JP2022156672A - Stator, brushless motor, and method for manufacturing stator - Google Patents

Abstract

To provide a stator in which the ends of coils are connected by a determined combination with a simpler configuration, and a method for manufacturing a stator capable of connecting the ends of coils by a determined combination more easily.SOLUTION: A stator 20 includes a plurality of coils, which are first to sixth coils, and a relay substrate 23 that electrically connects respective ends of the first to the sixth coils. The relay substrate 23 has a plurality of substrates to be laminated. Each of the plurality of substrates has a through hole electrically connecting the plurality of substrates to each other and a conductive unit having a predetermined planar pattern shape electrically connected to the through hole. The relay substrate 23 electrically connects the first to sixth coils so that they form a predetermined connection by he through hole and the conductive unit.SELECTED DRAWING: Figure 1

Description

The present invention relates to a stator, a brushless motor, and a method of manufacturing a stator.

Conventionally, as a brushless motor, there has been proposed a configuration in which a stator and a rotor rotatable with respect to the stator are provided, and U-phase, V-phase, and W-phase armature coils that are star-connected to each other are attached to the stator. (See Patent Document 1, for example).
Patent Document 2 proposes a moving coil for a linear motor, in which the moving coil is made of a four-layer substrate, and a plurality of coils each having a spiral conductor pattern are formed in parallel on each layer. The coils on each layer are electrically connected through through holes via insulating layers.

JP-A-2005-12955 JP-A-2002-112524

For example, the coils of a brushless motor are housed inside the cylindrical stator core. At this time, an annular printed circuit board for coil wiring is arranged at the end of the stator core, and a single-layer printed circuit board may be used as this printed circuit board.
At this time, it is necessary to connect the ends of the coils in a predetermined combination on a single-layer printed circuit board. At that time, it is necessary to make a predetermined connection by running the end of the coil outside the coil, and the coil length becomes longer than that of the cylindrical coil. If the coil wire of the coil is forcibly pushed in to suppress this, there is a risk of disconnection. Moreover, it is necessary to solder a plurality of ends of the coil to the same place on the printed circuit board, which is not easy to manufacture.
SUMMARY OF THE INVENTION An object of the present invention is to provide a stator in which coil ends are connected in a predetermined combination with a simpler structure. It is another object of the present invention to provide a method of manufacturing a stator that can more easily connect coil ends in a predetermined combination.

Under such an object, the present invention includes a plurality of coils, and a substrate portion electrically connecting each of the plurality of coils, the substrate portion having a plurality of laminated substrates, and a plurality of substrates. has through-holes for electrically connecting a plurality of substrates together, and conductive portions having a predetermined planar pattern shape electrically connected to the through-holes, and the substrate portion includes the through-holes and the conductive portions. It is a stator that electrically connects each of a plurality of coils so as to form a predetermined wire connection.

Here, the plurality of coils can be configured such that each end of the plurality of coils is electrically connected to the substrate.

Further, when a plurality of coils are star-connected, the plurality of substrates may include a neutral point substrate, which is one substrate provided with a conductive portion that forms the neutral point of the star connection. .

In addition, the plurality of substrates includes a U-phase substrate, which is one substrate provided with a conductive portion for electrically connecting the U-phase coils, and a conductive portion for electrically connecting the V-phase coils. It is possible to include a V-phase substrate, which is only one substrate, and a W-phase substrate, which is one substrate provided with conductive portions for electrically connecting W-phase coils.

Also, the plurality of substrates may include a terminal substrate which is one substrate provided with a conductive portion forming a U-phase terminal, a conductive portion forming a V-phase terminal, and a conductive portion forming a W-phase terminal. can be

Also, the terminal substrate may be provided with a conductive portion that forms part of the neutral point.

In addition, the plurality of substrates are conductive to draw the end of at least one of the U-phase coil, the V-phase coil, and the W-phase coil in a direction approaching the U-phase terminal, the V-phase terminal, or the W-phase terminal. It is possible to include a routing substrate, which is one substrate provided with a portion.

Further, when a plurality of coils are delta-connected, the plurality of substrates includes a conductive portion that electrically connects any one of the U-phase coil, the V-phase coil, and the W-phase coil to each other. can include an in-phase substrate, which is the one substrate on which the

In addition, the plurality of substrates includes a conductive portion that electrically connects any one of the U-phase coil, the V-phase coil, and the W-phase coil, and any two different-phase coils. It is possible to include a composite phase substrate, which is one substrate provided with a conductive portion for electrically connecting the coils.

Further, the plurality of substrates is one substrate provided with a conductive portion for electrically connecting any two of the U-phase coil, the V-phase coil, and the W-phase coil to each other. It is possible to include a certain first different-phase substrate and a second different-phase substrate, which is one substrate provided with a conductive portion for electrically connecting any two different-phase coils.

In addition, the plurality of substrates includes a conductive portion that electrically connects the other coils of the same phase among the U-phase coil, the V-phase coil, and the W-phase coil, and the conductive portion that forms a U-phase terminal; A terminal substrate, which is one substrate provided with a conductive portion forming a V-phase terminal and a conductive portion forming a W-phase terminal, may be included.

Further, on the first different-phase substrate or the second different-phase substrate, an end portion of at least one of the U-phase coil, the V-phase coil, and the W-phase coil is connected to a U-phase terminal, a V-phase terminal, or a W-phase terminal. It is possible to provide a conductive portion that is routed in a direction approaching the terminal.

Also, the respective ends of the plurality of coils can be brought together on one of the plurality of substrates that is disposed closest to the end, and can be electrically connected to the one substrate.

Further, each of the plurality of substrates is annular, the through hole has a groove shape provided on the inner peripheral surface of each of the plurality of annular substrates, and the ends of the plurality of coils have groove shapes. It can be fitted into the formed through-hole and guided to one of the plurality of substrates positioned closest to the end.

Also, the electrically insulating portions of each of the plurality of substrates can be prevented from being exposed from the inner surfaces of the through holes.

Further, the present invention is a brushless motor including the above stator and a rotor that is accommodated inside the stator and rotated by supplying power to the stator.

Further, the present invention includes a mounting step of mounting a substrate portion on the axial end side of the plurality of coils, and a connecting step of electrically connecting each end portion of the plurality of coils to the substrate portion. and the substrate section has a plurality of laminated substrates, and the plurality of substrates has through holes electrically connecting the plurality of substrates together and a predetermined planar pattern shape electrically connected to the through holes. A method for manufacturing a stator having a conductive portion, and electrically connecting each of a plurality of coils by the through hole and the conductive portion so as to form a predetermined wire connection.

Here, in the connecting step, the ends of the plurality of coils can be gathered to one substrate positioned closest to the end of the plurality of substrates and electrically connected to the one substrate. .
In addition, each of the plurality of substrates has an annular shape, and in the connecting step, the end portions of the plurality of coils are fitted into groove-shaped through holes provided on the inner peripheral surfaces of the plurality of annular substrates. , the ends of the plurality of coils can be electrically connected to one of the plurality of substrates after being guided to the substrate positioned closest to the end.
Furthermore, the connection step includes a first soldering step of soldering the ends collected on one substrate to the one substrate, and a portion adjacent to the solder soldered by the first soldering step, and soldering the ends together. and a second soldering step of further soldering the core wire at the end exposed by the cutting step and the solder soldered in the first soldering step. .

According to the present invention, it is possible to provide a stator in which coil ends are connected in a predetermined combination with a simpler configuration. In addition, it is possible to provide a method of manufacturing a stator that can more easily connect the ends of the coils in a predetermined combination.

