JP6953110B2 - Insulated laminated board structure of rotary electric machine and its manufacturing method - Google Patents

Description

The present invention relates to an insulated laminated plate structure of a rotary electric machine and a method for manufacturing the same.

Conventionally, a laminated iron core formed by laminating a plurality of steel plates formed by punching an electromagnetic steel plate using a press die is composed of a resin material for preventing electrical conduction between the coil and the laminated iron core. There is known an insulating laminated plate structure of a rotary electric machine formed by integrally molding a resin insulating portion to be formed (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 8-98473

However, after the resin insulating portion is integrally molded with the laminated iron core, the resin insulating portion is separated from the surface of the laminated iron core due to shrinkage and deformation of the resin in the process of curing the resin, and as a result, the insulating laminated plate structure of the rotary electric machine is used. There is a problem that the dimensional accuracy of the body is lowered.

The present invention has been made to solve the above-mentioned problems, and provides an insulating laminated plate structure of a rotary electric machine capable of preventing the resin insulating portion from separating from the surface of the laminated iron core, and a method for manufacturing the same. It is a thing.

The insulating laminated plate structure of a rotary electric machine according to the present invention is an insulating laminated plate structure of a rotating electric machine provided with a laminated iron core in which steel plates are laminated and a resin insulating portion covering the surface of the laminated iron core. Has a teeth portion and a teeth tip portion that is provided at the radial end portion of the teeth portion and projects in the circumferential direction. A stop groove is formed, and the resin insulating portion is provided in the resin retaining portion provided in the retaining groove and in the resin provided on both sides of the resin retaining portion in the circumferential direction facing the radial direction at the tip of the tooth. It has a peripheral portion or a resin outer peripheral portion, and a retaining groove is formed on a surface of the tip of the tooth that faces the air gap between the stator and the rotor.

According to the insulating laminated plate structure of the rotating electric machine according to the present invention, it is an insulating laminated plate structure of the rotating electric machine provided with a laminated iron core in which steel plates are laminated and a resin insulating portion covering the surface of the laminated iron core. The laminated iron core has a notched steel plate having grooves formed on the side surfaces, and the side surface of the notched steel plate on which the grooves are formed is covered with a resin insulating portion, so that the resin insulating portion is integrally formed with the laminated iron core. After that, in the process of curing the resin, the resin that has flowed into the groove serves as a resin retaining portion, and it is possible to prevent the coated insulating portion from separating from the surface of the laminated iron core.

It is a perspective view which shows the insulation laminated rotor which concerns on Embodiment 1 of this invention. It is an exploded perspective view which shows the insulation laminated rotor of FIG. It is a perspective view which shows the laminated iron core of FIG. It is a top view which shows the steel plate of FIG. It is a top view which shows the notched steel plate of FIG. It is a top view which shows the insulation laminated rotor of FIG. It is a perspective view which shows the cross section along the line VII-VII of FIG. It is a side view which shows the insulation laminated rotor of FIG. FIG. 8 is a cross-sectional view taken along the line IX-IX of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a top view which shows the modification of the dovetail groove of FIG. It is a perspective view which shows the resin injection position and the cross section of the resin retaining part in the insulator integral molding process. It is a perspective view which shows the deformation example of the laminated iron core of FIG. It is a top view which shows the notched steel plate of FIG. It is a top view which shows the modification of the insulation laminated rotor of FIG. FIG. 8 is a perspective view showing a cross section taken along the line XXIX-XXIX of FIG. 28. It is a side view which shows the insulation laminated rotor of FIG. 28. It is a cross-sectional view taken along the arrow XXXI-XXXI line of FIG. 30. It is a perspective view which shows the deformation example of the laminated iron core of FIG. It is a top view which shows the notched steel plate of FIG. 32. It is a top view which shows the modification of the insulation laminated rotor of FIG. FIG. 3 is a perspective view showing a cross section taken along the line XXXV-XXXV of FIG. 34. It is a side view which shows the insulation laminated rotor of FIG. 34. It is a cross-sectional view taken along the line XXXVII-XXXVII of FIG. 36. It is a perspective view which shows the main part of the insulation laminated stator which concerns on Embodiment 2 of this invention. It is an enlarged view which shows the insulation division laminated laminated iron core of FIG. 38. It is a perspective view which shows the insulation division laminated iron core of FIG. 38. It is a perspective view which shows the divided laminated iron core of FIG. 38. It is a top view which shows the steel plate of FIG. 41. It is a top view which shows the notched steel plate of FIG. 41. It is a top view which shows the insulation division laminated iron core of FIG. 40. It is a perspective view which shows the cross section along the XLV-XLV line of FIG. 44. It is a side view which shows the insulation division laminated iron core of FIG. 44. FIG. 6 is a cross-sectional view taken along the line XLVII-XLVII of FIG. It is a perspective view which shows the resin injection position and the cross section of the resin retaining part in the insulator integral molding process. It is a perspective view which shows the modification of the insulation division laminated iron core of FIG. 40. It is a perspective view which shows the divided laminated iron core of FIG. It is a top view which shows the notched steel plate of FIG. It is a top view which shows the insulation division laminated iron core of FIG. 49. It is a cross-sectional view taken along the line LIII-LIII of FIG. 52. It is a side view which shows the insulation division laminated laminated iron core of FIG. FIG. 5 is a cross-sectional view taken along the line LV-LV of FIG. 54. It is a perspective view which shows the modification of the insulation division laminated iron core of FIG. 40. It is a perspective view which shows the divided laminated iron core of FIG. 56. It is a top view which shows the notched steel plate of FIG. 57. It is a top view which shows the insulation division laminated iron core of FIG. 57. FIG. 5 is a cross-sectional view taken along the line LX-LX of FIG. 59. It is a side view which shows the insulation division laminated iron core of FIG. 56. FIG. 6 is a cross-sectional view taken along the line LXII-LXII of FIG. 61.

