JP4437395B2 - Motor stator - Google Patents

Description

  The present invention relates to a motor stator having a stator core configured by connecting a plurality of divided cores in an annular shape.

  As a stator of a brushless motor or an AC motor, one having a stator core having a configuration in which divided cores are connected in an annular shape is known, and FIGS. 5A to 5D are front views showing an example of such a motor stator. FIG. 3 is a side view, a cross-sectional view, and a back view. As shown in these drawings, the motor stator 100 includes a stator core 3 having a configuration in which a plurality of divided cores 2 are connected in an annular shape, and a disk-shaped connection board 4 attached to the stator core 3 in a coaxial state. . A coil winding 6 is wound around the salient pole portion 2a of each divided core 2 via a bobbin 5 made of an insulating resin, and the coil winding 6 is connected to the connection board 4 side. Further, the surfaces of the bobbin 5, the coil winding 6 and the connection board 4 are covered with an insulating coating layer 7 made of an insulating resin, as indicated by a broken line.

  FIG. 6 shows the split core 2 around which the coil winding 6 is wound via the bobbin 5, and (a) is an inner peripheral side end view when viewed from the inner peripheral side of the stator core 3. (B) is the side view, (c) is an end view on the outer periphery side when viewed from the outer periphery side of the stator core 3, and (d) is a front view when viewed from the direction of the central axis of the stator core 3. It is. As shown in these figures, in the split core 2, the bobbin 5 is fitted to the salient pole 2a protruding from the inner peripheral surface of the core body 2b, and the coil winding 6 is wound around the cylindrical body 5a of the bobbin 5. It has been. An outer peripheral flange 5b extending in the orthogonal direction is formed at the outer peripheral side end of the stator core 3 in the cylindrical body 5a, and is also orthogonal to the inner peripheral side end of the stator core 3 in the cylindrical body 5a. An inner peripheral flange 5c is formed. Both flanges 5b and 5c have a rectangular outline shape, and their heights H (5b) and H (5c) from the connection board 4 (the length in the central axis direction of the stator core 3) are substantially the same. The width W (5b), W (5c) in the orthogonal direction is wider on the outer peripheral flange 5b.

  Next, the surface of the stator assembly 10 including the stator core 3, the bobbin 5, the coil winding 6, and the connection board 4 is covered with an insulating resin. That is, as shown in FIG. 7, the stator assembly 10 is inserted into the cavity 220 for injection molding, and in this state, the disk gate 221 disposed at the portion corresponding to the central opening 4a of the wiring board 4 enters the cavity. Insulating resin is injected. The injected resin passes through the molding portion 222 for molding the insulating coating layer of the wiring board 4 from the inside in the cavity toward the outside in the radial direction, and covers the surface of the bobbin 5 and the coil winding 6. It flows into the forming part 223 for forming the layer.

  Here, on both sides of the coil winding 6, the inner peripheral flange 5 c and the outer peripheral flange 5 b of the bobbin 5 are located. Therefore, the molded portion 223 in the cavity 220 is concentrically divided by these flanges 5 b and 5 c into three annular portions 231, 232 and 233, and the outermost annular portion 233 is defined by the core body 2 b of the split core 2. It is divided in two. For this reason, the resin material injected into the cavity 220 is between the inner peripheral flange 5c, between the inner peripheral flange 5c and the cavity inner peripheral surface, between the outer peripheral flange 5b, or between the outer peripheral flange 5b and the cavity inner periphery. It is necessary to flow into each compartment part between the planes. However, since the gap between these portions is narrow, there is a problem that it is difficult for the resin material to turn to every corner of the molded portion 223. In particular, it is difficult for the resin material to turn around the partition portion 233a farthest from the gate 221 in the outermost annular portion 233. If the resin material cannot sufficiently wrap around every corner, the insulating coating layer 7 has a defective portion or a portion with insufficient thickness, and the insulating performance is deteriorated.

  If the injection pressure of the resin material is increased, the resin material can be filled to every corner in the cavity 220. However, when the injection pressure is increased, the resin bobbin 5 in the stator assembly 10 inserted in the cavity may be deformed, and the insulating coating layer 7 may be formed in this state. If the bobbin 5 is deformed, the withstand voltage of the entire stator may be reduced.