1 is a cross-sectional view of a brushless motor according to an embodiment; FIG. (a) and (b) are examples of perspective views showing how a wire is wound around a bobbin. It is an example of a wiring diagram when the coreless coil according to the present embodiment is configured by star connection. (a) to (f) are diagrams showing substrates constituting relay substrates in the case of star connection. It is the figure which showed becoming star connection by using a board|substrate. 8A to 8F are diagrams showing other examples of substrates constituting relay substrates in the case of star connection; FIG. It is an example of the wiring diagram in the case of comprising the coreless coil which concerns on this Embodiment by delta connection. 4(a) to 4(e) are diagrams showing substrates constituting relay substrates in the case of delta connection. FIG. It is the figure which showed becoming delta connection by using a board|substrate. (a) to (d) are diagrams explaining the connection process.

Hereinafter, embodiments will be described in detail with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view of a brushless motor 1 according to this embodiment.
A brushless motor 1 according to this embodiment includes a rotor 10 , a stator 20 , and a housing 30 that accommodates the stator 20 .

The rotor 10 is housed inside the stator 20 and is rotated by supplying power to the stator 20 . The rotor 10 has a rotating shaft 11 and a main magnet 12 attached to the rotating shaft 11 . Below, the axial direction of the rotating shaft 11 may be simply called "axial direction." In addition, in the axial direction, the left side of FIG. 1 may be referred to as "one side" and the right side of FIG. 1 may be referred to as "the other side".
The rotating shaft 11 is, for example, a solid cylindrical member. The main magnet 12 can be exemplified as a cylindrical magnet magnetized with two poles.

The stator 20 is composed of a plurality of coils that form a cylindrical shape as a whole, and includes a coreless coil 21 in which the ends of these coils are connected in a predetermined combination, a cylindrical stator core 22 that holds the coreless coil 21, It has a relay board 23 provided on the other end surface of the stator core 22 and a lead wire 24 connected to the relay board 23 . The relay substrate 23 is provided on the axial end side of the plurality of coils, and functions as an annular substrate portion that electrically connects the respective ends of the plurality of coils. The stator 20 will be detailed later.

The housing 30 includes a cylindrical case 31 in which both ends in the axial direction of the rotating shaft 11 are open, a one-side plate 32 that covers the opening on one side of the case 31, and a plate on the other side that covers the opening on the other side of the case 31. 33. In addition, the housing 30 is held by the one-side plate 32 and includes a one-side bearing 34 that rotatably supports one end of the rotary shaft 11 and a rotatable support of the other end of the rotary shaft 11. The other side bearing 35 is provided.
The one-side plate 32 and the other-side plate 33 are substantially cylindrical members that hold the one-side bearing 34 and the other-side bearing 35 inside, respectively, and are fitted inside the case 31 . One side bearing 34 and the other side bearing 35 can be exemplified as ball bearings.

Further, the brushless motor 1 is provided on the other side of the other side bearing 35 so that the rotor 10
and a cover 90 covering the detection device 50 .
The detection device 50 will be detailed later.

The cover 90 is a bottomed cylindrical member, and has a cylindrical portion 91 and a disc-shaped portion 92 that covers the opening on the other side of the cylindrical portion 91 .
The outer peripheral surface of the other-side plate 33 is fitted into the inner peripheral surface of the cylindrical portion 91 . Further, the cylindrical portion 91 is formed with a communication hole 911 that communicates the inside and the outside. A grommet 912 is fitted in the communication hole 911 , and the lead wire 24 is protruding out of the cover 90 through a hole formed in the grommet 912 .

(Configuration of detection device 50)
The detection device 50 has a magnetic sensor 51 , a sensor substrate 52 on which the magnetic sensor 51 is mounted, and a magnet unit 60 having a sensor magnet 61 provided to face the magnetic sensor 51 .

The magnetic sensor 51 can be exemplified as a Hall IC having a Hall element whose electrical characteristics (resistance) change under the action of a magnetic field. The magnetic sensor 51 has a first sensor (not shown), a second sensor (not shown), and a third sensor (not shown). When viewed from the other side in the axial direction, the first sensor, the second sensor, and the third sensor are arranged counterclockwise around the axis of the rotating shaft 11 in order at intervals of 120 degrees. It is mounted on the substrate 52 . An output signal from the magnetic sensor 51 is transmitted through a signal line 514 extending out of the cover 90 through a hole in a grommet 912 fitted in the cover 90 .

The sensor board 52 is fixed to the other side surface of the other side plate 33 of the housing 30 with, for example, screws. The sensor substrate 52 is fixed so that the arrangement positions of the first sensor, the second sensor, and the third sensor with respect to the coreless coil 21 are predetermined positions. Note that the sensor substrate 52 may be adhered to the other side plate 33 .

The magnet unit 60 includes a sensor magnet 61, a yoke 70 attached to the other end of the rotating shaft 11 projecting from the housing 30, and a sandwiching member 80 attached to the yoke 70 and sandwiching the sensor magnet 61 together with the yoke 70. and

The yoke 70 has a cylindrical yoke-side cylindrical portion 71 and a disc-shaped yoke-side disc-shaped portion 72 extending outward from the other end of the yoke-side cylindrical portion 71 .
A male thread (not shown) is formed on the outer peripheral surface of the yoke-side cylindrical portion 71 . A groove 712 recessed from the inner peripheral surface is formed along the entire circumference of the inner peripheral surface of the yoke-side cylindrical portion 71 .
The yoke-side disk-shaped portion 72 has, around the yoke-side cylindrical portion 71 , a protruding portion 721 cylindrically projecting from one surface of the yoke-side disk-shaped portion 72 to one side.

The sandwiching member 80 has a cylindrical sandwiching side cylindrical portion 81 and a disk-shaped sandwiching side disc portion 82 extending outward from the other end of the sandwiching side cylindrical portion 81 .
A female screw (not shown) that is tightened by a male screw formed on the yoke 70 is formed on the inner peripheral surface of the holding-side cylindrical portion 81 .
A plurality of (for example, two) through-holes 821 are formed in the sandwiching-side disk-shaped portion 82 at regular intervals in the circumferential direction.

The sensor magnet 61 can be exemplified as a ring-shaped magnet magnetized with two poles. The inner diameter of the sensor magnet 61 is equal to or larger than the outer diameter of the projecting portion 721 of the yoke 70 , and the outer diameter of the sensor magnet 61 is equal to or smaller than the outer diameter of the yoke-side disk-shaped portion 72 of the yoke 70 . The size of the sensor magnet 61 in the axial direction, in other words, the sensor magnet 61
is greater than or equal to the axial size of the protrusion 721 of the yoke 70 .

In the magnet unit 60 configured as described above, the female thread formed in the sandwiching member 80 is tightened to the male thread formed in the yoke 70 while the sensor magnet 61 is arranged around the projecting portion 721 of the yoke 70. It is The female thread formed in the sandwiching member 80 is tightened with the male thread formed in the yoke 70 until the other side surface of the sandwiching member 80 hits the one side surface of the sensor magnet 61 . As a result, the sensor magnet 61 is sandwiched between the yoke-side disk-shaped portion 72 of the yoke 70 and the sandwiching-side disk-shaped portion 82 of the sandwiching member 80, and is restrained from moving in the axial direction. In addition, the radial movement of the sensor magnet 61 is suppressed by the contact of the inner peripheral surface with the outer peripheral surface of the projecting portion 721 of the yoke 70 .