Embodiment 1.
FIG. 1 is a perspective view showing an insulated laminated rotor according to a first embodiment of the present invention. In the first embodiment, the insulated laminated rotor 1 will be described as an example of the insulated laminated plate structure of the rotary electric machine. The insulated laminated rotor 1 includes a shaft 2 serving as a rotation shaft and an insulated laminated iron core 3 fixed to the shaft 2.

FIG. 2 is an exploded perspective view showing the insulating laminated rotor 1 of FIG. The insulated laminated iron core 3 includes a laminated iron core 301a and a resin insulating portion 302 provided on the surface of the laminated iron core 301a. The resin insulating portion 302 is composed of, for example, a thermoplastic resin such as PPS, LCP, PBT, POM, PA, PET, an epoxy resin, or a thermosetting resin such as BMC. The insulating laminated iron core 3 is formed by integrally molding the resin insulating portion 302 with the laminated iron core 301a.

The method for manufacturing the insulated laminated rotor 1 includes a method of integrally molding the resin insulating portion 302 on the laminated iron core 301a and then assembling the shaft 2 on the laminated iron core 301a, and a method of assembling the shaft 2 on the laminated iron core 301a and then assembling the resin insulating portion 302. There is a method of integrally molding the laminated iron core 301a, and any method may be used.

A coil (not shown) is attached to the resin insulating portion 302. The resin insulating portion 302 has an insulating laminated iron core tooth tip portion 303, an insulating laminated iron core tooth winding portion 304, an insulating laminated iron core tooth side surface portion 305, and a resin outer peripheral portion 306. A coil (not shown) is wound around an insulated laminated iron core tooth winding portion 304 and an insulated laminated iron core tooth side surface portion 305. The insulating laminated iron core 3 and the coil (not shown) are electrically insulated via the resin insulating portion 302.

FIG. 3 is a perspective view showing the laminated iron core 301a of FIG. The laminated iron core 301a has a central portion 307 of the laminated iron core in which a through hole into which the shaft 2 is inserted is formed, a laminated iron core tooth portion 308 projecting radially outward from the central portion 307 of the laminated iron core, and a diameter of the laminated iron core tooth portion 308. It has a laminated iron core tooth tip portion 309 which is provided at the outer end portion in the direction and projects in the circumferential direction. In this example, the radial direction is the radial direction centered on the axis of the insulated laminated iron core 3. Further, in this example, the circumferential direction is the circumferential direction centered on the axis of the insulated laminated iron core 3. The laminated iron core teeth portion 308 has a pair of laminated iron core teeth side surface portions 310 facing in the circumferential direction. The laminated iron core tooth tip portion 309 has a laminated iron core outer peripheral portion 311 facing outward in the radial direction. The outer peripheral portion 311 of the laminated iron core constitutes the outer peripheral portion of the laminated iron core 301a.

The laminated iron core 301a is formed by laminating a plurality of steel plates 312 and at least one notched steel plate 313a. FIG. 3 shows an example in which the laminated iron core 301a includes a single notched steel plate 313a. By sandwiching the notched steel plate 313a between the steel plates 312 and laminating them, a retaining groove 314a is formed in the side surface portion 310 of the laminated iron core teeth.

FIG. 4 is a plan view showing the steel plate 312 of FIG. The steel plate 312 cut out into a desired shape includes a steel plate central portion 315 having a through hole into which the shaft 2 is inserted, a steel plate tooth portion 316 protruding radially outward from the steel plate central portion 315, and a steel plate tooth portion 316. It has a steel plate tooth tip 317 that is provided at the outer end in the radial direction and projects in the circumferential direction. The steel plate tooth portion 316 has a steel plate tooth side surface portion 318 facing in the circumferential direction. The steel plate tooth tip portion 317 has a steel plate outer peripheral portion 319 facing outward in the radial direction.

FIG. 5 is a plan view showing the notched steel plate 313a of FIG. In the notched steel plate 313a, dovetail grooves 320a, which are grooves, are formed in each of the pair of steel plate tooth side surface portions 318. The steel plate tooth side surface portion 318 serves as a tooth side surface portion in the notched steel plate 313a. Other configurations of the notched steel sheet 313a are the same as those of the steel sheet 312. The dovetail groove 320a has, for example, a recessed dimension of 1.0 mm to 2.0 mm and a width dimension of 2.0 mm. As shown in FIG. 3, by laminating a plurality of steel plates 312 and notched steel plates 313a, a laminated iron core 301a in which a retaining groove 314a is formed in the side surface portion 310 of the laminated iron core teeth can be obtained.

6 is a plan view showing the insulated laminated rotor 1 of FIG. 1, and FIG. 7 is a perspective view showing a cross section taken along the line VII-VII of FIG. The resin insulating portion 302 is provided in a retaining groove 314a formed by laminating a plurality of steel plates 312 and a notched steel plate 313a, and forms a resin retaining portion 321a in which the injection-molded resin is cured and integrated. Have.

8 is a side view showing the insulated laminated rotor 1 of FIG. 1, and FIG. 9 is a cross-sectional view taken along the line IX-IX of FIG. The resin retaining portion 321a is formed by curing the injection-molded resin in the retaining groove 314a of the side surface portion 310 of the laminated iron core tooth. Since the retaining groove 314a is cut out in the shape of the dovetail groove 320a, the resin thin film of the insulating laminated iron core tooth side surface portion 305 and the surface of the laminated iron core 301a are perpendicular to the surface of the laminated iron core tooth side surface portion 310. It does not separate in the direction, so that it is possible to prevent a gap 322a from being generated between the insulating laminated iron core tooth side surface portion 305 and the laminated iron core 301a. Due to this effect, it is possible to prevent the winding region 323a from being suppressed, and it is possible to obtain a rotary electric machine having high performance. The shape of the dovetail groove 320a is not limited to the shape shown in the figure.

