Y direction from the boundary position of the joint end portion 400 (hereinafter, “pressed portion”). (Also referred to as 220 ") is pressed in the mold clamping direction (that is, clamped in the vertical direction). That is, in this embodiment, as a preferred example, the pressed portion 220 is adjacent to the joint end portion 400 in a continuous manner. That is, the pressed portion 220 is set from the boundary position of the joint end portion 400. The boundary position of the joint end portion 400 is a boundary position between the portion where the molded portion 60 is not formed and the portion where the molded portion 60 is formed. However, in the modified example, the pressed portion 220 may be adjacent to the joint end portion 400 via a relatively small distance. That is, the pressed portion 220 may be set from a position away from the tip end side of the joint end portion 400 by a relatively small distance with respect to the joint end portion 400.

In this embodiment, the boundary position of the joint end portion 400 (that is, the boundary position between the joint end portion 400 and the pressed portion 220) is preferably set to the portion of the two coil conductors 22a having a coating. That is, the pressed portion 220 is preferably a portion of the two coil conductors 22a having a coating. As a result, the molded portion 60 can be extended to the portion having the coating of the two coil conductors 22a.

In this embodiment, as an example, as shown in FIG. 4B, the upper mold 70 has a protruding portion 72 projecting downward on the lower surface side (the surface side facing the lower mold 80 in the vertical direction) and Y. It is on the Y2 side. The protrusion 72 is provided one by one corresponding to each set of the two sets of joint end portions 400. The protrusion 72 extends in the X direction over the entire width of the coil conductor 22a. Specifically, the protruding portion 72 extends over the entire opening width (width in the X direction) of the openings 71A and 71B that position the joint end portions 400 of each set in the X direction. The lower end surface 721 of the protruding portion 72 abuts on the upper surface of the upper coil conductor 22a. In the example shown in FIG. 4B, the protruding portion 72 extends a relatively long distance in the Y direction. Further, in the example shown in FIG. 4B, the openings 71A and 71B are formed by the inlet forming portions 73 and 74 that come into contact with the end surface 80A of the lower mold 80 on the Y2 side in the Y direction from the Y2 side in the Y direction during mold clamping. It is formed. In this case, the protruding portion 72 is formed between the root portions (upper edge portions) of the entrance forming portions 73 and 74 (between the X directions).

Further, in the present embodiment, as an example, as shown in FIG. 4B, the lower mold 80 has a protruding portion 82 projecting upward on the upper surface side (the surface side facing the upper mold 70 in the vertical direction). It is on the Y2 side in the Y direction. The protrusion 82 is provided one by one corresponding to each set of the two sets of joint end portions 400. The protrusion 82 extends over the entire width of the coil conductor 22a in the X direction, similarly to the protrusion 72 described above. The upper end surface 821 of the projecting portion 82 abuts on the lower surface of the lower coil conductor 22a. In the example shown in FIG. 4B, the protruding portion 82 extends in the Y direction by a relatively short distance (a distance shorter than that of the protruding portion 72). However, in the modified example, the protruding portion 82 and the protruding portion 72 may be provided so as to completely overlap each other when viewed in the Z direction.

According to such a configuration, the upper mold 70 and the lower mold 80 are placed on the Y2 side (diameter inside) in the Y direction with respect to the joint end portion 400 of the two coil lead wires 22a in the molded state. It can be pressed in the mold clamping direction (vertical direction) by the projecting portion 72 and the projecting portion 82, respectively. In this case, of the two coil conductors 22a, the portion of the two coil conductors 22a that overlaps both the protruding portion 72 and the protruding portion 82 when viewed in the Z direction corresponds to the pressed portion 220.

Here, a part of the effect of this embodiment will be described with reference to the comparative examples shown in FIGS. 6A to 6C in comparison.

6A to 6C are explanatory views of a comparative example, and FIG. 6A is a cross-sectional view of the upper mold 70'and the lower mold 80'in a molded state according to the comparative example, and FIG. 4B of the present embodiment. It is a figure to be contrasted with. Further, FIG. 6B is a cross-sectional view of the upper mold 70'and the lower mold 80' in which the two coil conductors 22a are set, in a molded state, and is a diagram to be compared with FIG. 4C of this embodiment. .. FIG. 6C is an explanatory view when the two coil conductors 22a move from inside the upper mold 70'and the lower mold 80'.