When assembling the magnet unit 60 , an adhesive may be applied between the male thread formed on the yoke 70 and the female thread formed on the sandwiching member 80 . This makes it difficult for the sandwiching member 80 to fall off from the yoke 70 . Also, an adhesive may be applied between the other side surface of the sensor magnet 61 and the one side surface of the yoke-side disk-shaped portion 72 of the yoke 70 . This makes it difficult for the sensor magnet 61 to fall off the yoke 70 . Alternatively, an adhesive may be applied between one surface of the sensor magnet 61 and the other surface of the sandwiching-side disc-shaped portion 82 of the sandwiching member 80 . This makes it difficult for the sandwiching member 80 to fall off the yoke 70 and the sensor magnet 61 .

Further, since a plurality of through holes 821 are formed in the sandwiching member 80, when the female thread formed in the sandwiching member 80 is tightened to the male thread formed in the yoke 70, the sandwiching member 80 is rotated. can be inserted into the plurality of through-holes 821 and rotated. This makes it easier to fasten the sandwiching member 80 to the yoke 70 .

The magnet unit 60 is attached to the other end of the rotating shaft 11 .
Here, a groove 111 recessed from the outer peripheral surface is formed over the entire circumference of the other end of the rotating shaft 11 . A circlip 112 is fitted in the groove 111 . The circlip 112 can be, for example, a donut shape with a notch formed in a part in the circumferential direction.
The magnet unit 60 is fitted from one end of the yoke-side cylindrical portion 71 of the yoke 70 to the other end of the rotating shaft 11 . Then, the circlip 112 fitted in the groove 111 of the rotating shaft 11 is inserted into the groove 712 formed in the yoke 70 until it is fitted. By fitting the circlip 112 into the groove 712 formed in the yoke 70, the magnet unit 60 is restrained from moving in the axial direction.

(Regarding the stator 20)
First, a method of manufacturing the stator 20 will be described.
(winding work)
The coreless coil 21 is wound by a predetermined number of turns by winding a magnet wire (hereinafter sometimes referred to as "wire") wound on one bobbin on a winding frame rotated in one rotation direction. It has 6 coils.

FIGS. 2A and 2B are examples of perspective views showing how the wire 410 is wound around the bobbin 400. FIG.
First, as shown in FIG. 2(a), the wire 410 is wound around a winding frame 400 having a hexagonal prism shape. In this case, first, the winding frame 400 in the shape of a hexagonal prism is rotated in one direction of rotation by a predetermined number of turns, and the wire wound on the bobbin (not shown) is wound around the winding frame 400 to obtain a predetermined number of turns in one direction of rotation. A shunt first coil 211 is formed. Subsequently, the wire is pulled out by a predetermined length from the winding end of the first coil 211, bent and folded back, and the folded back is returned to the winding end of the first coil 211, thereby forming the first lead-out portion 221. to form Note that the winding start side of the first coil 211 may be referred to as a first winding start end portion 211s.

Next, the winding frame 400 is rotated in one rotation direction by a predetermined number of rotations to wind the wire wound on the bobbin around the winding frame 400, and the second coil 212 wound in the one rotation direction by a predetermined number of turns is wound. Form. Subsequently, the wire is pulled out by a predetermined length from the winding end of the second coil 212, bent and folded back, and the folded back is returned to the winding end of the second coil 212, thereby forming the second lead-out portion 222. to form

After that, the above steps are repeated three times to form a third coil 213, a fourth coil 214, and a fifth coil 215 wound by a predetermined number of turns in the same rotational direction. Further, a third lead-out portion 223 is provided between the third coil 213 and the fourth coil 214, a fourth lead-out portion 224 is provided between the fourth coil 214 and the fifth coil 215, and a winding end portion of the fifth coil 215 is provided. , a fifth lead-out portion 225 is formed.

Then, after forming the fifth lead-out portion 225, the winding frame 400 is rotated in one direction of rotation by a predetermined number of turns, and the wire wound around the bobbin is wound around the winding frame 400 by a predetermined number of turns in one direction of rotation. A shunt-turned sixth coil 216 is formed. Subsequently, the wire is pulled out from the winding end of the sixth coil 216 to form a sixth winding end portion 216 e that becomes the winding end portion of the sixth coil 216 .

After that, as shown in FIG. 2B, the bent portions of the first, second, third, fourth, fourth, and fifth lead portions 221, 222, 223, 224, and 225 are cut off.
Specifically, the bent portion of the first lead-out portion 221 is cut, and a first winding end portion 211e that becomes the winding end portion of the first coil 211 and a second winding end portion that becomes the winding start end portion of the second coil 212 are cut. 212 s of winding start ends are formed.
In addition, the bent portion of the second lead-out portion 222 is cut, and a second winding end portion 212e that becomes the winding end portion of the second coil 212 and a third winding start portion that becomes the winding start end portion of the third coil 213 are formed. and a portion 213s.
Further, the bent portion of the third lead-out portion 223 is cut, and a third winding end portion 213e that becomes the winding end portion of the third coil 213 and a fourth winding start portion that becomes the winding start end portion of the fourth coil 214 are formed. 214s.
Further, the bent portion of the fourth lead-out portion 224 is cut, and a fourth winding end portion 214e that becomes the winding end portion of the fourth coil 214 and a fifth winding start portion that becomes the winding start end portion of the fifth coil 215 are formed. 215s.
Further, the bent portion of the fifth lead-out portion 225 is cut, and a fifth winding end portion 215e that becomes the winding end portion of the fifth coil 215 and a sixth winding start portion that becomes the winding start end portion of the sixth coil 216 are formed. forming a portion 216s.

After that, with the first to sixth coils 211 to 216 taped and temporarily fixed, the first to sixth coils 211 to 216 are pulled out from the winding frame 400 and tilted to remove the flat coil (not shown). Generate.
After that, the flat coil is wound around a cylindrical or cylindrical jig to form a cylindrical coil (not shown), which is adhered to the inner peripheral surface of a stator core (not shown). Further, a relay board (not shown) is adhered to the other end surface of the cylindrical stator core, and the ends of the first coil 211 to the sixth coil 216 are wired and soldered to the relay board. The lead wires 24 are soldered to the relay board. These first to sixth coils 211 to 216 are examples of a plurality of coils forming a cylindrical shape as a whole.

At this time, the ends of the first to sixth coils 211 to 216 are electrically connected to the relay board by soldering in two cases: star connection and delta connection. .

(Star connection)
Here, the case where the coreless coil 21 is configured by connecting the first to sixth coils 211 to 216 by star connection will be described.
FIG. 3 is an example of a wiring diagram when the coreless coil 21 according to the present embodiment is configured by star connection.
When wiring the end portions formed in the cylindrical coil to the relay substrate 23, the first winding end portion 211e, the third winding end portion 213e, and the fifth winding end portion 215e are connected to form a middle wire. and point terminal 219 . Also, the third winding start end portion 213s and the sixth winding start end portion 216s are connected. Furthermore, the fifth winding start end portion 215s and the second winding start end portion 212s are connected. Furthermore, the first winding start end portion 211s and the fourth winding start end portion 214s are connected. The sixth winding end portion 216e, the second winding end portion 212e, and the fourth winding end portion 214e are phase terminals.