Hereinafter, the shape of the dovetail groove 320a in the notched steel plate 313a will be described. FIG. 10 is a plan view showing a modified example of the dovetail groove 320a of FIG. The dovetail groove 320a has a circular shape having a diameter dimension in which the widthwise dimension of the opening 324 of the dovetail groove 320a is equal to or greater than the plate thickness dimension of the notched steel plate 313a and larger than the widthwise dimension of the opening portion 324 of the dovetail groove 320a. By having the portion 325, a retaining collar portion 326 can be formed in the opening 324 of the dovetail groove 320a. For example, in the case of a notched steel plate 313a having a plate thickness dimension of 0.5 mm, the dimension in the width direction of the opening 324 of the dovetail groove 320a is 0.5 mm to 0.8 mm, and the diameter dimension of the circular portion 325 is 1.0 mm to. The width dimension of the flange portion 326 is 1.5 mm, and the width dimension is 0.25 mm to 0.5 mm.

The center line of the opening 324 and the center line of the circular portion 325 do not necessarily have to coincide with each other. FIG. 11 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the center line 328 of the circular portion 325 may be offset by 0.2 mm from the center line 327 of the opening 324. FIG. 12 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the circular portion 325 may be arranged in an asymmetrical shape so that the circular portion 325 is arranged on only one side with the center line 327 of the opening 324 as the center.

FIG. 13 is a plan view showing a modified example of the dovetail groove 320a of FIG. The same effect can be obtained even if the dovetail groove 320a is rectangular. It has a rectangular portion 330 having a rectangular width dimension that is equal to or greater than the thickness dimension of the notched steel plate 313a and larger than the width dimension of the opening 329 of the dovetail groove 320a. As a result, a retaining collar portion 331 can be formed in the opening 329 of the dovetail groove 320a. For example, in the case of a notched steel plate 313a having a plate thickness dimension of 0.5 mm, the dimension in the width direction of the opening 329 of the dovetail groove 320a is 0.5 mm to 0.8 mm, and the dimension in the width direction of the rectangular portion 330 is 1. The width dimension of the flange portion 331 is 0 mm to 1.5 mm, and the width dimension is 0.25 mm to 0.5 mm.

The center line of the opening 329 and the center line of the rectangular portion 330 do not necessarily have to coincide with each other. FIG. 14 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the center line 332 of the rectangular portion 330 may be offset from the center line 332 of the opening 329 by 0.2 mm. FIG. 15 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the rectangular portion 330 may be arranged in an asymmetrical shape so that the rectangular portion 330 is arranged on only one side with the center line 332 of the opening 329 as the center.

FIG. 16 is a plan view showing a modified example of the dovetail groove 320a of FIG. The same effect can be obtained even if the dovetail groove 320a is a triangle. The width dimension of the opening 334 of the dovetail groove 320a is equal to or greater than the thickness dimension of the notched steel plate 313a, and the dovetail groove 320a has a triangular portion 335 having a width dimension larger than the width dimension of the opening 334 of the dovetail groove 320a. Therefore, a retaining flange 336 can be formed in the opening 334 of the dovetail groove 320a. For example, in the case of a notched steel plate 313a having a plate thickness dimension of 0.5 mm, the dimension in the width direction of the opening 334 of the dovetail groove 320a is 0.5 mm to 0.8 mm, and the dimension in the width direction of the triangular portion 335 is 1. The width dimension of the flange portion 336 is 0 mm to 1.5 mm, and the width dimension is 0.25 mm to 0.5 mm.

The center line of the opening 334 and the center line of the triangular portion 335 do not necessarily have to coincide with each other. FIG. 17 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the center line 338 of the triangular portion 335 may be offset by 0.2 mm from the center line 337 of the opening 334. FIG. 18 is a plan view showing a modified example of the dovetail groove 320a of FIG. For example, the triangular portion 335 may be arranged in an asymmetrical shape so that the triangular portion 335 is arranged on only one side with the center line 337 of the opening 334 as the center.

The same effect can be obtained by roughly cutting out the contour of the notched steel plate 313a and providing fine protrusions or dents in the dovetail groove 320a. FIG. 19 is a plan view showing a modified example of the dovetail groove 320a of FIG. By arranging the semicircular protrusions 340a on one surface or both sides of the opening groove side surface 339 perpendicular to the surface of the laminated iron core tooth side surface portion 310, a retaining shape can be formed. For example, in the case of a notched steel plate 313a having a plate thickness dimension of 0.5 mm to 0.8 mm, the diameter dimension of the semicircular protrusion 340a is 0.5 mm to 0.8 mm. FIG. 20 is a plan view showing a modified example of the dovetail groove 320a of FIG. A semi-circular recess 341a can be arranged on one or both sides of the opening groove side surface 339 perpendicular to the surface of the laminated iron core tooth side surface 310 to form a retaining shape. For example, in the case of a notched steel plate 313a having a plate thickness dimension of 0.5 mm, the diameter dimension of the semicircular recess 341a is 0.5 mm to 0.8 mm.

FIG. 21 is a plan view showing a modified example of the dovetail groove 320a of FIG. The protrusion 340b is not limited to a semicircular shape, and the same effect can be obtained even if it is rectangular. FIG. 22 is a plan view showing a modified example of the dovetail groove 320a of FIG. The recess 341b is not limited to a semicircular shape, and the same effect can be obtained even if it is a rectangle. FIG. 23 is a plan view showing a modified example of the dovetail groove 320a of FIG. The protrusion 340c is not limited to a semicircular shape, and the same effect can be obtained even if it has a triangular shape. FIG. 24 is a plan view showing a modified example of the dovetail groove 320a of FIG. The dent 341c is not limited to a semicircular shape, and the same effect can be obtained even if it has a triangular shape. Further, a plurality of protrusions 340a, 340b, protrusions 340c, recesses 341a, recesses 341b, and recesses 341c may be provided on the same opening groove side surface 339.