The upper mold 70'and the lower mold 80'according to the comparative example are provided with neither the protruding portion 72 nor the protruding portion 82 with respect to the upper mold 70 and the lower mold 80 according to the present embodiment. different. That is, the upper mold 70'and the lower mold 80' according to the comparative example do not press the two coil conductors 22a in the mold clamping direction (vertical direction) in the mold clamped state.

In such a comparative example, as schematically shown in FIG. 6C, the two coil conductors 22a move in the upper mold 70'and the lower mold 80'due to the injection pressure during injection molding. There is a risk that it will end up. Specifically, due to the injection pressure, a force that moves from the inside of the upper mold 70 and the lower mold 80 to the Y2 side (inward in the radial direction) acts on the two coil conductors 22a, and 2 One coil lead wire 22a may move to the Y2 side in the Y direction through the openings 71A'and 71B'. As described above, the two coil conductors 22a are held with respect to the stator core 211 in the slot 2111, but can be displaced to some extent outside the slot 2111.

If the two coil conductors 22a move in the upper mold 70 and the lower mold 80 as in the case of such a comparative example, there is a possibility that the molded portion 60 is not formed in a desired manner. For example, when the two coil conductors 22a move inward in the radial direction due to the injection pressure during injection molding, the molding portion 60 is located in the region where the coating is removed from the ends of the two coil conductors 22a. May not be formed. In the example schematically shown in FIG. 6C, of the two coil conductors 22a, the portion 225 from which the coating has been removed protrudes from the molding space 30. In this case, the molded portion 60'is not formed on a part of the portion 225 from which the coating has been removed, out of the ends of the two coil conductors 22a.

On the other hand, in the present embodiment, as described above, the upper mold 70 and the lower mold 80 press the two coil conductors 22a in the mold clamping direction (vertical direction) in the molded state. By doing so, it is possible to effectively prevent the two coil lead wires 22a from moving in the upper mold 70 and the lower mold 80 due to the injection pressure during injection molding. That is, since the two coil lead wires 22a are pressed in the mold clamping direction (vertical direction) by the upper mold 70 and the lower mold 80, they receive a force that moves to the Y2 side in the Y direction due to the injection pressure. However, it is difficult to move to the Y2 side in the Y direction. Therefore, according to this embodiment, the positional deviation of the work (two coil conductors 22a) due to the injection pressure during injection molding can be effectively reduced. As a result, it is possible to effectively reduce the possibility that the molded portion 60 is not formed on a part of the portion 225 from which the coating has been removed from the ends of the two coil conductors 22a.

Hereinafter, by pressing the two coil conductors 22a in the mold clamping direction (vertical direction) by the upper mold 70 and the lower mold 80 in this way, the two coil conductors are caused by the injection pressure during injection molding. The function of reducing the possibility that the 22a moves inward in the radial direction is also referred to as a "positional deviation prevention function due to pressing in the mold clamping direction".

Here, the above-mentioned function of preventing the position shift due to pressing in the mold clamping direction is effective when the pressing pressure is relatively high.

Therefore, the pressing force for realizing the function of preventing the position shift due to the pressing in the mold clamping direction described above is preferably adapted so as to generate an indentation 900 (schematically shown in FIG. 2) on the coating of the pressed portion 220. Will be done.

Specifically, the dimension L1 (an example of the first distance) of the vertical gap between the protruding portion 72 and the protruding portion 82 is preferably a coil conducting wire with respect to the regular cross-sectional shape of the pressed portion 220. It may be set as small as the thickness of the coating of 22a (for example, about 2 mm). The regular cross-sectional shape is a cross-sectional shape based on a design value that does not include tolerances. Further, as shown in FIG. 4B, the dimension L1 corresponds to the vertical separation distance between the upper mold 70 and the lower mold 80 passing through the pressed portion 220 in the molded state.