  In view of these points, an object of the present invention is to propose a motor stator having a bobbin shape suitable for forming an insulating coating layer having no defect such as a defect without deformation of the bobbin. .

In order to solve the above problems, the motor stator of the present invention is
A stator core configured by connecting the split cores in an annular shape, a disk-shaped wiring board that is arranged adjacent to the stator core in a coaxial state and has an opening at the center, and an insulating resin in each split core A stator assembly with coil windings wound through a bobbin consisting of
Wherein the stator assembly bobbin, and a said coil winding and the connection board insulating coating layer covering the surface of,
The bobbin includes a cylindrical body around which the coil winding is wound, an outer peripheral flange formed at an outer peripheral end of the stator core in the cylindrical body, and the stator core in the cylindrical body. An inner peripheral flange formed on an inner peripheral end of the outer peripheral flange, and a positioning convex portion formed on an end surface of the outer peripheral flange attached to the connection board, the positioning convex part on the connection board It is inserted and fixed in the formed insertion groove,
The contour shape of the outer peripheral side flange and the inner peripheral side flange when viewed from the direction of the central axis of the cylindrical body part is a chamfered part in which the four corners of the square are chamfered in a range where the coil winding is not exposed. It has a shape with
The insulating coating layer is injection-molded by injecting an insulating resin into the injection-molding cavity from the center of the opening of the wiring board in a state where the stator assembly is inserted into the injection-molding cavity ,
Thus the chamfer, between the inner peripheral side flange and between adjacent said outer peripheral side flange adjacent the gap for smoothly flowing the injected resin during injection molding of the insulating coating layer is formed It is characterized by that.

In the motor stator of the present invention, a gap for smoothly flowing the injected resin can be formed between the inner peripheral surface of the cavity and the outer peripheral flange in a state where the stator assembly is inserted into the injection molding cavity. Further, the height of the outer peripheral flange from the connection board is set lower than the height of the inner flange from the connection board .

  In the present invention, the contour shapes of the outer peripheral side flange and the inner peripheral side flange of each bobbin in the stator assembly are adjacent to each other by making the chamfered portions chamfered with sufficient size at the four corners of the quadrangle. A gap is formed between the outer peripheral flanges and between the adjacent inner peripheral flanges so that the injected resin can smoothly flow during the injection molding of the insulating coating layer. In addition, the height of the outer flange from the connection board is lower than that of the inner flange so that the injected resin can sufficiently flow to the corner of the cavity farthest from the gate during the injection molding of the insulating coating layer. It is.

  Therefore, according to the present invention, it is possible to reliably fill the injection resin to every corner of the cavity in which the stator assembly is inserted without increasing the injection pressure when forming the insulating coating layer. Therefore, there is no defect in the insulating coating layer, and there is no adverse effect that the bobbin is deformed when the insulating coating layer is formed and the insulation withstand voltage of the entire motor stator is lowered.

  Hereinafter, an example of a split core type motor stator to which the present invention is applied will be described with reference to the drawings.

  FIGS. 1A to 1D are a front view, a side view, a cross-sectional view, and a rear view showing a split core type motor stator of this example. As shown in these drawings, the basic structure of the split core type motor stator 1 is the same as the motor stator 100 shown in FIG. That is, a stator core 3 having a configuration in which a plurality of divided cores 2 are connected in an annular shape, and a disk-shaped connection board 4 attached to the stator core 3 in a coaxial state. In addition, the coil winding 6 is wound around the salient pole portion 2a of each divided core 2 via a bobbin 11 made of an insulating resin, and the coil winding 6 is connected to the wiring board 4 side. Further, the coil winding 6 and the connection substrate 4 are covered with an insulating coating layer 7 made of an insulating resin, as indicated by a broken line.