Next, the manufacturing process will be described. First, the iron core laminating process will be described. The laminated iron core 301a of the present invention is composed of a steel plate 312 and a notched steel plate 313a. By punching a silicon steel sheet or an electromagnetic steel sheet using a press die, a steel sheet 312 and a notched steel sheet 313a having a desired shape can be obtained. Further, a steel plate 312 and a notched steel plate 313a having a desired shape can also be obtained by cutting out with a wire-cut electric discharge machine.

After that, at least one notched steel plate 313a is sandwiched and laminated on the plurality of steel plates 312 to obtain a laminated iron core 301a in which the retaining groove 314a is formed. A plurality of retaining grooves 314a may be provided in the side surface portion 310 of the laminated iron core teeth as long as there is no problem in the function of the insulating laminated rotor 1. Further, since the steel plate 312 and the notched steel plate 313a have the same shape except for the dovetail groove 320a, the steel plate 312 and the cut plate can be cut by preparing a press die capable of replacing the parts for punching the side surface portion 318 of the steel plate tooth. The notched steel plate 313a can be continuously punched and laminated.

Next, the insulator integral molding process will be described. FIG. 25 is a perspective view showing a resin injection position and a cross section of the resin retaining portion 321a in the insulator integral molding step. The laminated iron core 301a and the shaft 2 are placed inside a molding die (not shown). The molding die is composed of a mold inner wall (not shown) and a resin injection hole 342 that seal the upper surface, the lower surface, the outer peripheral surface, and both side surfaces of the laminated iron core tooth portion 308 of the laminated iron core 301a. For example, the resin injection hole 342 is arbitrarily provided at a position where the insulating laminated iron core tooth winding portion 304 is formed, and the molding resin is injected from the resin injection hole 342. The arrows in the figure indicate the direction in which the resin flows from the resin injection hole 342. The injected molding resin flows through a cavity portion which is a space between the inner wall of the mold and the laminated iron core 301a (not shown), covers the laminated iron core 301a, and is cured to form an integrated resin insulating portion 302. In the process of the molding resin flowing through the cavity portion forming the insulating laminated iron core tooth winding portion 304, the molding resin is filled in the retaining groove 314a provided on the side surface portion 310 of the laminated iron core tooth and cured to prevent the resin retaining portion. 321a is formed. In the insulating laminated iron core tooth winding portion 304, the resin insulating portion 302a is separated from the surface of the laminated iron core tooth side surface portion 310 in the direction perpendicular to the surface of the laminated iron core tooth side surface portion 310 to form a gap. Prevents 322a from occurring.

Next, a modified example of the installation position of the resin retaining portion 321a will be described. FIG. 26 is a perspective view showing a modified example of the laminated iron core 301a of FIG. The laminated iron core 301b includes a plurality of steel plates 312 and a notched steel plate 313b, and is configured by laminating each of them. A retaining groove 314b is formed on the inner side surface in the radial direction of the tip portion 309 of the laminated iron core tooth.

27 is a plan view showing the notched steel plate 313b of FIG. 26. In the notched steel plate 313b, a dovetail groove 320b is formed in the tip portion 317 of the steel plate tooth. For example, the dovetail groove 320b has a recessed dimension of 1.0 mm to 2.0 mm and a width dimension of 2.0 mm. By laminating the steel plate 312 and the notched steel plate 313b, it is possible to obtain a laminated iron core 301b in which a retaining groove 314b is formed in the tip portion 309 of the laminated iron core tooth.

FIG. 28 is a plan view showing a modified example of the insulating laminated rotor 1 of FIG. 1, and FIG. 29 is a perspective view showing a cross section taken along the line XXIX-XXIX of FIG. 28. The resin insulating portion 302 has a resin retaining portion 321b in which injection-molded resin is cured and integrated in a retaining groove 314b formed by laminating a plurality of steel plates 312 and notched steel plates 313b. ing.

FIG. 30 is a side view showing the insulated laminated rotor 1 of FIG. 28, and FIG. 31 is a cross-sectional view taken along the line XXXI-XXXI of FIG. In the retaining groove 314b of the tip portion 309 of the laminated iron core tooth, there is an integrated and cured resin retaining portion 321b. Since the retaining groove 314b is cut out in the shape of the dovetail groove 320b, the resin thin film of the insulating laminated iron core tooth tip 303 and the surface of the laminated iron core 301b are perpendicular to the surface of the laminated iron core tooth tip 309. This prevents the gap 322b from being created without leaving in the direction. Due to this effect, it is possible to prevent the winding region 323b from being suppressed, and an efficient rotary electric machine can be obtained. The shape of the retaining groove 314b is not limited to the dovetail groove shape, and the same effect can be obtained by, for example, roughly cutting out the surface.

FIG. 32 is a perspective view showing a modified example of the laminated iron core 301a of FIG. The laminated iron core 301c includes a plurality of steel plates 312 and a notched steel plate 313c, and is configured by laminating each of them. A retaining groove 314c is formed in the outer peripheral portion 311 of the laminated iron core at the tip portion 309 of the laminated iron core tooth.

FIG. 33 is a plan view showing the notched steel plate 313c of FIG. 32. In the notched steel plate 313c, a dovetail groove 320c is formed in the outer peripheral portion 319 of the steel plate, which is the radial outer surface of the steel plate tooth tip portion 317. The outer peripheral portion 319 of the steel plate is the outer peripheral portion of the notched steel plate 313c. For example, the dovetail groove 320c has a recessed dimension of 1.0 mm to 2.0 mm and a width dimension of 2.0 mm. By laminating the steel plate 312 and the notched steel plate 313c, it is possible to obtain a laminated iron core 301c in which a retaining groove 314c is formed in the outer peripheral portion 311 of the laminated iron core at the tip portion 309 of the laminated iron core tooth.