Although the upper mold 70 and the lower mold 80 having a specific structure are shown in FIGS. 3A to 5B and the like, the structures of the upper mold 70 and the lower mold 80 have the above-mentioned mold clamping directions. It is optional as long as the function of preventing the position shift due to the pressing of is realized. Therefore, the upper mold 70 and the lower mold 80 have a configuration other than the configuration related to the above-mentioned position shift prevention function due to pressing in the mold clamping direction. It may be the same as or different from the lower resin molding die and the upper resin molding die disclosed in Japanese Patent Application Laid-Open No. 2019-106828 to be incorporated.

Next, a further preferable configuration of the upper mold 70 and the lower mold 80 of this embodiment will be described with reference to FIGS. 7A and 7B, together with FIG. 5B described above.

FIG. 7A is an explanatory view of a regular cross-sectional shape of the pressed portion 220, and FIG. 7B is an explanatory view of the cross-sectional shape of the pressed portion 220 when the upper mold 70 and the lower mold 80 are in the mold clamping state. It is explanatory drawing. In FIGS. 7A and 7B, the flat wire (conductor portion) 221 and the coating 222 of the two coil conductors 22a having the joint end portions are schematically shown in a cross-sectional view.

As shown in FIG. 7A, the pressed portion 220 has a vertical dimension α0 (an example of the first dimension) and a lateral dimension β0 (an example of the second dimension) in a normal cross-sectional shape. As described above, the regular cross-sectional shape is a cross-sectional shape based on a design value that does not include tolerances. Therefore, the dimension α0 and the dimension β0 are design values that do not include tolerances and are uniquely determined from the design drawing.

As described above, in the two coil conductors 22a, when the upper mold 70 and the lower mold 80 are in the mold clamping state, the pressed portion 220 is pressed in the vertical direction, so that the pressed portion 220 is deformed. sell.

In this respect, the upper mold 70 and the lower mold 80 preferably have the vertical dimension of the pressed portion 220 reduced to the dimension α1 (<α0) and the lateral dimension to the dimension β1 (> β0). Configured to increase. In this case, the upper mold 70 and the lower mold 80 are configured so that the dimension L1 (see FIG. 5B) of the vertical gap of the pressed portion 220 in the mold-tightened state matches the dimension α1. You can.

The dimension α1 is a dimension related to the pressing force described above, and may be adapted so that the difference from the dimension α0 corresponds to the total thickness of the upper and lower coatings, for example. For example, the dimension α1 may be a value obtained by subtracting about 2 mm from the dimension α0.

Further, the upper mold 70 and the lower mold 80 are preferably placed between the upper mold 70 and the lower mold 80 and the two coil conductors 22a in the state before the mold is tightened (that is, before pressing). It has a gap in the X direction. Hereinafter, the gap in the X direction before mold clamping, which is the gap between the upper mold 70 and the lower mold 80 and the two coil conductors 22a, is simply "a gap in the X direction before mold clamping." Also called.

In the case of a configuration having a gap in the X direction before mold clamping, the side surface of the pressed portion 220 in the X direction is subjected to a force (including frictional force) in the vertical direction by the upper mold 70 and the lower mold 80 during mold clamping. ) Can be prevented. In the case of a configuration in which there is substantially no gap in the X direction before mold clamping, the side surface of the pressed portion 220 in the X direction is subjected to a force in the vertical direction by the upper mold 70 and the lower mold 80 during mold clamping. Easy to receive. When such a force in the vertical direction is received, inconveniences such as peeling of the coatings on the side surfaces of the two coil conductors 22a in the X direction are likely to occur. That is, at the time of mold clamping, the upper mold 70 and / or the lower mold 80 may move in the mold clamping direction while hitting the side surfaces of the two coil conductors 22a in the X direction, thereby damaging the side surfaces. There is. On the other hand, in the case of a configuration having a gap in the X direction before mold clamping, such inconvenience can be effectively prevented.

By the way, in the case of a configuration having a gap in the X direction before mold clamping, while the above-mentioned effect can be obtained, there is a possibility that the resin material may leak from the gap in the X direction during injection molding. For example, FIG. 8 is a perspective view showing a molding portion 60'formed by the upper mold 70'and the lower mold 80' according to the above-mentioned comparative example with reference to FIGS. 6A to 6C. In the comparative example, as described above, since there is a gap in the Z direction before molding in addition to the gap in the X direction before molding, the resin material easily leaks from these gaps during injection molding. In FIG. 8, the leaked resin material forming portion 601 is shown. It is desirable that such leakage of the resin material does not inherently occur from the viewpoint of insufficient amount of resin in a part of the molded portion 60'(for example, sink marks) and from the viewpoint of efficient use of the resin material. ..