3, the coreless coil 21 connects the third coil 213 and the sixth coil 216, the fifth coil 215 and the second coil 212, and the first coil 211 and the fourth coil 214 in series. It becomes a three-phase star-connected coil. In the following description, the phase composed of the third coil 213 and the sixth coil 216 is the V phase, the phase composed of the fifth coil 215 and the second coil 212 is the U phase, and the phase composed of the first coil 211 and the fourth coil 211 is hereinafter described. A phase configured with the coil 214 may be referred to as a W phase. The sixth winding end portion 216e is a V-phase terminal, the second winding end portion 212e is a U-phase terminal, and the fourth winding end portion 214e is a W-phase terminal.

However, the phase composed of the third coil 213 and the sixth coil 216 is the W phase, the phase composed of the fifth coil 215 and the second coil 212 is the U phase, and the phase composed of the first coil 211 and the fourth coil 214 is A phase composed of may be the V phase. Further, the phase composed of the third coil 213 and the sixth coil 216 is the U phase, the phase composed of the fifth coil 215 and the second coil 212 is the V phase, the first coil 211 and the fourth coil 214 are A phase composed of may be the W phase.

In the present embodiment, this connection is realized by making the relay board 23 a multi-layered structure composed of a plurality of annular boards. Note that the shape of the substrate is not limited to an annular shape.
FIGS. 4(a) to 4(f) are diagrams showing substrates constituting the relay substrate 23 in the case of star connection.
The relay board 23 includes a board 236 shown in FIG. 4(a), a board 235 shown in FIG. 4(b), a board 234 shown in FIG. 4(c), a board 233 shown in FIG. 4(d), and a board 233 shown in FIG. and the substrate 231 shown in FIG. 4(f) are laminated in this order from one side to the other side in FIG. In other words, the relay board 23 has a plurality of laminated annular boards 231 to 236 . In this case, the substrates 231 to 236 can also be said to be first to sixth layer substrates, respectively.
The substrates 231 to 236 are composed of an electrically insulating insulating portion forming the base of these substrates 231 to 236 and an arc-shaped planar pattern provided on the surface of the insulating portion of these substrates 231 to 236. and through holes for electrically connecting the substrates 231 to 236, respectively. Note that the planar pattern shape of the conductive portion is not limited to an arc shape.

The conductive portion is formed by copper plating or the like and has conductivity.
As a conductive portion, a conductive portion 236d is provided in the substrate 236 shown in FIG.
Further, a conductive portion 235d is provided in the substrate 235 shown in FIG. 4(b).
Further, the substrate 234 shown in FIG. 4C is provided with a conductive portion 234d.
Furthermore, the substrate 233 shown in FIG. 4D is provided with a conductive portion 233d.
Furthermore, the substrate 232 shown in FIG. 4E is provided with a conductive portion 232d.
Further, conductive portions 231d1 to 231d12 are provided in the substrate 231 shown in FIG. 4(f).
In the substrates 231 to 236, conductive portions other than the conductive portions 231d1 to 231d12, the conductive portions 232d, the conductive portions 233d, the conductive portions 234d, the conductive portions 235d, and the conductive portions 236d are not provided.

The through hole is electrically conductive because the entire inner surface of the through hole is plated with copper or the like.
As the through holes, through holes S11 to S21 are formed in the substrates 231 to 236, respectively, and the substrates 231 to 236 are electrically connected in the stacking direction at the through holes S11 to S21. The through-holes S11-S21 are through-holes formed in the substrates 231-236, respectively, in this case. The shape of the through holes S11 to S21 when viewed from above the substrates 231 to 236 is not particularly limited, and may be rectangular, circular, elliptical, or the like. Only the copper plating or the like forming the through holes S11 to S21 is exposed from the inner surfaces of the through holes S11 to S21, and the insulating portions of the substrates 231 to 236 are not exposed.

Further, as shown in FIG. 4A, in the substrate 236, the through holes S11, S18 and S21 are electrically connected to the conductive portion 236d.
Further, as shown in FIG. 4B, in the substrate 235, the through holes S15 and S20 are electrically connected to the conductive portion 235d.
Furthermore, as shown in FIG. 4C, in the substrate 234, the through holes S14 and S19 are electrically connected to the conductive portion 234d.
Furthermore, as shown in FIG. 4D, in the substrate 233, the through holes S12 and S17 are electrically connected to the conductive portion 233d.
Furthermore, as shown in FIG. 4E, in the substrate 232, the through holes S13 and S16 are electrically connected to the conductive portion 232d.

Furthermore, as shown in FIG. 4(f), in the substrate 231, the through holes S21 and S11 are electrically connected to the conductive portion 231d1. Similarly, in the substrate 231, the through hole S12 and the conductive portion 231d2 are electrically connected, and the through hole S13 and the conductive portion 231d3 are electrically connected. Furthermore, the through-hole S14 and the conductive portion 231d4 are electrically connected, and the through-hole S15 and the conductive portion 231d5 are electrically connected. Furthermore, the through hole S16 and the conductive portion 231d7 are electrically connected, and the through hole S17 and the conductive portion 231d9 are electrically connected. Furthermore, the through hole S18 and the conductive portion 231d10 are electrically connected, and the through hole S19 and the conductive portion 231d11 are electrically connected. Furthermore, the through hole S20 and the conductive portion 231d12 are electrically connected.

In the present embodiment, among the substrates 231 to 236, the substrate 231 is the end portions of the first coil 211 to the sixth coil 216, that is, the first winding start end portion 211s to the sixth winding start end portion 216s and the first winding start end portion 211s to the sixth winding start end portion 216s. The winding end portion 211 e to the sixth winding end portion 216 e are soldered and used to electrically connect these ends to the relay board 23 . Further, the substrate 231 is used for soldering the lead wires 24 which are external wiring for the stator 20 and electrically connecting the V-phase, U-phase, and W-phase lead wires 24 to the relay substrate 23 .

Here, the conductive portion 231d1 of the substrate 231 and the first winding end portion 211e are connected to the fifth winding end portion 215e. Similarly, the conductive portion 231d2 is connected to the fifth winding start end portion 215s. A sixth winding end portion 216e is connected to the conductive portion 231d3. Furthermore, the sixth winding start end portion 216s is connected to the conductive portion 231d4. Furthermore, the fourth winding start end portion 241s is connected to the conductive portion 231d5. Furthermore, the fourth winding end portion 214e and the W-phase lead wires 24 are connected to the conductive portion 231d6. Furthermore, each lead wire 24 of the V-phase is connected to the conductive portion 231d7. Furthermore, the second winding end portion 212e and the U-phase lead wires 24 are connected to the conductive portion 231d8. Furthermore, the second winding start end portion 212s is connected to the conductive portion 231d9. Furthermore, the third winding end portion 213e is connected to the conductive portion 231d10. Furthermore, the third winding start end portion 213s is connected to the conductive portion 231d11. Furthermore, the first winding start end portion 211s is connected to the conductive portion 231d12.

Also, the substrates 231 to 236 are used as substrates for realizing the star connection shown in FIG. That is, the substrates 231 to 236 are used as first to sixth multilayer substrates for star connection. That is, the star connection is formed by intra-substrate connection in which the plurality of substrates 231 to 236 are electrically connected to the conductive portions through the through holes S11 to S21.