34 is a plan view showing a modified example of the insulating laminated rotor 1 of FIG. 1, and FIG. 35 is a perspective view showing a cross section taken along the line XXXV-XXXV of FIG. 34. The resin insulating portion 302 has a resin retaining portion 321c in which injection-molded resin is cured and integrated in a retaining groove 314c formed by laminating a plurality of steel plates 312 and a notched steel plate 313c. ing.

36 is a side view showing the insulated laminated rotor 1 of FIG. 34, and FIG. 37 is a cross-sectional view taken along the line XXXVII-XXXVII of FIG. In the retaining groove 314c of the outer peripheral portion 311 of the laminated iron core in the tip portion 309 of the laminated iron core tooth, there is an integrated and cured resin retaining portion 321c. Since the retaining groove 314c is cut out in the shape of the dovetail groove 320c, the resin thin film of the resin outer peripheral portion 306 and the surface of the laminated iron core 301c are separated from each other in the direction perpendicular to the surface of the laminated iron core outer peripheral portion 311. This makes it possible to prevent the gap 322c from being generated. Due to this effect, it is possible to prevent the outer diameter dimension from swelling, the air gap between the rotor and the stator can be reduced, and at least one of the miniaturization of the rotary electric machine and the improvement of the performance of the rotary electric machine. Can be obtained. The shape of the retaining groove 314c is not limited to the dovetail groove shape, and the same effect can be obtained by, for example, roughly cutting out the surface.

The insulated laminated plate structure according to the first embodiment can be applied to a rotor of a rotary electric machine for a servomotor, a fuel injection valve opening / closing timing control unit, an air conditioner fan motor, and an in-vehicle fuel pump unit. It is an insulated laminated board structure.

Embodiment 2.
FIG. 38 is a perspective view showing a main part of the insulating laminated stator according to the second embodiment of the present invention. In the second embodiment, the insulating laminated stator 4 will be described as an example of the insulating laminated plate structure of the rotary electric machine. The insulating laminated stator 4 includes a plurality of insulating divided laminated laminated iron cores 401a connected to each other and arranged in an annular shape. In FIG. 38, six insulation-divided laminated iron cores 401a, which are half circumferences, are shown.

FIG. 39 is an enlarged view showing the insulating divided laminated laminated iron core 401a of FIG. 38. The insulating divided laminated iron core 401a includes a divided laminated iron core 402a and a resin insulating portion 403 provided on the surface of the divided laminated iron core 402a. The resin insulating portion 403 is composed of, for example, a thermoplastic resin such as PPS, LCP, PBT, POM, PRT, an epoxy resin, and a thermosetting resin such as BMC and SMC. The resin insulating portion 403 is integrally molded with the divided laminated iron core 402a by injection molding. A coil (not shown) is wound around the insulated split laminated iron core 401a. The split laminated iron core 402a and the coil are insulated via the resin insulating portion 403.

FIG. 40 is a perspective view showing the insulating divided laminated laminated iron core 401a of FIG. 38. The resin insulating portion 403 includes a tooth tip protruding portion 404, a tooth tip portion 405, a back yoke flange portion 406, a tooth curved surface winding portion 407, and a tooth side winding portion 408. A coil (not shown) is wound around a tooth curved surface winding portion 407 and a tooth side winding portion 408.

FIG. 41 is a perspective view showing the divided laminated iron core 402a of FIG. 38. The split laminated iron core 402a is provided at the radial inner end of the split laminated iron core back yoke portion 409, the split laminated iron core tooth portion 410 projecting radially inward from the split laminated iron core back yoke portion 409, and the split laminated iron core tooth portion 410. It is provided and has a split laminated iron core tooth protruding portion 411 that protrudes in the circumferential direction. The divided laminated iron core tooth portion 410 has a divided laminated iron core tooth side surface portion 412 facing in the circumferential direction. The split laminated iron core back yoke portion 409 has a divided laminated iron core outer peripheral portion 413 facing outward in the radial direction. The divided laminated iron core tooth protruding portion 411 has an inner peripheral portion 414 of the divided laminated iron core tooth facing inward in the radial direction. The inner peripheral portion 414 of the divided laminated iron core teeth serves as the inner peripheral portion of the notched steel plate 416a.

The divided laminated iron core 402a is formed by laminating a plurality of steel plates 415 and at least one notched steel plate 416a. FIG. 41 shows an example in which the divided laminated iron core 402a includes a single notched steel plate 416a. By sandwiching the notched steel plate 416a between the steel plates 312 and laminating them, a retaining groove 417a is formed in the side surface portion 412 of the divided laminated iron core teeth.

42 is a plan view showing the steel plate 415 of FIG. 41. The steel plate 415 cut into a desired shape is provided at the steel plate back yoke portion 418, the steel plate teeth portion 419 protruding radially inward from the center portion of the steel plate back yoke portion 418, and the radial inner end portion of the steel plate teeth portion 419. It has a steel plate tooth tip portion 420 that protrudes in the circumferential direction. The steel plate tooth portion 419 has a steel plate tooth side surface portion 421 facing in the circumferential direction. The steel plate tooth tip portion 420 has a steel plate inner peripheral portion 422 facing inward in the radial direction.

FIG. 43 is a plan view showing the notched steel plate 416a of FIG. 41. In the notched steel plate 416a, a dovetail groove 423a, which is a groove, is formed on the side surface portion 421 of the steel plate tooth. Other configurations of the notched steel sheet 416a are the same as those of the steel sheet 415. The dovetail groove 423a has, for example, a recessed dimension of 0.5 mm to 3.0 mm and a width dimension of 1.0 mm to 5.0 mm. By laminating a plurality of steel plates 415 and notched steel plates 416a, a divided laminated iron core 402a in which a retaining groove 417a is formed in the side surface portion 412 of the divided laminated iron core teeth 412 can be obtained.