In view of this point, the upper mold 70 and the lower mold 80 preferably have dimensions L2 in the X direction of the openings 71A and 71B in the mold-tightened state (see FIG. 5B) (an example of the second distance). Is configured to match dimension β1. In this case, in the state before mold clamping (that is, before pressing), there is a gap in the X direction (dimension β0 and dimension β1 or dimension L2) between the upper mold 70 and the lower mold 80 and the two coil conductors 22a. A gap due to the difference between and) will be formed. According to this configuration, the above-mentioned effect (the effect of protecting the coating on the side surfaces of the two coil conductors 22a in the X direction) can be obtained by having a gap in the X direction before mold clamping, and the joint end portion can be protected. It is possible to effectively prevent leakage of the resin material from the boundary position (regular boundary position) to the inside in the radial direction. Specifically, when the dimension L2 matches the dimension β1, the gap in the X direction before the mold clamping is filled in the mold clamping state. As a result, it is possible to effectively prevent the resin material from leaking inward in the radial direction from the boundary position (regular boundary position) of the joint end portion.

In this embodiment, the openings 71A and 71B in the mold-fastened state are formed only by the upper mold 70 (specifically, the inlet forming portions 73 and 74). However, the openings 71A and 71B in the mold-clamped state may be formed only by the lower mold 80. Alternatively, the openings 71A and 71B in the mold-clamped state may be formed in cooperation with the upper mold 70 and the lower mold 80. For example, instead of the entrance forming portion 73, a similar entrance forming portion that is vertically opposite to the entrance forming portion 73 may be formed on the lower mold 80 side.

Next, another embodiment will be described with reference to FIGS. 9 and later.

In the above-described embodiment, the molding portion 60 is molded by the upper mold 70 and the lower mold 80 that are molded in the vertical direction, but the mold that is molded in the direction intersecting the vertical direction is used. It is also possible to form a molded portion at the joint end portion of another form.

FIG. 9 is a diagram showing an example of a mold configuration in which the mold is molded in the Y direction. FIG. 10 is an explanatory view of a molding method of the molding portion 60A using the mold configuration of FIG. FIG. 11 is a perspective view showing a molding portion 60A formed by the mold configuration of FIG. 9. FIG. 9 shows an example of the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 that are molded in the Y direction.

The outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 may be substantially the same as the upper mold 70 and the lower mold 80 described above, except that the mold clamping directions are different. The outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 form a molding space corresponding to the above-mentioned molding space 30 in a molded state. The outer diameter side resin molding die 140 and the inner diameter side resin molding die 150 are molded with the joint ends of the two coil conductors 22a set in the molding space. As in the case of the upper mold 70 and the lower mold 80 described above, the tip side of the joint end is located on the inner side of the molding space (the side far from the openings corresponding to the openings 71A and 71B). Is set to. Then, the melted resin material is sent into the molding space in the molded state through the resin injection recess 160, and the molding portion 60A is formed after curing and mold release.

Similar to the above-mentioned upper mold 70 and lower mold 80, the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 have two coil lead wires 22a (an example in this embodiment) in a molded state. As a result, two sets of two coil conductors 22a) are pressed in the mold clamping direction (Y direction). Specifically, the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 are on the lower side (the side far from the molding space) of the joint end portion 400 of the two coil lead wires 22a in the molded state. , Press in the mold clamping direction (Y direction). Therefore, the same effect as that of the upper mold 70 and the lower mold 80 described above can be obtained for the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150. The outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 can also have various preferable configurations and modifications described with respect to the above-mentioned upper mold 70 and lower mold 80.

Since the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 are molded in the Y direction, the joint end portion (target portion where the molding portion 60A is formed) of the two coil conductors 22a is Y. It is suitable when it extends in a direction intersecting the directions (for example, in the vertical direction) (see FIG. 10). In this case, for example, with respect to the joint end portion of the two coil conductors 22a, the outer diameter side resin molding mold 140 is from the radial outside, and the inner diameter side resin molding mold 150 is from the radial inside to the radial direction (Y direction). ), The joint end can be accommodated in the molding space.