FIG. 5 is a diagram showing star connection by using substrates 231-236.
In the substrate 236 shown in FIGS. 4A and 5, the through holes S11, S18, S21 and the conductive portion 236d form the third winding end portion 213e, the fifth winding end portion 215e and the first winding end portion 211e. are connected to form the neutral point of the star connection. That is, the substrate 236 plays the role of the neutral point terminal 219 . Further, the substrate 236 functions as one substrate provided with a conductive portion 236d that forms the neutral point 219 of the star connection.
In the substrate 235 shown in FIGS. 4B and 5, the first winding start end 211s and the fourth winding start end 214s are connected and connected by the through holes S15 and S20 and the conductive portion 235d. . As a result, the W-phase coils 211 and 214 are connected in series. In this case, the substrate 235 functions as a W-phase substrate, which is one substrate provided with a conductive portion 235d that electrically connects the W-phase coils 211 and 214 to each other.
Further, in the substrate 234 shown in FIGS. 4(c) and 5, the third winding start end portion 213s and the sixth winding start end portion 216s are respectively connected and connected by the through holes S14, S19 and the conductive portion 234d. . As a result, the V-phase coils 213 and 216 are connected in series. In this case, the substrate 234 functions as a V-phase substrate, which is one substrate provided with a conductive portion 234d that electrically connects the V-phase coils 213 and 216 to each other.

Furthermore, in the substrate 233 shown in FIGS. 4D and 5, the fifth winding start end portion 215s and the second winding start end portion 212s are connected and connected by the through holes S12 and S17 and the conductive portion 233d. be. As a result, U-phase coil 215 and coil 212 are connected in series. In this case, the substrate 233 functions as a U-phase substrate, which is one substrate provided with a conductive portion 233d that electrically connects the U-phase coils 215 and 212 together.
Further, in the substrate 232 shown in FIGS. 4(e) and 5, the sixth winding end portion 216e and the V-phase lead wire 24 are connected and connected by the through holes S13 and S16 and the conductive portion 232d. . That is, the substrate 232 plays a role of pulling the sixth winding end portion 216e in a direction approaching the V-phase terminal. Therefore, the substrate 232 functions as a routing substrate, which is one substrate provided with a conductive portion 232d that guides the sixth winding end portion 216e of the V-phase coil 216 in a direction approaching the V-phase terminal.
Furthermore, in the substrate 231 shown in FIGS. 4(f) and 5, the U-phase lead wire 24 and the second winding end portion 212e are connected by a conductive portion 231d8. Further, the W-phase lead wire 24 and the fourth winding end portion 214e are connected by the conductive portion 231d6. In this case, the substrate 231 functions as a terminal substrate provided with a conductive portion 231d8 forming a U-phase terminal. Further, the substrate 231 functions as a terminal substrate provided with a conductive portion 231d6 forming a W-phase terminal.
The fifth winding end portion 215e and the first winding end portion 211e are connected by the through hole S21, the through hole S11, and the conductive portion 231d1. In this case, the substrate 231 functions as a terminal substrate provided with a conductive portion 231d1 that forms part of the neutral point. The fifth winding end portion 215e and the first winding end portion 211e are electrically connected by through holes S11 and S21 and a conductive portion 236d in the substrate 236 shown in FIG. Since the substrate 231 shown in FIG. 4F is also electrically connected, the electrical connection is more reliable.
The substrate 231 functions as a terminal substrate provided with a conductive portion 231d7 forming a V-phase terminal.

It can also be said that the substrates 233, 234, and 235 are substrates for electrically connecting two in-phase coils of U-phase, V-phase, and W-phase, respectively.

Also, the through-holes can be formed in the shape of grooves provided on the inner peripheral surfaces of the plurality of circular substrates 231 to 236, respectively. At this time, the through-hole has conductivity because the entire inner surface of the groove is plated with copper or the like. At these through holes, the substrates 231 to 236 are electrically connected in the stacking direction. The shape of the groove when viewed from above the substrates 231 to 236 is not particularly limited, and may be rectangular, triangular, semicircular, U-shaped, V-shaped, or the like. Only the copper plating or the like forming the through holes S11 to S21 is exposed from the inner surfaces of the through holes S11 to S21, and the insulating portions of the substrates 231 to 236 are not exposed.
Here, the case where the groove shape is U-shaped will be described below.

FIGS. 6A to 6F are diagrams showing other examples of substrates forming the relay substrate 23 in the case of star connection.
The relay board 23 includes a board 256 shown in FIG. 6A, a board 255 shown in FIG. 6B, a board 254 shown in FIG. 6C, a board 253 shown in FIG. 6D, and a board 253 shown in FIG. and the substrate 251 shown in FIG. 6(f) are laminated in this order from one side to the other side in FIG. In other words, the relay board 23 in this case has a plurality of laminated annular boards 251 to 256 .
The substrates 251 to 256 are composed of an electrically insulating insulating portion forming the base of these substrates 251 to 256, and an arc-shaped planar pattern provided on the surface of the insulating portion of these substrates 251 to 256. and through holes for electrically connecting these substrates 251-256.

As the conductive portion, a conductive portion 256d is provided in the substrate 256 shown in FIG. 6(a).
In addition, the substrate 255 shown in FIG. 6B is provided with a conductive portion 255d.
Further, the substrate 254 shown in FIG. 6C is provided with a conductive portion 254d.
Further, a conductive portion 253d is provided in the substrate 253 shown in FIG. 6(d).
Furthermore, the substrate 252 shown in FIG. 6E is provided with a conductive portion 252d.
Further, conductive portions 251d1 to 251d4 are provided in the substrate 251 shown in FIG. 6(f).
The substrates 251 to 256 are not provided with conductive portions other than the conductive portions 251d1 to 251d4, the conductive portions 252d, the conductive portions 253d, the conductive portions 254d, the conductive portions 255d, and the conductive portions 256d.

Through holes S31 to S43 formed in substrates 251 to 256 are provided as through holes. At these through holes S31 to S43, the substrates 251 to 256 are electrically connected in the stacking direction. However, in the case of the present embodiment, the through holes S31-S43 are U-shaped opening to the inner peripheral side of the substrates 251-256. When the through holes S31 to S43 are U-shaped, a first winding start end 211s to a sixth winding start end 216s and a first winding end end, which are ends of the first coil 211 to the sixth coil 216, are formed. 211e to the sixth winding end portion 216e can be fitted into the through holes S31 to S43 when leading to the substrate 251. FIG.

Further, as shown in FIG. 6A, in the substrate 256, the through holes S31, S40 and S43 are electrically connected to the conductive portion 256d.
Furthermore, as shown in FIG. 6B, in the substrate 255, the through holes S35 and S42 are electrically connected to the conductive portion 255d.
Furthermore, as shown in FIG. 6C, in the substrate 254, the through holes S34 and S41 are electrically connected to the conductive portion 254d.
Furthermore, as shown in FIG. 6D, in the substrate 253, the through holes S32 and S39 are electrically connected to the conductive portion 253d.
Furthermore, as shown in FIG. 6E, in the substrate 252, the through holes S33 and S37 are electrically connected to the conductive portion 252d.
Furthermore, as shown in FIG. 6(f), in the substrate 251, the through holes S31 and S43 are electrically connected to the conductive portion 251d1. Furthermore, the through hole S36 and the conductive portion 251d2 are electrically connected, the through hole S37 and the conductive portion 251d3 are electrically connected, and the through hole S38 and the conductive portion 251d4 are electrically connected.

In this case, the form of electrical connection by the conductive portion and the through hole is the same in each of FIGS. 6(a) to (f) and each of FIGS. 4(a) to (f). Therefore, the same can be said for FIG. 5 if the substrates 231 to 236 are replaced with the substrates 251 to 256, respectively.
In addition, the first to sixth winding start end portions 211s to 216s and the first to sixth winding end portions 211e to 216e, which are the end portions of the first to sixth coils 211 to 216, are connected to the substrate. The parts to be soldered to 251 are the same as those to be soldered to the board 231 described above.