44 is a plan view showing the insulated division laminated iron core 401a of FIG. 40, and FIG. 45 is a perspective view showing a cross section taken along the line XLV-XLV of FIG. 44. The resin insulating portion 403 is provided in a retaining groove 417a formed by laminating a plurality of steel plates 415 and a notched steel plate 416a, and forms a resin retaining portion 424a in which the injection-molded resin is cured and integrated. Have.

FIG. 46 is a side view showing the insulated division laminated iron core 401a of FIG. 44, and FIG. 47 is a cross-sectional view taken along the line XLVII-XLVII of FIG. By curing the resin injection-molded in the retaining groove 417a formed in the retaining groove 417a formed in the side surface portion 412 of the divided laminated iron core 402a, the resin retaining portion 424a integrated with the tooth side winding portion 408 is formed. NS. As a result, the resin insulating coating that covers the side surface portion 412 of the split laminated iron core tooth does not separate from the side surface portion 412 of the split laminated iron core tooth 412 in the direction perpendicular to the surface of the side surface portion 412 of the split laminated iron core tooth. It is possible to prevent a gap 425a from being formed between the side winding portion 408 and the divided laminated iron core 402a. Due to this effect, it is possible to prevent the winding region 426 from being suppressed, and an efficient rotary electric machine can be obtained. The dovetail groove 423a of the notched steel plate 416a is not limited to the shape shown in the drawing, and for example, the same effect can be obtained by providing the notched steel plate 416a with fine protrusions as in the first embodiment.

Next, the manufacturing process will be described. First, the iron core laminating process will be described. The divided laminated iron core 402a of the present invention is composed of a steel plate 415 and a notched steel plate 416a. By punching a silicon steel sheet or an electromagnetic steel sheet using a press die, a steel sheet 415 and a notched steel sheet 416a having a desired shape can be obtained. Further, a steel plate 415 and a notched steel plate 416a having a desired shape can also be obtained by cutting out with a wire-cut electric discharge machine.

After that, at least one notched steel plate 416a is sandwiched and laminated on the plurality of steel plates 415 to obtain a divided laminated iron core 402a having a retaining groove 417a. A plurality of retaining grooves 417a may be provided in the side surface portion 412 of the divided laminated iron core teeth as long as there is no problem in the function of the insulating laminated stator 4. Further, since the steel plate 415 and the notched steel plate 416a have the same shape except for the dovetail groove 423a, the steel plate 415 and the cut plate can be cut by preparing a press die capable of replacing the parts for punching the side surface portion 421 of the steel plate teeth. The notched steel plate 416a can be continuously punched and laminated.

Next, the insulator integral molding process will be described. FIG. 48 is a perspective view showing a resin injection position and a cross section of the resin retaining portion 424a in the insulator integral molding step. The divided laminated iron core 402a is placed inside a molding die (not shown). The molding die is composed of a mold inner wall (not shown) and a resin injection hole 427 that seal the upper surface, the lower surface, the outer peripheral surface, and both side surfaces of the teeth portion of the divided laminated iron core 402a. For example, the resin injection hole 427 is arbitrarily provided at a position where the tooth curved surface winding portion 407 is formed, and the molding resin is injected from the resin injection hole 427. The arrows in the figure indicate the direction in which the resin flows from the resin injection hole 427. The injected molding resin flows through a cavity, which is a space between the inner wall of the mold and the divided laminated iron core 402a (not shown), and is cured after filling to cover the divided laminated iron core 402a and integrate resin insulation. Part 403 is formed. In the process of the molding resin flowing through the cavity portion forming the tooth side winding portion 408, the molding resin is filled in the retaining groove 417a provided in the split laminated iron core tooth side surface portion 412 and cured to prevent the resin retaining portion 424a. Is formed. In the resin retaining portion 424a, the resin insulating portion 403 is separated from the surface of the divided laminated iron core tooth side surface portion 412 in the direction perpendicular to the surface of the divided laminated iron core tooth side surface portion 412 in the tooth side winding portion 408 to form a gap. Prevents 425a from occurring. Moreover, since it is divided for each tooth, the mold and equipment can be miniaturized.

Hereinafter, a modified example of the installation position of the resin retaining portion 424a will be described. FIG. 49 is a perspective view showing a modified example of the insulated split laminated iron core 401a of FIG. 40. The insulating split laminated laminated iron core 401b includes a split laminated laminated iron core 402b and a resin insulating portion 403, and is configured by laminating each of them. The resin insulating portion 403 is different from the insulated split laminated iron core 401a in that the resin insulating portion 403 has a resin outer peripheral portion 428 provided on the outer peripheral surface of the divided laminated iron core 413 which is the outer peripheral surface of the divided laminated iron core 402b in the radial direction. By winding the coil around the teeth curved surface winding portion 407 and the teeth side winding portion 408, the insulation split laminated iron core 401b and the coil are electrically insulated via the resin insulating portion 403.

FIG. 50 is a perspective view showing the divided laminated iron core 402b of FIG. 49. The split laminated iron core 402b is provided at the radial inner end of the split laminated iron core back yoke portion 409, the split laminated iron core tooth portion 410 projecting radially inward from the split laminated iron core back yoke portion 409, and the split laminated iron core tooth portion 410. It is provided and has a split laminated iron core tooth protruding portion 411 that protrudes in the circumferential direction. The divided laminated iron core tooth portion 410 has a divided laminated iron core tooth side surface portion 412 facing in the circumferential direction. The split laminated iron core back yoke portion 409 has a divided laminated iron core outer peripheral portion 413 facing outward in the radial direction. The divided laminated iron core tooth protruding portion 411 has an inner peripheral portion 414 of the divided laminated iron core tooth facing inward in the radial direction.