9 to 11 show an outer diameter side resin molding mold 140 and an inner diameter side resin molding mold 150 having a specific structure, but the structures of the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150. Is arbitrary as long as the above-mentioned function of preventing misalignment due to pressing in the mold clamping direction can be realized. Therefore, the outer diameter side resin molding mold 140 and the inner diameter side resin molding mold 150 are disclosed in, for example, Japanese Patent Application Laid-Open No. 2019-106828. It may be the same as or different from the outer diameter side resin molding mold and the inner diameter side resin molding mold.

Further, the examples shown in FIGS. 9 to 11 relate to a mold configuration in which the mold is clamped in the Y direction, but can also be applied to a mold configuration in which the mold is clamped in the X direction (tangential direction in the circumferential direction).

Although each embodiment has been described in detail above, the present invention is not limited to a specific embodiment, and various modifications and changes can be made within the scope of the claims. It is also possible to combine all or a plurality of the components of the above-described embodiment.

<Additional notes>
Regarding the above examples, the following will be further disclosed. Of the effects described below, the effect related to each additional form with respect to one form is an additional effect resulting from each of the additional forms.

(1) One form includes a step of preparing a plurality of coil conductors (22a) in which ends extending to the outside of the slot (2111) of the stator core (211) are joined to each other.
In a state where the joined ends (400) of the plurality of coil conductors are positioned in the molding space (30) formed by the first molding mold (70, 140) and the second molding mold (80, 150). , The molding step of molding the first molding mold and the second molding mold, and
With the first molding die and the second molding die molded by the molding step, the molten molding material is sent into the molding space, and the molding portion (60, 60A) of the molding material is sent to the end portion. With an injection molding process to form
The mold clamping step is a method for manufacturing a stator (21), which comprises pressing the plurality of coil conductors in the mold clamping direction by the first molding die and the second molding die.

According to this embodiment, since a plurality of coil conductors are pressed in the mold clamping direction in the mold clamping step, it is possible to reduce the positional deviation of the work (coil conductors) due to the injection pressure during injection molding.

(2) Further, in the present embodiment, preferably, the plurality of coil conductors each have an insulating coating (222) around the conductor portion (221), and at least at the end portion of the coating. Some have been removed
The pressed portion (220) pressed in the mold clamping step in the plurality of coil conductors includes a portion where the coating has not been removed.

In this case, it is possible to form a molded portion on the entire portion where the coating is removed at the end portion.

(3) Further, in the present embodiment, preferably, the first molding die and the second molding die have a first distance (L1) in the molding direction passing through the pressed portion in a molded state. ) Only separated from each other,
The first distance is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step, and is smaller than the first dimension (α0) in the mold clamping direction.

In this case, it is possible to control the pressing mode (pressing pressure, depth of indentation that can occur, etc.) on the pressed portion according to the design dimensions.

(4) Further, in the present embodiment, preferably, the first distance is set so that the pressure in the mold clamping direction causes an indentation (900) on the coating in the pressed portion.

In this case, the plurality of coil conductors can be pressed with an appropriate pressing force that causes indentation on the coating. As a result, the positional deviation of the work (coil conductor) due to the injection pressure during injection molding can be effectively reduced.

(5) Further, in the present embodiment, preferably, the first molding die and the second molding die are in a molded state, passing through the pressed portion and intersecting the mold clamping direction. An opening (71A, 71B) having a distance (L2) is formed to form an opening (71A, 71B).
The second distance is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step, and is larger than the second dimension (β0) in the intersecting direction.

In this case, it is possible to reduce the inconvenience caused by the movement of the first molding die and the second molding die at the time of mold clamping accompanied by mold closing. That is, there is a possibility that the first molding die and / or the second molding die moves in the mold clamping direction while hitting the side surface of the pressed portion (the side surface in the direction intersecting the mold clamping direction), thereby damaging the side surface ( Inconvenience) can be reduced.