(delta connection)
Here, the case where the coreless coil 21 is configured by connecting the first to sixth coils 211 to 216 by delta connection will be described.
FIG. 7 is an example of a wiring diagram when the coreless coil 21 according to the present embodiment is configured by delta connection.
When wiring the ends formed in the cylindrical coil to the relay board 23, the sixth winding end portion 216e and the fifth winding end portion 215e are connected, and the fifth winding start portion 215s and the second winding start portion are connected. 212 s of ends are connected.
Further, the second winding end portion 212e and the first winding end portion 211e are connected, and the first winding start portion 211s and the fourth winding start portion 214s are connected.
Further, the fourth winding end portion 214e and the third winding end portion 213e are connected, and the third winding start portion 213s and the sixth winding start portion 216s are connected.

Then, the sixth winding end portion 216e and the fifth winding end portion 215e, the second winding end portion 212e and the first winding end portion 211e, the fourth winding end portion 214e and the third winding end portion 213e are Phase terminal. In this case, the phase terminals are V-phase, U-phase and W-phase in order.
However, the sixth winding end portion 216e and the fifth winding end portion 215e are phase terminals for the W phase, the second winding end portion 212e and the first winding end portion 211e are the phase terminals for the U phase, and the fourth winding end portion. The end portion 214e and the third winding end portion 213e may be used as V-phase phase terminals.
Also, the phase composed of the third coil 213 and the sixth coil 216 is the U phase, the phase composed of the second coil 212 and the fifth coil 215 is the V phase, the first coil 211 and the fourth coil 214 are A phase composed of may be the W phase.

In the present embodiment, this connection is realized by making the relay board 23 a multi-layered structure composed of a plurality of annular boards.
FIGS. 8A to 8E are diagrams showing substrates constituting the relay substrate 23 in the case of delta connection.
The relay board 23 includes a board 275 shown in FIG. 8(a), a board 274 shown in FIG. 8(b), a board 273 shown in FIG. 8(c), a board 272 shown in FIG. 8(d), and a board 272 shown in FIG. are laminated in this order from one side to the other side in FIG. In other words, the relay substrate 23 has a plurality of stacked circular substrates 271 to 275 . In this case, the substrates 271 to 275 can also be said to be first to fifth layer substrates, respectively.
The substrates 271 to 275 are composed of an electrically insulating insulating portion forming the base of these substrates 271 to 275, and an arc-shaped planar pattern provided on the surface of the insulating portion of these substrates 271 to 275. and through holes for electrically connecting these substrates 271 to 275 to each other.

As the conductive portion, a conductive portion 275d is provided in the substrate 275 shown in FIG. 8(a).
Further, conductive portions 274d1 and 274d2 are provided in the substrate 274 shown in FIG. 8B.
Furthermore, the substrate 273 shown in FIG. 8C is provided with a conductive portion 273d.
Further, a conductive portion 272d is provided in the substrate 272 shown in FIG. 8(d).
Further, conductive portions 271d1 to 271d4 are provided in the substrate 271 shown in FIG. 8(e).
The substrates 271 to 275 are not provided with conductive portions other than the conductive portions 271d1 to 271d4, the conductive portion 272d, the conductive portion 273d, the conductive portions 274d1, 274d2 and the conductive portion 275d.

Through holes S51 to S63 formed in substrates 271 to 275 are provided as through holes. At these through holes S51 to S63, the substrates 271 to 275 are electrically connected in the stacking direction. Further, in the case of this embodiment, the through holes S51 to S56 and S58 to S63 form a U-shape opening toward the inner peripheral side of the substrates 271 to 276, as in FIG. The through hole S57 is formed as a through hole.

Further, as shown in FIG. 8A, in the substrate 275, the through holes S52 and S59 are electrically connected to the conductive portion 275d.
Furthermore, as shown in FIG. 8B, in the substrate 274, the through holes S55 and S62 are electrically connected to the conductive portion 274d1. Further, through holes S56 and S60 are electrically connected to conductive portion 274d2.
Furthermore, as shown in FIG. 8C, in the substrate 273, the through holes S51, S53 and S57 are electrically connected to the conductive portion 273d.
Furthermore, as shown in FIG. 8D, in the substrate 272, the through holes S58 and S63 are electrically connected to the conductive portion 272d.
Furthermore, as shown in FIG. 8E, in the substrate 271, the through holes S54 and S61 are electrically connected to the conductive portion 271d1. Furthermore, the through hole S56 and the conductive portion 271d2 are electrically connected, the through hole S57 and the conductive portion 271d3 are electrically connected, and the through hole S58 and the conductive portion 271d4 are electrically connected.

In the present embodiment, among the substrates 271 to 275, the substrate 271 is the first to sixth winding start end portions 211s to 216s, which are the ends of the first to sixth coils 211 to 216, and the first winding start end portion 211s to the sixth coil start end portion 216s. The winding end portion 211 e to the sixth winding end portion 216 e are soldered and used to electrically connect these ends to the relay board 23 . Further, the board 271 is used for soldering the lead wires 24 which are external wiring for the stator 20 and electrically connecting the V-phase, U-phase, and W-phase lead wires 24 to the relay board 23 .

Here, the through hole S51 of the substrate 271 is connected to the fifth winding end portion 215e. Similarly, the through hole S52 is connected to the fifth winding start end 215s. A sixth winding end portion 216e is connected to the through hole S53. Furthermore, the sixth winding start end 216s is connected to the through hole S54. Furthermore, the fourth winding start end 214s is connected to the through hole S55. Furthermore, the fourth winding end portion 214e and the W-phase lead wires 24 are connected to the through hole S56 and the conductive portion 271d2. Furthermore, each lead wire 24 of the V phase is connected to the through hole S57 and the conductive portion 271d3. Further, the second winding end portion 212e and the U-phase lead wires 24 are connected to the through hole S58 and the conductive portion 271d4. Furthermore, the second winding start end portion 212s is connected to the through hole S59. Furthermore, the third winding end portion 213e is connected to the through hole S60. Furthermore, the third winding start end portion 213s is connected to the through hole S61. Furthermore, the first winding start end 211s is connected to the through hole S62. Furthermore, the first winding end portion 211e is connected to the through hole S63.

Further, substrates 271 to 275 are used as substrates for realizing the delta connection shown in FIG. That is, the substrates 271 to 275 are used as first to fifth multilayer substrates for delta connection, respectively. In other words, the delta connection is formed by intra-substrate connections in which the plurality of substrates 271 to 275 are electrically connected to the conductive portions through the through holes S51 to S63.

FIG. 9 is a diagram showing delta connection by using substrates 271-275.
In the substrate 275 shown in FIGS. 8A and 9, the fifth winding start end portion 215s and the second winding start end portion 212s are connected and connected by the through holes S52 and S59 and the conductive portion 275d. As a result, U-phase coil 215 and coil 212 are connected in series.
Further, in the substrate 274 shown in FIGS. 8B and 9, the first winding start end portion 211s and the fourth winding start end portion 214s are connected and connected by the through holes S55 and S62 and the conductive portion 274d1. . As a result, the W-phase coils 211 and 214 are connected in series. Further, in the substrate 274, the fourth winding end portion 214e, the third winding end portion 213e and the W-phase terminal (the conductive portion 271d2 of the substrate 271) are connected by the through holes S56 and S60 and the conductive portion 274d2, respectively. be done. As a result, the W-phase coil 214, the V-phase coil 213, and the W-phase terminal are connected.