  FIG. 2 shows the split core 2 around which the coil winding 6 is wound via the bobbin 11, and (a) is an inner peripheral side end view when viewed from the inner peripheral side of the stator core. (b) is a side view thereof, (c) is an outer peripheral side end view when viewed from the outer periphery side of the stator core, and (d) is a front view when viewed from the direction of the stator core central axis. As shown in these drawings, in the split core 2, the bobbin 11 is fitted on the salient pole 2a protruding from the inner peripheral surface of the core body 2b, and the coil winding 6 is wound around the cylindrical body 12 of the bobbin 11. It has been. An outer peripheral flange 13 that extends in the orthogonal direction is formed at the end of the cylindrical body 12 on the outer periphery side of the stator core, and also extends in an orthogonal direction at the end of the cylindrical body 12 on the inner periphery side of the stator core. An inner peripheral flange 14 is formed.

  The outer peripheral side flange 13 has a rectangular outline as a whole, the height from the connection board 4 is H (13), and the width in the orthogonal direction is W (13). Positioning projections 132 protrude from a lower side end surface 131 attached to the connection board 4 of the outer flange 13, and these projections 132 are inserted and fixed in insertion grooves formed in the connection board 4. . Moreover, the outer peripheral side flange 13 is made into the chamfered parts 133-136 by which the four corner parts were chamfered in the shape of a triangle. A large gap is formed between the adjacent outer flanges 13 by these chamfered portions 133 to 136. The amount of chamfering is a range in which the coil winding 6 is not exposed to the outside from the outer flange 13 when viewed from the direction along the central axis L of the bobbin cylindrical body 12.

  On the other hand, the inner peripheral flange 14 also has a rectangular outline as a whole, the height from the connection board 4 is H (14) higher than the outer peripheral flange 13, and the width is larger than that of the outer peripheral flange 13. It is set to narrow W (14). The four corners of the inner peripheral flange 14 are also chamfered, the corners on both sides of the lower side of the connection board 4 are small chamfered portions 141 and 142, and the corners on both sides of the opposite upper side are large chamfered portions 143, 144. These chamfered portions 141 to 144 are also for increasing the gap formed between the adjacent inner peripheral side flanges 14. Further, the amount of chamfering is a range in which the coil winding 6 is not exposed to the outside from the inner peripheral flange 14 when viewed from the direction along the central axis L of the bobbin cylindrical body 12.

(Formation of insulation coating layer)
In manufacturing the motor stator 1 having this configuration, first, the split core 2 around which the coil winding 6 is wound via the bobbin 11 is manufactured. The divided core 2 is connected and fixed in an annular shape on the connection board 4 to constitute the stator core 3 and to connect the coil windings 6. Next, the surface of the stator assembly 10 assembled in this way is insulated. The insulating coating layer 7 is formed by injection molding.

  As shown in FIG. 3, a stator assembly is inserted into a cavity 220 for injection molding, and in this state, an insulating resin is interposed via a disk gate 221 disposed at a portion corresponding to the central opening 4a of the connection board 4. Is injected into the cavity. Here, the cavity 220 formed between the upper mold 21 and the lower mold 22 has an annular shape, and a molded portion 222 for forming a portion of the insulating coating layer 7 covering the surface of the connection substrate 4; And a molding portion 223 for forming a portion of the insulating coating layer 7 covering the surface of the bobbin 11 and the coil winding 6.

  When the stator assembly 10 is inserted into the cavity 220 with the wiring board 4 facing upward, the inner flange 14 is higher in height than the outer flange 13 of the bobbin 11, so that it is flat with the outer flange 13. As shown in FIG. 4A, a gap 23 through which the injected resin can flow quickly is formed between the bottom surfaces 224 of the cavities.

  Further, since chamfered portions 133 to 136 and 141 to 144 are formed at the four corners of the outer peripheral side flange 13 and the inner peripheral side flange 14 of the bobbin 11, respectively, the gap between adjacent outer peripheral side flanges 13 is shown in FIG. ), Gaps 24a and 24b through which the injected resin can flow quickly are formed. Further, as shown in FIG. 4B, gaps 25a and 25b through which the injected resin can flow quickly are also formed between the adjacent inner peripheral flanges 14.