(6) Further, in the present embodiment, preferably, in a state where the first molding die and the second molding die are molded, the dimension of the cross-sectional shape of the pressed portion and the dimension in the intersecting direction. Increases from the second dimension due to deformation of the pressed portion due to pressing in the mold clamping direction.

In this case, the gap that may occur due to the difference between the second distance and the second dimension, and the gap in the intersecting direction between the first molding die and the second molding die and the pressed portion, is the die. It is reduced by the deformation of the pressed portion due to the pressing in the tightening direction. As a result, leakage of the molding material from the first molding mold and the second molding mold during the injection molding process can be reduced by deformation of the pressed portion. Therefore, leakage of the molding material from the boundary position of the pressed portion can be effectively reduced.

(7) Further, in the present embodiment, preferably, in a state where the first molding die and the second molding die are molded, the dimension of the cross-sectional shape of the pressed portion and the dimension in the intersecting direction. Increases up to the second distance.

In this case, the gap that may occur due to the difference between the second distance and the second dimension, and the gap in the intersecting direction between the first molding die and the second molding die and the pressed portion, is the die. It is filled by the deformation of the pressed part due to the pressing in the tightening direction. As a result, leakage of the molding material from the first molding die and the second molding die during the injection molding process can be prevented by deformation of the pressed portion. Therefore, leakage of the molding material from the boundary position of the pressed portion can be effectively prevented.

(8) Further, in the present embodiment, the boundary of the pressed portion is preferably located on the boundary of the range in which the molded portion is formed in the plurality of coil conductors.

In this case, the possibility that a part of the molded portion is molded by the molding material leaking from the boundary of the pressed portion can be effectively reduced.

(9) In another form, the molded portion (60, 60A) is injection-molded on a plurality of coil conductors (22a) in which the ends extending to the outside of the slot (2111) of the stator core (211) are joined to each other. It is a manufacturing device for the stator that is molded by
With the first molding mold (70, 140),
A second molding die (80, 150) that is molded with respect to the first molding die is provided.
The first molding die and the second molding die form a molding space (30) for locating the joined ends (400) of the plurality of coil conductors in a molded state, and the plurality of molding dies. This is a manufacturing device for the stator (21) that presses the coil conductor of the above in the mold clamping direction.

According to this embodiment, since a plurality of coil conductors are pressed in the mold clamping direction in the mold clamping step, it is possible to reduce the positional deviation of the work (coil conductors) due to the injection pressure during injection molding.

(10) Further, in the present embodiment, preferably, the plurality of coil conductors each have an insulating coating (222) around the conductor portion (221), and at least at the end portion of the coating. Some have been removed
The pressed portion (220) pressed in the mold clamping direction in the plurality of coil conductors includes a portion where the coating has not been removed.

In this case, it is possible to form a molded portion on the entire portion where the coating is removed at the end portion.

(11) Further, in the present embodiment, preferably, the first molding die and the second molding die have a first distance (L1) in the molding direction passing through the pressed portion in a molded state. ) Only separated from each other,
The first distance is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step, and is smaller than the first dimension (α0) in the mold clamping direction.

In this case, it is possible to control the pressing mode (pressing pressure, depth of indentation that can occur, etc.) on the pressed portion according to the design dimensions.

(12) In the present embodiment, preferably, the first molding die and the second molding die are in a molded state, and a second distance in a direction that passes through the pressed portion and intersects the mold clamping direction. An opening (71A, 71B) having (L2) is formed to form an opening (71A, 71B).
The second distance is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step, and is larger than the second dimension (β0) in the intersecting direction.

In this case, it is possible to reduce the inconvenience caused by the movement of the first molding die and the second molding die at the time of mold clamping accompanied by mold closing. That is, there is a possibility that the first molding die and / or the second molding die moves in the mold clamping direction while hitting the side surface of the pressed portion (the side surface in the direction intersecting the mold clamping direction), thereby damaging the side surface (the side surface). Inconvenience) can be reduced.