Further, in the substrate 273 shown in FIGS. 8(c) and 9, the through holes S51, S53, S57 and the conductive portion 273d form the sixth winding end portion 216e, the fifth winding end portion 215e and the V-phase terminal (substrate). 271 are connected and wired. As a result, the V-phase coil 216, the U-phase coil 215, and the V-phase terminal are connected. The fifth winding end portion 215e and the sixth winding end portion 216e are routed toward the V-phase terminal by the conductive portion 273d provided between the through holes S53 and S57.
Further, in the substrate 272 shown in FIGS. 8(d) and 9, the through holes S58 and S63 and the conductive portion 272d form the second winding end portion 212e, the first winding end portion 211e and the U-phase terminal (substrate 271). 271d4) are connected and wired. As a result, the U-phase coil 212, the W-phase coil 211, and the U-phase terminal are connected.
Furthermore, in the substrate 271 shown in FIGS. 8(e) and 9, the third winding start end portion 213s and the sixth winding start end portion 216s are connected and connected by the through holes S54, S61 and the conductive portion 271d1. be. As a result, the V-phase coils 213 and 216 are connected in series.

The substrates 275, 274, and 271 are connected to the same-phase coils of the U-phase coils (the coils 215 and 212), the W-phase coils (the coils 211 and 214), and the V-phase coils (the coils 213 and 216), respectively. It functions as an in-phase substrate which is one substrate provided with conductive portions 275d, 274d1, and 271d1 for electrically connecting the .
Further, the substrate 274 functions as a composite phase substrate that is one substrate provided with a conductive portion 274d2 that electrically connects any two different phase coils (in this case, the coil 213 and the coil 214). .
Further, the two substrates selected from the substrates 272, 273, and 274 electrically connect any two of the U-phase coil, the V-phase coil, and the W-phase coil to each other. A first different-phase substrate, which is one substrate provided with a conductive portion for connection, and a second substrate, which is one substrate provided with a conductive portion for electrically connecting any two other coils of different phases. It functions as a heterogeneous substrate.
Further, the substrate 271 is a conductive portion that electrically connects other coils of the same phase among the U-phase coil, the V-phase coil, and the W-phase coil (in this case, the V-phase coils 213 and 216). 271d1, a conductive portion 271d4 forming a U-phase terminal, a conductive portion 271d3 forming a V-phase terminal, and a conductive portion 271d2 forming a W-phase terminal.
The substrate 273 is provided with a conductive portion (part of the conductive portion 273d) that draws the end of the V-phase coil (coil 216) in a direction approaching the V-phase terminal.

The through holes S51 to S63 may be formed as through holes as shown in FIGS. 4(a) to 4(f).
Also, in the above example, the substrate 231 , the substrate 251 and the substrate 271 are provided on the other side of the stator 21 , but they may be provided on one side of the stator 21 .

In the stator 20 described above, the relay board 23 is a multi-layer board, and the wiring within the board is made by the multi-layer board. As a result, when the first to sixth coils 211 to 216 are star-connected or delta-connected, the burden of connecting the ends of the coils is reduced. Also, the work for mounting the relay board 23 becomes easier. In addition, it is easy to thicken the conductive portion of each substrate. That is, when a plurality of substrates are to be combined, it is necessary to make the conductive portions thin at the portions where the conductive portions overlap so that they do not come into contact with each other. In the substrate of the present embodiment, the wiring does not change even if the order is changed for the substrates of the second and subsequent layers. Therefore, the assembly of the relay board 23 is also easy.
Furthermore, the ends of each coil need not be routed excessively to connect. Furthermore, the need for aerial wiring to connect the ends in the air is eliminated. As a result, disconnection at the ends can be suppressed.
In addition, since the ends of the coils are less likely to be bent and the stress caused by this is reduced, breakage of the ends can be suppressed.

In the stator 20 described above, the ends of the coils are gathered on the substrate 231 or the like closest to the edge of the relay substrate 23, and soldering or the like is performed on the substrate 231 or the like. and electrically connected. This makes work such as soldering easier. Furthermore, the need for aerial wiring to connect in the air is eliminated. Furthermore, the lead wire 24 can also be soldered to the relay substrate 23, and the lead wire 24 can be easily connected.

(Soldering method)
As described above, the substrates 231, 251 and 271 are provided with the first winding start end portion 211s to the sixth winding start end portion 216s, which are the ends of the first coil 211 to the sixth coil 216, and the first winding end portion 211s to the sixth winding start end portion 216s. The end portion 211e to the sixth winding end portion 216e are soldered.
In this case, the ends of the first to sixth coils 211 to 216 are gathered on the substrate 231, the substrate 251, or the substrate 271, which is one of the substrates located closest to the end of the relay substrate . Further, in the case where the substrate 251 or the substrate 271 has a U-shaped through hole, each of the ends of the first coil 211 to the sixth coil 216 is fitted in the through hole and is conducted to the substrate 251 or the substrate 271. be killed. Then, it is electrically connected to the substrate 251 and the substrate 271 by soldering.
Among the methods for manufacturing the stator 20, a soldering method for performing such soldering will be described below. Here, the substrate 251 having a U-shaped through-hole will be described as an example.

First, the relay board 23 is attached to the end portions of the first to sixth coils 211 to 216 in the axial direction (attachment step).
Next, the ends of the first to sixth coils 211 to 216 are soldered to the substrate 251 for electrical connection (connection step).

FIGS. 10A to 10D are diagrams explaining the connection process.
In the connecting step, first, as shown in FIG. 10A, the ends T of the coils are brought together on the substrate 251 on the othermost side of the relay substrate 23 . At this time, the end portion T of each coil is guided from the lower side of the substrate 251 in the drawing and extends upwardly of the substrate 251 . If the substrate 251 has a U-shaped through hole S, the ends of the first to sixth coils 211 to 216 are fitted into the through hole S of the substrate 251 and guided to the substrate 251 .

Next, as shown in FIG. 10B, the ends T gathered on the substrate 251 are soldered to the substrate 251 (first soldering step). FIG. 10B shows the case of soldering with solder H1. This soldering is temporary soldering. As a result, the end portion T is temporarily fixed to the substrate 251 . Further, when the substrates 252 to 256 are stacked on the substrate 251, the melted solder H1 runs along the inner surfaces of the through holes S of the substrate 251 and wets the inner surfaces of the through holes S of the substrates 252 to 256. spread.

Further, as shown in FIG. 10(c), the end portion T is cut at a location adjacent to the solder H1 soldered in the first soldering step (cutting step). As a result, the core wire 410a, which is an internal conductive portion, is exposed as a cross section.

Then, as shown in FIG. 10(d), the core wire 410a of the end portion T exposed by the cutting step and the solder H1 soldered in the first soldering step are further soldered (second soldering step). . Thereby, the solder H1 and the solder H2 covering the core wire 410a are formed. As a result, through hole S and core wire 410a are electrically connected via solders H1 and H2.

As the wires forming the coils of the first coil 211 to the sixth coil 216, for example, litz wires (twisted wires) may be used for high-speed rotation. At this time, in the conventional single-layer printed circuit board, when soldering the litz wire, the insulation layer of the twisted multiple strands is melted or scraped to remove the strands inside the litz wire. It is difficult to ensure continuity by performing preliminary soldering. In addition, if the coil end is bent near the cylindrical outlet, the wire may be broken because the wire is thin.