The divided laminated iron core 402b is formed by laminating a plurality of steel plates 415 and at least one notched steel plate 416b. By sandwiching the notched steel plate 416b between the steel plates 415 and laminating them, a retaining groove 417b is formed in the outer peripheral portion 413 of the divided laminated iron core.

FIG. 51 is a plan view showing the notched steel plate 416b of FIG. 50. The notched steel plate 416b has a dovetail groove 423b formed on the radial outer surface of the steel plate back yoke portion 418. The steel plate back yoke portion 418 is an outer peripheral portion of the notched steel plate 416b. Other configurations of the notched steel plate 416b are the same as those of the steel plate 415. The dovetail groove 423b has, for example, a recessed dimension of 0.5 mm to 3.0 mm and a width dimension of 1.0 mm to 5.0 mm. By laminating a plurality of steel plates 415 and notched steel plates 416b, a divided laminated iron core 402b in which a retaining groove 417b is formed in the outer peripheral portion 413 of the divided laminated iron core can be obtained.

52 is a plan view showing the insulated division laminated iron core 401b of FIG. 49, and FIG. 53 is a cross-sectional view taken along the line LIII-LIII of FIG. 52. The resin insulating portion 403 is provided in the retaining groove 417b formed by laminating a plurality of steel plates 415 and the notched steel plates 416b, and the injection-molded resin is poured and cured to form the back yoke flange portion 406. It has a resin retaining portion 424b integrated with the outer peripheral portion.

54 is a side view showing the insulated division laminated iron core 401b of FIG. 49, and FIG. 55 is a cross-sectional view taken along the line LV-LV of FIG. 54. The resin formed by injection molding into the retaining groove 417b formed in the outer peripheral portion 413 of the divided laminated iron core back yoke portion 409 of the divided laminated iron core 402b is cured, so that the resin is the outer peripheral portion of the back yoke flange portion 406. A resin retaining portion 424b integrated with the outer peripheral portion 428 is formed. As a result, it is possible to prevent the resin insulating coating covering the outer peripheral portion 413 of the divided laminated iron core from being separated from the outer peripheral portion 413 of the divided laminated iron core in the direction perpendicular to the surface of the outer peripheral portion 413 of the divided laminated iron core, and a gap 425b is generated. can. Due to this effect, the inner diameter dimension of the insulating laminated stator 4 can be stabilized, the design clearance between the insulating laminated stator 4 and the rotor in the radial direction can be reduced, and a compact and efficient rotary electric machine can be obtained. be able to. The dovetail groove 423b of the notched steel plate 416b is not limited to the shape shown in FIG. 51, and for example, the same effect can be obtained by providing the notched steel plate 416b with fine protrusions or dents.

FIG. 56 is a perspective view showing a modified example of the insulated split laminated iron core 401a of FIG. 40. The insulating split laminated laminated iron core 401c includes a split laminated laminated iron core 402c and a resin insulating portion 403, and is configured by laminating each of them. The resin insulating portion 403 is different from the insulated split laminated iron core 401c in that the resin insulating portion 403 has a resin inner peripheral portion 429 provided on the inner side surface in the radial direction of the tooth tip portion 405. By winding the coil around the teeth curved surface winding portion 407 and the teeth side winding portion 408, the insulation split laminated iron core 401c and the coil are electrically insulated via the resin insulating portion 403.

FIG. 57 is a perspective view showing the divided laminated iron core 402c of FIG. 56. The split laminated iron core 402c is provided at the radial inner end of the split laminated iron core back yoke portion 409, the split laminated iron core tooth portion 410 projecting radially inward from the split laminated iron core back yoke portion 409, and the split laminated iron core tooth portion 410. It is provided and has a split laminated iron core tooth protruding portion 411 that protrudes in the circumferential direction. The divided laminated iron core tooth portion 410 has a divided laminated iron core tooth side surface portion 412 facing in the circumferential direction. The split laminated iron core back yoke portion 409 has a divided laminated iron core outer peripheral portion 413 facing outward in the radial direction. The divided laminated iron core tooth protruding portion 411 has an inner peripheral portion 414 of the divided laminated iron core tooth facing inward in the radial direction.

The divided laminated iron core 402c is formed by laminating a plurality of steel plates 415 and at least one notched steel plate 416c. By sandwiching the notched steel plate 416c between the steel plates 312 and laminating them, a retaining groove 417c is formed in the inner peripheral portion 414 of the divided laminated iron core teeth.

FIG. 58 is a plan view showing the notched steel plate 416c of FIG. 57. In the notched steel plate 416c, a dovetail groove 423c is formed in the inner peripheral portion 422 of the steel plate of the steel plate tooth tip portion 420. Other configurations of the notched steel sheet 416c are the same as those of the steel sheet 415. The dovetail groove 423c has, for example, a recessed dimension of 0.5 mm to 3.0 mm and a width dimension of 1.0 mm to 5.0 mm. The divided laminated iron core 402c does not have to sandwich the notched steel plate 416c between a plurality of steel plates. For example, the divided laminated iron core 402c has a retaining groove 417c that opens in one direction in the laminating direction in the inner peripheral portion of the divided laminated iron core 402c by laminating a plurality of steel plates 415 and notched steel plates 416c side by side. It may be formed, or only the notched steel plate 416c may be formed without including the plurality of steel plates 415.

59 is a plan view showing the insulated division laminated iron core 401c of FIG. 57, and FIG. 60 is a cross-sectional view taken along the line LX-LX of FIG. 59. The resin insulating portion 403 is provided in the retaining groove 417c formed in the inner peripheral portion 414 of the divided laminated iron core tooth of the divided laminated iron core 402c, and the injection-molded resin is poured and cured to form the tooth tip portion 405. It has a resin retaining portion 424c integrated with the resin inner peripheral portion 429.