1 Manufacturing equipment 21 Stator 211 Stator core 2111 Slot 22 Coil 22a Coil conductor 220 Pressed portion 221 Flat wire (conductor portion)
222 Coating 30 Molding space 60 Molding part 60A Molding part 61 First covering part 62 Second covering part 63 Connecting part 63a Resin injection part 70 Upper mold 71 Resin injection recess 71A Opening 71B Opening 72 Protruding part 721 Lower end surface 73 Inlet forming part 74 Inlet forming part 80 Lower mold 80A End face 82 Protruding part 821 Upper end surface 140 Outer diameter side resin molding mold 150 Inner diameter side resin molding mold 160 Resin injection recess 400 Joint end part 402 Welded part (joint part)
900 indentation

Claims (12)

The process of preparing a plurality of coil conductors in which the ends extending to the outside of the slot of the stator core are joined to each other, and
The first molding die and the second molding die are molded with the joined ends of the plurality of coil conductors positioned in the molding space formed by the first molding die and the second molding die. Molding process and
In a state where the first molding die and the second molding die are molded by the mold clamping step, the molten molding material is sent into the molding space, and injection molding is performed to form a molded portion of the molding material at the end portion. With process
The mold clamping step is a method for manufacturing a stator, which comprises pressing the plurality of coil conductors in the mold clamping direction by the first molding die and the second molding die. Each of the plurality of coil conductors has an insulating coating around the conductor portion, and at least a part of the coating is removed at the end portion.
The method for manufacturing a stator according to claim 1, wherein the pressed portion of the plurality of coil conductors pressed in the mold clamping step includes a portion where the coating is not removed. The first molding die and the second molding die are separated from each other by a first distance in the mold clamping direction passing through the pressed portion in the molded state.
The method for manufacturing a stator according to claim 2, wherein the first distance is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step and is smaller than the first dimension in the mold clamping direction. The method for manufacturing a stator according to claim 3, wherein the first distance is set so that an indentation is generated on the coating in the pressed portion by pressing in the mold clamping direction. The first molding die and the second molding die form an opening having a second distance in a direction of passing through the pressed portion and intersecting the mold clamping direction in the molded state.
The second distance is any one of claims 2 to 4, which is the dimension of the cross-sectional shape of the pressed portion before being pressed in the mold clamping step and is larger than the second dimension in the intersecting direction. The method for manufacturing a stator according to the above. In a state where the first molding die and the second molding die are molded, the dimension of the cross-sectional shape of the pressed portion and the dimension in the intersecting direction is the dimension of the pressed portion by pressing in the mold clamping direction. The method for manufacturing a stator according to claim 5, wherein the size increases from the second dimension due to the deformation of the second dimension. 6. The dimension of the cross-sectional shape of the pressed portion and the dimension in the intersecting direction increases up to the second distance in a state where the first molding die and the second molding die are molded. The method for manufacturing a stator according to the above. The method for manufacturing a stator according to any one of claims 2 to 7, wherein the boundary of the pressed portion is located on the boundary of the range in which the molded portion is formed in the plurality of coil conductors. It is a stator manufacturing device that molds a molded part by injection molding on a plurality of coil conductors in which ends extending to the outside of the slot of the stator core are joined to each other.
With the first molding mold
A second molding die that is molded with respect to the first molding die is provided.
The first molding die and the second molding die form a molding space for locating the joined ends of the plurality of coil conductors in the molded state, and the plurality of coil conductors are molded. A stator manufacturing device that presses in a direction. Each of the plurality of coil conductors has an insulating coating around the conductor portion, and at least a part of the coating is removed at the end portion.
The stator manufacturing apparatus according to claim 9, wherein the pressed portion pressed in the mold clamping direction in the plurality of coil conductors includes a portion where the coating is not removed. The first molding die and the second molding die are separated from each other by a first distance in the mold clamping direction passing through the pressed portion in the molded state.
The stator manufacturing apparatus according to claim 10, wherein the first distance is the dimension of the cross-sectional shape of the pressed portion before being pressed at the time of mold clamping and is smaller than the first dimension in the mold clamping direction. The first molding die and the second molding die form an opening having a second distance in a direction of passing through the pressed portion and intersecting the mold clamping direction in the molded state.
The stator manufacturing apparatus according to claim 10 or 11, wherein the second distance is a dimension of the cross-sectional shape of the pressed portion before being pressed at the time of mold clamping and is larger than the second dimension in the intersecting direction. ..

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