According to the soldering method described above, the end portion T is temporarily fixed in the first step. At this stage, the insulating layer on the side of the wire is melted and soldered to the core wire 410a, but it cannot be said that the wire is reliably conducting. Therefore, in the present embodiment, by cutting the end portion T of each coil in the cutting step, the core wire 410a, which is the internal conductive portion, is exposed as a cross section. Then, in the second soldering step, the core wire 410a of the cross section is soldered. As a result, the cross-section of the wire without the insulating layer is exposed, and by soldering the core wire 410a of the cross-section with the temporarily fixed solder H1, reliable conduction with the wire can be ensured.

Further, according to the soldering method described above, it is possible to insert the wire into the U-shaped through hole S and solder the wire in a linear form. Therefore, when soldering, there is no need to bend the ends T of the coils for soldering, and there is little risk of disconnection. Also, the wires at the soldered portion do not come apart, improving workability and reliability of continuity.
The soldering method of the present embodiment can be applied not only to litz wires (twisted wires) but also to single wires.

Although the present embodiment has been described above, the technical scope of the present invention is not limited to the range described in the above embodiment. It is clear from the scope of claims that various modifications and improvements to the above embodiment are also included in the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 1... Brushless motor 10... Rotor 11... Rotating shaft 12... Main magnet 20... Stator 21... Coreless coil 23... Relay board. DESCRIPTION OF SYMBOLS 30...Housing 50...Detecting device 51...Magnetic sensor 52...Sensor board 60...Magnet unit 211...First coil 212...Second coil 213...Third coil 214...Fourth coil 215... Fifth coil, 216... Sixth coil, 231 to 236, 251 to 256, 271 to 275... Substrate, S (S11 to S11, S31 to S43, S51 to S63)... Through hole, 410... Magnet wire

Claims (20)

a plurality of coils;
a substrate portion that electrically connects respective ends of the plurality of coils;
with
The substrate section has a plurality of laminated substrates,
each of the plurality of substrates has a through hole electrically connecting the plurality of substrates, and a conductive portion having a predetermined planar pattern shape electrically connected to the through hole;
The substrate portion is a stator that electrically connects each of the plurality of coils to a predetermined wire connection by the through hole and the conductive portion. 2. The stator according to claim 1, wherein the plurality of coils are star-connected or delta-connected by electrically connecting respective ends of the plurality of coils to the substrate. 3. The method according to claim 2, wherein when the plurality of coils are star-connected, the plurality of substrates include a neutral point substrate, which is one substrate provided with the conductive portion forming the neutral point of the star connection. stator. The plurality of substrates include a U-phase substrate which is one substrate provided with the conductive portion for electrically connecting the U-phase coils to each other, and the conductive portion for electrically connecting the V-phase coils to each other. 4. The stator according to claim 3, comprising: a V-phase substrate, which is one substrate provided with the W-phase coils; and a W-phase substrate, which is one substrate provided with the conductive portions for electrically connecting the W-phase coils. The plurality of substrates include a terminal substrate that is one substrate provided with the conductive portion forming the U-phase terminal, the conductive portion forming the V-phase terminal, and the conductive portion forming the W-phase terminal. 5. The stator of claim 4 comprising. 6. The stator according to claim 5, wherein the terminal substrate is provided with the conductive portion forming part of the neutral point. The plurality of substrates are adapted to direct an end portion of at least one of a U-phase coil, a V-phase coil, and a W-phase coil toward the U-phase terminal, the V-phase terminal, or the W-phase terminal. 7. The stator according to claim 5 or 6, further comprising a routing board, which is one board on which said conductive parts to be routed are provided. When the plurality of coils are delta-connected, the plurality of substrates may be the conductor for electrically connecting any one of the U-phase coil, the V-phase coil, and the W-phase coil to each other. 3. A stator as claimed in claim 2 including an in-phase substrate which is one substrate provided with sections. The plurality of substrates includes the conductive portion electrically connecting any one of the U-phase coil, the V-phase coil, and the W-phase coil with the same phase, and any two different phase coils. 9. The stator according to claim 8, further comprising a composite phase substrate, which is one substrate provided with the conductive portion for electrically connecting the coils. The plurality of substrates is one substrate provided with the conductive portion for electrically connecting any two of the U-phase coil, the V-phase coil, and the W-phase coil to each other. 10. The method according to claim 9, further comprising a certain first different-phase substrate and a second different-phase substrate which is one substrate provided with the conductive portion for electrically connecting any two different-phase coils. stator. The plurality of substrates include the conductive portion electrically connecting the other coils of the same phase among the U-phase coil, the V-phase coil, and the W-phase coil, and the conductive portion forming a U-phase terminal. 11. The stator according to claim 10, further comprising a terminal substrate, which is one substrate on which said conductive portions forming V-phase terminals and said conductive portions forming W-phase terminals are provided. On the first hetero-phase substrate or the second hetero-phase substrate, an end portion of at least one of a U-phase coil, a V-phase coil, and a W-phase coil is connected to the U-phase terminal, the V-phase terminal, or the 12. The stator according to claim 11, wherein the conductive portion is provided to be routed in a direction approaching the W-phase terminal. 13. The apparatus according to claim 7, wherein the ends of each of the plurality of coils are gathered on one of the plurality of substrates and are electrically connected to the one substrate disposed closest to the end. stator. each of the plurality of substrates has an annular shape, and the through hole has a groove shape provided on an inner peripheral surface of each of the plurality of annular substrates;
14. The stator according to claim 13, wherein the end portions of the plurality of coils are fitted into the groove-shaped through holes and guided to the one substrate positioned closest to the end portion among the plurality of substrates. 15. The stator according to claim 14, wherein the electrically insulating portion of each of said plurality of substrates is not exposed from the inner surface of said through-hole. A stator according to any one of claims 1 to 15;
a rotor housed inside the stator and rotated by supplying electric power to the stator;
brushless motor. A mounting step of mounting the substrate portion on the end side of the plurality of coils in the axial direction;
a connecting step of electrically connecting respective ends of the plurality of coils to the substrate;
including
The substrate section has a plurality of laminated substrates,
each of the plurality of substrates has a through-hole connecting the plurality of substrates and a conductive portion having a predetermined planar pattern shape electrically connected to the through-hole;
A method of manufacturing a stator, wherein each of the plurality of coils is electrically connected to a predetermined wire connection by the through hole and the conductive portion. 18. The connecting step according to claim 17, wherein the end portions of the plurality of coils are gathered to one of the plurality of substrates positioned closest to the end portion and electrically connected to the one substrate. stator manufacturing method. Each of the plurality of substrates is annular, and in the connecting step, end portions of the plurality of coils are inserted into the groove-shaped through holes provided on the inner peripheral surfaces of the plurality of annular substrates. 19. The method according to claim 18, wherein the end portions of the plurality of coils are electrically connected to the one substrate after guiding the ends of the plurality of coils to the one substrate positioned closest to the end portion among the plurality of substrates. stator manufacturing method. The connecting step includes
a first soldering step of soldering the ends gathered on the one substrate to the one substrate;
A cutting step of cutting the end portion at a location adjacent to the solder soldered in the first soldering step;
a second soldering step of further soldering the core wires of the ends exposed by the cutting step and the solder soldered in the first soldering step;
20. The method for manufacturing a stator according to claim 18 or 19, comprising:

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