  When the stator assembly 10 is inserted into the cavity 220, the inner peripheral side flange 14 and the outer peripheral side flange 13 concentrically divide the cavity into three annular portions 231 to 233. These gaps 23, 24a, 24b, The injection resin can smoothly flow between the three annular portions 231 to 233 by 25a and 25b. In particular, the lower partition portion 233a of the outer annular portion 233 farthest from the gate 221 is reliably filled with the injected resin via the gap 23 between the outer flange 13 and the cavity bottom surface 224. It can be done.

  As a result, the molding resin material injected from the gate 221 is surely filled into the molding portions 222 and 223 for molding the insulating coating portions of the connection substrate 4, bobbin 11 and coil winding 6, and these portions. Thus, the insulating coating layer 7 in a state where the insulating coating is reliably insulated is formed. In addition, since the injected resin can be spread to every corner of the cavity 220 without increasing the injection pressure, the bobbin 11 is deformed during injection molding, and the dielectric strength of the entire motor stator 1 is reduced. Also does not happen.

(A) thru | or (d) are the front view, side view, sectional drawing, and back view which show the split-core type stator to which this invention is applied. (A) thru | or (d) are the inner peripheral side end view, side view, outer peripheral side end view, and front view which show the division | segmentation core of FIG. It is explanatory drawing which shows the state which forms the insulating coating layer by the injection molding on the surface of a stator assembly. It is explanatory drawing which shows the clearance gap for resin distribution | circulation formed between the outer peripheral side flange and inner peripheral side flange in the bobbin of the stator assembly inserted in the cavity for injection molding. (A) thru | or (d) are the front view, side view, sectional drawing, and back view which show a general split-core type stator. (A) thru | or (d) are the inner peripheral side end view, side view, outer peripheral side end view, and front view which show the division | segmentation core of FIG. It is explanatory drawing which shows the problem at the time of insulation coating layer formation.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Motor stator 2 Divided core 2a Salient pole 2b Core main body 3 Stator core 4 Connection board | substrate 5, 11 Bobbin 5a, 12 Cylindrical trunk | drum 5b, 13 Outer side flange 133-136 Chamfer part 5c, 14 Inner side flange 141-144 Chamfer Part 6 Coil winding 7 Insulating coating layer 23, 24a, 24b, 25a, 25b Gap 220 Cavity 221 for injection molding Gate 222, 223 Molding part 231, 232, 233 Toroidal part 233a Partition part

Claims (1)

A stator core configured by connecting the split cores in an annular shape, a disk-shaped wiring board that is arranged adjacent to the stator core in a coaxial state and has an opening at the center, and an insulating resin in each split core A stator assembly with coil windings wound through a bobbin consisting of
An insulating coating layer covering a surface of the bobbin, the coil winding and the wiring board of the stator assembly;
The bobbin includes a cylindrical body around which the coil winding is wound, an outer peripheral flange formed at an outer peripheral end of the stator core in the cylindrical body, and the stator core in the cylindrical body. An inner peripheral flange formed on an inner peripheral end of the outer peripheral flange, and a positioning convex portion formed on an end surface of the outer peripheral flange attached to the connection board, the positioning convex part on the connection board It is inserted and fixed in the formed insertion groove,
The contour shape of the outer peripheral side flange and the inner peripheral side flange when viewed from the direction of the central axis of the cylindrical body part is a chamfered part in which the four corners of the square are chamfered in a range where the coil winding is not exposed. It has a shape with
The insulating coating layer is injection-molded by injecting an insulating resin into the injection-molding cavity from the center of the opening of the wiring board in a state where the stator assembly is inserted into the injection-molding cavity,
By the chamfered portion, a gap is formed between the adjacent outer peripheral flanges and between the adjacent inner peripheral flanges for smoothly flowing the injected resin during the injection molding of the insulating coating layer .
In the state where the stator assembly is inserted into the injection molding cavity, the connection of the outer peripheral flange is formed so that a gap for smoothly flowing the injected resin can be formed between the inner peripheral surface of the cavity and the outer peripheral flange. A motor stator in which a height from a substrate is lower than a height of the inner peripheral flange from the connection substrate .

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