FIG. 61 is a side view showing the insulated split laminated iron core 401c of FIG. 56, and FIG. 62 is a cross-sectional view taken along the line LXII-LXII of FIG. The resin injection-molded in the retaining groove 417c formed in the inner peripheral portion 414 of the divided laminated iron core tooth in the divided laminated iron core 402c is cured, so that the resin is integrated with the resin inner peripheral portion 429 in the tip portion 405 of the tooth. Part 424c is formed. As a result, the resin insulating coating covering the inner peripheral portion 414 of the divided laminated iron core teeth is separated from the inner peripheral portion 414 of the divided laminated iron core teeth in the direction perpendicular to the surface of the inner peripheral portion 414 of the divided laminated iron core teeth, and a gap 425c is generated. Can be prevented. Due to this effect, the inner diameter dimension of the insulating laminated stator 4 can be stabilized, the design clearance between the insulating laminated stator 4 and the rotor in the radial direction can be reduced, and a compact and efficient rotary electric machine can be obtained. be able to. The dovetail groove 423c of the notched steel plate 416c is not limited to the shape shown in FIG. 58, and the same effect can be obtained by providing, for example, fine protrusions or dents on the notched steel plate 416c.

The insulating laminated stator 4 according to the second embodiment is a stator of a rotary electric machine for a servomotor, a fuel injection valve open / close timing control unit, an air conditioning fan motor, an in-vehicle fuel pump unit, and a hoisting machine. It is an insulating laminated plate structure that can be applied to.

1 Insulated laminated rotor, 2 shaft, 3 Insulated laminated iron core, 4 Insulated laminated iron core, 301a, 301b, 301c Laminated iron core, 302 Resin insulation part, 303 Insulated laminated iron core Teeth tip, 304 Insulated laminated iron core Teeth winding part, 305 Insulated laminated iron core tooth side surface, 306 resin outer circumference, 307 laminated iron core center, 308 laminated iron core tooth, 309 laminated iron core tooth tip, 310 laminated iron core tooth side surface, 311 laminated iron core outer circumference, 312 steel plate, 313a, 313b, 313c Notched steel plate, 314a, 314b, 314c Retaining groove, 315 Steel plate center part, 316 Steel plate tooth part, 317 Steel plate tooth tip part, 318 Steel plate tooth side part, 319 Steel plate outer circumference, 320a, 320b, 320c Dovetail groove , 321a, 321b, 321c Resin retaining part, 322a, 322b, 322c gap, 323a, 323b winding area, 324 opening, 325 circular shape, 326 collar, 327 center line, 328 center line, 329 opening, 330 Rectangular part, 331 flange part, 332 center line, 333 center line, 334 opening, 335 triangle shape, 336 flange, 337 center line, 338 center line, 339 opening groove side surface, 340a, 340b, 340c protrusion, 341a, 341b, 341c dent, 342 resin injection hole, 401a, 401b, 401c insulation split laminated steel core, 402a, 402b, 402c split laminated steel core, 403 resin insulation part, 404 tooth tip protrusion, 405 tooth tip, 406 back yoke Flange, 407 Teeth curved surface winding part, 408 Teeth side winding part, 409 Divided laminated iron core back yoke part, 410 Divided laminated iron core Teeth part, 411 Divided laminated iron core Teeth protruding part, 412 Divided laminated iron core Teeth side part, 413 division Outer circumference of laminated iron core, inner circumference of 414 divided laminated iron core teeth, 415 steel plate, 416a, 416b, 416c notched steel plate, 417a, 417b, 417c retaining groove, 418 steel plate back yoke part, 419 steel plate tooth part, 420 steel plate tooth tip Part, 421 Steel plate tooth side part, 422 Steel plate inner peripheral part, 423a, 423b, 423c Dovetail groove, 424a 424b, 424c Resin retaining part, 425a, 425b, 425c gap, 426 winding area, 427 resin injection hole, 428 resin outer peripheral part, 429 resin inner peripheral part.

Claims (4)

An insulating laminated plate structure of a rotary electric machine provided with a laminated iron core in which steel plates are laminated and a resin insulating portion covering the surface of the laminated iron core.
The laminated iron core is
With the teeth department
It has a tooth tip that is provided at the radial end of the tooth and projects in the circumferential direction.
A retaining groove is formed at the center of the tip of the tooth, which is a surface facing the radial direction and is in the circumferential direction.
The resin insulating portion includes a resin retaining portion provided in the retaining groove and a resin inner peripheral portion or a resin provided on both sides of the resin retaining portion in the circumferential direction facing the radial direction of the tip of the teeth. It has an outer peripheral part and
The retaining groove is an insulating laminated plate structure of a rotating electric machine formed on a surface of the tip of the teeth facing the air gap between the stator and the rotor. The insulating laminated plate structure of a rotary electric machine according to claim 1, wherein the shape of the retaining groove is a dovetail groove shape. The insulating laminated plate structure of a rotary electric machine according to claim 1, wherein protrusions or dents are formed on the inner peripheral surface of the retaining groove. A method for manufacturing an insulating laminated plate structure in which a resin is integrally molded on the surface of a laminated iron core in which steel plates are laminated.
The laminated iron core has a teeth portion and a teeth tip portion provided at a radial end portion of the teeth portion and projecting in the circumferential direction, and is a surface facing the radial direction at the tooth tip portion and is a center in the circumferential direction. A retaining groove is formed in the
When the resin is integrally molded on the surface of the laminated iron core, the resin that has flowed into the retaining groove forms a resin retaining portion and a surface facing the radial direction at the tip of the teeth on both sides of the resin retaining portion in the circumferential direction. A rotary electric machine that forms an inner peripheral portion of the resin or an outer peripheral portion of the resin provided, and the retaining groove is formed on a surface of the tip of the teeth that faces the air gap between the stator and the rotor. Method of manufacturing an insulated laminated board structure.

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